COOLERGrate Cooler is from Claudius Peters (CPAG) design , double stage Cooler with Drive from Hydraulic System For Grate 1 rated motor Hydraulic is 25 kW ,1750 rpm Grate 2 rated motor Hydraulic is 34.5 kW , 1750 rpm Hydraulic oil Volume is 1000 litreRated capacity for this cooler is 3300 tpd

Fig. Hydraulic Drive Motor, 2 motor for each grate

Fig Cylinder Block and Cylinder Drive

II.1 CPAG CoolerII.1.1 AERATION SYSTEMCPAG Every Chamber in Grate 1 have individual Fan for Beam Aeration

Condition : - ensure enough air to Beam (Fixed and Move) - reduce termal stress into the beam - more effective cooling for Clinker

HCRDI

Schematic HCRDI Cooler

Condition: - 1 Fan in Quarry Side (FA 26) and 1 Fan in Sea Side (FA 27) for supplying aeration into all chamber in Grate 1 - Air flow from 1 Fan is distributed into 17 point for Fixed Beam and 17 point for Moving Beam aeration - Risk for not enough flow for beam aeration - increase thermal stress into the beam and grate plate - potentially not suefficient cooling for clinker

II.1.2 Beam Design Grate 1CPAG

Condition : closed design material spillage will collected in the beam (maintaining Moving Frame and Fixed Frame from the risk of being bent)

II.1.3 Grate 1 T Bolt Position

II.1.4 Moving Frame CPAG

Condition : Moving Frame is consist from two piece , not directly one piece This will reduce the risk from bent.

II.1.5 Seal Air FanCPAG

Condition : Seal Air Fan , for presurrizing bearing shaft housing , prevent any dust going into bearing

II.1.6 Hydraulic TankCPAG

Condition : Volume Hydraulic Tank Nominal volume tank only 1000 ltr , actual can be less , because pumping from under of the tank

II.1.7 Mini Fan for Cylinder Block SolenoidCPAG

Condition : Mini fan in Cylinder Block Solenoid Maintain temperature solenoid, prevent failure of solenoid

II.1.8 Hydraulic PipingCPAG

Condition : Hydraulic Piping, Using special piping for hydraulic and the joint, reliable from leaking problem and safety matter

II.1.9 BEAM DESIGN (2 PIECES)CPAG

Condition : Beam consist from 2 pieces (not long one piece) Lower Risk from Bent, easier for maintenance (replacing beam)

II.1.10 Wedge and Collar DesignCPAG

Condition : Wedge Collar to maintain Moving Frame position More reliable, not easily broken.

II.2 COOLER ALIGNMENTAfter dismantling all Grate Plate in 2nd Grate , inspection started with visual inspection above grate 2 related . beam condition and wear in side wallFig.1 Moving Beam position (no gap in CCR side) Wear

Fig.2 Grate plate damage and Wear in Wedges

Many rows in Grate 2 also having the same wear condition in side wall like above

Inspection was conducted to measure 2 condition : 1. Center Beam centerline to both middle moving frame2. Center Beam centerline to end wall

Measurement from Center Frame to both middle moving frame showing result as below: Fig.3 Schematic Measurement Center Fixed Frame-Middle Moving Frame

Showing that maximum gap is on Chamber 1 (2 mm). It means if adjustment conducted in moving frame, we can only do for 1 mm to make it level which is too little and will having not significant effect.

Next inspection is conducted to check the centerline Fixed Frame to each Side Moving Frame

Fig.4 Schematic measurement Center Fixed Frame - Side Moving Frame

Measurement from Centre Fixed Beam to each Side Moving Frame showing difference maximum 10 mm in the end which proven to us that Movable Beam in Grate 2 is not in the same line to each side wall and made wear condition as above. Because adjustment in Moving Frame will not give significant result, adjustment is needed conducted by repositioning the movable beam to make the same gap.

We continued with checking Beam Levelling in Grate 2

Fig.5 Beam Level Check

Result that we got as below

Result showing many rows is not in the level position (more than 1mm). Ajustment shoud be conducted.Recalculating the value and giving result adjustment needed as below

Fig.6 Shimming in Moving Beam Grate 2

GRATE 1 ALIGNMENT

In Grate 1 ,replacement of 80 grate plate is conducted due to thickness already reach below 7 mm Also 1 movable beam is replacing because burn out.

After new movable beam is installed , beam levelling check is conducted to check cooler alignment by using transit level. Result Beam Levelling check

We see in many row beam condition is not in the level position. Allowable for level beam only + 1 mmAdjustment is needed to levelling the beam. After calculated adjustment needed as below

Target LEFT SIDE CENTER LEFT CENTER RIGHT RIGHT SIDEMFM 544 554 remove 11 mm remove 11 mm remove 11 mm remove 11 mmF 564 573 remove 10 mm remove 10 mm remove 10 mm remove 10 mmM 578 588 remove 3 mm remove 4 mm remove 3 mm remove 5 mmF 598 607 remove 3 mm remove 4 mm remove 5 mm remove 7 mmM 612 622F 632 641M 646 656F 666 675M 680 690F 700 709M 714 724F 734 743M 748 758 add 4 mm add 4 mm add 4 mm add 2 mmF 768 777M 782 792F 802 811M 816 826 add 4 mm add 3 mm add 4 mm add 6 mmF 836 845 add 3 mm add 2 mm add 3 mm add 4 mmM 850 860 add 3 mm add 2 mm add 3 mm add 5 mmF 870 879M 884 894 add 5 mm add 4 mm add 4 mm add 5 mmF 904 913M 918 928 add 3 mm add 5 mm add 4 mm add 6 mmF 938 947 add 3 mmM 952 962 add 4 mm add 3 mm add 2 mm remove 4 mmF 972 981 remove 4 mm remove 5 mm remove 5 mm remove 5 mmM 986 996 Remove 2 mmF 1006 1015 remove 5mm remove 7 mm remove 8 mm remove 5 mm