Uguide 1451

08 33 4136 00
USER'S GUIDELINES 08 44 1451 00

Page 1
The Buyer: TIANJIN CEMENT INDUSTRY DESIGN & RESEARCH INSTITUTE

CO. LTD.
The End User: CASPI CEMENT KAZAKHSTAN
-------------------------------------
ROTAFLAM KILN FIRING SYSTEMS
-------------------------------------
Our Ref.: CONTRACT N° 08 33 4136 00 / 08 44 1451 00
Your Ref.: SINOMA/CASPI/2007/03

F126 (M) 005
--------------------------------------
PILLARD TIANJIN
Address : 88, Dong Fang Road, Free Trade Zone, Tianjin.

300461 PR CHINA
* Telephone +86 10 65 69 88 00
* Telefax +86 10 65 69 88 03
Beijing contact address :Room 503A, Tower B, Derun Tower,

3 Yongandongli Jia, Jianwai Ave,
Chaoyang District, Beijing 100022
PR CHINA
FIVES PILLARD
08 33 4136 00
Page 2
SUMMARY
SUMMARY............................................................2
PART 1 - PRELIMINARY SAFETY RECOMMENDATIONS........................5
PART 2 - TECHNICAL DATA...........................................10
PART 3 – FLOW SHEET...............................................12
PART 4 - SCOPE OF SUPPLY..........................................13
A: ROTARY KILN FIRING EQUIPMENT...................................13
A.1 - ONE (1) ROTAFLAM® ROTARY KILN BURNER FOR COAL/OIL FIRING .....................................................13
A.2 - ONE (1) GAS ELECTRIC IGNITOR ........................................................................................................................13
A.3 - ONE (1) TELESCOPIC COAL CONNECTION PIPE..............................................................................................14
A.4 - ONE (1) BURNER TROLLEY ..................................................................................................................................14
A.5 - SET OF MCRC OIL GUNS .......................................................................................................................................14
A.6 – MANUAL DIESEL OIL VALVE TRAIN ................................................................................................................14
A.7 – ONE (1) OIL PUMPING SET FOR KILN BURNER...............................................................................................15
A.8 – TECHNICAL SPECIFICATION FOR PRIMARY AIR DEVICE TO BE SUPPLIED ...........................................15
A.9 – EMERGENCY COOLING DEVICE TO BE SUPPLIED BY CLIENTS.................................................................15
A.10 – SPARE PARTS........................................................................................................................................................15
B: PRECALCINER FIRING EQUIPMENT...................................16
B.1 – FOUR (4) PRECALCINER BURNERS COAL FIRING..........................................................................................16
B.2 – TECHNICAL SPECIFICATION FOR PRECALCINER BURNERS PRIMARY AIR FAN TO BE SUPPLIED BY
OTHERS..............................................................................................................................................................................16
B.3 – SPARE PARTS..........................................................................................................................................................16
C: COMMISSIONING..................................................17
PART 5 – ERECTION.................................................18
5.1 - SUBJECT ....................................................................................................................................................................18
5.2 - PRELIMINARY ACTIONS .......................................................................................................................................18
5.3 - BEFORE ASSEMBLY ...............................................................................................................................................19
5.4 – FITTING THE SKIDS................................................................................................................................................20
5.5 - INSTALLATION OF EQUIPMENTS AND PIPING ................................................................................................20
5.6 - CONNECTING PIPING .............................................................................................................................................20
5.7 - ELECTRICAL PART (Not supplied by FIVES PILLARD).......................................................................................21
5.8 - RECOMMENDATIONS FOR FIELD TESTING ......................................................................................................21
5.9 - KILN BURNER ERECTION......................................................................................................................................23
5.10 – PRECALCINER BURNERS ERECTION ...............................................................................................................27
5.11 – REFRACTORY LINING .........................................................................................................................................29
5.12 – TELESCOPIC PIPE .................................................................................................................................................30
PART 6 - PRELIMINARY CHECK BEFORE START-UP........................31
6.1 - GENERAL REMARKS ..............................................................................................................................................31
6.2 - SAFETY RULES ........................................................................................................................................................31
6.3 - FLUID DISTRIBUTION CHECKING .......................................................................................................................32
6.4 – PUMPING SET CHECKING.....................................................................................................................................32
6.5 – FANS CHECKING (Not supplied by FIVES PILLARD)..........................................................................................33
PART 7 – START-UP.................................................34
7.1 - OIL PUMP START-UP ..............................................................................................................................................34
7.2 - BURNER PRINCIPLE................................................................................................................................................35
7.3 - ADJUSTMENT PRINCIPLE OF THE RV2 ..............................................................................................................37
7.4 - START-UP..................................................................................................................................................................39
7.5 - POWER RISE .............................................................................................................................................................40
7.6 - FLAME SHAPE ADJUSTMENT IN OPERATION ..................................................................................................41
7.7 - TEMPORARY ACTIONS ..........................................................................................................................................42
7.8 - SPECIFIC INSTRUCTIONS FOR START-UP..........................................................................................................43
PART 8 - FUNCTIONAL DESCRIPTION...................................46
8.1 - GENERALITIES.........................................................................................................................................................46
8.2 - ROTARY KILN CONTROL SYSTEM (not supplied by FIVES PILLARD)............................................................48
PART 9 - SAFETY CHECKS/MAINTENANCE................................52
FIVES PILLARD
08 33 4136 00
Page 3
9.1 - MAINTENANCE........................................................................................................................................................52
9.2 - SAFETY CHECKS .....................................................................................................................................................53
9.3 – BURNER TIP REPLACEMENT ..........................................................................................................................54
PART 10 - DRAWINGS LIST...........................................78
10.1 – MECHANICAL DRAWINGS ...............................................................................................................................78
10.2 – PILOT IGNITOR BOX – ELECTRICAL DIAGRAM – STE-057EN .....................................................79
PART 11 – LISTS AND SPECIFICATION.................................80
11.1 – PACKING LISTS .............................................................................................................................................81
11.2 – PRIMARY AIR FAN SPECIFICATIONS .....................................................................................................82
11.3 – MOTORS & INSTRUMENTS LIST.................................................................................................................83
11.4 – PARTS LIST.....................................................................................................................................................84
11.5 – QUALITY DOCUMENTS ....................................................................................................................................85
0 13/02/2009 MH Original issue DAN HBI

Rev. DATE AUTHOR MODIFICATIONS CHECK APP'D
FIVES PILLARD
08 33 4136 00
Page 4
PREFACE
These instructions have been prepared to serve as a guide in operating and maintaining the equipment
furnished by this company. It is not intended to cover all possible variations in equipment nor to
provide for specific operating problems which may arise, should additional information be required,
this company or its field representatives should be contacted.
It must be recognized that no amount of written instructions can replace intelligent thinking and
reasoning on the part of the equipment operators, especially when coping with unforeseen operating
conditions. It is the operators responsibility to become thoroughly familiar not only with the immediate
FIVES PILLARD supplied equipment but also with all pertinent control equipment, satisfactory
performance and safety depend to a great extent on proper functioning of controls and auxiliary
equipment.
The operation and performance of any auxiliary equipment and controls not furnished by this company
is the sole responsibility of the operating personnel.
FIVES PILLARD
08 33 4136 00
Page 5
PART 1 - PRELIMINARY SAFETY RECOMMENDATIONS
Attention !
It is imperative that Chapter 1 is read and scrupulously applied -
Chapter 1 concerns safety recommendations which are of paramount
importance for the prevention of accidents.
All information concerning safety and operation should be read before
using the equipment supplied. This guide should be made available to all
users by the person to whom it is addressed.
It is necessary to follow any precautions which are mentioned.
PRELIMINARY
• The operators as well as those responsible for maintenance must be competent, and to have acquired the
necessary training as per current legislation requirements in effect, concerning the equipment supplied for
which these User's guidelines have been written.
• The User's guidelines are not exhaustive. Its purpose is limited to being a guide to readers already presumed
competent with knowledge of the standard Codes of Practice. If it contains any omission or any eventual
imprecise instructions, this cannot be used to show Fives Pillard's responsibility in part for any wrong
operation or mistake in operating or maintenance, or to show that Fives Pillard's role as advisor has not been
fulfilled.
• Fives Pillard cannot accept responsibility when the faults observed have their source in equipment which has
not been supplied by them.
In particular, this is the case when burner management systems or electric wirings or some instrument control
systems are not of Fives Pillard's supply and that such equipment is defective.
• The condition of existing equipment at site which is not covered by a contractual guarantee period by FIVES
PILLARD, still in force at the moment of the carrying out of the contract - in particular new equipment not
supplied by FIVES PILLARD and older equipment out of guarantee, whatever the origin, for which adequate
maintenance by the client determines its conditions - is of the clients responsibility ; the client recognises
having taken all necessary measures to enable their use during the carrying out of the contract as per the usual
regulations, such that they work without fault.
• Unless written otherwise and stipulated in the text of the contract for the present guide, the installation must
be placed (by the Client) under permanent human surveillance.
• The FIVES PILLARD personnel is under orders from the Client's representative in the heating plant (or on
the site) as a sub-supplier serviceman. The Client assumes the role of main contractor ; notably establishing
conditions and planning operations. The FIVES PILLARD personnel follows his instructions and gives
assistance in order to carry out the tasks expected.
The control and custody of the Client's items shall not be transferred to FIVES PILLARD, and shall rest, at
all times, with the Client.
FIVES PILLARD
08 33 4136 00
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RECOMMENDATIONS CONCERNING SAFETY
• Following European standards about safety in force concerning heating plants (in particular the decision n°
99-1046 dated 13.12.1999 and decree dated 15.03.2000 related to the running of pressurized equipment, or
more generally the European Directive 97/23/CE dated 29.05.1997) is mandatory. When no standard is
applicable the respect of the CEOC (Colloque Européen Des Organismes de Contrôle) recommendations is
advised by FIVES PILLARD.
• Distance between the last gas shut-off valve and the burner : for safety reasons, this distance must be reduced
as much as possible. A max value of about 1 m is advisable. All the personnel concerned must be qualified
and competent.
• Replacing equipment with others on the burner lines may be dangerous. Notably the replacement of a worn
part by a new one (or a clogged part by a clean one) on a combustible fuel line or atomising fluid line
(compressed air, steam) may lead to a modification of the fuel flow or of the combustive flow leading to a
fuel/combustive ratio modification which could allow substochiometric operation (releasing unburnt
explosive gas in the furnace) or with too much excess air (creating flame instability, risk of explosion).
Similar risks exist when modifying functions, adjustments, parameters and timings influencing safety. The
Client must take particular care when doing so.
• The occurrence of the following events causes an immediate shutdown and preventative measures which call
for competent personnel :
∗ flames are not immediately extinguished when instruction is given to shut-off fuel supply,
∗ leak of main fuel, or ignition fuel either internal or external,
∗ insufficient combustive purge time before relighting up,
∗ poor electrical isolation,
∗ suspicious odour which could be due to a leak or poor combustion,
∗ risk of rags, calamine, deposits inside fuel lines or combustive ducts,
∗ firing under lack of air or with high excess air,
∗ unstable flame (s),
∗ instability of process physical values or of measurements and actions,
∗ unusual vibrations, or noises, of mechanical or acoustical origin,
∗ imprecision of mechanisms for setting fuel, combustive, atomising fluid flows.
• The following facts are dangerous, and against Professional Codes of Practice :
∗ lack of compliance with Standards or Professional Codes of Practice of the start-up sequence or associated
time periods, notably due to modifications,
∗ abnormal adjustment of safety instruments component thresholds (pressure, temperature switches, limit
switches, etc),
∗ shunt, by-pass or disconnection of components instruments, detectors, probes which are involved in safety
or in alarm, notably :
flame detector(s), or use of flame detector(s) which are already known to be unreliable or unsure and
having presented some operational discrepancies,
∗ leaving a component or instrument involved in safety or in alarm in operation which has already presented
some operational discrepancies,
∗ reducing the combustive purging time sequences for the furnace/generator and flue gas ducts,
∗ interventions on the heating equipment without stopping combustion,
∗ use of an industrial programmable controller (IPC) which is not secured by a separate risk chain rising
relays for the essential safeties of the generator,
∗ modification of software which leads to any of the above events. A recording of all software modifications
(even minor) must be available in order to confirm that no risk exists,
∗ use of a program stored in a RAM (volatile memory), all programs must be stored in a non-volatile
memory,
∗ upsetting the air/fuel ratio for some operational phases of the combustion,
∗ ignition at too high a load,
∗ inverting the connections on a limit switch,
FIVES PILLARD
08 33 4136 00
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∗ upsetting safety shut-off times for the burner(s) which are set by standards in force or CEOC
recommendations,
∗ start-up of an electrostatic precipitator unit before complete purging of the furnace/generator and flue gas
ducts of at least 3 times the total volume at a flow which must be at least 50 % of the maximum flow (or 4
times the total value, but flow has to be 40 % of maximum),forcing valves to open or shut position or
manual operation having an influence on the normal position of valves, cocks, dampers, registers,
incliners, etc... fuel, combustive, ignition fuel, atomising fluid,
∗ mechanical disconnection of a command (by rod assembly or otherwise) of vanes, cocks, dampers,
registers, incliners, etc... on fuel combustive ignition fuel, atomising fluid, if the unit is not shutdown
(stopped),
∗ the presence of water, oil or impurities in the compressed air used for safety systems or control systems,
∗ abnormal pressure at supply points for compressed air for safety control. This pressure, taking into
account eventual supply fluctuations of the network, shall in all eventualities stay :
− at least 1 bar above the minimum pressure specified in the contract,
− at least 1 bar lower than the maximum pressure specified in the contract,
at the inlet of each safety component concerned,
∗ presence of condensed water in the atomising steam line of the burner(s) (such presence causes bad liquid
fuel atomisation in the furnace with possible accumulation of unburnt gas or even liquid deposits ; it may
also lead to a modification of the liquid fuel flow and coke deposits on the burner head causing a
deterioration in combustion conditions),
∗ abnormal pressure or flow of fuel,
∗ abnormal pressure of the atomising steam,
∗ inverting circuits controlling compressed air for safety,
∗ inverting the flexible hose or piping connections to the burners,
∗ inverting the assembly order and/or positioning order of burner atomising sets,
∗ new attempt to start the furnace/generator after one aborted try without any particular precaution. It is
crucial after one failed attempt, and before any further attempt, to find out the reason for the failure then to
resolve the problem, and to carry out a furnace/generator and flue gas ducts purge for a much longer
period than usual,
∗ insufficient cleaning of the piping before a new start-up which could be blocked or clogged by anything
such as deposits, impurities, rags, fluff, calamine, welding bits, also applying to fuel flow control valves
(liquid or gas fuels), in particular when pipework modifications have been carried out where weldings
have been made.
All deposits or cloggings must be removed as they may either block or else become lodged inside a shut-
off device and impede its closing or its sealing.
• After any incident, the installation should not be restarted without proper corrective measures being taken.
• Notably, any replacement of a component or equipment part which could modify the combustive/fuel ratio
must give rise to particular care when checking.
When the Client decides to request FIVES PILLARD assistance service for the new starting-up, it is
incumbent on the Client to carefully inform FIVES PILLARD about any intervention the Client has made on
any component or equipment, as well as to carefully inform FIVES PILLARD about any risk(s) related to the
plant or unit condition.
• Fire protection equipment shall be installed and ready to use in the boiler house as per local regulation and
international standard requirements.
• When re-starting a plant or unit, further to a repair or modification, it is mandatory to carry out a combustion
check over all its operational range.
• Verification and Maintenance of safety equipment :

During the guarantee period, the user must obtain, under its sole responsibility, that any intervention on the
goods supplied by FIVES PILLARD be achieved exclusively by FIVES PILLARD personnel.
After the end of the guarantee period, the user must obtain under its sole responsibility that any intervention
on the goods be carried out exclusively by adequately trained personnel who have acquired the mandatory
skill enabling them to master all safety and reliability problems with relation to the use of such goods.
FIVES PILLARD
08 33 4136 00
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During all the "lifetime cycle" of the plant or unit (in terms of the international standard n° 61508 concerning
operational safety), tests concerning the plant or unit operation must be performed on all safety components
or equipment, with a frequency as defined by an authorised body, in order to maintain the level of safety of
the plant or unit.
The attention of the user is particularly drawn to the necessity of keeping the instrumentation (probes,
detectors, indicators, recorders and equipment responsible for realising a function which conditions the safety
level) in good condition, in addition to those which may influence the combustive/fuel ratio. Notably :
∗ tightness of each safety shut-off valve for fuel flow (and ignition fuel) and perfect operation of their pilots
(in general compressed air controlled safety valves, 2 or 3 ways),
∗ safety shut-off time : When a shut-off (stopping) is necessary or required, the execution time must be less
than 1 second,
∗ perfect operation of the risk chain (of the BMS) (including perfect wiring and connections) commanding
each safety shut-off valve for fuel flow (including its pilot),
∗ perfect operation of furnace purging sequence (by combustive) within a sufficient time and flow,
∗ perfect operation of all instruments and detectors in charge of detecting any eventual anomaly of the
combustive/fuel ratio, notably :
Oxygen analysers - CO : A regular periodic check is required to ensure no drifting and to ensure that the
main safeties : insufficient O2 % or excess of CO are operating perfectly,
An immediate corrective action is mandatory when an abnormal indication (easy to verify with hand
analysers) is observed,
∗ flame detectors or ionisation detectors of the burner igniters, any abnormality should lead to immediate
replacement. The presence of condensed water in flame detectors (scanner/box) or igniters must lead to an
immediate preventive replacement,
∗ fuel flow and combustion air flow measuring instruments : periodic checks (see manufacturers manuals),
∗ pressure switches / temperature safety switches : as above,
∗ gas leak detectors, atmosphere : as above,
∗ automation and control/regulation instruments : as above,
∗ more generally, any abnormal observation or defect when detected, must be immediately analysed in order
to find out the origin and cause and take a corrective action without any delay, in order to avoid any risk of
deterioration of the combustion process and its permanent control as well as of the combustive/fuel ratio,
which may lead to an accident,
∗ explosion relief valves (or traps, dampers) of the generator(s) or furnace(s), kiln(s) (good adjustment and
set point, no overcharge, risk of falling mastered),
∗ safety relief valves, explosion traps, discharge valves, check valves on circuits of pressurised
fuel : as above.
∗ sufficient screwing of assemblies (flanges, screws) of pressurised circuits overall if they are at high
temperature (heavy oil, thermal oil).
More generally, the time period of checks must comply with European Standards in force and Standard
Codes of Practice notably the CEOC Recommendations.
We advise the Client to impose a weekly check list of verifications from their staff.
The user must in addition take particular care that :

∗ the equipment is well protected against the presence of water, humidity and climatic conditions.
∗ the cooling devices and ventilation are in good condition.
∗ the venting devices are in good condition.
∗ the earthing circuit quality is periodically checked.
• Operations for modification or replacement of electrical equipment should only be carried out after shutdown
of the corresponding supply circuit, in the absence of any voltage.
FIVES PILLARD
08 33 4136 00
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Instructions to be written and distributed by the Client to its personnel

Maintenance, checking and use of the installation equipment (including but not limited to control and safety
devices) should be subject to service instructions which are to be clear, precise, and available to all personnel
concerned, so that they cannot ignore it. It is the Client's duty to ensure that all operators have read and taken
into account the content of these "User guidelines".
The above documents are to be regularly kept available by the Client :

1. In all cases
◊ A maintenance log book, for each steam or super heated water equipment, on which are recorded the tests,
examinations, cleanings and repairs.
◊ An installation booklet, in which are mentioned :
⇒ The characteristics of the equipment used
⇒ The conditions of operation of the thermal production equipment sets
⇒ The results of tests carried out during periodic visits as per regulations.
Furthermore, the competent personnel should :
◊ Ensure a permanent presence in the building where the generator is situated with a direct view of the
safety and control equipment, or in a building next door where the safety and control equipment is
situated.
◊ Periodically check the proper operation of the devices acting on the safety level : these checks, their date
and hour, as well as the observations, should be recorded in the record book of the Client.
2. According to each case :
◊ With permanent presence (general case) :
⇒ A record book, giving identity of the personnel and the type of intervention.
◊ Without permanent human presence (particular case, if expressly stipulated in the contract concerned by
these "User guidelines") :
⇒ A record of the installation, or an automatic recording device on which is shown :
− The carrying out of the periodic checks for the safety devices with a signature by the personnel
having made the checks.
− Carrying out of the periodic checks.
− Water analysis check carried out.
− All incidents, tests, work carried out in the installation.
The installation log book acts as a record book during a fault, or an intervention requiring a return to
operation with permanent human presence.
The record book and the log book of the installation are to be presented during the occasion of each
inspection.
FIVES PILLARD
08 33 4136 00
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PART 2 - TECHNICAL DATA
2.1 - ROTARY KILN
− Process DRY
− Product CLINKER
− Kiln output TPD (max) 5 500
− Rotation acw
− Kiln length m 72
− Kiln diameter m 4.56
− Slope % 3.5
− Precalciner burner number 4
− Precalciner/main burner ratio (design) 60/40
− Specific heat consumption(design) kcal/kg 750
− Secondary air temperature °C 1 050
− Cooler type GRATE
2.2 - FUELS
2.2.1 – Diesel oil
− LHV kcal/kg 10 000

− Pressure at burner bar g 30
− Viscosity at burner cSt 1.5
2.2.2 – Pulverised fuel
− Type COAL
− LHV kcal/kg 6 280
− Temperature at burner °C max. 65
− Conveying air temperature °C 65
− Conveying air flow rate Nm3/hr 2563
− Nominal flow rate kg/hr 10953
− Residual moisture content % wt max 2
− Volatile matter % wt 22.5
− Sulfur content % wt 0.6
− Ash content % wt 18
− Fineness :
Retained at 90 µm % wt max 12
Retained at 200 µm % wt max 1
2.3 - UTILITIES
Electricity supply
− For instruments 220 V, 1 Ph, 50 Hz

− For motors 380 V, 3 Ph, 50 Hz
− Motor insulation IP 54
− Transmitter output 24V, 4-20mA
Instrument air
− Pressure bar g max. 7

bar g mini. 5
− Quality Dry, clean and oil free
FIVES PILLARD
08 33 4136 00
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Geological conditions
− Atmosphere non aggressive

− Altitude m(asl) 165
− Installation indoor
Plant site conditions
− Ambient temperature °C max. 29.5

°C min. -21
− Relative humidity % max 75
% min 45
FIVES PILLARD
08 33 4136 00
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PART 3 – FLOW SHEET

N° DESCRIPTION
Z-264793/A Kiln burner - Process flow sheet
Z-264794/A Precalciner burners – Flow sheet
Z-264795/0 Diesel oil high pressure pumping set – Flow sheet
Z-264796/0 Diesel oil MCR valve train – Flow sheet
Item code for equipment:
XSV D AC 06
n° of Item
Type Localisation Fluid concerned
Type codes:
TI: Temperature indicator (temperature gauge)
TSL: Temperature switch Low
PI: Pressure indicator
PSL: Pressure switch Low
PT: Pressure transmitter
PC: Pressure controller
ME: Electrical motor
FE: flow element
FT: Flow transmitter
FIT: Flow indicator & transmiter
FQY: Flow differential Calculator
FIC: Flow indicator & Controller
XSV: Solenoid valve
ZSL: Position limit switch Low
ZSH: Position limit switch High
HCV: Hand Control Valve
FCV: Flow control valve
BZ: Electrical transformer
XSL: Flame detection
Localisation code:
A : For all supply
Fluid code:
AC: Compressed air (Instrument)
FL: Heavy oil
AB: Primary air
CP: Coal transport air
AL: Purging fluid
GA: Gaseous fuel
EQ: Equipment (not fluid)
FIVES PILLARD
PRIMARY AIR
FLOW = 9500 Nm 3/hr
STATIC PRESSURE = 294 mbar g
AT BLOWER DISCHARGE
Fives Pillard
13, Rue Raymond Teissere
13272 Marseille Cedex 8 - FRANCE
Tel : +33 (0)4 91 80 90 21
Fax : +33 (0)4 91 25 72 71
E-mail : fivespillard@fivesgroup.com
Fives Pillard
Tel : +33 (0)4 91 80 90 21
Fax : +33 (0)4 91 25 72 71
COMBUSTION EQUIPMENT & CONTROL SYSTEMS
13, Rue Raymond Teissere - 13272 MARSEILLE France Tel. (33) 4 91 80 90 21 Fax (33) 4 91 25 72 71 info@pillard.com
08 33 4136 00
Page 13
PART 4 - SCOPE OF SUPPLY
A: ROTARY KILN FIRING EQUIPMENT
A.1 - ONE (1) ROTAFLAM® ROTARY KILN BURNER FOR COAL/OIL FIRING
− Burner output MW 80
− Burner hot end length m 8.5
− Total length (approx.) m 13.8
− Weight with refractory lining (approx.) kg 10800
− Refractory lining (recommended thickness) mm 80
− Total combustion air flow Nm³/hr 88 000
− Primary air flow Nm³/hr 9 500
− Coal flow rate kg/hr (norm.) 10 953
− Conveying air flow rate kg/hr (norm.) 2 563
− Oil flow rate kg/hr 1 500
comprising :
− Burner complete with swirl, axial, central primary air and coal streams.
The outer firing tube hot end is easily replaceable.
− The relative position of axial air and radial air pipes is adjustable so as to be able to modify the tip flow rate of each
stream and hence enable flame shaping to suit the kiln (jacks are supplied for axial and radial air circuits).
− Burner tip made out of heat resisting cast iron, and easily replaceable.
− Coal inlet section complete with interchangeable wear insert .
− Throttle valves for swirl/axial/central air adjustment during start-up only, complete with locking device.
− Air flow measuring element for axial, radial and total primary air amount delivered loose, to be installed y others on the
primary air ducts.
− One (1) set of pressure gauges for primary air, and coal conveying air.
− One (1) central jacket tube for oil gun.
− One (1) jacket tube for ignitor
− Refractory lining and anchors of outer pipe to be supplied and installed by others. PILLARD to provide full specification
and drawings for installation at site
A.2 - ONE (1) GAS ELECTRIC IGNITOR
− One (1) gas/electric ignitor with :

• one (1) HT transformer.
• two (2) flexible hoses for gas and air
• one (1) ionization rod c/w flame relay
• one (1) ignition electrode.
• one (1) manual isolating valve at gas line inlet
• one (1) Y filter.
• one (1) hand operated pressure control valve
• one (1) pressure indicator
• two (2) 2-way safety shut-off valves
• one (1) control panel including :
∗ circuit breaker on power supply
∗ two (2) push buttons : stop and start
∗ two (2) lights : flame detection and power on
∗ one (1) set of terminal strips for connection of instruments and interfaces
The ignitor panel is supplied internally wired and shop tested. All the internal wiring is tagged.
FIVES PILLARD
08 33 4136 00
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A.3 - ONE (1) TELESCOPIC COAL CONNECTION PIPE
Average length 4 250 mm, adjustment range ± 750 mm.

The telescopic pipe enables horizontal, vertical and axial adjustments of
burner position without alteration of main coal line connections.
− The pipe length comprises :

• two (2) sliding tubes, flanged connections.
• seal at outer pipe end to ensure tightness with inner pipe.
• two (2) knuckle joints with seals.
• c/w flanges and fixing device.
A.4 - ONE (1) BURNER TROLLEY
Pillard to supply complete overhead trolley with gear motor and worm jack. The trolley enables horizontal, vertical and
axial adjustments of burner position in the kiln. All angle adjustments will be manual whilst travel in and out of the kiln will
be motorized. Mechanical checking of travel rails has to be done by customer. Travel rails for trolley are not part of our
supply.
Note :
- Our drawings are based on equipment available on the French market. Convertion to other standards is to be made by
yourselves.
- Pillard needs with the order, following up to date drawings :
• supporting rails position
• kiln hood
• burner platform
A.5 - SET OF MCRC OIL GUNS
− One (1) oil gun, complete MCRC type

− Two (2) flexible hoses with quick coupling for oil flows
− Two (2) sets of diesel oil injectors including :
• Three (3) atomisers
• Three (3) orifice plates
• one (1) special tool for burner assembly
A.6 – MANUAL DIESEL OIL VALVE TRAIN
To be installed close to burner.
Shop assembled, complete on base frame, including :
Instruments :
− Three (3) pressure gauges c/w isolating cocks.
Oil supply line :
− One (1) shut-off valve, hand operated

− One (1) filter.
− One (1) flow meter
Return flow control :
− One (1) oil flow control valve, hand operated.
FIVES PILLARD
08 33 4136 00
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− One (1) flow meter

− One (1) non-return valve
− One (1) shut-off valve, hand operated
Air purging of oil line :
− One (1) shut-off valve, hand operated.

− One (1) filter.
− One (1) non-return valve
− Two (2) isolating valves, hand operated.
Note: The calculation of the difference between the incoming flow and the return to be carried by others
A.7 – ONE (1) OIL PUMPING SET FOR KILN BURNER
Oil pump specifications as follows:

− Flow rate kg/hr 2200~2500
− Discharge pressure bar.g 30
− Electrical motor :
. installed power kW 4
. motor speed rpm 2 900
Shop assembled, complete on base frame, including:

− One (1) inlet isolating valve.
− One (1) suction filter with vent and drain.
− One (1) low pressure switch.
− One (1) pump c/w direct drive motors with relief valve.
− One (1) pressure control valve, hand operated .
− One (1) pressure gauges.
− One (1) non return valve.
− One (1) outlet isolating valves.
A.8 – TECHNICAL SPECIFICATION FOR PRIMARY AIR DEVICE TO BE SUPPLIED
− One (1) primary air fan, centrifugal type, direct driven, static pressure 2 500dapa, flow 10 000 Nm3/hr with:
- Three ( 3 ) flexible hose (length= 5m max) for connection to burner.
A.9 – EMERGENCY COOLING DEVICE TO BE SUPPLIED BY CLIENTS
− One (1) emergency cooling air fan, centrifugal type, direct driven, static pressure 1 000 daPa, flow 1800 m3/h :
Note : At it is a safety device, this emergency fan has to have a back up power supply to ensure burner cooling in case of
general shutdown.
A.10 – SPARE PARTS
One (1) outer pipe without refractory lining and anchors.
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B: PRECALCINER FIRING EQUIPMENT
B.1 – FOUR (4) PRECALCINER BURNERS COAL FIRING
− Number 4
− Burner output (per burner) MW 30
− Burner hot end length m 1.5
− Refractory lining (not included) mm 50
− Primary air flow (for 4 burners) Nm³/hr 12 000
− Oil flow rate (for 4 burners) kg/hr 16 500
− Conveying air flow Nm³/hr 3056
Our offer is for four (4) precalciner burners designed according to the same principles as the ROTAFLAM® rotary kiln
burner. Flame stability is ensured by a front stabilising plate.
Shop assembled, each burner includes:
− One (1) central jacket pipe

− One (1) annular circuit for pulverised coal
− One (1) burner pipe set complete with central and swirl air streams
− One (1) mounting flange
Burner tip is made out of heat resistant material and easily replaceable. The outer firing tube is easily replaceable too.
− Anchors and refractory lining of outer pipe are to be supplied and installed by others. PILLARD to provide full
specification and drawings for installation at site.
B.2 – TECHNICAL SPECIFICATION FOR PRECALCINER BURNERS PRIMARY AIR FAN TO BE

SUPPLIED BY OTHERS
− One (1) primary air fan (supplied by client), centrifugal type, direct driven, static pressure 1 200dapa, flow 12 000 m3/hr
with:
B.3 – SPARE PARTS
One (1) outer pipe without refractory lining and anchors.
FIVES PILLARD
08 33 4136 00
Page 17
C: COMMISSIONING
Our offer is for two (2) weeks of commissioning, including the engineer return plane ticket and traveling time. (Food,
lodging and local travel expenses are not included).
Commissioning is as per our standard conditions.
The weeks of commissioning is for working 8 hrs per day between 8 am

and 6 pm from Monday to Friday and 8 hrs on Saturday (48 hrs in all).
Considering that we pay our man an extra rate of 50 % overtime for the
hours he works above 35 hrs, the total man-hours allowed for are :
- 35 hrs/week x 2 weeks x 1 engineer = 70

13 hrs overtime x 1.5 x 2 weeks x 1 engineer = 21
_____________
91 man-hours
Should our man be required to work hours outside the frame laid out above, this is to be agreed with our personnel at site
and any arrangement is possible as long as the total man-hours including overtime allowed for in our original quotation is
not exceeded.
The overtime hours are calculated as follows :

- Base rate for Kazakhstan: EUR 138 / hr for 40 hrs per week
- Weekday (8 A.M. to 6 P.M.) above 8 hours-worked 150% of basic rate
Sunday and holidays 200% of basic rate
Nights (6 PM to 8 AM) 200% of basic rate
FIVES PILLARD
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Page 18
PART 5 – ERECTION
5.1 - SUBJECT
The present leaflet is aimed at indicating general guidelines for assembly and fitting of FIVES PILLARD's
equipment.
It relates especially :
• The assembly order of main equipment
• Particular cautions to be taken during fitting
It draws attention to the precautions to be taken according to material particularities. This leaflet must therefore
be considered as a basic guidelines to understanding and installing the plant. It could be modified according to
local fabrication conditions and site practice.
Responsibility for the assembly, however, rests with the local Works Supervisor.
5.2 - PRELIMINARY ACTIONS
5.2.1 - Precautions on receipt
• The equipment was carefully checked before dispatch and should be in perfect working order on reception at
site.
• As soon as the equipment arrives at site, it should be very carefully checked. Special attention should be
taken over the fragile items ; instrumentation etc., which should not have been damaged during transport and
handling.
• In the case of a problem, take the necessary action towards the transportation company and immediately
contact FIVES PILLARD for information/action.
5.2.2 - Precautions to be taken during long storage
For storage periods over 6 months, the following precautions should be taken for items which are fitted with
bearings.
During the storage period, turn shaft once week by hand so that bearings and others do not stay positioned in the
same way for too long.
• Electric motor
• Pumps
• Fans
• Actuators
• Other equipment with bear
5.2.3 - Storing the equipment
General
On arrival, the various pieces of equipment should be placed in a clean dry storage area.
Normal storage
Storage for relatively long periods is to be made in the best conditions, away from humidity so as to avoid
oxidation of various pieces.
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Machined surfaces are covered in a removable covering or in grease. For long periods of storage before
commissioning, the equipment should be checked periodically and the machined surfaces covered or greased
occasionally.
Storage should be in an area large enough to allow inspection and easy maintenance. Further the storage area
should be sheltered and keep the equipment away from any sudden temperature changes, or dust or foreign
matter.
5.3 - BEFORE ASSEMBLY
5.3.1 - General verifications
Positioning area :
Before fitting the equipment, check :
• The positioning area fits the size of the equipment
• The positioning area is completely flat with no irregularities
Supporting structures/equipment :
This check is mainly for the dimensions and positioning of the supporting structures.
Free spare/access :
Check that the size of the equipment to be installed is compatible with the access areas foreseen.
5.3.2 - Handling conditions
Precautions
• Avoid shocks which risk damaging the equipment
• Follow the fixing/lifting points.
Lifting points
• Where the equipment does not have lifting lugs :
∗ It is advisable to use textile lifting straps.
∗ Lifting points are on the metallic chassis, or metallic areas on strengthened parts.
Points not to be lifted

• On wear areas likely to deform
• On the following items :
∗ valves, stop cocks
∗ flow meters
∗ control valves
∗ piping
∗ etc...
This list is just a selection.
5.3.3 - Choosing the way to handle the equipment
• The equipment should be handled according to how heavy the load is.
• The lifting capacity should be at least 1.5 times the load.
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5.4 – FITTING THE SKIDS
Handling capacity
• The handling capacity for each skid must be the twice of those mentioned on each drawing.
• After positioning, assemble the different part of valve train when necessary with gaskets and bolts supplied
by Fives Pillard
• Drill holes on the concrete floor according to the holes of the valve trains frames.
• Cleans the holes by means of compressed air.
• Place expansion bolts supplied and tighten them (torque 12 mdaN).
5.5 - INSTALLATION OF EQUIPMENTS AND PIPING
BOILER HOUSE
Install :
• high pressure pumping set for kiln and precalciner burners
• heavy oil heating set for kiln and Precalciner burners
FIRING FLOOR AREA
Install :
• MY oil valve train
• ignition valve set
PRECALCINER TOWER AREA
Install :
• MC oil valve train
• 2 local shut off valve set
5.6 - CONNECTING PIPING
5.6.1 - Execution
The connecting pipes which are fitted to our equipment should not experience loads at the connections.
They should be supported near the equipment.
5.6.2 - Checking after welding
On pumps
The connecting flanges to the pumps, after unscrewing should not :
• Show any reaction to the pump flanges
• Be out of line
• Be un-parallel
5.6.3 - Tightness test

All the sub-supplies and/or piping items which are delivered by FIVES PILLARD under this purchase order
have been subject to a tightness test.
FIVES PILLARD
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The connecting pipes are to be tested such that the sub-equipment is not put under pressure; there is a high risk
of equipment degradation of the equipment (gaskets, instrumentation, etc...).
5.6.4 - Cleaning the lines

The connecting piping is to be carefully cleaned so as to remove all trace of :
• Abrasive particles
• Welding
• Rust
• Calamine
• Foreign particles
• Water, etc...
5.6.5 – Insulation
All heavy oil, thermal oil and steam piping must be insulated with mineral wool at site by others in order to
reduce the temperature lost through the line.
For the same reason, and also to prevent any thermal paint damage, all our valve trains and pumping set painted
in GREY SILVER (code IV of our PAINTING SPECIFICATION) must be insulated at site by others.
IMPORTANT:
1) On the thermal oil piping, the flanges must be free of lagging in order to check visually the eventual leak.
2) The surface use to cover the pipe lagging must be flame proof.
5.7 - ELECTRICAL PART (Not supplied by FIVES PILLARD)
5.7.1 - Cabling runways

The cable runways should
• Be as short as possible
• Not interfere with equipment dismounting
NB : Analog signal cables should be separated from control, power cables.
5.7.2 - Electrical connections

The cables should not pull on the packing glands.
NB : Foresee a loop on the instrument connections.
5.7.3 - Electric cable protection

Electric cables installed near where an accidentally lick of thermal oil is possible, must be protected in regard to
avoid any damage.
5.7.4 - Grounding
All equipment must be connected to the ground.
5.7.5 - Wiring to FIVES PILLARD supplied cabinet or local control box

Follow carefully the electrical drawings, respect the different electrical connection (voltage, polarity); do not
supply the electrical voltage on cabinet or local box without Pillard's servicemen authorization.
5.8 - RECOMMENDATIONS FOR FIELD TESTING
Equipment supplied by FIVES PILLARD:
All piping of equipments supplied by FIVES PILLARD for this contract have been submitted to hydraulic test
and compressed air leakage test in our workshop.
So it is not necessary to proceed to test at site on such equipment.
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5.8.1 - PIPING TESTING
a) Heavy oil/diesel oil lines
Water hydraulic test should be carried out. The test pressure should be:
60 bar for high pressure pipes (nominal pressure = 40 bar)
15 bar for low pressure pipes (nominal pressure = 6 bar)
Pressure remains stable during at least 30 minutes.
b) Thermal oil lines
Two test have to be achieved.
1- Pneumatic test
Test to be carried out with compressed air at the maximum pressure allowed by local regulation.
Welds shall be inspected one by one; applied to the flanges connection, material suitable for leakage detection.
If pneumatic test is successful, proceed to the next test.
2- Hydraulic test
This test has to be carried out with thermal oil only (no water)
The test pressure should be 18 bar.
Pressure remains stable during 30 minutes.
Each line should be tested separately
During tests, FIVES PILLARD equipment skids has to be protected against test pressure by blind plates
mounted in between connecting flanges.
Note: Thermal oil tracing lines on skids should be directly connected to piping before pressure test. (Socket
welding)
c) Natural gas, Nitrogen, Compressed air
Hydraulic test with water is to be carried out.

Test pressure should be 15 bar.
d) Hydraulic test certificate
Hydraulic test certificates will be requested by FIVES PILLARD commissioning engineer before to fill the
lines. Without these certificates, FIVES PILLARD won't start commissioning.
5.8.2 - TANK TESTING
a) Thermal oil storage (not supplied by FIVES PILLARD)
Design code: CODRES 91

Storage is used only under atmospheric pressure
Hydraulic test with water is to be carried out with test pressure of 1.5 bar
Pressure should remain stable during one hour.
IMPORTANT: After testing, thermal oil tank must be removed from water and moisture and dried with hot air
because of incompatibility between water and thermal oil.
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5.9 - KILN BURNER ERECTION
5.9.1 - Refractory lining on kiln burner

Refractory lining must be cast on the kiln burner before erection.
Refer to appendix 9.
5.9.2 - Burner trolley

Mechanical checks must be performed to ensure sufficient stiffness of the rails and trolley. Please refer to the
loads indicated on the general arrangement drawing (Z-263735/B)
The kiln burner trolley must be manufacture according to the manufacturing drawings supplied by Fives Pillard.
5.9.3 - Combustion air duct connections (not supplied by FIVES PILLARD)
Piping
• Piping dimension, quality and design must meet standard and rules requirements.
• Weld the loose flange for the connection with the flexible hoses (usually packed on the flexible hose inlet or
outlet flanges if the flexible hoses are supplied by Fives Pillard).
• Install the air flow element ducts supplied delivery loose by Fives Pillard. Take care on this installation
since a wrong design can affect flow measurement.
Welding
All the welding of the pipe must be made by qualified welder according to the rules of the country and
applicable specifications.
Execution
The connecting duct should be supported near the flexible hoses flange.
Cleaning the lines

The connecting piping is to be carefully cleaned so as to remove all trace of:
• Welding
• Rust
• Calamine
• Water, etc...
Painting
• Supports and piping must be painted according to site specifications.
• Colour: The colour must be chosen according to country rules or standard specifications.
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5.9.4 - Burner erection
• Install burner beside the burner trolley,

• Lift the burner on the trolley
handling capacity: 16 000 kg
Note: during lifting proceed, carefully to avoid any shocks on refractory lining and on steel expansion sleeve.
• Connect the burner to the trolley,
• Tight the bolts,
• Release gently the weight of the burner to the trolley,
• Check no major deformation occurs on the trolley.
• Disconnect the burner from the crane (nobody has to stay bellow the burner).
• Check the orientation device movement.
• Move the trolley on the rails.
• Modify burner opening in the kiln hood if necessary.
• Move the burner in position in the kiln and check if a sufficient trim can be get to be able to position the
flame in the kiln as required.
Fitting of the instrumentation on the burner:

• Install the burner pressure gauges according to the assembly drawing Z-265811/A.
Fitting of the flexible hoses (not supply by FIVES PILLARD):

• Install air flexible hoses as shown on the general arrangement drawing Z-264797/A by means of bolts and
gaskets not supplied by FIVES PILLARD.
Important: Remove the locking accessories of compensators installed on the primary air duct after Rotaflam
burner erection.
Important: The railway must be erected according to the general arrangement drawing Z-263735/B with the
slope indicated.
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1. Setting the burner penetration in the kiln - refer to the enclosed sketch
The adjusting principle to remember is the following: whatever the penetration of the burner in the rotary
kiln, the kiln burner axis must be aligned with the kiln axis. The kiln burner is therefore inclined from the
horizontal of the value of the kiln slope p (%). This principle enables the flame to be centred in the kiln and
minimises as much as possible the risk of sulphur volatilisation, particularly in the case of sulphur containing
fuels.
During the establishment of the arrangement drawing of the burner on the kiln, Fives Pillard shows the burner
penetrated in the kiln of a value equal to half of the stroke C compared to the "hot spot" HWP (position of the
nose ring, hot kiln).
The standard lengths of the primary air flexible hoses and the telescopic coal pipe allow a adjustment of the
burner penetration P in the kiln from 0 (HWP) to C, where:
• C = 1000 mm for "Portland" cement rotary kilns
• C = 1500 mm for lime rotary kilns
In the case of rotary white cement kilns and depending on the type of clinker cooling (quenching water bath,
water spray, …), the stroke C can be more or less than 1000 mm.
Except the case where the travel rails of the kiln burner support trolley are inclined same value as the kiln
slope (in this case, the axes of the burner and kiln remain aligned whatever the penetration of the burner in the
kiln), any adjustment inducing a burner penetration different from the value C/2 (i.e. 500 mm for "Portland"
cement rotary kilns) causes a misalignment of the burner in the kiln: the axes of the burner and the kiln are no
more aligned, but parallel.
However, once the burner axis aligned with the kiln axis at C/2, when modifying the penetration of the burner
in the kiln, the misalignment of the burner in the kiln is very low, and even negligible ; for example, if p =
3,5% and stroke = 500 mm, the maximum misalignment is 500 x 0,035 = 17,5 mm.
To modify the position of the burner in the kiln while keeping parallel the burner and kiln axes, it is necessary
to modify by the same value the vertical position of the 2 front and rear attachment points (front pivot and
beam end) of the burner on its trolley (note that the burner beam generally consists of a type HEB supporting
iron). The vertical adjustment of the 2 attachment points are carried out:
• For the rear attachment point: with the help of a manual screw jack (adjusted by ratchet)
• For the front attachment point: with the help of a manual screw jack or using shims. In the absence of
screw jack, shims of thickness 10, 20 and 50 mm are delivered with the kiln burner support trolley when
this one is supplied by Pillard. Access to these shims requires temporarily easing the strain on the support
trolley by supporting the burner weight, in order to insert the appropriate thickness shims or to withdraw
all or part of the existing shims
Note (for information only):

To keep the burner and kiln axes aligned when the penetration of the burner in the kiln is different from the
value C/2, two cases may then arise:
• The penetration P of the kiln burner is less than C/2: the 2 attachment points must be lowered by the value
(C/2-P).tgα, where α is the kiln inclination angle (tgα = p/100)
• The penetration P of the kiln burner is over C/2: the 2 attachment points must be raised by the value (P-
C/2). tgα
The total adjustment range of P is therefore equal to ± (C/2).tgα, Pillard’s standard provides for a possible
adjustment range of ± 50 mm.
FIVES PILLARD
08 33 4136 00
Page 26
2. Adjusting the burner inclination in the kiln - refer to the enclosed sketch
It is also possible, if necessary (orientating the kiln burner on the clinker bed for example), to change the
burner inclination angle. The possible adjustment angle β is ± 3 ° from the kiln axis. The "envelope" curve is
a cone with the head located on the burner axis, aligned with the front pivot position, and a head half angle
equal to 3 degrees.
These adjustments are obtained:
• For a inclination in the vertical plane: with the manual screw jack located at the rear attachment point
• For a inclination in the horizontal plane: with a "small" trolley located at the rear attachment point and
being able to move transversely thanks to 2 threaded rods with lock nuts which are manually adjustable
with a spanner. This transverse trolley moves by slipping, helped by the presence of 2 bronze pads fixed
on the trolley and each equipped with 2 greasers
• For a inclination in a plane other than vertically or horizontally: by simultaneously adjusting both the
manual screw jack and the transverse trolley
Two rulers, graduated in mm allow to visualise the transverse H = L1.tg β and vertical V = L1.tg β
movements of the rear attachment point, where L1 is the distance between the front attachment point (front
pivot) and the rear attachment point (beam end). The total adjustment range of each H and V movement is
equal to ± L1.tg3°.
Standard, 2 possibilities depending on the load values applied to the burner attachment points on its trolley:
Overhead kiln burner support trolley Floor kiln burner support trolley
Load on front pivot: Load on front pivot: 29 Load on front pivot: Load on front pivot: 33
20 T max T max 18 T max T max
Load on beam end: Load on beam end: 16,5 Load on beam end: Load on beam end: 16,5
9,5 T max T max 9,5 T max T max
L1 length 2500 mm 3300 mm 2000 mm 2500 mm
Possible ± 131 mm ± 173 mm ± 105 mm ± 131 mm
movement
For a movement H of the "small" transverse trolley, the movement of the burner end in a horizontal plane
from the kiln axis is H.L2/L1, where L2 is the distance between the front pivot and the burner end (usually,
L2 = burner hot end length + 300 mm).
For a movement V of the manual screw jack, the movement of the burner end in a vertical plane from the kiln
axis is V.L2/L1.
Note:
a) Ruler scale for transverse movement: -150 / +150 mm
Ruler scale for vertical movement: -200 / +200 mm (this scale takes into account the vertical movement
for both penetration adjustment and inclination of the burner)
b) The diameter of the hole for the passage of the burner in the kiln firing hood must be such as to allow the
adjustment of the penetration and the inclination of the burner in extreme cases: penetration from 0 to C
and inclination of ± 3°
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08 33 4136 00
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5.9.5 - Kiln burner air flow elements
Piping concerning Axial air flow element FE AAB30 is design for DN200. Maximal pressure drop between outlet
air fan and inlet burner axial pipe mustn't be over than 20 mbar.
Piping concerning Radial air flow element FE AAB31 is design for DN150.
Maximal pressure drop between outlet air fan and inlet burner radial pipe mustn't be over than 20 mbar.
Piping concerning Total air flow element FE AAB32 is design for DN300.
5.9.6 - Ignitor valve train
When the burner is in the kiln, check future position of the ignition valve set to be able to connect it with the
flexible supplied.
- The ignitor box is placed as closest as possible to the burner
- Run a pipe from the main valve train to the ignitor valve train.
5.10 – PRECALCINER BURNERS ERECTION
5.10.1 - Refractory lining on precalciner burner
Refractory lining must be cast on the precalciner burner before erection.
5.10.2 - Combustion air connections (not supplied by PILLARD)
Piping
• Piping dimension, quality and design must meet standard and rules requirements.
• Weld the loose flange for the connection with the flexible hoses (usually packed on the flexible hose inlet or
outlet flanges if the flexible hoses are supplied by Pillard).).
Welding
All the welding of the pipe must be made by qualified welder according to the rules of the country and
applicable specifications.
Execution
The connecting duct should be supported near the flexible hoses flange.
Cleaning the lines

The connecting piping is to be carefully cleaned so as to remove all trace of:
• Welding
• Rust
• Calamine
• Water, etc...
Painting
• Supports and piping must be painted according to site specifications.
• Colour: The colour must be chosen according to country rules or standard specifications.
5.10.3 – Precalciner Burners erection on the preheater tower
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08 33 4136 00
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• Each supporting device (see on the general arrangement drawings Z-266901-1/B) should be manufactured by
the customer in order to fit burners.
• Handling capacity: 5 000 kg

Note: during lifting proceed, carefully to avoid any shocks on refractory lining.
• Tight the bolts,
• Release gently the weight of the burner to the support.
Check no major deformation occurs on the support.
Fitting of the instrumentation:

• Install the burner pressure gauges according to assembly drawing Z-265652/0
FIVES PILLARD
08 33 4136 00
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5.11 – REFRACTORY LINING
FIVES PILLARD
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TECHNICAL DATA
BASACAST LC 60-717 F
PRODUCT TYPE : Alumina - Silica product

: Low cement castable
PRE Class & group...(ASTM C-401) : Class I - Group 160 (ASTM Class E)
VDEh Code : 0 0 1 8 03 70 27
Maximum recommended temperature : 1600°C
Main component : Bauxite
Type of bond : Hydraulic
Appearence : Dry
Packaging : Sacks or big bags
Shelf life : 6 months in temperate conditions
Installation method : Vibrating
Maximum grain size : 8 mm
Material required : 2.70 T/m³
Drinking water required for mixing on site : 6.5 / 7.5 litres per 100 kg of dry material
: to be adjusted for desired consistency
Guidelines : Installation Nr 6
AVERAGE
PRODUCT PROPERTIES STANDARD UNITS
VALUES
CHEMICAL ANALYSIS
Calcined basis
Al2O3 EN 1402-3 76.0 %

SiO2 EN 1402-3 17.0 %
CaO EN 1402-3 1.3 %
Fe2O3 EN 1402-3 1.2 %
PHYSICAL PROPERTIES
Measured on samples prepared according to EN 1402-5 -
Bulk density
after drying at 110 °C EN 1402-6 2.80 g/cm3
after firing at 800 °C EN 1402-6 2.80 g/cm3
Cold crushing strength
after drying at 110 °C EN 1402-6 50 MPa
after firing at 800 °C EN 1402-6 60 MPa
Permanent linear change
after firing at 800 °C EN 1402-6 -0.1 %
after firing at 1400 °C EN 1402-6 +0.3 %
Thermal conductivity
at a mean temperature of 800 °C CALD 016 2.47 W/mK
Commercial Code : MAL70012 Version : 2 Date : 14/09/2007
The data are current production averages. They cannot be used as limits for a specification.
CALDERYS
file://C:\Documents%20and%20Settings\STHERON\Local%20Settings\Temp\MAL7... 18/03/2008
Page 1 sur 1
TECHNICAL DATA
PHLOX 1500 C SR
PRODUCT TYPE : Alumina - Silica product

PRE Class & group...(ASTM C-401) : Class I - Group 150 (ASTM Class D)
Main component : Chamotte
Appearence : Dry
Packaging : Sacks
AVERAGE
VALUES
CHEMICAL ANALYSIS
Calcined basis
SiO2 EN 1402-3 50.3 %

Al2O3 EN 1402-3 43.0 %
CaO EN 1402-3 2.5 %
Fe2O3 EN 1402-3 1.4 %
PHYSICAL PROPERTIES
Measured on samples prepared according to EN 1402-5 - -
Bulk density
after firing at 1500 °C EN 1402-6 +0.2 %
CALDERYS
Page 1 sur 1
TECHNICAL DATA
GIBRAM SR
PRODUCT TYPE : Alumina product

PRE Class & group...(ASTM C-401) : Class I - Group 160 (ASTM Class E)
Main component : Bauxite
Appearence : Dry
Packaging : Sacks
AVERAGE
VALUES
CHEMICAL ANALYSIS
Calcined basis
Al2O3 EN 1402-3 82.5 %

SiO2 EN 1402-3 12.4 %
Fe2O3 EN 1402-3 1.5 %
CaO EN 1402-3 1.2 %
PHYSICAL PROPERTIES
Measured on samples prepared according to EN 1402-5 - -
Bulk density
Open porosity
after firing at 800 °C EN 1402-6 17 %
CALDERYS
1
Installation guidelines Nr.6

