GB/T 32994-2026Rotary kilns for the cement industry (English PDF)

5.1 Basic Requirements

5.1.1 Rotary kiln products shall comply with the provisions of this document and be designed and manufactured in accordance with the approved design drawings and technical documents.

5.1.2 The limit deviations of un-specified tolerances for machined parts on the drawing shall conform to the m-grade requirements in GB/T 1804-2000.For non-machined parts... The limit deviations of unspecified dimensional tolerances for machined parts shall conform to the requirements of grade V in GB/T 1804-2000.Unspecified dimensions of machined parts... The positional tolerance should not be lower than the K-grade specification in GB/T 1184-1996.

5.1.3 Welded parts shall comply with the provisions of JC/T 532.

5.1.4 Carbon steel welding electrodes, low alloy steel welding electrodes and welding wires shall comply with the provisions of GB/T 5117, GB/T 5118 and GB/T 8110 respectively.

5.1.5 The design of the rotary kiln shell lining should comply with the provisions of JC/T 2196-2013.For rotary kilns used in co-processing, the shell and lining should preferably be in close contact. Take anti-corrosion or isolation measures.

5.1.6 The thin oil lubrication system of the main reducer shall comply with the provisions of GB/T 38275-2019.

5.1.7 The hydraulic system for the thrust rollers shall comply with the provisions of GB/T 3766.

5.2 Overall Machine Requirements

5.2.1 The basic parameters of the rotary kiln shall conform to the provisions of Table 1 or the design drawings and relevant technical documents.

5.2.2 The rotational speed of the main drive of the rotary kiln should be adjustable, and the adjustment ratio should not be less than 1.10.

5.2.3 Heat insulation devices shall be installed between the roller bearing assembly, the thrust roller device, the transmission device and the cylinder.

5.2.4 Lubrication devices should be installed on the contact surfaces between the tire and the support roller and the retaining roller, and lubrication devices should preferably be installed between the tire and the pad.

5.3.1 Cylinder

5.3.1.1 The mechanical properties of the cylindrical plate shall not be lower than those specified in Q235C of GB/T 700-2006.

5.3.1.2 The surface quality of the cylindrical plate shall comply with the requirements of

5.6 in GB/T 3274-2017.

5.3.1.3 For plates with a thickness of not less than 38mm or a rolled width exceeding 1900mm, the edge width of the finished product should be 60mm after cutting. Ultrasonic testing of the area should meet the quality level of Grade II in Table 4 of GB/T 2970-2016.

5.3.1.4 Except for the transition plates under the tire and on both sides of the tire, the width requirements for the cylinder plates are as follows:

a) The distance between the circumferential weld of the lower section of the gear ring and the weld connecting the spring plate should not be less than 100mm;

b) The distance between the circumferential weld and the edge of the manhole should not be less than 100mm.

5.3.1.17 The length deviation of the large section leaving the factory is ±0.025% of the length of the section.

5.3.1.18 The welding bevels at both ends of the factory-delivered section should be machined at the factory.

5.3.1.19 The requirements for the pad plate under the tire cylinder are as follows:

a) The weld for fixing the backing plate and the backing plate itself should not overlap with the longitudinal weld of the cylinder, and the distance between the edges of the two welds should not be less than 50mm;

b) The backing plate should be tightly fitted to the cylinder before welding;

c) After the pad is welded to the cylinder, the outer surface of the pad should be machined;

d) The longitudinal weld seam where it meets the positioning block welded to the cylinder should be ground smooth.

5.3.2 Large gear ring

5.3.2.1 The mechanical properties of the large gear ring material shall not be lower than those specified in GB/T 37400.6-2019 for ZG35Mn.

5.3.2.2 The large gear ring shall be heat treated, and the surface hardness of the tooth tip circle shall not be less than 185HB.

5.3.2.3 The manufacturing precision of the large gear ring shall meet the requirements of grade 9 in GB/T 10095.1-2022.

5.3.2.4 The rim thickness of the large gear ring should be uniform, and its deviation should be -5% to 10% of the designed rim thickness.

5.3.2.5 The machined surfaces of the large gear ring shall be subjected to ultrasonic testing, and the testing level shall reach level 3 in Table 4 of GB/T 37400.14-2019.

5.3.2.6 The tooth surfaces of the large gear ring, the machined surfaces of the half-face, the plane of the spring plate connecting boss, and the surface of the boss's R-zone should be subjected to magnetic particle testing, with a testing level of It should meet Level 3 in Table 19 of GB/T 37400.14-2019.

5.3.3 Pinion

5.3.3.1 The mechanical properties of the pinion material shall not be lower than those specified for 35CrMo in GB/T 33084-2016.

5.3.3.2 The pinion shall be heat-treated, and the surface hardness of the tooth tip circle shall not be less than 230 HB, and shall be higher than that of the tooth tip circle of the large gear ring. 20HB or above.

