Você está na página 1de 19

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page1of19

AsktheKilnDoctorYourQuestion
PhillipsKilnServicesBlog
Friday,April16.2010
AsktheKilnDoctorYourQuestion

Quicksearch
>

Tosubmityourquestion,justclickonthe"Comments"linkbelow.ThenfillouttheCommentformtoleaveyour Archives question. PostedbypetelaskieinASKTHEKILNDOCTORat05:22|Comments(201)|Trackbacks(0) August2011 July2011 Trackbacks June2011 TrackbackspecificURIforthisentry Recent... Older... NoTrackbacks Categories Comments Displaycommentsas(Linear|Threaded) ASKTHEKILN aftershimmingpads3/16"ontyreclosesttothefeedendourkiln.thefeedtubestarteddraggingthespiralplatesinsideof DOCTOR KilnShellSeals thekiln,howmuchdidthisraisetheendofthekilnbyaddingtheseshims KilnTires #1MikeWilcoxenon2010-06-0410:37(Reply) Thekilnshellwillberaisedbythethicknessoftheshim(X)atthesupportpier.Howthattranslatesatthefeedendof (Tyres) Lubricationof theshellrequiresknowingthedistancetothenexttire(L)andthedistancetothefeedend(L2).Amountraisedatthe RotaryKilns feedend=(L+L2)/LxX.Eventhisisapproximateasshellsaghasnotbeentakenintoaccountbutlikelyclose RollerSkew enough. #1.1WalterGebharton2010-06-2913:29(Reply) RotaryKiln Pleasehelpmewiththeformulawhichcalculatestheshimmingpads(loosenpads)forthekilntyre. Alignment #1.2HongMinhon2011-01-1123:20(Reply) Shell Anewentry"CalculatingColdGap"showstheformulas. ShellFlex #1.2.1WalterGebharton2011-01-1206:11(Reply) SupportRollers TheGearand whereisthepropersettingforlimitswitchesonthrustrolls.wehavealowandhighalarmandjustbeyondthesewehave Pinion alow/lowandahigh/highwitchtripoutthekilndrive ThrustRollers #2RandyScotton2010-06-0506:01(Reply) Beforegivingpossibleanswerstothisquestioncanyoutellusifthiskilnisfittedwithahydraulicthrustmechanism orareboththrustrollersfixed?
Go!

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page2of19

#2.1WalterGebharton2010-06-3008:30(Reply) plslneedsometechnicalpointforwhitemetalbearingscrapingforbluematchingcontactbetweenbearingand Allcategories shaft #2.1.1faridon2011-06-2023:23(Reply) SyndicateThisBlog Ifneededscrapeeachsideofthebearingthreetimes,oncefromnearbottomallthewaytothetop,secondly frommidwaytothetopandfinallythelastthirdtothetop. RSS0.91feed Atthebottomtheshaftshouldhavecontactwiththesleevefornomorethan1/7thofhalfcircle~about25 RSS1.0feed degrees. RSS2.0feed Thefinishedsleeveshouldhaveasmoothgraduallythinningcontourupeachside. ATOM0.3 Afterassemblythetotalclearancebetweenshaftandtopofthebearingshellshouldbenolessthan0.002"/inch feed shaftdiameter. ATOM1.0 #2.1.1.1WalterGebharton2011-07-0714:46(Reply) feed sir RSS2.0Comments kilnratedcapacity250tph,maindriveratedcapacity520kwnormalrunningcurrent650-750amps.Butcurrent frequentlyvaryingfrom650-1100ampssometimes2000ampsalso.canigetthesolution.whatarethefactorsaffecting BlogAdministration this. #3jayamuruganon2010-06-1007:03(Reply) Youdonotmetionwhatprocessthiskilnis.Letusassumeitsacementkiln.Thistypeofprocessispronetobuilding Openloginscreen acoatingontopoftherefractorylining.Mostlythiscoatingisnotuniformaroundthecircumference.Thisproduces animbalance,whichcausesthemotortoloadupastheeccentricweightisdriventothetop(hiamperagedrawonthe motor)andthenitactuallyassiststhemotoronthewaydown(minimumamperagedrawonthemotor).This phenomenonistransientbecauseitfollowsthechangesincoatingformation.Ifthisswinginmotorsampsisconstant anddoesnotchangesignificantlyovertime(afewweeksorso)thentheimbalancemaybeduetopermanentdamage tothekilnshellsuchasasignificantbendintheshell.Thereareotherpossibilitiesaswell. #3.1WalterGebharton2010-06-3009:18(Reply) DearSir, Wefoundproblemtodayevening(12-06-2010)atGirthgearandPinionContact.Atoneparticularpositionjerkingis occuringwhenGirthgearmeshwithPinion.Loadisgraduallyincresinganddecreasing(160-280). #4Nagaraja.Con2010-06-1205:27(Reply) Pleasedeterminewherethegearsplicejointsareinrelationtothepinionwhenthisjerkingactionhappens. #4.1WalterGebharton2010-06-3009:27(Reply) dearsir cementkilnhaving1100tpdcapacityinshutdownperiodmachinedrollerreplacdatpier-1(towardsdischargeend)in runningreplacedrollerdownhillsiderollerthrustboltsarecuttingmanytimes.kilnwasfloatingupwardsand downwardsbutrolleraxialthrustalwaysuphillsideandkilntakingmoreams(trip)andtyrehavingconcaveshapeso therollercontactingareawaslessandtakenleadwiretestthisrollertakingloadanddownhillsidebearing90deg temperature detailsoftyre&roller oldrooler diamer=1180 tyrediameter=3550 centerdistannce=1186 newroller diameter=1152 shimaddednewroller=13mm kilntripmanytimespleasegivegoodseggestion thankingyousir y.sureshnaidu #4.2y.sureshnaiduon2010-07-2719:00(Reply) Clearlyagoodrolleralignmentisnecessary. #4.2.1WalterGebharton2010-08-2811:47(Reply) Re:KilnRotationalspeedv'sthroughput Hellokilndoctor MyquestionismoreprocessorientatedhoweverIamhopingtherearesomeruleofthumbdesigntheoriesthatmaybe knowntoyou. Wehaveakilnthatisoperatingataround60%ofit'sdesignmaxspeed.Recentlytheflowthroughthekilnhasbeen unstable,andwearegettingsurgeswhichaffectprocessquality.Ihavebeenaskedtolookatwhetherthekilnrotational speedissufficienttoprovidesteadyflowthroughthekilnatthesenewtonnages. Mylogicsaysifthekilnisrunfasteritwillallowmorematerialtorunthroughitsteadily,howeverwehaverunthesame speedfor12yearsandarehesitanttochangelestweencounteranydifficultieswiththedrives. Canyouofferanyassistance? Regards AndyHolben #5Andyon2010-06-1721:20(Reply)

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page3of19

Withoutknowingtheprocess(whichweasamechanicalservicescompanywillalwaysknowtoolittleabout)only somegenericcommentsareoffered.Therelationshipbetweenkilnspeed,slope,length,diameter,andnaturalangleof reposeofthematerialisusuallycalculatedusingtheUSBureauofMinesretentiontimeformula; T=(1.77xLx(A)^0.5)/(PxDxN) Where A=thenaturalangleofreposeofthematerialindegrees P=slopeofthekilnindegrees D=theinsidediameterofthekilninfeet L=lengthofthekilnshellinfeet N=rotationspeedinrevolutionsperminute T=retentiontimeinminutes Calculatetwice;oncewiththefeedmaterialcharacteristicsandagainwithproductcharacteristicsandaveragethe two.Wheninternalliftersarepresent,asistypicalwithdryers,thetimeisusuallyincreased50% Whenyousayyougetsurges,thiscouldbearesultofthematerialproperties(naturalangleofrepose)changingat somepointsinthekiln.Addingmorefeedonlywillchangethebeddepthbutnotretentiontimeandthatwillaffect heattransferandefficiency.Changingfeedplusspeedproportionatelykeepsaconstantbeddepthbutreduces residencetimerequiringahigherfiringrateandsoon. #5.1WalterGebharton2010-06-3009:45(Reply) Iwanttoknowthesafetyfeaturesforthekilninpowerfailurecrashstop. Whateffect[doesthishaveon]thekiln? #6sumeitsharmaon2010-06-2204:22(Reply) Hotkilnsthatstoprotatingriskpermanentshellwarping.Theresultisoftenreferredtoasbentshell,adogleg,a crankandsoon.Whensevere,thedamagecanbepermanent.Thesafetyfeaturestopreventthisisanindependent auxiliarydriveusuallyagasordieseldrivenengineandintropicalclimatesputtingthekilnunderrooftopreventthe doubleeffectofatorrentialdownpourinconjunctionwithapowerfailure. #6.1WalterGebharton2010-06-3011:28(Reply) howmuchthetolreancesarethereforthekilngirtggearAxial&radialrunout? Axialrunouttolerance:0.001inchesperfootofgearpitchdiameter. Radialrunouttolerance:0.0015inchesperfootofgearpitchdiameter. WG #6.2sumeitsharmaon2010-07-0102:55(Reply) Inourkilntherollerbearingsare[spherical]rollerbearings.Theyarefrequentlydamaged.Wewanttochangeitto bronzehalfbearingbushing.RPMofthekilnis5.Whatprecautionshouldwetake? Regards Usman #7Usmanon2010-06-2511:10(Reply) Sphericalrollerbearingsfittedonkilntrunnions(supportrollers)areextremelydifficulttoalign.Consequently failuresaremorefrequentthansleeveorbronzebushingtypebearings.Occasionallythesphericalrollerbearingsare abandonedforthatreason.Thisisaveryexpensivesolution.Thereisawayaroundtheproblem.Ourrecently developedThrustMonitorSystemelectronicallymonitorsrolleralignmenttomakesureitis100%correct.Adding thissystemassuresthefullB10lifeisreachedforeverybearing.TheThrustMonitorsystemcanberetrofittedtoany bearingsizeorstyleinoneortwodays.Subsequentlyrolleralignmentcanbeperfectlytunedtooperatingspeeds, loadsandtemperature.Allthisatsmallfractionofthepricetochange,rollers,bearingsandsupportbases,which wouldberequiredtoswitchfromsphericalstobushings. #7.1WalterGebharton2010-06-3011:45(Reply) Dearsir, Foryourinformationourkilngirthgearmodule25andnos.ofteeth196,iwouldliketoknowthatisitnecessarythat thegirthgearjointboltispre-heatedinoilbathupto120degreecentigratebeforetighteningtheboltinhotkilngirthgear joint.boltisHTandM39x180mmlong.whatisthecorrectstepstofitboltinkilngirthgearjoints,pleasesuggested me. thanks, sunilkumar cementmanufacturingcompanyltd. lumshnong meghalaya,india. contactno.+919862009412. #8sunilkumaron2010-07-0605:04(Reply) Thereareprocedures,wheretheboltisheatedtocertaintemperature,whichstressesthebolttopre-determinedstress whencoolingdown.Thisprocedureshouldbeusedonlyifthegearisdesignedforit.Otherwiseitisalwaysagood ideatohavetheboltsatthesametemperaturewiththegear.Normallythisisnotaproblem,butifthegearishotand theboltsarecool,theyshouldbewarmedupbeforeassembly. #8.1WalterGebharton2010-08-3015:40(Reply) mycementkilnis6.2mdia&92mlength.having2thrustrollerswithhydraulicdrive.whatshouldbetheaverage floatinginmmofthekilnwhenupordown.andalsoweareoftenfacinginsupportrollerbearing(bronzemetal) temperatureincreases&sometimesthetempshootshighleavingwithsmoke&sometimesoiltemphigh.whythis

