2012 04 09 Quy Trinh Lap Dat Day Chuyen 5000t Cua HCRDI

CNBM FULEI(SHANGHAI)CONSTRUCTION CO.
,LTD Vie 5000t/d clinker & cement production line
Vietnam
5000T/D Clinker & cement production line
Installation Scheme
Edit CompanyCNBM FULEI (SHANGHAI) CONSTRUCTION

CO.,LTD
Edit Date2012-4-7
CNBM FULEI(SHANGHAI)CONSTRUCTION CO.,LTD Vie 5000t/d clinker & cement production line
6.1 Main program construction Instruction

6.1.1 Rotary Kiln Installation Program
6.1.1.1 Overview
A rotary kiln is the most critical equipment in the manufacture process of a cement factory.
The high thermal load and continuous production system demand a strict installation quality,
which will determine the normal operation of the production process line of the factory as a
whole. Therefore, advanced construction methods and testing measures must be adopted during
construction to strictly control the quality of every working procedure. In the course of
construction, we shall strictly confirm to the design drawings and the national technical standards
and specifications concerned. The key and hidden works will not be initiated unless confirmation
and joint endorsement are made by the owners or their designated experts on the site. Any
unqualified work shall not be passed to the next procedure.
6.1.1.2 Main Parts of Rotary Kiln
A rotary kiln is made up of the brace device, cylinder, transmission device, hydraulic thrust
roller, kiln rear seal device, kiln head seal shield and lubricant hydraulic system, etc.
6.1.1.3 Specification and Performance of Rotary Kiln
Specification Production capacity 5000t/d
Brace points Pitch 4%
Transmission Main motor power
mode
Weight Rotation speed 0.4~4.0r/min
6.1.1.4 Flow chart of rotary kiln construction (See Diagram 1) and installation network plan (See Diagram 2 )
Diagram 1 Flow Chart of Rotary Kiln Construction
Foundation part Foundation acceptance Foundation marking off Benchmark plate pre-burying Sand pile making Blocking iron fixing
Bush scratching and Pedestal alignment and Foundatio Pedestal fine Jockey pulley group
Brace part Ex-storage check pressure test placing n grouting alignment alignment
Rotation part Equipment ex-storage Dimension check Cylinder butt Cylinder Belt Cylinder group Cylinder
board welding hoisting assembl alignment welding
y
Transmission Equipment Girth gear pre- Girth gear Swaying value Transmission device Initial alignment Transmission
part ex-storage installation placing measurement installation & grouting fine alignment
Kiln rear seal shield Lubrication/hydraulic system Other parts installation

Other part Kiln head seal shield installation
installation installation
Commissioning
Diagram 2 Rotary kiln installation network plan

Week 1 Week2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12
Comstruction preparation
Foundation
acceptance,marking
off,Mortar pilemaking
Network Diagram
Equipment Jockey pulley
out-of- pedestal
storage- installation
checkup
Jockey
Jockey pulley
pulleys
bush
alignment and
scratching
imstallation
Cylinder
Girth gear Transmission
hoisting and
pre-assembly alignment imstallation
Kiln welding Transmissions

preparation Kiln welding alignment
Lubrication/
hydraulic Sealing
systen shield device
installation installation commissioning
6.1.1.4.1 Construction Preparation

6.1.1.4.1.1 Organize the construction staff and make them familiar with the technical
documents, such as the drawings and installation specifications etc., and conduct the
technical disclosure.
6.1.1.4.1.2 Know the delivery of the equipment and the storage spot.
6.1.1.4.1.3 Prepare the construction machine & tools and materials. Switch on the
power supply.
6.1.1.4.1.4 Check the specification, size, number and quality of the equipments
according to the delivery list.
A. Check the pedestal to see whether there is distortion; Measure the clearance
between screw holes on the pedestal and the size of the pedestal.
Every group of the jockey pulley, bush and bearing block shall be checked as a whole.
Pay much more attention to the diameter of the jockey pulley and the centre height of the
bearings.
B. Check the size of belt (belting roller) and the kiln where the belt is fixed. Note that
the inside diameter of the belt and the pad diameter of the cylinder must reserve the value
of the thermal expansion of the cylinder.
C. Check the cylinder; measure the actual length of every cylinder, the center
clearance between the two belts, and the total length of the cylinder. Use these dimensions
to make foundation paying off, and it is better to carry out the measurement when the sun
shines not directly or in the morning. Note that the measurement shall be made under 1kg/m
pulling force of the tape ruler. Measure the ovality of the cylinder; check whether there are
U signs.
D. Check the teeth space of the girth gear (especially the teeth space at the interface of
the two semicircles), the diameter of the addendum circle and the deviation at the interface
of the girth gear.
Note: When checking the equipment, attention must be paid on the temperature. It is
recommended not to change the staff and measuring devices during the whole process of
construction.
6.1.1.4.2 Foundation Acceptance and Marking off
Foundation acceptance is one of the major procedures in the equipment installation. The
acceptance task shall be performed jointly by the staff both from the civil engineering
party and the factory before the equipment is assembled. Acceptance records should be
made.
The dimension of the foundation, the centre line, elevation, the relative position and
dimension of foundation bolt holes shall be in accordance with the construction drawings
and acceptance specification. See the allowable deviation in the following table.
Parts for Checking Allowable Parts for Checking Allowable
Deviation Deviation
Foundation Size 30mm Central Position of 10mm
Foundation Bolt Holes
Parts for Checking Allowable Parts for Checking Allowable

Deviation Deviation
Benchmark Elevation Vs. Factory Foundation Bolt Holes 20mm
Zero Elevation Depth 0mm
Space between Center Lines
Foundation elevation Foundation Bolt Holes 5/1000
Perpendicularity
Bury the cross and longitudinal center benchmark plates and set one benchmark elevation on
every foundation. Draw the cross and longitudinal center line of the rotary kiln according to the
belt transmission concrete foundation. The deviation of the space between two adjacent kiln piers
in the cross direction shall not exceed 1.5mm, whereas the one of two kiln piers which are
jointed fore and aft shall not overrun 6mm.
Note: The space in cross direction shall consist of the measured dimension of the cylinder and the
expansion value.
Draw the cross and longitudinal center lines of the transmissions according to the accurately
adjusted kiln center line. Check the sedimentation of the foundation regularly.
It is recommended to bury the benchmark plate 1000mm under the earth on both sides of
the foundation. The measurement shall be carried out by designated staff regularly with fixed
equipments, the original records of which should be made.
6.1.1.4.3 Blocking Iron Placing & Installation of Steel Pedestal and Jockey Pulley
A. Lay the blocking iron according to the structure of the steel pedestal and the location of
foundation bolts. The foundation should be roughened and made holes, and cleaned. The surface
of the flat steel blocking iron must be smooth, with no burrs or unevenness. Remove the rust and
clean it before the installation.
B Mortar Pier Making
In order to improve the alignment accuracy of the equipment installation, mortar pier
blocking iron method is adopted.
When making the mortar piers, roughen the foundation and flush it with water.
Mortar pier mixing ratio: 525 cement: River sand (medium grain): water = 1: 1: appropriate
amount
Mortar pier alignment: employ the pitch gauge (same with the kiln cylinder pitch), gradienter
and surveyors level for the alignment. The levelness shall be no more than 0.2mm/m, whereas the
elevation deviation no more than mm.
Water the mortar piers and cure it. The steel pedestal can be installed only when the strength of
the mortar pier exceed 75%.
C. Steel pedestal installation: Before the installation, the steel pedestal must be cleaned, while the
cross and longitudinal center lines shall be marked off. Pay attention to the location of the steel
pedestal with thrust roller. Draw the cross and longitudinal center lines of the jockey pulley bush
base according to the lines of the steel pedestal and mark the punching place. The installation
sequence is from the steel pedestal on the belt transmission foundation to the direction of the kiln
head. See the allowable deviation of alignment and inspection tools in the following table.
Inspection Items Allowable Inspection Allowable

Deviation Items Deviation
Cross and longitudinal center line
Elevation
Cross levelness and longitudinal
inclination
D Second fine alignment: After the anchor bolt hole grouting is cure to reach the design
requirement, the foundation bolt can be tightened for fine alignment, with the same allowable
deviation above. If there is no problem in the recheck, joint inspection and confirmation shall be
conducted.
E Jockey pulley group installation:
Preparation before installation: clean the bush base, mark the cross and longitudinal center
lines and make the sample punching marks.
Hydraulic test of spherical bush: test pressure is 0.6Mpa, and the pressure retention is eight
minutes.
Jockey pulley bush scratching and grinding: the number of the contacting points between
the axis and the bush shall be no less than 1 2/cm 2 , while the side clearance between the
bush and the axis neck is between 0.001 and 0.0015D (D is the diameter of the axis). The
clearance out of the contacting angle should be increased regularly, and the variation of the
clearance shall be measured under four conditions. The contacting angle should be in
accordance with the drawings.
The contacting points of the spherical bush and bearing shall no less than 1 2/2525mm. The
circular area with a margin about 50mm can allow a clearance around 0.1mm.
The contacting points between the bush back and the spherical bush shall be no less than
3/2525mm.
After the assembly of the jockey pulley group, the sum of the clearance between the thrust
rings on both sides and the bush shall meet the requirements of the drawings. In addition, the
total clearance shall be reserved in the bearing of material outlet.
The installation sequence of the jockey pulley group is the same with the steel pedestal.
Make sure the surfaces of the bush base and steel pedestal are clean when hoisting.
Jockey pulley group alignment: when hoisting the jockey pulley group, the cross and
longitudinal center line of the bush base should be aligned with the one of the steel
pedestal. Tighten the connection bolts. Align against the 3 brace(the one on the belt
transmission foundation) as the benchmark.
Note: Before hoisting 3 brace, make sure that the thrust roller is cleaned and can rotate
smoothly. Fill certain amount of lubricant.
See the allowable deviation of the alignment and inspection tools in the following table.
Inspection Item Allowable Inspection Item Allowable
Deviation Deviation
Jockey pulley pitch Cross span of two adjacent jockey
pulley groups
Top face levelness of two Superposition degree of two jockey
Inspection Item Allowable Inspection Item Allowable

Deviation Deviation
jockey pulleys within same pulleys cross center line within same
group group
Top face center elevation of two parallel degree of two jockey pulley
adjacent jockey pulleys longitudinal center line
Cross span of two adjacent Superposition degree of two jockey
jockey pulley groups pulley cross center line within same
group
Parallelism of two jockey
pulley longitudinal center line
6.1.1.4.4 Kiln Cylinder Hoisting and Alignment
6.1.1.4.4.1 Preparation Work before Hoisting Kiln Cylinder
Check the cylinder and belt and make sure no burr, rust or filth can be found on the head
face of the cylinder, the belt and the underlying plate of the belt.
Check the ovality of the cylinder with special tools. Its roundness should be no less than 0.002D (D is
the cylinder diameter). The cylinder under belt and girth gear should not be larger than 0.0015D.
Measure the perimeter out of the head face of the cylinder with steel type ruler and put down
the records. The perimeter difference between two connected cylinders shall be within
0.002D and no larger than 7mm.
Check the cylinder to see if there are U signs.
Prepare the cylinder group connection fixture, and place them along the inner circle of the
cylinder which is equally divided into eight parts. Note that two adjacent cylinders should
stagger along the longitudinal weld. The staggering angle shall be no less than 45.
Check the inside diameter of the belt and the diameter of the pad plate at the belt of the
cylinder to see whether the clearance meet the requirements of the drawings.
The inner circle of the cylinder shall be equally divided into 12 or 16 parts. Find out the
center of the cylinder with a drawing gauge and fix a valve on the center.
Draw the center line for belt on the cylinder according to the measured data of each
cylinder. The space deviation between the center lines of two belts should not exceed
5mm, while the one between the head belt and the rear belt should not be larger than
10mm.
Preparation of the hoisting site: the streets in the construction site must be unobstructed,
whereas the roadbed should be flat and solid so as to make the crane arrive at the kiln pier
successfully. The kiln pier ground shall also be flat and solid, the elevation of which must
meet the requirements. The ground shall be covered with thick steel plate, preparing for the
ground coupling and hoisting of the kiln.
Prepare the tools before hoisting the cylinder. Check the hoisting equipments and riggings
to make sure they are safe and reliable.
6.1.1.4.4.2 Cylinder Hoisting and Alignment
A. Cylinder hoisting & installation sequence
The kiln cylinder shall be moved to the construction site in seven sections. The serial
number is: from the kiln head: D1 D2 D3 D4 D5 D6 D7 D8 and D9. See the
theoretical length and weight, as well as measured length in the table below.
Serial No. Theoretical Weight (t) Theoretical Length (mm) Measured Length (mm)
D1
D2
D3
D4
D5
D6
D7
D8
D9
After the preparation for the hoisting, according to the cylinder weight and the hoisting
capacity of the crane, decide whether to fix belts on the ground and the reasonable hoisting
sequence of the cylinder, so as to reduce the load of butting work of cylinder in the air.
Generally the hoisting sequence is D8 D7 D6 D5 D4 D3 D1 and D2. However,
other sequences should be also considered according to the condition on site.
Use the 150t crane for the hoisting and placing of each cylinder. Adjust the butt joint with
pull bolts and press plates.
B. Cylinder Alignment
Kiln cylinder center positioning: Equally divide the inner perimeter of the cylinder (a non-
machining workpiece), into 12 parts. Find out the center of the 3 circles respectively with
point 1, 4, 7 and 10, point 2, 5, 8 and 11; point 3, 6, 9 and 12. Then the center of the
geometric figure formed by these three centers is the center of the kiln. Stick the coordinate
paper on the center and find the center of the outer circle in the same way.
The 2 vertical welds of the butt joint shall stagger, and the butt joint staggering of the kiln
cylinder shall be no more than 2mm.
Cylinder Axis Alignment
Align with laser theodolite, the radial jitters of the center shall be no more than the data as
follows:
5mm at the material inlet and outlet; 4mm at the girth gear and the belt; 8mm at the butt joint
of the kiln.
6.1.1.4.5 Cylinder Welding
Cylinder welding is one of the main procedures in the kiln installation. The quality of the
welding counts directly to the normal operation and service life span of the kiln. Much
importance must be attached to the welding so as to guarantee the construction quality.
6.1.1.4.5.1 Preparation before Welding
The welder should first undergo tests. Only when he passes the sample dialysis, bending
and tensile strength tests and turn out to be qualified can he go to the post.
Clear away all the paints, rust, burr or other filth in an area 40mm around the welding
groove. The welding shall not begin until the luster of the parent metal appears. The
welding rod must be dried and the temperature kept.
Check the angle, depth and clearance of the weld groove process comprehensively. Adjust
those grooves if the deviation of the relative angle is comparatively large, or the clearance is
too large (or too small), or the depth is not enough, and make records. Adopt corresponding
measures so as to ensure the welding equality.
Check each part of the kiln and clear all the factors that may affect the rotation of the kiln.
Recheck the radial jitter of each welding spot, the kiln head and the end.
6.1.1.4.5.2 Local Spot Welding Beforehand
The circle shall be equally divided into eight parts and spot welded. The length of the spot
welding is 150200mm, while the height is 56mm.
The sequence of the spot welding is 180from up to down respectively.
6.1.1.4.5.3 Cylinder Welding
Arrange the procedure for every trial welding according to the cylinder alignment.
The welding shall begin at the weld close to the bull gear so as to reduce the direct impact
of welding distortion on transmission accuracy.
After the welding of the outer weld bond, re-check the radial jitter of the above parts and
compare with the one before welding. Clear away the inner brace and then repeat the work
above. After the welding, measure each point again and keep all the measure data of every
procedure.
Welding method: adopt direct current welding machine, manual electric arc welding
machine for rendering and automatic welding machine for welding.
Weld quality check: The ultrasonic defect detection shall reach Class II in JB1152. Doubtful points
which are discovered in ultrasonic defect detection must be checked by X-ray detection, which shall
reach Class III in GB3323
6.1.1.4.6 Transmission device installation and alignment
6.1.1.4.6.1 Bull gear installation & alignment
Before the installation, clean the tooth face, semicircular gear engagement surface and the
linking hole of the gear teeth and spring plate. No oil filth or sundries should be left.
Pre-assembly the interface of the bull gear on the ground and check its tooth form,
addendum circle, nodal circle and tooth face; check the clearance at the engagement surface.
Mark the location of the bull gear on the cylinder and rubdown the weld at spring plate so as
to ensure the close engagement of the cylinder and the spring plate.
Fix the spring plate on the girth gear on the ground. Pay attention to the rotating direction;
hoist to the right place with a crane.
Place the special tools for bull gear installation on the bull gear, equally occupying four
points of the gear. Weld the arm of the brace onto the cylinder. Conduct the bull gear initial
alignment, and rotate the kiln and measure:
Allowable deviation of bull gear radial jitter: 1.5mm
Allowable deviation of bull gear ends jitter: 1.0mm
If the result of the check meets all the requirements, press the spring plate and weld. The
spring plate must be closely engaged with the cylinder. The welding must follow certain
sequence. After the welding, please recheck the radial jitter and the end jitter of the bull
gear.
6.1.1.4.6.2 Installation & alignment of pinion and speed reducer
When installing the pinion, please consider the expansion of the bull gear according to the
design, and measure the inclination.
Adjust and measure the clearance of the addendum circles of both bull gear and pinion. The
clearance can be recorded by 0.25M+(23)mm (M is gear modulus).
The engagement surface of the gear teeth face shall not be less than 50% along the tooth
length, and no less than 40% along the tooth height.
The pinion connects with the low speed shaft of the speed reducer, while the reducer with
the major motor. The deviation in axiality shall not be larger than 0.2mm.
Auxiliary transmission installation and alignment
Gear shield installation
6.1.1.4.7 Installation of lubrication & hydraulic system and cooling water pipe
6.1.1.4.8 Installation of Kiln Rear Seal Device and Kiln Head Seal Shield
6.1.1.4.9 Test Run
After the accomplishment of every procedure of rotary kiln installation, the no-load test run of single
machine can begin. The brick laying of the cylinder can only be started after the qualified operation.
Single machine operation time:
Main motor: 2 hours; Main reducer: 4 hours; Kiln: 8 hours test run records
Note: The temperature of jockey pulley bearing bush should not exceed 65 , while the
transmission bearing bush and reducer shaft should be no more than 70 . The length of
the engagement surface of the belt and the jockey pulley shall be no less than 75% of the
belt width.
Inspection: the engagement of the hydraulic thrust roller with the belt; the lubricant supply
in each point, oil pressure, the supply of cooling water, the seal of every part, oil leakage,
equipment vibration and noise and looseness of the joints.
6.1.1.5 Safety Precautions
All those who enter the construction site should abide the Safety Regulations issued by
our company. New staff shall receive the III class safety education. They shall be informed
of both technical and safety details.
Hoisting device must be in the charge of a specially assigned person; before the hoisting,
meeting about work safety shall be held.
Measure and calculate strictly the weight of the articles for hoisting. Select the hoisting
place and avoid crane overloading.
Make sure there must be trial hoisting before the formal one. When hoisting weight, no
person shall be under it. Warning line shall also be set.
All the steel wire buckles shall be fastened; the steel wire string and the buckle must meet
all the requirements.
When cleaning the equipment, smoking is forbidden. Dont litter the rinsing oil.
The voltage of illuminating bulb in the kiln should not exceed 36v.
6.2 construction proposal of kiln inlet frame and pre-heater

