Professional Documents
Culture Documents
BA C07143 USA
Part B:
State:
413.480 / 01.2007
Table of Contents of
Sub-assembly Descriptions
(Section: III B)
Edition: 03.2008
GB 413-0038 USA
Page 1 of 5
Former edition:
GB 413-0038 en
Contents
Page
Drawing No.
2.
3.
ZD 413-151
5.
6.
7.
8.
Special descriptions:
Tire fastening mechanism . . . . . . . . . . . . .
Adjusting instructions . . . . . . . . . . . . . . . .
Expansion and shrinkage processes . . . .
Brick retaining rings for rotary kilns. . . . .
Kiln centerline surveying . . . . . . . . . . . . . .
BA 413-0171 USA
BA 413-005/1 USA
BA 413-049/1 USA
BA 413-064/2 USA
BA 413-0226 USA
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 certain 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 operation 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
2.
Bearing assemblies
-
3.
4.
5.
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
A thrust roller bracket with built-in thrust roller which can be shifted on two guide rails and
is carried in anti-friction bearings
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
Drive
-
Wheel protection box with inspection doors and acceptance device for the spray lubrication system
Main gearbox
Coupling between main gearbox and main motor including dual shoe brake and limit
switch
Centrifugal clutch with centrifugal bracket between auxiliary gearbox and motor
Motor
Inlet
-
Pneumatic seal
6.
7.
8.
9.
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
Accessories
-
Temperature monitoring of bearings of supporting rollers, thrust roller, pinion and main
gearbox
Graphite lubrication for lubricating the anti-friction bearings of the thrust-roller bracket
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)
Optional equipment
-
Relatyrex
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
GB 413-0001 USA
Page 1 of 3
Former edition:
GB 413-0001 en
Operating instructions
to rotary tube
Edition: 03.2008
Fig. 3
Edition: 03.2008
GB 413-0001 USA
Page 2 of 3
Former edition:
GB 413-0001 en
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
BA 413-064
BA 413-0171
BA 413-138
BA 413-0233
BA 413-049
BA 841-......
General
Edition: 03.2008
GB 413-0001-01 USA
Page 1 of 1
Contents
Former edition:
GB 413-0001-01 en
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General information
Note!
See information in the General section Operating instructions
rotary kiln tube of the Technical Machinery Documentation.
Edition: 03.2008
GB 413-0001-02 USA
Page 1 of 1
Former edition:
GB 413-0001-02 en
Contents
Page
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.:
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.
Edition: 03.2008
GB 413-0001-03 USA
Page 1 of 3
Former edition:
GB 413-0001-03 en
Contents:
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1
2.2
2.3
Rotary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tire sections with fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Girth gear section with sprig plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information
Note!
See information in chapter Design and Functioning in
section "Operating instructions rotary kiln tube" of the
Technical Machinery Documentation.
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.
On the outlet side, the last tube section only comprises a chamfer for welding the outlet end section with the spring seal.
2.2
2.3
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.
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.
Transport
Edition: 03.2008
GB 413-0001-04 USA
Page 1 of 1
Contents:
Former edition:
GB 413-0001-04 en
Page
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 instructions rotary kiln" of the Technical Machinery Documentation.
Assembly
Edition: 03.2008
GB 413-0001-05 USA
Page 1 of 30
Former edition:
GB 413-0001-05 en
Contents:
Page
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1
3.2
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.2
4.2.1
4.2.2
4.2.3
Preparatory works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Matching of the tube elements/round seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the round seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation of pulling and pressure angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lifting and ratchet tackle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Screw-type blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wedge-type carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Force pieces with hydraulic lifting blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Welding of the round seams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly of the kiln tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Supporting scaffolding (e.g., for a rotary kiln 4,6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Travelling path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Regulations for welding of kilns of structural steels and special structural steels. . . . . . . . . . . . . 21
Weld seam check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1
Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1
Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Information
Note!
See information in chapter Assembly in section Operating instructions
rotary kiln tube of the Technical Machinery Documentation.
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
3.1
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 supporting points.
The brick-retaining ring on the inlet side is welded in as directed by the brick supplier.
3.2
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
4.1.2
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).
4.1.4
4.1.5
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 elements. 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 alternatingly welded to the entire inner circumference of the section at a distance of approcimately 300400 mm. At particularly out-of-round points, further wedge-type carriers are welded. The tube offset 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.
2.
3.
Upon overpressing of the tube offset, the wedges must be hit back which, for reasons of
space, is frequently very difficult.
4.
4.1.8
4.1.9
4.1.10
4.1.11
2.
Spacer lock
3.
Bracings
4.
Supports
5.
6.
7.
Connection girders
8.
Bracket carriers
9.
Bracket elements
GB 413-0001-05 USA; Page 6 of 30
10.
Friction carriage
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 position 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; however, 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).
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 carriers. 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 distribution girders (item 6) and balancing liner plates are installed. Upon smaller loads, also suitable 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 scaffolding.
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.
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
DI =
UI
DII =
V=
UII
( DII - DI )
2
Calculation example:
Given: UI = 14445 ; UII = 14461
Searched for: DI ; DII and V
DI =
DI =
UI
14445
3,1416
DI = 4598
====
( DII - DI )
U
DII = II
V=
14461
DII =
3,1416
V=
DI = 4603
====
V = 2,5
===
( 4603 - 4598 )
2
2
Preliminary assembly of the kiln tube sections to suitably assembly tube section length, partly performed on the ground.
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
DIN EN 10025
DIN EN 10028
Material-No.
1.0116
1.0038
1.0050
1.0570
S 235 J2G3
S 235 JRG2
E 295
S 355 J2G3
1.0425
1.0481
1.5415
1.7335
P 265 GH
P 295 GH
16 Mo 3
13 CrMo 4-5
DIN EN 10113
The following references must be observed and followed for a proper execution as directed and
for an economic operation:
Caution!
