User Manual
HYDRAULIC STATION
OCS-25ML
1
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User Manual
Table of Contents
1. General provisions-----------------------------------------------------------------------2
2. Security considerations -----------------------------------------------------------------4
3. Product nameplate-------------------------------------------------------------------------6
4. Introduction to working principle --------------------------------------------------7
5、OCS Main technical parameter -------------------------------------------------------9
6. Routine maintenance. -------------------------------------------------------------------10
7. Quality assurance -------------------------------------------------------------------------11
8. Common fault and troubleshooting methods------------------------------------12
9. List of reference drawings --------------------------------------------------------------13
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User Manual
1. General provisions
This operating and maintenance manual is only applicable to Ф4.4x65m rotary kiln
retainer wheel hydraulic system (schematic diagram No.
LAC-LLS-OCS-005-04-00000).
This manual guides users on the correct use of the hydraulic system, and relevant
operators should have a basic hydraulic knowledge and read this manual carefully
before transport, installation, commissioning, operation, maintenance and caring of
this equipment, to ensure the safety of related personnel and equipment. This
manual should be placed in the vicinity of related equipment or to specialized
personnel to facilitate timely access.
When the equipment is transferred to a third party as a whole, please transfer this
manual together with relevant technical information and drawings. End users must
use this equipment in strict accordance with the requirements of this manual and
relevant technical information and drawings. Any changes relevant to this
equipment need to be approved by Lincoln Company. Lincoln company will not
assume any responsibility for the equipment damage caused by any individual
behaviors as shown in the following:
z Do not carefully read this manual, especially the security considerations
in this manual but operate the equipment without authorization;
z Use third-party spare parts not approved by Lincoln company;
z Users are unauthorized to change the medium specification or use the
media that do not meet the requirements;
z Pipelines at the site are not prepared as required, mainly including the
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User Manual
use of steel pipes that do not meet the requirements, the on-site
prepared pipeline not washed or failing in meeting the provided
cleanliness level after washing.
In the event that users find the content not set out in the manual in use will be
guided by relevant international, national and industry standards, please arrange
corresponding experienced professionals to conduct the work concerned.
Quality management system
The hydraulic equipment is produced in strict accordance with the quality
management system of Lincoln company, and Lincoln company’s quality
management system has been given BVQI ISO9001 certificate.
System test
All OCS equipment of Lincoln company before leaving the company has undergone
the static pressure and overall performance test.
The static pressure test is mainly to test whether the anti-pressure ability of system
machine can meet the design requirements.
The performance test is mainly to detect whether design parameters of the system
and electrical and mechanical components meet the requirements.
A test report is issued for All OCS system tests according to Lincoln company’s
quality management system.
Overall dimensions and weight
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User Manual
The actual length of this equipment is about 990mm, its height is about 1020mm
and its width is about 575mm.
Oil return opening is 08L tube inserting fitting, with a center height of 715mm.
The system’s oil outlet is 08L tube inserting fitting, with a center height of 850.5mm.
The size of this equipment’s anchor hole: 530x470, and that of bolt hole is ф12x4.
Equipment weight: about 260Kg.
2. Security considerations
All operations on the system, including adjustment, maintenance and
pipeline connection are completed by qualified hydraulic personnel;
After the repair and maintenance of the system are completed, all
safety devices are restored to their factory states;
The reliability of electric switches in the system must be regularly
checked;
The reliability of electric heaters on the side of the fuel tank must be
regularly checked;
While the system is working its working conditions, such as noise,
heat and pressure should always be checked; in case of abnormal
findings, it is essential to process in time and troubleshoot before the
system can be put into operation;
Nonessential personnel are forbidden to enter the working area of the
system while the system is working;
The system’s working area must be well ventilated;
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User Manual
The system must be arranged at the site to ensure that the electric
control box is easily operated, and to prevent that the power supply
can be quickly cut off under emergency situations;
Oil pump motor must rotate correctly, that is, its direction of rotation
is in line with the arrow shown on the motor;
The medium ISOVG46 anti-wear hydraulic oil is used in the system,
and no other specification of hydraulic oil can be used;
All valves at the correct positions should be checked before the
system starts, and it shall ensure that the setting values of the
overflow valve are the factory settings;
Do not operate the equipment while taking medicine or under bad
physical condition;
Place an emergency oil leakage collection tool near the equipment to
avoid pollution and to protect the environment;
At the time of maintenance, proper tools are used to disassemble
and repair relevant parts;
Any work on the system in operation is not allowed;
No open flame shall not be used around petrol filling station and
explosive, flammable and corrosive substances shall not be kept;
Field power connection must be done by relevant qualified personnel;
It must verify that the provided power supply meets the requirements
of the corresponding electrical components; before power on, make
sure again whether the wiring is correct and firm, and the cables in
use must meet the peak load requirements and are provided with
sufficient safety margin;
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Power leakage be tested after the petrol filling station is powered on;
3.Product nameplate
The nameplate shown above shows some important information of the equipment,
such as system model, nominal pressure, nominal flow rate, order number,
production serial number, and overall weight, which are the important basis for
identifying and understanding the system.
