Machine manual

en-21020.171-F

DOPOL® - Compressed-air cleaning system

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
DOPOL® - Compressed-air cleaning system

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-2
3.2 Mode of functioning..................................................................................3-4
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Checks after assembly..........................................................................6-1
6.1 Setting and adjustment.............................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-1
7.3 Trouble shooting.......................................................................................7-2
7.4 Repair....................................................................................................... 7-2
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1

en-21020.171-F
Machine manual Technical data
DOPOL® - Compressed-air cleaning system 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers’
documentation.

Information on the intended use

The compressed-air cleaning system is part of the DOPOL
preheater.

Basic data
Year of manufacture............................................................................
Design..........................Automatic compressed-air cleaning system
Control................................................Infinitely variable time switch
Quantity of compressed air..................................................litre/min
Pressure...............................................................................8 - 10 bar

Solenoid valve
Type.....................................................................................................
Number................................................................................................

Pressure monitor
Type.....................................................................................................

Compressor plant
Type of compressor.............................................................................
Suction capacity..........................................................................m3/h
Quantity delivered........................................................................m3/h
Maximum pressure........................................................................bar
Operating voltage...........................................................................Hz
Control voltage................................................................................Hz

Vessel
Capacity of vessel........................................................................litre
Pressure of vessel.........................................................................bar
Machine manual Safety
DOPOL® - Compressed-air cleaning system 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 The compressed-air cleaning system is part of the DOPOL
preheater for the kiln plant.
Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machinery other than for the specified purpose
is forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.
 One of cyclone stage can include a gamma ray emitter
installed for monitoring the filling level. The national rules for
radiation protection must be observed.
 All platform openings must be closed and properly secured.
Safety Machine manual
2 DOPOL® - Compressed-air cleaning system

Maintenance
 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
 Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance hatches are opened.
 The plant manager must take adequate safety precautions
before, during and after all maintenance work for the
protection of the maintenance and operating personal. After
the maintenance work, it is of vital importance to make sure
that nobody is locked in the preheater!
 Danger! You can suffer severe burns at the preheater. Do not
touch the preheater while the preheater is hot.
 When automatic air cannons are used, the remaining pressure
must be relieved after their electrical switch-off before the
preheater doors or poke holes may be opened. Remaining air
pressure causes the air cannons to operate!
 There is a danger for people to stumble over the brackets on
the platforms of the preheater cyclones. Everybody entering
the platforms must wear protections clothes.
 Only authorized and instructed personnel may open the doors
and locks on the plant manager’s instruction.
The doors and locks are so designed that they can be secured
with padlocks.
 Even after a longer cooling-down period be careful when
opening doors and maintenance holes. After a cooling-down
period there is still a danger of being burnt by spurting raw
meal.
 Everywhere in the preheater, overpressure may have been built
up due to a power failure. Do not open any doors or poke holes
if there is an overpressure.
 Danger! When the individual cyclone stages are cleaned
through the poke holes, hot raw meal can gush out due to
clogging. Use blow lances of maximum lengths, wear
protective clothes and make sure that the escape routes are
free.
Machine manual Safety
DOPOL® - Compressed-air cleaning system 3

 Only the special cleaning equipment foreseen for this purpose

may be used for eliminating caking and clogging of the
preheater.
 Do not enter the machine interior before you have sufficiently
purged it with fresh air and before it has cooled down
sufficiently. Make sure that you have enough oxygen inside the
machine and that hot gas cannot flow in.
 When performing work inside the machine, fresh air from an
outside source must be continuously pumped into the machine
or induced by sucking so that the inhaled air remains free of
noxious matters. Aeration with pure oxygen is not permitted.
Use dust protection masks as protection against the high rate
of dust which must be expected.
 While the preheater is cleaned, access to the rotary kiln and
the clinker cooler must be made impossible. Raw meal can
flush through the kiln to the clinker cooler. There is danger of
suffocating and getting buried with raw meal.
 Make sure that raw meal and loose parts cannot fall down on
you from upper section when you work inside the machine.
Take care that people in downstream plant sections are not
endangered. There is danger of suffocating and getting buried.
 For maintenance work in the plant’s interior space it may
become necessary to erect auxiliary platforms. Such auxiliary
platforms must be firm and steady.
 Prior to any work at the cyclone, the gamma ray emitter must
be switched off and safeguarded by padlocking according to
regulations.
 Make sure that the guards on all flap valves completely cover
the working distance of the sliding weights because otherwise
people’s limps are in danger of being cut off.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 De-energize the electrical parts before starting any
maintenance work.
 All electric lines in the area of the preheater must be protected
from contact with falling hot raw meal. Suitable covers must
be installed.
 After all maintenance work all earthing cables must be
checked for proper functioning.
Safety Machine manual
4 DOPOL® - Compressed-air cleaning system

 Strictly observe the welding instructions when performing any

welding work.
 When performing arc-welding or arc-gouging, the welding
personnel must be protected from contact with electrically
conducting parts.
 Never place the welding current source in closed rooms with
electrically conducting walls. For lighting the inside, only 24 V
lamps are permitted.
 If electrical welding is executed on any part within the
machine, the welding current must never be conducted through
sliding or anti-friction bearings, other moveable connections or
measuring equipment. Return lead welding current must
always be connected close to the point of welding and directly
connected to the part being welded.
 All safeguards have to be re-installed when maintenance work
has been terminated. Close inspection flaps and maintenance
hatches properly after you have made sure that all personnel
have come out of the machine.
Machine manual Components and mode of functioning
DOPOL® - Compressed-air cleaning system 1

3 Components and mode of functioning

The DOPOL preheaters are equipped with an automatic

compressed-air cleaning system. In preset intervals, particularly
critical points are blown through as a precautionary measure.
This helps to prevent the formation of caking or the settling of
deposits. The following drawing shows the compressed-air
cleaning system (17) including a compressor (17.1) that is
installed in a two-string DOPOL preheater.

Figure 1
Components and mode of functioning Machine manual
2 DOPOL® - Compressed-air cleaning system

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

Items in the drawing

17.1 Central or individual compressor plant
17.2 Pressure vessel
17.3 Piping arranged in the preheater tower
17.4 Connecting fittings to the consumers

All connecting fittings to the individual consumers (17.4) in the

conical lower sections of the cyclones, the dispersing boxes and
the meal chutes consist of the following components:

17.10Compressed air from the pipe network

17.11 Compressed air to the consuming points (blow-in tube)
17.12 Solenoid valve
17.13Manually actuated valves
17.14Manually actuated emergency valve
Machine manual Components and mode of functioning
DOPOL® - Compressed-air cleaning system 3

Figure 2
Components and mode of functioning Machine manual
4 DOPOL® - Compressed-air cleaning system

3.2 Mode of functioning

The solenoid valve control system controls the blowing and the
„off“ periods of the compressed-air cleaning system in adjustable
intervals. You are advised to change the cycle times that were set
during the commissioning phase only after having operated the
plant with the initial setting for a longer period of time. It is also
possible to control the compressed-air cleaning system by hand.
The compressed-air cleaning system is usually operated at a
pressure of 7 bar. If the pressure falls below 4 bar, a fault
indication will be triggered.
The first air blasts are always directed into the lower sections of
the preheater. The space thus blown free will serve to collect any
sliding-down material blown off in sections arranged further up.
Via permanently installed connections in the relevant points it is
possible to connect additional blowing lances with the
compressed-air cleaning system. The blowing lances and the
pertaining hose lines and coupling sections are provided in
different lengths and included in the scope of supply. It is thus
possible to blow additional compressed air into the preheater
system through the cleaning ports of the cyclones, the dispersing
boxes and the meal chutes.

DANGER
Hot raw meal can eject when poke holes are opened.
Beware of mortal danger.
Use blowing lances of maximum length, wear suitable safety clothing, and
keep the escape routes free.
When cleaning the preheater with manual special cleaning equipment:
Mortal danger! You could suffer severe burns.
Only use the special cleaning equipment provided (blow lances).
Machine manual Transport and assembly
DOPOL® - Compressed-air cleaning system 1

4 Transport and assembly

4.1 Transport and storage requirements

The machine is transported in single parts or in sub-assemblies.

It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
Measurement and control equipment must be stored in buildings
which are well aerated and must be protected against moisture.

4.2 Assembly

General requirements
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview on the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.

NOTE
Final assembly and assembly inspection by an assembly
specialist from POLYSIUS AG are preconditions for our warranty.

We recommend that the assembly work is supervised from start

to finish by specialists from POLYSIUS AG.

Careful selection of the used tools and appliances and the

personnel is important for the correct execution of the assembly
work.

CAUTION
If electrical welding is carried out in any place of the machine, welding
current must never be conducted through plain bearings and antifriction
bearings, other moveable connections or measuring equipment to prevent
damage to such parts.
Return lead (of welding current) must always be directly
connected to the part being welded.
Transport and assembly Machine manual
2 DOPOL® - Compressed-air cleaning system

For the mounting and connection of the control equipment please

observe the relevant instructions in the documentation of the
sub-suppliers.

NOTE
All electrical conduits in the preheater area must be protected
from contact with hot raw meal by suitable covers..
Machine manual Lubrication
DOPOL® - Compressed-air cleaning system 1

5 Lubrication

CAUTION
Ensure that the lubricants are stored, used and disposed of in an
environmentally-friendly manner and observe your national
environmental legislation when handling lubricants.

Lubrication chart

Lubrication points
No. Qty. Designation Remark
1 1 Compressor plant according to the instructions of
the manufacturer
Machine manual Checks after assembly
DOPOL® - Compressed-air cleaning system 1

6 Checks after assembly

NOTE
It is a prerequisite of our warranty that the checks are carried out
in the presence of and according to the instructions of specialists
from POLYSIUS AG.

After completion of the assembly work all parts of the plant must
be checked according to the list below. Take particular care that
all material remnants, tools and assembly aids are removed.
 Make sure that nobody is near the blow-out ports!
 Block any access to all blow-out ports!
 Have all screws been firmly and properly tightened?
 Have all flanged connections been tightly screwed up?
Have the seals specified for that purpose been inserted?
 Have all non-conductive connections been bridged by earthing
strips?
 Are all the doors and inspection ports properly and tightly
closed?
 Have all guards and all warning signs been properly mounted?
 Have all platforms openings been properly closed and
secured?
 Are all special cleaning equipment present and in good
working order?

6.1 Setting and adjustment

The setting of the cycle times depends on the individual

operational requirements. You will find the relevant information in
the operation manual for the entire plant.
Machine manual Maintenance
DOPOL® - Compressed-air cleaning system 1

7 Maintenance

7.1 Inspection

DANGER
The whole preheater is very hot.
You are in danger of suffering very severe burns!
Use suitable protective clothes!

No. Work to be performed Frequency Remarks

1 Check the oil level, temperature and once per day
compressor pressure of the
compressor plant
2 Check the solenoid and manually weekly
actuated valves at the consuming
points for functioning
3 Check the tightness of the weekly
connecting couplings and manual
cleaning lances
4 Inspection work on the compressor as required according to the
plant instructions of
the
manufacturer

7.2 Servicing

DANGER
Use of automatic air cannons after their electric switch off.
The remaining pressure must be relieved before the doors and
poke holes are opened.
Remaining pressure causes the air cannons to operate. Danger!

No. Work to be performed Frequency Remarks

Maintenance Machine manual
2 DOPOL® - Compressed-air cleaning system

1 Drain the condensate at the once per day

compressed-air reservoir
2 Maintenance work on the compressor as required according to the
plant instructions of
the
manufacturer
3 Replace leaky valves, hoses and as required
pipes

7.3 Trouble shooting

Measures to eliminate faults on the regulating and control

equipment can be found in the operation manual for the entire
plant.
Replace defective solenoid valves at the individual consuming
points in accordance with the instructions given in section Repair
of this machine manual. It is not necessary to shut down the
complete compressed-air cleaning system for this purpose.
If faults occur on the compressor plant, additional information
regarding causes and eliminations of faults can be taken from the
subsuppliers’ documentation.

7.4 Repair
Before performing any repair work, make sure all electrical components
are disconnected.

DANGER
The whole preheater is very hot.
You are in danger of suffering very severe burns!
Use suitable protective clothes!

Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system or other
sensitive parts of the machine are kept free of contamination.
You may replace defective solenoid valves at the individual
consuming points while the system is running. It is not necessary
to shut down the compressed-air cleaning system for this
purpose.
In order to replace defective solenoid valves at the individual
consuming points proceed as follows:
 open the manually actuated emergency valve (17.14),
 close the manually actuated valves (17.13),
Machine manual Maintenance
DOPOL® - Compressed-air cleaning system 3

 replace the solenoid valve (17.12),

 open the manually actuated valves (17.13),
 close the manually actuated emergency valve (17.14).

Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Checks after
assembly.
Machine manual Spare parts
DOPOL® - Compressed-air cleaning system 1

8 Spare parts

Notes for enquiring about and ordering spare parts

Dear Customer,
POLYSIUS AG strive to render your enquiring about and ordering
of spare parts as easy, and as a consequence, as efficient as
possible. For this purpose we have prepared a table summarising
all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the page with the respective table and mark those
parts which you require with a cross in the column Order or
Enquiry.
If the table relates to more than one machine, please also inform
us of the POC of the machine for which you require the spare
parts.
Spare parts Machine manual
2 DOPOL® - Compressed-air cleaning system

Figure 3

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

17.12 Solenoid valve 1 piece

17.13 Manually actuated valves 1 piece

17.14 Manually actuated 1 piece

emergency valve
Machine manual Appendix
DOPOL® - Compressed-air cleaning system 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of this
folder.

Designation Drawing no.

Assembly drawing

9.2 Subsuppliers’ documentation

Solenoid valve

Pressure monitor

Compressor plant

Vessel