6.2.1 over-view
n the cement production technical process adopting new drying method and resolving outside the kiln, the
kiln rear frame and pre-heater are the key equipment in the whole production process, and this equipment
mainly makes use of the residual heat to dry, preheat and resolve the raw materials so as to make the
production capacity of the kiln increase by times and decrease the energy consumption. The construction
cycle lasts long, with great difficulty. Therefore, how to ensure the installation cycle and quality of the kiln
rear frame and pre-heater become the key points of installation.
6.2.2 The relevant parameters of the kiln rear frame and pre-heater are as follows:
Frame form: Steel pipe concrete column
Layers of frame: Six layers (steel structure)
Weight of pre-heater: About 600 tons
Pre-heater form: Double series five class cyclone pre-heater with decomposition furnace
6.2.3 Construction organization structure
Project manager department
Other logistic departments Manufacturing technical department Quality inspection department
Kiln rear machine Kiln rear furnace building

Kiln rear electrical section installation section section
Rivet driver Rivet driver Lifting Welder Scaffold Locksmit

group one group two group group group h group
6.2.4 Technical specification

6.2.4.1 The deviation between the column center and steel pedestal is5mm;
6.2.4.2 The allowable deviation between the elevation of the column top surface and the designed elevation
is -20~20mm;
6.2.4.3The roughness of the column top surface is 5mm;
6.2.4.4 The distance deviation between columns shall not be more than1/1000 of the spacing and the whole
length shall not be longer than 10mm;
6.2.4.5 The deviation of the column verticality shall not be more than 1/1000 and the total height shall not
be higher than 20mm;
6.2.4.6 The deviation in the corresponding diagonal of the upper and lower column shall not be more than
1/1000 and the total length shall not be longer than 20mm;
6.2.4.7 The deviation of the plane diagonal shall not be more than 3mm.
6.2.5 Construction Preparation

6.2.5.1 Site Preparation: According to the site situation of the kiln rear area, the following working areas are
designed:
6.2.5.2 Machine/tool Preparation
Crane: two 36B type automatic elevating tower crane;
One 25ton truck crane
One 50ton truck crane
Transporting vehicle: One 30T platform truck
20 AC welding machine, 4 DC welding machine , 3 sets of CO2, 12 air cutting machines, 2 overhead
cranes, 1 cable lift, 20 manual pull hoists in different specifications
Main road
Grouping platform site
B
yp
Kiln rear frame as
s
ai
Tower r
crane ex
ha
us
t
sy
st
e
m
Rotary
kiln
main road
6.2.5.3 Human resource deployment

Engineer: 1 Tehcnician:5
Welder: 36 Locksmith: 12 Rivet driver: 23
Electrician: 2 Lifting worker: 3 Full time safety personnel: 1
6.2.6 Construction Procedure

6.2.6.1 Drawing and Instruction
6.2.6.1.1 Organize the construction personnel to familiarize the technical data, such as the drawings and
installation instruction, and properly make the work of technical disclosure.
6.2.6.2 Equipment Unpacking and Ex-storage Inspection
.6.2.1 According to the drawing and packing list, check the specification and quantity of the spare parts,
carefully verify the spare parts with same structure and different materials and make sure their installation
position
.6.2.2 Carefully verify the grouping marks on the equipment
.6.2.3 Check whether distortion or damage occurs to the parts.
.6.3 Foundation acceptance and marking off
.6.3.1 Under the support of the developing unit and supervision unit, the foundation acceptance shall be
carried out jointly with civil construction unit and the civil construction unit is required to transfer the
handover materials of the qualified foundation.
.6.3.2 Reexamine the foundation according to the materials provided by the civil construction unit, carry out
the foundation marking off, measure the center line, the center position of the column foot, elevation and its
diagonal size.
.6.3.3 Requirement on Foundation Center Line
Based on center line of the rotary kiln, measure the center line of the pre-heater and the frame, and the
allowable deviation is10mm.
.6.3.4 The deviation of the plane position of the anchor bolt in every direction shall not be more than 10mm.
.6.3.5 The allowable deviation of the plane elevation of the anchor bolt is +10mm.
.6.4 Arrangement of blocking iron
.6.4.1In order to ensure the installation quality of the equipment, adopt the construction method of the mortar
pier blocking iron.
.6.4.2 Flat blocking iron=16mm. The designed blocking iron group under the column foot, and the
specification is 320140mm.
Add one layer of mixed cement mortar and vibrate one layer with hammer, generally it is better to have three
layers and the vibration shall not stop until water comes out.
.6.4.3 Put the prepared flat blocking iron in the cement mortar pier and the upper surface of the flat blocking
iron shall be about 5mm higher than the upper surface of the cement mortar pier.
.6.4.4 Measure the elevation and levelness on the flat blocking iron, generally the elevation is required not to
be more than5mm and levelness shall be 5mm/m.
.6.4.5 Care it by adding water, and installation can be carried out after 7 days of curing with the ambient
temperature up to more than 20 centigrade, and it shall be delayed when the temperature is very low.
6.2.6.5 Column installation (hoisting)
.6.5.1.1 The equipment as column must be first delivered to the construction site from the manufacturing
place and then hoisted with the tower crane as per the equipment sequence number. This is operated by
special staff by communication facilities as talkie-talkie and whistle.
6.5.1.2 Hoisting of column and beam
Hoisting is operated in the following sequence: hoisting column, perimeter beam, supporting beam, sub-beam
and profiled bar beam. Every column is fixed temporarily by two adjusting threads after they are in position
and the verticality of column must be adjusted to the right position, which can be oriented by anchor with
taper of 1:10 and then can be adjoined by bolts required by the drawing specifications.
.6.5.2 Column and beam alignment
.6.5.2.1 Span measurement
The span is aligned by and jack, and the anchor block is dug on the concrete frame and span alignment must
be controlled within 10mm.
6.5.2.2 Elevation measurement
Allowable deviation of the column base to the designed elevation can be 10mm.
Height difference between column bases can be allowed to 5mm.
.6.5.2.3 Column verticality. Two pairs of screws are fixed within the vertical surface of the column, the
alignment is done through screws and, the column verticality is less than 5/1000.
.6.5.2.4 The offset of the centerline to the positioning axes is less than 10mm.
.6.5.3 The alignment and inspection of steel frame must take into consideration of changes of external
environment, such as wind, difference in temperature and sunlight area.
.6.5.4 After installation of the main building surface, steel pipe column will be put for grouting. See Code on
Construction and Acceptance of Concrete Structure and descriptions of steel pipe concrete column in the
frame structure drawing.
6.6 Pre-heater Installation
.6.6.1 Foundation acceptance and laying off
Reserved holes on the platform of every layer of frame must be checked according to equipment and
technical drawings to see whether the position, direction and size of holes meet the requirements of the
drawing.
6.6.1.1 The vertical centerline of the smoke box, vertical and horizontal centerline of the column of kiln rear
frame must be drawn according to the centerline of rotary kiln.
.6.6.1.2 Vertical and horizontal centerline of the position of pre-heater equipment on every layer must be
drawn according to the centerline of frame column and inspected and corrected by the centerline of rotary
kiln.
.6.6.2 Smoke Box Installation
.6.6.2.1 When smoke box is hoisted to the right position, the centerline of smoke box surface must have the
same axiality with the centerline of rotary kiln, which is 5mm.
.6.6.2.2 The gradient of smoke box surface must be horizontal with that of kiln surface, the distance between
the two surfaces must meet the requirements of designing, and the error shall be not more than 5mm.
.6.6.2.3 The center elevation of smoke box must meet the requirements of designing , and the error shall be
not more than 5mm.
.6.6.2.4 Inspect whether the requirements mentioned above are met, if so, the final positioning is carried out
to the smoke box.
.6.7 Steel structure frame wielding
.6.7.1 Preparation before wielding
.6.7.1.1 Welder selection: BX3-500-2 type AC welder and bronze wire of 50mm2 as welding wire.
.6.7.2 Welding Rod
Q235 Steel: For frame beam, column and joint, use E4316 welding rod and others use E4303 welding rod.
Q345Steel: E50 welding rod is adopted.
.6.7.3 Welding requirements: Consideration shall be taken into for welding work so as to prevent from
distortion after welding and reduce internal stress of welded parts therefore, welding must be carried out
according to construction drawing and frame welding operation requirements.
.6.7.3.1 Operation for welding frame steel structure shall strictly conform to Q/JCJ05-82 Stipulation from
Steel Made Machine Welding Technological Requirements and relevant regulations in Specification for
Welding of Steel Structure, JGJ81-91 established by State Building Materials Bureau.
.6.7.3.2 Anti-distortion method must be used in welding column and perimeter beam and leave the margin for
contracting after welding so as to prevent structure from distortion. Welding of every layer must adopt
symmetry welding and the column on the same layer must be welded at the same time, and joint of perimeter
beam on the same layer must be welded at the same time.
.6.8 Welding Quality Inspection
6.8.1 Visual dimension of welds shall conform to state standard, GB10854-89, Visual Dimension of Steel
Structure Weld.
.6.8.2 Weld quality inspection shall conform to relevant requirements of national standard, GB50205-200,
Code on Construction and Acceptance of Steel Structure.
.6.8.3 Appearance inspection must be carried out to all welds to see whether the size of weld accords with the
designing requirement, whether there exist some flaws such as cut in, air vent, dregs, crackle and broken
trough not welded fully. In addition to the visual examination to cut butt welding and cut tee welding, the 2nd
Class weld examination shall be carried out to such members such as column, beam and supporting, etc. and
the inspection quality must reach the 2nd Class quality standard. The 1 st Class weld inspection must be
carried out to the joint area of beam and post and the inspection quality must reach 2 nd Class quality standard.
The inspection shall be carried out to the weld of butt joint among columns and beams, the inspection of weld
shall not be lower than 2nd Class weld quality inspection standard and shall reach 2nd Class quality standard.
Air vent: This is not allowed to happen for second weld; The 3rd Class weld is not allowed to have five air
vents within one meter.
Undercut: 5mm shall not be exceeded for 2 nd Class depth and the total length can not exceed 10% of the total
length of weld; 5mm shall not be exceeded for third depth and the total length can not exceed 20% of the
total length of weld.
6.2.6.9 Anticorrosion of kiln rear frame and pre-heater
.6.9.1 Only after the welding and alignment of the equipment are inspected to be qualified can the next
procedure be carried out.
.6.9.2 There must be no burrs and welding scar, etc. in the appearance of the equipment. Rust can be got rid
of by sand blasting machine. .
.6.9.3 Then paint is sprayed or brushed to the two bottoms and two surfaces of the equipment (Group A and B
epoxy rich zinc primer, sea blue and scarlet chloridized rubber finish are applied for kiln rear frame; Group A
and B inorganic silicon high-temperature primer and silver powder organic silicon anti high temperature
finish are applied for pre-heater.
.6.10 Installation and alignment of the second layer frames
.6.11 Installation of decomposition furnace
.6.11.1 Installation of C5 cyclone cylinder, C5 and decomposition furnace

.6.11.1.1 Cyclone cylinder and pipe are paired on steel platform on the ground and then are hoisted to their
position.
.6.11.1.2 Cyclone cylinder and pipe are in their position and the deviation with the datum line shall not be
more than 5mm .
.6.11.1.3 Cyclone cylinder shall be installed horizontally, with the levelness of 5mm/m.
.6.11.1.4 Cyclone cylinder roof is lifted according to the designing requirement with the deviation of
elevation not more than 5mm.
.6.11.1.5 The blocking iron under cyclone cylinder and piper base shall contact fully with the base, and
welded on the floor but not be allowed to weld with the base.
.6.11.1.6 The deviation of the central distance between the two cyclone cylinders is not more than 5mm.
.6.11.1.7 Axiality of cyclone cylinder with pipe shall be 10mm.
.6.11.1.8 While installing the internal pipe of the cyclone cylinder, it shall be ensured that the internal pipe
shall be in line with central axis of cyclone cylinder.
.6.11.1.9 Alignment of cyclone cylinder shall take consideration of the alignment of the lower cone.
.6.11.1.10 The welding requirement shall conform to Q/JC05-82, Technical Specification of Steel Building
Materials Machine Welding.
.6.11.1.11 All internal temporary supporting must be removed and cleaned out after the installation of cyclone
cylinder, pipe and unloading pipe and before sealing.
.6.11.1.12 Every flange link place should be tight not to leak gas and every hole door shall not leak gas after
installation.
.6.11.2 Installation of expansion joint
.6.11.2.1 The direction in the air current or the material current shall be carefully checked before installation
and can not be installed in reverse, at the same time, bolts shall be adjusted along perimeter to adjust upper
and lower flange spacing of expansion joint to the designed size and it is forbidden to compensate the
deviation of installation by regulating flange height of the expansion joint.
.6.11.2.2 In the course of installation, adjusting bolt shall not be removed at will and shall be removed after
the installation of a whole set of system.
.6.11.2.3 In the course of installation, the axiality of the expansion joint with the upper and lower joint
sections shall be 10mm.
.6.11.3 Installation of raw material distributor, wind lock valve and material spreading plate
.6.11.3.1 Laying of the inside fire-resistant lining of the raw material distributor, wind lock valve and material
spreading plate shall be very carefully and its surface shall be smooth, especially the transition area. At the
most narrow area, the spacing shall meet the designing requirements and the inside laying work shall be
carried out on the ground as much as possible.
.6.11.3.2 The raw material distributor, wind lock valve and material spreading board, etc. shall be checked
and adjusted before installation, to be reliable and flexible.
.6.11.4 Installation of air pipeline and air shot
.6.11.4.1 The air pipeline shall be installed after air shot, air gushing ring and pneumatic valve are positioned.
The installation shall be based on the design drawing, and the pipeline shall be arranged according to the site
situation and arranged reasonably.
.6.11.4.2 The position of air shot shall conform to the standard of the design drawing. If design drawing has
no requirement, the engineer on the site shall decide the position.
6.2.6.11.5 Installation of the ladder and platform

