Rotary kiln installation construction plan
Rotary kiln is the main equipment used by cement plants for cement clinker calcination. Its main structure is composed of kiln cylinder, supporting device, kiln head, kiln tail sealing device, transmission device, feeding and calcining device, which is the most critical equipment in cement production process. The rotary kiln with Ф 4.8* 72m and 5000t/d kiln decomposition furnace is selected for this project.
1. Technical performance
Kiln specifications: inner diameter Ф 4.8m, total length 72m;
kiln slope (sin Ф): 3.5%;
speed: main drive 0.396~3.96r/m, auxiliary drive 11.45r/h;
support number ( supporting rollers): 3;
required power: 630KW main transmission power, auxiliary drive 75KW;
number of gear wheels: two hydraulic gear wheels, the distribution of the support 2-3;
scale: 5000t / d clinker;
total kiln Weight: 829.804t.
2. Working principle
The cylinder of the rotary kiln is rolled from steel plate. The cylinder is reinforced with refractory lining and has a specified slope with the horizontal line. It is supported by three belts on each gear support device. A large ring gear is fixed on the cross-inner cylinder near the belt by a tangential spring steel plate, and a pinion gear is meshed therewith. During normal operation, the main drive motor transmits power to the open gear device via the final drive to drive the rotary kiln.
The material is calcined from the kiln into the kiln. Due to the tilting and slow rotation of the cylinder, the material rolls both in the circumferential direction and in the axial direction, and the process of decomposition and firing is continued. Finally, the raw material is cooled by the kiln head cover into the cooler.
3、Structural characteristics The
cylinder is made of 20g carbon steel plate for boiler (GB713-86) and is automatically welded. The wall thickness of the cylinder is 28mm for the general cylinder, 32mm for the firing zone, 75/80mm for the wheel belt, and 42/55mm thick transition section from the bottom of the wheel to the span, thus making the design of the cylinder more It is reasonable to ensure that the rigidity of the section improves the stress state of the supporting device. At the inlet and outlet ends of the cylinder, kiln mouth shields with high temperature resistance and wear resistance are installed. The kiln head guard and the cold air sleeve form a circular space of the sleeve, and the cold air is blown from the bell mouth to the cylinder to cool the non-working surface of the kiln head guard to facilitate long-term safe operation of the part. There are three rectangular real wheel belts on the cylinder. The gap between the wheel belt and the cylinder pad is determined by the amount of thermal expansion. When the kiln is in normal operation, the wheel belt can be appropriately placed on the cylinder to reduce the radial deformation of the cylinder and increase the rigidity of the cylinder.
The hydraulic thrust wheel device is used to withstand the sliding force of the entire kiln, which drives the kiln upwards. The correct distribution of the span between the support points makes the design of each gear bearing device more reasonable. Each bearing is equipped with a temperature measuring device. The operating temperature of each bearing can be transmitted to the central control room for display and inspection.
The transmission system uses a single transmission, and the high-start torque cement industrial rotary kiln special DC-slewing motor drives the second hard-toothed cylindrical gear reducer, and then drives the open gear pair of the kiln. The transmission adopts a flexible shaft coupling. Section to increase the smoothness of the transmission. An auxiliary transmission device connected to the security power supply can ensure the operation of the kiln when the main power supply is interrupted, preventing the cylinder from bending and facilitating maintenance.
A tachogenerator is provided at the rear of the main motor to indicate the actual speed of the kiln.
Due to the strong thermal load and continuous production work system in the production of rotary kiln, the installation quality is very strict, and the quality of its installation is directly related to the normal operation of the whole production line, so during construction Advanced construction methods and testing methods should be used to strictly control the construction quality of each process. During the construction process, we will strictly follow the design drawings and relevant national technical standards and specifications for installation and construction. The key and concealed projects will be confirmed and signed by the owners and their appointed on-site experts. The unqualified projects will not be transferred to the next process.
Second, the rotary kiln installation flow chart
Rotary kiln installation flow chart
III, construction preparation
1, the construction workers familiar with the drawings, installation instructions and other technical information, do a good job of technical;
delivery2, understand the arrival of equipment and equipment storage location, etc.
3 Prepare the construction machinery and materials, and connect the construction power;
Fourth, the rotary kiln parts inspection
The characteristics of the rotary kiln are: large body, heavy tonnage, and a thin-walled cylinder-based machine in the process of transportation, transportation and installation. It is easy to produce deformation in the middle. Therefore, all components, especially the cylinders, must be checked against the drawings before installation. The quality inspection and size checking of the components must be done in order to deal with the problems found in the inspections in a timely manner.
1. Inspection of thesupporting device
base of the1.1 The supporting base is welded by profile steel, which requires no deformation. The hole spacing of the bolts and the thickness of the base are measured. The design drawings and the actual dimensions on the foundation and the actual hole size of the bracket bearing assembly hole are compared. Compare and check the centerline of the vertical and horizontal lines on the base. Through the actual thickness check, the error correction value of the base elevation is measured.
1.2 According to the center position of the foot hole on the bearing base and the center line of the base, draw the vertical and horizontal center line on the roller bearing.
2, theroller and roller bearing inspection
specific requirements of theare as follows:
visual inspection, no matter whether the roller or the bearing can be cracked, deformed and combined size error. The surface roughness of the contact portion should be consistent with the design.
Measure the diameter of the roller, the width, the diameter of the roller journal and the center height of the bearing. These dimensions should be compared to the design. If there is any discrepancy, the drawings should be corrected according to the actual size. The outer diameter of the roller should be matched in pairs. The pairing combination number must not be confused.
Check the contact between the bearing housing and the spherical back. If it does not meet the requirements, it should be scraped. The following table shows the specific requirements
between Roller Bearing Specifications
with red Dan oil is applied to the journal, and each copper tile is scraped and tested according to the following table. If it does not meet the requirements, it should be scraped again.
The bearing should be subjected to a hydraulic test with a test pressure of 0.6 MPa and no leakage within 8 minutes.
3, kiln inspection
kiln body is made up of many sections of joint welding, is the main body of the rotary kiln. Most of the equipment transportation is disintegrated into the factory. Therefore, the cylinders of each section must be carefully inspected. The main inspection items are as follows.
Roundness inspection, check the roundness of each end of the kiln body, the roundness deviation (the difference between the maximum and minimum diameter of the same section) shall not exceed 0.002D (D is the diameter of the kiln body), the lower section of the belt and the lower ring of the large ring The knot shall not be greater than 0.0015D. If it exceeds this value, it can be adjusted in the diameter direction with a jack or other means.
For the measurement of the circumferential length, the outer circumference of the two joints of the kiln section is measured with a steel tape measure. The two ends are required to be equal. The deviation shall not be greater than 0.002D and the maximum shall not be greater than 7mm.
Check local deformation: The kiln body should not have local deformation, especially the interface.
According to the interface word code of the kiln section, determine the installation position and arrange the sections in order, then measure the following dimensions of each section section by section.
The actual length dimension of each section of the
kiln; the distance from the centerline position of the belt to the joint edge of the kiln section; the distance from theedge of the joint section of the
midline position of the large ring gear to thekiln section.
Check the design drawings according to the measured dimensions to ensure the correct position of the belt and the large ring gear. The length of each section shall be trimmed, and the gap between the trimming and the section shall be considered at the same time.
4.checking thebelt and the retaining ring
Beforeinstallation of the, first check the surface of the belt for cracks, sand holes and casting defects that affect the strength and rigidity. Next, use the ground gauge and steel tape to check the actual size of the outer and inner diameters of the belt and record it for installation. The inner diameter of the wheel should meet the matching clearance with the pad and meet the requirements of the thermal expansion of the kiln. In addition to measuring the actual size, the outer diameter of the wheel should meet the clearance between the pad and the requirements for the thermal expansion of the kiln. In addition to measuring the actual size of the outer diameter of the wheel, it should be noted whether the roundness and the end face runout error are within the allowable range of the drawing. In addition, check the retaining ring for deformation; check the fit size of the pad on the kiln section. Should be strict (with no gaps). The inner diameter should be 2 - 3mm larger than the outer ring size of the kiln reinforcement plate.
5, Transmission and large ring gear inspection
The speed of the cement rotary kiln is slow, generally between 0.5-1.5r/min. Therefore, in order to meet the requirements of large speed ratio, there must be a set of reduction gears. They are the main reduction gear (including open size gears); the auxiliary transmissions (including the disconnectors, anti-backup devices, etc.); all kinds of couplings should be inspected and inspected before installation, especially the transmission base and the basic ground. Check the assembly dimensions of the bolt position, etc.
