iS F.L.SMIDTH INSTRUKTIONER INSTRUCTIONS —_INSTRUCTIONS ANWEISUNGEN INSTRUCCIONES _INSTRUGOES v 2031-15 1/9 ROTARY KILN LIVE-RINGS (KILN TYRES) Manufacture MGN: 5830 Enclosures: Ultrasonic test report, u 4561-03 Vv 2031-13-1 Inspection form U 1171-02 V 2031-13-11 Permissible surface defects Vv 2031-13-111 In the text reference is made to the following instruction manuals, etc Ultrasonic test report u 4561 Inspection form vu 171 Contents: Page: I. GENERAL 2 2. ROUGH-MACHINING 2 3. NON-DESTRUCTIVE TESTING 3 3.1 Magnetic particle flaw detection 3 3.2 Ultrasonic testing 3 3.3 Hardness test 5 4. REPAIRS OF ROUGH-MACHINED LIVE-RINGS 5 5. PINISH-MACHINING 6. IDENTIFICATION MARKS 8 7. RUST PROOFING 8 8. PACKING 8 9. INSPECTION 8 EFr/MGHVv 2031-15 2 1. MATERIAL QUALITY The material specification in the order sheet must be strictly observed. (Normally FLS Mat.325). Further, to prevent an excessive formation of nitri- des, the residual aluminium content must not exceed 0.05 &. The actual content of residual aluminium must appear from the charge certificate along with the more usual requirements i.e.: 1) Chemical analysis 2) ¥ield stress, tensile strength, elongation, reduction af area, hardness and charpy-V at room temperature. The casting technique used must be such as to ensure @ degree of homogenity that does not require repairs by welding. Weld repairs will only be accepted as an exception and only when of limited size. See section 4. The live-ring must be heat-treated to a fine grained structure and elimination of internal stresses to the greatest possible extent. 2. ROUGH-MACHINING The live-ring must be rough-machined to an allowance of 3-5 mm on all surfaces, for final machining. Do not forget however, that the finishing tolerance on the outer diameter is 0/+30, and on the width 0/420 mm. With xegard to the NDT-test described in the following section, the surface roughness of the roughmachined live-ring must not exceed R, = 16 microns.v 2031-15 3 3. NON-DESTRUCTIVE TESTING (NDT) 3.1 Magnetic particle flaw detection (preferably with a fluorescent liquid) Examine the rough-machined surfaces 100% in accordan- ce with an acknowledged international standard (SEP, ASTM, BS or similar). The magnetic particle flaw detection must be of the wet type. A current of 40-60 A/cm electrode gap must be used for the test. The biggest permissible surface defects within an area of 105 x 140 mm (ISO sheet size A6) would be the ones shown in enclosure No. III, For linear defects as in Fig. 2 For non-linear defects as in Fig. 3 Note! Indications must not be closer, larger nor of greater number that shown in the figures which have been drawn on a 1:1 scale. Surface defects due to segregation will only be accepted when the indications in question are local colour variations only, found on an otherwise un- broken surface, such as "ghost lines" or similar. In other words, no surface defects (discontinuities) will be accepted if they exceed those shown in figs. 2 and 3 in enclosure No. III. Cavities/channels, etc. beneath the surface, caused by segregation, will be judged according to the acceptance criterion for UT-tests, as stated in sub- section 2.2.2. 3.2 Ultrasonic test A 100% ultrasonic test must be carried out from the outer cylindrical face and from the riser side of the casting. The examination must be made with a 2 MHz normal probe of 24 mm dia. and otherwise in compliance with an internationally acknowledged standard (SEP, ASTM,