The document contains measurements and analysis from an inspection of a kiln. It analyzes factors like bearing loads, shell profiles, temperatures, and roller alignments. The analysis found minor issues like high throw on one tyre but concluded the overall condition of the kiln is acceptable, with wear and stresses within design limits. Some recommendations include installing shims under specific bearings.

1. Customer Services

2. Customer Services
Terminology

3. Customer Services
Terminology

4. Customer Services
Kiln Axis - Results
0 0
0 0 0
0

5. Customer Services
Load on bearings and tyres
Numbers can change, depending on the kiln
calculations which will be stated in the final report
Bearings
Utilization Bending stress Hertz pressure
(design limit: ≤ 100%) (design limit: ≤ 60 N/mm2
) (design limit: ≤ 550 N/mm2
)
[%] [N/mm
2
] [N/mm
2
]
I 89 57 540
II 84 52 520
III 91 58 545
Consequences for bearings and tyres
(as measured)
Support
No.
Tyres

6. Customer Services
Kiln Axis
Recommended Corrections
It is not recommended to adjust the kiln axis

7. Customer Services
Stiffness
Matrix
Numbers can change, depending on the kiln
calculations which will be stated in the final report
Support
No.
I II III
I -4 6 -4
II 8 -10 8
III -4 5 -4
by lowering a support by 10 mm)
Stiffness matrix
(change of reaction in %

8. Customer Services
Do
D <
Do
D >
Do
ω = 0
Tyre Migration
The tyre migration is acceptable for all piers.
Numbers can change, depending on the kiln
calculations which will be stated in the final report
2012 Present
Relative
ovality, ωrel
Tangential
bending
stress
Relative
ovality, ωrel
Tangential
bending
stress
[%] [N/mm
2
] [%] [N/mm
2
]
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
Tyre migration - Ovality
Tyre
No.
Tyre migration
measurements
At the tyre migration
measured
At optimum tyre
migration of 10 mm/rev.
[mm/rev.]

9. Customer Services
Bending stresses in kiln shell

10. Customer Services
FLS-Rollers
max. ± 0.15 mm
Transducer
Recorder
Kiln cranck
Left-hand roller Right-hand roller
[± mm] [± mm]
I 0,01 0,02
II 0,01 0,02
III 0,02 0,02
Supporting roller shaft deflections
Support No.
There is no indication of a crank in the kiln.

11. Customer Services
Kiln shell profile analysis
Position Throw Angel Position Throw Angel Position Throw Angel
[mm] [± mm] [deg] [mm] [± mm] [deg] [mm] [± mm] [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
Throw of kiln shell
The measured throw of kiln shell is acceptable
and no big deformations of the shell was found.

12. Customer Services
The ideal situationThe ideal situationThe ideal situationThe ideal situation
Thrust roller 70 % - Supporting rollers 30 %
Axial balance of the kiln

13. Customer Services
Left roller Right roller Left roller Right roller [bar]
I Uphill Uphill 3.5 2.3
II Uphill Uphill 3.0 2.5 *
III Uphill Uphill 2.0 0.5
Evaluation of axial thrust
Support
No.
Direction of thrust
Temperature difference
between thrust face and
journal
*)
Thrust
device
pressure
[°C]
The axial balance of the kiln is acceptable
Axial balance pressent situation

14. Customer Services
Outlet
Right RollerLeft Roller
CInlet
COutlet
Bearing 4
Bearing 3 Bearing 2
Bearing 1
Outlet side Inlet side
[mm] [mm]
I 4388 4391 4391
II 4616 4628 4629
III 4360 4374 4375
Supporting rollers - Centre distances
Support No.
Present
Designed
[mm]
The difference in center distances is acceptable which
also is indicated by the axial balance
Center distances

15. Customer Services
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
Side guides - Wear
Support
No.
Type
Side guide width Clearance
[mm] [mm]
Side guides
The wear of side guides and clearance is
acceptable.

16. Customer Services
Wobbling
Standard: max. +/-1
mm
Wobbling of tyres
Trans
ducer
Tyre
throw
Co
mpu
ter
Tyre I 1,8
Tyre II 0,4
Tyre III 0,9
Tyre throw [± mm]
The throw of tyre I is too high.
The throw of tyre at pier II and III
are acceptable.

17. Customer Services
Rollers Inclination
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
Inclination of tyre and supporting rollers [%]
Support
No.
Left-hand roller Right-hand roller
The inclination of supporting rollers is
acceptable.

18. Customer Services
Shims under bearings
Shims
Bearing 1 Bearing 2 Bearing 3 Bearing 4
I 0,0 0,0 0,0 0,0
II 0,0 0,0 0,0 0,0
III 0,0 0,0 0,0 0,0
Thickness of shims [mm]
(existing)
Support
No.
Right-hand roller Left-hand roller
Bearing 1 Bearing 2 Bearing 3 Bearing 4
I 1,0
II
III 0,6 0,7
Thickness of shims [mm]
(to be installed/removed)
Support
No.
Right-hand roller Left-hand roller

19. Customer Services
Rollers Profiles
Support
No.
Left Straight
Right Straight
Left Straight
Right Straight
Left Concave 1mm
III Right Concave 2mm
*
Condition of rolling surfaces
Supporting rollers Tyres
I
Straight
II
Straight
The condition of rolling surfaces is acceptable

20. Wobbling of gear rim
Axial limits:
+/- 0.75 mm (old kilns)
+/- 0.50 mm (new kilns)
Axial throw [± mm] 0,7
Radial throw [± mm] 1,6
Girth gear throw The axial throw of the GG is
acceptable.
The radial throw of GG is
acceptable.

21. Customer Services
Clearance
Left side Right side
The clearance between girth gear and pinions is
acceptable.

22. Customer Services
Pinion
temperature
gradient
1/2 L 1/4 L Center 1/4 L 1/2 L
Temperature
Temp. Diff.
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
It is not possible to measure the temperature
gradient of pinions because of fixed tubes on
the lub. System.

23. 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.

24. Customer Services
Pinion
Right Left
The condition of pinions seems acceptable.

25. Customer Services
Tyres-Diameters
Original value
Temperature
measured
[ºC]
Diameter [mm]
at temperature
measured
Diameter [mm]
at 20ºC
Diameter [mm]
at 20ºC
I 124 6914 6905 6904
II 134 6999 6989 6904
III 148 6904 6893 6904
Tyre No.
Tyres - Temperatures and diameters
Measurements taken during the inspection

26. Customer Services
Rollers diameters
Original value
Support
No.
Temperature
measured
[ºC]
Diameter [mm]
at temperature
measured
Diameter [mm]
at 20ºC
Diameter [mm]
at 20ºC
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
Supporting rollers - Temperatures and diameters
Measurements taken during the inspection
III

27. Customer Services
Position of Tyres on Supporting
Rollers
W
R
W
TS
1
S
2
S3S
4
W
R
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
Positions of tyres on supporting rollers
Positions of tyres [mm]
Support
No.
The position of tyres on supporting rollers is
acceptable.

28. Customer Services
Temperatur kiln shell
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
Kiln shell temperatures [ºC]
Tyre No.
Inlet side Outlet side
There is no indication of a thermal crank in the
kiln.

29. Customer Services
Temperatur bearing pier I
RightLeft
4
23
1
52
44.2
49.7
43
46.5
52
44.5
48.5
43
47.5

30. Customer Services
Temperatur bearing pier II
RightLeft
4
23
1
55
46
52.5
46
49
55
46
52
45
49.5

31. Customer Services
Temperatur bearing pier III
RightLeft
4
23
1
54.5
45
54
44
51
60.5
48.5
58.5
47
52.5

32. Customer Services
Lubrication of bearings
Pier II-III
Pier I

33. Customer Services
Thrust Rollers - Alignment
2188
2187
4375
Difference in centre distance
Measured distance left side
Measured distance right side
Difference in centre distance
The position of thrust roller is acceptable

34. Customer Services
Contact between Thrust Rollers and tyre
90 %
? Bar

35. Customer Services
Thrust Rollers - Surface
The surface of thrust roller and thrust face
is acceptable.

36. Customer Services
Foundations
Difference in height between the foundations
Pier I Pier II Pier III
outlet Inlet Outlet Inlet Outlet Inlet
Orginal 2020 2020 0 0 0 0
Measured -2019.7 -2020.1 0.7 1.1 0.1 0
Accumulated change -0.3 -0.4 0.3 1.4 1.5 1.5

37. Customer Services
Inlet / outlet seal
The condition of inlet and outlet seal is
acceptable.