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23
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Kiln Shell under Tyre: BP
010 Rev. N 00
SUMMARY
SUMMARY DESCRIPTION
DESCRIPTION FORMS
FORMS APPENDICES
APPENDICES
Operational Phases
Phase Estimated Estimated Est. cost
Description
no. Quantity Unit Cost ( Php )
Phase 1 Site Preparation
Phase 2 Dismantling / Rigging down of old Kiln shell
Phase 3 Rigging up / Mounting / Alignment of the new Kiln shell
Phase 4 Housekeeping
Total
Labor
Estimated Estimated Est. cost
Phase
Description N of
no.
N of Men Hours ( Php )
Mechanical 1
Phase 1
Contractor I lot
Mechanical 1
Phase 2
Contractor I lot
Mechanical 1
Phase 3
Contractor I lot
Mechanical 1
Phase 4
Contractor I lot
Page 1 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Total
Materials
Phase Estimated Estimated Est. cost
Description
no. Quantity Unit Cost ( Php )
Scaffolding pipes (assorted lengths) & clamps 1 lot
Wood blocks, 12 x 12 x 6 10 pcs
BI pipes, 6 x 20, sch 40 1 lot
BI pipes, 8 x 20, sch 40 1 lot
Phase 1
Structural steel 1 lot
Oxygen gas 4 cyls
Acetylene gas 2 cyls
Welding rod, 7018 - 1/8 10 kgs
Oxygen gas 6 cyls
Acetylene gas 3 cyls
Welding rod, 7018 - 1/8 15 kgs
Phase 2
BI pipes, 4 x 20, sch 40 1 lot
Plate, MS 12mm x 4 x 8 1 pc
Grinding disc, x 4 x 8 10 pcs
Oxygen gas 6 cyls
Acetylene gas 3 cyls
Welding rod, 7018 - 1/8 25 kgs
Welding rod, 7018 5/32 50 kgs
Phase 3
BI pipes, 4 x 20, sch 40 1 lot
Plate, MS 12mm x 4 x 8 1 pc
Grinding disc, x 4 x 8 10 pcs
Gouging rod, 6mm 20 kgs
Oxygen gas 6 cyls
Phase 4 Acetylene gas 3 cyls
Total
Page 2 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Toolbox 2 boxes
Wire rope sling, 2t, 1t 6 pcs
Shackles, 12mm, 20mm, 50mm 6 pcs
Total
Page 3 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Phase 1: Executioner
Site Preparation
Step 1.1: 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
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
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.
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).
Page 5 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Step 1.12: 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
Executioner
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
REF: Polysius Tech. Doc. Vol.
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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
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
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!
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.
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
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Fig 8. Executioner
Step 2.9: 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.9
Fig.10
Page 9 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
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 the
area. Slowly swing the boom eastward & position the
damaged shell on the space near POLCID. Lower down the
shell, release the lifting cables & shackles from the hook of the
mobile crane.
Step 2.13: Manual grinding to smoothen the cut edges of existing shell
on both ends leaving clean & smooth beveled edges.
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
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Phase 3:
Mounting / Rigging up & Alignment of the
new Kiln shell section (Including trye)
Page 11 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Cleaning of plates, wedges & axial fixation Centering fo tyre by means of shims
(radial wise) & stopper (axial wise)
Page 12 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Installation of tyre
X
A
C
Support rollers
Fig. 13
A: Backing plates
B: Reference line on the new kiln section
C: Backing plates
D: Distance between reference line and tyre
E: Distance between outside of kiln shell and tyre
X: Distance between backing plates and reference line
Page 13 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
F F
F F
F
F
F
Fig. 14
Fig 15
Page 14 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
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.
Page 15 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
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
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Step 3.10: 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
Executioner
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
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Inspect for inclusions, if present, grind out & re-weld. See
next page (Full welding procedures refer top Annex C )
Fig. 23
Page 18 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Page 19 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
*** 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 3.14: 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
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
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 3.19: Reinstallation of kiln shell cooling fans, ducting and other kiln
accessories in place. Full welding of ducts & supports.
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 3.5: Travel the mobile crane outside the kiln area.
Page 21 of 32
REF: Polysius Tech. Doc. Vol.
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Kiln Shell under Tyre: BP
010 Rev. N 00
Additional
Additional Safety
Safety aspects
aspects
Additional
Additional Comments
Comments
Reference
Reference Documents
Documents
Page 22 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Annex A:
Preassembly / Installation tolerances
Section 1 Section 2
A B
(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.
Page 23 of 32
REF: Polysius Tech. Doc. Vol.
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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
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
wobble
Page 24 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Annex A:
Rotary kiln: inlet and outlet
Diameter
Radial runout
Page 25 of 32
Backlash
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Axial runout
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.
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
Page 26 of 32
REF: Polysius Tech. Doc. Vol.
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010 Rev. N 00
Regarding the position and number of measuring points see measuring protocol
1001 Alignment of kiln sections.
Annex B:
Page 27 of 32
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Page 28 of 32
REF: Polysius Tech. Doc. Vol.
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Annex B:
Pre-Heating Requirement (p.1)
Page 29 of 32
REF: Polysius Tech. Doc. Vol.
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Annex B:
Page 30 of 32
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Pre-Heating Requirement (p.2)
Page 31 of 32
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Page 32 of 32