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CHAPTER -13

Operation & Maintenance Instruction for Rotary Equipment
1.0 Introduction This manual addresses those specific areas relative to the proper operation and maintenance of Tekno-Kom Rotary equipment.

NOTE

All Commercial Purchased Vendor Equipment Instruction Sheet and Manuals for specific components such as speed reducers shall be referred to used in conjunction with this document.

2.0

General Maintenance Schedule. The following is a suggested General Maintenance Schedule for Tekno-Kom rotary equipment. Depending upon the specific equipment characteristics and service, the general maintenance schedule may require customer modification.
NOTE

A regular General Maintenance Schedule is both critical to personnel safety and the expected life cycle of the equipment.

2.1 Daily Maintenance Tasks 1. Conduct a walk-by inspection of the unit.  Are there any noticeable differences since the last inspection?  Is there any discoloration or hot spots evident on the shell?  Listen for any unusual sounds. 2. Check condition of discharge and feed end seals.   Is there any leakage of excess air or product? What is the condition of the seal?

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Operation & Maintenance Instructions for Rotary Equipment
3. Check condition of each pier top.    Do tires and rollers have full-face contact? Is there any movement between the pier top and support frame? Are there any loose anchor bolts on the support frame?

4. Check the condition of the tire on each pier.      Is there any spalling or ridging on the tire face? Has the tire developed a wobble? Since the last inspection, has the tire position changed relative to the stop blocks or wedges? Are there any broken welds on the wedges, retaining bands, or between the tires and filler bars? Is the tire centered over the carrying roller?

5. Check the condition of the carrying rollers on each pier.  Are the rollers thrusting uphill or downhill?  Is there spalling or ridging on the roller face?  Is oil leaking from the roller housing?  Does the surface of the bearing housing feel unusually warm?  Do the bearing have adequate lubrication? 6. Check the condition of the thrust rollers.  Is the unit against the uphill or downhill thrust roller?  Is there spalling or ridging on the roller surface? 7. Check the condition of the drive system.       Has the pattern of gear/sprocket contact changes? Are there any loose or missing flange bolts or gear mounting lugs? Is the automatic gear/sprocket lubrication system functioning properly? Is there adequate gear lubrication? Are their any unusual sounds coming from the drive system? Is there any new noticeable vibration?

2.2 Weekly Maintenance Tasks 1. Check creep or gap of tires on all piers.  Has level of creep increased since the last inspection?
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2. b) Chain Drives 1. 2. Check drive train coupling for wear and replace if needed. Check chain lubricant and clean area if needed.5 Annual Maintenance Tasks a) General 1.4 Semi-Annual Maintenance Tasks a) General 1. 2. Refer to manufactures instructions. Check condition of welds on gear flange or mounting lugs. Clean the pier tops of dirt. 3 . 2.  Are the rollers thrusting uphill or downhill? 3. 3. 4. Weld repair cracks in shell. 2. 2. Clean and inspect all bearings. Inspect shell for cracks under rings. Refer to Tekno-Kom. Check the alignment of the unit.Operating & Maintenance Instruction for Rotary Equipment 2. Check for pitch line separation of gear and pinion. Check drive motor. 5. 3. Check the alignment of the unit. Check for excessive ring and roller wear. Check for pitch line run-out of gear and pinion. 3. Change gear lubricant and clean gear area if needed. Refer to manufactures instruction. 2. c) Gear Drives 1.3 Monthly Maintenance Tasks 1. 3. Check the condition of the rollers at each pier. oil or product spillage. Check radial alignment of drive chain and driver sprocket adjust as required. Flush gearbox (speed reducer) Oil and replace. 4. Inspect drive-coupling members. Refer to Tekno-Kom. Refer to manufactures instructions. wedges ( Tire support blocks) and support bands. “Installation Instruction For Rotary Equipment”. “Installation Instruction For Rotary Equipment”. Check radial alignment of gear and pinion. 6. 2. Refer to manufactures instructions. Change grease on pinion shaft and support roller bearings. Refer to bearing manufactures instructions.

