唐山安装工程公司—46 回转窑安装作业指导书-en.docx

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1、Work Instructions for Cement Machinery andEquipment InstallationWork Instructions for Rotary Kiln InstallationCBMLQEMS.03.465. Supporting roller installationNo.ContentInspection itemTechnical requirementsMain points in operationTest device5.1Positioning of supporting rollersTransversal central devia

2、tion0.1min/mThe supporting rollers on the driving side will be positioned first, then other supporting rollers can be aligned with this as reference. The transversal positioning of supporting rollers on the driving side can be performed with reference to 2.2 and 4.6, and for longitudinal positioning

3、, see 5.2.Max. transversal central deviation0.5mm5.2Supporting roller installation and alignmentIA1-A3IIA2-A4I0.5mm1- Transversal CL Base / Base centerlineDial gauge caliperJ 1 1 J J _l1/rJ.人3-A2=?一 A4 一1A1 - Atheorl |A2-A(heorl0.5mmm. lIA1-A2IIB1-B2I 1.0mmr*11111, B1 -11 A- 1- 本Ai*1 aGrade I steel

4、tape, and 200N spring scale1A1 - Atheorl |B1-B(heorl1.0mmIC1-C2IID1-D2I 1.5mm十 11-No.J B2 11NO.2N0.3|H-Htheorl0.5mmH3 _ uPrecision levelj -H21 :-IlNo.ContentInspection itemTechnical requirementsMain points in operationTest device0.05mm/mMeasuring position:center of main line1 - square leveon upper e

5、dge of roller2 - slope gaug3 - rollerr 1IJ-4? 口| / 2Slope gauge and square levelij1A0.1 mmRoller6. Shell installationNo.ContentInspection itemTechnical requirementsMain points in operationTest device6.1Check shell length and circumferential lengthCircumferential length deviation of adjacent joints3

6、mmLJ-nent in tu ion, more s7y perpend all be measC0tdr plate 年-k ShellSteel tapeLi-L2lmmLaLa-Lb 1.5mm，o mutual 1.ections shicular sections. In case of ured.6.2Determine shell axial centerDiameter of center hole2mmMake measurei excessive devialMarking gauge6.3Fitting the live ringDetermine the fittin

7、g sequence for shell according to the lifting equipment capacity.6.4Prepare shell alignment tools-15()0152,1 J20Fixing support95J 15():WedgeJ25Shell6.5Shell assembling and installationXlmm，/sSteel rulert2mmt6.6Arrangement of connecting platesSpacing in circumferential length direction500mm at least

8、16 at equal spacing1.5001rmR8ILNo.ContentInspection itemTechnical requirementsMain points in operationTest device6.7Align the shell coaxialityLive ring and ring gear(p2mmLaser transitLaser transit/ r1 / 1 只E Head and tail(p3mmOther locations(p4mm,No. 3 gear rimNo. 2No. 16.8Shell weldingAfter qualifi

9、cation of the above items, the Owner and Supervisor will make a joint inspection, and shell welding will be performed when no defect is found. A joint inspection will be performed again after welding of outer joints. Signature and record must be made for each joint inspection. During welding, the sh

10、ell shall be rotated by means of the auxiliary driving system. “Welding of rotary kiln shelT, shall be implemented.Welding test and weld seam check7. Installation of gear rim and pinionsNo.ContentInspection itemTechnical requirementsMain points in operationTest device7.1Ring gear pre-assembling and

11、fittingClearance 80.04mm/ /1/1Feeler gaugeClearance depth 150mmry/ /-11Clearance rangecircumferential二一 !length/5Hi.37.2Gear rim alignmentRadial playAxial play1 mmGear rimDial gaugeDial gaugeDini QaiiQe 1llllllllllll*gauge 1No.ContentInspection itemTechnical requirementsMain points in operationTest

12、device7.3Ring gear welding or rivetingWhen connection is made by welding, 1/3 of the total work quantity can be done before completion of shell welding, and the remaining 2/3 can be done after shell welding.Pinion installationLateral gapTop clearance deviation on both sidesAs per design requirement0

