POSITIONING OF NEW SHELL,ALIGNMENT & WELDING.

1: Arrest the new kiln shell assembly with wire rope slings & shackles securely hooked on the mobile
crane, ready for lifting. Ensure that the shell to be lifted have slope same that of the kiln.
2: Slowly Lift & Position the new kiln shell at the extreme discharge end.
3: Slowly & precisely, lower down the new kiln shell assembly to rest & aligned on the existing kiln
shell. The boom should be steady.
4: Install a series of axial, radial alignment fixtures inside the old kiln shell. They should be welded
uniformly around the inside part of the old & new kiln shell and are spaced uniformly through out
the circumference and are as shown in fig.1

Fig.1

Fig.2

5: On alignment, check the offset at the joint there may be some trimming required for a good fit up.
When positioned, the joint for welding should be with a 3mm root face bull nose to both parts.
Ensure that we have 3 mm gap between the shells at joint at the time of alignment for proper
penetration of the weld.
6: Weld the draw bolt brackets to the new kiln shell section. Insert 30mm fully threaded draw bolts
across the joint & attach four (4) hexagonal nuts per bolt, (2pcs outside & 2 pcs inside) this is to
create a push & pull mechanism. 12 push & pull mechanisms need to be provided along the
circumference.
Push Pull Mechanism
(Axial Alignment Fixture)

Fig. 3
7: Weld in place a series of approx. 20 screw blocks to the new kiln shell section so that they cross the
joint. These will be used to adjust & align both cylinders Fig

Fig. 4

Page 1

8: Manually rotate the kiln in order to conduct a true alignment check. Take runout readings at 12 points
around the circumference.
9: If the test proves unsatisfactory, the strong backs are released by gouging and the draw bolts are
adjusted where necessary. Strong backs then re-welded and a further alignment check is
conducted until the kiln measures a true alignment. Fig.
Fig. Check alignment and completely weld along one side, a series of approx. 15 strong backs across the
joint.

Fig.5
10: Prior to welding, PRE-HEAT IS CRITICAL. The correct pre-heat temperature has been calculated
and is as per attached Annex A.
Pre-heat of 120C to a distance of 150mm from each side of the joint. A thermal crayon
(preferably a pyrometer) Fig., should be used to monitor the temperature and ensure that this
temperature of 120c is maintained throughout the welding process. Re-heat as necessary.

Fig. 6

NOTE: The welding electrodes should be heated for four (4) hours in a suitable baking oven.
11: Commence welding from the outside of the kiln, Annexure-D showing two (2) welders at 3 O
clock & 9 Oclock position. Working continuously around the clock. Deposit fully a single root
pass weld using 3.2mm electrodes. De-slag thoroughly using an air chisel. Inspect the weld
and if require grind out & re-weld. For welding positions need to be taken during welding are as
per Annexure-B.

Page 2

Fig. 7
12: Welding should carried out in the form multilayer but not in the form of weaving in order to reduce
the stresses and to control the runout.
13: Once the final run from out side is in progress remove the axial, radial alignment fixtures and
Start gouging from inside. Using proper size carbon electrodes & the air arc gouging process,
Conduct an internal root preparation by back gouging, so that the root weld is removed
Completely. Grind the back gouged area so that smooth finish will be achieved. Back gouging
process is as shown in Fig.

Page 3

Fig 8

14: Ensure that the pre-heat is maintained & deposit an internal root weld, using 3.2mm electrodes.
Complete hot pass & cap with 4.0mm electrodes. Inspect & Grind completely the welding to
avoid any slag and undercuts, which can have the effect of multiplying the stress.

Fig. 9

15: Weld joint should be tested for 100% radiograph / UT upon completion. Gouge & re-weld any
defects.
16: Check the Final Run out Readings.
17: While carrying out the final run of Welding from outside ,assemble the Nose ring blocks (Tip
Casting) and carry out beveling of Hood Edges at the cut location.
18: Assemble the Hood and Weld it.
19: Erect the outlet end seal and position the cooling air duct.

Page 4

Annexure A:

Pre Heating Requirement

Page 5

Annexure- B:
Pre-Heating Requirement (p.2)

Page 6

Annexure D : PREFERABLE KILN SHELL WELDING SEQUENCE.

Annex - D.--PREFERABLE KILN SHELL WELDING SEQUENCE.

O

O
O

90

90

225

180

135

225

180

270

270

45

A.1) Root Run from Outside.

A.3) Root Run from Outside.

A.4) Root Run from Outside.

315

135

45

225

225

225

45

135

45

315

45

A.2) Root Run from Outside.

90

180

Continuation of Outside Welding.

O

315

315

135

B.1) Continuation of Outside Welding.B.2) Continuation of Outside Welding.B.3) Continuation of Outside Welding.
O

315

45

45

225

225

135

315

C.1)

135

C.2)

During the Final Run of Outside Welding start Inside Welding.

Page 7