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    16 0002 0184 1

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    Wilber Arpi Herencia

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    © All Rights Reserved
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    \mnaer Zz INFORMATION ONLY PUEBLO VIEJO PROJECT A2UL EQUIPMENT NO: PV-1-6187-KLN-105-205-305 AK 640 — DRAFT ERECTION MANUAL (Example derived from AK504 For the 3 x 500 tpd oil fired Maerz PFR-Lime Shaft Kilns 9.1.2009 AL s maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-8187-KLN-105-205-205 ‘AK 640 ~ DRAFT ERECTION MANUAL / 08 Jan-2009// AL Table of Contents 1. Preamble. 2 General Remarks 2.1 Organisation and coordination on site. 22 Salety on ste 23 Preparation of erection wot 42 Preparation work in the workshop... 43 Erection equipment and tools. 44. Preparation of erection 4:41, Checking of mater supe 442 Anchor holes 443 Stairs and railings, 444 Kiln centre ines. 445. Pre-assembling 446 Base plates 447 Welding... 448 Electrodes 4.5. Time sequence of erection 4.5.1. Discharge traps, discharge hopper, discharge platform 13 45.2 Stairs onto kiln foundation and Blower house 4 453 Anchor bolts and plates cna 45.4 Kiln supporting structure and discharge hopper ower pat cA 4541 Columns... 18 4542 Discharge hopper lower par... 16 454.3 Support structure — upper par oo 17 485 Discharge tables and supporting column : oe 456 Shaft Part! : 19 45.7 _ Discharge hopper ~ upper part 20 4.5.7.1 Discharge hopper upper part - conical part 20 4572 Discharge hopper upper part - "Cross ers 457.3 Discharge hopper upper part ~ Cone and side plates 22 488. Kiln shafts l-V 23 4581 Shaft parti 2a 4582. Shaft part 28 4583 Shaft part lv 25 4584 —— ShaftpatV 28 45.9 Stairs and platforms 29 455.10 Shaft raps. 2 45.11 Reversal traps for air and waste gas, reversal traps waste gas ~fiter, combustion and cooling air relief traps. . 32 4.5.12 Poking doors 33 4.5.13 Cover in connecting channel and inspection hole oo 33 45.14 Small platform to shaft so 33 \ Sinaer Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN.105-205-305 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jar-2009 / AL_ 48 Parts which are mounted during or after brick ning 34 4.8.1 Poking doors and plugs : 34 4.62 _ Rollers for discharge tables, driving rods and stripping plates 4.6.3 Expansion joint sheet. 484 Rupture sheets 465 Level indicator 466 Reversal box: 4.6.7 Single doors... 4.6.8 Protection plates for doors. 46.9 Kin hopper / Weigh hopper 4.6.10 Skip hopper. : 46.11 Preheating valve 46.12 Compensator.. 46.13 Protection tube for measuring points. 4.6.14 Packing cord for steel structure 38 48.18 Silicone rubber seals... 39 46.16 Burer lances. 39 46.17 Preheating buiner 39 4.6.18 MAERZ plate. 40 4.6.19 Installation of limit switches. 40 48.20 Rotating bucket, 4 4621 Kiln hopper... “42 46.22 Combustion air duct, cooling air duct, eoleing cs, lance cooing a pip, ing main or 46.23 Stack 48.24 Kiln housing, 4.6.25. Railings for platforms, stairs and blower house. 4.628 Waste gas ducts, 4.627 Condensate pipe 4.8.28 Stack after fiter 4.6.29 Insulation of waste gas duct 416.30 Preheating piping smn 4.6.31 Crane girder between the shat. 48.32 Airshock blowers. lance cooling air Brick fining... 5.1 Storage and transport of materials 52. Erection erew for round kilns 53. Tools and equipment vo 52 54 Tools and auxiliary material for brick laying 53 5.5 _ Brick transport and scaffolding inthe kiln 54 5.6 Advice and recommendations for refractory brick lining 54 5.8.1 General remarks 54 582 Scaffolding 54 56.3 Expansion 55 5.6.4 Brickwork structure 55 5.7 Health protection and safety at work 66 6. _Airsupply.. 67 6.1 Erection of blowers, 87 Y \ maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-205.305 ‘AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2009 / AL. 7. _ Firing equipment... 7.4 Start-up bumer and start-up piping 8._ Oil firing system.. 8.1 Oilstorage 82 Pumping and fiter station. 83 Oil pre-heater finest fiter and oll measurement ve BB 84 Dosing pumps 85 Reversal valves 88 Piping, 8.7 Start-up bumer and start-up piping 88 Bummer lances 9. Hydraulic installation, 9.1 Preparatory work 8.2 Installation of the pumping group 83 Installation ofthe blocks... 8.4 — Mounting of the cylinders 85 Erection of piping... 10. Electrical, measuring and control equipment, 10.1 General 10.2. Installation and cabling ofthe equipment 40.2.1. Panels, motors, cable trays. 10.22 Limit switches. 10.23 Measuring and control equipment, 10.2.3. Temperature measurement 10.232 Pressure measurement 102.33 Flow measurement 10234 Weighing systems 11. Completion of erection run. Snaer. Zz AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1.6187-KLN-105-205.305 [AK 640 ~DRAFT ERECTION MANUAL /09 Jan-2009 / AL 4. Preamble This erection manual contains information on the scope and time sequence of a lime kiln erection Its based on practical experience gained by Maerz during erection of a big number of Parallel Flow= Regenerative Lime Shaft Kilns, in short PFR-Kilns or Maerz-Kilns in European countries, ‘The manual contains important technical and organizing information in exemplary form which should faciltate erection work. does, however, not replace the engagement of specialized and experienced contractors to execute the various kinds of erection works, such as steel structure erection, refractory bricklaying, electric installation, piping, etc, as well as of an experienced director of erection or site Supervisor responsible for the entie works. Specialized erection contractors may and will adjust the exemplary erection advice given by Maerz based on their own experience as well as on local and timing conditions. Maerz strongly recommends calling one ofits experienced engingers to supervise and coordinate kiln erection. In case the client does not call for a Maerz engineer to supervise erection the indispensable coordination with Maerz must be established and maintained through the nominated Maerz project manager. ’ maerz [AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1.6187-KLN-105-205.205 ‘AK 840 DRAFT ERECTION MANUAL /09 Jan-2009 /AL 2. General Remarks 24 Organisation and coordination on site tis important o hold a coordination meeting on the future site well in advance before starting erection work. The designated director of erection of the client, the Maerz site supervisor = in case Maerz has been entrusted with the turn-key supply of the lime kiln plant or has been awarded the supervision of erection by the client ~ and the erection supervisors for steel structure and refractory bricklaying should attend this meeting. The following issues should be discussed and agreed upon: ‘+ Location of the new plant ‘© Available space for cranes and pre-assembly work ‘Storage and transport facies for materials and equipment (storage bay, approx. 10x30x8 'm, forklift truck) = Office and communication facies for site and erection supervisors + Rooms and sanitary faciltis forthe erection personnel ‘+ Time frame for the entre erection work in view of personnel available planned dally and weekly working hours, international and local holidays as well as climatic conditions to be expected, Ithas been found to be an advantage that representatives of the client and/or Maerz in case Maerz has been appointed as site supervisor - are visiting once or repeatedly the workshop where the steel structure for the kiln is fabricated. On occasion of these visits any questions of the steel fabricator can be discussed as well as the max, possible extent of pre-assembly work in the workshop depending on transport facilties and crane capacity available onsite. At the same time quality standards applied in steel structure fabrication can be checked, Coordination meetings have to be held whenever required during erection work. The responsible representative of the client, the Maerz site supervisor -ifon duty - and the erection supervisors of the Contractors and subcontractors shall participate. Possible issues to discuss are e.g Insufficient safety procedures + Delays in the erection caused e.g. by delayed supplies of material and equipment, shortage of personnel or bad weather ‘+ Quality problems with material or erection work ‘+ Interpretation problems on drawings or other engineering documents Whenever questions on engineering documents supplied by Maerz show up, Maerz has to be contacted for clarification before proceeding with any further work. § maerz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-208-205 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 / AL 22 23 Safety on site The client being the owner ofthe site is in the frst place responsible for enacting all relevant safety measures in this area, All general or other safety rules, regulations or instructions issued by any local authorities andlor the lent/piant owner must be brought tothe attention ofthe Maerz personnel of any personnel of hired Contractors on site by designated representatives ofthe clienVowner. MAERZ’ and the contractor's personnel are bound to obey to all such rules, regulations and instructions on the site. Before starting any work on site all necessary insurance policies must be taken out by the parties, involved, ‘Signs limiting the access to the site and the lime kiln plant to authorised personnel only as well as warning signs or plates indicating the potential risks and dangers emanating from erection work and the operation of existing kins and other installations must be placed by the clientplant owner at every access or other exposed location. Preparation of erection work Immediately after the site supervisor has artived on site and has installed his ste office a Coordination meeting with the client's director of erection and - if already present on site -the erection ‘supervisor ofthe steel structure firm has to be arranged, All previous agreements have to be checked and confirmed, any necessary changes and adjustment fo be discussed. Local site concitions have to be studied in detail, the location of the pre-assembly yard, the erection crane and other auxiliary erection equipment has to be determined. Free accessibilly tothe kiln, the pre-assembly yard and the storage areas must be granted. Materials and equipment already supplied tothe site as well as their appropriate storage has to be checked. Any missing parts must be called. ‘The procedure and sequence of erection has to be discussed with the client and all contractors. Involves, Careful study of the entre plant helps to detect possible bottlenecks and space problems in time. Snaer yA ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-8187-KLN-105-205.308 ‘AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2008 J AL 3 Civil work (@rawings 001.0, 008.0, 46) A/T In this case the existing foundation of a previous project will be used. The drawing 001.0 shows all the necessary modifications ofthe existing foundation, Parts of the existing bolts wil be reused. When taking away the old equipment, they must be not be damaged ‘The old grouting must be removed as well Al i work sucha in oundton, bower house, exes une etpansiy of he Chet based on tout raving tom Mace Toe Nace ie snceaat ea Pees ssthe kn ouncafon canbe tuner od Tsp cl trs earache need vera foaaon bye che esse ea ae Saag cmaaencereel The plant level +0 or +1 m has to be determined and wel visibly marked on the kil foundation weatherproof by the client. s maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-15187-KLN-105-205.305 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2008 AL 4. 