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page4of19

supportrollerbearingtemperaturesarehighwhenthekilnisrunningnormal. pl.reply #9shaktivelmuruganon2010-07-1012:16(Reply) Theamountofkilnfloatwillbenomorethanthedifferenceinwidthofthepinionandgear.Thegearwillmovefrom oneedgeofthepniontootherbutmustneveroverhangethepinioneitherontheuphillordownhillside. Highbearingtemperaturesarecausedbyhighthrustloads(badalignment);canalsobecausedbyadamagedshaft duetooilcontaminationorbyoilofinsufficientviscosity. #9.1WalterGebharton2010-08-2811:35(Reply) Wehavea3tirekiln,whichislessthan6monthsold withthefollowingdimensions. KilnShellOD=5030mm(includingpadplates) KilnTireID=5040mm TempofShellatSupport1&3=200to2500C TempofTire=125to1500C Measuredcreep=between5to11mm(average8mm) Measuredairgap=between3to6mm(average5mm) TempofShellatSupport2=280to3000C TempofTire=170to1800C Measuredcreep=between0.5to0.8mm(average0.7mm) Measuredairgap=between1to2mm Wewouldrequestyoutokindlyadvicemeonhowtocalculateandadjusttheshimsinalltiresinordertoavoidseizure ofthetireandalsoforsafeoperationofthekiln.Ineedyourimmediateadvicewithsuggestionsandsomereference studymaterialordocuments.Canyoualsogivemeguidelinesashowmuchcoldgaptobemaintainedinalltires. #10C.S.LakshmiNarayanaon2010-07-1906:45(Reply) Thestandardhotgapateachtireismeasuredintermsoftiremigration(creep)pershellrevolution.Thenormalrange is6to12mm.Thecorrectionformulawouldbebycreepreduction.e.g.thecreepis40mmandneedstobereducedto 6mm.40-6=36mmreductionisneeded.Thereforethegapneedstobereducedby36/PI=11.5mmsincethisinvolves twochairplates,eachmustbemadethicker(shimplatesadded)by11.5/2=5.7mm. Incasethecreepislessthan6mmsomesafetymargineislost.Heatingthetireisonesolution.Tiswouldmean enclosingthetiresimilartoagearguardhousingandliningitwithinfraredheaters.Anextrememeasurebutithas beendonebefore.Otherwisekeepingaclosewatchandnotlettingthecreepstopcompletelyisallyoucando. #10.1WalterGebharton2010-08-2812:08(Reply) Howtomeasurethemigrationofthekiln&whatisthestandardvalueofmigrationakilnshouldbemaintened #11RameshEshwaranon2010-07-2104:07(Reply) Thequestionisnotclear;isitkilnuphilltodownhilltravel?Inwhichcasethatwouldbethedifferencebetweenthe pinionwidthandthegearwidth.Isittiremigration?Inwhichcaseitwouldbe6to12mminthehotoperating condition. #11.1WalterGebharton2010-08-2811:38(Reply) DearSir, OurKilnis4.11dia&64mtslong.Thethicknessofchairplateis22mm. Kindlyletmeknowthestandardairgaptobemaintenedbetweeentheshell&tyre&theformuladecidingthesirgap. OurKilnis4.11dia&64mtslong.Thethicknessofchairplateis22mm #12RameshEshwaranon2010-07-2323:24(Reply) Thestandardhotgapateachtireismeasuredintermsoftiremigration(creep)pershellrevolution.Thenormalrange is6to12mm.Thecorrectionformulawouldbebycreepreduction.e.g.thecreepis40mmandneedstobereducedto 6mm.40-6=36mmreductionisneeded.Thereforethegapneedstobereducedby36/PI=11.5mmsincethisinvolves twochairplates,eachmustbemadethicker(shimplatesadded)by11.5/2=5.7mm. #12.1WalterGebharton2010-08-2811:45(Reply) DearSir, WehavePolysiuscementkiln5600TPD,thethrustdevicepressureisvaryingfrom40barsto80andthethrustdevice movetooandfroby1mmineachrevolutionofkiln.Thisisanewlyerectedkilnandlasttimeitwasrunningwith constantpressureatthehydraulicthrustdevice. Regards. #13Shamsalambanagshon2010-08-0304:29(Reply) Thisphenomenonisusuallyattributedtoanunevenshelltemperaturecausedbyunevencoatinginthekilnnearthe thrusttire.Thiscauesthetheshelltobendandresultsinadditionalaxialrunoutofthetirecausingthethrustcycles. Thissymptomwillcomeandgoasthecoatingchanges. #13.1WalterGebharton2010-08-2811:52(Reply) OurKilntyrematerialShortspecificationisGS-20Mn5.SowhatdoesGSstandsfor? #14Nagaraja.Con2010-08-1004:50(Reply) GSiscaststeel.Theothersarepercentagesofotheralloys. #14.1WalterGebharton2010-08-3015:38(Reply) Inspectionofour#2Tirerecentlyledtoasnappingsoundthatiscomingfromthetireitself.Itisalwaysinthesame location.Tireitselfisthrustingdownandinspectionrevealsnothing.theretainingringIthoughtmaybebitingasthe soundalwayscomesfromthetopofthekiln.Anysuggestions? #15KeithPoston2010-08-2013:28(Reply)

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page5of19

Possiblyafillerbarisbeingbentbythetiremigrationandthenwhenitreachesnearthetopthetireloosesgriponit (duetotherunninggapatthetopoftheshell)anditsnapsback.Trylubricatingtheboreofthetirewithamixtureof powderedgraphitemixedinwaterwithsomesoap(emulsifier)andthatmayrelievethesymptom. #15.1WalterGebharton2010-08-2812:01(Reply) IhaveakilnthedesigndrawingshowszerogapbetweentheChairplatesandthetyre.Becauseofthecreepthatistaking place,thegapbetweentheChairplatesandtheTyrewithinashorttimeofoperation.Ifleftunattendedthegapcan increaseupto5-6mm. Myquestioninthisinstancewherethethermalexpansionofthekilnisnotaconsideration,whyshouldInotstopthe creepbymechanicalmeans.NoteIamqueryingthestoppageofonedegreeoffreedomthatistherotationoftyreonthe axisofthekiln,butnotstoppingtheflexingofthetyreontheYaxis(vertical). Pleasecomment. #16DanielMassieon2010-08-2923:51(Reply) Whenthereisnoreasontohaveacreepingtire(typicallywhenthetemperaturedifferencebetweentireandshellis lessthan100C)thenzerocreepmeansnowearandtear,lesson-goingmaintenanceoverthelonghaul;adesirable situation.Theproblemisonceatiredoescreepthereisnoeasywaytostopit.Weldingisnotrecommended.Thebest retrofitthatcanusuallybedoneistightlyshimmedfillerbars.Wedgesystemsusuallybreakfree.Thebestdesignis withthetireshrunkfitdirectlyontheshell. #16.1WalterGebharton2010-08-3015:25(Reply) ASSUMINGTHATKILNISPERFECTLYOK,IFANYROLLERSTOPSASTYREGETSOFF(SAMEROLLER WASMOVINGNORMALLYEARLIER&ROLLERSNOTDISTURBED),DOESTHISPHENOMENONHAVE ANYRELATIONSHIPWITHSHELLTEMPPROFILE/KILNPROCESSPARAMETER?PLEXPLAIN CONSIDERINGSPONGEIRONKILN,4PIERS,4.3MID,80MLONG. #17nanduon2010-08-3013:10(Reply) Whenakilntyreliftsoffarollerandtherollerstopsturningthisisadirectresultofthekilnshellbendingduetoa significantimbalanceoftheshelltemperatureonesidetootherinthevicinityofthetire.Typicallythecauseofsuch shelltemperatureprofileimbalanceisabuildupofmaterialinsidetheshellthatactsasaninsulatinglayer.Whensuch builduporcoatinginsidetheshellisnotuniformaroundthecircumferencetheexternalshelltemperaturecanvary widelytherebybendingtheshell.Mosttimesthisisatransitoryconditionthatrightsitself.Thisphenomenonmay alsocauseamechanicalimbalanceonthekilnrotation,whichcanbeseenasapronouncedloadcycleonthekiln motoramperagedraw.Thepowerswingsonthemotor(s)willbeinphasewiththekilnrotationalfrequency. #17.1WalterGebharton2010-08-3015:36(Reply) IsthereanyworkedoutexampleoraformulathatIcanusetoestablishtheforcethatiscausingthecreep? Thanks. #18DanielMassieon2010-08-3019:59(Reply) Theforcethatiscreatingcreepissimplytherotatingshell.Sincetheshelldiameterundertheringissmallerthanthe boreofthering,theshellcompletesitsrotationsoonerthanthering.Thedifferenceiswhatwecallcreep. #18.1WalterGebharton2010-08-3113:16(Reply) IntheTechpapterreferhttp://www.kiln.com/technical/tech_papers_display.php?Rotating-kiln-tyres-lubricating-between -the-tyre-and-shell-1;section'Whatiscreepandwhyisitnecessary?'thereisareferencetosplinedtyresupportdesigns. SinceIamintheprocessofreplacingatyreinoneofthedrum(granulator),Iwouldliketoconsiderthisdesignasan option. Cansomeoneassisttolocatewherethisdesignisavailable. Thanks #19DanielMassieon2010-08-3117:33(Reply) Migratingortyresthatcreep(theyslowlyrevolvearoundtheshellabout1/2"perturn)isaneconomicalmeansof protectingrefractoryinadirectfiredoperation.Ifthereisnorefractoryinthevesseltoprotectthenwhyputupwith theassociatedwear-and-tearandtheongoingmaintenancethatsrequiredwithmigratingtyres?Asplinedtyreisa meansoflockingthetirefromrotationaroundtheshellbutstillleavingroomforthedifferentialthermalexpansion betweenshellandtire.Splinedtyresalsodramaticallyreduceshellflexing,againadesirablefeaturethatimproves refractoryperformanceandincreasesservicelife.Itisaveryexpensivedesign(availablefromPolysius,F.L.Smidth andothers).Forvesselslikegranulatorsthathavenorefractoryormoregenerallyspeaking,vesselswhosedifference inshelltotiretemperaturedoesnotexceed200Fmigratingtyresarenotrecommended.Tyresonsuchvesselsare bestshrunkfitdirectlytotheshellwithouttheuseoftheintermediatesupportchairsorfillerbars. #19.1WalterGebharton2010-09-0106:01(Reply) DearSir, WehaveaThreesupportFLSkilnof3800TPD.WehaveahydraulicthrustdeviceaninthecircuitoftheHTD (Hydraulicthrustdevice)accumulatorwithprchargingpressureof30bars. Myquestionis,howmuchaxial/thrustloadshouldcomeonthrustdeviceifitismechanicalandifitishydraulic. Is10barasanormaloperatingpressureonhydraulicthrustdevicefor3800TPDdoesmakesensethatitistakingthe requiredload. Whatshouldbetheminimumpressureand%loadonhydraulicthrustdevice. Whethermechanicalbalanceandprocessparameterscomeintheroleforthis. #20SanjaySharmaon2010-09-0206:44(Reply) inourkilnsupportrolleruphillsidebearing,rollerspinslightlymorethandownhillsidewhatdoesmeanstellmethe thrustofroller? #21sandeepon2010-09-0806:14(Reply) Yourquestionisambiguous.Pleaserestateandelaborateclearly.

