General Maintenance and Alignment of Rotary Equipment · The shell under the tire and gear...
Transcript of General Maintenance and Alignment of Rotary Equipment · The shell under the tire and gear...
Presented By…
Three Generations
Specialize in Design and Fabrication Unmatched Engineering In Rotary
Equipment 50 Years Field Service Experience
Components of Rotary Equipment Alignment of Trunnions, Tires, Pinions, Gears,
and Thrust Rolls Lubrication of Components
Daily, Weekly, and Annually Inspections General Maintenance
Shell
Flights Discharge Barrel
Trunnion (Support) Bases
Trunnion
Rollers(Rolls) Thrust Rollers Pillow Block
Bearings Adjusting Screws
Tires(Riding Rings) Floating Pad (Filler Bars)
Tire Retaining Bars
Side Blocks
End Blocks
Shims
Shim Keeper
Gear Ring Pinion
Jack Shaft
Chain Reducer
Sprocket
Firing Hoods Combustion Chamber
Discharge Hoods
Seals Conveyors
Case In Point: The more the tire keeps the shell round (contained), The less the pad is allowed to warp (deflect) and the less working (thus cracking) of welds
There is hardly a mechanical adjustment so simple and yet so often incorrectly made, as the training of trunnion rolls to make the cylinder “float” between the thrust rolls.
“y” is known from the original manufacturer’s design. (Height of shell in hood) “h” Add ½ the diameter of the tire and ½ the diameter of the trunnion. “x” Can be calculated “α” Can be calculate. (generally around 30 ° angle)
y
h
x x y h
x α
α α
Move Trunnions to neutral position. ( “X” dimensions are equal)
Shim pillow blocks of smaller
diameter trunnion rolls. If Tires are different sizes shim all
pillow block bearings the same amount to obtain the correct height of drum.
Now make skew adjustments to float drum
y
h
x x y h
x α
α α
The ideal position is light “off-and- on” contact between the riding ring and the downhill thrust roll.
“Training” of trunnion rolls is the
same as skewing rollers under a heavy box, to affect a sideward as well as forward motion.
When the trunnion rolls are exactly
parallel to the cylinder axis and to the face of the riding rings, there is NOT enough force from the rolls to balance the “downward” thrust of the cylinder in the direction of its slope.
To offset this tendency and
overcome this force, a slight skewing of the trunnion rolls is all that is required.
First, number the adjusting screws. Make sure adjusting screws are tight against bearings. Next, take all tension off the bearing bolts.
Set up a magnetic based dial indicator
behind the bearing. Establish good contact with bearing base and set indicator to zero.
Screw in adjusting screws (2), (3), (6), and (7)
EXACTLY at .010” each. Snug down bearing bolts and rotate cylinder with power for ten (10) minutes (BY THE CLOCK).
If the cylinder does not change axial
position, loosen bearing hold down bolts and proceed this time by placing dial micrometer at base of bearing. Screw out adjusting screws (1), (4), (5) and (8) at exactly .010 each.
FE C L
C L
DE
36” 36”
36” 36”
36”
36”
36”
36”
Pier # 1
Pier # 2
The drum will float downhill with the slope of the dryer until the thrust roll stops the drum
C L
C L DE
FE 29.9” 36.1”
36.1” 29.9”
36.1”
36.1”
29.9”
29.9”
Pier # 1
Pier # 2
C L
C L DE
FE 36.1” 29.9”
29.9” 36.1”
29.9”
29.9”
36.1”
36.1”
Pier # 1
Pier # 2
Uphill Skew All Trunions Downhill Skew All Tunnions
C L
C L
DE
FE 29.9” 36.1”
36.1” 29.9”
29.9”
29.9”
36.1”
36.1”
Pier # 1
Pier # 2 Uphill Skew Pier #2
Downhill Skew Pier #1
Opposing Forces
C L
C L
DE
FE 36.1” 36.1”
29.9” 29.9”
29.9”
29.9”
36.1”
36.1”
Pier # 1
Pier # 2
Pigeon Toed – Opposing forces Pier # 2
Downhill Skew Pier # 1
Offset the thrust roll centerline 0.25” toward the downward rotation 0.38” Gap between Thrust Rolls and Tire Pinion and Tires on Rolls in perfect position when dryer resting on downhill thrust.
Train the empty cylinder to favor the downhill thrust roll in “float” or actual light contact on the lower thrust roll.
When the cylinder is loaded with material it will
have a tendency to move downhill due to the extra weight. Watch the cylinder movement and adjust only if necessary to keep the fully loaded cylinder “floating” between the thrust rolls.
A properly adjusted set of trunnion rolls will
cause a constantly loaded cylinder to “float” between the thrust rolls for weeks at a time without the riding ring touching either of them.
Preferably the tire should be resting on the
downhill thrust roll approximately 80% of the time. When empty, the cylinder should travel uphill against the upper thrust roll (feed end thrust roll).
Steel flake forming on shafts of Trunnion Rolls
Regular patterns forming on Tires Uneven polish on Tires Rolled over edges on Tires Mushrooming of Thrust rolls Tunnion Shafts breaking
Bearings failing(overheating)
Backlash can be measured as shown
A strobe can be used to see contact surface in operation
Infrared temperature measurements Dotted lines shows misaligned temperature
profile Solid line shows correctly aligned temperature
profile
The fact that there are so many variations and methods, lubricants and operating conditions, it becomes impractical to make specific
recommendations covering all cases.
HAND LUBRICATION: Pour buckets of hot grease on gear, brush grease on gears, grease pans etc.
MECHANICAL: Automatic greasing systems spray
grease directly on gears intermittently. Bearings are sealed and a large grease reservoir
requires only occasional lubricant replenishing. A graphite stick holder is available to provide
continuous lubrication of the thrust rolls, tires and trunnions .
How do I get the full lifetime of the components?
How often should I perform
maintenance? What will it cost?
Pitting Spalling Cracking
Marking
Irregular Face Profiles
Improves Mechanical Efficiency
No Costly Downtime
Maximizes Equipment Life
Reduces Operation Costs
Vibration Rolled over edges High power consumption Alignment issues Premature bearing failure Damaged bases, piers, and footings
Hot spots evident on dryer shell? Any unusual sounds or vibrations? Leakage of air or product at feed or discharge
hoods? Condition of nose ring seal? Support frames and piers vibrations or movement? Tire patterns, ridging, wobble, pad welds and
movement? Dryer thrusting uphill or downhill? Bearing temperatures normal? Spray grease on gear operating?
Startup emergency drive engine Check graphite block lubrication Check creep or gap on tires Lubricate between floating pads and tire ID Clean pier tops and remove built up product Check all lubrication levels
Check pitch line separation on gear and pinion Check pitch line run out Check condition of welds on gear flange or spring
flange Check for excessive ring or roller wear
Change gear lube and clean sump and gear area Change grease on pinion shaft bearings Change grease in thrust roller bearings Inspect dryer shell for cracks under tires
Check refractory for wear
Inspect drive coupling grid members
Check alignment and elevation of each pier Adjust the rollers to neutral to retrain the dryer Weld repair cracks in shell, floating pads and
support bars Clean and inspect gear, repair broken bolts and
flanges
Clean and grease adjustment bolts
ITEM CHECKED Sunday Monday Tuesday Wednesday Thursday Friday Saturday COMMENTS Discharge Seal
Dryer Shell
Discharge End Tire Condition
Discharge End Trunnions Condition
Riding Ring and Trunnion-Contact Pattern
Thrust Roller Surface
Feed End Seal
CONDITION KEY: E=EXCELLENT G=GOOD F=FAIR P=POOR Feed End Tire Condition
Feed End Trunnions Condition
Tire Position on Trunnions
Trunnion Bearings and Seals
Trunnion Bearing Temperature
Floating Pads- Condition and Welds
Retaining Bands-Condition and Welds
Gear Contact Pattern
Gear Lubrication Spray System
Gear Sound
Graphite Lubrication
Setup A Daily, Monthly, Quarterly and Annually Inspection Log
Borax Management for allowing the presentation of this information.
Joseph Menzia for his knowledge from 50 years of experience in equipment repair.
Ed Parsons, a long time colleague, for providing his expertise in the engineering and operation of rotary equipment .
And finally, for your patience and interest in Rotary
Equipment, we thank you.