PRECOMMISSIONING CHECKS IN PYRO Preheater Tower Area.

Verify that the refractory has been installed correctly. The surface of castable
should be smooth to prevent build up. Check that the proper angles are
maintained as per drawings. The kiln inlet should be free of ski slopes where
as material would be directed up into the gas flow. Change over gates tend to
be problematic, refractory can impede movement. Clearances can be too small
at the point of movement and excessive at the division head below the gate.
Proper refractory thickness and clearances can be checked in feed pipes,
tertiary air dampers, riser restrictor and other critical areas.
Check all tipping valves for sufficient side clearance and ease of movement.
Lower stage tipping valves should have at least 12mm clearance on each side.
Counter weight arms should be mounted properly, at the correct angle with
shaft keys installed. The last stage tipping valves can have an ellipse cut into
the bottom of the plate to allow material flow at all times.
Check that instrumentation ports are located in the proper positions. The gas
exit thermocouples are located at the top of the stage not the exit risers, gas exit
pressure taps should be in the risers. The cone pressure taps should be mounted
on a 450 angle. Ensure that material temperature thermocouples contact
material without creating blockages. All ports are open and not plugged with
refractory. Check that pressure transmitters are piped correctly. All
instrumentation transmitters need to be clearly marked. Refer to the burner
bible section M for more information.
Check that change over gates are sealed completely to one side when set 100%
to the other side.
Check that cleanout and air blaster ports pipes are flush with the refractory and
not plugged.
Check that the splash plates on feed inlets are installed correctly and secured.
Verify that the Calciner feed inlet is installed correctly.
All trash and construction debris must be removed, stages cannot be blocked.
Locate measuring ports and calcination sample ports. These will be used for
process trouble shooting and performance testing. A list can be generated
including marked up drawings to show details of these ports.
Ensure safe access to instruments, cleanout ports, tipping valves, and air
blasters.
Check that the Calciner burners are installed correctly and in the proper
location, including the burner station, piping, valve rack, cooling air fan, etc.
Check kiln feed inlet seal for proper installation.
Have all stages clearly marked.