ETA Inspection and Maintanance - ETA 10+15_Rev_09_09

Picture no. 1

Claudius PetersClinker Cooler Technology

Picture no. 2

Claudius PetersClinker Cooler Technology

Inspection and Maintenance

Picture no. 3

Inspection and maintenance

Picture no. 4


- Foreign bodies

Remove foreign bodies, e.g. plastic bags, from the ventilator suction area.

- General status

Check the general status and any discrepancies of the clinker cooler, e.g. leaks in the hydraulic system, gaps in the air lines, altered running noises, rust fall-through in the lower section of the cooler etc.

Note:

All discrepancies must be documented in writing and in the form of digital photos and sent to Claudius Peters without delay.

Daily inspection (visual controls)

Picture no. 5

- Once a week

The entire interior lighting in the ETA clinker cooler must be switched on once a week. Visual inspections via the peepholes in the lower section of the cooler should establish whether there is any clinker in the lower section of the cooler interior and whether any areas can be detected in which clinker has collected owing to leakages in the lane seal.

- Drive module interior

The interior of the drive module must be inspected in the area of the hydraulic cylinder for any leaking hydraulic oil. If it transpires that hydraulic oil is leaking, the cooler must be switched off and the leak repaired. If it is not possible to switch off the cooler immediately, the oil level should be checked on the hydraulic plant. The hydraulic oil must not fall below the minimum level. Top up the hydraulic oil if necessary. If the hydraulic oil is not topped up, the entire hydraulic plant can incur such damage as to render it non-functioning. The hydraulic plant should be filled in accordance with the hydraulic operating instructions.

Weekly inspection


Picture no. 6


- Oil leaks should always be repaired as quickly as possible

- If larger volumes of clinker or oil slicks have accumulated in the interior of the lower section of the cooler, closer inspection and documentation of the actual situation is required. The actual situation must be communicated immediately to Claudius Peters in the form of a written description. If possible, digital photos should be taken and enclosed with the report for Claudius Peters.

Attention

Picture no. 7

- During an inspection stop, the entire clinker must be removed from the HE module and lane bottoms, including the protective clinker layer on the lane bottoms. The entire lane bottom sealing system must then be examined for damage. Damaged components must be replaced with new components or repaired if possible. If any hard-faced plates reveal signs of extensive wear, they may be re-faced. If wear is apparent in other areas where there is no hard-facing, such areas can also be protected by means of hard-facing. The following hard-facing electrodes should be used for this purpose:

- E10–UM–65GRZ as per DIN 8555, e.g. UTP Ledurit 65 or 76 from Böhler, whereby the processing information provided by the supplier must be observed

Inspection stop


Picture no. 8

- The hard-faced plates in the area of the HE module transverse seal are ground and may not be retrofitted with hard-facing. If these hard-faced plates show signs of wear, they should be replaced by new ones.


Attention

Picture no. 9


- Grain fraction of 16 to 32 mm. The share of grains smaller than 16 mm must not exceed 5%. Bulk density of approx. 1.6 t/m³. Specifications as per EN12620.

- Rounded stones with a smooth and flat circular shape or surface from streams or rivers can be assumed. Broken bits may only be present in the smallest of volumes.

- Unbroken, natural grains of rock which are washed and only contain low volumes of broken bits or pieces which can become detached.

- Gravel is not permitted.

- 520 kg/m² can be applied as a guideline for the pebbles volume required.

HE module

- Before putting the cooler back into operation, clinker must be spread to a minimum height of 30 cm on all of the grate plates in the HE module. The pebbles specified above can also be used for the first filling of the HE-Module.

Lanes

- The lanes must be filled with pebbles as specified above at least as far as the top edge of the longitudinal seals and/or to the top edge of the lane transverse webs.

Guidline for first filling of lanes (pebbles)

Picture no. 10


Lane flange fastening

- The fastenings for all lane flanges must be inspected visually. The flanges are tightened using 4 x M30 screws. The specified clearance of 10 mm between the lanes should be measured. If the clearance is greater than 13 mm, the screws must be burned off and replaced with new screwed elements. 21CrMoV57 should be used as screw material. The thread in the new screws should be coated with hot grease such as Molycote HSC Plus. The screws should be tightened to 880 Nm and the locknuts secured via tack-welding, whereby the correct electrode must be observed – please refer to the spare parts documentation.

