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EXTERNAL ALIGNMENT PROCEDURE

F()R

ROTARY KILNS. COOLER, DRYERS, AND SIMILAR ROTATfNG MACHINES

FULI-ER CDMPANY

124 BRIDGE STREET, CATASAUQUA, PA. 18032, U.S.A. aUSliIlOIARY OF GENERAL AMEF.AICAN TRANSPORTATION CORF'OAATION

cOMPAmB AND AFFIlJATE91N PARl8. fRANCE • LONOON. ENGLAND. SAN 9ESASTi,MI. ap~ • MEXICO CIfY, MEXICO. TOKYO. JAPAN • SYDNEY. AlJSTll.At.lA • TORONTO AND MON"ffiEAL. CANADA • 6AO PAULO, 81UZJL • JOJ.IANNESIlURIl. SOUTH AfRICA' DUSsaOOAF, WEST GERMANY

]28-15-1-880 I Sheet r of J3

TABLE OF CONTENTS

INTRODUCTION

• • • • • • • ., • • t • • • • • • • • • • • • • • •

REFERENCE HEASUREH£NTS

• • • .. t·. • • • • •

• .• • • • • • 4 •

SETUP FOR HORIZONTAL MEASUREMENTS

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Chec:klng for Pi er Sh t ft i ng . ••••••••. • • • • • •

Hod ~onta I Alignment Check •••••••••••••••••

Alternate Setup •••. ' .•••••••••••••••••

SETUP FOR VERTrCAl MEASUREMENTS

•••• ",.J ••••••

VERT'CAL ALIGNME~T

. . . . . .. . , . . . . . .. . . . , . . . .. .

CORRECTING ALIGNHENT

• • • • • , • • • II·. • • , •

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3 5 6 8

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9 11

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INTRODUCTION

These procedures are In.tended for use In checking shell allgnment.on a rota~y kiln. cooler, dryer, or s lml.l ar type of rot.atlng machine from the outside when benchmarks are not avaIlable as reference points.

A series of procedures are requl red to make a complete alignment check by this method. It is Important to ·perfonn them all, to make accurate setups, slghtlngs, and measurements, and to record data carefully. In many cases, making sketches to depict the condItIons will clarify the nature of an alIgnment problem and help determine the best course for cor rect lng It.

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Refer to the macnlnels Installation, operation, and maintenance Instructions for addftlonal pertInent alignment Information.

REFERENCE MEASUREMENTS

Prepare a sketch of the machIne. showing and IdentIfying each riding ring and support roller. Make the followIng measurements and calculations, recording them on the sketch:

Measure the circumference of each riding ring and calculate its radl us.

Measure the circumference of each support roller and calculate its radl us.

Measure the clearance between each rld·lng ring find the pads on the shell at the top of the machine.

Retain this information for use In making calculatIons and in determining appropriate correctIons in shell alignment.

SETUP FOR HORIZONTAL MEASUREMENTS

In the setup procedure which follows. the object I~ to accurately locate

a transit on a preselected horizontal offset line which Is parallel to the centerlIne of the machine. Once the Instrument Is in the desired position, it 1s left there until all horizontal measurements have been completed. The first and last piers are used as reference points under the assumption that neIther of them has shifted. Subsequent measurement may Indicate this assumption to be wrong and require the selection of other refe rences.

Two horizontal measurements wi \1 be mad a on each pier. As shown In Figure 1, measurements for pier shifting will be made from the cen te r l l ne mark on each support frame and alignment measurements from the horizontal diameter of each riding ring. The location of the offset, therefore, must be selected to permit a clear view of these points through the transit when it Is set up on the firing floor. The offset may be to either side of the

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CENTERLINE MARK ON SUPPORT

OFFSET

MEASUREMENTS FOR SHELL ALIGNMENT

MEASUREMENTS FOR PIER ·SHIFTING

FIGURE 1 HORIZONTAL' MEASUREMENTS

machine. If any enclosures obstruct the line of sight, remove sections of wall siding as necessary.

After se l ect l ng a sul table location for the offset, proceed as follows:

a. Set the transit on the firing floor at a location which gives a clear view along the offset to each of the points where measurements will be made.

b. Select a straIght rod or piece of wood approximately 2 inches by 2 inches and of $ufflclent length to reach from the center of a support mechanism to a polnt at least 6 Inches beyond the offset.

c. Measure the horizontal distance from the selected location of the offset to the centerline mark On the support frame of the reference pier at the discharge end.

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d. From the squared end, measure an equal amount on the rod and make a pencl l mark.

e. At the feed-and pl e r , carefully a'llgn the squared end of the rod with the center l Ine mark on the support frame.

f. Holding the rod horizontally level on the feed-end pier and parallel to the edge of the support beam, sight on Its premarked reference point and lock the transit to prevent Its turning. Hold a pencil point or small target at the reference point to facilitate 5 I ghtf ng •.

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g. Move the rod to the refererrce pier on the discharge end andpos ltlon It in the same way.

h. Without dlsturoing the transit except for elevatIon, sight on the rod at the dIscharge-end pier and mark the point at which the line of sight crosses it. Measure the distance between this point and the p rema rked re fe ren ce po In t.

i. Adjust the position of the transit as necessary until the vertical hair falls on the reference mark when the rod Is placed on both reference piers.

Completion of this procedure locates the transit's line of sight to be equidistant from the machine's centerline at the reference piers and establishes the offset from which the horizontal measurements can be made.

CHECKING FOR PI~R SHIFTING

With the instrument In the setup condition, perform the following at each support mechanism:

a. Hold the rod horizontally level and parallel to the edge of the support frame beam. Move It as necessary to align the reference mark wIth the telescope's vertical hairline.

b. Measure and record the distance from the squared end of the rod to the centerline mark on the support frame. The measurement Indicates the amount the pier has shifted horizontally.

The figures recorded wi 11 be used In determining the type and amount of corrective alignment to be taken after all measurements have been taken.

If significant varlatlons have been recorded, prepare a sketch showing the relative positions of all support mechanism centerline marks. Analysis

of the sketch may indicate that corrective alignment can be minimized by selecting one or two different reference piers.

The feed-end and discharge-end piers are used Initlal1y because of their being at the ends of the shell and because, wIth housings and and other equipment attached to them, corrections are not as easily made at these

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locations. If chan91ng a reference potnt Is advisable give special consideration to the thrust pier. Usua~ly It Is desrrabl~ to avoid changes In the mesh and alignment of the drive and pInion gears or In the al ignment of the other drive components. In addl t Ion , the relationship of the thrust roller centerline and the k l In centerline established 'at Installation must be maintaIned, and there 15 little lateral adjustment which can be made to a thrust roller.

HORIZONTAL ALIGNMENT CHECK'

The object of the horizontal alignment check Is to determine the amount the shell's actual centerlIne deviates from Its true centerline In the horizontal direction. Quarterpolnt readings from the riding rings to the offset are taken on each pier and compared with a similar dimensIon derIved from the precedl n9 measurements . The dl fferences be-tween them represent the horizontal deviation of the centerline. Proceed as follows:

a. Square at least One end of a straight pIece of 2 Inch, by 2 inch wood, tong enough to extend from the horlzontel diameter of the shell to a point about 6 Inches beyond the offset.

b.

Using a centerhead and level In the manner shown In Figure 2, determine and mark the horizontal centerpoint on the face of each riding ring. Level carefully to obtaTn an accurate mark.

Hold the squared end of the rod against the centerpoint mark on the first riding ring, keeping It horizontally level and at rIght angles to the ring.

With the transit still In Its setup posltlon~ sight on the rod and mark the point where the line of sight Intersects It. Measure and record the distance from the squared end to the mark.

c.

d.

e.

Repeat steps c. and d. at each riding ring.

Referring to Figure ). determine for each riding ring the dimension Ze by subtractln9 the calculated riding ring radius R tn the reference measurements from the distance em measured In the check for pier shifting.

f.

g.

Compare the Z distances measured In steps d. and e. with the Zc figures calcuTated in step f. Differences between the two figures at each pier represent the deviation of the actual centerlIne from the true one.

h.

Rotate the shell 90t 180, and 270 degrees, making and recqrdlng Zm measurements for each riding ring at each quarterpolnt.

I.

Compare all four quarterpolnt measurements at each riding ring to determine if an average dev l at Ion dimension should be calculated for ~ny ring prior to using the figures In the realignment analysis.

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CENTERPOINT

RIDING RING

CENTERHEAD

LEVEL

FIGURE 2

RIDING RING HORIZONTAL CENTERPOINT

This completes the horIzontal measurements. Proceed with the vertical setup and checks.

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RADIUS R (Calcufated)

OFFSET

Zm (Measured)

Z c (Calculated)

CENTERLINE MARK

em (Measured)

FIGURE 3

HORIZONTAL MEASUREMENTS & CALCULATIONS

ALTERNATE SETUP

At some installations It is Impossible to sight the transit from the firing room floor for horfzontal measurements. In such cases, it 15 usually possible to make the setup on a corner of the pier at the discharge end and gain a clear I ine of sight by removing guards, ralls, and other minor obstructions. To use this method, proceed as fol lows:

a. Select a point On the pier whIch will give line of sight visibility to each pier and rIding ring. Mark the point wi th a punch.

b. Setup and align the transit wHh the punch mark, using the plumb bob.

c. Measure the distance from the punch mark on the pier to the cen te rline mark on the support frame beam.

d. At t~e feed-end pier, establish a reference poInt on the pIer the exact dIstance from the centerlIne mark measured In step c.

e. SIght the telescope on the feed-end reference mark and lock the trans it.

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This completes the setup. Us-e the procedure detaf'led in the precedlnj' . paragraphs to make the horizontal measurements.

SETUP FOR VERTICAL MEASUREMENTS

rn the setup procedure for vertlca1 measurements, the object Is to accurately position the transit on a line·parallel to the centerlIne of the machine but offset above the shell. Once the rnstrument Is at the desired height and the telescope locked at. the machfoe's angle of slope, it is left there until all vertical measurement s nave· been completed. Th I s procedure uses the discharge-end and feed-end rl·dlng rings as reference points.