4a 42 43 Steel structure and mechanical parts General ‘The contractors entrusted withthe fabrication and erection of the steel structure must comply with the. following quality requirements + According to German rules: DIN 18800, part 7, “Grosser Eignungssnachweis" + According to European rules: EN 729-3, Standard Quality Requirements, ie. among other things: - the welders must be certified according to EN 287 + appropriate welding control according to EN 719 must also be granted sit. Preparation work in the workshop + Allstee! structure has to be fabricated in units according to the indications on Maerz ravings and the maximum allowed transport dimensions and weights *+ During manufacturing in the workshop special attention has to be paid to the indications on ‘drawing 346.0 “General Tolerances" ‘+ Allparts have to be provided in the workshop with weather proof markings of the centre lines (kin and shaft centre lines) and advice for the correct assembly on site + Allnumbering and indications have to correspond to the drawing numbers and item ‘numbers on the drawings + Lugs and hooks for transport by crane have to be provided on all parts + Allmechanical parts have to be assembled before ther transport to site and their correct functioning must be checked ‘+ To avoid any deformation during transport and handling by crane all shaft parts as well as pipe ends have to be provided with sifening braces ‘+ Whenever possible all small accessories and parts have to be mounted already in the workshop in order to facilitate erection on site + Rust protection painting - and possibly also finish painting - suitable for the prevailing ‘operating temperatures and ambient conciions have to be applied on all steel parts, all ‘machined parts have to be protected against mechanical damage and corrosion. Erection equipment and tools The folowing list of erection equipment is typical, not binding and may vary according to local ‘conditions and practical experience of the erection contractor ‘+ 1150 t mobile crane with 40 m mast + 1.180 ton mobile crane or rotary-tower crane with a 60 to 70 m mast, depending on kiln size, for temporary use 110 fon electric winch with 200 to 300 m rope 1S ton electric winch with 100 m rope 6 electric welding machines 300 A ED with all necessary accessories, 4 magazine hand lamps 24 V 4 electric extension cables 20 m Snaer Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1.6187-KLN-106-205.205 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2008 / AL + electric extension cables 50m ‘+ Shand driling machines: two light and one heavy one with 10 cylindrical spiral drils, 2 3 to 40mm and 10 conical spiral drils, © 11 to 25 mm ‘+ 4 mobile cutting torch sets with gas and oxygen bottles wit al exible hoses, manometers and necessary cutting tips 1 grinding machine, bi-directional 2 manual grinding machines with flexible axle 4 air compressor, 12 ma/min, 10 bar 3 air hoses with connections, 30 m 4 air hammer 1 air driling machine with striking mechanism 2 air screw drivers, 1" 4 manual tackle blocks, 3 tons 4 ratchet hoists, 3 tons (3 m long chain with ratchet) 2 hydraulic hoists, 10 tons 2 hydraulic hoists, 0 tons, long 2 hydraulic hoists, 60 tons, short 2 manual winches, 3 to 10 tons 2 stock winches, 10 tons 4 stock winch, 5 tons 6 tool boxes with all standard tools 6 sets of heavy hammering spanners, 46 fo 65 mm 6 sets of fixed spanners, 13 to 85 mm 4 sets of stud drivers for socket head cap screws, 3 to 27 mm 1 torque wrench, % 2 to 10 kpm, with nut set for socket head cap screws, 3 to 27 mm 2 sets of nuts for drive-serews, 1", 14 t0 48 mm & 4 boxes with nuts, extension and ratchet 4 boxes with nuts for socket head cap screws, %', 14 to 19 mm 4 sets of screw drivers, 3, 5; 7,10 8 sledge hammers, 2 x 10 kg, 3x 3kg, 3x 1.5kg 8 jemmies, 2 30 mm 10 small pinch bars 2 thickness gauges, short 2 thickness gauges, long 4 spring angles rulers, 2m long various punches, 18, 20, 22 mm & various knockout keys for git keys, 45 x 25 x 300 mm 3 frame spirit levels 1 hose leveling instrument, 30 m 10 metric measures 2 measuring tapes 3 manual pumps 4 wire ropes with loop. 4 m, @ 36 mm wire ropes with loop, 2m. @ 16 mm 1 wire rope, 100 m, 216 mm 3 hinged pulleys, 5 tons \ Snaer Zz EQUIPMENT NO: PV-1-6187-KLN-108-205-205 |AX 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 / 3 double pulleys, § tons 20 driling clamps, © 16 mm 3 coils Nylon string, 500 m, 2 to 3 mm & 6 heavy screw clamps, 300, 500, 750 8 smooth-cut and rough files 2 flat, spoon and triangular serapers 4 rope ladders various hemp ropes 2 ladders each of 4m, 5m, 6 mlength 10 shackles M16 10 shackles M24 pipe bending machines and special tools for mounting of hysraulic piping cabins for personnel and tools storage room as required ‘Above lst is based on long standing experience in the erection of ime kilns. It is neither exhaustive nor limiting, and can vary depending on local conditions, size of pre-assembled equipment and routine of the erection company. 44 Preparation of erection 44.1 Checking of materials supplied ‘Check condition and completeness of materials already supplied and make sure that all required equipment willbe timely supplied to ensure correct sequence of erection, 44.2 Anchorholes CCheck the correct position of all holes for the kln anchor bolts. They must be completely clean and free from dust. Use compressed air for cleaning. 443° Stairs and railings All alings on kiln foundation must be mounted and access to the foundation must be possible by means of a stair with handrails, 444 Kiln centre lines Clearly mark the centre lines of the kin and the shafts on the kiln foundation. 445. Proassembling Due to transport canditions all shaf parts may not be supplied in one piece. They have ta be ‘assembled and welded on the pre-assembly yard adjacent to the kiln foundation, The pre-assembly yard must be levelled and located within the operating range ofthe erection crane, Whenever possible the platforms are welded onto the respective shaft pars already on the ground, lited together with them and brought into final position § \ maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-205.905 AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 446 Base plates Base plates as well as shim plates of various thicknesses have to be prepared for the columns of the kiln supporting structure. 