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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
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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
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HCRDI
Schematic HCRDI Cooler
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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
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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
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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
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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)
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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
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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
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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.
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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
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Fig.5 Beam Level Check
Result that we got as below
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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
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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
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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