TomTom-Tools GmbH

Zelgli 20 Phone: +41 79 774 06 44

8905 Arni Info@tomtom-tools.com
Switzerland www.tomtom-tools.com

User Manual:

Kiln Shell Laser

With Rotation Trigger

1. INTRODUCTION:
The Kiln Shell Laser is a measurement tool, which measures the deformations in
rotary kilns, dryers or other slow rotating cylinders during operation.
The tool can be used to measure just one cross section, a specific area containing a
few cross sections of interest or the whole kiln to get the full picture.
The steel shell of rotary kilns is exposed to high temperature. In case of excessive heat the shell
might deform. In areas with deformations the refractory installation becomes typically difficult, which
has a negative impact on its lifetime.
To measure the shape (roundness and eccentricity) of the shell, the Kiln Shell Laser is placed along
the rotating kiln and measures continuously the distance to the shell surface. Deformations result in
changes of the distance and will be recorded by the laptop PC, which is connected via Bluetooth
with the laser. From each measured position a graph with the cross-section of the kiln is generated.
Several measurements along the kiln can be combined in the software to a full 3d graph.
The 3d graph shows the severity of the deformations in different colors. It is a great help to identify
the areas where special attention to the refractory is required. In case of reduced refractory life time,
due to shell deformation, the software helps to decide, which shell sections need to be replaced.

1.1 Safety:

Rotary kilns and dryers, where this tool typically is used, are huge rotating equipment with many
pinch points and hot surfaces which can cause serious injuries. Therefore only specialized and
trained personnel shall work close to these machines. To use the tool, follow strictly the local safety
rules given by the respective plant / factory / local authorities and discuss the application with the
safety engineer in charge.
The tools provided by TomTom-Tools GmbH have proven their functionality in various applications;
nevertheless TomTom-Tools GmbH does not take any responsibility for the application on site
regarding safety. The plant is responsible for the safety, according to the local law, in a way that
nobody can be hurt or injured. The application and safety instructions below are guidelines and not
exhausted which include the experience from previous measurement campaigns and might need to
be adapted to the local safety requirements.

27 April 2017
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Caution:
Laser Beam:
Visible laser radiation, do not stare into beam
Class 2 laser product

Magnet Fields:
Be aware of the strong magnet field of the magnet
Keep the tool away from people with pace makers or any other sensitive
item as credit cards or magnetic data carrier.

Gloves:
Wear proper gloves to protect your hands from hot and rough surfaces and
sharp edges.

Hot Surface:
The kiln shell might be very hot. Do not touch it and keep sufficient distance.

Radio Waves:
Be aware of the radio waves (Bluetooth) which are emitted from the tool as
well from the Bluetooth adapter on the computer.
Do not keep the tool unnecessary in operation; switch it off, after usage.

Pinch Points:
Do not put your hands nor any items close or into pinch points
(e.g. girth gear / pinion, kiln tires / support rollers,…)
Keep safe distance to avoid getting caught by moving parts.
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TABLE OF CONTENT

1.  Introduction: .............................................................................................................................1 

1.1  Safety: ....................................................................................................................................1 
1.2  Measuring Principle: ..............................................................................................................4 
1.3  Tool Kit includes: ...................................................................................................................5 
2.  Main Components ...................................................................................................................6 
3.  Software:...................................................................................................................................6 
3.1  Bluetooth Adapter..................................................................................................................6 
3.2  Installation: .............................................................................................................................7 
4.  Connect The Device with the Laptop ...................................................................................8 
5.  Measurements .........................................................................................................................9 
5.1  Set Up the Measurement Window........................................................................................9 
5.2  Bring the tool in position ..................................................................................................... 10 
5.3  Take Measurements .......................................................................................................... 10 
5.4  Display Results ................................................................................................................... 12 
5.5  Denseness of Cross Sections............................................................................................ 13 
6.  Data Review........................................................................................................................... 14 
6.1  Change Window Range ..................................................................................................... 14 
6.2  Removal of Outliers (wrong points) ................................................................................... 14 
7.  Kiln Assessment in 3d View ............................................................................................... 15 
7.1  Topography View ............................................................................................................... 15 
7.2  Create a 3D Kiln Model ...................................................................................................... 16 
7.3  The different ways to display.............................................................................................. 16 
7.4  Add Tires and Girth Gear ................................................................................................... 16 
7.5  Limits................................................................................................................................... 20 
8.  Report..................................................................................................................................... 21 
8.1  Export to Excel ................................................................................................................... 21 
8.2  Create a report ................................................................................................................... 21 
9.  Rotation Trigger (Optional) ................................................................................................. 22 
9.1  Connect the Rotation Trigger with the PC ......................................................................... 22 
9.2  Attach Rotation Trigger to Kiln ........................................................................................... 22 
9.3  Combined Measurement with Kiln Shell Laser and Rotation Trigger .............................. 22 
10.  Dimensions Rotation Trigger ............................................................................................. 23 
11.  Dimensions Kiln Shell Laser............................................................................................... 24 
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1.2 Measuring Principle:

The Kiln Shell Laser kit consists mainly of a battery powered distance laser sensor with a high
range Bluetooth connection and a heat shield.
The measuring principle of the distance laser sensor is based on optical phase comparison
measurement. The laser which hits the kiln surface gets partially reflected. A very sensitive optical
sensor located in the same housing as the laser is measuring the returned light reflected by the kiln
shell. The laser light is modulated and the phase shift between outgoing and incoming light gives
the distance.
To measure the shape (roundness and eccentricity) of the shell, the Kiln Shell Laser is placed along
the rotating kiln and measures continuously the distance “a” to the shell surface. Deformations
result in changes of the distance and will be recorded by the laptop PC, which is connected via
Bluetooth to the laser. From each measured position a graph with the cross-section of the kiln is
generated. Several measurements along the kiln can be combined in the software to a full 3d
graph.
The Kiln Shell Laser takes in the standard setting 10 readings per second (10Hz). To reach a
sufficient resolution in the graph; the shell is typically measured during two kiln revolutions. For
special application, in case the reflection on the surface is sufficient, it is possible to increase the
sampling rate to 50Hz.

a) Schematic with Laser on a tripod

Shell surface
to measure

Center of
Rotation

Recorded
Distance

Kiln Shell Laser

on Tripod
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b) Examples: Run-Out Measurement of Kiln Shell

Laser on tripod Laser fixed with G-clamp

1.3 Tool Kit includes:

The Kiln Shell Laser is coming as a tool kit in a strong and tight transport case, which includes the
following items:
1. Kiln Shell Laser with Bluetooth interface
2. Heat Shield with magnets
3. Battery Charger with different plug adapters (100…240VAC)
4. G-Clamp to hold the laser, in case no tripod is available
5. USB Bluetooth Adapter (below heat shield)
6. USB Memory Stick with manual and software “Measurement Studio”
7. Tripod (optional)

6
1
3
Transport Case
Type: Peli 1470 4
42.9x33.6x11.4cm

Tripod in separate bag:

40x12x12cm

Weight total: 7.5kg

2 5
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2. MAIN COMPONENTS

Status LED

Matnetic
Heat Shield Charger Plug

Power Switch
Base plate with
different threads
(M6 and UNC¼”)

Kiln Shell Laser

3. SOFTWARE:

3.1 Bluetooth Adapter

To make sure, the data connection between the Kiln Shell Laser Sensor and the PC is reliable,
even in the difficult environment around a rotary kiln, it is recommended to use the Bluetooth
adapter (Parani UD100), which is included in the tool kit.
Note:
• Typically the distance between the Kiln Shell Laser and the laptop is short; hence the inbuilt
Bluetooth of the PC is strong enough and can be used to connect.
• In case a stronger connection is required, use the USB Bluetooth adapter UD100.
Windows recognizes the hardware and automatically install the suitable driver
• To make sure, the PC is connecting via the USB Bluetooth adapter and not via the inbuilt
Bluetooth, it is recommended to switch off the inbuilt Bluetooth (e.g. by putting Laptop to
flight mode)
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3.2 Installation:

The software (TomTom-Tools Measurement Studio), which is used for the Kiln Shell Laser,
comes along with the equipment on a USB memory stick. Nevertheless it is recommended to
install the software from www.tomtom-tools.com , where always the latest version is available.
During any start of the Measurement Studio, it is checking for updates if the computer is connected
to the internet. In case of available upgrades the user gets asked if they should be downloaded and
installed.

