Machine manual

en-21020.161-H

DOPOL® 90 C-type cyclone stage

Code Word

Order Number

POLYSIUS Order Code (POC)

Technical data Machine manual
2 DOPOL® 90 C-type cyclone stage

en-21020.161-H
Machine manual Contents
DOPOL® 90 C-type cyclone stage

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 Description of functioning.........................................................................3-5
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparations for the test run.................................................................6-1
6.1 Setting and adjustment.............................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-3
7.3 Trouble shooting.......................................................................................7-4
7.4 Repair....................................................................................................... 7-5
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1

en-21020.161-H
Machine manual Technical data
DOPOL® 90 C-type cyclone stage 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

Bulk material.......................................................................................
See also Operation Manual of the kiln plant.

Basic data
Year of manufacture............................................................................
Series/type........................................................................................C
Design size..........................................................................................
Nominal diameter of the cyclone.................................................mm
Nominal diameter of the gas duct................................................mm
Type of dip pipe............................................Segment dip pipe (16.4)
Diameter of the dip pipe...............................................................mm
Nominal length of the dip pipe.....................................................mm
Nominal width of the meal chute.................................................mm
Nominal width of the dispersing box............................................mm
Nominal width of the expansion joint..........................................mm
Lining thickness of the cyclone............................................150 mm
Lining thickness of the gas duct...........................................150 mm
Lining thickness of the meal chute.........................................85 mm

Flap valve (16.9)

Design size..........................................................................................
see Machine Manual......................................................................No.
Machine manual Safety
DOPOL® 90 C-type cyclone stage 1

2 Safety

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

Use
 The cyclone stage forms part of the DOPOL® preheater for the
kiln plant.
Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machinery 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.
 All platform openings must be closed and properly secured.
Safety Machine manual
2 DOPOL® 90 C-type cyclone stage

Maintenance
 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
 Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance hatches are opened.
 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 preheater!
 Danger! You can suffer severe burns at the preheater. Do not
touch the preheater while the preheater is hot.
 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!
 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.
 Only authorized and instructed personnel may open the doors
and locks on the plant manager’s instruction.
The doors and locks are so designed that they can be secured
with padlocks.
 Even after a longer cooling-down period be careful when
opening doors and maintenance holes. After a cooling-down
period there is still a danger of being burnt by spurting raw
meal.
 Everywhere in the preheater, overpressure may have been built
up due to a power failure. Do not open any doors or poke holes
if there is an overpressure.
 Danger! When the individual cyclone stages are cleaned
through the poke holes, hot raw meal can gush out due to
clogging. Use blow lances of maximum lengths, wear
protective clothes and make sure that the escape routes are
free.
Machine manual Safety
DOPOL® 90 C-type cyclone stage 3

 Only the special cleaning equipment forseen for this purpose

may be used for eliminating caking and clogging of the
preheater.
 Do not enter the machine interior befor you have sufficiently
purged it with fresh air and before it has cooled down
sufficiently. Make sure that you have enough oxygen inside the
machine and that hot gas cannot flow in.
 When performing work inside the machine, fresh air from an
outside source must be continuously pumped into the machine
or induced by sucking so that the inhaled air remains free of
noxious matters. Aeration with pure oxygen is not permitted.
Use dust protection masks as protection against the high rate
of dust which must be expected.
 While the preheater is cleaned, access to the rotary kiln and
the clinker cooler must be made impossible. Raw meal can
flush through the kiln to the clinker cooler. There is danger of
suffocating and getting buried with raw meal.
 Make sure that raw meal and loose parts cannot fall down on
you from upper section when you work insite the machine.
Take care that people in downstream plant sections are not
endangered. There is danger of suffocating and getting buried.
 For maintenance work in the plant’s interior space it may
become necessary to erect auxiliary platforms. Such auxiliary
platforms must be firm and steady.
 Prior to any work at the cyclone, the gamma ray emitter must
be switched off and safeguarded by padlocking according to
regulations.
 Make sure that the guards on all flap valves completely cover
the working distance of the sliding weights because otherwise
people’s limps are in danger of being cut off.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 De-energize the electrical parts before starting any
maintenance work.
 All electric lines in the area of the preheater must be protected
from contact with falling hot raw meal. Suitable covers must
be installed.
 After all maintenance work all earthing cables must be
checked for proper functioning.
Safety Machine manual
4 DOPOL® 90 C-type cyclone stage

