The kiln can be installed by following methods.

Moving track,

1. A supporting structure or supports

2. By pre-assembled at the ground.

The following are the factors which help us to decide the factor to be used specific site conditions as well as
on the

1. Lifting appliances and transport means available at the site, such as gantry crane, mobile crane or
derrick crane.

2. Kiln diameter

3. The heaviest single item to be mounted

The correct kiln assembly is the precondition for trouble-free operation later. It must be carried out
with utmost care. The erection company is responsible for observation of the safety regulations.

1. Installation-related information for the construction of kiln foundations

1.1 Construction:

a. All sheets and angles shown in the machine arrangement plans and on which the position markings of
all foundations shall later be made, shall be permanently anchored in concrete.

b. It is the building contractor's responsibility that these items as well as other steel parts to be placed in
the concrete will be at the site in time and that they will be put in the correct place.

c. All anchor holes shall be covered until assembly of the machines to prevent clogging.

d. The pockets shall afterwards be grouted with cement with the anchor bolts in such a manner that
perfect bonding with the concrete is ensured.

e. The foundation surfaces on which the sealing mortar is placed shall be rough. Defective concrete,
residual oil, dirt, dust and mortar as well as other loose objects must definitely be removed.

f. The reinforcements for the first-stage concrete shall sufficiently protrude in the grouting layers, if
required. Reinforcements which are in the way when mounting the base frames or the like shall be
laid round the profile concerned but not be cut off.

g. Prior to starting machine assembly, the ACTUAL dimensions of the first-stage concrete shall be
entered by the building contractor in an "as built plan". That plan shall be handed over to the
assembly management; changes, if any, shall be agreed upon with the assembly management

h. Steel components which are to be embedded in concrete and/or steel component surfaces that come
into contact with concrete shall be covered.
 i. Following assembly all machine base frames shall be under poured with low-shrinking grout.

j. All concrete surfaces which come into contact with the grout shall be previously wetted in such a way
that they will not withdraw any mixing water from the grout thus warranting per- fect bonding with
the foundation proper.

k. After hardening, the grout shall at least feature the strength of the structural concrete.

l. Protective railings round pits, coverings for platform openings as well as all platforms and stairs do
not belong to the machine supply. Unless otherwise specified they shall be mounted as instructed by
the building contractor.

1.2 Special information

a) The installation material delivered with the equipment shall be adapted to the specific site conditions.

b) All completed installation jobs shall be documented by a dimensional record.

c) If shims are used for equalizing differences in height, these shims shall be safeguarded against
dislocation by tack welding and it shall be made sure that they will not perform resilient move- ments.
As a general rule, the shims shall always be arranged on both sides of the bolts.

1.3 Check Points

To warrant perfect functioning of the kiln, particularly important criteria shall be duly observed with
special care already during kiln assembly. Some of these criteria have been listed below:

a) Vertical and longitudinal centrelines as well as slope of all base frames

b) Position and alignment of the kiln centreline

c) Concentricity and run-out of tyres and ring gear

d) Alignment of supporting roller and thrust roller bearings

Set up and alignment of the drive.

2. Safety Guidelines

a) All parting lines at housings, gearboxes, etc. as well as all pipes (oil, water, air) shall be tight and be
checked for unhindered passage.

b) Surfaces protected by preservation shall be cleaned and the necessary corrosion protecting agent be
applied.

c) all screwed connections shall be verified for tight seating prior to completion of the assembly.

d) Requested safeguards must have been installed.

e) Inlet and outlet seal shall feature good contact and function perfectly.
 f) The tube must be carefully safeguarded against turning during any job inside or at the kiln tube.

g) Except for welding clearly specified as being necessary for assembly, all welding work to the kiln
direct is prohibited.

h) When carrying out electric welding at the kiln make sure that cur rent can never flow into the
bearings nor over contact points like tyre/supporting roller, tyre/thrust roller and ring gear/pinion.

i) When carrying out work to the kiln when electric lights and instruments have to be taken to the kiln
inside observe the regulations of the boiler construction industry.

e) All protective devices shall be installed functionally safe. The installation of the protective devices
shall be carried out as defined in the drawings as well as the information contained in the different
sub-assembly descriptions. i.e. by doweling in the foundation recesses and/or the protective devices
shall

Be fastened to the specified location by welding/bolting.

f) In the event of deviations at the buildings or with respect to the dimensions, the protective devices
shall be adapted during installation in such a manner that their protective functions are fulfilled in
every respect.

g) Bench marks should be provided at the foundations to facilitate later dimensional checks.

h) It should above all be made sure during kiln installation that functionally associated sub- assemblies
will not mechanically interfere with each other due to dimensional tolerances. In other words,
rotating parts shall not come into contact with stationary components (except for seals); seals shall be
well seated at all sides, etc.

i) Rotation check of all motors as well as of all rotating kiln components shall be made during final
acceptance of the assembly work.

j) Make sure that lubrication of the bearings will be ensured during every kiln revolution.

3. Measuring procedure prior to starting kiln assembly

a) Fix the benchmarks of longitudinal and lateral centrelines of the kiln and of the distances as
described

b) Align the base frames relative to the supporting rollers and the thrust rollers as well as align the
supporting and thrust rollers themselves as described for the sub-assemblies (see sub- assembly
descriptions in this section).

3.1 Ascertaining and fixing the kiln centreline, the lateral axes relative to the base frames
(supporting rollers), benchmarks

a) The starting points for ascertaining the kiln centreline and benchmark ± 0.00 is already marked in
the Colleagues GA drawing of Pre heater near inlet Chamber as Kiln cold working point for
measuring the base frames
 b) The starting points for the kiln centreline are located in the Preheater on "Inlet chamber" and on the
burner platform "kiln hood"

c) Normally, the building company roughly marks the longitudinal and the lateral kiln axes at the kiln
foundations on the concrete (by means of a pencil).

d) The measuring plates with marks - illustration Fig 4 refers - shall be placed on these marks in
inclined position.

e) When doing so it shall be duly considered that the measuring plates are taken as reference for
marking the lateral axes for measuring the elevation of the base frames later - illustrations Fig 5.

f) The points roughly marked by the building company shall under no circumstance be referred to for
aligning the supporting roller base frames.

g) The longitudinal kiln axis shall be marked from the axis starting points with a theodolite or a
tightened cable (rope) with a plumb bob on the measuring plates with marks previously mounted
with mortar and bolted to the plates (illustrations Fig 3,Fig 2, Fig 4, Fig 5, Fig 7 refer).

a) After the longitudinal kiln axis has been marked, an auxiliary axis shall be marked at one side on
all foundations, i.e. outside the kiln area; that auxiliary axis shall run exactly parallel to the
longitudinal kiln axis. When the markings of the longitudinal kiln axis are in part no longer
accessible, this auxiliary axis is used for exactly repeating measurements nevertheless.

3.2 Fixing the kiln centreline with Theodolites

a) The accuracy of optical measuring instruments may be impaired by environmental influences.

b) When fixing the longitudinal kiln axis the instrument shall be positioned perpendicular to one of
the starting points for the axis, e.g. starting point 1 and the gratitude of the theodolite shall most
exactly be adjusted to starting point 2 (illustration Fig 3 refers).

c) Subsequently, the plates with the markings on the foundations shall be pointed with the telescope
of the theodolite.

d) To ensure a bright background, Spanish white shall previously be applied to the measuring plates
with marks.

e) The kiln axis is transferred to the measuring plate by a scribing iron starting from the vertical line
of the graticule (light mark).

f) After these axis markings have been applied, the transfer from starting point 2 is carried out at
reverse sequence.

g) Afterwards, the accuracy of the longitudinal kiln axis shall be checked and finally marked by a
strong mark at option on foundation II or III from point 3 newly determined relative to star- ting
points 1 and 2.
 h) Care shall be taken that the kiln axis is permanently marked as far as possible into the pre- heater
but at least underneath the complete Inlet chamber and on the burner platform beyond the kiln
hood rails, e.g. for assembly of the kiln firing system. It will be best to use measuring plates with
marks as well.

3.3 Fixing the kiln axis with a steel rope of approx. 5 - 8 mm diameter

a) Fixing the kiln axis by means of a theodolite should be given preference to determining the axis
by means of a steel rope.

b) Fixing the kiln axis by means of a steel rope can and must only be done at no wind at all.

c) Set up a robust and stable steel structure behind the axis starting points in the preheater and on
the burner platform over which the steel rope can be routed and independently fixed and
tensioned (1.5 t pulling device).

d) Align the steel rope with plumb bobs to starting points 1 and 2 and safeguard it on the structure
against sliding to the side, e.g. by providing for a notch in which the rope is placed.

e) Transfer the kiln axis to the measuring plates with markings provided on the foundations for the
kiln axis by means of plumb bobs and mark it permanently (illustrations Fig 2 and

Fig 6refer).

f) Then dismantle the steel rope axle.

