A4-P 1.0 en

FLSmidth Cross-Bar Cooler
CB Cooler
Installation instructions
Created by: JBPe

Approved by: MIOL
FLSmidth, 21-Sep-12 70018475-1.0
70018475-1.0
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Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installa-
tion, operation and maintenance of the equipment. An exhaustive enumeration of
all conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instructions, and which the operator is/or feels unable to handle, it is recom-
mended that FLSmidth is contacted without undue delay for advice on appropriate
action.
All references to relevant safety standards are given at the EC declaration of con-
formity if required.
Reference by seller to any international or national standard does not incur an
obligation on seller to provide any recipient, reader or user of the documentation
with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected at his own
cost to obtain necessary knowledge of the contents of any of the standards
referred to.
Safety
Potential safety risks, and correct mode of conduct subject to such risks, are con-
tinuously described in the text in relation to specific actions.
See instructions 32031 for general safety rules and the separate equipment-specific
safety instructions for a complete list of all unforeseen risks in connection with the
installation, operation and maintenance of the equipment.
Definitions and abbreviations

Authorized person A person who is qualified and who, by the responsible man-
ager, is entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is capable of
doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM Operation and Maintenance
Legend
Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
Warning text is concluded with a filled black triangle to symbolize end of warning
text.
Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or
parts of the installation.
Attention text is concluded with a filled black square to symbolize end of attention
text.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Table of contents
1.0 Introduction ............................................................................................ 5
2.0 Design .................................................................................................... 6
2.1 Units ................................................................................................. 6
2.2 ABC inlet ........................................................................................... 7
2.3 Lower frame work and cooler housing ................................................... 8
2.4 Drive system...................................................................................... 9
2.5 Fans ................................................................................................11
2.6 Crusher ............................................................................................11
3.0 Operating principle ..................................................................................13
3.1 Clinker cooling ..................................................................................13
3.2 Clinker conveying system ...................................................................14
4.0 Installation .............................................................................................16
4.1 General view of installation .................................................................16
4.1.1 Prior to installation ....................................................................17
4.1.2 Lifting gear ...............................................................................17
4.2 Cooler foundation ..............................................................................18
4.2.1 Before starting cooler installation ................................................18
4.2.2 Standard cooler foundation.........................................................20
4.3 Installation of Lower frame work .........................................................22
4.3.1 Side frames and centre supports .................................................23
4.3.2 Install bottom plate frame and hydraulic pressure pipes .................28
4.3.3 Install bottom frame floor plates .................................................36
4.4 Installation of units ............................................................................39
4.4.1 Preparation of units ...................................................................39
4.4.2 Unit installation .........................................................................43
4.4.3 Unit alignment ..........................................................................46
4.4.4 Sealing unit compartments .........................................................49
4.4.5 Install unit longitudinal beams ....................................................52
4.5 Installation below grate line ................................................................55
4.5.1 Install service corridor ceilings ....................................................55
4.5.2 Install partition plates ................................................................60
4.5.3 Install service corridor hydraulic pipes and hoses ..........................62
4.5.4 Hydraulic cylinders ....................................................................65
4.5.5 Hydraulic cylinder hoses .............................................................67
4.5.6 Remove transport locks and install inter-modular strap ..................68
4.5.7 Mechanical flow regulators .........................................................70
4.6 Installation above grate line................................................................71
4.6.1 Install overlapping C-profiles and air distribution upper ..................71
4.6.2 Cross-bars................................................................................74
4.7 Installation of ABC inlet ......................................................................76
4.7.1 ABC inlet support frame .............................................................77
4.7.2 ABC inlet grate line installation ...................................................79
4.7.3 ABC inlet under grate installation ................................................83
4.8 Installation of discharge assembly and clinker crusher ...........................89
4.8.1 Discharge hopper and support for clinker crusher ..........................90
4.8.2 Discharge parts .........................................................................93
4.8.3 Clinker crusher .........................................................................97
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4.9 Installation of discharge assembly and outlet HRB .................................98

4.10 Installation of discharge assembly and HRB MF IN ............................. 101
4.11 Installation of top casing................................................................. 106
4.12 Installation of Kiln hood .................................................................. 114
4.12.1 TAD sliding seal ..................................................................... 117
4.12.2 Installation of kiln seal dust return .......................................... 118
4.13 Installation of gangways ................................................................. 119
4.14 Installation of air blasters ............................................................... 120
4.15 Installation of access doors and inspection parts ................................ 126
4.16 Installation of water injection .......................................................... 128
4.17 Installation of refractory ................................................................. 130
4.18 Installation of signs ........................................................................ 131
4.19 Installation of lights & instrumentation ............................................. 132
5.0 Prepare for trial run ............................................................................... 139
6.0 Trial run............................................................................................... 140
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1.0 Introduction
This instruction manual describes a procedure and a sequence which may be ap-
plied during installation. Still it must be emphasised that installation always must
be carried out on basis of the assembly drawings.
Figure 1: FLSmidth Cross-Bar Cooler with outlet HRB
The FLSmidth Cross-Bar cooler (CB cooler) is a grate cooler which receives the hot
clinker from the kiln, cooling down the clinker to a temperature which is appropriate
for the subsequent transport to grinding plant or plant storage.
Some of the thermal energy contained in the clinker is simultaneously recuperated

to the kiln, calciner, raw mill or elsewhere in the plant.
The horizontal CB cooler is basically built from a modular concept with a number of
units (1) assembled width -and lengthwise. A lower frame work (2) is supporting
the units and cooler housing (3). A number of fans (4) are supplying cooling air for
cooling of the clinker and the optimised clinker conveying system is controlled with
a hydraulic drive unit (not shown).
This instruction manual only relate to the CB cooler installation. See separate
instruction manuals for adjacent or auxiliary machines such as burner, fans and
crusher.
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2.0 Design
2.1 Units
Figure 2: Typical unit design

The CB cooler is basically built from a modular concept with a number of units
assembled width -and lengthwise.
A unit always consist of a number of upper air distribution plates (1), cross bars (2)
and structural beams (3). Depending on unit size, the number of upper air distribu-
tion can be 4 or 6 wide and 5 or 7 long.
Each lane of movable frame consists of a number of cross bars (2) connected to
drive plate (4). Each drive plate is supported by two bearings (6). Above unit shows
three lanes of movable frames. C-profiles (5) are part of the sealing preventing
under-grate spillage of clinker.
Only some units will have hydraulic cylinders (7) installed. In these units the cylin-
der brackets (8) will be pre-installed from workshop and cylinders are to be in-
stalled during cooler installation.
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2.2 ABC inlet
Figure 3: ABC fixed inlet
An Air-Blast Controlled (ABC) fixed inlet prevents the formation of snowmen and
gives an optimal start to the cooling process with a more uniform clinker layer. The
ABC inlet is the FLSmidth standard fixed inlet. It is designed for cooling clinker
directly from the kiln outlet at temperatures around 1400C.
The ABC inlet basically consist of a structural frame (1), a number of grate plates
(2), air blasters (3), manifolds (4) and check valves (5).
Air blasters are releasing air through the grate plates directly into the clinker layer
and thereby moving clinker layer or big agglomerations making it capable of effec-
tively fighting 'snowmen'. Each air blaster covers a zone of grate plates and can
release air separately or synchronous with some or all remaining air blasters.
Size of ABC inlet, number of air blasters and number of grate plate rows are de-
pending on cooler size.
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2.3 Lower frame work and cooler housing
Figure 4: Lower frame work and cooler housing

Lower frame work is installed on the finished cooler foundation, which is typically
made of concrete.
Lower frame work (1) is a structural frame for supporting the cooler and creating
air tight under-grate chambers for cooling air.
Service corridors (2) are equipped with observation ports which make it possible to
monitor the mechanical flow regulators in the under-grate chambers during opera-
tion.
Cooler housing consists of top casing (3) and kiln hood casing (4). The steel casings
are lattice constructions which cover the grate line and are clad internally with
refractory lining.
In case of a clinker crusher installation in the outlet of the cooler, a chain curtain is
installed to protect against impacts from coarse lumps that are thrown back by the
clinker crusher.
In case of water injection for cooling the air going into excess air duct, the water
spray nozzles are typically installed in the sides of the cooler top casing between
the recuperation zone and the excess air duct.
A number of access doors and inspection hatches are installed into the cooler
housing for access and inspection purposes.
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2.4 Drive system

The clinker conveying system is driven by a hydraulic drive which basically consists
of a hydraulic power unit (HPU), hydraulic cylinders and hydraulic piping arrange-
ment connecting the HPU with cylinders.
The hydraulic cylinders are moving each cross bar lane in reciprocating movement
and thus transporting the clinker, see section 3.2
The HPU is connected to a Local Control Panel (LCP) featuring a Programmable

Logic Controller (PLC).
Always check hydraulic vendor instruction and FLS hydraulic instruction manual for
installation instructions and procedures for correct handling of hydraulic compo-
nents.
Attention
It is of vital importance that the hydraulic system is kept clean.
If sealing is not done properly it will introduce contamination and possibly corrosion
to the hydraulic piping system, which can cause serious damage to hydraulic
pumps, cylinders, seals, valves or other hydraulic parts and consequently break-
down of machinery.
Figure 5: Hydraulic power unit (HPU)

The HPU consists of a number of motors and pumps installed in a steel rack in
which also a tank for hydraulic oil is installed.
One motor/pump unit is installed for each cross bar lane consisting of main pumps
with built on proportional valve and a combined servo- and boost pump at the same
shaft.
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A standby pump for backup of main pump is optional and can also be used for
hydraulic flushing purpose. In case no standby pump is installed then a separate
flushing pump is supplied.
Hydraulic piping
The hydraulic piping arrangement consists of a number of pre-fabricated pipes and
hoses for installation internally in cooler.
A piping package for installation between cooler and HPU is supplied. These pipes
must be adapted on site with necessary bending and flaring.
Hydraulic cylinders
Figure 6: Typical hydraulic cylinder layout for one lane of movable frame
2 or 4 hydraulic cylinders are installed in each movable cross bar lane.
The direction of the cylinder is depending on the location in the cooler; nearest inlet
or nearest outlet. As shown on figure 6 above, cylinders in inlet end and outlet end
are installed in opposite direction.
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2.5 Fans
Fans supply air to each under-grate chamber. Each of the chambers in the cooler
receives air from separate fans.
Each fan is normally supplied with a silencer, blow pipe, unitary base, isolation
dampers and two expansion joints (one at the inlet and one at the outlet of the
fan).
The volume flow rate of air into the under-grate chamber is controlled using either
a variable speed drive or an inlet vane damper equipped with an actuator.
2.6 Crusher
The standard FLSmidth crusher is a Heavy-duty Roll Breaker (HRB), typically
installed in the cooler outlet, but a mid-cooler HRB is also possible. For outlet
position, a clinker crusher is also possible. Regardless of crusher type and position,
see separate installation instruction for details.
Figure 7: HRB MF
When the scope of supply includes a HRB, clinker is pushed directly into the feed
opening on this machine. Clinker fines pass through the gaps between transport
rolls (1). Coating and clinker lumps are crushed at the crushing rolls (2). This
material along with the fines is discharged down into the clinker conveying system.
Each roll is driven by an electro-mechanical drive (3) controlled by a frequency
inverter.
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Figure 8: Clinker crusher

