This document summarizes the inspection and alignment of a cooler with two grates. Measurements showed gaps of up to 10 mm between moving frames and side walls in the second grate, indicating misalignment. Beam levels in both grates also varied by over 1mm in places. Adjustments are recommended by adding or removing shims of up to 11 mm to realign the moving frames and level the beams.

1. 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

2. 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

3. HCRDI
Schematic HCRDI Cooler

4. 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

5. 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

6. 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

7. 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)

8. 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

9. 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

10. 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.

11. 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

12. Fig.5 Beam Level Check
Result that we got as below

13. 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

14. 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

15. 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
Target LEFT SIDE CENTER LEFT CENTER RIGHT RIGHT SIDE
M
F
M 544 554 remove 11 mm remove 11 mm remove 11 mm remove 11 mm
F 564 573 remove 10 mm remove 10 mm remove 10 mm remove 10 mm
M 578 588 remove 3 mm remove 4 mm remove 3 mm remove 5 mm
F 598 607 remove 3 mm remove 4 mm remove 5 mm remove 7 mm
M 612 622
F 632 641
M 646 656
F 666 675
M 680 690
F 700 709
M 714 724
F 734 743
M 748 758 add 4 mm add 4 mm add 4 mm add 2 mm
F 768 777
M 782 792
F 802 811
M 816 826 add 4 mm add 3 mm add 4 mm add 6 mm
F 836 845 add 3 mm add 2 mm add 3 mm add 4 mm
M 850 860 add 3 mm add 2 mm add 3 mm add 5 mm
F 870 879
M 884 894 add 5 mm add 4 mm add 4 mm add 5 mm
F 904 913
M 918 928 add 3 mm add 5 mm add 4 mm add 6 mm
F 938 947 add 3 mm
M 952 962 add 4 mm add 3 mm add 2 mm remove 4 mm
F 972 981 remove 4 mm remove 5 mm remove 5 mm remove 5 mm
M 986 996 Remove 2 mm
F 1006 1015 remove 5mm remove 7 mm remove 8 mm remove 5 mm