Kiln Inlet Section Casting Procedure (LAFARGE)

SOP Title:

Kiln Inlet section casting procedure

LEC kiln Inlet section

Design Description 1) Kiln Inlet Plates: Nose-ring plates casting area = 80 mm Expansion Joint = On Radial 3.0 mm Rigid Board (Nefalit) On Axial 3.0 mm ply wood Type of Castable = REFRAMULLITE 63 AR LCC

Date

3

Material Material required

Provider

Comments

General Drawing

Shift Team Leader

Validated drawing with CTC

V Anchors for kiln outlet

Shift Team Leader

216 Pieces, SS-310

Omega anchors for kiln outlet

Shift Team Leader

216 Pieces, boiler steel H1 / A 42 Cp

V Anchors for kiln outlet (deformed area)

Shift Team Leader

324 Pieces, SS-310 Sheet

Omega Anchors for kiln outlet (Deformed area)

Shift Team Leader

324 Pieces, , boiler steel H1 / A 42 Cp

V Anchors for NR

Shift Team Leader

360 Pieces, SS-310 Sheet

Omega anchors for NR

Shift Team Leader

360 Pieces, SS-310 Sheet

Plastic caps

Shift Team Leader

2000 plastic cap (8mm) (For V Anchors in kiln outlet) Mild steel electrode

Welding rods for

Shift Team Leader

(For omega Anchors in kiln outlet) Mild steel electrode (For V Anchors in kiln NR) SS electrode (For V Anchors in kiln NR) SSl electrode

Expansion joint

Shift Team Leader

Nefalit 3 mm thickness

Dry joint

Contractor

Plywood with thickness 3 mm maximum

Concrete

Shift Team Leader

For NR REFRAMULLITE 63 AR LCC For kiln outlet section& deforemd shell is GIBRAM SR

Water container

Contractor

Scaled container

Vibrator

Contractor

40 to 50 mm Ø

Mixer

Contractor

Vertical

All Material Selection

CTC Validated

Type of Castable and Anchors Date

4

Procedure and Quality Control Implementation

Quality Control Approver

Comments

Certified welder

Kiln Tech.

We dried welding electrode in oven at recommended Temp.

Contractor mason

Kiln Tech.

We Grinded Shell properly on OMEGA Positions

Marking OMEGA

Kiln Tech.

Kiln & Kiln Hood + TAD Supervisor

Followed Lafarge Standard

Welding OMEGA

Certified welder

Kiln Tech.

Continous welding

OMEGA Control

Kiln & Kiln Hood + TAD Supervisor

Shift coordinator

Visual and Pictures + hammering each OMEGA

V Double Tack Welding

Certified welder

Kiln Tech

Regular inpection by our Refractory Team

V Double Tack Welding Control

Kiln & Kiln Hood + TAD Supervisor

Shift coordinator

Visual and Pictures compare position/LPCL Drawing for Anchors

Water measurement

Contractor mason

Kiln Tech

Mixing water Temperature

Contractor mason

Kiln Tech

Mixing

Contractor mason

Ball test after mixing before casting

Kiln Tech

Vibrating

Contractor mason

Kiln Tech

Joint installation

Kiln Tech

Kiln & Kiln Hood + TAD Supervisor

Procedure Used Dry welding electrodes Proper shell grinding on OMEGA positions

ANCHORING

CASTING

Kiln & Kiln Hood + TAD Supervisor Kiln & Kiln Hood + TAD Supervisor

Using proper measurement tools Used mixing water temperature between 25 - 30 deg.C in current Winter Seasons by External Heating. Followed supplier procedure Esured proper water mixing We took special care of anchors during vibration On radial we use Nefalit (3mm) On axial we use ply wood (3 mm)

Curing time

Shift coordinator

Shift Team Leader

More than one day

Preheating/Drying Curve

CRO

Kiln Coach/ Shift Team Leader

Followed Lafarge Standard Preheating / Drying Curves

CURING TIME

Date

5

EMCC kiln outlet section

LEC kiln outlet section Kronex 40 Bricks

40 cm

40 cm

40 cm

120 cm

Anchors dimensions of kiln inlet sector

140 mm

100 mm

OMEGA STEEL ASI 310 Ø= 10 mm

V ANCHOR STEEL ASI 310 Ø= 8 mm