44.7 Welding (Drawings 245.0 and 349.0) Drawing 345.0 “Comparison of materials" contains information regarding mata used as well comparison of diferent standards, Drawing 349.0 “Welding symbols” explains the symbols used in Maerz drawing® AN ‘old and new standards. Furthermore it contains criteria for checking welding seams. ‘The following criteria have to be observed for checking welding seams, ‘+ For visual inspection standard EN 25817 equal to ISO 5817 has to be followed. Category Chas to be maintained, " * Colour penetration test Metal check), The welding Seams ibe checked ae indicated on drawing 349.0. g + Non-destructive welding seam testing following the recommendations in DIN 18000 A7. 10 % of the seam length has to be checked by ultrasonic tests or X-ray examination. ‘These 10 % must be faultless. Welding seams of all welders employed have to be tested, ‘The Maerz lime kin is working under pressure: All welding seams must therefore be executed absolutely aright. As the final tightness tests are executed only after having finished steel structure erection and refractory brick lining when most welds on the inside of the shaits are no longer accessible absolute tightness is a must during manufacturing in the workshop and erection on site (On the Maerz workshop cats for workshop welding and on site welding are shown. These proposals may be amended'or revised in view of local conditions andlor economic. considerations. In certain areas ofthe steel structure itis important to provide possibilities for thermal expansion during future kiln operation In order to alow proper expansion only welds shown on the drawings must be executed. When carrying out any welding work, especially during the fnal stage of erection, during ‘commissioning and kin operation special attention has to be paid to earthing which never must run through load cells, hydraulic eyinders andior bearings to avold damaging these components, 448 Electrodes __Pihly the following two types of electrodes are necessary for stee! structure erection, + For the welding of steel $235JRG2 (St 37.2) to heat resisting steel, material No, 1.4841. ‘28 well as for he welding of steel S235JRG2 (St 37.2) to stainless steel, material No. 1.4301, Maerz recommends to use a type of electrode corresponding to the following standards: DIN 6586 € 25 20 820+ Iso 3581 £25208 Snaer. Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-8187-KLN-105-205.305 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 / AL AWS AISFA5.4-81 31045 + For the welding of steel $236JRG2 (St 37.2) to steel $235JRG2 (St 37.2) Maerz recommends to use a type of electrode corresponding to the folowing standards: DIN 1913: 51 498 (R) 10 180 2560: E51 48 12026 AWSISFAS.1 E7018, 45° Time sequence of erection ‘The following description is based on experience from erection of Maerz-Kilns. Specialized and experienced erection contractors may adapt the procedures described below to their own practice, 4.5.1 Discharge traps, discharge hopper, discharge platform (Drawings 017.0, 351.0 and 358.0) ‘The discharge traps should already be completely assembled in the workshop and tested for correct functioning, ‘The sealing edges of the discharge traps must be properly machined and chamfered so that the silicone rubber seals are not damaged. Discharge traps, Discharge hoppers, Discharge platform The locking device for the traps (drawing 014.0) must also be mounted already inthe workshop. It the hydraulic cylinders are already available in the workshop the correct trap position can be determined already there. It's recommended to dismantle the cylinders again to avoid any damage {during welding work when mounting the traps on site, I the cylinders are mounted together with the traps, they should be inthe entered position Snaerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-6187-KLN-105-205.305 |AK 640 — DRAFT ERECTION MANUAL /09 Jan-2009 / AL To avoid damaging the silicone rubber seals those should only be mounted just before stating cold tests and pressure tests on the kin, ‘The discharge traps are assembled with the discharge hoppers on the assembly yard near the kiln foundation. Discharge traps and discharge hoppers are then entered into the kil foundation, ified up to the platform level and placed on the already mounted beams of the platform. At this stage the erection ofthe discharge platform can be completed and the access ladder, i any, ‘mounted. In case no ladder is provided for a connection is made to the stair onto the kil foundation, see following chapter The protection grid for the counter weights (drawing 015.0) wil only be mounted in the final stage of ‘erection after having completed all adjustment work. 4.5.2 Stairs onto kiln foundation and blower house (Drawings 384.0 and 385.0) The stairs onto the kiln foundation (¢rawing 384.0) are mounted at the very beginning of kin erection. Simultaneously the railings provided for must be mounted. On the kiln foundation atleast provisional ralings have to be mounted for safety reasons which should be easy to remove and install again as ‘equited by the following kiln erection. ‘The stair onto the blower house (drawing 385.0) is mounted together withthe hand rails @s soon as the blower house is completed. 45.3 Anchor bolts and plates (Drawing 023.0) Anchor bolts The anchor plates are inserted into the lateral openings in the foundation and shimmed. The anchor bolts hammerhead bolts) ae inserted from abave and turned by 90 °to the stop. Check the correct, Position of the bolts and secure them with a welding point inthis postion. Snaer Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205-305 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 /AL Grouting with cement must take place after erection and aligning of the kiln supporting Structure (drawing 024.0) has been completed latest after shaft | (045.0) has been erected. 