_ Lead wire Ø 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. Adjustment or cutting of kiln roller in relation to kiln axis.
iii. Position (laterally) of kiln rollers.
iv. Proportional loud on individual supports.
v. Eccentricity if any in the kiln tube.

_ Lead wire test also shows whether to carry out kiln alignment test with levelling
instrument.

PROCEDURE

_ Mark 3 axis A, B & C on kiln shell @ 120° apart.

_ Sequence of axis should be in relation to the direction of rotation of kiln viewing
from burning platform.
_ At each support six (06) lead wire test are made i.e 3 at each roller i.e one at each
axis.
_ The six lead wire specimen should be marked as shown in fig. 1.
_ The length of lead wire specimen should be equal to width of kiln roller +200 mm
D IAL F

Direction of rotation of kiln viewing from outlet & clockwise

A Left hand roller

IBL
B
ICL
C

IAR
Right hand roller

A t1 t4 t5 t6 t7 t8 t9 t10
t2
IBR
Outlet of kiln

Inlet of kiln

B
ICR
C

Width of roller

1
ANALYSIS

Figure. 1 shows 6 lead wire specimen taken as indicated by marking, at

support No.1.
Measurement of rolled lead wire is done as follow: -
On graph / white sheet, mark off width of tyre. Divide it into equal 12 parts & draw
parallel lines for each axis of rollers. The line in the middle is marked centre line of tyre.
At extremes, mark with D & F for outlet & inlet sides respectively. Now place lead wire
one by one at right angles to parallel lines with ends of rolled portion of wires exactly
over the two extreme lines. In this position, lead wires are to be fixed & width t1, t2 etc to
be measured & these measurements are to be relocated in the table.
Now take average value of each half of the lead wire & enter in the table i.e

t D = t1 + t2 + t3 + t4 + t5

tF = t6 + t7 + t8 + t9 + t10

EXAMPLE
Table – 1

Support Outlet end measured Averag Inlet end measured Averag Difference
No.1 width e width e tD - tF
t1, t2, t3, t4, t5 tD t6, t7, t8, t9, t10 tF
Right A 32, 32, 31, 28, 28 30.2 27, 27, 26, 24, 24 25.6 + 4.6
hand B 35, 34, 34, 32, 32 33.4 32, 31, 31, 29, 29 30.4 + 3.0
roller ® C 26, 25, 25, 24, 24 24.8 24, 23, 23, 22, 21 22.6 + 2.2
Average 29.5 26.2 + 3.3
Left A 25, 26, 27, 27, 28 26.6 29, 31, 32, 33, 33 31.4 - 4.8
hand B 29, 29, 30, 31, 32 30.2 32, 33, 34, 34, 35 33.6 - 3.4
roller ® C 20, 21, 21, 22, 23 21.4 23, 24, 24, 25, 26 24.4 - 3.0
Average 26.1 29.8 - 3.7
Table – 2
Support I axis Right hand roller Left hand roller
(R) (L)
tD A 30.2 26.6
B 33.4 30.2
C 24.8 21.4
tF A 25.6 31.4
B 30.4 33.6
C 22.6 24.4
Sum 167.0 167.6
Average width of lead wire tR = 2 7.83 tL = 27.93
Difference tL - tR 0.1
tR + tL / 2 tav = 27.88

2
CUTTING OF KILN ROLLERS
An example shows that tD values at the right hand
roller are larger than the tF values which means that surface pressure between tyre & the
right hand kiln roller is greatest at the side nearest the outlet end.
Consequently the roller has been cut in the proper direction in relation to the direction of
rotation of the kiln.
The difference between tD & tF values is measure of amount to which the roller has been
cut.

