Rotary Kiln Erection

Orientation & Common Terminology for Reporting Kiln Details
Feed End of Kiln(s) (Also referred to as “Uphill” or “High-End” Area)

Counter- Kiln thrust tire(s) with Clockwise
Clockwise
(Lefthand) tapered side-faces. Kilns (Right-hand) (Straight Spur or Single Helical)
with hydraulic thrust Referred to as “Girth”, “Bull” or
assemblies will utilize a tire Gear “Main” Gear. Indicate “left” or
Gear with a taper on the downhill “right” side of the kiln when
side-face only. looking uphill towards feed end.
Kiln thrust roller assemblies.
Indicates pier numbers starting at discharge or feed end
3 1 Both sides of the thrust tire

except when units are
hydraulically controlled.
Kiln drive pinion(s). Arrows A

A B indicate position of pinion B
when a single drive
arrangement is used for kiln
2 2 A B rotation(s) as shown. Pinions B A
shown at outside positions are
for dual-drive assemblies.
A - Indicates down-turning
A B Kiln Support Rollers also B A side of kiln and in-running
called “Carrying Rollers”, rollers.
Trunnions”, “Wheels”, and
“Rolls”. B - Indicates up-turning side of
the kiln and out-running
Plain tires, or riding rings rollers.
(with straight side-faces).
1 3
Kiln "Rolling" or "Contact" Kiln
Discharge surfaces (faces). Discharge
Left End Right Left End Right
Do not refer to "compass"
directions or local geography Material discharge
Material discharge when reporting problem zones.
(spill ) (spill )
SM
KILN OVERHEAD 001.CDR Maintenance Seminar

Kiln Support Frame Setting Reference
Frame CL
D D
Elevation C Elevation E
Elevation F
(Approx.)
Elevation A B G
1
2”
3 2
Frame CL
Pier CL
4
L
Bolt C
Bolt CL
1 - 2” Allowance for grout between frame and rough pier top.

2 - Elevation reference plug. Set in pier on beam-web CL. Locate plug 6” outward from end of beam.
3 - 5” long shims. (Refer to kiln installation instructions).
4 - Anchor bolts added to prevent “rolling” of beams.
Refer to foundation drawing and roller assembly drawings for elevations, frame dimensions and slope of the kiln.
A - Reference elevation for support assembly.
B - Frame height (may vary after machining, use design dimension for calculation of top surface elevations).
C - Elevation A plus dimension B. (Not for actual test work).
D - Calculate rise or drop from frame CL to high or low beam CL to suit designed slope of equipment.
E - Elevation = C plus rise for D.
F - Elevation = C minus drop for D.
Carefully check and record elevation at top of plug.
F = Required elevation at CL on machined top surface of beam minus reference plus elevation.
Use dimension G for setting elevation of control beam. Use precision straightedge with slope test block and machinists
level or inclinometer for follow-up slope adjustment of the frame.
SM

Kiln Support Frame Adjustment and Tests
NOTE:
Frames must be aligned on CL’s Slope tests require a sturdy
parallel to each other. and accurate straightedge that
Refer to installation will totally span both beams of
instructions for dimension F all frames in the arrangement.
tolerances and test
procedures.
B
D
A E
Use a precision spirit NOTE:
level for test work. A Roller assemblies are to be
stainless steel v-block set before grouting frames.
is supplied for test work, Final test for slope is made
or use an inclinometer. on top of each roller.
A - Refer to installation instructions for preparation of shims. Stacks must be tight.

B - Elevation tolerance + _ 1/16” or + _ 1.50 mm for frame.
C - Slope tolerance 0.002” per foot or 0.15 mm / 1000 mm.
D - Straight-edge must be parallel to frame C L.
E - Maximum gap 0.004” / or 0.10 mm under straightedge.
F - Cross-level tolerance 0.002” or 0.05 mm per foot at bearing zones (0.15 mm / 1000 mm at bearing zones).
SM

Kiln Support Frame Spacing Test Points
Slope Dimension (Shown on Foundation Drawing)

NOTE Erecting Test Dimension NOTE
Support Frame
Kiln
Kiln
Support
Support
Base Dimension Pier
Pier
(Shown on Foundation Drawing)
NOTE: “Support Roller Assembly” drawing numbers for each pier are shown on the “Foundation”
drawing. Refer to the correct drawings for piers being checked. These drawings show the dimension from frame CL
to beam CL for each assembly (frame & roller dimensions may vary from pier to pier).
Add half-frame dimensions for piers being checked and subtract total from slope dimensions shown on foundation
drawing to obtain test dimension (as shown above in sketch).
Use spring scale to apply 20 to 25 lb’s or 9 - 12 kg. tension to tape line (depending upon wind conditions).
Check tape line temperature and make allowances for possible variation for dimension being checked.
SM

Kiln Support Frames Spacing, CL & Parallelism Tests
Kiln Support Frame

Kiln Support Frame
Diameter B *
C’s Marked on all Piers by Layout Engineer

Diameter A
L
Diameter A
All Beam CL’s marked at factory

Dia
m ete
r C
Kiln and Frame CL Marked on Piers by Layout Engineer
Diameter A
Diameter A
C
ter
ia me
D
Diameter B *
Erecting test dimension

NOTE NOTE
Slope Dimension (from foundation drawing)
Measured and Marked on Piers by Layout Engineer
NOTE - Frame dimensions shown on “roller assembly” drawings. Align frames on CL’s, adjust for elevation, slope and
cross-level.
Dimension A - Nominal dimension from frame CL, measured and marked equally at all test points (in field at time of installation).
Dimension B - Test dimension from frame spacing and parallelism. (Tolerance 1/16” or 1.50 mm).
Dimension C - X-Test to verify frame CL alignment.
* Use spring scale at 20 to 25 lb’s or 9 - 12 kg. tension on tape line. Check tape line temperature and allow for expansion or
contraction of line.
SM

Testing New Kiln Support Roller Installations,
or Re-Aligning Older Equipment
This methold applies only when
roller surface is cylindrical. Slope gage block
to be accurate within
Or use slope block on shafts. 0.0005’ in 12” length or
Slope -
gauge V-bar with 0.05 mm / 1000 mm.
The inclinometer is also an
12”, graduated vial,
accurate method.
machinist level.
A
Kiln may be Use tight wire or
on slow straightedge for
rotation projection of offset
if plumb bob line across beams.
is suspended B
in oil.
Plumb bobs C
in oil
Measuring to plumb
lines is not completely
Adjust shims accurate (rollers may be
as needed for final tapered).
true-up of frame.
(Slope & transverse-level
tolerance @0.002” per foot or
Install boards at inner
0.15 mm / 1000 mm).
edges of beams for ramming
Fill anchor bolt sleeves high strength non shrink
with high strength grout. grout from outside edges
of beams.
A - Establish offset reference lines at both edges of frame. Offsets must be parallel to, and symmetrical about the verified true kiln CL.
B - Use adjustment screws to set roller assemblies parallel to the kiln CL .
C - Measure from plumb lines to offset lines.
SM

Recommended Water Piping Arrangement
for Kiln Support Roller Assemblies
A - Roller adjusting assembly. Keep these zones open for roller re-setting work.
B - Flexible lines to allow for possible 4” to 5” or

100 mm to 150 mm movement.
C - Inlet water master value.
D - Control value at inlet line to each water jacket.
E - Funnel arrangement for drain lines. D

AR NT
I NWSTME R
J U LE
AD ROL LY
B OF SEMB
AS
B
D
AR NT
I NWSTME R
JU LE
AD ROL LY
OF SEMB
AS
E
D NOTE -
Keep lines clear of end plates
to allow for bearing inspection
C and maintenance work.
SM

Handling Kiln Tires for Installation on Pads with Slide Bar Arrangement
A
A
B C
B
A - Longer timbers for clean and soft
A - Timbers in place between rolling surface.
ground and tire.
B - Belt wrapped around tire and tied “Plumb” position of tire
B - Rubber belting for protection with wire.
of tire surfaces. after pick-up.
C - 3 wraps of 1” wire rope hitched to A
Pads
A B crane hook.
C B
A - Kiln tire section on elevated saddles. A - Circumferential sling for moving tire into position
Set level as possible. on pads. Place wire rope inside rubber hose split
lengthwise and tied with baling wire.
B - Tire in position for resting on shell section.
B - Use 4 spacer bars with centering gussets and end
C - Set tire on 4” by 4” timbers for removal of set-screws.
wire rope and belt material.
SM

Crane Hitch Arrangements for Handling Kiln Shell Sections
(Off-Loading and at Assembly Area)
Preferred arrangement, using a spreader beam and Acceptable hitch arrangement, but anti-creep
two cradle slings. Two cranes should be used for gussets should be installed to prevent wire ropes
longer shell sections with two heavy padded from crawling toward each other when the crane
sections for riding rings. starts to pick up the load. Calculate the sling
tension for the included angle & use an adequate
capacity slings.
SM

