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Claudius Peters
Clinker Cooler Technology
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General status
Check the general status and any discrepancies of the clinker cooler, e.g. leaks in the hydraulic system, gaps in the air lines, altered running noises, rust fallthrough in the lower section of the cooler
etc.
Note: All discrepancies must be documented in writing and in the form of digital photos and sent to Claudius Peters without delay.
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Weekly inspection
Once a week The entire interior lighting in the ETA clinker cooler must be switched on once a week. Visual inspections via the peepholes in the lower section of the cooler should establish whether there is any clinker in the lower section of the cooler interior and whether any areas can be detected in which clinker has collected owing to leakages in the lane seal. Drive module interior The interior of the drive module must be inspected in the area of the hydraulic cylinder for any leaking hydraulic oil. If it transpires that hydraulic oil is leaking, the cooler must be switched off and the leak repaired. If it is not possible to switch off the cooler immediately, the oil level should be checked on the hydraulic plant. The hydraulic oil must not fall below the minimum level. Top up the hydraulic oil if necessary. If the hydraulic oil is not topped up, the entire hydraulic plant can incur such damage as to render it non-functioning. The hydraulic plant should be filled in accordance with the hydraulic operating instructions.
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Attention
Oil leaks should always be repaired as quickly as possible
If larger volumes of clinker or oil slicks have accumulated in the interior of the lower section of the cooler, closer inspection and documentation of the actual situation is required. The actual situation must be communicated immediately to Claudius Peters in the form of a written description. If possible, digital photos should be taken and enclosed with the report for Claudius Peters.
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Inspection stop
During an inspection stop, the entire clinker must be removed from the HE module and lane bottoms, including the protective clinker layer on the lane bottoms. The entire lane bottom sealing system must then be examined for damage. Damaged components must be replaced with new components or repaired if possible. If any hard-faced plates reveal signs of extensive wear, they may be re-faced. If wear is apparent in other areas where there is no hard-facing, such areas can also be protected by means of hard-facing. The following hard-facing electrodes should be used for this purpose: E10UM65GRZ as per DIN 8555, e.g. UTP Ledurit 65 or 76 from Bhler, whereby the processing information provided by the supplier must be observed
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Attention
The hard-faced plates in the area of the HE module transverse seal are ground and may not be retrofitted with hard-facing. If these hard-faced plates show signs of wear, they should be replaced by new ones.
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Defective thermocouples
Defective thermo couplings secured to the lanes must be replaced by new ones. The thermo couplings are located under the first lane (inlet module) and on top of the lane (lane transverse webs), in a protective arrangement within a sheet steel housing.
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Defective halogen lamps arranged in the individual air chambers within the lower cooler section must be replaced with new ones. Do this by unscrewing the locknut from the side wall support. The entire lamp can then be removed from the air chamber and a new halogen lamp inserted in the socket.
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Roller
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All rollers
All rollers must be fully lubricated using 450 - 500 gr LGH B2 lubrication manufactured by SKF. Grease complying with DIN 51825: KP2N-20 can also be used. A pneumatic barrel pump can be used for filling in the lubricating grease. The filling volume can be set by fitting a flow meter. The old grease is forced out by a pipe on the pillow block and can be collected in a basin. The roller, side flanged wheel on the cover and the guide rail must be inspected for wear. The cover screws (item 110) must not have slackened but if they have, these screws must be tightened to 110 Nm. Roller wear may be max. 8 mm in relation to the diameter, i.e. minimum diameter = 222 mm. But please ensure that the dust fall-through into the lower section can increase with roller wear as the clearances in the longitudinal seals also increase. In the case of more extensive wear, the worn roller and side flanged wheel should be replaced with new components. The clearance between the guide rail and the side flanged wheel on the cover should not be more than 4 mm on either side. In the case of more extensive wear, the worn covers should be replaced with new ones.
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Level radar
If a level radar device is fitted, its antenna must be inspected for wear. If it displays extensive signs of wear, the aerial must be replaced with a new one. Furthermore, please check whether the PTFE seal needs to be replaced. Please refer to the Saab Tank Radar PRO User Manual; Radar level metering device in units 2-7.