5.3.3.3 The manufacturing precision of the pinion shall conform to the requirements of grade 9 in GB/T 10095.1-2022.

5.3.3.4 The pinion shall be subjected to ultrasonic testing, and the testing level shall reach level 3 in Table 2 of GB/T 37400.15-2019.

5.3.4 Pinion Shaft

5.3.4.1 The mechanical properties of the pinion shaft material shall not be lower than those specified in GB/T 33083-2016, section 45.

5.3.4.2 The pinion shaft shall be heat treated, and the hardness of the outer cylindrical surface shall not be lower than 210HB.

5.3.4.3 The pinion shaft shall be subjected to ultrasonic testing, and the testing level shall reach level 3 in Table 2 of GB/T 37400.15-2019.

5.3.5 Support Roller

5.3.5.1 When the material of the support roller is a casting, its mechanical properties shall not be lower than those specified in GB/T 37400.6-2019 for ZG35CrMo.

5.3.5.2 When the material of the support roller is a forging, its mechanical properties shall not be lower than those specified for 35CrMo in GB/T 33084-2016.

5.3.5.3 The support roller shall be heat treated, and the hardness of the outer surface shall not be lower than 190HB.

5.3.5.4 The hardness of the outer circle of the support roller should be at least 20 HB higher than that of the outer circle of the tire.

5.3.5.5 The thickness deviation of the rim and hub of the roller after rough machining should not exceed 5% of the design dimension.

5.3.5.6 The tolerance of the outer diameter of the support roller shall not be lower than IT11 grade in Table 1 of GB/T 1800.2-2020.

5.3.6 Roller Shaft

5.3.6.1 The mechanical properties of the roller shaft material shall not be lower than those specified in material grade 45 of GB/T 33083-2016.

5.3.6.2 The roller shaft shall be heat treated, and the hardness of the outer surface shall not be lower than 210HB.

5.3.6.3 The surface roughness requirements for the shaft are as follows:

a) The surface roughness at the mating points with the liner and seals should not be less than Ra 1.6 µm;

b) The surface roughness at the mating point with the support roller should not be less than Ra3.2µm.

5.3.6.4 The coaxiality tolerance of the shaft diameter at the mating point between the shaft and the support roller to the journals at both ends of the bearing bush shall not be lower than that specified in Table B4 of GB/T 1184-1996. Level 7.

5.3.6.5 The cylindricity tolerance at the mating points of the shaft with the support roller and bushing should not be lower than grade 7 in Table B2 of GB/T 1184-1996.If the shaft diameter is large... The cylindricity tolerance should be equal to or greater than 600 mm, and the cylindricity tolerance should conform to the provisions of Table 3.

5.3.6.6 The roller shaft shall be subjected to ultrasonic testing, and the testing level shall reach level 3 in Table 2 of GB/T 37400.15-2019.

5.3.7 Tires

5.3.7.1 When the tire material is a casting, its mechanical properties shall not be lower than those specified in GB/T 37400.6-2019 for ZG35Mn.

5.3.7.2 When the tire material is a forging, its mechanical properties shall not be lower than those specified for 35SiMn in GB/T 33084-2016.

5.3.7.3 The tire should be heat-treated, and the hardness of the outer surface should not be less than 170HB.

5.3.7.4 The inner diameter of the tire and the outer diameter of the cylinder pad should be machined to fit together and meet the design clearance requirements.

5.3.7.5 Tires shall undergo ultrasonic testing. The testing grade for cast tires shall reach Level 3 in Table 4 of GB/T 37400.14-2019, and forged tires... The testing level should reach Level 3 in Table 2 of GB/T 37400.15-2019.

5.3.7.6 The working surface of the cast tire shall be subjected to magnetic particle testing, and the testing grade shall meet the requirements of Table 19 of GB/T 37400.14-2019. Level 3.

5.3.9 Thrust wheel shaft

5.3.9.1 The mechanical properties of the wheel axle material shall not be lower than those specified in GB/T 33083-2016, section 45.

5.3.9.2 The thrust roller shaft shall be heat treated, and the hardness of the outer surface shall not be lower than 210HB.

5.3.9.3 The wheel shaft shall be subjected to ultrasonic testing, and the testing level shall reach level 3 in Table 2 of GB/T 37400.15-2019.

5.3.10 Roller bearing liner

5.3.10.1 The mechanical property requirements for the roller bearing liner material are as follows:

a) When using cast aluminum bronze, the content should not be lower than the requirement of ZCuAl10Fe3 in GB/T 1176-2013;

b) When using cast zinc alloy, the requirements shall not be lower than those specified in ZA27-2 of GB/T 1175-2018.

5.3.10.2 The casting quality of zinc alloy lining tiles shall conform to the requirements of GB/T 16746, and the casting quality of copper alloy lining tiles shall conform to GB / The provisions of T13819.

5.3.10.3 The diameter of the inner cylindrical surface of the liner should be greater than the nominal diameter of the journal of the support roller shaft, with the difference being 0.2%~ 0.3%.

5.3.10.4 The coaxiality tolerance of the center lines of the inner and outer cylindrical surfaces of the lining tile shall not be lower than grade 7 in Table B4 of GB/T 1184-1996.

5.3.10.5 The perpendicularity tolerance of the shoulder end of the lining tile to the inner cylindrical surface shall not be lower than grade 6 in Table B3 of GB/T 1184-1996.

5.3.11 Spherical bearing pad for roller bearings

5.3.11.1 The mechanical properties of the spherical bearing pad material for the roller bearing shall not be lower than those specified in GB/T 9439-2023 for HT200.

5.3.11.2 The spherical bearing pads of the roller bearing shall undergo a water pressure leak-free test.

5.3.11.3 The positional tolerance of the center of the spherical tile relative to the axis of the inner cylindrical surface and its symmetrical center line along the axial direction shall be Sphi

0.10 mm.

5.3.12 Roller bearing housing

5.3.12.1 The mechanical properties of the roller bearing housing material shall not be lower than those specified in GB/T 9439-2023 for HT200.

5.3.12.2 The height difference between the center of the bearing housings at both ends of the same roller bearing assembly shall conform to IT10 grade in Table 1 of GB/T 1800.2-2020.

5.3.13 Main heat-resistant steel components

5.3.13.1 The mechanical properties of the kiln head guard plate material shall not be lower than those specified in JB/T 6403-2017 for ZG40Cr25Ni20.

5.3.13.2 The mechanical properties of the kiln tail guard plate material shall not be lower than those specified in JB/T 6403-2017 for ZG35Cr24Ni8Si2N.

5.3.13.3 The mechanical properties of the kiln head air cooling jacket material shall not be lower than those specified in GB/T 4238-2015 for 06Cr19Ni10.

5.3.15 Monitoring Device

5.3.15.1 Rotary kiln users should be equipped with cylinder temperature monitoring devices and tire slippage monitoring devices.

5.3.15.2 The main bearings of the rotary kiln support device and the thrust roller device shall be equipped with temperature detection devices.

5.3.15.3 The pinion bearing shall be equipped with a vibration detection device and a temperature detection device.

5.3.15.4 Rotary kilns shall be equipped with kiln displacement limiting devices.

5.4.1 Assembly

5.4.2 Installation The installation of rotary kilns shall comply with the requirements of GB/T 50561.

5.5 No-load test run

5.5.1 During no-load test run, the temperature rise of the sliding bearing of the support roller should not exceed 30K.

5.5.2 During no-load test runs, the temperature rise of bearings in motors, reducers, and pinion gear units should not exceed 25K.

5.5.3 During operation, there should be no abnormal vibration or noise, lubrication and sealing should be normal, and there should be no loose bolts.

5.6 Safety

5.6.1 Interlocking devices should be installed between the main drive and auxiliary drive of the rotary kiln.

5.6.2 An emergency independent power source should be provided for the auxiliary drive device of the rotary kiln.

5.6.3 Protective covers should be installed on high-speed couplings, open gears and other transmission components in the rotary kiln drive system.

5.6.4 A braking device should be installed in the auxiliary drive device of the rotary kiln.

5.6.5 Safety warning signs should be set up in locations where danger may occur, and the safety warning signs should comply with the provisions of GB 2894.

5.6.6 Electrical safety shall comply with the provisions of GB/T 5226.1.

5.7 Appearance Quality

5.7.1 The structural components of the rotary kiln shall be sandblasted to remove rust, and the treatment grade shall not be lower than Sa2 grade in Table 1 of GB/T 8923.1-2011.

5.7.2 The painting of rotary kiln components shall comply with the provisions of JC/T 402.

5.7.3 The paint on rotary kilns should not be corroded or peeling, and the surfaces of machined parts should not be damaged by bumps or other impacts.

6.1 Overall Machine Requirements

6.1.1 For the inspection of rotational speed in 5.2.2, the number of revolutions of the kiln cylinder within a certain time period is measured on-site and calculated.

6.1.2 For the inspection of the insulation device in 5.2.3, visual inspection shall be adopted.

6.1.3 For the inspection of the lubrication device in 5.2.4, visual inspection shall be adopted.

6.2 Major Components

6.2.1 The material properties of the main components of the rotary kiln shall be tested in accordance with relevant standards and test reports shall be provided.

6.2.2 The surface roughness of the main components of the rotary kiln is tested using a roughness tester or a roughness comparison sample block.

