Kiln Insp E English

Plant - Country
Kiln No. …, dia. x ….. m, ……… Cooler
Period of Inspection: date - year
Mechanical Kiln Inspection
Type E
Kiln Inspection Report
Plant: ……… ……….., Kiln No. … Customer Services

Country: ………
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Order No.: ..-…… …/…, ………………….. …………….. 1
Plant - Country
Inspection of Kiln No. …, dia. x …….. m, …….. Cooler
Client representatives........................Mr ………………………..
Mr ………………………..
Mr ………………………..
FLS specialists ..................................Mr ………………………..
Mr ………………………..
Participants in final meeting .............Mr ………………………..
Mr ………………………..
Mr ………………………..
Mr ………………………..

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CONTENTS
Page
(1) Introduction...........................................................................................................................4
(2) Conclusions ..........................................................................................................................6
(3) Recommended Actions ........................................................................................................7
(4) Terminology .......................................................................................................................10
(5) Inspection Activities Carried out -Measurements and Calculations Performed..............11
(5.1) Kiln Shell...................................................................................................................11
(5.1.1) Kiln Shell - Temperatures..............................................................................11
(5.1.2) Kiln Shell - Side Guides.................................................................................12
(5.1.3) Kiln Shell - Crank Indication.........................................................................13
(5.1.4) Kiln Shell - Wobbling ....................................................................................16
(5.2) Live Rings .................................................................................................................17
(5.2.1) Live Rings - Temperatures and Diameters....................................................17
(5.2.2) Live Rings - Migration...................................................................................18
(5.2.3) Live Rings - Reduction in Migration.............................................................22
(5.2.4) Live Rings - Lubrication................................................................................23
(5.2.5) Live Rings - Wobbling...................................................................................24
(5.2.6) Live Rings - Positions on Supporting Rollers...............................................26
(5.3) Supporting Rollers ....................................................................................................27
(5.3.1) Supporting Rollers - Temperatures and Diameters.......................................27
(5.3.2) Supporting Rollers - Centre Distances ..........................................................28
(5.3.3) Supporting Rollers - Inclination ....................................................................29
(5.4) Bearings for Supporting Rollers...............................................................................32
(5.4.1) Bearings for Supporting Rollers - Positions..................................................32
(5.4.2) Bearings for Supporting Rollers - Temperatures ..........................................33
(5.4.3) Bearings for Supporting Rollers - Lubrication..............................................35
(5.5) Baseplates..................................................................................................................36
(5.5.1) Baseplates - Levelling....................................................................................36
(5.6) Drive Station .............................................................................................................38
(5.6.1) Drive Station - Wobbling of Gear Rim .........................................................38
(5.6.2) Drive Station - Root Clearance......................................................................38
(5.6.3) Drive Station - Position of Gear Rim to Pinion ............................................38
(5.7) Kiln Axis ...................................................................................................................39
(5.7.1) Kiln Axis - Measuring Results ......................................................................40
(5.7.2) Kiln Axis - Calculations.................................................................................41

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Page
(6) Visual Inspection................................................................................................................44
(6.1) Kiln Shell...................................................................................................................44
(6.1.1) Kiln Shell - Side Guides and Live Ring Supporting Blocks ........................45
(6.2) Live Rings .................................................................................................................46
(6.3) Supporting Rollers ....................................................................................................47
(6.4) Bearings for Supporting Rollers...............................................................................49
(6.5) Drive Station .............................................................................................................51
(6.6) Thrust Device............................................................................................................52
(6.7) Axial, Mechanical Balance of the Kiln....................................................................53
(6.8) Inlet Seal....................................................................................................................54
(6.9) Outlet Seal.................................................................................................................55
(7) List of Enclosures
Enclosure
Deflection Variations / Supporting Roller Shafts ....................................................... 1a - f
Wobbling of Kiln Shell / Polar Diagrams ............................................................ 2a - e
Kiln Crank Diagram............................................................................................................ 3
Live Ring Migration............................................................................................................ 4
Axial Wobbling of Live Rings..................................................................................... 5a - c
Axial Wobbling of Gear Rim...................................................................................... 6
Guide Block / Arrangement Drawing ......................................................................... 7
Tool for Profile Measurement of Supporting Rollers ........................................................ 8
Work Sheets for Surface Measurement
of Supporting Rollers and Live Rings.................................................................. 9a - c

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(1) Introduction
The inspection was carried out in accordance with agreement between

………………………, and ………………, ref. ……………., of (date).
The purpose of the visit was to carry out a type “E” kiln inspection.
The kiln was started up in (year) as a 2-support kiln with a …… cooler. It was converted in
(year) and is now a 3-support kiln with a ……. cooler. The present output is approx. …. tpd.
A hydraulic thrust device is located at support III. The drive station consists of a gear rim
and one pinion on the outlet side of live ring III.
The kiln was last inspected by FLS in (month/year) and has operated satisfactorily since
then. According to the client, the life of the lining is very satisfactory.
In our report on the inspection in (month/year), ref. …/…, ………, of (date), we listed a
number of actions that should be taken. However, of the recommended actions, only the
supporting rollers at support I have been machined.
-- o --
The purpose of the activities performed in a type “E” kiln inspection is to determine the
measures (i.e. adjustments, replacements, modifications, or repairs) that have to be taken to
achieve and maintain a high availability level of the kiln system.
The most important factors contributing to high kiln availability are to maintain:
* correct axial, mechanical balance of the kiln, meaning that the axial thrust of the
kiln must be absorbed by both the supporting rollers and the thrust roller. When the
axial, mechanical balance of the kiln is correct, the supporting rollers absorb
approx. 30% of the axial thrust, and the thrust roller absorbs the remainder;
* optimum load distribution on the kiln supports, meaning that the radial load on
each individual supporting roller must be kept within the limits defined when
dimensioning the kiln;
* good, mechanical operating condition of the kiln system, meaning that, e.g., the
degree of ovality and crank formation must not exceed the limits considered
acceptable.

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In order to attain the above objectives, various requirements must be met, including the
following:
* The kiln axis must be correctly adjusted.
* The positions (skewing and inclination) of the supporting rollers must be correct.
* The rolling surfaces of supporting rollers and live rings must be truly cylindrical.
The inspection and measuring activities carried out during the inspection of this kiln have
been supplemented with calculations made at FLS-Copenhagen taking the present loads on
and stresses in kiln shell, live rings, supporting rollers, and bearings for the supporting rollers
into account. These calculations are based on the measurements taken, on information from
the client about the weight of the kiln lining and coating, and on the own weight of the kiln.

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(2) Conclusions
The following conclusions can be drawn on the basis of the measurements and observations
made at the plant during the inspection combined with the calculations made at FLS-
Copenhagen:
Our impression of the kiln was that this production line is in a very good state of
maintenance. This impression that was, in fact, confirmed by the visual inspection is indeed
reflected in a very high run factor. However, the standard of cleaning should be raised
considerably as a high standard of cleaning is the best possible precondition of sustaining the
standard of maintenance that has been achieved.
The kiln axis measured indicates a fully satisfactory load and stress distribution, and there is
therefore no need for any adjustment of the supporting rollers.
For the sake of the drive station, the gear rim should be aligned during a prolonged shutdown
of the kiln. The heavy axial wobbling of the gear rim has a damaging effect on both gear rim
and pinion, and only alignment of these components can extend their life.
-- o --
Should the above conclusions contain recommendations warranting the implementation of

specific activities, these activities are listed in section (3), “Recommended Actions”.
We suggest that the next kiln inspection should be carried out in approx. 3 years, i.e. in
(year).

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(3) Recommended Actions
As a result of the inspection carried out by FLS, we recommend that the client should take
the actions stated below:
(A) Actions to be taken as soon as possible:
* Intensify the cleaning effort at all the supports, on the baseplates, and under the
supporting rollers. Please see section (6).
* The system applying lubricant between the moving parts and the stationary wear
parts at the inlet seal should be put in working order. Please see sections (6) and
(6.8).
* Check of the spray lubrication system. Please see section (6).
(B) Actions to be taken during the next kiln shutdown:
* On the kiln drive, all the pinion and intermediate pinion bearings need draining
of oil and thorough cleaning out which also means each bottom housing between
front and rear sections (communicating channel). Use a proper flushing oil to
finish. Top bearing covers should be removed one at a time to assist this
function. Take the opportunity to also check the lubrication cups (one or two are
loose and out of line). Replace seals as necessary and attend to leaks,
particularly on the upper main pinion bearing. Furthermore, check that the shaft
scrapers are in satisfactory condition and ensure that they are in the correct
direction when being replaced.
* The oil pipework, sight glasses, etc. associated with each bearing must be
cleaned out and then re-sealed. Do not forget to clean out the small vent hole in
the top cap of the sight glasses.
* As the majority of dust is entering the bearings through the badly sealing top
inspection cast flaps, take the opportunity to re-machine these flaps to improve
the sealing ability. Otherwise it will be the same old story next year.
* Fill in new oil in each bearing and check that the lubrication is satisfactory
before the kiln is re-started. Do not overfill the bearings.
* During the kiln stoppage, both gear sumps/casing should be cleaned out. The
position of the main drive pinion should then be ascertained, and if axial
movement is confirmed, a decision is to be made as to whether any practical
action can be taken.

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In an ideal situation, the gear rim tooth tip burrs should be removed but only if
this is going to be done properly and the metal filings/grindings are thoroughly
cleaned off afterwards. If this was the case, the tooth tips of the pinion could
also be carefully dressed up and the side scrapers for the gear rim reinstated.
As stated previously, there is little point in realigning the gear rim until it is
reversed.
The sliding inspection cover on the top of the intermediate gearing casing cover
should be improved, not only to provide a more sealed plate to prevent ingress
of dust but also for safety reasons (open rotating gears).
The security of the locking plates for spring plate pins seems to continue in their
variety. Some conformity should be applied to all of these. The comments made
in our report of (year) still apply.
Check the oil level of the main drive gearbox and adjust, if necessary. Measure
when stationary and in a cold state.
* At the inlet seal, check that grease is actually reaching the various termination
points. Look at seal wear and take action accordingly.
* At the outlet seal, lift up a number of the lamella seals at various points in order
to help judge wear.
(C) Actions to be taken when convenient:
* Reconditioning of the marker plate of bearing 4 at support III. Please see section
(5.4.1).
* Removal of remnants of weld material. Please see section (6.1).
* Modification of the safety guards between supporting rollers and live rings. Please
see section (6.2).
* Check of the rolling surfaces of live rings and supporting rollers. They should be
machined if they are not truly cylindrical. Please see sections (5.3.3) and (6.3).
* Adjustment of the inclination of the left-hand supporting roller at support I. Please

see section (5.3.3).

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Adjustment of the inclination should be followed up by adjustment of the skewing

of the supporting rollers at support I to ensure correct axial, mechanical balance of
the kiln.
(D) Preventive maintenance:
* The side guides on the outlet side of live ring III should be replaced as soon as
possible. Please see sections (5.1.2) and (6.1.1).
(E) Future activities (for planning purposes):
* Machining of supporting rollers and live ring at support I, if necessary. Please see
section (5.3.3).
* Reduction in the axial wobbling of the gear rim.


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(4) Terminology
The following terms are identical with those used in all other FLS documentation and will be
used throughout this report.
* Right-hand/left-hand side of the kiln:
The right-hand/left-hand side of the kiln is determined as seen from the kiln outlet
towards the inlet, i.e. against the material flow direction.
* Numbering of bearings for the supporting rollers:
At each support, the bearings for the supporting rollers are numbered from 1 to 4,
starting with bearing 1 on the right-hand side of the support at the kiln outlet and
continuing anticlockwise as shown in Fig. 1 below.
Bearing 3 Inlet Bearing 2
Left Right
Bearing 4 Bearing 1
Outlet
Fig. 1: Numbering of bearings for supporting rollers.
* Numbering of supports:
The kiln supports are numbered I - III starting from the kiln outlet.
* Direction of rotation:
The direction of rotation of the kiln - anticlockwise - is determined as seen from the
kiln outlet towards the inlet, i.e. against the material flow direction.

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(5) Inspection Activities Carried out -

Measurements and Calculations Performed
The following is a detailed description of the scope of the FLS inspection programme, its
results, and the general and specific impact of the mechanical condition of the kiln
components on the operation.
(5.1) Kiln Shell
The physical condition of the kiln shell, especially the keeping of its “circular” shape while
rotating, is one of the most important factors when it comes to maintaining a high availability
level of the kiln system.
It is common knowledge that the deformations occurring in the kiln shell while rotating are
greatest under and in the vicinity of the live rings. Such deformations, which, naturally, are
transmitted to the kiln lining, have an extremely great impact on the stability of the coating
and the durability of the refractory lining. In addition to this, severe deformations lead to
correspondingly great stresses in kiln shell and welds, and these stresses may contribute to
formation of cracks.
The logical consequence of this is that the below-mentioned activities are carried out with
the purpose of describing and evaluating the present, physical condition of the kiln.
(5.1.1) Kiln Shell - Temperatures
The highest and lowest kiln shell temperatures on both the inlet side and the outlet side of all
live rings were measured by means of a radiation pyrometer (emission factor ε = 0.95).
A great temperature difference at a particular measuring point is usually caused by varying

thickness of lining and/or coating. This is an unfortunate phenomenon as the result may be
what is called a thermal crank in the kiln shell, leading in its turn to increased loads on both
the kiln shell and the supports.
The measurements recorded during the inspection are shown in the table overleaf.

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Kiln shell Inlet side Outlet side

temperature
(ºC) High Low Difference High Low Difference
At live ring I 372 327 45 344 248 96

At live ring II 296 239 57 291 222 69
At live ring III 229 137 92 181 124 57
As will appear from the above table, the greatest temperature difference was recorded on the
outlet side of live ring I.
In the present case, the temperature differences measured are so small that there is no major
risk of increased loads, and this evaluation is, in fact, supported by the result of the crank
inspection. Please see section (5.1.3).
(5.1.2) Kiln Shell - Side Guides
The purpose of the side guides is to keep the live rings in their axial position on the kiln
shell. This implies that the axial thrust from the kiln shell is transmitted via the contact faces
between live rings and side guides, and there is a higher or lower degree of relative, radial
movement between these components depending on the degree of kiln shell ovality.
Therefore, there is a risk of wear at these points.
A new FLS kiln has a total clearance between live ring and side guides of approx. 4 mm
(indicated by “c” and “d” in Fig. 2 below).
a c d b
Fig. 2: Side guides for live ring fitted on

live ring supporting blocks (type A).

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Side guides Type Clearance (mm) Width (mm)

c d a b
At live ring I A 12 - 15 0 165 - 170 165 - 170
At live ring II A 0 6 - 10 190 190
At live ring III A 20 0 45 98
As will appear from the above table, the clearances between live rings and side guides
measured during the inspection range from 6 mm to 20 mm.
A comparison between the above measurements and those taken during the inspection in
(month/year) shows that the intervening period has seen only insignificant wear on the side
guides.
The wear on the side guides on the outlet side of live ring III is very marked and the side
guides should be replaced as soon as possible.
Regarding lubricants and lubrication methods, please see section (5.2.4).
(5.1.3) Kiln Shell - Crank Indication
In a new kiln erected in the correct way, the gravity axis of the kiln shell coincides with
its axis of rotation. If it should at a later date turn out that these axes are forcibly
coinciding at a support, a kiln crank is said to have developed. Crank formation can get
so severe that live ring and supporting rollers lose contact with each other during part of
the kiln rotation.
In most cases, such cranks develop as a result of irregular thickness of the coating causing
uneven heating of the kiln shell in the burning zone of the kiln. This type of crank, called a
thermal crank, can be reduced by changing the composition of the raw materials and/or the
burning process and by choosing the right type of lining.
A mechanical crank is usually caused by superheating of part of the kiln shell due to loss of
lining. Other examples of causes of mechanical cranks are failure to bar the kiln during cool-
down (resulting in permanent deformation of the kiln shell) and welding together of
misaligned kiln sections, e.g. due to unprofessional repair work.
A mechanical crank can be eliminated by cutting the kiln shell in two or more places
followed by appropriate re-alignment of these kiln sections and then re-welding. This
method necessitates a shutdown of the kiln during the repair.

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Alternatively, a mechanical crank can under certain circumstances be straightened by using a

heat method developed by FLS allowing the kiln to continue normal operation. However,
both methods require extensive preparations and a great deal of experience to be successful.
During operation, the gravity axis of the kiln shell is forced to coincide with its axis of
rotation under the live rings. The existence of crank formation in the kiln shell will therefore
manifest itself as variations in the load on the individual supports occurring cyclically during
the rotation of the kiln.
The variations in the deflection of the supporting roller shafts during the rotation of the kiln
directly reflect the additional loads imposed on the supports as a result of the presence of a
thermal and/or a mechanical kiln crank. These additional loads can become so great that they
cause fatigue fractures in the supporting roller shafts and increase the stress level in the kiln
shell at the supports, causing crack formation and increased ovality, which may in their turn
reduce the life of the kiln lining.
The deflection variations of the supporting roller shafts are measured by means of a sensitive
longitudinal transducer coupled to a measuring and recording instrument or a laptop
computer via a data collector. The measuring set-up is shown in Fig. 3 below.
Fig. 3: Set-up for measurement of the deflections of supporting

roller shafts.
The deflection variations measured during the inspection are shown in the table overleaf, and
the curve patterns recorded during the measuring process appear from Enclosures 1a - f.

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Left-hand Right-hand
Deflection variation supporting supporting
per kiln revolution roller shaft roller shaft
(± mm) (± mm)
Support I 0.07 0.08
Support II 0.04 0.08
Support III 0.05 0.06
The measurements taken in (year) resulted in the following deflection variation values:
Left-hand Right-hand
Deflection variation supporting supporting
per kiln revolution roller shaft roller shaft
(± mm) (± mm)
Support I 0.01 0.03
Support II 0.04 0.07
Support III 0.04 0.01
In case deflection variations exceeding ± 0.15 mm are measured on one or both of the
supporting roller shafts of a support (the supporting rollers and shafts are assumed to be of
FLS design), a closer investigation is required in order to determine whether the kiln has a
thermal crank (i.e. varying according to the operational conditions) or a mechanical crank
(i.e. a permanent one).
In case of a mechanical crank, we recommend that a full crank inspection be performed in

order to determine the crank's size and position in the kiln shell.
As will appear from the above table, the largest deflection variations were measured at
support I. The values measured are markedly lower than the limit of ± 0.15 mm mentioned
above.

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A comparison between the two sets of measurements shows that the deflection
variations of the supporting roller shafts measured now and in 2000 are almost
identical. The differences at the individual supports must be caused by thermal factors
or minor mechanical crank formation in the kiln shell, the latter evaluation being
based on the fact that the wobbling values of live rings I and II are higher than those
measured in 2000. Please see section (5.2.5). However, we still consider the deflection
variations measured to be at a satisfactory level.
(5.1.4) Kiln Shell - Wobbling
The geometrical deviation between the gravity axis of the kiln shell and its axis of rotation is
called the wobbling of the kiln shell. In an old kiln, the wobbling of the kiln shell normally
varies in terms of both magnitude and direction throughout the whole length of the kiln.
The purpose of measuring the wobbling of the kiln shell is to analyse the causes of possible
wobbling of the live rings and/or the gear rim. A longitudinal transducer in contact with the
kiln shell and coupled to a measuring and recording instrument or a laptop computer via a
data collector is used for measurement of the wobbling of the kiln shell at a suitable number
of points along the kiln. All measurements refer to the same starting point, which is normally
the position of the manhole.
Polar diagrams are drawn on the basis of the above measurements. From the polar diagrams,
the magnitude and direction of the wobbling of the kiln shell can be determined at each of
the points chosen.
A total of 5 polar diagrams were drawn on the inlet sides and outlet sides of live rings I and
II and on the outlet side of the gear rim. The measuring points appear from Enclosures 2a - e,
which also show the wobbling of the kiln shell at the measuring points in question.
The axonometric axis of the kiln, the kiln crank diagram, appears from Enclosure 3.
The measurements taken of the wobbling of the kiln shell explain why the axial wobbling of
live rings I and II has increased. Please see section (5.2.5). The kiln shell has become more
warped between supports I and II since the last kiln inspection. The wobbling of the kiln
shell on the outlet side of the gear rim has not changed. During a shutdown, the hot kiln has
in all probability been at rest at the same position for too long time. No action is necessary at
the present moment, but the wobbling of kiln shell and live rings should still be
measured/kept under observation.

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(5.2) Live Rings
(5.2.1) Live Rings - Temperatures and Diameters
During the inspection, the live ring temperatures were measured by means of a radiation
pyrometer (emission factor ε = 0.95) in the middle of the side faces of the live rings and on
both the inlet side and the outlet side. Then the average temperature was calculated.
The average temperatures appear from the table overleaf.
The diameters of the live rings are calculated on the basis of measurements of their
circumferences. Electromechanical measuring equipment developed by FLS for this specific
purpose is used for these circumferential measurements that are taken while the kiln is in
normal operation.
The results of the diameter measurements taken during the inspection appear from the table
below, which also shows the original diameters of the live rings (at 20°C).
Measurements taken during the inspection Original value

Live rings
Temperatures and Temperature Diameter (mm) Diameter (mm) Diameter (mm)
diameters measured at temperature
at 20ºC at 20ºC
(ºC) measured
Live ring I 208 5168.6 5157 5160
Live ring II 142 5060.9 5052 5052
Live ring III 100 5017.4 5013 5020
The temperatures measured are acceptable and do not deviate significantly from those
measured in (month/year).
The diameter values measured deviate from the measurements taken in (year) pari passu with
the live ring temperatures measured, these temperatures being momentary values.
The diameters of the live rings calculated at 20ºC have remained more or less unchanged as
compared with the measurements taken during the inspection in (year). The above table also
shows that the diameter of live ring II calculated at 20ºC has not decreased since it was
installed in (year). The reductions in the diameters of live rings I and III are caused by wear
owing to the highly dust-infected atmosphere (dust coming from kiln No. ..).
Each live ring will be dealt with separately in the visual inspection part of this report. Please
see section (6.2).

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(5.2.2) Live Rings - Migration
Live ring migration is the relative, tangential, rolling movement of contact points on kiln
shell (live ring supporting blocks) and live ring in relation to one another during one
revolution of the kiln. The migration is a direct measure of the circumferential difference,
and accordingly of the diameter difference, between live ring and kiln shell and an indirect
measure of the ovality of the kiln shell. Therefore it is an important indicator of the
mechanical condition of the kiln.
It should be borne in mind that kiln shell ovality is actually generated between kiln shell and
live ring due to the rigidity of and the loads on the live ring and to the diameter difference
between live ring and kiln shell. This means that the highest degree of ovality is found under
the live ring, gradually decreasing as the distance from the live ring increases.
This is the reason why FLS has chosen to investigate the ovality by measurement of the live
ring migration in preference to the more traditional Shell Test method, as measurements by
the latter method must necessarily be taken at some distance from the live ring showing,
consequently, a lower degree of ovality.
The live ring migration is measured during normal operation of the kiln by means of an
instrument like the one shown in Fig. 4 below, the migration being directly measurable as the
length of period of the graph drawn.
Live ring
Magnet
Pencil
Magnet
Supporting block
Fig. 4: Measurement of live ring migration.
In a new FLS kiln, the live ring migration will under normal operational conditions be
approx. 10 mm per revolution of the kiln corresponding to a relative FLS ovality of the kiln
shell of approx. 0.30%, which in its turn corresponds to a calculated Shell Test ovality of
approx. 0.50%.

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Generally, ovality corresponding to live ring migration of 10 - 15 mm per revolution of the

kiln will have no harmful effect on the kiln lining. However, if the migration exceeds approx.
20 mm, this indicates that the ovality of the kiln shell has reached a size that will most
probably contribute to a reduction in the life of the lining. Such a high degree of ovality will
also add to the stress level in kiln shell and welds, and this may contribute to crack
formation.
Consequently, FLS recommends that measurement of the live ring migration, the related live
ring temperatures, and the temperatures on the surface of the kiln shell on both sides of the
live rings should form an integral part of the normal, preventive maintenance programme
carried out at the plant. This will enable monitoring of variations in the live ring migration,
allowing the necessary steps to counter any problems to be taken.
The migration values measured during the inspection are shown in the table below. Please
also see Enclosure 4.
Live ring migration (mm/rev.)
Live ring I 14.0

Live ring II 12.5
Live ring III 19.0
The following live ring migration values were measured during the inspection in (year):
Live ring migration (mm/rev.)
Live ring I 12.0

Live ring II 3.0
Live ring III 14.0
The migration of all the live rings has increased since the last kiln inspection. The increase is
most probably due to wear on the inside rolling surfaces of the live rings or wear on the
outside surfaces of the live ring supporting blocks as a consequence of the highly dust-
infected atmosphere at the kiln. However, the migration of the live rings is still at a
satisfactory level, and this evaluation is, in fact, supported by the calculations shown in the
table overleaf.

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FLS has used the kiln axis measured and the available data on the existing lining and coating
for making a complete re-calculation of the kiln. The calculated values of the tangential
bending stress in the kiln shell under the live rings are shown in the table overleaf.
Live ring migration Live ring migration

(measured) (10 mm)
Tangential Tangential
FLS calculation Relative bending Relative bending
ovality stress in the ovality stress in the
kiln shell kiln shell
(%) (N/mm²) (%) (N/mm²)
At live ring I 0.19 23.7 0.15 18.3
At live ring II 0.26 28.2 0.23 24.1
At live ring III 0.32 34.5 0.24 23.5
The kiln dimensioning process aims at ensuring a satisfactory service life of the kiln given a
proper standard of maintenance. A factor that must be taken into account is that the above-
mentioned value of relative FLS ovality of the kiln shell of 0.30% and tangential bending
stress in the kiln shell under the live rings of 30 N/mm² may occasionally be slightly
exceeded even in good plant operating practices (please see the survey of kiln design values
in section (5.7.2) on calculation of the kiln axis).
Our calculations show that the ovality and bending stress values are satisfactory at the
migration measured.
An increase in the live ring migration indicates an increase in the clearance between live ring
and kiln shell and, consequently, in the ovality of the kiln shell. On the other hand, a
reduction in the live ring migration indicates a reduction in the clearance between kiln shell
and live ring, and this may result in jamming and constriction (please see Fig. 5 overleaf).
An increase in the live ring migration is normally attributable to one or a combination of the
following causes:
* Wear on the live ring supporting blocks or, where such blocks are not fitted, on
the kiln shell itself, caused by ineffective lubrication between live ring and live
ring supporting blocks. This may for instance be the case if the environment at the
live ring is very dirty.

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As described in section (5.2.4), to ensure effective lubrication, it is necessary to use:
- correct lubricant;
- correct lubricating method;
- correct lubricating frequency.
Fig. 5: Constriction of kiln shell under live ring.
* Constriction caused by superheating of the kiln shell under the live ring. This
situation may arise if, e.g., the kiln lining gets worn or falls out or if the coating
does not have the thickness required.
As to the latter point, starting up a kiln with a new lining is a particularly critical
matter. If start-up (heating) is effected too quickly, the kiln shell may expand so
much that it gets jammed under the live ring. This may lead to a permanent
deformation of the kiln shell, resulting in an increased clearance between live ring
and live ring supporting blocks (kiln shell) when temperatures return to normal and
the kiln contracts.
If the kiln suffers from constriction, it may be impossible to do a proper piece of

lining installation work, and the result of this may be an unacceptably short life of
the lining. In such a situation, the kiln section in question should be replaced.

