SOP Title:

Kiln Inlet section casting procedure

LEC kiln Inlet section
 Design Description

1) Kiln Inlet Plates:

Nose-ring plates casting area = 80 mm

Expansion Joint = On Radial 3.0 mm Rigid Board (Nefalit)
On Axial 3.0 mm ply wood
Type of Castable = REFRAMULLITE 63 AR LCC

Date 3
 Material
Material required Provider Comments
General Drawing Shift Team Leader Validated drawing with CTC

V Anchors for kiln outlet Shift Team Leader 216 Pieces, SS-310
Omega anchors for kiln outlet Shift Team Leader 216 Pieces, boiler steel H1 / A 42 Cp

V Anchors for kiln outlet (deformed area) Shift Team Leader 324 Pieces, SS-310 Sheet

Omega Anchors for kiln outlet (Deformed area) Shift Team Leader 324 Pieces, , boiler steel H1 / A 42 Cp
V Anchors for NR Shift Team Leader 360 Pieces, SS-310 Sheet

Omega anchors for NR Shift Team Leader 360 Pieces, SS-310 Sheet

Plastic caps Shift Team Leader 2000 plastic cap (8mm)

(For V Anchors in kiln outlet) Mild steel electrode
(For omega Anchors in kiln outlet) Mild steel electrode
Welding rods for Shift Team Leader
(For V Anchors in kiln NR) SS electrode
(For V Anchors in kiln NR) SSl electrode
Expansion joint Shift Team Leader Nefalit 3 mm thickness
Dry joint Contractor Plywood with thickness 3 mm maximum
For NR REFRAMULLITE 63 AR LCC
Concrete Shift Team Leader
For kiln outlet section& deforemd shell is GIBRAM SR
Water container Contractor Scaled container
Vibrator Contractor 40 to 50 mm Ø
Mixer Contractor Vertical
All Material Selection CTC Validated Type of Castable and Anchors

Date 4
 Procedure and Quality Control
Quality Control
Procedure Implementation Comments
Approver
Used Dry welding We dried welding electrode in oven at
Certified welder Kiln Tech.
electrodes recommended Temp.
Proper shell grinding on
Contractor mason Kiln Tech. We Grinded Shell properly on OMEGA Positions
OMEGA positions
Kiln & Kiln Hood + TAD
Marking OMEGA Kiln Tech. Followed Lafarge Standard
Supervisor
ANCHORING Welding OMEGA Certified welder Kiln Tech. Continous welding
Kiln & Kiln Hood + TAD
OMEGA Control Shift coordinator Visual and Pictures + hammering each OMEGA
Supervisor
V Double Tack Welding Certified welder Kiln Tech Regular inpection by our Refractory Team
V Double Tack Welding Kiln & Kiln Hood + TAD Visual and Pictures compare position/LPCL
Shift coordinator
Control Supervisor Drawing for Anchors
Water measurement Contractor mason Kiln Tech Using proper measurement tools
Used mixing water temperature between 25 - 30
Mixing water Temperature Contractor mason Kiln Tech deg.C in current Winter Seasons by External
Heating.
Kiln & Kiln Hood + TAD
Mixing Contractor mason Followed supplier procedure
Supervisor
CASTING Ball test after mixing before Kiln & Kiln Hood + TAD
Kiln Tech Esured proper water mixing
casting Supervisor
We took special care of anchors during
Vibrating Contractor mason Kiln Tech
vibration
On radial we use Nefalit (3mm)
Kiln & Kiln Hood + TAD
Joint installation Kiln Tech
Supervisor
On axial we use ply wood (3 mm)

Curing time Shift coordinator Shift Team Leader More than one day
CURING TIME
Kiln Coach/ Shift Team Followed Lafarge Standard Preheating / Drying
Preheating/Drying Curve CRO
Leader Curves

Date 5
EMCC kiln outlet section
 LEC kiln outlet section
Kronex 40
Bricks 40 cm 40 cm

40
cm

120 cm
 Anchors dimensions of kiln inlet sector

140 mm

100 mm

OMEGA STEEL ASI 310

Ø= 10 mm

V ANCHOR STEEL ASI 310

Ø= 8 mm