F03 * SD08 No. R2160-SM | : ©3.6X52m Rotary kiln Instruction Manual TCDRI,P.R.CHINAR280 | Contents SM.1 Specifications SM.2 Structure and Working Principles SM.3 Installation Requirements SM.4 Adjnstment of Supporting Roller Unit by Pressing Fuse SM.5 Hydraulic Thrust Roller Unit MS.6 Pneumatic System for Dealing of Kiln Inlet and its Lubrication System MS.7 Test Running MS.8 Routine Maintenance MS.9 Abnormal Appearances, Their treatment and Safe-Attentions ‘MS.10 Starting and Stopping Processes of Kiln * MS.11 Labrication and Cooling MS.12 Maintenance $M.13 Lubrication List SM.14 Wearable PartsRaito Specifications Internal diameter of shell 3.6m Length of shell 52m Slope (sin) 3.5% Number of Supporting Units 3 Capacity (Operation with precalciner preheater) 900t/d Rotation Speed. driven by main drive . 0.35~3.5t/min driven by anxiliary drive 79th Driving moters (Single drive) Main drive ‘Auxiliary drive Type Power(kW) | Rotation type | Powex(kW) | Rotation Speed Speed (min) (cimin) ZSNG315-09 |__ 220 1000 Yt60E- 15 1460 2 Gear reduce Type ‘Speed j Type Speed ‘| ~_ ratio ratio ‘ZSY560 Special order Symmetric double input | __ 32 [Bee 39.063, shaft ‘Maximum weight to be lifted: Maximum shel! section 29.35 Weight of tyre 22.17 Gear reducer 51 Weight of supporting unit with hydranlic thrust roller unit 36.64 including roller-bearing unit (12.15) roller baseftame > 85) thrust roller baseftame (721) The total weight of Rotary kiln including the above mentioned equipment which form a complete set with kiln, but not including the internal refractories: 334t Attached: R2160.8 Installation tool kit of rotary kiln (® Basic configuration Drawing No. Name and size Quantity weight(kg) R2160.8-1 Ruler(L=3840) 2 tL R2160.8-2 Battering rule(3.5%) 2 612 R2160.8-3 Measuring platform (typeI) 2 28 ~ Foundation benchmark 12 20.88 . Sheil sustaining frame 1 3124 R2160.8.3 Roller centre caltipers 1 438 R2160.8.4 Adjusting screw sustaining frame 6 297.32R2160.8.5 Instratlation tools for girth gear, 4 SRA (II) Options Drawing No. or type 4405, KAS.02 Total weight: 4119.1 Name, development Quantity organization, mannfacture works Transverse deformation measuring unit of rotary kiln shell developed by Tianjin cement Industry Design and Research Institure, Manufactured by Wuxi Building Material Instrument Manufacture works Tyre clearance measuring unit developed by Tianjin Cement Industry Design and Research Institute, Manafactured by Wuxi Building Material Instrument ‘Mannfacture Works Dynamic parameter measuring unit of rotary kiln axis developed and mannfactured by Kaishi Seientifie and Technical Development Cooperation of Wuhan University of Science and Technology2160 Structure and working principte ‘The kiln shell is of rulted and welded stec! plate construction. The intemal surface of shel! is lined with refractories. The kiln is arranged with a slight slope supported by supporting units through 3 tyres. The girth gear is installed on the kiln shell within the span near.the inlet by tangent spring plates. There is a pinion underneath which meshes with the girth gear. During normal operation, the main drive motor transmit power to gear reducer, pinion, girth gear and finally drive the kiln shell. ‘The material enters the kiln from the inlet. As the kiln shell is oblique and. rotates slowly, the material tumbles circumfrentially and.moves axially from the inlet to the ontlet simultaneously. At the same time the material is subjected to calcinating and sintering processes (the material has been already subjected to precalcinating in precaleiner). Finally, the clinker produced falls into the cooler through the firing hood. ‘The fuel is injected into the kiln at the kiln head. The exhaust gas produced during burning is drawn out through the kiln inlet after its heat exchange with the material. The bumer is not included in the design. The main structure characteristics of the kiln are as follows: 1. The kiln shell is made of rolled killed stee] plated and automaticly welded. The stee! plates are guranteed for five items of mechanical properties (0 », 0 », 6%, and cold-bending test), Thickness of shell: 40mm under tyres, 22mm in the sintering zone 32mm for transition plates between the shell sections under tyres and shell section in span, 20mm for general shell sections. This arrangement of shell thickness can gurantee both the transverse rigidity of shell and desirable loading condition of the suppurting unit: At the inlet end and the outlet end, the kiln shel sections are furnished with the brick retaining blocks made of heat-resistant and wear-resistant steel. At the outlet end, the brick retaining block and cooling air socket form a circular space with checkers, through which the cooling