Fuller KilnErection

Orientation & Common Terminology for Reporting Kiln Details
A - Indicates down-turning
side of kiln and in-running
rollers.
B - Indicates up-turning side of
the kiln and out-running
rollers.
(Straight Spur or Single Helical)
Referred to as Girth, Bull or
Main Gear. Indicate left or
right side of the kiln when
looking uphill towards feed end.
Gear
Gear
Right Right
Kiln
Discharge
End
Kiln
Discharge
End
Material discharge
(spill )
Material discharge
(spill )
A
A
A B
A
A
B
B B
B

Clockwise
(Right-hand)
Left Left
B A
Kiln thrust tire(s) with
tapered side-faces. Kilns
with hydraulic thrust
assemblies will utilize a tire
with a taper on the downhill
side-face only.
Kiln thrust roller assemblies.
Both sides of the thrust tire
except when units are
hydraulically controlled.
Kiln drive pinion(s). Arrows
indicate position of pinion
when a single drive
arrangement is used for kiln
rotation(s) as shown. Pinions
shown at outside positions are
for dual-drive assemblies.
Kiln Support Rollers also
called Carrying Rollers,
Trunnions, Wheels, and
Rolls.
Plain tires, or riding rings
(with straight side-faces).
"Rolling" or "Contact"
surfaces (faces).
Do not refer to "compass"
directions or local geography
when reporting problem zones.
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3 1
2 2
1 3
KILN OVERHEAD 001.CDR
Feed End of Kiln(s) (Also referred to as Uphill or High-End Area)
Counter-
Clockwise
(Lefthand)
Maintenance Seminar
SM
Elevation F
D
D
B
G
Elevation C
Elevation E
Elevation A
2
4
3
1
F
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C
L
F
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C
L

P
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C
L
B
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C
L
B
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C
L
(
A
p
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x
.
)
2
Kiln Support Frame Setting Reference

1 - 2 Allowance for grout between frame and rough pier top.
2 - Elevation reference plug. Set in pier on beam-web C
L
. Locate plug 6 outward from end of beam.
3 - 5 long shims. (Refer to kiln installation instructions).
4 - Anchor bolts added to prevent rolling of beams.
A - Reference elevation for support assembly.
B - Frame height (may vary after machining, use design dimension for calculation of top surface elevations).
C - Elevation A plus dimension B. (Not for actual test work).
D - Calculate rise or drop from frame C
L
to high or low beam C
L
to suit designed slope of equipment.
E - Elevation = C plus rise for D.
F - Elevation = C minus drop for D.
F = Required elevation at C
L
on machined top surface of beam minus reference plus elevation.
Use dimension G for setting elevation of control beam. Use precision straightedge with slope test block and machinists
level or inclinometer for follow-up slope adjustment of the frame.
Refer to foundation drawing and roller assembly drawings for elevations, frame dimensions and slope of the kiln.
Carefully check and record elevation at top of plug.
KILN OVERHEAD 002.CDR Maintenance Seminar
SM
Frames must be aligned on C
L
s
parallel to each other.
Refer to installation
instructions for dimension
tolerances and test
procedures.
NOTE:
Use a precision spirit
level for test work. A
stainless steel v-block
is supplied for test work,
or use an inclinometer.
Roller assemblies are to be
set before grouting frames.
Final test for slope is made
on top of each roller.
NOTE:
Slope tests require a sturdy
and accurate straightedge that
will totally span both beams of
all frames in the arrangement.
Refer to installation instructions for preparation of shims. Stacks must be tight.
Elevation tolerance
+_
1/16 or
+_
1.50 mm for frame.
Slope tolerance 0.002 per foot or 0.15 mm / 1000 mm.
Straight-edge must be parallel to frame C
L
.
Maximum gap 0.004 / or 0.10 mm under straightedge.
Cross-level tolerance 0.002 or 0.05 mm per foot at bearing zones (0.15 mm / 1000 mm at bearing zones).
A -
B -
C -
D -
E -
F -
Kiln Support Frame Adjustment and Tests
D
F
B
E
C
A
Maintenance Seminar
SM
Kiln Support Frame Spacing Test Points
NOTE: Support Roller Assembly drawing numbers for each pier are shown on the Foundation
drawing. Refer to the correct drawings for piers being checked. These drawings show the dimension from
(frame & roller dimensions may vary from pier to pier).
Add half-frame dimensions for piers being checked and subtract total from slope dimensions shown on foundation
drawing to obtain test dimension (as shown above in sketch).
Use spring scale to apply 20 to 25 lbs or 9 - 12 kg. tension to tape line (depending upon wind conditions).
Check tape line temperature and make allowances for possible variation for dimension being checked.
frame C
L

to beam C
L
for each assembly
Slope Dimension (Shown on Foundation Drawing)
Erecting Test Dimension
Base Dimension
Support Frame
(Shown on Foundation Drawing)
NOTE NOTE
Kiln
Support
Pier
Kiln
Support
Pier
SM
Kiln Support Frames Spacing, C
L
& Parallelism Tests
*
Use spring scale at 20 to 25 lbs or 9 - 12 kg. tension on tape line. Check tape line temperature and allow for expansion or
contraction of line.
NOTE

-

Frame

dimensions

shown

on

roller

assembly

drawings.

Align

frames

on

C
L
s, adjust for elevation, slope and
cross-level.
Dimension A - Nominal dimension from frame C
L
, measured and marked equally at all test points (in field at time of installation).
Dimension B - Test dimension from frame spacing and parallelism. (Tolerance
Dimension C - X-Test to verify frame C
L
alignment.
1/16 or 1.50 mm).
Slope Dimension (from foundation drawing)
D
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C
D
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C
Diameter B
*
Diameter B
*
D
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A
D
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A
D
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A
D
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A
Erecting test dimension
Kiln and Frame C
L
Marked on Piers by Layout Engineer
K
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A
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C
L
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C
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NOTE NOTE
Measured and Marked on Piers by Layout Engineer
Maintenance Seminar
SM
A - Establish offset reference lines at both edges of frame. Offsets must be parallel to, and symmetrical about the verified true kiln C
L
.
B - Use adjustment screws to set roller assemblies parallel to the kiln C
L
.
C - Measure from plumb lines to offset lines.
Testing New Kiln Support Roller Installations,
or

Re-Aligning

Older

Equipment
Slope -
gauge V-bar with
12, graduated vial,
machinist level.
Kiln may be
on slow
rotation
if plumb bob
is suspended
in oil.
Slope gage block
to be accurate within
0.0005 in 12 length or
0.05 mm / 1000 mm.
Use tight wire or
straightedge for
projection of offset
line across beams.
Plumb bobs
in oil
Measuring to plumb
lines is not completely
accurate (rollers may be
tapered).
Install boards at inner
edges of beams for ramming
high strength non shrink
grout from outside edges
of beams.
Fill anchor bolt sleeves
with high strength grout.
Adjust shims
as needed for final
true-up of frame.
(Slope & transverse-level
tolerance @0.002 per foot or
0.15 mm / 1000 mm).
This methold applies only when
roller surface is cylindrical.
Or use slope block on shafts.
The inclinometer is also an
accurate method.
C
C
B
A
Maintenance Seminar
SM
Recommended Water Piping Arrangement
for Kiln Support Roller Assemblies
A - Roller adjusting assembly. Keep these zones open for roller re-setting work.
B - Flexible lines to allow for possible 4 to 5 or
100 mm to 150 mm movement.
C - Inlet water master value.
D - Control value at inlet line to each water jacket.
E - Funnel arrangement for drain lines.
NOTE -
Keep lines clear of end plates
to allow for bearing inspection
and maintenance work.

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A
S
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B
L
Y
I
B
A
E
D
C
B
SM
A
B
B
C
A
A
B
C
Pads
A
B
Handling Kiln Tires for Installation on Pads with Slide Bar Arrangement
A - Timbers in place between
ground and tire.
B - Rubber belting for protection
of tire surfaces.
A - Kiln tire section on elevated saddles.
Set level as possible.
B - Tire in position for resting on shell section.
C - Set tire on 4 by 4 timbers for removal of
wire rope and belt material.
A - Circumferential sling for moving tire into position
on pads. Place wire rope inside rubber hose split
lengthwise and tied with baling wire.

B - Use 4 spacer bars with centering gussets and end
set-screws.
A - Longer timbers for clean and soft
rolling surface.
B - Belt wrapped around tire and tied
with wire.
C - 3 wraps of 1 wire rope hitched to
crane hook.
Plumb position of tire
after pick-up.
Maintenance Seminar
SM
Crane Hitch Arrangements for Handling Kiln Shell Sections
(Off-Loading and at Assembly Area)
Preferred arrangement, using a spreader beam and
two cradle slings. Two cranes should be used for
longer shell sections with two heavy padded
sections for riding rings.
Acceptable hitch arrangement, but anti-creep
gussets should be installed to prevent wire ropes
from crawling toward each other when the crane
starts to pick up the load. Calculate the sling
tension for the included angle & use an adequate
capacity slings.
SM
Crane Hitching for Kiln Shell Sections
Hitch Angles and Stress on Lines
Diameter
Diameter
1000 lbs. 1000 lbs.
2000 lbs. 1 Part line
Weakened
Splice
kinks
shell
Kiln Shell
Choker no good for
handling kiln shells.
Kiln Shell
2 parts
of line
Go with Cradle for
Handling Kiln Shells
Sling hitching angles and stress on lines
for each ton to be hoisted.
Diameter
2000 lbs.
1
4
1
5

l
b
s
.
1
4
1
5

l
b
s
.
45 45
90
Diameter
2000 lbs.
1
1
5
5

l
b
s
.
1
1
5
5

l
b
s
.
60
60
Maintenance Seminar
SM
Kiln Shell Support
L
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W
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Longitudinal welds at ends of shell
sections are to be set 180 apart
for field joints unless shown
otherwise on erection
drawings.
1 X 4 X 24 strongback bars may
be used to guide shell section
into position for field joint connection.
Locate at spaces required for
setting all strongback bars for joint.
Typical crib stack shown with jack, steel plate and
saddle arrangement for adjustment work.
Maintenance Seminar
SM
Alignment Fittings
Edges of adjacent
shell sections
Strong-back
Push - Pull
Adjust Bolts
Adjusting lug
Maintenance Seminar
SM
Gauge
Blocks
Field Joints
Feed End
Batter Board with
Center Hole and Card
Batter Board Locations
Maintenance Seminar
SM
Checking Alignment
Tumble or rotate instrument 180 for test at discharge end target.
Instrument cross-hairs or center of a laser beam must be within 3/32 or 2.5 mm of target center at all
test positions.
Feed End
Field Joints
Gauge
Blocks
Discharge
End
Transit Replacing
Batter Board
Maintenance Seminar
SM
Steel Spider
(1 of Several Types)
2 X 6
Board
Wood Wedges
2 or 50 mm Diameter Hole
Drilled at C
L
s
2 or 50 mm Diameter Hole
Drilled at C
L
s
(2) 1/4 Diameter
Bolts at
Each Plate
1/4 X 4 X 4
Steel Plates
2 X 6
Board
Kiln Shell Alignment Test Batter Boards
SM
A - 4 X 6 index card held in place by thump tacks (or staples) and push pin.
B - Shows card turned and pinned to clear 2 or 50 mm diameter hole for through sight to next targets. Card
can be returned precisely on starting position for target re-check.
A
BB
Kiln Alignment Target and Layout Trammel
Cut beam to
form pointed
end.
New kilns only-
In tire sections - use steps in
machined reference plates as
guide point for trammel layout
on targets.
3/4 X 1 1/2 trammel beam (wood)
Sharp pencil in trammel clamp.
Starrett No. 59 or similar.
Maintenance Seminar
SM
Details on card:
Center by
first set
of quarter
points
Center by
second set of
quarter points
Selected
center
B
1
A
1
A
2
B
2
A
3
B
3
A
4
B
4
Second set of quarter
points identified
by Bs
First set of quarter
points identified
by As
Shell
Center points
Arcs and diagonals
for first points
are solid, dashed
for the second set
Card on
batter board
45 offset
Locating the Center of the Shell
Maintenance Seminar
SM
Kiln Shell Section Alignment Tests (Alternate Arrangement)
After aligning and tack-welding span A, as for 2-section 2-support kiln (figure kiln overhead 014.cdr) or when this length
has been factory built, alignment of following spans can usually be achieved by adjusting support rollers.
completion of joint in span A will eliminate need for support at joints in following spans. Actual support
requirements will depend on section design for shipping.
Usually
Actual sequence of installation and alignment must be determined on-site to suit actual number of shipping sections.
For Alignment of Kiln with Sections as Shown Above
Finish span A as in test for 2-section, 2-support kiln (shown in figure kiln overhead 014.cdr).
Set transit on kiln axis. Lock on target 5. Cross-check on targets 4, 3, 2, 1.
Lock transit on target 8. Back-check on 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of site within 3/32 or
2.50 mm of target centers.
Lock transit on target 11. Back-check on 10, 9, 8, 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of sight within
3/32 or 2.50 mm of target centers.
Minor errors on short fore-sight will grow on each following target. Avoid errors, save time and avoid confusion by
working from most-distant far-sight.
1 2
3
4 5 6 7 8 9
10 11
Span A
Pier 1
Pier 2
Pier 4
Pier 3
Span B
Span C
Maintenance Seminar
SM
Kiln Shell Field Joint Bracing and Tack Welding
Weld remaining end of strongback
after kiln shell alignment is acceptable.
Prewelded end
Tighten all nuts in push/pull
bolt arrangements.
Edges of adjacent
shell sections
Tack weld in bevels, at least 6 or 150 mm long, at fixtures used for alignment of adjacent plates.
Deposit root weld bead.
Maintenance Seminar
SM
Riding Ring Location
Thrust
Discharge
end
Change pier numbers to suit actual arrangement
The dimensions indicated are specified on the foundation drawing. The tolerance on the location of each
ring is
+_
1/4 inch (6.35 mm).
Cold dimensions on the foundation drawing are at 70 F (21 C). Record shell temperature for
calculation of expansion or contraction relative to the control temperature for adjustment of allowance for
expansion at each support roller position.
Maintenance Seminar
SM
Temporary Support Chair for a Kiln Spring Gear
1 axial adjustment bolts.
6 long (typical).
Typical gear chair
( 1 of a set ) for
temporary duty.
2 X 6 (or to suit) bolt
for gear radial adjustments.
Kiln Shell
Chair in position to
support and adjust
the gear for correction
of axial and radial runout.
Kiln gear with tangential springs
Maintenance Seminar
SM
Gear Guard and Splash Band Assembly
C
F
F
D
C
E
A
B Feed End
A - Gear guard section
B - Flange joint for removable panel
C - Splash band sections
D - Spring plate for gear
E - Kiln shell plate
F - Spacer guides
Splash band installation notes:
1 - Prepare and install spacer guides.
2 - Install segments with care.
3 - Align and tighten flange joints.
4 - Align and tach weld panel butt joints.
5 - Verify straightness and clearance all
around.
6 - Weld flanges to shell. Must be oil tight.
7 - Remove scraps. Clean off weld spatter.
NOTE:
If conduit must pass through bands to reach a thermocouple, install before guard assembly work.
Maintenance Seminar
SM
Kiln Support Roller Adjustment and Testing
Low end of kiln
(discharge)
Bearing end
plate with
thrust washer
Roller shaft should be in
contact with this thrust
washer. End plate should
sound solid when tapped
near center with a hammer.
Roller shaft should not be
in contact with this thrust
washer. End plate should
sound hollow when
tapped near center with a
hammer.
Bearing end
plate with
thrust washer
Low end
of kiln
(discharge)
Kiln moves
toward feed end
Rollers move
toward discharge end
Rotation
In
In
Support
Roller
Riding
Ring
View toward feed end
Rollers move
Kiln moves
toward feed end
Rotation
In
In
Support
Roller
Riding
Ring
Maintenance Seminar
SM
Ideal Roller Skewing:
All rollers should be pushing uphill slightly or neutral.
With a two thrust roller system (as here) the kiln should be floating between the thrust rollers.
With a one thrust roller system there should always be contact between thrust roller and tire pressure
200-800 psi or 15 to 60 bar.
Drive Lower Thrust Roller
Feed End
Discharge
End
Skewing Rollers
Maintenance Seminar
SM
Beam
top
Support
roller Plumb
lines
Plumb
bobs in
oil
B
B
A
Kiln may be
on slow rotation
if plumb bob
is suspended
in oil *
Dial-indicators (1 at each bearing base) are used
for control of final true-up alignment work
and for all skewing adjustments.
Bearing
Base
A
Offset reference line
(may be a tight wire
or a straightedge at
established reference
marks).
Support Roller Assembly Alignment Control
High

temperature

metal

surfaces
can

cause

severe

burns.

Moving

(rotating)

machinery

can
cause

hands

and

arms

to

become

caught.
Avoid personal injury.
* - This procedure is not valid if the roller is cone shaped or distorted on the rolling contact surface.
A

