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General causes for replacing the Support Roller are :

a. Scoring in shaft due to entry of foreign particles.


Why Support Roller Needs Replacement?



General causes for replacing the Support Roller are :

Scoring on Bearing Liner
Why Support Roller Needs Replacement?



General causes for replacing the Support Roller are :

b. Step formation in roller.

Why Support Roller Needs Replacement?



General causes for replacing the Support Roller are :

c. Wear in the O/D of the Roller.


Why Support Roller Needs Replacement?


Conical Taper Wear Concave/ Convex Wear

General causes for replacing the Support Roller are :

d. Fitting between Roller & Shaft.

e. Cracks in Shaft/ Roller.




Why Support Roller Needs Replacement?


1. It is advisable to replace the support rollers in pair.
2. Take Kiln shut down.
3. Provide V saddle supports below the Kiln Tire and lift the Kiln by Hydraulic Jacks so
that tire is free from supporting rollers.
SADDLE SUPPORT Contd...
SADDLE SUPPORT AT SITE Contd...
SADDLE ON LOAD KILN LIFTED Contd...
GAP BETWEEN
ROLLER & TYRE
1. Mark the present location of the support rollers.
INITIAL LOCATION OF BEARING HOUSING MARKES ON THE BASE FRAME
2. Unscrew the thrust bolts and push out support roller assembly away from the kiln
center line.
3. Remove the support roller bearings after resetting the support roller over some
packing.
4. Lift the support rollers and take away.
5. Take out the bearing liners and blue match it with shaft of the new support roller.
1. Assemble the bearing liners back in the bearing.
2. Bring in the new support roller and assemble it with its bearings.
3. Push in the new support roller assembly. Assemble the thrust bolts.
4. Check alignment of support rollers with respective kiln center line axis.
5. Lower the Kiln over new support rollers.
After opening the Bearing the liner metal has to be scrapped to
make a line contact with the shaft.
Bearing collar also scrapping has to be done and match with the
roller collar area.
The spherical seat of the bearing also has to be checked.
There will be nos on each bearings according to that blue match
has to be done on the support Roller shafts.
Punch the same no on the shaft also.

1
2
3
4
For Blue matching the bearing liner with shaft we have to slide
the bearing liner above the shaft Axially.

For Blue matching the bearing liner collar with support roller
collar we have to slide the bearing on the shaft Radially.

For spherical seat of the bearing with housing has to be
checked by rotating the bearing axially and radially.
What are the three main reasons for making roller adjustments on rotary
equipment?
Primarily, adjustments should be performed with the ultimate goal to control the
axial thrust of the unit, while relieving the thrust pressure on the individual rollers.

Another important reason for regular adjustments is to correct any alignment
imbalances, focusing on OEMspecified positions for the rollers.

Thirdly, adjustments are conducted in case of mechanical problems with the unit.
For example, a unit with a hot or damaged bearing may have to be adjusted to
compensate for the problematic roller, relieving the thrust on the individual
bearing. This, of course, is an extreme measure, but unfortunately more common
than it should be. Compensating for one individual bearing can cause the others to
absorb the load, increasing wear and failure in other areas. When good
preventative maintenance programs are in place, we notice that such reactionary
solutions arent necessary.
What type of wear conditions will affect the thrust of the unit?
Most common wear conditions are concave and convex wear patterns where the
tire wears in a crowned type pattern and the roller wears in a dishedout shape as
the tire sits down into it. This should be of concern because it means the tire has
been mechanically locked into place as it wears down into the rollers and cant move
very well in one direction or another. This can also lead into further thrusting issues
and possibly bearing problems on individual rollers.
Contd.
In order to minimize the additional thrust on any one roller and distribute the load
to the others, we have to skew the rollers intrinsic to the design of the unit. If you
look at the diagram below, you will notice where, in one case, we put pressure on
the downhill side of the rollers.
Contd.
A common practice we see often is adjusting only one roller to try to drive the unit.
This happens mainly because it is the easiest to access, or may be the coolest roller
in an extremely hot environment. The result is having a single roller taking on the
majority of the units thrust and, because of its negative long term effects, we do not
recommend this practice.
Another type of wear pattern that can occur over an extended period of time is
conical or tapered. This is a particularly concerning type of wear because it can
cause the axis of the tire to tilt and drive into the retaining blocks, leading to
mechanical as well as thrust problems.
Contd.
Some more wear patterns you may encounter diagonal marks are indication of
roller maladjustment; a band of pitting marks on one side of the unit can mean
there is too much pressure on that side; and flat spots are noticeable when other
problems arise with the unit, so make sure to look into all possible causes before
making the adjustment.
Contd.
What are some indicators that the rollers are misadjusted?
There are three primary signs to look for: temperature, vibration and wear patterns.

An increase in the temperature in the bearing taking the load is a very strong indicator
of excessive thrust and wear. Unusual vibration signals the bearings are overloading.

Thirdly, we look for specific wear patterns. The unit might present concave or convex
patterns; spalls or metal flaking where the tires are thrusting too hard; diagonal marks
showing a excessively skewed roller; or even flat spots, indicating the gear is bottoming
in the pinion. Any of these signs point to undesirable mechanical conditions and
adjustments will need to be made.
Contd.
What is the best way to adjust rollers to not have alignment issues?
The best way to adjust your units rollers falls within the best practices of alignment
procedures outlined in your OEM specifications. The key adjustment advice we can
offer is to always balance the load between all rollers versus one particular roller. It is
a common practice as well to adjust the height of the gear from bottoming in the
pinion by moving the rollers in on the drive pier. This will eventually cause a
misalignment of the unit that can contribute to wear conditions.
Contd.
For the kiln to go up
How should be skewed the rollers ?
As the Tractors front tires
Kiln discharge
1. CHECK
Surface
Contact
Weather Tyre Lifts in Same Position
Step Formation to be Removed
Graphite Blocks
Thrust ( Principle/ Types-Disc, Washer, Brass Ring Bolted to Mounting),
Direction & Amount.

2. Methods to Check Thrust (Fuller Instrument, Knocking with Hammer,
Shiny Surface of Disc, Position of Supp. Roller)

3. Skewing Causes Thrust

4. Skewing Causes more Stress in the System, Accelerates Wear


5. CHECK
Lubrication
Water Flow
Journal Condition
Bearing Liner Once in Three Years
Replace Oil/ Clean Sump Every Six Months or Earlier if Contamination
Due to Dusty Environment takes Place
Oil Tray Perforations/ Slope
Chemically Clean Water Jackets Regularly, depending Upon Quality of
Cooling Water
Thrust Plate/ Washer for Roughness

6. Heating Up of Bearings
Check for Presence of Above Factors
Provide External Cooler for Oil
If Symptoms Persist (More that 02 hrs or so), plan to Stop the Kiln, Inspect
& take action accordingly