Crane Hitching for Kiln Shell Sections
Hitch Angles and Stress on Lines
Diameter
1000 lbs. 1000 lbs.
Splice 1 Part line 2000 lbs.

kinks Diameter
shell
Weakened 2 parts
of line
.
lbs
115
60°
Kiln Shell Kiln Shell s. 1
lb 90° 415
5
115
lbs
15 l
14 45° 45° bs.
.
60°
2000 lbs. 2000 lbs.
Diameter Diameter
“Choker” no good for Go with “Cradle” for
handling kiln shells. Handling Kiln Shells
Sling hitching angles and stress on lines

for each ton to be hoisted.
SM

Kiln Shell Support
Longitudinal welds at ends of shell

sections are to be set 180° apart
for field joints unless shown
otherwise on erection al
drawings. it udin
ng
Lo ld
We
l
ud ina
t
ngi
Lo ld
We
1” X 4” X 24” strongback bars may

be used to guide shell section
into position for field joint connection.
Locate at spaces required for
setting all strongback bars for joint. Typical crib stack shown with jack, steel plate and
saddle arrangement for adjustment work.
SM

Alignment Fittings
Adjusting lug
Strong-back
Edges of adjacent
shell sections
“Push” - “Pull”
Adjust Bolts
SM
KILN OVERHEAD 012.CDR

Maintenance Seminar
Checking Alignment
Feed End
Field Joints
Gauge
Blocks
Discharge
End
Transit Replacing
Batter Board
Tumble or rotate instrument 180° for test at discharge end target.
Instrument cross-hairs or center of a laser beam must be within 3/32” or 2.5 mm of target center at all
test positions.
SM

Kiln Shell Alignment Test Batter Boards
Steel Spider
(1 of Several Types)
Wood Wedges 2” or 50 mm Diameter Hole

Drilled at CL’s
2” X 6”
Board
1/4” X 4” X 4”
2” or 50 mm Diameter Hole
Steel Plates
Drilled at CL’s
(2) 1/4” Diameter

2” X 6”
Bolts at
Each Plate Board
SM

Kiln Alignment Target and Layout Trammel
Sharp pencil in trammel clamp.

“Starrett” No. 59 or similar. A
3/4” X 1 1/2” trammel beam (wood)
New kilns only-

B
In tire sections - use steps in
machined reference plates as
guide point for trammel layout
Cut beam to on targets.
form pointed
end.
A - 4” X 6” index card held in place by thump tacks (or staples) and push pin.
B - Shows card turned and pinned to clear 2” or 50 mm diameter hole for through sight to next targets. Card
can be returned precisely on starting position for target re-check.
SM

Locating the Center of the Shell
First set of quarter
points identified
by “A”s Arcs and diagonals
45° offset for first points
Second set of quarter A1 are solid, dashed
points identified for the second set
by “B”s
B4 B1
Card on
batter board
A4 A2
Shell Details on card:

Center points
Selected Center by
B3 B2 second set of
center
quarter points
A3
Center by
first set
of quarter
points
SM

Kiln Shell Section Alignment Tests (Alternate Arrangement)
Span “A” Span “B” Span “C”
3 4 5 6 7 8 9 10 11
1 2
Pier 1 Pier 2 Pier 3 Pier 4
After aligning and tack-welding span “A”, as for 2-section 2-support kiln (figure kiln overhead 014.cdr) or when this length
has been factory built, alignment of following spans can usually be achieved by adjusting support rollers.
Usually completion of joint in span “A” will eliminate need for support at joints in following spans. Actual support
requirements will depend on section design for shipping.
Actual sequence of installation and alignment must be determined on-site to suit actual number of shipping sections.
For Alignment of Kiln with Sections as Shown Above

Finish span “A” as in test for 2-section, 2-support kiln (shown in figure kiln overhead 014.cdr).
Set transit on kiln axis. Lock on target 5. Cross-check on targets 4, 3, 2, 1.
Lock transit on target 8. Back-check on 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of site within 3/32” or
2.50 mm of target centers.
Lock transit on target 11. Back-check on 10, 9, 8, 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of sight within
3/32” or 2.50 mm of target centers.
Minor errors on short fore-sight will “grow” on each following target. Avoid errors, save time and avoid confusion by
working from most-distant far-sight.
SM

Maintenance Seminar
Kiln Shell Field Joint Bracing and Tack Welding
Weld remaining end of strongback

after kiln shell alignment is acceptable.
Edges of adjacent
shell sections
Prewelded end
Tighten all nuts in push/pull

bolt arrangements.
Tack weld in bevels, at least 6” or 150 mm long, at fixtures used for alignment of adjacent plates.
Deposit root weld bead.

SM

Riding Ring Location
Discharge
end
Thrust
Change pier numbers to suit actual arrangement

The dimensions indicated are specified on the foundation drawing. The tolerance on the location of each
ring is +
_ 1/4 inch (6.35 mm).
“Cold” dimensions on the foundation drawing are at 70° F (21° C). Record shell temperature for
calculation of expansion or contraction relative to the control temperature for adjustment of allowance for
expansion at each support roller position.
SM

Maintenance Seminar
Temporary Support Chair for a Kiln Spring Gear
Kiln gear with tangential springs
1 ½” axial adjustment bolts. Kiln Shell

6” long (typical).
Chair in position to
support and adjust
the gear for correction
of axial and radial runout.
Typical gear chair
( 1 of a set ) for
temporary duty.
2” X 6” (or to suit) bolt
for gear radial adjustments.
SM

Maintenance Seminar
Gear Guard and Splash Band Assembly
Feed End B
A - Gear guard section
A B - Flange joint for removable panel
C - Splash band sections
D - Spring plate for gear
E - Kiln shell plate
F - Spacer guides
Splash band installation notes:
1 - Prepare and install spacer guides.

2 - Install segments with care.
3 - Align and tighten flange joints.
C 4 - Align and tach weld panel butt joints.
C 5 - Verify straightness and clearance all
E around.
F D 6 - Weld flanges to shell. Must be oil tight.
F
7 - Remove scraps. Clean off weld spatter.
NOTE:
If conduit must pass through bands to reach a thermocouple, install before guard assembly work.
SM

Kiln Support Roller Adjustment and Testing
View toward feed end View toward feed end

Riding
Ring Kiln moves Riding Kiln moves
toward feed end Ring toward feed end
Support
Roller
In In
Rotation Rotation
Low end
of kiln
In (discharge) In
Rollers move Support Rollers move
toward discharge end Roller toward discharge end
Bearing end Bearing end

plate with plate with
thrust washer thrust washer
Roller shaft should be in Roller shaft should not be

contact with this thrust in contact with this thrust
washer. End plate should washer. End plate should
sound “solid” when tapped sound “hollow” when
near center with a hammer. Low end of kiln tapped near center with a
(discharge) hammer.
SM

Skewing Rollers
Discharge Lower Thrust Roller Drive Feed End

End
Ideal Roller Skewing:
All rollers should be pushing uphill slightly or neutral.
With a two thrust roller system (as here) the kiln should be floating between the thrust rollers.
With a one thrust roller system there should always be contact between thrust roller and tire pressure
200-800 psi or 15 to 60 bar.
SM

Support Roller Assembly Alignment Control
Dial-indicators (1 at each bearing base) are used
for control of final true-up alignment work
and for all skewing adjustments.
Kiln may be
Beam Support on slow rotation
top roller Plumb if plumb bob
A
lines is suspended
in oil *
Bearing
Base
A
B
B Offset reference line
(may be a tight wire
High temperature metal surfaces or a straightedge at
can cause severe burns. established reference
Plumb
Moving (rotating) machinery can bobs in marks).
cause hands and arms to become caught. oil
Avoid personal injury.
A - Scribe beam surface at edge of bearing base to establish reference points for measuring bearing movement during
the roller relocation work period.
B - If it is possible to work simultaneously at both bearing positions, use 2 plumb lines for measuring movement.
* - This procedure is not valid if the roller is cone shaped or distorted on the rolling contact surface.
SM

Kiln Support Roller Bearing Bushing Lubrication
Rotation B
Rotation A
Roller Shaft
180° B
bearing
bushing A Shaft Rotation Shaft
Recessed Zone
(Both Edges) B Rotation
Sketch shows recessed zones of

bushings filled with oil for formation
of oil “wedges” which taper to “a few mils” A
film thickness at the longitudinal pressure
line. Wedges are shown for both directions
of shaft rotations.
SM

Temporary Kiln Support Jacking Kiln Shell to Unload Support Rollers
Shell Diameter (outside)
Kiln Shell
36°
72°
Variable
All pieces
from 1 1/4”
plate
Saddle for Kiln/Shells
Chord Length
Kiln Saddle Dimensions
72° = 5 spaces @ 0.587785 X outside diameter = Chord Length
Rule of thumb:
“Chord Length” does not apply when designing a saddle for under a riding ring. A saddle for a riding ring must
straddle a tie beam between support frame beams and must be designed to fit between rollers on that frame.
Saddle width should be same as width of nearest tire but not less than 12”.
SM

