Machine manual

en-21017.801-I

Throttle valve in the tertiary air duct

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Throttle valve in the tertiary air duct

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-4
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for test run.........................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-4
8 Spare parts............................................................................................. 8-5
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1

en-21017.801-I
Machine manual Technical data
Throttle valve in the tertiary air duct 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers’
documentation.

Information on the intended use

Regulation of tertiary air flow
See also Operation Manual of the kiln plant !

Basic data
Year of manufacture............................................................................
Construction size................................................................................
Dimensions..........................................................................................
Weight..................................................................................................

Operation of the throttle valve

Actuator
Type.....................................................................................................
Operating torque...........................................................................Nm
Connected voltage............................................................................V
Frequency........................................................................................Hz
Machine manual Safety
Throttle valve in the tertiary air duct 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 The machine is exclusively intended for use in a tertiary air
duct.
Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machine other than for the specified purpose is
forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.

Maintenance
 Ensure that all machines and motors whose operation might
endanger persons or equipment are switched off, isolated and
safeguarded against restarting for the entire duration of the
maintenance work.
 Ensure that all rotating parts of the machine have come to a
halt before the removal of guards or opening of access doors or
inspection flaps.
Safety Machine manual
2 Throttle valve in the tertiary air duct

 Before performing any work on the machine, make sure there

is no burning hazard.
 De-energize the electrical parts before starting any
maintenance work.
 Everywhere in the preheater, overpressure may have been built
up due to a power failure. Do not open the throttle valve from
the local switch until no
more overpressure exists in the preheater.
 When automatic air cannons are used, the remaining pressure
must be relieved after their electrical switch-off before the
preheater doors or poke holes may be opened. Remaining air
pressure causes the air cannons to operate!
 Only authorized and instructed personnel may open the
throttle valve on the plant manager’s instruction.
 The plant manager must take adequate safety precautions
before, during and after all maintenance work for the
protection of the maintenance and operating personal. After
the maintenance work, it is of vital importance to make sure
that nobody is locked in the machine!
 Danger! You can suffer severe burns at the preheater. Do not
touch the preheater while the preheater is hot.
 For maintenance work make sure that the throttle valve has
cooled down sufficiently, you have enough oxygen inside the
machine and that hot gas cannot flow in. Use dust protection
masks as protection against the high rate of dust which must
be expected.
 There is a danger for people to stumble over the brackets on
the platforms of the preheater cyclones. Everybody entering
the platforms must wear protections clothes.
 All electric lines in the area of the preheater must be protected
from contact with falling hot raw meal. Suitable covers must
be installed.
 Strictly observe the welding instructions when performing any
welding work.
Machine manual Safety
Throttle valve in the tertiary air duct 3

 If electrical welding is executed on any part within the

machine, the welding current must never be conducted through
sliding or anti–friction bearings,
other moveable connections or measuring equipment. Return
lead welding current must always be connected close to the
point of welding and directly connected to the part being
welded.
 After all maintenance work all earthing cables must be
checked for proper functioning.
 All safeguards have to be re-installed when maintenance work
has been
terminated. Close inspection flaps and maintenance hatches
properly after you have made sure that all personnel has come
out of the machine.
Machine manual Components and mode of functioning
Throttle valve in the tertiary air duct 1

3 Components and mode of functioning

The throttle valves with refractory lining have been specially

developed for use in the tertiary air ducts.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings attached.

The throttle valve comprises basically:

 the split housing with refractory lining;
 the valve blade and the shaft made of highly heat–resistant
cast steel;
 the actuator.
Components and mode of functioning Machine manual
2 Throttle valve in the tertiary air duct

Items in the drawing

1 Housing
2 Valve blade
3 Shaft
4 Bearing
5 Linkage
6 Operating lever
7 Actuator
Machine manual Components and mode of functioning
Throttle valve in the tertiary air duct 3

Figure 1
A = horizontal
Components and mode of functioning Machine manual
4 Throttle valve in the tertiary air duct

3.2 Mode of functioning

The throttle valve in the tertiary air duct reduces the flow rate of
the tertiary air to the set value required to ensure optimal burning
in the rotary kiln and in the precalciner.
Machine manual Transport and assembly
Throttle valve in the tertiary air duct 1

4 Transport and assembly

4.1 Transport and storage requirements

The machine is transported in single parts or in sub–assemblies.

