Rotary Kiln Services 2013 Prices

Address: BOSB Birlik Sanayi Sitesi 5.
Cadde No:32 34520 Beylikduzu Istanbul TURKEY

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20
URL: www.ozekmakina.com E-Mail: bilgi@ozekmakina.com

Document Nu: 20130822 Page: 1 / 8

To :

Subject : Document Nu : Sent to : Date :
Purchase department

Quote 20130822 - 22
nd
August 2013

SUBJECT:

Quotation for the works listed below.

SCOPE OF THE WORK :

FULL KILN ANALYSIS

- Basic mechanical kiln inspection.
- Horizontal and vertical axial deviations.
- Kiln slope.
- Individual tyre, roller and gear slopes.
- Tyre and 5 point roller diameters.
- Under tyre gaps, tyre relative movement.
- Roller working angles.
- Roller skew.
- Girth gear/pinion gear 10 point backlash measurement.
- Wobbling (Tyres and girth gear).
- Ovality.
- Shell deformation analysis. (Reports for full shell and individual sections for every 1 meter.)
- Full kiln analysis report presentation.

ALIGNMENT SUPERVISION (Depending on the report result.)

- Alignment (Roller Skewing) supervision of the rollers depending on the hot kiln alignment
report.

IN SITU TYRE/ROLLER/THRUST ROLLER RESURFACING (Depending on the report result.)

- Machining and grinding the supporting roller side of tyre.
- Machining and grinding the thrust roller side of tyre.
- Machining the tyre side of thrust roller.
- Machining the tyre side of supporting roller.

Address: BOSB Birlik Sanayi Sitesi 5. Cadde No:32 34520 Beylikduzu Istanbul TURKEY
Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

TECHNICAL SPECIFICATIONS:

All the equipments which will be used in this work will be provided by OZEK MAKINA.
220V and 380V continuous electrial power, oxygen welding, lighting and the scaffold in the rotary kiln
piers will be provided by CUSTOMER.
A room close to the working area which will be used as an office will be provided by CUSTOMER.
All the safety clothing objects will be provided by OZEK MAKINA.
CUSTOMER is responsible of securing all crew and the equipments during working period.

PAYMENT OF THE EXTRA COSTS:

DESCRIPTION COST
PAID BY
OZEK MAKINA CUSTOMER
VISA
Consultancy and embassy payments
- x -
FLIGHT TICKETS
Istanbul-Plant-Istanbul Flight tickets
for 5 people.
- x -
TOOL BOX CARGO (ISTANBUL TO PLANT)
Tool Box; Sizes: 1 x 1 x 2 m Weight: 1000 Kg
All consultancy, air cargo and customs
payments including re-import payments.
- x -
TOOL BOX CARGO (PLANT TO ISTANBUL)
Tool Box; Sizes: 1 x 1 x 2 m Weight: 1000 Kg
All consultancy, air cargo and customs
payments including import and re-export
payments.
- - x
HOTEL
For 5 people for 10 nights including
breakfast.
- - x
FOOD
Lunch, dinner and night breakfast for 5
people.(15 per meal) The team may use
plant refectory for lunch, dinner and night
breakfast for night shift.
- - x
TRANSFERS OR CAR RENTAL
10 days price for a mid class car rental.
CUSTOMER is responsible for all transfers
for airport-hotel-airport and plant-hotel-
plant.
- - x
TOTAL - - -

- Ozek Makina Works with 5 people team for resurfacing projects and 3 people team for full kiln
analysis projects.
- Tool Box is used during resurfacing projects.
- All the costs of plant side including importing the tool box and re-exporting will be paid by
CUSTOMER.
- Due to the night shift works and unplanned site visits, car rental might be a better option for all
transfers.
- The team needs an office with internet connection close to the kiln during all works.

