Refractory work procedure of clinker cooler and kiln hood

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I – General introduction – project figures

Tam Diep cement plant is being built in assembly line of Denmark with capacity of 4.1 million tons per year.

Department: 441 is the most important one of project having area of 42.894 x 22.600m2 and installed from EL 32.100 – > 57.050 – > 64.600 -> 72.800.

Item 441.360 involves with refractory work whose function are protecting the machine against thermal inpact during the process. Therefore the lifetime of machine greatly belongs to the quality of refractory castable and brick laying work.

II – Technical requirement

Refractory work of kiln hood and clinker cooler is executed in relevant with drawing no: 2.4969/69; 24969/71; 24969/62; 24969/63; 24969/70; 24969/72 and 7.949726-A.

When handling with casting and brick laying of kiln hood and clinker cooler, some important paramerters should be taken in account such as.

– Clinker cooler has the lenght 28.8m, with 4.21m and 4.102m in hight.

– Kiln hood has the lenght 6.196m, hight 24m ( from EL 57.100 to EL 72.800) and width is 7.200m.

– Clinker cooler 441.200 is laid by brick KRONEX85, KRONEX 50, KRONEX 30 and a back-up insulation 100mm. When the work is carried out, some important sections near the kiln hood such as section A-A, B-B, C-C section F-F in the middle and sections K-K, L-L in the rear ) according to drawing 24969/69) should be taken in account because those section specity castable area. Beside, in process of castble work ( thickness of 100mm) in the side plates and especially on the ceiling of machine frome section E-E to section M-M (Drawing 24969/69) the bolted on formwork should be prepaired. The detail of formwork, see attached drawing.

III – Preparation work

1. Fabricate brick support

– Brick support is fabricated according to sketch

– Working scaffoding

– Shuttering work for casting of side plates

– Fabricated steel wedge for brick laying work, which are inclined surface of 45⁰.

– Fabricate wood wedge

– Before brick laying work start, all welding slag and dust inside machine have to be cleaned. The mechanical work has to be finished, inspected and approved.

– The material received from store has to checked to make sure that the pallet is still not opened before, all bricks ans castable material have no sign of damage and getting wet.

– The material received from store has to put in areas which keep out of moiture ans has to be carefuuly covered by tarpaulin and nylon sheets.

– The material has be reckoned to get for enough consuming, flexible plan according to working procedure.

– In kiln hood, due to 4 hight vertical side plates so the scoffoding is needed. Therefore, when working, the scaffoding, people ans transport equipment has to be observed.

2. Transportation equipment.

– Include one truck 10 tons, moveble crane 10 tons, trailer 20 tons, crane GROVER 30 tons are used for material loading and unloading and lifting into working area of clinker cooler and kiln hood.

– When transport, material has to be covered by tarpaulin

– The road for transportation has to be paved by small ton on supported by sleepers in case of jerky road.

3. Cleaning and dimension marking

– Before castable and brick laying work starts, all mechanical work of linker cooler and kiln hood has to be finished.

– All equipments relating to refractory work have to be checked.

– After all areas which are to be laid by brick have been cleaned, the specific centerline is to be marked. All planes, lines, centerlines are determined by theodilite, spirit level, plum line, scale meter.

– When all preparation work has finished, the material is transported into working area.

IV- Working plan

Due to the technical requirement of refractory work in items of clinder cooler and kiln hood has to be highly precise, the work is difficult and complicated while the crane can not be used inside so material transport is mainly manual besides, the working area is quite unsafe. Therefore, the working plan should be flexible to avoid accident of workers and equipments.

A – Working area preparation and gathering material

– Because the working area for gathering material locate highly from ground so we use crane TADANO 30 tons and 50 tons to lift material up. The refractory material and auxiliaries when received from the store have to be check for sure the type, quality and matches with packing list and design. When material gathered to working area, thay have to be sorted out and covered by tarpaulin and steel sheet to keep out of rain and falling things.

B – Keeping store and site office preparation

– Site office for storing documentation, meeting and work execution.

– 2 containers for storing small material, working tools and safety equipments. Besides, there are equipment box located on site.

C – Manpower: total: 68 people

– Team leader:        1

– Engineer, technical:    2

– Shuttering worker: 12

– Welder:             4

– Electrician:        2

– Crane driver:       4

– Maison:             20

– Other:         25

D – Working machine

Desides, therefore are small tools for marking such as: Punch tool, small hammer, marking pens, wood and steel wedge.

V – Working plan

Manpower  is to be divided into two teams and working in 2 shifts. The back-up insulation, brick laying and castable work will be carried out when the mechnical work have finished.

Using crane 10T, crane TADANO 30T and 50T for lifting material up to all floors then move material to working area by hoist 3T and by hand and enough for consumption.

+ Before the refractory work start, the bricks have to be  checked and the damaged ones have to be rejected.

+ The work is carried out from the front to the back up item 441.200 then come to item 441.100 kiln hood. At item 441.200 one layer 130mm castable is put first, then brick laying is carried out on top so in order to be ensure the quality of work according to design of FLS, the refractory and brick laying work has to be approved by FLS, JEL and TDCC in advance.

+ Before casting for side plates, all anchors have to be stable, formwork are plane and bolt on are tighten up to ensure they have not be moved when casting.

+ After casting the bottom, the brick laying has not b divided from marking line. Especially, in the kiln hood, brick laying is carried out from the bottom with high accuracy. 4 side plates have to be laid by brick simultenously in th reason of adusting scaffolding.

