_ Lead wire 2 ~ 3 mm

_ Keep lead wire at right angle to direction of rotation

_ Information drawn from test
i. Surface pressure between tyre & kiln roller.
ii. Adustment or cutting of kiln roller in relation to kiln a!is.
iii. "osition #laterally$ of kiln rollers.
i%. "roportional loud on indi%idual supports.
%. &ccentricity if any in the kiln tube.
_ Lead wire test also shows whether to carry out kiln alignment test with le%elling
instrument.
PROCEDURE
_ 'ark ( a!is A) * & + on kiln shell , -./0 apart.
_ Se1uence of a!is should be in relation to the direction of rotation of kiln %iewing
from burning platform.
_ At each support si! #/2$ lead wire test are made i.e ( at each roller i.e one at each
a!is.
_ 3he si! lead wire specimen should be marked as shown in fig. -.
_ 3he length of lead wire specimen should be e1ual to width of kiln roller 4.// mm
-
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Width of roller
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t1
t10 t9
t8 t7 t6
t5 t4
t2
ANALYSIS
5igure. - shows 2 lead wire specimen taken as indicated by marking) at
support 6o.-.
'easurement of rolled lead wire is done as follow7 8
9n graph : white sheet) mark off width of tyre. ;i%ide it into e1ual -. parts & draw
parallel lines for each a!is of rollers. 3he line in the middle is marked centre line of tyre.
At e!tremes) mark with ; & 5 for outlet & inlet sides respecti%ely. 6ow place lead wire
one by one at right angles to parallel lines with ends of rolled portion of wires e!actly
o%er the two e!treme lines. In this position) lead wires are to be fi!ed & width t-) t. etc to
be measured & these measurements are to be relocated in the table.
6ow take a%erage %alue of each half of the lead wire & enter in the table i.e
t ; < t- 4 t. 4 t( 4 t= 4 t>
>
t5 < t2 4 t? 4 t@ 4 tA 4 t-/
>
EXAMPLE
Table 1
Support
No1
Outlet e!" #ea$ure"
%&"t'
t1( t2( t3( t)( t*
A+era,
e
tD
I!let e!" #ea$ure"
%&"t'
t-( t.( t/( t0( t11
A+era,
e
t2
D&33ere!4e
tD 5 t2
Bight A
hand *
roller C +
(.) (.) (-) .@) .@ (/.. .?) .?) .2) .=) .= .>.2 4 =.2
(>) (=) (=) (.) (. ((.= (.) (-) (-) .A) .A (/.= 4 (./
.2) .>) .>) .=) .= .=.@ .=) .() .() ..) .- ...2 4 ...
A+era,e 20* 2-2 6 33
Left A
hand *
roller C +
.>) .2) .?) .?) .@ .2.2 .A) (-) (.) (() (( (-.= 8 =.@
.A) .A) (/) (-) (. (/.. (.) (() (=) (=) (> ((.2 8 (.=
./) .-) .-) ..) .( .-.= .() .=) .=) .>) .2 .=.= 8 (./
A+era,e 2-1 20/ 5 3.
Table 2
Support I a7&$ R&,'t 'a!" roller
8 R 9
Le3t 'a!" roller
8 L 9
t; A
*
+
(/.. .2.2
((.= (/..
.=.@ .-.=
t5 A
*
+
.>.2 (-.=
(/.= ((.2
...2 .=.=
Sum -2?./ -2?.2
A%erage width of lead wire tB < . ?.@( tL < .?.A(
;ifference tL 8 tB 11
tB 4 tL : . ta+ : 2.//
.
CUTTIN; O2 <ILN ROLLERS
An e!ample shows that t; %alues at the right hand
roller are larger than the t5 %alues which means that surface pressure between tyre & the
right hand kiln roller is greatest at the side nearest the outlet end.
+onse1uently the roller has been cut in the proper direction in relation to the direction of
rotation of the kiln.
3he difference between t; & t5 %alues is measure of amount to which the roller has been
cut.
5or right hand roller
A < t; D t5 < =.2 mm
* < t; D t5 < (./ mm
+ < t; D t5 < ... mm
A%erage %alue < A 4 * 4 + < (.( mm
(
Ese a%erage %alue for the purpose of comparison
If the kiln a!is is straight without any eccentricity & if the condition of the %arious
bearing surfaces are good) then three difference t; D t5 one for each a!is #A) * & +$ will
be almost e1ual.
3he a%erage %alue for the left hand roller calculated in the same manner is _ (.? mm.
6egati%e %alue shows that cutting of the rollers are towards opposite direction to that of
the right hand rollers. 3he a!is of roller should be parallel after adustment and the %alue
t5 thus being larger than t;. 3he two rollers on same support must be cut towards
opposite sides to make their a!is parallel.