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page6of19

#21.1WalterGebharton2010-10-2909:08(Reply) PLEASEPROVIDETHEDETAILSTOFINDOUTKILNINCLINATIONFORRUNNINGANDINSTANDSTILL CONDITION. #22Nagaraja.Con2010-09-2023:30(Reply) Afullalignmentsurveyneedstobedonetoestablishthisaccurately.Otherwisejustmeasuretheslopeofanybase. #22.1WalterGebharton2010-10-2909:07(Reply) Whatarethedailychecklistforthekiln? #23shakil(Homepage)on2010-10-0603:48(Reply) DuringplannedUTinspection,acrackwasdiscoveredatashaftofasupportrollerofatwo-supportacementkiln(FLS Rotaxtype). Thecrackdimensionsareapprox.50mmX50mmandtheshaftdiameteris650mmatthissection(thefirstcontactpoint oftherollerborewiththeshaft). Therotarykilnisinoperationfrom2003,overallconditionisverygood,withoutanysignificantproblems. Whataretheprospectsforthedevelopmentofthiscrackandwhatcanyouadviceforthenextsteps? Asthisisatwo-supportkiln,isthereanydangerfortherotarykilntoskipoverthesupportstationsincaseofashaft totalfailure?!!! #24DimitrisDelavogiason2010-10-0804:55(Reply) Onthefaceofthislimitedinformationthissoundslikeanextremelyseriousproblem.Suggestthattherollerbe replacedimmediately.Shaftsfailroutinelyandwithatwosupportkilntheresultingdamagewillbeunpdredictable andpotentiallycatastrophic. #24.1WalterGebharton2010-10-2908:36(Reply) Ihavestartedtonoticeblue-purplelinesonmytyreatthehotendofmykiln,butthetemperatureofthetyreisabout91 deg.C.TheKilnisusedforaluminaandtheareaisdustysometimes.Iwasthinkingofaloadingproblembutthebearing temperaturesareok.Whatiscausingtheselines? #25Adrianon2010-10-0818:50(Reply) Blue-violetcolorsareduetosurfaceheatchangingthereflectivityofthesurface.Thisiscommonwithfreshly machinedsteelsurfaces. #25.1WalterGebharton2010-10-2908:18(Reply) DearSirs; myqustionis,istheiranybadsideeffectfromtheindustrialwaterinsidepipelineifistoppedtheplantmorethanone monthwithoutworking,thewatercirculationwillstoptoo,soiftheplantcompletelystoppedformorethanonemonth, maywefacemechanicalproblemsfromthewaterduetothisstoppage?andidtheirisexpectedproblemshowwecan solvethisproblemsorhowwecancleanthelinesagainafterworkingtheplant #26AdelOnsion2010-10-1701:22(Reply) Whatkindofplantareyoutalkingabout?Whereisitlocated? #26.1WalterGebharton2010-10-2908:11(Reply) itisCEMENTplant,itislocatedatEGYPT #26.1.1AdelOnsion2010-11-0323:51(Reply) Tobesafewhynotjustblowoutthewaterusingcompressedair.Somecondensationwillstillprobablyoccur butatleastthatwaterwillbepureandnotbeacidic. #26.1.1.1WalterGebharton2010-11-1314:26(Reply) thankyousomuch #26.1.1.1.1AdelOnsion2010-11-2400:57(Reply) Tobesafewhynotjustblowoutthewaterusingcompressedair.Somecondensationwillstillprobablyoccurbutat leastthatwaterwillbepureandnotbeacidic. #26.2WalterGebharton2010-11-1314:24(Reply) DearSirs, Regarding:CrackedRoller Wewerecontactedbyabearingmanaufacturertodoaexpansionheatingjobonanewcastroller,theyinstructedusto heatuptherollerto290Candholdfor8hours,theywouldthenmeasuretheIDoftherollerandifexpandedenough inserttheshaft(storedindryice)intotheroller.Weraisedtherolleratarateof65Cp/handhelditat290Cforabout8 hrs.WhentheywantedtomeasuretheIDtheynoticedthepresenceofcrackingontheinsideboreoftheroller. Theyarenowtryingtoblameusforthecrackingbasedonthefactthatwehadheatersontheoutsieoftherollerand noneontheinside. Couildyoupleasehelpmewiththefollowing; 1.Wouldthisrollerhavehadtoundergoneheattreatmentinthemanufacturingprocess(normalizing). 2.wouldtheabsenceofheatersontheinsideborecauseanyproblems. Eagerlyawaitingyourreply, KindRegards, JohnDickinson #27JohnDickinsonon2010-10-2423:34(Reply) Weonlydealwithfordgedrollersunlesstherollerisverylarge.Whatisthediameterandwidthofthisroller?Who manufacturedit?Onlytheywouldknowifitwasheattreated.Whenweshrinkfitrollersontoashaftweleavethe shaftatambient(20C)andheattherollerinanoventoabot300-350Cforabout12hours.Wehavenoexperience with"heaters"applieddirectlytoaroller. #27.1WalterGebharton2010-10-2908:08(Reply)

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page7of19

Whyprejackingpumpisnotusedinkiln? withTechnicalcalculation. #28Zahirkhiraon2010-10-2607:06(Reply) Pleaseprovidephysicalandchemicalpropertiesofeasybarforlubricationofkilntyres. #29akon2010-10-2804:48(Reply) Pleasecontactkilndoctor@vsnl.com #29.1WalterGebharton2010-10-2907:49(Reply) Pleasedefinewhata"prejackingpump"? #29.1.1WalterGebharton2010-10-2907:53(Reply) inmyplantkilntorqueproblem,allparameterarenormal,sopleasegivesolutiononkilntorqueincreses #30vaibhavon2010-10-2807:55(Reply) Thereisnotenoughinformationgiventoprovideananswer. Firsttheentireweightoftheoperatingkilnanditsslopeisneeded.E.g.1000tonsat3%slope.Thenthetheoreticalload onthethrustrollerwouldbe30tons.Nowaddsomesafetyfactorformisalignedrollers,tirewobble,shellbends,things likethat.Saythisis100%.Sonowtheloadis60Tonthethrustroller. Nextyouneedtoknowthediameterofthehydraulicthrustrams(totalpistonarea),whichwillallowyoutocalculatethe expectedpressure. WhynotjustasktheOEM? #31WalterGebharton2010-10-2907:09(Reply) Pleasedescribeindetailwhatyoumeanby"kilntorqueproblem"? #32WalterGebharton2010-10-2907:43(Reply) hidears Ihaveaquestionaboutsupportingrollers.whatisthereasonofrollerscabing.infactwhyfallalotofsoftscabingpieces fromrollersurfacewhenkilnisrunninghot thanksalot #33hadion2010-10-3100:05(Reply) Thisisasimplecaseofbadrolleralignment.Findtheneutralpointandmovenomorethanabout0.5mmonone bearingforskewifneeded. #33.1WalterGebharton2010-11-1314:14(Reply) Thisisasimplematterofbadrolleralignment.Movetherollertotheneutralpointandifneededmoveonebearingno morethanabout0.5mmforpositiveskew. #33.2WalterGebharton2010-11-1314:17(Reply) dearsir whatarethereasonsofdifferettemp.onthewidthorthetyreandwhatisthepermisbbletemp.differencesonthekiln tyre'swidth? withbestregard #34Alishahsavaron2010-11-0703:33(Reply) Theheatinthetyrecomesfromtheshell.Thereforetheshellishotterononesideofthetyrecomparedtotheother. Thereisnodangertothetyrenomatterwhatthetemperaturedifferenceis. #34.1WalterGebharton2010-11-1314:30(Reply) Theotherday,Iwaspreheatingacementkilnafterarefractoryjob.thekilnwasclearofallinternalcoating.Ihadto aborttheheatupduetoextenuatingcircumstancesandIwasaskedbymyoperator,whatshouldbetherotationschedule. TherewasnomaterialinthekilnsoIhadadvisedhimthatno"barring"wasrequired.Afterafewminutes,Irealizedthat Iwaswronginmyadvicetotheoperator.Thisonlyhighlightedsomeignoranceofprocedurestoprotectthekilnduring thisstrangesituation.Canyougivemefromfirstprinciplestheproceduresandthereasoningbehindsomeofthe standardproceduresexplainingthemechanicalstressesthatthekilnshellwouldbeexperiencingduringkilnheatupand cooling. #35AlonzoRamsaranon2010-11-0719:20(Reply) Volumescanbewrittenonthistopic.Icanjustgiveafewpointersinthisforum.Offirstconcernistherefractoryby avoidingrapidchangesintemperature(thermalshock).Temperatureincreasesanddecreasesshouldneverexceed50? Cperhourpreferablylowerthanthatsay20to30?C.Thisisbasedonkilnexitgastemperatures.Duringheatuptire migrationshouldnotreducetozero,ifitdoestheheatupistooaggressive.Oncooldownreducethedraftfantoa minimumthatjustkeepsthefeedendofthekilnfromgoingtopositivepressure.Stoppingahotkilnformorethan10 minutesriskswarpingtheshell,thiscouldbeirreversible.Barring,incrementalrotationevery10minutesorso, avoidsthatrisk.Thehotkilncouldbestoppedindefinitelyifthetemperaturecouldbelockedinbystoppingthedraft completely.Unfortunatelyfewkilnshavethatfacility,e.g.inletandoutletshutoffdampers.Barringintervalsare increaseduntiltheshelltemperaturedropsbelow150?Catwhichpointthekilncanbecompletelystopped. #35.1WalterGebharton2010-11-1314:50(Reply) Whyisthetemperaturedifferentialsoimportanttoconsiderwhentakingcreep.Iunderstandthatthetemperature differentialbetweenthetyreandtheshellshouldnotexceed180oC.Whatisthereasoningforthis. #36AlonzoRamsaranon2010-11-0809:47(Reply) Itsnotsomuchamatteroftemperaturedifferencebuttheunderstandingthatresidualcreepisasafetymargin.The maximumallowabletemperaturedifferencewillvaryforeachtyredependingonitsmass,widthtothickness proportionsandlocationonthekiln.Whenthedifferenceishighenoughthatthetyrestopscreepingthesafetymargin islostandafurtherincreaseinshelltemperatureriskscrushingrefractoryandpermanentlyneckingtheshell.6to12 mmresidualcreepatoperatingtemperaturesisconsideredideal. #36.1WalterGebharton2010-11-1315:02(Reply) DearSir What`sthemeaningofteethprofilecorrection.andwhycouldwefoundthat`stermatlargegears.Arethereany precautionsthatmustbeobservedwhendealingwithsuchgears.