Click to download
the Software

Click to install
the Software
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4. CONNECT THE DEVICE WITH THE LAPTOP

When the software installation is completed, it starts automatically.
To connect a tool for the first time it has to be paired with the computer.
To do so, follow this sequence:
• Switch on the Kiln Shell Laser (green LED).
• Click on “Tools / Bluetooth Devices / Add a device”
• Wait until the tool got found
Note: Depending on the search speed of the computer, it might take up to one minute.
• Select the device, which has to be connected; (here the Kiln Shell Laser) and click “OK”

Fig. 4.1
(Add Device)

Fig. 4.2
(Connect Device)

• The Kiln Shell Laser gets added to the Device List

• To connect the Kiln Shell Laser, click on the “Connect” Button

Fig. 4.3
(Device Window)
To connect
click here To switch laser
ON and OFF

Device can be
connected, when
displayed here
(in black letters)

Measured Distance
in mm

Selection of
measuring mode
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5. MEASUREMENTS

5.1 Set Up the Measurement Window

• To start a new measurement, click on “Measurement / New / Shell Runout”

Fig. 5.1.1

• The first position will be displayed as per default

• More position can be added by clicking “Add ” as shown in Fig. 5.1.2
• Put some additional useful information about the measurement into the “Settings Window”
• Specify if the “0m” Position is at the inlet or outlet side of the kiln

Fig. 5.1.2

Message Bar

Enter additional
Information

Select the Method to indicate the kiln rotation

(see the chapter “Rotation Tigger)

Define location
of Zero Point

Add new position

Enter measurement
position [m]
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5.2 Bring the tool in position

The Kiln Shell Laser has to be placed below or beside the kiln at the location, which has to be
measured. The laser beam has to be perpendicular to the shell surface and pointing towards the
center (according Fig. 5.2.1).
Fig. 5.2.1

90°

Measurement Distance:
The maximum distance for the Kiln Shell Laser depends on the influence of disturbance.
Typically the tool is used within the distance of 4...20m. In case of strong sunlight, measure at the
shady side, not where the sun is directly shining onto the kiln.
In case the kiln surface is reflecting the laser light well (not too much corrosion), and the
measurement is done at night, where no sunlight disturbs the laser receiver, distances up to 50m
are possible.

5.3 Take Measurements

To start the measurement, enter the position [m] on the computer screen and push the
Start button or [F5].

Select the sense of rotation (View from Kiln Inlet)

After that, the values will appear on the computer screen (green points)
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Note:
To be able to place the measured points correctly into the graph and to calculate the position of the
eccentricity, the software needs a reference signal. This reference signal has to be given, in the
moment when the reference point is in line with the laser point.
Typically the manhole in the kiln shell is used as reference point.
It is utmost important to use the same reference point for all measurements.

Each time when this reference point is passing the position of the laser, click on or push the
button [F9] to indicate the kiln rotation. A yellow line in the graph will show the position of the
reference point.
Optionally a Rotation Trigger is available, which makes the rotation indication easier
(see chapter 9 “Rotation Trigger”)
After 2…3 complete kiln revolutions, sufficient data are collected and the measurement can be
stopped. To stop the measurements push the Stop button or [F6].
Fig. 5.3.2
To switch to Radar
or Topography chart

Measured
Values

Enter position
on the kiln [m]
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• Eccentricity: shows how much the girth gear is out of the center of rotation, it is the
distance between the center of rotation and the center of the girth gear (blue arrow)
• “Peak at”: indicates the angle (purple arrow) where the peak of the eccentricity is located. It
is counted in degrees after F9 was pressed. The position of F9 appears in the radar chart
on top at °0.
• Roundness Deviation: shows the maximal deviation from the ideal circle. It is a +/- value
(green arrows)
• Total Run-Out: is the combination of eccentricity with roundness deviation. It corresponds
directly to the measured values. The Total Run-Out is a +/- value (red arrows)

5.4 Display Results

The values can also be displayed in a Radar Chart, which appears as the measured cross section.
Each measurement is shown in a row of the table below the graph window. More measurements
can be added by clicking the “Add” button. The rows get automatically sorted by the position [m]
value.
Fig.5.4.1
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5.5 Denseness of Cross Sections

The more cross sections are measured, the more detailed becomes the picture of the kiln. But in
most cases, only some areas are from interest. Here some examples:

• In areas of refractory failures:

to check if a roundness deviation in the shell is the root cause

• Kiln Inlet and outlet:

to know the impact on the seals

• In areas of kiln tires:

to see the impact of the shell deformations on the tire wobbling, to understand their
correlation and to identify the location of possible correction cuts.

• In areas, where shell sections need to be replaced

to find good locations with low run-out where new shell pieces easily can be connected

• Shell in the area of the girth gear:

in case of a replacement of the gear, if the shell needs to be replaced as well

In most cases, for a general overview, the kiln is measured every 1…2m. In case of localized
refractory failure, it might make sense to measure the affected area every 0.5m or even less. It will
provide a clearer picture of the “steepness” of the deformation in longitudinal direction.

Readings are taken at various

positions along the kiln

Note:
To ease the orientation along the kiln, it is recommended to mark the meter positions. That can be
fix marks either on the catwalk beside the kiln or even better, directly on the kiln shell.
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6. DATA REVIEW
The Data can be reviewed in all the 3 different charts (Line Chart, Radar Chart and Topography).
Nevertheless the easiest way is to browse through the data first in the Line Chart, to see if the
readings are good or if they have to be repeated.

6.1 Change Window Range

Some of the measured points might be out of the displayed range. These are typically wrong
readings or outliers coming from pieces welded to the kiln shell.
To get also these points displayed, the range can be changed by right mouse click onto the vertical
axis and increasing the “Range Max” value.
Fig.5.6.1 (change display range)

Outliers coming
Outliers coming from from man hole
a welded piece on
the kiln shell

To increase the range

Right mouse click on of the graph
axis to open the
“Range Window”

6.2 Removal of Outliers (wrong points)

The shell run out measurement might be disturbed in some areas; for example by pieces welded to
the kiln shell, by the man hole or by components from the tire fixation hardware. Hence the graphs
might include wrong points.
These outliers can easily be detected and removed in the linear graph.
• Click on the “Select Data” button
• Select the outliers with the cursor (drag from top left to right down)
• Delete the selected points by pushing the “Delete” button or by right mouse click
Note:
It is recommended to make a backup copy of the file before deleting any points.
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Fig. 6.2.1 (delete outliers)

“Select Data”
Button

Points to delete

7. KILN ASSESSMENT IN 3D VIEW

To get a clear picture about the deformation in the kiln shell there are ways to display the data in 3d.
The simple way is the “Topography View” which is good for static analysis and printouts.
The much more powerful tool is the 3d modelling of kiln. It is animated and shows the center line
with its eccentricity .and can combine the shell deformation readings with other measurement
results.

7.1 Topography View

The Topography View is displayed as shown in the following window.

To colorize the deformations, select the “Amplitude” or “Curvature” view.
(see also 7.3 )
Fig. 7.1.1 (Topography view)

Choose the way

to display
To zoom, rotate and move; use the mouse or the arrow buttons in combination with “Shift” and
“Ctrl”
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7.2 Create a 3D Kiln Model

The full functionality will be given, when the measurement file is displayed in the 3d Model
To add a file into the 3d viewer, open the measurement file, drag it from “Measurements” and drop
it to “3D Kiln View”.
Or do it by right mouse click as shown in the picture below.

7.3 The different ways to display

The deformations are exaggerated to make them visible on the computer screen. There are
different possibilities to visualize the deformations.
• Shell View: shows just the kiln shell as it is, without color coding
• Amplitude: shows the height of the deformations in different colors
• Grid: displays the grid lines but hides the shell surface. It allows the view inside the kiln to
the blue center line (Shell Axis)
• Curvature: shows the steepness of the deformations in the kiln shell. This is the most
important indicator for the refractory installation. Sharp / abrupt changes in the kiln shell
have a negative impact on the refractory life time (see also chapter “Limits”)
• Replacement*: gives indications, which sections are out of limits, where a close look on the
refractory life time is recommended and which section might need to be replaced.
(* under construction)

7.4 Add Tires and Girth Gear

To get a more realistic view and for better understanding, the kiln piers and the girth gear can be
added. To do so, click on the “Add” button and place them to the respective meter position
(see next picture)
It is recommended to measure also the run-out of the tires and girth gear with the help of the
Inductive Distance Measurement (IDM) Tool Kit.
The results of these run-out measurements can also be added and displayed in the 3d model.
To add run-out measurements:
• Open the file with the tire or girth gear readings
• Drag and drop them into the 3d model (as done before with the Shell Run-Out file)
• Than safe the 3d model
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Fig.7.4.1: Amplitude View

Grid is located at the

selected cross section

Enter position
Girth Gear

To add a pier

Enter positions
of the piers

Fig.7.4.2: Grid View (including girth gear measurement results)