When a clinker crusher (not standard) is installed, the clinker is pushed over the
outlet grizzly bars (1) which allows clinker fines to pass down into the clinker
conveying system. The larger clinker is crushed inside the clinker crusher by rotat-
ing hammers.
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3.0 Operating principle

The FLSmidth Cross-Bar Cooler features a completely stationary grate line with no
under-grate spillage or conveying system.
The fixed inlet grate plates and cooler air distribution plates are fixed and the grate
line is sealed. The under grate chambers are air tight and the clinker transport
system is separated from the grate line.
Self-adjusting mechanical flow regulators provides constant air flow through the
clinker layer and a stable operation.
3.1 Clinker cooling
Figure 9: Air distribution plate with mechanical flow regulator
Each air distribution plate (1) in the FLSmidth Cross-Bar Cooler is equipped with a
mechanical flow regulator (MFR) that regulates the airflow via a self-adjusting
regulator (2). This optimal principle of continuous airflow helps optimise heat
recuperation and distribution of air throughout the entire cooler.
The MFR maintains a constant airflow through the air distribution plate and clinker
bed (3), irrespectively of clinker bed height, particle size distribution or tempera-
ture. Cooling air can flow thru idle hole (8), gaps (9) and holes in tongue (10)
Should the restriction of airflow through one area of the clinker layer change, the
MFR automatically compensates for the variations in restriction and maintains the
desired airflow based on simple physics, without operator intervention.
In case of high clinker bed resistance (4) the regulator will be in an open position
with low pressure drop over the MFR (6), and in case of low bed resistance (5) the
regulator will be more closed with higher pressure drop over the MFR (7).
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3.2 Clinker conveying system

A system of reciprocating cross bar
lanes (4) located approximately
60mm above the air distribution
plates, are used to convey and shear
the clinker while at the same time
preparing the clinker for efficient
exposure to the cooling air.
Importantly, the conveying system is

completely independent from the
cooling system. Thus, unlike other
coolers, there is no deterioration of
cooling efficiency over time since
there are no gaps between grate
plates which increase with time.
The cross bar cooler's drive mecha-

nism is designed to obtain optimal
transport efficiency. Each lane of
movable frames in the cooler is
operated by 2 or 4 hydraulic cylin-
ders, depending on the cooler size,
and has an independent drive. While
all cross bars move in a shuttle
motion, the movement of each lane
can also be separately adjusted to
accommodate diverse clinker bed
conditions.
The principle of the clinker conveying

system is that all cross bar lanes are
moving forward simultaneous (1)
then moving the clinker layer towards
the cooler outlet. Then every other
cross bar lane is moving backwards
(2) and then the remaining cross bars
lanes move backwards (3) to com-
plete the cycle.
The hydraulic pump for the cross bar

lanes is controlled by a pump
mounted proportional valve, through
a signal from a pressure transmitter,
which measures the air pressure in
grates above compartment 2. The
over-pressure in the compartment is
Figure 10: Principle of clinker conveying system
constantly maintained within prede-
termined limits.
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If the air pressure in the compartment under the grate tends to drop because the
clinker bed is too thin, the pumps proportional valve will reduce the speed of the
cross bars so that the bed thickness is increased. Conversely, if the bed thickness is
too large, this will lead to a rising pressure in the compartment under the grate,
causing the pump proportional valve to increase the cross bar speed.
If the clinker is too coarse it will be easy to penetrate the clinker bed, and this will
lead to a drop in pressure, and hence a reduction of the cross bar speed. In rare
cases, this may cause the grate to be filled completely, and may result in overload-
ing of the grate line. The operator must be aware of this situation.
Attention
Maintaining sufficient clinker bed depth is critical at all times, meaning minimum
600mm.
The operator should be aware that even a low increase in drive speed can lower the
bed layer. Bed layer lower than 600mm can cause serious heat deformations and
other damage to grate line components and consequently breakdown of machinery.
The operator must carefully read the cooler process instruction manual for details
on correct cooler operation.
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4.0 Installation
This instruction manual generally uses a CB cooler size 16 x 56, 3 units wide and 7
unit long as an example, but is applicable for any size CB cooler.
Installation inspection
Quality control! The words "Installation inspection" or "Erection inspection" in any
drawing or text mean that the installation supervisor must carry out an inspection
and approve installation status before continued installation may commence.
4.1 General view of installation
Figure 11: CB cooler for outlet clinker crusher

This instruction manual describes the installation of the FLSmidth Cross-Bar Cooler.
Figure shows a cooler for outlet crusher, but a mid-cooler crusher is also possible
(not shown). Some of the important parts are:
(1) Cooler foundation (10) Discharge assembly

(2) Side frame (11) Top casing
(3) Bottom frame (12) Kiln hood
(4) Centre supports (13) Access and Observation parts
(5) Unit
(6) Service corridor and partition plates Gangways (not shown)
(7) Hydraulic cylinders Refractory (not shown)
(8) ABC inlet Lights and instrumentation (not shown)
(9) Air blasters Signs (not shown)
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See separate instruction manuals for:

Heavy-duty Roll Breaker (not shown) or clinker crusher
Hydraulic power unit (not shown)
Water injection (not shown)
4.1.1 Prior to installation

Units are typically transported inside containers and it is recommended to keep all
units inside containers until installation.
For actual positions of fans, hot-air ducts and hydraulic station, see relevant gen-
eral arrangement drawings.
Considerations must be given to the size of units and other parts when planning the
installation sequence, in order to ensure that the parts can be moved into the
building at the appropriate point in time during installation.
The instruction manual describes a procedure and a sequence which may be applied
during installation. A levelling instrument and a theodolite must be used during
installation. The instruments must be verified prior to use.
4.1.2 Lifting gear

Hoists, trucks and smaller mobile cranes can be used for handling frame parts,
units, motors and fans.
Always check weights in parts lists and accumulate if preassembly is done prior to
lifting. Below table shows approx. standard unit weights, not including lower frame
work, cast parts or hydraulic cylinders.
CB cooler standard unit weight [kg]
1200 mm wide 1800 mm wide

(4 grates) (6 grates)
3000 mm long
1600 2400
(5 grates)
4200 mm long
2300 3400
(7 grates)
Refractory, castable or bricks for lining the top part of the cooler must be hoisted
up to a platform beside the cooler or lowered down through holes in the top part of
the cooler, e.g. where a suspended brick lining is to be installed. Lifting gear for
buckets with ready mixed castable must be made available.
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4.2 Cooler foundation

The CB cooler is installed on a number of foundation plates which are grouted and
bolted to the concrete foundation. The foundation plates have welded on threaded
rods which are later used when fastening side frames and centre supports.
4.2.1 Before starting cooler installation
Step 1 Identify cooler centre line

Checking is done using a spirit level, levelling device and a theodolite. If a
theodolite is not available at all times, use a stretched-out piano wire for lines.
Figure 12: Identify cooler centre line
Centreline: The centreline must be identifiable at all stages of installation. There-

fore, it is prudent to fabricate and weld on a simple fitting at each end of the cooler
- the following procedure is suggested:
For example, the fittings may be fabricated from steel reinforcement-bars or

round bar which can be fixed by angle iron.
Attach the round bars by welding at the ends (1) so that they form a shackle
which is pointing towards the centre of the cooler, as viewed in the longitudinal
direction.
On the shackles, mark out a point from the centreline using a theodolite.
Then use a hack saw to make one, and only one notch in the designated area
(2). Henceforth, it will be possible to establish the centreline (4) very quickly by
suspending a piano wire, with a weight (3) attached on each end, from the two
sawed marks on the shackles.
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Step 2 Check correct positions from kiln
Figure 13: Cooler concrete foundation
Make sure that centrelines and levels have been set correct in relation to the kiln,
so the cooler will be positioned in its correct position. Verify the height from kiln hot
working point (1) to cooler base concrete/base frame (2) is correct. Check for the
correct cooler offset (3) (centreline) in relation to the kiln. See general arrange-
ment drawings and cooler Outline & Load drawings.
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4.2.2 Standard cooler foundation

Always follow the Outline and load drawings for the cooler foundation. Following is
a general description of the cooler foundation.
In some cases the support is steel frame and thus the grouting is not applicable. In
case of steel foundation frame, go to step 2.
Step 1
Install foundation
plates
Check that base con-

crete foundation is
carried out according to
cooler Outline & Load
drawings.
Install shims (3) at all

locations where side
frame columns (4) are
to be installed. See
Outline & Load drawings
for position of columns.
Additionally shims (5)

are required on oppo-
site side of foundation
bolts.
Figure 14: Installation of foundation plates
Install foundation plates (6) with foundation bolts (1) on shims. Rough align foun-
dation plate and finish first grout (2).
Tighten foundation bolt nut (8) and install additional nut for locking.
Fine align all foundation plates within 2mm and grout second time (7).
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Step 2 Cooler foundation layout
Figure 15: Cooler foundation layout
The installed cooler foundation layout is depending on the cooler size. Number of
lanes wide (1) and number of rows (2) is depending on the number of cross bar
units assembled width and lengthwise.
Step 3 Check cooler foundation
Check that centrelines and levels have been set correct in relation to the kiln so the
cooler will be positioned in its correct position. Verify the height from kiln hot
working point to cooler base concrete/ base frame is correct. Check for the correct
cooler offset (centreline) in relation to the kiln. See general arrangement drawings
and cooler Outline & Load drawings.
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4.3 Installation of Lower frame work
Figure 16: Lower frame work
Lower frame work is installed on the finished cooler foundation. Correct alignment
and installation of Side frames (1) and centre supports (2) is the basis for the cross
bar units which will be installed afterwards.
Air tight installation of bottom plate (3) and partition plates (4) are important to
create chambers for under-grate cooling air. Hydraulic piping (5) installation must
be carried out in parallel with the bottom plate installation.
Partition plates (4) and service corridors (10) (11) are part of the lower frame
work, but notice these parts are only to be installed after installation of units.
Lower frame work design depends on the location in the cooler. In general the
references will be: Fixed inlet lower frame (6), inlet lower frame (7), intermediate
lower frame (8), outlet lower frame (9), standard service corridor (10) and service
corridor with hydraulic connections (11).
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4.3.1 Side frames and centre supports

