REFRACTOTRY INSTALLATION TECHNIQUES

1
IN CEMENT INDUSTRY

Chapter 1
Preparation procedures prior to the Kiln Shutdown Plan

Observance of proper preparation procedures prior to the

shutting down of Kiln for maintenance schedule is one of the
important procedures in ensuring the efficiency of the
shutdown process, as well as to ensure that the time span
involved and budgets are in accordance to the established
Operation and Maintenance Plan (Manual). The processes
involved prior to the shutting down of Kiln require advance
preparation of at least one month, by observing and
implementing the following tasks:

1.1 Inspection of Kiln Migration

- For the cement Kiln, both migration and ovality

values of the Kiln shall be measured and compared
with each other prior to its shutdown. The respective
values of both migration and ovality must be within
the allowable range.
- The Kiln migration values shall be monitored and
recorded weekly. The data of kiln migration shall be
used together with the kiln ovality values, which are
vital indicators prior to the shutting down of Kiln, and
during the full production capacity. The observed data
of both kiln migration values and kiln ovality values
should be at least 1 month prior to the shutting of the
Kiln. Thus, if any value deviate from the standards
(acceptable range), the refractory lining under the tyre
areas could have been affected from the excessive
external compressive stress thereby creating cracks or
spalling effect which will consequently reduce the
service life of refractory lining.
- The migration and ovality values are to be jointly
evaluated in drawing conclusion and setting a Kiln
 REFRACTOTRY INSTALLATION TECHNIQUES
2
IN CEMENT INDUSTRY

Stop Plan which would set the adjustment target of

the migration value of each tyre.

1.2 Allocation of Refractory Maintenance Area

- The previous refractory maintenance records of each

zone in the Rotary Kiln, as shown in the past Kiln
maintenance schedule are important inputs in
determining the present refractory maintenance
operations.
- The current condition of the Kiln operating prior to
the implementation of maintenance schedule must be
monitored whether there has any abnormalities
occurred in the refractory. For example, the outside
shell temperature of the Rotary Kiln, Cyclone
Preheater and Clinker Cooler should be checked
whether any of their surface areas have been
experiencing raised in temperature values beyond the
normal standards. These data are necessary inputs in
determining the refractory maintenance plan of each
area.
- For the outside surface wall of the Cyclone Preheater,
Hot Air Duct, Calciner and various Down Pipes,
where the damages of the refractory had been
temporarily repaired by the use of box welding (Fig.
1.1), they must be included in the present Kiln Stop
Plan by replacing its steel wall surface and the
refractory should be repaired/replaced by inside
maintenance approach, which is more appropriate.
- To enhance the efficiency of refractory installation
tasks, there must be an agreed scope of work between
the two working teams, the Cement Production Team
and the Refractory Installation Team. This will ensure
that there will be no conflicts and problems occur
during the Kiln maintenance operations, and the scope
 REFRACTOTRY INSTALLATION TECHNIQUES
3
IN CEMENT INDUSTRY

of the refractory maintenance tasks have been

properly defined and planned and therefore achieving
the objective of best quality of work within the
required timeframe.
 REFRACTOTRY INSTALLATION TECHNIQUES
4
IN CEMENT INDUSTRY

Fig. 1-1: Pictures of the refractory installation in Hot Air

Duct, refractory repaired by box welding [outside
maintenance approach]

1.3 Inspection of the refractory inventory, condition and

quantity

- The planner shall monitor the quantity and conditions

of all available refractory in the warehouse and
compare them with the estimated quantity required in
the schedule/plan (the quantity can be estimated based
on the previous record of the area to be replaced or
repaired) for at least 3 months in advance to give the
refractory manufacturer sufficient time to deliver the
products, based on the Kiln Stop Plan.
- The preparation or estimates of the quantity of
refractory for the Cyclone Preheater and Clinker
Cooler can be obtained from the average number of
 REFRACTOTRY INSTALLATION TECHNIQUES
5
IN CEMENT INDUSTRY

refractory used during each of the previous Kiln

maintenance schedule.
- During 2-4 weeks prior to the kiln shutdown, the
quantity and conditions of the refractory shall be
again re-checked to confirm their availability in the
warehouse and readiness for use.
- In addition, the routine inspection on the conditions
and quantity of refractory shall also include inspection
of other accessory materials to be used with the
refractory; such as various grades of Anchors for each
corresponding areas, Welding Electrode, Card Board,
Plywood, Wax, and etc.
- The proactive preparation and systematically storage
of materials and establishment of efficient material
withdrawal system will contribute to the reduction of
materials loss/wastage.

