8/19/2019 Kiln Miscellaneous
1/69
8/19/2019 Kiln Miscellaneous
2/69
Kiln Inlet Seal
Kiln Outlet Seal
Thrust Roller
Hydraulic Thrust Roller
Kiln Maintenance Checklist
The Good Old Days
Kiln MiscellaneousKiln Miscellaneous
8/19/2019 Kiln Miscellaneous
3/69
Kiln Inlet SealKiln Inlet Seal
8/19/2019 Kiln Miscellaneous
4/69
Kiln Inlet SealKiln Inlet Seal
The kiln seal prevents cold air from entering the processand driving up fuel costs. The seal must remain tight whileaccommodating kiln run-out and longitudinal movement.
8/19/2019 Kiln Miscellaneous
5/69
Kiln Pneumatic Inlet SealKiln Pneumatic Inlet Seal
The pneumatic seal consists of two slidingsurfaces pushed together by pneumatic cylinders.
PneumaticCylinders
8/19/2019 Kiln Miscellaneous
6/69
Kiln Inlet SealKiln Inlet Seal
Spring Loaded
Graphite Plug
Seal Detail
PneumaticCylinders
8/19/2019 Kiln Miscellaneous
7/69
Kiln Inlet Seal DetailKiln Inlet Seal Detail
Graphite Seal Cord
Wire Rope
Graphite Plugs
Rotating KilnShell
Rotating Sealing
Surface
Stationary Sealing
Surface
Sliding Contact
Stationary KilnInlet Hood
8/19/2019 Kiln Miscellaneous
8/69
Kiln Inlet SealKiln Inlet Seal
The seal is suspended by a carriage which allows it tomove longitudinally as the kiln expands and contracts.
Carriage
Turnbuckle
8/19/2019 Kiln Miscellaneous
9/69
Pneumatic Inlet SealPneumatic Inlet Seal
The pneumatic cylinders, when pressurized,will press the two seal halves tightly together.
Stationary
Seal HalfRotating Seal
Half
8/19/2019 Kiln Miscellaneous
10/69
8/19/2019 Kiln Miscellaneous
11/69
Filter, Regulator, LubricatorFilter, Regulator, Lubricator
8/19/2019 Kiln Miscellaneous
12/69
Kiln Inlet SealKiln Inlet Seal
The seal’s sliding surfaces are graphite lubricated.
Spring Loaded
Graphite Plug
Graphite Plugs in
Seal Plate
8/19/2019 Kiln Miscellaneous
13/69
Kiln Inlet CastingsKiln Inlet Castings
Castings on the inlet hood and kiln inletcone keep the castable refractory inplace. Inspect them at annual shutdown.
8/19/2019 Kiln Miscellaneous
14/69
Spring Plate Inlet SealSpring Plate Inlet Seal
8/19/2019 Kiln Miscellaneous
15/69
Spring Plate Inlet SealSpring Plate Inlet Seal
8/19/2019 Kiln Miscellaneous
16/69
8/19/2019 Kiln Miscellaneous
17/69
No, covering the spring plates with plastic won’t help.
Spring Plate Inlet SealSpring Plate Inlet Seal
8/19/2019 Kiln Miscellaneous
18/69
8/19/2019 Kiln Miscellaneous
19/69
Kiln Outlet SealKiln Outlet Seal
The spring plate outlet seal has become theoutlet seal of choice. The seal can withstandthe harsh conditions at the kiln hood.
8/19/2019 Kiln Miscellaneous
20/69
Kiln Outlet SealKiln Outlet Seal
Spring Plate WireRope
8/19/2019 Kiln Miscellaneous
21/69
Kiln Outlet SealKiln Outlet Seal
Counterweight
Spring plates are wrapped with a counterweighted wirerope arrangement to keep them tight against the cowl.
8/19/2019 Kiln Miscellaneous
22/69
ForcedAir
Cooling
Kiln Outlet SealKiln Outlet Seal
A stainless steel cowl at the kiln outlet provides anair channel for cooling of the kiln discharge castingsand the spring plate contact surface.
8/19/2019 Kiln Miscellaneous
23/69
Kiln Outlet SealKiln Outlet Seal
Spring plates are bolted on and are easily replaced.
8/19/2019 Kiln Miscellaneous
24/69
Kiln OutletKiln Outlet SealSeal
Dust from kiln hood puffing falls down the chutes tothe drag chain conveyor or into the clinker cooler.
The Old Way The Better Way
8/19/2019 Kiln Miscellaneous
25/69
Kiln Outlet SectorKiln Outlet Sector
The kiln nose rings sees severe service and must beregularly inspected for refractory and casting failure.
8/19/2019 Kiln Miscellaneous
26/69
Kiln Outlet SealKiln Outlet Seal
This alternate spring plates design featuresoutwardly protruding spring plates.
8/19/2019 Kiln Miscellaneous
27/69
Kiln Outlet SealKiln Outlet Seal
Outwardly protruding spring plate design.
8/19/2019 Kiln Miscellaneous
28/69
8/19/2019 Kiln Miscellaneous
29/69
8/19/2019 Kiln Miscellaneous
30/69
Thrust Roller AssemblyThrust Roller Assembly
OilSeal
Oil LevelPipe
SphericalBearingsTie
Rod
Tire
Shims
Clearance
Keep the clearance to a minimum (6mm),and adjust the shims to keep the kiln gearin proper longitudinal alignment.
8/19/2019 Kiln Miscellaneous
31/69
Thrust Roller AssemblyThrust Roller Assembly
Set
Screws
The kiln position can be controlled byadjusting set screws on this thrust roller base.
8/19/2019 Kiln Miscellaneous
32/69
Thrust Roller PositionThrust Roller Position
Stop Ring
Thrust
Tire
The thrust roller is positioned to maintain proper hotrunning alignment between kiln gear and pinion.Repositioning may be necessary as stop rings wear.
8/19/2019 Kiln Miscellaneous
33/69
Thrust Roller MisalignmentThrust Roller Misalignment
A misaligned thrust roller will result in vertical forceson the roller as shown above.
Roller Tilted to Left Roller Tilted to Right
Roller Offset to Left Roller Offset to Right
8/19/2019 Kiln Miscellaneous
34/69
Thrust Roller MisalignmentThrust Roller Misalignment
An improperly aligned thrust roller can ride out ofits socket, causing damage to tire stop blocks.
8/19/2019 Kiln Miscellaneous
35/69
8/19/2019 Kiln Miscellaneous
36/69
Fuller Thrust RollerFuller Thrust Roller
8/19/2019 Kiln Miscellaneous
37/69
Fuller Thrust RollerFuller Thrust Roller
8/19/2019 Kiln Miscellaneous
38/69
Hydraulic Thrust RollerHydraulic Thrust Roller
8/19/2019 Kiln Miscellaneous
39/69
Hydraulic Thrust RollerHydraulic Thrust Roller
The hydraulic thrust roller maintains a constant,controlled force on the thrust tire and keeps thekiln in an electronically determined position.
8/19/2019 Kiln Miscellaneous
40/69
8/19/2019 Kiln Miscellaneous
41/69
Hydraulic Thrust RollerHydraulic Thrust RollerBreather
Oil Level
Sight Glass
Guide Bar
GreaseFittings
The spherical bearings are lubricated with ISO VG1000 gear oil. Guide bars are grease lubricated.
8/19/2019 Kiln Miscellaneous
42/69
Thrust RollerThrust Roller
The roller surface is graphite lubricated.
8/19/2019 Kiln Miscellaneous
43/69
Hydraulic Thrust RollerHydraulic Thrust Roller
8/19/2019 Kiln Miscellaneous
44/69
Hydraulic CabinetHydraulic Cabinet
The hydraulic power unit is normallyplaced beneath the kiln’s thrust pier.
8/19/2019 Kiln Miscellaneous
45/69
Hydraulic CabinetHydraulic Cabinet
Accumulator
Pump
DirectionalValve
Relief
ValveTank
8/19/2019 Kiln Miscellaneous
46/69
Di ti l V lDi ti l V l
8/19/2019 Kiln Miscellaneous
47/69
Directional ValveDirectional Valve
A directional valve directs fluid to the thrustcylinder, or allows the cylinder to bleed down.
H dH d i A lti A l t
8/19/2019 Kiln Miscellaneous
48/69
HydroHydro--pneumatic Accumulatorpneumatic Accumulator
An accumulator stores hydraulic energy. It is used tomaintain a steady force on the thrust tire eventhough the tire wobbles slightly as the kiln turns.
8/19/2019 Kiln Miscellaneous
49/69
H dH d ti A l tti A l t
8/19/2019 Kiln Miscellaneous
50/69
psig
0
500
1000
1500
2000
psig
0
500
1000
1500
2000
psig
0
500
1000
1500
2000
System PressureLess Than pprecharge
System Pressureat pmax
System Pressureat pmin
HydroHydro--pneumatic Accumulatorpneumatic Accumulator
When hydraulic pressure increases and decreasesthe gas is compressed and expanded.
H dHydro ti A l tpneumatic Accumulator
8/19/2019 Kiln Miscellaneous
51/69
HydroHydro--pneumatic Accumulatorpneumatic Accumulator
The accumulator is pre-charged with nitrogento approximately half of the expected averageoperating hydraulic pressure.
Danger!
Do not charge withair or oxygen!
P R li f V lP R li f V l
8/19/2019 Kiln Miscellaneous
52/69
Pressure Relief ValvePressure Relief Valve
A pressure relief valve limits hydraulic pressure inthe system. This prevents excessive downhill kilnforce from damaging the thrust roller.
Hydraulic FilterHydraulic Filter
8/19/2019 Kiln Miscellaneous
53/69
Hydraulic FilterHydraulic Filter
An in-tank filter with a 10 micron elementkeeps hydraulic fluid clean. The protruding redbutton indicates the element needs changing.
8/19/2019 Kiln Miscellaneous
54/69
Thrust Cylinder LVDTThrust Cylinder LVDT
An LVDT (linear variable differential transformer)mounted in the hydraulic cylinder measures thedistance that the cylinder rod is extended.
Thr st S stem LVDT CabinetThrust System LVDT Cabinet
8/19/2019 Kiln Miscellaneous
55/69
Thrust System LVDT CabinetThrust System LVDT Cabinet
The LVDT signal goes to a cabinet where the kiln’s hotrunning axial position is set and where alarms areprogrammed for excessive uphill and downhill kiln position.
8/19/2019 Kiln Miscellaneous
56/69
Fuller Hydraulic Thrust RollerFuller Hydraulic Thrust Roller
8/19/2019 Kiln Miscellaneous
57/69
8/19/2019 Kiln Miscellaneous
58/69
Preventive Maintenance ChecklistPreventive Maintenance Checklist
DailyDaily
8/19/2019 Kiln Miscellaneous
59/69
DailyDaily
Thrust Roller
• Kilns with one thrust roller (mech. or hyd.)
– visual check of the thrust rollers including recording
of the thrust pressure (ideal 500 psi, can vary from200-800 psi). Maximum design pressure is 1200-1300 psi
– check the temperature of the thrust roller housing
and face.
• Kilns with two thrust rollers
– Observe the kiln position relative to the uphill or
downhill thrust rollers – Check temperature of the housing and thrust roller
face if there is constant contact.
DailyDaily
8/19/2019 Kiln Miscellaneous
60/69
Seals
• Visually check feed and discharge seals
Gear
• Visually check the gear and pinion
Rollers and Live Rings
• Visually check all roller and tire surfaces
• Lubricate contact faces between tires and shell
mounted tire pads and stop blocks using a mixture ofgraphite powder and water.
DailyDaily
D ilD il
8/19/2019 Kiln Miscellaneous
61/69
Temperatures
• Record kiln shell temperatures andinclude a night visual inspection for “hotspots”
DailyDaily
W klWeekl
8/19/2019 Kiln Miscellaneous
62/69
WeeklyWeekly
• Check and record direction of thrust on allrollers.
• Check lubrication on all support rollers.
• Check oil levels in support roller bearingsand thrust roller bearings.
• Check and record the tire creep andclearance.
• Record related shell and tire temperatures.
• Check condition of tire stop blocks andwear rings.
WeeklyWeekly
8/19/2019 Kiln Miscellaneous
63/69
• Check general condition of kiln
shell.
• Check contact patterns between
gear and pinion by observing theoil smear on the contact face for atleast one full kiln rotation.
WeeklyWeekly
AnnuallyAnnually
8/19/2019 Kiln Miscellaneous
64/69
ua yy
• Perform complete check of kiln alignmentutilizing the laser or mechanical alignmentmethod. Kiln alignments should be completed
after major repairs have been made to the kiln.
• With this information recorded and compared,
a problem should be caught before a realdilemma occurs (i.e. an unplanned shutdown).
• Prior to planned kiln shutdowns, an extensivemechanical inspection should be completed todetermine repairs required.
8/19/2019 Kiln Miscellaneous
65/69
The Good Old DaysThe Good Old Days
8/19/2019 Kiln Miscellaneous
66/69
The Good Old DaysThe Good Old Days
8/19/2019 Kiln Miscellaneous
67/69
RivetsRivets
8/19/2019 Kiln Miscellaneous
68/69
8/19/2019 Kiln Miscellaneous
69/69
Don’t Be Mean to Your KilnDon’t Be Mean to Your Kiln