+ When working with above layer of bricks, bricks are put in order of each course around kiln hood and 2 side plates of clinker cooler. When working, the fabricated wood wedges and bolt on have to be used to keep brick in position. Besides the hydraulic jack is used to get the bricks tightly in course and ensure the design gaps before using key brick. The key brick of each course must be used with the right quantity ans adhere to design requirement. When one course is finished, the next course starts.

+ When put the brick tightly, knock gradually by lather-covered hammers and mallets. The steel hammers have not be used.

+ In proceed of work, no equipments relating shell be dismantled, the laying bricks have not be used as support. When transport material, scaffolding, the care must be paid attention to prevent from dropping.

+ When working, everybody has to execute in relavent with technical instruction of FLS expert, TDCC supervisors, JEL supervisors and strictly adhering to documentation, manual instruction. The design has not be changed except having approved upon in writting by FLS, JEL and TDCC.

+ The scaffolding has to be paved by thick wood, in which less than 10 people stand, the maximum quantity of brick is 60 pieces.

+ After compeleted build the vertical mortar line and horizontal mortar line. Must used the jack to press them, checking dimensions as requirement after that applied lock brick.

+ Ensure the surface flatforms are smooth, safety. Do not too many bricks on the flatform.

+ If stage completed building, to arrange people who had experiences and  professional and also electrician to move scaffoldings, electric wires…etc.

Quality

+ Ensure the dimensions of mortar line as requirement.

+ Ensure the ratio of mortar mixing, refractory which were not pock-marked or spongy.

+ Ensure the dimension of slot expansion joint.

+ When building for Clinker and kiln hood besides, they must have two equal shapes and obey the instruction and to intruct of FLS supervisor and JEL.

+ At high level position, if lifting up the brick or cement, we have to use the cage-net,  ( to be ensure lift – cables with radius is F12 per packages less than 1.5 ton. Cable for puley is F18 at least 2 or 4 pieces).

Working safety procedure

1. The all workers who was trained through safety and certified are permitted to work with have good health are arranged to work at high level
2. They must wear enough personnel protection equipments, such us: shoes, helmet and protection uniforms and when working at level from above 2m,

– There should be platform or safety net from above and under the work location. It is forbidden people who drank to work at site.

3. When working inside clinker and kiln hood. It must use lamp of 36V or higher.
4. Before working, check the scaffoldings, ladders, and other equipments and tools, if they are safe then can be used.

– Supply enough fresh water when working.

– Do not throw any materials from the high level. There should be safe method to bring them down ( if necessary).

– Around the working area, there should be safety notice plates, safety tapes around the working area which are dangerous. It is forbidden people from walking under the working area.

– When working high above, tools, cutter machine, float, hammers..etc. must be kept inside package, the package must be equiped with hooks.

5. It is strict forbidden on using barbed for scaffoldings and the scaffoldings it must be welded by skillful and certified welders.
6. When working with hand tools such as: drillers, grinders, the workers must wear protection glasses and the electric wires must be in good condition.
7. Only specialized riggers are permitted to work on lifting work, cables must be tightened in compliance with the procedure. Do not use hands to pull the goods over hand-rails but use hooks and rope.
8. It is strict forbidden people to walk under and on working area.

– Worker preserves right to stop working if he finds it is not safe.

9. Obey strictly regulations on fire and exploration at site. Fire extingushers and sand should be kept at convenient and suitable area.
10. When repairing electric. There must be at least 02 persons, notice should be placed at area of electric repair and on electric box. Electric equipments must be grounded when repairing.
11. Gas cylinders and oxygen cylinders must be placed far from each another, at certain place and far from welding touch at least 10m.
12. Transportation of equipments and materials.

– Check transportation means before loading the goods

– When transporting by man-cart, put shim on the wheels and support the handlebars.

– Workers should go beside the cart and take care when the cart running down a slope more than 15⁰.

– When unloading the goods, cartwheels must be stopped by shims firmly.

– When transporting by truck, the size of goods must be calculated. Pay attention to rigging work.

13. Welding and cutting of metals or bricks

Before welding and cutting metals or bricks, check the working area to ensure it will not danger. If it ought to weld at flammable area, arrange at least 2 persons to preserve for accident.

Electric welders should be equiped with leather gloves and isolation shoes.

14. Painting work

Stop fire around the painting area.

Working in airtinht location should be ventilated by fans, use lamp of 36v to get enough light.

15. When removing the scaffoldings, it should be done from the top and from out side. Fasten the safety belt onto firm location. Place safety notice at area of scaffoldings removing, to stop people from walking. If facing troubles, inform immediately to the supervisors or another authority person for solution.
16. If it has an accident.

When accident happens, give first aid immediately to the casualty. Inform the incharge person and take him to nearest hospital or health.

First aid to the electric-shock person.

Choose safety method to detach the victim out of the electric source. Cut off the electric source. If it is high above, support net should be arrange under the location before cutting off the power source. Bring the victim to the cool and well-aired place, then loose his clothes, put him laying on his back and his head is a little upwards. If he shocks ( hart stops from beating) and stop from breathing, resuscitate him  and massage his thorax ( cooperate 02 person to do every 5 times of heart pressing and 1 time of resuscitating). Call nearest health care person. It is forbidden to bring the victim to hospital if there are not breathing and heart pressing devices.

17. Clean working area everyday when completing the work. Waste material is put at specified place ensure the working be clear.
18. Obey regulations of team leader at site.

The above are regulations for all staffs who participate working on at site and specially on the clinker and kiln hood. Everybody must obey strictly accordingly, whoever, makes mistake on these will be pernalized in compliance with those stipulated by the company, the site management board and according to the state laws.

we at infinity  for cement equipment update the book and reports and excel sheets and manuals every month and send them free if you bought the package, you buy it one time only and you get updates forever