Customer Services
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Customer Services
Terminology
Customer Services
Terminology
Customer Services
Kiln Axis - Results 0
0
Customer Services
0
0
0
0
Load on bearings and tyres Consequences for bearings and tyres (as measured) Tyres
Bearings Support No.
Utilization (design limit: ≤ 100%)
Bending stress
Hertz pressure
(design limit: ≤ 60 N/mm 2 ) (design limit: ≤ 550 N/mm 2 ) 2
2
[%]
[N/mm ]
[N/mm ]
I
89
57
540
II
84
52
520
III
91
58
545
Numbers can change, depending on the kiln calculations which will be stated in the final report
Customer Services
Kiln Axis Recommended Corrections
It is not recommended to adjust the kiln axis
Customer Services
Stiffness Matrix
Stiffness matrix (change of reaction in % by lowering a support by 10 mm) Support No.
I
II
III
I
-4
6
-4
II
8
-10
8
III
-4
5
-4
Numbers can change, depending on the kiln calculations which will be stated in the final report
Customer Services
ω=0
Tyre Migration
Do D> Do D<
Tyre migration - Ovality Tyre migration measurements Tyre No.
2012
At the tyre migration measured
Relative Present ovality, ωrel
Tangential bending stress 2
Do
At optimum tyre migration of 10 mm/rev. Relative ovality, ωrel
Tangential bending stress 2
[mm/rev.]
[%]
[N/mm ]
[%]
[N/mm ]
I
3
15
0.30
23
0.27
19
II
1
12
0.26
21
0.24
19
III
11
12
0.29
24
0.25
18
The tyre migration is acceptable for all piers. Numbers can change, depending on the kiln calculations which will be stated in the final report Customer Services
Bending stresses in kiln shell
Customer Services
Kiln cranck Supporting roller shaft deflections Recorder
Left-hand roller
Right-hand roller
[± mm]
[± mm]
I
0,01
0,02
II
0,01
0,02
III
0,02
0,02
Support No.
There is no indication of a crank in the kiln.
Customer Services
Transducer
FLS-Rollers max. ± 0.15 mm
Kiln shell profile analysis Throw of kiln shell Position [mm]
Throw [± mm]
Angel [deg]
Position [mm]
Throw [± mm]
Angel [deg]
Position [mm]
Throw [± mm]
Angel [deg]
1000
3.8
287
30000
1.5
7
57500
2.6
193
3000
2.8
292
32500
1.3
121
60000
2.7
190
6200
1.3
227
35000
2.3
84
62500
2.7
263
7200
T1
37000
2.8
101
65000
4.3
241
8200
1.9
137
38000
T2
66800
2.1
249
10000
2.0
151
39000
0.5
129
70200
1.4
293
12500
4.9
96
42000
3.1
244
72000
1.5
284
15000
4.5
71
43000
3.8
288
74000
0.1
216
17500
4.3
62
45000
1.1
264
75000
T3
20000
2.2
48
47500
0.7
355
76000
0.6
142
22500
1.4
97
50000
1.0
115
79000
2.2
105
25000
1.3
112
52500
2.4
143
82000
5.8
137
27500
1.5
65
55000
3.8
118
84000
8.8
139
The measured throw of kiln shell is acceptable and no big deformations of the shell was found. Customer Services
Axial balance of the kiln The ideal situation
Thrust roller 70 % - Supporting rollers 30 %
Customer Services
Axial balance pressent situation
Evaluation of axial thrust Direction of thrust
Temperature difference between thrust face and
Support No.
journal
*)
Thrust device pressure
[°C] Left roller
Right roller
Left roller
Right roller
I
Uphill
Uphill
3.5
2.3
II
Uphill
Uphill
3.0
2.5
III
Uphill
Uphill
2.0
0.5
[bar]
*
The axial balance of the kiln is acceptable
Customer Services
CInlet Bearing 3 Left Roller
Outlet
Center distances
COutlet
Supporting rollers - Centre distances Designed [mm]
I
Present Outlet side [mm]
Inlet side [mm]
4388
4391
4391
II
4616
4628
4629
III
4360
4374
4375
The difference in center distances is acceptable which also is indicated by the axial balance
Customer Services
Right Roller Bearing 1
Bearing 4
Support No.