Proceed as follows:

a. Set the transit on top of the firehood with ·the line of sight along the centerll.ne of the machl.near.l·d·at the shell's angle of slope. Adjustments to this Initial setup will be made In subsequent steps. As necessary, remove panels from enclosures to gain a clear vIew of each riding rIng.

b. Square at least one end of a straight plece of 2 inch by 2 Inch wood, long enough for' convenient uSe in making the measurements

described below. .

c. Using a centerhead and level In the manner Illustrated In Figure 4, locate and mark the top end of each ridIng ringls vertical diameter.

d. At the feed-end riding ring, use a.Ieve l to hold the wooden rod plumb with the back edge of the squ~red end against the centerline mark in the 'manner shown in. FI~ure 5.

e. Sight ontbe vertical rod and mark the: point where the telescope's horizontal hair crosses the r6d. Use a pencil point or a small rectangular target to assist in sighti'ng.

f. Repeat 5te~~ d. ~nJ·e~ at the discharge-end riding rln~

g. Make a correction to account for any differences in ridIng ring radi i which Were calculated under the paragraph entitled REFERENCE MEASUREMENTS. If one ring Is smaller than the other, add the difference to the smaller and make a new mark on the rod for that ring.

h. Adjust the position of the 'transit until the marks as corrected l ns tep g.both..fall on the.ho~Tzontql hal r without changing the l ns t r-umenr ; When alIgnment Is abhle~e.d~ Icck the .transit. No further changes in height or elevatIon will be made unti 1 all vertical measurements have been completed.

This completes the vertical setup. The t rans i t l s line of sIght Is now

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vertical from and parallel to the machine's true centerlIne.

CENTERHEAD

RIDING· RING

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CENTERPOINT

FIGURE 4

RIDING RING VERTrCAL CENTERPOINT

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LINE OF SIGHT

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LEVEL

CENTERLINE MARK RIDING RING

FIGURE 5

TECHNIQUE FOR VERTICAL MEASUREMENTS

VERTICAL ALIGNMENT

The object of the vertical alignment check ·1, to determine the amount th, she I I' s actual centerline deVlat.s from the true cente rn ne In the ve r-

ti cal direction. Quarterpoln' reeding, from the riding ring' to the off-

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When making adjustments, keep the axis of each roller paralTel to the axis of the machine. ParallelIsm can usually be determined by usIng a trammel to measure from the center of the roller shaft to the centerlIne mark on the support frame. On floating kl lns , reskew the rollers after the machine is back in operation.

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INSTRUCTION MANUAL FOR

ROTARY KILNSJ COOLERS) DRYERSJ AND SIMILAR ROTATING Mr\CHINERY

L

FULLER'COMPANV

A GATX COMPANY

P,O. BOX 29, CATASAUQUA, PENNSYLVANIA 18032, U.S.A.

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COMPANIES ANO AFFilIATES IN PARIS, FRANCE. LONDON, ENGLAND. SAN SE8ASnAN, SPAIN. MEXICO CITY,MEXICO • TOKYD, JAPAN. SYDNEY. AUSTRALIA TEHRAN. IRAN • T0l10NTO ANO MONTREAL, CANADA. BAD PAULO. 6RAZIL • JOHANNESBURIJ, SOUTH AFRICA. DU8SElOOfll', WEST GERMANY

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TABLE OF CONTENTS

r NTRODUCn ON

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INSTALLATION

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• «

Pre·fnstalJatfon Considerations Foundations Support MechanIsms Shell

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Main Gear and Pinion

orr ve Un' ts •

Electrical fnstallatlon Fire Hood

Feed Hood

Nose RIng

Burner ••

Refractory LinIng Check-Out

Drying R~fractory Post-InstallatIon Idle Tfme

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• • • oil • • •

OPERATING f NSTRU CT IONS • • • • • • • ·
Safety · ·
Stopping . · • • •
Emergency Shut-Down • · • · ·
Power Failure • • • • • • · • · · ·
Auxiliary Orlve · • • .. • • · • · • •
Skewing ~llers · • • • • • • • · • • • .
Cold Weather Operation • • • • • • • • · • MAINTENANCE

Check I Is ts and Records Lub r I cation

Ki In Alignment Auxiliary Drive Unit Refractory

Main Gear and PinIon

Support-Roller Bearings Thrust~Ro'Jer Sleeve Bearings Errat1c KIln Rotation

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SPARE AND REPLACEMENT PARTS

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5
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26
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INTRODUCTION

These instructions cover the Installation, operation and maIntenance of Rotary Kilns, but because of the many simllarltle~ which exist, they are also generally applicable to Coolers, Dryers, and other rotating machines.

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Machines of this type do not operate in an independent environment, but are always part of a system which Includes a number of other pIeces of equipment, all of which must function together under close control. The system can exist in many sizes and configurations dependIng on the ~pplication. The same Is true for these machines. In addition, the nature of the feed materIal and the results to be achieved determine the characteristics of the process and the detailed design of the machine. For these reasons, each machine varies as necessary to accommodate the application. Regardless of these cons l derat lons , all of these rotary machines are similar in basic design, function In the Same ways, have the same basic relationships with other elements In the system, ·and require the same general considerations far installation, operation, and maIntenance. It Is these factors with whIch these instructions deal.

I NSTALLA T·ION

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Installation is to be made In accordance with the drawings provided. They define the physical arrangements, per t I nent dimensions, mechanl.cal and electrical Interconnections, ratings, capacitIes. loads, and other

. characteristics, data, and Information needed In the erection and Installation of all components supplied. The arrangement and assembly drawings designate all parts by Item numbers. The parts l l s ts are arranged In accordance wlth these Item numbers and Identify each item by its proper name.

While there Is a general, over~al I sequence of installation which wIll be fol lowed, there are many details for which the sequence will be determined by conditions existing on site, some of which will be determined by the design and configuration of the machIne itself, and others ·for whIch the sequence can be determined by local preference. Also, many different methods and techniques can be used to achieve the deslred results in a satIsfactory manner. In those Instances where these instructions provlde·tne detaIls of a technique, the purpose is to suggest one which has been used successfully rather than to Indicate a mandatory course.

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This section of these instructions provides an overview of the lnstalla-

t I on and presents I mportant data 11 on f nd I v" dua I a55emb Ii es components a~d various other facet~ of installation which will be helpful In deter~ mIning and employIng the sequences and techniques used at a specific site.

PRE-INSTALLATION CONSIDERATIONS

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The Kiln includes pr-eclsTon bearings and a number of machined surfa~es and' parts, . all of which .requl re protect Ion from.adverse amb-ient condl w Hans •. ' Al though these components are adequate ly protected for sh i pment ,

'the protective materIals have a re l at l ve ly l lml ted life and should not be depended upon for extensive periods. At the tIme that each of these coro~ ponents Is to be Incorporated Into the assembly or mated with other parts, I't Is essential that It be cleaned and Inspected thoroughly .. Bearings . must be cleaned, flushed, and lubricated. Coat all Internal surfaces of bearings with bearing lubricating all. Do not use grease. If the bearings will be Idle for an extended period after cleaning, it Is suggested that undiluted STP Oi I Treatment or· an equivalent product be used to form the coating.

The Kiln Is shipped In a disassembled s tate for erection on-s l te , The shell is shipped In sections which must be pOSitioned, aligned, and welded· together. Before Installing parts, remove the protective coatings appl led for protection during shipment. Machrned surfaces, 011 passages and

pipes, water passages and pIpes, and reservoirs must be free of all foreign matter. Inspect all machined surfaces and screw threads to be sure they are fn·proper·condltion for assembly.

Whenever practical, the Kiln should be enclosed in a suItable structure to protect it· from-wlnd , rain, and snow. These elements tend to cool the she'll and put compress I ve forces on the ref racto ry wh I ch can cause I t to crack. Rotation of the Kiln cannot be. stopped In the presence of these elements because the uneven cooling can cause serious warping which may be both difficult and expensIve to correct.

FOUNDATIONS

The Kiln and Its drive units are to be Installed upon foundations which'

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must be designed to support the weight of the equipment and the loads o:currlng durIng operation. These loads and the general foundation outlInes are Identified on the drawings, but the detailed design Is dependM ent upon the nature of the geologIcal substructure on whIch they rest at the specific site. Particular attention must be given to avoiding condftions which could result In settling. The ability of the Kiln to retain Its al ignment depends prlmarfly upon the foundations remaining fixed.

It Is of particular importance that the piers are properly located with respect to elevation, spacing, and alignment. The alignment of the Kiln and center-toMcenter spacing of various components depends on the precise location of the foundations and foundation bolts. Their positions should be checked and rechecked to ascertain that they remain fixed. The top of the foundations should be left rough to provide good anchorage for grout.

To aid future Kiln alignment checks, permanent bench marks should be provided on each pier. The bench marks should be brass plugs located on the top of the piers on each centerline in the plan view. ,Bench marks for use In checking for movement of the foundations should be established away from the foundations .

. The location of foundation bolts with respect to both plan and elevation should be checked carefully against certified drawings. Their location with respect to those on other pIers must also be checked. Frequently, the longitudinal centerline through the piers is obstructed. In such a case, run an offset line on the side away from the drive and measure all locations from it. Use diagonal measurements to verify that the bolts

have ,been located squarely. Make certain that allowance Is made for shims, grout, equIpment bases, and mountIng hardware.

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SUPPORT MECHANISMS

After the foundations have been completed, the support mechanisms must be assembled on the piers. The frame is the first component to be mounted, and it is positioned with particular care. The bearings and rollers are then placed on the frame, located with respect to the frame's centerline. and aligned with respect to each other.

FRAMES

The Installation of the frames requires the use of shims. It Is recorn-

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mended that the supply of steel shim stock for use on each pier ccns l s ts of 00: plege each of 1/16-tncht 1/4-lnch, 3/8-rnch. and 1/2-inch thickness In 3-lnch widths and 16-foot lengths; two pIeces I-Inch thick by e!ther 3 or 2 Inches wIde and 16 feet long; and standard rolls of 6-1nch wide s tcck In thicknesses of 1/32-fnch, ,010 Inch, .008 Inch •• 006' Inch',

.004 Inch, and .002 inch. Cut the shims to 4-inch lengths. '

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NOTICE

SETTING THE FRAMES FOR THE SUPPORT ROLLERS IS THE MOST I HPORTANT AND TI ME CONSUM I NG PART OF THE t,NSTALLATI ON PROCESS. IT MUST BE DONE WITH PARTICULAR CARE AND EACH STEP CHECKED AND RECHECKED. THE FINAL CHECK IS TO BE MADE IN THE EARLY MORNING BEFORE DIRECT RAYS FROM THE SUN AFFECT THE SETTING.

Each frame rests on stacks of shims which ra lse It to the specified e le.vat Ion, The stacks of shIms are located On both sides of each foundation bolt. The bottom shim In each stack Is usually of I-Inch-thick stoc~, set in grout, and leveled In the transverse direction but parallel to the slope of the Kiln In the longitudinal direction. The bottom shim Is set low enouqh to allow additIonal shll1Jl1lng. The s-him should be centered with ,respect to the web of the support beams rather than the anchor bolts. The anchor bo l t s pass through the sides of the beam flanges and using them as

a reference would result in the shims being Incorrectly located. The bottom shim In each stack is'set by placIng a small amount of grout under it, then carefully posItioning It. The grout should be allowed to set for one to two hours J then the l eve loess and 'slope rechecked. After the shim has been positioned accurately, wrap the grout in wet burlap and allow It to set for 24 hours, After this period, recheck the shlm's position,

Once the bottom shims have been properly posItioned and verified, the frame can be p I aced on them. The top can be I dent! f l ed because j t and the inner edges of the top flanges have been machined. Some frames are marked to indIcate the feed sIde. When tnls mark Is present, set the frame so that It Is on the up-htll sIde. Unless the KIln Includes a hydraulic thrust system, only one thrust frame will be provided. ThIs frame is used under, the rIdIng ring closest to the girth gear. To assist In alignment,

,both centerlines of the fr.ames are marked by saw cuts in the flanges.

Each frame must be set to the exact elevation, slope, and center-to-center distance between piers specified. Add shims to each stack to ra lse the frame to the specified elevation and. set the centerllnes of the frame to the centerl Ines of the pier. A block tapered to the correct slope is provided for each installation. It should be used In conjunction wIth a

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machinlstls leve_] to achieve the specified angle. The center~to-center distance from one pier to the next is measured 'with a tape. It is mandatory to use a spring scale to apply tension to the tape while the measurement Is beIng made and a thermometer to Indicate the temperature of the tape at the time of the measurement. The tape measurement must be corrected to a temperature of 700F.

When the frame has been accurately posItioned and bolted down. °it is rechecked. The center-to-center distance from one pier to the next should be within plus or minus 1/16-lnch. The tolerance on the elevation Is plus or minus 1/16-lnch. The slope must be w1thin 0.002 inch-per-foot, and In the transverse direction it must be within 0.002 inch-per-foot of being levei. The final check of the slope is made ,on the rollers after they have been assembled to the frame. At that time It may be necessary to make mInor adjustments In the shImmIng to keep the Installation with-

in the specified tolerance. 0

BEARINGS AND ROLLERS

After the frame is In place and secured, the bearings and the rollers they support are assembled to it. The machined surfaces on the frame are lubricated wIth a graphited grease or some other anti-seizing grease before placing the bearings on It. When ant l-f rl ct lon bearings are provl ded , they are assembled to the rollers at the factory. When sleeve bearings are supplied, they mus t-be assembled to the rollers on-site. They may be assembled In place or subassembled first then lifted into place.

If the bearings and the roller are assembled in place, one bearing is mounted on the frame, the end of the roller shaft slipped into it, then the oth~r bea~in9 s1 ipped onto the other end of the shaft. The shaft must be supported in positIon so that the second bearing can slide across the frame and onto the shaft. Rollers are stamped to identify the feed end and must be posItioned accordingly. It Is also permissable to 5ubassemble the roller, shaft, and bearings on the ground and 1 ift them into position as a un i t.

When' lifting a bearing-roller subassembly, It Is mandatory that a proper 51 ing arrangement be used. Provide a sling for each bearing and use a spreader bar. Make certain that the roller shaft will be In constant, full contact wIth the bearings and that the entire subassembly will remain level while It 15 being lifted.

CAUTION

DO NOT LIFT THIS SUBASSEMBLY BY THE ROLLER

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Set the bearings from trammel measurements made between the rollers and the centerline marks on the frame. If the Installation Is being made from an offset line, the roller nearest the line should be set from the line, and the opposIte roller set by a pin gauge between the rollers. When the bearings ar~ properly set, both rollers wtll be parallel to each other and

to the longitudinal centerline. Check for parallelism by placIng a straightedge across' the machIned edges on the ends of both rollers. It Is not Important for the ends of the rollers to be In line with each other; only

. that they be parallel.

Sleeve bearings are not secured to the frames, but provls Ions are made for each anti-friction bearIng to be held down by four bolts.

After sleeve be~rjo9s and theIr rollers have been assembled and posItioned. they must be checked for shaft end-play. Total space for movement of the shaft must be not less than that shown below for the corresponding roller sIze.

ROLLER DIAMETER

MINIMUM ENO"PLAY 1/16-lnch 1/8-1 nch 3/16Ylnch 1/4-lnch

33 through 39-lnch 42 through 72-lnch 78 through 84-lnch 90 Inch and up

If additional clearance Is required, either remove stock from one of the thrust key~ mounted be tween the bearIng base and the support or Insert gaskets behind one of the end covers.

With the sleeve bearings and rollers set, the seals, oil elevators, and other ancillary Items can be Installed when It Is convenient to do so. A shaft seal Is Installed on the s l de of the bearIng nearest the roller and· held in place with a cOVer plate. Otl-flll pipes for the bearings are in two sizes. The longer up-right pipe belongs on the down"hIII bearing; the shorter one up-hlll. The threads on the all fill pipes should be covered with pipe fltter's dope or teflon tape and screwed In tightly to avoid leaks.

The bearing e~d plate must be removed to Install theoi I tray and the oil elevators. Care must be taken In Installing the tray to allow clearance for the elevator to rotate wl thout strikIng It. In assembling the oil elevators, make certain that lock washers are placed on the bolts and that the bolts are secured tightly to the end of the shaft. It is possible to Install the elevators backwards. Check them with respect to the direction of roller rotation and verify that they are Installed to f l l l with all at the bottom of the sump, 11ft it, then pour It at the top of the shaft.

Water must be piped to each bearing for cooling. A suggested pIping arrangement is shown on Figure 1 which also tabulates the quantIty of

]28-75-1-8800 Sheet 8 of 46

water required at each pier according to t~e size of rollers employed. Oraln J rnes should include an air-break and funnel to permit observation of the flow and to make temperature checks. Because the movement of the bearing toward or away from the shell can range between four and frye inches, the lnlet lines must Incorporate flexible sections. The funnel for the drain lines must be of a design which wilT also acconmodata such movement. Instal1 a valve In each Inlet line to permit control of the flow. Locate pIping so that it doesn't Interfere with the Use of the bearing positioning screws. The piping and funnels are not normally sup-

plied as part of the Kiln. .

After final assembly of a bearing has been completed. fil I Its sump with oil. Refer to the lub-r l cat l on instructions In the MAINTENANCE Section.

THRUST ROLLERS

Thrust rollers are installed before the she1 t sections are posItioned. Offset them 1/16 to 1/8 inch toward the downward-turning side of the shell so that when they are in ~ontact with the rotating riding ring there will be a small, downward thrust to keep them seated In their support brackets. There is an o l l+f l I I standpipe for each thrust roller. The longer one goes on the down-hill roller; the shorter one up-hill.

Shims placed between the back of the brackets and the lug on the top of the frame are ~sed to achieve and maintain the specified spacing between the thrust rollers and the riding ring. The lr final Installation cannot be completed until the shell Is Installed, welded, and the riding rIng is in its final locatIon. After this has been accomplished, and if they are included for this Installation, the bracket and block of graphite by which the face of each thrust roller Is lubricated can' be mounted.

On full thrust machines, only the dOWn-hIll thrust roller has the full thrust capabilIty. If this thrust roller contains a sleeve bearing, it Will be water-cooled and it will be necessary to Install pipIng to and from It. If a hydraul Ie thrust mechanIsm 15 provided, refer to tne separate Instructions for pertinent InstallatIon informatIon.

GROUTING

When the mounting of the components of the support mechanIsm has been completed, the frame can be grouted. The shrms must remain In place. If there r s any grease or of I on the top of the p le r , f t must be removed or neutrallzed; otherwIse, it wil1 prevent the grout from bonding.

The rough top of the pIer must be thoroughly saturated wIth water to

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·prevent.absorption of water from the grout and to Insure a good bond bebNeen toe grout and the concrete. Keep the pier wet for at least 12 hours before grouting If the foundation 15 less than 28 days old and for at least 24 hours if it is more than 28 days old.

The grout should be dry-packed If practical, otherwise, concrete of 2-to- 3-lnch slump can be used. If des fred, a metallic ncn-shr l nktnq grout can he used wIth standard cement. Use one part cement to one.part coarse, clean sand. ~f the grout thickness specified on the drawing fs 2-1/2

. Inches or more, add one part 3/8-fnch or liZ-inch clean stone.

Start from the outside of the beams and work from the Inside only when grout from the outs ide appears on the los r de. Grout must fi 11 the. space under the beams to insure full bearing at all poInts. It is customary to grout up onto the beams to at least the top surface of the bottom flange.

The grout should sat from 18 to 24 hours at temperatures above 700F pefore the forms are removed. I f the temperature Is below 70oF, the followIng applies: at 60oF, 2-1/2 days; at 4ooF, 4-1/2 days. The grout should be allowed to set for at least 7 days before the equipment is placed. in

"operation. If the grout manufacturer's Instructions are available, however • . follow them.

After the forms are removed, the edges of the grout should be kept damp for several days, then a comaerc lal curing compound app l I ed,

SHELL

The shel l is sh I pped In se.ct l ons , the lengths of which are determined by I imItations Imposed by transportation and handling facilities. Bracing is welded inside each section for shipment to help prevent distortion

wlli Ie it Is being handled. Depending on the diameter of the shell. the riding rings mayor may not b~ factory-assembled to their shell sections, If they are not, they must be put on before the shell sections are pOSitioned on their support rollers. After the sections are hoisted into position. they are aligned, then welded together. The alignment of the shell Is a critical aspect of the Installation and must be accomplished wi th accuracy.

MOUNTING RIDING RINGS

Al I riding rings are not Identical, and there may be a difference between the up-hill and the down-hill side. It is necessary to check the drawings

728-75-1-8800 Sheet 'I of 46

and the parts themselves to determIne which ring mounts on a given shell section and what Its orientation should be.

87fore assembling a rIng to Its shell sectIon, clean the bore of ' the

rIng and the mountIng pads on the shell, then lubricate them with a heavy graphite-treated grease. The ring Is then supported, usually by" a"sllng , threaded through the boret and gurded onto the shell. PosItion It between the lines scribed on the pads. A third line Is also present, but It Is offset for use in makIng measurements. In handlIng the rings, protect' their machined surfaces.

Because of variations which can occur at the JoInts between sections, the final positioning of the rldl"ng rIngs should not be made until 'after the shell is welded. Refer to the paragraph ent-1tled SETTING THE RIDING RINGS.

SHELL ERECTION AND ALIGNMENT

Shell sectIons are usually Itfted onto the rollers by cranes, then suppo rted by sui table temporary structures. If cribbing Is used, it should be ~ullt carefully using only sound timbers. If A-frames 'are used, they must be sturdy and rIgid. Handle the shel I ,sectIons In a manner which will protect them from distortion.

The shell sections are to be positioned so that the longitudinal seams do not form continuous lines. 'When there are two seams, position each section so that '1 ts seams 'are about 90 degrees apart from those In the adjacent section. When there Is only one seam, posItion each sectIon so that its seam Is about 180 degrees apart from the one In the adjacent section. Sometl~s it Is necessary to rotate the shell with a winch or,some other source of power to secure this alignment. If a cable Is wrapped around

the shell for this purpose, keep It as close as practical to the riding ring. Another technique I~ to slip a bar between the mounting pads undet the 'riding ring and loop the cable, around It.

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Provisions are normally made for the supportIng structure to Incorporate Jacks to adjus t the position of the shell sections. Construct cradles which will distribute the force from the Jacks over an area large enough to avoId distorting the shell. 00 not place a Jack in dIrect contact with the she l l ,

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With the sections supported In positIon as close as practical to each other, remove the Internal bracl'ng at the Joint ends. Do not disturb the bracing at the riding rings. Because of handling and shipping, It may be necessary to correct out-of-round conditions at the Joint ends to secure proper mating for welding. A number of alignment fixtures are then tempo ra r l lv welded into position around the InsIde of the shell at the Joint to draw the tw~ edges together and a1 Igo them with each other. Some

72.8-75- J. B800 Sheet 12 of 46

al ignment fittings are supplied, but generally the dogs, wedges, and strongbacks must be fabricated in the field from plate supplied for 'this purpose.

A typical arrangement of fixtures at a Joint are shown in Figure 2. The dogs and wedges are used to secure alignment; the strongbacks are then welded in positIon to retain It. Alignment fixtures remain in place until the outside of the joInt has been welded. Refer to the paragraph entitled WELDING SHELL JOINTS for Instructions.

CHECKING ALIGNMENT

After al I sections have been aligned through the use of the adjustment devices, the overall alignment of the shell must be checked. The usual procedure is to install a series of batter boards on the Inside diameter of the shell at key locations, determine the center of the shell at these locations. then USe a transIt to check the alignment of this series of centerpoint5. Adjustments In the alignment of the shell sections are then made as necessary. Several fixed I ights are required in the Kiln, along with a portable light whIch can be taken to any location throughout its length. Field telephones or two-way radios are invaluable for communic~tion during the checkIng process.

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CAUTION

UNEQUAL TEMPERATURES, EVEN A fEW DEGREES, W[LL CAUSE A KILN TO BOW. WHlLE MAKING THE FINAL ALIGNMENT OF THE SHELL, ADJOINlNG KILNS OR OTHER SOURCES OF HEAT SHOULD BE SHUT DOWN, AND THE WORK SHOULD BE PERFORMED ON A CLOUDY DAY OR AT NIGHT SO THAT THE SHELL IS NOT HEATED UNEVENLY BY THE SUN,

The internal metal bracing at riding ring locations should be removed. Batter boards, usually 2 x 8'5, are set across the diameter of the Kiln

728· 75- , .. 8800

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and wedged tightly to prevent any movement. ' As shown in Fi'gure 3,

boards should be located at both ends of each riding ring, near the Joint between each section. and near the feed end. PosItion th~' boards at the field Jo lnts and feed end about 18- inches to the down-hl l l s Ide. Those at the rfdfng rIngs should be located close to'the gauge blocks. The center of each board is located and a hole about two Inches In diameter Is bored through it a,t that point. A ffle card is then tacked over the hole usIng two or three thumb tacKS across the top edge and one to hold the bottom edge in place.

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At the feed end and at the fIeld Jotnts. two sets of quarter points are used to locate the center of the Kiln on the cards In the manner shown In

Figure 4. '

The first set of quarter points - four points on the inside of the shell which are 90 degrees apart with respect to the center - are established Immediately to the down-hill side of each batter board. A trammel fItted with a pencil and set to be about 3/4-1nch longer or shorter than the inside radius of the Kiln is then used to swIng an arc from each of the quarter points. These arcs will Inscribe a figure on the card which is, ess~ntially, a square. Drawing the diagonals to this square wit I establish the tenter point of the Kiln as determined by this set of quarter

po Ints.

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Offset the second set,of quarter points 45 degrees from the first set and use them In the same ~ay to determine the center point of the Kiln again. If the two centerpoints do not coincide, mark a point half-way between them and Identify l t as the center. Refer to Figure 4.

Only one set of quarter points Is used at ridIng ring locatIons, and these are establ fshed on the lower step of the gauge blocks Inside the shell. SwIng the arcs from them and draw the two diagonals to locate the center po Int.

At the batter board on the down-hill side of the rIdIng rIng closest to the discharge end, drop a plumb-bob from the center point on the card to the shell. Mark the point on the shell with a' center punch, then set

the length of the trammel to be exactly equal to the vertical distance from the punch mark to the center point. Remove the batter board from this locat Ion , position a transit over the center mark, and set its he l qht to equal the length of the trammel. Refer to Figure 5. Set and level the instrument carefully.

Remove+ the thumb tack from the bottom of a 11 cards between the trans i t and the most dIstant riding ring, bend them upward, and secure them with the tack so that the holes are unobstructed. Sight on the center point of the second card at the last ring. This establIshes the centerline of the Kiln against which the center point On each of the other cards is to be checked.

728-75-1-8800 Sheet 15 of 46

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FIRST SET OF QUARTER r. POINTS IDENTIFIED

BY ""~ ,,. OffSET

SECOND SET OF Al .

QUARTER POINTS

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·-CENTER POINTS

DETAilS ON CARD:

SELECTED CENTER

CENTE·R·BY FIRST ssr OF QUARTER POINTS,-------'

fIGURE 4 lOCATING THE CENTER OF THE SHELL

CARD ON BATTER BOARD

ARCS AND DIAGONALS FOR FIRST POINTS

ARE SOLID;OASHED FOR THE SECOND SET

728-75-1-8800 Sheet 17 of ~6

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128·15'" "'8800 Sheet 18 Of 46

Without changing the Instrument, sight on each card In succession, including the one at the feed end, and make a penc l l mark at 'the precise point where the I ine of sIght through the lns trement l'nte+sects It.

Sight on the tIp of a sharp pencil being moved across the card until It is aligned with the crossed hairs. The objective of this check is to determine the amount of misalignment at each location so that correctIons can be made to get the center point on each card as close to being coincident wIth the poInt established by the Instrument as It Is practIcal to achIeve. Any adjustment which can be made to improve alignment should be made.

At field joints and at the feed end. the center point of each card must be within 3/32-fnch of the point estBbl ished by the Instrument. At the riding rings the alIgnment is partIcularly Important, and there are two factors to consider. The offset at both locations on each ring must be reduced to a minimum. but they must also relate to each other In that any discrepancies which remain after adjustment has been completed must fall within the same quadrant when viewed through the Instrument. If one centerpoint Is on the opposite side of either centerline from the other, there wIll be an undesIrable motion In the ring section when the machine Is placed In operation.

Discrepancies at riding ring locations are corrected by adjusting the rollers. If the frames and rollers were Installed carefully, any adjust .. ment required should be minor. Misalignments at the other locations are corrected by adjusting the Jacks used to support and positIon the Kiln sections, adjusting the alignment fixtures inside the KIln at the jOints, or both.

If any adjustments are required, recheck the alignment of all points after they have been made. When the alignment has been satIsfactorily established, leave the instrument, batter boards, and alignment devices in place. AlIgnment Is checked after the Joints have been partially welded and again after the welding has been completed.

WELDING SHELL JOINTS

When the alignment is satisfactory, the strongbacks are welded across the seams and a series of tack welds are made on the Inside to maintain the alignment. The checking of alignment, the welding of strongbacks, and the tacking of joints should be accomplished In one night.