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page8of19

Regards Ali #37AliAwad(Homepage)on2010-11-1508:19(Reply) Teethprofilecorrection,ifminor,couldmeanusingapastetypelubricantthatfillsinsmallpits.Itcouldalsomeana running-incompoundthatpolishesnewlymachinedgearteeth.Itcouldalsomeanrecuttingofthegear. #37.1WalterGebharton2010-11-1509:58(Reply) DearSir Profilecorrectionijustaskedmeantadifferantaddendumgears,alargeoneatpinion,andsmallatgithe. regards #38Ali(Homepage)on2010-11-1510:58(Reply) Soundslikeamismatchedpinionwasinstalled.Thepinionwouldhavetohavetheoutsidediametermachinedto reducetheaddendum. #38.1WalterGebharton2010-11-1618:54(Reply) DearSir. IWasn'tmeaningmismatchinggearsincontactbutimeantaspurgearswithcorrectedprofileandthatterms pointingtoThedistancebetweenthepitchlineoftherackandtherollinglineiscalledcorrectedprofileDM.The correctedprofileispositivewhenthepitchlineoftherackisabovethecuttingpitchcircleofthegear.Inthe oppositecasethereisminuscorrection. Forexample:- forstandersgearsaddendumequalthemodule. Forcorrectedprofilegearstheaddendumequalmodule+DM. Soineedtoresendmyquestionifyoudon`tmind,,Arethereanyprecautionsthatmustbeobservedwhendealing withsuchgears.. Regards #38.1.1Ali(Homepage)on2010-11-2509:28(Reply) Yourterminologyisstillconfusing.Pitchlinescommonlyscribedintobothsidesofbothgearandpinionand aretangentwhenthepinioniscorrectlyalignedtothegearforbothspurgearsandhelicalgears. #38.1.1.1WalterGebharton2010-12-0714:13(Reply) Inmyapplicationthetemperaturesareunder100degC. Creepiscausingwearandincreasingthegapbetweenthetyreandchairplate. Toovercomethisissue,therearecaseswherethechairplateshavebeenweldedtothetyre.Thisdidnotsolvethe problembecausetheweldshearedoffwhichIbelievewouldbeduetoflexingofthetyrethattakesplaceduringits rotationalcyclewiththeloadinthedrum.CorrectmeifIamwrong. Afterfairbitofthinking,Iamreachingaconclusionthatifthethermalgrowthtoclosethegapbetweenthetyreandthe chairplateisnotanissue,thanthetyreshouldbepartofthedrum.CorrectmeifIamwrongonaccountaswell. Inoldmachinerywherethetyreisfreetocreepandwherethegrowthofthedrumduetoheatisnotanissue,thetyre shouldbestoppedfromcreeping. Iamthinkingintermsofdegreeoffreedomofthethetyre.Axialdegreeoffreedomisstoppedbystopblocks.Vertical freedomofmovement(90degtoaxisofdrum)downwardisstoppedbychairplates,upwardisleftfree.Thirddegreeof freedom,sideways(90degtoaxis)issimilartoverticalaxis,thefourthbeingrotationalwhichcausesthecreepand subsequentlywear. Tostopthisrotationalfreedomofmovement,Iamthinkingoffabrackettoclamponthetyrefromunderside.This bracketwouldrestagainstthestopblocksofthetyre.Thecontactsurfacewouldbelubricatedtoallowfreemovementof thetyreinhorizontalandverticalaxis. AnycommentsFororAgainstthisconclusion. Daniel #39StoppingtheCreepon2010-11-1521:37(Reply) Youarecorrectonmostcountsexceptclampingthetyremaynotworkjustlikeweldingdidnotwork.Theclamps willlikelyripaway. Justasaby-the-way;whenthetemperaturedifferencebetweentheshellandthetyreisunder100?Ctheoriginal constructionshouldbetohavethetyresshrunkfitontotheshell.Shrinkingasaretrofit,althoughnotimpossiblemay notbepractical. Thebestapproachwouldbetoinstallnewchairplatesastightlyaspossible.Withalittleheattheshellexpansion shouldlockupthetyre,whichiswhatyouwant.Somecreepwhenheatingupandcoolingdownwillofcoursestillbe there,whichwilleventuallycausewearagain.Atthatpointrepeattheprocess.Shortofgettingashrinkfit(replacing asectionofshellwithanewshrunkontyre)thatwillbethemostcosteffectiveapproach. #39.1WalterGebharton2010-11-1619:18(Reply) Walter, Mythoughtsarethattheweldingdidnotworkbecausetheforcesinthedirection(90degtoaxis)werehigherthanthe tensilestrengthoftheweld.Mythoughtsarethatundershear(Shearforcebeingtheforcethatcausesthecreep)wastoo highfortheweld. Slippageoftheclampisexpected,henceIwasplanningtoinstall4clamps.Ithoughtofgivingthisatryinsteadof

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page9of19

dentingthesideofthetyretolocatethetheclampingbots? Understandingthatalltheturningforceistakenbythegirthgearandpinionassembly,whatisthevalueoftheforcethat causesthecreep.AssumeSpeedreducerand200kWmotordriveand200Tonneweightinthedrum. Canyouassistinestablishingtheforcethatisbetweenthetyreandthetrunnioncausingthecreep. Thanks, Daniel #40DanielMassieon2010-11-1621:21(Reply) Anymechanical"clamps"nomatterhowmanyyouputonarelikelytogiveupsoonerorlater.Anymeaningful calculationoftheforcesinvolvedwouldbenearimpossible.Theprimarymoveristhegear,whichturnstheshell.The shellthendragsthetirearound.Thetirebeinglargerindiameterthanthetopsofthechairsdoesn'tquitemakeafull turnwhentheshelldoes.Thisdifference,thedifferenceintheircircumferences,weseeascreep.Sothefirstforceis simplythepowerdrawnbythemotor.Howmuchofthatpoweristransferredtoanyonetire? Nextistheweightofthekiln.Thereactionatanygivenpierisactuallycalculated,whichallowsoptimumpier locationandsizingtires,rollersbearings,platethicknessetc.Thatweightcanbetransferredtoasingleclampsince theshellmovesupanddownwrttothetireasseenwhenyoucomparetheirrelativepositionsatthetopandbottom. Howdoassurethatalltheclampstaketheirproportionateload?PolysiusandlaterFLShavesuccessfullydesigned suchasystemthatiscalledTheSplinedTireandtheTangentialSupportrespectively. Thenthemostelusiveforceofallisthefactthattheshellandtireflexastheyturn.Thiswillbetheprinciplecauseof weldfailure.Theforceontheweldisonethingandlikelynotenoughtofailitbuttheforcereverseswitheveryturn oftheshell.Sincetheshellandtiredonotmoveasone(whichtheywoulddowhenthetireisshrunkon)theyflex independently.Sothereyouhaveit;aforcethatdrivesthetireandareversingforceduetogravitythatindependently flexesbetweenshellandtire. #40.1WalterGebharton2010-11-2206:59(Reply) H1!Walter, Couldyoupleaseexplain 1.WhatisTangentialSupportdesign? 2.Whenthetyreflexes,theforcereverses,butthedirectionisstilltowardsthecentreorawayfromthecentreofthe drum.AmIrightinsayingthat? IfyesthanIwouldstatethattheclampfacethatisleaningagainstastoppermountedontheshellofthedrumwould haveaslidingmotion.AmIrightinsayingthat? Thanks, Daniel #41DanielMassieon2010-11-2222:30(Reply) Ihaveputapictureofatangentialsupportedtireontheblogpage.Alsopostedistheoriginaldesignpatentedby Polysiusin1969.Theillustrationisanextractfromthepatent. Asfarasyoursecondpointisconcerned;bothtireandshellflex.Atthebottomtheshellpushesdownandmostlyfits flushwiththetire.Atthetopinthecaseofamigratingtire,theshellmovesdownawayfromthetire,creatingthegap atthetop.So,ifwelookatthetireandshellsrelativemovementtheycomeincontactandseparateonceeach revolutionaswellasmovecircumferentiallyonewithrespecttotheother.Also,theydonotrotateastrueeccentric circles;itsmoreofanovalpathforboth.Thisresultsinanassemblywhereitisverydifficulttomechanicallystop creep.Thesplineddesigneffectivelyusesakeybetweeneachchairpadsuchthattheshellissuspended(or tangentiallysupported)at3oclockand9oclocksothereisalmostasmuchgapatthebottomasthereisatthetop. Gravity(shellflexakaovality)stillhasaneffectsotheuppergapwillstillbelarger. #41.1WalterGebharton2010-11-2311:43(Reply) Inthetangentialsupportdesign,itappearsthatlugsareboltedontothesidesofthetire.Eachlughavingtwosay M20bolts.IfIweretodeveloptheconcepttofurthermydesiretostopthecreep,Icouldrestthislugagainsta circularpinweldedontotheshell.Thiswouldgivealinecontact.Thelugwouldslideoverthepinatthecontact line. Theissuenowwouldbesheeringoffthepinfromtheshell.Thiscanbeovercomebymanylugs,asisthecasein thetangentialsupportdesign. Whatdoyouthink? #41.1.1DanielMassieon2010-11-2418:03(Reply) Inthetangentialdesignthe"bolts"actuallygorightthroughthetyre. Isuspectthatanyclampingdeviceonthetyrewillslipnomatterhowmanyareputon. WalterG #41.1.1.1WalterGebharton2010-12-0713:49(Reply) Whatismeantbygirthgearandpinionmodule? #42Suresh(Homepage)on2010-11-2503:04(Reply) "Module"istheunitofsizethatindicateshowbigorsmallagearis.Itistheratioofthereferencediameterofthe geardividedbythenumberofteeth. http://www.khkgears.co.jp/en/gear_technology/pdf/module.pdf #42.1WalterGebharton2010-12-0713:55(Reply) WearefacingaprolemofthekilnRPM frequently,sometimesreducingandstopped automatically.Istpairthrustrollerdimensions9mmdifferenceondiameter.Balancingbyshim.Whattodo?

