Rotary Kiln Inlet With Pneumatic Seal

Machine manual
en-KP.JNT.003.A
Rotary kiln inlet with pneumatic seal
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
Rotary kiln inlet with pneumatic seal
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-10
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
4.3 Checks prior to the refractory lining work 4-4
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Preparation for test run 6-1
6.2 Checks prior to the test run 6-1
6.3 Setting and adjustment 6-1
7 Maintenance 7-1
7.1 Safety instructions 7-1
7.2 Inspection 7-3
7.2.1 Inspections during operation 7-3
7.2.2 Inspections during a longer stoppage of the kiln plant 7-4
7.3 Servicing 7-4
7.4 Repair 7-5
8 Trouble shooting 8-1
8.1 Safety instructions 8-1
8.2 Faults, causes and elimination of faults 8-3
9 Spare parts9-1
9.1 Suggestions for enquiries and orders of spare parts 9-1
9.2 Spare parts9-1
10 Appendix 10-1
10.1 Technical drawings 10-1
10.2 Subsuppliers' documentation 10-1
en-KP.JNT.003.A
Machine manual Safety
Rotary kiln inlet with pneumatic seal 1
1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The rotary kiln inlet with pneumatic seal is a component of the rotary kiln. Be
sure to comply with the specification of the intended use in section Technical
data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transport instructions in this machine manual refer exclusively to the
transport of the machine at the plant site.
● Only use suitable hoisting and load-carrying equipment which is in serviceable
order and has a sufficient load-bearing capacity.
● Never work under a suspended load.
Safety measures for refractory lining work
● Carry out an inspection and maintenance of the holding brake of the rotary
kiln drive in accordance with the subsupplier's instructions before you start
any refractory lining work (see machine manual of the Rotary kiln drive). The
holding brake must always be in a safe and reliable condition.
● Ensure that the holding brake of the rotary kiln drive is always closed as long
as personnel or movable equipment are in the rotary kiln.
● Do not open the holding brake for turning the rotary kiln until all personnel and
movable equipment have been removed from the rotary kiln.
● Refractory lining work may only be carried out section by section to prevent
the torque from exceeding the permissible holding torque of the rotary kiln
drive's holding brake.
en-KP.JNT.003.A
Safety Machine manual
2 Rotary kiln inlet with pneumatic seal
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
● The plant management has to ensure that the whole area of the rotary kiln is
cordoned off, so that it is impossible for persons to come into contact with
rotating parts.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Before beginning any repair work, make absolutely sure that the rotary kiln
has swung to a complete stop in its centre of gravity position and has been
secured by means of the holding brake of the rotary kiln drive.
● Before performing any work on the machine, make sure that there is no risk of
burns when touching the machine.
● Do not permit work on the stopped rotary kiln to be carried out without suitable
fall protection.
● Ensure that all rotating parts of the machine have come to a complete
standstill before you remove any protection devices or open any covers.
● Only specially authorised and trained personnel may open the inspection
ports. There is danger of being burned by hot gas or spattering hot material!
● Before performing any work on the machine, make sure that no hot material is
in the machine when inspection covers and service covers are opened.
● Switch off the power supply to the electrical components before beginning any
maintenance work.
● Make absolutely sure that the pneumatic piping is relieved of pressure before
disconnecting it.
en-KP.JNT.003.A
Machine manual Safety
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
● Wear dust protection masks when work is carried out in the machine, as a
large amount of dust has to be expected.
● Remove incrustations and possibly loose refractory lining at the ceiling before
inspecting the machine.
● Make absolutely sure that the material has an adequate bearing capacity or
suitably cover the material before inspecting the machine.
● Only use 24 volt lamps to illuminate the interior of the machine.
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
● After all maintenance work, check that there are no leaks in joints and
connections.
● Check that all signs are complete and distinctly legible. Provide new signs, if
necessary.
en-KP.JNT.003.A
Machine manual Technical data
2 Technical data
Note
Information concerning the electrical equipment is contained in the separate
electrical documentation or in the subsuppliers' documentation.
Specification of the intended use

See the operating manual of the rotary No.
kiln plant
Basic data
Year of manufacture
Nominal diameter of the rotary kiln at mm

the inlet
Length of inlet end section mm
Number of segments Piece(s)
Pneumatic cylinder
Qty. Piece(s)
Conditioning unit for compressed air

Qty. Piece(s)
en-KP.JNT.003.A
Machine manual Components and mode of functioning
3 Components and mode of functioning

3.1 Components
Note
Some details of the drawings in this manual may not be identical with the
drawings supplied under the contract.
en-KP.JNT.003.A
Components and mode of functioning Machine manual
Fig. 1
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No. Name Description

1.0 Rotary kiln inlet
2.0 Inlet seal
3.0 Seal suspension
A Rotary kiln shell
B Kiln inlet housing
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Fig. 2

1.1 Inlet end section
1.2 Inlet segments with bolted connection
2.0 Inlet seal
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Fig. 3

2.4 Pneumatic cylinder with heat insulation
2.10 Slide-off preventer
2.12 Lubrication piping with grease nipple
3.0 Seal suspension
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Fig. 4
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1.0 Rotary kiln inlet
1.4 Support ring
1.4.1 Wear ring type T with bolted connection, for mounting on the support ring
2.4 Pneumatic cylinder
2.4.1 Abutment
2.4.2 Heat insulation
2.7 Sealing ring
2.7.1 Wear ring type D with bolted connection, for mounting on the sealing ring
2.8 Sealing cord, complete
2.8.1 Rope joint
2.8.2 Wire rope clamp
2.8.3 Pin with split pin and washer
2.8.4 Eye disc with hexagon nut
2.8.5 Spring
2.9 Non-rotating ring
2.10 Slide-off preventer not illustrated
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Fig. 5
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2.4 Pneumatic cylinder
2.5 Compressed air supply Complete
system
2.5.1 Gate valve
2.5.2 Compressed air vessel Optional
2.5.3 Non-return valve
2.5.4 Compressed air hose
2.6 Conditioning unit
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3.2 Mode of functioning

The rotary kiln inlet (1.0) forms the transition between the rotary kiln shell (A) and
the inlet housing (B). The material is fed via the inlet chute of the inlet housing
and the inlet end section (1.1) into the rotary kiln. The pneumatic inlet seal (2.0) is
the connecting link between the inlet end section (1.1) and the non-rotating inlet
housing (B).
The conical shape of the inlet end section prevents the feed material from flowing
back.
The pneumatic inlet seal (2.0) prevents inleakage of false air into the rotary kiln.
The inlet segments (1.2) support the front row of refractory bricks and protect the
inlet end section (1.1) against overheating.
The sealing ring (2.7) is fastened on gimbals to the inlet housing (B) by means of
the seal suspension (3.0). It supports the pneumatic cylinders (2.4) and the
sealing cord (2.8) of heat resistant material which is fitted around the non-rotating
ring (2.9) and tensioned by springs.
To prevent seizing between the rotating wear ring type T (1.4.1) and the
stationary wear ring type D (2.7.1), a combination of different materials was
selected. At the same time, the joint is discontinuously lubricated by a lubricating
device (2.12).
Sealing against rotating and axial movements is achieved by means of two
different functional groups.
1. Rotation
The wear rings (1.4.1 and 2.7.1) take up the rotational movement by being
pressed against each other by the pneumatic cylinders (2.4).
The pneumatic cylinders (2.4) are able to ensure perfect sealing even if the
rotary kiln inlet (1.0) wobbles.
The contact pressure of the pneumatic cylinders (2.4) must be set so low
that the sealing surfaces just make gentle contact. The supply pressure to
the pneumatic cylinders (2.4) can be adjusted on the pressure reducing
valve of the conditioning unit (2.6). Optimum operating conditions are
attained with an air pressure between 0.5 and 1.5 bar.
2. Axial movements
The sealing cord (2.8) guided by the sealing ring (2.7) and tensioned around
the non-rotating ring (2.9) takes over the axial share of the sealing function.
During axial movement of the rotary kiln the sealing cord rolls on the non-
rotating ring (2.9).
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Powdery feed material which passes into the area of the seal is carried away by
webs welded into the support ring (1.4) and returned to the rotary kiln.
Excessive quantities of dust which accumulate in the rotary kiln due to
accumulation of feed material can, however, not be transported. In these cases
the cause must be found and eliminated by suitable measures.
en-KP.JNT.003.A
Machine manual Transport and assembly
4 Transport and assembly

4.1 Transport and storage instructions
The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable lifting equipment is employed for lifting all the parts
from the transport vehicles and transferring them to the storage area.
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
moisture, soiling and damage. Never place the parts directly on the ground.
Components such as motors, couplings, gear units, pumps, hydraulic/pneumatic
components, measurement and control equipment must be stored in well-
ventilated rooms and must be protected against moisture. Covers, plugs, etc.
must not be removed until the final assembly.
Make absolutely sure that the wear protection lining and the refractory materials
are stored in accordance with the subsupplier's instructions.
If lengthy storage is required, check the protective coating and repair it if
necessary.
4.2 Assembly
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches and
hydraulic pumps of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
mounting supports, depends on the conditions in your plant.
Note
The basic safety instructions must be complied with. Also refer to the section
Safety.
en-KP.JNT.003.A
Transport and assembly Machine manual
CAUTION
Welding current
Moving connecting elements or sliding surfaces could be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
Note
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
Sequence of the kiln inlet section assembly:

● Bolt the inlet segments (1.2) to the inlet end section (1.1).
● Secure the bolted connections at the inlet segments by means of tack
welding.
● Align the inlet end section with the rotary kiln shell and brace it by means of
tensioning blocks and supporting brackets. Alternatively, you can already align
the inlet end section with the subsequent kiln shell section and brace it with
tensioning blocks and supporting brackets during the preassembly of the kiln
shell.
● Perform a concentricity test and axial run-out measurement of the rotary kiln
inlet (measurement record is required).
● Realign the rotary kiln inlet if necessary.
● Weld the circumferential weld between the inlet end section and the kiln shell.
● Check the circumferential assembly weld for cracks.
● Perform a concentricity test and axial run-out measurement of the rotary kiln
inlet after the welding (measurement record is necessary).
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Machine manual Transport and assembly
Sequence of the kiln inlet seal assembly:

● Install the non-rotating ring (2.9) at the inlet housing (B).
Note
The joints of the non-rotating ring (2.9) must be positioned vertically.
● Align the contact surfaces with each other and weld them. Then grind off the
weld overfills.
● Weld the flange of the non-rotating ring (2.9) to the inlet housing (B).
● Install the support ring (1.4) with the wear ring (1.4.1) to the rotary kiln inlet
(1.0).
● Install the sealing ring (2.7), the wear ring (2.7.1) and the seal suspension
(3.0).
Note
Align the sealing ring in such a way that there is uniform distance between the
sealing ring (2.7) and the non-rotating ring (2.9) around the entire
circumference.
● Install the sealing cord (2.8).
Note
For inserting the sealing cord (2.8) force off the sealing ring (2.7) from the non-
rotating ring (2.9).
● Mount the pneumatic cylinders (2.4), and install the abutments (2.4.1) and the
heat insulation (2.4.2).
● Mount the slide-off preventer (2.10).
● Install the compressed air supply system (2.5) including the conditioning unit
(2.6).
● Tension the sealing cord.
Note
The sealing cord (2.8) must tightly encircle the non-rotating ring (2.9). However,
make absolutely sure that the tensioning ropes of the tensioning device are not
too tight, as this would impair the optimum functioning of the seal.
● Install the refractory material in the kiln inlet housing and in the kiln shell in
accordance with the instructions given in section Checks prior to the
refractory lining work.
en-KP.JNT.003.A
Transport and assembly Machine manual
Note
We suggest you secure the marked screws / nuts by a welding spot after having
completed the final assembly / cold test run.
Fig. 6
4.3 Checks prior to the refractory lining work

● Have all temporary assembly scaffolds and assembly aids been removed from
the inside of the inlet end section (1.1)?
● Have all assembly appliances welded onto the inside of the inlet end section
(1.1) been removed? Have the welds been ground level without any notches?
● Has the circumferential assembly weld been checked for freedom from
cracks?
● Is edge misalignment plus assembly weld cap on the inner surface of the
assembly weld seam less than 4 mm?
● Have the inlet segments been properly tightened and secured?
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Machine manual Lubrication
5 Lubrication
Note
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
subsuppliers and products approved by POLYSIUS AG. It is the responsibility of
the lubricant subsupplier to select appropriate lubricants corresponding to the
lubricant reference numbers. POLYSIUS AG accepts no liability for the
correctness of these data. If you wish to use a lubricant that is not included in
the Table of lubricants, you have to first obtain the express permission of
POLYSIUS AG. The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.
CAUTION
Lubricants that are not properly stored, used and disposed of are an
environmental hazard.
They can harm humans, animals and plants.
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.
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Lubrication Machine manual
Fig.. 7: Lubrication points
Lubrication points Quantity (ltr, kg) per Lubrication intervals (weeks)

lubrication point
No. Qty. Designation Lubricant Initial Topping Topping up First Further

ref. no. filling up change changes
1 1 Compressed air oiler of 3 0.2 As As required

the conditioning unit (2.6) required
2 2 Grease nipple 85 0.05 0.05 1 x per shift
The different makes of lubricants corresponding to the lubricant reference numbers are shown in the Table of
lubricants in the supplement Important notes on the documentation. The supplement is contained in this folder or at the
beginning of the overall documentation.
Tab. 1: Lubrication chart
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Machine manual Commissioning
6 Commissioning
6.1 Preparation for test run
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.
6.2 Checks prior to the test run

After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and auxiliary assembly devices have first been carefully
removed.
● Has the refractory lining been installed in accordance with the subsupplier's
instructions?
● Has all auxiliary assembly equipment been removed from the outer shell?
● Have all welded-on assembly aids on the outer shell been removed and have
the welds been ground level without any notches?
● Is the design-specific radial space between the inside diameter of the
refractory lining and the inlet trough maintained during the whole rotation?
● Is the inlet seal (2.0) so aligned that the sealing ring (2.7) moves freely around
the entire circumference?
● Has the sealing cord (2.8) been tensioned?
● Does the slide-off preventer (2.10) actually prevent the sealing cord (2.8) from
slipping off the non-rotating ring (2.9) when the seal is open?
● Is compressed air of 4 to 10 bar available before the conditioning unit (2.6)?
● Has the operating pressure of approx. 0.5 to 1.5 bar been set on the
conditioning unit (2.6)?
● Is compressed air being supplied to all pneumatic cylinders (2.4)?
● Do all pneumatic cylinders (2.4) move easily?
● Are the pneumatic cylinders (2.4) free of leaks?
● Is the water separator of the conditioning unit (2.6) in perfect condition?
● Is the compressed air oiler of the conditioning unit (2.6) functioning properly?
● Is the lubrication piping (2.12) filled with grease? Has the lubrication gap
between the wear rings of type T and those of type D been lubricated?
6.3 Setting and adjustment

Set the seal suspension (3.0) of the pneumatic seal so that there is a uniform
gap of approx. 5 to 10 mm between sealing ring (2.7) and non-rotating ring (2.9)
around the entire circumference.
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Machine manual Maintenance
7 Maintenance
7.1 Safety instructions
DANGER
The rotary kiln and the rotary kiln inlet are hot.
You may suffer very severe burns.
Always use the required protective clothing.
DANGER
It is forbidden to carry out work at rotating machines.
You could be severely injured.
The plant management has to ensure that the whole area of the machine is
rotating parts.
DANGER
Never open doors or manholes during operation!
You could be very severely injured by material falling out or spattering.
I. Always observe the respective signs!
II. Only specially authorised and trained personnel may open the
inspection ports.
DANGER
Before beginning any maintenance work, make absolutely sure that the
rotary kiln has swung to a complete stop in its centre of gravity position
and has been secured by means of the holding brake of the rotary kiln
drive.
You could fall from the rotary kiln.
Do not work on the rotary kiln without suitable fall protection.
DANGER
The machine contains parts under voltage.
Switch off the power supply to all electrical components before starting
any maintenance work.
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Maintenance Machine manual
DANGER
There is hot combustion gas inside the rotary kiln.
There is mortal danger due to carbon monoxide!
Make absolutely sure that there is no longer any carbon monoxide in the
rotary kiln and wait until it has cooled down before going inside.
DANGER
Coatings in the machine can fall down or give way.
You could be buried alive or sink into the material.
I. Remove incrustations and possibly loose refractory lining at the ceiling
before inspecting the machine.
II. Make absolutely sure that the material has an adequate bearing
capacity or suitably cover the material before inspecting the machine.
CAUTION
Welding current
being welded.
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7.2 Inspection
7.2.1 Inspections during operation
No. Work to be performed Frequency Comments

1 General visual inspection for overheating or local 1 x per shift
thermal deformation
2 Regular check of the temperature of the inlet end 2 x per shift
section (1.1) using the scanner or the radiation
pyrometer
3 Visual inspection for gaping sealing surfaces between Daily
the wear rings (1.4.1 and 2.7.1)
4 Check for material escaping in the area of the seal Daily
5 Visual inspection of all pneumatic cylinders (2.4) for Daily Pneumatic
uniform pressure application cylinders must
move
6 Check the water separator of the conditioning unit (2.6) Daily
7 Check the compressed air oiler Daily
8 Check the air pressure after the pressure reducing valve Daily Optimum
(supply pressure of the pneumatic cylinders (2.4)) value approx.
0.5 to 1.5 bar
9 General visual inspection for cracks Monthly
10 Check the wear ring type T (1.4.1) for wear Monthly Min. thickness
15 mm
11 Check the wear ring type D (2.7.1) for wear Monthly Min. thickness
15 mm
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7.2.2 Inspections during a longer stoppage of the kiln plant

1 Check the sealing cord pretensioning (2.8) Every 6
months
2 Check the compressed air piping for leaks Every 6
months
3 Check the inlet segments (1.2) for deformation and Every 6
wear months
4 Check the refractory lining thickness Every 6 Wear limit:
months 50% of
original
refractory
lining
thickness
7.3 Servicing
1 Empty the water separator As required
2 Replace the compressed air oiler As required
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7.4 Repair
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Note
We recommend having the repair work carried out under the supervision of an
expert from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoists,
depends on the operating conditions in your plant.
General
Note
The basic safety instructions must be complied with. Also refer to the section
Safety.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
Note
Repair measures are limited to work on the pneumatic cylinders (2.4) and the
conditioning units (2.6), as well as replacement of wear parts, such as the wear
rings (1.4.1 and 2.7.1), the sealing cord (2.8) and the refractory lining.
Every 2nd pneumatic cylinder (2.4) is connected to ring piping. For replacement
purposes, the respective ring piping can be shut off. The sealing function is then
temporarily maintained by half the pneumatic cylinders.
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Note
We recommend having all repair work on the machine other than the above
carried out under the supervision of a specialist from POLYSIUS AG.

1 Replace the wear ring type D (1.4.1) As required Min.
thickness
15 mm
2 Replace the wear ring type D (2.7.1) As required Min.
thickness
15 mm
3 Replace the inlet segments (1.2) As required
4 Replace the pneumatic cylinders (2.4) As required
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.
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Machine manual Trouble shooting
8 Trouble shooting
8.1 Safety instructions
DANGER
The rotary kiln and the rotary kiln inlet are hot.
You may suffer very severe burns.
Always use the required protective clothing.
DANGER
It is forbidden to carry out work at rotating machines.
The plant management has to ensure that the whole area of the machine is
rotating parts.
DANGER
Never open doors or manholes during operation!
You could be very severely injured by material falling out or spattering.
I. Always observe the respective signs!
II. Only specially authorised and trained personnel may open the
inspection ports.
DANGER
Before beginning any maintenance work, make absolutely sure that the
rotary kiln has swung to a complete stop in its centre of gravity position
and has been secured by means of the holding brake of the rotary kiln
drive.
You could fall from the rotary kiln.
Do not work on the rotary kiln without suitable fall protection.
DANGER
The machine contains parts under voltage.
Switch off the power supply to all electrical components before starting
any maintenance work.
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Trouble shooting Machine manual
DANGER
There is hot combustion gas inside the rotary kiln.
There is mortal danger due to carbon monoxide!
Make absolutely sure that there is no longer any carbon monoxide in the
rotary kiln and wait until it has cooled down before going inside.
DANGER
Coatings in the machine can fall down or give way.
You could be buried alive or sink into the material.
I. Remove incrustations and possibly loose refractory lining at the ceiling
before inspecting the machine.
II. Make absolutely sure that the material has an adequate bearing
capacity or suitably cover the material before inspecting the machine.
CAUTION
Welding current
being welded.
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Machine manual Trouble shooting
8.2 Faults, causes and elimination of faults

Note
Consult the subsupplier's documentation for additional information on faults,
their causes and their elimination.
Fault Cause Elimination

Gaping of the inlet seal The air pressure before the Set correct air pressure
pneumatic cylinders (2.4) has
failed or is too low
Individual pneumatic cylinders Replace the faulty pneumatic
(2.4) do not work cylinders (2.4)
Leaks in the compressed air Seal the respective point of
piping connection or replace the respective
piping section.
Local thermal The refractory lining in the inlet Shut down the rotary kiln
deformation, bulges on end section (1.1) is damaged immediately, complying with the
the inlet end section stopping conditions, and replace the
(1.1) due to refractory lining according to
overheating subsupplier's instructions.
In the case of damage to the inlet
end shell section or inlet segments:
Repair or replace the damaged
sections.
In serious cases: Replace the
respective shell section.
Material escaping from The feed material is banking Alter the mode of operation of the
the area of the seal up due to coating in rotary kiln rotary kiln to avoid coating
or coating rings
(see operating manual)
Overfilling of the rotary kiln Reduce the feed rate or increase the
kiln rotation speed
(see operating manual)
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.
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Machine manual Spare parts
9 Spare parts
9.1 Suggestions for enquiries and orders of spare parts
Dear customer, Polysius AG wants to make spare part enquiries and spare part
order placements 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 corresponding table. Complete the
columns for quantity and units. Mark the parts you require with a cross in the
column Order or in the column 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.
9.2 Spare parts
en-KP.JNT.003.A
Spare parts Machine manual
Fig. 8
en-KP.JNT.003.A
Machine manual Spare parts
No. Name Qty. Unit Order Enquiry

1.1 Inlet end section 1 Piece(s)
1.2 Inlet segments with bolted connection 1 Set
1.2.1 Bolted connection 1 Set
1.4.1 Wear ring type T with bolted connection 1 Set
2.7.1 Wear ring type D with bolted connection 1 Set
2.8 Sealing cord, complete 1 Set
en-KP.JNT.003.A
Spare parts Machine manual
Fig. 9
No. Name Qty. Unit Order Enquiry

2.4 Pneumatic cylinder Piece(s)
2.5.1 Gate valve Piece(s)
2.5.2 Compressed air vessel Piece(s)
2.5.3 Non-return valve Piece(s)
2.5.4 Compressed air hose Piece(s)
2.6 Conditioning unit Piece(s)
en-KP.JNT.003.A
Machine manual Appendix
10 Appendix
10.1 Technical drawings
Note
For drawing numbers, please refer to the table of contents of this folder.
Assembly drawing
10.2 Subsuppliers' documentation
Pneumatic cylinder
en-KP.JNT.003.A

Rotary Kiln Inlet With Pneumatic Seal

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Rotary Kiln Inlet With Pneumatic Seal

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Rotary Kiln Inlet With Pneumatic Seal

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Machine manual

Rotary kiln inlet with pneumatic seal

POLYSIUS Order Code (POC)

Specification of the intended use

Nominal diameter of the rotary kiln at mm

Length of inlet end section mm

Number of segments Piece(s)

Conditioning unit for compressed air

3 Components and mode of functioning

No. Name Description

No. Name Description

No. Name Description

No. Name Description

No. Name Description

3.2 Mode of functioning

4 Transport and assembly

Sequence of the kiln inlet section assembly:

Sequence of the kiln inlet seal assembly:

● Install the sealing cord (2.8).

4.3 Checks prior to the refractory lining work

Fig.. 7: Lubrication points

Lubrication points Quantity (ltr, kg) per Lubrication intervals (weeks)

No. Qty. Designation Lubricant Initial Topping Topping up First Further

1 1 Compressed air oiler of 3 0.2 As As required

2 2 Grease nipple 85 0.05 0.05 1 x per shift

Tab. 1: Lubrication chart

6.2 Checks prior to the test run

6.3 Setting and adjustment

7.2.1 Inspections during operation

No. Work to be performed Frequency Comments

7.2.2 Inspections during a longer stoppage of the kiln plant

No. Work to be performed Frequency Comments

No. Work to be performed Frequency Comments

8.2 Faults, causes and elimination of faults

Fault Cause Elimination

9.2 Spare parts

No. Name Qty. Unit Order Enquiry

No. Name Qty. Unit Order Enquiry

10.2 Subsuppliers' documentation

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