Chapter 4

Inspection and
Maintenance of
Dry Kilns and Equipment
Kiln structure 87 Adequate kiln maintenance is as essential to efficient
Walls, roofs, and ceilings 87 dry kiln operation as good design and construction.
Prefabricated aluminum panels 88 Adequate maintenance can be accomplished only
Masonry 88 through regular, frequent inspections of the kiln and
Doors 89 auxiliary equipment. If inspections reveal the need for
Floors 89 repairs or replacements, they should be made as soon
Rails and rail supports 89 as possible to avoid drying problems.
Recording-controlling instruments 90
Proper location of control sensors or bulbs 90 Regular, systematic inspections should cover such items
Dry-bulb sensors 90 as the kiln structure; doors; floor; tracks; control equip-
Wet-bulb sensors 90 ment; heating, spraying, and venting system; trucks;
Equilibrium moisture content and lumber-handling equipment; and general housekeeping.
relative humidity sensors 91 To make sure that inspections are thorough, the op-
Care of recording-controlling instruments 91 erator should note the condition of the kiln structure
Calibration of recording-controlling instruments 91 and the equipment on a checklist. The checklist at the
Heating systems 92 end of this chapter can be made to fit any specific kiln
Steam-heated kilns 92 installation.
Improperly insulated feedlines 92
Leaking pipes and unions 92
Sagging and distorted pipes 93 Kiln Structure
Defective valves and regulators 93
Faulty pressure gauges 93 Dry kilns are required to withstand much harsher con-
Faulty automatic and manual valves 93 ditions than those conditions that ordinary buildings
Faulty steam traps 93 are subjected to, regardless of the materials used in
Direct-fired kilns 94 construction. Kilns must withstand not only extreme
Humidification systems 95 external weather conditions but also even more extreme
steam spray 95 internal conditions. Relative humidity can vary from
water spray 95 5 to 95 percent, and temperatures can change from
Venting systems 95 -20 °F (ambient) to 250 °F during operation of a high-
Air-circulation systems 95 temperature kiln. In addition, vapors that arise from
Kiln trucks 96 the woods being dried are often corrosive. Structural
Use of protective coatings 97 components of the kiln and the internal protective coat-
Housekeeping and maintenance around dry kilns 9 7 ings must be capable of withstanding this broad range
Locating problems in kiln maintenance of operating environments.
and operation 97
Tables 99 Walls, Roofs, and Ceilings
Appendix. Kiln inspection checklist 100
The majority of today’s commercially built steam-
heated or direct-fired dry kilns are made of either
Chapter 4 was revised by R. Sidney Boone, (1) prefabricated aluminum panels on a steel or alu-
Research Forest Products Technologist, and minum structural frame or (2) masonry, primarily con-
William T. Simpson, Supervisory Research crete block or light-weight aggregate block and some-
Forest Products Technologist. times precast concrete. Although aluminum prefab-
ricated kilns require a larger capital investment, the
amount of maintenance required is considerably less
than that required by a concrete block structure.

87
Prefabricated Aluminum Panels Masonry

The prefabricated aluminum panel for walls and roofs Masonry kilns may develop cracks from expansion and
of dry kilns was developed in the mid-1950’s, and by contraction caused by temperature changes inside the
1960 it had received rather widespread acceptance. kiln during the drying run. This problem is sometimes
Early designs used the type of insulation board then exaggerated by a large temperature difference between
in common use in residential and commercial buildings. the inside and outside environments. Most concrete,
Later designs used fiberglass insulation, and more re- including concrete blocks, is rather porous and can ad-
cent designs use a rigid foam insulation. The design sorb large quantities of water vapor from the kiln atmo-
and construction of panels for walls, roofs, and doors sphere. If cracks are not sealed when small, they will
are frequently the same, although in some cases pan- increase in size, which leads to excessive heat and va-
els for roofs are thicker and have more insulation. The por losses and premature failure of the entire structure.
aluminum panels generally are not affected by the ex- Large cracks may also cause cold zones in the kiln that
pansion and contraction that occurs in a kiln cycle, slow up drying and permit mold and stains to develop
even those cycles in which dry-bulb temperatures go on the lumber located in those zones.
as high as 250 to 300 °F. At operating temperatures
above about 215 °F, some manufacturers prefer fiber- Proper maintenance of concrete kilns or concrete parts
glass insulation; others prefer rigid foam insulation in of a kiln consists of prompt recognition and repair of
the aluminum panels. problem areas. Some good maintenance practices for
concrete kiln structures are as follows:
Insulation values for aluminum panel kilns range from 1. For all kilns constructed of masonry or wood (or
an R value of about 16 for 2-in-thick panels to about lined with plywood), coat the inside surfaces with
32 for 4-in-thick panels. In contrast, concrete block
a vapor- and corrosion-resistant material before the
kilns have R values ranging from only 1 to 3, depend- kiln is used and whenever required thereafter. Usu-
ing on thickness, type of aggregate, and whether or not ally recoating is necessary every 2 to 5 years. Suit-
the cores are filled with insulation. A wood-frame wall able coatings can be obtained from dry kiln manu-
will have an R value of 4 to 5 when the stud space is facturers or other knowledgeable suppliers. Never
not filled with insulation and a value of about 12 when put vapor-resistant coatings on the exterior surfaces
filled with insulation. of masonry or wooden dry kilns, though a water-
repellent coating can be applied if desired.
Maintenance of aluminum panels usually requires only
ensuring that moisture does not get past the skins and 2. As soon as possible, seal cracks that develop in the
wet the insulation, reducing its value. This means re- structure as a result of repeated expansion and con-
pairing (sealing) any holes or tears in the skins as soon traction of the building material. If the cracks are
as they are noticed. Care should also be taken to re- small, a coating of kiln paint may be sufficient, but
pair any separation between the aluminum skin and larger cracks should be filled with mastic, mortar,
the metal frame around each panel. Moisture can enter or cement. Coat the mortar or cement fillers with a
the interior of the panel and wet the insulation through kiln paint after they have set.
this avenue as well as through holes in the skins. Weep 3. Cracks that develop because of settling of the struc-
holes are usually put in the bottom of the panels for
ture can be temporarily repaired in the same man-
draining water that may build up in the panel, but the ner as expansion and contraction cracks. To re-
weep holes must be kept open and free from sawdust or duce future maintenance costs, however, determine
dirt. the cause of the settling and correct it as soon as
possible.
Steel components of a dry kiln must be protected from
water vapor as well as corrosive vapors that are emit- 4. Openings in the kiln structure for steam lines, tub-
ted from certain woods during drying, such as oak and ing, fan shafts, and the like should be as small as
hemlock. This is commonly done by painting or spray- possible. Insert sleeves in the openings and plug the
ing a vapor- and corrosion-resistant paint or coating on space not occupied by pipe with epoxy or silicone
the steel members. Recoating is usually necessary every compounds or some similar material.
2 to 5 years. Suitable coatings can be obtained from
5. Promptly caulk with a nonhardening filler any open
dry kiln manufacturers. joints and splits that occur in wood or plywood
dry kilns. Refasten all loosened boards as soon as
possible.
6. Use noncorrosive metal fastenings if possible.
7. Immediately repair or replace failed supporting
members of the structure

