Repl of Kiln Shell Under Tyre

REF: Polysius Tech. Doc. Vol.
23
REV: 13/10/2003
Kiln Shell under Tyre: BP 010 – Rev. N° 00
SUMMARY
SUMMARY DESCRIPTION
DESCRIPTION FORMS
FORMS APPENDICES
APPENDICES
Description : CUTTING & REPLACEMENT OF KILN SHELL SECTION

Service / Department : MECHANICAL
Duration of Stoppage : TWELVE (12) Days (288 Hrs)
Location : KILN LINE D – KILN SHELL UNDER TYRE N°3
Operational Phases
Estimated Estimated Est. cost
Phase no. Description
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
N° of Men N° of Hours ( Php )
Mechanical 1
Phase 1
Contractor I lot
Mechanical 1
Phase 2
Contractor I lot
Mechanical 1
Phase 3
Contractor I lot
Mechanical 1
Phase 4
Contractor I lot
Total
Page 1 of 30
REF: Polysius Tech. Doc. Vol. 23
REV: 13/10/2003
Materials
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, 8”Ø x 20, sch 40 1 lot
Phase 1
Structural steel 1 lot
Oxygen gas 4 cyls
Acetylene gas 2 cyls
Welding rod, 7018 - 1/8”Ø 10 kgs
Oxygen gas 6 cyls
Phase 2
Plate, MS –12mm x 4’ x 8’ 1 pc
Grinding disc, ¼” x 4” x 8” 10 pcs
Oxygen gas 6 cyls
Welding rod, 7018 – 5/32”Ø 50 kgs
Phase 3
Plate, MS –12mm x 4’ x 8’ 1 pc
Grinding disc, ¼” x 4” x 8” 10 pcs
Gouging rod, 6mmØ 20 kgs
Oxygen gas 6 cyls
Phase 4 Acetylene gas 3 cyls

Total
Tools & Equipment

80T Mobile Crane 1 unit
Welding machine, 300 A 3 units
Cutting outfit with accessories 2 units
Chain block, 5t 1 unit
Phase 1 Chain block, 3t 4 units
Wood blocks 1 lot
Toolbox 2 boxes
Wire rope sling, 2t, 1t 6 pcs
Shackles, 12mmØ, 20mmØ, 50mmØ 6 pcs

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REV: 13/10/2003
Phase 2

Automatic cutting machine 1 unit
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REV: 13/10/2003
Chain block, 3t 4 units
Wood blocks 1 lot
Carpenter’s level 1 pc

Gouging machine with compressor 1 unit
Automatic cutting machine 1 unit
Phase 3 Chain block, 5t 1 unit
Wood blocks 1 lot
80T Crane 1 unit

Phase 4
Wood blocks 1 lot
Total
Remarks by: Quality

Procedures Assessment
Checked:
Phase 1: Executioner
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
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REV: 13/10/2003
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 a nd
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.
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 !!!
Remarks by: Quality

Assessment
Checked:
Executioner
Fig. 2
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REV: 13/10/2003
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.
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
Remarks by: Quality

Assessment
Checked:
Executioner
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REV: 13/10/2003
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.
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.
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REV: 13/10/2003
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.
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REV: 13/10/2003
Remarks by: Quality

Assessment
Checked:
Fig 8. Executioner
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
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
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REV: 13/10/2003
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.
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
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Lifting of tyre Installation of the tyre unto the shell
Cleaning of plates, wedges & axial fixation Centering fo tyre by means of shims
(radial wise) & stopper (axial wise)
Positioning of tyre fixation Tack welding of tyre fixation
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Installation of tyre
X
A
C
Support rollers
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

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Centering of tyre to kiln shell section
F F
F F
F
F
F
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

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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.
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.
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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.
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.
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Fig. 21
Remarks by: Quality

Differences in the diameters have to be uniformly distributed on the Assessment
circumference to avoid edge misalignment. Checked:
Max. differences in the edge misalignment are 1 mm. (Polysius data)
Executioner
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 3.2mm Ø electrodes. De-slag thoroughly using an air
chisel. Inspect for inclusions, if present, grind out & re-weld. See next page
(Full welding procedures – refer top Annex C )
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Fig. 23
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*** 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.
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.
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Step 3.19: Reinstallation of kiln shell cooling fans, ducting and other kiln accessories in place.
Full welding of ducts & supports.

Phase 4:
Safekeeping
Additional
Additional Safety
Safety aspects
aspects
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.
Step 3.5: Travel the mobile crane outside the kiln area.
Additional
Additional Comments
Comments
Reference
Reference Documents
Documents
Page 20 of 30
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Annex A:
Preassembly / Installation tolerances
Page 21 of 30
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Rotary kiln: Installation of kiln shell section
Section 1 Section 2
Measurement not taken in the area of

the longitudinal weld approx. +/- 300
mm
A B
(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.
Distance between supports L
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
for splined tyres:
Difference in radial runout
max. +/- 1,0 mm
Page 22 of 30
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600 mm
Measurement not taken in the area of (Distance of measuring points

the longitudinal weld approx. +/- 300 from weld approx. 100 mm)
mm A B
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.
about 100 mm
E
wobble
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
Page 23 of 30
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Diameter
Max. radial runout: +/- 0.2 % of the diameter
Rotary kiln: girth gear
Radial runout
Axial runout
The following only applies to new girth gears: Backlash
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) for all applies: 0.07 x module
absolute
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:
Page 24 of 30
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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.
outside
edge misalignment
max. 4 mm
inside
Rotary kiln: inlet / outlet seal
max. +/- 0,2% of the diameter
max. +/- 0,1% of the diameter
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:
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Annex B:
Pre-Heating Requirement (p.1)
Page 27 of 30
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Annex B:
Page 28 of 30
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Pre-Heating Requirement (p.2)
Page 29 of 30

Repl of Kiln Shell Under Tyre

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REF: Polysius Tech. Doc. Vol.

Description : CUTTING & REPLACEMENT OF KILN SHELL SECTION

Tools & Equipment

Estimated Estimated Est. cost

150T Mobile Crane 1 unit

80T Crane 1 unit

Remarks by: Quality

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

Remarks by: Quality

Step 1.11: Erection of all necessary scaffoldings ( to be done by Lafarge accredited

Remarks by: Quality

Fig.6 (First Cut) Fig. 7 (True Length Cut line)

Remarks by: Quality

Fig. 9 Fig.9 Fig.10

Lifting of tyre Installation of the tyre unto the shell

Positioning of tyre fixation Tack welding of tyre fixation

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

Centering of tyre to kiln shell section

Centering of tyre to kiln shell section

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

Remarks by: Quality

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

Rotary kiln: Installation of kiln shell section

Measurement not taken in the area of

Distance between supports L

Measurement not taken in the area of (Distance of measuring points

Maximum axial runout (mm):

D (mm) Max. axial runout (mm)

< 5,000 +/- 0.00011 x D

Rotary kiln: girth gear

The following only applies to new girth gears: Backlash

Rotary kiln: inside

Weld reinforcement and edge misalignment

Rotary kiln: inlet / outlet seal

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

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

Attachment: - 1002 Alignment of kiln sections

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