air from cone-type opening is blown onto the inner surface of the brick retaining block for its long service life, There are three solid rectangular type tyres on the kiln shell. The clearances between the tyre and the tyre pad depends on the thermal expansion: During the kiln operation, the tyre can be put on the kiln with suitable degree of tightness to reduce the transverse deformation of kiln shell. To ensure the reliable operation of the two supporting units close to the hot end of kiln, where the working temperature is high, the special air cooling devices under the tyres are provided. (Drawing No. R2174) 2.The hydraulic thrust roller unit is applied, which undertakes downwards sliding force of the kiln and noves the kiln upwards.The proper distribution and arrangement of all the supports lead to the reasonable design of bearing units of all the supporting units. Every soller bearing unit is furnished with temperature metering devices. The working temperatures of every bearing bush can be displayed on site and menitored in the ceetral ‘contro! room. 3. The signle drive system is applied for the kiln. The kiln is driven by the high starting torque DC. motor specially designed for rotary kiln through the three sage hardened-surface gear reducer, the pinion, girth gear, the elastic rubber block coupling, which improves the stability of system mechanical operation. The driving system is also provided with the auxiliary device connecting to the stand-by power source to ensure the kiln inching to prevent the kiln from becoming bent when the main power source is off and~y R2io easy maintenance. ‘The main motor is furnished with tachesmetry generator to indicate the actual rotation speed of kiln. 4. The air sealing, the labyrinth and spring stee! sheet type sealing are combined for the kiln hot end seating. The suitable amount of cooling air from. the cone-type opening is blown onto the. trick retaining block and get out. from the top. Because the overlaped the heat-resistant spring steel sheets are pressed on the cylinder of the cooling air socket with suitable degree of tightness, the sealing function is still kept is good condition even when the kiln shell at the hot end possibly swings. 5. The air sealing at kiln inlet adopts the mechanism combining spring pressing rods and the graphite block sealing. The device has advantages of easy installation, safe and reliable operation.2 R21 60 Installation requirements Before installation, the relavent drawings and technical documents should be got femiliar with to inderstand the equipment structures, installation requirements. ARer this, determine the unstallation sequence and methods, prepare the necessary installation tools and equipment. Afterwards, carry out the installation with the best of caze. Check foundation, draw datum lines 1. Correct the drawings, and measure the lengths of all the shell sections. For the calculation of actural distances between two neighbouring tyres under cold state, the calculation clearace of 2mm between two neighbouring shell sections is considered for fal clearance between two neighbouring shell sections and welding contraction. - Calculate the actual distances between the two neighbouring tyres under cold state, then calculate the correspording thermal expansions, finally, calcuate the distances both along the kiln axis and along horizontal direction between the neighbouring supporting units, and accordingly, correct the relavent dimensions in drawings. 2. According to the corrected drawings, check the foundation dimensions, especially, the foundation center distances. If there is any contradiction, the following measures should be taken: (1) The deviations of tess than Smm between any dimensions in the corrected drawings and the corresponding dimensions of foundation are allowed. (2) If the above mentioned deviations are 5~20mm, the gaps between the neighbouring shell sections can be adjusted. ‘The interface gap can be adjusted in the range of 3mm, (G) If the above mentioned deviations is larger than 10mm, besides the sheel sections interface gap adjustment, the positions of supposting units should be adjusted. According to the actual dimensions after the adjustments, correct the distance dimensions atong the kiln axits between the neighbouring supporting units in drawings, calculate the corredponding dimensions along horizontal direction. Measure the dimensions of roilers and roller beatings, correct the elevation dimensions of top generatrixes of roller working surfaces. 