DEFLOCULATED CASTABLES
STORAGE
Medium,low and ultra low cement castables,li
ke all hy
drauli
c castable,are sensi
ti
ve to humi
dityand thus must be stored i
na
dryplace. I
ncold weather condi
ti
ons,the castable should be stored for a mi
nimum of 48hours before use at abov
e 15°C.
PREPARATION OFADJACENTSURFACES
Anyequi pment or tools comingi
nto contact withcastable must be clean. L
oose materi
al should be removed from adj
acent
surfaces and ex
isti
ngrefractorymateri
als moistened thoroughly
.
MIXING WATER
Mixi
ng water must be of dri nkable quali
ty as defined by European regulations (Directi
ve 2455/2001/ EC). The i
deal water
temperature is between15°C and 25°C.The quanti tyof water used should be withi
nthe i ndi
cated li
mits onthe bags. Avoid
excess water as i
t reduces strengthand increases set ti
mes and shri
nkage.
MIXING
Never split a bag. It i
s necessaryto av oid contami
nati
on duri
ng thi
s phase. Ensure all equi
pment and tools are clean. An
i
ntensive paddle type mixer has to be used.
Drymixing: 10to 30seconds before addi
ngwater;i
f the product i
s suppli thseparate bi
ed wi nder,i
t should
be added before drymi
xi
ng
Water addition: start wi
ththe mi
nimum limits
Mixing time: approx i
mately5minutes after addi
ti
onof water
PLACING OFTHECASTABLE
The castable should be i nstalled withi
n 15 mi nutes of mixing (for an ambient temperature between 5and 25°C) . Vibrating
pokers or external vi
brators should be used. Howev er,care should be takennot to ov
er vibrate. The appearance of a flat and
shi
nnysurface i ndicates good densi fi
cati
on. Do not smoothwi tha trowel.
CURING
Forms maynormallybe remov ed between12and 24hours after the product has beencast. I ncold conditi
ons this peri
od may
extend. Generallycastable must be mai
ntained i
na humi d atmosphere for 24hours after casti
ng. The castable should not be
exposed to ei
ther freez
ingor extremelyhot condi
ti
ons duri
ngcuring.
DRYING AND HEATING UP

Eachmonoli thic refractoryli
ninghas to be dried. Too rapid heati
ngupcancause bond di srupti
on,spallingand cracking. For
preci
se control use thermocouples placed onthe hot face. Astandard curv
e apply
ingto all situati
ons does not ex
ist,eachlining
beinga particular case.
Howev er for a standard i

nstallati
onupto 150mm thi
ckness,wi
thout other products to be dri
ed,the followi
ngsafe i
ndi
cati
ons
should be considered:
ambi ent to 150°C @15°C/ hour

at 150°C 1hr per 10mm thi
ckness
150to 350°C @ 15°C/ hour
ckness
350°C to 600°C @15°C/ hour
ckness
600°C to serv i
ce Temp. @ 25°C / hour
Please contact Caldery

s for speci
fi
c dryi
ngi
nstructi
ons to sui
tyour i
nstallati
on.
SAFETY
Protecti
onmeasures i
ndi
cated i
nour MSDSshould be observ
ed.
DISCLAIMER
These guidelines are i
ntended for i
nformationpurposes only.
Anytechni cal advice,recommendati ons or information contai ned herein are given byCalderys in good faith,
based onCalderys’current knowledge and experi ence of the products and are deemed to be accurate. However,
Calderys undertakes no li
abili
tyor responsibili
tyof anyki nd whether express or i
mplied i
nrespect thereof.
Users are advised that these guideli
nes are necessarycondi tions but maynot be suffici
ent. Specifi
c conditi
ons,
suchas the nature of the surfaces,the thi
ckness of the li
nings or thei
rintended use should be takeninto account
wheni nstalli
ngthe products.
Nr.6-Defloculated Castables-ENU.doc 08.2005

Calderys – ResearchCentre –4Allée de L
ausanne –F38070Sai
nt Quenti
nFallav
ier - 1/
1-
OU (OR)
08 33 4136 00
Page 30
5.12 – TELESCOPIC PIPE
FIVES PILLARD
TELESCOPIC PIPE
1/2
1 - GENERALITY
Each telescopic pipe is design for a specific burner with the appropriate coal transport air flow rate.
It allows easy burner adjustment inside the kiln. Therefore, its stroke is 1.5 m.
2 - DELIVERY
The telescopic pipe is delivered with a counter flange, bolts and gasket to ease installation on the coal
conveying pipe.
It is on retract position with bolts (items 18 and 19 on transportation figure), this bolts need to be removed
before installation.
3 - INSTALLATION
(Refer to sketch attached in appendix)
The installation of the telescopic pipe needs to be done when the burner and its trolley are installed.
• Put the burner tip flush with the kiln noose ring.
• Lift the telescopic pipe in position using the lifting lugs (item 2) and connect it to the burner.
• Adjust telescopic pipe position
The knuckle ball can allow angle adjustment up to 10 degree. If necessary bolts (item 9) can be slightly
unscrewed. When position is found satisfactory, install coal inlet flange to coal conveying pipe and weld it.
• Around 1m before the coal inlet flange on the coal conveying pipe made a fixed support.
• Disconnect lifting device from telescopic pipe and move the burner ahead by 1.5m inside the kiln to verify
burner adjustment ability. If necessary bolts (item 11) can be slightly unscrewed.
• When installation is performed, tight all flange bolts, tight gently bolts (items 9 and 11).
• Ensure that electrical continuity between burner, telescopic pipe and coal conveying pipe is made by the
way of bounding wires.
4 - MAINTENANCE
Telescopic pipe is maintenance free device.

However, it may be necessary to change a set of seals.
4.1 - REPLACEMENT OF THE KNUCKLE BALL SEALS
4.1.1 - Ball dismantling
Prior to dismantling, support the pipes properly to avoid stress and distortion.
Remove flange (4) by unscrewing bolts (9).
Remove disks (3) by unscrewing bolts (10).
Slide out the knuckle ball in order to have access to the seal (item 8).
4.1.2 - Remounting
Please note that the seals must be replaced every time the knuckle seal has been dismantled.
Once the old seal (item 8) has been removed, clean its housing well. Make sure it is oil free.
PILLARD
TELESCOPIC PIPE
2/2
The new seal string is to be cut to the proper length to fit the housing. Allow a slight over length to ensure a
slight compression of the seal. The cut must be clear, clean and bevelled edge. Glue the cut with Sicomet
brand glue (or equivalent). Also, glue the seal in its housing. Make sure the seal sits properly in its housing
before mechanical re-mounting.
Re-assembly the ball, making sure not to damage the seals.
Re-position disk (3), secure it with bolts (10) which are to be tightened firmly.
Re-position flange (4), secure it with bolts (9) which are to be tightened gently.
4.2 - PACKING GLAND
4.2.1 - Dismantling
Prior to dismantling make sure the pipes are supported properly to avoid stress or distortion.
Remove bolts (11) in order to slide out compression flange (7).
Slide out inner tube.
4.2.2 - Remounting
Please note that seals (12) must be replaced every time flange (7) has been dismantled.
The new seal strings must be cut to correct length to fit the housing. The cut must be clear, clean and bevelled
edge. Each seal cut must overlap the next at approx. 60° angle.
Once the old seals (12) have been removed, clean the housing well. Make sure it is oil free.
Re-introduce the inner tube. Shim the tubes for concentricity.

Slide in the first ring seal to the end of the housing, using a non-metallic tool. Slide in the second ring, making
sure the cut is at 60° angle to the previous ring cut. Proceed the same way for the remaining
2 seals.
Re-assembly compression flange (7) with bolts (11) which are to be tightened gently.
4.3 - CHARACTERISTICS
4.3.1 - Seals for knuckle balls

Quantity 4
Material Synthetic rubber
Dimensions, each 20mm dia., approx. 1500 mm long
Glue Sicomet 8300 (content : Cyanoacrylate)
brand or equivalent
4.3.2 - Seals for gland packing

Quantity 4
Material Ceramic fiber
Dimensions, each 20 x 20, approx. 1300 mm long
Appendix : Telescopic pipe sketch.
PILLARD
TELESCOPIC PIPE
Appendix
PILLARD
08 33 4136 00
Page 31
PART 6 - PRELIMINARY CHECK BEFORE START-UP
6.1 - GENERAL REMARKS
After final erection (or before re start-up of the plant after a plant shut down for maintenance), the followings
inspections must be carried out:
• Read the supplier documentation.
• Prepare necessary drawings, equipment and tools.
• Know and be in accordance with functional conditions, specific characteristics (fuel type, flow rate, pressure,
temperature ...) and any local conditions.
• Verify the good state of each device to be installed and cleaned.
• Verify that all the piping is connected.
• Verify that all equipment are in place and correctly connected (pump, manometer, …).
• Verify that all manually operated are closed.
• Verify the good position of all the limit switches.
• Verify the status of all the automatic valves (normally closed, normally open).
• Verify that all local electrical cabinet have their general switch in stop position.
• Check that all the control cabinet are powered off.
• Perform a continuity check on all the wires.
• Check programming of controllers.
• Check that all chain-guard and heat protection are in place.
• Ensure availability of all the different used fluids.
• Select the atomising unit versus fluid used to start.
• Insert ignitor and atomising gun in the burner.
• Check tightness of the flexible connections.
• Pressure gauges are installed.
• Pumps and fans are free to rotate by hand (check before long stop also).
• Actuate all the valves by hand to detect an eventual hard point.
• Check all limit wiring
6.2 - SAFETY RULES
The basic cause of explosions is the ignition of an accumulation of a combustible and air mixture within a
confined space.
All gaseous fuels can form an explosive mixture with air. Consequently, for installation safety it is necessary that
burner operation be placed under permanent prevent conditions favourable for the formation of such a mixture to
occur.
Operation must be independent from errors, which can be avoided through the strict application of the operating
personnel.
Danger may exist during the operation of the installation in the following cases :
• Unburnt oil in the combustion gases
• Sudden flame failure, with unconsummated oil being continually discharged into the furnace without burning
• Working defect
• Unsuccessful attempts at ignition without proper purging
FIVES PILLARD
08 33 4136 00
Page 32
Whatever the particular arrangements adopted for this safety system may be, the following rules must be strictly
observed :
• The presence of abnormal working conditions must lead to irreversible closing of the safety shut-off valves
• Breakdown in electrical current must immediately lead to the interruption of the safety shut-off valves and the
opening of the safety vent valve.
IMPORTANT: Fire protection equipment shall be installed and ready for use in the boiler house as per local
regulation and international standard.
6.3 - FLUID DISTRIBUTION CHECKING
Check list
• Connection of piping lines up and downstream are correctly made.
• Actuate all the valves by hand to detect an eventual hard point.
• Filter screen is clean and installed.
Electrical check
• Before to do it check compressed air pressure is above 6 bars and open compressed air valve.
• Ensure that gas automatic valve train is isolated from main gas supply,
• For each normally closed valve
* valve is closed (limit switch ZSH is not reached and limit switch ZSL is reached)
* valve is open when powered (limit switch ZSH is reached and limit switch ZSL is not reached)
• For each normally open valve
* valve is open (limit switch ZSH is not reached and limit switch ZSL is reached)
* valve is closed when powered (limit switch ZSH is reached and limit switch ZSL is not reached)
• Gas or Fuel flow control valve (FCV)
* open compressed air isolating valve and set pressure at 4 bars
* send 100 % of the load (20 mA) to positioner item ZC
- valve open up to maximum position
- feed back item ZT is going up to 100 % when applicable
*send 0 % of the load (4 mA) to positioner
- valve close up to minimum position
- limit switch item ZSL is reached
- feed back is going to minimum position when applicable
6.4 – PUMPING SET CHECKING
Check list
• All material is in good shape.
• Connections of piping up and downstream are correctly made.
• Strainers screens are cleaned and installed.
• Pumps must be free to rotate by hand (check after long stop also).
• Straight in line position of pump drive.
• If the two above points have been checked with success, try the rotation way by a short electric impulsion.
• Actuate all the valves by hand to detect and eventual hard point.
Filling method
Before first starting (or after dismount) pump must be filled with oil to avoid any damages due to dry running.
FIVES PILLARD
08 33 4136 00
Page 33
6.5 – FANS CHECKING (Not supplied by FIVES PILLARD)
• Connections of ducting lines are correctly made.

• Remove coupling guard.
• Check :
∗ Coupling alignment
∗ Wheel and motor must be free to rotate by hand
∗ Reinstall coupling guard.
• If the above point have been checked with success, try the rotation way.
FIVES PILLARD
08 33 4136 00
Page 34
PART 7 – START-UP
7.1 - OIL PUMP START-UP
Filling method
Before first starting (or after dismount) pump must be filled with oil to avoid any damages due to dry running.
First start for heavy oil HP pumping set
• Inlet valve is fully open (suction side)

• Outlet valve is fully open (discharge side)
• The suction return valve GFL 42 is fully closed
• The tank return valve GFL 43 is fully opened
• Pressure regulating valve is fully open
• Check inlet pressure by pressure gauge: normal range is between 4 and 6 bar.
Starting conditions are met

• Low pressure circulating pump is running when required
• loop Low pressure switch is satisfied
• Start/stop motor by local action
• Pump must run smoothly without noise
Discharge press set

• After one or two hours running
• Open the suction return valve GFL 42
• Close the tank return valve GFL 43
• Close slowly pressure regulating valve until pressure reach 20 bar. Control pressure by pressure gauge.
Pressure will be readjusted during normal operation to reach 40 bar.
Checking
• Check inlet pressure or gauge is above 1 bar
• If pressure drop below 1 bar : stop the unit and clean screen strainer or change the cartridge.
Normal start
• Start/stop motor by local or remote action
• Motor stop automatically by system failure.
Daily check
• Suction pressure gauge P > 1 bar
• Discharge pressure gauge P is constant.
FIVES PILLARD
08 33 4136 00
Page 35
7.2 - BURNER PRINCIPLE
• The ROTAFLAM V2 (RV2) is a heating equipment dedicated to rotary kiln burners.

It is an evolution and improvement of the well-known ROTAFLAM burner.
General arrangement principle
Fuel channels are positioned inside axial and swirl air channels and around the stabilizer (for pulverized
fuels, gas, etc…) or in the middle of the stabilizer (for liquid fuels, alternative solid and liquid fuels and
gas when injected with a gun). This arrangement allows:
• Formation of a re-circulating vortex at the flame root creating perfect stability even in cold kiln
conditions.
• The flame shape to be kept under control.
• A fuel-rich flame (aerodynamic pinching).
• Conditions at the flame core substantially reduce NOx formation.
Figure 1 : ROTAFLAM V2 general arrangement
Primary air arrangement principle
Like the ROTAFLAM, the ROTAFLAM V2 (RV2) is highly flexible with its 2 separate primary air
channels whose outlet tip cross sections are adjustable.
• The axial primary air channel blows out high speed air and without any divergence.
• The swirl primary air channel blows out high speed air in rotation.
The adjustable air flow distribution between the 2 air channels allows kiln operating conditions to be
optimized by adjusting the flame shape. The principle of these two channels is the following:
•
• High primary air axial momentum
The high primary air axial momentum at the tip outlet has two purposes:
- Drawing in and progressively mixing the secondary air into the flame.
FIVES PILLARD
08 33 4136 00
Page 36
This effect is controlled and

optimized by a patented and
adjustable arrangement of slots and
annular cross sections at the burner
axial tip.
- Keeping the flame diameter under control.
• Swirl air principle

The swirl air causes rotation inside the flame to help the fuel and primary air to mix. It will
modify the flame shape by influencing the flame diameter.
The RV2 burner is generally designed for a primary air consumption of 7 to 11% of total combustion air
according to the fuel. Primary air optimization is carried out by a Fives-Pillard Commissioning Engineer
during stable kiln operation.
Fuel arrangement principle
The RV2 burner can operate with the following fuels:

• Pulverised solid fuel such as coal, petcoke, lignite, anthracite, which are blown throught an annular
channel around the central stabiliser
• Gas (natural gas, COG, LDG, …) which is ejected through an annular gas channel or gas gun.
• oil (heavy oil, crude oil, diesel oil, …) pulverized by oil guns placed in the center of the burner
• alternative liquid and /or solid fuels ejected from the burner center
• With mixed fuels of any proportions.
RV2 Typical burner tip arrangement
Axial air
Swirl air
Gas
Pulverised solid fuel
Central air /
Flame stabiliser
Jacket tube for ASF/ etc..
Ignitor
Jacket tube for Oil gun
Figure 2: Rotaflam V2 burner tip typical arrangement
FIVES PILLARD
08 33 4136 00
Page 37
The axial and swirl air SLOTS

• The axial air will produce strong flame (high momentum). The
slots improve the secondary air absorption inside the flame, while
the annular gap still insures a narrow flame by constriction (no
divergence). The ratio between slot sections and annular section is
modified and optimized by the axial tip adjustment. ANNULAR
• The swirl air (divergent) allows modification of the rotation GAP
(swirl). With a higher swirl, the flame becomes slightly wider and
the mix between fuel and air is quicker.
Axial arrangement
The gas channel (if provided)
The gas is ejected through a swirler at around 300 m/s.
The outlet cross section can be adjusted in order to control the gas jet by modifying its outlet
velocity.
The pulverised solid fuel (coal or petcoke) channel (if provided)

The pulverised coal is supplied through this channel using the requested amount of conveying air.
The coal is blown out with a low divergence and an adjustable velocity of up to 35 m/s max
depending on the pulverised fuel characteristics (volatile matter, grinding fineness, …). The
velocity is changed by modifying the outlet cross section when the burner is fitted with an
adjustable coal tip section, or adding additional conveying air when the burner is fitted with an
additional coal conveying air channel using primary air to increase the coal tip velocity.
The Central air / Stabilizer

This channel is partially closed by a flame stabilizer through which passed a low quantity of air.
The stabilizer consists of a refractory steel disk drilled with holes to allow the central air to hold
the flame to the disk face.
The Jacket-tube(s)
Its allows an oil or gas fuel gun to be installed for start-up or full flow purpose
Some additional jacket-tube(s) can be provided to receive:
• the ignitor and/or
• alternative fuel (liquid or solid) injection pipes
7.3 - ADJUSTMENT PRINCIPLE OF THE RV2
Axial adjustment
The axial can be adjusted by moving (advancing or withdrawing) the axial inner tube of about 20
mm. The adjustment of this axial position modifies the flame temperature profile, thanks to:
- the variation of the ratio between slot and annular cross sections at the tip
- the variation of the primary air flow rate
In open position (Example position indicator on "0"):

In this position, the axial cross section is at the minimum, slightly reducing the primary air and
increasing the drawing of hot secondary air into the flame, giving a hotter flame root.
FIVES PILLARD
08 33 4136 00
Page 38
In closed position (Example position Indicator on "20"):

In this position, the axial cross section at the tip is at maximum, thereby maximizing the primary
air and minimizing the flame diameter.
These adjustments will allow a hotter or colder flame root to be achieved, by keeping
constant the pressure at the burner inlet. Indeed, the axial valve (V1) is usually fully open.
(It may be partially closed in specific cases such as in burner over sizing, special operating
conditions, …)
- A too low axial air pressure adjustment (by closing the axial valve) will produce a long
!
and lazy flame which is usually not suitable for good kiln operating conditions.
- A too hot flame root (by opening the axial tip too much, too fine grinding, …) will
!
naturally reduce burner tip lifetime.
Swirl air adjustment

The swirl is controlled by the swirl air momentum (momentum = mass x velocity = k x flow rate x
pressure0.5). When the swirl momentum is reduced, the swirl decreases and the flame becomes
thinner. When the swirl momentum is increased, the flame is wider.
The swirl momentum can be adjusted:
- either by acting on the swirl air pressure (decreasing the pressure will decrease the flow rate
and the outlet velocity). The swirl air pressure can be reduced up to 80 mbar g. by the V2
radial air valve or,
- by modifying the swirl cross section by advancing or withdrawing the inner swirl tube
(decreasing the cross section will decrease the flow rate)
Adjustment systems
Accuracy of tip adjustments is obtained by the following devices:
Position
indicator
Handle
Figure 3 : Adjusting device
FIVES PILLARD
08 33 4136 00
Page 39
Summary of the various possible adjustements
Burner flame shape according to adjustments (for secondary air temperature > 800°C)
- SWIRL +
MOST USUAL SETTING
Short flame
Thin and short flame
+
Maximum axial air flow – tip in reduced position Maximum axial air flow – tip in reduced position
Reduced swirl air flow – tip in reduced position High swirl air flow – tip in opened position
IMPULSE
Long flame Wide and long flame !

Caution
Reduced axial air flow – tip in opened position Reduced axial air flow – tip in opened position
-
Reduced axial pressure Reduced axial pressure

Reduced swirl air flow – tip in reduced position High swirl air flow – tip in opened position
The burner settings shall be completed by experimented operators and the impacts on process operating conditions
(kiln shell temperature,clinker quality, emissions, coating ...) shall always remain under their control.
7.4 - START-UP
7.4.1 - Checking and pre-setting
Once mechanical checks have been carried out:

• tips properly assembled, with a regular annular space between them,
• Ignitor and oil gun positioned as follows :
FIVES PILLARD
08 33 4136 00
Page 40
o ignitor tip : -200 mm inside from stabilizer plate,

o oil gun tip : + 15 mm outside from stabilizer plate…
• Check that when all tips extremities are flush, i.e. in the same vertical plane,
o the axial position indicator indicates the "in line" mark (different from "0")
o the position indicators of the other tips (swirl, coal if any, central) indicate "0"
• Note : In the case of a Coal/Heavy Oil and/or Natural Gas burner open the cooling air on the
pulverised coal and natural gas channels when they are not in use.
7.4.2 - Primary air fan
Start-up the primary air fan and check the flow and discharge pressure.
7.4.3 - Ignition
7.4.3.1 – Adjust the primary air valve opening (or blower speed) to get about 30 mbar pressure at the
burner inlet.
Start-up the ignitor or place a manual ignitor up near the burner tip.
Check that this ignitor produces a large enough and properly stabilized flame.
7.4.3.2 - Start the oil or gas fuel at its start-up flow.
7.4.3.3 - As soon as the flame is present, open the central air channel (V3 on figure 2) to position 8.
7.4.3.4 - Stabilize the flame by controlling the opening of the manual primary air channel
valve and then stop the ignitor.
7.4.3.5 - Take the following readings:

∗ air pressure on each channel
∗ valve positions
∗ fuel pressures
This data will be used during future start-up operations.
7.5 - POWER RISE
The kiln is heated as per customer's procedures, taking into account its requirements in term of:
- Shell temperature
- Flame shape
- Thermal profile (which depends on process: dry line, wet line, …)
The Pillard start-up engineer will gradually open the primary air valves (or adjust blower speed) as the
fuel flow rate increases in order to keep the flame stable. The axial and swirl tip remain at the 0
position.
By mid-load axial and swirl valve are usually full opened and the tips at the 0 position.
In any case, the flame must never touch the brick lining.
Note : Coal inlet
FIVES PILLARD
08 33 4136 00
Page 41
When the kiln is hot enough, the system can be progressively changed from oil/gas to
pulverised coal/petcoke without forgetting to close the cooling valve. The burner coal tip is still
kept in the "0" position.
7.6 - FLAME SHAPE ADJUSTMENT IN OPERATION
7.6.1 - PRIMARY ADJUSTMENTS
Once kiln operation has fully stabilized, the flame shape is optimized as described in the previous
chapter "adjustment principle".
Each setting must be carried out in stages, avoiding several adjustments over a period of 24 hours and,
together with the customer, taking into account the following factors:
• Kiln shell temperature (scanner)

• Sulphur volatilization factor
• Temperature in the burning zone
• Secondary air temperature
• Kiln inlet box temperature
• O2 and CO at kiln inlet
• Distribution of secondary air at cooler outlet
• Clinker quality
The adjustments are obtained by moving the axial and radial tip by 5 to 10 mm.
The most usual settings of the RV2 are:
Axial air:
o Valve : Fully open
o Pressure : 200 to 300 mbar g. (according design)
o Tip position between 0 and – 20 mm according to optimal adjustment
Swirl air:
o Valve between fully open to partially closed in order in order to reach a pressure of 100
to 200 mbar g.
o Tip position : 0 to -20 mm
Note: in case of high shell temperature in the first meter of the kiln, and once the swirl
tip is closed, swirl air pressure reduction is an efficient solution to greatly decrease the
swirl.
Central air:
o Valve : Fully open to 50% closed
o Pressure : 40 to 100 mbar g.
o Tip position : 0 mm for coal to -40 mm for fuel oil/gas
Standard adjustments: 9 to 11% total primary air.
In all cases, make sure there is a sufficient air flow rate in the axial air channel in order to ensure burner
cooling. The flow rate required is at least 2,5% primary air compared with the theoretical combustion
air requirement.
FIVES PILLARD
08 33 4136 00
Page 42
Insufficient flow rate of primary air circulating in the axial air pipe could damage the condition of the
burner tips and in some cases may cause destruction of the outer pipe.
Note:
• With a pulverised coal/fuel oil and/or natural gas burner, the burner settings shall be optimized
when firing pulverised coal. In fuel oil or natural gas firing, these settings may remain the same
and flame shape optimization can be achieved by acting on the liquid fuel or gas tip jet spread.
• Burner settings shall be completed by experienced operators and the impacts on process operating
conditions (kiln shell temperature, clinker quality, emissions, coating …) shall always remain
under their control.
7.6.2 - PULVERISED FUEL ADJUSTMENTS (IF PROVIDED)
If the conveying air flow rate is too low, the pulverised fuel velocity at the tip can be increased by
opening the valve V4.
Note:
- In any case, when pulverised fuel is not used, some cooling air must be sent through the pulverised
fuel channel by opening the valve V4 to 100%
- In any case, when pulverised fuel is used, if needed, some sweeping air must be sent into the rear part
of the pulverised fuel channel by opening the valve V4 (to about 10% open).
7.7 - TEMPORARY ACTIONS
In particular operational circumstances, it may be necessary to have the burner operate under extreme
conditions.
The following operating modes can only be used for short periods and must not be considered as
settings:
• Very wide flame :

∗ Radial air tip at position 0, maximum swirl pressure and reduced axial pressure
This may lead to a lost of coating and an early deterioration of the refractory lining.
!
• Very long flame :

∗ Closure of the axial and swirl valves to reduce pressure
• Very hot flame root :

∗ Axial tip at position 0
∗ Radial tip at reduced position
!
This may lead to a reduced lifetime of the burner tips.
If rings form:
• First: do not alter the air adjustment, but modify the burner penetration inside the kiln.
• Second step (if not sufficient): modify the swirl and momentum to modify the flame shape.
FIVES PILLARD
08 33 4136 00
Page 43
7.8 - SPECIFIC INSTRUCTIONS FOR START-UP
7.8.1 - General remarks on adjustments
Burner start-up will be firing natural gas or fuel oil if possible.
If not, start with the fuel which is the easiest to use:
• It must be a liquid fuel.

• It must be introduced into the kiln through the central jacket-tube or through a tube placed in the
central air stream.
We chose to describe the different start-up steps in a sequential way. There are two kinds of start-up:
Case A - Adjustments on a cold kiln
These adjustments are temporary:
• For stopping periods greater than 6 hours.

• Until you reach 20 % of the nominal calorific power of the burner.
• To take care of the refractory lining after replacement.
Case B - Adjustments on a hot kiln
These adjustments are almost permanent.

So the only modifications required hereafter are those for the adjustment of the flame shape by acting
only on the relative displacements of the burner tip.
This configuration is required:

• When the stopping period is less than 6 hours.
• As soon as the flow rate of the liquid start-up fuel reaches the calorific power threshold of 20%, and
up to the nominal burner calorific power.
In a general way:
• These 2 adjustment configurations are for a complete and original set of FIVES-PILLARD burner
tips, exclusive of any other parts or modification or alteration of the original parts.
• If several fuels are used, the optimized adjustments for one of them is transposable for the others, or
even for dual fuel use, in the following order:
* pulverised coal (if used)
* natural gas (if used)
* any other gaseous fuel
* the more difficult the fuel is to burn
• Independently of the fuel and the type of start-up, the start-up configuration must be reliable so as to
allow:
∗ the longevity of the refractory lining (the first rise in temperature is used to dry the refractories).
∗ the temperature display of the kiln lining from the sintering zone.
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Therefore, the typical non aggressive flame required for RV2 burner start-up is a long flame, free of
any pulsation.
7.8.2 - Previous check-up of burner tip position
a) Generally, the burner will be restarted after a kiln shutdown with no modification to the tip position.
In this case, it must be restarted with the preceding and optimized adjustments used the day of the
shutdown.
On the contrary, for a first start-up or after modification of the burner tips, it is necessary to follow
the adjustments noted in figure 1:
* position of the central stabilizer: 40 mm for gas or oil (0 mm for coal).
* the other set of tips remain in the "0" position.
These adjustments will be carried out and checked with the scales' values.
They will also be checked directly at the burner tips, before placing the RV2 burner in the kiln.
b) When the burner's nose is outside the kiln, the centering of the different tips and the condition of the
refractory castable must be checked. It is a good idea to take a photo of the tips.
7.8.3 - Position of the air sweeping channel valves
So as to make sure of the air sweeping of gas and coal channels (if they exist) when they're not used, it
is IMPERATIVE to make sure of the circulation of air in these channels by completely opening the
valves. Otherwise the burner tips could be damaged.
7.8.4 - Start-up of the primary air fan
Make sure that the static pressures in all the air channels are at the approximate required values (usually
180-240 mbar g. for primary air and 50-100 mbar g. for central air) .
7.8.5- Start-up of the ignitor with an electrode (if existing)
Adjust the ignitor’s air flow rate (taken from the central air stream by the central air valve) so as to
enable ignition with the electrode.
If ignition with the electrode fails, follow the same procedure for the manual start-up by placing an
ignitor near the burner's nose.
7.8.6 - Adjust the start-up fuel flow rate and immediately make sure of the proper position of the air
sweeping valves.
7.8.7 - Once the flame is stabilized
• Gradually increase the fuel supply, in the case of a cold kiln. For the first fire-up, the fuel supply
gradient will depend on the rising temperature gradient given by the people in charge of kiln
operation.
• Stop the ignitor.
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7.8.8 - Using coal fuel if required
It's IMPERATIVE to be sure of the gas channel’s sweeping and to isolate the sweeping circulation
from the coal channel.
7.8.9 - Adjust the burner's position in the kiln
Use the burner trolley, and burner adjustment's device.
7.8.10 - Programmed shutdown
Maintain the primary air fan in operation for at least 6 hours so as to cool the burner (inlet damper
if it exists to 20 % of the nominal flow rate).
Note: if the burner is to be withdrawn when the kiln is still hot, it must be done slowly (1m every 30
min) to avoid thermal shock on the refractory castable of the outer pipe.
7.8.11 - Emergency shutdown
The emergency fan must automatically start-up to take the place of the primary air fan and cool/sweep
the burner outer pipe.
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PART 8 - FUNCTIONAL DESCRIPTION
8.1 - GENERALITIES
8.1.1 - Management of gas electric ignitor:
Before gas pilot ignition, check that the gas pilot is in working
position (pull it in into his own jacket tube).
Note: When main flame is established and gas pilot is off, to protect
the tip from over heat remove the gas pilot back about 1 meter.
8.1.1.1 - Start-up procedure
The operator pushes the start button, when conditions below are checked:
Starting conditions
• Process safety is satisfied from client
• Ignition flame not detected XSL AEQ10
• Emergency stop not actuated
• CO too high not detected from client
If all above conditions are fulfilled, it causes:

Time To:
• Ignition transformer is energised BZ AEQ 10
• Opening of ignition gas valves XSV AGA 05 & XSV AGA 06
Time To + 10’’:
• Ignition transformer is desenergised
• Torch flame is checked by flame controller XSL AEQ 10
Ignition light is "on"
8.1.1.2 - Shut-down procedure
The ignitor will stop only if the operator presses ignitor Stop Press
Button
8.1.1.3 - Shut-down by safeties
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If one of the following safeties appears, the burner is on shut-down.

• Ignition flame not detected XSL AEQ10
• Emergency stop
• Process safeties not satisfied From client
8.1.1.4 - Alarm
An alarm is activated if the igniter is off and the ignitor detection

in on: XSL AEQ10
8.1.2 – Primary air blower and emergency air fan management (supplied by other)
The axial air channel may be fed with the primary air blower (normal operating) or with cooling air fan
(in case of a main air blower shut-down). The primary air blower and the cooling air fan are not part of
FIVES PILLARD's scope of supply.
The distribution of air is managed by the two automatic valves (AAB40 & AAR06) controlled by THE
control cabinet (supplied by other).
These two valves are not part of FIVES PILLARD's scope of supply.
Note :
The primary air blower and the cooling air fan management is not supplied by Fives Pillard. The
pressure control and the safety conditions for the primary air blower operation are managed by other.
The inputs necessary for the control cabinet are:
- Valve AAB40 opened (ZSH) or closed (ZSL)
- Valve AAR06 opened (ZSH) or closed (ZSL)
- Primary air blower in operation or not
- Cooling air fan in operation or not
The start-up order and the shut-down order for the primary air blower and for the cooling air fan are
given by the control cabinet.
8.1.2.1 - Normal operation
• Valve AAB 40 is opened ZSH AAB40

• Valve AAR 06 is closed ZSL AAR06
• Primary air blower is running. AAB52
• Cooling air fan is not running. AAR01
Starting procedure
The operator pushes the start button, when conditions below are checked:
• Outlet air temperature not high TSH AAB53
• Outlet air temperature not very high TSHH AAB53
• Outlet air temperature not high PSH AAB54
• Emergency stop not actuated
• Valve AAB 40 is opened ZSL AAB40
• Valve AAR 06 is closed ZSH AAR06
• Primary air blower is not running From client
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Shut down by safeties

• Blower or fan in operation discrepancy AAB52 & AAR01
• Outlet air temperature very high TSHH AAB53
• Outlet air pressure very high PSH AAB54
• Emergency stop
• Valve AAB 40 is closed ZSL AAB40
• Valve AAR 06 is opened ZSH AAR06
Alarms
• Outlet air temperature high TSH AAB53
8.1.2.2 - Safety state
• Valve AAB 40 is closed ZSL AAB40

• Valve AAR 06 is open ZSH AAR06
• Primary air blower is not running. AAB52
• Cooling air fan is running. AAR01
8.1.2.3 - Cooling alarms
• Valves AAB40 discrepancy ZSL/H AAB40

• Valves AAR06 discrepancy ZSL/H AAR06
Caution:
Primary air blower AAB52 (supplied by other)

• Motor ME AAB 52 must keep running 6 hours after the burner has been stopped in order to cool the
burner.
• When a primary air valves alarm is active, the operator must go on site to check the discrepancy.
Emergency fan AAR01 (supplied by others)

• Failure of primary air blower or power failure starts automatically the emergency air fan, after 10
seconds timing. The axial circuit is cooled by emergency air fan in order to avoid destruction of
outer pipe by overheating.
• If the emergency air fan is stopped for any reasons, the burner will have to be taken outside from
the kiln in order to protect it against the heat. In any case the burner can remain in the hot kiln with
out any primary air
As it is a safety device, this emergency fan has to have a back up power supply to ensure burner
cooling in case of general shutdown
8.2 - ROTARY KILN CONTROL SYSTEM (not supplied by FIVES PILLARD)
Protection and interlocks
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Sequences have to be executed by a programmable controller or other. However, a certain number of

protections are duplicated by a cabled logic risk channel.
These protections are as follows :

• Emergency controller watch dog (W.D.)
• Customer safeties process (system) including mainly :
∗ ID fan stop
∗ CO to high
The negative feed back from one of these protections cuts off the voltage of solenoid valves.
Emergency stop
Negative feed back from one of emergency stop cuts off the voltage of :
• Motor outgoing lines
• Solenoid valves
• Ignition transformer
Main safeties
Causing shutdown of the burner and prohibiting start-up :
• Safeties process (system / CO)
• Watch dog
• Emergency stop
• Primary air fan
• Oil valves discrepancy (if existing)
• * Purging compressed air valves discrepancy (checked with ZSH and ZSL limit switches)
* Oil low pressure on high pressure pumping set (checked with PSL low pressure switch)
Primary air fan (supplied by other)

Start-up
The operator pushes the start button of the primary air fan motor
Feed back within 5 seconds.
• Motor is running
Feed back failure gives an alarm.
Emergency fan (supplied by others)

• Automatic start-up if selected.
• Failure of primary air fan or power failure start automatically the emergency air fan, after 10
seconds timing. The axial circuit is cooled by emergency air fan, in order to avoid destruction of
outer pipe by overheating.
Rotaflam burner
Coal cooling circuit manual valve item AAB 08
Oil selected only

• Valve item AAB08 is 100 % opened under operator control.
Feed back within 5 minutes.
• Limit switch item ZSH AAB08 is detected.
Feed back failure within 5 minutes stops oil firing.
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Coal selected only

• Valve item AAB08 is partially closed (10 % opened) under operator control.
• Limit switch item ZSL AAB08 is detected.
Feed back allows coal firing.
Oil and coal selected

• Valve item AAB08 is partially closed (10 % opened) under operator control.
• Limit switch item ZSL AAB08 is detected.
In case of wrong position, an alarm will appear.
Start-up of main firing
Starting conditions
• No main safety failure
• Ignition allowed
• Gas pilot on (if needed)
Oil firing selected

• Oil return flow manual control valve is at minimum firing position
• Valve item AAB08 100 % opened (checked with its ZSH limit switch)
Coal firing selected

• Oil return flow manual control valve is at minimum firing position
• Valve item AAB08 partially closed (10% opened) (checked with its ZSL limit switch)
COAL SELECTED
Under customer control. Just check general start-up main firing (see here above)
ROTAFLAM BURNER
During coal firing and even in dual firing (oil and coal), the position of cooling shut-off valve item
AAB08 is partially closed (10 % opened) under operator control. Check with limit switch item
ZSL AAB08.
In case of wrong position it will not possible to use coal as main fuel.
HOW TO SWITCH FUELS

Switch oil to coal firing
Oil firing is in operation :
• Start-up the coal transport air blower and check inlet pressure at burner (pressure gauge item
PI ACP02 about 10 to 30 mbar g.)
• Cooling valve item AAB08 partially closed (10 % opened) (detected by the limit switch item
ZSL AAB08)
• Start coal firing at minimum dosing position
Coal should be ignited from oil flame is sufficient secondary air temperature is reached.
To keep the same Rotaflam heat output, reduce oil firing flow during coal firing flow increasing.
Switch coal to oil firing
• Start oil firing at minimum flow position
Oil should be ignited from coal flame.
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To keep the same Rotaflam heat output, reduce coal firing flow during oil firing flow increasing.
• When coal flow rate is at minimum, stop dosing system and coal transport air blower (procedure to
be described by others)
• Open valve item AAB08 at 100 % (detected by the limit switch item ZSH AAB08)
Dual firing oil and gas (if existing)

First fuel selected should be ignited by mean of gas ignition burner. Second fuel should be ignited from
the first fuel selected. Valve item AAB08 is partially closed (10 % opened) as transport air blower is
ON.
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PART 9 - SAFETY CHECKS/MAINTENANCE
9.1 - MAINTENANCE
The necessary maintenance of the goods consists in assuring that all parts be maintained in good
working order. It is important that the equipments concerned should be maintained by or under the
supervision of competent persons in accordance with good practice and according to any instructions
specially advised and, where appropriate, with particular reference to information specified on sub-
supplier leaflets.
It is the Purchaser's responsibility to ensure that a safe system of work shall be adopted by all personnel
involved in the maintenance and that access of specific equipment is restricted to authorised personnel
only.
All moving parts of the equipment supplied are suitably guarded to prevent injury personnel.
Equipment must be electrically isolated before removal of guards.
Care must be taken to avoid the generation of local frictional heat caused by misalignment of
mechanical parts or the generation of sparks by metallic contaminants of the feed entering mechanical
equipment.
Inspection doors must not be opened when the plant is in operation.