Jacking Kiln Shell to Unload Support Rollers
Drive wedges and/or filler plates between tire and pads to eliminate top
clearance for early pick-up of the tire when jacking against the saddle.
Clearance
Tire
Slow Rise Edge Shell Brace

Prepare 12
or more
On Pier Surface Shell Saddle

Arrangement
SM

Jacking Kiln Tire to Unload Support Rollers
Clearance
Tire
Shell Brace
Preferred Jacking Arrangement ( when possible)
Refer to the foundation drawing for the kiln for the pier loading figure at the tire to be raised;
jacking capacity for that area will be indicated by the vertical load shown for that pier.
SM

Familiarization -
Kiln Support Roller Bearing Oil Level and Leakage
Maximum oil Maximum oil

level in the level in the
downhill housing uphill housing
B
A
Slope Line
Pier Surface
Pier Work Point Imaginary Level Line
A - No oil leaks at downhill shaft seal except when overfilled, dirt and rainwater enter housing when seal is bad, as
when a liner is badly damaged.
B - Shaft seals are not dams. Oil level must not reach seals at uphill bearing assemblies.
SM

Self Aligning Ball and Socket Type Bearing FLS “58”
“Type RA” Design Bearing
Support Roller With Journal
Oil Trough
Felt
Oil Cup
Seal Oil
Heat Shield
Scraper
Thrust Ring
Liner
Oil Gauge
Stop Block Spherical Liner/

Water Jacket
SM

Bearing end Bearing end

plate with plate with
thrust washer thrust washer
Roller shaft should Low end of kiln Roller shaft should

be in contact with this (discharge) not be in contact
thrust washer. End plate with this thrust
should sound “solid” washer. End plate
when tapped near should sound “hollow”
center with a hammer. when tapped near
center with a hammer.
SM

View toward feed end

Riding
Ring Kiln moves
toward feed end
Support
Roller
In
Rotation
Low end
of kiln
(discharge)
In
Rollers move
toward discharge end
Counterclockwise Rotation
SM

View toward feed end
Riding Kiln moves

Ring toward feed end
In
Rotation
Low end
of kiln
(discharge)
In
Rollers move
Support toward discharge end
Roller
Clockwise Rotation
SM

Kiln Support Roller Skewing
Roller Adjustment Rule of Thumb
High End
In
In
Kiln
Bearing
Kiln Bearing
Support Support
Roller Roller
Kiln Bearing Rotation Bearing
Kiln
In
In
Moving (rotating) machinery.
Personal contact can cause

hands and arms
to become caught in pinch points.
Counterclockwise Kiln Rotation

SM

Kiln Support Roller Skewing
Roller Adjustment Rule of Thumb
High End
In
In
Kiln
Bearing Bearing Kiln
Support Support
Roller Roller
Bearing Rotation Kiln
Bearing
Kiln
In
In
Moving (rotating) machinery.
Personal contact can cause

hands and arms to become
caught in pinch points.
Clockwise Kiln Rotation

SM

Normal Offset Position of Thrust Rollers
Rotation
Idle
Down Correct
Down Down
1/16” to 1/8”
Roller Kiln
Centerline Centerline

Thrust rollers must be offset from the true frame longitudinal centerline toward the down - turning side of the kiln
for normal (safe) operation.
SM

Wrong Offset Position of Thrust Rollers
Rotation
Up
Idle
Wrong
Up Up
Any amount
Kiln Roller
Centerline Centerline

Thrust rollers will rise, or try to rise, out of their bearing bases when their centerlines cross over the true
frame centerline toward the up-turning side of the kiln, and when the kiln shifts toward its own downturning
side.
SM

Plain Roller Support Assembly
Oil Tray Inspection Port

Oil Seal
(See Detail)
Bearing Housing
Oil Bucket Wheel
Thrust Washer
Feed End
CL Roller
Detail
Oil Level and
Oil Fill Pipe
Bearing
Roller Shaft
Adjustment Plate
SM

Thrust Roller Assembly
Two Thrust Roller System
Thrust Riding Ring
Thrust Roller Feed End

Shell
See
Oil Level & Detail Thrust Roller
Oil Fill Pipe
Thrust
Roller
Housing
Shims
Thrust Rod
Oil Spherical
Seal Roller Bearings
Detail
SM

Thrust Roller Assembly
C-C
C
Thrust Roller Frame
SM

Hydraulic Thrust Roller Assembly
Fixed Uphill Stop Thrust See
Shell with Brass Plate Support Riding Thrust Roller
Rod Boot Ring Detail
Thrust Roller
Thrust Roller Thrust
Movement Housing Button
“A” (Sht. Hydraulic

Cylinder
To Hydraulic
Power Unit
Stroke
Adjuster
Lower Thrust
Thrust Housing Spherical Housing Support
Thrust Support Rod Roller
Roller Bearings
Frame Upper Thrust
Housing Support Drain Plug Oil
Seal
Feed End
Detail
NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown
SM

Hydraulic Thrust Roller Assembly
Feed End
Operation of Limit Switches
L Roller Support &

Thrust Riding Ring
A - Stops Hydraulic Pump Set Thrust Riding Ring
B - Pressure in System Relieved
C - Sounds Alarm
D - Shuts Kiln Drive Down Thrust Roller
E - Starts Hydraulic Pump Set A Cam Follower
F - Sounds Alarm
G - Shuts Kiln Drive Down
C
Limit Switch
Assembly
CL
D C B A E F G
Bumper + + + + + + +
Assembly Riding
CL Kiln
Ring
Pier 3 Pier 2
Hydraulic
Power Unit Hydraulic
Cylinders
Hydraulic Thrust Orientation
(Single Hydraulic Cylinder May be Used)
A-A
SM

Routine Checkout at Kiln Tire Sections
View at Allowance for

Top Position Shell Expansion
Shell Cold: Clearance for expansion at top of kiln
Shell (pads) rest in normal position inside the tire
SM

Maintenance Seminar
Shell Overheated
and Choked
Inside Tire
Expansion
Shell overheated and choked inside tire. Shell expands proportional to internal heat, but must bend at sides of tire.
Tire retainers on bend pads bite into the tire, tire and retainers become worn. When shell temperature returns to
normal, shell pad to tire clearance is excessive.
No shell migration may eventually be followed by permanent kiln shell choke-down deformation.
SM

Field Installation of Kiln Tire Section Spider Bracing
Pre-Welded
End @ 90°
Brace No. 1 Sag From Start
Brace No. 2
Now Tight Second

Weld
When the pre-welded end of Brace No. 1 is at the top of the shell after 90° of rotation, shell sag moves the loose
end against the bottom of the shell and in position for welding.
Brace No. 2, and possibly No.’s 3 and 4, will be needed for pad replacement work requiring frequent rotation
of the shell.
Spider bracing is for holding the shell as round as possible for pad replacement work. Before welding bracing
to the shell, verify roundness by using trammel layout work for marking the shell axis on Brace No. 1 to establish
a reference point for radius measurements.
SM

Almost zero
clearance.
Shell continues
View at to migrate within
Top Position the tire.
Shell Hot: Normal Operation

Check (frequently) each tire section in the kiln arrangement. When shell migration in not recorded, the kiln shell
is very near the point of serious deformation damage plus shell and refractory breakdown problems.
SM

Clearance
When normal coating builds up on refractory, the main shell returns to normal diameter but the permanently
deformed tire section shell is small in relation to the tire bore diameter.
With the tire in a normal alignment position the kiln shell is misaligned at the low-riding deformation zone.
Excessive down tire follows choke-down deformation.
SM

Maintenance Seminar
Shell sags away

from the tire
Clearance
3 Spreads
Horizontal Major Axis
2
1 1
4
1 - Install support plates at both sides of the shell.
2 - Lift bracing leg onto support plates. Check squareness.
3 - Hold end of brace against the shell for welding.
4 - Rotate shell 90° to place weld at top center position.
SM

Riding ring on rollers
Clearance and a 0.3% ovality
0.775” (example only).
Shell held in round condition

by internal bracing
True roundness is a goal

Seldom - if ever - Reality
Clearance Clearance
0.6125” 0.6125”
New measurement problems must be considered when/if internal bracing holds the shell in a perfectly round condition.
If the riding ring rests on support rollers, ovality will not have changed; now measurements will be between a round
shell and an oval riding ring.
When the riding ring is on the support rollers, and the kiln shell is round (after bracing), measure clearances at both
sides at the horizontal centerline, and at top-dead-center between shell pads and the riding ring bore surface. Add
dimensions recorded for these three check points, then divide the total by two to determine the actual diameter for
shell pads and riding ring bore.
SM

Jacking a Kiln Shell to Unload Support Rollers
Clearance
Tire
Shell Brace
Saddle Under the Kiln Shell
Clearance between the tire and pads at the top of the shell is usually overlooked when all other details have been
considered in arrangements for jacking up the kiln shell to take a tire off the support rollers for maintenance work
on the roller assemblies in position on the support frame, or for lifting out one or both assemblies for work at ground
level or in the maintenance shop.
SM

