Rotary kiln under erection

Product Description

ROTARY KILN ERECTION PROCEDURE

(On behalf of KINC Mineral Technologies Pvt. Ltd.)

1. Purpose

This procedure outlines the step-by-step method for the erection and alignment of a Rotary Kiln system, ensuring proper installation, accuracy, and safe execution as per engineering drawings and standards.

2. Scope

Applicable for the erection of Rotary Kiln, including:

• Kiln Shell Sections

• Support Rollers and Base Frames

• Girth Gear and Pinion Assembly

• Drive System

• Inlet & Outlet Seals

• Refractory Installation

• Associated Ducts, Fans, and Auxiliary Systems

3. Responsibilities

• KINC Site In-charge: Overall supervision and coordination.

• Erection Team: Execution as per drawings and safety norms.

• Client Representative: Verification and approval at key stages.

4. Equipment and Tools Required

• Hydraulic Cranes (suitable capacity)

• Chain Blocks, Slings, and Lifting Tackles

• Precision Leveling Instruments (Theodolite, Dial Gauges)

• Torque Wrenches

• Alignment Tools and Feeler Gauges

5. Pre-Erection Activities

1. Verify civil foundation levels and centerline coordinates as per approved foundation drawings.

2. Ensure anchor bolts are properly grouted and cured.

3. Clean all base plates and bearing surfaces.

4. Check for any transport damages on kiln shell sections and equipment.

5. Arrange all tools, lifting devices, and manpower at site.

6. Erection Procedure

6.1 Support Structure & Base Frame

• Position and fix base frames on foundation bolts.

• Level and align base frames to within specified tolerances.

• Grout and allow adequate curing time.

6.2 Support Rollers Assembly

• Place support roller shafts on bearings and adjust height and slope.

• Ensure proper axial alignment between roller centers.

6.3 Kiln Shell Erection

• Begin from the feed end and proceed section by section.

• Lift each shell section using cranes and position it over the support rollers.

• Align the shell longitudinally with the kiln centerline.

• Check ovality, runout, and slope (as per design inclination).

• Weld shell joints after proper fit-up and tack welding inspection.

6.4 Girth Gear and Pinion Assembly

• Mount the girth gear on the designated shell flange.

• Perform radial and axial runout checks.

• Align pinion with the girth gear maintaining specified backlash.

• Tighten bolts to the recommended torque values.

6.5 Drive Assembly Installation

• Install gearbox, motor, and couplings on the drive base frame.

• Check centerline alignment between motor, gearbox, and pinion.

• Ensure smooth rotation of the kiln during trial runs.

6.6 Inlet and Outlet Seals

• Mount inlet and outlet sealing systems.

• Ensure proper sealing clearance and flexibility for kiln expansion.

6.7 Refractory Lining (Post-Alignment)

• After mechanical alignment and trial rotation, proceed with refractory installation.

• Maintain expansion joints and anchoring per design.

• Dry-out and curing to be carried out as per refractory suppliers instructions.

7. Final Alignment and Trial Run

• Perform final alignment of rollers and shell slope.

• Rotate kiln manually and under power to confirm smooth operation.

• Check vibration, axial movement, and gear meshing noise.

• Record and submit alignment report to the client.

8. Safety Precautions

• All personnel must wear PPE (helmet, gloves, safety shoes, harness).

• No work under suspended loads.

• Follow KINC and site-specific safety protocols.

• Lifting tools must have valid test certificates.

9. Documentation

• Foundation Inspection Report

• Erection Checklist

• Alignment Report

• Trial Run Record

• Handover Certificate