Bearing 2
Side guides
Side guides - Wear Support No.
Side guide width
Clearance
[mm]
[mm]
Type
Outlet side
Inlet side
Outlet side
Inlet side
I
C
70
70
0
20
II
C
60
60
20
0
III
C
60
60
0
5
The wear of side guides and clearance is acceptable.
Customer Services
Wobbling of tyres Tyre throw
Tyre throw [± mm] Tyre I
1,8
Tyre II
0,4
Tyre III
0,9
Co mpu ter
Trans ducer
Wobbling Standard: max. +/-1 mm
The throw of tyre I is too high. The throw of tyre at pier II and III are acceptable.
Customer Services
Rollers Inclination Inclination of tyre and supporting rollers [%] Left-hand roller Support No.
Right-hand roller
Upper limit
Measured
Lower limit
Upper limit
Measured
Lower limit
I
3,980
4,035
4,000
4,000
4,025
4,020
II
3,980
4,003
4,000
4,000
4,010
4,020
III
3,980
4,020
4,000
4,000
4,035
4,020
The inclination of supporting rollers is acceptable.
Customer Services
Shims under bearings
Shims Thickness of shims [mm]
Thickness of shims [mm]
(existing)
(to be installed/removed)
Support No.
Right-hand roller
Left-hand roller
Bearing 1 Bearing 2 Bearing 3
Bearing 4
Support No.
I
0,0
0,0
0,0
0,0
I
II
0,0
0,0
0,0
0,0
II
III
0,0
0,0
0,0
0,0
III
Customer Services
Right-hand roller Bearing 1
Bearing 2
Left-hand roller Bearing 3 Bearing 4 1,0
0,6
0,7
Rollers Profiles Condition of rolling surfaces Support No. I II III
Supporting rollers Left
Straight
Right
Straight
Left
Straight
Right
Straight
Left
Concave 1mm
Right
Concave 2mm
The condition of rolling surfaces is acceptable
Customer Services
Tyres Straight Straight *
Wobbling of gear rim
Axial limits: +/- 0.75 mm (old kilns) +/- 0.50 mm (new kilns)
Girth gear throw Axial throw [± mm]
0,7
Radial throw [± mm]
1,6
The axial throw of the GG is acceptable. The radial throw of GG is acceptable.
Clearance
Left side
Right side
The clearance between girth gear and pinions is acceptable. Customer Services
Pinion temperature gradient Temperatur gradient of left pinion 1/2 L
1/4 L
Center
1/4 L
1/2 L
Temperature Temp. Diff.
Temperatur gradient of right pinion 1/2 L
1/4 L
Center
1/4 L
1/2 L
Temperature Temp. Diff.
It is not possible to measure the temperature gradient of pinions because of fixed tubes on the lub. System. Customer Services
Girth gear
The condition of GG is acceptable, but pittings at the inlet side of GG could indicates a misalignment between GG and pinions. Customer Services
Pinion Right
Left
The condition of pinions seems acceptable.
Customer Services
Tyres-Diameters
Tyres - Temperatures and diameters Measurements taken during the inspection Original value Tyre No.
Temperature measured [ºC]
I
124
6914
6905
6904
II
134
6999
6989
6904
III
148
6904
6893
6904
Customer Services
Diameter [mm] Diameter [mm] Diameter [mm] at temperature at 20ºC at 20ºC measured
Rollers diameters
Supporting rollers - Temperatures and diameters Measurements taken during the inspection Temperature measured [ºC]
Support No.
Original value
Diameter [mm] Diameter [mm] Diameter [mm] at temperature at 20ºC at 20ºC measured
Left
64
1803
1802
1800
Right
67
1802
1801
1800
Left
70
2204
2203
1800
Right
76
2204
2202
1800
Left
83
1803
1802
1800
Right
74
1802
1801
1800
I
II
III
Customer Services
Position of Tyres on Supporting Rollers Positions of tyres on supporting rollers Positions of tyres [mm] Support No.
Width of supporting roller (WR)
Width of tyre (WT)
S1
S2
S3
S4
[mm]
[mm]
I
160
160
160
160
1000
680
II
90
100
100
90
1100
910
III
145
155
155
145
1000
700
The position of tyres on supporting rollers is acceptable.
Customer Services
W R S3
S 4 S 1
W T W R
S 2
Temperatur kiln shell Kiln shell temperatures [ºC] Inlet side
Outlet side
Tyre No. High
Low
Difference
High
Low
Difference
I
257
247
10
253
235
18
II
281
253
28
265
250
15
III
255
240
15
270
255
15
There is no indication of a thermal crank in the kiln.
Customer Services
Temperatur bearing pier I Left 43
Right 3
43
47.5
46.5
52
52
48.5
49.7
44.5
44.2
4 Customer Services
2
1
Temperatur bearing pier II Left 45
Right 3
46
49.5
49
55
55
52
52.5
46
46
4 Customer Services
2
1
Temperatur bearing pier III Left 47
Right 3
44
52.5
51
60.5
54.5
58.5
54
48.5
45
4 Customer Services
2
1
Lubrication of bearings
Pier I Pier II-III
Customer Services
Thrust Rollers - Alignment
Difference in centre distance
Customer Services
Measured distance left side
2188
Measured distance right side
2187
Difference in centre distance
4375
The position of thrust roller is acceptable
Contact between Thrust Rollers and tyre
90 % ? Bar
Customer Services
Thrust Rollers - Surface
The surface of thrust roller and thrust face is acceptable.
Customer Services
Foundations
Difference in height between the foundations Pier I Orginal Measured Accumulated change
Customer Services
Pier II
Pier III
outlet
Inlet
Outlet
Inlet
Outlet
Inlet
2020
2020
0
0
0
0
-2019.7
-2020.1
0.7
1.1
0.1
0
-0.3
-0.4
0.3
1.4
1.5
1.5
Inlet / outlet seal
The condition of inlet and outlet seal is acceptable. Customer Services
Terminology
Customer Services
Terminology
Customer Services
Kiln Axis - Results 0
0
Customer Services
0
0
0
0
Load on bearings and tyres Consequences for bearings and tyres (as measured) Tyres
Bearings Support No.
Utilization (design limit: ≤ 100%)
Bending stress
Hertz pressure
(design limit: ≤ 60 N/mm 2 ) (design limit: ≤ 550 N/mm 2 ) 2
2
[%]
[N/mm ]
[N/mm ]
I
89
57
540
II
84
52
520
III
91
58
545
Numbers can change, depending on the kiln calculations which will be stated in the final report
Customer Services
Kiln Axis Recommended Corrections
It is not recommended to adjust the kiln axis
Customer Services
Stiffness Matrix
Stiffness matrix (change of reaction in % by lowering a support by 10 mm) Support No.
I
II
III
I
-4
6
-4
II
8
-10
8
III
-4
5
-4
Numbers can change, depending on the kiln calculations which will be stated in the final report
Customer Services
ω=0
Tyre Migration
Do D> Do D<
Tyre migration - Ovality Tyre migration measurements Tyre No.
2012
At the tyre migration measured
Relative Present ovality, ωrel
Tangential bending stress 2
Do
At optimum tyre migration of 10 mm/rev. Relative ovality, ωrel
Tangential bending stress 2
[mm/rev.]
[%]
[N/mm ]
[%]
[N/mm ]
I
3
15
0.30
23
0.27
19
II
1
12
0.26
21
0.24
19
III
11
12
0.29
24
0.25
18
The tyre migration is acceptable for all piers. Numbers can change, depending on the kiln calculations which will be stated in the final report Customer Services
Bending stresses in kiln shell
Customer Services
Kiln cranck Supporting roller shaft deflections Recorder
Left-hand roller
Right-hand roller
[± mm]
[± mm]
I
0,01
0,02
II
0,01
0,02
III
0,02
0,02
Support No.
There is no indication of a crank in the kiln.