3. Foundating mark out (1) Mark.the horizontal datum line on the side surface of foundation apporximately Im from the ground. The elevation plates are burried at the four comers of the foundations. ‘The elevation deviation of daturm level must the less than 0.5mm. (2) Mark the longitudinal central line, their deviations must not, be larger, than 0.5mm, (3) According tot the corrected drawings, Mark the foundation transverse central lines on the horizontal datum lines for all the foundations. The deviations of distance between the two neighbouring supporting unit centers should not be farger than 1.5mm, the deviation of distance between the foundation center close to the inlet and the foundation center close to the outlet should not be larger than 3mm. :-. Rare Installation of supporting units Whether the kiln central line maintains a straight line during the kiln operatio depends on, firstly, the locations of supporting units. Therefore, a great attention should by paid to the installation of supporting units. The following requiements must be staisfied fo) the installation of supporting units: 1. After the precise base frame alignement; the following requirement should by followed: Permissible baseframe longtudinal central line deviation 0.5mm Permisible center distance deviation for the two neighbouring baseframes 13mm Penmissble center distance deviation for the baseframe ” close to the inlet and the baseframe close to the outlet 3mm. Pemissible level deviation for the two neightlouring base frames 9.5mm Permissible level deviation of the baseframe clos to the intet and the baseframe outle mm Permissible slope deviation of machined surfaces of baseframes of supporting units 0.05mm/m 2, During the roiler bearing unit assembly, the position numbers of bearing housings sphericat beatings and bearing bushes must be checked, Only after it is confirmed that thi above mentined parts have the same position number, they can be assemblem to an uni By meaus of color painting, the contracting spots should be distributed uniformly along tht entire genieratrix width of bearing bushed and should be contincously distributed on thi middle zone of entire contacting width of bushes. Otherwise, the scraping and grindin, should be carried out at site, The number of contacting spots between the journa! ant bearing bush can not be less than 1 spot within the area of 10X 10mm, and the number contacting spots between the spherical bearing and lower beating housing can not be les than 1 spot within the area of 25 25mm, However, within the ring zone with the width o 50mm at the two sides of the spherical bearing, a clearance of 0.1mm is allowed. Checl the clearances at the two sides of contacting zone between the joumal and bearing bus! with the inserting gauge. At the point where the inserting gange is inserted 10mm clearance of about 0.24mm should be generally maintained, if the side cleararce is no enough, the scraping and grinding should be carried out, ‘ 3, Install the roller-bearing unit on the baseframe after adjustment,the followin} requirements should be satified: . (1)The roller shafe collar at the upper end should contact the bearing bush flang while at the lower end, a clearance of 4mm between the roller shaft collar and bearing bus flange should be reserved. Confirm the side surface.of rims of two rollers should be af the same plane, its permissible deviation is 0.5mm cheeked with straight ruler, (2) The distances between the central lines of two rollers and the longitudinal centra} line should conform to the requirements specified in the drawing, the permissible deviatioros Ratt of which can not exceed 0.5mm. (3) Examine the working surface of every roller with the slope ruler and the level. ‘The slops at the top generatrixes of rollers should be identical, the permissible deviation is 0.0Smm/m. For one supporting unit, the connecting line through the middles of the above mentioned generatixes of two rollers should be horizontal, its permissible deviation is 0.05mm/m. Ifthe deviation exceeds the above mentioned limit, the adjustment by inserting shims under the bearing pedestals can be carried out, @) Measure the elevation of the middle of top generatrix of every roller, the elevation differences for all the supporting units should conform to the corresponding dimensions in the comected drawing, the permissible elevation deviation for the two neighbouring supporting units can not be larger than 0.5mm, the permissible elevation deviation for the supporting unit close to the infet and the supporting unit close to the outlet can not be larger than Imm. (5) With theodolite examination, the top generarix of every roller should be within the plane which ablique to horizontal plane with a slope of 3.5%, if there is some error in elevation or slop, the adjustments by the adjusting bolts,~ 3) During the welding of shell, any other work can not be carried on inside kiln. Installation