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page10of19

#43JatinChandraDadhara(Homepage)on2010-11-2510:28(Reply) Thequestionisnotwellunderstood.Doyoumeanthekilnstopsrotatingbecausethemotorstallsduetohigh loading?Ifsoyoursupportrollersarebadlyaligned. Walter #43.1WalterGebharton2010-12-0713:25(Reply) DearSir, IwanttoaskthatinfindingRetentiontimeofkilnincementmanufacturingthereisafactor"11.2"Iwanttoaskthat howandfromwhereitcomes. thanksalot waitingeagerlyfortheanswer Regards Kamran #44KamranZafaron2010-11-2814:39(Reply) TheUSBureauofMinesretentiontimeformula; T=(1.77xLx(A)^0.5)/(PxDxN) Where A=thenaturalangleofreposeofthematerialindegrees P=slopeofthekilnindegrees D=theinsidediameterofthekilninfeet L=lengthofthekilnshellinfeet N=rotationspeedinrevolutionsperminute T=retentiontimeinminutes Iamnotsurewherethe"11.2"comesfrom. #44.1WalterGebharton2010-12-0714:22(Reply) DearSir, Daersirwehaveasmallrotarykilnburningwastematerials.Weareinashutdownperiodandhaveremovedthefeed endwebcosealforrenewal. Thesealrunsurfacehasbecomeveryhardandbegantodelaminatefromthemainshell.(6mmthickapprox) Canyouadviseifthisisaseperatematerialfromthemainshell.Photocanbesuppliedformoreinformation #45AlanCampbellon2010-11-2906:20(Reply) Aphotowouldcertainlyhelp.Webbcosealsusuallyrunonawrapperplatethatprotectstheshell.Isitperhapsthe wrapperthatisseparatingfromtheshell? #45.1WalterGebharton2010-12-0807:55(Reply) HiWalter, HowcanIknowthatthekilnrollerisatitsneutralpositionbeforeIstartre-alignment? #46adamhohyeson2010-12-0502:48(Reply) Thefirststepinanyrolleradjustmentshouldbetofloattherollerthroughitsneutralpositionandgofromthere. Providedtherollerisfittedwithasleevebearingithasanaxialfloatofabout6to12mm.Adjustsothattheroller movesaxiallyfromthecurrentposition(normallyitshouldsitdownhillforpositivethrust)insmallincrementsof about0.01mm.Waitabout1/2hourbetweenmoves(waitingtimedependsonkilnspeed).When,withthelastmove, therollershiftsaxiallyyouknowyouhavecrossedtheneutralpointwithinthemagnitudeofthelastmove.Carefully observealltheroller'sbearingtemperaturesthroughthisprocess. #46.1WalterGebharton2010-12-0808:08(Reply) dearsir lastweekiwastakenkilnaxialpressurereadingsasbelow. 1.kiln1stpierrighthandsideroller(viewfromkilnoutletend) moved1mmuphilltodownhill axialpressure-150bar feed-260Tph thrustposition--0.4 rpm-4.5 time-10.35am bearingdia400x480 2.kiln1stpierlefthandsideroller(viewfromkilnoutletend) moved1mmdownhilltouphill axialpressure-170bar feed-270Tph thrustposition--1.9 rpm-4.2 time-11.15am bearingdia400x480 3.kiln2ndpierrighthandsideroller(viewfromkilnoutletend) moved1mmdownhilltouphill axialpressure-470bar feed-275Tph thrustposition--2.5 rpm-4.2 time-11.55am bearingdia500x600

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page11of19

4.kiln2ndpierlefthandsideroller(viewfromkilnoutletend) moved4mmdownhilltouphill axialpressure-430bar feed-285Tph thrustposition--2.7 rpm-4.0 time-12.35pm bearingdia500x600 5.kiln3rdpierrighthandsideroller(viewfromkilnoutletend) moved8mmdownhilltouphill axialpressure-100bar feed-240Tph thrustposition--2.6 rpm-3.9 time-9.45am bearingdia400x480 6.kiln3rdpierrighthandsideroller(viewfromkilnoutletend) moved8mmuphilltodownhill axialpressure-100bar feed-220Tph thrustposition--1.7 rpm-3.6 time-9.00am bearingdia400x480 whyaxialpressureismore? whatitindicates? whichparametersihavetocheck? isthereanyrelationb/wgraphitelubricationofrollerandtyre? #47ramarajuon2010-12-2000:13(Reply) Pleaseclarify; "moved8mmuphilltodownhill" whathasmoved-theroller? whydiditmove? "thrustposition--1.7" howisthismeasured;fromwhatreferenceisthismeasured? #47.1WalterGebharton2010-12-2307:28(Reply) thesereadingsarekilnaxialpressurereadings (moved8mmuphilltodownhill)means thegapb/wbearingthrustcollartorollershaftthrustringis8mm,rollershaftthrustringmoved8mmdownside. ("thrustposition--1.7")meanswheniwastakingpressurereadingsatthattimekilnhydraulicthrustpositionis -1.7 #47.1.1ramarajuon2010-12-2402:25(Reply) youroriginalquestions: whyaxialpressureismore? Axialpressureonthesupportrollersvarieswithrollerskew(alignment),degreeoftyrewobble(axialrun-out) andwithhydraulicthrustrollersystempressure. whatitindicates? Ifpressuresarenotequalitmeanstherollersarenotoptimallyaligned.Additionallythepressurewillvary duringeachshellrotationproportionaltothetyre'saxialrun-out.Thehydraulicthrustsystemwillalsoaffect theaxialpressure.Toaligntherollerscorrectlyandtobalanceaxialthrustorneutralizetherollersthehydraulic thrustsystemshouldbeshutoffforatleast12hoursbeforemeasurements/adjustmentsaremade. whichparametersihavetocheck? Floatingtherollers(withthehydraulicsystemturnedoff)towithin0.1mmofneutralwouldbeideal. isthereanyrelationb/wgraphitelubricationofrollerandtyre? Graphiteblocklubricationhelpsreducewearontherollingsurfacesifrollerskewisnotperfect. #47.1.1.1WalterGebharton2010-12-2509:03(Reply) imworkinginaironorepelletplant.iwanttoknow"howkilnsupportrolleralignmentisdone" #48satishon2010-12-2200:21(Reply) Dothesupportrollersusesphericalrollerbearingsoraretheysleevejournalbearings? #48.1WalterGebharton2010-12-2307:23(Reply) DearSir Ourkilnisa3pier,3.8mdiaand56mlengthwithfixedtyre(i.e.thetoothedtyre)pleaseadviseforthefollowing: 1-Althoughwehavingfixedringwhichovalityissupposedtobelimitedwhydoesthechairpadwelldscrackinpier1 (outlet)?

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page12of19

2-Althoughthemaximumrunoutofkilnshellis1inchandmaximumtemperaturedifferentis130whydoesthetyre2 (middle)liftsfromtheleftroller?coulditbepossiblewithtyrefixing? 3-Whydoesthetyre2(middle)goesofffromonlyoneoftherollers(leftone)andnottheother? 4-Asamatterofprinciple,whataretheplus/minuspointsoffixedtyresystemcomparedtoloosetyresupport? #49m.j.yaghooton2010-12-2204:53(Reply) 1)Chairpadweldswillcrackduetoexcessiveloading/stress.Thismaynotbedirectlyrelatedtoexcessiveovality. 2)thetyreliftingofftherollershasnothingtodowiththemethodoftyrefixing.Itistheresultofabendintheshell usuallyatemporaryconditioncausedbyunevenclinkercoating. 3)Asymetricallift-offcouldbeduetorollermisalignmentorloading. Isittheupturningsideordownturningsidewheretherollerliftsoff? 4)Thesplinedortangentialsupportsystemofatyreisprimarilyemployedtoreducetheovality(theamounttheshell flexesduringrotation)oflargediameterkilnshells.Reductionsaretypically4:1comparedtotheconventional migratingtyrewiththesameshelldiameter.Thisshouldtranslateintomuchlongerrefractorylife.Asecondary advantageisreducedmaintenancesincewearduetotyremigrationhasbeeneliminated.Disadvantagesareahigh capitalcostandcostlierrepaircostswhensucharerequired. #49.1WalterGebharton2010-12-2307:34(Reply) itisdownturningsidewheretherollerliftsoff. #49.1.1m.j.yaghooton2010-12-2606:13(Reply) Isuggestthepossibilitythattheaddedweightofthematerialloadinsidethekilnontheupturningsideis keepingthetyreincontactwiththeroller,whereasonthedownturningside,thelessloadedside,allowsthe bendintheshelltoliftthetyreawayfromtheroller.Thismaybeatransientconditionwhichcouldcorrect itselfovertime. #49.1.1.1WalterGebharton2010-12-2610:51(Reply) whyFlotingTyre. whatisthatPIwhichumentioninmethodofreducingthrTyreCreep. pleaseanswermyquation Thankingyou PRABHUGOUDAU #50PrabhuGoudaUon2010-12-2902:24(Reply) Afloatingtireallowsfordifferentialthermalexpansionbetweenshellandtiretoprotecttherefractoryfrombeing crushed. PI=3.14. #50.1WalterGebharton2011-01-0309:39(Reply) kindlydescribetheloadingpatternofsphericalrollerofsupportrollerbearings #51manojon2011-01-0822:09(Reply) Thequestionisveryvague,pleaseelaborate.Isthereaparticularproblemyouaretryingtosolve? #51.1WalterGebharton2011-01-1006:54(Reply) iwannaaskeverybody,ourkilnhas79mlengthand3mofdiameter.it'ssupportedbythreetyre.thecaseisintyre number2.ifoundanabnormalsoundinbearingnumber2.canyouexplaintomewhatthproblemis?? thanxbefore.... #52blackstrezzon2011-01-1019:06(Reply) Whatisthequalityofthesound?Isitclicking,snappingorsqealing? #52.1WalterGebharton2011-01-1100:23(Reply) respectedsir, Iravibelwalexecutiveengineeratharimachineltd.wearehavingaproblemthatthesupportroller,thataremanufacture isoflowhardness(round180bhn)whatremediesshouldbetakentobringitto280-300bhn,thechangeinproperties (chem,mech.)doesnotmuchconsidertotheparty plzadvicesirastheyare12inno.worthnearly1crore. #53Ravibelwalon2011-01-1902:48(Reply) Ifthesearelargekilnrollers,theycanbesleevedwithhardermaterialsleeves. Smallrollers(forusthelimitis36)canbeflamehardened,butitneedstobedonerightnottoleaveanysoftspots. Thiswouldbesurfacehardenedonly.Sleeveswouldbethroughhardened. #53.1WalterGebharton2011-01-1919:00(Reply) kilnshellcrackobservedjustbelowtyre.oneplateof1.5m*1.5mfixedoverthecrackareainsidethekilnand welded.Thereafterrefractorycastingisbeingdone.Thismeans,tocoveruptheshellcrack,1.5*1.5mplateisnowin betweencrackedshellandrefractorycasting.Thereisagapofabout20mmbetweentwoplatesforshelldeformation. Questionis:-(1)whatwillbetheeffectoftrappedairinbetweenthetwoshells.(2)shouldthegapbetweentheshellsbe filledupbyrefractorymaterial. #54m.s.vason2011-01-2604:12(Reply) Shellcracks,especiallyunderatyre,cannotbesuccessfullyrepairedusingsuchpatchplates.Thecrackmustbe repaireddirectlyintheplatethatiscracked.Repairsmustbemadefrombothsides,whichmeansmovingthetyreto gainaccess.Iftheshellplateismorethan20yearsoldwerecommendreplacingthewholesectionofshellunderthe tyregoingatleast300mmpastthecircumferentialweldateachsideofthetyreuphillanddownhill. #54.1WalterGebharton2011-01-2611:08(Reply)