Side frames and centre supports will form a structural frame on which the cooler
units will be installed.
Before starting side frame installation, verify that cooler foundation steel plates are
level within 2mm, see section 4.2.2.3
Step 1 Place side frames, centre frames and install bracings
Figure 17: Place side frames, centre frames and install bracings
Check with side frame assembly drawing that holes for doors and fan ducts are cut
in workshop.
Weld on bracing brackets (1) to side frames (2) and centre supports (3)
Place side frames (2) and centre supports (3) on steel base plates and install
bracings (4).
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Step 2 Bolt side frames and inlet walls
Figure 18: Bolt side frames and inlet walls
All side frames and inlet walls are connected through bolts (1) in the top square
tube. The inlet wall(s) (2) have additional bolts connecting it sideways (3)
The foot plates of side frames are prepared with holes (4) which are corresponding
to the extruding foundation bolts (5) and threaded rods (6)
Note that side frame and centre support layout is depending on cooler size. For the
smallest cooler which is one unit wide there is no centre supports. For coolers with
two or more units assembled in width, centre supports will be installed between
each adjacent unit. Always see cooler outline & load drawings and side frame
assembly drawing.
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Step 3 Check layout dimensions and make required adjustment
Figure 19: Check layout dimensions

Check correct
layouts accord-
ing to hot point
(1) and cooler
centre line (2).
Check width
dimensions (3)
and cross
dimensions (4).
Check dimen-
sion between
side frames
(5).
If necessary,
adjust position
of side frames
and centre
supports to
obtain required
dimensions.
Figure 20: Check side frames and centre frames dimensions
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Step 4
Fasten side frames and
centre frames to foundation
plates
Install foundation bolt guide

washer (1) and make sure it is
concentric with threaded rod (2).
Weld to steel frame (3) and

torque nut (4) according to side
frame assembly drawing. Install
additional nut for locking. Figure 21: Install side frame guide washers
Step 5
Weld side frames and
inlet walls
All side frames are welded

in the top connection
between top square tubes
(1).
Additional, all inlet walls are

to be welded (2). All weld-
ing to be air tight.
Figure 22: Weld side frames and inlet walls
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Step 6
Install fixed inlet
UNP-beam
Weld on UNP beams

(1) for fixed inlet
support
It is important to check
correct positioning of
UNP beam with side
frame assembly draw-
ing because this will
influence the position-
ing of unit installation
later.
Figure 23: Install UNP supporting beam
Step 7 Dimension check
Re-check width and cross dimensions according to step 3.
Step 8
Install
pressure
tubes
Cut 44mm
holes in side
frames and
install pres-
sure tubes (1)
Figure 24: Install pressure tube
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4.3.2 Install bottom plate frame and hydraulic pressure pipes

Bottom plate frame serve the purpose of structural support to floor plates. Hydrau-
lic piping is incorporated in the bottom plate frame and must be installed in correct
sequence. See bottom frame assembly drawings for installation details.
Always check hydraulic instruction manuals for correct procedures for handling
hydraulic components and installation.
Step 1 Fixed inlet bottom plate frame
Figure 25: Install fixed inlet bottom plate frames
Install fixed inlet bottom plate frames (1). Bottom plate frame is fastened to side
frames (2) and centre supports (3) by welding. No hydraulic pipes preparation is
required in the fixed inlet section.
Step 2 Inlet bottom plate frame

Install inlet bottom plate frames. Similar to fixed inlet there is typically no hydraulic
pipes preparation required, but checking with assembly drawings must always be
done before installation.
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Step 3 Service corridor hydraulic support plates
Figure 26: Install service corridor hydraulic support plates
Check the hydraulic piping diagram and bottom frame assembly drawings to see
location and quantity of hydraulic cylinders. Number of cylinders in each movable
frame can be two or four depending on cooler size.
Service corridor nearest cylinders (1) will have hydraulic connections and requires a
hydraulic support plate.
Install hydraulic support plates (2) and weld to side frames (3) and centre frames
(4).
Remaining service corridors (5) does not require hydraulic support plates.
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Step 4 First intermediate bottom plate frame
Figure 27: Install first intermediate bottom plate frame. Side frames (3) removed for clarifica-
tion
Install first intermediate bottom plate frame (1) nearest cooler inlet.
Do not install all intermediate bottom plate frames at this point. Hydraulic pressure
pipes (2) and return oil pipe must be inserted before proceeding with next interme-
diate bottom plate frame.
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Step 5 Insert hydraulic pipes
Figure 28: Insert hydraulic pipes

Intermediate bottom plate frames (1) between service corridors with hydraulic
connections must have hydraulic pipes inserted. The installation of hydraulic pipes
must be done sequentially correct, immediately after installation of one intermedi-
ate bottom plate frame and before proceeding to next bottom plate frame section.
Insert hydraulic pressure pipes (2) and return oil pipe (3) into holes in bottom plate
frame (4). Insert pipes from outlet end towards inlet end. Place welding plates (5)
and pipe clamps (6); do not weld at this time.
Ensure correct position of pressure pipes A and B and return oil pipe according to
hydraulic piping diagram. Also check dimension on pipes. Typically the return oil
pipe diameter is different from pressure pipes.
Prior to installation it must be verified that all pipes are cleaned and all open ends
or connections are sealed off (7) according to hydraulic instruction manuals. Pipe
seals are only to be removed immediately before assembly with adjacent pipe, hose
or other hydraulic fitting.
Attention
It is of vital importance that the hydraulic system is kept clean.
If sealing is not done properly it will introduce contamination and possibly corrosion
to the hydraulic piping system, which can cause serious damage to hydraulic
pumps, cylinders, seals, valves or other hydraulic parts and consequently break-
down of machinery.
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Step 6 Install remaining intermediate bottom plate frame and hydrau-

lic pipes
Install all remaining intermediate bottom plate frames and insert pipes in each
bottom plate frame before proceeding to the next. Make sure all pipes are inserted
and can be assembled in line before welding of lower bottom frame to side frame
and centre support.
Step 7 Assemble hydraulic pressure pipes
Figure 29: Assemble hydraulic pressure pipes
Connect all hydraulic pipes lengthwise (1) by assembling all adjacent pipe unions
(2). Only remove pipe sealings immediately prior to assembly. For assembly in-
structions refer to hydraulic instruction manuals.
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Step 8
Align hydraulic pressure
pipes length -and
crosswise
Align hydraulic pipes

length (1) and crosswise
before installing pipe
clamps.
Distance (1) from partition

wall to hydraulic tee to be
approximately the same in
both ends of the cooler.
Figure 30: Align hydraulic pressure pipes
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Step 9
Install pipe
clamps
After hydraulic
pressure pipes
are aligned;
Weld plate (1) to
lower bottom
frames and
tighten pipe
clamp screws (2)
to secure pipes.
Figure 31: Install pipe clamps
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Step 10 Install hydraulic piping insulation
If the plant is situated in a cold climate zone, all the hydraulic pipes must be insu-
lated. Cold climate zone is for plants with minimum ambient temperatures below
-20C.
Figure 32: Hydraulic piping insulation for cold climate conditions
Wrap all pipes with insulation material (2) and aluminium cap (1). Join the insula-
tion at unions and install additional aluminium cap (3).
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4.3.3 Install bottom frame floor plates

Floor plates closes off the bottom frame and weldings must be air tight to form
cooling air chambers without leakage.
Step 1 Install fixed inlet floor plates
Figure 33: Install fixed inlet floor plates
Install fixed inlet floor plates (1) and cover plates (2). Welding to be air tight.
Step 2 Install outlet unit floor plates and cover plates

Install floor plates and cover plates in outlet section.
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Step 3 Install floor plates for inlet and intermediate sections
Figure 34: Install inlet and intermediate floor plates
Install floor plates (1) for inlet and intermediate sections.
Cover plates to be installed in positions (2) and (3) after hydraulic pressure test,
see section 5.0
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Step 4 Install service corridor floor plates
Figure 35: Install service corridor floor plates
Install service corridor floor supports (1) and install service corridor floor plates (2)
loose. Only weld floor plate after hydraulic pipes have been pressure tested. Note
that corridors with hydraulic piping and hoses have different plate design.
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4.4 Installation of units
Figure 36: Installation of units on lower frame work

The cooler grate line is defined from a number of different units installed length
-and crosswise. Notice that units used in the same cooler can be in different width
and lengths. In general, the types of units are for inlet/outlet (1) and intermediate
(2) position in the cooler.
4.4.1 Preparation of units

Before starting unit installation, verify that side frames, inlet walls, centre supports,
bracings and bottom frame with internal hydraulic pressure pipes are installed.
Check that unit supports on side frames and centre supports are aligned correct.
Figure 37: Position of units in cooler according to marking numbers. Arrow marks the clinker
flow direction
Unit identifi-
cation
Unit layout
and number-
ing is defined
when looking
in the direc-
tion of clinker
flow. Unit
marking
number is
identifying the Figure 38: Unit marking plate
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position of each individual unit, where the first number indicate the lane from left
side seen in clinker flow direction and the second number indicate the row from
inlet. Thus unit 1.1 will be the inlet unit installed in left side of the cooler. Unit
marking plates notes the unit position and the clinker flow direction.
Installation marks
Punch-marks in the
unit end trays (1)
indicate alignment to
adjacent unit when
installed.
Figure 39: Unit installation punch-marks in trays
Transport assembly
Figure 40: Unit transport assembly

Units are typically shipped 'stacked' and inside containers. Units should not be
removed from containers until installation is imminent. Be careful not to damage
units when removing assembly from containers and disassembling from transport
beams (1). See unit lifting assembly drawing.
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Inspection of units
Check that all units are free from

transport damage e.g. nothing has
been bend.
The drives are locked with brackets

(1). Only remove these after all
units are installed and drives are
about to be connected lengthwise
through inter modular straps.
Figure 41: Unit transport lock
Some unit parts are shipped loose and can only be installed after unit installation.
This applies for mechanical flow regulators, cross bars, some upper air distribution
plates, overlapping c-profiles and seal block for inlet/outlet units. Check with unit
assembly drawings.
Lifting of units
Figure 42: Lifting of 7 grates long and 5 grates long units respectively
Lifting of a single unit is done through four lifting points below the upper air distri-
bution plates. Install lifting eye bolts (1), through which the unit can be lifted.
Extreme care must be taken to avoid hitting and bending the units and the multi-
tude of parts sticking out.
Notice that the sling angle must be in the range 60-90 (2).
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Clean assembly surfaces
Figure 43: Unit assembly surfaces

