INSTALLATION MANUAL FOR

LEVEL CONTROL DIAPHRAGM

Customer : QESHM CEMENT

Mill Size : CM # 2, Dia. 3000 x 11000 L.
G.A. Drawing # : W5/5299/4 Rev-0.
Page : 1 to 11.

Contents:

Safety Measures : p2

Preparation and General Advice : p3

Spare parts &

Welders’ qualification : p4

Necessary tooling
Electrodes specification : p5

Assembling instructions : p6-8

Cylindrical Lifter setting : p9

Grounting Specification : p 11

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 SAFETY MEASURES

1. It is of prime importance that each person working inside and outside of the facility keeps a lock,
including the supervisor. When working inside the mill, the locks of each person must be put on
Main OBC (Oil Circuit Breaker) in its OFF position.

2. All people working in the facility should have met all required safety equipments.

3. All equipment should be taken out of the mill prior to rotation of the mill.

4. Prior to the rotation of the mill, all individuals must be explicitly warned against the dangers of
falling objects from the mill during rotation.

5. We decline any responsibility of any accident which could happen during or after the completion of
the installation even when it has been supervised by a member of our company.

Our responsibility is strictly restricted to the cover of our supervisor.

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 Preparation and General Advice
To assemble the diaphragm, the mill shell lining rings adjoining the diaphragm upstream and
downstream should be taken out for a length equal to minimum diaphragm width.

The free portion of the mill shell must be well cleaned from grease or rust, and the eventual damages of
the mill shell, should be repaired in order to ensure suitable setting of the frame parts.

The Vega diaphragm is designed to provide for a clearance between the frame peripheral ring and the
mill shell. The frame rests on the mill shell through adjusting shims and has to be assembled to meet
its nominal diameter.

The main pieces of the frame are match-marked with stamped figures.
For a proper erection, the parts will be assembled with the marks facing the mill inlet end and in the
sequence shown on the general arrangement drawing.

Every bolt assembly and weld, mentioned in the instructions, are detailed on the general arrangement
drawing. An eventual adjustment of the cast pieces must only be carried out with Zircon grinding
wheels
Any Arc-air or torch cut is prohibited due to their lack of accuracy and the risk of breakage of pieces.

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Spare Parts
We recommend applying solely to us or to the original dealer for spare parts
The general arrangement drawing shows the complete bill of material.
Any enquiry should indicate: - the General Arrangement drawing number
A. the item, mentioned in the 1st column, as “SR. NO.”
B. the required quantity and the exact description of parts.

Required welders qualifications

The welders should be qualified for all positions pressure vessels welding and should meet the
following tests of the ASME boilers and pressure vessels code or equivalent:

- Reduced section tensile tests,

- Guided bend tests,
- Arc electric process,
- Filler metal f-4,
- Multiple pass, all positions,
- Thickness ¾” and over.

All the welds on the diaphragm should be performed by qualified welders and the internal stresses must
be relieved by peening for all the passes.

The first pass of any weld should be executed with 3.15 diameter electrodes and the pieces to be
welded should be pre heated up to 150°C at least in case of excessive cold or humidity.

When an external weld is completed; it must be properly ground flush before proceeding to the next
stage.

When a piece must be welded as well on on both front & back face, 2 welders will be required and
should work simultaneously, one on each side of the frame.

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Equipments requested for the installation of a Vega diaphragm

a. Pneumatic Torque Wrench with socket for M 30 & M 33 - Nut : 1 Set

b. Mechanical Torque Wrench ( ratchet type ) adjustable up to 120kg mt. with

Socket for M 30 & M33 Nut. : 1 Set

c. Box wrench for M16 Bolts. : 1 Set

d. Mechanism to rotate the mill slowly
e. Cramp Bars 750 mm long. : 2 Nos.
f. Hoist/chain pulley block – power/ manually operated – capacity - 1 Ton. : 1 No.
g. Lamps : 4 Nos.
h. Cutting Torch with gas cylinders : 1 Set
i. Welding Machine AC / DC – 500 Amp with cable. : 2 Sets.
j. Oven for Pre – heating of welding rods. : 1 No.
k. Welding electrodes E-7018 (Low hydrogen input) required
for welding of Level Control Diaphragm
Dia 3.15 mm 2000 Nos.
Dia 5.00 mm 2500 Nos..

Electrodes
Use only low hydrogen electrodes E 7018 or E 7016 ASTM according to AWS or E 5143B10
according to DIN 1913.

Characteristics

Yield point: > = 420 N/mm2

Tensile strength = 540 N/mm2
Elongation A5 = 28%
Kv = 180 J at 20° C
28 J minimum at 40° C

Length: 300 mm Efficiency = 115 – 120 %

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1. Location of the Diaphragm in the mill
a. Determine the row(s) of mill shell holes to be used for the diaphragm fixing :
Mark on the mill shell the location of the parting plans of the peripheral frame
sections (SR. NO. 5,6) and number the mark like the sectors. The partition of the
peripheral ring section, circled on the drawing, should correspond to the axis of the
manhole of the nearest compartment.

b. Measure the inside diameter of the mill shell in the four parting planes of the ring and
determine the value of the 8 theoretical clearances between the mill shell and the
peripheral ring in those positions. The 8 values are half of the differences between the
measured diameters and the diaphragm nominal one. Prepare 16 sets of adjusting
shims (SR. NO. 1, 2, 3, 4), with an overall height equal to the calculated gaps within 0
to +2 mm and numbered like the ends of the corresponding sectors.

2. Installing the Peripheral Frame Section

a. Set the peripheral frame sections on the mill shell and slip the adjust shims
according to measured clearance under the ends of each sector. Bolt the ring sections
where the shims support them.

b. Check that the diameter D = 2610 + 2 & B = 189.2 + 1.5 of the grate bolt holes are
within the indicated tolerances.

c. Measure the distances between the mill shell and the peripheral ring everywhere
adjusting shims are shown on the drawing and note the values on the ring. Lift up
successively each peripheral frame section, place the corresponding sets on the mill
shell and lay down the peripheral frame sections on the shims.

d. Introduce all the remaining fixing bolts and temporally tighten them to 30 kgm.

e. Fill up all the clearances between the peripheral frame and the mill shell with any
suitable and easy flow able material, resistant to the temperature in the mill (i.e.
silicone, polyurethane, mortar or equivalent). For guidance, the specifications of the
mortar are given on p.no.11.
After filling loosen slightly the fixing bolts of the ring and retighten them at one time.

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 3. Assembling the Central Frame Section and preparing the Air Passage Screen
1. Assemble the Central frame sections (SR. NO. 7) to the peripheral ones with the
erection fish plates (SR. NO. 12). Just them so that their front faces are lined up with
the peripheral ring within + 1 mm and also one with regard to the other one form a
single plane within 2 mm by using a string

2. To keep the setting of the pieces, set and tack weld the posts/double Posts on the 2
faces of the frame. Check that they are lined up with the peripheral frame sections
and the central frame sections.
When all the pertinent dimensions are within the tolerances, tack weld the central
frame section with 20 mm long spots to the peripheral ones.

3. Weld the central frame sections to the single post & Double post.

∗ In the 1st sector carry out the 1st pass of the circumferential welds between the
posts and the peripheral frame section then between the posts and the central
frame sections.
∗ Unbolt the erection fish-plates and perform the 1st pass of the circumferential
welds between the half drilled posts
∗ Then proceed to the 1st pass of the corresponding welds of the other sectors,
progressing as for the 1st pass of the 1st sector.
∗ The further passes will be carried out complying with the same process as for the
1st pass, until all the grooves are filled up.

4. Introduce all the components of the air passage screen into the 1st compartment of the
mill.
Assemble the 2 parts of the air passage screen (SR. NO. 17).
Weld the parts along the chamfered ends taking care of the flatness of the assembly
during the work.
Remove all the eventual additional wedges and flame cut any temporary tack weld which could have
been used for the frame sections assembly.

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4. Bolting the Cast Pieces and installing the Central Devices
a. Install the mill shell lining rings contiguous to the diaphragm.
Assemble simultaneously the grate plates (SR. NO. 15) and the backside plates (SR.
NO. 14). When 2 grate plates are bolted, air passage screen into the notch between
the cast pieces and the front face of the frame sections.
Clamp the screen to the central frame section opposite to these 2 grates.

b. Bolt the ball ejectors (SR. NO. 20); half the quantity of cylindrical lifters (SR.
NO. 18) with their suitable position.

c. Finally, check the tightening torque 800 NM + 5% of the grates bolts and tack weld
every nut to the screw inside the mill.

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 Setting of the cylindrical lifters of a Vega diaphragm
For the diaphragm first run, the cylindrical lifters should be set as indicated in the assembling
manual.

The setting is satisfactory when, after a working period in equilibrium, in the compartment
preceding the diaphragm the material is:

- To the minimum, level with the upper part of the ball charge on 95% of its surface.
- Or, to the minimum, 5 cm above the ball charge.

Between the material filling limits defined above, the volume load corresponding to the top of the
balls will normally be higher by 2 to 3% than the ball volume load when the mill is empty of
material.

If after a working period in equilibrium, the material level is not between the limits defined above;
one or two cylindrical lifters should be fully closed or opened, depending on whether there is too
little or too much material.

When a fine adjustment to the level is required it can be made by moving one or two cylindrical
lifters hole by hole.

The cylindrical lifters should preferably be settled when they are above the material level within the
diaphragm; it may be difficult to rescrew tightly a cylindrical lifter immersed in material.

When the cylindrical lifters are settled properly, their bolts have to be tack welded.
In most of the cases, electric ears have proved to be inadequate to estimate the material level in a
compartment upstream of a Vega diaphragm; they indicate the overloading before there is enough
material to fill completely the voids of the balls.

Enclosed Sketch :

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:

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 Grouting between the Mill shell and the Vega diaphragm
The purpose is just to avoid the circulation of abrasive material which could after several years
cause the wear of mill components like shell or mill bottom in hidden and inaccessible spaces.

The mortar must resist the mill temperature and must be flow able enough to fill completely
interstices of 5 mm width. Its consistence must be adapted to the size of the cavities by adding
water if necessary.

Usually the grout is made of river sand mixed with normal Portland cement in the proportion of
250 kg of cement for 1m3 and 125 1 of water mixed in a concrete mixer. The quantity of water
depends on the sand humidity and must be adapted to get the required workability of flow ability.

When the volume and shape of the cavities are wider than 50 mm, mortar can be replaced by
concrete composed of 1m3 of gravel 0/15 mm, 600 1 of river sand and 300 kg of normal Portland
cement. If available the gravel can be replaced by vermiculite or argex (insulating granulates of
respectively + 6 mm diameter or 12 mm diameter).

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ADDRESS : POST BOX NO- 4275, A1- 314 , AJMAN FREE ZONE, AJMAN, UAE
PHONE# - 00971 6 7420241 FAX : 00971 6 7420281