Page 1

Kiln Shell Replacement

• Kiln Shell Replacement – What can go wrong

• Determination on the Line of cutting
• Kiln Shell Measurements
• Kiln Manufacture
• Kiln Shell Inspections
• Logistics Checks
• Support Saddles
• Kiln Shell Replacement
• Symptoms of Kiln Diseases
• Kiln Axis Alignment check by Polscan
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Kiln Shell Replacement – What can go wrong

Tyre not in the centre of roller Tyre offset from the centre of roller

Tyre

•Due to improper reference data for shell cutting. •High wear on rollers and tyre surfaces.
•Shell Deformation, Cranking. •Roller shaft & bearing failures.
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Kiln Shell Replacement – What can go wrong

Girth-Gear centre not

matching pinion centre,
leading to:

• Step formation in
pinion tooth.
• Crack in Girth
gear/pinion.
• Pitting in pinion/ girth
gear.
• Tip loading of pinion/
girth gear.

Due to improper reference data for shell cutting.

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Kiln Shell Replacement – What can go wrong

Step formation between

adjacent shell section leading
to:

• Frequent Refactory failure.

• Cracks in circumferential
welding joints.

Due to different diameters of shell being welded together.

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Determination on the Line of cutting

Proposed line of cutting (red color)

Establish the location of shell

from nearest tire.

>50mm >50mm

30mm

Section to be replaced,
Correct length of
75mm 50mm
30mm thickness 50mm 75mm Tire 75mm
Shell Section to be
replaced

>1000mm >1000mm
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Shell Thickness Measurements

Established line of measurement

Proposed line of cutting

100mm 100mm
30mm

Kiln Shell Section 75mm Tire

75mm 50mm
50mm proposed to be
replaced

A B
Positions Sections
Compare the average thickness with the
A B
design thickness.
Measured Drawing Measured Drawing

0
• Alarm shell thickness level for shell
45
replacement planning has to be defined
90
by the plant, considering the corrosion
135
rate, type of fuel used, kiln area, etc.
180 •A guide line for planning should start at
225 70-75% of original shell thickness.
270

315
• Limit level at 60% of original thickness.
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Shell Internal Diameter Measurements

Established line of measurement

Proposed line of cutting

100mm 30mm
100mm

Kiln Shell Section 75mm Tire

75mm 50mm
50mm proposed to be
replaced

A B

Sections Measurement & Calculation

Circumference, C (mm) Thickness , t (mm) OD = C / 2 π ID = OD - t Drawing value

Measurements to be taken in cold condition of kiln.

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Kiln Shell Run out at the Established location

Established line of measurement

A Proposed line of cutting B

100mm 30mm
100mm

Kiln Shell Section 75mm Tire

75mm 50mm
50mm proposed to be
replaced

Ra Rb
•Measure runout using measuring
Position At Section A At Section B

Runout Ra (Max. Ra) – Ra Runout Rb (Max. Rb) – Rb

scale / marker.
1

2 •Measure the runout by rotating the

3

4
kiln and keeping the pointer/scale in
5 one position.
6

7 •Measurement should be taken at

8
least at 8 or 12 equal positions along
kiln circumference
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Kiln Manufacture – Shell Plate

Choice of material
Construction application
Pressure vessel application
High temperature application

Stock Material Vs Indent Material

Stock Material L6, L9, L12 x W3, generally availability as ex-stock
Indent Material L x W general no limit 4 – 5 mths delivery
Kiln Dia 5 m, L required 15.7 m
1 x Longitudinal Seam
2 x Longitudinal Seams
Mill Certificates
Chemical analysis, mechanical
properties & ultrasonic test
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Kiln Manufacture – Shell Plate

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Kiln Manufacture – Production of Kiln Shell

Ultrasonic inspection before rolling – spot or 50%
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Kiln Manufacture – Production of Kiln Shell

trasonic inspection before rolling – 100%
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Kiln Manufacture – Shell Plate

1 long welds

Is 2 longitudinal welds acceptable ?

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Kiln Shell Manufacturing

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Kiln Manufacture – Production of Kiln Shell

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Kiln Manufacture – Production of Kiln Shell

Assembly of shell sections
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Kiln Manufacture – Production of Kiln Shell

Assembly of shell sections
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Kiln Manufacture – Production of Kiln Shell

Welding Procedure
external

internal
Preassembly

Outside welding

Gouging

Max deviation 4 mm
Inside Welding
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Kiln Manufacture – Dimensional Checks

Tolerance on Length
Tolerance on circumference
Tolerance on diameter
Tolerance on ovality
Tolerance on roundness
Tolerance on squareness
Tolerance on section alignment
Tolerance on weld caps
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Kiln Manufacture – Dimensional Checks

Length of Section

D Position Length (mm)

A
C
B

B C

D
A

Max. Allowable: ±2 mm

Measure the length of shell on the

inside of shell on 4 positions at 90º
apart.
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Kiln Manufacture – Dimensional Checks

External Circumference Length

Position Length (mm)

B
a b

Tolerance: ±6 mm
±3 mm (under tire)

To be checked at both ends of

section.
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Kiln Manufacture – Dimensional Checks

Diameters Validation Sections Positions Internal Ø

(mm)
Average Ø
(mm)