88
Steel components of a dry kiln must be protected from Floors
water vapor as well as corrosive vapors that are emit-
ted from certain woods during drying, such as oak and The floors of most commercial dry kilns are con-
hemlock. This is commonly done by painting or spray- structed of concrete. In some small kilns, usually
ing a vapor- and corrosion-resistant paint or coating on operated on a part-time basis and perhaps home
the steel members. Recoating is usually necessary every designed, the floor may be crushed stone, lumber,
2 to 5 years. Suitable coatings can be obtained from or even dirt or sand. All types of floors require
dry kiln manufacturers. maintenance.

Doors Good maintenance practices for kiln floors include the

following:
Doors are frequently the weakest and most troublesome 1. Provide a waterproofing treatment on new concrete
part of a kiln structure. They are often damaged when floors to prevent spalling or scaling. Treat again
they are opened or closed carelessly, when a forklift op- when necessary.
erator does not pay attention when loading or unload-
ing the kiln, or when an improperly blocked truckload 2. Repair and seal cracks in concrete floors that
of lumber in a track-loaded kiln rolls into the doors. develop because of settling or expansion and
The common use of prefabricated aluminum doors, contraction of the concrete.
on both aluminum prefabricated kilns and masonry 3. For stone, dirt, or sand floors, maintain an even floor
kilns, has solved many of the problems associated with level, filling holes and leveling as needed.
doors on the dry kilns of the 1930’s, 1940’s, and 1950’s.
During that time, it was difficult to design and build a 4. Provide proper drainage of site so that rain and
large door that was strong, lightweight, easy to handle, surface runoff do not flood kiln floor.
well insulated, and resistant to corrosion.
Rails and Rail Supports
Doors, door hangers, stops, rollers, roller tracks, and
gaskets that are poorly maintained cause excessive Generally, rails and rail supports in kilns with fans or
losses of heat and vapor and are difficult to open and
blowers located above or on the sides of the drying
close. Lower temperatures occur near damaged or
compartment are not troublesome, since the rails are
poorly fitted doors because of cold air infiltration,
usually well supported and anchored. Weak rails or
and drying is slower in that zone. In high-temperature
rail supports in old converted natural-circulation kilns
kilns, large amounts of condensate form on the frame-
and in older design forced-circulation kilns, where the
work near the doors when they are opened at the com- fans or the air-supply ducts are located below track
pletion of the kiln run. Steel members should be ad-
level, may collapse or spread under heavy loads. Fail-
equately protected to prevent excessive corrosion and ure of the rails or rail fastenings can seriously damage
rust. Neglect of doors and door equipment may also kiln equipment, injure workers, and result in lost drying
create a hazard to workers. Some good maintenance time.
practices for door and door equipment are as follows:
Good maintenance practices for rails and rail supports
1. Immediately repair or replace damaged door
include the following:
hangers, rollers, and roller tracks.
1. Immediately replace or tighten broken or loose rail
2. Lubricate parts in accordance with the manufac-
fastenings.
turer’s recommendations.
2. Promptly realign spread rails and securely fasten
3. Repair or replace torn or missing gasket material or
them to the rail supports.
gaskets that no longer provide an adequate seal.
3. Leave a break in the rails under the doors to min-
4. Instruct or warn lift truck operators to be alert to
imize rail corrosion caused by condensate dripping
minimizing damage to doors (also to walls and
from the doors.
baffles) when loading or unloading the kiln.
4. As needed, apply corrosion-resistant paints to the
5. In package-loaded kilns, ensure that piles are stable
rails, metal rail supports, and rail fastenings.
and will not tip over into doors or walls.
6. In track-loaded kilns, block wheels of standing
loaded kiln trucks, so that the trucks cannot roll
into the kiln door.

89
Recording–Controlling Instruments degrade. Using brackets furnished by the kiln manu-
facturers and following the instructions for installation
Accurate control of both the dry- and wet-bulb temper- should ensure satisfactory readings from the sensors.
ature (or dry-bulb and relative humidity) is essential
for efficient kiln operation. The most common and the Wet-Bulb Sensors
best method of control is the use of semiautomatic or
fully automatic recording-controlling instruments. (See The wet-bulb sensor must be located so that air circu-
Equipment to Control Drying Conditions section in lates around it at all times. Experience suggests that
ch. 2 for a detailed description of control instruments.) air speeds as low as 150 ft/min are satisfactory, but
Although these instruments are usually efficient, they more reliable readings are obtained at air speeds of 300
are at times troublesome. Some problems are associ- to 600 ft/min or higher. Only one wet-bulb sensor is
ated with improper location of the sensors or bulbs. located in each kiln because the wet-bulb temperature
Once sensors and bulbs are properly located, problems is essentially the same throughout the kiln and is not
may arise from improper calibration, faulty flow of wa- as variable as the dry-bulb temperature. The wet-bulb
ter to the wet-bulb pan, and dirty wet-bulb wicks. The sensor should be located about the middle of the kiln
efficiency of air-operated instruments may be seriously lengthwise and at a height above the floor that allows
impaired by oil, water, and dirt in the compressed air. convenient inspection of wick and water level. Improper
Approximately 25 percent of pneumatic instrument fail- location and care of the wet-bulb sensor result in poor
ures can be attributed to a contaminated air supply. control of the wet-bulb temperature. When the kiln
is operating, the wick must be kept wet by a constant
Proper Location of Control Sensors or Bulbs supply of clean water to the water pan or reservoir. A
dry or partially dry wick will result in an actual wet-
bulb temperature in the kiln lower than that recorded
Dry-Bulb Sensors
or indicated on the instrument. The instrument then
To accurately sense temperature, the sensor must be signals the vents to open in an effort to reduce humid-
mounted in the main airstream flowing in the plenum. ity. Therefore, occasional cleaning of the water reser-
It cannot be too close to the wall or to the load of lum- voir and flushing of the supply line are recommended.
ber. Care must also be taken not to place the sensors The flow of water to the water reservoir is usually con-
and capillary tubes too close to steam pipes or other trolled by a needle valve, which needs to be regulated
sources of heat that may give false readings. The tradi- from time to time. If the flow of water is too rapid, its
tional approach has been to have at least two dry-bulb temperature may be too low when it reaches the bulb,
sensors and one wet-bulb sensor in a kiln. Longer kilns and the thermometer can give a false reading.
usually have four dry-bulb sensors and one wet-bulb
sensor. This is known as a dual end control system; one In some steam-heated kilns, condensate from the drain
set of dry-bulb sensors is located about one-fourth to end of the coils is used to supply water to the wet-
one-third the length of the kiln from one end and the bulb wick. The condensate is piped from the drain line
other set, one-fourth to one-third the distance from the through a coiled copper tube for cooling and then piped
to the water reservoir. In using this system, care must
other end. The dry-bulb sensors are mounted on oppo-
site walls of the kiln and are hooked up such that the be taken to assure that the water is adequately cooled,
bulb on the entering-air (hottest) side of the load pro- for water that is too hot will also give false readings.
vides the signal that is sent to the instrument. When
The wet-bulb sensor itself should never, under any cir-
the airflow is reversed by the fans, the bulb on the op-
cumstances, touch the water in the reservoir nor should
posite side of the kiln becomes the controlling bulb.
water drip directly on the sensor.
Dry bulbs that are improperly located may result in
very high temperatures that increase drying losses or
in very low temperatures that prolong drying time and The water reservoir should be equipped with an over-
flow line that has its discharge end outside the kiln,
result in mold and stain.
and the water supply should be regulated so that
Although it is common to locate one of the dry-bulb the discharge is a very slow drip, not a steady flow.
sensors near the wet-bulb sensor, never locate the dry- The overflow line must be kept open to prevent wa-
bulb sensor below the wet-bulb sensor. If the wet-bulb ter spilling over the top of the pan into the kiln. If the
water reservoir overflows, or if liquid water falls on the kiln is shut down for a day or more, shut off the water
dry-bulb sensor, it will be cooled and will thus sense a supply; if the temperature in the kiln is likely to drop
below freezing during this time, drain the water lines
temperature that is lower than the actual temperature.
and water reservoir. After a shutdown, the wick should
This false lower temperature causes the heat valves to
be replaced when the kiln is restarted.
open, resulting in kiln overheating and the potential for

90
A dirty or badly encrusted wick affects wet-bulb con- entering the instrument. The trapped oil or moisture is
trol. The wet-bulb wick should be made of highly ab- blown from the dripwell or trap at least once daily by
sorbent cloth. Replace the wick frequently with a new opening a blowoff valve. Usually the elements in filters
or laundered one whenever the kiln is loaded with a must be replaced once a year or more frequently if they
new charge of lumber or more frequently if necessary. become discolored.

The wet-bulb sensor in a gas-filled or liquid-vapor sys- Repairs to electronic or computerized recorder-
tem is frequently plated to minimize corrosion. When controllers should be made only by an experienced
changing the wick, check the bulb for pitting or other technician or authorized serviceperson. The skills and
surface deterioration. When necessary, have the bulb tools needed are different from those used in gas-filled
replated or replaced by the instrument manufacturer. systems. For those instruments controlling air-actuated
valves, the compressed air supply must be clean and
Because of the cooling effect of evaporation, the wet- protected from oil and moisture. The clock must be
bulb temperature in a dry kiln is usually lower than lubricated occasionally. The slide wires on the servo
the dry-bulb temperature; at no time can it be higher. motors may need to be cleaned if pen response becomes
If the reading is higher, the instrument is out of sluggish.
calibration.
Calibration of Recording–
Equilibrium Moisture Content and Controlling Instruments
Relative Humidity Sensors
When instruments are out of calibration, the actual
Some recorder-controllers and some drying systems use drying conditions within the kiln differ from those
sensors that tense equilibrium moisture content or rel- recorded on the chart, and serious kiln-drying defects
ative humidity directly, rather than indirectly through or increased drying time may result. Because a new
wet-bulb thermometry. While the manufacturer’s in- instrument may be jarred during shipment, check cal-
structions should be followed to the letter, the same ibration at two or three points over total range at the
general principles for locating dry-bulb sensors apply to time of installation. Thereafter, check it for accuracy
wet-bulb sensors. frequently by using thermometers.

Care of Recording–Controlling Instruments Recalibration of a recorder-controller found to be in er-

ror is not difficult, but it should be done carefully. The
The period of reliable performance of control instru- equipment required includes a liquid container and an
ments can be greatly increased by proper care. The accurate temperature-measuring device. Because the
parts of a recorder-controller are precision built and difference in height between bulbs of gas-filled systems
can be easily damaged. However, they are well pro- and the recorder-controller case affects the recorded
tected against injury and dust, and they will give trou- temperature, verify that the bulbs are at the correct
blefree service for many years if the case is not left height in relation to the instrument by checking the no-
open too long at a time. Replace broken cover glass im- tation on the information plate inside the instrument
mediately. Never use compressed air, brushes, or cloth case. Calibrate the instrument with the bulbs at about
to clean off dust that may settle within the instrument the same height above or below the instrument case as
case. they will be in service. Height does not affect resistance
temperature detectors (RTD). Two people are required
Generally, repairs of gas-filled or liquid-vapor systems for the calibration-one at the sensor in the liquid con-
should not be attempted in the field. Instrument repair tainer and one at the instrument.
and cleaning require special tools, skills, and equip-
ment. Such work should be done at the manufacturer’s The procedure for calibration is as follows:
plant or by an authorized serviceperson. 1. Fill the liquid container with water or oil at least as
deep as the sensors are long, so that the sensors can
The only part of the control instrument that requires be completely submerged. Heat the water to 200 °F
lubrication is the clock, and this should not be done or the oil to about 280 °F, and place the container
too frequently. Never lubricate the pivot points on the near the sensors.
linkage arms.
2. Remove the sensors from their fastenings and com-
The compressed air flowing into an air-operated instru- pletely submerge in the heated liquid. If the dry-
ment must be free of oil and moisture. The quality of and wet-bulb sensors are located together in the
the compressed air is very important. For this reason, kiln, calibrate them together. Avoid sharp bends in
the air is passed through a filter dripwell or trap before the tubing of gas-filled systems. The sensors should

91
 not touch the sides or bottoms of the container. In a Some kiln operators prefer not to adjust the instrument
dual dry-bulb system, only one sensor usually needs pens or control-setting indicators. Instead, they list the
calibration. If there has been a difference in the calibration data and place this list near the face of the
temperatures recorded by the dry-bulb thermome- instrument. These data are used as a guide for setting
ters at fan reversal during kiln operation, check each the instrument in kiln runs.
sensor separately. The person stationed at the liquid
container should gently and constantly stir the liquid Resistance sensors can be calibrated as outlined above,
during calibration. or they can be calibrated quickly with precision electri-
cal resistors. (For a more complete discussion, see the
3. After about 10 min, the person at the liquid con-
section on semiautomatic control systems in ch. 2.)
tainer should take a temperature reading of the hot
liquid with the thermometer or other device. The Dry kiln operators should be familiar with the man-
person at the instrument then records this read-
ufacturer’s instructions for the care and maintenance
ing together with the corresponding temperature
of recorder-controllers. If the instrument should fail,
indicated by the instrument.
trained service people should be contacted for advice
4. Record these two temperatures every 20 °F as the and service.
liquid gradually cools. If cool liquid is added to re-
duce calibration time in gas-filled systems, let 5 to
Heating Systems
10 min elapse before temperatures are taken, so
that the temperature change is reflected at the in-
A correctly designed and properly maintained heating
strument, Resistance systems stabilize almost im-
system produces uniform drying conditions in a kiln.
mediately. Make periodic check readings until the Unfortunately, the maintenance of heating systems is
liquid temperature drops to below the lowest kiln
often neglected, and the consequent nonuniform drying
temperatures used at the plant.
conditions cause kiln degrade, extended drying time,
5. If the indicated temperatures on the instrument nonuniform moisture in the lumber, and increased dry-
chart are consistently lower or higher than the wa- ing cost. On the other hand, frequent inspection and
ter temperatures by a constant amount, adjust the prompt corrective action can minimize, if not eliminate,
recorder pen arms upward or downward by that many adverse effects.
amount by turning the small screw located on the
pen arm or the pen arm pivot. If the differences Steam-Heated Kilns
between the indicated temperatures and the water
temperatures are not constant, a trained technician Problems that occur with steam-heated kilns include
should make the adjustment. A correction chart can improperly insulated feedlines, leaking pipes and
be made so that the instrument can be used in the unions, sagging and distorted pipes, defective valves
interim until it is adjusted. and regulators, faulty pressure gauges, faulty automatic
6. The next step, the adjustment of the control-setting and manual control valves, and faulty steam traps.
indicator, should be made only by a knowledgeable,
experienced person. The indicator is adjusted while Improperly Insulated Feedlines
the compressed air or electricity is on. Lower the
temperature-setting indicator to a temperature be- Insulate all main feedlines from the boiler to the
low that indicated by the pen on the chart and then kiln to reduce losses in steam temperature, pres-
move the indicator slowly upward until the motor sure, and consumption. In control rooms or other
valve it controls begins to open. Record the temper- areas frequented by workers, steam lines, headers, and
ature shown by the setting indicator. Then move the valves should be insulated for safety. The insulation on
setting indicator slowly downward until the motor many steam feedlines is either improperly installed or
valve begins to close and record the indicated tem- damaged. Replace deteriorated or damaged insulation
perature. If the average of the two recorded temper- as soon as possible.
atures is different than the temperature indicated
by the pen, move the control-setting indicator-
Leaking Pipes and Unions
by means of adjustment screws on the indicator-
upward or downward by the amount of the
Leaking pipes, caused by corrosion or mechanical dam-
difference.
age, increase steam consumption. If the leak occurs
within the kiln, this will affect the wet-bulb tempera-
ture. Repair or replace leaking pipes. When necessary,
clean all pipes and fittings.

92
Sagging and Distorted Pipes Manual valves are used extensively on steam heating
systems. These valves, which are usually of the gate
Feedline and coil supports frequently fail, causing the type, should be operated wide open or completely
pipes to become distorted and to sag. Condensate and closed. Open or close the valves occasionally to keep
scale accumulate in the sagged pipes and eventually them from rusting or corroding in the open or closed
plug them. Sagging coils will become water logged, position. If leaks occur around the valve-stem packing
thereby drastically reducing their ability to transfer nut, follow the procedure outlined for faulty automatic
heat to the kiln. Straighten or replace sagging and dis- valves. Keep replacement valves and spare parts on
torted pipes. Protect pipe supports against corrosion, hand.
and reinforce or replace them when examination shows
they are failing. Faulty Steam Traps

