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
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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.