Retrofit Guideline – IKN Clinker Cooler

A0552 – Rajashree #3
 Contents
1 Introduction .................................................................................... 4

2 Safety .............................................................................................. 5

3 IKN Glossary .................................................................................. 5

4 Prerequisite .................................................................................... 6
4.1 Delivery of IKN Supply and Unloading .......................................................6
4.2 Warehouse, Storage Area and Pre-assembly Area ...................................6
4.3 Dismantling and Demolition of Existing Equipment ...................................7
4.4 Cooler Centre Line and IKN Base Line ......................................................7
4.5 Loads to be Moved and/or Lifted ................................................................7
4.6 Monorail ......................................................................................................8
4.7 Manpower, Equipment and Tools ..............................................................9
4.7.1 Manpower ...................................................................................9
4.7.2 Equipment .................................................................................10
4.7.3 Tools .........................................................................................10
4.7.4 Consumables ............................................................................12

5 AG 5000: Civil Work ..................................................................... 12

5.1 Cooler Level Foundation ..........................................................................13
5.2 Hydraulic Room Foundation .....................................................................13

6 Pre-assembly Activities .............................................................. 14

6.1 AG 0500: KIDS .........................................................................................14
6.2 AG 0500: Triple Packs .............................................................................16
6.3 AG 0200: Fans and Air Ducts ..................................................................16
6.4 AG 1300: Roller Crusher ..........................................................................16
6.5 AG 1000: LPS Units .................................................................................18
6.6 AG 1400: Hydraulic Power Pack (HPP) ...................................................19
6.7 Other Works .............................................................................................20

7 Shutdown Activities .................................................................... 20

7.1 Demolition Work (Outside IKN Responsibility) .........................................20
7.1.1 Refractory Demolition Work (Outside IKN Responsibility) ........21
7.1.2 Existing Cooler Including Grate and Fans ................................22

8 Installation Work .......................................................................... 23

8.1 AG 1800: Cooler Housing Including Doors and Inspection Ports ............23
8.2 AG 1000: Movable Structure ....................................................................25
8.3 AG 1100: Fixed Structure .........................................................................28
8.4 AG 0500: Air Beams and Grate Elements (Coanda Nozzle) ...................28
8.5 AG 1300: Roller Crusher ..........................................................................30
8.6 AG 0200: Air Ducts and Fans ..................................................................32
8.7 AG 7000: Air Blower Units (Outside IKN Supply) ....................................32

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 8.8 AG 8000: Electrical Work (Outside IKN Supply and Responsibility) ........33
8.9 AG 0600: Kiln Hood ..................................................................................34
8.10 Dep. 15 AG 0760: Kiln Outlet Seal ...........................................................35

9 Tolerances .................................................................................... 37

10 Preparations for Cold Commissioning ...................................... 39

11 Preparations for Hot Commissioning ........................................ 40

12 3D Views (example) ..................................................................... 41

Tables
Table 1. Assembly Group Overview .........................................................................6

Illustrations
Fig. 1. Monorails Attached to the Concrete Girders of the Burner Floor ...............8

Fig. 2. Monorail and Hoist Installed Inside Existing Cooler Housing .....................9

Fig. 3. Pre-assembly of KIDS ..............................................................................14

Fig. 4. Installation of Pre-assembled KIDS .........................................................15

Fig. 5. Pre-assembly Triple Packs.......................................................................16

Fig. 6. Pre-assembly Crusher Casing .................................................................17

Fig. 7. Pre-assembled LPS Units ........................................................................18

Fig. 8. Shop-assembled Hydraulic Power Pack ..................................................19

Fig. 9. Pipe-Flaring Machine ...............................................................................20

Fig. 10. Marking out of Refractory for Demolition ..................................................21

Fig. 11. Removal of the Existing Cooler Grate ......................................................22

Fig. 12. Opening for LPS Units..............................................................................23

Fig. 13. Cooler Back Wall ......................................................................................24

Fig. 14. Pre-assembled LPS Unit ..........................................................................25

Fig. 15. Integrated LPS-Stands .............................................................................26

