70000482_a4-p________3.0_en

Rotary kiln Kiln tyre with tangential suspension Installation instructions

Created by: KarS Approved by: DJ FLSmidth, 23-Mar-12

70000482-3.0

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Foreword The present instructions are concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur during manufacture, installation, operation and maintenance of the equipment. An exhaustive enumeration of all conceivable situations, which may occur, cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instructions, 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. All references to relevant safety standards are given at the EC declaration of conformity if required. Reference by seller to any international or national standard does not incur an obligation on seller to provide any recipient, reader or user of the documentation with samples or copies of the said standard(s). Hence, any recipient, reader or user of the documentation is expected – at his own cost – to obtain necessary knowledge of the contents of any of the standards referred to. Safety Potential safety risks, and correct mode of conduct subject to such risks, are continuously described in the text in relation to specific actions. See instructions 32031 for general safety rules and the separate equipment-specific safety instructions for a complete list of all unforeseen risks in connection with the installation, operation and maintenance of the equipment. Definitions and abbreviations Authorized person Skilled person SDS MSDS OM

A person who is qualified and who, by the responsible manager, is entrusted with certain tasks. A person who, after an education as a craftsman, is capable of doing skilled work. Safety Data Sheet (in US known as MSDS) Material Safety Data Sheet Operation and Maintenance

Legend Warning This symbol indicates dangers which, in case of non-observance, may cause fatal or serious personal injuries! Warning text is concluded with a filled black triangle to symbolize end of warning text.  Attention This symbol indicates important information where specific attention and caution is needed. For example to avoid damage to or destruction of the equipment and/or parts of the installation. Attention text is concluded with a filled black square to symbolize end of attention text. 

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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Table of contents 1.0 Introduction ............................................................................................ 4  1.1 Construction and operating principle ..................................................... 4  2.0 Installation .............................................................................................. 4  2.1 General ............................................................................................. 4  2.2 Mounting of bushings on tyre sides ....................................................... 4  2.3 Tightening of bolts with a hydraulic bolt tensioner .................................. 5  2.4 Welding of retainer blocks to kiln shell .................................................. 6  2.4.1 Marking-off................................................................................ 6  2.4.2 Welding .................................................................................... 7  2.4.3 All-welding ................................................................................ 8  2.4.4 Welding procedure ..................................................................... 8  2.5 Checking of welds ..............................................................................12  2.6 Mounting of tyre on kiln shell ..............................................................12  2.7 Mounting of remaining retainer blocks ..................................................13  2.8 Adjustment of tyre position .................................................................14  2.9 Mounting of axial retainers .................................................................15  2.10 Mounting of first set of brackets ........................................................18  2.11 Mounting of wedges, cover plates, etc. ...............................................20  2.12 Erection of kiln shell and tyre on support ............................................21  ............................................................................................................21  2.13 Mounting of remaining parts..............................................................22  2.14 After erection ..................................................................................23  3.0 Operation ...............................................................................................24  4.0 Maintenance ...........................................................................................24  4.1 Lubrication .......................................................................................24  4.2 Cleaning ...........................................................................................24  4.3 Inspection and adjustment .................................................................24  4.4 Checking of condition .........................................................................24  4.4.1 Kiln shell, retainer blocks, axial retainers .....................................25  4.4.2 Wedge system ..........................................................................25  4.5 Spring tension ...................................................................................25  5.0 Key to figures and enclosures ...................................................................26  6.0 Enclosures .............................................................................................27  7.0 Page for notes ........................................................................................33

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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1.0 Introduction 1.1 Construction and operating principle The tangential suspension of the kiln shell in the kiln tyres is achieved with kiln tyres having cylindrical inner and outer faces and with all suspension parts placed outside the kiln tyre. This allow for easy access for inspection and maintenance. The suspension parts comprises retainer blocks welded onto the kiln shell and resting on brackets bolted to the sides of the kiln tyre with through-going bolts. For wear compensation and to ensure an even angular distribution of the load to be transferred from the kiln to the kiln tyre, slide shoes and spring-loaded wedges are inserted between the retainer blocks on the kiln and the brackets on the kiln tyre. The optimal load distribution is further ensured by a certain flexibility of the brackets. The small motions due to temperature expansions and different ovality will be between the slide shoes and the brackets, and the material combination will cause the wear to take place on the replaceable slide shoes. However, the system requires no periodic maintenance such as wedge adjustment, lubrication etc.

2.0 Installation Installation inspection Quality control! The words "Installation inspection" or "Erection inspection" in any drawing or text mean that the installation supervisor must carry out an inspection and approve installation status before continued installation may commence. 

2.1 General Guidelines for the assembly of the tyre, the suspension parts and heavy kiln shell with adjoining shells are given in this instruction manual. Part of the erection is done on the ground. The tyre is thus fixed in its final position on the kiln shell before the assembled parts are lifted on to the supporting rollers of the support. The alignment and assembly of the kiln shells between 2 or more supports must then be carried out so that it is possible to turn the heavy kiln shell before the mounting of the suspension parts can be completed. Erection must be planned so that the time required for welding of the retainer blocks on one or more kiln shells will be available. The instruction manual also lays down rules of operation and maintenance.

2.2 Mounting of bushings on tyre sides Mount the bushings (02) on the sides of the tyre by means of one third of the tensioning bolts (03) while the tyre (01) is blocked up horizontally on the floor, see Fig. 1. Note that the holes are not evenly distributed on the circumference of the tyre, but are grouped in threes. The bushings are to be inserted in the holes which are equidistant from the two neighbouring holes. 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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The blocking-up on which the tyre rests must be arranged to allow access from below to the holes in which the bushings are to be mounted. Before mounting of the bolts, the contact surfaces between tyre and bushing must be degreased carefully with a suitable solvent, e.g. ESSO's Solvesso 100, turpentine or any similar aliphatic solvent. Do not use paraffin oil which furthers rusting. The rust-inhibiting coating must be removed completely from the sides of the tyre.

Fig. 1.

Tyre and bushings

2.3 Tightening of bolts with a hydraulic bolt tensioner Mount the bolt tensioner (05) over the nut, see Fig. 2. To prevent deformation of the top of the bushing, a thrust waster (25) is inserted between the bolt tensioner and the bushing. The threaded section (06) of the bolt tensioner must mesh with a bolt length corresponding to at least one thread diameter. The bolt tensioner is connected via the hydraulic high-pressure hose (07) to the hand pump (08) which is equipped with a pressure gauge. To use the hydraulic tool it is necessary that the supplier's instructions should be followed. Based on information received from the supplier, the hydraulic pressure which corresponds to the pre-tightening force indicated on the arrangement drawing can be determined. It is important that the correct pre-tightening force should be obtained as accurately as possible for all bolts.

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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Fig. 2. Hydraulic tool The bolts are tightened in the following way: Apply the pressure in three steps, 1/3 - 2/3 - 3/3 pressure, with an intermediate relief of the bolt tensioner, the nut being tightened with the lever (09) whenever pressure is applied. This is done to equalise sagging of thread and joint faces. During any relief, the threaded section (06) of the bolt tensioner must be tightened manually to bottom the piston. It is very important that the maximum delivery head printed on the bolt tensioner should not be exceeded as this may damage the seals in the lifting jack.

2.4 Welding of retainer blocks to kiln shell 2.4.1 Marking-off Place the kiln shell (11) on a roller bed or some other kind of support on which it can be rolled. While the kiln shell rests on the bed and before the tyre is mounted, the positions of the retainer blocks on both sides of the tyre must be marked off carefully. Two grooves are turned on the kiln shell corresponding to the centrelines of the retainer blocks which are also marked off. To ensure that the retainer blocks on both sides of the tyre will be placed exactly opposite to each other, an axial generatrix must be marked off on the kiln shell spanning from one circle to the other. This can be done with beam compasses or an optical measuring instrument. Using the generatrix the kiln shell is marked off in a number of pitches corresponding to the number of retainer blocks. Marking-off is done on both sides of the tyre in the two centrelines. To do so precisely it is necessary to measure the circumference of the kiln shell and divide the circumference by the number of retainer blocks. The circumference of the kiln shell is entered in inspection form U 6091; see enclosure 3.

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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To check the marking-off, it will be of advantage to make an extra generatrix, offset through approx. 180º from the first generatrix, in order to check that the pitches are identical on both sides so that the retainer blocks are placed exactly opposite to each other. If the kiln shell is painted or corrosion-proofed in some other way, this surface coating must be removed completely before welding is started. If the kiln shell is to be butt-joined with other new kiln shells, it is important that the white line in the kiln shell should be taken into account when the retainer blocks are positioned. The retainer blocks must be positioned so that the erection wedges (13) to be mounted later (see section 3.7) in positions 45º and 135º are between the pitch of the retainer blocks, the white line being in the correct position. Normally, the white line must be at the bottom. The first block must be positioned and tack-welded parallel to the circular line so that its one surface of contact is accurately flush with the marked-off generatrix as shown in Fig. 3.

