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REF:

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Kiln Shell under Tyre:

Rev. N 00
SUMMARY
SUMMARY

Description :

DESCRIPTION
DESCRIPTION

FORMS
FORMS

BP

APPENDICES
APPENDICES

CUTTING & REPLACEMENT OF KILN SHELL

SECTION
Service / Department : MECHANICAL
Duration of Stoppage : TWELVE (12) Days (288 Hrs)

Operational Phases
Phase
no.
Phase 1
Phase 2
Phase 3
Phase 4

Estimated Estimated Est. cost

Description

Quantity Unit Cost

( Php )

Site Preparation
Dismantling / Rigging down of old Kiln shell
Rigging up / Mounting / Alignment of the new Kiln shell
Housekeeping

Total

Labor
Phase
no.
Phase 1
Phase 2
Phase 3
Phase 4

Description
Mechanical
Contractor
Mechanical
Contractor
Mechanical
Contractor
Mechanical
Contractor

Estimated Estimated Est. cost


N of
N of Men Hours
( Php )
1
I lot
1
I lot
1
I lot
1
I lot

Page 1 of 32

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Kiln Shell under Tyre:

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Total

Materials
Phase
no.

Phase 1

Phase 2

Phase 3

Phase 4

Description
Scaffolding pipes (assorted lengths) & clamps
Wood blocks, 12 x 12 x 6
BI pipes, 6 x 20, sch 40
BI pipes, 8 x 20, sch 40
Structural steel
Oxygen gas
Acetylene gas
Welding rod, 7018 - 1/8
Oxygen gas
Acetylene gas
Welding rod, 7018 - 1/8
BI pipes, 4 x 20, sch 40
Plate, MS 12mm x 4 x 8
Grinding disc, x 4 x 8
Oxygen gas
Acetylene gas
Welding rod, 7018 - 1/8
Welding rod, 7018 5/32
BI pipes, 4 x 20, sch 40
Plate, MS 12mm x 4 x 8
Grinding disc, x 4 x 8
Gouging rod, 6mm
Oxygen gas
Acetylene gas

Estimated Estimated Est. cost


Quantity Unit Cost

( Php )

1 lot
10 pcs
1 lot
1 lot
1 lot
4 cyls
2 cyls
10 kgs
6 cyls
3 cyls
15 kgs
1 lot
1 pc
10 pcs
6 cyls
3 cyls
25 kgs
50 kgs
1 lot
1 pc
10 pcs
20 kgs
6 cyls
3 cyls

Total

Tools & Equipment


Phase
no.
Phase 1

Description
80T Mobile Crane
Welding machine, 300 A
Cutting outfit with accessories
Chain block, 5t
Chain block, 3t
Wood blocks

Page 2 of 32

Estimated Estimated Est. cost


Quantity Unit Cost
1
3
2
1
4
1

unit
units
units
unit
units
lot

( Php )

REF:

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Kiln Shell under Tyre:

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Toolbox
Wire rope sling, 2t, 1t
Shackles, 12mm, 20mm, 50mm

Phase
no.

Phase 2

Phase 3

Phase 4

Description

2 boxes
6 pcs
6 pcs

Estimated Estimated Est. cost


Quantity Unit Cost

150T Mobile Crane


80T Mobile Crane
Welding machine, 300 A
Automatic cutting machine
Cutting outfit with accessories
Chain block, 5t
Chain block, 3t
Wood blocks
Carpenters level
Wire rope sling, 2t, 1t
Shackles, 12mm, 20mm, 50mm

1
1
4
1
2
1
4
1
1
6
6

unit
unit
units
unit
units
unit
units
lot
pc
pcs
pcs

150T Mobile Crane


80T Mobile Crane
Welding machine, 300 A
Gouging machine with compressor
Automatic cutting machine
Cutting outfit with accessories
Chain block, 5t
Chain block, 3t
Wood blocks
Carpenters level
Wire rope sling, 2t, 1t
Shackles, 12mm, 20mm, 50mm

