Manual Hornos KHD

Sub-assembly description
BA C07143 USA
Part B:
• Sub-assembly descriptions for rotary kiln -

GB 413-0038 USA
Drawing No. ZD 413-0187
State: 413.480 / 01.2007

Cover sheet 7 von 23
Technical Machinery Documentation Edition: 03.2008
Table of Contents of GB 413-0038 USA

Sub-assembly Descriptions Page 1 of 5
(Section: III B)
Contents Page
1 Contents of sub-assembly description: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Introduction in sub-assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Sub-assembly drawing - ZD 413-0187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

GB 413-0038 en
Former edition:
1 Contents of sub-assembly description:

BA No. Drawing No.
Sub-assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0187
1. Rotary tube . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001 USA ZD 413-0178
2. Bearing assembly I and II . . . . . . . . . . . GB 413-0002 USA ZD 413-0184
3. Longitudinal guide system

of the kiln . . . . . . . . . . . . . . . . . . . . . . . . BA 413-151 USA ZD 413-151
Hydraulic unit. . . . . . . . . . . . . . . . . . . . . BA 413-0255 USA
4. Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 413-0271 USA
5. Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020 USA ZD 413-0189
Pneumatic inlet seal . . . . . . . . . . . . . . . BA 413-0273 USA ZD 413-0200
6. Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030 USA ZD 413-0192
7. Accessories . . . . . . . . . . . . . . . . . . . . . . . . .For relevant documents see under

"List of separate documentation"
8. Optional equipment . . . . . . . . . . . . . . . . . .For relevant documents see under

Modifications in this edition:
Special descriptions:
• Tire fastening mechanism . . . . . . . . . . . . . BA 413-0171 USA
• Adjusting instructions . . . . . . . . . . . . . . . . BA 413-005/1 USA
• Expansion and shrinkage processes . . . . BA 413-049/1 USA
• Brick retaining rings for rotary kilns. . . . . BA 413-064/2 USA
• Kiln centerline surveying . . . . . . . . . . . . . . BA 413-0226 USA
GB 413-0038 USA; Page 2 of 5
Table of Contents of Sub-assembly Descriptions (Section: III B)
2 Introduction in sub-assembly description
Note!
The descriptions of the sub-assemblies always relate only to

the components which are supplied by HWI or as drawings.
For example, if the customer provides the gears with attach-
ments, the description of the sub-assembly drive only relates
to girth gear and pinion.
The rotary kiln consists of the following machine components:
1. Rotary kiln tube
2. Bearing assemblies
3. Longitudinal kiln guide system
4. Drive
5. Inlet
6. Outlet
7. Accessories
8. Optional equipment
9. Inner assemblies (if applicable)
Depending on the specific case, it may be that either all nine components are installed or only single
ones, e.g., the drive or just an inlet seal. The different machine components are matched to and
combined with each other relative to the particular plant design. Special attention is attached to cer-
tain criteria, such as service life and parts commonality, when selecting machines and units.
The machine components of the rotary kiln are robust, powerful and well-suited for continuous oper-
ation — even in case of harsh environmental conditions.
Provided the kiln is carefully serviced and operated gently as specified, it will operate essentially
trouble-free over many decades.
The different kiln components are made up of the following parts:
1. Kiln tube
- A tube with welded-in i.e., sections, manhole covers and brick retaining rings
- Mounted tires, loose sliding plates and a sturdy locking device
- Sliding plates for receiving the ring-gear fastening mechanism
GB 413-0038 USA; Page 2 of 5

GB 413-0038 USA; Page 3 of 5
2. Bearing assemblies
- Bearing brackets with built-in supporting rollers and shafts, base frames embedded in
concrete in the foundation with anchoring system and locking elements for the bearing
brackets
3. Longitudinal kiln guide system

- A thrust roller bracket with built-in thrust roller which can be shifted on two guide rails and
is carried in anti-friction bearings
- Single-acting hydraulic pressure cylinder
- Complete hydraulic unit with piping up to the pressure cylinder and a local pressure
gauge
- Base frame with anchoring system and locking device for the thrust roller bracket
4. Drive
- Split ring gear fastened to the kiln tube in a resilient manner
- Pinion with shaft carried in single-pinion bearing brackets in anti-friction bearings
- Base frame with anchoring system and locking device
- Wheel protection box with inspection doors and acceptance device for the spray lubrica-
tion system
- Coupling between transmission gear and main gear
- Main gearbox
- Base frame with anchoring system and fastening elements
- Lubrication set for lubricating the main gearbox
- Coupling between main gearbox and main motor including dual shoe brake and limit
switch
- Main motor (part of electrical engineering)
- Coupling between main and auxiliary gearbox
- Auxiliary gearbox with built-in free-wheel and attached flange pump
- Centrifugal clutch with centrifugal bracket between auxiliary gearbox and motor
- Motor
- Centrifugal clutch between motor and diesel engine
- Diesel engine with attached gearbox
- Base frame with anchoring system
5. Inlet
- Conical cast segment ring
- Scoop ring with built-in scoop pockets
- Pneumatic seal
GB 413-0038 USA; Page 3 of 5

GB 413-0038 USA; Page 4 of 5
6. Outlet
- Outlet ring with welded-in cast brick-retaining ring and welded-on supporting arms onto
which the single-part cast segments are plugged
- Spring-loaded seal
- Split closed circular cooling pipeline
- Two cooling air fans
- Collecting chute for clinker dust
- Kiln hood with split door, measuring socket, inspection doors
- Seal between kiln hood and clinker cooler
7. Accessories
- Temperature monitoring of bearings of supporting rollers, thrust roller, pinion and main
gearbox
- Grease spray unit for lubricating pinion and ring gear
- Graphite lubrication for lubricating the anti-friction bearings of the thrust-roller bracket
- Grease lubrication system for the thrust roller running surface
- Manual spray unit for lubricating tire bore and tire locking blocks
- Supply unit for cooling water (air) (for supporting roller bearings, main gearbox)
- Guards as protection against radiant heat and inadvertent contact (supporting roller
bearings, thrust roller bracket, drive)
8. Optional equipment
- Relatyrex
- Tire section cooling system, two fans/tire
- Ring gear cooling system, two fans
- Sintering zone cooling system, either displaceable or stationary type
9. Inner assemblies (if applicable)
GB 413-0038 USA; Page 4 of 5

GB 413-0038 USA; Page 5 of 5
3 Sub-assembly drawing - ZD 413-0187
GB 413-0038 USA; Page 5 of 5

GB 413-0038 USA
• Kiln tube - GB 413-0001 USA

State: 413.480 / 01.2007

Operating instructions GB 413-0001 USA
to rotary tube Page 1 of 3

GB 413-0001 en
Former edition:
Fig. 3
Contents of the operating GB 413-0001 USA
instructions to rotary tube Page 2 of 3
Contents of the operating instructions:

State: 03.2008 General . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-01 USA
* General information
State: 03.2008 Safety and Health . . . . . . . . . . . . . . . . . . . . GB 413-0001-02 USA

* Safety information
* General safety information

GB 413-0001 en
Former edition:
State: 03.2008 Design and functioning . . . . . . . . . . . . . . . . . GB 413-0001-03 USA

* Design
* Functioning
State: 03.2008 Transport . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-04 USA

* Transport
State: 03.2008 Assembly . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-05 USA

* Information
* Tyres, tyre fastening
* Tube- and tyre sections
* Welding and weld seam check
* Girth gear and girth gear fastening
* Deviations from the rated measure in the kiln length
* Deviations from the rated measure - foundation height
* Deviations from the rated measure - diameter of tyres and roller
* Documentation of the rotary tube positions
State: 03.2008 Commissioning . . . . . . . . . . . . . . . . . . . . . GB 413-0001-06 USA

* Preparatory measures
* Commissioning conditions
State: 03.2008 Operation . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-07 USA

* Operating conditions
State: 03.2008 Maintenance . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-08 USA

* Information
* Inspection, maintenance and repair
* Installation of spare parts
State: 03.2008 Spare parts keeping and after-sales service . . . . . GB 413-0001-09 USA
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0178
GB 413-0001 USA; Page 3 of 3
Contents of the operating instructions to rotary tube
Further pertaining operating instructions:
• BA 413-064
• BA 413-0171
• BA 413-138
• BA 413-0233
• BA 413-049
Commissioning - operating instructions
• BA 841-......
Pertaining technical delivery specification:
FV 413-007, Part 1 and Part 2
GB 413-0001 USA; Page 3 of 3

GB 413-0001-01 USA
General
Page 1 of 1
Contents Page
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0001-01 en
1 General information
Former edition:
Note!
See information in the “General” section “Operating instructions

rotary kiln tube” of the Technical Machinery Documentation.
GB 413-0001-02 USA
Safety and Health
Page 1 of 1
Contents Page
1 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GB 413-0001-02 en
Former edition:
1 Safety information
The rotary tube is a hazardous zone which is secured against free access.
Two risks must be particularly pointed out, i.e.:
• Risk of winding up by rotating tire, girth gear, fixings, holders,

yokes and manhole cover.
• Risk of burning due to hot shell surface of the rotary tube.
Generally, repair and checking works are only permitted to be performed at the rotary tube
with the tube standing still or slowly turned via the auxiliary drive.
2 General safety information
Note!
Further safety information as per section "Operating instructions

rotary kiln", item "General safety information" of the Technical
Machinery Documentation.
Otherwise, all legal safety and accident prevention regulations must be observed.
GB 413-0001-03 USA
Design and functioning
Page 1 of 3
Contents: Page
2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Rotary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Tire sections with fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0001-03 en
2.3 Girth gear section with sprig plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Former edition:
3 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Note!
See information in chapter “Design and Functioning“ in

section "Operating instructions rotary kiln tube" of the
Technical Machinery Documentation.
2 Design
Note!
The following item numbers refer to drawing No. ZD 413-0178 in

the annex to this description.
2.1 Rotary tube

The rotary tube (item ) is made of structural steel plates.
The plate thicknesses depend on the admissible reference tensions of the tube. Near the
tires (Item 2) and the girth gear (Item 3), the tube sections are reinforced.
In the inlet area, the tube section ends with a flange (Item 4) and a sheet cone (Item 5).
The scoop ring with the spring seal is bolted to the flange (Item 4). In front of the sheet
cone (Item 5), a brick-retaining ring (Item 6) is welded, taking the thrust of the bricks in the
conical inlet area.
The position of the brick-retaining ring is determined by the brick supplier.

GB 413-0001-03 USA; Page 2 of 3
On the outlet side, the last tube section only comprises a chamfer for welding the outlet end sec-
tion with the spring seal.
2.2 Tire sections with fastening

The non-worked tire sections are chamfered at their ends and executed with a round seam
chamfer for welding the field sections.
As in the case of the field sections, also at the inner side of the tire section at both ends, subsidi-
ary lines for the assembly are punched in to ensure parallelism when welding the sections toge-
ther.
The tires are loosely mounted to the tire sections and underlaid with slide plates (item 8). On the
longitudinal axis, the tires with the guide blocks (Item 9) are fixed.
Depending on the tire clearance at the respective assembly, the slide plates are of different thick-
ness. Observe the correct assignment.
The guide blocks (item 9) on the inlet side are of identical design as on the outlet side.
They are arranged such that the slide plates can be withdrawn without any problem without
requiring to burn off the guide blocks.
To permit the replacement of the slide plates, only the retaining plates (item 10) must be remo-
ved. The retaining plates are not welded to the tube but only to the guide blocks so that the for-
mation of cracks in the tube is avoided.
On the tire sections, a marking is punched in permitting the exact positioning of the guide blocks.
2.3 Girth gear section with sprig plates

The girth gear section (Item 11) is of similar design as the tube sections. Its thickness is matched
to the reinforcement sections connected to the tire section. With more than 10 spring plates (Item
12), the girth gear section accommodates the split girth gear (item 3).
The spring plates are fastened to the girth gear with screw-type bolts (item 13) and with cap
screws (Item 14) to the girth gear section. The spring plate end on the tube side has oblong holes
facilitating the alignment of the girth gear.
3 Functioning
The rotary tube is the part of the rotary kiln plant, where the flowing in raw meal is burnt to clinker.
During the burning process, the tube is subject to high thermal stress.
To avoid overheating, the inside of the tube is completely lined with refractory bricks.
The suitable brick quality and laying of the bricks in an expert-like manner has to be performed
duly observing the bricklining instructions of the brick supplier. The brick-retaining rings must be
aligned rectangularly to the circular weld seams.
GB 413-0001-03 USA; Page 2 of 3

GB 413-0001-03 USA; Page 3 of 3
The brick ring following the outlet-side brick-retaining ring must be laid with particular care. It
must be in complete contact with the entire surface to ensure that the brick thrust is uniformly
accepted. Also see BA 413-064.
The rotary tube is supported on the supporting rollers and is driven via the girth gear, the driving
force being transmitted onto the tube via the tangentially arranged spring plates. These resilient
connection elements also balance the thermal expansion of the kiln tube and, in this way, avoid
that girth gear or tooth engagement are affected.
GB 413-0001-03 USA; Page 3 of 3

GB 413-0001-04 USA
Transport
Page 1 of 1
Contents: Page
1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0001-04 en
Former edition:
1 Transport
The rotary tube provided with priming is delivered to the site in reinforced transport units.
Tire fastening, spring plates, manhole covers and hardware are transported in boxes and
grate boxes.
The transport packing and preservation of the tires and of the girth gear depends on the
destination and the transport route.
Note!
Also see chapter "Transport" in section "Operating instruc-

tions rotary kiln" of the Technical Machinery Documenta-
tion.
GB 413-0001-05 USA
Assembly
Page 1 of 30
Contents: Page
1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Tires, tire fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Tube- and tire sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GB 413-0001-05 en
3.1 Condition upon delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Signing of the tube elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Former edition:
4 Welding and weld seam check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Preparatory works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1.1 Matching of the tube elements/round seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1.2 Mounting the round seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1.3 Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1.4 Installation of pulling and pressure angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1.5 Lifting and ratchet tackle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1.6 Screw-type blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1.7 Wedge-type carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1.8 Force pieces with hydraulic lifting blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.9 Welding of the round seams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.10 Assembly of the kiln tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.11 Supporting scaffolding (e.g., for a rotary kiln Ø 4,6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.12 Travelling path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1.13 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Regulations for welding of kilns of structural steels and special structural steels. . . . . . . . . . . . . 21
4.2.3 Weld seam check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Girth gear and girth gear fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Deviations from the rated measure in the kiln length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Deviations from the rated measure - foundation height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8 Deviations from the rated measure - diameter of tires and roller . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.1 Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Documentation of the rotary tube positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

GB 413-0001-05 USA; Page 2 of 30
Assembly
1 Information
Note!
See information in chapter “Assembly” in section “Operating instructions

Note!
The item numbers indicated below refer to drawing No. ZD 413-0178 in the
annex to this description.
Note!
See description:
- Tire fastening BA 413-0171
- Girth gear alignment BA 413-138
- Manufacturing instructions FV 413-007
2 Tires, tire fastening

To avoid an exchange by mistake during the installation of the tires, refer to data on the tire itself.
Nevertheless, it is recommended to check the main measures - in particular the tire bore.
The same applies for the slide plates and the fixing elements.
Prior to mounting the parts, the protective painting must be removed from the slide and rolling
surfaces and be replaced by suitable lubricants or preservation agents.
3 Tube- and tire sections
3.1 Condition upon delivery

In the case of the rotary tube, tire and tube sections (field sections) are to be distinguished. The
sections are prepared in the workshop ready for being connected, provided with reinforcements
and signed. Depending on the diameter of the rotary kiln, for reasons of transport and weights,
the tube sections are delivered to the site as individual sections or as so-called “long transport
tube sections”, which were assembled in the workshop from several individual sections.
To ensure an alignment of the rotary tube without deflection, the tire sections are generally deliv-
ered as individual parts (sometimes with welded reinforcement sections.)
On the tire section, the position of the tire is punched in.
Following these punched-in markings, some or all of the outlet-side guide blocks are distributed
over the circumference and tack-welded.
GB 413-0001-05 USA; Page 2 of 30

GB 413-0001-05 USA; Page 3 of 30
Assembly
The tube sections (field sections) are simple tube elements which can differ in length depending
on the graduation and have different plate thicknesses.
Depending on the assembly equipment and the local situation, the tube section is mounted into
the tire (horizontal installation) or the tire is mounted onto the tube section (vertical installation),
see detail “S”. Then the slide plates are slid between tire and tube shell. The parallelism of the
slide plates to the kiln axis must particularly be ensured to avoid jamming.
If corrections must be made, they are to be performed at the guide blocks and not at the slide
plates. (Rolled slide plates can possibly not be withdrawn; also spare slide plates would not fit
without subsequent working).
After the installation of the slide plates, the residual guide blocks (item 9) and the retaining plates
(item 10) are welded in place.
Note!
Further information regarding tire fastening can be found in BA 413-0171.
All tube sections are delivered with chamfered welding edges for welding the round seams.
When assembling the transport sections, the longitudinal seams must be offset by 180° or 90°.
The joints of the tube sections are aligned according to the punched-in subsidiary lines and the
inner diameters; possible dimensional deviations must be uniformly balanced.
The tire sections of all assemblies must be on one axis; only in this way, a centrical movement of
the rotary tube is possible.
Theoretical support:
Theoretically, the smooth field sections between the tire sections can be installed eccentrically to
the kiln axis; in this case, the tube would run like a crankshaft, but always centrically at the sup-
porting points.
The brick-retaining ring on the inlet side is welded in as directed by the brick supplier.
3.2 Signing of the tube elements

The individual tube elements or transport sections are marked by a continuous numbering with
Roman numerals, beginning with the figure I at the kiln inlet.
The tube sections belonging together are continuously marked with identical letters, beginning
with A-A at the kiln inlet (see kiln drawing and dispatch sketch).
Nameplates installed in the joint areas of every transport section serve for the more detailed
identification with specific data.
(Nameplate designation HM 105 x 148 HU 699 acc. to drawing 850-17-299 EE).
GB 413-0001-05 USA; Page 3 of 30

GB 413-0001-05 USA; Page 4 of 30
Assembly
4 Welding and weld seam check
Note!
Also see FV 413-007; Part 1 and 2.
4.1 Preparatory works

Prior to starting welding, extensive and thorough preparations must be made.
Only when all necessary pre-conditions have been met, the welding works can be made.
4.1.1 Matching of the tube elements/round seam

As already mentioned under 3.2, on the assembly nameplate, the circumference of the inner sec-
tion is indicated for every tube joint seam.
Due to the manufacturing method, normally, the inner tube diameter specified by the manufactur-
ing area cannot be observed so that the actual tube diameter can only be calculated via the inner
circumference determined after the manufacture (see Fig. ZB 413-0005).
Upon the assembly of the tube elements, from the different tube diameters, an offset over the
entire length of the round seam results. This offset must be uniformly balanced over the tube cir-
cumference with the aid of a template. Balancing must be made in the kiln interior, which particu-
larly applies to the round seams on either side of the tire sections. The template, Fig. ZB 413-
0006, must be especially manufactured on the site for every round seam.
4.1.2 Mounting the round seam

For mounting of the round seam, the following assembly aids are required (see Fig. ZB 413-0007
to ZB 413-0012):
- Skids
- Assembly of pulling and pressure angle
- Lifting or ratchet tackle
- Screw-type blocks (force piece)
- Carriers with wedges (force piece)
- Force piece with hydraulic lifting blocks
4.1.3 Skids
The skids serve for roughly combining the tube elements. Normally, 4-6 skids are symmetrically
distributed over the circumference and welded into the tube element with the smaller diameter
(Fig. ZB 413-0007).
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Assembly
4.1.4 Installation of pulling and pressure angles

The pulling and pressure angles for the assembly comprise two reinforced angles and a threaded
spindle with nuts and washers. Normally, they are welded into the interior of the tube elements
on either side of the round seam and serve for the parallel alignment of the tube elements
towards each other.
The number of the pulling and pressure angles for the assembly depends on the site conditions
and must be determined by the fitter. In the case of light field sections which are mounted on the
floor or on the supporting scaffolding, the parallel alignment can be made using the lifting tackles
which are slung to the tube reinforcements.
When aligning the tire sections, however, the pulling and pressure angles must be used, i.e.
depending on the kiln diameter, 8-12 units per round seam (Fig. ZB 413-0008).
4.1.5 Lifting and ratchet tackle

With the lifting or ratchet tackle, the parallel alignment and the alignment of the tube elements
among them can be performed. The equipment can be slung at the tube reinforcements or at
additionally welded eye plates (Fig. ZB 413-0009).
4.1.6 Screw-type blocks

With the screw-type blocks, the offset of the individual tube elements is uniformly balanced over
the tube circumference. To that end, the screw-type blocks (2 units, each) are alternating welded
to the entire inner circumference of the round seam at a distance of approximately 700 mm.
At particularly out-of-round points, further screw-type blocks must be welded. By tightening or

loosening the compression screw, the offset of the tube shell is balanced (Fig. ZB 413-0010).
4.1.7 Wedge-type carriers

The wedge-type carriers can be used instead of the screw-type blocks for mounting the tube ele-
ments. This should only be done if screw-type blocks are not available and cannot be procured
(Fig. ZB 413-0011).
The wedge-type carrier comprises the carrier proper and the wedge. The carriers are alternat-
ingly welded to the entire inner circumference of the section at a distance of approcimately 300-
400 mm. At particularly out-of-round points, further wedge-type carriers are welded. The tube off-
set is balanced by driving in the wedges underneath the recess between the wedge-type carriers.
Here, the wedges are driven in from the side of the carrier, which is fastened by 2 spot-weldings.
The wedges must be secured against falling down by tack-welding.
Disadvantages compared with the screw-type block include:
1. Precision alignment to 1/10 mm not possible;
2. Use on narrow space not possible;
3. Upon overpressing of the tube offset, the wedges must be hit back which, for reasons of
space, is frequently very difficult.
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Assembly
4. Annoying noise development, in particular upon works on Sundays and holidays.
4.1.8 Force pieces with hydraulic lifting blocks

Force pieces with hydraulic lifting blocks are used for the parallel matching of the tube elements
among them and for balancing the tube offset especially at flat areas of the tube shell.
Force pieces and lifting blocks must generally be secured against slipping and hitting off, unin-
tended turning over, etc. (Fig. ZB 413-0012).
4.1.9 Welding of the round seams

The completely mounted field sections must be tack-welded and the round seams be finish-
welded (see item 4.2). The assembly aids must be removed for being reused later on. Remaining
tack-weld seams of the assembly aids must be ground to the level of the sheet. Damaged kiln
sections (scores) must be welded and then ground to the level of the sheet.
4.1.10 Assembly of the kiln tube

Also see Technical Delivery Regulations for Rotary Tubes FV 413-007, Part 1, 2.
Prior to the assembly of the kiln tube, the auxiliary structure and the lifting equipment must be
installed and provided, respectively, depending on the assembly procedure.
See operating instructions “Rotary kiln”.
A further pre-condition is the finish-mounted kiln support as well as the rough installation of the
individual parts, assembly sections, tire sections with mounted tires etc. on the kiln tube axis.
4.1.11 Supporting scaffolding (e.g., for a rotary kiln Ø 4,6)

Before mounting the supporting scaffolding, the base frame must be aligned to the rollers. The
supporting scaffolding comprises the following:
1. Supporting girder (thrust girder)
2. Spacer lock
3. Bracings
4. Supports
5. Load distribution and balancing material
6. Runways (operating platform)
7. Connection girders
8. Bracket carriers
9. Bracket elements
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Assembly
10. Friction carriage
See pictures ZB 413-0013 to ZB 413-0015.
The supporting carriers (item 1) (IPE 550) must be mounted at the respective kiln inclination
between the individual foundations from base frame to base frame or between kiln inlet at the
preheater and assembly I and between kiln outlet at the burner platform and the last assembly.
It must be particularly made sure that the measure indicated in the drawing between “Upper edge
base frame” and “Upper edge supporting girder” is observed.
The spacer locks (Item 2) (Æ 65 x 9 with pressure chuck) and bracing angle (item 3) are bolted
between the webs of the supporting girders (item 1) laid in parallel using the gusset angles (L
200 x 100 x 16). Here, it must be made sure that the centre of the supporting scaffolding field is
precisely matching the longitudinal kiln axis.
In the case of large spans between the individual foundations, the supporting girders (item 1)
must be supported at the points indicated in the respective assembly drawing. This is done with
the aid of supports (item 4), which are bolted underneath.
The supports (item 4) normally comprise 2 supporting girders of steel sections connected by
spacer girders and bracings. At their base, they are provided with pressure claws permitting an
alignment at the desired height with the aid of hydraulic pumps.
Caution!
Prior to supporting, it must be checked, whether the ground is capable of

bearing (cable ducts, underground tube ducts etc.)
The runways (item 5) on either side of the supporting girders are made by clamping continuous
angular sections (L 180 x 80 x 12) crosswise underneath the supporting girders and then placing
wooden beams on them.
Clamping is done with clamping angles (L 120 x 80 x 12) mounted to the lower flanges of the
supporting girders. The supporting angles of the runway are arranged at a distance of always 1.5
meters and their long arms show downwards. On the right and the left of the supporting girders,
they protrude such that 4 wooden beams and one beam are always in an inclined upward posi-
tion can be accommodated. At the end of the runway angles, the railing rods are bolted in place.
Upright wooden beams are placed against them to avoid falling down of tools, etc.
Towards the outside, the runways are secured by ropes wound through the railing rods at the
height of the knees and of the railing. The runways must be continuously mounted along the
entire supporting scaffolding.
Note!
The runways serve as operating platforms and for placing down tools; how-
ever, they are not meant as supporting surface for pumps!
Moreover, the supporting scaffolding also comprises the bracket elements (item 9), the bracket
carriers (item 8) and the connection girders (item 7).
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Assembly
A bracket element (item 9) comprises web plate, blades and reinforcing ribs. The upper flange
blade and the web plate are always matched to the outer diameter of the kiln to be installed. To
achieve an as exact and plain contact surface between kiln tube and bracket element, the
bracket elements can be matched to the different outer diameters of a kiln using shims. Always
two identical bracket elements form one bracket pair. The bracket pair is bolted to the bracket
carrier (item 8) arranged cross to the longitudinal kiln axis.
In its central area, the bracket carrier, an IPB 450 of 4.0 m in length is reinforced by two plates
welded in parallel to the web between upper and lower run. In a cross-direction, it is braced with
ribs. It uniformly distributes the load over the connection girders (item 7) and friction carriages
(lined rollers) (item 10) onto the supporting girders (item 1).
The connection girders 7 (IPE 300-1200 long) are bolted crosswise underneath the bracket carri-
ers. At the ends of the connection girders, supporting areas for hydraulic pumps are provided for
by welding of protruding girder elements (IPB 200). Between connection girder and supporting
girder, friction carriages can be used for displacing the load or blocks for placing down the load.
To avoid lateral sliding down of the friction carriages (item 10) upon a displacement, at their outer
sides, the supporting girders are provided with guide strips (FL 30 x 50).
When mounting the supporting girders to the foundations of the assemblies at the preheater and
the burner platform, for a better load distribution and for adjusting to the desired height, load dis-
tribution girders (item 6) and balancing liner plates are installed. Upon smaller loads, also suit-
able beams of hard wood can be placed underneath.
Depending on the situation, likewise, load distribution girders, stacking irons, liner plates, crane
mats etc. are placed underneath the supports (item 4). When the supporting elements should
come into contact with cable ducts or other supply ducts in the ground, these must be bridged by
cross girders or be bypassed by supports in the ground.
4.1.12 Travelling path

The travelling path essentially comprises the same structural elements as the supporting scaf-
folding.
Contrary to the supporting scaffolding, the travelling path girders are continuously mounted at the
respective kiln inclination from the kiln inlet at the preheater beyond the foundations of the
assemblies towards the kiln outlet at the burner platform. Also here, the measure between upper
edge base frame and upper edge travelling path girder given in the drawing must be exactly
observed.
The entire construction of the travelling path is dimensioned considerably stronger since, to give
an example, it must carry a load of approximately 200 t. This means that an individual travelling
path girder can accept an individual load of approximately 50 t at any point of its length.
The travelling path girders are designed such that, in the area of the roller and drive assemblies,
they can be withdrawn. This is necessary for the assembly of a kiln, which is only accessible from
one point. Here the rollers must first be placed onto the individual foundations via the travelling
path and be placed down laterally to the travelling path. After having closed the travelling path by
the installation of the removable parts of the travelling path girders, the assembly of the kiln tube
elements can be started.
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Assembly
After the kiln tube elements with the tires have been slid into their limit position, the tires can be
slid together again. This is a disadvantage compared with the supporting scaffolding as, in the
case of the supporting scaffolding, the tires can be placed onto the pertaining base frame and
durably mounted.
For kiln bearings, which are assembled on the site and whose bearings must be bedded in on the
site as well, it is always recommended to first move them over the travelling path and mount
them in the specified position onto the base frame. Then, the completely mounted tire bearing
must be laterally displaced, until the travelling path can be closed.
As already mentioned above, the travelling path is used where an unhindered access to the
entire kiln line is not possible. Placing the kiln elements onto the travelling path can be done at
any access point, from where the parts are moved into their final position.
4.1.13 Illustrations
850-17-299 EE - Assembly nameplate
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Assembly
ZB 413-0005 - Offset at the round seams
UI UII
DI =
π DII =
π
( DII - DI )
V=
2
Calculation example:
Given: UI = 14445 ; UII = 14461
Searched for: DI ; DII and V
UI U ( DII - DI )
DI = DII = II V=
π π
14445 14461 ( 4603 - 4598 )
DI = DII = V=
3,1416 3,1416 2
2
DI = 4598 DI = 4603 V = 2,5
==== ==== ===
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Assembly
ZB 413 - 0006 - Template for offset
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Assembly
ZB 413-0007 - Skids for the assembly of the tube sections
Example:
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Assembly
ZB 413-0008 - Pulling- and pressing angle - parallel tube section alignment
Example:
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Assembly
ZB 413-0009 - Lifting tackle/eye plate - joining of the tube sections
Example:
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Assembly
ZB 413-0010 - Screw-type block for precision-mounting

of the tube sections
Example:
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Assembly
ZB 413-0011 - Wedge-type carrier for mounting the tube elements
Example:
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Assembly
ZB 413-0012 - Force piece - rounding of the tube sections
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Assembly
ZB 413-0013 - Kiln tube assembly with supporting scaffolding

Example:
Preliminary assembly of the kiln tube sections to suitably assembly tube section length, partly performed on the ground.
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Assembly
ZB 413-0014 - Cross section supporting scaffolding

Example:
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Assembly
ZB 413-0015 - Detail supporting scaffolding - longitudinal section

Example:
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Assembly
4.2 Welding
4.2.1 General
The weld seams are prepared such that welding can be performed by hand or according to the
submerged-arc method. The height of the weld seams or the offset in the tube section in the tube
interior must not exceed 2 mm.
The special references in the execution drawings regarding the quality of the weld seams must
be observed.
The executing welding company is obliged to evidence the quality The assessment is made by
the (executing) institute in charge according to the regulations indicated in the welding test plans.
As far as required, the costs for the checks as well as for repairs will be borne by the welding
company.
In case of differing assessments of the welding company and the institute, our responsible site
manager will make a final decision.
4.2.2 Regulations for welding of kilns of structural steels and

special structural steels
General remarks
These assembly regulations serve as working instructions for the site upon welding works to the
following steels:
Material-No.
As per DIN EN 10025 - 1.0116 S 235 J2G3
1.0038 S 235 JRG2
1.0050 E 295
1.0570 S 355 J2G3
DIN EN 10028 - 1.0425 P 265 GH

1.0481 P 295 GH
1.5415 16 Mo 3
1.7335 13 CrMo 4-5
Fine-grained structural steels DIN EN 10113
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Assembly
The following references must be observed and followed for a proper execution as directed and
for an economic operation:
Caution!
Welding at temperatures below +5°C should be avoided.

Welding below + 0°C is prohibited.
a) Preparation of the working place
b) Welding machines and equipment
c) Heat treatment upon welding of fine-grained steels
d) Tack-welding and welding of the root pass
e) Filler metal as per DIN EN 499
f) Filler metal for submerged-arc welding, EN 756 / EN 760
g) Seam preparation and building up of a weld seam
h) Assembly aids
i) Jointing and grinding
Note a) Preparation of the working place

The area respectively to be welded must be protected against weather influences
which could affect the welding result.
This comprises:
- Protection against sudden temperature deviations

- Protection against rain
- Protection against excessive cooling down by wind
The ground of the welding machines must always be clamped to the part (kiln tube) to
be welded.
Caution!
During all welding works, it must be avoided that welding currents flow
through bearings (anti friction and slide bearings) as well as over the
toothings.
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Assembly
Note b) Welding machines and equipment

Depending on the electrode type and the planned type of welding, welding transform-
ers or welding rectifiers shall be used as welding current generator. The machine type
coming into question must have suitable characteristics for welding of lime-basic elec-
trodes. In particular, an excessively long electric arc must be avoided which strongly
reduces the protective effect of the gas flow from the electrode lining and can lead to
the formation of pores in the weld seam.
For jointing with the electric carbon arc, a welding current source is necessary having a
capacity of at least 600 Ampere.
Welding transformers are not suited for welding of lime-basic electrodes as they only
generate alternating current.
Note c) Heat treatment upon welding of fine-grained steels

According to the regulations of the steel manufacturer, prior to welding, all seams
including tack-welded seams and weld seams for all assembly aids must be amply pre-
heated, i.e. ,100 mm on either side of the parts to be welded.
During welding, it must be made sure that the temperature is maintained. The preheat-
ing temperature is 100°C. Preheating is realized with propane gas (if necessary, with a
neutral oxygen-acetylene flame). The temperature is checked with color-changing pins
(thermochromic pins). Sufficient keeping warm during welding must be ensured. (After
burning, leave burner still on the seam for some time).
The regulations for working of fine-grained structural steel SEW 088 and prEN 1011
must be observed.
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Assembly
Note d) Tack-welding and welding of the root pass

Also see Fig. 1.
Tack-welding over 8
points. These welding
Applying of the root points must be
layer by two weld- extended to approxi-
ers. They weld in mately 500 mm after
one axis whose the completion of the
points are opposite assembly. Then,
to each other. place the root into the
remaining open areas.
Fig. 1
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Assembly
Note e) Filler metal as per DIN EN 499

As filler metal for manual arc welding, the electrode E424B42H5 is used. The electrode
is welded to the plus pole of the direct current.
The electrodes must be stored at a dry place on the site and must be dried again 2
hours before welding at 300 - 350°C (see instructions on the packing).
Only small quantities for one section shall be handed over to the welders to ensure dry
welding of this electrode type (use electrode bag!).
Note f) Filler metal for submerged arc welding, EN 756 / EN 760

Beyond arc welding, also the submerged arc welding method is applied for round
seams or longitudinal seams.
Filler metals:
Electrode wire of quality S 2, EN 756
The wire must be free from grease and rust.
The welding powder is an alkaline powder in agglomerated condition.