Saddle under the kiln shell
By the time the upper pads touch the tire jacks are fighting all shell weight to adjacent tire sections.
Two to four times the jacking capacity anticipated for lifting the shell will be required if tire to pad clearance is
not considered (especially when excessive).
SM

Maintenance Seminar
NOTE:
Saddle under the kiln shell
Excessive pad to tire clearance is a handicap for jacking up kiln shell.
NOTE: The tire will not rise until top area clearance is eliminated by the rising shell.
SM

Maintenance Seminar
Jacking Kiln Shell to Unload Support Rollers
Clearance
Tire
Slow Rise Edge Shell Brace

Prepare 12
or more
On Pier Surface Shell Saddle

Arrangement
SM

Maintenance Seminar
Typical Procedure for Removing Roller Assemblies
from the Support Frame
3 3
2
1 - Spider bracing (installed before locking out the kiln drive system, including the auxiliary drive arrangement).
2 - Timber cribbing stack with hydraulic jacks in place under steel saddle. Saddle and jack arrangement must raise
the kiln shell just enough ( 1/32”, 1 mm, or less ) to be fully loaded for removal of both roller assemblies. *
3 - Install steel or hardwood columns for security of the temporary support arrangement during the pad removal and
replacement work period.
* - If the tire is rising with the shell. If clearance between the tire and shell pads was not accounted for, excessive
jacking will be required to lift the tire away from the support rollers.
SM

Typical Procedure for Removing Fuller/Traylor Roller Assemblies
Pier Slope
Top Line
Level Line
Pier Reference
Work Point
“Cutaway” view of roller assembly bearing bases shows internal arrangement of components with critical clearances.
Whenever roller and bearings are to be lifted as a complete assembly, hitching arrangements must hold bearings in
full-line contact with shafts, and with no contact at shaft seal zones.
A - Remove shaft seals. Insert wood or rubber wedges between shaft and seal inset in housing. Secure these wedges
with at least one wrap of duct tape (or similar material).
B - Edges of frame beams have machined insets for control of shaft clearance between bearing end plates. Key bars
at bottom positions on housings hold bearing housings in position against machined edges for operation of the
assembly. One or both keybars must be removed to avoid interference when the complete roller assembly is
moved toward the outside end of the support frame.
SM

Maintenance Seminar
Prepare hitching material similar to the arrangement shown in these sketch sheets. Distance between connecting
points must place the crane hook, spreader bar and shackles far enough above the kiln horizontal centerline for
flexibility in the lines for lift-out maneuvering.
Remove all cooling water input and drain pipes from bearing bases. Remove bearing adjustment lug and screw
combinations from frame beams. Prepare beam surfaces for outward travel of the roller assembly.
Jack or pull the assembly outward on the frame until motion is stopped by roller contact against the tie-beam at the
end of the frame.
SM

Typical Procedure for Removing Fuller / Traylor Roller Assemblies
Place timbers at the ground level work area for support of the assembly with the roller off the ground The low-end
bearing housing will touch down, and hitching will become loose, before the other bearing housing rests on its own
support timbers.
SM

Look for stencil-letter
identification of the
feed end area of the
roller.
FEED
E
ND
Move bearing housing:
OUT / OFF
IN / ON
Uphill ( or feed end )

bearing housing
Removing and/or resetting a bearing housing at ground level
SM

Maintenance Seminar
Move the roller into its realignment position and into a load carrying condition. Reassemble all pipe fittings, guards
and other items which may have been removed for crane handling maneuvers. If internal fittings had not been
reinstalled at ground level, remove end plates for final fit-up work. Re-fill bearing lubricant reservoirs. Remove
pedestals, jacks, saddle and cribbing.
SM

New Pads for Choked-Down Tire Sections
(Clearance
Tire Exaggerated
for Clarity)
Level Tire CL
Slope Shell CL
True Kiln Axis
Thrust Roll Thrust Roll

Roller at
Far Side
Align the kiln shell before shutting down for repair work. Cold-condition external alignment procedures are not
acceptable unless excess clearance and other deviations are accounted for. Kiln shell section alignment is critical
at all tire positions, alignment of tires is not necessarily kiln shell section alignment.
SM

2
Level 1 1
Slope
Preparation:
1 - Install spider bracing. (See bracing installation procedure on other sheets). Bracing must be installed before the
kiln auxiliary drive system is secured, along with the main drive motor, to prevent accidental rotation during the
repair work period.
2 - Remove retainers at the side of the tire toward the direction of movement away from pads. Grind off weld scraps.
3 - Remove thrust roller assemblies.

SM

Maintenance Seminar
3 4
Level
Slope
2
Preparation: 1
1 - Install steel saddle and two (or more) hydraulic jacks in a convenient location that will not interfere with work.
2 - Back support rollers away from the frame center line to let the tire move downward.
3 - As rollers move outward, check tire to shell clearance all around. Stop roller adjustment work when the tire is
in balanced position around the shell.
4 - Install skid bars at the top of the shell. Use shims for adjusting bar height for smooth movement of the tire.
5 - Mark the shell to indicate original position of tire.

SM

Level
Slope
1
Preparation:
1 - Install a tight arrangement of steel or hardwood pedestals between the support surface and saddle.
2 - Start to jack or tug the tire off pads and onto skid bars.
SM

Level
Slope
Preparation:
1 - Move the tire far enough onto skid bars to allow for installation of new extra long pad plates.
2 - The bottom of the tire will swing toward a “plumbed” position if not restrained. Install gusset plates at the
bottom of the shell to hold the tire away from the pad zone.
3 - Remove both roller assemblies for free access to the shell.
4 - Start pad removal work.

SM

Maintenance Seminar
STRAIGHTEDGE
Level
Slope
Preparation:
1 - Finish pad removal work. Grind down weld scraps. Remove caked dirt, rust and oil from the shell at the pad zone.
2 - Use a straightedge or a tight line for measurement from undamaged shell surfaces to the top of the depressed shell.
Measure at several points around the shell for a realistic approach for planning and preparing filler material.
The depressed zone must be filled for support of new pads. Any unfilled space, however small it may be, will allow
new pads to bend to fill the spaces as soon as rotation starts after the kiln is returned to the production department.
SM

New Pad Plate
Rolled Filler Plate
STRAIGHTEDGE
Level
Slope
Stacked Shim Plates
A “typical”, but unsatisfactory shim stack arrangement for filling spaces between shell and pads is shown at the
bottom of the shell. Since “all-position” fit-up work is necessary, shim stack installation is tedious (and frustrating)
work. Shim stacks are rarely, if ever, tight enough to prevent pad distortion when the work is called “finished”.
A more acceptable filler arrangement is shown at top of the shell, a rolled plate, at a thickness determined by prior
measurement, is used with appropriate thickness-adjustment shims for a more secure packing arrangement. In this
arrangement filler plates are welded to pad plates, not to the shell.
SM

Lubricate
New Shell Pads

Level
Slope
Lubricate
When new pad plates, with fillers, are secure around the shell, lubricate surfaces to facilitate movement of the
entire to the predetermined operating position for that particular tire.
SM

New Shell Pads
1 - Adjust tire position in relation to original reference lines.
2 - Install temporary gusset plates to lock the tire for rotation.
3 - Return support rollers to positions on the frame. Adjust for recalculated set points which consider new
conditions at the tire.
4 - Move the thrust roller into position at the clear area.
5 - Remove skid bars: Grind down weld scraps.

SM
Welded End Loose End Welded End Loose End
CL Tire
Do Not Weld
Gusset to Pad 3/8 to 3/4 TYP
3/8 to 3/4
Pad Pad Pad Pad
Loose End Welded End Loose End Welded End
Hold Down 3/8 to 3/4

Gusset Retainer Block A TYP
4” X 4” X Variable Length
Spacer Pad to Suit Spacer Pad
(Loose End)
Dia.
1/16” Tire 1
A
A-A
Alternate tire retainer arrangement. Semi-floating pad design.
SM

5
6 7
Tire
1 - Be sure that rollers are carrying the load of tire and shell.
2 - Remove pedestals, jacks and saddle.
3 - Reset thrust roller assembly.
Slope 8 8 4 - Adjust thrust roller assemblies for proper clearance in

relation to the tire and in relation to support roller
centerlines.
5 - Kiln rotation is required for testing for tire wobble.
6 - After tire wobble has been eliminated, install tire retainers.
7 - Remove temporary tire-locking gusset plates.

