FONS DELTA COOLER

BREAK DOWN AND ROOT CAUSE FAILURE ANALYSIS REPORT

OUTAGE REPORT:

DATE OF OCCURANCE: 22/06/2019 TIME: 11:00 AM

1. INTRODUCTION: On 22/06/2019, 11:00 AM, material got accumulated in 1 st under grate

compartment.

2. SUMMARY: Grate plate of C3 Lane got damaged and resulted in stockpile in 1 st chamber of cooler
under grate plates.

3.PLANT STATUS PRIOR TO STOPPAGE: All parameters were normal prior to this stoppage.

4.EVENT: On 22/06/2019 plant stopped at 11:00 AM, due to WAPDA shutdown. Inspection of chamber
was performed as per routine and above mentioned plates were found damaged.

5. ROOT CAUSE FAILURE ANALYSIS:

Following points to be considered before analyzing the situation:

Key points:

 All grate plates are equipped with the patented constant air flow regulation: STAFF (Stepped Air
Flow Function).The STAFF plates ensure correct air distribution throughout the clinker layer.
 The labyrinth seal ensures no through fall of clinker to the under grate compartments.
 Each lane is supported by unique bearing system; “The Four Joint Mechanism” that carries the
lanes and ensures a linear horizontal motion and there is no side motion of lanes by axial lock of
the complete bearing system. Therefore the Four Joint mechanism makes it possible to have a
wear resistant labyrinth seal between the lanes.
 The cooler is equipped with a double door sluice system, enabling authorized people to enter
the under grate compartment during operation, without disturbing the cooler operation and
without any requirement for lowering the fan speed. Without using any tools the compartments
are entered.
Findings:
Followings reasons seem to be the probable cause of this breakdown.
 During physical inspection the castable between MS wall of cooler and fix plate was not present.
May be this led to impact of temperature on plates.
 The STAFF plates were not functioning properly, hindering the flow of air. Thus resulting in
temperature rise.
 This breakdown may also be linked to chemistry of material i-e material with higher
temperature ultimately effected plates.
 6. ACTIONS TAKEN: Following corrective actions were taken:

 The damaged grate plates were replaced.

 Castable was filled between Cooler’s wall and fixed plate.
 L-type Seal between fix plate and wall was replaced. This seal prevents leakage of material
but gets damaged if temperature of material has directly impacts on it.

7. FINAL STATUS:

Kiln-II started on 28/06/2019. Inspection of Under grate compartments have been increased and no
abnormality has been observed.

8. RECOMMENDATIONS:

 Weekly Inspection: During operation, persons should be trained and assigned to work around
the cooler and inspect the under grate compartments that no clinker is present in under grate
compartment.
 Monthly Inspection: The Four Joint Mechanism bearing systems consist of spherical sliding
bearings. The greasing system and the hoses from the single line Block to the greasing point
should be inspected by entering the compartments. Inspect that all hoses are connected.
 Yearly Inspection: At least once in year, the excessive grease coming out of each bearing
greasing point be removed by a cloth. Clearance should be detected in each side of each Four
Joint Mechanism. By looking and measuring each joint when jacking it up and down if clearance
is more than 2mm, replace such bearings.
 Seal and Grate Plate Replacement: The grate plates in the moveable lanes and seal between
them be replaced as per requirement and proper record to be maintained for future use.
 Installation of Cameras: Operator to be provided internal view of under grate compartments
through cameras in each chamber.
 Temperature Monitoring of each Zone: Temperature sensors to be installed in material
chamber after specified distances to observe the temperature of material at various stages
along the length.

PREPARED BY:

REVIEWED BY:

APPROVED BY: