PHILLIPS KILN SERVICES LTD.

SHELL
INSPECTION
Identification of
Mechanical Problems and
Symptoms

REGULAR OBSERVATION REVEALS PROBLEMS

This training is intended to be a rotary unit, namely kiln, dryer, or granulator walk-by.
Observation techniques will identify potential problems while the unit is in normal
operation. The definition of terms and the names of parts will be established. You will
be provided with tools to assist in your own walk bys throughout this training.
Rotary units of any kind require a large capital outlay and are expensive to operate.
When the unit is damaged to the point of breakdown, the cost of operation is
significantly increased. Taking a unit off-line and bringing it back up again, and
repairing or replacing its parts is always costly. Serious damage rarely happens in
one day. Usually it is the accumulation of a series of small problems left unattended
or unrecognized that finally causes a failure.
An ounce of prevention is worth a pound of cure. With improved skills of recognition it
is possible to exercise preventive maintenance effectively, thereby eliminating, or
certainly reducing, expensive and unexpected shutdowns.

Shell Inspection Identification of Mechanical Problems & Symptoms Page 1

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The outline for 2-pier alignment is really meant for new installations where the rollers
are fitted with spherical roller bearings. Once a rotary dryer, cooler, granulator,
lets just call them units, are installed subsequent alignment is deceptively simple.
In short the steps would be:
1) Grind the rollers and tires
2) Set zero skew on all the rollers
3) Shim for contact
4) And if necessary float the unit

The difficulty is finding that elusive sweet spot, the zero skew position of each roller.
As it turns out the traditional method by working to a centerline that is physically
measuring the position of the bearings is very difficult to do to the degree of
accuracy needed. If the rollers were to be fitted with sleeve bearings, alignment
would entail nothing more than floating the rollers, provided the bases were
correctly sloped and no shimming is required. For spherical roller bearings
monitoring the axial force on the roller rather than measuring its position solves
the problem. But more of this later.

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INTERPRETING OVALITY CURVES

There are a variety of common variations to the typical curve that is frequently
displayed by some kilns. Using the electronic ovality beam these signatures are
easy to see. With a little practice, a great deal of additional information about the
behavior of the kiln shell can be deduced beyond just establishing the ovality
measurements themselves. The more typical signatures are shown in the
illustration above. In the following slides actual examples from our files are shown.

Page 3 Ovality Analysis

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 The GEAR & PINION
Identification of
Mechanical Problems

No discussion of troubleshooting kilns, dryers, and other rotary equipment would be complete
without the inclusion of the special problems of gears, pinions, and drive trains. Understanding the
mechanical function of these parts and the differences in their design will help to focus on areas
that may cause problems in the future, or may already be causing problems.
The alignment and mesh of the gear and pinion, the lubrication that is used, and the other
components involved in the drive train, are all areas that should be carefully inspected on a regular
schedule.
Covered in this section are the two most common types of gear mounting arrangements, their
pros and cons, and a recommended inspection program. Characteristics, advantages and
disadvantages of different types of lubrication are discussed as well.

Gears Page 4
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