Defective Valves and Regulators Consult kiln manufacturers, engineers, and steam-trap
manufacturers on trap installations to minimize fail-
Fluctuations in steam pressure caused by faulty ures in the trapping system. The following summary
pressure-reducing valves and regulators result in will assist the operator in locating and correcting trap
nonuniform drying conditions. If adjustment does not problems.
correct the condition, repair or replace the defective
parts. The failure of a steam trap to discharge may be due to
(1) excessive operating pressures, (2) failure of conden-
Faulty Pressure Gauges sate to reach the trap, (3) a plugged bucket vent (in
the case of bucket traps), (4) dirt in the trap, (5) worn
The pressure gauges used in conjunction with the re- or defective parts, or (6) excessive back pressures in
ducing valves and regulators occasionally go out of cal- the condensate return line. Excessive operating pres-
ibration. Recalibrate the gauges at intervals against a sures in the steam feedline may be caused by the failure
gauge known to be accurate or replace them. of the reducing valve or pressure regulator, by inaccu-
rate readings on the pressure gauge, or by the raising of
steam pressures beyond the operating range of the trap.
Faulty Automatic and Manual Valves Failure of the condensate to reach the trap may be due
to a closed motor valve on the feedline, a closed manual
Automatic valves that control steam flow may leak or valve in the line between the coils and the trap, open
fail to open or close properly. Failure of an air-operated or leaking bypass valves that allow the condensate to
motor valve to open is usually associated with a leak flow around the trap, or water-logged steam lines. Dirt,
in the air supply line, a damaged diaphragm, or an rust, or scale in the condensate may plug the bucket
overtight packing nut that causes mechanical bind- vent. This problem can be minimized by installing a
ing. Some valves have a compression spring that fa- strainer ahead of the trap and cleaning it at frequent
cilitates opening; others have springs that facilitate intervals. A strainer will also prevent the trap body
closing. The springs should be checked periodically
from becoming filled with dirt. Install blowoff valves on
for proper adjustment and functioning. Failure of elec- all traps, and blow out the traps for a short period each
trically operated valves may be associated with power day the kiln is in operation.
failure, damaged wiring, or faulty motor. A valve that
leaks because of worn parts or the presence of scale on Continuous discharge of water from a trap can be
the seat can usually be detected by a slow, continuous caused by the inadequate size of the trap or trap ori-
rise in temperature above the set point. A valve that fice (that is, an opening too small for the steam pres-
is slow to open or fails to open can be detected by a sure used), rust or scale under the seat in a disc trap, a
slow drop in temperature below the set point when the worn seat that prevents proper closing, or a rusted bel-
instrument is calling for heat. lows. These difficulties can be prevented by installing a
trap that has been sized correctly and is large enough
Repair or replace faulty valves. Keep a spare mo- to handle the peak condensate load, which will usually
tor valve on hand as well as extra motor valve parts, occur during the warmup period.
including diaphragms, springs, packing compound,
valve stems, and valve seats. If leaks occur around the If the trap blows live steam, the discharge valve may
valve-stem packing nut, tighten the nut or replace the not be seating. A bucket-type trap that blows live
packing. steam may have lost its prime. A badly worn valve
seat or dirt lodged between the valve and valve seat
will cause improper seating of the valve. A trap that

93
loses its prime is usually subjected to sudden or fre- Let us assume the upstream pressure in the piping sys-
quent drops in steam pressure. If this occurs frequently, tem is 150 lb/in2-gauge, and the pressure downstream
install a good check valve ahead of the trap. Maintain- of the trap is 15 lb/in2-gauge. The pyrometer measures
ing a fairly constant supply of steam pressure will also an upstream temperature of 335 °F and a downstream
minimize this problem. temperature of 225 °F. (File or wire-brush the pipe at
points of measurement to provide good contacts for the
Worn or defective trap parts may cause complete fail- tip of the pyrometer.) Table 4-2 shows that for an up-
ure. Some parts can be easily replaced on the job with stream pressure of 150 lb/in2-gauge, a pyrometer read-
very little, if any, loss in operating time. Replace- ing between 348 °F and 329 °F should be obtained. For
ment is even simpler if a bypass line has been installed a downstream pressure of 15 lb/in2-gauge, a pyrome-
around the trap. When a defective trap cannot be re- ter reading of between 238 °F and 225 °F is desirable.
paired on the job, replace it with a new or recondi- We can conclude, therefore, that the trap is functioning
tioned trap. Repair the defective trap at the first op- properly.
portunity. Annual cleaning and overhaul of all traps is
recommended. Now let us assume the same pressures, but a pyrometer
reading of 335 °F upstream and 300 °F downstream
Trap failure can be detected by observing discharge of the trap. The insufficient spread between the two
from the trap, obtaining temperatures on the supply temperatures indicates that live steam is passing into
and discharge sides, or listening to the action of the the condensate return line. The trap has failed while
trap. The discharge action of most traps can be ob- open, and it needs to be repaired or replaced.
served from test outlets. These should be opened fre-
quently. If steam discharges continuously from a cor- In still another example, suppose the pyrometer read-
rectly sized trap, the trap is not functioning properly; ings are 210 °F on both sides of the trap. Such a read-
determine the cause and correct it. Do not confuse ing is all right downstream, where we know the pres-
flash steam with live steam. Flash steam, which is due sure is 15 lb/in2-gauge. However, this reading is too
to pressure changes, is white as it leaves the test valve. low upstream where we know the pressure is 150 lb/in2-
Live steam generally appears in a continuous flow, and gauge. The low upstream temperature probably indi-
it is transparent as it leaves the test valve. cates a restriction in the line that is reducing the pres-
sure to the trap. A clogged strainer may be the culprit;
By listening carefully to traps during operation, traps blow out the trap before looking any further for a cause
can be checked without visual observation of the con- for the problem.
densate discharged. This method is, therefore, much
more convenient when working with a closed conden- Although these examples deal with a closed return sys-
sate return system. The necessary equipment consists tem, the temperature measurement method can also be
of an industrial stethoscope or a homemade listening used to check traps that discharge to the atmosphere.
device such as a 2-ft length of 3/16-in steel rod in a file In this situation, of course, the downstream pressure is
handle, a piece of wood dowel, or a screwdriver (table always atmospheric.
4-1). With a little practice, the operation of the inter-
nal components of the trap can be heard with any of Direct-Fired Kilns
these homemade devices merely by placing one end of
the tool against the trap bonnet and the other end to In direct-fired kilns, the hot gases produced by burning
your ear. gas, oil, or wood waste are discharged directly into the
kiln. Burners commonly have electrically or pneumati-
A steam trap is essentially an automatic condensate cally modulated fuel valves. Temperature-limit switches
valve, the only function of which is to pass condensate are located on the inlet and discharge ends of the com-
and hold back steam. This definition implies that a bustion chamber and are set to shut down the burners
significant temperature differential exists between the if they overheat beyond the predetermined set point.
upstream and downstream sides of a properly function- Careful attention should be paid to proper monitor-
ing trap. Trap performance, therefore, can be checked ing and maintenance of all sensors, temperature-limit
by measuring temperatures on the pipeline immediately switches, and safety equipment associated with the
upstream and downstream of the trap. Two require- burner. Manufacturer’s recommendations and instruc-
ments for this method are a simple contact pyrometer tions and State safety codes should be closely followed.
for making the measurements on the surface of the pipe
and a knowledge of line pressure upstream and down-
stream of the trap. For each steam pressure, there is a
corresponding steam temperature. Table 4-2 shows typ-
ical pipe surface temperature readings corresponding to
several operating pressures.

