011-repl of kiln shell under tyre

8/18/2019 011-Repl of Kiln Shell Under Tyre

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REF: Polysius Tech. Doc. Vol.23

REV: 13/10/2003

Kiln Shell under Tyre: BP010 – Rev. N° 00

Operational Phases

Phaseno.

DescriptionEstimatedEstimated Est. cost

!antit" #nit $ost % Php &

Phase 1 Site Preparation

Phase 2 Dismantling / Rigging down o old !iln shell Phase 3 Rigging up / "ounting / #lignment o the new !iln shell

Phase $ %ouse&eeping

'otal

(a)or

Phaseno.


N° o* +enN° o* ,o!rs % Php &

Phase 1 "echanical 1 'ontractor ( lot

Phase 2 "echanical 1

'ontractor ( lot

Phase 3 "echanical 1

'ontractor ( lot

Phase $ "echanical 1

'ontractor ( lot

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APPENDICESAPPENDICESSUMMARYSUMMARY DESCRIPTIONDESCRIPTION FORMSFORMS

Description : $#''-N / REP($E+EN' OF -(N 2,E((2E$'-ON

Ser)ice / Department * +E$,N-$(

Duration o Stoppage * '3E(VE %14& Da"s %455 ,rs&


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'otal

+aterials

Phaseno.


!antit" #nit $ost % Php &

Phase 1

Sca+olding pipes ,assorted lengths- clamps 1 lot

ood loc&s 12 12 45 10 pcs

6( pipes 47 205 sch $0 1 lot

6( pipes 87 20 sch $0 1 lot

Structural steel 1 lot

9ygen gas $ cyls

#cetylene gas 2 cylselding rod :018 ; 1/87 10 &gs

Phase 2

9ygen gas 4 cyls

#cetylene gas 3 cyls

elding rod :018 ; 1/87 1< &gs

6( pipes $7 205 sch $0 1 lot

Plate "S =12mm $5 85 1 pc

>rinding disc ? $ 8 10 pcs

Phase 3

9ygen gas 4 cyls

#cetylene gas 3 cyls

elding rod :018 ; 1/87 2< &gs

elding rod :018 =


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Toolo 2 oes

ire rope sling 2t 1t 4 pcs

Shac&les 12mm7 20mm7


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Proced!res

Phase 1*2ite Preparation

2tep 1.1: or&ers shall at all times wear saety helmets saety shoessaety goggles when doing grinding or chipping wor&s

welding mas& during welding wor&ing and welding glo)es

human harness or saety elts when climing more that three, 3- meters.

2tep 1.4: Prepare inspect test integrity o chain loc&s le)er loc&s toe used or the Ao. Bi&ewise inspect chec& the integrity wirerope or we slings shac&les to e used or liting. Cnsure thatthese tools euipment are sae @t or use.

2tep 1.7* Prepare inspect test integrity o the oygen;acetylene hoses gauges to e used or the Ao.. Prepare inspect the integrityo the welding cales to e used. Test the welding machines toe used or the Ao. Cnsure these euipment accessories aresae @t or use.

2tep 1.8: Site preparation ac& @lling o area where the crane is to epositioned and mounted. 6ac&@lled material must e le)eled compacted in order to ensure that the crane can e properly steadily positioned. Secure all eisting canals trenches yinstalling temporary co)ers.

2tep 1.9: (nstallation o power distriution control panel or 'ontractor5stools and euipment such as welding machines grinders drillstroule lights etc. at the tapping location assigned y ER''electrical department.

2tep 1.: Earication o spider supports ull welding inside the spare &ilnshell.See Eig.1 elow.

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Remar&s y*

Cecutioner

Fuality#ssessment'hec&ed*


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Fi;. 1

2tep 1.


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2tep 1.14: Earication o temporary structural steel supports using 1$ 8: ls/t or columns eams and girders. Earication o wedges

Aigs strong o mounting plates using 1Hmm thic& mild steel

plates.(nstallation ull welding o all o all necessary supports to the!iln Shell. See @gure 3 elow. Details o supports on separatesheet.

