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en-21020.153-F
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en-21020.153-F
Machine manual Technical data
DOPOL® 90 cyclone stage type B-CC 1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.
Basic data
Year of manufacture............................................................................
Design size..........................................................................................
Nominal diameter of the cyclone.................................................mm
Nominal diameter of the gas duct................................................mm
Type of dip pipe....................................Multi-element dip pipe (18.4)
Diameter of the dip pipe...............................................................mm
Nominal length of the dip pipe.....................................................mm
Nominal width of the meal chute.................................................mm
Nominal width of the dispersing box............................................mm
Nominal width of the expansion joint..........................................mm
Lining thickness of the cyclone............................................190 mm
Lining thickness of the gas duct...........................................190 mm
Lining thickness of the meal chute.........................................85 mm
2 Safety
NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.
Use
The cyclone stage forms part of the DOPOL® preheater for the
kiln plant.
Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
Any use of the machinery other than for the specified purpose
is forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
The observance of these and the maintenance instructions is
part of the specified use.
Maintenance
Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance hatches are opened.
The plant manager must take adequate safety precautions
before, during and after all maintenance work for the
protection of the maintenance and operating personal. After
the maintenance work, it is of vital importance to make sure
that nobody is locked in the preheater!
Danger! You can suffer severe burns at the preheater. Do not
touch the preheater while the preheater is hot.
When automatic air cannons are used, the remaining pressure
must be relieved after their electrical switch-off before the
preheater doors or poke holes may be opened. Remaining air
pressure causes the air cannons to operate!
There is a danger for people to stumble over the brackets on
the platforms of the preheater cyclones. Everybody entering
the platforms must wear protections clothes.
Only authorized and instructed personnel may open the doors
and locks on the plant manager’s instruction.
The doors and locks are so designed that they can be secured
with padlocks.
Even after a longer cooling-down period be careful when
opening doors and maintenance holes. After a cooling-down
period there is still a danger of being burnt by spurting raw
meal.
Everywhere in the preheater, overpressure may have been built
up due to a power failure. Do not open any doors or poke holes
if there is an overpressure.
Danger! When the individual cyclone stages are cleaned
through the poke holes, hot raw meal can gush out due to
clogging. Use blow lances of maximum lengths, wear
protective clothes and make sure that the escape routes are
free.
Machine manual Safety
DOPOL® 90 cyclone stage type B-CC 3
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract..
Figure 1
Components and mode of functioning Machine manual
2 DOPOL® 90 cyclone stage type B-CC
NOTE
The interior of the B-CC - type cyclone stage is provided with a
refractory lining.
Machine manual Components and mode of functioning
DOPOL® 90 cyclone stage type B-CC 3
Figure 2
Components and mode of functioning Machine manual
4 DOPOL® 90 cyclone stage type B-CC
Figure 3
Machine manual Components and mode of functioning
DOPOL® 90 cyclone stage type B-CC 5
The following diagram shows the gas stream (white arrows) and
the raw meal stream (black arrows) in the B - CC type cyclone
stage.
Components and mode of functioning Machine manual
6 DOPOL® 90 cyclone stage type B-CC
Figure 4
Machine manual Transport and assembly
DOPOL® 90 cyclone stage type B-CC 1
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
4.2 Assembly
General requirements
NOTE
Final assembly and assembly inspection by an assembly
specialist from POLYSIUS AG are preconditions for our warranty.
CAUTION
If electrical welding is carried out in any place of the machine,
welding current must never be conducted through plain bearings
and antifriction bearings, other moveable connections or
measuring equipment to prevent damage to such parts.
Return lead (of welding current) must always be directly
connected to the part being welded.
Machine manual Transport and assembly
DOPOL® 90 cyclone stage type B-CC 3
Assembly sequence
If the overall situation on the construction site allows it, the pre-
assembly of and the welding work on all structural parts will be
performed on the ground. The refractory lining will be installed
only after the structural parts have been assembled. The
mounting of the cyclone stages also requires that the gas ducts
and the cyclones are pre-assembled and welded up separately on
the ground.
The openings and holes for the poke holes and connections of the
compressed-air cleaning system as well as any other
breakthroughs (e.g. for sensors and probes) must be made before
applying the refractory lining. If these openings and holes were
made subsequently, you would have to drill through the hard
lining. On the one hand this would be most difficult and
troublesome and on the other hand you would damage the
refractory lining at the respective points.
NOTE
All electrical conduits in the preheater area must be protected
from contact with hot raw meal by suitable covers.
Machine manual Lubrication
DOPOL® 90 cyclone stage type B-CC 1
5 Lubrication
NOTE
This machine/unit requires no lubrication.
Machine manual Checks after the assembly
DOPOL® 90 cyclone stage type B-CC 1
NOTE
It is a prerequisite of our warranty that the first test run is carried
out in the presence of specialists from POLYSIUS AG and in
accordance with their instructions.
7 Maintenance
7.1 Inspection
CAUTION
Do not touch the preheater surfaces during operation or just
after plant stoppage.
All preheater surfaces are extremely hot. You are in danger of
suffering severe burns! Suitable protection clothes must be
worn.
cracks
Machine manual Maintenance
DOPOL® 90 cyclone stage type B-CC 3
DANGER
The cyclone stage can include a gamma ray emitter installed for
monitoring the filling level.
You are exposed to radioactive beams.
Prior to any work at the cyclone, the gamma ray emitter must be
switched off and safeguarded by padlocking according to
regulations.
DANGER
When you are inside the preheater, raw meal can fall down on
you.
You can suffocate or buried with raw meal.
Do not enter the preheater unless you have made sure that no
coating can fall down on you.
Entering the inside of the preheater:
Inside the preheater you can breathe in raw meal dust and/or
be exposed to extremely hot temperatures.
Before it may be entered, the preheater must be scavenged
with fresh air and it must have cooled down. Make sure that
hot gases cannot come into the preheater. A dust protection
mask must be worn inside the preheater.
Do not enter the machine interior before sufficient time has
passed for the machine to cool down and become free of gas.
For all work inside the machine, you have to make sure that raw
meal and loose parts cannot fall down on you from the upper
section. Furthermore you must take care that people in
downstream plant sections are not endangered.
deformations
3 Check the refractory lining for
spalling, cracks and mismatch and
check filling
mats in the expansion joints of the
refractory lining
7.2 Servicing
DANGER
Use of automatic air cannons after their electric switch off.
Remaining pressure causes the air cannons to operate.
Danger!
The remaining pressure must be relieved before the doors
and poke holes are opened.
Cleaning of preheater
Danger! You can suffocate or get buried by raw meal in the
rotary kiln and the cooler.
Access to the rotary kiln and the cooler must be made
impossible during the cleaning work in the preheater.
The plant manager is responsible for setting up adequate
safety barriers.
Work performed inside the preheater
Danger! You can get locked in the preheater unintentionally!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect
the maintenance and operating personnel.
Machine manual Maintenance
DOPOL® 90 cyclone stage type B-CC 5
NOTE
Clean the plant parts not only inwards but also outwards. Clean
the platforms around the plant parts. Remove any material
required for servicing and repair work and close and secure all
existing platform openings.
DANGER
Hot raw meal can eject when poke holes are opened.
Beware of mortal danger.
Use blowing lances of maximum length, wear suitable safety
clothing, and keep the escape routes free.
The cakings coming off when blowing out the upper parts of the
cyclone can thus slide down into the „cavities” blown out further
down.
7.4 Repair
DANGER
The cyclone stage can include a gamma ray emitter installed for
monitoring the filling level.
You are exposed to radioactive beams.
Prior to any work at the cyclone, the gamma ray emitter must be
switched off and safeguarded by padlocking according to
regulations.
DANGER
Use of automatic air cannons after their electric switch off.
Remaining pressure causes the air cannons to operate.
Danger!
The remaining pressure must be relieved before the doors
and poke holes are opened.
Cleaning of preheater
Danger! You can suffocate or get buried by raw meal in the
rotary kiln and the cooler.
Access to the rotary kiln and the cooler must be made
impossible during the cleaning work in the preheater.
The plant manager is responsible for setting up adequate
safety barriers.
Work performed inside the preheater.
Danger! You can get locked in the preheater unintentionally!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect
the maintenance and operating personnel.
When performing work inside the machine, fresh air from an
outside source must be pumped in or induced by sucking so that
inhaled air remains free of noxious matters. Aeration with pure
oxygen is forbidden. Use dust protection masks as protection
against the high rate of dust which must be expected.
For all work inside the machine, you have to make sure that raw
meal and loose parts cannot fall down on you from the upper
section. Furthermore you must take care that people in
downstream plant sections are not endangered.
CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Checks after
assembly.
8 Spare parts
Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placement as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the columns
Quantity and Unit. Please mark those parts which you require with a cross in the
column Order or Enquiry. Send the title page together with the table to the Spare
Parts Department of POLYSIUS AG.
If the table relates to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
Spare parts Machine manual
2 DOPOL® 90 cyclone stage type B-CC
Figure 5
Machine manual Spare parts
DOPOL® 90 cyclone stage type B-CC 3
Spare parts access door, cover and manhole cover (50 - 55)
Figure 6
Machine manual Spare parts
DOPOL® 90 cyclone stage type B-CC 5
51 240x360 1 piece
(steel plate)
52 Cover120x240 1 piece
(steel plate)
Figure 7
9 Appendix
Cyclone stage