Beruflich Dokumente
Kultur Dokumente
ROTARY KILN
70000456-1
KILN SUPPORT. Type SA
VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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Contents: Page:
1. General notes .................................................................................. 4
2. Construction and operating principle ..... 6
2.1.1 Bedplate ....................................................................................................................... 6
2.1.2 Supporting bearings ..................................................................................................... 6
2.1.3 Supporting rollers ......................................................................................................... 6
2.1.4 Kiln tyre ........................................................................................................................ 7
2.2 Bedplate ..................................................................................................................... 7
3. Erection ........................................................................................... 8
4. Operation ........................................................................................ 8
4.1 Position of supporting rollers........................................................................................... 8
4.2 Axial loading.................................................................................................................... 9
4.3 Position of kiln tyre ........................................................................................................ 11
4.4 Lead wire tests .............................................................................................................. 11
4.5 Special conditions in connection with kiln start-up ........................................................ 11
5. Maintenance .................................................................................. 12
5.1 Preventive maintenance, survey ................................................................................... 12
5.1.1 Lubrication.................................................................................................................. 14
5.1.2 Cleaning ..................................................................................................................... 13
5.1.3 Inspection and adjustment ......................................................................................... 14
5.1.4 Checking of condition................................................................................................. 15
5.1.5 Replacement .............................................................................................................. 16
5.2 Faults and remedial action............................................................................................ 16
5.2.1 Fault 1: ....................................................................................................................... 16
5.2.2 Fault 2: ....................................................................................................................... 17
5.2.3 Fault 3 ........................................................................................................................ 17
5.2.4 Fault 4: ....................................................................................................................... 18
6. Key to Appendices ......................................................................... 19
APPENDICES:
App. 1. Sketch of bearing shell.............................................................................................. 21
App. 2. Graphite lubrication................................................................................................... 23
App. 3. Cooling water arrangement....................................................................................... 25
App. 4. Adjustment of self-adjusting support beam .............................................................. 27
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NOTE !
1. GENERAL NOTES
The rotary kiln supports are of paramount importance for
ensuring stable kiln operation.
In addition to operational losses, inadequate maintenance and
inspection procedures may involve substantial expenditure for
the replacement of components.
REQUIREMENT:
Support to be used only for the specified purpose.
MANDATORY!
The directions outlined in instruction No. ref. 3
"General safety regulations at erection site" must be
strictly observed at the site of erection. This
instruction manual must be scrutinized by the client,
the erection contractor and FLS representatives
before erection work is started.
MANDATORY!
The erection/maintenance activities described in the
following sections must only be carried out by skilled
machine specialists or subject to the supervision of
such specialists.
MANDATORY!:
In connection with arc welding and when operations
involving blowtorching with gouge are carried out, the
return cable must always be attached to the object
subjected to welding, as close as possible to the area
of welding.
The return cable must never be attached in a way
which will cause the return current to be passed
through parts not connected to the object being
welded, for example: moving parts, bearings,
electrical installations or any other parts.
A return current through a bearing may give rise to
welding scars which will cause severe damage to
bearing.
A return current through electrical installations may
cause serious damage to protective earth lines
(extremely hazardous condition!) or electronic
equipment.
3. INSTALLALTION
See separate erection instruction manuals, ref. 1
4. OPERATION
4.1 Position of the supporting rollers
For kilns featuring hydraulic thrust device and semi-dry
supporting rollers, correct positioning of the supporting rollers
is of paramount importance. Basically, the centrelines of the
supporting rollers must be parallel to the kiln axis/the kiln tyre
axis, in the vertical plane as well as in the plane of inclination.
As a result, pure rolling will occur between the supporting
rollers and the kiln tyre without any axial reaction.
At the self-adjusting support, the latter will ensure parallelism
in the vertical plane, and, therefore, the main focus of the
adjustments must be to ensure parallelism in the plane of
inclination.
As previously mentioned, the primary aim is to ensure parallel
positioning of the supporting rollers. However, in actual
practice it will not be possible to maintain parallel positioning
of the supporting rollers, the preferred option is to allow the
supporting rollers to impact the kiln in the ascending direction
so that the axial thrust of the supporting rollers will help
relieve the loading of the thrust device. See sub-section 2.1.3.
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IMPORTANT:
THIS DOES NOT APPLY TO FRICTION-DRIVEN
SUPPORTING ROLLERS. OIL MUST NOT BE POURED
OVER THESE ROLLERS!
Use an oil grade similar to that used in the supporting roller
bearings. This will ensure that the kiln lies true against the
thrust roller at all times, even if some of the rollers have been
positioned so that they exert an upward thrust on the kiln. The
thrust against the trust roller, from the supporting rollers
exerting a downward pressure on kiln, will be simultaneously
reduced due to decreased friction between the supporting
rollers and kiln tyre.
For the same reason, there will a minor axial impact on the
thrust ring of the supporting roller shaft against the collar of
the bearing shell, thereby reducing the risk of hot-running.
Immediately after start-up, the position of the supporting
rollers must be checked and adjusted by means of the axial
measuring equipment.
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5. MAINTENANCE
5.1 Preventive maintenance, survey
Pos. Text 1. 2. 3. 4. 5.
00 Support . T T T .
02 Rocker bearing . . T . .
04 Elastomer block . . T . T
05 Bearing beam . . T . .
06 Supporting roller T . T T .
08 Central frame . . T . .
10 Supporting bracket . . T . .
11 Supporting bearing . . T . .
14 Kiln tyre T . T . .
15 Graphite . . T . T
lubrication
5.1.1
Lubrication
Kiln tyre/supporting rollers
Graphite is used for lubricating the running path between kiln
tyre and supporting rollers.
On a ROTAX-2 kiln, graphite lubrication is applied only on
support 1, NOT on the driving support with friction drive.
Lubrication is effected by means of a graphite block (15)
(99.5% graphite) which is fitted in a frame, see Appendix 2,
with the block resting owing to its dead load against the
running path of one supporting roller. The graphite is rubbed
off on the running path, thereby causing lubrication to be
effected. From the supporting roller the graphite is transferred
to the kiln tyre and to the second supporting roller.
Use graphite only, thereby ensuring ensure a bright and semi-
dry surface on the supporting rollers and kiln tyre.
In case of flakes of graphite being subsequently formed on
the kiln tyre and supporting rollers, such flakes can easily be
removed using an oil-saturated cloth. The oil must be wiped
off again after the flakes have been removed.
When approximately one half of the graphite block is affected
by wear-induced erosion, it will be possible to compensate for
the smaller weight by placing a piece of iron on top of the
graphite block. However, it is essential to ensure that the iron
is shaped and fitted so that it will be impossible for it to leave
the holder; otherwise, the iron will be trapped between the kiln
tyre and supporting roller or between supporting roller and
graphite holder.
5.1.2 Cleaning
Support (00)
Remove dust and graphite flakes from the running path of the
supporting rollers on a regular monthly basis.
Remove dust and impurities from bedplate, supporting roller
bearing housings, and, if incorporated, thrust device, on a
regular monthly basis.
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5.2.2 FAULT 2:
Bright stripes and formation of bevel edges on supporting
rollers and kiln tyre.
CAUSE:
Touch the water outlet connection of bearings. If shock
impacts are ascertained, this is evidence of axial sliding
between supporting roller and kiln tyre caused by misaligned
supporting rollers.
REMEDY:
Check the axial reaction using the axial measuring equipment
ref. 5 and readjust the position of the supporting rollers.
5.2.3 FAULT 3
Bearing temperature too high.
CAUSE:
Radiant heat from kiln.
REMEDY:
Check that the heat shield of the bearing has been mounted.
If necessary, mount an additional shield between kiln shell
and the supporting roller bearing.
CAUSE:
Excessive axial load on the thrust collar of bearing shell.
REMEDY:
Check the load using the axial measuring equipment. Relieve
the bearing by ensuring that the axial load is evenly
distributed between all supporting roller bearings and the
thrust device. See instruction manual ref. 5.
CAUSE:
Faulty lubrication and/or cooling of the bearing.
REMEDY:
See instruction manual ref. 4.
CAUSE:
Excessive transmission of heat from supporting rollers and
kiln tyre.
REMEDY:
As an emergency option, it will be possible to cool down the
roller by means of water. See instruction manual ref. 4
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5.2.4
FAULT 4:
Pittings on kiln tyre and supporting rollers.
CAUSE:
Excessive surface pressure between kiln tyre and supporting
rollers.
REMEDY:
Adjust the inclination of the supporting rollers, and, if
necessary, re-align the kiln.
Machining of the damaged components must be carried out.
Consultations with the FLS service department are
recommended in case of need to turn off or to grind the
surface of the supporting rollers.
5.2.5 FAULT 5:
Splaying of supporting roller.
CAUSE:
Incorrect position of supporting roller.
Inadequate lubrication.
Inadequate standards of clean-up.
REMEDY:
The supporting roller which is worn hollow must be turned off
through machining if concave configuration is more than 1
mm.
If the kiln tyre is affected by convexity due to wear exposure,
more than 1 mm, the kiln tyre must also be turned off.
Consultations with the FLS service department are
recommended in case of need to turn off or to grind the
surface of the kiln tyre.
Adjust the position of the supporting rollers and check the
lubrication unit.
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6. KEY TO APPENDICES
01. Bedplate for rocker bearing
02. Rocker bearing
03. Self-adjusting support beam
04. Elastomer bearing
05. Bearing beam
06. Supporting roller
07. Adjusting screw
08. Frame structure
09. Hinged bearing
10. Supporting bracket
11. Supporting bearing
12. Supporting beam
13. Kiln foundation
14. Kiln tyre
15. Graphite block
16. Heat shield
17. Jack
18. Pressure plate
19. Rocker plate
20. Seal
21. Intermediate
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17. Jack
18. Pressure plate
19. Rocker plate
20. Seal
21. Intermediate
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