Problems and solutions in the process of rotary kiln cylinder installation Henan Hongxing


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Problems in the installation of rotary kiln shell and its treatment

stay Rotary kiln In the installation process of the cylinder, affected by various factors, some common problems are easy to appear, such as the inconsistent groove of the butt joint, the out of tolerance of the misalignment at the butt joint, and the straightness after the cylinder assembly. Aiming at these problems, the effective methods are given below.

 Rotary kiln shell

1. Inconsistent groove of butt joint and treatment measures

10 pieces of 90 ° bending plates with clearance adjustment can be made with 3mmx40mm flat steel. The 90 ° bending plates are evenly distributed and spot welded at the corresponding groove of the second large section, and the right angle side is placed in the inner side of the cylinder, so that the butt groove of the second large section can be formed into a right angle plane artificially. Then 16 tension bolts (m48x400mm) are used to connect the two sections, and the gap between the two sections is 3mm. Adjust the misalignment of the cylinder by adjusting the pressure plate, and weld the 8 connecting plates across the welding seam uniformly in the cylinder after passing the test. First, the outer circumferential seam is welded by manual arc welding. After several layers of welding, the circumferential seam in the cylinder body is gouged to produce a new V-shaped groove, and then manual welding is carried out. After several layers of welding, the welding stops and the whole full welding is carried out after the cylinder body is aligned.

2. Out of tolerance of misalignment at the interface and treatment measures

The serious alignment misalignment has a negative impact on the cylinder alignment. Therefore, the following measures are taken.

(1) For the large segments assembled on site, measure the perimeter of two pairs of each segment, and calculate the diameter and misalignment. During the alignment, try to adjust the misalignment according to the large diameter to the large diameter and the small diameter to the small diameter.

(2) For the large section of the small section of the butt weld misalignment out of tolerance area, repair processing. Among them, the weld with misalignment less than 6 mm shall be ground to achieve a smooth transition; the weld with misalignment greater than 8 mm shall be ground at high place and repaired at low position, and the staggered area shall be smoothly transferred according to 1:5 gradient; the local concave area shall be repaired and ground after welding.

3. Straightness out of tolerance after cylinder assembly and treatment measures

The following measures can be taken to solve this problem.

(1) Weld the support frame at the butt joint of each large section, find out the cylinder center point on the support frame and mark it.

(2) Take the connecting line of the cylinder center at the head and tail wheel belts as the reference line, and mark the deviation value between the section center and the reference line.

(3) Rotate the cylinder properly, turn the center point of a section above the reference line, and use the self weight of the cylinder to make the cylinder sink and make the center point close to the reference line. After confirmation, reinforce the connecting bolts and plates.

(4) For the parts with large deviation, loosen the connecting bolts and connecting plates properly, and then align them. After the parts are qualified, re connect and fix them.

(5) Local bending parts are heated by flame to correct bending.

(6) Manual arc welding is used for back sealing of outer circumferential seam. The groove gap is filled, and the groove is ground with grinding wheel, and then manual welding is carried out until submerged arc welding can be carried out. Among them: after 2-3 layers of submerged arc welding for outer circumferential seam, the inner circumferential groove of cylinder is processed by carbon arc air gouging until the welding flesh of outer ring seam is seen; automatic submerged arc welding is used for inner circumferential seam, and the weld reinforcement is less than 0.5mm; the outer ring seam is fully welded with submerged arc welding, and the weld reinforcement is less than 2mm.

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