Fig. 16. Alignment of the Drive Reaction Buttress with the Distance Gauge ........26

Fig. 17. Installation of the Drive Yoke....................................................................27

Fig. 18. Membrane Housing ..................................................................................27

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 Fig. 19. Assembly of the Wear Spacers, Outer Boards and Wear Boards ...........29

Fig. 20. Compartment Wall Sealing.......................................................................29

Fig. 21. Side Sealing .............................................................................................30

Fig. 22. Crusher in Maintenance Position .............................................................31

Fig. 23. Installation of Crusher Roller ....................................................................31

Fig. 24. Cooler Fans ..............................................................................................32

Fig. 25. Heat-Resistant Expansion Jet Nozzles ....................................................33

Fig. 26. Preassembled Kiln Hood lifted into Position ............................................34

Fig. 27. Kiln Outlet Seal .........................................................................................35

Fig. 28. Seal Direction ...........................................................................................36

Fig. 29. Correctly Installed Sealing Lamellas ........................................................36

Fig. 30. Incorrectly Installed Sealing Lamellas ......................................................37

Fig. 31. AG001 Sealings .......................................................................................41

Fig. 32. AG002 Air Ducts .......................................................................................42

Fig. 33. AG007 Dust Pipe ......................................................................................43

Fig. 34. AG011 Fixed Grate Structure ...................................................................44

Fig. 35. AG013 Roller Crusher ..............................................................................45

Fig. 36. AG014 Hydraulics ....................................................................................46

Fig. 37. AG016 TDE ..............................................................................................47

Fig. 38. AG017 Clinker Discharge .........................................................................48

Fig. 39. AG018 Cooler Housing ............................................................................49

Fig. 40. AG020 Platforms and Stairs .....................................................................50

Fig. 41. AG050 Foundations .................................................................................51

Fig. 42. AG070 Air Blower Unit .............................................................................52

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 Project details
Production Capacity 5.300 tpd
Cement Plant RAJASHREE CEMENT WORKS
Location Rajashree
Purchaser Ultratech Cement Limited
Contract Number 95070_016_0000_S2_000_N_H

1 Introduction
This installation guideline specifies necessary services for the installation of an IKN
Pendulum Cooler in terms of basic information in a key-worded and summarized way.
Additionally it gives proposals for the execution of works and activities beyond IKN‟s
responsibilities.

This document describes the necessary workload, items for the mechanical
installation of the IKN pendulum cooler and refractory work (outside IKN‟s scope). A
list of preparations for the cold and hot commissioning can be found in this document
as well, whereas the range of the electrical installations is not included.

The sequence of steps indicated in this guideline for installation is subject to revision
and may be altered by the IKN supervisor according to local conditions and/or on the
completion of interfaces. The work and activities are described generally and are
based on the experience gained with previous installations. Individual pre-conditions
and necessary details should be verified by the installation company through an
advance inspection on site. Special attention should be paid to site access and rigging
options.

The selection of a suitable installation company and the delegation of work tasks is the
responsibility of the customer. The major items subject to the cooler installation and
installation works are:

 unloading and unpacking of the IKN supply

 unloading and unpacking of the locally manufactured supply

 local transportation at site

 provision of tools and cranes for installation

 supply of consumables like standard welding electrodes, gas, nitrogen, hydraulic

oil and grease for first filling

 depending on the given time schedule, pre-assembly of the new equipment

 installation of the new equipment

 mechanical installation of electrical field equipment

 attendance at the cold test runs with a suitable crew

 touch-up painting as required, clearing-up and cleaning of the site.

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 During the whole installation period the contractor must provide sufficient manpower
with regard to number and skill level.

All site assembly, installation and modification works must be of good workmanship
and in accordance with IKN‟s high quality standards. All work will be executed under
continuous supervision of an IKN supervisor.

2 Safety
Please refer to the Operation and Maintenance Manual for safety instructions.

3 IKN Glossary

Assembly
Assembly Group (AG) Description
Group No.
0000 General assembly
0100 Sealing
0200 Air ducts, cooling fans
0300 Heat shield
0500 Air beams, Coanda nozzles
0600 Kiln hood
0700 Kiln outlet seal
1000 Mobile grate structure
1100 Fixed grate structure
1300 Crusher
1400 Hydraulics
1600 TDE
1700 Clinker discharge
1800 Cooler housing including doors (AG 1900)
2000 Platforms, stairs

5000 Foundations
5900 Refractory
7000 Pneumatics, air blowing units
8000 Electrical equipment
9000 Water injection
9900 Spare parts

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 Table 1. Assembly Group Overview

All IKN cooler assembly group layout and sub-assembly layout drawings are
numbered with an 18 string alpha-numeric code which has the following format:
A0XXXxxx(Dep)xxxx(AGN)------(sequential number).

This numbering format contains:

 the IKN project number (A0XXX)

 the department number (DEP) – 016 for the clinker cooler

 the assembly group number (AGN) – 0000 for the general layout of the cooler,
0100 for sealing, and so on.

The IKN cooler general assembly drawings are numbered with an 18 string alpha-
numeric code, which has the following format: M1xx(DEP)xx(AGN)xx00(SUB)--------
(sequential number).

This numbering format contains:

 M1 followed by the department number (DEP) – 16 for the clinker cooler

 the assembly group number (AGN) – 0100 for sealing

 numbering for subassembly drawings (SUB).

Drawings are sorted into their respective assembly groups in the drawing list included
in the document: A0XXX_016_0000_H9_001_D_A_Drawings_Parts_Lists.

4 Prerequisite
4.1 Delivery of IKN Supply and Unloading

The overseas parts of the IKN Pendulum Cooler equipment will be delivered by truck
transport in 40' standard or high cube containers. To ease unloading it is
recommended to have an unloading ramp available or to place the containers on even
ground. The packing list will indicate a colli numbering from 1 - 6 corresponding to the
"sequence of installation", i.e. the colli marked with No. 1 contain the parts and
equipment that will be needed first for the cooler installation. Then all colli showing No.
2 will be needed and so on. This identification must be considered for the storage of
the goods. Easy access should be given at any time. It should generally be possible to
reach and unpack any colli or container, also by rearranging the storage pattern if
necessary.

4.2 Warehouse, Storage Area and Pre-assembly Area

A covered warehouse area of approx. 150 m² is required for the storage of the IKN
hydraulic and electrical equipment; please refer to the IKN packing list for the storage
instructions.

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 A storage area of approx. 1000 m² has to be made available for the IKN supply portion
and a pre-assembly area of about 300 m², directly at the site. A short and
unobstructed access route from the warehouse and storage area(s) to the
construction site must be ensured.

A storage container with installed shelves (ideally a 40‟ container) should be placed in
the direct vicinity of the cooler construction site, preferably in a shady area. This
container will be needed to store small parts (bolts, nuts, etc.) in order to have them
well-sorted and quickly available. The IKN supervisor will determine which packages
will be unpacked for this purpose.

4.3 Dismantling and Demolition of Existing Equipment

The equipment that must be dismantled includes the existing cooler grate, grate drive,
crusher, discharge chutes, fans and auxiliary equipment. The demolition work includes
predetermined parts of the cooler housing and hoppers and the existing crusher and
fan foundations. The scope and time frame of dismantling and demolition remains the
responsibility of the customer.

4.4 Cooler Centre Line and IKN Base Line

The centre lines or reference lines must be made clearly visible by means of marked
embedded or bolted steel plates, imprints or colour marks at the beginning and at the
end of the cooler building or installation area. For pre-assembly and final installation of
the IKN Clinker Cooler, the IKN base line or equivalent must be marked the same way
and according to the layout ("no marks = no starts"). This applies for the pre-assembly
and the final installation period.

4.5 Loads to be Moved and/or Lifted

During the assembly and installation works, individual parts with a weight of up to 10 t
and pre-assembled components with a weight of up to 40 t will have to be moved
and/or lifted.

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 Fig. 1. Monorails Attached to the Concrete Girders of the Burner Floor

4.6 Monorail

The installation of a monorail underneath the roof of the cooler is recommended as

help for the installation works. The minimum lifting capacity should be 15t. For ease of
installation there should be two hoists installed on the monorail. The arrangement and
design of the necessary anchoring points is outside of IKN responsibility.

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 Fig. 2. Monorail and Hoist Installed Inside Existing Cooler Housing

4.7 Manpower, Equipment and Tools

The size of the construction teams, parts and materials as listed below are exemplary
for the mechanical installation of an IKN Pendulum Cooler, but do not replace or limit
the manpower requirements, standard tools and equipment for construction and
installation works in general. Items and manpower must be made available as soon as
needed respectively on short notice.

4.7.1 Manpower

Based on the assumption that the work crews will consist of qualified millwright fitters
the following minimum team sizes are recommended for the pre-assembly and
installation of the clinker cooler:

 pre-assembly: 10 fitters (including at least 3 fitters with all welding certificates up

to 4G for structural welding)

 installation (two shifts): 16 fitters per shift (including at least 6 fitters with all
welding certificates up to 4G for structural welding)

 during certain phases of the installation work, especially after completion of the
upper and lower cooler housing, it will be necessary to have at least 5 dedicated
welders available per shift in addition to the installation team

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 4.7.2 Equipment

 welding outfits with a capacity of > 300 A

 welding outfits for shielded arc welding (e.g. CO2)

 blow-torch cutting-off machines including gas bottles (for plates thickness of 5...50
mm)

 crane capable of lifting and positioning the above mentioned loads

 fork lift (5 t) and 1 truck

 monorails – refer to IKN layout drawings for required locations and capacity

 power supply points (distribution cabinets)

 extension cables (50 m) with sockets

 lights with extension cables

 concrete mixer and 2 concrete vibrators

 lagging, lining boards

 levelling instruments (e.g. smart level)

 auxiliary beams and u-channels

 chain blocks @ 3 t

 chain blocks @ 5 t

 chain blocks @ 10 t
 plumbs and 100 m of steel wire ø1 mm

 equipment for painting

 equipment for refractory works

 equipment for concrete works

 equipment for grouting.

4.7.3 Tools

 pick hammers

 right angle grinders, large

 right angle grinders, small

 halogen lamps (500 W)

 portable searchlights (75 W)

 electric hand drill machine

 set of steel drill bits (5…20 mm)

 electric drill hammer

 set of concrete drill bits (12…24 mm)

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  electric impact wrenches driver (17…36 mm)

 isolating transformers
 grab trolleys (3 t/10 m) with metal rope

 grab trolleys (5 t/25 m) with metal rope

 rollers for metal rope

 screw jacks 2 t

 hydraulic jacks 20 t/ø100

 hydraulic jacks 10 t/ø50

 plain slings (1 m) with 2 hard eyes

 sling bands (4 t, 1 m)

 sling bands(4 t, 2 m)
 shackles (A1.6)

 shackles (A2.5)

 crowbars (1.5 m)
 torque wrench (10…120 Nm, 400 Nm, 730 Nm und 1100 Nm)

 hexagon socket (18 mm)

 facilities to transport plate steel

 facilities to transport steel profiles

 screw clamps (0…300 mm)

 screw clamps (100…400 mm)

 handspikes (0.5 m)

 ring and fork wrenches (17, 19, 24 mm)

 pipe wrench

 sledge hammers (5 kg, 1.5 m)

 hammers (1 kg)

 hose water level

 levels (1 m)

 levels (0.5 m)

 smart levels (2x).

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 4.7.4 Consumables

 water of drinking quality for concrete / grout

 normal concrete
 non-shrinking concrete for grouting

 auxiliary materials such as:

 mild and stainless steel welding rods

 reeled filler wire

 oxygen

 acetylene

 shielding gas

 compressed air

 grinder- and cutting discs

 lubricants, etc.

 supply of personal safety equipment, e.g. gloves or glasses, are outside IKN
responsibility.

5 AG 5000: Civil Work

The modification of the existing foundations must be done in line with customer
instructions and drawings where all IKN requirements and specifications for civil and
foundation work are incorporated. The loads indicated in IKN drawings are mechanical
loads without calculation of any civil safety factor. IKN is not responsible for the
supervision of these works.

The complete foundation work has to be finished and checked prior to the start of the
mechanical installation.

The scope of the civil work includes the following modifications:

 foundations
 embedded base plates

 embedded frames and beams.

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 5.1 Cooler Level Foundation

 foundation at cooler level to be checked for capability of bearing cooler equipment

loads indicated in IKN load drawing

 foundation at cooler level to be modified according to the IKN drawing

 existing crusher foundation to be removed as indicated in the corresponding

drawing

 preparation (cleaning of parts and area, removal of possible obstacles etc.) of the
foundation area for the mechanical installation.

5.2 Hydraulic Room Foundation

 building of hydraulic room, openings for doors, ventilation and pipe outlets
according to IKN drawings

 installation of the foundations including oil resistant basin and embedded steel
frame for the power pack unit as shown in the corresponding drawing

 preparation (cleaning of parts and area, removal of possible obstacles etc.) of the
foundation area for the mechanical installation.

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 6 Pre-assembly Activities
6.1 AG 0500: KIDS

Fig. 3. Pre-assembly of KIDS

 pre-assemble the support frame and check the level accuracy with an optical level

 mount and align the side and centre supports of the KIDS onto the support frame

 mount the air beams onto the side supports and tighten the connecting bolts after
checking the level

 install three Coanda nozzles (left, middle and right) on each air beam to check the
alignment of the beams

 push the support plates of the centre support upwards until they touch the air
beams and weld according to the drawing

 mount the distribution air ducts under the KIDS air beams
 mount the Coanda nozzles and thermocouples onto the air beams

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 Fig. 4. Installation of Pre-assembled KIDS

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 6.2 AG 0500: Triple Packs

 position the triple pack pre-assembly stand in the pre-assembly area

 mount two fixed and one movable air beam on the pre-assembly stand

Fig. 5. Pre-assembly Triple Packs

 align the beams with the alignment aid

 install the bridge plates, the lifting lugs and the brackets on the fixed air beams

 mount the grate plate packages on the air beams.

6.3 AG 0200: Fans and Air Ducts

 pre-assemble air ducts, fans including compensators and silencers (apply sealing
cord for flange connections).

6.4 AG 1300: Roller Crusher

 pre-assemble front, back and side walls

 align crusher housing according to markings and pins and weld only lower
crusher side walls

 install crusher rollers

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 Fig. 6. Pre-assembly Crusher Casing

 install and connect central lubrication system including hoses

 depending on lifting capabilities take out crusher rollers for final installation
 pre-assemble upper and lower sealing frames.

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 6.5 AG 1000: LPS Units

 place opposite LPS units on even ground and insert pendulum beam

Fig. 7. Pre-assembled LPS Units

 pin pendulum beam to spring plates of LPS and fix into center position with
mounting plate.

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 6.6 AG 1400: Hydraulic Power Pack (HPP)

Fig. 8. Shop-assembled Hydraulic Power Pack

 position oil pan for the HPP inside hydraulic room, align and fix to ground with
anchors

 place the HPP onto the oil pan, align and bolt to oil pan

 install the distribution cabinet of the hydraulic drive

 place the PC-cubicle and fix into place

 place the local control board of the hydraulic drive and fix into place

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 Fig. 9. Pipe-Flaring Machine

 mount and connect the piping between the HPP up to the cooler inlet, use pipe
flaring machine (IKN supply) where applicable, some pipes may have to be
welded

 ensure adequate ventilation within hydraulic room

 install piping for water supply and drainage

6.7 Other Works

 identify, group and prepare equipment for later use

 mark openings for cut-outs on cooler housing

7 Shutdown Activities
7.1 Demolition Work (Outside IKN Responsibility)

 safety platform within the cooler throat will be necessary in case work on the kiln
and the cooler are carried out at the same time at the same time

 ensure safe working conditions for the entire area

 ensure unrestricted access during demolition work

 remove all instruments which are to be reused

 disconnect derelict electrical cooler equipment for demolition

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 7.1.1 Refractory Demolition Work (Outside IKN Responsibility)

 remove refractory in KIDS area

Fig. 10. Marking out of Refractory for Demolition

 partially remove the cooler refractory on the side walls for installation of the new
grate system

 check if the refractory needs to be removed for the monorail installation

 clean the cooler grate and the under grate compartments

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 7.1.2 Existing Cooler Including Grate and Fans

Fig. 11. Removal of the Existing Cooler Grate

 remove existing cooler grate, including grate system, sealing, compartment walls,
drive units and support structure

 disassemble air ducts between fans and cooler housing

 cut openings into lower cooler housing for grate suspension units (LPS within
existing housing) and new air ducts
 cut openings into lower cooler housing for new grate drive

 transport the dismantled cooler parts to the scrap yard

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 Fig. 12. Opening for LPS Units

8 Installation Work
8.1 AG 1800: Cooler Housing Including Doors and Inspection Ports

 install transverse beams to support lower compartment walls

 position lower part of compartment walls, align and weld to support beams
respectively fix to the concrete with stud anchors

 assemble and install cooler inlet base frame

 assemble and install cooler housing front walls, drive reaction buttress and cooler
inlet roof

 install pre-assembled KIDS

 assemble and install segments of lower cooler housing for cooler housing
modification
 close lower cooler housing at back by inserting back wall

 install bridge of roller crusher

 position panels of upper cooler housing for cooler housing modification, align and
tack weld

 after installation of LPS stands, weld lower cooler housing airtight – inside and
outside
 weld the upper cooler housing airtight – inside and outside

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  mount all doors and inspection ports

Fig. 13. Cooler Back Wall

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 8.2 AG 1000: Movable Structure

 the support stands for the LPS units need to be installed prior to the installation of
the mobile structure

Fig. 14. Pre-assembled LPS Unit

 lift the LPS units into the cooler through openings in the housing and position
them on the support stands

 align the LPS units in the centre position and fix the position with the mounting
plate

 align and adjust the LPS with the total station together with the IKN supervisor
and secure the position by tightening the temporary jack bolts.

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 Fig. 15. Integrated LPS-Stands

 mount the movable frame on top of the pendulum beams

 align the complete movable structure and confirm with the total station together
with the IKN supervisor

 connect the drive yoke to the movable frame

 mount the fork flange on drive the drive yoke

 mount the fork flange on the drive reaction buttress using the adjusting sleeves
and the distance gauge for alignment

Fig. 16. Alignment of the Drive Reaction Buttress with the Distance Gauge

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 Fig. 17. Installation of the Drive Yoke

 after alignment fix the movable structure in the centre position, tighten the bolts
with the correct torque and weld according to the drawing
 fit and align the membrane housing of the hydraulic drive to the cooler front wall

Fig. 18. Membrane Housing

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  install the sealing, cover plates and inspection ports at the LPS units
 install the upper part of each compartment wall around the movable frame

 mount the guide rollers under the pendulum beams at each LPS unit

 install the hydraulic cylinder

8.3 AG 1100: Fixed Structure

 position the side support beams of the fixed structure inside the cooler

 mount the triple packs on the mobile frame

 equip the fixed air beam consoles of the first and last triple pack along the length
of each side support beam with the conical alignment washers

 bolt the side supports of the fixed structure to the first and last triple pack along
the length of each side support beam
 mount the support brackets under the fixed side support beams and weld them to
the lower cooler housing

 attach the compartment wall supports to the side support beams, cut to length,
align and weld to the compartment wall

 replace the conical alignment washers in the fixed air beam consoles with the
normal washers and tighten all the bolts with 390Nm

 weld the fixed structure side supports together

8.4 AG 0500: Air Beams and Grate Elements (Coanda Nozzle)

 install the wear spacers on the outside of each row

 install the outer boards on the fixed rows

 mount the wear boards on the outer boards with T-bolts

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 Fig. 19. Assembly of the Wear Spacers, Outer Boards and Wear Boards

 sealing and Compartment Walls

Fig. 20. Compartment Wall Sealing

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  mount the sealing between KIDS and cooler grate