Check chain lubricant and clean area if needed. Clean and inspect gear. Refer to Tekno-Kom installation manual for chain replacement. Check gear teeth for abnormal wear. 7. Change grease on pinion shaft and support roller bearings. c) Gear Drives 1. 2. 4. Inspect. Check and repair welds on gear flange or mounting lugs and gear if needed. repack and change lubrication on pinion bearings. Check radial alignment and wear of drive chain and driver sprocket. 3. Check for loose nuts or bolts on gear mounting flange. clean. Check for loose nuts or bolts on the chain mounting sprocket and pedestals. 4 . Change gear lubricant and clean sump and gear area if needed.Operating & Maintenance Instruction for Rotary Equipment b) Chain Drives 1. 3. Check radial alignment of gear and pinion. Refer to bearing manufactures instructions. 2. 8. 6. Adjust alignment or replace as required. 5.

NOTE 3. therefore.1 Lubrication Chart Lubrication Chart Recommended Lubricant Service Frequency Mobilgear SHC-150 New Reducers-after intial 250 Temp .0 Daily operation (General) Table 1. Temp.0 Lubrication The following lubrication instructions although based on operational experience may very depending upon special site conditions.2. every 6months top-up.0 Table 1. EXXON RONEX MP or Based on 12 hours as per Day Equivalent every 3 months. SAE 20 OR 30 as applicable Component Speed Reducers Thrust & Trunnion Bearings Trunnion & Tire ( Riding Ring) Conact Surface 5 .30° F to +250° F. SAE 20 OR 30 as applicable Refer to paragraph 3.20°F (-29°C) to + 325°F (+163°C) General – Brush Every 40 hours for 8 hours Application: Refer to 3. Or Equivalent Operation hours.6 Specific – Auto Lubricators: Refer to 3.Operating & Maintenance Instruction for Rotary Equipment 3.

anti-oxidizing and extreme pressure additives are often helpful. and to smooth the chain’s engagement with the sprocket. to flush out wear debris and foreign materials. °F -20 to + 80 +10 to +110 +20 to + 130 +30 to +140 +40 to + 150 Temperature.2 Chain Lubricants A chain lubricant should have low enough viscosity to penetrate into critical internal surfaces and high enough viscosity. to carry away heat. Recommended viscosity for various surrounding temperature ranges are shown in Table 1. Users should use grease only when fittings for injecting the grease into the chain joints are provided. or necessary additives. users generally should not apply greases to chains in service because they are too thick to penetrate into the internal bearing surfaces of the chain. lubrication may be needed to inhibit rust and corrosion. and be clean and free of corrodents. While detergents are not normally needed. to maintain an effective film at the prevailing temperature and pressure. A good grade of non-detergent petroleum base oil usually is acceptable. the heavier grade should be used. The lubricant should have the capability to maintain the desired lubricating qualities under prevailing operating conditions. antifoaming. 3. Impure oils should be avoided. °C -29 to + 27 -12 to +43 -7 to + 54 -1 to + 60 +4 to + 66 Note : When the temperature range permits a choice. 6 . Acids or abrasives in the oil can permanently damage the chain. However. and to cushion impact forces. 3.2. Additionally.1 Needed for Lubrication Chain lubrication is needed mainly to slow the wear between the pins and bushings in the chain joint. Recommended Oil Viscosities for Various Temperatures Recommended Grade SAE 10 SAE 20 SAE 30 SAE 40 SAE 50 Temperature.2.Operating & Maintenance Instruction for Rotary Equipment Table 1. The chain manufacturer often uses grease or petroleum jelly as an initial lubricant.

