ROTARY KILN

Erection

Approved date:

Created by:

Approved by:

Doc. No.: 18051-041.1

 ROTARY KILN
18051-04-1.1

Table of contents:
Page
1 Blocking-up with concrete ............................................................................... 3
2 Placing of bedplates....................................................................................... 3
2.1 Coarse alignment........................................................................................... 3
2.2 Final alignment.............................................................................................. 4
3 Mounting of bearing beams and self-adjusting support beams ............................... 5
3.1 Preparatory work ........................................................................................... 5
3.2 Mounting of bearings beams ........................................................................... 5
3.3 Mounting of self-adjusting suppport beams etc.. ................................................ 6
3.4 Fine adjustment of bearing beams ................................................................... 6
4 Mounting of bearing block for thrust device ....................................................... 7
5 Appendices .................................................................................................. 7

List of appendices:
Appendix 1 18051-04-I .................................................................................................. 8
Appendix 2 18051-04-II ................................................................................................. 9
Appendix 3 18051-04-III ...............................................................................................10
Appendix 4 18051-04-IV ...............................................................................................11
Appendix 5 18051-04-V ................................................................................................12
Appendix 6 18051-04-VI ...............................................................................................13
Appendix 7 18051-04-VII ..............................................................................................14

List of figures:
Figure 1 ....................................................................................................................... 5
Figure 2 18051-04-I ...................................................................................................... 8
Figure 3 18051-04-II ..................................................................................................... 9
Figure 4 18051-04-III ...................................................................................................10
Figure 5 18051-04-IV ...................................................................................................11
Figure 6 18051-04-V ....................................................................................................12
Figure 7 18051-04-VI ...................................................................................................13
Figure 8 18051-04-VII ..................................................................................................14

In this manual, reference is made to the following instruction manuals:

Inclinometer 19921
Kiln arrangement drawing
Assembly drawing of bedplate & bearing block

Measuring tools required:

Telescope instrument
Precision straightedge
Spirit level
Inclinometer (supplied by FLS)
Precision angle
Plumb and cord

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ROTARY KILN
18051-04-1.1

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 Blocking-up with concrete

See Appendix 1.
After the check measurements of the kiln foundations have been made, deviations
will quite often be ascertained between the actual heights of the foundations and the
theoretical heights stated on drawings, causing variations in the 100 mm clearance
(h) between the foundation and the lower edge of the bedplate.
To avoid excessive usage of block-up material, it is advisable that the main part of
the block-up is executed in concrete, poured in situ in wooden frames, the height of
which must be adapted to suit the levelling of the foundations.
The frames are made with a cut-out in order to accommodate a supporting iron (see
figure), which is to be embedded in the block-up. The wooden frames can be adjusted
by performing a measurement from the upper edge of this iron - prior to pouring so
that the final precision alignment of the bedplate can be maintained within a limit
range of 10 mm.

2 Placing of bedplates
2.1 Coarse alignment
See Appendices 2 and 3.
Note!
Be aware that the anticipated inclination deviations may occur. See
arrangement drawing.
Check that the bedplates (02) (the frame structures) are placed on the proper
foundations. The distance 2 x Z (refer Fig. 6) on the frame structure must be
equal to the value stated on the arrangement drawing for the foundation
concerned.
Prior to the mounting of the bearing beams and the self-adjusting support
beams, the frame structure (02), support beams (01) and supports (06) and
(07) for self-adjusting support beams and jacks must be embedded, and the
concrete must have hardened so that the required load-carrying capacity for
the ensuing erection operations is achieved.
The frame structure (subsequently referred to as the frame) is shop-fitted with
welded-on pads (05) positioned so in relation to the hinged bearings (03) that
one side of the pads provides accurate indication of the centreline of the
support (the kiln). All pads should be placed on the same side when mounting
the frames. It is unimportant which side is chosen since the frames are
symmetrical.
Place the foundation bolts in the respective holes. If the holes are too deep,
the bolts can be placed in cut-out cover plates as shown in Fig. 5 on Appendix
2.

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 ROTARY KILN
18051-04-1.1

Place support beams (01) and frames (02) on the foundation.

Centrelines and cross lines are plotted on the foundation as benchmarks in
order to ensure that the frames are placed horizontally.
The horizontal line of sight which is plotted on the foundation constitutes the
reference line for subsequent measuring of the height "H" of the individual
frames. Dimension "H" is indicated on the arrangement drawing.
Initially, place the frames in the correct positions in relation to the other
frames in the longitudinal direction of kiln (see arrangement drawing).
Subsequently, the frames must be adjusted laterally as well as vertically.
Use the telescope instrument and the precision angle mentioned in the
instruction manual concerned with the alignment of supporting roller bearings
and supporting rollers.
On a provisional basis, suspend the 4 hinged pivots (04) from their bearings,
and set the direction of inclination by means of the inclinometer which is
placed both on the upper and lower hinged pivot (refer Fig. 4), whereafter the
inclination is calculated as described in the instruction manual for the
inclinometer.
Then align the two support beams (01) so that they are positioned at the
correct distance from the frame and placed at the same height and so that
their inclination corresponds to that of the lowermost girder in the frame.

