15-2525 Thatta Cement - Maintenance Guidelines

8/18/2019 15-2525 Thatta Cement - Maintenance Guidelines

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Customer: XXXXFacility: XXXXUC Commission no.: XX/XXXX

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OPERATING & MAINTENANCE MANUAL

ROTARY KILN BURNER

SECTION 12

Inspection- and maintenance guidelines

12.7 Changing the burner nozzles and the baffle plate

12.8 Changing the burner jacket tube


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Customer: Thatta Cement CompanyFacility:UC Commission Nr.: 15/2525

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12.7 Changing the burner nozzles and the baffle plate

a. Generalb. Changing the nozzlesc. Changing the baffle plate

a. General

This maintenance instruction describes how to change nozzles and the baffle plate ofthe rotary kiln burner.

In order to ensure easy assembly of the nozzles and prevent wear of the threads, allthreads should be coated with lubricating spray or paste. The compound used must beresistant to high temperatures (for example: OKS white allround paste 250/2501).

Due to the conical nozzle design the nozzles have to be installed from the inside to theoutside.

Special tools A special tool, one or more nozzle wrenches, are required to change the nozzle. Thenozzle wrenches are designed separately for each burner and are included in theshipment.

NOTE! All nozzles have a right-hand thread


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Setting device for nozzle adjustment

Coal channels and gas channels can be equipped with individual devices for axialadjustment of the relevant nozzle. If so, put the nozzle into the maintenance positionusing the setting device before changing the nozzle.

Fig. 12.1: Scale setting example

For the coal nozzle, position “0” isthe scale setting for maintenance(All non-adjustable nozzles are

mounted flush with the baffle plate)

For the gas nozzle, position “S” isthe scale setting for maintenance(The gas nozzle is pushed forward

for easier installation)


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b. Changing the nozzles

Procedure

Disassembly

1. Secure the nozzle with a suitable lifting device against falling.2. To change the nozzle, use the correct nozzle wrench.

Place the bolts on the nozzle wrench into the corresponding holes on the nozzle.Loosen the nozzle by turning the wrench.

3. When the nozzle is loosened, unscrew it manually.

Assembly

1. Secure the nozzle with a suitable lifting device against falling.2. Manually screw the nozzle in.3. Place the bolts on the nozzle wrench into the corresponding holes on the nozzle.

Tighten the nozzle with the nozzle wrench.

CAUTION!Risk of injury due to falling equipment!Due to its weight, a falling nozzle can cause serious injury.

Therefore:- Prior to work on the nozzle, secure it against falling.

Fig. 12.2: Use the nozzle wrench to loosen thenozzle

Fig. 12.3: Unscrew nozzle manually


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c. Changing the baffle plate

To remove the baffle plate, the inner-most nozzle must be removed. The baffle plate isheld in place between the nozzle and bolt.The images below show the nozzle head with the inner-most nozzle alreadydisassembled.

Procedure

1. Remove the inner-most nozzle, based on the description above.2. Remove the baffle plate.

The assembly of the baffle plate is done in reverse order.

Fig. 12.4: Inner-most nozzle, disassembled Fig. 12.5: Removing the baffle plate


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12.8 Assembly and disassembly of burner jacket tube

a. Generalb. Removing front part - divisible burner jacket tubec. Placing front part - divisible burner jacket tubed. Removing rear part - divisible burner jacket tubee. Placing rear part - divisible burner jacket tubef. Removing jacket tube - non divisible burner jacket tubeg. Placing jacket tube - non divisible burner jacket tubeh. Replacing packing cordsi. Replacing nozzle ring and front part of burner jacket tube


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a. General

Two executions of the burner jacket tube are possible: Divisible execution (consisting of the front and back jacket tube)

Non-divisible execution (jacket tube in one piece).

Points 12.7b to 12.7e are valid for the “divisible jacket tube” execution

Points 12.7f and 12.7g are valid for the "non-divisible jacket tube“ execution

b. Removing front part – divisible burner jacket tube

The front part of divisible jacket tube can be independently removed from the rear partof the jacket tube. The front part of the jacket tube has a length of approximately1200 mm.

