Alkali Bypass Installation PDF

Preheater
Bypass Mixing Chamber
Installation instructions
Created by:
Approved by:
FLSmidth, 06-Nov-13 70020035-1.0
Preheater
70020035-1.0
Page 2 of 24
Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installa-
tion, operation and maintenance of the equipment. An exhaustive enumeration of
all conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instructions, and which the operator is/or feels unable to handle, it is recom-
mended that FLSmidth is contacted without undue delay for advice on appropriate
action.
All references to relevant safety standards are given at the EC declaration of con-
formity if required.
Reference by seller to any international or national standard does not incur an
obligation on seller to provide any recipient, reader or user of the documentation
with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own
cost – to obtain necessary knowledge of the contents of any of the standards
referred to.
Safety
Potential safety risks, and correct mode of conduct subject to such risks, are con-
tinuously described in the text in relation to specific actions.
See instructions 32031 for general safety rules and the separate equipment-specific
safety instructions for a complete list of all unforeseen risks in connection with the
installation, operation and maintenance of the equipment.
Definitions and abbreviations

Authorized person A person who is qualified and who, by the responsible manag-
er, is entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is capable of
doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM Operation and Maintenance
Legend
Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
Warning text is concluded with a filled black triangle to symbolize end of warning
text. 
Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or
parts of the installation.
Attention text is concluded with a filled black square to symbolize end of attention
text. 
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Table of contents
1.0 Introduction ............................................................................................ 4
1.1 Design .............................................................................................. 4
1.1.1 Mixing chamber ......................................................................... 6
1.1.2 Spring hanger ............................................................................ 7
1.2 Operating principle ............................................................................. 8
2.0 Installation .............................................................................................. 8
2.1 Planning and installation procedures ..................................................... 8
2.1.1 Check the availability of all materials and equipment prior to the
commencement of work. ..................................................................... 9
2.1.2 Planning and schedule ................................................................ 9
2.1.3 Auxiliary tools ............................................................................ 9
2.2 The task on a step-by-step basis .......................................................... 9
2.2.1 Preparations .............................................................................. 9
2.3 Steps ...............................................................................................11
2.3.1 Welding the gas inlet to the front plate of the smoke chamber ........11
2.3.2 Casting of inlet refractory ...........................................................11
2.3.3 Inserting and adjusting the damper blade ....................................12
2.3.4 Installing the mixing chamber and quench air inlet ........................17
2.3.5 Installing the spring hangers ......................................................19
2.3.6 Adjusting the support rods and de-blocking of the spring hanger..... 22
2.3.7 Connecting the ducts to the rest of the bypass system ...................23
2.4 Installation documentation .................................................................24
2.4.1 Quality documentation ...............................................................24
2.4.2 Release note to commence test or operation.................................24
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1.0 Introduction
1.1 Design
The bypass system is made up of several components, Figure 1 shows how a
typically bypass installation could look like:
Figure 1: Typically bypass installation

1: Bypass exit gas duct 4: Quench air inlet duct
2: Spring hangers 5: Quench air fan
3: Bypass mixing chamber
The two main components are described in this instruction:

• Bypass mixing chamber (page 5, Figure 2).
• Spring hangers (page 5, Figure 3 and page 6, Figure 4).
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Figure 2: Bypass mixing chamber
Figure 3: Spring hangers <= size 2000
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Figure 4: Spring hangers > size 2000
1.1.1 Mixing chamber

See Figure 5
The mixing chamber (2) which is the key component of the bypass is supported by
the spring hangers (1), one on each side of the bypass.
The gas inlet (4) is supported by the front plate of the kiln riser transition piece (3),
just above the kiln inlet.
Figure 5: Mixing chamber

1: Spring hangers 3: Kiln riser transition piece, front plate
2: Mixing chamber 4: Gas inlet
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1.1.2 Spring hanger

See Figure 6
The spring hanger supports the mixing chamber and levels out the thermal expan-
sion with its two variable spring loaded hangers (2).
Figure 6: Spring hangers
1: Weld on eye plate/clevis 4: Cross bar

2: Variable spring hanger 5: Support rod
3: Adjustable rod
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1.2 Operating principle
Figure 7: Operating principle

1: Gas outlet 2: Kiln gases
3: Quench air inlet
The bypass mixing chamber works, as part of a bypass system, by letting part of
the kiln gases (2) escape out of the kiln system. The bypass chamber has a quench
air inlet (3) for letting cooling air into the bypass mixing chamber.
For further operational information, see separate bypass operation instructions.
2.0 Installation
Installation inspection
Quality control! The words "Installation inspection" or "Erection inspection" in any
drawing or text mean that the installation supervisor must carry out an inspection
and approve installation status before continued installation may commence. 
2.1 Planning and installation procedures

Ensure that current detailed specifications and drawings are available for carrying
out the work.
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2.1.1 Check the availability of all materials and equipment prior to the
commencement of work.
2.1.2 Planning and schedule

The installation of bypass mixing chamber must be co-ordinated with the construc-
tion of adjacent mechanical equipment, buildings and steel structures. The following
measures should be considered in the planning of installation activities:
• Check the availability of all materials and equipment prior to the commencement
of work.
•
• Define critical tasks and ensure that a critical task to be performed can be com-
pleted before end of shift.
•
• Ensure current detailed specifications and drawings are available for carrying out
the works.
•
• Ensure space for pre-assembly of the bypass mixing chamber.
•
• Ensure space for storing of refractory materials.
•
• Check that work area is protected in accordance with current site regulations.
2.1.3 Auxiliary tools

Lifting tools MUST be available at all times.
2.2 The task on a step-by-step basis
2.2.1 Preparations
Determine whether the bypass has to be installed as a left (Figure 8) or right
(Figure 9) configuration.
Figure 8: Left configuration Figure 9: Right configuration
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Kiln riser transition piece (2) and support structure (1) for fixating the spring
hangers must be in place.
Figure 10: Kiln riser transition piece and support structure
1: Support structure 2: Kiln riser transition piece
Cast the refractory for the mixing chamber and the quench air inlet.
See separate refractory drawing.
Figure 11: Casting of mixing chamber

1: Refractory casting
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2.3 Steps
2.3.1 Welding the gas inlet to the front plate of the smoke chamber
• The gas inlet (1) is placed in the right angle and aligned to the oval hole in the
front plate (2) of the smoke chamber and then welded into place.
• See bypass OL drawing for welding details.
Figure 12: Welding of gas inlet

1: Gas inlet 2: Front plate
2.3.2 Casting of inlet refractory

• The inlet can now be casted.
• See separate refractory drawing.
Figure 13: Inlet refractory

1: Refractory casting
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2.3.3 Inserting and adjusting the damper blade
Figure 14: Location of damper

1: Damper
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Figure 15: Damper parts

1: - 9: Nut
2: Bolt 10: Spring, compression
3: Nut 11: Stuffing box/packing
4: Lever 12: Upper shaft
5: Screw 13: Damper blade
6: Parallel key 14: Lower shaft
7: Bearing 15: Screw
8: Screw 16: nut
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• Insert the Shafts (12, 14), stuffing box with packing (11), springs (10), lever (4)
and bearings (7) (at this point tighten the screws that holds the bearing only by
hand and do not tighten the bearing set screws), into the mixing chamber.
Figure 16: Inserting the shafts and bearings
• Insert the damper blade (13) and tighten all the screws (15).
Figure 17: Inserting the blade
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• Align the shaft to be concentric with the hole in the mixing chamber and tighten
the bearing screws.
• Adjust the distance from the damper blade (6) to the inside of the refractory
lining on the lever arm side, to be 10mm.
Figure 18: Blade clearance and shaft concentricity
• Tighten the bearing set screws.

• Check for free movement of the damper blade.
Figure 19: Tightening the set screws Figure 20: Free movement
•
Bearing set screw
Tighten the set screws ONLY ON THE BEARING NEAREST TO THE LEVER ARM,
as shown on page 15, Figure 19, this is due to the difference in the thermal expan-
sion in the shafts and the mixing chamber housing 
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• Before welding adapt the slot link to fit the arc of damper regulation arm.
• Tighten bolt to secure wanted position of damper blade.
Figure 21: Installing the slot link
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2.3.4 Installing the mixing chamber and quench air inlet
Figure 22: Lifting the mixing chamber into place

• Apply sealing cord and lift the mixing chamber into place.
Smoke chamber front plate

To prevent the front plate from buckling, the mixing chamber must be firmly sup-
ported until the spring hangers are installed 
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• Tighten all screws.
Figure 23: Tighten all screws
• Apply sealing cord and lift the quench air inlet into place.
Figure 24: Installing the quench air inlet
• Tighten all the screws.
Figure 25: Tighten all screws for the quench air inlet
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2.3.5 Installing the spring hangers
Figure 26: Spring hangers
Spring hangers
The spring hangers shown in this chapter are for mixing chambers up until size
2000, but the installing procedures are the same for sizes above 2000.
See order for actual size 
• Align the weld-on eye plates vertically with the centre of the holes in the mixing
chamber and weld them in-place.
Figure 27: Aligning and welding on the eye plates
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• Assemble the two spring hangers.

• Position 5,6,11 and 12 are to be installed at a subsequent point in time.
Figure 28: Spring hanger assembly

1: Clevis 5: Support rod 9: Clevis
2: Var. spring hanger 6: Washer 10: Clevis
3: Adjusting rod 7: Threaded rod 11: Nut
4: Cross bar 8: Nut 12: Nut
Securing of spring hangers

The variable spring hangers are blocked in the installation position from the factory.
DO NOT remove the securing clamp and blocking devise at this point 
• Attach the spring hangers to the above supporting structure.
Figure 29: Spring hangers installation
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• Measure the distance of the rods and cut them into the right lengths.
• Ensure that there is enough over length for threading.
Figure 30: Rod length
• Attach the support rods to the clevises and tighten the upper nuts.
• Tighten the lower nuts until the washers have contact with the support bracket
surface and then approx. 1/2 turn more, make sure that the cross bar stays at a
horizontal level.
Figure 31: Installing the support rods
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2.3.6 Adjusting the support rods and de-blocking of the spring hanger
Bypass ducts
Ensure that no ducts are connected to either the gas outlet or to the quench air
inlet 
• Remove the clamp from the blocking device and remove the blocking device
itself. If the blocking device is not detached, it may be necessary to loosen or
tighten the nuts on the support rods in order to take the load off the blocking
device.
Mandatory!
DO NOT use force to remove the blocking device. The spring hanger contains a
large compressed spring and may cause physical damage. 
Figure 32: Removal of blocking device
• With the blocking device now removed the indicator should be aligned with the
label for cold position (white)
• If this is not the case, adjust the adjusting rod by loosening the upper nut on the
adjusting rod and turning the lower part of the spring hanger until the indicator is
level with the label for cold position.
Figure 33: Adjusting the spring hanger
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• Tighten the lock nuts.
Figure 34: Lock nuts
2.3.7 Connecting the ducts to the rest of the bypass system

• The ducts from the gas outlet and to the quench air inlet can now be attached.
Supporting of ducts
Make sure that both the ducts are supported in such a way that NO loads are
transferred to the bypass mixing chamber 
Figure 35: Connecting the ducts
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2.4 Installation documentation
2.4.1 Quality documentation

Once the installation of the bypass mixing chamber is completed, a final installation
check is needed to determine that the specified and necessary safety equipment
comprising guards and shut-off mechanisms have been manufactured and fitted
and that the installation is completed prior to the commissioning of the plant.
The installation contractor must provide documentation of this final installation

check as a specific test report outlining the specific activities.
2.4.2 Release note to commence test or operation

Once the installation of the Bypass mixing chamber is completed a release note
must be signed by an authorized person to declare that the installation is completed
and that test and operation of the Bypass mixing chamber can commence.

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Preheater

Bypass Mixing Chamber

Definitions and abbreviations

Figure 1: Typically bypass installation

The two main components are described in this instruction:

Figure 2: Bypass mixing chamber

Figure 3: Spring hangers <= size 2000

Figure 4: Spring hangers > size 2000

1.1.1 Mixing chamber

Figure 5: Mixing chamber

1.1.2 Spring hanger

Figure 6: Spring hangers

1: Weld on eye plate/clevis 4: Cross bar

1.2 Operating principle

Figure 7: Operating principle

For further operational information, see separate bypass operation instructions.

2.1 Planning and installation procedures

2.1.2 Planning and schedule

2.1.3 Auxiliary tools

2.2 The task on a step-by-step basis

Figure 8: Left configuration Figure 9: Right configuration

Figure 10: Kiln riser transition piece and support structure

1: Support structure 2: Kiln riser transition piece

Figure 11: Casting of mixing chamber

Figure 12: Welding of gas inlet

2.3.2 Casting of inlet refractory

Figure 13: Inlet refractory

2.3.3 Inserting and adjusting the damper blade

Figure 14: Location of damper

Figure 15: Damper parts

Figure 16: Inserting the shafts and bearings

Figure 17: Inserting the blade

Figure 18: Blade clearance and shaft concentricity

• Tighten the bearing set screws.

Figure 21: Installing the slot link

2.3.4 Installing the mixing chamber and quench air inlet

Figure 22: Lifting the mixing chamber into place

Smoke chamber front plate

• Tighten all screws.

Figure 23: Tighten all screws

Figure 24: Installing the quench air inlet

• Tighten all the screws.

2.3.5 Installing the spring hangers

Figure 26: Spring hangers

Figure 27: Aligning and welding on the eye plates

• Assemble the two spring hangers.

Figure 28: Spring hanger assembly

Securing of spring hangers

• Attach the spring hangers to the above supporting structure.

Figure 29: Spring hangers installation

Figure 30: Rod length

Figure 31: Installing the support rods

Figure 32: Removal of blocking device

Figure 33: Adjusting the spring hanger

• Tighten the lock nuts.

Figure 34: Lock nuts

2.3.7 Connecting the ducts to the rest of the bypass system

Figure 35: Connecting the ducts

2.4 Installation documentation

2.4.1 Quality documentation

The installation contractor must provide documentation of this final installation

2.4.2 Release note to commence test or operation

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