and welding of kiln shell 1. Preparations (1) Cary out the trial assembly according to the number marks at the Kiln shell section interfaces (or continuous line marks at the kiln shell interfaces) on the ground. (2) Check the two interfaces of the kiln shell section to be onnected, the interface perimeter tolerance is 8mm, the out-of-roundness to lerance is 8mm, if the out o! roundness exceeds the figure, the shel! must be corrected by the installation tools, (3) Measure the intemal diameters and extemal diamenters of tyre pads for every supports, check if the tyre gaps for every supports conform to the requirements specified ir the drawings. (4) Clear away burr, greasy dirt, rust ete. Keep clean and dry on the interface surfaces of the kiln shell. 2. Assembly and alignment of the kitn shell ‘The sequence of assembling and alignment of the kiln shell is decided at site. T. censure the clearance of 1~3mm between two neighbouring shell sectoins, 16 piece of stee sheets of 100% 100mm with the theikness of I~3mm are uniformly inserted between tw interface surfaces of two shel! sections, As the welding gose on, the above steel sheet should be taken away one by one. It is not allowed to take al! the steel sheets on on circumferential seam. Pay attention to check if the relative locations between tyres an rollers conforin (o for cofd state. These in drawings, its permissible deviation is Smm. ‘After measurement and adjustment of the kiln shell, The following requirement should be satisfied. (1) The tolerances of radial nmouts of shel girth gear position, 6mm for any other locations. (2) The intemal surfacee of circumferendial seams of shell should be guaranteed be flat and neat, the maximum permissible offset of two neighbouring shell interface edges on any position of circumferenfal seam is 2mm. 3. Welding of shell ‘The welding of kiln shell is a key part in a kiln instatlation. The welding quality wil directly effect on the operation and service life of kiln, it must be paid more attention t especially the following points shoule be emphasised. (1) Only thoese welding workers who have passed the examination are allowed t work in the shell welding. (2) Depending on the working conditions, for the shell welding, manual welding fo the back cover and ‘automatic welding for outside can be applied. The quality of weldin; wire used for the automatic welding and quality of welding rod for the manual welding should be equivelant to that of the O8A welding wire and that of the E4315 (GBSI11 welding rod, respectively. Before the welding rod are used, they should be dried for ‘hours at the temperature of 250°C Smm at the inlet and outlet, 2mm at the (4) During runing, winding and snowing, welding can not be carried on. If tht ambient temperature is below 5°C, groove preheating, thermal retardation after weldin and adjustment of welding process should be made. If the kiln shell is exposed to th sunlight, the temperature difference the facing sunlight side and shadow side will leads tte a Rat. flexure of shell, the shel! welding can not be carried on, If the one side of shell is subjected to heat radiation from the neighbouring operating Kila, ‘The kiln central line may flex. In this case the heat insolation measure by asbestos board protection should be taken before welding. (5) The are starting points and the arc extinction points between two neighbouring welding layers can not be overlaped. ‘The welding appearance defacts and slag inclusions, air cavity and cracks ec. At the welding seams are not allowed. Every welding seam must be detected. The interstions of longitudinal and transverse welding seams and othei positions of welding seams where the welding qualityies are doubted should be detected by rays or altrasonic detection, The examined results of ray detection must conform to the requirements of grade II in GB3323. The examined results of altrasonic detection mmust conform to the requirements of grade JI. in JB1152, If not, the suitable remedy measures must be taken. The examination regulations are in the basis of JC333. (©) After the shell welding, check if the relative positions of tyres and rollers consistent. with the corresponding dimensions under cold state in the drawings. Th corresponding permissible deviation is Smm. The proper unitform gap between tyres an retaining blocks according to the drawings. (7) After the adjustment and assembly of entire shell in the basis of'above mention requirements, the center of shell transverse section under tyre I shoule be slightly below the connecting fine through the centers of shell transverse sections under tyre I and tyre UI] by a small amount, which is the range of 1.5mm~2mm. 10R2tbo Installation of driving system After the assembly of shell, the installation should be carried on. It is allowed that the driving system is installed after the shell sections are femporarity connected for the kiln shell inching to align and to weld the shell. 