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4lant Client Contract Code Contract No.

Document ID
NPK PVFCCo PVFCCo-NPK PIN-EQS-7010-DZ-0004-037 66-0194

Main

Erection Manual Coater Drum


Rev 00 Page 1 of 99

CLIENT :PETROVIETNAM FERTILIZERS AND CHEMICAL CORPORATION,VIETNAM (PVFCCo)


ROJECT :PHU MY NPK PLANT PROJECT,VIETNAM
EPC CONTRACT NO. :369 / 2015 / PVFCCo /DTXD-TKIS-PTSC / X-NPK

14.06.16. ATH / SVH

00 For Information 10-06-16 PSA 10-06-16 ASM 10-06-16 SRH 4


Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -

Barcode
Copyright 2015 : All rights reserved
ThyssenKrupp Industrial Solutions (India) Private Limited
thyssenkrupp Industries India

Erection Manual
For
Coater Drum 2.2 x 7M

Project: NPK Plant Project, Vietnam


Client: Thyssenkrupp Industrial Solutions (India) (TKIS)

TKIS PO NO: 38010823 DTD. 29-10-2015

TKII Work Order No.: 3M0049

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Index
1. Introduction and Pre-Requisites before actual Mechanical Erection
a. General Information related to project/Equipment
b. Safety Recommendations related to work
c. Transportation, Unloading and Storage and preservation details
d. Foundations
2. Mechanical Erection Instructions for Coater
a. Reference Documents
i. Drawings
ii. List and Details of Tools and Tackles - with scope
iii. Fabrication Drawings of Temporary Erection Structure with MTO
iv. Resource and Machinery Requirement
b. Erection activities and sequence
i. Checking and Hand-Over of Foundations
ii. Support Roller Assembly Erection and Alignment
iii. Erection of Shell
iv. Grouting of Base-frames
v. Girth Gear Erection and Alignment
vi. Drive Assembly Erection and Alignment
vii. Guards Erection and Assembly
viii. Inlet Hood and Seal
ix. Outlet Hoods and Seal
x. Electrical Installation
xi. Lubrication System Installation
3. Erection schedule for Coater
4. Quality Assurance :
a. Protocols & ITP
b. WPS
c. Consumables specification with estimated qty

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1. Introduction and Pre-Requisites before actual Mechanical Erection


a. General Information related to project/Equipment

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Coater 3.2x7m will be dispatched as a single unit, the details of which are as follows:

Dispatchable unit1
Length - 7000 mm
Weight - ~ 6400 kg
Tyre Weight ~725 kg
Tyre OD 2463 mm

Coater Drum
Process Parameters
Material : NPK / DAP
Bulk density : 890 - 1060 kg/m3
Feed Size : >4mm - 5%
: 2-4 mm - 85%
: <2 mm - 10%
Feed Moisture (Normal/Maximum) : 1.3-1.5% / 1.5%
Capacity (Normal) : 25-35 TPH
Capacity (Design) : 50 TPH
Duty per day : 24 Hrs
Product Moisture : 1.3-1.5 % / 1.5%

Equipment details
Coater Drum Size : 2200 mm Dia. x 7000 mm Long
Slope : 3.3 %
Shell Plate Thk : 10 mm Min
Coater Drum Speed : 7 rpm

Riding Rings
Diameter : 2272 ID mm - 2463 OD mm
Width : 130 mm

Trunnion Rollers
Diameter : 500 mm
Width : 130 mm

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Thrust Rollers
Diameter : 300 mm
Width : 120 mm
Bearing Type : Roller bearing

Coater Drum Inlet Chute


Type : Male 60 min. slope
Feed end seal : Labyrinth Seal

Coater Drum Outlet Chute


Type : Female 60 min. slope
Feed end seal : Labyrinth Seal

Ring Gear
Type : Spur teeth
No. of Teeth : 176
Module : 16
Face Width : 160 mm

Pinion
Type : Spur teeth
No. of Teeth : 23
Module : 16
Face Width : 175 mm

Girth Gear Lubrication System


Lubrication Type : Grease Spray
Air requirement for lubrication : 80 NLPM (Preliminary)
System

Drive System
Gearbox type : Helical
Main motor power : 37 kW,
Main motor speed : 1500 rpm
Drive arrangement : Girth gear & pinion

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1. Introduction and Pre-Requisites before actual Mechanical Erection


b. Safety Recommendations related to work

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Safety Recommendations related to work:


1. While pulling the drums inside the building, proper locking should be done from both the sides.
2. While doing any welding work at site, proper earthing to be made sure.
3. While welding at height, proper scaffolding to be provided.
4. Ventilators to be provided inside the shell while welding to avoid suffocation.
5. Proper care to be taken while operating the hydraulic jacks.
6. Proper care to be taken while working under suspended load.

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1. Introduction and Pre-Requisites before actual Mechanical Erection


c. General Transportation, Unloading and Storage and preservation
detail

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Please refer below sketches / drawings for transportation of ODC consignment.

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Please refer below sketch for unloading of drum shells.

After the Dryer and cooler shell are brought inside the building, the space emptied can be used
to unload the Granulator and coater shells and the tyres.

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STORAGE AND PRESERVATION DETAILS

Open storage Heavy Fabricated Materials / Voluminous Cargo:-


All the fabricated items need to be stored properly with proper supports to avoid any damage to
part as well as water ingress. When material arrive at the site, all parts must be placed on wooden
beams with the provision of suitable protection against rain, contamination and damage. The
parts must not be stored directly on the ground.
Fabricated material such as drum shells, feed and discharge hoods, base frames etc preferably
be unloaded near the respective buildings and on levelled and compacted surface with proper
elevated support with adequate tarpaulin sheets.
Lack of adequate support in the centre of housings & base frames could lead to buckling of
equipments, hence required intermittent supports should be provided.
No material should be stacked on one above the other, except where crating of material is
possible however, care should be taken so that there is no deformation on stacking.

Covered Storage:-
All equipments / items like gear boxes, motors, couplings, lubrication system, crusher, roller
assembly, pinion drive assembly etc shall be stored in covered storage.
All machined components should be stored in covered storage area.
All machined surfaces should be protected against falling objects to avoid peel off of the tectyl
paint and well protected from water / moisture and dust ingress.
All Electrical & Instrumentation items and hydraulic systems and parts like and not limited to
measuring, sensing, weighing, analysers, power etc. shall be stored in covered areas.
In general the storage area must be dry, well aerated and ventilated, and shall be protected
against moisture, acids, and other chemical agents.
No material should be stacked on one above the other, except where crating of material is
possible however care should be taken so that there is no deformation on stacking.
No machined surface should be stacked on one above the other.
Since the materials are susceptible to mishandling, hence it is necessarily important that proper
care is adopted for handling and storage of equipments, preferably critical and sensitive parts be
stored in covered storage.
Note:
Any alterations, gas cutting, welding OEM must be consulted in writing.
While moving / transferring any material at site, proper lifting slings, ropes, tools and tackles
should be employed.
Items specifically mentioned above but not limited to shall be stored in proper manner to avoid
any damage, pilferages, etc.