Fig. 21. Side Sealing

 mount the sealing between the cooler grate and the transition to the crusher

 fit the side sealing plates on the sides of the KIDS

 fit the side sealing plates along the sides of the cooler grate
 set the clearance of the labyrinth seals around the longitudinal beams of the
mobile frame

 fit and weld the upper parts of the compartment walls and weld air tight

8.5 AG 1300: Roller Crusher

 install maintenance rail system

 position and weld the lower sealing frame on the crusher base frame

 assemble and weld the lower crusher housing in maintenance position on the rails

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 Fig. 22. Crusher in Maintenance Position

 mount the crusher rollers and the upper crusher housing

 pre-assemble the upper sealing frame on the crusher

Fig. 23. Installation of Crusher Roller

 pull the crusher into working position

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  align the upper sealing frame and weld it to the crusher bridge

8.6 AG 0200: Air Ducts and Fans

 install the air ducts of the fans including compensator (apply silicone and sealing
cord for flange connections)

 place all the fans into position on shims and align with the air ducts

 anchor the fans to the ground

 grout all fans and silencers with non-shrinking concrete

 mount and weld the flap adjustment mechanism

 mount the pressure and flow transducers

 install the instrumentation piping

Fig. 24. Cooler Fans

8.7 AG 7000: Air Blower Units (Outside IKN Supply)

 install all heat-resistant expansion jet nozzles and the pipes through the cooler
housing, close openings with cover plates
 weld the flanges to the blow pipes

 mount the pressure vessels including solenoid valves

 install maintenance unit and mount the piping to the vessels

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 Fig. 25. Heat-Resistant Expansion Jet Nozzles

8.8 AG 8000: Electrical Work (Outside IKN Supply and Responsibility)

 install cables and connect all drives, instruments, distribution cabinets, etc.

 install cables and connect the PC-cubicle

 install direct telephone line for the modem or prepare a network connection for
internet access

 install console on cooler front and side wall

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 8.9 AG 0600: Kiln Hood
Depending on the available lifting equipment and the site conditions, the kiln hood can
be lifted into position fully assembled. However, this is not recommended for
completely new installations. The following describes the sequence, if lifted into place.
The assembly sequence in general is the same if the kiln hood is installed in its final
position.

An area of 300 m2 should be made available for pre-assembly on even ground.

Beams for proper alignment should be made available by others.

Group segments of kiln hood

 Prepare segments for rigging and installation

 Place lower segments onto ground, align and tack weld

 Place remaining segments, align and tack weld

Fig. 26. Preassembled Kiln Hood lifted into Position

 Install inspection ports and prepare kiln hood door for assembly

 Weld hood segments air tight - do not weld arch segments around opening for kiln
insert point, since kiln will be installed after hood installation

 Cross brace hood for lifting

 Weld refractory anchors

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 8.10 Dep. 15 AG 0760: Kiln Outlet Seal
 Install mounting ring on the kiln hood

 Install the seal plates on the mounting ring

 Install the nozzle ring

 Install the cooling fans including ducting

 Install the hopper and dust pipe to the cooler housing

Fig. 27. Kiln Outlet Seal

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 Fig. 28. Seal Direction

direction of kiln rotation

Fig. 29. Correctly Installed Sealing Lamellas

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 Fig. 30. Incorrectly Installed Sealing Lamellas

9 Tolerances
Where levelling of equipment is required, IKN has foreseen adjustment bolts or shims
for easy alignment. The reference for any installation work will be the movable
structure which will be aligned together with the IKN supervisor by using a Leica total
station. Alignment work of the movable structure first becomes necessary for the units
consisting of LPS stands with their pendulum cross beams. The LPS units are
designed for alignment via adjustment bolts. The equipment of the movable structure
is prepared for the temporary insertion of prisms which are reference points for the
alignment by means of a Leica total station. The movable structure was furthermore
completely pre-assembled at the workshop and was there prepared with pins as far as
possible.