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

PRICING:

SUBJECT DURATION KILN SPEED AMOUNT PRICE
Full kiln analysis.
9
Days
Up To
4 rpm
1 15.000,00 USD
Alignment supervision.
4
Days
Up To
4 rpm
1 7.000,00 USD
Machining and grinding the supporting roller
side of tyre.
6
Days
Up To
3 rpm
1 20.000,00 USD
Machining and grinding the thrust roller side
of tyre. (One side only)
4
Days
Up To
3 rpm
1 16.000,00 USD
Machining the tyre side of thrust roller.
2
Days
Up To
4 rpm
1 2.500,00 USD
Machining the tyre side of supporting roller.
2
Days
Up To
5 rpm
1 3.500,00 USD
BUNDLE PRICE FOR THRUST ROLLER PIER

- Machining and grinding the supporting
roller side of tyre.
- Machining and grinding the thrust roller
side of tyre. (One side only)
- Machining the tyre side of supporting
roller.
8
Days
Up To
3 rpm
1
Set
32.000,00 USD

- Valid as a whole.
- Please see additional costs section.
- 1.500 USD /day will be added to price for alignment supervision works more than 4 days.

ESTIMATED TIME TABLE:

DAYS 1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
Full Kiln Analysis BI*
Roller Resurfacing 1 2 3 4 5 6
Tyre Resurfacing Pier 1 with thrust roller (Bundle) Pier 2 Pier 3
Alignment (Skew)

* BI: Basic Inspection including diameter measurements of tyres and rollers.
- Estimated durations might change due to the tyre wear and kiln conditions.

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

TERMS:

Half of the total price will be paid cash or via bank transfer when quotation signed.
Balance will be paid cash or via bank transfer at the end of the bussiness.

Please use following account info for advance payment.

ACCOUNT OWNER Ozek Makina - Hatice Ozek
BANK Akbank
BRANCH Buyukcekmece
IBAN TR510004600197001000204703
SWIFT CODE AKBKTRIS

VALIDITY:

Price offer is valid as a whole till 31.12.2013

Best Regards,
Zeki ZEK

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

APPENDIX

EQUIPMENT LIST:

All the tools listed below are packed in a w:100 X l:200 X h:100 cm closed metal box and all weights
(including the box itself) 1000 kg.

Tool box will be insured by the carrier company.

UNIT QUANTITY
(Label A,B,E) Portable lathe unit
Three types of portable lathe support moving by the power of electric motor used for mounting
and auto moving lathe tools.
1 Set
(Label C) Portable lathe leaning apparatus
A set of iron mounts which is used for installing and bending the portable machining and grinding
tool over the rotary kiln tyre.
1 Set
(Label D) Pulley carriers
Two types of pulleys which are used for carrying the PMGT by hanging the pulleys on scaffold.
3 Set
(Label F,G) Grinding motor
Two different sized electrik motor bowl grinders which are used for grinding the rotary kiln tyre.
2 Set
(Label 1,2) Tool Box : Diameter measurement tools
Electronic meaurement tools which are used for on-site measurement needs.
2 Set
(Label 3) Tool Box : Safety clothing sets
Safety gloves, safety glasses, dust masks, earplugs
20 Set
(Label 4) Tool Box : Repair tools, bolts, wrencehs, lathers
Wrench sets, screwdrivers, bolts, lathe cutting tools
1 Set
(Label 5) Tool Box : Hammers, screwdrivers, wrenchs, allen
Hammers, allen wrenches, wrench sets
1 Set
(Label 6) Tool Box : Extension cords, switchers, lights
Extension cords, plug multiplexers, switchers
1 Set
(Label 7) Tool Box : Electricity supply units
Electricity suppliers
1 Set
(Label 8) Tool Box : Grinders
Handy Grinder power tools and spare disc grinders.
1 Set
(Label 9) Tool Box : Mini welder and electrode
Portable welding machine and spare elctrodes.
1 Set
(Label 10) Tool Box : Tea Set
Water boiler, tea cups, tea, coffee, sugar
1 Set
(Label 11) Tool Box : Bowl Grinders
Spare bowl grinders
1 Set

Apart from this tool box,

- Oxygen cutting set
- 4 industrial type, middle size climating fans
- For the scaffold; (4 pieces) 3,5 meters long scaffold masts, (8 pieces) 3,5 m long scaffold pipes
and (8 pieces) 1,2 meters short scaffold pipes. If it is clamp style we will also need clamps.
- 220 and 380 V continuous electric energy
- 200mm U style 3 meters long iron.
- 120 mm L style bracket iron 2 pieces 6 meters long
- A crane or high-up to lift the tool box nearby the pier.

will be provided by CUSTOMER.