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page13of19

Whatisthecalculationfortapershim. Howtomaketapershims. #55sumankumarneogion2011-01-2608:55(Reply) TaperedshimsaremadebyusingBlanchardgrindingwheretheshimplateismagneticallyheldforgrinding.The thinnestedgeisnormallykepttoaminimumof3mm.Theangleofthetaperdependsontherequiredcorrectiontothe slope,sothethickestedgeoftheoppositeshimwilldependonthewidthofeachhousingandthedistancebetween housings.Shimsmustbethefulllengthandwidthofeachbearinghousingfootprint.Greatcautionmustbeexercised tonotcomprimisefittedkeysbetweenhousingsandbasesasthehousingswillberaisedwhenshimsareintroduced. #55.1WalterGebharton2011-01-2611:16(Reply) dearsir, ihave3.95diax61mtrlengthkiln. kilnfloat(thrust)settingis-5to+5. whatisthekilnfloating(up&down)timefrequency? isthereanychanceincreasekilnfloatsetting? #56ramarajuon2011-02-0506:35(Reply) Pleaseprovidetheunitsfor-5to+5. #56.1WalterGebharton2011-02-1015:38(Reply) Hellothere, Iwouldliketoaskyouropiniononthemeritofinstallingaroofcoveroverarotarykilninatropicalclimatewhere heavysuddendownpourisexpected. WeareinstallingakilninsuchalocationandthereisadebatebetweentheOperation&Maintenanceandconstruction folks.Theconstructionfolksaresayingthattheheavyrain;wheneverithappens,willnotcreateathermalstresstothe shellandsuchnoproblemwiththerefractoryshouldbeexpectedasaresult.TheOperationandMaintenanceguysseem tothinkotherwise.Theshellsurfacetemperaturewillbearound150degC. Anyonecancomment? Thanks #57KhairulJaison2011-02-0901:52(Reply) Thereisariskifthereisnoauxiliarydriveinstalled.Whenaseverestormariseswithheavyrainthereisalsoagood possibilityofelectricaldisturbanceandpowerfailures.Nodangertothekilnandrefractoryexistsevenduringheavy downpoursaslongasthekilncontinuestorotate.Theworstcasescenariowithnocoverisduringaheavydownpour apowerfailureoccursandthekilnstopsrotating.Inthatcasetheriskforrefractoryfailureandseverebendingofthe kilnshellalongitslengthisveryhigh.Suchbendsmaybeirreversible.Naturallytheauxiliarydrivemusthaveits ownindependentpowersupply,typicallyagasordieselenginethatisroutinelystarted(weekly)toassure100% availability.Ifoneisinstalledandreliablethenkilncovers(whicharecomparativelyexpensive)areoptional. #57.1WalterGebharton2011-02-1015:34(Reply) DearSir, Eitheritisbettertolubricatethekilnsupportingrollerduringlight-upafteralongshutdownofthekilnornot.Because aspermyperceptionitwillelongatewithtemperatureatthesametimetwodrymetalsurfaceswillrubagainsteach other,speciallywhenrotationkeptstoppedduringlightup. #58shamsAlamon2011-02-1903:59(Reply) Yesitisrequiredtolubricate,thisshouldnotbeanoption.Whenthekilnisstanding,oildrainsoutofthebearing. Thenwhenitisstartedthereisashortmomentofmetaltometalcontact,somebearingmaterialislostandthebearing becomesslightlydamaged.Theysayifthekilnisneverstoppedthebearingswouldlastforever.Unfortunately nothingisforever.Theprocedureshouldbetodrain1litreofoilfromthebearingandpouritbackontothe distributiontrayabout10minutesbeforestartingkilnrotation. #58.1WalterGebharton2011-02-2006:13(Reply) Sir, Sometimewefeelhighvibrationatgithgear(thiscomeonceinrotation)andsometimethereisnovibrationatgith gear?Pleaseansawarandoblige #59MustamerKhanon2011-03-0222:36(Reply) Thisisexcessiveradialrun-outduetotransientthermalbendsinthekilnshell.Movealltherollersonthepinionside ofthekilnclosertothecenterofthekilnuntilthevibrationsstops. #59.1WalterGebharton2011-03-2105:09(Reply) Dearsir Iwouldliketoknowthequalityofnewgenerationofkilnsupportingrollerbearings(kindofmainmetal)inF.L.Sor Polysiuskilns. withbestregards #60Alikeighobadion2011-03-0723:27(Reply) YoushouldaskF.L.S.andPloysius.Wearenottheirspokesmen.Theydonotinformusofwhatmaterialstheyusein theirdesigns. #60.1WalterGebharton2011-03-2105:11(Reply) hisiriwanttoknowhowtocalculateairgapeoftiresatthetimeofkilnrunning #61kalyanchakravarthion2011-03-1723:05(Reply) Takethemeasuredcreep(tyremigration)foronerevolutionanddividebyPI(3.14....) #61.1WalterGebharton2011-03-2105:12(Reply) Whichisabettermodernkiln2-supportor3-supportandwhy? #62GVRamaKrishnaon2011-03-2604:02(Reply) Assumingtheproductioncapacitiesarethesamechoosetheonewiththelowercost.

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page14of19

#62.1WalterGebharton2011-04-0714:01(Reply) hisirwehave3mtrdiaand46.3lengthkilninourcementmanufacturingindustryandourproductionwas1600 TPD.Thekilnwas3pierKILN.pleaseTELLMEABOUTkilnThermalexpansionandwhatistheformulaofthermal expansioncalculationandourkilnthermalloadwas2.5G.cal/HR/M^2 #63kalyanchakravarthi(Homepage)on2011-04-0423:23(Reply) Expansion=Lengthxchangeintemperaturexcoefficientofexpansion E=LxTxC EandLwillbethesameunits C~6.8x10-6formildsteelwhenTisinFahrenheitdegrees C~12x10-6formildsteelwhenTisinCentigradedegrees CvaluesshownareapproximatesinceCisitselfafunctionoftemperature.Usuallythewholelengthofthekilnis dividedintoanumberofsectionswitheachassignedanaverageexternalshelltemperatureandacorresponding coefficientofexpansion.Thesearethensummedtogettheoverallchangeinlength. Forexamplefrom20Cambient; 10meters@300Cexpands10x(300-20)x12.5x10-6=0.035meters 10meters@150Cexpands10x(150-20)x11.8x10-6=0.015meters Totalexpansion:50mm #63.1WalterGebharton2011-04-0714:40(Reply) hisirourkilnlengthis45mtrs,Dia3.0mtr,changeintemparaturewas320-120andiwanttoknowourkilnthermal expansionpleaseexplainme Thankingyousir, Regards, T.Kalyanchakravarthi #63.1.1kalyanchakravarthi(Homepage)on2011-04-1323:00(Reply) Themethodforcalculationisgivenabove. #63.1.1.1Anonymouson2011-04-2109:42(Reply) Dearsir, ourkilnhadmechanicalthrustrollersatoursite.OurproblemisKILNwascontinuouslyfloatingatthetoponlybyusing graphitepowderorrawmillpowderwearechangingthekilnpositionintobottomeventhoughalsokilnwasnot floatingatbottommorethan30mntsinourobservationwefoundthatourKILNhaddownhilltendencyinour experiencemechanicalthrustweshouldhaveuphilltendencyisitcorrectornotpleasegivemeyourprecious recommendationsandfurtherproceedingsproceedings thankingyousir, Withregards, T.KalyanChakravarthi. #64kalyanchakravarthi(Homepage)on2011-04-0423:36(Reply) Puttingabrasivematerialontherollersandtyres(suchasrawmeal)isdestructiveandshouldnotbedone.Yourkiln needstohavetherollersproperlyalignedandskewedtocontrolthekilnposition. #64.1WalterGebharton2011-04-0809:31(Reply) DearSir, WehavethreetyrePolysiuskilnwithDiameter5m.Wegotzeromigrationoftyre3towardoutlet. Wechecktheairgapphysicallybutphysicallytherewaszeroairgapallaroundthekilnaswell. Noconsiderablecrankwasobserved. Incoldconditiontheairgapwasabout18mm. Atthetimeofzeroairgaptheaverageshelltemperaturewasabout300Candthetemperatureofthetyrewasabout100 C. Ifweconsiderthecoefficientofthermalexpansionas0.000012m/mCsostillthereshouldbeanairgapof7to8mm. Butwhywegotzeroairgap/zeromigrationitisoutofmyunderstanding, Pleasehelpusinthisregardtounderstandtheproblem. Bestregards. #65ShamsAlamon2011-04-1309:24(Reply) Simplystatedyourmeasuredtemperaturesarenotaccurate.Youcanonlymeasuresurfacetemperatures.Thereisa heatgradientthroughboththeshellandthetyre.Clearlytheaverageinternaltemperaturesaremuchhigherormore specificallytheinternaldifferenceinshelltotyretemperaturemustbehigherthanyouaremeasuring. #65.1WalterGebharton2011-04-2109:05(Reply) Dearsir,myquestionis, ourformulaforcalculatingretentiontimeis11.4*L/(Speed*Diameter*Slope) Ihavebeentoldtofindouthowthatformulacomesabout #66cosmas(Homepage)on2011-04-1315:26(Reply) TheUSBureauofMinesretentiontimeformula; T=(1.77xLx(A)^0.5)/(PxDxN) Where A=thenaturalangleofreposeofthematerialindegrees P=slopeofthekilnindegrees D=theinsidediameterofthekilninfeet L=lengthofthekilnshellinfeet N=rotationspeedinrevolutionsperminute T=retentiontimeinminutes