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Attention
The radar device electronics are cooled via a compressed air connection. When the compressed air fails, the electronics are not cooled but rather destroyed. A water separator must be integrated in the compressed air line as otherwise a water/slick mixture can become deposited in the aerial and an incorrect clinker bed height is displayed. If damage is established, please document using a digital camera and send the photos along with a written description to Claudius Peters without delay.
Note Only original Claudius Peters parts should be used as spare parts. Please refer to the Spare Parts documentation.
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Dismantling rollers
Dismantling Drive the hydraulic cylinder into the front end position (max. cylinder stroke = 420 mm); the piston rod is fully extended. Knock out the clamping sleeves. Remove the screws. Support the lane in the roller area. Secure the roller using lifting rope and then pull down from the transverse girder support. Only one roller may be dismantled per lane at any one time. Only once the roller has been fully re-assembled may the next roller be dismantled. Assembly Slide the new roller under the guide rail and position. Knock in the clamping sleeves. Mount the fastening screws and tighten to 380 Nm. Dismantle the provisional lane support.
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1 2 3 4
longitudinal sealing Screw to fix longitudinal sealing Steel part, top section Lower side wall
5 6 7 a
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1 Screw to fix lengthwise sealing 2 3 4 Adjustable screw Seal flat steel Seal plate
a After assembly, seal gaps between sealings with Epple 37. b Gap 1-2 mm
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Central longitudinal sealing for 2nd module to outlet module, 55 to 82kg Dismantling the central longitudinal sealing
1 Central longitudinal sealing 2 Epple 37 Seal 3 Joggle 4 Fastening screw 5 Retaining washer 6 Washer
7 8 9 a b c
Walking lane Sealing plate Sealing flat iron After assembly, seal gaps between lengthwise sealings with Epple 37. Walking lane Gap 1-2mm
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Dismantling
Unscrew the fastening screws. Detach the joggle Pull out the lengthwise sealing Examine the seal flat steel for wear: if the specified gap of 1-2 mm is wider due to wear and the gap can not be set by means of readjustment owing to the extent of wear, a new seal flat steel must be fitted
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Assembly
- Slide in the longitudinal sealing. - If screws in the lengthwise sealing are damaged, new screws must be used. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus - Insert the fixing screws along with the washers and retaining washers. - Set a gap of 1-2 mm. - Tighten the fixing screws to a torque of 135 Nm - Weld the joggle to the lengthwise sealing transverse fin ensuring the correct electrode. Please also refer to the module on Spare Parts - Weld half the perimeter of the washer to the lengthwise sealing - Fill sealing putty, e.g. Epple 37, into the lengthwise sealing gap (area covering the lengthwise sealings) Note: Prior to putting the cooler back into operation, the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP
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Side sealing for 1st module (inlet module), 65 to 115 kg Dismantling the side sealing, 1st module
1 2
3 4
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Dismantling
Use the hydraulic cylinder to pull the side lane towards the cooler outlet, i.e. the hydraulic cylinder piston rod is fully retracted and in rear cylinder end position Remove the fireproof mass from the longitudinal sealings Disassemble the transverse sealing plate Dismantle the side sealing Examine the internal longitudinal sealing components for signs of wear as well as their gaps
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Assembly
Fill the nut with hot grease, e.g. Molykote HSC Plus If screws in the longitudinal sealing are damaged, new screws must be used. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus. Please refer to the respective instructions for the next steps in assembling the longitudinal sealing. Install the transverse sealing plate
ATTENTION! The longitudinal sealings ground hard-faced plate (in the area of the cross sealing) must be aligned in such a way that it is at right angles to the HE modules ground hard-faced plate. Note: Prior to putting the cooler back into operation, the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP
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Central longitudinal sealing for 1st module (inlet module), 73 to 82 kg Dismantling the central longitudinal sealing, 1st module
Key to Fig. 6-07: 1 Roller 2 Lane 3 Clamping sleeve a Rear end position of cylinder b Clinker flow direction
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4 5
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Dismantling Drive the hydraulic cylinder into central position (max. cylinder stroke = 420 mm). Drive the hydraulic cylinder in the adjacent lane into central position (max. cylinder stroke = 420 mm). Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and then pretension them. D=12 mm steel cables should be used with a strap at the end.