NOTICE

DO NOT ROTATE THE SHELL TO FACILITATE WELDING DURING THE ALIGNMENT AND TACK-WELDING PERIOD

Prior to welding, verify that the al'lgnment fittings lns lde the KIln are tight, then weld eIght or more 1-lnch x 4-fnch x 20-lnch strongbacks edgewise across the Joints In the manner shown In Figure 2. With the strongbacks in place, about 8 tack welds, each about to Inches 10ngJ should be spaced ar9und the Joint. TackIng should be done with 5/32- or 3/16wlnch diameter AmerIcan WeldIng Society (AWS) £ 6010 or 70XX serIes electrodes.

After· the tack welds are completed, recheck the alignment. When It Is

sat l sfactorv , the outside of the Joint cen. be completely welded using either a manual or an automatic procedure. The weld must he cleaned of slag, loose deposits. and all defects after each pass. In completing the outside of the Joint, weldIng should be done In the down-hand or flat. position. prefe rab ly using AWS 7018 er 7028 series electrodes at least .1/4- inch In dl ameter.

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After most of the weldIng on the outside of the Joint Is completed. the alignment fittings. excluding the strongbacki. can be removed. The strongbacks remain in place until all weldtng on the Joint I~ completed.

Prepare th~ insfde of the joint by chippIng or arc-aIring Into the root bead of the outside weld to insure full penetration. Clear the joint of slag, loose deposits, and defects before startIng to weld. Again, weld In the down-hand position and clean the Joint before st~rtjng each addl~ tronal pass. The reinforcement on the butt welds shal I be not less than

. 1I32-inch and not greater than 1I16-lnch. Best results are achieved if the we I ding at each jot nt Is accomp I f shed wI thout interrupt I on.

After all weldIng has been completed, remove all of the strongbacks, patch the scars. and grind the surfaces to be smooth and flush with the she l l ,

Do not weld when the surfaces of the Joint are wet, when rain or snow is falling on them, or Ice has formed on them. If the temperature of the base metal is lower than 320F but higher than 50oF, an area extending 6 inches on each side of the seam should be heated to at least 600F before welding Is started. If the temperature of the metal is 500F or lower. postpone the welding unt ll conditions Improve.

~eldlng Stainless Steel

Sometimes the shells or certain other components which must be welded are stainless steel. Usually, the pertfnent drawings In such cases will specify the electrode to be used. If they do not, the following tabulatIon can be used to make the proper selection. The electrodes should not exceed 3/16-1nch dIameter. Do not WeaVe the bead or weld in excess of the size stipulated on the drawing.

728-75 .. 1 .. 8800 Sheet 20 of 46

JOINT METALS

Type 321 to Type 321 Type 321 to Type 304L Type 304L to Type 304L Type 309 to Type 309 Type 321 to Carbon Steel Type 304L to Carbon Steel Type 309 to Carbon Steel Type 309S to Type 309S Type 3095 to Carbon Steel

WELD METAL EJ47** or E309Cb E347*k or E309Cb E308L

E309

E310Cb** or E310 E310Cb** or E310 E309Cb or E310 E309Cb

E310Cb

** Preferred electrode.

SETTING THE RIDING RINGS

A·fter the shell Joints have been completed the t l res are to be set temporary , all except the thrust t l re which 15 set permanently. The ridIng rrngs are I to be temporarily located as per Fig. 6 and foundation drawing.

For temporary setting, weld (4} gussets 611 x 611 X Jill with a til fIl let weld ·on each sfde of the riding rIng equally spaced between the pads.

·When locating the tires with respect to the thrust, use a tape. Use a spring scale to apply tensron to the tape whIle the measurement '5 beIng made and a . thermometer to indicate the temperature of the tape at tIme of measurement,

. correct measurement to lOoF •

. The setting of the tires to a final location Is done to eliminate the error

'In calculated expansions based on assumed temperatures. After the kiln has operated and rt has been decIded how much to move each riding ring Into a permanent position. locate and weld the retainers on the side tn which the tire Is to be moved. Weld In accordance with. the shell assembly drawing.' After

one side 'of the retainers have been welded, burn off the 611 gussets on that

.. s lde and adjust rolls to !rove the tIre In dl rect lon desired. After the tl re has' moved ; weld retainers on the other s Ide With a 1/t611 gap between tire and retalner with tire against the retainers on the other side.

Since the thrust ring is permanently attached initially, the shrrmling behind the thrust rollers then can be adjusted to attain the speclfrc spacing between them and the l r. riding ring.

MAIN GEAR AND PINION

In installing the main gear and pinion, the main gear Is mounted around the shell, then the pinion i5 mounted on a base adjacent to It and posi-

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tloned to mesh with It. Separate instructions are provided which detail adjusting, aligning, meshing, and checking the gear and pinion Installation. The main gear comes in two halves. The pinion shaft and the two bearings which support lt are factory-assembled. Some Installations In~ elude two pinions Instead of one, but the same techniques are used to Install both of them.

MAIN GEAR

The ma ln gear is a precision component requl ring careful handling and precise Installation. At the time of Installation, remoVe preservatives and all foreign matter, then Inspect the gear carefully.

The spring pl ares are attached to the halves of the gear while they are stIll on the floor. They must be assembled to the gear In the direction which will place them under tension while the Kiln is rotating during normal operation. After the spring plates are attached, tie them In place, position the gear halves around the ·Kiln shell. and bolt them together. The halves are match-marked to identify mating surfaces. The halves must be drawn tightly together and closed properly before al (gnlng the gear.with respect to the shell. Feeler gauges should be used to verify that metal-to-metal contact has been secured. Improperly closed joints could result in rapid wear. Separate instructions are provided

.to cover the assembly of the gear.

The gear must be located at the point along the centerline specified by the drawings, It must be perpendicular to the shell, and must be concent r lc with it. They are not normally supplied as part of the Kiln, but many erectors fabricate Jacking frames of the type shown In Flgure 7. Four or more frames are set between the shell and the gear at opposing locations and are adjusted as necessary to pOSition the gear.

Final centering and checking for radial and rim-face run-out must be

done with Indicators in accordance with the detailed procedures provided separately. When the gear is properly set, weld the spring plates to the shell.

Start welding at the tangent point of the plates and work toward, then across, the end. After all plates are welded, remove the jacking frames.

PIN[ON

At Installation, it is essential that both pinion bearings be opened, the grease removed, and the bearings cleaned thoroughly. The grease with whIch they are packed is for protection durIng shipment only and is not intended

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'as an operatlona' lubricant. A light coating of lubricant should be applied to the bearings and to all machined." surfaces. Oependlng on the tnstallation, these bearIngs can be eIther 01 I or grease lubricated.

Mount the pre-assembled pInion assembly to the base with the fixed bearing at the location specified on· the drawIng. Set the shaft to the same slope as the Kiln. Shim as required, but shim over the·entlre contact· area - not Intermittently. Refer to the separate Instructions provided for details in securing proper alignment. tooth contact. and the f-lnal positioning of the pinion assembly with respect to the gear.

GEAR GUARD

Once the main gear and pinion are tn their final positions, the gear guard which encloses both of tharn can be Installed. Before enclosing them, however, .give the gear and pinIon teeth a thin coating of gear lubricant to prevent dry contact before the lubrIcation system has the opportunity .to cover them.

The part of the seal which gets welded to the shell mus t be positioned first.· The guard Is In sect Ions which have been match-marked at the factory to simplify the assembly procedure. ShIms are placed under the support legs of the guard to gain the proper concentrIcIty of the mating sections of the seal.

GEAR AND PINION LUBRICATION SYSTEM

The girth gear and pinion are lubricated either by a spray system or by 01 I idlers. The InstallatIon and adjustment of the gear spray system Is to be accomplished in accordance with the manufactu~er's instructions. The spray panel is to be mounted on the gear guard in the manner shown

on the drawings. The other components of the system are located for convenlence'at the site.

When oil idlers are used, they are mounted on a bearing-supported shaft In the gear guard under either the pInion or the gear. The bottom of toe gear guard then serves as the 011 sump. A number of Idler gears are provIded. Place the first one near the end of the gear with which It meshes so that 011 will run along the teeth during normal rotatIon, then locate the others at about lO-lnch intervals unless the drawings specify a different spacing. The idlers are secured In place with set screws. Once they are positioned, no further adjustment or alignment Is needed. Install the oil fill standpipe to the gear guard.

728-75-1-8800 Sh6!t 25 of 1;6

DRIVE UNITS

Va:' ous comb i nat Ions of motors I speed reduce rs , coup I I ngs, and auxl l i ary units are used to drive different Kilns. The manufacturer's Instructions whic~ are to be used In InstaJllng'~ach of the units provl ded will be. suppl ied separately. The various units included are identified on the drawl ngs.

In most Installations, each unit has Its own base which must be Independently set, aligned, and grouted. The entire drive train should be aligned and bolted temporarily untIl final adjustments have been made on the gear and plnton. At that poInt, each base Is rechecked and adjusted as necessary to comply with final 811gnment tolerances. Anchor bolt sleeves ~ay then be filled with grout. The frames should be grouted on the following day.

Occas lana I J y. all d rl ve un I ts a re moun ted on a conmon ad] us tab I e base which. in t~rn, Is mounted on a sub-base. This sub-base must be accurately pos l t loned, grouted, and have all anchor bolts sledged tight before the base can be mounted to It. The base can be moved In or out to adjust for backlash between the gear and prnlon, but It can be moved only a small amount to -Improve tooth contact, so per t l cul ar care must be exercised in settIng the sub-base and base. It Is Important that sub-base elevatIon allows for addItive shimming at drIve components which are Installed on the main base.

ELECTRICAL INSTALLATION

The lns te l Lat l on of power, control, and InstrumentatIon devices and circuItry are covered In separate instructions which include appropriate Interconnection lnfo rmat lon , Instructions. and schematics. In many cases, however, the detaIled electrical l n s tal l at lon - conduit layouts, switch locations, wIre siZes, etc. - has not been designed. and the associated safety switches, electrical wires, conduIt. and wiring devIces are not supplied, Select and l.ns ta l l electrical devl ces and materials whIch are compatible with the characteristIcs and ratIngs of the electrical equIpment which Is provIded as part of the system. Electrical specifications - voltage, fre~uency, phase, and current or power requirements - for the equipment s upp l l ed are included on the drawings or in the literature furnished. Follow-the InstructIons of the manufacturers for wIring all

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electrical devices provided. Make certain that the specified rated voltage will be applied at the terminals of each piece of equipment under all operating conditions.

Design the electrical Installation to conform to the requirements of the National Electric Code and any appHcable state and local codes. Pay particular attentIon to -the ·safety requirements and protective features of all devices used.

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Some Installations include Instrumentation which Is mounted through the side of the Shell. In such cases, trolley wIres which encircle the

shell and stand-off Insulators to support them are supplIed to pick-up signals from the sensors. Pantographs and their supportIng base are supplied to transfer the signals from the rotatIng trolley wires to eXternal circuitry, Drawings are provided with the KIln whIch show the Installation of the trolley wires, Insulators, pantographs. and base. information on the sensors, instrumentation, and Interconnecting circuitry is provided In separate electrIcal system Instructions.

It is Important to braze and grind Joints in the trolley wires carefully so that the transfer of sIgnals is as effective as practical.

'FIRE HOOD

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The fire hood fs not put on until after the shell has been assembled and all gned.

There are many different kinds of fire hoods, but they are relatively simple enclosures to erect and assemble In accordance with the dral'Vings provided. All fire hoods are refractory-lined. Most types are not bolted down and many are equipped with wheels. Particular care must be taken in assemblIng the seal between the fire hood and the shell.

FEED HOOD

The type and configuratIon of the hood on the feed-end also varies a great deal and depends upon the equipment whIch will be located at

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Sheet 27 of 46

that end to feed material Into the Kiln and to handle the hot 9 se

leaving it. a ,5

While Installation must be performed In accordance with ·the drawings provided for the specific hood supp l led , refer also to the l nst.ructIons for the interfacing equipment. They may include information' which wi 11 clarify the instal fatlan of the hood Itself. .

Special attention will be requIred In Installing the seal between the hood and the Kj In snell. The type used varIes according to .the epp l l+ Cation. Some feed-end hoods requIre, a refractory linIng.

NOSE RING

On the larger machInes equIpped with a nose rIng for cooling, the cowl and support sections must be welded on-site. On smaller machines, these parts are assembled to the shell section at the factory. I n both cases ~ the segments which close the area between the cowl and the end of the shell are bolted into position on-site. All necessary holes and bolts are provided.

If the cowl Is 'welded on-site and a carbon seal is to be Installed between the nose ring and the fire hood, it wIll be necessary to grind the welds In the area where the seal plates wIll be in contact with the cowl.

The fan is Installed at a convenient location which will limit the length'of duct lnq, Refer to the fan manufacturer's Instructions for InformatTon on providing a foundation for and Installing the fan and its drive. The ducts are to be supported Independently so that the l.r weight Is not carried by the fan housfng .

. BURNER

The burner and the equipment associated wfth It Is Installed in accordance wIth Its manufacturer'S Instructions.

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REFRACTORY LINING

-In most lnatel let lons , the refractory lining required In the Kiln is not Included with the equIpment provided. Separate arrangements are usually made with other sources for procuring approprIate refractory material and having it installed. Brick-retainIng rrngs which are to be welded inside the shell as the refractory Is Installed are provided. One ring should be installed 18 to 24 Inches from the discharge end. The rest are usually equally spaced throughout the length of the Ki In. Consult the refractory supplier for hIs preferences on the number and location of rings with respect to the refractory beIng installed.

llsua l l y , refractory Is installed along the length of 'the Kiln to a

ring location. Ihe ring, whIch is In 4 or 6 segments, Is held tightly against the brick while it is welded to the shell. Install.atlon of refractory then resumes. Welding the rings In position while the refractory- is being Instal led avoids the necessity of cutting refractory to fit between previously Installed rlogs.

While the refractory is being installed. the Kiln is rotated as neceSsary to permit the work to be performed In the most advantageous position.

CHECK .. QUT

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Because the Kiln will be placed In limited operation to dry the refractory lining, a thorough check of the installation should be made to verify that It Is ready to be started and operated. This inspection should include the following points:

All temporary forms and supports used during Installation of the refractory have been removed.

80th the interior and the surrounding area have been cleaned; they are free of all foreign matter and refuse - partIcularly combustibles.

Components of the Kiln requIring it - rIding rings, thrust rollers, bearings. reducer s , motors, couplings, fans, etc., - have been properly lubrrcated. Lubrication systems are operable.

7t8-75-1-8aoo Sheet 29 of ~6

Controls and Instruments are ready for operatIon.

The rotatIon of all motors Is In the required direction.

After the Inspection has been completed, the Kiln Is rotated and Its com~ ponents checked to make certeln they operate satisfactorily. The main drive Is started at its lowest' speed and the following conditions are veri fied:

The girth gear and plnton, bearings, and sImilar devices are being lubricated.

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Cooling water Is flowing tnrough the bearing on the support rc l l ers •.

AI1 rollers are in contact wIth 'the ridrng rings.

Drive units are properly adjusted.

The seals are making proper contact.

The speed is then increased In steps up to the maximum. and all components are observed for proper operation at each step. The Kiln is stopped after the check has been completed.

DRYING REFRACTORY

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The refractory lining must be thoroughly dried before the Kiln Is placed In service. During thIs process the burner Is started and run on a low fire and the Kiln Is rotated slowly. DryIng normally takes about 48 hours, but instructions wl l l be available from the manufacturer for the refractory used on the Installation.

In l t l al-lv , rotate the KIln approximately ona-ha l f revolution every half hour. As drying progresses and ~ little more heat Is used. change the rotation to be about one~thlrd turn every 20 minutes. then one-quarter turn every 15 mInutes. As the temperature Is Increased, the Kl In should be run continuously at Its lowest speed. The objectives are to heat evenly, to dry the refractory uniformly, and to avoid heatIng one side of the Kiln excessively so that a danger of warping exists.

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POST-INSTALLATION IDLE TIME

If the Kiln will be Idle after lns te l lat lon has been completed, It should be rotated for about 15 minutes each week to cIrculate oil through bearings, speed reducers, and simIlar components.

OPERATING

INSTRUCTION'S

The satisfactory operation of a Kiln Is prImarily dependent upon the experience and capability of the operator. It requires a thorough knowledge of the process, of the material being processed, and of the equipment itself. It also requires skl l l at accurately interpretIng the state of the materIal and influences of the many variable, interacting conditions which exist during operation and In achievIng precise responses from the equipment when adjustments are necessary.

The less sophistIcated installatIons depend heavIly on the operator exercising direct manual control. As the complexity of the installation IncreaseS and more operations become automated, the emphasis Is shifted to the operator establlshln9 the control points to which the circuitry must respond, monitoring the operation of the system, and being prepared to intervene ln the event of a malfunction.

The capabilitIes offered and functions performed by the Instrumentation and control system are covered in separate Instructions prepared for each installation. The paragraphs which follow present general instructions and procedures concerned with the mechanical operation of the Kiln.

SAFETY

Because of the high temperatures, both Internal ~nd external. the entire Ki In must be treated as a dangerous area. Skin temperatures generally range from a low of about 3000F up to about 6000F.

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Sheet 31 of lj6

WARNING

SAFETY PROCEDURES MUST BE OBSERVED AT ALL TIMES

Personnel working on the pIers or other ,locations where they can come into contact wIth the shell must be safety conscious to avoid Inadvertent contact.

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"

Care must be taken In openIng Inspection ports In the fire hood. Be-

cause the Kl In Is under suctIon, hot gases should not escape from an open port when the Kiln Is operating under normal conditions. There should be an Inward flow or air. However, hot dust from any kind of puffing In the fIre hood can be blown In the operator's face. Pro-

, 'teet I on for the' face and eyes must be worn at these times.

STOPPING

The primary concern In stopping the Kiln Is protecting the refractory from the effects of sudden temperature changes.

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RotatIon of the Kiln Is continued at progressIvely lower speeds as the temperature drops. When low temperatures are reached. the rotation can be reduced to a fractIon of a turn aaeh hour. It should be stopped com~ pletely only when the danger of creating local hot spots and warping of the shell no longer exist.

EMERGENCY SHUT-DOWN

The shut--down action to be taken In an emergency s l tuat I on l svdependerrt upon -the nature of the emergency and its anticipated duration and can be determined only at the time and on the basis of an evaluation of the

51 tuat'Ion by expe r I enced personae 1.

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Most such situations arise because of a malfunction In another piece of

. equipment In the system, and materfal cannot be processed through the kiln until a repair 1s effected. In many Instances, a complete shutdown Is not required. In all cases the priority of consideration must be first to the safety of personnel, then to the protection of equipment, and finally to the product or materIal In process. In considerIng equipment, the kiln Is given a high prIority because of the time and expense requtred to effect repairs as well as Its original cost.

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POWER FAILURE

In the event of a power failure, It Is vital to the shell that the aux-

. iJlary drive be started Immediately so that rotation can continue. Refer· to the separate Instructions provided for the auxiliary drive to become familiar with the starting sequence and control procedures. Failure to keep a hot shell rotating results In damage to the refractory and warping of the shell. Any warping 15 serious, but it can become so severe that corrective measures become both dIfficult and expensive.

Mo·st power failures occur during storms when there Is rain, wind, snow, or various combinations of these elements, each of which has a significant cooling effect on the shell. In addition to causing a rapid heat transfer from the 1 ining, this cooling of the shell tends to cause It to

. contract and exert a compressive force on the refractory, causing It to crack· and loosen.

