预热器安装作业指导书-en.doc

Work Instructions for Cement Machinery and Equipment InstallationWork Instructions for Preheater InstallationCBMI.QEMS.03.49I. Work steps for preheater installationAcceptance of foundation Acceptance of preheater equipment Installation of feed chamberInstallation of calcinerInstallation of C5 cycloneInstallation of C4 cycloneInstallation of C3 cycloneInstallation of C2 cycloneInstallation of C1 cycloneInstallation of connection duct from C5 to C4Installation of connection duct from calciner to C5Installation of connection duct from C4 to C3Installation of connection duct from C3 to C2Installation of connection duct from C2 to C1Installation of expansion joints and valvesInstallation of feed systemInstallation acceptance and trial runII. Quality control planItems of process controlContents of inspectionNo.DescriptionInspection typeInspection categoryControl typeDocument typeDocument description 1.1Self review/ joint review of drawingsRecord of self review/ joint review of drawing1.2Technical instructions for worksRecord of work instruction1.3Acceptance of foundationDIM1Inspection report for civil works reserved1.4Inspection of preheater equipmentDIM1PN2.1Installation of feed chamberDIM2PNCBMIJXYRQ0013.1Installation of calcinerDIM2PNCBMIJXYRQ0024.1Installation of cycloneDIM1PN4.2Installation of connection ductDIM1PN4.3Installation of C5 cycloneDIM1PNCBMIJXYRQ003 and 0044.4Installation of C4 cyclone and its ductDIM1PNCBMIJXYRQ003 and 0044.5Installation of C3 cyclone and its ductDIM1PNCBMIJXYRQ003 and 0044.6Installation of C2 cyclone and its ductDIM1PNCBMIJXYRQ003 and 0044.7Installation of C1 cyclone and its ductDIM1PNCBMIJXYRQ003 and 0044.8Installation of cyclone and its connection ductDIM1PNCBMIJXYRQ003 and 0045.1Installation of expansion joints and valvesDIM1P5.2Installation of feed systemDIM1PInspection type: DIMdimensions check, DPdye penetration test, MPmagnetic powder test, MTmechanical test for samplesRDradiographic test, RTrunning test, SCspecial check, USultrasonic test, VCvisual check.Document type: Ninspection record, Rreport.Control type: Eensured item, Bbasic item, Pitem with permissible deviationInspection category: 1self inspection, 2joint inspection.III. Work process control procedure for preheater installation1. Preparation for worksNo.ContentInspection itemTechnical requirementsMain points in worksTest device1.1Self review/ joint review of drawingsCBMI.QEMS.03.071.2Technical instructions for worksCBMI.QEMS.03.091.3Acceptance of foundationDIM As per “Foundation acceptance”1.4Inspection of preheater equipment1.4.1Inspect pipe or cylinder cylindricalityCylinder cylindricality1-20.3%DGrade I steel tape1.4.2Inspect edges of longitudinal butt weld seamsEdges of longitudinal butt weld seamsL=D/6, and500mmL800mmProtruding h14mmTemplateFeeler gaugeConcaving h22mm1.4.3Inspect cylinder end planesEnd plane deviationS2mmShell or pipeGrade I steel tapePlumb line1.4.4Inspect cylinder peripheral lengthDiff. of max. and min. periph. length(D5000mm)L1-L26mmPeriph. length LShell or pipeGrade I steel tape Diff. of max. and min. periph. length (D5000mm)L1-L24mm1.4.5Inspect the flangeFlange surface planenessD1500mmF1500mmF3mm2. Installation of feed chamber:No.ContentInspection itemTechnical requirementsMain points in worksTest device2.1Installation of feed chamberThe feed chamber shall be installed with the rotary kiln centerline as reference. It is lifted to place and coarse alignment is made first (it should be lower than the design elevation), and after completion of rotary kiln installation, make precision alignment for it.Gap between feed chamber and tailB=LActual-LTheor.LTheor.=a+bAs shown: when the center of live ring is to the right of roller, a shall be positive.8B10mmLive ringRollerHot pointShellFlue chamber Grade I steel tapeCoaxiality of feed chamber outlet CL with kiln CL2mmGrade I steel tapeParallelism of feed chamber outlet plane and kiln plane1mm/mGrade I steel tapeChamber center elevation 2mmLevel3. Installation of calciner:No.ContentInspection itemTechnical requirementsMain points in worksTest device3.1Before lifting, correct direction for shell assembling must be ensured. The installation shall include reference selection, foundation setting out, lifting base and lower shell, horizontal alignment, vertical alignment, upper shell installation, horizontal and coaxial alignment and welding. Setting out shall be referenced to the tower centerline and process layout drawing design position, and welding will be made between calciner base parallels and steel beams, and no welding will be made between base and parallels.Deviation of calciner center position from design position on drawinge13mmGrade I steel tapee23mmCalciner assembling and installation verticalitye15mmView AView ACalciner lower shellCalciner upper shellActual centerline Steel tapeTransitLevelPlumb linee25mmTop horizontality deviation0.5mm/m4. Installation of cyclones and ductsNo.ContentInspection itemTechnical requirementsMain points in worksTest device4.1Installation of cyclones1. The center of cyclone and its base should be located with respect to the frame centerline and the design position on process layout drawing, and due attention should be paid to the direction and angle of cyclone.2. The installation shall include platform setting out, cyclone base center setting out, installation