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Operational Phases

Phase

no.

Description

Estimated Estimated Est. cost

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

Phase

no.

Description

Estimated Estimated Est. cost

N° of Men

N° of

Hours

( Php )

Phase 1

Mechanical 1 Contractor I lot

Phase 2

Mechanical 1 Contractor I lot

Phase 3

Mechanical 1 Contractor I lot

Phase 4

Mechanical 1 Contractor I lot

APPENDICES

APPENDICES

SUMMARY

SUMMARY

DESCRIPTION

DESCRIPTION

FORMS

FORMS

Description :

CUTTING & REPLACEMENT OF KILN SHELL

SECTION

Service / Department :

MECHANICAL

(2)

Total

Materials

Phase

no.

Description

Estimated Estimated Est. cost

Quantity Unit Cost

( Php )

Phase 1

Scaffolding pipes (assorted lengths) & clamps 1 lot

Wood blocks, 12” x 12” x 6’ 10 pcs

BI pipes, 6”Ø x 20’, sch 40 1 lot

BI pipes, 8ӯ x 20, sch 40 1 lot

Structural steel 1 lot

Oxygen gas 4 cyls

Acetylene gas 2 cyls

Welding rod, 7018 - 1/8ӯ 10 kgs

Phase 2

Oxygen gas 6 cyls

Acetylene gas 3 cyls

Welding rod, 7018 - 1/8ӯ 15 kgs

BI pipes, 4”Ø x 20’, sch 40 1 lot

Plate, MS –12mm x 4’ x 8’ 1 pc

Grinding disc, ¼” x 4” x 8” 10 pcs

Phase 3

Oxygen gas 6 cyls

Acetylene gas 3 cyls

Welding rod, 7018 - 1/8”Ø 25 kgs Welding rod, 7018 – 5/32”Ø 50 kgs BI pipes, 4”Ø x 20’, sch 40 1 lot Plate, MS –12mm x 4’ x 8’ 1 pc Grinding disc, ¼” x 4” x 8” 10 pcs Gouging rod, 6mmØ 20 kgs

Phase 4

Oxygen gas 6 cyls

Acetylene gas 3 cyls

Total

Tools & Equipment

Phase

no.

Description

Estimated Estimated Est. cost

Quantity Unit Cost

( Php )

Phase 1

80T Mobile Crane 1 unit

Welding machine, 300 A 3 units

Cutting outfit with accessories 2 units

Chain block, 5t 1 unit

Chain block, 3t 4 units

(3)

Toolbox 2 boxes

Wire rope sling, 2t, 1t 6 pcs

Shackles, 12mmØ, 20mmØ, 50mmØ 6 pcs

Phase

no.

Description

Estimated Estimated Est. cost

Quantity Unit Cost

( Php )

Phase 2

150T Mobile Crane 1 unit

80T Mobile Crane 1 unit

Welding machine, 300 A 4 units

Automatic cutting machine 1 unit

Cutting outfit with accessories 2 units

Chain block, 5t 1 unit

Chain block, 3t 4 units

Wood blocks 1 lot

Carpenter’s level 1 pc

Wire rope sling, 2t, 1t 6 pcs

Shackles, 12mmØ, 20mmØ, 50mmØ 6 pcs

Phase 3

150T Mobile Crane 1 unit

80T Mobile Crane 1 unit

Welding machine, 300 A 4 units

Gouging machine with compressor 1 unit

Automatic cutting machine 1 unit

Cutting outfit with accessories 2 units

Chain block, 5t 1 unit

Chain block, 3t 4 units

Wood blocks 1 lot

Carpenter’s level 1 pc

Wire rope sling, 2t, 1t 6 pcs

Shackles, 12mmØ, 20mmØ, 50mmØ 6 pcs

Phase 4

80T Crane 1 unit

Welding machine, 300 A 3 units

Cutting outfit with accessories 2 units

Chain block, 5t 1 unit

Chain block, 3t 4 units

Wood blocks 1 lot

Carpenter’s level 1 pc

Wire rope sling, 2t, 1t 6 pcs

Shackles, 12mmØ, 20mmØ, 50mmØ 6 pcs

(4)

Procedures

Phase 1:

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 Contractor’s

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.

Remarks by:

Executioner

Quality

Assessment

Checked:

(5)

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 !!!

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.

Remarks by:

Executioner

Quality

Assessment

Checked:

(6)

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

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

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.

Remarks by:

Executioner

Quality

Assessment

Checked:

(7)

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 Ø 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.

(8)

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 o’clock 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.

(9)

Fig 8.

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

Remarks by:

Executioner

Quality

Assessment

Checked:

(10)

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.

(11)

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

12-o'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

(12)

Cleaning of plates, wedges & axial fixation Centering fo tyre by means of shims (radial wise) & stopper (axial wise)

(13)

Installation of tyre

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

NOTE: When welding is carried, GROUND (Return) cable

must be directly connected to the part being

welded !!!

E

B

X

D

A

C

Support rollers

(14)

Centering of tyre to kiln shell section

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

F

F

F

F

F

F

F

F

(15)

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.

(16)

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.

(17)

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

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)

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 120°C 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 120°c 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

Remarks by:

Executioner

Quality

Assessment

Checked:

(18)

Inspect for inclusions, if present, grind out & re-weld. See next page (Full welding procedures – refer top Annex C )

(19)
(20)

*** 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 8mmØ 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 3.2mmØ electrodes. Complete hot pass & cap with 4.0mmØ 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 4.0mmØ or 5.0mmØ electrodes.

(21)

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.

(22)

Additional Safety aspects

Additional Safety aspects

Additional Comments

Additional Comments

Reference Documents

Reference Documents

(23)

Annex A:

Preassembly / Installation tolerances

Rotary kiln: Installation of kiln shell section

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.

A

B

Measurement not taken in the area of the longitudinal weld approx

.

+/- 300 mm

(24)

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

600 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.

E

A

B

for splined tyres:

Difference in radial runout

max. +/- 1,0 mm

Measurement not taken in the area of the longitudinal weld approx

.

+/- 300 mm

wobble

about 100 mm

(25)

D

Maximum axial runout (mm):

D (mm)

Max. axial runout (mm)

< 5,000

+/- 0.00011 x D

5,000 – 6,000

+/- 0.00013 x D

> 6,000

+/- 0.00014 x D

Annex A:

Rotary kiln: inlet and outlet

Max. radial runout: +/- 0.2 % of the diameter

Rotary kiln: girth gear

Radial runout D ia m et er

(26)

The following only applies to new girth gears:

Outside diam. of girth gear (mm) 3100 3400 3700 4300 4900 5500 6100 6700 7300 gr.7300

Max. perm. axial runout (mm)

absolute 0.45 0.55 0.65 0.90 1.10 1.20 1.45 1.75 2.00 2.00

Max. perm. radial runout (mm)

absolute for all applies: 0.07 x module

Backlash Se (mm) cold condition up to Ø 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.

Rotary kiln: inlet / outlet seal

Axial runout

inside

outside

max. 4 mm edge misalignment

(27)

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:

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

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

(28)
(29)

Annex B:

(30)
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(32)

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