The large ring gear should be pre-assembled for inspection. Use the sleeper pad to flatten the two half interface bolts to find the center. Check the diameter of the crown circle with the ground gauge. The roundness tolerance value is 0.004D (D is the large gear diameter, indicating the actual speed ratio. Proof large ring gear and one spring Whether the steel plate has deformation, damage, etc. The inner diameter of the large ring gear should be greater than 3 -5mm than the outer diameter of the kiln body and the height of the spring plate.
The maximum deviation of the circumference at the large ring gear interface should not exceed 0.005m (modulus ).
collation pinion gear shaft and bearing size and dimensions mating.
6, gear wheel and other partsto check
in orderand flag kiln and remain stable up and down movement of the axial position of the cylindrical body, a pair of set up in a rotary or several Locking wheel device.
All the above-mentioned roller parts or their hydraulic transmission parts should be inspected and paid attention to the following matters:
the outer surface of the retaining wheel, the surface of the support, the upper and lower machining surfaces of the base and the guide shaft, etc. And damage, etc.
Measure the distance between the bolt holes on the left and right seats of the signal retaining wheel, check whether the two correspond to each other; check the corresponding position deviation of the base bolt hole of the base. Measure the distance of the base anchor bolt And use this as a benchmark to draw the horizontal center line on the base.
Check whether the taper angle of the control wheel meets the design requirements.
Check whether the hydraulic system parts are complete.
Other rotary kiln parts, including the activity kiln head, kiln tail smoke The chamber, the sealing device at both ends, and the coal injection device shall be checked according to the drawings and inspected.
5. Basic acceptance and underline
inspection is a major process in the installation of equipment. This work shall be the same as that before the installation of the equipment. and other units factory acceptance, and make inspection records.
1, basic dimensions, center line, elevation, position of anchor bolt holes each size, construction drawings shall comply with regulatory requirements and acceptance, which allow deviation below.
foundation kiln Allowable deviation
2 , the vertical and horizontal center markers are embedded, and one is set on each foundation. The elevation reference point of the elevation.
3. Based on the concrete foundation with the transmission, draw the vertical and horizontal centerline of each foundation of the rotary kiln. The deviation of the lateral center distance between the adjacent two kiln piers shall not exceed ± 1.5mm, and the lateral center distance between the first and second kiln piers deviation does not exceed
3mm.Note: center distance should be added to the kiln shell expansion amount measured size
transverse4, draw the center line of the aspect of the transmission according to the corrected accurate kiln center line
5, the case of periodic inspection on the settlementsettle.
to The standard plate is buried on the two sides of the foundation at + 1000mm. It is suitable for setting, setting up the instrument, timing, and making the original record.
6. Mounting of the horn and the steel base and the supporting wheel
1. According to the structure of the steel base and Place the horn on the anchor bolts. The foundation should be shoveled and shoveled and cleaned. The surface of the steel flat horn should be flat and no burrs or unevenness should be allowed. Rust and clean before placing.
2, the horn arrangement of the
horn is composed of a pair of diagonal horns, a flat horn. In order to improve the accuracy of equipment installation, the mortar bolster method is adopted.
When making the mortar pier, the foundation should be chiseled and rinsed with water; the
mortar pier mix ratio: 525# cement: river sand (medium sand): water=1: 1: the right amount of
mortar pier is correct: use and kiln cylinder The same degree of inclination gauge, level and level are corrected, the level is not more than 0.2mm / m, and the deviation of the elevation is not more than ± 0.5mm.
The mortar pier is sprinkled and maintained, and its strength is up to 75%. The steel base can be installed above.
Diagonal horn specifications: 180*700*40* 5mm
slope: 1: 20
flat horn specifications: 200*720* 20mm
3, steel base installed
steel base before installation, first of all to clean, draw vertical and horizontal center line Pay attention to the position of the steel base with the retaining wheel. According to the longitudinal and horizontal center lines of the steel base, draw the vertical and horizontal center lines of the support tile seat, and mark it with Yangchong.
The installation sequence is generally from the steel base on the basis of the belt drive to the kiln head direction installation; after the
steel base is placed on the horn, the suspension line makes the vertical and horizontal center lines of the steel base and the vertical and horizontal center lines on the foundation Coincidence, the deviation is allowed to be 0.5mm, and then the longitudinal centerline is checked by the theodolite. The longitudinal centerline of the steel base coincides with the longitudinal centerline of the foundation, and the horizontal centerline distance of the upper surface of the base is measured by a steel ruler. Then, at the diagonal of the two points at the lateral center point, the longitudinal and horizontal levels of the base are checked with a flat-foot pad inclination gauge, and finally the level difference of each base is measured by a water level meter.
Finding the accuracy, correcting the deviation, see the table below,
arranging the deviation, allowing the deviation
secondary strength of thefound in the anchoring strength of the ground hole, the tightening anchor bolts are searched, and the allowable deviation is the same as above. After no review, the inspection will be confirmed.
4, the wheel set installation (see the picture below)
4 . 1 Before installing the seat, prepare the
cleaning tile seat, draw the vertical and horizontal center line, and mark the
spherical pressure of the spherical tile. The test pressure is 0.6Mpa, and the pressure is kept for 8 minutes
. The roller bearing is scraped: the contact angle between the shaft and the tile is 60. ° -70 ° (contact angle is in accordance with the drawings) The contact point is not
less than 1-2 points/cm 2 for thealignment, and the side clearance between the bearing and the journal is 0.001-0.0015D (D is the axis) Diameter), the gap outside the contact angle range should be gradually increased, and the gap between theshould be measured in four conditions to be
spherical tile and the bearingno less than 12 points / 25 × 25mm 2 . The contact surface of the substrate portion of the bearing pad is formed into a continuous narrow fine line. However, a ring of about 50mm on the edge is allowed to have a gap of about 0.1mm. The gap between the lining and the journal is checked by a feeler gauge. It is generally required to be 0.5~0.6mm when it is inserted into the 100mm. When the side gap is insufficient, it should be scraped. . If there are special requirements for bearing tile scraping, it shall be in accordance with the requirements of Party A or the manufacturer of the equipment.
4 . The installation and2 watts is the
installation sequence of thesame as that of the steel base. When hoisting, ensure that the upper surface of the tile seat and the steel base are clean and lubricated to prevent the bearings from being exposed.
4 . 3 After the adjustment ofinclination of theinclination of the
thesupporting roller, after the adjustment of thesupporting roller, the following steps are completed before the journal contacts the lining: the left and right lateral centers of the supporting roller are overlapped, and the deviation is not more than 0.5 mm. The inspection must be fixed to the bearing in the bearing. On the plate, the thrust surface of the tile lining and the thrust washer are in close contact with each other. The jack is used to lift the roller, and the total clearance t between the thrust surface of the bearing and the thrust washer is adjusted to maintain 5 -8 mm.
The vertical center line of the supporting wheel set first measures the top level of the supporting wheel, and the elevation of the adjacent two supporting wheel sets allows 0.5 mm.
Use the theodolite and the sample rod to measure the center line of the roller to be arranged in parallel. On the same straight line in the longitudinal direction of the kiln, use two rods on the top of the vertical surface of the bracket, and the rod is perpendicular to the kiln center line. The length of the sample rod is made according to the center distance of the two supporting rollers and the size of the supporting wheel, and the center is drawn with thin lines. The straightness of the longitudinal center line of the supporting wheel set is allowed to be ± 0.5 mm. The
above steps are used to tighten the connecting bolts, and the III supporting wheel is used. Benchmark, find the II, I wheel, keep the span deviation less than 1.5mm.
7. Install the hydraulic wheel
1. Before installing the wheel, clean the hydraulic wheel and turn it flexibly. Ensure that the wheel and the wheel are tightly fitted. The shaft and bearing should be cleaned, filled with grease, and scraped if necessary, requiring flexible rotation.
2. The position of the retaining wheel should be in accordance with the design regulations.
8. Wheel belt installation
1. Wheel installation is ground installation method , that is, the wheel and the whole body are hoisted.
2. Check the installation dimensions of:
the wheel beltBefore installation, remove the paint, rust, etc. from the belt, the ferrule (stop) and the pad, and apply a layer of grease.
checkthe plate cylinder and the belt Gap: allowed deviationshould meet drawing
ring with the receiving memberthewheel band mounted on both sides of the ring (note that the word of the retaining ring on the cylinder good codeword) belt pad The board should be tightly fitted and there should be no gaps. The gap between the
side of the belt and the fixed retaining ring is allowed to be different: 2mm for each hot and cold end.
Inspection method: feeler gauge.
9. Lifting of the rotary kiln cylinder, lifting of the
kiln cylinder 250t The crawler is hoisted, and the lifting sequence is determined according to the site conditions and the cylinder section is set on the ground.
1 . Preparation of the kiln cylinder before the lifting
of the cylinder and the belt to ensure the end face of the cylinder and the wheel and wheel of the wheel The belt should be free of burrs, rust and dirt.
Use special tools to check the ovality of the cylinder. The out-of-roundness should be less than 0.00 2D (D is the diameter of the kiln body). The cylinder under the belt and the large ring should not exceed 0.0015D. Use a steel plate to measure the circumference of the outer end of the cylinder and make a record. The difference between the circumferences of the end faces of the two cylinders should be less than 0.002D and the maximum should not be more than 7mm. (This work is carried out when the equipment is inspected and accepted) 16 equals the outer circle of the cylinder and is outside the cylinder The serial number, to the cylinder-side white line as a starting point,opposite to the cylinder
a centrally located cylindrical bodyschematic
axis of the kiln shellalignmenta schematic view of
mark 1a steering order, 2, 3, ...... numeral 16, for measuring and drawing electrode .the diagram of
inthe solid cylindrical wheel width and length of each belt is drawn from the plate with two center distance and belt edge, and a transverse centerline drawn on the idler wheel torr;
group of kiln shell : The ground group is opposite to the cylinder body, and the four pulley brackets are used to support the cylinder body. The cylinder body is based on the white line, the two white lines are aligned, and the white line direction is correct, and the tension bolt is used to connect. Adjusting the iron block to be welded in place for the mutual alignment of the center of the two barrels. After adjustment, the two sections of the cylinder are fixedly connected by the lap plate; the two cylinder groups are measured by the polar coordinate method. Whether the rear center line is in a straight line, the center deviation of the cylinder is: 4mm at the fulcrum, 4mm at the large gear, 12mm at the rest, 5mm at the kiln head and the kiln.
Prepare the cylinder group connection fixtures and distribute them equally on the circumference of the cylinder;
preparation for the hoisting site: the roads at the construction site are required to be smooth, and the roadbed should be smooth and strong so that the crane can reach the bottom of the kiln pier smoothly. The ground of the kiln pier must also be flat and strong, and the elevation must meet the requirements. Cover the thick steel plate on it to prepare the kiln body;
before lifting the hull, prepare the lifting equipment, check the lifting equipment and rigging, be sure to Safe and reliable.
2, cylinder lifting
Φ 4.8 * 72m kiln cylinder is generally divided into 9 sections into the site, the number is: from the kiln tail for D1, D2, D3, D4, D5, D6, D7, D8, theoretical length and weight and measured The length is shown in the table below.
kiln shell weight data
according to the actual situation, the choice of 25 0T crawler crane hoisting.
Due to the supply reason, the actual arrival is 9 cylinders. For this purpose, the first section (from the kiln end) and the second section are on the ground to form the D1 section.
The kiln cylinder lifting sequence is: D1 - D2 - Set No. III wheel belt - D5 - D3 ~ D4 - Set II wheel belt - D8 - Set I wheel belt - D7.
The D1 section cylinder is hoisted by a hoisting machine through the pulley block, and a crane is used to hoist it to the corresponding position and is connected by a pulley block.
The D2 section is hoisted in place and is firmly supported. To ensure safety, the No. III wheel is brought in place once.
D3, D4 tube body ground pair, after the D5 hoisting in place to complete the corresponding bindings and then hang D3-D4, one pair of pairs, group pairing order: D2, D3 joint interface first group is finished Then connect the D4 and D5 interfaces.
After the D1 to D5 cylinders are closed, the second belt is set.
The D8 cylinder is hoisted in a single section. In order to facilitate the control of the height of the center, the kiln head is supported by a steel bracket. First, 4 to 5 layers of sleepers are placed on the platform beam of the second layer of the cooler, and the steel bracket is placed on the sleepers to achieve the required Support height. Then set the I wheel. Lift the D6 and D7 cylinders in sequence.
The specific lifting sequence diagram is shown in the attached figure.
After the kiln body is hoisted and finished, the pole figure is drawn to control the installation quality. The pole coordinate measuring point is the horn of each support part. Theeach group and the kiln head kiln
body are hoisted
rear end of. The measurement starts from a fixed point and measures the measurement point in the diameter direction. And make a polar map. This figure reflects the eccentricity of the cylinder, and the contour reflects the degree of deformation of the cylinder.
The specific method is as follows:
On the plum blossom frame at the interface of the cylinder, a photometric shutter is installed, so that the laser beam passes through the respective gates for alignment.
4. Inspection items and allowable deviation:
The radial circular runout at the center of the cylinder shall not be greater than the following values:
the center of the cylinder at the large ring gear and the belt is 4 mm, the center of the cylinder at the rest is 12 mm, and the kiln head and the kiln end are 5 mm.
detecting cylinder integrally alignment schematicpoints,
afterkiln pass the inspection spot welds of the cylinder immediately. The welding requirements are detailed in the kiln body welding.