3. 3. the oil. This enables gravity and centrifugal foce to carry the lubricant into the critical bearing areas. That discoloration indicated that red iron oxide (rust. 3. 3. Having long sections of chain run through the oil bath can cause oil forming and overheating. a short section of the chain runs through the oil in the bottom of the chain casing. The methods normally listed are manual. Again.2. the user applies oil periodically with a brush or spout can.3 Lubrication of Chain Drives The recommended method of lubrication for chain drives is indicated in the power rating tables published in ASME B29 Series Standards and in various manufactures catalogs. oil is dripped between the link plate or sidebar edges at a rate from four to 20 drops per minute.2. hematite. contact for details 7 . The oil level should extend only to the pitch-line of the chain at its lowest operating point. but a longer interval may be used if experience shows it is adequate for that particular drive. the amount of oil and the frequency of its application must be adequate to prevent the formation of a reddish brown discoloration in the chain joints. The amount of oil and the frequency of its application must be adequate to prevent the formation of a reddish brown discoloration in the chain joints.3 Gear Drive Lubrication As recommended by your lubrication supplier.) is being generated in the chain joints because they are not receiving sufficient lubrication. depending on speed. The preferred frequency is once every eight hours. In drip lubrication of multiple strand chains.should be applied to the upper edges of the link plate or sidebar in the lower span of the chain.2.Operating & Maintenance Instruction for Rotary Equipment 3.4 Manual Lubrication In manual lubrication. etc.5 Drip Lubrication In drip lubrication.2. In all methods. a wick-packed distribution pipe may be used to uniformly distribute oil to all rows of link plates or sidebars. and oil bath. drip.6 Oil Bath Lubrication In oil bath lubrication.

the chain is loaded repeatedly in tension. Second.1 Chain Failure The three most common ways that a chain may fail are tensile.1 Troubleshooting General Type of Failure Thrust Wear Roll- Probable Cause Corrective Action tracking Align Shell – See Installation Manual. In a fatigue failure. In this second stage. there is a short period of rapid initial. Align Shell – See Installation Manual. or run-in wear. In a wear failure. high spots are worn off the pins and bushings and minor misalignments are quickly worn away. material is removed by sliding. fatigue and wear. or lubricated wear. In this first stage. or sliding combined with abrasion or corrosion. there is a period of constant slow. Replace bearing. at a load below the yield strength (the chain is not stretched). or it is literally pulled apart.0 4. In a tensile failure.2 Chain Drives 4.2. First. These cracks continue to grow until the chain breaks. until microscopic cracks develop in the link plates or sidebars.2. 4. tracking Align Shell – See Installation Manual. Resuface Trunnion/Tire Surface (Contractor) Replace Bearings or Rebuild Trunnion Roll. wear between the pin and bushing causes the chain to elongate (grow longer but not stretch) until the chain will not fit the sprockets correctly or will not maintain correct spacing or timing. the chain is overloaded in tension until it is stretched so badly it will not function properly. the pins are seated properly in the bushings and the bearing areas 8 . Chain wear elongation usually progresses through three stages as shown in Figure 2.2 Chain Wear Most often. until the chain will not function properly (will not fit the sprockets) or the remaining material is so thin that it lets the chain break. Recondition or replace Thrust Roll. Premature Improper shell (alignment) Thrust RollBearing Failure Premature Improper shell (alignment) Trunnion Roll/ Tire – Premature Wear Shell will not Track Properly after Alignment Improper Shell tracking (alignment) Worn Trunnion Roll/Tire Surface – No Flat/Flush Trunnion Bearings Worn 4.Operating & Maintenance Instruction for Rotary Equipment 4. Sometimes wear between the roller and bushing or wear between the link plates or sidebars and guides causes the chain to malfunction.

or chain elongation on the sprocket may have caused loads on individual joints to increase dramatically. Misaligned drive. provide cover as needed Check for proper lubrication. Check cylinder tracking. In this final stage. Check Alignment and adjust as required. second 100 hours. Provide adequate cover for environmental material surrounding drive. Eliminate overload or shock load condition.Operating & Maintenance Instruction for Rotary Equipment are normally well lubricated. there is another period of rapid. or terminal wear. And finally. or the hard case on pins and bushings may have worn through.2. Once a year thereafter. replace as necessary. lubrication may have become ineffective or failed completely. Troubleshooting Excessive Chain or Sprocket Wear Excessive Drives Noise Chain Breakage 9 . Corrective Action Check environmental abrasiveness. third 500 hours. Worn chain or sprockets.3 Chain Troubleshooting Table Type Maintenance Inspect for Wear and Alignment What To Do Initial inspection 24 hours. 4. Check sprocket contact pattern for even wear.

Provide adequate cover for environmental material surrounding drive. replace as necessary.0 Trunnion Roll Rebuilding Instructions. provide cover as necessary. Remove overload condition. Worn gears. 1) Introduction The following instructions are for the purpose of providing basic guidelines for the rebuilding of the trunnion rolls. Inspect for noticeable wear that may inhibit normal operation. Eliminate overload or shock load conditions. Check tooth contact pattern for full-face contact Corrective Action Check environmental abrasiveness. 10 . It is recommended if these conditions are observed that the trunnion roll be refaced.3 Gear Drives Type Maintenance Inspect for wear and Alignment What To Do Initial inspection 24 hours. second 100 hours. For those special conditions or questionable clarify of the instructions. Troubleshooting Excessive Gear Wear Gear Breakage Disfiguration of Gear Tooth 5. 2) Required Parts and Tools The following parts and tools are required for re-building the trunnion roll:     Box wrenches 2 Shim sets 2 roller bearing sets Bearing grease ( refer to instruction sheets with bearings) 3) Disassembly    Jack-up the drum Inspect the trunnion roll face for galling or irregular flatness. Misaligned drive. Once a year thereafter. Clean out any debris from the trunnion roll and cast hubs. third 500 hours. Engineering department should be consulted.Operating & Maintenance Instruction for Rotary Equipment 4.

flinger.Operating & Maintenance Instruction for Rotary Equipment 4) Reassemble   Pack the Pedestal and cup bearings with grease and install. Save the shims for later reference. 5. o Bolt on the Pedestals and torque the bolts down in a systematic diagonal manner. For those special conditions or questionable clarify of the instructions Tekno-Kom Engineers engineering department should be consulted. Inspect for noticeable wear that may inhibit normal operation. It is recommended if these conditions are observed that the thrust roll be refaced.  Inspect the condition of the retaining ring. 2) Required Parts and Tools The following parts and tools are required for re-building the trunnion roll:  Box wrenches  2 shim sets  2 roller bearing sets  Bearing grease (refer to instruction sheets with bearings) 3) Disassebly Study the general bearing diagram included with these instructions:  Un-bolt the cast hubs on both sides of the thrust roll. Replace these items excessive wear is observed.  Clean out any debris from inside the thrust roll and cast hubs. bearing sets and shims. The trunnion roll should rotate with minor resistance. The following instructions are trial and error: o Match the new shims against the old shims that were removed and install the new shims as a starting point.  Inspect the thrust roll face for galling or irregular flatness. 11 . collar. flinger and collar. o Try to rotate the trunnion roll by hand.0 Thrust Roll Rebuilding Instructions for Rotary Equipment 1) Introduction The following instructions are for the purpose of providing basic guidelines for the rebuilding of the Tekno-Kom Engineers internal bearing thrust rolls.  Remove the retaining ring.

o Try to rotate the trunnion roll by hand.  If the trunnion roll rotates freely – disassemble and add shims as required. flinger and collar. The following instructions are trial and error: o Match the new shims against the old shims that were removed and install the new shims as a starting point.Operating & Maintenance Instruction for Rotary Equipment 4) Reassemble    Pack the cone and cup bearings with grease and install. 12 . The trunnion roll should rotate with some resistance. Reassemble the retainer. o Bolt on the cast hubs and torque the bolts down in a systematic diagonal manner.  If the trunnion roll is difficult to turn or is locked – disassemble and remove shims as required.