6.6.12 Installation of the third layer frames and pre-heater
6.6.12.1 Hoisting and alignment of column and ring beam
6.6.12.2 C4 Installation of cyclone cylinder, feeing pipe, Rising Pipeline and expansion joint
6.6.12.3 Installation of various distributors, valves, air duct and air shot
6.6.13 Installation of the fourth layer frames and pre-heater
6.6.13.2 C3 Installation of C3 cyclone cylinder, feeding pipe, Rising Pipeline and expansion joint
6.6.13.3 Installation of various distributors, valve, air duct and air shot
6.6.14 Installation of the fifth layer of frames and pre-heater
6.6.15 Installation of the sixth layer frames and pre-heater
6.6.16 Installation and alignment of different accessory equipment
6.2.7 Plan of construction period
The whole construction period lasts290days (it begins with the installation of the second column on the first
layer of frames after the installation of the kiln rear frame foundation).
6.2.8 Safety technical measures
6.2.8.1 All personnel entering the construction site must fulfill the relevant requirements in "Safety
Production Procedure" issued by the headquarters. The 3-class safety education will be provided to new
workers, the safety disclosure should be carried out while carrying on the technical disclosure.
6.2.8.2 All working personnel entering the construction site must wear the safety helmet, and it is forbidden
to wear the slippers, high-heeled shoes, skirt and shorts to enter the site.
6.2.8.3 Personnel engaged in high altitude work shall have the physical examination, and those who are not
qualified are forbidden to engage in the work high above the ground.
6.2.8.4 Personnel engaged in the work high above the ground shall wear the safety belt and the slip resistance
shoes. All articles must be fastened to avoid falling down and getting hurt.
6.2.8.5 Two-layer safety nets shall be set up for the frame construction, ladders and the scaffold must be
checked carefully before being used, anyone is forbidden to engage in the overhead work after drinking.
6.2.8.6 Special protection facilities must be set up when multi-storey alternate work is carried out, and there
must be at least two personnel every storey and the cover must be set up to cover the hole.
6.2.8.7 In case of a six grade strong typhoon, heavy fog, heavy snow and thunder storm, the overhead work is
strictly forbidden.
6.2.8.8 Hoisting must be commanded by special person, and safety meeting must be held before hoisting.
6.2.8.9 The weight of lifted object must be checked and strictly calculated before elevation, the lifted position
must be chosen and the elevator is forbidden to work with overload.
6.2.8.10 The trial lifting must be carried out before hoisting, any person is forbidden to stand under the lifted
object after the lifting and the boundary line shall be set up when the equipment is hoisted.
6.2.8.11 When the equipment is put in position, do not insert the hand and the foot between the lifted object
and the sleeper and the cushion.
6.2.8.12 Tower cranes must be provided with the earth devices.
6.2.8.13 such explosive articles as oxygen cylinders and acetylene bottles, etc. are forbidden to collide and
shine directly under the sun.
6.2.8.14 the explosive articles shall be cleaned out within 10 meters of the welding (cutting) work, and
burning and explosion shall be prevented from occurring because of welding sparks between upper and lower
layers.
6.2.8.15 The voltage of the lighting bulb in pre-heaters shall not exceed 36 volts.
6.2.8.16 For other precaution, please refer to relevant content of the installation safety practice measures and
safety construction measure network in the construction organization design.
6.2.9 construction on grouting on steel column for kiln inlet
1prepare for materials
material name specification Amount Origin
Normal silca cement 42.5Rgrade
sand middle sand
Stone Diameter 05~2.0cm
Additive Dehydrate
2perimeter
1 Grade of concrete C40
2 Water and motors 0.45mm
3 slump 15-18cm
4 if the there is no requirement , refer the followed table
Item Cement Sand Stone Water Additives Note
Amount/cube 400 740 1085 185 25
mixing of concrete 1 1.85 2.71 0.46 0.06
amount of 50kg/cement 50 92.5 135.5 23 3
3technical measurement
1 inside steel concrete adopts thrown down without ofnon-vibrating concrete construction, watered by
method of continuous cast down every tops the tops of concrete, use within the next 4m insert the vibrating
ofnon-vibrating concrete evenly and close-grained, make, no holes phenomenon.
2.Seal the cover plate ,after 10hours , the staffs shall make hole of top cover plate, and make the pressure of
cement motor more compatible and the strencgth shall be 50%, the sealing pre-hole with welding
3.Each columns of the same layers shall be cast at one time.
4 The concrete shall be fixed at the surface of column , and the tightness shall be 50-100mm, then grout
concrete
5 Concrete shall be put into steel with hopper at one time, amount of grouting shall be 0.5m3
6After dispatching from the mixer, about one hours, then grouting concrete
77When mixing concrete, the worker shall sample the concrete at least 2times
6.2.10 Pre-heater Installation

6.2.10.1 Foundation acceptance and laying off
Reserved holes on the platform of every layer of frame must be checked according to equipment and
technical drawings to see whether the position, direction and size of holes meet the requirements of the
drawing.
The vertical centerline of the smoke box, vertical and horizontal centerline of the column of kiln rear frame
must be drawn according to the centerline of rotary kiln.
Vertical and horizontal centerline of the position of pre-heater equipment on every layer must be drawn
according to the centerline of frame column and inspected and corrected by the centerline of rotary kiln.
6.2.10.2 Smoke Box Installation
When smoke box is hoisted to the right position, the centerline of smoke box surface must have the same
axiality with the centerline of rotary kiln, which is 2mm
The gradient of smoke box surface must be horizontal with that of kiln surface, the distance between the two
surfaces must meet the requirements of designing, and the error shall be not more than 1mm.
The center elevation of smoke box must meet the requirements of designing , and the error shall be not more
than 2mm.
Inspect whether the requirements mentioned above are met, if so, the final positioning is carried out to the
smoke box.
6.2.10.3 Cyclone cylinder and pipes installation
Cyclone cylinder and pipe are paired on steel platform on the ground and then are hoisted to their position.
Cyclone cylinder and pipe are in their position and the deviation with the datum line shall not be more than
2.5mm .
Cyclone cylinder shall be installed horizontally, with the levelness of 0.5mm/m.
Cyclone cylinder roof is lifted according to the designing requirement with the deviation of elevation not
more than 1mm.
The blocking iron under cyclone cylinder and piper base shall contact fully with the base, and welded on the
floor but not be allowed to weld with the base.
The deviation of the central distance between the two cyclone cylinders is not more than 5mm.
Axiality of cyclone cylinder with pipe shall be 5mm.
While installing the internal pipe of the cyclone cylinder, it shall be ensured that the internal pipe shall be in
line with central axis of cyclone cylinder.
While installing the internal pipe of the cyclone cylinder, it shall be ensured that the internal pipe shall be in
line with central axis of cyclone cylinder.
Alignment of cyclone cylinder shall take consideration of the alignment of the lower cone.
All internal temporary supporting must be removed and cleaned out after the installation of cyclone
cylinder, pipe and unloading pipe and before sealing.
Every flange link place should be tight not to leak gas and every hole door shall not leak gas after
installation.
6.2.10.5 Installation of expansion joint
The direction in the air current or the material current shall be carefully checked before installation and can
not be installed in reverse, at the same time, bolts shall be adjusted along perimeter to adjust upper and lower
flange spacing of expansion joint to the designed size and it is forbidden to compensate the deviation of
installation by regulating flange height of the expansion joint.
In the course of installation, adjusting bolt shall not be removed at will and shall be removed after the
installation of a whole set of system.
n the course of installation, the axiality of the expansion joint with the upper and lower joint sections shall be
4mm.
6.2.10.6 Installation of raw material distributor, wind lock valve and material spreading plate
Laying of the inside fire-resistant lining of the raw material distributor, wind lock valve and material
spreading plate shall be very carefully and its surface shall be smooth, especially the transition area. At the
most narrow area, the spacing shall meet the designing requirements and the inside laying work shall be
carried out on the ground as much as possible.
The raw material distributor, wind lock valve and material spreading board, etc. shall be checked and
adjusted before installation, to be reliable and flexible.
6.2.10.7 Installation of air pipeline and air shot
The air pipeline shall be installed after air shot, air gushing ring and pneumatic valve are positioned. The
installation shall be based on the design drawing, and the pipeline shall be arranged according to the site
situation and arranged reasonably.
The position of air shot shall conform to the standard of the design drawing. If design drawing has no
requirement, the engineer on the site shall decide the position.
6.2.11 Commissioning
6.2.11.1 The cyclone cylinder, gas conduit, feeding pipe and decomposition furnace shall be checked to see
whether foreign matters exist there.
6.2.11.2 The cyclone cylinder end plane and the feeing pipeline shall be checked to see whether they are
unblocked.
6.2.11.3 Inspection doors shall be checked to observe whether the peep hole is sealed tightly.
6.2.11.4 All inspection doors and peep holes shall be closed after inspection.
6.2.11.5 Commissioning of pre-heaters and kiln systems

Construction Preparation
foundation Acceptance & Laying Off
Smoke box Installation
Rising Pipeline
Installation
C5 Cyclone Cylinder Installation -Decomposition Furnace Installation
Bricklaying of C5 Cyclone and

Installation of C3 Cyclone Cylinder and C4 Rising Decomposition Furnace
Pipeline
Bricklaying of C5 Rising Pipeline and C4
Cyclone Cylinder
Installation of C2 cyclone cylinder and C3 rising pipeline
Bricklaying of C4 Rising Pipeline and C3

Cyclone Cylinder
Installation of C1 cyclone cylinder and C2 rising pipeline
Bricklaying of C3 rising pipeline and C2
cyclone cylinder
Installation of C1 rising pipeline

Bricklaying of C2 rising pipeline and
feeding pipe
Installation of Installation of expansion joint, wind C1 cyclone cylinder heat

feeding pipe blocking valve and distributor preservation
Installation of material spill plate, Commissioning

repair door, inspection door, air shot,
compressed air pipeline and operation
platform
Week 1 Week2 Week 3 W

eek 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10
Foundation
Comstruction acceptance,marking
preparation off,making Mortar
Alignment of
Network Diagram
bearing
Equipment baseplate
ex-warehouse, installation
acceptance
and check
Mill body Bearing Mill body Imstallation of

check imstallation location/baseplatelining board and
grouting alienate board
Transmission
device
base rack
Installation of cooling
installation
pipeline inside mill
Feeding and
Installation of speed
output device
reducer rotary part
installation
Installation of
filter device
lubrication
system of speed
reducer commissioning
Completion
6.3proposal of raw mill

Raw material milling is an extremely important section in the process line of a cement factory. The quality of
mill installation is directly related to the normal production of the entire line and economic benefits after
putting into production. The Loesche erect mill includes the following characteristics: the flat mill trays and
conical mill roll with an abrasion-resistant lining plate and adopting 4-mill roll hydraulic; a light oil-pressure
supply equipment to turn out the mill roll on the mill to facilitate maintenance of the mill; mill roll hoisted
automatically from the mill tray to reduce start torque when the mill starts with loads; a protection equipment
on the mill, and when mill roll pressure is higher or lower than the scope set, giving alarm and stopping
automatically to ensure safe operation of the mill; the hydraulic system of the mill having two functions of
automatic control and manual control able to improve agility and credit of operation; separate hydraulic
pressurizing equipments for each mill roll, and each hydraulic cylinder provided with enough accumulator to
ensure minimum fluctuation of mill roll pressure during operation so as to ensure stable operation of the mill;
adopting direct current for separators, by changing rotate speed to satisfy with requirements of product
fineness in various conditions to make fineness adjustment smart and convenient. The vane is adjustable, and
changing sections of the vane can adjust air speed of the vane to suit different materials; adopt conical
structures and expansion sheath structures to connect the mill roll sleeve and the wheel hub, and the mill roll
axes and the rocker to ease disassembly. Comparing with the ball mill, main advantages of this mill are: with
a higher milling efficiency, shortening the technical flow largely, with a lower electrical consumption and
performing grinding of materials under a certain pressure.
6.3.1 the structure of vertical cement mill as followed
6.3.2 It is mainly composed of the mill pedestal, the gear case extraction slide rails, the support rack of the
mill roll and the pedestal of the hydraulic cylinder, the gear case and the drive equipment, the mill tray
equipment, the mill roll equipment, the annulus slot and the air room, the rocker equipment, the cylinder of
the mill, the choosing powder machine, the three-door device, the hydraulic system, the lubricant system, the
air supply system, and the control switches.
6.3.3 onstruction procedure flow chart of erect mill (Diagram 1) and installation network plan diagram
(Diagram 2)
Foundation Foundation marking embedding benchmark foundation making mortar

acceptance off plate roughening pier
Equipment pedestal group installation of the installation of the

ex-warehouse welding main machine speeder reducer base
pedestal plate
installation of the motor grouting of the installation of the installation of the installation of the air
pedestal pedestal support rack speed reducer room, the lower cone and
the bottom steel platform
installation of the installation of the mill Installation of the installation of the installation of the
mill tray and tray shell, mill roller powder selection main motor
accessories machine
installation of the oil supply system, the grease supply

system, the air supply system, the cooling system and the
hydraulic system
6.3.4 construction procedure

6.3.4.1 Construction preparation
.1 Organize construction personnel to familiarize drawings, installation instructions and other technical
materials, and perform technical disclosure.
2 Clean up the site, determine places to pile up equipments, and be familiar with status of equipment delivery.
.3 Preparing construction tools and materials, and connect the main power.
.4 Building the grouping steel platform.
6.3.4.2 Ex-warehouse, acceptance and inspection of equipment
During equipment acceptance, check the following parts and make equipment inspection records.
Whether parts are all ready; sealing status of bearings; sealing and cleaning status of the air supply system,
the lubricant system and the hydraulic system; cleanliness of the reducer and engagement of the gears; the
number and dimensions of parts and damage or distortion; dimension and damage or distortion of main
conjugations and connections; and whether marks of parts are obvious.
During Ex-warehouse, pay attention to the following content:
Equipments shall be delivered out of the warehouse in sequence to avoid repeated delivery and return; during
hoisting, protect equipments from distortion and damages of equipments; prohibit to tie ropes at the contact
surfaces and matching surfaces; when piling equipments, level up and fill up stably to protect equipments
from distortion; after ex-warehouse, it is the best to put parts needing dampproof and waterproof in a time
into rooms or adopt appropriate dampproof measures; properly keep consumables or parts not to be installed
immediately for installation before commissioning.
Conduct the equipment foundation acceptance with the Owner and the civil construction unit.
Implementing EN/ASTM/DIN technical standards and according to technical requirements of the equipment
drawing, the quality requirements of foundation dimension and location of the equipment are shown in the
following table.
Allowed deviation
Item Allowable Item Allowable
deviation (mm) deviation
(mm)
Elevation of foundation -20mm0mm Dimension of foundation 30mm
distance of centerlines 1mm Depth of anchor hole 020mm
Center position 10mm Elevation of plant 3mm
Verticality of the hole wall 51000
Setting the center plate, and each benchmark and landing mark shall be set for the each foundation , the
center plate shall be made by 1005010 steel plate, make bench mark and landing peeking mark to be
smoothly
requirement on foundation marking line
The deviation of longitude centerline of center plates and longitude centerline of designed drawing shall
not more than 3mm
Latitude center Deviation of two foundation shall not more than 0.5mm, deviation of diagonals shall
not more than 1mm
Center deviation of one center lines for mark plates shall not more than 0.5mm
Deviation of bench mark elevation shall not more than 0.5mm
making record of marking lines
6.3.4.5 Installation of the speed reducer baseplate
Find the gyration center point at the static pressure bearing of speed reducer.
Clean up the connection surface of speed reducer and machine seat and check the size.
Apply a layer of lubrication grease on the machine seat surface, to make the speed reducer glide on it and
facilitate alignment.
Levling of the speed reducer is mainly to use the position of the high-speed axle to make the turning central
point intersect with the central intersecting point of the four support frames.
Check the positioning pin connecting the speed reducer and the machine seat, and it shall keep in good touch
on all the length.
Check whether the speed reducer and the machine seat is connected firmly, and tighten the connecting bolt
symmetrically according to the torque required in the drawing
6.3.4.6 installation on three hydraulic tank
There are 12 plates of bottoms plates on the foundation hole,there are three pieces of brackets 01
fixed on bottom plate
Cleaning up the anchor screw, and erect themes and lower components
Locates hydraulic tanks bracket and alignment
Lay out the a,b lines, and mark one parallelism lines oo' at the left side , and make distance ooand b is
0.5774Dmm( D is diameter of mill disc)
Mark parallelism lines AABB and a axle and make distance among them is D
MMis the required points and the lines connected I and III is the center points lines
In accordance with distance center of mill machine and center of hydraulic tank, mark the center of
hydraulic tank
Alignment on center lines of brackets, ensure that elevation devication of bracket shall be within
0.5mm, levelness shall be 0.2mm/m
O b
(d)
A M A
a a
B M B
O (d)
b
6.3.4.7 Installation of motor base

the surface of motor pedestal and reducers shall be the same, and ensure that center of motor and
reducer shall be the same
level of motor pedestal and reducer pedestal shall be the same
6.3.4.8 Installation of the mill shell
Pair the upper cylinder of the mill on the standard platform before installation, after it is aligned and
reinforced, conduct the welding according to Welding process card
Cube and ring seam shall be adjusted by the Irion
hen pairing the mill, please refer to China industrial technical standard, JCJ03 90 ITEM2.6.2, and the
following shall be endured when hoisting is completed:
Measured the diameter , and dievation of measured shall not more than 3mm
Size of convex-concave shall not more than 4mm
alignment on mill shell
The deviation of centerline of shell and speed reducer 0.5mm
. The levelness of upper shell shall be checked with 0.02mm/m gradienter and the total length shall not longer
than 0.2mm
. The height from the upper surface of the shell to the bottom must accord with the dimension of the drawing.
Grouting on the hulls anchor screw
After the result of anchor screws grunting is okay, take the anchor screw then take alignment
6.3.4.9 Installation of the speed reducer
Find the gyration center point at the static pressure bearing of speed reducer.
Clean up the connection surface of speed reducer and machine seat and check the size.
Apply a layer of lubrication grease on the machine seat surface, to make the speed reducer glide on it and
facilitate alignment.
6.3.4.10 installation sealing equipments
After alignment, fix the anchor screw,
6.3.4.11 Installation of the mill disc

Clean the connection surface of the mill disc and the speed reducer and check the positioning pin hole at
the bottom of the mill disc.
The center intersecting point of the 4 braces shall be used to determine the center point of positioning
in the alignment of the mill disc.
Alignment levelnesss mill discs deviation shall be 0.2/1000mm
After completion on mill disc, and welding
Sealing gap of sealing things shall be 0.51.7mm
6.3.4.12 installation of spray ring
Connect the supporting ring and spray ring , and assembly supporting plate
6.3.4.13 installation of grounding linen plate
The firstly , erect the located pin of linen plate, and erect the linen plate, and fixed pinch
6.3.4.14 installation scrapper
While erecting scrapper of 8 mill disc, ensure there is gap between scrapper and middle board, and after
installation, and welding jointed bolt
6.3.4.15 Installation of mill roll
Stall the rocker-arm device before installing the mill roll vertically, totally four groups.
Install four rocker-arm axle collets on the rocker-arm before installing the rocker arm.
Loosen the bolt fixing the rocker bearing, drill the bolt of the conical bearing sheath in, and then open the
cover of the bearing and exam every part carefully. At last, conduct hoisting and alignment after checking
installation dimension.
Attention
While erection, the flange of shaft and flange of center rim shall not contacted , and not cause the
supply dysfunction of oil and sealing air.
6.3.4.16 installation of hydraulic tank and pull rod
When erection, painting epoxy resin
6.3.4.17
installation of classifier
Pre-assemble and measure the lower and the upper shell of the powder selection machine on the
standard steel platform and make acceptance according to China industrial standard,
Classifier is constituted by the rotor, chute plate, hull of it, and cone pipe, cone valves
The hull of classifier shall be attached by the hull of mill machine, and its components shall pre-
assembly at the workshop.
erection procedure
Welding the hull of classifiers together
welding components of rear cone pipe together
The made pipe of rear material shall be fixed on the hull of classfier, and make the center lines of rear
materials cone pipe and hull to be the same . its deviation of coaxlity of inner and out hull shall be 4mm
Erect the chute plate
Erect the rotor
Checking that rotors shall rotates well, and gap between rotor and cap shall meet the requirement
Checking that rotor and circle of chute plates shall be have the concentric cirles, and set the chute plates
at right angle , and fix the distance between sealed ring and rotor blade, and after adjusting gap, then seal ring
shall be welded at the cap
erect the transmission parts of classifier
Alignment on coupler on classifiers transmission parts, amd the gap of couplers shall be 6-12mm, and
verticality of main shaft shall within 0.1mm/m
6.3.4.18 Installation of the mill disc and accessories
omit
6.3.4.19 welding and assembling the vertical mill
The welding quality is very important, and not cause the deform, the deviation of dimension shall
be within the allowed area, and ensure that most of parts shall share the coaxlity
assembly erection of shell
Measured the three direction of diameter, and devation of jointed place shall not be more than 3mm,
convex-concaves size of welding seam shall not more than 4mmunfitness of butt joint shall not be within
0.5mm
prepare for welding
in accordance with the mechiancial function and chemical function , the staffs shall use the welding
material and welding method
dot welding The material and method of dot welding and formal welding shall be the same, length
of doting welding shall 50mm
welding vertical mill
Pedestal welding: Host standby for welding strander beam coupling parts, welding aperture for double-
sided unilateral groove and before opening the horn of groove joints. The first time by the 3.2 welding rod.
First should guarantee the penetration, electrode for back and forth swung repeatedly, so that the fusion is
good. After welding slag, clear with polishing machine for carefully polished.
welding hull
welding sequence: the welding seam of lower hull shall be regarded as the double sides (X type),
processing bottom welding with3.2welding rodthen go on welding for the next layerroot carefully
when clear positive left when welding defects such as porosity, slag, and carefully polished. Qing root
finish junior inline groove welding, the first next shell welding as a whole, combine it with
transmission pedestal welding for an organic whole
The attention shall including the following points: 1,processing the bottom welding shall be good and
welding strength shall be level, if not meet the requirement , the work shall done to rip out the defectives, and
shall done accordance with the relevant parameter
welding quality
Before checking quality , the worker shall clean up the welding slag and welding seams shall be even
without blur, and crack
Checking seam shall meet the requirement
Checking the unfitness of butt joint of shall not more than 10mm, the length of butt joint shall not more
than 10% of welding total length
Ensure that air hole, slag , if it did, the staffs shall have to fix it
The staffs shall take detecting defective work with ultrasonic
Equipment commissioning
Prepare working: organized commission team, and prepare tools and drawing, form, record
Checking the jointed bolt of device and pins and fixers are good
Ensure there are no wastes things in the grinding chamber, classifier and rotating valves, and workers
have to clean up
Ensure that rotor of classifiers and rotor blades and hull of classifier shall no touched
Checking all the moving location shall be normal
Checking all the doors and checking doors sealing
Ensure that tanks and filters of hydraulic station and pump shall be cleaned, and add the grease in
accordance with requirement; checking the pouring oil of motor bearing, and checking all kinds of valves of
supplying oil pipe, and ensure closing direction shall be right
Ensure that the gas and water and oil shall be clean, before commission, take test on water and pressure
Checking that connected parts of coupling joints shall be good before commission
Clean up the waste things around device
Checking that safety board shall be hung at the dangerous place
Running time of trial running without loader of single machine and sequence
2-4h
1-2h 2h 2h 1-2h
1-2h 4h 4h 2h
1-2h
1-2h
1-2h1-2h
1-2h
1-2h
The time of trial running of signle machine without loader is time of continues time for single machine,
if the breakdown happen to equipment, and workers shall stop machine to check.
Attention during the commission
Before take commission, the staffs shall take dot movement to make motors direction; and during
commission , the staffs shall check oil lines , water lines, gas lines, and the reading value of meters
Checking all the lubricant points and oil level of oil tanks location
checking the obstacles of up-rising and landing of grouting roll
During the commission , the operator have to watch the equipments, and look into the bearing lubricant
, temperature rising and vibrating , if the abnormal things happen , just to fix
6.4 Common Machinery Equipment Installation Program

The special equipment of a cement plant mainly includes the belt conveyor, drag chain,
air chute, weigh feeder, lifter, fan, pump, compressor, etc. with the general
characteristics for mechanical installation and the general installation processes as
follows:
Layingoff/placi
ng, leveling
Construction and aligning
conditions Unpacking Equipment
and storage foundation
Equipment installation
Grouting Blocking iron Anchor bolt
Installation of Commissioning Acceptance

hydraulic,
pneumatic and
lubrication pipeline
6.4.1Construction conditions
6.4.1.1 Before the construction, the technical documents of the design and the
equipment shall be available.
6.4.1.2 Before construction, full preparation and reasonable arrangement shall be
made fro the temporar y facili ties, transportation roads, water sources, compressed air,
lighting, fire facilities, main materials, machine and tools, labor force, etc.
6.4.1.3 Before the construction, the works of the factory roofing, outer walls, doors
and windows, internal rendering, etc. shall have been completed; the relevant
foundation terrace, ditches, etc. completed; the concrete strength shall be no less
than 75% of the design strength; the building materials, earth, foreign objects, etc.
at and near the installation site shall be fully cleared.
6.4.1.4 When utilizing the building structures as the force bearing points to hoist
and handle the equipment, the bearing capacit y of the structures shall be calculated
and, the approval shall be obtained from the design unit if necessar y.
6.4.2 Unpacking inspection and storage
6.4.2.1 6.4.2.1 The equipment unpacking shall be conducted under the participation
of the developing unit and the following items shall be inspected and the relevant
records be made.
6.4.2.2 Carton No., number of cartons and package.
6.4.2.3 Name, model and specification of equipment.
6.4.2.4 Packing List, technical documents, information and special tools of

equipment.
6.4.2.5 Any damage or loss of equip ment, and damage or rust on the surface, etc.
6.4.2.6 Other matters to be recorded.
6.4.2.7 The equipment, spare parts and the special tools shall all be properl y stored,
without causing an y deformation, damage, rust, mixing, loss, etc.
6.4.3 Equipment foundation
6.4.3.1 The position, size and the quality requirement of the equipment foundation
shall conform to the applicable national standard, Code on Construction and
Acceptance of Reinforced Concrete Works, and the information or the records of
acceptance shall be made.
6.4.3.2 The oil stains, crushed stones, earth, accumulated water, etc. on the surface
of the equipment foundation and the reserved holes of the anchor bolt shall be full y
cleared, the thread and the nut of the reserved anchor bolt shall be properl y protected
and the surface for placing the blocking irons shall be made flat.
6.4.3.3The foundation requiring pre-compacting shall be properl y pre-compacted
and the record of the pre-compacting and settlement shall be kept.
6.4.4 Laying off, placing, aligning and leveling
6.4.4.1 Before the equipment is put to place, the benchmark lines for installation
shall be drawn according to the installation drawing and the axis or the boundary
lines and the elevation lines of the relevant buildings.
6.4..4.2 For the equipment mutually connected, linked or arranged, the common
installation benchmark lines shall be marked, if necessar y, the general or permanent
central benchmark plate or the benchmark line shall be buried according to the
actual require ments of the equipment.
6.4.4.3 For the distance between the benchmark line of the plane installation and the
actual foundation axis or the actual axis and the boundar y line of the factory wall
(column), the allowable deviation shall be20 .
6.4.4.4 The allowable deviation between the plane, line or the point of the
equipment position benchmark and the plane position and the elevation of the
installation benchmark Allowable deviation between the plane position and
elevation of the equipment and the installation benchmark line
Item Allowable deviation
Plani metric Elevation
position
Not related with other machine 10 +20 -10
Related with other machine 2 1
6.4.4.5 After deter mining the plane, line and the point of the positioning benchmark
for the equipment alignment and leveling, the alignment and leveling shall be
carried out on the given measurement position, which can not be changed when
making the inspection and the re-inspection.
6.4.4.6 When there is no requirement in the technical document of the equip ment,
the location to measure the leveling and aligning of equipment shall be selected
from the following positions:
6.4.4.6.1 The main working plane of equipment
6.4.4.6.2 The orientation plane of the brace glide parts.
6.4.4.6.3 Keep the orientation plane or axis of the transmission parts.
6.4.4.6.4 Surface with higher process precision on the components.
6.4.4.6.5 Main couture to be horizontal or vertical on the equipment.
6.4.4.6.6 On the continuous transportation equipment and steel structures, it is
suitable to select the adj ustable places, with the distance between two measurement
points no more than 6m.
6.4.4.7 The deviation from the equipment installation precision shall meet the
following requirements:
6.4.4.7.1 Deviation available to compensate the stress or caused from temperature
change;
6.4.4.7.2 Deviation resulting from compensating the wear during use;
6.4.4.7.3 Not increasing power loss;
6.4.4.7.4 Make smooth rotation;
6.4.4.7.5 Reduce the stress of components under the action of load;
6.4.4.7.6 Facilitate connection and coordination of relevant components;
6.4.4.7.7 Facilitate increase in process precision;
6.4.4.8 Measurement of the straightness, parallelis m and axialit y adopting the
horizontall y drawing steel wire method shall meet the following requirements:
6.4.4.8.1 It is appropriate to select the entire piece of steel wire in the diameter of
0.35 0.5 ;
6.4.4.7.10 The both sides shall be supported on a same elevation with slide wheels.
6.4.4.7.11 The selection of the plummet shall be dependent on the horizontal pull
force caused from the plummet and the diameter of the steel wire.
6.4.5 Anchor bolt
6.4.5.1 The anchor bolts in the buried reserved holes shall meet the following
requirements:
6.4.4.8 .1 The anchor bolts in the buried reserved holes shall meet the following
requirements:
6.4.4.8 . 1.1 The anchor bolts in the reserved holes shall be vertical and not slant.
6.4.4.8 . 1.2 The distance of an y part of the anchor bolt to the hole walls shall exceed
15, and the bottom of the anchor bolt cannot touch the hole botto m.
6.4.4.8 . 1.3 the oil stain, oxidation scale, etc. on the anchor bolt shall be full y cleaned
and, the threaded parts shall be applied with little grease.
6.4.4.8 .1.4 The nut and the washer, gasket and the equipment pedestal shall be
closel y contacted.
6.4.4.8 .1.5 After the bolt is tightened, the nut shall be exposed, with the length 1/3
2/3 of the bolt diameter.