The essential advantage of this execution is that only the front part has to be removed.This offers advantages if:

Little space is available for assembly / disassembly

The front part of the refractory is subject to highest wear

The burner jacket tube is particularly long

To keep the time to replace the front jacket tube to a minimum, a prelined front jackettube should be available.

CAUTION!Risk of injury due to hot jacket tube.

Contact with the hot jacket tube can lead to serious injuries.Therefore:

- Before disassembling the jacket tube, cool the burner toambient temperature.

- Secure burner on the burner trolley or take other measuresto have the burner in a secure position for assembly /disassembly of the burner jacket tube.

Fig. 12.6: Exchange procedure demonstration


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Fig. 12.7: Fastening device


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1) The MAS-swirl setting has be in position 1 or 2.

2) Loosen the hex nut (1) including the lock nut. Unscrew both nuts back to thefastening lever (2).

3) Push the connecting rod (5) with the fastening lever (2) forward.

NOTE!Depending on the burner size the divisible execution can be equippedwith 2 or 3 fastening devices. The description is valid for bothexecutions.

Use a M30

wrench.

The maximumallowed torque is

120 NM

Fig. 12.8: Loosen the hex nut

Fig. 12.9: Loosened nuts


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4) Turn the fastening lever into the “UNLOCKED” service position (see also view „Z“ infig. 12.7 above)

5) The fastening device is unlocked.

Fig. 12.10: “Unlocked“ position of the fastening lever

Service position

Fig. 12.11: fastening part of clamping lever, in service position


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6) The front part of the jacket tube (3) can now be removed using a lifting device (seedetails "A“ and "B“ in fig. 12.7 above).The front part of the jacket tube has to be removed with utmost care to prevent jamming of the jacket tube. All clamping levers (2) must remain in "service position"!

7) Before placing the front part of the jacket tube back on the burner, check the flamesetting device, the condition of the MAS hoses as well as the condition of thepacking cords. Repair or replace any defective parts.

Fig. 12.12: Partly removed front part of jacket tube


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c. Placing front part – divisible burner jacket tube

1) To ensure complete sealing between front and rear part of the jacket tube, makesure that the sealing surface of both parts as well as the packing cords areabsolutely clean. If the packing cord is damaged, it has to be replaced.

2) The front part of the jacket tube has to be placed centric with great care. The frontpart of the jacket tube is pushed back until the gap between front and back part is10-20 mm (see the Detail "B" in fig. 12.7 above). Damage to the MAS hoses, theflame setting device, and the packing cord must be avoided.

3) The hexagonal nut (1) including lock nut must be screwed back to the fasteninglever (2). Push the connecting rod (5) with the clamping lever in the direction of thenozzle head, until the hex nut (1) is in line with the guidance pipe (4).

4) Turn the fastening lever (2) into the “locked” position (see View “Z” in fig. 12.7above).

5) Screw the hex nut (1) in the direction of the nozzle head tighten it. The front jackettube is brought into its final position by the connecting rod(s).

6) After the assembly is complete, fix the hex nuts (1) with the locking nuts. Ensure thatall the clamping levers (2) are in operating position.

NOTE!The maximum allowed torque of the hex nuts (1) is 50 NM.


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Fig. 12.13: Removing the rear part of the jacket tube

d. Removing rear part – divisible burner jacket tube

Prior to removing the rear part of the jacket tube, the front part of the burner jacket tubehas to be removed.

1) All clamping levers (2) remain in the “unlocked“ position.

2) To remove the rear part of the jacket tube, make sure that the burner cannot tipover. Ensure a secure stand of the burner.

3) Loosen the screws on the flange connection of the rear part of the jacket tube.

4) The rear part of the jacket tube has to be removed with utmost care to prevent jamming of the jacket tube. All clamping levers (2) must remain in the "unlocked"

position!

e. Placing rear part – divisible burner jacket tube

1) All clamping levers (2) remain in the "unlocked“ position.

2) The rear part of the jacket tube has to be placed centric with great care. Damage tothe MAS hoses, the flame setting device and the packing cord as well as jamming ofthe rear part of the burner jacket tube must be avoided.

3) Tighten the screws on the flange connection of the jacket tube.

4) The front part of the burner jacket tube may be installed.


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f. Removing jacket tube – non divisible burner jacket

tube

1) The MAS flame setting must be in position 1 or 2.

2) Loosen the screws on the flange connection of the jacket tube.

3) The burner jacket tube has to be removed with utmost care to prevent jamming ofthe jacket tube. Damage to the MAS hoses, the flame setting device and thepacking cord must be avoided.

4) Before placing the burner jacket tube back on the burner, check the flame setting

device, the condition of the MAS hoses as well as the condition of the packingcords. Repair or replace any defective parts.

g. Placing jacket tube – non divisible burner jacket tube

1) The burner jacket tube has to be placed centric with great care. Damage to the MAShoses, the flame setting device and the packing cord as well as jamming of the rearpart of the burner jacket tube must be avoided.

2) Tighten the screws on the flange connection of the jacket tube.


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h. Replacing packing cords

During the change of the jacket tube (both divisible and non-divisible execution),replace the packing cord (29).

To remove the packing cord, first remove the clamping sleeves ø2,5 x 20mm (29A).Cut the new packing cord (made of fiberglass/graphite 10 x 10 mm) at an angle andplace it. Fix the new packing cord with the clamping sleeves.

Also replace the packing cord (30) at the divisible execution every time it isdisassembled. It is replaced by a packing cord (12 x 12 mm made out offiberglass/graphite), which is also cut diagonally at the ends.

The packing cord helps avoid leakages. Replace it with great care!


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i. Replacing nozzle ring and front part of burner jackettube

The jacket tube consists of three welded parts. Nozzle ring (1), front jacket tube (2),and rear jacket tube (3).

To replace the nozzle ring and/or the front jacket tube, the joint weld must beseparated. Make sure that the recess forcentering is not destroyed. After separation,remove the rest of the old joint weld and

prepare the parts for new welding.Then, weld the replacement partscorresponding to the following instructions.

Item

Nr.

Description

1 Nozzle ring

2 Front jacket tube

3 Rear jacket tube

Fig. 12.15: Jacket tube example

1 2 3

Fig. 12.14: Burner jacket tube


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Welding instructions front welding joint (Detail X)

Welding guidelines

Accuracy level for dimensions without tolerance info,in accordance with EN ISO 13920

B/F

Stress relieved No

Pressure tested - bar

Leak tested No

Quality levels of the welding connection acc. ENISO 5817

C

Welding process -

Welding filler materials Böhler FOX FA

Test procedure VisualPreheating - °C

As the mechanical stress between the nozzlering (1) and the front jacket tube is low, they areconnected by an intermittend weld. This allowsthe nozzle ring to be replaced easily andwithout damaging the recess for centering.

Type øD N1 L1 A1 N2 L2 A2

M.A.S./3/… 457 7 110 95 3 50 380

M.A.S./4/… 508 8 110 90 3 50 430

M.A.S./5/… 550 9 100 90 3 50 475

M.A.S./6/… 610 10 100 90 4 50 390

M.A.S./7/… 660 10 110 100 4 50 430M.A.S./8/… 711 11 110 90 4 50 470

M.A.S./9/… 762 12 110 90 5 50 400

Fig. 12.16: Welding joint “Detail X“

CAUTION!Damaging the centering recess.When opening the welded joints, ensure that the centering recesses arenot damaged.


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Welding instructions rear welding joint (Detail Y)

Welding instructions

Accuracy level for dimensions without tolerance info,in accordance with EN ISO 13920

B/F

Stress relieved No

Pressure tested - bar

Leak tested No

Quality levels of the welding connection acc. ENISO 5817

C

Welding process -

Welding filler materials Böhler NIBAS 70/20Böhler CN23

Test procedure VisualPreheating - °C

Due to the high mechanical stress between thefront jacket tube (2) and the rear jacket tube (3),these parts are continuously welded.

Fig. 12.17: Weldingjoint Detail “Y”

15-2525 Thatta Cement - Maintenance Guidelines

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