Machine manual

en-21022.241-G

DOPOL® Tertiary air duct

MSC with extraction from
cooler

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
DOPOL® Tertiary air duct MSC with extraction from cooler

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-4
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-3
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-4
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1

en-21022.241-G
Machine manual Technical data
DOPOL® Tertiary air duct MSC with extraction from cooler 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Information on the intended use

See the operating manual of the rotary kiln plant !

Basic data
Year of manufacture............................................................................
Weight..................................................................................................
Nominal diameter of the main duct..............................................mm
Nominal diameter of the branch element................................... mm
Nominal diameter of the top air duct.......................................... mm
Thickness of the refractory lining.........................................155 mm

Throttle device (6.9)

See machine manual ..................................................................No.

Throttle device (6.10)

See machine manual ..................................................................No.
Machine manual Safety
DOPOL® Tertiary air duct MSC with extraction from cooler 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 The tertiary air duct is a component of the DOPOL® preheater
for the kiln plant.
Be sure to comply with the stipulations concerning 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 the observance of the
instructions in the machine manual and the compliance with
the maintenance instructions.

Transport and assembly

 All transportation instructions in this machine manual refer
exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
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.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut it down immediately.
 Existing platform openings must be closed or properly
safeguarded.
Safety Machine manual
2 DOPOL® Tertiary air duct MSC with extraction from cooler

Maintenance

 Ensure 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 performing any work on the machine, make sure that
there is no danger of suffering burns when touching the
machine and that no hot material is in the machine when
inspection and service covers are opened.
 Before, during and after maintenance work the Plant Manager
must make absolutely sure that the working area is cordoned
off and made safe, and that all possible measures are taken to
assure the safety of the maintenance personnel.
After the maintenance work is concluded, make absolutely
sure that no persons are shut inside the preheater.
 Do not touch the surface of the tertiary air duct anywhere. It is
hot! Danger of suffering burns.
 When using automatic air blast units, let the residual pressure
escape after the air blast unit has been electrically switched
off before opening the doors and poke holes. Danger of
unintentional shooting, due to residual pressure.
 At all cyclone stages of the preheater there are supporting
brackets on the platforms. The danger of stumbling makes
protective clothing necessary.
 Doors and sealing covers may only be opened by specially
authorised and trained personnel on the express orders of the
plant manager!
The doors and sealing covers are so designed that they can be
secured by padlocks.
 Even after a longer cooling-down period, be careful when
opening doors and maintenance openings. There is still the
danger of being burned by raw meal spurting out.
 In the case of a power failure in the kiln plant, overpressure in
the entire preheater may occur. Do not open the doors or poke
holes until there is no overpressure in the preheater.
 Only use the specially provided cleaning devices for
eliminating caking and blockages of the tertiary air duct.
Machine manual Safety
DOPOL® Tertiary air duct MSC with extraction from cooler 3

 Do not enter the interior of the plant component until you have
sufficiently purged it with fresh air and it has sufficiently
cooled down. Make sure that there is sufficient oxygen inside
the machine and that no hot gases can enter it.
 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.
Use dust protection masks as protection against the large
quantities of dust which must be expected.
 Make absolutely certain that nobody can gain access to the
clinker cooler while the tertiary air duct is being cleaned. It is
possible that raw meal could flush through right into the
clinker cooler. Danger of being buried alive and dying of
suffocation!
 When performing work inside the machine, make sure that no
raw meal or other loose parts can fall down on you from the
upper section and make sure that persons in subsequent plant
sections are not endangered. Danger of being buried alive and
dying of suffocation!
 For maintenance work to be carried out inside the plant, you
may have to install auxiliary platforms. These auxiliary
platforms must be of stable design.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances for cleaning the machine.
 Switch off the power supply to the electrical components
before commencing any maintenance work.
 All electric cables in the vicinity of the preheater must be
protected against contact with hot raw meal falling from the
preheater.
Provide suitable covers.
 After all maintenance work, check all the earthing bridges to
ensure that they will function correctly.
 Strictly observe the welding instructions when performing any
welding work.
 When electric arc welding or cutting are being performed, you
must ensure that the personnel cannot come into contact with
electrically conductive components.
Safety Machine manual
4 DOPOL® Tertiary air duct MSC with extraction from cooler

 Never situate the source of the welding current in a confined

space where walls have conductive properties. Only use 24-
Volt lamps for illuminating the interior of the machine.
 If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other movable connections or measuring devices.
Always directly connect the welding current return lead to the
part being welded.
 Remount all protection devices when maintenance work has
been finished. Make absolutely sure that no persons are inside
the plant component before properly closing the inspection
and service covers again.
 Machine manual Components and mode of functioning
DOPOL® Tertiary air duct MSC with extraction from cooler 1

3 Components and mode of functioning

Within the kiln plant, the function of the tertiary air duct MSC (6)
is to supply the calciner with additional combustion air. This
additional combustion air is hot exhaust air from the clinker
cooler. The following figure shows the tertiary air duct MSC,
connected to the clinker cooler.

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® Tertiary air duct MSC with extraction from cooler

Items shown in the drawing

6.1 Main duct

6.2 Top air duct
6.3 Extraction chamber
6.4 Supports
6.5 Sliding-element expansion joint (side of the cooler)
6.6 Sliding-element expansion joint (side of the calciner)
6.7 Expansion joint (top air duct)
6.8 Expansion joint (extraction chamber)
6.9 Throttle device in the main pipe
6.10 Throttle device in the top air duct
6.11 Tensioning rope
50, 53 Access doors and manhole covers

NOTE
Some of the supports (6.4) are designed as joint. These supports
follow the changes in piping length. The other supports are
designed as rigid support brackets.
The tertiary air duct MSC is provided with an internal refractory
lining.
For inspection and maintenance work on the tertiary air duct
MSC, access doors are provided.
 Machine manual Components and mode of functioning
DOPOL® Tertiary air duct MSC with extraction from cooler 3

Figure 2
Components and mode of functioning Machine manual
4 DOPOL® Tertiary air duct MSC with extraction from cooler

3.2 Mode of functioning

The tertiary air duct MSC runs from the extraction chamber (6.3)
along the rotary kiln in the direction of the precalciner.
The tertiary air is conducted through the main duct (6.1) and
through the top air duct (6.2) in the calciner for two-stage
combustion in two levels.
The air is distributed by the throttle devices (6.9 and 6.10).
In the following figure, the arrows represent the gas stream in the
tertiary air duct MSC.

NOTE
For further information see the separate machine manual for the
transition element AS.
 Machine manual Components and mode of functioning
DOPOL® Tertiary air duct MSC with extraction from cooler 5

Figure 3
Machine manual Transport and assembly
DOPOL® Tertiary air duct MSC with extraction from cooler 1

4 Transport and assembly

4.1 Transport and storage instructions

The machine is transported in single parts or in subassemblies. It

must be ensured that suitable lifting equipment is employed for
lifting 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.
Refractory lining material must be stored in accordance with the
supplier’s instructions.

4.2 Assembly

General notes
The following assembly instructions do not detail the individual
steps for assembling the machine units but rather give 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 these assembly
instructions.

NOTE
It is a prerequisite of our warranty that final assembly and
assembly inspection are undertaken by an assembly specialist
from POLYSIUS AG.

We recommend that the assembly work is supervised from start

to finish by an assembly specialist from POLYSIUS AG.
A careful selection of the tools and appliances as well as the
assembly personnel to be employed is important for the correct
performance of the work.

CAUTION
If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring
devices, in order to prevent damage to these parts.
Transport and assembly Machine manual
2 DOPOL® Tertiary air duct MSC with extraction from cooler

Always directly connect the welding current return lead to the

part being welded.
Machine manual Transport and assembly
DOPOL® Tertiary air duct MSC with extraction from cooler 3

Sequence of assembly

If the overall situation on site permits, all components can be

preassembled and welded on the ground.
The arrangement of the tertiary air duct is shown in the general
arrangement drawing and the assembly drawing.
Do not install the refractory lining until all components have been
mounted.
You must make the openings and breakthroughs for the
observation ports, as well as all other openings (e.g. for sensors
and probes) before installing the refractory lining. If these
openings and breakthroughs are subsequently installed, you have
to drill through the hard lining. This, firstly, causes a lot of work
and secondly, the refractory lining would be damaged at the
respective points.
In this phase of installation, also make the evaporation holes
which are required for drying the refractory lining prior to the first
commissioning of the plant.

NOTE
Make sure that all electric cables in the vicinity of the preheater
are protected with covers against contact with hot raw meal.
Machine manual Lubrication
DOPOL® Tertiary air duct MSC with extraction from cooler 1

5 Lubrication

CAUTION
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.

Lubrication chart

Lubrication points

No. Qty. Designation Comment

1 Throttle device in the main See separate machine manual

pipe

2 Throttle device in the top air See separate machine manual

duct
Machine manual Preparation for the test run
DOPOL® Tertiary air duct MSC with extraction from cooler 1

6 Preparation for the 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.

6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run,
check all parts of the plant according to the list below. Make
absolutely sure that any material remnants, tools and assembly
aids have been completely removed.
 Were all bolts tightened according to instructions?
 Were all flange connections screwed on tightly?
Were the prescribed seals fitted?
 Was the refractory lining installed in accordance with the
manufacturer’s instructions? Was the prescribed setting time
adhered to?
 Were all non-conductive connections bridged with earthing
straps?
 Were the transport and assembly securing devices of the
expansion joints removed?
 Were the expansion joints installed with the prescribed
preloading?
 Were the sliding-element expansion joints correctly adjusted?
 Were all doors and inspection ports tightly sealed?
 Were all protection devices and all warning signs correctly
mounted?
 Were support brackets ensuring correct functioning installed?
 Were the evaporation openings drilled for hardening and drying
of the refractory lining closed again?
(Only for the first commissioning!)
 Were all measurement holes sealed with the provided sealing
covers? (Only for the first commissioning!)
 Were the tensioning ropes, if installed, correctly tensioned with
the aid of the turnbuckles?
Machine manual Maintenance
DOPOL® Tertiary air duct MSC with extraction from cooler 1

7 Maintenance

7.1 Inspection

Inspection work is, as far as possible, subdivided into:

 Inspections during operation and
 Inspections during a longer stoppage of the kiln plant

Inspections during operation

CAUTION
Do not touch the preheater surfaces during operation and
immediately after a shutdown.
All the surfaces of the preheater are hot. Danger of suffering
burns!
Wear the required protective clothing.

No. Work to be performed Frequency Comments

1 Check plates and welds on the duct weekly

and its supports for cracks
2 Check the duct for swellings and weekly
bulges
3 Check anchorages of the supports for weekly
perfect condition
4 Check support brackets weekly
5 Check the pretensioning of the weekly The tensioning
tensioning ropes (6.11) (if existing) ropes must not
sag
6 Checking of foundations for every 3 When no
settlement or tilting months foundation
settlements can
be detected
after one year,
the intervals can
be extended to
once per year.
Maintenance Machine manual
2 DOPOL® Tertiary air duct MSC with extraction from cooler

NOTE
Permitted foundation settlements:
1. Acceptable settlements of the foundations relative to the
preheater and/or the burner’s platform: max. 25 mm.
2. Settlements transversally to the tertiary air duct axis (tilting of
the foundation on one side): max. 5 mm.
3. Difference between the settlements of neighbouring
foundations: max. 5 mm.

Inspections during a longer stoppage of the kiln plant.

Be sure to allow an adequate time for cooling down and

degassing before anybody goes inside the plant.

When performing work inside the machine, make sure that no

loose parts can fall down on you from the upper section and make
sure that persons in subsequent plant sections are not
endangered.

DANGER
Because of raw meal falling down when you enter the interior of
the tertiary air duct.
You could be suffocated or buried alive.
Do not enter the interior of the tertiary air duct until you have
made absolutely sure that no deposits of meal can fall on you.
When entering the interior of the tertiary air duct.
You could inhale raw meal dust and be exposed to high
temperatures.
Do not enter the interior of the tertiary air duct until it has
been flushed with fresh air and has cooled down. Make
absolutely sure that no hot gases can enter. Wear a dust
protection mask.

No. Work to be performed Frequency Comments

1 Check the refractory lining for annually

smooth surface and perfect edges
2 Check throttle devices for ease of annually
movement and wear
3 Check the ease of movement and annually
proper functioning of the
compensation elements
Machine manual Maintenance
DOPOL® Tertiary air duct MSC with extraction from cooler 3

4 Check the height and type of the annually see note

clinker dust deposit

NOTE
According to experience, the height of the deposits does not
change after the plant has been in operation for some time. Due
to the deposits, an optimum dust-conveying speed occurs in the
duct. After a stable dust deposit has become established, all
subsequent clinker dust is carried by the gas into the calciner. It
is therefore not always necessary to clean out the dust from the
tertiary air duct.

7.2 Servicing

DANGER
Because of raw meal falling down when you enter the interior of
the tertiary air duct.
You could be suffocated or buried alive.
Do not enter the interior of the tertiary air duct until you have
made absolutely sure that no deposits of meal can fall on you.
During all work carried out inside the tertiary air duct.
Mortal danger! You could be accidentally shut in the tertiary
air duct.
Before, during and after maintenance work the Plant Manager
must make absolutely sure that the working area is cordoned
off and made safe, and that all possible measures are taken
to assure the safety of the maintenance personnel.

No. Work to be performed Frequency Comments

1 Repair damaged refractory lining as required Fill expansion

joints in
accordance with
manufacturer’s
instructions
2 Replace damaged throttle devices as required
3 Replace damaged expansion joints as required
Maintenance Machine manual
4 DOPOL® Tertiary air duct MSC with extraction from cooler

4 Height corrections with packing as required If the foundation

plates at the supports settlements are
larger than
permitted.

7.3 Trouble shooting

Trouble shooting measures for possible faults are described in

the operating manual of the overall plant. If faults occur in the
throttle devices, consult the relevant machine manual for exact
information.
Machine manual Maintenance
DOPOL® Tertiary air duct MSC with extraction from cooler 5

7.4 Repair

Before beginning any repair work, switch off the power supply to
all electrical components.
Ensure absolute cleanliness at all times during repair work in
order to prevent dirt from entering the bearings, the drive units or
other sensitive parts of the machine or plant.

DANGER
During all work inside the tertiary air duct.
Mortal danger! You could be accidentally shut in the tertiary air duct.
Before, during and after maintenance work the Plant Manager must make
absolutely sure that the working area is cordoned off and made safe, and
that all possible measures are taken to assure the safety of the maintenance
personnel.

During a longer kiln stoppage, check the filling mats in the

expansion joints of the refractory lining and replace them if they
are even only slightly damaged. The ceramic fibre mats and also
other fillers in the expansion joints between the bricks prevent
the expansion joints from being blocked by dust and raw meal.
Blocked expansion joints can no longer compensate for the
thermal expansion of the bricks. The refractory lining and the
steel parts may be damaged.
The refractories drawing shows the position of the expansion
joints.

CAUTION
After you have completed the repair work you must check the machine/plant
again according to section Preparation for test run.

Tools and auxiliary devices

No special tools are required for repair work on the machine.
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 conditions in your plant.
Machine manual Spare parts
DOPOL® Tertiary air duct MSC with extraction from cooler 1

8 Spare parts

Suggestions for enquiries and orders of 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® Tertiary air duct MSC with extraction from cooler

Figure 4
 Machine manual Spare parts
DOPOL® Tertiary air duct MSC with extraction from cooler 3

Code Word: Order-Number: POC:

Item Designation Qty. Unit Order Enquiry

6.5.1 Guide duct 1 Piece

6.5.2 Sliding-element expansion 1 Piece

joint

6.5.3 Seal (packing) 1 Piece

6.6.1 Guide duct 1 Piece

6.6.2 Sliding-element expansion 1 Piece

joint

6.6.3 Seal (packing) 1 Piece

6.7.1 Expansion joint 1 Piece

6.7.2 Expansion joint 1 Piece

6.8.1 Expansion joint 1 Piece

6.8.2 Packing 1 Piece

6.11 Tensioning rope 1 Piece

Figure 5
Spare parts Machine manual
4 DOPOL® Tertiary air duct MSC with extraction from cooler

Spare parts for the access doors (50) and the manhole covers (53)

Figure 6

Code Word: Order-Number: POC:

Item Designation Qty. Unit Order Enquiry

50 Access door 450 x 900 1 Piece

(steel)

50.1 Access door 450 x 900 1 Piece

(cast metal)

53 Manhole cover Ø 420 1 Piece

(steel)

53.1 Manhole cover Ø 420 1 Piece

(cast metal)
Machine manual Appendix
DOPOL® Tertiary air duct MSC with extraction from cooler 1

9 Appendix

9.1 Technical drawings

Designation Drawing no.

Tertiary air duct