Appendix-4

APPENDIX-4
ERECTION MANUAL OF
ROTARY KILN
CONSULTATION
FOR REFERENCE
DRAWN CHECKED REVIEWED APPROVED

SNNC
SIGNA
TURE
DATE
JOB No
Delivery
Note
PROJECT ENGINEERING CENTER
CONSTRUCTION DEPT.
Rev. No. R0 APPROVED
REVIEWED
CHECKED
PREPARED
DATE DRAWING No.

Total
( 19 SHEETS COVER INC.)
Installation Manual for Kiln
CONTENTS
No Item Page
Ⅰ. INSTALLATION PROCEDURE 1
1. Kiln foundation 1
2. Preparation for installing Base frame 2
3. Mounting Base frame 3
4. Pre-centering of Base frame 3
5. Final centering of Base frame 4
6. Setting Roller bearings and installing Rollers 5
7. Confirmation of Rollers 6
8. Other works for Roller support 8
9. Installation of Kiln shell 8
10. Centering of Kiln shell 9
11. Welding of Shell 11
12. Installation of Girth gear and Pinion 12
13. Installation of Drive unit 14
14. Installation of Kiln hood 16
15. Installation of Feed side air seal 16
16. Installation of Lubrication unit, Oil unit 16

Installation Manual for Rotary Kiln
I. INSTALLATION PROCEDURE
No. Description(English) Remarks
1. Kiln foundation
1) Confirmation of Kiln foundation
The foundation supplied by the Customer shall be
checked and if the dimensions are not conformed to
the drawing, inform to the customer to be rectified.
(1) Mark the center line of the Kiln on the foundation.

(2) Mark the center lines of the roller bearings at the right
angle to the Kiln center line, by using a compass or a
theodolite.
(3) Mark the center lines of the pinion, gear reducer, motor
and inching device.
(4) Check the positions of foundation bolt holes.
(5) Mark the positions of liners based on the drawing.
Charging Food Girth gear

Kiln center Gear reducer
Pinion Combustion hood
No.3 Roller bed center
Motor
Pinion Motor
No.5 Roller bed center
Gear reducer
No.1Roller bed center
No.4 Roller bed center No.2 Roller bed center
1

(7) Check the height of the foundations.
No.5 Roller bed No.3 Roller bed No.1 Roller bed
Charging Food No.4 Roller bed No.2 Roller bed Combustion hood
h4 h3 h2 h1
2. Preparation for installing Roller bed

(1) The layer of floating cement on the foundation shall
be removed by chipping and a rough surface shall
be bared.
(2) Install the basic pads(8sets for roller bed) Setting base
plate from work, grouting
(3) Other base plates with erection liners shall be M16 Bolts, nuts,
attached to the roller bed with flat bars、bolts and Flat bars shall
and nuts at each position be arranged
B－B by Constructor
A
Base frame
Base plate
Erection liner Base

Layer
50
B
A－A A
Position of
Basic pad
M16 Bolt
FB32～38 M16 Nut
B B
2

3. Mounting Roller bed
(1) Before mounting the Roller bed, insert anchor bolts
into the anchor holes of the foundation. Alternatively,
put the bolts into each hole of the Roller bed before
lifting it.
(2) Mount the Roller bed on the foundation, adjusting the
center marks.
4. Pre-centering of Roller bed

(1) Check the displacement between the center marks
of the foundation and the Rolller bed. Span: L=±2mm
(2) Measure the dimensions of span and diagonal line Diagonal:
of the Roller bed. |L1－L2|, |L3－L4|, |L5－L6|, |L7－L8|≦2mm
|S1－S2|, |S3－S4|, |S5－S6|, |S7－S8|≦2mm
(3) Measure the height of the Roller bed using a Y-level, H = (Planned) ± 3mm
taper gauge(s) and a scale. h = (Planned) ± 1mm
L7 L5 L3 L1
S7 S8 S5 S6 S3 S4 S1 S2
L8 L6 L4 L2
h4
h3 h2
h1
H4 H3 H2 H1
No.5 No.4 No.3 No.2 No.1
3
No.5 No.4 No.3 No.2 No.1 Installation Manual for Rotary Kiln

(4) After measuring and adjusting, pour mortar into the
anchor holes.
(5) After grouting the anchor bolts, pour non-shrink
mortar up to the level of baseplates of erection
liners.
Erection liners Temporary stoppers

should be arranged
by Constructor
Chipping area
form
50
straight edge
5. Final centering of Base frame
After tightened the anchor bolts, the same positions
with pre-centering shall be measured.
(1) Check the displacement between the center marks Span: L=±2mm
of the foundation and the Roller bed. Diagonal:
(2) Measure the dimensions of span and diagonal line |L1－L2|, |L3－L4|,
of the Roller bed. |L5－L6|, |L7－L8|≦2mm
|S1－S2|, |S3－S4|,
|S5－S6|, |S7－S8|≦2mm
(3) Measure the height of the Roller bed using a Y-level, H = (Planned) ± 3mm
taper gauge(s) and a scale. h = (Planned) ± 1mm
4

(4) Check the inclination of Base frames using taper Inclination:
gauges. ≦0.1mm／M
Constructor shall arrange "straigth edge" and
"precision level (0.02mm/M)" A－A B－B
B
Precision level
Straight edge Straight edge
Taper gauge
A A
Roller bed
6. Setting Roller bearings and installing Rollers

1) Assemble the lower housings on the base frame
according to the coincident marks.
In this case, the key of the base frame and key way of
the housing shall be contacted at the feed side.
Feed side Discharge side

Housing
Base frame
Gap
2) Assemble back metal and bearing metal on the

housing after removing anti-corrosive paint from
them and applying "Molykote" lubricant or grease.
3) Assemble roller and roller shaft on the bearing
metals after applying oil.
5

4) Position the roller toward the discharge side as
shown in the sketch.

Roller
0 3mm
7. Confirmation of Rollers (expected)

1) Place a theodolite at the center of base frame, and
check the positions of the rollers as shown in the b1～b20 : ±1mm
sketch. |b1－b2|, |b3－b4|, |b5－b6|, |b7－b8|, |b9－b10|≦0.5mm
2) Check the positions of roller bearings by their |b11－b12|, |b13－b14|, |b15－b16|, |b17－b18|, |b19－b20|≦0.5mm
coincidence marks against the base frame.
C－C
C
Theodolite
b19 b17 b15 b13 b11 b9 b7 b5 b3 b1
b20 b18 b16 b14 b12 b10 b8 b6 b4 b2
B
C
b1 b2
B
No.5 No.4 No.3 No.2 No.1
6
View B－B
Roller bed
Coincidence mark
3) Check the inclination Inclination(expected):

≦0.1mm/M
Precision level
Taper gauge
4) Check gaps between the shaft and metal (For reference)

As the data at shop
Thickness gauge Thrust clearance

0
(Radial clearance) Radial clearance
7

8. Other works for Roller support
1) Connect cooling water pipes to bearing seating. No leakage at
After completed piping, carry out air tightness test Test press. = 5kgf/cm2
on each connecting point.
2) Check the tightening condition of anchor bolts.
3) Tack-weld the taper liners not to loosen.
Roller bed
Taper liner
Tack welding
4) Grout around the Roller bed on the foundation.
9. Installation of Kiln shell

1) Prior to installing the kiln shell, install the lower
parts of the Combustion hood　and Chargning hood.
2) The sequence of installation of Kiln shell blocks is

as follows.

Girth gear No.3 Tyre No.2 Tyre No.1 Tyre
No.5 Tyre No.4 Tyre
⑦ ⑧ ⑫ ⑬ ⑮ Lower part of
⑤ ④ ③ ② ① ⑥ ⑨ ⑩ ⑪ ⑭ outlet hood
8

3) When installing the shell and tyre, support the shell
temporarily as shown in the sketch.
Reinforcing plate
Temporary support
4) Connect shells with connecting pieces and pulling Clearance:

bolts adjusting the clearance between shells, and t≦2mm
using aligning pieces and push bolts difference of Difference of surface
inside surfaces of shells. x≦2mm
Push bolt
Aligning piece
Connecting piece Pulling bolt
Inside
Inside x≦2mm
Outside
Outside
t≦2mm
10. Centering of Kiln shell

1) The centering of the shell shall be carried out at the
following stages.
9

(1) After completed connection and adjustment of
each shell blocks (without rotating the shell)
(2) After welding one seam of inside the shell
(3) After completed inside welding and outside
gouging.
(4) After completed outside welding (Final)
2) The method of centering is "Internal centering" : φ3mm

using a light and sight-through-fixtures on the : φ6mm
following positions.
Observation
No.5 Tyre No.3 Tyre No.2 Tyre No.1 Tyre
Feed side No.4 Tyre Girth gear
Light
3) Prepare "Sight-through-fixtures" as shown in the

following sketch.
φ3mm (φ6mm) Hole
Tin plate
□100
4) Details of the procedure for internal centering

will be instructed by the supervisor at site.
10

11. Welding of Shell
1) Welding rod
Girth gear
(1) Use low-hydrogen type, 490N/mm2 class welding No.5 Tyre No.4 Tyre No.3 Tyre No.2 Tyre No.1 Tyre
rod such as LB-52 (Kobe Steel) shall be used.

(2) Dry up welding rods thoroughly just before using,
at the temperature of 300～350℃ for 0.5～1 hour.
CWL-2 CWL-1 CWL-2 CWL-1 CWL-4 CWL-3 CWL-4 CWL-3 CWL-4
2) Welding sequence CWL-2 CWL-5
CWL-2 CWL-2 CWL-4
(1) Welding of the shell can be started after each shell
is fixed by reinforcing plates (RK7806-④).
(2) The first seam of inside welding shall be done with- Detail of weld bevel(Field bevel)
out rotating the shell (to be welded by all positions). ＣＷＬ－１ (t30－t30) ＣＷＬ－２ (t30－t50) ＣＷＬ－３ (t35－t35)
It shall be conducted by "Symmetrical welding 60゜±5゜ 60゜±5゜ 60゜±5゜
method", which the shell circumference is divided （Outside） 1
4 （Outside）（Outside）
11
into 8 sections and welded from one position to the
11
13
±1
2±1
50
2±1
30
30
35
2
opposite position in turn.
17
20
17
6R （Inside） 6R （Inside） 6R （Inside）
(3) The second and later seams shall be welded by flat Gousing
0+2
60゜±5゜ Gousing
0+2
60゜±5゜ Gousing
0+2
60゜±5゜
0 0 0
position (F) with rotating the shell.
(4) After completed inside welding, remove off harmfull ＣＷＬ－４ (t35－t50) ＣＷＬ－５ (t50－t50)
60゜±5゜
matters on the inside welding seams by arc-air 60゜±5゜
（Outside）
gouging. Start outside welding after inspecting and 1
4 （Outside）
13
19
grinding the gouged surface.
±1
±1
35
50
2
50
2
20
3) Inspection of welded seams
29
6R 0+2 （Inside）
60゜±5゜ 0+2 （Inside）
(1) Allowable height of beads are as follows. Gousing 0 6R
Gousing 0
60゜±5゜
Inside e 8 4
Inside : e≦0.5mm Symmetrical welding 2 6
method
Outside : e≦3mm 5 1
3 7
Outside e
11

(2) Harmful welding defects such as under-cuts, blow- (2)
holes, etc. are not allowed.
(3) After completed welding, UT(Ultra-sonic inspection) JIS Z 3060-1994 (3)
or RT(Radio-graphic inspection) on T-cross joints JIS Z 3104-1968
shall be executed.
The seam of field welding shall be tested by
Magnetic Particle Examination.
12. Installation of Girth gear and Pinion
1) Installing Girth gear
(1) Before installing the girth gear, all the spring plates
shall be fixed to the girth gear with pins and tempo-
rary binding wires.
(2) Fix each spring plate on the shell tightening only
idle bolt , as shown in the following sketch.
Spring plate
This bolt shall be tightened

(3) For adjusting spring plates, the base of push bolt shall be welded.
(4) Other bolts shall be tightened after completed the centering of Girth gear.
2) Centering of Girth gear.
(1) Mark numbers 1～10 on the girth gear dividing Side face deflection:
equally the circumference of the gear with paint. |A－B|／2≦1mm
(2) Set dial gauges at the side face and at the outer Outer circumference:
circumference of the gear as shown in the following C≦1.5mm
sketch, and check the deflections.
(3) After completed centering of girth gear,
drill the reamer holes from inside of shell.
12

1
10 2
9
3 A(B)
B A
8 4
7 C5 C
6
3) Installing Pinion
(1) Adjust the pinion confirming the pitch circle, back- Backlash (t1+t2):
lash, top clearance and the diference of center planned －0～+2mm
positions. Top clearance: h
to be measured for reference
Girth gear
Gap of both sides shall be measured
t1 t2
Pinion
h
Heat expansion
(2) Check the tooth contact applying red-lead on the L≧50%

teeth of pinion and rotating the shell. H≧25%
Record the contact condition at 10 positions.
13

(3) Check the clearances between the shaft and metals. Clearance in each
position to be uniform
Thrust clearance Radial clearance

Thickness gauge
(Radial clearance)
13. Installation of Drive unit

1) Installation of Gear reducer
Install the gear reducer based on the instruction
manual by the manufacturer.
Adjust the centering of the coupling to keep the A (Max.－min.)≦0.1mm
following standard. B (Max.－min.)≦0.1mm
Distance C:
Planned ±0.5mm
Gear Reducer
Gear Coupling
Pinion Gear Deflection of outer circumference A Deflection of side face B
1 1
4 2 2
4
3 3
C
14

2) Installation of Main motor
Install the motor keeping the centering of the D (Max.－min.)≦0.4mm
coupling as follows. E (Max.－min.)≦0.25mm
Elastic Pin Clearance F:

Coupling Planned ±0.25mm
Inching Device
Gear Reducer
Main Motor
F Deflection of outer circumference D Deflection of side face E
1 1
Torsion Shaft 2 4 2
4
3 3
3) Installation of Inching device

Install the inching device keeping the centering of G (Max.－min.)≦0.05mm
the coupling as follows. H (Max.－min.)≦0.05mm
Distance I:
Planned ±0.5mm
Deflection of outer circumference G Deflection of side face H

Inching device I
1 1
H
G 4 2 4 2
Gear
3
3
15

14. Installation of Kiln hood
(1) Before installing the discharge part of the shell,
the lower part of combustion hood shall be put on the foundation.
(2) After completed installation and centering of the
kiln shell, the lower part of the hood shall be fixed
to the foundation.
(3) Assemble the upper part hood, discharge side air
seal and burning equipment in order.
15. Installation of Feed side air seal

(1) After comleted installation and centering of the
kiln shell, the charging hood shall be fixed to the
foundation.
(2) Assemble the seal frame, seal plate and other parts.
16. Installation of Lubrication unit, Oil unit

1) The following units shall be installed in place.
The level shall be adjusted by combination liners.
(1) Lubrication unit for pinion bearing
(2) Lubrication unit for Gear reducer
(3) Oil pressure unit for Moving thruster
2) Piping
(1) The lubrication piping shall be fabricated at shop and
assembled at the site.
(2) All the lubrication and oil pipings shall be pickled
at the site.
(3) After completed the piping work, perform flushing
using flushing oil until all the foreign matters are
removed.
16
17. Scoop feeder and Fan

(1) Install bucket, gate, lever, etc.
(2) Install Dust cover. Dust cover
(3) Install Fans.
(4) Install ducts.
For installing Fans, ducts, Kiln shell should be turned to

top position.
Fan Secondary air duct

Rail for burner hanger.
primary air duct
18. Burning equipment
(1) Pre-assemble and install rail for burner hanger.

(2) Install burner hanger.
(3) Castable work for Burner.
(4) Install burner.
Install primary and secondary duct.
Install maintenance deck.
Install accessories.
Burner
Rail for burner hanger and Burner, etc. should bring into
burner floor before upper roof is closed.
17
19. Caster Anchor
(1) Mark position of caster anchor on the inside of Kiln.

(2) Weld caster anchoｒs according to the drawing.
(3) Welding rod should be supplied by Constructor.
For welding anchors, Kiln shell should be turned accordingly.
20. Clinker Crusher
(1) Install clinker crusher.

(2) Install hydrauric motor
(3) Install hydrauric piping.
Direction of
insirt
18

21. Rotation method of Kiln shell temporally
(1) Kiln Shell should be rotated by inching motor during

--Welding of Shell
-- Tooth contact of Girth gear and Pinion
--Installation of Sccop feeder equipment
--Refractory work of Kiln Shell
(2) Temporary electric souce, panel, cable should be
arranged by Constructor.
19
20

Appendix-4 - Erection Manual KILN

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DRAWN CHECKED REVIEWED APPROVED

DATE DRAWING No.

2. Preparation for installing Base frame 2

3. Mounting Base frame 3

4. Pre-centering of Base frame 3

5. Final centering of Base frame 4

6. Setting Roller bearings and installing Rollers 5

8. Other works for Roller support 8

9. Installation of Kiln shell 8

10. Centering of Kiln shell 9

11. Welding of Shell 11

12. Installation of Girth gear and Pinion 12

13. Installation of Drive unit 14

14. Installation of Kiln hood 16

15. Installation of Feed side air seal 16

16. Installation of Lubrication unit, Oil unit 16

No. Description(English) Remarks

(1) Mark the center line of the Kiln on the foundation.

Charging Food Girth gear

No. Description(English) Remarks

2. Preparation for installing Roller bed

Erection liner Base

No. Description(English) Remarks

4. Pre-centering of Roller bed

No.5 No.4 No.3 No.2 No.1

No. Description(English) Remarks

Erection liners Temporary stoppers

No. Description(English) Remarks

6. Setting Roller bearings and installing Rollers

Feed side Discharge side

2) Assemble back metal and bearing metal on the

No. Description(English) Remarks

Feed side Discharge side

7. Confirmation of Rollers (expected)

No. Description(English) Remarks

3) Check the inclination Inclination(expected):

4) Check gaps between the shaft and metal (For reference)

Thickness gauge Thrust clearance

No. Description(English) Remarks

2) Check the tightening condition of anchor bolts.

3) Tack-weld the taper liners not to loosen.

4) Grout around the Roller bed on the foundation.

9. Installation of Kiln shell

2) The sequence of installation of Kiln shell blocks is

Feed side Discharge side

No. Description(English) Remarks

4) Connect shells with connecting pieces and pulling Clearance:

10. Centering of Kiln shell

No. Description(English) Remarks

2) The method of centering is "Internal centering" : φ3mm

3) Prepare "Sight-through-fixtures" as shown in the

φ3mm (φ6mm) Hole

4) Details of the procedure for internal centering

No. Description(English) Remarks

rod such as LB-52 (Kobe Steel) shall be used.

No. Description(English) Remarks

This bolt shall be tightened

No. Description(English) Remarks

Gap of both sides shall be measured

(2) Check the tooth contact applying red-lead on the L≧50%

No. Description(English) Remarks

Thrust clearance Radial clearance