Pitch

P

Kiln circumference Number of retainer blocks

Fig. 3. Positioning of retainer block

2.4.2 Welding All welding of retainer blocks must be done by certified welders according to FLS instruction manual ref. 5. For safety regulations, welding equipment, storage of electrodes, etc., reference is made to instruction manual ref. 4 for manual arc welding. While the kiln shell (11) is resting on the roller bed or a similar support, and before the tyre is mounted, the retainer blocks (12) can be fixed to one side of the tyre, see Fig. 3. The retainer blocks are positioned relative to the marking-off and tack-welded at four corners to the kiln shell, see Fig. 3. The tack-weld is carried out with a root run electrode in a way that ensures that the retainer block will not turn or retreat. When all retainer blocks on one side have been tack-welded to the kiln shell, the distance is measured between every two retainer blocks. The mutual distance between retainer blocks must be within a tolerance of ± 0.5 mm. 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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Before welding of the retainer blocks can be started, the erection supervisor must approve as well as enter the pitch distances between the retainer blocks in inspection form U 6091, see enclosure 3. Mounting check

2.4.3 All-welding If the erection supervisor has approved the positions of the retainer blocks, allwelding of the retainer blocks mounted can be carried out, but it requires that the kiln shell can be rotated as the cover runs must be welded in "flat downhand/horizontal" position because of the type of electrode. As most welders are not familiar with the cover run electrode which is a ø6 mm basic high-yield electrode, it is recommended that the welders should be given the opportunity of testing this electrode on some test blocks in order to become familiar with the electrode. Because of the time consumption it is recommended that the welds should be made simultaneously by two welders, i.e. one welder on either side of the retainer block. It should also be considered to work shifts. Because of the importance of these large welds it is recommended that expert welders should be used.

2.4.4 Welding procedure The following welding procedure must be observed for all retainer blocks. Turn the kiln shell until the retainer block to be welded is in top position. Stage 1: The heat-affected zone (HAZ) of the retainer block and the kiln shell is pre-heated to 150º-170ºC. It is important that pre-heating should be done evenly around the retainer block, and that spot-heating does not occur. Execute bottom run at ends of retainer block. Bottom run consists of 5 weld beads (No. 1 to 5 on figure 4) with ø3.25mm rod FLS material 9727. Length of bottom run must be minimum the total width of retainer block.

Fig. 4. Bottom run Weld two layers of of transition material on kiln shell, illustrated as bead No. 6 and 7 on figure 5, 6 and 7. For this purpose ø3.25 or ø4.0mm rod FLS material 9727 is use

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Fig. 5. Transition layers

Fig. 6. Transition and filling-up layers

Fig. 7. Transition and filling-up layers Final filling-up is carried out with ø4 rod FLS material 9719 or ø4mm rod FLS material 9721. Filling-up is foreseen to be executed in 3 layers as illustrated in figure 6, 7 and 8. 3 layers are not mandatory.

Fig. 8. Filling up layers Layers must be completed as steps in order to secure a defect-free transition to subsequent welding on the sides, see figure 6 and 7.

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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Stage 2

A: ø4, Mat.9727 B: ø4, Mat. 9721 C: ø6, Mat. 9719 Fig. 9. Welding procedure

Stage 3

Stage 4

D: E: F:

Layer 1 Layer 2 HAZ: 150-170°C

Stage 2: The retainer block is welded on with the number of bottom runs indicated on the arrangement drawing. When the first bottom run is welded and a tack-weld is reached, it is important that the tack-weld is ground away completely. If the tackweld is not ground away completely, it may result in errors during the subsequent ultra-sound testing.

Stage 3: Weld two bottom runs against the kiln shell; use the same electrode as for the other bottom runs, see Fig. 9. Be aware that the bevelling of the retainer block narrows at the ends. The a-dimension must, therefore, also be correspondingly smaller at these points. It will be of advantage to scratch the outline of the weld on the kiln shell in order that the welder will know where the weld is to end.

Stage 4: To reduce the welding time as much as possible, the weld should be filled with a ø6 mm basic high-yield electrode (FLS material 9719). This electrode must be welded in "flat downhand/horizontal" position. Where it is difficult to get all the way into the corners with the ø6 mm electrode, a smaller electrode, ø4 mm mat. 9721, must be used. The same electrode is also used at the top of the weld. Experience shows that it is difficult for some welders to give the weld surface an even finish. If this is so, it can be permitted to cover the entire weld with the electrode ø4 mm mat. 9721, see Fig. 9. Retainer block and surrounding shell area must be covered by insulating blankets immediately after completion of welding to prevent too rapid cooling (to work as

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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post-heat treatment). Insulation can be removed when temperature are below 150C and thus allowing cooling off freely. To measure the dimension of the weld it is recommended that a template should be made with a bevelling corresponding to the a-dimension. Experience has shown that the most common welding defect on the retainer blocks is slag deposits. It is, therefore, important to inform the welders that such defects cannot be accepted. A nice transition must be ensured between weld and kiln tube without undercut. If an undercut is found, it must be ground away and repaired. At the ends of the retainer blocks it may be difficult to make soft weld transitions to the kiln tube. It is, therefore, important that careful grinding should be carried out here to remove all signs of notching.

Grinding of weld transition to kiln shell: Transition to be executed as shown at figure 10, and to dimensions shown at arrangement drawing. Final surface roughness Ra max. 6.3. To be obtained by: Hand machining with hard metal file. Hand grind with grinding stone. Hand grind / polish with one-hand polish machine for ø115mm soft disc. Hand grind / polish with rotating lamella emerald cloth. Use grain size 60 and 120 emerald cloth / soft disc. It is important to remove all remaining signs of the hard metal file process. Tools recommended for grinding / polish: One-hand polish machine for approx. ø115mm soft disc. Discs for above machine with grain size 60 and 120. High speed grinder for grinding and polish tools with ø6mm shaft, 2500-3000 rpm, 0.65 kW electrical or air driven. Lamella emerald cloth grinding cylinder, ø4020mm, grain size 60 and 120. Rotating grinding stone, cylindrical with flat end, cylindrical with rounded end and conical. All approx. ø12 with shaft ø6mm. High speed grinder for rotating hardmetal file with ø6mm shaft, 25000-30000 rpm, 0.3 kW electrical or air driven. Rotating hardmetal file, cylindrical with rounded end. Approx. ø12 with shaft ø6mm.

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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Fig. 10. Transition zone grinding

2.5 Checking of welds Welding of retainer blocks (12) and axial retainers (14) must observe weld seam class B, see arrangement drawing. The welds of the retainer blocks are checked 100% with ultra-sound. The ultrasonic test is made with a normal sound head from the inside of the kiln shell; an angular sound head being used on the outside of the kiln shell. The ultrasonic test (UT) should be made immediately after termination of the welding work for every row of retainer blocks. Any repairs can thus be made when space conditions are good. To avoid defects in welds it may be recommended that ultrasonic testing should be carried out after welding of the first 3-4 retainer blocks. This test is an indication of the welding quality. Moreover a Magnetoflux test (MT).

2.6 Mounting of tyre on kiln shell The kiln shell with stiffening brace must be supported so that it rests horizontally on the ground. The supports must be placed so that the tyre can be moved so far in

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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under the kiln shell that it will be possible to move the blocking-up to the opposite side of the tyre. Position the tyre over the kiln shell as close to the blocking-up as possible. Support the tyre strongly and move one support of the kiln shell to the side from which the tyre was introduced. It is important that the kiln shell should be horizontal. Then move the tyre in position as close as possible to the blocks already mounted on the heavy kiln shell, see Fig. 11. It must be ensured that the tyre stands independently and steadily on its blocking-up and is secured against overturning. Be aware that mounting of the remaining retainer blocks will require that the kiln shell can be turned without conflicting with the tyre.

2.7 Mounting of remaining retainer blocks The retainer blocks (12) are now mounted on the side of the tyre where they have not yet been mounted. The retainer blocks are positioned on the basis of the marking-off already made, see sub-section 2.4.1. All retainer blocks are tack-welded and their mutual distances are entered in inspection form U 6091, see sub-section 2.4.2.

Fig. 11. Blocked-up kiln shell and tyre When the kiln tube is turned, it must be seen that the bolts with bushings (02) do not jam between some of the welding-on retainer blocks. Mounting check After the erection supervisor has approved the positioning of the retainer blocks, they are all-welded as described in sub-section 2.2.4 As mentioned in section 2.5, it can be recommended that a ultrasonic test should be made at the present time and that any repairs should be made before erection is continued.

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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2.8 Adjustment of tyre position In order to obtain centring of tyre and kiln shell, the outside diameter of the kiln shell must be calculated from the circumference entered in inspection form U 6091. The inside diameter of the tyre can be seen on the kiln tube drawing/position drawing. The radial clearance can be calculated from the above drawing. The four sets of erection wedges (13) are adjusted to make their height correspond to the calculated radial clearance, and the wedges are tack-welded mutually. The wedges are later to be used for positioning of kiln shell and tyre relative to each other. The kiln shell must be supported evenly as close to the heavy shell as possible, but however not so close as to hamper subsequent mounting of wedges, springs, etc., see section 2.12. The support must be carried out so that the kiln is carried at an encircling angle of at least 70º at the bottom, see enclosure 2. A roller bed cannot be used. The support must be adapted with wooden blocks. It is very important that the kiln tube should be absolutely horizontal. It can be checked with a levelling instrument or a theodolite. The supports must be placed on a stable base; if possible on a concrete deck which does not subside. The kiln shell must be turned so that the white line is positioned correctly relative to any other adjoining kiln shells. Four sets of erection wedges (13) are mounted in the interval between kiln and tyre. The wedges are placed between the pitches of the retainer blocks in positions approx. 45º and 135º so that there are two sets of wedges on either side of the tyre, see Fig. 12. Each set of wedges may be tack-welded to the kiln shell. Prior to mounting of the wedges they should be coated well with molybdenum sulphide MoS2 or a similar material, inside and out. In this way it will be easier to adjust the tyre to the correct position and to remove the wedges later.

G: Wooden blocks. Fig. 12. Positioning of erection wedges, etc.

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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The tyre support can now be removed and the tyre be lowered so that it rests on the erection wedges (13) and the special stiffening braces (23). Check that the same radial clearance exists on the entire circumference. If necessary, shims can be inserted between erection wedges and tyre. The clearance may be entered with advantage on a polar diagram. Turn the tyre to make its pitches coincide with those on the kiln shell, X = X, see Fig. 13.

Fig. 13. Centering of tyre It must also be checked that the tyre is positioned right between the centrelines for the retainer blocks turned on the kiln shell.

2.9 Mounting of axial retainers While the tyre rests on the erection wedges (13), mount the two axial retainers (14) on one side of the tyre in the positions approx. 45º and 135º. The two axial retainers must be placed so as to fit in with the pitch of the suspension; see enclosure 5 and the arrangement drawing. The axial retainers must be mounted so that the distances between their surfaces of contact on the tyre and the line turned on the kiln shell are identical, see Fig. 14. The correct distance is indicated on the arrangement drawing. When the correct adjustment has been made, the axial retainers are tack-welded to the kiln shell.

Fig. 14. Adjustment of axial retainers

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By the use of a lifting jack placed on the opposite side of the tyre the tyre can be pushed up against the two axial retainers, see Fig. 15.

Fig. 15. Adjustment of tyre When the axial alignment has been checked, the remaining axial retainers (14) must be welded on both sides of the tyre. The axial retainers must be placed so that they match the pitch of the suspension, see enclosure 5 and the arrangement drawing. The heat-affected zone (HAZ) of the axial block and the kiln shell is pre-heated to 150º-170ºC. It is important that pre-heating should be done evenly around the axial retainer block, and that spot-heating does not occur. Welding to be made with electrodes with type FLS material 9727. On one side of the tyre a shim of a thickness of 2 mm is inserted between axial retainers and tyre. All the axial retainers are welded to the a-dimension indicated on the arrangement drawing. As the kiln shell cannot be turned, it is necessary to weld the axial retainers in position welding. For welding check, see section 3.4. After finishing the welding of the axial retainers these must be ground according to the following description. Indicated areas must be rounded off and a smooth transition to adjacent areas be executed by grinding: The round face next to welding foot (see fig. 16) Transition between welding and axial retainer (see fig. 17) The transition between welding and kiln shell (see fig 17) Corner between round face next to welding foot and side face of axial retainer (see fig. 17) Zones are indicated with circles at Figure 16, and approximate shapes after completed grinding are illustrated on Figure 17. We recommend that the following tools be used for grinding: Hard-metal-file with oval shape (ø12 outer diameter and ø6 shaft); Hard-metal-file with conical shape (ø12 as max. diameter and ø6 shaft); Flexible rotating axle with chuck suitable for ø6 shaft and approximately 6000 rpm (see figure 18).

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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Fig. 16. Round face next to welding foot

H: Grind smooth. Fig. 17. Welding transition and corner to be ground

Fig. 18. Grinding tool

By measuring the clearance between tyre and kiln shell on the entire circumference, it is checked that the tyre is centred radially on the kiln shell within a tolerance of ± 0.5 mm. If this is not the case, the tyre must be lifted and the erection wedges be adjusted; if necessary, shims are inserted between wedges and tyre.

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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2.10 Mounting of first set of brackets After adjustment of the tyre position relative to the retainer blocks the first set of brackets (10) must be mounted. It consists of two left-hand and two right-hand brackets positioned symmetrically around a bushing on either side of the tyre (01), see Fig. 19 and enclosure 1. The brackets are cleaned and degreased carefully with the same solvent as described in section 2.2. Brackets that is mounted on lower half of tyre can be held and positioned by use of a mounting tool, see Fig 20, fixed onto a fork lift, a lifting table or similar lifting device (not supplied with the equipment), see separate arrangement drawing for details. It is important that the brackets should be placed so that they are forced completely against the centre bushings (02), see Fig. 20. A check must be made with a feeler gauge.

Fig. 19. One set of brackets

Fig. 20. Mounting tool for brackets

There is a keyway for a key (26) in the joint face of the brackets facing the tyre. The key, which also fits the groove on the side of tyre (01) serves to ensure that bracket (10) is inclined and positioned correctly relative to the pitch diameter, øD1, see Fig. 21.

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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Fig. 21. Tyre with bracket, bolt and key

At the same time as the key guides the bracket on the side of the tyre, the bracket is forced in position by wooden wedges so that the bracket lies true against bushing (02). Subsequently, the bolts (03) and the nuts (04) are tightened manually. When it has been checked that the brackets bear against the centre bushings (02) and that the "inclination" is correct, the bolts are tightened by means of the hydraulic nut as described in section 2.2. Check that the distance X between the retainer blocks and the four brackets is the same, see Fig. 19. If not, the tyre must be turned. Then the rest of the brackets, or minimum 6 sets of brackets evenly distributed on the circumference, are mounted; however, brackets are not to be mounted where the erection wedges are located as in this case the wedges cannot be removed later.

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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2.11 Mounting of wedges, cover plates, etc. Cover plates and associated parts are to be mounted on both sides of the tyre between the mounted bracket pairs and retainer blocks, see enclosure 1.

Fig. 22. Arrangement of wedge link Before wedge (15), wear shoe (16) and cover plate are mounted, screw pin bolt (24) completely home in threaded hole in retainer block. See Fig. 22. Fasten the cover plate on the retainer blocks using nuts (28). Make sure that the joint faces are absolutely clean and that any paint has been removed. Place wear shoe (16) and wedge (15) between bracket and retainer block. When wear shoe and wedge have been positioned correctly, insert the wedge by means of a few light hammer blows. The nuts (28) of the cover plates are tightened with a torque spanner to the tightening torque indicated, see arrangement drawing. It must be seen that the surfaces of contact have been cleaned and degreased and that the screw threads have been coated with PBC (Poly-Butyl-Cuprysil) from Poul Products, England, or a similar product, and that the treaded holes have been cleaned with an air jet. For cleaning, use the solvent described in section 2.2. Instead of PBC, the following products can be used: Klüber Lubrication Reiner Chemie Molub-Alloy Chesterton Achesons Colloind Company Never-Seez Compound Corp.

Grafloscon, Wolfracoat C Ceplattyn HT 491-C Nickel Anti-Seize Compound Oildag Never-Seez

It may be advantageous to wait mounting the spring system until the kiln section has been mounted on the support. However, make sure that the mounted wedges are firmly fixed when lifting the kiln section.

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.

Rotary kiln 70000482-3.0 Page 21 of 33

2.12 Erection of kiln shell and tyre on support At this stage the kiln tube is mounted with tyre (01), axial retainers (14) and a minimum of 6 sets of bracket pairs with associated parts on both sides of the tyre, see enclosure 1. The kiln shell with the tyre mounted can then be lifted on to the supporting rollers. All stiffening braces must be mounted before the kiln tube is lifted. The kiln tube with tyre is lifted together on to the supporting rollers by running steel wires round the kiln shell on both sides of the tyre, see Fig. 23.

Fig. 23. Lifting the kiln section When the kiln section has been lifted on to the rollers, the kiln tube will be suspended from the brackets (10) mounted on the tyre. The erection wedges (13) must then be removed from the clearance between kiln and tyre. The kiln shell can then be bolted to the adjoining kiln shell(s) and aligned relative to it/them as described in the erection manual for the kiln.

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.

Rotary kiln 70000482-3.0 Page 22 of 33

Fig. 24. Measurement of kiln tube untrueness

The alignment tolerances for the heavy kiln shell with tyre can be seen in the kiln erection manual. The untrueness of the kiln shell can be measured with a depth gauge, on both sides of the tyre, from a fixed point to the machined heavy kiln shell, see Fig.24. Enter the measurements in the polar diagram for the tyre inlet and outlet side. An eccentricity of 1.4 mm of the kiln shell in the tyre is permissible. The eccentricity is determined by comparing the centres of the two polar diagrams. The distance through which the centres are offset in the same direction is the eccentricity. The untrueness is the difference between centres. After alignment by means of polar diagrams the kiln sections are to be welded together.

2.13 Mounting of remaining parts After the erection wedges (13) have been removed, the remaining brackets are mounted with wedges, wear shoes and cover plates as described in section 2.11. Mounting is to be carried out in 90º position (top), and the kiln must be barred between each set mounted. In the 90º position the brackets are not loaded by the reaction from the kiln. When mounting is done in this position, it must, therefore, be ensured that kiln and tyre still centre. It is advantageous to mount the spring system together with the remaining parts on top of the kiln. Align spring holder (22) according to wedge (15) so that spindle (20) can be centred, and weld it to the kiln shell. See Fig. 24. The distance to centre of retainer block is specified on the arrangement drawing.

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.