1, The longitudinal welding seams of shell under the girth gear must be ground flat and neat with emery wheel, the welding seam width to be ground shou!d be SOmm wider than the spring plate width at its each side. 2. By means of the installation tools, adjust the girth gear position until the radical runout of tooth top circle is within 1.5mm, and the runout of datum end plane is within Imm according to the drawings. 3, The installation orientation of spring plates should be made the pure tension loading to be taken by the spring plates. After installation of reaming bolts of spring plate and girth gear, the shim of 0.3mm is inserted between the washer at the side Gtting surface. and the yoke plate of spring plate, after the stotted nut is tightened up and the split pin is put in, the shim is removed maintening a clearane of 0.8mm. 4, The transverse position of driving system baseframe depends on the position of the ‘kiln central line. the thermal expansion should be considered to determine the axial position of the girth gear center. (be careful that the width center of the tyre at inlet of roler at this time), the elevation level of the base frame depends on the elevation level of the supporting unit at the inlet, the slope of the baseframe is the same as that for the supporting unit, 5. The position of pinion unit is based on the position of girth gear, the dimensions for its location should conform, to those in the drawings, their permissible deviations are 2mm, the slope is adjusted with battering rule, its permissible error is 0,0Smm/m. Within one turn of kiln, the variation range of tooth top clearance of pinion and girth gear are 9~ 10mm under cold state, and are not.less than 7mm when the normal operation temperature of kiln is reached. Check the contacting state of pinion and gitth gear, the contacting area should be larger than 40% along the tooth height and larger than 50% along the tooth width, 6. The coaxiality tolerance between the output shaft of main gear box and pinon shaft is (0.2mm. transverse position deviation and slope deviation measured on the connecting surface of lower housing of main gear box.with the upper housing should not be larger than 0.05mm/m. uw- R21 Roller adjustment by pressing fuse ‘The primary work of the kilns maintenance is the adjustment of rollers, it is impor often to observe the roller operation and to judge roller loading and contact state betwe the roller and tyre by experience. Adjustment of rollers are usually practised by means 0 pressing fuse test. The precondition for pressing fuse test is that the surface of the tyre ant roller should be smooth and flat. During the test the fuse with diameter of 2mm (usuall; 0A) is put on the surface of roller between roller and tyre straightly along the generatris of roller (Fig 1). Then, the shapes of the pressed fuse are analysised, which results in th judgements about the contact state and loading between the roller and tyre, the bendin; state and the maximum excentricity position of kiln central line. Case I in Fig 2. indicated the arrangement of roller paralell to tyre. The pressur between them is distributed uniformly along their entire widths. The shape of pressed fus is rectangular, If all the pair of roller and tyre are adjusted to this state, when the kil rotates it will move down by its own downwards sliding fore. It there is hydraulic thrus roller in design. Lf can control the downwards movement of kiln. Case I indicate desired working condition, Case 2, 3 are that the roller axes and oblique to the kiln central line in the plant perpendicular to the connecting line between the centers of roller and tyre. In the case, th maximum contact pressure is located at the central part of contacting zone, the shape o pressed fuse appears rhombics. If the rotation direction is as shown in Fig 2, in case the kiln is pushed upwards while in case 3 the kiln is pushed downwards. Case 4 is that the roiler is oblique in vertical plane, the maximum contact strss occurs at lower end and the shape of pressed fuse appears triangle, Since the roller is not obliqui to the central line of kiin axes. There is no force in horizental plane, accordingly the kilr doesn’t tend to ascend or descent in axial direction, Case 5.6 show that the axes of roller are oblique to the kiln-contral line both it horizental direction and in vertical direction. In this case, the shape of pressed fuse for the ‘two eases also appear triangle. For caseS, the maximum contact pressure occurs at