Kiln Miscellaneous

8/19/2019 Kiln Miscellaneous

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Kiln Inlet Seal

Kiln Outlet Seal

Thrust Roller

Hydraulic Thrust Roller

Kiln Maintenance Checklist

The Good Old Days

Kiln MiscellaneousKiln Miscellaneous


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Kiln Inlet SealKiln Inlet Seal


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The kiln seal prevents cold air from entering the processand driving up fuel costs. The seal must remain tight whileaccommodating kiln run-out and longitudinal movement.


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Kiln Pneumatic Inlet SealKiln Pneumatic Inlet Seal

The pneumatic seal consists of two slidingsurfaces pushed together by pneumatic cylinders.

PneumaticCylinders


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Spring Loaded

Graphite Plug

Seal Detail

PneumaticCylinders


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Kiln Inlet Seal DetailKiln Inlet Seal Detail

Graphite Seal Cord

Wire Rope

Graphite Plugs

Rotating KilnShell

Rotating Sealing

Surface

Stationary Sealing

Surface

Sliding Contact

Stationary KilnInlet Hood


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The seal is suspended by a carriage which allows it tomove longitudinally as the kiln expands and contracts.

Carriage

Turnbuckle


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Pneumatic Inlet SealPneumatic Inlet Seal

The pneumatic cylinders, when pressurized,will press the two seal halves tightly together.

Stationary

Seal HalfRotating Seal

Half


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Filter, Regulator, LubricatorFilter, Regulator, Lubricator


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The seal’s sliding surfaces are graphite lubricated.

Spring Loaded

Graphite Plug

Graphite Plugs in

Seal Plate


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Kiln Inlet CastingsKiln Inlet Castings

Castings on the inlet hood and kiln inletcone keep the castable refractory inplace. Inspect them at annual shutdown.


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Spring Plate Inlet SealSpring Plate Inlet Seal


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No, covering the spring plates with plastic won’t help.



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Kiln Outlet SealKiln Outlet Seal

The spring plate outlet seal has become theoutlet seal of choice. The seal can withstandthe harsh conditions at the kiln hood.


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Spring Plate WireRope


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Counterweight

Spring plates are wrapped with a counterweighted wirerope arrangement to keep them tight against the cowl.


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ForcedAir

Cooling


A stainless steel cowl at the kiln outlet provides anair channel for cooling of the kiln discharge castingsand the spring plate contact surface.


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Spring plates are bolted on and are easily replaced.


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Kiln OutletKiln Outlet SealSeal

Dust from kiln hood puffing falls down the chutes tothe drag chain conveyor or into the clinker cooler.

The Old Way The Better Way


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Kiln Outlet SectorKiln Outlet Sector

The kiln nose rings sees severe service and must beregularly inspected for refractory and casting failure.


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This alternate spring plates design featuresoutwardly protruding spring plates.


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Outwardly protruding spring plate design.


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Thrust Roller AssemblyThrust Roller Assembly

OilSeal

Oil LevelPipe

SphericalBearingsTie

Rod

Tire

Shims

Clearance

Keep the clearance to a minimum (6mm),and adjust the shims to keep the kiln gearin proper longitudinal alignment.


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Thrust Roller AssemblyThrust Roller Assembly

Set

Screws

The kiln position can be controlled byadjusting set screws on this thrust roller base.


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Thrust Roller PositionThrust Roller Position

Stop Ring

Thrust

Tire

The thrust roller is positioned to maintain proper hotrunning alignment between kiln gear and pinion.Repositioning may be necessary as stop rings wear.


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Thrust Roller MisalignmentThrust Roller Misalignment

A misaligned thrust roller will result in vertical forceson the roller as shown above.

Roller Tilted to Left Roller Tilted to Right

Roller Offset to Left Roller Offset to Right


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Thrust Roller MisalignmentThrust Roller Misalignment

An improperly aligned thrust roller can ride out ofits socket, causing damage to tire stop blocks.


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Fuller Thrust RollerFuller Thrust Roller


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Fuller Thrust RollerFuller Thrust Roller


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Hydraulic Thrust RollerHydraulic Thrust Roller


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The hydraulic thrust roller maintains a constant,controlled force on the thrust tire and keeps thekiln in an electronically determined position.


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Hydraulic Thrust RollerHydraulic Thrust RollerBreather

Oil Level

Sight Glass

Guide Bar

GreaseFittings

The spherical bearings are lubricated with ISO VG1000 gear oil. Guide bars are grease lubricated.


