Report about the repairation of the Raw mill Slide Ring and shell (Modification)

Repairing the wears and
cracks in the Raw Mill
Tyre and shell
MBCC
ASEC
Castolin
2013
Eng. Moaaz Emad Gaber
17-10-2013

PM Management
Inspection Department
Page 1 of 50
MBCC Project
Introduction:
MBCC line start at 2003 and about the raw mill line1
 Designed by: FULLER Company
 TIRAX MILL S 5.8 x 11.5 + 4.65
 Capacity: 380 ton /hour
 Outlet slide ring : Drawing number 1.740541

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MBCC Project
How we discover the problem?
The Raw mill line 1 has a problem in the temperature of the outlet shoe bearings and Thrust bearing, the
raw mill shutdown continuously
So ASEC take some actions:
1- Change the thrust bearing due to it have a wear
2- Change the oil due to it was very dirty
3- Before the previous action we erect a new seal and new felt because we think that the dust come
from the outlet to the tank casing
4- However all previous action the raw mill still shutdown continuously and also the oil is very dirty
5- So we check the shoe bearing and we found that it was in good condition
At September 2013 take decision by ASEC. T.M. Manager to check the Tyre and the Shell from inside
because we put a low probability that we have cracks under the liners beside the Outlet Slide ring which
cause a lot of dust inlet to the oil tank
After we remove the 2 rows beside the Outlet Slide ring and all liners in the Outlet Slide ring we found that
we have grooves in the Tyre and Outlet Slide ring and also we have 2 cracks in the Tyre above the position
of the seal
Some useful information:
Some useful information will use if you do root cause analysis for this problem (RCA):
1- The main function of the shell liners is protect the shell from the charges
2- The row of the liners beside the Outlet Slide ring is boltless liners and according to the design ( see
drawing number 1.743188)
Point no. 17: to improve retention of the boltless liners (position 04.01.03.19) use following procedure:
apply light coat of filler compound to the shell, in area under the liners and apply heavier layer at the
corner of the shell and the slide ring web. Set the liners and press them into the compound. Use Norbak
FEL-PRO 99695 or equivalent. Mill shell surface to be clean, free of oil and grease
3- This mill is Air swept mill
4- ASEC never change before the liners of the two rows beside the Outlet Slide ring since 2003 (form the
commissioning)
5- Also the liners in the Outlet Slide ring (row no. 4) ASEC never change it before since 2003 (form the
commissioning)
6- From the measuring of alignment by Plysios, they confirm us that there are misalignment in the
Concentricity (axial direction) about 1 mm
7- When ASEC change the shoe bearings at outlet, they remove the shell nuts of the row before the
boltless liners

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MBCC Project
To solve the problem:
At September 2013 take decision by MBCC and ASEC to solve the problem
1- MBCC ask Plysios about recommendations
2- MBCC prepare a new Tyre and new section
3- ASEC prepare a new liners (Boltless liners, Outlet Slide ring liners and last row shell liners)
4- Request offer from MESSER Eutectic Castolin Egypt LLC
5- ASEC appointed two coordinator engineers (Eng. Moaaz Emad and Eng. Ahmad Monir)
Main jobs of the coordinator engineers:
 Coordinate between MBCC and Castolin
 Take the measuring of RUNOUT
 Measure any deformation possible in the surface of Tyre
 Prevent Castolin from making any actions that could adversely affect in the mechanical parts
of mill (shoe bearing – heating – lubrication system – cooling……… etc.)
 Follow-up welding operations and its compliance with the correct procedures
 Facility any obstacles facing Castolin
 Record and take any comments and notes
 Write daily report about this job and send it to our mangers
 Estimate the rate of Castolin working
Recommendations of Plysios Company:
Dear Eng. Sameh,
Here are the comments of Lionel following his inspection at site regarding the repair procedure
To repair the Tyre of the RM 1:
Phase 1: preparation of the repair works
 Dismantling of the internal parts, cleaning of the area of repair (you will need the mill to rotate during
the repair)
 Dismantling of the Tyre housing to have access to the rolling surface
 Control of the wobble and Tyre rolling part deformation
 Erection of the scaffoldings
 Erection of a specific device to support the dial gauges measuring the eventual deformation on the
rolling surface
 Manufacturing of scrapers to take off the oil and clean the rolling surface before the dial gauges while
the mill is rotating

