SAW - kiln

Date 02-16-2010 18:11

zambrota,
your company has bought a cement kiln that cost a lot of money. Didn't the kiln manufacturer supply the assemblying and erecting instructions? If not, you should demand them, it's their obbligation to furnish them.
Quite often, however, equipment manufacturers don't supply erection instructions, or the ones they supply are quite vague, so the purchaser is compulsed to buy the services of their field engineer, which are not cheap, by the way.
Dear zambrota, in my opinion, the instructions you're asking for are complex and too long to explain, and fall beyond the purpose of this Forum. My advice is that your company calls in the manufacturer's field engineer or appoints a welding consultant.
Do you Gentlemen who are frequentors of this Forum think the same way?
Giovanni S. Crisi
Sao Paulo - Brazil

By js55

Date 02-16-2010 22:27

Giovanni,
I sure ain't no kiln guy. But in my assessment the fit up, welding, and rolling per se are not the problem (assuming you can move this monster with relative ease). This is not unlike some big pressure vessels we've done. Dogging for ovality, bed rollers for welding, and a double bevel to reduce welding time and weld material consumption seem pretty basic here.
You can run SAW tracking for the ID and syncronize your "can" roll with your travel speed. Use a closed butt and backgouge. Then run a standard manipulator boom with SAW on the OD.
The problem to me is how long is this thing and keeping it all in square through its length.
I am not disagreeing with you however. Not at all. It seems that some professional help is certainly called for here.

By zambrota (**)

Date 02-17-2010 08:55

Thanks js55,

FYI

Kiln material is ASTM A36, five sections, 20m long each, i.e. 100m total length

By ssbn727 (*****)

Date 02-17-2010 01:37

What you're describing sounds very much in my mind like a submarine missile tube!!! :) :) :)

What grade material???

If you're not sure how to approach this job, then get in touch with these folks especially if you're using their SAW equipment:

http://www.lincolnelectric.com/knowledge/custsolutions/weldtech.asp

Want to read some of their success stories with SAW??? Here you go:

http://www.lincolnelectric.com/knowledge/articles/content/gulfmarine.asp

http://www.lincolnelectric.com/knowledge/articles/content/jered.asp

http://www.lincolnelectric.com/knowledge/articles/content/bergsteel.asp

http://www.lincolnelectric.com/knowledge/articles/content/ward-tank-submerged-arc.asp

http://www.lincolnelectric.com/knowledge/articles/content/horsburgh-scott-submerged-arc.asp

http://www.lincolnelectric.com/knowledge/articles/content/fike-submerged-arc.asp

I would seriously call these folks especially if you already have their equipment to weld this job you're talking about... If you don't have Lincoln equipment, then why don't you get in touch with the SAW Equipment Mgfr. and ask them for some technical assistance??? And if they will not provide you with help,
well then I believe it's quite obvious what to do - don't you??? ;) ;) ;) BTW, do you have any of the Lincoln educational books??? The Procedure Handbook of Arc Welding should be a valuable resource for this application as well as some of the other books they offer in the James F. Lincoln Foundation webpage:

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=PH

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=DWS

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=TS

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=DW

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=D810.17

https://ssl.lincolnelectric.com/lincoln/apdirect/item.asp?prodnum=D417

Call them... Pick their brains!!! :)

Respectfully,
Henry

By zambrota (**)

Date 02-17-2010 08:53

Thanks Henry,

FYI

Kiln material is ASTM A36, five sections, 20m long each, i.e. 100m total length

By ssbn727 (*****)

Date 02-17-2010 14:16 Edited 02-17-2010 15:19

Call these folks and ask them what they know and if you can get them to talk, then it's a match made in - well you know what I mean!!! :) :) :)

http://www.industrialkiln.com/index.php

These folks are pretty good also:

http://www.rodewelding.com/steel-fabrication/rotary-kilns.asp

These folks are no slouches either:

http://www.milwaukeeboiler.com/portal.htm

Here's a General maintenance agreement from Rotary Kiln and Dryer metal of America:

http://www.rotaryservicecompany.com/Web%20General%20Maintenance%20Agreement%20_2_%20_2_.pdf

Here's a forum where you can ask specific questions:

http://www.bulk-online.com/Forum/showthread.php?t=13652

You can also contact these folks also:

http://www.a-cequipment.com/company/default.asp

These folks do UT and specialize in rotary type equipments such as Rotary Kilns, etc.:

http://www.ultroninc.com/utrotary.htm

Then of course, these folks do some intersting work also:

http://216.216.92.11/profile/default.cfm?content=10000003

Here's an interesting article:

http://cementamericas.com/mag/cement_new_techniques_kiln/

These folks do some excellent (nice plug for you Chet!!! :) :) :) ) work and are world class manufacturers and installers of these systems:

http://www.cianbro.com/CurrentProjects/PastHighProfileProjects/LehighPortlandCementPlantModernization/tabid/344/Default.aspx

These folks are also World class also:

http://www.metsodrives.com/miningandconstruction/mm_pyro.nsf/WebWID/WTB-041117-2256F-9708E?OpenDocument&mid=422120DE1F259295C22575BC003FCEFD

I'd pick their brains a bit if I could get them to talk:

http://www.feeco.com/ProductsandServices/ProductLine/ThermalProcessing/tabid/86/RotaryKilns.aspx?gclid=CInG29nF-Z8CFUVn5Qodr28ZVw

These folks also:

http://www.louisvilledryer.com/?gclid=CMuL4aLG-Z8CFZdM5Qodp09EVw

Finally, I would get in touch with these folks who recently acquired A C equipment out of Milwaukee, and are affiliated with ThyssenKrup:

http://www.polysius.com/fileadmin/user_upload/prospekte/Prospekte_ab_2008/Service_2008/1611_gb_Service.pdf

Oh! I almost forgot to mention the Prestigious Charles Brown Company:

http://www.charlesbrowncompany.com/

And these folks:

http://www.aasteelfab.com/fabrication.php

Well there you have it Zambrota... I believe out of all these contacts ,at the very least you should find one or two who will assist you in answering most, if not all of your questions regarding the welding and fabrication of Rotary Kilns and Dryers based on the amount of experience they have so long as you ask very, very nicely and demand absolutely nothing - CAPECHE??? ;) ;) ;)

Respectfully,
Henry