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page15of19

#66.1WalterGebharton2011-04-2109:21(Reply) DearSir, Iwanttoknowhowwewillcalculateprimaryairinputquantityforkilnasperkilndia,lengthandkilnfeedtonnegeper hourpleasetellmetheformulaForexampleourKILNdIA3.0Mtrs,Length45Mtrsandkilnfeedinput110tonsperhour anddayproductionwas1600tons pleasegivemetheclarification thankingyousir, bestregards, T.Kalyanchakravarthi #67kalyanchakravarthi(Homepage)on2011-04-1323:22(Reply) Primaryairisthefunctionoftheburnerdesignandthefiringrate.Youmustgetthisinformationfromtheburner supplier.Kilnorcalcinerburnersvarygreatlywithrespecttointernaldesignandfueltypee.g.coal,oil,naturalgasor alternativefuels.Thereisnoformula.Eachburnerisdesignedforspecificapplications.Typicallyprimaryairis between5to15%ofstochiometricair.Usuallywhenthesecondaryairispreheatedbytheprocessalowerprimaryair yieldsbetterfuelconsumption/tonproduct. #67.1WGebhart(Homepage)on2011-04-2109:53(Reply) hello iwouldliketoaskhowtomeasurekilnmigrationandtherefrenceformeasurementtaken.thkx #68abebealemayehuon2011-04-1504:12(Reply) see"measuringcreep"onthekilndoctorblogmainpage #68.1WalterGebharton2011-04-2819:03(Reply) DearSir, WearehavingthecementkilnwhichwassuppliedbytheFLS(4.32diaX67meterlG)anditsageis02years.Andin thiskilnatdischargepierbothrollersandtyrehavinganonsignificantpittingmarks. Wedonthavinganyfollowingdefectsinthekiln Thereisnosignificantcrankonthekiln(mech/thermal) Axisofthekilnisabsolutelystraight. Contactbetweenrollerandtyreis90-95% Wearenotusinganyoil/waterontherollingsurfaces Axialrunoutofthetyreiswithinthelimit. Hertzpressureisalsowithinthelimit. Pleaseinformuswhatcouldbepossiblereasonsforthecause. Regards, GKrishna #69Kumaron2011-04-2205:02(Reply) Withoutseeingthese"nonsignificantpittings"itisimpossibletocomment.SendpicturestoPKS@kiln.com #69.1WalterGebharton2011-04-2818:59(Reply) Sir, IsitanewtrendtohaveallthreeTire/Supportrollersofsamesizesin3pierkiln?Ifsocanyoupls.givethererefrence. Regards Rao #70Raoon2011-05-0201:26(Reply) R/S, Iamnarendrakumar,workinginspongeironplantat(GUJ)inINDIA.myquestionisthatmykilnisworkingin upwardmotion.meanswhenwerunthekilnitstendencytogoupwardside&inrainydaysorjustinrainitdoesslipat supportrollers.duetothiswestoppedthekiln.sopleasetellmethereasonbehindthis. REGARDS, narendrakumar. #71narendrapooniaon2011-05-0312:03(Reply) Thesupportrollersarenotcorrectlyaligned. #71.1WalterGebharton2011-05-2619:36(Reply) dearsir wewehaveFLSkilnoflenght75mtrs anddiameter4.75capacity8100tpd. problem:huntinginHTDsystempressurebetween10barto35barineveryrevolutionofkilnandHTDpositionvary between3to4mmwhenhuntingobserved. onobservatingthatoutoftyretotalcontactsurfacecircumference,11%circumferencesurfacenotcameincontactwith

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page16of19

rollersurfcaeandagapisobservedof1mmappoxineveryrevolution. Bothsupportingrollerthrustisbetweenallowablelimitthatisbetween40barto160bar. ourHTDhasbeenreplacedwithnewoneandafterthatsurfacegrindingoftyreandthrustrollerhavebeenalreadydone. pleasegivemereasonofHTDsystempressurehuntinganditssolution??? #72BALWANTSINGHRAWATon2011-05-0700:47(Reply) Thecyclicalpressureisduetotyrewobble[axialrun-out].Thisislikelyduetotemporarythermalbendsintheshell orpossiblyincorrecttyreinstalltionorpermanentshelldamagethathasbenttheshell. #72.1WalterGebharton2011-05-2619:40(Reply) HowcanIdeterminetherequiredwheelwidthtosupportarotarykilnatthetire?Iknowthetireandwheelhardness, speed,normalforce. IcancalculateHertzianstresseasilyenough,butwhatistheallowablestress? #73BobBartlett(Homepage)on2011-05-1518:29(Reply) Hertzsurfacepressure<58,000-62,000psi=400-428MPadependingonapplication(speed,etc.).Generallythe tirewidthisincreaseduntilthemaxallowableHertzpressureissatisfied.Thereareotheroptions. #73.1WalterGebharton2011-05-2620:14(Reply) OurDrycementkilndiais3mtrandlengthis48mtr.Thereisnocoating/ringformationinsidethekilnbutkilnmain motorloadisrunningonhighersideafterlastshutdown.Earlieritwas100to150ampinnormalwhilenowitisaround 250to400ampwithsamefillinglevel. Pleasesuggestpossiblereasonandsolution. #74V.K.Sharmaon2011-05-2220:52(Reply) Listalltheworkandchangesdonetothekilnduringtheshutdown.Revieweachcarefullytodeterminifanycould haveaddedweightorincresedfriction. #74.1WalterGebharton2011-05-2620:20(Reply) iwanttoknowtheequationsthecalculatingthekilnmigration,toimpelementitonoursystem #75MoradMakramon2011-05-2305:40(Reply) Ifyouarereferringtothetyremigrationaroundtheshell;thisisameasuredvaluenotacalculatedone. #75.1WalterGebharton2011-05-2620:22(Reply) Dearsir, I've2questions 1.What'stheoiltestmethodtodetrminethethrustofakilnsupportrollerhavingsphericalrollerbearings. 2.wehaveakilnhaving04supportpiers.ifigive10mmshimbeloweachsupportrollerbearingplummerblockthenby whatheightthekilnaxiswillbelifted. #76manojkumarsahooon2011-05-2900:25(Reply) 1.Ithinkthisislikelythe"sliptest".AshotofWD40acrossthefaceoftheroller;asitgoesthroughthepinchpoint willcauseaknockinthebearingswhenskewispresent. 2.10mm #76.1WalterGebharton2011-05-3006:37(Reply) plsinformmeabouttherecommandedtemp.forwhitemetalbearingswhichuseinginkilnsuppotingrollerwithmineral (shellomala680)andsyntetic(mobilSHC639)oil #77faridon2011-06-0303:53(Reply) Wecannotcommentaboutspecificoilsorbrands.Themaximumallowabletemperatureisbasedonwhattheoilcan tolerate.Thatmeanshowhotcantheoilgetbeforeitloosesitsviscosityandmetaltometalcontactresults.Ingeneral mineraloilsmuststaybelowabout90C.Somesyntheticscangomuchhigheruptoabout230C.Forkilnrollersthe oilviscosityistypicallybetween1700to2000SSU@38Cunlessthekilnmanufacturerhasmadeother recommendations.Thefinalselectionoflubricantmusttakeseasonalchangesintoaccountaswell. #77.1WalterGebharton2011-06-1615:36(Reply) HelloSir,iamfacingaprobleminkilnwhichiamnotabletofigureout.oursisa2500tpdcementkilnwith3tireand rollersupport.itsnormaltorqueis500amps.butrecentlythetorquecurveisfollowingacris-crosssine-coscurve.amps intially150ampsden200,300,400,500,anddenagain400,300,200andthisgoesonandon.ihavenoticedthistime intervalis22fullrpm.fullrpmofourkilnis4.4andalsothrustersarefitted.coatingisaminorproblemhere. #78gyandweepon2011-06-0705:35(Reply) Areyourthrustershydraulicallydriven.Ifsopleasecheckthecycletime. #78.1WalterGebharton2011-06-2020:51(Reply) Iwouldliketoaskyouropiniononthefollowing: DuetounevencoatingintheKilnwehavealargedifferenceofthetemeperaturearoundtheKilnshellatbase2.Thisis creatingathermalcrankoftheshellwitharesultthetiretobepartiallyliftedofthesupportingrollerateveryrevolution oftheKiln.Alsoineveryrevolutiontheshaftoftherollerispushedandfloadsbackandforwardfromonethrustcolllar totheothercreatingastrangenoise.Weareveryconcernedofthehighstressesontherollersandshafts.Thisstarted initiallyatbase2butnowthesamepatternishappeningatallbasesandrollers.Howcanwereducethethermalcrank effectwithouthavingtostopthekiln. Thankyouverymuch #79ChristoforosNicolaideson2011-06-0712:01(Reply) DearSir MyNameisKalyan IwanttoknowaboutGirthgearpresuureangle,howwewillcalculateitandhowitworkspleasegivetheanswer Thankingyousir #80T.Kalyanchakravarthi(Homepage)on2011-06-0823:12(Reply)

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page17of19

Iregretwearenotgeardesignersormanufacturers.Isuggestyouconsultamachineryhandbook. #80.1WalterGebharton2011-06-2020:46(Reply) Whatcouldbetheposiiblereasonsforgirthgearjointboltfailurewhenrootgapiswithinacceptablelimit. #81sumanneogion2011-06-0907:04(Reply) Possiblereasons;Excessiveaxialrunout,boltsarenotofthecorrectmaterial,boltsdonothavethecorrectdiameter, boltsarenottorquedcorrectly. #81.1WalterGebharton2011-06-2020:42(Reply) Kindlyconfirmmethemimimamgaprequirementin-betweenkilnshellandtopfaceofthrustroller. #82selvakumaron2011-06-1300:21(Reply) Thethrustrollermustnevercomeincontactwithanythingonthekiln.Thedistanceisthereforeamatterofsafety.I wouldsuggestanythinglessthan50mmcanbepotentiallydangerous.Thethrustroller(s),ifincorrectlypositionedon theupturningsideofthekilncenterlinecanbedrawnupandhitthekilnorthetirestopblockswithcatastrophic results.Thrustrollersmustalwaysbeoffsetabout5mmtowardsthedownturningsideofthekilncenterline. #82.1WalterGebharton2011-06-1615:49(Reply) Assumingthatthisisjustatemporarybendtheonlycorrectionpossibleistogetthecoatinginthekilnmoreeven.This isaprocess/operationalproblem.Unevencoatingismostlyattributedtothermalshocksoratleastthermalvariations. Whentheprocessisstablethetemperatureprofilewillalsobestableandanevencoatingbuilds.Thisisonlyone possibilitythereareothersalsoprocessrelated.Whentheprocessisstraightenedoutsowillbethekiln. #83WalterGebharton2011-06-1615:57(Reply) kindlyconfirmmethatwhatisthelimitationofsimplateprovidedtoreducethecreeporhotgap #84selvakumaron2011-06-2303:43(Reply) Aftershimming,inthecoldcondition,theoriginalcoldclearancemustberestored.Eachtirewillhaveadifferent coldclearance.TheseareusuallygivenonthekilnGeneralArrangementdrawings. #84.1WalterGebharton2011-07-0714:49(Reply) Couldyoupleasetoinformmewhatwillbehappenedifthesplashplateinpreheatercyclonewaswornout #85MohamedSaeedon2011-06-2604:04(Reply) Youwillloosethermalefficiencyofthatcyclone. #85.1WalterGebharton2011-07-0714:50(Reply) DearSir, Myquestioniswhythekilnwillhavethethermalexpansiontowardsdownhillsidefromtheinlettyre,whyitcantbe towardsinletside. plzinformme. #86kumaron2011-07-0123:57(Reply) Thekilnexpansionanchorpointisthethrusttire.Fromthethrusttiretofeedendexpansionwillbetothefeedend. Fromthethrusttiretothedischargeendexpansionwillbetothedischargeend. #86.1WalterGebharton2011-07-0714:53(Reply) Inourplantthebearingsofsupportingrollersofkilnaresphericalrollertype.ThisisaChineseplant.Originallyitwas designedfor2rpmspeed.Lateronin2006itwasupgradedfrom1000to1900tons/dayandthespeedincreasedfrom 2rpmto4.8withoutanychangesinthelubricationandbearingsystem.Theproblemisthatbearingfailsfrequently causingheavyproductionloss.ToovercomethisproblemwewanttoreplacethesebearingswithBronzehalfsleeve bushbearingwithhousingwhichwealreadyhavearrangedfromJAVEDANCEMENT,POLYSIOUSPLANTthatwas alsodesignedfor2rpm. Inthisconnectionwewanttoknowyourviewswhetheritisfeasibleornot.Ifitispossibleyouarethenrequestedto pleaseaskyourrepresentativeinPakistantosendatechnicalteamtosurveytheplantregardingtheabovejobandquote forthesame. #87MohammadUsmanon2011-07-0806:45(Reply) Changingtosleevetypebearingsislikelyyouronlyoption.Therollersandsupportbaseswillalsohavetobe changed.Theshaftswillbealargerdiameterwithsleevebearings.Thesleevebearingsneedtobeofthetypewithan internalsphericalseatsothatthebrasslinercanalignitselftotheshaft.Thebearingsshouldalsohaveboltsholdingit tothebase.Polysiusdomakebearinghousingswithinwhichthesleeveisfixedandwhichhavenoholddownbolts. At4.8rpmthislatterdesignwillbenobetterthanyoursphericals. #87.1WalterGebharton2011-07-1107:20(Reply) Sir, ThebearingofpolysiusplantisboltedwiththehousinglikeFullerplantofJavedancementonwhichyouhave workedduringerection&commisioning.Thelubricationsystemisofbuckettype.Isitenoughorneedsextra lubrication?Pleaseletusknow. #87.1.1MohammadUsmanon2011-07-1321:01(Reply) HowdidyouknowIworkedintheJavedanplant? Ifthebucketwheeloilingsystemwasdesignedfor2rpmitmustbemodifiedtoworkat4.8.Theangleofthe bucketsmustbeincreasedsothattheoildoesnotovershootthetray.Ihavenoexperiencewithsuchadramatic changeofspeedinthisrespectsoIdonotknowwhatthenewangleshouldbe.YoucouldaskPolysiusor F.L.Smidtotherwiseyoumayhavetobuildateststandtofindoutwhatthebestangleis. Thebestsolutionistoaddanelectriclubricationpumpthatcirculatestheoil,whichcanfilterandcooltheoilat thesametime.Asmallpumpstationateachbearingwouldstartcirculatingtheoilpriortoeverystartofthe kilntherebydramaticallyimprovingthelifeofthebearings. Mostofthebearingdamageoccursonstartupbecausetheoilingwheelhastomakeaturnbeforeanyoilis deliveredtotheshaft. #87.1.1.1WalterGebharton2011-07-1414:27(Reply) KilnDoctor, wehavea60ftby6ftrotarykilnusedforreactivatingcarbon.Acontractorwasremovingoldrefactorybyblastingand rippedatearinthesideofthekilnaboutinthemiddle.Thisis1/4inchplate.Thetearwasputbackintopostionand

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page18of19

weldedinplace.Idon'tthinkthiswillholdup.Iwantthemtomakebetterrepairsbeforethenewrefactoryisputbackin. Howshoulddamagelikethisberepaired? #88JohnPeterson2011-07-1208:25(Reply) Theonlysatisfactoryrepairwouldbetoreplacethedamagedsectionoftheshell.Shellsaremadein"cans"about8 feetlong.Thesecansareweldedtogethercircumferentiallytomakeuptheneededlengthofshell.Whenreplacinga sectionthecutsshouldbeatleast6awayfromanexistingcircumferentialweld.Plusthelocationofthecutline shouldbenolessthanacanawayfromthenextcircumferentialseamontheremainingshell.Inotherwordswith therepairedsectioninplaceyoudonotwanttwocircumferentialseamslessthanacanapart. #88.1WalterGebharton2011-07-1414:09(Reply) INOURCEMENTPLANTWEFINDFREQUENTRUNNINGOFTHUSTERPUMPINKILNANDWEHAVE CHANGEDTHEFLOWCONTROLVALVEINBOTHRETURNANDPUMPINGBYNEWONEBUTSTILL THEREISNOIMPROVEMENTINTHUSTERPUMPRUNNINGISSAMEASBEFORETHECHANGINGTHE PREVIOUSVALVE.WEARENOTABLETOINCREASETHEOFFTIMEOFTHUSTERTIME(APPROX.4 HOURS) THUSTERPUMPRUNNINGTIME ONTIME:20MINS OFFTIME:5MINS #89varathuon2011-07-2104:30(Reply) Yoursupportrollersareoutofalignment.Theymustbesetclosertotheirneutralskewpositionsinordertoallow yourhydraulicthrustsystemtofunctioncorrectly. #89.1WalterGebharton2011-07-2419:18(Reply) whatcouldbethepossiblecausesofkilnampsfluctuation.Thekilnisatwindrivespongeironkiln.Ampsvariationis upto200ampsforbothmasterandslave.Butatanyinstantoftimetheampsvariationbetweenmasterandslaveis within50amps. -Unevencoatingformationisnotsosignificantinthekiln. #90sumankumarneogion2011-07-2104:40(Reply) Therecouldbeacoupleofissuesoracombinationofthemcausinganampcycle.Typicallyitisanimbalanceinthe kilnweightsuchasabuildupofmaterial,acoatiingforexampleontherefractorywhichisnotuniformaroundthe circumference.Itmayalsobeabendinthekilnshell,whichalsoactslikeanimbalance.Suchabendmaybe temporary,thermallyinducedagainbyunevencoatingoritmaybepermanentshelldamagecausedbyarefractory failure. #90.1WalterGebharton2011-07-2419:25(Reply) DearDr.Kiln, Doyouhaveanyknowledgeaboutlowemissivitycoatingsorpaintappliedtothehotzoneofthekiln?Thegoalwould betokeepthetemperatureinsidethekilnthesamewhilereducingtheamountoffuelburnt.Arethereanyadverseeffects ofdoingthis?Arethereanymodificationstothekilnthatwouldhavetobedonebeforeapplyingacoating? #91MichaelKyleon2011-07-2211:31(Reply) Loweringtheradiantheatlossoftheshell,whichcanbeasmuchas6%ofthesystemheatinputbyusingalow emissivitycoatingisanageoldendeavor.Theproblemisthecostofapplyingandmaintaintaningsuchacoating. Technologyisalwayschanging.Thekilnshellisatoughenvironment.Wearenotawareofanycoatingthatsurvives foranylengthoftimeandwhoseappplicationandmaintenencecostdoesn'toutstripthesavingsinfuelefficiency. Simplyevaluatingsuchsavingsafteranapplicationrequiresanagreeduponbenchmark.Allsuchmeasurementsare froughtwithuncertainty.Consequentlywearenotawareofanycoatingthathasbeensuccessful. #91.1WalterGebharton2011-07-2419:48(Reply) Dearkilndoctor, Inspongeironpkant,wearefacinghotspotproblems,whichoccursnearlyeitheruphillordownhillsideoftyre.4months ago,wefacedthisproblemdownhillsideofoutlettyre(nearabout2.5mfromtyrecentre)andnowitsstartedtooccur atdownhillsideoftyreno3fromoutletend. Plgivemethesolutionstorelievefromthisproblemasthisproblemcausestostopthekilnfrequenly. Givesolutions,whatshouldwetakepreventiveandanyremedialactions? #92sivanandyon2011-08-0111:40(Reply) Justreportinghotspotsandtheirlocationsisinsufficientinformationtosuggestremedialactions.Theactionrequired ismorein-depthinvestigation.Hotspotsmeanslocalizedrefractoryfailure.Acompletehistoryofrefractory installationneedstobereviewed.Whattypeofrefractoryisfailing?Isitonlyonetypeorareseveraltypesinvolved? Howlonghastherefractorybeeninserviceatthehotspot?Arethefailedareasprevioussitesoffailureand/orrepair? Trytonarrowdownthevariables.Failurescangenerallyresultfrominappropriatetypeofrefractoryforthelocation, badinstallationoroperationalproblemssuchasthermalshockduetorapidchangesinfiringrates,rapidstartups/cool down.Bynarrowingdownthesegeneralvariablesfurthersubclassificationscanbeinvestigated. #92.1WalterGebharton2011-08-0618:09(Reply) AddComment Name Email Homepage Inreplyto
#92.1: Walter Gebhart on 2011-08-06 18:09

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011

KilnDoctorbyPhillipsKilnServices#comments

Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only.

Page19of19

Comment Enclosingasterisksmarkstextasbold(*word*),underscorearemadevia_word_. Standardemoticonslike:-)and;-)areconvertedtoimages. TopreventautomatedBotsfromcommentspamming,pleaseenterthestringyouseeintheimagebelowin theappropriateinputbox.Yourcommentwillonlybesubmittedifthestringsmatch.Pleaseensurethat yourbrowsersupportsandacceptscookies,oryourcommentcannotbeverifiedcorrectly. Enterthestringfromthespam-preventionimageabove: RememberInformation? Subscribetothisentry


Submit Comment Preview

Submittedcommentswillbesubjecttomoderationbeforebeingdisplayed.

Ifyouareinterestedinprofitingfromanindustryleader,orlearningmoreaboutourservicesandproducts,contactus 2011PhillipsKilnServices at Ltd. USAandCanada800-831-0876|outsideUSA+1402-494-6837|info@kiln.com

http://www.kiln.com/kilnblog/blog.php?/archives/4-Ask-the-Kiln-Doctor-Your-Question.html 9/1/2011