Picture no. 11


HE-Module Slot Plates

- The HE module Slot Plates must be inspected for wear. If extensive signs of wear are apparent, the worn grate plates must be replaced. If the slots have become clogged with clinker, they should be cleaned. All slot plates should be dismantled. This will enable inspection of the aeration box underneath in terms of whether clinker has become lodged in the aeration boxes. Clean the aeration system if necessary. When the grate plates are re-assembled, the screw threads should be coated with hot grease before assembly, e.g. using MolykoteHSC plus.

Picture no. 12


HE-Module scraper with refractory- The HE module scraper must be inspected

for deformation and refractory concrete wear. Please ensure that the gap between the hard-faced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. If major deformation is established which can lead to operating faults, the scraper may need to be removed and aligned or a new scraper installed. Claudius Peters should be informed and the damage should be documented in the form of a photo.

- The refractory concrete must be replaced or repaired in the case of major wear preventing the HE module aeration box from being sufficiently protected against wear and heat.

- Open gaps through which clinker can getinto the space underneath the HE Module can be closed by welding flat steel bars to the transverse sealing plates.

Picture no. 13


HE-Module scraper without refractory

- The HE module scraper must be inspected for deformation wear. Please ensure that the gap between the hard-faced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. If major deformation is established which can lead to operating faults, the scraper may need to be removed and aligned or a new scraper installed. Claudius Peters should be informed and the damage should be documented in the form of a photo.

- Open gaps through which clinker canget into the space underneath the HE Module can be closed by welding flatsteel bars to the transverse sealingplates.

Picture no. 14


HE-Module with air vessel: scraper- The HE module scraper must be inspected

for deformation wear. Please ensure that the gap between the hard-faced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. If major deformation is established which can lead to operating faults, the scraper may need to be removed and aligned or a new scraper installed. Claudius Peters should be informed and the damage should be documented in the form of a photo.

- Open gaps through which clinker can get intothe space underneath the HE Module can beclosed by welding flat steel bars to thetransverse sealing plates.

- The protective grates above the cover plates (15) may only be removed for cleaning the space above as long as the hydraulic system is secured against movement and the lanes are fixed in their positions. Otherwise there is danger of life!

Picture no. 15


Hydraulic cylinder screwed connections on lane

- The screwed connection between the hydraulic cylinder and lane (front cylinder fastening) must be tightened to 160 Nm and the screwed connection between the hydraulic cylinder and steel construction on the lower cooler section (rear cylinder fastening) must be tightened to 570 Nm

alternative hydraulic cylinder installations

Picture no. 16


Defective thermocouples

- Defective thermo couplings secured to the lanes must be replaced by new ones. The thermo couplings are located under the first lane (inlet module) and on top of the lane (lane transverse webs), in a protective arrangement within a sheet steel housing.

Picture no. 17


- Defective halogen lamps arranged in the individual air chambers within the lower cooler section must be replaced with new ones. Do this by unscrewing the locknut from the side wall support. The entire lamp can then be removed from the air chamber and a new halogen lamp inserted in the socket.

Defective halogen lamps

Picture no. 18


- Ceramic plates at the end of the longitudinal sealings have to be taken out of the fastening pockets and inspected for wear. If they are not excessively worn, they can be re-used, otherwise they have to be replaced. In case of re-using existing plates, they should be re-inserted into the fastening pockets turned by 180°( old front side is new back side).

Ceramic plates at ends of longitudinal sealing

Picture no. 19


Roller

Picture no. 20


All rollers

- All rollers must be fully lubricated using 450 - 500 gr LGH B2 lubrication manufactured by SKF. Grease complying with DIN 51825: KP2N-20 can also be used. A pneumatic barrel pump can be used for filling in the lubricating grease. The filling volume can be set by fitting a flow meter. The old grease is forced out by a pipe on the pillow block and can be collected in a basin.

