INSTRUKTIONER INSTRUCTIONS INSTRUCTIONS

70002372-1 1/39
ANWEISUNGEN INSTRUCCIONES INSTRUCÕES

GRATE COOLER SF 3x5 F

CIS-ADP & 5 CROSS BAR COMPARTMENTS
Process instructions

SHARGH CEMENT - IRAN

Reference is also made to:

Flow sheet 10053075

_____________________________________________________________

Contents: Page:

1. GENERAL NOTES 3
2. CONSTRUCTION AND OPERATING PRINCIPLE 4
3. START OF COOLER 16
4. OPERATION 19
5. STOP OF COOLER 29
6. INTERLOCKING, PROGRAMMING AND 31
CONTROL CIRCUITS
7. OPERATING PARAMETERS AND ALARM LIMITS 36

August/2005/RLA/HLy
____________________________________________________________
FLSMIDTH A/S, VIGERSLEV ALLÉ 77
DK-2500 VALBY, DENMARK
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NOTE!

The present instruction manual is dealing with the

situations which, according to the experience of
FLS, are the most likely to occur. An exhaustive
enumeration of all conceivable situations, which
may occur during the erection/operation/maintenance
of the plant/machine/equipment, cannot be provided.

Consequently, if an unforeseen situation should

arise, which the operator is/or feels unable to
handle, we would recommend that FLS is contacted
without undue delay for advice on appropriate
action.

SEPARATE INSTRUCTION MANUALS

The plant under review also comprises several other

instruction manuals containing detailed information
about the single machines or arrangements.
 70002372-1

1. GENERAL NOTES

The primary objective of the present manual is to

provide guidelines for start-up, normal operation and
stopping of the clinker cooler.

The directions, outlined in the manual, are basically

of general character, since many relevant factors
relate to specific or local conditions. Therefore, a
clear and adequate description hereof cannot be
provided in an instruction manual.

This manual is intended for introducing the operator

to the SF cross-bar clinker cooler system. It should
also help the operator when he has to make decisions
in a given operating situation.

In this manual it is presumed that the panel

equipment has been installed and tested and that the
equipment is operational to its full extent.
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2. CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction

See separately forwarded flow sheet No. 10053075.

Cooling rate. The SF cross-bar cooler receives hot

clinker of approximately 1450°C from the rotary kiln.
The clinker is cooled to a temperature approximately
70°C higher than the ambient temperature at a
production of 3400 t/24 h.

Cooler efficiency. More than 75% of the thermal

energy contained in the clinker is recuperated. It is
returned to the kiln as combustion air for both the
kiln burner and the calciner burner.

Clinker conveying. The clinker is discharged from the

kiln into the cooler inlet section.
The clinker is transported through the cooler by a
hydraulic drive system, pushing the clinker backward
in the cooler, by means of a number of cross bars.

Clinker cooling. The clinker is cooled by cooling air

supplied by six (6) fans.
The fans are delivering the cooling air to the Under
Grate Compartments (UGCs).
From the UGCs the air is forced to pass trough the
Mechanical Flow Regulators (MFRs), and further up
trough the grate plates (ADPs, Air Distribution
Plates), and the clinker bed on top of the grate
plates.

Heat recuperation. When the cooling air is passing

trough the clinker layer, heat is transferred from
the clinker to the air. The clinker is cooled and
cooling air is transformed in to hot combustion air
for the kiln and calciner.
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Advantage of SF cooler grate plate design. The grate

plates are stationary, and it includes no moving
parts. Therefore the SF cooler grates have no fall-
trough of clinker dust, and thus no spillage removal
system is needed.
A layer of material is maintained between the cross
bars and the grate plates. This layer decreases or
almost eliminates wear on the grate plates
themselves.

During normal production, with a normal clinker layer

in the cooler, large coating pieces and even hard
refractory lining present no problem to the cross
bars.
However, the cross bar is not intended to transport
large hard coating lumps or refractory lining
material as it may damage the cross bars.
With a normal clinker layer in the cooler, such
material will ride on the top of the clinker bed, and
cause no harm. But in an empty or partly empty
cooler, these lumps could get in between the cross-
bars, and cause harm to them, for instance during
emptying out the cooler.
This kind of material has to be removed by hand from
the cooler, when the cross bars get visual during
emptying.

The grate system of the cooler comprises of

The clinker cooler has six (6) compartments,

consisting of one (1) CIS-ADP (Controlled Impact
System with ADP) and five (5) cross-bar sections.

2.1.1 Controlled Impact System (CIS-ADP)– Compartment

The inlet sections are constructed in modular form.

Each module is four ADPs wide and five ADPs long. The
modules are positioned side by side

This compartment (CIS-ADP) is (3) three modules wide.

This is equal to twelve (12) ADPs wide and five (5)
rows long placed in a 15 degree sloped step pattern
in the longitudinal direction.
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Air blasters are installed in the cooler inlet wall.

There are a series of air blaster channels (ABC) in
front of rows 1 through 6.
The selection of ABCs can be changed during operation
to any of the five rows, as also the sequence of
shooting can be changed during operation.
Two air blasters – are installed to blow kiln sealing
dust back into the cooler.

