Rotary Kiln, Erection: Kiln Shell and Live Rings With Loose Supporting Blocks, On Supports Type R58

Rotary kiln, erection
Kiln shell and live rings with loose supporting

blocks, on supports type R58
Installation, operation and maintenance
Approved date:
Created by: KAR-IN
Approved by:
Doc. No.: 18091-10-2.0

Rotary kiln
18091-10-2.0
List of contents:
Page:
1 General information ....................................................................................... 5

2 Erection preparations ..................................................................................... 5
2.1 Erection conditions ........................................................................................ 5
2.2 Kiln turning during erection............................................................................. 6
2.3 Inspection of the kiln sections ......................................................................... 6
2.3.1 ....................................................................................................... 6
2.3.2 ....................................................................................................... 6
2.3.3 ....................................................................................................... 7
2.3.4 ....................................................................................................... 7
2.3.5 ....................................................................................................... 7
2.3.6 ....................................................................................................... 7
2.4 Assembly of kiln sections ................................................................................ 7
3 Mounting of live rings and supporting sections ................................................... 8
3.1 Supporting sections ....................................................................................... 8
3.2 Preparations ................................................................................................. 9
3.3 Mounting of live rings on kiln sections without supporting blocks ......................... 9
3.3.1 ......................................................................................................10
3.3.2 ......................................................................................................10
3.3.3 ......................................................................................................10
3.3.4 ......................................................................................................11
3.4 Mounting of live rings on kiln sections with supporting blocks of steel.................. 11
3.5 Seal between live rings and kiln shell .............................................................. 12
3.6 Provisional fastening of live rings .................................................................... 12
3.7 Checking ..................................................................................................... 13
4 Erection of light-duty kiln sections .................................................................. 13
4.1 Standard kiln sections ................................................................................... 13
4.2 Kiln sections at Unax cooler ........................................................................... 14
5 Checking the eccentricity of kiln section ........................................................... 14
5.1 General notes ..............................................................................................14
5.2 Supporting sections ...................................................................................... 15
5.2.1 ......................................................................................................15
5.2.2 Drawing of polar diagrams ................................................................. 17
5.2.3 Tolerances ....................................................................................... 18
5.2.4 Alignment of supporting sections ........................................................ 18
5.3 Welded joints ............................................................................................... 18
6 Centralization/alignment of kiln sections prior to welding .................................... 19
6.1 General notes ..............................................................................................19
6.2 Kiln section 1 ...............................................................................................20
6.3 Assembly 2-1 and 3-2 ...................................................................................21
6.4 Assembly 4-3 ............................................................................................... 21
6.5 Tolerances ................................................................................................... 21
7 Control levelling prior to welding .................................................................... 21
8 Welding of circular seams .............................................................................. 22
9 Welding of live ring guides ............................................................................. 22
9.1 Checking the bay lengths of kiln ..................................................................... 22
9.2 Correction of live ring positions ...................................................................... 22
9.3 Finish mounting of live rings .......................................................................... 23
9.3.1 Live rings with supporting blocks ........................................................ 23
9.3.2 Welding together of wear rings ........................................................... 23
2/36 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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9.3.3 Guide flaps (24)................................................................................24

9.3.4 Mounting of wear rings (22) and guide blocks (08)................................25
9.3.5 ......................................................................................................25
9.3.6 ......................................................................................................26
9.3.7 ......................................................................................................26
10 Removal of shields ....................................................................................... 27
11 Appendices ................................................................................................. 27
List of appendices:
Appendix 1 Erection photos 18090-09-I ......................................................................... 28

Appendix 2 Erection photos 18090-09-II ........................................................................ 29
Appendix 3 Erection photos 18090-09-III ....................................................................... 30
Appendix 4 Erection photos 18090-09-IV ........................................................................ 31
Appendix 5 Erection photos 18090-09-V ......................................................................... 32
Appendix 6 Completed copy of inspection form U 4791-04, page 1 .................................... 33
Appendix 7 Completed form of inspection form U 4791-04, page 2 .................................... 34
Appendix 8 Kiln alignment, tools ................................................................................... 35
Appendix 9 Kiln alignment. Copy of inspection form U 5431-01 ......................................... 36
List of figures:
Figure 1 ....................................................................................................................... 8
Figure 2 ..................................................................................................................... 11
Figure 3 ..................................................................................................................... 12
Figure 4 ..................................................................................................................... 12
Figure 5 ..................................................................................................................... 13
Figure 6 ..................................................................................................................... 15
Figure 7 ..................................................................................................................... 16
Figure 8 ..................................................................................................................... 16
Figure 9 ..................................................................................................................... 17
Figure 10 .................................................................................................................... 20
Figure 11 .................................................................................................................... 23
Figure 12 .................................................................................................................... 24
Figure 13 .................................................................................................................... 25
Figure 14 .................................................................................................................... 26
Figure 15 .................................................................................................................... 26
Figure 16 Erection photos 18090-09-I ............................................................................ 28
Figure 17 Erection photos 18090-09-II ........................................................................... 29
Figure 18 Erection photos 18090-09-III.......................................................................... 30
Figure 19 Erection photos 18090-09-IV .......................................................................... 31
Figure 20 Erection photos 18090-09-IV .......................................................................... 32
Figure 21 Completed copy of inspection form U 4791-04, page 1 ....................................... 33
Figure 22 Completed form of inspection form U 4791-04, page 2 ....................................... 34
Figure 23 Kiln alignment, tools ...................................................................................... 35
Figure 24 Kiln alignment. Copy of inspection form U 5431-01 ........................................... 36
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 3/36
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Text reference is made to the following instruction manuals etc.:
Kiln arrangement drawing

Rotary kiln. Erection
Erection report 18341
Assembly of divided kiln section 18301
Burner's platform 18181
Automatic welding 18101
Manual arc welding 18101
Auxiliary equipment for erection 18041
Rotary kiln. Maintenance.
Supports 19031
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NOTE!
The present instruction manual is concerned with the situations, which, according to
the experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of
all conceivable situations, which may occur during erection, operation and maintenance
of the rotary kiln cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.
1 General information
In the present manual directions are given for the erection of kiln shell and live rings,
centralization of kiln shell and welding-on of live ring guides.
Before the kiln shell is erected, it is essential that bedplates, bearings and supporting
rollers have been properly aligned and that the bedplates have been grouted in place
in accordance with the relevant instruction manuals.
The order or priority for the erection of the single kiln sections depends on the local
conditions. It is standard procedure to start off with that part of the kiln which
supports the gear rim of the drive station so that the barring device can be deployed
at earliest possible point in time.
This procedure is followed in the present manual, but, essentially, the line of
procedure is the same regardless of the starting point for erection.
2 Erection preparations
2.1 Erection conditions
The following factors require attention and evaluation before the kiln sections
are placed on the supports:
A. Adequacy of transport facilities?
Inlet and outlet sections of special importance in this respect.
B. Availability of required lifting gear?
See manual for auxiliary equipment for erection.
C. Availability of kiln turning facilities? Refer sub-section 2.2
D. Are the supplied kiln sections welded into reasonably large units? For weld-
up of kiln sections see instruction manual for automatic welding.
NOTE!
The number of kiln sections which can advantageously be welded up at ground
level is limited. If the sections are too long, it may prove difficult - during the
subsequent weld-up of the sections - to meet the specified tolerance range for
the axial run-out on live rings. See form U-4791 in erection report with
annotations.
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2.2 Kiln turning during erection