94
Humidification Systems The controller and the vent systems should be adjusted
so that venting and spraying cannot occur at the same
time. This obviously wastes energy, and in cold cli-
Steam Spray mates the spray can condense on contact with cold
air and cause accelerated corrosion of any steel sur-
Steam sprays supply moisture to the kiln atmosphere face with which the condensate or “rain” comes into
when required to maintain the desired relative humid- contact.
ity. Saturated or “wet” steam is preferable to super-
heated or “dry” steam for this purpose. Using low pres- Although vents can be manually or automatically op-
sure steam or installing a desuperheater in the steam erated, automatic ones are recommended. To prevent
line are common ways of obtaining saturated steam
excessive venting, frequently inspect the system and
(see discussion of humidification in ch. 2). Manual or
keep it in good repair. This generally means going
automatic valves controlling the flow of steam spray
on the kiln roof rather than observing the vents from
into a kiln require the same maintenance as those used groundlevel. The inspection and maintenance of vents
in steam-heating systems. Follow the inspection and require the following:
maintenance procedures as discussed for heating sys-
tems. A flow of steam or condensate from the steam 1. Keep the linkage system connecting two or more
spray line when the valves are closed indicates leakage vent lids or dampers lubricated and inspect it pe-
through the control valve. A falling wet-bulb temper- riodically for damage and excessive wear at pivot
ature when the control instrument is calling for steam points. Straighten, repair, or replace bent, broken,
spray indicates there is an inadequate supply of spray or excessively worn pins, hinges, rods, chains, and
into the kiln or the steam spray motor valve has failed levers.
to open. Repair or replace defective valves immediately. 2. Inspect the vent lids or dampers when they are in a
closed position. If the lids or dampers are partially
The steam spray lines usually slant downward from the open, adjust the linkage so that the lids or dampers
feed end. Usually a small drain line discharging out- fit tightly. This adjustment can be made quickly and
side the kiln is provided to drain off the condensate easily on most kilns.
that collects at the low end. Keep this drain line open.
Inspect the steam spray line itself periodically to see 3. Install gaskets around vent openings if there is ex-
that the discharge holes or nozzles are open and that cessive leakage when the vent lids are closed.
the pipe has not been bent or turned so that the spray 4. Avoid overventing. Adjust the linkage so that the
discharges onto the lumber or the instrument control lids or dampers are open just wide enough to obtain
bulbs. the desired venting. High winds will often keep vent
lids open even if no air is supplied to the control
Water Spray valve. This can be corrected with a counterweight.
5. Examine air lines or electric circuits connecting the
Occasionally water spray lines are installed in kilns to vent mechanism to the control instrument for air
supply moisture when required for humidification. Gen- leaks and short circuits.
erally, water spray cannot supply sufficient water vapor
required for effective conditioning treatments. Inspect 6. Keep the compressed air used to operate the vent
the valves frequently that control the flow of water into mechanism dry and free of oil. Water in the air
the spray line and repair or replace defective valves im- supply line may freeze the motor valve during cold
mediately. Open plugged spray holes or nozzles and weather. If dry compressed air cannot be obtained,
repair or replace damaged lines. protect the air supply line against freezing.

Venting systems Air-Circulation Systems

Most kilns are provided with ventilators for exhaust- The uniform circulation of air in a kiln is extremely im-
ing hot, moist air from the kiln and taking in fresh air. portant for proper drying, and it is dependent on well-
Excessive venting increases heating and humidification maintained air-circulation equipment. Any failure or
requirements, and it should be avoided by proper ad- damage to the component parts of the air-circulation
justment and maintenance of the venting system. An system extends drying time and may also result in
effective and low-cost method for preventing excessive nonuniform drying. Therefore, the maintenance and
venting is the installation of an air exhaust valve on the care of the component parts of the air-circulation
air line at the vent control valve. system are essential.

95
The items to be checked in the periodical inspection of 4. Fans
the air-circulation system and some of the maintenance
a. Repair minor damage to fans; replace badly
procedures include the following:
damaged fans.
1. Fan motors
b. Keep fans tight on fan shafts.
a. Lubricate fan motors in accordance with the
c. See that the clearance between the tips of fan
manufacturer’s instructions. Replace leaky
blades and the fan shroud conforms to the
bearing seals.
manufacturer’s recommendations.
b. Keep windings and armatures free of dust. Dry
d. Ensure that all fans are rotating in the same di-
compressed air may be used for blowing out dust.
rection and that all reverse at the proper time.
c. Keep motor mounts and anchor bolts tight. This is especially important to check in cross-
shaft fan arrangement.
d. Protect fan motors located outside the kiln from
the weather. Caution: Exercise extreme care when fans must
be inspected while they are running. Do not
e. Properly ventilate the control room to avoid stand on fan deck when fans are running; rather,
overheating fan motors. stand on ladder and look over edge of fan deck.
f. In the kiln, use fan motors designed for high Serious injuries have resulted from carelessness
temperatures and high relative humidities. during the inspection of moving fans.

