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

Material
Material required
General Drawing V Anchors for kiln outlet Omega anchors for kiln outlet V Anchors for kiln outlet (deformed area) Omega Anchors for kiln outlet (Deformed area) V Anchors for NR Omega anchors for NR Plastic caps

Provider
Shift Team Leader Shift Team Leader Shift Team Leader Shift Team Leader Shift Team Leader Shift Team Leader Shift Team Leader Shift Team Leader

Comments
Validated drawing with CTC 216 Pieces, SS-310 216 Pieces, boiler steel H1 / A 42 Cp 324 Pieces, SS-310 Sheet 324 Pieces, , boiler steel H1 / A 42 Cp 360 Pieces, SS-310 Sheet 360 Pieces, SS-310 Sheet 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 Dry joint Concrete Water container Vibrator Mixer All Material Selection

Shift Team Leader Contractor Shift Team Leader Contractor Contractor Contractor CTC Validated

Nefalit 3 mm thickness Plywood with thickness 3 mm maximum For NR REFRAMULLITE 63 AR LCC For kiln outlet section& deforemd shell is GIBRAM SR Scaled container 40 to 50 mm Vertical Type of Castable and Anchors
Date 4

Procedure and Quality Control

Procedure
Used Dry welding electrodes Proper shell grinding on OMEGA positions Marking OMEGA ANCHORING Welding OMEGA OMEGA Control V Double Tack Welding V Double Tack Welding Control Water measurement Mixing water Temperature Mixing CASTING Ball test after mixing before casting Vibrating

Implementation
Certified welder Contractor mason Kiln Tech. Certified welder Kiln & Kiln Hood + TAD Supervisor Certified welder Kiln & Kiln Hood + TAD Supervisor Contractor mason Contractor mason Contractor mason Kiln Tech Contractor mason

Quality Control Approver

Kiln Tech. Kiln Tech. Kiln & Kiln Hood + TAD Supervisor Kiln Tech. Shift coordinator Kiln Tech Shift coordinator Kiln Tech Kiln Tech Kiln & Kiln Hood + TAD Supervisor Kiln & Kiln Hood + TAD Supervisor Kiln Tech Kiln & Kiln Hood + TAD Supervisor Shift Team Leader Kiln Coach/ Shift Team Leader

Comments
We dried welding electrode in oven at recommended Temp. We Grinded Shell properly on OMEGA Positions Followed Lafarge Standard Continous welding Visual and Pictures + hammering each OMEGA Regular inpection by our Refractory Team Visual and Pictures compare position/LPCL Drawing for Anchors 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) More than one day Followed Lafarge Standard Preheating / Drying Curves Date 5

Joint installation

Kiln Tech

Curing time CURING TIME Preheating/Drying Curve

Shift coordinator CRO

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 = 10 mm

V ANCHOR STEEL ASI 310 = 8 mm