Soft Pyrojet Butrner - P-13-0052 PDF

TECHNICAL MACHINERY
DOCUMENTATION
OF
Pyrojet Burner
STAR CEMENT MEGHALAYA LTD.
PO LUMSHNONG,
East Jaintia Hills Distt.
MEGHALAYA
P-13-0052
STAR CEMENT MEGHALAYA LTD.
Equipment – Pyro-Jet Burner HPJ/ 289 KO)
Item-no. Com.-no Gr. Designation
481 BU1 P-13-0052 Pyrojet Burner
“Safety and Health”
Section 0: Preface, sub-division and overview
Section I: Acceptance and test certificates, certificates
Section II: Customer-specific characteristic and technical data
Section III: Operating instructions

Part III.A: General part - Pyrojet Burner
Part III.B: Burner carriage standing
Part III.C: Handling of lubricants
Part III.D: Table of Lubricants
Section IV: Spare Parts List
Section V: Documents for assembly of the machine
Ordner / Book Seite / Sheet Abteilung / Dep. Datum/

Date:
1-1 1-1 PM-T-TD (CSC-I) 06.2020
Manual Doc. No. P-13-0052
AMENDMENT SHEET Rev. No. R0

No. of Volume 1 No.
Customer : STAR CEMENT MEGHALAYA LTD. LINE-II, MEGHALAYA
Star Cement Meghalaya Limited, Post Office Lumshnong, East Jaintia Hills District,
Plant :
Meghalaya-793210,(INDIA)
Contract Item No. : 481 BU1
Order No. : P-13-0052

Letter Ref. Volume No. Section No.
S.No. Date of Letter Remarks (Add/ Remove/ Replaced)
No. affected affected
Page 1 of 1
Doc. No.: DO P-13-0052 en
Technical Machinery
Documentation
Pyrojet Burner
Volume 1 of 1
Customer : STAR CEMENT MEGHALAYA LTD.
Star Cement Meghalaya Ltd., Line-II, Post

Plant : Office - Lumshnong, East Jaintia Hills
District, Meghalaya -793210, (INDIA).
Contract Item
: 481 BU 1
No.
HW Comm.
: P-13-0052
No.
State : 06.2020
Technical Machinery Documentation
Edition: 11.2010
Page 1 of 1
Note!
Also machines and plants (hereinafter

referred to as “products”) built according
to the respectively approved technical
rules and considered a “safe product” can
entail risks for persons, objects or the
environment, in particular, if they are ope-
rated improperly and/or by untrained staff
and/or used not as directed and/or started
or operated disregarding the instructions.
Therefore, a sufficient knowledge of all

relations is compulsory, e.g. of transport,
assembly, commissioning, operation,
maintenance up to the use and disposal of
working materials and auxiliaries as they
are described in the detailed accompa-
nying documents
The Technical Machinery Documentation -

here in particular operating manual Chap-
ter „Safety and Health“- must be read and
observed by any person in charge of work
such as transport, erection, commissio-
ning, operation, maintenance and disposal
of utilities and auxiliary materials. It inclu-
des important instructions on how to ope-
rate the machine in a proper and
economical manner.
Sprache: englisch
Technical Machinery Documentation State: 02.2011
“Safety and Health” BA 822-0004/1 en

General References in
Page 1 of 10
Operating Instructions
Contents Page
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11.2010
3. Risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BA 822-0004 en
Previous edition:
4.1 Warning references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.2 Safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Requirements to the users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Operating instructions / training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Use as directed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Conversions, changes of the operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9. Safety measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9.1 Prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

9.2 During operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9.3 Guards and safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.4 Protective equipment and clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10. Assembly, inspection, maintenance work and repairs . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.2 Welding and torch cutting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10.3 Shifting, loading, transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10.4 Electrical equipment and machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10.5 Hydraulic and pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.6 Working materials and auxiliaries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.7 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.8 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Shutting down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.1 Emergency disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Company name to Humboldt Wedag
12. Recognizing of operational failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alterations in this edition:
BA 822-0004/1 en
“Safety and Health” General References in Operating Instructions
1. Preface
The following safety and health regulations must compellingly be considered and observed by
all persons or organisations coming into contact with the works and the operation of the product.
Moreover, the regulations in the respective product-specific operating instructions must be
observed.
2. Introduction
The HUMBOLDT WEDAG supplies machinery and plants for the cement and mineral industry all
over the world.
Without exception, these are declarable investment goods; they must be safely and economically
operated over many years. They comprise many individual components which interact
mechanically, electrically and from the process point of view.
• Also machines and plants (hereinafter referred to as “products”) built according to the
respectively approved technical rules and considered a “safe product” can entail risks for
persons, objects or the environment, in particular, if they are operated improperly and/or
by untrained staff and/or used not as directed and/or started or operated disregarding the
instructions.
Therefore, a sufficient knowledge of all relations is compulsory, e.g. of transport, assembly,

commissioning, operation, maintenance up to the use and disposal of working materials and
auxiliaries as they are described in the detailed accompanying documents.
• The accompanying documents include e.g. packing and storage regulations, installation
and assembly instructions, commissioning regulations, directions for use, operating
instructions, functional and system descriptions.
• Every supplier of individual declarable components is contractually obliged to also supply

the respective accompanying documents together with the component supplied by him.
The information required in different phases and by different users can be filed in one document
or in different documents depending on their extent. All accompanying documents being part of
the supply are collected in one documentation and supplied in the contractually agreed number
of copies.
• Not considering special accompanying documents such as “Assembly Documentation”,

which only describe the first installation, the accompanying documents for the own
products of the HUMBOLDT WEDAG are designated “Technical Machinery
Documentation”.
• Synonymously, suppliers and various laws, directives and standards also use other
designations such as “Instructions for use”, “User information”, “Operator information”,
“product documentation” and similar.
In place of the different terms, below, exclusively the term Operating Instructions will be used.
Page 2 of 10
BA 822-0004/1 en
3. Risks
Machines and plants entail risks for persons, objects or the environment, e.g.:
• Risks due to supplied energy

(e.g. electrical, pneumatic, hydraulic energy)
• Risks due to heat sources
• Risks due to excessively high noise levels
• Risks due to radiation
• Risks due to vibrations
• Risks due to working materials and products
• Risks due to dismantling or putting out of function of safety devices and guards
Note!
Not all risks can be excluded by design measures.
4. Operating instructions
Operating instructions are written for the respective user. They contain the necessary information
about the product to allow it to be used for the intended purpose, properly effectively and safely
to the full extent.
• Operating instructions must be considered compulsory by all persons or organisations

charged with works on the product, e.g. transport, assembly and disassembly,
commissioning, operation, maintenance as well as with the use and disposal of working
materials and auxiliaries.
• Operating instructions are part of the product and must be transferred to the new owner in
case of a resale.
• Depending on field of application and complexity of a product, the extent of operating

instructions can considerably differ.
• Operating instructions must always be kept handy at the place of operation of the product
for consultation.
• Operating instructions warn of obvious and foreseeable misuse
• Among other things, operating instructions deal with residual risks, which cannot be
avoided by design measures.
• Special reference is made to the observation of the pictographs and signal words on the
product and in the instructions.
Note!
The HUMBOLDT WEDAG will not be liable for damage due to the
non-observance of the operating instructions.
Page 3 of 10
BA 822-0004/1 en
4.1 Warning references
Special action-related warning references in the operating instructions draw the attention to risks,
which can occur in a special situation or in connection with a special behaviour. These
references are found directly before the dangerous actions.
Note!
The operator of the plant is responsible for the consideration and

observation of the warning references.
4.2 Safety references
Safety references are part of a package of measures for protecting the user of the product
against risks, which can occur by the use. For example, they point out
• Residual risks and hazards upon use of the product as directed
• Safety measures required for a riskless handling of the product
• Circumstances under which the product must not be used.
Safety references in the operating instructions are highlighted against the residual text by special
warnings, signal words (e.g. “DANGER”, “WARNING”, “CAUTION” and/or by their typographic
appearance).
Note!
The operator of the plant is responsible for the consideration and

observation of the safety references.
5. Requirements to the users
Actions on the supplied product may only be performed by qualified users. This particularly
applies to repair works on electrical, mechanical, hydaulic and pneumatic systems.
• Users can be for example: Operators, assembly staff, repair staff
• Actions can be for example: Operating, mounting, maintaining.
Note!
The operator is responsible for selecting the respective persons

and to check and secure the qualification of the charged users.
Page 4 of 10
BA 822-0004/1 en
6. Operating instructions / training
Duly considering the laws, regulations, directives and national regulations for the prevention of
accidents in force at the respective place of installation as well as internally applicable working,
operating and safety regulations, if any, the operator of the plant is obliged to prepare working
place descriptions and special internal operating instructions/regulations for his staff and the
operating personnel (user).
Note!
Prior to starting actions in and on the plant, the operator of the

plant is obliged to perform training measures and, in dangerous
plant sections, to install well visible warnings and/or hazard
warnings in the respective national language(s) and, if necessary,
emphasize them by the use of hazard symbols.
Like references directly installed on the machine such as a sense-of-rotation arrow, warnings
and safety references must be observed and, therefore, be kept in completely legible condition.
7. Use as directed
The conception of the product assumes a special kind of use. Therefore, it may only be used as
directed. The use as directed is described in the respective operating instructions. In this respect,
the technical specifications with information on the admissible field of application must be
particularly considered, e.g. the admissible environmental and operating conditions.
Another or deviating use is considered not as directed.
Note!
The manufacturer of the plant will not be liable for damage

resulting from a use not as directed.
Deviating local conditions or applications, which were not expressly notified to the manufacturer,
cannot be considered for the manufacture of the product and, thus, cannot be included in the
operating instructions. If cases of that type become known, this urgently requires an agreement
with the manufacturer.
• Depending on the extent of the deviation, it may become necessary that the user has to
operate the plant under his own responsibility or to shut it down, if required.
A further operation of the plant can only be decided on, when the manufacturer and other
competent parties, if any, have been notified of the special changed conditions and measures for
a safe operation have been agreed and realised.
8. Conversions, changes of the operating mode
Conversions and changes of the operating mode deviating from the original conception, can
affect the safety and must not be performed without examination by and approval of the
manufacturer.
Page 5 of 10
BA 822-0004/1 en
9. Safety measures
9.1 Prior to commissioning
Prior to every commissioning, the operator must make sure that
• the plant has no obvious defects,
• all transport guards have been removed,
• all preparatory work has correctly been terminated and checked.
• the product is in proper condition and has been prepared for commissioning duly
considering the operating instructions,
• qualified staff with reasonable safety clothing is available,
• all signal, warning, protective and safety devices are mounted and properly functioning
(e.g. emergency-off systems, protective linings, light barriers, protective doors, separating
and not-separating guards, acoustic warning systems, optical warning systems),
• the trial run with all required setting works has been successfully terminated,
• the safe functioning of the operating and monitoring systems is ensured,
• risks of any kind, e.g. by explosive gases, inflammable dust and electrical lines are
excluded,
• the plant sections requiring supervision permit an unhindered access,
• no persons or obstacles are within the hazard zone of the plant,
• no person can be jeopardized by the connection of the plant,
• and similar
9.2 During operation
During operation of the plant, the operator must make sure that
• the access to the plant is prohibited for unauthorized persons,
• components cannot be put into operation by unauthorized persons,
• authorized persons can enter the plant only after consulting with the operator,
• all components are only operated in technically proper condition and as required for
operation,
• the plant is only operated as directed,
• no inspection doors or covers can be opened, which can entail hazards during operation,
• no persons are transported with material conveying systems (e.g. belt conveyors),
• the plant sections with hazard potential are not left without supervision during operation,
• work on live parts may only be performed by persons charged and trained in this respect,
• lines and sets may not be touched, if the temperature of their outer walls could
exceed 70°,
• cleanliness and clearness of the working place and on and around the machines is
ensured,
• the location and the operation of fire extinguishers is known to the operating staff,
Page 6 of 10
BA 822-0004/1 en
• the rooms are sufficiently vented and ventilated,
• for the case of emergency, first-aid measures to a sufficient extent must be ensured,
• and similar
9.3 Guards and safety systems
• The plant may only be operated with all guards and safety systems. This includes e.g.
mechanical and electrical contact guards, safety valves, contact thermometers, contact
switches, emergency-off switches etc.
• Generally, no guards and safety systems may be dismantled or put out of operation or
modified. This also applies to trial operation.
9.4 Protective equipment and clothing
• The operating staff must be instructed by the operator to wear the personal, well-fitting
protective clothing.
10. Assembly, inspection, maintenance work and repairs
10.1 General
• Assembly, inspection, maintenance work and repairs may only be performed by qualified
and experienced persons, who have been informed on the proper use of tools, lifting- and
transport facilities, who are accordingly trained and also make use of their knowledge.
• The respective references in the operating instructions must be observed.
• The indicated check and inspection intervals must be observed. Irrespective of the above,
the plant must be checked every day for oil leakages and damage.
• All work on the plant is permitted only during a standstill. The procedures for shutting down
described in the operating instructions must be observed.
• Prior to starting the work, the plant must be secured against unintended or unauthorized
connection. (Close main command unit, withdraw key and/or mount warning at the main
switch).
• Prior to the new connection, all guards and safety systems must be mounted or rendered
properly functioning again. Then, a function check of the safety systems must be made.
• Loosened screw unions must be strongly tightened again after the completion of the works
duly considering the specified tightening torques.
• The safe accessibility and working on the working levels must be ensured by climbing
aids, runways and working platforms.
Caution!
Machine parts must not be used as climbing aids.
• All handles, steps, railings, pedestals, platforms, ladders, runways and working platforms
must be kept free from contamination, snow and ice.
• During work at a great height, falling guards must be worn.
• In particular when opening noise-protection hoods, an ear protection must absolutely be

worn.
Page 7 of 10
BA 822-0004/1 en
• The regulations for the use of spray or detergents must be observed.
Caution!
Risk of intoxication and/or burns.
10.2 Welding and torch cutting work
• Prior to welding- or torch-cutting works, the machine/the plant and its environment must be
cleaned from dust and inflammable matter.
• Inflammable parts such as rubber and plastic parts must be covered.
• Ensure a sufficient ventilation.
• Welding instructions must be observed.
10.3 Shifting, loading, transport
• For shifting, loading and transport, the respective safety measures must be taken and the
applicable local accident prevention regulations be observed.
• Furthermore, preparatory measures must be taken such as shutting down, emptying of

containers, fixing of loose parts etc.
• Depending on the instructions given in the operating instructions, prior to the transport, a
suitable and environmental-friendly packing should be ensured, if necessary.
• Machine parts and larger sub-assemblies may only be loaded or transported with
approved, suitable and technically proper loading systems, auxiliary equipment, lifting
facilities, vehicles as well as load carrying means having a sufficient carrying capacity.
• The slinging points for load carrying means may be taken from the respective operating
instructions.
• Shifting, loading and transport of loads may only be performed by experienced and
qualified persons.
10.4 Electrical equipment and machines
• It must be made sure that only qualified persons perform works on electrically operated
machines and systems or that they are supervised by responsible expert staff able to
recognize possible hazards and to avoid them.
• Electrically operated machines and systems are provided with touching guards, which
must by no means be removed during operation.
• The removal of guards can cause serious risks to health or material damage.
• Electrical equipments must regularly be inspected and checked. Defects such as loose
cable connection must be eliminated without delay and in a workmanlike manner.
• Works on motors and generators may only be performed, if these are standing still and the
plant is voltageless and secured against re-starting. During works on voltage-carrying
parts, a second person must be present who, in an emergency case, can activate the
emergency-off switch or the main switch with disconnection of thevoltage. The working
area must be cordoned off with a red-white locking chain and a warning. Only voltage-
insulated tools may be used.
Page 8 of 10
BA 822-0004/1 en
• During works on high-voltage sub-assemblies, after having released the voltage, the
supply cable must be connected to the ground and the components be short-circuited with
a grounding rod.
10.5 Hydraulic and pneumatic system
• Work on pneumatic/hydraulic systems may only be performed by qualified persons with

special knowledge and experience in pneumatics/hydraulics.
• Lines, hoses and screw unions must regularly be checked for leakages and externally
visible damage.
• Defects must be eliminated without delay.
• Hose connections must be replaced at the specified or reasonable intervals, even if

externally no safety-relevant defect can be recognized.
• Prior to starting the repair works, the affected system section must be rendered
pressureless.
10.6 Working materials and auxiliaries
• When handling oils, greases and other chemical substances, observe the specific safety
regulations.
• When handling hot working materials and auxiliaries, there is the risk of scalding or
burning.
• The operator must make sure a safe and environmentally friendly disposal of working
materials and auxiliaries.
10.7 Lubricants
• For a proper operation, observe the correct selection of the lubricants and observe the
lubricating intervals.
• The lubricants and intervals indicated in the operating instructions must be observed.
10.8 Spare parts and accessories
• The operator is informed of the use of spare parts meeting the technical requirements
specified by the manufacturer. This is ensured when using genuine spare parts.
• The liability of the HUMBOLDT WEDAG is excluded in case of damage due to the use of
unsuitable spare parts.
Page 9 of 10
BA 822-0004/1 en
11. Shutting down
• Before leaving the control stand or the plant, the operator must convince himself that the
plant is controlled by a suitable representative or is shut down.
11.1 Emergency disconnection
• In case danger, it must be possible to shut down the plant after the activation of the (easily
accessible!) emergency-off switches.
• After an emergency shutdown, the plant may only be connected again, if the reason for
the emergency shutdown has been eliminated.
12. Recognizing of operational failures
• Deviations from normal operation such as increased temperatures, vibrations, noise,

indicate that important functions may be affected.
• If a direct risk for persons and plant sections is recognized, the next emergency-off switch
must be activated without delay and/or the competent operating and maintenance staff be
informed.
13. Storage
• In case of an extended storage time, please bear in mind that the storage time and/or the
storage conditions can affect e.g. the efficiency period of the lubricants and seals.
Page 10 of 10
Technical Machinery
Documentation
Pyrojet Burner
Section – 0
 Preface, arrangement and sub-division of the Technical

Machinery Documentation
(VG P-13-0052 en)
State : 06.2020
VG P-13-0052 en
Preface Page 1 of 2
This Technical Machine Documentation serves as user information and is meant to facilitate get-
ting familiar with the machine and making optimum use of its possible applications as provided.
It must permanently be available at the place of application.

Previous edition:
The Technical Machine Documentation - here in particular operating manual Chapter „Safety“-
must be read and observed by any person in charge of work such as transport, erection, com-
missioning, operation, maintenance and disposal of utilities and auxiliary materials. It includes
important instructions on how to operate the machine in a proper and economical manner.
Due to existing national regulations the Technical Machine Documentation has to be supplemen-
ted by directives concerning the prevention of accidents and environmental protection.
Moreover, also the approved technical rules on safe and proper operation must be observed.
Copyright
Copyright existing on this Technical Machinery Documentation remains the property of the KHD
Humboldt Wedag.
They contain regulations and drawings of technical nature which must not - nor in whole nor
partly - be distributed or used without authorization for competition purposes or disclosed to
others unless this has not been expressedly approved. A non-observance will entail damages
Mailing address
Humboldt Wedag India Pvt.Ltd.

A-36, Mehtab House,
Mohan Co-operative Estate, Mathura Road,

New Delhi, India
Telephone: + 91-11-42101100/1200
Fax: +91-11-42101104/1105
Website: www.khd.com
Arrangement and sub-division VG P-13-0052 en

of the Technical Machinery
Page 2 of 2
Documentation
“Safety and Health” BA 822-0004/1 en

Note! General References in Operating Instructions
State: 02.2011
SECTION 0: * Preface VG P-13-0052 en

Previous edition:
State: 06.2020 * Arrangement and sub-division of the

SECTION I: Acceptance and test certificates, certificates DA P-13-0052 en

State: 06.2020
SECTION II: Customer-specific characteristic TD P-13-0052 en

State: 06.2020 and technical data
* Characteristic data
* Technical data with List of lube points
SECTION III: Operating instructions

State: 09.2020 * General part BA 407-0797_R2 en
„PYRO-JET-Burner“
* Operating instructions BA 407-0753_R1 en
„Burner carriage, standing
BA 822-0001 en
* Handling of lubricants
HW 6302/15
* Table of lubricants
SECTION IV: Spare Parts List EL P-13-0052 en

State: 06.2020
SECTION V: Documents for the assembly of the machine MU P-13-0052 en

State: 06.2020
Technical Machinery
Documentation
Pyrojet Burner
Section – I
 Acceptance & test certificates, certificates of the

(DA P-13-0052 en)
State : 06.2020
Acceptance and test certifica- DA P-13-0052 en

tes, certificates Page 1 of 2
Contents: Page
Previous edition:
• Noise emission values at the working place . . . . . . . . . . . 2

Noise emission values at the DA P-13-0052 en
Page 2 of 2
working place
CERTIFICATE
High Pressure PYRO-JET-Burner. . . . . . . . . . . . . . . . . : HPJ/ 289 KO
Order-No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : P-13-0052
Previous edition:
The working places of the operating staff for the PYRO-JET-Burner are not determined.
Due to the plant-specific arrangement of the PYRO-JET-Burner including its individual sets within the
thermal plant, noise emissions are generated which can only be measured during plant operation.
The operator must make sure that directly after commissioning, the acoustic power level is measured
during normal operation at all operating positions (e.g. control stand, maintenance and control positi-
ons).
If the measurements indicate that the admissible limit value is exceeded, the staff must wear personal
protective equipment (ear protection).
The operating condition of the PYRO-JET-Burner for the measured values must be designated "normal
operation".
Technical Machinery
Documentation
Pyrojet Burner
Section – II
Customer specific characteristic & technical data –

(TD P-13-0052 en)
 Characteristic data
 Technical data
State : 06.2020
Customer-specific characteristic TD P-13-0052 en
and technical data Page 1 of 13
Contents Page
1. Characteristic data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 General data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Dimensions, space requirement, weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5.1 Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5.2 Burner carriage, Roof Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Previoud edition:
2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Burner data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Burner Outflow Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Primary air values Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Burner carriage, Roof Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.1 Setting device (movement of Burner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.2 Drive Existing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Burner Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Log for burner adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Diagram primary air- Optimum (Low Nox Operation) & Diagram primary air (Design)
10
2.9 Adjustments on the PYRO-JET Burner during commissioning . . . . . . . . . . . . . . . 11
3. Location of lube points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Lube point drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 List of lube points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Page 2 of 13; TD P-13-0052 en
Customer-specific characteristic and technical data
1. Characteristic data
1.1 General data
Customer/ordering party . . . . . . . . . . . . . . . . . . . : Star Cement Meghalaya Ltd., Line - II.

