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MECHANICAL EQUIPMENT
1.
GENERAL
The following Design Criteria shall apply to all mechanical Equipment. The
given Design Criteria identify the minimum Equipment requirements. The
project specific requirements are outlined in Contract Annex 6 (Plant
concept and process description) and Contract Annex 7 (Scope of Works)
All Equipment to be supplied shall be of robust design and manufacture
and shall correspond to state of the art of cement manufacturing
technology. Selected Equipment shall have a high degree of availability,
require minimum maintenance and operate with high efficiency. Electrical
and thermal energy consumption shall be low. Equipment shall be
designed for heavy-duty industrial application, capable of handling very
abrasive materials in dusty environments. The Equipment shall be suitable
for continuous operation at uniform maximum load without adverse effect
on the life or maintenance of the Equipment under prevailing conditions.
Furthermore it shall be suited to all local climatic and operating conditions
at the site. Buildings, housings and frames shall be protected against
corrosion, especially for plant located in the neighborhood of an ocean or a
sea and for Equipment handling raw material as slag and petcoke in
ambient temperature. Mixing of material with moisture content over 1 %
with cement or clinker in Equipment when the internal temperature is below
the dew point shall be forbidden. Equipment such as bucket elevator, bag
filter and components such as ducts shall be insulated when the
temperature of the casing can go below the dew point of one of the gas
components. Anti-corrosion- and anti-coating mechanisms shall be part of
the Equipment.
The Equipment shall be designed with sufficient safety margins from a
technical and process performance point of view. It shall be capable of
restarting after stopping due to power failure or other process related
interruptions (i.e. interlock).
1.1.1
Rotary Kiln
1.1.1.1
The maximum gas velocity at the cylindrical kiln inlet section shall be
10.2 m/s. Gas velocity to be based on project gas flow and inside
lining without kiln charge.
1.1.1.2
1.1.1.3
The Contractor shall prove the kiln design by static load calculations,
as well as by submitting shear, bending and reference stress
diagrams.
For 3 support kilns, kiln shell material shall be 16Mo3 (or equivalent)
starting from kiln discharge to tire #2 (including first section uphill).
The remaining shell can be made of S235JRG2 or equivalent.
For 2 support kilns, 50% of the kiln length from kiln discharge, shell
material shall be 16Mo3 (or equivalent). The remaining shell can be
made of S235JRG2 or equivalent.
The thickness changes from one kiln shell section to the other shall
not exceed 25% (e.g. 80-60 / 60-45 / 45-35 / 35-25mm).
The tire shell section has to be equipped with a chamfer (< 15) to
smoothen the thickness change to the neighboring shell section.
The first and the last tire must have the same diameters and width
that a spare tire would fit on both places.
The support rollers of the first and the last station and their bearings
must be interchangeable.
The roller bearing housing must be equipped with an oil sight glass
for checking oil level
The bearings must have lubrication with forced oil circulation for slow
(inching) rotation speed. Oil filter must be installed in the stream
coming from the pump.
The specific bearing pressure must be below 4.5 N/mm 2 (radial load
on bearing divided by projected bearing area)
1.1.1.4
The Hertzian pressure on kiln tires shall not exceed 450 N/mm 2 for
rigid supports or 550 N/mm2 for supports with self-alignment
capabilities.
The Contractor shall prove the kiln tire designs by static load
calculations, which show bending stress and Hertzian pressure.
Kiln Drive
1.1.1.5
The auxiliary drive must be designed for a fixed speed 0.1 rpm and
include an over running clutch and anti-rollback devices.
Conical kiln shell outlet for brick retention is preferred for kilns with
diameters >=4.6 m. Cone angle must be <12 to allow use of
standard bricks.
Minimum specific installed cooling air flow is 5 m 3/s per m shell length
to be cooled. Minimum requirement is to simultaneously cool 20% of
the kiln length with this specific cooling air flow. The system must
allow to move these 20% within 60 % of the total shell length on the
discharge side.
Additional cooling air fans for cooling of the tire shell sections (uphill
and downhill) with minimum 20 m3/s per tire must be provided.
This requirement does not apply to the feed side tire.
Nose ring cooling air nozzles shall be arranged evenly around 360
degrees of the kiln circumference.
Minimum nose ring cooling air shall be 0.33 m3/s per meter of kiln
shell circumference. The air pressure at the nozzle inlets shall be
minimum 20 mbar. For kilns with diameter 4.6 m, two cooling air
fans shall be provided.
Kiln drive and roller bearings shall have a heat shield to protect them
from heat emitted by the kiln.
1.1.1.6
1.2
The tertiary air duct take-off shall be from the kiln hood.
The seal between the kiln discharge hood and the grate cooler shall
be of the labyrinth type.
Openings shall be provided at kiln hood back wall and at kiln hood
side walls for observation of burner and flame and clinker discharge.
Bearings
The Contractor shall ensure that the bearings used in his supply shall be of
the standard types and sizes produced by the International bearing
manufacturers. Moreover, he shall provide a list of all bearings mounted in
the equipment as well as in all electric motors.
All roller bearings contained in main process equipment such as kiln
drive, ID fan, cooler exhaust fan which normally will operate
continuously 24 hours are to be sized for a theoretical lifetime of at
least 100,000 hat full load.
1.3
1.4
1.4.1
Durability
SG
1,3
Strength
SB
1.8
1.4.2
1.4.3
Couplings
The coupling shall have elastic and damping properties in order to
compensate for the tolerated deviation from ideal alignment and to reduce
load peaks in the drive train.
1.4.4
> 1.1
Breakage safety
> 1.4
Scuffing safety
> 1.5
The gear reducers shall be designed for a lifetime of not less than 100'000
hours of operation.
Contractor shall provide a print out of the calculation showing all decisive
input values (geometry, kinematical data, quality of gearing,
correction factors and the operational coefficients such as application
factor, transverse coefficient, face coefficient, dynamic factor, power
distribution factor, etc.) and the resulting stresses, allowable levels
and the safety factors.
Additionally the teeth profile modifications shall be listed and provided with
comments.
Contractor shall provide detailed interlocking diagram showing warning and
trip limits with descriptions of actions to be taken at warning limit to
avoid tripping.
1.4.5
Closed Reducers
The gears and speed reducers shall be designed for an input speed of
maximum 1500 rpm for 50 Hz motors or 1800 rpm for 60 Hz motors.
Large gears and speed reducers for Equipment, such as crushers,
raw mill, cement mill and where otherwise applicable, shall be
designed for input speeds of 1000 rpm for 50 Hz motors or 900 rpm
for 60 Hz motors. Exceptions are only allowed for ball mills equipped
with central drives. In this case Supplier shall prove that the specified
speed limits cannot match his standard design for reducers.
The housing of reducers shall be equipped with a fine dust filter (maximum
10 m) in the desiccant breather.
Design and heat dissipation calculations of the external oil cooling
Equipment are subject to approval in writing by the Owner.
Inspection doors and openings have to be positioned for easy visual
inspection of gear wheels and for maintenance purposes.
Reducer and motor for all mills (raw- and cementitious materials) shall be
equipped with condition monitoring Equipment including at least
vibration
sensors,
temperature
measurements,
pressure
measurements and oil sample points.
1.4.6
1.4.7
Hydraulic Drives
Hydraulic drives shall be of the hydrostatic type.
Hydraulic drives shall be of the compact type; factory assembled as far as
possible on a rigid frame and shall be arranged for easy handling and
installation. A stand-by pump shall be included.
Hydraulic drives shall include kidney filters for the main hydraulic system.
1.5