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COOLER

Grate 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 litre
Rated 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 Cooler


II.1.1 AERATION SYSTEM

CPAG
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 1

CPAG

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 Fan


CPAG

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

II.1.6 Hydraulic Tank


CPAG

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 Solenoid


CPAG

Condition : Mini fan in Cylinder Block Solenoid


Maintain temperature solenoid, prevent failure of solenoid

II.1.8 Hydraulic Piping


CPAG

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 Design


CPAG

Condition : Wedge Collar to maintain Moving Frame position


More reliable, not easily broken.

II.2 COOLER ALIGNMENT


After dismantling all Grate Plate in 2nd Grate , inspection started with visual inspection above grate 2 related .
beam condition and wear in side wall
Fig.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 frame
2. 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 mm
Adjustment is needed to levelling the beam. After calculated adjustment needed as below

M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F

544
564
578
598
612
632
646
666
680
700
714
734
748
768
782
802
816
836
850
870
884
904
918
938
952
972
986
1006

Target

LEFT SIDE

CENTER LEFT

CENTER RIGHT

RIGHT SIDE

554
573
588
607
622
641
656
675
690
709
724
743
758
777
792
811
826
845
860
879
894
913
928
947
962
981
996
1015

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