Kiln-Alignment-Analysis Alignment Type,Condition,Key

Kiln alignment analysis is a critical predictive and preventive maintenance procedure for rotary kilns and dryers. Proper alignment ensures even load distribution across the support systems, minimizes mechanical stress and wear, and maximizes refractory life and overall kiln availability.
Alignment Type,Condition,Key Benefit
Hot Kiln Alignment,Kiln is operating under normal load and temperature.,Accounts for the thermal expansion and operational stresses that affect the true hot kiln axis. This is the most representative and commonly used method.
Cold Kiln Alignment,Kiln is shut down and cooled.,Allows for thorough inspection and measurement of all mechanical components and foundation elements without thermal interference.

1. PHILLIPS KILN SERVICES LTD.
KILN ALIGNMENT KILN ALIGNMENT
ANALYSISANALYSIS
an Overview of
The Direct Method
Patents:United States# 5,148,238
#5,146,795
5,491,553
Mexico #172518
Canada #1325680
#2150585
Korea#90-15348
Europe
#0,420,663
Japan #2865410

2. • No preventive maintenance
Consequences of Not Checking Consequences of Not Checking
AlignmentAlignment
Alignment:Alignment:
Preventive Maintenance
• Unpredictable outages
• Low kiln availability
• High long term costs
• Acceptance of high wear rates
• Less than optimum operation

3. P1
P2

4. Alignment of a third and
subsequent points can be
measured in deviation
from the reference line
P1
P2
H
V
Horizontal = H
Vertical = V

5. P1 … P(n) are points of the kiln shell at each pier.
Alignment is achieved when all points are moved to
the reference line.
What are
these points?
How are
they
defined?
P1
P2 P3
P4
P5
Accuracy
of
Alignment
Accuracy
of
Locating Points
=

6. Internal Alignment
Setting targets inside the kiln – NEW KILNS
(Bore Sight Alignment)

7. When working inside the kilnWhen working inside the kiln
certain preparations are necessary.certain preparations are necessary.
• Kiln is shut down and cool.Kiln is shut down and cool.
• Reposition the kiln at least three times.Reposition the kiln at least three times.
• The feed end target may be in chains.The feed end target may be in chains.
• Coating and refractory must be penetrated to the shellCoating and refractory must be penetrated to the shell
• Targets must be set at each support.Targets must be set at each support.
Not Suited for Preventive MaintenanceNot Suited for Preventive Maintenance

8. Fig A Fig B Fig C Fig D
Establishing The Axis of Rotation Using The Bore Sight

9. Fig E
R
R
R
Point #1
Point #2
Point #3
Locating The Center of Rotation

10. Fig A Fig B Fig C Fig D
Establishing The Axis of Rotation Using The Bore Sight

11. External Alignment
Procedures are complex
• Centers are not measured. They
are geometrically determined.
• No references.
• Worn roller and tire diameters to
be accurately measured.
• The shell is eccentric in the tire.
• The tire exhibits ovality.

12. Hot External Procedures are extrapolations
of Cold External Methods
• Plumb bobs, optical instruments, and laser theodolites have been used.
• All treat rotation as an obstacle.
• All target the kiln tire.
• All find centers indirectly from component geometry.

13. 1)Ovality: A B C
Internal & External MethodsInternal & External Methods
Have Difficulties with Locating A Have Difficulties with Locating A
Physical CenterPhysical Center
A
B
C
6) Rollerspacing is very
difficult to measure.
5) Accurate diameters???
4) Permanent shell
distortions
3) Movement or Pitching
2) Shell Eccentricity (gap)

14. Where P1 & P2 are
centers of rotation.
P1
P2

15. Rotation Is Required To Find The Center Of Movement
Laser #1
Laser #2
Laser #3 {Position (x3, y3, z3)}
The center of rotation is found without any
measurement of the support geometry!
Z
Y
X
Reference Frame
Center of Rotation
Physical Shell Center
Mean Positions 1, 2, & 3
Rotating Kiln Shell
The center of the unique circle defined
by mean points #1, 2, & 3 is the center
of rotation of the shell!

16. Alignment

17. • measures ~ 2000 kiln positions
• from six locations per tire
• using 12 shell rotations.
• to calculate 1 point for each tire:
• which is the center of the kiln shell’s rotation
Laser Measurement Apparatus

18. Laser Measurement Apparatus
• Continuous scan during shell rotation.
• Shell, not tires, are targeted.
• Prism locates apparatus in reference grid.
• X, Y, Z addresses are accurate to 1mm.

19. Reference Prism one of several around the kiln

21. SLOPE: The vertical
position of each roller.
Only with proper slope and
skew can face contact be
maximized.
SKEW: The degree to
which the rollers
deviate from parallel
in relation to the axis
of the shell.

22. Elevation
Plan
3mm [0.11”]
1mm [0.04”]
3mm [0.10”]
6mm [0.23”]
Axis
G
e
a
r
G
e
a
r
A
x
is
Alignment Analysis
16mm [0.64”]11mm
[0.43”]
7mm [0.26”]
C Gear
L
5mm [0.21”]
4mm [0.16”]
LC Gear

23. RecommendedRecommended
Roller AdjustmentsRoller Adjustments
C Gear
L
26mm [1.01”]19mm [0.75”]12mm [0.49”] 12mm [0.47”]1mm [0.05”]
31mm [1.24”]19mm [0.75”]11mm [0.42”] 7mm [0.27”]13mm [0.51”]

24. 3mm [1/8”]
Accuracy of Locating
The Centers of Rotation
1mm [0.04”]

25. •Refractory •Tires
•Kiln Shell •Support Rollers
•Tire Shell Pads •Roller Shafts
•Tire Retainers •Support Bearings
AlignmentAlignment::Preventive Maintenance
An Aligned Kiln Reduces Stresses On:

26. 5
10
15
20
25
30
35
0 90180270360
Kiln Shell Phrenograph
Complete Shell Profile
Split is at the
manhole.
Drive
pier
tire
Center tire
Discharge end tire
Areas exceeding
diameter by ±1/2”

27. Position
1
5
10
15
20
25
30
35
39
Max.
0.17
0.19
0.23
0.30
0.27
0.20
0.24
0.24
0.27
0.19
0.21
0.29
0.32
0.47
0.50
0.43
0.24
0.17
0.23
0.46
0.54
0.57
0.51
0.51
0.48
0.49
0.53
0.45
0.43
0.36
0.24
0.27
0.55
0.38
0.56
0.39
0.44
0.25
0.15 300
300
290
300
300
310
300
300
310
320
300
300
290
290
290
290
290
290
290
170
170
170
160
180
170
190
190
160
150
150
170
90
90
180
50
50
300
170
170
* *
Run-Out Angle of
Occurrence
Tire #4
Expected Run-Out due to manufacturing tolerance
Kiln Shell Run-Out
T
y
p
.






4
.
6
'
S
h
e
ll

L
e
n
g
t
h
SHELL RUN-OUT
MEASURES SHELL
MOVEMENT
ANGULAR OCCURRENCE OF
THE MAXIMUM RUN-OUT
AXIS OF ROTATION
AXIS OF THE SHELL
SHOWS THE DIFFERENCE
BETWEEN THE GEOMETRIC
CENTER & THE CENTER OF
ROTATION.

30. • Revenue Generator
SUMMARY
Why Alignment and
Ovality Are Important
• New Kiln Benchmark
• Preventive Maintenance
- Monitor Conditions
- Plan Maintenance Work
- Avoid Unexpected Failures

31. •Since 1989, More Than 50 Kilns Per Year
•Mining
•Chemical
•Lime Recovery (Pulp & Paper)
•Cement
•More than 1,000 in the last 5 years
•In more than 40 countries
•More than FLS and Polysius put together
For the Record

32. For the Record
•Allis Chalmers
•Ahlstrom
•Fuller
•F.L.Smidth
•Polysius
•KHD
•Kennedy Van Saun (KVS)
•Vulcan
•Kobe
•Mitsubishi
•Veba
•Zkett
•Miag
•O & K
•Fief Caille Babcock
•Prerov
•I.H.I.
•Cleé
•Vickers Armstrong
•Edgar Allen
•Lurgi