Clinker distribution. A casting curb on each side of

the cooler inlet is provided to achieve a better
clinker distribution on the grate area.
(Casting curb = Called a horse shoe, a specially
formed refractory side wall, covering a total area of
1.6 m2).

Grate temperatures. Within the CIS-ADP, some air

distribution plates are equipped with thermocouples
for measuring the grate plate temperatures. These
temperatures are monitored in the CCR.

IT IS IMPERATIVE THAT AN ADEQUATE CLINKER BED DEPTH

IS MAINTAINED IN THE COOLER.

If the bed is too low the retention time of the

clinker in the cooler will be too short, and that
will affect the clinker temperature.

Clinker flow on CIS. In the CIS section, the clinker

flow is controlled by the clinker layer on the cross
bar section, the airflow to the CIS, and the air
blaster shooting sequence.
The retained clinker flow forms a protective layer of
colder clinker, offering protection to the ADP-plates
against the incoming hot clinker from the kiln.

NOTE!

INSPECTION AND MAINTENANCE IN OR UNDER THE COOLER

MUST NOT TAKE PLACE IF THE FLAME IS LIT IN THE KILN.

NO PERSONNEL MUST ENTER THE CROSS BAR COOLER UNLESS

IT IS CERTIFIED THAT THE PRE-HEATER CYCLONES AND
CALCINER ALL ARE EMPTY OF MATERIAL.
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ALL AIR BLASTERS MUST BE EMPTIED OF AIR AND ISOLATED

SO NO AIR CAN FLOW INTO THE AIR TANKS INTENTIONALLY
OR UNINTENTIONALLY.

With empty cooler. PLYWOOD PLATES MUST BE PLACED ON

TOP OF THE CROSS BARS USING THESE AS
WORKING/INSPECTION PLATFORMS. THIS WILL PREVENT A
SERIOUS ACCIDENT IF A PERSON IS STANDING WITH HIS
FEET IN THE CLINKER BETWEEN THE CROSS BARS IF THE
CROSS BARS START BY ACCIDENT.

INSPECTION OF THE UNDER-GRATE COMPARTMENTS AND THE

MFR´S MUST BE CARRIED OUT EXCERSISING CARE AS
OSCILLATING HYDRAULIC DRIVE BARS WILL CAUSE DANGER IF
STARTED DURING THE INSPECTION.

THE FOLLOWING PRODUCTION MACHINERY MUST ALL BE

ISOLATED AND RESPECTIVE REPAIR STOPS SECURED WITH
PAD-LOCKS:
THE KILN FEED SYSTEM
THE KILN
THE FUEL SUPPLY TO THE KILN
THE PRIMARY KILN FAN
THE ID-FAN
THE COOLER
THE CHOCK BLASTERS
THE COOLING FANS
THE CROSS BAR TRANSPORTATION SYSTEM
THE CLINKER CRUSHER
AND THE CLINKER TRANSPORT
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2.1.2 Cross bar sections – Compartments 2,3,4,5 & 6

The cross bar sections are constructed in modular

form. Each total module is four ADPs wide and
fourteen ADPs (grate plates) long. The modules are
set side-by-side and end-to-end.

This cooler is identified as a 3 x 5 unit, i.e. three

modules (12 plates) wide and five modules (70 plates)
long.

Under grate compartments (UGC). The cross bar modules

consist of an under-grate chamber with the grate
plates at the top.
Each set of 3 modules placed side-by-side form an
under-grate compartment (UGC).
For this cooler there are 5 UGCs in total for the
cross bar sections.
Each compartment in the cross bar section is twelve
(12) air distribution plates wide and fourteen (14)
rows long.
Each of the five (5) UGCs has one fan supplying
cooling air. The fans are K21, K31, K41, K51 & K61.
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The mechanical flow regulator (MFR).

Each ADP in the cross bar sections, just as for the
CIS-ADP, is equipped with an MFR (mechanical flow
regulator). The regulators will open or close to
provide a constant mass flow of cooling air to each
ADP plate. Please also refer to section 2.1.3.

Importantly, the mechanical flow regulators maintain

the constant flow of cooling air by compensating for
changes in the resistance of the clinker layer
without adding to the static pressure requirements of
the fan. The regulators will provide flow as long as
cooling air is available irrespective of the clinker
bed height, particle size distribution, temperature,
etc.
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Hydraulic cooler drives. The cooler has tree

independent hydraulic drive systems, designated drive
1, 2, and 3 respectively.
Drive 1 is to the left of the cooler seen in the
direction of clinker flow. Drive no 2 is the centre
drive, and no. 3 is the right side of the cooler.

Cross bars. Each drive consists of cross bars, where

every second cross bar is reciprocating and every
other is stationary.
The cross bars are elevated approx. 50 mm above the
air distribution plates, which again are installed on
a five 40 slope downwards from the kiln.
Six cross bars within the second compartment is
equipped with thermocouples for measuring the cross
bar temperature.

Each module has its own cross bar drive mechanism,

including a hydraulic cylinder.
The five modules from front to back (longitudinal
direction) are mechanically interconnected, so that
they move synchronically.
The hydraulic drive cylinders are located in the
under-grate compartments and provide the back and
forth movement of the cross bars.