4. Introduction to working principle
The hydraulic station is a special hydraulic station for ф4.4x65m rotary kiln retainer
wheel of cement plant in the building materials industry.
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As the rotary kiln is tilted, it is in the downward trend under the kiln body’s own
gravity, and the retainer wheel forces the kiln body under the action of the hydraulic
system to channel or controlled decline according to the desired speed, so as to
effectively ensure uniform wear of the tyre and riding wheel, and to greatly reduce
the adjustment workload of the riding wheel. The normal stroke of the retainer
wheel from up to down is controlled by the upper/lower limit switch of the I gear.
The limit position (alarm position) of the retainer wheel from up to down is
controlled by the upper/lower limit switch of the II gear. The II gear of limit switch
plays a role of security protection when the I gear of limit switch fails.
The working principle of the retainer wheel hydraulic system is as shown in Figure
LAC-LLS-OCS-005-04-00000. The system is provided with two sets of
micro-metering piston pumps with adjustable flow, namely 1-1 and 1-2, of which
one is in use while the other is for standby in the course of normal working, but the
two pumps are also allowed to start for special needs. The rotary kiln starts and at
the same time, the motor of the petrol filling station pump (1-1 or 1-2) starts; oil
through the filter (11-1 or 11-2), one-way valve (12-1 or 12-1), one-way throttle
valve 18, ball valve 19, and accumulator unit 20 enters the retainer wheel cylinder.
Under the action of pressure oil, the fuel tank drives the retainer wheel to force the
rotary kiln to move upward. The upward movement speed of the rotary kiln is
controlled by adjusting the output flow of the metering piston pump (1-1 or 1-2). In
the process of upward movement of the kiln, the electromagnetic ball valve 15 is
always in the state of power shutdown. When the kiln body is upward moved to the
retaining wheel block and meet the upper limit switch of the I gear, the limit switch
is triggered and sends out a signal; then, the working oil pump (1-1 or 1-2) motor is
powered off, the electromagnetic ball valve 15 is powered on and opened and
begins to move downward under the kiln body’s own weight, and the oil through the
accumulator unit 20, ball valve 19, one-way throttle valve 18, and electromagnetic
ball valve 15 returns to the fuel tank. The downward movement speed of the kiln
body is controlled by the one-way throttle valve 18 and in the process of downward
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User Manual
movement of the kiln body, the electromagnetic ball valve 15 is always in the
charged state. When the kiln body moves down to the retainer wheel and meet the
lower limit switch of the I gear, the limit switch triggered and sends out a signal; the
electromagnetic ball valve 15 is powered off and closed, and the working oil pump
(1-1 or 1-2) motor restarts to begin with next cycle at the same time. Whether the
kiln body moves up or moves down, the ball valves 3-1, 3-2 and 19 in the system
must be open, and the needle valve 17 is closed.
If the system pressure rises due to pipeline blockage or other failures, when it is
more than the setting value of the overflow valve 13 (12MPa), the overflow valve is
open and the extra oil liquid flows back to the fuel tank. The overflow valve 13 is
used to set the maximum working pressure of the system.
The filter 11-1 or 11-2 is provided with a diifferential pressure alarm switch; when
the filter cartridge is clogged, its front and back pressure diifference increases;
when it reaches the set value of the diifferential pressure alarm switch (5bar), the
diifferential pressure alarm switch is triggered and alarms.
The temperature switch 6 mounted on top of the fuel tank is a double setpoint
temperature switch for controlling the electric heater 4 to start/stop. When the oil
temperature is below the set value 10℃ of a contact point on the temperature
switch 6, the electric heater 4 starts heating the oil. When the oil temperature in the
tank rises to the set value 35℃ of a second contact point of the temperature switch
6 the heater is powered off and stops heating.
