The challenge
The preheater tower is the structural core of the kiln line. Its steel frame, bracing and cyclone supports work under thermal cycling, vibration and heavy dust deposits.
The result is fatigue cracking at welded joints, bolts losing their pre-load and corrosion under dust layers. Inspecting the full height with scaffolding would have meant a long kiln shutdown.
Scope of works
- Rope access team under an IRATA Level 3 supervisor, with ISO 9712 certified NDT technicians
- 100% visual testing of columns, girders, bracing and beam-to-column connections
- Ultrasonic thickness measurements on primary steel, duct shells and cyclone brackets
- Calibrated bolt torque audit to EN 1090-2, re-torquing loose bolts
- Dye penetrant testing of critical node welds and cyclone supports
Outcome
The plant received a complete integrity record of the tower: thickness readings, torque results and weld findings. Loose bolts were re-torqued and defects located before they could cause a kiln stop, with the tower in full operation throughout. See all NDT and structural inspections.
Photo record