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MBCC Project
 Specific measurements to define precisely the dimension of the 20 external and internal
reinforcements to be fixed to avoid any deformation.
 Manufacturing of the reinforcements (some of them will need to be machined to ensure a correct
assembly and prevent any deformation)
 Erection of the reinforcements
Note: the only way to avoid the deformation is to really erect with care and accuracy the reinforcements.
Phase 2: repair of the grooves ( worn areas)- preheating T°: 100/120°C
Those areas have to be repaired first as maximum of the deformation is likely to be done during this
phase. A very careful job has to be done with a continuous measurement of the eventual deformation with
the dial gauges.
Phase 3 : repair of cracks )- preheating T°: 100/120°C and eventual grinding of the rolling surface if
deformation out of tolerances.
Prepare from warehouse a set of spare bearings for startup.
Lionel is ok on the report made by Marian at site and attached to this email.
Estimated schedule:
Phase 1: 2 weeks
Phase 2&3: 4-5 weeks
Supervision:
We have no supervisor available for the moment to supervise this repair. It is not possible for Lionel to
escape one day a week the Lafarge kiln shell repair as they are facing a lot of technical difficulties. Lionel
could be available in 2 or 3 weeks. We are very sorry for that.
As discussed on telephone, the invoice was actually sent to plant, a new DHL with the invoice addressed
to your office in Maadi is sent today. Besides, we are still waiting for the payment of the invoice for the
Polmill service ( invoice n° F91300544, 15425 €).
Cordialement / Best regards
Virginie EMKEYES
Service Business development Manager
POLYSIUS S.A.S. - Une entreprise de THYSSENKRUPP
770, avenue Guilibert de la Lauzière
13290 Aix-en-Provence
Tel: 33 (0)4 42 16 61 44
Fax: 33 (0)4 42 39 40 27
Mobile: 33 (0)6 77 38 94 01
Email: virginie.emkeyes@thyssenkrupp.com

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MBCC Project
Offer of MESSER Eutectic Castolin Egypt LLC:
Reference: - MEC/EG/MBCC/003-Modified
Date: 7th
of September 2013
From: MESSER Eutectic Castolin Egypt LLC
To: MBCC Misr BeniSwif Cement Company
Subject: Offer for raw mill shell crack repair and shell rebuilding
Attention: Dr. Eng. Antar Ghazy Plant Manager
Dear Sir,
Specialized in wear protection, Castolin Eutectic has developed during its 107 years of existence, a wide range of
technologies and products to combat wear in cement industry, and in order to help in solving your repair and
maintenance problems, MESSER Eutectic Castolin Egypt has the honor to pledge our experience and technical support to
your reputable company throughout providing the optimum recommendation for the repair of the "raw mill shell crack
repair and shell rebuilding", and we would like to submit our offer for the considered job as follows.
Your scope of work:
1. Your side shall provide proper scaffolding/illumination inside/outside the mill to work around the clock.
2. Your side shall provide ordinary labor to carry out proper housekeeping of the mill interior, also proper cleaning
for the worn out areas to repaired and rebuilt.
3. Your side shall provide a source of compressed air at pressure of 6bar, complete with hoses to mill proximity.
4. Your side shall arrange for any precautions related to safety and firef ighting, also any arrangements to
prevent fire in the tire casing due to presence hydraulic oil inside.
5. Your side shall provide means of natural ventilation within the mill interior; all relevant dampers shall be kept open
during the full span of repair operations.
6. Your side shall provide a set of 2 propane cylinders for heating purposes, also 1 set of Oxy-fuel cutting if
required.
7. Your side shall provide a set of 4 dial gauge indicators at least to monitor the influence of welding operations and
consequently any distortion might occur on radial measurement of the mill shell, also your side shall provide a
dedicated technician for this job.
8. Your side shall provide us with technical data on the material of the mill shell to determine the preheating
temperatures.
Our scope of work:
1. Our side will provide the skillful welders, gouging & welding consumables, welding machines, hand grinders, and
any other tools required for welding cracks and rebuilding worn out thickness from inside.
2. Our side will provide a complete repair procedure and a competent technical supervision during the repair, the
procedure is based on the below mentioned data and shall be approved from your side prior to
proceeding with the repair.
3. The technical scope of this offer includes repair by welding of 2 cracks in the mill shell, and rebuilding worn out
areas of mill shell, these cracks/areas are:
 Groove#1 (in the 120mm tire thickness) with Length of approximately 7000mm, average 200mm in
width, average 67mm in thickness (58mm min. thickness), and no cracks detected.
 Groove#2 (in the 55mm tire thickness) with Length of 1000mm, average 140mm in width, average
10 mm in thickness (5mm min. thickness), with a crack of 1050mm in length.
14 mm in thickness (10mm min. thickness), with a crack of 430mm in length.
26mm in thickness (22mm min. thickness), no apparent cracks based on initial inspection (no proper
cleaning).

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MBCC Project
 Groove#5 (in the 55mm tire thickness) with Length of 1150mm, average 130mm in width, approx.
20mm thickness with no apparent cracks based on initial inspection (no proper cleaning).
 Groove#6 (in the 55mm tire thickness) with Length of 700mm, average 100mm in width, approx.
26mm in thickness with no apparent cracks based on initial inspection (no proper cleaning).
4. The technical procedure of this offer covers fitting and welding of stiffeners for distortion control inside and
outside the mill all around the circumference, then rebuilding groove#1 by welding using XuperNucleoTec
2222 till a thickness 5mm below the nominal thickness.
5. The technical procedure of this offer covers opening cracks in 10 O'clock positions by grinding and further
welding using XuperNucleoTec 2222 under preheating (100°C min. to remove the chill).
6. The technical scope of this offer also covers rebuilding each groove#2~6 by welding using XuperNucleoTec
2222 till a thickness 5mm below the nominal thickness.
7. Upon approval of this procedure from your side, MEC Egypt guarantees only the mechanical properties of our
welding consumables, and possess no liability towards other for any consequent damage/distortion/misalignment
due to faults in this specific repair procedure, faults in welding joints or welded sections within 48hours upon
completion will be our responsibility, if we started welding at the original base material and not on already
repaired surfaces. In that case repairing and applying the needed welding material is free of charge. The
mobilization/transportation costs have to be paid in any way by our side.
General Terms and Conditions:
1. Cost:
 For welding consumables: the cost for welding electrodes XuperNucleoTec 2222 in any diameter
will be 790EGP per Kg.
 For Service activities:
 Option 1: The cost for service activities will be on daily basis at a price of 6800 EGP/day
(2 shifts per day, 12hours/shift).
 Option 2: The cost for service activities will be on Kg consumption basis at price of 580
EGP/kg consumed.
2. Payment:
 50% of payment for welding consumables against your commercially clear order, balance shall be
upon delivery.
 50000EGP of payment for service activities in advance, balance shall be against job completion.
3. Notification period required prior to the execution of the job on-site shall be 2 days in-advance.
4. 10% Sales Tax to be added.
5. This offer is valid only for 3 weeks from the date of submitting.
6. Order to be placed only on MESSER Eutectic Castolin Egypt LLC.
Regards
Application Specialist
Eng. Mahmud Ezz El-Arab

PM Management
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MBCC Project
According to Polysius recommendation ASEC have some comments:
1- We need a detailed time schedule to follow the repair procedures and to prepare the needed parts
and spares.
2- We agree on reinforcement (Brackets) from inside, but we have comments on welding the
reinforcement from outside as it might cause deformation from thermal stress.
3- Regarding the welding steps we recommend starting with welding the cracks and then completely
the cracks grooves.
4- We do not recommended to weld the grooves beside the mill head (in the corner of mill) because it
is very risky, but we recommend to fill this grooves with filling material (as Belzona or any other
equivalent material)
Procedures or reparation:
 Prepare the mill (remove old liners - cleaning – scaffoldings – ventilation - source of comprised air –
weld4 beams to fix the Dial Indicators – numbering the end of mill from 1 to 58 ……… etc. )
 Fixed 20 Bracket to reinforced the mill from outside and inside
 Weld the grooves in the Tyre corner till thickness 5mm below the nominal thickness
 Weld the grooves in the Outlet Slide ring till thickness 5mm below the nominal thickness
 Weld the grooves in the line of the boltless liners till thickness 5mm below the nominal thickness
 Weld the cracks from inside the mill till thickness 5mm below the nominal thickness
 Back weld for small and big cracks from outside of mill
 Measure the deformation in the surface of the Tyre and measure radial RUNOUT continuously after
and during welding
 Put Belzona in the corner and under the boltless liners till a thickness reach to the nominal thickness
 Erect new liners

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MBCC Project
 Prepare the mill
1- Remove old liners
2- Cleaning (inside mill - position of dial indicator)

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3- Weld 4 beams to fix the Dial Indicators
4- Ventilation (ASEC prepare a suction fan)

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MBCC Project
 Fixed 20 Bracket to reinforced the mill from outside and inside
Before we reinforce the mill MBCC take the 1st
radial RUNOUT measurement (10-9-2013)
How we measure the radial RUNOUT?
 We used 4 Dial indicators in 0,90,180 and 270 degree in position A,B,C and D
 The dial touch the Tyre from out side
 The diameter of the Tyre in the position of measuring is 5800 mm from inside and 5900 mm from
outside
 We divide the end of Tyre to 58 points (same the number of shell liners)
 Each dial indicator take 12 reading at points 1,5,10,15,20,25,30,35,40,45,50 and 55
 Start at point 1 in position C

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MBCC Project
1st
radial RUNOUT measurement by using 4 Dial indicators (10-9-2013)
1st
point A (mm) B (mm) C (mm) D (mm)
1 -0.02 0.05 0 -0.1
5 -0.02 0 0.02 -0.1
10 -0.02 -0.3 -0.2 -0.3
15 -0.02 -0.2 -0.05 -0.22
20 0.02 -0.02 0 -0.2
25 -0.02 0.03 0.05 -0.2
30 0 0.05 0.05 0
35 0.1 -0.15 0.28 0
40 0.1 0.1 0.26 0.15
45 0.02 0.1 0.18 0
50 -0.02 -0.03 -0.05 -0.2
55 -0.02 0.04 -0.02 -0.2
1 -0.02 0.05 0 -0.1
The profile of the Tyre in each position became