5, wheel position correction and welding of wear rings.
Check the span of the kiln, that is, check the center span between the belts before finalizing the belt.
Correction of the position of the belt: The third belt, the belt at the thrust stop, must be at the center of the roller. Then adjust the position of the I and II wheel belts so that the center line position of the belt is properly offset, and the offset amount corresponds to the expansion value of the kiln body. See the craft drawings.
After the wheel position adjustment is completed, they are fixed by the support plate.
X. Installation of transmission large gearsinstallation
1. Beforeof transmission large gears, it should be cleaned and free of oil and debris.
2, the large gear should be pre-grouped on the ground, check the gap between the two half-circle interface, should ensure that it fits tightly. The ring gear roundness deviation should also be checked. Inspection method: Use a 0.04mm thick feeler gauge.
3. The spring plate should be mounted on the large gear on the ground. For the split lifting, please pay attention to the bolt holes on the spring plate and the ring gear.
4, remove the two halves of the ring gear, first hang the lower half of the ring gear, temporarily placed on the foundation pier.
5. Lift the upper half ring and install it on the upper semicircle of the cylinder.
6. Connect the interface bolts of the two semicircular gears and check the interface clearance.
7. Temporarily fix the large ring gear on the cylinder with a special tool and start to align;
check the level of the large gear. Inspection method: Turn the kiln to find the right one. The tools are a tilt gauge and a frame level.
Check the large ring gear runout. The allowable deviation of radial runout is not more than 1.5mm, and the allowable deviation of end face runout is not more than 1mm. Measurement method: dial indicator. The specific measurement method is shown in the following figure: The
large-toothed ring runout measurement diagram shows that
the deviation between the large ring gear and the adjacent centerline of the adjacent wheel belt is not more than 3 mm.
8. When the large ring gear is completed, it should be checked with the supervisor and the owner's representative. After passing the certificate, both parties will be granted a visa. Then, the large gear is fixed on the cylinder by rivets or countersunk bolts, and the riveting work of the spring plate is completed. Finally, the radial and end face deviations of the ring gear are reviewed.
9. Install the transmission device:
According to the basic scribe line, install the pinion gear, main reducer and auxiliary transmission device one by one. Pay attention to the following points:
Find the center position of the pinion gear and the deviation from the center mark is not more than 2mm. The pinion axial centerline should be parallel to the longitudinal centerline of the kiln.
Adjust the contact between the large ring gear and the pinion gear and the tip clearance. Generally, the top clearance is 0.25m + (2 -3mm ) [m is the gear modulus].
Contact spots on the tooth surface of the large and small gears should not be less than 40% along the tooth direction. The length along the tooth should not be less than 50%.
The pinion shaft and the reducer are connected, and should be installed according to the position of the pinion. Each drive shaft should be parallel. The coaxiality of the main motor output shaft and the input shaft of the reducer reaches Φ 0.1mm, and the coaxiality of the other couplings must reach Φ 0.2mm.
XI. Installation of other ancillary equipment
including lubrication, sealing, cooling system, kiln seal and kiln seal.
Twelve, the barrel welding
barrel welding work is a major construction process in the kiln installation work, the welding quality is good or bad, directly affecting the normal operation and service life of the kiln. In order to ensure the quality of construction, we must pay attention to the welding work of the kiln cylinder.
Φ 4.8* 72m rotary kiln is planned to be made by manual arc welding and CO 2 automatic welding.
1.pre-weld preparation work
Selection of welding materials and welding methods for.
The selection of welding materials will be selected according to the requirements of the equipment and process drawings. The welding method is to adopt manual welding and bottoming, and automatic welding forming welding method. The specific welding process will be determined after the equipment drawings and process drawings are on site.
The welder conducts the test before the operation, and passes the fluoroscopy, bending and tensile strength test of the sample. After all the qualified,removed before the
the paint, rust, burr and other debris in the range of 40mm on both sides of the groove should bewelding. The bare base material is exposed to start welding. The welding rod should be dried and well insulated;
the angle, depth and clearance of the groove processing should be thoroughly checked, and the deviation of the relative angle is large. The groove with too large (small) clearance and insufficient depth should be corrected and recorded. Take appropriate measures to ensure the quality of the welding process;
inspect all parts of the kiln, the various factors that affect the clearance of the kiln body is rotated;
re-test each weld, kiln, kiln runout before welding;
measures the rotation of the rotary kiln: Considering the supply time of the large ring gear, the rotation of the rotary kiln will not be able to be welded by the auxiliary drive setting, and the winch will be used for the turning. Before welding, add lubricant to each roller bearing, wipe the dirt on the surface of the roller, set a clear contact signal at the welding location and the rotating position. During the welding process, care should be taken to avoid the coating or the electrode tip falling on the surface of the roller;
Do a good job of protecting and safely welding the outer port.
