USA Maintenance Seminar

Clinker Cooler Maintenance

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 USA Maintenance Seminar

Coolers

PART 1

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 Introduction
• Agenda
• Importance

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 SAFETY

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 SAFETY CONCERNS

• ROTATING MACHINERY

– FANS
– CLINKER BREAKERS
– V-BELT DRIVES
– SPROCKETS & CHAIN
– COUPLINGS

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 SAFETY CONCERNS

• RECIPROCATING EQUIPMENT

– PINCH POINTS
• GRATES
• SHAFT SEALS
• WHEELS & TRACKS

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 SAFETY CONCERNS

• STORED ENERGY
– HYDRAULICS
– COMPRESSED AIR
• SPILLAGE VALVES
• AIR BLASTERS
– GRATE LINE
– PROCESS

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 SAFETY CONCERNS

• HEAT

– CLINKER
– REFRACTORY
– EQUIPMENT

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 SAFETY CONCERNS

• PYRO-PROCESSING EQUIPMENT

– KILN TURNING
• COATING & BRICKS
– PREHEATER PLUGS
– WATER POCKETS IN WET PROCESSES
– PROCESS DUCTS BUILD-UPS

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 SAFETY CONCERNS

• Work Conditions

– Individual Components are Cumbersome

– Entries & Exits Limited Size
– Spilled Material could cause Falls

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 Maintenance & Operation
• Go Hand-in-Hand
• Cannot have good Operation without Good
Maintenance
• &Vice-Versa

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 COOLER NOMENCLATURE

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 CFG Cooler

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 Stationary supports air supply –
End view

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Moveable grate air supply – End
view

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 Side view of grate

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 Fresh air cooler vent system
arrangement, venting to atmosphere

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 Recirculating cooler vent air system
arrangement

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 Typical Cooler Vent

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Grate line
configurations
 • Set Cooler at Mid-Stroke
• Locate Cooler Centerline
• Install Movable Frame Parallel to Cooler Centerline and Square it.
• Check Elevation of Movable Frame in Relation to Side Frame
• Ensure that Crosshead Shaft is Square to Movable Frame –
Use 3-4-5 Triangle
• Center Supports on Centerline
• Check Spacing Between Supports
• Make Sure Supports are on Ten Degree Slope
• Supports & Fingers Should be Flat
• All Stationary Supports Should Have at Least 1/8 inch Shim
• Install Grates
• Equalize Gaps

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 Section thru grate plate support
with grate plate attached

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 Single width grate plate

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 Typical grate arrangement

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 Double width grate plate

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Typical “dead grate” arrangement

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 TYPICAL SECTION AT MOVEABLE
GRATE PLATE SUPPORT

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 TYPICAL SECTION AT STATIONARY
GRATE PLATE SUPPORT

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 Adjustable pusher

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 Controlled flow grate plate

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 DEAD GRATE SYSTEM

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 DEAD GRATE SYSTEM
SHOWING NEW LIP SEAL

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 End of Cooler Part 1

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 DEAD GRATE PLATE

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 Questions?

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 USA Maintenance Seminar

Clinker Cooler Maintenance

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 USA Maintenance Seminar

Clinker Coolers

PART 2

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 • Set Cooler at Mid-Stroke
• Locate Cooler Centerline
• Install Movable Frame Parallel to Cooler Centerline and Square it.
• Check Elevation of Movable Frame in Relation to Side Frame
• Ensure that Crosshead Shaft is Square to Movable Frame –
Use 3-4-5 Triangle
• Center Supports on Centerline
• Check Spacing Between Supports
• Make Sure Supports are on Ten Degree Slope
• Supports & Fingers Should be Flat
• All Stationary Supports Should Have at Least 1/8 inch Shim
• Install Grates
• Equalize Gaps

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 Sealed bushing design

1. Replaceable hardened
sleeves for shaft protection
2. Spring-loaded teflon seals
for retention of lubricant
and prevention of
infiltration of foreign
particles

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 ANTI-FRICTION BEARINGS

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 WHEEL TRACKS

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TYPICAL EXTERNAL WHEEL
HOUSING

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TYPICAL EXTERNAL WHEEL
HOUSING

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 ENCLOSED WHEEL BOX

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 ENCLOSED WHEEL BOX
SECTION “A-A”

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 INTERNAL WHEEL
SECTION “A-A”

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 INTERNAL WHEEL

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 OLD STYLE INTERNAL WHEEL

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 ROLLER ASSEMBLY

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 BEARING AND CARTRIDGE

•Roller bearings in halves •Close grained cast iron split cartridge

•Spherically machined outside diameter
•Aluminum triple labyrinth seals
•Equal distribution

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 PEDISTAL AND FLANGE

•Ring design permits high •Unit mounted against a vertical

loads in radial direction or horizontal face
•Face can be recessed for pilot

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 The End

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 Questions?

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