6.4.4.8 .1.6 The anchor bolt shall be tightened when the concrete in the reserved hole
reach over 75% of the design strength, with the even tightening strength for all
bolts.
6.4.5.2 The T head anchor bolt adopted or fixed shall meet the following
requirements:
6.4.4.8 . 1.7.1 The T-head anchor bolt and the foundation plate shall be used together
as per the specification, conforming to the applicable national standard, T-head
Anchor Bolt and, T-head Anchor Bolt Foundation Plate.
6.4.4.8 . 1.7.2 The main dimension in installation of the T-head anchor bolt shall
conform to relevant national codes.
5.11.5.4.8 .1.7.3 The buried T-head anchor bolt foundation plate shall be solid and flat.
Before the bolt is installed, the te mporary cover shall be added for protection,
avoiding ingress of oil, water, foreign objects, etc. into the holes.
6.4.4.8 .1.7.4 The bare rod of the anchor bolt and the foundation plate shall be
applied with antirust paint.
6.4.4.8 .1.7.5 The seal fill ing in the reserved holes or the pipe formwork shall
conform to the design specification.
6.4.5.3 Installation of the expansion anchor bolt shall meet the following
requirement:
6.4.4.8 .1.8.1 The center line of the expansion anchor bolt shall be laid off as per the
construction drawings.
6.4.4.8 . 1.8.2 The boring holes for inserting in the expansion anchor bolt shall not
contact with the steel bar, buried pipe, cable, etc. in the foundation or the members,
and the reserved holes can not be adopted.
6.4.4.8 .1.8.3 The strength of the foundation concrete for inserting in the expansion
anchor bolt shall not be less than 10Mpa.
6.4.4.8 .1.8.4 The expansion anchor bolt shall not be placed in the parts of the
foundation concrete or the reinforced concrete with cracks.
6.4.4.8 . 1.8.5 The boring diameter and the depth of the expansion anchor bolt shall
meet relevant requirements, and the boring depth can exceed 5 10 of the required
value. The hole diameter and the depth after boring shall be inspected timel y.
6.4.5.4 The anchor bolts cast and buried in the equipment foundation shall conform
to the following requirements:
6.4.5.4.18.11.5.4.8 . 1.8.1 The coordinate and the dimension of the anchor bolt shall meet
the requirements of the construction drawings, and the allowable deviation of the size
of the equipment foundation shall also confor m to relevant requirements.
6.4.4.8 . 1.8.2 The part of the anchor bolt exposed from the foundation shall be
vertical. The pedestal of the equipment inserted into the anchor bolt shall be reserved
the margin for adj ust ment, and no anchor bolts shall be seized.
6.4.6 Blocking iron
6.4.5.1 The blocking iron for aligning and leveling of equipment shall conform to the
installation criteria, design or technical documents of various machinery equipment.
The slant blocking iron and flat blocking iron commonly used for the equipment
shall be selected as per requirements.
6.4.5.2 When bearing the load of the equipment, the position and the number of the
blocking iron groups shall meet the following requirements:
6.4.5.2.1 Beside each anchor bolt, there is at least one group of blocking iron.
6.4.5.2.2 Under the precondition that the blocking iron group can be placed stabl y
and shall not affect the grouting, it shall be placed near the anchor bolt and under
the main stress position of the pedestal.
6.4.5.2.3 The distance between every 2 adj acent blocking iron groups shall be 500
1000.
6.4.5.2.4 The area of each blocking iron group shall be calculated as per the
equipment load.
6.4.5.2.5 On either side of the equipment pedestal with joints shall be placed a
blocking iron group.
6.4.6.3 Leveling with the slant blocking iron or the flat blocking iron shall meet the
6.4.6.3.1 The blocking iron group to bear the load shall be the paired slant blocking
iron, and after leveling, it shall be welded securel y before and after the grouting b y
tack weld. The bent-head paired slant blocking iron can be fixed by the grouting can
be saved of the welding.
6.4.6.3.2 For the equipment bearing heav y load or having strong and continuous
vibration, it is suitable to use the flat blocking iron.
6.4.6.4 Each group of the blocking iron shall be arranged orderl y and stable and
properl y contacted. After the equipment leveling, each group of the blocking iron shall
all be compacted tightl y, and a hammer is used to knock gently to check each group
according to the sound. For an equip ment in high speed operation, when adopting the
0.05 spacer gauge to check the spacing between the blocking irons and between the
blocking iron and the bottom place of the pedestal, the sum of the inserted lengths at
both sides of a same section of the blocking iron shall not exceed the length or 1/3
width of the blocking iron.
6.4.6.5 After the equipment leveling, the outside edge of the equipment bottom plane
shall be exposed on both sides of the blocking iron, for the flat blocking iron, exposing
10 30 , and the slant blocking iron, 10 50mm. The length of the blocking iron group
extending into the equipment pedestal shall exceed the center of the equipment anchor
bolt.
6.4.6.6 After the leveling of the equipment installed on a metal structure, all the
blocking irons shall be welded securel y to the metal structure with tack welding.
6.4.6.7 After the leveling of the equipment installed on a metal structure, all the
blocking irons shall be welded securel y to the metal structure with tack welding.
6.4.6.8 The blocking iron shall be adjusted with bolts, and the leveling shall
conform to the require ments below:
6.4.6.6.1 The thread parts and the slide face of the adj ustment block shall be applied
with the lubrication grease with good water resistance.
6.4.6.6.2 The leveling shall be conducted with the method of the adj ustment block
lifting. When it is required to lower the lifting block, the block shall be lowered first,
followed b y the lifting up adj ustment. When it is leveled, there shall be margin reserved
of the adj ustment block for adjustment.
6.4.6.6.3 The padding base of the blocking iron shall be poured securely with
concrete, but the active parts not poured.
6.4.6.9 The adj ustment screw adopted in the equipment shall meet the following
requirements:
6.4.6.7.1 After leveling the adj ustment screw not as the permanent brace, the
blocking irons shall be used to compact tightl y the equipment under the pedestal, and
then the adjustment screw can be loosened.
6.4.6.7.2 The thickness of the brace of the adj ustment screw shall be more than the
diameter of the screw.
6.4.6.7.3 The brace shall be level and installed securely on the foundation plane.
6.4.6.7.4 The length of the adjustment screw (as a permanent brace) extending the
bottom plane of the equipment pedestal shall be less than the screw diameter.
6.4.6.10 When adopting the mortar base method to place the blocking iron, the
technical requirements for mixing the mortar base concrete and the construction
method shall conform to relevant requirements.
6.4.6.11 When adopting the mortar jack method to place the blocking iron, the
construction method shall conform to requirement.
6.4.6.12 The shock absorption blocking iron adopted for the equipment shall meet
the following requirements:
6.4.6.12.1 The foundation or the terrace shall conform to the technical specification of
the equipment. Within the coverage of the equipment, the elevation difference of the
terrace (foundation) shall not exceed 30% 50% of the adjustment value of the
shock absorbing blocking irons. The place to put the shock absorbing blocking irons
shall be flat and smooth.
6.4.6.12.2 According to the require ment for equipment, the shock absorption
blocking iron can be fixed without the anchor bolts or with the expansion anchor bolts.
6.4.6.12.3 In equipment leveling, the stress on each blocking iron is basicall y the
same and, some margins shall be reserved within the scope of adj ust ment. After
completion of leveling, the nut shall be locked securel y.
6.4.6.12.4 When the rubber t ype shock absorption blocking iron is used, one more
ti me of leveling shall be made after 1-2 weeks of equipment leveling.
6.4.7 Grouting
6.4.7.1 The grouting of the reserved holes for the anchor bolts or that between the
equipment pedestal and the foundation shall conform to the requirement in the
national standard, Code on construction and acceptance of reinforced concrete
works.
6.4.7.2 Before grouting the reserved holes, the place for grouting shall be full y
cleaned. The fine crushed stone concrete shall be adopted for grouting, with the strength
one grade higher than that used for the foundation or the terrace. It shall be compacted
when grouting, to ensure the anchor bolt shall not slant and affect the installation
precision of equipment.
6.4.7.3 When the close contact of the grouting la yer with the surface of the equipment
pedestal, the shrinkage free concrete or cement mortar shall be used.
6.4.7.4 The grouting layer shall not be less than 25mm thick. The grouting la yer used
onl y for fixing the blocking iron or preventing the ingress of oil and water and easy
for grouting, the thickness can be less than 25 .
6.4.7.5 Prior to grouting, the steel for m shall be laid, the distance from the outer form
to the outside edge of the equipment pedestal shall not be less than 60mm, and after
the form is removed, the surface shall be made the float work
6.4.7.6 When full grouting is not required under the equipment pedestal, and the
grouting la yer shall stand the equipment load, the inner form shall be laid.
6.4.8 Installation of equipments
6.4.8.1 Before installation, learn the structures and technical requirements of equipments, review and
clean all matching dimensions, relevant precision, fitting surfaces and sliding surface of all components and
parts installed on site, and assemble them according to marks and assembly sequences.
6.4.8.2 When performing cleaning, adopt corresponding labor protection and fire protection, poison
proofing, explosion proofing and other technical safety measures as per the actual situation and cleaning
methods.
6.4.8.3 If there is any rust on the surface of the equipment or components and parts, perform de-rusting
operation first.
6.4.8.4 It is suitable to use alkalescence cleanser and emulsified oil cleanser to remove rust and dirt on
the surface of components.
6.4.8.5 It is better to adopt the following methods to clean the equipment and apply antirust grease:
6.4.8.5.1 For partial cleaning of the equipment, and large and medium parts, it is better to adopt the
solvent oil, aviation wash gasoline, light diesel oil, ethanol and metal cleanser specified in current national
standard for wiping and brushing.
6.4.8.5.2 For medium and small parts with a complicated shape, it is suitable to use corresponding
cleanser to dunk. Dunking time shall be 2~20min with temperature and characteristics of cleanser, and
requirements of components. Generally, it is better to adopt multi-step cleaning method or combining
dunking and rinsing to cleaning. When adopting heated cleaning, control the temperature of the cleanser and
keep parts cleaned away form the wall of the container.
6.4.8.5.3 For components with a complicated shape and heavily contaminated, adopt solvent oil, stream,
hot air, metal cleanser and other cleanser for spray rinsing.
6.4.8.6 It is suitable to use corresponding thinners or paint remover to clean antirust paint on the surface
of the equipment.
6.4.8.7 After cleaning up, it is necessary to dry components and parts immediately, and adopt anti-rerust
measures.
6.4.8.8 Installation of conve yor belt
6.4.8.8.1 Assembly rack (including the middle rack and legs of the middle rack) shall comply with the
a Misalignment of the centerline of the rack and the longitudinal centerline of the conveyor shall not
exceed 3mm;
b Non-verticality degree of legs of the middle rack or non-verticality degree to the ground of the
building shall not exceed 3/1000.
cThe assembly of the middle rack shall answer for the following requirements:
Non-verticality degree of the rack in the plumb surface shall not exceed 1/1000 of the length;
Right and left, and height deviation at the joints of the middle rack shall not exceed 1mm;
Deviation of the middle racks space L shall not exceed 1.5mm, and relative elevation shall not exceed
2/1000 of the spacing.
6.4.8.8.2 Misalignment of the traverse centerline of the support roll and the longitudinal centerline of the
conveyor shall not be more than 3mm. The position of the tensioning roller after connecting with the
conveyor shall be confirmed as per forms of the tensioning equipment, core materials of the conveyor belt,
length of the belt and the start/braking requirements, and in general, it shall comply with the following
requirements:
To the winch or the helix tensioning equipment, the forward loosening course shall not be less than
100mm;
To the vertical or the vehicle tensioning equipment, the forward moving course shall not be less
than 400mm, and the backward course shall be as 1.5-5 times as the forward (to nylon canvas belt
or a conveyor more than 200m, and a conveyor started directly by a motor or with a brake
requirement, the tensioning course shall be the maximum value).
)
6.4.8.8.3 The assembly of cleaning equipment shall comply with the following requirements:
The cleaning surface of the scrape shall contact with the rubber belt, and the contact length shall not
be less than 85%;
Axes of the rotary cleaning brush shall be parallel with the mill roll, and the brush shall contact with
the rubber belt, and the contact length shall not be less than 90%.
6.4.8.8.4 The work contact angle of the belt check equipment shall not be smaller than 70, and the
reverse angle of the mill roll check equipment shall not be bigger than 30.
6.4.8.8.5 When assembling the drive equipment, the weight deviation of ball bearings in each
compartment of the powder coupling shall not exceed 1% of the regulated weight.
6.4.8.8.6 The connecting way of the conveyor belts shall be conform to the instruction and the
technical criteria.
6.4.8.9 Installation of slat conveyor
6.4.8.9.1 The assembly of the frame shall comply with the following requirements:
Misalignment of the centerline of the rack and the longitudinal centerline of the conveyor shall not
exceed 2mm;
Non-verticality degree of supports or non-verticality degree to the ground shall not exceed 2/1000
6.4.8.9.2 Laying of rails shall comply with the following requirements:
Non-verticality degree of the rails in the plumb surface shall not exceed 3mm every 5m, and shall
not exceed 5mm totally.
Misalignment of the centerline of the two rails and the longitudinal centerline of the conveyor
shall not exceed 2mm;
Deviation of the space between two rails shall not be more than 2mm;
Un-levelness on the vertical direction shall not be more than 1/1500, and not more than 10mm
totally.
Joints of rails shall be smooth, and its deviation shall not exceed 1mm on the right and left, and the
deviation of height shall not exceed 0.5mm (rails of foundry cart conveyor shall decrease along the moving
direction), deviation of joint gaps shall not exceed mm.
Relative elevation of the two rails: to the one with the rail space less than 500mm, it shall not be more than
1mm; to the one with the rail space more than 500mm, it shall not be more than 2mm. (The flexure of the
rails of foundry cart conveyor shall decrease to the side of the curvature center.)
6.4.8.9.3 Assembly of guide rails shall comply with the following requirements:
Misalignment of the centerline of the guide rails and the longitudinal centerline of the conveyor shall not
exceed 1mm; Deviation of the space between two rails shall not be more than 1mm; Joints of rails shall
smooth, and its deviation shall not exceed 0.2mm on the right and left, and the deviation of height shall not
exceed 1mm.
Deviation of joint gaps shall not exceed 1mm.
The guide surface shall be smooth, and the non-verticality shall not be more than 10/1000.
6.4.8.9.4 Assembly of the tensioning device of the foundry cart conveyor shall comply with the
Joints of mobile rails and fixed rails shall be flat, and its deviation shall not exceed 0.2mm on the right and
left, and the height deviation shall not exceed 0.3mm. The extrusion part shall be made to be a slope less than
1/100;
Joints of mobile guide rails and fixed guide rails shall be flat, and its deviation shall not exceed 0.2mm on the
right and left, and the height deviation shall not exceed 1mm.
Slippers and the slide of the tensioning device shall contact closely to each other, and the partial gaps shall
not be more than 1mm.
6.4.8.10 Scoop hoisting machine
Non-verticality of shells of the hoisting machine shall not be more than 1/1000, and shall not exceed 1/2000
of the height totally, measuring on the outside edge of each joint.
Each joints of the shell of the machine used for conveying powder materials shall be closely connected.
Misalignment of the centerline of the hopper and the centerline of the traction rubber belt shall not exceed
5mm, and connection bolts between the hopper and the traction rubber belt shall be stable and locked
securely.
The joints of the traction rubber belts may be lapping type, of which the lapping lengthen shall be at least 3
hoppers, and the distance between the center of the connection bolts and ends of the traction rubber belt shall
not be shorter than 50mm.

After adjusting the traction rubber belt or chain to a proper work tension, the left course of the tensioning
equipment shall be longer than 50% of the total course.
The two traction chains of a double-chain hoisting machine shall be properly matched to make the two
parallel parts consistent.
Adjusting bolts and sliding plates of the tensioning equipment shall be flexible without restriction.
6.4.8.11 Screw conveyor
6.4.8.11.1 Assembly of shells shall comply with the following requirements:
Misalignment of the centerline of each section of shells and the centerline of the base at the two
ends shall be compliant with regulations:
Misalignment of the centerline of each section of shells
Length of the conveyor (m) 3 15 >15 30 >30 50 >50 70
Misalignment shall not exceed (mm) 4 6 8 10
Malposition at the joints of the inside surface of adjacent shells shall not be more than 3mm, and
connection of shells shall be tight.
Transverse non-levelness degree shall not be more than 2/1000;
Gaps between end faces of the hanging bearing and the inner surface of the connection flange shall
accord with regulations.
Spacing between end faces of the hanging bearing and the inner surface of the connection flange
Screw nominal diameter (mm) 150,200,250 300,400,500,600
Spacing not be less than (mm) 1.5 25
6.4.8.11.2 Connections between the inlet and the hopper, and the outlet and the hopper shall be tight and
proper.
6.4.8.11.3 After assembly, the conveyor shall run smoothly.
6.4.9 Installation of hydraulic, pneumatic and lubricant pipelines
6.4.9.1 Preparation of pipes
6.4.9.1.1 Check all hydraulic, pneumatic and lubricant pipes and pipeline accessories to confirm whether
their materials, specifications and number are complied with requirements of the design.
6.4.9.1.2 Generally, the mechanical method shall be adopted to cut the hydraulic, pneumatic and
lubricant pipes. Quality of cutting surfaces, the welding groove type of the pipe, machining methods and
dimensions shall comply with national standards.
6.4.9.1.3 It is appropriate to cold bend the pipes of the hydraulic and the lubricant system.
6.4.9.2 Welding and installation of pipes
6.4.9.2.1 During pipe connection, forced butt aligning, heating pipes, adding eccentric pads or multi-
layer pads shall not be adopted to eliminate deviation of joint faces.
6.4.9.2.2 To pipes with a working pressure lower than 6.3Mpa, quality of the weld shall not be lower
than standards of the level weld; to pipes with a working pressure larger than 6.3Mpa, quality of the weld
shall not be lower than standards of the level weld.
6.4.9.2.3 When laying pipes, the distance between the outer wall of the pipe and the edge of pipe
fittings near the pipe shall not be shorter than 10mm, and flanges or active joints in the same line shall
interlace with each other more than 100mm. Pipes passing through a wall shall be encased with a sleeve, and
the distance between its joints and the wall shall be more than 800mm.
6.4.9.2.4 When connecting pipes with the equipment, the equipment shall not bear additional outside
force, and it is necessary to avoid foreign matters entering the equipment or elements.
6.4.9.2.5 The allowable deviation of pipe coordinate position and elevation is 10mm, and that of the
leveling degree and the verticality are 2/1000, and spaces between the outside walls and the height of pipes
on the same surface shall be consistent.
6.4.9.3 Acid wash, flush, purge and painting of pipes
6.4.9.3.1 The acid wash to de-rusting shall be adopted for pipes of the hydraulic and lubricant system.
The acid wash shall be performed after collocation of pipes and they being in the conditions of rinsing. For
pipes painted, remove all paint before acid wash.
6.4.9.3.2 After qualified acid wash, the working medium or other liquids equivalent to working medium
shall be used to flush the pipes of the hydraulic and lubricant system, and it is suitable to adopt a circulation
flush.
6.4.9.3.3 After the pipe flush and before dismantling the joints, the ends shall be sealed immediately.
When needing to weld the pipe, perform acid wash and rinsing for the pipe again.
6.4.9.3.4 Painting of pipes shall be carried out as per relevant regulations.
6.4.10 Commissioning
6.4.10.1 Before commissioning, the equipment shall be meet the following conditions:
6.4.10.1.1 Construction of the equipment, its accessories and pipes shall all be completed, and the
construction records and information shall be complete.
6.4.10.1.2 Energy sources, medium, materials, tools, inspection instruments, safety protection measures
and appliances needed must comply with requirements of commissioning.
6.4.10.1.3 Prepare a commissioning program or a commissioning operation procedure for large,
complicated and precision equipments.
6.4.10.1.4 The equipment and the surroundings shall be fully cleaned, and there shall not be any
powder or noisy operations near the equipment.
6.4.10.2 Commissioning of the equipment shall include the following contents and procedures:
6.4.10.2.1 Adjustment test of electrical (instrument) operation control system and instrument
6.4.10.2.2 Check and adjustment test of hydraulic, pneumatic, lubricant, cooling and heating systems.
6.4.10.2.3 Combined adjustment test of the machine and all other systems.
6.4.10.2.4 No-load operation commissioning
6.5 Bricklaying construction program/ Chng trnh xy lp VLCL.

