Rotary kiln

Repairs
Replacement of kiln section

Approved date:

Created by:

Approved by:

Doc. No.: 19341-01-1.0

 Rotary kiln
19341-01-1.0

Table of contents
Page
1 General information ....................................................................................... 3
1.1 ................................................................................................................... 3
1.2 ................................................................................................................... 3
1.3 ................................................................................................................... 3
1.4 ................................................................................................................... 3
2 Working sequence ......................................................................................... 3
3 Measuring of defective kiln section ................................................................... 4
4 Marking ....................................................................................................... 4
5 Bracing ....................................................................................................... 5
6 Preparation of new kiln section ........................................................................ 5
7 Flame cutting ............................................................................................... 5
8 Positioning and checking of new kiln section ...................................................... 6
9 Welding ....................................................................................................... 6
9.1 Tack-welding................................................................................................. 6
9.2 Welding on the outside ................................................................................... 6
9.3 Welding on the inside ..................................................................................... 7
9.4 NDT inspection .............................................................................................. 7
10 Divided kiln sections ...................................................................................... 7
11 Supporting section with live ring ...................................................................... 7
12 Appendices .................................................................................................. 8

List of appendices:
Appendix 1 19340-01-I Marking ...................................................................................... 9
Appendix 2 19340-01-II Assembly..................................................................................10
Appendix 3 19340-01-III Supports .................................................................................11
Appendix 4 19340-01-IV Welding ...................................................................................12

List of figures:
Figure 1 Marking ........................................................................................................... 9
Figure 2 Assembly ........................................................................................................10
Figure 3 Supports .........................................................................................................11
Figure 4 Welding ..........................................................................................................12

Text reference is made to the following instruction manuals:

Rotary kiln erection

Kiln shell and live rings 18091
Arc welding automatic/manual 18101
Certification of welders 18291
Assembly of divided kiln sections 18301
Erection report 18341

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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 manufacture, installation, operation and
maintenance of the equipment, 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
1.1
This instruction manual is concerned with the replacement of kiln sections, i.e.
both light sections and heavy sections for live rings.

1.2
Replacement may be required because of bulges or cracks in the kiln shell or
other forms of deformation so severe that the brick lining tends to work loose.
Untrueness of the kiln shell, a condition referred to as a crank, causing
supporting rollers and live rings to be overloaded to such an extent that the
kiln section must be replaced, is also regarded as deformation.

1.3
Extensive repairs are needed in connection with the replacement of a kiln
section, and, therefore, the operation should not be started unless the kiln is
simultaneously subjected to a major overhaul, so that any other irregularities
can be put right during the repair work.
During the overhaul special attention must be given to all matters related to
the alignment of the kiln. It is advisable that exact measurements of the kiln
axis be taken so that all faults are recorded.
The main aim is to have the kiln emerge as a newly erected kiln after the
repairs have been made, with the kiln correctly placed on its support with the
right axis characteristics.

1.4
The crane capacity needed during repairs must be available as must lifting
gear, hydraulic jacks, timber and sleepers for support etc..
Flame cutting and welding operations must be handled by skilled workers. The
welding operators must be well-trained and they must hold valid certificates.
For welding of plates having a thickness in excess of 30 mm the welders will be
required to perform a test at site before they are assigned to kiln welding
operations. See instruction manual 18291.

2 Working sequence
A defective kiln section can be replaced in the sequence stated below:
A. Measuring for new kiln section.
B. Marking for cut-out of defective kiln section.
C. Bracing of kiln shell.
D. Flame cutting and removal of defective kiln section.

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 Rotary kiln
19341-01-1.0

E. Preparation of new kiln section.

F. Alignment check-up.
G. Bracing prior to welding.
H. Welding and inspection of welds.

3 Measuring of defective kiln section

See Appendix 1.
Measuring is needed so that a new kiln section can be ordered.
Before the kiln is shut down for repairs, the following points must be checked while
the kiln still maintains its operating temperature:
The position of the live rings on the supporting rollers.
The contact between live rings and supporting rollers. (Lead wire test).
The lead wire test indicates the level of contact between live ring and supporting
roller prior to cutting of kiln shell. Subsequent lead wire tests will show whether the
contact level has altered during alignment and weld-up in connection with the repairs.
Live ring migration.
Contact between live ring and the thrust device.
Next, after the kiln has been shut down, that part of the kiln where the damage is
ascertained must be inspected and measured. Determine the length of the kiln shell
section which needs replacing. For determination of the length it will be necessary to
take into account whether it was necessary to alter the position of the live rings on
the supporting rollers in connection with the measuring of kiln. Allowance for the pre-
calculated expansion of the kiln at the kiln seals must also be made.
After this has been done, the circumference of the kiln shell must be carefully
measured at point where the two sections are to be made.
The longitudinal and circumferential measurements and, on heavy kiln sections, the
live ring migration are needed for ordering of the new kiln section.

4 Marking
See Appendix 1.
First mark out the two intersection lines along which the kiln shell is to be cut.
The two intersection lines A and B must be marked out while the kiln is barred.
Therefore, the kiln must not be moving in the longitudinal direction. Check that the
kiln bears well against the thrust device during barring.
Where a hydraulic thrust device is fitted, check that it does not cause the kiln to
move.
The distance between the intersection lines A and B must be L + S mm, where L is
the length of the new kiln section and where S is the width of the cutting joint.
Also mark out two measuring lines C and D at a distance of 100 mm from the cutting
lines.
The lines can be marked off by means of a stationary, spring-loaded scriber as shown
in Fig. 2.
Fix the marked lines with centre marks.
Mark out a generatrix on the inside of the kiln shell, across the damaged area and the
two intersection lines, so that the two parts of the kiln, by means of the generatrix,

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Rotary kiln
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can be returned to the same position relative to one another as before the repair
work.

5 Bracing
See Appendices 2 and 3.
Remove the brick lining and kiln internals, if any, from the interior of the kiln shell.
Mount a stiffening brace (01) at the top and bottom, respectively, of the two
intersection lines, so that the cross section of the kiln shell is protected against
deformation.
On the inside of the kiln shell a wooden bulkhead should likewise be fitted above the
upper intersection line, so as to prevent dust and dirt from the remaining part of the
kiln lining and charge from reaching the repair area during barring of the kiln.
The kiln shell must be carefully supported on both sides of the repair zone and also
under the defective kiln section. The supports must be sturdy and stable, and, if
possible, arranged so that they can be lowered sufficiently to permit barring of the
kiln. See examples of supports given in Appendix 3. It may be necessary to fit an
internal stiffening brace so as to withstand the pressure from the hydraulic jacks
(06).

6 Preparation of new kiln section

Check measurements to be taken of the length and circumference of the new kiln
section. As indicated in Appendix 1, the two circumferential measurements on the
adjoining ends of the old and the new kiln section must never differ by more than 10
mm.
Check that the bevels of the new kiln section has been made in accordance with the
directions given on drawing. Bevels to be stripped of anti-corrosion agent or paint.
Bevels to be clean and bright.
Do not remove the stiffening braces of the kiln section.
Check that a generatrix, similar to those marked at the two ends of kiln, has been
marked on the inner kiln section so that the new kiln section can be placed correctly
in relation to the old kiln sections.
Check that the kiln section is equipped with the necessary erection angles.

7 Flame cutting
Check that it is impossible for the kiln to move in its longitudinal direction, both
during and after cutting operations.
Also ensure that the kiln is locked, so that it is impossible to start the kiln.
Flame cutting must be performed from the outer side of the kiln. This is best done by
means of a controlled cutting machine with automatic drive. If the cutting machine
proper is not equipped with guides, it can f. inst. be controlled by angles which are
welded to the kiln shell.
By using a cutting machine it is possible to apply chamfers during the cutting
operation, corresponding to the required weld bevel of the kiln end. As a main rule, a
chamfer of 30 degrees during cutting is recommended.
The cutting operation may f. inst. be handled so that the kiln is first cut at one
intersection line. Then the second intersection line is cut in such a manner that 4
sections are left over, two sections with length of 1 m at the top and bottom, and two
having a length of 200 mm offset through 90˚ relative to the first two. Then the two
sections with a length of 1 m are cut with the help of the cutting machine, and the

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 Rotary kiln
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defective kiln section is strapped in the erecting crane, whereafter the last two
sections are cut with the help of a manually-controlled blowpipe.
Afterwards the defective kiln section must be removed.
The bevel of the two kiln ends must now be completed so that the bevel corresponds
to that on the new section.
The bevel can be made with the cutting machine, but it must be machined through
grinding or milling so that it is clean and smooth, and free from oxide scales. See
Appendix 4.

8 Positioning and checking of new kiln section

See Appendices 2 and 4 and instruction manual 18091.
Use the crane to lift up the kiln section. Make sure that its inclination is roughly
identical to that of the kiln, and position it between the two kiln ends.
Fix the supplied erection angles (02) by welding on the inside of the existing kiln
sections, so that the angles are placed opposite the erection angles in the new kiln
section.
Place the stay bolts (03) in the erection angles and assemble the kiln sections.
Weld on the adjusting irons (04) on the outside or inside of the kiln shell, at points
where it will be necessary to inter-adjust the two kiln edges. Mount at least four
adjusting irons, so that it is possible to spread any diametrical differential evenly
across the entire circumference.
After the kiln sections have been interaligned and after the stay bolts have been
tightened, the supports under the sections must be lowered with caution so that only
the tension bolts hold the kiln shell together.
Now, the kiln can be barred and during kiln barring a check must be run to ensure
that the kiln section is centralised and that throw-outs, if any, are held within the
tolerance limits. See instruction manual 18091 for centralisation of kiln sections by
means of polar diagrams.
After centralisation of kiln sections, a number of flat irons (05) (see Appendix. 4)
must be welded to the inside of the kiln shell, across the welded joint so as to ensure
that the two shell ends remain in the same position when the kiln is barred during
tack welding operation. The flat irons must be welded on with a one-sided fillet weld,
which can be removed by grinding so that flame cutting, which may damage the kiln
shell, is avoided.