5rom abo%e it indicates that rollers are pushing the kiln upwards towards inlet : feed end.
5ollowing are cutting %alue) which should not be e!ceeded #for guidance only$.
=&"t' o3 t>re Cutt&!, +alue 8a+era,e9
*11 ## 2* ##
-11 ## 31 ##
.11 ## 3* ##
/11 ## )1 ##
011 ## )* ##
1111 ## *1 ##
If the cutting angle is too great) the surface pressure will become e!cessi%e and there will
be o%erloading of material. 5urthermore) the purpose of cutting the rollers i.e to fi! the
kiln in a certain a!ial position through a uniform a!ial pressure from kiln rollers will be
defeated.
(
LATERAL POSITION O2 <ILN ROLLERS
3he calculated a%erage %alues of t; & t5
shall determine a%erage width tB & tL of lead wire specimen after rolling.
3he a%erage surface pressure on right hand rollers corresponds to rolled a%erage width
tB < .? F @( mm while tL < .?.A( mm is %alue of left hand roller gi%ing difference of /.-
mm only) so a%erage pressure on both rollers is almost e1ual and rollers conse1uently are
situated at an e1ual distance from centre line of kiln.
If the difference e!ceeds -/G rollers should be adusted laterally. 5or rollers at support of
girth gear) difference upto ./G may be permitted.
LOAD ON INDI?IDUAL SUPPORT
5inally the a%erage width t a+ is calculated for all
the lead wire specimen which ha%e been rolled by the tyre.
t a+ is the e!pression of total pressure on the support e!erted by the tyre and thus gi%es
our indication of load on particular support. 3he %alue found for t a%. is compared with t
a%. of the roller supports & particularly compare it with past test for particular support.
INCORRECT INCLINATION O2 <ILN ROLLERS
If the lead wire test specimen shows
that cutting of the roller is normal but at the same time) an e!amination of the bearings of
kiln rollers shows that particular roller is pushing the kiln downward in the direction of
outlet end of the kiln) then it is clear that bearing surface of the roller is not parallel with
the kiln a!is & that it will be necessary to correct the inclination of rollers by placing
suitable shim under one of the supporting bearing.
TROU@LE
i$. CUR?ED <ILN AXIS
If there is cur%ature or ecentricity in
kiln shell) the pressure between the tyre & the corresponding roller shall %ary during
rotation of the kiln.
&!ample showing the effect of eccentricity in the kiln a!is. Bolling effect of lead wire
specimen %aries between A) * & +
=
A
C
B
In pre%ious e!ample) calculation gi%en on proceeding pages show some eccentricity of
kiln a!is indicated by rolling effect being greatest at * a!is.
A fair indication of the direction of the eccentricity) if any in the kiln a!is is obtained by
tracing a diagram as follows7 8
Starting at point 9) set out
( lines 9A) 9* & 9+ -./0
apart) 3hen for each roller
calculate
tA < t; 4 t5
.
t* < t; 4 t5
.
t+ < t; 4 t5
.
that is width at A) * & + a!is
In the diagram) then set out # using double siHe scale$
3hrough points a)b and c) trace a circle with its center '. 5rom 9) set out a line passing
through ' intersecting circle at ;.
A lead wire test taken on the kiln at ;8a!is situated I0 angle apart from a!is A towards
direction * will show the greatest rolling effect to be %erified on diagram) which is e1ual
to distance 9; as measured on the diagram.
If the greatest a%erage width t; is di%ided by the smallest a%erage width and result is
found more than -.() then kiln tube will ha%e to be straightened.
3he ma!imum surface pressure between a kiln roller and corresponding tyre may be so
great that there is great risk of pitting being caused unless the kiln is straightened.
LATERAL DISPLACEMENT O2 <ILN ROLLER.
If the amount of rolling to
which the lead wires are subected is greater at one roller than that of other) the rollers are
displaced laterally. 3he pressure originality from the girth gear may to some e!tent cause
non8uniform rolling. 3he rollers therefore should not be adusted laterally unless it has
been established through optical le%elling that adustment is re1uired.
In the e!ample abo%e) the a%erage width of lead wire specimen after rolling was
tB < .?.@( mm #Bight hand roller$
tL < .?.A( mm #Left hand roller$
5rom abo%e) it appears that the a%erage width of two specimens is wearily e1ual.
>
B
!
"
C A
D
O

tA
tC
tB
*y di%iding the greater of these a%erage %alues by lesser one we ha%e
< .?.A(
.?.@( < -.//=
3his %alue is generally acceptable for this ratio of surface pressure.
Batio of surface pressure acceptable
i$. 5or girth gear support < -./> F -..
ii$. 5or other support < -./ F -.-
If the ratio e!ceeds the %alue gi%en abo%e) the support in 1uestion i.e alignment of the
kiln will ha%e to be checked by le%elling test and if necessary to be corrected.
?ERTICAL DISPLACEMENT O2 TYRE
Jhere a%erage %alue at any one support
de%iates materially from that at the other supports) it may be necessary to adust the
distance between the rollers or in other words) the %ertical position of the tyre. Jhere
necessiated by the design or where it is desired to obtain to some e!tent a standardisation
of spare parts) a wider tyre is often used there and conse1uently a%erage particular
pressure at a particular support is lower.
A lower a%erage pressure would gi%e no cause for an!iaty but if a%erage pressure is
abnormal or greater) an optical le%elling check should be carried out and the alignment of
the kiln if necessary be corrected.
SUMMARY
Lead wire test is a rough method & this test will show) howe%er whether
an optical check is re1uired immedietely.
3he difference between rolled width i.e t; D t5 will depend on the width of tyre and other
things and should not e!ceed > G hereof.
An eccentricity present in the kiln tube will gi%e %ariation in a%erage rolled width
tA < t; 4 t5 of the lead wire originality from the same kiln roller. If the a%erage
. width %aries by more than (/ G) then the nature and e!tent of
eccentricity should be in%estigated by other method and correction of kiln tube should be
taken under consideration. If the a%erage width of all rolled lead wires coming from the
one & same kiln roller e!ceed more then -/ G than the a%erage width of all lead wires
coming from the outer roller on same support #5or support at girth gear it is ./ G$) than
alignment of kiln must be checked by le%elling method.
It is general rule that alignment of kiln must be checked by le%elling method if a%erage
surface pressure at any one support is un8usually great or low in proportion to the surface
pressure at the other support.
2
ANALYSIS O2 DI22ERENT CASES
5rom the gi%en figures a F e) of lead wire
test passing through straight and obli1ue kiln rollers respecti%ely) the corresponding
effect on the a!ial displacement of kiln and wear as the roller faces can be seen from the
below sur%ey.
CASE 8a9 Boller is completely in parallel position & surface pressure is e1ual
throughout the width.
_ 3endency for displacement is neutral. If all the rollers were set in the
position) the component of the kiln load starting downward toward the
outlet would soon o%ercome the friction between the rollers and the tyres
and kiln would come to rest against thrust roller station and wear will be
uniform.
CASE 8b9 Surface pressure is greatest at the center.
_ 3endency for displacement at indicated direction of rotation towards the
right i.e towards the upper side.
Jear. If the roller has been cut to e!cessi%e angle) the centre of the roller face
should be hollowed and pitting any occur. If the longitudinal tra%el of kiln
causes series of slides between the roller & tyre faces during e%ery
re%olution of the kiln) facetting will occur.
6ote If the angle to which the roller is test) as shown in fig.+ is kept a minimum
so that center line of the roller is only slightly out of parallel with center
line of the kiln as in fig. a) the surface pressure distribution will be as
fa%ourable and the roller shall push the kiln in the proper direction with
suitable force and so assist in maintaining the proper displacement and
operation position of the kiln.
CASE 849 Surface pressure is highest at the right hand of the roller
3endency for displacement is neutral. As for as wear is concerned a
hollow will be produced in the right hand half of the roller face) scaling
occurs at the right hand edge which becomes round and pitting may occur.
CASE 8"9 Surface pressure is highest at the right hand end of the roller.
3endency for displacement shall be at the direction shown in figure i.e
towards left i.e upwards and wear shall same as in case d.
?
CASE 8e9 Surface pressure is highest at the left end of roller.
3endency for displacement is at the direction of rotation shown in figure
i.e towards right) wear is same as for case d but at the left hand end.
@
a #
1 2
3
4 5 6
d
e
*y passing a lead wire between the roller and tyre) it is possible from its rolled shape to
conclude how the a!ial position of kiln roller must be relation to the tyre.
3he lead wire test should be e!tended so that it will pro%ide more e!act information such
as) whether kiln a!is straight) cur%ed or winding and if so as to where the degree of
eccentricity is at a ma!imum.
If kiln a!is is straight) the surface pressure between the tyres and rollers will be constant
or uniform. If the kiln a!is is cur%ed or winding) on the other hand) so that there is
eccentricity at the center plane of the tyres) the surface pressure i.e width of lead wire will
not be same during the whole of kiln rotation.
2INAL CONCLUSION
In case of any misalignment at one or more of supports)
carry out complete realignment and or in case of any regular wear) it may become
necessary to return or mo%e kiln roller during operation.
In general) any ir8regularity found through systematic checkup) may be rectified by
adustment of the kiln rollers.
A
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