ABSTRACT

This project has been undertaken to investigate into the failure of Trunnion shaft of Floating
kiln/Dryer and to suggest proper maintenance to avoid it in future at Coromandel Fertilizers
Limited, Kakinada. The design values were taken from the Dorr-Oliver Manual and updated
current values from the department.Suggestions are made from viewpoint of a Mechanical
Engineer.
 ACKNOWLEDGEMENT

It gives me great pleasure to present my report on “Skewing and principle of alignments with
respect to downhill and uphill thrust loads corresponding to equal load distribution to support
rollers for floating kiln/Dryer” with reference to Coromandel Fertilisers Limited, Kakinada.
I would like to express my gratitude to the following people without whose support, help and
encouragement, the completion of this project would not have been possible.

•I would like to thank Mr Arun Leslie George, Sr. Vice President – HR, for providing me an
opportunity to do the project in CFL, Kakinada.
•I am also grateful to the HR-Department in Hyderabad and also in Kakinada especially to Ms
Lancelot and Mr. Mani Prasad for their hospitality.
•I would like to extend my thanks to my project guide Mr. M.Rajesh, Manager (Mechanical), CFL,
Kakinada for giving his valuable time and encouragement to help me put forward my best
effort
•I would like to thank Mr. Arjun, Deputy Manager-DAP Mechanical for sparing his focus and time
towards this project.
•I also wish to thank the entire maintenance department of CFL Kakinada especially Mr. David
Raju, Mr. T. Nagesh, Mr. Vithal Raju and others without whose skill and extensive
experience in the field the plant would not have functioned properly let alone their involvement
in the completion of this project.
•Finally I thank all the people who have helped me throughout this project, inside and outside the
plant whose names are too numerous to mention.
 Index

•Introduction
•Rotary Kiln
•Skewing
•Checking Thrust
•Lead wire test
•Advantages of proper skewing
•Thumb rule
•The Problem
•Operating Conditions
•Dryer Specifications
•Assessment of Dryer
•Assumptions
•Force Analysis
•Conclusion
•Suggestions
•References
•Summary
 INTRODUCTION
This research work is to study the cause of failure of support roller shafts in the Dryer-A in the
DAP plant at CFL Kakinada and to suggest proper maintenance and planning for skewing rotary
equipment in the future.

Rotary Kiln:

In the fertilizer industry, rotary kilns are of three types:

Granulator: Conversion of material to granules.

Dryer: Reducing moisture content in material.
Cooler: Cooling the material to appropriate delivery temperature.

Rotary kiln
The rotary kiln is supported by four support rollers called trunnions.As the dryer is inclined to
assist material conveyance, it tends to slide down when it is rotated.This tendency to move along
the axis is called thrusting.To prevent complete slide off, rollers on feed end and discharge end
are provided.These rollers are called thrust rollers and are not exactly designed to completely
take the axial force of the kiln.Hence a mechanical adjustment called skewing is done to the
equipment to support the rollers.

Skewing
Skew is the adjustment made to a roller by pivoting the roller on the midpoint of the roller shaft.
The basic purpose of skewing is THRUST CONTROL. Skewing accelerates the wear and tear of
the support mechanisms but allows thrust mechanisms to operate successfully. When a roller is
skewed, the line contact between the roller and tyre surface almost becomes a point contact. Too
little skew will cause the kiln to continue floating downwards. Too much skew will cause an
unnecessary amount of wear on the trunnion and thrust face of the tire. The force required to
prevent the dryer from going downhill is provided by the rolling action of the trunnion on the dryer.
Hence the thrust load is relieved by slippage. Skewing should be monitored by dial indicators and
must be done while the unit is in operation.
Checking Thrust
A dial gauge is arranged against the bearing housing and then graphite is applied on the roller.
Thus the thrust load will be neutralized allowing the bearing to relax its position. The direction of
movement of the bearing determines the direction of thrust. When a tissue paper is rubbed
across the face of the trunnion, one direction is felt smooth and the other rough. A log book is to
be maintained and the bearing temperatures are to be noted along with time taken as soon as an
adjustment is made. If the shell is balanced such that it the load on the thrust rollers is negligible
then it is supposed to be floating.
.

Lead wire test

To determine the exact point of contact where the force of the tyre is acting, a lead wire test is
used. A lead wire is passed paraxially to the trunnion on its surface. The lead wire deforms at
the point where the contact area is maximum. Thus the point of action of force is known.

Advantages of proper skewing

•Distribution of the unit’s thrust load evenly.

•Reduction of trunnion wear rate.
•Distribution of Tangential load on the trunnion such that the bearings have equal distribution of
tangential load.
•Reduction of stresses in tyres and other support components.
•Reduction in motor’s power consumption.
Thumb rule

•THE HAND RULE

•Fingers They curl in the direction the top of the roller is moving.
•Index finger Points the direction which the bearing is going to be moved.
•Thumb Points the direction the shell will move.
The Problem
The problem with the equipment under study (Dryer-A DAP plant)
The trunnion shaft under running condition has been sheared. This has been a consistent
failure over the span of a few months.
The suspicion for the root-cause of failure is on

Misalignment of the kiln or support rollers.Fault in material of construction or design.Misalignment

of pinion and girth.

Operating conditions
Location : A-train, DAP plant, CFL Kakinada
Dryer supplied by : Hindustan Dorr-Oliver Limited
Commissioned on : 1988
Elevation : 2608 mm above mean sea level
Slope : 1:30
Speed : 3.8-4.3 rpm
Direction of rotation : Clockwise when viewed from discharge
Ambient air temp : 15.5-46¢ªC
Material Handled : Diammonium phosphate
Particle size : -5 to +14 Mesh tyler
Bulk density : 1041kg/m³
Dryer capacity : 300 tonnes per hour
Last cold alignment on : April 2005
Last hot alignment on : February 2002
 Dryer Specifications
SHELL
Slope (inclination)-1/30
Speed -3.8-4.3 rpm
Outer diameter-3660 mm
Length-24384 mm
Thickness-20 mm (32 mm under girth and tires)

TYRES
Cast steel IS 2644 Gr-700
Width-380 mm
Inner Diameter-3746.5mm
Outer Diameter-4000.5mm
Tire-tire distance-12800 mm
Tire- drive distance- 1220 mm

TRUNNIONS
Cast steel IS 2644 Gr-700
Width-432mm
Inner Diameter-915mm

RING GEAR
Cast steel IS 2644 Gr-700; (207-230 BHN)
Module-25
No. of teeth-180
Pressure angle-20

PINION
Forged steel BS 970 EN24; (250-300 BHN)
Module-25
No of Teeth-22
Pressure angle-20

MOTOR
Power-350 hp
Speed-1490 rpm

COUPLING
Formsprag model 16A-1; Falk Steel flex 1200 T 10

GEAR BOX
Elecon SCN 500
Ratio-40:1
Input speed-1490
Output Speed-37.25
 Assessment of dryer
The measurable parameters are load, speed, bearing temperatures and mass flow rate.
The observable parameters are thrust of the kiln, creep and Points of contact of the tyres on the
trunnions (through lead wire test)

Assumptions
The following assumptions are made as the deviations are impossible to verify without high
precision measuring equipment and also for reducing mathematical complexity.
•The kiln is aligned perfectly to the center-line.
•There girth and pinion alignment is perfect.
•The trunnions, tyres and rollers are designed according to manual.
•The shell is circular and ovality is negligible.
•The material flow inside the kiln is uniform.
•The kiln is perfectly cylindrical.
•The self-aligning bearings used on each trunnion share the thrust load equally.
 Force Analysis
All the forces acting on the dryer are
1.Gravitational force
2.Forces between girth and pinion
3.Forces between thrust rollers and tyres.
4.Forces between Support rollers and tyres.

Here the forces are resolved along three mutually perpendicular axes
Axial force (thrust force) (X-axis)
Vertical force (Y-axis)
Horizontal force (Z-axis)
Gravitational force
Total assumed weight of kiln=W=50 tonnes=50000 kgs
Centre of mass of kiln from centerline is assumed to be at lc=1200mm
Inclination= È=arctan(1/30)
Hence the force is split into two components:
Force along X-axis=WsinÈ=16.34 Newtons
Force along Y-axis=-WcosÈ=490.20 Newtons
 Forces between girth and pinion
•It is assumed that girth and pinion are aligned properly and no thrust force component evolves
from the mating gears.
•Power supplied = 260 kilowatts
•Efficiency=97%
•Hence Power delivered=252.2kw
•Angular velocity of pinion=35.18 rpm
•Hence supplied torque=(252.2x1000x60)/(35.18x2ð)=68.457 KNm
•Let total force applied by pinion is Fp
The Pressure angle is designed at 70¢ª to the line joining centres.
•Hence tangential force is Fpsin70¢ª
•Torque=(tangential force) x (pinion pitch radius)
•Hence 68.457x1000=Fpsin(70)x550/1000
•Fp=132.455 kN
And the pinion is aligned such that the line joining centres is 60¢ª to horizontal.
•Hence force angle with horizontal is ä=50¢ª
•Force along Y-axis=Fpsinδ= 101.466KN
•Force along Z-axis=-Fpcosδ=-85.14KN
 Forces between thrust rollers and tyres
•When the kiln is thrusting uphill or down hill, the thrust roller is in contact with the tyre.
•This thrust roller cannot entirely bear the thrust of the kiln.
•If the kiln is thrusting, a lot of torque goes into rotating the thrust roller and assisting in its wear.
•Hence for optimum power, it is better to reduce the time where the kiln is thrusting the thrust
rollers of the kiln.
•Hence the case we consider the thrust forces to be negligible in either cases.
Forces between support rollers and tyres
All trunnions are assumed to be skewed to assist the kiln thrusting uphill.Hence the contact
between the tyre and a trunnion becomes a point contact.Hence the resultant force at the point
contact is resolved into three components along the axis.It is assumed that the trust load is equal
for all the trunnions at normal condition. The deflection or skewing changes only the point of
contact of force on the trunnion and also the thrust force and tangential force acting on the
trunnion.The normal force undergoes negligible change as a result of skewing.

The deflection or skewing changes only the point of contact of force on the trunnion and
also the thrust force and tangential force acting on the trunnion.The normal force undergoes
negligible change as a result of skewing.The maximum angle that can be skewed is
arctan(.2/725)=.02¢ªThe design trunnion diameter is 915mm but the existing trunnions are slightly
deviant from the design.It is hence assumed that all the trunnions are arranged such that there is
no horizontal or vertical deviation from center line.

For Northeast trunnion

•Angle of normal force with horizontal=60.19¢ª
For Northwest trunnion
•Angle of normal force with horizontal=60.3¢ª
For Southeast trunnion
•Angle of normal force with horizontal=60.12¢ª
For Southwest trunnion
•Angle of normal force with horizontal=60.12¢ª
By Newtonian mechanics
Solving for forces along X-axis
Fx1+Fx2+Fx3+Fx4=WsinΘ
As equal thrusts are present,
Thrust force on each trunnion=Fx1=Fx2=Fx3=Fx4=16340/4=4085KN
Solving for forces along Y-axis
Fy1+Fy2+Fy3+Fy4+Fpsinδ=WcosΘ
Fy1+Fy2+Fy3+Fy4=131.79KN
Solving for forces along Z-axis
Fpcosδ+Fz1+Fz3=Fz2+Fz4
Fz2+Fz4-Fz1-Fz3=63.197KN

Solving for Moment about X-axis

363.939xSin20x550
+1997{Fy1xsin(60.19)-Fz1cos(60.19)}
+1998{Fy3xsin(60.12)-Fz3cos(60.12)}
=1997{Fy2xsin(60.3)-Fz2cos(60.3)}
+1998{Fy4xsin(60.12)-Fz4cos(60.12)}
The tangential component of the force also depends a great deal on skewing angle.So we
cannot estimate it

Solving for moment about Y-axis

The moments of thrust loads cancel each other.
Fpcosδx17982+(Fz3-Fz4)x5182+(Fz1-Fz2)x19202=0
1136408+(Fz3-Fz4)x5182+(Fz1-Fz2)x19202=0
Solving for moment about Z-axis
WcosÈx12192=(Fy1+Fy2)x19202+(Fy3+Fy4)x5182
The moments of thrust loads are negligible.

All the given variables cannot be determined from given data.Hence an alternate
assumption can be made.

Load on each trunnion

For maximum load on a particular trunnion, the force given by girth gear should not be taken to
account.
Hence the maximum force is 490.2kNnormal.
When it is split equally, the normal force we get is approximately 490.2/cos30/4=141.51KN
For safety it is preferred that the load be 150KNnormal on each trunnion.
Hence loads on a trunnion:
Normal load : Fn=150KN
Tangential load : Ft=9KN
Thrust Load : Fa=4.085KN

If load is acting at a distance ‘X’ from bearing contact, The moment at the point of
shearing is
Moment M= Fn*X*136/725
where the distance between the bearings is 725mm and distance between point of shearing
and bearing is 136mm
Here the total bending stress is given by Bending stress= M*y/I + Fa/A
where
I is the area moment of inertia of the plane of shearing=ðd^4/32=81996549mm^4
d is diameter of shearing plane=170mm
y is distance of shearing point from centre=d/2=85
A is area of plane =ðd^2/4=22698 sqmm
Tensile stress= Fa/A= 0.18 Mpa
This is negligible compared to stress due to bending moment.

The torsion is given by

T=torquexd/2J
where
J is polar moment of inertia at shearing plane=ðd^4/64=40998275 mm^4
Diameter of trunnion=906-915mm
Torque=radius of trunnion x Ft= 4077000 Nmm.
Torsion stress = 8.45 Mpa
This can also be neglected in comparison with Bending stress.
Breaking stress for steel =225 BHN=735 Mpa
hence for preventing failure of trunnion with a minimal factor of safety,
735=My/I.
The distance ‘X’ calculated is very large compared to the shaft length.
So there is no problem with the material.

ip
 Conclusion
Since there is no problem with material or construction of the shaft for the given condition,
It is suggested that the problem lies in alignment of the trunnion with the centerline.
Hence it is suggested that proper re-alignment be given to the equipment and a consistent
logging of readings for skewing and alignment must be maintained.

Suggestions
•The northwest trunnion should be replaced if possible as it has a great deviation in diameter
resulting in
 References
•BOOKS : Strength of Materials by
Stephen Timoshenko
•EBOOKS

•WEBSITES : www.wikipedia.org
www.kiln.com

•CFL DATA : Rotary Equipment Volume I by

Hindustan Dorr-Oliver LTD
Philips kiln services

•SOFTWARES USED : MS Office

www.cflindia.com

Summary