Rotary kiln 70000482-3.0 Page 23 of 33

Fig. 25. Spring system Having welded the spring holder to the kiln shell, mount the spindle with spring, spring guide and nut. Tension the spring by means of the nut to the dimension specified on the arrangement drawing.

2.14 After erection Before the kiln is started up all retainer blocks and cover plates must be stamped with numbers as shown on the arrangement drawing. The first digit of the stamped number indicates the numbering of the bracket pairs on the circumference. (Normally, there are from 10 to 14 pairs). The last digit indicates on which side relative to the bracket pair the plate is mounted when viewed in the direction of the tyre (L = left, R = right). See U-5791 too. Using inspection form U 5791, the lengths of the spring columns and the positions of the wedges are to be measured after erection has been completed, but before the kiln is put into operation. The measurement must be within an accuracy of 1 mm. The erection supervisor must see that these measurements are taken for all spring columns and entered in the inspection form together with the numbering of the cover plates. Enclosure 4 & 5 is a copy of a completed inspection form. After the kiln has been put into operation and at the forthcoming kiln stop the erection supervisor must see that these measurements are repeated and the measured values entered in the inspection form.

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.

Rotary kiln 70000482-3.0 Page 24 of 33

3.0 Operation Please see section 1.0 regarding operation principles for the tangential suspension.

4.0 Maintenance Preventive maintenance, survey: Pos. Text 00 11 15 20 10 12 14

1.

Arrangement Kiln shell Wear compensating wedge Spring Bracket Retainer blocks Axial retainer

Lubrication Cleaning Inspection and adjustment Checking of condition Replacement

2.

3.

4.

A A A A

S

A T A A T T T

5.

T

D = per 8-h operation S = weekly M = monthly A = yearly T = see text below

A number in front of the letter indicates the frequency of procedure. For example, 2M = twice a month

4.1 Lubrication It will not be necessary to lubricate the components.

4.2 Cleaning Normal cleaning.

4.3 Inspection and adjustment The tangential suspension must be checked visually during normal operation at least weekly. Any irregularities must be reported and if necessary, the kiln must be stopped for further examination.

4.4 Checking of condition The condition of the entire arrangement must be inspected. It must be ensured that the condition of the entire arrangement is satisfactory and that all cover plates (27) are tightened at the torque specified on the arrangement drawing.

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.

Rotary kiln 70000482-3.0 Page 25 of 33

4.4.1 Kiln shell, retainer blocks, axial retainers As a precaution to avoid or minimize (in the worst case) the risk of breakdown, stoppage or damage, it is recommended that inspections for cracks in the welding area of the retainer blocks(12) and axial retainers(14) are carried out annually. However, inspections should be done on a more frequent basis if they reveals any conditions of concern that do not warrant immediate repair. FLS are prepared to provide such assistance on request in performing these inspections or any corrective or preventive repairs that might become necessary or prudent. If cracks or any other contition are revealed during the inspection, that warrants preventive action, FLS recommend that to take immediate steps to repair the cracks by following the procedures recommended by FLS. The kiln shell must be examined for cracks in the welding area of the retainer blocks and the axial retainer:  100% visual inspection, without dismounting any parts.  20%, randomly selected, to be inspected with dye-penetrant liquid.  Remove coverplate, wedge and slide shoe to allow access to the transverse weld adjacent to the wedge. On the axial retainers special attention must be to the ends of the welding seams located nearest to the tyre, as indicated with circles on fig. 17. If cracks are discovered during any of the above-mentioned tests, we recommend that a 100% inspection with dye-penetrant liquid to be carried out and a repair of all cracks to be executed immediately. Contact FLS for detailed procedure regarding repair of cracks.

4.4.2 Wedge system Check the condition of the wedge system by measuring the position of spring spindle (20), S1, see inspection form, enclosure 5. This condition must be checked annually. The worn parts must be replaced when the wear is 5 mm. 5 mm wear corresponds to dimension S1 which is reduced by about 32 mm relative to the mounting position.

4.5 Spring tension The springs should be re-tensioned once a year to ensure a constant pre-tension on wear-compensating wedges (15). Tension the springs to the distance specified on the arrangement drawing. Complete inspection form U 5791 and file it, see enclosures 5 and 6.

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.

Rotary kiln 70000482-3.0 Page 26 of 33

5.0 Key to figures and enclosures 01 02 03 04 05 06 07 08 09

Tyre with holes Bushing Tensioning bolt Cylindrical nut Hydraulic bolt tightener Hydraulic bolt tightener, threaded section Hydraulic high-pressure hose Hand pump with pressure gauge Lever for tightening of nut

10 11 12 13 14 15 16

Bracket (set) Heavy kiln shell (kiln section) Retainer block One set of erection wedges Axial retainer Wear-compensating wedge Wear shoe

20 21 22 23 24 25 26 27 28

Spindle for spring Spring Spring holder Stiffening brace Screw Thrust washer Key Cover plate Nut

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.