4.5.4 Kiln supporting structure and discharge hopper lower part 45.4.4 Columns (Drawing 021.0) The columns of the supporting structure (6 pieces per shaft) are placed on the foundation, levelled by means of shim plates and provisionally fixed with the anchor bolts ag CICERO Kiln supporting structure - columns maerz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-8187-KLN-108-205.305 ‘AK 640 — DRAFT ERECTION MANUAL /08 Jan-2008 AL 4.5.42 Discharge hopper lower part (Drawings 021.0 and 028.0) Kiln supporting structure - columns ‘The hoppers above the discharge traps (drawing 020.0) are ited and placed between the columns of the supporting structure. Take care thatthe cooling air inlet is orientated to the correct side ( not ‘shown on the sketch) ‘The discharge hoppers — lower part (drawing 028.0) are completely assembled on the assembly yard. The doors (040.0) can be pre-mounted as wel 3 of he 6 columns ate tited outwards and the discharge hoppers are lifted in-between the columns The columns are putin vertical position and the discharge casing rests on the brackets on the inner side ofthe columns, Snaer Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-205-305 ‘AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2008 AL 4.84.3 Support structure — upper part (Drawings 021.0 and 028.0) 021.0 prepare on ground Kiln supporting structure ~upper part ‘The 12 columns have to be naw aligned finaly. “The upper frame will be prepared on ground and lifted on to the colurans. It must be welded thoroughly withthe columns as shown on the drawings. ‘Between tne brackets and the discharge casing shims have to be placed so that al 6 brackets Support evenly. The columns and the discharge hopper are not welded together! Now the hopper above discharge trap (020.0) can be lifted init final position, fixed provisional with the bolts on 028.0 and welded air— tight to the discharge hopper (not shown on the sketch). Singer: Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205.305 AK 640—DRAFT ERECTION MANUAL / 09 Jan-2000 / AL 4.5.5 Discharge tables and supporting column (Drawings 030.0 033.0) [ae Discharge tables and supporting column The discharge tables (drawing 030.0) pre-assembled on the ground. Following the actual width “x” the upper support plate forthe rllers are welded to the lower side of the tables. In this phase the tables mounted without the rollers (031.), as brick lining willbe easier with the lowered tables. The support column (033.0) is put onto 0280.0 in this stage s maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-8187-KLN-105-205.305 ‘AK 640 ~ DRAFT ERECTION MANUAL /09 Jan-2009 / AL 45.8 Shatt Part! (Drawings 045.0) Following the instructions on drawing 045.0 shaft pat | is transported to site in one piece or in ‘several segments. To maintain the correct shape of the shaft during transport and erection the single ‘segments have to be stiffened with bracings. After welding the transport sections the shape must Be within the given form and orientation tolerances. ‘The segments are assembled near the kiln foundation tothe biggest size possible and then lied in ‘one piece onto the kin supporting structure (drawing 021.0) Ys Shaft After proper adjustment the segments are welded inside and outside, Subsequently the bottom plates (item 1 and 2 in drawing 045.0) are welded to the discharge hopper (drawing 027.0) and the kiln supporting structure (drawing 02.0). Snaer Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205.305 AK 640 - DRAFT ERECTION MANUAL / 09 Jan-2009 /AL Finally the connecting stfeners between supporting structure 021.0 and shaft part 1 are inserted and welded, After the shaft lis placed the shims under the support columns can be replaced by grouting concrete. The anchor bolts (023.0) must be tightened befare going on with the erection, 45.7 Discharge hopper~ upper part 4.8.7.1 Discharge hopper upper part - conical part (Brewing 027.0) ‘split in 2 parts | | am. | VU) OL vr Tr Sj jam i Yy = YZ, = Ld 3 was 8 a Discharge hopper upper part ~ conical part! Thisis a dificult step, as the inner diameter ofthe bottom plate of the shaft | and the outer diameter of te conical part must fit together. Itis recommended to bring the conical part spit in two halves into the shalt, This makes adoptions. easier. The parts must fit well ogether. Otherwise the welding between shaft and conical part can not be executed properly. ‘The conical part has also to be welded towards the discharge hopper ~ lower part. Many of the seams must be welded air— tight. Snaer. Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205.305 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 /AL ‘There are stifeners between 021.0 and 027.0 which have to be mounted inthis phase, 4.5.7.2 Discharge hopper upper part -“Cross' emer | aaa ree) i \ || aes! Po Ui \ Te ey Discharge hopper upper part “cross” After the conical partis putin position and welded, the pre- assembled "Cross" is placed in the 4 pockets of the conical part Ione arm of the cross is not seating solidly ~shim it and tack weld the shims, The “cross” must also lay on the supporting column (033,) in the centre ‘To allow thermal expansion, the cross must not be welded into the pockets, Snaer. Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-205-305 [AK 640 RAFT ERECTION MANUAL / 09 Jan-2009 / AL. 4.5.7.3 Discharge hopper upper part - Cone and side plates (Drawing 027.0) 27D) Those stops can be taken, after brick lining is finished, ‘The discharge table must be in its final position and ramming mass for fling the cones must be available. ‘The side plates are fixed by the bolts, adjusted in the correct distance to the discharge tables and finally welded onto the structure ‘The cone is put onto the cross and welded toi. After filing it wth ramming mass its closed with the casted cone tip, See also chapter 4.6.2 Snaer Zz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205.305 [AK 640 - DRAFT ERECTION MANUAL / 09 Jan-2009 /AL Kiln shafts -V part. 45.8.1 Shaft part Il (Drawing 047.0) ‘haf par Il (drawing 047.0) is also pre-assembled onthe assy yt near he kn foundation Sha hon Mle onto shat par lin wo ov twee sectons depenangent crane capac. 