INSTRUCTION MANUAL .

ROTARY KILN 70000457-1

Alignment of supporting roller bearings

and supporting rollers. Support type SA

ERECTION

In the text, reference is made to:

Ref. 1 *) Rotary kiln

General kiln instruction manual
Erection, operation and maintenance
Ref. 2 *) Rotary kiln plant, (dry process)
Safety regulations
Ref. 3 *) General safety regulations at sites of erection
Ref. 4 *) Rotary kiln
Alignment of self-adjusting bedplate
Erection

*) See note Instruction manual references in section 1.

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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CONTENTS: PAGE:
1. General notes .................................................................................. 4
2. Construction and operating principle ................................................ 5
3. Installation ....................................................................................... 6
3.1 Alignment of supporting bearings and supporting roller bearings................................... 6
3.2 Installation of supporting roller ........................................................................................ 6
3.3 Positioning of the supporting bearings relative to kiln axis.............................................. 7
3.4 Measuring tools............................................................................................................... 7
3.4.1 Theodolite .................................................................................................................... 7
3.4.2 Measuring tools............................................................................................................ 7
3.4.2.1 Measuring with tools ................................................................................................. 8
3.5 Marking the zero position of the bearings ..................................................................... 10
4. Operation ...................................................................................... 11
5. Maintenance .................................................................................. 11
6. Key to Appendices ......................................................................... 12

Edited by: KelH Translated by: Pages: 21

Approved by: KelH MGN code: 5A10
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APPENDICES:
App. 1. Sketch of bearing shell.............................................................................................. 13
App. 2. Erection tools ............................................................................................................ 15
App. 3. SA support ................................................................................................................ 17
App. 4. SA support ................................................................................................................ 19
App. 5. Marking plates........................................................................................................... 21
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NOTE!
The present instruction manual is concerned with the situations which,
according to the experience of FLS, are the most likely to occur. An
exhaustive enumeration of all conceivable situations which may occur in
connection with the installation, operation and maintenance of the kiln cannot
be provided.

Consequently, if a situation should arise, the occurrence of which is not

foreseen in the instruction manual, and which the operator is/or feels unable
to handle, we would recommend that FLS is contacted without undue delay
for advice on appropriate action.

1. GENERAL NOTES
This instruction manual describes how to perform the final
alignment of supporting roller bearings and supporting rollers
on a self-adjusting support, type SA.
It is a foregone conclusion that the bedplate has been aligned
and embedded exactly as specified in relevant instruction
manuals, see ref. 1.

References to instruction manuals

In the text of this instruction manual, reference is made to an
instruction manual reference No. where this is deemed to be
relevant.
The titles of all instruction manuals referred to are listed on the
front page of this instruction manual, with indication of the
number referred to.
Reference to other instruction manual numbers is done via the
General kiln instruction manual, ref. 1 in which relevant
instruction manual numbers can be identified on the basis of the
title of the relevant manual.

REQUIREMENT:
Bearings to be used exclusively for the aforementioned purpose!

MANDATORY!
The directions outlined in instruction No. ref. 2
"General safety regulations at erection site" must be
strictly observed at the site of erection. This
instruction manual must be scrutinized by the client,
the erection contractor and FLS representatives
before erection work is started.
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MANDATORY!:
The erection/maintenance activities described in the
following sections must only be carried out by skilled
machine specialists or subject to the supervision of
such specialists.

MANDATORY!:
In connection with arc welding and when operations
involving blowtorching with gouge are carried out, the
return cable must always be attached to the object
subjected to welding, as close as possible to the area
of welding.
The return cable must never be attached in a way
which will cause the return current to be passed
through parts not connected to the object being
welded, for example: moving parts, bearings,
electrical installations or any other parts.
A return current through a bearing may give rise to
welding scars which will cause severe damage to
bearing.
A return current through electrical installations may
cause serious damage to protective earth lines
(extremely hazardous condition!) or electronic
equipment.

Where ERECTION CHECK is specifically called for in the

erection manual, this means that the FLS erection supervisor
must inspect and approve the parts mounted before permission
to proceed with the erection work can be given.