Fi;. 7

2tep 1.17: Earication machining o our ,$- pieces ac&ing plates,machined rectangular 2< mm thic&ness- These plates to ewelded to the &iln shell. These ac&ing plates will wor& asstoppers and must e positioned precisely or the @nal positiono the tyre

2tep 1.18: Earication o one , 1 - spider supports to e welded inside thespare shell. Eig.1#nother two , 2 - spider supports to e welded inside theeisting shell. See Eig.$

Phase 2*Dismantlin; A$!ttin; / Ri;;in; do=n o* theold iln shell section %-ncl!din; t"re&

2tep 4.1: #ter !iln shell cooling down perorm an 9)ality chec& o &ilnshell eore cutting. Record your readings or reerence.

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Remar&s y*

Cecutioner



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2tep 4.4: 'hec& the radial runout o the tyre in the actual installation."easurement should e ta&en in 3 and H oIcloc& position atthe same time. Please use Polysius measuring Protocol #nne

6. Record your readings or reerence.

2tep 4.7: "ar&ing on &iln shell or cutting. "ar& reerence lines net tothe &iln section that has to e remo)ed. The reerence linesha)e to e mar&ed on the remaining part o the &iln not onthe scrap tyre sectionJ These reerence lines ha)e to e madey means o a scrier. Kse )isile and permanent mar&ing in&.

2tep 4.8: Eour ac&ing plates ,machined rectangular 2< mm thic&ness-ha)e to e welded to the &iln shell. These ac&ing plates arewor&ing as stoppers and must e positioned precisely or the@nal position o the tyre. Eig. 13

2tep 4.9: Eull welding o two , 2 - spider supports inside the eisting shellappro ,1- 9LC meter ac& rom the replacement section

Aoints. #ngle sections :


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Fi;. 9

2tep 4.8: #rrest the damaged &iln section ,including tyre- with litingwe /wire rope slings shac&les. Cnsure that all liting

euipment are capale o liting the total weight o the damageshell M the riding ringJ

'rane outrigger must e properly spread in place on @rm stale grounds / surace. Biting angle heights and tolerancesmust e strictly oser)ed. Slings and liting cales must e o adeuate siGes to withhold the load eing lited.

2tep 4.9: 'onnect the liting slings to the 120;t moile crane the hoo&positioned perpendicularly on top o the &iln shell and is onstandy.

2tep 4.: 'areully position the magnetic trac& automatic cutting machinearound the circumerence o the &iln and secure with clampspaying attention to the mar&ed lines. See photos elow.

Fi;. %First $!t& Fi;. < %'r!e (en;th $!t line&

2tep 4.


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Fi; 5.

2tep 4.@: Swi)el the magnetic trac& automatic cutting head at 30N angle repeat the process on the true cut line. Eig.H = this will e+ecta chamer lea)ing a 2mm wide root ace ull nose. Eig 10.Bea)e the our , $ - uncut sections as with pre)ious cuts.

Fi;. @ Fi;.@Fi;.10

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Remar&s y*

Cecutioner



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2tep 4.10: 'arry out the same cutting process in this manner on the otherend o the damaged shell section so as to lea)e a truemeasure or the aricated &iln cylinder. Eig.11.

Fi; 11

2tep 4.11: ith the 120;t moile crane ready to lit the damaged shell,including tyre- cut the our ,$- remaining uncut portions o the shell on oth ends.

2tep 4.14: Slowly with precise timing lit the cut &iln shell out o thearea. Slowly swing the oom eastward position thedamaged shell on the space near P9B'(D. Bower down theshell release the liting cales shac&les rom the hoo& o themoile crane.

2tep 4.17: "anual grinding to smoothen the cut edges o eisting shellon oth ends lea)ing clean smooth e)eled edges.

2tep 4.18: Ksing compressed air gouging machine remo)e all weldedportions on the stopper loc&s o the @ller ars ,aial radialstoppers- around the shell. Eig.12. %aul store thesepieces to designated sae area or re;use later.

Fi;. 14

2tep 4.19: #s soon as the tyre has een stripped rom the old shell thetyre has to e thoroughly inspected or signs o wear crac&sall throughout the circumerence.

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Phase 3*

+o!ntin; A Ri;;in; !p / li;nment o* thene= iln shell section %-ncl!din; tr"e&

2tep 7.1: Eour ac&ing plates ,machined rectangular 2< mm thic&ness-ha)e to e welded to the &iln shell. These ac&ing plates arewor&ing as stoppers and must e positioned precisely or the@nal position o the tyre.% Re*erence: Pol"si!s +onta;e (a!*rin; ;ro) e &.Reer to installation o tyre Eig 1$.

2tep 7.4: The tyre has to e shited against these stoppers centered inradial direction and then another $ ac&ing plates ,Eig.1$-ha)e to e positioned against the tyre and then welded to the&iln shell.

2tep 7.7: #ter that the tyre @ation as to e installed step y step in 12;oIcloc& position and tac& welded. #ter the installation o all@ations the welding o the @ations can e started. The aial@ation or the tyre must not e welded at this point o thepre;assemly

Biting o tyre (nstallation o the tyre unto the shell

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'leaning o plates wedges aial @ation 'entering o tyre y means o shims,radial wise- stopper ,aial wise-

Positioning o tyre @ation Tac& welding o tyre @ation

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$enterin; o* t"re to Ciln shell section

Fi;. 18

Centering of tyre to kiln shell section

Distance E to e measured y means o shim plates to e made uniorm on thecircumerence.Shim plates to e remo)ed eore start;up o &ilnJ

Fi; 19

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F

F

F

F

F

F

F

F


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NO'E: 3hen =eldin; is carried> RO#ND %Ret!rn& ca)lem!st )e directl" connected to the part )ein;=elded ???

2tep 7.8: #rrest the new &iln shell assemly with we / wire rope slings shac&les = securely hoo&ed on the moile crane ready orliting.

2tep 7.9: Slowly swing the oom westward position new &iln shell on thespace or replacement. Eig.14.

Fi;. 1

2tep 4.7: Slowly precisely lower down the new &iln shell assemly to rest aligned on the eisting &iln shell. The oom should e steady.

2tep 7.7: (nstall ull weld a series o rac&ets or draw olts inside the old

&iln shell. They should e welded uniormly around the insidepart o the old &iln shell at oth ends and are spaced appro.$00mm apart.

Two ,2- main )ersions o draw olt rac&ets are used.P9BQS(KS recommend an angle cleat design ,while E.B.S.choose a K section ormat-. Pre;assemly / (nstallationtolerances = reer to #nne #

Fi;.1<

2tep 7.8: 9n alignment there may e some trimming reuired or a good@t up. hen positioned the Aoint or welding should e a 40Nincluded angle = single V preparation with a 2mm root aceull nose to oth parts.

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2tep 7.9: 'hec& alignment and completely weld along one side ,eisting&iln shell- a series o appro. 1< strong ac&s across the two

Aoints. Eig. 18.

Fi;.15

2tep 7.: eld the draw olt rac&ets to the new &iln shell section. (nsert30mm ully threaded draw olts across the Aoint attach our

, $ - heagonal nuts per olt , 2pcs outside 2 pcs inside - =this is to create a push pull mechanism.

2tep 7.


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2tep 7.10: ( the test pro)es unsatisactory the strong ac&s are releasedy gouging and the draw olts are adAusted where necessary.

Strong ac&s then re;welded and a urther alignment chec& isconducted until the &iln measures a true alignment. Eig. 21.

Fi;. 41

Dierences in the diameters have to )e !ni*orml" distri)!tedon the circ!m*erence to avoid ed;e misali;nment.+a. dierences in the ed;e misali;nment are 1 mm.%Pol"si!s data&

2tep 7.11: Prior to welding PRC;%C#T (S 'R(T('#B. The correct pre;heattemperature has een calculated on #nne 6. ,"ethod casestudy or the welding o !iln sections pro)ided or Rugy'ement 'rown %ouse y "i&e 6edord-

Pre;heat o 120N' to a distance o 1


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(nspect or inclusions i present grind out re;weld. Seenet page ,Eull welding procedures = reer top #nne ' -

Fi;. 47

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During the complete repair the &iln should e rotated manually asnecessary to assist con)enient weld positioning , $.2m &iln 8 spo&es $.8m &iln m 10 spo&es -.

2tep 7.17: The hot pass intermediate welding can e completed instages to @ll 2/3 o the weld preparation. D9 L9T '#P. Tootain optimum mechanical soundness = wea)ing must ea)oided thereore use stringer eads up to a deposit widtho twice the electrode diameter.

2tep 7.18: Return to the inside o the &iln and y gouging remo)e therac&ets screw loc&s spider supports. >rind to smooth@nish gouged areas. Eig. 2$.

Fi; 48

Ksing 8mm7 caron electrodes the air arc gouging processconduct an internal root preparation y ac& gouging into theeternal root weld to a depth o appro. 10;1rind properly the

K to remo)e all gouging residues.

2tep 7.19: Cnsure that the pre;heat is maintained deposit an internalroot weld Eig.2< using 3.2mm7 electrodes. 'omplete hotpass cap with $.0mm7 electrodes. >rind internal suraceUush as welds let proud undercut can ha)e the e+ect o multiplying the stress.

Fi;. 49

2tep 7.1: Return to outside o the &iln shell continue / complete @llingand capping weld deposits ensuring stringer ead ormatusing $.0mm7 or


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2tep 7.1ouge re;weld any deects.

2tep 7.1@: Reinstallation o &iln shell cooling ans ducting and other &ilnaccessories in place. Eull welding o ducts supports.

NO'E: 3hen =eldin; is carried> RO#ND %Ret!rn& ca)lem!st )e directl" connected to the part )ein;=elded ???

.

Phase $*2a*eCeepin;

2tep 8.1: Remo)al o all temporary welded supports pad eyes grindingto smoothen area.

2tep 7.4: Remo)al o all sca+olding pipes ,y the Sca+olding 'ontractor-

2tep 7.7: Disconnect the welding cales , ground cale - rom the &ilnarea. %ouse&eeping o all oygen acetylene cylinders.Cmpty cylinders should e returned ac& to the warehouse.

2tep 7.8: >eneral cleaning o wor& area and remo)al o ac&@lledmaterials to ER'' designated area. Ksing the Payloader loadall these scrap haul to the scrap yard or proper disposal.

2tep 7.9: Tra)el the moile crane outside the &iln area.

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dditional 2a*et" aspectsdditional 2a*et" aspects

dditional $ommentsdditional $omments

Re*erence Doc!mentsRe*erence Doc!ments


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nne :

Preassem)l" A -nstallation tolerances

Rotar" Ciln: -nstallation o* Ciln shell section

Section 1 Section 2

,Distance o the measuring points rom the peripheral weld appro. 100 mm-

(n case the )alue measured at # is mm the maimum permissile de)iation o the )alue measuredat 6 is M/; 1< mm.

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A B

"easurement not ta&en in thearea o the longitudinal weld appro. M/; 300 mm

Distance etween supports B


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"a. radial runout* M/; 00< o distance B ut not more than M/; < mm.Readings in a distance o M/; 300 mm rom longitudinal Aoints ha)e not to e considered.

These tolerances are also applicale or the preassemly o transport units on supports ,on rollerloc&s etc.-.

(n case o a repair ,o the old &iln- the measured )alues may e


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D

"aimum aial runout ,mm-*

D %mm& +a. aial r!no!t %mm&

W


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The ollowing only applies to new girth gears*

9utside diam. o girth gear ,mm- 3100 3$00 3:00 $300 $H00


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Regarding the position and numer o measuring points see measuring protocolX1001 #lignment o &iln sections.

#ttachment* ; 1002 #lignment o &iln sections; 101$ #lignment o girth gear

nne B:

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ma. M/; 01 o the diameter

ma. M/; 02 o the diameter


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nne B:PreG,eatin; Re6!irement %p.1&

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nne B:

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PreG,eatin; Re6!irement %p.4&

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011-repl of kiln shell under tyre

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