Good housekeeping is important and any spillages or leakages of flammable dust must be cleaned up
immediately to avoid accumulations.
If maintenance involves working inside or around combustion chamber, all necessary safety
precautions must be taken (safety harnesses, protective clothing, safety helmets and safety glasses). If
maintenance involves any welding, cutting, permits must be issued by the Operations Department to
confirm it is safe for this work to be conducted, and all earths to electronic equipment in the vicinity
should be disconnected.
If maintenance work is being performed during a shut-down, ensure that all tools and materials have
been removed from the equipment after the work is completed.
All instruments and gauges should be regularly checked for accuracy.
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9.2 - SAFETY CHECKS
OPERATORS TRAINING
All operators or other persons who are supposed to work on firing installation must get a special
training before to get any responsibility.
Following safety checks have to be done during operation.
Periodic checking
• Safety instruments
• Strainer screen not clogged
• Fire protection device (test to be registered)
• Ground insulation (test to be registered)
Permanent checking
• Pressures
• Temperatures
• No leaks.
CAUTIONS
The installation must run without any safety device or automatic control device deconnected or out of
order.
DO NOT SMOKE.
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9.3 – BURNER TIP REPLACEMENT
DESCRIPTION FOR REPLACEMENT OF ROTAFLAM BURNER TIPS
1 - PRELIMINARY
2 - PRECAUTIONS
3 - DISMANTLING OF MAIN PARTS
3.1 - Outer refractory lined tube

3.1.1 - With the Rotaflam burner fitted to the carriage
3.1.2 - With the Rotaflam burner removed from the carriage
3.2 - Radial air tube
3.3 - Coal tube
3.4 - Central air tube
3.5 - Jacket tube
4 - SPECIAL POINTS
4.1 - Handling
4.2 - Help for dismantling
4.3 - Setting/removing assembly parts
5 - REPLACEMENT OF TIPS
5.1 - Welded tips

5.1.1 - Axial outer tip tag 02
5.1.2 - Central stabiliser tag 09
5.2 - Threaded tips

5.2.1 - Axial air inner tip tag 03
5.2.2 - Radial air tip tag 04
5.2.3 - Coal tip tag 08
6 - POST RE-ASSEMBLY CHECKS
6.1 - After replacement of part(s) of tip

6.2 - During a kiln stop
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1 - PRELIMINARY
This guide is not exhaustive. Its purpose is limited to being a guide to readers already presumed competent ; if it
contains any omission or any imprecise instructions, this cannot be used to show Fives Pillard’s responsibility in
part of any wrong operation or mistake in operating or maintenance, or to show that Fives Pillard’ role as advisor
has not been fulfilled.
2 - PRECAUTIONS
ROTAFLAM burner is withdrawn from the kiln and left to cool. All the safety rules have to be closely followed.
3 - DISMANTLING OF MAIN PARTS
3.1 - Outer refractory lined tube
Two ways are possible :
3.1.1 - with the Rotaflam burner fitted to the carriage (refer to sheet 7)
• Before dismantling the refractory lined tube, check the presence of a reference mark on the flange of the
leading end and the intermediate part.(When reassembling, one must reset the reference marks so that the
leading end is put back into its initial position.)
In the opposite case it is necessary to mark the position of the flanges before dismantling them.
• Lift the refractory lined tube by its centre of gravity with a lifting device . This is to obtain balance so as to
limit rubbing during dismantling.
• Slowly unscrew bolts from flange whilst checking the correct position of the centre of gravity.
• IMPORTANT : During this operation the inner axial pipe must be free from any load .It will not resist to the
load from the refractory lined tube.
• Slide out the refractory lined tube.
• Take care of refractory lining during dismantling.
RE-FITTING :
Proceed in the reverse sequence as that for dismantling. Please note that the gasket has to be replaced every time
the joint has been dismantled.
3.1.2 - With the Rotaflam burner removed from the carriage (refer to sheet 8)
• The refractory lined tube is to be rested on two support points.(wooden wedges)

• Lift the rear part of the burner by its centre of gravity with a lifting device . This is to obtain balance so as to
limit rubbing during dismantling.
• Slide out the rear part of the burner ,together with the inner pipe. During this operation slinging points may be
moved.
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RE-FITTING :
3.2 - Radial air tube (refer to sheet 9)
• Lift the rear part of the burner by its centre of gravity with a lifting device . This is to obtaining balance so as
to limit rubbing during dismantling.
• Slide out the rear part of the burner ,together with the inner pipe. During this operation slinging points may be
moved.
RE-FITTING :
3.3 - Coal tube (refer to sheet 11)
Proceed exactly the same way as for the radial air tube (chapter -3-2)
During these operations take care of the expansion joint.
NOTE : Sometimes the special wear piece inside the back side of radial air circuit may slide with the coal tube.
In this case do not forget it during remounting.
RE-FITTTING :
3.4 - Central air tube (refer to sheet 12)
Proceed exactly the same way as for the radial air tube (chapter -3-2)
During these operations take care of the expansion joint.
RE-FITTING :
3.5 - Jacket tube (refer to sheet 13)
Proceed exactly the same way as for the radial air tube (chapter -3-2) . However if the set is not heavy,
dismantling can be carried out by hand.
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4 - SPECIAL POINTS
4.1 - Handling
• No slinging point is in a position to stress the expansion joints.

• Synthetic slings are preferable to metallic ones.
4.2 - Help for dismantling
In order to help whilst dismantling the tubes, following equipment may be used :
• Horizontally mounted cranes.
• Mechanical or hydraulic jacks.
4.3 - SETTING/REMOVING ASSEMBLY PARTS
FLANGE SEPARATION : (refer to sheet 14)
• Check the presence of the reference mark on both flanges. If not, a reference mark must be made.
• Use a wedge by tapping gently or use the threaded holes if existing with extracting screw.
• Don't damage sealing surfaces.
FLANGE SETTING : (refer to sheet 15)
• Each channel with an expansion joint is fitted with an anti-rotation device.

Locking is achieved by trapping a mobile centering tab between 2 fixed tabs.
It is therefore important to align the flanges correctly at the end of the positioning manoeuvres. Manually
check that the mobile tab is between the 2 fixed tabs with the space between flanges at approx. 100 mm.
5 - REPLACEMENT OF TIPS (refer to sheet 16)
5.1 - Welded tips
5.1.1 - Axial outer tip tag 02 (refer to sheet 1)
Outer tube has to be removed from ROTAFLAM. Refer to chapter 3.1

• Break away the refractory lining until the weld appears.
• Grind off the existing weld or cut away the weld with flame plasma torch. Once the old tip is removed, put
the chamfer in order to have its face perfectly flat and perpendicular.
• Temporally weld 4 or 6 flat steel pieces on SS ferule tag 14 to help tip positioning. .Slide the new tip and
position it according to sheet 1.
• Check :
∗ 1 to 2 mm gap between pieces should be disposed such that the weld has sufficient penetration.
∗ Concentricity and parallelism of pieces.
• Now welding preparation is over.
Use suitable weld rods according to metal quality
∗ Cast SS tip tag 02 : welding rod type SAFINOX R CND 25.20 or equivalent
∗ SS ferrule tag 14 : welding rod type SAFINOX R CND 25.20 or equivalent
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In order to avoid any distortion during welding we recommend :

∗ Tack weld in at least 4 to 6 spots.
∗ Weld in diametrically opposite sectors.
5.1.2 - Central stabiliser tag 09 (refer to sheet 2)
Jacket tube set has to be removed from ROTAFLAM. Refer to chapter 3.5
• Grind off the existing weld or cut away weld with flame plasma torch. Once the old tip is removed put the
chamfer in order to have its face perfectly flat and perpendicular.
• Install the new tip and position it according to sheet 2.
• Check :
∗ 1 mm gap between pieces should be disposed such that the weld has sufficient penetration.
∗ Concentricity and parallelism of pieces.
∗ Now welding preparation is over.
Use suitable weld rods according to metal quality
∗ SS tube (stabiliser side): welding rod type SAFINOX R 308L (18/8) or equivalent
∗ Carbon steel tube : St 37 or equivalent
• Weld must be carried out with a lack of penetration to allow oil gun or other to go through freely.
5.2 - Threaded tips
5.2.1 - Axial air inner tip tag 03 (refer to sheet 3)
• Outer tube has to be removed from ROTAFLAM. Refer to chapter 3.1

• Unscrew the tip tag 3 anti-clockwise with a chain or strap wrench. Tap gently with a hammer in order to free
it. Always taking care otherwise the threads may be damaged. If difficult to remove, heat up the female
screwed thread portion to eliminate the seizing with an expansion.
RE-FITTING :
Two cases are possible :
Case 1
Existing threaded part tag 13 fit with new axial inner tip tag 03.
Proceed in the reverse sequence as that for dismantling. Coat threaded parts with high temperature grease.
Smoothly tighten the thread.
Case 2
Existing threaded part tag 13 does not fit with new axial inner tip tag 03.
Remove the threaded tube as follows :
Grind off the existing weld or cut away weld with flame plasma torch. Once the old tube is removed put the
If needed, temporally weld 4 or 6 flat steel pieces on circuit tube to help threaded tube positioning. .Slide the
new threaded tube and position it according to the sheet 3.
Check :
• 1 to 2 mm gap between pieces should be disposed such that the weld has sufficient penetration.
• Concentricity and parallelism of pieces.
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Use suitable weld rods according to metal quality as st 37 or equivalent.
RE-FITTING :
Proceed exactly the same way as for above case 1.
5.2.2 - Radial air tip tag 04 (refer to sheet 4)
Case 1
The axial air tip tag 03 is already dismantled.
Proceed as described below.
Case 2
The axial air tip tag 03 is not dismantled.
Radial air tube has to be removed from ROTAFLAM. Refer to chapter 3.2.
Unscrew the tip tag 04 anti-clockwise with a chain or strap wrench. Tap gently with a hammer in order to free it.
Always taking care, otherwise the threads may be damaged. If difficult to remove, heat up the female screwed
thread portion to eliminate the seizing with an expansion.
RE-FITTING : Two cases are possible :
Case 1
Smoothly tight the thread.
Case 2
Remove the threaded tube as follows :
If needed, temporally weld 4 or 6 steel flat pieces on circuit tube to help threaded tube positioning. .Slide the
new threaded tube and position it according to the sheet 4.
Check :
• 1 mm gap between pieces should be disposed such that the weld has sufficient penetration.
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RE-FITTING :
5.2.3 - Coal tip tag 08 (refer to sheet 6)
Case 1
The radial air tip tag 04 is already dismantled.
Proceed as described below.
Case 2
The radial air tip tag 04 is not dismantled.
Coal tube has to be removed from ROTAFLAM. Refer to chapter 3.3.
Unscrew the tip tag 08 anti-clockwise with a chain or strap wrench. Tap gently with a hammer in order to free it.
Always taking care, otherwise the threads may be damaged. If difficult to remove, heat up the female screwed
thread portion to eliminate the seizing with an expansion.
RE-FITTING :
Case 1
Smoothly tight the thread.
Case 2
Remove the threaded tube as follow :
If needed weld temporally 4 or 6 steel flat pieces on circuit tube to help threaded tube positioning. .Slide the new
threaded tube and position it according to the sheet 6.
Check :
• 1 mm gap between pieces should be disposed such that the weld has sufficient penetration.
RE-FITTING :
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6 - POST RE-ASSEMBLY CHECKS
6.1 - After replacement of part(s) of tip (refer to sheet 16)
REFER TO SHET 16
Before re-inserting the ROTAFLAM burner in the rotary kiln it is absolutely imperative to check the zero
position of the tip. For the zero position of the tip refer to sheet 16. The reference position set before shipment
(size A= 17 mm).
Therefore, align all the tips for vertically face flush position. Only the tip tag 02 has to be forward as shown on
the sheet 16. This alignment is carried out by mean of turn buckles or cylinders on the side of the burner. In this
position the indicator of each channel must be on « zero » on the aluminium scales. If this is not the case, remove
the rivet of each scale showing a deviation from zero. Reposition the scale with zero aligned with the arrow
indicator. This operation finished, fix each indicator that has been adjusted by installing a new rivet.
Keep in your records for each channel the distance between expansion joint flanges when tips are at "0 position".
All tips have to be re-positioned as it was before dismantling.
IMPORTANT :
This above checking is to be carried out even in the case of a simple replacement time when at least one piece is
dismantled.
6.2 - During a kiln stop
In order to avoid faulty referencing of the tip settings it is desirable that the temperature of the refractory lining
of the supporting tube does not exceed 100 °C. If thus is not the case, let the front part cool down.
ENCLOSURES :
Sheet 1 - Axial outer tip tag 02
Sheet 2 - Central stabiliser tag 09
Sheet 3 - Axial inner tip tag 03
Sheet 4 - Radial air tip tag 04
Air swirler tag 05
Sheet 5 - Gas tip tag 06
Gas swirler tag 07
Sheet 6 - Coal tip tag 08
Sheet 7 - Dismantling of outer refractory lined tube
ROTAFLAM burner fitted to the carriage
Sheet 8 - Dismantling of outer refractory lined tube
ROTAFLAM burner removed from the carriage
Sheet 9 - Dismantling of radial air tube
Sheet 10- Dismantling of gas tube
Sheet 11- Dismantling of coal tube
Sheet 12- Dismantling of central air tube
Sheet 13- Dismantling of jacket tube(S)
Sheet 14- Typical flanges separation
Sheet 15- Flanges setting
Sheet 16- Tips at zero position
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SHEET 1
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SHEET 2
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SHEET 3
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SHEET 4
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SHEET 5
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SHEET 6
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SHEET 7
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SHEET 8
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SHEET 9
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SHEET 10
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SHEET 11
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SHEET 12
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SHEET 13
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SHEET 14
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SHEET 15
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SHEET 16
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PART 10 - DRAWINGS LIST
10.1 – MECHANICAL DRAWINGS
Rev Drawing N° Description Type
B Z-263735 ROTAFLAM KILN BURNER GENERAL ARRANGEMENT

B Z-263737 ROTAFLAM KILN BURNER ASSEMBLY
A Z-263812 OVERHEAD TROLLEY ASSEMBLY
0 Z-263858 TELESCOPIC PIPE ASSEMBLY
0 Z-265185 MCRC VALVE TRAIN ASSEMBLY
FIVES PILLARD
1220/2
1216/4
DETAIL 4 DETAIL 5
LA
RA E
LEVE RVIC
A ENE EN SE VED AE
M IS EMO MISENLEVER
BE RRE USE
TO E
A
TO B EN SERV LA
B FO BEFOE REMO ICE
RE U VED
SE
R A LA
A ENLEVESERVICE
MISE EN MOVED
TO BE RE USE
BEFORE
08 33 4136 00
Page 79
10.2 – PILOT IGNITOR BOX – ELECTRICAL DIAGRAM – STE-057EN
FIVES PILLARD
PILOT
IGNITOR BOX
E
D
C
B
A 25/03/2008 CCH HP UPDATED TITTLE BLOCK FIVESPILLARD
0 06/07/2007 CCH HP ORIGINAL ISSUE
REVISION DATE DRAWN CHECKED CHANGES
ELECTRICAL DIAGRAM
S
I
Z A3
E
FIVES PILLARD
Tel : +33 (0)4 91 80 90 21
Fax : +33 (0)4 91 25 72 71
STE-057 Sh.01/ 11
THIS DOCUMENT BELONGS TO FIVES PILLARD, IT CANNOT BE COPIED, REPRODUCED OR
OTHER WISE GIVEN TO ANY PERSON WITHOUT PRIOR WRITTEN PERMISSION.
THIS DOCUMENT BELONGS TO PILLARD, IT CANNOT BE COPIED, REPRODUCED OR OTHER WISE GIVEN TO ANY PERSON WITHOUT PRIOR WRITTEN PERMISSION.
LETTER CODES FOR ITEMS DESIGNATION ON THE DRAWING LETTER CODES
E : MISCELLANEOUS Q : CIRCUIT BREAKER/ISOLATING SWITCH A/ APPARATUS IN THE CABINETS

KA 1 20
F : FUSE/THERMAL RELAYS R : POTENTIOMETER/RESISTOR
ORIGINAL SHEET NUMBER
H : LIGHT/HORN S : SELECTOR SWITCH/PUSHBUTTON
RELAY ITEM ON ORIGINAL SHEET
I : INDICATOR T : TRANSFORMER
NATURE OF MATERIAL - SEE ELEMENT DESIGNATION
KA : RELAY U : RECTIFIER
EXAMPLE : KA RELAY - F FUSE
KM : CONTACTOR V : DIOD
M : MOTOR X : TERMINAL B/ WIRING

03 20
10 ORIGINAL SHEET NUMBER

MECHANICAL ITEM P.I.D. : ZSL 508
THREAD NUMBER ON ORIGINAL SHEET
LOCAL APPARATUS TO BE CONNECTED BETWEEN
TERMINALS 10 AND 11 OF THE CABINET
11 PE C/ CONTACT REPORT IN THE DRAWING
13 14 20 6
WIRING FOR LIMIT SWITCHES ON VALVES AND TAPS
23 24
33 34 COLUMN NUMBER ON SHEET WHERE
43 44
ELECTRICAL CONTACT ELECTRICAL CONTACT ELECTRICAL CONTACT ELECTRICAL CONTACT
THE CONTACT IS USED
OPENED IF LIMIT SWITCH CLOSED IF LIMIT SWITCH CLOSED IF LIMIT SWITCH OPENED IF LIMIT SWITCH
(FOR CLOSING) IS NOT (FOR CLOSING) IS (FOR OPENING) IS NOT (FOR OPENING) IS SHEET NUMBER (WHERE THE CONTACT IS USED)
OPERATED OPERATED OPERATED OPERATED
D/ TERMINALS VIEW IN THE DRAWING

RELAY AND RELAYED CONTACT TYPE IN THE DRAWING
FUSE TERMINAL PIN DISCONNECTING TERMINAL PIN

RELAY
MAKE CONTACT
(DELAYED WHEN OPERATING)
FUSE TERMINAL PIN
RELAY COIL (SLOW OPERATING) WITH LED
MAKE CONTACT
(DELAYED WHEN RELEASING) NEUTRAL TERMINAL PIN
RELAY COIL (SLOW RELEASING)
ORDINARY TERMINAL PIN

WIPING CONTACT RELAY MAKE BEFORE BREAK
"NO + NC"
MULTIFUNCTION RELAY
M
THE DRAWING IS SHOWN OUT OF VOLTAGE AND WITH GENERATOR OUT OF SERVICE
01 03
0 1 2 3 4 5 6 7 8 9
REVISION
LEGEND STE-057 SHEET 02
A
SHEET DESIGNATION REV. SHEET DESIGNATION REV.