2, positioning spot welding formal welding has a close relationship, so the welding process requirements are strict, the welding material type should be matched with the weldment material, the electrode must be dried and insulated at 350 °C for 1 hour before welding, positioning spot welding along the inner circumference 8, etc. At the same time, two welders are spot welded at the same time. Each length of spot welding is 350-400mm, the height is about 6mm, and it is not more than 6mm. The spot welding must ensure penetration. The welding line energy should be the minimum allowable value. In the case of undercut and damage to the machined surface, the position of the tack weld shall be placed within the weld bead and required to be welded by a welder with a certificate.
3, barrel welding
according to the situation of the cylinder alignment, arrange each weld weld test procedure;
construction welding work should first weld the weld close to the transmission gear, to reduce the direct impact of welding deformation on the transmission accuracy;
The inner weld of the cylinder is welded by manual arc welding, and the outer weld is welded by CO2 gas shielded automatic welding.
Both the inside and the outside are welded at the same time at 180 degrees symmetrical position, and the kiln body is rotated, and the welding is always maintained in the vertical position, and the welding is performed in four times. The welding sequence inside and outside the cylinder is as shown in the following figure:
welding order inside the kiln cylinder. Welding order outside the
kiln cylinder After the sealing of the inner side of the kiln cylinder is completed, the root of the kiln shell must be welded after grinding the roots with a grinding wheel.
Welding outer section: The first layer is made by manual arc welding. It must be welded and the depth is consistent, and it should not be too thin to prevent it from being burned through during automatic welding. C0 2 automatic welding should be uniform in height and height and width in each layer. . The welding process parameters should be controlled during the surface welding;
after the external welding joints are welded, the above-mentioned radial runout should be re-measured, recorded, and compared with the pre-weld, after the internal support is cleaned, repeat the above work. ;
gouging: gouging required to weld a first layer, defects are still found to be partially removed. In order to ensure that the welding quality should be corrected after the rooting is removed, make it a “V” type slit; the
inner section welding;
after the welding, the slag on the surface of the weld and the spatter on both sides should be cleaned and the weld be inspected. The quality of the appearance, after the inspection is qualified, the welder's stamp is placed on the welds and parts specified in the process;
the points are re-measured, and the measurement data of each process is saved.
4, weld quality inspection
weld surface should be smooth and scaly, uniform width and uniform, weld surface and heat affected zone must not have cracks, arc pits, slag inclusions, pores and other defects, weld undercut depth should not exceed 0.5mm The continuous length of the undercut shall not exceed 100mm, the total length of the undercut shall not exceed 10% of the length of the weld. The height of the outer weld of the cylinder shall not exceed 3mm, the internal firing zone of the cylinder shall not be greater than 0.5mm, and the other sections shall not be greater than 1.5. Mm , the lowest point of the weld shall not be lower than the surface of the cylinder and shall be full; when using ultrasonic flaw detection, each weld shall be inspected, and the length of the flaw is 25% of the weld, which is required to reach Class II of JB1152, and the suspected point of ultrasonic flaw detection Must be determined by radiographic inspection. When using radiographic inspection, it should reach Grade III in GB3323, and the weld intersection must be inspected.
5, welding safety technical measures
Welding work in the kiln tube body, should be kept ventilated, lighting application of low-voltage power supply (below 36V). The power tool is strictly connected to the grounding protection according to the regulations, and is equipped with a reliable leakage protection device.
When welding, the welding ground wire should be directly connected to the workpiece. It is not allowed to lap the ground wire on the equipment, so that the equipment constitutes a welding circuit; the ground wire is not allowed to be attached to the temporary attachment of the pressure-bearing equipment (including steel bars and scaffolding). Temporary support).
Thirteen, the testrotary kiln
run of theis the general inspection of the quality of the commissioning and the quality of the installation. Therefore, the commissioning of the equipment after installation or before the handover is an important part of equipment management and should be paid enough attention.
