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COMMISSIONING AND TRAINING SERVICE PROGRAM

An important question to consider when researching improvements or changes to your Refractory Installation Equipment is, does the manufacturer provide after sales service, training, and commissioning of new equipment? Assembly guides, instruction manuals and the likes are very helpful and should be utilized to their fullest. But when a trained, experienced technician is available to walk you through the equipment the first time coupled with all those guides and manuals, you can be certain you’ll have the upper hand. Outages can be very costly, especially if your equipment is not ready at the call of duty. Bricking Solutions not only stands behind everything we manufacturer, but we also stand right next to you as a support system to insure your refractory installation equipment will give you the best performance each and every outage.

          The beginning of that support system starts with our New Machine Commissioning which is the first step to putting you back in charge, saving time and money by being prepared and familiar with your equipment in advance of your upcoming outage. Thus eliminating problems that are often overlooked due to time constraints and emergency shut downs. During the first day of this three day job site visit, our skilled technician will literally begin by taking you step by step from unpacking the crate(s) to assembly, usage, maintenance, and storage. Taking this first in depth look at our bricking machine, its components and tools is especially helpful to the entire crew. The second day the crew will get their hands dirty as they install the machine in the kiln and have hands-on demonstrations of the re-bricking processes using the bricking machine. Answers and questions along with a review of critical considerations and warnings take up the last day.

DAY 1

  1. Meet with plant personnel, tour kiln, locate machine, outline commissioning schedule, and general orientation.
  2. Pre assembly of machine, preparation for assembly and operation in the kiln, plus maintenance and storage instructions.
    1. Uncrate the machine and check that all parts are present and in good condition from transport.
    2. Review Assembly Manual and note all WARNINGS! on overload/capacity, casters, rotate machine movement.
    3. Supervision of the assembly of the machine using color code as key (about 3 hours the first time) in a clean open area with the plant personnel responsible for operations and maintenance. Check fit and finish. Discuss proper transportation and assembly inside the kiln to minimize time frame.
    4. Discuss the operation of the machine. With air to the machine demonstrate operations of our machine with special attention to the keying section and the movement of the double arches.
    5. Maintenance – Discuss and demonstrate maintenance procedures with attention to rubber "o" rings and nylon rotors of air cylinders. Lube/filter adjust/bleeders and machine air pressure.
    6. Storage - Discuss the importance of proper care to limit the amount of dust, heat, and moisture subjected to the machine. Also note and/or repair any issue’s that exist.
    7. Other - If the machine was not furnished with decking or scaffold steps, supervise the construction of same.
    8. Disassemble the machine, arrange for transportation of the machine to the kiln and staging of components for assembly in the kiln. Keeping in mind “color code,” “assist and photos,” and “order of assembly.”
 cement plant
commissioning

Day 2

  1. Review manuals and discuss organization and installation steps.
  2. Install bricking machine in the kiln (about 1-1/2 hours). Before loading, recheck all hardware to be tight.
  3. Demonstrate and supervise the operation of the machine in the kiln -day crew.
         a.   Set up and adjustments
         b.   Fill lube – Show how to check and set lube/setting
         c.   Technique – Wing and key cylinder set then master valve
         d.   Movement of arches – Check and set machine air pressure
         e.   Discuss safe movement of machine in kiln
         f.   Monitor progress
  4. Repeat for night crew. At the beginning of each shift, check that all hardware is tight. Open bleeders to drain any unwanted fluid. Check lube/oil levels.

Day 3

  1. Check caster rotation for correct placement and lock in place.
  2. Check progress in kiln. Answer any questions. Review critical considerations. Review WARNINGS!
  3. Meet with plant supervisor and make a list of things that need to be done and followed up on. Set date for report to plant on commissioning and arrange for departure.