01 COVER SHEET A
02 LEGEND A
03 SUMMARY A
04 220 V / 50 Hz SINGLE PHASE FEEDING A
05 GAS IGNITOR START-UP A
06 IGNITOR TRANSFORMER & SOLENOID VALVES CONTROL A
07 INDICATING LAMPS AND CLIENT'S INTERFACE A
08 220 V / 50 Hz SINGLE PHASE FEEDING A
09 XC1 TERMINAL CONNECTION DIAGRAM A
10 FRONT VIEW & INTERNAL FRONT VIEW BOX - EQUIPMENT LOCATION A
11 CABLE SCHEDULE A
02 04
0 1 2 3 4 5 6 7 8 9
REVISION
SUMMARY STE-057 SHEET 03
A
QS1.04
3x20A
L1 T1 02.04
L2 T2 01.04
L3 T3
G/Y
PE
1 3
GROUND BAR
QF1.04
2A (D)
2 4
03.04
04.04
+CLIENT
1 2 PE
XP
G/Y
220V N / Sh.05-00
220V Ph / Sh.05-00
CLIENT
220 V / 50 Hz SINGLE MAIN BREAKER 220 VAC MAIN

PHASE FEEDING SWITCH DISTRIBUTION
P = 255 VA
I = 1,2A Nominal
Icc = 15 KA P = 255 VA
03 05
0 1 2 3 4 5 6 7 8 9
REVISION
220 V / 50 Hz SINGLE PHASE FEEDING STE-057 SHEET 04
A
Sh.04-05 / 220V Ph 04.04 04.04 04.04 04.04 04.04 04.04 220V Ph / Sh.06-00
14 6
XC1 03 67
KA1.05 KA3.05
Sh.05-01 Sh.05-05
+IGNITOR 10''
04 68
5
X1
05.05
E1.06 8
SHUNT 21 XSL AEQ 10 21
KA5.05 IGNITOR
Sh.05-08 FLAME DETECTION
SB2.05
IGNITOR STOP
22 22
9 PUSHBUTTON
HS2 AEQ 10
10 06.05
X1
06.05
REMOTE
03.05
LOCAL
13 5 21 13
XC1 33
SA1.05
HS3 AEQ 10
03.05
22 34 14
Sh.07-01
10.05
01.05
11.05
03.05
12
XC1
07.05
07.05
03 13 13 03 X1 13
+CLIENT
KA2.05 KA2.05 KA3.05 SB3.05 X2
2
Sh.05-03 Sh.05-03 SB1.05 Sh.05-05
CLIENT'S CABINET
FAULT ACKNOWLEDGMENT 10'' IGNITOR START-UP
04 14 14 04 X2 14
PUSHBUTTON PUSHBUTTON
Sh.07-08
HS1 AEQ 10
KA1
08.05
1 PE
04.05
04.05
X2
09.05
02.05
03
KA4.05
Sh.05-06 11 PE
04 XC1
09.05
09.05
G/Y
A1 A1 A1 A1 A1
KA1.05 KA2.05 KA3.05 KA4.05 KA5.05
A2 A2 A2 10'' A2 A2
Sh.04-05 / 220V N 03.04 03.04 03.04 03.04 03.04 03.04 220V N / Sh.06-00
03 04 Sh.05-05 03 04 Sh.05-01 03 04 Sh.05-04 03 04 Sh.05-04 03 04
13 14 Sh.07-06 13 14 Sh.05-02 13 14 Sh.06-04 13 14 Sh.07-08 13 14
21 22 Sh.07-06 23 24 Sh.07-07 23 24 Sh.06-04 21 22 Sh.07-08 21 22 Sh.05-02
31 32 33 34 Sh.07-02 33 34 31 32 31 32 Sh.06-04
43 44 Sh.07-01 43 44 43 44 43 44 Sh.07-06 43 44
53 54 55 56 53 54 Sh.07-03
61 62 Sh.07-07 61 62 Sh.07-06
67 68
Sh.05-08
AVAILABILITY IGNITOR FAULT IGNITOR IGNITION

START-UP TRANSFORMER STOP
04 06
0 1 2 3 4 5 6 7 8 9
REVISION
GAS IGNITOR START-UP STE-057 SHEET 05
A
Sh.05-09 / 220V Ph 04.04 220V Ph / Sh.07-03
04.04
13
KA3.05
Sh.05-05
14
01.06
04.04
31
KA5.05
Sh.05-08
32
02.06
G/Y
01.06
4 PE 2
XC1
+IGNITOR
8 PE 6
X1
Sh.05-03 /
Sh.05-03 /
Bn
Bk
G/Y
G/Y
8 10
XC1
E1.06 1 10 8 9 4
TV1.06
IONY 2501
Bu
3 6 5 XSV AGA 05 XSV AGA 06
Bu
3 1
X1
3 1 7 PE 9 PE
XC1
G/Y
G/Y
03.06
03.06
03.04
23
BE AEQ 10 KA3.05
Sh.05-05
24
Sh.05-09 / 220V N 03.04 03.04 220V N / Sh.07-03
XSL AEQ 10 BZ AEQ 10 XSV AGA 05 XSV AGA 06
IGNITOR FLAME IGNITION IGNITION GAS IGNITION GAS

DETECTION TRANSFORMER UPSTREAM DOWNSTREAM
VALVE CONTROL VALVE CONTROL
FUSE 5x20 250mA H.R. FUSE 5x20 2A H.R. FUSE 5x20 500mA Tempo. FUSE 5x20 500mA Tempo.
05 07
0 1 2 3 4 5 6 7 8 9
REVISION
IGNITOR TRANSFORMER & SOLENOID VALVES CONTROL STE-057 SHEET 06
A
Sh.06-09 / 220V Ph 04.04
Sh.06-09 / 220V N 03.04
1 3
FU1.07
10x38
0,5A gG 2 4
09.07
09.07
13
SB1.07
LAMPS TEST 14
09.07
09.07
PUSHBUTTON
10.07
03.07
33
SA1.05
10.07
10.07
Sh.05-05
34
13 21 61 23 13 21
KA1.05 KA2.05 KA4.05
02.07
Sh.05-01 Sh.05-03 Sh.05-06

04.07
06.07
14 22 62 24 14 22
11.07
13.07
14.07
43 33 53
10.07
KA1.05 KA2.05 KA4.05
09.07
08.07
Sh.05-01 Sh.05-03 Sh.05-06
44 34 54
01.07
05.07
07.07
G/Y
61 43
XC1
15 16 17 18 19 20 PE KA4.05
Sh.05-06
62 44
12.07
X1 X1 X1 X1
HL1.07 HL2.07 HL3.07 SB3.05
White Green Red Sh.05-05
Green X2
X2 X2 X2
08.07
08.07
08.07
+CLIENT
1 2 3 4 5 6 PE
X1
CLIENT'S CABINET
XL2 AEQ 10 XL1 AEQ 10
AVAILABILITY IGNITOR FAULT IGNITOR 220 VAC AVAILABILITY IGNITOR FAULT IGNITOR
OPERATING POWER ON OPERATING
06 08
0 1 2 3 4 5 6 7 8 9
REVISION
INDICATING LAMPS AND CLIENT'S INTERFACE STE-057 SHEET 07
A
QS1.04
GROUND BAR
EXTERNAL
P01
U1000R2V
3Gxxmm²
THE SECTION DEPEND
OF THE DISTANCE
1 2 PE
G/Y
CLIENT
-XP
07 09
0 1 2 3 4 5 6 7 8 9
REVISION
220 V / 50 Hz SINGLE PHASE FEEDING STE-057 SHEET 08
A
08
0
XC1
EXTERNAL
PE
1
END PE
03.06
1
1
KA3.05:23
02.06
6
2
KA5.05:32
03.04
3
3
KA5.05:A2
2
C04
IGNITOR
U1000R2V
04.04
8
7G1,50mm²
4
-X1 CONNECTOR
KA3.05:67
03.05
5
10
SB1.05:13
04.04
5
6
KA5.05:21
3
03.06
7
XC1:1
XC1 TERMINAL CONNECTION DIAGRAM

01.06
8
KA3.05:14
C05
XSV AGA 05
U1000R2V
3G1,50mm²
PE
03.06
9
4
XC1:7
01.06
XC1:8
10
C06
XSV AGA 06
U1000R2V
3G1,50mm²
PE
09.05
1
KA4.05:A1
11
5
10.05
2
SA1.05:14
12
-X2
CLIENT
C07
U1000R2V
3G1,50mm²
PE
PE
01.05
KA2.05:03
13
6 04.04
QF1.04:4
14
TO SHUNT
01.07
1
KA1.05:44
15
03.07
2
SA1.05:33
16
05.07
3
KA2.05:34
17
04.07
4
KA2.05:33
18
-X1
CLIENT
C08
U1000R2V
07.07
5
7G1,50mm²
KA4.05:54
19
06.07
6
KA4.05:53
20
STE-057
8
PE
PE END
SHEET 09
9
A
10
REVISION
ITEM ON THE
ITEM
EQUIPMENT LABEL
DRAWING
BOTTOM VIEW 1 QS1.04 LOAD BREAKER SWITCH 3x20A
SCALE: 1/2
2 HL1.07 PILOT LIGHT -WHITE- 220 VAC POWER ON
3 HL2.07 PILOT LIGHT -GREEN- AVAILABILITY
9 8
HL3.07 PILOT LIGHT -RED- IGNITOR FAULT
AEQ 40
25
5 SB3.05 ILLUMINATED PUSHBUTTON, SPRING RETURN "N/O" -GREEN- IGNITOR START-UP
8
80 6 SB2.05 PUSHBUTTON, SPRING RETURN "N/C" -RED- IGNITOR STOP
1 7 SA1.05 LONG HANDLE SELECTOR SWITCH 2 POSITION STAY PUT "N/O" LOCAL / REMOTE
8 SB1.05 PUSHBUTTON, SPRING RETURN "N/O" -YELLOW- FAULT ACKNOWLEDGMENT

CABLE GLANDS NOT SUPPLIED
9 SB1.07 PUSHBUTTON, SPRING RETURN "N/O" -BLACK- LAMPS TEST
BY PILLARD E.G.C.I.
SIDE VIEW FRONT PANEL INSIDE FRONT PANEL
AEQ 40
100
1
2 1
0 1
QS1.04
70
220 VAC
3 4 (25x60)
(25x60)
KA1.05 KA3.05 KA5.05 QF1.04
500
455
220 VAC
5 6
FU1.07
70
KA2.05 KA4.05
7 220 VAC (25x60)
70
8 9 XC1
80
Tel : +33 (0)4 91 80 90 21
Fax : +33 (0)4 91 25 72 71
100
Plan Année de fabrication / N° contrat
Drawing
Year of manufacturing / FIVES PILLARD reference
ATTENTION Mise en service et maintenance uniquement par des spécialistes

BEWARE Operation and maintenance by specialist only
Leading Engineers & Suppliers of Combustion Solutions
250 400
490
SCALE : 1/5 in A3
WEIGHT : 30kg ~
ENCLOSURE TYPE NUMBER : NEMA 4
09 11
0 1 2 3 4 5 6 7 8 9
REVISION
FRONT VIEW & INTERNAL FRONT VIEW BOX - EQUIPMENT LOCATION STE-057 SHEET 10
A
Cables schedule
Nb of
TAG NUMBER cores ø Cable type Length from to Observations
P01 3G 0,00 mm² U1000R2V +CLIENT-XP QS1.04
C01 1x 1,00 mm² CAB_HT BE AEQ 10 IGNITOR - TV1.06 SUPPLY BY PILLARD

C02 1x 1,00 mm² CAB_ION IGNITOR - E1.06 BE AEQ 10 SUPPLY BY PILLARD
C03 1G 6,00 mm² U1000R2V IGNITOR - E1.06 BE AEQ 10 SUPPLY BY PILLARD
C04 7G 1,50 mm² U1000R2V XC1 IGNITOR - X1 (CONNECTOR)
C05 3G 1,50 mm² U1000R2V XC1 XSV AGA 05
C06 3G 1,50 mm² U1000R2V XC1 XSV AGA 06
C07 3G 1,50 mm² U1000R2V XC1 CLIENT - X2
C08 7G 1,50 mm² U1000R2V XC1 CLIENT - X1
10
0 1 2 3 4 5 6 7 8 9
REVISION
CABLE SCHEDULE STE-057 SHEET 11
A
08 33 4136 00
Page 80
PART 11 – LISTS AND SPECIFICATION
FIVES PILLARD
08 33 4136 00
Page 81
11.1 – PACKING LISTS
FIVES PILLARD
EDITION : 18/02/2009
NOMENCLATURE D'EXPEDITION
PACKING LIST
CLIENT : TCDRI for CASPI Cement Contract N° 08.33.4136.00
Responsable d'expedition : M. YANG Visa : MH Date : 19/12/08
IAP : MH Rev : 00
Nature du colis Longueur : cm Poids brut : kg N° Colis
Nature of package Length : gross weight : VOLUME : Package N°
Case Largeur : cm Poids net : kg 0,000 m3 01/01
Type Width : Net weight :
According Hauteur : cm Lot : Stockage XX Page
4B / SEI Height : Lot : Storage 1 / 2
BdT POSITION QTE DESIGNATION
ITEM QTY DESCRIPTION
DESTINATION
CASPI CEMENT
KAZAKHSTAN
CLIENT
TCDRI
N°1 Yinheli Bei Road - Beichen District
Tianjin - CHINA
MARKS
XINXIANG ZHENXIN CEMENT CO
CONTRACT NUMBER : 08.33.4136.00

SUB-CONTRACT NO.:
PACKAGE NO.: 01/01
GROSS WEIGHT (KG):
NET WEIGHT (KG):
DIMENSIONS L X W X H (CM) :
NAME OF GOOD: ROTAFLAM KILN BURNERS & FIRING

EQUIPMENT
ITEM NO:
PACKAGE NO: 01/01
GROSS WEIGHT: KG
NET WEIGHT: KG
DIMENSION (LxWxH): x x cm
MANUFACTURER: FIVES PILLARD
CONTAINS
D07 AEQ 01 1 ROTAFLAM kiln burner

D32 1 Spare outer pipe for kiln burner
D08 CEQ 4 Precalciner burners

D32 1 Spare outer pipe for precalciner burner
Stockage préconisé X Stockage extérieur XX Stockage emplacement couvert
Recommended storage Outdoor storage Sheltered storage
XXX Stockage batiment fermé XXXX Stockage salle air conditioné
Indoor storage Air conditioned storage
Imprimé nomenclature d'expédition G:\DE4\Af f 2008\08441451 - 08334136 TCDRI f or CASPI\CHAP 07-EXPEDITION\Packing list FINAL.xls AQ013-1a
EDITION : 18/02/2009
NOMENCLATURE D'EXPEDITION
PACKING LIST
CLIENT : Xinxiang Zhenxin Cement Company Contract N° 08.33.4116.00
Resposable d'expedition : M. YANG Visa : MH Date : 30/07/08
IAP : MH Rev : 00
Nature du colis Longueur : cm Poids brut : kg N° Colis
Nature of package Length : gross weight : VOLUME : Package N°
Case Largeur : cm Poids net : kg 0,000 m3 01/01
Type Width : Net weight :
According Hauteur : cm Lot : Stockage XX Page
4B / SEI Height : Lot : Storage 2 / 2
BdT POSITION QTE DESIGNATION
ITEM QTY DESCRIPTION
D11 FE AAB 30 1 Air flow sensor

FE AAB 31 1 Air flow sensor
FE AAB 32 1 Air flow sensor
D11 AAB27 1 Axial air flexible hose

AAB28 1 Radial air flexible hose
AAB29 1 Flexible hose
D11 ACP01 1 Telescopic pipe
D11 CAB 105 1 Air flexible hose for precalciner burner