of lower cone and base (including verticality and horizontality alignment), upper volute installation (including verticality, horizontality, upper and lower coaxiality alignment), welding and inner cylinder installation and welding.3. The cyclone base parallels shall be in full contact with the base, and be welded on floor, but no welding must be made between parallels and base.4.2Installation of connection ducts1. The center of duct and its base should be located with respect to the frame centerline and the design position on process layout drawing, and due attention should be paid to the direction and angle of the duct2. Before connecting ducts, the upper and lower cyclones shall have been installed in place. The duct shall be assembled into two parts on ground, the upper duct and lower duct.4. For lifting the lower duct, alignment shall be made for its verticality and horizontality.5. Lift the upper duct, adjust its position, direction, angle, make alignment for its verticality, horizontality and upper and lower coaxiality, and weld it with the lower duct and cyclone.6. The duct lower base parallels shall be in full contact with the base, and be welded on floor, but no welding must be made between parallels and base.No.ContentInspection itemTechnical requirementsMain points in worksTest device4.3Installation of C5 cycloneDeviation of center position from design positione13mmKiln sideSteel tapeTransitPlumb linee23mmCalciner outlet end plane and C5 inlet plane center deviatione33mm4.4Installation of C4 cyclone and its connection ductDeviation of center position of cyclone and its connection ducte13mmDuctKiln sideSteel tapeTransitPlumb linee23mme33mme43mmDeviation of duct outlet end plane from cyclone inlet plane centere53mm4.5Installation of C3 cyclone and its connection ductDeviation of center position of cyclone and its connection ducte13mmDuctKiln sideSteel tapeTransitPlumb linee23mme33mme43mmDeviation of duct outlet end plane from cyclone inlet plane centere53mm4.6Installation of C2 cyclone and its connection ductDeviation of center position of cyclone and its connection ducte13mmDuctKiln sideSteel tapeTransitPlumb linee23mme33mme43mmDeviation of duct outlet end plane from cyclone inlet plane centere53mmNo.ContentInspection itemTechnical requirementsMain points in worksTest device4.7Installation of C1 cyclone and its connection ductDeviation of center position of cyclone and its connection ducte13mmDuct Kiln sideSteel tapeTransitPlumb linee23mme33mme43mmDeviation of duct outlet end plane from cyclone inlet plane centere53mm4.8Installation of cyclone and its connection ductCyclone installation verticality1mm/mCyclone Loading steel beamConnection ductCyclone centerlineCyclone centerlineDuct centerlineUpper level cycloneSteel tapeTransitLevelPlumb lineConnection duct installation verticality1mm/mCyclone and duct coaxiality deviations25mmCyclone top elevationh10mmCyclone top horizontality0.5mm/m5. Installation of expansion joints, valves and feed system:No.ContentInspection itemTechnical requirementsMain points in worksTest device5.1Installation of expansion joints and valves1. Before installation, carefully verify the air and material flow direction to prevent reversed installation.2. The spacing of upper and lower flange planes of expansion joints shall conform to the design dimensions (if not, adjust it with bolts on them), and it is not allowed to adjust with screws the deviation resulted from installation. It shall be removed after completion of installation.3. Flap gates and dust removal valves shall be checked and adjusted before installation, and can be installed only when they are flexible and reliable. The weld seams must be air tight. The concrete opening covers on equipment must be welded on shell after the masonry has dried.5.2Installation of feed system1. The feed system can be installed only after completion of installation and alignment of corresponding ducts and cyclones, and the connection locations can be adjusted as appropriate according to site conditions.2. Before installing the feed pipe, it shall be assembled and lined in advance. The assembling and welding must be done after the cast material has thoroughly dried. Care shall be taken not to damage the lining during handling and installation.3. Fiber wool resisting high temperature shall be filled in the gap of cast material between feed pipe sections.Equipment Installation Inspection RecordCBMIJXYRQ001Sub-projectTail of kilnJob No.EquipmentFeed chamberWork itemInstallation of preheaterInspection typeJoint inspectionTest dateNo.Inspection itemPermissible deviationActual deviation1Gap between flue chamber and kiln tail8mmB10mm2Coaxiality of feed chamber outlet plane centreline and kiln centreline2mm/m3Parallelism of feed chamber outlet plane and kiln end plane1mm/m4Feed chamber center elevationmmIllustration and remarksRoller ringLive ringHot pointShellFlue chamberContractor:Date Supervisor (Owner site representative):Date: Equipment Installation Inspection RecordCBMIJXYRQ002Sub-projectTail of kilnJob No.EquipmentCalcinerWork itemInstallation of preheaterInspection typeJoint inspectionTest dateNo.Inspection itemPermissible deviationActual deviation1Deviation of calciner center position from design position on drawinge13mm2e23mm3Deviation in calciner assembling and installation verticalitye15mm4e25mm