7A 470 ! J ! aia Shaft part It ‘To faciltate erection wedged steel sheets are prepared and welded onto the edge of shaft part Snaer Z ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-208-305 [AK 640 — DRAFT ERECTION MANUAL / 08 J shaft part II shaft part | | Erection accessory ‘These plates will faciltate the joining ofthe two shaft parts. After proper alignment shaft part Il must be hermetically welded onto shaft part |. Any stiffeners mounted for shipment of the parts and ‘erection accessories are to be removed after completion of the assembly. 4.8.2 Shaft parti (Drawing 048.0) ‘Shaft parts Il are already completely assembled in the workshop before being supplied to the erection site. Platform beams and sheeting should be already welded on the pre-assembly yard in order to facilitate the following erection work. \ Sinaerz EQUIPMENT NO: PV-1-6187-KLN-105-208-305 [AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2008 AL. Shaft part it ‘Shaft pants ilar lited and placed on shaft parts Il using erection accessories similar to the ones for shaft parti Snaer Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205.305 [AK 40 ~ DRAFT ERECTION MANUAL /09 Jan-2008 / AL flat iron | hy LL 7 INE/ @ Erection accessory When mounting shaft parts II attention has to be paid to place the auxiliary openings in the correct position. ‘The brackets must be carefully welded on both sides onto the ring channel shatt part 4.5.8.3 Shaft part IV (Drawing 048.0) Similar to shatt pars ill shaft parts IV (drawing 049.0 or 051.0) are already completely assembled in the workshop before being supplied to the erection site. Depending on the kiln type platform beams land sheeting should be already welded on the pre-assembly yard in order to facitate the following, erection work. e maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1.6187-KLN-105-205.305 'AK 640 — DRAFT ERECTION MANUAL /09 Jan-2008 AL 049.0 —| Shaft part IV SShait parts 1V are lifted and placed on shaft parts Ill using erection accessories similar to the ones for shaft par Il When mounting shaft part IV on shaft part Il attention has to be paid tothe correct position of the siifeners on both parts and the auxiliary openings, Snaerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-5187-KLN-105-205-305 [AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 / AL. 4.5.84 Shaft part V (Drawing 052.0 for rotating bucket charging device) Also shaft parts V 052.0 have been pre-assembled in the workshop before being shipped to the ste. ‘A300 mm dia, rupture disk can be installed in shaft part IV to prevent the pressure in the shafts to ‘exceed 500 mbar, = & (050.0/052.0- Ei Shaft part V The lance boxes should also be already installed. If this is not the case the lance boxes are installed fon the assembly yard and completely welded. Welding of lance boxes at a later stage, after having ‘mounted the shaft parts, requires much welding in a dificult working positon, s maerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-108-205-205 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 /AL ‘The positon ofthe lance boxes according tothe situation plan on the respective drawing 067.0 has tobe checked carefully ‘The cover sheets on top ofthe brickwork are to be mounted and welded only after completion of the brick laying work (tem 6 and 13 drawing 052.0) The distributors (drawing 055.0) installed in shaft part V are mounted only after completion of the fefractory hing and after removal ofthe cable winches forthe brick transport. In case no cable winches had been installed the distributors can be installed at an earlier stage. (On the flange on top of the shaft the shaft closing trap 082.0 willbe botted. ‘Now shaft parts V ae lifted and positioned on shaft parts IV. Pay attention thatthe postion of all Connecting openings and doors correspond tothe relevant drawings, 4.5.9 Stairs and platforms (Drawings 384.0, 386.0, 387.0, 958.0, 961.0, 362.0 , 964.0, 365.0 386.0 368.0 and 370.0) ‘The stairs are supplied to site in ready assembled units ‘According to the progress in erection the stars | and Il (drawings 386.0 and 287.0) are mounted. Incase platforms could not be attached to the shaft parts already on the assembly yard this should be done in accordance with the progress of erection. It's ahvays desirable to assemble platform ‘segments fo the maximum extent on the assembly yard and to lit and weld them to the shatts subsequently. The stairs are altached to the corresponding connections and welded. The steel flooring isto be fixed 1s soon as possible to the platform beams to allow safe walking on the platforms. Stair connections on the platforms are to be welded round about ‘The bolts for fixation ofthe stairs are to be secured after bolting by means of the spit pins supplied with the stairs, To avoid accidents all railings on stars and platforms are to be mounted immediatly. If this is not possible provisional railings and closings have to be mounted. All supports of stairs and platforms on the kiln shafts, the foundation or on the flor are to be ‘mounted right away, Nmaerz EQUIPMENT NO: PV-1-5187-KLN-105-205.305, [AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2009 / AL. 3700 368.0 366.0. , Nel ee Stairs and platforms. Now the inner supporting frames (drawing 371.0) are completely assembled, ited, aligned, bolted {and welded onto the charging platform (drawing 366.0), \ Snaer: Zz EQUIPMENT NO: PV-1-6187-KLN-105-205.05 [AK 640-— DRAFT ERECTION MANUAL /09 Jan-2009 / AL —GTED) ciome (Groin beans 556, Dp Enforced plate between shaft and platform The 10 mm sheets