6.2.3 The hardness of the main components shall be tested using a portable hardness tester. The test locations and number of test points shall be as follows:

a) For the inspection of large gear rings, small gears, tires, retaining rollers, and support rollers. when the diameter is 2m or less, the inspection points are evenly distributed at 4 locations; when the diameter is... When the diameter is 2m (excluding) to 4m, 6 detection points are evenly distributed; when the diameter is 4m (excluding) to 6m, 8 detection points are evenly distributed; when the diameter is... When the diameter is 6m or more, 10 detection points are evenly distributed, and three points (upper, middle, and lower) are detected at each point.

b) For the inspection of shaft-type parts, the inspection location should be the relevant mating area.

6.2.4 Ultrasonic testing of components should be performed after rough machining or heat treatment, and magnetic particle testing should be performed after finish machining. Magnetic particle testing of welds... This should be done after the weld seam has been ground.

6.2.5 The inspection items and test methods for major components shall be carried out in accordance with Table 4.

6.3.1.1 For the inspections in

5.4.1.1 and 5.4.1.2, visual inspection shall be adopted.

6.3.1.2 For the inspection of the scraping requirements of the roller bearing assembly in 5.4.1.4, the contact angle can be converted into the contact length from the contact surface diameter. The gaps were measured using a steel tape measure, the contact width was measured using a feeler gauge, and the contact points were measured using a coloring method.

6.3.1.3 For the inspection of the center height deviation of the bearing housing in the same roller bearing assembly as described in 5.4.1.5, a level, straightedge, and height gauge shall be used in conjunction. Testing.

6.3.2 Installation The inspection of rotary kiln assembly and installation shall be carried out in accordance with the methods given in GB/T 50561.

6.4.1 For the inspection of bearing temperature rise in

5.5.1 and 5.5.2, before the rotary kiln is lined, the main motor drives the rotary kiln to run unloaded for 4 hours. Then, a temperature measuring instrument was used for detection.

6.4.2 For the inspection of the operation status in 5.5.3, visual inspection shall be adopted.

6.5 Safety

6.5.1 For the inspections of 5.6.1, 5.6.2,

5.6.3 and 5.6.4, visual inspection shall be adopted.

6.5.2 For the inspection of 5.6.5, the method given in GB 2894 shall be followed.

6.5.3 For the inspection of 5.6.6, the method given in GB/T 5226.1 shall be followed.

6.6 Appearance Quality

6.6.1 For the inspection of the sandblasting and rust removal treatment in 5.7.1, the method given in GB/T 8923.1-2011 shall be followed.

6.6.2 For the inspection of the paint in 5.7.2, it shall be carried out according to the method given in JC/T 402.

6.6.3 For the inspection of the appearance of the rotary kiln in 5.7.3, visual inspection shall be adopted.

7.2 Factory Inspection

7.2.1 Each component of the product shall be inspected by the manufacturer's quality inspection department. Some components may be inspected at the user's site before leaving the factory.

7.2.2 Product components shall undergo factory inspection according to Table 5, and a certificate of conformity shall be issued after the inspection is passed.

7.2.3 The factory inspection items shall be in accordance with the provisions of Table 5.

7.3 Type Testing

7.3.1 Type testing shall be conducted under any of the following circumstances.

a) During the trial production and type approval of new products;

b) When significant changes in the structure, materials, or processes of an existing product may affect its performance;

c) When production resumes after a one-year hiatus;

d) When the delivery inspection results differ significantly from the previous type inspection results.

7.3.2 The type test items are all items in

7.4 Judgment Rules

7.4.1 If all the inspection items in Table 5 are qualified during the factory inspection, the product is deemed qualified.

7.4.2 Type testing is conducted on the basis of passing the factory inspection. If all tested items pass, the product is deemed qualified. If any item fails to pass, the product is deemed qualified. If repairs are permitted and the product passes a re-inspection, it is considered (qualified); otherwise, it is considered (unqualified).

8.2 Packaging

8.2.1 Support devices should be added to both ends of the large sections of the cylinder and the tire section of the cylinder when leaving the factory.

8.2.2 Reinforcement measures should be taken to prevent deformation of the semi-gear ring.

8.2.3 The packaging of rotary kilns shall comply with the provisions of JC/T 406.

8.2.4 The packaging label should include.

a) Receiving unit and factory address;

b) Main product names and models;

c) Factory serial number and box number;

d) External dimensions, gross weight, and net weight;

e) Name of the manufacturer.

8.2.5 The accompanying technical documents shall include.

a) Product instruction manual;

b) Product certificate;

c) Packing list;

d) Product installation diagram.

8.3 Transportation and Storage

8.3.1 The shipment of rotary kilns shall meet the requirements for land, water or sea transportation.

8.3.2 Important parts such as tires and large gear rings should be stored horizontally.

8.3.3 Components should be stored with measures to prevent rain and rust.

8.3.4 Components stored for more than 6 months should be inspected and maintained regularly.