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OPERATING & MAINTENANCE MANUAL

ROTARY KILN BURNER

SECTION 12
Inspection- and maintenance guidelines
12.7
12.8

Changing the burner nozzles and the baffle plate

Changing the burner jacket tube

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12.7

Changing the burner nozzles and the baffle plate

a. General
b. Changing the nozzles
c. Changing the baffle plate

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

NOTE!
All nozzles have a right-hand thread

In order to ensure easy assembly of the nozzles and prevent wear of the threads, all
threads should be coated with lubricating spray or paste. The compound used must be
resistant 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 the
outside.
Special tools
A special tool, one or more nozzle wrenches, are required to change the nozzle. The
nozzle wrenches are designed separately for each burner and are included in the
shipment.

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Setting device for nozzle adjustment
Coal channels and gas channels can be equipped with individual devices for axial
adjustment of the relevant nozzle. If so, put the nozzle into the maintenance position
using the setting device before changing the nozzle.
For the coal nozzle, position 0 is
the scale setting for maintenance
(All non-adjustable nozzles are
mounted flush with the baffle plate)

For the gas nozzle, position S is

the scale setting for maintenance
(The gas nozzle is pushed forward
for easier installation)
Fig. 12.1: Scale setting example

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b. Changing the nozzles

Procedure

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.
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.

Fig. 12.2: Use the nozzle wrench to loosen the

nozzle

Fig. 12.3: Unscrew nozzle 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.

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c. Changing the baffle plate

To remove the baffle plate, the inner-most nozzle must be removed. The baffle plate is
held in place between the nozzle and bolt.
The images below show the nozzle head with the inner-most nozzle already
disassembled.
Procedure
1. Remove the inner-most nozzle, based on the description above.
2. Remove the baffle plate.

Fig. 12.4: Inner-most nozzle, disassembled

Fig. 12.5: Removing the baffle plate

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

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12.8

Assembly and disassembly of burner jacket tube

a.
b.
c.
d.
e.
f.
g.
h.
i.

General
Removing front part
- divisible burner jacket tube
Placing front part
- divisible burner jacket tube
Removing rear part
- divisible burner jacket tube
Placing rear part
- divisible burner jacket tube
Removing jacket tube
- non divisible burner jacket tube
Placing jacket tube
- non divisible burner jacket tube
Replacing packing cords
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

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

b. Removing front part divisible burner jacket tube

The front part of divisible jacket tube can be independently removed from the rear part
of the jacket tube. The front part of the jacket tube has a length of approximately
1200 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 jacket
tube should be available.

Fig. 12.6: Exchange procedure demonstration

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Fig. 12.7: Fastening device

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NOTE!
Depending on the burner size the divisible execution can be equipped
with 2 or 3 fastening devices. The description is valid for both
executions.
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 the
fastening lever (2).
Use a M30
wrench.
The maximum
allowed torque is
120 NM

Fig. 12.8: Loosen the hex nut

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

Fig. 12.9: Loosened nuts

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4) Turn the fastening lever into the UNLOCKED service position (see also view Z in
fig. 12.7 above)

Fig. 12.10: Unlocked position of the fastening lever

5) The fastening device is unlocked.

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 (see
details "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"!

Fig. 12.12: Partly removed front part of jacket tube

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

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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, make
sure that the sealing surface of both parts as well as the packing cords are
absolutely 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 front
part of the jacket tube is pushed back until the gap between front and back part is
10-20 mm (see the Detail "B" in fig. 12.7 above). Damage to the MAS hoses, the
flame setting device, and the packing cord must be avoided.
3) The hexagonal nut (1) including lock nut must be screwed back to the fastening
lever (2). Push the connecting rod (5) with the clamping lever in the direction of the
nozzle 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. 12.7
above).
5) Screw the hex nut (1) in the direction of the nozzle head tighten it. The front jacket
tube is brought into its final position by the connecting rod(s).

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

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

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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 tube
has 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 tip
over. 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!

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

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 to
the MAS hoses, the flame setting device and the packing cord as well as jamming of
the 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
tube

jacket tube non divisible burner jacket

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 of
the jacket tube. Damage to the MAS hoses, the flame setting device and the
packing 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 packing
cords. 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 MAS
hoses, the flame setting device and the packing cord as well as jamming of the rear
part 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 2,5 x 20mm (29A).
Cut the new packing cord (made of fiberglass/graphite 10 x 10 mm) at an angle and
place it. Fix the new packing cord with the clamping sleeves.
Also replace the packing cord (30) at the divisible execution every time it is
disassembled. It is replaced by a packing cord (12 x 12 mm made out of
fiberglass/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 jacket

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

Fig. 12.14: Burner jacket tube

Item
Nr.
1
2
3

Description
Nozzle ring
Front jacket tube
Rear jacket tube

To replace the nozzle ring and/or the front

jacket tube, the joint weld must be
separated. Make sure that the recess for
centering is not destroyed. After separation,
remove the rest of the old joint weld and
prepare the parts for new welding.
Then,
weld
the
replacement
parts
corresponding to the following instructions.

Fig. 12.15: Jacket tube example

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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
Stress relieved
Pressure tested
Leak tested
Quality levels of the welding connection acc. EN
ISO 5817
Welding process
Welding filler materials
Test procedure
Preheating

B/F
No
- bar
No
C
Bhler FOX FA
Visual
- C

As the mechanical stress between the nozzle

ring (1) and the front jacket tube is low, they are
connected by an intermittend weld. This allows
the nozzle ring to be replaced easily and
without damaging the recess for centering.

Fig. 12.16: Welding joint Detail X

Type
M.A.S./3/
M.A.S./4/
M.A.S./5/
M.A.S./6/
M.A.S./7/
M.A.S./8/
M.A.S./9/

!
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D
457
508
550
610
660
711
762

N1
7
8
9
10
10
11
12

L1
110
110
100
100
110
110
110

A1
95
90
90
90
100
90
90

N2
3
3
3
4
4
4
5

L2
50
50
50
50
50
50
50

A2
380
430
475
390
430
470
400

CAUTION!
Damaging the centering recess.
When opening the welded joints, ensure that the centering recesses are
not 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
Stress relieved
Pressure tested
Leak tested
Quality levels of the welding connection acc. EN
ISO 5817
Welding process
Welding filler materials
Test procedure
Preheating

B/F
No
- bar
No
C
Bhler NIBAS 70/20
Bhler CN23
Visual
- C

Due to the high mechanical stress between the

front jacket tube (2) and the rear jacket tube (3),
these parts are continuously welded.

Fig. 12.17: Weldingjoint Detail Y

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