Following the complete alignment of the movable structure, the movable air beams will
be installed onto the saddles that are located on the movable beams. Contact
surfaces on the air beams and movable beams are machined. For this reason, only
the position to the centre line needs to be confirmed to be +/- 1 mm since the movable
air beams are the reference for the installation of the fixed structure. Tolerances as
above apply.

The fixed air beams will be mounted, with shims for height adjustment, on the fixed
structure and need to be aligned with the movable air beams. This is done with the
IKN alignment tool. The alignment tool has a mechanical bed stop for reference.

The alignment of the buttress fork flanges for the hydraulic cylinders has to be carried
out with the distance gauges and a high-accuracy spirit level (machine level).

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 The boxes of the Coanda nozzles need to be installed parallel to each other. The
overall width of each row as well as the clearance against the next row must be
+/-1 mm.

The remaining installation of the sealing, crusher, housing segments, air ducts, etc.
are all relative to the grate structure and may require minor adjustment in order to limit
the overall alignment work. The air ducts of the cooling fans contain necessary loose
flanges to compensate any difference between the fan position and the position of
connection to the housing.

The installation of the remaining cooler equipment has to be of good workmanship and
according to IKN‟s high quality standards.

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 10 Preparations for Cold Commissioning
In order to make sure that the cooler is ready for cold commissioning, a set of photos
should be sent to the IKN service department (service@ikn.eu). The following should
be visible on these photos:
 hydraulic power pack

 hydraulic control board (HCB) from inside and outside

 hydraulic cylinder
 main electrical cabinet (CGS) from inside and outside

 local control board (LCB) from inside and outside

 if applicable, inside and outside views of local boards and terminal boxes supplied
by IKN, but not mentioned above.

The following must be available before arrival of the IKN commissioning engineer:

 hydraulic oil to fill the tank, type and quantity according to the specification
included in the IKN manual*

 grease for the roller crusher bearings, type and quantity according to the
specification included in the IKN manual*

 cooling water, type and quantity according to the specification included in the IKN
manual* (if applicable)

 nitrogen gas to fill the accumulator tanks, quantity according to the specification
included in the IKN manual*

 electrical power

 clean, dry compressed air for the air blowing units and the heat shield, in case
installed the latter

 all items belonging to assembly group 9900 „installation and commissioning

spares.‟

All cable connections as shown in the IKN wiring diagrams must have been
completed. Filling of hydraulic oil and nitrogen gas into the respective tanks should
only be done in the presence of the IKN engineer. Communication between the IKN
PLC and the plant control system must have been established and running. The
cooler grate must be clear of scaffolding and obstructions and completely clean after
completion of the refractory work.

* Please see the “Introduction” section of the IKN operation and maintenance manual.

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 11 Preparations for Hot Commissioning
In order to make sure that the cooler is ready for hot commissioning, the following
points should be fulfilled:

Equipment declared as LOCAL portion in the IKN contract

 cold commissioning of this equipment should be finished, including signal check,
no load test and communication to the plant control system

 basic interlocks for this equipment should be implemented.

Cooling fans:

 the pressure and flow transducers should be connected mechanically and

electrically.

Plant Control Software:

 tables for grate speed and fan flow set points should be prepared. Please see the
section „Interlocks‟ of the IKN Operation and Maintenance Manual.

IKN Grate:

 the cooler grate needs to be completely clean for the final inspection and fan test
run before start-up.

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 12 3D Views (example)

Fig. 31. AG001 Sealings

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 Fig. 32. AG002 Air Ducts

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 Fig. 33. AG007 Dust Pipe

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 Fig. 34. AG011 Fixed Grate Structure

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 Fig. 35. AG013 Roller Crusher

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 Fig. 36. AG014 Hydraulics

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 Fig. 37. AG016 TDE

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 Fig. 38. AG017 Clinker Discharge

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 Fig. 39. AG018 Cooler Housing

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 Fig. 40. AG020 Platforms and Stairs

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 Fig. 41. AG050 Foundations

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 Fig. 42. AG070 Air Blower Unit

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