Contact surfaces, e.g. on unit beams (1), are corrosion protected from workshop
and must be cleaned and dry before installation.
Clean thoroughly with aliphatic solvent derived from mineral oil, e.g. white spirit.
Do not use diesel or kerosene.
Grounding cables (2) are installed between the movable lanes and supporting
beams to protect the bearings in case of welding. Ensure that grounding cables are
not damaged during transport or installation.
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4.4.2 Unit installation

Step 1 Place inlet unit
Figure 44:Place inlet unit

Shims in different thicknesses are supplied for all units. Install 5mm of shims on all
unit supports (1). Rough align top surface with a levelling instrument within 2mm.
Then place the centremost inlet unit (2) to begin with. Insert bolts (3) to secure
units, but some alignment must be foreseen before tightening bolts to correct
torque.
For a cooler which is more than one unit wide, the remaining inlet units can also be
placed now.
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Step 2 Check position of inlet unit
Figure 45: Inlet unit installed against UNP beam
Inlet unit is installed adjacent to UNP beams (1). Check distance from hot point to
inlet unit and align according to dimension on main assembly drawing.
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Step 3 Insert T-bars and angle steel
Figure 46: Insert T-bars and angle steel loose

Angle steel is used for frame stiffening and sealing between side frames and unit
trays. T-bars are used for frame stiffening and sealing between adjacent unit trays.
Insert angles under the tray in each side (1) and insert T-bars (2) between each
unit below trays.
Angles and T-bars are not to be welded until units are finally aligned. Keep these
parts loose supported at this stage.
Step 4 Place remaining units
Figure 47: Place remaining units, T-bars and angle steel

Place all remaining units and insert T-bars and angles at each row of units before
proceeding to the next.
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4.4.3 Unit alignment

Start aligning the centre row of units. In case of asymmetric unit layout start with
the unit row closest to the cooler centre line.
Step 1 Align unit height
Figure 48: Measure height of drive plates positioned above all bearings
Place all drive plates in a straight vertical position and measure height of drive
plates at positions above all bearings (1).
5mm shims are supplied for all unit supports, see section 4.4.2.1, and can be used
to align all drive plates in each individual movable frame to be within 2mm height.
Step 2 Align units length-wise
Figure 49: Align unit length-wise

Units must be aligned length wise by keeping the dimension tolerance 600mm (1)
between the last tray ear (2) in a unit and the first tray ear (3) in next unit. Start
from inlet end.
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Step 3 Align units width-wise
Figure 50: Align units width wise

Align units width wise by aligning punch-marks (1) and (2) in adjacent units.
The theoretical clearance between drive plate and c-profile is 0,75mm. This clear-
ance can be distributed on both sides of the drive plate, so in some cases it will be
big on one side and small on the other. Important is that some clearance is always
available on at least one side.
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Step 4 Tighten unit support bolts
Figure 51: Fasten unit support bolts

Tighten all side frame and centre support bolts (1) according to required torque.
See main assembly drawing for torque. Install additional nut for locking.
Check that height /width and length alignment described in step 1 to 3 is still
correct.
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4.4.4 Sealing unit compartments

Seal welding of trays and installation of seal plates is required in order to close of
the under-grate cooling air compartment.
Unit sealing plates are typically installed in the outlet end of each unit, but always
check with assembly drawings for any deviations.
Step 1 Welding of T-bar
T-bars are used for frame stiffening

and sealing of units to adjacent
units in order to prevent cooling air
from leaking in these areas.
Weld T-bars to trays from top in

cut-outs (1). Remove air distribu-
tion plate upper (2) if necessary.
Figure 52: Welding of T-bar
Step 2 Welding of angle steel
Angle steel is used for frame stiffening

and sealing of units to side frame in
order to prevent cooling air from
leaking in these areas.
Weld angle steel to tray (1) and to

side frame (2) from top. Remove air
distribution plate upper (3) if neces-
sary. Also weld angle steel to tray
from below, see assembly drawing for
details.
Welding to be air tight.
Figure 53: Welding of angle steel
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Step 3 Welding of trays
Figure 54: Welding of trays

Weld adjacent trays (1). Remove air distribution plate upper if necessary.
Step 4 Install seal plates
Figure 55: Install steel plates to seal above H-beams in outlet end of units.
Install seal plates in outlet end of all inlet and intermediate units at side frames (1)
and below T-bars (2).
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Step 5 Install steel plates between unit H-beams
Figure 56: Install steel plates to seal H-beams in outlet ends of units.
Install steel plates (1) in outlet end of units to seal between beams in unit joints.
Step 6 Install sealing-bolts and washers
Figure 57: Install bolts and washers to seal off unused holes in outlet ends of units.
Install bolts and washers (1) to close of holes used for transport brackets and holes
in unit beams towards side frame.
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4.4.5 Install unit longitudinal beams

Longitudinal beams must be installed and connected lengthwise as part of the units
structural frame.
Step 1 Install side joint plate
Figure 58: Side joint plates

For 7 grates long units the centre beam design requires installation of side joint
plates (1) between adjacent units on both sides of the units centre beams. This is
not applicable for 5 grates long units.
See bolt tightening torque on units assembly drawing.
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Step 2 Install longitudinal beams
Figure 59: Longitudinal beams

Install longitudinal beams (1) between all units through-out the length of the
cooler. See bolt tightening torque on units assembly drawing.
Figure 60: Outlet unit
Longitudinal beams are only installed internally in units and between adjacent
units. Above figure shows the outlet unit seen from crusher side.
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Step 3 Install beam mounting plates
Figure 61: Beam mounting plates

All units have preassembled longitudinal beams which must be connected through-
out the length of the cooler by installing beam mounting plates (1) on both sides on
each longitudinal beam. See bolt tightening torque on units assembly drawing.
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4.5 Installation below grate line
4.5.1 Install service corridor ceilings

Step 1 Install ceiling supports
Figure 62: Standard ceiling supports

Install ceiling supports (1) between side frames and centre supports.
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Step 2 Install steel plates connecting ceiling supports
Figure 63: Install ceiling parts

Install steel plates (1) for connection between ceiling supports.
Install parts for sealing between H-beam and ceiling (2).
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Step 3 Prepare service corridor ceilings

Ceilings are
typically
supplied
assembled.
Before
installation,
ceiling-
assembly
must be
disassem-
bled by
loosening
the ceiling
bolts (1)
lowering the
ceiling
retainer bars
(2) and
sliding out
ceiling plates
Figure 64: Service corridor ceiling (3).
Step 4 Install service corridor ceilings
Figure 65: Install ceiling frames

Install ceiling frames (2) on ceiling supports (1) by sliding it in.
Ceiling frame must be welded to all supports and to adjacent ceiling frame. All
welding to be air tight.
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Step 5 Install service corridor ceiling plates
Figure 66: Install ceiling plates

Check that sponge rubber seal (1) is glued on to ceiling plates (2).
Slide in ceiling plates and fixate with ceiling retainer bars (3) and tighten ceiling
bolts (4).
Installation sequence: Due to accessibility, service corridor ceiling plates should

not be installed until mechanical flow regulator has been installed, see section 4.5.7
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Step 6
Install ceiling supports side
Install side support plates for

ceiling (1) at side frame.
Some adjustment of side sup-

port plates might be required
with angle grinder.
Figure 67: Install ceiling support side plates
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4.5.2 Install partition plates

Step 1
Install fixed inlet
partition plates
Install fixed inlet

partition plates (1).
Figure 68: Install fixed inlet partition plates
Step 2
Install service corri-
dor partition plates
Install service corridor

partition plates (1).
Cover plates will be

installed in positions (2)
and (3) after hydraulic
pressure test, see
section 5.0
Ensure to weld bracings

to partition plates.
Figure 69: Install service corridor partition plates
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Note that in service corridor with

hydraulic connections, the partition
plate nearest hydraulic cylinders is
prefabricated with holes for install-
ing welding bulkhead connections.
Figure 70: Partition plate for hydraulic connec-

tions
Outlet partition plates should be installed with the discharge parts and crusher.
Depending on the cooler and crusher type, see section 4.8, 4.9 or 4.10
Step 3 Install longitudinal partition plates

Wide coolers require longitudinal partition plates to divide the under-grate cham-
ber.
Figure 71: Section cut showing installation of longitudinal partition plates

Install longitudinal partition plates (1) and (2) in the under-grate chamber accord-
ing to assembly drawings.
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4.5.3 Install service corridor hydraulic pipes and hoses

Step 1 Install bleed off valves and return oil pipe
Figure 72: Bleed off valves and return oil pipe

Install pipe clamps (1) and pipe (2) for return oil in opposite end from incoming
hydraulic pipes. See position and follow instructions from hydraulic piping diagram
and hydraulic instructions.
Install flow switches, non return valve and reducer unions (3) (supplied as one
assembled unit).
Weld on bleed off valve brackets (4) and install bleed off valves (5).
Install hydraulic hoses (6) connecting bleed off valve to return oil pipe.
Install hoses (7) to ends of pressure pipes, but do not connect to bleed of valve
until flushing of hydraulic system is completed. Keep hose ends sealed off (8) or
install ball valve to prepare hoses for flushing.
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Hydraulic hoses must not be installed stretched out but on the contrary it must be
installed with a bend shape to compensate for pressure surges in the hydraulic
system.
Installation sequence: Due to risk of contamination or damage, it is recom-

mended not to install service corridor hydraulic parts until complete cooler casing
has been installed, see section 4.11
Step 2 Install welding bulkhead connections and hydraulic hoses
Figure 73: Welding bulkhead connection

Install welding bulkhead connections (1) in partition walls nearest hydraulic cylin-
ders. Welding to be air tight.
Install union tees (2) at all pressure pipes.
Install hydraulic hoses (3) connecting pressure pipes to welding bulkhead connec-
tions.
Hydraulic hoses must not be installed stretched out but on the contrary with a bend
shape to compensate for pressure surges in the hydraulic system.

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Step 3 Install pressure pipes for inlet connections
Figure 74: Install pressure pipes for incoming lines

Install mounting rails (1), pipe clamps (2), pressure pipes (3) and return oil pipe
(4) for incoming lines.
Depending on the position of the hydraulic pump station (HPU), the position of
incoming lines and bleed off valves can be reversed. Always keep shortest possible
distance between HPU and incoming lines.