Welding at temperatures below +5C should be avoided.
Welding below + 0C 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)
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.
Tack-welding over 8
points. These welding
points must be
extended to approximately 500 mm after
the completion of the
assembly. Then,
place the root into the
remaining open areas.
Fig. 1
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 favorable structural condition. For the individual layers, it must absolutely be made sure that
the correct temperature is observed. It must not exceed 250C (thermochromic pins).
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 preheating to 100-150C is necessary. Interruptions should be avoided.
The risk of crack formation can be reduced if the preheating temperature (100C) is
maintained also 1 hour after welding and the material is then slowly cooled down (reheating, covering by mineral wool mats).
4.2.3
Caution!
When mounting the spring plates, the correct sense of rotation must absolutely 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 complete 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.
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.
GB 413-0001-05 USA; Page 28 of 30
8.1
Calculation example
2
2
( 3675 3204, 3 ) = 1799, 5
2
2
( 3725 3204, 3 ) = 1899, 5
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.
Commissioning
Edition: 03.2008
GB 413-0001-06 USA
Page 1 of 2
Contents:
Page
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Commissioning conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Former edition:
GB 413-0001-06 en
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)
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.
Commissioning conditions
Note!
References given in the operating instructions BA 841- must
absolutely be observed!
Also see chapter Commissioning in section Operating instructions 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.
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
- BA 413-0233
(Spray lubrication)
(Splash lubrication)
Operation
Edition: 03.2008
GB 413-0001-07 USA
Page 1 of 1
Contents:
Former edition:
GB 413-0001-07 en
Page
Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operating conditions
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 maintained there.
This measure avoids the kiln sliding too rapidly into the direction of the outlet due to leakages 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 inclined).
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 program.
Note!
See commissioning instructions
BA 841-....
It is important that the shrinking tensions which built up between the tires and the supporting 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.
Maintenance
Edition: 03.2008
GB 413-0001-08 USA
Page 1 of 4
Former edition:
GB 413-0001-08 en
Contents:
Page
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
2.1
2.2
2.3
Information
Note!
For maintenance lists, see section "Maintenance" of the Technical Machinery Documentation and section "Operating instructions rotary kiln tube" (section IIIA)
Spare parts lists as per section "spare parts" of the Technical
Machinery Documentation.
The item numbers indicated below refer to drawing No.
ZD 413-0178 in the annex to this description.
If, for example, partial lining defects should occur, red spots develop which, if not eliminated in time, can lead to dent-like deformations and restrictions.
Red spots can be covered by the meal accretions when suitably operating the kiln, provided the spots are not too large.
Upon the next shutdown, such an area must be repaired.
2.1
2.2
2.3
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 instructions BA 413-0171.
As regards the material strength of the kiln shell, a maximal temperature of 350C is a reference value as, upon higher temperatures, the strength values for the normally used materials are no more clearly defined.
Up to a shell temperature of 400C, there is no direct risk, if the kiln is continuously turned.
Upon temperatures above 400C, there is a serious risk for the rotary kiln shell.
Causes for such high shell temperature can be:
If excessively high shell temperatures should occur, the causes must be eliminated immediately.
By a continuous temperature monitoring of the kiln shell, e.g., with the SCANEX diagnostical 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 temperature difference at the circumference.
By measuring and checking the kiln shell temperatures, changes and their influences are
recognized in time and defects avoided.
Note!
Detailed procedure as per BA 413-0171.
If spring plates are installed, also the fastening bolts must be completely replaced and, if necessary, also the supporting shoe with the threaded bores.
Edition: 03.2008
GB 413-0001-09 USA
Contents:
Former edition:
GB 413-0001-09 en
General information
General information
Note!
Page 1 of 1
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Former edition:
GB 413-0002 en
Operating instructions to
supporting roller bearing
Edition: 03.2008
GB 413-0002 USA
Page 1 of 2
Former edition:
GB 413-0002 en
Contents of the
operating instructions to
supporting roller bearing
Edition: 03.2008
GB 413-0002 USA
Page 2 of 2
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
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State: 03.2008
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State: 03.2008
General
Edition: 03.2008
GB 413-0002-01 USA
Page 1 of 1
Contents
Former edition:
GB 413-0002-01 en
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General information
Note!
See information in the chapter General, in section Operating
instructions rotary kiln tube of the Technical Machinery Documentation.
Edition: 03.2008
GB 413-0002-02 USA
Page 1 of 1
Former edition:
GB 413-0002-02 en
Contents
Page
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety information
The supporting roller bearing is located within a hazardous zone where the following risks
must be kept in mind:
Note!
Further safety information as per the "Operating instructions
rotary kiln" section, item "General safety information" of the
Technical Machinery Documentation.
Otherwise, all legal safety and accident prevention regulations must be observed.
Edition: 03.2008
GB 413-0002-03 USA
Page 1 of 4
Former edition:
GB 413-0002-03 en
Contents:
Page
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1
1.2
1.3
1.4
1.5
1.6
Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design
1.1
1.2
The supporting roller bearing is made of grey cast iron and executed as double slide bearing.
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.
Control openings have been provided for in the top sections of the bearing blocks which are covered 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
Oil type
Oil change
Oil type and oil change are punched into a sheet strip by the operator and slid into the nameplates 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 supported 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
1.5
Resistance thermometer
Threaded bores are provided for in the bearing top sections through which the resistance thermometers (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
Functioning
The bearing blocks with the installed supporting roller vertically support the rotary tube. The supporting 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 continuous reduction of the generated friction heat and of the dissipated heat taken by the bearing
body.