....................................... Star Cement Meghalaya Ltd.
Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Post Lumshnong, Distt. East Jaintia Hills
Meghalaya,-793210. INDIA
Contract item no. . . . . . . . . . . . . . . . . . . . . . . . . . : 481 BU1
KHD-order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . : P-13-0052
Machine identification . . . . . . . . . . . . . . . . . . . . . : PYRO-JET Burner
Machine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . : HPJ/ 289 KO

Year of construction . . . . . . . . . . . . . . . . . . . . . . . : 2020
Assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . : 307-011-130630224 BA
Installation data:
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Approx. 427 m above sea level
Ambient temperature . . . . . . . . . . . . . . . . . . . . . . : Min 7.1°C/ Max.40.2°C
Rel. Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Min. 31 / Max. 98.1
Max. Wind Velocity. . . . . . . . . . . . . . . . . . . . . . . . : 17.8 Km/hr
1.2 Field of application
For firing of specified fuel types in the rotary kiln.
Date of fuels: see Item 1.3.
Page 2 of 13; TD P-13-0052 en

TD P-13-0052 en; Page 3 of 13
1.3 Fuels
Type of fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . : solid / liquid fuels
Solid fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Coal/ Pet coke
Throughput capacity . . . . . . . . . . . . . . . . . . . . . . : 13.287/ 8.858 t/h

Net calorific value Hu . . . . . . . . . . . . . . . . . . . . . . : 5200/ 7800 kcal/kg
Thermal capacity . . . . . . . . . . . . . . . . . . . . . . . . . : 289 KO
Volatiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a. %
Ash contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a. %
Moisture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a. %
Fineness (retained on 0,09 mm) . . . . . . . . . . . . . : n.a. %
Specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a. t/m3

Sulphur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a. %
TD P-13-0052 en; Page 3 of 13

Page 4 of 13; TD P-13-0052 en
1.4 Identification code
HPJ/ 289 KO
Coal / Oil
Heating efficiency
Pyro-Jet
High pressure
1.5 Dimensions, space requirement, weight
1.5.1 Burner
Dimensions:
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 12810 mm
Rated width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Ø 406.4 excluding refractory
Length refractory lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 8000 mm
Weight:
Burner excluding refractory lining . . . . . . . . . . . . . . . . . . . . . . : 5031 kg
Burner including refractory lining . . . . . . . . . . . . . . . . . . . . . . : 8385 kg
1.5.2 Burner carriage, Roof Mounted
Dimensions:
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Existing
Width B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a.
Height H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : n.a.
Weight:
Burner carriage with drive . . . . . . . . . . . . . . . . . . : n.a
Page 4 of 13; TD P-13-0052 en

TD P-13-0052 en; Page 5 of 13
2. Technical data
2.1 Burner data
Control range coal firing . . . . . . . . . . . . . . . . .: 10 : 1
Control range oil firing . . . . . . . . . . . . . . . . . . .: 8:1
Burner pipe diameter. . . . . . . . . . . . . . . . . . . .: Ø 606.4 mm with refractory
2.2 Burner Outflow Components
S.No. Nozzle-/Duct Qty. Dimensions (mm) Remarks
1 Support tube outside 1 Ø 406.4 x 12.7 x500
2 Nozzle Plate (Optimum LowNox) 1 Ø 406.4/270 x 100 1593 mm2
2.1 Nozzle Plate Design 2566 mm2
3 Coal dust nozzle internal 1 Ø 198/ 140 x 180 32556 mm2
4 Nozzle pipe complete 1 Ø 168.3 /140 x 330
5 Swirl 1 Ø 153 x 70 2521 mm2
TD P-13-0052 en; Page 5 of 13

Page 6 of 13; TD P-13-0052 en
2.3 Primary air values Design
Primary air
Stat.
Quantity portion
Systems Pressure
(m3/h) Coal/ Pet coke
(mbar)
(%)
Swirl air fan 1534 160 1.6

Jet air rotary pistonblower 3069 900 3.2
Compressor for coal 3322 600 3.36
transport
2.4 Burner carriage, Roof Mounted
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .: Existing
Travelling speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 4 m/min
2.4.1 Setting device (movement of Burner)
Horizontal direction . . . . . . . . . . . . . . . . . . . . . . . : Screw jack

Vertical direction. . . . . . . . . . . . . . . . . . . . . . . . . . : --
Angular direction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
Page 6 of 13; TD P-13-0052 en

TD P-13-0052 en; Page 7 of 13
2.4.2 Drive Existing

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........
Rating of the drive shaft. . . . . . . . . . . . . . . . . . . . : .......
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........
Type of lubrication . . . . . . . . . . . . . . . . . . . . . . . . : ........
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : ........
2.5 Rating plate
HPJ/289
21771 -- --
13.287/ -- --
10:1
10
289
2020
P-13-0052
TD P-13-0052 en; Page 7 of 13

Page 8 of 13; TD P-13-0052 en
2.6 Burner Record
In this record shall be noted measures carried out on the burner, such as reconstructions, design
changes (if required, by stating the order no. of the firm in charge of this work). Exchanges of spare
parts etc., as well as operating problems. The manufacture should duly be informed..
Reason for Modification

Delivery Manufacturer informed
Date Kind ob probelem
No. Date:
Kind of spare part excange
Page 8 of 13; TD P-13-0052 en

TD P-13-0052 en; Page 9 of 13
2.7 Log for burner adjustment
After the alignment of the burner, we generally recommend to mark on the kiln axis (abt. 3% incli-
nation) the zero position of the burner prior to commissioning.
Every further change during operation shall be documented without delay and can be read from
according scales mounted for that purpose.
A scale at the rear suspension is meant for the height adjustment, the second scale for the lateral
adjustment.
For moving the burner further into or off the kiln, the customer must mount a scale besides the
burner carriage.
Note!
Recommendation for the zero point of the burner travelling carriage:

An immersion depth of the burner mouth into the kiln of 1000 mm is
recommended related to the "kiln point cold".
TD P-13-0052 en; Page 9 of 13

2.8 Diagram primary air- Optimum (Low Nox Operation) & Diagram primary air (Design)
Page 10 of 13; TD P-13-0052 en;

2.9 Adjustments on the PYRO-JET Burner during commissioning
Coal-Transport- Con.
Oil Coal Swirl air Jet air Bypass Blow off Remarks
Air Swirl-Jet
Date Time Pres- Pres- Pres- 0 = closed;

l/h kg/h Flap Flap Flap Flap Flap
sure sure sure 8 or 90 = open
0-8 mbar 0-8 bar yes/no mbar 0-8 0 - 90 0 - 90

TD P-13-0052 en; Page 11 of 13
Page 12 of 13; TD P-13-0052 en
3. Location of lube points
3.1 Lube point drawing
Burner carriage
Geared motor
Page 12 of 13; TD P-13-0052 en

Machine–Type: PYRO-JET Burner HPJ/289 KO List of lube points
Handling of lubricants TD P-13-0052 en; Page 13 of 13
Caution!
see BA 822-0001
3.2 List of lube points
Item-No
Lubricating of lubri- Changing Inspection Refilling volume
No of lubri- Designation of lubricating Total filling volume First change Lubricant type
points cating intervals intervals Oil[l] / Remarks
cating points points Oill [l] / grease[kg] after[h] Oil / grease
drawing point s [h] [h] grease[kg]
drawing
1 2 3
see point 3.1 1 1 Geared motor 7.3 l 350 1 year 6 month CLP 220
2 4 Roller support 0.5 kg 3 years 6 month K3K-20
3 1 Chain 0.1 kg 6 month K3K-20
4 2 Screw Jack 2.6 kg 3 years 1 year K3K-20
5 2 Gear 2.0 l 3 years 1 year CLP 220
6 2 Supporting roller 0.1 kg 3 years 1 year K3K-20
7 1 Bolts 0.1 kg 6 month K3K-20
8 1 Clevis Pin 0.1 kg 6 month K3K-20
1 Item-no. of the lubricating points drawing

3 Remark: e.g. reference to separate documentation
2 Number of lubricating points of identical size
Technical Machinery
Documentation
Pyrojet Burner
Section-III
Operating Instructions:
a) General part Pyroject Burner - BA 407-0797_R2 en
b) Burner Carriage, standing – BA 407-0753_R1 en
c) Handling of Lubricants – BA 822-0001 en
d) Table of Lubricants – HW 6302/15
State : 06.2020
Technical Machinery
Documentation
Pyrojet Burner
Section – III A
Operating Instructions –
 General part `Pyrojet Burner - BA 407-0797_R2 en
State : 06.2020
Contents of the BA 407-0797_R2 en

Operating instructions Page 1 of 1
State 12.2007 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-01 en

* Introduction
BA 407-0797_R1 en State: 09.2012
* Explanation of symbols and information

* Field of application
* Copyright
State 12.2007 Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-02 en

* Safety information
Previous edition:
* Proper use
State 09.2012 Design and functioning . . . . . . . . . . . . . . . . . . . . BA 407-0797-03_R1 en

* Design
* Functioning
State 12.2007 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-04 en

* Packing
* Transport
* Degree of decomposition
* Sensitivity
* Paint
* Intermediate storage
* Scope of supply
* Storage of damaged parts
State 12.2007 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-05 en

* General instructions
* Conditions for arrangement
* Erection
* Erection of accessory equipment
State 09.2012 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-06_R1 en

* Instructions
* Collection of operating data
* Commissioning
* Operation of pressure gauges
* Commissioning of accessory equipment
State 09.2016 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-07_R1 en

* Normal operation
* Shutdown of the PYRO-JET-burner
* Operational safety
* Elimination of failures
* Pipe clogging and remedial action
State 09.2012 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0797-08_R1 en

* Inspection and servicing
* Reconditioning of the PYRO-JET-burner
* Repair tools and devices
State 12.2007 Spare parts keeping and after-sales service . . . . . . . . . BA 407-0797-09 en

* Spare parts keeping
* After sales service addresses
BA 407-0797-01 en
General
Page 1 of 3
Contents Page
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Explanation of symbols and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Field of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BA 407-0797-01 en
4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
1 Introduction
These information are meant to be read and observed in all items by those being respon-
sible for the Humboldt Wedag-PYRO-JET-Burner.
The complete technical documentation must always be kept near the PYRO-JET-Burner.
Details of particular importance for the use of the PYRO-JET-Burner are pointed out in the
operating instructions.
Only the knowledge of the present operating instructions (BA) may ensure a trouble-free
operation of the PYRO-JET-Burner. Therefore, it is very important that these operating
instructions are really known to the persons in charge.
We recommend to carefully study the present instructions as the manufacturer will not be
liable for damage and operational failures resulting from the non-observance of these
instructions.
The firing plant must only be assembled, serviced and operated by suitably trained and
qualified staff.
If, nevertheless, problems should occur during operation, please contact our after sales
service or the spare parts department or one of our agencies. They will be readily pre-
pared to assist you (refer to chapter " Spare parts keeping and after-sales service").
The present operating instructions exclusively refer to the PYRO-JET-Burner with the
auxiliary equipment included in the supply.
The illustrations are binding, however not true to scale.
We reserve the right to make technical changes necessary for improving the butt
stripping machine which are deviating from the descriptions and data given in these
Note!
This operating manual is a preliminary version, which, upon

commissioning, will be supplemented by data and instruc-
tions in accordance with the respective special plant opera-
ting conditions.
Page 2 of 3; BA 407-0797-01 en
General
2 Explanation of symbols and information
2.1 Safety symbol
In the present operating instructions (BA), this symbol appears in

connection with all safety information concerning the danger to
life and persons. Observe these information and behave most
carefully in such cases. Also inform all other users of these safety
information. apart from the information given in this BA, the gene-
rally applicable regulations for safety and accident prevention
must be observed.
2.2 Attention reference
Caution!
This reference appears anywhere in the present BA where features

of particular importance must be observed to follow the regulations,
directives, information or the correct course of the works and to
avoid damage to or the destruction of the equipment and/or other
plant sections.
2.3 Information
Note!
This reference draws your attention to general operating informa-

tion which must be particularly observed.
2.4 Ear protection information
This symbol will appear near all safety information in the present
operating instructions (BA), where due to the influence of noise,
hearing defects may occur. Observe this information and absolu-
tely wear your personal protection aids, e.g. ear protection.
Page 2 of 3; BA 407-0797-01 en
BA 407-0797-01 enPage 3 of 3
General
3 Field of application
The PYRO-JET-Burner is a combination bumer, which - depending on design - enables simulta-

neous firing of solid, liquid and gaseous fuels or altenatively firing with varying fuel portions.
Caution!
The PYRO-JET-Burner has only been designed for the field of application
indicated in section "Customer-specific characteristic and technical data/
Field of application".

Prior to using the PYRO-JET-Burner beyond the contractually stipulated
field of application (see secton "Customer-specific characteristic and
technical data/Field of application"), consult the after-sales service of the
Humboldt Wedag (address as per section "Spare parts keeping and after-
sales service" as, otherwise, a warranty will not be given
4 Copyright
The copyright to the present operating instructions (BA) remains with the Humboldt Wedag. The
instructions are meant for the installation, operating and supervision staff. They contain regulati-
ons and drawings of technical nature which must not - nor in whole nor partly - be distributed or
used without authorization for competition purposes or disclosed to others unless this has not
been expressedly approved. A non-observance will entail damages.
Humboldt Wedag 
http:/www.khd.com
BA 407-0797-01 en; Page 3 of 3

Technical Machine Documentation State: 12.2007
Safety and Health BA 407-0797-02 en
Page 1 of 7
Contents Page
1. Explanation of symbols and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Attention reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Ear protection information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BA 407-0797-02 en
2. Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Person-related safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
2.2.1 Risks to health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Machine-related safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Safety references and regulations for handling coal dust . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety references and regulations for handling fuel gas . . . . . . . . . . . . . . . . . . . . . 7
3. Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. Explanation of symbols and information
1.1 Safety symbol

connection with all safety information concerning the danger to life
and persons. Observe these information and behave most carefully
in such cases. Also inform all other users of these safety informa-
tion. Apart from the information given in this BA, the generally
applicable regulations for safety and accident prevention must be
observed.
Caution!
This reference appears anywhere in the present BA where features

of particular importance must be observed to follow the regulati-
ons, directives, information or the correct course of the works and
to avoid damage to or the destruction of the machine and/or other

plant sections.
1.3 Information
Note!
This reference draws your attention to general operating informa-

tion which must be particularly observed.
Page 2 of 7; BA 407-0797-02 en
Safety and Health
This symbol will appear near all safety information in the present
operating instructions (BA), where due to the influence of noise,
hearing defects may occur. Observe this information and absolu-
tely wear your personal protection aids, e.g. ear protection.
2. Safety information
2.1 General safety information
• The PYRO-JET burner has been constructed according to the approved technical rules and
regulations and is operationally safe. However, this machine can entail risks, if it is impro-
perly operated by unskilled staff or is used in another way than directed or commissioned or
operated not observing the instructions given.
• The competences during assembly, dismantling and re-assembly, commissioning, operation

and maintenance must be clearly defined and observed to avoid unclear competences
under the aspect of safety.
• During all works concerning assembly, dismantling, re-assembly, commissioning, operation,

conversion, adaptation and maintenance, the disconnection and safety procedures laid
down in the Technical Machine Documentation must be observed.
• No working method is permitted which could affect the safety of the PYRO-JET burner or
jeopardise the staff.
• By suitable instructions and checks, the user must ensure cleanliness and clearness of the
working place at the PYRO-JET burner.
• Unauthorised conversions and changes affecting the safety of the PYRO-JET burner are not
permitted.
• All repair works at the PYRO-JET burner must generally be made with the system standing
still and cooled down.
• Generally, for the installation and operation of the PYRO-JET burner, the applicable legal
regulations and directives must be observed, in particular the accident prevention regulati-
ons for firing systems.
• Hazardous areas must be marked and their access blocked. It is not permitted to enter such
areas.
Prior to first starting up, safety and monitoring facilities must absolutely
be installed. They must by no means become out of order or put out of
functioning.
Page 2 of 7; BA 407-0797-02 en
BA 407-0797-02 en; Page 3 of 7
Safety and Health
• The removal or putting out of functioning of safety devices, e.g. for repair works is only per-
mitted during a standstill of the PYRO JET burner. After the completion of the works, the
safety devices must be mounted again or put into operation.
• Works and repairs at the PYRO JET burner are only permitted to be performed upon agree-
ment with the shift leader in charge.
• The mentioned regulations reduce the risk of hazards, if the activities are performed with the
necessary and directed care.
The access to the rotary kiln plant is only permitted with the required pro-
tective clothing.
2.2 Person-related safety references
• The PYRO JET burner must be operated, maintained and repaired exclusively by authori-
sed, trained and skilled staff. This staff must have been given a special training by the
respective person in charge as regards possible dangers.
• Every person who, on the premises of the user, is in charge of assembly, dismantling, re-
assembly, operation and maintenance (inspection, maintenance, repairs) of the PYRO JET
burner must have read and understood the complete operating instructions and, in particu-
lar, the chapter "Safety".
Caution!
The operator is recommended to have this confirmed in writing in every

individual case.
• The operating staff is obliged to notify without delay any changes noticed at the PYRO JET
burner affecting the safety.
• The operator must oblige himself to always keep the PYRO JET burner in a proper condition
and to operate it under safe circumstances.
• The person responsible in the sense of this description is the person charged by the opera-
tor with the management of and the responsibility for the PYRO JET burner.
• To permit the safe performance of maintenance and/or repair works, the operator has to
nominate a responsible shift leader who will co-ordinate these works and determine the
competences between operating- and maintenance staff.
• The access to and inspection of the PYRO JET burner is only permitted, if:
– all systems are secured against re-starting
– the responsible shift leader has been informed
– the PYRO JET burner has been moved out and cooled down
– all safety measures have been taken.
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Page 4 of 7; BA 407-0797-02 en
Safety and Health
With the rotary kiln plant running, it is prohibited to stay in the dangerous
zone!
• In the burner area, working places in the sense of the working place regulations are the par-
ticularly specified, closed rooms such as switching- and operating stands as well as other
rooms for masters, offices or workshops which must not be assigned to the area influenced
by the burner, i.e. which must be protected against radiation heat, noise and dust.
• The environment of the PYRO JET burner with platforms, runways etc. is subjected to high
temperatures and dust loads and is no working place. The access to the specified areas
with suitable protective clothing is only meant for the purpose of inspections as well as main-
tenance and repair measures or, if required, for determining measured values.
• Works on electrical systems are only permitted to be performed by skilled staff.
Wear the specified personal ear protection.
Wear the specified protective clothing.
2.2.1 Risks to health
• The PYRO JET burner can entail the following risks for the staff due to improper operation,
maintenance, assembly or conversion:
– Burns by radiated heat, touching of hot surfaces, emerging of hot media.
– Injury of the ears by medium to heavy noise emissions.
– Risk of fire or explosion due to emerging coal dust, gas or oil.
– Risk of electrical injuries due to short to earth, short-circuit or capacitate charge.
– Risk of slipping, tumbling, falling due to residues of oil, dust, coal dust or insufficient
lighting.
– Breathing of gases or coal dust in case of defective seals.
– Risk of squeezing or hitting on machine parts or when moving out the burner or due to
lacking protective or warning devices.
Page 4 of 7; BA 407-0797-02 en
BA 407-0797-02 en; Page 5 of 7
Safety and Health
2.3 Machine-related safety references
• Prior to starting the works, the drives and auxiliary devices must be secured against uninten-
ded connection. This is possible with a lockable local switch.
• The working instructions for isolating or closing the main fuse must be given in writing and
must be signed by the responsible electrician after the completion of the works.
• Remove protective devices only upon a standstill of the secured drives.
• Prior to starting after repair works, check, whether all protective devices have been mounted
again.
• The carrying capacity of the lifting facilities must at least correspond to the weight of the bur-
ner.
• Only suitable and properly functioning lifting facilities are permitted to be used.
• After the electric installation or repairs to the electric system, the protective measures
applied must be tested (e.g. grounding resistance).
• Regularly check warning paintings and renew them, if necessary.
• All warnings at the PYRO JET burner must completely be kept in a legible condition.
• Maintenance and inspection intervals (see section "Maintenance/Maintenance- and Inspec-

tion List") are only permitted to be performed by skilled staff.
• Only use genuine spare parts as these meet the requirements of the manufacturer. When
using other spare parts, there will be no liability from our side.
• All works on the PYRO JET burner must generally be performed upon a standstill in cold
and secured state.
• During operation, protective devices of the machine must be in the protecting position as
directed.
Note!
In addition, the safety references in the enclosed documentations of the

suppliers must be observed.
• For cooling the burner, the primary air blower must always be ready for operation. To that
end, the blower must be interlocked with the emergency power supply of the overall plant.

If an emergency power supply should not exist, the burner must be withdrawn from the hot
kiln system within 20 minutes.
2.4 Safety references and regulations for handling coal dust
The safety regulations for the coal dust firing systems in the area of the burner platform are the
same as for the entire residual coal dust firing systems, e.g. mill, bins, dosing.
Generally, for handling of coal dust, the respective official rules and regulations or the accident
prevention regulations will apply. In particular, the following safety references must be observed:
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Page 6 of 7; BA 407-0797-02 en
Safety and Health
– Coal dust whirled up in the air entails the risk of fire and explosion. Therefore, never whirl up
coal dust.
– Stored coal dust has the tendency to self-ignition.
– Some types of coal dust release narcotising and explosive gases.
– Keep the plant absolutely clean. Motors and switches must be kept free from coal dust
deposits.
– During operation, do not open manholes and inspection flaps in the grinding and bin system
as, by the entrance of air, the system being under negative pressure can generate an explo-
sive dust-air mixture. For the same reasons, possible leakages at containers and pipelines
must be eliminated without delay. Coal dust emerging from the system must be removed
with a vacuum cleaner.
– Open flames and smoking in rooms where works with coal dust take place are generally
prohibited.
– Welding at coal dust bearing parts is only permitted with the system shut down after tho-
rough cleaning and observing the strictest precautionary measures. (Written approval of the
plant management required).
– Monitor the temperature of the stored coal dust.
– In case of an acute risk of fire or explosion, immediately interrupt the supply of coal dust and
avoid the entrance of fresh air and prevent the coal dust from being whirled up.
– If possible, endangered bins must be run empty into the firing system. If this should not be
possible, quench the fire. An indicator for a risk is, e.g., the rise of the temperature or of the
CO-content in the bin.
– Fires in bin-stored or stockpiled coal dust must not be fighted with a water jet but only with
an extinguishing method suitable for coal dust (e.g. steam, foam, carbon dioxide, nitrogen
etc.).
– Spread, smouldering or burning coal dust can also be extinguished with wet bags which
must permanently be kept wet.
– Extinguishing systems, pressure relieving facilities such as explosion flaps etc. and shut-off
gates must be regularly checked.
– Do not enter a bin filled with coal dust. Enter emptied bins only with the approval of the plant
management after sufficient ventilation and in the presence of a second person. Secure the
entering person with a rope. Secure the rope and keep oxygen breathing systems available.
– Prior to entering the mill, it must be made sure that the mill cannot start by removing the
main fuse of the mill motor.
– When starting the firing system after an operational failure, e.g. upon a current supply fai-
lure, the coal dust volumes deposited in the transport system can enter the burner or the
firing compartment without control. Measures must be taken to avoid a deflagration or
explosion. For example, reduce the set fuel oil volume (if this is not automatically set to "0"
upon an operation failure) or increase the O2- or combustion air volume or empty the
system by inching operation at smallest speeds and then start coal dosing again at the
smallest volume.
– Prior to every start of the burner, the required blowers/compactors must be connected and a
normal pressure drop must exist before starting the coal dust dosing system (increased
pressure indicates cloggings).
– Make sure that the burner carrier tube and all coal dust carrying lines etc. are always groun-
ded to avoid electrostatic charging.
Page 6 of 7; BA 407-0797-02 en
BA 407-0797-02 en; Page 7 of 7
Safety and Health
2.5 Safety references and regulations for handling fuel gas
The firing system is constructed according to the general DVGW-regulations (German Associa-
tion of the Gas- and Water Industry), TRD 412 (Technical Regulations for Pressure Vessels) as
well as the DIN-, VDE-, VDI- and the accident prevention regulations (VBG-regulations) and
must be operated observing all of them.
In case of danger due to emerging gas resulting from leakages, fire, flame blow-off etc., the local
emergency-off switch near the burner platform must be activated. If this should not be possible,
the emergency-off switch in the not endangered area of the escape way must be activated.
Moreover, particularly observe the enclosed operating instructions for auxiliary equipment and
fittings, see chapter "List of the separate documentations".
The gas-bearing lines must regularly be checked with a gas detection instrument.
Possible welding works to the pipeline after the operation of the burner system must only be per-
formed, after the pipeline has been cleaned from the gas residues (blown off). The pipeline must
be secured against following up gas which can be realised with a plug-on disc or a blind flange at
the manual shut-off cock in front of the respective fitting path. Furthermore, an inertisation with
CO2 or N2 is recommended.
Smoking and open flames are prohibited during all works on gas-bearing lines.
3. Proper use
• The PYRO JET burner is only permitted to be operated under the conditions laid down in the
"Technical data/Field of application". Any use beyond this is considered not as directed. The
manufacturer will not be liable for resulting damage, the risk will be borne by the user alone.
• The proper use also includes the observation of the conditions for assembly, dismantling
and re-assembly, commissioning, operation and repairs as well as of further regulations of
the Technical Documentation.
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BA 407-0797-03_R1 en
Design and functioning
Page 1 of 11
Contents Page
1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0797-03 en State: 12.2007
1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Burner with three inslide burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 Identification of burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Function principle of PYRO-JET-burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Burner functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Previous edition:
2.4 Influencing the flame shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Influencing the flame position in the kiln. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.6 Connection of the fuel and air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Safety devices and functional requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Operation course, monitoring and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.9 Foreign body separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.10 Typical outflow conditions at PYRO-JET-burner . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Design
1.1 General
Depending on specific design, the PYRO-JET-burner enables firing of coal, oil, gas or a
mixture of these fuels. The burner is supported on the burner carrier in that manner that it
can be swivelled and displaced. Coal dust is pneumatically supplied via telescopic pipes.
Fuel oil and gas are fed via hose connections. Swirl- and Jet-air are connected to the pri-
mary air distributor via flexible hose connections.
Note!
The Item numbers refer to the documentation drawing "coal

dust burner" in section "List of the documentation and
spare part drawings".
Page 2 of 11; BA 407-0797-03_R1 en
1.2 Burner with three inslide burner
For illustration see documentation drawing “Coal dust burner “ in the section “List of documenta-
tion and spare parts drawings“.
For identification of burner components, see item 1.3
The burner essentially consists of concentrically arranged tubes which form ducts and which are
identified by numbers from the inside towards the outside.
Duct 1 is formed by 3 supporting tubes (12.5), i.e. a supporting tube for the gas lance, oil
nozzle assembly and a supporting tube for the ignition burner. The supporting tubes
are guided or centred in the internal burner pipe (12.4).
Duct 2 conveys the swirl air and ends at the burner mouth with the swirl body (12.8) which is
tack-welded onto the supporting tubes for the slide-in burners (12.5).
Duct 3 conveys the carrier air laden with coal dust and ends at the burner mouth in an annu-
lar gap which is conically opening outwards. For reasons of wear, the conus angle of
the coal dust nozzle has been kept small.

To the coal dust pipe (12.3) separating the coal dust and jet air duct, the outer nozzle
disc (12.6) is welded. The inner coal dust nozzle (12.7) is screwed into the inner
nozzle pipe (12.4.1) which separates ducts 2 and 3 - combined with the inner burner
pipe (124). The inner burner pipe (12.4) is guided or centred with supporting ribs in the
coal dust pipe (12.3).

The coal dust is directed to duct 3 via the coal dust socket mounted with an inclination.
This connection socket is provided with an inspection opening with cover from where
the coal dust inlet area can be inspected.