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1. Introduction and Pre-Requisites before actual Mechanical Erection


d. Foundations

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Please refer below sketch for the foundation details of Coater drum.

Handing over the foundation:


Civil department should give the following before handing over the foundation for mechanical
erection.
1. Insert plates at inlet & outlet side.
2. Reference elevation mark at inlet & outlet on insert plate.
3. Centre line of Coater at inlet side outlet side.
4. Centre line of drive includes centre line of main gear box, main motor.
5. All foundation pockets should be clean till the depth.
6. After providing all the above details all the concern department should sign the protocol.

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2. Mechanical Erection Instructions for Coater


a. Reference Documents
i. Drawings

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Reference Documents / Drawings for Mechanical Erection Instructions for Coater


Sr.
Document Description TKIS Document ID TKII Drawing no.
No.
1 GA Drawing [70CO2001] PIN-EQS-7010-DZ-0004-001 FRT-RD-00112
FRT-RD-00044,
2 Foundation Load data [70CO2001] PIN-EQS-7010-DZ-0004-002
FRT-RD-00121
Support Roller Shaft Assembly
3 PIN-EQS-7010-DZ-0004-007 FRT-RD-00052
Drawing [70CO2001]
Thrust Roller Shaft Assembly Drawing
4 PIN-EQS-7010-DZ-0004-010 FRT-RD-00096
[70CO2001]
Pinion Shaft Assembly Drawing FRT-RD-00063,
5 PIN-EQS-7010-DZ-0004-014
[70CO2001] FRT-RD-00062
6 Tyre Fastening Drawing [70CO2001] PIN-EQS-7010-DZ-0004-015 FRT-RD-00036
Roller Station Assembly Drawing -
7 PIN-EQS-7010-DZ-0004-017 FRT-RD-00077
Feed End [70CO2001]
Roller Station Assembly Drawing -
8 PIN-EQS-7010-DZ-0004-018 FRT-RD-00117
Discharge End [70CO2001]
9 Drive Assembly Drawing [70CO2001] PIN-EQS-7010-DZ-0004-019 FRT-RD-00206
Roller base frame - Feed End
10 PIN-EQS-7010-DZ-0004-025 FRT-RD-00066
[70CO2001]
Roller base frame - Discharge End
11 PIN-EQS-7010-DZ-0004-026 FRT-RD-00065
[70CO2001]
12 Drive base frame [70CO2001] PIN-EQS-7010-DZ-0004-027 FRT-RD-00171
13 Inlet Hood Seal Drawing [70CO2001] PIN-EQS-7010-DZ-0004-030 FRT-RD-00173
Discharge Hood Seal Drawing
14 PIN-EQS-7010-DZ-0004-031 FRT-RD-00174
[70CO2001]
Inlet Hood Assembly Drawing
15 PIN-EQS-7010-DZ-0004-033 FRT-RD-00166
[70CO2001]
16 Transportation Drawing [70CO2001] PIN-EQS-7010-DZ-0004-035 FRT-RD-00011
17 Shell Assembly Drawing [70CO2001] PIN-EQS-7010-DZ-0004-037 FRT-RD-00004
Foot print for support structure for
18 PIN-EQS-7010-DZ-0004-038 FRT-RD-00245
Cooler [70CO2001]
Transportation sketch for Coater drum
19 FRT-RD-00297
lifting by single crane [70CO2001]
Tyre erection base frame for ground
20 FRT-RD-00303
assembly [70CO2001]
Erection saddle R=1510 for Coater
21 FRT-RD-00307
drum [70CO2001]
Temporary roller support arrangement
22 FRT-RD-00302
for Coater [70CO2001]

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2. Mechanical Erection Instructions for Coater


a. Reference Documents
ii. List and details of tools and tackles - with scope

List and Details of Tools and Tackles - with scope

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List below is considering erection of all four drums, the list is not exhaustive.
Sr.
Description Qty
No.
Tools & Tackles by Erection Contractor
1 Auto level / Total Station 1 No.
2 Master level 0.02 mm per meter 2 Nos.
3 Dial gauges 0-10 mm with magnetic stand 10 Nos.
4 Filler gauges 6, 12 length starting from strip thickness 0.03 4 Nos. each
5 Main heating oven (400 deg. Cent.) 1 No.
6 Portable oven (200 deg. Cent.) 6 Nos.
7 Heating torch 6 Nos.
8 Motorised winch (10 tons) 2 Nos.
9 2 sling for handling shell and tyre (16 meter) 4 Nos.
10 Piano wire 100 kg
11 Measuring tape 50 / 30 / 15 / 5 meters 2 Nos. each
12 Spring balance (20kg) 2 Nos.
13 Crawler mounted cranes (250 tons and 130 tons) 1 No. each
14 Pick and carry crane (25 tons) 1 No.
15 Water level (6mm x 50m) 4 Nos.
16 Vernier calliper 2 Nos.
17 Inside and outside micro-meter 1 No. each
18 Centre / Number and letter punch 1 No. Each
19 AG-4 / AG-7 / GQ-4 grinding machine 4 Nos. Each
20 Grinding and Cutting wheels 100 No. each
21 Concrete drilling machine (max. inches dia.) 2 Nos.
22 Hydraulic jack (100 tons) 2 Nos.
23 Hydraulic jack (50 tons) 4 Nos.
23 Button and bottle jack (25 tons) 2 Nos. Each
24 Torque wrench Mechanical (3900Nm) 2 Nos. Each
25 Torque wrench Hydraulic (10,000 Nm) 1 No.
26 Shim cutter 2 Nos.
1 No. Each for all
27 Ring and D type spanner / hammering spanner
sizes
28 Chisel and hammer 10 Nos.
1 No. Each of
HN 18-20
HN 21-22
29 Adapter sleeve lock nut spanner
TMFN 30-40
TMFN 40-52
TMFN 52-64
30 Chain block - Long lead (10 tons) 4 Nos.
31 Chain blocks 5 ton and 2 ton 4 Nos. Each
32 Oil stone 4 Nos.
33 D.P. set 30 Sets
34 Allen key 7/8 & 1 for girth gear fixing bolt 4 Nos. Each
Tool box consist of steel scale (6 & 12), mechanical plumb, hack saw
35 5 Nos.
frame with blade, Ring and D type spanners up to 46 mm, Allen key set,

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box spanners with ratchet up to 46 mm, spirit level, flat and smooth files,
hammer, cutting flair, nose flair, circlip flair, screw driver, slide wrench,
Persian blue etc.
36 Emery wheel / paper, ribbon rough and smooth both As required
37 Scaffolding, pipes and clamps As required
38 Tarpaulin As required
39 Tube cutter / bender (die size as required) 2 Nos. Each
40 Chain wrench, pipe wrench 2 Nos.
41 Wire brush & Chipping hammer 10 Nos.
42 Pyrometer (200 degree centigrade max.) 2 Nos.
43 Diamond wheel with machine for concrete grinding 2 Nos.
Temporary fabricated support rollers with frame for drum erection and
44 10 Sets
rotation as per TKII drawing no. FRT-RD-00302-1/0
45 Welding Rectifier 650 Amperes 6 Nos. Min.
46 Brass and SS shims less than 1 mm As required
47 Buffing wheel 25 Nos.
48 All required lifting slings/ belts, D shackles, pulleys, bull dog grip etc. As required
Bunch of small slings for fixing pulleys, chain blocks and holding shell
49 As required
during dragging
Oil bath (site fabricated steel box) for coupling heating for assembly
50 1 No.
Size: 1100x1100x600mm
51 Burnt engine oil / used oil 600 Ltrs.
Special Tools & Tackles by TKII
1 Tensioning devices for Coater and Coater 1 Set
2 Shell erection wedges and clits for Coater and Coater 1 Set
3 Earthing clits for all drums 1 set
4 Slope measuring scale for each drum 1 No.
5 Hydraulic jack for drum lifting for maintenance for all drums 1 No per drum
6 Hydraulic button jacks for base frame adjustment for all drums 4 Nos per drum

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2. Mechanical Erection Instructions for Coater


a. Reference Documents
iii. Fabrication Drawings of Temporary Erection Structure with MTO
- Shall be submitted separately.

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2. Mechanical Erection Instructions for Coater


a. Reference Documents
iv. Resource and machinery requirement
- Please refer Annexure I

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AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
TobeginwiththeCoatererectionworkthefoundationofinlet&outletsideshould
becompletedinallrespect.Ajointprotocolshouldbemaintained&signedbythe
civildepartmentfromclientside,thesupplier&theerectioncontractor,Thecivil
departmentshouldgivethefollowingbeforehandingoverthefoundationfor
Autolevel,
mechanicalerection.
Totalstation,
a Insertplatesatinlet&outletside 1MillFitterand
1 Pianowire, 2days
b Referenceelevationmarkatinlet&outletoninsertplate 1Helper
Plumb,
c CentrelineofCoateratinletside&outletside.
Fittertoolbox
d Centrelineofdriveincludescentrelineofmaingearbox,mainmotor.
e Allfoundationpocketsshouldbecleantillthedepth.
Afterprovidingalltheabovedetailsalltheconcerndepartmentshouldsignthe
f protocol.

Totalstation,
Themechanicalcontractorshouldnowstarttheerectionactivities.Thecontractor
1MillFitter, Centrepunch,Hammer,
shouldfirstmarkallthecentrelinesatinlet,outletside.Theelevationmarkshouldbe Angle50x50x6
2 1Helperand Markingthread, 2days
transferredatallthedesiredlocations.TheCoatercenters,thesupportrollerbearing 20meter
1Welder Pianowire,
centersthestraightdistance&thediagonalshouldbechecked&marked.
50mtape

Slopemeasuringblock,
Masterlevel(.02mm/
Groutingofpadplateof25mmthkonwhichpackingplatesandtaperwadgeswill
Padplates25mmthkas 1MillFitterand mtraccuracy),Chipping
3 restshouldbedone.Thelevelofthepadplateshouldbecheckedinboththeaxis. 3days
required 2Helper chisel,Hammer,
Usemasterlevel&taperblockof3.3%slopeforleveling.
Daimondcuttergrinding
wheel
AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
Aftercompletingthepadplategrouting,thefoundationisreadyforsupportroller
baseframeerection.Withsuitablecrane,Winch,chainblockserectallthebase
framesattheirdesiredposition.Ensuretheorientationofbaseframebefore
loweringonthepackingplates.Alignallthebaseframes.Thealignmentchecksareas
below(asperapprovedITP)
a BaseframecentrewithrespecttoCoatercentre.
b Inclineddistanceofbaseframefloatingbearingtofixbearing.
c Digonaldistanceofbaseframefloatingbearingtofixbearing.
d Elevationofallthebaseframes.
Plumb,
e Baseframeslopetobecheckedbymasterlevelbyusingtaperblock. Solidpackingplates
Pianowire,
asrequired
f Axialgapbetweenbearinghousing&bearingouterraceonfloatingsideonly. 50mtape,
(1mmto25mm),
1Millfitter, Springbalance20kg,
g Dialreadingofbearings.[Axialalignment] stainlesssteelshims Machinetaper
1Fitter, Autolevelwith
h Torquetighteningofholdingdownbolts. ofthickness0.05mm, wedges8xperroller
4 2Helper, measuringscale, 10days
i Measurementofbearingclearances. 0.1mm,0.25mm, stationbaseframe
2Rigger, Slopemeasuringblock,
j Fillthebearingwithrequiredlubricant. 0.5mmand1mm,Steel
1Welder Masterlevel,
Aftercheckingalltheaboveaprotocolshouldbemaintained&shouldbesignedby forlockingthebase
k GrindingmachineAG4,
alltheconcerndepartments. frame
Fillerguage,
l Afterallthechecksaredonethebaseframeshouldbetemporarylocked. (Channel,Beam,Pipe),
Verniercalliper
Ensurethefoundationboltsseating&theboltshouldremainverticalbefore GP2groutingmaterial
m releasingforpocketgrouting.Theirshouldbeatleast4/5threadsabovethenutof
foundationbolts.
Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
n
basis.Curingtimeshouldbe7days.
Torquetighteningofallthefoundation.Anydifferenceobservedinelevationafter
toquetighteningmustbecorrected.Allthechecksmentionedinpointnumber5.To
o
berepeated&finalprotocoltobemade.Lockallthepackingplateswitheachother
bysuitablesteelrod.