1
A
A B 2
C
3 3

4
4 2
1
B
2

3
1 4

1
C
2

Measure internal diameter of shell at

every 45º for position 1,2,3,4. Repeat Max. Allowable: ±0.05% of Ø
for sections A, B, C. Calculate the (example: 2mm for Ø4000mm)
average diameter and compare with
the design diameter.
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Kiln Manufacture – Dimensional Checks

Ovality of Section Ends Sections Positions Internal Ø
(mm)
Max.- Min. Ø (mm)

1
A B C A
2

1
B
2

1 4

1
C
2

2 3
4 4

Difference between the biggest and the

Tolerance: ±0.2% of Ø
smallest diameter in the same section
(example: 8mm for Ø4000mm)
to be within ±0.2% of the design
diameter. Repeat the same
measurement for section A, B and C.
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Kiln Manufacture – Dimensional Checks

Roundness Validation

Deformations to be check using a steel

template with a chord length of 1500mm
and the inside radius of kiln.

• Max. Allowable: 8 mm
• 5 mm (under tire) Radius of Kiln

L-1500mm

Steel Template
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Kiln Manufacture – Dimensional Checks

Squareness Validation

Diagonal Length Opposite Diagonal

C D G H (mm) Differences (mm)

AG AG - CE

CE

BH BH - DF
B A
F E
DF

Measure the shell diagonally. Max. Allowable: ±6 mm

Rotate the shell section 90º and
repeat the measurement. Calculate
the difference for opposite diagonals.
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Kiln Manufacture – Dimensional Checks

Tolerance on Sections Alignment

Section 1 Section 2 Distance of the measuring points from the

peripheral weld is approx. 100mm.
Max. permissible deviation is ±1.5 mm.

A
B
Distance between supports L

Max. Radial Runout: ±0.05% of the distance L

but not more than ±5 mm.
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Kiln Manufacture – Dimensional Checks

Tolerance on Weld Caps

outside
Edge misalignment

max. 3 mm

inside

Max. Allowable: ±3 mm
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Kiln Shell Inspections

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Logistics Checks
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Logistics Checks
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Support Saddles with Hydraulic Jacks

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Support Saddles
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Kiln Shell Replacement

Marking cutting lines

First Cut
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Kiln Shell Replacement

Second Cut Third Chamfer
Cut

Prepared Joint
On Exist Section
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Kiln Shell Replacement

Kiln Ready for Final

Cut
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Kiln Shell Replacement

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Kiln Shell Replacement

Lifting in of pre-assembled kiln section

Lifting in of pre-assembled tyre section

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Supervision Services - Chamfering of tyres or rollers

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Symptoms of Kiln Diseases

Cracks Wears Lining Loss Hot Bearing

Where Where Where Where

? ? ? ?

Kiln Tyre / Tyres / Tyre Between Below Journal Thrust

Shell Rollers Rollers Shims Tyres Tyres Bearing Collar

Diseases of Kiln Diseases of Kiln Diseases of Kiln Diseases of Kiln

Kiln Axis Kiln Axis Kiln Axis Ovality Crank Kiln Axis Kiln Axis Skewing

Crank Crank Skewing Process Ovality Crank

Ovality Lining Quality Lubrication

Corrosion
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Cracks
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Wear & Overheating

Wobble on downhill side Wobble on uphill side

Overheating on Tyre
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Lining Loss & Overheating

Overheating under tyre

Brick failure under the tyre

(approx. 3 x 1 m)
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Shell Crank Measurement

A series of polar diagrams gives a picture of the shell crank.

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Effect of Kiln Crank – Tyre lifting off Supporting Roller

Tyre lifting from the supporting rollers:

• All load will be transferred to the other supporting roller stations!

• Opposite kiln position -> More load / stress on these supporting rollers!
• Additional stress on the tyre and kiln shell!
• Uneven wear on roller and tyre surfaces when contact appears
Page 45

Kiln Crank – Hot Spot

A hot spot left unattended will wrinkle the shell and create a crank. Refractory bricks
will no longer stay in place and the shell section will have to be replaced at great
expense.
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Kiln Crank

Kiln crank can be caused by poor

alignment of kiln sections during
Kiln crank can be caused by assembly or repair.
weld shrinkage at a temporary
shell patch.
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Effects of Roller Skewing

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Effects on Ovality

Longitudinal cracks
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Effects of Radial Deformation

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Kiln Axis Alignment check by Polscan

 Adjustment of Support Rollers
Adjustment of Kiln Axis

Determine Kiln Axis after Adjustment

Determine the Shifting Path of Support Rollers
Shell Ovality
Ovality

Shell Profile Analysis (Deformation)

Kiln Shell Deformation

Eccentricity (Crank)
Shell Temperatures Measurements
Axial Run-out (Wobbling) of Tyres / Girth Gear
Roller Axle Deflection (Crank)
Tyres / Rollers Diameters (Taper / Concave / Convex)
Rotary Kiln Axis

Relative Movement (Creep) - Tyre & Shell

Rollers Inclination, Concentricity, Contact Angles
Polscan Options & Modules

Kiln Axis (Vertical & Horizontal)

Temperatures of Tyre & Shell Beneath Tyre
Support Rollers Skewing
Girth Gear & Pinion Root Clearance
Inspection Modules
Inspection Options

POLSCAN
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