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Copyright 2015 : All rights reserved
ThyssenKrupp Industrial Solutions (India) Private Limited
thyssenkrupp Industries India
Erection Manual
For
Granulator Drum 3.3 x 9M
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 Granulator
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 Granulator
4. Quality Assurance :
a. Protocols & ITP
b. WPS
c. Consumables specification with estimated qty
Granulator 3.3x9m + 700mm Grizzly will be dispatched as single unit, the details of which are as follows:
Dispatchable unit1
Length - 9000 mm
Weight - ~ 24000 kg
Tyre Weight ~3800 kg
Tyre OD 3710 mm
Granulator Drum
Process Parameters
Material : NPK / DAP
Bulk density : 940-1100 kg /m3 (At drum out)
Feed Size : >4mm 4-8%
: 2-4 mm 18-32%
: <2 mm 59-79%
Capacity (Normal) : 110 - 200 TPH
Capacity (Design) : 250 TPH
Duty per day : 24 Hrs
Product Moisture : 2.35-2.65% / 4 %
Equipment details
Granulator Drum Size : 3300 mm Dia. x 9000 mm Long
Slope : 3%
Shell Plate Thk : 16 mm Min
Granulator Drum Speed : 7 - 10 rpm
Grizzly
Width : 700 mm
Riding Rings
Diameter : 3413 ID mm - 3710 OD mm
Width : 290 mm
Trunnion Rollers
Diameter : 810 mm
Width : 330 mm
Thrust Rollers
Diameter : 450 mm
Width : 170 mm
Bearing Type : Roller bearing
Set of Lining
Lining Material : EPDM Rubber
Enlargement : 300 %
Specific weight : 1200 kg/m3
Abrasion resistance : 200 mm3
Hardness : Shore 60
Tear Resistance : 35 kg/cm
Breaking load : 12 MPa
Temperature resistance : 180 C
Ring Gear
Type : Spur teeth
No. of Teeth : 174
Module : 24
Face Width : 280 mm
Pinion
Type : Spur teeth
No. of Teeth : 23
Module : 24
Face Width : 330 mm
Drive System
Gearbox type : Helical
Main motor power : 225 kW,
Main motor speed : 1500 rpm
Aux. motor power : 15 kW
Aux. motor speed : 1500 rpm
Drive arrangement : Girth gear & pinion
Speed control : Variable frequency drive
PN slurry pipe
Length : 6220 mm
Pipe Size / Schedule : DN100 Sch 40S
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.
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.
Please refer below sketch for the foundation details of Granulator drum.
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,
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
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 Granulator and cooler 1 Set
2 Shell erection wedges and clits for Granulator and cooler 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
Totalstation,
Themechanicalcontractorshouldnowstarttheerectionactivities.Thecontractor
1MillFitter, Centrepunch,Hammer,
shouldfirstmarkallthecentrelinesatinlet&outletside.Theelevationmarkshould Angle50x50x6
2 1Helperand Markingthread, 2days
betransferredatallthedesiredlocations.TheGranulatorcenters,thesupportroller 20meter
1Welder Pianowire,
bearingcentersthestraightdistance&thediagonalshouldbechecked&marked.
50mtape
Slopemeasuringblock,
Masterlevel(.02mm/
Groutingofpadplateof25mmthkonwhichpackingplatesandtaperwadgeswill
Padplates25mmthkas 1MillFitterand mtraccuracy),Chipping
3 restshouldbedone.Thelevelofthepadplateshouldbecheckedinboththeaxis. 3days
required 2Helper chisel,Hammer,
Usemasterlevel&taperblockof3%slopeforleveling.
Daimondcuttergrinding
wheel
Groundassemblyoftyreongranulatorshell.Markthecentrelineoftyre&chair
platesoninlet/outletsidegranulatordrumfromtheedge.Placethegranulator Steelframe,Support
drumonatemporarystructurealongwithsaddle.Fixthechairplatesasperthe roller,Scapfolding,
6Rigger,2Helper, Crane,
4 positionsmarked&tackweldwiththedrum.Insertthetyreontothedrum&slideit Gratings,Axial Axialalignmentbrackets 3days
1Millfitter,1Welder 1''sling
toitsrequiredposition.Fixthetyreretainingring&lockittemporarywithstoppers. alignmentbrackets,
Fixtheaxialalignmentbracketsalongwithjackbolt&weldittothedrum,Takethe Woodensleppers
airgapreadings&makeaprotocol.