Rotary kiln 70000482-3.0 Page 27 of 33

6.0 Enclosures

Enclosure 1. Arrangement suspension parts

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.

Rotary kiln 70000482-3.0 Page 28 of 33

Holes for fastening of wooden blocks Load on saddle KN P < 750 P < 1100 P < 1500 P < 2000

Thickness (T) mm 15 18 22 25

Width (W) mm 300 350 400 450

Welding (a) mm 4 5 6 7

Enclosure 2. Supporting of kiln.

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.

Rotary kiln 70000482-3.0 Page 29 of 33

Plant: Sent by:

With letter to:

Date:

Document No.: U6091-01 Page No.: No. of pages:

1 1

Rotary Kiln Measuring of retainer block positions Tangential suspension No.: Support No.

Outlet side:

mm

Inlet side Block No. I1-I2

X

Outlet side Block No. O1-O2

I2-I3

O2-O3

I3-I4

O3-O4

I4-I5

O4-O5

I5-I6

O5-O6

I6-I7

O6-O7

I7-I8

O7-O8

I8-I9

O8-O9

I9-I10

O9-O10

I10-I11

O10-O11

I11-I12

O11-O12

I12-I13

O12-O13

I13-I14

O13-O14

I14-I1

O14-O1

X

I6

X ±0.5

mm

X ±0.5

I5

Measuring of kiln shell circumference Inlet side:

I7

Inlet side FLS:

Client:

Contractor:

Enclosure 3. Inspection form U6091

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.

Rotary kiln 70000482-3.0 Page 30 of 33

Plant: Sent by:

With letter to:

Date:

Document No.: U6091-01 Page No.: No. of pages:

1 1

Rotary Kiln Measuring of retainer block positions Tangential suspension No.: Support No.

mm

Outlet side:

mm

X

Outlet side Block No. O1-O2

I2-I3

O2-O3

I3-I4

O3-O4

I4-I5

O4-O5

I5-I6

O5-O6

I6-I7

O6-O7

I7-I8

O7-O8

I8-I9

O8-O9

I9-I10

O9-O10

I10-I11

O10-O11

I11-I12

O11-O12

I12-I13

O12-O13

I13-I14

O13-O14

I14-I1

O14-O1

X

I6

X ±0.5

Inlet side Block No. I1-I2

X ±0.5

I5

Measuring of kiln shell circumference Inlet side:

I7

Inlet side FLS:

Client:

Contractor:

Enclosure 4. Inspection form U6091

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.

Rotary kiln 70000482-3.0 Page 31 of 33

Document No.: U5791-03 Page No.:

Plant: Sent by:

With letter to:

Date:

No. of pages:

1 1

Rotary Kiln Measuring of retainer block positions Support No. Tangential suspension No.: Kiln position (Cold/Hot):

FLS:

2L (left)

Outlet side Wedge No.

S1/S2

Seen against tyre

O1L O1R O2L O2R O3L O3R O4L O4R O5L O5R O6L O6R O7L O7R O8L O8R O9L O9R O10L O10R O11L O11R O12L O12R O13L O13R O14L O14R

S2S2

S1/S2

2R (right)

S1S1

Inlet side Wedge No. I1L I1R I2L I2R I3L I3R I4L I4R I5L I5R I6L I6R I7L I7R I8L I8R I9L I9R I10L I10R I11L I11R I12L I12R I13L I13R I14L I14R

Client:

Contractor:

Enclosure 5. Inspection form U5791

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.

Rotary kiln 70000482-3.0 Page 32 of 33

Document No.: U5791-03 Page No.:

Plant: Sent by:

With letter to:

Date:

No. of pages:

1 1

Rotary Kiln Measuring of retainer block positions Support No. Tangential suspension No.: Kiln position (Cold/Hot):

FLS:

2L (left)

Seen against tyre

S1/S2

Client:

S2S2

S1/S2

Outlet side Wedge No. O1L O1R O2L O2R O3L O3R O4L O4R O5L O5R O6L O6R O7L O7R O8L O8R O9L O9R O10L O10R O11L O11R O12L O12R O13L O13R O14L O14R

S1 S1

Inlet side Wedge No. I1L I1R I2L I2R I3L I3R I4L I4R I5L I5R I6L I6R I7L I7R I8L I8R I9L I9R I10L I10R I11L I11R I12L I12R I13L I13R I14L I14R

Contractor:

Enclosure 6. Inspection form U5791 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.

2R (right)

Rotary kiln 70000482-3.0 Page 33 of 33

7.0 Page for notes

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.