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INSTRUCTION MANUAL .

ROTARY KILN 70000484-1

Oil start pump for supporting roller


bearing RKB

Installation, operation and maintenance

In the text, reference is made to:

Ref. 1 *) Rotary kiln


General kiln instruction manual
Erection, operation and maintenance
Ref. 2 *) General safety regulations at sites of erection
Ref. 3 *) Rotary kiln
Supporting roller bearing
Erection

*) See note Reference to instruction manuals in section 1.

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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CONTENTS: PAGE:
1. General notes ....................................................................................................... 4
2. Construction and operating principle ...................................................................... 6
3. Installation ............................................................................................................ 6
4. Operation ............................................................................................................. 8
5. Maintenance ....................................................................................................... 10
6. Key to Figures and Appendices ........................................................................... 12
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APPENDIX:
Appendix 1. Arrangement 13

Edited by: KelH Translated by: JRo Pages: 13


Approved by: KelH MGN code: 5A10
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NOTE !
The present instruction manual is concerned with the situations
which, according to the experience of FLS, are the most likely to
occur. An exhaustive enumeration of all conceivable situations
which may occur in connection with the installation, operation and
maintenance of the pump cannot be provided.

Consequently, if a situation should arise, the occurrence of which


is not foreseen in the instruction manual, and which the operator
is/or feels unable to handle, we would recommend that FLS is
contacted without undue delay for advice on appropriate action.

1. GENERAL NOTES

Oil start pumps are incorporated on supporting roller bearings


type RKB and they are used for low-speed operation of kiln.
Overall, the purpose is to pump oil from the sump to the
supporting roller bearings up to the oil tray at the top of the
supporting bearing, thereby supplying the additional oil
required for the lubrication of bearings. See instruction
manual ref. 3.

References to instruction manuals


In the text of this instruction manual, reference is made to an
instruction manual reference No. where this is deemed to be
relevant.
The titles of all instruction manuals referred to are listed on the
front page of this instruction manual, with indication of the
number referred to.
Reference to other instruction manual numbers is done via the
General kiln instruction manual, ref. 1 in which relevant
instruction manual numbers can be identified on the basis of the
title of the relevant manual.

REQUIREMENT:
Pump to be used exclusively for the aforementioned purpose!
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MANDATORY!
The directions outlined in instruction No. ref. 2
"General safety regulations at erection site" must be
strictly observed at the site of erection. This
instruction manual must be scrutinized by the client,
the erection contractor and FLS representatives
before erection work is started.

MANDATORY!:
The erection/maintenance activities described in the
following sections must only be carried out by skilled
machine specialists or subject to the supervision of
such specialists.

MANDATORY!:
The erection/maintenance activities described in the
following sections must only be carried out by skilled
machine specialists or subject to the supervision of
such specialists.

MANDATORY!:
In connection with arc welding and when operations
involving blowtorching with gouge are carried out, the
return cable must always be attached to the object
subjected to welding, as close as possible to the area
of welding.
The return cable must never be attached in a way
which will cause the return current to be passed
through parts not connected to the object being
welded, for example: moving parts, bearings,
electrical installations or any other parts.
A return current through a bearing may give rise to
welding scars which will cause severe damage to
bearing.
A return current through electrical installations may
cause serious damage to protective earth lines
(extremely hazardous condition!) or electronic
equipment.

Where ERECTION CHECK is specifically called for in the


erection manual, this means that the FLS erection supervisor
must inspect and approve the parts mounted before permission
to proceed with the erection work can be given.
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2. CONSTRUCTION AND OPERATING PRINCIPLE

An oil pump (8) is mounted on RKB supporting roller bearings


(1) specifically for the purpose of supplying oil to the bearing
journal when the kiln is rotating at a low speed, i.e. less than
0.5 rpm. The oil pump is a gear wheel pump which supplies
approximately 5 litres of oil per minute.

The oil is directed from the base part (2) of the bearing
housing directly to the pump from which it is pumped to the
top part of the bearing housing (3) and led down to the oil tray
(4).

At the pump outlet end, a flow sensor (12) is mounted; its


function is to give alarm in case of a zero flow rate during the
operation of the pump.

Lockout of kiln motor as a result of irregularities during pump


operation is not foreseen, but an alarm must be tripped if a
zero flow rate is ascertained.

3. INSTALLATION

See separate arrangement drawing indicating the installation


procedures for the oil pump system.

All pipes, fittings and hose must be cleaned prior to


installation.

The flange with oil level glass (5), bends, fittings and ball
valve (6) is mounted on the bearing housing. The bearing
housing is equipped with threaded holes at the base part for
mounting the bracket (7) for motor (9) and pump (8). The
bracket is a two-part configuration, so that it can be adjusted
in relation to the fitted bends and ball valve between the oil
level glass and the suction port of the pump.

Pipes and fittings are mounted on the pressure port of the


pump. The prefabricated pipe (11) for flow sensor must be
mounted as shown on the arrangement drawing. The pipe
must not be bent nor shortened.
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Pipes and fittings must be mounted on the top part of the


bearing housing as indicated on the arrangement drawing.
Parts to be connected by means of a hose (13).

During installation, it is essential to ensure that the pumps are


mounted in correct manner, see Fig. 1. The pumps have been
configured so that for every bearing two pumps are supplied
for installation on left-hand bearings and 2 pumps for
installation on right-hand bearings, see Fig. 1.

Left position Right position

Fig. 1. Position of bearings


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The built-in pressure control valve (10) must recirculate the oil
to the suction side. It is essential to check that the valves on
all pumps have the correct orientation. If incorrectly
positioned, the valves can be turned quite easily, see Fig. 2.

Fig. 2. Oil pump

Reference is also made to the instruction manual for the


supplied motor/pump.

The handle on the ball valve (6) should be dismantled to


ensure that the ball valve cannot be inadvertently closed. It
should only be possible for ball valve to be closed if the pump
is dismantled for maintenance work.

4. OPERATION

The pump must be in operation when the kiln speed is less


than 0.5 rpm. This will ensure that a sufficient amount of oil is
fed to the bearing journal when the speed is low.

Prior to start-up of the pump, a check is needed to ensure that


the bearing is filled with oil. The ball valve must be open. Dry-
running of pump must never occur since this will cause severe
damage to the pump.
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In connection with the installation procedures, or if the bearing


housing has been opened, the bearing must be cleaned very
carefully before it is filled with oil.

Because of the high oil viscosity and the very small oil column
height between bearing housing and pump, the suction side of
the pump does not incorporate a sieve or a filter.

So, for enhancing the service life of the pump, it is very


important that the oil which is fed to the pump has the
maximum degree of cleanliness.

Trouble-shooting procedures in connection with any


operational problems with the pump, reference is made to the
pump instruction manual.
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5. MAINTENANCE

Preventive maintenance, survey:

Pos. Text 1. 2. 3. 4. 5.
01 Supporting bearing 2A
08 Oil pump 2A 2A 2A
09 Motor 2A 2A 2A
12 Flow sensor A A A

D = per 8-hour A number in front of


operation the letter indicates
S = weekly the frequency of
M = monthly procedure.
A = yearly For example, 2M =
T = see text in twice a month.
instruction manual
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Check that all ingoing and outgoing pipe connections relative


to the supporting bearing (1) are tight. Check the oil level in
the bearing.

During normal operation, no maintenance of any significance


is required for the pump (8) and motor (9). However, it is
essential to check for any abnormal sounds from the pump or
motor during operation. Check also for any oil leakage from
the pump. Se pump instruction manual if leakage from shaft
seals is observed.

Check that all bolts at the bracket (7) between supporting


bearing (1) and the motor (9) are fully tensioned.

Check the functionality of flow sensor (12).


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6. KEY TO FIGURES AND APPENDIX

01 Supporting bearing

02 Bearing housing, base part

03 Bearing housing, top part

04 Oil pan

05 Oil level glass

06 Ball valve

07 Bracket for motor/pump

08 Oil pump

09 Motor

10 Pressure control valve

11 Pipe for flow sensor

12 Flow sensor

13 Hose
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Appendix 1. Arrangement