Customer Services
Transducer
FLS-Rollers max. ± 0.15 mm
Kiln shell profile analysis Throw of kiln shell Position [mm]
Throw [± mm]
Angel [deg]
Position [mm]
Throw [± mm]
Angel [deg]
Position [mm]
Throw [± mm]
Angel [deg]
1000
3.8
287
30000
1.5
7
57500
2.6
193
3000
2.8
292
32500
1.3
121
60000
2.7
190
6200
1.3
227
35000
2.3
84
62500
2.7
263
7200
T1
37000
2.8
101
65000
4.3
241
8200
1.9
137
38000
T2
66800
2.1
249
10000
2.0
151
39000
0.5
129
70200
1.4
293
12500
4.9
96
42000
3.1
244
72000
1.5
284
15000
4.5
71
43000
3.8
288
74000
0.1
216
17500
4.3
62
45000
1.1
264
75000
T3
20000
2.2
48
47500
0.7
355
76000
0.6
142
22500
1.4
97
50000
1.0
115
79000
2.2
105
25000
1.3
112
52500
2.4
143
82000
5.8
137
27500
1.5
65
55000
3.8
118
84000
8.8
139
The measured throw of kiln shell is acceptable and no big deformations of the shell was found. Customer Services
Axial balance of the kiln The ideal situation
Thrust roller 70 % - Supporting rollers 30 %
Customer Services
Axial balance pressent situation
Evaluation of axial thrust Direction of thrust
Temperature difference between thrust face and
Support No.
journal
*)
Thrust device pressure
[°C] Left roller
Right roller
Left roller
Right roller
I
Uphill
Uphill
3.5
2.3
II
Uphill
Uphill
3.0
2.5
III
Uphill
Uphill
2.0
0.5
[bar]
*
The axial balance of the kiln is acceptable
Customer Services
CInlet Bearing 3 Left Roller
Outlet
Center distances
COutlet
Supporting rollers - Centre distances Designed [mm]
I
Present Outlet side [mm]
Inlet side [mm]
4388
4391
4391
II
4616
4628
4629
III
4360
4374
4375
The difference in center distances is acceptable which also is indicated by the axial balance
Customer Services
Right Roller Bearing 1
Bearing 4
Support No.
Bearing 2
Side guides
Side guides - Wear Support No.
Side guide width
Clearance
[mm]
[mm]
Type
Outlet side
Inlet side
Outlet side
Inlet side
I
C
70
70
0
20
II
C
60
60
20
0
III
C
60
60
0
5
The wear of side guides and clearance is acceptable.
Customer Services
Wobbling of tyres Tyre throw
Tyre throw [± mm] Tyre I
1,8
Tyre II
0,4
Tyre III
0,9
Co mpu ter
Trans ducer
Wobbling Standard: max. +/-1 mm
The throw of tyre I is too high. The throw of tyre at pier II and III are acceptable.
Customer Services
Rollers Inclination Inclination of tyre and supporting rollers [%] Left-hand roller Support No.
Right-hand roller
Upper limit
Measured
Lower limit
Upper limit
Measured
Lower limit
I
3,980
4,035
4,000
4,000
4,025
4,020
II
3,980
4,003
4,000
4,000
4,010
4,020
III
3,980
4,020
4,000
4,000
4,035
4,020
The inclination of supporting rollers is acceptable.
Customer Services
Shims under bearings
Shims Thickness of shims [mm]
Thickness of shims [mm]
(existing)
(to be installed/removed)
Support No.
Right-hand roller
Left-hand roller
Bearing 1 Bearing 2 Bearing 3
Bearing 4
Support No.
I
0,0
0,0
0,0
0,0
I
II
0,0
0,0
0,0
0,0
II
III
0,0
0,0
0,0
0,0
III
Customer Services
Right-hand roller Bearing 1
Bearing 2
Left-hand roller Bearing 3 Bearing 4 1,0
0,6
0,7
Rollers Profiles Condition of rolling surfaces Support No. I II III
Supporting rollers Left
Straight
Right
Straight
Left
Straight
Right
Straight
Left
Concave 1mm
Right
Concave 2mm
The condition of rolling surfaces is acceptable
Customer Services
Tyres Straight Straight *
Wobbling of gear rim
Axial limits: +/- 0.75 mm (old kilns) +/- 0.50 mm (new kilns)
Girth gear throw Axial throw [± mm]
0,7
Radial throw [± mm]
1,6
The axial throw of the GG is acceptable. The radial throw of GG is acceptable.
