Rotary kiln spherical tile craze emergency response plan

Rotary kiln spherical tile craze emergency treatment scheme 2020 - 01 - 09 1 fault phenomenon a company & empty; 5. 4 m× 82 MB of rotary kiln was completed and put into production in October 2017, between December 2017 and April 2018 winter peak production period, the residual water in the water roller tile and tile with compressed air to blow dry, on April 28, 2018, the kiln ignition temperature, 29, after feeding the normal temperature, normal lubrication. Kiln feeding on April 30, 450 t/h, inspection personnel inspection found when corner roller kiln head supporting wheel tile ( As shown in figure 1, 1 - for short 1 # wheel (w) Shaft seal leakage is serious, the roller oil without oil level displays, wheel inside the tank is full of oil-water mixture. Open the cover after the observation hole and side cover found that circulating water leakproof, import and export joint roller inside the bowl is only a small amount of oil emulsion turbidity, bearing with spherical tile surface in drip drip, preliminary suspect spherical channel leakage, damage. Layout schematic chart 1 kiln head wheel 2 fault diagnosis and emergency plans to determine fault found although temperature is not high, but the axial plane cannot establish an effective oil film, continue to work at any time may burn, decided to shut down. Through communication with the design institute, the company spherical tile for non-standard design, do not have the same type spare parts, processing new tiles need to be more than 20 d, cycle is too long can't meet the production requirements. In order to minimize losses, must carry on the emergency treatment of sphere tile, ensure that rotary kiln in the shortest possible time. Barrel temperature cooled to about 50 ℃, with two 500 t hydraulic top 1 belting leather jacking, with 300 t hydraulic top roller jacking, copper tile and sphere tile, down the group identified as spherical tile damage of channel. Observed the crack condition as shown in figure 2. Figure 2 above spherical channel crack spherical watts crack, crack circumference direction along the tile surface is about 1000 mm long, 1 ~ 2 mm wide. Roller spherical tile is made of grey cast iron HT2040, not only the welding performance is poor, they cannot guarantee the bearing load, after welding and the welding conditions and welding technology demanding. Such as welding processing, needs to be heated to 300 ~ 600 ℃ and constant temperature, is used for welding of ductile cast iron welding rod heated to 150 ℃, and then make welding welding, welding must be carried out in the process of stress elimination. Combined with the field situation, there is no guarantee that the welding conditions and welding quality. Measured on either side of the tile surface crack plane gap in 0. 06 ~ 0. 1 mm, the question of company technical staff after discussion don't think too much influence on the stress of the copper tile, therefore decided to adopt the following solution to repair: first use mechanical fixed to continue to develop ways to prevent crack; The second special metal repairing adhesive crack sealing daub; Finally using surface repairing adhesive for leveling spherical tile surface. 3 urgent measures implementation process ( 1) Will the oil on the surface of the sphere tile internal and clean. （ 2) In the distance, respectively, to open the crack 2 ~ 3 mm on both ends & empty; Check in, depth of 6 mm is equal to the spherical channel wall 50 mm. （ 3) On both sides along the crack processing 30 mm wide 20 mm deep V groove and wool processing. （ 4) In spherical surface with the vertical direction of crack processing nine aspect deeply 120 mm & times; 30mm× 20 mm oval groove, the distance of about 110 mm, on both sides of groove machining 2 M16 threaded hole, as shown in figure 3. Figure 3 of sphere tile cracks by mechanical fixed way, 5) Use & delta; = 16 mm of Q235B steel making 9 pieces of 120 mm & times; 30 mm connection plate, sink hole drill steps on both ends with square threaded hole corresponding to the groove. （ 6) With M16 & times; 50 mm socket head bolts ( 10. 9) Work out slope will connect plate installed on the square groove, the crack on both sides of the spherical navarre, avoid cracks continue to grow. （ 7) With the crack after cleanser, apply respectively special glue to fill wall of micro cracks, with a special metal repairing adhesive on crack filling, leveling, daub after the completion of the electricity heating drying, heat preservation. （ 8) Repairing adhesive completely after solidification, channel of sphere tile cleaning, suppression test, pressure is zero. 13MPa（ 50% of the standard test pressure) And pressure maintaining 15 min. （ 9) Back pack bearing, spherical watts after grinding tests, due to the bearing shell strain and produce certain deformation after spherical tile cracks, bearing and shaft in 30 mm & times; 30 mm only 1 ~ 2 area contact point, contact less research is difficult, need to be adopted in the operation of the high viscosity of lubricating oil in the tile is heavy. 4 treatment effect back after completion of loading, feeding, feeding rate of t/h and steadily from 260 to 530 t/h, tile temperature display is normal, basic remain at around 30 ℃, found no leaking. During the subsequent operation, to extend the use of time, keep the inventory in about 90% of the rated capacity, success to shutdown maintenance. This event after 144 h feeding operation, is a more successful case of repair, hope to provide reference in dealing with similar ideas. （ Source: China cement spare parts network)