I. General Provisions

1. These specifications apply to the operation and management of rotary cooling (rotary drum cooling) equipment in fertilizer production workshops, covering the entire process of pre-production preparation, production operation, and maintenance.
2. Operators must pass training before taking up their posts. Before operation, they shall become familiar with the equipment structure and the contents of these specifications.
3. The rotary drum cooler mainly consists of a drum, motor, reducer, support roller device, thrust roller device, lifting plates, feeding device, discharging device, induced draft fan, and sealing cover. Through the cooperation of drum rotation and the induced draft system, the material fully contacts cold air to achieve uniform cooling.

II. Pre-Production Preparation Stage

Pre-Startup Inspection

1. Equipment integrity inspection: Check whether all parts are installed securely and whether fasteners are loose. Check whether there are foreign objects or accumulated material in the drum; clean them promptly if present. Before restarting equipment that has been out of service for a long time (over 30 days), test the motor insulation with a megohmmeter to prevent motor burnout.
2. Lubrication system inspection: Check whether transmission parts (such as chains, gears, bearings, etc.) are well lubricated; add lubricating oil when necessary.
3. Drum and surrounding inspection: Confirm that there are no obstacles around the drum that would hinder operation, that the sealing cover is intact, and that the induced draft pipe connections are normal. Check whether the riding ring and support rollers are in good contact.
4. Electrical inspection: Power connections should be firm and reliable, insulation should be good, grounding should be correct, and instrument indications should be normal.
5. No-load trial run: For newly installed or overhauled equipment, after startup first check whether the rotation direction is correct (if reversed, stop immediately and adjust). Feed material only after confirming smooth operation, no abnormal noise, and no friction noise. Newly installed equipment should undergo a no-load trial run of no less than 8 hours. Check the transmission device for vibration and impact; the motor temperature rise must not exceed 40°C.

2.2 Material Preparation

1. Confirm that the material to be cooled contains no hard foreign matter such as iron blocks or stones, so as to avoid damaging the lifting plates or drum.
2. A foreign matter removal device should be installed at the feed inlet to control the entry of foreign matter from the source.

III. During Production Operation

3.1 Startup Sequence

1. This machine must be started under no-load conditions. Startup with material is strictly prohibited.
2. Start the induced draft fan first (used in conjunction with the cooler). After it runs normally, start the main motor of the cooler.
3. After the equipment runs smoothly, start the upstream feeding equipment.

3.2 Operation Monitoring

1. Feeding operation: After the cooler runs smoothly, start the feeding equipment for uniform feeding. After normal discharge, the sealing cover should always remain closed.
2. Bearing temperature monitoring: During operation, frequently check the temperature rise of each bearing. Normal temperature is ≤60°C. If it exceeds this value, stop immediately and inspect.
3. Operation status monitoring:
   • Closely monitor the operating sound. If abnormal sound or severe vibration is found, stop immediately and inspect.
   • Inspect once per hour: remove attached debris from the girth gear surface and roller surface.
   • Check the drum for axial movement and vibration. The riding ring should not show obvious vibration.
4. Discharge effect monitoring: Regularly check the discharge temperature to confirm that the cooling effect meets process requirements. When the discharge temperature is too high, check the induced draft fan air volume and the wear condition of the lifting plates in the drum.