Thrust Roller Tire Thrust Roller
8 - Remove internal spider bracing. Grind down weld scraps.
3 Roller 4
1
2
SM

Floating Pad Design
5” 8”
TYP.
3 Sides Fillet
R 3/4 Anti-Rotation Plate
Weld 2-
Size
Pad Guide Bar 1” Thick
Pad 1” TYP 1/8”
9”
Width Gap
Must Make Contact on 1 Side
1/4” TYP
R 3/4
TYP. R 3/4 A A Axial Pad Retainer 1” Thick
3 Sides 5/8
Wear Ring Retainer
1” Chamfer
Wear
8” Pad Length 8” Ring Height of
Pad 1” Anti-Rotation
Min. Min. Wear Ring Plate
Min. Thickness
5” Riding Ring Pad
Taper Shell
Thickness
TYP
Pad Heavy Shell Plate Fillet Weld Size
Thickness 1/16” or 2 mm Downhill Side Only
A-A
In this arrangement pads are not welded to the shell at all.
The shop installed cost for this arrangement is high, but the future field replacement of pads is simpler and less
expensive.
The continuous wear rings installed between the riding ring end faces and wear ring retainers reduces bearing pressure
and gouging in the riding ring end faces and also increase wear life of the components.
It is very easy to reduce tire creep: Install shims between shell and pads and tack weld new shims to pads.
SM

Maintenance Seminar
Using Wedges for Longitudinal Shifting of Tire
Lube
ote
Molyk
Cold Kiln
Weld Wedge to Tire
Weld Wedge to Pad
Move Tire Rotation & Creep
Creep (Mark on Pad)

Mark on Tire
Opposed Wedges. Smooth slide surfaces per machine shop procedures.
SM

Using Chains for Longitudinal Tire Movement
24”
Ignore triangle
in chain
Chain 2”
hook-up
3/8”
Maintenance problem:
Tire in offset operating position

on rollers. 2” move required in
longitudinal direction on shell
Clearance - tire to pad at TDC

is 3/8” for this example.
Tire
24” Straight Line CL
No push or pull mechanical assistance. Roller

No wedges. C
L
No “assist” from roller thrust reaction on tire.
SM

Using Chains for Longitudinal Tire Movement
Start
24” Straight Line
Clearance tire to pad at TDC = 3/8”
. Tire
3/8” . .5  = 0.2387324”
Diameter X  = 0.750” creep/rev. Shell Creep/Rev. 3/4
Draw
Must shift tire 2” (Constant) 24” Constant Tire
“X” Changing
Right triangle re-calculation to suit creep @3/4”/rev. X number of revolutions: 24” chain constant hypothenuse.
Rev. Number Total Creep New “X” Dimension Draw

1 0.750 ” 23.988 ” 0.012
2 1.500 23.953 0.047
3 2.250 23.894 0.108
4 3.000 23.812 0.188
5 3.750 23.705 0.295
6 4.500 23.574 0.428
7 5.250 23.419 0.581
8 6.000 23.238 0.782
9 6.750 23.031 0.988
10 7.500 22.798 1.202
11 8.250 22.537 1.482
12 9.000 22.248 1.751
13 9.750 22.937 2.070
Approximately 13 revolutions to move tire 2”. No allowance for elongation of chain under load. Calculate
for actual creep and length of chain(s).
SM

Maintenance Seminar
Measurement of Shell Migration
to Determine Shell Pad to Tire Diameter
Shell Advances Inside Tire

Measure Amount of Creep
As Seen From Under

the Kiln Shell
Count kiln revolutions after placing matchmarks. Measure distance between matchmarks after “X” number
of kiln revolutions, then divide that dimension by kiln revolutions during the test period to determine shell
migration (creep) for each revolution of the kiln.
SM

Tracing Arrangement for Recording Pad-to-Tire
Clearance and Migration (Creep)
A - Magnetic base with post for spring-loaded pencil holder
B - Magnet-backed tracing surface holding panel
The kiln shell migrates within the tire;

It is not the tire that “creeps”.
In the sketch above, the tracing surface is set

on the side of the tire and the magnet-supported
pencil is placed on the trailing edge of the
card as determined by rotation direction
of the kiln. A
Height of wave patterns is a recording of

actual clearance between shell pads and End
tire bore. This dimension when divided Start B
by 1/2 Pi, indicates actual pad-to-tire
diameter.
Distance between start/stop points indicates shell

migration within the tire for each kiln revolution.
Shell migration divided by Pi ( ) indicates pad-to-tire
diameter, but this dimension is not valid for follow-up
calculations when affected by lubrication.
NOTE: Kilns with floating shell pads --- DO NOT PLACE MAGNETIC BASE ON A LOOSE PAD.
SM

Spring-Loaded Pencil Holder for Pad/Tire Clearance
and Creep Tracings
Spring
5/16” Diameter X 1 1/2” Retainer Pencil Holder
(Retained) Block & Post (Tubing) Standard
Pencil
1 1/2”
Drill & Tap
10-24 X 1” Deep
6”
10-24 Slotted
Capscrew X 3/4 Long
Permanent Horseshoe Magnet
(10 Lb. Pull)
Description Material
Magnet General - #351-6 Pencil must move freely in tube (no slop).
Ret/G Block 1/2” Hex Bar X 2” LG
Ret/G post & block (tackweld). Drill, ream, tap.
Ret/G Post 1/2” Hex Bar X 1” LG
Cap Screw (Slotted) 10-24 X 3/4” LG
Spring to be retained at end shown.
Holder Chromed Tubing (Plumbing)
Spring 5 /16” Diameter X 1 1/2” LG (Medium Ten.)
Tire clearance & creep tracing-pencil holder.
Pencil Standard HB (No Eraser)
(Berol Black Warrior #372)
SM

Tracing-Paper Surface for Pad/Tire Clearance
and Creep Tracings
2 1/2”
1” TYP.
8 1/2”
Drill & Countersink
To Suit 10-24 Csk Screw
(TYP) 2 places 1/8” Tempered
Bolt & Nut to Magnet Hardboard
Permanent Horseshoe Magnet

10 Lb. Pull (General #351-6)
Two Spring Clips (Small)
Cut strips of manila file folder sheets to fit on hardboard surface. Hold strip in place with spring clips.
Tire clearance & creep tracing board

SM

Maintenance Seminar
Shelltest Measuring Unit “Holderbank” System
Distorted Cross-Section
Principle of
Distortion Measurement
d b
d
a
h
A 1m
L=
D Shelltest Diagram
== h
C 15
Recorder System
“Holderbank”
h
15. h
B E G
Ovality: = 2 (a - b)
= 4 .d 2 .
h
3 F H
SM

Maintenance Seminar
Ovality
A B C D
2 3
1, 2, 3, Shell Lines
A, B, C, D Measuring Planes 1
Diagram of One 2 3
Measuring Plane
1
3 2 3
12
SM

Ovality Limits as Function of Kiln Diameter
%
0.8
0.6
% Ovality
0.4
0.2
0
3 4 5 6 m
Kiln Diameter
SM

View at Allowance for
Top Position Shell Expansion
SM

Maintenance Seminar
Shell Advances Inside Tire
Measure Amount of Creep
As Seen From Under

the Kiln Shell
End
Start B
SM

Permanent Shell Deformation
Shell Overheated
and Choked
Inside Tire
Expansion
Clearance
SM

Maintenance Seminar
Difference in Diameter ( )
Tire
†
Gap at Top (G )
= G† :
D
Distorted Shell
Crush Zones
for
Brick Lining
Tire
CL
CL
Shell
Note Note
Note: Deflection also occurs at contact points where the tire rides on support rollers.
SM

All Details Must be
Checked Prior to Kiln Properly Aligned
Planning a Schedule Slope is Exactly as Planned.
for True-Up Grinding Rollers Set to Compensate for
All Dimensional Variables.
Hot Position
No Axial Runout on Roller
(Wobble) Through
360° Rotation
Tire CL Roller on Planned
Radius 90°
Radius Slope Per Test with
Gauge Block & Level
90°
or Inclinometer
Roller CL
As seen
from Frame
Long’l CL 180° Liner
180° Liner Matched Liners
Frame Slope True
Planned Slope
Level Line
SM

Tire Ovality - Removal of Metal May Not be Feasible
Rough Outside
Minor Axis
Rough Inside
Major Axis
ce
ete ren
am fe
Is Bore Worn
Di um
r
and Grooved?
nd irc
Fi e C
To sur
ea
M
Measure Thickness (t)
Anticipate refractory problems starting at about 0.5% shell ovality. Some older tires started (new) thin
and at critical ovality. Ovality increases when tire is cut too thin for roller supported operation.
SM

Maintenance Seminar
Ovality When Tire is Too Thin
(and has Bad Inside and Outside Surfaces)
Excess Shell
Clearance
Sag
When a tire is too thin
the combination of sag, crimping and
excessive clearance can account for
shell ovality approaching 0.9%.
Check out shell ovality factors before
arranging for tire true-up.
(May need replacement parts).
Crimping
Rollers
SM

Maintenance Seminar
Longitudinal Fractures at Shell Pads
Excess
Clearance Thin Tire
Shell
Sag
Crimping
Rollers
Thin tires and excess clearance contribute to shell ovality and fracture at pad welds or in shell plate
at toes of welds.
SM

Load
Concentration
Narrow
Tire
Welds Break, Blocks Fall Off
Welds and/or Pads Break

and Fall Out & Off
Longitudinal Fracture
Lines Form in Shell
Tire section “CHOKE” deformation
SM

Maintenance Seminar
Excessive
Clearance
Sag
Bending Zones
Crush Points for Bricks
Fatigue Points for Shell
Laminated Zones Resist Bending
Flex
Welds
Pad Pad
Shell
Shell
Shell ovality and pads with full length longitudinal welds, may also include pads with intermittent stitch welds.
SM

Maintenance Seminar
Tire
Fillet Weld Fillet Weld
Pad
Shell
Original longitudinal welds must be removed for repair of fractures.