Results from Girth Gear

Run-Out measurement
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Fig.7.4.3: Curvature View

By selecting “Curvature View” the changes in the curvature are displayed. In other words, it shows
how much the straightness and the roundness are changing within a specific area, or how abrupt
the deformations are.
Abrupt or sudden changes in the shape have a negative impact on the lifetime of the refractory
bricks. (See more in the chapter “Limits”

Fig.7.4.4: Orthogonal View

By bringing the kiln into orthogonal position, in this example can be seen easily that…
• The kiln is not straight, high eccentricity at kiln inlet (see blue center line)
• The tire #1 is wobbling heavily
Click here for
• The girth gear runs well
Orthogonal Orientation
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Fig.7.4.5: Combined View, Radar and 3D window open

By dragging out the windows, several graphs can be displayed simultaneously. This makes it easy
to understand, how the cross section looks like at each position of the kiln.
While scrolling through the list of the measurement points, the 3d view is showing the position and
the radar chart the shape of the cross section at the same time.
This applies as well for the run-out measurement of the girth gear and the tires.

To restore the default window view, click on “Tools / Reset Window Layout”
Fig. 7.4.6

Note:
There is also a video available under www.tomtom-tools.com , which shows how to use the Kiln
Shell Laser and the Measurement Studio.
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7.5 Limits

The experience on refractory life has shown clearly, that a good roundness of the kiln shell is the
key, whereas the impact of eccentricity can be neglected. Just the pure amplitude of deformations
in a kiln shell does also not give sufficient information about the situation. The “smoothness /
sharpness” of deformations has to be considered. A smooth deformation, even with high amplitude,
might still allow the proper installation of refractory, whereas an abrupt change of curvature typically
reduces the refractory lifetime drastically.
TomTom-Tools Ltd. does not provide guide lines about deformation values or limits.
It has to be discussed with the refractory suppliers, how much deformation can be allowed.
Out of experience the following table can be taken as an example but might need to be adjusted
to the specific case:

a) Sharp or Abrupt Shell Deformation

X
L

b) Smooth Shell Deformation

X
L

The „Sharpness “of a shell deformation has a much higher impact on the refractory than its amplitude

No problem To be monitored Might need replacement

Note:
The decision to replace a piece of kiln shell should be based also on the refractory lifetime history
and not only on deformation measurement results
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8. REPORT

8.1 Export to Excel

All data can easily be exported to excel.

Fig.8.1.1

8.2 Create a report

The measurements can be extracted into a report. All additional information

from the “Settings Window” is included in the report as well.

Fig. 8.2.1

TomTom-Tools GmbH Switzerland www.tomtom-tools.com info@tomtom-tools.com

z Page 22 April 27, 2017

9. ROTATION TRIGGER (OPTIONAL)

The Rotation Trigger is a small unit, which provides via Bluetooth the rotation position of the kiln
during the measurement campaign. It minimizes the need for the manual rotation indication
(pushing “F9” button, see in chapter 5.3 “Take Measurement”)

9.1 Connect the Rotation Trigger with the PC

The Rotation Trigger is equipped with a long range Bluetooth transmitter and gets connected to the
PC in the same way as the Kiln Shell Laser (see chapter 4).
Note:
To have a reliable Bluetooth signal, it is required to connect via the USB Bluetooth
adapter UD100 and not via the inbuilt Bluetooth connection of the Laptop.

9.2 Attach Rotation Trigger to Kiln

Typically the rotation trigger remains at the same place on the kiln during the whole measurement
campaign; hence it has to be attached where the temperature is low. In most cases, the side face of
the girth gear is the best location.
Note:
It is important to attach it to one or the other side face (see picture below)
It has not to be aligned in a special way.
Do not attach it on a tire unless the temperature is below 70°C.
Fig.9.2.1 Fig.9.2.2 Rotation Trigger

Rotation Trigger
attached to the side face

9.3 Combined Measurement with Kiln Shell Laser and Rotation Trigger

To use the signal coming from the Rotation Trigger it has to be selected it in the “Settings Window”.
(See picture)

Select the Trigger

Note: In the moment when the reference point (typically the man hole) is in line with the laser point,
“F9” has to be pushed. With the Rotation Trigger this still applies for the first time of each
measurement point; in the consecutive revolutions it will be done automatically.
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10. DIMENSIONS ROTATION TRIGGER

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11. DIMENSIONS KILN SHELL LASER