Detailed rotary kiln incinerator furnace dryer installation guide step-by-step

Overview of cement plant rotary furnace installation project

This cement plant rotary furnace is equipped with a rotating drum with a specification of φ2200×18000 in the concentrate drying plant. The dryer has a total weight of 63 tons. The basic design parameters can be found in the rotary drying equipment technical documents. The installation shall be carried out according to the design and construction drawings and GB50291-98 “Mechanical Equipment Installation Engineering Construction and Acceptance Specifications”, Cement Machine Standard JCJ03-90 “Cement Machinery Equipment Installation Engineering Construction. It shall be carried out by the requirements of “Working and Acceptance Specifications” and “General Parts”.

Cement rotary kiln furnace installation procedure flow diagram

Construction preparation→Foundation acceptance and retest→Equipment out-of-warehouse transportation→Cleaning and inspection→Backing plate installation→Installation, alignment, and grouting of the supporting roller group→Precise alignment, measurement, and adjustment of the supporting roller group→Installation of the stop wheel→Installation of the wheel belt→ Body hoisting → body docking and alignment → body welding → body weld quality inspection → large ring gear installation → transmission device installation → nose and tail seal and gear cover installation → test run before lining the body → lining inside the machine → hydraulic station, lubrication station, water spray device installation → trial operation after lining inside the machine → handover acceptance.

Limestone rotary kiln construction preparation

First, organize self-review and joint review of process drawings and equipment drawings to understand the rotary drum dryer working principles, performance, and difficult problems that may be encountered during construction, learn installation specifications, collect relevant technical information, prepare construction plans and construction measures, and do the following four points:

Basic inspection and acceptance
Check whether the center line and elevation points provided by the civil engineering unit are correct.
Check the foundation’s overall dimensions, foundation elevation dimensions, the geometric dimensions mutual position dimensions of the basic holes, etc. See the table below for specific requirements

Rotary kiln dryer installation Item check up list	Requirement
Civil foundation dimensions	±30
Civil foundation coordinate position (vertical and horizontal center lines)	±20
Civil foundation elevation	0~20
Distance between center lines	1
Reference point to workshop zero elevation	±3
Anchor holes	±3
Embedded anchor bolts	±2
Embedded steel plate	±5

To ensure a tight bond between the two groutings, the foundation surface must be roughened.
All remaining formwork and exposed steel bars other than concrete must be removed, and remove all debris, dirt, and water from the equipment installation site and foot holes.
The surrounding area of the foundation must be filled levelly and compacted.
Bury the vertical and horizontal central elevations and elevation datum points on the foundation, as shown in the figure below.

Lime rotary kiln dryer civil foundation marking principle

Draw the longitudinal centerline with a deviation not greater than ±0.5mm;
Draw the transverse centerline, and the deviation between the transverse centers of two adjacent foundations shall not be greater than ±1.5mm, the center distance deviation between the first and last two foundations shall not be greater than ±6mm.
Draw the vertical and horizontal cross lines of the transmission part based on the corrected and accurate rotary dryer center line;
According to the standard level points in the factory area, measure the elevation of the datum point above the foundation as the installation. The deviation of the reference point for installing equipment shall not be greater than ±1mm.

Inspection before installation of activated carbon rotary kiln

For appearance inspection of naked equipment, the installation unit shall carefully check the equipment number, specification, quantity, and appearance of the equipment for defects according to the required equipment detailed list or equipment packing list, together with the construction unit, and communicate with the construction unit The unit handles exit procedures and fills in equipment inspection records.
Unpacking of equipment is carried out at the installation site. After the boxed equipment is shipped out of the warehouse, the installation unit, together with the construction unit, carefully counts and checks the number of spare parts and components of the equipment based on the installation diagram of the equipment and the packing list provided by the manufacturer. and quality, and carefully fill in the equipment unpacking inspection record, confirmed by both parties. The installation unit is not allowed to unpack it by itself.
The technical documents that come with the rotary kiln furnace (such as product instructions, factory inspection and test records,
Packing list, etc.) and product certificate, the construction unit shall promptly provide the installation unit (original or duplicate Parts) as technical references and delivery materials for equipment installation, and the construction unit retains the originals.
Special tools and easily damaged and easily lost parts brought with the machine must be recorded during acceptance and handed over to the installation unit. After the installation is completed, the installation unit returns the special tools and excess parts to the construction unit and goes through the handover procedures.
During the equipment acceptance, if any problems with the quantity and quality of the equipment are found, equipment inspection records shall be made and the construction unit shall be responsible for solving them.
During acceptance, if internal parts of the equipment that are difficult to inspect are found to have missing parts or quality problems during the installation, cleaning, and assembly processes, communicate with the construction unit promptly, and the construction unit will be responsible for solving the problem, or entrust the installation unit to handle it.
After the equipment is received and shipped out of the warehouse, the installation unit shall be responsible for safekeeping.
Easily lost and wearing parts (such as pressure gauges, thermometers, oil cups, copper tubes, etc.) should be installed before the equipment is commissioned and kept properly after leaving the warehouse. The holes in the installation parts should be temporarily sealed promptly. Get in dust and debris.
After unpacking and leaving the warehouse, spare parts with protective coverings such as machined parts and precision accessories should not be removed prematurely. If there is any damage, repair the protection in time to avoid damage to the spare parts. Rotary dryer installation plan.
In addition to the above, equipment inspection and size verification must be done before installation. If the inspection results are inconsistent with the design, the installation unit and construction unit will work together with the design unit to correct the design drawings. Check the following:

Limestone rotary furnace civil base inspection:

Check whether the kiln civil base is deformed, and measure the distance between the screw holes of the base and the thickness of the base.

Check the vertical and horizontal center lines of the base
Inspection of supporting wheels and bearings:
Check the specifications of supporting wheels and bearings
Check the contact between the supporting wheel bearing seat and the spherical surface.
The cooling water tile of the bearing needs to be tested for pressure. The test pressure is 0.6MPa and is guaranteed for 8 minutes. There must be no leakage.

Rotary kiln barrel shell inspection:

Inspection of roundness—focus on inspection at both ends of each cylinder section.
The roundness deviation (the difference between the maximum and minimum diameters of the same section) shall not be greater than 0.002D (D is the diameter of the cylinder, and the lower cylinder section of the wheel belt and the lower cylinder section of the large ring gear shall not be greater than 0.0015D

cement dryer furnace circumferential inspection:

The circumferential lengths of the two docking interfaces are equal, the deviation shall not be greater than 0.002D, and the maximum greater than 7mm.
There should be no local deformation of the body, especially at the interface. For local deformation, it can be used cold working or hot working methods to repair, and the number of times of heating should not excee two times.
Check the following dimensions of the cement dryer body: the length of the machine body, the size from the center line of the wheel belt to the edge of the machine body interface, and the size from the center position of the large ring gear to the edge of the machine body interface.

calcination furnace other installation check-up list

Check the matching dimensions of the wheel belt and the machine body. Generally, the outer diameter of the machine body plus the size of the backing plate, Should comply with drawing requirements.
Inspection of large ring gear and transmission equipment.
Check the specifications of the large ring gear and the spring plate. The inner diameter of the large ring gear is smaller than the outer diameter of the machine. The sum of the height dimensions of the spring plate is 3 to 5 mm larger.
The maximum circumferential deviation at the interface of the large ring gear shall not be greater than 0.005m (module).
Check the specifications of the pinion and the matching dimensions of the gear shaft and bearing.
Inspection of reinforcing rings and tire retaining rings, the reinforcement ring and wheel belt retaining ring must not be deformed, and their inner diameter is larger than the outer diameter of the body reinforcement plate, the circle size is 2~3mm larger.

Incineration kiln supporting wheel/roller installation steps

The installation of supporting wheels is planned to adopt combined lifting, use a truck crane for lifting.
Cleaning the supporting wheel and scraping the bearing.
Clean the components or parts, and check that they are correct according to the drying equipment matching code and number assemble, if there is no character code, the number will be re-coded, and the corresponding stamp will be stamped.
Check the coordination between the bearing bush and the journal. If it does not meet the requirements, it needs to be scrapped.
The contact angle between the bearing bush and the journal is 60° to 75°, and the contact points are no less than 1 to 2
points/cm2.
The side clearance between the bearing bush and the journal is 0.001~0.0015D on each side (D is the straight diameter of the shaft path).
The contact points between the back of the bearing bush and the spherical bush should be no less than 3 points/2.5×2.5cm2.
The contact points between the spherical tile and the bearing seat are no less than 1 to 2 points/2.5×2.5cm2.

Installation of kiln supporting roller base frame: Center position measurement

To align the center position, align the center + word line of the base with the center + word line of the base. The longitudinal centerline of the two supporting wheels coincides with the transverse centerline of the base, and the deviation is not greater than ±0.5mm. The transverse center line of the supporting wheel coincides with the transverse center line of the base, and the deviation is not greater than 0.5mm. At the same time, the amount of string momentum on both sides of the supporting wheel is equal.

Furnace supporting roller device elevation and slope measurement

When aligning, measure the elevation of the top surface of the kiln supporting wheel/roller based on the center of the top surface of the supporting wheel. The inclination measurement of the supporting wheel is carried out at the same time as the elevation measurement, and the deviation shall not be greater than 0.1mm/m. The top surfaces of the two supporting wheels (located at the vertices of the two lead vertical surfaces perpendicular to the longitudinal center line) should be horizontal, and the deviation shall not be greater than 0.05mm/m. The relative difference between the transverse center spans of two adjacent roller sets shall not be greater than 1.5mm. The diagonal difference shall not be greater than 3mm.

Inspection item of alignment of 3-way supporting wheel set

Recheck the longitudinal center position: Use a theodolite at the nose or tail of the machine to check the center of each set of supporting wheels center position, or hang a steel wire on the longitudinal pay-off frame at the nose and tail to check the longitudinal centerline deviation, It shall not be larger than ±0.5mm.
Review of the transverse center distance: based on the transverse centerline of the supporting roller group on the transmission basis, measure the lateral center span size of the two adjacent supporting roller groups toward the nose and tail of the machine respectively. The deviation shall not be greater than ±1.5mm. The lateral center span deviation of the two adjacent supporting roller groups shall not be greater than ±3mm. The deviation of the two adjacent supporting roller groups shall not be greater than ±3mm. The difference between the transverse center span diagonals shall not be greater than ±3mm.
The relative elevation and deviation of two adjacent roller groups shall not be greater than 0.5mm. The elevation deviation of the first and last two roller groups (not counting the height difference caused by the slope) shall not be greater than the sum of the relative elevation differences of adjacent blocks, and its maximum value shall not be Greater than 2mm.

Things to note after installing the calcination kiln dryer supporting roller

After the general review of the installation of each group of supporting wheels is completed, in addition to meeting the above requirements, the following must also be fullfilled:

When assembling the upper and lower bearing seats, lead oil seals must be added to the contact surfaces, end faces and pipe fitting connection outlet, no oil leakage, water leakage, etc. shall be allowed. The cooling water circuit shall undergo a 6Kg/cm2 water pressure test and shall not leak.
After assembly, apply anti-rust oil to all exposed processed surfaces, and all open holes and pipe opening are all tightly blocked with cotton gauze to prevent water and dust from entering.
The water throwing ring is installed on the oil shoulder side of the supporting wheel shaft. Then mark the mutual positions of the base and the bearing, and then proceed to the next process.

Rotary dryer thrust roller wheel installation instruction

Before installation, clean the shaft and bearings, fill them with grease, and scrape them if necessary.
The installation position of the blocking wheel complies with the design requirements, and the blocking wheel and the wheel belt fit closely.
After the device is installed on the base, it is required that the support shaft of the gear wheel cannot move axially.
After installation is completed, the gear wheel must not be stuck when manually rotated. Push with 4000-5000 Newton force
The movable gear wheel is required to slide evenly on the gear wheel support shaft without getting stuck.
After the oil cylinder is installed, perform an oil pressure test, the test pressure meets the requirements of the design and technical documents, and no leakage occurs in any part. The gear wheel bearings are lubricated by thin oil circulation, and there must be no leakage at the joint heads and the joint surfaces of the end covers.

Rotary dryer riding ring installation manual

Assemble the rotary kiln dryer riding ring wheel belt and the machine body, and initially position them on the ground, using a truck crane to coordinate.
Before assembling, remove paint, rust, etc. from the wheel belt, ferrule (block), and backing plate, and apply a layer of grease.
Check the gap between the wheel belt and the backing plate, and finally install the retaining rings on both sides of the wheel belt (note that the characters on the retaining rings match the characters on the machine body). The retaining rings on the wheel belt fit closely with the backing plate on the machine body.
The wheel belt/kiln riding ring is assembled with the dryer body and initially positioned on the ground. Use a truck crane to coordinate.
Before assembling, remove paint, rust, etc. from the wheel belt, ferrule (block), and backing plate, and apply a layer of grease.
Check the gap between the wheel belt and the backing plate, and finally install the retaining rings on both sides of the wheel belt (note that the characters on the retaining rings match the characters on the machine body). The retaining rings on the wheel belt fit closely with the backing plate on the machine body.
The gap between the wheel belt and the retaining ring is generally 2 to 3 mm.
The rolling ring and the supporting wheel are all in contact, and the center line of the fourth gear rolling ring width is in the middle of the width of the supporting wheel.
The distance deviation between the center lines shall not be greater than 2mm.

Limestone rotary calcinatiner cylinder hoisting specifications

Install temporary brackets and three platforms between the four sets of supporting wheel foundations. The height should be the same as that of the foundation.
The base elevation should be the same, and the length of the bracket and platform should be sufficient to accommodate the machine body during docking to provide sufficient operating space. The width and length shall be subject to the requirements.
Before hoisting the machine body, each supporting wheelset and transmission system must be installed and debugged.
Use two 125T truck cranes to gradually lift the split body to the foundation and the stand platform and the standby body are assembled and then welded. Suspenders, ropes, ropes, and other equipment must be strong and reliable.
Pay attention to the stability of the temporary supports and platforms. The supports must be rooted to the ground (with anchors pit is appropriate), other wise the rotary dryer may tilt during the installation process.
After installation and commissioning, remove the temporary supports and platforms.

Preparation and inspection of rotary kiln barrel connecting

Before docking, make and adjust the number of sets of idlers according to the segmentation of the machine body upon arrival.
Remove flash, burrs, oil and rust at the joints. If there is any local deformation, processing is required.
On the inner surface of the docking point of the machine body, the counterpart connecting plate and docking screws supplied with the equipment will be installed. The bolts are assembled and welded according to uniform distribution requirements.
Adjust the docking body to be on the same center line, and the deviation must meet the requirements. press set
Leave a welding gap as required in the technical documentation, then tighten the connecting bolts and perform body rotation inspection. Check the tire center distance and other items.
Radial runout value of the center of the body (at the large ring gear and wheel belt, and at the center of the rest of the body
position, nose and tail) before welding after the adjustment is qualified.
The length of the contact surface between the tire belt and the supporting wheel shall not be less than 70% of its working surface, and the axis of the machine body shall be adjusted after adjustment, check that the distance between the center line of the tire belt width and the center line of the wheel width meets the requirements.
After all inspections of the body pass, the welds of the body will be fixedly welded.

Preparation work before welding of cement plant rotary kiln barrel

Welders must be tested before welding. Only those who pass the perspective inspection, bending test, and tensile strength test are allowed to participate in body welding work.
The welding rods used for body welding comply with the relevant regulations of GB5117 and Q/JCJ105, and their quality guarantees that the mechanical properties of the weld are not lower than the mechanical properties of the base metal.
The welding rod must be dried before use at a temperature of 250 to 300°C and a drying time of 1 hour. After drying, the electrode is cooled to about 150°C and stored at a constant temperature. It can be taken as needed to avoid staying in the air for a long time.
Before welding, check the groove form and size of the cylinder. There should be no delamination, cracks, slag inclusions and other defects that affect the quality at the groove. The angle of the groove is generally 60°, and the deviation is not more than ±5°. The interface gap deviation is not greater than ±0.5mm.
Remove flash, burrs, paint, rust and other dirt before welding. Any uneven areas must be dealt with in advance.
The longitudinal welds should be staggered to each other, the stagger angle should not be less than 45°, and the offset of the machine body should not be allowed greater than 2mm.
The welding of the machine body must be carried out after the machine body has been properly aligned. It is best to use the auxiliary motor to turn the machine for welding after the transmission equipment is installed.
After the machine body is docked and aligned correctly, fixed welding can be carried out. Using welding rods and welding drying machine welding rods are the same.
In order to ensure the welding quality, welding slag, etc. must be removed with a small pointed hammer and wire brush after each layer of welding, and the special high points must be polished smooth with a hand grinding wheel.

Rotary dryer barrel welding quality inspection

Weld appearance inspection: The surface of the weld should be in the shape of smooth fine scales, with no unevenness at the joints. There must be no cracks on the weld surface and heat affected area. The depth behind the weld shall not be greater than 0.5mm, the continuous length of the undercut shall not be greater than 100mm, and the total length of the weld undercut shall not be greater than 10% of the weld length.
Weld height: The outer part of the cylinder shall not be larger than 3mm, the fired zone inside the cylinder shall not be larger than 0.5mm, and the other sections shall not be larger than 1.5mm. The lowest point of the weld shall not be lower than the surface of the cylinder and shall be full.
Weld flaw detection inspection: Flaw detection inspectors must have technical examination certificates. The welds at the 32mm wall thickness of the cylinder are inspected by “X-ray flaw detection, and the rest are inspected by ultrasonic flaw detection. When using ultrasonic flaw detection, each weld should be inspected, and the flaw detection length should be 25% of the weld. The quality assessment reaches level II in JB1152 as qualified.
Doubtful points discovered during ultrasonic flaw detection must be determined by radiographic flaw detection. When using radiographic flaw detection, each weld should be inspected, and the flaw detection length is 15%, and the intersection of the welds must be inspected with emphasis.
The quality assessment reaches level III in GB3323 as qualified. When the weld is unqualified, double the length of the weld will be inspected. If it is unqualified again, a 100% inspection will be performed on the weld. The number of repairs on any part of the weld shall not exceed two times. Excessive repairs must be approved by the technical director and kept on file.

Installation of rotary incinerator girth gear

The large ring gear must be pre-assembled before hoisting to the rotary incinerator. The joints of the two halves of the ring gear are closely fitted. Use a 0.04mm thick feeler gauge around the interface to check. The insertion area shall not be greater than 1/5 of the perimeter length, and the insertion depth shall not be greater than 100mm.
When hoisting the large ring gear, pay attention to checking the bolt hole numbers on the spring plate and the ring gear.
Rotate the body, adjust the large ring gear and measure the radial direction and end face swing value of the large ring gear. The deviation is: the radial swing deviation shall not be greater than 1.5mm, and the end face swing deviation shall not be greater than 1mm.
The deviation of the transverse centerline between the large ring gear and the adjacent wheel belt shall not be greater than 3mm.
The tangential spring plate is installed before the large ring gear is hoisted, and is fixed on the ring gear along the tangential direction. After the lifting adjustment, the spring plate is temporarily fixed on the cylinder, and the radial and end face swing deviations are re-measured. After the requirements are met, the spring plate is temporarily fixed on the cylinder. , can be drilled and riveted. The riveting quality of the large ring gear spring plate shall be implemented in accordance with the relevant provisions of JGBJ205 “Construction Acceptance Code for Steel Structure Engineering”.

What is the metal chain installation inside of the rotary kiln?

Before installing the metal chain inside the rotary kiln, check its quality and length. The chain must not have cracks.
The installation starting point of the rotary kiln chain shall be according to the design regulations, generally starting from the feed end of the cylinder. And find out that the contacts are scanned in a circular order, and after completing one circle, turn around and install the other half circle.
The chain and the trough frame are connected with bolts. After the bolts are tightened, they must be welded to prevent the nuts from loosening move.
Fill in the lining material inside of the rotary kiln after all the chains are installed properly.

Rotary drum dryer test operation sequence

The test run time before laying bricks shall be subject to the requirements of the equipment technical documents: 2 hours of no-load test run of the motor, 2 hours of auxiliary motor driving, 4 hours of no-load test run of the motor with reducer, and 4 hours of no-load test run of the main motor with equipment. 8 hours. The drum dryer should be slowly rotated 90° or 180° with auxiliary transmission at intervals to prevent deformation.
Installation of the nose and tail seals and gear covers: Install the nose, tail seals and gear covers after the trial run before inlaying bricks. The installation of the nose covers is based on the designed construction drawings and the specific requirements of the equipment technical documents. , pay attention to the connection size, insulation layer construction, and sealing must meet the requirements.

Inspection contents before comissioning of the lime rotary dryer：

Check whether there is any debris, welding slag, etc. on the surface of the supporting wheel and the belt.
Check the cleanliness of the inner surface of the tire belt and the surface of the wheel belt pad. If necessary, blow with a compressed air net.
The meshing situation of the large and small gears of the transmission
Sealing condition of kiln head and kiln tail.

Inspection items during rotary furnace trial operation

Check the bearing temperature rise of the motor, reducer and transmission parts, and check the oil supply of the reducer
Condition.
Check the oil supply, water supply and temperature rise of each supporting wheel bearing.
Check the movement of the machine body and debug the supporting wheels to ensure that the machine body moves up and down smoothly.
According to the movement direction of the machine body, determine the twisting direction of the supporting wheel, and then move the supporting wheel bearing jackscrew to achieve the purpose of adjustment.

How to adjust the position of the supporting wheel during operation of the rotary kiln

The adjustment work of the supporting wheels starts with each pair of supporting wheels at the feed end of the machine. Try to keep the center line of each supporting wheel near the discharging end of the machine body and the firing belt parallel to the center line of the machine body to avoid the large ring gear in the machine. Adjust the transmission and machine head supporting wheel sets. When adjusting the supporting wheel, do it while the machine body is rotating. A small amount of movement of 30° to 60° is allowed each time to gradually meet the requirements.

Conslusion

Installing a rotary kiln is a complex yet rewarding process that demands meticulous planning, precise execution, and a thorough understanding of the equipment and its operational environment. By following the steps outlined in this guide, from initial site preparation and alignment to final commissioning and testing, you can ensure that your rotary kiln operates efficiently and safely, maximizing its longevity and performance. Remember to adhere to all safety protocols, utilize professional expertise when necessary, and perform regular maintenance checks