Webinarinspections PDF

Kiln & Dryer Maintenance
INSPECTIONS/
TROUBLESHOOTING
IKD Training Webinar
Presenter Bio
JOHN ROSS
30+ years of experience servicing rotary equipment
(kilns, dryers & ball mills) in the mining, cement,
lime, chemical, fertilizer, food, and asphalt
industries
OEM certified kiln / dryer maintenance instructor.
Alignment specialist, who has authored, and
published maintenance articles.
RULES of the WEBINAR

This is our first live session please be patient and tell us
how we did.
If you encounter technical difficulties during this session,
call 877-316-6140 and mention webinar troubles. You will
be transferred to someone who will help!
We encourage your questions! Your microphones will be
muted for the most part of the webinar. Please type your
questions inside the box in your control panel (right side of
screen). Questions will be answered during several breaks
in the presentation.
Session will be recorded. A link to the recording will be

available to you after the webinar.
Kiln & Dryer

Maintenance
Troubleshooting/Inspections
Daily Inspections
A maintenance walk-by inspection performed daily

Check the Dryer drive amperage for sudden increases
Check the bearing temperatures for changes
Check the riding ring/support roller faces for new wear
Check the drive system for vibration and visually inspect
the drive gear and pinion alignment
Check the axial thrust of the Dryer, (uphill or downhill)
Check lubrication on support & thrust rollers
Check the gear lubrication systems
Weekly Inspections
Check the Dryer drive amperage for the past several days for
fluctuations
Check the relative movement of the riding rings on floating
style (creep) on all piers
Check dryer seals and shell run-out on the feed and discharge
ends of kiln
Check the welds on filler bars, retaining blocks/rings and on
shell section seams
Check the temperature of the gear and pinion mesh
Check the temperature of the riding ring & support roller
contact area
Monthly Inspections
Check the pitch line separation between the
drive gear and pinion/s for changes in the gear
mesh
Check dust filters on air intakes of drive motors
Inspect gear reducer oil levels and all drive
bearings for high operating temperatures
Perform vibration analysis of the gear and
pinion, gear reducer and drive system bearings
Quarterly Inspections
Check the pitch line separation between the drive gear
and pinion/s for changes in the gear mesh
Check dust filters on air intakes of drive motors
Inspect gear reducer oil levels and all drive bearings for
high operating temperatures
Perform vibration analysis of the gear and pinion, gear
reducer and drive system bearings
Annual Inspections
Piers-Check Elevation and Alignment
Check Dryer Alignment
Carrying Roller-Check Adjustment
Gear Flange Bolts-Check Tightness
Gear Joint Bolts-Check Tightness
Pinion-Check Radial Alignment
Drive-Check Alignment
Gear and Pinion Teeth-Condition
Support Frames-Condition
Gear Guard (W/Spray System)-Lubricant Build-Up
Support roller and Thrust Mechanism
Inspect and Service Speed Reducers, Motors, etc., per
Manufacturer's Instructions.
Ultra-sound Roller Shafts
Types of wear on
Tires/Rollers
CONCAVE AND CONVEX WEAR PATTERNS
CONICAL OR RADIAL TAPER WEAR PATTERNS
UNEVEN WEAR ON SURFACES

SPALLING AND PITTING ON WEAR SURFACES
VARIOUS OTHER WEAR CONDITIONS
TAPERED/CONCIAL WEAR PATTERNS
TAPERED/CONCIAL WEAR PATTERNS
GAP
BETWEEN
TIRE &
RETAINERS
Hot bearing temperatures will generate from excessive thrust

on the internals of the bearings.
Hot bearings can cause the bearing internals to overheat and
lose lubrication and cause a premature failure..
Excessive thrust can overload thrust roller mechanisms and
cause failure or damage.
Wear will be accelerated on the surfaces of the tires and
support rollers. This will make minor support roller moves
next to impossible.
Serious mis-adjustments will cause high axial loads of the tire
against the retaining blocks/rings.
Mis-adjusted support rollers will create a drag on the kiln
shell & increase the kiln drive loads.
Unit alignment will be affected by long-term misadjustment
of support rollers.
UNEVEN WEAR PATTERNS
UNEVEN WEAR PATTERNS
DIAGONAL WEAR PATTERNS
DIAGONAL WEAR PATTERNS
HORIZONTAL WEAR PATTERNS
OTHER WEAR PATTERNS
EXCESSIVE AXIAL THRUST
Resurfacing of Wear Patterns
KILN SHELL CONDITIONS

Filler bar & retaining block/ring welds
Kiln shell weld seams
Hot spots and shell deformation

Kiln shell crankshaft or run-out
Gear Design & Wear Issues
SLIGHTLY APART
ACCEPTABLE
TANGENT
ACCEPTABLE
SCRIBE PITCH LINE SETTING

FIGURE 21
OVERLAPPING
UNACCEPTABLE
Gear & Pinion Pitch Lines
Girth Gear Bottoming in

Pinion Gear
False Bottom on Girth Gear
Root to tip interference
Loaded on both flanks
Scuffing- transfer of metal

by adhesion and welding
AGMA 1010-E95
Tooth Hammer excessive backlash
& dual drives
Pitting poor lubrication or

heavy load
Abrasion dirty lube
Rippling poor lubrication

heavy load

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Kiln & Dryer Maintenance

RULES of the WEBINAR

Session will be recorded. A link to the recording will be

Kiln & Dryer

A maintenance walk-by inspection performed daily

UNEVEN WEAR ON SURFACES

Hot bearing temperatures will generate from excessive thrust

Resurfacing of Wear Patterns

KILN SHELL CONDITIONS

Hot spots and shell deformation

Gear Design & Wear Issues

SCRIBE PITCH LINE SETTING

Gear & Pinion Pitch Lines

Girth Gear Bottoming in

False Bottom on Girth Gear

Root to tip interference

Loaded on both flanks

Scuffing- transfer of metal

Pitting poor lubrication or

Rippling poor lubrication

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