around the shafts must be welded completely to the platform before the erection of the higher platforms. This plates transfers shear forces from the kiln to onto the shaft Hereafter the outer supporting frames (drawing 372.0) are mounted together with the stone distributing platform (drawing 368.0) and the sione hopper platform (drawing 370.0). Thus the ‘connection between outer and inner supporting frames is established, Also on these platforms the covering sheets are not yet definitely mounted but only after installation ofthe pipe work The stairs as per drawing 987.0 are mounted according to the progress of erection Do never forget to install provisional protection railings on stairs and platforms in case definitive railings cannot yet be mounted, Snaerz ‘AQUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-108-205-305, [AK 640 - DRAFT ERECTION MANUAL / 09 Jan-2009 / AL. 45.10 Shaft traps (Orawing 082.0) ‘The completely pre-assembled shaft traps (drawing 082.0) are put on the flanges on top of the shaft V (052.0). The housing ofthe trap is sealed by 155.0 and bolted with 48 M 20 bolts, frevlie opiate pI = ‘Shaft closing trap 4.5.11 Reversal traps for air and waste gas, reversal traps waste gas — filter, ‘combustion and cooling air relief traps {Brawings 090.0, 097.0, and 100.0) {In most cases the hydraulic cylinders are only available on site and thus have to be mounted there and their exact and final position checked All raps are assembled and tested already in the workshop, The lever arms for the hydraulic cylinders are only provisionally stitched onto the trap shafts. The fina position of the arms is determined on site when mounting the hydraulic cylinders. All seals on auailary openings as well as the scone rubber seals on traps and doors are to be mounted only after completion of the welding work to prevent damage tothe seals before starting up the kiln \ Sineer. Zz EQUIPMENT NO: PV-1.6187-KLN-105-205.205 ‘AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2008 AL. The traps are lifted in complete urits, aligned in ther final position and then welded, Pay attention that all hydraulic cylinders, doors and openings are easily accessible. During erection al relevant indications on the drawings have to be carefully observed. When adjusting traps and relief valves make sure that rubber seals and steel sealing rings fit together accurately. Before final adjustment ofthe traps the rubber seals have to be mounted. Before starting tightness tests on the kin all asbestos free seals and silicone rubber seals have to be mounted on ‘auxiliary openings and doors. CCheck the easy and safe access to all greasing nipples, if necessary, greasing pipes have to be: extended. ‘The reversal traps for combustion air and waste gas are mounted on the supports as shown on ‘drawing 404.0 depending on the kiln type. Follow the same procedure as desctived above for Installation ofthe traps with the exception of the fixation of the support on the platform which is done Only aftr installation ofthe traps. The supports are completely pre-assembled and then positioned fon the platform. Afterwards the reversal raps are mounted. Aer completion of the trap installation, the supports are welded onto the platform. 45.12 Poking doors (Drawings 058.0 and 059.0) ltems 16, together with 10, 14 ,17 and 18 are welded into shaft pars Il before starting brick laying. Al other items on drawing 058.0 are mounted after completion of the brick lining work. Take care of the right orientation of the wedges as shown on the drawing in the plan of situation, 4.5.13 Coverin connecting channel and inspection hole (Drawings 060.0 and 061.0) ‘The cover withthe inspection hole forthe poking holes is installed atthe end of erection ‘The cover in the connecting chanel must be mounted before completion ofthe channel roof brick Work: Up to that moment refractory materials can be brought into the kiln through this opening. The sealing string is inserted already when mounting the cover. 4.5.14 Small platform to shaft (Drawing 148.0) ‘The small platform is supplied pre-assembled and then mounted. The appertaining ladder and the railing are installed ater the platform has been mounted, When installing the platform pay attention to the accessibility of the inspection doors in shaft pars IV and V and to prevent any colision of ladder and railings with ring mains for lance cooling air or fuel. Snaer Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-206-205 {AK 640 ~ DRAFT ERECTION MANUAL / 09 Jan-2009 AL. 4.6 Parts which are mounted during or after brick lining 46.1 Poking doors and plugs (Drawings 058.0 and 059.0) Allitems on drawing 058.0 with the exception of items, 10, 14, 16, 17, and 18 (see further above) are ‘mounted after completion ofthe brick lining ‘The measuring plugs are also mounted after completion ofthe brick laying, the thermometers and thermocouples, however, are only installed shortly before start-up ofthe kin. ‘The plugs are filed with ceramic fibre mat on site 48.2 Rollers for discharge tables, driving rods and stripping plates (Drawings 027.0,030.0, 031.0 and 032.0) cylinder $01.0 i L 25 Laz 050.0 roller support) | O57 Aligning of the discharge tables Lift the tables and insert the lower roller support plates onto 028.0 ~ Tack weld these plates. Place the rollers 031.0 with their teeth between the support plates and lower the discharge tables onto the roles. Mont the driving rod and the hydraulic cylinder. Move the whole uni tll the hydraulic cylinder is ‘exactly in its middle position (75 mm stroke to each side.) \ Ninaerz EQUIPMENT NO: PV-1.6187-KLN-105-205-305 [AK 640 — DRAFT ERECTION MANUAL / 0 2009 AL CCheck the distances (x and Y) between the edge of conical part ofthe discharge hopper upper part tothe rim of the discharge tables, These distances must be the same, necessary cul the tube of the driving tod or put shims under the end plate til the distance X = Y. In this