2.2 Final alignment

See Appendices 2, 3 and 4.
After the coarse alignment has been completed successfully, the foundation
bolts can be grouted in their holes, up to approx. 200 mm from the surface of
the foundation.
After the concrete has hardened sufficiently to permit tightening of the bolts,
the precision alignment of frame and support beams can be made.
In addition to the inclinometer, a telescope instrument is also used for the fine
alignment. (See Appendix 4). The burners platform is used as bench- mark,
or, if the platform has not yet been executed, the elevation level indicated on
the foundation drawing for the burners platform is used as benchmark. The
rule must be placed vertically in the centreline of the kiln.
When measurements are taken it is necessary to ensure that all welded-on
pads (05) lie exactly in the centreline of kiln, since the pads are subsequently
used as reference points in connection with the final mounting of the
supporting rollers on the frames.
After the fine alignment of frame and support beams has been completed,
mount the baseplates (06) and (07) for the supports of the self-adjusting
support beams and jacks. (See below Fig. 1).

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ROTARY KILN
18051-04-1.1

F = h x inclination in %

For b and h, see assembly drawing.

Figure 1

It is of crucial importance that the baseplates are mounted in strict accordance

with the indicated measurements, and that they are absolutely horizontal in
the transverse direction and that their inclination is correct. The supports must
be blocked up in such manner that they cannot be displaced during grouting
operation.
For measurements b and h, see assembly drawing.
For grouting procedure, see relevant instruction manual.
During grouting and setting phase, the supporting roller bearings and thrust
devices can be made ready for erection and the preparatory work described in
sub-section 3.1 can also be executed.

3 Mounting of bearing beams and self-adjusting support beams

3.1 Preparatory work
See Appendices 3 and 5.
Weld the supplied frames (08) for fixed stops onto the support beams through
light tack-welding. Make sure that the frames are orientated as indicated on
the figure and that they are placed at the stipulated distance from the
centreline of the support (kiln). See assembly drawing and Fig. 7 on Appendix
3.
Weld in the same manner the rectangular frames (11) for the elastomer
bearings (12) onto the self-adjusting support beams so as to ensure that the
distance "A" (refer Fig. 9) indicated on the assembly drawing is observed and
so that the frames are placed with the largest length transverse to the self-
adjusting support beams.
The supports (14) for positioning of two light-duty 5-ton jacks (13) must also
be executed on the self-adjusting support beams. See Fig. 10. The support can
for example be made from DIP 16.

3.2 Mounting of bearings beams

See Appendices 5 and 6.
The remaining parts of the bedplate cannot be mounted until the concrete used
for grouting has hardened and achieved the required load-carrying capacity.
Place the fixed stops (15), including all discs (16) and guide plate (22) (see
Fig. 13) in the respective frames on the support beams so that they can
provide the necessary support for the bearing beams during the subsequent
erection work.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
18051-04-1.1

Clean the bores of the bearing beams and the hinged bearings of the frame
very carefully. The hinged pivots (04) must also be cleaned, and all parts must
be smeared with a layer of NEVER-SEEZ.
Mount the bearing beams.
Place the side guides (23) and fix them to the support beams by welding. It is
very important that the clearance "s" (refer Figs. 14 and 16) between guide
and bearing beam corresponds to that to that between the hinged bearing and
bearing beam. Use a feeler gauge for checking.
For welding instructions see assembly drawing.
Side guides to be mounted prior to the mounting of the self-adjusting support
beams.

3.3 Mounting of self-adjusting suppport beams etc..

See Appendix 5.
Mount the rear seal-off sector (20) on the rocker bearing (17) and fix the
bearing on the self-adjusting support beam.
Clean the pressure surface very carefully, with subsequent application of a thin
layer of NEVER-SEEZ.
Screw an eyebolt into the designated hole on the self-adjusting support beam
so that it can be lifted up and hang freely.
Place the elastomer bearings (12) in their frames on the self-adjusting support
beam.
Then lead the self-adjusting support beam under the bearing beams, until the
seal-off sector (20) is flush with the rear edge of the frame for thrust pad (18).
Place the thrust pad (18) plus a 5 mm shim pad (19) in the frame. Make sure
that the pad makes full contact with the rear edge of the frame, exerting,
simultaneously, a light pressure against the seal-off sector. (Refer Fig. 11).
Since the self-adjusting support beam remains suspended from the eyebolt, its
position can be adjusted quite easily. Check that the centre markings "M" in
Fig. 11 are on line and that the ends of the self-adjusting support beam is
placed at the same distance "f" (Fig. 12) from the end of the two bearing
beams.
Then lift the self-adjusting support beam up against the bearing beams until
the elastomer bearings bear lightly against the beams. The bearing beams
must not be lifted clear of their fixed stops.
Place the supports (14) and the jacks (13) on the embedded baseplates, and
activate the jacks so that lifting gear and eyebolt can be removed.
Remove also the thrust pad (18) and the 5 mm shim pad.

3.4 Fine adjustment of bearing beams

See Appendix 5.
Use the jacks to lift the self-adjusting support beam so much that the discs
(16) can be removed.
Then lower the self-adjusting support beam until the two bearing beams are
placed horizontally. Use a spirit level for checking.
Measure the distance "Y" (Fig. 11) between the rocker bearing and the
embedded support.

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ROTARY KILN
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Adapt the height of thrust pad (18) plus intermediate plates (19) so that the
final height becomes Y + (1.5 2) mm.
Clean the pressure surface on the thrust pad very carefully and apply a thin
layer of NEVER-SEEZ to the surface.
Lift the self-adjusting support beam approx. 10 mm, and place the thrust pad
and intermediate plate of the frame on the embedded support.
Lower the self-adjusting support beam onto the thrust pad and check
simultaneously that the centre markings "M" on the thrust pad are on line and
that the different surfaces are flush.
Mount the remaining seal-off sectors around the rocker bearing.
The mounting and fine alignment of bearing beams and self-adjusting support
beam on one half of the support have now been completed.
Transfer lifting gear etc. to the second half and mount this half in accordance
with the same procedure.
After the mounting and fine alignment of both halves has been completed, the
four fixed stops (Fig. 13) must be remounted so that the overall height of pad
(21) plus the discs (16) and guide plate (22) is equal to the distance "a" 2
mm.
Subsequent to that the bedplate will be ready for the mounting of supporting
roller bearings, supporting rollers and accessories.

4 Mounting of bearing block for thrust device

See Appendix 7 and assembly drawing.
The bearing block cannot be positioned nor finish-welded until the supporting roller
bearings and supporting rollers have been mounted and the bearings closed.
It is very important that the centreline of the bearing block (thrust roller) is lying
exactly in the marked centreline of the frame, which is the basis for the centreline of
the kiln.
The bearing block must also have the correct inclination and it must be placed at the
correct distance from the centre of the kiln tyre. This distance is measured from the
centre of the frame and out to the threaded holes for the thrust roller block (given as
(F) on the figure).
Check that these requirements are met, and then weld on the bearing block to the
frame. Finally the bearing block must be grouted in accordance with the directions
given in relevant instruction manual.

5 Appendices
See next pages.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
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Appendix 1 18051-04-I

Horizontal line of sight

HL = Height to lower edge of bedplate

HF = Height of crude foundation

H = HL - HF

Figure 2 18051-04-I

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN
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Appendix 2 18051-04-II

arrangement drawing
For H, see
Horizontal line of sight

Cross line
Centreline

Horizontal line of sight

01. Support beam

02. Frame structure (frame)
03. Hinged bearing
04. Hinged pivot
05. Pad, for indication of kiln centre
Figure 3 18051-04-II

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
18051-04-1.1

Appendix 3 18051-04-III

(See arranged
drawing)

01. Support beam

03. Hinged bearing
05. Pad, for indication of kiln centre
06. Baseplate for jack
07. Baseplate for self-adjusting support beam
08. Frame for fixed stop

Figure 4 18051-04-III

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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18051-04-1.1

Appendix 4 18051-04-IV

Kiln axis in horizontal plane (centreline)

Fine alignment of bedplate prior to grouting.

See Fig.7
Measurement with levelling instrument
Measurement with theodolite

Figure 5 18051-04-IV

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
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Appendix 5 18051-04-V

04. Hinged pivot 15. Fixed stop

08. Frame for fixed stop 16. Disc for fixed stop
09. Self-adjusting support beam 17. Rocker bearing
10. Bearing beam 18. Thrust pad
11. Frame for elastomer bearing 19. Intermediate plate for thrust pad
12. Elastomer bearing 21. Pad for fixed stop
13. Jack 22. Guide plate for fixed stop
14. Support for jack
Figure 6 18051-04-V

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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18051-04-1.1

Appendix 6 18051-04-VI

01. Support beam

03. Frame structure (frame)
10. Bearing beam
15. Fixed stop
23. Side guide
Figure 7 18051-04-VI

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
18051-04-1.1

Appendix 7 18051-04-VII

24. Bearing block for thrust device

Figure 8 18051-04-VII

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