 Strictly observe the welding instructions when performing any

welding work.
 When performing arc-welding or arc-gouging, the welding
personnel must be protected from contact with electrically
conducting parts.
 Never place the welding current source in closed rooms with
electrically conducting walls. For lighting the inside, only 24 V
lamps are permitted.
 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.
 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
DOPOL® 90 C-type cyclone stage 1

3 Components and mode of functioning

The C-type cyclone stage is the last cyclone stage in the DOPOL®
90 preheaters. The following diagram shows an C-type cyclone
stage (16) that is installed in a two-string DOPOL® 90 preheater.

NOTE
The C-type cyclone stage may consist of one or more cyclones
per string. The number of cyclones depends on the throughput of
the respective DOPOL® 90 preheater.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

Figure 1
Components and mode of functioning Machine manual
2 DOPOL® 90 C-type cyclone stage

Items in the drawing

16.1 Cyclone cone with support brackets

16.2 Cyclone’s upper part
16.3 Cyclone cover
16.4 Segment dip pipe
16.5 Meal chute
16.6 Gas duct
16.7 Dispersing box
16.8 Expansion joint
16.9 Flap valve
50 - 55 Access door, cover and manhole cover

NOTE
The depicted cyclone stage type C consists of two cyclones per
string. Depending on the throughput of the preheater, the cyclone
stage type C can also consist of one or several cyclones per
string.
The interior of the C-type cyclone stage is provided with a
refractory lining.
Machine manual Components and mode of functioning
DOPOL® 90 C-type cyclone stage 3

Figure 2
Components and mode of functioning Machine manual
4 DOPOL® 90 C-type cyclone stage

Segment dip pipe (16.4)

Figure 3
Machine manual Components and mode of functioning
DOPOL® 90 C-type cyclone stage 5

3.2 Description of functioning

Every cyclone stage basically performs the following two

functions:
 it heats up the raw meal in the gas stream,
 it separates the raw meal and discharges it via the meal chute.
The C-type cyclone stage is the last cyclone stage in the DOPOL®
90 preheaters. This cyclone stage is designed for a high degree of
raw meal separation. The raw meal fed into the gas duct (16.6) is
conveyed into the cyclone by the exhaust gas. In this cyclone the
raw meal is separated and passes through the meal chutes (16.5)
and the dispersing box (16.7) to the gas duct of the next lower
cyclone stage. The dispersing box hereby effects the uniform
distribution of the raw meal in the gas duct. The exhaust gas
flows through the dip pipe (16.4) into the exhaust gas duct.
The following drawing shows the gas stream (white arrows) and
the raw meal stream (black arrows) in the C-type cyclone stage.
Components and mode of functioning Machine manual
6 DOPOL® 90 C-type cyclone stage

Figure 4
Machine manual Transport and assembly
DOPOL® 90 C-type cyclone stage 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.
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.

NOTE
Final assembly and assembly inspection by an assembly
specialist from POLYSIUS AG are preconditions for our warranty.
We recommend that the assembly work is supervised from start
to finish by specialists from POLYSIUS AG.
Careful selection of the used tools and appliances and the
personnel is important for the correct execution of the assembly
work.