The walls of duct 3 are protected against wear by a ceramic lining in the area of the
coal dust feed. The lining comprises small glued on wear-resistant ceramic plates.
The ceramic war protection of the outer area of duct 3 is glued onto the inner sides of
pipe half shells which are slid into the coal dust pipe (12.3). At the end flange of duct
3, the pipe half shells are secured against swirling and slipping by weld points. The
ceramic wear protection of the inner area of duct 3 is glued onto the surface of the
inner burner tube (12.4).The ceramic lining can be inspected through the inspection
opening of the coal dust socket. The surfaces of the parts of the coal dust outlet
system subject to wear are especially treated.
Duct 4 conveys the jet air and ends at the burner mouth with the nozzle disc (12.6), which is
welded to the coal dust pipe (12.3) and the burner supporting pipe (12.1). The nozzle
disc is provided with jet nozzle bores.
The burner tubes expand during operation to different degrees. The thermal expansions are
balanced by the axial compensator (12.2) which is accordingly pre-stressed, i.e. depending on
the burner design and size, it is extended by 10 to 30 mm.
All parts of the burner outlet system, except for the oil inslide burner, are ending flush in cold con-
dition. Tolerances of + 1 mm are admissible. The oil inslide burner is protruding by 10 + 1 mm
over the burner mouth to balance the thermal expansion during operation.
All flanged connections are bridged with copper wire to safely ground electrostatic charges.
Page 2 of 11; BA 407-0797-03_R1 en

BA 407-0797-03_R1 en; Page 3 of 11
Note!
The bolts, nuts and washers of the grounding bridging are corrosion-pro-
tected.
The outer cooling shell (12.60) must be locally provided with a refractory lining.
Duct 2 (swirl air) and duct 4 (jet air) are flanged via supports to the primary air distributor. Bet-
ween supports and primary air distributor, always one throttle flap and connection socket for
pressure measuring instruments are provided for.
Prior to feeding coal dust, a short connection line between primary air line and coal dust duct are
arranged. This bypass comprises a throttle flap and a blow-back valve.
1.3 Identification of burner components
For illustration see documentation drawing “Coal dust burner “ in the section “List of documenta-
tion and spare parts drawings“.
Identification of burner components see in the section .
Item
12.1 Burner carrier tube
12.2 Axial expansion joint
12.3 Coal dust tube V
12.4 Inner burner tube V
12.5 Carrier tube for additional/insertion burner
12.6 Outer ring V
12.6.1 Burner carrier tube section replaced during repairs V*)
12.7 Nozzle plate V*)
12.8 Outer nozzle tube V 1)
12.9 Inner coal dust nozzle V
12.10 Inner nozzle tube V 1)
12.11 Swirl element V
12.12 Insertion burner/additional burner
12.13 Seal V*)
12.14 Seal V*)
12.15 Seal V*)
12.16 Grounding wire
12.17 Washer(corrosion-resistant)
12.18 Bolt (corrosion-resistant)
12.19 Protective ceramic wear lining V
12.19.1 Protective ceramic wear lining for repair V*)
12.20 Adhesive f. protective ceramic wear lining V
12.20.1 Adhesive f. protective ceramic wear lining for repair V*)
12.21 Heat-resistant lubricant (e.g. Anti Seize AS 2000)
12.22 Heat resistant sealing agent (e.g. WEVOPAT)
12.23 Refractory lining
12.24 Coal dust connection socket
12.25 Half tube shells (with protective ceramic wear lining)
12.30 Special repair welding electrode DIN8556 E2520 B20+ V*)
BA 407-0797-03_R1 en; Page 3 of 11

Page 4 of 11; BA 407-0797-03_R1 en
12.31 Special repair welding electrode DIN8556 E18 MN 6B20+ V*)

12.32 Special repair welding electrode DIN1913 E5143RR(B)8 V*)
V: wear part/consumables/auxiliaries.
*): these parts resp. materials must be kept available during commissioning
1): for order placing, specify the length
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BA 407-0797-03_R1 en; Page 5 of 11
2 Functioning
2.1 General
The design of the PYRO-JET combination burner is based on the practical experience of many
years considering the results of extensive studies of research and development.
The Humboldt Wedag developed the PYRO-JET burner for the economic firing of coal dust in the
rotary kiln. During the development, the findings of the proven Humboldt high-pressure gas bur-
ner were utilised for the rotary kiln which can be operated without primary air.
The PYRO-JET burner is a combination burner. Depending on its design, solid, liquid and
gaseous fuels can be fired at the same time or alternatively at different portions.
The essential advantages of the PYRO-JET burner are the following:
– High efficiency, low primary air requirement
– Combustion suitable for rotary kilns
– Tight flame, also for short rotary kilns
– Optional fuel combination
– Use also of coal of minor quality
– Large control range of the fuel throughput
– Primary air portion and flame shape can be varied without influencing the pneumatic coal
dust transport
– High availability
– Reduction of the NOx emission
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Page 6 of 11; BA 407-0797-03_R1 en
2.2 Function principle of PYRO-JET-burner
The PYRO-JET burner is meant for introducing the processed fuel into the kiln such that it is
intensely mixed with the combustion air, rapidly ignited and completely combusted. The correct
design and setting of the firing system is decisive for the uniform, continuous and economic ope-
ration of the rotary kiln.
The course of the heat transition via convection and radiation depends on the burner conditions
and the respective kiln plant. The most favourable flame shape must be set during commissio-
ning. Here, it must be made sure that rotary kiln components such as the inlet and outlet seg-
ments as well as the refractory bricklining are not overheated. For a low heat consumption, a
short flame is favourable. This requires the rapid mixture of fuel and combustion air which shall
be available as about 1000°C hot secondary air at sufficient volumes.
The secondary air flows into the kiln only at low velocity. The desired rapid mixture of fuel and
combustion air requires an acceleration of the secondary air velocity. This is achieved by blowing
in part of the primary air through nozzles. The jet effect of the nozzles is such strong that hot
secondary air is sucked into the burner mouth. In this way, the fuel is strongly whirled with the
secondary air, resulting in a rapid ignition and a good combustion at short flame. Swirling of the
coal particles in the burner must be renounced in view of the connected wear and clogging. The
flame length is also essentially determined by the fuel type and the size of the fuel particles, the
grain distribution, the moisture and the dosing constancy. Generally, with increasing portion of
volatiles, the burning time is reduced. Other influences such as the agglomeration of the coal
particles can be counter-acted.
The combustion time is a function of the coal grain size. It increases at a square ratio with the
particle edge length. The optimal grain fineness is best determined via tests in the respective
plant considering the coal grinding costs. An approximate guideline for the grinding fineness can
be that the screen residues at 0.09 mm in % by volume should be 0.5 to 1 time the content of
volatiles in percent of the water-free coal.
To reduce the risk of self-ignition, the coal dust moisture must not fall below the following values:
for hardcoal: 1-2%
for lignite: 10-12%
A further pre-condition for an optimal combustion course is the uniform and continuous fuel sup-
ply. Deviations from the dosing constancy of + can be tolerated.
Deviations in the calorific value of coal dust and of the chemical composition are disadvan-
tageous. Disturbing components such as sulphur, chlorides and similar must be limited in their
portions. Where this is not possible, e.g. different coal types can be blended.
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BA 407-0797-03_R1 en; Page 7 of 11
2.3 Burner functions
The required portion of primary air is about 10-14 % by volume of the entire combustion air
volume and is made up as follows:
3.0-40 % by volume Transport air for the coal dust

6.5 % by volume Swirl air
3.5 % by volume Jet air
A smaller volume of primary air is flowing via bores from duct 2 into duct 1 to form the oil spraying
cone and to cool the inner part of the burner mouth as well as the inner part of the inslide burner.
The air pressures in front of the nozzles (see section "Customer-specific characteristic and tech-
nical data / Primary air volumes") determine the velocities in the individual duct outlets. The
dependences are represented in the diagram of the primary air outlet speeds ("Performance dia-
gram primary air", see section "Customer-specific characteristic and technical data"). They are
approximately the following:
Coal dust transport air abt. 25 - 30 m/s

Swirl air abt. 150 - 160 m/s
Jet air abt. 300 - 350m/s
Due to the special arrangement of the burner outlet system, the fuel mixture is introduced into the
burning compartment such that, due to turbulences, re-circulation and the free jet effect, a good
mixture, a rapid ignition and a good combustion result.
The effect of the swirl air is that the coal dust, which is entering the burning compartment in a fun-
nel-shaped flow, is coming into contact with oxygen on the shortest possible way.
The negative pressure of up to 12 mbar in the whirl core generates a re-circulation. Hot gases
are flowing back to the flame starting point and stabilise the flame.
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Page 8 of 11; BA 407-0797-03_R1 en
2.4 Influencing the flame shape
The flame shape in the rotary kiln can be influences by changing of the primary air volumes for
swirl air and jet air or of the pressures at the throttle flaps.
The flame shape can also be influenced by a variation of the nozzle outlet speed of the fuel mix-
ture (mostly coal dust). One option is to admix conveying air to the fuel transport air (coal dust
transport air) prior to entering the annular duct 3. The statical pressure of the additional convey-
ing air must always be higher than the statical pressure in the coal dust conveying line. If the sta-
tical pressure in the coal dust conveying line is higher than in the air supply line, the shut-off flap
between air line and coal dust conveying line must not be opened. When adjusting the throttle
flap, make sure that the velocity limits (for coal dust min. about 25 m/s and max. about 30 m/s)
are observed. Excessively low speeds will entail clogging by deposited coal dust or pulsations by
the "dune effect". Higher velocities favour the wear in the burner.
For major variations of oufflow velocities, order suitable nozzle plates or Jet nozzle inserts resp.
as special accessories.
During normal operation at a secondary air temperature of at least 800 C, the following inter-
relations are generally applicable.:
Jet air Swirl air coal dust conveying air
Extension of flame length reduction reduction increase
Shortening flame length increase increase reduction
With a view to flame formation, the solid fuel types may have characteristics of their own.depen-
ding on the oufflow velocity.The optimal outflow velocity can be determined by tests during com-
missioning and operation.
For optimizing burner and /or flame shape. Also consider all essential kiln data. 
These, in particular, are:
– kiln shell temperature
– analytical waste gas values O2, CO, NOx
– waste gas temperatures
– coating conditions inside rotary kiln and preheater
– gas resistances
– power consumption of kiln drive.
2.5 Influencing the flame position in the kiln
The flame direction and the immersion depth of the burner in the kiln are adjusted according to
the operation conditions of the respective rotary kiln. The burner carrier to which the burner is
fastened permits the horizontal adjustment and the introduction or retraction, respectively, of the
burner into/from the kiln and turning it to either side by about 3°.
2.6 Connection of the fuel and air lines
According to the movement possibilities of the burner, the supply lines are designed flexibly or
movable. Normally, the coal dust is pneumatically fed via telescopic pipes. Fuel oil, gas, swirl-
and jet air are supplied via flexible hose connections.
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BA 407-0797-03_R1 en; Page 9 of 11
2.7 Safety devices and functional requirements
To avoid electrostatic charging of the burner, all coal dust carrying systems and supply lines are
grounded.
All coal dust conveying systems and the burner are of pressure-resistant design without pressure
relief for 10 bar. Hence, in case of an explosion, there is no risk of bursting, as the explosion
pressure in the closed vessel is 9 bar at a maximum
The control system is designed such that the fuel can be released, if previously the rated value
has been set to "0".
Triggering of the fuel distribution is realised such that the fuel supply upon starting is not automa-
tically released and, during normal operation, the fuel supply is automatically interrupted within
about 1 second and during starting within 5 seconds, if:
1. the required atomisation pressure has been fallen below 

(time function element jet air: up to 5 min. follow up, swirl air: only alarm)
2. the set fuel volume is exceeded (e.g. +5% : 10 sec.)
3. the combustion air supply fails
4. the conveying air supply fails
5. the waste gas blower (preheater blower) fails or the waste gas flap is closed
6. the limit values of O2 and CO, the firing compartment pressure or the waste gas tempera-
ture are exceeded
7. the OFF-switch on the burner platform or in the control stand is activated
8. a failure disconnection has taken place
9. the main switch was activated
10. the burner or the burner lance were turned out or extracted
11. the conveying air pressure is exceeded over a time of 3 seconds
If the causes 1. to 11. have been eliminated, the burner can only be started manually.
Upon starting of the firing system after an operational failure, e.g. upon a power failure, coal dust
deposited in the transport system can enter the burner or the firing compartment without control.
Measures must be taken to avoid a deflagration or explosion, e.g. reducing the fuel oil volume (if
this should not be automatically set to "0" upon an operational failure) or increasing the O2- or
combustion air volume or running the system empty via inching operation at smallest speeds and
then starting the coal dosing system with the smallest volume.
Prior to starting the coal dust firing system, start the inslide burner.
Upon combined operation, only start with oil or gas. Prior to connecting the coal firing system, the
oil or gas volume is accordingly reduced or, depending on the kiln situation, the combustion air
volume increased. Such, the O2 portion of the waste gases is automatically increased.
BA 407-0797-03_R1 en; Page 9 of 11

Page 10 of 11; BA 407-0797-03_R1 en
If a burner failure was due to clogging of the coal dust conveying system, the conveying paths
must be cleaned before re-starting.
To ensure the necessary cooling of the burner by fresh air, in case of a black out or other distur-
bancies, operate the cooling air fan permanently with the emergency power supply.
2.8 Operation course, monitoring and control

Note!
For the operation course, in particular control, monitoring and regulation,

the documents in the documentation for the plant and the electric system
must be observed.
(Humboldt Wedag supply or customer supply acc. to contract).
The PYRO-JET burner is normally operated by hand, i.e. all connection-, ignition- and discon-
nection procedures as well the control of the burner performance are made or initiated manually.
The disconnection of the burner by the response of safety devices such as air lack control, CO-
max. limitation or flame monitoring systems can be considered an automatic procedure.
Requirement see under item 2.7 and information in chapter “Commissioning“, item 3.1.
The cold starting phase must be visually monitored and the fuel supply stopped in case of a
flame blow-off.
2.9 Foreign body separator
According to the experience made, the coal dust is not always free from foreign bodies. These
can cause operational failures, e.g.:
• Blocking of rotary locks and conveying pumps
• Explosions by the generation of sparks or running hot of the conveying pump bearings or
seals.
Conveying ducts can clog in particular in the areas of changing cross sections. The increased
resistances cause failures in the dosing- and conveying system as well as damage to the seals.
In the clogged areas, an increased wear at the pipelines occurs due to the increased velocity and
formation of whirlings. The risk of explosion rises by possibly emerging coal dust.
Therefore, we recommend the installation of foreign body separators at the following points:
1. for the coal dust supply, in front of the conveying elements for silo feeding
2. in the coal dust discharge system underneath the silo
3. in the coal dust transport line prior to entering the burner.
Foreign body separators can be ordered and delivered as special accessories.
Page 10 of 11; BA 407-0797-03_R1 en

BA 407-0797-03_R1 en; Page 11 of 11
2.10 Typical outflow conditions at PYRO-JET-burner
Designation:
1 Nozzle Plate
2 Swirler
3 Coal dust nozzle
4 Coal dust tube outside
5 Coal dust tube inside
6 Support tube outside
BA 407-0797-03_R1 en; Page 11 of 11

BA 407-0797-04 en
Transport
Page 1 of 3
Contents Page
1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Degree of decompositon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BA 407-0797-04 en
4 Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
6 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 Storage of damaged parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Packing
The transport route is a factor in determining the type of packing used. Unless otherwise
specified or agreed in contract, Humboldt Wedag packing standards shall be used..

The symbols on the packing must be observed.
e.g.:
Page 2 of 3; BA 407-0797-04 en
Transport
2 Transport
For the transport, the burner is bolted to wooden girders and for sea transport packed in a box.
The openings, e.g. burner mouth and pipe connections, must be protected against the ingress of
foreign bodies and dirt with the aid of wooden discs.
Depending on the possibilities or the contractual agreements, loose hardware and pipelines must
be bundled or packed in boxes, special supply parts such as ignition burners, valves, switches,
fittings etc. must be standard-packed by the Humboldt Wedag suppliers; depending on the con-
tractual agreements, they are dispatched, as sea-worthy collective packing.
3 Degree of decompositon
The PYRO-JET burner is dispatched in assembled condition without refractory lining.
The refractory lining with anchoring must be mounted at the place of application prior to commis-
sioning.
4 Sensitivity
Be careful when tansporting the PYRO-JET burner to avoid damage due to the influence of force
or careless loading and unloading.
During transport, avoid the formation of condensed water due to high temperature deviations.
On the site, store the PYRO-JET burner and its accessories such that they are protected against
weather influences.
The PYRO-JET burner proper must be treated with the common care.
5 Paint
For the paintin, the respective order-related special regulations will apply. Otherwise, the burner
is delivered with a shop primer painting. The cover painting is made by the customer or a person
charged by him.
6 Intermediate storage
If the PYRO-JET burner is not mounted directly after its delivery, it must be carefully stored at a
protected place. It must be properly covered to avoid the entrance of dust and moisture.
The PYRO-JET burner is delivered with its blank parts preserved protecting these parts for about
1 year. If the storage should exceed this period, the preservation must be renewed (the preserva-
tion agent can be removed with a solvent)
Page 2 of 3; BA 407-0797-04 en
BA 407-0797-04 en; Page 3 of 3
Transport
7 Scope of supply
The contents of the packages is indicated in the package lists whose completeness must be
checked upon receipt.
Note!
Any damage must be notified to the forwarding agent as well as to

the supplier. A copy of that notification is submitted to the 
Humboldt Wedag.
8 Storage of damaged parts

All damaged parts must be intermediately stored in a separate locked store and disposed, if
required.
BA 407-0797-04 en; Page 3 of 3

BA 407-0797-05 en
Assembly
Page 1 of 4
Contents Page
1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Conditions for arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Dimensions, space requirement and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0797-05 en
3 Erection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
3.1 Burner erection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Transport guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Erection of accessory equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 General instructions
We strongly recommend to have erection and commissioning carried out by Humboldt
Wedag staff, as we shall not be liable for any damage due to improper and unqualified
workmanship.
The PYRO-JET-burner is delivered in assembled state (see chapter "Transport ").
2 Conditions for arrangement

For arrangernent planning it must be made sure that adequat space is available around
the PYRO-JET-Burner to facilitate erection and reconditioning work.
The arrangement drawing, the basic information on erection of the PYRO-JET-burner

include data on dimensions, weights, loads, design instructions (connections) etc. were
already handed over to you
2.1 Dimensions, space requirement and weights
Dimensions:
Main dimensions assembled

PYRO-JET-Burner: (see Section "Customer-specific characteristid and 
technical data")
Burner weight: (see Section "Customer-specific characteristid and 

technical data")
2.2 Lifting device
For erection and reconditioning of the PYRO-JET-burner, use a crane which can be moved
in all directions
Page 2 of 4; BA 407-0797-05 en
Assembly
3 Erection
Erection (installation) is done in accordance with the arrangement drawing.
The parts of the PYRO-JET-Burner provided with a special marking must be fitted by strictly
observing this marking
3.1 Burner erection
The PYRO-JET burner is ready for installation, except for the refractory lining. The connection
flanges and the burner mouth are closed to avoid the ingress of foreign bodies and dirt. The
locks must only be removed directly prior to mounting the connections.
The blank parts at the burner mouth which are accessible from the outside, in particular the air
ducts and nozzles, are freed from preservation agents with solvents.
The refractory lining and the pertaining fastening anchors must be mounted as directed in the
special working regulations and must be carefully treated. The following criteria must be fulfilled
and checked:
• Uniform surface appearance and uniform thickness of the lining
• Chippings, break-outs and abnormal crack formations are inadmissible
• Anchors must not be visible.
• At the front face, the mass must be uniformly compacted and the material thickness must
also be uniform. The edge must be sharp-edged without break-outs and with sufficiently
compacted mass.
• Uniform coloration of the surface (different coloration indicates the existence of moisture, oil
or grease of different qualities).
• Arrangement and number of expansion- or working joints in circumferential direction, in lon-

gitudinal direction, with expansion joint material.
Caution!
Observe the regulations of the supplier of the refractory material!
It is recommended to perform the installation at a protected place, e.g. under the roofing of the
burner platform.
For a further storage, the burner must be covered with a PVC-foil or a canvas such that it is pro-
tected against rain, splash water and condensed water.
It must be stored on wooden beams which are cut out according to the round shape of the burner
(see fig. 407-005).
During the installation on the burner carrier, particularly save the refractory lining. It is recommen-
ded to mount near the centre of gravity a pre-shaped, about 3-5 mm thick and about 1 m long
sheet bandage (see Fig. 407-005).
Page 2 of 4; BA 407-0797-05 en
BA 407-0797-05 en; Page 3 of 4
Assembly
For in-plant transportation between workshop and burner plaftorm, it may be advisable to manuf-
acture a transport carriage (Fig. 407-006 refers).
The burner is fastened to the burner carrier by a plug-bolt connection and secured.
The plug-bolt connection must be lubricated.
The insertion burner(s) is (are) slid into the carrier tube(s) and fastened.
– Measured in cold state, oil insertion burners are protruding by about 10 cm over the front
face of the burner mouth. Deviations of + 1.0 mm are tolerated.
– Gas insertion burners are ending flush with the front face of the burner mouth.
It must be checked, whether all nozzles and pipes in the mouth area are arranged concentrically.
A deviation of the width of the annular gap width of the coal dust nozzle of max. 1.5 mm is admis-
sible.
Note!
Foreign bodies in the air- and conveying lines lead to operatio-

nal failures.
Therefore, the ducts of the burner and the pertaining lines must be kept absolutely clean during
the assembly. Upon completion of the assembly, for all lines and their connections, a pressure
check with the 1.5-fold of the operating pressure must be made. Leakages must be sealed.
A trial run with all blowers and compactors for at least 8 hours is recommended at fully opened
throttle flaps. The burner outlet system must be checked again. Possibly existing foreign bodies
must be removed. Here, dismantling of the outlet system may become necessary.
See respective references in chapter "Maintenance"
BA 407-0797-05 en; Page 3 of 4

Page 4 of 4; BA 407-0797-05 en
Assembly
3.2 Transport guard
The transport guard of the burner compensator must be removed after the installation and prior
to starting up of the burner (see fig. 407-008).
Fig. 407-007 Securing of axial expansion joints for transport or repair purposes.
Prior to commissioning:
1. Removal of Items 1+2 on site
2. Flange screws, lockwashers, washers and nuts fitted according to 
assembly drawing - see Fig. 407-008
transport guard replaced by flange screws Remove expansion joint fixing

prior to starting up
Caution!
Risk of burner deformation!

If, instead of the guiding bolts with unilateral thread, guiding bolts with
thread on either side or threaded rods were used - e.g. for fixing the compen-
sators (see Fig. 407-009), these must absolutely be removed prior to starting
up or be replaced by flange bolts as, otherwise, the burner could be
destroyed during operation.
4 Erection of accessory equipment

See the relevant documentation under section "List of the separate documentation".
Page 4 of 4; BA 407-0797-05 en
BA 407-0797-06_R1 en
Commissioning
Page 1 of 8
Contents: Page
1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0797-06 en state: 12.2007
2 Collection of operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 PYRO-JET-burner interlocklng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Burner regulation during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Burner regulation during operational standstills . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
3.4 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.5 Preconditions for operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.6 Start-up of burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.7 Setting data for burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.8 Adjustment of flame shape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Operation of pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Commissioning of accessory equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Instructions
The first starting up strongly influences the optimal operation of the PYRO-JET burner.
In view of multifarious influences, we urgently recommend to take the services of Hum-

boldt Wedag staff for commissioning. This should not be done only under the aspect of
warranty, but at the same time:
– the PYRO-JET burner is checked
(possible transport damage, assembly mistakes),
– depending on the contractual agreements, the firing system is checked,
– the optimal performance and the respective operating data are determined,
– the operating staff is familiarised with the plant,
– additional advice for the operation of the PYRO-JET burner, its maintenance and
repair is given.
2 Collection of operating data

Note!
The optimal operating- and setting data for starting and

continuous operation as well as possible changes must
always be entered in writing into the operation data sheets
"Burner history" and "Settings at the PYRO-JET burner
during commissioning" of the Technical Machine Documen-
tation under section "Customer-specific and technical
data".
Page 2 of 8; BA 407-0797-06_R1 en
Commissioning
3 Commissioning
Mainly, the following works must be performed during commissioning:
1. General inspection of the burner system.
2 Check of the safety devices and of the interlocking
3. Trial run of all blowers and compactors over 8 hours at completely opened throttle flap.
4. Performance check of the blowers and compactors; measurements of the pressure deve-
lopment at the burner system and recording of the measured values.
5. Setting of the most favourable flame shape and alignment of the burner. The most favou-
rable flame shape and direction must be matched for every individual kiln considering the
respective operating conditions.
3.1 PYRO-JET-burner interlocklng

For commissioning, the pre-conditions of the kiln plant are absolutely necessary. See standard
interlocking plan of the rotary kiln plant. Mainly, the waste gas transport, preliminary aeration,
rotary kiln operation, waste gas analysis threshold values O2 and CO must be observed. The
rated value of the fuel volume control must always be set to "0" or basic load when starting. The
flame monitoring "AUTOMATIC" or "MANUAL" must be secured. The following safety systems
for lack of pressure or overpressure must be activated on the primary air and coal dust conveying
air side:
1. Jet air - lack of pressure PAS 

If a minimum pressure is fallen below, an alarm is released. If the cause cannot be elimi-
nated, after 0-15 minutes, the fuel supply is disconnected (preliminary "rated value" 0.2
bar).
2. Conveying air pressure 2 x PAS ++ coal proportioning system

(max. pressure)
The conveying system must be monitored and interlocked for min. pressure and max.
pressure.
2.1 The max. pressure PAS ++ (preliminary rated value" 0.2 bar) must not be exceeded.