3.3 Shutdown Operation

1. Normal shutdown:
   • Stop feeding: First stop the upstream feed conveyor (or elevator, etc.) and cut off the incoming material.
   • Empty material: Let the cooler continue running until the residual material in the drum is completely discharged and no material flows out of the discharge outlet. This step is crucial. If the machine is stopped before the material is fully discharged, residual material will adhere to the drum inner wall and lifting plates; after hardening, the next startup will be difficult, and it may even cause excessive starting current and burn out the motor.
   • Shut down the main machine: After confirming that the drum is empty, shut down the main motor of the cooler.
   • Shut down the induced draft fan: After the main machine has completely stopped, shut down the induced draft fan. If the induced draft fan is stopped first, residual heat in the drum cannot be discharged, which will affect the cooling effect and may damage seals.
   • Power isolation and tagging: Disconnect the main power of the equipment control cabinet and hang a “Stopped / Do Not Operate” warning sign.
2. Emergency shutdown (abnormal shutdown):
   • Immediately press the emergency stop button or cut off power to perform emergency shutdown.
   • Handling after emergency shutdown: The cause of the fault must be identified and eliminated before restarting according to the “Startup Sequence.” It is strictly prohibited to force startup before the fault is eliminated. At the same time, the emergency shutdown time, cause, and handling process shall be recorded in detail in the Equipment Operation Record.
3. Post-shutdown on-site handling (mandatory):
   1. Internal inspection and cleaning: Open the inspection door and check whether material adheres to the drum inner wall and lifting plate surfaces. Clean promptly if any, especially accumulated material at the roots of the lifting plates, to prevent hardening from affecting the next lifting effect.
   2. Anti-rust treatment: After cleaning, apply an appropriate amount of waste engine oil or anti-rust oil to the girth gear surface, riding ring surface, support roller surface, and exposed gears to prevent rust in open-air or humid environments.
   3. Close sealing doors: After confirming that no tools or debris are left inside, close and lock all inspection doors to prevent dust entry or rain ingress (outdoor models).
4. Shift-change shutdown requirements:
   • Before handover, the equipment must be stopped and cleaned, and the Equipment Operation Record and Shift Handover Record must be truthfully filled in, noting the equipment operation status during the shift (key parameters such as bearing temperature, discharge temperature, and current), abnormalities, and countermeasures.
   • Before startup, incoming shift personnel must re-confirm the equipment status against the inspection requirements in the “Pre-Production Preparation Stage.”

IV. Maintenance and Care

4.1 Daily Maintenance (Each Shift)

1. Cleaning: After each shift, clean residual material inside and outside the equipment to prevent caking and corrosion of the equipment and next blockage. Clean residual material inside the drum and check the wear degree of the lifting plates.
2. Inspection: Check whether all parts operate normally. Pay attention to checking the wear degree of wearing parts.
3. Lubrication: Check whether transmission parts (such as chains, gears, bearings, etc.) are well lubricated; add lubricating oil when necessary.

4.2 Regular Maintenance

1. Lubrication maintenance cycle:
   • Regularly lubricate support rollers, thrust rollers, and transmission gears.
   • The injected lubricating oil must be clean, and seals must be good.
   • (Note: For detailed lubrication guidance, see the equipment lubrication nameplate.)
2. Wearing parts inspection and replacement: Regularly inspect support rollers, seals, bearings, sealing gaskets, and other wearing parts, and replace them in time. Severely worn V-belt transmission parts should be replaced in time.
3. Electrical system: Check motor insulation performance every six months. Inspect circuits to eliminate leakage and short-circuit hazards.
4. Rotating parts inspection: Regularly check rotating parts for flexibility and whether there is jamming. Regularly add grease to sprockets and other parts.

4.3 Long-Term Shutdown Maintenance

When the equipment is out of service for more than 30 days, the material in the drum must be completely discharged and cleaned, and anti-rust grease should be applied to exposed parts such as gears, girth gear, riding rings, and support rollers. Before restarting, perform a motor insulation test with a megohmmeter, trial run according to the no-load trial run requirements, and only feed production after confirming normal operation.

4.4 Fault Handling Principles

1. If abnormal noise, excessive bearing temperature, severe vibration, etc. are found, stop immediately; restart only after the cause is identified and the fault is eliminated.
2. It is strictly prohibited to run equipment with faults, and strictly prohibited to perform maintenance or cleaning while the equipment is running.
3. When repairing transmission parts or entering the drum interior, cut off power and hang a “Do Not Close Switch” warning sign. Entering the drum interior also requires the confined space operation procedure of “ventilate first, test second, work last.”

V. Common Faults and Remedies