The floating ball liquid level switch 10 is used to control the oil level in the fuel tank;
when the oil level in the tank drops below the position of a floating ball above, a
"low level" alarm signal is given out to remind users to fill oil intp the tank. When the
oil level in the tank drops below the position of a floating ball below, a "very low
level" alarm signal is given out, and starting the electric heater 4 is prohibited.
In order to guarantee the stability of the hydraulic retainer wheel in operation, the
accumulator unit 20 is arranged on the pressure oil pipeline at the exit of the oil
station and in the front of the oil inlet of the oil-retainer wheel cylinder.
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User Manual
The digital display pressure switches 16-1 and 16-2 are a double setpoint pressure
switch, and according to the actual on-site situations electrically, the pressure
signals collected by the digital display pressure switches 16-1 and 16-2 can be
used for alarm protection.
The upward movement speed of the kiln body is controlled by adjusting the variable
body knob on the piston pump (1-1 or 1-2), and the knob is positioned at the top of
the pump and motor shaft coupling. When the scale increases, the upward
movement speed of the kiln body rises. When the scale decreases, the downward
movement speed of the kiln body slows down. The details refer to the metering
pump manual.
The downward movement speed of the kiln body is controlled by adjusting the
one-way throttle valve 18. The one-way throttle valve-18 is a thread throttle valve,
as shown below:
Wherein, a is the adjusting stroke, the maximum adjusting stroke is amax=6mm, and
the effective adjusting stroke is 0-4mm. At a=0 (the throttle screw flushes with the
locking nut), the degree of throttling is the largest, and the downward movement
speed of the kiln body is the smallest at this location. When the red mark circle
on the throttle screw is exposed (adjusting the end of the stroke is allowed at this
point), it is the terminal for throttle, the degree of throttling is the least, and the
downward movement speed of the kiln body is the highest at this location. Before
adjusting, the sealed locking nut should be completely loosened, so that the elastic
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seal is loose and enters into the threaded section. The sealed locking nut is locked
after adjusting.
5. Main technical parameters
1. System norminal pressure: 120bar
2. System nominal flow rate: 5mL/min~25mL/min
3. Working medium: the cleanliness level of the anti-wear hydraulic oil ISOVG46 is
not lower than NAS 1638, 9.
4. Oil supply temperature: 30℃ ~ 40℃
5. Filtration accuracy: 10um
6. Motor: 0.37KW/400VAC/50HZ/3PH
7. Electric heater: 1KW/230VAC/50HZ/3PH
8. Accumulator gas (nitrogen) pressure: minimum working pressure of the rotary
kiln in normal operation as guaranteed on the site.
6. Routine maintenance
To ensure that the system is working properly, to extend the service life of all
components of the system, and thus to ensure the normal work of the host, daily
maintenance and caring of the hydraulic system should be strengthened.
1. The maintenance operators planned for engaging in the hydraulic system must
be trained to get knowledge of the hydraulic system’s principle, structure and
operating points; they can post after they are qualified through training;
2. The leakage of the joints of the pipelines and components of the system is daily
checked, and any unusual situation should be reported for timely handling;
3. The operating parameters of the system are daily checked and recorded, and
any unusual situation should be reported for timely handling. The main operating
parameters are as follows:
3.1 Pressure: the pressure value indicated on the pressure gauge.
3.3 Temperature: temperature of the oil in the fuel tank.
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3.4 Fluid level: fluid level in the tank.
3.5 Noise: noise of the pump in operation.
4. The parameter setting values of switches in the system should be re-corrected
after the system has run continuously for a month.
5. The filters in the system should be replaced in a timely manner upon alarm, and
the old filter cartridge is disconnected for cleaning or replacement;
6. The pump coupling is periodically checked and, it is replaced if necessary;
7. The nitrogen pressure of the accumulator is detected on a regular basis and it is
supplemented if necessary;
8. The pressure gauges and thermometers in the system should be calibrated
every other year, and the calibration should be administered by a special agency;
9. The system’s oil is sampled and tested after the system has run continuously for
six months, and all oil should be replaced or processed if any of the physical and
chemical indexes has reached the criteria for waste;
10. The petrol station near shall be ventilated and dried, and use of open flame and
storage of flammable, explosive and corrosive substances are strictly prohibited.