thi lower end while in case 6, the maximum contact pressure occurs at the higher end the kil tends to be pused to descend. The test procedures are as follows: (1) Number and mark the measuring points on the kiln shel! close to the tyre fo1 every support. For each support, there are three points, which are.uniformly distributed o1 the external circumference of kiln shell. The measuring points with the same number for all the supports should be located on the same generatrix of kiln shell. (2) The testing fuse should be strengthed straight and a little bit longer than the widd: of the corresponding roller. According to the measuring point numbers, number the testing fuses for every support, and then these fuses are put beside the corresponding tyre ir sequence. @) Measure the width, and thickness of pressed fuses, and fill up the Fig 3 with measuring results. (4) Draw the broken line plot in which the abscissa shows the circumferential position of the kiln shell, the ordinate shows the. width of pressed fuse. Then, analysis the measured results presented in the analysis table, Take the measured results in Fig 3, as 12Rag example, the analysis is as follows: ‘Those rollers whose states are case 1 are basicly paralell to the kiln central line, th widths of perssed fuses are smaller, it implies the loads in these supports are not large of the abundance of contact strength is larger. The rollers whose states are case 2 are oblique lightly and it is notices at field that two rollers at this support all moved downwards, there is a tendancy that the kiln pushed upwards, the judged roller obliquenesses are shown in Fig 3. The fact that th Width of pressed fuses for the left roller are larger than those for the right rotler indicat the left roller is closer to the kiln central fine than the right roller. The broken line plo} implies the kiln shell is slightly bent and is convex to measuring point 3. The rollers whose states are case 3 are also oblique. It was observed at field that th ‘svo rolters a the support all move upwards ie. there was a tendancy that the kiln is pushe downwards. The roller oblique states judged are shown in Fig 3. The widths of presse fused for the two rollers are almost equal, which implies the two roller are loade uniformly. The widths of pressed fuses at this support larger than those for other support ittindicates the large supporting load and smaller margin of contact strength i, ¢. two ce are closer to the kiln central line than the rollers for other supports. The broken line show: that the kiln shell is stightly bent and is roughly convex to point 2. “The rollers whose states are case 4 are a little bit higher at the lower end. It is notice on site that the rollers moved upwards, i,e, the kiln tends to descend. The judged mt obliqueness is sown as Fig 3. The broken line indicates that the shell is slightly bent an convex to point 2. To judge the beding state of kdin central line more precisely, one circumference 0 kiln shell can be uniformly divided into 6 or 9 sections by 6 or 9 measuring points, ge. 0 or two measuring points can be added respectively between measuring point 1~2, 2~3 3~1. Take the left roller in case 2 as an example, the modified broken line plot is shown i Fig 4 for 6 measuring points on one circumference of kiln shell, which indicates the kil shell is convex to the point between 3~ ‘During the installation of kiln, it is ensured that axes of rollers, are parallel to the kil ceatral line.,The shape of pressed fuse shou!d appear rectingular. The loading of evt roller can be roughly judged according to the width of pressed fuse. Those rollers, wh Toads are larger than what they should be, can be drawn parallelly out a lite bit from kib centrat line, conversely, the roller can be parallel moved towards the kiln central line litte bit. It is noticed that the adjusting amount for each time can not be too large. ‘The nonnal operating condition should be reached by multiple adjustments Generally, the only 1/8~1/16 turn adjustment of roller bearing pedestal setting bolts will give difference pressing fuse test results, The detailed records should be made by th: relavent plant department for the every adjustment so as to facilfate correct judgement o| practical state of kiln, ‘The different roller oblique directions“in. horizontal plane for any two supprots rq not allowed, The case 2 and 3 in Fig 3 show the different roller directions for two support and case 4 shows the different roller oblique directions in one support. The roller obliqui states in ease 2,3,4 are all not allowed. the reason, for this is those roller obtique states lea to undesirable countact between the roller and tyre, the forces acting on tyre by the rolle| 1%