Tires and Ovality
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Transcript of Tires and Ovality
![Page 1: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/1.jpg)
Rotary Kiln Maintenance Rotary Kiln Maintenance SeminarSeminar
Tires and Ovality
![Page 2: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/2.jpg)
Tires and OvalityTires and Ovality
� Tires and Tire Mounting� Tangential Suspension� Tire Clearances� Ovality� Tire Creep and Top Clearance� Correcting Ovality� Tire Pad and Stop Block Repairs� Tire Crack Repair
![Page 3: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/3.jpg)
Tires and Tire MountingTires and Tire Mounting
![Page 4: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/4.jpg)
Kiln Tire Support SystemKiln Tire Support System
Tires are mounted over support pads with machined O.D.’s. Precise clearances are maintained to allow for different rates of expansion between kiln tire and kiln shell.
Machined SurfaceMachined
Surface
![Page 5: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/5.jpg)
Pads are not welded to the shell, but are trapped in place by guide bars. Stop blocks are welded on one side only, alternating from one side to the other.
Tire AttachmentTire Attachment
![Page 6: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/6.jpg)
Tire AttachmentTire Attachment
A loose stop ring is placed between the stop block and the tire. Wear takes place on the replaceable ring, not on the stop blocks.
Stop Ring
Stop Block
Guide Bars
Machined Support Pad
![Page 7: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/7.jpg)
Tire AttachmentTire Attachment
This shows a slightly different version of the floating pad, stop ring design.
![Page 8: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/8.jpg)
Bolted Support PadsBolted Support Pads
Some FLS kilns have bolted support pads. Bolting avoids heavy welds which lead to shell cracks. The above arrangement uses a wear ring between stop blocks and tire.
![Page 9: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/9.jpg)
Bolted Support PadsBolted Support Pads
This arrangement for smaller, light duty kilns uses stop blocks directly against the tire, i.e., without the use of wear rings.
![Page 10: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/10.jpg)
On kilns without wear rings, when the blocks eventually wear down, they have to be cut off and new ones re-welded.
Tire AttachmentTire Attachment
![Page 11: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/11.jpg)
Tangential SuspensionTangential Suspension
![Page 12: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/12.jpg)
Tangential SuspensionTangential Suspension
The tire is fixed and does not creep inside the shell. Shell expansion is accommodated with a system of spring-loaded wedges.
![Page 13: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/13.jpg)
Tangential SuspensionTangential Suspension
Tangential suspension reduces ovality. Forces on the shell are tangent rather than radial.
![Page 14: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/14.jpg)
Tangential SuspensionTangential Suspension
Brackets are bolted onto the tire. “Dog bones” keep the tire in position. Wedges keep the brackets tight against the dog bones. Springs keep the wedges tight as dimensions change with heat expansion.
Tire Bracket
“Dog Bone”
Wedge
Spring
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Tangential SuspensionTangential Suspension
Tire Bracket“Dog Bone”
Wedge
Spring Rod
Wedge Retainer
![Page 16: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/16.jpg)
Tangential SuspensionTangential Suspension
A completed tire section ready for installation.
![Page 17: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/17.jpg)
Tangential SuspensionTangential Suspension
Wedges are held in position with retainer brackets bolted to the top of the “dog bones”.
![Page 18: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/18.jpg)
Tangential SuspensionTangential Suspension
The spring rod pushes the wedge in to maintain a tight fit between dog bones and brackets as the kiln shell expands and contracts.
![Page 19: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/19.jpg)
Tangential SuspensionTangential Suspension
As the wedges wear, the spring length increases. Periodically, check the distance and adjust the spring tension as required.
![Page 20: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/20.jpg)
Tangential SuspensionTangential Suspension
“Dog bones” are attached to the shell with heavy welds. Periodically inspect the welds for cracks.
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Tangential SuspensionTangential Suspension
Tire bolts are hydraulically tightened to specification.
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Hydraulic Bolt Tensioning ToolHydraulic Bolt Tensioning Tool
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Tire ClearanceTire Clearance
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Tire ClearanceTire Clearance
Tires are mounted over support pads with machined O.D.’s. Precise clearances are maintained to allow for different rates of expansion between kiln tire and kiln shell.
Machined Surface
![Page 25: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/25.jpg)
Tire ClearanceTire Clearance
It is necessary to have clearance between the tire support pads and tire I.D. to accommodate heat expansion of the shell. Cold clearance is typically 6-12 mm for a new kiln, depending on the location of the tire.
Normal Cold Clearance
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Tire ClearanceTire Clearance
The shell will heat up faster and expand more than the tire, and clearance will diminish. Normal hot running clearance should be from 0 to 3 mm (�”).
Normal Hot Running Clearance, 0-3 mm
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Rate of ExpansionRate of Expansion
Example. A kiln shell with 5 meter (5000 mm) diameter at 20º C is heated to 320º C. The shell expands
5 meters x (320 - 20) = 15 mm100
Rule of Thumb
Expansion of Steel (approx):
1mm / Meter/ 100ºC
![Page 28: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/28.jpg)
OvalityOvality
A kiln shell is not stiff enough to support its own weight. When placed on the ground it collapses to an oval shape.
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OvalityOvality
When placed inside a rigid tire the shell’s deformation is reduced, but it will still collapse if there is any clearance present. The amount it collapses depends on the amount of clearance and on the stiffness of the shell.
![Page 30: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/30.jpg)
Shell and Tire DeformationShell and Tire Deformation
Shell deformation also occurs because the tire is not absolutelyrigid. Due to elasticity of both shell and tire, the actual top clearance is 1.5 to 2 times the difference in diameter.
Perfectly Round
Shell and Tire
Deformed Shell and Tire
Difference in diameters
Actual Top Clearance
![Page 31: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/31.jpg)
Ovality and Brick ProblemsOvality and Brick Problems
Kiln shell ovality causes continuous flexing of the brick lining as the kiln turns.
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Excessive ovality will damage the refractory lining, typically with scattered spalling and single brick fall-out among otherwise undamaged areas.
Ovality Refractory DamageOvality Refractory Damage
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Shell Cracks Due to OvalityShell Cracks Due to Ovality
Excessive ovality may cause longitudinal cracks in the shell beneath the tires.
![Page 34: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/34.jpg)
Shell Cracks Due to OvalityShell Cracks Due to Ovality
This shell crack was caused by excessive ovality. The heavy welding used to attach the support pad was a contributing factor.
![Page 35: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/35.jpg)
Definition of OvalityDefinition of Ovality
Dh
Dv
Absolute OvalityΑΑΑΑ = DH - DV
Relative Ovalityαααα = (DH – DV )/D
Different definitions of ovality are in use. This definition takes into account both shell and tire deformation. Ovality is usually expressed in percent.
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Relative Ovality
αααα = 0
(shell is round)
Relative Ovality
αααα > 0
(shell is deformed)
Relative OvalityRelative Ovality
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Ovality LimitsOvality Limits
Ovality as a function of kiln diameter. Exceeding these limits will cause refractory and shell problems.
![Page 38: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/38.jpg)
Heating the kiln up too fast can result in bottle-necking (pinching) of the shell inside the tire. Excessive heating, i.e., after loss of refractory under the tire, will also cause bottlenecking.
Causes of Excessive OvalityCauses of Excessive Ovality
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Causes of Excessive OvalityCauses of Excessive Ovality
Because of its massive size, the tire will change temperature more slowly than the shell. If the kiln is heated up too fast the shell will become restricted inside the tire anddeformation will result.
![Page 40: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/40.jpg)
After the shell becomes deformed and temperatures return to normal, there will be excessive running clearance and ovality, resulting in refractory damage.
Excessive Running Clearance
Causes of Excessive OvalityCauses of Excessive Ovality
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Measuring OvalityMeasuring Ovality
The shell-test device measures the kiln shell’s actual radius of curvature during rotation. From this data the shell stresses can be precisely calculated.
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Measuring OvalityMeasuring Ovality
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Measuring OvalityMeasuring Ovality
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Measuring OvalityMeasuring Ovality
Shell-test device
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Ovality (%) = 4D²δδδδ x 100% 3dn
Ovality CalculationOvality Calculation
D = outside diameter of the shell at the test location (meters)
dn = nominal inside diameter of the shell (mm)
δ = δ/15, deflection measured from the shell test diagram (mm)
![Page 46: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/46.jpg)
Sample Calculation
Tire #1, Station #1, Downhill
ovality (%) = 4D²δ x 100%3dn
ovality (%) = 4(3.727m)²(12mm/15) x 100%3(3657.60mm)
ovality (%) = 0.406%
OvalityOvality
![Page 47: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/47.jpg)
Tire Creep and Top ClearanceTire Creep and Top Clearance
![Page 48: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/48.jpg)
Because of the slight difference in diameter between the tire ID and shell (support pad) OD, the shell rolls inside the tire as the kiln turns. This gives the appearance that the shell is “creeping’ inside the tire.
CreepCreep
![Page 49: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/49.jpg)
Place a chalk-mark on the tire and another right next to it on the shell. After one revolution, measure the distance between the two marks. This distance is the creep.
Measuring CreepMeasuring Creep
Creep
![Page 50: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/50.jpg)
Creep is the difference in circumference. Therefore,
Measuring CreepMeasuring Creep
Creep
Creep ����
= Difference in Diameter
![Page 51: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/51.jpg)
Top clearance depends on the difference in diameter and on the shell stiffness. The stiffness factor is normally between 1.5 and 2.0, depending on how thick the shell plate is.
Top ClearanceTop Clearance
Top Clearance = Difference in Diameter x Stiffness Factor
![Page 52: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/52.jpg)
Measuring Creep and Top ClearanceMeasuring Creep and Top Clearance
Top clearance and creep can be measured with this simple device.
![Page 53: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/53.jpg)
Measuring Creep and Top ClearanceMeasuring Creep and Top Clearance
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This is a data sheet of 5 kiln revolutions. The distance between waves is the creep. The height of the wave is the top clearance. Always record tire and shell temperatures and identifying data (kiln no., tire no., date).
Measuring Creep and Top ClearanceMeasuring Creep and Top Clearance
![Page 55: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/55.jpg)
Measuring Creep and Top ClearanceMeasuring Creep and Top Clearance
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Measuring Creep and Top ClearanceMeasuring Creep and Top Clearance
![Page 57: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/57.jpg)
Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
Excessive clearance can be removed with the installation of shims beneath the support pads.
Shims
![Page 59: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/59.jpg)
Shim thickness is calculated to give a hot running clearance of about 3 mm (�”).
Correcting OvalityCorrecting Ovality
ShimShim
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If the kiln shell becomes deformed it is necessary to replace the tire section. Ovality can be reduced by installing temporary pads with filler plates, but bricks will never fit properly on the inside of the kiln shell.
Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Correcting OvalityCorrecting Ovality
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Tire Pad and Stop Block RepairsTire Pad and Stop Block Repairs
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Regularly inspect the supporting pads and stop blocks for weld cracks and repair at the next kiln stop. Waiting too long will only cause problems to compound.
Tire Pad and Stop Block RepairsTire Pad and Stop Block Repairs
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Tire Pad and Stop Block RepairsTire Pad and Stop Block Repairs
Replace stop blocks when wear becomes excessive. Do not use shims as shown, as they probably won’t last.
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Excessive stop block wear on the thrust tire is especially problematic since it can affect the gear’s position on the pinion.
Tire Pad and Stop Block RepairsTire Pad and Stop Block Repairs
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Tire Pad and Stop Block RepairsTire Pad and Stop Block Repairs
Heavy welds directly on supporting pads frequently crack due to temperature fluctuations and fatigue stress. The floating pad design solves these problems.
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Floating Tire Pad DesignFloating Tire Pad Design
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Wear Ring InstallationWear Ring Installation
Wear Rings
Anti-Rotation
Bars
Wear Rings
Anti-Rotation
Bars
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Wear Ring InstallationWear Ring Installation
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Wear Ring InstallationWear Ring Installation
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Fractures at Shell PadsFractures at Shell Pads
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Fractures at Shell PadsFractures at Shell Pads
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Fractures at Shell PadsFractures at Shell Pads
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Fractures at Shell PadsFractures at Shell Pads
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Fractures at Shell PadsFractures at Shell Pads
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Tire Crack RepairTire Crack Repair
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Ultrasonic Inspection of TiresUltrasonic Inspection of Tires
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Tire Repair WeldingTire Repair Welding
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Tire Repair WeldingTire Repair Welding
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Tire Repair WeldingTire Repair Welding
![Page 95: Tires and Ovality](https://reader033.fdocuments.net/reader033/viewer/2022050618/577c851c1a28abe054bbbd60/html5/thumbnails/95.jpg)
Tire Repair WeldingTire Repair Welding
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Tire Repair WeldingTire Repair Welding
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Tire Repair WeldingTire Repair Welding
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Tire Repair Welding
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Tire Repair WeldingTire Repair Welding
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Tire Repair WeldingTire Repair Welding