Standard Operating Procedures
(SOP) for Clinker Cooler
A. Startup Procedures
1. Check to ensure the breakers are on.
2. Start the clinker transport system.
3. Start cooler bearing air.
4. Start the clinker breaker.
5. Start the #1 drive fans.
6. Start the undergrate fans on #2, 3, and 4 drives.
7. Start # 4, 3, 2, and 1 drives.
B. Shutdown Procedures (Normal/Emergency)
a. Normal Procedures
1. The cooler will be shutdown in the reverse order of the
startup procedures.
2. The cooler and transport system should be run for four hours
after the kiln feed has stopped to ensure that it is empty
before any maintenance is performed.
b. Emergency Procedures
1. The same procedures will be followed as in a normal
shutdown, though some steps may be bypassed depending
on the nature and of the emergency.
C. Malfunctions
Malfunction May Results In Corrective Documentation
Description Actions/Procedures
Failure of #1 drive Shutdown of Inspect and repair and/or Malfunction
position sensor cooler replace sensor, as necessary. Report Generated
Excess Emissions
Fan failures (bearings Clinker cooled at Shut down kiln and/or cooler, Malfunction
and electrical faults) a reduced rate, as necessary. Inspect and Report Generated
cooler does not repair fan, as necessary. If
provide available, use stand-by
secondary air to undergrate fan.
kiln
Excess Emissions
Loss of hydraulic Motion loss of Shut down and inspect to Malfunction
pressure to #1 drive grates determine cause of failure. Report Generated
Excess Emissions Repair as necessary.
Loss of hydraulic oil Motion loss of Shut down and inspect Malfunction
cooling system grates cooling system and repair, as Report Generated
Excess Emissions necessary.
Failure of tipping Inability of Inspect valves and/or shut Malfunction
valves cooler to down cooler, as necessary. Report Generated
discharge clinker Repair and/or replace valves
Excess Emissions as necessary.
Plant power failure Shut down of Inspect to determine cause of Malfunction
cooler failure. Repair, if possible, or Report Generated
Excess Emissions notify proper authorities.
Loss of grate Buildup of Inspect for broken or missing Malfunction
clinker in bottom grate. Repair and/or replace Report Generated
of cooler as necessary.
Excess Emissions
Broken support beam Excess Emissions Shut down and inspect for Malfunction
broken beam. Repair and/or Report Generated
replace as necessary.
Bearing failure Loss of drive Shut down and inspect Malfunction
shaft bearing. Repair and/or Report Generated
Excess Emissions replace as necessary.
Failure of adjustable Excess Emissions Inspect drive to determine Malfunction
frequency drive cause of failure. Repair Report Generated
and/or replace as necessary.
Failure of drive gear Excess Emissions Shut down and inspect Malfunction
reducer reducer to determine cause of Report Generated
failure. Repair and/or replace
as necessary.
Motion indicator Excess Emissions Inspect indicator and/or shut Malfunction
failure down cooler, as necessary. Report Generated
Repair and/or replace as
necessary.
Motor failure Loss of power to Shut down and inspect motor Malfunction
cooler drive to determine cause of failure. Report Generated
Excess Emissions Repair and/or replace as
necessary.
PLC failure Shut down of Inspect to determine cause of Malfunction
cooler failure. Repair as necessary. Report Generated
Excess Emissions
Failure of DC drive Excess Emissions Shut down and inspect drive Malfunction
to determine cause of failure. Report Generated
Repair and/or replace as
necessary.
Loss of wire(s) Excess Emissions Inspect to determine cause of
failure. Shut down cooler as
necessary. Repair and/or
replace wire(s), as necessary.
Clinker cooler drives Shut down of Inspect to determine cause of Malfunction
failure cooler and/or kiln failure and repair and/or Report Generated
Excess Emissions replace as necessary.
Cooler clinker breaker Slowing or Inspect to determine cause of Malfunction
failure stopping kiln failure and repair and/or Report Generated
Excess Emissions replace as necessary.
Clinker bucket Shut down of kiln Inspect to determine cause of Malfunction
elevators failure Excess Emissions failure and repair and/or Report Generated
replace as necessary.
Clinker tunnel Shut down of kiln Inspect to determine cause of Malfunction
conveyors failure Excess Emissions failure and repair and/or Report Generated
replace as necessary.
Lube system failure Excess Emissions Inspect to determine cause of Malfunction
failure and repair and/or Report Generated
replace as necessary.
Water spray system Excess Emissions Inspect to determine cause of Malfunction
failure failure and repair and/or Report Generated
replace as necessary.
Plant air failure Excess Emissions Inspect to determine cause of Malfunction
failure and repair and/or Report Generated
replace as necessary.
