PHILLIPS KILN SERVICES LTD.

REGULAR OBSERVATION REVEALS PROBLEMS

This training is intended to be a rotary unit, namely kiln, dryer, or granulator walk-by.
Observation techniques will identify potential problems while the unit is in normal operation.
The definition of terms and the names of parts will be established. You will be provided with
tools to assist in your own walk bys throughout this training.
Rotary units of any kind require a large capital outlay and are expensive to operate. When
the unit is damaged to the point of breakdown, the cost of operation is significantly
increased. Taking a unit off-line and bringing it back up again, and repairing or replacing its
parts is always costly.
Serious damage rarely happens in one day. Usually it is the
accumulation of a series of small problems left unattended or unrecognized that finally
causes a failure.
An ounce of prevention is worth a pound of cure. With improved skills of recognition it is
possible to exercise preventive maintenance effectively, thereby eliminating, or certainly
reducing, expensive and unexpected shutdowns.

Shell Inspection Problems & Symptoms

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The kiln was operating before you began working at the plant, and chances are it will
continue to operate long after you leave. The level of maintenance that prevailed before
may have been disorganized and inadequate. If this was acceptable, it is often easier to
continue bad habits than to initiate good ones. A history of poor maintenance and poor
operation may cause a company to accept abnormally high costs of operation. This affects
the bottom line.
Reviewing the basics and understanding the function of the units parts is key to reestablish
or reinforce maintenance tasks. This leads to reduced operating costs and maximizing the
remaining service life of the equipment.
Rotary kilns are mechanically very simple devices. Their size is intimidating, however
identification and recognition equal trained observation. Once the nature of a problem is
identified through trained observation, a plan to resolve the problem can be formulated.

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Shell Inspection Problems & Symptoms

The unit walk-by starts with the shell, the units largest component and then covers
all its support and drive components. Each chapter of this manual completes a
section of the walk-by. Your own walk-bys should be conducted daily, with the main
focus on changes in condition from one day to the next.
This chapter focuses on shell inspection and the three main areas of shell stress;
cracks, permanent shell damage from thermal distortion, and temporary shell
problems caused by unit misalignment.

Shell Inspection Problems & Symptoms

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Cracks extending from filler bar welds.

Longitudinal cracks run with the length of the shell axis, and are usually a result of a
stress concentration caused at a weld attachment.
The most common cracks are found in the shell near or under the tire at the weld
attachment of the filler bars. It also occurs in the area where the gear mounting plates are
welded to the shell. Cracks also occur at the point retaining rings are welded to the shell.
These areas of the shell are highly stressed. When there are stress risers from weld
attachments they should be inspected regularly for crack initiation. Cracking in these areas
may also be aggravated by excessive flexing of the shell plate.

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Shell Inspection Problems & Symptoms

Figure 5: Mechanical Loads

CRACKS
The severest sign of shell stress is cracks in the steel plate. The shell stresses that lead to cracking are
caused by the following factors:
Thermal expansion

Friction

Tire Thrust

Ovality

During the normal operation of any kiln shell the temperature fluctuates,
causing the shell to expand and contract. The tire support pads expand and
contract at a different rate than the shell, creating stresses in the welds used to
attach the bars to the shell. These stresses are created from both longitudinal
and circumferential forces.
Tires are mounted loosely on the shell to allow for the different rates of thermal
expansion of the tire and the shell. As a result, the tire will have circumferential
movement relative to the shell. This is referred to as creep or slip. There is
generally a sliding component from this action that creates stress in the welds
attaching the tire pads to the shell.
As the unit is moving axially by carrying roller adjustment or thrust roller
positioning, a force is transferred from the tire to the shell. This force is applied
on the retaining rings or tire stops and consequently causes stress in the welds
that attach the tire stops and the support pads to the shell.
Excessive flexing of the shell as it turns causes stress in the shell plate. The
welds that attach the tire support pads create a stress riser that can lead to
fatigue cracks in the shell plate.

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Drilling the end of a crack, to (5 to 10mm) diameter is a temporary measure used to try
to stop the crack from propagating. It is important to try to do this as soon as a crack is
detected. Circumferential cracks are far more dangerous than longitudinal cracks as they
may travel sufficiently around a shell in a short period of time causing catastrophic failure.
See page 12!

