Dryer Installation Instructions

Dryer Installation Instructions

1. Before installation

Before installation, you must be familiar with the drawings and relevant technical documents, understand the equipment structure and installation technical requirements, determine the installation sequence and method according to specific conditions, prepare necessary installation tools and equipment, prepare construction organization design and installation plan, and carry out careful construction to complete the installation task with high quality and speed.

During the equipment acceptance (handed over by the construction unit), the installation unit should check the integrity and quality of the equipment parts. If there are defects caused by insufficient quantity or manufacturing, transportation and storage, the relevant units should be notified in advance to try to make up and eliminate the defects. For the relevant important dimensions related to the installation quality, they should be checked according to the drawings, recorded and agreed with the design unit for correction.

Before installing the parts, cleaning work must be carried out to remove dirt and rust. Before disassembly, the drawings must be familiar and the structure must be understood to avoid damage to the parts. And the relevant numbers and signs of mutual cooperation should be checked and supplemented in advance to avoid confusion or loss of parts and affect assembly. Disassembly and cleaning work must be carried out in a clean environment. After cleaning, the parts that need to be rust-proof should be oiled immediately. The oil used should meet the lubricating oil quality specified in the drawings, and then immediately and properly sealed to prevent pollution or rust.

During the lifting and handling of parts, the lifting equipment, wire ropes, hooks and other tools used must have sufficient safety margins. The wire ropes are not allowed to come into direct contact with the working surface of the parts. The horizontal handling of parts must be balanced. The cylinder sections are not allowed to be inverted or upright. The cylinder sections, wheel belts and supporting wheels and other cylindrical parts must be firmly fixed on the wooden frame. Then, the rollers are supported from below and then towed by the winch. It is not allowed to be pulled forward directly on the ground or on the rollers.

If the cylinder needs to be rotated in order to install and align the large gear ring and the cylinder, the wire rope can be wound around the cylinder and then towed by the winch or a hitchhiker. The circumferential force required to rotate the empty cylinder can be considered as 20 tons. When selecting the diameter of the wire rope, the safety factor shall not be less than 2. It is best to temporarily install the transmission device to rotate the cylinder.

2. Check the foundation and foundation marking:

First, the drawing should be corrected: according to the actual size between the two wheel tyres, add a little thermal expansion to obtain the inclined size of the two-stage support device, calculate its horizontal spacing size, and correct the size on the drawing.

According to the "center mark plate layout drawing" proposed by the installation unit, check whether the position of all the main center lines buried and the center mark plates of the concerned center lines are correct, and check the overall dimensions, elevation, center line position, anchor bolt hole position of the equipment foundation by comparing the drawing to meet the requirements.

Foundation tolerance: The allowable error of the foundation overall dimensions is ±30mm; the allowable error of the foundation plane elevation is ±2mm; the allowable error of the distance between the center lines is ±1mm; the error of the benchmark elevation to the zero point elevation of the factory area is ±3m; the allowable error of the center position of the anchor bolt hole is ±10mm, the allowable error of the depth dimension is ±20mm; the allowable error of the elevation is ±5mm.

Foundation marking: Draw the longitudinal center line, take the center point of the rotary dryer and the tail foundation as the standard, find the center line of each center mark plate, the allowable deviation shall not exceed, draw the transverse center line, find the transverse center distance of each foundation, the allowable error of the transverse center distance of the two foundations shall not exceed; according to the accurate center line of the calibrated dryer. Make the longitudinal and transverse cross lines of the transmission part, and draw the horizontal reference line (i.e. elevation line). According to the zero point of the factory area, make a horizontal reference line at a height of 1m from the ground on the side of the foundation, which is used for the preliminary positioning of the equipment elevation. The elevation error between the reference point and the reference line shall not exceed ±3mm.

3. Installation and maintenance of the supporting device

Whether the center line of the cylinder can maintain a straight line depends on the positioning of the supporting device, so the installation of the supporting device should be highly valued.

1. Installation or maintenance of the roller group

When installing the roller, first find the center position, and align the center cross line of the base with the center cross line of the base. The longitudinal center lines of the two rollers are equal to the longitudinal center line of the base and meet the drawing size. The allowable error shall not exceed mm. The transverse center lines coincide with each other, and the allowable error is mm. At the same time, the movement of the two sides of the rollers should be equal.

Clean the parts of the roller group, and calibrate the rollers locally and on the top seat according to the position specified in the drawing.

General inspection after the roller assembly (i.e. center inspection), inspection of the longitudinal center position, hang a steel wire according to the center mark plate of the head and tail of the dryer, and check whether the center position of each group of rollers is correct. The allowable error shall not exceed, and the transverse center distance shall be reviewed. The transverse center line on the transmission foundation shall be used as the standard, and the transverse center distance dimensions of the two roller groups are measured to the head and tail of the dryer respectively. The allowable error is 3mm.

Elevation and slope inspection Elevation inspection: mainly measure the relative slope elevation of the head and tail roller assembly of the dryer, and the allowable error shall not exceed 5mm.

After the roller installation review is completed, a mark should be made on the base directly opposite the center of the roller bearing seat for future maintenance or operation adjustment.

Remove the dirt in the anchor bolt hole, and then pour concrete to about 200mm from the top surface of the foundation. After the curing period, tighten the nut and make another general review. If there is no error, the cylinder can be hoisted.

2. Installation or maintenance of the stopper

The initial installation of the stopper should be carried out before the cylinder is hoisted. After the cylinder is hoisted and aligned, the offset of the axis of the stopper to the center line of the roller must occur on the side opposite to the rotation direction of the cylinder, and shall not exceed 2mm.

The stopper and roller should be in uniform contact after installation.

3. Installation or maintenance of the cylinder

The assembly of the cylinder and the roller is generally carried out on the ground. The assembled cylinder is lifted and gently placed on the supporting wheel device. After the cylinder is assembled, a certain amount of thermal expansion gap should be reserved between the roller and the pad.

After the final assembly and adjustment of the cylinder, the radial runout and end face runout of the gear ring and the radial runout of the two ends of the cylinder should meet the requirements in the table.

unit：mm

4. Installation or maintenance of transmission device

Installation of gear ring: remove the paint and rust on the spring plate and the inner ring of the gear, clean the interface surface of the gear and apply dry oil. The half gear is generally hoisted in the cylinder, and installed after alignment. When hoisting, the numbers of the screw holes on the spring plate and the gear should be aligned. The interface should fit tightly without gaps, and the bolts should be tightened. Use the gear installation tool to adjust the lateral and radial swing deviations of the gear ring so that they do not exceed. The lateral centerline deviation between the gear ring and the cold end roller ring shall not exceed 3mm.

Installation of transmission equipment: Find the center position of the gear according to the center mark plate, and the allowable deviation is ±2m. Use the bevel gauge on the pinion transmission shaft neck to measure the bevel of the pinion. The allowable error is the same as the bevel of the supporting wheel shaft. Adjust the contact condition and tooth top clearance of the gear. When determining the tooth top clearance, in addition to considering the thermal expansion of the gear ring, the radial deviation of the gear ring must also be considered. The tooth top clearance is generally specified as 1/7 of the full height of the tooth or 1/5 of the module, and the contact length is not less than 70% of the tooth width.

5. Test run and acceptance

It is necessary to check whether the installation is in accordance with the drawings, whether the connecting bolts are tightened, and whether the lubricants are added to the lubrication points according to the specified brand.

No-load test run

Before the whole drum dryer is tested, it is necessary to carry out a single machine no-load test run. The motor is tested for 2 hours at no load. Check and record the current, temperature rise and pay attention to whether the sound is normal. The whole drum dryer is tested for no load for no less than 8 hours. After that, the following inspections are required after 48 hours of loading and load operation:

(1) Whether the transmission device has vibration, impact and abnormal noise, and the meshing and contact conditions of large and small gears. The motor temperature rise should not exceed 40℃, and the current should not exceed its rated value.

(2) The drum should not have movement and shaking, and the roller should not have shaking and obvious vibration.

(3) The contact length between the roller and the support wheel is more than 70% of the roller width. Check the contact condition of the retaining wheel.

(4) Whether the sealing fish scales at both ends of the drum are closely attached to the surface of the drum and there should be no warping.

(5) Lubrication and oil leakage of each lubrication point, oil quality, etc.; the temperature rise of each bearing shall not exceed 60℃.

(6) Check whether the connecting bolts are loose, and tighten the bolts of each part again, especially the matching bolts of the large gear, the fixing bolts of the retaining wheel, and the sealing bolts at both ends of the cylinder.

(7) Check the meshing condition of the transmission gear and the reducer gear. The meshing surface should not have pitting, scars, scars and other defects.

Load test

After the drum is dry, hot air is passed through, and the temperature is gradually raised to the working temperature. At the same time, materials are added into the equipment until the normal load is reached. Run for 8 hours under normal load and repeat the requirements of the idling test.

4. Safety precautions:

4.1 Any repair work must be carried out after the machine is shut down, and a "Do Not Start" sign should be hung on the motor switch.

4.2 Do not use your hands or other objects to reach into the bearing, reducer or large gear housing to carry out any repair inspection or cleaning work during operation, and do not remove safety protection facilities.

4.3 Do not tie a rag to your hands or fingers to wipe the surface of the machine around the rotating parts. Be careful not to wrap the wiping material around the rotating parts, especially the supporting wheels.

4.4 Work clothes should be tied tightly to avoid the rotating parts of the machine from tangling the corners and sleeves of the clothes, causing personal accidents.

4.5 Maintenance tools and parts must not be placed on the rotating parts, especially on the supporting wheels.

4.6 Before starting the machine, a strict inspection must be carried out to ensure that no one is in the cylinder and a warning signal is issued before starting.

5. Shutdown and inspection:

During production, it is sometimes necessary to shut down for a short period of time for inspection and repair work. Although the number of shutdowns should be reduced as much as possible, it cannot be avoided. Whether it is a long-term or short-term shutdown, all relevant production positions should be contacted before the shutdown.

5.1 Short-term shutdown

Just after the shutdown, the whole machine is in a hot state. If the cylinder is not rotated frequently, the center line of the cylinder will bend. It is particularly important and cautious to ensure that the center line does not bend. Do not neglect it.

For this reason, it is recommended:

In the first hour after shutdown, turn the cylinder 1/4 turn every 5-10 minutes.

In the second hour after shutdown, turn the cylinder 1/4 turn every 15-20 minutes.

In the third hour after shutdown, turn the cylinder 1/4 turn every 30 minutes.

5.2 Long-term shutdown and inspection:

5.2.1 After shutdown, turn the cylinder according to the above-mentioned specified cycle until it is completely cooled and people can enter the cylinder.

5.2.2 Inspection after shutdown:

1. Whether the local cooling water has been completely drained.

2. The condition of each wear surface, the clearance between the shaft and the bearing, and the clearance between the large and small gears.

3. Whether all the connecting bolts are loose or damaged, especially the connecting bolts of the large gear ring, the welds of the cylinder and the pad have cracks, etc.

4. Whether the lubricating oil of each lubrication point needs to be replaced, cleaned or replenished. If replacement is required, the stored oil should be drained, removed and refilled.

5.3 Lubrication and cooling:

Another important task in maintaining large-scale dryers is to lubricate the moving parts of the dryer well in order to extend the life of the parts and reduce the repair cost.

When lubricating the dryer, pay attention to the following matters:

5.3.1 Lubricating oil and grease should be used correctly. When using substitutes, they must meet the requirements of the specified oil quality performance. Only oil with higher viscosity can be used to replace oil with lower viscosity.

5.3.2 The machine runs continuously for 400-500 hours. After the gears and bearings run in, all the oil should be released, and the oil pool 8.3.2 should be cleaned and the oil should be changed. In the future, the oil should be changed every 6 months. The waste oil can be mixed with oil if it is carefully filtered and not deteriorated.

5.3.3 Check the oil level once per shift. If the oil level drops to the lower limit of the oil level indicator scale, it must be refilled immediately to the upper limit of the oil level indicator.

5.3.4 When oil leakage is detected, measures should be taken immediately to eliminate the cause of the oil leakage. Once the oil leak flows to the foundation, it should be handled in time to avoid corrosion of the foundation.

5.3.5 After a long period of stoppage, before starting, oil must be poured into the oil pan of the supporting roller sliding bearing with an oil pot, and then started. When the transmission is used for a long time, it should be checked frequently and oiled as needed.

The workers who maintain the dryer should also pay attention to the roller circulation cooling system; the water level in the water tank can be controlled by rotating the PVC pipe. You should always check whether there is water flowing out of the water pipe. When the machine is shut down for a long time or in winter, all cooling water should be drained to avoid ice and cracking.

6. Use and Maintenance

1. During normal operation, the inlet hot flue gas temperature is 800~350℃, and the outlet hot flue gas temperature is 50~150℃

2. Check whether the lubrication points of the roller, roller, and roller bearing are filled with sufficient oil

3. Check whether there is any crack in the weld between the roller and the pad, and whether there is any excessive wear between the roller and the roller

4. Check whether the contact between the roller and the roller is good, and the contact surface is not less than 70% of the width of the roller

5. Check whether the thrust of each roller is evenly upward.

6. Check whether the fastening bolts and anchor bolts are loose or broken.

7. Check whether the foundation is vibrating, cracked, or sinking.

8. Check whether the wheel rotates quickly, whether the contact with the roller is good, and whether there are abnormal phenomena such as fluffing, shelling, and heating of the bearing

9. Check whether the cylinder moves quickly and stably, and whether the seal is worn or leaking.

10. Check whether the transmission device vibrates, and whether the oil volume of the lubrication point is sufficient.