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MBCC Project
Our comments:
 MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and this is fatal
mistake because how we can measure the reading less than 0 mm? and from the analysis of the reading
we can observe that the minimum reading is -0.3 mm
 From me (Eng. Moaaz) I adjust my dial indicator in position D at one in small scale to can read the
negative values
 MBCC forget take the measurements in the surface of the Tyre so we didn’t have any reference for the
surface of the Tyre
After we take 1st
radial RUNOUT measurement we reinforced the mill by brackets from outside and
inside according to:
From Inside the mill: 10 Brackets (600 x 600 x 40 mm)
Length of layer: Horizontal 150 mm, number of pass: 2
Length of layer: Vertical 150 mm, number of pass: 2
From Outside the mill: 10 Brackets (350 x 600 x 40 mm)
Length of layer: Horizontal 100 mm, number of pass: 2
Length of layer: Vertical 100 mm, number of pass: 3
Castolin use Nickel material to weld any layers in the Horizontal direction
Position of fixation at points 1,6,12,18,24,30,36,41,47 and 53 see Map drawing

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MBCC Project
After weld the reinforcements completely we take 2nd
radial RUNOUT measurement by using 4 Dial
indicators and also we take the 1st
measurements in the surface of the Tyre to measure the effect of
reinforcement of mill (13-9-2013)
Position of fixation at points 1,6,12,18,24,30,36,41,47 and 53 see attach drawing
2nd
2nd
radial RUNOUT (13-9-2013)
1 -0.2 0 0 -0.2
5 -0.25 0.01 0.02 -0.2
10 -0.25 0.02 0.02 -0.2
15 -0.25 0.03 0.09 -0.2
20 -0.15 0.35 0.02 -0.18
25 -0.25 0.02 0 -0.2
30 -0.25 -0.05 0 -0.2
35 -0.25 0.03 0.08 -0.2
40 -0.1 0.45 0.2 -0.08
45 -0.05 0.03 0.4 0.01
50 -0.23 0.65 0.42 0.1
55 -0.25 0.06 0.45 -0.09
1 -0.2 0 0 -0.2
The profile of the Tyre in each position became
1st
radial RUNOUT (10-9-2013)
1 -0.02 0.05 0 -0.1
5 -0.02 0 0.02 -0.1
10 -0.02 -0.3 -0.2 -0.3
15 -0.02 -0.2 -0.05 -0.22
20 0.02 -0.02 0 -0.2
25 -0.02 0.03 0.05 -0.2
30 0 0.05 0.05 0
35 0.1 -0.15 0.28 0
40 0.1 0.1 0.26 0.15
45 0.02 0.1 0.18 0
50 -0.02 -0.03 -0.05 -0.2
55 -0.02 0.04 -0.02 -0.2
1 -0.02 0.05 0 -0.1

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MBCC Project
Our comments:
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and this is
fatal mistake
 There are different between 1st
and 2nd
readings
 From the schedule comparison we can observe that the point 50 have the biggest different
 Also we measure the deformation of the surface Tyre
How we measure the deformation of the surface Tyre?
 We used 2 Dial indicators in the same line A and B
 The dial touch the Tyre from outside
 The diameter of the Tyre in the position of measuring is 5800 mm from inside and 6040 mm from
outside
 We divide the end of Tyre to 58 points (same the number of shell liners)
 Each dial indicator take 12 reading at points 1,5,10,15,20,25,30,35,40,45,50 and 55

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MBCC Project
1st
measurements in the surface of the Tyre
1st measurements in the surface of the Tyre (mm) 13 - 9 -2013
Point A B Difference
1 0.02 0.02 0
5 0.01 0.01 0
10 -0.01 -0.01 0
15 -0.11 -0.1 -0.01
20 0.3 0.3 0
25 0.05 0.05 0
30 0.04 0.04 0
35 0.04 0.03 0.01
40 0 0 0
45 0 0 0
50 0.01 0.01 0
55 0.05 0.05 0
1 0 0 0
The profile of the Tyre became

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MBCC Project
Our comments:
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and this
is fatal mistake
 This readings are excellent, the two line A and B are in the same line and the difference can be
neglected but this readings are not accuracy
Recommendations of MBCC (Mr. Maryan)
 Weld the reinforcement of the cracks by steel bars Ø 25 mm according to call phone with Mr. Lionel
(Plysios) today
 Weld the grooves on left and right side (length = 100 mm, height = 30-35 mm) and the position of
the welder at 2 and 10 o`clock
 After this job must check the Tyre and shell by gauge. If appear deformation
 If the reading are not exceed 1.00 mm start weld continuous 5 layers and re-check again
 Welding will be done between the two shoe bearings only for groove
 Weld the grooves in the Tyre corner till thickness 5mm below the nominal thickness
Information about the grooves in the Tyre corner:
 The grooves between point 15 to point 25(about 3068 mm) and between point 35 to point 51 (about
5000 mm)
 The total length of the grooves in the Tyre corner about 8000 mm
 The nominal thickness in this grooves equal 120 mm
 We divide the corner grooves to small parts 400 mm
 We do a welding map for the grooves in the Tyre corner

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MBCC Project
The steps of welding in the grooves in the Tyre corner:
1) First step:
Castolin start weld two small parts at point 51 and 31
Position of welder: at 10 and 2 o`clock
Dimension: Core Length = 100 mm, and height = 30-35 mm
Before welding any points in the grooves of corner Castolin must weld bars at the ends of cracks
according to the procedures of Lionel (Polysius), but they did not do that
We have a recommendation from Eng. Emam about the low pressure pump will work continuous
during Castolin are welding to help in the decrease of temperature in the shoe bearings
After finish welding we take 3th
radial RUNOUT measurement by using 4 Dial indicators and also
we take the 2nd
measurements in the surface of the Tyre (14-9-2013)