Make OP 100 - Oerlikon.
DIN EN 760 A AB 1 76 AC
After 2 hours, welding powder must be re-dried at 300-350°C. For welding, only re-
dried and warm powder is permitted to be used. When picking up the non-molten and
warm powder, it must be made sure that no dust particles and residues enter the weld-
ing powder.
The welding voltage upon submerged arc welding must be at least 23 V. It must, how-
ever, not exceed 35 V. A welding speed must be selected which is not below 35 cm/min.
Note g) Seam preparation and building up the weld seam
Fig. 2
The flanks of the weld seam or the areas to be welded must be dry and free from scale,
rust and contaminations.
During welding, as many thin beads should be applied as possible to achieve a favor-
able structural condition. For the individual layers, it must absolutely be made sure that
the correct temperature is observed. It must not exceed 250°C (thermochromic pins).
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Assembly
Upon welding of the final pass, a height banking in horizontal position (w) of 2 mm and
in vertically ascending position (s) of 2.5 mm are admissible.
After every interruption of the works including cooling down of the material, new pre-
heating to 100-150°C is necessary. Interruptions should be avoided.
The risk of crack formation can be reduced if the preheating temperature (100°C) is
maintained also 1 hour after welding and the material is then slowly cooled down (re-
heating, covering by mineral wool mats).
Note h) Assembly aids

Assembly aids should be welded as little as possible. If this cannot be avoided, welding
must be made using an electrode with large expansion (EN 499: E42 4B42 H5), (dou-
ble-pass welding). Auxiliary assembly weldings in the case of fine-grained steels must
be made in two single passes with preheating to 100°C. Tack-weldings should have a
length of 50 mm at a minimum.
For removing assembly aids welded on one side, the hollow weld is notched by grind-
ing and broken off over the notched seam. In the case of assembly aids welded on two
sides, notching is made on one side and the residues are broken off over the non-
notched seam. If assembly aids are burnt off, the torch cut must be distant enough from
the base material to avoid a thermal influence. At those points where assembly aids
were mounted, the surface must be ground smooth and the material checked for cracks
(spot check). Upon grinding off of the residues, an excessive spot heat must be
avoided.
Note i) Jointing and grinding

Working out of the seam root - in the case of fine-grained steels, preheating is neces-
sary (50°C) - is performed with an electric carbon arc (gouging torch).
The carbon rods have a diameter of 6 or 8 mm. The compressed air with a pressure of
approximately 4-5 bar must be cleaned from water and oil.
After jointing, the seam root must be ground metallically blank.
To avoid cracks caused by grinding, the grinding disc must be permanently moved dur-
ing grinding. An excessive grinding pressure must be avoided. Upon temperatures
below + 5 °C, the material must also be heated up to 50°C to avoid thermal shock
cracks during grinding.
When grinding within the seam joints, only grinding machines with electrical drive shall
be used. It must be avoided that, when using a compressed-air machine, oil is
entrained into the weld seam joint.
4.2.3 Weld seam check

All weld seams must be subjected to a thorough check.
Circumference and quality of the check are laid down in the Manufacturing Instructions FV 413-
007.
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Assembly
5 Girth gear and girth gear fastening

The girth gear is delivered in two halves.
Normally, the halves are individually mounted.
Caution!
When mounting the spring plates, the correct sense of rotation must abso-
lutely be made sure. The tube is drawn off the girth gear and not pushed.
View: always from outlet to inlet.
The 10 girth gear shoes (item 15), to which the spring plates (item 12) are bolted with the girth
gear, are only tack-welded in the workshop to permit corrections during aligning of the girth gear.
The threaded bores for the cap screw (item 14) must be covered with Anti-Seize or a similar
grease to facilitate dismantling. The reference surfaces of the girth gear halves must be in com-
plete contact to ensure a proper screw connection.
The screw bolts shall only be tightened with a dynamometric key (defined tightening torque).
Further information for the assembly and the alignment of the girth gear may be taken from
BA 413-138 and the assembly drawings.
Caution!
Also during the assembly phase, e.g., for welding of the tube sections, the
girth gear must not be driven without sufficient lubrication of the tooth
flanks.
First rolling of the tooth flanks is of decisive importance for the service life
of the girth gear and the pinion. In this early state, frequently, the first
cracks are already developing which can, later on, lead to considerable
damage.
6 Deviations from the rated measure in the kiln length

The lengths of the individual tube sections have a tolerance of ± 2 mm.
The inaccuracies can be up to + 100 mm depending on the kiln length. This means that the
machines and facilities, which are to be mounted to the kiln ends and are depending on the
length measures of the kiln, must initially be mounted only loosely.
Especially in regions with hot climate, the shell temperature on the sunny side must be observed.
(The thermal expansion of steel is 1.2 mm at 100°C and 1 m length.) At a length of a tube section
of 10 m and at a temperature difference of 60°C between the sunny side and the shady side, the
length change is
10 x 1.2 x 0.6 = 7.2 mm
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Assembly
7 Deviations from the rated measure - foundation height

The height measure from assembly to assembly is permitted to deviate from the rated measure
by 5 mm at a maximum. As soon as this measure is exceeded, the position of the supporting
roller bearings must be accordingly corrected. See calculation examples under 7.1.
In the case of unstable grounds, it is recommended to check the height markings at the individual
kiln foundations. This in particular applies to regions, where the ground tends to sink and earth-
quakes can occur.
7.1 Calculation example
5600 + 1800
Z = ------------------------------ = 3700
2
X = 3700 × sin 30° = 1850
Y = 3700 × cos 30° = 3204, 3
If the kiln tube is lifted by 40 mm, for the measures Y' and X', the following calculation results.
Y′ = 3204, 3 + 40 = 3244, 3
2 2
X′ = ( 3700 – 3244, 3 ) = 1788, 9
This means that every bearing must be slid towards the inside by 1850 - 1788.9 = 71.1.
If the kiln tube shall be lowered by 40 mm, for Y” and X”, the following calculation results:
Y′′ = 3204, 3 – 40 = 3164, 3

2 2
X′′ = ( 3700 – 3164, 3 ) = 1917, 6
This means that every bearing must be slid towards the outside by 1917-1850 = 67.
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Assembly
8 Deviations from the rated measure - diameter of tires and roller
8.1 Calculation example
5600 + 1800- = 3700

Z = -----------------------------
2
X = 3700 × sin 30° = 1850
Y = 3700 × cos 30° = 3204, 3
If the diameter of tire or roller is reduced by 50 mm, the measure is:

Z′ = 3700 – 25 = 3675
2 2
X′ = ( 3675 – 3204, 3 ) = 1799, 5
That means, every bearing must be displaced by

A = 1850 - 1799,5 = 50,5 mm
towards the inside.
If the diameter of tire or roller increases by 50 mm, the measure is:

Z′′ = 3700 + 25 = 3725
2 2
X′′ = ( 3725 – 3204, 3 ) = 1899, 5
That means, every bearing must be slid by

B = 1899,5 - 1850 = 49,5 mm
towards the outside.
From this example, it can be seen. Measures A and B are nearly identical.
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Assembly
General rule:
In case of changes of the measures of a total of 50 mm, the change of the diameter (tire and/or
supporting roller) = displacement path to the inside or outside.
9 Documentation of the rotary tube positions

After the completion of the assembly of the rotary tube, the position of the tires and the girth gear
to the supporting rollers/thrust rollers or to the pinion must be documented.
These basic values are important to permit the determination of the final position of the support-
ing rollers/thrust rollers and of the pinion after some weeks of varying operating conditions.
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GB 413-0001-06 USA
Commissioning
Page 1 of 2
Contents: Page
1 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Commissioning conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0001-06 en
Former edition:
1 Preparatory measures
Prior to commissioning and after the completion of all assembly works, the rotary tube
must be subjected again to a thorough inspection and functional check.
The following must be particularly observed:
a) Have all assembly aids and facilities been removed from the rotary tube?
b) Have all springs plates been arranged in the correct sense of rotation?
c) Have all manhole covers been closed and secured?
d) Have the contact surfaces tire/guide block at all assemblies been sufficiently covered
with lubricant?
After the final check and necessary repair works, if any, commissioning can be performed.
2 Commissioning conditions
Note!
References given in the operating instructions BA 841-… must

absolutely be observed!
Also see chapter “Commissioning” in section “Operating ins-

tructions rotary kiln”
The rotary tube does not require special measures to be taken prior to starting the plant.
After the ignition of the burner, the time schedule given in the commissioning instructions
BA 841-… must be observed.
A deviation from the start-up program can lead to a restriction of the tube in the tire area
and, hence, damage to the bricklining.
GB 413-0001-06 USA; Page 2 of 2
Commissioning
Also cold sets between tire and slide plates can occur, which lead to the formation of chips and
material breakouts. See BA 413-0171.
In particular during the initial phase of commissioning, special attention must be paid to the girth
gear to exclude initial damage to the gear flanks. Observe the position of the girth gear to the
pinion, temperature changes on the inlet and outlet side of the girth gear, backlash etc.
Note!
Also see
- BA 413-138 (Spray lubrication)
- BA 413-0233 (Splash lubrication)
GB 413-0001-06 USA; Page 2 of 2

GB 413-0001-07 USA
Operation
Page 1 of 1
Contents: Page
1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0001-07 en
1 Operating conditions
Former edition:
Note!
Also see chapter "Operation" of the operating instructions

to the rotary kiln.
During operation, the rotary kiln must be carefully observed and, if abnormal changes
should occur, suitable measures must be taken. See chapter "Maintenance".
An important operating phase is the planned shutdown of the plant. Prior to starting the
shutting down program, the rotary tube must be moved to its topmost position and main-
tained there.
This measure avoids the kiln sliding too rapidly into the direction of the outlet due to lea-
kages in the hydraulic system and the thrust roller housing reaching the mechanical stop.
If the kiln remains at the mechanical stop for a longer time and is neither turned nor tilted,
there is the risk of an overload (about the 8-fold of the force of its dead weight when inc-
lined).
Note!
Also see BA 413-049.
If the circumstances permit it, this procedure should also be followed up on extraordinary
shutdowns. If not, interval turning should be made as early as possible.
As with start-up, shutting down of the plant must also take place as specified in the pro-
gram.
Note!
See commissioning instructions

BA 841-....
It is important that the shrinking tensions which built up between the tires and the suppor-
ting rollers are balanced.
In case of heavy rainfalls, depending on the shell temperature of the kiln, the auxiliary
drive should be used to keep the tube constantly rotating.
GB 413-0001-08 USA
Maintenance
Page 1 of 4
Contents: Page
1 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Inspection, maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Preliminary bending of the kiln axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Lasting deformation of the kiln axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Measurement and monitoring of the kiln shell temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0001-08 en
3 Installation of spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Former edition:
1 Information
Note!
For maintenance lists, see section "Maintenance" of the Tech-

nical Machinery Documentation and section "Operating ins-
tructions rotary kiln tube" (section IIIA)
Spare parts lists as per section "spare parts" of the Technical

The item numbers indicated below refer to drawing No.

ZD 413-0178 in the annex to this description.
2 Inspection, maintenance and repair

The rotary tube as part of the kiln plant should be inspected daily (see section "Mainte-
nance" of the Technical Machinery Documentation). Any irregularities must be eliminated.
When and how this has to take place is decided by the plant manager or a staff member
nominated by him. In particular, proper functioning of the rotary kiln must be ensured.
Upon changing operating conditions, not only the geometry of the kiln can change, but
also the shell surface.
If, for example, partial lining defects should occur, red spots develop which, if not elimina-
ted in time, can lead to dent-like deformations and restrictions.
Red spots can be covered by the meal accretions when suitably operating the kiln, provi-
ded the spots are not too large.
Upon the next shutdown, such an area must be repaired.
Observe all safety regulations in the chapter "Safety".

GB 413-0001-08 USA; Page 2 of 4
Maintenance
2.1 Preliminary bending of the kiln axis

Preliminary bending of the kiln axis can occur if the plant is shut down and it is not made sure in
time that the system is cooled on either side with the main or auxiliary drive. The material layer in
the kiln which is still hot keeps the lower side of the material warm, while the upper side can cool
down. Under normal weather conditions, the kiln can remain stationary for about 15 minutes
without the risk of serious deformations.
If, however, the kiln can be turned only later on, i.e., after 15 minutes, it must not be completely
turned. When turning it by always 400-500 mm, an as uniform shell temperature as possible is
reached.
The above in particular applies when the kiln is started up or upon a power failure and, at the
same time, during heavy rainfalls. Upon rainfalls, bending can occur already after some minutes.
The resulting bend will regulate itself without lasting damage after the shell temperature has
been balanced again.
2.2 Lasting deformation of the kiln axis

A lasting deformation results if a bricklining defect occurs which leads to larger red hot spots in
circumferential direction of the tube.
In the long run, such a damage can only be eliminated by replacing the tube section.
2.3 Measurement and monitoring of the kiln shell temperature

For various reasons, measurement and monitoring of the kiln shell temperatures are very impor-
tant for a safe and trouble-free kiln operation.
• The heating and cooling procedures as well as the continuous operation of the kiln must be
monitored, duly observing the instructions of the manufacturer of the refractory material.
Note!
Moreover, the tire clearance must be monitored - see operating ins-

tructions BA 413-0171.
• As regards the material strength of the kiln shell, a maximal temperature of 350°C is a refe-
rence value as, upon higher temperatures, the strength values for the normally used materi-
als are no more clearly defined.
Up to a shell temperature of 400°C, there is no direct risk, if the kiln is continuously turned.
Upon temperatures above 400°C, there is a serious risk for the rotary kiln shell.
Causes for such high shell temperature can be:

– Insufficient, defective or too thin bricklining
– Wrong bricklining quality
– Wrong flame guiding at the rotary kiln burner
GB 413-0001-08 USA; Page 2 of 4

GB 413-0001-08 USA; Page 3 of 4
Maintenance
If excessively high shell temperatures should occur, the causes must be eliminated immedi-
ately.
• By a continuous temperature monitoring of the kiln shell, e.g., with the SCANEX® diagnosti-
cal aid via infrared light, the development of bricklining defects can be counter-acted in time.
The actual lining thickness, the accretion situation and the heat loss are caught early and
calculated.
Changing accretion situations permit conclusions to changes in the raw meal chemistry, the
fuel properties or the flame guiding.
A strongly unilateral accretion over an extended length can become critical for the kiln tube,
as the temperatures over the circumference of the tube can be very different and this, in
turn, can lead to a distortion of the kiln tube. When operating such distorted tube, increased
tensions can cause cracks in the kiln shell. Also the supporting and driving elements (tires,
supporting rollers, girth gear, pinion, foundations etc.) are subjected to an increased stress.
Unilaterally forming accretions must be recognized in time so that they can be counter-acted
by changing the flame guiding.
A kiln which is already distorted must be aligned directly when in warm condition again. To
that end, the kiln is stopped for a short time in a position which leads to balancing of the tem-
perature difference at the circumference.
By measuring and checking the kiln shell temperatures, changes and their influences are
recognized in time and defects avoided.
3 Installation of spare parts

Defective components affecting proper functioning of the rotary tube should be replaced by new
ones for reasons of economy and safety.
Spare parts are only permitted to be installed and dismantled

when the rotary kiln is cold.
The safety references and regulations must be observed.
When installing spare tire or tube sections, ensure that the torch cut for the new round seam is
not guided within the old one, but at least 50 mm behind it. That means that the old round seam
must also be removed.
The distance between the new round seam and the old one must be 500 mm at a minimum.
If slide plates are replaced, the sheet thickness must previously be determined.
If guide blocks are completely or partly replaced, exact flushing of the contact surfaces to the tire
must be ensured.
GB 413-0001-08 USA; Page 3 of 4

GB 413-0001-08 USA; Page 4 of 4
Maintenance
Note!
Detailed procedure as per BA 413-0171.
If spring plates are installed, also the fastening bolts must be completely replaced and, if neces-
sary, also the supporting shoe with the threaded bores.
GB 413-0001-08 USA; Page 4 of 4

Spare parts keeping and GB 413-0001-09 USA

after-sales service Page 1 of 1
Contents:
GB 413-0001-09 en
Former edition:
Note!
See the information in “Spare parts keeping and after-sales

service" in section "Operating instructions for rotary kiln"
of the Technical Machinery Documentation.
GB 413-0038 USA
• Bearing assemblies I and II

- GB 413-0002 USA
State: 413.480 / 01.2007

Operating instructions to GB 413-0002 USA
supporting roller bearing Page 1 of 2

GB 413-0002 en
Former edition:
Contents of the GB 413-0002 USA

operating instructions to Page 2 of 2
supporting roller bearing
State: 03.2008 General . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0002-01 USA

State: 03.2008 Safety and Health . . . . . . . . . . . . . . . . . . . . . GB 413-0002-02 USA


GB 413-0002 en
Former edition:
* Design
* Functioning
State: 03.2008 Transport . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0002-04 USA

* Transport
State: 03.2008 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0002-05 USA

* Information
* Base frame and anchoring
* Bearing block with installed supporting roller
* Assembly of bearing, supporting roller and axle on the site
State: 03.2008 Commissioning . . . . . . . . . . . . . . . . . . . . . . GB 413-0002-06 USA

* General Information
* Start of commissioning
* Completion of commissioning
State: 03.2008 Operation . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0002-07 USA


* Information
State: 03.2008 Spare parts keeping and after-sales service . . . . . . GB 413-0002-09 USA
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0184
Further pertaining operating instructions:
BA 413-005
BA 822-0001 - Handling of lubricants
HW 6302 - Table of lubricants

GB 413-0002-01 USA
General
Page 1 of 1
Contents Page
GB 413-0002-01 en
Former edition:
Note!
See information in the chapter “General”, in section “Operating

instructions rotary kiln tube” of the Technical Machinery Docu-
mentation.
GB 413-0002-02 USA
Safety and Health
Page 1 of 1
Contents Page

GB 413-0002-02 en
Former edition:
The supporting roller bearing is located within a hazardous zone where the following risks
must be kept in mind:
• Risk of winding up by rotating holders of the kiln tube.
• Risk of burning by the hot kiln tube.
• Risk of pulling in by the tire rolling on the supporting rollers.
Note!
Further safety information as per the "Operating instructions

rotary kiln" section, item "General safety information" of the
Technical Machinery Documentation.
GB 413-0002-03 USA
Page 1 of 4
Contents: Page
1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Supporting rollers with axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Supporting roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Graphite lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Heat protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0002-03 en
1.5 Resistance thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 Base frame with fixing and anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Former edition:
2 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Design
1.1 Supporting rollers with axles

The supporting rollers (1) are made of cast steel or forged steel and mounted in hot condi-
tion onto the axles. For taking the axial pressures, every second axle is also provided with
shrunk-on collar rings (2). The collar rings have oil collection grooves.
Oil scoop rings (9) are mounted at the front sides of the axles, oil scoop rings.
The supporting rollers are 50mm wider than the tires.
1.2 Supporting roller bearing

The supporting roller bearing is made of grey cast iron and executed as double slide bear-
ing.
The bearing shells (7) are half-shells made of special alloyed material.
The bearing seat is enclosed by two chambers through which the cooling water flows.
Underneath the water chambers, oil ducts are laid ensuring the oil balance in the front and
rear oil chambers.
Via scoop pockets (10) flanged to the axle, oil is directed onto the journal via the baffle
plates (4, 11) and then drawn into the bearing shells.
The standard equipment of a bearing comprises on the water inlet side a short pipeline
(26) with control gates (27) and on the water outlet side an overflow hopper (25) for the
pressureless cooling water discharge.
GB 413-0002-03 USA; Page 2 of 4
Control openings have been provided for in the top sections of the bearing blocks which are cov-
ered with Plexiglas panes (18) and aluminium covers (15).
Towards the supporting roller side, the bearing housing and the rotating axle are sealed by a
stuffing box (29) against the entrance of water and dust.
The head side of the bearing housing is closed with a front cover (6).
The exact center of the bearing is marked with a 5 mm bore at the front end of the bearing block
bottom section. Underneath, a longitudinal opening is provided for extending over the entire
width of the oil chamber. This opening is closed with a sheet plate (19).
In this sheet plate or in the lower section of the cast body, an oil draining screw (23) is mounted.
The oil level is checked with an oil dipstick (13) located in the upper section of the bearing block.
The oil dipstick has a maximum and a minimum marking.
The bearing inner space is vented via venting screws arranged in the vertex of the bearing block
top section.
At the front sides of the bearing, nameplates are mounted (20) indicating the following data:
– Bearing type
– Bearing point
– Oil type
– Oil change
For example:
Type DGL 550 = bearing type
Bearing point II LT = assembly II, left top
Oil type = to be entered by the operator
Oil change = to be entered by the operator
Oil type and oil change are punched into a sheet strip by the operator and slid into the name-
plates from the side.
1.3 Graphite lubrication

The contact surface of the supporting roller is lubricated with graphite. The graphite lubrication
(44) comprises a graphite block (46), an adapter element (45) of hard wood and a weight sup-
ported in articulated hinges.
1.4 Heat protection

The bearing body, in particular the bearing journal area, is protected against dissipated heat by a
heat protection shield (40).
This is a double-walled construction which is fastened to the bearing.
The pulling in area of tire/supporting roller is protected by protective plates (41).
GB 413-0002-03 USA; Page 2 of 4

GB 413-0002-03 USA; Page 3 of 4
1.5 Resistance thermometer

Threaded bores are provided for in the bearing top sections through which the resistance ther-
mometers (43) are introduced.
The sensors of the thermometers are in contact with the bearing shell collars, i.e., the surfaces
where the highest temperatures are expected.
The measured data are transmitted to the control stand.
1.6 Base frame with fixing and anchoring

The bearing blocks are placed on base frames (30) which are mounted in the foundations.
The base frames are made of several parts and of welded design.
The installation surfaces for the bearing blocks and the joints of the individual connection girders
are mechanically worked.
The base frames are anchored with foundation bolts in the foundation.
The bearing blocks are radially and axially kept in place with fixing elements. Some bearing
blocks are additionally flanged to the base frame with hammer head bolts (38).
The fixings are made of loose fixing blocks (33) and fixing elements (35-37) rigidly mounted to
the base frame. The rigid radial fixing comprises a retaining plate (36) with welded in articulated
bolts (37) plugged into the base frame, a pair of wedges (35) and spacer plates which are
clamped between the wedges and the worked contact surfaces of the bearing block.
The retaining plate is additionally bolted to the base frame plate with two screws.
The rigid axial fixing comprises a sheet block rigidly welded to the base frame and loose spacer
plates. The radial and axial fixing blocks included in the supply unpacked only serve for adjusting
or displacing the bearing blocks.
2 Functioning
The bearing blocks with the installed supporting roller vertically support the rotary tube. The sup-
porting rollers are arranged to the tires at an angle of less than 30°.
The bearing blocks accept radial as well as axial forces. The radial forces are introduced into the
supporting roller axle and then into the bearing shells, the axial forces via the collar rings into the
bearing shell collar.
Lubrication is done via scoop pockets which scoop the oil from the sump and pour it via the baffle
plates onto the shaft journals. The excessively scooped oil volume is collected in the upper
chamber above the shaft journal and in the space at the partition surface of the bearings so that
always sufficient oil is available to ensure an optimal oil supply.
The water flowing through the water chamber and around the bearing shell makes sure a contin-
uous reduction of the generated friction heat and of the dissipated heat taken by the bearing
body.
GB 413-0002-03 USA; Page 3 of 4

GB 413-0002-03 USA; Page 4 of 4
The flow volume can be regulated as required with a control valve. This is of particular advantage
if, upon a temperature rise at a bearing, the latter can be supplied with a larger water volume.
Normally, a temperature rise occurs, if the oblique setting of the bearings is not correct (see BA
413-005). In this case, the collar ring presses the shaft too strongly against the bearing shell col-
lar and this area is overheated.
This is the most frequent cause for bearing defects. The position of the collar ring towards the
bearing shell collar can be checked through the cover opening in the bearing block top section. A
temperature increase is immediately detected by the resistance thermometer and transmitted to
the control stand so that measures can be taken without delay, e.g., a reduction of the axial pres-
sure by reducing the friction between tire and supporting rollers.
In such a case, mostly the graphite lubrication is not sufficient and an additional volume of lubri-
cant must be applied to the contact surfaces.
GB 413-0002-03 USA; Page 4 of 4

GB 413-0002-04 USA
Transport
Page 1 of 1
Contents: Page
1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0002-04 en
Former edition:
1 Transport
Normally, the bearing block is delivered to the site with the supporting roller and shaft
already installed. In the case of bearing blocks with split pan, a suitable wooden substruc-
ture must be built onto which the bearing with the hanging supporting roller is placed and
tightened with ropes.
The contact surfaces of the roller must be protected with wooden boards.
The bearing covers are closed to prevent the entry of foreign particles into the bearing
interior. Hardware such as water connections are packed in boxes. The bearing is shipped
without oil filling.
For transport, the bearing block unit may be slung only at the suspension eyes or hooks
that are color-marked and specifically provided for that purpose.
Note!
Also see the "Transport" chapter in the "Operating instruc-

tions rotary kiln" section of the Technical Machinery Docu-
mentation.
GB 413-0002-05 USA
Assembly
Page 1 of 14
Contents: Page
1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Base frame and anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Preliminary assembly of the base frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Preparatory measures for the final assembly and alignment of the base frames . . . . . . . . . . . . . . . . . 2
2.3 Tools and aids for aligning base frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GB 413-0002-05 en
2.4 Aligning the base frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.5 Control measurements and entering of data into the measuring protocol for rotary kilns and drums with
Former edition:
measuring plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Grouting of the base frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 List of pictures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Bearing block with installed supporting roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Assembly of bearing, supporting roller and axle on the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Information
Note!
See information in the “Assembly” chapter in the “Operating instructions

rotary kiln tube” section of the Technical Machinery Documentation.
Note!
Observe installation references in the assembly drawings!
2 Base frame and anchoring

2.1 Preliminary assembly of the base frames

In the workshop, the base frames are mechanically worked in assembled condition, provided
with measuring points and, for the transport, disassembled into several pieces.
Prior to assembly, the mechanically worked surfaces must be cleaned, i.e., protective paint-
ings must be removed. The frames, in particular the worked surfaces, must be carefully
checked for defects which could affect the aligning precision or the assembly.
The frame is assembled on the ground, generally on a plain surface.

GB 413-0002-05 USA; Page 2 of 14
Assembly
When the frame is completely assembled, all mechanically worked frame elements must form a
plain surface without offsets. The measuring points must be flush in all directions and axes. This
is checked with a ruler (for reasons of stiffness, with I-shaped cross section) with a precision
according to DIN 874, Sheet 1, for precision mechanical engineering.
2.2 Preparatory measures for the final assembly and

alignment of the base frames
The first work to be done is to determine height and position of the lining (stack of lining plates of
different thickness) between upper edge of foundation and lower edge of base frame.
Perform the following steps:
3. Transmit cross axis Qa-Qc onto the base frame foundation (recess in the concrete base)
and mark it with chalk (see Fig. ZB 413-0020).
4. Starting from the cross and kiln axis, determine the position of the liner plate stacks and
mark it with chalk. For number and arrangement of the liner plate stacks, see Fig. ZB 413-
0020.
5. Irregularities in the foundation surface near the liner plate stacks must be balanced with a
mortar layer following the inclination of the kiln.
6. Take height of grouting from construction drawing and installation plan. For minimum
grouting height, see Fig. 413-0020.
7. Measure the ACTUAL height of the base frames and compare it with the RATED height as
per Fig. ZB 413-0021 and the base frame assembly drawing (order-dependent).
8. Determine the height of the individual liner plate stacks from reference points Qa, Qb and
Qc (see Fig. ZB 413-0020 and ZB 413-0021). The reading must remain by 3-5 mm below
the RATED height. The kiln inclination is also decisive for lining the remaining intermediate
space.
9. Pile up liner plate stack and combine the plates of every stack to a block by tack-welding.
10. Place base frame. Check whether the foundation bolts can still be tightened after
placement of the base frame. Otherwise, the foundation bolts must be suspended into the
anchoring holes of the foundations prior to placing the frame.
Caution!
Instead of the liner plate stacks, also levelling spindles can be used.
The height is adjusted with a fork wrench at the spindle nut. The levelling
spindles are also grouted.
GB 413-0002-05 USA; Page 2 of 14

GB 413-0002-05 USA; Page 3 of 14
Assembly
2.3 Tools and aids for aligning base frames

Toothed-rod winches, lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 t
Hydraulic presses (Lukas), lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 20 t
Levelling instrument
Measuring rod with millimeter graduation (see Fig. ZB 413-0022)
3 suspension angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 400 mm long
Flat angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 400 mm long
Measuring tape (plastic-coated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 m long
Steel measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 mm long
Steel measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 mm long
3 rulers (depending on kiln size, for reasons of stiffness

with I-shaped cross section, DIN 874, Sheet 1) . . . . . . . . . . . . . . 3-5 m long
Steel wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 0.5 mm
General fitter's tools
Spacer screws as per Fig. ZB 413-0023
Possibly required number of levelling spindles with accessories
2.4 Aligning the base frames

1. For the measuring points and axes on the base frames, see fig. ZB 413-0021.
2. For the proper running of a rotary kiln, the precise alignment of the base frames is of
decisive importance.
These works must be performed with utmost care. For the alignment, a tolerance of
+ 0.10 mm for height, inclination and surface evenness is binding; and for axes + 0.50 mm
is binding.
3. The first work to be done is aligning the placed base frame to the kiln cross and longitudinal
axes within a range of millimeters.
4. Next, match the spacer screws as per Fig. ZB 413-0023 and the arrangement as per Fig.
ZB 413-0020 and weld them in place. The spacer screws are also grouted later on. With
the spacer screws, the base frame must be aligned to the kiln cross and longitudinal axes
according to the specified tolerance.
5. The foundation bolts must now be mounted and grouted.
The hardening time for the grouting compound is approximately 3 days.
GB 413-0002-05 USA; Page 3 of 14

GB 413-0002-05 USA; Page 4 of 14
Assembly
6. After hardening, the base frame must be aligned with the levelling instrument to the
specified rated height and inclination via the measuring points on the base frame and the
markings on the foundations. Also see reference in Fig. ZB 413-0021.
To ensure the complete contact of the kiln bearings, the contact surface must be checked
with rulers reaching over the entire length and width of the base frame and accordingly
aligned (for tools see Item 2.3).
Irregularities in the surfaces must be balanced with additional liner plate stacks or using
clamp-type bridge girders and presses (see Fig. ZB 413-0024). The clamp-type bridge
girders must be removed only after grouting and hardening of the base frames (for control
measurements and grouting, observe Item 2.5 and 2.6).
In the case of base frames for bearing blocks with split (open) pan (roller sagging towards
the bottom), it must be made sure that the water draining tube is welded in at the deeper
side of the pan.
All foundation bolts must be repeatedly tightened during the alignment. After grouting and
hardening of the base frames, the foundation bolts are finally re-tightened.
7. It is considered understood that the base frame of an assembly must be seen as one unit.
This means that, according to the specified tolerances, the axes of the frames must be
flushing, the height be identical and the inclination meet the requirements of the kiln
installation plan.
2.5 Control measurements and entering of data into the measuring protocol
for rotary kilns and drums with measuring plan
See “Operating instructions rotary kiln”.
Prior to grouting of the base frames, generally, the rated dimensions according to the kiln instal-
lation plan as well as the pertaining measured values (actual measures) must be checked
together with the representative of the customer and/or the representative of Humboldt Wedag.
The values must be entered into the measuring plan and confirmed by the signature of the cus-
tomer or Humboldt Wedag.
The control measurements must be repeated prior to commissioning and to handing over of the
kiln to the customer.
All subsequent works at the kiln, e.g., repairs, start with a control measurement as described
above and with the comparison with the old measurements (settlings!).
2.6 Grouting of the base frames

Grouting of the base frames must be supervised by the assembly staff. Here, it must be made
sure that the foundations are free from contaminations, oil, grease, etc., that the specified grout-
ing height is observed, permanent openings at the frame are well and safely covered and that,
during the compaction of the concrete, shakers do not come into contact with the concrete.
GB 413-0002-05 USA; Page 4 of 14

GB 413-0002-05 USA; Page 5 of 14
Assembly
2.7 List of pictures
ZB 413-0020 - Assembly of the base frames

ZB 413-0021 - Supporting roller base frames, survey
ZB 413-0022 - Measuring rod
ZB 413-0023 - Spacer screw with pressure plate
ZB 413-0024 - Clamp-type bridge girders
2.7.1 ZB 413-0020 - Assembly of the base frames
Assembly of the base frame:
1. Assembly of the base frame on the ground on an even surface

2. Transmit cross axis Qa-Qc onto the base frame foundation
3. Mark position of the liner plate stacks
4. Apply fine layer of mortar in direction of kiln inclination
5. Pile up liner plate stack up to 3-5 mm below RATED height and weld in place
6. Place base frame (if required, previously suspend anchor)
7. Align base frame to longitudinal and cross kiln axis (+0.5 mm)
8. Match spacer screws and weld them in place
9. Mount foundation bolts and grout them
10. Align inclination of base frame at RATED height (+ 0.10 mm)
GB 413-0002-05 USA; Page 5 of 14

GB 413-0002-05 USA; Page 6 of 14
Assembly
2.7.2 ZB 413-0021 - Supporting roller base frame, survey
GB 413-0002-05 USA; Page 6 of 14

GB 413-0002-05 USA; Page 7 of 14
Assembly
2.7.3 ZB 413-0022 - Measuring rod
Item Units Object Length kg/m kg

1 1 Round rod 16 Ø 2100 1,58 3,32
2 1 Sheet 30 · 4 400 0,94 0,38
3 1 Handle O 8Ø 210 0,34 0,07
4 1 Clamp Bl. 30 · 4 40 0,94 0,04
Total weight 3,81
====
GB 413-0002-05 USA; Page 7 of 14

GB 413-0002-05 USA; Page 8 of 14
Assembly
2.7.4 ZB 413-0023 - Spacer screw with pressure plate
Item Units Object Length kg/m kg

1 1 Pressure rod 100 490 10,6 5,19
2 1 Sheet60 · 10 90 4,71 0,42
3 1 Hex. bolt M24 - DIN 933-m 100 0,423 0,42
4 1 Nut M 24 - DIN 555 0,103 0,10
5 1 Washer 25 - DIN 126 0,031 0,03
6 1 Pressure plate 80 · 10 500 6,28 3,14
Total weight 9,30
====
8 units per base frame = 74,40
====
16 units per assembly = 148,80
=====
GB 413-0002-05 USA; Page 8 of 14

GB 413-0002-05 USA; Page 9 of 14
Assembly
2.7.5 ZB 413-0024 - Clamp-type bridge girder
GB 413-0002-05 USA; Page 9 of 14

GB 413-0002-05 USA; Page 10 of 14
Assembly
3 Bearing block with installed supporting roller

Normally, the support is supplied with installed roller and axle. For the transport, the contact sur-
faces of the axles are treated with a preservation agent soluble in oil.
The completely assembled bearings must be inspected upon their arrival on the site to make
sure that they have not been damaged during the transport, i.e.:
• Visual check of the unit for ruptures or deformations as well as contaminations
• Check of the preservation of the contact surfaces outside and inside the bearing
If there should be signs of an insufficient preservation, the roller with axle must be rotated 180°.
With opened bearing cover, it must be checked, whether rusty areas can be found.
In this case, the bearing must be dismantled (i.e., lift roller with axle off the support) and all
defects must be thoroughly eliminated.
For the subsequent preservation, all blank areas must be coated with a thick layer of oil, in partic-
ular those areas which are not supplied with oil upon turning of the roller. This applies to the
entire area marked in Fig. 1 with “I”. Ensure utmost cleanliness prior to and during the assembly
(inserting the axle in the bearing shells).
Fig. 1
Next, the bearing top sections must be mounted and the bearings filled with oil through the cover
opening. If the oil volume specified for the bearing is temporarily unavailable, it is sufficient to
only pour approximately 1 liter onto the shaft. Then, the cover is closed with screws and secured
with a split pin against unauthorized opening.
GB 413-0002-05 USA; Page 10 of 14

GB 413-0002-05 USA; Page 11 of 14
Assembly
During assembly, the bearing blocks are placed onto the already-aligned base frames and are
aligned exactly to the kiln axis. The seat surfaces are covered with a solids-containing lubricant,
e.g., Anti-Seize AS 2000, Berlub FCC, or Wolfracoat C-Fluid.
After having precisely positioned the bearing blocks, the hammer head bolts (38) are tightened
and the fixings (35-37) fixed with wedges, the axial wedges being welded only temporarily. If the
originally determined expansion of the kiln should not be reached, a later displacement of the
bearing blocks in the direction of the longitudinal axis is possible.
An axial and radial displacement of the bearing blocks is possible, since oblong holes are pro-
vided for in the bearing blocks and in the seats of the base frames.
When displacing the bearing blocks, attention must be paid to a possible change occurring at the
water connection.
The graphite lubrication (44) must be installed according to the installation plan. It must always
be mounted to the side where the supporting roller turns into the bearing pan, not vice-versa.
The connection cables for the screwed-in resistance thermometer (43) must be laid such that
they are protected against dissipated heat and mechanical damage.
To complete the bearing assembly, the heat protection (40) and the touching guard tire/support-
ing roller must be mounted to the bearing block.
GB 413-0002-05 USA; Page 11 of 14

GB 413-0002-05 USA; Page 12 of 14
Assembly
4 Assembly of bearing, supporting roller and axle on the site

The assembly of the bearing is made on the already aligned base frame or in a site workshop.
The following working steps are required:
a) Dismantle bearing top sections (12) and clean the oil chambers of the bottom section; possi-
bly rinse with diesel oil.
b) Close cleaning opening again with cover (19).
c) Loosely place oil scoop ring (9) in the bearing block; previously, clean scoop pockets (10).
d) Mount lower half of the stuffing box (28) (if included in the supply unpacked) and insert seal-
ing cord. After having inserted the axle, the ends are cut to size. They should overlap by
approximately 30 mm and be diagonally cut.
e) Clean bearing journal and collar rings (2) of the axle and apply touch up ink.
Fig. 2
f) Sling roller with axle according to Fig. 2 and carefully lower it into the bearing bottom section.
Avoid damaging of the collars of the bearing shells, detail “B”.
Fig. 3
GB 413-0002-05 USA; Page 12 of 14

GB 413-0002-05 USA; Page 13 of 14
Assembly
g) With the roller still being suspended, turn the bearing shells out by 20° as shown in Fig. 3,
then lower the roller.
Secure bearing shell with simple angle iron, detail “E”.
h) With the lifting device D, turn the shaft against the angle iron
– Lift roller
– Turn out bearing shell and check contact pattern; if necessary, correct by scraping.
i) - Fig. 01 shows a correct contact pattern
- Fig. 02 shows a wrong contact pattern

i.e. a correction by scraping is necessary, until Fig. 01 is achieved.
- Fig. 03 Contact portion in the collar area of the bearing shell too large, reworking by scrap-
ing as per Fig. 04.
Reworking by scraping shall balance working imprecisions. Use a three-edged scraper and
never emery paper.
Thoroughly clean bearing from chips and dust.
The contact surface shall correspond to approximately 20% of the bearing inner surface.
For a subsequent preservation, all blank areas must be covered with a thick oil layer, in par-
ticular those areas, which are not supplied with oil when the roller is turning, see Fig. 1.
GB 413-0002-05 USA; Page 13 of 14

GB 413-0002-05 USA; Page 14 of 14
Assembly
j) After scraping, lower roller (1), clean the partial areas of the bearing bottom section and uni-
formly apply a pasty sealing compound.
k) Place bearing top section (5, 12) and insert fitting pins.
l) Insert sealing cord (29) and mount upper half of the stuffing box (28), slightly tighten bolts.
m) Mount oil scoop ring and check position to the oil collection plates (see Fig. 5 and 6), correct,
if necessary. It must be made sure that leaking oil is caught by the collection plates.
Fig. 5 Fig. 6
n) Clean bearing front cover (6), apply pasty sealing compound and mount it.
o) Next, mount bearing top sections (5, 12) and fill the bearings with oil through the cover open-
ing.
If the specified oil volume is temporarily unavailable, it is sufficient to only pour approxi-
mately 1 liter onto the shaft. Next, the cover (15) is closed and secured with a split pin
against unauthorized opening.
Caution!
Performed checks of the bearings and subsequent preservation must be

recorded in a protocol.
Reworking, if any, of the respective bearing points, e.g., DGL 550 III RO,
must be notified to the Humboldt Wedag in writing.
After installation of the supporting rollers in the bearing block and placing of the bearing onto the
base frame, the steps described under Item 3 must be followed.
GB 413-0002-05 USA; Page 14 of 14

GB 413-0002-06 en
Commissioning
Page 1 of 2
Contents: Page
3 Starting of commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0002-06 en
4 Completion of commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Former edition:
Note!
See information in the “Commissioning” chapter of the “Oper-

ating instructions rotary kiln tube” section of the Technical
After completion of the assembly and prior to commissioning, the bearing block must be
subject again to a thorough inspection and functional check.
The following must be checked:
a) Does the bearing contain a sufficient oil volume?
b) Have the oil baffle plates (4, 11) been mounted on the correct side?
c) Can the oil scoop pockets(10) freely move and do they scoop sufficient oil?
d) Have the Plexiglas panes (18) been mounted in the cover openings?
e) Have the resistance thermometers (43) been connected?
f) Are the water connections properly functioning?
g) Have the graphite lubrications (44) been mounted on the correct side?
h) Have the hand protection plates (41) been mounted between tire and roller?
i) Have all fixings (35) been retained in place by wedges?