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Thrust RollerThrust Roller

The roller surface is graphite lubricated.


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Hydraulic CabinetHydraulic Cabinet

The hydraulic power unit is normallyplaced beneath the kiln’s thrust pier.


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Hydraulic CabinetHydraulic Cabinet

Accumulator

Pump

DirectionalValve

Relief

ValveTank


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Di ti l V lDi ti l V l


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Directional ValveDirectional Valve

A directional valve directs fluid to the thrustcylinder, or allows the cylinder to bleed down.

H dH d i A lti A l t


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HydroHydro--pneumatic Accumulatorpneumatic Accumulator

An accumulator stores hydraulic energy. It is used tomaintain a steady force on the thrust tire eventhough the tire wobbles slightly as the kiln turns.


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H dH d ti A l tti A l t


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psig

0

500

1000

1500

2000

psig

0

500

1000

1500

2000

psig

0

500

1000

1500

2000

System PressureLess Than pprecharge

System Pressureat pmax

System Pressureat pmin


When hydraulic pressure increases and decreasesthe gas is compressed and expanded.

H dHydro ti A l tpneumatic Accumulator


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The accumulator is pre-charged with nitrogento approximately half of the expected averageoperating hydraulic pressure.

Danger!

Do not charge withair or oxygen!

P R li f V lP R li f V l


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Pressure Relief ValvePressure Relief Valve

A pressure relief valve limits hydraulic pressure inthe system. This prevents excessive downhill kilnforce from damaging the thrust roller.

Hydraulic FilterHydraulic Filter


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Hydraulic FilterHydraulic Filter

An in-tank filter with a 10 micron elementkeeps hydraulic fluid clean. The protruding redbutton indicates the element needs changing.


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Thrust Cylinder LVDTThrust Cylinder LVDT

An LVDT (linear variable differential transformer)mounted in the hydraulic cylinder measures thedistance that the cylinder rod is extended.

Thr st S stem LVDT CabinetThrust System LVDT Cabinet


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Thrust System LVDT CabinetThrust System LVDT Cabinet

The LVDT signal goes to a cabinet where the kiln’s hotrunning axial position is set and where alarms areprogrammed for excessive uphill and downhill kiln position.


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Fuller Hydraulic Thrust RollerFuller Hydraulic Thrust Roller


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Preventive Maintenance ChecklistPreventive Maintenance Checklist

DailyDaily


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DailyDaily

Thrust Roller

• Kilns with one thrust roller (mech. or hyd.)

– visual check of the thrust rollers including recording

of the thrust pressure (ideal 500 psi, can vary from200-800 psi). Maximum design pressure is 1200-1300 psi

– check the temperature of the thrust roller housing

and face.

• Kilns with two thrust rollers

– Observe the kiln position relative to the uphill or

downhill thrust rollers – Check temperature of the housing and thrust roller

face if there is constant contact.

DailyDaily


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Seals

• Visually check feed and discharge seals

Gear

• Visually check the gear and pinion

Rollers and Live Rings

• Visually check all roller and tire surfaces

• Lubricate contact faces between tires and shell

mounted tire pads and stop blocks using a mixture ofgraphite powder and water.

DailyDaily

D ilD il


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Temperatures

• Record kiln shell temperatures andinclude a night visual inspection for “hotspots”

DailyDaily

W klWeekl


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WeeklyWeekly

• Check and record direction of thrust on allrollers.

• Check lubrication on all support rollers.

• Check oil levels in support roller bearingsand thrust roller bearings.

• Check and record the tire creep andclearance.

• Record related shell and tire temperatures.

• Check condition of tire stop blocks andwear rings.

WeeklyWeekly


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• Check general condition of kiln

shell.

• Check contact patterns between

gear and pinion by observing theoil smear on the contact face for atleast one full kiln rotation.

WeeklyWeekly

AnnuallyAnnually


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ua yy

• Perform complete check of kiln alignmentutilizing the laser or mechanical alignmentmethod. Kiln alignments should be completed

after major repairs have been made to the kiln.

• With this information recorded and compared,

a problem should be caught before a realdilemma occurs (i.e. an unplanned shutdown).

• Prior to planned kiln shutdowns, an extensivemechanical inspection should be completed todetermine repairs required.


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The Good Old DaysThe Good Old Days


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The Good Old DaysThe Good Old Days


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RivetsRivets


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Don’t Be Mean to Your KilnDon’t Be Mean to Your Kiln

Documents

Kiln Miscellaneous