If it is exceeded during operation, after 1 second, the fuel supply is interrupted 
(pipe clogging).
2.2 The min. pressure PAS -

As a pre-condition for the fuel supply, the min.-pressure must exist in front of the coal 
proportioning system. If that value is fallen below, the fuel supply is stopped.
3. Swirl air pressure PA - (preliminary "rated value" 10 mbar)

In case of a lack of pressure, an alarm is released. The cause must be eliminated within
15 min. - otherwise manual disconnection to avoid bad burning or the formation of
CO.During operation, the following setting options are existing:
Page 2 of 8; BA 407-0797-06_R1 en
BA 407-0797-06_R1 en; Page 3 of 8
Commissioning
3.2 Burner regulation during operation

Mainly, the following works must be performed during commissioning:
1. Setting of favourable relative velocities between air and fuel via the throttle flaps.
2. Changing the primary air volume.
3. Changing the entering depth of the burner mouth into the rotary kiln.
4. Setting of the burner inclination.
5. Changing of the primary air temperature (if the respective facilities are existing).
3.3 Burner regulation during operational standstills

During the standstill, the following setting options are given:
1. Changing of the nozzle cross sections via nozzle change and, hence, changing of the out-
let velocity of air and fuel.
2. Changing of the flowing angle via nozzle change or adjustment of the nozzles and, hence,
influencing of the mixture of fuel and air.
3. Changing of the fuels or the mode of operation.
4. Purchase of rapidly burning out fuels.
5. Reduction of the fuel moisture.
6. Variation of the coal dust fineness.
7. Measures for reducing the entrance of dust with the secondary air.
8. Measures for increasing the primary air temperature.
9. Avoiding of serious accretions as well as of rings in the sintering zone by influencing the
physical and chemical properties of the burning material and of the fuels.
BA 407-0797-06_R1 en; Page 3 of 8

Page 4 of 8; BA 407-0797-06_R1 en
Commissioning
3.4 Ignition
3.4.1 Normal ignition

The ignition can take place with the aid of an ignition burner or a slow match wick.
With cold kiln, first the ignition burner must be ignited and only then oil or coal shall be fed.
With cold kiln, the flame must be monitored with a flame governor or by an especially charged
person.
In case of a flame blow-off, the fuel supply must immediately be stopped manually via emer-
gency-off keys.
Prior to every new fuel supply, the fire compartment must be sufficiently ventilated. Normally, an
air throughput rate is sufficient which corresponds to the double volume of the burning compart-
ment and of the preheater.
To reduce the risk of deflagration, during the rinsing-/ignition time, the risk of deflagration must
be reduced by disconnecting the high voltage and rapping gears of the electrical waste gas
dedusting systems. The spray electrodes must be grounded.
After a heating up time of at least 4 hours, the ignition burner can be shut down (if the flame does
not blow off).
3.4.2 Ignition at hot kiln bricklining

In exceptional cases, e.g. after a short operation interruption, the burner can be ignited at the
light-red glowing bricklining in the sintering zone of the kiln.
The temperature of the bricklining and of the burning material shall be higher than 800°C. Pos-
sibly, the kiln must be "tilted" prior to the ignition so that new hot surfaces of bricklining and bur-
ning material are generated.
Caution!
In case of doubt, always ignite with ignition burner or slow match

wick.
3.5 Preconditions for operational readiness

1. Rotary kiln and preheater plant are ready for operation.
2. The burner is introduced into the kiln head and adjusted.
3. The primary air blowers are running.
4. The coal dust conveying systems are cleaned, free from coal dust and ready for operation.
5. Fuels are available, the operational safety is ensured, negative pressure in the kiln head is
existing.
Page 4 of 8; BA 407-0797-06_R1 en
BA 407-0797-06_R1 en; Page 5 of 8
Commissioning
3.6 Start-up of burner equipment

Setting data see Item 3.7
Air volume data as per section "Customer-specific characteristic and technical data".
Observe the performance diagrams and characteristic lines of the primary air generator and of
the flowing out speeds, see section "Customer-specific characteristic and technical data".
1. With cold rotary kiln, start with oil/gas. The waste gas fans must be controlled such that
always sufficient combustion air is available. In the kiln head, a pressure must establish
permitting without any problem the electrical ignition or the ignition via slow match wick,
depending on the design. Normally, this is the case at a pressure of about -0.1 to -0.3 bar.
2. Ignition only with twist air at about 10-30 % air (flap position about 1-2) After the ignition,
the twist air is increased to about 50% (flap position about 4) and during heating up, jet air
for cooling the nozzle disc is added, about 10% (flap position about 2).
3. After heating up of the kiln and starting production, the system is converted by steps from
oil/gas to coal dust as fuel. After the reduction of oil-/gas fuel, start with a coal dust feed
volume which meets about 10% of the heat requirement.
4. Prior to connecting the coal dust dosing system, at the kiln inlet, an additional oxygen
excess volume must be available which is by 2-3% higher than normally.
5. Matched to the operating conditions of the kiln system, the coal dust volume is increased
by small steps, the oil volume accordingly reduced, until the desired ratio of coal dust to oil
is reached.
6. During normal operation, a secondary air temperature of 800° to 900° must be maintained
to ensure an optimal combustion.
7. During operation, a minimal jet- and twist air volume of about 10-20%, each, must not be
fallen below to always ensure a sufficient cooling of the burner outlet system.
8. The procedure for re-starting of the burner after an operation interruption depends on the
temperature in the kiln. If the temperature is still high enough and even short heating up is
not necessary, the system can immediately be continued to be run at the desired coal
ratio.

If the kiln temperature is too low, the system must be heated up and the coal dust volume
be increased by steps.
BA 407-0797-06_R1 en; Page 5 of 8

Page 6 of 8; BA 407-0797-06_R1 en
Commissioning
3.7 Setting data for burner equipment

For arrangement of the specified flaps and systems and for quantity data, see the data sheets in
the section “Documents for the assembly of the machine".
Caution!
Adjusting flap no. 1 is always open.

The cooling air fan (flap 5 "open") is permanently conveying.
Flap 4 is opened only, if the cooling air fan should fail; then, flap 5
"closed".
Caution!
3.7.1 PYRO-JET-burner starting with kiln in cold state

Start with an oil ouantity of approx 10 %
Starting sequence:
1. Swirl air fan "switch on"
Swirl air damper No. 2 "open" - approx. 10-30 %
Swirl air damper No. 3 "closed"
Emergency cooling damper No. 4 "closed"
2. Conveying air blower "off"
(pneumatic conveyor )
3. Jet-air blower "off"
Jet air damper No. 4.1 "closed"
Jet air damper No. 4.2 “closed"
3.7.2 Heatlng-up of klln

Heating-up period > 6 h with an oil ratio of approx. 10 % and a coal ratio of approx. 10 %
1. Swirl air fan "remains switched on "

Swirl air damper No. 2 "open" - 75 %
Swirl air damper No. 3 “closed "
Emergency cooling damper No. 4 "closed "
2. Conveying airblower "switch on"
(pneumatic conveyor)
3. Jet-airblower "switch on"
Jet air damper No . 4.1 "closed "
Jet air damper No .4.2 "open" -100 %
4. Coal proportioning system "switch on"
Stepwise increase the throughput volume of flap 4.2 and simultaneously throttle the throughput
rate of flap 1, until flap 4.2 is loaded by 100%.
Page 6 of 8; BA 407-0797-06_R1 en
BA 407-0797-06_R1 en; Page 7 of 8
Commissioning
3.7.3 Normal kiln operation

A Oil = 0 kg / h ; coal = max . throuohput

All blowers have been switched on
Swirl air damper No . 2 "open"-100 %
Swirl air damper No . 3 " closed "
Jet air damper No . 4 " closed "
Jet air damper No 4.1 " closed "
Jet air damper No 4.2 " open " 100 %
B Normal operation oil = 50 % ; coal = 50 %

All blowers have been switched on
Swirl air damper No. 3 "closed "
Jet air damper No. 4 "closed “
Jet air damper No. 4.2 "open" - 100 %
C Normal operation oil = 100 % ; coal = 0 %

Jet-air blower switched on
Swirl air fan switched on
Conveying air blower switched off
Swirl air damper No. 3 “open"
Jet air damper No. 4 "closed "
Jet air damper No. 4.2 "open"
3.8 Adjustment of flame shape

If setting data were already determined during practical operation, these must be observed.
See data sheet in the section " Costumer-specific characteristic and technical data“.
Adjust a short flame during starting:

• recommended pressure setting for swirl air: 20 to 40 mbar *)
• recommended pressure setting for Jet-air : 100 to 200 mbar *)
Adjust an optimal strong flame during stable production conditions:

• recommended pressure setting for swirl air: 100 to 160 mbar *)
• recommended pressure setting for Jet-air : 500 to 900 mbar *)
*) to be determined during commissioning
The flame shape can also be adjusted by varying the oufflow velocity in the coal dust nozzle. If
required, additional conveying air can be added to the coal dust conveying air prior to entering
the annular duct (see also "Design and Functioning", item 2.5)
BA 407-0797-06_R1 en; Page 7 of 8

Page 8 of 8; BA 407-0797-06_R1 en
Commissioning
4 Operation of pressure gauges

For description of pressure gauges, see relevant documentation under section “List of separate
documentation".
The pressure gauges located at various measuring points of firing plant, have been equipped
with cocks. For taking the pressure readings, these must be opened and afterwards closed
again. This will ensure a longer life. This especially applies the pressure gauge of the coal dust-
duct. The shut-off cocks must only be set to two positions (according to the symbols at the stop-
cock). Other positioning results in wrong measurements ( see Fig. 407-010)
In case of incorrect cock positioning, the connection hose at the coal dust duct leading up to the
pressure gauge, is clogged with coal, as in this context, coal dust-laden air will always escape
through the blow-off opening. For cleaning, this connection hose must be withdrawn from the
nipple and blown free with the aid of compressed air.
Caution!
Never inject compressed air at the check cock (in horizontal posi-
tion), as this may imply danger to damage the pressure switch .
5 Commissioning of accessory equipment

Please refer to the relevant documentation included in the section “List of separate documenta-
tion".
Page 8 of 8; BA 407-0797-06_R1 en
BA 407-0797-07_R1 en
Operation
Page 1 of 3
Contents: Page
1 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0797-07 en State: 12.2007
2 Shutdown of the PYRO-JET-burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Elimination of failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
5 Pipe clogging and remedial action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Normal operation
There is no difference between normal starting of the PYRO-JET- burner and the proce-
dure described in chapter "Commissioning".
For operation of accessory equipment, please refer to the documentation included in the
section “List of separate documentation“.
2 Shutdown of the PYRO-JET-burner

The firing equipment must be shut down in accordance with the instructions for the rotary
kiln plant. A basic requirement is to:
1. Stop coal dust dosing.
2. Empty the coal dust conveying system.
3. Stop the insertion burner.
4. Swirl air fan should be on DG set when main power fails, it continue to run for coo-
ling purpose.
5. Pneumatic valve which is in primary air distributor should be fully closed when get-
ting power from main supply However, main suply fail, this valve should be open so
that the swirl air can be passed to jet air channel. Again when main power come
back, this valve must be in closed condition without failing.
6. Cool the burner lance with primary air during the shutdown procedures.
a) If the burner lance is not withdrawn from the kiln head, cooling can be stop-
ped as soon as the kiln has cooled down to approx. 500° C.
b) If the burner lance is withdrawn from the kiln head. cooling has to be stopped
shortly before the burner lance has been completely withdrawn from the kiln
head.
Caution!
When taking out the burner lance, make sure that the bur-
ner lance seal at the kiln head is not damaged, e.g. by coa-
tings on the refractory lining or a distortion in the pipe or
by the positon of the burner lance!
Page 2 of 3; BA 407-0797-07_R1 en
Operation
3 Operational safety
Irrespective of the instructions given below the local safety

regulations are definitely applicable to PYRO-JET-burner
operation.
4 Elimination of failures
Signs Cause Measures
4.1 Flame pulsation 1. Fluctuating of coal dust a) Ensure a uniform coal

accompanied by CO-fluctua- dosing dust flow discharged
tions in the kiln inlet from silo
b) Throttle dosing control
2. Secondary air tempera- Raise secondary airtempera-

ture too low ture
3. Insufficient conveying Reduce pipe cross section

velocity in coal dust pipe
4.2 Flame has a long black core, 1. too narrow cross section a) Reduce coal dust
increased CO-values at kiln at coal dust outlet duct, conveying air rate
inlet the out-flow velocity is b) Install a nozzle of larger
too high outflow cross section
2. insufficient flow of Jet-air Increase the Jet-air supply by

flap adjustment
3. excessive coarse ground Increase grinding finness and

coal, raw coal too wet drying
4.3 Flame burning directly at the 1. Excessive amount of Reduce Jet - air volume by
burner outflow Jet - air flap adjustment
2. Too large cross section a) Add coal dust conveying

of coal dust nozzle air
b) Install a coal dust nozzle

of smaller outflow sect.
4.4 Partial burning of flame on 1. Foreign matter in coal Replace foreign matter
one side dust outlet duct or coal
dust nozzle
2. Supporting ribs for coal Replace inner nozzle tube to

dust pipe damaged ensure concentric arrange-
ment of the annular coal dust
nozzle
Page 2 of 3; BA 407-0797-07_R1 en
BA 407-0797-07_R1 en; Page 3 of 3
Operation
Signs Cause Measures
4.5 As by 4.1 to 4.4 1. Outer tube of duct 3 Replace or repair for sealing
Wear of Jet-nozzles hole worn out, depending on defective tubes (provisional
pressure conditions,coal remedy by way of pressure
dust enters duct 4 or Jet balancing )
- air duct 3
4.6 As by 4.1 to 4.4 1. Inner tube of duct 3 See 4.5 above
Wear of swirl elements worn-down, dependin-
gon pressure conditions
coal dust enters duct 2
or swirl air duct 3
4.7 Failures in pneumatic coal 1. Ccoal dust too wet See operation manual for
dust conveying coal dust conveying system
Coal dust deposits 2. Dosing error

Pulsations 3. Shortage of conveying
air
Pipe clogging 4. Coal contains sticky con-

stituents
5 Pipe clogging and remedial action
When carrying out work on coal dust-conveying pipes, observe the

relevant safety regulations, see chapter "Safety and Health" .
In case of total pipe clogging of coal dust-conveying pipes, dismantle pipes and empty clogged
pipe sections.
Also clean the dosing unit and existing connections at dedusting equipment.
At the beginning point of clogging, find out the cause in the relevant pipe section, remove foreign
matter, if any, and replace worn-down parts.
Caution!
For reassembly, make sure that e.g. flanged connections are

tightly screwed up and that existing seals are correctly fitted.
Major amounts of coal dust must not be stored in open air, since this
may imply a self-inition danger.
Remove them using a vacuum cleaner.
BA 407-0797-07_R1 en; Page 3 of 3

BA 407-0797-08_R1 en
Maintenance
Page 1 of 13
Contents Page
1 Inspection and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0797-08 en state:12.2007
1.2 Burner inspection and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Reconditioning of the PYRO-JET-burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Exchange of nozzle plate (12.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Exchange of inner coal dust nozzle (12.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Exchange of swirl element (12.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Previous edition:
2.5 Dismantling and installing of insertion burners - aditional burner/ignition burner -. . . . . . . 5

2.6 Dismantling and installing of carrier tube for insertion burners (12.5) . . . . . . . . . . . . . . . . 6
2.7 Dismantling and installing of inner burner tube (12.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Dismantling and installing of coal dust tube (12.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.9 Dismantling and installing the axial compensator (12.2) . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.10 Exchange of inner nozzle tube (12.4.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.11 Repair of burner carrier tube (12.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.12 Repair of protective ceramic wear lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.13 Checks and treatment of reconditioned burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Repair tools and devises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Repair tools and devises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Inspection and servicing
1.1 Instructions
To avoid production losses which could occur during required maintenance and reconditio-
ning work on the PYRO-JET-burner, we strongly recommend to hold a complete PYRO-
JET-standby burner in reserve.
During inspection and servicing work, observe chapter

"Safety and Health“.
Operational failures caused by insufficient or unqualified inspections and maintenance,

may cause substantial repair costs and extended PYRO-JET-burner standstills. Therefore
regular inspections and maintenance are absolutely required.
Due to the varying operating conditions, it cannot be determined in advance, at what inter-
vals a wear check, inspection, maintenance and reconditioning must be carried out. A sui-
table inspection routine should be determined in due consideration of the locally prevailing
operating conditions.
At regular intervals, which are governed by the coal dust's abrasive behaviour, the wall
thicknesses of the coal dust conveying lines should be checked, e.g. using ultrasonic
measuring equipment.
For further advise, do not hesitate to consult our experts

Page 2 of 13; BA 407-0797-08_R1 en
Maintenance
1.2 Burner inspection and servicing
During normal operation:

– The burner itself requires no maintenance
– Pipes and flanged connections must be checked for tightness within the scope of
inspection routine
– Inspection of burner lance: eliminate excessive coatings.
Burner inspection and servicing is carried out during a plant standstill. To that end, the burner
must be taken out of the kiln head. 
(See chapter "Operation", item 2, Section 4 b)
Possibly required action for

Inspection jobs
eliminating failures
Checks of pipes and ducts for foreign matter eliminatie foreign matter
Check burner axial expansion joint  repair or replacement

for tightness
Check of burner ducts for wear depending on degree of scaling:

a) clean parts
b) replace scaled parts
Insertion burner clean burner nozzles

(do not damage the nozzle bore)
Check of swirl element for wear check of swirl element for wear
Check of inner coal dust nozzle for wear depending on wear state:
a) repair by hardfacing
b) replace inner coal dust nozzle
Check outer coal dust outlet surface for wear replace worn-down nozzle element
Check jet air bores for clogging clean clogged bores
Check nozzle plate resp. replace nozzle plate

Jet - nozzles for wear
Check burner axial expansion replace untight expansion joint

joint for tightness
Check of burner ducts for wear depending on wear state:

a) repair by hardfacing
b) repair- of ceramic lining
(coal dust duct)
c) replacement of ducts
Check of telescopic tube seals retighten stuffing box sealing screws,

replace gaskets, if required
Check pressure gauge connection clean connection lines

lines for deposits
Check of lined bends of the coal dust convey- repair defective spots
ing pipes for wear
Page 2 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 3 of 13
Maintenance
Upon standstill of the kiln plant after an extended operation period ( more than 3 months of con-
tinuous operation), or if there are signs indicating that operational failures or serious damage to
the burner can be expected in the near future (e.g. state of refractory lining ), the burner must be
replaced by the burner held in reserve .
Regarding inspection and maintenance of accessory equipment, such as fans, rotary piston blo-
wer, fittings, etc., included in our scope of supply, the maintenance and operating instructions
included in the section "List of separate documentation" must be observed.
The firing plant must be inspected at least once per year by a supervisor of the user.
2 Reconditioning of the PYRO-JET-burner
2.1 Instructions
For identification and items, see chapter "Design and Functioning", item "Identification of burner
components" and the attached burner drawing under section "List of documentation und spare
parts drawings".
Prior to start of reconditioning work, it must be made sure that all required spare parts are avai-
lable.
The reconditiong work described below are to be carried out after the burner has been withdrawn
from the kiln head and cooled down .
Depending on kind and place for burner reconditioning work, it may be required to
• retract the insertion burners or to completely take them out of the burner
• dismantle supply lines, such as hoses, flexible connections, telescopic tubes etc.
Note!
The Item numbers refer to the documentation "Coal dust burner"

in section "Documentation- and spare parts drawings".
2.2 Exchange of nozzle plate (12.6)
1. Fix the pre-stressed axial expansion joint (12.2). To that end remove several opposite
arranged flange screws from the connection flange of burner carrier tube (12.1) and the end
flange of duct 4. At these places threaded bolts of corresponding length with thread on both
sides and nuts must be screwed in between the flanges. It is advisable to measure the
flange distance of the pre-stressed expansion joint and to note it for reassembly.
BA 407-0797-08_R1 en; Page 3 of 13

Page 4 of 13; BA 407-0797-08_R1 en
Maintenance
2. Cut-off the weld with whitch the outer ring of the nozzle plate (12.6) is welded to burner car-
rier tube (12.1), (see point A of burner drawing) with a carbon electrode or a cutting-off disc.
Caution!
The weld cannot be cut-off with gas cutting torch!
3. Separate supporting tube at least 200 mm behind the end so that there is no access any
more to the coal dust pipe (12.3).
4. Separate coal dust pipe (12.3) at a certain distance behind the weld seam and withdraw
nozzle disc (12.6).
Caution!
New spare nozzle discs (12.6) are supplied at different lengths;

they are used to balance the separations at the coal dust pipe
(12.3). Therefore, when ordering spare units, always indicate the
desired length. The nozzle disc is surface-treated and must not be
reworked upon installation.
The exact position of the separation point must be matched to the
spare part to ensure that the outlet sections of the assembled
burner are in a flushing position.
5. Equalize separation point at the remaining pipe ends (12.3 + 12.1) correctly and rectangu-
larly to the pipe axis and place a weld seam.
6. Remove preservation coating from the spare nozzle disc.
7. Weld new nozzle disc (12.6) to remaining coal dust pipe (12.3). To that end, first tack-weld
nozzle disc crosswise over the circumference and then weld it in place.
Caution!
Check and make sure that the nozzle disc is exactly welded con-
centrically and coaxially.
8. Weld spare pipe element to the remaining burner supporting pipe (12.1). Then, weld it to
the nozzle disc (12.6) in its front area. Here, use the electrode type indicated in the drawing.
Caution!
Make sure that the weld seams between the individual ducts are
tight. Perform tightness check with 1.5-fold operating pressure.
For that purpose, the nozzle openings must be closed and a
check performed with leakage spray or soap solution.
9. Mount support tube (12.1) with refractory lining again and fasten it.
Page 4 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 5 of 13
Maintenance
11. Remove fixing of axial expansion joint again and mount flange bolts.
Caution!
When the fixing of the axial expansion joint is not removed, the
burner can be destroyed during operation.
2.3 Exchange of inner coal dust nozzle (12.7)
1. Unscrew inner coal dust nozzle (12.7) from the inner nozzle pipe using the burner nozzle
key included in the supply. The burner nozzle key must be positioned in the provided ope-
nings which must previously be cleaned.
2. Clean thread and front face of the inner nozzle pipe (12.4.1)
3. Replace worn down inner coal dust nozzle (12.7).
4. Remove preservation painting of the inner spare coal dust nozzle (12.7). Clean thread and
sealing surface.
5. Grease thread of the inner coal dust nozzle (12.7) and of the inner nozzle pipe (12.4.1) with
heat-resistant lubricant (e.g. Anti-Seize).
6. Apply heat-resistant special sealant (e.g. WEVOPAT) to the sealing surface of the inner
coal dust nozzle (12.7) and the front face of the inner nozzle pipe (12.4.1).
7. Bolt inner coal dust nozzle (12.7) into the inner nozzle pipe (12.4.1) and tighten it.
2.4 Exchange of swirl element (12.8)
1. Unfix the two screws of the twist body (12.8) and withdraw twist body.
2. Replace worn down swirl element (12.8).
3. Remove preservation painting of the spare swirl element (12.8).
4. Fasten twist body (12.8) with 2 screws.
2.5 Dismantling and installing of insertion burners 

- aditional burner/ignition burner -
The insertion burners must always be dismantled before starting dismantling of the burner tubes
(12.1/12.3/12.4/12.5) and of the axial expansion joint (12.2).
See respective instructions of the insertion burner supplier
BA 407-0797-08_R1 en; Page 5 of 13

Page 6 of 13; BA 407-0797-08_R1 en
Maintenance
2.6 Dismantling and installing of carrier tube for insertion burners (12.5)
1. Dismantle the insertion burners.

(see 2.5)
2. Dismantle the swirl element (12.8)

(see 2.4, Item 1)
3. Unscrew bolts of the end flange of duct 2.
4. Withdraw carrier tube set (12.5) from the inner burner tube (12.4).
5. Replace damaged carrier tube set (12.5)
6. Check inner burner tube (12.4) internally for deposits and contaminations. Clean it, if
necessary.
7. Clean sealing surfaces of the end flange of duct 2.
8. If required, renew sealing (12.11).
9. Insert some bolts into the end flange of the inner burner tube (12.4) and suspend sealing
(12.11).
10. Slide carrier tube set (12.5) into the inner burner tube (12.4)
Caution!
Prior to inserting the carrier tube set (12.5), check inner burner tube (12.4) for
left objects such as tools, cleaning rags etc.
11. Screw in flange bolts and tighten them crosswise.
Caution!
Mount a grounding wire to one of the flange bolts. Here, a corro-

sion-protected bolt with nut and washer must be used.
In this area, flange contact surfaces must be metallically blank.
12. Check swirl element (12.8) for wear and, depending on its condition, re-use or replace it. 
(See 2.4, Items 2 to 6)
13. Install the insertion burners.

(see 2.5)
Page 6 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 7 of 13
Maintenance
2.7 Dismantling and installing of inner burner tube (12.4)

Caution!
Prior to dismantling the inner burner tube (12.4), mark the installa-
tion position at the end flange of duct 3.
1. Dismantle the burner parts as per 2.6, Items 1 to 4.
2. Dismantle inner coal dust nozzle (12.7).

(see 2.3, Items 1 and 2).
3. Unscrew bolts of the end flange of duct 3.
4. Withdraw inner burner tube (12.4) by about 2.5 m form the coal dust tube (12.3).
5. Grind tack weld spots from the tube half shells with ceramic wear protection at the end
flange of the coal dust tube (12.3) and dismantle tube half shells.
Caution!
Mark installation position of the tube half shells!
6. Completely withdraw inner burner tube (12.4) from the coal dust tube (12.3).
7. As required:
• Replace inner burner tube (12.4).
• Repair minor partial wear erosions by hardfacing.
• Repair the ceramic lining

(see 12.3.5)
• Replace the inner nozzle pipe

(see 2.10)
8. Check coal dust tube internally for deposits and contaminations. Clean, if necessary.
9. Clean sealing surfaces of the end flange connection of duct 3.
10. If required, renew seal (12.10).
11. Insert some bolts into the end flange of the coal dust tube (12.3) and suspend sealing
(12.10).
12. Slide inner burner tube (12.4) into the coal dust tube (12.3) up to a distance of about 2.5 m
between the end flanges.
Caution!
Prior to inserting the inner burner tube (12.4), check coal dust
tube (12.3) for left objects such as tools, cleaning rags etc.
BA 407-0797-08_R1 en; Page 7 of 13

Page 8 of 13; BA 407-0797-08_R1 en
Maintenance
13. Install tube half shells with ceramic lining into the coal dust tube (12.3) and tack-weld them
at the end flange of the coal dust tube (12.3). Observe marking of the installation position of
the tube half shells.
14. Completely slide inner burner tube (12.4) into the coal dust tube (12.3).
Caution!
1.) When inserting or sliding in the inner burner tube, make

absolutely sure that the ceramic lining is not damaged.

2.) When installing the inner burner tube (12.4), observe marked
installation position.
If marking was forgotten or is not existing:
Im Bereich des Abschlußflansches des Kanals 3 liegt das
Near the end flange of duct 3, the inner burner tube (12.4) is
arranged by 10 mm eccentrically to the coal dust tube (12.3)
on the axis "centre coal dust socket - centre coal dust tube
(12.3)"; this means that the part of annular duct 3 showing
towards the coal dust socket is accordingly wider than the
opposite part. Therefore, when inserting the inner burner
tube (12.4), make sure that it is turned into the correct 
position.
15. Position flange bolts and tighten them crosswise.
Caution!
To one of the flange bolts, a grounding wire must be fastened. At

this point, use a corrosion-protected bolt with nut and washer.

Here, the flange contact surfaces must be metallically blank.
16. Check inner coal dust nozzle (12.7) for wear and, depending on its condition, re-use or
replace it.
(see 2.3, Items 3 to 7)
17. Further procedure or assembly of the burner as per 2.6, Items 6 to 13.
Page 8 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 9 of 13
Maintenance
2.8 Dismantling and installing of coal dust tube (12.3)

Caution!
Prior to dismantling the coal dust tube (12.3), mark the installation
position at the end flange of the burner carrier tube (12.1) and at
the end flange of duct 4 (if necessary, with intermediate marking
at the axial compensator (12.2).
1. Dismantle the burner parts as per:

2.2, Items 1 to 5 as well as 
2.7, Items 1 to 6
2. Unscrew bolts of the flange connection between burner carrier tube (12.1) and axial com-
pensator (12.2).
Caution!
To protect the axial compensator against possible damage when

withdrawing the coal dust tube, it must be dismantled together
with the coal dust tube.
3. Withdraw coal dust tube (12.3) - connected with the coal dust connection socket - together
with the axial compensator (12.2) from the burner carrier tube (12.1).
4. Depending on the requirements:
• Replace axial compensator

(see 2.9)
• Replace worn down coal dust tube (12.3)
• Düsenscheibe (12.6) ersetzen

(see 2.2)
5. Check burner carrier tube (12.1) internally for deposits and contaminations; clean, if
required.
6. Clean sealing surfaces of the flange connection between burner carrier tube (12.1) and
axial compensator (12.2).
7. If required, renew seal (12.9).
8. Insert some bolts into the flange of the burner carrier tube (12.1) and suspend seal (12.9).
9. Insert coal dust tube (12.3) with axial compensator (12.2) into the burner carrier tube (12.1).
Caution!
Prior to inserting the coal dust tube (12.3), check burner carrier
tube (12.1) for left objects such as tools, cleaning rags etc.
BA 407-0797-08_R1 en; Page 9 of 13

Page 10 of 13; BA 407-0797-08_R1 en
Maintenance
Caution!
1.) When inserting or bolting the flanges, observe correct 

position of the coal dust connection socket or the marking
for the installation position.

2.) Mount a grounding wire to one of the flange bolts. At this
point, a corrosion-resistant bolt with nut and washer must be
used. Flange contact surfaces must be metallically blank in
this area.
11. Install the nozzle disc (12.6)

(see 2.2, Items 6 to 11).
2.9 Dismantling and installing the axial compensator (12.2)
2. Unscrew bolts at the end flange of duct 4 and withdraw axial compensator (12.2) over the
coal dust tube (12.3.
3. Replace damaged axial compensator (12.2).
4. Clean sealing surfaces at the end flange of duct 4 and of the axial compensator (12.2).
5. Renew seal (12.9).
6. Insert some bolts into the end flange of duct 4 and suspend seal (12.9).
7. Slide axial compensator (12.2) over the coal dust tube (12.3).
8. When installing a new or not pre-stressed axial compensator (12.2), it must be pre-stressed
with the aid of threaded bolts (see 2.2, Item 2).
Caution!
Mount grounding wire to one of the flange bolts. Here, a corro-

sion-resistant bolt with nut and washer must be used.
Flange contact surfaces must be metallically blank.
Caution!
Particularly observe 2.2, Item 11.
Page 10 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 11 of 13
Maintenance
2.10 Exchange of inner nozzle tube (12.4.1)

2. Separate inner nozzle pipe (12.4.1) adjacent to the weld seam (abt. 30 mm) at the inner
burner tube (12.4).
Caution!
Spare parts for the inner nozzle pipe (12.4.1) are supplied at diffe-
rent lengths to balance the separations at the inner burner tube
(12.4). Therefore, when ordering spare parts, always indicate
which length or renewal stage is desired.
The inner nozzle pipe including the supporting and guide ribs is
surface-treated and must not be re-worked upon installation. The
exact position of the separation point must be matched to the
spare part so that outlet parts of the assembled burners are
ending flush.
(See 2.14, Item 2).
3. Precisely equalise separating point at the remaining inner burner tube (12.4) rectangularly
to the tube axis and provide it with a weld seam chamfer.
4. Weld new inner nozzle pipe (12.4.1) to the remaining burner tube (12.4). To that end, first
crosswise tack-weld the inner nozzle pipe (12.4.1) at some points over the circumference
and then weld into place.
Caution!
Observe and make sure that the inner nozzle pipe spare part
(12.4.1) is carefully welded in concentrically and coaxially.
2.11 Repair of burner carrier tube (12.1)

1. Withdraw cooling pipe (12.60) towards the front together with refractory lining
2. Dismantle nozzle disc (12.6)

(See 2.2, Items 1 to 5).
3. Separate burner carrier tube (12.1) up to the defective area.
4. Precisely equalise separating point at the remaining burner carrier tube (12.1) rectangularly
to the tube axis and provide it with a weld seam chamfer.
5. Balance the reduction of the burner supporting pipe by the installation of a pipe element of
suitable new length.
6. Weld spare tube element to the remaining burner carrier tube (12.1).
Caution!
Make sure that the complete nozzle disc is correctly welded in 7.

Further procedure or assembly of the burner as per 2.2, Item 6 
to 18.
7. Further procedure or assembly of the burner as per 2.2, Items 6 to 11 .
BA 407-0797-08_R1 en; Page 11 of 13

Page 12 of 13; BA 407-0797-08_R1 en
Maintenance
2.12 Repair of protective ceramic wear lining
2. Heat up worn down ceramic residues on the inner burner tube (12.4) and in the tube half
shells (12.3.5) and remove them with a spatula.
3. Carefully clean surfaces with a solvent.
Caution!
The gluing surfaces must be free from grease and dry.

Sand blasting or similar is not required.
4. Apply a thin layer of a special ceramic glue (e.g. Weicon Silicon Type HAT 300) to the
gluing surfaces using a toothed spatula.
Caution!
The ceramic plates must be laid into the moist cement.

Gluing on a dried surface affects the adhesion properties. There-
fore, apply glue only to a surface to which the objects to be glued
can be applied within the specified time.
5. Immerse ceramic plates, which are glued onto a foil with their top sides, into the applied
adhesive surfaces. Have them dry or set for 24 hours.
Caution!
The ceramic plates must be laid diagonally to the tube axis on the
inner burner tube (12.4).
The ceramic plates in the tube half shell must be laid in parallel or
rectangularly to the tube axis.
6. After setting of the glued areas, the foils must be carefully removed from the surfaces of the
ceramic plates.
Caution!
Foils which have not been removed, will become loose during
operation and can lead to cloggings of the coal dust nozzle.
Page 12 of 13; BA 407-0797-08_R1 en

BA 407-0797-08_R1 en; Page 13 of 13
Maintenance
2.13 Checks and treatment of reconditioned burner
Beyond the specified checks described with the working steps, the following checks are neces-
sary:
1. All parts of the outlet system of the burner mouth must be concentrically arranged. In case
of differences of >1.5 mm of the annular gap of the coal dust nozzle, corrections are neces-
sary, e.g. by replacing the inner nozzle pipe.
2. The front faces of all parts of the outlet system must end flush in one plain. Tolerances of +/
- 1 mm are admissible.
Only the oil insertion burner is protruding by 10 mm +/- 1 mm with cold burner.
3. All ducts must be free from foreign bodies and contaminations, as this could lead to clog-
gings during operation.
The specified checks should suitably be made during the respective repair working steps to
avoid that the completely assembled burner must be dismantled again for necessary corrections.
After completion of the repairs or the respective repair steps, all burner openings must be closed
to avoid the entrance of foreign bodies and dirt.
If the overhauled burner is stored e.g. as spare burner, suitably protect it (also see references
under "Assembly, Item 3.1).
Prior to starting up the overhauled and connected burner, a trial run with all blowers and compac-
tors is recommended for at least 8 hours with fully opened throttle flaps (see references under
"Assembly"., Item 3.1).
3 Repair tools and devises

For screwing in and out the burner nozzle disc and the coal dust disc, use the burner nozzle key
included in the supply.
Otherwise, the PYRO-JET burner can be maintained and repaired with the standard tools of a
maintenance workshop.
BA 407-0797-08_R1 en; Page 13 of 13

BA 407-0797-09 en
Spare parts keeping and
after sales service Page 1 of 2
Contents
1 Spare parts keeping
2 After sales service addresses

BA 407-0797-09 en
Availability of the most essential spare and wear parts at the place of installation is an
Previous edition:
important precondition for continuous functioning and operational readiness of the 

PYRO-JET-burner.
For ordering spare parts, please use the spare parts lists.
The spare parts drawings listed in the spare parts list are meant to provide further informa-
tion.
We only guarantee for genuine spare parts made available by us.
In case of installing and fitting spare parts and auxiliary equipment other than those deli-
vered by us, the warranty of Humboldt Wedag will be invalidated. Please consider that
often special manufacture and delivery specifications exist for in-plant manufactured parts
and parts of third-party firms and that spare parts, which always meet the latest state of
technology and the most recent legislative regulations are offered by us.
The following data are required for ordering spare parts:

Order-No. *
Identification
Characteristic data
Ordering-no. *
Spare parts list no. *
Burner-no.
Spare parts drawing no.
Item-no. *
Quantity *
Note!
The data marked with * must be absolutely indicted for ordering.


Upon spare parts ordering for the inner nozzle pipe (12.4.1), the desired
length or renewal stage must be indicated.

Upon spare ordering for the burner supporting pipe (12.1), the desired
length of the supporting pipe and for the complete nozzle disc (12.6), the
desired length of the supporting pipe end piece (12.1) must be indicated.

(The Item numbers refer to the documentation drawing in section "Docu-
mentation- and spare parts drawings")
Page 2 of 2; BA 407-0797-09 en
Spare parts keeping and after sales service

If you should need a service fitter, please inform us accordingly. He will visit you without long wai-
ting times.
Address of our spare parts distribution:

Please visit our website at http://www.khd.com for contact information.
Locations and persons to contact:

http://www.khd.com/contact.html
KHD Regional Custumer Service Centers:

http://www.khd.com/regional-centers.html
Page 2 of 2; BA 407-0797-09 en
Technical Machinery
Documentation
Pyrojet Burner
Section – III B
 Burner Carriage, standing
(BA 407-0753_R1 en)
State : 06.2020
Contents of the BA 407-0753_R1 en

Operating instructions of the Page 1 of 1
burner carriage
State 05.2011 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-01 en

* Introduction
BA 407-0753 en State:05.2011
* Field of application
* Copyright
State 05.2011 Safety and Health . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-02 en

Previous edition:

* Safety information
* Proper use
State 09.2012 Design and functioning . . . . . . . . . . . . . . . . . . . . BA 407-0753-03_R1 en

* Functioning
* Design
State 05.2011 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-04 en

* Packing
* Transport
* Sensitivity
* Paint
* Intermediate storage
* Scope of supply
* Storage of damaged parts
State 05.2011 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-05 en

* General instructions
* Assembly
State 05.2011 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-06 en

* Operation at the end of the erection and
trial operation without material
* Commissioning
State 05.2011 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-07 en

* Controlling of the burner carriage motor
State 05.2011 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . BA 407-0753-08 en

* Maintenance and installation of spare and wear parts
* Inspection, maintenance und repair
State 05.2011 Spare parts keeping and after-sales service . . . . . . . . BA 407-0753-09 en

* Spare parts keeping
* After sales service addresses
BA 407-0753-01 en
General
Page 1 of 3
Contents Page
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Explanation of symbols and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Field of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
1 Introduction
These information are meant to be read and observed in all items by those being respon-
sible for the Humboldt Wedag-burner carriage.
The complete technical documentation must always be kept near the burner carriage.
Details of particular importance for the use of the burner carriage are pointed out in the
Only the knowledge of the present operating instructions (BA) may ensure a trouble-free
operation of the burner carriage. Therefore, it is very important that these operating
instructions are really known to the persons in charge.
We recommend to carefully study the present instructions as the manufacturer will not be
liable for damage and operational failures resulting from the non-observance of these
instructions.
The firing plant must only be assembled, serviced and operated by suitably trained and
qualified staff.
If, nevertheless, problems should occur during operation, please contact our after sales
service or the spare parts department or one of our agencies. They will be readily pre-
pared to assist you (refer to chapter " Spare parts keeping and after-sales service").
The present operating instructions exclusively refer to the burner carriage.
We reserve the right to make technical changes necessary for improving the butt
stripping machine which are deviating from the descriptions and data given in these
BA 407-0753-01 en
General
2 Explanation of symbols and information
2.1 Safety symbol

connection with all safety information concerning the danger to life
and persons. Observe these information and behave most carefully
in such cases. Also inform all other users of these safety informa-
tion. apart from the information given in this BA, the generally appli-
cable regulations for safety and accident prevention must be
observed.
Caution!
This reference appears anywhere in the present BA where features of
particular importance must be observed to follow the regulations,
directives, information or the correct course of the works and to avoid
damage to or the destruction of the equipment and/or other plant sec-
tions.
2.3 Information
Note!
This reference draws your attention to general operating information
which must be particularly observed.
This symbol will appear near all safety information in the present ope-
rating instructions (BA), where due to the influence of noise, hearing
defects may occur. Observe this information and absolutely wear your
personal protection aids, e.g. ear protection.
Page 2 of 3
BA 407-0753-01 en
General
3 Field of application
Caution!
The burner carriage has only been designed for the field of application indi-
cated in section "Customer-specific characteristic and technical data/Field of
application".
Prior to using the burner carriage beyond the contractually stipulated field of
application (see secton "Customer-specific characteristic and technical data/
Field of application"), consult the after-sales service of the Humboldt Wedag
(address as per section "Spare parts keeping and after-sales service" as,
otherwise, a warranty will not be given
4 Copyright
The copyright to the present operating instructions (BA) remains with the Humboldt Wedag. The
instructions are meant for the installation, operating and supervision staff. They contain regulations
and drawings of technical nature which must not - nor in whole nor partly - be distributed or used wit-
hout authorization for competition purposes or disclosed to others unless this has not been expres-
sedly approved. A non-observance will entail damages.
Humboldt Wedag
http:/www.khd.com
Page 3 of 3
BA 407-0753-02 en
Safety and Health
Page 1 of 4
Contents Page
1. Explanation of symbols and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Attention reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Ear protection information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
2.2 Safety information for persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2.1 Risks to health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety information for machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Explanation of symbols and information
1.1 Safety symbol
In the present operating instructions (BA), this symbol

appears in connection with all safety information concer-
ning the danger to life and persons. Observe these informa-
tion and behave most carefully in such cases. Also inform
all other users of these safety information. Apart from the
information given in this BA, the generally applicable regu-
lations for safety and accident prevention must be obser-
ved.
Caution!
This reference appears anywhere in the present BA where
features of particular importance must be observed to fol-
low the regulations, directives, information or the correct
course of the works and to avoid damage to or the destruc-
tion of the machine and/or other plant sections.
1.3 Information
Note!
This reference draws your attention to general operating
information which must be particularly observed.
BA 407-0753-02 en
Safety and Health
This symbol will appear near all safety information in the present ope-
rating instructions (BA), where due to the influence of noise, hearing
defects may occur. Observe this information and absolutely wear your
personal protection aids, e.g. ear protection.
2. Safety information
2.1 General safety information
• The burner carriage burner has been constructed according to the approved technical rules
and regulations and is operationally safe. However, this machine can entail risks, if it is impro-
perly operated by unskilled staff or is used in another way than directed or commissioned or
operated not observing the instructions given.
• The competences during assembly, dismantling and re-assembly, commissioning, operation

and maintenance must be clearly defined and observed to avoid unclear competences under
the aspect of safety.
• During all works concerning assembly, dismantling, re-assembly, commissioning, operation,

conversion, adaptation and maintenance, the disconnection and safety procedures laid down in
the Technical Machine Documentation must be observed.
• No working method is permitted which could affect the safety of the burner carriage or jeopar-
dise the staff.
• By suitable instructions and checks, the user must ensure cleanliness and clearness of the
working place at the burner carriage.
• Unauthorised conversions and changes affecting the safety of the burner carriage are not per-
mitted.
• All repair works at the burner carriage must generally be made with the system standing still
and cooled down.
• Generally, for the installation and operation of the burner carriage, the applicable legal regulati-
ons and directives must be observed, in particular the accident prevention regulations for firing
systems.
Page 2 of 4
BA 407-0753-02 en
Safety and Health
2.2 Safety information for persons
• The burner carriage must be operated, maintained and repaired exclusively by authorised, trai-
ned and skilled staff. This staff must have been given a special training by the respective per-
son in charge as regards possible dangers.
• Every person who, on the premises of the user, is in charge of assembly, dismantling, re-
assembly, operation and maintenance (inspection, maintenance, repairs) of the burner carriage
must have read and understood the complete operating instructions and, in particular, the
chapter "Safety and Health".
Caution!
The operator is recommended to have this confirmed in writing in every
individual case.
• The operating staff is obliged to notify without delay any changes noticed at the burner carriage
affecting the safety.
• The operator must oblige himself to always keep the burner carriage in a proper condition and
to operate it in a safe condition.
• Works on electric systems are only permitted to be performed by skilled staff.
Wear the prescribed personal ear protection.
Wear the prescribed protective clothing.
2.2.1 Risks to health
• The burner carriage can entail risks for the staff due to improper operation, maintenance and
conversion:
– Risk of squeezing and hitting when moving the burner carriage.
– Tilting of the burner carriage when wrongly dimensioning the counterweight.
Page 3 of 4
BA 407-0753-02 en
Safety and Health
2.3 Safety information for machinery
• Prior to starting the works, the drives and auxiliary devices must be secured against unintended
connection. This is possible with a lockable local switch.
• The working instruction for isolating or closing the main fuse must be given in writing and must
be signed by the responsible electrician after the completion of the works.
• Remove protective devices only upon a standstill of the secured drives.
• Prior to starting after repair works, check, whether all protective devices have been mounted
again.
• The carrying capacity of the lifting facilities must at leas correspond to the weight of the burner.
• Only suitable and properly functioning lifting facilities are permitted to be used.
• After the electric installation or repairs to the electric system, the protective measures applied
must be tested (e.g. earthing resistance).
• Regularly check warning paintings and renew them, if necessary.
• All warnings at the burner carriage must completely be kept in a legible condition.
• Maintenance and inspection intervals (see section "Maintenance/Maintenance- and Inspection

List") and are only permitted to be performed by skilled staff.
• Only use genuine spare parts as these meet the requirements of the manufacturer. When using
other spare parts, there will be no liability from our side.
• All works on the burner carriage must generally be performed upon a standstill in cold and
secured state.
• During operation, protective devices of the machine must be in the protecting position as direc-
ted.
Note!
In addition, the safety references in the enclosed documentations of
the suppliers must be observed.
3. Proper use
• The burner carriage is only permitted to be operated under the conditions laid down in the
"Technical data/Field of application". Any use beyond this is considered not as directed. The
manufacturer will not be liable for resulting damage, the risk will be borne by the user alone.
• The proper use also includes the observation of the conditions for assembly, dismantling and
re-assembly, commissioning, operation and repairs as well as of further regulations of the Tech-
nical Documentation.
Page 4 of 4
BA 407-0753-03_R1 en
Page 1 of 2
Contents Page
1 Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 407-0753-03 en State: 05.2011
2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
1 Functioning
The burner carriage serves for accommodating and adjusting the burner. The position of
the burner mouth and of the flame in the rotary tube is of utmost importance for the burning
procedure (see burner documentation).
With the burner carriage and the pertaining adjusting devices, the burner can be rapidly
and at any time brought into various positions for operation and maintenance.
For the adjustment in axial direction as well turning in the horizontal and vertical plain,
electrical, pneumatical or manually operated travelling and lifting devices are available.
In case of a power supply failure, the burner can be moved out of the burning compartment
via manually operated emergency systems arranged at the burner carriage.
Caution!
Manual operating means are only permitted to be mounted
in cases of emergency and must absolutely be removed
prior to motorised operation.
The burner carrier or the burner carriage can be designed for being moved at the kiln head
suspended to a rail or running on rails on the burner platform.
The opening at the kiln head must be sufficiently large according to the maximal turning
path and the maximally extracted operating position of the burner. For burner carriages
running on rails, the torque generated by the largely protruding burner is balanced by
counterweights on the burner carriage and, in this way, tilting of the burner carriage is avo-
ided.
When dimensioning the counterweights, consider accretions on the burner and, in particu-
lar cases, product accretions falling from the rotary kiln onto the burner mouth.
If necessary, in operating position, the burner carriage can be equipped with a resilient
fastening system.
In particular cases, primary air fan, fittings and ignition devices can be installed on the bur-
ner carriage.
The supply systems of current, air and fuel are of flexible design to permit the easy activa-
tion of the control units on the burner carriage.
BA 407-0753-03 en
2 Design
The burner carriage is predominantly of welded design and comprises the following main compon-
ents:
Item no. No. Designation
33.02 1 Drive axle compl.
33.03 4 Cover bearing DIN 505 L 110 and screw union
33.04 1 Axle compl.
33.08 4 Rollers with adapter spring
33.11 1 Chain sprocket for roller chain (axle side) with

adapter spring
33.12 1 Geared motor with screw union
33.17 1 Chain sprocket for roller chain (motor side) with

adapter spring
33.18 1 Roller chain 28-B1x48 pitcheslong, DIN 8187 with

screw element F28-B1, DIN 8187
33.23 2 Spindle-type lifting element with screw union and

adapter spring
33.24 2 Bevel gear with screw union and adapter spring
33.28 1 Connection bush
33.30 2 Hand wheel compl. with axle
33.31 2 Spacer bush
33.32 1 Connection bolt

burner carriage / spindle-type lifting element
33.36 1 Supporting roller compl. right
33.37 1 Supporting roller compl. left
33.40 1 Connection bolt burner /burner carriage
33.41 1 Connection bolt burner /burner carriage
33.50 1 Bearing with screw union
33.55 1 Suspension rope DIN 3088
33.56 2 Bolt
33.57 2 Linch pin
Note!
The data refer to the documentation drawing "Burner carriage" in
section "List of the documentation and spare parts drawings".
Page 2 of 2
BA 407-0753-04 en
Transport
Page 1 of 2
Contents Page
1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
5 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7 Storage of damaged parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Packing
The transport route is a factor in determining the type of packing used. Unless otherwise
specified or agreed in contract, Humboldt Wedag packing standards shall be used..
The symbols on the packing must be observed.
e.g.:
BA 407-0753-04 en
Transport
2 Transport
The burner carriage is transported in mounted condition without counter weight, burner etc.
The parts are packed as far as required
The special contractual regulations will apply.
3 Sensitivity
The burner carriage should be transported carefully to avoid damage due to influence or force or
uncareful loading and unloading.
During transportation, avoid a formation of condensation water due to major temperature fluctuati-
ons.
On site, store the burner carriage and the accessory equipment at a weatherproof place.
Treat the burner carriage itself with usual care.
4 Paint
The paint is subject to the relevant special order-specific provisions. Otherwlse, the burner is delive-
red with a shop-primer coat. The top coat is applied by the customer or his authorized representati-
ves.
The repair and finish painting will be applied ont he site by the customer or his authorized represen-
tative.
5 Intermediate storage
If the burner carriage is not mounted directly after delivery, it must be carefully stored in a protected
place . It must be properly coated to avoid penetration of dust and moisture.
The burner carriage is delivered with a preservation for the blank metal parts, which shall protect the
parts for approximately 1 year . In case of an intermediate storage beyond this period, preservation
will be necessary again . (The preservation can be taken off by a solvent).
6 Scope of supply
The contents of the packages is indicated in the package lists whose completeness must be chek-
ked upon receipt.
Any damage must be notified to the forwarding agent as well as to the supplier. A copy of that noti-
fication is submitted to the Humboldt Wedag GmbH.
7 Storage of damaged parts

All damaged parts must be intermediately stored in a separate locked store and disposed, if
required.
Page 2 of 2
BA 407-0753-05 en
Assembly
Page 1 of 2
Contents Page
1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Previous edition:
1 General instructions
We strongly recommend to have erection and commissioning carried out by Humboldt
Wedag staff, as we shall not be liable for any damage due to improper and unqualified
workmanship.
The burner carriage is delivered in assembled state (see chapter "Transport ").
2 Assembly
The erection of the burner carriage, the drive and the protective hood must take place duly
observing the accident prevention regulations and the general erection rules for fitters and
electricians.
The burner carriage is assembled on the site observing the data given in the parts lists and
in the machine assembly drawing.
(Delivery state see chapter “Transport“).
If motor, coupling and protective hood have been delivered unpacked, the pillow block fra-
mes and the drive motor are aligned with the aid of shims and a feeler gauge.
When installing the travelling rails, ensure correct alignment to guarantee easy movement
of the burner carriage.
To avoid that the service life of the chain is affected, take care when installing the geared
motor that the chain sprockets are precisely flush-mounted and the chain is correctly ten-
sioned.
Note!
Observe the pertaining sub-suppliers documentation (see
section “List of separate documentation“).
BA 407-0753-05 en
Assembly
Prior to trial operation at the end of the erection and trial operation without material, check again the
following points:
1. Is the oil volume in the geared motor sufficient and is the venting hood open?
2. Have all lubricating points been supplied with grease?
3. Is the system ready for operation, have foreign parts been removed from the running surfaces
and connections unfixed? Are all flexible parts freely movable?
4. Have all regulations of the geared motor and special documentation been observed?
5. Are all screw unions tight?
6. Have all guards been mounted?
7. May the adjusting devices and hand wheels be easily turned?
8. Has the motor been correctly connected as indicated on the nameplate?Have the travel limi-
ting and range switches been correctly mounted?
9. Switch on the motor.
Caution!
Is the SENSE OF ROTATION correct compared with the indication in the
keys? If not, change poles !
10. Sind genügend Gegengewichte montiert?

Consider loads onto the burner caused by accretions.
Page 2 of 2
BA 407-0753-06 en
Commissioning
Page 1 of 1
Contents: Page
1 Operation at the end of the erection and trial operation without material . . . . . . . . . . . . . 1
2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Operation at the end of the erection and trial operation wit-

hout material
Previous edition:
Prior to trial operation at the end of the erection and trial operation without material, check
again the following points:
1. Is the oil volume in the geared motor sufficient and is the venting hood open?
2. Have all lubricating points been supplied with grease?
3. Is the system ready for operation, have foreign parts been removed from the run-
ning surfaces and connections unfixed? Are all flexible parts freely movable?
4. Have all regulations of the geared motor and special documentation been obser-
ved?
5. Are all screw unions tight?
6. Have all guards been mounted?
7. May the adjusting devices and hand wheels be easily turned?
8. Has the motor been correctly connected as indicated on the nameplate?

Have the travel limiting and range switches been correctly mounted?
9. Switch on the motor.
Caution!
Is the SENSE OF ROTATION correct compared with the indication
in the keys? If not, change poles !
10. Have the counter weights been correctly tared? Consider loads onto the burner
caused by accretion.
2 Commissioning
After these check works and after having checked the electrical interlocking, operation
may be started.
Check current consumption, travelling speed etc. Enter readings into the report and the
Caution!
Prior to turning the burner, unfix the catching device. Immediately
after termination of the adjusting works, that device must be
adapted to the burner with minimum gap.
BA 407-0753-07 en
Operation
Page 1 of 1
Contents:
1 Controlling of the burner carriage motor

Previous edition:
1 Controlling of the burner carriage motor

Operation via swivel key in local operation after release from the control center and unfi-
xing of the connections such as kiln head seal, stuffing boxes of the telescopic tubes as
well as lines.
Limit switch: for travel limitation
for travel limitation

with flame
Limit siwtch: for travel limitation

hose dismantling
for height and side
Limit switch: normal position closed contacts

BA 407-0753-08 en
Maintenance
Page 1 of 2
Contents Page
1 Maintenance and installation of spare and wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Inspection, maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Inspection of the burner carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Maintenance of the burner carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Repair of the burner carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
1 Maintenance and installation of spare and wear parts

The burner carriage is a relatively robust machine.
However, a regular check must not be renounced.
In particular, observe mainteance and installation instructions.
2 Inspection, maintenance and repair

The time sequence and information on inspection, maintenance and repair as well as re-
lubrication are specified in the special documentation (see section „List of separate Docu-
mentation“).
Note!
“Documentation drawing burner carriage“ see section
“List of documentation and spare parts drawings“.
2.1 Inspection of the burner carriage
Inspection Measuring
Machine part Inspection
interval instrument
Geared motor for abnormal noise, monthly Contact thermo-

temperature, meter,
leakages, ammeter
vibration,
current consumption
Coupling for crack 6 months
Pillow block frame noise sporadically touch with hand

Fixed bearing temperature
Movable bearing
Chain drive for tension 6 months
Lifting elements for tight seating 6 months

Screw union cracks,
cleanliness
Lubrication as per list 6 months
Limit switch for functioning 6 months
Machine complete Damage to the surface 6 months

protection
BA 407-0753-08 en
Maintenance
2.2 Maintenance of the burner carriage
Maintenance
Machine part Maintenance
interval
Geared motor see manufacturer

documentation
Coupling
Pillow block frame Remove used grease and 6 months

dirt
Chain drive for tension 6 months
Lifting elements Remove used grease and 6 months

dirt
Screws Re-tighten
Lubrication Re-lubricate as directed see list
Limit switch
Machine complete Clean and repair defective

surfaces
2.3 Repair of the burner carriage
Machine part Repair Material
Geared motor Replace damaged parts such

as shaft seal, bearing, too-
thed wheels
Coupling Replace defective parts
Pillow block frame Replace defective parts or

treat with spray gun and treat
mechanically
Chain drive Replace
Limit switch Completely replace damaged

parts
Machine complete Renew painting
Page 2 of 2
BA 407-0753-09 en
Spare parts keeping and
Page 1 of 2
after sales service
Contents

Availability of the most essential spare and wear parts at the place of installation is an
Previous edition:
important precondition for continuous functioning and operational readiness of the

burner carriage.
For ordering spare parts, please use the spare parts lists.
The spare parts drawings listed in the spare parts list are meant to provide further informa-
tion.
We only guarantee for genuine spare parts made available by us.
In case of installing and fitting spare parts and auxiliary equipment other than those deli-
vered by us, the warranty ofHumboldt Wedag GmbH will be invalidated. Please consider
that often special manufacture and delivery specifications exist for in-plant manufactured
parts and parts of third-party firms and that spare parts, which always meet the latest state
of technology and the most recent legislative regulations are offered by us.
The following data are required for ordering spare parts:

Order-No. *
Identification
Characteristic data
Ordering-no. *
Spare parts list no. *
Burner-no.
Spare parts drawing no.
Item-no. *
Quantity *
Note!
The data marked with * are absolutely required for ordering.

BA 407-0753-09 en
Spare parts keeping and after sales service
Address of our spare parts distribution:

Please visit our website at http://www.khd.com for contact information.
Locations and persons to contact:

http://www.khd.com/contact.html
KHD Regional Custumer Service Centers:

http://www.khd.com/regional-centers.html
Page 2 of 2
Technical Machinery
Documentation
Pyrojet Burner
Section – III C
 Handling of Lubricants– BA 822-0001 en
State : 06.2020
Operating Manual
BA 822 - 0001 en
Handling
of
Lubricants
State: 11.2010
Contents of operating manual BA 822 - 0001 en

„Handling of Lubricants“ Page 1 of 1
General . . . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 01 en

Introduction
Copyright
Container types and -sizes
Lubricant selection
Safety . . . . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 02 en

Safety instructions
BA 822-0001 en
Previous edition:
Transport . . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 03 en
Storage. . . . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 04 en

General instructions
Central lubricant store
Intermediate store
Outdoor storage
Marking . . . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 05 en
Lubrication . . . . . . . . . . . . . . . . . . . . BA 822 - 0001 - 06 en

Planning and organization
Lubricant filling
Used oil disposal . . . . . . . . . . . . . . . . . BA 822 - 0001 - 07 en

General BA 822-0001-01 en
Page 1 of 3
Contents Page
1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BA 822-0001 en
3. Container types and -sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Previous edition:
4. Lubricant selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Introduction
This operating manual is applicable in case larger amounts of lubricants are transported to
and stored on a Humboldt Wedag site. At the same time it is meant to provide a support in
the handling of lubricants.
2. Copyright
Copyright existing on this operating manual (BA) remains the property of Humboldt Wedag
GmbH. This manual is intended for the use by erection-, operating- and supervisory
personnel. It contains regulations, information and instructions.
Page 2 of 3; BA 822-0001-01 en
General
3. Container types and -sizes
When ordering lubricants, the most suitable container type must be provided. The container
types and -sizes are dependent on the quantity required per lubricant type.
Distinction has to be made between:
• containers for lubricating oils and
• containers for lubricating greases.
Lubricant Container type Contents
container 500 to 1000 Ltr.

barrel, drum 200 Ltr.
oil garage drum *) 50 Ltr.
can * 5 and 20 Ltr.
can * 5 Ltr.
can * 0,25; 0,5; 1; 5 Ltr.
barrel, drum 180 kg

hobbock * 25 and 50 kg
Grease drum * 50 kg
pail * 5 ; 10; 15 kg
can * 1 and 5 kg
cartridge * 0,4 kg
*) these are generally one-way containers
Examples:
drum garage drum hobbock barrel, drum
Drums which can be reconditioned offer the possibility of multiple use, which lowers disposal
costs and diminishes environmental nuisance caused by waste.
Page 2 of 3; BA 822-0001-01 en
BA 822-0001-01 en; Page 3 of 3
General
4. Lubricant selection
In each case of application the lubricant has to meet a number of individual requirements.
Decisive for the selection of a lubricant are
• the quality and

• the specific application.
An important aspect is a reduction of brands.
The number of lubricant brands has preferably to be kept at a

minimum. A multitude of lubricant brands results in confusions,
high procurement costs and thus in high storage costs.
Listed in Humboldt Wedag lubricant chart HW 6302 are renow-

ned lubricant suppliers resp. -manufacturers.
BA 822-0001-01 en; Page 3 of 3

Safety BA 822-0001-02 en
Page 1 of 2
1. Safety instructions
Handling of lubricants does not involve any dangers, if they are applied appropriately,
efficiently and in compliance with the required personal precautionary hygienic measures.
Accidents or gross abuse may entail injuries to health and environmental nuisance.
BA 822-0001 en
Danger
Previous edition:
• A longer effect on the skin may result in skin injuries.

• When using high-pressure grease guns operating at
pressures up to 400 bar resp. in case of defective
pressure oil lines, injuries caused by the grease-/oil jet
may involve tissue injuries.
• Contingent environmental nuisance.
Safety measures
• Avoid contact with skin, eyes and clothing.
• Wear protective clothing, rubber gloves, anti-skid shoes,
safety goggles.
• Keep away from food.
• Keep the workplace clean.
• Keep container tightly closed.
• Use protective skin agents.
First aid
• Put off wet clothes.
• Upon eye contact with oil, rinse with lots of water.
• Upon eye contact with grease, rinse with lots of hot
water.
• Upon contact with the skin, wash off with water and
soap.
• Injuries caused by grease-/oil equipment require
immediate hospital treatment.
Action to be taken in case of trouble

• Take up leaks with a spatula or the like.
• Use non-combustible granular binders
(e.g. sand, diatomite).
• Collect leaks.
• Drawing-off and filling must only be carried out in sumps
set up on secured surfaces.
• Used oils, in particular oils containing halogen, must be
collected separately.
• Avoid a penetration of lubricants into the ground or

watercourses.
Page 2 of 2; BA 822-0001-02 en
Safety
Precautionary measures
• Draw up an alarm schedule.

• Procure safety data sheet from the manufacturer resp.
supplier.
• Draw up a list of stored lubricants, quantities, potential
dangers.
• Identify and mark storage areas for separate storage of
different products.
• Provide the ground surface so that it is resistant to and
impermeable by the products to be stored.
• Protect the storage surface from surface water (rainwater).
• Provide sumps for collecting leaks.
• Keep binders in readiness.
• Provide for a place for storage of waste.
• Provide for a collecting place for unknown products.
Page 2 of 2; BA 822-0001-02 en
Transport BA 822-0001-03 en
Page 1 of 2
Medium lubricant quantities are generally transported in upright drums and/or in the con-
tainer types mentioned in Section "General/Container Types and -Sizes".
The local hazardous goods regulations for road transportation

must be observed.
§
BA 822-0001 en
Previous edition:
The containers must be locked up.
The drums must have been secured on the transporting surface

to avoid slipping and tilting.
Suitable for short in-plant transport ways are two-wheeled drum

carts.
A use of pallets on which the containers are placed and secured

enables transporting by forklift truck.
Lubricant drums must not be rolled.

When reloading and unloading lubricant drums, unloading aids,

e.g. unloading platforms and drum tongs must be used.
Page 2 of 2; BA 822-0001-03 en
Transport
If no unloading aids are available, the drums with the bottom

section ahead, can slide down from wooden- or metal shot lad-
ders. The difference in elevation between loading- and ground
level can thus be bridged.
Drums must not be thrown off from the loading surfaces (wag-
gon, truck, ramps) (also not when resting on a padding). The
thin-walled iron drums used today are particularly sensitive
against shocks. Upon heavy drum deformations, an application
of barrel-mounted pumps can no longer be ensured. The contai-
ner seams may tear up and the covers snap off.
Suitable for transporting are iron drums without inside paint or

colour
tin plate containers with inside paint. The container material sel-
ection is influenced by the possibility of a reaction of the lubri-
cant with the container wall and by the requirements made of tin plate
the strength.
Page 2 of 2; BA 822-0001-03 en
Storage BA 822-0001-04 en
Page 1 of 6
Listed below are general instructions for lubricant storage outside water protection areas.
Storage of lubricants is subject to a number of legal impositions.

§
BA 822-0001 en
The lubricant supplies must be calculated so that the current

Previous edition:
demand including contingent demand fluctuations will be

covered.
In case of delivery problems provision has to be made for a

minimum supply volume sufficient for up to 4 months.
According to the German mineral oil tax law, unpaid and tax-
paid lubricants have to be stored separately.
For avoiding mixing-up of lubricants in the lubricant store and in

the entire plant, all containers, tanks, tap points etc. have to be
provided with a permanent marking.
Lubricants already stored for a longer time must be issued first

to avoid quality losses.
Lubricants stored for a too long time should be checked for their
state before being used.
The lubricant store has to be arranged so that the lubricant can

be stored dry and free from frost (e.g. emulsifiable oils).
Page 2 of 6; BA 822-0001-04 en
Storage
Storage tanks should be equipped with inclined or tapered bot-

toms so that settled water and other contaminations can be
drained from the bottommost point.
Drum cocks enable quick tapping and locking up. Oil puddles
are reduced.
Storage tanks with galvanized inside are not suitable. Under the
influence of certain lubricant additives, zinc soaps may form
inside the tanks which have a detrimental effect on the quality.
Water-mixable and non-water-mixable lubricants must be

stored separately.
In areas where temperatures drop below 0 C, provision has to

be made for a heating device.
Special police safety instructions for the prevention of fire are

applicable to a storage of mineral oil products of a flash point
below 100 C, which are ranking among the combustible fluids
(e.g. solutions, cleaning agents, special oils, light fuel oils etc.).
For used lubricants, provision has to be made for additional

space, split up by brands and, if required, for an installation for
filtering and regenerating.
Filled cans-containers must be stackable without being defor-

med.
Page 2 of 6; BA 822-0001-04 en
BA 822-0001-04 en; Page 3 of 6
Storage
Central lubricant store
When setting up a lubricant store the legal regulations must be

observed. §
• The location of the lubricant store has to be selected so that delivery, distribution and
issuance of lubricants as well as collection of used lubricants is possible within shortest
ways at minimum cost. Essential influencing factors are :
- soil quality and -load capacity,

- surface shape and size of the available place,
- climate,
- conditions of environmental protection,
- dpossibilities of connection to existing transport systems and
- the cost of land.
• The type and size of a central lubricant store depends on the plant size. Provision
should be made for the following rooms:
- lubricant store and pump room,

- filling room,
- drum store for lubricating greases,
- storage room for small containers,
- lubricant issuance room,
- used oil treatment room and
- room for combustible fluids.
(This room must be separate from the other lubricant rooms).
BA 822-0001-04 en; Page 3 of 6

Page 4 of 6; BA 822-0001-04 en
Storage
The storage rooms must not have bottom drains.
The access ways must be passable by electric- or forklift trucks.
Drum shelf systems ensure better access and overall view.
Provision of oil collecting sumps.
Intermediate store
Intermediate stores can offer economic advantages (short ways and short waiting times).
Analogously applicable are the same conditions as for the central store.
• An intermediate store is only intended for receiving those lubricant quantities, which
are required for covering the demand for normal servicing jobs.
• Larger volumes must be ordered from the central store well in time.
Page 4 of 6; BA 822-0001-04 en
BA 822-0001-04 en; Page 5 of 6
Storage
Outdoor storage
If an outdoor storage is inevitable, the storage place must be

roofed. The lateral openings must be closed (cover, boards or
the like).
Drums must be stored horizontally, preferably in slightly inclined

position. Rain- and condensation water can run off and not
accumulate around the faucet.
The faucet must be below the oil level.
The drums must not be set up on the soil.
The drums must be proctected from rolling away by wooden

wedges.
BA 822-0001-04 en; Page 5 of 6

Page 6 of 6; BA 822-0001-04 en
Storage
An outdoor storage in upright position adversely influences the lubricant. Rainwater and dust coll-
ect on the drum bottom. Temperature fluctuations cause changes of the volume inside the drum.
The drum breathes. Past the faucet, the water is sucked into the drum inside.
Consequences:
• The lubricant quality is impaired.
• In case of sodium greases penetrated water results in an emulgation of the grease
surface.
• Lime soap greases decompose upon thermal effects and become unfit for use.
• For transformer and switch oils already minor water traces may reduce the dielectric
strength.
• When opening containers stored outdoors, dust, quicksand and other contaminations
can penetrate into the drum and mix with the lubricant. Contaminated lubricants result
in increased abrasion and may clog the lubricating and spraying equipment.
• Due to the influence of weathering phenomena, lettering, brand identifications and -
markings may become illegible and the lubricants may be no longer distinguishable.
A mixing up of lubricants, improper application resp. a mixture of two non-miscible lubricants may
result in undesired side effects.
Page 6 of 6; BA 822-0001-04 en
Marking BA 822-0001-05 en
Page 1 of 2
Markings are allocated to the different lubricant types, which consist of abbreviations, code
letters, additional code letters and simple symbols (geometric symbols).
Uniform marking on the lubricant containers, issuing vessels, distributing tanks (oil cans,
grease guns), filling lines and lubricating points reduces the danger of confusions and use
of the wrong lubricant types.
BA 822-0001 en
• Any marking must only be used once and always for the same lubricant type
Previous edition:
only.
• The markings must be permanently affixed (self-adhesive plastic sheets, colour
markings with template etc).
• Marking in accordance with DIN
Symbol according to
Lubricant designation DIN 51 502
with registered example
lubricating mineral oils

oils
mineral oils hardly combusti-

ble hydraulic fluids
synthesis and partial synthe-

sis fluids on mineral oil base
on mineral
oil base
lubricating
greases
on synthesis
oil base
Page 2 of 2; BA 822-0001-05 en
Marking
• If all or several lubricating points on an equipment or machine have to be serviced with

the same lubricant type, a yellow plastic sheet with the respective DIN- or brand
symbol can be affixed at a conspicuous point.
Example for in-plant marking by colours, abbreviations, code letters and symbols :
Page 2 of 2; BA 822-0001-05 en
Lubrication BA 822-0001-06 en
Page 1 of 3
Contents Page
1. Planning and organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lubricant filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Planning and organization

BA 822-0001 en
Previous edition:
In accordance with the plant conditions it shall be checked,

whether and to what extent a specially trained lubrication crew
can be employed.
Employment of a special lubrication crew ensures proper

maintenance of the machinery and plants.
Lubricating instructions shall be prepared for each machine and

plant. These lubricating instructions form part of the operating
manual. i
A lubricating time schedule guarantees perfect lubrication at

fixed times.
The person in charge of lubricating must be precisely instructed

on the lubricating action to be carried out.
Shortcomings at the lubricating equipment and damage to

machinery have to be reported in writing (notification of defect).
Page 2 of 3; BA 822-0001-06 en
Lubrication
Lubricating cars facilitate transportation of lubricants and tools, if any, to the lubrication points.
The condition of the lubricants (quality, quantity), lubricating

equipment and lubricating devices has to be checked at deter-
mined intervals.
The lubricant cost has to be ascertained and allocated. The cost

of lubrication for an individual machine, machine group or plant
section has to be determined depending on plant conditions
resp. on the value of individual machine or plant. This individual
determination has the advantage that it becomes evident
already after a short time for which machine high resp. low lubri-
cation costs are accruing. The amount of lubrication costs is
mainly influenced by
• the lubricating cycle,

• the lubricant quality,
• lubricant selection and
• state of machine and plant.
Page 2 of 3; BA 822-0001-06 en
BA 822-0001-06 en; Page 3 of 3
Lubrication
2. Lubricant filling
Only use the filling devices provided for that purpose (drum
cocks, barrel-mounted pumps).
Ensure utmost cleanliness. Avoid lubricant contaminations.
After having taken out the lubricant, opened containers must

immediately be closed again.
Avoid lubricant mixtures.
Use a flowmeter. Oil filling is thus facilitated.
Do not mix up filling devices for grease and oil.
BA 822-0001-06 en; Page 3 of 3

Used Oil Disposal BA 822-0001-07 en
Page 1 of 2
1. Used Oil Disposal
Used oils are semifluid or fluid substances which wholly or partly consist of mineral oil or
synthetic oil including oil-bearing residues from containers, emulsions and water-oil mixtu-
res.
Applicable in the Federal Republic of Germany is the "pay as you pollute" principle, which
means that the used oil owner is responsible for proper disposal.
BA 822-0001 en
Previous edition:
Used oil categories

To be separately stored and collected are :
Category 1,
Used oils suitable for reconditioning
• combustion engine and gear oils
mineral machine-, turbine-, metalworking- and hydraulic
oils, provided these do not contain more than 4 ppm PCB
(polyvinyl chloride) and/or 0.2 % total halogens
Category 2,
Used oils which are contaminated, but may be incinerated in
plants approved of for that purpose
• metalworking oils and insulating oils on mineral oil base
with higher contents of harmful substances
• vegetable lube oils
Category 3,
Used oils that have to be disposed as special waste
• all hydraulic fluids originating from pit coal mining as well
as other used oils, provided these do not belong to
categories 1 and 2 (e.g. solid, oil-bearing residues, water-
oil mixtures, contents of oil separators, oil filters)
• oils of unknown origin, the analyzing result of which does
not enable an allocation to categories 1 and 2
The mixing prohibition must be observed

do not mix usable used oils of categories 1 and 2 1
2
Collection points
Used oils and other waste must only be handed over to collec-
tors approved of by the competent authorities.
The waste owner must make sure that
• the collector possesses a collection and transport permit
(permit in accordance with the local law on waste
disposal
• the vehicle has be licensed for transportation in
accordance with the local hazardous goods regulations
for road transportation
Page 2 of 2; BA 822-0001-07 en
Used Oil Disposal
Requirements in accordance with law on waste disposal, used

oil regulations and decree on the collection, transport and
supervision of waste and tailings.
Waste oil disposal is done by waste oil collection companies. In
§
this context, the used oil owner has the following responsibili-
ties:
• duty of evidencing correct declaration of the used oil
• duty of evidencing under regulations on the collection,
transport and supervision of waste and tailings
(AbfRestÜberwV) and
• duty of complying with the prohibition of mixing.
Requirements in accordance with the hazardous goods regulati-

ons for road transportation Regarding used oil handing over for
transportation by the disposal company, the used oil owner has
the following responsibilities:
• availability of the check certificate
• duty of reporting
• specification of the maximum permissible filling degree
and
• hand-over of accident instruction sheets.
Page 2 of 2; BA 822-0001-07 en
Technical Machinery
Documentation
Pyrojet Burner
Section – III D
 Table of Lubricants– HW 6302/15
State : 06.2020
Schmierstofftabelle
Table of lubricants
Sachgemäße Schmierung mit den für den jeweiligen Verwendungszweck bestgeeigneten
Schmierstoffen ist zur Erhaltung der Betriebssicherheit und angemessener Lebensdauer
unbedingt erforderlich. Es ist nicht möglich, mit den in diesem Schmierplan angegebenen
Richtwerten die Schmierstoffe vollkommen zu charakterisieren. Die Verantwortung für die
richtige Auswahl der Schmierstoffe unter Berücksichtigung der örtlichen Gegebenheiten und
der Einsatzbedingungen derartiger Industrieanlagen sowie des letzten Standes der
Schmiertechnik liegt ausschließlich beim Schmierstofflieferanten.
Für Mängel oder Schäden, die auf falsche Auswahl von Schmierstoffen zuruckzuführen sind,
haften wir nicht.
Zusammenfassend empfehlen wir, nur hochwertige Schmierstoffe zu verwenden, die
entsprechend unseren Richtwerten von namhaften Gesellschaften verantwortlich ausgewählt
wurden.
For maintaining the reliability of operation and an adequate service life proper lubrication with
lubricants most suitable for the individual application, is absolutely necessary. It is not possible
to fully characterize the lubricants with only the standard values indicated in this lubrication
chart. The responsibility for the correct choice of the lubricants-taking into account the local
conditions and working conditions in such industrial plants as well as the latest developments
of lubrication technology exclusively lies with the lubricant supplier.
We do not warrant for defects or damage which can be attributed to the use of unsuitable
lubricants.
In summarizing we would recommend that only high quality lubricants be used which have
been responsibly selected by reputed firms in accordance with our standard values.
KHD Humboldt Wedag

Colonia Allee 3 • D-51067 Köln
HW 6302/15
March 2017
Seite/Page 2 von/of 18; HW 6302/15
Spezifikation / Specifications
Kin.Viskosität bei FZG-Schadens-

Kennzeichnug nach Viskositätsklasse Flammpunkt
Symbol Schmieröle nach
as per
Viscosity class
Kin.viscosity at
40 °C Flash point
Pourpoint kraftstufe
DIN ISO 3016 FZG load stage
accounted to ISO 3448 DIN EN ISO 2592
DIN 51 502 Lubricating oils DIN
ISO VG
DIN EN ISO 3104
> °C
< °C DIN 51 354
(mm2/s) DIN ISO 14635-1
HLP 32 HYDRAULIKÖL
mit Wirkstoffen zur Erhöhung des Korrosionsschut-
32 28,8 ... 35,2 175 -18 10
zes und der Alterungsbeständigkeit sowie mit Wirk-
stoffen zum Herabsetzen der Reibung und des
Verschleißes im Mischreibungsgebiet.
HLP 46 HYDRAULIC OIL
51 524-2 46 41,4 ... 50,6 185 -15 10
with additives increasing the protection against cor-
rosion and the resistance to aging and with additives
for reducing the friction and the wear in the mixed
HLP 68 friction zone. 68 61,2 ... 74,8 195 -12 10
1)
CLP 46 GETRIEBE- UMLAUF- UND 46 41,4 ... 50,6 175 -12 12
LAGERSCHMIERÖL
CIRCULATION LUBE OIL (GEAR AND
BEARING LUBRICATING OIL)
CLP 68 68 61,2 ... 74,8 180 -12 12
MINERALÖL
mit Wirkstoffen zum Erhöhen des Korrosionsschut-
zes und der Alterungsbeständigkeit sowie mit Wirk-
CLP 100 stoffen zum Herabsetzen der Reibung und des
100 90 ... 110 200 -12 12
Verschleisses im Mischreibungsgebiet
max. Ölsumpftemperatur: 80 °C
CLP 220 51 517-3 220 198 ... 242 200 -9 12

SYNTETISCHES ÖL
CLP 320 MINERAL OIL

with additives increasing the protection against cor-
320 288 ... 352 200 -9 12
rosion and the resistance to aging and with additives
for reducing the friction and the wear in the mixed
friction zone
CLP 460 max. oilsumptemperature: 80 °C 460 414 ... 506 200 -9 12
SYNTETICAL OIL
CLP 680 Flenderfreigabe bevorzugt 680 612 ... 748 200 -3 12

2)
LUFTVERDICHTER - mit Wirkstoffen

VDL 100 COMPRESSOR OIL - with additives 51 506 100 90 ... 110 205 -9 -
3)
Kennzeichnug nach Konsistenzklasse Walkpenetration Tropfpunkt

Symbol Schmierfett nach
NLGI-Klasse Penetration worked Drop point
Gebrauchs-Temperaturbereich
as per Service temperature range
accounted to Consistency DIN ISO 2137 DIN ISO 2176
DIN 51 502 Lubricating greases DIN
NLGI-Class 0,1 mm > °C
°C
WÄLZ- UND GLEITLAGERFETT

Lithium-verseift, mit Wirkstoffen zum Erhöhen des
KP 2K-20 Korrosionsschutzes und der Alterungsbeständigkeit, 2 265 ... 295 180 -20 ... +120
wasserbeständig.
51 825
ANTIFRICTION AND PLAIN BEARING GREASE
Lithium saponified, with additives for increasing the
KP 3K-20 protection against corrosion and the resistance to
3 220 ... 250 185 -20 ... +120
aging, water-resistant. 4)
GETRIEBEFLIESSFETT
Natrium-verseift, langfaserig mit EP-Wirkstoffen
GP 00F-20 GEAR GREASE
- 00 400 ... 430 150 -20 ... +80
Sodium saponified, fibrous containing EP-additives
HOCHTEMPERATURFETT
KP 2P-20 für Wälz- und Gleitlager, Lithium-verseift
(lithiumverseift) 2 265 ... 295 260 -20 ... +160
HIGH TEMP.: BEARING GREASE
(Lithium saponified) for antifriction and plain bearings, Lithium saponified
HOCHTEMPERATURFETT (SCHWERLASTFETT)
KP 2P-20 für Wälz- und Gleitlager, Polyharnstoff-eingedickt
(Polyharnstoff- HIGH TEMP. BEARING GREASE (HEAVY
eingedickt) 2 265 ... 295 260 -20 ... +160
WEIGHT GREASE)
(organic polymer for antifriction and plain bearings,
base grease) organic polymer base grease 5)
WÄLZ- UND GLEITLAGERFETT 51 825
für Schneckenlager, Lithium-verseift
KP 1K-20 ROLLER- AND PLAIN BEARING GREASE
1 310 ... 340 - -20 ... + 120
for screw conveyor bearings, Lithium saponified
MEHRBEREICHSSCHMIERFETT
Lithium-komplex verseift
KP 2N-10 UNIVERSAL GREASE
2 265 ... 295 190 -10 ... + 140
Lithium-complex saponified 6)
TIEFTEMPERATURFETT
für Wälz- und Gelenklager
KPE 2K-40 LOW TEMPERATURE GREASE
2 265 ... 295 170 -40 ... + 120
for antifriction and spherical plain bearings 6)
1), 2), 3), 4), 5) and 6) see page 14

HW 6302/15; Seite/Page 3 von/of 18
Empfohlene Schmieröle /
Lubricating oils recommended
Kennzeichnug nach
Symbol
accounted to
DIN 51 502
BECHEM
HLP 32 OSO 32 Aral Vitam GF 32
STAROIL NR 32
HL-32
BECHEM
STAROIL NR 46
HL-46
BECHEM
STAROIL NR 68
HL-68
BECHEM
CLP 46 OSO 46 Aral Degol BG 46
STAROIL G 46
-
BECHEM Gearlube
CLP 68 BLASIA 68 Aral Degol BG 68
STAROIL G 68 SP-68e
BECHEM Gearlube
STAROIL G 100 SP-100e
BECHEM Gearlube
STAROIL G 220 SP-e220
BECHEM Gearlube
BECHEM Gearlube
BECHEM Gearlube
STAROIL G 680 SP-680s
DICREA 100 BECHEM

VDL 100 DICREA ESX 100
Aral Motanol HE 100
STAROIL LV 100
-
Kennzeichnug nach
Symbol
Empfohlene Schmierfette /
accounted to
DIN 51 502 Lubricating greases recommended
KP 2K-20 GR MU/EP 2 Aralub HLP 2 HIGH-LUB LT 2 EP ML-160
HIGH-LUB L 3
KP 3K-20 GR MU/EP 3 -
HIGH-LUB LT 3 EP
ML-160/3
AUTOL Top 2000 CSR-300

GP 00F-20 Getriebefließfett 0/00
Aralub FDP 00 HIGH-LUB GF 550
SAM-2810
AUTOL TOP 2000

KP 2P-20 High Temp
(Aralub MKL 2) BERUPLEX LWB 2 GM-400s
auf Anfrage
KP 2P-20 for inquiry
- BERUTOX M 21 KN BRB-700
KP 1K-20 GR MU/EP 1 - HIGH-LUB LT 1 EP CSR-100
AUTOL TOP 2000

KP 2N-10 High Temp
Radlagerfett Beruplex LWB 2 GM-400s
PPE 2K-40 AUTOL Top 2000 Bio - Berulub KR-EP 2 SAM-2020

Kennzeichnug nach
Symbol
accounted to
DIN 51 502
Renolin B 10 VG 32
Renolin MR 10 VG 32
HLP 32 FLUID DRIVE HM-32 Servosystem HLP 32
Renolin ZAF B 32 HT
LAMORA HLP 32
Renolin ZAF D 32 HT
Renolin B 15 VG 46
Renolin MR 15 VG 46
Renolin ZAF B 46 HT
LAMORA HLP 46
Renolin ZAF D 46 HT
Renolin B 20 VG 68
Renolin MR 20 VG 68
Renolin ZAF B 68 HT
LAMORA HLP 68
Renolin ZAF D 68 HT
Renolin ZAF B 46 HT
CLP 46 FLUID DRIVE HM-46 Servosystem CLP 46
Renolin CLP 46 plus
Klüberoil GEM 1-46 N
Renolin CLP 68
CLP 68 BESLUX GEAR 68 Servosystem 68
Renolin CLP 68 plus
Servocirol 100 Renolin CLP 100

CLP 100 BESLUX GEAR XP 100
Servosystem 100 Renolin CLP 100 Plus
Renolin CLP 220

CLP 220 BESLUX GEAR XP 220 Servosystem 220
Renolin CLP 220 Plus
Renolin CLP 320

Renolin CLP 460

Renolin CLP 680

VDL 100 BESLUX GEAR XP 100 Servopress 1000 Renolin 504 VG 100 Klüber-Summit DSL-100
Kennzeichnug nach
Symbol
accounted to
CENTOPLEX 2
KP 2K-20 G. A. Nr. 850 EP-2 Servogem super HT Renolit FEP 2
CENTOPLEX 2 EP
KP 3K-20 G. A. Nr. 850 EP-3 Servogem super HT Renolit FEP 3 CENTOPLEX 3
Servogrease CG20 Renolit SO-GFB (Na-Seife) MIKCROLUBE GB 00

G 00F-20 G. A. Nr. 850 EP-00
Servogrease RN Renolit GFW 00 (Li-Seife) (Li-Seife/Sil)
K 2P-20 Klüberplex BEM 41-132

(lithiumverseift) G. A. Plex 2 Servogem HTXX Renolit Duraplex EP 2 (Li-Seife)
(KPHC2N-30 L)
(Lithium saponified)
K 2P-20
(Polyharnstoff-
eingedickt) G. BESLUX KOMPLEX M-2 Servogem super HT Renolit PU 8-061/2 PETAMO GHY 133 N
(organic polymer
base grease)
KP 1K-20 G. A. Nr. 850 EP-1 Servogem super HT- Renolit Duraplex EP 1 MICROLUBE GL 261
KP 2N-10 G. BESLUX PLEX EH-2 Servoplex LC-2 Renolit FAP 502 Klüberplex BE 31-502
G. BESLUX BIOGREASE Servogem 2 ISOFLEX NBU 15

KPE 2K-40 M-2/HT Servogrease repair compound
PLANTOGEL ECO 2 S
Klübersynth BL 42-42
Kennzeichnug nach
Symbol
accounted to
DIN 51 502
Mobil DTE 24 Q8 Haydn 32 Tellus S2 MX 32

HLP 32 Renolin B 10
Mobil DTE 10 Excel 32 Q8 Holst 32 Tellus S3 M 32

HLP 46 Renolin B 15

HLP 68 Renolin B 20
Q8 Goya 46 (Tellus S2 MA 46)

CLP 46 Renolin B 15 (Mobil DTE 25)
Q8 Holst EP 46 (Voltrol 46)
Q8 Goya 68
CLP 68 GEARMASTER® CLP 68 Mobilgear 600 XP 68 Q8 Holst 68 Omala S2 G 68
Q8 Holst EP 68
Q8 Goya 100
CLP 100 GEARMASTER® CLP 100 Mobilgear 600 XP 100 Q8 Goya NT 100 Omala S2 G 100
Q8 El Greco 100
Q8 Goya NT 220
CLP 220 GEARMASTER® CLP 220 Mobilgear 600 XP 220
Q8 El Greco 220
Omala S2 G 220
Q8 Goya NT 320
Q8 El Greco 320
Omala S2 G 320
Q8 Goya NT 460
Q8 El Greco 460
Omala S2 G 460
Q8 Goya 680
Q8 Goya NT 680
Omala S2 G 680
Q8 Schubert 100
VDL 100 RENOLIN 504 Mobil Rarus 427
Q8 Schumann 100
Corena S2 P 100
Kennzeichnug nach
Symbol
accounted to
LAGERMEISTER LP 2
Mobilgrease XHP 222
KP 2K-20 LAGERMEISTER BF 2
Mobillux EP 2
Q8 Rubens EM 2 Gadus S2 V100 2
LAGERMEISTER EP 2
Unirex N 3 Q8 Rembrandt 3 Alvania RL 3
KP 3K-20 STABYL L 120
Mobillux EP 3 Q8 Rembrandt EP 3 Gadus S2 V100 3
GEARMASTER® LI 400
G 00F-20 (GP 00P-40 Lithiumkomplex)
Mobillux EP 004 Q8 Rubens 00 Gadus S2 V220 00
(GP 00N-30 (Lithiumkomplex))
K 2P-20
(lithiumverseift) LAGERMEISTER LX EP 2 - Q8 Rubens WB/b Gadus S3 T220 2
K 2P-20
(Polyharnstoff-
eingedickt) LAGERMEISTER XXL (Mobil Polyrex EM) - Gadus S3 T100 2
(organic polymer
base grease)
Mobilgrease XHP 221

KP 1K-20 LAGERMEISTER BF 1
Mobilux EP 1
Q8 Rembrandt EP 1 Gadus S2 V220 1
KP 2N-10 Lagermeister TS Mobilgrease XHP 222 Q8 Rubens WB/b Gadus S3 V220C 2
STABYL ECO EP 2
KPE 2K-40 STABYL ECO S 12
Mobil SHC Grease 102 EAL - Naturelle Grease S5 V120P 2
Kennzeichnug nach
Symbol
accounted to
DIN 51 502
SRS Wiolan HS 32 Tribol HM 943 32

ClarityHydraulic Oil AW 32 Azolla ZS 32
HLP 32 SRS Wiolan HX 32
Rando HD 32 Azolla AF 32
Hyspin AWS 32
SRS Wiolan HB 32 Hyspin ZZ 32
Hyspin AWS 46
Hyspin AWS 68
(Chevron Industrial EP/Machine
AW Oil 46) Azolla ZS 46 Alpha SP 46
CLP 46 SRS Wiolan HX 46
(Texaco Auriga EP 46) Azolla AF 46 Alpha EP 46
(Caltex Pinnacle EP 46)
Alpha SP 68
SRS Ersolan 68 Meropa XL 68 Carter EP 68
CLP 68 SRS Ersolan synth GF 68 Meropa 68 Carter XEP 68
Optigear BM 68
Optigear EP 68
SRS Ersolan 100 Meropa XL 100 Carter EP 100 Alpha SP 100

Optigear BM 100
Optigear EP 100
Alpha SP 220
SRSErsolan 220 Meropa XL 220 Carter EP 220
Optigear BM 220
Optigear EP 220
SRS Ersolan 320 Meropa XL 320 Carter EP 320 Alpha SP 320

Optigear BM 320
Optigear EP 320
Alpha SP 460
SRS Ersolan 460 Meropa XL 460 Carter EP 460
Optigear BM 460
Optigear EP 460
Meropa XL 680 Carter EP 680 Alpha SP 680

CLP 680 SRS Ersolan 680
Meropa 680 Carter XEP 680
Optigear BM 680
Optigear EP 680
Compressor Oil EP VDL 100
Dacnis 100
VDL 100 SRS Wiolan CD 100 Cetus PAO100
Dacnis SH 100
Aircol PD 100
Hipersyn100
Kennzeichnug nach
Symbol
accounted to
Multis EP 2 Tribol GR 100-2 PD
KP 2K-20 - Multifak EP 2 Multis Complex EP 2 Tribol GR 4020/220-2 PD
Ceran XM 220 Spheerol EPL 2
Multis EP 3 Tribol GR 400-3 PD

KP 3K-20 - Starplex EP 3
Multis Complex EP 3 Spheerol EPL 3
Tribol 3020/1000-00 PD
G 00F-20 - Marfak 00 Multis EP 00
Tribol GR 100-00 PD
K 2P-20 (Chevron Multifak EP 2 Multis 2

Tribol GR 4747/220-2 HT
(lithiumverseift) - Texaco Multifak EP 2 Multis Complex EP 2
Spheerol SY 2202
(Lithium saponified) Caltex Multifak EP 2) Ceran XM 220
K 2P-20 Altis MV 2 Tribol GR PS 1 HT (NLGI 1)

(Polyharnstoff- - High temp premium 2
eingedickt) Altis EM 2 Tribol GR XT 2 HT
(organic polymer
Spheerol EPL 1
KP 1K-20 - Multifak EP 1 Multis EP 1 Tribol GR 100-1 PD
Tribol GR 4020/220-1 PD
Multis Complex EP 2 Tribol GR 4020/220-2 PD

KP 2N-10 - Starplex EP 2
Ceran XM 220 Spheerol EPLX 200-2
KPE 2K-40 - - - Tribol GR 3785/220-1.5

Kennzeichnug nach
Symbol
accounted to
DIN 51 502
HLP 32 Balmerol Protomac HLP 32 Enklo HLP 32
HLP 46 Balmerol Protomac HLP 46 Enklo HLP 46
HLP 68 Balmerol Protomac HLP 68 Enklo HLP68
CLP 46 Balmerol Protomac HLP 46 Enklo HLP 46
CLP 68 Balmerol Protogear AM 68 Parthan EP 68
VDL 100 Balmerol Protopress 100 Hycom VDL T 100
Kennzeichnug nach
Symbol
accounted to
Balmerol Liplex EM 2 Lithon 2
KP 2K-20 Balmerol Olitec LL EP 2 Lithon EP 2
Balmerol Liplex EM 3 Lithon 3

KP 3K-20 Balmerol Olitec LL EP 3 Lithon RR 3 (S)
G 00F-20 Balmerol Olitec LL EP 00 Lithon EP 00
K 2P-20 Lithoplex HTX 2

(lithiumverseift) Balmerol Liplex EM 2
Tisona M2
K 2P-20
(Polyharnstoff-
eingedickt) Balmerol Liplex EM 2 -
(organic polymer
base grease)
Lithoplex HTX 1
KP 1K-20 Balmerol Olitec LL EP 1
Lithon EP 1
Balmerol Licom 2 Premium

KP 2N-10 (Blue)
Lithoplex 2
KPE 2K-40 - -
Spezifikation / Specifications
Viskositätsklasse Schmierstoff- Kin.Viskosität bei

Flammpunkt
Viscosity class Kin.viscosity at Pourpoint
SAE J 300 Bezeichnung 100 °C
Flash point
DIN ISO 3016
DIN ISO 2592
Anforderung nach DIN EN ISO 3104 < °C
> °C
requirement for Type of Lubricant (mm2/s)
ACEA E2/API CD
> 4,1 215 -33
SAE 10 W
ACEA E2/API CD
12,5 ... 16,3 225 -25
SAE 15 W-40 DIESELMOTOREN-
SCHMIERÖL
ACEA E2/API CD DIESEL-ENGINE OIL

5,6 ... 9,3 230 -25
SAE 20
ACEA E2/API CD
9,3 ... 12,5 230 -18
SAE 30
OTTOMOTOREN-
ACEA B3/E2
SCHMIERÖL 12,5 ... 16,3 225 -25
SAE 15 W-40 OTTO-ENGINE OIL
ATF
GM-Specification AUTOMATIC-
6,5 ... 8,5 190 -45
Typ A, Suffix A TRANSMISSION
FLUID
API GL 4
> 7,0 225 -30
SAE 80 W KRAFTFAHRZEUG-
GETRIEBEÖL
AUTOMOBIL
API GL 5 GEAR OIL
13,5 ... 24 240 -20
SAE 90
Motoren-Schmieröle / Engine lubricating oils
Viskositätsklasse
Viscosity class
SAE J 300
Anforderung nach
requirement for
BECHEM STAROIL
ACEA E2/API CD I-SIGMA monograde
Turboral 10W Multigrade LL SAE 10 Super MG
SAE 10 W 10W-20
W-40
BECHEM STAROIL
ACEA E2/API CD I-SIGMA universal DL
Turboral 15W-40 MULTIGRADE S3 HD Superior
SAE 15 W-40 15W-40
SAE 15W-40
BECHEM STAROIL
(Turboral 20W-20) MULTIGRADE S3 HD Pride
SAE 20 10W-20
SAE 20W-30
BECHEM STAROIL
(Turboral 30) MULTIGRADE S3 HD Pride
SAE 30 30
SAE 20W-30
BECHEM STAROIL
ACEA B3/E2 I-SIGMA performance
(TRONIC 15W-40) MULTIGRADE S3 HD Superior
SAE 15 W-40 E3 15W-40
SAE 15W-40
BECHEM
GM-Spezification
ROTRA ATF Getriebeöl SGF 84 FLUID GETRIEBEÖL Transfluid A
Typ A, Suffix A ATF 415 A
Viskositätsklasse Empfohlene Schmierstoffe /

Viscosity class
SAE J 300
Anforderung nach
Lubricating recommended
requirement for
Kraftfahrzeug-Getriebeöle / Automobil gear oils
API GL 4 BECHEM Staroil

ROTRA HY DB 80W Getriebeöl EP 80W Servomesh SP
SAE 80 W SAE 80 W
BECHEM
API GL 5 ROTRA MP DB 85W- Getriebeöl Hyp
HYPOIDGETRIE- Servomesh EE
SAE 90 90 85W-90
BEÖL SAE 90
Viskositätsklasse
Viscosity class
SAE J 300

Anforderung nach
requirement for
ACEA E2/API CD BRADOL MF-10W TITAN Balmerol Protomac

SERVO SUPER MG
SAE 10 W TO-4 UNIVERSAL HD 10 W Ultra 10W
BRADOL MULTIGRA- TITAN

ACEA E2/API CD Balmerol Excel Turbo
DEO SHPD SAE SERVO SUPERIOR UNIVERSAL
SAE 15 W-40 15W40 HD 15W-40
CH-4 15W-40
TITAN
ACEA E2/API CD
- SERVO PRIDE UNIVERSAL -
SAE 20 HD 20W-20
ACEA E2/API CD BRADOL SERIE III TITAN

SERVO PRIDE Balmerol PRD 30
SAE 30 SAE 30 UNIVERSAL HD 30
BRADOL MULTIGRA-
ACEA B3/E2 TITAN Balmerol Gold Pre-
DEO SHPD SAE SERVO SUPERIOR
SAE 15 W-40 15W40
TRUCK 15W-40 mium CF-4 15W-40
GM-Spezification FLUID DRIVE DX SERVO TRANS-

TITAN ATF 10 Balmerol Trans Q
Typ A, Suffix A DX-II FLUID A

Viscosity class
SAE J 300
Anforderung nach
requirement for
API GL 4 SUPER EXTRA

SERVOMESH SP TITAN GEAR MP 80 Balmerol HP 80W
SAE 80 W GEAR SAE 80 W EP
Balmerol HP 90 (SPL)
API GL 5 EXTRA
SERVOMESH EE TITAN GEAR HYP 90 Balmerol HP 85W-90
SAE 90 GEAR SAE 90 EP
(SPL)
Viskositätsklasse
Viscosity class
SAE J 300
Anforderung nach
requirement for
ACEA E2/API CD
- - Q8 T 520 10W Rimula R3 10W
SAE 10 W
ACEA E2/API CD Mobil Delvac