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4.5.4 Hydraulic cylinders

Hydraulic cylinder brackets are installed in units from workshop. Before installing
hydraulic cylinders, check with hydraulic piping diagram that brackets are installed
in correct positions.
Attention
For CB cooler with crusher in outlet position all cylinders in one cooler are same
size.
For CB cooler with internal HRB, cylinders in first and second cooler step may be
two different sizes. This is depending on the length of each cooler step
Step 1 Place cylinder
Figure 75: Hydraulic cylinder

Position the hydraulic cylinder (1) in brackets, with closing plugs (2) for hose
connection facing down.
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Step 2 Install connection pins
Figure 76: Connection pins for hydraulic cylinders

Connection pins are made with a force fit through the brackets and the spherical
bearings in the cylinders.
Initially, smear the connection pin (1) with a small amount of oil and then "drive" it
very carefully into its proper position using a lead hammer or freezing it with liquid
nitrogen or CO2 before it is installed.
Step 3
Install
circlip
Install circlips
(1) on both
sides to lock
connection
pins.
Figure 77: Circlips for connection pins
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4.5.5 Hydraulic cylinder hoses

Install hydraulic
cylinder hoses (1)
to bulkhead con-
nections (2) in
partition wall.
Notice that each
cylinder typically
requires two differ-
ent types of hoses.
Do not connect
hoses to cylinders
at this stage, but
leave the ends
sealed off (3) or
connect hoses
through ball valve,
prepared for flush-
ing of hydraulic
system.
Figure 78: Hydraulic cylinder hoses not connected to cylinders
Attention
In order to prevent pollution of hydraulic cylinder it is very important not to connect
hydraulic hoses to cylinder at this stage. Only connect hydraulic hoses to cylinders
after flushing of hydraulic system has been completed.
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4.5.6 Remove transport locks and install inter-modular strap

Step 1 Remove transport locks
Figure 79: Remove transport lock

Remove transport locks (1) in all units' moveable lanes.
Step 2 Install inter-modular strap
Figure 80: Install inter-modular strap

Install inter modular strap (3) to connect moveable lanes through-out the length of
the cooler.
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Contact surfaces are corrosion protected from workshop and must be cleaned and
dry before installation. Clean thoroughly with aliphatic solvent derived from mineral
oil, e.g. white spirit.
Do not use diesel or kerosene.
Attention
Clean inter modular strap surfaces and correct bolts tightening torque are essential
for the power transmission of the cooler drives. Torque must be checked with units
assembly drawings.
Step 3 Check stroke-length

Now check the movement of all movable lanes by moving them back and forth
mechanically. It must be possible to move the lanes 170m from the centre posi-
tion = 340mm stroke length of cylinders.
If stroke length in movable lanes is less than 340mm then the length alignment of
cylinders is not correct and must be adjusted. Some corrections can be achieved by
loosening the inter modular straps and adjusting it within the bolt holes before
tightening bolts again.
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4.5.7 Mechanical flow regulators

Mechanical flow regulators are designed to maintain a constant air flow through the
air distribution plate and the clinker layer, irrespectively of the clinker bed height,
clinker particle size distribution, temperatures etc. However the air flow require-
ment depends on the location in the cooler and thus there are different mechanical
flow regulators to accommodate different flow requirements.
Figure 81: Mechanical Flow Regulator (MFR)

Check with Flow regulator diagram for correct type of regulator (1) for each air
distribution plate. The identification number is marked on each regulator bottom
(2). Install regulator (3) to its correct position and secure with screw (4).
Installation sequence: Due to risk of refractory spillage, mechanical flow regula-

tors should not be installed until installation of refractory lining in top casing and
kiln hood is complete.
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4.6 Installation above grate line

Installation of cross bars, remaining c-profiles and air distribution upper will com-
plete the cooler grate line installation.
4.6.1 Install overlapping C-profiles and air distribution upper
Figure 82:Install C-profiles

Install C-profiles (1) in all junctions between units. Weld C-profiles to tray ears (2)
to keep them in place. The C-profiles has to go in easily, light hammer blows can be
used.
Check that C-profiles in all other positions are installed from workshop and welded
from on both sides of drive plates.
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The theoretical clearance between

drive plate and c-profile (1) is
0,75mm. This clearance can be
distributed on both sides of the
drive plate, so in some cases it will
be big on one side and small on the
other. Important is that some
clearance is always available on at
least one side.
Figure 83: Clearance between drive plate and C-

profiles
Attention
Clearance must be available on at least one side of the drive plate to avoid build-up
of hydraulic pressure and mechanical damage during test run and operation.
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Figure 84: Install air distribution upper

A number of upper air distribution plates have been removed or shipped loose in
order to provide room for the unit installation. Install all air distribution upper (1)
secure with washer (2) and bolt (3).
Now check that grate line installation is completed for upper air distribution plates
and c-profiles.
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4.6.2 Cross-bars
Step 1 Install cross-bars on drive plates
Figure 85: Inlet cross-bars and standard cross-bars

Install the standard cross bars (1) on the drive plates (2). Drive plates have cham-
fered edges (3) where cross bars are installed for correct fit. Be careful when
installing to ensure correct fit.
Notice that cross bar design is different for inlet bars (4) and outlet ends. Different
cross bar design occurs here with various lengths and some without pusher-face.
Design is individual for each cooler size; always check with cross bar layout draw-
ing.
Cross bars might in some cases come in two different materials. In that case, the
more heat resistant material is installed in the inlet end of the cooler. Check the
cross bar layout on assembly drawing for correct positions.
Step 2 Inlet bars
Check dimension
between inlet bar
(1) and seal block
(2). Dimension
(3) should be
10.5 mm.
Shims (4) are

installed below
seal block and can
be removed to
obtain required
dimension.
Figure 86: Inlet bar
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Step 3 Install cross bar wedges
Figure 87: Install wedges and pins

To lock the cross bar in place, insert wedges (1) and drive them in (hard) with a
sledge hammer.
Drill 8mm holes through the wedges (2). Make sure the holes are drilled all the way
through the wedges.
Install spring pins (3) and make sure the spring pins are installed fully in place
through the wedge hole.
Protruding parts of the wedges (4) to be cut flush with the cross bar, using an angle
grinder. Leave 10mm on the thin edge for easier removal during maintenance.
After the wedges have been cut, fill the gabs between wedge and cross bar with
silicone.
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4.7 Installation of ABC inlet
Figure 88: ABC inlet

The Air Blast Controlled inlet is the FLSmidth standard fixed inlet. It is designed for
cooling clinker directly from the kiln outlet at temperatures around 1400C.
Air blasters are releasing air through manifolds (1) and grate plates (2) directly into
the clinker layer and thereby moving clinker layer or big agglomerations making it
capable of effectively fighting 'snowmen'.
The ABC inlet grate plates form an inclination towards the cooler grate line. Number
of rows (3) can be 5 or 7 depending on cooler size. Number of installed blast grates
in each row is increasing towards the cooler grate line, and the lower row (4) will
have the same number of blast grates installed as the number of cooler grates
wide.
For small sizes the support frame can be one part and for bigger coolers the sup-
port frame will be welded together from separate supports which are all installed on
the lower frame work. Masonry plates (5) are installed to shape the fixed inlet and
the lining towards the cooler.
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4.7.1 ABC inlet support frame

Step 1 Position support frames and align to cooler centre line
Figure 89: ABC inlet support frame

Position support frames on lower frame work and align according to cooler centre
line. Weld between adjacent support frames (1). Welding to be air tight.
Step 2 Weld to UNP beams
Align support frames to be flush with

UNP beam (1) and weld from inside
(2).
Figure 90: Welding ABC inlet support to UNP
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Step 3 Weld to side frames and inlet walls
Figure 91: Welding ABC inlet support to side frames and inlet walls
Weld to side frames (1) and inlet walls (2).
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4.7.2 ABC inlet grate line installation

Step 1 Install air blast valves, check valves and grate plates
Figure 92: Blast grates and valves

Verify that air blast valves (1) are installed on check valves (2) from workshop.
Install gasket (3), check valve (2) and blast grate (4). Secure with T-bolts (5) and
tighten nut to correct torque (6) and install additional nut for locking.
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Step 2 Check grate plates layout
Figure 93: ABC inlet grate plate layout
The grate plates come in two different materials. The general material of the grate
plates is a heat resistant material B (1), and for the grate plates in the drop zone, a
very heat resistant material A (2).
Above figure shows a typical layout with the very high heat resistant blast grates
(A) in the drop zone. The layout varies with cooler size and can also vary for spe-
cific projects. Therefore it is required to always check ABC inlet assembly drawings
for correct layout.
Attention
It is very important that the blast grates are installed in its correct positions.
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Step 3 Install masonry plates
Figure 94: ABC inlet masonry plates

Install masonry plates (1). A number of slots in the outer grate plates will be inside
the masonry plates (2) and must be welded to close off from air flow.
Fill small layer of refractory (3) in required positions on support frame.
See welding and refractory details on ABC inlet assembly drawing.
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Step 4 Install heat shields
Figure 95: Heat shield for ABC inlet

Install heat shield (1) on ABC inlet support frame with bolts (2) and then weld the
plate to support frame from top (3).
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4.7.3 ABC inlet under grate installation
Step 1 Install mechanical flow regulators
Figure 96: Mechanical flow regulator

Check with Flow regulator diagram for correct type of regulator for each grate plate
(1). The identification number is marked on each regulator bottom (2). Install
regulator (3) to its correct position and secure with screw (4).
Installation sequence: Due to risk of refractory spillage, mechanical flow regula-

tors should not be installed until installation of refractory lining in top casing and
kiln hood is complete.
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Step 2 Insert pipe manifolds
Figure 97: ABC inlet pipe manifolds

Unless pipe manifolds can come through door or fan openings in side frames, they
should be placed loose inside support frame before support frame is placed and
welded to side frames.
Place pipe manifolds (1) into its positions and support properly. It is recommended
to wait fixating the manifolds until piping installation is complete. Tack weld to
support frame (2) and supports (3) at this time.
Pipe manifolds have a number of open steel tubes (4) which can be horizontal,
vertical or both in same manifold. Ensure correct alignment of steel tubes.
Number of manifolds and design is depending on fixed inlet size, check with ABC
inlet support frame assembly drawing.
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Step 3 Install piping arrangements and supports
Figure 98: ABC fixed inlet piping arrangement

Piping arrangement has various designs. The three typically used (1) (2) (3) are
shown above and the bigger piping arrangements require a pipe support, which
comes in two different designs (4) (5) depending on the position. See ABC inlet
piping arrangement assembly drawing for details.
Use Teflon-tape for sealing between the outlets on the manifold and union on the
piping arrangement (6).
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Step 4 Install rubber hose
Figure 99: Rubber hose connection

Cut rubber pipe and install (1) to connect between piping arrangements (2) and
check valve (3). Secure with clamps (4).
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Step 5 Install connection pipes for air blasters
Figure 100: Connection pipes for air blasters