GB 413-0002-06 USA; Page 2 of 2
Commissioning
3 Starting of commissioning
When the final checks (and corrections, if any) have been performed, commissioning can be
started.
During commissioning, particularly at the beginning, it must be locally checked whether every-
thing is functioning as specified.
In particular, observe the following:
a) Refill the oil supply system, if necessary
b) The temperature of the bearings
The position of the bearings

The collar rings!
If required, correct oblique setting, see BA 413-005.
c) The cooling water flow
d) The contact pattern of tire/supporting roller
e) The tightness of the stuffing boxes
4 Completion of commissioning
In the last phase of commissioning, the actual expansion of the kiln under different operating
conditions is normally determined so that the bearings can be finally positioned.
With the displacing tools included in the supply, the bearing can be slid into the desired position.
Displacements towards or off the kiln axis (oblique setting) generally take place during operation;
displacements in longitudinal direction can be made during operation or upon a standstill. During
operation, the contact surfaces of the rollers must be wetted with oil to reduce the friction resis-
tance.
Caution!
If the bearing is displaced during a standstill, the kiln must be lifted and
the bearing relieved.
When the bearing is finally in the intended position, at the front side, an inclined marking bore of
4 mm is made, see detail “Z”.
After the completion of commissioning, the final position of the bearings must be recorded in the
protocol, which means:
– Position of the supporting rollers towards the tire
– Distance among the bearings
– Oil pattern at the collar rings.
GB 413-0002-06 USA; Page 2 of 2

GB 413-0002-07 USA
Operation
Page 1 of 1
Contents: Page
GB 413-0002-07 en
Former edition:
Note!
Also see chapter "Operation" of the operating instructions

to the rotary kiln of the technical machinery documenta-
tion.
During operation, the bearings must be watched carefully.
In particular, the temperatures must be observed. Suitable measures should be taken if a

temperature rises. See the “Maintenance” chapter.
During particularly low temperatures in the winter, the flowing ability of the oil must be
observed. If required, heat the bearing or the oil.
This is especially true if the plant is re-started after an extended shut-down during the win-
ter.
GB 413-0002-08 USA
Maintenance
Page 1 of 8
Contents: Page
1 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Behavior upon failures (running hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GB 413-0002-08 en
3.1 Installation of new bearing shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Installation of new stuffing box packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Former edition:
3.3 Replacement of the graphite blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.4 Replacement of the oil chamber seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Replacement of the resistance thermometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Information
Note!
For maintenance lists, see the “Maintenance” chapter of the

Technical Machinery Documentation section and the “Operat-
ing instructions rotary kiln tube” section.
Spare parts lists as per the “spare parts” section of the Tech-
nical Machinery Documentation.

As regards which items and how things must be inspected, maintained and repaired and
what must be done in case of a failure, see Item 2.1 and the maintenance lists.
Observe the supplementary references:
a) Standstill in winter
Upon a standstill in winter, the chambers of the water cooling system must be emp-
tied. This can be done - depending on the bearing type - by draining or pressing out
the water with the aid of compressed air.
GB 413-0002-08 USA; Page 2 of 8
Maintenance
b) Bearing temperature
The bearing temperatures are permanently monitored by the resistance thermometers (43).
During normal operation, a bearing shell temperature of about 40-60°C will establish. If this
reading should change, an immediate local inspection is required checking the following
items:
• Temperature and oil pattern at the collar rings.
• Oil flow from the scoop ring and distribution on the surface of the axle.
• Shell temperature in the area of the tire.
• Tire temperature.
Caution!
Observe adjusting instructions BA 413-005!
c) Oil change
The oil change must be made at the intervals specified in the lubrication list. After the oil has
drained through the drain opening, the cleaning cover (19) must be unscrewed to clean the
oil sump.
Fig. 9
First filling of the bearing with oil can be made through the bearing cover (15).
Utmost cleanliness in any respect must be ensured. For welding of the rotary kiln and during
bricklining upon the initial make-up, the rotary kiln tube is turned extremely slow and partly at
large intervals, always by a few centimeters only.
GB 413-0002-08 USA; Page 2 of 8

GB 413-0002-08 USA; Page 3 of 8
Maintenance
To also ensure in these cases that the bearing surfaces are sufficiently supplied with oil,
approximately 1 liter of oil must be filled in through the opening, Item “O” (Fig. 9 and 10).
It must be made sure that the oil is filled in at the “drawing

in” side (see Fig. 10).
After filling, the openings must be closed again with plugs

(22).
Only use clean instruments. The covers (15) remain

closed.
Fig.10
d) Oil emerging from the bearing inner side (stuffing box)
If the bearing should lose oil at the inner side, presumably a too high oil level is the cause;
the collar ring is within the oil sump.
At the drain screw (23), approximately 1 liter of oil must be drained by steps until the bearing
is tight.
During this measure, the oil emerging from the scoop ring must be observed. A sufficient oil
volume must flow onto the axle or the oil baffle plate.
e) Graphite lubrication
The graphite lubrication system (46) is subject to a normal consumption and is used depend-
ing on the oblique kiln setting, i.e., for stationary thrust roller blocks, it is pressed against the
roller only for the downward movement of the kiln while for hydraulic rollers, it is in perma-
nent contact.
Further references regarding lubricants may be taken from the order-related list of lubricants
and BA 822-0001 as well as HW 6302.
GB 413-0002-08 USA; Page 3 of 8

GB 413-0002-08 USA; Page 4 of 8
Maintenance
2.1 Behavior upon failures (running hot)
Immediate Trouble shooting and

Failure possible causes Remarks
remedies failure elimination
I. High bearing 1) Too high axial - Do not shut down - Check position of - Spare bear-
temperatures pressure plant! central axes of sup- ing shells
(acoustical between collar Turn further with porting rollers and available?
and optical ring and bear- auxiliary drive. rotary tube
alarm) ing shell collar
- Apply oil or - If required, oblique
(running hot) grease to roller setting of rollers (see
surfaces BA 413-005, Item 5)
- Pour oil by hand - Change bearing - Call for spe-

onto collar ring shell, if necessary cialist, if nec-
essary
2) Contaminated - Pour much oil - Oil change

slide bearing onto journal
- Clean journal with
shells
- Apply oil or linen cloth during
grease onto the operation
roller surfaces
- Replace bearing
shell, if necessary
- Smooth shaft
3) Insufficient lubri- - Pour oil by hand - Oil level

cation of journal onto rotating jour-
- Proper functioning of
nal
oil scoop pockets
- Check housing for
cracks
- Check oil baffle plate
- Cooling water in oil?
4) Too little cooling - Open valves - Pump system in ser- - Spare part
water vice? available?
- Install cooling - Check valves and

blower lines
5) High shell and - Have roller run - Upon next standstill, - Sufficient
tire temperature through a water renew bricklining bricks avail-
bath able?
- Install cooling air

blower
GB 413-0002-08 USA; Page 4 of 8

GB 413-0002-08 USA; Page 5 of 8
Maintenance
Immediate Trouble shooting and

Failure possible causes Remarks
remedies failure elimination
II. Oil emerging 1) Too high oil - Lower oil level mak-
at shaft seal level ing sure that the oil
scoop pockets pour
enough oil onto the
shaft journal
2) Worn down seal - Renew seal - Spare seal

available?
III. Oil emerging - Refill oil - Upon next standstill, - Use electrode
from cracks in properly weld crack for grey cast
- Temporarily weld
bearing hous- iron GG 25,
crack
ing GG 30
- Observe oil level
IV. Position of 1) Foundation low- - Permanently - Newly measure - Lifting blocks

supporting ered observe bearing position of the bear- available for
roller bearing temperature ing block lifting the kiln
2) Fixing detached
changed and displac-
- Observe oil pat- - Bring bearing block
3) Deformed rotary ing the bear-
tern at collar rings into correct position
kiln tube hitting ing block?
against roller - After commission-
ing, oblique setting
of bearing block
- Clearly mark position
of bearing block
V. Noise in bear- 1) Oil scoop ring or - Shut down kiln - Dismantle front - Spare scoop
ing oil scoop pock- cover and tighten pockets avail-
ets loose and loose parts able?
dragging at
- Change oil
housing or oil
baffle plate - Replace bearing - Spare bear-
shell ing shells
2) Bearing shell
available?
collar worn
down
GB 413-0002-08 USA; Page 5 of 8

GB 413-0002-08 USA; Page 6 of 8
Maintenance

Defective components affecting proper functioning of the bearing should be replaced for eco-
nomical reasons AND safety reasons.
Safety references and instructions must be observed.
Information for the installation of important spare parts hereby follows:
3.1 Installation of new bearing shells

The normal wear at bearing shells is very low.
If bearing shells must be replaced, always replace two bearing shells at the same time.
The following working steps are required (see Fig. 7 and 8):
Fig. 7
GB 413-0002-08 USA; Page 6 of 8

GB 413-0002-08 USA; Page 7 of 8
Maintenance
Fig. 8
1. Support tire.
2. Press out bearing by some millimeters.
– Loosen oil scoop ring (9) and place it into the bearing bottom section, Item “N” (Fig. 9)
– Remove upper half of stuffing box ring (26), Item “M” (Fig. 9)
3. Remove bearing top section
4. Lift axle with roller by some millimeters
5. Turn out bearing shell
6. Insert new shells
7. Lower and completely turn axle to check the contact pattern of the contact surface in the bearing
shell (see item 4 h. of the installation instruction in the “Assembly” chapter)
8. As soon as the contact pattern is ideal, complete bearing installation and bring it into its original
position again
9. Perform precision adjustment of bearing as per BA 413-005
GB 413-0002-08 USA; Page 7 of 8

GB 413-0002-08 USA; Page 8 of 8
Maintenance
3.2 Installation of new stuffing box packings

The stuffing box packing (29) serves as seal against water and dust, however not as seal against
emerging oil (see 2 (d)).
The packing is replaced by removing the stuffing box and first inserting the lower half of the spare
packing, then the upper one.
3.3 Replacement of the graphite blocks

The replacement of the graphite blocks at the bearing blocks does not entail any problem. It can
be made during operation.
It must only be made sure that the holder (44) is free from dirt and incrustations so that the
wooden block (45) and the graphite block (46) can freely move. Only in this way, a proper press-
ing onto the roller surface is ensured.
3.4 Replacement of the oil chamber seal

If this seal (21) should be defective, all of the oil must be drained to permit the installation of a
new seal. Also see 2 (c).
3.5 Replacement of the resistance thermometer

When replacing the resistance thermometer (43), ensure that the sensor is in complete contact
with the bearing shell, i.e., it must be kept in the contact bore of the bearing shell by spring pres-
sure. An incorrect installation will lead to incorrect temperature measurements.
GB 413-0002-08 USA; Page 8 of 8


Contents:
GB 413-0002-09 en
Former edition:
Note!

GB 413-0038 USA
• Longitudinal kiln guide system - BA 413-151 USA

• Hydraulic unit - BA 413-0255 USA

For relevant documents see under
“List of separate documentation”
State: 413.480 / 01.2007

Hydraulic thrust roller bracket HDR 50 BA 413-151 USA

(mechanical components) Page 1 of 8
Safety
to be ensured by proper and careful mounting, operation and maintenance.
BA 413-151 en
Former edition:
This symbol precedes all important safety rules

contained in these operating instructions
Please observe these rules and proceed with the

utmost caution. Pass an all safety rules to other
users as well.
Apart from the rules included in these operating

instructions, the general mandatory safety rules
in accordance with the laws of your country must
be observed.
Copyright
The copyright to the present operating instructions (BA) remains with Hum-
boldt Wedag, Inc. (HWI). These instructions are meant for the installation,
operating and supervision staff. They contain regulations and drawings of
technical nature which must not — neither in whole nor in part — be distrib-
uted or used without authorization for competition purposes or disclosed to

others unless this has not been expressly approved. A non-observance will
entail damages.
Humboldt Wedag, Inc.
400 Technology Parkway

Norcross, Georgia 30092
USA
Phone: 770-810-7300
BA 413-151 USA; Page 2 of 8
Hydraulic thrust roller bracket HDR 50 (mechanical components)
Contents Page
1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Erection and installation of spare parts. . . . . . . . . . . . . . . 4
2.1 First erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installation of anti-friction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Installation of bearing bushes and guide rods . . . . . . . . . . . . . . . . . . . . 6
2.5 Replacing the hydraulic compression cylinder . . . . . . . . . . . . . . . . . . . . 7
2.6 Replacing seals (5.1) in the hydraulic compression cylinder . . . . . . . . . 7
3 Commissioning and servicing . . . . . . . . . . . . . . . . . . . . . . 7
Pertaining drawings Drawing no. ZD 413-151
BA 413-005/1
BA 413-049/1

1 General description
The hydraulically-operated thrust roller assembly is meant to counteract the
downward motion of the rotary kiln tube and also to move the kiln upward and
downward by 50 mm in longitudinal direction, thereby avoiding the formation of
running marks in the tire- and supporting roller surfaces.
In general, the rotary kiln tube is equipped with a maximum of three identical
thrust roller assemblies, with each being located at that side of the types that
faces the outlet end and in the direct vicinity of the girth gear transmission.
– The thrust roller (3) is carried in anti-friction bearings running in a housing

(2).
– The housing (2) is supported on two lateral guide rods (4) and bearing
bushes (17/22) which needs no servicing.
– The guide rods run in solid journal bearings in the bottom section (1) and
are secured at their top ends by mechanisms ensuring their being locked in
axial direction. The sliding surfaces of the guide rods are protected by col-
lars (26 against fouling.
– A hydraulic compression cylinder (5) initiating the longitudinal movement,
has been arranged in the housing center (2).
– The bearings and sliding surfaces are lubricated with a separate oil supply
system (circulation oiling).
– The oil required for lubrication of the anti-friction bearings is pumped
through the housing (2) via a pipeline joined to the housing cover (15) and
recycled to the system over the oil sump (2.1).
– The creep oil at the lower side of the thrust roller is collected by the ring
(3.1) and returned to the oil collection basin.
– The temperature of the top anti-friction bearing is monitored by a pick up
unit (38).
– The contact surfaces of the thrust rollers are lubricated with graphite or a
grease lubrication pump (50-56) which works in intervals.
– The contact surfaces of the thrust rollers are lubricated with graphite or a
grease lubrication pump (50-56) which works in intervals.

2 Erection and installation of spare parts
2.1 First erection

The thrust roller bracket is delivered in already assembled.
The grease supply connections have been equipped with plug bolts. These shall
be removed and the grease lines shall be laid in a workmanlike manner accord-
ing to the workshop drawing.
The thrust rollers must be mounted according to the assembly drawing. Here, it
must be particularly made sure that:
– The contact surface of the thrust roller is in exactly parallel contact to the
contact surface of the tire, Fig. 1 “B”
– The lower thrust roller edge is 5 mm underneath the tire, Fig. 1 “A”
– The thrust roller bracket is displaced by 5 mm to the longitudinal tube axis,
i.e., opposite to the sense of rotation, Fig. 2.
The bore for connection of the temperature pick-up (38) has been plugged with a
bolt for the transportation. When inserting the temperature pick-up, ensure -that
its tip will be in contact with the anti-friction bearing.

2.2 Wear parts

The standard parts being subject to wear are:
- the anti-friction bearings, item 6-12
- the guide rods, item 4
- the collars, item 25,26
- the seals, item 5.1,18,19,20
- the friction bearings, item 17,22
- the brush, item 55,56
These parts should be kept on stock at all times. Moreover, the thrust roller
should be considered as a spare part. Although the kiln system can temporarily
be operated with only one thrust roller, it must be duly considered that it will take
relatively long to procure new ones.
2.3 Installation of anti-friction bearings

The thrust roller bracket must be completely dismantled for replacing the bear-
ings (6-12). This procedure shall be carried out in the workshop or in an
enclosed room.
The following operations have to be carried out:
a) Housing (2) to be supported on wooden wedges or round irons to relieve the

guide rods (4), see Fig. 3, Item “W”.
b) Loosening the retaining device at the guide rods (4) and removing the col-
lars (25,26) and then pressing out or drawing out the guide rods. If required,
a lug can be welded to the front end.
c) The component housing/thrust roller is placed on the supporting structure

so that the thrust roller is in contact with the supporting structure. Bearing
covers (14,15) are removed and the plate (12), the axial roller race (11), the
housing plate (10), the axial roller race (9), the spacer ring (13) and the plate
(8) are disassembled.
d) The housing (2) is withdrawn from the thrust roller together with the outer
rings of the anti-friction bearings (6,7).
e) The outer rings of the anti-friction bearings can be removed manually.

f) After removing the retaining device of the bearing (31) and (44) at the thrust
roller, the inner rings of the anti-friction bearings should be heated slightly by
an autogenous welding torch to facilitate withdrawal of the rings.
g) To ensure correct bearing plays when fitting the new anti-friction bearing,
consult the directives issued by the manufacturers of these bearings.
2.4 Installation of bearing bushes and guide rods

Upon installing new bearing bushes, new guide rods should be fitted as well. It is
necessary to have both sides replaced simultaneously since the housing will oth-
erwise be tilted on the guide rods.
If necessary, the jobs can be carried out locally during a standstill. Due to the
danger of fouling, an enclosed room will be preferable for the job. If the jobs shall
be performed without dismantling the complete thrust roller bracket, this shall be
done as specified below:
a) The roller with the housing is taken to a limit position (see Fig. 3) and the
housing is supported in this position (W). The following procedure is similar
to that described under 2.3 a and b above:
The disks (16) are removed and

the bush (17/22) withdrawn. The
cavity must be cleaned (by wash-
ing out) and the new bush shall
be introduced.
After finishing one side, the housing is taken to the other end position for
carrying out the jobs at that end.
b) Inserting the new guide rods should be done with utmost care, the contact
surfaces. The guide rods should be slightly greased previously to avoid
damaging.

2.5 Replacing the hydraulic compression cylinder

Relieve pressure to the hydraulic line (61) to the cylinder (5) (see operating
instructions from the hydraulic aggregate) so that following jobs for removing the
cylinder can be done:
a) Loosening the connecting line (61) at the cylinder.
b) Removing the retaining ring (23) and loosening the securing bolts beside.
c) Withdrawing the compression cylinder towards the rear.
2.6 Replacing seals (5.1) in the hydraulic compression cylinder

See operating instruction/spare parts list of the foreign documentation.
3 Commissioning and servicing
When commissioning the kiln system, the information given in operating instruc-
tion BA 413-049/1 “Expansion and shrinkage phenomena at the rotary kiln
tubes” shall be duly observed. These instructions point out the dangers existing
upon heating up or cooling down a rotary kiln.
Otherwise servicing is restricted to the following:
1 Observation of the pressures prevailing in the hydraulic system.
2 Observation of the position of the tires relative to the thrust roller.
3 Detection of strange noises.
Note 1: The downward movement of the rotary kiln as well as the position of the
supporting roller axes towards the kiln axis are decisive for the pressure
generated by the longitudinal kiln guiding system. It is known by experi-
ence that these pressures equal approximately 100 bar at a maximum.
If pressures are maintained over extended periods which substantially

exceed 100 bar, the bearing positions should be corrected. See also our
operating instruction BA 413-005/1.

If the kiln continues upward movement without being forced to do so by

the hydraulic system, a correction as described above must likewise be
carried out.
Note 2: The contact pattern on the thrust roller surfaces indicates whether the
thrust roller bracket has been optimally aligned relative to the contact
surface of the tire. If required, shims shall be placed underneath the
bracket for better alignment.
Note 3:Normally, operation of the thrust roller will not be accompanied by

unusual noise. Rhythmic noises synchronous with revolution of the sup-
porting roller suggest an irregular rotary movement. It must then be
checked whether the contact surfaces are clean or whether the roller
interferes with anything while revolving. If the origin of the noise is
located in the bearings, then operation of the thrust roller bracket must
be stopped immediately to avoid consequential damage to the housing
or the thrust roller shaft.
In addition, the anti-friction bearings require checking and replacing, if

necessary.

BA 413-0255 USA
Hydraulic system
Page 1 of 13
Safety
ensured by correct assembly, proper operation,
thorough maintenance and care
BA 413-0255 en
Former edition:
This symbol precedes all important safety references in the

following operating instructions.
Observe these references and behave particularly carefully

in these cases. Also inform other users of these safety
instructions.
Beyond the references given in these operating instruc-

tions, the general safety and accident prevention regula-
tions of your legislator must be observed.
Copyright
The copyright to these operating instructions (BA) remains with the Humboldt Wedag, Inc.
These operating instructions are meant for the assembly, operating and supervision staff.
It contains regulations and drawings of technical nature; this document may not be repro-
duced, distributed or used for competition purposes without authorization, neither wholly
nor in part, or to be disclosed to others. Any nonobservance of this notice will entail a claim
for indemnification.


USA
Phone: 770-810-7300
BA 413-0255 USA; Page 2 of 13
Hydraulic system
Contents: Page
1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Commissioning and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Filling and bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Adjustments and repairs to the hydraulic system . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Control system (contactless way measurement) . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Operation with main and auxiliary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Description of functions effective when stopping the kiln plant. . . . . . . . . . . . 9
2.6 Maintenance of the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Scheme 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8 Scheme 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Scheme 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825-12-818 DU sheet 1+2
Relevant documents: BA 413-005/1

BA 413-049/1
BA 413-0255 USA; Page 2 of 13

BA 413-0255 USA; Page 3 of 13
Hydraulic system
1 Hydraulic system
Oil is supplied to the hydraulic cylinder of the thrust roller bracket from a hydraulic system (items
1 thru 32). The hydraulic system has been designed such that the thrust roller is displaced very
slowly, thus minimizing abrasion at tire and thrust roller.
The hydraulic system is of standardized design and can therefore be used for all thrust roller
brackets. Only the drive unit may differ with regard to voltage and/or frequency. The rated pres-
sure always remains 210 bar. The individual components have been combined to a hydraulic
integrated unit and screwed together.
The hydraulic system consists of:
item 1 standard tank
which includes the oil filling and venting filter, oil level indicator for oil levels up to 50
mm above tank bottom and 50 mm below tank lid, cleaning cover, oil drain plug and
spare parts cabinet.
item 2 radial piston pump
item 3 pump carrier with assembly plate
item 4 flexible coupling
item 5 flange-mounted three-phase motor
item 6 non-return valve
item 7 collecting plate made up of items 8 - 17
item 8.1 safety and shut-off block
item 8.2
item 8.3 pressure control valve
item 9 shut-off valve
item 10 4/3-way solenoid valve
item 11 pressure switch
item 12 pressure control valve
item 13 4/3-way solenoid valve
item 14 rectifier plate with 4 non-return valves
item 15 adapter plate with screw-type filter elements
item 16 flow control valve
item 17 2/2 directional seat valve
item 18 hydraulic reservoir
item 19 pressure gauge 0 - 400 bar
item21 non-return valve
item 22 filter
item 23 high-pressure hose
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BA 413-0255 USA; Page 4 of 13
Hydraulic system
item 31 shut-off valve

item 33 filling and testing device (in spare parts cabinet)
item 34 4/3-way solenoid valve (in spare parts cabinet)
2 Commissioning and maintenance
2.1 Filling and bleeding the hydraulic system
Note!
This includes Scheme 1.
Scheme 1 refers.
The pressure reservoir, item 18, shall be preloaded with nitrogen to 70 - 90 bar using the filling
device.
The standard oil tank, item 1, shall be filled with hydraulic oil up to the upper oil level mark.
Caution!
Have oil filled in through filter!
Flow control valve, item 16, shall be fully opened (value set on scale = 10)
Shut-off valve, item 8.1, in position “closed”.
Shut-off valve, item 8.2, in position “closed”.
Shut-off valve, item 31.1, in position “open”.
Shut-off valve, item 9.1, in position “open”.
Open bleeding valve at hydraulic cylinders (e.g., ball cock).
Undo connection pipe at radial piston pump, item 2.
Switch on drive unit, item 5. Valve, item 13, is at the same time switched to upward movement
(solenoid Y1 is activated).
The connection pipe shall be re-fitted as soon as the radial piston pump delivers oil.
If no oil emerges, hydraulic oil shall be filled in at the pump connection until continuous delivery
has been established.
Afterwards, the pipeline shall be re-fitted.
The hydraulic cylinders shall be closed if oil emerges at their bleed valves.
Flow control valve, item 16, shall be set to scale reading 1 - 2 after the above jobs have been
completed.
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BA 413-0255 USA; Page 5 of 13
Hydraulic system
2.2 Adjustments and repairs to the hydraulic system
Note!
See Scheme 1.
Setting pressure control valve, item 12

Switch on drive unit, item 5.
Remove protective cap of pressure control valve, item 12 and undo locknut.
Set ¾-way valve, item 13, manually to downward movement of the kiln (press in and hold the
black knob, item 13B). Set pressure to 210 bar by turning the screw at the pressure control valve,
item 12 (hexagon socket), either clockwise or counterclockwise. Indication on pressure gauge,
item 20.
Pressure control valve, item 8.3
Protects the hydraulic reservoir, item 18, against excessive pressure. This valve has been set in
the factory and provided with a TÜV*) seal (*German technical supervisory board). Do NOT
change this valve setting!
Pressure gauges, items 19 and 32.1
Indicate the operating pressure at which the kiln tube moves upward (towards the inlet).
Pressure gauge, item 20
Indicates the pressure to which the pressure control valve, item 12, has been preset (210 bar).
Since the delivery rate of the pump exceeds the volume handled by the flow control valve, item
16, a proportion of the oil is recirculated to the tank via pressure control valve, item 12.
Setting the pressure switches, item 11
3. Electrical pressure switch
Adjust pressure switch, item 11.1, in such a manner (setscrew with scale) that the drive
unit is switched off at 120 bar (pressure gauge, item 19).
Carefully open shut-off valve, item 8.2 until the pressure drops to 90 bar (pressure gauge,
item 19). Pressure switch, item 11.2, to be adjusted such that the drive unit, item 5, is
switched on again.
4. Electronic pressure switch
Set potentiometer P1 to 90 bar so that the drive unit, item 5, is switched on.
Set potentiometer P2 to 120 bar so that the drive unit is switched off.
Additional data can be obtained from data sheet of the subsupplier.
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BA 413-0255 USA; Page 6 of 13
Hydraulic system
Repairs to the hydraulic reservoir

The following safety measures must be taken when performing repairs to the hydraulic reservoir
(during operation):
- Close shut-off valve, item 8.1
- Open shut-off valve, item 8.2, thereby depressurizing the hydraulic reservoir and the pipe sys-
tem.
- Depressurize the hydraulic reservoir by means of the filling device.
Depressurizing the hydraulic system
To do so, open shut-off valves, item 8.2, 8.1.
2.3 Control system (contactless way measurement)
Note!
See Diagram 2.
The longitudinal movement of the kiln tube +25 mm related to the central position of the tire takes
place via a contactless measurement with a supersonic sensor. An instrument carrier serving for
taking the sensor is mounted to tire I (zero assembly) on the inlet side (see drawing 825-12-818
DU Sheet 1+2). The measuring direction of the sensor is towards the front face of the tire and,
hence, monitors the change. The active measuring range of 80 mm is between -30 mm lower tire
position and +50 mm limit switch EMERGENCY-OFF upper tire position. To the lower tire posi-
tion, an analog signal of 4 mA and to the upper tire position an analog signal of 20 mA are
assigned.
Further limit value setting are: GW1 +25 mm
GW2 +30 mm
GW3 -25 mm
GW4 -30 mm
Due to the heat dissipation of the kiln, it is necessary to cool the sensor with water. At the instru-
ment carrier, a supply cabinet is arranged in which a flow meter monitors the flow of the cooling
water of about 1 l/min. Upon a failure of the cooling water, an optical warning is given at the con-
trol cabinet.
If the longitudinal movement of the rotary tube is exceeded by 50 mm in the direction of the inlet
related to the central position of the tire, a limit switch with tappet guiding and stop roller is acti-
vated, thereby disconnecting the drive system of the rotary tube. The limit switch mounted to the
instrument carrier serves as an EMERGENCY-OFF switch and protects the rotary tube from
damage.
Sensor, flow governor and limit switch are wired to a terminal box at the instrument carrier. From
there, further signals are made available to the control cabinet and control stand. The indicating
instrument required for positioning of the tires, the transmitter, the measuring transducer etc., is
located in the control cabinet.
BA 413-0255 USA; Page 6 of 13

BA 413-0255 USA; Page 7 of 13
Hydraulic system
Advance limit value GW 1 (+25 mm)

Switches off the pump unit of the hydraulic set after 25 mm of longitudinal kiln movement
(in the direction of kiln inlet) related to the tire center position. The downward movement of
the kiln tube (in the direction of the kiln outlet) has thus been initiated.
Advance limit value GW 2 (+30 mm)
Switches off the pump unit of the hydraulic system after another 5 mm longitudinal kiln
movement in the direction of the inlet, thereby triggering an alarm signal.
In case the kiln tube does not continue downward movement, the reason must be diag-
nosed locally.
Return limit value GW 3 (-25 mm)
Switches on the pump unit of the hydraulic system after 25 mm of longitudinal kiln move-
ment (in the direction of kiln outlet) related to the tire centre position. The upward move-
ment of the kiln tube (in the direction of the kiln inlet) has thus been initiated.
Return limit value GW 4 (-30 mm)
Switches on the pump unit of the hydraulic system after another 5 mm longitudinal kiln
movement in the direction of the outlet thereby triggering an alarm signal. In case the kiln
tube does not continue upward movement, the reason must be diagnosed locally because
the thrust roller will run up against the mechanical stop of the thrust roller bracket after fur-
ther 10 mm longitudinal kiln movement in the direction of the outlet.
Limit switch, (+50 mm)
Functions as an “EMERGENCY OFF” switch and should be adjusted such that after 50 mm
longitudinal kiln movement in the direction of the inlet - related to the tire center position -
the kiln drive unit is switched off.
Monitoring of the limit values via time-lag relay

The limit values GW 1, 2 and GW 3, 4 are monitored via a time-lag relay, i.e., if a limit value
responds, the relay is started and, within a preset time determined by tests (e.g., 10 minutes), the
rotary tube must release this limit value again by its longitudinal movement, otherwise an alarm is
released.
A third time-lag relay monitors the longitudinal movement of the rotary kiln, i.e., within the preset
time (e.g., 360 min.), one of the limit values or the limit switch must be acknowledged, otherwise
an alarm is released. The preset time depends on the duration of one upward or downward kiln
tube movement which period has to be determined by way of tests.
In case of an alarm signal, the reason must be found locally.
2.4 Operation with main and auxiliary drive
The hydraulic pump for longitudinal kiln tube movement starts immediately and automatically
after the main motor has been switched on.
The hydraulic system will operate fully automatically after the main motor has been started.
BA 413-0255 USA; Page 7 of 13

BA 413-0255 USA; Page 8 of 13
Hydraulic system
Description of functions upon upward kiln movement
Note!
See Diagram 1.
– The drive unit, item 5, will be started as soon as the kiln tube has reached its bottommost
switching point limit value GW3 (-25 mm).
– At the same time, the 4/3-way valve, item 13, is switched to upward movement (solenoid Y1
is activated).
– The hydraulic oil flows to the pressure reservoir and the hydraulic cylinder via the filter, item
15, and the flow control valve, item 16.
– The pressure reservoir compensates the pressure fluctuations which are transmitted to the
thrust roller due to the tumbling movement of the tire.
– Upward kiln movement in the direction of the inlet proceeds at intervals controlled by two
timers (intervals and operating times).
– The pump unit, item 5, is switched off as soon as the kiln tube reaches is topmost switching
point limit value GW1 (+25 mm).
– The 4/3-way valve, item 13 (solenoid Y1), returns to 0-position.
– At the same time, 4/3 valve, item 10, and 2/2-way valve, item 17, are switched to downward
movement (solenoids Y4 and Y5 are activated). A timer controls opening of the valve (e.g.,
15-30 seconds - to be ascertained by way of tests).
The pressure inside the hydraulic system shall be reduced to such a level by opening the valves
that “coasting” of the kiln tube in the direction of the inlet will be avoided. An operating pressure
of, e.g., 60 bar is reduced to 30 bar.
Solenoids Y4 and Y5 drop out after expiration of the time set for the timer. Reversal of the
movement has been terminated.
Description of functions during downward movement
Note!
See Diagram 1.
Downward movement of the kiln towards the outlet also proceeds at intervals, i.e., controlled by
two timers (interval, operating, time).
The timer which determines the interval keeps the valves, items 13 (solenoid Y2) and 17 (sole-
noid Y5), closed. Hence, the kiln tube is unable to change its present position.
As soon as the timer for valve opening starts running, the 4/3 way valve, item 13, and the 2/2-
way valve, item 17, are opened (solenoids Y2 and Y5 pick up). The oil flows back to the tank over
flow control valve, item 16, and filter, item 15. The kiln tube moves towards the outlet as long as
the valves are opened.
BA 413-0255 USA; Page 8 of 13

BA 413-0255 USA; Page 9 of 13
Hydraulic system
Opening and closing of the valves continues until the kiln tube has reached its bottommost
switching point limit value GW3 (-25 mm) where another upward movement is initiated.
Time setting for upward and downward movement of the kiln tube
Upward and downward kiln tube movement is controlled by different timer settings for intervals
and operating time.
The period of upward and downward kiln movement can be influenced by altering the setting of
the flow control valve, item 16. Small value set on the scale = slow upward movement; large
value set on the scale = fast upward movement.
All settings will have to be determined by way of tests so that the kiln makes approximately one
upward and one downward movement during each shift.
2.5 Description of functions effective when stopping the kiln plant
Note!
See Diagram 1.
When the kiln main drive or the auxiliary drive is at standstill, 4/3-way valves, items 10 and 13,
are switched to upward kiln movement (solenoids Y3 and Y1 are activated). During that operating
state, the pressures are markedly higher than under standard operating conditions.
The kiln tube must be brought to its topmost end position before stopping the plant. To minimize
downward slip of the kiln tube, the hydraulic system shall be pressurized during the complete
shutdown period. The hydraulic system is controlled over the pressure switch, items 11.
As soon as the pressure inside the system reaches 120 bar, pressure switch, item 11, stops
hydraulic pump, item 5. In case the pressure drops to 90 bar - attributable, e.g., to leakages - the
pump unit is re-started by pressure switch, item 11, and switched off after a pressure of 120 bar
has been restored.
The intermittent switching on and off described above avoids uninterrupted operation of the
hydraulic system during complete plant shutdown.
Important notes!
In view of the high shrinkage forces, efforts should be made not to have the thrust roller
contact the thrust roller bracket. This means that the kiln tube should by all means be main-
tained in its topmost position with the aid of the hydraulic system.
BA 413-049 refers.
The contact surfaces of the supporting rollers must be thoroughly lubricated with graphite
when starting and stopping the kiln during the first weeks of plant shutdown.
During shrinking (cooling down) of the kiln tube, the latter must definitely be turned regu-
larly (see also corresponding instructions).
BA 413-0255 USA; Page 9 of 13

BA 413-0255 USA; Page 10 of 13
Hydraulic system
The hydraulic system must continuously be supplied with current (i.e., also during a shut-
down period of several weeks). The system has been connected to the emergency power
supply unit.
During normal operating conditions, the hydraulic system shall be operated at a pressure of
50-60 bar.
2.6 Maintenance of the hydraulic system
The filter installed in the adapter plate, item 15, and the return filter, item 22, shall be thoroughly
cleaned approximately 50 hours after first start-up of the facility; they require cleaning again after
another 150 hours and afterwards regularly at intervals of approximately 4 months.
The oil level in the standard tank, item 1, shall be checked daily during the commissioning phase
- afterwards at least once a month.
The initial pressure in the hydraulic reservoir, item 18, must be measured during the commission-
ing phase, after 50 hours and again after 150 hours of operation. Thereafter, a check every 6
months will be enough.
The hydraulic oil must be changed once a year.
The pressure control valves, items 8.3 and 12, as well as the pressure switch, items 11, shall be
checked once every 12 months.
Measures to be taken in case of failures

The following checks are required if the upper and lower limit positions are exceeded or if the kiln
tube remains at the same location:
– Checking the electrical system of the complete equipment
– Checking the mechanical components of the hydraulic systems
– Checking the mechanical components of the thrust-roller bracket
– Checking the position of the supporting roller bearings relative to the tube centerline - see
also BA 413-005 and BA 413-049
BA 413-0255 USA; Page 10 of 13

BA 413-0255 USA; Page 11 of 13
Hydraulic system
2.7 Scheme 1
BA 413-0255 USA; Page 11 of 13

BA 413-0255 USA; Page 12 of 13
Hydraulic system
2.8 Scheme 2
Control
BA 413-0255 USA; Page 12 of 13

BA 413-0255 USA; Page 13 of 13
Hydraulic system
2.9 Scheme 3
BA 413-0255 USA; Page 13 of 13

GB 413-0038 USA
• Drive - GB 413-0271 USA
State: 413.480 / 01.2007

Operating Manual State: 03.2008
Operating Manual-No.:
ROTARY TUBE DRIVE BA: 413-0271 USA
page: 1 of 42
Table of contents
1. General Description
2. Erection and Commissioning
3. Maintenance and installation of spare parts
Annex: Test records, sheets 1 ... 14
SAFETY
careful maintenance and service
This symbol identifies all important safety instructions in this operating manual.
Observe these instructions and proceed with utmost care. Ensure that other users
are familiar with all safety instructions. As well as the instructions contained in this
manual, the general and locally prevailing safety and accident prevention regulations
shall be observed.
COPYRIGHT
Copyright existing on this operating manual remains the property of HWI. This manual is intended for the use of
assembly, operating and supervisory personnel. The operating manual contains technical specifications and
drawings. Unauthorized reproduction of these, either in whole or in part, is not permitted. Unauthorized
distribution or processing for the purposes of competition and use of the contents by third parties is not permitted.

Norcross, Georgia 30092 USA
Phone 770-810-7300
Alterations in this edition: Previous edition:

BA 413-0271
BA 413-0271 USA, page 2
1. GENERAL DESCRIPTION
1.1 Description of the drive
1.1.1 Work - speed - power
1.1.2 Construction of the rotary tube drive
1.1.3 Functioning
1.1.4 Dimensions
1.1.5 Quality assurance
1.1.6 Operation
1.2 Description of sub-groups and components
1.2.1 Gear drive, transmission
1.2.1.1 Ring gear
1.2.1.2 Pinion, pinion shaft, coupling
1.2.1.3 Pinion bearing assembly
1.2.1.4 Wheel guard, thermal protection, coupling guard
1.2.1.5 Grease spray lubrication
1.2.2 Main drive
1.2.2.1 Main gear
1.2.2.2 Couplings
1.2.2.3 Double shoe brake
1.2.2.4 Main motor
1.2.3 Auxiliary drive
1.2.3.1 Auxiliary gear with free wheel
1.2.3.2 Couplings
BA 413-0271 USA, page 3
1.2.3.3 Electric motor, internal combustion engine
2. ERRECTION AND COMMISSIONING

2.1 Ring gear
2.2 Pinion-bearing-base frame-coupling
2.3 Measuring and alignment of the drive units
2.3.1 Base frame
2.3.2 Measuring vertical and lateral eccentricity of the
ring gear
2.3.3 Measuring the
- pitch circle distance
- backlash
- bottom clearance
2.3.4 Tooth bearing (test record)
2.3.5 Couplings (test record)
2.4 Wheel guard, thermal protection, coupling guard
2.5 Locking of units prior to commissioning
2.6 Checks and activities before and during commissioning
3. Maintenance and Installation of Spare Parts
3.1 Servicing the drive
3.2 Stockkeeping of spare parts
Annex: Test records ( sheets 1 ... 14 )

BA 413-0271 USA, page 4
1. GENERAL DESCRIPTION
This operating manual is applicable to rotary tube drives in general, i.e.,, to

drives for rotary kilns, rotary coolers and drums.
Design and construction of rotary tube drives may differ, depending on the
specific process requirements, the plant-related functions and the makes of
the different components. Consequently, the descriptions and information
contained in this operating manual must be adapted accordingly.
The drives come up to approved rules of technology.
1.1 Description of the drive
1.1.1 Work - speed - power
The material to be thermally treated is transported from the inlet to the outlet
side of the tube via rotation of the inclined tube. The retention time of the
material inside the tube can be influenced by the rotation speed.
The work to be performed by the rotary tube drive predominantly consists of

friction and lifting.
Friction work has to be done during starting and operation to overcome the
frictional resistance in the bearings (tire and supporting roller bearings), at the
seals and in the drive proper.
BA 413-0271 USA, page 5
Friction work is of no more than minor significance for work as a whole.

However, if this statement is to be true, the plant and its components must
have been properly aligned (i.e., normal friction and load conditions).
Otherwise, that percentage may increase to a multiple of the standard figure.
Lifting work is markedly greater than friction work. It results from the kidney-
shaped material layer which - due to rotary movement and material friction on
the inside tube wall - rests off-center in the tube. Its size depends on the
degree of filling, the specific weight of the filling and the angle of repose. In
addition, it is influenced by inner tube assemblies which have a bearing on the
location of the center of gravity of the material filling within the tube cross
section.
Forming of coatings, accretions and ringing inside the tube will, in part, alter
the degree of filling and, consequently, the lifting work.
Material that has been irregularly distributed over the tube circumference
(such as accretions at one side, non-uniform brick-lining wear) results in
imbalances and, hence, in fluctuations of the required lifting work during every
tube rotation.
The drive power of the rotary tube results from the work performed by the
drive during one unit of time.
The optimal rotary tube speed is adjusted during plant commissioning with
due regard to process aspects. The kiln will absorb a specified average power
at this speed (= working point).
The following power diagrams for a rotary kiln are a typical example of the
interrelations that exist between speed n, effective drive power Pe and motor
rating Pmot
at constant throughput (t/d) => fig. 1 and

at constant filling (t) => fig. 2.
BA 413-0271 USA, page 6
P Mot at n max
100%
80%
motor rating
at constant torque fP
60%
Pe
(P +P ) working point
lift fric
40%
kiln capacity at
constant throughput fn
20%
kiln filling at
at constant throughput n operation
n max
1250 -1
250 400 600 800 1000 1200 1400 1500 [ min ]
control range 3:1
control range 6:1
83,3% n Mot
fig. 1 16,7% 26,7% 40% 53,3% 66,7% 80% 93,3% 100%
P at n
Mot max
100%
80%
motor rating
at constant torque fP
60%
Pe
(P +P ) working point
lift fric
40%
fn
20%
kiln capacity at
at constant filling n operation
n
( throughput ≅ speed ) max
1250
-1
250 400 600 800 1000 1200 1400 1500 [ min ]
control range 3:1
control range 6:1
83,3% n Mot
fig. 2 16,7% 26,7% 40% 53,3% 66,7% 80% 93,3% 100% P Mot
bei n max. = motor rating at max. speed (kW)
P e bei n Betr. = effective capacity at operating speed (kW)

fn = difference between n op. und n max.
fP = difference between Pe and power available from the
motor at the specific operating speed
BA 413-0271 USA, page 7
The characteristic motor curve shows that the rated throughput of the plant
can only be reached within a specific speed range. Consequently, the
throughput has to be reduced at low speed (generally, motor overloading is
only feasible up to 10% for no more than a limited period).
Beyond the working point concerned, a "speed reserve" fn up to maximum

speed exists. The system moreover includes a power reserve fp from this
working point up to motor rating. This power reserve is ample and allows
reliable production operation even in case of fluctuating and excess power
absorption (e.g., due to coating failures).
In the event that the rotary tube cannot be started from stand-still with the aid
of the main drive or if operation under extreme conditions (excess filling, one-
side coating, tube bending after power failures) is impossible with the main
drive, the system will have to be operated with the auxiliary drive. In general,
the torque transmittable with the auxiliary drive amounts to twice the rated
torque of the main drive. All drive units have been designed for these
operating conditions. However, because of the then-critical oil supply to the
supporting roller bearings, the auxiliary drive should not be used for tube
rotation longer than necessary.
1.1.2 Construction of the kiln tube drive (=> fig. 3)
The rotary tube drive consists of the following sub-groups:
- the gear drive with pinion-bearing-base frame-coupling incl.
• split ring gear (1)

• ring gear fastening mechanism (2)
• pinion and pinion shaft (3)
• pinion bearing and base frame (4)
• wheel guard (5)
• grease spraying system (6)
BA 413-0271 USA, page 8
- the main drive including
• couplings (8,9,10)
• double-shoe brake (11)
• base frame (12)
• lubrication and cooling unit - if required (13)
• main motor, variable-speed type (14)
- the auxiliary drive including
• auxiliary gear (15)

• overrunning clutch (16)
• coupling with centrifugal brake (17)
• base frame (18)
• auxiliary electric motor (19)
• centrifugal clutch (20)
• flange gear (21)
• auxiliary internal combustion engine (22)
• flange lubrication pump (23)
- accessory equipment including
• thermal protection (24)

• coupling guard
• monitoring and control devices.
BA 413-0271 USA, page 9
C 1
5
E
F
8
A 24
7
3
3 D
11 10
9 B 4
4
16 14 6 view X
15
G H
17
19 23
20 13 12
21
fig. 3
22 18
BA 413-0271 USA, page 10
1.1.3 Functioning
During normal operation, power is transmitted from the main motor via main
gear and pinion-bearing-base frame-coupling to the ring gear fastened to the
rotary tube. During that operating mode, the auxiliary drive is disconnected by
the overrunning clutch and not operating.
When using the auxiliary system, the power is transmitted from the auxiliary
motor or auxiliary internal combustion engine via the auxiliary gear, main gear,
pinion-bearing-base frame-coupling to the ring gear.
Depending on plant type and specific process requirements, the rotary tube
speed normally varies between approximately 2 and 4 rpm at maximum motor
speeds of 1,500 rpm. The operating speeds range between approximately 80
and 90% of the maximum speeds.
The above tube speeds are achieved by reduction ratios provided for in the main
gear and the gear drive.
The motor speeds are infinitely variable, e.g., between either 250 and 1,500 or
500 and 1,500 rpm, for adjusting the required operating speeds of the rotary
tubes.
The tube speeds are by the factor 20 to 30 lower upon use of the auxiliary
system which corresponds to the reduction ratio of the auxiliary gear.
Consequently, one tube rotation will take approximately 10 to 20 minutes.
Rotary tube gear drives are also termed "open gear drives" due to the fact that
the shafts of ring gear and pinion are not carried in a joint housing. Perfect gear
meshing and correct lubrication are of vital importance for proper torque
transmission from the pinion to the ring gear and further on to the rotary tube.
BA 413-0271 USA, page 11
1.1.4 Dimensions
The drive gear and the balance of drive components have been dimensioned on
the basis of the torques obtained from drive calculation and with due regard to
the cyclic dynamic and thermal loads resulting from varying operating
conditions. The drive elements are extensively safeguarded against
deformation, breakage and wear. The gear drive and the gear units have been
calculated in accordance with DIN 3990, which means that they meet all
requirements concerning permissible surface pressure, tooth strength and
required safety against seizure.
Quality assurance has been implemented by extensive tests and checks of

which documentary proof has been given in certificates/records.
Material testing of the ring gear made of high-grade heat-treatable steel casting,
for instance, includes non-destructive testing of the two ring gear halves as well
as destructive testing of cast-on test pieces.
However, the drive system can fulfill its task of ensuring trouble free continuous
operation in every respect only if it is maintained in perfect condition and
provided mechanical and thermal overload, as well as faulty operation are
avoided.
BA 413-0271 USA, page 12
1.1.6 Operation
Consequently, correct operation of the drive and its components is an absolute

must. It requires the operation sequence chart as well as the control diagram to
be duly observed. In addition, the enclosed instructions for operation and
servicing of the drive units issued by the relevant manufacturers shall be
adhered to.
Special attention shall be paid to correct meshing of ring gear and pinion(s). The
teeth must not under any circumstance run on the tooth root. If so, the rotary
tube weight would rest on the drive gear and entail serious damage (gear and/or
bearing breakage). The drive is exclusively meant to transmit torques.
For checking tooth meshing, the rolling circles have been provided with
conspicuous grooves at both tooth faces of ring gear and pinion(s). After
completion of erection, the distance between the rolling circles amounts to 0 mm
(cold kiln).
The above distance may undergo minor changes due to the influence of non-
uniform thermal expansion and settlement during the running-in phase.
BA 413-0271 USA, page 13
Gear meshing shall in particular be checked after re-adjustment of the

supporting roller bearings (e.g., displacement transverse to the tube centerline
after centerline surveying), exchange of supporting rollers or after replacement
of sliding plates of the tire-fastening mechanisms. "Chatter marks" visible on the
contact surfaces of the supporting roller assemblies adjacent to the drive are an
unmistakable sign of poor tooth meshing.
Abnormal operating conditions shall be avoided.
The following clauses contain further information and regulations.
See also the attached erection record.

BA 413-0271 USA, page 14
1.2 Description of sub-groups and components (fig. 3)
1.2.1 Gear drive, transmission
The power to drive the rotary tube is generated by a gear drive made up of ring
gear (1) and pinion (3). Depending on the size of the plant and the power
required, either one or two pinions are installed.
1.2.1.1 Ring gear
The split ring gear is made of heat-treated steel casting. The ring gear halves
are exactly centered relative to each other by two fitted bolts and connected by
means of anti-fatigue screws.
The gear cutting is of straight-tooth type featuring addendum modification which

ensures smooth running combined with a high carrying capacity. The ring gear
is joined to the rotary tube by 10 tangentially mounted spring steel plates (2)
which make good for thermal expansion of the tube.
Ring-gear fastening to the tube is of symmetrical arrangement which means that

the ring gear may be reversed after wear of the tooth surfaces on one side.
Ring-gear reversing should be accompanied by reversing of the pinion(s), thus
making sure that afterwards the so far unused and not deformed tooth surfaces
mesh.
BA 413-0271 USA, page 15
1.2.1.2 Pinion - pinion shaft - coupling
The pinion is forged of heat-treated steel of higher strength than the girth gear. It
is fitted to the pinion shaft like the coupling half and fastened and secured with
tangential wedges.
To ensure bearing over the complete width of the ring gear tooth surface during
longitudinal movement of the rotary tube, the pinion face width is by 50 mm
wider than that of the ring gear.
The pinion shaft is carried in two self-aligning roller bearings. Since the fixed
bearing (A) by experience must be replaced more frequently, it is not usually
mounted between pinion and coupling, but instead at the other (free) shaft end
that features easier access. Consequently, the coupling half need not be
withdrawn upon exchange of the fixed bearing.
1.2.1.3 Pinion bearing assembly
The housings of the pinion bearings are of one-piece welded design. The oblong
holes in the feet allow displacement transverse to the tube centerline.
The bearing housings can be shifted axially within the oblong holes of the base
frame (4).
The bearing housing has been sealed towards the shaft with a packing; the
open face has been closed by a cover. The antifriction bearings are grease
lubricated. The grease is pressed into the bearings over nipples by means of
manually operated devices. Please consult the lubrication list for details of
grease types, quantities and change intervals.
Used grease can be drained through screw-type openings provided in the lower
part of the bearing.
BA 413-0271 USA, page 16
Resistance thermometers for monitoring the bearing temperature have been

screwed in the upper part of the bearing. The relevant openings have been
closed by screws during transportation.
The bearing boxes have been screwed to the base frame and additionally
safeguarded against displacement by locking blocks. Grease drippings from the
ring gear and pinion is collected in pan (B) mounted below the pinion. This pan
shall be regularly emptied. To that end, the front cover must be unscrewed and
the used, thickened grease scraped out with a rake and the pan carefully rinsed.
Upon failure of the grease spray lubrication system (6), the pan may - as an
emergency measure - be used for splash lubrication. The oil/grease level should
in that case not be above the pinion tooth root.
The used and contaminated, but still liquid oil/grease can be drained through a
drain opening in the front cover. The thickened and contaminated residue must
be scraped out with a rake – as in the case of a splash lubrication.
The drain opening is intentionally arranged higher so that, if the opening should
not be closed by mistake, a still sufficient oil volume remains in the pan to
ensure the proper lubrication of the pinion.
1.2.1.4 Wheel guard - thermal protection - coupling guard
Ring gear and pinion are protected against dust and rain by a wheel guard (5).
The design of that guard allows observation and re-tightening of the ring gear
fastening screws - if necessary - without having to dismantle segments of the
wheel guard.
Labyrinth seals (C) mounted on both sides between ring gear and wheel guard
not only prevent the escape of grease, but also the penetration of dirt and rain.
BA 413-0271 USA, page 17
An inspection opening which accommodates the grease spray lubrication

system has been mounted to the front, i.e., at the height of the pinion. The
sidewalls of that box have been provided with doors that allow observation and
assessment of tooth meshing.
The complete rotary tube drive system (i.e., pinion bearing, main drive, auxiliary
drive) is covered by a canopy (7) and thus protected against heat radiated from
the tube. The canopy consists of a supporting structure (D) onto which double-
walled panels (E) have been slid that allow easy dismantling if required.
Like ring gear and pinion, all other rotating drive components, i.e., the couplings,
have been provided with guards.
1.2.1.5 Grease spray lubrication system
The meshing of ring gear and pinion is supplied with lubricant over an
automatically operating grease spray lubrication system.
During the running-in process, a running-in lubricant is used which is changed

over to a operational lubrication after the running-in time (approximately 300-500
operating hours); see also the running-in conditions from the lubricant-
manufacturer.
The nozzles (F) installed at the height of tooth meshing ensure a uniform and
economic grease spraying onto the carrying parts of the pinion tooth surfaces.
In general, the spraying unit (G), the compressor (H) and the switchbox are
installed in an easily accessible room in the lower part of the foundation.
Please consult the manufacturer's documentation for details of equipment

description, commissioning and servicing of the unit.
Information about the lubricant quantity to be sprayed onto the tooth surfaces at
given intervals should also be taken from the above papers. That quantity also
has a bearing on the condition of tooth surfaces and bearing.
BA 413-0271 USA, page 18
The suitable lubricants have been specified in the lubricant lists.
The responsibility for correct selection of lubricants with due regard to the
specific site conditions and the application, as well as state of the art of
lubrication technology is exclusively with the lubricant supplier and the plant
user.
1.2.2 Main drive
During normal production operation, the rotary tube system is operated with the
main drive which has been designed for 24-hour continuous operation and
changing operating conditions. The tube speed can be infinitely varied within
given ranges with the aid of the main motor (14), i.e., matched to the operating
status of the plant. This mode also allows partial-load operation. In case
abnormally high power/current input is observed, the reasons for such
phenomenon must be immediately diagnosed and eliminated.
1.2.2.1 Main gear
Generally, the gear unit (7) of the main drive is a 3- or 4-stage spur gear. This
type of gear is particularly suitable for transmitting the torques of high-speed
motors to low-speed driven machines. They are highlighted by excellent
efficiency and operational reliability. Moreover, they are characterized by long
service spans and insensitivity to harsh operating conditions.
The gears are manufactured of high-grade case-hardened steel. The gear

cutting is case-hardened and ground with high precision.
All shafts are carried in anti-friction bearings. The temperature of every bearing
is monitored in the bearing housing by resistance thermometers or sensors.
BA 413-0271 USA, page 19
Depending on its size and the application concerned, the gear unit will be
splash-lubricated (with or without cooling coil) or else fitted with an external oil
lubrication system (13). The gear boxes are made of high-grade grey cast iron
or of welded steel. The feet are provided with oblong holes which facilitate
subsequent alignment. The oil drain cock has been closed by a plug to avoid
damage (opening during operation)
1.2.2.2 Couplings
As a general rule, the main gear and the pinion-bearing-base frame-coupling (8)
as well as main motor (10) and auxiliary gear (9) have been joined by flexible
couplings. They are perfectly suited to attenuate impacts and vibrations.
Moreover, they allow minor parallel and angular inaccuracies of the connected
shafts and absorb slight longitudinal movements. The machines concerned are
thus protected against breakage and premature wear.
If required for structural reasons, crowned denture clutches may be used as

well. These self-lubricating clutches are characterized by similar advantages as
flexible couplings but are of more compact design. They require little
maintenance - change of lubricant 1 x /year.
Depending on the particular requirements, the coupling halves are made of grey
cast iron, cast steel or steel. The torque is transmitted via bolts with slip-on
plastic buffers. The bolts can be replaced without having to push the coupling
halves apart.
BA 413-0271 USA, page 20
1.2.2.3 Double shoe brake
The double-shoe brake (11) is mounted to the flexible coupling (10) between
main motor and main gear. It is exclusively meant as stop brake, e.g., during
brick-lining of the tube or in case of repairs. It shall in no case be used for
decelerating the rotating tube.
The holding torque is adjusted with the aid of a spring. It exceeds the maximum
torque of the auxiliary drive.
Safety instruction:
Any job to be done inside and to the rotary tube requires

measures in addition to application of the stop brake which will
reliably prevent rotation of the tube in case of a slipping brake.
Placing wooden wedges in the gaps between supporting rollers
and tires, i.e., at the left- and right-hand supporting rollers, has
proved an efficient locking of the tube.
As soon as the tube can be rotated after completion of the jobs

without involving any danger, make sure all wedges are removed
before starting the drive motors. Moreover, the brake shall be
released beforehand.
BA 413-0271 USA, page 21
1.2.2.4 Main motor
Normally, the main motor is a thyristor-controlled d.c. motor or a squirrel-cage

motor with variable frequency drive, both featuring an infinitely variable speed
range of 1 : 6 (e.g., 250 to 1,500) or 1 : 3 (e.g., 500 to 1,500 rpm). The torque is
constant within every speed range. The starting torque amounts to 2.5-times the
rated torque and it must be available for 10 sec. After this period of time, the
current is limited to 110%. This reduced power requirement is restricted to a
maximum of 2 hours to prevent damage to the drive.
BA 413-0271 USA, page 22
1.2.3 Auxiliary drive
The functions of the auxiliary drive are the following:
- rotating the tube in case of power failures

- driving the rotary tube in case this is difficult or impossible at
abnormally high countertorque
- starting and stopping the system, including intermittent operation
turning of the tube by approximately 1/4 of a rotation
- turning the tube during repairs or brick-lining work
1.2.3.1 Auxiliary gear with free wheel
Normally, auxiliary gear (15) is a two- or three-stage spur gear or straight bevel
gear unit with built-in free wheel (16) at the output shaft.
The free wheel has the effect of an overrunning clutch. The main drive can be
switched on in case the system is operated with the auxiliary units. The free
wheel ensures automatic overrunning of the auxiliary drive which will in that
case be switched off.
A flange pump (23) is mounted to the second end of the drive shaft of the
auxiliary gear. It supplies oil to the main gear during operation with the auxiliary
drive. The oil drain cock is closed by a plug to avoid damage (opening during
operation).
1.2.3.2 Couplings
The auxiliary gear is joined to the auxiliary electric motor over a brake/coupling
combination. It consists of a centrifugal brake, a centrifugal clutch and a fluid
clutch respectively.
BA 413-0271 USA, page 23
Because of the changed direction of force, the overrunning clutch (free wheel)
will not uncouple the main gear from the auxiliary gear upon swinging back of
the rotary tube (deliberate swinging back) and the centrifugal brake flanged to
the auxiliary gear will decelerate the gear unit at approximately 2,000 rpm. If not,
there would be danger that the auxiliary drive would be seriously damaged by
excess speed (approximately 30,000 rpm).
The auxiliary electric motor is joined to the internal combustion engine by a

centrifugal clutch.
1.2.3.3 Auxiliary electric motor and internal combustion engine
- An electric motor (19) and

- an internal combustion engine (22)
are used as auxiliary drive motors.
The electric motor is a three-phase motor (squirrel-cage rotor) with two shaft
ends. An internal combustion engine (diesel or gasoline) has been connected to
the second shaft journal over a centrifugal clutch (20). Normally, the higher
speed of this engine (relative to that of the auxiliary electric motor) is reduced by
an intermediate gear (21) to approximately 1,000 rpm.
The internal combustion engine is an additional safeguard to allow turning the

hot tube even upon failure of the power supply in order to prevent tube bending
and shrinkage stress.
BA 413-0271 USA, page 24
Caution!
Even at a reliable power supply, the internal combustion engine shall

continuously be ready for operation. It is well known by experience that the
power supply can be interrupted unexpectedly, e.g., after a lightning strike.
Therefore, the operating staff shall ensure that the tank always contains
sufficient fuel (observe for evaporation). Moreover, the internal combustion
engine shall be repeatedly started at specified intervals (at least once per
month) to check its functioning (observe suppliers' instructions).
In case no internal combustion engine is available, the auxiliary electric motor

must be connected to the emergency power supply to allow turning of the rotary
tube with the auxiliary drive even upon failure of the main power supply.
Obviously, the emergency generating set shall permanently be in functional
condition.
Starting of the auxiliary drive must not be made impossible by electrical

interlocking.
BA 413-0271 USA, page 25
2. ERECTION AND COMISSIONING
2.1 Ring gear
The ring gear is mounted in accordance with the HUMBOLDT WEDAG

instructions for rotary kilns. Make sure the correct direction of rotation of the
tube is maintained when fitting the spring steel plates. The rotary tube shall be
drawn but not be pushed by the ring gear springs. The sense of rotation shall be
fixed when viewing from the outlet to the inlet!
The joining faces of the ring gear halves shall be in close contact. There must be
no gap in the tooth space.
BA 413-0271 USA, page 26
Caution !
Make sure that the connecting screws of the ring gear halves are only tightened
with a hydraulic screwdriver!
During initial assembly, the ring gear is no more than roughly aligned. See
section 2.3 on next age for details of precise alignment.
Ring gear and pinion have been coated with an oil-soluble anti-corrosive varnish
(such as, e.g.,, Klübertop KB 118) which is decomposed during machine
operation.
Consequently, the varnish need not be removed before start-up.
Safety instructions:
Precautionary measures to be observed when handling

lubricants, including drilling and cutting oils, production and
functional oils (except white oils for medical use and Vaseline):
a) Avoid extensive, intense skin contact; wear protective

gloves and aprons, if necessary.
Apply suitable protective skin ointment prior to carrying out

any job.
Clean oil-contaminated skin thoroughly with water and skin

protecting cleansing agents or soap after completion of the
jobs and before food breaks. Use rich skin cream to replace
the natural fat of the skin.
b) Immediately change oil-soaked clothing. Do not carry oiled

rags in your trouser pockets.
c) If possible, avoid inhaling of oil mist and vapor.

BA 413-0271 USA, page 27
2.2 Transmission
Normally, the transmission is delivered to the site completely assembled (except

for the locking device), i.e., base frame - pinion bearing assembly - pinion shaft
with pinion and coupling half.
The complete unit is pushed towards the ring gear and roughly aligned.
After the main drive has been coupled, the tube can be slowly turned for
welding. Before turning, viscous oil shall be amply applied to the tooth surfaces
by hand, i.e., prior to every turning.
2.3 Measuring and alignment of the drive units
Test protocols shall be worked out (see forms A,B, and C attached) to furnish
proof of correct alignment of ring gear - pinion - transmission and to have
records available for later checks.
The original of the corresponding form shall be signed by the erection foreman,
his direct superior and the customer or an inspector authorized by the customer.
2.3.1 Base frame
If only a single drive has been installed, the height of the pinion base frame is
aligned relative to the base frame of the nearest roller assembly.
Maximum permissible deviation: ± 2 mm.

BA 413-0271 USA, page 28
In longitudinal tube direction, the base frame is exactly inclined in accordance

with the rotary tube inclination with the aid of a level.
Maximum permissible deviation: ± 0.1 mm over 1 m in length.
The method is the same for double drive systems, but the difference in height
between the two pinion base frames must be measured in addition and entered
in the record.
The seating surfaces of the two base frames shall be flush and plane-parallel.
See also test record "A", sheets 3 ... 4
Measuring instruments:
levelling instrument
ruler
spirit level
Information concerning grouting of the base frames:
Please consult document 841-39-002 for details and requirements concerning

the construction of foundations, etc.
2.3.2 Measuring vertical and lateral eccentricity
Vertical and lateral eccentricity of the ring gear should be recorded during
alignment. During this alignment phase, the pinion can be adjusted to a
preliminary backlash of 6 - 8 mm.
BA 413-0271 USA, page 29
Unless already done at the shop, the ring gear will be marked at both faces with
embossed figures 1 to 10 at 10 points of the circumference (i.e., always below
the spring claw).
Measuring tool: dial gauge
Permissible deviation: (see test record "E", sheets 12 ... 14)
for pitch circle dia. (mm): lateral eccentricity (mm): vertical eccentricity (mm):
3.000 ... 5.000 ± 0,5 ± 2,0

> 5.000 ... 7.000 ± 1,0 ± 3,0
2.3.3 Measuring the pitch circle distance, backlash and top

clearance
Before measuring and recording backlash and bottom clearance, tooth meshing
shall be aligned in accordance with the distance requested for the grooved pitch
circles.
The first measurement shall be made after the tube has been completely brick-
lined.
The second measurement shall be taken during the first extended shutdown of
the system with a cold rotary tube. The tube should have been operating before
for approximately 2 weeks.
Measuring tool: feeler gauge
(see also erection record and test record "E", sheets 12 ... 14)
BA 413-0271 USA, page 30
2.3.4 Tooth bearing
The tooth bearing is checked while the system is warm.
Efforts should be made to reach uniform bearing over the complete tooth
surface of ring gear and pinion, i.e., corresponding to 100% bearing. The
maximum deviation may be 10% of the optimal bearing.
In case tooth bearing differs from one side to the other and shows unsatisfactory
uniformity, attempts should be made to improve it by an additional precise
alignment.
In addition to correct tooth meshing, good bearing is the most important

precondition for perfect power transmission by the gear drive.
Localized overload of the tooth surfaces will result in damage and premature
wear.
2.3.5 Couplings
Positioning of the different drive units relative to each other is measured and
recorded at the couplings. The permitted deviations are given in the mounting
instructions of the coupling manufacturers.
Measuring tools:
ruler
feeler gauge
See also test record "C", sheets 8 ... 10.

BA 413-0271 USA, page 31
2.4 Wheel guard, thermal protection, coupling guard
The wheel guard, the thermal protection for the drive and the coupling guards
are mounted in accordance with the general instructions.
Concerning the wheel guard, care shall be taken that the butt seams of the oil
collecting pan and labyrinth seal have been welded oil tight.
All parting surfaces shall be carefully screwed together with the use of packing
cord. The inspection doors shall close dust-tight.
Safety instruction:
The rotating tube and the rotary drive elements as well as the
surface temperatures of plant components may create hazards in
the installation.
Therefore, it must be ensured prior to start-up that all covers,

such as wheel guard, thermal protection and coupling guards
have been safely mounted, all openings closed and all devices for
the safety of personnel been installed.
As a general rule, it is strictly forbidden to stay within the danger

zone of the installation. The responsibility for suitable guard rails
and written warnings is that of the user. The protective devices
and guard rails must not be removed during operation of the
plant.
BA 413-0271 USA, page 32
2.5 Locking of units prior to start-up
The following components shall be locked after the complete drive has been
finally aligned:
- All fastening screws of the connection between spring steel plate/tube and
spring steel plate/ring gear shall be retightened.
- Place wedges below pinion bearings and drive them in.
- Lock gear unit with blocks that have been welded to the base frame at a
distance of 8 - 10 mm from the gear unit. This gap is filled with shims. This
will facilitate later corrections.
top view
spacer
plates
pillow block of spacer

locking device gear and pinion locking device plates
resp.
base frame pillow block of

gear and pinion
base frame resp.
fig. 6
2.6 Checks and activities before and during commissioning
The following aspects must be checked prior to start-up:
- Oil level of the gear units!
- Have the pinion bearings adequately filled with grease?
- Are the resistance thermometers operable?

BA 413-0271 USA, page 33
- Does the grease spray system operate perfectly?

Check spray pattern!
- Is sufficient lubricant available?
- Are the recommended lubricants used? (see also under 2.7:

"Requirements to be met by the lubricants")
We recommend the following lubricants for grease lubrication

(alphabetical order):
running-in lubricant operational lubricant

Ceplattyn RN Ceplattyn KG10 HMF
Grafloscon B-SG 00 Ultra Grafloscon C-SG 0 Ultra
HUMBOLDT WEDAG normally delivers a 200 kg barrel with the equipment to

make sure that an adequate amount of suitable running-in lubricant is available
for the start-up phase.
The lubrication grease is supplied to the nozzles from a barrel pump and
sprayed with the aid of compressed air. The nozzles must be adjusted so that
they are directed onto the load-bearing tooth surfaces of the pinion(s). The
spray cones shall overlap and the complete face width shall be sprayed.
Caution !
Do not assume that the grease is distributed at the tooth contact by tooth
pressure. Unsatisfactory spraying of tooth areas will soon display damaged
tooth surfaces (pitting).
The load capacity of the gear drive has been calculated in accordance with DIN
3990. Therefore, it includes the required safety margins against tooth breakage,
pitting and wear.
BA 413-0271 USA, page 34
Despite the above safety measures, the formation of running-in pitting during the
running-in phase of the drive gear (when the correct tooth bearing has not yet
been established) cannot always be avoided. They are not an indication of
unsatisfactory dimensioning or poor quality but are the result of machining-
related surface roughness of the tooth surfaces. In other words, they are part of
the smoothing process during the running-in period. This phenomenon is not a
deficiency.
According to DIN 3990, sheet 1, gears are considered resistant to fatigue load if
pitting decreases per unit of time at unchanged operating conditions (degressive
formation of pitting).
An evaluation of pitting, i.e., whether it is degressive (= permitted) can be made

after 106 load cycles at the earliest.
Progressively increasing pitting and breaking out of material after running-in of a

correctly aligned gear drive normally suggest lack of lubricant or inappropriate
lubricant.
During the first 2 weeks of start-up operation, the lubrication set is adjusted to
permanent lubrication.
Initially, 2 checks are necessary per shift; after 3 days, no more than 1 check
per shift. Provided the condition of the tooth surface is satisfactory, the
lubrication set can be changed over to intermittent operation. The amount of
lubricant needed shall be fixed on the basis of the recommendations made by
the lubricant manufacturers.
The intervals shall be set by careful watching of the tooth bearing. They should
not be longer than 10 minutes at a spraying time of approximately 5 minutes.
Based on the application of identical lubricant quantities, shorter intervals will
always be more appropriate than long ones.
Disturbances that have been indicated shall be eliminated without delay.

Unsatisfactory lubrication will soon entail serious damage to the tooth surfaces.
BA 413-0271 USA, page 35
After locating and eliminating the reason of deteriorated tooth bearing and
noticeable scores, material “spalling”, etc., lubrication shall immediately be
changed to permanent operation until regular checks show an improvement.
In case the tooth bearing is unsatisfactory during the start-up phase and if
normal conditions cannot be reached by re-adjustments, corrective lubricant
shall be used.
We recommend:
- Ceplattyn RN
- Grafloscon B-SG 00 Ultra.
The above lubricants shall be employed in accordance with the instructions

issued by the manufacturers.
The wheel guard shall be regularly cleaned during the running-in period to
prevent abraded particles from reaching the tooth surfaces thereby destroying
the lubricant film.
After optimal tooth bearing has been reached, the position of the pinion pillow
block shall be marked and fixed on the base frame.
Repair lubricants shall only be used at the presence of a specialist of the

lubricant producers and only in manual spraying systems operated by
appropriately trained personnel. Failure to do so involves the risk of unintended
damage beyond repair.
BA 413-0271 USA, page 36
2.7 Requirements to be met by the lubricants
- they must be free of bitumen, heavy metals, chlorine and solvents
- they must be available worldwide.
Designation Requirement Tolerance values Method

1. capable to be sprayed 1. spray test by the manufacturers of the satisfactory spray pattern at test conditions as per main supplier of
spray unit -10 °C, 0 °C, 20 °C spray unit
2. wear properties 2.1 FZG test A/2,76/50 spec. wear < 0,2 mg/kWh DIN 51 354
failure load stage > 12
2.2 Timken test OK load > 206 N (45 lbs) ASTM D 2509
abrasion < 5 mg
2.3 VKA test welding load > 6000 N DIN 51 350, part 1
3. corrosion protection 3.1 SKF-Emcor test corrosion degree 0/0 DIN 51 802
properties
3.2 Copper strip tarnish test corrosion degree 0 - 100 DIN 51 811
4. behaviour in the presence 4.1 static test assessment category 1 - 40 DIN 51 807, part 1
of
water 4.2 water tolerance class max 1
5. Thermal stability 5.1 thermal load capacity of the bis +200 °C
lubricating film
5.2 functioning of the lubricating film bis ca. -30 °C
5.3 drop point > 150 °C DIN 51 801 / ISO 2176
6. penetration 6.1 Penetration 340 - 400 1/10 mm DIN 51 804, part 1 / ISO 2137
7. consistency 7.1 consistency class NLGI Klasse 0 - 00 DIN 51 818
BA 413-0271 USA, page 37
Designation Requirement Tolerance values Method

8. base oil 8.1 mineral- oder synthetic oil
8.2 kinematic viskosity 500 - 1000 mm²/s bei 40 °C DIN 51 562
9. thickener 9.1 aluminium complex soap or to be specified by suppliers
equivalent thickener
10. solid lubricant 10.1 natural graphite min. content 8 %
Reinheitsgrad > 99,,5 %
Partikelgröße
min. 50 % < 10 μm
10.2 other solid lubricants of similar wear by suppliers
protection properties see also under 2.1 - 2.3
above
BA 413-0271 USA, page 38
Test in four-ball tester, DIN 51 350, part 4
Determination of the welding load of consistent lubricants with additives for high
surface pressures (EP lubricants).
The lubricant is tested in a four-ball system which consists of a rotating ball

which slides on 3 identical balls at selectable test loads. The welding load is
determined during this procedure.
FZG gear test, DIN 51 354
Test conditions: A/2, 76/50
Test gears run in a splash lubrication bath at constant speed and specified initial
and operating temperatures of the lubricant bath. Following the test procedure,
tooth surface load capacity, welding load and wear properties are determined by
the condition of the gears.
By definition, the failure load stage is the stage where more than 20% of the
tooth surfaces of the pinion have been destroyed by welding.
A/2, 76/50:
Test gear pair - type A: tooth form A has been chosen for standard tests
because it features a one-side addendum modification, thus resulting in a high
slide velocity for gear cuttings susceptible to pitting.
2.76 circumferential speed (in m/sec.)

50 initial temperature (in °C)
Timken wear test, ASTM D 2509
The Timken wear test is used for classification and differentiation of greases
characterized by weak, average or pronounced EP properties.
BA 413-0271 USA, page 39
The permissible load is the maximum load where neither scoring nor gear
scuffing occurs.
Testing of lubricants for corrosion-preventing properties,

DIN 51 802
Corrosion testing in accordance with the SKF EMCOR method. The lubricant
mixed with water is tested in self-aligning roller bearings. The outer rings of the
bearings tested are examined for corrosion after a specified running time.
Corrosion degree: 0 no corrosion
Copper strip tarnish test, DIN 51 811
Testing the corrosive effect of lubricants on copper. A mechanically ground

copper strip is kept for 24 hours in a sample of lubricating grease which has
been brought to a specified test temperature. Subsequently, the degree of
corrosion is assessed by the tarnish intensity.
Corrosion degree: 1 - 100

1: no corrosion. Weak tarnish
100: The test has been carried out at 100°C.
Test of the behaviour of greases in the presence of water,

DIN 51807, part 1
A layer of lubricating grease applied to a glass plate is exposed to the effect of

still water for 3 hours. All changes of the lubricating grease are recorded.
Assessment category: 1 - 90
1: minor changes
90: The test has been carried out at 90°C.
BA 413-0271 USA, page 40
3. MAINTENANCE AND INSTALLATION OF SPARE PARTS
3.1 Maintenance of the drive
The rotary tube drive shall be regularly watched and checked.
The following aspects shall be considered during daily checks:
Tooth meshing:
- Do all nozzles spray uniformly over the complete width of

the pinion tooth surface?
- Does the tank contain sufficient grease?
- Is the bearing okay?
- Do the tooth surfaces run parallel to each other with no wobbling?
- Are backlash and bottom clearance sufficient?
- Are abnormal noises or vibrations noticed?
Drive units:
- Does the ring gear move unhindered inside the wheel guard?
- Did the position on the base frame remain unchanged?
- Are abnormal noises or vibrations noticed?
- Is the oil level of the gear units okay?
- Are there any leakages?
- Are pinion and couplings still in their original position?

BA 413-0271 USA, page 41
- All screwed connections of the complete drive unit are subject to

dynamic alternating loads. These connections shall be checked for firm
seating and perfect condition during every inspection and whenever
possible (e.g., plant shutdown).
Important note !
Make sure that the welding current is never conducted over drive components
and bearings when carrying out welding jobs to the rotary tube! Have the
earthing points located as closely as possible to the point of welding.
Provided a water-cooling system has been installed at the main gear unit, the
cooling water shall be drained and/or blown out if there is danger of frost during
plant shutdown.
Repairs shall be performed only by qualified personnel. Improper repairs may

result in serous risks and damage.
Caution !
Moreover, consult the inspection, maintenance and repair instructions of the

relevant manufacturers.
Safety instruction:
Before re-starting the plant after maintenance and repair

measures, ensure that all covers have been safely fixed, all
openings closed and all devices for the safety of operating
personnel properly installed.
BA 413-0271 USA, page 42
3.2 Stockkeeping of spare parts
Stockkeeping of spare parts should be based on the information given in the

spare parts lists of the relevant manufacturers.
This is applicable to:
couplings, clutches
gear units, including lubrication and cooling equipment
double-shoe brake
motors, internal combustion engine
complete spray system
Two anti-friction bearings and seals should be kept in stock at all times for the
pinion bearings and one set of fastening screws for the ring gear.
Make sure that nothing but original spare parts are used!
Enclosure to
Test records BA 413-0271 USA
sheet 1
ENCLOSURES
Explanations
Installation - test records
sheet 3 record A - base frame / single-drive system
sheet 4 - base frame / double-drive system
sheet 5 record B - rotary tube / single-drive system
sheet 6 - rotary tube / double-drive system
sheet 7 - rotary tube / twin-drive system
sheet 8 record C - coupling play / single-drive system
sheet 9 - coupling play / double-drive system
sheet 10 - coupling play / twin-drive system
Commissioning - test record
Sheet 11 test record D - rotary tube drive
Operating - test record
Sheet 12 test record E - ring gear/ pinion – single-drive system
Sheet 13 - ring gear/ pinion – double-drive system
Sheet 14 - ring gear/ pinion – twin-drive system

Enclosure to
Test records BA 413-0271 USA
sheet 2
Explanation:
Forms have been attached to the operating manual which must be completed
by the installation and commissioning staff and countersigned by the plant
operator.
These documents not only furnish proof of proper installation and

commissioning, but will also be of help in case of repair and alignment jobs to
the drive units to be carried out later.
Moreover, the plant operator is given a tool to take down the actual condition
of tooth engagement (test record E, sheets 12 ... 14) to enable the specialized
HUMBOLDT WEDAG department to initiate the correct measures, if required.
Test record A: Enclosure to
BA 413-0271 USA
base frame – single-drive system
sheet 3
reference level
1;3 2;4
SE
inlet side
1 2
y
x
3 4
outlet side SA
date 1 2 3 4 SE SA x y
Refection Site
Customer:
foreman: manager:
1 copy of this record handed over to: Mr.
on . .20
Test record A: Enclosure to
BA 413-0271 USA
base frame – double-drive system
sheet 4
reference level
1;5 2;6 3;7 4;8
SE1 SE2
inlet side
1 2 3 4
x y x
5 6 7 8
outlet side SA1 SA2
Datum 1 2 3 4 SE1 SA1 x y SE2 SA2 5 6 7 8
Errection Site
Customer:
foreman: manager:
on . .20
Enclosure to
Commissioning record B:
BA 413-0271 USA
single gear drives of rotary tubes
sheet 5
Com.-no.: Plant:
1. Values measured for 1 rotation: left side right side
- pitch circle distance W max / W min / mm / mm
- backlash F max / F min / mm / mm
- bottom clearance K max / K min / mm / mm
2. Bearing of tooth surfaces max.: % / min.: %
Direction of rotation viewed from

Inlet / Outlet
(cross out untrue expression) X
X rolling circle driven

girth gear
F
W
rolling circle driving

pinion
The values entered are confirmed to be correct:
Place Date Signature of represen- Signature of

tative of the customer: HUMBOLDT
WEDAG-
representative:
Enclosure to
BA 413-0271 USA
double gear drives of rotary tubes
sheet 6
Com.-no.: Plant:
pinion I pinion II
1. Values measured for 1 rev.: inlet side outlet side inlet side outlet side
- pitch circle distance W max / W min / mm / mm / mm / mm
- backlash F max / F min / mm / mm / mm / mm
- bottom clearance K max / K min / mm / mm / mm / mm
2. Bearing of tooth surfaces max.: %min.: % max.: %min.: %

Inlet / Outlet
(cross out untrue expression) X X
pinion II pinion I

girth gear
F
W

pinion
The values entries are confirmed to be correct:

WEDAG-
representative:
Enclosure to
BA 413-0271 USA
twin gear drives of rotary tubes
sheet 7
Com.-no.: Plant:
pinion I pinion II
1. Values measured for 1 rev.: inlet side outlet side inlet side outlet side
- pitch circle distance W max / W min / mm / mm / mm / mm
- backlash F max / F min / mm / mm / mm / mm
- bottom clearance K max / K min / mm / mm / mm / mm
2. Bearing of tooth surfaces max.: %min.: % max.: %min.: %

Inlet / Outlet X
(cross out untrue expression)
X
pinion II pinion I

girth gear
F
W

pinion
The values entered are confirmed to be correct:

WEDAG-
representative:
Enclosure to
Test record C:
BA 413-0271 USA
Coupling clearance for single-drive system
sheet 8

inlet / outlet
( cross out untrue expression )
A
E E
D
B
F B
C F
driving driven
C
For max. permitted deviations, see

instruction manual of coupling manufacturers
date of measurement:
coupling clearance vertical and lateral

( see assembly drawing "drive" for nominal value ) eccentricity
A B C D E F
Erection Site Customer:

foreman: manager:
1 copy of this record handed over to : Mr.
on . .20
Enclosure to
Test record C:
BA 413-0271 USA
Coupling clearance for double-drive system
sheet 9

inlet / outlet
coupling II coupling I
A
E E
D
B
F B
C F
driving driven
C

coupling I coupling II
coupling clearance vertical and coupling clearance vertical and
(see assembly drawing. lateral (see assembly drawing. lateral
"drive" for nominal value ) eccentricity "drive" for nominal value ) eccentricity
A B C D E F A B C D E F

foreman: manager:
on . .20
Enclosure to
Test record C:
BA 413-0271 USA
Coupling clearance for twin-drive system
sheet 10

inlet / outlet
coupling II coupling I
A
E E
D
B
F B
C F
driving driven
C

coupling I coupling II
coupling clearance vertical and coupling clearance vertical and
(see assembly drawing. lateral (see assembly drawing. lateral
"drive" for nominal value) eccentricity "drive" for nominal value) eccentricity
A B C D E F A B C D E F

foreman: manager:
on . .20
Enclosure to
TEST RECORD D
ROTARY TUBE DRIVE
BA 413-0271 USA
sheet 11
General data:
Plant / customer: .................................................................................................................................
Test results (drive) for rotary kiln: .................................. inclination: ......................................... %
Main motor installed: ................. kW; (thyristor contr. / frequency contr./ others ........................ )
Kiln speeds: max. = .................... rpm ; min. = ................... rpm ; operation approx.. ............ rpm
Test results table no.: ...........
duration clinker- operation power required assessment of coating situation
date time of test production speed main motor e. g., thickness, length, rings,
(h) (t/day) (rpm) (kW) uniform, ...
Remarks:
enclosure to
Test record E:
Girth gear - pinion for single-drive system
BA 413-0271 USA
sheet 12
Sense of rotation viewed from inlet / outlet
girth gear half II

W = dist. of rolling circles
8 K = clearance
9 7 S = side clearance
F = flank clearance
10 6 E = inlet side
A = outlet side
inlet outlet
1 5
2 4 girth gear half I SE
3 SA
girth gear
WA
WE FE
KA
KE FA
test point
W ,W ,K ,K ,S ,S
E A E A E A
pinion
Measurement made when point 1, 2, ... passed the test point
Date of measurement: Remarks:
radial axial
test point WE WA KE KA SE SA
1
2
I 3
4
5
6
7
II 8
9
10
foreman: manager:
on: . . 20
enclosure to
Test record E:
Girth gear - pinion for double-drive system
BA 413-0271 USA
sheet 13
(cross out untrue expression
girth gear half II

8
9 7 K = clearance
S = side clearance
F = flank clearance
10 6 E = inlet side
A = outlet side
outlet
1 5 inlet
2 4 girth gear half I SE SA

3
Girth gear
WA
WE FE
KA
test point 2 KE FA
W ,W ,K ,K ,S ,S
E A E A E A
Test point 1
pinion
W ,W ,K ,K ,S ,S
E A E A E A
Measurement made when point 1, 2, ... passed the test point 1 or 2
radial axial radial axial

test point W E1 W A1 K E1 K A1 S E1 S A1 W E2 W A2 K E2 K A2 S E2 S A2
1
2
I 3
4
5
6
7
II 8
9
10
foreman: manager:
on: . . 20
enclosure to
Test record B:
Girth gear - pinion for twin-drive system
BA 413-0271 USA
sheet 14

Girth gear half II

8 7
K = clearance
9 6 S = side clearance
F = flank clearance
10 E = inlet side
5 A = outlet side
inlet outlet
1 4
2 3 Girth gear half I SE SA
girth gear
WA
WE FE
KA
KE FA
Test pint 2 Test point 1
W ,W ,K ,K ,S ,S W ,W ,K ,K ,S ,S pinion
E A E A E A E A E A E A
Measurement made when point 1, 2, ... passed the test point 1 or 2
radial axial radial axial

test point W E1 W A1 K E1 K A1 S E1 S A1 W E2 W A2 K E2 K A2 S E2 S A2
1
2
I 3
4
5
6
7
II 8
9
10
foreman: manager:
on: . . 20
GB 413-0038 USA
• Inlet - GB 413-0020 USA

• Pneumatic inlet seal

- BA 413-0273 USA
State: 413.480 / 01.2007

for the inlet Page 1 of 2

GB 413-0020 en
Former edition:
Contents of the operating GB 413-0020 USA
instructions for the inlet Page 2 of 2
State: 03.2008 General . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020-01 USA

State: 03.2008 Safety and Health. . . . . . . . . . . . . . . . . . . . . GB 413-0020-02 USA

GB 413-0020 en

Former edition:

* Design
* Functioning
State: 03.2008 Transport . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020-04 USA

* Transport
State: 03.2008 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020-05 USA

* Inlet ring
* Scoop ring
* Inlet seal
State: 03.2008 Commissioning . . . . . . . . . . . . . . . . . . . . . . GB 413-0020-06 USA

State: 03.2008 Operation . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020-07 USA


State: 03.2008 Spare parts keeping and after-sales service . . . . . . GB 413-0020-09 USA
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0189
GB 413-0020-01 USA
General
Page 1 of 1
Contents Page
GB 413-0020-01 en
Former edition:
Note!

GB 413-0020-02 USA
Safety and Health
Page 1 of 1
Contents Page

GB 413-0020-02 en
Former edition:
The outlet area is a dangerous zone which is secured free against by a chain.
• Winding-up risk due to rotating holders and yokes.
• Burning risk due to hot clinker(dust) which can possibly

emerge from the kiln.
Generally, repair and control works are only permitted to be made with the tube outlet
standing still or being slowly driven by the auxiliary drive.
Prior to starting a repair, it must be made sure that no clinker is within the area to be
repaired - clean previously.

Note!

GB 413-0020-03 USA
Page 1 of 3
Contents: Page
1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Inlet ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Scoop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GB 413-0020-03 en
2 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Former edition:
1 Design
Note!
The following item numbers refer to drawing No. ZD 413-0189 in

1.1 Inlet ring

A conical inlet ring (item 1) forms the front side of the rotary kiln. It is made up of 10-18
cast segments which are fastened to the end flange (item 3) of the tube with bolts.
The extension of the inlet ring up to the tube shell is accomplished via a welded sheet
cone (item 4).
Moreover, hand openings (item “A”) in the kiln shell which can be reached through the fas-
tening bolts cause a uniform circulation of air and cooling of the inlet area.
GB 413-0020-03 USA; Page 2 of 3
For reasons of durability, the inlet area is always lined with bricks (see picture 413-045). If excep-
tionally the lining shall be made with refractory compound, the segments of heat-resistant cast
steel must be pre-heated for welding on anchors,
1.2 Scoop ring

The scoop ring (item 5) is a sheet steel structure with welded, circulation-air-cooled lifting pock-
ets (item 6) which return raw meal to the kiln which possibly emerged from it and was collected
by the scoop ring. At the external circumference of the scoop ring, two openings are arranged
with bolted covers (item 7). An emergency check of the inlet area in cold state can be made
through the openings and e.g., welding cables for repair welding etc., can be passed through if
the kiln cannot be accessed.
Also upon the emergency check, all safety regulations as per chapter “Safety” must be observed.
The complete scoop ring is bolted to the kiln flange (item 8) and is hence following the rotation.
GB 413-0030-03 USA; Page 2 of 3

GB 413-0020-03 USA; Page 3 of 3
The spring-loaded segment seal is bolted to the front side of the scoop ring; whose wear seg-
ments (item 10, 20) slide in the internal cylinder of the scoop ring. The sliding surface is such
large that the expansion and the intended longitudinal kiln movement can be balanced.
1.3 Seal
The inlet seal comprises a number of individual segments (item 10, 20) which are mounted
together to form a segment ring which is pressed against the wear flange (item 13) of the inlet
chamber with the aid of tension springs (item 12).
During the longitudinal kiln movement, the wear segment ring (item 10, 20) reciprocates on the
inner side of the scoop ring.
This ring (which is movable in itself) is in close contact with the mating flange via the resilient
lever system; it takes the rotating radial and axial movements of the kiln and seals the area
against the ingress of wrong air.
2 Functioning
The hot and pre-neutralized raw meal is fed via a brick retaining dish (item 24) protruding into the
rotary kiln inlet.
The inlet-side cone in the kiln tube ensures a safe accommodation of the raw meal volume
required for the kiln throughput which, due to the rotation and the inclination of the kiln tube, is
further transported towards the outlet.
The scoop ring also rotating and fastened to the kiln tube returns possibly overflowing hot meal
into the process circuit of the rotary kiln (see item 2.1 in chapter “Maintenance”).
The spring-loaded segment seal between the rotating kiln and the stationary inlet chamber
• Largely prevents the entrance of wrong air into the kiln interior.
• Safely balances all position changes due to temperature influences, the intended longitudi-
nal movement as well as a possible eccentricity of the rotary kiln
• Works at low wear, permits the rapid recognition of irregularities and is highly service-
friendly.
It is extremely important that the friction surfaces (item “B”) are ALWAYS in contact during oper-
ation.
Here, it is important that only the lowest pressing force is set for sealing to keep the wear as low
as possible.
Note!
It is not the task of the seal to avoid that raw meal emerges from
the kiln.
GB 413-0030-03 USA; Page 3 of 3

GB 413-0020-04 USA
Transport
Page 1 of 1
Contents: Page
1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0020-04 en
Former edition:
1 Transport
The scoop ring is normally delivered in two parts to the site.
The split scoop ring halves are braced for the transport to avoid deformations.
The cast segments for the inlet ring, wear segments, holder, yoke, bolts and the other
hardware are dispatched on pallets, in boxes or crates.
Note!
Also see chapter "Transport" in section "Operating instruc-

tions rotary kiln" of the Technical Machinery Documenta-
tion.
GB 413-0020-05 USA
Assembly
Page 1 of 4
Contents:Page
1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Inlet ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Scoop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0020-05 en
4 Inlet seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Former edition:
4.1 Assembly plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Information
Note!
The item numbers indicated below refer to drawing No. ZD 413-0189 in

2 Inlet ring
The cast segments (item 1) are individually bolted to the tube end flange (item 3).
Caution!
Ensure that the contact surface is smooth and even; re-grind the sur-
faces, if required.
The transition cast segments - sheet cone must be in one plane (flat) with no steps.
Note!
The exact position of the brick retaining ring is determined by the brick
lining company as a function of the brick measures.
3 Scoop ring
Normally, the scoop ring is delivered to the site in two parts. Prior to being fastened, the halves
must be welded together on the kiln tube; previously, a transport bracing must be made.
GB 413-0020-05 USA; Page 2 of 4
Assembly
The scoop ring is tightened with ratchets through the previously bolted flange ring (item 9),
aligned and tack-welded. After positioning, the final position of the scoop ring is determined by
repeated turning of the kiln and checking it for centricity. The flanged ring (item 9) and the scoop
ring (item 5) are then welded together.
Caution!
The inlet chamber must be mounted so that, with cold kiln and central set-
ting of the tire on the supporting rollers of the roller assembly being the
closest one to the drive (the so-called zero-assembly), the measurement of
105 mm can be determined at four points on the circumference of identical
distance to each other.
GB 413-0020-05 USA; Page 2 of 4

GB 413-0020-05 USA; Page 3 of 4
Assembly
Note!
Absolutely observe the assembly instructions as per “Operating instruc-

tions for the inlet chamber” of the preheater!
4 Inlet seal
The spring-loaded inlet seal must be mounted with utmost care according to the assembly plan.
Failure to follow these assembly instructions will result in an improper functioning of the seal.
The subsequent elimination of defects requires a considerable expenditure and entails high
costs.
4.1 Assembly plan

1. Check whether the wear flange (item 13) of the inlet chamber is in a rectangular position to
the kiln axis.
2. Check whether the direction of rotation of the seal is identical with the direction of rotation
of the kiln, i.e., the wear segment ring (item 10, 20, 21) is pulled by the yokes (item 11) and
not pushed.
Caution!
The direction of rotation is always determined from the outlet, i.e., from the
burner platform.
The indication must be made as follows:
• Direction of rotation “right” - seen from the outlet clockwise
• Direction of rotation “left” - seen from the outlet anti-clockwise.
3. Prior to inserting the wear segments (item 10, 20) into the scoop ring (item 5), the entire
sliding surface of the scoop ring must be checked for precise manufacture. It must be
smooth and even so that the wear ring can freely slide in the scoop ring.
Hooking must be absolutely excluded. If required, re-grind sliding surface.
4. A yoke (item 4) with holder is temporarily bolted to the bottom section of the scoop ring and
the pertaining wear segment (item 10) inserted into the scoop ring. The pressure leg of the
yoke is turned into the acceptance basket of the segment overlapping, slid against the seg-
ment plate and secured with the screw-type bolts (item 22).
Caution!
The pressure leg of the yoke must be aligned centrically to the centre of
the kiln.
This exact alignment is the pre-condition for proper functioning of the seal
in operating condition.
GB 413-0020-05 USA; Page 3 of 4

GB 413-0020-05 USA; Page 4 of 4
Assembly
Tension spring and chain are always suspended after the installation of the second seg-
ment but not yet finally tightened.
5. Between scoop ring and segment (item “C”), an air gap of 0.5 to 1.0 mm is provided for.
The set gap permits the free movement of the wear segment ring in operating condition.
The sliding gap is achieved by setting the adjusting nut at the hinge shaft of the yoke in the
hinge holder.
6. Tighten bolts (item 14).
7. In the same way, mount residual segments except for the end segment (item 20).
Here, upon the arrangement of the segments, it is important to ensure the exact distribution
on the circumference and the gap between the segments. Uniformly distribute the gaps
over the circumference. Each gap should be 10 mm (item “D”); if it is smaller than 5 mm,
the segments must be re-worked.
For assembly reasons, the segment holder (item 21) of the end segment is not welded.
The end segment closes the segment ring.
The last segment holder (item 21) is then welded in place. Ensure at this time that the step
in the overlapping in radial and axial direction is identical to those of the adjacent segments
on the left and the right.
8. After the desired position of the yoke and, hence, the position of the wear ring has been
set, the hinge shaft of the yoke in the hinge holder is fixed with nuts (item 15, 16).
9. The pulling lever (item 19) with the welded castellated nut is then brought into an approxi-
mately 60° position according to the direction of rotation of the kiln and connect with the
yoke via split pins. In addition, the castellated nut is secured with a counter-nut (item 18).
10. All tension springs (item 12) are finally suspended and pre-tensioned by about 100 mm.
The final pressing force is determined only during commissioning and accordingly set. It
must be tried to achieve the highest sealing effect at lowest pressure and, consequently,
lowest wear. The pressing force should be between about 5 to 8 kg.
All yokes and wear segments are now checked for unhindered movement by a tensile test.
It must be made sure that the yokes are not twisted and the wear plates are freely movable
towards each other in their support in the scoop ring and in the gap area.
The springs are covered by a heat protection (item 23).
GB 413-0020-05 USA; Page 4 of 4

GB 413-0020-06 USA
Commissioning
Page 1 of 1
Contents: Page
GB 413-0060-02 en
Former edition:
After the installation work has been completed but before commissioning, the inlet must be
subjected to a careful inspection and functional check.

a) Is the direction of rotation correct?
b) Has the measure of 105 mm from the end of the scoop ring up to the inlet chamber
flange been observed?
c) Can the wear segment ring freely move in the scoop ring?
d) With suspended segments, is there, in the peak area, a gap between segment ring
and scoop ring?
e) Have tension springs been correctly suspended and uniformly pre-tensioned?
f) Have the castellated nuts been connected by split pins and the counter nuts been
tightened?
g) Is the wear segment ring in close contact with the mating flange over the entire cir-
cumference?
After the final check and possible required corrections have been made, the kiln inlet is
ready for commissioning o the kiln.
During commissioning, it must be closely inspected to ensure that the seal is properly
functioning. Possible installation imprecisions must be corrected.
GB 413-0020-07 USA
Operation
Page 1 of 1
Contents: Page
GB 413-0020-07 en
Former edition:
Nor prior to starting, nor after shutting down of the plant, the inlet requires particular
measures.
During operation, due to the different thermal expansion, the kiln reaches its operating
length and a specific pressing force is established at the contact surfaces. After a longer
time, a uniform wear can be noticed at these surfaces. The wear can be influenced by
reducing the pressure. The tension of the springs shall only lead to it that the wear seg-
ment ring is in contact with the mating flange of the inlet housing (to avoid the ingress of
wrong air).
Caution!
A higher pressure does not increase the sealing function.
This force is still changed only to a minor degree due to the intended upward and down-
ward movement of the kiln by 50 mm.
During normal operating conditions, a trouble-free functioning of the sealing elements can
be expected.
A particular lubrication of the sliding surfaces is normally not necessary. Instead, it may
even increase the wear if the lubricant is mixed with the raw meal dust (effect as that of
grinding paste).
GB 413-0020-08 USA
Maintenance
Page 1 of 5
Contents: Page
1 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Undesired meal emerging from the seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GB 413-0020-08 en
Former edition:
1 Information
Note!
For maintenance lists, see section “Maintenance” of the Tech-

Spare parts lists as per section “spare parts” of the Technical



The inlet area as part of the kiln system is inspected daily (see section “Maintenance” of
the Technical Machinery Documentation). If irregularities are noticed, these must be elimi-
nated without delay.
When and how this has to take place, is decided by the plant manager or a staff member
nominated by him. In particular, proper functioning of the seal must be ensured. By chang-
ing operating conditions, the pressing force can change. If such a condition should occur,
the tension springs must be released or re-tensioned.
GB 413-0020-08 USA; Page 2 of 5
Maintenance
This maintenance activities must not be made only during a standstill with cold kiln, but they can
also be made with a slowly rotating kiln (operation with the auxiliary drive).
All safety instructions of the “Safety” chapter must be observed.
2.1 Undesired meal emerging from the seal

If larger volumes of raw meal should flow off the inlet, the causes must be found.
• Normally, the reasons for such a condition are process-related. If accretions should form in
the inlet area of the kiln, the raw meal cannot flow freely and back-clogging occurs..
Part of the accumulated raw meal then flows via the brick-lined rim of the conical inlet ring
into the scoop ring.
The lifting pockets of the scoop ring can return only part of the flowing in raw meal into the
kiln; the rest is pressed outwards through the seal.
GB 413-0020-08 USA; Page 2 of 5

GB 413-0020-08 USA; Page 3 of 5
Maintenance
• A further cause for the emerging raw meal can be a damage to the brick-retaining dish and/
or the destruction of the brick lining.
Over a long period of time, leaking hot raw meal can damage the inlet seal which results in an
undesired, increased ingress of wrong air.
Wrong air increases the heat consumption within the burning process and can also cause accre-
tions of raw meal (condensation of alkalines) at the walls of the inlet chamber.
Therefore, the defects must be eliminated and the cleaning works performed as soon as possi-
ble.
It must be ensured that the segments (item 10, 20, 21) (except for a gap of 1 mm) are in close
contact with the scoop ring. If the gap is larger, in particular in the upper position, the yokes (item
11) must be reset with the aid of the nuts (item 15, 16).
It is also important that the segment ring (item 10, 20, 21) is always in contact with the sliding sur-
face of the inlet chamber flange (item 13) due to the spring force. If this flange is no longer in a
rectangular position to the kiln axis due to thermal influences, the spring force will not be suffi-
cient and the segment ring should be pressed off the flange during a rotation and remain in this
position. Also clamping of the wear segments to the inlet chamber neck would have the same
result.
In such a case, the flange and the inlet chamber neck must be aligned after the brick lining has
been broken off.
GB 413-0020-08 USA; Page 3 of 5

GB 413-0020-08 USA; Page 4 of 5
Maintenance
The measure of 105 mm must exist at 4 points over the circumference.
GB 413-0020-08 USA; Page 4 of 5

GB 413-0020-08 USA; Page 5 of 5
Maintenance

Damaged components affecting proper functioning of the inlet area should be replaced by new
ones for economical and also safety reasons.
Removal and installation of spare parts is only permitted when

the kiln is cold.
The safety instructions and information must be observed.
The replacement of tension springs or wear segments does not require a high expenditure.
If the wear segment ring is worn down or deformed, it should be completely replaced. The
replacement of individual segments should be avoided, if possible in view of the possible step
formation in the wear surfaces and the related worse sealing effect.
The locking chain must be properly mounted after the repair work
is completed.
GB 413-0020-08 USA; Page 5 of 5


Contents:
GB 413-0020-09 en
Former edition:
Note!

BA 413-0273 USA
Pneumatic inlet seal
Page 1 of 2
Contents Page
1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Assembly and installation of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Maintenance and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Pneumatic seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BA 413-0273 en
Former edition:
Drawing No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0200, sheet 1
1 Description
The flat seal is held in two adjustable suspensions which can be moved on two levels. The
gap between the rotary tube and the inlet chamber is sealed by a loose segment ring (Item
1, 2) welded together. Depending on its size, it is pressed against a surface of the scoop
ring equipped with wear segments by 8 to 12 pneumatic cylinders (Item 5).
The radial seal (Item 4) is realized via a stuffing box packing which is pressed by a sheet
ring with adjusting bolts onto the inlet chamber trunnion.
To the outer rim of the segment ring, retaining plates are welded to which the pneumatic
cylinders (Item 5) are welded with bolts. A damping plate protects the cylinders against
radiation heat.
If compressed air is applied to the cylinders, they are supported by a counter-bearing and
the piston rod presses the sealing ring (Item 1 and 1) against the rotating wear ring of the
scoop ring (Item 1).
The cylinders are controlled via a simple pneumatic system.
2 Assembly and installation of spare parts

The assembly follows the normal assembly regulations.
In particular, it must be made sure that the segment ring (Item 3) can be freely moved to
permit an adaptation to the changing movements of the scoop ring.
Also, the contact surfaces of the wear ring must be even and flat to ensure that they are in
perfect contact during operation.
The radial seal (Item 4) must be preloaded such that it is supported on the inlet chamber
trunnion, but can follow the axial movements of the segment ring (Item 3).
The inlet chamber trunnion on which the radial seal (Item 4) is displaced must be aligned
circularly and centrically; the surface (weld seams) must be even.
BA 413-0273 USA; Page 2 of 2
Pneumatic inlet seal
Prior to the assembly, the pipelines must be thoroughly cleaned to avoid damage to the cylinder
or failures of the valves.
3 Maintenance and commissioning

Prior to commissioning, among others, the following must be confirmed:
– All cylinders and the pneumatic system are properly functioning.
– The wear rings are in full contact with each other.
– The radial seal (Item 4) is supported such on the shell that it can be easily slid.
During operation, the pneumatic seal must be inspected daily paying particular attention to the
extracted pistons.
If the piston rods must be replaced if they should jam (be distorted). The segment ring should always
be uniformly loaded.
Caution!
The pressure to be applied must be determined during operation. It

should only be high enough that a close contact of the wear rings is
ensured (approximately 0.2 - 0.4 bar). An extremely high pressure
leads to premature wear of the rings, in the extreme case even to a
distortion of the holder and the pistons.
Overfilling of the kiln causes larger volumes of raw meal to leak from the seal.
A ring formation in the kiln due to adhering material in the inlet area will also lead to leakage of raw
meal.
The compressed air system must be disconnected upon extended standstills and when inspecting the
sealing surfaces for wear. When the kiln cools down, a gap to the wear segments forms which should
be sufficient for the check.
3.1 Pneumatic seal

For the inlet seal, two complete sets of wear segments including fastening bolts as well as a complete
set of hydraulic cylinders should be kept available.
These parts must absolutely be kept on stock.
Caution!
Dismantling and newly mounting are only permitted to be performed

with the plant standing still and having cooled down.
Note!
The permanent monitoring of the O2 increase in the inlet area is the

most reliable sign for proper functioning of the seal.
BA 413-0273 USA; Page 2 of 2

GB 413-0038 USA
• Outlet - GB 413-0030 USA

State: 413.480 / 01.2007

of the outlet Page 1 of 2

GB 413-0030 en
Former edition:
GB 413-0030 USA; Page 2 of 2
Contents of the operating instructions:

State: 03.2008 General . . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-01 USA
State: 03.2008 Safety and Health . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-02 USA

State: 03.2008 Design and functioning . . . . . . . . . . . . . . . . . . GB 413-0030-03 USA

* Reference
* Outlet end section
* Outlet seal
* Outlet cooling and dust chute
* Kiln hood
State: 03.2008 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-04 USA

* Transport
State: 03.2008 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-05 USA

* Information
* Outlet end section
* Outlet segments
* Spring-loaded outlet seal
* Outlet cooling and dust chute
* Kiln hood
State: 03.2008 Commissioning . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-06 USA

State: 03.2008 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-07 USA

State: 03.2008 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030-08 USA

* Information
State: 03.2008 Spare parts keeping and after-sales service . . . . . . . GB 413-0030-09 USA
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0192
GB 413-0030 USA; Page 2 of 2

GB 413-0030-01 USA
General
Contents Page
GB 413-0030-01 en
Former edition:
Note!

GB 413-0030-02 USA
Safety and Health
Contents Page

GB 413-0030-02 en
Former edition:
The outlet area is a dangerous zone which is secured free against by a chain.
• Winding-up risk due to rotating holders and yokes.
• Burning risk due to hot clinker(dust) which can possibly

emerge from the kiln.
Generally, repair and control works are only permitted to be made with the tube outlet
standing still or being slowly driven by the auxiliary drive.
Prior to starting a repair, it must be made sure that no clinker is within the area to be
repaired - clean previously.

Note!

GB 413-0030-03 USA
Design and Functioning
Contents: Page
1 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Outlet end section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Outlet seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0030-03 en
4 Outlet cooling and dust chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Former edition:
5 Kiln hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Reference
Note!
The following item numbers refer to drawing ZD 413-0192

enclosed to this description.
2 Outlet end section

The hot clinker flows from the rotating kiln tube into the kiln hood shaft. During this pro-
cess, the discharge edge of the outlet end section is extremely stressed by the flow of mol-
ten material and is therefore particularly designed and made of high-quality materials.
The outlet end section is a double-walled, air-cooled sheet structure which is welded on-
site to the end of the kiln tube.
The outer cooling shell (5) is connected to the tube section (6) by spacers and cross hold-
ers (7) uniformly distributed over the circumference.
This flexible construction permits a free expansion of the individual elements so that a dis-
tortion and deformation among them is avoided.
The double-walled outlet end is completed with a heat-resistant cast segment ring (1). It
comprises individual segments which are plugged onto the supporting arms (2), welded to
the tube and then bolted into place (3, 4).
The segments are designed such that on one hand, with their-nose-like contact surface,
they keep the last 4 brick rows in position without any problem. On the other hand, they
ensure an optimal cooling effect thanks to their cavitations.
GB 413-0030-03 USA; Page 2 of 3
Design and Functioning of the outlet
The main thrust of the kiln brick lining is taken by the brick-retaining ring (8), which is welded in 4
brick rows before the outlet end of the kiln tube.
It comprises heat-resistant cast segments connected to the kiln tube by a slot weld.
The rectangularity and plain arrangement of the brick-retaining ring to the kiln axis is of high
importance for the durability of the bricklining.
Already minor deviations can cause the destruction of the bricklining in the outlet area and lead
to serious damage of the entire outlet.
3 Outlet seal
The gap between the cooling shell (5) and the kiln hood is covered by a spring-loaded seal.
It comprises a great number of individual sheet segments (10, 11) which is pressed against the
stationary wear ring (9) of the kiln hood via a lever system (12).
This spring-loaded lever system does the following:

• Permits a high flexibility of the sealing surface.
• Largely prevents the entrance of wrong air into the kiln interior.
• Safely accepts all position changes due to temperature influences, the intended longitudinal
movement as well a possible eccentricity of the rotary kiln.
• Operates with low wear development, permits the rapid recognition of irregularities and is
highly service-friendly.
It must be made sure that in any operating condition contact at the friction surfaces (Item A) is
ensured. Here it is important that only the lowest possible pressing force is set for sealing to keep
the wear low.
Note!
The seal is not meant for preventing clinker to emerge from the
kiln.
4 Outlet cooling and dust chute

The outlet end section is cooled with air over its entire circumference. Here, the cooling air is
directed via baffle plates through the supporting arm up to the hollow tappet of the outlet seg-
ments.
Cooling is realised via pipelines with nozzles (24) mounted around the cooling ring. The pipelines
are split and connected to two blowers (25)
GB 413-0030-03 USA; Page 2 of 3

GB 413-0030-03 USA; Page 3 of 3
Design and Functioning of the outlet
The blowers (25) are driven via a flexible coupling (30) by a motor (31). The drive shaft (27) with
the impeller (26) is supported in two antifriction bearings (28, 29).
The cooling air is directly blown into the annular gap to be cooled. Possibly emerging clinker dust
is collected in a dust chute and lead into the cooler or onto the drag chain.
5 Kiln hood
The kiln hood is a stable sheet steel housing and internally brick-lined.
The rotary kiln protrudes into the front headwall; the lower part of the kiln hood is directly con-
nected to the cooler. The gap between both units is filled by a flexible, heat-resistant seal.
In the rear wall, a split door is arranged having an opening for the burner lance.
Laterally to the kiln door, connections for the tertiary air line or the dust settling chamber have
been provided for.
Various measuring sockets and inspection hole doors are welded into the rear wall and the lat-
eral walls of the kiln hood.
The kiln hood is anchored in the foundation with two bolts. This type of anchoring permits a cross
and longitudinal expansion of the kiln hood upon temperature difference.
GB 413-0030-03 USA; Page 3 of 3

GB 413-0030-04 USA
Transport
Contents Page
1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GB 413-0030-04 en
Former edition:
1 Transport
The outlet section is normally delivered to the site in completely mounted condition.
It is braced and transported in a vertical position, supported on the tube section edge (not
on the segment ring).
Caution!
When tightening the outlet section with ropes, particular attention

must be paid to the displacement of the center of gravity in the
upper area.
The dust chute, the pipelines as well as the fastening material are transported on pallets,
in boxes or in grate boxes. Becausenof its large dimensions, the kiln hood is normally not
shipped as one unit, but - matched to the logistic requirements - in several transport units
which are suitably braced and marked for the assembly.
Note!
Also see “Transport” in section “Operating instructions rotary

kiln” of the Technical Machinery Documentation.
Assembly GB 413-0030-05 USA
Contents: Page
1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Outlet end section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Outlet segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GB 413-0030-05 en
4 Spring-loaded outlet seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Former edition:
4.1 Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 Outlet cooling and dust chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Kiln hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Information
Note!
The item numbers indicated below refer to drawing No. ZD 413-0192 in

2 Outlet end section

The outlet end section is radially braced and normally delivered with bolted protection seg-
ments. The welded connection in the area of the round seam is executed as X-seam and is
welded manually or by the submerged arc procedure.
GB 413-0030-05 USA; Page 2 of 5
Assembly of the outlet
3 Outlet segments
Onto the supporting arms of heat-resistant cast steel (e, Fig. 413-039), which are protruding over
the end rim of the outlet tube and are fastened there by welding, the segments (d) also made of
heat-resistant cast steel are slid and screwed in place with bolt (a).
The bolts (a) and the grinding cams (b, c) always form a three-point support. If required, the
cams must be somewhat re-ground.
The bolts (a) are coated with anti-seize paste and tightened by hand; the bolt head is secured by
a spot weld (f).
Segments flushing with the tube

diameter.
Flushing also in circumferential

direction, to achieve a proper sur-
face for the bricklining.
Re-work if necessary.
Observe references for the make-

up of the refractory lining.
GB 413-0030-05 USA; Page 2 of 5

GB 413-0030-05 USA; Page 3 of 5
4 Spring-loaded outlet seal

The wear ring (9) is bolted to the kiln hood. It must be checked with a shifting square at a mini-
mum of 4 points on the circumference to determine whether the wear ring is in a rectangular
position to the kiln axis.
4.1 Assembly sequence

1. Check whether the flange of the kiln hood (outlet housing) is in a rectangular position to the
kiln axis. The center of the flange and of the rotary kiln outlet must coincide. A maximal
deviation of 20 mm upon new installation must not be exceeded.
2. Check whether the execution of the seal corresponds to the direction of kilm rotation. The
segment ring (10, 11) is pulled by the yokes (12) and not pushed; that means that seen in
rotation direction, the respective pressing end of the yoke is always behind the hinge bear-
ing point.
Caution!
The direction of rotation is always determined by the outlet, i.e., seen from
the burner platform into the direction of the preheater.
Indications are made as follows:

Direction of rotation “right” - clockwise seen from the outlet.
Direction of rotation “left” - counterclockwise seen from the outlet.
3. rackets (20) for fastening the seal are welded to the outer shell (cooling ring) (5) of the out-
let at regular distances. The holders with yokes (12) are bolted to these fastening brack-
ets. The also rotating wear segments including yokes are mounted laterally to the rotary
tube to permit an unhindered movement of the seal; these segments also come into con-
tact with the stationary flange, at the latest after tensioning of the chains.
It is best to mount the segments on the side showing downwards. The tension springs are
also suspended after the installation of the second segment, but not yet tensioned.
Caution!
Make sure that the outer cooling shell area (5) is plain and smooth so that
the segments cannot interlock.
GB 413-0030-05 USA; Page 3 of 5

GB 413-0030-05 USA; Page 4 of 5
4. When mounting the X-part wear ring comprising wear segments (10) and one end seg-
ment (11), make sure that the distance between the individual segments is uniformly dis-
tributed. Every gap should be 16 mm. If it is smaller than 8 mm, the segments must be re-
worked.
An unhindered sliding of the wear plate overlappings must be ensured; if necessary, the
flat irons must be re-ground.
In the case of the end segment (11), the segment holder (13) is not welded for reasons of
assembly.
The end segment completes the segment ring.
Now, the last segment holder is welded.
Caution!
At this time it must be made sure that the offset of the overlapping in radial
and axial directions is identical with those of the segments adjacent on the
right and left.
After having achieved identical segment gaps, the mounted yokes (12) with the bolted
hinged holders are tack-welded to the fastening brackets after their rectangular alignment.
The yokes must be suspended laterally on the horizontal axis at the side of the tube show-
ing downwards. In this way, with a slowly rotating tube, segment by segment is sus-
pended and pressed onto the cooling shell by the yoke.
The distance “Y” depends on the thermal expansion of the kiln.
Caution!
Remove any tools or other devices used for assembly after com-
pletion of the installation of the yoke fastening device.
Caution!
The pressure leg of the yoke must be in a central position to the

center of the kiln.
This exact alignment is the pre-condition for proper functioning of
the seal during operation.
As a checking criterion, the yokes must permit a rotation around their fulcrum. Only then
should the nuts be tightened and countered.
5. The levers (16) for tensioning chains and tension springs are in a position of about 120° to
the yoke arms (12)
GB 413-0030-05 USA; Page 4 of 5

GB 413-0030-05 USA; Page 5 of 5
6. The tension springs and chains (17, 18) are pre-tensioned from 330 mm to 450-500 mm
after having been suspended. This value depends on the pressure generated onto the
contact surface of the mating flange and must be kept as small as possible (approximately
7 kg per segment).
5 Outlet cooling and dust chute

Dust chute, spoilers, nozzle and pipeline are mounted according to the common regulations for
assembly works. The dust return line must be laid as required by the local conditions. If the pipe-
line must be laid with an inclination, the largest possible inclination shall be attempted to avoid
jamming of the flowing off clinker dust.
During the installation of the blower (25), it must be made sure that the housing is not distorted.
The shaft (27) with the impeller (26) must permit an unhindered rotation.
6 Kiln hood
In view of its size, the kiln hood (32) is delivered to the site in several braced and marked units.
The installation takes place according to the common assembly regulations. Here, the following
must be particularly observed:
• The kiln hood is positioned according to the system point (P) of the kiln tube,
• The flange ring (9) is in a central and rectangular position to the kiln axis so that the wear
ring of the outlet seal (10, 11) is in complete contact with the contact surface,
• The slide door (33) permits unhindered movement,
• The flexible sealing elements (34) between kiln hood and cooler are close to each other and
are kept in position by flat irons (35) avoiding a displacement by possible overpressure,
• After the completion of the installation of the kiln tube and the outlet, the kiln hood is brought
into its final position and anchored with the bolts (36).
GB 413-0030-05 USA; Page 5 of 5

GB 413-0030-06 USA
Commissioning
Contents: Page
GB 413-0030-06 en
Former edition:
After the termination of the installation works and prior to commissioning, the outlet must
be subjected to a careful inspection and functional check.

a) Is the direction of rotation correct?
b) Has the distance between the bracket (cooling shell) and the flange ring (kiln hood)
been observed?
c) Can the wear segment ring move freely on the cooling shell?
d) With hanging segments, is there a gap between segment ring and cooling shell in the
vertex?
e) Have the tension springs been correctly suspended and uniformly pre-tensioned?
f) Have the crown nuts been fastened with split pins and the counter nuts been tigthen-
ed?
g) Is the wear segment ring in full contact with the mating flange over the entire circum-
ference?
h) Have all measuring instruments been connected to the kiln hood?
i) Are the cooling air blowers properly functioning and correctly interlocked?
Prior to starting up the cooling air blowers, observe the following:
1. Check direction of rotation (observe arrows on housing).
2. The drive motor (31) must always be connected by an expert electrician who
also compares the voltage and frequency indicated on the motor nameplate with
the existing mains. The motor must generally be protected by a motor protection
switch. In the case of blowers with a relatively high speed and a large flywheel
effect (extended running-up time), special switches with delayed triggering must
be used. Although the drive motor has a relatively high power reserve, it is
recommended to measure, upon commissioning, the current consumption of
the motor with an ammeter. If the current consumed by the motor is higher than
indicated on the nameplate for the respective voltage, the motor is running at
overload. In this case, the volume of conveying air must be strongly reduced
(throttle gate) until the current consumption is reduced again to the rated value.
3. All guards (e.g. coupling guard) must have been properly mounted.
GB 413-0030-06 USA; Page 2 of 2
Commissioning of the outlet
4. The blower (25) must be started with closed throttle gate to accelerate starting.
5. The blower is only permitted to be operated with connected pipelines, as otherwise the
motor could be overstressed.
6. Check smooth running of the antifriction bearings (28, 29). Considering the grease
volume control, the bearings must be re-lubricated after about 1 hour, then every 24
hours thereafter and finally at the specified re-lubrication intervals (see lubrication ins-
tructions).
Upon first starting up or upon every re-lubrication, the bearing temperature will in-
crease. After a short running time, however, the normal temperature is reached again.
The temperature of the bearings should not exceed 80 °C. The felt seal (28) between
the antifriction bearing housing and the drive shaft must not be maintained.
After the final check and possible required corrections have been made, the kiln outlet is ready
for commissioning of the kiln.
During commissioning, it must be closely observed whether the seal is properly functioning. Pos-
sible installation imprecisions must be corrected.
GB 413-0030-06 USA; Page 2 of 2

GB 413-0030-07 USA
Operation
Page 1 of 1
of the outlet
Contents: Page
GB 413-0030-07 en
Former edition:
The kiln outlet requires particular measures after start-up and before shutting down of the
plant.
During operation, due to the different thermal expansion, the kiln reaches its operating
length and a specific pressing force is establishing at the contact surfaces. After a longer
time, a uniform wear can be noticed at these surfaces. This wear can be influenced by
reducing the pressure. The tension of the springs shall only lead to it that the wear seg-
ment ring is in contact with the mating flange of the kiln hood (to avoid the ingress of wrong
air).
Caution!
A higher pressure does not increase the sealing function.
This force is still changed only to a minor degree due to the intended upward and down-
ward movement of the kiln by 50 mm.
A trouble-free functioning of the sealing can be expected during normal operating condi-
tions.
A particular lubrication of the sliding surfaces is normally not necessary. Instead, such
lubrication can even increase the wear if the lubricant is mixed with the clinker dust (with
an effect as that of grinding paste).
Caution!
Ensure that the outlet is sufficiently cooled and protected against

overheating.
Maintenance GB 413-0030-08 USA
Contents: Page
1 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Outlet end section with segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Spring-loaded seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Outlet cooling and dust chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GB 413-0030-08 en
2.4 Kiln hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Former edition:
1 Information
Note!
For maintenance lists, see section “Maintenance” of the Tech-

Spare parts lists as per section “spare parts” of the Technical



The outlet area as part of the kiln system should be inspected daily (see section “Mainte-
nance” of the Technical Machinery Documentation). If irregularities are noticed, these
must be eliminated without delay.
When and how this has to take place is decided by the plant manager or a staff member or
his designate. In particular, proper functioning of the seal must be ensured. By changing
operating conditions, the pressing force can change. If such a condition should occur, the
tension springs must be released or re-tensioned.
This maintenance activities can be performed not only during a standstill with cold kiln, but
with the kiln rotating slowly (using the auxiliary drive).
Observe and follow all safety instructions in the “Safety”

chapter.
GB 413-0030-08 USA; Page 2 of 4
Maintenance of the outlet
2.1 Outlet end section with segments

The outlet end section is no spare part in the common sense. Its service life, however, strongly
depends on the condition of the brick lining and the protective segments.
In practice, a service life of about 10 years and of 2 - 4 years for the protective segments was
experienced.
The protective segments are stressed by

• Temperature
• Alkalies and sulphur
• Pressure of the 4 bottom-most brick rows
• Wear
The firing nozzle should protrude into the kiln by at least 1 m (2 m is preferred) to already use the
kiln end as cooling zone.
The influence of the alkalies is a function of the chemical composition of the raw material and
can, therefore, only be controlled in this way. Likewise, the sulphur content in the fuel is hazard-
ous to the segments.
On the other hand, the brick pressure can be influenced by suitable brick laying techniques.
This means that the regulations for the suppliers of the refractory brick lining must be observed.
2.2 Spring-loaded seal

The outlet area, in particular however the spring-loaded seal, should be optically checked during
the daily controls.
The following must be observed:

1. The springs must be tensioned; re-tension, if required.
2. The segments (10, 11) must be in contact with the external shell (5) (except for a gap of 3
mm at a maximum). If the gap is larger, especially in the lower position, the yokes (12) must
be reset with the aid of the bolts (15).
3. Due to the spring force, the segment ring (10) must always be in contact with the wear sur-
face of the flange (9). If this flange is no longer in a rectangular position to the tube axis by
the influence of temperature, the spring force is no longer sufficient. This means that the
segment ring would be pressed off upon a rotation and would remain in this position.
In this case, the flange must be adjusted.
Caution!
For rotary kiln seals:

Operation should take place at a slightly negative pressure to
avoid fine clinker dust whirled up from the clinker cooler penetrat-
ing the seal in the kiln hood area.
GB 413-0030-08 USA; Page 2 of 4

GB 413-0030-08 USA; Page 3 of 4
2.3 Outlet cooling and dust chute

For the service life of the outlet, particularly the protective segments, a properly functioning cool-
ing system is of utmost importance.
Here, it is important to ensure that the cooling blowers are always connected during operation;
upon a stop, however, but also during slowing down of the plant, they must be disconnected to
avoid partial cooling (point cooling) of the nose ring, which would lead to deformations.
If larger volumes of clinker emerge from the outlet area, the causes must be found.
Normally, these causes are related to the process.
A remedy must be found without delay so that the spring-loaded seal is not damaged. Cleaning
work must be performed to permit that newly emerging clinker is immediately recognized.
2.4 Kiln hood

During the daily check of the kiln hood, the following must be particularly observed:
• Position and condition of the kiln hood flange for taking the spring-loaded seal.
• Seal kiln hood - cooler.
• Seal kiln hood - burner.
• Has the kiln hood door been correctly closed?
• Have all required measuring instruments been connected?
• Are the inspection hole devices in proper condition?
Upon a standstill, it must be checked, whether the kiln hood door can be easily slid and locked.
In view of the hot and dusty environment in which the kiln hood door is moved, it must be
ensured that the chain of the sliding roller assembly (37) is regularly lubricated with heat-resistant
grease.
GB 413-0030-08 USA; Page 3 of 4

GB 413-0030-08 USA; Page 4 of 4

Damaged components affecting proper functioning of the outlet area should be replaced by new
ones both for economical but also safety reasons.
Removal and installation of spare parts is should be done only

when the kiln is cold .
The safety instructions and information must be observed.
The replacement of tension springs or wear segments of the spring-loaded seal is quite easy.
If the wear segment ring is worn down or deformed, it must be completely replaced. Due to the
possible step formation in the wear surface and considering the resulting deteriorated sealing
effect, it must be avoided to replace individual segments.
The protective segments are typical wear parts; at least one set — including bolts — should be
kept on stock.
For replacing the protective segments, the brickwork must be broken out. The weld point “f” (see
Fig. “Outlet segments” in the “Assembly” chapter) at the bolt head is removed and the screw
union loosened. If this is not possible, the bolt head and part of the shaft must be chamfered.
When mounting the new segments, the references given under Item 3 in “Assembly” chapter
must be observed.
Further explanations may be taken from BA 413-064/2.
A set of sealing elements should be kept on stock for sealing the kiln hood against the cooler,
The same applies to the sliding device (roller assembly) of the kiln hood door and the measuring
instruments.
GB 413-0030-08 USA; Page 4 of 4


of the outlet
Contents:
GB 413-0030-09 en
Former edition:
Note!

GB 413-0038 USA
• Accessories
State: 413.480 / 01.2007

GB 413-0038 USA
• Optional equipment
State: 413.480 / 01.2007

GB 413-0038 USA
Special descriptions
• Tire fastening mechanism - BA 413-0171 USA
• Adjusting instructions - BA 413-005-1 USA
• Expansion and shrinkage processes

- BA 413-049-1 USA
• Brick retaining rings - BA 413-064-2 USA
• Kiln centerline surveying - BA 413-0226 USA
State: 413.480 / 01.2007

Loose tire with tire section BA 413-0171 USA

and tire fastening Page 1 of 27
Safety
by correct assembly, proper operation,

careful maintenance and care
BA 413-0171 en
Former edition:
This symbol indicates all important safety references in the

present operating instructions.
Observe these references and, in these cases, behave par-

ticularly careful. Notify these safety instructions also to
other users.
Beyond the references in these operating instructions, the

general safety and accident prevention regulations of your
legislator must be observed.
Copyright
The copyright to these operating instructions remains with Humboldt Wedag, Inc. The
instructions are meant for the assembly, operating and supervision staff. The operating
instructions contain regulations of technical nature and drawings which are not permitted
to be multiplied, distributed or used for competition purposes without authorization, neither
in whole nor in part, unless expressly approved. Nonobservance of the above will entail
claims for indemnification.
Mailing address

USA
Phone: 770-810-7300
Fax: 770-810-7333
BA 413-0171 USA; Page 2 of 27
Loose tire with tire section and tire fastening
Contents: Page
1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1.1 Dimensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1.2 Quality assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.1 Measuring the ovality according to the shell test method . . . . . . . . . . . . . . . . . . . . .6
1.2.2 Assessment of the ovality by measuring the relative movement . . . . . . . . . . . . . . .8
1.3 Tire fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.3.1 Cold gap KSP (= diameter difference in cold condition) . . . . . . . . . . . . . . . . . . . . .11
1.3.2 Hot gap WSP (= diameter difference in operating condition) . . . . . . . . . . . . . . . . .11
1.3.3 Axial movement of the tire, axial gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.3.4 Radial movement of the tire relative to the tube . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.3.5 Wobbling of the tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 Maintenance, measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Pre-conditions for a trouble-free operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3 Measures for avoiding narrowings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.4 Calculation example for determining the diameter difference . . . . . . . . . . . . .19
2.5 Rehabilitation measures for narrowings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.5.1 Replacement or lining of the slide plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.5.2 Repair of worn down guide strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.7 Equalizing the contact surfaces of tires, supporting rollers and

thrust rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BA 413-0171 USA; Page 2 of 27

BA 413-0171 USA; Page 3 of 27
1 Description
1.1 Tires
The tires have a rectangular solid-profile cross-section and are mechanically worked on either
side. All forces and loads from the rotary tube are directed via the tires into the tire assembly and
further into the foundations.
Beyond this function as supporting elements, the tires are meant for providing the relatively “soft”
rotary tube with the necessary circular stiffness.
Therefore, proper functioning of the tires is of utmost importance.
1.1.1 Dimensioning
Dimensioning of the tires is based on the assembly load resulting from the statical rotary tube
calculation considering the alternating dynamical and thermal stress upon different operating
conditions. The tires are highly resistant to deformation, rupture and wear. As such, they meet all
requirements regarding admissible
• Ovality
• Tension in the cross section
• Hertzian stress between tire and supporting roller/thrust roller
The stiffness of the tires, i.e., a small deformation under stress is of high importance for the dura-
bility of the bricklining. This so-called “ovality” of the tires is calculated according to Nies and is
indicated in percent (%) of the internal diameters of the sheet shell (= rated tube diameter).
For the calculated ovality of the tires, the ovality value of max. 0.2% is common in the cement
industry and recommended by the manufacturers of refractory materials has been taken as a
basis.
Calculation formula (acc. to Nies):
With P = Assembly load in N calculated from the tube statics assuming the common
load values for a geometrically straight rotary tube (incl. tire weight)
Rs = Center-of-gravity radius of the tire (cm)
E = Modulus of elasticity (N/cm²
I = Moment of inertia (cm4)
ϑ = Radius change
ω = Difference between large and small diameter of the deformed tire bore
BA 413-0171 USA; Page 3 of 27

BA 413-0171 USA; Page 4 of 27

The quality assurance is realized via extensive material tests such as
• Non-destructive tests with the tires and
• Destructive tests with samples of identical material
Tire materials coming into question are high-quality types of cast steel, cast tempering steel or
forged steel with matched mechanical properties.
1.2 Ovality
Ovality in connection with rotary tubes generally means the change of the shape of the shell plate
during a tube rotation. The ovality is of decisive importance for the durability of the rotary tube lin-
ing.
The ovality is a function of the transverse force and depends on the stability (circular stability) of
the tire, the tube plate thickness in the tire area and the diameter difference d (see Fig. 5).
With the frequency of the tube rotation, the size of the transverse force can be subjected to
heavy deviations. The cause is a distortion of the tube axis by local or linear exceeding of the
normal shell temperature. Moreover, the transverse force can permanently change due to lower-
ing of the foundation, different narrowings of the tire sections or by wrong positioning of the tires.
The deformation of the tube (ovality) is generally dependent on two parameters:

• Ovality of the tire
• Deformation of the tube in its upper vertex (flattening)
The stiffness of the tires can be evidenced by calculation as already mentioned under 1.1.1 and,
at the indicated limit value of max. 0.2% ovality related to the rated rotary tube diameter, it offers
the required safety.
The tube plate thickness near the tire influences the ovality only to a minor degree, which could
be confirmed by numerous practical measurements in the last years. The reason is that the
rotary tube - irrespective of its plate thickness - is always the clearly “softer” component com-
pared with tire and, in its lower section, adapts itself to the bore of the stiffer tire (see Fig. 7, pic-
ture C).
BA 413-0171 USA; Page 4 of 27

BA 413-0171 USA; Page 5 of 27
Differences regarding the deformation can only occur in the relatively small area of the upper flat-
tening (see Fig. 1.1, 1.2).
Deformation of the tire section Deformation of the tire section

with normal plate thickness at insufficient plate thickness
Fig. 1.1 Fig. 1.2
The diameter difference d between tire and tube is of considerably higher importance. It is
dimensioned so that during normal operation, a small gap width S is establishing between tire
and tube and, consequently, a relative movement.
Relative movement is the dimensional displacement of a point of the rotary tube shell against the
tire during one rotation. Depending on the rotary tube size, in warm operating condition, up to a
maximum of 25 mm/rev. are admissible.
During heating up of the rotary tube - but also during production operation, if the accretions fall
down in the area of the tire - the shell temperature rises more rapidly than the temperature of the
tire. Normally, the tire gap is sufficient to balance this temperature difference. Nevertheless, the
kiln shell temperature must be monitored since, in the extreme case, if there is no tire gap, com-
pressive strain can occur in the tube shell which exceeds the proportionality limit of the material.
This means lasting narrowing of the tube and, as a result, an increased ovality when the normal
temperature difference between tire and tube section is restored.
Note!
In our chapter “Commissioning” of the operating instructions, the

“particular features during the drying and heating up phase” are
described. They must absolutely be observed!
In the following text, measuring methods for the determination of the tube ovality are described
and limit values indicated.
BA 413-0171 USA; Page 5 of 27

BA 413-0171 USA; Page 6 of 27
1.2.1 Measuring the ovality according to the shell test method

One option to directly measure the ovality during normal production operation is the shell test
method. An instrument was developed (see Fig. 3) to scan the curvature change of the rotary
tube shell during one rotation. The instrument comprises a measuring bar, a scanning pin and a
recording unit. From the data recorded, the ovality can be determined using a calculation for-
mula.
According to bricklining companies, an ovality (%) of up to 1/10 of the rated tube diameter in
meters (m) is considered not critical but normal. Higher ovality values are mostly critical (see Fig.
2).
For an internal tube diameter of 4.6 m, the approximate upper limit for the tube ovality is 0.1 x 4.6
(m) = 0.46%.
A negative influence of higher ovality values on the service life of the lining can mostly be clearly
noticed. Rehabilitation methods are described under 2.5.
Inter-relation between admissible ovality and kiln diameter.
Fig. 2
BA 413-0171 USA; Page 6 of 27

BA 413-0171 USA; Page 7 of 27
The measuring instruments can be obtained from the following manufacturers:

• · Messr.
HOLDERBANK
Management and Consulting Ltd.
CH - 5113 Holderbank AG
Switzerland
• · Messr.
REFRATECHNIK GmbH
Rudolf-Winkel-Straße 1
D - 37079 Göttingen
Germany
Fig. 3
BA 413-0171 USA; Page 7 of 27

BA 413-0171 USA; Page 8 of 27
1.2.2 Assessment of the ovality by measuring the relative movement

During normal production operation:
a) If a shell test measuring instrument is not available, conclusions regarding the ovality can
be drawn on the basis of the relative movement between kiln tube and tire.
The most simple method is a to apply a marking with a chalk line on rotary tube shell and
tire. In case of large relative movements, one tube rotation is sufficient. In case of smaller
relative movements, it is recommended, to measure the displacement of the two markings
after 10 rotations (also see Fig. 4) and to divide them by 10.
Depending on the rotary tube size, in warm operating conditions, a relative movement of
max. 25 mm/rotation can be considered normal.
If, despite a straight kiln axis, lining defects near the tires repeatedly occur and the relative
movement for smaller rotary tubes should be more than 15 mm and for larger ones more
than 25 mm, the increased walking work of the rotary kiln (ovality) can be the cause of fre-
quently occurring defects.
b) A more exact method for measuring the relative movement than that described above is to
have the relative movement recorded by a circulating recorder (see Fig. 6). This method
has become generally known in the meantime.
A pen fastened with magnets on the tube shell presses against a recording plate also fas-
tened with magnets on the tire. The recorded curve indicates the degree of ovality.
Fig. 4
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c) A further method for determining the relative movement is the comparison of the speeds of
tire and rotary tube (RELAtireX® method). The rotations of the motor shaft counted by the
instrument, divided by the overall transmission ratio (gear and girth gear - pinion transmis-
sion) indicate the number of tube rotations. At the same time, the rotations of the tire are
counted (also see ZKG No. 12/1976 and tire section cooling, page 17).
• For a tightly seating tire, the following results:

counted motor shaft rotations
= rotations of the tube = rotations of the tire
i-totally
• Below, an example for the calculation of the relative movement with loose tire.
Outer diameter slide plate:5200 mm
Counted motor shaft rotations: 14020

i-totally (i1 x i2 ist): 700 : 1
Counted tire rotations: 20
14020
Number of tube rotations: --------------- = 20, 028
700
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On that basis, the relative movement per tube rotation is then calculated:
If the control center comprises a computer system, counting and calculating of the value can also
be realized via the computer so that the relative movement can be determined at any time.
1.3 Tire fastening

The tire fastening (Fig. 5) comprises the following:
• loosely inserted slide plates Item 1
• lateral guide strips Item 2
• lateral fixing cams Item 3
• welded slide plate fixing Item 4
The thickness of the replaceable slide plates depends on the tire width and the selected diameter
difference d between tire bore A and slide plate outer diameter B.
Fig. 5
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1.3.1 Cold gap KSP (= diameter difference in cold condition)

The specified diameter difference d between tire bore and external slide plate diameter is, with
cold rotary tube, between 3 and 15 mm depending on the size.
1.3.2 Hot gap WSP (= diameter difference in operating condition)

During normal operating, the rotary tube has a higher temperature than the tire. From the differ-
ent thermal expansion, the hot gap resulting which is smaller than the cold gap (see Item 1.3.1).
Remark:
The terms “tire gap”, “cold gap” and “warm gap” are frequently used such that misunderstandings
result.
Therefore, the terms should always be clearly used as described in these instructions, e.g.:
• Diameter difference d
• Relative movement ΔU
• Gap width in the vertex S.
When indicating measured values, always indicate to which kiln condition the data refer: cold kiln
or kiln at operating temperature (see Fig. 6).
Schematic representation of the Schematic representation of the

theoretical diameter difference d in actual gap S in the upper vertex in
manufacturing condition (without load) operating condition (with load),
deformation of the tire not considered
Fig. 6
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1.3.3 Axial movement of the tire, axial gap

The lateral guide strips are mounted so that in a horizontal direction, the tire has an axial gap of
about 5 mm, i.e., in the central position of the tire, about 2.5 mm on either side (see Fig. 5, item
X). This gap ensures the unhindered movement of the tire and prevents it from being jammed.
During kiln operation, it may be noticed that the tire, due to its axial gap, moves between the lat-
eral guide strips. This means that it is in contact with the upper or lower strips or takes an inter-
mediate position. In any case, the respective contact surface must be lubricated as described in
the maintenance reference.
One reason for the movement of the tire from one side to the other can be that the axial move-
ment (hydraulic displacement) of the kiln tube influences the ring. This will be the case, if very
constant temperatures prevail in the entire tire fastening system and the supporting rollers
remain largely thrust-free.
However, it is frequently noticed that, for a longer time or even predominantly, the tire is in con-
tact with the guide strip only on one side and stress is acting only on this side. This condition is
not critical (here again, lubrication of the axial contact surface is required).
The reasons for this are the different temperatures in the tire, in the supporting roller and in the
kiln shell.
Differences in the tire width lead to different diameters from one to the other side, i.e., the tire
becomes somewhat conical.
The same applies to the supporting roller(s).
Temperature differences in the kiln tube on both tire sides also lead to it that the tube becomes
conical. The larger tube diameter is on the side with the higher temperature.
All mentioned influences can occur alone or in combination. By temperature measurements, it

was determined that normally the greatest influence results from different tube temperatures,
e.g., caused by different accretion situations or bricklining conditions. But also outer influences
can be of importance such as wind and rain.
It was observed that the tire always tends to move axially towards the highest shell temperature
(= largest kiln shell diameter). Following the course of the movement, this is a logical procedure
which can also be observed during other applications, e.g., in case of a flat belt drive where the
belt is always running in the direction of the largest disc diameter.
To get a clear impression of the situation, it is recommended to measure all temperatures and to
evaluate their effects.
1.3.4 Radial movement of the tire relative to the tube

In Fig. 7, picture C, the course of the movement during one tube rotation is represented.
In the shaded area, the rotary tube is in tight contact with the tire; at point “'a”, the tire and the
tube are drifting apart and at point “b”, both parts are in tight contact again, i.e., nearly no friction
wear occurs. The movement of the tube in the tire is more of rolling nature. An internal lubrication
of the tire to support the rolling movement is normally not necessary.
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If, nevertheless, material break-outs are noticed at the slide plates, the cause is a sudden over-
heating of the shell plate in a restricted area with the tire still remaining relatively cold. The pres-
sure forces in the contact area are so large that a partial cold set results. As soon as the
temperatures of tire and tube become nearly identical, a relative movement takes place. This will
first be only a few centimeters so that the welding point is displaced only to a minor degree during
the tube rotation. The folded up material becomes larger with every rotation and breaks off as a
chip when reaching the external edge of the slide plate.
If such a case should occur, the inner surfaces of the tire and also the lateral contact surfaces of
the guide elements should be lubricated. This slows down the formation of chips and completely
stops it after a certain time.
To largely prevent the chip-forming effect, upon the new installation of slide plates, the surface
showing towards the tire bore must be lubricated. The lubricant “Anti Seize Nickel” proved well
here. However, it should b aimed at avoiding such a cold set just from the beginning, i.e., tube
section and tire must be heated up such uniformly that always a small tire gap is existing.
Fig. 7
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1.3.5 Wobbling of the tire

By the bending-free fastening of the tire on the kiln tube during normal kiln operation, the free
movement of the tire in axial and radial direction is ensured (see item 1.2.3 and 1.2.4). If all oper-
ating directions are observed - e.g., the starting and shutting down procedures, behavior upon
failures - the different thermal expansions are balanced by the tire fastening.
The position on the kiln tube is determined by:

• The lateral fixings which are mounted exactly rectangularly to the kiln axis
• The cylindrical seal between tire and slide plate/kiln tube
• The cylindrical contact surface of the tire and of the supporting rollers
• The contact of the tire with the thrust roller
Due to the operating stress acting on the kiln, the kiln tube is subject to a flexible deformation
which is calculated as bending line of the kiln axis. The inclined position of the kiln tube resulting
from the bending line is only a few tenth millimeters over the tire width which is accepted by the
kiln shell as deformation and does not lead to wobbling of the tire.
If, however, bending of the tube has occurred due to partially more heated up tube areas and the
tire gap is very small or = 0 and possibly heavy temperature differences in longitudinal direction
and/or over the circumference exist, wobbling of the tire during one kiln rotation can occur.
Wobbling of the tire can only be eliminated by eliminating the causes; e.g., the increase of the tire
gap can most simply be remedied by direct cooling of the tire section. In view of the existing axial
gap of about 5-10 mm, tire and supporting roller will largely come into contact despite the still
existing tube bending.
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2 Maintenance, measures
2.1 Pre-conditions for a trouble-free operation

The tires can fulfill their function during normal operation only if they are really sound and
mechanical and thermal overloads are avoided. Below you will find some useful information:
a) Avoiding of damage to the surface
– Lubrication of the contact surfaces tire/supporting rollers
– Lubrication of the contact surfaces tire/thrust rollers
– Lubrication of the lateral guide strips
– No entrance of foreign bodies between the contact surfaces
– Do not lead welding current over the tires
– Do not ignite electrodes at the tire
– Remove burrs and build-ups
Defects at the tires result in increased notch tensions which are low at smooth tires.
Because the notch impact strength of the tire material is strongly reduced at low tempera-
tures, it is recommended to preheat damaged tires prior to starting the kiln at temperatures
of below 0 °C as it is also suggested for internally geared tires.
Preheating should always take place over an extended period of time prior to turning the
kiln (about 1 day), uniformly distributed over the circumference using hot gases and a gas
burner with soft flame or similar. The surfaces should be heated up to about 20°C.
b) Avoiding of overloads
– Maintaining the geometrically straight tube axis (correct position of the supporting rollers
also after the foundation has lowered, installation of new tube sections and bearing
assemblies)
– Avoiding/eliminating lasting tube distortions as they can occur after a sectional over-
heating of the tube
– Ensure correct position of tire to supporting rollers in axial direction
– Ensure correct position of the thrust roller to the tire, check pressure
– Avoiding an extreme increase of the assembly loads as they would result from heavy
bricklining, heavy inner assemblies or a heavy satellite cooler
– Avoiding thermal overload of the tires as they can occur upon overheating of the tube
underneath the tire in case of defective bricklining
Tire overloads can never be caused by the pressure of the tube in the tire bore at an
excessively small tire gap. After the limit of proportionality of the tube material has been
exceeded, such cases always lead to narrowing of the “softer” rotary tube compared with
the tire.
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2.2 Lubrication
Between the lateral surfaces of the tire and the lateral guide strips (Fig. 7), a relative movement
takes place. To minimize the wear at these surfaces, they must be lubricated on a daily basis.
Here, a lubricant with a high solids portion on graphite or copper basis should be used, e.g., the
following products:
Address Product
Weidling GmbH + Co. KG WEICON Anti-Seize

Postfach 84 60
Königsberger Str. 255 (Urgently recommended for the
D - 48157 Münster first lubrication)
Germany
Carl Bechem GmbH Berulub FCC

Weststr. 120
D - 58089 Hage
Germany
K.S. Paul GmbH PBC

Ronsdorferstr. 53
D - 40233 Düsseldorf
Germany
Klüber Lubrication München KG Wolfracoat C Fluid

Geisenhausenerstr. 7 Wolfracoat C Paste
D - 81379 München
Germany
Fuchs Lubritech GmbH Ceplattyn HT

Hans-Reiner-Str. 7-13
D - 67685 Weilerbach
Germany
At high temperatures, the carrier oil of the lubricant evaporates after the application. The solids
portion, however, adheres to the surface and fulfills the lubricating function in the application
area. It is recommended that a spatula, brush or portable spraying devices (available from the
above companies) be used to apply the lubricant.
In view of the high temperatures, an automatic lubrication is difficult.
Observe safety references in the “Technical Machine Documentation”.
In practice and despite a thorough lubrication, material break-outs occurred at the guide strips
and the tire surfaces. This means that forces were acting whose size was far beyond the admis-
sible limit values. The following example gives an explanation.
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If the shell temperatures besides the tire are higher than underneath it, the rotary tube expands
and the lateral guide strips jam against the lateral tire surface (Fig. 8, picture B). By the punctual
loads occurring here, material erosion can result.
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2.3 Measures for avoiding narrowings

As already mentioned under Section 1.1.3, narrowings are the consequence of an excessive
irregular heating up of tube and tire.
In particular upon heating up the plant or in case of defective brickwork in the tire area, the risk of
narrowings is high as the rotary tube shell is heated up relatively rapid and the tire takes the heat
considerably slower.
Caution!
Observe that the shell temperature proper is not the cause of the
narrowing, but instead the temperature difference between tire
and tube.
Also at a relative low shell temperature, narrowings can occur.
At a diameter difference of 10 mm, the admissible temperature difference is Δt :
At Δt = 160 °C, the diameter difference between tire and tube would be zero. If the tempera-
ture difference increases by further 50°C, the limit of proportionality of the shell plate is
reached.
Upon heating up, it is difficult to assess whether a gap still exists between tire and tube because
the tube cannot be continuously turned. Here, it is recommended to monitor the temperature at
tire and tube with the aid of an adhesion thermometer.
It is important that the tire section and the tire are heated up and operated at as small a tempera-
ture difference as possible. Of course, the heating up instructions of the brick suppliers must also
be observed. Possibly, blowers must be used to cool the tube shell. The same applies if during
production operation narrowing must be expected due to sudden partial heating up of the tire
section.
Information on tire section cooling and its control:
If the rotary kiln has already been equipped with a tire section cooling system, axial blowers
are rigidly installed at both outlet-side bearing assemblies. The blowers must be positioned so
that the emerging cooling air flow is acting onto the tire section on either side of the tire, but
not the tire proper.
In addition, the blowers approximately positioned in the kiln center must be aligned so that the
air flow can escape over the kiln, i.e., upwards. If the heated up air would be pressed under-
neath the kiln, an undesired temperature increase at the bearings, etc., would result.
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The tire section cooling can be done manually if the tire gap becomes too small and jamming
of the tire shall be avoided; if a RELAtireX® system is installed, the tire section cooling can be
controlled automatically.
By no means should the tire section cooling be permanently ON!

An unnecessary increase of the tire gap would result.
To avoid excessive temperature differences between ring and tube, also an external heating up
device for the tire can be mounted. This not very expensive method (heat supply into a housing
arranged around the tire) was little used in practice as its reliably is not yet proven.
If, in the tire area, a lining defect is noticed (red spot), the plant must be put out of operation.
For rotary kilns, it is disadvantageous if a damage occurs underneath or adjacent to a tire seat.
As it is known, the beginning of the sintering zone is a critical area for the brickwork (changing
accretion conditions). For statical reasons, often just here a tire assembly is arranged.
In particular for this zone, the operator and the brick supplier must co-operate to optimally protect
the mechanical parts of this zone.
Here, it must be kept in mind that a change of the burning process (short flame or long flame) as
well as changes in the raw meal composition immediately entail a change of the accretion behav-
ior in the kiln. These plant-related requirements must be considered when selecting the brick
quality and the determination of the zones.
As soon as defects on the rotary tube become noticeable, the required rehabilitation should be
made to its full extent and without delay. In this way, longer operating phases become possible
and consequential damage to the mechanical parts is avoided.
2.4 Calculation example for determining the diameter difference

The plant section “tire seat” requires particular attention.
Therefore, a measuring log should be prepared for every tire assembly of the rotary tube. It is
recommended to determine at least twice per week the existing relative movement between tire
and tube and to enter the readings into the log. Such changes can be recorded and used for the
comparison with recordings on lining defects. The lateral surfaces should also be checked at
least twice per year and the gap widths between tire and guide strip entered in a log.
If rehabilitation measures become necessary, first the diameter difference must be determined.
To that end, the method described below has proven well.
This proven measuring method refers to the cold rotary tube as well as to the operated warm
rotary tube. While upon the cold measurement, the cold gap specified for the assembly must be
considered, upon the warm measurement in normal operating condition, a measurement to be
repeated on several days is required. The smallest value determined during the measurement is
considered when newly determining the slide plate thickness D. Here, it is necessary to have the
rotary tube perform at least one rotation and to measure the relative movement ΔU with the aid of
the curve recorder (see Fig. 4) or using the markings on tire and tube. ΔU divided by 3.14 (Π) is
the actually existing diameter difference d.
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BA 413-0171 USA; Page 20 of 27
Relative movement Gap widthS Slide plate thickness

ΔU D (exist.)
Assy. I
Assy. II
Assy. III
Meßprotokoll
2.5 Rehabilitation measures for narrowings

If, due to a narrowing, a rehabilitation or slide plate thickness measurement is indispensable, the
replacement of the slide plates can be a rapid remedy.
2.5.1 Replacement or lining of the slide plates

The following cases can occur
Case I:
The tire gap is too large and the rehabilitation is realized by installing new slide plates.
This is done as follows:

• Determine the actually existing diameter difference (see item 2.4).
• Determine the new slide plate thickness considering the desired gap and the current slide
plate thickness.
with
D1 = New slide plate thickness
D = Current thickness of the slide plate (e.g., 25 mm)
d1 = Calculated actually existing diameter difference

(e.g., 16 mm) between tire and tube
d2 = Desired diameter difference for the cold tube (e.g., 10 mm,

as a function of tube diameter and assembly, e.g., inlet, center, outlet).
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BA 413-0171 USA; Page 21 of 27
In this example, instead of the currently existing 25 mm thick plates, now 28 mm thick plates
must be installed.
The length of the plates depends on the tire width; the width must re-measured at the existing
plate.
The bending radius must be matched to the outer tube diameter “C”.
The material for the plates can be normal construction steel.
New slide plates can also be welded together of two plates, that is:
• One plate already kept on stock or base plate manufactured previously and a lining plate to
achieve the total thickness.
• The lining plate should not be thinner than 3 mm and be of material St 52-3N.
The thinner lining plate is welded underneath the slide plate (see Fig. 10, item 1 and 2).
Case II:
The tire gap is too large and the rehabilitation is made by placing lining plates underneath the still
used slide plates; e.g., the lining plates must be 3 mm thick (28-25 = 3 mm). See Fig. 8, 9, 10, lin-
ing plates of material St 52-3N.
This temporary solution should be substituted soon by 28 mm thick plates.
In Case II, the slide plates are lifted and the lining plates slid between slide plate and tire!
The somewhat protruding head sides of the lining plates are tack-welded to the slide plate (see
Fig. 10, Item 1, 3).
Fig. 8
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BA 413-0171 USA; Page 22 of 27
The replacement or lining of the slide plates is always made at the vertex of the rotary tube. The
lateral fixings (Fig. 5, item 4) are unfixed, the old plates (Case II) withdrawn and replaced by new
ones and, in Case II, lined with lining plates.
If sliding in should be difficult due to an insufficient correspondence of the tube and slide plate
radii, the slide plates must be matched.
The previously chamfered slide plate fixings are welded to the cams again as illustrated in Fig. 5,
Detail “X”.
During the works on the tire fastenings, all parts loosely placed
on the rotary tube must be secured against slipping.
For the works, all necessary safety measures must be taken (safe
climbing, secured standing surface and railings)!
Fig. 9
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BA 413-0171 USA; Page 24 of 27
2.5.2 Repair of worn down guide strips

If guide strips are worn down by 15 mm or more, the original axial gap of 5 mm should be
restored.
Such repair works are relatively simple. The tire must be pressed off the worn-down contact sur-
face and an accordingly thick lining plate welded to the guide strip (see Fig. 9, item 1).
The ends of the lining plates should be slightly inclined, see Fig. 9.
2.6 Rehabilitation measures for tube bulges underneath the tire

If underneath the tire, a lining defect has led to local overheating, the tube shell will bulge inwards
at this point. Depending on its size, this bulge can entail further defects.
Due to the wedge-shape of the bricks, particular difficulties result for the bricklining, see Fig. 11.
Fig. 11
Regarding suitable measurements for the refractory lining, we refer to the information given by
the suppliers of the refractory material.
Upon every tube rotation, moreover, a shock-like load will occur when the flattened tube area is
entering the tire bore.
In such a case, the loosely placed slide plates between tire and tube permit a rapid remedy
against these shock-like loads.
First, the defective area is moved to the vertex of the tube and the slide plate in this area is with-
drawn.
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The tube is then turned by 180° so that this area is positioned at the bottom and there, the gap
between tire bore and tire section can be measured. Upon measuring, it must be checked,
whether the bulge is located centrally or laterally displaced to the tire (see Fig. 12).
Fig. 12
Depending on the situation, the slide plate must be lined either with plates of identical or different
thickness or with flat steel (see Fig. 13). The lining must not be thicker than the measured gap.
Fig. 13
(for a clear representation, not true to scale)
Although this work takes up much time and requires skill, the expenditure will be worthwhile, as
the plant can be further operated up to a final rehabilitation of the damaged areas.
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Depending on the extent and serious nature of the defects, the following final rehabilitation mea-
sures come into question:
• Inserting of a plate patch
(disadvantage: under the tire, welding is only possible from the inside if the tire is not axially
displaced)
• Installation of a new tire section with fastening.
2.7 Equalizing the contact surfaces of tires, supporting rollers and thrust
rollers
In the case of plants without hydraulic system for that purpose, the longitudinal movement of the
rotary tube is initiated by setting the supporting roller axles into an oblique position. In this way,
the contact surface of the tires gets a slightly convex shape, while the shape of the supporting
rollers becomes concave. This can essentially affect the tube movement. It is recommended to
make a correction by overturning or grinding the surfaces. A turning device is schematically rep-
resented in Fig. 14, picture A.
If required, the works can be made with temporary facilities. Companies active in this field (e.g.,
DIW Indumont) are availing on equipment and experienced staff.
For tubes with a hydraulic system for the longitudinal movement of the tube, the surface of the
tire is stressed by supporting and thrust roller at two contact surfaces arranged at an angle of 90°
towards each other (see Fig. 14). Over time, the rounded edge becomes sharpened by the con-
solidation of the surface. Chamfer the surface by grinding as, otherwise, the surface would be
damaged or would crack. Cracks in the sharp-edged bur can develop to cracks in the tire if the
bur is not ground off . The works can be performed during operation.
Due to the same cause, above the thrust roller contact surface, a slight build-up can form on the
tire front face (see picture B). This build-up must also be removed by grinding - in particular
directly after the new alignment of the supporting roller bearings - to avoid that from there uncon-
trolled forces are vertically introduced into the thrust roller assembly.
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BA 413-0171 USA; Page 27 of 27
To counteract the formation of build-ups, the tires are provided with a turned-in circular groove at
the tire front face, see Fig. 14.
BA 413-0171 USA; Page 27 of 27

Adjusting instructions BA 413-005-1 USA

for rotary kilns,
Page 1 of 29
drying and cooling drums
Safety
BA 413-005 en
Former edition:
thorough maintenance and care.
This symbol is adjacent to all important safety references in

the present operating instructions.
Observe these references and behave particularly careful in

these cases. Also inform other users of these safety
instructions.
Beyond the references given in these operating instruc-

tions, observe and follow the general safety and accident
prevention regulations of your legislator must be observed.
Copyright
The copyright to these operating instructions (BA) remains with the Humboldt Wedag Inc.
These operating instructions are meant for the assembly-, operating- and supervision
staff. It contains regulations and drawings of technical nature which are not permitted to be
multiplied, distributed or used for competition purposes without authorisation, nor wholly,
nor in part, or to be disclosed to others. The non-observance will entail a claim for indemni-
fication.
Humboldt Wedag, Inc

USA
Phone 770-810-7300
Telefax 770-810-7333
BA 413-005-1 USA; Page 2 of 29
Adjusting instructions for rotary kilns, drying and cooling drums
Contents: Page
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Rotary tube assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.2 Rotary tube movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Rotary tube drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Design position of the supporting rollers for clockwise rotation. . . . . . . . . . . . . . . . . . . . . . . . . .7

3.1 Possible defect: rotary tube remains at bottom position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Possible defect: rotary tube remains at topmost position . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4 Design position of the supporting rollers for counterclockwise rotation. . . . . . . . . . . . . . . . . . .13
4.1 Possible defect: rotary tube remains at bottom position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.2 Possible defect: rotary tube remains in the top position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5 Measures to be taken in case of excess temperature at one of the supporting roller bearings 19
5.1 Checking the cooling water supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5.2 Checking the oil supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.3 Checking the oblique position of the bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6 Measures to be taken in case of excess temperature of one thrust roller bearing . . . . . . . . . .20
6.1 Possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7 Deformation of the contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
8 Instructions for oblique setting of the supporting roller brackets . . . . . . . . . . . . . . . . . . . . . . . .21

8.1 Fixing the bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
8.2 Recording the prevailing oil pattern at the collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
8.3 Oblique setting of the supporting roller bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
9 Displacement of the supporting roller bearings in the direction of the axis . . . . . . . . . . . . . . . .22
Oil film at the collar ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Form to the counterclockwise rotating tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Form to the clockwise rotating tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Lateral blocking of the supporting roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Longitudinal blocking of the supporting roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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BA 413-005-1 USA; Page 3 of 29
1 General
1.1 Rotary tube assembly
The tires with the supporting rollers and bearings form the supporting points of the rotary tube.
Upon first assembly, the tube comprised of assembled sections is mounted exactly straight, i.e.,
with flush central axis with inclination. For functioning of the tube as well as of the following
refractory lining, a straight kiln axis is of utmost importance
During the assembly of the rotary kiln tube (ambient temperature), the thermal expansion in the
later operating condition is considered and the supporting rollers are mounted displaced against
the tires in longitudinal tube direction by the measure “X”.
The thermal expansion of a tube, in particular for rotary kilns, is subject to considerable
deviations. Wear of the bricklining or changes in the accretion behavior as well as the ambient
temperature (summer/winter) are the causes. In the sintering zone - here between assemblies II
and III - deviations of up to 150°C - also within short periods of time - are common.
Example: Shell temperature 250°C or 400°C (corresponding to
t=150°C) at 28 m tube length results in a length difference
due to thermal expansion of 50 mm.
The measures indicated in the installation plans are based on empirical values of several hun-
dreds of kiln plants. For the shell in the sintering zone, for example, a temperature of about
320°C is used as a basis so that the deviation from the previously mentioned extreme values (50
mm at 250°C or 400°C) is about + 25 mm. These 25 mm are considered a reliable deviation and,
first, do not require a correction.
Therefore, it is not necessary to permanently match the position of the supporting rollers to the
actual conditions.
After a constant kiln operation has been achieved, a possibly necessary correction of the bearing
position will be made by our commissioning staff.
If other thermal expansions should occur due to other long-term operating conditions later on, the
operator is responsible for making suitable corrections.
In case of lasting or major deviations from the actual length changes, follow the instructions
under Item 9.
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BA 413-005-1 USA; Page 4 of 29
1.2 Rotary tube movement
To accomodate the changing expansion conditions, the supporting rollers are executed wider
than the tires by 50 mm. To avoid that in the course of time the contact surfaces enter each
other, the rotary tube is forced into an upward and downward movement (see 1.3) so that no
locally restricted wear can occur. The following sketch shows which effects unilateral wear can
have if the supporting rollers are permanently in a wrong position to the tires.
Assembly I: Fixed assembly

1. Stationary thrust rollers:
Restriction of the upward and downward movement by the two thrust rollers
to a path of 60 mm.
2. Hydraulic thrust rollers:

Restriction of the upward and downward movement by limit switches to an
additional path of 50 mm.
Assembly II. Run-in supporting roller, since the previously calculated thermal expansion was
exceeded (measure X selected too small).
Consequence:
Upon cooling down of the kiln tube, also the tire will put itself against the run-in
edge as shrinking takes place in the direction of the arrow.
Assembly III: Run-in supporting roller, since the previously calculated thermal expansion was
not achieved (measure X selected too large).
Consequence:
If the shell temperature suddenly increases, the tire will move into the direction of
the arrow and put itself against the run in edge.
In both above-mentioned cases, considerable damage to the supporting roller/supporting roller
bearings and thrust roller assemblies can result.
The mentioned running in of the contact surfaces is a process which develops over years.
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BA 413-005-1 USA; Page 5 of 29
1.3 Rotary tube drift
The rotary revolving tube is subject to downward movement due to gravity because it is inclined
as it is turned.
To maintain the rotary tube position in axial direction, it is necessary to counteract the downward
movement as described below:
1 In case of stationary thrust rollers by oblique setting of the latter, i.e., by slanting the roll-
ers relative to the rotary tube axis. The correct slanted (oblique) position of the supporting
rollers relative to the tube axis results in an upward screw movement of the tube. Due to
the friction between tire and supporting rollers, the slanted rotary tube is moved upward in
axial direction. This longitudinal movement is restricted by the uppermost of the two thrust
rollers mounted on both sides of the tire near the pier located close to the drive. The
friction between tire and supporting rollers is reduced by the use of graphite plates or the
application of graphite paste on the running surface of the rollers. Due to its slanted
position, the rotary tube moves again downward until the tire touches the bottom thrust
roller. After removal of the graphite plates, the lubricating film disappears from the running
surfaces after some time and the kiln again moves in upward direction.
2 The downward-acting force of the tube is reduced by slanting the tube less than for kilns
with stationary thrust rollers. This reduction results in the hydraulic pressing force of
approximately 60 bar being enough to press the kiln tube upward, i.e., in the direction of
the kiln inlet. Friction and wear are substantially reduced by lubrication of the contact
surfaces of thrust rollers and tire.
The upward and downward movements are restricted by electrical limit switches which
are actuated by coming into contact with the tire side surface at the pier equipped with
hydraulic thrust roller bracket.
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BA 413-005-1 USA; Page 6 of 29
2 Adjustment procedure
The correct adjustment of the rotary tube bearing assemblies relative to the longitudinal guide
system is of vital importance for the service life of the tires, the supporting rollers and the thrust
rollers. Extremely high temperatures beyond 70 °C measured in the supporting or thrust roller
bearings are an unmistakable sign of faulty adjustment. Initial slanting of the rotary tube or its
adjustment is carried out by our erection engineers or under the direction of the commissioning
engineer.
The direction of slanting (oblique setting) of the supporting rollers relative to the kiln tube axis
depends on the sense of rotation of the rotary tube (see also pages 6 and 12). For every
correctly slanted bearing, the collar of the bearing which faces the kiln tube outlet end shall be
metallic bright (i.e., without oil film) and thus correspond to the situation “loaded” (page 22
refers). The collars of the supporting roller shafts which belong to the supporting roller assembly
to maximum load must all be in compliance with the “neutral” situation (page 22 refers). In other
words, supporting roller axis and rotary kiln axis are parallel to each other.
For three supporting roller assemblies subject to identical load, the assembly of maximum
temperature should be oriented in parallel.
The two bearings of each supporting roller have a common bracket. A clearance of 1-2 mm has
been provided between the collars of the supporting roller shafts and the shoulder of the bearing
shells. In case the supporting roller is subject to axial pressure which is transmitted to the bearing
shells over the collars, the collar on the side subject to load will not have an oil film while
(corresponding to the clearance mentioned above) the collar on the other side of the supporting
roller displays a clearly visible oil film (page 22 refers).
Under no circumstances shall a tooth bearing pattern which might be noticeable on the running
surfaces of the tires be referred to for judging on the roller position.
When slanting the supporting rollers, it shall be duly considered that shifting the bearings by
fractions of a millimeter away from the kiln tube centerline and in the direction of the centerline
may be sufficient. Consequently, slanting shall be done by steps and the effect of every shifting
of the bearings on the longitudinal guiding of the tube will be checked and waited for, respec-
tively. The hinged bearing covers are opened for observing and checking the shaft collars. Make
sure that no dirt penetrates through the opened covers!
Provided that the bearings have been correctly slanted, the temperatures at the collar will be
below 50 °C.
The supporting roller will press the rotary tube upward if no oil film exists on the collar of the
bearing which - corresponding to the tube inclination - is located at the bottom.
The supporting roller will press the rotary tube downward if no oil film exists on the collar of the
bearing located at the top.
See also page 22.
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BA 413-005-1 USA; Page 7 of 29
3 Design position of the supporting rollers for clockwise rotation
Direction of rotation clockwise (seen from the outlet)
The above sketch shows a rotary tube with three supporting roller assemblies with the highest
load on assembly II, which shall be in a neutral position to the rotary tube axis.
BA 413-005-1 USA; Page 7 of 29

BA 413-005-1 USA; Page 8 of 29
Direction of rotation clockwise (seen from the outlet)
The above sketch shows a rotary tube with two supporting rollers.
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BA 413-005-1 USA; Page 9 of 29
3.1 Possible defect: rotary tube remains at bottom position
Sketch A:
Sketch A represents a clockwise rotating tube with three supporting roller assemblies (seen from
the outlet).
It shows all rollers in the correct position. If, despite this situation, no upward movement takes
place, either one or both rollers of assemblies I or III have been given an insufficient oblique ori-
entation. In this case, it is recommended to have assembly I or III displaced by fractions of a mil-
limeter in the direction of the arrow.
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BA 413-005-1 USA; Page 10 of 29
Sketch B:
Sketch B represents a clockwise rotating tube with three supporting roller assemblies (seen from
the outlet).
According to this sketch, roller I L has been given a faulty oblique position. It presses the rotary
tube downward. The shaft collar of the bottom bearing will show an oil film. This situation must be
remedied by a displacement in the direction of the arrow.
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BA 413-005-1 USA; Page 11 of 29
3.2 Possible defect: rotary tube remains at topmost position
Sketch C:
Sketch C represents a clockwise rotating tube with three supporting roller assemblies.
The rollers are correctly positioned. Since, however, oblique positioning is too pronounced, it is
recommended to have the bearings of assemblies I or III displaced by fractions of a millimeter in
the direction of the arrow.
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BA 413-005-1 USA; Page 12 of 29
Sketch D
Sketch D represents a clockwise rotating tube with the supporting roller assemblies.
Roller II L, which should actually be in a neutral position, i.e., parallel to the rotary tube axis, has
the tube move upwards. The bearing has to be displaced in the direction of the arrow until the
collar surfaces feature an oil film at either side.
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BA 413-005-1 USA; Page 13 of 29
4 Design position of the supporting rollers for counterclockwise

rotation
Direction of rotation counterclockwise (seen from the outlet)
The above sketch represents a rotating tube with three supporting rollers, with the highest load
on assembly II, which should be in a neutral position to the rotary tube axis.
BA 413-005-1 USA; Page 13 of 29

BA 413-005-1 USA; Page 14 of 29
Direction of rotation counterclockwise (seen from the outlet)
The above sketch represents a rotary tube with two supporting rollers.
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BA 413-005-1 USA; Page 15 of 29
4.1 Possible defect: rotary tube remains at bottom position
Sketch A:
Sketch A represents an counterclockwise rotating tube with three supporting roller assemblies.
It shows all rollers in the correct position. If, despite this situation, no upward motion takes place,
either one or both rollers of assemblies I or III has given an insufficiently oblique orientation. In
this case, it is recommended to have the assemblies I or III displaced by fractions of a millimeter
in the direction of the arrow.
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BA 413-005-1 USA; Page 16 of 29
Sketch B:
Sketch B represents a counterclockwise rotating tube with three supporting roller assemblies.
According to this sketch, roller I L has been given a faulty oblique setting. It presses the rotary
tube downward. The shaft collar of the bottom bearing will show an oil film. This situation must be
remedied by a displacement in the direction of the arrow.
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BA 413-005-1 USA; Page 17 of 29
4.2 Possible defect: rotary tube remains in the top position
Sketch C:
Sketch C represents a counterclockwise rotating tube with three supporting roller assemblies.
The rollers are correctly positioned. Since, however, oblique positioning is too pronounced it is
recommended to have the bearings of assemblies I or III displaced by fractions of a millimeter in
the direction of the arrow.
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BA 413-005-1 USA; Page 18 of 29
Sketch D:
Sketch D represents a counterclockwise rotating tube with three supporting roller assemblies.
Roller II L, which should actually be parallel to the rotary tube axis, has the tube move upward.
The bearing has to be displaced in the direction of the arrow until the collar surfaces show an oil
film at either side.
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BA 413-005-1 USA; Page 19 of 29
5 Measures to be taken in case of excess temperature at one of

the supporting roller bearings
In case excess temperatures are noticed for the bearing, the following checks and measures
have to be carried out:
5.1 Checking the cooling water supply system
Cooling water flow, volume and pressure must be checked and, if necessary, re-adjusted. Care
must be taken that the greater water volume flows through the chamber besides the collar. In
case of unsatisfactory cooling water pressure, the pressure at the hazarded bearing should be
increased by throttling (restricting, closing) the valves at the neighboring bearings.
5.2 Checking the oil supply system
The oil level of the bearing must be verified and in particularl whether the oil supply to the bearing
is ensured by transfer of the oil from the scoop ring onto the oil collector plate and the shaft.
5.3 Checking the oblique position of the bracket
The oblique orientation of the bracket, i.e., the off-parallelism of the shaft axis relative to the
rotary tube axis, shall be verified by inspecting the oil film at the collar, which is called “neutral”
(refer to sheet 22), “loaded” or “unloaded”. If a visual inspection shows the situation specified as
“loaded” and the high bearing temperature is definitely due to the missing oil film on the collar,
the excess temperature must be attributed to a too-pronounced oblique orientation of the bracket
and, hence, of the roller. As an immediate remedy, graphite paste or oil shall be applied onto the
contact surfaces of the pertinent supporting roller. This will reduce the friction between
supporting roller and tire and also reduce the axial pressure generated by the tire. Preparations
can now be made for correcting the oblique orientation of the bracket with the roller.
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BA 413-005-1 USA; Page 20 of 29
6 Measures to be taken in case of excess temperature of one

thrust roller bearing
6.1 Possible causes
a) Insufficient lubricant supply
b) Insufficient cooling water supply for thrust roller brackets with water-cooling system
(sleeve bearings)
c) Excessive axial pressure due to incorrect adjustment at the supporting roller assemblies
d) Excessive heat radiation from the tube.
The trouble sources according to items a and b (above) must be checked visually and are easily
remedied by suitable measures.
Excessive radiation is caused by poor condition of the kiln lining. If that situation cannot be
changed, cooling air fans can be installed which directly supply air to the hot bearing points. If
that becomes permanent, it may be advisable to provide for an additional heat-protective shield.
Excessive bearing temperatures are mostly due to the axial pressure of the rotary tube.
Adjustment of the supporting roller bearings as detailed under item 2 causes axial pressure of
the rotary tube. This axial pressure must be absorbed by the thrust roller brackets. An excessive
axial pressure may entail overheating of the thrust roller brackets.
Next, it should immediately be verified which supporting roller bearing(s) has/have been given an
oblique orientation directed downward and cause(s) the axial pressure.
This shall be done as described under item 2 above.
In dangerous situations the contact surfaces of the supporting roller which have been given a
faulty oblique orientation must be amply supplied with oil, thus having the rotary tube “float” on
the supporting rollers, implying an immediate reduction of the dangerous axial pressure. This
measure offers sufficient time for initiating the corresponding adjustments.
7 Deformation of the contact surfaces

An excessive axial pressure may likewise exist even if the temperatures of the thrust roller
bearings are not extraordinarily high, which is reflected by the condition of the thrust roller con-
tact surfaces and by the lateral surfaces of the tires.
If these surface features deformation, the axial pressures are too high, which must be remedied
by corresponding readjustments.
This applies to stationary - as well as to hydraulically - moved thrust roller brackets.
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BA 413-005-1 USA; Page 21 of 29
8 Instructions for oblique setting of the supporting roller brackets
8.1 Fixing the bearing bracket
Fixing a bracket in the desired position, i.e., at a specified distance from the tube axis, is done
with the aid of eight T-head bolts (item 1, sheet 27), which are tightened with the aid of a box
wrench. After tightening of the T-head bolts and with the tire resting on both supporting rollers of
the pertinent assembly, friction between the brackets and the base plates in the concrete
foundation is not overcome by the horizontal forces of the tube weight associated to the
particular roller assembly. The friction between the bracket and the base plate is made up not
only of the preload of the T-head bolt, but also of the vertical component of the stationary tube
load, of the bracket- and supporting-roller weight as well as of the surface characteristics of the
base plate grouted into the concrete foundation and the underside of the bracket.
For additionally securing the bracket against being displaced away from the tube axis, retaining
blocks (item 2, sheet 27) have been provided.
As a safeguard against displacement along the tube axis, blocks have been welded onto the
base plates (see item 1, sheet 28).
To prevent jamming of the bracket between the welded blocks when positioning it obliquely to the
tube axis, spacer plates have been fitted between the blocks and the brackets (item 2, sheet 28)
that are removed during the oblique setting procedure.
8.2 Recording the prevailing oil pattern at the collars
On the basis of the sketches available for orientation of the different brackets, it will have to be
found out whether the top- or bottom-most roller of the bracket (relative to the tube inclination)
has to be displaced towards the rotary tube axis or away from it.
8.3 Oblique setting of the supporting roller bearings
a) The initial position of the bracket must be marked on the base plate and at the bracket
using paint and a marking tool.
b) The spacer plates (item 7, sheet 27) must be removed.
c) The retaining bracket (item 3, sheet 27) must be placed into the recess of the base plate.
d) The hydraulic jack (item 4, sheet 27) shall be arranged between retaining bracket and
bearing.
e) The T-head bolts (item 1, sheet 27) shall be loosened.
f) The jack shall be firmly pressed against the bearing with the aid of a manually-operated
pump (item 5, sheet 27).
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BA 413-005-1 USA; Page 22 of 29
g) Wedges shall be loosened (item 6, sheet 27) and the pressure at the jack reduced or
increased and the wedges driven in again.
h) The collar rings shall be observed for at least 30 minutes until the next adjustment is
carried out.
The bearing bracket is displaced until the desired oil film pattern has been obtained (see
also sheet 22).
i) The T-head bolts shall be tightened and the spacer plates (item 7, sheet 27) fastened.
j) Pressure shall be bled and the jack and retaining bracket removed.
During shifting of the bearings, is must be made sure that also the opposite bearing seat can
freely adjust itself relative to the roller axis. Otherwise, the edges of the bearing shells could be
deformed.
Caution!
Even if the visual pattern is satisfactory after all adjusting jobs have been
completed, the oil film of the collar rings must be observed for several
morer days since it may happen that the axle in the bearing shell forms a
new contact pattern, thus again changing the bearing position.
These instructions include the sketches showing an „counterclockwise rotating tube“ and a
„clockwise rotating tube“ (sheet 23, 25). They show the ideal setting of the supporting roller bear-
ing relative to the rotation of the tube.
The space left for corrections should be used for entering details about positioning of the
bearings after each adjusting operation. Not only positioning, but also the amount of
displacement must be taken down.
9 Displacement of the supporting roller bearings in the direction

of the axis
If the bracket is displaced in the direction of the kiln axis, the welding blocks (item 1, sheet 28)
must be removed, if required, and the retaining brackets (item 3, sheet 28) welded.
The bearing bracket is displaced with the aid of the jack (item 5, sheet 28) and the manual pump
(item 4, sheet 28).
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BA 413-005-1 USA; Page 23 of 29
If the bearing has been arranged in the desired position, the blocks (item 1, sheet 28) are welded
and the spacer plates (item 2, sheet 28) fitted.
Caution!
A sectional iron (item 6, sheet 28) must be placed between the

bracket and the jacks. Otherwise, the bracket wall could be
deformed.
After shifting, it must be made absolutely sure, whether the

position of the supporting roller has been changed relative to the
kiln axis. Watch oil pattern at the collar ring for a few days.
Oil film at the collar ring
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BA 413-005-1 USA; Page 24 of 29
Form to the counterclockwise rotating tube
BA 413-005-1 USA; Page 24 of 29

BA 413-005-1 USA; Page 25 of 29
Form to the counterclockwise rotating tube
BA 413-005-1 USA; Page 25 of 29

BA 413-005-1 USA; Page 26 of 29
Form to the clockwise rotating tube
BA 413-005-1 USA; Page 26 of 29

BA 413-005-1 USA; Page 27 of 29
Form to the clockwise rotating tube
BA 413-005-1 USA; Page 27 of 29

BA 413-005-1 USA; Page 28 of 29
Lateral blocking of the supporting roller bearings
BA 413-005-1 USA; Page 28 of 29

BA 413-005-1 USA; Page 29 of 29
Longitudinal blocking of the supporting roller bearings
BA 413-005-1 USA; Page 29 of 29

Expansion and BA 413-049-1 USA

shrinkage process Page 1 of 15
on rotary kiln tubes
Contents Page
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Heat supply, expansion and corrections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Load distribution, vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BA 413-049/1 en
4 Distribution of forces parallel to the kiln axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Former edition:
5 Stress exerted on tire and supporting roller due to axial movements caused by heat . . . . . 8
6 Axial movement of the rotary kiln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Load distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2 Heating up of the rotary kiln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3 Cooling down of the rotary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.4 Standstill of the kiln plant over an extended period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Lubrication of tire and roller contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Measures to be taken upon failure of the drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 General
From daily routine work we know that too little attention is paid to the processes taking
place when heating up and cooling down a rotary kiln tube.
For example, marks due to friction are very frequently noticeable in longitudinal direction
on the contact surfaces of the supporting rollers and tires — a clear indication that the
rotary kiln tube has not been rotated sufficiently to reduce stresses. Damage to the
machine parts and particularly to the thrust roller brackets is an inevitable consequence.
In the following, we give a description of the problems involved. For special consideration
is Section 6.3 and the calculation example contained therein is to be taken into consider-
ation.
BA 413-049-1 USA; Page 2 of 15
Expansion and shrinkage process on rotary kiln tubes
2 Heat supply, expansion and corrections
The amount of heat supplied to the kiln shell is governed by several factors and differs from zone
to zone depending on the length of the tube. It is influenced by:
• The heat offer from the burner
• The position of the burner lance and the flame shape
• The thickness and insulating capacity of the refractory bricklining
• The thickness of the coating adhering to the lining
• The quantity of the oil filling
• The ambient temperature
Among the factors mentioned above, it is especially the thickness of the bricklining and coating
that cannot be determined in advance. Therefore, it is likewise not possible to exactly calculate
the thermal expansion of the kiln tube in the direction of the longitudinal axis in advance which
varies during operation. It is, however, possible to specify reference values which are required for
erection of the roller assemblies (Figs. 1-5 for a kiln in cold state).
BA 413-049-1 USA; Page 2 of 15

BA 413-049-1 USA; Page 3 of 15
By way of approximation, longitudinal expansion can be determined as follows:
Δ=τ.1.α
where Δ relates to expansion, 1 to the length to which Δ refers, α to the heat expansion
coefficient and τ to the average temperature minus the ambient temperature.
If the length of the zone in question is specified with 1 = 26 m, its average temperature with
τ = 290 °C (empirical value) and the expansion coefficient of steel with α = 0.0125 mm/m °C, the
result for the calculation is as follows:
Δ = (290-20) x 26 x 0,0125 = 87 mm
As the kiln is moved upward and downward around the center of the fixed assembly ± 25 mm,
i.e., in cold as well as in hot state (longitudinal kiln guidance), it is known from experience that an
expansion near the fixed station cannot influence the center position. Therefore, the expansion
zero point, relative to which all other tires are offset by dimension x (Fig. 5) is assumed at this
point.
The measures calculated on the basis of this formula and taken into consideration for erection
may later deviate from the actual values when commissioning the rotary kiln so that a correction
of the supporting roller position will be required. The design of the base frame, Fig. 6, permits an
adaptation by shifting the bearings in longitudinal kiln direction.
BA 413-049-1 USA; Page 3 of 15

BA 413-049-1 USA; Page 4 of 15
This adaption should only be made after an operating period of 2-3 months when the shell
temperature has reached stable values which can then be assessed with sufficient certainty. In
this context, deviations of ± 25 mm are first left out of consideration. It is only after about 12
months that an adaptation must be carried out after it has turned out that the deviation value is
almost identical during all operating states.
These adjustments must only be made by the plant operator.
In case of a possible displacement in axial direction, both bearings must be shifted to an identical
degree so that both rollers of a bearing assembly will be in alignment in transverse direction to
the kiln axis.
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BA 413-049-1 USA; Page 5 of 15
3 Load distribution, vertical
When determining the spacing between the assemblies of a rotary kiln, a preferably uniform
assembly load should be selected, since this will ensure an identical design and a use of identical
spare parts. However, depending on the type of rotary kiln, often there are substantial differences
in the load and dimensioning of the respective assemblies. This particularly applies to rotary kilns
with satellite coolers, for which e.g., load distributions as shown in Fig. 7 occur.
Assembly I: QI = 560 t
II: QII = 650 t
III: QIII = 1 320 t
IV: QIV = 425 t
2 955 t
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BA 413-049-1 USA; Page 6 of 15
4 Distribution of forces parallel to the kiln axis
The forces taking effect parallel to the kiln axis are dependent on the mass distribution along the
kiln axis, the angle of inclination, and the spacing between the bearings as well as the tube rigid-
ity.
One of the essential forces taking effect parallel to the kiln axis is the friction force between tire
and supporting roller. It is governed by the vertical loads, the surface roughness, lubrication of
the contact surfaces and the state of wear.
The following will be applicable:
a) In case of cylindrical contact surfaces (Fig. 8) as is true for tires and supporting rollers, the
following will be applicable to force P which is required for shifting the cylinders relative to
each other at a given load Q:
b) In case of concave or convex surfaces (Fig. 9), force P required for a relative motion
equals:
BA 413-049-1 USA; Page 6 of 15

BA 413-049-1 USA; Page 7 of 15
c) In case of contracted surfaces (Fig. 10), force P, acting in positive direction, equals:
P=Qxμ
The maximum of the force acting in negative direction Poo is only determined by the rigidity
of supporting roller or tire.
The supporting roller bearings (axial collar rings) take up a part of the axial forces resulting from
the friction between tire and roller, whereas the axial forces beyond that amount are taken up by
the thrust roller bracket.
Especially in cases as represented in Figs. 9 and 10, these forces may cause damage to the
thrust rollers or their supports, which can be avoided by keeping the profile of the contact
surfaces cylindrical in the manner described below:
• Optimal adjustment of the tire and supporting roller center during operation in accordance
with operating manual BA 413-005.
• Uniform upward and downward movement of the rotary kiln tube ensured by inclining the
supporting roller axles to the kiln axis or by a properly functioning hydraulic system for
longitudinal movement of the kiln.
• If necessary, the cylindric profile of the contact surfaces affected by running marks can be
restored by truing up or grinding.
BA 413-049-1 USA; Page 7 of 15

BA 413-049-1 USA; Page 8 of 15
5 Stress exerted on tire and supporting roller due to axial

movements caused by heat
During heating up and cooling down of the kiln tube it will expand or shrink, especially in
longitudinal direction (Fig. 11). In addition to the given radial load (hertzian pressure), the contact
surfaces will additionally be subject to an axial sliding stress which is governed by the friction
coefficient of the contact surfaces.
Rotating the tube reduces effective friction and thus the load on the contact surface. If e.g., the
rotary kiln is not rotated sufficiently, the contact surfaces will be affected by wear phenomena as
shown in Fig. 12.
These are running marks formed as a result of the hertzian pressure and the thrust load (= high
friction coefficient).
This means: if the kiln tube is not turned sufficiently or if the contact surfaces have not been
lubricated adequately, the material structure undergoes plastic yielding, and the material piles up
which results in considerable roughening of the surface. Although these wear marks disappear
during kiln operation, they substantially increase the forces acting in longitudinal kiln direction by
the roughness formed. A further indicator for insufficient turning or turning of the kiln by 1/4 of a
rotation are crackling noises.
BA 413-049-1 USA; Page 8 of 15

BA 413-049-1 USA; Page 9 of 15
Tire and supporting roller are dimensioned for a permissible hertzian pressure of approx.
42 kN/cm², corresponding to a normal value for the rolling friction and the material used.
This means that in state of rest the surfaces must not slide on each other at the given hertzian
pressure, as otherwise the permissible load would be 4-5-times higher.
The friction coefficient depends on the surface roughness and the material pairing. The “Dubbel”
pocket book for mechanical engineering states a value of 0.1-0.35 for static friction with steel on
steel, unlubricated, and a value of 0.1 for lubricated surfaces. Example given in Fig. 14.
Forces A and B are identical and equal

A = B = uxQ.
Hence, the following applies for non-lubri-
cated
surfaces:
300 x 0,35 = 105 t,
and for lubricated surfaces:
300 x 0,1 = 30 t.
It cannot be established to which extent the

forces may increase when the contact surfaces as shown in Fig. 12 have roughened. It can be
assumed that a friction value of 0.35 will be reached.
A result of the above explanations is the requirement to turn the kiln fully or to at least turn it
by 1/4 of a rotation (i.e., by 300-500 mm) so as to keep the friction, and thus the forces, at a low
level. If it is not possible to rotate the kiln, the contact surfaces must be properly lubricated, see
Section 6.3, Section 7 and Section 8 of this document).
The grease used for lubricating the girth gear is a suitable lubricant. If this is not available, vis-
cous oil may also be used.
BA 413-049-1 USA; Page 9 of 15

BA 413-049-1 USA; Page 10 of 15
During the expansion or shrinkage process, the static friction between the tire and supporting
roller produces compression and/or tensile stresses in the kiln shell which will increase until the
resulting force overcomes the friction force between tire and rollers (see Fig. 15) and the rotary
tube is offset in a jerk-like manner by the value of the change in length.
6 Axial movement of the rotary kiln
The following considerations are based on an example where an extreme situation has been
selected for a satellite rotary kiln with hydraulic thrust roller assembly.
6.1 Load distribution
In the following example, the weight forces at assemblies I-V are shown in Fig. 7, Chapter 2. The
kiln has a total weight of 2,955 t.
6.2 Heating up of the rotary kiln
When heating up the rotary kiln, it can be assumed that the expansion “originates” from
assembly III as it is subject to maximum load. Thus, rather the tires at the other assemblies will
be offset relative to their supporting rollers than the tire of assembly III.
To prevent having the kiln extend beyond a certain point in the direction of the inlet, the hydraulic
system of the thrust roller assembly as well as the kiln drive will be stopped as soon as this point
has been reached. Nevertheless, it cannot be precluded that the kiln exceeds that point and
damages the inlet chamber seal. This is possible in cases where thermal expansion takes place
more rapidly than the downward motion and can be counteracted by lubricating the supporting
rollers of assemblies II to IV, by which a more rapid downward motion of the rotary kiln will be
achieved.
BA 413-049-1 USA; Page 10 of 15

BA 413-049-1 USA; Page 11 of 15
6.3 Cooling down of the rotary tube
Before the rotary kiln is shut down, it should be run up to the upper limit position of the hydraulic
system for longitudinal guidance of the kiln. Moreover, after plant shutdown, the hydraulically
controlled thrust rollers must continue to force the kiln in the direction of the inlet.
If the displaceable thrust roller has a non-positive contact to the thrust roller bracket, Fig. 16, the
latter will be subjected to an extremely high load. Force P to be taken up by the thrust roller
bracket is calculated from the bearing forces, the angle of inclination and the friction value.
Fig. 17 shows an example calculated for a kiln which has not been rotated frequently enough, for
which the rotary kiln’s angle of inclination has been left out of consideration.
BA 413-049-1 USA; Page 11 of 15

BA 413-049-1 USA; Page 12 of 15
a) all assemblies non-lubricated

P = R2 + R 3 + R 4
P = (Q2 + Q3 + Q4) x 0.35 = 838 t
R2, R3, R4: friction forces between supporting rollers and tires, friction value μ =
0.35 (non-lubricated)
b) assy II, III und IV lubricated, assembly I non-lubricated

P = (Q2 + Q3 + Q4) x 0.1 = 240 t
μ = 0.1 (lubricated)
For comparison:
At an inclination of 3.5% the component of the weight load parallel to the rotary kiln axis equals
(~ 2°)
Qges. x sin 2° = 2 955 x 0.035 = 103 t.
Hence, the load exerted on the thrust roller assemblies in case of non-lubricated surfaces is up to
8-times as high as the downward pressure. For lubricated surfaces, the load is twice as high as
the downward pressure.
The following reference values are applicable to stopping of the kiln plant:
Environmental influences such as rain and wind have not been considered.
BA 413-049-1 USA; Page 12 of 15

BA 413-049-1 USA; Page 13 of 15
6.4 Standstill of the kiln plant over an extended period
The kiln tube must be moved towards the inlet until reaching the limit position switch A before
stopping the rotary kiln plant for an extended period of time.
As a result of cooling down, the rotary tube travels downward so that the tire moves the thrust
roller until it hits the thrust roller bracket (see Fig. 16 under Section 5.3). To keep this load as low
as possible, the supporting roller contact surfaces of assemblies II, III and IV must always be
lubricated during the downward motion. The rotary kiln should be rotated by a few hundred milli-
meters once each week so that the surfaces will always be properly lubricated and possible
loads, if any, are reduced.
Adhesive lubricants are suitable for lubricating as are used for girth gear lubrication; it will also be
possible to use highly viscous oils.
The hydraulic system must always be kept in operation, i.e., also during standstills of the kiln.
7 Lubrication of tire and roller contact surfaces
If the kiln must not be rotated, all supporting rollers must be lubricated except for the rollers of the
fixed assembly (which is the assembly near the kiln drive) before the thrust roller comes into
contact with the thrust roller bracket. Otherwise, the thrust roller bracket would be additionally
loaded with the increased friction force of the offset supporting roller assemblies.
BA 413-049-1 USA; Page 13 of 15

BA 413-049-1 USA; Page 14 of 15
In case of cooling down of the rotary tube in Fig. 20, it shrinks on either side in the direction of
assembly II, as this is the assembly subject to maximum load. Therefore, highest friction forces
occur there which inhibit a movement. If the thrust roller finally hits the thrust roller bracket, the
latter takes up the friction forces of assemblies II and III if the tube is not rotated. The contact
surfaces of assemblies II and III should be greased for ensuring a stress relief for the bearing
bracket. However, assembly I must remain in dry state. Similarly, assembly III remains dry in
case of the kiln shown in Fig. 21.
BA 413-049-1 USA; Page 14 of 15

BA 413-049-1 USA; Page 15 of 15
8 Measures to be taken upon failure of the drive
In case of a complete failure of the drive, e.g., due to loss of power, failure of the auxiliary drive or
destruction of a central drive component, the kiln will stop, which likewise may be applicable to
the burner. This entails cooling down of the rotary tube which will initiate a shrinkage process.
Due to the friction forces opposing shrinkage, tensions are built up inside the tube which may
result in further damage. To counteract this phenomenon, the contact surfaces of tire and sup-
porting rollers should be greased. To that end, the kiln tube should be rotated by approx. 100
mm. The manner in which the rotary motion can be performed is shown in Fig. 22:
The kiln can be moved in the manner illustrated by means of a hydraulic lifting jack (100 - 1 200
t) and a prop, which can be placed in one of the handless at the kiln inlet.
Before doing so, a larger quantity of adhesive lubricant must however be pressed into the gap
between the tire and roller. As a function of the tube's direction of rotation, the lubricant must be
supplied so that it will be drawn between tire and supporting roller by the rotary motion as shown
in Fig. 23. Left-over adhesive lubricants also used for the girth gear are also suitable for greasing.
Otherwise, also viscous oil can be used.
The tire assembly next to the drive is, however, not greased in order to maintain a preferably high
friction between tire and roller.
BA 413-049-1 USA; Page 15 of 15

Brick retaining ring and BA 413-064-2 USA

protective segments Page 1 of 12
at the rotary kiln outlet
Contents Page
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Development and experience made with the use of brick retaining rings. . . . . . . . . . . . . . . . . . . 3
3 Determination of damage causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Measure for avoiding defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

BA 413-064/2 en
Former edition:
4.1 Selection of the suitable brick quality and correct laying of the bricks . . . . . . . . . . . . . . . . . . . . . 7
4.2 Slow starting and heating up of the kiln plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Avoiding excessive sintering zone cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Roofing of the outlet zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Setting as small a gap as possible between tire section and tire bore . . . . . . . . . . . . . . . . . . . . . 8
4.6 Rendering the kiln operation uniform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 New bricking up and repair of the bricklining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Bricking up the outlet zone with ramming compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Arrangement of several brick retaining rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BA 413-064-2 USA; Page 2 of 12
Brick retaining ring and protective segments at the rotary kiln outlet
1 Introduction
At the outlet end, the refractory lining of rotary kilns is restricted by particularly shaped protective
segments of heat-resistant steel casting. These segments protrude into the firing compartment of
the kiln head and are, therefore, subject to high thermal loads. Although a separate air cooling
removes heat from the segments, they are permanently exposed to temperatures between 700°
and 1,000°C (glowing red to light-red), which reduces the strength of the heat-resistant cast
steel.
To accept the thrust of the bricklining caused by the kiln restriction and its rotary movement, a
separate brick retaining ring is arranged some brick rows in front of the kiln outlet end. Depend-
ing on the kiln size, this brick retaining ring is 70 mm high and about 180 mm wide. The retaining
ring made of several parts (segments) is connected with the kiln shell by slot welding. Thus, with-
out dismantling bricks, the brick ring is in complete contact with the surface of the side of the
retaining ring showing towards the kiln inlet. The brick retaining ring is covered by a complete
brick.
The protective segments comprise noses which keep the last brick rows of the kiln bricklining in
position.
The protective segments do not accept brick thrust.
BA 413-064-2 USA; Page 2 of 12

BA 413-064-2 USA; Page 3 of 12
2 Development and experience made with the use of brick retain-

ing rings
In the past, an upright flat iron ring of 80x30 mm cross section was used as retaining ring.
One brick row had to be dismantled and, consequently, lost its stability. Break-outs occurred and
even a complete destruction of the respective brick row. A reduction of the height of the brick
retaining rings to 60 mm did not bring about an improvement.
Also an increase of the brick strength from 40 N/mm2 to 60 N/mm2 as well as a reinforcement of
the brick retaining noses did not solve the problem.
Also a further attempt to stop the brick thrust by a conical brick retaining ring of heat-resistant
cast steel failed. The radial forces resulting from the brick thrust caused chipping off of the inter-
nal heads of the bricks resting on the retaining ring.
BA 413-064-2 USA; Page 3 of 12

BA 413-064-2 USA; Page 4 of 12
Then, in co-operation with the brick supplier, the new brick retaining ring described under item 1
was developed.
With the use of this ring, only in individual cases, defects occurred at the kiln outlet end. These
defects were characterized by the following features:
• The brick retaining noses of the outlet segments were bent outwards.
• The last brick row was slid onto the now conically shaped brick retaining nose and broke out.
• A helical twisting of the brickwork could be noticed.
• After the removal of the bricklining, the dragging traces (blank scours) could be seen on the
kiln shell.
BA 413-064-2 USA; Page 4 of 12

BA 413-064-2 USA; Page 5 of 12
3 Determination of damage causes

During the examinations, it was striking that defects occurred already some months after first
bricking up or, in the majority of all cases, suddenly and after years of completely normal kiln
operation.
It was found that changes can develop within the kiln system leading to an extremely high brick
thrust in the direction of the outlet end.
This extremely high thrust force is the main cause for the mentioned mechanical defects at the
bricklining and the protective segments. It occurs if the following factors simultaneously occur:
• Loose brickwork in front of the brick retaining ring; the outer diameter of the bricklining is
smaller than the inner diameter of the kiln shell, which results in a relative movement
between brickwork and kiln shell.
• Individual brick rings which are not rectangular to the kiln axis and are in tight contact to the
kiln shell (see left side Fig. 413-034) and/or brick retaining rings which have not been
mounted rectangularly to the kiln axis. They cause a wedge-like effect and helically displace
the brickwork behind in the direction of the outlet (right side).
BA 413-064-2 USA; Page 5 of 12

BA 413-064-2 USA; Page 6 of 12
BA 413-064-2 USA; Page 6 of 12

BA 413-064-2 USA; Page 7 of 12
4 Measure for avoiding defects
4.1 Selection of the suitable brick quality and correct laying of the
bricks
For the selection of the suitable brick quality and the correct laying of the bricks, the bricklining
instructions of the brick supplier must be observed.
The brick rings must be aligned rectangularly to the kiln axis or in parallel to the circular weld
seams.
4.2 Slow starting and heating up of the kiln plant

For slowly starting and heating up of the kiln plant, the heating up curves must be considered
which are specified by the manufacturer of the refractory material.
In case of an excessively rapid temperature rise in the tire area of the kiln, the tire is heated up
much slower than the shell plate. The latter is then stressed beyond the flexible deformation limit
and a lasting narrowing will result. This will increase the ovality of the kiln shell and walking of the
brickwork (see Fig. 413-035). An increased wear and chipping off of the bricks will then make the
brickwork become loose.
BA 413-064-2 USA; Page 7 of 12

BA 413-064-2 USA; Page 8 of 12
Moreover, by a too-rapid heating up, the brickwork is axially and radially expands more rapidly
than the kiln shell; increased brick thrust and loosening of the bricklining are the consequences.
4.3 Avoiding excessive sintering zone cooling

The extreme lowering of the kiln shell temperature in plants with installed cooling air fans (or
even water sprinkling) causes an extreme temperature difference between brickwork and kiln
shell. The reduced expansion of the kiln shell, in turn, causes an increased brick thrust and loos-
ening of the bricklining.
4.4 Roofing of the outlet zone

To avoid an excessively rapid cooling down of the kiln tube upon a current failure and, hence, a
standstill of the kiln at simultaneous rainfall, the outlet zone must be roofed. Otherwise, the kiln
would shrink more rapidly than the internal brickwork. The consequences would be the same as
described under Item 4.3.
4.5 Setting as small a gap as possible between tire section and tire
bore
By this measure, defects can be avoided which are due to an increased ovality of the kiln tube.
The reduction of the gap can be realized by replacing the loose tire shoes (or slide plates) (see
our operating instructions “Loose tire with tire section and tire fastening”) or, in case of older
plants, by inserting thin shims. The last-mentioned method can be locally applied with simple
means; however, it is not a permanent solution.
As a reaction on the increased ovality, also the relative movement between tire and kiln shell is
increasing; the latter should not exceed 25 mm/U
4.6 Rendering the kiln operation uniform
Caution!
Frequent disconnecting (cooling down) is disadvantageous for

the plant.
BA 413-064-2 USA; Page 8 of 12

BA 413-064-2 USA; Page 9 of 12
5 New bricking up and repair of the bricklining

Twisted brickwork must be broken out after the occurrence of defects but prior to rehabilitation
works. It must be made sure that the remaining brickwork is in a rectangular position to the kiln
axis. If this is not the case, the rectangular position must be restored again by matching the brick
row to be newly installed. Here, the minimum brick length “Y” must not be smaller than half the
normal brick length “X” (see Fig. 413-036 and 413-037).
Caution!
Within the brick rings, the brickwork must not be toothed, i.e., laid
in a cascade-like manner.
X = Normal brick length

Y = Minimum brick length
Z = Deviation of the brick ring level to the kiln cross axis
BA 413-064-2 USA; Page 9 of 12

BA 413-064-2 USA; Page 10 of 12
In this connection, it must be considered that, upon a partial renewal of the lining, the axial
expansion joints of the newly installed zone must be dimensioned larger than indicated by the
brick supplier for the original bricking up. This is necessary, as the expansion joints in the remain-
ing old lining are no more fully functioning due to the displacement of bricks and because of clog-
ging. The expansion of this existing zone and, hence, the resulting brick thrust must be also be
accepted by the new joints.
BA 413-064-2 USA; Page 10 of 12

BA 413-064-2 USA; Page 11 of 12
6 Bricking up the outlet zone with ramming compound

A method successfully realized in some cement rotary kilns is bricking up with monolithically
installed refractory ceramic compound.
BA 413-064-2 USA; Page 11 of 12

BA 413-064-2 USA; Page 12 of 12
Here, the selection of the suitable material as well as the careful application is decisive for the
service life.
Also the number and distribution of the Y-anchors as directed by the supplier of the refractory
compound must be observed.
Disadvantage:
The new bricking up of the monolithically installed outlet zone requires a very high work expendi-
ture, as the residues of the old bricking up are very difficult to break out (with a rock drill). Bricking
up takes more time than a bricklining proper.
7 Arrangement of several brick retaining rings

Generally, it can be assumed that all metallic parts protruding into the brickwork disturb the brick
union and are therefore undesired.
Assuming, however, that a brickwork which is not laid rectangularly to the kiln axis (see Fig. 413-
034) is the main cause for defects in the outlet area, several brick retaining rings could serve as
a marking to ensure the exact laying of the bricklining. The height of these rings could possibly
be smaller (40-50 mm) and the rings would have to be covered with bricks.
Additional brick retaining rings not arranged in the kiln outlet area are not permitted to be
installed in the direct vicinity of tires (minimum distance about 5 m from the ring center), as the
larger ovality of the shell plate in these zones will lead to defects in the brickwork of kiln tube.
In the case of long kilns, heavily distorted tubes with considerable geometry deviations etc., upon
agreement with the supplier of the refractory material, also 2 brick retaining rings at a distance of
about 1 m can be installed in the outlet area. By the distribution of the brick thrust to 2 brick rings,
the service life of the kiln can be increased.
BA 413-064-2 USA; Page 12 of 12

Surveying of kiln centerline and BA 413-0226 USA
readjustment of rotary kilns Page 1 of 2
The assembly of new rotary kilns with placement of foundation frames, bearing alignment,
slope determination (with due regard of tire and roller diameters), etc., is carried out at
ambient temperature.
The tube, which is comprised of sections suitable for assembly, is aligned exactly straight,
(i.e., with flush centerline) and then welded. This straight kiln centerline is of vital
importance both for proper functioning of the kiln, but also for refractory lining of the tube
to be carried out afterwards.
BA 413-0226 en
Former edition:
During operational condition deviations from a straight kiln axis (e.g., due to tube deforma-
tions or settling of the foundation) as well as worn running surfaces of tire and supporting
rollers, changed load distribution at the piers for kilns with 3 or more bearing assemblies
will result. We know of cases in practice where the load acting on the assemblies has
increased to more than twice the standard value. The specific load acting on the different
components under these circumstances is correspondingly high.
Relief of one assembly always means a higher load acting on the neighboring assembly/
assemblies. That effect will be more intense the stiffer a kiln is and - vice versa - the effect
will be less intense the more flexible a kiln is.
A kiln is considered stiff if the bearing distances are short and the shell plate relatively
thick. A soft kiln is characterized by wide bearing distances and relatively thin shell plates.
Normal preheater/kilns with 3 bearing assemblies have relatively short bearing distances
due to their length/diameter ratio. In general, these kilns are stiff. Consequently, the effect
of foundation settling and deformation of the kiln axis have large effects on the kiln statics.
For kilns with only 2 bearing assemblies, the loads acting on the assemblies do not mutu-
ally influence each other under the conditions outlined above; the specific load acting on
the components does not undergo any change.
Despite the fact that the permitted specific loads are low when dimensioning the kiln, it has
to be carefully watched upon operation of kilns with 3 or more piers that damage due to
excess load is prevented. Kilns can nowadays be monitored and surveyed by modern
methods assisted by EDP - one of these methods is the PYROCHECK® adopted by HWI.
The current longitudinal kiln axis is most accurately determined by means of surveying
with the aid of a laser. This PYROCHECK® ascertains the actual (tire)-centers of the rota-
ting elements and calculates the horizontal and vertical deviations of the centers to each
other.
Fluctuating temperature of the tires attributable to varying operating conditions result in

changes of their diameters and deviations from the straightness of the longitudinal kiln
axis. In order not to have to carry out measurements permanently and perhaps to make
necessary new adjustments, many years of practical experience enabled fixing a tolerance
limit for deviations in elevation and lateral deviations of the longitudinal kiln axis at the bea-
ring assemblies.
A maximum deviation of 4 ... 5 mm is accepted and considered negligible for preheater/

kilns with 3 bearing assemblies unless there are additional negative effects that influence
the load acting on the kiln tube.
BA 413-0226 USA; Page 2 of 2
Surveying of kiln centerline and readjustment of rotary kilns
For long kilns (wet/dry kilns) with correspondingly wide distances between the bearings, maxi-
mum deviations of 6 ... 7 mm are accepted.
In case the deviations determined at the bearing assemblies exceed the above limits, the posi-
tions of the supporting roller bearings transverse to the kiln axis will have to be shifted in compli-
ance with the figures ascertained by PYROCHECK®.
The constraint-free tire fastening mechanism of HWI ensures perfect transfer of force from the
tube to the tire and further on into the bearing system within and even outside the tolerance limits
mentioned earlier.
Signs of an inadmissibly large deviation of the kiln centerline from a straight line may be the fol-
lowing:
• Foundation settling/-shifting
• Dislocation/exchange of supporting rollers
• Exchange of tires of changed diameter
• Tires having come off their rollers
• Re-working at tire and roller diameters
• Heavy deformation of the kiln shell and/or radial deflections at the inlet and the outlet
• Cracks in the kiln shell
• Increased bearing temperatures
• Increased/fluctuating power input at the drive
• Pronounced increase of the relative motion of the tire
• Bricklining problems
• Generally major modifications or repairs
In case no acceptable explanations can be found for the above phenomena, we recommend that
a PYROCHECK® be performed.
BA 413-0226 USA; Page 2 of 2

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What are the main components of a rotary kiln?

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What is the purpose of surveying the kiln centerline?

What is the purpose of surveying the kiln centerline?

Sub-assembly description

• Sub-assembly descriptions for rotary kiln -

State: 413.480 / 01.2007

Table of Contents of GB 413-0038 USA

1 Contents of sub-assembly description: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Introduction in sub-assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 Sub-assembly drawing - ZD 413-0187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Contents of sub-assembly description:

Sub-assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0187

1. Rotary tube . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001 USA ZD 413-0178

2. Bearing assembly I and II . . . . . . . . . . . GB 413-0002 USA ZD 413-0184

3. Longitudinal guide system

Hydraulic unit. . . . . . . . . . . . . . . . . . . . . BA 413-0255 USA

4. Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 413-0271 USA

5. Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0020 USA ZD 413-0189

Pneumatic inlet seal . . . . . . . . . . . . . . . BA 413-0273 USA ZD 413-0200

6. Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0030 USA ZD 413-0192

7. Accessories . . . . . . . . . . . . . . . . . . . . . . . . .For relevant documents see under

8. Optional equipment . . . . . . . . . . . . . . . . . .For relevant documents see under

Table of Contents of Sub-assembly Descriptions (Section: III B)

2 Introduction in sub-assembly description

The descriptions of the sub-assemblies always relate only to

The rotary kiln consists of the following machine components:

1. Rotary kiln tube

3. Longitudinal kiln guide system

9. Inner assemblies (if applicable)

The different kiln components are made up of the following parts:

GB 413-0038 USA; Page 2 of 5

Table of Contents of Sub-assembly Descriptions (Section: III B)

3. Longitudinal kiln guide system

GB 413-0038 USA; Page 3 of 5

Table of Contents of Sub-assembly Descriptions (Section: III B)

9. Inner assemblies (if applicable)

GB 413-0038 USA; Page 4 of 5

Table of Contents of Sub-assembly Descriptions (Section: III B)

3 Sub-assembly drawing - ZD 413-0187

GB 413-0038 USA; Page 5 of 5

• Kiln tube - GB 413-0001 USA

State: 413.480 / 01.2007

Operating instructions GB 413-0001 USA

to rotary tube Page 1 of 3

Contents of the operating GB 413-0001 USA

instructions to rotary tube Page 2 of 3

Contents of the operating instructions:

State: 03.2008 Safety and Health . . . . . . . . . . . . . . . . . . . . GB 413-0001-02 USA

* General safety information

State: 03.2008 Design and functioning . . . . . . . . . . . . . . . . . GB 413-0001-03 USA

State: 03.2008 Transport . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-04 USA

State: 03.2008 Assembly . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-05 USA

State: 03.2008 Commissioning . . . . . . . . . . . . . . . . . . . . . GB 413-0001-06 USA

State: 03.2008 Operation . . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-07 USA

State: 03.2008 Maintenance . . . . . . . . . . . . . . . . . . . . . . . GB 413-0001-08 USA

Contents of the operating instructions to rotary tube

Further pertaining operating instructions:

Commissioning - operating instructions

Pertaining technical delivery specification: