CONTRACT INSTRUCTION MANUAL No.: 70021679 AIR SEPARATOR SEPAX 500M-222 CUSTOMER NAME: PLANT LOCATION: FLSMIDTH CONTRACT NUMBER: FLSMIDTH EQUIPMENT NUMBER: MANIKGARH CEMENT, GADCHANDUR MAHARASHTRA, INDIA 10-20708 533.SR300, 533.MD302, 533.L303, 533.GS305, 533.FV306, 533.FV308 Ver. By Date Description 1.0 A Vijayakumar | “daJan 2073 Oniginal Issue Gismiotn FLSmidth Pvt Led. FLSmidth house 34. lysmoor Kelambakkam (Old exhadalipuesi road) CHENNAI 600 403, INDIA. Document 70021679 Version La)INDEX DESCRIPTION SECTION 4 - INSTRUCTIONS FOR FLSMIDTH PRODUCTS Erection, operation and maintenance for SEPAX 2S SEPAX Running in and operation Manufacturing instructions, Grease Lubrication, Unit GLU Shrink dise mounting and dismantling SECTION 2~LIST OF PARTS Main Parts List for Air separator SEPAX 500M-222 Separate Parts List for Module Top 2 Separate Parts List for Module Separator 2 630mm Cone vaive Separate Parts List for Module Bottom 2 Air separator Sluice Valve @200 Separate Parts List for Access platforms SECTION 3 -~ FIELD ERECTION AND ASSEMBLY DRAWINGS Main Arrangement Drive arrangement Grease Lubrication Unit Cyclone assembly 1 Cyclone assembly 2 Top arrangement Bearing arrangement Separator arrangement 1 Outlet valve assembly Bottom module assembly Sluice valve assembly Platform assembly Document 70021679 3703-11 33331-04 3461-06 30000970 39801-03 80046230 50044387 50044202 so030214 50044563 5.025630 50046710 1030675 10292573 1.217843 1.225878 40211074 10219560 10232655 10221036 2.070177 10219438 2.078974 10232464 24 10 10 7.0 10 10 10 10 10 1.0 1.0 10 10 1.0 20 20 1.0 40 10 1.0 1.0 10 10 10 Version 1.0DESCRIPTION SECTION 4 ~ SUPPLEMI ‘AL VENDOR INFORMATION SHAFT LUBRICATION SYSTEM Operation & maintenance manual for centralised grease lubrication system Dimensional sketch for grease lubrication system MOTOR Dimension drawing for Motor REDUCER Dimensional sketch for reducer with couplings Operation and maintenance manual for Gearbox SECTION 5 - WEAR PROTECTION INFORMATION SEPARATOR ‘Ceramic wear protection Installation Manual Document 70024679 DOCUMENT —REV/VER 60115620 10 60092475 10 60118381 10 60093110 10 60114486 1.0 5.705990 10 Vossion 1.0 TAB 4PART-1Separator SEPAX 2S Installation, operation and maintenance Approved date: Created by: GR-IN Approved by: Doc. No.: 37031-11-2.1Separator SEPAX 25 Giismiotn 37031-11-2.1 List of contents: Page: 1 General information...csssssssssescsssteeeeecssstiessnssnnescanneses 4 2 Construction and operating principle. 4 21 4 244 4 212 oS 22 4 . . . 5 3. Installation , seosssneeetssusuneesssccniesssssinessssoseeeasen 6 BL seve eos 28 3.2. Installation sequence .. 6 4 Operation ...... 8 41 Trlal-run . 8 AAD ce ceoceisnnneesenionnsanieeeninas 8 AMZ cece 9 4.2 Initial start-up. 9 4.21 o 8 4.2.2 9 4.2.3 9 4.2.4 5 Maintenance... 5.1 Preventive maintenance 5.1.1 Lubrication 5.1.2 Cleaning . 5.1.3 Checking of condition... 2 Faults and remedy. V3 REPS easesscsnsernesene 5.3.1 Replacement of rotor (15). seeaeenesagtinnnee 5.3.2 pe cone 32 5.3.3. Replacement of bearings (39) and (40) «sss. 12 B34 eecesees sane eee 3 6 Appendices 13 Appendix 1 Layout sketch Appendix 2 Bearing housing Appendix 3 Outlet valve Appendix 4 Flow measuring points 17 List of fiqures: Figure 1 Layout sketch........ Ficure 2 Bearing housing Ficure 3 Outlet valve .. Figure 4 Flow measuring points Jpay Tre teanaion eabboneied by #5 document Te peDnlny Sha Canta BIRpTY OF SET Dr eiay noe be mupncated, dscosed or utired manout keen ceraan Hom FES,Separator SEPAX 25 37031-11-2.1 f tabl Table 1 Preventive and maintenance. eostenennans seen 10 Tha iteriatn Farn ed By Te decuiem We wapreinny and cence] Opes PFESOAEH Nap nor Pe cuplentes, beset gr utiaea weave mien conser 8"Separator SEPAX 25. Gismiorn rosie NOTE! The present instruction manual is concerned with the situations, which, according to the experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all conceivable situations, which may occur during the installation, operation and maintenance of the seperator cannot be provided Consequently, if 2 situation should arise, the occurrence of which is not foreseen in the | instruction manual, and which the Speretor 'sfor feels unable to handle, it is recommended that FLSmicth is contacted without undue delay for advice on appropriate action. { content of abrasive dust. Nota! ‘The bearing arrangement of the separator Is very crucial as concerns correct lubrication. The bearings operate at high temperature, with vibrations and have vertical shafts. The bearing housing is subjected to varying negative oressure and surrounded by exit gas with a high Therefore it is very important that the bearings are charged with clean lubricating grease at the intervals and of the quality and quantity specified in sub-sections 5.1 and 5.1.1. 1 General information The SEPAX separator is used In a closed-circuit grinding plant for separation of the fines from the coarse material which Is received from the mill. Subsequently, the fine fraction is separated in 4 cyciones, arranged in a planetary system, and at this stage the fines are referred to as the finished product The coarse fraction Is recycled to the mill inlet for further grinding The grime function of the separator is to improve the grinding efficiency of the grinding plant, ut also to widen the scope far adjustment and control of the fineness of the finished product. See Appendices 1 and 2 2a The 3 main features of the separator are ‘The separator section (01}, the dispersion section (02) and the cyclone section (03). 244 ‘The separator section consists of a separator housing (13) which rests on a Supporting bracket (17) and is provided with suspension brackets (50) for the cyclone section (03). ‘The separator housing contains a rotor (15), which is surrounded by @ series of fixed, vertical guide vanes (14) Under the rotor there is a cone (16) with a reject outlet (18). The outlet is provided with 2 weighted and springloaded cone valve (19) which functions as an air lock. The outlets (11) for the separation air and the fine fraction are mounted in the top part (10) of the separater and conduct the air inte the cyclone section. APT TSE vernonia iy Be esumene a uv wry ond waPPaT Ear ont of SE ad mor nut dupcated 2Separator SEPAX 25 37031-11-2.1 2.2 2.4.2 The_cyclone_section_ (03) consists of 4 cyclones (51), arranged in a planetary system, in which the finished product is precipitated when the fine fraction leaves the air separator together with the separation air, The airstream leaves the cyclones through two parallel duct systems (34) for air discharge. The rotor (15} is equipped with vertical blades (32). Its shaft (30) is connected to the rotor by means of a fixed flanged coupling (12). The shaft is supported by a bearing housing (08) (see Appendix 2) in two spherical roiler bearings (39) and (40), Bearing (39) mainly functions as thrust beering, whilst beering (49) functions as journal bearing. The bearings are grease-lubricated. The rotor is driven through 3 gear unit (06) which is mounted on a bracket (07) on top of the flange (38) of the bearing housing, The gear unit is provided with a supporting bracket for a thyristor motor (04). Flexible couplings (05) are inserted between the gear unit and the motor and between motor and separator. 