1
1
4
1
1
2
1
4
1
1
6
6

unit
unit
units
unit
unit
units
unit
units
lot
pc
pcs
pcs

80T Crane
Welding machine, 300 A
Cutting outfit with accessories
Chain block, 5t
Chain block, 3t
Wood blocks
Carpenters level
Wire rope sling, 2t, 1t
Shackles, 12mm, 20mm, 50mm

1
3
2
1
4
1
1
6
6

unit
units
units
unit
units
lot
pc
pcs
pcs

Total

Page 3 of 32

BP

( Php )

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Procedures
Phase 1:
Site Preparation
Step 1.1:

Remarks by:

Executioner

Workers, shall at all times wear safety helmets, safety shoes,


safety goggles
when doing grinding or chipping works,
welding mask during welding, working and welding gloves,
human harness or safety belts when climbing more that three
( 3) meters.

Step 1.2: Prepare, inspect & test integrity of chain blocks, lever blocks to
be used for the job. Likewise, inspect, check the integrity wire
rope or web slings & shackles to be used for lifting. Ensure that
these tools & equipment are safe & fit for use.
Step 1.3: Prepare, inspect & test integrity of the oxygen-acetylene hoses &
gauges to be used for the job.. Prepare & inspect the integrity
of the welding cables to be used. Test the welding machines to
be used for the job. Ensure these equipment & accessories are
safe & fit for use.
Step 1.4: Site preparation & back filling of area where the crane is to be
positioned and mounted. Backfilled material must be leveled &
compacted in order to ensure that the crane can be properly &
steadily positioned. Secure all existing canals & trenches by
installing temporary covers.
Step 1.5: Installation of power distribution control panel for Contractors
tools and equipment such as welding machines, grinders, drills,
trouble lights, etc. at the tapping location assigned by FRCC
electrical department.
Step 1.6: Fabrication of spider supports & full welding inside the spare kiln
shell.
See Fig.1 below.

Page 4 of 32

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Kiln Shell under Tyre:

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BP

Fig. 1
Step 1.7: Beveling of the spare kiln shell. Refer to Fig.2. Smooth finish
grinding of the bevel led parts adhering to the angles specified
in the drawing.

NOTE:

When welding is carried, GROUND (Return) cable


must be directly connected to the part being
welded !!!
Remarks by:

Executioner

Fig. 2
Step 1.8: Fabrication of saddle and adjusting bolts and other accessories
necessary during kiln alignment.
Step 1.9: Position the 120-ton mobile crane at the POLCID side. This must
be properly oriented prior to any lifting activities. Crane
outrigger must be properly spread in place on firm & stable
grounds / surface. Lifting angle, heights and tolerances must be
strictly observed. Slings and lifting cables must be of adequate
sizes to withhold the load being lifted.
Step 1.10: Removal of air ducts of 2 units kiln shell cooling fans & other
kiln accessories
that can obstruct during the kiln replacement works. Store &
haul these kiln accessories to designated area for safekeeping
( these are to be re-installed later after kiln shell replacement).
Step 1.11: Erection of all necessary scaffoldings ( to be done by Lafarge accredited
contractor) including platforms & ladders.

Page 5 of 32

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Step 1.12:

BP

Fabrication of temporary structural steel supports using W14 x


87 lbs/ft for columns, beams and girders. Fabrication of wedges,
jigs, strong box & mounting plates using 19mm thick mild steel
plates.
Installation & full welding of all of all necessary supports to the
Kiln Shell.
See figure 3 below. Details of supports on separate
sheet.

Fig. 3
Step 1.13: Fabrication & machining of four (4) pieces backing plates
(machined, rectangular, 25 mm thickness) These plates to be
welded to the kiln shell. These backing plates will work as
stoppers and must be positioned precisely for the final position
of the tyre

Step 1.14: Fabrication of one ( 1 ) spider supports to be welded inside the


spare shell. Fig.1
Another two ( 2 ) spider supports to be welded inside the
existing shell. See Fig.4

Remarks by:

Phase 2:
Dismantling /Cutting & Rigging down of the
old Kiln shell section (Including tyre)
Step 2.1:

After Kiln shell cooling down, perform an Ovality check of kiln


shell before cutting. Record your readings for reference.

Page 6 of 32

Executioner

Quality
Assessment
Checked:

REF:

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Kiln Shell under Tyre:

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Step 2.2:

Check the radial runout of the tyre in the actual installation.


Measurement should be taken in 3 and 9 o'clock position at
the same time. Please use Polysius measuring Protocol Annex
B. Record your readings for reference.

Step 2.3:

Marking on kiln shell for cutting. Mark reference lines next to


the kiln section that has to be removed. The reference lines
have to be marked on the remaining part of the kiln, not on
the scrap tyre section! These reference lines have to be made
by means of a scriber. Use visible and permanent marking ink.

Step 2.4:

Four backing plates (machined, rectangular, 25 mm thickness)


have to be welded to the kiln shell. These backing plates are
working as stoppers and must be positioned precisely for the
final position of the tyre. Fig. 13

Step 2.5:

Full welding of two ( 2 ) spider supports inside the existing shell


approx (1) ONE meter back from the replacement section
joints. Angle sections 75mm x 75mm x 10mm welded to a
400mm center disc. This is to maintain cylindrical
dimensions throughout the repair works. Fig.4

Fig 4

Step 2.6:

The weight of the kiln must be supported by hydraulic jacks,


mounted upon wooden sleepers or fabricated steel support
structures either side of the replacement area & are located
under the spider stiffeners. Fig.5.

Page 7 of 32

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Fig. 5
Step 2.4:

Arrest the damaged kiln section (including tyre) with lifting


web /wire rope slings & shackles.
Ensure that all lifting
equipment are capable of lifting the total weight of the damage
shell + the riding ring!
Crane outrigger must be properly spread in place on firm &
stable grounds / surface. Lifting angle, heights and tolerances
must be strictly observed. Slings and lifting cables must be of
adequate sizes to withhold the load being lifted.

Step 2.5: Connect the lifting slings to the 120-t mobile crane, the hook
positioned perpendicularly on top of the kiln shell and is on
standby.
Step 2.6: Carefully position the magnetic track automatic cutting machine
around the circumference of the kiln and secure with clamps
paying attention to the marked lines. See photos below.

Fig.6

(First Cut)

Fig. 7

(True Length Cut line)

Step 2.7: The first cut must be made 150mm inside the required length
around the circumference, leaving four ( 4 ) sections intact,
approx. 300mm wide at 12, 3, 6 & 9 oclock positions. Fig.6
Step

2.8:

Re-set the track & now, cut the circumference on the true
length cut line,Fig. 7 This will leave four ( 4 ) 150mm sections
uncut. Fig 8.

Page 8 of 32

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Kiln Shell under Tyre:

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Remarks by:

Fig 8.
Step 2.9:

Executioner
Swivel the magnetic track automatic cutting head at 30 angle
& repeat the process on the true cut line. Fig.9 this will effect
a chamfer leaving a 2mm wide root face bull nose. Fig 10.
Leave the four ( 4 ) uncut sections as with previous cuts.

Fig. 9
Fig.10

Fig.9

Page 9 of 32

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Kiln Shell under Tyre:

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Step 2.10:

Carry out the same cutting process in this manner on the other
end of the damaged shell section, so as to leave a true
measure for the fabricated kiln cylinder. Fig.11.

Fig 11
Step 2.11:

With the 120-t mobile crane ready to lift the damaged shell
(including tyre), cut the four (4) remaining uncut portions of
the shell on both ends.

Step 2.12:

Slowly & with precise timing, lift the cut kiln shell out of
area.
Slowly swing the boom eastward & position
damaged shell on the space near POLCID. Lower down
shell, release the lifting cables & shackles from the hook of
mobile crane.

Step 2.13:

Manual grinding to smoothen the cut edges of existing shell


on both ends leaving clean & smooth beveled edges.

the
the
the
the

Step 2.14: Using compressed air & gouging machine, remove all welded
portions on the stopper blocks of the filler bars (axial & radial
stoppers) around the shell. Fig.12.
Haul & store these
pieces to designated safe area for re-use later.

Fig. 12
Step 2.15:

As soon as the tyre has been stripped from the old shell the
tyre has to be thoroughly inspected for signs of wear & cracks
all throughout the circumference.

Page 10 of 32

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Phase 3:
Mounting / Rigging up & Alignment of the
new Kiln shell section (Including trye)
Step 3.1:

Four backing plates (machined, rectangular, 25 mm thickness)


have to be welded to the kiln shell. These backing plates are
working as stoppers and must be positioned precisely for the
final position of the tyre.
( Reference: Polysius _ Montage Laufring grob e ).
Refer to installation of tyre, Fig 14.

Step 3.2: The tyre has to be shifted against these stoppers, centered in
radial direction and then another 4 backing plates (Fig.14)
have to be positioned against the tyre and then welded to the
kiln shell.
Step 3.3: After that the tyre fixation as to be installed step by step in 12o'clock position and tack welded. After the installation of all
fixations, the welding of the fixations can be started. The axial
fixation for the tyre must not be welded at this point of the
pre-assembly

Lifting of tyre

Page 11 of 32

Installation of the tyre unto the shell

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Cleaning of plates, wedges & axial fixation

Positioning of tyre fixation

Page 12 of 32

Centering fo tyre by means of shims


(radial wise) & stopper (axial wise)

Tack welding of tyre fixation

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Installation of tyre

X
C

D
E

Support rollers

Fig. 13

A:
B:
C:
D:
E:
X:

NOTE:

Backing plates
Reference line on the new kiln section
Backing plates
Distance between reference line and tyre
Distance between outside of kiln shell and tyre
Distance between backing plates and reference line

When welding is carried, GROUND (Return) cable


must be directly connected to the part being
welded !!!

Page 13 of 32

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Centering of tyre to kiln shell section


F
F

F
F
F

Fig. 14
Centering of tyre to kiln shell section
Distance F to be measured by means of shim plates to be made uniform on the
circumference.
Shim plates to be removed before start-up of kiln!

Fig 15

Page 14 of 32

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NOTE:

When welding is carried, GROUND (Return) cable


must be directly connected to the part being
welded !!!

Step 3.4: Arrest the new kiln shell assembly with web / wire rope slings &
shackles securely hooked on the mobile crane, ready for
lifting.
Step 3.5: Slowly swing the boom westward & position new kiln shell on the
space for replacement. Fig.16.

Fig. 16
Step 2.3: Slowly & precisely, lower down the new kiln shell assembly to rest
& aligned on the existing kiln shell. The boom should be steady.
Step 3.3: Install & full weld a series of brackets for draw bolts inside the old
kiln shell. They should be welded uniformly around the inside
part of the old kiln shell at both ends and are spaced approx.
400mm apart.
Two (2) main versions of draw bolt brackets are used.
POLYSIUS recommend an angle cleat design (while F.L.S.
choose a U section format). Pre-assembly / Installation
tolerances refer to Annex A

Fig.17
Step 3.4: On alignment, there may be some trimming required for a good
fit up. When positioned, the joint for welding should be a 60
included angle single V preparation with a 2mm root face
bull nose to both parts.

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Step 3.5: Check alignment and completely weld along one side (existing
kiln shell), a series of approx. 15 strong backs across the two
joints. Fig. 18.

Fig.18
Step 3.6:

Weld the draw bolt brackets to the new kiln shell section. Insert
30mm fully threaded draw bolts across the joint & attach four
( 4 ) hexagonal nuts per bolt, ( 2pcs outside & 2 pcs inside )
this is to create a push & pull mechanism.

Step 3.7:

Weld the draw bolt brackets to the new kiln shell section. Insert
30mm fully threaded draw bolts across the joint & attach four
( 4 ) hexagonal nuts per bolt, ( 2 pcs outside & 2 pcs inside )
this is to create a push & pull mechanism. Fig. 19.

Fig. 19
Step 3.8:

Weld in place a series of approx. 30 equally spaced screw blocks


to the new kiln shell section so that they cross the joint. These
will be used to adjust & align both cylinders Fig. 20.

Fig. 20
Step 3.9:

Manually rotate the kiln in order to conduct a true alignment


check. As the kiln rotates, 12 datum points are selected &
measured using a polar diagram, one (1) meter away from the
each joint. This determines the true center line of the kiln.

Page 16 of 32

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Step 3.10:

BP

If the test proves unsatisfactory, the strong backs are released


by gouging and the draw bolts are adjusted where necessary.
Strong backs then re-welded and a further alignment check is
conducted until the kiln measures a true alignment. Fig. 21.

Fig. 21
Differences in the diameters have to be uniformly distributed
on the circumference to avoid edge misalignment.
Max. differences in the edge misalignment are 1 mm.
(Polysius data)

Remarks by:

Executioner
Step 3.11:

Prior to welding, PRE-HEAT IS CRITICAL. The correct pre-heat


temperature has been calculated on Annex B. (Method case
study for the welding of Kiln sections provided for Rugby
Cement Crown House by Mike Bedford)
Pre-heat of 120C to a distance of 150mm from each side of
the joint. A thermal crayon (preferably a pyrometer) Fig. 22,
should be used to monitor the temperature and ensure that
this temperature of 120c is maintained throughout the
welding process. Re-heat as necessary.

Fig. 22
NOTE:

The welding electrodes should be heated for two (2) hours


in a suitable baking oven.

Step 3.12:

Commence welding from the outside of the kiln, Fig. 24


employing two (2) welders on each joint working continuously
around the clock. Deposit fully a single root pass weld using a
3.2mm electrodes. De-slag thoroughly using an air chisel.

Page 17 of 32

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Inspect for inclusions, if present, grind out & re-weld. See


next page (Full welding procedures refer top Annex C )

Fig. 23

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*** During the complete repair, the kiln should be rotated manually as
necessary to assist convenient weld positioning ( >4.2m kiln =
8 spokes; 4.8m kiln =m 10 spokes ).
Step 3.13:

The hot pass, intermediate welding can be completed in


stages to fill 2/3 of the weld preparation. DO NOT CAP. To
obtain optimum mechanical soundness weaving must be
avoided, therefore, use stringer beads up to a deposit width
of twice the electrode diameter.

Step 3.14:

Return, to the inside of the kiln and by gouging, remove the


brackets, screw blocks & spider supports. Grind to smooth
finish gouged areas. Fig. 24.

Fig 24
Using 8mm carbon electrodes & the air arc gouging process,
conduct an internal root preparation by back gouging into the
external root weld to a depth of approx. 10-15mm. This will
also remove any possible slag inclusions. Grind properly the
U to remove all gouging residues.
Step 3.15:

Ensure that the pre-heat is maintained & deposit an internal


root weld, Fig.25 using 3.2mm electrodes. Complete hot
pass & cap with 4.0mm electrodes. Grind internal surface
flush, as welds left proud & undercut can have the effect of
multiplying the stress.

Fig. 25
Step 3.16:

Return to outside of the kiln shell & continue / complete filling


and capping weld deposits, ensuring stringer bead format,
using 4.0mm or 5.0mm electrodes.

Page 20 of 32

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Step 3.17:

Wire brush thoroughly the inside & outside welded joints of the
kiln shell.
Visually inspect the finished
welded joints.
Suspected areas should be investigated by using dye
penetrant (preferably ultrasonic testing).

Step 3.18:

Weld is subject to a 100% radiograph upon completion. Gouge


& re-weld any defects.

Step 3.19:

Reinstallation of kiln shell cooling fans, ducting and other kiln


accessories in place. Full welding of ducts & supports.

NOTE:

When welding is carried, GROUND (Return) cable


must be directly connected to the part being
welded !!!

Phase 4:
Safekeeping
Step 4.1:

Removal of all temporary welded supports & pad eyes, grinding


to smoothen area.

Step 3.2:

Removal of all scaffolding pipes (by the Scaffolding Contractor)

Step 3.3:

Disconnect the welding cables ( ground cable ) from the kiln


area. Housekeeping of all oxygen & acetylene cylinders.
Empty cylinders should be returned back to the warehouse.

Step 3.4:

General cleaning of work area and removal of backfilled


materials to FRCC designated area. Using the Payloader, load
all these scrap & haul to the scrap yard for proper disposal.

Step 3.5: Travel the mobile crane outside the kiln area.

Page 21 of 32

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Additional
Additional Safety
Safety aspects
aspects

Additional
Additional Comments
Comments

Reference
Reference Documents
Documents

Page 22 of 32

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Annex A:

Preassembly / Installation tolerances


Rotary kiln:

Installation of kiln shell section

Section 1

Section 2

Measurement not taken in the


area of the longitudinal weld
approx. +/- 300 mm

(Distance of the measuring points from the peripheral weld approx. 100 mm)
In case the value measured at A is x mm, the maximum permissible deviation of the value measured
at B is +/- 1,5 mm.
Distance between supports L

Page 23 of 32

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Max. radial runout: +/- 0,05 % of distance L but not more than +/- 5 mm.
Readings in a distance of +/- 300 mm from longitudinal joints have not to be considered.
These tolerances are also applicable for the preassembly of transport units on supports (on roller
blocks etc.).
In case of a repair (of the old kiln) the measured values may be 50 % higher, provided that there are no
significant plastic deformations of the kiln shell.

Annex A:
Rotary kiln:

installation of kiln tyre section / transition section


for splined tyres:
Difference in radial runout
max. +/- 1,0 mm

600 mm

Measurement not taken in the


area of the longitudinal weld
approx. +/- 300 mm

(Distance of measuring points


from weld approx. 100 mm)

In case the value measured at A is x mm, the maximum permissible deviation of the value measured
at B is +/- 1.5 mm.
In case of a repair (of the old kiln) the measured values may be 50 % higher provided that there are
no significant plastic deformations of the kiln shell.
about 100 mm
E

Page 24 of 32

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Maximum axial runout (mm):


D (mm)
< 5,000
5,000 6,000
> 6,000

Max. axial runout (mm)

+/- 0.00011 x D
+/- 0.00013 x D
+/- 0.00014 x D

Annex A:

inlet and outlet

Diameter

Rotary kiln:

Max. radial runout:

+/- 0.2 % of the diameter

Rotary kiln:

girth gear
Radial runout

Page 25 of 32

Backlash

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Axial runout

The following only applies to new girth gears:


Outside diam. of girth gear (mm)
Max. perm. axial runout (mm)
absolute
Max. perm. radial runout (mm)
absolute
Backlash Se (mm) cold condition

3100
0.45

3400
0.55

3700
0.65

4300
0.90

4900
1.10

5500
1.20

6100
1.45

6700
1.75

7300
2.00

gr.7300
2.00

for all applies: 0.07 x module


up to 5400 mm: 2 mm + 0.3

More than 5400 mm: 3 mm + 0.3

For the girth gear measurement Krupp Polysius measuring forms have to be used.

In case girth gears are turned, they are mainly aligned according to the tip/root clearance.

Annex A:
This clearance must be recorded prior to the dismantling and is decisive for the alignment after reinstallation unless other
conditions (consultation with the specialist department) must be considered.

Rotary kiln: inside


Weld reinforcement and edge misalignment
Differences in the diameters have to be uniformly distributed on the circumference to avoid edge misalignment.
Max. differences in the edge misalignment are 1 mm.

outside

edge misalignment
max. 4
mm

inside

Rotary kiln: inlet / outlet seal

Page 26 of 32

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

max. +/- 0,2% of the diameter

max. +/- 0,1% of the diameter

Regarding the position and number of measuring points see measuring protocol
1001 Alignment of kiln sections.

Attachment:

- 1002 Alignment of kiln sections


- 1014 Alignment of girth gear

Annex B:

Page 27 of 32

BP

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

Page 28 of 32

BP

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

Annex B:
Pre-Heating Requirement (p.1)

Page 29 of 32

BP

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

Annex B:

Page 30 of 32

BP

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

Pre-Heating Requirement (p.2)

Page 31 of 32

BP

REF:

23

Polysius Tech. Doc. Vol.

REV: 13/10/2003

010

Kiln Shell under Tyre:

Rev. N 00

Page 32 of 32

BP

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