Hydraulic pumps. The three (3) independent drive

systems share one common hydraulic pump station,
consisting of three (3) operating pumps (one pump for
each drive) and one (1) stand-by pump. The
transportation mechanism of the cooler permits
separating the left, middle and the right side of the
cooler.
This allows for additional control of the cooler with
the capability of operating each drive system
independently.

2.1.3 Working principle of the ADP system with MFR

The purpose of the ADP system is to have complete

control of the airflow distribution to each
individual air distribution plate.

The MFRs eliminate the influence of the varying

clinker bed depth on the air distribution, and for
example, the influence of segregation of the coarse
and fine clinker fractions.
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The MFRs are hanging in a rectangular tower, placed

below each of the individual air distribution plates.
The hanging MFR acts as variable orifice that moves
relative to the difference in pressure on either side
of the MFR.

The MFR will open (hanging more vertically) when

clinker layer offers more resistance to the air flow
(delta P over the MFR decreases).

The MFR will close (hanging in an angle from vertical

to 450) with a lower material resistance to the
airflow. (Higher delta P over the MFR)

The MFR only introduces a pressure drop to itself in

the event that the resistance of the clinker layer is
below normal. (Only if the designed air flow for the
MFR is exceeded).

The MFRs come in various capacity ranges, which makes

it possible to create an airflow distribution pattern
to suite a specific clinker granulometry. Therefore,
several sizes of MFRs can be found within the same
section.
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12

The MFR is described by two characteristics:

One characteristic is the maximum pressure drop that

the MFR can compensate for.

The other characteristic is the flow rate that the

MFR can maintain within the before mentioned range of
operation.

The MFRs are marked with 5 to 7 digit identifiers.

The first 4 to 6 digits show the flow of kg/m2/min.

The last digit shows the range of differential

pressure of operation in hundreds of mmWG.

Examples: A MFR type 40404, has a flow rate of 40 to

40 kg/m2/min with a differential pressure
of 400 mmWG range of operation.

A MFR type 1201203, has a flow rate of 120

to 120 kg/m2/min with a differential
pressure of 300 mmWG range of operation.

The MFR will maintain the airflow to the ADP

according to the identifier, when the MFR is within
its range of operation – which means NOT FULLY OPEN
NOR FULLY CLOSED.

In fully open position – (hanging vertical) the

airflow to the ADP is exactly or less than for what
the MFR is designed.

In fully closed position – (~45° angle) the airflow

to the ADP is exactly or greater than for what the
MFR is designed.
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The MFRs are accessible from the UGCs. They can

easily be replaced by lifting of the MFR from its
hinge rod, no tools are required other than an Allan
key to lock the security bolt, which ensures that the
regulator cannot fall off.

CIS-ADP section consists of:

Compartment 1: Five (5) rows inclined, three (3)

modules of four (4) grate plates wide giving a total
of (12 x 5) = 60 ADPs

The three CIS-ADP modules form one compartment.

The rest of the cooler is divided into five (5)
compartments;

Compartment 2: Fourteen (14) rows, three (3) modules

Twelve (12) plates = 12 x 14 = 168 ADPs

Compartment 3 as 2 = 12 x 14 = 168 ADPs

Compartment 4 as 2 = 12 x 14 = 168 ADPs

Compartment 5 as 2 = 12 x 14 = 168 ADPs

Compartment 6 as 2 = 12 x 14 = 168 ADPs

Total 840 ADPs
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The CIS-ADP section and each compartment are provided

with a total of six (6) cooling fans.

Pressure output Cooling area

mbar M2
Fan No. K11 77 6.2
Fan No. K21 73 16.38
Fan No. K31 70 16.38
Fan No. K41 60 16.38
Fan No. K51 55 16.38
Fan No. K61 50 16.38
In total 88.10

Pressure Gauges
Six (6) pressure transmitters are installed for
registration of each compartment pressure with local
and remote indication in the control room.

Fans
All fans normally feature flow measurement, amperage
reading and fan speed with remote indication to the
control room.

Grate temperatures
6 NiCr-Ni thermocouples are mounted as follows

3 units on the fixed cross bars in compartment 2.

3 units on the movable cross bars in compartment 2.

There is remote indication to the control room of all

grate temperatures.

Power failure
In the event of power failure, no cooling fans are
connected to the emergency power generator.

It is prohibited to operate the cross bar system

without having the cooling fans in operation.

Hydraulic drive stations

The equipment consists of hydraulic cylinders, 15 all
together. Three hydraulic pumps are installed and one
spare pump with one common oil tank.
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Each pump unit consists of a main pump, a

proportional valve, a pressure limit valve and a
booster pump. It is very important that the hydraulic
oil and the entire hydraulic pipe system are
completely clean before the pipe system is connected
to the pump and the hydraulic cylinders.

The hydraulic oil must have a temperature ≥ 25°C

before the drive can be started. The hydraulic oil
can be heated by internal circulation. The pumps
cannot be started if the temperature of the oil is ≤
9°C. If the oil temperature on the other hand
increases to 50°C the automatic water-cooling is
started. If the temperature continues to rise and
60°C is reached, then an alarm for high hydraulic oil
temperature is activated. Is there lack of cooling
water or any other reason for no cooling? When the
temperature reaches 65°C then the pump station is
automatically stopped by the local control cabinet.

Start-up of cooler from central control

Before a start-up from the central control is
performed, all the no-load tests of the hydraulic
system must have been performed successfully
including a start-up from the local control cabinet.

The local control cabinet is changed to central

control.
Remember to check that the suction-valve for the
circulation pump is open.

No interlock alarms must be activated.

The alarms could be temperatures, levels etc.

All hand-operated valves must be in open position.

For more detailed information, please see instruction

No. 37921.
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3. START OF COOLER

The personnel must be well informed about the control

system, layout and operating principle. This
particularly applies to the knowledge of all
interlocking diagrams specifying protective, safety
and operational interlocking.

3.1 Preparation

The following jobs must be completed prior to the

start-up:

A) All machines of the cooler installation must have

been trial-run and the set-points are:

Fan K11 410 Nm3/min

Fan K21 960 Nm3/min
Fan K31 960 Nm3/min
Fan K41 840 Nm3/min
Fan K51 710 Nm3/min
Fan K61 555 Nm3/min

Confirmation of the volume being delivered by the

fan should be made using both the piezometre
value and the fan power consumption (kW).

B) The entire electrical and electronic control

system must have been tested to ensure that all
interlocking (i.e. safety, protective and
operational interlocking) are active and function
as intended.

C) All alarm limits must have been set.

D) The MFRs must be able to move freely from fully

open to fully closed. The types of MFRs installed
must be according to the desired flow pattern.

E) All access doors to the UGCs must be closed.

F) The UGC fans must be started individually and the

respective compartments checked for adequacy of
airflow through each of the slots of the
individual ADPs into the over-grate area.
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All ADPs must be free of debris (steel pieces,

refractory bricks, castable, etc.)

When the fans are running, remove castable and

any other sticky material from the grate plates.

G) The entire grate line must be covered with a

protective layer of minimum 50 mm cold clinker
nodules, preferably containing next to no dust.

The clinker can be charged to the inlet of the

cooler and distributed gradually, by jogging the
cooler drives.
The cooler is ready for operation, when the
clinker is evenly distributed, over the whole
grate and starts to leave the cooler.

NOTE!
If the cooler drives are used for distributing
the protective clinker layer, remember that all
the cooling fans must be in operation and
sufficient airflow must be supplied to the UGC to
prevent the airflow slots from becoming blocked
and/or prevent fall-through of clinker to the
under-grate areas.

3.2 Cooler and kiln outlet lining

If special requirements for the first-time drying-out

of refractory castables have been stipulated by the
supplier of the grate cooler lining, it is essential
to ensure compliance with such requirements during
the start-up procedure.

If it is not possible, separate drying-out of the

local areas in the grate cooler must be carried out.
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3.3 Readiness for start-up

Having complied with the above, the electrical and

the mechanical departments must announce that the
installation is ready for start-up.

3.4 Inspection

Make the following inspection and check during the

heating-up.
Watch the cooler lining during heating up.

3.5 Clinker transport

If the kiln is filled with materials, it is required

during the heating-up to carry the materials away.
The fans and the clinker breaker, transport and dust
conveyance should be started, and the cooler drives
should be operated intermittently.

NOTE!

Air must be supplied via all the cooling fans K11,

K21 K31, K41, K51 and K61 whenever the cooler drives
are in motion.
Failure to maintain adequate airflow while the drive
is in motion may result in blockage of the airflow
slots or material fall-through into the compartments.
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4. OPERATION

Gradually turning the kiln will be necessary and

clinker will begin to leave the kiln. The grate
cooler must be started and the following procedure
must be followed to discharge any material that will
fall into the cooler:

A. Start the clinker transport.

B. Start the dust conveying system such as the drag

chain below the cooler excess air filter.

C. Start the clinker crusher.

D. Start the cooler excess air fan, and adjust the

negative pressure in the kiln hood to about 0.5
mbar and set the PI(D)-regulator in automatic
mode. Note! It is desirable to place the cooler
excess air fan in automatic mode as early into the
preheat mode as possible. Once the excess air fan
automatically controls the kiln hood draft, it is
easy to bring any remaining cooling fans on line.

E. Start the remaining cooling fans.

F. If the kiln hood pressure regulation is not tuned

satisfactory, return the controller to manual.

G. Start the grate drives and let them remain in

continuous operation.

4.1 Airflow rates during start-up

The following airflow rates are expected during

start-up (~75% of normal):

K11 310 Nm3/min

K21 720 Nm3/min
K31 720 Nm3/min
K41 630 Nm3/min
K51 535 Nm3/min
K61 415 Nm3/min
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Use the set-points of the PI(D)-regulators for

setting of all the airflow rates. This means that the
cooler will be controlled automatically right from
the start.

The ADP temperatures of the stationary inlet, as well

as the temperatures of the cross bars in the second
compartment must be monitored carefully.

4.2 Initial operation

As the clinker starts to be discharged from the kiln,

the cooler drives must be put into operation if they
have not been in continuous operation during the
heating-up period.

As the clinker layer builds, the UGCs will begin to

pressurise and the cooling air to the UGCs should be
adjusted to ensure adequate cooling of the clinker
all the way through the cooler to the desired
discharge temperature.

To establish and maintain an adequate clinker bed

depth the speed of the cooler drives must be
increased in proportion to the kiln output. It is
suggested to keep (manually) increasing the cooler
drives speed, to attain a pressure of 70-90 mbar
under the first cross bar compartments (UGC 2) as a
preliminary target value. The clinker bed is
maintained at 500-650 mm.

UNDER NO CIRCUMSTANCES MUST THE PRESSURE AT ANY OF

THE COMPARTMENTS FALL BELOW 30 mbar.

An optimisation of the clinker bed depth will take

place when the kiln performance becomes more stable.

If the clinker tends to accumulate excessively on the

CIS-ADP area, or if agglomeration of clinker occurs,
the air blasters can be programmed to shoot more
frequently to facilitate movement of the clinker, and
to avoid agglomeration.
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4.3 Cooler operation

The main functions of the SF-cooler are:

A) To recuperate the maximum amount of thermal energy

to ensure a good operating economy in the kiln
system.

B) To cool the clinker from the kiln to the desirable

temperature.

4.3.1 Drive speed control

The drive control has been made to facilitate

selection between three different transport patterns.

- Random mode (transport and reverse strokes are

individually controlled for each drive)
- Shuttle mode (synchronized transport strokes and
two step reverse strokes; at first the central
drive and when in reversed position the outer
drives)
- Synchro mode (synchronized transport strokes and
synchronised reverse strokes)

In random mode the three hydraulic drives are working

position wise independently, but speed wise
coordinated with the central drive as the reference
drive and the outer drives running in ratio to that.
The speed ratio control provides control of different
transport capability across the cooler.

Similar control ability is established in the shuttle

and synchro modes by setting the length of the
strokes of the outer drives in ratio to the stroke
length of the central drive.

The drives always start in random mode, but during

operation the mode can be switched to shuttle or
synchro. If during operation one of the drives stop,
the mode switches to random.

The cross bar speed is controlled by the pressure of

the first UGC. The set-point for the controller will
in automatic mode maintain the clinker bed depth
accordingly:
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If the bed depth is decreasing, the compartment

pressure will decrease, and the speed (SPM) will
reduce.

If the bed depth is increasing, the compartment

pressure will increase, and the speed (SPM) will
increase.

Note! On kilns where there is a change of fuel (coal

to gas to waste fuels), or change of clinker type,
the clinker granulometry can change dramatically.
In this case, the set-point for the cooler drive
control should be changed to give an optimum bed of
clinker, in order to maintain the best possible
efficiency of the cooler, consequently recuperating
most possible heat from the clinker.

4.4 Cooling fan control

Shortly after start-up of the cooler, the fan flow

control should be placed in automatic mode for
maintaining sufficient airflow to the UGC. The set
point of the airflow control must gradually be
increased as the clinker bed depth is reaching the
desired level typically 500-650 mm.

IMPORTANT!
When the desired bed depth and the required airflow
have been reached to the UGC for cooling the clinker,
the MFRs should be within their operation range not
fully open not fully closed.

4.4.1 Visual inspections of under-grate area

Regular, periodic inspections of the under-grate area

should be made to ensure that the MFRs are operating
as described. No clinker fall-through and no leaking
of hydraulic oil from the hydraulic system. During
normal operation, also bolted connections in the
under grate compartment should be monitored. During
start-up, frequent inspections are required.
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NOTE!

All under-grate inspections, when the cooler & kiln

are in operation, are performed EXTERNALLY through
the large inspection glasses.

4.4.2 Visual inspections of clinker layer

Regular, periodic inspections of the clinker layer

should be made to ensure the clinker is cooled
sufficiently through the cooler passage.

A cooler in stable operation has a uniform flow of

clinker across the entire grate area.
The airflow through the clinker bed should be
sufficient to keep the surface of the clinker bed
slightly percolating (small sized clinker are
hovering above the clinker surface) without any major
blow-through.

No red hot clinker should be observed beyond the

first half of the cooler.

The ADPs and the cross bar temperatures must normally

be less than 100°C and 150°C respectively. Otherwise,
it will be necessary to increase cooling air.

The kiln speed must be reduced if the temperature

rise is due to a “surge of material” from the kiln.

4.5 Normal operation

The kiln performance is optimized by ensuring that

operational adjustments of the kiln and cooler are
restricted to an absolute minimum. The necessary
adjustments should be carried out on a step-by-step
basis.

Occasionally, hot dust may “float” too far downstream

in the cooler. This may give rise to thermal damage.
This condition is characterised by the appearance of
“red rivers”, often along the sides of the cooler.
This is normally because the clinker bed is not blown
through in a uniform manner.

Corrective action can be taken by adjusting cross bar

speed/clinker bed depth.
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It is essential to ensure that the airflow at the CIS

inlet section is adequate, since this airflow is a
contributory factor for distribution of clinker
across the whole cooler area.

When the optimal thickness of the clinker bed and the

cooling airflow is obtained, the cooling air will
make the small clinker “wave” on the surface of the
clinker bed. Hereby the most effective cooling will
be achieved across the entire width of the grate.
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4.6 Operating parameters and alarm limits

EXPECTED OPERATING DATA

Nm3/minute Nm3/minute mbar

alarm
K11 410 245 70-90
K21 960 575 65-85
K31 960 575 60-80
K41 840 500 50-70
K51 710 425 45-65
K61 555 330 40-60

Fixed Cross bar <150°C Alarm 300°C

Module Cross bar <400°C Alarm 600°C
Pressure in kiln -0.5 mbar Alarm 0.0 mbar
hood
Grate temp. <100°C Alarm 300°C
normal

When all control loops are active, the loops will

ensure control of:

- The clinker bed depth.

- The airflow to the UGCs.
- The pressure at the kiln hood.
- The excess air temperature.

And thereby indirectly control of:

- The clinker temperature.

4.7 Trouble shooting guide

4.7.1 Low bed depth

The cooler drives should be slowed down to maintain

an adequate bed depth.
A change in burning conditions will result in
different pressure drop as clinker granulometry is
changed.
 70002372-1

26

Cross bar speed should be changed by changing the

pressure set-point.

4.7.2 MFR regulator fully open (majority in the

compartment)

The clinker bed depth is too high.

Increase the drive speed or lower the pressure set-
point to lower the pressure drop across the bed.

The under-grate airflow may be inadequate.

The fan speed, fan load (kW), and piezometre set-
point should be checked to verify that the desired
airflow is being delivered.

4.7.3 MFR regulator fully closed (majority in the

compartment)

The airflow to the ADP could be higher than the MFR

is designed to handle.
Reduce the airflow to the correct level.
The bed depth may be too low.
The drives should be slowed down to build an adequate
bed depth.

4.7.4 Clinker fall through

Clinker fall through.

The UGC pressure should be checked that it is in fact
> 30 mbar. If the pressure is too low, pressure must
be increased.
If fall through is occurring and is persistent;
Stop the cooler and inspect the internals.
The U-profile and the C-profile on the drives should
be thoroughly inspected.

4.7.5 Caking or crusting of the clinker bed

The cooler drive speed should be increased to keep

the clinker in constant motion.

The airflow, especially on the CIS, should be

increased to ensure proper cooling of the clinker
which should prevent clinker agglomerations.
 70002372-1

27

4.7.6 Poor material distribution on the CIS-ADP

The distribution of clinker is dictated by the amount

of CIS airflow, and the grate speed.
If build-up or “snowman” formations occur, increase
air blaster sequence time or switch air blast
channels to problem areas.

4.8 Alarm

4.8.1 Alarm for insufficient airflow

If one of the cooler fans stops, the interlocking

will stop the cooler drive IMMEDIATELY AND THE KILN
after 0-5 minutes.

If no fans are stopped, but the low flow alarm

persists, make sure there is sufficient compartment
pressure and then check the flow transmitter. If
pressure cannot be obtained, the cooler drive must be
stopped.
Due to the risk of increased thermal loading,
stringent monitoring of the grate temperature and the
crossbar temperatures is required.

The grates and their supports may sustain damage if

maintained in operation while a fan is stopped.

A grate, where the cross bars are stopped, will not

sustain damage if only a small amount of cold air is
being injected.

4.8.2 Alarm for high grate temperature

The cooling airflow is insufficient or the bed

thickness is incorrect, normally too small.

Check the airflow rate, or change the grate speed,

normally in the downward direction.

The cooling airflow may also be excessive, causing

the bed to be destabilised. This is observed visually
in the cooler, all MFR are fully closed also high ADP
temperatures and high compartment pressure can be
observed.
 70002372-1

28

Reduce the airflow to the particular area.

4.8.3 Alarm for excess air

The air may be too hot.

Increase the amount of cooling air.

 70002372-1

29

5. STOP OF COOLER

The kiln production line may be stopped according to

given schedules or because of operational upsets.

5.1 Normal stop

In a normal stop sequence, the cooler and cooling

fans are not stopped until,

- The feed to the cooler is stopped.

- All material in the cooler has been sufficiently
cooled.

Note: The cooler should not be emptied.

Maintain a normal layer of clinker in the cooler,
until the kiln has been cooled off completely, and
inspection has been carried out in the kiln.
After eventual repairs in the kiln and discharge of
old lining or crust are finished first then will it
be practical to empty out the cooler.

Emptying of the cooler by means of the drives must be

done with great care.
The clinker bed should be visually monitored during
emptying out, and the drive must be stopped, when the
crossbars get visual, if there are still large or
hard lumps on top of the grate. Such material must be
taken out by hand.

The cooler will not be empty when it has reached the

point where it will no longer convey material. The
permanent layer of clinker below the crossbars will
remain.

The stop sequence during a controlled kiln stop is;

- When the kiln stops, STOP the cooler drives.

- Follow the normal kiln stop procedure. As soon
as the ID-fan stops then the airflow to the
cooler is automatically reduced to a preset
percentage of the actual cooling air level
(~30%). This percentage can be individually set
for each cooling fan. Maintain sufficient air to
all the UGCs to keep the ADPs and cross bars
cool, and to prevent fall-through of material
into the UGCs.
 70002372-1

30

If the kiln stop lasts for more than a day, the

cooling fans are stopped, when the clinker has been
cooled off.

For short duration kiln stop, it is recommended to

stop the cooler drives and jog the drives
periodically to maintain the bed depth in the cooler.
Supply only enough air to cool the ADPs and cross
bars as well as to prevent fall-through.
This will effectively keep the heat in the system,
and result in a shorter duration before the kiln can
return to full capacity.

NOTE! THE COOLER DRIVES MUST NOT BE IN OPERATION

UNLESS THE COOLING AIR FANS K11, K21, K31, K41, K51 &
K61 ARE IN OPERATION and providing sufficient flow
and pressure.

The cooler does not need to be emptied for material

unless this is necessary in order to carry out
repairs. For repair works, it is only necessary to
empty out material in local areas.

5.2 Unscheduled stoppage – total power failure

All machines and motors are stopped.

The emergency power supply is automatically switched

on, hence making it possible to rotate the kiln and
cool down the burner pipe.

If an emergency air supply facility is not available

for cooling the cross bar cooler FLS can recommend
that all manhole doors for all compartments to be
opened.
The natural draught up through the clinker bed will
then prevent the unlikely but still possible long-
term overheating of the ADPs from occurring.
 70002372-1

31

6. INTERLOCKING, PROGRAMMING AND CONTROL CIRCUITS

The various motors, machines, dampers and other

equipment are operated and controlled by the central
control system. In the following, the proposed
structure of the control system is described seen
from the operational and process point of view. A
proposal for grouping of the motors, are given below.

It must be noted that the proposed structure is not

necessarily the structure installed.

The general and special rules of interlocking are

listed. A survey of all process related measurements
and their treatment is given in section 7.

Finally, a list of control loops is presented.

6.1 Interlocking

The detailed interlocking, as programmed, is

described in the interlocking diagrams. However, main
philosophy is given below.

The general rule of operational interlocking is that

no machine can be restarted before the subsequent
machine has been started. Inversely, stop of any
machine will cause the stop to the machine before.
This follows the process order.

Protection interlocking like

Bearing temperature
Vibrations
Winding temperature
Minimum oil level
Minimum and maximum oil pressure
Speed monitors
Maximum material level, etc.

These alarms will stop the machine in question

immediately.
 70002372-1

32

Examples

If the speed monitor of an air sluice does not

indicate any rotations, then the motor for this air
sluice will stop. If the vibration level of the kiln
ID-fan is high, then the motor of this fan will stop.
If the bearing temperature of the clinker crusher is
above the maximum temperature allowed, then this
clinker crusher will stop.

Special interlocking

The special interlocking will be described in the

section below as well as in the diagrams giving the
process instrumentation (DIAGRAMS as described in
section 7).

In the control system the various motors and machines

will be arranged in a number of groups for common
start and stop.

6.2 Programming

From the central control room the grate cooler can be

operated by selection of a number of programs and a
number of direct functions.

The programs, installed in the control system, will

perform the start and stop procedures for the
machines divided into groups. Further the operation
is automatically supervised, checking constantly all
interlocking for operation, protection and safety.

The direct functions consist of opening and closing

of dampers and speed control of motors.

The following programs are proposed. (Please note

that the groupings of machines may be carried out
differently to the proposal, but the main idea should
be kept).
 70002372-1

33

1. Clinker crusher, clinker transport and dust

transport
2. Cooler ESP
3. Cooler excess air fan.
4. Cooler fans.
5. Cooler drives.

Some of the equipment can be operated individually:

Fan dampers.
Change-over gates.
Fan motors with speed regulation, and cooler drives.

6.3 Comments to programs

For details of programming, reference is made to the

separate documentation for the PLC-system. However,
in the following some important notes are pointed out
in relation to each program. In general all
transportation equipment should stop with a minimum
delay of 15 minutes to empty the system.

1. Clinker transport, and dust transport system

Selection between 2 sub-programs.

A. To clinker silo(s).
B. To off-standard silo.
Conditions to be fulfilled in order to produce:
Clinker storage unit must not be full.
Transport route defined.
Stop sequence, remember time delay.
The dust transport system will stop if the clinker
transport stops.

2. Cooler ESP

Conditions to be fulfilled in order to produce:

Program 1 in operation

2. Cooler excess air fan

Conditions to be fulfilled in order to produce:

The excess air fan stops if the temperature of
the excess air has passed 450°C.
 70002372-1

34

3. Cooler fans

Conditions to be fulfilled in order to produce:

Cooler excess air fan in operation.
If the cooler excess air fan stops, then the flow
from the cooler fans must automatically be reduced
by a preset percentage of the nominal flow (~40%).
The percentage can be set individually for each
fan.

During start-up special permission can be given for

operation of the fans individually.

When the kiln stops then the cooler fans are

automatically to a preset percentage (~30%) of the
actual cooling air level. This interlock can be
cancelled during the pre-heating period.

4. Cooler drives

Conditions to be fulfilled in order to produce:

Program 1, 2 & 3 are in operation, and the
clinker crusher is in operation.
Cooler fans for CIS-ADP section and all 5
compartments are in operation.
During start-up special permission can be given
for operating the grate to remove any
accumulation of material at the kiln outlet.

Stoppage:
The following will stop the cooler drives after a
certain delay.

- Stop of kiln drive, delayed 0-5 minutes

- Stop of excess air fan, delayed 0-5 minutes
- Stop of ID-fan, delayed 0-5 minutes
- Stop of dust transport from ESP, delayed 0-
20 minutes
- Stop of clinker crusher, no delay
- Stop of clinker transport, no delay
- Stop of one of the cooling fans, no delay
 70002372-1

35

If one cooler drive stops, then the remaining

independent cooler drives can continue to operate
up to 8 hours (reduce production if necessary). If
more than one cooler drive stop then the kiln stops
within 0-5 minutes.

If any of the fans K11, K21, K31, K41, K51 and K61
are stopped, then the cooler drive must be stopped
immediately.

This must then immediately be proceeded by stoppage

of the kiln if the fans remain stopped for more
than 0-5 minutes.

The cooler drives must NOT be started until cooling

air has been re-established.

6.4 Control loops

The following control loops are foreseen:

- The pressure in the kiln hood is controlled by

adjusting the speed of the excess air fan.

- The speed (SPM) of the central cooler drive is

controlled by means of the compartment pressure
in the 1st compartment just after the 15°
inclined part (CIS). The expected operation
pressure for controlling the drive is between
60-90 mbar.

- The speed of drives 1, & 3 is controlled by the

speed of central drive 2.

- The control of the airflow to the under-grate

compartments is individually accomplished by
using a piezometre sensor equipped at the fan
inlet and the fan speed.

- The amount of cooling air is reduced to a preset

percentage (~30%) of the of the actual cooling
air level if the kiln stops.

- The amount of cooling air is reduced by a preset

percentage (~40%) of the actual cooling air
level if the excess air fan stops.
 70002372-1

36

7. OPERATING PARAMETERS AND ALARM LIMITS

The following tables are a survey of the expected

normal operating parameters and the normal alarm
limits. The operating parameters stated are for
guidance only and apply to the normal, stable
operating situation. The operating limits stated are
meant as guidance for start-up. It will be possible
to adjust many of them with advantage later on in
order to make them more suitable for the actual
operation.

Concerning many of the alarm limits they will also

have to be adjusted according to local conditions as
factors like the lubrication oil selected, the
ambient temperature, etc. will affect the values.

In every single case, the mechanical and/or

electrical departments must approve the change and
fixing of the alarm limits for protection of the
machines. Normally, the alarm limits for the
operating parameters will be the responsibility of
the production management.

SEE ALSO INSTRUCTION MANUAL 28581 AS WELL AS FLOW

SHEET FOR CODES AND INSTRUMENTATION.

The following notes refer to the tables listed below

a To be fixed in accordance with the specifications

in separate machine instruction.
b To be fixed in accordance with the electrical
documentation.
c To be fixed empirically so the alarm is not
activated under normal operating conditions.
x The normal value is either given in above text or
has to be evaluated during commissioning.
+ Indication given according to range of instrument.
 70002372-1

37

SHARGH CEMENT

IRAN

SF CROSS BAR
COOLER 3x5 F

UNIT

Kiln hood mbar -1 1)

°C 1050
Compartment 1 °C 50 300
CIS-ADP mbar 77 +
Compartment 2 mbar 73 + a)
Compartment 3 mbar 70 + a)
Compartment 4 mbar 60
Compartment 5 mbar 55
Compartment 6 mbar 50
Grate mbar x + 2)
pressure
Left module hyd.P x a) 4)
s/min x 3)
Cr.b.t x 300
fixed
cr.b.t x 600
movable
Centre module hyd.p x a) 4)
s/min x 2)
cr.b.t x 300
fixed
cr.b.t x 600
movable
Right module hyd.p x a) 4)
s/min x 3)
cr.b.t x 300
fixed
cr.b.t x 600
movable
 70002372-1

38

SHARGH CEMENT

IRAN

SF CROSS BAR
COOLER 3x5 F

UNIT

s/min=strokes 1) Excess air fan speed control.

per minute
cr.b.t= 2) The speed of drive 2 (Centre Drive) is controlled
cross bar by the UGC pressure for 1st compartment after CIS
temperature inlet.

3) Drive 1 & 3 as a ratio of the set-p. of Drive 2

4) Drive 1,2 & 3 speed control to prevent overload

 70002372-1

39

SHARGH
CEMENT

IRAN

SF CROSS BAR
COOLER 3x5 F

UNIT

Cooler fan Nm3/m 410 165 245 + 5)

K11 mbar 77
kW x
Cooler fan Nm3/m 960 385 575 + 5)
K21 mbar 73
kW x
3
Cooler fan Nm /m 960 385 575 + 5)
K31 mbar 70
kW x
3
Cooler fan Nm /m 840 335 500 + 5)
K41 mbar 60
kW x
3
Cooler fan Nm /m 710 285 425 + 5)
K51 mbar 55
kW x
3
Cooler fan Nm /m 555 220 330 + 5)
K61 mbar 50
Excess air Speed x 1)
fan %
kW x
Excess air °C 300 435 450
6)
Clinker Amps. x
crusher
5) Flow regulation by motor frequency control.
6) When exceeding the MAX III temperature the excess
fan will stop.

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