Bricklaying program for rotary kiln/ VLCL cho l nung.
1.1 Preparation/ Chun b:
1.1.1 Be familiar with the requirement of the drawing, the bin discharge end of the kiln and the tail of
the kiln (feeding end) use casting material; other parts shall use firebrick of different material. u tin
phi tham kho yu cu bn v thi cng, phn u v cui l s dng b tong chu nhit, phn cn li s
dng cc loi gch chu la khc nhau.
1.1.2 Check the cleanness in the kiln: in the place of bricklaying, check whether the protrusive height in
the inner weld is higher than the height required by the kiln welding. The place higher than the required
height shall be polished./ Kim tra v sinh bn trong l: cc mi hn trong l khng c cao hn tiu
chun, nu khng t cc mi hn ny phi c nh bng.
1.1.3 Ex-warehouse examination: when the pack is opened, the firebrick shall be examined one by one.
Pick out the damaged brick or the brick that is different in geometric dimensions, which cannot be
used./Kim tra gch xut ra t kho: khi m kin hng a gch vo xy lp, cn kim tra tng vin.
Loi nhng vin gch v hoc kch thc hnh hc khng t.
1.1.4 Machine preparation/ Dng c cho thi cng
No. Equipment and machine/ Qty / Purpose /
Dng c my mc S lng Mc ch
1 Bricklaying machine/ 1 set Bricklaying
My xy gch
2 Mixer/ 1 set Mixing casting material
My trn b tong loi nh
3 Electric welder/ Welding anchor fastening parts
Hn in
4 Grinder/ 5 set Grind the welding scars or welds on
My mi the inside of the mill cylinder in
excessive height
5 Brick cutting machine/ 1 set Cutting improper bricks

My ct gch
6 Ink box, cotton thread, 1 set Drawing lines in the kiln cylinder
drawing gauge/ Mc v,
dy ch, thc thng bng
7 36V light fitting/ 4 units Lighting
n 36V
8 Hammer/ Ba 10 Bricklaying
9 Cart/ Xe ct kt 2 Delivering bricks into the kiln/
Vn chuyn gch vo l
10 Formwork/ Vn khun Several Making casting material/ Dng cho
b tng
1.1.5 Construction personnel/ Nhn lc:
There are two shifts: Skillful bricklayers: 30; laborers: 20; woodworkers: 2; welder: 1. /Lm vic 2 ca:
cng nhn k thut xy gch 30 ngi, lao ng ph thng 20 ngi, ghp vn khun 2 ngi, th hn
01 ngi.
1.2 Construction period/ Thi giant hi cng.
According to two-shift work time, it is scheduled to complete the construction in 15 days./ Vi thi
gian lm vic 2 ca/ngy, trong 15 ngy hon thnh vic xy l.
1.3 Requirement of bricklaying construction/ Yu cu vic xy gch chu la.
Bricklaying for firebrick in kiln is dry bricklaying.
1.3.1 Drawing line/ V ng sinh
According to the vertical centerline of the kiln, draw at least 8 vertical centerlines parallel to the kiln
barrel and a 4m crosswise direction (circle direction) line to control the quality of bricklaying./ V t
nht 8 ng sinh chy dc l v song song vi vnh chn
1.3.2 The first line of every section of the kiln barrel starts from the lower part of the kiln barrel. Carry out
bricklaying according to the vertical line drawn on the kiln shell and the guide plane of kiln shell. At the
same time, use the first line of brick as standard to lay vertically about 2-3m on the lower part of the
barrel, and use bricklaying machine; then carry out roundabout bricklaying and seal the mouth. When
there are 6-7 lines of bricks left for the kiln lining, arrange the fore shaft in a curve combination way. At
the last 2-3 lines, seal the outer fore shaft of the kiln lining. The 2-3 lines bricks of the fore shaft shall be
laid at the same time, and shall be knocked into from the side of the neck brick plane, but the last brick
of each section shall not be knocked into from the side, instead, the brick shall be treated and knocked
into from the top. However, the bottom and the side shall be sealed with heat resistant mortars. Finally,
the iron plate shall be knocked into the surrounding brickwork joint to make it fast./ Vng u tin ca l
v tr thp nht l tip xc vi vnh chn ca l. t gch theo ng sinh
When laying bricks, pay attention to the protection of the surface of the brick, and use a rubber clock or
wood plate as a cushion to avoid damaging the corner of the brick.
1.3.3 Bricklaying in alternate joint: inner liner vertical laying joint shall be done according to the vertical datum
line, which shall be in the same plane with the kiln axis. The distortion of every meter shall not go beyond
3mm; the error for the same section shall not go beyond 20mm.
1.4 Construction of casting material
1.4.1 Clean the surface of the kiln barrel.
1.4.2 Weld the anchoring piece section by section;
1.4.3 Before casting, remove the rust on the anchoring piece and apply 2mm thick asphalt paint as dilatation
joint.
1.4.4 Divide the kiln for every 600~1200mm in circle and construct section by section.
1.4.5 Formwork material: Metal formwork shall use the steel plate with thickness over 3.2mm, while the
thickness of the wooden formwork shall be more than 20mm. In the construction, it shall be sufficiently re-
fixed; protrusion is not allowed. Oil shall be applied on the formwork.
1.4.6 When casting, use vibrating club to compact for closeness.
1.4.7 The place that is well cast shall be cured for at least 8h before formwork stripping. After stripping, it
shall be cured with water spray for 2 days.
2. Bricklaying plan for kiln hood and cooling machine
22.1 Preparation before bricklaying
According to the requirement of dimensions, pre-process the following formwork
2.1.1 Cast the formwork for access hole casting material lining
2.1.2 Cast the formwork for observing hole casting material
2.1.3 Cast the formwork for burner hole casting material lining
2.1.4 When laying the top casting material, open holes in the top cover in advance according to the drawing;
in case of no requirement, the diameter of the holes shall be 120~150mm, and the spacing shall be
600~800mm.
2.1.5 Necessary tools for laying, cutting bricks, drilling bricks and others
2.1.6 Antisticking agent, such as butter, graphite powder;
2.1.7 Mud box for holding mud
2.2 Construction of casting material
2.2.1 Choose the right fire-resistant material according to the drawing and design, deliver to the construction
site and add right amount of water. The amount of water shall be strictly controlled; according to the
construction requirement of the fire-resistant material, combined with the actual on-site conditions. The
proportion of water shall be determined with awarders, providers, supervisors and construction quality
inspectors and strictly controlled in the construction to avoid influencing the quality of bricklaying.
2.2.2 Clean the shell body cast before casting.
2.2.3 Weld the anchoring piece according to the drawing, remove the rust on the anchoring piece and apply
2mm thick asphalt paint.
2.2.4 Prepare formworks
2.2.5 When casting, use vibrating club to compact for closeness.
2.2.6 The place that has been cast shall be cured for at least 8h before formwork stripping. After stripping, it
shall be cured with water spray for 2 days.
2.3 Laying firebricks
2.3.1 Choose the right and qualified firebricks according to the drawing. When laying bricks, use high-
temperature wearable binder to bind or high aluminum cement; the brick joint shall be about 2mm; use
calcium silicate board as thermal protective coating
2.3.2 Use alternate joint laying for upright wall; use through joint laying for the arch top;
2.3.3 For the arch top and front wall door arch the kiln hood, prepare arch abutment support; laying
bricks according to the arch abutment support. The width of the surface of the arch abutment may be 1-2
times of the width of the arch brick.

2.3.4 First lay the edge skew of the upright wall; then set the arch abutment support and lay the front
wall door arch. The laying shall begin from the sides; the top-sealing brick shall be inlayed tightly, to
make the joint as narrow as possible; processing bricks shall not be used for top-sealing brick, and the
processing bricks shall be the distance of 3-4 bricks off the top-sealing.
2.3.5 When laying the last row of arch, arch abutment support may not be used at the beginning; the
support may be set while laying bricks. Use supporting piece to hole so as not to let the brick falling off.
2.4 Laying calcium silicate plate
The calcium silicate plates can be laid directly with block when they are on the plane, but they shall be
inlayed into the arc after being cut into strips. Binding mortar of 2~3mm for calcium silicate plates may
be used between the calcium silicate plates and shell body. When the working layer is fire-resistant
casting material, to prevent the calcium silicate plates from absorbing water, which can lead to
insufficient water for casting material and affect the strength, waterproof material such as asphalt shall
be applied at the connecting part of calcium silicate plates and casting material. The calcium silicate
plates are fragile, so they shall be handled with care. When cutting, steel saws, wood saws and others
may be used.
3. Bricklaying program for lining of pre-heating system
3.1 Refractory brick laying
3.1.1 The place where calcium silicate plates, aluminum silicate fiber are applied in the barrel, they shall be
applied according the requirement as is required in the above construction. For the plane where the calcium
silicate plates or aluminum silicate fiber contacts the refractory brick, the surface of the calcium silicate plates
or aluminum silicate fiber shall be applied with asphalt to prevent absorbing water and stripping off. The
application work may be done at the same time of bricklaying.
3.1.2 Simultaneous construction may be done where inner-layer light insulating bricks and outer-layer
refractory bricks are used. According to different refractory bricks, different refractory mud shall be chosen.
After laying each brick, it shall be beaten with a club to force out extra refractory mud; the brick joint shall be
about 2mm. The beating shall be light so as not to damage the inner-layer insulating bricks.
3.1.3 The brick joint shall be uniform and upright. The joints for the up-down bricks and in-out bricks shall
be staggered. The working plane shall be smooth. Before the fire mud is completely hardened, scrape extra
fire mud and use fire mud for pointing joint.
Leave dilatation joint in advance according the drawing (usually 10mm)
3.2 Construction requirement for refractory casting material
In the pre-heater device, the place of abnormal type shall adopt refractory casting material.
3.2.1 Before construction, check whether the welded anchoring piece (Y type or V type) is complete and fast;
in case of any defect or flimsiness, re-welding must be carried out.
3.2.2 Make and support the formwork as per the thickness required in the drawing. The surface of the
formwork shall be smooth. The place shall be left for dilation joint on the casting material. Burning pieces
shall be fixed on the formwork (made from plywood or hardboard). They must be fixed, so as not to fall
when casting the material. When stripping the formwork, the burning plate may be left in the casting
material.
3.2.3 Before casting, asphalt shall be applied on the clinchers; any place that contacts casting material shall
be treated for waterproofing.

The casting area shall not be too big, commonly 1.5~2.0 m 2. Any place where it is over 2.0 m 2 shall be cast
section by section.
3.2.3 When casting, ensure that the casting is compact and uniform to avoid dead corners. Machines shall be
used for vibrating. When stripping formworks, check them carefully. In case of serious damage, remedial
measures must be taken.
3.2.4 Carefully cure after construction, and often keep the surface wet at least for 3 days.
Outer heat preservation construction program
1. Preparation before construction
1Check if raw material complies with operational requirement.
2) Strictly choose heat preserving material, which shall be no crack and unevenness on the surface.
3) Prepare rolling machine, line pressing machine, nip machine and other machine for constructing
machines and carry out test run.
4) Prepare electric drill, screwdriver, clippers, handsaw and other tools.
5) Prepare drills, self tapping screw and other auxiliary materials.
6) Prepare dustproof breathing mask, gloves and other labor protecting articles.
3.2.4 Carefully cure after construction, and often keep the surface wet at least for 3 days.
6.6 Outer heat preservation construction program

1. Preparation before construction
1Check if raw material complies with operational requirement.
2) Strictly choose heat preserving material, which shall be no crack and unevenness on the surface.
3) Prepare rolling machine, line pressing machine, nip machine and other machine for constructing
machines and carry out test run.
4) Prepare electric drill, screwdriver, clippers, handsaw and other tools.
5) Prepare drills, self tapping screw and other auxiliary materials.
6) Prepare dustproof breathing mask, gloves and other labor protecting articles.
6.6.2. Method and key points for construction
6.6.2.1 Construction of heat preserving layer
1) Use 16 galvanized iron wire to tie the pipe shell on the pipe and the spacing of tying shall not go
beyond 200mm.
2) The vertical joint of the pipe shell shall be staggered.
3) The place of the vertical joint of the horizontal pipe shall not be set within 45of the vertical
centerline (see the following diagram)
4) For the heat-preserving layer of the angle fitting, the straight pipe shell shall be processed into an
angle laying For the insulating layer of the short-radium angle fitting on the medium- and low-temperature
pipe of metric diameter 70mm, if it is difficult to work it into the angle type, soft felt can be used to tie the
lay it.
45 45
Allowed scope Allowed scope
45 45
6.6.2.2 Construction of protective layer

The protective layer of common pipes: 0.5mm; the protective layer of hot air pipe and smoke pipes:
0.8mm.
1) The aluminum-skin protective layer is the external diameter of the heat preserving layer plus lap joint
dimension of 3050mm.
2) The dimensions of ring aluminum lap joint of the pipe shall not be less than 50mm; protruding ribs
shall be pressed out at the lap joint end. The lap joint shall be arranged as downstream, i.e. the ring lap joint
face downwards and in the same direction with the slope of the pipe.
3) The self-tapping screws are used to fix the protective layers, the spacing for which shall be 200mm.
4) The joint and protrusion of the protective layers of airduct and smoke duct shall be set alternately.
When laying off, lay out and draw line according to the contour of the device, and leave room of 2050mm,
considering the type of joint, sealing requirement and the amount of dilation and contraction.
5) For the dimensions of the lap joint of the protective layer on the angle fitting and the straight pipe
section, the high-temperature pipe is 75150mm, while the low-temperature pipe is 5070mm.
6) The ring joint of the protective layer of the pipe shall be made into movable joint.
6.6.3. Quality inspection
6.6.3.1 Inspection of heat-preserving layers
The sampling points distribution for the inspection of heat-preserving layers: Inspect three places every
50m2for the device and every 50m for the pipe; any device and pipe whose work load is less than 50m 2 or
50m shall also be inspected three times. When one place is not qualified, choose more points near the
unqualified place for inspection, if of them are still not qualified, then it is determined that the place is
unqualified.
The joint shall be filled and solid.
The scope for the thickness offset: +10mm and -5mm
6.6.3.2 Inspection of protective layers
Use a 1m long guiding rule to check; the deviation is not allowed to go beyond 4mm.
Inspection of the outer appearance:
No looseness, falling off, flanging, breach, or wrapped joint of obvious cut pit.
The ring joint and the vertical joint of the protective layer shall be vertical to each other and shall be straight
lines. The ring joint of the protective layer of the pipe shall be vertical to the axis of the pipe, while the
vertical joint shall be parallel to the axis of the pipe.
The direction of the joint shall be the same as the slope of the device and the pipe.
The overlapping joint of the aluminum protective layer shall not be less than 20mm, while the dilation place
shall not be less than 50mm; and in the open air or wet conditions, not less than 50mm for overlapping joint
and not less than 75mm for the dilation place.
6.6.4. Milestone of quality control
1) The quality assurance system shall be established with chief engineer of the project as quality
assurance engineer and trade managers as members, to implement quality control
2In the process of the construction, after each process, each group shall self-check and fill in the self-
check record if qualified; the technicians shall file the construction record documents, fill in the quality joint
inspection notice to inform the engineers of Quality Safety Inspection Section to carry out joint inspection.
When the joint inspection is passed, the engineers of Quality Safety Inspection Section shall inform the
owner (or the supervisor), Quality Supervising Station or Labor Department of, in writing, the control points
that are subject to their inspection 48h in advance.
3 The owner has the right to inspect the quality control points of any degree.
4 The process for the construction quality control is as follows:
6.7 Electrical, automation construction technical program
6.7.1 Simple working procedure of electrical and automation construction
As a modern cement production line, it is necessary to realize the automatic control and the real time
monitoring of the production process during the system operation, so as to ensure the product quality and
environmental protection. The electric control system and automatic monitoring system as the core of the
control, as well as the computer system, the brain of a cement plant, play the essential role in cement
plants. Therefore, the construction quality of the electric, automatic works shall be directly related to the
normal operation of the production line, concerning the economic benefits of the cement plant directly.
Simple working procedure of electric automatic construction
Drawing review and Installation of bus

Installation of tray/cabinet
Material Laying of cable protection pipe
technical disclosure
Lightning proof Installation of cable support Installation of transformer

earthing
Making & installation of cable support Cable laying Making cable end
and electrical facility foundation
Making instrument
measuring point holes Installation of bridge frame Installation of Twisted line of cable
and installation of equipment beside
socket holes the machine
Lightin
g works Wire connection for
Safety protection motor inspection
Installation of and welding
sensor elements Power supply/distribution
and supply- System Adjustment test
taking operation
Instrument calibration
components
Installation of System test Test of control circuit

Installation of instrument and other
instrument pipeline control equipment
6.7.2 Plan of the electric automation installation network
Laying of cable protection pipe
Lightning proof earthing
Comstruction preparation
Installation of
tray/cabinet and Adjustment
transformer test
Making installation ofcable
Plan of electric automatiom
support and electrical facility

foundation bridge frame
installation network
Installation of bridge frame
Cable laying Wire connection for

Twisted line motor inspection
Circuit test
System power
Dotting and test
supply/
of DCS system
distrbutiom
Installation of measuring Installation of Installation System
Completiom and
commissioniong
components instrument calibration test
The relevant diagram of the electric automation installation network plan shall be developed and revised
according to the time limit for the whole project, the situation of the equipment delivery, the plan of civil
construction and the situation of equipment installation, mainly to properly control the cycle plan for the
entire project constructs well.
6.7.3 Preparation for construction
Preparation for construction is a complicated project, which will directly affect the future construction
progress and quality. It includes the construction drawing review, development of construction plan,
preparation of the plan of labor force, materials, machines and tools, etc., preparation of the main
materials, auxiliary materials, machines and tools, personnel and other necessary measures. The project
technical staff together with the Owner, design institute, supervision department and the technical staff
from manufacturer of equipment shall carry out the construction drawing review, understand the actual
conditions of the site constructing, and know the designer's intention and the characteristics of the
products. In this course, the system of self-review and joint review of drawings and the review criteria
according to the construction drawing shall be strictly followed, combining the experience of the past
construction so that any problem likely to occur shall be solved in advance or the reasonable construction
technical program can be developed.
6.7.3.1 Drawing review and technical disclosure
Calculate the load, capacity of the motor and the sectional size of cable in each shop, and verify the
feasibility of mutual compatibility.
Determine the rational bridge frame, the direction of pipeline and the laying method.
Determine the benchmark point or benchmark line for measuring the coordinate and the elevation of the
electric wire leading end.
Check and calculate the size of cable channels and confirm the way of arrangement.
Check the location and size of preburials and reserved hole, which shall conform to the designing
requirement, and the preburials shall be secure.
811.7.3.2 Development of material plan and construction program
Analyze the list of the equipment and materials, make the plan of equipment and materials and
relevant construction program, try to make it rational for use, and convenient for operation, to ensure
materials are used rationally and highly efficient.
6.7.3.3 Equipment unpacking, inspection and ex-storage
6.7.3.3.1 Before the equipment unpacking, the design and construction drawings or the technical
documents and the packing list, equipment forms ,etc. shall be available.
6.7.3.3.2 Before the equipment unpacking, such works as the roofing, outer wall, doors and windows,
inside white-brushing of the factory, and foundation terrace, ditches, etc. shall have been completed,
in which the strength of concrete shall not be less than 75% of the designed strength. The construction
site shall be cleaned and the materials, earth and sundries shall be cleared so that the equipment can
be delivered in for indoor installation at any time after the equipment unpacking.
6.7.3.3.3 When utilizing the structure of the building as the force bearing point for lifting and
handling the equipment, it is necessary to calculate the bearing capacity of the structure, and if
necessary, the consent of the designing unit shall be obtained.
6.7.3.3.4 The equipment unpacking shall be made with the participation of relevant personnel of the
developing unit, to check the following items, and make records:

6.7.3.3.4.1 Carton No., quantity of cartons and package.
6.7.3.3.4.2 Name, type and specification of the equipment, the quantity of spare parts.
6.7.3.3.4.3 Packing list, technical documents of equipment, information and specific purpose tools.
6.7.3.3.4.4 Whether there is any loss or damage, or surface damage and rust of the equipment, etc.
6.7.3.3.4.5 Other matters to be recorded.
6.7.3.3.5 The equipment, components and specific purpose tools shall be kept properly to prevent
deforming, damaging, corrosion, mixing or loss, etc.. The measures for damp proof and dust proof of the
equipment shall be made for those already out of warehouse.
6.7.3.3.6 The record of equipment ex-storage shall be properly made, and the unqualified ones shall be
treated jointly with the personnel of the Owner and the detailed records shall be kept.
6.7.4 Installation construction of electrical equipment
After the equipment ex-storage, installation of electrical components and electrical equipment shall be
carried out according to the requirements of national standard, construction norm and construction
drawing specification. For conceal project or key construction procedures, the joint inspection shall be
timely conducted accompanying the quality inspection department of the Owner to obtain the approval,
then the next process can begin. The records of all installations shall be properly made and the approval
with signature from the quality inspection department of the Owner shall be obtained in time. All the
records shall be compiles and filed on time.
6.7.4.1 Installation of cable protection pipe
6.7.4.1.1 Material preparation
Check the technical documents and the appearance of the products after it arrives at the site, and
measure it according to the requirement of drawings. There shall be no breakage, crack, tiny
holes, iron scrap and burr, etc. in the steel pipe.
For the electric construction materials, metal materials for wiring works and accessories, the
zinc-plated products or those coated with the antiseptic paint shall be adopted.
6.7.4.1.2 Preparation for machine/tool
It is necessary to prepare the main machine/tools before construction, generally including the
following:
Screwdrivers (I shape and cross screwdrivers of all specifications), pipe bender (pipe handle
pipe bender and pulley pipe bender), pipe cutter, percussion electric drill, electric hammer,
pipe scissors board, electrician knife, hack saw, band tape, electric welding machine, oxygen,
acetylene, megohm meter, etc.
6.7.4.1.3 Operation process
6.7.4.1.3.1 S teel pipe de-rusting and painting
6.7.4.1.3.2 Laying off. The positioning shall be accurate. The pipe ends with the diameter
above 32mm shall be made into the bugle shape.
6.7.4.1.3.3 The pipe mouth is smooth with complete protection ends and, damp proof
measures in the damp conditions.
6.7.4.1.3.4 When bending the pipes, there shall not be cracks or concave marks, and the bending
radius shall not be less than the minimum bending radius of the cables. Generally, in case of the
open la ying, the bending radius is not less than 6 times of the pipe diameter; in case of the
hidden laying, it is not less than 10 times. Bending of each pipe shall conform to the following
requirements: the length of the pipe shall not be more than 18m for one bend; not more than 12m for
two bends, and not more than 6m for three bends.
6.7.4.1.3.5 Connection. There shall be no burr or any other protruding thing inside the pipe
likely to damage the cable insulation when connecting the pipe.
6.7.4.1.3.6 Put into the leading iron wire
6.7.4.1.3.7 Fixing. The fixing shall be secure. The installation must obey the principles of
horizontal and vertical straight, and conform to the design requirement. When assembly the pipes
in rows, the bending shape of steel pipes shall be the same or compatible to each other. The bends of
each cable shall be no more than 3 and the right-angle bends no more than 2.
6.7.4.1.3.8 Anticorrosion and earthing. The pipes shall be provided with reliable earthing and
anticorrosion measures. And over 6 round steel shall be adopted for welding at the point of earthing
bridge connection of the steel pipes, with the length of welding no less than 10mm.
6.7.4.2 Installation of bridge frame
6.7.4.2.1 Construction of the bridge frame shall be in accordance with requirements of the
construction drawing or the installation in the direction of the bridge frame determined in the construction
review.
6.7.4.2.2 Check the strength of the bridge frame and the count materials before construction.
6.7.4.2.3 Marking off. Make leveling and alignment with the color chalk, according to the principles
of horizontally and vertically straight. Determine the layers and the arrangement of supporting points.
The distance between two holding arms of the bridge frame is 0.8m, and there must be two or more
supporting points at the corner.
6.7.4.2.4 Installation. Bolts shall be adopted for connection. The connection board of the ladder frame
(tray) shall be connected firmly, and the round end must be in the bridge frame with the nut on the outside
of the ladder frame (tray) to prevent cable scratch. The electric welding is not allowed for the operation on
the bridge frame. The bending radius at the bending of the cable bridge frame shall not be less than the
minimum allowable bending radius of the biggest cable. Every hanger of the ladder grame (tray) shall be
firmly fixed and there shall be set the expansion seam at the respective place of the cable bridge frame in
the building.
6.7.4.2.5 Installation of isolation board. Add the isolation board when laying cable of different
voltage on the same bridge frame.
Earthing of bridge frame. Every bridge frame shall be properly earthed. The twisted copper wires shall be
used as the earth connection between bridge frames and every layer of the bridge frame shall be earthed,
and for the bridge frames in every plant, the bridge frame earthing downward lead must be provided.
However, the cable bridge frame shall not be used as the equipment earthing body.
6.7.4.3 Making and installation of the cable support frame
6.7.4.3.1 Confirm the specification, quantity and materials required to make the support frame.
6.7.4.3.2 De-rusting, straightening and laying off of the materials
6.7.4.3.3 Making support frame. The support frame shall be flat and straight with no obvious twist
and the spacing between layers is identical with the deviation not more than 2mm. The support frame
must be flat without any sharp protruding objects.

6.7.4.3.4 Anticorrosion, to be made after making and piled as classified.
6.7.4.3.5 Installation. Keep it horizontally and vertically straight when installing the support frame.
The distances of support frames is less than 800mm and, when in the bending place less than 500mm. The
distances from the topmost surface and the bottom of the cable support frame to the roof board or to the
channel ground shall accord with the requirement of national standard and design requirement. In case of
any special landform and he requirements can not be met, prior approval must be obtained.
6.7.4.3.6 Earthing of support frame. Earthing of cable support has high requirement, the qualified full
length flat rolled steel must be adopted. There must be two times of length of flat-rolled steel at the flat-
rolled steel overlapping joints, fully welded on four sides. When the earthing flat steel is buried in civil
construction, it shall be connected before installation of the support frame, and connected with the main
earthing line of the factory, so as to ensure the reliable earthing of the support frame.
6.7.4.3 Tra y/cabinet installation
6.7.4.3.1 Secondary transport of tra y/cabinet
It shall be fixed firmly during transportation to prevent knocking, damage of the components,
instrument and paints. Transport shall be made with crane or truck or manpower according to the
weight and size of tray/cabinet and the condition of the on-site construction. It is forbidden to hoist the
equipment by slings attached to the components.
6.7.4.3.2 Installation and making of the tray/cabinet base
The s ize for making and installation of the foundation section steel of the tray/cabinet shall accord
with the requirement of equipment dimension. The baseplate for fixing the base shall be pre-buried in
the construction of foundation or terrace. During the process of installation, first to weld the flat
steel with the base channel steel, then weld the base channel steel with thee baseplate. The blocking
irons for alignment shall not be more than three and welded with the section steel together. The
foundation section steel shall have two or more earthing points. The allowable deviation and methods
of inspection are shown in the following table.
Allowable deviation and inspection methods foundation installation of cabinet (tray)
Items Allowable Methods of inspection
deviation
Foundation Straight degree on Per meter 1mm Inspection of lining and
Total length 5mm
section steel the top measurement
Straight degree on Per meter 1mm
Total length 5mm
the side
6.7.4.3.3 Installation of distributing cabinet
6.7.4.3.3.1 When the tray/cabinet is in the room, construction shall be conducted according to the
drawing. When there is no clear indication in the drawing:
As to the high-voltage cabinet with the leads in the back or the side, the distance to the wall shall
not be smaller than 600mm.
As to the high-voltage cabinet without any lead in the back or the side, the distance to the wall
shall not be smaller than 200mm.
For the low-voltage cabinet installed by the wall, the distance to the wall shall not be smaller than
25mm.
The width of inspection passage shall not be smaller than 1000mm.

6.7.4.3.3.2 Install tray/cabinet according to the fixed sequencer and datum line
6.7.4.3.3.3 After alignment, the cabinet and the foundation channel steel, cabinet to cabinet and,
cabinet and two sides of the baffle shall be fixed securely. The connection between cabinets and the
cabinet and two sides of the baffles shall be with the bolts. It is better to use bolts to connect the cabinet
and the foundation channel steel. If it is required to adopt spot welding in the requirement of the drawing,
then conduct as per the drawing.
Allowable deviation and inspection method of cabinet (tray) foundation installation
Items Allowable Methods of inspection
deviation
Installation of Straight degree on Vertical degree per 1.5mm Inspection with suspension
cabinet (tray) the tray top meter wire, and ruler
Two adjacent trays 2mm Inspection with ruler,
spacer tape
Top rowed trays 5mm Inspection with pull wire and
ruler
Roughness degree Two adjacent trays 1mm Inspection with ruler and
on the tray surface spacer tape
S urfaces of rowed 5mm Inspection with pull wire and
trays ruler
Seams between trays 2mm Inspection with spacer tape
6.7.4.3.3.4 When installing the distributing cabinet at shaking places, it is necessary to take the
precaution against vibration
6.7.4.3.3.5 The connection between the cabinet and the equipments inside and between all equipment
shall be firm. It is not suitable to weld tightly the main control cabinet, the relay protection cabinet and the
automatic cabinet with the foundation profiled steel.
6.7.4.3.3.6 The earthing of cabinet (tray) must be firm and perfect. The cabinet door with electric
equipment that can be opened shall be earthed with the flexible lead and the metal frame reliably.
6.7.4.3.3.7 The nameplate and the sign frame of the drawer type distributing cabinet shall be
complete, accurate and clear. The cart, drawer type cabinet are pushed and drawn flexibly with no hinder.
The interlocking of the secondary return circuit changeover contact, machinery and electrical machine
acts accurately and reliably. The position of electrical test shall be correct.
6.7.4.3.3.8 E quipment inside the tray/cabinet and wire connection
The equipment inside the tray/cabinet shall be intact and complete, fixed firmly, and the operation parts
shall be flexible and accurate. The phase sequence of the tray/cabinet and the bus with two power supplies
shall be the same. The phase sequence of the tray/cabinet and the bus arranged in opposition shall be
arranged symmetrically and the color mark of the bus is uniform. The secondary wire connection is
accurate and secure. The connection of the lead and the appliances or terminals is tight and the signs are
clear and complete. The connection of earthing and the neutral wire shall be secure and reliable. When
there are both the earthing bus and the earthing neutral wire in the same tray/cabinet, the two kinds of
wires shall be separated, using a same bus to connect both the earthing and the neutral wire is not allowed.
6.7.4.6 Cable la ying
6.7.4.6.1 Make the appearance inspection and the insulating resistance test of the cable before laying
it. The cable above 6kv shall have the withstand voltage and leakage tests. Those blow 1kv shall be tested
using the megameter for test, to be above 10 mega Ohm. Make proper storage of the cables out of storage
with the damp proof measures.
6.7.4.6.2 Before the cable is laid, it is necessary to check whether the type, specification, length are
the same as that of designing materials. There shall be no twisting, damage and connections on the cable.
6.7.4.6.3 Consider the capacit y of equipment to see whether the cable can bear the
rated current of the equipment and do not use the small one to replace the big one.
6.7.4.6.4 Do not destroy the cable ditch and waterproof layer of the cable tunnel when the cable is
laid
6.7.4.6.5 When the cable is being laid, there shall be the reserves length near the connection between
the terminal end and beginning end of the cable. The direct buried cable shall be laid in wave shape and
reserve some margin in total length. The electric cables in parallel operation shall be identical in length.
6.7.4.6.6 Arrange each cable roll rationally, reduce the numbers of cable connections, reserve the
appropriate length to be suitable for actual wiring and reduce the cable waste.
6.7.4.6.7 The cable shall be led from the top of the tray when laying cable to prevent friction and drag on
the support frame and ground. There shall not be mechanical damage that has not been removed.
6.7.4.6.8 The distance between every support point of cable shall accord with the designing
requirements, and if no relevant requirement, the distance shall not be lager than the data in the following
table.
Distance between cable support points
Laying La ying on support
Levelness Verticalit y
method
Cable t ype
Electri Full plastics 400mm 1000mm
Medium/low voltage 800mm 1500mm
c cable
cables outside full plastics
High voltage over 35KV 1500mm 2000mm
Control cable 800mm 1500mm
6.7.4.6.6.9 Cables in different t ypes and different voltage grades shall be laid in
separate layers, to avoid electromagnetic interference. The cables shall be arranged in
order with no crossing, and bound securel y. Those laid verticall y or in the inclination
exceeding 45on each support shall be fixed on the bridge frame in the spacing of 2m;
while those laid horizontall y shall be fixed at the head and end and the bending
places, and if there are requirements on the cable spacing, the cables shall be fixed
every 5 10m. Those laid on the support or the bridge frame shall be in two layers ,
and the interposing or three layers are not allowed.
Bending of cables must have a certain bend radius, not less than the data in the table
below:
Ratio between minimu m allowable bending radius and outer diameter of cable
(multiple):
Cable t ype Multi core Single core
Control cable 10D
Cable t ype Multi core Single core

Rubber No lead cover or steel 10D
insulated armor
Exposed lead cover 15D
electric cable
sheath
Steel armor sheath 20D
PVC insulated electric cable 10D
AC polyeth ylene electric cable 15D 20D
Oil immersed Lead cover With ar mor 15D 20D
Without 20D
cable
armor
Oil filled lead cover cable 20D
Douter diameter of cable
6.7.4.6.6.10 After la ying the cable, the cable marking boards shall be placed at both
ends, the middle connections of the cable, the tunnel and the shaft, indicating the
cable No., usage, type and direction. The cable in parallel shall be marked with the
sequence No., visible and free from erase.
6.7.4.6.6.11 Cables for straight burial and laying in pipeline shall conform to
relevant standards.
6.7.4.6.6.12 Proper protection shall be made to cables laid to avoid an y damage.
6.7.4.6 Installation of transformer
6.7.4.6.1 Acceptance of transformer foundation
6.7.4.6.2 An inclination of 1% 1.5% shall be reserved when installation of the
foundation track of the transformer.
6.7.4.6.3 Equipment loading/unloading, transportation and unpacking inspection
6.7.4.6.4 Installation of transformer bod y
The ropes for hoisting must be checked and qualified. The steel wire must be fixed
to the lifting hook of the oil tank, and the lifting ring on the top cover of the
transformer can only be used to lift the core, but for lifting the entire transformer.
The transformer shall be installed to the correct position, the filling volume and
the oil class must be accurate, and the oil level is clear and there is no leakage
from the oil tank.
There is a 1-1.5% rising slope on the top cover of the transformer fitted with the
gas relay along the air direction of the gas rela y.
After installation, the electric and welding operations are not allowed on the
transformer bod y.
6.7.4.7 Inspection of the transformer bod y
6.7.4.7.1 Installation of accessories
The inside of the accessories directl y connected with the oil tank shall be full y
cleaned, installed securel y and connected fir ml y, without oil leakage. The bending
radius of the expansion thermometer capillary is less than 50mm, without bruising
and the sudden kinking of the pipes, and the part in excessive length shall be
coiled in order, and the temperature cover bushing is filled full y with oil. The
transmission part of the loaded pressure adjusting switch is properly lubricated,
flexible and accurate in action.

6.7.4.7.2 Line connection
The high/low voltage sides and the cable or the bus bar shall be connected closely and
securel y, the locking device of the connection screw shall be complete and the
ceramic bush not under outside force. The lead connecting the accessories on the
equipment bod y is provided with the protection pipe, and the protection pipe and the
connection cabinet are fixed securel y. The phase sequence of the low voltage bus and
the color marks are coincident.
6.7.4.7.3 Transformer earthing
The transformer body shall be earthed reliabl y. The zero line is connected downward
along the transformer to the wire of the earthing device, fixed reliabl y. The earthing
wires around the transformer room shall be laid 300mm awa y from the terrace, all the
support in the room shall be connected to the earthing bus, and for the overlapping,
the length shall be not less than 2.5 times that of the bus width.
6.7.4.7.4 Installation of high voltage separation switch
The connection terminal and the current carrying part of the isolating switch shall be
clean and well contacted, and the insulator surface is clean, with no damage or crack,
and the ceramic and the iron are bond securel y. The operating mechanism is in
flexible action, full locking, short idle stroke of the On/OFF switch and vibration
free, reliable earthing and correct phase sequence.
6.7.4.7.5 Installation of high/low voltage bus
The rectangular bus shall be cold bent, not hot bent; and the contact face of the
bus after being processed must be flat and smooth; as for the value of decrease
after fine process, the copper bus shall be no more than 3%, the aluminum bus no
more than 5%. When the bus is bent to 90, the torsion length shall be 2.5 5
ti mes that of the bus width. When adopting the bolt for overlapping on the
rectangular bus, the support edge between the connection and the support
insulator shall be less than 50mm and the upper part bus end and the beginning
of the lower part bus flat bend no less than 50mm. The copper bus at the high
temperature and humid place outdoor must be hot dipped with tin, while those in
dry place indoor can be directl y connected. When multiple buses are superposed,
the bending degree shall be identical.
Bus bending radius and overlapping standard
Bus t ype Bending Bus sectional size Mini mum bending radius
Copper Aluminum Steel
method
Rectangular Horizontal 505 or below 2a 2a 2a
12510 or below 2a 2.5a 2a
bus bending
Vertical 505 or below 1b 1.5b 0.5b
12510 or below 1.5b 2b 1b
bending
Rod type bus 16 or below in diameter 50 70 50
30 or below in diameter 150 150 150
In the Table above, a the thickness of bus, bthe width of bus.
In case of horizontal connection of the hard bus, the bolt shall be put from the bottom
to the upside, and the nut is put at the maintenance side in other cases. It is
recommended that the length of the bolt is 2 3 threads longer than the nut. When the
bus is connected with the connection terminal, the connection ter minal of the
electrical equipment shall not be under additional stress. In case the bus is installed
horizontall y, there shall be a 1 1.5mm clearance between the clamping fixture and
the bus; in case the bus is placed verticall y, there shall be a 1.5 2mm clearance
between the upper pressing board and the bus.
The phase sequence, serial No., direction and the marks of the bus bar shall be correct
after installation.
During installation, the safet y clearance between the bus and the inactive components
and between buses shall meet the relevant require ments
6.7.4.8 Twisted wire of cable
6.7.4.8.1 Making high voltage cable end
Conduct insulation test, mark properl y the core wires, which shall be identical
with the power supply phase sequence.
Str ipping and cutting the outer protection la yer, welding the earthing line,
stripping the overall insulation, separating the core wires, inserting the fillings,
wrapping the sealing tape, affixing the thermal shrinkage cable end, adding the
thermal shrinkage cable end, etc. shall be conducted carefull y as per the
requirements. The work from stripping and cutting of the cable end to the
completion of making shall be done once for all, to avoid dampness.
The high voltage cable end shall be sealed tightl y, full y filled with fillings, to
make the surface smooth, without sand holes or cracks.
The cable ends (middle ends) shall be marked with obvious signs of phases,
identical with the phase sequence of the sys tem.
When pressing and connecting the copper (aluminum) nose, the transparent
pol yeth ylene tape shall be used to seal the lower end of the copper nose, to avoid
water ingress into the core.
6.7.4.8.2 The cable ends shall be fixed securel y, in correct phase sequence and no
damage to the cable.
6.7.4.8.3 The straight buried cable ends shall be provided with complete protection
measures, with correct and obvious signs.
6.7.4.8.4 After the cable ends are installed into the cabinet, the bending radius
shall meet the relevant construction requirements.
6.7.4.9 Motor inspection and wire connection
6.7.4.9.1 DC motor
Measure the insulation voltage value of the exciter winding and the armature;
Measure the DC insulation voltage value of the exciter winding;
Measure the AC withstand voltage test value of the exciter winding and the
armature.
Inspection of the brush: The brush and the converter ring collector shall
properl y contacted, able to move upward and downward in the brush chamber, and
the brush is in normal pressure, the lead and the brush frame connected firml y,
and there occurs no obvious spark during operation. The lifting device of the
winding motor brush acts reliabl y, and the short0cut blades contact properl y, with
the movement direction identical with that of the marks.
Items required to be inspected according to other specifications and the
equipment requirements:
6.7.4.9.2 Inspection of AC motor
aMeasurement of insulation resistance
Measure the insulation resistance between phases and phase to ground of the
motor with megohm meter of respective grade, and the relevant resistance is no
less than 0.5M.
bMeasurement of DC resistance
Measure the DC resistance of each winding with the dual arm electric
bridge. For the motor with no less than 100K W or the voltage of over 1KV,
the difference of the DC resistance between each winding shall be less than
2%.
cAC withstand voltage test of the stator winding
d Items required to be inspected according to other specifications and the
equipment requirements.
6.7.4.9.3 Wire connection
The cable terminal and the motor binding post shall be connected firml y, and
sealed properl y. The motor binding post can not be under stress and sufficient
safet y distance shall be kept between the connection terminals.
6.7.4.9.4 Earthing
The shell of each motor shall be reliabl y earthed.
The earthing bolts in the connection cabinet must be connected with the main
earthing wire through the lead of sufficient capacit y.
6.7.4.9 Construction of lightning proof earthing works
6.7.4.9.1 Installation of lightning rod (net) and other support parts
It shall be in correct position, even distribution, reliable fixing, and proper anti-
corrosion. The rod is vertical, the size, specification and the bending radius are
correct and, the qualit y of the rod and the support components conform to the
design requirements.
6.7.4.9.2 La ying of the earthing zero line
The earthing flat steel shall be flat, straight and secure, the spacing of the fixing
points is even, the earthing wire crossing the wall is provided with protection
pipe and the painted corrosion coating is complete and intact.
The connection weld is flat, smooth and full, without obvious air holes.
Requirement on welded length of earthing wire
Item Required data Inspection method

Overlapping length Flat steel 2b Measuring
Round steel 6d
inspection
Round steel and 6d
flat steel
Number of edges for flat steel 3 Visual inspection
overlapping welding
The protection pipe of the lightning proof earthing lead shall be fixed fir ml y,
and the breaking connection card shall be provided to facilitate test and
inspection. The galvanizing and the tinning of the contact surface shall be
complete and the bolts be tightened with no omission.
The earthing zero line shall be provided with proper anticorrosion treatment.
6.7.4.9.3 Installation of earthing bod y
It is in correct position and secure connection, and the burial depth is no less than
0.6m to the ground. The overlapping of the earthing body with the earthing bus
shall be welded, conform to relevant requirement and the earthing bodies shall be
evenly distributed. The earthing resistance shall meet the design requirements.
The electrical earthing and the automation concealing earthing shall be separated.
6.7.4.9.4 The records of the concealed works shall be complete and correct.
6.7.5 Construction of automation instrument works
6.7.5.1 Installation facilities and equipment storage
6.7.5.1.1 Arrangement of construction site
At the installation site for measurement of the control instruments, the following
construction sites shall be set up:
Work room and work site: The window/door can be closed firml y, with sufficient
light, no rain leakage and flat ground. Inside is provided with 30K W 3-phase 4-
wire power suppl y, the clean and corrosion proof water supply and the working
platform meeting the construction require ments.
6.7.5.1.2 Arrangement of storage room
6.7.5.1.3 Arrangement of laboratory
6.7.5.1.4 Deplo yment of installation tools and machinery
6.7.5.1.5 Equipment storage
6.7.5.1.5.1 The equipment and materials delivered to the site shall be sent into the
warehouse and properl y stored as per the required storage conditions.
6.7.5.1.5.2 The measuring instruments, control instruments, computers and the
peripherals and other precision equipment shall be stored in the heat preservation
warehouse with the temperature of 5 40 and the relative humidity not more
than 80%.
6.7.5.1.5.3 The operating mechanism, various leads, valves, pipes, etc. shall be
stored in the sealed warehouse.
6.7.5.1.5.4 When moving the equipment from the place with low ambient
temperature and lower than -5 to the heat preservation warehouse, the
equipment shall be placed in the warehouse for 24 hours before the unpacking is
made.
6.7.5.1.5.5 If it is not installed after the unpacking inspection is made, the
precision equipment shall be recovered the necessar y package and properl y stored.
6.7.5.2 Boring of the instrument measuring points and installation of socket
6.7.5.2.1 Selection of boring position
The boring position of the measuring points shall be selected as per the
requirements of the design the manufacturer. If there are no requirements, it shall
be selected as per the relative position of the measuring points and the equipment,
pipelines, valves, etc. in the process flow syste m diagram, according to the
following requirements;
6.7.5.2.1.1 The measuring holes shall be selected on the straight line sections of
the pipeline, avoiding the valves, bends, T-pipes, maj or and minor ends, baffles,
manholes, hand holes, etc., that ma y affect the flow speed of the media or cause
leakage.
6.7.5.2.1.2 It is not appropriate to make holes or welding at the welds and the
edges.
6.7.5.2.1.3 The distance between the supply-taking components shall be more than
the outer diameter of the pipe, but not less than 200 . When the measuring holes
for pressure and temperature are at a same place, the pressure measuring hole
must be bored in front of the temperature measuring hole (as per the medium flow
direction).
6.7.5.2.1.4 Among the pressure or temperature measuring holes at a same place,
the one used for automatic control sys tem shall be in the front.
6.7.5.2.1.5 The measuring, protection and automatic control instruments shall not
share a same measuring point.
6.7.5.2.1.6 The suppl y- taking components and the sensor components shall be
installed at the places ease for maintenance and repair.
6.7.5.2.2 Boring of measuring holes
6.7.5.2.3 Selection and installation of socket
6.7.5.3 Installation of temperature measuring components
6.7.5.3.1 The inserting depth of the temperature measuring components shall meet the
relevant requirements.
6.7.5.3.2 The temperature measuring components shall be installed at the place t ypical
of the measured medium temperature, but not installed at the valves, bends or
near the blind spots of the pipeline and the equipment.
6.7.5.3.3 When the inserting depth of the temperature measuring components exceeds
1m, it shall be installed as verticall y as possible, otherwise, proper measures shall be
taken to prevent the protection pipe from bending, e.g. adding the support frame or
the protection pipes.
6.7.5.3.4 When installing temperature measuring components on the low pressure
pipeline with higher medium flow speed or gas-solid mixed pipeline, measures shall
be taken to avoid impact and wear of the temperature measuring components.
6.7.5.3.5 The thermal resistance of the te mperature of the material cabin shall be
measured, with the inserting direction identical to that of the material loading.
6.7.5.3.6 When adopting the thread or flange method for installation of the temperature
measuring components bearing the pressure, the sealing must be made at the
connection faces.
6.7.5.3.7 For the horizontall y installed thermal resistance and the thermocouple, the
entrance hole of the connection cabinet is generall y downward.
6.7.5.4 Installation of pressure-taking device
6.7.5.4.1 Selection of pressure measuring points
6.7.5.4.1.1 The pressure-taking hole for the gas medium is at the upper part of the
pipeline.
6.7.5.4.1.2 The pressure-taking hole for the liquid medium is at the lower part of the
pipeline, but not at the bottom.
6.7.5.4.1.3 The pressure-taking hole for the steam medium is at the upper part of the
pipeline and below the horizontal center line.
6.7.5.4.1.4 For the points to measure the pressure below 0.1Mpa, the elevation shall
be as close to the measuring instrument as possible, to avoid any
additional error caused from the liquid column.
6.7.5.4.1.5 The measuring points for secondary wind pressure shall be between the
secondar y wind adj usting gate and the secondar y wind nozzle.
6.7.5.4.2 Forms and installation of pressure-taking device
The pressure-taking device is used to take the static pressure in the container
or the pipeline static pressure, whose end shall be aligned with the inner wall,
not inserted into the inner wall, with no burrs, otherwise, resistance shall be
caused to the medium, to form the eddy current and cause error in
measurement under the effect of the d ynamic pressure.
6.7.5.4.2.1 The pressure-taking device shall consist of the pressure-taking socket,
pressure-guiding pipe and the suppl y- taking valve.
6.7.5.4.2.2 When measuring the pressure of the gas with trace ashes, the pressure-taking
device shall be provided with the stopper for blow wash and the re movable pipe
connection; in case of the horizontal installation, the pressure-taking pipe shall be
slant and downward.
6.7.5.4.2.3 When measuring the pressure of the gas-powder mixing, the pressure-taking
device must be provided with the sediment tank in sufficient capacit y, in which the
dust is separated from the air and the resultant returns to the gas-powder pipeline b y
means of the dust weight. 6.7.5.5 Installation of throttling device
6.7.5.6 Installation of water level & supply-taking components
6.7.5.7 Installation of composition analysis instru ments and sampling devices
6.7.5.8 Installation of instrument pipeline
Selection of the materials and specification of the instrument pipeline, selection of the
laying route, installation method and the air-tightness of the pipeline, etc. shall
directly affect the accuracy of the measure ment, which reflects the qualit y of the
measure ment indication and the automatic adjustment.
6.7.5.8.1 The instrument pipeline (including conduits and fitt ings) can be divided into the
following in respect of the functions:
Measuring, sampling, signal, air suppl y, heat suppl y, waste discharge and
cooling pipelines.
6.7.5.8.2 Requirement for pipeline la ying
6.7.5.8.2.1 Before the conduit installation, the steel grade and the size shall be
checked, and the appearance inspection and the inner cleaning shall be performed.
6.7.5.8.2.2 The conduit shall be laid at the position required in the design, if no
requirement is made in the design, the following principles shall be followed
according to the actual situation of the site:
The conduit shall be laid in the route as short as possible to reduce the
time lag in measurement and improve the sensitivit y.
Do not la y at the places likel y to occur mechanical damage, dampness,
corrosion or vibration.
La y at the places ease for repair.
La y in the places with the ambient temperature of +5 +50 , otherwise,
provide the antifreeze or heat insulation measures.
The oil pipeline shall be laid away from the hot surface and, parallel
arrangement over the hot surface is strictl y forbidden.
The differential pressure pipeline shall not be close to hot surfaces, and
the ambient temperature of the positive and the negative pipelines shall
be identical.
The heat expansion of the main equipment shall be considered when
laying the pipeline.
The pipeline shall be laid in a centralized wa y, in the route parallel with
the main structure.
The conduit shall not be laid directl y on the ground, and the route
selected shall not affect the inspection and repair of the main body
equipment.
6.7.5.8.2.3 The pipeline laid horizontall y shall maintain certain slope, generall y
over 1:100, and for the differential pressure pipeline, over 1:12.
6.7.5.8.2.4 The pipeline shall be laid in order and good appearance and fixed
securel y, avoid bending and crossing as mush as possible, an y abrupt or
complicated bending is not allowed. For the pipelines laid in rows, the bend
curvatures shall be the same.
6.7.5.8.2.5 The pipeline shall be air-tightness, with no leakage. After it is
qualified in the air-tightness test, the surface shall be applied with antirust paint,
in which the high temperature pipeline with the high te mperature resistance
antirust paint. The gas-water pipeline shall be heat preserving.
6.7.5.8.3 Inspection before pipeline installation
6.7.5.8.4 Bending of conduit
6.7.5.8.5 Connection of conduits
6.7.5.8.7 Installation of instrument valves
6.7.5.8.8 Test of pipeline air-tightness
6.7.5.8.9 Installation of waste discharge pipeline
6.7.5.9 Connection electric wires and cables
6.7.5.10 Installation of instrument and equip ment
6.7.5.11 Adjustment and calibration of instruments and circuits
6.7.5.12 Safet y Protection

2012 04 09 Quy Trinh Lap Dat Day Chuyen 5000t Cua HCRDI

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CNBM FULEI(SHANGHAI)CONSTRUCTION CO.

,LTD Vie 5000t/d clinker & cement production line

Edit CompanyCNBM FULEI (SHANGHAI) CONSTRUCTION

6.1 Main program construction Instruction

Kiln rear seal shield Lubrication/hydraulic system Other parts installation

Diagram 2 Rotary kiln installation network plan

Kiln welding Transmissions

6.1.1.4.1 Construction Preparation

Parts for Checking Allowable Parts for Checking Allowable

Inspection Items Allowable Inspection Allowable

Inspection Item Allowable Inspection Item Allowable

6.2 construction proposal of kiln inlet frame and pre-heater

Project manager department

Other logistic departments Manufacturing technical department Quality inspection department

Kiln rear machine Kiln rear furnace building

Rivet driver Rivet driver Lifting Welder Scaffold Locksmit

6.2.4 Technical specification

6.2.5 Construction Preparation

Grouping platform site

6.2.5.3 Human resource deployment

6.2.6 Construction Procedure

.6.11.1 Installation of C5 cyclone cylinder, C5 and decomposition furnace

6.2.6.11.5 Installation of the ladder and platform

6.2.10 Pre-heater Installation

6.2.11.5 Commissioning of pre-heaters and kiln systems

foundation Acceptance & Laying Off

Smoke box Installation

C5 Cyclone Cylinder Installation -Decomposition Furnace Installation

Bricklaying of C5 Cyclone and

Bricklaying of C4 Rising Pipeline and C3

Installation of C1 rising pipeline

Installation of Installation of expansion joint, wind C1 cyclone cylinder heat

Installation of material spill plate, Commissioning

Week 1 Week2 Week 3 W

Mill body Bearing Mill body Imstallation of

6.3proposal of raw mill

Foundation Foundation marking embedding benchmark foundation making mortar

Equipment pedestal group installation of the installation of the

installation of the oil supply system, the grease supply

6.3.4 construction procedure

6.3.4.7 Installation of motor base

6.3.4.11 Installation of the mill disc

6.4 Common Machinery Equipment Installation Program

Installation of Commissioning Acceptance

6.4.2.4 Packing List, technical documents, information and special tools of

2/3 of the bolt diameter.

not be shorter than 50mm.

6.5 Bricklaying construction program/ Chng trnh xy lp VLCL.

5 Brick cutting machine/ 1 set Cutting improper bricks

times of the width of the arch brick.

be treated for waterproofing.

6.6 Outer heat preservation construction program

Allowed scope Allowed scope

6.6.2.2 Construction of protective layer

Drawing review and Installation of bus

Lightning proof Installation of cable support Installation of transformer

Installation of System test Test of control circuit

Laying of cable protection pipe

Lightning proof earthing

support and electrical facility

Installation of bridge frame

Cable laying Wire connection for

developing unit, to check the following items, and make records: