FLSmidth Inc. Capacitacion de Proyectos Giismiotn Mecanico SBC PPT 0001Training Manual Disclaimer General: This Training Manual is for training purposes, and is only intended to introduce the student to concepts relating to the operation and use of equipment furnished by F.L.Smidth Inc. (“FLS”). The information contained in this Training Manual will not be automat ly updated. Unless otherwise specifically informed by FLS’ trainer (and then only to the extent so informed), the Training Manual and operational training provided by FLS are not intended to be a stitution for and are not a substitution for any training required by law, code or regulation, including but not limited to MSHA and OSHA. When actually operating or maintaining ‘equipment furnished by FLS, consult with and utilize the operation, maintenance and instruction manuals and other documentation furnished for use with such specific equipment. Further, follow all safety policies and procedures established by your employer. Warning: All warnings, cautions, and notes contained in equipment operation, maintenance, and instruction manuals and all jobsite safety policies and procedures established by your employer must be closely adhered to and followed to avoid or the risk of serious personal injury and/or property damage. Please note that this Training Manual is not a contract or an agreement, This manual and all training are being provided pursuant and subject to the terms, conditions and other parts of the contract between FLS and the purchaser of the Training Services. Nothing in this manual is intended to modify, amend or replace any part of that contract. Use of Training Materials This Training Manual and all information that it contains is the proprietary and confidential property of F. L. Smidth, Inc., and is intended solely for the use of the student to whom it is provided by F.L.Smidth Inc. No part of this Training Manual may be duplicated, disclosed or provided, directly or indirectly, to any third party without the prior written consent of F. L. Smidth, Inc.Giismiotn Mechanical Manual TABLE OF CONTENTS Page ATOX Mill 1 Pre Heat Tower SLC 78 Gas Conditioning Tower 114 Coolax Clinker Cooler 128 Cooler Hydraulics 177[smo ATOX Vertical Roller Mill [smo Vertical mills Gsm im @® ceoe.rrareeac ere rocco IY Gsmon Lan roller mill for raw material TH sd roller mil Raymond Coal MillsThe first ATOX mill was introduced in1920 In 1922 *ATOX" was registered. on the market Around 1980 a new concept for the ATOX mill was developed and introduced to the market More than 130 ATOX mills have been sold- [Esmior tro tiitin Eismiorn Atox Raw Mills - Type 45[Emir ATOX Coal Mill [smo ATOX Raw Mills Operational Experience ‘capacity: Up to around 500 t/h + From “non-abrasive” to “very abra + Sticky and non-sticky Moisture content from < 1% to > 18% Grindability from < 3 kWh/t to > 11 kWh/t Final product: From < 59% to > 20% on a 90 um sieve[ism ATOX Coal Mills - Operating Experience + Capacity: Up to around 70 t/h All types of coal: Anthracite, pet-coke, normal bituminous coal and lignite Feed moisture up to 25% Final product from <3 9 to > 20 9% on 2.90 mm sieve Esmiorn ATOX Mill - Basic Concept The grinding table has 3 horizontal arinding track encircled by + Adjustable dam ring + Adjustable nozzle ring + Air guide cone The three cylindrical rollers are rigidly connected to a common centerpiecemorn ATOX Mill - Basic Concept + The roller assembly is kept centered on the grinding table land prevented from rotating by three torque rods + The grinding pressure is exerted hydraulically through three pull rods attached to the ‘outer end of each roller shaft morn ATOX Mill Concept - Advantages +The grinding track is horizontal and the center of gravity for the roller system can only move vertically > +All impact forces and dynamic reactions are only vertical and thus ‘easy to accommodate ‘The extremely low mass of the roller suspension system means low inertia and thereby low dynamic forces[Eemiorn ATOX Mill Concept - Advantages Due to @ patented toe-in of the { rollers, the roller bearings are only exposed to well defined radial loads, and - due to the low mass of the suspension system - only to very small inertial forces in case of vibrations. Esmorn ATOX Mill Concept - Advantages Segmented wear parts for both rollers and table allow use of the most wear resistant materials without risk of cracking, Roller segments can be reversed enabling high material utilisation to be achieved also in case of uneven wear[Esmiorn ATOX Mill Concept - Advantages + When the wear segments of an lL ATOX mill are wearing the whole roller assembly moves only veitically = + Higher tlisation of thicker wear segments than in mills, where the rollers are on swingarms + Thicker wear segments —> + Longer stand-times ATOX Mill Concept - Advantages Rollers with larger diameter + Permit a proportional thicker and less critical grinding bed being less Sensitive to uneven wear and less critical concerning foreign bodies in the mill eee + Allow 2 proportional coarser feed, which reduces the requirements on pre crushing.ATOX Mill Concept - Advantages Easy starting procedure: + The rollers are lifted hydraulically before start + No auxiliary drive required + Less demand on the mill motor - it starts with no load + Hydraulic system designed to eliminate pressure chocks and to permit a very easy and smooth start [smiorn ATOX Mill Concept - Advantages Unrestricted airflow under the grinding table + Low pressure loss and unrestricted air distribution to the 360° nozzle ring + The standard ATOX mill can handle also the extra amount of gas required by specially wet or easy to grind materials without having to go to oversized mill housing - only the nozzle ring and the separator must be adapted to the higher airflow[Eemiorm j ATOX Mill Concept - Advantages ‘Compact design Easy arrangement of inlet ducts Only one service access door required Easy to fit into a constricted space Minimum cost of civil werk Eismiom Atox Mill for grinding of raw materials Circulation of material[smorn Atox Raw Mill, 3 fan system EEsmiom Atox Millsystem ‘Accumulator with nitrogene Hydraulic cylinder isms Hydraulic tension system Pre-charged hydraulic ‘Accumulator w/nitrogen[smo Stroke limiting assembly SN cotindrieat sleeve at pull rod seal Esmiom Grinding bed measuring Layer thickness: adjusted) seal bleed lineEsmorm Hydraulic accumulator w/nitrogen “Automotive” valve type EEsmiorn Double Rod SealHeat to 250 deg. C Insertion into And use mounting tape cylinder [Esmiorm Instrumentation Instrumentation 1 top position indicator for each roller 1 layer thickness meteringEEsmiom Safety 0. Mechanical support for pistons: H + Required during maintenance + with lifted rollers [Esmiorn Hydraulic Pump Station.[emir Hydraulic tools for bolt tensioning Chart for selecting required pressure ce “aT iFEmon Torque rod assembly Pre-stressed rubber elements Centralization of roller assembly Feed Systems with Rotary Feeder + Rotary Sluice — Suitable for sticky material More simple than a triple-flap sluice = Less false air ~ Feed flow more continuous ~ Cells lined with hard faced a plate for abrasion resistance and long life - Removable covers for maintenance 8smo Feed System with Double Feed Screw The main concern is check the screw bearing for coal dust accumulation on the non crive [smo Improvements to Original Design + The axial thrust bearing has been changed from pure hydrostatic bearing to more simple and reliable submerged hydrodynamic/semi-hydrostatic bearing with supplementary high pressure oil supply. + The design grinding pressure has been increased from 600 kN/m? to 800 KN/m? for increased mill capacity. 19Eismorn Grinding Roller Configuration + Larger roller bearings (due to increased grinding pressure) + Improved sealing system + Lubrication changed from grease to oil lubrication with continuous oil filtering and conditioning [emo Y-Profile Grinding Table + Grinding table changad from T-profile to Y-profile for enhanced rigidity and better fixation of segments 20Ebmom Tension Rods Improved tensioning system Induding - among others - tension rods with pre-stressed bolted connections instead of fatigue prone threaded joints Eismiorm Wear protection parts 4). Stainless stee! lining in chute 2). Steel lining in mill housing 3) Roller hub wear cover: Chromium carbide & composite plate. 4) Joint head wear cover: Chromium carbide & composite plate.Wear protection parts (6), Dam ring top: Hardox 400. 7). Bottom plate: Densit lining 18) Torque rod wear cover: Stee! 9) Sealing air pit carbide & composite chromium te, 10) Water injection pipe: chromium ‘carbide & composite plate 11) Sluice: Rubber lined with wear resistant liner & Hardox vanes smo FLS RAR Separator + The original static separator replaced by a high-efficiency dynamic separator[smiorm Material recirculation - Vibration conveyor [smiorn MAAG Planetary Gearbox 2EEsmorm Planetary WPU Gear Unit - Design [smo Axial thrust pad bearings‘Table Liners Y Profile Table Table serapers Scraper for rejects[smiorm Scraper and table seal adjustments Distance should be aprox. 6 t010mm + Check to make sure that the lower plate Densit cover is as even as possible other wise it will be worn out by the scraper. [smo Scraper and table seal adjustments ele seal ring needs to be 3 ® adjusted between .5 to i 1.7mm to ensure proper sealing under the table Sto 1.7mmEEbmiorn Dam Ring configurations ‘Ee iS of oe a t te hes ie OR a Pw yw OY a yh yoy [Esmiorn Dam Ring Configurations[smo Water injection system [smo Joint head connections[smo (Wear protection [smiorn Separator reject pipe[smorn Roller lubrication aEbmiorn Grinding Roller Lubrication + Internal hub bores: Emo Grinding Roller Lubrication 2[morn Hydraulic nut for spherical bearing: + Adjustment of bearing Removal of sleeve Ebmiorm Cavity for sealing air Grease of seals[Esmiorm Grease of seals Preventive maintenance schedule for lubrication bie ee et 1. Lubrication {are Fiennes [= epee ||| nl Se ‘ ete 2 a= : 4. Checking of condition —— fBececenere (= Per § Hour Operation “A meaner sn fort of oe Wer indicates (including lubricants) ees eesti eri 6. Performance test Se Meaty Bh Tec ionEEsmiom Differential pressure Pipe at air inlet duct [smo Coal Mill Gear Pump Station.Eemiom Coal mill - Feed screw, external Emo Coal mill - Feed screw, internal discharge 36Esmiom Coal mill - Densit wear protection of mill shell smo Wear segments for rollers and table + How long time will they last? + Difference between roller & table segments? + When to rotate or replace? + Can I refurbish? + Depends of operation experience more than actual wear depth. + Record the wear profile using the supplied tools for estimating actual life time. + Compare wear with operation performance 37[ismiorn Wear profile on + Ni Hard Tire segments, wear is on the outside EEsmiorm Wear profile on Tire segments + Ni Hard Tire segments on a Coal Mill, wear is on the outside 38[smiorn Wear profile on Tire segments + Extreme wear on Tire segment, in the middle of the face [smo Wear on the Table liners — Holding Clamps + The table shows even wear, but already under the holding clamps 9. of wear segments ‘The wear rates differ from 0.2 to 20 g/ton Table segments wears more than roller segments 1) Raw mills - content of quartz in mill feed may reduce the life time 2) Cement mills at 1 to 2 g/ton (desired life time 15000 hours) 3) Slag mills: = 10-12 g/ton for slag mills without hard-facing - Lifetimes down to 3000-6000 hours = 0.5 % free iron is normal (0.1% more gives 10 % more wear) = Consider to install iron removal equipment at recirculation system [smorm Refurbishing of wear segments Cladding as opposed to fusion bonding ‘Automated welding equipment 2-4 welding heads ( each of 8 kg/hour) Up to a total of 2000 kg No grinding or preheating required Consider down time and cost savings 40[Esmiorn Tire Segments Replacement + Seomented wear parts for both rollers and table allow use of the most wear resistant materials without risk of cracking + Roller segments can be reversed enabling high material utilisation to be achieved also in case of [emiorn Wear measurement and trend smo NFm Wear measurement on tire segments jneiog lsaton atrna sats oy [bmiorn Wear measurement on tire segments 42[smo Wear measurement on table liners aroxam ‘owarsloonee soca af weston cia ans ‘Scenes bie = Tar eres | as pei [rem EEsmiom Wear measurement on table liners Gap Represents negative wear on the table liners 43[smo Welding of roller segments [smo Welding of grinding table[smiorn Replacement of Roller Station Emo Te EY Structural support Replacement of Roller Station =a gate | | Ts Bz ES é Sai ww/maehine shoe 45[ismorm Replacement of Roller Station [smorm Replacement of Roller Station Dismount all bolts that are fastening the center piece Dismount all bolts that fasten to the ‘moment arm.[smo Replacement of Roller Station + Start the hydraulic system for the pressure for the grinding table + Open the inspection ( big ) doors for taking the grinding roller outside. + Tt is necessary to bring the dismounted roller to the workshop for dismounting all systems inside the roller [smiorm Dismantling the rollers inside the mi body 7[smo Dismounting of sealing air rings [smo Dismantling the roller aaa a[ismiorn Dismantling the roller (Continued) ‘The grinding roller must be positioned in a vertical position Dismount the top cover for air sealing, DDismount the cover for oil sealing Dismantling the roller ial ct a—r ‘To dismount the conical piece in the spherical bearing, turn the clamp backwards and set it against 49EEsmorm Dismantling the roller emorn Dismount distance ring Dismount the inner race of the cylindrical roller bearing iE fr }it pS Dismount the end r ff ‘cover with the sealsan aon Dismount the hardened seal Clean the shaft before rings ‘emounting all pieces Note: The rings can not be reused since in order to take them out they have to be heated up. Emon Remounting all pieces; Assembly of bearings, shaft and hub + Check that the hub interior is clean, If possible, mount the bearings in the hub by heating latter to 120-C above ambient and bearing temperatures + IF heating is not possible, apply the folowing alternative method Use a mixture of dry ice and alcohol to cool down the spherical roller bearing (45) and the outer race of the cylindrical roller bearing (43). +The temperature must not drop below minus 50°C. + Hub temperature to be approx. plus 20°C. 51[smiorn Remounting all pieces; Assembly of bearings, shaft and hub + When using this mounting method it is important to make sure to remove the condensed water resulting from the temperature equalization. Bearings must be smeared thoroughly with rust-proofing oil to eliminate any risk of rust formations. + Place hub (39) so that itis possible to insert the outer race for bearing (43), the outer spacer ring (44) and roller bearing (45) into the hub, See encl. II [smiom Remounting all and hub ces; Assembly of bearings, shaft + If bearings (45) and (43) have Identical outside diameters, it may be Useful to temporarily mount cover ($4). Then place the hub with the open side upwards and mount bearings and spacer ring so that they rest on the cover. Remove cover (54) when temperature equalization has taken place. + Note! + Ifthe roller bearings are provided with lubrication groove and the outer race is perforated by lubrication channels, these must be plugged to enable future hydraulic dismant bearings[emorn Remounting all pieces; and hub Assembly of bearings, shaft Sealing air and oll channels to be thoroughly cleaned with dry and clean compressed air. Place the shaft in upright position, standing on its flange. Apply corrosion-inhibiting grease, e.g Never Seez, to the shaft at points where bearings and rings are to be located Mount sealing air ring (52) on the shaft. [emo Remounting all pieces; and hub - » + Assembly of bearings, shaft + Mount the wear rings (55) and (42) and inner race of cylindrical roller bearing (43) on the shaft. + Mounting is done by heating the parts to 120°C above the ambient temperature, where after the parts are lowered down over the shaft 53emo and hub: Remounting all pieces; Assembly of bearings, shaft Mount the inner bearing spacer ring (44) fon the shaft. Locking (35) prevents the ring from turning relative to the shaft Special grease, Kluber NOSOL UTA 4 or similar grease, to be applied to the outer race on shaft seals (61). Place the shaft seals in bearing cover (54). Do not forget spacer ring (73). Mount inner sealing air ring (53) on bearing cover (54) [smo Remounting and hub | pieces; Assembly of bearings, shaft + Carefully lower the complete bearing cover (54) onto shaft and wear ring (42). + Take care that sealing rings (61) are not overioaded. + Support the bearing cover so that the shaft seals do not slide over the rear edge of the slide ringEsmorn Mounting of hub on shaft Mounting is done by lowering the hub With the inserted bearings and rings very carefully down over the vertical, shaft, 1 thin layer of oll must be applied to the rollers in bearing (43) ‘The hub with bearings must be able to ass unhindered down over the shaft until the roller bearing (45) lands on the innermost bearing spacer ring (44), check that the roller is centered in the spherical roller bearing, Remounting the roller ‘To remount the sleeve, set the hydraulic nut jainst_ the clamp and apply hydraulic force to set back in place.[emo Mounting of hub on shaft ix the bearing cover (54) to the hub before the mounting operation is continued, Tighten all screws and bolts to the comect torque eve. See assembly crawings Then insert the dismantling bushing (46) between the shaft and the inner race of the bearing so that the parts make full contact [emo Mounting of hub on shaft -silt in the bushing to be ying in the horizontal plane of the shaft as tlustrated ‘Screw the hydraulic nut (70) onto. the Aismanting bushing (46) so that the full thread of the nut is active, The piston of the mut must be turning away from the bearing (45). Mount the retainer plate (65) on the shaft (50) 0 that the free holes are positioned opposite the oll ways in the dismantling bushing, ‘Then tighten up the screws until the retainer plate bears well against the rut. 56[smiorn Mounting of hub on shaft ‘Place the roller so that the shaft is in horizontal position, ‘Mount the hydraulic equipment on ‘ismantiing bushing as well as on the hydraulic nut, For ol grade, see parts st. ‘Hydraulic pressure to be applied to the dismantling bushing (46). sTun the shaft until it has been ascertained that the rollers in the spherical roller bearing are centered, ‘Forcing on the shaft to be started as soon as the full pressure is available, by ‘applying pressure to the hycraulic nut Mounting of hub on shaft sNOTE | ‘Maximum permissible pump pressure 100 MPa (1000 bar). ‘Check the bearing clearance in bearing (45) and keep turning the shaft throughout the forcing-on process sDiscontinue forcing-on process when the clearence Is vithin the 50-100 ym range. ‘Relieve the hydraulic pressure from the bushing, ‘Check the clearance again. If tis not within the tolerance range, repeat forcing-on process unt itis within 50-100 +Dismantle the hydraulic equipment. Measure the distance (x) from the end of the dismanting bushing to the inner race of bearing (45). ‘Adapt rotainer ring (47) in accordance with the ‘ascertained dimension so that the sing, when mounted, is Deering against the cismanting bushing as well as the inner race of bearing 7[emiorn Mounting of outer covers Smear the outer ring on the shaft seals (69) with special grease, Kluber NOSOL UTA 4 oF similar grade, anc place the shaft seals in the bearing po cover (57), ; i “Do ot rg space vin (74 Wana RD sear om sntscstre ardnn NE > (49) onthe bearing cover (57). A YJ sThen tower the complete bearing : cover (57) very carefully down over the vertical shaft. Tien a screws — im —_| to the spectied torque lever. “Mount the sealing ai ring (48). ‘Check that the sealing ar gap between (48) and (49) 1s not ‘more than 0.5 mmEEsmor column 5 ole in iota late oo ack Dismantling of the gear unit Typical arrangement Remove nuts & Bottom plate @) [smiorn Hydraulic UnitEmon Bladder Type Accumulator im Emon Bladder Accumulator Operation @ Stree Syston Presse Ste rs 60Eismiorm Hydraulic accumulator w/nitrogen “Automotive” valve type [smiom Layer Thickness metering CIemir Safety 7 a Mechanical support for pistons: amar + Required during maintenance with lifted rollers [Esmiom ATOX Raw Mill - Hydraulic Pump Station[bmiorm ATOX Raw Mill - Main Pump Emo Solenoid Operated Directional Control Valve a Bearer Tw0-Position, Four-WayValve is Spring Offset TBPA[Esmiorw Standard Cover Configuration Sandand Cover Configumton Esmorn Hydraulic Diagram[Esmorn Simplified Circuit Setting of minimum pressure in accumulators [ismiorn Roller Lifting 65Femi Solenoid Pi! [smo Solenoid Pilot Valves — Lowering & GrindingLemons Rollers Lowering EEsmiorn Rollers Down & Grindingsmo Grinding - Constant Grinding Pressure [morn[Esmiorn [Esmior Setting the grinding pressure + The pre-charging pressure can only be checked during standstill and when the oll pressure indicated on the pressure gauge is zero + NOTE: Every time the pressure side has been relieved, the accumulators must be refilled with oil prior to starting (roller lift) may take place. 69fe re [smiorn Grinding pressure con ‘ions nad + No prior determination of the Accumlstor voliae per ectuetor: 1x 10 14¢ra# will depend on the characteristics Ble e example: A mill, type 20, the S| a an cressre wil tty be wang [| He range 70 - 130 bar. 2 at im en PF which sets the limits for meximum grinding — LL 6? | pressure “Pwimax. "and. minimum” grinding Dreseure Pw/min. Eismiorm Permissible grinding pressure + In an ATOX mill there is always @ co-relation between the hydraulic grinding pressure Pw (bar) in the actuators and the specific grinding Pressure KT (kN/m2 ) which is an expression for the mechanical load fon the mil. + The co-relation between Pw and PF it taken from the table in Fig. 2 and Is marked (A). + The correlation between Pw and KT appears from the curve marked @) * Note: Some non-FLS gear units used on ATOX mills are only designed for a load of KT ~ 600 kN/m2, which corresponds to a 7Adjustment of the cartridge valve + If the pressure is higher than the pressure appearing from the table in Fig. 2 in column (61/62 off the selected pre-charing pressure Pf, turn the adjusting screw on cartridge valve counter-clockwise untill pressure gauge reads the pressure specified in the table. + Raise and lower the rollers a few times and check that the pressure indicated on pressure gauge still corresponds to the value in the table when the rollers are in position "UP". n[smo MAGG Gear Box Lub System[Esmiorn RAR LVT Separator [ismorm RAR LVT Separator > PROVEN RAR SEPARATOR DESIGN NOW INCORPORATES LVT CONCEPTS, INCLUDING: ¥ Larger rotor D/H ratio ~ Larger radial air velocity through the rotor New suspension of reject cone Filling mantle for increased air velocity in mill housing a[emir Separator Gas and Material Flow Variable _, ‘Speed Drive From Mill Emo Particle Force Balance Aerodynamic drag wants to pull the particle to the outlet duct Gravity wants to pull the particle down to the reject hopper. Centrifugal force pulls the particle to the outside of the separator where the drag is lower. m[Ebmiomn Particle trajectories & forces ek Toe rotor M7 3 — ota) vair, radial “ON zy guide =P \ vanes ‘small ==) (fixed) particles Sy! Sd x SY large particles Esmorn Separator TroubleshootingTmo Separator Top Rotor Seal The top seal must be kept as tight as possible to avoid coarse Particles finding their way into the product. [smo Separator Top Rotor Seal 2mm vertical clearance horizontal clearance 76[Esmiorn Separator Top Rotor Seal ‘The seal is adjustable by shimming up the mounting bolts with washers. The rotor position on the rotor shaft also affects the top clearance. 7[emir Preheater 5-STAGE SLC [smiorn Preheater SafetyEmon Preheater Flush dda Never work anywhere on a kiln system while a preheater vessel is plugged. If the plug breaks free it will rush like water through the system, burning everything in its path [emo Preheater Flush These men were working inside a kiln when a preheater flush occurred. Two fatalities resulted.Esmiorn Preheater Flush These _men were working outside a clinker cooler when a preheater flush occurred, spewing hot material through an ‘open man-door. Two fatalities resulted. [Emiorn Protective Clothing When working with hot dust a complete fireproof suit must be worn. 80Femi Hot Dust Hot dust can unexpectedly blow out through any opening in the system. Keep doors and ports closed! Hot dust can ignite flammable materials in the area. [smo Dust Hazard Know where your shower and eyewash stations are! i | at[bmi Fall Protection Always wear your safely harness when working above ground, [emo Heights High places can be dizzying. Always tie off with a safety belt. a2emo Air Blaster Air blasters contain high pressure air that discharges rapidly. They can be deadly. Always disable air blasters when working in the blast zone. smo Air Blasters Kiln Intet Hood Cooler Iniet Air blasters are often placed near the kiln inlet and outlet, They must be disabled when working nearby. (Mirae ar 83Emirs Air Blasters Discharge Lock Out the Test That the Air the Tank Air Valve the Tank is Empty [smo Air Blaster Shutoff Valve ‘Some air blasters may be equipped with a shutoff valve on the discharge. However the air supply stil needs to be disabled when working inside.smiorm Air Blasters Safety Line Safety Line Air blasters must be equipped with a safety restraint line to provent the tank from flying off in the event the pipe flange breaks free. [Esmorn Lockout/Tagout Follow your plant's safety lockout procedures. Lock out all equipment affecting the area in which you are working. 85[smiorn Carbon Dioxide 20.95% O2 0.03% CO2 Carbon dioxide is @ normal product of the biological process, but too much CO2 can kill Kiln exhaust gas contains approximately 35% CO2. This heavier-than-air gas tends to accumulate in low lying areas. Make sure all enclosed areas are properly vented before entering. RES 86morn Combustibles Lock out all fuel systems before entering the kiln. ci aS | [emir Steam Explosions Use of water around a kiln can be deadly. Water coming into contact with hot kiln feed or clinker can vaporize in an instant, causing a steam explosion. Especially, be careful around wet process kilns. 87EEsmiors Steam Explosions This man was working in a clinker transport tunnel when hot material flushed out into standing water in the elevator pit. He was killed by the steam explosion. Make sure all instrumentation, safety interlocking and operator training is complete before start-up. 88EEsmorm EEsmiornGismiorn Stadesitito# Gsm[emiorn Calciner [morn Preheater CyclonesEEsmiorn Preheater Cyclones Material Separation Heat Transfer > Heat transfer in inlet > Separation in cyclone > Funetion of velocity, geometry & Thimble [Esmiorn Cyclone Gas Material The cyclone separates material from the gas stream. era 92[bmiorn Cyclone Central Tube Insulation Brick and Castable Cleanout Port / +The central tube promotes swirling of gas. + The cyclone is lined with insulation and refractory. + Cleanout ports allow cleaning with air lances. [smo Design of LP Cyclone Types Lower stace WITH CENTRAL 1.stace 2. STAGE mupoLe stace ‘Tobe 9mm Rerainy —Y24nm Releaary 14mm Relacary__tN4mm Reodory 3Tismiorm Cast Central Tube + The second lowest and middle cyclone stages have replaceable, segmented, cast steel central tubes. Emorn Cast Steel Liners i EAH TTDI PEP PIED EETP AMPA my[Esmiorn Cast Steel Liners + Easy to install liners, it is important to measure the thickness of the plates to monitor and map wear EEsmorm Cast Central Tube + The top row segments are bolted into the cyclone exit duct. The rest are hanging without bolts. At _ the bottom is a locking element to fix the segments. 95,[smiorn Cast Central Tube ———_ Hanger | Standard Element et PF — Locking Element View from inside View from outside [smorm Cast Central Tube — Bolted Support Ring 7 ™ Hooked, Hanging # Segments + Central tubes require periodic replacement due to high temperature oxidation, This is facilitated by a segmented, hanging design. Only the support ring is bolted[Esmiorn Cast Central Tube + Segments are easily handled by one or two persons. [Esmior Fabricated Central Tube + The second cyclone stage has @ pendulum (or link) mount plate steel central tube. aSplash Boxes smo Material Inlet + Material coming down the feed pipe hits the spreader plate (splash box) and spreads out into the gas duct. © The spreader plate angle is adjustable.[Esmiorn Material Inlet Material entering the duct is pulled upward by the gas stream. [Esmiorm Material Inlet The spreader plate (splash box) angle can be adjusted to optimize the dispersion of material into the duct. 99[smom Material Inlet Esmorn Preheater Tipping Valve (Sluice Flap) Prevent "short-circuit" of air = 100[smiorn [Esmiorn Preheater Tipping Valve Under top three stages: + Under bottom — two fabricated flaps stages: cast flaps 101[smiorn Preheater Tipping Valve + The flaps do not close completely. This aids in preventing material blockages. [bmi Under stage 1 102Emo Under stage 2 [smior Under stage 3 103[ismiorn Under stage 4 Esmiorn Under stages 4 & 5Esmiom Preheater Dividing Gate otaing conta Pcs, numaent Goes tena spit between ett oo tet and Rig Looe By rotating the central piece, the percentage of material flowing into each leg can be controlled. 105Emo Preheater Dividing Gate ‘A gearmotor and drive chain are used to rotate the center part of the gate to any position from 0° to 180°. [smo Preheater Dividing Gate Removal of ‘center Section The center section can be slid out horizontally, without disturbing the feed pipes above and below. 106[Esmiorn Preheater Tipping Valve The heat-resistant steel valve flap can be easily replaced by removing the cover and lifting It out. Preheater Diverter Gate By rotating the central flap, the percentage of material flowing into each leg can be controlled,[smo Preheater Diverter Gate A Beck actuator and linkage drive are used to rotate the internal flap through a 56.5° range of motion.[emo Preheater Hoisting Damper [smiom Multi-port Air blasters Three multi-port assemblies (with 5 ports) supplied with preheater. Cleaning required in kiln feed hood (4 ports) and lowest two cyclone cones (2 ports each).[Esmiorn 2-Way Expansion Joint [smorn Preheater Hoisting Damper 110[smorn Preheater Hoisting Damper Esmorn Preheater Hoisting Damper Uparades: + Damper Blade Solid Refractory ~ Fully Fired ign Performance Refractory Eliminated Cooling Fan Smoother Operation / Reauced Binding Improved Damper Guide Improved Chain Guide Improved Chain Support Larger Platform Improved Guards Improved Couplings Retrofittable "1[ismiom Preheater Hoisting Damper me Quick change of solid refractory tongue and large platform.[smom ‘Access doors 113Gas Conditioning Tower [Zemin General Description + The purpose of the gas conditioning tower (GCT) is to cool the exhaust gases from the preheater tower or the alkali bypass. + The gases are cooled by injecting finely atomized water through dual fluid nozzles mounted in the cone section of the ct. + The atomized droplets evaporate in the gas stream over the length of the GCT. + Cooled gases exit the GCT while excess dust drops out the bottom of the tower + The system is controlled by an Allen Bradley PLC operating on a PID loop, 18[smiom Main Equipment + Gas conditioning tower + Water injection equipment Water tank Pump and valve skid (3 pumps) Spray lances + Dust handling equipment Screw conveyor Flap valve Rotary valve Slide Gates + Compressed air equipment “Air compressors Air receiver [Esmiorn Gas Conditioning Tower + The GCT is a larger chamber or duct used to cool dust laden ‘gases from the preheater tower. + The inlet cone of the tower is were the water injection takes place + Surrounding the inlet cone is a maintenance platform where spray lances and instrumentation can be accessed. + There are thermocouples mounted at the inlet, outlet, and midpoint on the GCT to provide temperature feedback to the PLC. + Mineral wool fiber with aluminum cladding is used to insulate the cr. 15EEsmiorm Preheater Gas Conditioning Tower [smior General Arrangement 116[smiorn Dust Handling Equipment + The purpose of the dust handling equipment is to remove dust that accumulates in the bottom of the GCT. + Dust is transported by a reversible screw conveyor mounted to the hopper of the GCT. + Under normal conditions dry dust is conveyed to a rotary feeder. + In the event of wet material accumulating in the hopper, the screw will change direction and be conveyed to a double tipping valve. E B Screw Conveyor aTGismom Screw Conveyors + Required lubrication ~Gear reducer “Flange mounted bearing + Periodic inspections “Trough ~ check for wear, alignment, and loose bolts “Screw ~ check for damage or wear on flights and shaft Seals - check for leakage, adjustment, and wear Guards ~ check nuts and bolts for tightness, [smo Slide gates + Periodic inspections Frame - check for weat, alignment, and loose bolts Gate - check for wear, alignment, and loose bolts Seals ~ check for leakage, adjustment, and wear Pneumatic cylinder ~ check for wear, alignment, leakage + Equipment setpoints ~Compressed air ~ set to minimum of 5.5 bar or 80 psi[ismiorn Flap Valves = ener | [smo Rotary Feeder 119EEbmorn Rotary feeder + Required lubrication -Gear reducer + Periodic inspections —Check equipment for unusual vibration, noise or excessive operating temperatures ~Check Valve flange, purge connections, and all fasteners for tightness “Inspect equipment for leakage - dust and oil [smo Water Tank 120Emo Pump and valve skid [smo Pump and valve skid" z 3 9 = s S 3 = 5 a — 3 ésaa Piping supply to tower [smiorn Piping supply from water tank and air comp | slEmon Spray Nozzle [Eismiorn Spray nozzleEemiorn Water lance arrangement [Esmiorm Example of ’ Spray Lance Layout (Preheater GCT) Pow, 125[Esmiom Spray Lance Assembly St ome (Preheater GCT) Lis | Esmiorn Thermocouple Layout[smo Water injection equipment Required maintenance + Water Tank Clean inside of tank annually Periodically inspect the operation of the automatic fill valve and level switches Pump set ~Clean inlet basket strainer weekly ~Pumps - inspect shaft seals for leakage annually -Valve rack ~ verify calibration of pressure transmitter and flow meter annually ~Spray lance ~ remove from tower, inspect, and clean nozzle cap bi-monthly or as needed ET Esmiorn Control System + Designed to control the temperature of the exhaust gases from the preheater tower -opens/closes valves on the valve rack to control gas temperature and to ensure proper atomization of the Injection water “continuously regulates the air and water pressure at the lances to ensure proper water atomization controls safety interlocks and the starting of the water pumps var[Eemiom Coolax Cooler [morn 128Lockout Safety [smiom Cooler Lockout Safety + Before Entering Cooler + Kiln drive + Kiln auxiliary drives + Kiln burner gas valve / kiln coal + Bleed air to air blasters and lock inlet valve closed + Cooler drive hydraulic pumps + Cooler fans + Clinker breaker + Never enter or work near the cooler while a preheater vessel is plugged! GEE | 129Esmiorn Preheater flush Re 7 Never work anywhere on a kiln system while a preheater vessel is plugged Hf the plug breaks free it will rush like water through the system, burning everything in its path, emo Air blasters at cooler inlet Numerous air blasters are used at the cooler inlet eeEmon Air blasters Lock out the air supply valve Discharge the tank ‘Shut Off the air supply Test that the tank is empty [smo Air blaster shutoff valve Some air blasters may be equipped with a shutoff vaive on the discharge. 131Emo Lock out combustibles noe Lock out all fuel systems before entering any part of the pyro- processing system In ation to fre and exploston nazar, aol are Ene [ismiom Lock out all fans Cooler Vent Fan Preheater ID Fan coco Bumer primary air fan 132[moors Lock out the cooler drives Many pinch-points exist both above and below the grate line. Lock out all cooler drives before entering any part of the cooler. [smiorn Bleed down hydraulic accumulators Accumulators store hydraulic energy. Failure to bleed down the ‘accumulator pressure can cause a drive to move even without the pump running. 133[Esmiorn Lock out the heavy duty roll breaker ‘All motors andlor hydraulic systems must be locked out [emiorn Hammer Crusher[ismorn Harsh conditions at cooler inlet The ‘snowman” may eventually build up and require a kiln stop to remove it, 135[Esmiorm Eye and face protection required Never open an inspection port without proper protective clothing [Esmiorm Other things to consider + Confined Spaces ~ Cooler under grate area + Large Cumbersome and Heavy Components = Lighting + Personal Safety ~ Head, Eyes, Ears and Respiratory 136Pmorn CFG Air Diagram ‘Tam Diep, Coolax 1284¢ (1206/1229/1224/1225) ee @ rt[Esmiorm Grate details Aj. racesbietn Fixed beamPreventive Maintenance [emo Preventive Maintenance 142Eismiom Air system [smo FLEXIBLE CONNECTION 139Emon Maintenance + Basics (Specially for daily control): See. Hear Feel smell une[smo Pocket Grate CFG [ismiorm Pocket Grate CFG[Emir Preventive Maintenance 2002 8 1 Eismior Preventive Maintenance 143Emon Preventive Maintenance Emorn Preventive Maintenance[smiorm Preventive Maintenance 3 eos bbd 145Pemiomm Preventive Maintenance as by wy 146Esmiorn Cross View Emo Length View var[emir Internal air system ett = = = wo te [iemiorn Top View of Cooler 148[mio Beam Alignment [smo Details 149Emm Side Seals Erection 28, 88 Ly Emon Side Seals ErectionPismo Fixed Inlet Details 800 9 Hydraulic Drive System 151LEsmorn Hydraulic Drive System [Esmior Hydraulic Drive System[smorn Hydraulic Drive System Cylinder Design [Esmiorn Hydraulic Dri System af[Esmiomm Hydraulic Drive System EEbmiorm[Esmiorm Control System f aiaiaae [Esmiorn Shock Blasters[emo Fixed Inlet Esmiorn Shock Blasters 156[smo Shock Blasters Snow Man [Esmiom Shock Blasters 197[Esmiom Shock Blasters ' pana by ©. 34 90 sreetetbow Air titerregutorubrcator D. Quick exhaust vale. Lockout ball valve E Elericalsolenedvaie L Check ave F Beating 1 av suo 10 sak LS | [smiorn Shock Blasters 158[smiorn Shock Blasters Eismiorn Cooler Outlet 159Eismior Cooler Outlet [emiorn Cooler Outlet 4[smo Clinker breakers [Esmiorn Cooler Discharge End Arrangement with Clinker Breaker[smo Hammer Shaft and Hub Assembly EemormEismiorn Field Removal of End Hammers smo164smiorn Hammer Crusher morn Hammer Crusher[smo Hammer Crusher Bolt diameter Ms Mio M20 M24 M33 Ms6 Torque Bott quatity | 180 4.6 106 180 425 212 Nm 18056 | 1808.8. 30 170 335 Nm Nm [ismiorn Hammer Crusher max2/38 As 187[smi Hammer Crusher [smiorm Hammer CrusherEemorn Hammer Crusher bearing [smorn Hammer Crusher[ismiorn Hammer Crusher 2 leaning 3 lnepetion and adjstnents 4 Checking of eondiion 5 Replacement il lubicaas) 6 Peommance tes[emo Fan Silencer[smo Maintenance Basics (Specially for daily control): 1.See. 2.Hear 3.Feel 4.Smell 1m[ism Lubrication System ay Span ae ti oy an ‘ep 2 [smior Lubrication System[Esmiorn Preventive Maintenance Emir Water Injection 174Ebmiorm Water Injection [smiorn Red River 175[smo END OF SHOW QUESTIONS? 116COOLAX COOLER Hydraulic System Mikael Heymann Olsen Engineering, Hydraulics 445 3618 22.21 ‘hae ean enema com Eismiorn cota Viner’ os 1 COOLAX COOLER Hydraulic System Cylinder locations EEsmiom ame Vins wCOOLAX COOLER Hydraulic System Hydraulic Cylinder COOLAX COOLER Hydraulic System Trae Double acting cylinder mor. —t aes. 178COOLAX COOLER Hydraulic System Flushing valve = [ismiorn COOLAX COOLER Hydraulic System a Internal boost Punp ed ene. 179COOLAX COOLER Hydraulic System — Boost pump, accumulator and filter Bemierte COOLAX COOLER Hydraulic System Boost pressure relief & Piston vanesCOOLAX COOLER Hydraulic System ses Proportional —, Directional valve x NERD ds smiom COOLAX COOLER Hydraulic System Pistons and pump station set-up for one drive. Schematic view Grey.COOLAX COOLER Hydraulic System Hydraulic circuit diagram Pismo 7 Hydraulic diagram Partial view One drive myer...COOLAX COOLER Hydraulic System Hydraulic diagram Partial view ‘One pump unit a COOLAX COOLER Hydraulic System Hydraulic diagram Taek Partial view 8 Eismiorn insite” 183COOLAX COOLER Hydraulic System Closed circuit pump P11/P 14. Emon vineutute™ ’ 7 COOLAX COOLER Hydraulic System [ismiorm InstituteBmore. SEBS . COOLAX COOLER Hydraulic System smorm vnsutute™ BRINE » 195COOLAX COOLER Hydraulic SystemCOOLAX COOLER Hydraulic System COOLAX COOLER Hydraulic System Stand-by Pump EEbmorm 187COOLAX COOLER Hydraulic System ver aoa Smycyy, WAS o Intiate COOLAX COOLER Hydraulic System myer... Ome .COOLAX COOLER Hydraulic System Ln Ome . COOLAX COOLER Hydraulic System >) ? = Esmom Vineet O@KE »COOLAX COOLER Hydraulic System [Esmiorn COOLAX COOLER Hydraulic System EismiormCOOLAX COOLER Hydraulic System View of tank top omer @aHa . vnseute COOLAX COOLER Hydraulic System Components. Pos. 11, Conditioning/ext. boost pumpCOOLAX COOLER Hydraulic System Components. Pos. 11, Conditioning/ext. boost pump Vane pump Gsmiom aS . Vnstute COOLAX COOLER Hydraulic System Components. Pos. 13, Pressure relief valveCOOLAX COOLER Hydraulic System Components. Pos. 13, Pressure relief valve smo Sale » COOLAX COOLER Hydraulic System Components. Pos. 22, Closed loop axial piston pump Emon 4 vsutute” BENS . 193COOLAX COOLER Hydraulic System Components. Pos. 22, Closed loop axial piston pump smo vinettute™ COOLAX COOLER Hydraulic System Components. Pos. 22, Closed loop axial piston pump TYCOOLAX COOLER Hydraulic System Components. Pos. 22, Axial piston pump C01 digtat feedback Cylner postion feedback OTH. Institute COOLAX COOLER Hydraulic System Components. Pos. 22, Axial piston pump [ibmiorn Inserate 195COOLAX COOLER Hydraulic System Components. Proportional valve on Pos. 22, Axial piston pump 4Dc01 control valve COOLAX COOLER Hydraulic System toni [morn Tins’COOLAX COOLER Hydraulic System Components. Pos. 25 f Hydraulic k accumulator. i Eemiorn r vette” COOLAX COOLER Hydraulic System Components. Pos. 25, Hydraulic accumulator. fae [imiorn 197COOLAX COOLER Hydraulic System Components. Pos. 8, Oil cooler. [Esmom r Tnseute’ COOLAX COOLER Hydraulic System Hydraulic Cylinder Esmom 198COOLAX COOLER Hydraulic System Maintenance. Basics (Specially for daily contro’ 1.See. 2.Hear 3.Feel 4.Smell Homo. @ COOLAX COOLER Hydraulic System Maintenance. 1.See. The Daily routine often carried out by the operator is, to control: ~ Oillevels ~ Filter indicators ~ Leakages ~ Water content in the oil ~ Foaming Gsmom @COOLAX COOLER Hydraulic System Maintenance. 2.Hear. - When a pump starts to change sound level or sound characteristics - Whistling sounds from shafts, leakages - Wear of couplings - Cavitation - Vibration COOLAX COOLER Hydraulic System Maintenance 3. Feel. - Feeling on the pipes for increased temperature or lack of same. Temperature changes are indication of abnormalities. - Low temperature in accumulator systems is sign of seldom intervention. - Feeling for leakages is dangerous!!! An hydraulic jet can cut a limb with ease!!! Hydraulic oil is poisonous if penetrating under the skin, vnsttute 200COOLAX COOLER Hydraulic System Maintenance. 4. Smell. ~ Defect hydraulic oil, has a particular smell (Burt oil) - Burt rubber. - Burnt plastics more, vsteute™ COOLAX COOLER Hydraulic System Maintenance. Other routines/Controls: - Logbook - Laboratory analysis. ~ On-line filtration - Pressure monitoring. - Hydraulic tester - Follow check list on instruction manuals for pump stations smiorn aa Vnsttute™ gliaCOOLAX COOLER Hydraulic System END OF PRESENTATION DTH Insenuce Vmax 202fiésm DTH 2040 Avenue C Bethlehem, PA 18017 Telephone: 610-264-6017 Fax: 610-264-6031 E-Mail: flsinstitute.us@flsmidth.com