213 The dispersion section (02) consists of a riser duct (21) and a base part (24). The inlet pipe (20) for grinding material is located in the riser duct. The inlet pipe is equipped with an air lack (22) and a spreader plate (23). In the base part there is a spreader cone (25) as well as air intake (27) and outlet {28} for material drop-through. ‘The operating principles of the SEPAX separator are as follows: The separation eir flows through the separator} the airstream enters through air intake (27) and leaves the separator through the outlets (11) The ground material from the mill enters through inlet pipe (20), passes the air lock (22) and falls down on the spreader plate (23) whereafter the material is dispersed as it Js swept upwards in the airstream On its way from the intake point the separation air passes the cone (25), which also participates in the dispersion of the grinding material, so as to prevent material dropping through from building up in the air intake (27) Tne material drop-through consists of heavy elements in the grinding material, 35 for instance worn grinding media and nibs which bypass the cone (25) and drop into the base part for subsequent discharge through the outlet (28) Afterwards the mixture of separation air and grinding material flows up through the riser duct to the separator unit. Here the mixture first passes the series of fixed guide vanes (14) before it enters the rotor. The guide vanes ensure that the airstream is evenly distributed across the entire rotor. Separation is now effected which involves that the mixture of air and grinding material is swirled along by the rotor blades so that the coarse fractions are thrown against the fixed guide vanes as a result of the centrifugal force, so that the coarse fraction drops into the reject cone (16). Fram here the tailings are returned to the mill. The fine fraction passes the rotor and is conducted by the separation air to the cyclone section where it is precipitated as the finished product. Te bioTmali Savgmlea by Tra document propnetany Bad eoNMIENCEI Sot may not be dupicatee aclesed er urnred wecet wen concGismiotn Separator SEPAX 25 37031-11-2.1 3 Unstallation [In instances where the installation manual calls for an INSPECTION to be! carried out, this means that the parts mounted must be inspected and approved by the FLS installation supervisor before the installation work can be continued. Installation to be made in accordance with the following drawings. 3a 3.2 Foundation and installation drawing. Assembly drawing of bearing housing. (See parts list sheet 02, line 23). Assembly drawing of separator section (See parts list sheet 06, line 23). Assembly drawing of dispersion section. (See parts list sheet 07, line 23). Assembly drawing of cyclones. (See parts list sheet 11, line 23) Flanged joints to be packed with waterproof sealing cord. See also assembly drawings. NOTE! Certain installation-related operations may have been performed in the workshop during the trial assembly. Installat In sequence 1. Mount and align the inlet cone with supporting bracket (17), The upper edge must be horizontal and circular. 2. Orientation of the upper part of riser duct to be related to reject outlet, and fix the riser duct by welding. Align outlet pipe for tallings (18) in accordance with the reject cone (16) end fix it to riser duct (23) and reject cone (16) by welding. 3. Orientation of riser duct (24) with the inlet for grinding material (20) to be related to the associated Fluxoslide, whereafter the riser pipe Is fixed by welding. 4. Orientation, with spreader cone (25) in lowermost position, of air intake (27) relative to the pipe system and weld to base part (24). 5. Mount louvre side plates (63). Secure nuts by welding. Place guide vane ring (14) 09 reject cone (16) 6. Mount and align the separator housing (13) on the inlet cone (17). In the process, check that the top flange is concentric with the inlet cone (17), that it is placed in the horizontal plane, and that it is circular. We would recommend that spacer flange (22) be mounted both during tack welding operation and during the final welding operation INSPECTION sn? Thc Ty aua Hane ed by Or dork aR pre alp a cancer papery oF FES ‘Sno map nor be uphated,sscinsey pr utinms what Witen consort Hei PLOTSeparator SEPAX 25 Sonat Gismiorn 7. Finish-weld the parts (13) and perform final welding to inlet cone (17). 8. Mount spacer flange (29) with packing between the top flange on separator housing (13) and spacer flange (29) 9. Place and centralise rotor (15), with fitted sealing ring (31) in the separator, loosely supported on the spacer flange (29). 10.Orientation of top part (10) to be related to cyclones and place it on the spacer flange (29) 11.Mount top cover (09) with sealing cord to the top part (10). Align the top part with top cover so that it is horizontal and concentrie with the inlet cone (17) and spacer flange (29). INSPECTION 12.Fix the top part (10) to spacer flange (29) by welding. 13.Prlor to mounting the assembled bearing housing make the following checks: Dismount the upper bearing cover (37). Check that the bearing is free from corrosian and completely filled with grease, ‘At the same time check that clean grease protrudes from the lubrication duct and that Its opening is free when the bearing housing has been assembled Loosen the lower bearing cover (41) and pull it so far away from the bearing housing as the flanged coupling (12) permits. Check to the extent possible that the bearing is filled with grease and thet there are no indications of corrosion if this inspection gives rise to assume that something is wrong, the flanged coupling must be dismounted to permit convenient access to the bearing Remeount the lower cover when everything has been found to be in arder, Fix the bearing housing (08) on top cover (09). 