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 DOPOL® 90 C-type cyclone stage
Machine manual Transport and assembly
DOPOL® 90 C-type cyclone stage 3

Assembly sequence

If the overall situation on the construction site allows it, the pre-
assembly of and the welding work on all structural parts will be
performed on the ground. The refractory lining will be installed
only after the structural parts have been assembled. The
mounting of the cyclone stages also requires that the gas ducts
and the cyclones are pre-assembled and welded up separately on
the ground.
 Mounting of dip pipe acc. to dwg..
The meal chutes (16.5) are generally mounted according to the
following procedure:
 Arrange the meal chutes in the DOPOL® preheater so that they
fit perfectly,
 remove the fitted-in meal chutes,
 when on the ground again provide them with the refractory
lining,
 install the fitted-in and lined meal chutes by finally mounting
them in the cyclone stage.
Observe the mounting instructions in the machine manuals of the
flap valve (16.9). The refractory lining is subject to the
instructions of the respective manufacturer.
The openings and holes for the poke holes and connections of the
compressed-air cleaning system as well as any other
breakthroughs (e.g. for sensors and probes) must be made before
applying the refractory lining. If these openings and holes were
made subsequently, you would have to drill through the hard
lining. On the one hand this would be most difficult and
troublesome and on the other hand you would damage the
refractory lining at the respective points.
We recommend, furthermore, that in this mounting phase you also
provide the evaporation holes required for the drying process of
the refractory lining and for the first commissioning of the plant.

NOTE
All electrical conduits in the preheater area must be protected
from contact with hot raw meal by suitable covers..
Machine manual Lubrication
DOPOL® 90 C-type cyclone stage 1

5 Lubrication

NOTE
This machine/unit requires no lubrication.
Machine manual Preparations for the test run
DOPOL® 90 C-type cyclone stage 1

6 Preparations for the test run

NOTE
It is a prerequisite of our warranty that the first test run is carried
out in the presence of and according to the instructions of
specialists from POLYSIUS AG.

After completion of the assembly work all parts of the plant must
be checked according to the list below. Take particular care that
all material remnants, tools and assembly aids are removed.
 Have all screws been firmly and properly tightened?
 Have all flanged connections been tightly screwed up?
Have the seals specified for that purpose been inserted?
 Has the refractory lining been applied in accordance with the
manufacturer’s instructions? Has the prescribed hardening
period been observed?
 Have all non-conductive connections been bridged by earthing
strips?
 Have the safety devices for transportation and erection been
removed?
 Have the cyclone covers (16.3) and the expansion joints (16.8)
of steel been mounted with the specified pretension?
 Are all the doors and inspection ports properly and tightly
closed?
 Have all guards and all warning signs been properly mounted?
 Have all measuring boreholes been closed by the specified
seals?
 Have all flap valves (16.9) been set for normal operation?
 Have the evaporation holes provided for the hardening and
drying of the refractory lining been closed again?
(Applies only to the first commissioning!)
 Have all platforms openings been properly closed and secured?
Preparations for the test run Machine manual
2 DOPOL® 90 C-type cyclone stage

6.1 Setting and adjustment

The flap valves (16.9) must be adjusted by you in accordance with

the actual operational requirements. Please refer to the separate
Machine Manual. You will find the number of the Machine Manual
in the Section Technical data.
Machine manual Maintenance
DOPOL® 90 C-type cyclone stage 1

7 Maintenance

7.1 Inspection

If possible, inspection work is divided into:

 Inspections during operation and
 inspections during a longer kiln stoppages

Inspections during operation

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.

No. Work to be performed Frequency Remarks

1 Check the welds at the cyclone daily
covers (16.3) and at the gas inlets
2 Check all expansion joints, flanged daily inleaking air may
connections and flap valves (16.9) for be detected by
hissing and
inleaking air whistling noises
3 Check the entire plant for local daily a burnt paint
overheatings coat indicates a
damaged lining
4 Check the entire plant for wall daily deformations
deformations point to a
damaged
lining due to
inadequate joint
clearances
5 Check the expansion joints (16.8) for daily to be detected
dust deposits by
a tapping test
6 Check the flanged connections for daily
tightness
Maintenance Machine manual
2 DOPOL® 90 C-type cyclone stage

