Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
23
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SUMMARY
SUMMARY
Description :
DESCRIPTION
DESCRIPTION
FORMS
FORMS
BP
APPENDICES
APPENDICES
SECTION
Service / Department : MECHANICAL
Duration of Stoppage : TWELVE (12) Days (288 Hrs)
Operational Phases
Phase
no.
Phase 1
Phase 2
Phase 3
Phase 4
Description
( 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
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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
( 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
Description
80T Mobile Crane
Welding machine, 300 A
Cutting outfit with accessories
Chain block, 5t
Chain block, 3t
Wood blocks
Page 2 of 32
unit
units
units
unit
units
lot
( Php )
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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
1
1
4
1
2
1
4
1
1
6
6
unit
unit
units
unit
units
unit
units
lot
pc
pcs
pcs
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
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BP
( Php )
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Procedures
Phase 1:
Site Preparation
Step 1.1:
Remarks by:
Executioner
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.
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Quality
Assessment
Checked:
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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:
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
Quality
Assessment
Checked:
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Step 1.12:
BP
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
Remarks by:
Phase 2:
Dismantling /Cutting & Rigging down of the
old Kiln shell section (Including tyre)
Step 2.1:
Page 6 of 32
Executioner
Quality
Assessment
Checked:
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Step 2.2:
Step 2.3:
Step 2.4:
Step 2.5:
Fig 4
Step 2.6:
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Fig. 5
Step 2.4:
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
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.
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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
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Quality
Assessment
Checked:
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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:
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.
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Phase 3:
Mounting / Rigging up & Alignment of the
new Kiln shell section (Including trye)
Step 3.1:
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
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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
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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
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NOTE:
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:
Fig. 20
Step 3.9:
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Step 3.10:
BP
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:
Fig. 22
NOTE:
Step 3.12:
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Assessment
Checked:
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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:
Step 3.14:
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:
Fig. 25
Step 3.16:
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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:
Step 3.19:
NOTE:
Phase 4:
Safekeeping
Step 4.1:
Step 3.2:
Step 3.3:
Step 3.4:
Step 3.5: Travel the mobile crane outside the kiln area.
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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:
Section 1
Section 2
(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
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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:
600 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
wobble
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+/- 0.00011 x D
+/- 0.00013 x D
+/- 0.00014 x D
Annex A:
Diameter
Rotary kiln:
Rotary kiln:
girth gear
Radial runout
Page 25 of 32
Backlash
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Axial runout
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 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.
outside
edge misalignment
max. 4
mm
inside
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Regarding the position and number of measuring points see measuring protocol
1001 Alignment of kiln sections.
Attachment:
Annex B:
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Annex B:
Pre-Heating Requirement (p.1)
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Annex B:
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