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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 ............................ 7
2.1 Construction .....................................................................................7
2.2 Operating principle ...........................................................................8
3. INSTALLATION ............................................................................. 13
3.1 Installation of the mechanical parts................................................13
3.2 Installation of the hydraulic system ................................................15
3.3 Installation of electrical supervisory and control system.................16
3.3.1 Longitudinal transducer 16
3.3.2 Separate limit stop KDS 1 17
3.3.3 Separate limit stop KDS 2 17
3.4 Posting of signs and mounting of guards ................................................ 157
4. OPERATION.................................................................................. 18
4.1 Preparing the mechanical system for operation .............................18
4.2 Preparing the hydraulic system for operation.................................18
4.2.1 Procedure for preparing the hydraulic system 18
4.3 Checking and adjustment...............................................................20
4.4 Day-to-day operational checks during start-up perod.....................20
5. MAINTENANCE ............................................................................. 21
5.1 Preventive maintenance ...................................................................201
5.1.1 Lubrication 22
5.1.2 Cleaning 22
5.1.3 Inspection and adjustment 23
5.1.4 Checking of condition 23
5.1.5 Replacement 24
5.1.6 Performance test 24
5.2 Faults and remedial action .............................................................24
5.2.1 Thrust device failure 24
5.2.2 Kiln tyre runout 25
5.2.3 Position of supporting rollers 25
5.2.4 Position of thrust rollers 26
5.3 Replacement of parts. ....................................................................27
6. KEY TO APPENDICES .................................................................. 28
APPENDICES:
App. 1. Thrust roller .................................................................................... 31
App. 2. Thrust roller with ancillary equipment ............................................. 33
App. 3. Pipe diagram (schematic diagram)................................................. 35
App. 4. Functional diagram ......................................................................... 37
App. 5. Hydraulic cylinder ........................................................................... 39
App. 6. Safety switch, KDS 1 ...................................................................... 41
App. 7. Safety switch, KDS 2 ...................................................................... 43
App. 8. Calibration of transducer ................................................................ 45
App. 9. Dismantling of thrust roller.............................................................. 47
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NOTE!
The present instruction manual is concerned with the situations which,
according to the experience of FLS, are the most likely to occur. An
exhaustive enumeration of all conceivable situations which may occur
during the installation, operation and maintenance of the thrust device
cannot be provided.
1. GENERAL NOTES
The function of the hydraulic thrust device is to transfer the axial
load from the rotary kiln from one to several supports and to
maintain the rotary kiln in the axial direction within a specific area
on the supporting rollers.
REQUIREMENT:
Thrust device to be used exclusively for the predefined purpose!
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MANDATORY!
The directions outlined in instruction No. ref. 2 "Rotary kiln
plant (dry process), safety regulations must be strictly ob-
served.
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 con-
nected 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 (an extremely
hazardous condition!) or electronic equipment.
MANDATORY!
Strict compliance with the directions outlined in instruction
No. ref. 3 "General safety regulations at erection site" must
be ensured. This instruction manual must be scrutinized by
the client, the erection contractor and FLS representatives
before erection work is started.
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MANDATORY!
The accumulators must only be charged with nitrogen (N)
to the specified precharging pressure.
MANDATORY!
Disassembly of the hydraulic system to take place only
when the pressure in the hydraulic system has been re-
duced to atmospheric pressure.
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2.1 Construction
The thrust device consists of a mechanical part, a hydraulic system
and an electrical supervisory and control system.
Dependent on the size of the load, the thrust device may consist of
one or several mechanical units, which are mounted on separate
supports.
If the thrust device consists of more than one unit, only one unit, i.e.
the master unit, will be connected to the electrical supervisory and
control system. The other unit(s) will serve exclusively as slave
units, which are hydraulically connected only to the master unit.
The master unit is always placed on the support closest to the kiln
drive.
The master unit and slave unit are of identical mechanical design.
One unit consists of a roller whose conical running face is in con-
tact with a similar conical running face on the kiln tyre, as well as a
hydraulic cylinder which will absorb the axial load exerted on the
roller and transmit it to the support.
See Appendices 1 and 2.
The thrust roller (75) runs in a bearing block (83) which is provided
with roller bearings. The suspension of the bearing block from the
two guide shafts (81) will allow the bearing block to be displaced in
the axial direction.
The guide shafts rest in two bearing blocks (80 + 84) which are
fixed to the support. The hydraulic cylinder (45) is placed in the
bearing block which is closest to the kiln outlet.
The roller bearings in the bearing block run in an oil bath.
The bearing bushings (82) of the guide shafts are grease-
lubricated.
The conical running face of the thrust roller is lubricated by a
weighted graphite block (87) fitted in a holder on the bearing block.
The hydraulic system (see Appendix III) consists of a pump station
and a pipe system connecting the pump station to the hydraulic
cylinder(s).
The pump station is a mild-steel frame in which the oil tank as well
as pump unit, filters and valve arrangement are mounted. The pipe
system consists of a pressure system and a return flow system
which can be short-circuited through a needle valve (40).
The pressure system incorporates a hydro-pneumatic accumulator
(23).
The primary function of the accumulator is to absorb pressure
variations in the hydraulic system in case of kiln tyre runout and to
ensure that the thrust roller remains in contact with the kiln tyre
when the upward migration of the kiln occurs.
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The electrical supervisory and control system consists of a longitu-
dinal transducer (49) and two separate limit stop switches (50) and
(51).
The longitudinal transducer registers the movements of the thrust
roller, and hence the movements of the kiln tyre. In case of any up-
ward movement of the kiln tyre, the thrust roller will be moved ac-
cordingly due to the hydraulic pressure from the accumulator. The
limit stop switches (50) and (51) are actuated, respectively, by the
bearing block through an arm and by the kiln tyre (see Appendices
6 and 7).
2.2 Operating principle
Correctly adjusted, the supporting rollers of the kiln will take up 10-
50% of the axial load of the kiln. This means that the load on the
thrust device will be relieved, but entails also that the remaining
load will be exerted on the thrust device, preventing the supporting
rollers from forcing the kiln away from the thrust rollers.
When the thrust device has one or several slave units in addition to
the master unit, the load will be evenly distributed between the
thrust rollers due to the fact that the hydraulic cylinders are hydrau-
lically interconnected. Therefore, they are capable of compensating
for the changes in the distance between the individual kiln tyres
which may be caused by thermal conditions inside and around the
kiln.
These thermal conditions may, inter alia, be the reason why the kiln
tyre at the master unit is moving away from its zero position.
Since the primary function of the thrust device is to maintain the kiln
in the axial direction, it will react to the kiln tyre migrations, attempt-
ing to keep the centreline (at the master unit) of the kiln tyre within
a range of plus/minus 5 mm from the neutral position. Minor move-
ments within this range - due, for example, to kiln tyre runout - will
be taken up by the hydraulic accumulator.
For kiln equipped with girth gear the neutral position will coincide
with the centreline of the supporting rollers.
For a kiln with drive effected through the supporting rollers, the neu-
tral position will be displaced from the centreline of the supporting
rollers to compensate for the weight of the drive unit. See the posi-
tion drawing of kiln for the position of the neutral point relative to the
centreline of the supporting rollers.
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The thrust device will react to the movements of the kiln tyre/kiln in
the following manner:
A downward movement of the kiln tyre, out of the neutral zone,
will trigger the following action:
The longitudinal transducer (49) registers the movement. The oil
pump (08) is started, thrusting the kiln upward again, back to the
neutral zone. See fig. 1.
Fig. 1
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The oil pump will be stopped when the kiln tyre has reached the zero
position.
The hydraulic pressure will then be exerted on the non-return valve
(11).
This operating situation will prevail as long as the kiln/kiln tyre are
positioned in the neutral zone. See fig. 2.
The system pressure must now be 50 70 bar.
Fig. 2
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An upward movement of the kiln tyre, out of the neutral zone, will trigger
the following action:
The longitudinal transducer (49) will register the movement. The accumu-
lator will ensure that the thrust roller maintains contact with the kiln tyre.
The solenoid-operated directional seat valve (13) is energized. The oil
from the hydraulic cylinders and accumulator can now be recirculated
through the system back to the tank. (See Fig 3). The pressure transducer
(18) will trip alarm in case of a pressure drop to level below 10 bar.
The pressure will not drop to a level below 3 bar because of the non-
return valve (30).
If the kiln is unable to move downward unaided, it will be necessary to ad-
just the position of the supporting rollers.
When thrust roller/kiln tyre/kiln have migrated downward, back to the neu-
tral zone, the voltage from the solenoid-operated seat valve must be de-
energized, and, again, the hydraulic pressure will be exerted on the non-
return valve (11).
Fig. 3
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If, in spite of the thrust device, the kiln/kiln tyre is moving more
than 10 mm downwards from the zero position, the longitudinal
transducer will trip an alarm. The kiln motor will be cut out in event
of a further 5 mm downward migration of the kiln/kiln tyre.
See the functional diagram in Appendix 4.
When the kiln is shut down, the valve (40) must be opened/closed
every 24 hours in order to equalize the pressure between the front
side and back side of the piston. This is done to prevent ingress of
dirt and moisture into the cylinder.
For additional safety, the thrust device is provided with two sepa-
rate limit stop switches (50) and (51). The kiln must be stopped in-
stantaneously in case any of these limit stop switches are activated.
3. INSTALLATION
The thrust roller must not be dismantled during erection. After a unit
has been released from the transport frame (96) (see Appendix 1),
it must be mounted in the assembled condition on the bedplate.
Follow the directions given on the arrangement drawing of the
thrust device. At some supports, the unit must be mounted on a
bracket which must first be mounted on the bedplate.
Mount the oil level pipe (85) and air filter (94) on the unit, and fill oil
into the bearing housing up to the mark on the oil level glass (See
Appendix 2).
Oil quality: FLS MAT No. 7158.
Mount the master unit on the bedplate or on the bracket mounted
on the bedplate. The thrust roller must be positioned at the correct
distance away from the centreline of the supporting rollers. The
bearing block of the unit must be centrally positioned on the guide
shafts, i.e. the dimensions "a" and "b" must be of equal size. See
Fig. 1. Distance pieces of identical size are fitted at "a" and "b" to
facilitate the operation. See Appendix 1.
ERECTION CHECK
Align the thrust roller so that its rate of inclination is consistent with
that of the kiln and so that it will be horizontally positioned at right
angles to the kiln axis. The axis of rotation of the thrust roller must
be exactly in the vertical plane of the kiln. See Fig. 4.
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Fig. 4
Fit the adjustment wedges (91) and fix them by welding to the bed-
plate as indicated in Appendix 2.
Fit the holder (86) for graphite block (87), guard (95) for cylinder
block and the two-part channel (88).
70000448-3 15
Fig. 5
ERECTION CHECK
4.4 Daily operational checks during start-up period
1. Always ensure that the protective caps are fitted to the
measuring nipples (20), (24), (42) and (43).
2. Make sure that the cover plates and panels have been fitted
on the pump station.
3. Check the visual indicator of the return filter.
4. Check the oil level in the tank of the pump station.
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5. MAINTENANCE
5.1
Preventive maintenance, survey
.1 Lubrication
.2 Cleaning
.3 Inspection and adjustment
.4 Checking of condition
.5 Replacement (incl. lubricants)
.6 Performance test
Pos. Text .1 .2 .3 .4 .5 .6
00 Thrust device . S . . . .
01 Pump station . S S A T 2A
03 Suction filter . A . . . .
23 Accumulator . . A A . .
26 Air filter/sieve . A . . . .
28 Return filter . . . S A .
45 Cylinder . . . 2A . .
50 Limit switch KDS1 . . . S . 2A
51 Limit switch KDS2 . . . S . 2A
75 Thrust roller T . D . . .
77 Roller bearing S . . . A .
78 Roller bearing S . . . A .
79 Roller bearing S . . . A .
82 Bearing bushing M . . . . .
83 Bearing block . . D . . .
94 Air filter . A . . . .
Accumulator (23)
Check the precharging pressure. In case of a significant drop in
pressure, and if a leakage is suspected, the accumulator must be
checked as described in the suppliers instruction manual, ref. 10.
Cylinder (45)
Cylinders to be vented every 6 months, see sub-section 4.2.1.
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Limit stop switch KDS1 (50)
Check that the position of the roller arm on the switch and that of
the activation frame (58) are correct.
If the pump or pump motor should fail when the kiln is "in downward
position", and the kiln must be lifted to neutral position, this can be
done by means of a hydraulic hand pump which is connected to
measuring nipple (20) or (42).
The hand pump must only be operated with very small oil quanti-
ties.
In case of a pipe rupture on the pressure side, the kiln will force the
thrust rollers downward towards the outlet, until the bearing block of
the master unit is made to rest on the distance ring (90). At this
point in time, an alarm has already been triggered by the monitoring
system, and if no further action is taken, the kiln motor will be cut
out automatically.
Fig.6
70000448-3 27
01 Pump station
02 Pump station oil tank
03 Suction filter
04 Ball valve
05 Hose. Suction side of pump
06 Motor for pump
07 Coupling between motor and pump
08 Pump
09 Hose. Pressure side of pump
10 Hose. Drain from pump
11 Spring-loaded non-return valve
12 Ball valve
13 Directional valve, electrically controlled
14 Pressure gauge for system pressure
15 Hose. Pressure gauge
16 "Mini-Mess"-coupling for pressure gauge
17 Hose. Pressure transmitter
18 Pressure transmitter
19 "Mini-Mess"-coupling for pressure transmitter
20 "Mini-Mess"-coupling for system pressure control
21 Pressure-limiting valve
22 Flow control valve
23 Hydraulic accumulator
24 "Mini-Mess"-coupling for return flow pressure control
25 Emergency stop
26 Air filter
27 Level switch: Trips alarm in case of low oil level in oil tank
28 Return flow filter
29 Ball valve
30 Spring-loaded non-return valve in return line
31 Oil level glass
32 Drain cock
33 Pressure gauge
34 "Mini-Mess"-coupling
35 Hose for test pressure gauge Testing and
36 Vent pipe venting equipment
37 Fitting
38 Stop valve
39 "Mini-Mess"-coupling
40 Stop valve
41 Stop valve
42 Measuring nipple. Pressure side on cylinder
43 Measuring nipple. Piston rod side of cylinder
45 Hydraulic cylinder
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46 Magnet
47 Plastic disc
48 Protective tube
49 Longitudinal transducer
50 Limit stop switch, KDS1
51 Limit stop switch, KDS2
53 Frame for KDS2
56 Baseplate
57 Bracket and baseplate for limit stop switch, KDS1
58 Arm for activation of limit stop switch, KDS1
75 Thrust roller
76 Thrust roller shaft
77 Upper spherical roller bearing
78 Lower spherical roller bearing
79 Spherical axial roller bearing
45 Hydraulic cylinder
49 Longitudinal transducer
75 Thrust roller
76 Thrust roller shaft
77 Upper spherical roller bearing
78 Lower spherical roller bearing
79 Spherical axial roller bearing
08 Pump
13 Directional valve, electrically controlled
18 Pressure transmitter
50 Limit stop switch, KDS1
51 Limit stop switch, KDS2
49 Longitudinal transducer
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33 Pressure gauge
34 "Mini-Mess"-coupling
35 Hose for test pressure gauge Testing and
36 Vent pipe venting equipment
37 Fitting
38 Stop valve
39 "Mini-Mess"-coupling
42 Measuring nipple. Pressure side on cylinder
43 Measuring nipple. Piston rod side of cylinder
45 Hydraulic cylinder
46 Magnet
47 Plastic disc
48 Protective tube
49 Longitudinal transducer
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15
45 Hydraulic cylinder
49 Longitudinal transducer
97 Thrust disc
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98 Forklift truck
99 Lifting table with overhang
100 Temporary support for overhang of lifting table
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