7 Check the meal chutes (16.5) for daily

cracks
Machine manual Maintenance
DOPOL® 90 C-type cyclone stage 3

Inspections during longer kiln stoppages

DANGER
When you are inside the preheater, raw meal can fall down on
you.
You can suffocate or buried with raw meal.
Do not enter the preheater unless you have made sure that no
coating can fall down on you.
Entering the inside of the preheater:
Inside the preheater you can breathe in raw meal dust and/or
be exposed to extremely hot temperatures.
Before it may be entered, the preheater 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 inside the preheater.
Do not enter the machine interior before sufficient time has
passed for the machine to cool down and become free of gas.
For all work inside the machine, you have to make sure that raw
meal and loose parts cannot fall down on you from the upper
section. Furthermore you must take care that people in
downstream plant sections are not endangered.
Make sure that the automatic shock blowers are de-pressurized
before you open any doors or poke holes.

No. Work to be performed Frequency Remarks

1 Check the
 cyclone inlets,
 impact surfaces of the dispersing
boxes,
 dip pipes,
 walls and covers
for extraordinary formation of
coating and deposits
2 Check the dip pipes (16.4) for
deformations
3 Check the refractory lining for
spalling, cracks and mismatch and
check filling
mats in the expansion joints of the
Maintenance Machine manual
4 DOPOL® 90 C-type cyclone stage

refractory lining.
Machine manual Maintenance
DOPOL® 90 C-type cyclone stage 5

7.2 Servicing

The plant should be cleaned in regular intervals. This can either

be done automatically with the compressed-air cleaning system
or manually by means of the blowing lances. In any case the
blowing-out procedure should be directed „from the bottom
upwards”. Cavities will thus be formed in the lower parts and
cakings which have been blown out further up may slide down
into these cavities.

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.
Cleaning of preheater
Danger! You can suffocate or get buried by raw meal in the
rotary kiln and the cooler.
Access to the rotary kiln and the cooler must be made
impossible during the cleaning work in the preheater.
The plant manager is responsible for setting up adequate
safety barriers.
Work performed inside the preheater.
Danger! You can get locked in the preheater unintentionally!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect the
maintenance and operating personnel.

NOTE
Clean the plant parts not only inwards but also outwards. Clean
the platforms around the plant parts. Remove any material
required for servicing and repair work and close and secure all
existing platform openings.

No. Work to be performed Frequency Remarks

1 Repair the refractory lining and the as required The position of
filling mats in the expansion joints the expansion
Maintenance Machine manual
6 DOPOL® 90 C-type cyclone stage

joints is shown
in the brick-
lining drawing.
2 Repair or replace dip pipes as required
3 Replace defective meal chutes as required
Machine manual Maintenance
DOPOL® 90 C-type cyclone stage 7

7.3 Trouble shooting

You should first remove cakings and cloggings by using the

compressed-air cleaning system. The operation manual for the
entire plant explains how you may adjust the blowing intervals to
the prevailing operational requirements and how you may
produce individual air blasts to clean certain points in a carefully
directed way.

DANGER
Hot raw meal can eject when poke holes are opened.
Beware of mortal danger.
Use blowing lances of maximum lenght, wear suitable safety clothing, and
keep the escape routes free.

In addition, the compressed-air cleaning system allows the

connection of blowing lances in several points.
You should in any case proceed as follows:
 first blow out the lower parts of the cyclone,
 then blow out the upper parts.
The cakings coming off when blowing out the upper parts of the
cyclone can thus slide down into the „cavities” blown out further
down.
Maintenance Machine manual
8 DOPOL® 90 C-type cyclone stage

7.4 Repair

Before performing any repair work, make sure all electrical

components are disconnected.
While repair work is being performed, the whole working area
must be secured so as to prevent access to unauthorized
persons. Block up the working area and keep the escapes clear.
More extensive repair work must only be carried out during a
longer-term standstill of the plant. In those cases make sure that
it is impossible to unintentionally switch on any plant
components: disconnect motors and electrical connections and
immobilize movable mechanical parts.
Machine manual Maintenance
DOPOL® 90 C-type cyclone stage 9

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.
Cleaning of preheater:
Danger! You can suffocate or get buried by raw meal in the
rotary kiln and the cooler.
Access to the rotary kiln and the cooler must be made
impossible during the cleaning work in the preheater.
The plant manager is responsible for setting up adequate
safety barriers.
Work performed inside the preheater:
Danger! You can get locked in the preheater unintentionally!
Before, during and after all maintenance work, the plant
manager must take adequate safety precautions to protect the
maintenance and operating personnel.

