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    Kiln Line One Shell Replacment-11

    Uploaded by

    RahwaRecho
    The document describes the kiln line one shell replacement process which included: fabricating a new shell by selecting materials, preparing and welding sections; erecting the shell by dismantling the old shell and installing the new sections in alignment; and testing the completed replacement including ovality measurements and painting. Some challenges were faced in maintaining tolerances during installation and corrections were needed for ovality near support welding joints.

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    Kiln Line One Shell Replacment-11

    Uploaded by

    RahwaRecho
    73 views31 pages
    The document describes the kiln line one shell replacement process which included: fabricating a new shell by selecting materials, preparing and welding sections; erecting the shell by dismantling the old shell and installing the new sections in alignment; and testing the completed replacement including ovality measurements and painting. Some challenges were faced in maintaining tolerances during installation and corrections were needed for ovality near support welding joints.

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    The document describes the kiln line one shell replacement process which included: fabricating a new shell by selecting materials, preparing and welding sections; erecting the shell by dismantling the old shell and installing the new sections in alignment; and testing the completed replacement including ovality measurements and painting. Some challenges were faced in maintaining tolerances during installation and corrections were needed for ovality near support welding joints.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    73 views31 pages

    Kiln Line One Shell Replacment-11

    Uploaded by

    RahwaRecho
    The document describes the kiln line one shell replacement process which included: fabricating a new shell by selecting materials, preparing and welding sections; erecting the shell by dismantling the old shell and installing the new sections in alignment; and testing the completed replacement including ovality measurements and painting. Some challenges were faced in maintaining tolerances during installation and corrections were needed for ovality near support welding joints.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 31

    Kiln line one Shell Replacement Process

    Kiln line one Shell Replacement Process


    Content
    • Introduction
    • Problem of kiln shell bulged outside
    • Man Power Selection
    • Methodology of shell fabrication
    • Fabrication of shell
     Material Selection
     Material Preparation
     Material fabrication and welding
    • Kiln shell Erection
     Installation supports
     Dismantling of old shell
     Installation of different section kiln shell
     Alignment shell welding
     Welding every section joint
     Painting of shell
    • Testing
    Introduction
    • Rotary kiln is most important machine in the cement plant.
    • The down time of the kiln extremely affects the production process efficiency, product
    quality and profitability.
    • Therefore, maintaining with certified man power and using quality material is come to be
    reliable operation of a rotary kiln is very important.
    Problem of kiln shell Bulged outside
    • Root Cause (Why):-

    Shell thickness is deteriorated by 65% to design thickness at deformed shell


    section (Reference shell thickness report) due to corrosion/scaling of shell &
    ageing of kiln shell. Power fluctuations, lack of emergency backup and Sem
    Scanner created non-uniform operational temperatures and thermal expansion
    forces on kiln shell affected the less thick shell area
    Cont…
    Man Power Selection (Certified welder)

     Example participant certified welders of MIE


     Welders Supervisors
    • Getachew T Kidane
    • Berket T Mechelle
    • Andom A Danial
    • Taddele A
    Methodology of Shell Replacement

    Drawing preparation and approval:- actual measurement shall be taken when the kiln is in cold environment

    conditions not done

    Material test and approval:-Base material properties shall be tested and checked with properties indicted in the

    standard and not send to client

    Material Preparation :-Check the quantity and quality of the materials, Check the dimension of the sheet metal

    based on the specification, Cutting and chamfering by the given dimension, Rolling the sheet metal based on the

    specification, Check ovality and rolling radius of the shell segment

    Shell Fabrication:- Check the dimension of the plates, Joining and aligning plates, Tack and welding from the

    inside section, Turn over the section and weld outside, Prepare the Kiln shell section for assembling,

    Circumferential Welding from outside, Circumferential Welding from inside, Prepare the 12 spiders for each section

    (75*75*10mm), Tack reinforcements (spiders) with shell to minimize deformation


    Cont..
     Transportation, Site clearing and preparation for work

     Dismount the Existing Kiln:- make sure support with saddle near to cutting section and spiders the old
    shell

     Mount the new Kiln Shell:- alignment the old and new shell is critical and welding is recommended
    electrodes should be preheated for 2 hours at 200 °C in a suitable baking oven .

    Testing:- Visual inspection --- Done

    Dimension Test (DT) Done

    Penetrant test (PT)-- Done

    Ultrasonic test(UT). Done

    Magneto flux Test (MT) Not done

    X-ray testing at T joint- Not done due shortage of film but we take twice testing radiography
    Fabrication of shell
    Material Selection Specification
    Material Test Result A36 at MIE
    Cont…
    Methodology of shell fabrication from FLS
    Cutting and Rolling kiln shell at MIE
    Welding of Kiln shell Auto Submerged welding @MIE
    Welding of kiln shell Sections at MIE

    • Circumference L =+/- 5mm


    • ID = +- 1.5 mm
    • Length section = +/-1.5mm
    • Joining 2 section 90deg. Apart
    • Spider support each kiln section at both ends
    • Welding bead 1.5 inside, 3mm outside
    • But ID measurement not wear rate
    considered by designer
    Kiln Shell Erection
    Installation supports
    • The supports will prevent the kiln from falling to the ground if a crack should
    occur and can be used when the kiln section is replaced.
    Cont.…
    Dismantling of old shell
    • Fixing any mechanical part to prevent slide movement
    • Support kiln out late shell to prevent fall dawn due to unbalance load
    • To keep Existing center line
    But
    • Practically Not support in good manner in out late side
    • Due to this 7 cm move up ward b/s unbalance load between Supporting roller I
    in& out kiln sections
    • To gate Center line of kiln section in/out shell with respect of 4% (2.3 deg.) is
    difficult
    Cont.…
    Installation of different section kiln shell
     Kiln installation at three section done
     Section-1 dia. 3750, L= 2400 mm
     Totally at length gap between old and new shell error around 20 mm but The recommended tolerance 4 mm so
    that after supporting and live ring centerline checking we decide to correct this error kiln shell move up ward up
    15 mm. (gap 5 mm b/n kiln section)
     Due to internal measurement not taken and the old shell worn-out so at old and new dia. Difference is >8 mm but
    +/-1.5 tolerance so correct these half section is changed to minimize the error both inlate (old) and outlate (new )
    section so as much as possible in these section like cone shape done

     Section -2 dia. 3750, L= 10550 mm


    In this section the installation between new shells is almost done with in tolerance

     Section -3 dia. 3750, L= 3200 mm


    In this section especially to old section the in side dia.3750~3754 we add 200 mm cutting the inner dia. at this potion
    almost good so 2 mm error in radius
    Cont..
    Cont..
    Final Assembling
    Deep Penetration Test (DP test)
    Final welding
    Kiln Ovality Test With Excel
    Kiln Ovality Test With Excel @ 1st stand IS/OS
    Kiln Ovality Test With Excel @ 2nd stand IS/OS
    Brick installation
    N
    Pa o
    in
    in ted
    si
    s he de
    ll
    Testing and selection of painting
    Painting
    Conclusion

    • In general conclusion with respect of no experienced man power on kiln shell

    installation the kiln shell section replacement good done.

    • As indicating our ovality test measurement near to 1 st and 2 nd support welding

    joint the ovality is high (10mm) so it need farther correction.

    • In side kiln shell corrosion preventing painting is not done due to unavailability of

    paint so for next operation the wear rate as is.

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