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MBCC Project
Our comments:
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and
this is fatal mistake so we are not satisfying with this reading
 We don`t say that the readings are wrong, we say the readings are not accuracy so we will not put
the reading in the final report until we solve the disagreement about the adjusting of the dial
indicators
2) Second step:
Disagreement happened between Mr. Maryan (MBCC) and Eng. Moaaz (ASEC) about the
position of the next welding because Mr. Maryan (MBCC) want to weld at 5 and 7 o`clock that
mean above the shoe bearings
Eng. Moaaz (ASEC) refuse this position and we stopped the working and asked MBCC that we
need a clear explain about this point and give us a guarantee for the two shoe bearings because we
recommend that it is risky to weld above the shoe bearings and also attach it with official email or
memo from MBCC
After solve this Disagreement we start welding in the corner Tyre grooves
Welding Map: (2A) at point 47, 48, 49, (2B) at point 46, 45
Position of welder: at 6 o`clock
Dimension: (2A) Core Length = 440 mm, and height = 25-30 mm
(2B) Core Length = 510 mm, and height = 25-30 mm
After finish welding (2A and 2B) Castolin start welding the grooves (3A, 3B and 3C)
Welding Map: (3A) at point 18, 19, (3B) at point 15, 16, 17, (3C) at point 35, 36
Position of welder: (3A and 3B) at 6 o`clock, (3C) at 10 o`clock
Dimension: (3A) Core Length = 440 mm, and height = 20 mm
(3B) Core Length = 350 mm, and height = 20 mm
(3C) Core Length = 300 mm, and height = 20 mm
radial RUNOUT measurement by using 4 Dial indicators and also we
take the 3nd
Our comments:
 Castolin didn`t use and didn`t have air hammer
 Still Castolin continue welding without weld the bars at the ends of cracks according to the
procedures of Lionel (Polysius) and they weld it after we recommend them about that, but
after they are working in the grooves (2A and 2B) about 10 hours and only in the small crack
 Still Castolin continue welding without weld the bars at the end of crack according to the
procedures of Lionel (Polysius) however the big crack is at between point 15 and 19 which
mean in the face of grooves no. (3A and 3B) fatal mistake

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They weld it after we recommend them about that but after they are working in the grooves
number 3A and 3B but the big crack now is open little
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big)
and this is fatal mistake so we are not satisfying with this reading
 We don`t say that the readings are wrong, we say the readings are not accuracy so we will
not put the reading in the final report until we solve the disagreement about the adjusting of
the dial indicators
3) Third step:
Castolin start weld the grooves (4A, 4B, 4C and 4D)
Welding Map: (4A) at point 24, 25, (4B) at point 22, 23, (4C) at point 41, 12, (4D) at point 39, 40
Position of welder: (4A and 4B) at 6 o`clock, (4C, 4D) at 10 o`clock
Dimension: (4A) Core Length = 460 mm, and height = 20 mm
(4B) Core Length = 440 mm, and height = 20 mm
After finish the previous parts they start directly in (5A and 5B) without take any measurements
according to Mr. Maryan (MBCC) recommendation so we directly adjust the mill in the next
position of welding
Castolin start welding the grooves (5A and 5B)
Welding Map: (5A) at point 19, 20, 21, (5B) at point 38, 39
Position of welder: (5A) at 6 o`clock, (5B) at 10 o`clock
Dimension: (5A) Core Length = 740 mm, and height >10 mm
(5B) Core Length = 430 mm, and height >10 mm
Our comments:
 The welding (5A and 5B) are between old welding (5A between 3A and 4B) and (5B between
3C and 4C) and the connections between the parts of welding in the corner Tyre grooves
Castolin didn`t use Sharpoon they used Cutter disc to make the slops in the end of the old
welding we need technical consultation from ASEC
 Due to the previous point may be we need to make Ultrasonic Test (UT) after finish completely
 Mr. Maryan (MBCC) speak about that the oil in the outlet is very dirty and may be affect in the
Tyre, so we want to recommend you that may be we need to make a grinding for the Tyre

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MBCC Project
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and
this is fatal mistake so we are not satisfying with this reading
 We will not put the reading in the final report until we solve the disagreement about the adjusting of
the dial indicators
4) Forth step:
Castolin start welding the grooves (6A and 6B)
Welding Map: (6A) at point 48, 49, 50, 51, (6B) at point 30, 31
Position of welder: (6A) at 6 o`clock, (6B) at 3 o`clock
Dimension: (6A) Core Length = 730 mm, and height >10 mm
(6B) Core Length = 360 mm, and height >10 mm
After that Castolin adjust the mill to complete the welding of (5A) at point 19, 20, 21 to make the
height of the welding equal 30 mm
Castolin complete the welding (5A)
Welding Map: (5A) at point 19, 20, 21
Position of welder: at 6 o`clock
Dimension: (5A) Core Length = 740 mm, and height = 25-30 mm
In the same time Castolin start welding the grooves (6C)
Welding Map: (6C) at point 49, 47 under Bracket
Start time: 11:30 PM (18-9-2013)
End time: For (6C) 5:40 AM (19-9-2013)
Position of welder: (6C) at 10 o`clock
Dimension: (6C) Core Length = 730 mm, and height
After finish Castolin weld all empty grooves parts in the corner of the Tyre and at 21-9-2013 the
thickness of the Corner grooves became
X axis: value of the thickness (mm), Y axis: number of shell liners
0
5
10
15
20
25
30
35
40
45
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14
the thickness of grooves till the thickness
5mm below the nominal thickness

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MBCC Project
radial RUNOUT measurement also we take the 4th
measurements in the
surface of the Tyre (21-9-2013)
 Weld point 20,25,30,35 only at 10 or 2 o`clock with electrode not more than Ø 4 mm
 The same for point 40,45,50
 Electrode Ø 4 mm only 2 layers 400 mm
 Electrode Ø 3.5 mm only 4 layers 400 mm
Our comments:
 Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and this
is fatal mistake
 We will not put the reading in the final report until we solve the disagreement about the adjusting of
the dial indicators
 All readings are not accuracy so any action will take according this readings may be do opposite
result
5) Fifth step:
Castolin start re-building in the corner Tyre grooves to make the thickness 5mm blow the nominal
thickness
After welding for a few times we take 6th
radial RUNOUT measurement also we take the 5th
Still MBCC recommend us to adjust all dial indicators at zero in both scale (small and big) and
this is fatal mistake
So I asked Eng. Yehya Fathi to take a separate reading for ASEC after MBCC take his reading
which we say it not accuracy and after he discuss it with Eng. Emam they accept and give me
green light finally
ASEC do only the measurements in the surface of the Tyre
We will make a comparison between the measurements in the surface of the Tyre of MBCC and
ASEC

PM Management
Page 22 of 50
MBCC Project
5th
measurements in the surface of the Tyre (22-9-2013 MBCC)
5th measurements in the surface of the Tyre
(22-9-2013 MBCC)
Point A (mm) B (mm) Different (mm)
1 0 0 0
5 0.3 0.25 0.05
10 0.28 0.4 -0.12
15 0.15 0.52 -0.37
20 -0.22 -0.01 -0.21
25 0.05 0.1 -0.05
30 -0.05 0.1 -0.15
35 0 0.08 -0.08
40 -0.03 -0.02 -0.01
45 -0.05 -0.02 -0.03
50 -0.1 -0.02 -0.08
55 0.3 0.4 -0.1
1 0.01 0.03 -0.02

PM Management
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MBCC Project
Our comments:
 Min. reading equal (-0.02 mm) however we have some points below (-0.02 mm) but we can`t
read it because we adjust the two dial indicators at Zero in small and big scales
 The deviation between points 15 and 20 at position (B), the indicator move from (0.52 mm) at
point 15 to (0.01 mm) at point 20 the different equal (0.53 mm)
 The deviation between points 15 and 20 at position (A), the indicator move from (0.15 mm) at
 The deviation between points 55 and 1 at position (B), the indicator move from (0.40 mm) at
 Max. Deviation between position A and B at point 15 and equal (-0.37 mm)
 Note: from point 51, 52, 53 ............ 14 we didn`t have grooves, the big crack at points 16, 17, 18
and 19 and small crack at points 33 and 34

PM Management
Page 24 of 50
MBCC Project
5th
measurements in the surface of the Tyre (22-9-2013 ASEC)
5th
measurements in the surface of the Tyre
(22-9-2013 ASEC)
1 0 0 0
5 0.3 0.25 0.05
10 0.28 0.4 -0.12
15 0.15 0.6 -0.45
20 -0.3 -1 0.7
25 -0.02 0.05 -0.07
30 -0.03 0.1 -0.13
35 0.03 0.12 -0.09
40 -0.03 -0.28 0.25
45 -0.03 -0.17 0.14
50 -0.09 -0.48 0.39
55 0.28 0.38 -0.1
1 0 0.05 -0.05

PM Management
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MBCC Project
Our comments:
 Min. reading equal (-1.0 mm) because we adjust the two dial indicators at five in small and zero
in big scale
 The deviation between points 20 and 25 at position (B), the indicator move from (-1.0 mm) at
 The deviation between points 50 and 55 at position (B) , the indicator move from (-0.48 mm) at
 Max. Deviation between position A and B at point 20 and equal (0.7 mm)
 Now we can say that there are big different between the reading of MBCC (adjust the two dial
indicators at Zero in small and big scales) and the reading of ASEC (adjust the two dial indicators
at five in small and zero in big scale) because the adjusting of ASEC give him facility to measure
all negative value
 After we measure we send official memo for Eng. Emam about the comparison between the way
of MBCC measurement and the way of ASEC measurements
6) Sixth step:
Castolin continue re-building in the corner Tyre grooves to make the thickness 5mm blow the
nominal thickness
After welding for a few times we take the 6th
But now we solve the disagreement about the adjusting of the dial indicators and we reached to
agreement between us and MBCC that we will adjust the small scale in the dial indicator at 2 and
big scale at zero
So the next reading will be the reference and we will make the comparison between any reading
will take and the next reading