Plumb,
Fabricationoftemporarystructureinsidethebuildingforhandling,aligningthe 50mtape,
CoaterdrumandErectionsaddles. Steelforstructure, Plumb,50mtape,
Erectionsaddles, 1Fitter,6Rigger, Grindingmachine
5 10days
Temperorysupport 2Welder,2Helper AG4,Waterlevel,
rollers,Rail100m 1''sling,chainblocks5,2
RailtobefixedonthetopofstructureforslidingtheCoater. tons,Manilarope100
meters
AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
GroundassemblyoftyreonCoatershell.Markthecentrelineoftyre&chairplates
oninletsideofCoaterdrumfromtheedge.PlacetheCoaterdrumonatemporary Steelframe,Support
6Rigger,
structurealongwithsaddle.Fixthechairplatesasperthepositionsmarked&tack roller,Scapfolding,
1MillFitter, Crane,
6 weldwiththedrum.Insertthetyreontotheshell&slideittoitsrequiredposition. Gratings,Axial Axialalignmentbrackets 3days
1Welder, 1''sling
Fixthetyreretainingring&lockittemporarywithstoppers.Fixtheaxialalignment alignmentbrackets,
1Helper
bracketsalongwithjackbolt&weldittothedrum,Taketheairgapreadings&make Woodensleppers
aprotocol.
AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
7 Repeatthesameprocedurefortheothertyre.
Crane,10tonschain
LiftthecompleteCoaterassemblyalongwiththetyre&placeitonthestructure. 8Rigger,1MillFitter,
8 block2nos,1''sling, 2days
Dragtheassemblytillitreachestherequiredposition. 1Welder
Manilarope
Temporarysupport 8Rigger,1MillFitter,
9 LowertheCoaterontothesupportrollers. Hydraulicjack 1day
rollers 1Welder
2Rigger,1Welder,
10 RemovetheentirestructureafterloweringtheCoater 1day
1Helper
11 Erect&positionthethruster. 1MillFitter,3Rigger Chainblocks5,2tons 2day

PostioningoftyresshouldstartafterloweringtheCoateronthemainsupportrollers. Weldingelectrodes
7018,Weldingrectifier
1MillFitter,
650amps,Mainoven,
Alignboththetyres&makeaprotocol. 2Rigger,
12 Scapfolding&gratings Axialalignmentbrackets Portableoven,thermo 8days
1Helper,
chalkorpyrometer,
Checktheairgap&recordit. 2Welder
Heatingtorch,Dial
guage,Fillerguage
Aligntheretainingringonbothsides[uphill&downhill]&weldthestoppers.Before
weldingpreheatingofstoppersshouldbedone.

ShiftonehalfofgearatthebottomoftheCoater.Bymeansofchainblockliftthe
gear&boltitwithCoaterflange,Putfewbolts&tightit.Makesuitablearrangement
forrotationofCoater.Makeothersidethelockingarrangementtoavoid Torquewrench,
unbalancing.RotatetheCoatersuchthatbottomhalfnowremainsonthetop.Lift 1MillFitter, Winch10toncapacity
theotherhalfofgear&jointitwiththeprevioushalf.Checkthejointgap&ensureit 8Rigger, forgranulatorrotating,
13 Scapfolding&gratings Alignmentfixtures 8days
iszerobycheckingwithfillergauge.Torquetightenedthejointbolt. 1Welder, Fillerguage,
1Helper Dialguages3nos,
a Makethefixturesforaligningthegear.[Axial&radial]
Chainblocks10,5tons
b Checkthealignment&makeaprotocol.
c Flangeboltstobetorquetightened.
d Aftertorquetightenedrecheckthealignment&makeaprotocol.

Groundassemblyofpinionbearings.Initiallyidentifythepositionofbearings.Before
startingthebearingassemblycheck&cleanthepinionshaftsurface.
Bearinglocknut
Disel/Petrol,
a Checktheshaft&bearingsurface. tighteningspanner,
Cleaningcloth, 1MillFitter,
14 b Fitadaptorsleevandbearingsontheshaft. Fillerguage, 2days
Lubricant, 3Rigger
c Tightthelocknut. Suitabletorquewrench,
Oilbathtub
d Assembletheplummerblockanditssealingarangement. Fittertoolbox
e Fixthecoupling.
f Assemblethebearingonthepinionshaftmeasuretheclearances.
AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor

Slopemeasuringblock,
Masterlevel(.02mm/
Groutingofpadplateof25mmthkonwhichpackingplatesandtaperwadgeswill
1MillFitterand mtraccuracy),Chipping
15 restshouldbedoneondrivefoundation.Thelevelofthepadplateshouldbechecked Solidpackingplates 3days
2Helper chisel,Hammer,
inboththeaxis.Usemasterlevel&taperblockof3.3%slopeforleveling.
Daimondcuttergrinding
wheel

Crane,Winch,Chain
16 Erectthedrivebaseframe. 2Rigger,2Helper block5tons, 1day
1''Sling,Manilarope
Erectthepinionshaftassemblyonthepinionbaseframe.
a Alignthepinionassemblywithgirthgear.Checkthefollowing.
b Checkthebacklash,rootclearance&contact
c Checkthepinioncentrewithrespecttocoolercentre
17
d Checkdistancebetweenfixedbearing&floatingbearing.
e Checkelevationofbaseframe.
f Checkslopeofbaseframe.
g Afterallthechecksaredonethebaseframeshouldbetemporarylocked. Solidpackingplates Plumb,
Erectthemaingearbox asrequired Pianowire,
a Fixtheinput&outputcouplings (1mmto25mm), 50mtape,
b Alignthegearbox&checkthefollowing. stainlesssteelshims 1Millfitter, Springbalance20kg,
c Maingearboxoutputshaftcentrewithrespecttopinionbearingcenters. ofthickness0.05mm, 1Fitter, Autolevelwith
18 Machinetaper
d Elevationofgearboxshouldbecheckedatall4corners. 0.1mm,0.25mm, 2Helper, measuringscale, 15days
wedges12x
e Couplingtocouplingstraight&diagonaldistance. 0.5mmand1mm,Steel 2Rigger, Slopemeasuringblock,
f Masterlevelofgearbox. forlockingthebase 1Welder Masterlevel,
g Torquetighteningofgearboxholdingdownbolts. frame GrindingmachineAG4,
Erectthemainmotor (Channel,Beam,Pipe), Fillerguage,
a Radial&axialalignment. GP2groutingmaterial Verniercalliper
19
b Couplinggap.
c Torquetighteningofmotorholdingdownbolts.

Ensurethefoundationboltsseating&theboltshouldremainverticalbeforerealizing
20
forpocketgrouting.Theirshouldbeatleast4/5threadsabovethenut.

Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
21
bases.Curingtimeshouldbe7days.

Aftercuringfulltightenedthefoundationbolts.Anydeviationobservedshouldbe
22
corrected.Alltheabovepointstoberechecked&readingsshouldberecorded.
AnnexureI
Activityschedule,Resources&MachineryRequirmentforCoater
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
23 Installthelubricationunit.Levelthelubricationunit&releaseitforgrouting. 1Fitter,2Helper Waterlevel 1day
24 Completethepipingbetweenlubricationunit&maingearbox. 1Fitter,2Helper Fittertoolbox 1day
25 Filltherecommendedoilinmaingearbox. Lubricant 1Rigger 1day
1Fitter,4Rigger,1
26 Install&alignthetyreandgearguard&fixitssupport Scapfolding,gratings Chainblock,Sling1'' 2days
Welder
27 Propergap&sealingtobedonenearpinionshaft. 1Fitter,1Helper 1day
28 Installthelubricationunit&spraypanels 1Fitter,1Helper Fittertoolbox 1day

29 Completethepipingfromlubricationunittospraypanel. 1Fitter,2Helper Benchvice,pipebender 2days

a Erectthebottomhalfoftheinlethood
Plumb,Waterlevel,
b Erectthetophalfofinlethood 4Rigger,1Fitter,
30 1''sling,chainblocks 5days
c Installthesealingarrangementatinlet. 1Welder
5/2/1tons,Manilarope
d Alignthecompleteinlethopper&fixthesupports.
a Erectthebottomhalfoftheoutlethood
Plumb,Waterlevel,
b Erectthetophalfofoutlethood 4Rigger,1Fitter,
31 1''sling,chainblocks 5days
c Installthesealingarrangementatoutlet. 1Welder
5/2/1tons,Manilarope
d Alignthecompleteoutlethopper&fixthesupports.
32 InsertandfixtheCoatinglanceinsidethecoater.

Note
Allrequiredtools,tacklesandconsumables(likeelectrodes,oxygen,acetylene,
1 grindingwheels,oiletc.)requiredforerectionworktobesuppliedbyerection
contractor.
SpecialtoolsandtackleswillbesuppliedbyTKIIasperlistmentionaboveinpointno.
2
2.a.ii.
thyssenkrupp Industries India

2. Mechanical Erection Instructions for Coater


b. Erection activities and sequence

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Erection activities and sequence:


1. To begin with the Coater erection work the foundation of first & second pier should be
completed in all respect. A joint protocol should be maintained & signed by the civil
department from client side, the supplier & the erection contractor. The civil department
should give the following before handing over the foundation for mechanical erection.
a) Insert plates at inlet & outlet side
b) Reference elevation mark at inlet & outlet on insert plate.
c) Centre line of Coater at inlet side outlet side.
d) Centre line of drive includes centre line of main gear box, main motor.
e) All foundation pockets should be clean till the depth.

After providing all the above details all the concern department should sign the protocol.
2. The mechanical contractor should now start the erection activities. The contractor should
first mark all the centre lines at inlet, outlet & on all the piers. The elevation mark should
be transferred at all the desired locations. The Coater centers, the support roller bearing
centers the straight distance & the diagonal should be checked & marked. [Refer sketch
no.1]

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[Sketch no. 1]

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3. Grouting of pad plate of 25 mm thk on which packing plates and taper wedges will rest
should be done. The level of the pad plate should be checked in both the axis. Use master
level & taper block of 3.3 % slope for leveling.
4. After completing the pad plate grouting, the foundation is ready for support roller base
frame erection. With suitable crane, Winch, chain blocks erect all the base frames at their
desired position & elevation by giving solid placing plates & machine taper wedges.
Ensure the orientation of base frame before lowering on the packing plates. Align all the
base frames. The alignment checks are as below (as per approved ITP)
a) Base frame centre with respect to Coater centre
b) Inclined distance of base frame floating bearing to fix bearing.
c) Diagonal distance of base frame floating bearing to fix bearing.
d) Elevation of all the base frames.
e) Base frame slope to be checked by master level by using taper block.
f) Axial gap between bearing housing & bearing outer race on floating side only.
g) Dial reading of bearings. [Axial alignment]
h) Torque tightening of holding down bolts.
i) Measurement of bearing clearances.
j) Fill the bearing with required lubricant.
k) After checking all the above a protocol should be maintained & should be signed
by all the concern departments.
l) After all the checks are done the base frame should be temporary locked.
m) Ensure the foundation bolts seating & the bolt should remain vertical before
realizing for pocket grouting. There should be at least 4/5 threads above the nut.
n) Release the foundation for pocket grouting. Proper curing should be done on daily
bases. Curing time should be 7 days.
o) Torque tightening of all the foundation bolts. Any difference observed in elevation
after toque tightening must be corrected. All the checks mentioned in point
number 4 to be repeated & final protocol to be made. Lock all the packing plates
with each other by suitable steel rod.
5. Fabrication of temporary structure inside the building for handling, aligning the Coater
drum and Erection saddles. Rail to be fixed on the top of structure for sliding the Coater.
6. Ground assembly of tyre on Coater shell. Mark the centre line of tyre & chair plates on
inlet side of Coater drum from the edge. Place the Coater drum on a temporary structure
(Tyre erection base frame for ground assembly TKII Drawing No. FRT-RD-00303-2/0)

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along with saddle. Fix the chair plates as per the positions marked & tack weld with the
drum. Insert the tyre on to the shell & slide it to its required position. Fix the tyre retaining
ring & lock it temporary with stoppers. Fix the axial alignment brackets along with jack bolt
& weld it to the drum, Take the air gap readings & make a protocol.
7. Repeat the same procedure for the other tyre.
8. Lift the complete Coater assembly along with the erection saddles (TKII Drawing No. FRT-
RD-00307-3/0) & tyres & place it on the structure. Drag the assembly till it reaches the
required position.
9. Lower the Coater on to the support rollers (TKII Drawing No. FRT-RD-00302-1/0).
10. Remove the entire structure after lowering the Coater.
11. Erect & position the thruster.
12. Positioning of tyres should start after lowering the Coater on the main support rollers.
a. Align both the tyres & make a protocol.
b. Check the air gap & record it.
c. Align the retaining ring on both sides [uphill & downhill] & weld the stoppers. Before
welding preheating of stoppers should be done.
13. Shift one half of gear at the bottom of the Coater. By means of chain block lift the gear &
bolt it with Coater flange, Put few bolts & tight it. Make suitable arrangement for rotation
of Coater. Make other side the locking arrangement to avoid unbalancing. Rotate the
Coater such that bottom half now remains on the top. Lift the other half of gear & joint it
with the previous half. Check the joint gap & ensure it is zero by checking with filler gauge.
Torque tightened the joint bolt.
14. Ground assembly of pinion bearings. Initially identify the position of bearings. Before
starting the bearing assembly check & clean the pinion shaft surface.
a. Check the shaft & bearing surface.
b. Fit adaptor sleeve and bearings on the shaft.
c. Tight the lock nut.
d. Assemble the Plummer block and its sealing arrangement.
e. Fix the coupling.
f. Assemble the bearing on the pinion shaft measure the clearances.
15. Grouting of pad plate of 25 mm thk on which packing plates and taper wedges will rest
should be done on drive foundation. The level of the pad plate should be checked in both
the axis. Use master level & taper block of 3.3 % slope for leveling.
16. Erect the drive base frame.