- The roller, side flanged wheel on the cover and the guide rail must be inspected for wear. The cover screws (item 110) must not have slackened but if they have, these screws must be tightened to 110 Nm.

- Roller wear may be max. 8 mm in relation to the diameter, i.e. minimum diameter = 222 mm. But please ensure that the dust fall-through into the lower section can increase with roller wear as the clearances in the longitudinal seals also increase. In the case of more extensive wear, the worn roller and side flanged wheel should be replaced with new components.

- The clearance between the guide rail and the side flanged wheel on the cover should not be more than 4 mm on either side. In the case of more extensive wear, the worn covers should be replaced with new ones.

Picture no. 21


All inspection windows- All inspection windows in the lower and upper cooler sections must be cleaned

thoroughly. Inspection windows are also fitted in the interior longitudinal partion walls in the first module units (side aeration) on the lower cooler section.

Grate bar chute- The grate bar chute must be inspected for wear. If necessary, the worn grate bars

should be replaced.

Level radar- If a level radar device is fitted, its antenna must be inspected for wear. If it displays

extensive signs of wear, the aerial must be replaced with a new one. Furthermore, please check whether the PTFE seal needs to be replaced. Please refer to the Saab Tank Radar PRO User Manual; Radar level metering device in units 2-7.

Picture no. 22


Attention- The radar device electronics are cooled via a comp ressed air connection.

When the compressed air fails, the electronics are not cooled but rather destroyed.

- A water separator must be integrated in the compre ssed air line as otherwise a water/slick mixture can become deposited in the aer ial and an incorrect clinker bed height is displayed.

- If damage is established, please document using a digital camera and send the photos along with a written description to Claudius Peters without delay.

Note

Only original Claudius Peters parts should be used as spare parts. Please refer to the Spare Parts documentation.

Picture no. 23

Inspection and maintanance

Dismantling and assembling componentsRoller,185kg

Key to Fig. 6-01:1 Roller2 Lane3 Clamping sleevea Front end position of cylinderb Clinker flow direction

Picture no. 24


Dismantling

- Drive the hydraulic cylinder into the front end po sition (max. cylinder stroke = 420 mm); the piston rod is fully extended.

- Knock out the clamping sleeves. Remove the screws. Support the lane in the roller area. Secure the roller using lifting rope a nd then pull down from the transverse girder support.

- Only one roller may be dismantled per lane at any one time. Only once the roller has been fully re-assembled may the next rol ler be dismantled.

Assembly

- Slide the new roller under the guide rail and posi tion.

- Knock in the clamping sleeves.

- Mount the fastening screws and tighten to 380 Nm.

- Dismantle the provisional lane support.

Dismantling rollers

Picture no. 25


Guide rail, 81kg

Key to Fig. 6-02:1 Guide rail2 Lane3 Clamping sleevea Rear end position of cylinderb Clinker flow direction

Picture no. 26


Dismantling the guide rail

Dismantling

- Drive the hydraulic cylinder into the rear end pos ition (max. cylinder stroke = 420 mm); the piston rod is fully retracted.

- Only one guide rail may be dismantled per lane at any one time. Only once the guide rail has been fully re-assembled may the next guide rail be dismantled.

- Provide the lane with provisional support.

- Knock out the clamping sleeves. Remove the screws. Pull out the guide rail.

Assembly

- Slide the new guide rail over the roller.

- Knock in the clamping sleeves.

- Secure the guide rail with the screws. Screw torqu e: 380 Nm.

- Dismantle the provisional lane support.

Picture no. 27


longitudinal sealing for 2nd module to outlet modul e, 70 to 115kg

a Nut filled with grease4 Lower side wall

7 Fire-proof3 Steel part, top section

6 Lane2 Screw to fix longitudinal sealing

5 Bracket1 longitudinal sealing

Dismantling the longitudinal sealing(A)

Picture no. 28


Dismantling the longitudinal sealing(B)

1 Screw to fix lengthwise sealing

2 Adjustable screw

3 Seal flat steel

4 Seal plate

a After assembly, seal gaps between sealings with Epple37.

b Gap 1-2 mm

Picture no. 29


Dismantling

- The fireproof mass on the lengthwise sealing must be removed in this section. If the fireproof area is cut out using a circular saw and cooled with wat er during the cutting process, the following must be observed:

- All walking lanes and seals must be exhausted unti l clean.