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 collar 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 pressure 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 lubricant must be applied to the contact surfaces.
Transport
Edition: 03.2008
GB 413-0002-04 USA
Page 1 of 1
Contents:
Former edition:
GB 413-0002-04 en
Page
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 substructure 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 instructions rotary kiln" section of the Technical Machinery Documentation.
Assembly
Edition: 03.2008
GB 413-0002-05 USA
Page 1 of 14
Contents:
Former edition:
GB 413-0002-05 en
Page
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
2.1
2.2
2.3
2.4
2.5
Information
Note!
See information in the Assembly chapter in the Operating instructions
rotary kiln tube section of the Technical Machinery Documentation.
Note!
2.1
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
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 4130020.
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.
2.3
2.4
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.
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.
2.5
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.
2.6
2.7
List of pictures
ZB 413-0020
ZB 413-0021
ZB 413-0022
ZB 413-0023
ZB 413-0024
2.7.1
2.7.2
2.7.3
Item
1
2
3
4
Units
1
1
1
1
Object
Round rod 16
Sheet 30 4
Handle O 8
Clamp Bl. 30 4
Length kg/m
2100
1,58
400
0,94
210
0,34
40
0,94
Total weight
kg
3,32
0,38
0,07
0,04
3,81
====
2.7.4
Item
1
2
3
4
5
6
Units
1
1
1
1
1
1
8 units
Object
Pressure rod
100
Sheet60 10
Hex. bolt M24 - DIN 933-m
Nut M 24 - DIN 555
Washer 25 - DIN 126
Pressure plate 80 10
Length kg/m
490
10,6
90
4,71
100
0,423
0,103
0,031
500
6,28
Total weight
kg
5,19
0,42
0,42
0,10
0,03
3,14
9,30
====
= 74,40
====
= 148,80
=====
2.7.5
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 particular 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.
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 provided 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/supporting roller must be mounted to the bearing block.
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
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)
j)
After scraping, lower roller (1), clean the partial areas of the bearing bottom section and uniformly 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 opening.
If the specified oil volume is temporarily unavailable, it is sufficient to only pour approximately 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
Commissioning
Edition: 03.2008
GB 413-0002-06 en
Page 1 of 2
Former edition:
GB 413-0002-06 en
Contents:
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Starting of commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Completion of commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information
Note!
See information in the Commissioning chapter of the Operating instructions rotary kiln tube section of the Technical
Machinery Documentation.
Preparatory measures
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)
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)
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 everything 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
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 resistance.
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:
Operation
Edition: 03.2008
GB 413-0002-07 USA
Page 1 of 1
Contents:
Former edition:
GB 413-0002-07 en
Page
Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operating conditions
Note!
Also see chapter "Operation" of the operating instructions
to the rotary kiln of the technical machinery documentation.
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 winter.
Maintenance
Edition: 03.2008
GB 413-0002-08 USA
Page 1 of 8
Former edition:
GB 413-0002-08 en
Contents:
Page
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
2.1
3
3.1
3.2
3.3
3.4
3.5
Information
Note!
For maintenance lists, see the Maintenance chapter of the
Technical Machinery Documentation section and the Operating instructions rotary kiln tube section.
Spare parts lists as per the spare parts section of the Technical Machinery Documentation.
a)
Standstill in winter
Upon a standstill in winter, the chambers of the water cooling system must be emptied. This can be done - depending on the bearing type - by draining or pressing out
the water with the aid of compressed air.
b)
Bearing temperature
The bearing temperatures are permanently monitored by the resistance thermometers (43).
During normal operation, a bearing shell temperature of about 40-60C will establish. If this
reading should change, an immediate local inspection is required checking the following
items:
Oil flow from the scoop ring and distribution on the surface of the axle.
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.
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).
Fig.10
d)
e)
Graphite lubrication
The graphite lubrication system (46) is subject to a normal consumption and is used depending 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 permanent contact.
Further references regarding lubricants may be taken from the order-related list of lubricants
and BA 822-0001 as well as HW 6302.
2.1
Failure
I. High bearing
temperatures
(acoustical
and optical
alarm)
possible causes
1) Too high axial
pressure
between collar
ring and bearing shell collar
(running hot)
2) Contaminated
slide bearing
shells
Immediate
remedies
- Check position of
central axes of supporting rollers and
rotary tube
- Apply oil or
grease to roller
surfaces
- If required, oblique
setting of rollers (see
BA 413-005, Item 5)
- Change bearing
shell, if necessary
- Oil change
- Apply oil or
grease onto the
roller surfaces
Remarks
- Spare bearing shells
available?
- Oil level
- Proper functioning of
oil scoop pockets
- Check housing for
cracks
- Check oil baffle plate
- Cooling water in oil?
- Open valves
- Install cooling
blower
- Spare part
available?
- Sufficient
bricks available?
Failure
II. Oil emerging
at shaft seal
possible causes
Immediate
remedies
Remarks
- Renew seal
- Spare seal
available?
- Use electrode
for grey cast
iron GG 25,
GG 30
- Permanently
observe bearing
temperature
- Newly measure
position of the bearing block
- Lifting blocks
available for
lifting the kiln
and displacing the bearing block?
- Refill oil
- Temporarily weld
crack
- Observe oil level
IV. Position of
supporting
roller bearing
changed
1) Foundation lowered
2) Fixing detached
3) Deformed rotary
kiln tube hitting
against roller
V. Noise in bearing
- Dismantle front
cover and tighten
loose parts
- Spare scoop
pockets available?
- Change oil
- Replace bearing
shell
3.1
Fig. 7
Fig. 8
1.
Support tire.
2.
3.
4.
5.
6.
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.
3.2
3.3
3.4
3.5
Edition: 03.2008
GB 413-0002-09 USA
Contents:
Former edition:
GB 413-0002-09 en
General information
General information
Note!
Page 1 of 1
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Edition: 03.2008
BA 413-151 USA
Page 1 of 8
Safety
Former edition:
BA 413-151 en
Copyright
The copyright to the present operating instructions (BA) remains with Humboldt 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 distributed 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
Contents
Page
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1
First erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2
Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3
2.4
2.5
2.6
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 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 collars (26 against fouling.
The bearings and sliding surfaces are lubricated with a separate oil supply
system (circulation oiling).
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 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.
2.1
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 according 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 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:
-
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
b)
Loosening the retaining device at the guide rods (4) and removing the collars (25,26) and then pressing out or drawing out the guide rods. If required,
a lug can be welded to the front end.
c)
d)
The housing (2) is withdrawn from the thrust roller together with the outer
rings of the anti-friction bearings (6,7).
e)
2.4
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.
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:
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
2.6
a)
b)
Removing the retaining ring (23) and loosening the securing bolts beside.
c)
When commissioning the kiln system, the information given in operating instruction 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
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 experience 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.
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.
Hydraulic system
Edition: 03.2008
BA 413-0255 USA
Page 1 of 13
Safety
Former edition:
BA 413-0255 en
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 reproduced, 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.
Contents:
Page
1
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
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 pressure 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
item 3
item 4
flexible coupling
item 5
item 6
non-return valve
item 7
item 8.1
item 8.2
item 8.3
item 9
shut-off valve
item 10
item 11
pressure switch
item 12
item 13
item 14
item 15
item 16
item 17
item 18
hydraulic reservoir
item 19
item 20
item21
non-return valve
item 22
filter
item 23
high-pressure hose
item 31
shut-off valve
item 32
item 33
item 34
2.1
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.
2.2
4.
2.3
GW1
GW2
GW3
GW4
+25 mm
+30 mm
-25 mm
-30 mm
Due to the heat dissipation of the kiln, it is necessary to cool the sensor with water. At the instrument 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 control 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 activated, 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.
2.4
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).
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.
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 (solenoid 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 2/2way 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
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
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 maintained 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 regularly (see also corresponding instructions).
The hydraulic system must continuously be supplied with current (i.e., also during a shutdown 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
Checking the position of the supporting roller bearings relative to the tube centerline - see
also BA 413-005 and BA 413-049
2.7
Scheme 1
2.8
Scheme 2
Control
2.9
Scheme 3
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Operating Manual
State: 03.2008
Operating Manual-No.:
Table of contents
1.
General Description
2.
3.
Annex:
SAFETY
ensured by correct assembly, proper operation,
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.
Previous edition:
BA 413-0271
1.
GENERAL DESCRIPTION
1.1
1.1.1
1.1.2
1.1.3
Functioning
1.1.4
Dimensions
1.1.5
Quality assurance
1.1.6
Operation
1.2
1.2.1
1.2.1.1
Ring gear
1.2.1.2
1.2.1.3
1.2.1.4
1.2.1.5
1.2.2
Main drive
1.2.2.1
Main gear
1.2.2.2
Couplings
1.2.2.3
1.2.2.4
Main motor
1.2.3
Auxiliary drive
1.2.3.1
1.2.3.2
Couplings
1.2.3.3
2.
2.1
Ring gear
2.2
Pinion-bearing-base frame-coupling
2.3
2.3.1
Base frame
2.3.2
2.3.3
Measuring the
- pitch circle distance
- backlash
- bottom clearance
2.3.4
2.3.5
2.4
2.5
2.6
3.
3.1
3.2
Annex:
Test records
( sheets 1 ... 14 )
1.
GENERAL DESCRIPTION
1.1
1.1.1
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.
(t/d)
(t)
=>
=>
fig. 1
fig. 2.
and
100%
max
80%
motor rating
at constant torque
fP
60%
Pe
(P
lift
+P
fric
working point
40%
kiln capacity at
constant throughput
fn
20%
kiln filling at
at constant throughput
250
400
600
800
n
1000
1250
1200
66,7%
80%
fig. 1
16,7%
26,7%
P
100%
Mot
40%
at n
53,3%
operation
max
-1
n Mot
83,3%
93,3% 100%
max
80%
motor rating
at constant torque
fP
60%
Pe
(P
lift
+P
fric
working point
40%
fn
20%
kiln capacity at
at constant filling
( throughput speed )
250
fig. 2
bei n max.
400
600
800
n
1000
16,7%
26,7%
40%
53,3%
operation
1250
1200
max
80%
93,3% 100%
(kW)
P e bei n Betr.
fn
fP
n Mot
83,3%
66,7%
-1
(kW)
P Mot
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, oneside 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
couplings (8,9,10)
double-shoe brake (11)
base frame (12)
lubrication and cooling unit - if required (13)
main motor, variable-speed type (14)
1
5
2
5
X
1
E
F
8
24
7
3
D
3
9
11
10
4
16
view X
14
15
G
17
23
19
20
21
13
12
fig. 3
22
18
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.
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.
1.1.5
Quality assurance
1.1.6
Operation
1.2
1.2.1
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.
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.
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.
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.
1.2.3
Auxiliary drive
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.
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.
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.
2.
2.1
Ring gear
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.,, Klbertop 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.
2.2
Transmission
2.3
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.
2.3.2
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.
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)
0,5
1,0
2,0
3,0
2.3.3
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 bricklined.
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)
2.3.4
Tooth bearing
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.
2.4
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.
2.5
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.
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
locking device
pillow block of
gear and pinion
resp.
locking device
base frame
fig. 6
2.6
base frame
spacer
plates
pillow block of
gear and pinion
resp.
operational lubricant
Ceplattyn RN
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 machiningrelated 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.
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.
2.7
-
Designation
Requirement
Tolerance values
Method
1. capable to be sprayed
2. wear properties
DIN 51 354
ASTM D 2509
DIN 51 802
DIN 51 811
assessment category 1 - 40
max 1
bis +200 C
> 150 C
6. penetration
6.1 Penetration
7. consistency
NLGI Klasse 0 - 00
DIN 51 818
3. corrosion protection
properties
Designation
8. base oil
Requirement
Tolerance values
Method
9. thickener
to be specified by suppliers
min. content 8 %
Reinheitsgrad > 99,,5 %
Partikelgre
min. 50 % < 10 m
DIN 51 562
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
1 - 100
no corrosion. Weak tarnish
The test has been carried out at 100C.
1 - 90
minor changes
The test has been carried out at 90C.
3.
3.1
Tooth meshing:
-
Drive units:
-
Does the ring gear move unhindered inside the wheel guard?
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.
3.2
Enclosure to
Test records
BA 413-0271 USA
sheet 1
ENCLOSURES
Explanations
sheet 3
record A
sheet 4
sheet 5
record B
sheet 6
sheet 7
sheet 8
record C
sheet 9
sheet 10
Sheet 11
Sheet 12
Sheet 13
Sheet 14
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.
Enclosure to
Test record A:
BA 413-0271 USA
sheet 3
reference level
1;3
2;4
SE
inlet side
1
y
x
SA
outlet side
date
Refection
foreman:
Site
manager:
SA
Customer:
SE
Mr.
.
.20
Enclosure to
Test record A:
BA 413-0271 USA
sheet 4
reference level
1;5
2;6
SE1
inlet side
1
Errection
foreman:
7
SA2
SA1
outlet side
SE1 SA1
Site
manager:
SE2 SA2
Customer:
SE2
Datum
4;8
3;7
Mr.
.
.20
Enclosure to
Commissioning record B:
BA 413-0271 USA
single gear drives of rotary tubes
sheet 5
Com.-no.:
Plant:
left side
right side
W max / W min
mm
mm
- backlash
F max / F min
mm
mm
- bottom clearance
K max / K min
mm
mm
max.:
% / min.:
driven
rolling circle
girth gear
rolling circle
pinion
driving
Date
Signature of
HUMBOLDT
WEDAGrepresentative:
Enclosure to
Commissioning record B:
BA 413-0271 USA
double gear drives of rotary tubes
sheet 6
Com.-no.:
Plant:
pinion I
1. Values measured for 1 rev.:
inlet side
pinion II
outlet side
inlet side
outlet side
mm
mm
mm
mm
mm
mm
mm
mm
- bottom clearance
mm
mm
mm
mm
K max / K min
max.:
%min.:
max.:
%min.:
pinion II
X
pinion I
driven
rolling circle
girth gear
rolling circle
pinion
driving
Date
Signature of
HUMBOLDT
WEDAGrepresentative:
Enclosure to
Commissioning record B:
BA 413-0271 USA
twin gear drives of rotary tubes
sheet 7
Com.-no.:
Plant:
pinion I
1. Values measured for 1 rev.:
inlet side
pinion II
outlet side
inlet side
outlet side
mm
mm
mm
mm
mm
mm
mm
mm
- bottom clearance
mm
mm
mm
mm
K max / K min
max.:
%min.:
max.:
%min.:
pinion II
X
pinion I
driven
rolling circle
girth gear
rolling circle
pinion
driving
Date
Signature of
HUMBOLDT
WEDAGrepresentative:
Enclosure to
Test record C:
BA 413-0271 USA
sheet 8
A
E
E
A
driving
driven
C
eccentricity
Erection
foreman:
Site
manager:
Customer:
Mr.
.
.20
Enclosure to
Test record C:
BA 413-0271 USA
sheet 9
coupling I
coupling II
A
E
E
A
driving
driven
C
coupling I
coupling clearance
(see assembly drawing.
"drive" for nominal value )
Erection
foreman:
coupling II
vertical and
lateral
eccentricity
coupling clearance
(see assembly drawing.
"drive" for nominal value )
Site
manager:
Customer:
Mr.
.
.20
vertical and
lateral
eccentricity
Enclosure to
Test record C:
Coupling clearance for twin-drive system
BA 413-0271 USA
sheet 10
coupling II
coupling I
A
E
E
A
driving
driven
C
coupling I
coupling clearance
(see assembly drawing.
"drive" for nominal value)
Erection
foreman:
coupling II
vertical and
lateral
eccentricity
coupling clearance
(see assembly drawing.
"drive" for nominal value)
Site
manager:
Customer:
Mr.
.
.20
vertical and
lateral
eccentricity
TEST RECORD D
ROTARY TUBE DRIVE
Enclosure to
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
Remarks:
time
enclosure to
Test record E:
BA 413-0271 USA
sheet 12
Sense of rotation viewed from inlet / outlet
(cross out untrue expression)
10
5
2
II
outlet
SE
SA
girth gear
WA
WE
test point
KA
KE
FE
FA
W ,W ,K ,K ,S ,S
E
pinion
Remarks:
radial
test point
II
WE
WA
axial
KE
KA
SE
1
2
3
4
5
6
7
8
9
10
Erection
foreman:
Site
manager:
Customer:
Mr.
.
. 20
SA
enclosure to
Test record E:
BA 413-0271 USA
sheet 13
Sense of rotation viewed from inlet / outlet
(cross out untrue expression
II
10
5
2
inlet
SE
outlet
SA
Girth gear
WA
WE
test point 2
KA
KE
FE
FA
W ,W ,K ,K ,S ,S
E
Test point 1
pinion
W ,W ,K ,K ,S ,S
E
Remarks:
radial
test point
II
axial
radial
axial
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
3
4
5
6
7
8
9
10
Erection
foreman:
Site
manager:
Customer:
Mr.
.
. 20
enclosure to
Test record B:
BA 413-0271 USA
sheet 14
Sense of rotation viewed from inlet / outlet
(cross out untrue expression)
II
K = clearance
S = side clearance
F = flank clearance
10
5
1
E = inlet side
A = outlet side
inlet
outlet
4
2
SE
SA
girth gear
WA
WE
W ,W ,K ,K ,S ,S
W ,W ,K ,K ,S ,S
A
FE
FA
Test point 1
Test pint 2
E
KA
KE
pinion
Remarks:
radial
test point
II
axial
radial
axial
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
3
4
5
6
7
8
9
10
Erection
foreman:
Site
manager:
Customer:
Mr.
.
. 20
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Former edition:
GB 413-0020 en
Operating instructions
for the inlet
Edition: 03.2008
GB 413-0020 USA
Page 1 of 2
Former edition:
GB 413-0020 en
Edition: 03.2008
GB 413-0020 USA
Page 2 of 2
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
State: 03.2008
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0189
General
Edition: 03.2008
GB 413-0020-01 USA
Page 1 of 1
Contents
Former edition:
GB 413-0020-01 en
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General information
Note!
See information in the General section Operating instructions
rotary kiln tube of the Technical Machinery Documentation.
Edition: 03.2008
GB 413-0020-02 USA
Page 1 of 1
Former edition:
GB 413-0020-02 en
Contents
Page
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety information
The outlet area is a dangerous zone which is secured free against by a chain.
Two risks must be particularly pointed out, i.e.:
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.
Edition: 03.2008
GB 413-0020-03 USA
Page 1 of 3
Former edition:
GB 413-0020-03 en
Contents:
Page
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1
1.2
1.3
Inlet ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scoop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design
Note!
The following item numbers refer to drawing No. ZD 413-0189 in
the annex to this description.
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 fastening bolts cause a uniform circulation of air and cooling of the inlet area.
For reasons of durability, the inlet area is always lined with bricks (see picture 413-045). If exceptionally 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 pockets (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.
The spring-loaded segment seal is bolted to the front side of the scoop ring; whose wear segments (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.
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 longitudinal movement as well as a possible eccentricity of the rotary kiln
Works at low wear, permits the rapid recognition of irregularities and is highly servicefriendly.
It is extremely important that the friction surfaces (item B) are ALWAYS in contact during operation.
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
Transport
Edition: 03.2008
GB 413-0020-04 USA
Page 1 of 1
Contents:
Former edition:
GB 413-0020-04 en
Page
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 instructions rotary kiln" of the Technical Machinery Documentation.
Assembly
Edition: 03.2008
GB 413-0020-05 USA
Page 1 of 4
Former edition:
GB 413-0020-05 en
Contents:Page
1
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scoop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1
Assembly plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Information
Note!
The item numbers indicated below refer to drawing No. ZD 413-0189 in
the annex to this description.
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 surfaces, 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.
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.
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 setting 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.
Note!
Absolutely observe the assembly instructions as per Operating instructions for the inlet chamber of the preheater!
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 segment 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.
Tension spring and chain are always suspended after the installation of the second segment 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.
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 approximately 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).
Commissioning
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GB 413-0060-02 en
Page
Preparatory measures
After the installation work has been completed but before commissioning, the inlet must be
subjected to a careful inspection and functional check.
The following must be particularly observed:
a)
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)
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 circumference?
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.
Operation
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GB 413-0020-07 USA
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Former edition:
GB 413-0020-07 en
Page
Operating conditions
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 segment ring is in contact with the mating flange of the inlet housing (to avoid the ingress of
wrong air).
Caution!
This force is still changed only to a minor degree due to the intended upward and downward 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).
Maintenance
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Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
2.1
Information
Note!
For maintenance lists, see section Maintenance of the Technical Machinery Documentation.
Spare parts lists as per section spare parts of the Technical
Machinery Documentation.
The item numbers indicated below refer to drawing No.
ZD 413-0189 in the annex to this description.
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 eliminated 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 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 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).
2.1
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.
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 accretions 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 possible.
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 surface 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 sufficient 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.
The locking chain must be properly mounted after the repair work
is completed.
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GB 413-0020-09 USA
Contents:
Former edition:
GB 413-0020-09 en
General information
General information
Note!
Page 1 of 1
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BA 413-0273 en
Contents
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BA 413-0273 USA
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Page
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.1
Pneumatic seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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.
Prior to the assembly, the pipelines must be thoroughly cleaned to avoid damage to the cylinder
or failures of the valves.
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.
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Former edition:
GB 413-0030 en
Operating instructions
of the outlet
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GB 413-0030 USA
Page 1 of 2
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Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . ZD 413-0192
General
of the outlet
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GB 413-0030-01 USA
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GB 413-0030-01 en
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General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General information
Note!
See information in the General section Operating instructions
rotary kiln tube of the Technical Machinery Documentation.
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GB 413-0030-02 USA
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Page
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety information
The outlet area is a dangerous zone which is secured free against by a chain.
Two risks must be particularly pointed out, i.e.:
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.
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GB 413-0030-03 USA
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Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Outlet seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kiln hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reference
Note!
The following item numbers refer to drawing ZD 413-0192
enclosed to this description.
The outlet end section is a double-walled, air-cooled sheet structure which is welded onsite to the end of the kiln tube.
The outer cooling shell (5) is connected to the tube section (6) by spacers and cross holders (7) uniformly distributed over the circumference.
This flexible construction permits a free expansion of the individual elements so that a distortion 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.
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.
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:
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.
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.
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 connected 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 lateral 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.
Transport
of the outlet
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Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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!
Assembly
of the outlet
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GB 413-0030-05 USA
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Outlet segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4.1
Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Kiln hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Information
Note!
The item numbers indicated below refer to drawing No. ZD 413-0192 in
the annex to this description.
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).
4.1
Assembly sequence
1.
2.
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.
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 bearing 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 outlet at regular distances. The holders with yokes (12) are bolted to these fastening brackets. 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 contact 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.
4.
When mounting the X-part wear ring comprising wear segments (10) and one end segment (11), make sure that the distance between the individual segments is uniformly distributed. Every gap should be 16 mm. If it is smaller than 8 mm, the segments must be reworked.
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 showing downwards. In this way, with a slowly rotating tube, segment by segment is suspended 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 completion 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)
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).
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 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).
Commissioning
of the outlet
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Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparatory measures
After the termination of the installation works and prior to commissioning, the outlet must
be subjected to a careful inspection and functional check.
The following must be particularly observed:
a)
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 tigthened?
g)
Is the wear segment ring in full contact with the mating flange over the entire circumference?
h)
i)
Are the cooling air blowers properly functioning and correctly interlocked?
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.
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 instructions).
Upon first starting up or upon every re-lubrication, the bearing temperature will increase. 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. Possible installation imprecisions must be corrected.
Operation
of the outlet
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GB 413-0030-07 USA
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Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operating conditions
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 segment 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 downward movement of the kiln by 50 mm.
A trouble-free functioning of the sealing can be expected during normal operating conditions.
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
of the outlet
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GB 413-0030-08 USA
Page 1 of 4
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GB 413-0030-08 en
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Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
2.1
2.2
2.3
2.4
Information
Note!
For maintenance lists, see section Maintenance of the Technical Machinery Documentation.
Spare parts lists as per section spare parts of the Technical
Machinery Documentation.
The item numbers indicated below refer to drawing No.
ZD 413-0192 in the annex to this description.
The outlet area as part of the kiln system should be inspected daily (see section Maintenance 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).
2.1
Temperature
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 hazardous 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.
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 surface 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 penetrating the seal in the kiln hood area.
GB 413-0030-08 USA; Page 2 of 4
2.3
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.
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.
Edition: 03.2008
GB 413-0030-09 USA
Contents:
Former edition:
GB 413-0030-09 en
General information
General information
Note!
Page 1 of 1
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Accessories
For relevant documents see under
"List of separate documentation"
Sub-assembly description
GB 413-0038 USA
State:
413.480 / 01.2007
Optional equipment
For relevant documents see under
"List of separate documentation"
Sub-assembly description
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
Edition: 03.2008
BA 413-0171 USA
Page 1 of 27
Former edition:
BA 413-0171 en
Safety
by correct assembly, proper operation,
careful maintenance and care
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
Humboldt Wedag, Inc.
400 Technology Parkway
Norcross, Georgia 30092
USA
Phone: 770-810-7300
Fax:
770-810-7333
Contents:
Page
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
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
Maintenance, measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1
2.2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3
2.4
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
The stiffness of the tires, i.e., a small deformation under stress is of high importance for the durability 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
Assembly load in N calculated from the tube statics assuming the common
load values for a geometrically straight rotary tube (incl. tire weight)
Rs =
Radius change
Difference between large and small diameter of the deformed tire bore
BA 413-0171 USA; Page 3 of 27
1.1.2
Quality assurance
The quality assurance is realized via extensive material tests such as
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 lining.
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 lowering 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:
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 compared with tire and, in its lower section, adapts itself to the bore of the stiffer tire (see Fig. 7, picture C).
Differences regarding the deformation can only occur in the relatively small area of the upper flattening (see Fig. 1.1, 1.2).
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, compressive 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.
1.2.1
Fig. 2
Messr.
HOLDERBANK
Management and Consulting Ltd.
CH - 5113 Holderbank AG
Switzerland
Messr.
REFRATECHNIK GmbH
Rudolf-Winkel-Strae 1
D - 37079 Gttingen
Germany
Fig. 3
1.2.2
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 frequently 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 fastened with magnets on the tire. The recorded curve indicates the degree of ovality.
Fig. 4
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 transmission) 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).
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:
i-totally (i1 x i2 ist):
14020
700 : 1
20
14020
--------------- = 20, 028
700
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:
Item 1
Item 2
Item 3
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
1.3.1
1.3.2
Diameter difference d
Relative movement U
When indicating measured values, always indicate to which kiln condition the data refer: cold kiln
or kiln at operating temperature (see Fig. 6).
Fig. 6
BA 413-0171 USA; Page 11 of 27
1.3.3
1.3.4
If, nevertheless, material break-outs are noticed at the slide plates, the cause is a sudden overheating of the shell plate in a restricted area with the tire still remaining relatively cold. The pressure 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
1.3.5
The lateral fixings which are mounted exactly rectangularly to the kiln axis
The cylindrical contact surface of the tire and of the supporting rollers
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.
Maintenance, measures
2.1
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 overheating 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.
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
WEICON Anti-Seize
Berulub FCC
PBC
Wolfracoat C Fluid
Wolfracoat C Paste
Ceplattyn HT
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.
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.
2.3
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 t :
At t = 160 C, the diameter difference between tire and tube would be zero. If the temperature difference increases by further 50C, 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 temperature 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 underneath the kiln, an undesired temperature increase at the bearings, etc., would result.
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 behavior 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
Relative movement
U
Gap widthS
Assy. I
Assy. II
Assy. III
Meprotokoll
2.5
2.5.1
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 new slide plate thickness considering the desired gap and the current slide
plate thickness.
with
D1
d1
d2
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, lining 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
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
2.5.2
2.6
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 withdrawn.
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
Depending on the extent and serious nature of the defects, the following final rehabilitation measures come into question:
2.7
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
for rotary kilns,
drying and cooling drums
Edition: 03.2008
BA 413-005-1 USA
Page 1 of 29
Former edition:
BA 413-005 en
Safety
ensured by correct assembly, proper operation,
thorough maintenance and care.
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 indemnification.
Humboldt Wedag, Inc
400 Technology Parkway
Norcross, Georgia 30092
USA
Phone
Telefax
770-810-7300
770-810-7333
Contents:
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1
1.2
1.3
Adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3
3.1
3.2
4.1
4.2
Measures to be taken in case of excess temperature at one of the supporting roller bearings 19
5.1
5.2
5.3
Measures to be taken in case of excess temperature of one thrust roller bearing . . . . . . . . . .20
6.1
8
8.1
8.2
8.3
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
General
1.1
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 150C - also within short periods of time - are common.
Example:
The measures indicated in the installation plans are based on empirical values of several hundreds of kiln plants. For the shell in the sintering zone, for example, a temperature of about
320C is used as a basis so that the deviation from the previously mentioned extreme values (50
mm at 250C or 400C) 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.
BA 413-005-1 USA; Page 3 of 29
1.2
Assembly I:
Assembly II.
Fixed assembly
1.
2.
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.
1.3
In case of stationary thrust rollers by oblique setting of the latter, i.e., by slanting the rollers 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.
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.
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, respectively. 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.
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.
The above sketch shows a rotary tube with two supporting rollers.
3.1
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 orientation. In this case, it is recommended to have assembly I or III displaced by fractions of a millimeter in the direction of the arrow.
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.
3.2
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.
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.
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.
The above sketch represents a rotary tube with two supporting rollers.
4.1
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.
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.
4.2
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.
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.
5.1
5.2
5.3
6.1
Possible causes
a)
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)
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.
8.1
8.2
8.3
The initial position of the bracket must be marked on the base plate and at the bracket
using paint and a marking tool.
b)
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)
f)
The jack shall be firmly pressed against the bearing with the aid of a manually-operated
pump (item 5, sheet 27).
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 bearing 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.
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.
Expansion and
shrinkage process
on rotary kiln tubes
Former edition:
BA 413-049/1 en
Contents
BA 413-049-1 USA
Page 1 of 15
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stress exerted on tire and supporting roller due to axial movements caused by heat . . . . . 8
6.1
6.2
6.3
6.4
Load distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heating up of the rotary kiln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cooling down of the rotary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standstill of the kiln plant over an extended period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1
Modifications in this edition:
Edition: 03.2008
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 consideration.
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).
=.1.
where relates to expansion, 1 to the length to which refers, to the heat expansion
coefficient and 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
= 290 C (empirical value) and the expansion coefficient of steel with = 0.0125 mm/m C, the
result for the calculation is as follows:
= (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
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.
Assembly I:
QI
560 t
II:
QII
650 t
III:
QIII
1 320 t
IV:
QIV
425 t
2 955 t
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:
c)
In case of contracted surfaces (Fig. 10), force P, acting in positive direction, equals:
P=Qx
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.
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
Tire and supporting roller are dimensioned for a permissible hertzian pressure of approx.
42 kN/cm, 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.
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.
6.1
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
6.3
Fig. 17 shows an example calculated for a kiln which has not been rotated frequently enough, for
which the rotary kilns angle of inclination has been left out of consideration.
a)
b)
= 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.
6.4
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.
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.
Former edition:
BA 413-064/2 en
Contents
Edition: 03.2008
BA 413-064-2 USA
Page 1 of 12
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Development and experience made with the use of brick retaining rings. . . . . . . . . . . . . . . . . . . 3
4.1
4.2
4.3
4.4
4.5
4.6
Selection of the suitable brick quality and correct laying of the bricks . . . . . . . . . . . . . . . . . . . . . 7
Slow starting and heating up of the kiln plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Avoiding excessive sintering zone cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Roofing of the outlet zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting as small a gap as possible between tire section and tire bore . . . . . . . . . . . . . . . . . . . . . 8
Rendering the kiln operation uniform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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 1,000C (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. Depending 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, without 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.
Development and experience made with the use of brick retaining 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 internal heads of the bricks resting on the retaining ring.
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.
After the removal of the bricklining, the dragging traces (blank scours) could be seen on the
kiln shell.
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).
4.1
4.2
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
4.4
4.5
4.6
Caution!
Frequent disconnecting (cooling down) is disadvantageous for
the plant.
Caution!
Within the brick rings, the brickwork must not be toothed, i.e., laid
in a cascade-like manner.
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 remaining old lining are no more fully functioning due to the displacement of bricks and because of clogging. The expansion of this existing zone and, hence, the resulting brick thrust must be also be
accepted by the new joints.
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 expenditure, 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.
Edition: 03.2008
BA 413-0226 USA
Page 1 of 2
Former edition:
BA 413-0226 en
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.
During operational condition deviations from a straight kiln axis (e.g., due to tube deformations 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 mutually 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 rotating 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 bearing 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.
For long kilns (wet/dry kilns) with correspondingly wide distances between the bearings, maximum deviations of 6 ... 7 mm are accepted.
In case the deviations determined at the bearing assemblies exceed the above limits, the positions of the supporting roller bearings transverse to the kiln axis will have to be shifted in compliance 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 following:
Foundation settling/-shifting
Heavy deformation of the kiln shell and/or radial deflections at the inlet and the outlet
Bricklining problems
In case no acceptable explanations can be found for the above phenomena, we recommend that
a PYROCHECK be performed.