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17. Erect the pinion shaft assembly on the pinion base frame.
a. Align the pinion assembly with girth gear. Check the following.
b. Check the backlash, root clearance & contact
c. Check the pinion centre with respect to Coater centre
d. Check distance between fixed bearing & floating bearing.
e. Check elevation of base frame.
f. Check slope of base frame.
g. After all the checks are done the base frame should be temporary locked.
18. Erect the main gear box.
a. Fix the input & output couplings.
b. Align the gear box & check the following.
c. Main gear box output shaft centre with respect to pinion bearing centers.
d. Elevation of gear box should be checked at all 4 corners.
e. Coupling to coupling straight & diagonal distance.
f. Master level of gear box.
g. Torque tightening of gear box holding down bolts.
19. Erect the main motor.
a. Radial & axial alignment.
b. Coupling gap.
c. Torque tightening of motor holding down bolts.
20. Ensure the foundation bolts seating & the bolt should remain vertical before realizing for
pocket grouting. There should be at least 4/5 threads above the nut.
21. Release the foundation for pocket grouting. Proper curing should be done on daily bases.
Curing time should be 7 days.
22. After curing full tightened the foundation bolts. Any deviation observed should be
corrected. All the above points to be rechecked & readings should be recorded.
23. Install the lubrication unit. Level the lubrication unit & release it for grouting.
24. Complete the piping between lubrication unit & main gear box.
25. Fill the recommended oil in main gear box.
26. Install & align the gear guard & fix its support.
27. Proper gap & sealing to be done near pinion shaft.
28. Install the lubrication unit & spray panels.
29. Complete the piping from lubrication unit to spray panel.
30. Erect the feed hopper.

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a. Erect the bottom half of the inlet hood.


b. Erect the top half of inlet hood.
c. Install the sealing arrangement at inlet.
d. Align the complete feed hopper & fix the supports.
31. Erect the discharge hopper.
a. Erect the bottom half of the discharge hood.
b. Erect the top half of discharge hood.
c. Install the sealing arrangement at discharge.
d. Align the complete discharge hopper & fix the supports.
32. Insert and fix the Coating lance inside the coater.

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3. Erection schedule for Coater

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4. Quality Assurance :
a. Protocols & ITP

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Protocols & ITP:


1. List of Protocols:
a) KN.01en Vs02_Drum_Shell_Section_Lengths
b) KN.03en Vs02_Supporting_Rollers (Alignment)
c) KN.05en Vs01, Vs04_Axial_eccentricity_of_tyre
d) KN.06en Vs00_Contact_Situation_at_Rollers
e) KN.07en Vs02_Concentricity_drum_cylinder
f) TM.10en Vs04_Girth gear
g) KN.12en Vs01_Tyre_Shim_Plates
h) KN.20en Vs01 Measurement record for 2-support rotary drum
i) TM.03en Vs01_Meshing_-_Temperature

2. ITP:
For commented site ITP, please refer annexure II.

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a) Protocol- KN.01en Vs02_Drum_Shell_Section_Lengths

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b) Protocol- KN.03en Vs02_Supporting_Rollers (Alignment)

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c) Protocol- KN.05en Vs01, Vs04_Axial_eccentricity_of_tyre

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d) Protocol- KN.06en Vs00_Contact_Situation_at_Rollers

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e) Protocol- KN.07en Vs02_Concentricity_drum_cylinder

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f) Protocol- TM.10en Vs04_Girth gear

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g) Protocol- KN.12en Vs01_Tyre_Shim_Plates

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h) Protocol- KN.20en Vs01 Measurement record for 2-support rotary drum

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i) Protocol- TM.03en Vs01_Meshing_-_Temperature

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2. ITP
For Site ITP, refer annexure II

Erection Manual For Coater


CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

1 PRE ERECTION ACTIVITIES

Review with drawings / Packing list /


As per approved drawings. No records P W NA R
Name plate
1.1 Equipment on receipt at site

Match / erection marks. As per approved drawings No records P W NA -

Verify the signed foundation handing


KN.20en Vs01 Measurement
over protocol for dimensions / level / As per approved drawings / equipment
1.2 Take over of foundation record for 2-support rotary P W W RAN
centre line co-ordinates / number and layout / orientation drawing / template.
drum
size of pockets / foundation bolts.

Chipping & grouting of packing plate on


foundation for erection of equipment.
As per approved drawings / equipment
1.3 Preparation of foundation Marking of centre line on foundation, No records P W W RAN
layout / orientation drawing / template.
No./dia/length of anchor bolts,depth of
pocket,verticality of pockets.

Manufacturer's test certificate / Calibration


Calibration of testing & measuring
1.4 Range/ suitability/validity certificates from TKIS, India recognised Test certificates P H NA R
instruments.
laboratories

Preparation of erection scheme,


adequacy of erection space for Feasibility/safety considering plot plan,
1.5 receiving / erection of equipment, equipment layout, erection data sheet Feasible and safe erection scheme Approved erection scheme P H NA R
placement of main / trailing cranes and load chart. Physically check the area.
etc.

Fitness certificate & load chart and


Scrutiny of crane documents including
Adequacy of crane capacity, lifting validity. appropriate derating commensurate with Crane documents P W NA R
1.6 beam / slings / shakles / wire rpoes the age of the crane / safety factor.
etc,
General appearance No external damage. No records
P R NA R
Trial load test, if required. Passing the load test Test Certificate

Improvements made, if required, as per


As per soil investigation report. Soil reports P R NA R
Soil investigation report
Strengthening of soil at erection front,
1.7
if required Trial loading using moving loads, if No soil settlement noticed with visual
Approved Erection scheme P RAN NA RAN
required. inspection.

Page 1 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

2 INSTALLATION

Base Frame of Supporting rollers


2.1
(Before Pocket Grouting)

KN.20en Vs01 Measurement


100% dimensional checking. Measurement
2.11 Elevation record for 2-support rotary P W W R
within + / -1 mm
drum

100% dimensional checking. (Measured by KN.20en Vs01 Measurement


2.12 Centre Distance applying spring balance tension) record for 2-support rotary P W W R
Measurement within +/-2 mm drum

100% dimensional checking. (Measured by KN.20en Vs01 Measurement


2.13 Diagonal Distance applying spring balance tension) record for 2-support rotary P W W R
Measurement within +/-3 mm drum

KN.20en Vs01 Measurement


100% checking by taper block / auto level.
2.14 Baseframe Slope record for 2-support rotary P W W R
Levelling accuracy of 0.1 mm/ mtr.
drum

Levelling of base frames across the drum 100% checking by auto level. Levelling
2.15 PIN LI-CQA-204-F-02 P W W R
centreline. accuracy of 0.1 mm/ mtr.

As above from sr. no. 2.11 to


Completed initial alignment (as above
As above from sr. no. 2.11 to 2.15 2.16 and pocket grouting P H W R
from sr. no. 2.11 to 2.15)
clearance in writing
Pocket Grouting of Foundation
2.2
Bolts
Cleanliness of the pockets and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W W RAN
grout material

Base Frame of Supporting rollers


2.3
(After Pocket Grouting)

KN.20en Vs01 Measurement


100% dimensional checking. Measurement
2.31 Elevation record for 2-support rotary P W W W
within + / -1 mm
drum

100% dimensional checking. (Measured by KN.20en Vs01 Measurement


2.32 Centre Distance applying spring balance tension) record for 2-support rotary P W W W
Measurement within +/-2 mm drum

Page 2 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

100% dimensional checking. (Measured by KN.20en Vs01 Measurement


2.33 Diagonal Distance applying spring balance tension) record for 2-support rotary P W W W
Measurement within +/-3 mm drum

KN.20en Vs01 Measurement


100% checking by taper block / auto level.
2.34 Baseframe Slope record for 2-support rotary P W W W
Levelling accuracy of 0.1 mm/ mtr.
drum

Levelling of base frames across the drum 100% checking by auto level. Levelling
2.35 PIN LI-CQA-204-F-02 P W W W
centreline. accuracy of 0.04 mm/ mtr.

2.36 Tightnesss of Foundation Bolts 100% Hammer tight No records P W W W

2.37 Tightness of Packing Plate 100% Hammer tight No records P W W W

2.4 Support Rollers

KN.03en
100% dimensional checking. Measurement
2.41 Elevation Vs02_Supporting_Rollers P W W W
within +/-1 mm
(Alignment)
KN.03en
Centre to centre distance between rollers 100% dimensional checking. Measurement
2.42 Vs02_Supporting_Rollers P W W W
at same pier (Both uphill and downhill) within +/-0.5 mm
(Alignment)
100% dimensional checking. Measurement
2.43 Diagonal between rollers at same pier PIN LI-CQA-204-F-03 P W NA W
within +/-1 mm

100% checking by taper block / auto level.


2.44 Roller slope PIN LI-CQA-204-F-04 P W W W
Levelling accuracy of 0.04 mm/ mtr.

2.5 Thrust Roller Assly.

Centre to centre distance from nearest 100% dimensional checking. Measurement


2.51 PIN LI-CQA-204-F-03 P W W R
support rollers frame within +/- 1 mm.
100% checking by taper block / auto level.
2.52 Slope PIN LI-CQA-204-F-04 P W W R
Levelling accuracy of 0.04 mm/ mtr.
Levelling of thrust roller across the drum 100% checking by auto level. Levelling
2.53 PIN LI-CQA-204-F-04 P W W R
centreline. accuracy of 0.04 mm/ mtr.
Lowering of drum on support
2.6 As above As above Clearance in writing P H W R
rollers

2.7 Drum Erection

2.71 Shell Checking (Before positioning) Orientation As per approved drawing P W W RAN

Page 3 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
Dimensional check (Diameter) at 8 - 12
places at shell ends. Measurement within +/-
KN.07en
3.7 mm for dryer
Concentricity Vs02_Concentricity_drum_cy P W W RAN
+/- 3.0 mm for cooler
linder
+/- 3.3 mm for granulator
+/- 2.2 mm for coater

Weld Joint checking / Preparation As per approved drawing PIN LI-CQA-202-F-04 P W W RAN

Page 4 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
KN.01en
Longitudinal measurement. Acceptable
Overall Dimension Vs02_drum_Shell_Section_L P W W RAN
tolerance +/- 5 mm.
engths

2.72 Shell Fit up Joint Gap Asper drawing PIN LI-CQA-202-F-04 P W W RAN

Filler gauge measurement. Tolerance 1.5


Joint mismatch PIN LI-CQA-202-F-04 P W W RAN
mm.
+/- 3.7 mm for dryer
KN.07en
Radial run out at 8-12 positions at each +/- 3.0 mm for cooler
Vs02_Concentricity_drum_cy P W W RAN
joint +/- 3.3 mm for granulator
linder
+/- 2.2 mm for coater
PIN LI-CQA-202-F-05
Shell Flange runout (Radial & axial) +/- 2.5 mm P W W RAN
PIN LI-CQA-202-F-06

2.73 Shell Welding Clearance As above As above PIN LI-CQA-202-F-04 P H W R

2.74 Shell Welding

PIN LI-CQA-213-F-01
Establishment of WPS/PQR Approval of WPS/PQR ASME Sec IX - latest edition. P H NA R
PIN LI-CQA-213-F-02

Check welders certification and witness ASME Sec IX - latest edition. / approved
Welder Qualification PIN LI-CQA-213-F-03 P H NA R
tests WPS/PQR

ASME Sec IIC - latest edition. Approved


Consumables. Conformity to specification & validity. PIN LI-CMM-01-F-01 P R NA R
WPS and manufacturer's test certificates.

Shell Joint NDT 100% DPT after back chipping ASME section VIII PIN LI-CQA-214-F-01 P R NA R

Radiography of 100% T-Joint and 20% of


No defects PIN LI-CQA-216-F-01 P R NA R
circumferential seam.

2.8 Tyre

Measured at 8 - 12 axial positions (equally


distant) on each tyre. Runout within
KN.05en Vs01,
+/- 0.47 mm for dryer
2.81 Axial Runout Vs04_Axial_eccentricity_of_t P W W R
+/- 0.37 mm for cooler
yre
+/- 0.41 mm for granulator
+/- 0.27 mm for coater

100% dimensional checking as per


2.82 Retainer Block Fixing Inspection Format P W W R
approved drawing. Tolerance +/- 1 mm.

Page 5 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

2.83 Retainer Block Welding Visual inspection as per ASME section VIII Inspection Report P W NA R

Page 6 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
KN.06en
Tyre / Roller Contact 80 % Contact by visual inspection Vs00_Contact_Situation_at_ P W W RAN
Rollers

2.9 Drive Assembly

2.91 Girth Gear erection (Spring Mounted)

2.911 Spring plate

a Orientation 100% visual inspection as per drawing. No records P W W RAN

b Torque tightening of bolts Torque value as per drawing Torque Tighteneing Record P RAN W R

2.912 Girth Gear

a Gear Fit up As per assembly drawing No records P W W R

b Gear Joint Gap Within 0.05 mm No records P W W R

Axial run out -


+/- 0.59 mm for dryer
KN.08en Vs03_Girth_Gear -
+/- 0.42 mm for cooler
c Gear Axial and Radial Run Out for dryer and cooler P W W R
Radial run out -
+/- 1.05 mm for dryer
+/- 0.84 mm for cooler

d Torque Tightening of Gear Joining Bolts Torque value as per drawing Torque Tighteneing Record P RAN W R

2.92 Girth Gear Erection (Flange Mounted)

Axial run out -


+/- 0.2 mm for granulator
Gear Joining Flange Axial & Radial Run +/- 0.2 mm for coater
a As per drawing P W R
Out Radial run out -
+/- 0.3 mm for granulator
+/- 0.3 mm for coater

b Gear Fit up As per assembly drawing No records P W W R

Page 7 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

c Gear Joint Gap Within 0.05 mm No records P W W R

Axial run out -


+/- 0.25 mm for granulator
+/- 0.13 mm for coater TM.10en Vs04_Girth gear -
d Gear Axial and Radial Run Out P W W R
Radial run out - for granulator and coater
+/- 0.3 mm for granulator
+/- 0.18 mm for coater

e Torque Tightening of Gear Joining Bolts Torque Value as per drawing Torque Tighteneing Record P RAN W R

2.93 Pinion Erection

Pinion Base Frame (Before Pocket


2.931
Grouting)

100% dimensional checking. Measurement PIN LI-CQA-204-F-10


a Elevation P W W R
within +/-4 mm

100% dimensional checking. (Measured by


PIN LI-CQA-204-F-10
b Centre Distance applying spring balance P W W R
tension)Measurement within +/-2 mm
100% checking by taper block / auto level. PIN LI-CQA-204-F-10
c Baseframe Slope P W W R
Levelling accuracy of 0.1 mm/ mtr.

Levelling of base frames across the drum 100% checking by auto level. Levelling PIN LI-CQA-204-F-10
d P W W R
centreline. accuracy of 0.1 mm/ mtr.

As above from sr. no. 2.931


Completed initial alignment (as above
As above from sr. no. 2.931 a,b,c,d a,b,c,d and pocket grouting P H NA R
from sr. no. 2.931 a,b,c and d.)
Pocket Grouting of Foundation clearance in writing
2.932
Bolts
Cleanliness of the pockets and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W NA RAN
grout material

Pinion Base Frame (After Pocket


2.933
Grouting)

100% dimensional checking. Measurement PIN LI-CQA-204-F-10


a Elevation P W W W
within +/-2 mm

100% dimensional checking. (Measured by


PIN LI-CQA-204-F-10
b Centre Distance applying spring balance P W W W
tension)Measurement within +/-1 mm
100% checking by taper block / auto level. PIN LI-CQA-204-F-10
c Baseframe Slope P W W W
Levelling accuracy of 0.04 mm/ mtr.

Page 8 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

Levelling of base frames across the drum 100% checking by auto level. Levelling PIN LI-CQA-204-F-10
d P W W W
centreline. accuracy of 0.04 mm/ mtr.

e Tightnesss of Foundation Bolts 100% Hammer tight No records P W W W

f Tightness of Packing Plate 100% Hammer tight No records P W W W

2.934 Pinion Alignment

KN.08en Vs03_Girth_Gear -
As per drawing. Measured at 8 - 12 for dryer and cooler
a Root Clearance and Backlash P W W R
locations TM.10en Vs04_Girth gear -
for granulator and coater
KN.08en Vs03_Girth_Gear -
for dryer and cooler
b Contact with Gear Blue matching with 70-80% contact. P W W R
TM.10en Vs04_Girth gear -
for granulator and coater

c Free End Bearing Float 6 mm or as per drawing P W W R


PIN LI-CQA-204-F-11

As per drawing / recommended by bearing


Bearing - Radial Clearance P W W R
manufacturer PIN LI-CQA-204-F-11

Pinion Teeth Temperature (During pre +/- 2 degrees celsius across entire tooth TM.03en Vs01_Meshing_-
P W W R
commissioning trial run) flank. _Temperature

Main Gear box, Auxiliary Gear Box


2.94
and Motor

PIN LI-CQA-204-F-10
a Base Frame As per pinion base frame P W W R

As per supplier manual or 0.1 mm for axial PIN LI-CQA-204-F-14


b Coupling Alignment Axial and Radial Alignment P W W R
0.15 mm for radial. PIN LI-CQA-204-F-15

2.95 Gear Hood As per Drawing No records P RAN W R

Completed final alignment (as above sr. As above. Sr. no. 2 and final
As above (sr. no. 2) P H NA R
no. 2) grouting clearance in writing
Full Grouting of base plates and
3
foundation bolts
Cleanliness of foundations and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W NA RAN
grout material

Page 9 of 10
CLIENT LOGO CONTRACTOR LOGO

Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION

NNNN PIN LEP-CQA-002-A204

Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client

4 QC documents Check completeness & correctness As per drawing and specification QC dossier P H NA R

Legend:
P - Perform
H - Hold point ( further sequential work shall commence only after clearance from TKIS-India/TPI/PMC/Client - as applicable)
R - Review & approve
RAN - Random witness
W - Witness & approve

Page 10 of 10
thyssenkrupp Industries India

4. Quality Assurance :
b. WPS

Erection Manual For Coater Page 72 of 81


thyssenkrupp Industries India

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Erection Manual For Coater Page 80 of 81


thyssenkrupp Industries India

4. Quality Assurance :
c. Consumables specification with estimated qty
- Electrode : E7018
- Approx. qty: 50 Kgs

Erection Manual For Coater Page 81 of 81

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