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Shell Inspection Problems & Symptoms

Circumferential cracks most often occur on or near a circumferential weld seam or at a

shell opening such as a manhole or a patch plate. They are the result of poor quality
welding.
Circumferential cracks can also be the result of an undersized shell plate or lack of an
adequate transition area where a thick plate joins a thinner plate. If a unit is not in proper
mechanical alignment, as it makes countless revolutions, the operating stresses on these
seams will eventually cause weld seam failure.
Periodic shutdowns are extremely stressful on rotary equipment and produce rapid
expansion and contraction of the whole shell. Welded seams are subject to the greatest
stress.

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Any stress riser on a shell is a potential origin for cracks. Here we see a poorly welded
window or coupon in the shell which has caused the problem. All unnecessary welds,
lugs, or other miscellaneous items attached to the shell should be removed and the weld
scars carefully ground away. Any such item can lead to shell cracking.

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Shell Inspection Problems & Symptoms

Circumferential cracks are the most dangerous since they can run around the shell
very quickly and cause catastrophic failure. When a circumferential crack is
spotted it cannot be left unattended. Drilling the ends may have little effect although
it is worth a try. Watch and mark the progress of the crack hourly as a minimum
while some temporary strong backs are made up.
Strong backs or stiff backs need to be strong enough. The ones shown here were
too short, not long enough and only 1 [25 mm] thick. They cracked in half after one
month of service. Short of shutting the kiln down, continuing operating the kiln until
a new shell section arrives may require the strong backs to survive several
months.
Such cracks often show up at joints near the tire in plate that is several decades old.
In such cases simple repairs, even if done correctly, may not be a lasting. It is
advisable to replace the fatigued shell section completely.

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Strong backs that are expected to last a few months until repairs can be organized
and scheduled need to be heavy enough. Simple rectangular plates run the risk of
cracking the shell at their ends. This is particularly true on the end pointing to the
tire and if the tire is not far away.
Removing the corners as shown creates a soft foot, minimizing the risk of new
cracks developing there.
Make the plates 2 thick x 10 high by about 48 long. These are general guidelines
and are not based on any calculation or stress analysis. Kilns are very different in
terms of shell stresses at any given location. This is an emergency repair that must
be done quickly and using the closest sized available plate is inevitable. Just
remember bigger is better in this case.
The cutout or mouse hole is where the stress in the strong back will be the
greatest. In the previous slide thats where the cracks first started. Re-enforcing
that hole as shown will also minimize the risk of the plates starting to tear here.

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Shell Inspection Problems & Symptoms

The deflection and slope curves are important because they are used by the kiln
designer to locate the support piers such that the slope of the kiln shell is parallel to its
design slope. That is the slope value should be zero at the center of each support (the
red dashed lines). Note also how the shell sags between piers. When a kiln is modified
by a change in length, change in loading or change in the number of support piers, the
disregard of shell sag can lead to aggressive tire to side stop block wear.
The shell bending stress curve is used to determine the shell plate thickness. Note
that the saw tooth tips along this curve is where the shell plate changes thickness. The
stress on the kiln shell is greatest at these points and so these circumferential welds
should be the focus of your attention when making your daily inspections.
The shear stress in a typical kiln shell is very low and is rarely if ever a cause for failure.

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After a crack has been identified by visual inspection, a more thorough inspection using
NDT (Non-Destructive Testing) methods should be planned for all suspect areas. NDT is
performed with ultrasonic, or magnetic particle inspection, and dye penetrant.
Ultrasonic and x-ray testing requires trained technicians. Most companies do not have
this expertise in-house, so an outside contractor is employed. Both of these methods
identify subsurface cracks, which is important in defining the extent of cracking, so a repair
scope can be developed.
Dye penetrant testing is probably the simplest NDT procedure to perform and can usually
be performed by site technicians. Its use is limited to surface cracks and is a valuable tool
in the actual weld repair procedure.
Cracks are a sign of total failure and should never be ignored.

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Shell Inspection Problems & Symptoms

WELD PROCEDURES
When undertaking shell crack repair, a procedure must be developed that considers the
type of material, the thickness of the plate and any adverse conditions, such as extremely
cold ambient temperatures at the time of repair.
In general, the repair will require air arc gouging and grinding to remove the cracks from
both the inside and the outside of the kiln. This will ensure a successful repair by
completely removing the crack and fully penetrating the weld repair. Welding over the top
of the crack is a waste of time and money. The shell must be cleaned of all materials from
previous welds.
Any weld repair made during adverse weather conditions such as rain, snow, and cold
ambient temperature, will require special precautions, such as preheating the shell to at
least 150F / 65C to remove chill or moisture. The temperature should be monitored with
temperature sticks. Tarps should be set up to provide protection to the weld repair area. It
is critical that all welds on a kiln shell be of the highest quality because of the thermal and
mechanical stresses present in a kiln.
If a crack migrates under a tire, the tire must be moved in order to make the proper repairs.
If the unit is refractory-lined, the refractory area of the repair will need to be removed and
replaced. The underlying cause of the crack should be understood and corrected to
avoid reoccurrence.

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PLAN OF ACTION IF SHELL RIPS

1. Shut the unit down and position it where the emergency repairs can be most easily performed.
2. Weld strongbacks perpendicularly across the face of the weld tear. A strongback is a piece of A-36
iron approximately 1 thick by 6 - 8 high, and long enough to bridge the weld tear by at least 12 to 14
on either side.
3. Bring the unit back up long enough to completely run out the product that was in the unit at the time of the
breakdown.
4. Remove approximately five feet of brick on either side of the weld tear. Refractory may already be missing
due to the sudden misalignment caused by the weld tear.
5. Position the unit where the strongbacks are removed and install adjustment hardware on the inside of the
unit to reunite the separated parts of the kiln shell.
6. When the seam is welded together on the outside, remove the adjustment hardware on the inside. Back
gouge and weld the seam. Grind the seam as flush as possible.
7. It is necessary to install new strongbacks around the circumference of the failed seam. Otherwise the
weld failure will move to the part of the shell that does not have the benefit of the additional repair
hardware.
This method is a Band-Aid! Because shell stress and misalignment are present, the unit will not perform
properly. Catastrophic failure will occur elsewhere on the unit if proper repairs are not made. Installing a new
shell section at the area of weld failure, coupled with complete alignment analysis, is the most likely plan of
action.
As a result of the unit being suddenly stopped and allowed to cool in one position, the kiln shell will sag between
piers. This in itself is not the cause for alarm. The sag will diminish as the unit is brought up to production
temperature. Generally not all of the sag will disappear but the unit will true itself well enough to operate.

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Shell Inspection - Mechanical Problems & Symptoms

HEAT DAMAGE
Refractory-lined shells are prone to heat damage. When refractory fails, an area of the
shell is superheated and a hotspot occurs. A hot spot is seen as a bright red or yellow
area whose size can be as small as one brick or a much larger area. Blisters or bubbles on
the shell are also indicators of a serious heat problem which should not be ignored.
Thermal scanners use infrared beams strategically positioned to monitor a units shell
temperature during operation. These devices incorporate sophisticated software programs
to show you a real-time temperature as well as historical data on temperatures in various
zones of the kiln. A scanner can work well as a preventive tool by providing information on
potential problem areas, and allowing steps to be taken before refractory fails and shell
damage occurs.

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As the hot spot cools, it shrinks, flattens and discolors, often to black. This shrinkage which
is a result of the metal yielding during the time it was heated to the annealing range, 1125F
to 1250F/ 650C to 675C, affects the roundness of the shell.

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Shell Inspection Mechanical Problems & Symptoms

When one area shrinks it may cause another area to bulge. The shell, generally considered
to be a cylinder, no longer has a straight axis. It is now bent, or kinked, or as it is often
described in extreme cases, it has a dog leg or a crank shaft condition.

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DISTORTION FROM HEAT DAMAGE CREATES OTHER PROBLEMS

Distortion which is a bent axis, creates a multitude of problems depending on their
magnitude and location. In a localized area this out-of-round condition, whether its a flat
spot or a bulge, can make it difficult to achieve quality refractory installation. Premature
refractory failure due to mechanical instability often results.
Since the shell is no longer rolling as a straight cylinder it is subject to additional bending
stresses as its weight cycles from one roller to another. In extreme cases, a portion of the
load shifts from pier to pier. The rollers, shafts, bearings and bases, which are designed to
support a portion of the total rotating load, now bear a reduced load for part of each
revolution and a higher load for the balance of each cycle. A badly bent shell can induce
extremely high load peaks during each rotation cycle. In addition to the shell problems, this
overloading can lead to shaft failure, hot bearings or even support base damage.

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Shell Inspection Problems & Symptoms

Depending upon the location of the bend, the dog leg or crank shaft can also cause tires
to wobble. Wobbling tires not only exert cyclical loads into the rollers and shaft but also
reduce the contact area between the tire and the rollers. This increases the contact
pressure. If excessive, this can cause surface spalling of the tire and the roller faces. The
tire wobble also makes proper roller skewing difficult, if not impossible.
In the area of the girth gear, this will affect both the radial and axial run out of the gear,
causing accelerated wear of the gear teeth. Depending on the location of the dog leg,
the seal may be adversely affected as well.
Correcting the Problem: Depending upon the nature of the distortion, it may be possible to
reduce the bend in the shell by using localized heating and cooling procedures. Results are
not exact or reliable. In most cases a replacement shell section is required to effect a
reliable repair.

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MISALIGNMENT
When the support rollers are not set correctly to proportionally share the rotating load, the
kiln is misaligned. This condition causes serious overloading stress conditions, similar to
those caused by a bend in the shell. In contrast to cyclical load imbalance caused by a bend
in the shell, misalignment creates constant load imbalance because the rollers are not
holding the shell straight. The magnitude of the overloading is in direct relationship to the
magnitude of the roller displacement. The effect of misalignment can be the same as a
permanently deformed shell; cracks, premature refractory failure, hot bearings, etc.
Obvious signs of misalignment are excessive flexing, refractory failures, plate cracking and
roller shaft failures. One of the most obvious signs of misalignment is a rise in amp usage.
If amp usage is suddenly up, something is wrong.
Misalignment cannot be detected visually nor can it be determined on a trial-and-error basis
as can roller skew. In order to determine misalignment requires careful alignment
measurement and specialized tools and procedures. These procedures are covered in the
section Alignment Analysis.
Alignment measurement is performed by an outside service organization since very few
companies have a large enough number of units operating to warrant the expense of
acquiring specialized equipment and retaining qualified staff to perform this task.

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Shell Inspection Problems & Symptoms

Unlike cracks or heat damage, kiln misalignment cannot be detected visually. Careful
alignment measurements and analysis of the results are the only way to determine if roller
adjustments can reduce the stress on the kiln shell. Such adjustments once made where a
significant misalignment existed often results in a dramatic drop in kiln motor amperage
verifying that the energy used to turn the kiln has dropped.

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CONCLUSION - WHEN PROBLEMS ARE VISUALLY OBVIOUS, IT IS TOO LATE!

Preventive maintenance requires the use of analytical tools BEFORE damage becomes visually
obvious. Some plants are staffed and equipped to handle analytical testing. Most plants look for
outside help.
The problem of a damaged shell, whether from cracking, abrasion, erosion, heat distortion, or
misalignment will always lead to further problems. The shell is the largest component of a rotary unit
and it is predictable that when something is wrong with it you will begin experiencing related
problems, such as aggressive component wear and carrying roller adjustment problems.
Problems that have not yet produced visual symptoms must be identified. This involves using
analytical (measurement) tools. Some plants are staffed and equipped to handle analytical testing.
Most plants will look to outside help.

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Shell Inspection Problems & Symptoms

Understanding the mechanical function of all the parts and being able to identify
what areas need attention, will allow you to make the decisions about what can and
cannot be handled satisfactorily in-house.
Identifying the symptoms early and utilizing the proper analytical tools can allow time
to formulate and implement a plan of action. Failure to do so in some cases can lead
to catastrophic failure or unplanned outages.

Shell Inspection Problems & Symptoms

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