2. CONSTRUCTION AND OPERATING PRINCIPLE

See instruction manual for supporting roller bearings and
bedplate.
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3. INSTALLATION
3.1 Alignment of supporting roller bearings and supporting rollers
Final positioning of supporting roller bearings in the
longitudinal direction of kiln following the fine alignment,
embedment and finish-mounting of the complete bedplate,
inclusive of tilting beams.
NOTE!:
In connection with the alignment of bearings and supporting
rollers, it is very important to protect the open bearings
against exposure to contamination. The period during which
the bearings are unprotected must be reduced to an absolute
minimum. The supporting rollers must be individually aligned
and it is the responsibility of the erection supervisor to make
sure that the final installation of bearings will take place
immediately after the alignment work has been completed. If
the operation is interrupted, for example at the end of the
working day, it is essential to ensure that the bearings are
covered to extent necessary.
It would be advisable to close the oil pockets along the
journal, using a length of duct tape.
Just before the top part of the bearing is remounted, the
bearing must be blown clean, and the tape ducts must be
removed.
During the installation procedure, the inspection covers
should be effectively secured to prevent them from being
opened by any unauthorized persons.
3.2 Installation of supporting roller
See Appendix 4.
The position of the bearings must be adjusted in the
longitudinal direction of kiln after the supporting roller has
been mounted in the bearings, but not until it has been eased
off completely.
Bearings to be positioned so that there will be a clearance
ranging from 5 to 8 mm between the bearing shell and the
thrust ring of the supporting roller shaft at the inlet side when
the thrust ring is lying true against the bearing shell at the
outlet side. See Appendix 4.
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If the second supporting roller has been aligned, endeavours

are needed to ensure that the two supporting rollers, to
maximum practicable extent, are flush in the longitudinal
direction of the kiln.
The next step involves welding-on of the guide blocks (21) on
the bearing beams along the outer side of the bearings to
prevent displacement of the bearings when subjected to the
axial loads which are transmitted to the bearings via the thrust
rings of the supporting roller shaft. The blocks are shown in
Appendix 5.
3.3 Positioning of supporting roller bearings relative to kiln axis
Check that the centre marking of the bedplate (the frame
structure) consistently matches the markings of the other
bedplates (the projection of kiln in the horizontal plane). See
instruction manual ref. 4.
For measuring tools, see section 3.4.
If no irregularities are ascertained, the supporting roller can
be moved to its final position relative the centreline (kiln axis).
The main priority is to attain parallelism between the
supporting roller and kiln axis, and, therefore, it will be
possible to position each supporting roller separately, thereby
minimizing the period of time during which the individual
supporting roller bearing is open and unprotected.
3.4 Method of measuring
Different methods of measuring can be used. The two
methods described in this manual have a record of success.
3.4.1 Theodolite
A theodolite is mounted in the centreline of the kiln on one of
the foundations. From the theodolite, the distance is
measured from the centreline to each bearing in the centreline
of the kiln.
The final C-measurements are indicated on the position
drawing of kiln. A measuring ruler is laid up against the
supporting roller shaft and a readout of the distance C-r can
be obtained through the telescope of the theodolite, see
Appendix 3.
After the measurements have been taken, it is essential to
check the position of the theodolite itself and to check the
direction in relation to the kiln centreline.
3.4.2 Measuring tools
See Appendix 2.
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Make a set of measuring tools consisting of 1 measuring rod

