011-Repl of Kiln Shell Under Tyre

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Description :

DESCRIPTION DESCRIPTION

FORMS FORMS

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APPENDICES APPENDICES

CUTTING & REPLACEMENT OF KILN SHELL

SECTION Service / Department : MECHANICAL Duration of Stoppage : TWELVE (12) Days (288 Hrs)

Operational Phases Phase no. Phase 1 Phase 2 Phase 3 Phase 4

Estimated Estimated Est. cost

Description

Quantity Unit Cost

( Php )

Site Preparation Dismantling / Rigging down of old Kiln shell Rigging up / Mounting / Alignment of the new Kiln shell Housekeeping

Total

Labor Phase no. Phase 1 Phase 2 Phase 3 Phase 4

Description Mechanical Contractor Mechanical Contractor Mechanical Contractor Mechanical Contractor

Estimated Estimated Est. cost N° of N° of Men Hours ( Php ) 1 I lot 1 I lot 1 I lot 1 I lot

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Total

Materials Phase no.

Phase 1

Phase 2

Phase 3

Phase 4

Description Scaffolding pipes (assorted lengths) & clamps Wood blocks, 12” x 12” x 6’ BI pipes, 6”Ø x 20’, sch 40 BI pipes, 8”Ø x 20, sch 40 Structural steel Oxygen gas Acetylene gas Welding rod, 7018 - 1/8”Ø Oxygen gas Acetylene gas Welding rod, 7018 - 1/8”Ø BI pipes, 4”Ø x 20’, sch 40 Plate, MS –12mm x 4’ x 8’ Grinding disc, ¼” x 4” x 8” Oxygen gas Acetylene gas Welding rod, 7018 - 1/8”Ø Welding rod, 7018 – 5/32”Ø BI pipes, 4”Ø x 20’, sch 40 Plate, MS –12mm x 4’ x 8’ Grinding disc, ¼” x 4” x 8” Gouging rod, 6mmØ Oxygen gas Acetylene gas

Estimated Estimated Est. cost Quantity Unit Cost

( Php )

1 lot 10 pcs 1 lot 1 lot 1 lot 4 cyls 2 cyls 10 kgs 6 cyls 3 cyls 15 kgs 1 lot 1 pc 10 pcs 6 cyls 3 cyls 25 kgs 50 kgs 1 lot 1 pc 10 pcs 20 kgs 6 cyls 3 cyls

Total

Tools & Equipment Phase no. Phase 1

Description 80T Mobile Crane Welding machine, 300 A Cutting outfit with accessories Chain block, 5t Chain block, 3t Wood blocks

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Estimated Estimated Est. cost Quantity Unit Cost 1 3 2 1 4 1

unit units units unit units lot

( Php )

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Phase no.

Phase 2

Phase 3

Phase 4

Description

2 boxes 6 pcs 6 pcs

Estimated Estimated Est. cost Quantity Unit Cost

150T Mobile Crane 80T Mobile Crane Welding machine, 300 A Automatic cutting machine Cutting outfit with accessories Chain block, 5t Chain block, 3t Wood blocks Carpenter’s level Wire rope sling, 2t, 1t Shackles, 12mmØ, 20mmØ, 50mmØ

1 1 4 1 2 1 4 1 1 6 6

unit unit units unit units unit units lot pc pcs pcs

150T Mobile Crane 80T Mobile Crane Welding machine, 300 A Gouging machine with compressor Automatic cutting machine Cutting outfit with accessories Chain block, 5t Chain block, 3t Wood blocks Carpenter’s level Wire rope sling, 2t, 1t Shackles, 12mmØ, 20mmØ, 50mmØ

1 1 4 1 1 2 1 4 1 1 6 6

unit unit units unit unit units unit units lot pc pcs pcs

80T Crane Welding machine, 300 A Cutting outfit with accessories Chain block, 5t Chain block, 3t Wood blocks Carpenter’s level Wire rope sling, 2t, 1t Shackles, 12mmØ, 20mmØ, 50mmØ

1 3 2 1 4 1 1 6 6

unit units units unit units lot pc pcs pcs

Total

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( Php )

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Procedures Phase 1: Site Preparation Step 1.1:

Remarks by:

Executioner

Workers, shall at all times wear safety helmets, safety shoes, safety goggles when doing grinding or chipping works, welding mask during welding, working and welding gloves, human harness or safety belts when climbing more that three ( 3) meters.

Step 1.2: Prepare, inspect & test integrity of chain blocks, lever blocks to be used for the job. Likewise, inspect, check the integrity wire rope or web slings & shackles to be used for lifting. Ensure that these tools & equipment are safe & fit for use. Step 1.3: Prepare, inspect & test integrity of the oxygen-acetylene hoses & gauges to be used for the job.. Prepare & inspect the integrity of the welding cables to be used. Test the welding machines to be used for the job. Ensure these equipment & accessories are safe & fit for use. Step 1.4: Site preparation & back filling of area where the crane is to be positioned and mounted. Backfilled material must be leveled & compacted in order to ensure that the crane can be properly & steadily positioned. Secure all existing canals & trenches by installing temporary covers. Step 1.5: Installation of power distribution control panel for Contractor’s tools and equipment such as welding machines, grinders, drills, trouble lights, etc. at the tapping location assigned by FRCC electrical department. Step 1.6: Fabrication of spider supports & full welding inside the spare kiln shell. See Fig.1 below.

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Fig. 1 Step 1.7: Beveling of the spare kiln shell. Refer to Fig.2. Smooth finish grinding of the bevel led parts adhering to the angles specified in the drawing.

NOTE:

When welding is carried, GROUND (Return) cable must be directly connected to the part being welded !!! Remarks by:

Executioner

Fig. 2 Step 1.8: Fabrication of saddle and adjusting bolts and other accessories necessary during kiln alignment. Step 1.9: Position the 120-ton mobile crane at the POLCID side. This must be properly oriented prior to any lifting activities. Crane outrigger must be properly spread in place on firm & stable grounds / surface. Lifting angle, heights and tolerances must be strictly observed. Slings and lifting cables must be of adequate sizes to withhold the load being lifted. Step 1.10: Removal of air ducts of 2 units kiln shell cooling fans & other kiln accessories that can obstruct during the kiln replacement works. Store & haul these kiln accessories to designated area for safekeeping ( these are to be re-installed later after kiln shell replacement). Step 1.11: Erection of all necessary scaffoldings ( to be done by Lafarge accredited contractor) including platforms & ladders.

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Step 1.12:

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Fabrication of temporary structural steel supports using W14 x 87 lbs/ft for columns, beams and girders. Fabrication of wedges, jigs, strong box & mounting plates using 19mm thick mild steel plates. Installation & full welding of all of all necessary supports to the Kiln Shell. See figure 3 below. Details of supports on separate sheet.

Fig. 3 Step 1.13: Fabrication & machining of four (4) pieces backing plates (machined, rectangular, 25 mm thickness) These plates to be welded to the kiln shell. These backing plates will work as stoppers and must be positioned precisely for the final position of the tyre

Step 1.14: Fabrication of one ( 1 ) spider supports to be welded inside the spare shell. Fig.1 Another two ( 2 ) spider supports to be welded inside the existing shell. See Fig.4

Remarks by:

Phase 2: Dismantling /Cutting & Rigging down of the old Kiln shell section (Including tyre) Step 2.1:

After Kiln shell cooling down, perform an Ovality check of kiln shell before cutting. Record your readings for reference.

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Executioner

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Step 2.2:

Check the radial runout of the tyre in the actual installation. Measurement should be taken in 3 and 9 o'clock position at the same time. Please use Polysius measuring Protocol Annex B. Record your readings for reference.

Step 2.3:

Marking on kiln shell for cutting. Mark reference lines next to the kiln section that has to be removed. The reference lines have to be marked on the remaining part of the kiln, not on the scrap tyre section! These reference lines have to be made by means of a scriber. Use visible and permanent marking ink.

Step 2.4:

Four backing plates (machined, rectangular, 25 mm thickness) have to be welded to the kiln shell. These backing plates are working as stoppers and must be positioned precisely for the final position of the tyre. Fig. 13

Step 2.5:

Full welding of two ( 2 ) spider supports inside the existing shell approx (1) ONE meter back from the replacement section joints. Angle sections 75mm x 75mm x 10mm welded to a 400mm Ø center disc. This is to maintain cylindrical dimensions throughout the repair works. Fig.4

Fig 4

Step 2.6:

The weight of the kiln must be supported by hydraulic jacks, mounted upon wooden sleepers or fabricated steel support structures either side of the replacement area & are located under the spider stiffeners. Fig.5.

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Fig. 5 Step 2.4:

Arrest the damaged kiln section (including tyre) with lifting web /wire rope slings & shackles. Ensure that all lifting equipment are capable of lifting the total weight of the damage shell + the riding ring! Crane outrigger must be properly spread in place on firm & stable grounds / surface. Lifting angle, heights and tolerances must be strictly observed. Slings and lifting cables must be of adequate sizes to withhold the load being lifted.

Step 2.5: Connect the lifting slings to the 120-t mobile crane, the hook positioned perpendicularly on top of the kiln shell and is on standby. Step 2.6: Carefully position the magnetic track automatic cutting machine around the circumference of the kiln and secure with clamps paying attention to the marked lines. See photos below.

Fig.6

(First Cut)

Fig. 7

(True Length Cut line)

Step 2.7: The first cut must be made 150mm inside the required length around the circumference, leaving four ( 4 ) sections intact, approx. 300mm wide at 12, 3, 6 & 9 o’clock positions. Fig.6 Step

2.8:

Re-set the track & now, cut the circumference on the true length cut line,Fig. 7 This will leave four ( 4 ) 150mm sections uncut. Fig 8.

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Remarks by:

Fig 8. Step 2.9:

Executioner Swivel the magnetic track automatic cutting head at 30° angle & repeat the process on the true cut line. Fig.9 – this will effect a chamfer leaving a 2mm wide root face bull nose. Fig 10. Leave the four ( 4 ) uncut sections as with previous cuts.

Fig. 9 Fig.10

Fig.9

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Step 2.10:

Carry out the same cutting process in this manner on the other end of the damaged shell section, so as to leave a true measure for the fabricated kiln cylinder. Fig.11.

Fig 11 Step 2.11:

With the 120-t mobile crane ready to lift the damaged shell (including tyre), cut the four (4) remaining uncut portions of the shell on both ends.

Step 2.12:

Slowly & with precise timing, lift the cut kiln shell out of area. Slowly swing the boom eastward & position damaged shell on the space near POLCID. Lower down shell, release the lifting cables & shackles from the hook of mobile crane.

Step 2.13:

Manual grinding to smoothen the cut edges of existing shell on both ends leaving clean & smooth beveled edges.

the the the the

Step 2.14: Using compressed air & gouging machine, remove all welded portions on the stopper blocks of the filler bars (axial & radial stoppers) around the shell. Fig.12. Haul & store these pieces to designated safe area for re-use later.

Fig. 12 Step 2.15:

As soon as the tyre has been stripped from the old shell the tyre has to be thoroughly inspected for signs of wear & cracks all throughout the circumference.

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Phase 3: Mounting / Rigging up & Alignment of the new Kiln shell section (Including trye) Step 3.1:

Four backing plates (machined, rectangular, 25 mm thickness) have to be welded to the kiln shell. These backing plates are working as stoppers and must be positioned precisely for the final position of the tyre. ( Reference: Polysius _ Montage Laufring grob e ). Refer to installation of tyre, Fig 14.

Step 3.2: The tyre has to be shifted against these stoppers, centered in radial direction and then another 4 backing plates (Fig.14) have to be positioned against the tyre and then welded to the kiln shell. Step 3.3: After that the tyre fixation as to be installed step by step in 12o'clock position and tack welded. After the installation of all fixations, the welding of the fixations can be started. The axial fixation for the tyre must not be welded at this point of the pre-assembly

Lifting of tyre

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Installation of the tyre unto the shell

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Cleaning of plates, wedges & axial fixation

Positioning of tyre fixation

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Centering fo tyre by means of shims (radial wise) & stopper (axial wise)

Tack welding of tyre fixation

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Installation of tyre

A

X C

D E

B

Support rollers

Fig. 13

A: B: C: D: E: X:

NOTE:

Backing plates Reference line on the new kiln section Backing plates Distance between reference line and tyre Distance between outside of kiln shell and tyre Distance between backing plates and reference line

When welding is carried, GROUND (Return) cable must be directly connected to the part being welded !!!

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Centering of tyre to kiln shell section F F

F

F

F

F F F

Fig. 14 Centering of tyre to kiln shell section Distance “F” to be measured by means of shim plates to be made uniform on the circumference. Shim plates to be removed before start-up of kiln!

Fig 15

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NOTE:

When welding is carried, GROUND (Return) cable must be directly connected to the part being welded !!!

Step 3.4: Arrest the new kiln shell assembly with web / wire rope slings & shackles – securely hooked on the mobile crane, ready for lifting. Step 3.5: Slowly swing the boom westward & position new kiln shell on the space for replacement. Fig.16.