7. Quality assurance
Lincoln company shall provide quality warranty and lifetime technical support to the
hydraulic station within one year from the factory date (date of invoice). Lincoln
company’s branches and authorized agencies all over the world will provide you
with service at any time.
Scope of warranty:
1. Main components: electric pumps, valves, overflow valves, filters, electric
heaters, coolers, temperature sensors, pressure sensors, flow switches, and
mechanical instruments and so on.
Non-warranty Scope:
1. Filter cartridge of double drum filter and oil suction filter.
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2. The system or component damage caused by using the working media that do
not meet the requirements is not covered in the scope of warranty.
3. The damage caused by the installation and commissioning not in accordance
with the requirements of this manual is not covered in the scope of warranty.
4. Barbaric operation and human-caused damage.
5. Modification, retrofit and others on the petrol station.
6. Any consequence caused by unauthorized removal due to not informing Lincoln
and Lincoln-related institutions after a failure occurs within the warranty period.
8. Common fault and troubleshooting methods
Troubleshooting
No. Symptom Fault cause Remark
method
1. The opening and closing
pressure of the safety valve 13 Reset
is set too low
2. The bypass valve is not
Close it
closed
Pump 3. Pipeline leaks Check and process
outlet 4. The rotation direction of the
Check and process
pressure is motor is wrong
1
too low or 5. The pump does not rotate due Repair or replace
does not to the coupling fault the coupling
exist 6. The pump output oil is
insufficient or there is no oil Repair or change
output caused by,the pump the pump
fault
7. The running time for pumps Continue to run the
is inadequate pumps
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8. The pump delivery is too
Readjust
small
9. The fluid level in the tank is Supplement oil to
too low the provided level
10. The one-way valve at the exit
Repair or replace
of the standby pump is not
the one-way valve
closed
Discharge the air in
1. Air in the pipeline
the system pipeline
Excessive 2. The pump output flow Repair or replace
2 noise or fluctuation is too large the pump
vibration 3、3. The fixing screws of the Tighten loose
motor pump become loose screws
3 Filter
differential Clean or replace the
3 The filter cartridge is blocked
pressure filter cartridge
alarm
1. The system pressure is too
Check and process
low or there is no pressure
2. The system oil is mixed with Discharge system
The fuel
air air
tank does
3. The mechanical steering
not run or
4 mechanism of the cylinder has Check and process
the running
poor lubrication
speed is
4. The cylinder leaks much
unstable Repair or replace
inside
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9. List of reference drawings
1. Schematic diagram of ф4.4x65m rotary kiln retainer wheel hydraulic station,
diagram number LAC-LLS-OCS-005-04-00000;
2. Assembly diagram ofф4.4x65m rotary kiln retainer wheel hydraulic station,
diagram number LAC-LLS-OCS-005-04-10000;
3. Accumulator cell of ф4.6x65m rotary kiln retainer wheel hydraulic station,
diagram number LAC-LLS-OCS-005-04-20000;
4. Terminal block diagram of ф4.6x65m rotary kiln retainer wheel hydraulic station,
diagram number LAC-LLS-OCS-005-04-30000
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贝宁水泥项目主零件清单
Main parts list of CBMI-Benin Cement project
Lube Station P/N Description Remark
930724-25ML-H 9591902-304 Metering Pump 680-S-E
930724-25ML-H 9591902-306 Digital pressure swich PN7001+EVC001
930724-25ML-H 9591902-320 needle valve
930724-25ML-H 9591902-330 Thermometer switch LTD-N4-KK-140-20-+40C-IP65-25-KV2-NH-FS
930724-25ML-H 9591902-332 Themoter 30-EI-60E-140 0/100C
930724-25ML-H 9591902-346 MVP13H VALVE
930724-25ML-H 9591902-347 Single valve ER01
930724-25ML-H 9591902-348 Electronic valve GR2
930724-25ML-H 9591902-349 Valve FG1
930724-25ML-H 9591902-352 Energy reservation unit
930724-25ML-H 9591902-353 Filter
930724-25ML-H 9591902-362 Ball valve KH08S
930724-25ML-H 9591902-363 Ball valve KH10L
930724-25ML-H 9591902-364 Ball valve MVI-400-S
930724-25ML-H 9591902-477 Flowmeter YWZ-250t
930724-25ML-H 9591902-581 Heater 115000
930724-25ML-H 9591903-011 Shockproof pressure gage.213.53.063.G1/4.bottom
930724-25ML-H 9910FX-006 Pressure transmitter P50-GB350M4G14M
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