Kiln drive station and kiln drive to be erected on provisional basis at earliest
opportunity so that the kiln can be turned by means of the barring device. For
automatic welding of the seams the barring device must be held available in
order to attain a regular and correct turning speed. Since turning is also
required in connection with the erection and alignment of the gear rim of the
kiln drive, it must be possible to turn the kiln by means of hoists and winches.
It must be possible to turn the kiln shell sections over the full lengths when
the assemblies are centralized prior to the welding of the circular seams.
The instruction manual for auxiliary erection equipment contains data for the
hoists and winches required for turning of kiln.
Where hoists and winches are used for turning of kiln, these devices must
exert an upward thrust in order to reduce the friction in the bearings. For
instance place two hoists in the erection crane or in a mast. When turned, the
kiln will slide downwards towards the outlet end since the supporting rollers
are standing virtually parallel to the kiln axis. To compensate for this
phenomenon, the position of the kiln sections indicated on the position drawing
must be increased by 50-100 mm towards the inlet end.
Check that all kiln supporting roller bearings are filled with oil before kiln
turning is started. The journals of the supporting roller shafts must not be
"dry" when turning is commenced. Oil grade - similar to that applied to the
supporting roller bearings - to be poured over the journals just prior to kiln
barring operation.
The supporting rollers must never be placed at an angle ("skewing"). Place the
thrust rollers in their uppermost position, i.e. upwards towards the smoke
chamber.
2.3 Inspection of the kiln sections

2.3.1
The sub-division of the kiln shell into kiln sections required for reasons of
transportation is indicated on the dispatch drawing.
Check the length of the supplied kiln sections, and enter lengths on form
U-4691 in the erection report. Since the live rings may be axially displaced
on the finish-welded kiln shell, any deviations in the lengths of the kiln
sections will seldom affect the distance between the centrelines of the
bedplates. In that case, the position drawing should have been revised
when check measurements were performed in the workshop; however it is
advisable to check the measurements.
Check also the width of the live rings and the outside diameter. These
measurements must also be recorded in form U-4691 in the erection
report.
2.3.2
All kiln sections are match-marked and furnished with numbers. The lowest
number is assigned to the inlet section of the kiln.
On the inside of kiln sections there is a white painted line with arrow
heads. After the kiln sections have been placed on the supports and
assembled, these white lines must form a continuous line and all arrow
heads must be pointing in direction of the kiln inlet.
Use the kiln shell drawing and possibly dispatch or marking drawing to
check that the white line on kiln sections has the correct orientation in
relation to bolt holes for possible internal fittings, manholes etc.. Bolt holes
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for internal fittings to be placed correctly in relation to one another and

relative to the rotational direction of kiln.
2.3.3
At both ends the kiln sections are braced by means of a stiffening cross for
avoidance of damage during transportation. On heavy-duty kiln sections a
stiffening cross is also fitted at the centre of kiln section.
Use a standard pin gauge to check whether the kiln sections have been
deformed during transportation and check also that their cross section
remains circular at the end faces. In the affirmative, it is advisable to let
the stiffening crosses remain fitted on the kiln sections until the sections
have been laid up and assembled and until welding of the first bottom run
of the circular seams has been completed.
2.3.4
In event that severe deformation of the kiln sections is ascertained, f. inst.
damage incurred in transit, FLS-Head office must be notified of the nature
and extent of deformation in order to evaluate potential liability for
damages.
Alignment is necessary in case the cross section of a kiln section has been
deformed. Cut the stiffening cross, and align the cross-section by means of
jacks or tension bolts. It may be necessary to heat the kiln section. Use
tension bolts if alignment is made synchronously with the erection.
2.3.5
NOTE!
The centre stiffening crosses fitted on heavy-duty kiln sections must always
remain fitted until the erection of live rings is completed.
2.3.6
Check that the weld bevels of the kiln sections, as stipulated, are not
painted on section at least 50 mm away from the edge of the kiln section.
Rust and contaminants to be removed from weld bevels. If, inadvertently,
the bevels have been painted, the paint must be stripped off very carefully
since the strength of the weld is impaired by the gases produced in
connection with the burning of paint.
2.4 Assembly of kiln sections

For assembly of kiln sections at ground level or during erection use the
auxiliary tools shown in Fig. 1.
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01. Tension bolt

02. Erection iron
03. Adjusting iron, "dog"
Figure 1
Before the mounting of kiln sections is started, the erection supervisor must
inspect very carefully the welds applied for fixation of erection and adjusting
irons to the kiln shell. The stipulated a-dimension (see Fig. 1 and erection tool
drawing) and scope and quality of welds must be adhered to.
In workshop the erection irons (02) have been fixed by welding to the inside of
both kiln section ends, at location where the erection irons are placed opposite
matching irons on the adjacent kiln sections.
The erection irons can be assembled by inserting tension bolts (01) between
the erection irons on two kiln sections.
During erection the adjusting irons (03), also known as "dogs", are welded to
the inside of the kiln sections at locations where this is necessary in order to
centralize the two kiln sections in relation to one another. However, at least 4
adjusting irons must always be fitted on the same tube section to avoid
shearing.
Tension bolts and adjusting irons are included in the supply in required
quantities.
3 Mounting of live rings and supporting sections

3.1 Supporting sections
The supporting sections of kiln are heavy machined kiln sections, with or
without supporting blocks for the live rings.
If kiln section is equipped with supporting blocks, these blocks are normally
fitted on the kiln section in the workshop. In any event, the supporting blocks
are always match-marked with the kiln sections for clear indication of
relationship between support/block and the location of the single supporting
blocks on the circumference.
NOTE!
If erection of the cyclone tower or the smoke chamber has been completed, it
may be necessary, for reasons of space, to lay up the light-duty inlet section
(section No. 1) before erecting the heavy-duty kiln section for the upper
support. Raise kiln section No. 1 until its height is almost correct, and support
it in such manner that the heavy kiln section can be erected without any
problems.
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3.2 Preparations
Remove burns, rust-inhibiting agent and dirt from the live rings and their
contact face against kiln section/supporting blocks. Use a suitable solvent, f.
inst. ESSO Solvesso 100, turpentine, or a similar aliphatic solvent. Paraffin oil
should not be used due to its rust-promoting properties.
Check that the contact faces on kiln section/supporting blocks and live ring are
without flaws. Any damaged sustained during transportation to be repaired.
Tearing of supporting blocks or kiln section may occur during kiln
turning if the contact faces are flawed.
All contact faces to be smeared with the special lubricant specifically supplied
for this purpose. The lubricant normally supplied is PBC (Poly-Butyl-Cuprysil,
Poul Products, England), but the following products can also be used:
Klüber Lubrication : Grafloscon. Wolfracoat C
Reiner Chemie : Ceplattyn HT
Molub-Alloy : 491-C
Chesterton : Nickel Anti-Seize Compound
Achesons Colloids
Company : Oildag
Never-Seez
Compound Corp. : Never-Seez
Stiffening cross at the middle of kiln section to remain fitted until the live ring
has been installed.
Important!
During this operation special care must be exercised to prevent invasion of
impurities, weld spatter etc. to area between live ring and kiln section (live
ring blocks) where alien objects may give rise to tearing.
3.3 Mounting of live rings on kiln sections without supporting blocks

Two methods can be applied for mounting of the live rings. The method applied
depends on the lifting capacity available at site.
A. Mount the live ring on kiln section with the kiln section blocked up at ground
level.
B. Mount the live ring on the supporting rollers and lead the kiln section
through live ring.
Method A is by far the best option, but it is always necessary to ensure that
the total weight of sections and ring does not exceed the lifting capacity.
Method B is mainly used for the erection of large kilns. The method is more
complex since the slope of the kiln section must correspond to that of the live
ring when the section is led through the live ring and, through corrections, it is
necessary throughout the operation to ensure that the centreline of the kiln
section inside the live ring coincides with that of the live ring.
Where strapping of live rings occurs, it is important to protect its surfaces
against damage; this is done by inserting wooden shim pads or similar objects
between the lifting wires and the live ring.
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3.3.1
Procedure for mounting of live ring at ground level as follows:
Place the kiln section on the two blocks which are arranged so that the live
ring can be led so far over one end of kiln section that it is possible to fit
blocking under the kiln section on the other side of the live ring.
Lead the live ring over the kiln section, very closely to blocking, and
arrange for stable support of the live ring.
Now, place blocking under the free end of the kiln section, and remove one
of the two original blocks. It is very important that the kiln section is
placed in the horizontal position.
Now follow the check-up procedure described in sub-section 3.3.3 and
position the kiln section in the live ring as described in sub-section 3.3.4.
3.3.2
The mounting of kiln section in live ring, with the live ring placed on the
supporting rollers, can be effected as follows:
Turn the supporting section on the ground so that the white line with arrow
pointing in direction of kiln inlet is placed at the bottom of the section.
Raise the section, and centralize it very carefully with the live ring. Refer
Appendix 2.
Then push the kiln section through the live ring. Make sure that there is a
gap between kiln shell and live ring over the entire circumference.
When one of the two straps, used to suspend kiln during displacement,
reaches the live ring, the strap is slackened so that the kiln section is
brought to rest on the live ring. Now transfer the strap to the other side of
the live ring. See Appendix 3.
Installation procedure for live ring is described in the following.
Kiln section to be supported at both ends, f. inst. with railroad ties, after
the live ring has been mounted on the kiln section.
3.3.3
NOTE!
Regardless of method applied:
Operation to be suspended when the live ring is in contact with the
supporting face.
At this stage the erection supervisor must check:
 that the parts have been cleaned very carefully as emphasized earlier
 that the slope of kiln section and live ring is exactly the same
 that the cross-section of the kiln section is fully centralized relative to
the live ring
 that the parts have been thoroughly lubricated with the lubricant
supplied
 that the cross-section of the kiln section is circular
Theoretically, the diameter differential between kiln section and live ring is
in range 2-8 mm. Given the relatively narrow clearance between the kiln
section and live ring, it is very important to ensure maximum circularity of
the cross-section of the kiln section in order to avoid any complications
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during erection. Further, this is crucial in order to avoid tearing between

live ring and supporting face. Refer sub-section 2.3.5.
In case the kiln section is not fully circular, some of the supporting blocks
on the upper half of kiln section can be removed. After positioning the live
ring/kiln section, the dismantled blocks can be re-installed in the upper
position where the clearance is maximized. Cross at middle of kiln section
to be removed if necessary.
3.3.4
On completion of check-up procedure, the actual mounting operation can
be initiated.
Place the live ring in its proper position, if necessary by means of the jacks
depicted in Fig. 2. The supporting face features a line generated through
scratching and with a centre punch. During erection measurements must
be taken from this line up to the foremost edge of the live ring at different
points on the circumference. The X-dimension must be the same
throughout in order to ensure that the live ring does not stuck, but so that
the ring is placed at right angles to the supporting face.
Figure 2
3.4 Mounting of live rings on kiln sections with supporting blocks of steel
The installation procedure for live rings equipped with supporting blocks is
essentially the same as that described in sub-section 3.2.
The blocks always carry a number so as to indicate its exact location.
For example block no. 204 is placed on supporting section no. 2 at location
204.
In most cases, the blocks are supplied with the blocks bolted on to the
respective kiln sections. If not pre-fitted, the blocks must be fitted during
mounting. If necessary, it is acceptable to skip the mounting of 2 x 2 blocks in
the horizontal centreline of the kiln in order to facilitate the mounting of the
live ring.
If stop blocks (23) have been mounted, they must be dismounted on the side
of the supporting blocks on which the live ring must be mounted. If wear rings
(22) are supplied assembled and fitted on the kiln section, remove the wear
ring at the end of the supporting blocks from which the live ring must be
mounted. If the wear ring is supplied in two or four parts, the chief erector
may choose to weld the rings together and fit the ring on the kiln section
together with the live ring. Otherwise adhere to procedure described in sub-
section 9.3.1.
Blocks and the inner side of live ring must be lubricated as mentioned in sub-
section 3.1, item A. Subsequently, the live ring is pulled on, if required by
means of 3-6 bolts as indicated in Fig. 3. During operation the distance (x)
between the scratched and centre-punched reference line and live ring must be
measured.
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Figure 3
Place the live ring as closely to the centre of the supporting blocks as possible.
Mount the last wear ring.
Now mount all stop blocks (23) (see Fig. 14, sub-section 9.3.5) one either side
of the live ring as shown on kiln tube drawing. Prior to mounting the bolts,
smear the bolts with PBC on the underside of the bolt heads. PBC (see page
11) is a sealing agent which prevents water from entering the kiln during
erection and damaging the lining. Tighten the bolts to the specified torque, but
do not secure them.
It may be necessary to adapt the stop blocks by grinding if they do not lie
properly true against the kiln shell, e.g. because they are situated on a
longitudinal welded seam.
3.5 Seal between live rings and kiln shell

It is very important that access of particles to area between live rings and
supporting blocks is actively prevented during erection.
Figure 4
Such particles may cause severe tearing on the supporting blocks when the
kiln is started. All gaps to be cleaned through scavenging. Fill each hole
between live ring and supporting blocks on both sides with a suitable material
which can easily be adapted, as f. inst. expanded polystyrene, see Fig. 4. The
shields should not be removed until start-up of kiln is imminent. See section
11.
3.6 Provisional fastening of live rings

After the live ring is mounted and placed in the middle of the supporting
section, the live ring must be attached on provisional basis in this position.
3-4 guides fitted on both sides of the live ring will keep the ring in place. The
guides may be angle irons or the mentioned adjusting irons (dogs) which are
welded to the supporting blocks or the heavy-duty kiln section. See Fig. 5.
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Figure 5
When welding the guides in place, the distance between the welds and the live
ring must be minimum 100 mm. This distance is needed in order to permit
subsequent displacement of the live ring to the correct location, without the
live ring getting in contact with the welding zone.
Live ring and gap between live rings and kiln section/supporting blocks
to be protected against weld spatter.
3.7 Checking
Following mounting of live ring, check the surface of live ring and supporting
rollers and remove any weld spatter incurred on the surfaces despite the
caution exercised during mounting. Hence damage to the running path of the
supporting rollers during subsequent turning will be avoided.
4 Erection of light-duty kiln sections

4.1 Standard kiln sections
Mount the kiln sections between the supports and at inlet and outlet after all
live rings have been placed on the supporting rollers, with the heavy
supporting sections mounted in the live rings and supported by railroad ties or
similar objects.
Start with the light kiln section which supports the gear rim of kiln drive.
Always remember to turn the kiln section at ground level so that the
white line is placed at the bottom.
Lift the kiln section with the crane so that it is centralized with the heavy
section. In event that the white lines on the two kiln sections do not coincide
precisely, the kiln section suspended from crane must be turned. This is done
by slackening or pulling one of the two tackles holding the kiln section until the
two lines are lying on the same generatrix.
Check again that the kiln section being handled is the right one and that its
orientation is correct. Use the kiln drawing for checking, to eliminate risk that
the marking of the white line is incorrect. Always make sure that the bolt holes
for internal fittings, if any, are placed correctly both in relation to one another
and relative to the rotational direction of the kiln.
Assemble the two kiln sections as described in sub-section 2.4, and rig up a
support under the free end of the kiln section as shown in Fig. H in Appendix 4.
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Move the erection crane into position for mounting of the succeeding kiln
section, and mount this section and the adjoining sections in the same manner
until the assembled kiln sections cover the two foundations nearest the kiln
drive.
Kiln drive to be installed simultaneously. See separate instruction manual.
At stage where the kiln shell is stretching over two foundations, the supports
under the overhanging ends on the kiln sections can be lightened relative to
those for the first kiln sections, but it is crucial that the kiln sections with ends
placed more than 10-15 metres away from the centre of a live ring are
supported in proper manner.
Proceed with the erection of kiln sections, initially towards the inlet, and
subsequently from the kiln drive and downstream towards the burner's
platform. Refer sub-section 4.2.
4.2 Kiln sections at Unax cooler

On Unax kilns equipped with a support underneath the Unax cooler the
installation procedure for the lowermost kiln sections depends on whether the
tubular girder is mounted or not.
The mounting of the tubular girder, prior to or subsequent to the kiln shell
erection, is described in erection manual for the burner's platform.
If the tubular girder is fitted, and if the lowermost live ring is positioned on its
supporting rollers, two methods are applicable for the mounting of the
lowermost kiln section.
The short kiln sections can be welded up at ground level, whereafter, in the
assembled state, they are led over the tubular girder.
For this operation, substantial crane capacity, and preferably a gantry crane,
will be required. Further, it is essential that the erection is completed prior to
the mounting of live ring I and the kiln sections between support II and III.
The lowermost kiln sections can also be led over the tubular girder one by one,
with subsequent assembly of kiln sections. However, this would require cutting
of holes in the tubular girder, through which the welding of the circular seams
can be made. Holes to be so large that the inner run of the assemblies can be
welded. The location of the holes is indicated in the parts list for the burner's
platform. When the kiln sections are passed over the tubular girder, they must
have the same slope as the girder. This applies especially to the lowermost kiln
section, in that its uppermost machined section is to pass through the live ring
and the tubular girder.
5 Checking the eccentricity of kiln section

5.1 General notes
Following the assembly of kiln shell sections, the orientation of the parts in
relation to kiln axis must be checked. Measurements to be taken at point in
time where the kiln shell exhibits uniform temperature over the entire
circumference, i.e. preferably early in the morning. If erection is taking place
next to an operating kiln, shielding is needed for protection against heat
radiation.
The checking of kiln section positions is made on the basis of polar diagrams
drawn on the supporting sections and at the welded joints while the kiln is
turned.
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Consequently, all journals of supporting rollers must be carefully lubricated

with oil - oil grade to be identical to that used in the bearing before kiln
turning is commenced.
Since the prime aim is to minimize the turning operation, it is advisable to
check simultaneously all supporting sections and assemblies when the kiln is
turned.
In order to avoid displacement of the kiln sections when kiln is turned it is
possible to weld on flat irons 100 x 25 mm over the assemblies, on the inside
of kiln shell, using 6-8 welds per assembly. This procedure is adopted for
handling of large bay lengths where heavy loading of the tightening bolts is
involved. See Fig. 6.
Figure 6
Prior to alignment the flat irons are welded in place only on one side of the
assembly only, and must not be fixed by welding on the other side until the
alignment has been completed.
5.2 Supporting sections

The checking and alignment of kiln shell is primarily performed to ensure that
the centreline for all kiln sections and live rings coincides with the kiln axis. It
is of special importance that the supporting sections are centralized precisely
since the position of the live rings depends on it.
Consequently, check initially that the live rings are correctly installed on the
supporting blocks or kiln section. Measurement to be taken from the scratched
and centre-punched line to the sides of the live rings; check that the
measurement is maintained over the entire circumference.
Then execute two polar diagrams on each supporting section, one on either
side of the live ring, at the far edge of the supporting blocks or, if no
supporting blocks are fitted, at the far edge of the machined part of the kiln
section.
5.2.1
High degree of accuracy is needed when executing the polar diagrams on
the supporting blocks.
Use a depth gauge, similar to that depicted in Fig. 7 and measure from a
fixed point and up against the supporting blocks in the direction of the kiln
centre. For instance from a frame consisting of angle irons with a welded-
on guide as shown in Fig. 7. It is very important that the tongue of the
depth gauge is guided so that measuring is constantly performed in the
same direction towards the supporting blocks.
Rotary kiln
18091-10-2.0
Figure 7
The number of supporting blocks depends on the diameter of the kiln and
the live ring at the support concerned. For FLS kilns the live rings are
equipped with 24, 28, 32, 36, 40 or 44 supporting blocks.
It will suffice to perform measurements on 24 supporting blocks, evenly
distributed over the circumference of the kiln.
For instance if the live ring has 28 blocks, no measuring of every 7th block
is made; where equipped with 32 blocks, measuring is omitted on every
4th block, and if the number of blocks is 36, measuring on every 3rd block
is skipped. For larger diameters where 40 or 44 blocks are fitted, 16 and
20 blocks, respectively, are left out, evenly distributed over the
circumference, for example as shown in Fig. 8 where the arrows indicate
the blocks where measurements must be taken.
Figure 8
For instance, the measurements can be taken in the following manner,

using the form U-4791 from the erection report.
Find a supporting block which is placed on-line with the kiln manholes, or
having some other fixed reference point on the kiln. This block must be
marked with the figure 24. The same identification must appear at all
supports.
Turn block no. 24 to bottom position, and undertake the first measurement
(pos. 24) on this block.
Measurements to be taken on both sides of the supporting block as
indicated on page 1 in the form. Measuring data to be recorded in form in
the columns READING I (inlet end) and READING O (outlet end).
Turn the kiln until the next block is in bottom position, and mark this block
1. (Pos. 1).
Check on the form whether measurements are needed on this block. As set
out in the table, measuring on block No. 1 should only be omitted if the live
ring has 44 blocks.
Kiln turning, marking of blocks and measuring on the blocks mentioned in
the table to be continued until block No. 24 again passes the measuring
point.
Rotary kiln
18091-10-2.0
At the inlet end the supporting blocks are stamped with numbers, but
these numbers do not relate to any fixed reference point on the kiln
common to all supports, and, consequently, they cannot be used when
making the polar diagrams.
Measuring on supporting sections without supporting blocks is performed
by measuring to 24 positions on the circumference, i.e. at intervals of 15°.
Pos. 1 must be placed on-line with the very same manhole which was used
as benchmark for measurements undertaken on the supporting blocks.
5.2.2 Drawing of polar diagrams
See examples given in Appendices 6 and 7.
Measuring data to be entered on form U-4791 in columns READING I and
READING O. Identify the lowest value in each column and calculate
DIFFERENCE as the differential between the lowest value and the value for
each position.
Enter values (DIFFERENCE) in the figure on page 2 in the form.
Appropriate scale to be applied, f. inst. 1:0.2; readings to be plotted in
correct sequence from the dotted circle and towards the centre.
Plot a curve through the established points.
This curve represents the cross-section of the kiln shell at the measuring
point. Since the "diameter" of the curve is very small, and since the
deviations appear is given scale, the kiln profile will, quite naturally, appear
to be strongly deformed.
For clarity see Fig. 9 showing polar diagram representing a welded joint.
POS READING DIFFERENCE

12 210 10
1 207.5 7.5
2 208 8
3 211 11
4 213 13
5 211 11
6 207 7
7 202 2
8 200 0
9 209 9
10 209.5 9.5
11 209 9
Seen from outlet
12 210 10
Figure 9
Draw a new circle in the diagram with a pair of compasses.

The chosen centre and radius of the circle must be based on a competent
judgment so that the 4 greatest distances between the circle and the
Rotary kiln
18091-10-2.0
profile curve are almost identical and, in pairs, placed diametrically

opposed outside or inside the circle.
In given scale, the distance X between the 2 centres will indicate the
eccentricity of the kiln scale at the measuring point concerned.
The distance from the periphery of the last drawn circle and the profile
curve indicates the deformation of the kiln shell.
Diagrams I and O to be drawn on the same form so as to indicate more
precisely the inter-relation of any offset centres.
It is always necessary to indicate whether the diagrams are drawn before
or after welding by deleting the text not applicable, as shown in the
example in Appendix 6 and 7.
Copy of the polar diagrams showing that the alignment is satisfactory and
the kiln shell is ready for welding operation must be sent to FLS-Head
office. See erection report.
5.2.3 Tolerances
The axial run-out on the live rings must never be more than plus/minus 1
mm. This corresponds to a radial run-out, measured at the end of the
supporting blocks, of maximum plus/minus 0.4 mm, i.e. the kiln centre at
the cross-sections measured must not be offset by more than 0.2 mm.
Irregularities, unrelated to the radial run-out, may occur at the supporting
blocks. This fact must be taken into account when the location of the
centres is to be established.
Normally, an offset centre will be lying in two diametrically opposed
quadrants on the diagrams.
5.2.4 Alignment of supporting sections
As emphasized already, it is of paramount importance that the supporting
sections are centralized with the utmost precision.
When the live ring is fitted correctly on the supporting blocks, with no
deformation of kiln shell, porting blocks, with no deformation of kiln shell,
any eccentricity occurring is directly attributable to irregularities in the
assembly of the adjoining sections. Therefore, re-alignment must be made
through renewed assembly procedure.
Consequently, the polar diagrams for the supporting sections must be
compared with the diagrams drawn at the adjoining assemblies before any
alignment can be made.
5.3 Welded joints

At the welded joints between the kiln sections and at the inlet and outlet end
of kiln the polar diagrams are executed as follows:
At each measuring point mark off 12 generatrices on the kiln shell, inter-
spaced through 30°. Let generatrix No. 12 pass through the same manhole as
pos. 24 used to measure the supporting blocks. Mark the remaining
generatrices with numbers in sequential order as they pass the observer, with
the kiln being turned in correct direction of rotation.
Measurements to be taken radially against the kiln axis from a straight line
running parallel to the kiln axis.
In practical terms, it is best to establish the line by using tool similar to that
depicted in Fig. 10 on page 32.
Rotary kiln
18091-10-2.0
The tool consists of a wooden frame (12) with a sturdy base stabilized with
counterweights (15). Item (10) is a pointed reinforcement iron or round iron
bar bent into a handle at the lower end. The round iron bar can slide on the
wooden frame in a couple of bows (11), and it is equipped with a welded-on
indicator tip (14). A piece of paper (13) is placed under the indicator tip, and
when the pointed end of the round iron bar is pressed against the kiln shell,
the measurements can be plotted on the paper off the indicator tip.
Values recorded to be stated in form U-4781 in the erection report, and polar
diagrams to be drawn as outlined in sub-section 5.2.2. Use scale 1:1.
6 Centralization/alignment of kiln sections prior to welding

6.1 General notes
Fig. 10 on the next page presents an example of a nonaligned kiln with
associated forms and polar diagrams.
The alignment of the kiln is started at the inlet end. In case the eccentricity of
supporting section 2 is not held within the tolerance range, it is essential that
this problem be addressed on a priority basis.
If the supporting section is centralized, it must be ensured that any
subsequent alignment of the adjoining kiln sections do not have any adverse
impact on the centralization of the supporting section.
Rotary kiln
18091-10-2.0
10. Pointed bar iron

11. Bow
12. Wooden frame
13. Paper
14. Indicator tip
15. Counterweight
Figure 10
6.2 Kiln section 1

Kiln section 1, at the inlet, to be aligned as follows:
Turn kiln so that the generatrix (POS), where the smallest distance was
ascertained at measuring point involved (here POS 7), is placed in uppermost
position.
Slacken the assembly bolts in assembly 2-1 to such extent that the inlet end is
lowered by approx. 3 mm, i.e. half the eccentricity observed. In the table an
eccentricity of 6.5 mm is indicated. Execute a number of shim pads matching
the gap between kiln section 1 and 2 in the new position. Place the shim pads
in the gap, and re-tighten the assembly bolts.
Rotary kiln
18091-10-2.0
6.3 Assembly 2-1 and 3-2

According to the recorded measurements and the polar diagrams the kiln
section is centralized, but the kiln shell has incurred slight deformation. The
deformation may be due to a longitudinal weld, and it is so small as to have no
significance.
6.4 Assembly 4-3

At assembly 4-3 the offset centre for the dotted circle is offset in the direction
of POS 8, which is consequently turned in the uppermost position. On diagram
with dimensional stability the eccentricity can be measured to be 3 mm, i.e. for
proper alignment the assembly must be lowered by 3 mm. Alignment to be
made in the same manner as described above.
The deformation revealed by the polar diagram must be eliminated by means
of jacks inside the kiln shell. In shown example the jack is positioned so that it
extends the diameter 10-4. After the kiln shell has been straightened, it must
be maintained in the new position by means of extra adjusting irons ("dogs").
The outlined procedure should also be applied for alignment of all non-
centralized kiln sections, but always ensure that the alignment has no negative
impact on the alignment of the supporting sections.
6.5 Tolerances
At other points of the kiln shell, expect at the live rings, the tolerance for the
radial run-out depends on whether seals, UNAX cooler suspension, gear rim,
dust intake or other features are to be mounted at the welded joint.
In the affirmative, the run-out must be held within tolerance range of 2 mm
(kiln centre at the measured cross-section plus/minus 1 mm). At other joints
the tolerance is 3 mm (kiln centre at measured cross-section plus/minus 1.5
mm).
7 Control levelling prior to welding

Following the proper installation of kiln supports, i.e. foundations, bedplates,
bearings and supporting rollers, and when the centre distances, diameters on
supporting rollers and live rings and the height difference between bedplates are
correct, the kiln axis will also be correct, i.e. in compliance with the position drawing.
The degree of accuracy attained during mounting and alignment of the supports is
not attainable during control levelling, and, consequently, the control operation must
not, for example, involve any adjustment of the position of the supporting rollers.
However, control levelling is still recommended in order to identify possible errors in
measurement, the so-called 10-errors or decimal errors, which were not detected
during the alignment of the bedplates and mounting of bearings.
Consequently, control levelling should be undertaken, and the result should be sent
to FLS-H; however, adjustments of the supports based on control levelling must not
occur unless specific instructions to this effect are given by FLS-Head office.
Levelling operation should be undertaken by the erection supervisor in co-operation
with the welding instructor, and, where feasible, the operation should be repeated
with kiln turned through 180°.
Extreme care must be exercised during the operation, which must never take place
subject to strong solar radiation, which might cause cranking of kiln shell; instead the
operation should be conducted early in the morning.
Use form U-5431 for reporting to FLS-Head office. This form is shown in Appendix 9,
completed with a concrete example.
Rotary kiln
18091-10-2.0
Levelling to be done on top of kiln by means of a theodolite and a frame similar to

that shown in Appendix 8.
Place the theodolite on top of the kiln in the most appropriate manner so that the line
of sight is lying vertically above the kiln axis, and as parallel to the kiln slope as
possible. If a so called skewed sight line is applied during levelling, it will be
necessary to compensate for this phenomenon as indicated in given example. The
measurements can be taken either from the inlet or outlet end.
Where the range of vision is poor, or in case of inadequate magnification of the
instrument, it will be necessary to perform measurements in stages, which are
subsequently integrated graphically for verification of levelling.
The frame is equipped with a slide (19) which is moved up or down until the slit on
the slide is centralized in the telescope sight. Through the slit the position of the slide
can be marked on the wooden ruler (17) with a pencil.
Pencil stroke to be marked with the number of the support. Once levelling is finalized,
the height can be measured directly by means of a steel measuring tape or similar
object.
Appendix 9 gives an example of alignment of kiln with 4 supports. Compensation is
made for the skewed line of sight. The diameters of the live rings are indicated on the
position drawing, which also presents a view of the cold kiln axis for comparison with
that identified during levelling.
Heights h to be established on each live ring during levelling. Afterwards,
compensation is made for the skew sight line whereafter 50 per cent of the live ring
diameter is added to the found value. Hence the heights H emerge; these heights are
used for drawing of the kiln axis based on a straight line.
Form U-5431 to be sent to FLS-head office on finalization of control levelling.
8 Welding of circular seams

Once the control levelling has produced a satisfactory result, the circular seams on
kiln can be welded.
See separate instruction manual.
9 Welding of live ring guides

9.1 Checking the bay lengths of kiln
Check the bay lengths of the kiln, i.e. the exact distance from centre to centre
on the heavy-duty plate sections before the live rings are placed in final
positions.
This is necessary since the distances may deviate from the specified values,
partly because of minor inaccuracies during fabrication and partly due to
shrinkage of the welded seams. The shrinkage depends i.a. on the method
used for cleaning of the welded seams.
9.2 Correction of live ring positions

The erection supervisor must check that the sum of possible deviations is
roughly the same opposite and beneath the live ring at the thrust rollers. In
the affirmative, the live ring at the thrust rollers remains centrally placed on
the plate section. In case the dimensional deviations of the bay lengths occur
mainly on one half of the kiln, the live ring at the thrust rollers must be
displaced in order to distribute the deviations over both halves of kiln.
Rotary kiln
18091-10-2.0
Turn the kiln until the live ring at the thrust rollers nearest the gear rim is
placed centrally on the supporting rollers. If necessary, remove the provisional
live ring guides at one side of the live ring. If kiln is to be moved upwards
towards the smoke chamber, this must be done by means of the hydraulic
thrust device.
Displace the remaining live rings on the place sections so that the centrelines
of the rings are offset to extent corresponding to the calculated heat expansion
in relation to the centrelines of the supporting rollers; see position drawing.
9.3 Finish mounting of live rings

Once the live rings are placed in correct positions, secure them with guide
blocks which weld to the supporting blocks.
Mount wear rings between guide blocks and live ring for protection of the live
ring. The rings can be fitted together with the live ring as one unit or they can
be fitted as several parts and be welded together around the kiln.
9.3.1 Live rings with supporting blocks
Remove the temporary live ring guides on one side of the live ring, for one
live ring at a time.
9.3.2 Welding together of wear rings
If wear ring (22) is divided into two or four pieces when supplied, these
must be welded together during erection.
When supplied in four pieces, weld them together two and two before
mounting the two halves on the kiln.
Provide the individual wear ring pieces on the inside with 5 mm
intermediates (25) which tack-weld to the wear ring. See Fig. 11.
06. Live ring

09. Kiln shell
21. Intermediate, 4 mm
22. Wear ring
Figure 11
Then weld the two intermediates of the wear ring pieces to the supporting
blocks, placing the pieces diametrically opposite to each other at a distance
of 100-200 mm from the live ring, so that the two wear ring joints are
situated in the space between the supporting blocks. (See Fig. 12). It is
crucial that the distance between wear ring and live ring is identical on the
entire kiln circumference.
Rotary kiln
18091-10-2.0
04. Supporting block

06. Live ring
09. Kiln shell
22. Wear ring
26. Backing
27. Holding magnet
28. Flange
Figure 12
Provide a flange (28) made of a piece of flat iron. The flange must be tack-
welded to the wear ring before welding same together, so that the flange
forms a wall against which it is possible to weld.
NOTE!
When welding in the vicinity of the live ring it is important that the
shield illustrated in Fig. 4, sub-section 3.5, is intact, so that weld
splashes do not enter between supporting blocks and live ring.
Now weld the two wear rings pieces together around the kiln.
The weld joint must be as shown as Fig. 12. Use ceramic backings (26)
during welding. Ceramic backings are supplied in pieces of 120 mm and are
held in position with the supplied holding magnet (27).
The holding magnet may, e.g. be fastened with tape so as to ensure that
the backing is not displaced. To weld the wear ring use basic electrodes
FLS Mat. 721 or Mat. 722.
It is essential that weld stresses are as small as possible. Therefore
it is necessary to peen every single weld run to reduce weld
stresses as much as possible.
Having finish-welded the wear ring, chip off the tack welds for supporting
blocks and intermediates, remove the intermediates and grind of all
welding traces from the supporting blocks.
The two welds on the wear ring must likewise be ground plane on the side
facing the live ring. Flange (28) remains where it is.
9.3.3 Guide flaps (24)
Rotary kiln
18091-10-2.0
Now mount guide flaps (24) on the wear ring. Four guide flaps to be
mounted, 90° offset on the wear ring circumference. Fix them by welding
while the guide ring lies true against the live ring.
The guide flaps serve to ensure that during live ring migration, the wear
ring does not follows same, but is fixed relative to the kiln shell.
06. Live ring

22. Wear ring
24. Guide flap
Figure 13
9.3.4 Mounting of wear rings (22) and guide blocks (08)

Smear the contact face between live ring and wear ring with Never-Seez or
corresponding low-friction lubricant so as to ensure that sliding can take
place between the two components.
Then push up the wear ring so that it is in close contact with the live ring.
Weld guide blocks (08) to the supporting blocks so that they are in close
contact with the wear ring.
Prior to welding the guide blocks, make sure that the supporting block
(04), to which the guide block is to be welded, lies properly true against
the notch in stop blocks (23) on the side where the guide block is to be
fixed by welding.
Make sure again that no weld splashes enter between live ring and
supporting blocks.
9.3.5
When mounting wear ring and guide blocks on the other side of the live
ring, proceed in the same manner, however making sure that a total
backlash of 4 mm is established between live ring, wear rings and guide
blocks. See Fig. 14.
Rotary kiln
18091-10-2.0
04.Supporting block
08. Guide block for live ring
22. Wear ring
23. Stop block
24. Guide flap
Figure 14
9.3.6
Finally remove the hex. head bolts which retained the supporting blocks
during preliminary mounting. Plug the holes left by the hex. head bolts by
means of the supplied grooved cylindrical pins which must not be fixed by
welding.
04. Supporting block

05. Grooved cylindrical pin
09. Kiln shell
Figure 15
9.3.7
Check the fixture of stop blocks (23).
The torque must be 700 Nm.
Secure the nuts.
Rotary kiln
18091-10-2.0
10 Removal of shields
When start-up of kiln is imminent, the kiln shell between supporting blocks, opposite
the live ring, must be cleaned very carefully, and the shields must be removed.
All gaps to be cleaned by scavenging. Lubricate the accessible part of the live ring
underside as outlined in sub-section 3.2. Reference is also made to maintenance
manual for support 19031.
11 Appendices
See next pages.
Rotary kiln
18091-10-2.0
Appendix 1 Erection photos 18090-09-I
Figure 16 Erection photos 18090-09-I
Rotary kiln
18091-10-2.0
Appendix 2 Erection photos 18090-09-II
Figure 17 Erection photos 18090-09-II
Rotary kiln
18091-10-2.0
Appendix 3 Erection photos 18090-09-III
Figure 18 Erection photos 18090-09-III
Rotary kiln
18091-10-2.0
Appendix 4 Erection photos 18090-09-IV
Figure 19 Erection photos 18090-09-IV
Rotary kiln
18091-10-2.0
Appendix 5 Erection photos 18090-09-V
Figure 20 Erection photos 18090-09-IV
Rotary kiln
18091-10-2.0
Appendix 6 Completed copy of inspection form U 4791-04, page 1

Plant: Folax mill Kiln No.: U 4791-04
Page 01
Sent by : N.N With letter No.: Date: Number of pages 02
POLAR DIAGRAMS FOR SUPPORTING BLOCKS:
SUPPORT.: I
Diagrams Nos.: 3-0 + 3-I
Sets of retainer blocks: 28
Pos. No. 24 to be in line with main holes
Taken BEFORE/AFTER welding

POS READING "O" DIFFERENCE WHEN NUMBER IS BLOCKS EXCEEDS 24, TAKE POS READING "I" DIFFERENCE
MEASUREMENTS ON THE FOLLOWING BLOCKS
ONLY
24 119.3 0 24 24 24 24 24 24 96.1 0.4
1 119.4 0.1 1 1 1 1 2 1 96.1 0.4
2 119.4 0.1 2 2 3 3 4 2 96.0 0.3
3 119.4 0.1 3 4 4 5 5 3 95.9 0.2
4 119.4 0.1 4 5 6 7 7 4 95.9 0.2
5 119.5 0.2 5 6 7 8 9 5 95.9 0.2
6 119.5 0.2 7 8 9 10 11 6 95.8 0.1
7 119.5 0.2 8 9 10 11 13 7 95.8 0.1
8 119.5 0.2 9 10 12 13 15 8 95.8 0.1
9 119.6 0.3 10 12 13 15 16 9 95.7 0
10 119.6 0.3 11 13 15 17 18 10 95.7 0
11 119.6 0.3 12 14 16 18 20 11 95.7 0
12 119.6 0.3 14 15 18 20 22 12 95.8 0.1
13 119.5 0.2 15 17 19 21 24 13 95.8 0.1
14 119.5 0.2 16 18 21 23 26 14 95.9 0.2
15 119.5 0.2 17 20 22 25 27 15 95.9 0.2
16 119.5 0.2 18 21 24 27 29 16 96.0 0.3
17 119.4 0.1 19 22 25 28 31 17 96.0 0.3
18 119.4 0.1 21 24 27 30 33 18 96.1 0.4
19 119.4 0.1 22 25 28 31 35 19 96.1 0.4
20 119.4 0.1 23 28 30 33 37 20 96.2 0.5
21 119.3 0 24 28 31 35 38 21 96.2 0.5
22 119.3 0 25 29 33 37 40 22 96.1 0.4
23 119.3 0 28 30 34 38 42 23 96.1 0.4
24 119.3 0 24 24 24 24 24 24 96.1 0.4
NUMBER OF SUPPORTING 28 32 36 40 44 BETWEEN LIVE RING AND
BLOCKS KILN SHELL
Figure 21 Completed copy of inspection form U 4791-04, page 1
Rotary kiln
18091-10-2.0
Appendix 7 Completed form of inspection form U 4791-04, page 2

Plant: Folax mill Kiln No.: U - 4791-04
Page 02
SUPPORT No.: I
O
DIAGRAM No.: 3-0
Taken before/after welding
DIRECTION OF ROTATION SEEN FROM

OUTLET
TOTAL NUMBER OF
SUPPORTING BLOCKS: 28
SUPPORT No.: I I
DIAGRAM No.: 3-1
Taken before/after welding
DIRECTION OF ROTATION SEEN FROM

OUTLET
TOTAL NUMBER OF
SUPPORTING BLOCKS: 28
Figure 22 Completed form of inspection form U 4791-04, page 2
Rotary kiln
18091-10-2.0
Appendix 8 Kiln alignment, tools
16. Coach bolt

17. Fillet
18. Retaining iron
19. Slide
20. Spirit level
Figure 23 Kiln alignment, tools
Rotary kiln
18091-10-2.0
Appendix 9 Kiln alignment. Copy of inspection form U 5431-01

Plant: Folax mill Kiln No.: U 5431-01
Page 01
ROTARY KILN ERECTION CONTROL LEVELLING PRIOR TO WELDING
VERTICAL LEVELLING
Support No. I II III IV
Live ring radius R 3265 3390 3335 3290
Height measured from live H 408 268 300 317
ring to skew sight line
Distance from centre to A 3673 3658 3635 3607
skew sight line (r + h)
Correction for skew sight a 72 48 23 0
line
aI = AI - AIV
aII = aI(L2 + L3) L: L
aIII = aI x L3 : L
Distance from kiln centre H 3601 3610 3612 3607

to parallel sight line (A-a)
Kiln axis deviation from 0 -9 -11 -6
straight line (cold-state
kiln)
Remarks:
____________________________________________________________________
____________________________________________________________________
March 2, 1993 N.N.
Date Signature
Figure 24 Kiln alignment. Copy of inspection form U 5431-01

Rotary Kiln, Erection: Kiln Shell and Live Rings With Loose Supporting Blocks, On Supports Type R58

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Rotary Kiln, Erection: Kiln Shell and Live Rings With Loose Supporting Blocks, On Supports Type R58

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Rotary kiln, erection

Kiln shell and live rings with loose supporting

Installation, operation and maintenance

Doc. No.: 18091-10-2.0

1 General information ....................................................................................... 5

9.3.3 Guide flaps (24)................................................................................24

Appendix 1 Erection photos 18090-09-I ......................................................................... 28

Text reference is made to the following instruction manuals etc.:

Kiln arrangement drawing

2.2 Kiln turning during erection

2.3 Inspection of the kiln sections

for internal fittings to be placed correctly in relation to one another and

2.4 Assembly of kiln sections

01. Tension bolt

3 Mounting of live rings and supporting sections

3.3 Mounting of live rings on kiln sections without supporting blocks

during erection. Further, this is crucial in order to avoid tearing between

3.5 Seal between live rings and kiln shell

3.6 Provisional fastening of live rings

4 Erection of light-duty kiln sections

4.2 Kiln sections at Unax cooler

5 Checking the eccentricity of kiln section

Consequently, all journals of supporting rollers must be carefully lubricated

5.2 Supporting sections

For instance, the measurements can be taken in the following manner,

POS READING DIFFERENCE

Draw a new circle in the diagram with a pair of compasses.

profile curve are almost identical and, in pairs, placed diametrically

5.3 Welded joints

6 Centralization/alignment of kiln sections prior to welding

10. Pointed bar iron

6.2 Kiln section 1

6.3 Assembly 2-1 and 3-2

6.4 Assembly 4-3

7 Control levelling prior to welding

Levelling to be done on top of kiln by means of a theodolite and a frame similar to

8 Welding of circular seams

9 Welding of live ring guides

9.2 Correction of live ring positions

9.3 Finish mounting of live rings

06. Live ring

04. Supporting block

06. Live ring

9.3.4 Mounting of wear rings (22) and guide blocks (08)

04. Supporting block

Appendix 1 Erection photos 18090-09-I

Figure 16 Erection photos 18090-09-I

Appendix 2 Erection photos 18090-09-II

Figure 17 Erection photos 18090-09-II

Appendix 3 Erection photos 18090-09-III

Figure 18 Erection photos 18090-09-III

Appendix 4 Erection photos 18090-09-IV

Figure 19 Erection photos 18090-09-IV

Appendix 5 Erection photos 18090-09-V

Figure 20 Erection photos 18090-09-IV

Appendix 6 Completed copy of inspection form U 4791-04, page 1

Diagrams Nos.: 3-0 + 3-I

Sets of retainer blocks: 28

Pos. No. 24 to be in line with main holes

Taken BEFORE/AFTER welding

Figure 21 Completed copy of inspection form U 4791-04, page 1

Appendix 7 Completed form of inspection form U 4791-04, page 2

Taken before/after welding