When performing work inside the machine, fresh air from an

outside source must be pumped in or induced by sucking so that
inhaled air remains free of noxious matters. Aeration with pure
oxygen is forbidden. Use dust protection masks as protection
against the high rate of dust which must be expected.
For all work inside the machine, you have to make sure that raw
meal and loose parts cannot fall down on you from the upper
section. Furthermore you must take care that people in
downstream plant sections are not endangered.
Even after a longer cooling-down period be careful when opening
doors and maintenance holes. After a cooling-down period there
is still a danger of being burnt by spurting raw meal.
For maintenance work in the plant’s interior space it may become
necessary to erect auxiliary platforms. Such auxiliary platforms
must be firm and steady.
Maintenance Machine manual
10 DOPOL® 90 C-type cyclone stage

In case of a longer kiln standstill you should check the filling

mats in the expansion joints of the refractory brick lining and
replace them even if they are only slightly damaged. These
ceramic mats and also other filling materials in the expansion
joints between the bricks prevent the expansion joints from being
clogged by dust and raw meal. Clogged expansion joints would no
longer be able to compensate the heat expansion of the bricks.
The refractory lining as well as the steel parts might thus be
damaged.
The position of the expansion joints is shown in the brick-lining
drawing.

After completion of all maintenance measures:

Check that all inspection and maintenance ports have been
properly closed again and secured against any unintentional re-
opening.

Tools and auxiliary devices

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 Preparations for the test run.
Machine manual Spare parts
DOPOL® 90 C-type cyclone stage 1

8 Spare parts

Suggestions for spare part enquiries and

Dear Customer,
POLYSIUS AG are trying to make it as easy as possible for you to
make enquiries about spare parts and to order spare parts. For
this reason we have prepared a table indicating all details
required by our spare parts department for an efficient and quick
processing of spare part enquiries and orders.
Please copy the page with the table prepared by us and mark the
parts subject of your enquiry or order with a cross in the column
Order or Enquiry.
If the table refers to more than one machine, please indicate also
the POC of the machine for which the spare parts are needed.
Spare parts Machine manual
2 DOPOL® 90 C-type cyclone stage

Spare part segment dip pipe (16.4)

Figure 5

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

16.4 Segment dip pipe, 1 set

Machine manual Spare parts
DOPOL® 90 C-type cyclone stage 3

complete
Spare parts Machine manual
4 DOPOL® 90 C-type cyclone stage

Spare part exansion joint (16.8)

Figure 6

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

16.8 Expansion joint 1 set

Machine manual Spare parts
DOPOL® 90 C-type cyclone stage 5

Spare parts access door, cover and manhole cover (50 - 55)

Figure 7
Spare parts Machine manual
6 DOPOL® 90 C-type cyclone stage

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

50 Access door 450 x 900 1 piece

(steel plate)

50.1 Access door 450 x 900 1 piece

(casting)

51 Cover 240 x 360 1 piece

(steel plate)

51.1 Cover 240 x 360 1 piece

(casting)

52 Cover120 x 240 1 piece

(steel plate)

52.1 Cover120 x 240 1 piece

(casting)

53 Manhole cover Ø 420 1 piece

(steel plate)

53.1 Manhole cover Ø 420 1 piece

(casting)

54 Cover 140 x 160 1 piece

(steel plate)

54.1 Cover140 x 160 1 piece

(casting)

55 Cover Ø 130 x 82 1 piece

(steel plate)

55.1 Cover Ø 130 x 82 1 piece

(casting)
Machine manual Appendix
DOPOL® 90 C-type cyclone stage 1

9 Appendix

9.1 Technical drawings

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

Designation Drawing no.

Assembly drawing

Segment dip pipe