Make sure that none are missing or loose. Check the drum seal rings on the feed end. Make sure that none are missing or loose. Check the gap between each thrust roller and the tire. Where applicable. Make sure that none are missing. Make sure the gear reducer has the correct lubricant and filled to the correct level. Check the reducer mounting bolts. Make sure there is approximately 3/8” gap on each side of the tire when the tire is centered on the trunnion rolls. Check the motor mounting bolts.ANNUAL CHECK LIST ROTARY DRUM Ok? ITEM TO CHECK Check the slope of the drum. Check the drive base jacking bolts. Make sure that none are missing or loose. Check the trunnion jacking bolts. Check the drum seal ring bolts on the discharge end. Make sure that none are missing or loose. Check the trunnion jacking bolt lock nuts. Make sure that is according to the specifications. Before rotating the drum for the first time. Check the alignment and slopes of the driver and girth sprockets 13 COMMENTS . Make sure that none are missing or loose. Make sure that there are no gaps between the trunnion rolls and the Tires. Make sure that none are missing or loose. Check all coupling bolts and set screws. Check the thrust rollers jacking bolt lock nuts. make sure that fluid coupling has the correct lubricant and filled to the correct level. Make sure that none are missing or loose. Check the alignment of the coupling between the motor and reducer. Check the drive base jacking bolt lock nuts. Make sure that the trunnions are square and parallel to each other. Make sure that none are missing. Make sure that there is clearance around the entire circumference. check each trunnion. Check the thrust roller jacking bolts. Make sure that none are missing or loose.

Check the sprocket to pedestal mounting bolts. Check the chain guards. Make sure the drum is cleaned of all debris Make sure the feed breeching is cleaned of all debris. Make sure that none are missing or loose. Make sure that none are missing or loose. Make sure that none are missing or loose. Check the tension and condition of the drive chain Chain the pedestal to drum mounting bolts. Make sure the Trunnions are flushed with grease. make sure the drive chain is well lubricated before adjusting the chain tension and position of the drum rotating empty. COMMENTS 14 . Make sure that none are missing or loose. Check the trunnion guards. While the drum is rotating. Check the discharge breeching anchor bolts. Check the rpm’s of the drum. Make sure that they are all installed and that none of the mounting bolts are missing or loose. make sure the trunnions and tires are well lubricated before adjusting the position of the drum rotating empty. Check the feed breeching anchor bolts.OK ITEM TO CHECK Make sure that the coupling guard is in place. Where applicable make sure that the oil drip pans are in place. adjust the position of the drum running empty. Check the key steel that holds the driver sprocket to the reducer output shaft. Check the feed breeching assembly bolts. Make sure that the driver sprocket setscrews are tight. Check all lubrication cups. Check the discharge breeching assembly bolts. Make sure that none are missing or loose. Make sure that they are installed and will clear the tire across the entire range of the trunnion roll. Make sure it is not missing or loose. Make sure that none are missing or loose. Make sure the discharge breeching is cleaned of all debris. Make sure that they are installed and will clear the chain and pedestals across the entire range of the trunnion roll. While the drum is rotating. Make sure the Thrust Rollers are flushed with grease. While the drum is rotating.

Make sure that they are all tight. Check all trunnion jacking bolt lock nuts. with fertilizer. Make sure that they are all tight. Make sure that all of the drip rates are set correctly. Check for the correct rotation of the motor. adjust the position of the drum running loaded. While the drum is rotating. Make sure that they are all filled with lubricant. Check the motor amperage with the drum running empty. the following safety precautions must be strictly adhered to. Check all thrust roller jacking bolt lock nuts. 15 . DO NOT ROTATE THE SHEAVES BY TURNING THE BELTS BY HAND. All units must be de-energized and the motor starter for the unit must be turned off and tagged (use of the starter lockout is under the control of the maintenance personnel performing the work) WARNING. COMMENTS Note: Under all circumstances.Ok? ITEM TO CHECK Check all lubrication cups. Check all drive base jacking bolt lock nuts. Make sure that all of the brushes are set to the correct position. Make sure that they are all tight. DO NOT PUT HAND INSIDE OR NEAR THE UNIT OR MOVING PARTS WHILE THE UNIT IS RUNNING. Check all lubrication cups. without fertilizer. Record full amp rating on the motor nameplate. Check all lubrication cup assemblies. Check the condition of the motor wiring connections in the junction box mounted on the motor. Check the motor amperage with the drum running loaded.

