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.