Sheuld a sItuation arise where neither primary power nor the auxiliary drive is available to rotate a hot shell, an improvised means of rotation· must be devIsed. A tractor to pull a cable wrapped around the shell.or hydraulic Jacks pushing against bars placed between the pads under the riding rings Gould be used. A warped shell will alter proper gear and pinion mesh and could result in gearing rallure7

THE AUXILIARY DRIVE

Aside from emergency use to rotate the kIln durIng a power failure, some operators use the auxiliary drIve to rotate the kiln slowly or intermittently during the early stages of heatIng or the later stages of cooling. If this procedure is followed, it Is important to make certain that the lubrIcatIon system for the main gear remains in operatIon when the other power unIts are stopped. The auxilIary drive is an emergency system only and should not be used for continuous operation.

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WARNING

DO NOT USE THE MAIN DRIVE AND THE AUXILIARY DRIVE TOGETHER

Attempting to use both drives to start a Kiln can exert much more torque than the drive components can withstand. Personal Injury and serious damage to the InstallatIon can result.

SKEWI NG 'ROLLERS

Rollers are skewed on floating Kilns only. They remain parallel to the centerline on full thrust Kilns and those equipped with a hydraulic thrust mechanism. The purpose of skewing Is to cause the shell to operate In a position where t t. ts floating between the thrust rollers rather than'resting against either of them. By setting the rollers at slight angles to the shell they exert a thrust on It which 15 adjusted to counteract Its tendency to move down-hill. rlgure 8 shows the dIrection that rollers are to be skewed for both directions of rotation.

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At the time of installation. al I rollers were set with thet r center! l.nes parallel to the centerline of the Kiln so that when the Kiln Is first placed In operation. no roller wIll be exertIng a thrust in either the uphill or down-hill direction. While the rollers are in th l s neutral position. the adjusting bolts should be marked so that the amount each one Is subsequently turned to skew a roller can be seen. It is necessary to skew

all rollers sl1ghtly and In the same amount so that although each roller is at an angle to the Kiln, each set of rollers Is parallel with the other 'sets of'rollers.

NOTICE

ONE PERSON SHOULD HAKE ALL ADJUSTMENTS TO ALL ROLLERS ON THE KILN.

Adjustments are made In small Increments, all ro l l ers must be adjusted the

72.8-7S- J ·8800 Sheet 34 of 46

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same amount, and they must share the load equally. In addition, one person becomes familiar wIth the KIln and knows the change an adjustment will effect. For the-se reasons, one Indl vl dual should be assigned to make all roller checks and ~dJustments on the Kiln. He should maintain records of adJustm~nts and alI~nment checks to aid In future adjustments and alignment

correct Ions. .

Skewing and making adjustments to the skew are performed while the Kiln Is in operation and at its normal operating temperature. Hoving the rollers Inward with the Kiln stopped would be extremely difficult mechanically. Also, the adjustment should be made after the Kiln has completed Its thermal expansion.

'-

WARNING

BECAUSE ROLLERS ARE ADJUSTED WHILE THE MECHANISM IS rN MOTION, PERSONNEL MUST EXERCISE CAUTION TO AVOID INJURY

Although the parts are rotating at relatively low speeds, danger does exist. Personnel must exercise particular caution In keeplng··themselves

and. their clothing well clear of the moving parts. In addition, the exterior surface· of the shell will be hot enough to cause burns. If the guards are removed to make the adjustment, make certain they are re-Installed prope rl y afte rward.

Rollers are skewed through the use of the adjusting screws mounted In the support frame and pressing aglnst the base of each bearing. Turning a

screW moves the associated bearing, and the angle at which the roller addresses tne ridIng rIng Is changed a corresponding amount. On Kilns equipped.with the larger sIzes of rollers, hydraulic cylinders operated by a hand pump are mounted on the frame to move the bearIng. The screw 15 then used

to retain the bearing In its neVi position. The hold-down bolts on antifriction bearings must be loosened I'Ihlle their roller ls b~lng skewed.

\<Ihen It Is desired to move the Kiln up-hill, the bearing on the up-hili side of the roller on the upward-turnIng side of the Kiln is moved toward the riding ring as Illustrated in FIgure 8. The down-hill bearing on the downward-turning side of the Ki In would then be moved toward the ring the same amount. Hoving the· other pair of bearings would result In the Kiln moving down-hill, but th l s is rarely desirable. A small amount of up-hill thrust

is usually needed.

728w75-1-88oo Sheet )6 of 46

The direction a roller Is thrusting can be determined quickly by striking the end plates of the bearings with a small hammer. When a rol ter Is skewed to hold the Kl"ln up-hilt, the bearing plate on the down-hill bearIng wI1.1 have ia solid sound when it is struck, and the up-hill bearing will sound hollow. The opposite 15 also true. If the roller is set to move the Ki ] n down-h i II, the up-h 111 bear! n9 wi 11 have a so 11 d sound and the one down-hill will sound hollow.

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Adjustments are made in small ipcrements which are rarely larger than onesixteenth of a. turn of the screw. They should be made to all ro l le rs in the same amount so that the thrust 15 divided equally between all piers and between both rollers on each pIer. One roller is never set to thrust Tn the opposite dIrection from its matet nor is any paIr set to thrust In the opposite dIrection from the others.

When the rollers are first skewed from the neutral posItIon, a perIod of at least 6 to 8 hours should elapse before the riding ring contacts the upper thrust roller. I f the shell moves up-hl l l In less time, the rollers have been skewed too·much and must be adjusted to avoid unnecessary wear. DependIng on the size and speed of the KlIn, a perIod of from 2 to 8 hours may be required for the Kiln to adjust itself to a change made in the skew angle •

. ,' .

Once the .skew of the rollers has been set and the 10ao balanced among them, addItional adjustment should not be requIred for 8 long tIme. Some movement of the KIln may occur from time to time, but the change should be observed for a while to see If the condJtlo~ corrects Itself, if the change is too small to warrant an adjustment, or if an adjustment Is desIrable.

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COLD WEATHER OPERATION

For Kilns located tn areas subject to freezing weather, precautions must be taken to prevent coolIng water ·from freezing In the bearings or piping. During shut-down periods, oraln the water from the bearings.

MAINTENANCE

Maintenance of many components of the KIln, such as anti-frIction bearings,

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drive unIts, and the gear spray system. Is to be performed In accordance wIth the instructions of their Indlvldual manufacturers. In those ~nstances. the Infohnatfon avaIlable from the manufacturers Is provided separately. The InstructIons contained In this section pertain to components not otherwise covered or are supplemental to the separate materi al ,

CHECKLISTS AND RECORDS

Checklists should be prepared which include a routine for examining, lubricating, adjusting, and otherwise servicing the various elements of the installation so that nothing is Inadvertently overlooked.

Complete and continuous records should be maintained for the repaIr and 'replacement of the refractory lIning. The record should Indicate the date. make, and exact Iocat Ion of refractory material installed .. This record can assist in d~terminlng when to replace sections of the lining and to identify the type of material whIch has proven to be the most de-: slrable for the application.

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Records should also be kept of shBl1 alignment measurements, roller .a~Justments,·and gear checks.·

The burner daily report shou1d include the current or power beIng drawn by the Ki In motor. An Increase In power consumptIon may Indicate misalignment of the rollers.

LUBRICATION

Table 1 is a lubrication schedule which Identifies the types of lubricants to be used with the bearlngs and gears on the Kiln.

The oj 1 In all bearings on the KIln - support, thrust, and pinion - should be changed after the fl rst month of operatIon, then every 6 months unless the amount of contamination to which it is subjected requires that it be changed more frequently. The same applies when oil idlers are used to lubricate the girth gear and pinion. Although the gear spray system does not retain or re-use its lubricant, it does produce a sludge which accumulates in the bottom of the gear guard. Perlodfcally, the door near the

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-r-,

TABLE I

KILN, COOLER; AND DRYER LUBRICATION" SCHEDULE

CODE:

110 -Engine 011

120 - Turbine or CirculatIng Oil

220' - Extreme Pressure OIl (Lead-Naphthenate)

235 - Gear Lubricant (Residual Compound - With Dllutent) 370 - High Temperature E.P. Grease

ITEM CODE SPECI FI CAT I ONS APPROX.
NO. S.A.E. NO.
Roller Support Bearings:
.. ( 1) 0 f I 1 ub rl cated - 120 1650 S.S.U./I00oF.
(2) Grease lubricated - 370 NLGI #2
(3) Antj-friction oil type - 120 800 S.S.U./1OOoF 40
Thrust Roller Bearings:
( 1) S J eeve , 0 I I lubricated - 120 1650 S.S.U./l00oF. 50
(2) Anti-friction, 011 type 120 1850 S.S.U./1OOOF. 60 Pinion Shaft Bearings:

(I) Anti-friction, grease type (2) Anti-frlctionJ '011 type

(3) Sleeve, grease type

{4) SleeveJ all type

- 370

- 120

- 370

- 120

NLGJ #2

800 S.S.U./1000F. NLG~ #2

18,0 S.S.U./IOooF.

40 60

Girth Gear and Pinion:

(1) Intermittent spray system (2) OJ ling idler

(- 235 3000/8000 s.S.U./210oF. (- Z20* 500/800 S.S.U./210oF.

- 220 400/500 S.S.U./210oF.

Speed reducer) Coup J i ng5) Gasoline Engine)

- See Manufacturer's Instructions

Extreme pressure lubricants are not necessary in Kiln sleeve bearings.

If the USer prefers E.P. lubricants they should be chosen to be stable at temperatures over 200oF. Some of the more recently prepared lubricants do have this stability.

*Preferred

728"75"""8BOO Sheet 39 of 46

bottom of the guard should be opened and a hoe-type tool used to scrape the sludge out.

A graphited grease of the same type used at Installation should be used to lubricate between the ridIng rings and theIr mounting pads. A hand gun with an extended nozzle can be used.

The faces of the riding rings and rollers are lubricated only by the solid graphite plate mounted on one of the rollers In each support mech~ anlsm.

The graphite, held against the roller by Its own weight, provides adequate lubrication. Do not use all, water, or other lubricants. The face of each thrust roller and the side faces of Its riding ring are also lubricated by a graphite plate held agarn~t the thrust roller. No other type of lubricant should be used on these surfaces.

If the bearIngs on the support rollers are of the sleeve type, the caps should be opened perIodically while the Kiln Is In operation to Inspect the Interior and to determine If the bearing Is beIng lubricated adequately. Keep 'the oil-fill pipes on both the support and thrust bearings clean. Under some conditions, dirt can accumulate In these pipes and; if not cleaned out, can give a false Indication of the oil level. Inadequate lubrication leading to bearing fat1ure can result. Check'the ot l Teve l regularly, adding oil as necessary.

The contact faces of labyr1nth and rubbing-type al r seals should be lubricated wIth a graphtted 011 mixture. Seals which are effected through the use of graphite blocks wi i 1 requl re perfodJ c replacement. of the blocks but no lubrication.

KILN ALIGNMENT

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Kiln alignment should be checked periodically and corrected as necessary to avoid excessive wear on rings, rollers. gears, bearings. and seals

and to restrict cracking of the lining. The preferred method of checking alignment Is performed inside the KI In along the centerline. The procedure Is much the s ama as that used durIng InstallatIon except that checks are made only at ring locations. Refer to the paragraph In the INSTALLATION Section entitled CHECKING ALIGNHENr. There are instances where thIs technique cannot be employed and It is necessary to check the alignment from measurements made On the outside. Outside alignment is quicker, but not as accurate. A procedure which can be used Is available from the factory.

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Bench marks established while the Kiln was 'befng' Installed should be used to check the piers for shifting, or settling which could cause misalignment.

AUXILIARY DRIVE UNIT

The components of the auxilIary drIve must be checked regularly to malnta In them; n a con dl t lon where they wIll start l nmedl at.e ly when needed. Host are engine driven. and the engine should be started and rUn dally. The oil level and fuel level should be kept at the full mark. Maintain

a full charge on the starting battery. keep the terminals clean and tight, and add water as necessary to keep the cells full. The discharge-charge cycle'of startlhg and running the unit regularly Is advantageous to good battery life. Refer to the manufacturer's Instructions for these units.

REFRACTORY

The refractory lInIng should be inspected whenever an opportunity arises and, any damage repal red. Unusual operat l ng conditions sometimes cause the refractory to crack and to break loose from the Interior wh! l e the Kiln Is In operation, resulting In not spots on the shell which can glow and warp. in such cases it Is necessary to shut down as quickly as possible to repair the lining and patch the distorted shell.

Whenever the Kiln is relined or repairs are made to the lining, t!me must be allowed to permit thorough drying-before the Kiln is returned to service. Refer to the paragraph entitled DRYiNG REFRACTORY in the INSTALLATION Section.

MAIN GEAR AND PINION

The main gear and pinion should be Inspected periodically to ascertain that they are receiving adequate lubrication and that good contact and proper clearance exists between them. An annual check of backlash conditions should be made and the results recorded. Refer to the gear installation and alignment fnstructions provided separately. Wear on the ridins rings and support rollers will change the mesh of the gears. Even-

. 728-75"'~88{}o Sheet ~r of 46

tually, adjustments in the location of the support rollers may he necessary to maintain proper clearance.

The roller-to-race. clearance Oil the pinion shaft bearings should also be measured once each year. An apprecIable Increase In the clearance wi II Indicate the necessIty for changIng these Qearings. Be sure to record the measurements for future reference.

SUPPORT-ROLLER BEARINGS

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Per lodi cal ly roller end-play should be checked to determine the anount the thrust ~asher has worn. Measure and record the change in.and-play from when the thrust washer was new. Replace It when the measurement indi cates that the 011 grooves are worn away. Refer to the paragraph entitled INSTALLING BEARINGS AND ROLLERS.

If sleeve bearIngs are used, check for excess I ve wear of the bronze halfsleeve. Replace as necessary. Wear of the coverpJate on the roller side of the bearing would Indicate excessive wear of the sleeve. The seal on the roller sIde will also wear and should be replaced when it begIns to leak.

To replace a s l eeve , take the load of the Kiln off of the roller by supporting the shell in a cradle whIch can be Jacked up the amount necessary to unload the roller. Support the roller In a similar m~nne~. Remove the end cover from the bearing, unbolt the sleeve, and slIde it out the end. Lubricate th~ new sleeve so tnat there can be no Initial dry con-

tact, slide it Into position, and bolt it. .

Regardless of the type of bearing, .this same technique of supporting the shell and roller is used If an entIre bearing must be removed and replaced.

On Kilns equipped with antl~frlctlon bearings, meaSure the roller-to-race clearance once each year. An appreciable Increase In the clearance will indicate the necessity for changIng these bearings. Be sure to record the measurements for future reference.

THRUST- ROLLER SLEEVE BEARl NGS

Wear of the sleeve bearing on a thrust roller and the thrust ring under

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L

the roller shou Id be checked periodically.' Wear of the bearing can be determined by m~asurfng the amount of lateral"movement of the roller. The amount of thrust ring wear will be evident from Successive measurements made from the frame to the. top of the thrust roller.

The bearing sleeve fs press-fit Into the bracket with only enough interference to hold it in place. One screw through the sIde of the bracket and Into a hole In the wall of the bearing prevents rotatIon. To replace the sleeve, remove the bracket from the frame, lift the roller from it, remove the screw, then draw or press the old sleeve out. In p res s Ing ·the new sleeve In, align· it with respect to the screW' In the side.

Once the roller has been removed, the thrust ring can be removed and replaced without dlsassembJ Ing any other parts.

ERRATIC KILN ROTATION

Properly Installed, operated, and maintained Ki1ns rotate smoothly and steadily. Erratic rotation - bumping, jerking, or bouncIng - can be caused by a number of conditions. The- following paragraphs discuss causes of Irregular motion.

WARPED KILN SHELL

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Warping unbalances the weight distrIbution of the Kl In such that the convex zone is heavier. As this zone moves upward, rotation can stop momentarily as each pinion tooth moves away from the meshing girth gear tooth causing the next pinIon tooth to bump against the next g[rth.gear tooth.

Warpage can also cause the shell to rub Inside the fire hood, feed end housing, or at any po i nt where rigid structures are set close to the shell. This added pressure can Increase the gear bump mentIoned above, overload the drive motor to cause speed fluctuations, and force the shell to flex with each bump of the gear. In combination, these conditions can cause

the shell to bounce with enough force to be seen and felt.

SEAL RING PRESSURE

Air seals may bind or choke. When this happens, a chattering form of vibratIon can be started whIch will be transmitted throughout the Ki In.

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The condition will be aggravated if It begins before the Kiln has expanded fully. Continuing expan510n will place i,vere pressure on the

rubbing surfaces. .

IMPROPER LUBRICANT VISCOSITY

When the lubricant is not of the proper wetght or cl'asstflc8tton or is dIrty and sludge-fl·1ted, it can cause dr~g which will over load the motor. and, in seVere cases, damage· the roller $haft.

WORN THRUST WASHERS OR BEARING LINERS

After these parts have worn to the point that the effectIveness of the oil grooves has been sertously dimlnf5hed, the resulting Inadequate lubricatIon can cause a chatter or vibration and an overload condition for the dr l ve,

INADEQUATE COOLING

An inadequate flow of water to the bearings or blocked water pass~ges within the Jackets or piping can result in over-heating, affect the lubrication, and cause the snaft and bearing to seIze and result in drag and chat t er ,

EXCESSIVE BACKLASH

ExcessIve backlash wi 11 cause the KIln to Jerk as It rotates.

GEARS MESHING TOO DEEPLY

Improper gear a l i gnmen t 01" Kiln alIgnment may place the. gears too deeply in mesh causing the teeth to bottom and resulting In a sever bump as each tooth passes. With a warped she! I, the mesh can alternate between being too deep and too shallow on each revolution.

WORN RIDING RING PADS

Full-floating rings require small amounts of clearance which permit them

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t~ slip. Eventually, this space may.become excessiveJ the centerlrne will lower, and the girth gear wi1 I mesh ~oo deeply with the pInion.

IMPROPER ROLLER ALIGNMENT

AsIde from encouraging rapid wear, improper roller alignment can result in several forms' of irregular movement Including flexing of the ishe l l and too deep gear. mesh I ng accompan led by . react Ions wh i ch range from 11 ght vibration to severe bumping;· If. In a fJoatl'ng I)II~" .the rollers .. are

not properly skewed, excessive pressure on either thrust roller can cause a chatter-type vibration. Minor shifting, settl lng, or tiltIng of the piers wi 11 appea r as f mproper ro l I er al i gnment.

UNDERSIZE DRIVE MOTOR

At tImes and under certain conditions, the Kiln Is operable under feed and load conditIons greater than those of the original design. If a proportIonally larger motor and drive Is not Installed, the small motor will, at least, tend to have a fluctuating speed which Is transmitted to the Kiln as erratic rotation.

LOOSE FITTINGS AND UNITS

Loose fIttings or components can result In a variety of vibrations and erratic motions.

UNUSUAL MATERIAL CONDITIONS

Certain materials wIll shfft in an erratic manner rather than sliding or tumbl ing in the usual way. Such motion will affect Kiln rotation. At times, materTal accumulates to fonn slabs on the refractory linTng and have the same results as a warped shell.

LOW VOLTAGE

Low voltage at the drive motor can cause the speed to fluctuate and result in erratic rotatTon.

IMPROPERLY POSITIONED THRUST ROLLERS

Thrust raIlers are set 1/16- to l/8-inch off the centerline of the Kiln toward the inward-running side of the Krln to permit the riding ring to contact the roller rim on the down-sweep and keep the thrust roller seated

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in its housing. If the thrust _roller Is set to the up-sweep sl~e It

can be l l f't ed to rub against the ring retaining band and. in combination with the up-sweep p ressure , cause vlb ret lon,

SPARE -&- REPLACEMENT PARTS

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Parts lists and lists of reconmended spare parts are provIded separately. In ordering parts from the factory, be certain to specify the quant l ty , description, and part number for each one. Include- the serfal number of the machine on all orders and related correspondence.

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