SM

Maintenance Seminar
Refractory
Remove Refractory
to Expose Shell for Use Rotary Wire
Tracing and Repair Brush to Prepare
of Fractures Clean Surfaces for
Gouging & Welding
0.7 t
T
Shell
Fracture
Inside
Surface
Finish internal repair welds first
SM

Maintenance Seminar
Tire: Remove Move

One Set Tire Move
of Retainers Away Tire
Back
Trace
to
Ends
Shell Outside Surface
Finish
Gouge Weld
Outside
Inside
Finish External Repair Welds Last

SM

Maintenance Seminar
Hollow Tires & Rollers
Bore Zone
w
w
Old Style
llo
llo
Ho
Ho
Hollow Tire
Ta Tr
Real Thickness Varies
Apparent Thickness
Apparent Thickness
Real Thickness Varies
Ta Tr
w
llo Old Style
llo
Ho
Hollow Roller
Ho
Excessive cutting & grinding on faces of cored tire and rollers has been known to put holes in surfaces
above hollows. Do not reduce original diameters of hollow tires & rollers more than 3”.
SM

Cold Flow Ridges on Tires and Rollers
Tooling is not complete

without the capability
for removing ridges and
cutting edge radius or Kiln moves inside the tire
chamfer. with thermal changes in the
shell
Kiln shell
expansion &
contraction
Retainer blocks wear off at

Cold flow of surface metal
both sides of tire to relieve
forms ridges that may snap
pressure. Tire is “locked”
off and take along a chunk
in place on rollers by the
of surface metal
surface ripple pattern.
Ridges must be removed. Sided of tire and rollers must be scraped clean for test with a try square. High ridges
must be removed. Tool must be indexed for surface grinding parallel to shaft CL a nd true axis of tire.
SM

Maintenance Seminar
Warped Kiln Shell and Tire Runout
Convex Up
1 A B C
Hot Shell
Slope Line
Concave Up
2 A B C
Hot Shell Heavy Load
Slope Line
SM

Maintenance Seminar
Tire Wobble When Kiln Shell is Warped
Wobble Neutral Wobble

Gap Gap
0.0275” 0.0275”
3/16” 3/16”
Assume tire wobble (measured total) @ 3/8”. Tire outside diameter 16’. Tire face 28” (2.333’).
0.357” : 16’ = 0.0234” per ft. X 2.333’ = 0.055” : 2 = 0.0275” v-gaps 180° apart in cross-over cycles.
Grinding will form a “parallelogram” tire profile, pads will become deformed.
This condition is not a valid reason for grinding a tire for improved contact across roller faces.
Find and eliminate reason for wobble.
Do not arrange for cutting or grinding when axial wobble exceeds 0.125”.
SM

Maintenance Seminar
Formation of Concave/Convex Surfaces
Wobble Neutral Wobble

Gap Gap
3/16” 3/16”
Tire wobble not eliminated. Tire face becomes convex, roller faces become concave. Surface true-up is
needed but wobble should be eliminated before any cutting/grinding work is scheduled.
Roller faces will wear into concave contour. Tire face will wear into convex contour. With expansion/
contraction of the shell, large zone of tire moves onto a larger zone of the roller(s). Bearings are overloaded,
shell suffers from reaction to vertical misalignment.
SM

Maintenance Seminar
Aftereffect of Grinding a Tire with Axial Runout
Parallelogram
Tire Profile
After
A A Grinding B B B A
True Axis Runout Runout True Axis Runout

CL True Axis
B B A A A B
Start Rotation 180° From Start
Important Note:
Shell migrates inside tire. Starting with matchmarks AA and BB, first180° of rotation does not show
significant change of tire contact on rollers. In a regular cyclic sequence with migration of the shell,
when original matchmarks are 180° out of phase (BA & AB) original contact crossover v-gap will have
been doubled.
Two (2) full contact zones will be seen at crossover points 180° apart on the rotating tire.
SM

Maintenance Seminar
Aftereffects of Improper Roller Skewing
Tire & rollers

become cone Opposite thrust
shaped. Ridges direction of rollers
form at edges. Roller Tire Roller plus high pressure
Surfaces become and heat can destroy
deeply spalled. roller assemblies.
Plastic flow may

As Seen From Below Tire form ripples on
shafts & bearings.
Shaft true-up will
Long Term require shop work.
Toe-In Condition Will need new
bearing liners.
Tires & rollers need true-up grinding plus realignment, but ripples on shaft & bearing surfaces may
interfere with adjustments when high points meet and generate heat.
Obvious need for surface true-up, but feasibility of metal removal should be verified by ovality analysis.
SM

Maintenance Seminar
Grinding Prior to Kiln Shell Replacement Work
A B
A - Assume tire not centered on rollers because of wrinkles or other shell problems. Repair work will
move the tire to normal operating position on rollers.
B - Typical wear pattern after long-term operation with tire in offset position.
Tire & rollers must be trued up before shell repair work is started, or to eliminate overload &
misalignment in case of over-expansion or changing position of the thrust tire.
Roller set points must be recalculated to suit tire & roller dimensions after finishing the grinding
process.
SM

Maintenance Seminar
“Squareness” Control for Rollers
Unacceptable
Cone shaped roller. Surface not parallel to CL.
Acceptable
Surface parallel to CL.
SM

Maintenance Seminar
“Squareness” Control for Tires
Acceptable Unacceptable
CL Neutral
90° Tire CL
Surface is Surface is not
parallel to bore parallel to bore
Tire Tire
For control of surface concentricity, test with extra large square and
measure circumference at 3 control points across the face.
Control
Control
Control
CL Tire
Neutral CL
SM

Maintenance Seminar
Kiln Shell Damage and Temporary Repair
Fillet Weld Void Zones

Double “V”
Butt Weld
Fillet Weld
Shell
Wrapper
Shell Not
Repair Recommended
Section Temporary
First-Aid only
Longitudinal
Butt Weld
Good Repair Bad Repair
Repair of badly damaged kiln shell
SM

Kiln Shell Damage and Temporary Repair
Reinforcement
Band (Full Circle)
Fillet Welds
Kiln Shell
Reinforcing Band
t
u p por
S
Sup
p
ort
Kiln Shell
Supp
ort
t
uppor
S
Typical Field Cut
Longitudinal fractures at ring segments
SM

Tire and Pad Lubricant
for Rotary Kilns and Dryers
Product Description
SM

Maintenance Seminar
Kiln Shell Patch Plates Are Nothing More Than Temporary Band-Aids
Kiln Shell
Patch Plate
Circumferential Insert
Weld Shrinkage
Weld Shrinkage
Weld Shrinkage
Cumulative effect of weld
Longitudinal
Longitudinal
shrinkages will warp
patch-plate and surrounding
shell plate inward.
Circumferential
Weld Shrinkage
When a patch plate is installed between a riding ring and the end of the shell, anticipate warp-related
runout at the end of the shell and in the seal arrangement.
When a patch-plate is installed in shell between riding rings, anticipate riding ring wobble at the nearest
ring (or both) and also at the seal in most situations.
Start planning for shell replacement when two or more patch plates have been or must be installed.
SM

Kiln Shell Patch Plates are Nothing More than Temporary Band-Aids
Kiln Shell Patch Plate
Insert
Circumferential
Weld Shrinkage
In sketch all welding is done double-Vee

(butt joints)
Transverse weld shrinkage at
Weld Shrinkage
Weld Shrinkage
Patch plate is restrained at all edges.
Longitudinal
patch plate double-vee butt
Longitudinal
welds. Radius instead of 90° Transverse weld shrinkage for plate thickness
corners minimizes, but does not is shown in chart. Yield point of adjacent
eliminate stress concentration plate surfaces would be exceeded if the shell
points.
would not be free to move in any direction in
reaction to weld shrinkage stress forces.
Circumferential In actual installation and welding of shell

Weld Shrinkage patch plates and other inserts, limited shell
plate movement is possible but combined
weld shrinkage stress forces warp the surfaces
within and around the patch plate or “add-on”
0.15 fixture. Base metal at the welds is not far
Transverse Shrinkage (in.)
60° Single V from the yield point after welding.
t 0.10
60° Double V
0.05
0
1/4 1/2 3/4 1 1 1/4 1 1/2
t = Plate Thickness (in.)
SM