CAB 205 1 Air flexible hose for precalciner burner
CAB305 1 Air flexible hose for precalciner burner
CAB405 1 Air flexible hose for precalciner burner
D11 CCP 104 1 Coal flexible hose for precalciner burner

CCP 204 1 Coal flexible hose for precalciner burner
D13 1 Burner trolley
G06 AEQ 10 1 Ignitor

1 Skid for ignitor
1 Electrical box for ignitor
AGA 08 1 Flexible hose for gas
C03 1 Diesel oil valve train

1 Diesel oil high pressure pump
1 MCRC oil gun
AFL 01 1 Diesel oil flexible hose
AFL 02 1 Diesel oil flexible hose
AFL 03 1 Quick coupling
AFL06 1 Quick coupling
Stockage préconisé X Stockage extérieur XX Stockage emplacement couvert

Recommended storage Outdoor storage Sheltered storage
XXX Stockage batiment fermé XXXX Stockage salle air conditioné
Indoor storage Air conditioned storage
Imprimé nomenclature d'expédition G:\DE4\Af f 2008\08441451 - 08334136 TCDRI f or CASPI\CHAP 07-EXPEDITION\Packing list FINAL.xls AQ013-1a
08 33 4136 00
Page 82
11.2 – PRIMARY AIR FAN SPECIFICATIONS
FIVES PILLARD
Rev 0 25/07/2008
Technical specifications for kiln burner primary air blower and for cooling air fan
Project: TCDRI for CASPI Cement (Kazakhstan)
Data design
Technical specification Kiln burner primary air blower Cooling air fan
description (Volumetric roots type) (centrifugal type)
Quantity 1 1
Fluid to be handled Atmospheric air Atmospheric air
Site location Kazakhstan Kazakhstan
Atmosphere Dusty (Cement plant) Dusty (Cement plant)
Installation Outdoor Outdoor
Design site altitude 165 m 165 m
Design inlet temperature + 40 °C + 40 °C
Design flowrate 9500 Nm3/hr ( 192.8 m3/min at suction conditions) 1700 Nm3/hr ( 34.5 m3/min at suction conditions)
Minimum flowrate 4000 Nm3/h ( 81.2 m3/min at suction conditions ) 800 Nm3/h ( 16.2 m3/min at suction conditions )
Static discharge pressure 294 mbarg. 70 mbarg.
Primary air duct pressure drop Max. 20 mbar Max. 20 mbar
(between blower discharge and
burner)
Motor synchroeous speed 1500 rpm (50 Hz) 3000 rpm (50 Hz)
Motor body Cast iron body Cast iron body
Flowrate adjustment type Speed controlled by frequency converter By manual valve located at fan discharge
Machine equipped with - Common base frame with anti-vibration mountings for blower and - Common base frame with anti-vibration mountings for fan and
motor motor
- Inlet silencer-filter with clogging indicator and vacuum pressure - Inspection opening and plugged drain
switch - Direct coupling (fan impeller fixed directly on the motor shaft)
- Pulley/belt coupling - If necessary, inlet silencer with protection screen, in order to reduce
- Discharge silencer the sound pressure level to maximum 85 dB(A) at 1,5 m in free
- Discharge pressure relief valve field conditions
- Discharge non-return valve - Direct drive
- Discharge flexible sleeve - Flexible connection sleeve with back flange located at fan outlet
- Discharge pressure gauge
- Discharge high pressure switch IMPORTANT :
- Discharge thermometer - This emergency f an has to have a back-up power supply to ensure
- Discharge temperature sensor Pt100 type with electronic converter burner cooling in case of general shutdown
(output signal 4-20 mA) for "high temperature" alarm and "very high
temperature" safety thresholds
- Vent manual valve (to be installed on site at blower discharge duct)
- If necessary, noise enclosure with forced ventilation, in order to
reduce the sound pressure level to maximum 85 dB(A) at 1,5 m in
free field conditions
Applicable norms European norms European norms
Rev 0 25/07/2008
Technical specifications for precalciner burners primary air fan

Project: TCDRI for CASPI Cement (Kazakhstan)
Data design
Technical specification Precalciner burners primary air fan

description (Volumetric roots type)
Quantity 1
Fluid to be handled Atmospheric air
Site location Kazakhstan
Atmosphere Dusty (Cement plant)
Installation Outdoor
Design site altitude 165 m
Design inlet temperature + 40 °C
Design flowrate 12000 Nm3/hr ( 243.6 m3/min at suction conditions )
Minimum flowrate 5000 Nm3/h ( 101.5 m3/min at suction conditions)
Static discharge pressure 100 mbarg.
Primary air duct pressure drop Max. 20 mbar
(between blower discharge and
burner)
Motor synchroeous speed 3000 rpm (50 Hz)
Motor body Cast iron body
Flowrate adjustment type Speed controlled by frequency converter
Machine equipped with - Common base frame with anti-vibration mountings for blower and
motor
- Inlet silencer-filter with clogging indicator and vacuum pressure
switch
- Pulley/belt coupling
- Discharge silencer
- Discharge pressure relief valve
- Discharge non-return valve
- Discharge flexible sleeve
- Discharge pressure gauge
- Discharge high pressure switch
- Discharge thermometer
- Discharge temperature sensor Pt100 type with electronic converter
(output signal 4-20 mA) for "high temperature" alarm and "very high
temperature" safety thresholds
- Vent manual valve (to be installed on site at blower discharge duct)
- If necessary, noise enclosure with forced ventilation, in order to
reduce the sound pressure level to maximum 85 dB(A) at 1,5 m in
free field conditions
Applicable norms European norms
08 33 4136 00
Page 83
11.3 – MOTORS & INSTRUMENTS LIST
FIVES PILLARD
MOTOR AND SENSOR AND CONSUMER LIST UNIT : DIESEL OIL HP PUMP & VALVE TRAIN Rev 0
Date 05/12/2008
GENERAL FLOW SHEETS: Z-264795 & Z-264796
Items General datas Range Electrical
Rev ITEM FLOW SHEET Description Qty Supplier Manufacturer Type/Ref. Min. Nom. Max Unit Signal type Power supply Protection Freq Ph RPM Consumption
0 PSL DFD04 Z-264795 PRESSURE SWITCH LOW 1 OTHERS - 30 - bar DRY CONTACT - IP 54 mini - - - -
0 ME DFD05 Z-264795 PUMP MOTOR 1 OTHERS - - - - - 380 v IP 55 50 Hz 3 3000 -
0 ZSL BAC01 Z-264796 LIMIT SWITCH 1 OTHERS - - - - DRY CONTACT - IP 54 mini - - - -

MOTOR AND SENSOR AND CONSUMER LIST UNIT : BURNER Rev 0
Date 05/12/2008
ROTAFLAM GENERAL FLOW SHEET: Z-264793/A
Items General datas Range Electrical
Rev ITEM FLOW SHEET Description Qty Supplier Manufacturer Type/Ref. Min. Nom. Max Unit Signal type Power supply Protection Freq Ph RPM Consumption
0 XSV AGA05 Z-264793 SOLENOID VALVE 1 PILLARD LUCIFER E 321 K - - - - LOGIC 220 V IP 65 50 Hz 1 - 10 W
0 XSV AGA06 Z-264793 SOLENOID VALVE 1 PILLARD LUCIFER E 321 K - - - - LOGIC 220 V IP 65 50 Hz 1 - 10 W
0 XSL AEQ10 Z-264793 IGNITOR TRANSFORMER 1 PILLARD PILLARD T - - - - - 220 V IP 65 - - - 240 W
0 BZ AEQ10 Z-264793 FLAME DETECTION RELAY 1 PILLARD PILLARD RDF - - - - DRY CONTACT - IP 65 - - - -
0 ZSL AAB08 Z-264793 LIMIT SWITCH 1 PILLARD LEF LEF 102 - - - - DRY CONTACT - IP 65 - - - -
0 ZSH AAB08 Z-264793 LIMIT SWITCH 1 PILLARD LEF LEF 102 - - - - DRY CONTACT - IP 65 - - - -
0 ME AEQ05 Z-264793 TROLLEY MOTOR 1 PILLARD - - - - - 380 V IP 65 50 Hz 3 - 1.1 kW
0 ME AAB52 Z-264793 PRIMARY AIR FAN MOTOR 1 OTHERS - - - - - 380 V IP 65 50 Hz 3
0 PIC AAB52 Z-264793 PRESSURE CONTROLLER 1 OTHERS 4-20 mA or PROFIBUS PA IP 65 - -
0 PT AAB59 Z-264793 PRESSURE TRANSMITTER 1 OTHERS 4-20 mA or PROFIBUS PA - IP 65 - -
0 TSHH AAB53 Z-264793 TEMPERATURE SWITCH VERY HIGH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
0 TSH AAB53 Z-264793 TEMPERATURE SWITCH HIGH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
0 PSH AAB54 Z-264793 PRESSURE SWITCH HIGH 1 OTHERS DRY CONTACT - IP 65 - -
0 ME AAR01 Z-264793 EMERGENCY AIR FAN MOTOR 1 OTHERS - - - - - 380 V back-up power supply
IP 65 50 Hz 3
0 XSV AAB40 Z-264793 SOLENOID VALVE 1 OTHERS - - - - LOGIC 220 V IP 65 50 Hz 1
0 ZSL AAB40 Z-264793 LIMIT SWITCH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
0 ZSH AAB40 Z-264793 LIMIT SWITCH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
0 XSV AAR06 Z-264793 SOLENOID VALVE 1 OTHERS - - - - LOGIC 220 V IP 65 50 Hz 1
0 ZSL AAR06 Z-264793 LIMIT SWITCH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
0 ZSH AAR06 Z-264793 LIMIT SWITCH 1 OTHERS - - - - DRY CONTACT - IP 65 - -
08 33 4136 00
Page 84
11.4 – PARTS LIST
FIVES PILLARD
Date : 06/01/2009 Folio : 1/2
13, rue Raymond Teissère - 13272 Marseille Cedex 8 - France

Phone (33) 4 91 80 90 21 - Fax (33) 4 91 25 72 71 - E-mail : info@pillard.com - Web http://www.pillard.com
Order : 08.4.4.1451.00 08.3.3.4136.00

Drawing : Z-264793 ROTARY KILN
Revision : A OIL/COAL ROTAFLAM KILN BURNER
FLOW SHEET
PILLARD Customer
ISA Label
item item
SUPPLIED BY FIVES PILLARD
AAB06 Air butterfly valve
Air butterfly valve with high limit switch (ZSH) and low limit switch
AAB08
(ZSL)
AAB17 Isolating valve and pressure indicator (PI) for axial air
AAB18 Isolating valve and pressure indicator (PI) for radial air
AAB19 Isolating valve and pressure indicator (PI) for central air
AAB22 Flexible hose
AAB26 Flexible hose
AAB27 Axial air flexible hose
AAB28 Radial air flexible hose
AAB29 Central air flexible hose
FE AAB30 Flow meter for axial air
FE AAB31 Flow meter for radial air
FE AAB32 Flow meter for primary air
ACP01 Telescopic pipe
ACP02 Isolating valve and pressure indicator (PI) for coal channel
ACP03 Diaphragm seal
AEQ01 Kiln burner
AEQ02 Swivel device for orientation
AEQ03 Steel structure
AEQ04 Jack screw
AEQ05 Front wheel mounting and electrical motor (ME)
AEQ06 Rear wheels mounting
AEQ08 Diesel oil gun
Ignition torch with ignition transformer (BZ) and flame failure switch
AEQ10
(XSL)
AEQ20 Hydraulic cylinder
AEQ21 Hydraulic cylinder
AFL01 Supply oil flexible hose
AFL02 Return oil flexible hose
AFL03 Quick coupling on supply oil line
AGA01 Isolating valve
AGA02 Filter
PCV AGA03 Hand control valve/damper
PI AGA04 Pressure indicator
XSV AGA05 Solenoid valve
Date : 06/01/2009 Folio : 2/2

Order : 08.4.4.1451.00 08.3.3.4136.00

Drawing : Z-264793 ROTARY KILN
Revision : A OIL/COAL ROTAFLAM KILN BURNER
FLOW SHEET
PILLARD Customer
ISA Label
item item
XSV AGA06 Solenoid valve
AGA08 Flexible hose
NOT SUPPLIED BY FIVES PILLARD
Isolating valve pneumatically operated normally closed with
AAB40 solenoid valve (XSV), high limit switch (ZSH) and low limit switch
(ZSL)
Silencer with differential pressure indicator (DPI) and differential
AAB51
pressure low level switch (DPSL)
Pump with Electrical motor (ME), Frequency controller (SC) and
AAB52
Pressure indicator controller (PIC) of the primary air fan
High temperature switch (TSH) and Very high temperature switch
AAB53
(TSHH)
AAB54 High pressure switch (PSH)
AAB55 Pressure relief valve
AAB56 Pressure indicator (PI)
AAB57 Check-valve
AAB58 Flexible connecting sleeve
AAB59 Pressure transmitter (PT)
AAC01 Isolating valve
AAC02 Filter
AAR01 Cooling air fan with Electrical motor (ME)
AAR02 Compliant spool on the cooling air fan
Isolating valve pneumatically operated normally closed with
AAR06 solenoid valve (XSV), High limit switch (ZSH) and Low limit switch
(ZSL)
Date : 06/01/2009 Folio : 1/1

Order : 08.4.4.1451.00 08.3.3.4136.00

Drawing : Z-264794 PRECALCINER
Revision : A PULVERISED COAL FIRED PRECALCINER BURNERS
FLOW SHEET
PILLARD Customer
ISA Label
item item
CAB105 Primary air flexible hose
CAB110 Air butterfly valve
CAB111 Radial air butterfly valve
CAB119 Isolating valve and pressure indicator (PI)
CCP104 Pulverised coal flexible hose
CCP117 Diaphragm seal
CCP118 Isolating valve and pressure indicator (PI)
Date : 06/01/2009 Folio : 1/1

Order : 08.4.4.1451.00 08.3.3.4136.00

Drawing : Z-264795 DIESEL OIL HIGH PRESSURE PUMPING SET
Revision : 0 BURNED FLOWRATE = 1500 kg/h MAXI
FLOW SHEET
PILLARD Customer
ISA Label
item item
DFD01 Isolating valve hand operated
DFD02 Filter
DFD03 Isolating valve and pressure indicator (PI)
PSL DFD04 Low pressure switch
DFD05 Pump with Electrical motor (ME)
PCV DFD06 Pressure control valve
DFD07 Isolating valve and pressure indicator (PI)
DFD08 Check-valve
DFD10 Pressure relief valve
Date : 06/01/2009 Folio : 1/1

Order : 08.4.4.1451.00 08.3.3.4136.00

Drawing : Z-264796 DIESEL OIL "MCRC" MANUAL VALVE TRAIN
Revision : 0 BURNED FLOW RATE= 1500 kg/h MAXI
FLOW SHEET
PILLARD Customer
ISA Label
item item
BAC01 Isolating valve hand operated and low limit switch (ZSL)
BAC02 Filter
BAC06 Check-valve
BFD01 Isolating valve hand operated
BFD02 Isolating valve and pressure indicator (PI)
BFD04 Filter
BFD05 Flow meter (FE) and flow indicator (FI)
BFD12 Flow meter (FE) and flow indicator (FI)
HCV BFD15 Hand control valve/damper
BFD16 Check-valve
BFD17 Isolating valve hand operated
08 33 4136 00
Page 85
11.5 – QUALITY DOCUMENTS
FIVES PILLARD

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08 33 4136 00

USER'S GUIDELINES 08 44 1451 00

The Buyer: TIANJIN CEMENT INDUSTRY DESIGN & RESEARCH INSTITUTE

The End User: CASPI CEMENT KAZAKHSTAN

ROTAFLAM KILN FIRING SYSTEMS

Your Ref.: SINOMA/CASPI/2007/03

Address : 88, Dong Fang Road, Free Trade Zone, Tianjin.

Beijing contact address :Room 503A, Tower B, Derun Tower,

0 13/02/2009 MH Original issue DAN HBI

PART 1 - PRELIMINARY SAFETY RECOMMENDATIONS

RECOMMENDATIONS CONCERNING SAFETY

• Verification and Maintenance of safety equipment :

The user must in addition take particular care that :

Instructions to be written and distributed by the Client to its personnel

The above documents are to be regularly kept available by the Client :

PART 2 - TECHNICAL DATA

2.1 - ROTARY KILN

2.2.1 – Diesel oil

− LHV kcal/kg 10 000

2.2.2 – Pulverised fuel

− For instruments 220 V, 1 Ph, 50 Hz

− Pressure bar g max. 7

− Atmosphere non aggressive

Plant site conditions

− Ambient temperature °C max. 29.5

PART 3 – FLOW SHEET

Item code for equipment:

Type Localisation Fluid concerned

PART 4 - SCOPE OF SUPPLY

A: ROTARY KILN FIRING EQUIPMENT

A.2 - ONE (1) GAS ELECTRIC IGNITOR

− One (1) gas/electric ignitor with :

A.3 - ONE (1) TELESCOPIC COAL CONNECTION PIPE

Average length 4 250 mm, adjustment range ± 750 mm.

− The pipe length comprises :

A.4 - ONE (1) BURNER TROLLEY

A.5 - SET OF MCRC OIL GUNS

− One (1) oil gun, complete MCRC type

A.6 – MANUAL DIESEL OIL VALVE TRAIN

To be installed close to burner.

Shop assembled, complete on base frame, including :

− Three (3) pressure gauges c/w isolating cocks.

Oil supply line :

− One (1) shut-off valve, hand operated

Return flow control :

− One (1) oil flow control valve, hand operated.

− One (1) flow meter

Air purging of oil line :

− One (1) shut-off valve, hand operated.

A.7 – ONE (1) OIL PUMPING SET FOR KILN BURNER

Oil pump specifications as follows:

Shop assembled, complete on base frame, including:

A.8 – TECHNICAL SPECIFICATION FOR PRIMARY AIR DEVICE TO BE SUPPLIED

- Three ( 3 ) flexible hose (length= 5m max) for connection to burner.

A.9 – EMERGENCY COOLING DEVICE TO BE SUPPLIED BY CLIENTS

A.10 – SPARE PARTS

One (1) outer pipe without refractory lining and anchors.

B: PRECALCINER FIRING EQUIPMENT

B.1 – FOUR (4) PRECALCINER BURNERS COAL FIRING

Shop assembled, each burner includes:

− One (1) central jacket pipe

B.2 – TECHNICAL SPECIFICATION FOR PRECALCINER BURNERS PRIMARY AIR FAN TO BE

B.3 – SPARE PARTS

One (1) outer pipe without refractory lining and anchors.