Kiln Start Up in 7 Steps

1. If the kiln has been sitting idle, at least one cup of oil should be poured onto the top of every shaft through the bearing inspection port before rolling the unit. This must be done to prevent a dry start which will cause bearing damage. Check each pier to verify graphic block is installed on carrying roller(s) and thrust roller(s) faces.

2. Confirm oil level and coolant flow on every bearing along the length of the unit. Measure and record all shaft temperatures using a temperature gun pointed through the bearing inspection port. Record the condition of each shaft at this time also.

3. Inspect all bearing thrust positions and thrust button temperatures. Check position of gear relative to pinion location. Check lubrication/ gear sump to ensure oil level is correct and oiling pinion or spray system is working properly when kiln is rotating. Verify the tire is located in the correct position on the carrying roller(s). Check drive pier tire relative to thrust rollers (float between thrust rollers), and clearance of the shell in the hoods if possible.

4. Note that when fire is lit in the kiln, the kiln will be step rolled for approximately 8 to 24 hours before the main drive is engaged. This brings the shell up to temperature gradually and allows time for moisture removal from any new refractory. This also allows time for the shell and tire to expand. Rapid heat up will cause the shell to expand too quickly and cause a “coke bottle” effect under the tire. Because there is linear shell expansion, tire position on the rollers is an easy way to gage of the extent of warm up.

5. Recheck the shaft temperatures every 30-60 minutes when the kiln goes online to see if there is a pattern developing for warm bearings. Ensure oil is circulating properly through inspection ports in the housings.

6. Starting with any support rollers with downhill thrust, float the bearings by applying the opposite thrust force to the roller (If the support roller has uphill thrust perform incremental downhill adjustments until the support roller switches thrust). Adjust all bearings to neutral then add slight uphill thrust to all support rollers along the length of the unit.

7. Final adjustments on support rollers will be made after floating the bearings. When fine tuning the unit for thrust, allow 6 to 24 hours between adjustments. At the end of all adjustments the kiln should contact the downhill thrust roller for approx. 50% of one revolution. It is normal for thrust to vary slightly due to changes in load, temperature, weather conditions and lubrication. Be patient and take your time with all final roller adjustments.

Need more help? We offer start up assistance! 1(800) 331-5456