g. Protect fan motors against overloading. Relays 5. Fan baffles and floor
should be set to kick out under small overload. a. Repair or replace damaged fan baffles and floors.
h. Repair or replace damaged or badly worn motors. b. Keep anchor bolts in fan baffles tight to minimize
i. Have a qualified electrician inspect all elements of vibration and possible damage to fans.
the electrical circuits periodically and keep them
6. Load baffle system (includes top, floor, and end
in good condition.
baffles)
2. Fan shafts
a. Repair or replace damaged baffles.
a. Lubricate shaft bearings according to the man-
b. Lubricate baffle hinges.
ufacturer’s instructions and replace leaking oil
seals. c. Maintain pulleys and cables on hinged baffle
systems in good condition.
b. Keep bearing supports tight and aligned with the
shaft. Misalignment may overload the fan motor 7. Oil lines, connections, and bearings
and damage the fan shaft and bearings. a. Leaking oil lines, connections, and bearings in-
c. Keep fans shafts aligned, both horizontally and crease safety and fire hazards, create an adverse
vertically. working environment, and may stain the lumber.
d. Keep friction and babbitt bearings tight. b. Make a systematic inspection for oil leaks and
tighten loose connections.
e. Replace damaged or badly worn bearings.
c. Repair or replace damaged lines.
f. Replace or repair badly worn keys or keyways.
g. Keep shaft couplings tight.
Kiln Trucks
h. Replace damaged fan shafts.
3. Pulleys and belts Frequent inspection and proper maintenance of kiln
trucks can minimize downtime and accidents. Proper
a,. Keep pulleys tight on the shafts. lubrication will help extend truck life. Recommended
b. Replace badly worn or damaged pulleys to maintenance procedures are as follows:
prevent excessive belt wear or belt slippage. 1. Repair or replace damaged truck frames, axles, and
c. Tighten belts according to manufacturer’s bearings promptly.
recommendations. Do not overtighten. 2. Keep bolts and rivets in truck frames tight.
d. Replace badly stretched or damaged belts. 3. Repair or replace damaged metal or wood cross
e. Keep all belts uniformly tensioned or tight on supports.
multibelt systems. 4. Provide enough trucks so that no truck is loaded
over its capacity.

96
Use of Protective Coatings 8. Keep transfers, tracks, and tramways on the loading
and unloading ends of dry kilns in good alignment
Since ferrous (iron) metal in a dry kiln will rust or cor- and repair.
rode, frequent inspection of metal parts is essential.
9. Inspect stairways and ladders frequently and replace
Remove rust and coat the affected surface with a suit- weak members at once.
able protective paint. Such paints can be obtained from
dry kiln manufacturers. (If manufacturers do not have 10. Keep walkways along roof in good repair to provide
these paints, they may furnish names of suppliers.) access for inspection of vents, vent motor valves,
Typical areas of rapid corrosion are around doors, the vent linkages, oil cups for bearings, and other parts
lower 16 to 24 in of structural support columns (H or of the kiln.
I beams) in aluminum prefabricated kilns, any location
where a steel column or beam attaches to or extends
through the kiln floor or wall, and any other location Locating Problems in Kiln
where condensation can occur for a prolonged period. Maintenance and Operation
Heat- and vapor-resistant kiln paint or coating is nec-
essary for the inside of block and concrete kilns to pro- To assist the dry kiln operator in rapidly finding the
tect masonry against humidity and condensation and causes of poor drying, the common sources of trouble
to reduce heat and vapor transmissions. Do not ap- are outlined in this section.
ply to the outside of masonry kilns as the moisture will
be trapped in the wall and speed deterioration of the If the dry-bulb temperature does not reach the set
structure. point in a reasonable length of time, the causes may
be as follows:

Housekeeping and Maintenance 1. Steam pressure is too low.

Around Dry Kilns 2. Heat transfer is insufficient.
3. Heating coil is damaged, waterlogged, air-bound, or
Good housekeeping around dry kilns is essential. The
plugged.
possibility of injuries, damage to equipment, derailment
of kiln trucks, and fires can be minimized by keeping 4. Manual valves on steam supply or drain lines are
the dry kiln, operating room, and surrounding area closed or only partially open.
clean and free of safety and fire hazards. Good house-
5. Automatic motor valve fails to open.
keeping practices include the following:
6. Steam trap is defective.
1. Immediately pick up stickers that have fallen from
loads of lumber and place them in conveniently 7. Valves are open on bypass line around steam trap.
located sticker racks.
8. Back pressures in return line to boiler are
2. Pick up lumber that has fallen from loads and repile excessive.
it on the loads or return it to the storage area.
9. Venting is excessive.
3. Remove sawdust and other debris that collects on
10. Leakage from kiln structure and around doors is
kiln roofs or sifts into the kiln.
excessive.
4. Keep kiln walkways free of debris.
11. Recorder-controller system is malfunctioning
5. If possible, push any stickers or lumber that project because
into walkways back into the load to prevent in-
a. air or electrical signal fails to travel from
juries to workers. Boards projecting into plenum
controller to motor valve or
spaces or between vertical stacks of lumber can also
cause nonuniform air velocities through the loads of b. sensor bulb (gas-filled or RTD) is not working
lumber. properly.
6. Stop oil or grease leaks around bearings, fans, blow-
ers, and motors, and wipe up spilled oil or grease as
soon as possible. Use drip pans to catch oil or grease
that drips from bearings. Place oily or greasy rags
in closed containers.
7. Keep control rooms clean, free of accumulated de-
bris. and well ventilated at all times.

97
If dry-bulb temperature continues to climb above the 2. Cold zones may be caused by
set point, the causes may be as follows:
a. infiltration of colder air through cracks in the kiln
1. Automatic motor valve is leaking. wall or around doors,
2. Motor valve remains open. b. damaged fans or fan motors,
3. Heat is being transferred through a common wall c. short circuiting of the air because of faulty
from an adjacent kiln. stacking or inadequate baffling,
4. Heat from steam spray is excessive (more common d. improper drainage of condensate from coils, or
at low wet-bulb depressions or during conditioning
e. downdrafts through the vents.
phase of schedule).

Incorrect recording of dry- and wet-bulb temperatures

If the wet-bulb temperature fails to reach the set point
may be caused by
in a reasonable length of time, the causes may be as
follows: 1. control instrument that is out of calibration or
damaged,
1. Insufficient steam is entering the spray line because
2. improper air circulation over control bulbs,
a. steam supply to spray system is insufficient,
3. exposure of control bulbs or capillary lines to direct
b. automatic motor valve fails to open,
radiation from heating coils and feedlines or heat
c. manual valve on feedline is closed or only from steam spray,
partially open, or
4. water on the dry bulb,
d. holes or nozzles in spray line are plugged.
5. dirty or dry wet-bulb wick or wet-bulb wick made of
2. Leakage of heat and vapor from kiln structure or improper cloth,
around doors is excessive.
6. too fast or too slow waterflow to wet-bulb water
3. Venting is excessive. pan,
7. absence of wick on the wet bulb,
If the wet-bulb temperature continues to rise above the
set point, the causes may be as follows: 8. misplacement of wick on dry bulb instead of wet
bulb,
1. Motor valve on steam spray line is leaking.
9. wrong recorder chart, or
2. Motor valve on steam spray line remains open.
10. excess capillary tubing on gas-filled or liquid-vapor
3. Water is standing on kiln floor. systems rolled up in kiln (best to roll up excess
4. Steam or water lines in kiln are leaking. capillary tubing in control room rather than kiln).

5. Valve in bypass line around motor valve is open.

6. Venting is insufficient.
7. Wet-bulb wick is dry, dirty, or crusty.

If the lumber is not uniformly dried or has excessive

degrade associated with hot or cold zones within the
kiln, the causes may be as follows:
1. Hot zones may be caused by
a. higher than average air velocities across heating
coils because of faulty stacking and inadequate
baffling,
b. leakage of heat through a damaged wall common
to two kilns, or
c. leakage in heating coils.

98
Table 4-1—Operating sounds of various types of traps

Operating sounds of Operating sounds

Trap type properly functioning trap of failed trap

Disc (impulse Opening and snap-closing Normally fails

or thermodynamic) of disc while open—
cycles in excess
of 60/min

Mechanical Cycling sound of Fails while open—

(bucket) bucket as it opens sound of steam
and closes blowing through
Fails while
closed—no sound

Thermostatic Sound of periodic dis- Fails while

charge if on medium- closed—no sound
to-high load;
possibly no sound if
light load (throttled
discharge)

Table 4-2—Pipe surface temperatures at various steam

pressures

Pipe surface termperature

Steam pressure Steam temperature range
(lb/in2-gauge) (°F) (°F)

99
 Appendix-
Kiln Inspection Checklist

(Where maintenance or replacement is recommended, indicate kiln number.)

I. Kiln Structure
1. Doors and door hangers, present condition:
Do door hangers operate properly:
Do doors fit properly:
Do gaskets adequately seal door:
What maintenance a replacement is recommended:
2. Walls, present condition:
IS protective coating adequate (masonry kilns):
Are cracks repaired or holes patched:
What maintenance or replacement is recommended:
3. Structural steel members, present condition:
Is protective coating adequate:
What maintenance or replacement is recommended:
4. Roof or ceiling, present condition:
Is protective coating adequate to minimize corrosion and vapor transmission:
What maintenance or replacement is recommended:
5. Floors and walkways, present condition:
What maintenance or replacement is recommended:
6. Rails and supports, present condition:
What maintenance or replacement is recommended:
II. Control system
1. Recorder-controller, present condition:
Is correct chart paper on instrument:
Is recorder-controller properly calibrated:
Are capillary tubes protected:
Are leads and connections of RTD adequately protected:
Are bulbs or sensors properly located and mounted for accurate reading of kiln
conditions:
Does cellulose EMC wafer need replacing:
What maintenance or replacement is recommended:
2. Water supply:
Is water supply line to wet bulb open:
Is wet-bulb water pan clean:
Is water supply unusually hot or cold:
Is drain line from water pan open:

100
 Is wet-bulb wick replaced regularly:
What maintenance or replacement is recommended:
3. Air supply:
Is compressed air supply at correct pressure, clean, and uninterrupted:
Is compressor in good condition:
Are water and grease traps in good condition:
What maintenance or replacement is recommended:
III. Heating and Humidifying System
1. Steam feedlines and headers, present condition:
Are feedlines and headers properly insulated:
What maintenance or replacement is recommended:
2. Heating coils or ducts, present condition:
Are all pipes open to full flow of steam:
What is the condition of supports:
Is ductwork bent or otherwise damaged:
What maintenance or replacement is recommended:
3. Traps, present condition:
Are traps in best possible location:
What maintenance or replacement is recommended:
4. Condensate return line, present condition:
Are condensate pumps working properly:
Is line properly sized for volume carried:
What maintenance or replacement is recommended:
5. Automatic and manual control valves, present condition:
Are automatic control valves working properly:
Are springs and diaphragms working properly:
Are manual blowdown-valves provided for traps:
Are manual valves provided for shutting off individual coils:
Are check valves working properly:
What maintenance or replacement is recommended:
6. Spray lines, present condition:
Are spray holes or nozzles open:
Does condensate from spray line drip on lumber:
Is spray line properly trapped:
What maintenance or replacement is recommended:
7. Vents, present condition:
Do all vents open and close properly:
Do air motors and linkages work properly:
What maintenance or replacement is recommended:

101
 IV. Air Circulation System
1. Fans and motors, present condition:
What is the condition of electrical connections and switches:
Are fans slipping on shafts:
Are all fans turning in proper (same) direction:
What maintenance or replacement is recommended:
2. Shafts and bearings, present condition:
Are motors and shaft bearings properly lubricated:
What maintenance or replacement is recommended:
3. Fan baffles, cowling, and fan floor, present condition:
What maintenance or replacement is recommended:
4. Load baffles, present condition:
Can load baffles be improved:
What maintenance or replacement is recommended:
5. Air passageways (including ductwork in direct-fired kilns):
Are air passageways open and unobstructed:
Could air movement be improved:
What maintenance or replacement is recommended:
V. General Condition of Yard, Kilns, and Control Room
Does grading and surface of yard provide for good drainage directed away from kiln(s): —
Are alleys adequate for maneuvering lift truck:
Are kiln trucks in good condition:
What maintenance or replacement is recommended:
Is control room neat and clean:
Are good kiln records kept:
Are kilns and surrounding area neat and clean:

102