3.4 Fixing the distances between the foundations

a) As a general rule, all distances are related to the pier on which the thrust roller (near the drive) is
located. This is normally kiln foundation I.

b) During preparatory measures, i.e. when checking dimensional accuracy of the foundation, the
pockets shall be checked as to distance and whether they are true to line by the machine
arrangement plan. If no significant deviations (approx. ± 20 mm are permitted) are noted, point Qb
as per illustrations Fig 5and Fig 7, i.e. the axis point for the lateral axis shall be provisionally fixed
on foundation I along the longitudinal kiln axis and/or on the measuring plate with marking
intended for that purpose (which latter also serves as benchmark).

c) Only after the dimension to "Inlet chamber" (preheater platform openings to the lower cyclone
stage, etc.) has been checked from this axis point shall axis point Qb be permanently marked for the
lateral axis on foundation I. The measuring plate with markings shall afterwards be levelled to
NOMINAL elevation of the supporting roller base frames. The minor deviation that occurs relative
to the previously fixed lateral axis marking is negligible and will not be taken into account.

d) Fixing the additional points Qb on the lateral axis on foundations II, III, etc. shall always start from
the lateral axis reference point Qb of foundation I.
 e) The horizontal dimensions given in the machine arrangement plan determine the distances
between the individual foundations. The distances should preferably be measured with a levelling
instrument with graduated circle and angle measurement or by means of a tacheometer. When
using a tape measure this should preferably be plastic coated.

f) To prevent inaccurate measurements, the tape measure must not be sagging when measuring the
distance. At distances of more than 10 m it is already recommended no longer to tighten the tape
measure with a spring balance but to set up a through going light supporting structure (e.g. made of
wood) horizontally between the lateral axis measuring points of the foundations (illustration Fig
1refers).

g) Having established the above preconditions, the distances shall be recorded on the relevant
measuring plates with markings Qb, i.e. starting from foundation I. At the same time the measuring
plates with markings shall be levelled to the corresponding NOMINAL elevation of the supporting
roller base frames.

3.5 Ascertaining the lateral axis at right angle to the kiln axis with compasses

Illustrations Fig 8. Care shall be taken that the measuring plates with markings Qa and Qc on which
the lateral axis will be drawn are levelled to the relevant NOMINAL elevation of the supporting
roller base frames.

3.6 Ascertaining the lateral axis with theodolite

Place instrument perpendicular to lateral axis reference point Qb and exactly adjust the gra- ticule
to points 1 or 2 of the kiln axis. That adjustment will result in a scale number in the horizontal circle
of the measuring instrument. Either 90° or 100 centesimal degrees have to be

added to and/or subtracted from that scale number. These values will result in the right- angled
lateral axis which have to be transferred to the measuring plates Qa and Qc over the graticule in the
theodolite. The measuring plates with markings shall at the same time be levelled to the NOMINAL
elevation of the base frames.

3.7 Fixing the benchmarks on the basis of a measuring plan

a) The measuring plates at the right and left of the piers, of the burner building and at the pre- heater

shall be mounted by the building company in compliance with the information contai ned in the
machine arrangement plan.

b) Fixing the elevation of measuring plates 1 and 2 at the front side of the preheater depends on the
dimension between ± 0 and the centre of the base frame top - pier I (measuring plan under item 6
refers).

c) Fix contour line - 1000 - on the measuring plates provided at the right and left of the foundations
and have it permanently marked (measuring plan, detail "A" under item 6 refers).

d) Starting from ± 0 apply elevation given in the arrangement plan from centre of pier I to centre of the
base frame top to measuring plates 1 and 2 at the Preheater by means of a tape measure and
 levelling instrument and have it permanently marked. During the rest of the procedure these
elevations applied to the Preheater will serve for levelling the elevation of measuring plates Qa, Qb
and Qc located on pier I. The lateral axis is at the same time app- lied at right angle to kiln axis "A" on
the measuring plates Qa and Qc. Reference is made in this respect to items d) e) f) above.

The progress of the assembly work as well as examples for assembly regulations/guidelines for the
different sub-assemblies have been described in the section "Assembly" at the subassemblies
proper (sub-assembly descriptions in this section refer).

4. Brief description of the mechanical assembly procedure of a rotary kiln system (proposal)

1. Install the auxiliary structure for kiln assembly between the foundations.

2. Ascertain and fix the longitudinal kiln axis and the lateral axes relative to the base frame as well as
ascertaining the benchmarks and fixing the distances between the foundations

3. Place the base frames in the foundations as well as loose insertion of the anchor bolts.

4. Align the base frames.

5. Grout the anchor bolts.

6. Tighten the anchor bolts and realign the base frame once again with the aid of the levelling
instrument.

7. Check measuring and enter the test results in the test record/measuring plan

8. Provide for complete grouting of the base frames.

9. Place the supporting roller pillow blocks on the foundations and mount the T-head bolts.

10. Align the roller assemblies symmetrically to the kiln centreline by means of a levelling instrument
(theodolite).

11. Adjust side faces flush to each other by placing a ruler on the machined fronts of the supporting
rollers.

12. Check measuring and enter the test results in the test record/measuring plan.

13. Mount thrust roller brackets and align them.

14. Place tyre on supports in horizontal position above the ground.

15. Introduce the corresponding tyre section which has previously been provided at one side with stop
cams into the tyre.

16. Assemble conical inlet ring and scoop ring on the ground to first kiln section seen from the kiln inlet.

17. Mount outlet segments to outlet ring unless they have been delivered pre-assembled to the site.
Mount complete outlet ring on the ground to the last outlet-side kiln section.
18. Place feed-end chamber to front-most part of the supporting structure set up for kiln assembly and
draw feed-end chamber in the Pre heater tower to the specified location.

19. Place kiln sections on correspondingly prepared crossbeams for the assembly - starting at the kiln
inlet. Maintain a gap of 20 mm at a maximum between the different kiln sections.

20. In case of an enclosed burner platform, do not place the last tyre and following kiln sections in their
relevant positions. Introduce kiln hood through this gap over the outlet-end kiln foundation onto the
burner platform.

Concerning assembly of the kiln see item 46 and following.

21. Weld guide plates, screw-type supports and elbows for tension bolts in all kiln tube sections.

Depending on the kiln tube diameter their number varies between 6 and 12/section.

22. Draw the kiln sections together.(see also under section "Assembly" in the description of the sub-
assemblies "kiln tube") The point of reference for this assembly is tyre 1 located at the inlet-side kiln
foundation.

Check the alignment of the inside kiln shell line at several locations of the circumference. (See also
"technical supply stipulations for rotary tubes" no. FV Fig 7, part 2 which has been attached to that
section).

23. In case of varying pipe diameter/radius have the offset balanced by means of a template (illustration
413-018 contained in section "Assembly" under sub-assembly "rotary tube" refers).

24. Have sections root welded manually at the outside by the back-step method. Make absolu- tely sure
that the specified weld filler material (lime-basic covering) is used.

25. Place split ring gear on kiln tube, screw it up and roughly centre it with suitable device relative to
the kiln shell. Install spring plates.

26. Place drive pinion screwed to base frame on kiln foundation and hook in anchor bolts.

Align it with levelling instrument.

Make check measurements and enter the results in test record.

27. Grout anchor bolts.

Allow grouting to set.

28. Have drive pinion aligned once again with levelling instrument.

Make check measurements and enter the results in the test record (item 6 refers).

29. Completely grout the pinion bearing system.

30. Place main gearbox screwed to base frame on kiln foundation and hook in anchor bolts.Align it with
 levelling instrument.

Make absolutely sure that the gap at the coupling halves is maintained.

31. Grout anchor bolts.

Allow grouting to set.

32. Align once more by means of levelling instrument.

33. Completely grout gearbox bearing system.

34. Place auxiliary drive on foundation, assemble and grout it analogously to item 30-33 above.

35. Revolve kiln by means of the auxiliary drive. While doing so, align ring gear with respect to
concentricity and radial run-out. Check oil film at bearing collars.

Tighten ring gear spring plates at kiln shell and weld them as shown on the relevant drawing
(section "Assembly documents for machine assembly").

36. Carry out concentricity check of kiln tube as check measurement, in particular at the kiln inlet and
outlet zone.

Enter results of measurement in the test record (item 6 refers).

37. Weld kiln shell at the outside.

Machine welding

(Weld method / submerged arc welding)

Automatic revolving of the kiln by means of auxiliary drive controlled from the welding head. Duly
observe specified number of passes and welding material.

Manually grind root pass before starting welding with machine. In case of manual welding have kiln
tube revolved by sections.

Following outside welding of the kiln shell, root to be ground and welded at the inside.

38. Assemble inlet seal after the feed-end chamber has been aligned.

39. Remove all guide plates and angles mounted in the kiln tube for the tension screws.

40. The kiln is now ready to be brick lined.

41. Assemble ring gear guard and grease spraying unit.

42. Mount heat protecting device, water cooling system and temperature monitoring unit to the
different roller assemblies.

43. Mount graphite lubrication unit to the roller assemblies.

45. Mount kiln hood top on bottom section and weld the two parts gas-tight as shown on the relevant
drawing. Position kiln hood relative to the kiln.

46. Mount outlet seal to the kiln hood.

47. The kiln hood is now ready for brick lining.

48. Adjust kiln outlet seal.