回转窑说明书(英文版).doc

4.872m Rotary KilnInstruction ManualNo. R2360-SM-ENWROTE: CHECKED: APPROVED:CEMTECK, P. R. CHINA20011.03Table of ContentsNoContentsPage1Technical Performance22Structure and Work Principle43Installation Requirements64Support Roller Adjustment by Pressing Fuse155Hydraulic Thrust Roller Device226Trial Running267Operation Maintenance298Abnormal Phenomenon In Operation, Treatment and Safety Attentions319Starting and Stopping Processes of Kiln3410Lubrication and Cooling3611Maintenance3812Lubrication List4013Wearable Parts421. Technical performanceDiameter of kiln： 4.8mLength of kiln： 72mSlope ：（sin） 3.5%Number of supporting device： 3 Capacity (Operation with precalciner preheater) 5000t/dRotating speed： Driven by main drive：0.4564.56r/min Driven by auxiliary drive：13.19r/hDrive motor（single drive）：Main driveAuxiliary driveTypePower(kW)Rotationspeed(r/min)TypePower(kW)Rotationspeed(r/min)ZSN4-450-0927101000Y280S-4751480Reducer：Main driveAuxiliary driveTypeReduction ratioTypeReduction ratio JH800C-SW306-28 (Special order Symmetric double input shaft)26.812ZSY355-31.5-30.729Maximum weight of large parts to be lifted:Maximum shell section 65.7tWeight of tyre 1x45t, 1x57.6t, 1x46.2t Main reducer 13.36t Maximum weight of thrust roller device 81tMaximum support roller bearing group 41.18tMaximum support roller base plate 11tBase frame of thrust roller 5.24t The total weight of rotary kiln (without refractory): 843tAttached: Installation tools of rotary kiln R2166.8 (1) Basic configurationDWG No.Name and specification QuantityTotal weight(kg)R2166.8-1Ruler 2115.72R2166.8-2Slope gauge （3.5%）412.64R2166.8-3Flat 10.7R2166.8.1Elevation sign of base1222.8R2166.8.2Shell support and installation tools89212R2166.8.3Measuring device of support roller center distance28R2166.8.4Installation tools of girth gear4598.8R2166.8.5Stiffener41553.32R2166.8-4Spanner（1）220.62R2166.8-5Spanner（2）228.18R2166.8-6Spanner（3）233.16R2166.8-7Spanner（4）148.8R2166.8-8Spanner（5）171.7 (2) Optional measuring devices of rotary kilnDrawing No. or TypeName and manufactoryQuantity4405AShell radial deformation tester (developed by TCDRI, manufactured by WuXi Building Material Instrument Manufacture Works.1set6679Tyre gap tester (developed by TCDRI, manufactured by WuXi Building Material Instrument Manufacture Works1setKAS-02Dynamic parameter measuring units of rotary kiln axis(developed and manufactured by Kaishi Scientific and technical Development cooperation of WuHan university of Science and Technology)1set2. Structure and working principleThe kiln shell is made of rolled steel plates, internal surface of shell is lined with refractory, the kiln shell is arranged with a slight slope supported by support roller devices through 3 tyres. The girth gear is installed on the kiln shell within the span near the kiln inlet by tangent spring plates. There is a pinion which meshes with the girth gear under it. During normal operation, the main drive motor transmits power to main reducer, pinion, girth gear and finally drive the kiln shell.The material enters the kiln from the kiln inlet. As the kiln shell is oblique and rotates slowly, the material tumbles circumferentially and moves axially from the inlet to the outlet simultaneously. At the same time the material is subjected to calcining and sintering processes. Finally, the clinker produced falls into the cooler through the kiln 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 burner is not included in the design. 2.1 The main structure characteristics of the kiln are as follows:2.1.1 The kiln shell is made of rolled low-carbon steel plates Q235C, and it is usually welded automatically. Thickness of shell: 28mm for general plate，32mm for the sintering zone， 75/80mm under tyres、42/55mm for transition plates between the 75/80mm and 28/32mm plates. This arrangement of shell thickness is in more reason, it can guarantee both the radial rigidity and longitudinal flexibility of shell. At the inlet end and the outlet end, the kiln shell sections are equipped respectively with the nose ring segments made of heat-resistant and wear-resistant steel. At the outlet, there is a ring-shaped space between the kiln shell and cooling air sleeve, the cooling air from horn opening is blown onto the non-working surface of the nose ring, that is of benefit to increase this part service life. There are three solid rectangular type tyres on the kiln shell. The clearances between the tyre and the tyre support 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 radial deformation of kiln shell and increase rigidity of shell.2.1.2 The hydraulic thrust roller device is applied to undertakes downwards sliding force of kiln shell, and it can push the kiln shell moving up. The right arrangement of spans can make design of every support roller device more reasonable. Every support roller bearing group is equipped with one temperature metering device to measuring the working temperature of bush, the working temperature of lubrication oil can be displayed on site and monitored in the central control room. 2.1.3 The single drive system is adopted for the kiln. The kiln is driven by the special high starting torque DC governor motor through the three stage hardened-surface spur gear reducer, then drive opening mated gear of kiln, this drive device adopts diaphragm coupling to improve the stability of drive. The drive system is also provided with the auxiliary drive device connecting to emergency power source, in order to ensure the kiln inching to prevent the kiln from bending when the main power source is cut-off suddenly and easy maintenance.During normal operation when the main motor is on the jaw clutch disconnect the auxiliary drive from main gearbox, Signal is send out to central control room, The auxiliary drive is not allowed to start. On the other hand when the auxiliary motor is on jaw clutch connect the auxiliary drive with main gearbox. Signal is send out to central control room, The auxiliary drive is not allowed to start.The main motor is furnished with tachogenerator to indicate the actual rotation speed of kiln.3. Installation requirementsBefore installation, the correlative drawings and technical documents should be studied to understand the equipment structures and installation requirements. After this, determine the installation order and method, prepare the necessary installation tools and equipments. Afterwards, work out an installation plan, finally carry out the installation with the best of prepare.3.1 Check foundation, draw datum lines3.1.1 Correct the drawings, and measure the lengths of all the shell sections. Think about clearance and welding contraction of every interface, it is usually 2mm, then calculate the actual distances between two nearby tyres, after that calculate the corresponding thermal expansions, finally, calculate the distances both along the kiln axis and along the horizontal direction between nearby support roller devices, then correct the correlative dimensions in drawings.3.1.2 According to the corrected drawings, check the foundation dimensions, especially, the distance of foundation center. If there is any deviation, the following measures should be taken: If the dimension deviations are less than 5mm between the corrected drawings and the foundation, it is allowed; If the above mentioned deviations are 510mm, the gaps between the nearby shell sections can be adjusted. The interface gap can be adjusted in the range of 13mm; If the above mentioned deviations is larger than 10mm, besides the shell sections interface gap adjustment, the positions of support roller devices should be adjusted. According to the actual dimensions after adjustment, correct the distance dimensions along the kiln axis between the nearby support roller devices in drawings, calculate the corresponding dimensions along horizontal direction. Measure the dimensions of support rollers and bearings, correct the elevation dimensions of top generating line of support roller working surfaces.3.1.3 Foundation mark out Mark the horizontal datum line on the side surface of foundation approximately 1m from the ground. The elevation plates are buried at the four corners of the foundations. The elevation deviation of base level must be less than 0.5mm; Mark the longitudinal center line, the deviations must be less than 0.5mm; According to the corrected drawings, mark the foundation transverse center lines on the horizontal datum lines for all the foundations. The deviations of center distance between the two nearby support roller device centers should not be larger than 1.5mm, the deviation of center distance between the foundation center close to the inlet and the foundation center close to the outlet should not be larger than 3mm.3.2 Installation of support roller devicesWhether the kiln center line maintains a straight line during the kiln operation, it depends on: firstly, the locations of support roller devices. Therefore, more attention should be paid to the installation of support roller devices. The following requirements must be satisfied for the installation of support roller devices:3.2.1 After the sensitive adjustment of base plate, the following requirement should be followed:Permissible deviation of base plate longitudinal centerline is 0.5mm;Permissible deviation of center distance between two nearby base plates is 1.5mm;Permissible deviation of center distance between the base plate close to the inlet and the base plate close to the outlet is 3mm;Permissible datum mark deviation between the two nearby base frames is 0.5mm;Permissible datum mark deviation between the base plate close to the inlet and the base plate close to the outlet is 1mm;Permissible slope deviation for the machined surfaces of base plate is 0.05mm/m. 3.2.2 During installation of support roller bearing group, the serial numbers of bearing housings, spherical seat and bearing bushes must be checked. Only after it is confirmed that the above mentioned parts have the same serial number, they can be assembled to a group. By means of coloring method, the contacting spots on bearing bush should be distributed uniformly along the entire generating line width and continuously distributed on the middle zone of entire contacting width. Otherwise, the scraping and grinding should be carried out at site. The number of contacting spots between spherical seat and bearing bush can not be less than 1 within the area of 1010mm2 , and the number of contacting spots between the spherical seat and bearing housing can not be less than 1 within the area of 2525mm2. However, the ring zone within the width of 50mm at the two sides of the spherical seat, a clearance of 0.1mm is allowed; Check the clearances of two sides of contacting zone between the journal and bearing bush with the inserting gauge. At the point where the inserting gauge is inserted 100mm, a clearance about 0.60.7mm should be generally maintained, if the side clearance is not enough, the scraping and grinding should be carried out again.3.2.3 Install the roller-bearing group on the base plate, after adjustment, the following requirements should be followed: Thrust ring at the lower end of support roller shaft should contact with the bearing bush, and at the upper end, a clearance of 4mm between the thrust ring and bearing bush flange should be reserved. Confirm the lower end surface of two support rollers should be within same plane, its permissible deviation is 0.5mm checked with straight ruler; The deviation between the central lines of two support rollers and the longitudinal central line of base plate should conform to the requirements in the drawing, the permissible deviation of which can not exceed 0.5mm; Examine the working surface of every support roller with the slope gauge and the level instrument. The slopes at the top generating line of rollers should be identical, the permissible deviation is 0.05mm/m. For the same support roller device, the connecting line through the middles of the above mentioned generating line of two support rollers should be horizontal, its permissible deviation is 0.05mm/m. If the deviation exceeds the above mentioned limit, the adjustment by inserting shims under the bearing housing can be carried out; Measure the elevation of the middle of top generating line of every support roller, the elevation differences for all the support roller devices should conform to the corresponding dimensions in the corrected drawing, the permissible elevation deviation for the two nearby support roller devices can not be larger than 0.5mm, the permissible elevation deviation for the support roller device close to the inlet and the support roller device close to the outlet can not be larger than 1mm; With theodolite, the top generating line of every support roller should be within the plane which oblique to horizontal plane with a slope of 3.5%, if there is some error in elevation or slop, should be adjusted by the adjusting bolts until accord to above requirements completely .3.3 Installation and welding of kiln shell 3.3.1 Preparations . Carry 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; Check each end interfaces of the kiln shell section to be connected, the interface perimeter tolerance is 8mm, and the roundness tolerance is 8mm, if the roundness tolerance exceeds the requirment, the shell section must be corrected by the installation tools; Measure the internal diameters of tyre and external diameters of support pads for every supports, check if the tyre gaps for every supports conform to the requirements specified in the drawings; Clear away burr, greasy dirt, rust etc. Keep clean and dry on the interface surfaces of the kiln shell sections.3.3.2 Assembly and alignment of the kiln shellThe sequence of assembly and alignment of the kiln shell is decided at site. To ensure the clearance of 13mm between two nearby shell sections, 16 pieces of angle steel with the length of 100mm and the thickness of 2mm are uniformly inserted into interface surfaces of two nearby shell sections. As the welding goes on, these angle steel should be taken away one by one. It is not allowed to take away all the angle steel on one circumferential interface at same time. Pay attention to check if the relative locations between tyres and support rollers conform to the drawing in cold state, its permissible deviation is 5mm.After measurement and adjustment of the kiln shell, the following requirements should be satisfied: The tolerances of radial run-out of shell: 5mm at the inlet and outlet, 2mm at the girth gear, and 6mm at any other locations; The internal interface surface of shell should be guaranteed to be flush, the maximum permissible offset of two nearby shell sections interface edges on any circumferential position is 2mm.3.3.3 Welding of shellThe welding of kiln shell is a key job during kiln installation. The welding quality will directly effect on the normal operation and service life of kiln, it must be paid more attention to, especially the following points should be emphasized. Only those welders who have passed the examination are allowed to work in the shell welding; Depending on the welding conditions, for the shell welding, manual arc welding for back welding and automatic welding or manual welding for outside weld can be applied. The quality of electrode used for automatic welding should be equivalent to 08A electrode. The quality of electrode used for manual arc welding should be equivalent to E4315 (GB5117-95) electrode. Before welding , these electrode should be dried for 2 hours at the temperature of 250; During the welding of shell, any other work can not be carried on inside kiln; During raining, winding and snowing, welding can not be carried on. If the ambient temperature is below 5, groove should be preheated, thermal retardation after welding and adjust welding process. If the kiln shell is exposed in strong sunlight, the temperature difference between the facing sunlight side and shadow side will leads to flexure of shell, the shell welding can not be carried on. If one side of shell is subjected to heat radiation from the nearby operating kiln, the kiln center line may flex. In this case the heat insulation measure with asbestos board should be taken before welding; The striking weld points and the extinction weld points between two nearby welding layers can not be overlapped. The welding appearance defects such as slag inclusions, air cavity and cracks etc. at the welding seams are not allowed. Every welding seams must be detected. The intersections of longitudinal and transverse welds and other positions of welds where the welding quality are doubted should be detected by radiographic or ultrasonic in