For right hand roller

A = tD – tF = 4.6 mm
B = tD – tF = 3.0 mm
C = tD – tF = 2.2 mm

Average value = A + B + C = 3.3 mm

3
Use average value for the purpose of comparison

If the kiln axis is straight without any eccentricity & if the condition of the various
bearing surfaces are good, then three difference tD – tF one for each axis (A, B & C) will
be almost equal.
The average value for the left hand roller calculated in the same manner is _ 3.7 mm.
Negative value shows that cutting of the rollers are towards opposite direction to that of
the right hand rollers. The axis of roller should be parallel after adjustment and the value
tF thus being larger than tD. The two rollers on same support must be cut towards
opposite sides to make their axis parallel.
From above it indicates that rollers are pushing the kiln upwards towards inlet / feed end.
Following are cutting value, which should not be exceeded (for guidance only).

Width of tyre Cutting value (average)

500 mm 2.5 mm
600 mm 3.0 mm
700 mm 3.5 mm
800 mm 4.0 mm
900 mm 4.5 mm
1000 mm 5.0 mm

If the cutting angle is too great, the surface pressure will become excessive and there will
be overloading of material. Furthermore, the purpose of cutting the rollers i.e to fix the
kiln in a certain axial position through a uniform axial pressure from kiln rollers will be
defeated.

3
LATERAL POSITION OF KILN ROLLERS

The calculated average values of tD & tF

shall determine average width tR & tL of lead wire specimen after rolling.
The average surface pressure on right hand rollers corresponds to rolled average width
tR = 27 ~ 83 mm while tL = 27.93 mm is value of left hand roller giving difference of 0.1
mm only, so average pressure on both rollers is almost equal and rollers consequently are
situated at an equal distance from centre line of kiln.
If the difference exceeds 10% rollers should be adjusted laterally. For rollers at support of
girth gear, difference upto 20% may be permitted.

LOAD ON INDIVIDUAL SUPPORT

Finally the average width t av. is calculated for all

the lead wire specimen which have been rolled by the tyre.
t av. is the expression of total pressure on the support exerted by the tyre and thus gives
our indication of load on particular support. The value found for t av. is compared with t
av. of the roller supports & particularly compare it with past test for particular support.

INCORRECT INCLINATION OF KILN ROLLERS

If the lead wire test specimen shows

that cutting of the roller is normal but at the same time, an examination 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 axis & that it will be necessary to correct the inclination of rollers by placing
suitable shim under one of the supporting bearing.

TROUBLE
i). CURVED KILN AXIS
If there is curvature or ecentricity in
kiln shell, the pressure between the tyre & the corresponding roller shall vary during
rotation of the kiln.
Example showing the effect of eccentricity in the kiln axis. Rolling effect of lead wire
specimen varies between A, B & C

4
In previous example, calculation given on proceeding pages show some eccentricity of
kiln axis indicated by rolling effect being greatest at B axis.
A fair indication of the direction of the eccentricity, if any in the kiln axis is obtained by
tracing a diagram as follows: -
B
Starting at point O, set out D
3 lines OA, OB & OC 120°
apart, Then for each roller
calculate tB M

V°
tA = tD + tF O
2 tC tA

tB = tD + tF C A
2

tC = tD + tF
2

that is width at A, B & C axis

In the diagram, then set out ( using double size scale)

Through points a,b and c, trace a circle with its center M. From O, set out a line passing
through M intersecting circle at D.
A lead wire test taken on the kiln at D-axis situated V° angle apart from axis A towards
direction B will show the greatest rolling effect to be verified on diagram, which is equal
to distance OD as measured on the diagram.
If the greatest average width tD is divided by the smallest average width and result is
found more than 1.3, then kiln tube will have to be straightened.
The maximum 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 OF KILN ROLLER.

If the amount of rolling to
which the lead wires are subjected is greater at one roller than that of other, the rollers are
displaced laterally. The pressure originality from the girth gear may to some extent cause
non-uniform rolling. The rollers therefore should not be adjusted laterally unless it has
been established through optical levelling that adjustment is required.
In the example above, the average width of lead wire specimen after rolling was

tR = 27.83 mm (Right hand roller)

tL = 27.93 mm (Left hand roller)

From above, it appears that the average width of two specimens is wearily equal.