Rotary Kiln Installation and Maintenance Repair
A B
Equations For Calculating Shrinkage-
Transverse Weld Shrinkage (shrinkage perpendicular to the axis of a weld) is particularly important when the
shrinkage of individual welds is cumulative as, for example, in the shell-to-shell connections between rotary kiln
(and similar machines) riding ring positions (support points). Unless allowances are made for transverse weld
shrinkage - usually by spreading the joint open by the amount it will contract after welding - the cumulative
shrinkage of several shell-to-shell connections could be great enough to significantly shorten the span between
preset riding ring retainer locations or scribed reference lines.
For a given weld thickness, transverse shrinkage increases directly with the cross-sectional area of the weld. The
large included angles in (A) are for illustrative purposes only.
Source - Adapted from text in “The Procedure Handbook of Arc Welding” published by the Lincoln Electric
Company.
SM

Arrangement for Removing Bearing Housing End Plate
Kiln support roller
bearing base.
Housing end plate Remove tap bold from

with thrust washer end plate to verify
and oil level pipe. thread pitch and
diameter.
Prepare rods (cold rolled steel) for installation as shown, nuts are shown in position for safety stops, but
washers or short bars may be welded at end of rods for equally good results. Rods should not be more
than 24” long.
SM

Maintenance Seminar
Measurement of Shell Migration
to Determine Shell Pad to Tire Diameter
Place match marks

or reference line
at side of tire
Note rotation direction.
Use trailing end of retainer block for placing a soapstone mark (line) on the side of the tire.
SM

Maintenance Seminar
FLS Bearing 74, Type RB
Feed End
Stop Block
20 X 20 X 200 mm
5-6 mm Clearance
Zero Clearance
Discharge End
SM

Desperation
“Feed” stencil mark

Chamfer @ wiped (or ground)
1/8” X 45° off of the rim.
Downhill side “Feed” stencil mark

of roller wiped (or ground)
off of the end of
the shaft.
If original “feed” stencil marks have been eliminated by rubbing or by shop cleanup procedures, look for the
1/8” X 45° chamfer at one end of the roller bore zone. This chamfer will indicate the larger diameter of the
2-diameter bore for the roller.
The step-diameter lockup of roller and shaft requires the chamfer, indicating the larger shaft and bore diameter,
to be aimed toward the low, or discharge, end of the kiln.
FIGURE:
“Last resort” checkout of support rollers for correct installation on support rollers.
SM

Maintenance Seminar
450 mm Oil-Lubricated Supporting Roller Bearing
(Old Design)
SM

Maintenance Seminar
FLS Bearing Clearances in mm
Kiln erection Supporting rollers / bearings: Various tolerances in mm
Clearance Mean Mean Mean value
Journal Linear clearance (dp X dt X 1000)
at side clearance
dp - dt d
minimum dp - dt
d dt dp hot  
maximum cold x cold hot
0 +1,5 0,75  d =0,36
850 850 -0,1 850 +1,6 0,85 1,6 1,24 1,88 1,46
0 +1,2 0,6 0,30
710 710 -0,1 710 +1,3 0,7 1,3 1,00 1,83 1,41
0 +1,0 0,5 0,26
630 630 -0,1 630 +1,1 0,6 1,1 0,84 1,75 1,33
0 +0,9 0,45 0,24
560 560 -0,1 560 +1,0 0,55 1,0 0,76 1,79 1,36
0 +0,8 0,4 0,21
500 500 -0,1 500 +0,9 0,5 0,9 0,69 1,80 1,38
0 +0,7 0,35 0,19
450 450 -0,1 450 +0,8 0,45 0,8 0,61 1,78 1,35
0 +0,6 0,3 0,17
400 400 -0,1 400 +0,7 0,4 0,7 0,53 1,75 1,32
0 +0,5 0,25 0,15
360 360 -0,6 360 +0,6 0,35 0,6 0,45 1,67 1,25
0 +0,4 0,2 0,13
320 320 -0,1 320 +0,5 0,3 0,5 0,37 1,56 1,16
0 +0,4 0,2 0,12
280 280 -0,1 280 +0,5 0,3 0,5 0,38 1,78 1,35
0 +0,3 0,15 0,10
240 240 -0,1 240 +0,4 0,25 0,4 0,30 1,67 1,25
X) expansion at  t = 35° :  d 35 X 0,0012 X 1000 0,42 mm / m

SM
KILN OVERHEAD 204.CDR 100 Maintenance Seminar

FLS Bearing
Fig. 1
Fig. 4
Fig. 2
Fig. 3
T
3 5-8 mm
0 mm 0 mm
SM

Uneven Load Distribution
Skewed and Change

Parallel Skewed Only of Slope
Hertz Pressures at Supporting Rollers
SM

M a
M FV X a
FH
RL FV / 3 + FH
FV
30° RR FV / 3 - FH
RL RR
SM

Maintenance Seminar
P
L1 L2
R1 R2
R1 = (L2/L) P R2 = (L1/L) P
Load is off Center
SM

Maintenance Seminar
FLS Conversion Kit Instructions for 1930 Type Bearing
Installation of Klozure Seal Drill in bearing cap for 3 5/16” X 1-3/4” countersunk hd.
1 - Insert Klozure to lower half of seal retainer ring so that “A” screws with lockwashers for holding top half of seal ring
Bearing
the ends of Klozure Seal extend beyond the end of the Cap to bearing cap. Locate holes from seal ring.
seal retainer ring with equal distance (see assembly
sketch). See
Detail
2 - Attach clamping plate loose to retainer seal ring. “C”
3 - Install lower half retainer ring assembly to lower bearing

base by sliding the seal retainer ring, starting on the side
where bearing socket is below end of bearing base
(ref. assembly sketch) until retainer ring is flush with
bearing base.
4 - Tighten clamping plate bolts securely. See

Detail
5 - Using upper half retainer ring as template, drill 3 “D”
clearance holes for 5/16” bolts through bearing cap.
6 - Assembly upper half retainer ring to bearing cap. Bearing

(3 pieces 5/16” x 1-3/4” Long Screw). Base
A-A
7 - Gradually lower the bearing cap, insert the Klozure Seal

in the groove, so that the seal ends close at the top center.
B-B Bearing
8 - Tighten all bearing bolts securely. Ends of cap
Klozure Seal
while being
snaked thru 1/4 length
Seal Retainer Seal Retainer Klozure Seal
(lower half) bearing
(upper half) base
Patt. Number Klozure Seal
RK 5790A in position
Bearing
3/32 thick socket
Garlock O.H. Steel
Klozure clamping Clamping plate Clamping plate
Split Seal plate in position in position
to be fitted
Detail “C” in field Klozure Seal assembly
Scale: Full Size Detail “D”
SM

Maintenance Seminar
Tracing Clearance Between Kiln Tires and Spacer Pads
(Includes Shell Ovality)
Kiln Shell A - The tracing surface and marker may be installed
Kiln Tire with anywhere in the indicated zone. Actual position
(Riding Spacer Pads is selected for convenient and rapid set-up during
Ring) a brief pause on rotation.
“Y” “X”
B - Although actual conditions are variable, there is no
differential shell/tire movement during rotation from
Rotation C position “Y” to position “X”.
C - As the shell enters and passes through the

configuration shown between positions “X” and “Y”,
motion is recorded on the tracing surface. Shell
B
“creep” and pad to tire clearance appear as a wave
pattern on the chart.
Roller CL s
Sketch (below) shows magnet base with a
spring-loaded tracer arrangement mounted on the
surface of a spacerpad. Tracing surface is mounted
on the flat side-face of the tire (or riding ring).
A
Since the kiln shell will advance inside the tire during rotation Start
the marker must be placed on the tracing surface at the end of
the sheet trailing the direction of rotation. The sketch shows an
approximate pattern after four revolutions of the kiln.
Finish
High temperature metal surfaces can cause severe burns. Moving (rotating) machinery can cause hands and arms to
become caught. Avoid personal contact.
SM

Maintenance Seminar
450 mm Oil-Lubricated Supporting Roller Bearing
SM

Maintenance Seminar
Uphill and Downhill Thrust Roller
1”
1/4” 1/4”
SM

Radial Runout - Polar Diagram
12
Difference
Reading
11 1
Station
1 215 9 10 2
2 213 7
3 211 5
4 211 5
5 209 3 9 3
Approximate
6 206 0 Shell Center
7 207 1
8 209 3
9 208 2 8 4
10 212 6
11 214 8
12 216 10 5
7
1 215 1
6
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
SM

Not bad - very little shell deformation and a little out of center. Maintenance Seminar
12
Difference
Reading
Station 11 1
6 mm
1 417 6 21 mm
10 2
2 432 21
3 427 16
4 418 7 16 mm
5 420 9 9 3
6 425 14
7 435 24
7 mm
8 438 27
9 427 16
8 4
10 421 10
11 420 9
12 411 0
7 5
1 416 5
This is very bad. 6
Shell deformation as well as out of center (eccentricity).