PM Management
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MBCC Project
6th
6th
Reference
1 0 0 0
5 0.3 0.24 0.06
10 0.27 0.39 -0.12
15 0.12 0.6 -0.48
20 -0.3 -1.2 0.9
25 0 -0.03 0.03
30 -0.07 0.06 -0.13
35 -0.01 0.04 -0.05
40 -0.1 -0.33 0.23
45 -0.08 -0.24 0.16
50 -0.1 -0.52 0.42
55 0.32 0.38 -0.06
1 0 0.04 -0.04

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MBCC Project
Our comments:
 This readings is more accurate
 Now can measure any negative value until -2 mm
 Min. reading equal (-1.2 mm)
 The deviation between points 15 and 20 at position (B) not good, the indicator move from (0.60
mm) at point 15 to (-1.2 mm) at point 20 the different equal (1.8 mm)
 The deviation between points 20 and 25 at position (B), the indicator move from (-1.2 mm) at point
20 to (-0.03 mm) at point 25 the different equal (1.7 mm)
 The deviation between points 50 and 55 at position (B), the indicator move from (-0.52 mm) at point
50 to (0.38 mm) at point 55 the different equal (0.9 mm)
 Max. deviation between position A and B at point 20 and equal (0.9 mm)
 Continue Weld points 20,50 and 55 at 6 o`clock to decrease move this points in the direction of the
center mill
7) Seventy step:
Castolin Continue Weld in the corner and weld points 20,50 and 55 at 6 o`clock Tyre grooves until
the thickness at 24-9-2013 became
After welding for a few times we take the 7th
0
5
10
15
20
25
30
13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51
the thickness of grooves till the thickness
5mm below the nominal thickness

PM Management
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MBCC Project
7th
7th
measurements in the surface
of the Tyre (mm) (26-9-2013)
Point A B Different
1 0 0 0
5 0.3 0.25 0.05
10 0.3 0.39 -0.09
15 0.18 0.5 -0.32
20 -0.22 -1.2 0.98
25 0.01 -0.09 0.1
30 -0.06 0.02 -0.08
35 0.02 0.08 -0.06
40 -0.05 -0.39 0.34
45 -0.1 -0.31 0.21
50 -0.12 -0.55 0.43
55 0.35 -0.42 0.77
1 0.02 0.05 -0.03
6th
measurements in the surface
of the Tyre (24-9-2013)Reference
Point A B Different
1 0 0 0
5 0.3 0.24 0.06
10 0.27 0.39 -0.12
15 0.12 0.6 -0.48
20 -0.3 -1.2 0.9
25 0 -0.03 0.03
30 -0.07 0.06 -0.13
35 -0.01 0.04 -0.05
40 -0.1 -0.33 0.23
45 -0.08 -0.24 0.16
50 -0.1 -0.52 0.42
55 0.32 0.38 -0.06
1 0 0.04 -0.04

PM Management
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MBCC Project
Our comments:
 Still the Min. reading equal (-1.2 mm)
 From the comparison between this readings and the reference (24-9-2013) about all reading same
except point 55
 Point 55 changed from +0.38 to -0.42 mm (big division) change from positive to negative
 The Max. deviation between position A and B at point 20 changed from (0.9 mm) to (0.98mm)
Some photos of welding the grooves in the Tyre corner:
Welding the grooves in the Tyre corner
Temperature outer slide ring and shoe bearing during welding the grooves in the Tyre corner

PM Management
Page 30 of 50
MBCC Project
Welding the grooves in the Tyre corner
 Weld the grooves in the Outlet Slide ring till thickness 5mm below the nominal thickness:
Start welding all grooves in the outlet slide ring in three positions 6 o`clock, 10 o`clock and 2 o`clock
The grooves in the outer slide ring before start welding

PM Management
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MBCC Project
Welding grooves in the outlet slide ring
 Weld the grooves in the line of the boltless liners till thickness 5mm below the nominal thickness
Start welding all grooves in the line of the boltless liners in three positions 6 o`clock, 10 o`clock and 2
o`clock
The grooves in the line of the boltless liners before start welding

PM Management
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MBCC Project
Welding grooves the line of the boltless liners

PM Management
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MBCC Project
 Weld the cracks from inside the mill till thickness 5mm below the nominal thickness
Start procedures of welding small crack:
1- Reinforce small crack by bars at the ends of cracks according to the procedures of Lionel (Polysius)
2- Small welding paths in the crack
3- Make five bridges in the groove of the crack
4- Fill distances between bridges with welding
5- Make measurements during previous steps
Small crack before starting welding
Small welding paths in the crack

PM Management
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MBCC Project
Make five bridges in the groove of the small crack
Fill distances between bridges of small crack

PM Management
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MBCC Project
Measurements in the surface of the Tyre (3-10-2013)
The readings of two Dial indicators by (mm)
1 0 0 0
5 0.3 0.44 -0.14
10 0.25 0.44 -0.19
15 0.14 0.65 -0.51
20 -0.32 -1.28 0.96
25 -0.1 0 -0.1
30 -0.08 -0.04 -0.04
35 0.23 -0.18 0.41
40 -0.2 -0.36 0.16
45 -0.02 -0.48 0.46
50 0.18 -1 1.18
55 0.35 0.46 -0.11
1 0 0.03 -0.03

PM Management
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MBCC Project
Our Recommendations:
 point 50,49,51 weld only at 2 or 10 o`clock
 point 20 stop welding
 continuous with small crack
 Reinforced with bridge the big crack
Start procedures of welding Big crack:
Same procedures of small cracks reinforced, paths, bridges, fill distances and measurements
Make five bridges in the groove of the big crack

PM Management
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MBCC Project
Fill distances between bridges of big crack

PM Management
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MBCC Project
Measurements in the surface of the Tyre (7-10-2013)
The readings of two Dial indicators by (mm) 7-10-2013
1 0 0 0
5 0.3 0.25 0.05
10 0.22 0.33 -0.11
15 0.31 0.34 -0.03
20 0.2 -1.9 2.1
25 0.02 -0.03 0.05
30 0.02 -0.26 0.28
35 -0.6 -0.5 -0.1
40 -0.12 -0.46 0.34
45 0.02 -0.7 0.72
50 0.22 -1.28 1.5
55 0.38 0.26 0.12
1 0 0 0

PM Management
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MBCC Project
 point 20 stop welding
 continue welding big crack
 Back weld for small and big cracks from outside of mill
 Castolin start welding small crack and big crack from outside (back weld)
 The cracks are in the 2 slots of the Tyre
 Procedures: Heating – Open Cracks – Penetration Test – Heating – Welding (Back Weld) – Final
Penetration Test
 We made measurements after finish small crack and after finish big crack
 Position of welding at 12 o`clock
Some photos (Small crack):
Small crack between point 33 and 35

PM Management
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MBCC Project
Final penetration test for small crack
Some photos (Big crack):
Big crack before welding

PM Management
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MBCC Project
Big crack before welding
Big crack after open crack

PM Management
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MBCC Project
Big crack during welding
Big crack during welding

PM Management
Page 43 of 50
MBCC Project
Measuring of surface Tyre (10-10-2013)
The readings of two Dial indicators by (mm) 10-10-2013
1 0 0 0
5 0.3 0.21 0.09
10 0.15 0.31 -0.16
15 0.5 -0.15 0.65
20 0.55 -1.9 2.45
25 0.2 -0.4 0.6
30 0.05 -0.25 0.3
35 0.55 -0.69 1.24
40 0.05 -0.55 0.6
45 0.1 -0.83 0.93
50 0.2 -1.24 1.44
55 0.35 0.48 -0.13
1 0 0.03 -0.03

PM Management
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MBCC Project
 Measure the deformation in the surface of the Tyre after finish welding

PM Management
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MBCC Project
The circulation of the Tyre is not good so we need to measure the surface of the Tyre from outside
by water level at:
1- Points 50,51 and 52
2- Points from 15 to 22
We found that there are deformations in the surface of the Tyre
Maximum deformation at point 20 the different between 2 edges at same line equal 4.03 mm.
46 0.04 -1.18 1.22
47 -0.2 -1.35 1.15
48 -0.2 -1.1 0.9
49 0.03 -1.13 1.16
50 0.18 -1.24 1.42
51 0.3 -0.77 1.07
15 0.55 -0.5 1.05
16 0.65 -1.05 1.7
17 0.58 -1.85 2.43
18 0.5 -2.47 2.97
19 0.65 -3 3.65
20 0.75 -3.28 4.03
21 0.8 -2.88 3.68
22 0.7 -2.2 2.9
23 0.48 -1.68 2.16
24 0.25 -0.92 1.17

PM Management
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MBCC Project

PM Management
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MBCC Project
Final Recommendations:
1- Start put Belzona in the corner and under the boltless liners till the thickness reach to the nominal
thickness
2- Remove inlet brackets
3- After that erect new liners
4- Then change oil of the outlet lubrication unit

PM Management
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MBCC Project

PM Management
Page 49 of 50
MBCC Project
Comments after finish all jobs in the Tyre:
1- The Tyre has deformation and the big different at point 20 it equal 4.03 mm, is this value in the
acceptable rang or not?
We cannot answer this question without know what is the permissible moving in the shoe
bearings??
If we are in the out of permissible range, we will have metal contact between Tyre and shoe
bearing so friction and high temperature
And maybe we will need to change Shoe bearing
2- We need to grind the surface of the Tyre to decrease the different in the acceptable rang
3- From preparation department we need to prepare spare part of shoe bearing at outlet with all
accessories
4- From Vibration Department we need vibration analysis at least every 2 weeks
5- From CCR we need to observe the temperature of the shoe bearings at outlet and print trends
every days
6- Finally we cannot give MBCC any guaranty, so we will send this technical report to them and we
will wait there recommendations
Inspection engineer
Eng. Moaaz Emad

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