5
By dividing the greater of these average values by lesser one we have

= 27.93
27.83 = 1.004

This value is generally acceptable for this ratio of surface pressure.

Ratio of surface pressure acceptable

i). For girth gear support = 1.05 ~ 1.2
ii). For other support = 1.0 ~ 1.1

If the ratio exceeds the value given above, the support in question i.e alignment of the
kiln will have to be checked by levelling test and if necessary to be corrected.

VERTICAL DISPLACEMENT OF TYRE

Where average value at any one support
deviates materially from that at the other supports, it may be necessary to adjust the
distance between the rollers or in other words, the vertical position of the tyre. Where
necessiated by the design or where it is desired to obtain to some extent a standardisation
of spare parts, a wider tyre is often used there and consequently average particular
pressure at a particular support is lower.

A lower average pressure would give no cause for anxiaty but if average pressure is
abnormal or greater, an optical levelling 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, however whether
an optical check is required immedietely.
The difference between rolled width i.e tD – tF will depend on the width of tyre and other
things and should not exceed 5 % hereof.
An eccentricity present in the kiln tube will give variation in average rolled width

tA = tD + tF of the lead wire originality from the same kiln roller. If the average
2 width varies by more than 30 %, then the nature and extent of
eccentricity should be investigated by other method and correction of kiln tube should be
taken under consideration. If the average width of all rolled lead wires coming from the
one & same kiln roller exceed more then 10 % than the average width of all lead wires
coming from the outer roller on same support (For support at girth gear it is 20 %), than
alignment of kiln must be checked by levelling method.
It is general rule that alignment of kiln must be checked by levelling method if average
surface pressure at any one support is un-usually great or low in proportion to the surface
pressure at the other support.

6
ANALYSIS OF DIFFERENT CASES
From the given figures a ~ e, of lead wire
test passing through straight and oblique kiln rollers respectively, the corresponding
effect on the axial displacement of kiln and wear as the roller faces can be seen from the
below survey.

CASE (a). Roller is completely in parallel position & surface pressure is equal
throughout the width.
_ Tendency 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 overcome the friction between the rollers and the tyres
and kiln would come to rest against thrust roller station and wear will be
uniform.
CASE (b). Surface pressure is greatest at the center.
_ Tendency for displacement at indicated direction of rotation towards the
right i.e towards the upper side.
Wear. If the roller has been cut to excessive angle, the centre of the roller face
should be hollowed and pitting any occur. If the longitudinal travel of kiln
causes series of slides between the roller & tyre faces during every
revolution of the kiln, facetting will occur.
Note If the angle to which the roller is test, as shown in fig.C 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
favourable 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 (c). Surface pressure is highest at the right hand of the roller
Tendency 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 (d). Surface pressure is highest at the right hand end of the roller.
Tendency 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.

7
CASE (e). Surface pressure is highest at the left end of roller.
Tendency 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.

1 2 3

a b

4 5 6

d
e

8
By passing a lead wire between the roller and tyre, it is possible from its rolled shape to
conclude how the axial position of kiln roller must be relation to the tyre.

The lead wire test should be extended so that it will provide more exact information such
as, whether kiln axis straight, curved or winding and if so as to where the degree of
eccentricity is at a maximum.

If kiln axis is straight, the surface pressure between the tyres and rollers will be constant
or uniform. If the kiln axis is curved 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.

FINAL 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 move kiln roller during operation.
In general, any ir-regularity found through systematic checkup, may be rectified by
adjustment of the kiln rollers.

15.05
From air lift 13.32
15.02

15.04

15.01

15.26

15.25

15.27
15.07
15.08
15.22

15.19 At
Clinker tower
15.09 15.21
15.06

15.11

15.10 15.20

15.12 ~ 15.18 15.23

15.24
15.03