SM

12
Difference
Reading
Station
11 1
1 10 2
2
3
4
5 9 3
6
7
8
9 8 4
10
11
12 7 5
1
6
SM

Kiln Data Sheet
Kiln Size: Diameter(s) Length
Process Product Production TPD
3
Product Density: Lb/Ft3 Feed Density Lb/Ft
Feed Range: TPD, Kiln Slope % or In/Foot,
Rotation Speed (RPH): Maximum, Normal, Minimum
Distributed Loads, from Discharge End ( Ft. To Ft ):

3
Refractory Thickness (In’s) Lb/Ft From (Ft) to (Ft)
Ft.
Ft.
Ft.
Ft.
Ft.
Typical Coating build-up on Refractory Lining
Ft.
Ft.
Ft.
Item Quantity Thick Lb/Ft3
Ft. Tumbler*
Ft. Lifter
Ft. Lifter
Item Quantity Size Length
Ft. Chain
Ft. Chain
Ft. Chain
Ft. Chain
* “Tumblers” formed by refractory lay-up. If a “Trefoil” section is in place, or being considered, give dimensions location and Lb/Ft3.
Concentrated Loads: Distance from discharge end
Girth Gear Weight (Kips)
Refractory Dam @ High (In’s)
Tube Cooler Location
No. of Tube Coolers , Diameter (In’s) , Length
Feed End Seal Weight (Kips)
Discharge End Cowl & Air Seal Weight (Kips)
Discharge End Castings: Quantity Pounds Each
SM

Laser Kiln Survey
Layout of Offset Line
VII
II I
.6
.5
.4
.3
.2
Laser .1
X1
X2
SM

Maintenance Seminar
Laser Kiln Survey
Step 1
Tire
Offset Line
Measuring Points
Step 2
Tire
At
Slave
Laser
SM

Laser Kiln Survey
Step 3
Common
Reference
Target
Ar1
Ar2
Laser
Step 4
Pmax
P1
P2
Laser
SM

PMAX
Laserstråle C
R
90°
ZA
ZV
ZH H
ZV ZH
VR
VV
LR VH
R Y
HR
X1
X2
Y1
OSV.
SM
Maintenance Seminar
Enter Kiln Length and Dimensions Between Tire Centerlines
6 - Support Kiln
5 - Support Kiln
Feed End
4 - Support Kiln
Feed End
Discharge End
3 - Support Kiln
Feed End
2 - Support Kiln
Feed End
Feed End
Tire 1 Tire 2 Tire 3 Tire 4 Tire 5 Tire 6
L1 L2 L3 L4 L5 L6 L7
Feed End
Feed End
Feed End
Feed End
Feed End
Discharge End
1A 1B 2A 2B 3A 3B 4A 4B 5A 5B 6A 6B
Dim =
2S 3S 4S 5S Dim =
L1-1A
OHFE OHFE OHFE OHFE L7-6B
Feed
Disch Dim = Dim = Dim = Dim = Dim = End
End L2-(1B+2A) L3-(2B+3A) L4-(3B+4A) L5-(4B+5A) L6-(5B+6A) Over-
Over- hang
hang Basic Basic Basic Basic Basic 6S
OHDE Plate Plate Plate Plate Plate OHFE
Span 1 Span 2 Span 3 Span 4 Span 5
Zone Shell I Dia. Linear Feet Thickness Cone(s) (Yes or No)
OHDE
Span 1
Span 2
Span 3
Span 4
Span 5
OHFE
Transition Cone Diameters Length Thickness
&
SM

Kiln Stress Computer Program
For a Fuller Company computer data analysis of stress loading at:
- Kiln Shell
- Roller Assemblies
- Riding Ring (Tire) Ovality
Data to be obtained from plant-operator personnel, installation drawings, when available, and actual
measurements by plant and Fuller Company engineers.
CAUTION:
Drawings and records are often lost with turnover of plant personnel. Independent job shops and
contractors often supply and install replacement material and/or retrofit items which are sub-standard
or which change stress and loading factors.
With or without original reference information, actual lengths, widths circumferences and
thicknesses must be verified per accurate measurement procedures. Use an appropriately calibrated
ultrasonic thickness gauge for measurement of shell plate thickness, especially at zones affected
by erosion caused by abrasive or chemical reactions(s).
Kiln at (Company):
Plant Location:
Plant Telephone: ( ) -
Fax Number: ( ) -
Data From: Title / Department: Telephone Extension:
Fuller Company Engineer(s):
Checkout Date(s):
SM

Discharge End Heavy Material Flow
2nd 1st 1st 2nd
Int. Int. Int. Int.
1/2 H 1/2 H
Side “A” Side “B”
“Heavy” = Heavy shell plate under a riding ring (Tire)
SM

Maintenance Seminar
% or Inch Per Foot
Kiln Slope @
Level Line
Discharge End Heavy Material Flow

2nd 1st 1st 2nd
Int. Int. Int. Int.
1/2 H 1/2 H
Kiln Shell Dimensions Pier Locations from Discharge End

(Thickness X Linear Feet) 1st 2nd 3rd 4th 5th 6th
Heavy Plate “Heavy” = Heavy shell plate under a riding ring (tire)
1/2 H 1/2 H = CL of heavy plate to either of its ends
1st Int 1st Int = First intermediate plate
2nd Int 2nd Int = Second intermediate plate
1st Int + 1st Int (+) = First intermediate plate extended for gear
Side “A” or Side “B” Side “A” or “B” = 1/2H + 1st Int + 2nd Int plates
Tire Pads (Quantity)
Pad Length & Thickness
Tire Outside Diameter
Tire Width & Thickness
Roller Diameter & Width
Bearing Diameter & Length
SM

Radial Runout - Polar Diagram for Kiln Shell
12
Difference
Reading
11 1
Station
1 215 9 10 2
2 213 7
3 211 5
4 211 5
5 209 3 9 3
Approximate
6 206 0 Shell Center
7 207 1
8 209 3
9 208 2 8 4
10 212 6
11 214 8
12 216 10 5
7
1 215 9
6
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
SM

Not bad - very little shell deformation and a little out of center. Maintenance Seminar

Rotary Kiln Erection

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Rotary Kiln Erection

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Orientation & Common Terminology for Reporting Kiln Details

Feed End of Kiln(s) (Also referred to as “Uphill” or “High-End” Area)

3 1 Both sides of the thrust tire

Kiln drive pinion(s). Arrows A

KILN OVERHEAD 001.CDR Maintenance Seminar

1 - 2” Allowance for grout between frame and rough pier top.

KILN OVERHEAD 002.CDR Maintenance Seminar

A - Refer to installation instructions for preparation of shims. Stacks must be tight.

KILN OVERHEAD 003.CDR Maintenance Seminar

Slope Dimension (Shown on Foundation Drawing)

KILN OVERHEAD 004.CDR Maintenance Seminar

Kiln Support Frame

C’s Marked on all Piers by Layout Engineer

All Beam CL’s marked at factory

Kiln and Frame CL Marked on Piers by Layout Engineer

Erecting test dimension

Measured and Marked on Piers by Layout Engineer

Dimension C - X-Test to verify frame CL alignment.

KILN OVERHEAD 005.CDR Maintenance Seminar

KILN OVERHEAD 006.CDR Maintenance Seminar

B - Flexible lines to allow for possible 4” to 5” or

C - Inlet water master value.

D - Control value at inlet line to each water jacket.

E - Funnel arrangement for drain lines. D

KILN OVERHEAD 007.CDR Maintenance Seminar

KILN OVERHEAD 008.CDR Maintenance Seminar

KILN OVERHEAD 010.CDR Maintenance Seminar

Splice 1 Part line 2000 lbs.

Sling hitching angles and stress on lines

KILN OVERHEAD 009.CDR Maintenance Seminar

Longitudinal welds at ends of shell

1” X 4” X 24” strongback bars may

KILN OVERHEAD 011.CDR Maintenance Seminar

KILN OVERHEAD 012.CDR

Tumble or rotate instrument 180° for test at discharge end target.

KILN OVERHEAD 014.CDR Maintenance Seminar

Wood Wedges 2” or 50 mm Diameter Hole

(2) 1/4” Diameter

KILN OVERHEAD 015.CDR Maintenance Seminar

Sharp pencil in trammel clamp.

3/4” X 1 1/2” trammel beam (wood)

New kilns only-

KILN OVERHEAD 016.CDR Maintenance Seminar

Shell Details on card:

KILN OVERHEAD 017.CDR Maintenance Seminar

Pier 1 Pier 2 Pier 3 Pier 4

For Alignment of Kiln with Sections as Shown Above

Set transit on kiln axis. Lock on target 5. Cross-check on targets 4, 3, 2, 1.

KILN OVERHEAD 018.CDR

Weld remaining end of strongback

Tighten all nuts in push/pull

Deposit root weld bead.

KILN OVERHEAD 019.CDR Maintenance Seminar

Change pier numbers to suit actual arrangement

KILN OVERHEAD 020.CDR

1 ½” axial adjustment bolts. Kiln Shell

KILN OVERHEAD 021.CDR

Splash band installation notes:

1 - Prepare and install spacer guides.

KILN OVERHEAD 022.CDR Maintenance Seminar

View toward feed end View toward feed end

Bearing end Bearing end

Roller shaft should be in Roller shaft should not be