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

PRECONDITIONS:

We may require for a 5 minutes shut down for a short preparation. Apart from it, we do not ask for any
shut down or slow down up to 3,5 rpm during our work.

It is also recommended to clean around the pier, prepare the equipments which will be provided by the
company before starting.

QUALITY ASSURANCE:

We use special equipments developed by Ozek Makina team for all measurement needs during resurfacing
works and hot kiln alignment services. The presicion for diametral measurements is 0,1 mm and it is 1 mm
for our hot kiln alignment services.

Our team works coordinated with rotary kiln crew and gets regular information about serviced unit. All
shifts observes the unit and reports the situation to technical manager who is responsible of deciding the
procedure.

OHS MANAGEMENT:

Rotary kiln tyre resurfacing work is done on site during the regular conditions of kiln. A portable lathe unit
is installed on the side of tyre and crew stays over a 3 meter high scaffold during all working time. The
scaffold has stairs, seat and barrier for safety needs. The seat side is climated by 3 or 4 industrial type fans
to regulate the temperature caused by kiln. Scaffold is also covered by filet type canvas to avoid any
accident and the dust outside. Several heat shields are used for the kiln heat.

All crew uses safety clothes, helmet, safety gloves, safety glasses, dust mask and hearing protection
equipments during all working time on site.

All crew have been educated about personal protection safety rules regularly at the beginning of all site
works.

All team members are medically examined by occupational healt clinics for heavy industry standarts every
6 months. All clinic reports are stored by Ozek Makina. Name, blood type and citizenship numbers are also
written on all crews helmet.

All team members are insured by Turkish government social security foundation. All insurance costs are
monthly paid by Ozek Makina.

Ozek Makine uses in-factory clinic and ambulance for accidents and Zeki Ozek is responsible for OHS
management on site.

DURATION EXCEED:

Although it is not possible to estimate the duration before starting the work, we give 10 days as an average
working time for typical tyre problems. We are pricing the works as a whole independent from duration.
Several reasons like rotation speed, kiln shut down or tyre wobbling can cause a difference on duration.
We do not charge the delays caused by the customer up to 3 days. Delays over that period are charged 500
USD per day.

We can machine and grind the surface at rotation speeds up to 3,5 rpm and do not request any shut down
or slown down during working time. Slower rotation speed might cause duration exceeds depending on

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20

the wear level. We do not charge or accept any penalty for duration exceed caused by rotation speed and
wear level.

TERMS AND CONDITIONS:

Our resurfacing services consist of machining and grinding the surface by the help of a portable lathe
equipment. Ozek Makina, accepts the work as a predecided part of a sollution and does not claim that
resurfacing will solve the ongoing problems on kiln.

Ozek Makina is responsible of shaping the tyre and/or roller to the minimum diametral cylinder with N12
roghness standarts and after acceptance of work by the help of any measurements taken by the customer,
Ozek Makina does not guarantee for any term for its services which may be worn due to the wrong usages
or other problems.

TERMINATION:

This offer is valid as a whole for 6 months. Ozek Makina keeps its rights reserved to terminate the contract
in case of the conditions which do not let to work like high security problems, natural disasters and long
therm shut downs for over 15 days. If the contract is terminated by CUSTOMER during the working time,
Ozek Makina accepts the work is done and may claim to charge the full invoice price and additional costs.

Phone: +90 212 861 09 86 Fax: +90 212 861 53 02 DIRECT: +90 533 650 09 20


REFERENCES
OVER 100 ROTARY KILN SERVICES AT 60 PLANTS ACROSS 8 COUNTRIES SINCE 1968

www.rotarykiln.eu

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Address: BOSB Birlik Sanayi Sitesi 5.

Cadde No:32 34520 Beylikduzu Istanbul TURKEY

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