13、.1 mmDischa飞施Gearrim CL+ ( - Gear rim7.4Side clearance deviation on both sides70%i i Pinion CLaThe centerline distance of sear rim and ninions can be determined withIn tooth height direction50%reference to the diagram in 8.1.7.5Installation ofRadial play deviation0.1 mmAs perInstallation and alignme

14、nt for couplings”Dial gaugemotor reducerEnd play deviation0.1 mm7.6Grouting anchoring holesAs per “Grouting anchoring holes”7.7Precision alignment forRadial play deviation0.1 mmAs perDial gaugemotor reducer installationEnd play deviation0.1 mm8. Installation of other parts of equipmentNo.ContentInsp

15、ection itemTechnical requirementsIllustration or descriptionTest device8.1Installation of kiln tail sealsTo be installed as per drawings8.2Installation of kiln head hoodTo be installed as per drawings8.3Installation of kiln head sealsTo be installed as per drawings9. Trial runNo.ContentInspection it

16、emTechnical requirementsMain points in operationTest device9.1Inspection and lubricationCheck the seals at the kiln head and tail, live ring and supporting rollers, driving devices and other rotating and moving parts for free of foreign matter or interference, and tight connection of bolts. Fill in

17、specified amount of lubricant and hydraulic oil according to lubrication sheet.9.2Trial runBearing temperature riseOil and water supplyTrial run:1. Confirm that the motor is rotating in correct direction and then drive the rotary kiln to run for 2h.2. The main motor will run under no load for 8h for

18、 commissioning.3. The main motor will run with the reducer for 4h, and then with the rotary kiln for 8h.After masonry work is completed or the shell is left stand still for long time, the shell shall be turned by 90 degrees every 15 days.Point thermometer andvibrationmeterEauiDment InstaHation InsDe

19、ction RecordCBMIJXHZY001Sub-project Middle of kiln Job No.EquipmentRotary kilnWork itemParallelarrangementInspectionSelf inspection typeTest dateParallel No.Parallel sizeParallel quantityDimensionsA=mmA=mmB=mmSand abutmentheightWork team.ParallelWork controllerQuality inspectorDateDateDateSub-projec

20、tMiddle of kilnJob No.EquipmentRotary kilnWork itemBase installationInspection typeJoint / self inspectionTest dateInspection and test itemHeight and slope deviationLongitudinal center deviationmmLength mmElevation mmTransversal center distanceDiagonal lineHiH2ALaLbLiL2IIIIIIIIIIIIIIIIIIComparison i

21、temHtheor|H1-Htheorl|H2-HtheorlLtheor|La-LtheoiIILbLheorlIL1-L2IIIIIIIIIIIIIIIIIIITechnical requirementsv一_LL2A0.5mm|H-Htheorl0.5mm1DL|L-Ltheorl1.0mmBcaiinj? housin(? CLr1r一|L1-L2|1.0mm=LbA；XBase CLFtansionlevdan bC-二7BaseIIElevjlH Jh=c-arei. point | 卜日BaseConclusionWork teamDateWork controller(Date

22、Quality inspectorDateInspection and test itemSub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemBase installationInspection typeJoint / self inspectionTest dateBase horizontality (mm/m)1 - square level /Technical requirements: zl0.05mm/m1234TransversalLongitudinalTransversalLongitudinalTra

23、nsversalLongitudinalTransversalLongitudinalIIIIIIConclusionWork teamDateWork controllerDateQuality inspectorDateCB MIJXHZ Y004Sub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemCopper bushing scraping, grinding and installationInspection typeJoint / self inspectionTest dateInspection and t

24、est item1234ICornerNo. of contact pointsabcdabcdabcdabcd811234IICornerNo. of contact pointsabcdabcdabcdabcd811234IIICornerNo. of contact pointsabcdabcdabcdabcd8130 r7 一2 FiJ卜。lUi1ConclusionWork teamDateWork controllerCDateQuality inspectorDateIlliShell alignment and weldingPinion mountingPinion moun

25、ting)1Ring gear mounting0Fine alignment of gear rim and pinionMotor reducer oil station installationOther installation12Trial runSub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemSupporting roller installationInspection typeJoint / self inspectionTest dateInspection and test itemTechnical

26、 requirementTransversal center deviationRoller shaft parallelismRoller inclinationAbsolute heightDifferenceAi2AtheorAiA2A3A422HtheorHAIIIIIIA0.5mm|A-Atheor|S0.5mm0.05mm/m|H-Htheor|0.5mmConclusionWork teamWork teamDateWork controllerDateQuality inspectorDateSub-projectMiddle of kilnJob No.EquipmentRo

27、tary kilnWork itemSupporting roller installationInspection typeJoint / self inspectionTest dateInspection and test itemAiA?Atheor|Ai-Atheor|A2-Atheor|Cic2CtheorICrCtheorl|C2-Ctheor|I-IIII -IIITechnical requirement 1.0mm 1.0mm 1.0mmL0mmi 1Aii11- 1 1iiLXi i i iIiTT11A?11一 1IConclusionWork teamDateWork

28、 controller(DateQuality inspectorDateSub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemShell inspectionInspection typeJoint / self inspectionTest dateInspection and test itemSectionLiL2L3ULi-L2L3-L4LaLbLcLdLa-LbLc-Ld12345678Joint1-22-33-44-55-66-77-8Permissible deviationC. length aC. leng

29、th bTmax2mmXmaxlmmIk51 、7八/tL2aConclusionWork teamDateWork controllerDateQuality inspectorDateSub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemShell alignmentInspection typeJoint / self inspectionTest dateInspection and test itemRing gearLive ringHeadTailOther locations from head to tail

30、123mmmmmm(P2.0mm3.Omm4.0mmTechnical requirementsLaser transit0.11IL/1 1I1 */3 geair rimNo.2N0.1ConclusionWork teamDateWork controllerDateQuality inspectorDate . Sub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemGear rim and pinion alignmentInspection typeJoint / self inspectionTest dateIn

31、spection and test items for gear rim12345678Permissible deviationEnd play0bmax-bmin 1.0mmRadial play0amax-amin 1.0mm8max0.04mmLmax50mmInspection and test items on engagement1234Permissible deviationInletDischargeInletDischaigeInletDischargeInletDischaieInlet - dischargeTop gap0.1 mmLateral gap70%Con

32、tact length50%ConclusionWork teamWork teamWork controllerQuality inspectorSub-projectMiddle of kilnJob No.EquipmentRotary kilnWork itemInspection and lubricationInspection typeJoint / self inspectionTest dateInspection and testing itemNo.Description of lubricating pointDescription and type of lubric

33、antQuantity (1)RemarksWork teamDateWork controllerDateQuality inspectorDateIL Quality control planItems of process controlContents of inspectionNo.DescriptionInspection typeInspection categoryControl typeDocument typeDocument description1.1Self review/joint review of drawingsRecord of self review/ j

34、oint review of drawing1.2Technical instructions for worksRecord of work instruction1.3Acceptance of equipment2PNRecord of open-case inspection CBMI-GT-0061.4Acceptance of foundationDIM2RInspection report for civil works reserved2.5Arrangement of parallelsDIM1PNCBMI-JX-HZY0012.6Making sand abutmentMT

35、1BRStrength test report3.3Supporting base installation initial levelingDIM1BNCBMI-JX-HZY002/33.4Grouting anchoring holesSC2ERConcrete mixing ratio report + Inspection record for concealment works CBMI-GT-0083.5Supporting base installation precision levelingDIM2ENCBMI-JX-HZY002/34.1Supporting bushing hydrotestSC2BNCBMLPW-0064.2Copper bushing grounding and installationVC +DIM2BNCBMI-JX-HZY()()45.2Supporting roller installation and alignmentDIM2ENCBMI-JX-HZY005/66.1Shell inspectionDIM1PNCBMI-JX-HZY0076.5Shell assembling and install