Fig. 16 Step 2.3: Slowly & precisely, lower down the new kiln shell assembly to rest & aligned on the existing kiln shell. The boom should be steady. Step 3.3: Install & full weld a series of brackets for draw bolts inside the old kiln shell. They should be welded uniformly around the inside part of the old kiln shell at both ends and are spaced approx. 400mm apart. Two (2) main versions of draw bolt brackets are used. POLYSIUS recommend an angle cleat design (while F.L.S. choose a “U” section format). Pre-assembly / Installation tolerances – refer to Annex A

Fig.17 Step 3.4: On alignment, there may be some trimming required for a good fit up. When positioned, the joint for welding should be a 60° included angle – single “V” preparation with a 2mm root face bull nose to both parts.

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Step 3.5: Check alignment and completely weld along one side (existing kiln shell), a series of approx. 15 strong backs across the two joints. Fig. 18.

Fig.18 Step 3.6:

Weld the draw bolt brackets to the new kiln shell section. Insert 30mm fully threaded draw bolts across the joint & attach four ( 4 ) hexagonal nuts per bolt, ( 2pcs outside & 2 pcs inside ) – this is to create a push & pull mechanism.

Step 3.7:

Weld the draw bolt brackets to the new kiln shell section. Insert 30mm fully threaded draw bolts across the joint & attach four ( 4 ) hexagonal nuts per bolt, ( 2 pcs outside & 2 pcs inside ) – this is to create a push & pull mechanism. Fig. 19.

Fig. 19 Step 3.8:

Weld in place a series of approx. 30 equally spaced screw blocks to the new kiln shell section so that they cross the joint. These will be used to adjust & align both cylinders Fig. 20.

Fig. 20 Step 3.9:

Manually rotate the kiln in order to conduct a true alignment check. As the kiln rotates, 12 datum points are selected & measured using a polar diagram, one (1) meter away from the each joint. This determines the true center line of the kiln.

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Step 3.10:

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If the test proves unsatisfactory, the strong backs are released by gouging and the draw bolts are adjusted where necessary. Strong backs then re-welded and a further alignment check is conducted until the kiln measures a true alignment. Fig. 21.

Fig. 21 Differences in the diameters have to be uniformly distributed on the circumference to avoid edge misalignment. Max. differences in the edge misalignment are 1 mm. (Polysius data)

Remarks by:

Executioner Step 3.11:

Prior to welding, PRE-HEAT IS CRITICAL. The correct pre-heat temperature has been calculated on Annex B. (Method case study for the welding of Kiln sections provided for Rugby Cement Crown House by Mike Bedford) Pre-heat of 120°C to a distance of 150mm from each side of the joint. A thermal crayon (preferably a pyrometer) Fig. 22, should be used to monitor the temperature and ensure that this temperature of 120°c is maintained throughout the welding process. Re-heat as necessary.

Fig. 22 NOTE:

The welding electrodes should be heated for two (2) hours in a suitable baking oven.

Step 3.12:

Commence welding from the outside of the kiln, Fig. 24 employing two (2) welders on each joint working continuously around the clock. Deposit fully a single root pass weld using a 3.2mm Ø electrodes. De-slag thoroughly using an air chisel.

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Inspect for inclusions, if present, grind out & re-weld. See next page (Full welding procedures – refer top Annex C )

Fig. 23

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*** During the complete repair, the kiln should be rotated manually as necessary to assist convenient weld positioning ( >4.2m kiln = 8 spokes; 4.8m kiln =m 10 spokes ). Step 3.13:

The hot pass, intermediate welding can be completed in stages to fill 2/3 of the weld preparation. DO NOT CAP. To obtain optimum mechanical soundness – weaving must be avoided, therefore, use stringer beads up to a deposit width of twice the electrode diameter.

Step 3.14:

Return, to the inside of the kiln and by gouging, remove the brackets, screw blocks & spider supports. Grind to smooth finish gouged areas. Fig. 24.

Fig 24 Using 8mmØ carbon electrodes & the air arc gouging process, conduct an internal root preparation by back gouging into the external root weld to a depth of approx. 10-15mm. This will also remove any possible slag inclusions. Grind properly the “U” to remove all gouging residues. Step 3.15:

Ensure that the pre-heat is maintained & deposit an internal root weld, Fig.25 using 3.2mmØ electrodes. Complete hot pass & cap with 4.0mmØ electrodes. Grind internal surface flush, as welds left proud & undercut can have the effect of multiplying the stress.

Fig. 25 Step 3.16:

Return to outside of the kiln shell & continue / complete filling and capping weld deposits, ensuring stringer bead format, using 4.0mmØ or 5.0mmØ electrodes.

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Step 3.17:

Wire brush thoroughly the inside & outside welded joints of the kiln shell. Visually inspect the finished welded joints. Suspected areas should be investigated by using dye penetrant (preferably – ultrasonic testing).

Step 3.18:

Weld is subject to a 100% radiograph upon completion. Gouge & re-weld any defects.

Step 3.19:

Reinstallation of kiln shell cooling fans, ducting and other kiln accessories in place. Full welding of ducts & supports.

NOTE:

When welding is carried, GROUND (Return) cable must be directly connected to the part being welded !!!

.

Phase 4: Safekeeping Step 4.1:

Removal of all temporary welded supports & pad eyes, grinding to smoothen area.

Step 3.2:

Removal of all scaffolding pipes (by the Scaffolding Contractor)

Step 3.3:

Disconnect the welding cables ( ground cable ) from the kiln area. Housekeeping of all oxygen & acetylene cylinders. Empty cylinders should be returned back to the warehouse.

Step 3.4:

General cleaning of work area and removal of backfilled materials to FRCC designated area. Using the Payloader, load all these scrap & haul to the scrap yard for proper disposal.

Step 3.5: Travel the mobile crane outside the kiln area.

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Additional Additional Safety Safety aspects aspects

Additional Additional Comments Comments

Reference Reference Documents Documents

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Annex A:

Preassembly / Installation tolerances Rotary kiln:

Installation of kiln shell section

Section 1

Section 2

Measurement not taken in the area of the longitudinal weld approx. +/- 300 mm

B

A

(Distance of the measuring points from the peripheral weld approx. 100 mm) In case the value measured at A is x mm, the maximum permissible deviation of the value measured at B is +/- 1,5 mm. Distance between supports L

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Max. radial runout: +/- 0,05 % of distance L but not more than +/- 5 mm. Readings in a distance of +/- 300 mm from longitudinal joints have not to be considered. These tolerances are also applicable for the preassembly of transport units on supports (on roller blocks etc.). In case of a repair (of the old kiln) the measured values may be 50 % higher, provided that there are no significant plastic deformations of the kiln shell.

Annex A: Rotary kiln:

installation of kiln tyre section / transition section for splined tyres: Difference in radial runout max. +/- 1,0 mm

600 mm

Measurement not taken in the area of the longitudinal weld approx. +/- 300 mm

A

(Distance of measuring points from weld approx. 100 mm)

B

In case the value measured at A is x mm, the maximum permissible deviation of the value measured at B is +/- 1.5 mm. In case of a repair (of the old kiln) the measured values may be 50 % higher provided that there are no significant plastic deformations of the kiln shell. about 100 mm E

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D

Maximum axial runout (mm): D (mm) < 5,000 5,000 – 6,000 > 6,000

Max. axial runout (mm)

+/- 0.00011 x D +/- 0.00013 x D +/- 0.00014 x D

Annex A:

inlet and outlet

Diameter

Rotary kiln:

Max. radial runout:

+/- 0.2 % of the diameter

Rotary kiln:

girth gear Radial runout

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Backlash

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Axial runout

The following only applies to new girth gears: Outside diam. of girth gear (mm) Max. perm. axial runout (mm) absolute Max. perm. radial runout (mm) absolute Backlash Se (mm) cold condition

3100 0.45

3400 0.55

3700 0.65

4300 0.90

4900 1.10

5500 1.20

6100 1.45

6700 1.75

7300 2.00

gr.7300 2.00

for all applies: 0.07 x module up to Ø 5400 mm: 2 mm + 0.3

More than 5400 mm: 3 mm + 0.3

For the girth gear measurement Krupp Polysius measuring forms have to be used.

In case girth gears are turned, they are mainly aligned according to the tip/root clearance.

Annex A: This clearance must be recorded prior to the dismantling and is decisive for the alignment after reinstallation unless other conditions (consultation with the specialist department) must be considered.

Rotary kiln: inside Weld reinforcement and edge misalignment Differences in the diameters have to be uniformly distributed on the circumference to avoid edge misalignment. Max. differences in the edge misalignment are 1 mm.

outside

edge misalignment max. 4 mm

inside

Rotary kiln: inlet / outlet seal

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max. +/- 0,2% of the diameter

max. +/- 0,1% of the diameter

Regarding the position and number of measuring points see measuring protocol „1001 Alignment of kiln sections“.

Attachment:

- 1002 Alignment of kiln sections - 1014 Alignment of girth gear

Annex B:

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Annex B: Pre-Heating Requirement (p.1)

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Annex B:

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Pre-Heating Requirement (p.2)

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