-

Scribe

beam

surface

at

edge

of

bearing

base

to

establish

reference

points

for

measuring

bearing

movement

during

the

roller

relocation

work

period.
B - If it is possible to work simultaneously at both bearing positions, use 2 plumb lines for measuring movement.
Maintenance Seminar
SM
Rotation B
Rotation A
180
bearing
bushing
Kiln Support Roller Bearing Bushing Lubrication
Sketch shows recessed zones of
bushings filled with oil for formation
of oil wedges which taper to a few mils
film thickness at the longitudinal pressure
line. Wedges are shown for both directions
of shaft rotations.
A
B
Shaft Rotation
Shaft
Rotation
B
A
Roller Shaft
Recessed Zone
(Both Edges)
Maintenance Seminar
SM
Temporary Kiln Support Jacking Kiln Shell to Unload Support Rollers
Chord Length does not apply when designing a saddle for under a riding ring. A saddle for a riding ring must
straddle a tie beam between support frame beams and must be designed to fit between rollers on that frame.
Saddle width should be same as width of nearest tire but not less than 12.
Rule of thumb:
72 = 5 spaces @ 0.587785 X outside diameter = Chord Length
Shell Diameter (outside)
Kiln Shell
All pieces
from 1 1/4
plate
Saddle for Kiln/Shells
Chord Length
72
3
6
V
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Kiln Saddle Dimensions
Maintenance Seminar
SM
Jacking Kiln Shell to Unload Support Rollers
Drive wedges and/or filler plates between tire and pads to eliminate top
clearance for early pick-up of the tire when jacking against the saddle.
Shell Brace
Shell Saddle
Arrangement
Clearance
Slow Rise Edge
Prepare 12
or more
On Pier Surface
Tire
Maintenance Seminar
SM
Jacking Kiln Tire to Unload Support Rollers
Preferred Jacking Arrangement ( when possible)
Refer to the foundation drawing for the kiln for the pier loading figure at the tire to be raised;
jacking capacity for that area will be indicated by the vertical load shown for that pier.
Shell Brace
Clearance
Tire
Maintenance Seminar
SM
Familiarization -
Kiln Support Roller Bearing Oil Level and Leakage
A - No oil leaks at downhill shaft seal except when overfilled, dirt and rainwater enter housing when seal is bad, as
when a liner is badly damaged.
B - Shaft seals are not dams. Oil level must not reach seals at uphill bearing assemblies.
Pier Surface
Pier Work Point
Maximum oil
level in the
downhill housing
Maximum oil
level in the
uphill housing
Imaginary Level Line
A
B
Slope Line
Maintenance Seminar
SM
Support Roller With Journal
Self Aligning Ball and Socket Type Bearing FLS 58
Type RA Design Bearing
Felt
Seal
Oil Trough
Oil Cup
Thrust Ring
Liner
Oil Gauge
Spherical Liner/
Water Jacket
Stop Block
Heat Shield
Oil
Scraper
Maintenance Seminar
SM
Low end of kiln
(discharge)
Bearing end
plate with
thrust washer
Roller shaft should
be in contact with this
thrust washer. End plate
should sound solid
when tapped near
center with a hammer.
Roller shaft should
not be in contact
with this thrust
washer. End plate
should sound hollow
when tapped near
center with a hammer.
Bearing end
plate with
thrust washer
Maintenance Seminar
SM
Low end
of kiln
(discharge)
Kiln moves
toward feed end
Rollers move
Counterclockwise Rotation
Rotation
In
In
Support
Roller
Riding
Ring
Maintenance Seminar
SM
Low end
of kiln
(discharge)
Rollers move
Kiln moves
toward feed end
Rotation
In
In
Support
Roller
Riding
Ring
Clockwise Rotation
Maintenance Seminar
SM
Kiln Support Roller Skewing
Roller Adjustment Rule of Thumb
Moving (rotating) machinery.
Personal contact can cause
hands and arms
to become caught in pinch points.
Counterclockwise Kiln Rotation
In
In
In
In
Bearing
Bearing
Bearing
Bearing
Support
Roller
Support
Roller
Kiln
Kiln
Kiln
Kiln
Rotation
High End
Maintenance Seminar
SM
Kiln
Kiln
Kiln
Kiln
Kiln Support Roller Skewing
Roller Adjustment Rule of Thumb
Clockwise Kiln Rotation
In
In
In
In
Bearing
Bearing
Bearing
Bearing
Support
Roller
Support
Roller
Rotation
High End
Moving (rotating) machinery.
Personal contact can cause
hands and arms to become
caught in pinch points.
Maintenance Seminar
SM
Normal Offset Position of Thrust Rollers
Thrust rollers must be offset from the true frame longitudinal centerline toward the down - turning side of the kiln
for normal (safe) operation.
Down Down
Down
Kiln
Centerline
Roller
Centerline
Correct
Idle
Rotation
Maintenance Seminar
SM
1/16 to 1/8
Wrong Offset Position of Thrust Rollers
Thrust rollers will rise, or try to rise, out of their bearing bases when their centerlines cross over the true
frame centerline toward the up-turning side of the kiln, and when the kiln shifts toward its own downturning
side.
Idle
Up
Up Up
Wrong
Rotation
Kiln
Centerline
Roller
Centerline
Any amount
Maintenance Seminar
SM
Plain Roller Support Assembly
Detail
Roller Shaft
R
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C
L
Inspection Port
Oil Seal
(See Detail)
Oil Tray
Bearing Housing
Oil Bucket Wheel
Thrust Washer
Oil Level and
Oil Fill Pipe
Feed End
Adjustment Plate
Bearing
Maintenance Seminar
SM
Thrust Roller Assembly
Two Thrust Roller System
Detail
Oil
Seal
Oil Level &
Oil Fill Pipe
Thrust
Roller
Housing
Thrust Riding Ring
Feed End
Thrust Rod
Shims
Spherical
Roller Bearings
Thrust Roller
Thrust Roller
Shell
See
Detail
Maintenance Seminar
SM
Thrust Roller Assembly
Thrust Roller Frame
C
C
C - C
Maintenance Seminar
SM
Oil
Seal
Detail
Hydraulic Thrust Roller Assembly
Shell
Thrust
Roller
Frame
Upper Thrust
Housing

Support
Thrust Housing

Support

Rod
Drain Plug
Feed End
Lower Thrust
Housing

Support
Spherical
Roller

Bearings
A (Sht.
Fixed Uphill Stop
with Brass Plate
Support
Rod Boot
Thrust
Riding

Ring
Thrust Roller
Housing
Thrust Roller
Movement
Thrust Roller
Thrust
Button
Hydraulic
Cylinder
Stroke
Adjuster
NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown
To Hydraulic
Power

Unit
See
Detail
Maintenance Seminar
SM
Bumper
Assembly
Riding
Ring
K
i
l
n
C
L
A - A
Hydraulic Thrust Roller Assembly
Operation of Limit Switches
A - Stops Hydraulic Pump Set
B - Pressure in System Relieved
C - Sounds Alarm
D - Shuts Kiln Drive Down
E - Starts Hydraulic Pump Set
F - Sounds Alarm
G - Shuts Kiln Drive Down
Pier 3 Pier 2
Hydraulic
Cylinders
Hydraulic
Power Unit
Hydraulic Thrust Orientation
(Single Hydraulic Cylinder May be Used)
+ + + + + + +
D C B A E F G
Thrust Roller
Thrust Riding Ring
C
L

R
o
l
l
e
r

S
u
p
p
o
r
t

&
T
h
r
u
s
t

R
i
d
i
n
g

R
i
n
g
Feed End
Cam Follower
Limit Switch
Assembly
A
A
C
L
Maintenance Seminar
SM
Routine Checkout at Kiln Tire Sections
Shell Cold: Clearance for expansion at top of kiln
Shell (pads) rest in normal position inside the tire
Allowance for
Shell Expansion
View at
Top Position
Maintenance Seminar
SM
E
x
p
a
n
s
i
o
n
Shell Overheated
and Choked
Inside Tire
Shell overheated and choked inside tire. Shell expands proportional to internal heat, but must bend at sides of tire.
Tire retainers on bend pads bite into the tire, tire and retainers become worn. When shell temperature returns to
normal, shell pad to tire clearance is excessive.
No shell migration may eventually be followed by permanent kiln shell choke-down deformation.
Maintenance Seminar
SM
Field Installation of Kiln Tire Section Spider Bracing
When the pre-welded end of Brace No. 1 is at the top of the shell after 90 of rotation, shell sag moves the loose
end against the bottom of the shell and in position for welding.
Brace No. 2, and possibly No.s 3 and 4, will be needed for pad replacement work requiring frequent rotation
of the shell.
Spider bracing is for holding the shell as round as possible for pad replacement work. Before welding bracing
to the shell, verify roundness by using trammel layout work for marking the shell axis on Brace No. 1 to establish
a reference point for radius measurements.
Brace No. 1
Pre-Welded
End @ 90
From Start
Now Tight
Second
Weld
Brace No. 2
Sag
Maintenance Seminar
SM
Shell Hot: Normal Operation
Check (frequently) each tire section in the kiln arrangement. When shell migration in not recorded, the kiln shell
is very near the point of serious deformation damage plus shell and refractory breakdown problems.
Almost zero
clearance.
Shell continues
to migrate within
the tire.
View at
Top Position
Maintenance Seminar
SM
When normal coating builds up on refractory, the main shell returns to normal diameter but the permanently
deformed tire section shell is small in relation to the tire bore diameter.
With the tire in a normal alignment position the kiln shell is misaligned at the low-riding deformation zone.
Excessive down tire follows choke-down deformation.
Clearance
Maintenance Seminar
SM
1 - Install support plates at both sides of the shell.
2 - Lift bracing leg onto support plates. Check squareness.
3 - Hold end of brace against the shell for welding.
4 - Rotate shell 90 to place weld at top center position.
Shell sags away
from the tire
Clearance
Spreads
Horizontal Major Axis
1
1
2
3
4
Maintenance Seminar
SM
New measurement problems must be considered when/if internal bracing holds the shell in a perfectly round condition.
If the riding ring rests on support rollers, ovality will not have changed; now measurements will be between a round
shell and an oval riding ring.
When the riding ring is on the support rollers, and the kiln shell is round (after bracing), measure clearances at both
sides at the horizontal centerline, and at top-dead-center between shell pads and the riding ring bore surface. Add
dimensions recorded for these three check points, then divide the total by two to determine the actual diameter for
shell pads and riding ring bore.
Clearance
0.6125
Clearance
0.6125
Shell held in round condition
by

internal

bracing
True roundness is a goal
Seldom

-

if

ever

-

Reality
Clearance
0.775
Riding ring on rollers
and a 0.3% ovality
(example only).
Maintenance Seminar
SM
Jacking a Kiln Shell to Unload Support Rollers
Clearance between the tire and pads at the top of the shell is usually overlooked when all other details have been
considered in arrangements for jacking up the kiln shell to take a tire off the support rollers for maintenance work
on the roller assemblies in position on the support frame, or for lifting out one or both assemblies for work at ground
level or in the maintenance shop.
Saddle Under the Kiln Shell
Clearance
Tire
Shell Brace
Maintenance Seminar
SM
Two to four times the jacking capacity anticipated for lifting the shell will be required if tire to pad clearance is
not considered (especially when excessive).
By the time the upper pads touch the tire jacks are fighting all shell weight to adjacent tire sections.
Saddle under the kiln shell
Maintenance Seminar
SM
NOTE: The tire will not rise until top area clearance is eliminated by the rising shell.
Excessive pad to tire clearance is a handicap for jacking up kiln shell.
Saddle under the kiln shell
NOTE:
Maintenance Seminar
SM
Jacking Kiln Shell to Unload Support Rollers
Shell Brace
Shell Saddle
Arrangement
Clearance
Slow Rise Edge
Prepare 12
or more
On Pier Surface
Tire
Maintenance Seminar
SM
Typical Procedure for Removing Roller Assemblies
from the Support Frame
1 - Spider bracing (installed before locking out the kiln drive system, including the auxiliary drive arrangement).
2 - Timber cribbing stack with hydraulic jacks in place under steel saddle. Saddle and jack arrangement must raise
the kiln shell just enough ( 1/32, 1 mm, or less ) to be fully loaded for removal of both roller assemblies. *
3 - Install steel or hardwood columns for security of the temporary support arrangement during the pad removal and
replacement work period.
* - If the tire is rising with the shell. If clearance between the tire and shell pads was not accounted for, excessive
jacking will be required to lift the tire away from the support rollers.
1
2
3
3
Maintenance Seminar
SM
Typical Procedure for Removing Fuller/Traylor Roller Assemblies
Cutaway view of roller assembly bearing bases shows internal arrangement of components with critical clearances.
Whenever roller and bearings are to be lifted as a complete assembly, hitching arrangements must hold bearings in
full-line contact with shafts, and with no contact at shaft seal zones.
A - Remove shaft seals. Insert wood or rubber wedges between shaft and seal inset in housing. Secure these wedges
with at least one wrap of duct tape (or similar material).
B - Edges of frame beams have machined insets for control of shaft clearance between bearing end plates. Key bars
at bottom positions on housings hold bearing housings in position against machined edges for operation of the
assembly. One or both keybars must be removed to avoid interference when the complete roller assembly is
moved toward the outside end of the support frame.
Slope
Line
Pier
Top
Pier
Work Point
Level Line
Reference
Maintenance Seminar
SM
Prepare hitching material similar to the arrangement shown in these sketch sheets. Distance between connecting
points must place the crane hook, spreader bar and shackles far enough above the kiln horizontal centerline for
flexibility in the lines for lift-out maneuvering.
Remove all cooling water input and drain pipes from bearing bases. Remove bearing adjustment lug and screw
combinations from frame beams. Prepare beam surfaces for outward travel of the roller assembly.
Jack or pull the assembly outward on the frame until motion is stopped by roller contact against the tie-beam at the
end of the frame.
Maintenance Seminar
SM
Typical Procedure for Removing Fuller / Traylor Roller Assemblies
Place timbers at the ground level work area for support of the assembly with the roller off the ground The low-end
bearing housing will touch down, and hitching will become loose, before the other bearing housing rests on its own
support timbers.
Maintenance Seminar
SM
Move bearing housing:
Removing and/or resetting a bearing housing at ground level
Look for stencil-letter
identification of the
feed end area of the
roller.
IN / ON
OUT / OFF
Uphill ( or feed end )
bearing housing
FEED

E
N
D
Maintenance Seminar
SM
Move the roller into its realignment position and into a load carrying condition. Reassemble all pipe fittings, guards
and other items which may have been removed for crane handling maneuvers. If internal fittings had not been
reinstalled at ground level, remove end plates for final fit-up work. Re-fill bearing lubricant reservoirs. Remove
pedestals, jacks, saddle and cribbing.
Maintenance Seminar
SM
New Pads for Choked-Down Tire Sections
Align the kiln shell before shutting down for repair work. Cold-condition external alignment procedures are not
acceptable unless excess clearance and other deviations are accounted for. Kiln shell section alignment is critical
at all tire positions, alignment of tires is not necessarily kiln shell section alignment.
Tire
(Clearance
Exaggerated
for Clarity)
Thrust Roll
Roller at
Far

Side
Level
Slope
True Kiln Axis
Thrust Roll
Tire C
L
Shell C
L
Maintenance Seminar
SM
Preparation:
1 - Install spider bracing. (See bracing installation procedure on other sheets). Bracing must be installed before the
kiln auxiliary drive system is secured, along with the main drive motor, to prevent accidental rotation during the
repair work period.
2 - Remove retainers at the side of the tire toward the direction of movement away from pads. Grind off weld scraps.
3 - Remove thrust roller assemblies.
Level
Slope
2
1
3
1
Maintenance Seminar
SM
Preparation:
1 - Install steel saddle and two (or more) hydraulic jacks in a convenient location that will not interfere with work.
2 - Back support rollers away from the frame center line to let the tire move downward.
3 - As rollers move outward, check tire to shell clearance all around. Stop roller adjustment work when the tire is
in balanced position around the shell.
4 - Install skid bars at the top of the shell. Use shims for adjusting bar height for smooth movement of the tire.
5 - Mark the shell to indicate original position of tire.
Level
Slope
3
5
4
1
2
Maintenance Seminar
SM
Preparation:
1 - Install a tight arrangement of steel or hardwood pedestals between the support surface and saddle.
2 - Start to jack or tug the tire off pads and onto skid bars.
Level
Slope
2
1
Maintenance Seminar
SM
Preparation:
1 - Move the tire far enough onto skid bars to allow for installation of new extra long pad plates.

2 - The bottom of the tire will swing toward a plumbed position if not restrained. Install gusset plates at the
bottom of the shell to hold the tire away from the pad zone.
3 - Remove both roller assemblies for free access to the shell.
4 - Start pad removal work.
Level
Slope
Maintenance Seminar
SM
Preparation:
1 - Finish pad removal work. Grind down weld scraps. Remove caked dirt, rust and oil from the shell at the pad zone.
2 - Use a straightedge or a tight line for measurement from undamaged shell surfaces to the top of the depressed shell.
Measure at several points around the shell for a realistic approach for planning and preparing filler material.
The depressed zone must be filled for support of new pads. Any unfilled space, however small it may be, will allow
new pads to bend to fill the spaces as soon as rotation starts after the kiln is returned to the production department.
Level
Slope
STRAIGHTEDGE
Maintenance Seminar
SM
A typical, but unsatisfactory shim stack arrangement for filling spaces between shell and pads is shown at the
bottom of the shell. Since all-position fit-up work is necessary, shim stack installation is tedious (and frustrating)
work. Shim stacks are rarely, if ever, tight enough to prevent pad distortion when the work is called finished.
A more acceptable filler arrangement is shown at top of the shell, a rolled plate, at a thickness determined by prior
measurement, is used with appropriate thickness-adjustment shims for a more secure packing arrangement. In this
arrangement filler plates are welded to pad plates, not to the shell.
STRAIGHTEDGE
KILN OVERHEAD 076.CDR KILN OVERHEAD 076.CDR
New Pad Plate
Stacked Shim Plates
Rolled Filler Plate
Level
Slope
Maintenance Seminar
SM
Lubricate
Level
Slope
Lubricate
New Shell Pads
When new pad plates, with fillers, are secure around the shell, lubricate surfaces to facilitate movement of the
entire to the predetermined operating position for that particular tire.
Maintenance Seminar
SM
1 - Adjust tire position in relation to original reference lines.

2 - Install temporary gusset plates to lock the tire for rotation.
3 - Return support rollers to positions on the frame. Adjust for recalculated set points which consider new
conditions at the tire.
4 - Move the thrust roller into position at the clear area.
5 - Remove skid bars: Grind down weld scraps.
New Shell Pads
Maintenance Seminar
SM
Welded End
Do Not Weld
Gusset to Pad
Welded End
Welded End
Welded End
Loose End
Loose End
Loose End
Loose End
Pad
Pad Pad
Pad
Tire
C
L
TYP
TYP
3/8 to 3/4
3/8 to 3/4
3/8 to 3/4
A
A
T
ire 1
D
ia.
Spacer Pad
(Loose End)
A - A
Hold Down
Gusset Retainer Block
4 X 4 X Variable Length
to Suit Spacer Pad
Alternate tire retainer arrangement. Semi-floating pad design.
Maintenance Seminar
SM
1/16
1 - Be sure that rollers are carrying the load of tire and shell.
2 - Remove pedestals, jacks and saddle.
3 - Reset thrust roller assembly.
4 - Adjust thrust roller assemblies for proper clearance in
relation to the tire and in relation to support roller
centerlines.
5 - Kiln rotation is required for testing for tire wobble.
6 - After tire wobble has been eliminated, install tire retainers.
7 - Remove temporary tire-locking gusset plates.
8 - Remove internal spider bracing. Grind down weld scraps.
1
2
3
4
8
7
5
6
8
Tire
Tire
Slope
Roller
Thrust Roller
Thrust Roller
Maintenance Seminar
SM
In

this

arrangement

pads

are

not

welded

to

the

shell

at

all.
The

shop

installed

cost

for

this

arrangement

is

high,

but

the

future

field

replacement

of

pads

is

simpler

and

less

expensive.
The

continuous

wear

rings

installed

between

the

riding

ring

end

faces

and

wear

ring

retainers

reduces

bearing

pressure
and

gouging

in

the

riding

ring

end

faces

and

also

increase

wear

life

of

the

components.
It

is

very

easy

to

reduce

tire

creep:

Install

shims

between

shell

and

pads

and

tack

weld

new

shims

to

pads.

Floating Pad Design
Min. Min.
Wear Ring
1/16 or 2 mm Downhill Side Only
Heavy Shell Plate
Riding Ring
Pad Length
Pad
Min.
8 8
5
Taper
Pad
Thickness
1
Wear
Ring
TYP
Shell
Thickness
Pad
Thickness
Height of
Anti-Rotation
Plate
A - A
Fillet Weld Size
Maintenance Seminar
SM
2-
Pad
Width
9
TYP.
3

Sides
TYP.
3

Sides
1 Chamfer
5/8
Fillet
Weld
Size
A A
5 8
Anti-Rotation Plate
Must Make Contact on 1 Side
Wear Ring Retainer
1 TYP
TYP 1/4
Pad Guide Bar 1 Thick
Axial Pad Retainer 1 Thick R 3/4
R 3/4
R 3/4
1/8
Gap
Using Wedges for Longitudinal Shifting of Tire
Weld Wedge to Tire
Opposed Wedges. Smooth slide surfaces per machine shop procedures.
M
o
l
y
k
o
t
e

L
u
b
e
Weld Wedge to Pad
Rotation & Creep
Creep (Mark on Pad)
Mark on Tire
Move Tire
Cold Kiln
Maintenance Seminar
SM
Using Chains for Longitudinal Tire Movement
No push or pull mechanical assistance.
No wedges.
No assist from roller thrust reaction on tire.
Ignore triangle
in chain
hook-up
Tire
Roller
24 Straight Line
2
3/8
24
Maintenance problem:
Tire in offset operating position
on rollers. 2 move required in
longitudinal direction on shell
Clearance - tire to pad at TDC
is 3/8 for this example.

C
L
C
L
Chain
Maintenance Seminar
SM
1
2
3
4
5
6
7
8
9
10
11
12
13
0.750
1.500
2.250
3.000
3.750
4.500
5.250
6.000
6.750
7.500
8.250
9.000
9.750
23.988
23.953
23.894
23.812
23.705
23.574
23.419
23.238
23.031
22.798
22.537
22.248
22.937
0.012
0.047
0.108
0.188
0.295
0.428
0.581
0.782
0.988
1.202
1.482
1.751
2.070
Rev. Number Draw New X Dimension Total Creep
Clearance tire to pad at TDC = 3/8
3/8 . .5 = 0.2387324
Diameter X = 0.750 creep/rev.
Must shift tire 2
t
t
Tire
Tire
Draw
Start
24 Straight Line
Shell Creep/Rev. 3/4
(Constant)
24 Constant
X Changing
Using Chains for Longitudinal Tire Movement
Approximately 13 revolutions to move tire 2. No allowance for elongation of chain under load. Calculate
for actual creep and length of chain(s).
Right triangle re-calculation to suit creep @3/4/rev. X number of revolutions: 24 chain constant hypothenuse.
.
Maintenance Seminar
SM
As Seen From Under
the Kiln Shell
Measure Amount of Creep
Shell Advances Inside Tire
SM
Count kiln revolutions after placing matchmarks. Measure distance between matchmarks after X number
of kiln revolutions, then divide that dimension by kiln revolutions during the test period to determine shell
migration (creep) for each revolution of the kiln.
Measurement of Shell Migration
to Determine Shell Pad to Tire Diameter
A
B
End
Start
Tracing Arrangement for Recording Pad-to-Tire
Clearance and Migration (Creep)
A - Magnetic base with post for spring-loaded pencil holder
B - Magnet-backed tracing surface holding panel
The kiln shell migrates within the tire;
It is not the tire that creeps.
In the sketch above, the tracing surface is set
on the side of the tire and the magnet-supported
pencil is placed on the trailing edge of the
card as determined by rotation direction
of the kiln.
Height of wave patterns is a recording of
actual clearance between shell pads and
tire bore. This dimension when divided
by 1/2 Pi, indicates actual pad-to-tire
diameter.
Distance between start/stop points indicates shell
migration within the tire for each kiln revolution.
Shell migration divided by Pi ( ) indicates pad-to-tire
diameter, but this dimension is not valid for follow-up
calculations when affected by lubrication.
NOTE: Kilns with floating shell pads --- DO NOT PLACE MAGNETIC BASE ON A LOOSE PAD.
Maintenance Seminar
SM
Spring-Loaded Pencil Holder for Pad/Tire Clearance
and Creep Tracings
Pencil must move freely in tube (no slop).
Ret/G post & block (tackweld). Drill, ream, tap.
Spring to be retained at end shown.
Tire clearance & creep tracing-pencil holder.
Magnet
Ret/G Block
Ret/G Post
Cap Screw
Holder
Spring
Pencil
General - #351-6
1/2 Hex Bar X 2 LG
1/2 Hex Bar X 1 LG
(Slotted) 10-24 X 3/4 LG
Chromed

Tubing

(Plumbing)
5/16

Diameter

X

1

1/2

LG

(Medium

Ten.)
Standard

HB

(No

Eraser)

(Berol

Black

Warrior

#372)

Description Material
Standard
Pencil
Pencil Holder
(Tubing)
Drill & Tap
10-24 X 1 Deep
10-24 Slotted
Capscrew X 3/4 Long
Permanent Horseshoe Magnet
(10 Lb. Pull)
Retainer
Block & Post
Spring
5/16 Diameter X 1 1/2
(Retained)
6
Maintenance Seminar
SM
1 1/2
Tracing-Paper Surface for Pad/Tire Clearance
and Creep Tracings
Tire clearance & creep tracing board
Cut strips of manila file folder sheets to fit on hardboard surface. Hold strip in place with spring clips.
8 1/2
1 TYP.
1/8 Tempered
Hardboard
Permanent Horseshoe Magnet
10 Lb. Pull (General #351-6)
Drill & Countersink
To Suit 10-24 Csk Screw
(TYP) 2 places
Bolt

&

Nut

to

Magnet
2 1/2
Two Spring Clips (Small)
Maintenance Seminar
SM
E
G
H F
h
h
1
5
.
Recorder System
Holderbank
Ovality: = 2 (a - b)
3
= 4
.
d
2
.
h
h
=
Shelltest Diagram
=
15
a
Distorted Cross-Section
Principle of

Distortion

Measurement
Shelltest Measuring Unit Holderbank System
b
d
d
A
B
h
B
D
C
L

=

1
m
Maintenance Seminar
SM
D C B
1, 2, 3, Shell Lines
A, B, C, D Measuring Planes
A
1
1
1
2
2
2
3
3
3
1
2
3
Diagram of One
Measuring Plane
Ovality
Maintenance Seminar
SM
Ovality Limits as Function of Kiln Diameter
Kiln Diameter
%

O
v
a
l
i
t
y

3
0
%
0.2
0.6
0.4
0.8
4 5 6 m
e
Maintenance Seminar
SM
Allowance for
Shell Expansion
View at
Top Position
Maintenance Seminar
SM
A
B
End
Start
As Seen From Under
the Kiln Shell
Measure Amount of Creep
Shell Advances Inside Tire
SM
Clearance
E
x
p
a
n
s
i
o
n
Shell Overheated
and Choked
Inside Tire
Permanent Shell Deformation
Maintenance Seminar
SM
Difference in Diameter ( )
Gap at Top (G )
= G

D
:
Tire
Note Note
Note: Deflection also occurs at contact points where the tire rides on support rollers.
Distorted Shell
Crush Zones
for
Brick

Lining
C
L
C
L
Shell
Tire
Maintenance Seminar
SM
90
Roller C
L
Radius
No Axial Runout
(Wobble)

Through
360

Rotation
All Details Must be
Checked

Prior

to

Planning

a

Schedule

for

True-Up

Grinding
Radius
Roller

on

Planned
Slope

Per

Test

with
Gauge

Block

&

Level
or Inclinometer
Kiln Properly Aligned
Slope

is

Exactly

as

Planned.
Rollers

Set

to

Compensate

for
All

Dimensional

Variables.
Matched Liners
Frame

Slope

True
Planned Slope
Level Line
90
Tire C
L
Hot Position
on Roller
180 Liner
180 Liner
Maintenance Seminar
SM
As seen
from Frame
Longl C
L
Tire Ovality - Removal of Metal May Not be Feasible
Anticipate refractory problems starting at about 0.5% shell ovality. Some older tires (new) thin
and at critical ovality. Ovality increases when tire is cut too thin for roller supported operation.
started
Rough Outside
Rough Inside
M
i
n
o
r

A
x
i
s
Major Axis
T
o

F
i
n
d

D
i
a
m
e
t
e
r
Is Bore Worn
and Grooved?
Measure Thickness (t)
t
M
e
a
s
u
r
e

C
i
r
c
u
m
f
e
r
e
n
c
e
Maintenance Seminar
SM
Ovality When Tire is Too Thin
(and has Bad Inside and Outside Surfaces)
Sag
Shell
When a tire is too thin
the combination of sag, crimping and
excessive clearance can account for
shell ovality approaching 0.9%.
Check

out

shell

ovality

factors

before
arranging

for

tire

true-up.

(May

need

replacement

parts).
Excess
Clearance
Crimping
Rollers
Maintenance Seminar
SM
Longitudinal Fractures at Shell Pads
Thin tires and excess clearance contribute to shell ovality and fracture at pad welds or in shell plate
at toes of welds.
Sag
Shell
Thin Tire
Excess
Clearance
Crimping
Rollers
Maintenance Seminar
SM
Tire section CHOKE deformation
Load
Concentration
Narrow
Tire
Welds Break, Blocks Fall Off
Welds and/or Pads Break
and Fall Out & Off
Longitudinal Fracture
Lines Form in Shell
Maintenance Seminar
SM
Shell ovality and pads with full length longitudinal welds, may also include pads with intermittent stitch welds.
Bending Zones
Laminated Zones Resist Bending
Sag
F
l
e
x
Pad Pad
Excessive
Clearance
Crush Points for Bricks
Fatigue Points for Shell
Shell
S
h
e
ll
W
e
l
d
s
Maintenance Seminar
SM
Original longitudinal welds must be removed for repair of fractures.
Shell
Tire
Pad
Fillet Weld Fillet Weld
Maintenance Seminar
SM
T0
.
7
t
Remove Refractory
to Expose Shell for
Tracing and Repair
of Fractures
Use Rotary Wire
Brush to Prepare
Clean Surfaces for
Gouging & Welding
Shell
Inside
Surface
Refractory
Finish internal repair welds first
F
r
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t
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r
e
Maintenance Seminar
SM
Gouge
Finish
Weld
Outside
Inside
Finish External Repair Welds Last
Trace
to
Ends
Tire: Remove
One Set
of Retainers
Move
Tire
Back
Move
Tire
Away
Maintenance Seminar
SM
Shell Outside Surface
Hollow Tires & Rollers
Excessive cutting & grinding on faces of cored tire and rollers has been known to put holes in surfaces
above hollows. Do not reduce original of hollow tires & rollers more than 3. diameters
H
o
l
l
o
w
H
o
l
l
o
w
H
o
l
l
o
w
H
o
l
l
o
w
Bore Zone
Old Style
Hollow Tire
Old Style
Hollow Roller
Real Thickness Varies
Real Thickness Varies
Tr
Tr
Ta
Ta
Apparent Thickness
Apparent Thickness
Maintenance Seminar
SM
Cold Flow Ridges on Tires and Rollers
Ridges must be removed. Sided of tire and rollers must be scraped clean for test with a try square. High ridges
must be removed. Tool must be indexed for surface grinding parallel to shaft C
L
a nd true axis of tire.
Kiln moves inside the tire
with thermal changes in the
shell
Cold flow of surface metal
forms ridges that may snap
off and take along a chunk
of surface metal
Tooling is not complete
without the capability
for removing ridges and
cutting edge radius or
chamfer.
Retainer blocks wear off at
both sides of tire to relieve
pressure. Tire is locked
in place on rollers by the
surface ripple pattern.
Kiln

shell
expansion

&
contraction
Maintenance Seminar
SM
Warped Kiln Shell and Tire Runout
1
2
A
A
Hot Shell
Slope Line
Concave Up
Convex Up
Slope Line
Heavy Load
Hot Shell
C
C
B
B
Maintenance Seminar
SM
Tire Wobble When Kiln Shell is Warped
This condition a valid reason for grinding a tire for improved contact across roller faces.
Find and eliminate for wobble.
Do not arrange for cutting or grinding when axial wobble exceeds 0.125.
is not
reason
Neutral Wobble
3/16 3/16
Wobble
Gap
0.0275
Gap
0.0275
Assume tire wobble (measured total) @ 3/8. Tire outside diameter 16. Tire face 28 (2.333).
0.357 : 16 = 0.0234 per ft. X 2.333 = 0.055 : 2 = 0.0275 v-gaps 180 apart in cross-over cycles.
Grinding will form a parallelogram tire profile, pads will become deformed.
Maintenance Seminar
SM
Wobble Wobble Neutral
3/16
3/16
Gap
Gap
Formation of Concave/Convex Surfaces
Tire wobble not eliminated. Tire face becomes convex, roller faces become concave. Surface true-up is
needed but wobble should be eliminated before any cutting/grinding work is scheduled.
Roller faces will wear into concave contour. Tire face will wear into convex contour. With expansion/
contraction of the shell, large zone of tire moves onto a larger zone of the roller(s). Bearings are overloaded,
shell suffers from reaction to vertical misalignment.
Maintenance Seminar
SM
Aftereffect of Grinding a Tire with Axial Runout
Important Note:
Shell migrates inside tire. Starting with matchmarks AA and BB, first180 of rotation does not show
significant change of tire contact on rollers. In a regular cyclic sequence with migration of the shell,
when original matchmarks are 180 out of phase (BA & AB) original contact crossover v-gap will have
been doubled.
Two (2) full contact zones will be seen at crossover points 180 apart on the rotating tire.
A
A B
B
A A
AA
C
L
A
B B
B B
Parallelogram
Tire

Profile
After

Grinding
180 From Start
Start Rotation
Maintenance Seminar
SM
Runout
Runout Runout
True Axis
True Axis True Axis
Tires & rollers need true-up grinding plus realignment, but ripples on shaft & bearing surfaces may
interfere with adjustments when high points meet and generate heat.
Obvious need for surface true-up, but feasibility of metal removal should be verified by ovality analysis.
As Seen From Below Tire
Tire Roller Roller
Long Term
Toe-In Condition
Tire & rollers
become cone
shaped. Ridges
form at edges.
Surfaces become
deeply spalled.
Opposite thrust
direction of rollers
plus high pressure
and heat can destroy
roller assemblies.
Plastic flow may
form ripples on
shafts & bearings.
Shaft true-up will
require shop work.
Will need new
bearing liners.
Aftereffects of Improper Roller Skewing
Maintenance Seminar
SM
Grinding Prior to Kiln Shell Replacement Work
A - Assume tire not centered on rollers because of wrinkles or other shell problems. Repair work will
move the tire to normal operating position on rollers.
B - Typical wear pattern after long-term operation with tire in offset position.
Tire & rollers must be trued up before shell repair work is started, or to eliminate overload &
misalignment in case of over-expansion or changing position of the thrust tire.
Roller set points must be recalculated to suit tire & roller dimensions after finishing the grinding
process.
A B
Maintenance Seminar
SM
Unacceptable
Cone shaped roller. Surface not parallel to C
L
.
Squareness Control for Rollers
Surface parallel to C
L
.
Acceptable
Maintenance Seminar
SM
Squareness Control for Tires
Tire
C
o
n
t
r
o
l
C
o
n
t
r
o
l
C
o
n
t
r
o
l
Surface is
parallel to bore
Acceptable
90
Tire
Tire
Tire
C
L
C
L
C
L
Neutral
Neutral
Unacceptable
Surface is not
parallel to bore
For control of surface concentricity, test with extra large square and
measure circumference at 3 control points across the face.
C
L
Maintenance Seminar
SM
Kiln Shell Damage and Temporary Repair
Repair of badly damaged kiln shell
Fillet Weld
Bad Repair Good Repair
Shell
Repair
Section
Shell
Wrapper
Not
Recommended
Temporary
First-Aid

only
Longitudinal
Butt

Weld
Void Zones
Double V
Butt Weld
Fillet Weld
Maintenance Seminar
SM
Longitudinal fractures at ring segments
Kiln Shell Damage and Temporary Repair
Typical Field Cut
Kiln Shell
S
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p
p
o
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t
S
u
p
p
o
r
t
S
u
p
p
o
r
t
S
u
p
p
o
r
t
Kiln Shell
Fillet Welds
Reinforcement
Band (Full Circle)
Reinforcing Band
Maintenance Seminar
SM
Tire and Pad Lubricant
for Rotary Kilns and Dryers
Product Description
Maintenance Seminar
SM
Kiln Shell Patch Plates Are Nothing More Than Temporary Band-Aids
When a patch plate is installed between a riding ring and the end of the shell, anticipate warp-related
runout at the end of the shell and in the seal arrangement.
When a patch-plate is installed in shell between riding rings, anticipate riding ring wobble at the nearest
ring (or both) and also at the seal in most situations.
Start planning for shell replacement when two or more patch plates have been or must be installed.
Cumulative effect of weld
shrinkages will warp
patch-plate and surrounding
shell plate inward.
Circumferential
Weld

Shrinkage
Circumferential
Weld

Shrinkage
L
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g
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a
l
W
e
l
d

S
h
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i
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k
a
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e
L
o
n
g
i
t
u
d
i
n
a
l
W
e
l
d

S
h
r
i
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k
a
g
e
Patch Plate
Insert
Kiln Shell
Maintenance Seminar
SM
In sketch all welding is done double-Vee
(butt joints)
Patch plate is restrained at all edges.
Transverse weld shrinkage for plate thickness
is shown in chart. Yield point of adjacent
plate surfaces would be exceeded if the shell
would not be free to move in any direction in
reaction to weld shrinkage stress forces.
In actual installation and welding of shell
patch plates and other inserts, limited shell
plate movement is possible but combined
weld shrinkage stress forces warp the surfaces
within and around the patch plate or add-on
fixture. Base metal at the welds is not far
from the yield point after welding.
Transverse weld shrinkage at
patch

plate

double-vee

butt
welds.

Radius

instead

of

90

corners

minimizes,

but

does

not
eliminate

stress

concentration
points.
Circumferential
Weld

Shrinkage
0
t
1/4 1/2 3/4 1 1 1/4 1 1/2
0.05
0.10
0.15
Circumferential
Weld

Shrinkage
L
o
n
g
i
t
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d
i
n
a
l
W
e
l
d

S
h
r
i
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k
a
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e
L
o
n
g
i
t
u
d
i
n
a
l
W
e
l
d

S
h
r
i
n
k
a
g
e
Patch Plate
Insert
Kiln Shell
60 Single V
60 Double V
t = Plate Thickness (in.)
T
r
a
n
s
v
e
r
s
e

S
h
r
i
n
k
a
g
e

(
i
n
.
)
Kiln Shell Patch Plates are Nothing More than Temporary Band-Aids
Maintenance Seminar
SM
B
Rotary Kiln Installation and Maintenance Repair
Equations For Calculating Shrinkage-
(shrinkage perpendicular to the axis of a weld) is particularly important when the
shrinkage of individual welds is cumulative as, for example, in the shell-to-shell connections between rotary kiln
(and similar machines) riding ring positions (support points). Unless allowances are made for transverse weld
shrinkage - usually by spreading the joint open by the amount it will contract after welding - the cumulative
shrinkage of several shell-to-shell connections could be great enough to significantly shorten the span between
preset riding ring retainer locations or scribed reference lines.
For a given weld thickness, transverse shrinkage increases directly with the cross-sectional area of the weld. The
large included angles in (A) are for illustrative purposes only.
Source - Adapted from text in The Procedure Handbook of Arc Welding published by the Lincoln Electric
Company.
Transverse Weld Shrinkage
A
Maintenance Seminar
SM
Arrangement for Removing Bearing Housing End Plate
Prepare rods (cold rolled steel) for installation as shown, nuts are shown in position for safety stops, but
washers or short bars may be welded at end of rods for equally good results. Rods should not be more
than 24 long.
Housing end plate
with thrust washer
and oil level pipe.
Remove tap bold from
end plate to verify
thread pitch and
diameter.
Kiln support roller
bearing base.
Maintenance Seminar
SM
Place match marks
or reference line
at side of tire
Note rotation direction.
Use trailing end of retainer block for placing a soapstone mark (line) on the side of the tire.
Measurement of Shell Migration
to Determine Shell Pad to Tire Diameter
Maintenance Seminar
SM
Stop Block
FLS Bearing 74, Type RB
20 X 20 X 200 mm
5-6 mm Clearance
Zero Clearance
Discharge End
Feed End
Maintenance Seminar
SM
Feed stencil mark
wiped (or ground)
off of the end of
the shaft.
Feed stencil mark
wiped (or ground)
off of the rim.
Chamfer @
1/8 X 45
Downhill side
of roller
If original feed stencil marks have been eliminated by rubbing or by shop cleanup procedures, look for the
1/8 X 45 chamfer at one end of the roller bore zone. This chamfer will indicate the larger diameter of the
2-diameter bore for the roller.
The step-diameter lockup of roller and shaft requires the chamfer, indicating the larger shaft and bore diameter,
to be aimed toward the low, or discharge, end of the kiln.
Last resort checkout of support rollers for correct installation on support rollers.
FIGURE:
Desperation
Maintenance Seminar
SM
450 mm Oil-Lubricated Supporting Roller Bearing
(Old Design)
Maintenance Seminar
SM
FLS Bearing Clearances in mm
850 -0,1
710 -0,1
630 -0,1
560 -0,1
500 -0,1
450 -0,1
400 -0,1
360 -0,6
320 -0,1
280 -0,1
240 -0,1
850 +1,6
710 +1,3
630 +1,1
560 +1,0
500 +0,9
450 +0,8
400 +0,7
360 +0,6
320 +0,5
280 +0,5
240 +0,4
850
710
630
560
500
450
400
360
320
280
240
0,85
0,7
0,6
0,55
0,5
0,45
0,4
0,35
0,3
0,3
0,25
1,6
1,3
1,1
1,0
0,9
0,8
0,7
0,6
0,5
0,5
0,4
1,88
1,83
1,75
1,79
1,80
1,78
1,75
1,67
1,56
1,78
1,67
1,24
1,00
0,84
0,76
0,69
0,61
0,53
0,45
0,37
0,38
0,30
1,46
1,41
1,33
1,36
1,38
1,35
1,32
1,25
1,16
1,35
1,25
0
0
0
0
0
0
0
0
0
0
0
+1,5
+1,2
+1,0
+0,9
+0,8
+0,7
+0,6
+0,5
+0,4
+0,4
+0,3
0,75
0,6
0,5
0,45
0,4
0,35
0,3
0,25
0,2
0,2
0,15
=0,36
0,30
0,26
0,24
0,21
0,19
0,17
0,15
0,13
0,12
0,10
d
Journal
Kiln erection
Supporting rollers / bearings: Various tolerances in mm
Linear
Clearance
at side
minimum
maximum
Mean
clearance
dp - dt
cold
Mean
clearance
dp

-

dt
hot
Mean value
(dp

X

dt

X

1000)
d
dt
dp
A t 35 ) ~ x
/
cold
hot
d A
X) expansion at t = 35 : d A A 35 X 0,0012 X 1000
100
0,42 mm / m
Maintenance Seminar
SM
Fig. 4
Fig. 1
FLS Bearing
Fig. 3
Fig. 2
0 mm
5-8 mm
3
0 mm
T
Maintenance Seminar
SM
Uneven Load Distribution
Hertz Pressures at Supporting Rollers
Parallel
Skewed Only
Skewed and Change
of Slope
Maintenance Seminar
SM
RR RL
M
a
FH
FV
30
F / 3 + F V H \ R L
R R F / 3 - F V H \
F X a V M
Maintenance Seminar
SM
P
L2
L
R1 R2
R1 = (L2/L) P R2 = (L1/L) P
L1
Load is off Center
Maintenance Seminar
SM
Ends of
Klozure Seal
while being
snaked thru
bearing
base
Bearing
socket
Bearing
cap
Clamping plate
in position
Clamping plate
in position
Klozure Seal assembly
Klozure Seal
in position
1/4 length
Klozure Seal
Seal Retainer
(lower half)
3/32 thick
O.H. Steel
clamping
plate
to be fitted
in field
Detail D
Drill in bearing cap for 3 5/16 X 1-3/4 countersunk hd.
screws with lockwashers for holding top half of seal ring
to bearing cap. Locate holes from seal ring.
A - A
See
Detail
D
See
Detail
C
Bearing
Base
Bearing
Cap
A
B - B
FLS Conversion Kit Instructions for 1930 Type Bearing
Seal Retainer
(upper half)
Detail C
Scale: Full Size
Garlock
Klozure
Split Seal
Patt. Number
RK 5790A
1 - Insert Klozure to lower half of seal retainer ring so that
the ends of Klozure Seal extend beyond the end of the
seal retainer ring with equal distance (see assembly
sketch).
2 - Attach clamping plate loose to retainer seal ring.
3 - Install lower half retainer ring assembly to lower bearing
base by sliding the seal retainer ring, starting on the side
where bearing socket is below end of bearing base
(ref. assembly sketch) until retainer ring is flush with
bearing base.
4 - Tighten clamping plate bolts securely.
5 - Using upper half retainer ring as template, drill 3
clearance holes for 5/16 bolts through bearing cap.
6 - Assembly upper half retainer ring to bearing cap.
(3 pieces 5/16 x 1-3/4 Long Screw).
7 - Gradually lower the bearing cap, insert the Klozure Seal
in the groove, so that the seal ends close at the top center.
8 - Tighten all bearing bolts securely.
Installation of Klozure Seal
Maintenance Seminar
SM
Sketch (below) shows magnet base with a
spring-loaded tracer arrangement mounted on the
surface of a spacerpad. Tracing surface is mounted
on the flat side-face of the tire (or riding ring).
A - The tracing surface and marker may be installed
anywhere in the indicated zone. Actual position
is selected for convenient and rapid set-up during
a brief pause on rotation.
B - Although actual conditions are variable, there is no
differential shell/tire movement during rotation from
position Y to position X.
C - As the shell enters and passes through the
configuration shown between positions X and Y,
motion is recorded on the tracing surface. Shell
creep and pad to tire clearance appear as a wave
pattern on the chart.
Since the kiln shell will advance inside the tire during rotation
the marker must be placed on the tracing surface at the end of
the sheet trailing the direction of rotation. The sketch shows an
approximate pattern after four revolutions of the kiln.
High temperature metal surfaces can cause severe burns. Moving (rotating) machinery can cause hands and arms to
become caught. Avoid personal contact.
Tracing Clearance Between Kiln Tires and Spacer Pads
(Includes

Shell

Ovality)
Finish
Start
A
Maintenance Seminar
SM
Rotation
Kiln Tire
(Riding
Ring)
Kiln Shell
with
Spacer Pads
Roller s
X Y
B
C
C
L
450 mm Oil-Lubricated Supporting Roller Bearing
Maintenance Seminar
SM
1
1/4 1/4
Uphill and Downhill Thrust Roller
Maintenance Seminar
SM
Radial Runout - Polar Diagram
1
2
3
4
5
6
7
8
9
10
11
12
1
9
7
5
5
3
0
1
3
2
6
8
10
1
215
213
211
211
209
206
207
209
208
212
214
216
215
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
Not bad - very little shell deformation and a little out of center.
S
t
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i
o
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D
i
f
f
e
r
e
n
c
e
Approximate

Shell

Center
1
2
3
4
5
6
7
8
9
10
11
12
Maintenance Seminar
SM
Maintenance Seminar
SM
1
2
3
4
5
6
7
8
9
10
11
12
1
6
21
16
7
9
14
24
27
16
10
9
0
5
417
432
427
418
420
425
435
438
427
421
420
411
416
S
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i
o
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R
e
a
d
i
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g
D
i
f
f
e
r
e
n
c
e
This is very bad.
Shell deformation as well as out of center (eccentricity).
1
2
3
4
5
6
7
8
9
10
11
12
6 mm
21 mm
16 mm
7 mm
1
2
3
4
5
6
7
8
9
10
11
12
1
S
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i
o
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R
e
a
d
i
n
g
D
i
f
f
e
r
e
n
c
e
1
2
3
4
5
6
7
8
9
10
11
12
Maintenance Seminar
SM
Kiln Size: Diameter(s) Length
Process Product Production TPD
Product Density: Lb/Ft Feed Density Lb/Ft
Feed Range: TPD, Kiln Slope % or In/Foot,
Rotation Speed (RPH): Maximum, Normal, Minimum
Distributed Loads, from Discharge End ( Ft. To Ft ):
Refractory Thickness (Ins) Lb/Ft From (Ft) to (Ft)
Ft.
Ft.
Ft.
Ft.
Ft.
Typical Coating build-up on Refractory Lining
Ft.
Ft.
Ft.
Item Quantity Thick Lb/Ft
Ft. Tumbler*
Ft. Lifter
Ft. Lifter
Item Quantity Size Length
Ft. Chain
Ft. Chain
Ft. Chain
Ft. Chain
* Tumblers

formed

by

refractory

lay-up.

If

a

Trefoil

section

is

in

place,

or

being

considered, give

dimensions

location

and

Lb/Ft .
Concentrated Loads: Distance from discharge end
Girth Gear Weight (Kips)
Refractory Dam @ High (Ins)
Tube Cooler Location
No. of Tube Coolers , Diameter (Ins) , Length
Feed End Seal Weight (Kips)
Discharge End Cowl & Air Seal Weight (Kips)
Discharge End Castings: Quantity Pounds Each
3 3
3
3
3
Kiln Data Sheet
Maintenance Seminar
SM
H
X
X1
X2
.
3
.
2
.
1
.6
.5
.4
Laser
VII
II
I
Laser Kiln Survey
Layout of Offset Line
Maintenance Seminar
SM
Laser Kiln Survey
Step 1
Tire
Offset Line
Measuring Points
Tire
Slave
Laser
At
Step 2
Maintenance Seminar
SM
Laser Kiln Survey
Step 3
Laser
Laser
Ar1
Ar2
Common
Reference
Target
Step 4
Pmax
P2
P1
Maintenance Seminar
SM
ZH
ZA
ZV
ZV
VV
VH
ZH
OSV.
X2
X1
Y1
Y
H
C
PMAX
R
R
HR
LR
VR
90
Laserstrle
Maintenance Seminar
SM
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
D
i
s
c
h
a
r
g
e

E
n
d
D
i
s
c
h
a
r
g
e

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
F
e
e
d

E
n
d
2 - Support Kiln
3 - Support Kiln
4 - Support Kiln
5 - Support Kiln
6 - Support Kiln
Tire 1 Tire 2 Tire 3 Tire 4 Tire 5 Tire 6
L 7
6B 5B 4B 3B 2B 1B 6A 5A 4A 3A
2S
OHFE
3S
OHFE
4S
OHFE
5S
OHFE
2A 1A
L 6 L 5 L 4 L 3 L 2 L 1
Dim =
L1-1A
Disch
End
Over-
hang
OHDE
Basic
Plate
Span 1
Basic
Plate
Span 2
Basic
Plate
Span 3
Basic
Plate
Span 4
Basic
Plate
Span 5
Feed
End
Over-
hang
6S
OHFE
Dim =
L2-(1B+2A)
Dim =
L3-(2B+3A)
Dim =
L4-(3B+4A)
Dim =
L5-(4B+5A)
Dim =
L6-(5B+6A)
Dim =
L7-6B
Enter Kiln Length and Dimensions Between Tire Centerlines
Zone Shell I Dia. Linear Feet Thickness Cone(s) (Yes or No)
OHDE
Span 1
Span 2
Span 3
Span 4
Span 5
OHFE
Transition Cone Diameters Length Thickness
&
Maintenance Seminar
SM
Kiln Stress Computer Program
For a Fuller Company computer data analysis of stress loading at:
- Kiln Shell
- Roller Assemblies
- Riding Ring (Tire) Ovality
Data to be obtained from plant-operator personnel, installation drawings, when available, and actual
measurements by plant and Fuller Company engineers.
CAUTION:
Drawings and records are often lost with turnover of plant personnel. Independent job shops and
contractors often supply and install replacement material and/or retrofit items which are sub-standard
or which change stress and loading factors.
With or without original reference information, actual lengths, widths circumferences and
thicknesses must be verified per accurate measurement procedures. Use an appropriately calibrated
ultrasonic thickness gauge for measurement of shell plate thickness, especially at zones affected
by erosion caused by abrasive or chemical reactions(s).
Kiln

at

(Company):
Plant Location:
Plant Telephone: ( ) -
Fax Number: ( ) -
Data From:
Fuller

Company

Engineer(s):
Checkout

Date(s):
Title / Department: Telephone Extension:
Maintenance Seminar
SM
Material Flow Discharge End
Heavy
Side A
Side A
Side B
Side B
1st
Int.
1st
Int.
1/2H 1/2H
2nd
Int.
2nd
Int.
Heavy = Heavy shell plate under a riding ring (Tire)
Maintenance Seminar
SM
Material Flow Discharge End
Heavy
Side A
Side A
Side B
Side B
1st
Int.
1st
Int.
1/2H 1/2H
2nd
Int.
2nd
Int.
Level Line
Inch Per Foot
Kiln Slope @ % or
Kiln Shell Dimensions Pier Locations from Discharge End
(Thickness X Linear Feet) 1st 2nd 3rd 4th 5th 6th
Heavy Plate
1/2 H
1st Int
2nd Int
1st Int +
Side A or Side B
Tire Pads (Quantity)
Pad Length & Thickness
Tire Outside Diameter
Tire Width & Thickness
Roller Diameter & Width
Bearing Diameter & Length
Heavy = Heavy shell plate under a riding ring (tire)
1/2 H = C
L
of heavy plate to either of its ends
1st Int = First intermediate plate
2nd Int = Second intermediate plate
1st Int (+) = First intermediate plate extended for gear
Side A or B = 1/2H + 1st Int + 2nd Int plates
Maintenance Seminar
SM
Radial Runout - Polar Diagram for Kiln Shell
1
2
3
4
5
6
7
8
9
10
11
12
1
9
7
5
5
3
0
1
3
2
6
8
10
9
215
213
211
211
209
206
207
209
208
212
214
216
215
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
Not bad - very little shell deformation and a little out of center.
S
t
a
t
i
o
n
R
e
a
d
i
n
g
D
i
f
f
e
r
e
n
c
e
Approximate

Shell

Center
1
2
3
4
5
6
7
8
9
10
11
12
Maintenance Seminar
SM

Fuller KilnErection

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Fuller KilnErection

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Orientation & Common Terminology for Reporting Kiln Details

Kiln Support Frame Setting Reference

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