14. Mount flange coupling (12) and the lawermost nut for shaft (43) Do not forget to drill and fix the safety split pint INSPECTION 15.Tighten up flanged coupling (12} and rotor (15), Remove mounting bolts (60) INSPECTION 16. Let seal ring (31) remain loose, supported on the rotor. Insert bolts (61) so that they just reach through spacer flange (29). Turn the rotor slowly, with the sealing ring sliding on top, and minimum one complete turn for each of the following markings. Off each single supporting oracket on the sealing ring, mark off the highest sealing ring position relative to the spacer flange. Based on the marking, calculate the total thickness of the shims to be inserted off each single bracket connection, by adding 2 mm to the thickness which would position the sealing ring outside the marking INSPECTION The Waviation Devamfied by ts Tesomene We progr itary ara coutdcntay promot of FURIE Di map hot be duigatee, Uictued or uiined wenout wikten cement fear HSI warGiismiotn Separator SEPAX 2S 37031-11-2.1 17.Apply the sealing compound (62). 18.Centralise guide vane (14) around the rotor (15) INSPECTION 19.After guide vane (14) has been centered with the rotor, it is guided at the top by means of 16 guide blocks (64), which must be welded to spacer flange (29). Note that the activities specified in items 18 and 19 have normally been completed during trial mounting in workshop INSPECTICN 20.Mount wear plates, if any, in cyclones (51). 21. Suspend cyclones (51) from a crane and assemble them with flanges (49). 22, Check the axes of the cyclones with subsequent adaptation of the bracket parts for cyclone (50). INSPECTION 23.Fix brackets (50) and cyclones (51) to the separator by welding. 24, Dismantle the crane suspension 25.Weld the upper sections to the cyclones, and mount the duct system for air discharge (54) 26.Mount gear unit (06} on bracket for gear unit (97) and fix the parts on the separator, Check that the coupling halves engage correctly. 27, Mount connectors for flow measuring points (56) as indicated on Figure 4 Connectors to be positioned so that reasonable access conditions are provided and so that scanning with Pitot tubes can be made over the most representative flow in the cross-section involved. To complete the installation, advertising signs must be posted in 2 conspicuous place and scratches, if any, must be repaired with the paint supplied for this purpose. -~4 Operation 41 It wes checked in workshop that rotor (15) is circular and concentric. Prior to triai-run It must be checked that the bearings are charged with lubricating grease as specified in sub-section S.1.1 and that rotor (15) has not suffered damage during transport or installation INSPECTION 444 When trial-running at site, stepping up to full speed must be done siowly ang gradually, When triai-running, check that the vibration level of the separator is $0 low that the vibrations are not expected to cause damage to the separator or any nearby structures ‘A high vibration level may be caused either by imbalance or resonance in the support. Gyan Tie rate Tavares Socaent he Prapiay snd concen rey OTA dno may Rod Be cate, scosed ov wilt! wahout conten eorse Dt HM HC SMCR,37031-11-2.1 Separator SEPAX 25 Giismiorn 42 The vibration level can be reduced by balancing at site. The table below indicates the permissible rate of residual imbalance at the top and bottam of the rater, SEPAX size ]U (om) | S€PAK Sze | U tam) 250 iso) a85 416 265 so | 375 400 280 170 | 400 \790 | 300 270 425 920 35 aio | as 4050 335 360 Jars j 1210 Vibrations originating from resonance can be reduced temporarily by changing the speed and permanently by bracings which counteract the ascertained movements. Separator to be trial run for approx. 0 minutes as follows: 1, Operate the separator at 1/3 of the maximum speed for 30 minutes. 2. Operate the separator at half the maximum speed for 30 minutes. 3. Operate the separator at maximum speed for 30 minutes. Note! During the trial run the bearing temperature must not exceed 70°C. If the bearing temperature in any of the bearings should rise beyond this level, the trial run must be stopped for a few hours. When the separator is put back into operation the | bearing temperature will normally not become too high Check that the outlet valve (19) opens and closes without difficulty and that no friction occurs while the valve is moving. 41.2 Use the counterweight to balance the valve after the spring has been dismantled. After the vaive has been balanced, the spring must De mounted and tensioned until the valve is Just kept closed jal start-up 424 See separate instruction manual for cement mill plant with related Instruction manuals. 4.2.2 The rotor speed and the amount of separation air must be set for the nominal ratings given in the process manual for mill plant. 4.2.3 ‘The fineness of the finished product can be adjusted by changing the speed of the rotor and the amount of separation air es follows: 1, If the speed is stepped up the fineness of the finished product will be increased: “he ie pain Wonarnttea by sa nent fs Hie proprietary and covbaential property OF FLE rosa Seg mop ho be duce, diosa ws uitag momen nen consort 2m MSM A on?Giismiorn Separator SEPAX 2S 37031-11-2.1 2. If the speed is stepped down the fineness of the finished product will be reduced, 3. An increase in the air volume will result in 2 coarser finished product 4, Areduction in the air volume will result in a finer finished product. ‘The highest efficiency Vs, and hence the best grinding economy, is attained with a large air volume, For further details, see the process manual for the cement plant 424 Check the motions of the outlet vaive (19) at regular intervals. In case the outlet valve is not working regularly, the valve cone (47) must be balanced, This is done by moving counterweight (44) to another position or by tensioning the spring (46). See sub-section 4.3.2, _5 Maintenance Note! | The bearing arrangement of the separator is very crucial as concerns correct lubrication. The bearings operate at high temperature, with vibrauons and have vertical shafts, The bearing housing is subjected to varying negative | prassire srd surround by exit gas wits a fgh content of abrasiwedust. | Therefore t is very important that the oearings are charged with clean lubricating grease at the intervals and of the quality and quantity specified in sub-sections 5.1 and 5.113. Ibis ial th: made for 8 hours of operation in order to en: that no severe vibi ur while the separator, ratiol to make sure that outlet valve (19) is working properly, At the same time, check that the volume of fines separated by the cyclones is roughly the same. If not, it will be necessary to remove the possible plugaage, f. inst. fareign matter, wear plates which have worked loose or substantial material build-up in the cyclones or in the inlet and discharge pipes 5.1 Preventive maintenance 1 Lubrication 4 Checking of condition 06 Gear unit See separate instruction manual 19. | outlet vaive im J. | a ' 39 Upper roller bearing = S . . . Table 1 Preventive and maintenance Joya Pee wi vars fy tn aaa propia a woe Papas ae FT Te Se moy tbe doped ncogen wwe out aeten carmen fer sthSeparator SEPAX 25 sna Gismorn D_ = per 8-hour operation A number in from of the letter S = weekly indicates frequency of procedure. M = monthly For instance 2M = twice @ month A = yearly T= see text in instruction manual S11 Lubrication ler bear and Charge grease through the grease nipples of the bearings. For bearing (39) through grease nipple (35). For bearing (40) through grease nipple (36) rea The lubricating grease must be applicable at temperatures up to 1408C and have a basis oi! viscosity of more than 500 mm‘/s at 40°C and must contain EP additives and specially suited for lubricating bearings with vertical shaft, ive, have high achesion properties. Grease quantity: See table below. Separator type | Grease quantity in grammes i Bearing (39) | Bearing (40) 250 70 40 | 26s 70 40 280 70 40 300 90 60 j 31s 190 60 I 595 80 60 355 90 60 375 180 110 400 180 110 425 180 110 450 j 180 jt10 475 260 160 5.1.2 Cleaning General cleaning 9f and around the machine. The seperator must be kept clean $0 that leakages and oil spillage can be detected. 5.1.3 Checking of condition Separator (00 Inspect the separator. Check all parts for tightness, wear, corrosion and material cakings. Check for loose bolts at all joints. Outlet valve (19: Check the valve cone for material cakings and carrosion. Balance the cone as mentioned in sup-section 4.4.2 Tre iorntcn Faseinited by this document = tha prapn ataiy aa cavhae Grd ay no? Pa ourbeateT tsetse op wtuead or RD.t Wr(ismiorn Separator SEPAX 2S 37031-11-2.1 5.2 Faults and remedy Fault Irregular working of outlet valve (29) Remedy Tension the spring (46) and/or move the counterweight (44) a little further outwards on the lever (45) See also sub-section 4.1.2. Fault: Abnormal vibrations in the separator. Remedy: In case severe vibrations are ascertained in the separator, the mill Installation must be shut down immediately end the cause responsible for the vibrations must be Identified. The vibrations may be caused by material cakings on the rotor blades (32) or the reason may be that the wear rates on blades are so unevenly distributed that the resultant difference in weights gives rise to the vibrations. All material cakings ta be removed, and worn rotor blades, if any, to be reconditioned or replaced. if required, the rotor must be balanced, See sub-section 4.1.1 5.3 Repairs 5.3.1 Replacement of rotor (15) 1. Dismantie gear unit (06) with brackets (07) and moter (04). 2, Fasten the rotor (15) to sealing ring (31) with 4 installation screws (60), Release the rotor from the shaft by dismantling the flanged joint (12). Dismantie the top cover (09) with bearing housing (08) 5. Lift the rotor to one of the sides. 5.3.2 Sequence of remounting to be reversed relative to that applied during dismantling. Adjust the distance between sealing ring (31) and the upper limitation as descr bed in sub-section 3.2.16 After the rotor has been remounted, the separator must be trial run as mentioned in sub-section 4.1 5.3.3. Replacement of bearings (39} and (40) 1. Operations 1 through 4 mentioned in sub-section 5.3.1 to be carried out. 2. Dismantle elastic coupling (05). Dismantle shaft nut (43) Dismantle the flanged coupling half (12). Dismantle nut (33) with lock washer. Fa? 7 Te ator Wane By Bs dct ha Bocaretany a EPG aoal DETR 2 FSA ray wee be Guphcate, digclseu 0” utined mad mitten concent IID tH SmithSeparator SEPAX 25 37031-11-2.1 Dismantle the bearing housing covers (37) and (41). Force the shaft out of the bearing housing. For dismounting and mounting of roller bearings: See separate instruction manual 3. When remounting tne bearing Rousing unit, focus on the following points: A, Sealing rings (34) and (42) and shaft bushing (48) must not be scratched or otherwise damaged. B, Seal rings to be mounted as shown in Appendix 2. 5.3.4 Repair of hard-wearing castable or grouted-in wear reinforcement, to be made in accordance with the special directions given by the supplier. Generally speaking, reinforcing steel must be inserted by welding in connection with the casting, or grouting-in, in order to hold in place the castable, or the mortar. Mortar for basalt is normally: Cement/sand = 1/3 6 Appendices See next pages. The informacion anam™iten By this document 4 (he prayvietary anu Contidertes PrOBeYTY OF ELSIOIARA od boy nol be dusiaste erioeen ey und siiaut Wien consent fom FLSImth 1a?Gismiotn Separator SEPAX 25. 37031-11-2.1 Appendix 1 Layout sketch Gi, Separator section 23. Spreader plate 02, Dispersion section 24, Base part 03. Cycione section 25, Spreader cone 04, Thyristor motor with bracket, | 26. Collector box for material drop-through 05. Flexible coupling 27. Air intake 06. Gear unit 28. Outlet for material drop-through 07, Bracket for gear unit | 29. Spacer flange 28. Bearing housing 31. Sealing ring for rotor 09. Top cover with adjusting screw for | 32. Rotor blade bearing housing 49, Cyclone flange | 40. Top part 50, Suspension bracket for cyclone 11, Outlet for fines to cyclone 51. Cyclone 12. Flange coupling, shaft/rotor 52. Outlet for air 13. Separator housing 53, Outlet for finished product 14, Guide vanes 54. Duct system for air discharge 16. Reject cone 60. Mounting bolts Tayay The rmatien wararnite bv Wes ocurmert the prophecy ane canteen aroperty of PLS Can may sot a dunteorag octane aitrout w'eten consent fam F StSeparator SEPAX 25 Gimom 37031-11-2.1 (1? inlet cone with supporting bracket | 61. Adjusting screws: 18. Reject outlet 62. Sealing compound 19. Outlet valve 63. Wear plate for louvre 20. Inlet pipe 64. Guide block for iouvre pin 21. Riser pipe 22. air lock Figure 1 Layout sketch Appendix 2 Bea’ 9 housing Lo — 05. 07 08. haa. 30. 33. 34 35. L3s. Flexible coupling Bracket for gear unit Bearing housing Flange coupling, shaft/rotor Shaft Upper nut with lock washer Upper sealing rings Grease nippie for bearing (39) Grease nipple for bearing (40) Figure 2 Bearing housing 37. Upper cover for bearing housing 38. Flange for bearing housing | 39. Upper bearing 40. Lower bearing 41, Lower cover for bearing housing 42. Lower sealing rings 43. Lower nut for shaft 48, Shaft bushing Ths inion tanned By Os document is Pre prapiwtary aid TondaenIa DOpeny ot FLSMIarh Sind may rot be cucated, csclosed er uid winout tren consect Fos 1s/7Gismiorn Separator SEPAX 25 37031-11-2.1 Appendix 3 Outlet valve -| @ 18. Outlet valve | —! 44, Counterweight for cone valve Lever 46, Valve spring | 47, Valve cone Figure 3 Outiet valve, Jen ine inisinton anemia srs may By ais aacwinent ve te Broprotary Sid GanizenTa property OF FLSMIGG cate. ascised wr utlicer wAROe! iter canara Here: Sct37031-11-2.1 rator SEPAX Separator SEPAX 2S Gismiorn Appendix 4 Flow measuring points 56. Flow measuring point, i off In each cyclone inlet 98. 1.1/2 in. screw plug, 2540 59, 1.1/2 in, socket, 2400 Figure 4 Flow measuring points Fie adoration aiSiTRREO DY Wis GECUTETE TS We proprietary 27a coronal property of FESO Shut may not Be Oupteates, @Scosed or hve wnout wmean Eanes fmm FS warfis E LSMIDT INSTRUKTIONER: INSTRUCTIONS INSTRUCTIONS. ANWEISUNGEN — INSTRUCCIONES —_INSTRUCOES 33s3i-04 | 1/24 SEPAK Air Separator Running-ih and operation of air separator 33330-01-1 Sketch of bearing housing 33330-01-11 Sepax, type 1C, layout 33331-O01-I1T Sepax, type 2C, Layout 33331-O01-IV Tromp curve calculation form - example 33331-01-V Example of operating data from plant 33331-01-vVI Example of operating data from plant Example of operating data from plant Grain curve Grain curve Tromp curve Tromp curve Tromp curve Form U-631 (4) Form U-641 (1) Form U-501 (2) Form U-531 (2) Form U-541 (2) Form U-5421 (2) Tromp curve calculation form Text reference is made to_the following instruction Unidan mill a Mills, performance test, instructions Contents: 1. GENERAL 2. STRUCTURE AND OPERATING PRINCIPLE 3:_START AND STOP OF AIR SEPARATOR 4. RUNNING-IN 5. OPERATION _TROUBLE-SHOOTING AND_REMEDY 33331-O1-VII 33331-~O1-virr 33331-01-1% 33331-01-X 33331-01-xi 33331-01-xi1 33331 -Q1-xra1 33331-01-x1Vv 33331-O1-KV 33331-01-xvr 33331-01-xVaT 3331-O1-xVIIT 33331-03-rxx 33331-01-xx sso 23821 15 ig-.1- Bemark! Narrvarende instraktion omhandler de situationer, sont FLS bar ertaring for, er de aftest fore koromtende, En udtommende opregning af samtligt tenkelgesituationer, som mite kunne opsts under montage/sriftvedligeholdelse af anleggeUmaskinenudlstycetlader sig ikke gore. FLS skal Gerfor tirade, at sifremt der matte forehorume en situation, som ikke er omhaadet i instruktionen, og som brugeren ikke ereller vurderer sig selv fortrolig med handkeringen af, at FLS aden ugrundet ophold hontahtes med henblik pi indhentelse af nsermere veledning Note! ‘The present instruction manual is conceroed with the situations which, according to the experien- ce of FLS, are the most fikely to occur. An exhaustive enumeration of all conceivable situations which may occur dusing the erection/operation/maintenance of the plant/machine/equipment ‘cannot be provided. ‘Consequently, if situation should arise, the occurrence of which is eo! foreseen in the instruction manual, and which the operator isior feels unable to handle, we would recommend that FLS is contacted without undve delay for advice on appropriate action, Amportant! ‘Le présent manuel d'instructions teaite des situations qui, i la lunee des expériences de FLS en ta matitre sont celles que I'on rencontre le plus souvent. Une équmération exhaustive de toutes les situations susceptibles de se présenter au cours du montage/de exploitation’ de V'entretien de Winstallation/de la machine/de réquipemsent n'est tout simplentent pas faisable. FLS vous invite par conséquent & contacter ses services sans délai afin de recourie rapidement ‘aux prescriptions plus détaillées dans le cas ob il intervient une sitaation qui. alest pas troitée ans le maanuel et que utiisateur n'est pas ou ne se sent pas en mesure de ms Achtung! Dic vorliegende Anweisung behandelt de Situationen, die nach Erfahsung vou FLS am hiufigsten entstehen. Eine erschépfende Autzihlung aller denkbaren Situationen, die bei Montage/Betrieby Wartung der Anlage/Maschine/Ausrustung auftreten konnten, st nicht miglich. Deshalb empfichit FLS, dali falts eine Situation entstehen sollte, die nicht in der Anweisung, ‘behandelt ist, und mit deren Bewiltigung der Benutzer nicht vertraut oder in der Lage ist 20 bewaitigen, daB FLS ohne schuidhaftes Zigern hinsichilich der Einholung naherer Richthinien benachrichtige wird. Observar! Las presentes instruccioncs versan acerca de situaciones que, segin experiencia adquirida, son Jas ‘que $¢ originan ms cominmente. No es factible listar una enumeracién exhaustiva de todas tas ‘condiciones iranginables que pudieren surgir durante el montaje/secvicio‘mantenimiento de ka instalacién/maquinayequipo, Por consiguenteven el suputsto de que se originara-una situacién que no ha side tratada en las Instrucciones y com la cual el usuario no estima esta familiarizado, 0 no verse en condiciones de solucionarla por si mismo, FLS recomienda tocar contacto, sin demora infundada, con FLS can miras a solicitar instrucciones de caricter orientatorias. ‘Observart As presentes instrugies tratam de situagées que, segundo a experiéncia obtids, sio as que apare- ‘cer com miais frequéncia. Néo é viivel ama enumveracio exaustiva de todas as condigdes iniagin— ‘eis que possam surgir durante 2 montagenvservico/manutencio da instalagio’maquinalequipo. Por conseguinte, no caso de surgir utoa situngia que pio tenba sido abordada nas instrugies e com a qual o usuério estinya nio estar familiatizado, ou mio estar en condigdes de a solucionar, FLS recomenda contactar sem demora a FLS a fim de solicitar instrugies de earacter orientative.39331-04 2 1. GENERAL Sepax air separators are used in closed-circuit mill plants for cement and raw meal. The air separator's main purpose is to improve the grinding economy of the mill plant, but in addition it improves the possibility of changing and con- trolling the product fineness. The grinding economy measured in power consumption (kWh/t produced) depends on the air separator efficiency. Improvement of grinding economy in closed-circuit mill plants relative to straight-grinding mill plants may vary from negative values for a low- economy six separator and up to 50% improvement when grinding to the same sieve residue. In the present instruction manual it is assumed that mill operation has been optimised. See in- struction manual for mills. Procedure for start-up of mili plant with Sepax air separator. ed Inspection, a) Separator inspection. See section 5. Complete u-s421. b) Mill inspection and measuring. See instruction manual No. 23521. Complete form U-53t. ©) Check instrumentation and remedy any defects. d) Check other machines in connection with the mill plant. See appertaining instruction manuals.33331-04 3 Optimising the sir flow. See sub-section 4.2. @) Measuring of air flow. b) Test No. 1 at nominal air flow. ©) Test No. 2 at 90% of nominal air flow. 4) Test No. 3 at 110% of nominal airflow. @) Test No.4, find optimum. See section 5, @) Optimising the circulation number. See sub-section 5.5.1. Controlled grinding test. See instruction manual No. 23521. Complete the appertaining operation and inspection forms.33331-04 4 2. STRUCTURE AND OPERATING PRINCIPLE See enclosures I and 11, 2.1 The air separator consists of two main components: Separator unit (01) and dispersion unit (02). 21d The separator unit consists of separator housing (13) which rests on a supporting bracket (17). The separator housing contains = rator (15) which is surrounded by a rim of vertical fixed louvres (14). Under the rotor there is a cone (16) with outlet (18). The outlet is provided with a weighted and spring~ loaded cone valve (19) which serves as air sluice. Outlet (12) for the fine fraction is placed at the top of the separator housing. Rotor (15) is provided with vertical vanes (32). its shaft (30) is coupled to the rotor by means of a fixed flanged coupling (11). The shaft is supported in a bearing housing (08), see enclosure II, in two spherical roller bearings (39) and (40). Bearing (39) serves mainly as axial bearing, whereas beering (40) serves a radial bear- ing. The bearings are grease-lubricated. The rotor is driven by a gear unit (06), which is mounted on a bracket (07) on top of bearing housing flange (38). The gear unit ie a hollow sheft gear unit provided with bracket for at thyristor motor (03). There is an elastic coupling (05} between gear unit and motor.33331-04 8 2.2.3 Dispersion unit (02) consists of a riser piper (21) and a bottom section (24), The riser pipe com- prises inlet pipe (20) for material to be ground. The inlet pipe is provided with an air sluice (22) and a spreader plate (23). The bottom section con- teins @ spreader cone (25) and air intake (27) and outlet (28) for dropthrough. 2.2 The SEPAX air separator functions as follows Separation air flows through the air separator, entering through air intake (27) and leaving the Separator unit through outlet (12). The material to be ground from the mill enters through inlet pipe (20), passes air sluice (22) and @rops on spreader plate (23) and is spread into the ascending separation air. On its path from the intake the separation air passes cone (25) which assists to disperse the ma- terial to be ground (blend the material evenly in the sir) and prevents that the dropthrough is col- lected in air intake (27). The dropthrough consists of heavy objects in the material to be ground and nibs which are bypassed cone (25) down into the bottom section, and are carried away through outlet (28).33332-04 6 Subsequently the separation @ir and material to be ground flows up through the riser pipe to the sepa- ration section, Here the mixture passes the rim of fixed louvres (14) before flowing into the rotor. The louvres ensure an even distribution of the air over the entire rotor. Separation is now taking place, as the mixture of air and material to be ground moving into the ro- ver, is accelerated between the vanes up to the periferal rotor speed. The fines accelerate very fast ond can pass the ro- tor. The coarse and heavy particles accelerate slowly and are caught by the rotor vanes, flung towards the Louvres by centrifugal force and drop into cone (26) to the outlet for coarse material. From here the coarse material is returned to the mill. The fine frecticn passes the rotor and is carried to a filter or cyclones by the separation air, whe- re it is seperated as inished material. Air separators in which the fines are separated in a filter sre designated 1. (E.g. Sepax 355, type i). Air separators in which the fines are separated in eyclone(s) are designated 2. Layout examples of the two types appear from encio- sures III and Iv.32331-04 7 3. START AND STOP OF AIR SEPARATOR Start and stop of the air separator are part of the ordinary procedure for start and stop of closed-circuit mill plants. It is characteristic of Sepax air separators that a certain minimum sir volume must have been esta- blished before the elevator is started. Correct se- quence is not enough. There must also be a time delay so that the fan damper opens and the regulator maintains the air volume in dependence of the motor load. 4._RUNNING-IN Before running-in, the air separator must be inspected, Check and measure the following: Dispersion section: ~ placing of baffle plate (23) - diameter of baffle plate (23) - placing of cone (25) The baffle plate is normally placed at a distance of approx. twice the feed pipe diameter below the feed pipe and cone (25) in the lowest position, de~ termined by the bolt hole positions. Check the centring of the entire unit.33331-04 8 Rotor unit - Measuring of gap between rotor top flange (31) and seal ring (29). See enclosure 1. (Must be as small as possible, max. 5 mm). ~ Checking of concentricity ef rotor end louvres. Check the entire circuit for any leaks (false air sources), joints, hatches, etc. Sepax air separator has two control options: 21. Rotor speed. 2. Air volume, The two parameters are co-related so that it is possible to produce the same fineness at different rotor speeds, depending on the air volume. Control options: a) Constant air volume: Lower speed coarser product Higher speed - finer product b) Constant speed: Lower air volume = finer product Higher air volume ~ coarser product ¢) Contstant product finenes: Higher sir volume higher speed Lower air volume = lower speed33331-04 8 The nominal speed and air volume at the fineness concerned is specified in the Process Design dia~ gram. This is for guidance oniy, since the accu- rate air volume is unknown and may deviate from the nominal volume {measuring ineccuracy, false air volume, etc.). Running-in the Sepsx air separator consists mainly of optimising the air volume. See sub-section 5.2. The air volume must subsequently be kept constant end the fineness solely be determined by changing the rotor speed. 4.2 As the air volume has high influence on air separa- tor efficiency, ir must be ensured that the air vo- lume is correct so es to obtain optimum operation. Measuring of the air volume wili depend on the type of air separator. For__type 1¢ the air volume can be measured accura- tely in the air intake by means of a Pitot tube. See Fig. 1. Make measurements st 4 different air volumes and read the static pressure at the same time. Then trace a diagram, piotting the air volume relative to the static pressure.33331-04 10 @ amin ps mm W.6, Fig.2 The ratio between air volume and static pressure should be linear. For jiater air volume optimisation it will do to read the static pressure. To check, measure the air volume in the stack. This air volume includes the false air, hence it will be typically epprox. 108 higher. For air separator, type 2¢ there are no measuring Possibilities which ere sufficiently accurate. Fig. 3. shows the measurement after the air intake. Measurement is difficult and act quite reliable, because it is made close to the bend and nampered by a flat cone bottom right over the intake. Fig. 3LL The expected air velocity profile becomes: vines dime Fig. & Another possibility is to measure the air volume in the return air pipe. This may be quite difficult due to the dust in the air which obstructs the Pi- tot tube. Measurements should he made very fast, and the Pitot tube must be blown clean after each measurement. The measured air volume may contain a false air volume, depending on the position of the dedusting pipe. See enclosure Iv. It applies to both types that if the fan is provi- ded with a thyristor motor and automatic control of air volume, there will normally also be an air vo~ ume reading. The read sir volume will also inclu- de false air. The air volume reading must be checked by measuring with the Pitot tube in the stack or in the return air pipe at idling speed and at the same time read~ ing the air volume indicator.33331-04 iz © measured Q read Fig. 5 Now the reading can be used end corrected relative to the diagram. Moreover the fan diagram can be used to check and estimate the air volume. Only after the air volume has been determined it is Possible to actually optimise air separator opera~ tion. 4.2.2. Test No. 1 1. Start at nominal air volume. 2. Adjust the feed and air separator speed to the required fineness. 3. The mill plant must operate in balance for approx. § hours with this adjustment. Complete forms U-631 and U-641 hourly. If soe data are missing, the reason should be found (missing or detective instrument, no possibility of measuring, etc.). Apart from that, explain the reliability of the various readings and measurements. Instruments should have been checked and adjusted.33332-04 ia a) Braw samples of fines, material to be ground and coarse material hourly and screen them. Depend- ing on site conditions deverming. Blaine ISR Sieve residue, Alpine: 32y or 45p 63 or 90p and if it is possible to make a Ciles (or corre- sponding) analysis, grain curve and tromp curve may be determined by means of the average samp~ le. b) Send the average sample to the operational iabo- ratory for analysis ©) Calculate C, Vs, Bm, 5, kWh/t (mill and total) # t test No. 2 Start with the operational parameteres from test No. 1. When the mill is in balance, reduce the air volume by approx. 163 (only if acceptable on account of dropthrough}, and set the speed to the same Sieve residue on 32y (or finest sieve avail- able) as for test No. 1 Repeat items 3, a, b and cas in test No. 1 Test_No. 3 As tests No. 1 and 2 with an air volume of approx 20% above the nominal value. Begin 11 test runs using nominal operating parameters to serve as reference. Also record the following:33331-04 14 Clinker - chemical quality, fineness, temperature Clinker - directly from kiln or from store Additions ~ kind, fineness, water precentage Other circumstance which are assumed to influence operation, Based on these 3 tests it is possible to estimate which operating parameters are the optimum ones. They must be evaluated on the grounds of production to @ given fineness and the total power consump- tion. The lowest total specific power consumption (kwh/t) determines the operating parameters for the air se- parator. This does not necessarily be co-related with the efficiency vs of the air separator. Since the fineness is only a measure of strength, this evaluation must be revised when strength data are available (strengths from 1, 3, 7 and 28 days). if the best results are obtained at lower or higher air volume than the nominal value, it should be at~ tempted to further reduce or increase it to obtain optimum operation. Air volume changes are limited by: min. air - beginning feed split of material through outlet (28). Enclosure 1, max. air - fan capacity and/or air separator motor.33331-04 15 5. OPERATION Sele Regulation of product fineness Yhe fineness is regulated by means of the rotor speed. (Air volume is kept constant). if = finer product is required, increase the rotor speed. This will entail that the recycled material increases and the elevator control will reduce the feed cor- Fespondingly so that the total feed volume to the mill is kept constant. 5.2. Constant fineness control During normal operation it is best to control fine- ness on 45y and 32p sieves for ordinary and rapid- hardening cement. For super rapid, sieves eround 20y are better suited (e.g. LSR), but Alpine sieves finer than 32y are generally not sufficiently re- liable. Make sure that the sieve is calibrated and cleaned. Results of different sieving methods may deviate from each other, Therefore, used the same sieve and the same methods for comparisons {preferably also the same laboratory). Sieve analyses must he checked by the FLS laborato- ry Although Blaine surface is still used for operatio- Mal control, the air separator should be adjusted on the basis of sieve residues rather than Blaine. Sieve residues are a better measure of product qua- lity. Installation of a Sepax air separator will in most cases result in reduced Blaine, even with much smaller sieve residues and better strengths than previously obtained. ‘The reason is that the grain curve becomes steeper, typically 1-133331-04 16 5.3 Tromp curves If there is a possibility of making a Ciles (or corrsponding) analysis, the tromp curve should also be analysed. The tromp curve shows how big a portion of the dif- ferent grain sizes in the material to be ground end up in the coarse material. Same is either obtained as output from the Cilas apparatus, or an approximated tromp curve must be calculated manually. See enclosure v. The more sieves are used in the calculation the better approximation. The following results from the tromp curv: Cut size ( ) + is agrain size where 50% (by weight) go to the coarse mate- rial, depending on the product fineness and strengths. x, 50(p) Sharpness Riygjgg ~ 1% 8 measure of the tromp Curve steepness and is cal- culated as the ratio between a grain size where 25% go to the coarse material anda grain size where 75% go to the coarse mate- rial. Was/75. 18 elated to the cement strengths. Feed split, 6& - is a measure of how much fines end up in the coarse material and is read off as the curve minimum. 6 is related to grinding economy.33331-04 17 Aggregation = The "tail" which tromp curves (Dry-clogging) typically have at the fine end, is an expression of aggregation, See instruction manual 9S01, sub-sec~ tion 9.9 and enclosure 111. For an ideal air separator the tromp curve will be @ vertical line, i.e.#,..,. = 1 and 6 = 0. Typical / valves for 2 good air separator are, = 0.5-0.6 3/75, and 6 0-103. Major deviations from these values indicate that the air separator does not operate quite at opti- mum. if the curve flattens at the top this means that there is too much coarse materi] in the fines. See tromp curve examples in enclosures XI, XII, and XII XIII. 5.4. Evaluation of air separstor operation The most important factor for a mill plant is the total specific power consumption for e given pro- duct (strengths). All other parameters, such as: vs, B, yas Xeq / and also sieve residue and Blaine, are only of importance if their improvment reflects iower specific power consumption or improved strengths. Typical values: vs = 75-85% Bags ~ 0-5-0-6% 6 = 0-108 The specific power consumption (kih/t), economy (8), and cut size, (X,.), depend on the cement fi- neness and the individual plant.33331-04 18 Enclosures VI, VII and ViI1 show some operating data for mill plants with Sepax air separator. 5 Optimising operation. Partial optimisation has been accomplished in section 4 by optimising the air volume. The next step is to optimise the circulation number. 5.5.1 The circulation number is increased by increasing the coarse material volume. (Higher separator speed). The product becomes finer, and to maintain the fineness, the feed to the mill must also be stepped up. This will result in a higher volume of material to be ground. As long as the mill can transport this volume there is a profit: Higher production to the same fineness. The mill transport capacity depends on the mill de- sign and will vary from plant to plant Consequently, the mill transport capacity is one of the limitations to the circulation number. The other limitation is the air separator. At high- er feed to the air separator it will be loaded more. This will result in an increased feed spiit 6 The bigher volume of fine material in the recycled material will reduce the grinding capacity of the mill and production will drop. Find the optimum circulation number by trials at site. Suggested circulation numbers are specified in the Comminution Manual, ("The small red book- jet"), table b 7. These numbers must be multiplied by 0.8, because the specified circulation numbers apply to the dimensioning of conveyors.83331-04 19 Find the optimum circulation number at the lowest specific total power consumption, kwh/t produced. Complete operational optimisation by making cont- rolled tests, see instruction manual 23521. 6. TROUBLE-SHOOTING No clear figures can be specified which may serve to evaluate the power consumption. They may vary from plant to plant, depending on feed, mili ana other operational conditions. Any deviations from optimum operation will become evident in one or several of the following parameters: 1. Low efficiency, vs 2. Low circulation number 3. Grain curve 4. Tromp curve 6.1 Efficiency, Vs Efficiency, Vs, may be considered normal when it is within the range from approx. 70% measured on 32p Steve (or approx. 60% on 45y sieve) and higher, and if at the same time an improvement of vs does not result in improved grinding economy measured in kWh/t and/or cement strengths.33331-04 Reasons for low Vs may be the following: Cause Dispersion Dispersing arrangement. Air volume too small. Air volume too big. Uneven air distribution. Remedy, Adjustment of dispez- sing arrangement: Distance from baffie plate (23) to feed pipe (22}. Replace baffle plate (23) by bigger one. Cone (25). Adjust position. Check for false eir sources. Increase air volume an@ rotor speed. Try with smaller air volume and lower rotor speed. Air separator, type 2c has air intake positio- ned after a bend. a guide plate has been mounted to even out the air. Check the air ve- locity distribution at the air intake. (With Pitot tube).3331-04 Mounting inaccuracies. 6.1.2 Too much coarse material in the fines. 1 in case of uneven air distribution there is a possibility of mounting several guide plates. If so, contect FLS Head office. Check the dispersing arrangement - feed pipe (22), baffle piate (23), cone (25), intake (27) must be air centered relative to housing (26, 24) and riser pipe (21). Check whether distance between roter (15) and seal ring (29) is too big. Gap must be as small as possible. mally less than § mm, Nor- Check mill filter mate- rial (sieve residue on coarse sieves, e.g. 90u)}, if passing di- rectly to finished ma- terial. if too coarse, reduce draught through mill or convey filter material to air separator,