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Removing lanes
1 2
3 a
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1 2 3
a b c
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Remove the lane beside the side lane and place on top of the other lane. For the drive area only: Dismantle the cylinder fixture on the lane. Dismantle the guide rail from the side lane to be removed Dismantle the partition wall seal angle. Cut off approx. 50 mm of the partition wall under the lane (opposite the roller). Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws.
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Lower the lane by approx. 40 mm so that the lane can be pulled out sideways from the cover on the side sealing. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones. ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers.
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Assembling proposal 2
Before fitting the new lane, please examine whether it is the right one. This can be established by checking to see if the marking on the underside of the lane e.g. SB5 / SB7 is the same as the marking on the lane plan. Pull the lane into assembly position in the cooler. Use silicone to attach a new sealing profile D=12 mm, L=590 mm under the two flange areas.
Assembling lanes
Key to Fig. 6-13: 1 Sealing profile 2 Lane flange
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Mount all of the lane securing components. Tighten the screws to the specified torques. As a general rule, all parts displaying signs of wear must be replaced with new ones Slide the lane under the side sealing. Slide the guide rail under the lane and secure with the clamping sleeves. Use the screws to loosely secure the guide rail. Mount the new screws for securing the lane flange. Please observe the nut torque. Tack the locknuts for securing the flange to the screw threads ensuring the correct electrodes. ATTENTION! Prior to mounting all of the screws, coat the screw threads with Molycote HSC Plus hot grease.
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1 Cylinder position transmitter, arranged below 2 Steel part, lower section a Walking lane
Dismantle the mounting aids. Note: Prior to putting the cooler back into operation, the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP
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Central lane for 2nd module to outlet module, 510 to 950kg Dismantling the central lane, 2nd module
1 2 3
4 5 a
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Assembling lanes
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Mount all of the lane securing components. Tighten the screws to the specified torques. As a general rule, all parts displaying signs of wear must be replaced with new ones Mount the new screws for securing the lane flange. Please observe the nut torque. Tack the locknuts for securing the flange to the screw threads ensuring the correct electrodes.
ATTENTION! Prior to mounting all of the screws, coat the screw threads with Molycote HSC Plus hot grease.
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1 Cylinder position transmitter, arranged below 2 Steel part, lower section a Walking lane
Dismantle the mounting aids. Note: Prior to putting the cooler back into operation, the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP
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Side lane for 1st module (inlet module, 550 to 610 kg)
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Dismantling Drive the hydraulic cylinder in to the rear end position (max. cylinder stroke = 420 mm); the piston rod is fully retracted. Drive the adjacent central lane into the rear cylinder end position. Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. D=12 mm steel cables should be used with a strap at the end. Please refer to the respective instructions for all other mounting aids and how to secure the lanes. ATTENTION! The side lane is not easy to remove as the lane is arranged under the side sealing.
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2 dismantling proposals:
Proposal 1: Dismantle the side sealings in the area of the lane to be removed Dismantle the central longitudinal sealings in the area of the lane to be removed. Dismantle the cross sealing from the lane Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers.
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Proposal 2: Remove the central lane positioned beside the side lane and place it on the other lanes Dismantle the guide rail from the side lane to be removed Dismantle the partition wall seal angle. Cut off approx. 50 mm of the partition wall under the lane (opposite the roller) Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws Lower the lane by approx. 40 mm so that it can be pulled out sideways from the cover on the side sealing. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones. ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers.
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Assembling lanes
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Lane inlet
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Dismantling Drive the hydraulic cylinder in to the rear end position (max. cylinder stroke = 420 mm); the piston rod is fully retracted. Dismantle the central longitudinal sealings in the area of the lane to be removed Dismantle the cross sealing from the lane
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Inspection and maintenance Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. D=12 mm steel cables should be used with a strap at the end. Secure the lane with the lifting equipment. Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones
ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers
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Assembly Before fitting the new lane, please examine whether it is the right one. This can be established by checking to see if the marking on the underside of the lane e.g. SB2 is the same as the marking on the lane plan. Pull the lane into assembly position in the cooler. Use silicone to attach a new sealing profile D=12 mm, L=590 mm under the two flange areas.
Assembling lanes
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