1. Preparations before the operation of the rotary kiln
should be carried out once again for the elevation of each gear belt. If the variation exceeds the standard, it must be re-adjusted before re-commissioning. Single machine test operation is carried out in stages.
The previous test run of the brick shall be carried out according to the following regulations: the test run shall beshall be carried out
driven by the auxiliary motor for 2 hours;
the test run of the main motorwith the rotary kiln for 8 hours;bearing
2. The inspection work during the test run shall
check the reducer, the transmission gear and the axleWhether the oil supply condition is normal, the oil pressure of the deceleration cycle should be 0.2-0.3Mpa; whether the oil quantity of the support shaft is evenly distributed.
The temperature of each bearing pad was measured in excess of the following: 55 ° C for the roller bearing and the shaft reducing frog.
Pay attention to the turbulence of the kiln. If the kiln body is continuously swaying in one direction, it should be adjusted according to the kiln's turbulence method. Pay attention to the record.
Check the vibration of the machine and there should be no tremor in the kiln.
The windshield of the kiln head and the kiln end shall not be worn, and there shall be no running or missing materials.
The contact length of each roller to the wheel should not be less than 70% of the wheel.
After the test run is stopped, the grinding surface of the roller bearing and the journal should be inspected. The gear working surface has no defects such as pitting, spotting and scratches.
3, Load test run
load test run, that is, load linkage test run, generally should be run continuously for 72h or more before passing the test, if there is no problem during the test run, it will be transferred to trial production.
XIV. Safety and Civilization Construction Technical Measures
1. The construction period is tight, difficult, and there are many high-altitude operations. It is necessary to establish a safety first, prevention-oriented thinking, and strictly implement safety operation procedures to ensure the smooth progress of the project.
2. The construction personnel entering the site must strictly abide by the safety rules and regulations. Wear safety equipment, wear safety helmets, fasten seat belts at high altitudes, and electricians and welders must wear insulated shoes.
3. Set up a safety net for high-altitude construction. The scaffolding tower should be firm and reliable. The scaffolding should be tied according to the specifications. The springboard should be sealed. Strictly check the poles, springboards, rust, cracks, and unqualified use. Falling, high-altitude work is not allowed to wear hard-soled shoes.
4. The aerial work tools should be placed in a safe place, and the tool kit should be used up and down. Do not drop or drop anything from the height.
5. For the use of electric welding machine, the wire must be intact and leak-free. The oxygen and acetylene bottles must be managed by a special person, and no air leakage occurs. If the air leaks, it should be disposed of immediately to prevent fire and explosion accidents.
6. For the power tools used, the power supply must be equipped with an electric shock protector. The lighting must be safe and reliable, the electrician maintains strict management, and no one is allowed to move, preventing electric shock and injury. An electric shock protector should be installed in the light entering the container.
7. The hanging objects on the scene must be directed by a special person. The flag whistle is complete, the whistle is clear, and the idlers are exempt. When lifting, first turn the rod to the position where the hanging object is placed, then try to hang it, and then lift it to the corresponding height rod in place.
8. The slings and ropes used must be strictly inspected and meet the safety requirements.
9. Use electric welding, gas welding must prevent fires, and safety measures must be taken for construction where there is grease, such as fire extinguishers. Oxygen and acetylene bottles are placed at a fixed point and kept at a safe distance.
10. Strictly observe the safety production regulations during construction, and do not operate the equipment.
11. Safety slogans should be set up on the site. Measures such as guardrails and ambitions should be set up for the “four ports”
. The participants must obey the fingertips and obey the rules. For those who violate the regulations, they should be strictly punished according to the safety reward and punishment system.
13. Safety construction and civilized construction must be carried out during the construction process. Arrange the tools in strict accordance with the layout plan in the construction plan, clean up the waste and on-site hygiene at any time, and do the on-site security work.
XV. Quality Assurance Measures
1. Establish and improve the quality management assurance system.2. Conscientiously implement the quality policy and quality objectives formulated by our company, implement qualified quality inspection management personnel and quality inspection personnel to ensure the implementation of quality management throughout the process.
11 、制定严密科学地施工进度计划，严格遵守计划中每个节点的完成时限，对影响工程进度的关键环节，关键工艺、关键位置，提前组织工程技术人员研究讨论， 制定有效可行施工方案和解决的办法，以确保整个施工按计划进行，从而保证工程进度的实现。
12 、认真按ISO9000 标准，加强工程的生产技术质量，工期管理工作一丝不苟，全面完成施工任务。