position the teeth of the rollers 031.0 must be ina vertical line. For this reason move the lower ‘support plate tl the roller is vertical. Weld the plates after aligning. Check ifthe teeth do not touch on top or on bottom, Grease the teeth before putting the kiln into operation, Rollers for discharge table Its important that hydraulic cylinder and driving rod are lying in one and the same axis to avoid Unilateral stress on the piston rod packings and thus premature wear. In case of horizontal or vertical deviations itis a must to adjust the lange on the discharge table accordingly ‘The stripping plates (Item 14.15. on drawing 027.0), so far provisionally fixed with bolts, are now ‘lignes following the indications on the drawing, fixéd with the bolts and welded, The distance ‘between stripping plate and discharge table must be equal al along as otherwise uneven discharge ‘of lime would occur during kiln operation. Any adjusting work necessary later can only be done with a cutting torch 46.3 Expansion joint sheet (Brawing 056.0) ‘The expansion joint sheets are mounted in the course of brick laying work whenever the brickwork has reached the corresponding level. Pay attention thatthe brick range underneath the sheets is clean and plane, Snaer zZ ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO- PV-1-8187-KLN-105-205.305 [AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2009 / AL 464 Rupture sheets (Drawing 057.0) The angular frames for the rupture sheets together with the protection grids can elther be attached to shafl parts IV or V already in the workshop of on site Allother items are mounted after completion ofthe brick lining. Pay attention that the pins item 10, (13) are in a position not to damage the rupture sheets tem 7 (10). 465 Level indicator (Drawing 073.0) ‘The level indicators are completely assembled already in the workshop. As @ genetal rue the hydraulic drives and the encoders (function generatoritransmiter) are only available for mounting in 2 later stage. In this case follow the instructions on the drawing for mounting, ie os2.0 BN Snaer Zz ‘AZUL-PUEBLO VIEJO PROJECT EQUIPMENT NO: PV-1-6187-KLN-105-205-305 AK 640 — DRAFT ERECTION MANUAL / 09 Jan-2009 / AL Level indicator ~ tract of drawing 073.0 ‘Install chain drive and cylinder + Tum chain whee! tothe right until the hydraulic cylinder reaches the final lowest position + Fix the chain whee! near the vertical centre ine with the bolt and mount counter weight on the other end of the chain ‘+ Connect hydraulic components and the encoder. {tis important thatthe two level indicators have chains of identical length and that the counter Weights in both shafts have the same level position given an identical position ofthe drive. 46.6 Reversal box (Drawing 042.0) ‘The reversal boxes on the discharge table cylinders are fixed to the steel structure ofthe kiln in the final stage of erection. Pay attention to the accurate pasition of the boxes for subsequent installation of limit switches, 46.7 Single doors (Drawing 040.0) Generally all doors should already have been assembled with the corresponding kiln parts in the workshop without rubber seals this was not possible the doors should then be mounted inthe final stage of kiln erection after completion of refractory lining. Make sure thatthe spindle is greased already during storage to prevent rusting Protection plates for doors (Drawing 041.0) ‘The protection plates are to be mounted on the doors already in the workshop. 4.6.9 Kiln hopper/ Weigh hopper (Drawing 211.0) The kiln hopperis positioned and aligned on the platform (drawing 370.0). Only after having installed the vibrating feeders to the rotating buckets (drawing 4205.0), the kiln hopper is defintely welded In case the kiln hopper serves as @ weigh hopper it must not touch any other equipment During commissioning ofthe kin it may become necessary to install uide plates on the upper end of the hopper to prevent stone from falling out of the hopper during charging. 4.6.10 Skip hopper (Drawing 119.0) ssembled ‘Similar to the kiln hopper / weigh hopper described above the skip hopper is completely and tested in the workshop before shipping to site, The hydraulic cylinder is only mounted on site where the correct gistance between the fixing ‘openings is adjusted by means of fil plates item 32, 34 and 60. \maerz EQUIPMENT NO: PV-1-5187-KLN-105-205-305 {AK 640 - DRAFT ERECTION MANUAL / 09 Jan-2009 / AL. In case the hopper is used as weigh hopper the procedure for aligning and installing the load cells is. similar to the one described above (drawing 112.0) 4.6.11 Preheating valve (Drawing 122.0) ‘The valve is installed in the combustion air duct to contol the air volume to the start-up bumer during start-up of the ki, ‘The location of the preheating valve is shown on drawing 395.0, Pay attention to easy accessibility tothe valve from the platform and make suré that al movable parts are well lubricated 46.12 Compensator (Drawing 126.0, 127.0, 128.0, 129.0, 130.0 or 131.0) ‘The size of the compensator also depends on the kiln type. The compensator is also installed in the combustion air duct (drawing 395.0). 4.6.13 Protection tube for measuring points (Drawing 154.0) These tubes can either be mounted during the stee! structure erection or after completion ofthe brick lining work. Pay attention not to damage of spoil the threads at the tube tips. 4.6.14 Packing cord for steel structure (Drawing 186.0) ‘The packings shown on this drawing are used at lange connections and erection openings. The packings are installed shortly before starting the kiln tightness test. ‘These packings are to be glued on one side of the connection as shown on the drawing to prevent any displacement when mounting the counterpart. Asbestos-tree packings The packing cords for poking holes on circular kilns have to be cut as shown on the drawing and then

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