Clearance
Left side
Right side
The clearance between girth gear and pinions is acceptable. Customer Services
Pinion temperature gradient Temperatur gradient of left pinion 1/2 L
1/4 L
Center
1/4 L
1/2 L
Temperature Temp. Diff.
Temperatur gradient of right pinion 1/2 L
1/4 L
Center
1/4 L
1/2 L
Temperature Temp. Diff.
It is not possible to measure the temperature gradient of pinions because of fixed tubes on the lub. System. Customer Services
Girth gear
The condition of GG is acceptable, but pittings at the inlet side of GG could indicates a misalignment between GG and pinions. Customer Services
Pinion Right
Left
The condition of pinions seems acceptable.
Customer Services
Tyres-Diameters
Tyres - Temperatures and diameters Measurements taken during the inspection Original value Tyre No.
Temperature measured [ºC]
I
124
6914
6905
6904
II
134
6999
6989
6904
III
148
6904
6893
6904
Customer Services
Diameter [mm] Diameter [mm] Diameter [mm] at temperature at 20ºC at 20ºC measured
Rollers diameters
Supporting rollers - Temperatures and diameters Measurements taken during the inspection Temperature measured [ºC]
Support No.
Original value
Diameter [mm] Diameter [mm] Diameter [mm] at temperature at 20ºC at 20ºC measured
Left
64
1803
1802
1800
Right
67
1802
1801
1800
Left
70
2204
2203
1800
Right
76
2204
2202
1800
Left
83
1803
1802
1800
Right
74
1802
1801
1800
I
II
III
Customer Services
Position of Tyres on Supporting Rollers Positions of tyres on supporting rollers Positions of tyres [mm] Support No.
Width of supporting roller (WR)
Width of tyre (WT)
S1
S2
S3
S4
[mm]
[mm]
I
160
160
160
160
1000
680
II
90
100
100
90
1100
910
III
145
155
155
145
1000
700
The position of tyres on supporting rollers is acceptable.
Customer Services
W R S3
S 4 S 1
W T W R
S 2
Temperatur kiln shell Kiln shell temperatures [ºC] Inlet side
Outlet side
Tyre No. High
Low
Difference
High
Low
Difference
I
257
247
10
253
235
18
II
281
253
28
265
250
15
III
255
240
15
270
255
15
There is no indication of a thermal crank in the kiln.
Customer Services
Temperatur bearing pier I Left 43
Right 3
43
47.5
46.5
52
52
48.5
49.7
44.5
44.2
4 Customer Services
2
1
Temperatur bearing pier II Left 45
Right 3
46
49.5
49
55
55
52
52.5
46
46
4 Customer Services
2
1
Temperatur bearing pier III Left 47
Right 3
44
52.5
51
60.5
54.5
58.5
54
48.5
45
4 Customer Services
2
1
Lubrication of bearings
Pier I Pier II-III
Customer Services
Thrust Rollers - Alignment
Difference in centre distance
Customer Services
Measured distance left side
2188
Measured distance right side
2187
Difference in centre distance
4375
The position of thrust roller is acceptable
Contact between Thrust Rollers and tyre
90 % ? Bar
Customer Services
Thrust Rollers - Surface
The surface of thrust roller and thrust face is acceptable.
Customer Services
Foundations
Difference in height between the foundations Pier I Orginal Measured Accumulated change
Customer Services
Pier II
Pier III
outlet
Inlet
Outlet
Inlet
Outlet
Inlet
2020
2020
0
0
0
0
-2019.7
-2020.1
0.7
1.1
0.1
0
-0.3
-0.4
0.3
1.4
1.5
1.5
Inlet / outlet seal
The condition of inlet and outlet seal is acceptable. Customer Services
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