MIDC.27468779. Plot No. 19/4. Pimrpi. 16 . Pune – 411 019 Phone : 020.INSTALLATION INSTRUCTIONS FOR ROTARY EQUIPMENT Prepared by: Tekno-Kom Engineers F-II Block.

Doshi 17 . No.Installation Instructions for Rotary Equipment Manual Revision Log Date Rev.V. Page (s) Description of Revisions Number Approved By 2012 0 All New Issue S.

Both. Handling & Installation –General” manual shall be considered inclusive with this manual. NOTE Step #1 – Check Foundation Elevation. REMOVE THE RUBBER SHEET PRIOR TO START-UP. In such an event. NOTE It is imperative that the top of the foundation is within plus or minus 1/8”. “Common Sense & Rules of Good Practice” must be applied.Installation instructions for Rotary Equipment 1. The Tekno-Kom Engineers field representative should be consulted in any questionable matter requiring clarity. Prior to installation the dryer base.0 The following is a systematic approach to the proper erection of the subject equipment. 2. 0 this section addresses those specific areas relative to Rotary Equipment. The drawings in Addendum ‘A’ shows the proper lifting points for truck unloading and lifting for installation. check to see that the top of the concrete or the top of the support steel is correct per the design. The following installation instructions are to be used in conjunction with the appropriate general subject matter sections as identified in the “Table of Contencts”. Failure to so will damage the equipment. 18 . Rubber Sheet is provided between the trunnion Rolland the riding tire when the shell assembly is shipped setting on the trunnion roll bases. Unloading & Lifting Instructions. The Tekno-Kom Engineers “Equipment tagging. Excessive Deviation will inhibit the ability to properly level the rotary equipment at the required elevation. Individual job site conditions or unique construction crew constraints may warrant deviation from the following procedure.0 WARNIING 3.

in conjunction with a minimum of 1 inch thick of grout be employed. two heavy-duty hex nuts will be used on each anchor bolt. For purpose of leveling. “Dryer Installation Arrangement” NOTE The threads of the anchor bolts should be clean and greased for leveling purposes. and the other hex nut is to be used above trunnion base to snug down and lock the dryer frame into the set position. Refer to illustration. it is recommended anchor bolts and pipe sleeves. The anchor bolt should protrude a minimum of 3 inches above the concrete pier. One nut is to be beneath the trunnion base for jacking purposes. 19 .Installation instructions for Rotary Equipment Step #2 – Check Dryer Anchors for Rotary Equipment a) When supported on Concrete Foundation: When supported on concrete foundations.

The level should be positioned at the center point of the distance between the rollers. Then. The threads of the anchor bolts should be clean and greased for leveling purposes. 20 . starting with the farthest corner on the low side. “Dryer Installation Arrangement”. use the jacking nuts or shims to raise the lower end of the trunnion assembly. it is recommended threaded studs be welded to the steel in conjunction with base support shims be employed. Refer to illustration. for reference for steel support foundations. Generally. One nut is to be beneath the trunnion base for jacking purposes. Having observed the position of the bubble. Step #4 – Horizontal Leveling. NOTE Step #3 – Position Trunnion Assembly. For purposes of leveling. Position the trunnion assembly on the foundation. The threaded studs should protrude a minimum of 3 inches above the steel support deck. then place a bubble level on top of the straight edge. two heave-duty hex nuts will be used on each anchor bolt. and the other hex nut is to be used above the trunnion base to snug down and lock the dryer frame into the set position. Finger-tighten the jack nuts (or shim) at the center of the trunnion base until they are snug against the base.Installation instructions for Rotary Equipment Run one nut down on each anchor bolt with a flat washer loose on top of it. Place a straight edge across the top of the trunnion rollers. First. The flat washer should be positioned approximately 1 inch above the top of the concrete. six heavy hex nuts and washers will be required per trunnion base. repeat the same procedure to the far side of the trunnion assembly. This should be performed in a systematic procedure. b) When supported on a Steel Foundation: When supported on a steel foundation.

