Φ4.

8x72m Kiln

Installation & Operating Manual

SHANGHAI XINJIAN HEVAY MACHINERY CO.,LTD

3
2

1
Rev. No. Date Rev. Description Originator Checked Approved
版本号 日期 修改内容 修改人 检查 批准

编 制
兰华
Originator
www.xinjian.com.cn
校 对

Checked
 批 准 工程编号
史韶光 1800-13
Approved Job No.

日 期 文件号
2016.10 3A68-00 0
Date Doc. No.

Contents

1. Technical specifiction

2. Structure outline and working principal

3. Installation requirements

4. The adjusting roller system by rolled lead test

5. The hydraulic thrust roller assembly

6. The trial run

7. Regular maintenance in operation

8. Abnormal phenomenon in operation, processing method and the note

of security

9. The kiln stop and start

10. Lubricating and cooling

11. The examine and repair

12. The list of lubricate

13.The list of wear parts

1.Technical specification

Inner diameter of shell：4.8m

Length of kiln shell：72m

Inclination of kiln：（SinФ）3.5%

Number of kiln supports：3

Capacity of the kiln：（rotary kiln with calciner）5000 t /clinker/d

Speed of the kiln：

Main drive：0.456-4.56 r/min

Auxiliary drive：12.3 r/h

Motor
Main drive Auxiliary drive
Type Power Speed Type Power Speed
（kW） (r/min) （kW） (r/min)
DMI400T 710 1000 Y280S-4 IP54 75 1480

Reducer
Main drive Auxiliary drive
Type ratio Type ratio
JH800C-SW306-28 28 ZSY355-31.5-II 31.5

Weight of huge parts to be lifted:

Heaviest kiln shell: 69.062 ton

Tyre: 44.95 ton，45.62 ton，46.2 ton

 Main reducer: 13.36 ton

Support device with thrust roller: 60.1 ton，54.6 ton

Roller station: 6×20 ton

Roller base: 10 ton，8 ton，7.2 ton

Total weight of kiln：835.5 ton（but excluding the firebrick in shell）

2.Structure outline and working principle

The kiln shell, with the inclination of 3.5% from the horizontal, made of

rolled steel, lined with firebricks, is supported by three tyres on the three

supporting devices. A gear rim is fixed on the shell near the tyre of the

inlet by spring plate . The gear rim meshes with a pinion below. At

normal operating，the main motor drives rotary kiln through the main

reducer and open gearing.

The raw material is provided at the feed end for burning. Because of the

shell inclination and slow rotation, the material moves from high end to

low end in the kiln with the movement of both circumference and

longitude in the kiln shell where the process of calcining, burning,

cooling are carried out, the products of clinker is formed and fed to the

cooler.

The burner is provided at the outlet of the kiln, the exhaust gas after heat

exchanging with the material is derived by the feed end of the kiln.

2.1 The main features of the kiln in structure aspect:

 2.1.1The material of the shell is Q235C steel, the automatic

welding is adopted for all welding seams. The thickness of the shell

plates are 28mm generally, the thickness of the shell plates of clinkering

zone are 32mm, the thickness of the shell plates under the tyre are

75、80mm, the thickness of the shell plates of transition segment are

55、42mm, therefore, the design of shell is more reasonable, not only

ensure rigidity of cross-section of shell, and improves the stress state of

support device. The protection plates of heat resistant and wear resistant

materials are installed in the feed end and outlet end. The outlet nose ring

and air cooled cylinder form a sleeve tube space where the cold air is to

be blown into the non-work surface of outlet nose ring, it ensures that

outlet long time work safety. There are three solid tyres on the shell. The

clearance between the tyre and shim plate of the shell is decided by the

heat expansion of the shell. When Kiln normal operation, the tyre will

reasonably round the shell to reduce the radial deformation and increase

the rigidity of the shell.

2.1.2. The hydraulic thrust roller assembly is adopted to sustain the

slide down force of the kiln, this device can make that shell move up and

down. Because span between supporting points are properly assigned, the

design of all supporting structure is more reasonable. Each bearing are

equipped with temperature measurement device. The working

temperature of bearing bush and lubricating oil shall be sent to central

control room to display and order.

2.1.3 The driving system is a single side driving system by using one

set of DC motor to driver reducer，then to driver the open gear pair.

Flexible coupling is used to increase the stability of transmission. The

auxiliary drive with security power is provided to keep the kiln slowly

running in the case of power break of the main drive so as to prevent the

shell from deformation and repair easily. The main motor with speed

motor is provided to show its speed.

3.Installation Requirements

The drawing and related technical documents must be read carefully and

familiar with the equipment’s structure and to clear installation

requirements. According to the actual condition, determine the way and

procedure of the installation, prepare the necessary tools and devices to

work meticulous.

3.1Foundation examination and outline

3.1.1 Drawing modification: Measure the actual length of shell

section, considering 2mm clearance for welding contraction in the

welding joint. Get the actual distance between two adjacent tyres. Adding

a expansion amount in hot state, get a reasonable inclined figure of each

adjacent support rollers from which the horizontal distance could be

calculated. Modify the dimensions on the drawing.

 3.1.2 Check the foundation dimensions, especially the foundation

center distance according to the modified drawing. The following

measures must be taken if the distance is not conforming to each other：

3.1.2.1 If the dimensional deviation of revised drawing and the

corresponding size of the foundation is less than 5mm, it need not taken

any measures.

3.1.2.2 If the dimensional deviation is 5-10mm, please adjust the

clearance of the section before welding, the adjusting range of each is

from 1 to 3mm.

3.1.2.3 If the dimensional deviation is more than 10mm, not only

adjusting the joint clearance between kiln sections, but also regulating the

location of support devices during installation before welding, the

adjusting range of each is from 1 to 3mm. The drawing must be modified

once more according to the actual inclined distance measured and

calculate the horizontal distance, measure the dimensions of support

rollers and their bearings, modify the elevation of support rollers.

3.1.3 Line out the foundation

3.1.3.1 Line out the horizontal line on the side of the foundation

above the ground 1m, and pre-bury elevation plates on the 4 corners. The

deviation among the 4 elevation plates can not exceed 0.5mm.

3.1.3.2 Line out the longitudinal line with tolerance 0.5mm.

 3.1.3.3Draw the transverse centerlines of each foundation based on

revised drawing .The tolerance of center distance between two adjacent

foundation should not exceed 1.5mm and that between two ends

foundation should not exceed 3mm.

3.2The erection of support devices

The straightness of the centerline of the shell is based on the accuracy of

the position of the support devices. The erection of the support devices

must meet the following requirements:

3.2.1The base plate，after installation and adjustment, must satisfy

the follows:

The tolerance of longitudinal centerline of the base plate is 0.5mm.

The tolerance of centerline between the two adjacent base plate is 1.5mm.

The tolerance of centerline between the first and last base plate is 3mm.

The elevation tolerance between the two adjacent base plate is 0.5mm.

The elevation tolerance between the first and last base plate is 1mm.

The inclination deviation surface of the base plate’s machining

surface is 0.05mm/m.

3.2.2Before the rolling bearing is fitted, make sure the marks

stamped on the bearing housing, ball socket and liner identical.

With colour methods to check, the contact spot between bush and roller

shaft should be homogeneous, equivalentwidth along generatrix overall

 length, and continuous distribution in the middle area, otherwise, must

scraping.

The contact point ball socket and liner should not be less than 3 point per

25mmx25mm, the contact point between ball socket and bearing housing

should not be less than 1-2 point per 25mmx25mm.

3.2.3The baseplate, after installation and adjustment, must satisfy

the follows:

3.2.3.1The thrust collar on the low end (near the discharge end) of

The roller shaft should be contact with the end face of the liner. The 4mm

clearance should be kept on the high end. The sides of the rim of two

support rollers at the low end should be in a same plane, the deviation is

less than 0.5mm.

3.2.3.2The distance from two centerlines of two longitudinal support

rollers to that of baseplates should be the same and conformed with the

dimension on the drawing. The deviation is less than 0.5mm.

3.2.3.3 Check the inclination of each support roller by using

inclinometer and level. The deviation should be less than 0.05mm/m, The

center points on the top of two support rollers in the same group should

be in the same level. The tolerance should not exceed 0.05mm/m,

otherwise it is allowed to adjust it by filling shims under the bearing

housing.
 3.2.3.4 Measure the elevation of the center point on the top-face of

each roller. Elevation difference of all rollers should be coincided with

that of all baseplates on the modified drawing. The elevation deviation of

two adjacent rollers should not exceed 0.5mm. The deviation between the

first and last one should not be large than 1mm.

3.2.3.5 Check the top face of all support rollers with inclination of

3.5% to the horizontal by using a theodolite. It should be corrected by

adjusting the height of the base plates if any deviation happened.

3.3 Shell installation and weld

3.3.1 Preparation

3.3.1.1 Carry out the preliminary assembly on the ground according

to the number (or the continuous line mark).

3.3.1.2 Check the roundness of each shell section. The allowed

deviation of circumference should not exceed 8mm. The allowance of the

roundness should not exceed 8mm, otherwise it must be adjusted by the

erecting tool of the shell.

3.3.1.3Measure the inner diameter of the tyre and out diameter of the

support block of the shell to see if the tolerance meet the requirement on

the drawing.

3.3.1.4Smooth the rough and damaged edge, clean the oil and rust

on the ends to be connected on every shell section, maintain its clean and

dry.
 3.3.2 Alignment and assembly

The sequence of the shell assembly is to be decided by the site condition.

In order to ensure the tolerance of the welding joint of the shell is 1-3mm,

insert 32 pieces of angle shape steel plates with the width 25 mm and

thickness 2mm. When shell welding, this steel plates must be removed

one by one, no together. Please note that the position of the tyre on the

support rollers should be coincided with that indicated on the drawing in

cold state. The allowance is ± 5mm. The following requirements must be

met after measurement and

adjustment:

3.3.2.1The radial deviation of the kiln shell:

Shell at the inlet and outlet end: less than 5mm.

Shell under the gear rim: less than 2mm.

Shell at other places: less than 8mm.

3.3.2.2The ends of each shell to be connected should be conformed

to each other. The edge deviation to be contacted to should not be over

2mm.

3.3.3Kiln shell weld

The shell weld is very important procedure during the kiln assemble

which will effect the kiln operation and its working life. The following

requirement should be noticed:

3.3.3.1The welders should be qualified after examination.

 3.3.3.2According to field condition. The manual welding could be

adopted on the bottom layer inside the shell. The auto or hand welding

could be adopted on the outside of the shell. Automatic welding and

manual welding, carbon steel electrode and low alloy electrode should be

in accordance with GB/T5117-1995 and GB/T5118-1995. The welding

wire shall comply with the terms of GB8110. The welding wire must be

dried on the 250℃ for two hours before used and kept in absolutely dry

condition before they are used.

3.3.3.3Any other works are not allowed in the kiln shell during the

time of welding.

3.3.3.4The welding work is not allowed in rainy, windy and snow

days. The measures about the procedure and way of welding must be

taken if the welding work is under a low temperature condition.

(below5℃)such as pre-heat before welding and keep the temperature

after welding on the welding zone. After long time sunshine, the

temperature difference between kiln shell up and down surfaces may

cause the distortion of kiln shell. The welding work should not be

carried out now. If the operational heat radiated from one side causes the

distortion of kiln shell, the kiln shell must be heat-proof with asbestos

board, then, the welding work should be carried out.

3.3.3.5The weld arc starting point can not be overlapped. Any

appearance defaults such as hollow inside, undercut, slag creaks are not
allowed on the welding seams. Each welding seams shall be carry

through flaw detection. The RT or UT test must be taken on the cross

section of longitudinal and circular welding seams. The test result should

conform the classIII quality standard of GB3323 ( for RT) or classII

quality standard of JB1152 (for UT). Othewise the welding must be

repaired, The inspection rules are carried out according to the standard

JC/T333-2006.

3.3.3.6 After welding, the distance between the center of tyre’s

width and the center of support roller’s width should be conformed to the

dimension (in cold state) in the drawing. The allowance is ±5mm. The

tyre and block should be with uniform clearance according to the

requirements of drawing.

3.3.3.6 After the kiln shell installation is completed, the link

between the shell cross-sectional center under I, III tyres is a straight line,

compare with this line, the shell cross-sectional center under II tyres will

be droped, drop about 2.5-3mm.

3.4The driving system installation

It is better to install and fix the driving system temporarily as soon as the

kiln shell assembled to one piece. By turning the kiln shell, so as to

facilitate the alignment and weld of kiln shell. The election of driving

system must meet the following requirements.

 3.4.1The longitudinal welding seam on the shell where the gear rim

is to be fitted must be ground to flat by emery wheel. The each side

length of welding seam must be 50mm larger than the width of spring

plate.

3.4.2The extemal circular radial beat tolerances of the gear rim must

be limited within 1.5mm, the datum end beat tolerances of the gear rim

must be limited within 1mm. Aligned by adjusting bolts.

3.4.3Please note direction of the spring plate which can only bear the

tension force during the kiln is rotating. After spring plates and

connecting bolts of the gear rim installed, insert a 0.3mm shim between

the washer on one side and spring plate. Retain the nut with trough, put

the spilt pin on, then remove the shim. The clearance of 0.3 is to be

guaranteed after the shim removed.

3.4.4The transverse position of the base plate of the driving system

is to be decided by the center line of the kiln. The axial position of the

base plate of the driving system is to be decided by the center line of gear

rim, the thermal expansion is considered.（please note that width center of

kiln outlet’s tyre and width center of roller are coincide）.Its elevation is

to be decided by the elevation of the base plate of kiln outlet’s support

device and inclination should be the same to that of the base plate of

support device.
 3.4.5When install the pinion assembly, its location should be

conform to that in the drawing. The allowance should not exceed 2mm.

Align the inclination with a tape gauge, the allowance is 0.05mm/m.

When rotating the kiln under the cold state, the top clearance of teeth of

the pinion and gear rim is 11-12mm and that should not be less than 9mm

after the kiln put into operation, reaching the normal temperature. Check

the connecting condition between the gear rim and pinion. The contact

spot should not be less than 40% along the teeth height and 50% along

the teeth length.

3.4.6The axiality tolerance of the low speed shaft of the main

reducer and the shaft of the pinion is Ф0.2mm. The transverse horizontal

and longitudinal inclination of reducer should be measured at the

machined surface of the housing of the reducer. The deviation can not be

more than 0.05mm/m.

4. The adjusting roller system by rolled lead test

In order to keep the kiln in good condition, the correct adjustment

and maintenance of the support roller system is most important, that is to

understand the working condition of the support roller by observing its

running. Clarify the bearing force condition of the support roller and tyre

according to experience or by rolled lead test. The contact surface of the

support roller must be smooth and plain when rolled lead test. Insert a

Ф2mm lead wire( usually 15A fuse) into the space between tyre and
support rollers and turned as showed on drawing 1, then analysis

according to the shape of it to judge the contact condition and bearing

load condition of the support roller and tyre as well as to judge the

straightness of the centerline of the kiln shell.

The condition showed on case 1 of the drawing 2, indicates that the

support roller and tyre is exactly in parallel position, the load force is

evenly distributed on all surface width of the support roller. The shape of

the lead pressed is in square. If all the support rollers are adjusted to such

extent, the kiln’s self weight could cause the kiln flee towards down when

rotating. If the hydraulic thrust roller is used, the working position of case

1 is well.

The case 2 and case 3 show that the axial line of support roller has a

shearing force angle to the centerline of the kiln. At this time, the load is

mainly distributed on the centerline. The shape of the lead wire pressed is

in lozenge. If the running direction is as showed in drawing, the case 2

causes the kiln to move towards high end, the case 3 causes the kiln to

move towards low end.

The case 4 show that the axial line of support roller is askew only in

a vertical plane, the shape of the lead wire is in triangle and load is

mainly distributed on the low end. At this time, the axial line of support

roller has no a shearing force angle to the centerline of the kiln, the case 4

do not causes the kiln to move along the axis.

 case 5, case 6: The axial line of support roller has a shearing angle in

level to the centerline of the kiln, meanwhile it is askew only in a vertical

plane, the shape of the lead wire is also triangle. The case 5 shows that

the maximum forced of the contacting face of the support roller is on the

low end that causes the kiln to move towards high end. The case 6 shows

that the maximum forced of the contacting face of the support roller is on

the high end that causes the kiln to move towards low end.

4.1The way of the test is as follows:

4.1.1Divide the circumference of the shell into 3 equal sections and

mark the numbers according to each section, the same number of each

section of tyres should be in the same baseline.

4.1.2Pull a lead wire (a little wide than the width of tyre) into

straight and insert it into tyre to rolled according to the number of the

shell.

4.1.3Measuring the width and thickness of the rolled lead wire, fill

the data into tabulation of drawing 3.

4.1.4Take the width rolled as ordinate and the section length of

circumference of the tyre as abscissa, then analyses the information

according to the figures. In the case of drawing 3, analyzed as follows:

Case 1 shows that the position of the support roller is parallel with

the centerline of the kiln, the support force and contact strength is smaller

because the width of lead wire pressed is smaller.

 Case 2 shows that the position of the support roller is litter inclined,

by absolving the roller towards the low end(it can be analyzed that the

kiln will shift towards the high end), the roller is askew as shown, the

width of the lead wire pressed by the left support roller is wider than that

of the right, which indicates the left support roller is near the centerline of

the kiln too much. Besides, the line graph shows that the shell is bent to

the point 3 nearby somewhat.

Case 3 shows that the position of the support roller is also litter

inclined, by absolving the two rollers toward the high end (it can be

analyzed that the kiln will shift towards the low end), the roller is askew

as shown, the width of the lead wire pressed by the two support rollers is

nearly equal, which indicates the load of two support roller is nearly

uniform. Compare with other cases, the width of the lead wire pressed is

larger, which indicates the load of support also roller is larger and

position of two rollers is near the centerline of the kiln. Besides, the line

graph shows that the shell is bent to the point 2 nearby somewhat.

In case 4, the right support roller upsweeps towards the low end

which shift to the high end and cause the kiln shift towards the low end.

The left support roller upsweeps towards the low end which shift to the

low end and cause the kiln shift towards the high end. The roller is askew

as shown, the line graph shows that the shell is bent to the point 2 nearby

somewhat.
 If you want to know the exact location of the convex point of shell,

you can divide the shell in to 6 equal sections, even 9 equal sections,

increase 1to2 test points between 1-2,2-3,3-1. In the case of left roller in

case 2, after increase test points line chart is obtained as shown in figure

4, the line graph shows that the shell is bent between 1and 3.

The axial line of the support roller should be parallel with the

centerline of the kiln during installation. By using the lead wire test, the

width of the wire pressed is same. We can know a little force of the

support roller according to the width of the wire pressed, the more

stress’s roller is a little parallel away from the centerline of the kiln, the

low stress’s roller is closed to the centerline of the kiln, the adjusted

measure of each time should not be large，many adjustment is necessary

to achieve normal operation condition. Normally to say, turn the set

screw from 1/8 to 1/16 only, the reflex of lead wire is appeared. The

approval by the competent department of the factory should be necessary

during adjustments every time to correct judge the actual status of the

kiln. The positions of support roller are not shown as drawing 3 during

adjustments. The contact of roller and tyre is not better and the force

between roller and tyre is offseted each other in this state. The wear

between the roller and tyre and the consumption of motor power are

increased.

5. The hydraulic thrust roller assembly

The axial line of the support roller should be parallel with the centerline

of the kiln during installation. Because the shell is oblique, the kiln will

slide down because of its self weight. When using the hydraulic thrust

roller, the shell shall move up and down according to the preconceived

speed (usually about 2to3mm/hour), the contact and wear between the

roller and tyre are effective guaranteed and greatly save workload of the

adjusting roller. The usually up and down stroke of the hydraulic thrust

roller is ±10 mm. When up and down stroke reachs ±15 mm, the

warning signal shall be sent out. When up and down stroke reachs ±30

mm, the main motor shall be stopped power at once. Above stroke has

allowable little change of ±1-2mm by adjusting the limit switch. When

the main motor power cuts, the helper motor drives the shell to run

slowly.The hydraulic thrust roller assembly choose to TBY-12 thrust

roller hydraulic pressure station.

5.1 The working prinaple of thrust roller hydraulic pressure station is

shown as figure 5. The station is equipped with two set of micro-infusion

pumps 10 and its flow rate is adjustable. In normal working conditions,

the one works and another one is spare. But in special circumstances，two

set of micro-infusion pumps can work together at the same time . When

kiln start-up, at the same time, Start motor of the pump 10(When the kiln

turn first, the oil cylinder left cavity should be filled with hydraulic oil).

The oil pump10 draw oil from oil tank 3(the tank is over the pump)
through oil filter 6. the oil is sent to oil cylinder through one-way valve

and stop valves 9(please see direction of full line’s arrow). Below

pressure oil’s action, the oil cylinder’s piston push forward the thrust

roller to move upward. This moment, the electromagnet of change valve

7 is no electricity and in a closed state, to adjust micro-infusion pumps 10

can control the up speed of kiln. The up and down stroke of kiln depend

on the position of limit switch 18 and19. When thrust roller base come to

contact with upper limit switch 18, the oil pump will stop to supply oil for

system, at the same time, the electromagnet of change valve 7 in return

line start to move, the valve body open thoroughfare from oil cylinder to

oil tank 3, the status of

electromagnet will be maintain always.

At present, the pressure oil in oil cylinder is returned to the oil tank along

the direction of the dashed-line arrows by kiln body self weight, adjusting

throttle valve 8 can control the down slip speed of kiln body. When thrust

roller base come to contact with lower limit switch 19, the electromagnet

of change valve is no electricity, the valve body close the thoroughfare

from oil cylinder to oil tank under the action of the spring. The

oil pump shall be restarted meanwhile and Repeat the above procedure.

Because of oil-line plugging or other defects, when system’s oil pressure

is more than allowed, the oil opens the valve of relief valve and is

returned to the oil tank. The control of maximum allowable pressure in

line is realized by adjusting the spring of the relief valve. Normally, the

maximum allowable pressure of the system is not more than 11.7MPa.

The strainer 12 is installed in return line to avoid blocking of the throttle

valve 8. If the strainer is stoppage, its internal film shall be move because

of pressurizing. Therefore, the signaling lines is cut-in, the indicator light

or alarm bell will give an alarm, this movement, the filter cartridge is

replaced in time. The electric contact bimetal thermometer 2 is installed

in the oil tank, when working temperature is more than 35℃ given

temperature limit, the power of electrical heater shall be cut off, when

working temperature is less than 10℃, the power of electrical heater

shall be turn on.

When the kiln doesn’t work long time, to ensure the contact width of

all working surface between tyres and rollers are more than 3/4 of the

entire width, the kiln is stopped when tyre’s centerline is lower than the

roller’s centerline.

When the kiln doesn’t work long time, in order to cut off the passageway

between the oil cylinder and the oil tank and kept oil in oil cylinder for

turning kiln next, the power of the electromagnet of change valve 7 must

be switch off and keep its locked state when the main motor is power

interruption.

5.2 It is necessary to observe the pressure gage of oil station

frequently. The pressure shall be 4-6MPa at normal operating conditions,

not more than 8MPa, it is necessary to check reason and immediate

proceeding when the pressure is not normal.

5.3 The oil cylinder and base can't move easily, the piston rod shall

be taken out In the replacement of the piston seal.

5.4 It is necessary to take good case of oil station，to assure a safety

working condition of the oil station, the strict post responsibility system is

established according to relevant provision for its safety operation.

5.5. The other regulations refer to TBY-12 thrust roller hydraulic

pressure station.

6. The trial run

6.1Before trial run, check to see if the foundation elevation has

been varied, all bolts and nuts fixed, all lubrication points filled with

lubrication oil or grease. Please pour a lay of oil on the shaft journal of

support roller before turning the kiln. Check and to see if the water can go

through the cold water system. The trial run can only be carried out after

check and everything is all right.

6.2 The individual trial run of the equipment should be made before

complete try-operation. The main motor and auxiliary motor must be run

for 2 hours all, the main motor and auxiliary motor must drive the main

reducer and auxiliary reducer for 2 hours all, record the current and

temperature increasing and listening to any abnormal sound carefully.

 6.3 The trial run before firebricks constructed must be for 2 hours by

auxiliary motor, then for 8 hours by main motor. The following items

must be checked during the trial operation.

6.3.1 Check the lubricating condition on every lubricating point,

temperature increased, current, oil leakage etc. The temperature increased

should not exceed over 30℃ normally. The load of motor should not

exceed 15% over the rated power.

6.3.2 Check the vibration of driving system abnormal impacts

sound,

check to see if the contact between gear rim and pinion is correct.

6.3.3 Check the contact condition between tyre and roller and the

clearance between thrust ring and liner of the roller.

6.3.4 Check sealing system on two ends of kiln shell and cold air

blowing system. The over air leakage is not allowed.

6.3.5 Check the bolts and to its tightness.

6.4The trial run and kiln drying is to be carried out at same time

after the firebrick built. The following works should be must be checked.

Please check the temperature raised on each tank which should not

exceed 35℃.The temperature raised of the bearing should not exceed

40℃. The load of motor should not exceed 25% of the rated power.

Especially check and to see if the adjustment of the support roller is

correct. Such as the surface contact between support roller and tyre

evenly.

The other items to be checked are the same as before firebrick built.

7. Regular maintenance in operation

7.1Every part of the thrust roller and drive system must be checked

every hour, any abnormal sound, vibration and heating must be repaired

and adjusted.

7.2Check the contact condition between tyre and support roller to

see if it is in even wear and tear condition, if the load force is too large

and is there carve or scrap on the surface of the support rollers.

7.3According to the relative displacement of the tyre and its support

block in one revolution, judge the clearance and wear and tear condition.

Please check if there is any cracks on welding seams of the support

blocks. The lubricating grease is frequently inject between the tyre and its

support block and subplate.

7.4Check the foundation bolts and fix bolts on the driving base

plates to see if there is any looseness. If yes, please tight it.

7.5 Check vibration and subsidence of the foundation.

7.6 Check the sealing condition of the sealing devices both on inlet

and outlet; the wear and tear condition of the graphite block.
 7.7 Check the bearing temperature and lubricating condition of the

liner of support rollers shaft once an hour. Check and see if the space

between thrust roller and liner is in the right position.

7.8 Check and start the auxiliary motor without clutching once a

week so as to guarantee the smooth operation in case of the main power

cut off suddenly.

7.9 Check the temperature of the kiln shell frequently, especially in

the burning zone regularly and nearby II tyre keep the temperature below

380℃, can reach 410℃occasional, If kiln is still in operation under the

temperature of the kiln shell is more than 415℃, Should be regarded as

violation operation.

8. Abnormal phenomenon in operation, processing method and

the note of security

8.1 Abnormal phenomenon in operation and processing method

8.1.1The axial line of two support rollers in any station should be in

the right position. If not, please adjust it according the way mentioned

relevant.

8.1.2 The foundation had subsided, please reduce the speed of the

kiln and immediate processing.

8.1.3 The main power source suddenly cut off, please immediate

processing.
 8.1.4 The fire can not burn towards the firebrick directly. If “red

kiln”

phenomenon is found( the firebrick fell down or wear out), please stop

the operation at once and the kiln repair in hot state is not allowed.

8.1.5 When the surface of tyre and support roller are apart, please

find the cause and adjust it carefully.

8.1.6 The causes of polygon formed on the surface of the tyres and

support rollers and processing method:

8.1.6.1The shaft line of roller and center line of kiln are not parallel.

8.1.6.2 The incorrect mesh of pinion and the gear rim or the impact

caused by serious wear out of the teeth.

8.1.6.3 Uneven wear out of the liner happened, or the inclined

support roller caused, only a liner to be replaced.

8.1.6.4 Caused by slip and uneven surface wear out between tyre and

support roller.

8.1.6.5 The vibration caused by the foundation subsides or the

foundation not strong enough.

8.1.6.6 Worse lubrication and wear out too much between the

surface of the tyre and support roller.

8.1.6.7 Because of the default material of the tyre and roller, the

shape of “convexity” is formed in hard place, the shape of“concavity” is

formed in soft place.

 8.1.6.8 It could be ground to smooth if the wear out is not serious. If

the wear out is quite serious, it must machined by lathe.

8.1.7The reason of difficult start up is that the kiln stopped after a

short period without turning in time which caused shell centerline

winding. The bending point is below usual, if the winding is not serious ,

the bending point of kiln could be turned to above and heated. If the

temperature is higher, turn the kiln several revolutions, still let winding

point in up position. Repeat the step until the winding recovered.

If the winding is very serious, a overhaul is necessary.

8.2The note of security

8.2.1Any repair must take place after the kiln stopped and a notice

board marked with “ do not start up” should be put on the motor switch

cabinet.

8.2.2 Do not insert hand or other material into bearing, reducer or

gear rim cover to do any work during operation such as check, repair,

clean. The security facilities (for example coupling guard) can not be

dismantled. 8.2.3 Do not put repair tools and the spare parts on the

turning part of the machine, especially on the support rollers.

8.2.4 Please use watching glass when observe the burning from

observing hole. The direct watching is not allowed. Please close the door

of the observing hole after watching.

8.2.5 Please check the kiln thoroughly before starting the kiln. Only
no body is inside the kiln and alarming sounded, can the kiln be started

up.

9. The kiln stop and start

9.1 Short time stop

9.1.1The kiln is still in hot state in the initial period after the kiln

stopped, which will cause the centerline of the kiln distorted, please turn

the kiln frequently to avoid the center line winding, this is very important

and never neglected. The provisions are as follows:

Every 5-10 minutes: 1/4 revolution the first hour after kiln stopped

Every 15-20 minutes: 1/4 revolution the second hour after kiln stopped

Every 30 minutes: 1/4 revolution the third hour after kiln stopped

After that, turn the kiln once an hour, the range of turning is 1/4

revolution. The auxiliary motor shall be used in turn the kiln.

9.1.2 The air blower of coal burner will keep working till the kiln

cold down completely to prevent the coal burner is bending.

9.1.3 The cooling fan of outlet nose ring will keep working till the

kiln stop completely after 4 hours.

9.2 The kiln stop and check for long time

9.2.1 After the kiln stopped, turn the kiln according to the regulation

mentioned above till the kiln cold down completely and the people could

go inside of the kiln.

9.2.2Plase pull out of the coal burner when the fire off and the kiln
stopped, clean part or all material out from the kiln according to the

actual situation of maintenance.

9.2.3 The following items must be checked after the kiln stopped.

9.2.3.1 Check if the cooling water in each part has been drawn

completely during freezing temperatures.

9.2.3.2 Check the situation of end wearing surface, the clearance

between shaft and bush and the space between gear rim and pinion etc.

9.2.3.3 Check if there is any loose and damages of connecting bolts,

especially for the bolts connecting with the gear rim; any creaks on the

welding seams of the shells and blocks.

9.2.3.4 If the lubricating oil need to be changed, cleaned or refilled.

If yes, please discharge the original oil, clean and refill it.

9.3 The start and stop of the auxiliary driving

In order to avoid the shell distortion, the auxiliary driving could be used

for turning the kiln when the main power cut off. In the purpose of repair,

the auxiliary driving can also be used to turn a certain position, but when

using the auxiliary driving, the auxiliary driving could not be used for

long time( not exceed half an hour) because the rotating speed is very

slow and the oil spoon of the support roller bearing will form a

intermittence lubrication, otherwise the temperature and power capacity

increased and cause impact sound. If the continuous running is necessary,

please pay attention to lubrication of each bearing of the support roller.

The regular manual oil filling on the shaft journal is needed. Please note

the heating information of the bearing of the main reducer.The

operational sequence of “start” and “stop”

When using the auxiliary driving to run kiln, it is necessary that

helical clutch is meshed first of all. At this time, the travel switch is

pressed down by the lock block under the hand grip of helical clutch, the

power is connected to the auxiliary motor and no main motor. If main

motor need to start, except for the power of the auxiliary motor is cut off,

it is necessary first that the hand grip of helical clutch is moved and

helical clutch is not meshed. At this time, the lock block under the hand

grip depart from the travel switch and the travel switch automatic

reset，the main motor just possible is connected with power. That the

power of the main motor and auxiliary motor is connected or not is

controlled all by this travel switch.

Please note that never operate the clutch when the kiln in running.

The helical clutch should be in complete meshing unspaced.

If the position of teeth is not right, can turn the coupling of motor, it

is necessary that the coupling is out by hand and teeth must be withdraws

all.

10. Lubricating and cooling

The good lubrication of all moving parts is a very important job. The

reasonable lubricating can Prolong life parts and reduce the cost of
repairs. It is necessary that lubricant is regarded as a “mechanical

components” and be much accounted.

Please pay attention to the follows when lubricating and cooling the kiln

10.1 please use the lubrication oil or grease according to the usage

regulation. If use the substitution, the property must be conform with the

requirement. Only the high viscosity oil, can replace the low viscosity oil.

10.2 A new kiln runs continuously for 400-500 hours in order to

make the gear and bush work well and then the oil should be discharged

every 6-8 months after that.

10.3 Check the oil level every shift. If the oil is in the low level of

the oil indicator, please fill the oil to the top of the oil level indicator.

10.4 In case the oil leakage found, please find the cause of the

leakage and correct it. Please take measures to prevent the oil flow to the

foundation avoiding the foundation being corroded.

10.5 Starting again after the kiln stopped for long time, that the main

drive is used directly is unfavorable，but rather the auxiliary drive is used

to run kiln 1-2 revolution, then the main drive is used to run kiln, at this

time, the roller bearing should advance pouring the oil.

10.6 Please check if water cooling system is in normal condition.

Please discharge water in each cooling system to avoid freeze and pipe

damage in ling time stop or in winter. In order to run off the water from

the ball bush, please close the adjustable valve on the discharge pipe and
turn Tee joint in the water inlet for 90°immediately. Let the air in and

open the adjustable valve at once. The cooling water will flow out

because of the suction. If the water can not flow out completely, use the

compressed air from air hole of the valve.

10.7 The boshing of the roller is harmful to the surface between tyre

and roller and should not be used.

11. The examine and repair

After a long period operation of the kiln, the parts of the kiln will wear

out that will reduce the accuracy of the equipment and effect the output of

the kiln. The repair schedule shall be made in advance under the

preventive maintenance principle. The main repair methods is minor and

medium repair now, all those work must be carried out when the kiln

operation stopped for building the bricks. It is better to divide the

comparatively large repair in to 2-3 times when the kiln stopped for

building the brick. The repair of the driving system shall be carried out

after the building the bricks is finished, but it should be finished in short

time (such as from3-12 hours). The time of overhaul will need more time

(such as from 10-20 days). All the wear out and damaged parts must be

replaced. Check and adjust all points of the kiln such as replacing the kiln

shell section, gear rim, tyre, support roller, thrust roller and correct the

centerline of the kiln.

If the main parts of the kiln wear out to the following content, the parts

must be replaced:

11.1 The driving teeth wear out to the 30% of total thickness or the

gear rim has a irrevocable damage.

11.2The shell section has creaks or party distorted.

11.3 The 20% of cross surface of the tyre wear out or the surface

becomes taper shape, polygon and thorough creaks.

11.4 The 20% of diameter of shaft of the support roller or 20% of

the rim thickness or the surface of roller rim are wear out or surface of

roller rim become taper shape or through cracks. When replace the

support roller or shaft, its relative liner must be scraped or replace.

11.5 The bearing of the pinion drives and the thrust roller drives is

damaged.

12. The list of lubricate

lubricating point lubricate Service cycle

First Single oil Normal
name lubricating name change volume change
cycle cycle
way
Concentrated Please see the reducer instructions
main gear oil
Circulation
lubrication ISO-VG320CST 40℃
reducer
 Pool
Auxiliary gear oil
lubrication
ISO-VG320CST 40℃
reducer
Bearing of oil spoon N460 industrial gear oil, 600 500L 0.5-
roller continuous middle load（GB5903- hours 0.75
lubricating 1995） year
Bearing of Manual oil Extreme pressure lithium 600 60L 0.5-
thrust roller pump lubricating grease hours 0.75
No2（GB7323-1994） year
Bearing of Oil cup Extreme pressure lithium 600 Fill two-thirds Every
pinion lubricating grease hours space of rolling shift
device No2（GB7323-1994） bearing and once
bearing cavity
Big gear and Oil fog CKH viscosity level Please see the instructions of
pinion lubrication 220（SH/T0363-1992） lubricating device
Tyre and roller Continuous Graphite block 0.25-
Tyre and thrust touch 0.5year
roller
Inside surface Jet lubrication High temperature sealants Every day a Jet lubrication
of tyre and No7602 ZBE40017-88
bolster plate
Wheel bearing Oil cup Extreme pressure lithium Maintaining adequate
of kiln hood lubricating grease
No1（GB7323-1994）

13.The list of vulnerable parts

No. Drawing No. Name material Unit Quant remarks
weight ity
One
kiln
1 3A68-0401 Tyre Ⅰ 35CrMo 4494 1 Shell assembly
9
2 3A68-0402 Tyre Ⅱ 35CrMo 4561 1 Shell assembly
6
3 3A68-0403 Tyre Ⅲ 35CrMo 4621 1 Shell assembly
3
4 R2166.1-4 修 Feed protection plate ZGCr26Ni 110.5 18 Shell assembly
12
5 GB8-88 Bolt M30x130 A2-50 0.995 72 Shell assembly
6 ZGCr26Ni 47.43 Shell assembly
R2166.1-13 修 54
Outlet protection plate 12 0
7 GB8-88 Bolt M30x120 A2-50 0.842 162 Shell assembly
8 GB/T6170- A2-50 Shell assembly
0.18 234
2000 Num M30
9 R2166.1-5 修 Stop dog (Ⅰ,Ⅲ) Q235A 47.52 96 Shell assembly
10 Q235A 141.9 Shell assembly
R2166.1-9 修 bolster plate Ⅱ 24
2
11 R2166.1-6 修 Stop dog Ⅱ Q235A 47.52 48 Shell assembly
12 Q235A 141.3 48 Shell assembly
R2166.1-7 修 bolster plate(Ⅰ,Ⅲ)
7
13 ZG42CrM 1377 6 No I,Ⅱ,Ⅲ roller
3A68.2.1-2 roller
o 5 bearing
14 3A68.2.1-3 Roller shaft 45 6430 6 Same as above
15 3A68.2.1.2-10 Lining tile ZA303 198 12 Same as above
16 JB/ZQ4605-86 Spring 630 0.134 16 Same as above
17 Rubber I - 8 Same as above
R2166.2.1-17 Sealing ring（一）
2
18 Rubber I - 8 Same as above
R2166.2.1-18 Sealing ring（二）
2
19 R2166.2-8 Graphite block Graphite 8.26 3 Same as above
20 R2166.4.2-7 修 Pinion shaft 35CrMo 2073 1 Pinion device
21 R2166.4.2-3 修 pinion 42CrMo 2676 1 Pinion device
22 Bearing 23068 109 2 Pinion device
23 Thrust roller ZG35CrM 2 Thrust roller
R2166.5.1-12 2010
o device
24 2 Thrust roller
3A68.5.1-11 Thrust roller shaft 45 482.1
device
25 shaft sleeve ZQSn6-6- 8 Thrust roller
R2166.5.1-18 32.21
3 device
26 4.7 2 Thrust roller
R2166.5.1.1-3 Graphite block Graphite
device
27 GB/T 288- Bearing Thrust roller
1994 24164/W33/C3 251 2 device

28 Bearing 23056/W33 61.5 2 Thrust roller

device
29 GB5859-84 Bearing 9039432E 42.55 2 Thrust roller
device
30 GB/T 3452.1- O Sealing ring 4 Thrust roller
YI9424 0.03
2005 345x7.00G device
31 GB/T 3452.1- O Sealing YI9424 0.03 4 Thrust roller
 2005 ring109x5.30G device

14.附图清单:
序号 代 号 名 称 张数
1 3A68-00 Φ4.8×72 m Kiln 3
2 3A68-01 Seal of Kiln Head 2
3 3A68-02 Cooling Air Duct 1
4 3A68-03 Supporting EquipmentⅠ 1
5 3A68-04 Shell 1
6 3A68-05 Supporting Equipment Ⅱ 1
7 3A68-06 Drive Device 2
8 3A68-07 Girth Gear 1
9 3A68-08 Supporting Equipment Ⅲ 1
10 3A68-09 Seal of Kiln End 2
11 3A68-10 Pipeling System of Blocking-Wheel 1
3A68-11 Pipeling System of Rudecer
12 1
Lubrication
13 3A68-12 Cooling Air Duct of tyre 1
14 3A68-13 Installation tools 1
15 3A68.2.1 Riding Wheel Set 2