It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
Motors, couplings, gear units, measurement and control
equipment must be
stored in buildings which are well aerated and must be protected
against moisture.
Refractory material must be stored in accordance with the
suppliers’ instructions.

4.2 Assembly

General requirements
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview on the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.

CAUTION
If electrical welding is carried out in any place of the machine, welding
current must never be conducted through plain bearings and antifriction
bearings, other moveable connections or measuring equipment to prevent
damage to such parts.
Return lead (of welding current) must always be directly connected to the
part being welded.
Transport and assembly Machine manual
2 Throttle valve in the tertiary air duct

Assembly sequence

 Dismount valve blade (2) and shaft (3).

 In accordance with the separate instructions from the supplier
of the refractory material, the housing (1) must be lined.
 Install the assembled throttle valve in the tertiary air duct.
 The bearing (4) must be aligned in such a way that the shaft of
the valve is mounted horizontally “A“.

Figure 2

NOTE
During installation particular care must be taken to ensure that
the actuator (7) and operating lever (6) have the correct setting
angle, and that the valve blade (2) is offset by the required
amount from the centre. (See section 9.1 Technical drawings)
Machine manual Transport and assembly
Throttle valve in the tertiary air duct 3

CAUTION
The valve blade (2) and shaft (3) are made from heat-resistant cast steel and
are very sensitive to blows!
The valve or its component parts must never be struck with any tool!
Machine manual Lubrication
Throttle valve in the tertiary air duct 1

5 Lubrication

CAUTION
Ensure that the lubricants are stored, used and disposed of in an
environmentally-friendly manner and observe your national
environmental legislation when handling lubricants.

Lubrication chart

Lubrication points
No. Qty. Designation Remark
1 1 Actuator according to the instructions of
the manufacturer
Machine manual Preparation for test run
Throttle valve in the tertiary air duct 1

6 Preparation for test run

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Are all bolts firmly tightened?
 Are the connecting flanges bolted air tight? (Have the seals
intended for this purpose been inserted?)
 Is the actuator (7) connected to the power supply?
 Has the throttle valve been checked for smooth operation
(functioning)?
 Have all non-conductive connections been bridged by earthing
strips?
Machine manual Spare parts
Throttle valve in the tertiary air duct 1

7 Maintenance

7.1 Inspection

CAUTION
Do not touch the preheater surfaces during operation or just after plant
stoppage.
All preheater surfaces are extremely hot. You are in danger of suffering
severe burns! Suitable protection clothes must be worn.

DANGER
The throttle valve opens and closes automatically.
It could seriously injure you.
Before starting work on the throttle valve notify the control room personnel
and secure the throttle valve against unintentional operation.

No. Work to be performed Frequency Remarks

1 Check for burns once per day
2 Check of the refractory lining once per year
3 Check of valve blade (2) for wear once per year if the flow
velocity cannot
be changed by
adjusting the
valve blade, the
valve blade must
be replaced
4 Inspection work on the actuator according to the
instructions of
the
manufacturer
Spare parts Machine manual
2 Throttle valve in the tertiary air duct

7.2 Servicing

DANGER
Use of automatic air cannons after their electric switch off.
Remaining pressure causes the air cannons to operate.
Danger!
The remaining pressure must be relieved before the doors and
poke holes are opened.
Work performed inside the tertiary air duct.
You can get locked in the plant unintentionally! Danger!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect
the maintenance and operating personnel.
Entering the inside of the tertiary air duct.
You can breathe in raw meal dust and/or be exposed to
extremely hot temperatures.
Before it may be entered, the tertiary air duct must be
scavenged with fresh air and it must have cooled down. Make
sure that hot gases cannot come into the preheater. A dust
protection mask must be worn.

No. Work to be performed Frequency Remarks

1 Renew refractory lining as required
2 Renew valve blade (2) with shaft (3) as required
3 Maintenance work on the actuator according to the
instructions of
the
manufacturer
Machine manual Spare parts
Throttle valve in the tertiary air duct 3

7.3 Trouble shooting

DANGER
During work on the tertiary air duct.
The throttle valve opens and closes automatically, it could seriously injure
you.
Before starting work on the throttle valve secure the throttle valve against
unintentional operation. Notify the control room personnel.

CAUTION
Do not touch the tertiary air duct surfaces during operation or just after
plant stoppage.
All tertiary air duct surfaces are extremely hot. You are in danger of
suffering severe burns! Suitable protection clothes must be worn.

Fault Cause Elimination

Valve is jammed or
cannot be fully opened
or closed
Burn on the housing (1)
Actuator (7) and/or repair actuator and/or
operation lever (6) repair operation lever
defective
Accumulation of clinker after switching off the
dust inside housing (1) kiln system and allowing
time for cooling down,
the clinker dust must be
removed
Refractory lining renew refractory lining
defective

If faults occur that are not described above, additional

information regarding
causes and eliminations of faults can be taken from the
subsuppliers’ documentation.
Spare parts Machine manual
4 Throttle valve in the tertiary air duct

7.4 Repair

Before performing any repair work, make sure all electrical

components are
disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to
guarantee that the bearings, the drive system or other sensitive
parts of the machine are kept free of contamination.

DANGER
Use of automatic air cannons after their electric switch off.
Remaining pressure causes the air cannons to operate.
Danger!
The remaining pressure must be relieved before the doors and
poke holes are opened.
Work performed inside the tertiary air duct.
You can get locked in the plant unintentionally! Danger!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect
the maintenance and operating personnel.
Entering the inside of the tertiary air duct.
You can breathe in raw meal dust and/or be exposed to
extremely hot temperatures.
Before it may be entered, the tertiary air duct must be
scavenged with fresh air and it must have cooled down. Make
sure that hot gases cannot come into the tertiary air duct. A
dust protection mask must be worn.
 To allow replacement of the throttle valve blade (2) and the
shaft (3), it is only necessary to remove the upper section of
the housing (1).
 After undoing the bolts in the bearings, the valve blade, shaft
and bearings can be lifted out of the lower housing section.
 Installation of the new valve blade and shaft takes place in
reversed sequence. (See also section Transport and assembly )
 Before the new valve blade is installed, the bearings (4) must
be cleaned.

Tools and auxiliary devices

Machine manual Spare parts
Throttle valve in the tertiary air duct 5

No special tools are required for repair work on the machine.

However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the test run.

8 Spare parts

Notes for enquiring about and ordering spare parts

Dear Customer,
POLYSIUS AG strive to render your enquiring about and ordering
of spare parts as easy, and as a consequence, as efficient as
possible. For this purpose we
have prepared a table summarising all data required by our spare
parts department to ensure optimum processing in the most
speedy and trouble–free manner.
Please copy the page with the respective table and mark those
parts which you require with a cross in the column Order or
Enquiry.
If the table relates to more than one machine, please also inform
us of the AAT item of the machine for which you require the spare
parts.
Spare parts Machine manual
6 Throttle valve in the tertiary air duct

Figure 3
Machine manual Spare parts
Throttle valve in the tertiary air duct 7

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

2 Valve blade 1 set

3 Shaft 1 piece

4 Bearing, complete 2 set

4.2 Bearing housing 2 piece

4.3 Retaining ring 2 piece

4.4 Retaining ring 2 piece

4.5 Pivoting bearing 2 piece

5 Linkage 1 piece

6 Operating lever 1 piece

7 Actuator 1 piece
Machine manual Appendix
Throttle valve in the tertiary air duct 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of this
folder.

Designation Drawing no.

Throttle valve

9.2 Subsuppliers’ documentation

Refractory lining

Actuator