General Maintenance and Alignment of Rotary Equipment · The shell under the tire and gear \⠀猀瀀爀漀挀欀攀琀尩is designed to support th對e tire and drive system components.\爀䘀氀椀最栀琀猀㨀
Specialize in Design and Fabrication Unmatched Engineering In Rotary
Equipment 50 Years Field Service Experience
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Our leadership is built from well over 50 years experience. We have provided you with unmatched engineering…….. Jerome Menzia3/6/2009 There are three Generations of Menzia's working toward delivering a quality product to meet our customers expectations and project commitments. Jerome Menzia3/6/2009 Our over 30,000 square foot shop is equipped with over 100 ton crane capacity and houses our state of the art equipment used in the fabrication of rotary equipment. Alot of our tooling has been design by us to solve issues associated with field istallation and repair of rotary equipment. Jerome Menzia3/6/2009 Many of the designs of we use in our rotary equipment are based on the our extensive experience in the repair and maintenance of rotary equipment. Jerome Menzia3/6/2009 My father Joseph still works every day in the shop and brings over 50 years experience himself into every fabricated piece that leaves our shop.
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
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Shell: is fabricated from steel plate (varying in thickness & material) depending on process application and other factors such as: temperature, lengths, refractory, flights, etc. . The shell under the tire and gear (sprocket)is designed to support the tire and drive system components. Flights: Installed inside the drum to allow for push (spiral) and cascade (saw tooth, cup, J-flight and L-flight) of the product as it flows through the dryer. The combustion flight is also used in Direct Fire Dryers to insulate the primary heat zone.
Trunnion (Support) Bases
Trunnion
Rollers(Rolls) Thrust Rollers Pillow Block
Bearings Adjusting Screws
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Trunnion (Support) Bases: A steel frame where the trunnion rollers are set. Trunnion Rollers(Rolls): are generally fabricated from a forging, although cast trunnions remain commonly used. Thrust Rollers: operate off the side of either the downhill or uphill tire to maintain the drum in position on the trunnion rolls; as well as maintains proper mesh of the pinion gear on the drive gear.
Tires(Riding Rings) Floating Pad (Filler Bars)
Tire Retaining Bars
Side Blocks
End Blocks
Shims
Shim Keeper
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Tires(Riding Rings): fabricated either from a casting, forging, or rolled ring may be of any one of a number of widely used designs including segmented tires, lap-joint and single piece tires. Floating Pad: The most common method to mount the tire is the free-floating pads system. In some instances, tires are welded to a shell. Floating pads are locked, but NOT welded to shell. Using four side blocks, floating pad is held in place circumferentially. Floating pads are sized to allow greater than 60% coverage under the tire. Floating pads are held laterally by end blocks and by the tire retaining bands. The shims are held in place by the shim keeper.
Gear Ring Pinion
Jack Shaft
Chain Reducer
Sprocket
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The Gear Ring: is mounted to the shell. Gears typically are mounted to the shell via a mounting “flange” or tangential plates. Pinnion: is the drive gear for the gear ring. Jack Shaft: is a shaft that the pinnion or drive sprocket is mounted to allow easier access for alignment. Sprocket: is an alternative cost effective approach to rotate dryers. A chain around the shell is used to rotate the dryer.
Firing Hoods Combustion Chamber
Discharge Hoods
Seals Conveyors
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Firing Hoods and Combustion Chambers: Are included as required in accordance with the overall process application. The firing hood may be retractable or stationary. Seals: Primarily used to control the movement of air and product at the points where the feed or discharge ends of equipment. Many various adaptations are used in the industry.
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
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As you can see on the picture there are punched “Marks” at the center of the base indicating the centerline of the dryer. The trunnion shaft centerlines and the design distance from the centerline are also marked on the frame. The surface of the trunnion rolls MUST be parallel to the surface of the riding ring. The trunnion roll shafts of each pair of trunnion rolls must be absolutely parallel with each other. The cylinder MUST be carrying its normal load of material when the final adjustment is made. The finished top surfaces of the trunnion bases MUST NOT be warped by improper wedging and grouting of the bases on the foundations. The slope of the dryer is set by the mounting of the bases on the piers.
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.
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Positioning of thrust rollers has a direct impact on the dryer performance. The centerline of the thrust rolls on the trunnion base is offset by greater than 0.25” from the centerline between the trunnion roll shafts. This offset allows for the tire to rotate downward onto the thrust rolls forcing them onto the thrust shafts. The gap between the thrust rolls and the tires are set for safety reasons. This distance between the thrust rolls should be 0.38” greater than the width of the tire. This small allowable movement of the rotary dryer maintains the proper position of the tires on the trunnions as well as the pinion and bull gear positioning. The rotary dryer should be in perfect position when the tire is just touching the downhill thrust roll.
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)
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Many riding rings, trunnion rolls, and thrust rolls have been worn out long before they have been given a fraction of their proper service. Frequently the equipment manufacturer is blamed for using poor materials because of the rapid wear of riding rings and trunnion rolls. Improperly “trained” trunnion rolls may run for weeks without much evidence of distress. Once the distress shows up, the effect is cumulative and the trouble usually advances rapidly to a critical stage. A cylinder can be improperly adjusted on its rolls, and still float between the thrust roll, but it will wear out one set of trunnion rolls after another. (FE Pier Rolls opposing force to DE Rolls.) When a new cylinder is first put into service, the thing to watch is the surface of the riding rings. If they become smooth and bright, without “ripple” marks or small, seemingly slight “pattern” figures repeated over and over as the ring revolves.
Backlash can be measured as shown
A strobe can be used to see contact surface in operation
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Positioning of thrust rollers has a direct impact on the dryer performance. The centerline of the thrust rolls on the trunnion base is offset by greater than 0.25” from the centerline between the trunnion roll shafts. This offset allows for the tire to rotate downward onto the thrust rolls forcing them onto the thrust shafts. The gap between the thrust rolls and the tires are set for safety reasons. This distance between the thrust rolls should be 0.38” greater than the width of the tire. This small allowable movement of the rotary dryer maintains the proper position of the tires on the trunnions as well as the pinion and bull gear positioning. The rotary dryer should be in perfect position when the tire is just touching the downhill thrust roll.
Infrared temperature measurements Dotted lines shows misaligned temperature
profile Solid line shows correctly aligned temperature
profile
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Presentation Notes
Positioning of thrust rollers has a direct impact on the dryer performance. The centerline of the thrust rolls on the trunnion base is offset by greater than 0.25” from the centerline between the trunnion roll shafts. This offset allows for the tire to rotate downward onto the thrust rolls forcing them onto the thrust shafts. The gap between the thrust rolls and the tires are set for safety reasons. This distance between the thrust rolls should be 0.38” greater than the width of the tire. This small allowable movement of the rotary dryer maintains the proper position of the tires on the trunnions as well as the pinion and bull gear positioning. The rotary dryer should be in perfect position when the tire is just touching the downhill thrust roll.
Presenter
Presentation Notes
Positioning of thrust rollers has a direct impact on the dryer performance. The centerline of the thrust rolls on the trunnion base is offset by greater than 0.25” from the centerline between the trunnion roll shafts. This offset allows for the tire to rotate downward onto the thrust rolls forcing them onto the thrust shafts. The gap between the thrust rolls and the tires are set for safety reasons. This distance between the thrust rolls should be 0.38” greater than the width of the tire. This small allowable movement of the rotary dryer maintains the proper position of the tires on the trunnions as well as the pinion and bull gear positioning. The rotary dryer should be in perfect position when the tire is just touching the downhill thrust roll.
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