9 Welding
For general information as to welding of kiln shell, preheating, and handling of
electrodes etc. reference is made to instruction manual 18101.

9.1 Tack-welding
Tack welding to be performed from the outside. Length of tack welds to be 200
mm, with a spacing of 500 mm. Use a 4 mm electrode, Mat. 722.

9.2 Welding on the outside

The welds can be deposited either through manual or automatic welding.
Manual welding is performed with a step-by-step increase in the electrode
thickness, up to 8 mm. Use downhand welding, 1 metre per operation,
whereafter the welded seam must be cleaned and lightly peened in order to
reduce contraction strains. Afterwards the kiln must be barred, and another 1
m stretch is welded.

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Remove the external adjusting irons gradually as welding on the outside

proceeds.
The finished, external welds must be cleaned of weld spatter and ground
because of the subsequent NDT inspection.

9.3 Welding on the inside

Remove the stay bolts.
Chip the welded seam on the inside. Use a carbon arc cutter and 8 mm carbon
electrodes. Use a high-speed angular grinder to grind the joint so that it is
absolutely clean.
Next, weld the internal seams.
Remove erection angles and stiffening braces by means of a carbon arc cutter.
Scars caused by cutting to be repaired through welding and grinding.
Clean the welded seams and grind them so that they are flush with the inner
shell at points specified on drawing. On remaining seams the convexity must
never be larger than 3 mm.

9.4 NDT inspection

Welded seams to be subjected to an x-ray or ultrasonic inspection in
accordance with the requirements stated on drawing with respect to weld
quality. For rectification of faulty welds reference is made to instruction
manual 18101 for automatic welding.

10 Divided kiln sections

In certain cases, f. inst. where dictated by the space conditions at site or because of
the large kiln diameters involved, it may be advantageous to sub-divide the kiln
section into segments. The kiln section is divided into 2, 3 or 6 segments dependent
on the kiln diameter and the conditions of space. The kiln sections are divided along
generatrices with a distance of 180, 120 and 60 degrees, respectively.
The old kiln section can be sub-divided in the same manner during dismantling.
The supply includes miscellaneous items for the assembly of the kiln section. For
assembly and welding of a divided kiln section, see instruction manual 18301.
It is very important during assembly of the divided kiln sections that the circular
cross section of kiln is not altered by the longitudinal welds. Use a template to check
that circularity and convexity is held within the stated tolerance limits.
The template must cover at least 45˚ of the circumference of kiln section.
If welding has caused deformation of the circular cross section of the kiln shell it will
be necessary to straighten the shell. Otherwise, it would be impossible to install the
brick lining properly.

11 Supporting section with live ring

The supporting section is a heavy-duty kiln section, and, with the live ring, the kiln
section weight is substantial. Therefore, strong lifting gear is needed.
It is advisable to measure the throw-out of the live ring prior to dismantling,
whereafter the measurements are recorded on a form. The same measuring is also
required prior to the weld-up of the new and old kiln sections in order to check the
alignment of the new kiln section.
Marking, support arrangement and flame cutting to be made in the same manner as
for the light kiln sections.

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After the old kiln section with live ring has been dismantled, one set of live ring
guides is removed with a carbon arc cutter or a chipping hammer, and the section is
withdrawn from the live ring.
The new belt is mounted in the live ring and provisionally aligned and fixed as
described in instruction manual 18091. The stiffening brace must remain placed in
the heavy-duty kiln section until alignment and welding operations have been
completed.
When the live ring with kiln section is to be placed on the supporting rollers, it is very
important that the kiln section, when suspended from the crane, has the same rate of
inclination as the kiln.
To mount the kiln section and live ring, it is essential to know the location of the kiln
centre at the support involved, so that the kiln section can be mounted without
affecting the characteristics of the kiln axis. If the diameter of the new section is
larger than the old one, the kiln centre will be placed at a level slightly above the
previous one. Corrective action is taken by pulling the supporting rollers outwards a
little so that the kiln centre is lowered.
The assembly and welding procedures are similar to those for light kiln sections.
However, the tolerance for throw-out of live ring section is much smaller than for the
other kiln sections. See instruction manual 18091 and 18341 for alignment by means
of polar diagram.

12 Appendices
See next pages.

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Appendix 1 19340-01-I Marking

L+S

D1 D2 D3 D4

Figure 1 Marking

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Appendix 2 19340-01-II Assembly

01. Stiffening brace

02. Erection angle
03. Stay bolt
04. Adjusting iron
Figure 2 Assembly

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Appendix 3 19340-01-III Supports

06. Hydraulic jack

Figure 3 Supports

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Appendix 4 19340-01-IV Welding

Indvendig, inside,
intérieur, inner,
interior

a b c d˚ f˚
14 - 28 4 4 60˚ 60˚
30 - 40 6 10 60˚ 60˚
45 - 50 6 14 60˚ 60˚
55 - 57 6 20 60˚ 60˚
60 - 65 6 22 60˚ 60˚
70 - 75 6 25 60˚ 60˚
80 - 90 6 30

Figure 4 Welding

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.