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(5.2.3) Live Rings - Reduction in Migration
If the live ring migration increases to a point where the ovality and bending stress values
cause mechanical problems and/or problems with the lining, corrective action should be
taken to reduce the migration (and thus the ovality) in order to avoid a real breakdown. The
method to be applied depends on the type of kiln shell: with or without live ring supporting
blocks.
Kiln shell with live ring supporting blocks:
For this type of kiln shell, the clearance between live ring supporting blocks and live ring can
be reduced by installation of shims between the blocks and the kiln shell.
The average thickness “t” of such shims is calculated according to the following formula
where “v” is the live ring migration:
v − 10
t= (“t” in mm and “v” in mm/rev.)
2π
By installing shims with an average thickness of “t” mm, the live ring migration will be
reduced to 10 mm per revolution of the kiln.
We know from experience that the live ring migration can vary within pretty wide limits. To
take this natural variation into account, the following measuring programme must always be
carried out before deciding on the thickness of the shims to be installed under the live ring
supporting blocks:
* Measurement of live ring migration.
* Measurement of temperature on the side faces of the live ring (average).
* Measurement of the kiln shell temperature on both the inlet side and the outlet side
of the live ring.
These measurements must be taken at least twice every 24 hours for a period of 3 - 4 weeks.
It is a condition that the kiln is in normal operation throughout this period. Please note that,
as a rule, the lowest value of the live ring migration measured is to be used for
calculation of the shims. Moreover, the condition of the lining and the stability of the
coating in the kiln area in question must also be evaluated.

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(5.2.4) Live Rings - Lubrication
Where maintenance of live rings is concerned, use of the correct lubricating method is of
paramount importance in the following two areas:
* The contact faces between live ring and live ring supporting blocks/kiln
shell/side guides.
Lubrication should be carried out by means of a pump to ensure that the lubricant is
distributed over the entire contact face. Lubricate as required, however, at least
once or twice a month.
The following lubricants are suitable for this purpose:
Lubricant Producer Product

Chesterton 785 Parting Lubricant
Klüber Lubrication Wolframcoat C
Never-Seez Comp. Corp. Never-Seez 1
Fuchs Lubritech Ceplattyn HT
We normally recommend lubrication between live rings and live ring supporting
blocks and between side guides and live rings in order to reduce the wear between
these components and in order to avoid scuffing between live ring supporting
blocks and live rings.
However, considering the highly dust-infected atmosphere in the kiln building,

it is not always advisable to apply lubricant between live rings and side guides
and between live rings and live ring supporting blocks at the intervals
mentioned above as the combination of dust and lubricant will no doubt
accelerate the wear on the components. If lubrication is necessary, a mixture
of water and powdered graphite can be used.
* The contact faces between live ring and supporting rollers.
These areas should be lubricated with dry graphite only. (A liquid lubricant would
penetrate into micro-cracks on the surface and come under extremely high pressure
during the contact phase, thus further increasing the crack formation. Pitting or
scaling would invariably result.)
1
Never-Seez, which is supplied as a paste, can be mixed with oil to improve its flow between live ring and
live ring supporting blocks/side guides/kiln shell. In that case, the mixture ratio must be approx. 40%
Never-Seez to approx. 60% oil, and the oil used must have a high flash point.

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(5.2.5) Live Rings - Wobbling
The axial wobbling of the live rings is measured by means of a longitudinal transducer
coupled to a measuring and recording instrument or a laptop computer via a data collector
(please see Fig. 6 overleaf).
Wobbling of live ring
Recorder
Transducer
Fig. 6: Measurement of axial wobbling of live ring.
Measurement of the axial wobbling of live rings forms part of the evaluation of contact
conditions between live ring and supporting rollers. Severe wobbling of a live ring indicates
poor contact conditions, resulting in increased Hertz pressure, which in its turn causes wear,
convex/concave rolling surfaces, rolling-out of the rolling surfaces, as well as a risk of
pitting.
The permissible, axial wobbling of the live rings of a new FLS kiln is ± 1 mm.
The measurements taken during the inspection are shown in the table below. Please also see
Enclosures 5a - c.
Axial wobbling of live rings (± mm)

Live ring I 2.0
Live ring II 1.3
Live ring III 1.7

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The following wobbling values were measured during the inspection in (month/year):
Axial wobbling of live rings (± mm)

Live ring I 0.64
Live ring II 0.37
Live ring III 1.72
Comparing the two sets of measurements shows that the wobbling of live rings I and II has
increased. The cause is no doubt, as mentioned in section (5.1.4), that, during a shutdown,
the hot kiln has been at rest at the same position for too long time.
The polar diagrams drawn on the inlet sides and outlet sides of live rings I and II show
relatively heavy wobbling of the kiln shell, confirming the axial wobbling of the live rings
measured. No action in respect of the wobbling of the live rings is necessary at the present
moment, but it should be kept under observation, and in case the values measured continue
to rise, action should be taken possibly by cutting the kiln shell in two or more places.
If the wobbling of the kiln shell continues to increase, the result will be unacceptable, heavy
axial wobbling of the live rings which will damage the rolling surfaces of live rings and
supporting rollers as they will be worn into convex and concave configurations, respectively.

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(5.2.6) Live Rings - Positions on Supporting Rollers
Left
4 SR 3
S4 S3
S1 LR S2
1 SR 2
Right
Fig. 7: Position of live ring on supporting rollers.
The table below shows the positions of the live rings on the various supporting rollers using
the designations shown in Fig. 7 above.
Positions of Positions of live rings (mm) Width of Width of

live rings on supporting live ring
supporting rollers roller (SR) (LR)
S1 S2 S3 S4 (mm) (mm)
Support I 135 45 10 170 1200 1020
Support II 55 65 65 55 800 680
Support III 60 60 75 45 800 680
The positions of the live rings on the supporting rollers are satisfactory.

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(5.3) Supporting Rollers
(5.3.1) Supporting Rollers - Temperatures and Diameters
The supporting roller temperatures were measured by means of a radiation pyrometer

(emission factor ε = 0.95) in the middle of the side faces of the rolling surfaces of the
supporting rollers and on both the inlet side and the outlet side. Then the average temperature
was calculated.
The average temperatures appear from the table overleaf.
The diameters of the supporting rollers are calculated on the basis of measurements of their
circumferences. Electromechanical measuring equipment developed by FLS for this specific
purpose (the same equipment as that used for measuring the live ring circum-ferences) is
used for these circumferential measurements that are taken while the kiln is in normal
operation.
The results of the diameter measurements taken during the inspection appear from the table
overleaf, which also shows the original diameters of the supporting rollers (at 20°C).
Measurements taken during the inspection Original

Supporting rollers
value
Temperature Diameter (mm) Diameter Diameter
Temperatures and
measured at temperature (mm) at (mm) at
diameters
(ºC) measured 20ºC 20ºC
Left 75 2480.4 2478.4 2500
Support I
Right 75 2476.4 2474.3 2500
Left 72 1500.3 1497.4 1500
Support II
Right 70 1498.6 1499.1 1500
Left 59 1492.7 1491.8 1500
Support III
Right 65 1489.0 1488.0 1500
The temperatures measured are normal and therefore do not give rise to any further
comments.
It appears from the above table that the diameters of all the supporting rollers calculated at
20ºC have been reduced.

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The reduction in the supporting roller diameters at support I is mainly due to the rollers
having been machined but is also to some extent caused by the dust accumulating under the
supporting rollers. The latter problem is also in evidence at supports II and III.
The dust accumulating under the supporting rollers at all the supports should be
removed now and then in order to avoid unnecessary wear on the rollers.
The condition of each individual supporting roller will be discussed in section (6.3) on the
visual inspection of the rollers. Machining of the rolling surfaces of some of the supporting
rollers may be necessary as they are perhaps not truly cylindrical.
(5.3.2) Supporting Rollers - Centre Distances
The centre distance between the two supporting rollers at a kiln support is measured as the
distance between the centres of the two shaft ends on both the inlet side and the outlet side.
These measurements are taken to check the degree of parallelism between the supporting
rollers at each individual support.
Bearing 3 C inlet Bearing 2
Left side Right side
Bearing 4 C outlet Bearing 1
Fig. 8: Measurement of centre distances between supporting

rollers.

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The measurements recorded during the inspection appear from the table below.
Supporting rollers - C inlet C outlet C original

Centre distances (mm) (mm) (mm)
Support I 3787 3782 3830
Support II 3327 3328 3318
Support III 3254 3255 3262
The measurements recorded show that the centre distances at support I have changed since
the last inspection.
The parallelism between the supporting roller pairs measured during the last kiln inspection
was satisfactory. After machining of the supporting rollers at support I, the centre distances
were adjusted, and so was perhaps the inclination (?). In consequence, the skewing of the
rollers at support I has increased.
It appears from section (5.3.3) that the inclination of the left-hand roller at support I is
incorrect, and the question is whether the machining has made the supporting rollers truly
cylindrical. We recommend that the rolling surfaces of the rollers be measured. For further
details, please see section (6.3).
Correct skewing and inclination of the rollers and truly cylindrical rolling surfaces of live
rings and supporting rollers will reduce the risk of hot bearings and ensure correct thrust on
the thrust roller and good contact conditions between supporting rollers and live rings. For
further comments, please see section (6.7).
(5.3.3) Supporting Rollers - Inclination
The inclination of the supporting rollers was checked. This check is made primarily with a
view to analysing the axial, mechanical balance of the kiln, as axial thrust is generated if the
inclination of the supporting rollers deviates from that of the kiln (live rings) at the
corresponding positions, and secondarily in order to evaluate the causes of possibly poor
contact conditions between supporting rollers and live rings and between live rings and live
ring supporting blocks/kiln shell.
The targeted, ideal inclination for a set of supporting rollers corresponds to the inclination of
the kiln at the point in question, i.e. the nominal inclination of the kiln adjusted according to
the kiln deflection and to the desire for axial, mechanical balance and correct contact
conditions. The current, available data on the existing lining and coating conditions are
included in the calculation of these ideal values.

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The inclination was measured by means of an inclinometer designed by FLS for this specific
purpose. The inclinometer is fixed to the end faces of the supporting roller shafts by means
of magnets, usually permitting the measurement to be taken during normal kiln operation.
The table below shows the inclination values of the supporting rollers measured during the
inspection and the corresponding calculated, ideal values. The calculation of the ideal
values is based on the kiln inclination measured of 3.474%.
Inclination Left-hand supporting Right-hand supporting

of roller roller
supporting rollers Ideal Measured Ideal Measured
value value value value
(%) (%) (%) (%)
Support I 3.463 - 3.483 3.541 3.463 - 3.443 3.468
Support II 3.481 - 3.501 3.451 3.481 - 3.461 3.463
Support III 3.465 - 3.485 3.501 3.465 - 3.445 3.512
The thicknesses of the shims to be installed or removed in order to attain correct inclination
of the supporting rollers appear from the table overleaf.
Thickness
of shims Bearing 1 Bearing 2 Bearing 3 Bearing 4
(mm)
Support I 0.3 - - 1.6
Support II - 0.5 0.6 -
Support III - - - 0.4
If the difference between the calculated, ideal value and the one measured is too large (> 0.5
mm), the inclination of the supporting roller in question should be adjusted. This adjustment
is carried out by installation (+) or removal (-) of a shim of suitable shape and thickness
under one of the bearings for the supporting rollers.
Bearing 4 at support I is to be adjusted.


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We recommend the following procedure when adjusting the inclination of supporting rollers:
* Check the rolling surfaces (profiles) of live ring and supporting rollers.
If the surfaces are not level, i.e. if they have been worn into conical, convex, or
concave configurations, they should be machined. As to measurement of the
surfaces, please see the last part of section (6.3).
* Carry out machining, if necessary.
Machining of supporting rollers and live rings changes the axial and radial load
from the kiln on the rollers. It is therefore important that necessary adjustments of
the supporting rollers should be made as the machining operation proceeds in order
to avoid overheating of bearings and to maintain the axial, mechanical balance of
the kiln.
* During the first shutdown of the kiln after completion of machining, make the
recommended adjustments of the inclination at the support where machining has
taken place.
* After adjustment of the inclination, check the inclination of the supporting rollers.
Supplementary adjustments of the inclination may be necessary in a few cases.
The shims are made of mild steel plate in the dimensions indicated in Fig. 9 and the table
overleaf.
Fig. 9: Two-piece shim for adjustment of the inclination

of supporting rollers.

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Size of A B C D E
bearing
630 1550 500 130 85 1310
450 1250 400 100 80 1060
Adjustment of the inclination and skewing of supporting rollers must always be

succeeded by a check of the axial thrust from the kiln on the supporting rollers in
question and of the overall axial, mechanical balance of the kiln. This check is made by
measuring the bearing temperatures (please see section (5.4.2)) or by using the
equipment for measurement of the axial thrust (please see section (6.7)). The latter
method can only be used, however, if the rolling surfaces of supporting rollers as well
as live rings are truly cylindrical and if the journals of the bearings are in optimum
condition.
(5.4) Bearings for Supporting Rollers
(5.4.1) Bearings for Supporting Rollers - Positions
Marker plates like the one shown in Fig. 10 overleaf indicating the positions of the bearings
on the baseplates are installed during the erection of, among others, FLS kilns.
Fig. 10: Position of bearing on baseplate.
The present positions of the bearings were checked during the inspection and compared with
their original positions. The results appear from the table below. A negative “a”-value
indicates that the bearing in question has been moved inward towards the centreline of the
kiln.

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Positions of bearings Bearing 1 Bearing 2 Bearing 3 Bearing 4

a (mm) a (mm) a (mm) a (mm)
Support I *) - 18.0 - 36.0 **)
Support II + 2.5 + 2.5 + 4.0 + 1.5
Support III - 5.0 - 7.0 - 5.0 ***)
*) The marker plate is located between two lines scribed on the baseplate. These lines are
scribed at - 13/- 2.
**) The marker plate is located between two lines scribed on the baseplate. These lines are
scribed at - 15/- 4.
***) Defective marker plate.
The thickness “t” of any existing shims between baseplates and bearings installed to raise the
bearings with a view to adjusting the inclination of the supporting rollers is shown in the
table overleaf.
Thickness of shims Bearing 1 Bearing 2 Bearing 3 Bearing 4

t (mm) t (mm) t (mm) t (mm)
Support I 8.5 7.0 11.0 11.5
Support II 0.0 0.0 0.5 0.0
Support III 1.0 0.5 1.0 0.5
(5.4.2) Bearings for Supporting Rollers - Temperatures
The bearing temperatures were measured by means of a contact thermometer. The following
temperature measurements were taken on each bearing: two measurements on the journal,
one as close to the supporting roller as possible but inside the bearing housing and the other
at a point approx. 30 mm from the thrust collar (Txm and Txe, respectively), and one
measurement on the thrust collar (Txk). (Please note that in the bearings where thrust collar
and liner were not in contact, measurements were only taken at Txm and Txe.)

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Left
e= Journal at
thrust collar
k= Trust collar
m= Journal
Right
Fig. 11: Temperatures of bearings for supporting rollers.

Measuring points.
The normal temperature profile in a bearing will show the highest temperature at the
supporting roller, the temperature will decrease across the length of the journal, and the
lowest temperature will be registered on/at the thrust collar.
It is extremely important to be attentive to any changes in the temperature on the thrust collar
as such changes may indicate changes in the operational conditions. If the temperature on a
thrust collar (Txk) is more than approx. 2°C higher than that on the adjacent journal (Txe),
this may be an indication that excessive axial thrust is being transmitted through the bearing,
entailing a risk of its running hot. In such cases, corrective action to restore normal
temperatures should be taken as soon as possible.
In a new FLS kiln, where all rolling surfaces are truly cylindrical and general conditions are
ideal, the supporting rollers are adjusted so that all rollers exert a slight uphill thrust on the
kiln. These adjustments are made on the basis of measurements taken with equipment for
measurement of the axial thrust.
The bearing temperatures measured during the inspection are shown in the tables below. An
“x” indicates contact between the thrust collar and the bearing liner of the bearing concerned.

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Bearing Left-hand supporting roller

temperatures Bearing 4 Bearing 3
(°C) a4 T4k T4e T4m T3m T3e T3k a3
Support I - - 35.9 40.9 43.3 37.4 37.7 x
Support II x 37.3 35.9 40.0 35.7 32.2 - -
Support III - - 31.1 *) 33.4 29.6 30.2 x
Bearing Right-hand supporting roller

temperatures Bearing 1 Bearing 2
(°C) a1 T1k T1e T1m T2m T2e T2k a2
Support I x 36.4 36.3 40.1 42.6 36.5 - -
Support II - - 38.9 39.5 34.5 32.1 32.5 x
Support III - - 32.0 37.8 36.8 32.9 33.3 x
*) It was not possible to measure the journal temperature as the cover fitted on the
bearing housing could not be opened.
The bearing temperatures measured are satisfactory.
(5.4.3) Bearings for Supporting Rollers - Lubrication
The bearings of the rotary kiln are hydrodynamically lubricated journal bearings. Due to the
low speed of rotation, it is very important that the difference in diameters between the
journal and the bearing liner be exactly so great as to produce the wedge effect necessary for
the generation of an adequate oil film thickness.
Satisfactory operation of the bearings is therefore highly dependent on the use of an oil type
with the proper viscosity and on keeping the oil free of abrasive dust and other contaminants.

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Systematic maintenance of the bearings in accordance with directions given in the

instruction manuals for maintenance is of paramount importance to trouble-free operation of
the bearings.
FLS normally recommends the use of a mineral oil with FLS symbol EP-680 for lubrication
of bearings for supporting rollers. In case of abnormal overheating of a bearing, we
recommend the use of an oil type with FLS symbol EP-1000.
For further information, please see the relevant instruction manuals for maintenance.
(5.5) Baseplates
(5.5.1) Baseplates - Levelling
Fig. 12: Levelling of baseplate heights.
Any movement of the foundations may have a direct effect on the geometry of the kiln axis.
Such movements can be regarded as being composed of purely vertical movements, called
settlement, and rotations both in the vertical plane including the kiln axis and in a likewise
vertical plane being perpendicular to the kiln axis. The latter rotations, called tilting, interfere
with the horizontal component of the kiln axis whereas the vertical movements affect the
vertical component of the kiln axis.
To determine whether the foundations have moved, the differences in height between the
baseplates were measured at all supports during the inspection by means of a levelling
instrument (please see Fig. 12 above).

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The results of the levelling of the baseplates appear from the table below, which also shows
the original height differences between the baseplates.
Difference in height between Settlement of Accumulated

the foundations foundations difference in
height
Support Original Height Difference in
height measured height Change
(mm) (mm) (mm) (mm)
R-I 0 0 0 0
I - II 1325 1325 0 0
II - III 815 825 + 10 + 10
The tilting values shown in the table below are pure rotations around the baseplate centres.
Therefore, they are the same size numerically but given with opposite signs on the right-hand
and the left-hand sides of the baseplates, a “+” indicating the highest point. Please also note
that the tilting is stated as seen from the burner’s platform.
Difference in height from side to side

on baseplate front edge
Tilting of foundation Left-hand side Right-hand side
(mm) (mm)
Support I - 6.00 + 6.00
Support II + 0.75 - 0.75
Support III - 2.00 + 2.00
The measurements show that both settling and major tilting of especially foundations I and
III have occurred after the erection. It is not possible at the present moment to draw any
conclusions as to whether the settlement/tilting have stopped. The baseplates should
therefore still be checked at regular intervals.
The differences in height measured may vary slightly from inspection to inspection. The
reason why is that the measurements are taken along a hot kiln. To achieve accurate
measurements, the kiln must be completely cold, and the above values are therefore only to
be taken as a guide.

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(5.6) Drive Station
(5.6.1) Drive Station - Wobbling of Gear Rim
The wobbling of the gear rim was measured in order to evaluate the quality of mesh between
gear rim and pinion.
The axial wobbling was measured by means of a longitudinal transducer coupled to a site
computer (please see the figure in section (5.2.5) on wobbling of live rings). The results are
shown in Enclosure 6 from which it appears that the axial wobbling is ± 4.5 mm which is
very slightly up from (year). In a new installation, the permissible axial wobbling is ±
0.75 mm.
For safety reasons, the radial wobbling of the gear rim was not measured or observed.
However, measuring the movement of the adjacent downhill kiln shell gave a variation of
± 4.4 mm compared with ± 3 mm in (year). On this assumption, we may take it that the
estimated radial wobbling of the gear rim is in the order of ± 3.5 mm. In a new
installation, the permissible radial wobbling is ± 1.5mm.
(5.6.2) Drive Station - Root Clearance
Visual indication at one temporary stationary position gave a clearance between pinion tooth
and root of gear rim of 12 - 13 mm. This compares to a theoretical clearance of 10 mm.
(5.6.3) Drive Station - Position of Gear Rim to Pinion
Observations indicate that the pinion is in a similar position to that of the (year) inspection,
i.e. downhill. During a shutdown of the kiln, the exact situation should be ascertained and a
decision made on any action that may be required.

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(5.7) Kiln Axis
The loads in the kiln shell and on the supports are determined in the design phase assuming a
given geometry of the axis of rotation. To ensure that reactions are distributed evenly on the
two supporting rollers of a support, the horizontal component of this axis of rotation is
always straight. The vertical component of the axis of rotation, on the other hand, can
sometimes be recommended not to be straight as this may provide, e.g., better distribution of
the reactions on the various supports.
Consequently, any changes that may occur in the geometry of the axis of rotation in the
course of time entail changes in the distribution of loads in the kiln shell and on the supports.
Such changes in load, the magnitude of which is closely related to the rigidity of the kiln (i.e.
the relationship between kiln diameter, plate thickness of kiln shell, and distance between the
supports), may involve the risk of a breakdown or reduced service life of the kiln
components. Frequent checks of the kiln axis should therefore form an integral part of the
maintenance work done at the plant.
To be able to correctly evaluate the consequences of any deviation from the optimum kiln
axis, it is necessary to have detailed knowledge of both the rigidity of the kiln and the
strength of the individual components at the supports, i.e. the mechanical condition of the
kiln. Moreover, the measurements themselves must naturally be taken under the most
realistic conditions, i.e. while the kiln is in operation. The conclusions contained in this
inspection report are based on these basic assumptions.
Teodolite
Teodolite with laser
Fig. 13: Set-up for measurement of kiln axis (laser measurement).
The present kiln axis was determined by using two electronic precision theodolites, one of
which is equipped with a laser instrument (please see Fig. 13 above). Readings and

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calculations were made by means of a laptop computer integrated in the set-up but not shown
in the figure.
The coordinates of six points on the rolling surface of each live ring were determined in a
three-dimensional system of coordinates. Knowing these coordinates and the geometry of the
live rings, the coordinates of the centres of the live rings were calculated and the common
axis of rotation was determined.
The centres of the kiln shell were calculated on the basis of the centres of the live rings,
taking both ovality and temperatures into account.
(5.7.1) Kiln Axis - Measuring Results
At the time of measurement, the kiln axis deviated from a straight line under the live rings as
follows:
Kiln axis - Vertical Horizontal

Deviation from deviation 2 deviation 3
a straight line
(mm) (mm)
Support I 0 0
Support II -4 -2
Support III 0 0
Using supports I and III as fixed points (0), the current inclination of the kiln was calculated
to be:
3.474%
2
Positive deviations mean that the kiln axis measured is at a higher position than the straight line. Negative
deviations mean that it is at a lower position.
3
Positive deviations mean that the kiln axis measured is farther away from the basis line of the measurement
(the X-axis, please see the figure in section (5.7)) than the straight line. Negative deviations mean that it is
closer to the basis line.

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Fig. 14 below shows a schematic illustration of the kiln axis measured.
Fig. 14: Kiln axis measured (schematic).
(5.7.2) Kiln Axis - Calculations
The deviation of the kiln axis from its optimum shape affects the supports as well as the kiln
shell and the live rings. To illustrate the consequences, FLS has calculated the load on the
bearings for the supporting rollers and the stresses and ovality in kiln shell and live rings.
The calculations have been performed for both the measured and the recommended kiln axis,
and the results should be evaluated in relation to the following values which apply to the
design of a new FLS kiln:
* Longitudinal bending stress in the clear span of the kiln shell ................. 30 N/mm²
* Tangential bending stress in kiln shell under live rings ............................ 30 N/mm²
* Tangential bending stress in live rings....................................................... 60 N/mm²
* Hertz pressure ............................................................................................. 440 N/mm²
* Relative FLS ovality in kiln shell............................................................... 0.30 %
* Nies ovality in live rings............................................................................. 0.20 %
* Load on bearings......................................................................................... 4.4 N/mm²

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Please note that the above value of 4.4 N/mm² corresponds to a bearing load of 100%. As
far as the loads on the bearings of this kiln are concerned, please see the table below.
-- o --
The results of a calculation are shown in the tables below. In this calculation, the horizontal
component of the kiln axis is taken as straight, and the vertical component is taken as the kiln
axis measured.
Kiln axis measured Recommended kiln

axis
FLS calculation Load on bearings Load on bearings
(%) (%)
Support I 38 23
Support II 62 71
Support III 59 55
Kiln axis measured Recommended kiln axis

Bending Hertz Bending Hertz
FLS calculation stress in live pressure stress in live pressure
ring ring
(N/mm²) (N/mm²) (N/mm²) (N/mm²)
Support I 18 269.9 16 258.1
Support II 40 393.3 47 423.4
Support III 40 384.0 36 369.2

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Kiln axis measured Recommended kiln axis

Ovality Ovality
FLS calculation
Live ring Kiln shell 4 Live ring Kiln shell 4
(%) (%) (%) (%)
Support I 0.07 0.19 0.05 0.16
Support II 0.13 0.26 0.14 0.29
Support III 0.12 0.32 0.11 0.31
Comments on the kiln axis measured:
The greatest longitudinal bending stress calculated for the kiln shell is 18.2 N/mm² located
9820 mm from the middle of live ring I in the direction of the kiln inlet at the transition
between the 25 mm and 30 mm thick kiln sections. This bending stress level is acceptable
(please see the above design values).
Comments on a straight kiln axis:
The greatest longitudinal bending stress calculated for the kiln shell is 12.9 N/mm² located
900 mm from the middle of live ring III in the direction of the kiln outlet at the transition
between the 28 mm and 57 mm thick kiln sections. This bending stress level is acceptable
(please see the above design values).
The values resulting from our calculations of the kiln axis measured and of a straight
vertical kiln axis are almost identical. Consequently, we do not recommend any
adjustment of the vertical kiln axis measured.
The horizontal kiln axis deviates 2 mm from a straight line at support II which is
within the permissible range of variation of the method of measurement used.
Therefore no adjustment is to be made at this support.
4
This degree of ovality corresponds to the live ring migration measured.

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(6) Visual Inspection
The visual inspection constitutes an important part of the mechanical kiln inspection. Its
main objective is to give a description of the present, mechanical condition of the kiln,
including where and how it deviates from the original specifications as given in drawings,
instruction manuals, etc. In addition to design modifications, such indication of deviations
can also cover position and propagation of cracks and wear.
This kind of knowledge of the kiln components is essential for a reliable evaluation of how
the present, mechanical, operational conditions affect the availability of the kiln and how the
operational conditions can be improved.
Actions to be taken as soon as possible:
A very dusty environment is detrimental to the operation of any plant, and this kiln is no
exception. A real effort should be made to cure this problem and allow the plant to
function in a cleaner situation.
The auto greaser at the inlet seal should be seen to be working and supplying the seal
with grease (Mobile Temp 1) as discussed with Mr N. Appleyard at the plant.
The spray nozzles lubricating the gear rim should be cleaned and a test carried out to
determine whether the spray pattern is in accordance with the specifications. Spray
against a white sheet at set distance etc.
Normal checks in respect of air requirements, spray periods/frequency, and dosage of

lubricant should be carried out as discussed with Mr N. Appleyard at the plant. Please
note: From the hand-written notes on the control panel, the current spray period has
increased from the earlier setting.
(6.1) Kiln Shell
Our visual impression of the kiln was that the kiln shell surface was without bulges or
deformations. There were only few signs of thermal overload in the burning zone.
Thermal deformations in areas with welds may cause cracks. Therefore, during shutdowns,
welds and areas close to welds should always be checked for crack formation.
No cracks were observed in the welds on the parts of the kiln shell that could be inspected
from gangways, platforms, or from the ground.

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There are remnants of weld material in a few places on the kiln shell. These welds stem from
the erection of the kiln and from hooks for lifting of jacks etc. All such remnants must be
ground off, and the surface must be checked for cracks, as such remnants (even if they have
been present for many years) are potential starting points of cracks in the kiln shell.
(6.1.1) Kiln Shell - Side Guides and Live Ring Supporting Blocks
Side guides and live ring supporting blocks at supports I and II:
The original side guides and live ring supporting blocks at supports I and II have been
replaced by the design now used by FLS for new kilns. The problem is, however, that the
shims installed under the live ring supporting blocks tend to slide out. FLS is aware of the
problem, and minor design modifications have therefore been introduced. Please see
Enclosure 7, point (7).
Support I:
* Welds between side guides and live ring supporting blocks:
No cracks were observed in the welds between the live ring supporting blocks and the
side guides.
* Bolts for live ring supporting blocks:
All bolts and lock washers were intact.
* Live ring supporting blocks:
No cracks were observed in the live ring supporting blocks.
Support II:
side guides.


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Support III:
side guides.
The side guides on the outlet side are worn and should be replaced.
(6.2) Live Rings
Safety guards:
Due to the safety guards installed, it was not possible to evaluate contact conditions between
the live rings and the supporting rollers at any of the supports. The guards located between
live ring and supporting rollers on the side where live ring and supporting rollers move
downwards should be removed as they do not, in our opinion, serve any safety-related
purpose. The guards located on the other side should be modified in such a way that checks
of the contact conditions can be carried out.
Live ring I:
The condition of the rolling surface of this live ring is satisfactory. Insignificant pitting
formation was noted.
The surface of the life ring is almost plane.
Rolling-out was noted on the inlet side of the live ring (3 mm). No rolling-out on the outlet
side.
Live ring II:
The condition of the rolling surface of this live ring is satisfactory. Much, slight pitting
formation was noted, but this is of no consequence.

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Rolling-out was noted on the inlet side of the live ring (1 mm). No rolling-out on the outlet
side.
Live ring III:
The condition of the rolling surface of this live ring is satisfactory. Slight pitting formation
was noted. At the present moment, however, we do not expect it to cause any problems.
No rolling-out was noted on the inlet side of the live ring. The surface of the taper section of
the live ring is in satisfactory condition. It has been worn into slightly concave configuration.
(6.3) Supporting Rollers
Graphite lubrication between live rings and supporting rollers:
The graphite lubrication equipment should be cleaned and tested. Too much set clinker dust
and oil remnants (support III) prevent the free movement of the graphite blocks. We
definitely recommend that graphite be the only lubricant applied on the rolling surfaces.
Support I:
Both supporting rollers are of the anvil type.
The condition of the rolling surfaces of both supporting rollers is satisfactory.
The surface of the left-hand roller is almost plane. The right-hand one has been worn into
concave configuration (1 mm).
Rolling-out was observed on the inlet side of the right-hand roller (5 mm). No rolling-out on
the outlet side.
Rolling-out was observed on the inlet side of the left-hand roller (8 mm). No rolling-out on
the outlet side.

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Support II:
The right-hand supporting roller is of the box type whereas the left-hand one is of the anvil
type.
The condition of the rolling surfaces of both supporting rollers is satisfactory.
The surface of the left-hand roller is almost plane. The right-hand one has been worn into
slightly concave configuration.
No rolling-out was observed on the sides of any of the supporting rollers.
Support III:
Both supporting rollers are of the box type.
The condition of the rolling surface of the left-hand supporting roller is satisfactory. So is the
condition of the rolling surface of the right-hand one, but incipient pitting formation was
noted on its surface.
The surface of the left-hand roller has been worn into concavo-convex configuration (0.5 - 1
mm). The surface of the right-hand one has been worn into concave configuration (2 mm).
No rolling-out was observed on the sides of any of the supporting rollers.
-- o --
The above measurements of the rolling surfaces were taken with a straightedge and therefore
do not tell whether the supporting rollers and live rings are also conical. We recommend that
profile measurement of the rolling surfaces of supporting rollers and live rings be taken in
order to determine the degree of concavity/convexity/tapered wear.
Measuring of the surfaces can be carried out with the equipment shown in the sketch
attached (please see Enclosure 8) and by using the work sheets attached as Enclosures 9a - c,
but this measuring equipment can only be used for checking the surfaces of the supporting
rollers.
It is possible, however, to check the surfaces of the live rings with some accuracy by means
of a straightedge. The straightedge is placed at the top of the live ring. Then the distance
from the straightedge to the kiln shell is measured (both on the inlet side and on the outlet
side of the live ring) and also from the straightedge to the surface of the live ring. These
measurements will give a pretty good picture of the surface of the live ring.
We normally recommend machining when the conical and/or concave/convex configuration

of supporting rollers and live rings exceed 0.5 mm. Supporting rollers and live rings should
also be machined when their mutual area of contact is reduced by 20 per cent.

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If, for instance, the measurements show that one or more supporting rollers should be
machined, also the live rings should in all probability be machined. If only the supporting
rollers are machined, because this is a relatively easy job not requiring any special lathe,
problems will arise on the long view. Combined with the poor surface of a live ring, the good
surface of a supporting roller will soon be damaged.
(6.4) Bearings for Supporting Rollers
General remarks:
In order to prevent all fixing and adjusting screws of the bearing housings from being
covered by set clinker dust, we recommend that they be coated with grease and wrapped up
in sackcloth or the like.
Regular cleaning on the foundations should be introduced owing to the extremely dust-
infected atmosphere (dust especially coming from kiln No. ..). The standard of cleaning
should in particular be enhanced around the bearing housings, in the troughs under the
supporting rollers, and on the caps of the bearings. The dust has a directly damaging effect
on live rings, supporting rollers, and bearings.
The rubber sleeves around the inlets of the cooling water pipes into the bearing housings
cover openings which are notoriously very sensitive areas where dust can penetrate into the
lubricating oil. The sleeves should be replaced if they are cracked or defective in any other
way. As an extra precautionary measure against ingress of dust into the bearings at the
rubber sleeves, a layer of silicone can be applied between rubber sleeve and bearing housing.
-- o --
The following comments and recommendations apply to the bearings for the supporting
rollers at the respective supports. As to numbering of the bearings, please see Fig. 15
overleaf.
Support I:
Bearing No. 1: No comments except that there is some dust in the bearing.
Bearing No. 2: No comments except that there is a little dust in the bearing.

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Bearing 3 Inlet Bearing 2
Left Right
Bearing 4 Bearing 1
Outlet
Fig. 15: Numbering of bearings for supporting rollers.
Support II:
Bearing No. 1: The oil scraper and the felt seal between bearing housing and journal could
not be inspected as the inspection cover close to the supporting roller cannot
be opened. The cover knocks against the shield fitted alongside live ring and
supporting roller. The shield should be modified to enable inspection of the
bearing. In spite of the above, we saw some dust in the bearing.
Support III:
Bearing No. 3: The oil scraper is missing.
Bearing No. 1: The oil scraper and the felt seal between bearing housing and journal could
not be inspected as the inspection cover close to the supporting roller cannot
be opened. The cover knocks against the shield fitted alongside live ring and
supporting roller. The shield should be modified to enable inspection of the
bearing.

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(6.5) Drive Station
The drive station is relatively smooth in operation, but like the rest of the inlet end of the
kiln, it is suffering from high levels of dust settlement, mainly from the inlet end of the
adjacent kiln. Something should be done about this continued problem.
The basic gearing is similar to the gearing inspected in (year), but some changes have
occurred. In (month/year), a new drive pinion (non-FLS), intermediate gear/pinion, shafts,
and associated bearing liners were installed. The existing gear rim and spring plates were
purchased by the client direct from …….., in (year) and were erected by others sometime
later.
The profile of the gear rim teeth is still satisfactory, and wear on the contact surfaces is
uniform across the tooth width and consistent with the prevailing situation. Burrs are
evident on the tooth tips and on the ends of the teeth, showing that the profile is gradually
changing and hence producing these burrs (metal flow). Some old pitting and surface
disturbance have occurred at the pitchline of the teeth, but this is not altogether surprising
where there is a rolling but little or no sliding action, and initial pitting quite often occurs.
Furthermore, when pitting occurs, the metal particles that fall out can with the help of the
lubricant get caught up in the mesh and cause some disturbance to the tooth surfaces.
The pinion which as stated above is relatively new has a full profile with very mild tooth
tip burrs. Some incipient pitting is evident along the pitchline on the inlet side of the
teeth. This pitting is most likely the result of some mild misalignment with the gear rim,
particularly in the early stages, resulting in higher than normal surface pressure. The rest
of the pinion contact surfaces are smooth and polished. It does appear, however, that the
pinion has moved to a position downhill similar to that observed during the (year)
inspection, but the situation needs confirming when the kiln is stopped and it is safe to do
so. The excessive axial wobbling of the gear rim has no doubt some influence on this
situation.
The intermediate pinion and spur wheel appear to be operating satisfactorily. However,
the lubricant in the relevant sump for these components looks rather semi-solid rather
than semi-fluid, no doubt because of some dust contamination and a certain degreee of
solidifying through the heat of the kiln.
The lubricant used here is Mobilgear OGL 007, a specialist semi-fluid, open-gear
lubricant with extreme pressure additives and finely dispersed graphite for load carrying.
Lubrication of the gear rim is via four spray nozzles using Krafft KGP-2/P grease which
is a special, adhesive grease with high concentration of solid lubricant for highly loaded
open gears regularly lubricated by automatic spraying system.

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All the shaft bearings are still to a greater or lesser degree contaminated with dust.
Access is via the poorly sealed inspection covers. The upper bearing of the main drive
pinion shaft is suffering from a bad oil leak. All air bleed holes in the oil level sight glass
top caps are blocked.
The intermediate pinion and spur wheel are similarly suffering from some dust
contamination as the sliding inspection cover in the top casing is an ideal candidate for
entry of dust, and also a safety hazard.
The gear rim guard is open to dust contamination, and the gear rim side scrapers are
virtually non-existent.
The kiln main drive gearbox appears to be a little low on oil. The barring gear oil level is
satisfactory. The gear oil type used in both components is Mobilgear 634 and appears to
be clear and full-bodied. The drive torsion shaft/membrane coupling have non-FLS
membranes with the result that the shaft is running eccentrically.
(6.6) Thrust Device
A hydraulic thrust roller is located at support III.
Fig. 16: Hydraulic thrust device.


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The hydraulic thrust device is dimensioned to be capable of absorbing all of the axial thrust
from the kiln during operation or barring, allowing all supporting rollers to be placed parallel
to the kiln axis. However, in order to secure axial, mechanical balance of the kiln, the
supporting rollers are usually skewed so that approx. 30% of the axial thrust from the kiln is
apportioned evenly between them while the thrust device absorbs the remaining 70%.
The pressure in the pump station of the hydraulic thrust device should normally range
between 40 and 60 bar.
The surface of the taper section of the live ring is in good condition. It has been worn into
slightly concave configuration.
The taper rolling surface of the thrust roller is also in satisfactory condition. It has been worn
into convex configuration (approx. 0.5 mm).
Contact conditions between live ring and thrust roller are good.
We recommend thorough cleaning of the thrust device, and seals and piping system should
be checked and reconditioned in order to avoid oil spillage.
Moreover, both the top side and the bottom side of the thrust roller should be inspected
for cracks at least once a year as cracks are more easily detected if the thrust roller is
clean.
(6.7) Axial, Mechanical Balance of the Kiln
The concept of “axial, mechanical balance” covers the way in which a balance between the
various elements of axial thrust on the kiln is achieved. The axial thrust stems from four
different sources:
* The gravitational pull has an axial component arising from the inclination of the
kiln. This axial component exerts a constant, downhill thrust on the kiln.
* The reaction from the thrust roller in the opposite direction of the above-mentioned
gravitational pull. The primary task of this reaction is to counterbalance the
gravitational pull, but it also has to absorb any other downhill, axial thrust. This
means that the function of the thrust roller is to secure the position of the kiln/live
rings on the supporting rollers.

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* Axial thrust resulting from the contact between supporting rollers and live rings.
Such thrust that may become rather substantial is generated if the axes of rotation of
live rings/kiln and supporting rollers are not parallel, i.e. if a supporting roller is in a
skew position and/or if its inclination deviates from that of the kiln in this particular
place.
* Wear also affects the axial, mechanical balance of the kiln. If rolling surfaces have
been worn into concave, convex, or conical configurations, meaning that they are
no longer truly cylindrical, it may be difficult or even quite impossible to attain
axial, mechanical balance in a way that ensures a level of internal forces being as
low as possible. In such cases, supporting rollers and live rings should be machined.
Machining can be carried out during normal kiln operation by means of equipment
that can be purchased or hired from FLS.
When the above irregularities caused by wear have been eliminated, the supporting
rollers can be adjusted to a position almost parallel to the kiln axis. In case of FLS
kilns, this adjustment can be made on the basis of measurements taken with
the equipment for measurement of the axial thrust developed by FLS for this
specific purpose. With this equipment it is possible to attain optimum axial,
mechanical balance of the kiln so that supporting rollers and thrust device absorb
their respective share of the axial thrust exerted by the kiln. Under these conditions,
the contact faces between live rings and supporting rollers should be lubricated with
dry graphite only.
If leaving the limited and slow, axial movements made by the rotary kiln in relation to the
thrust device out of account, the kiln is always in axial, mechanical balance. This means that
the resulting, axial thrust from the kiln is insignificant. However, this insignificant, axial
thrust may on the one hand be composed of a number of unacceptably large, internal forces
acting in mutually opposite directions (e.g. caused by incorrect skewing and/or inclination of
the supporting rollers) subjecting the bearings to heavy thrust loads and increased risk of
overheating. On the other hand, the resulting, axial thrust from the kiln may also be
composed of acceptable, foreseeable, internal forces. For the sake of the availability of the
kiln, it is obvious that the latter situation is to be preferred.
(6.8) Inlet Seal
The inlet seal is spring loaded and supported on a vertical hanger support on either side.
The seal joint is relatively close but operating dry. There is very little evidence of grease
lubrication. The seal has an auto greaser but the fault light is on continuously. As found
during the previous inspection, runout at the seal gives a variation of some 30 - 40 mm
compared with approx. 20 mm during the inspection in (year).

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(6.9) Outlet Seal
The outlet lamella seal looks fine. All the lamella are in place, have the correct shape, and
are in close contact with the wear ring.
The total runout variation at this wear ring is in the order of 25 mm as compared with 12
mm previously. A check on the adjacent kiln shell indicated a similar reading of 25 mm.
The wear ring on the casing for air has been coated with low-thermal coating through an
arc spray patented by Eutectic Castolin Group. The deposit has a surface hardness of 600
HV and will work-harden to 1100 HV.

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What is the report inspecting?

What is the report inspecting?

What components of the kiln are inspected?

What components of the kiln are inspected?

Plant - Country

Kiln No. …, dia. x ….. m, ……… Cooler

Period of Inspection: date - year

Mechanical Kiln Inspection

Plant: ……… ……….., Kiln No. … Customer Services

Inspection of Kiln No. …, dia. x …….. m, …….. Cooler

Client representatives........................Mr ………………………..

FLS specialists ..................................Mr ………………………..

Participants in final meeting .............Mr ………………………..

Plant: ……… ……….., Kiln No. … Customer Services

Plant: ……… ……….., Kiln No. … Customer Services

Plant: ……… ……….., Kiln No. … Customer Services

The inspection was carried out in accordance with agreement between

Plant: ……… ……….., Kiln No. … Customer Services

* The kiln axis must be correctly adjusted.

Plant: ……… ……….., Kiln No. … Customer Services

Should the above conclusions contain recommendations warranting the implementation of

Plant: ……… ……….., Kiln No. … Customer Services

(3) Recommended Actions

(A) Actions to be taken as soon as possible:

* Check of the spray lubrication system. Please see section (6).

(B) Actions to be taken during the next kiln shutdown:

Plant: ……… ……….., Kiln No. … Customer Services

(C) Actions to be taken when convenient:

* Removal of remnants of weld material. Please see section (6.1).

* Adjustment of the inclination of the left-hand supporting roller at support I. Please

Plant: ……… ……….., Kiln No. … Customer Services

Adjustment of the inclination should be followed up by adjustment of the skewing

(D) Preventive maintenance:

(E) Future activities (for planning purposes):

* Reduction in the axial wobbling of the gear rim.

Plant: ……… ……….., Kiln No. … Customer Services

* Right-hand/left-hand side of the kiln:

* Numbering of bearings for the supporting rollers:

Bearing 3 Inlet Bearing 2

Fig. 1: Numbering of bearings for supporting rollers.

Plant: ……… ……….., Kiln No. … Customer Services

(5) Inspection Activities Carried out -

(5.1) Kiln Shell

(5.1.1) Kiln Shell - Temperatures

A great temperature difference at a particular measuring point is usually caused by varying

Plant: ……… ……….., Kiln No. … Customer Services

Kiln shell Inlet side Outlet side

At live ring I 372 327 45 344 248 96

(5.1.2) Kiln Shell - Side Guides

Fig. 2: Side guides for live ring fitted on

Plant: ……… ……….., Kiln No. … Customer Services

Side guides Type Clearance (mm) Width (mm)

Regarding lubricants and lubrication methods, please see section (5.2.4).

(5.1.3) Kiln Shell - Crank Indication

Plant: ……… ……….., Kiln No. … Customer Services

Alternatively, a mechanical crank can under certain circumstances be straightened by using a

Fig. 3: Set-up for measurement of the deflections of supporting

Plant: ……… ……….., Kiln No. … Customer Services