(18) and 2 measuring angles (14) as illustrated in Appendix 2.
Only one set of measuring tools is used for the entire kiln.
The measuring rod (18) must be straight, and its length must
be determined in relation to the largest c-measurement on the
position drawing. To prevent the rod from being turned when
measuring is done, a short piece of flat iron (19) is welded to
the rod as illustrated in Appendix 2, fig. 4.
The measurement C-r must be indicated on the measuring
rod for each support, for example by scribing thin lines using
white lacquer paint. The lines must be thin and sharp in order
to ensure precision of measurements. See Appendix 2, fig. 5.
Make the measuring angles (14) of sectional iron in a
dimension which will provide the necesssary degree of rigidity,
as illustrated in Appendix 2, fig. 1.
By welding on a thin plate (15) and on the basis of marking,
the centre of which must indicate the front edge of the
measuring angle (Fig. 3), the angle can advantageously be
used also for mounting the frame structures on the
foundations. In the vertical legs of the angles a number of
holes (16) must be drilled; the distance of these holes from
the foot of the angle must be equal to the roller centre height
J (see position drawing) + thickness of the plate (19), which is
indicated here to be 6 mm.
The number of holes depends on the specific number of
different bearing sizes (heights J) which exist for the kiln in
question.
3.4.2.1 Measuring with tools
One of the adjusting units (25) used for kiln erection can
advantageously be used; it should be tack-welded to the
bedplate so that the measuring angle can be moved to
different positions when alignment of the different bearings is
being carried out, see Appendix 3.
Fix the angles on the frame so that they lie true against a
piano wire or a straightedge which in turn must be lying true
against the centre marking blocks (22). See Appendix 4.
When fixing the angles, the inclinometer (17) should be used
to check that the angles are identically positioned. If
necessary, thin shims must be inserted under the end of the
foot of one angle.
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Effective clamping of the measuring angles must be ensured

to prevent them from coming out of alignment, even when
subjected to moderate impacts.
Place the measuring angle in the angle, and perform
measurements directly in relation to the bearing journal. The
mark for the support involved must be flush with the front
edge of the measuring angle when the distance is correct.
See Appendix 2, fig. 2.
When the distance at both bearing journals is correct, the
supporting roller will be correctly positioned relative to the
centreline (kiln axis).
Fix the bearings to the bearing beam, and make sure that the
adjusting screws (20) exert a moderate pressure against the
base of bearing.
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3.5 Marking the zero position of the bearings

On completion of check measurements, and any necessary
corrections, the zero position of the bearings on the bearing
beams must be marked off by means of clearly visible chisel
cuts or heavily inscribed lines immediately opposite each
other in bearing housing and bearing beam, possibly in guide
block (21), as illustrated in Appendix 5.
It is of paramount importance that this marking is done very
carefully, and as soon as the position of roller is found to be
correct this will be the only visual way of checking that the
bearings are correctly positioned during the ensuing erection
process.
The supplied brass plates (angles) (23) must not be mounted
until at the final stages of kiln erection; otherwise, they are
prone to disappear during the process. This factor further
emphasizes the importance of the chisel cut markings.
The brass plates must be mounted so that their edges are
flush and positioned exactly on-line with the marks on the
guide block. The pointed end of the plates must be facing
the adjusting screw (20). Threaded holes must be drilled in
the bearing housing as well as the guide block.
After the plates have been fixed by means of screws and the
screw heads have been secured by means of chisel cuts, the
two pointed ends must be very carefully trimmed (using a
smooth-cut file) so that they form a coinciding face (24).
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4. OPERATION

Not described in this instruction manual.

5. MAINTENANCE

Not described in this instruction manual.

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6. APPENDICES

01. Support plate for rocker bearing

02. Rocker bearing
03. Tilting beam
04. Elastomer bearing
05. Bearing beam
06. Supporting roller
07. Adjusting screw
08. Central frame
09. Hinged bearing
10. Supporting bracket with elastomer bearing
11. Bearing
12. Fondation bolts
13. Foundation
14. Measuring angle
15. Thin sheet with central marking
16. Hole for measuring rod
17. Inclinometer
18. Measuring rod
19. Flat iron
20. Adjusting screw
21. Guide block
22. Central marking block
23. Brass plate
24. Faces which must be flush
25. Adjusting unit
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Appendix 1. Sketch of bearing shell

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14. Measuring angle

15. Thin sheet with central marking
16. Hole for measuring rod
17. Inclinometer
18. Measuring rod
19. Flat iron
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Appendix 2. Erection tools

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25. Adjusting unit

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Appendix 3. SA support
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Appendix 4. SA support
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11. Bearing

20. Adjusting screw

21. Guide block

23. Brass plate

24. Faces which must be flush
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Appendix 5. Marking plates

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