“Trunnion Assembly Pitch” “Trunnion Assembly Pitch” 21 . or fall per foot.Installation instructions for Rotary Equipment Observe the bubble in the level. This level should be extended in the direction of illustration. such as a pair of nominal 2-1/2” x ¼” angles about 5-1/2 feet long. is shown on the field assembly drawing. Step #5 – Setting the Dryer Pitch. The required dryer pitch. Cross the angles perpendicularly with a four-foot level that has a bubble indicator. Span the trunnion rollers with straight edges of equal size. Repeat the above procedure as frequently as necessary until the bubble in the level appears to be approaching the center marks.

At this point. Measure down from this mark 1 inch. the base should be level lengthwise and titled to the right. When the trunnion base is securely down to a concrete foundation suitable non-shrinking grout should be poured between the trunnion base and the concrete foundation.Installation Instructions for Rotary Equipment Provide a level surface about four feet from the high edge of the Trunnion towards the low side. Let the level lie down across and bear on each of the two angles for straight edges. 22 . Using the jack nut on the low side. on the high side of the trunnion roller. As an alternative. the lower side of the trunnion assembly can be raised or lowered until the 1-inch mark is reached. while holding the level firmly in place. Assuring a desired fall of ¼” inch per foot. Mark the upright board (or batterboard). while moving the opposite end to the true level position. s straight piece of 1 x 4 or 1 x 6 lumber held plumb on a level surface will suffice. four feet would result in a 1 inch fall. Hold the level down on the straight edge (or angle). A temporary batter-board may be set up for this task. NOTE Make sure the trunnion bases are set to the drum pitch that is called out on the erection drawing Refer to Illustration. for deviations created by securing the nuts. Step #6 – Securing the Trunnion Base a) When Supported on Concrete Foundation: Put the washers and top-heavy hex nuts on all anchor bolts and snugdown. This area should be the width of the trunnion rollers. Check leveling again and compensate if necessary. “Dryer Installation Arrangement”. Mark the low-end position on he batter-board.

Step #7 – Cylinder Installation. inspect for full-face contact between the tire and the trunnion. 23 . If the tire is seated on the center of the trunnion. “Dryer Installation Arrangement”. When the trunnion base is securely bolted down to a steel support foundation steel shim stock should be placed between the trunnion base and the steel support foundation. on the thrust roll end of the cylinder. Check leveling again and compensate if necessary. Step #8 – Check Tire to Trunnion Contact. Check all four trunnions for full contact. then weld where practical the bottom of te support base and shim stock to the top of the steel support foundation. move each thrust roller away from the side of the tire. The thrust rolls are then set to allow for ¼-inch drift of the cylinder. Using light between the trunnions and under the tire. Use the jacking nuts carefully to eliminate any light seen due to the tire not being flush against the trunnion surface.Installation Instructions for Rotary Equipment b) When Supported on a Steel Foundation: Put the washers and top-heavy hex nuts on all threaded studs and snug down. approximately 1/8 inch. The thrust rolls should position the tire (riding ring) into the centroid of the trunnion rollers. for deviations created by securing the nutes. Refer to Illustration. The opposite tire edge should be flush with the trunnion roller edge nearest to the thrust assembly. for reference for the support on a steel foundation. NOTE Make sure the trunnion bases are set to the drum pitch that is called out on the erection drawing Weld the bottom of the support base to the shim stock. Lower the cylinder carefully into place.

Align the drive sprocket with the cylinder sprocket and secure. Refer to “Tekno-Kom installation instructions – General”. a ¼” shim. Use the adjustable motor base for setting the chain tension. Three sets of shims are usually included with the sprocket assembly. 24 . Put the ¼” shim on first. There should be uniform clearance around the shell outside diameter with in 3/8”. This provided the desired circumference of the completed sprocket to suit the pitch of the sprocket chain. after a trial run in order for the chain to seat properly between segment teeth. 1/8” shim and a 1/16” shim. NOTE After completion of the following steps. recheck the chain alignment and slack and adjust as necessary. Inspect the clearance between the shell outside diameter and where the shell enters the breeching. Align the motor drive base on its pad on the same plane as the cylinder Use the jack nuts on the anchor bolts to adjust to the proper pitch. for bolt identification markings and torque values. then the 1/8” shim and the 1/16” shim to the top. Step #10 – Install The Feed & Discharge Breechings Position the feed and discharge breeching. or 1/16” shim. Shim the breeching support base if required. Install the chain and leave some slack in the chain at the bottom. between the saddle and the sprocket. It may be necessary to remove the top. When grouted (or shimmed).Installation Instructions for Rotary Equipment Step #9 – Installing the Chain Drive Bolt on the saddles that support the sprocket segments torque the bolts tight based on the size and grade furnished. align the motor and reducer squarely with the cylinder. The chain should be taught on the top of the driver sprocket with some slack on the bottom of the driver sprocket.

