Shell Test

Shelltest
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Shelltest
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Holcim Group Support (optional) Title (optional) 05.11.2003/SN/SN
(optional) Filename.ppt
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Kiln downtime causes
§ The following is a typical breakdown of the downtime
causes for a kiln:
Frequency of shut-downs Causes of shut-downs
80% Brick lining failures
10% Mechanical failures
6% Electrical failures
4% Others
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Radial deformation and its effect
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Creep / Relative movement (loose tires)
To avoid permanent constriction of shell due to thermal

expansion the shell and tire have different diameter
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Since the kiln is almost round, the nominal radial clearance is equal to the
difference
between its shell circumference and the inner tire circumference divided
by π.
This relationship can be used for a simple measurement.
Sth = ∆U / π
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Plastic (permanent) deformation
Shell constriction
(restricted
expansion)
Buckling (local
overheating)
Crankshaft
(excessive
circunferential
temp. difference)
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Shelltest- what for?
§ The shelltest device measures the kiln shell radial
elastic deformation.
§ One of the main results of this test is the ‘Ovality’ value,
which is compared against the recommended value.
§ In addition, thanks to the graphical representation of the
deformed kiln cross section, information can be
obtained on:
4 Tire clearance
4 Tire stiffness
4 Roller adjustment (in some cases)
4 Kiln deformation (crankshaft)
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Shelltest device
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Measurement principle
§The kiln cross
section is rather
elliptical
§If the two axis (a and

b) are known, then
ovality can be
calculated
§Or, with the

magnitude of the
radial deformation δs
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Measurement principle
§ Through the Shelltest diagram, δs can be obtained, as

the maximum difference between sector height,
magnified by a factor of 15.
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How to measure
§ Ovality has to be measured as close as possible to the
tire, on both sides of it (feed and discharge side).
4 Watch out with the heat shields, in case they obstruct the
passage of the device!
§ As in the lead wire test, on each side of the tire, three
measurements have to be made (120° displacement).
4 Each set of points (A, B and C) must be collinear and
marked in a permanent way.
4 A single diagram disk can be used for the three
measurements (adjusting screw position has to be
modified, to avoid overwriting curves).
4 After each measurement, identify the resulting curve (A, B
or C) . If the curve is not easily readable, remark it with a
pencil).
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Form to be filled in for each diagram disk
Lines are already
drawn each mm
on the disk, to
easily determine
δs
Distance from
the tire center
to the actual
measuring point
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How to measure- Tips and tricks
§ The disk face must always point at the same side of the
kiln (whether feed or discharge end).
4 This reference has to be kept in mind when looking at the
curves
§ Be sure that the disk cannot rotate on its own (fasten it
with the small hole, which indicates as well the apex
point of the shell)
§ After attaching the device to the shell, do not stand right
underneath! (it may drop on top of your head)
§ Let the device make a whole revolution, before pushing
the pencil in; check that the pencil touches the disk
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How to measure- Tips and tricks
§ After each measurement, cool down the magnetic base
with water (otherwise, it will lose its strenght)
§ Wear personal protective equipment, including gloves.
§ Do not forget to measure relative movement (creep) on
each tire.
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Calculating ovality
It can be done graphically, or using the formula
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Calculating ovality
ω: relative ovality
d: external diameter where the gauge is placed (mm)
dn: nominal diameter of the section (mm)

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Calculating ovality
§ The graphic method is much easier
§ As the relative ovality limit values are given as a range,
it is not crucial to obtain a result with two decimal
places.
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Evaluation of results-Ovality value
§ The following graph shows the adequate relative ovality
ranges, according to the kiln diameter
§ If the value falls within this range or below, no corrective
action is required (tire shimming)
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Evaluation of results-Graphically
Case #1:
§ Low ovality
§ low clearance (no

flattening of the
shell at the top)
§ no deformation at
supporting areas
Result: Ideal situation – no actions rather than

periodic monitoring needed
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Evaluation of results-Graphically
Case #2:
§ High ovality
§ excessive
clearance
(flattening of the
shell at the top)
§ deformation at
supporting areas
(soft tire)
Result: Roller adjustment required, as well as

clearance decrease (tire shimming)
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Shell Test

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Shell Test

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Shelltest

Frequency of shut-downs Causes of shut-downs

80% Brick lining failures

10% Mechanical failures

To avoid permanent constriction of shell due to thermal

§If the two axis (a and

§Or, with the

§ Through the Shelltest diagram, δs can be obtained, as

d: external diameter where the gauge is placed (mm)

dn: nominal diameter of the section (mm)

§ low clearance (no

Result: Ideal situation – no actions rather than

Result: Roller adjustment required, as well as

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