- Walking lanes must be covered with wooden panels o f at least 20 mm thick as well as high-strength sealing foil to ensure that no water profiles can f low into the walking lane.

- The cooling water must be suctioned out permanentl y during cutting.

- The screws for fixing the side sealing can be unsc rewed as the nuts are welded to the sheet metal bracket on the lower side wall.

- Examining the seal flat steel for wear: if the spe cified gap of 1-2 mm is wider due to wear and the gap can not be set by means of readjustment owing t o the extent of wear, a new seal flat steel must be fitted.

- The gap should not be wider than 4 mm. If the gap is too wide, clinker can penetrate to the internal seal where it can cause extensive wear in terms of the sealing elements.

Picture no. 30


Assembly

- Fill the nut with hot grease, e.g. Molycote HSC plu s.

- The screws on the internal seal components to a to rque of 38 Nm.

- If screws in the lengthwise sealing are damaged, n ew screws must be used. Carefully coat the fixing screw threads with hot gr ease such as MolycoteHSC Plus.

- Mount the lengthwise sealing using fixing screws. Screw torque: 100 Nm.

- Inject new fireproof mass on to the lengthwise sea lings. ATTENTION!: The walking lane in this area must be covered before in jecting the mass.

The following must be observed when mounting longit udinal seals:

The longitudinal seal gaps must be sealed using new seals. A seal bonding agent can also be used instead of seals, e.g. Epple 37.

The longitudinal seals should be set so that the ga p between them and the seal flat steel is 1-2 mm. T he gap is adjusted by means of an adjustable screw.

Note:

Prior to putting the cooler back into operation, th e lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP

Picture no. 31


Central longitudinal sealing for 2nd module to outlet mo dule, 55 to 82kg

Dismantling the central longitudinal sealing

c Gap 1-2mm6 Washer

b Walking lane5 Retaining washer

a After assembly, seal gaps between lengthwise sealings with Epple 37.4 Fastening screw

9 Sealing flat iron3 Joggle

8 Sealing plate2 Epple 37 Seal

7 Walking lane1 Central longitudinal sealing

Picture no. 32

Dismantling


- Unscrew the fastening screws.

- Detach the joggle

- Pull out the lengthwise sealing

- Examine the seal flat steel for wear: if the specif ied gap of 1-2 mm is wider due to wear and the gap can not be set by means of readjustment owing to the extent of wear, a new seal flat steel must be f itted

Picture no. 33

Assembly


- Slide in the longitudinal sealing.

- If screws in the lengthwise sealing are damaged, ne w screws must be used. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus

- Insert the fixing screws along with the washers and retaining washers.

- Set a gap of 1-2 mm.

- Tighten the fixing screws to a torque of 135 Nm

- Weld the joggle to the lengthwise sealing transvers e fin ensuring the correct electrode. Please also refer to the module on Spare Parts

- Weld half the perimeter of the washer to the length wise sealing

- Fill sealing putty, e.g. Epple 37, into the lengthwi se sealing gap (area covering the lengthwise sealings)

Note:

Prior to putting the cooler back into operation, th e lanes and seal areas must be filled with pebbles in accordance wit h the specifications outlined by CP

Picture no. 34

Side sealing for 1st module (inlet module), 65 to 11 5 kg


Dismantling the side sealing, 1st module

4 Plate fastening2 Side sealing inlet module

3 Transverse sealing plate1 Hard-faced plate

Picture no. 35


- Use the hydraulic cylinder to pull the side lane t owards the cooler outlet, i.e. the hydraulic cylinder piston rod is f ully retracted and in rear cylinder end position

- Remove the fireproof mass from the longitudinal se alings

- Disassemble the transverse sealing plate

- Dismantle the side sealing

- Examine the internal longitudinal sealing componen ts for signs of wear as well as their gaps

Dismantling

Picture no. 36


- Fill the nut with hot grease, e.g. Molykote HSC Plu s

- If screws in the longitudinal sealing are damaged, new screws must be used. Carefully coat the fixing screw threa ds with hot grease such as Molycote HSC Plus.

- Please refer to the respective instructions for the next steps in assembling the longitudinal sealing .

- Install the transverse sealing plate

Assembly

ATTENTION!

The longitudinal sealing’s ground hard-faced plate (in the area of the cross sealing) must be aligned in such a way that it is a t right angles to the HE module’s ground hard-faced plate.

Note:

Prior to putting the cooler back into operation, th e lanes and seal areas must be filled with pebbles in accordance with the specific ations outlined by CP

Picture no. 37


Central longitudinal sealing for 1st module (inlet mo dule), 73 to 82 kg

Dismantling the central longitudinal sealing, 1st mo dule

Key to Fig. 6-07:1 Roller2 Lane3 Clamping sleevea Rear end position of

cylinderb Clinker flow direction

Picture no. 38


Dismantling

- Use the hydraulic cylinder to pull all of the side lanes towards the cooler outlet, i.e. the hydraulic cylinder piston rod is fully retracte d and in rear cylinder end position.

- Disassemble the transverse sealing plate.

- Dismantle the lengthwise sealing; please refer to t he respective instructions. The lengthwise sealing secured before that may also hav e to be dismantled.

Assembly

- If screws in the longitudinal sealing are damaged, new screws must be used. Carefully coat the fixing screw threads with hot gr ease such as Molycote HSC Plus.

- Please refer to the respective instructions for the next steps in assembling the lengthwise sealing.

- Install transverse sealing plate.

Note:


Picture no. 39


Side lane for 2nd module to outlet module, 510 to 950 kg

Dismantling the side lane, 2nd module

3 Guide rail

5 12 mm sealing profile2 Roller

4 Clamping sleeve1 Lane

Picture no. 40


Dismantling

- Drive the hydraulic cylinder into central position (max. cylinder stroke = 420 mm).

- Drive the hydraulic cylinder in the adjacent lane into central position (max. cylinder stroke = 420 mm).

- Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and then pretension them. D=12 mm steel cables should be used with a strap at the end.

Picture no. 41


Removing lanes

a Steel cable2 Rope end with strap

3 Rope (for lifting)1 Grip for cable pretensioning

Picture no. 42


Per cable, one 1.5 tonne grip is required for prete nsioning.

Plus 2 2.5 tonne steel claws with short steel cable and straps for lifting the lane.

4 BKS tensions with 3-metre chains for lifting the lane, each 2.0 tonnes.

4 shackles, each 2 tonnes.

4 rope pulleys for 12 mm steel cable.

- Secure the steel claws to the transverse fins of t he lane to be removed using a short cable and strap.

- Secure shackles to the short cable.

- Attach rope pulleys to the steel cable.

- Secure the BKS tensions to the short cable attache d to the steel claw and rope pulley.

- Pretension the BKS tension chains to secure the la ne.

ATTENTION!

The side lane is not easy to remove as the lane is arranged under the side sealing.

Picture no. 43


2 proposals for dismantling:

Picture no. 44


Proposal 1:

- Dismantle the side sealings in the area of the lane to be removed

- Dismantle the central longitudinal sealing in the area of the lane to be removed

- For the drive area only: dismantle the cylinder fi xture on the lane.

- Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws.

- Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys.

- Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones

ATTENTION!

The remaining lanes in the same lane must be secure d in such a way that they are unable to slide longitudinal during assembly and th ereby fall from the rollers.

Picture no. 45


Proposal 2:

Removing lanes

c Shorten the partition wall3 Partition wall

b Lane2 Seal angle

a Burn off nut1 Guide rail

Picture no. 46


- Remove the lane beside the side lane and place on t op of the other lane.

- For the drive area only: Dismantle the cylinder fi xture on the lane.

- Dismantle the guide rail from the side lane to be removed

- Dismantle the partition wall seal angle.

- Cut off approx. 50 mm of the partition wall under the lane (opposite the roller).


Picture no. 47


- Lower the lane by approx. 40 mm so that the lane c an be pulled out sideways from the cover on the side sealing.


- Dismantle all of the lane securing components and examine their function. If they can still be used, please use these components for the new lane. As a general rule however, all parts displaying signs of wear must be replaced with new ones.

ATTENTION!

The remaining lanes in the same lane must be secure d in such a way that they are unable to slide longitudinal during assembly an d thereby fall from the rollers.

Picture no. 48


Assembling proposal 2

- Before fitting the new lane, please examine whether it is the right one. This can be established by checking to see if the markin g on the underside of the lane – e.g. SB5 / SB7 – is the same as the markin g on the lane plan.

- Pull the lane into assembly position in the cooler .

- Use silicone to attach a new sealing profile D=12 mm, L=590 mm under the two flange areas.

Key to Fig. 6-13:1 Sealing profile2 Lane flange

Assembling lanes

Picture no. 49


- Mount all of the lane securing components. Tighten the screws to the specified torques. As a general rule, all parts dis playing signs of wear must be replaced with new ones

- Slide the lane under the side sealing.

- Slide the guide rail under the lane and secure wit h the clamping sleeves.

- Use the screws to loosely secure the guide rail.

- Mount the new screws for securing the lane flange. Please observe the nut torque.

- Tack the locknuts for securing the flange to the s crew threads ensuring the correct electrodes.

ATTENTION!

Prior to mounting all of the screws, coat the screw threads with MolycoteHSC Plus hot grease.

Picture no. 50


For the drive area only:

Mount the cylinder fixture on the lane. Tighten the screws to the appropriate torque.

Mounting the cylinder fixture

- Dismantle the mounting aids .

Note:


a Walking lane

2 Steel part, lower section

1 Cylinder position transmitter, arranged below

Picture no. 51


Central lane for 2nd module to outlet module, 510 to 950 kg

Dismantling the central lane, 2nd module

a Tacked nut3 Guide rail

5 12 mm sealing profile2 Roller

4 Clamping sleeve1 Lane

Picture no. 52


Dismantling

- Drive the hydraulic cylinder into central position (max. cylinder stroke = 420 mm).

- Mount the steel cables in the top section of the c ooler and tension

- Dismantle the central longitudinal sealings


- Dismantle the cylinder fixture on the lane.



- The remaining lanes in the same lane must be secur ed in such a way that they are unable to slide longitudinal during assembly and th ereby fall from the rollers.


Picture no. 53

Inspection and maintenanceAssembly

- Before fitting the new lane, please examine whethe r it is the right one. This can be established by checking to see if the marking on the underside of the lane –e.g. SB5 / SB7 – is the same as the marking on the l ane plan

- Pull the lane into assembly position in the cooler .



Assembling lanes

Picture no. 54


- Mount all of the lane securing components. Tighten the screws to the specified torques. As a general rule, all parts displaying si gns of wear must be replaced with new ones

- Mount the new screws for securing the lane flange. Please observe the nut torque.

- Tack the locknuts for securing the flange to the s crew threads ensuring the correct electrodes.

ATTENTION!

Prior to mounting all of the screws, coat the screw thre ads withMolycote HSC Plus hot grease.

Picture no. 55



Mount the cylinder fixture on the lane. Tighten the screws to the appropriate torque.

Mounting the cylinder fixture

- Dismantle the mounting aids.

Note:

Prior to putting the cooler back into operation, th e lanes and seal areas must be filled with pebbles in accordance with the specific ations outlined by CP

a Walking lane

2 Steel part, lower section

1 Cylinder position transmitter, arranged below

Picture no. 56


Side lane for 1st module (inlet module, 550 to 610 kg)

Key to Fig. 6-18:1 Lane inlet

Dismantling side lanes

Picture no. 57


Dismantling

- Drive the hydraulic cylinder in to the rear end position (max. cylinder stroke = 420 mm); the piston rod is fully retracted.

- Drive the adjacent central lane into the rear cylinder end position.

- Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. D=12 mm steel cables should be used with a strap at the end. Please refer to the respective instructions for all other mounting aids and how to secure the lanes.

- ATTENTION!

The side lane is not easy to remove as the lane is arranged under the side sealing.

Picture no. 58


2 dismantling proposals:

- Proposal 1:

- Dismantle the side sealings in the area of the lane to be removed

- Dismantle the central longitudinal sealings in the area of the lane to be removed.

- Dismantle the cross sealing from the lane




ATTENTION!

The remaining lanes in the same lane must be secure d in such a way that they are unable to slide longitudinal during assembly and thereby f all from the rollers.

Picture no. 59


Proposal 2:

- Remove the central lane positioned beside the side lane and place it on the other lanes

- Dismantle the guide rail from the side lane to be removed

- Dismantle the partition wall seal angle.

- Cut off approx. 50 mm of the partition wall under the lane (opposite the roller)

- Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws

- Lower the lane by approx. 40 mm so that it can be pulled out sideways from the cover on the side sealing.



ATTENTION!

The remaining lanes in the same lane must be secure d in such a way that they are unable to slide longitudinal during assembly and thereby f all from the rollers.

Picture no. 60


Assembly

- Before fitting the new lane, please examine whether it is the right one. This can be established by checking to see if the marking on the underside of the lane – e.g. SB1 / SB3 – is the same as the marking on the lane plan.

- Pull the lane into assembly position in the cooler.



Assembling lanes

Picture no. 61


- Mount all of the lane securing components (internal sealing parts). Tighten the screws to the specified torques. All components must be set to the specified gaps. As a general rule, all parts displaying signs of wear must be replaced with new ones

- Slide the lane under the side sealing.- Slide the guide rail under the lane and secure with the clamping sleeves.- Use the screws to loosely secure the guide rail.- Mount the new screws for securing the lane flange. Please observe the nut torque. - Tack the locknuts for securing the flange to the screw threads ensuring the correct

electrodes; please refer to the module of Spare Parts.ATTENTION!Prior to mounting all of the screws, coat the screw threads with Molycote HSC Plus hot grease.

- Position the central lane arranged beside the side lane and mount.- Mount the central longitudinal sealings- Re-weld the partition wall and mount the partition wall seal angle if dismantling is in

accordance with Proposal 2.- Dismantle the mounting aids.

Picture no. 62


Central lane for 1st module (inlet module), 590 kgDismantling the central lane

1 Lane inlet

Picture no. 63


Dismantling

- Drive the hydraulic cylinder in to the rear end position (max. cylinder stroke = 420 mm); the piston rod is fully retracted.

- Dismantle the central longitudinal sealings in the area of the lane to be removed

- Dismantle the cross sealing from the lane

Picture no. 64


- Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. D=12 mm steel cables should be used with a strap at the end. Secure the lane with the lifting equipment.




ATTENTION!

- The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers

Picture no. 65


Assembly

- Before fitting the new lane, please examine whether it is the right one. This can be established by checking to see if the marking on the underside of the lane – e.g. SB2 – is the same as the marking on the lane plan.

- Pull the lane into assembly position in the cooler.



Assembling lanes

Picture no. 66


- Mount all of the lane securing components. Tighten the screws to the specified torques. All components must be set to the specified gaps. As a general rule, all parts displaying signs of wear must be replaced with new ones.

- Lift the lane into position.- Mount the new screws for securing the lane flange. Please observe the nut torque.

- Tack the locknuts to the screw threads ensuring the correct electrodes; please refer to the Full Module documentation.

- Mount the cross sealing.

ATTENTION!Prior to mounting all of the screws, coat the screw threads with Molycote HSC Plus hot grease.

- Dismantle the mounting aids.

Note:Prior to putting the cooler back into operation, th e lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP.

Documents

ETA Inspection and Maintanance - ETA 10+15_Rev_09_09