5 Repeatthesameprocedurefortheothertyre
AnnexureI
Activityschedule,Resources&MachineryRequirmentforGranulator
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
Fabricationoftemporarystructureinside&outsidethebuildingforgranulator
erection. Plumb,
50mtape,
a RailtobefixedonthetopofstructureforslidingtheGranulator. GrindingmachineAG4,
Waterlevel,
Steelforstructure,Rail 1Fitter, 1''sling,
b Saddletobemodifiedforliftingpurpose. 100m, 8Rigger, Chainblocks5,2tons,
6 10days
Hydraulicjacks, 2Welder, Manilarope
Woodensleepers 4Helper Crane,
10tonchainblock,
Withsuitablecraneliftthegranulator&keepitonabovestructure.Makenecessary 2"slingforlifting&1
c arrangementfordraggingthegranulatortoitsposition.Nowliftthegranulatorupto inchslingfordragging,
topavailablespaceandsupportitwithsuitablestructure/woodensleepers. Manilarope100meters
Aftreliftingthegranulatortothetop,removethestructurefromthefloor&clearthe 4Rigger,
7
onlyareawheresupportrollerbaseframeistobemounted. 1Welder
Afterremovingthestructure,withsuitablecrane&chainblocksliftthebaseframe
alongwiththesupportrollers&positionit,andforalignmentcheckthefollowing.
a BaseframecentrewithrespecttoGranulatorcentre.
b Inclineddistanceofbaseframefromfixedbearingtofloatingbearing.
c Diagonalfromfixedbearingtofloatingbearingbaseframe. Solidpackingplates Plumb,
d Elevationoffixed&floatingbaseframes. asrequired Pianowire,
(1mmto25mm), 50mtape,
e Axialgapbetweenbearinghousing&bearingouterraceonfloatingsideonly.
stainlesssteelshims Springbalance20kg,
1Millfitter,
f Dialreadingofbearings.[Axialalignment] ofthickness0.05mm, Machinetaper Autolevelwith
1Fitter,
g Torquetighteningofholdingdownbolts. 0.1mm,0.25mm, wedges8xperroller measuringscale,
8 2Helper, 4days
h Measurementofbearingclearances. 0.5mmand1mm,Steel stationbaseframe Slopemeasuringblock,
2Rigger,
i Fillthebearingwithrequiredlubricant. forlockingthebase Masterlevel,
1Welder
j Baseframeslopetobecheckedbymasterlevelbyusingtaperblock. frame GrindingmachineAG4,
Aftercheckingalltheaboveaprotocolshouldbemaintained&shouldbesignedby (Channel,Beam,Pipe), Fillerguage,
k
alltheconcerndepartments. GP2groutingmaterial, Verniercalliper,
l Afterallthechecksaredonethebaseframeshouldbetemporarylocked. Molycot Dialgauge
Ensurethefoundationboltsseating&theboltshouldremainverticalbeforerealizing
m
forpocketgrouting.Theirshouldbeatleast4/5threadsabovethenut.
Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
n
bases.Curingtimeshouldbe7days.
AnnexureI
Activityschedule,Resources&MachineryRequirmentforGranulator
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
1Millfitter,
Torquetighteningofallthefoundationbolts.Anydifferenceobservedinelevation
1Fitter,
aftertoquetighteningmustbecorrected.Allthechecksmentionedinpointnumber Steelrod8mmthk, Suitablecapacitytorque
9 1Helper,
4toberepeated&finalprotocoltobemade.Lockallthepackingplateswitheach 100meters wrenchandsockets
1Rigger,
otherbysuitablesteelrod.
1Welder
Lowerthegranulatorontothesupportrollers. 8Rigger,1MillFitter,
10 Hydraulicjacks4nos 3days
Removetheremainingstructureafterloweringthegranulator. 1Welder,1Helper
11 Erect&positionthethruster. 1MillFitter,3Rigger Chainblocks5,2tons 2day
PostioningoftyresshouldstartafterloweringtheGranulatoronthemainsupport
rollers.
Weldingelectrodes
7018,Weldingrectifier
a Alignthetyreatinletsideandoutletsideandmakeaprotocol. 1MillFitter,
650amps,Mainoven,
2Rigger,
12 Scapfolding&gratings, Axialalignmentbrackets Portableoven,thermo 8days
1Helper,
b Checktheairgap&recordit. chalkorpyrometer,
2Welder
Heatingtorch,Dial
guage,Fillerguage
Aligntheretainingringonbothsides[uphill&downhill]&weldthestoppers.Before
c
weldingpreheatingofstoppersshouldbedone.
Shiftonehalfofgearatthebottomofthegranulator.Bymeansofchainblockliftthe
gear&boltitwithgranulatorflange,Putfewbolts&tightit.Makesuitable
arrangementforrotationofgranulator.Makeothersidethelockingarrangementto Torquewrench,
avoidunbalancing.Rotatethegranulatorsuchthatbottomhalfnowremainsonthe 1MillFitter, Winch10toncapacity
top.Lifttheotherhalfofgear&jointitwiththeprevioushalf.Checkthejointgap& 8Rigger, forgranulatorrotating,
13 Scapfolding&gratings, Alignmentfixtures 8days
ensureitiszerobycheckingwithfillergauge.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&MachineryRequirmentforGranulator
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%slopeforleveling.
Daimondcuttergrinding
wheel
AnnexureI
Activityschedule,Resources&MachineryRequirmentforGranulator
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
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.
Erectthemaingearbox Plumb,
Solidpackingplates
a Fixtheinput&outputcouplings Pianowire,
asrequired
b Alignthegearbox&checkthefollowing. 50mtape,
(1mmto25mm),
c Maingearboxoutputshaftcentrewithrespecttopinionbearingcenters. 1Millfitter, Springbalance20kg,
18 stainlesssteelshims
d Elevationofgearboxshouldbecheckedatall4corners. 1Fitter, Autolevelwith
ofthickness0.05mm, Machinetaper
e Couplingtocouplingstraight&diagonaldistance. 2Helper, measuringscale, 15days
0.1mm,0.25mm, wedges12x
f Masterlevelofgearbox. 2Rigger, Slopemeasuringblock,
0.5mmand1mm,Steel
g Torquetighteningofgearboxholdingdownbolts. 1Welder Masterlevel,
forlockingthebase
Erectthemainmotor GrindingmachineAG4,
frame
a Radial&axialalignment. Fillerguage,
(Channel,Beam,Pipe),
b Couplinggap. Verniercalliper
19 GP2groutingmaterial
c Torquetighteningofmotorholdingdownbolts.
d Fixthecouplingonauxiliarygearbox&motor.
e Erect&aligntheauxiliarydrive&releaseitpocketgrouting.
Ensurethefoundationboltsseating&theboltshouldremainverticalbeforerealizing
20
forpocketgrouting.Theirshouldbeatleast4/5threadsabovethenut.
Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
21
bases.Curingtimeshouldbe7days.
Aftercuringfulltightenedthefoundationbolts.Anydeviationobservedshouldbe
22
corrected.Alltheabovepointstoberechecked&readingsshouldberecorded.
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.
InsertthePNslurrypipe,Sulphuricaciddistributionpipe,Scrubberliquiddistribution
1Fitter,1Helper
33 pipe,Ammoniapipe,L.P.steaminjectorandreactorpipeandfixitwiththeinternal Fittertoolbox 5days
2Rigger,1Welder
supportpipewithpipeclamps.
34 Fixtherubberpanelsinsidethegranulatorshell. 1Fitter,2Helper Fittertoolbox 2days
Note
Allrequiredtools,tacklesandconsumables(likeelectrodes,oxygen,acetylene,
1 grindingwheels,oiletc.)requiredforerectionworktobesuppliedbyerection
contractor.
SpecialtoolsandtackleswillbesuppliedbyTKIIasperlistmentionaboveinpointno.
2
2.a.ii.
thyssenkrupp Industries India
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 Granulator centers, the support roller
bearing centers the straight distance & the diagonal should be checked & marked. [Refer
sketch no.1]
[Sketch no. 1]
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 % slope for leveling.
4. Ground assembly of tyre on granulator shell. Mark the centre line of tyre & chair plates on
inlet / outlet side granulator drum from the edge. Place the granulator drum on a
temporary structure (Tyre erection base frame for ground assembly TKII Drawing No.
FRT-RD-00303-2/0) along with saddle. Fix the chair plates as per the positions marked &
tack weld with the drum. Insert the tyre on to the drum & 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.
5. Repeat the same procedure for the other tyre.
6. Fabrication of temporary structure inside & outside the building for granulator erection.
a. Rail to be fixed on the top of structure for sliding the Granulator.
b. Saddle to be modified for lifting purpose.
c. With suitable crane lift the granulator & keep it on above structure. Make necessary
arrangement for dragging the granulator to its position. Now lift the granulator up to
top available space and support it with suitable structure / wooden sleepers.
7. After lifting the granulator to the top, remove the structure from the floor & clear the only
area where support roller base frame is to be mounted.
8. After removing the structure, with suitable crane & chain blocks lift the base frame along
with the support rollers & position it, and for alignment check the following.
a) Base frame centre with respect to Granulator centre.
b) Inclined distance of base frame from fixed bearing to floating bearing.
c) Diagonal from fixed bearing to floating bearing base frame.
d) Elevation of fixed & floating base frames.
e) Axial gap between bearing housing & bearing outer race on floating side only.
f) Dial reading of bearings. [Axial alignment]
g) Torque tightening of holding down bolts.
h) Measurement of bearing clearances.
i) Fill the bearing with required lubricant.
j) Base frame slope to be checked by master level by using taper block.
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.
9. 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.
10. Lower the granulator on to the support rollers. Remove the remaining structure after
lowering the granulator.
11. Erect & position the thruster.
12. Positioning of tyres should start after lowering the Granulator on the main support rollers.
a) Align the tyre at inlet side and outlet side and 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 granulator. By means of chain block lift the gear
& bolt it with granulator flange, Put few bolts & tight it. Make suitable arrangement for
rotation of granulator. Make other side the locking arrangement to avoid unbalancing.
Rotate the granulator 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.
a) Make the fixtures for aligning the gear. [Axial & radial]
b) Check the alignment & make a protocol.
c) Flange bolts to be torque tightened.
d) After torque tightened recheck the alignment & make a protocol.
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 bearing on the pinion shaft measure the clearances.
e) Assemble the Plummer block and its sealing arrangement.
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 % slope for leveling.
16. Erect the drive base frame.
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 Granulator 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.
d. Fix the coupling on auxiliary gear box & motor.
e. Erect & align the auxiliary drive & release it pocket grouting.
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 tyre and 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.
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. With suitable chain block insert the internal support pipe inside the granulator and fix its
supports at inlet and outlet and complete the sealing at both ends.
33. Insert the PN slurry pipe, Sulphuric acid distribution pipe, Scrubber liquid distribution
pipe, Ammonia pipe, L.P. steam injector and reactor pipe and fix it with the internal
support pipe with pipe clamps.
34. Fix the rubber panels inside the granulator shell.
4. Quality Assurance :
a. Protocols & ITP
2. ITP:
For commented Site ITP, please refer annexure II.
2. ITP
For Site ITP, refer annexure II
Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION
Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
Page 1 of 10
CLIENT LOGO CONTRACTOR LOGO
Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION
Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
2 INSTALLATION
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.
Page 2 of 10
CLIENT LOGO CONTRACTOR LOGO
Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION
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
2.35 PIN LI-CQA-204-F-02 P W W W
centreline. accuracy of 0.04 mm/ mtr.
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
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
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
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STANDARD ITP FOR ROTARY DRUM ERECTION
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
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
Shell Joint NDT 100% DPT after back chipping ASME section VIII PIN LI-CQA-214-F-01 P R NA R
2.8 Tyre
Page 5 of 10
CLIENT LOGO CONTRACTOR LOGO
Annexure II
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STANDARD ITP FOR ROTARY DRUM ERECTION
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
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
b Torque tightening of bolts Torque value as per drawing Torque Tighteneing Record P RAN W R
d Torque Tightening of Gear Joining Bolts Torque value as per drawing Torque Tighteneing Record P RAN W R
Page 7 of 10
CLIENT LOGO CONTRACTOR LOGO
Annexure II
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STANDARD ITP FOR ROTARY DRUM ERECTION
Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
e Torque Tightening of Gear Joining Bolts Torque Value as per drawing Torque Tighteneing Record P RAN W R
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.
Page 8 of 10
CLIENT LOGO CONTRACTOR LOGO
Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION
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.
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
Pinion Teeth Temperature (During pre +/- 2 degrees celsius across entire tooth TM.03en Vs01_Meshing_-
P W W R
commissioning trial run) flank. _Temperature
PIN LI-CQA-204-F-10
a Base Frame As per pinion base frame P W 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
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
4. Quality Assurance :
c. Consumables specification with estimated qty
- Electrode : E7018
- Approx. qty: 100 Kgs