1.4 Inspection of tools and equipment

- An inspection of the tools and equipment, which are

to be used for removing and installing the refractory,
in terms of their usage condition, availability,
quantity, and quality to sufficiently meet the bulk of
work should be done at least one month prior to the
scheduled Kiln shutdown. These tools and equipment
include:
o Demolishing Car
o Cavo Car
o Mult-O-Ring
o Air Breaker
o Pan Mixer; the gap/distance between the
propeller and the floor bed should not be less
than 0.5 mm. and not more than 10 mm. to the
wall. If the distance exceeds the standard, a
corresponding adjustment can be done by
 REFRACTOTRY INSTALLATION TECHNIQUES
6
IN CEMENT INDUSTRY

installing steel plate (through welding) to

adjust the distance. The Pan mixer must also
be cleaned.
o Hydraulic Jack; hydraulic supports lining
during the movement of Mult-O-Ring to
install the refractory in the proceeding rings.
o Vibrator
o Refractory brick cutter and a diamond blade;
the brick cutter shall be a non-water cooling
type, since the basic bricks should not be wet
or hydrated.

Fig. 1-2: Picture of a brick cutter with the blade

o Hacksaw and Wood Saw; for preparation of

wooden forms/ moulds for castable
installation.
 REFRACTOTRY INSTALLATION TECHNIQUES
7
IN CEMENT INDUSTRY

Fig. 1-3: Picture of a hacksaw

o Air Compressor; to be used during the

installation of rotary kiln refractory bricks in
the upper half portion.
- The aforementioned tools and equipment must be
inspected and certified by the safety department to
prevent any possible danger during the usage.
- The handling equipment/ machine/ vehicle such as
Lift, Folk Lift, Truck, Hand Lift, Crane, Hoist, and
Belt Conveyer are necessary to be checked and
inspected for their efficiency and capability to
effectively hold the weight of the refractory to be
handled or lifted.
- Prepare sufficient number of the personal protective
equipment, for example Safety Shoes (heat steel head,
heat resistance and heel covered safety shoes are
necessary for refractory inspection in the kiln during
immediate shutdown given that the kiln is still hot),
Dust Filler Mask, Goggle (protection of dusts and tiny
objects into the eyes), Safety Belts (for working in
high elevated areas, for instance, Cyclone Preheater),
and Safety Helmet. Also, make use of personal
 REFRACTOTRY INSTALLATION TECHNIQUES
8
IN CEMENT INDUSTRY

protective equipment and install safety signs to

control and ensure safety awareness.

Fig. 1-4: Picture of the personal protective equipment

Fig. 1-5: Picture of the required personal protective

equipment and safety signs to control and ensure
safety awareness before engaging in the work
 REFRACTOTRY INSTALLATION TECHNIQUES
9
IN CEMENT INDUSTRY

1.5 Preparation of workforce plan for refractory

maintenance work

- The exact timetable in the Kiln Stop Plan, including

the allowable working time and amount of work to
remove and install refractory on various areas, must
be notified to the responsible persons who are directly
in-charge of refractory works, at least 1 month in
advance, to be able to prepare adequate manpower
that correspond to the amount of work.
- A capacity building or training on refractory
knowledge for the operators; both in theory and
implementation, and by evaluating their
understanding and skills prior to the scheduled Kiln
maintenance will enhance the ability of the operators/
workers to achieve better efficiency, quality, and
accuracy.
- There must also be training provided on work
guidelines, safety in workplace, first aid procedures,
and evacuation plan in case of emergency. After the
training, workers must be evaluated for their
knowledge and understanding in order to be
documented as certified personnel and allowed to
work.

1.6 Preparation of storage areas layout for the refractory

and tools and equipment

- There must be an arrangement of the storage area for

the refractory and tools and equipment in the working
areas so as to ensure convenience and efficiency in
mobilizing the materials.
- The storage area within the working areas must be
under the shade and away from rainstorm; for
instance the area below Cyclone Preheater for
 REFRACTOTRY INSTALLATION TECHNIQUES
10
IN CEMENT INDUSTRY

refractory, the area below Clinker Cooler for the

refractory to be used in the Rotary Kiln and Clinker
Cooler.
- In the absence of adequate storage area, refractory and
tools and equipment may be laid in the ground yard
but shall be fully covered with water-proof cover
sheets.
- The laying of the refractory in the storage areas shall
be systematically arranged by their quality, and
shapes or sizes and sequence of their usage, especially
in close areas.