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, installa-
tion, 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 recom-
mended 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 con-
formity 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 con-
tinuously 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 A person who is qualified and who, by the responsible man-
ager, is entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is capable of
doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM 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
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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 brack-
ets. 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 re-
quires 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.
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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 care-
fully 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 infor-
mation 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.
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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 correspond-
ing 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 circumfer-
ence 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 enclo-
sure 3.
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To check the marking-off, it will be of advantage to make an extra generatrix,

offset through approx. 180 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 45 and 135 are between
the pitch of the retainer blocks, the white line being in the correct position. Nor-
mally, 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.
Kiln circumference
Pitch P
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.
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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 inspec-
tion 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, all-
welding 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 down-
hand/horizontal" position because of the type of electrode.
As most welders are not familiar with the cover run electrode which is a 6 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 150-170C.
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 3.25mm 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 3.25 or 4.0mm 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 4 rod FLS material 9719 or 4mm 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.
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Stage 2 Stage 3 Stage 4
A: 4, Mat.9727 D: Layer 1
B: 4, Mat. 9721 E: Layer 2
C: 6, Mat. 9719 F: HAZ: 150-170C
Fig. 9. Welding procedure
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 tack-
weld 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 6
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 6 mm electrode, a
smaller electrode, 4 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 4 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
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post-heat treatment). Insulation can be removed when temperature are below

150C 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 ac-
cepted.
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 115mm 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. 115mm soft disc.

Discs for above machine with grain size 60 and 120.
High speed grinder for grinding and polish tools with 6mm shaft, 2500-3000 rpm,
0.65 kW electrical or air driven.
Lamella emerald cloth grinding cylinder, 4020mm, grain size 60 and 120.
Rotating grinding stone, cylindrical with flat end, cylindrical with rounded end and
conical. All approx. 12 with shaft 6mm.
High speed grinder for rotating hardmetal file with 6mm shaft, 25000-30000 rpm,
0.3 kW electrical or air driven.
Rotating hardmetal file, cylindrical with rounded end. Approx. 12 with shaft
6mm.
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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
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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 in-
spection 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.
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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 calcu-
lated 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 70 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. 45 and 135 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.
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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. 45 and 135. The two axial
retainers must be placed so as to fit in with the pitch of the suspension; see enclo-
sure 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
150-170C.
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 transi-
tion 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 re-
tainer (see fig. 17)
Zones are indicated with circles at Figure 16, and approximate shapes after com-
pleted grinding are illustrated on Figure 17.
We recommend that the following tools be used for grinding:
Hard-metal-file with oval shape (12 outer diameter and 6 shaft);
Hard-metal-file with conical shape (12 as max. diameter and 6 shaft);
Flexible rotating axle with chuck suitable for 6 shaft and approximately 6000 rpm
(see figure 18).
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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 circumfer-
ence, it is checked that the tyre is centred radially on the kiln shell within a toler-
ance 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.
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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 de-
scribed 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 com-
pletely 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, D1,
see Fig. 21.
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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.
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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 tight-
ening 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:
Klber Lubrication Grafloscon, Wolfracoat C

Reiner Chemie Ceplattyn HT
Molub-Alloy 491-C
Chesterton Nickel Anti-Seize Compound
Achesons Colloind Company Oildag
Never-Seez Compound Corp. 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.
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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 sus-
pended 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.
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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 90 position (top), and the kiln must be barred
between each set mounted. In the 90 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 cen-
tred, and weld it to the kiln shell. See Fig. 24.
The distance to centre of retainer block is specified on the arrangement drawing.
Rotary kiln
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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. (Nor-
mally, 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.
Rotary kiln
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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 1. 2. 3. 4. 5.
00 Arrangement A S A
11 Kiln shell A T
15 Wear compensating wedge A A T
20 Spring A A
10 Bracket T
12 Retainer blocks T
14 Axial retainer T
Lubrication D = per 8-h operation

Cleaning S = weekly
Inspection and adjustment M = monthly
Checking of condition A = yearly
Replacement 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.
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 correc-
tive 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 enclo-
sures 5 and 6.
Rotary kiln
70000482-3.0
Page 26 of 33
5.0 Key to figures and enclosures
01 Tyre with holes

02 Bushing
03 Tensioning bolt
04 Cylindrical nut
05 Hydraulic bolt tightener
06 Hydraulic bolt tightener, threaded section
07 Hydraulic high-pressure hose
08 Hand pump with pressure gauge
09 Lever for tightening of nut
10 Bracket (set)
11 Heavy kiln shell (kiln section)
12 Retainer block
13 One set of erection wedges
14 Axial retainer
15 Wear-compensating wedge
16 Wear shoe
20 Spindle for spring

21 Spring
22 Spring holder
23 Stiffening brace
24 Screw
25 Thrust washer
26 Key
27 Cover plate
28 Nut
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Page 27 of 33
6.0 Enclosures
Enclosure 1. Arrangement suspension parts
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70000482-3.0
Page 28 of 33
Holes for fastening of

wooden blocks
Load on saddle Thickness Width Welding

KN (T) mm (W) mm (a) mm
P < 750 15 300 4
P < 1100 18 350 5
P < 1500 22 400 6
P < 2000 25 450 7
Enclosure 2. Supporting of kiln.
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Page 29 of 33
Plant: Document No.:

U6091-01
Sent by: With letter to: Date: Page No.: 1
No. of pages: 1
Rotary Kiln
Measuring of retainer block positions
Tangential suspension No.:
Support No.
I5
Measuring of kiln
shell circumference
Inlet side: mm
Outlet side: mm
X 0.5
Inlet side Outlet side
Block No. X Block No. X
I1-I2 O1-O2
I2-I3 O2-O3
I3-I4 O3-O4
I4-I5 O4-O5 I6
I5-I6 O5-O6
I6-I7 O6-O7
I7-I8 O7-O8
I8-I9 O8-O9
I9-I10 O9-O10 X 0.5
I10-I11 O10-O11
I11-I12 O11-O12
I12-I13 O12-O13
I13-I14 O13-O14
I14-I1 O14-O1
I7
Inlet side
FLS: Client: Contractor:
Enclosure 3. Inspection form U6091
Rotary kiln
70000482-3.0
Page 30 of 33

U6091-01
No. of pages: 1
Rotary Kiln
Support No.
I5
Measuring of kiln
shell circumference
Inlet side: mm
Outlet side: mm
X 0.5
Block No. X Block No. X
I1-I2 O1-O2
I2-I3 O2-O3
I3-I4 O3-O4
I4-I5 O4-O5 I6
I5-I6 O5-O6
I6-I7 O6-O7
I7-I8 O7-O8
I8-I9 O8-O9
I9-I10 O9-O10 X 0.5
I10-I11 O10-O11
I11-I12 O11-O12
I12-I13 O12-O13
I13-I14 O13-O14
I14-I1 O14-O1
I7
Inlet side
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Page 31 of 33

U5791-03
No. of pages: 1
Rotary Kiln
Support No.
Kiln position (Cold/Hot):

2L (left) 2R (right)
Wedge Seen against tyre
S1/S2 Wedge No. S1/S2
No.
I1L O1L
I1R O1R
I2L O2L
I2R O2R
I3L O3L
I3R O3R
I4L O4L
I4R O4R
I5L O5L
I5R O5R
I6L O6L
I6R O6R
I7L O7L
I7R O7R
I8L O8L
I8R O8R
I9L O9L
I9R O9R
I10L O10L
S2S2
I10R O10R
I11L O11L
I11R O11R
I12L O12L
I12R O12R
S1S1
I13L O13L
I13R O13R
I14L O14L
I14R O14R
Rotary kiln
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Page 32 of 33

U5791-03
No. of pages: 1
Rotary Kiln
Support No.
Kiln position (Cold/Hot):
2L (left) 2R (right)
Inlet side Outlet side Seen against tyre
Wedge Wedge
S1/S2 S1/S2
No. No.
I1L O1L
I1R O1R
I2L O2L
I2R O2R
I3L O3L
I3R O3R
I4L O4L
I4R O4R
I5L O5L
I5R O5R
I6L O6L
I6R O6R
I7L O7L
I7R O7R
I8L O8L
I8R O8R
I9L O9L
I9R O9R
I10L O10L
S2S2
I10R O10R
I11L O11L
I11R O11R
I12L O12L
I12R O12R
S1
I13L O13L
S1
I13R O13R
I14L O14L
I14R O14R
Rotary kiln
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Page 33 of 33
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Rotary kiln

Kiln tyre with tangential suspension

Created by: KarS

Definitions and abbreviations

1.1 Construction and operating principle

2.2 Mounting of bushings on tyre sides

Fig. 1. Tyre and bushings

2.3 Tightening of bolts with a hydraulic bolt tensioner

Fig. 2. Hydraulic tool

2.4 Welding of retainer blocks to kiln shell

To check the marking-off, it will be of advantage to make an extra generatrix,

Fig. 3. Positioning of retainer block

2.4.4 Welding procedure

Fig. 4. Bottom run

Fig. 5. Transition layers

Fig. 6. Transition and filling-up layers

Fig. 7. Transition and filling-up layers

Fig. 8. Filling up layers

Layers must be completed as steps in order to secure a defect-free transition to

Stage 2 Stage 3 Stage 4

post-heat treatment). Insulation can be removed when temperature are below

Grinding of weld transition to kiln shell:

Transition to be executed as shown at figure 10, and to dimensions shown at

Final surface roughness Ra max. 6.3.

Tools recommended for grinding / polish:

One-hand polish machine for approx. 115mm soft disc.

Fig. 10. Transition zone grinding

2.5 Checking of welds

2.6 Mounting of tyre on kiln shell

2.7 Mounting of remaining retainer blocks

Fig. 11. Blocked-up kiln shell and tyre

As mentioned in section 2.5, it can be recommended that a ultrasonic test should

2.8 Adjustment of tyre position

Fig. 12. Positioning of erection wedges, etc.

Fig. 13. Centering of tyre

2.9 Mounting of axial retainers

Fig. 14. Adjustment of axial retainers

Fig. 15. Adjustment of tyre

Fig. 16. Round face next to welding foot

Fig. 17. Welding transition and corner to be ground

Fig. 18. Grinding tool

2.10 Mounting of first set of brackets

Fig. 21. Tyre with bracket, bolt and key

2.11 Mounting of wedges, cover plates, etc.

Fig. 22. Arrangement of wedge link

Instead of PBC, the following products can be used:

Klber Lubrication Grafloscon, Wolfracoat C

2.12 Erection of kiln shell and tyre on support

Fig. 23. Lifting the kiln section

Fig. 24. Measurement of kiln tube untrueness

2.13 Mounting of remaining parts

Fig. 25. Spring system

2.14 After erection

Lubrication D = per 8-h operation

4.3 Inspection and adjustment

4.4 Checking of condition

4.4.1 Kiln shell, retainer blocks, axial retainers

If cracks are discovered during any of the above-mentioned tests, we recommend

4.4.2 Wedge system

4.5 Spring tension

5.0 Key to figures and enclosures

01 Tyre with holes

20 Spindle for spring