- Q8 T 520 15W-40 Rimula R4 X 15W-40
SAE 15 W-40 Super E 1400 15W-40
ACEA E2/API CD
- (Mobil Delvac 1320) Q8 T 520 SAE 20 (Rimula R3 20W-20)
SAE 20
ACEA E2/API CD
- Mobil Delvac 1630 Q8 T 520 SAE 30 Rimula R3+ 30
SAE 30
(Engine Oil DG
ACEA B3/E2 Mobil Super 10W-40
- Q8 T 750 15W-40
SAE 15 W-40 1000 X1 15W-40 Rimula R3 U+ 10W-
40)
GM-Spezification Mobil
- Q8 Auto 14 Spirax S1 ATF TASA
Typ A, Suffix A ATF 200

Viscosity class
SAE J 300
Anforderung nach
requirement for
API GL 4 Titan Cytrac MB

Mobilube GX-A 80W Q8 T 35 80W Spirax MA 80W
SAE 80 W SYNTH SAE 75W90
API GL 5 Titan Cytrac HSY Mobilube HD-A 85W-

Q8 T 35 SAE 90 Spirax MB 90
SAE 90 75W90 90
Viskositätsklasse
Viscosity class
SAE J 300
Anforderung nach
requirement for
Ursa Heavy Duty SAE

10W
ACEA E2/API CD Tection Monograde
SRW Rekord 10W Chevron Delo 400 SAE Rubia S 10W
SAE 10 W 10W
10W
Ursa LA-3 SAE 10W
Ursa Heavy Duty SAE

15W-40 Tection 15W-40
ACEA E2/API CD
SRS Rekord 15/40 Chevron Delo 400 LE Rubia XT 15W-40 Tection Global 15W-
SAE 15 W-40 SAE 15W-40 40
Ursa LA-3 SAE 15W-40
Ursa Heavy Duty 20W-

ACEA E2/API CD 20 Tection Monograde
SRS Rekord 20W20 Rubia S 20W-20
SAE 20 Chevron Delo 400 SAE 20W-20
20
Ursa Heavy Duty SAE

30
ACEA E2/API CD (Tection Monograde
SRS Rekord 30 Chevron Delo 400 SAE Rubia S 30
SAE 30 30
30)
Ursa LA-3 SAE 30
ACEA B3/E2 SRS Multi-Rekord Ursa Heavy Duty SAE GTX Professional A3
Rubia XT 15W-40
SAE 15 W-40 Plus 15W-40 15W-40
No TASA product. Clo-

sest match: Texamatic
GM-Spezification SRS Wiolin ATF 2453 4291 ATF DEX III Multi-
Fluide CC
Typ A, Suffix A A Chevron Automatic vehicle
Trans. Fluid MD-3
Havoline Multi-Veh. ATF

Viscosity class
SAE J 300
Anforderung nach
requirement for
Geartex EP-A SAE 80W
SRS Wiolin ML 4; Universal EP SAE 80W
API GL 4
SRS Wiolin Mehr- Gear Oil GL-4 SAE EB 80W-90 Manual EP 80 W
SAE 80 W zweck-Getriebeöl 80 80W-90 Translube LD
SAE 80W-90
Geartex EP-B SAE 85W-
90;
Geartex EP-C SAE Transmission SYN FE
Axle EPX 90
SRS Wiolin HL 5; 80W-90; 75W-90;
API GL 5 Axle Long Drain 80W-
SRS Wiolin Multigear SAE 80W-90; EP-B 80W-90;
SAE 90 Hypoid-Getriebeöl 90 Multigear EP-5 SAE Transmission TM
90
80W-90 Axle Z Limited Slip 90
80W-90
Delo Gear EP-5 SAE 90
Viskositätsklasse
Viscosity class
SAE J 300
Anforderung nach
requirement for
ACEA E2/API CD
HYLUBE X-3-10W
SAE 10 W
ACEA E2/API CD
HYLUBE LL 15W40
SAE 15 W-40
ACEA E2/API CD
HYLUBE X-3-20
SAE 20
ACEA E2/API CD
HYLUBE X-3-30
SAE 30
ACEA B3/E2
HYLUBE LL 15W40
SAE 15 W-40
HP AUTOMATIC
GM-Spezification
TRANSMISSION
Typ A, Suffix A FLUID A

Viscosity class
SAE J 300
Anforderung nach
requirement for
API GL 4
HP GEAR OIL EP 80
SAE 80 W
API GL 5
HP GEAR OIL XP 90
SAE 90
Sonderschmierstoffe / Special lubricants
Sprühschmierung für offene Antriebe an Rohrmühlen- und Drehrohröfen *)

Spray application for open gear drives at mills and rotary kilns *)
CEPLATTYN KG 10 HMF Berluit GA 400

GRAFLOSCON C-SG 0 ULTRA
CEPLATTYN KG 10 HMF-1000 Berluit GA 800
Grease GRAFLOSCON C-SG 1000 ULTRA
CEPLATTYN KG 10 HMF-2500 Berluit GA 2500
GRAFLOSCON C-SG 2000 ULTRA
CEPLATTYN KG 10 LC
CEPLATTYN SF 10
Fluid Klüberfluid C-F 3 ULTRA Berugear HV 20
CEPLATTYN GT 10
*) Die Einsatzempfehlung des geeigneten Schmierstoffes für den Anwendungsfall erfolgt vom jeweiligen Lieferanten, ggf. sind Modifikationen an
der Sprühanlage notwendig. Die Hinweise in der Betriebsanleitung zum Drehrohrofen beachten.
The recommendation of the suitable lubricant for the application is carried out by the respective suppliers, when indicated, modification in the spray
unit are necessary. Observe the instructions in the operating manual for rotary kiln.
Grundier- u. Einfahrschmierstoffe für offene Antriebe an Rohrmühlen und Drehrohröfen

Priming and running in lubricants for open gear drives at mills and rotary kilns
GRAFLOSCON A-G 1 ULTRA CEPLATTYN 300 Berluit 443

(Grundierung / Priming) (Grundierung / Priming) (Grundierung / Priming)
Grease
GRAFLOSCON B-SG 00 ULTRA CEPLATTYN RN Berluit EL 420
(Einfahrschmierstoff/Starting lub.) (Einfahrschmierstoff/Starting lub.) (Einfahrschmierst./Starting l.)
CEPLATTYN GT P (Priming)
Klüberplex AG 11-462 (Priming) Berugear HV PR (Priming)
CEPLATTYN GT RN (Einfahr-
Fluid Klüberfluid B-F 2 ULTRA (Einfahr- Berugear HV RI (Einfahr-
schmierstoff/Starting lubricant)
schmierstoff/Starting lubricant) schmierstoff/Starting lubric.)
CEPLATTYN SF RN
Öl für Offenrollenlager mit MAIN-Metall Lagerschalen bei Umgebungs-temperaturen < -

10°C
Oil for Kiln roller bearing with main metal bushing for ambient temperature < -10°C
GEARMASTER® ECO
460 (biologisch abbau-
bar /
OMALA HD 460 Klübersynth GEM 4-460 N Berusynth GP 460
biological degradable)
GEARMASTER® SYN
460
Sonderschmierstoffe für HW Ofenrollenlager

Special lubricants for HW Kiln roller bearing
Schmierstoffe für Ventilatorlager mit Betriebstemperaturen > 100°C und > 120°C
Van bearing lubricants for high temperature applications > 100°C and > 120°C**)
Berutox FH 28 KN URETHYN E/M2

(Fett: Mindestanforderung (Fett: Mindestanforderung PETAMO GY 190
KP2P-20, Grundölviskosität KP2P-20, Grundölviskosität (Fett: Grundölviskosität
Grease 150 150 160mm2/s
Grease: min. requirement Grease: min. requirement Grease: Base oil viskosity
KP2P-20, Base oil viscosity KP2P-20, Base oil viscosity 160mm2/s)
150) 150)
Fluid BERUSYNTH GP 100 GEARMASTER SYN 100 Klübersynth GEM 4-100 N
> 100°C Öl/oil (PAO) 100 mm2/s Öl/oil (PAO) 100 mm2/s Öl/oil (PAO) 100 mm2/s
BERUSYNTH EP 100** GEARMASTER PGP 100**
(ÖL: Polyglycol basierend (ÖL: Polyglycol basierend Klübersynth GH 6-100**
Fluid
Grundölviskosität 100 Grundölviskosität 100
> 120°C
Oil: polyglycol based Oil: polyglycol based Öl/oil (PG) 100mm2/s
Base oil viscosity 100) Base oil viscosity 100)
**) Gehäuseinnenlackierung mit 2-Komponenten Lacken / Housing inner coating with 2-Component coats
Laufringinnenschmierung an Trocknern und Öfen

Internal lubrication of riding rings fitted to rotary kilns or dryers
CEPLATTYN® HT (schwarz /
black) WOLFRACOAT C Fluid Berulub VPN 13 Ringlub
CEPLATTYN® TL (silber / silver)
Sonderschmierstoffe für HW Rollenpressen

Special lubricants for HW roller presses
Fett für hochbelastete Wälzlager von Rollenpressen bei kompl. Fettschmierung
Highly stressed roller bearing grease of roller presses for complete grease
lubrication
Mobilith SHC
STABYL HD 1500
Klüberlub
(bleifrei / non-leaded)
BE 41-1501 synthetisches EP- Tribol GR 3020/
STABYL LTS MO
(bleifrei / non-leaded) Schmierfett/ 1000-2 PD
(einsetzbar bis -30 °C /
applicable up to -30 °C) synthetic EP
Grease
FAG Arcanol L223V

HIGH-LUB FA 50 SKF LGEV2-1000
(bleifrei/non-leaded)
HIGH-LUB FA 50 MO (bleifrei/non-leaded)
Aracanol Load 1000
Öl für hochbelastete Wälzlager bei Ölschmierung 1)

Highly stressed roller bearing oil for oil lubrication 1)
GEARMASTER®
Klübersynth ECO 460 *)
EG 4-460 *) (biologisch abbaubar /
Klübersynth biological degradable)
GEM 4-460 N *) GEARMASTER®
SYN 460 *)
Fett für Lagerlabyrinthe bei Ölschmierung 1)
Grease for bearing labyrinths for oil lubrication 1)
STABYL ECO EP2

POLYLUB WH 2 (biologisch abbaubar /
Klüberbio BM32-142 biological degradable)
LAGERMEISTER TS
1) Öle und Fette sind aufeinander abgestimmt immer vom gleichen Hersteller einzusetzen.
1) Oil and grease are to be applied always matched by the same manufacturer.
*) je nach Betriebstemperatur auch ISO VG 680 / depending on operating parameters also ISO VG 680
1) HYDRAULIC OIL
General application- Hydraulic system. Lubricant for rolling and plain bearings and for lubrication of gear units where the use of extreme
pressure gear Oil is not required. Property- Hydraulic oil, HM consists of highly refined paraffinic base stocks with additives to prevent rust,
oxidation and wear.
2) ENCLOSED GEAR UNIT OIL
General application - Lubrication of low and high-load gear units and bearing of KHD design. For gear units form other supplier: See special
recommendation from the supplier in question. Suitable for use at operationg T < 90°C approx. Property- This mineral oil consists of highly
refined paraffinic base stocks with additives to prevent rust, wear and foam. The oil yields extreme pressure properties. General requirement-
The oil must be able to run with a filter reduction rate of beta 10 >75 (10my absolute filtration) defined in ISO4572 (Multipass test), without
loss of additives.
3) COMPRESSOR OIL,MINERAL OIL
General application- Lubrication of air compressors, i.e. piston and rotary compressors for production of compressed air. Compressor outlet
temperature < 220°C. Property- Compressor oil are made of highly refined paraffinic base stocks with additives to prevent oxidation, rust,
foaming and wear.
4) ANTIFRICTION AND PLAIN BEARING GREASE
General application- General industrial lubrication. Electrical motor and generator. Large bearings > 75 mm bore. Lubrication of all types of
roller and plain bearing for medium to high loads and moderate to high speeds (dN-factor < 200.000). Special application: Solyvent damper,
bearing and ball joint at temperature up to 110 ºC. Property -The multipurpose grease and the low-temperature grease consist of a highly
refined mineral oil or polyalphaolefin with a thickener added as well as additives to prevent corrosion and oxidation. Multipurpose grease and
low-temperature grease is not mixable unless thickener is of the same type. Grease of NLGI 3 is not pump able.
5) HIGH TEMPRATURE BEARING GREASE
General application- Rolling and plain bearings in mechanical or electrical equipment. High operation temperatures. Special application:
Solyvent damper, bearing and ball joint at temperature up to 350 ºC. Property- High-temperature grease consists of highly refined mineral oil
or synthetic oil (perfluoroalkyl ether oil. PTFE) with a thickener added as well as additives to prevent corrosion and oxidation. High-
temperature grease must be suitable for centralised lubrication systems. General requirement- Information on water resistance must be
required for every single product. Corrosion protection must be agreed with supplier.
6) MULTIPURPOSE AND LOW TEMPRATURE GREASE
General application- Rolling and plain bearings in mechanical/electrical high-speed equipment with low to moderate operating temperatures.
Property- The multipurpose grease and the low-temperature grease consist of a highly refined mineral oil or polyalphaolefin with a thickener
added as well as additives to prevent corrosion and oxidation. Multipurpose grease and low-temperature grease is not mixable unless
thickener is of the same type. Grease of NLGI 3 is not pump able.
Hindustan Petroleum Corporation Delhi - 110092, India

FUCHS EUROPE Schmierstoffe GMBH, Friesenheimer Straße 15, D-68169

Eni Schmiertechnik GmbH, Paradiesstraße 14, D-97080 Würzburg, Germany Mannheim, Germany
KLÜBER LUBRICATION MÜNCHEN SE & Co. KG, Geisenhausenerstraße 7,

Aral Aktiengesellschaft, Überseeallee 1, D-20457 Hamburg, Germany
D-81379 München, Germany
FUCHS LUBRITECH GMBH, Werner-Heisenberg-Straße 1, D-67661

CARL BECHEM GMBH, Weststraße 120, D-58089 Hagen, Germany Kaiserslautern, Germany
Chevron Global Lubricants, Technologiepark Zwijnaarde 2, B-9052

Gent/Zwijnaarde, Begium Esso DeutschlandGmbH, Caffamacherreihe 5, D-20355 Hamburg,
Germany
BP Europa SE Industrieschmierstoffe (Castrol), Erkelenzer Straße 20, D-41179

Mönchengladbach, Germany Q8 Oils, Petroleumkaai 7, B-2020 Antwerp, Belgium
BRUGAROLAS, S..A., Poligono Cova Solera 36-44, 08191 Rubi,

Barcelona, Spain Shell DeutschlandOilf GmbH, Suhrenkamp 71-77, D-22284 Hamburg,
Germany
Indian Oil Corporation Ltd., G-9, Ali Yavar Jung

Marg. Bandra (East), Mumbai - 400 051, India SRS Schmierstoff Vertrieb GmbH, Neuenkirchener Straße 8, D-48499
Salzbergen, Germany
TOTAL Deutschland GmbH, Jean-Monnet-Straße 2, D-10557 Berlin, Germany P.O.Box No. 16791, Sion Mumbai 400 022, India
Balmer Lawrie & Co Ltd, P-43, Hide Road Extension, Kolkata - 700088, India

Servo Indian Oil Corporation Limited,
G-9 Ali Yavar Jung Marg, Bandra (East), Mumbai
Technical Machinery
Documentation
Pyrojet Burner
Section – IV
 Spare parts List

(EL P-13-0052 en)
State : 06.2020
Spare parts List EL P-13-0052 en
Page 1 of 1
• Spare parts- Pyrojet Burner
S.
Description Document No.
No
1 Pyro-Jet Burner 307-011-130630224
1.1 Support tube 307-011-130630227
1.2 Compensator 400 NB
1.3 Coal dust pipe 307-011-130630228
1.4 Wearing insert 307-011-130630229
1.5 Intern.burner pipe complete 307-011-130630230
1.6 Supporting pipe for additional burner 307-011-130630231
1.7 Nozzle plate complete 307-011-130630031
1.7.1 Nozzle plate 307-011-130630033
1.8 Coal dust nozzle internal 307-011-100486
1.9 Nozzle pipe complete 307-011-103570536
1.10 Swirler 307-011-130630029
1.11 Cross - Beam 307-031-130630231
Technical Machinery
Documentation
Pyrojet Burner
Section – V
 Documents for the assembly of the machine

(MU P-13-0052 en)
State : 06.2020
Technical Machinery Documentation State : 06.2020
MU P-13-0052 en
Documents for the assembly
Page 1 of 1
of the machine
Contents:
Previous edition:
Group No. Group Name Drawing No.
11 Pyrojet Burner 307-011-130630224 BA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
200 NB
(Jet air) 15 125 NB 24 18 27 22
(Swirl air)
A 500 X A
A-A (1 : 10)
4
100
80
n606,4
n406,4
B B
C 10 8 9 7 1 3 6 5 4 23 26 2 16 19 C
D 9833 275 D
6887 Overall length 240 ±35mm

5649 3 3 fitted with 35mm initial stress.
E E
U S2 S1 W
n406,4
n606,4
A A
n88.9x3.2
480
F n100 F
Y
Patenterteilung oder Gebrauchsmuster-Eintragung vorbehalten.
Weitergabe sowie Vervielfältigung dieser Unterlage, Verwer-
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
3 3
pflichten zu Schadenersatz. Alle Rechte für den Fall der
,5
tung und Mitteilung ihres Inhalts nicht gestattet, soweit
120
70
n
2000
8000
G 14 G
12304
12607
12810
H H
USE OR COMMUNICATION OF THE CONTENTS THEREOF, ARE FORBIDDEN
MENT OF DAMAGES. ALL RIGHTS ARE RESERVED IN THE EVENT OF THE

WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAY-
GRANT OF A PATEN T OR THE REGISTRATION OF A UTILITY MODEL OR

COPYING OF THIS DOCUMENT, AND GIVIN G IT TO OTHERS AND THE
Z (1 : 2) M)*
Before assembly this areas are to be greased
J with heat resistant lubricant (Anti Seize). J
Z
n13
K K
425
DESIGN .
480
Refractory and anchorage to be fitted on
L site by specialized company in this branch. L
Expansion joints are to be provided.
Before fitting the refractory material coat
the burner with bitumen or wax approx. 1-2mm thick.
n406,4
n284
n153
n198
n131
8220 2200
BIRKOSIT sealing putty to be applied to
faces prior screwing.
M 14 M
10 8 9 7 5 3 6 1
N W (1 : 10) N
500 500
V (1 : 5)
U (1 : 10) 43`1
V
X (1 : 2)
P
27 17 Tightness test of the jet air channel (between item 1, 2, P
7 3 & 4) to be carried out with min. test pressure of 2 bar.
45 °
500
(this welding seam are to test with leckage spray)

8 20 24
43`1
Leakage at site with leakage detector spray.

Y (1 : 2) S1 = 5031 kg
9 weight of burner without brick lining
10 3 21 S2 = 8385 kg
weight of burner with brick lining
Q
4 25 Exact position of centres of gravity S1 and S2
are to be determinated during assembly.
Q
12
n 100
SURFACE TEXTURES W O RK: / W EIG H T S. PAR TSL IS T P RO JE CTIO N
28
DIM ENS IO NS /Ma ße in mm
43`1
AC C. I SO 1 30 2 B ea rbe ite t : 25 .09 .20 19 AAS H G e wic h t s . S tü ck list e METHO D

S IZE/ Ma ß ISO 1 4 4 05 -1 Da rste llu n g s-
TO L ERA TIO N/ To el rie ru n g ISO 80 1 5 IN MICR OMETER S C H ECKE D: /
met h od e
G e p rü ft : MATER IAL S . P AR TS L IST
G EO METR IC TO L ERA NC ING PER 1 1 01 A ND 2 76 8 -m-K ISO 12 8
11 Fo rm-, L a g e-, Allg .- To le ra n ze n n . I SO 1 1 01 u . ISO 2 7 6 8-m-K O b e rf äl c h en -A ng a b en D OC . TYPE: / SCA LE :/ We rkst of f s . Stü ck list e
n70,5
DIM ENSI O NS WI THO UT IN DI CATI O N O F TO L ER AN CES na c h IS O 13 0 2 D ok um en ta rt: IDWNM Maßs ta b :

Ma ße o h ne To le ra n z an g ab e in µm
DESIGNATIO N:/
N O N -C U TT IN G
M AC H I NE D
M E D IU M C O A R SE
C U TS
B renn s c hn ti t e
W E LD E D
S TR U C TU R E
WO RKPIECE EDGES ACC. Benennung:
s pa nend s panlos
s<5 0 s >5 0
Sc hw eiß- We rkstü ckka nten nach
Pyro-jet-burner high pressure
n70
13
m itte l g rob k ons tr uk tion ISO 13 715
IS O 2 768 IS O 27 68 IS O 9 013- 431 IS O 90 13-4 32 ISO 139 20-B , -F
-0 ,3
W ELDI NG SEAMS WITHO UT SPEC IFICATIO NS O F QU ALITY C LASS +0 ,3
Pyr o- je t- bu rn er
Schweisszusatzwerkstoffe fuer Montagenaehte Sch weißn äh te oh ne Be wertu ng sgru pp en -An ga be
R 43`1 750 Note for errectors !

29 consumable welding materials for site welds
ACC. / n ach I SO 5 81 7-C
R
Before assembling item 3 and item 5, All flanged coupling joints must be
We rkstoffpaarung
material match
Stabelektrode
stick e le ctro de
PAR T-N O: /
Teil e-Nr.:
SH EETS IZE:/
Form at:
LAN GU AGE: /
Sprac he
R EV.: /
R ev .:
item 4 & 5 are screwed together. 1.0254 - 1.0254

EN 499 - E 38 0 RR 12 HUMBOLDT A0 EN/
earthed using copper strands (DIN 191 3 - E S t 32 RR 6)
1.4848 - 1.4848
EN 1 600 - E 25 20 B 22
WEDAG 307-011-130630224 00
2018
(DIN 855 6 - E 25 20 B 20 +1. 4842 )
R EPLAC EMENT FOR :/ S HEE T:/B a
l t t:
EN ISO 1 4172 - E Ni 6 082 (NiCr20 Mn3 Nb)
1.0254 - 1.4848 AWS A5.11 -0 5: E NiCrFe-3 (Mat erial No. : 2.4 648 )
Ersatz f ür: S HEE TS:/ Blät ter
001/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
DIN A0

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TECHNICAL MACHINERY

Item-no. Com.-no Gr. Designation

481 BU1 P-13-0052 Pyrojet Burner

“Safety and Health”

Section 0: Preface, sub-division and overview

Section I: Acceptance and test certificates, certificates

Section II: Customer-specific characteristic and technical data

Section III: Operating instructions

Section IV: Spare Parts List

Section V: Documents for assembly of the machine

Ordner / Book Seite / Sheet Abteilung / Dep. Datum/

AMENDMENT SHEET Rev. No. R0

Order No. : P-13-0052

Customer : STAR CEMENT MEGHALAYA LTD.

Star Cement Meghalaya Ltd., Line-II, Post

Also machines and plants (hereinafter

Therefore, a sufficient knowledge of all

The Technical Machinery Documentation -

“Safety and Health” BA 822-0004/1 en

4.1 Warning references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5. Requirements to the users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Operating instructions / training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8. Conversions, changes of the operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9.1 Prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10. Assembly, inspection, maintenance work and repairs . . . . . . . . . . . . . . . . . . . . . . . . . 7

11. Shutting down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

11.1 Emergency disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

12. Recognizing of operational failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

“Safety and Health” General References in Operating Instructions

Therefore, a sufficient knowledge of all relations is compulsory, e.g. of transport, assembly,

• Every supplier of individual declarable components is contractually obliged to also supply

• Not considering special accompanying documents such as “Assembly Documentation”,

“Safety and Health” General References in Operating Instructions

• Risks due to supplied energy

• Risks due to heat sources

• Risks due to excessively high noise levels

• Risks due to radiation

• Risks due to vibrations

• Risks due to working materials and products

Not all risks can be excluded by design measures.

• Operating instructions must be considered compulsory by all persons or organisations

• Depending on field of application and complexity of a product, the extent of operating

• Operating instructions warn of obvious and foreseeable misuse

“Safety and Health” General References in Operating Instructions

4.1 Warning references

The operator of the plant is responsible for the consideration and

4.2 Safety references

• Residual risks and hazards upon use of the product as directed

• Safety measures required for a riskless handling of the product

• Circumstances under which the product must not be used.

The operator of the plant is responsible for the consideration and

5. Requirements to the users

• Users can be for example: Operators, assembly staff, repair staff

• Actions can be for example: Operating, mounting, maintaining.

The operator is responsible for selecting the respective persons

“Safety and Health” General References in Operating Instructions

6. Operating instructions / training

Prior to starting actions in and on the plant, the operator of the

Another or deviating use is considered not as directed.