Install connection pipe (1) connecting pipe manifold (2) to air blasters. Gaskets (3)
to be installed between flanges.
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Step 6 Weld pipe manifold and supports
Figure 101: Welding of pipe manifolds and supports

Finish welding to secure pipe manifold (1) (2) and install support for manifold (3).
Holes in top casing skin plates (4) to be cut at site if not done in workshop.
Flanges (5) and air blasters are not to be installed at this point, but only after the
cooler top casing is installed.
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4.8 Installation of discharge assembly and clinker crusher

In case of clinker crusher (1) follow this section. In case of Heavy-duty Roll Breaker
(HRB) in outlet position go to section 4.9 or HRB in mid-cooler position go to sec-
tion 4.10
Figure 102: Discharge assembly with clinker crusher

Discharge assembly for clinker crusher (1) includes side frame (2), support for
grizzly bars (3) (only upper support for grizzly bars shown), grizzly bars (4) wear
plates (not shown) and outlet partition plates (not shown).
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4.8.1 Discharge hopper and support for clinker crusher
Step 1 Install support for discharge hopper
Figure 103: Support for discharge hopper

Place support for discharge hopper (1) on shims (2) distributed on all 4 sides of the
base concrete (3). A suitable number of shims must be installed on all four sides to
support the discharge hopper.
Then grout (4) between base concrete and support for discharge hopper.
Support for discharge hopper can also be installed in sequence with the cooler
foundation.
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Step 2 Install discharge hopper
Figure 104: Installation of discharge hopper

Install discharge hopper (1) on the support frame.
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Step 3 Support for clinker crusher
Figure 105: Support for clinker crusher

Check that base concrete foundation is carried out according to cooler Outline &
Load drawings.
Install shims (3) on both sides of all foundation bolt holes. Insert foundation bolts
(1) on support for clinker crusher (4) and place in position on shims. Level the
support frame by adjusting shims and then finish first grout (2) around foundation
bolts.
Torque foundation bolt nut (6) and fine align support frame. Then make second
grouting (5).
Support for clinker crusher can also be installed in sequence with the cooler founda-
tion.
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4.8.2 Discharge parts
Step 1
Install side frames
Install side frame discharge (1) and

sampling system (2).
Figure 106: Side frame discharge and

sampling system
Step 2
Install end plate
Install end plate (1) by

welding it to side
frames (2) and support
for clinker crusher (3).
Figure 107: End plate
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Step 3
Install lower support for grizzly
bars
Install lower support (1) for grizzly

bars and weld to side frames (2)
and end plate.
Figure 108: Lower support for grizzly bars
Step 4 Install upper support for grizzly bars
Figure 109: Upper support for grizzly bars

Install upper support for grizzly bars (1). Upper support can be bolted to side
frames (2) for fixating while welding to side frames and outlet units.
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Step 5
Install outlet partition plates
Install outlet partition plates (1) and

cover plates (2)
Figure 110: Outlet partition plates for clinker

crusher (discharge parts not shown)
Step 6 Install steel plate
Figure 111: Install steel plate against partition plate (end plate and supports for grizzly bars
not shown)
Install steel plate (1) against outlet partition to seal off the discharge compartment.
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Step 7
Install side beams and
wear plates
Install side beam (1) and

wear plates (2), (3) in each
side.
Figure 112: Side beam and wear plates
Step 8 Install grizzly bars
Figure 113: Grizzly bars installation

Install grizzly bars (1) and lock bars (2) to lock in position.
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4.8.3 Clinker crusher

Step 1 Install clinker crusher
Figure 114: Discharge assembly with clinker crusher

Clinker crusher flange (1) must be bolted together with clinker crusher (2). Then
place it in correct position on clinker crusher support frame (3).
Install foundation bolts (4) between clinker crusher and torque first nut (5) accord-
ing to discharge assembly drawing. Then secure it with the second nut (6).
Weld clinker crusher flange (supplied with clinker crusher) to end plate (7). Welding
to be air tight.
Follow the separate clinker crusher installation instruction for more detailed de-
scription on installation of clinker crusher and its drive system.
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4.9 Installation of discharge assembly and outlet HRB

In case of Heavy-duty Roll breaker (HRB) installed in cooler outlet position, the
discharge assembly basically consist of a steel frame installed above the HRB.
Figure 115: Discharge assembly with Heavy-duty Roll Breaker
Step 1 Install HRB foundation

Check that the HRB foundation is finished according to cooler O&L drawings and
HRB installation instruction before installing the discharge assembly.
HRB foundation can also be installed in sequence with the cooler foundation.
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Step 2 Install discharge assembly
Figure 116: Discharge assembly (HRB not shown)

Discharge assembly basically consist of Outlet beams (1), outlet side supports (2),
end support (3) and columns for end support (4). These parts can be installed by
first bolting together in its correct position and then do the welding.
Upper air distribution plates (5) to be removed for welding access.
All welding to be air tight.
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Step 3
Install outlet partition plates
The outlet partition plates (1) will be

pre-fabricated with flanges for
removable plates.
Purpose of removable plates is to get

access to the seal between HRB and
cooler casing.
Install cover plates (2) when parti-

tion plates are in place.
Figure 117: Outlet partition plates for HRB

(discharge parts not shown)
Step 4 Install HRB base frame and HRB

Now the discharge hopper can be installed, the HRB base frame and HRB can be
pulled into correct position and HRB installation can be finished according to sepa-
rate installation instruction.
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4.10 Installation of discharge assembly and HRB MF IN
Figure 118: CB cooler with HRB MF IN and discharge hopper

In case of Heavy-duty Roll breaker Modular Frame INternal (HRB MF IN) installed in
mid cooler position, the discharge assembly basically consist of a steel frame (1)
and a discharge hopper (2).
The HRB MF IN (3) is installed on a support frame (4) and special top casing design
(5) in this area must be thoroughly checked with assembly drawings.
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Step 1 Install outlet partition plates
Figure 119: Outlet partition plates and second cooler step inlet wall.
Install outlet partition plates at first cooler step (1) and second cooler step (2).
Install inlet wall (3) for second cooler step.
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Step 2 Install discharge assembly

Discharge as-
sembly consist of
Outlet beam (1),
outlet side
supports (2), end
support (3),
discharge hopper
(4) and columns
for end support
(5). These parts
can be installed
by first bolting
together in its
correct position
and then do the
welding.
Upper air distri-

bution plates (6)
to be removed
for welding
access.
All welding to be
Figure 120: Discharge assembly for CB cooler with HRB MF IN air tight.
Step 3 Install HRB MF IN support frame
Figure 121: Support frame for HRB MF IN

Install the HRB MF IN foundation frame (1) according to cooler O&L drawings and
HRB MF IN installation instruction.
Foundation frame can also be installed in sequence with the cooler foundation.
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Step 4 Install HRB MF IN
Figure 122: Install HRB MF IN

Install the HRB MF IN (1) on its support frame. Gear units and cooling air manifolds
(not shown) to be installed after the HRB MF IN is lifted into position to avoid
damage to these parts during lifting.
For installation of HRB MF IN see separate installation instruction and assembly

drawings.
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Step 5 Support for cooler casing around HRB MF IN
Figure 123: Support for cooler casing around HRB MF IN

Support for cooler casing around HRB MF IN basically consist of inlet beam (1), side
supports (2), frame work for HRB refractory wall (3) and support columns (4).
These parts can be installed by first bolting together in its correct position and then
do the welding.
Upper air distribution plates (5) to be removed for welding access.
All welding to be air tight.
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4.11 Installation of top casing

The cooler casing is a lattice construction made from structural steel. A number of
pre-fabricated plates, columns, beams etc. is assembled to create the air tight
cooler casing. Insulation and refractory will be installed on the inside of top casing,
see Installation of refractory section.
Figure 124: CB cooler top casing

Some of the important items in the cooler top casing is; Inlet wall (1), side walls
(2), columns (3), roof sections (4), bull nose (5), Excess air duct (6), End wall (7),
Chain curtain (8) (only used with hammer crusher), Refractory shelves (9).
Side plates are prefabricated with various openings/holes (10) prepared for access
doors, inspection hatches, camera etc.
Adequate precautions are needed to protect the air distribution plates and cross-
bars against any damage resulting from falling parts, before installation of casing
parts.
For complete overview and details of top casing, see top casing assembly drawings.
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Inlet wall
Figure 125: Inlet wall with cooler centre line and kiln centre line
In case the inlet wall has been split into two or more pieces for transportation, start
welding the different sections together in as large piece as possible before lifting
into position. Check correct alignment with kiln centre before welding.
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Side plates
Figure 126: three Side plates sections showing bolted connections and weldings
There are two different standard side plates. When installing, first place side plates
(1) and then place side plate (2) into position. Side plates to be bolted together (3)
before welding plates together on the inside (not shown). Side plate angle is placed
on the side frame and welded inside (4) and then columns are welded to side frame
(5). See welding details on top casing assembly drawings.
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Excess air duct
Figure 127: Excess air duct

Excess air duct basically consist of the following parts, mentioned in recommended
installation sequence; excess air side casing (1), excess air side sections (2),
excess air roof section (3) and transition (4). For correct positioning and welding
details, see top casing assembly drawing.
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Roof sections and bull nose
Figure 128: Roof section and bull nose

After installation of side walls (4) the top casing roof can be installed.
Bull nose (1) is the transition to the top casing roof, which consists of standard roof
sections (2) and (3). Adjacent to roof sections (2), weld straps (5) are installed.
Close gaps (6) by welding to keep the inside of top casing air tight.
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End wall
Figure 129: End wall for CC

End wall design is depending on type of crusher. For CC the end wall (1) is a 'sand-
wich' plate with insulation in between.
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Figure 130: End wall for HRB
For HRB the end wall (2) is a single plate design which, after finished top casing
installation, will be clad with refractory.
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Support for lining
Support for lining (1) must

be installed at site.
Notice that special welding

electrode, FLS code 9727, is
required for these supports
due to the heat resistant
materials.
Figure 131: Refractory shelves
Chain curtain
Only applicable when crusher
type is CC.
A chain curtain is to be in-

stalled in the sides (1), roof
(2) and across the cooler (3)
to protect the refractory lining
and insulation trays from
clinker which are ejected from
the rotating hammers. Brack-
ets to be installed before
refractory and chains to be
installed after refractory work
is finished. All shackles and
bolts/nuts to be tack welded
after installation.
During commissioning, check

if chain curtain spacing is
close enough to protect the
above mentioned parts
against damage. If necessary,
the spacing of the chain
curtain must be improved.
Figure 132: Chain curtain assembly
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4.12 Installation of Kiln hood

The kiln hood, installed on the burner platform, is a lattice construction made from
structural steel. A number of pre-fabricated plates, columns, beams etc. is assem-
bled to create the air tight kiln hood casing. Insulation and refractory will be in-
stalled on the inside of the casing, see Installation of refractory, section 4.16.
Adequate precautions are needed to protect the ABC grate plates, air distribution
plates and cross-bars against any damage resulting from falling parts, before
installation of casing parts.
Figure 133: CB cooler kiln hood

Kiln hood is supported in two sides (1) on special foundation plates, flexible for heat
expansion. Side wall on kiln side (2) is inclined to be perpendicular to the kiln
whereas the side wall on burner side (3) is vertical. The standard kiln hood roof (4)
is arced shaped.
Split slide door (5) can be rolled sideways for access. Holes for scaffolding (6) are
prepared on both sides of the kiln hood. Sliding seal is standard for the TAD take-
out. Bottom of kiln hood is connected to the cooler top casing by an expansion joint
(7).
In general the plate sections for side and roof can be bolted together before weld-
ing. The exact kiln hood shape and design is project specific. For complete overview
and details of kiln hood, see kiln hood assembly drawings.
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Kiln hood foundation

Check that base concrete foun-
dation is carried out according to
cooler Outline & Load drawings.
Install shims (3) at all locations

where columns (4) are to be
installed. See Outline & Load
drawings for position of columns.
Additionally shims (5)

are required on both sides of
foundation bolts.
Install foundation plates (6) with

foundation bolts (1) on shims.
Rough align steel base plate and
finish first grout (2).
Tighten foundation bolt nut (8)

and install additional nut for
locking.
Fine align all foundation plates

within 2mm and grout second
time (7).
Figure 134: Installation of foundation plates
After kiln hood casing is installed

in correct position and finish-
welded:
Install foundation bolt guide

washer (1) and make sure it is
concentric with threaded rod (2).
Weld to steel frame (3) and

torque nut (4). Install additional
nut for locking.
Figure 135: Install guide washers
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Split slide door
Figure 136: Split slide door on kiln hood

Split slide door is basically assembled from two half's (1) and (2). Rollers (3) make
it possible to slide the doors to the side for maintenance access. Inspection hatches
(4) are installed for inspection purpose and bracket (5) can be used for camera
installation if applicable.
Cooler seal
The connection between kiln

hood and cooler top casing is
sealed with flexible insulation
material (1)
A U-profiled beam (2) is press-

ing insulation material against
top casing flange (3) and kiln
hood flange (4) by tightening
screw (5) and thereby creating
the seal.
Figure 137: Cooler seal cross section
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Support for lining

Support for lining to be installed according to assembly drawing similar to support
for lining in top casing.
4.12.1 TAD sliding seal
Figure 138: TAD sliding seal assembly

Sliding seal sealing house (1) must be welded to kiln hood (2) before tertiary air
duct (TAD) is installed. After TAD is installed then install ceramic packing (3) and
packing holders (4).
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4.12.2 Installation of kiln seal dust return
Figure 139: Kiln seal dust return
The dust return from kiln seal is typically lead into the cooler through the cooler
inlet wall (1) through one or two dust pipe assemblies (2). Holes for the dust pipe
through the inlet wall to be cut at site, see dimensions on main assembly general
drawing.
Dust is entering the pipe from top (3) and is lead into the cooler through the in-
clined pipe, air blaster will be installed in position (4) see installation of air blasters.
Inside of dust pipe (5) to be lined with Densit- refractory before installation. See
specification on dust pipe assembly drawing.
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4.13 Installation of gangways
Figure 140: Gangways and ladders
For installation of gangways (2), rails and ladders (1) see 'Gangways and ladders'
assembly drawing.
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4.14 Installation of air blasters
Figure 141: Installation of air blaster

The air blast system consists of a number of air blasters (1) mounted on the mani-
folds for the ABC inlet and on the inlet wall. Air blasters also to be installed on dust
return (2). Air blasters in inlet wall are blasting through nozzles (3).
Number of air blasters and tank size is depending on ABC inlet size and must be
checked on assembly drawings.
Holes for air blast connections in casing plates to be cut at site if not done in work-
shop.
Air blasters can have canisters installed (optional, not shown) for lower air con-
sumption.
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Step 1 Jet nozzles in inlet wall
Figure 142: Jet nozzles for air blasters

On the inlet wall, install air blast nozzles (1) by welding the nozzle flange to skin
plate of inlet wall.
Check assembly drawings for correct position of nozzles according to ABC inlet,
refractory and horse shoe.
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Step 2 Air blasters in inlet wall
Figure 143: Air blasters on inlet wall

Install air blasters (1) on the inlet wall nozzles and air blaster (2) on the dust return
flange.
Step 3 Air blasters for ABC blast grates
Figure 144: Air blasters for ABC fixed inlet manifolds

Install air blasters (1) on manifolds (2) for ABC inlet. Each air blaster is connected
to a number of blast grates through a manifold. Typically, air blasters are installed
on both sides of the cooler. Flanges (3) are welded air tight to close off around the
manifolds.
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Flange must be welded to manifold before air blaster installation, see section 4.7.3
step 6
Step 4
Install safety wire
As a precaution in case the air blaster

connection breaks during blast, install
safety wire (1) on all air blasters.
Figure 145: Air blaster safety wire
Step 5 Connect to compressed air

See details on the assembly drawings and vendor instruction.
Figure 146: Compressed air inlet supply

The local compressed air line is connected to the following parts: filter/regulator
and lubrication unit (1), non return valve (2), ball valve (3) and pressure switch
(4). Compressed air is then lead to air blasters and solenoid cabinets.
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Figure 147: Compressed air piping to air blasters and solenoid cabinets
Install piping connecting the compressed air to each air blaster (1) and install
required amount of ball valves, pipe clamps (4) and drains in the piping.
Install piping connecting compressed air to solenoid cabinets (3) and piping con-
necting solenoid cabinets to air blaster valves (2).
Step 6
Safety relief valve
All air blasters have a relief valve (1) which,

for safety reasons, must be activated manually
before entering the cooler. Always shut off
compressed air supply to air blasters and
activate relief valves manually to empty tanks
before entering the cooler.
Check that relief valves are working as re-

quired after installation of air blasters.
Figure 148: Safety relief valve
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Step 7 For cold climate only

If the plant is situated in a cold climate zone, all the solenoid cabinets and quick
exhaust valves must be insulated and heated. For air blasters, cold climate zone is
for plants with minimum ambient temperatures below -25C.
Figure 149: Cold climate protection of solenoid cabinet and quick exhaust valves
Install insulation and heating element for solenoid cabinets (1) and thermo-hood
with heating element for quick exhaust valves (2).
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4.15 Installation of access doors and inspection parts
Figure 150: Access doors, observation ports and inspection hatches

See main assembly drawings and main assembly general drawings for positions of
access doors (2), inspection hatches (1) and observation ports (3).
Access doors
A number of access doors of different design provide access to under grate com-
partment and above grate for inspection and maintenance. See individual assembly
drawings of the access doors.
Observation ports
Observation port frame and

glass is supplied as one unit (1)
glued together with silicone.
Install gasket (2) and observa-

tion port plate (3) and bolt to
partition plate.
For further details see individual

assembly drawings of the access
doors, inspection hatch and
Figure 151: Observation port
observation ports.
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Inspection hatch for top casing
Inspection hatch (1) is installed in order to

enable inspection of the cooler operation
and clinker flow.
Install ball valve (2) and piping (3) con-

necting to under-grate chamber air (4).
A constant air flow from under-grate is for

cleaning (blowing dust) and cooling pur-
pose.
Air flows from piping through a hollow shaft

and out through holes in inspection hatch
inside.
See details on inspection hatch assembly

drawing.
Figure 152: Inspection hatch for top

casing
Inspection hatch for kiln hood
Inspection hatch for kiln hood (1) is

not installed with piping, but instead
with needle valve (2).
Connect plant compressed air to

needle valve and adjust to ensure
constant air for blowing dust inside
(and cooling of hatch).
Figure 153: Inspection hatch for kiln hood
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4.16 Installation of water injection
Figure 154: Water injection

Depending on scope of supply and type of air filter, water injection is only applica-
ble for some coolers.
Water injection nozzles (1) are typically installed on both sides of the cooler, lo-
cated between recuperation zone and excess air duct. See cooler O&L drawing pl. A
for details.
See separate instruction and assembly drawing for installation of water injection.
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For cold climate only

If the plant is situated in a cold climate zone, all water injection pipes and compo-
nents must be insulated and installed with heat tracing. Cold climate zone is for
plants with minimum ambient temperatures below -20C.
Figure 155: Heat tracing and insulation of water injection piping
For pipes (4) and other water injection components, install heat tracing (3), insula-
tion (2) and aluminium cap (1).
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4.17 Installation of refractory

See refractory lining, cooler and kiln hood assembly drawings for details. In case of
cooler with Internal HRB, also see HRB frame refractory detail drawings (part of
HRB documentation).
Attention
Refractory castable must not under any circumstances get into contact with the
openings in the air distribution plates. If this should happen, the airflow through the
grate plates will be stopped, causing the air distribution plates to be severely
damaged at the initial stage of start-up because of inadequate cooling.
Appropriate protection of air distribution plates and cross bars may take the form of
25mm plywood placed on top of a plastic foil layer, laid out across the entire grate
area during installation of cooler top casing and refractory work. For further details,
see relevant instruction manual for refractory lining.
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4.18 Installation of signs

The CB cooler has a number of signs and nameplates to be installed. See main
assembly general drawing for position of FLS-signs and nameplates.
Figure 156: Example of safety signs to be installed near inspection hatch
A number of safety signs are to be installed according to 'Safety signs for grate
cooler' assembly drawing. Examples of safety signs (1) (2) at inspection hatch is
shown above. The general safety sign for the cooler (3) is to be located at all ladder
access ways.
Figure 157: Examples of safety signs
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4.19 Installation of lights & instrumentation

The instrumentation layout may vary from cooler to cooler. In general a number of
instruments are used on the cooler, and below it is shown in principal for a cooler
with outlet CC crusher. For general information on positions and installation of
instrumentation, see 'Instrumentation layout' drawing. Also see more details on
instrumentation drawings.
Figure 158: General instrumentation for CB cooler with outlet crusher
(1) Position transmitter

(2) Thermocouple, fixed inlet
(3) Junction boxes for thermocouple, fixed inlet
(4) Thermocouple, units
(5) Junction boxes for thermocouple, units
(6) Grate pressure measurement
(7) Compartment pressure measurement
(8) Compartment lamps
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(9) Flow switch for hydraulic drive system

(10) Thermocouple, kiln hood
(11) Junction box for kiln hood thermocouples
(12) Kiln hood pressure measurement
(13) Thermo hood for air blasters (only for cold climate)
(14) Solenoid valve cabinets for air blasters
(15) Lubrication for CC bearings
(16) Thermocouple, CC bearings
(17) Speed monitor (proximity switch) for CC
In the following pages, instructions are given for some of the instruments. For
complete details, refer to above mentioned drawings.
Position transmitter
All lanes in the cooler are connected length-ways with inter modular straps (see
section 4.5.1.3) so all cylinders (two or four) in each lane are working together. The
position and movement of cylinders length-ways are controlled by position trans-
mitters.
Figure 159: Position transmitter layout for crusher in outlet position and for cooler with mid-
HRB.
For cooler with outlet CC or outlet HRB:
Position transmitters are installed in all drives at each inlet (1) and outlet (2) units.
For coolers with mid-HRB:

As standard, position transmitters (1) + (2) + (3) + (4) are installed in all drives at
each inlet and outlet units. In some coolers, the last outlet units (4) do not have
the position transmitter installed due to limited space.
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Figure 160: Installation of position transmitter

The transducer (1) is to be installed on the bracket (2) which is welded on the unit
frame in the workshop. Make sure it is pointing towards the outlet end.
The floating ring magnet (3) is bolted to a support (4) which again is bolted to drive
profiles (5). Note that the plate and screws in contact with the floating magnet
must be of a non-magnetic material.
With the drives in neutral position, align the position transmitters lengthwise thus
the floating magnet is in the middle of the measuring length of 350mm. The cooler
stroke length is typically 300mm which then will be in the centre of the measuring
length.
Distance between magnet and position transmitter (6) to be adjusted to 3mm. This
must also be adjusted with the drives moved in forward and backward positions.
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Thermocouple, ABC inlet

Typically 2 or 3 thermocouples are installed in the ABC inlet drop zone. See 'Instal-
lation of thermocouple ABC inlet' drawing for details.
Figure 161: Thermocouple for ABC inlet
Pipe for thermocouple (1) is part of the support frame from workshop. Holes in
check valve (2) to be cut on site. Install thermocouple for ABC inlet (3) and make
sure the feeler gauge is pressed against the ABC grate plate.
Before start-up, test the temperature readings from thermocouples are correct.
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Thermocouple, units
Number of thermocouples installed is depending on the cooler width, and thus one
thermocouple is installed for each unit row.
Thermocouples are installed in inlet unit when these are 7L (4200mm long). If inlet
unit is 5L (3000mm long) the thermocouples are installed in first intermediate unit.
See 'Installation of thermocouple units' drawing for more details on position and
installation.
Figure 162: Thermocouple for units

Cut wear plate (1) in ADP upper (2) and drill 20mm hole (3) in ADP upper and
through the tray plate. Now remove ADP upper and drill 30mm hole in tray (4) by
extending before drilled 20mm hole.
Reinstall ADP upper and install half nipple thus it is concentric to hole in ADP upper
and weld it to tray from below (4). Mount the thermocouple connector (5) on the
half nipple.
Insert the thermocouple (6) into the thermocouple connector thus the thermocou-
ple protection pipe (7) is sitting 33mm (8) above the ADP upper. Test the thermo-
couple spring mechanism when installing thermocouple block (9).
Before start-up, test the temperature readings from thermocouples are correct.
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Compartment lamps
Figure 163: Compartment lamps

Compartment lamps (1) are installed in all under-grate compartments. See 'In-
strumentation layout' and 'Observation light assembly' drawings for details.
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Grate pressure measurement

Grate pressure is measured in the inlet unit(s) and used for operational purposes.
For cooler with internal HRB, measurement is to be installed in inlet units for both
upper and lower cooler section. In general, see installation details for pressure
piping on the pressure piping assembly drawing.
Figure 164: Pressure piping for grate pressure measurement (side frames not shown)
Depending on cooler size, the number of measuring points can be from two to five.
Above figure shows two measuring points (1), which through piping, are connected
to one pressure measurement (2) at the side frame. If measuring points are four or
five, there will be two pressure measurements, one on each side of the cooler (not
shown).
Threaded holes in trays (1) to be cut at site from top after removing ADP upper for
access. Then install the pressure piping and its brackets (3) and pipe clamps (4).
Pipes to be installed with a downward slope of 2 toward the outside of the cooler
and with pressure measurement placed higher than pipe connection to avoid con-
densation.
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5.0 Prepare for trial run

On completion of the installation process, check the cooler grate line and under-
grate compartments for any presence of foreign objects and clean the cooler to
ensure trouble free operation of all units. Also check that installation is complete for
associated machinery such as fans and crusher.
The movement of all cross bar lanes must be checked before they are tested with
the hydraulic drive by moving them back and forth mechanically. It must be possi-
ble to move the drives 170m from the centre position = 340mm stroke length of
cylinders. Use the manual hand pump supplied for the hydraulic station, when
performing this procedure.
If stroke length in cross bar lanes is less than 340mm then the length alignment of
cylinders is not correct and must be adjusted. Some corrections can be achieved by
loosening the inter modular straps and adjusting it within the bolt holes before
tightening bolts again.
Flushing of hydraulic system

Once all the field piping is installed then flush the hydraulic system according to the
procedure described in the hydraulic instruction manual.
After flushing is finished, connect hoses to all cylinders and bleed off valves. All
connections must be absolutely clean and tightened to avoid oil leaks and contami-
nation. Pump oil into the entire hydraulic piping system and then purge air from
highest piping points and from all cylinders.
Install cover plates

After pressure testing of hydraulic system, install remaining cover plates in the
bottom frames and floor plates in the service corridors; see section 4.3.3.3 /
4.5.3.2 and 4.3.3.4
Grease level in bearings

Check that all unit bearings are filled with grease from workshop and refill if neces-
sary. Also check grease level in crusher bearings, and in case of HRB also check the
gearbox oil level.
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6.0 Trial run
Trial run procedure

All machines in the cooler must be maintained in continuous operation for 24 hours
to make sure that the machines function as intended when the kiln is started, and
to ensure that irregularities, if any, are remedied with minimum delay.
Check that drive plates are not getting too hot from the friction with the c-profiles.
Temperature rise above 40C should be corrected. This condition can be measured
with an infrared temperature measuring device from the under-grate chamber.
Only run the drives at low speed until it has been verified that the temperature in
the drive plates are stable. For safety reasons, the cooler drives must be temporar-
ily stopped when measuring the temperatures.
Check points during trial run

During the trial run, the machines must be constantly checked with respect to
abnormal sounds, squeaking, screeching scraping and hot running of bearings.
The entire under-grate chamber, the duct connections and the top casing and kiln
hood must be inspected for air leaks.
Check that all mechanical flow regulators are clean and moving freely.
Check manually, when the drives are stopped, but with the fans still running, that
air is penetrating through all openings in the air distribution plates. Cleaning of the
plates can be done by subjecting them to light hammer blows or by cleaning the
pockets and slots using a piece of flat iron or by similar means. Also clean the
mechanical flow regulators.
Check for any leaks in the hydraulic piping, and that there are no sounds in the
system which could indicate trapped air in the hydraulic system. Knocking sounds
in the systems could indicate defective valves. Listen to pumps; no sounds of
cavitations must be heard. Remedy irregularities, if any.
Check points after trial run

On completion of the trial run make the following checks:
Re-torque the bolts below grate level, especially in all moving parts and cylinder
brackets.
Check that the drives are capable of unimpeded movement.
Check all bearing rollers; do they move freely without any sounds.
Check that all c-profiles are fixed in their position; they must not move, espe-
cially check the c-profiles in the inlet and outlet.
Check that the inlet cross-bars and outlet cross-bars don't scrape excessively on
the seal blocks.
Check that the partition walls are tight.
Check all cylinders and hydraulic pipes for leaks.
Check that all bolts in the inter-modular straps are tightened to correct torque.
Before operation fill minimum 300mm clinker layer throughout the fixed inlet and
cooler grate line for heat protection.
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After about one week of operation, and depending on the operating situation, a
shutdown of short duration should be planned in case the cooler has not been
stopped for any other reasons. The above mentioned check points can be carried
out without necessitating entry into the cooler grate level.

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FLSmidth Cross-Bar Cooler

Created by: JBPe

Definitions and abbreviations

4.9 Installation of discharge assembly and outlet HRB .................................98

Figure 1: FLSmidth Cross-Bar Cooler with outlet HRB

Some of the thermal energy contained in the clinker is simultaneously recuperated

Figure 2: Typical unit design

2.2 ABC inlet

Figure 3: ABC fixed inlet

2.3 Lower frame work and cooler housing

Figure 4: Lower frame work and cooler housing

2.4 Drive system

The HPU is connected to a Local Control Panel (LCP) featuring a Programmable

Figure 5: Hydraulic power unit (HPU)

2 or 4 hydraulic cylinders are installed in each movable cross bar lane.

Figure 8: Clinker crusher

3.0 Operating principle

3.1 Clinker cooling

Figure 9: Air distribution plate with mechanical flow regulator

3.2 Clinker conveying system

Importantly, the conveying system is

The cross bar cooler's drive mecha-

The principle of the clinker conveying

The hydraulic pump for the cross bar

4.1 General view of installation

Figure 11: CB cooler for outlet clinker crusher

(1) Cooler foundation (10) Discharge assembly

See separate instruction manuals for:

4.1.1 Prior to installation

4.1.2 Lifting gear

CB cooler standard unit weight [kg]

1200 mm wide 1800 mm wide

4.2 Cooler foundation

4.2.1 Before starting cooler installation

Step 1 Identify cooler centre line

Figure 12: Identify cooler centre line

Centreline: The centreline must be identifiable at all stages of installation. There-

For example, the fittings may be fabricated from steel reinforcement-bars or

Step 2 Check correct positions from kiln

Figure 13: Cooler concrete foundation

4.2.2 Standard cooler foundation

Check that base con-

Install shims (3) at all

Additionally shims (5)

Step 2 Cooler foundation layout

Figure 15: Cooler foundation layout

Step 3 Check cooler foundation

4.3 Installation of Lower frame work

Figure 16: Lower frame work

4.3.1 Side frames and centre supports

Step 1 Place side frames, centre frames and install bracings

Step 2 Bolt side frames and inlet walls

Figure 18: Bolt side frames and inlet walls

Step 3 Check layout dimensions and make required adjustment

Figure 19: Check layout dimensions

Figure 20: Check side frames and centre frames dimensions

Install foundation bolt guide

Weld to steel frame (3) and

All side frames are welded

Additional, all inlet walls are

Figure 22: Weld side frames and inlet walls

Weld on UNP beams

Figure 23: Install UNP supporting beam