DGC’s Mechanical Services Division recently completed a Pre-Dryer overhaul project for a client in South Africa. The Division specialises in providing a wide range of specialist services for Rotary Kilns / Vessels that are tailored for the main rotary equipment, as well as its associated peripherals. The project was completed in 26 days, well within the scheduled 32 day shutdown period. This was a direct outcome of utilising the company’s advanced planning and scheduling techniques in conjunction with our well qualified and experienced personnel.
There were no reported Health Safety and Environment (HSE) incidents throughout the project. In pursuit of this, extremely rigorous internal and client specific HSE procedures were continuously adhered to. Other notable interventions included detailed rigging studies, permit systems and continuous risk assessments.
Below is an outline of some of the major stages that were involved in the project:
FABRICATION OF NEW SHELL AND ACCESSORIES The first stage of the project involved the Division’s specialised Fabrication and Welding Services, these are provided for a wide range of metals including Copper, Brass, Stainless steel and all forms of Carbon steel. A new shell was fabricated offsite, at the company’s workshops according to the client’s specifications and all applicable standards.
The following components were also designed and manufactured at DGC’s facilities: Girth gear Pinion gear Drive system base Riding rings Drum spiders The new assembled unit was then transported ready for installation at the client’s site. REMOVAL OF OLD PRE-DRYER As soon as the client’s scheduled maintenance shutdown began, DGC was involved with the complete decommissioning, dismantling and removal of the existing (old) Pre-Dryer and its surrounding equipment. This was preceded by a significant amount of preparatory works like the removal of the building’s roof to allow big components to be extracted using rigging techniques. INSTALLATION OF NEW DRYER
Following the complete removal of the old unit, all relevant preparation works were done and advanced rigging techniques were employed to carefully place the new unit in position. This was done within the constraints posed by surrounding structures and other contractors performing their shutdown tasks. The entire unit and its associated mechanical equipment was then fully installed. COMPREHENSIVE ALIGNMENT
Finally, comprehensive alignment of the new Pre-Dryer was done. This is a crucial step as the majority of challenges associated with rotary vessels can generally be attributed to misalignment issues.