If abrasives come in contact with the chain. lubrication becomes more difficult. abrasive particles tend to adhere to the chain surfaces and act as a lapping or grinding compound. c) Abrasive Atmosphere. a brush or wiper can be used to clean the chain and apply new lubricant. the lint or dust will clog the chain joint clearances and prevent penetration of the oil into the joints. When lubricants are applied externally. a) Clean Atmosphere. Failur to do so may result in equipment damage and/or personal injury. Otherwise. Under extreme conditions it is sometimes advisable to avoid chain lubrication. Chains operating in a relatively clean atmosphere can be lubricated by brush or drip feed oilers.Installation Instructions for Rotary Equipment Step #11– Check Lubrication CAUTION Gearboxes are normally shipped DRY. NOTE Trunnion rolls and thrust roller bearings are normally shipped packed with grease. or by applying the lubricant manually with a brush or oilcan. Where large volumes of lint or non-abrasive dust are present. 25 . b) Atmosphere Laden with Lint or Non-Abrasive Dust. Oil must be added prior to operation.

indicating a gap of . jack the dryer slightly off the trunnion and put a thin shim under the trunnion bearing. “Cylinder Movement”. 26 . NOTE The objective alignment condition is to have the shell rotating where the tire on each end continuously just humps the thrust roller and the thrust roller only turns momentarily. This may only take a ¼ or ½ turn of setscrew. This procedure may take several hours. If more than a full turn of the set screw is required to push the trunnion up to the tire. Rotate the cylinder slowly under power. or if the cylinder tends to bear hard contiuously one way or the other. observe the tire and trunnion face contact.005 inches or so of surface contact on one side of a trunnion tighten the set screws on that side to push the trunnion up to the tire. If some light is seen.Installation Instructions for Rotary Equipment d) The following is a recommended lubrication chart for normal conditions: Lubrication Chart Recommended Lubricant EXXON RONEX MP or Equal – NLGI Grade 2 for use at temperatures at or above -29OC (-29OF) SAE 10W Oil Refer to Manufacturers Instruction Manual SAE Component Trunnions & Thrust Rollers Fluid Couplings Speed Reducers Chain Step #12– Tracking & Aligning the Cylinder NOTE The following procedure is tie consuming and requires patience. it is better to return the set screw to its original position. Rotate the cylinder under power. See Illustration. With a light under the tire and between the trunnions. Inspect for floating or drifting between the thrust rollers. There should be no light showing between them.

27 .Installation Instructions for Rotary Equipment “ Cylinder Movement”.

Results might become apparent immediately. (in case a tire is hearing hard against the down hill thrust roller) follow the procedures shown above to adjust the gudgeons or pillow blocks. reverse the adjustments described above. To move the cylinder towards the discharge end. to ensure the shafts are still exactly parallel. a cylinder may have to run several minutes before it will begin to move in the new direction. After obtaining desired movement. (When possible. it is preferable and easier to adjust these screws while the cylindere is turning). Results may be immediate. or the cylinder may run several minutes before it starts its movement.Installation Instructions for Rotary Equipment To move the cylinder towards the feed end. Re-start and observe. 28 . However. check each set of trunnions as shown on Illustration “Trunnion Assembly Alignment”. Assume a counter-clockwise rotation towards the thrust roller end. Turn all setscrews ¼ turn. If the cylinder tends to run towards the thrust roller end. without danger. turn all #1 set screws ¼ turn.

29 .