ThyssenKrupp Robins, Inc.

EQUIPMENT EVALUATON REPORT

Client: Address: Attention: Phone Number: Fax Number: Inspection Date: Equipment:

Lake Charles Harbor & Terminal District,

Bayou Dinde Rd., Lake Charles, LA, 70602 USA

250 Industrial Rd., Pascagoula, MS 39581-3201, USA Donald Brinkman Director of Engineering 337/ 493-3526 337/ 493-3623 03/26/2008 KRUPP (RE&C) Bridge BWR Contract #1816
mailto: dbrinkman@portlc.com

Service Contract Number: SC 67D Inspection Performed By: George Morea Mechanical Engineer Customer No.

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TABLE OF CONTENTS:

PAGE:

1.0 Introduction:

2.0 Equipment Description / As Designed:

3.0 BWR Mechanical Evaluation and Recommendations:

4.0 Pictures:

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1.0 Introduction: ThyssenKrupp Robins, Inc. has been contracted by Lake Charles Harbor & Terminal District, to perform a general evaluation at the solids handling facility in Lake Charles, LA USA for the existing KRUPP (RE&C) Bridge BW Reclaimer. Original contract: RE&C #1816 Bridge Bucket Wheel Reclaimer. The above is covered in this report, together with proposed improvements, conclusions and recommendations. The findings detailed below reflect the condition in which the equipment has been found during the site visit. As the system evaluation is based on visual observations, relevant samplings and brief operation trials of various function of the equipment, there is always a possibility that hidden or latent defects may not be detected during the course of the inspection. Annual, periodic reviews completed by TKRI and carried out on the equipment are not meant to replace regular scheduled maintenance procedures. It is therefore essential that all operation and maintenance personnel assigned to the machine, continually monitor the performance of the equipment, within the original design specifications and report any unusual conditions so proper repair procedures will be addressed. All operation and maintenance personnel should be trained to observe critical components during equipment operation and routine maintenance activities. Photographs and any relevant drawings are attached to further clarify recommendations. The observations and recommendations that are part of this report list items that have been found in need of attention. Upon request, ThyssenKrupp Robins, Inc. can provide field service assistance and technical support regarding the following recommendations, or any repair and installation procedure.

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For technical support and parts information, please call: Service Department: Jurgen Lukas Manager, Service Department:
Phone: 303/793-2635 Fax: 303/770-2153
e-mail: mailto:jurgen.lukas@thyssenkrupp.com

George E. Morea Mechanical Engineer, Service:

Phone: 303/793-2636 Fax: 303/770-2153
e-mail: mailto:george.morea@thyssenkrupp.com

Parts Department: Michelle Miller Spare Parts Administrator:

Phone: 303/793-2624 Fax: 303/770-2153
e-mail: mailto:michelle.l.miller@thyssenkrupp.com

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2.0 Equipment Description / As Designed:

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3.0 Bucket Wheel Reclaimer - Mechanical Evaluation and Recommendations: The following is a summary of items that need to be brought to your attention, together with our conclusions and recommendations based on the observations taken during the site visit. The Bridge Bucket Wheel Reclaimer evaluation has been performed with the equipment operating under no load condition due to the fact that no ship was available for unloading the reclaimed material. All descriptions and findings related to the machine will be referred as A side (Control room) and B side (Cable reel side). Photographs and any related drawings are attached for your reference and to support and detail the following recommendations.
The general condition of the machine show extensive wear on all mechanical parts and corrosion of structural members, typical for machines operating in this type of environment and being in service for over 30 years. The visual structural evaluation revealed defects that raise concerns regarding the safe and reliable operation, overall integrity of the equipment and its related components. Mechanical and structural operating performance aspects of the bridge BWR are addressed in the following TKRI report.

3.01 Structural Components: When material and water are allowed to accumulate on the machine structure, there is a substantial risk of accelerated paint coating damage, corrosion and progression toward loss of sectional integrity of steel members.
(Please refer to paragraph 3.15 Bridge Conveyor Belt)

Structural fatigue, rust penetration of steel beams and edge corrosion of structural members will occur. Ultimately, this will lead to component failures. Main reclaimer bridge (Both ends of bridge structure) shows advanced stages of structural deterioration at the flanged connecting point with the pendulum bearing frame.
(Please refer to paragraph 3.12 Spherical Bearings / Ball and Socket Assembly A and B sides)

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Structural damage of both travel drive end frames was noted due to previous equipment over-skew.
(Please refer to paragraph 3.13 Skew Control Mechanism)

Completely corroded structural bolts and nuts have been found, a condition that will allow the structure to flex during the reclaiming process allowing excessive vibrations and loads to build-up into the structure.
The entire BW reclaimer equipment need to be closely inspected for corrosion and rust damage, all areas affected need to be repaired or replaced, and painted to minimize the effects of the corrosion process.

Replace all corroded splice plates, steel members and mounting structural bolts. Repair / replace structural damaged steel members of both harrow frames. Replace corroded / damaged lubrication lines. Regular inspections related to the equipment structural integrity are recommended. Various locations, hand rails and stairs bent / damaged. Repair / replace. All areas that are showing signs of corrosion need to be sandblasted, primer coated and painted to control the corrosion process, if the steel integrity of the base metal is still in place.

Immediate replacement of slotted end (A side) bridge to end frame connecting pin required. (Detail 57-P2 see drawing below). Immediate replacement of fixed end (B side) bridge to end frame connecting pin required. (Detail 57-P1 see drawing below).

Bridge BW Reclaimer End frames, key plan.

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3.02 Bogie Weldment Balancing Pins: Travel drive bogies, balancing pins are showing wear and corrosion at the pin / bogie weldment contact point. Excessive wear of the balancing pins will prevent the bogies to float over the vertical misalignments of the rails. This will create holding forces unevenly distributed between the A and B sides of the bridge, inducing a torque moment above the allowable limits, in the structure of the BW Reclaimer while travelling.
Replacement of ALL worn bogie balancing pins is recommended.

3.03 Bucket Wheel Frames: (Both left and right BW). Both Bucket Wheels are showing wear of mechanical parts and extensive wear and corrosion of structural members. Measurements of the bucket wheel elevations have been taken, showing a difference of 1 between the A and B BW frames. Advanced corrosion of the splice plates and mounting structural bolts of the BW frame segments was noticed to the extent that existing splice plates have a thickness of 1/8 (original plate ) Extensive wear and misalignment of the side rail segments was noticed. Extensive wear of the inner ring rail, guide rolls and vertical guide wheels was noticed. Rusted through BW dust cover and mounting supports (both sides). All four side guide rolls misaligned in relation to the centerline of the BW frame. All back plate (Ring chute) assemblies are positioned too far from the wheel frame, therefore allowing a gap of approximately 4-6 between the ring chute and the BW frames at the lower elevation point. This condition will result in loss of material reclaimed capacity.
Immediate replacement of both A & B Bucket Wheels ring girder, splice plates together with structural mounting hardware, required. Immediate replacement of both BW frames side guide rails together with structural mounting hardware, required. Immediate replacement of both BW frames inner rails together with structural mounting hardware, required.

Replace AR liners and mounting hardware of the back plate assembly (ring chutes), both A & B Bucket Wheels. Adjust all back plate assemblies within 1-2 clearance with the ring chutes.

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Replace both A & B Bucket Wheels dust covers, complete together with rubber seals, clamp brackets and mounting hardware. Replace all side guide rollers, double bogie assemblies and the vertical rolls on both E & W Bucket wheels.

Bridge BW Reclaimer BW frame, Side guide roller assembly GA.

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Bridge BW Reclaimer BW frame, Side guide roller assembly, Erection diagram. Bridge BW Reclaimer BW frame, Stabilizing roller assembly, Erection diagram.

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Bridge BW Reclaimer BW frame, Stabilizing roller assembly, GA.

3.04 BW Chains and Sprockets: (Both left and right BW). All drive chains of the bucket wheel drives have been replaced and are approximately three weeks old. Some are showing wear of the inside of the chain links, both BW. Unequal chain tension between the two drives of the same BW was observed. This condition allows the tighter chain / BW sprocket to accelerate faster than the other creating a lateral rocking motion of the entire BW frame. Chain sprockets, shafts and bearings are showing wear and centerline misalignment in relation to the centerline of the chains. Replace worn BW drive chain sprockets. Verify and correctly adjust by matching the distance between the centerline of sprockets and chains. Adjust tension both BW drive chains equally. Monitor condition of chain, sprockets, shaft and bearings including the drive chains tension regularly.

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3.05 Bucket Wheel Drives: (both E side & W side BW drives) Both BW drives are showing normal operation at this time. Sprocket rack segments on the side of the bucket wheel frame are showing normal wear at this time. The rack segments are manufactured interchangeable, therefore when one side of teeth wears out the sprocket racks may be relocated from one side of the digging wheel to the other so that the unworn side of teeth could be used. We strongly recommend verifying the load sharing of the BW drives for equal torque transfer to the drive chains.
(All BW drives reducer and motor nameplate must be the same).

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3.06 BW Carriage: Carriage frame shows advance stages of corrosion over the entire structure. Carriage horizontal guide rolls, both sides, are showing wear of the wheel running face that will increase the allowable lateral free play that the carriage can take during operation (digging). At the same time, the truck assemblies (vertical wheels) are showing difference in wheel diameters (approx. ) Vertical wheels are showing worn flanges. This will transfer the lateral forces from the harrow scraping against the pile during reclaiming process, into the head beams A & B resulting in the machine travelling skewed and tripping the travel drives on overload.

Replacement of the carriage frame splice plates and structural bolts is recommended. Monitor wear, replace if necessary all carriage horizontal guide rolls and vertical wheels Properly adjust the clearance between the horizontal guide rolls and the rail. 3.07 BW Carriage Drive Chains and Sprockets:

Immediate replacement of the vertical and horizontal connecting pins of the carriage center frame is required.

The carriage chains were found to be within reasonable mechanical condition at the time of the inspection. Minimal lateral free-play was noticed on the chain inner rollers.
Immediate replacement of both chain tension equalizer beams and pins required.

Monitor chain wear on a regular basis. Monitor equal chain tension both sides. Shorten chains if necessary / replace if stretched.

3.08 BW Carriage Drive: BW carriage drive is showing normal operation at this time 3.09 Harrows: Presently the material angle of repose does not match the actual inclination angle of the harrow frame resulting in excessive forces being induced into the BW frame / equipment structure during reclaiming process. Adjust harrow angles (Approximately 2 degrees above the material angle of repose) in accordance to the materials natural angle of repose.

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Harrow scraping pins showing different lengths and mounting angles in relation to the harrow frame (Perpendicular installation to the harrow frame required) Install missing scraping pins. Replace all worn / bent scraping pins.
(Please refer to paragraph 3.01 Structural Components)

3.10 Travel Drives: Designed step-in distance for reclaim is ~ 6-7@ each pass. Adjust step-in distance during reclaiming according to specifications. Movement in the torque arm of the reclaimer travel drives is visible during the slow-down and stop of the equipment. Travel drive A side: Replace secondary chain (Outside chain) of the driven wheels Install missing A side chain guard of the outside chain. Drain, flush and refill reducer with oil to the specified level. Monitor all travel drive reducers oil level on a regular basis. Travel drive B side shows misalignment between the main drive sprocket and drive chain. Both balancing tensioner sprockets are engaging the primary chain on the side of the links due to the misalignment of the drive sprocket. Left tensioner arm damaged as a result chain misalignment. Replace damaged left tensioner arm. Replace secondary chain (Outside chain) of the driven wheels Drain, flush and refill reducer with oil to the specified level. Monitor all travel drive reducers oil level on a regular basis.

Immediate repairs / alignment required for the B travel drive main drive sprocket and chain.

Clean extreme material build-up around bogies, travel wheels and rails. 3.11 Outside Rails: The rails are showing horizontal and vertical misalignment, condition that will greatly affect the correct equipment operation. Bridge conveyor belt misalignment will occur due poor condition to the rails. Maintenance personnel described having misalignment problems with the BWR bridge conveyor during reclaiming.

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This is a direct result of the reclaimer operating on misaligned rails in conjunction with the condition of the spherical bearings.
(Please refer to paragraph 3.12 Spherical Bearing)

Generally, the maximum allowable rail tolerance is about over the length of the bogie frame; (please refer to recommended rail tolerances detailed in the maintenance manual). The rail misalignment is a major contributing factor to the loud noises and vibrations being heard as the reclaimer travels along the rails. They are generated by the lateral movement of the head beams / drive bogies against the rail surface, when the dynamic loads induced into the bridge overcome the friction factor at the rail/wheel contact point.

Immediate rail repair and alignment is required over the entire area of the coke storage yard.

To verify the correct rail alignment it is necessary to complete a detailed survey. Replace all rotten, damaged wood ties. Broken or worn-out rails, splice plates, mounting bolts, rail spikes, etc. also need to be replaced. Verify that embedding ballast is level (compacted) and clean for proper rail support and water drainage. Replace ballast if crushed. Clean the material build-up along the entire length of the reclaimer rails.

3.12 Spherical Bearings / Ball and Socket Assembly A and B sides: Both spherical bearings of the BW reclaimer bridge are showing vertical and horizontal misalignment. Excessive wear of the spherical bearings combined with the rail misalignment will prevent the end frames to float over the vertical horizontal imperfections of the rails. This will allow the equipment structure to overstress exceeding design limits, during operation.
Therefore the constant variation of the dynamic loads transferred into the bridge during the reclaiming process, could exceed allowable stresses with respect to calculated yield point of the framework elements resulting in potential major mechanical and structural failures.

Machine travelling skewed, tripping the travel drives on overload, belt misalignment and possible over-turning and derailment could occur.

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B side bearing: NE SW

RECLAIMER BRIDGE

HEAD BEAM TRAVEL DRIVE

2 SE

PILE, Reclaiming Direction

SW RAIL

3 3/8 SW

The measured edge gap of the bearing shows a difference of approximately over the transversal axis. The vertical / horizontal misalignment, measured at the time of the inspection, is over the allowable limit tolerances.

Immediate replacement of both A and B spherical bearings including all mounting hardware, lubrication lines, etc is required.

3.13 Skew Control Mechanism: New skew control mechanism was installed new several months ago. The reclaimer structure shows major structural damage of the bridge end connection to the spherical bearings, both ends. The structural damage is directly related to past over-skew occurrences. Torque the mounting bolts of the skew control arm at each end for accurate detection and control of the bridge alignment. Skew control adjustments will have to be performed after the replacement of both spherical bearings is completed. Regular inspections of the skew control mechanism and related electrical controls must be completed regularly for safe equipment operation. 3.14 Travel Wheels: Travel wheels are showing wear of the wheel-running surface and wheel flanges. This will cause a problem with the traveling of the equipment for the reason that wheels with different diameters on the same bogie, are transferring unequal rotation / traction ratios (the slower wheel acting as a brake for the faster wheel) Therefore, high loads can build up into the bridge allowing it to travel skewed and resulting in premature wear of the drive components and structural parts of the machine. Replacement of the worn out driven wheels is recommended. If replacement of driven, travel wheels is decided, driven wheels have to be replaced in pairs because of diameter / wheel speed considerations.

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3.15 Bridge Conveyor Belt: Maintenance personnel described having misalignment problems with the BWR bridge conveyor during reclaiming. This is due to the B side pendulum bearing and rail condition which allow the bridge frame to flex over the allowable limits during operation.
(Please refer to paragraph 3.12 Spherical Bearings)

Extremely high amounts of material spilled over the entire structure of the bridge. This will cause a problem with extra load added to the structure.
Immediate installation of missing skirt-board along the entire length of the conveyor, both sides, required. Immediate cleaning of the material build-up on along the conveyor deck and bridge frame of the BWR is required.

Adjust / replace if necessary all belt cleaners. Adjust primary and secondary belt wipers, loading areas. Adjust skirt-boards both head end chutes and BW center chutes for proper clearance to the belt. Repair dust covers of both bucket wheels. Replace worn / damaged rollers of the bridge conveyor Replace bearing of the bent pulley, A side discharge conveyor end.

3.16 Electrical: Recommendations have been made to upgrade the equipment controls to automatic operation by fully integrating interlock safety system of equipment and installing a new PLC control unit. Commissioning of all belt misalignment switches, speed switches, material flow and belt loading monitoring devices together with the safety interlock system of the BWR required. Repair loose electrical wires / connections various locations on the equipment. 3.17 Sealing Belt Bridge Conveyor: The entire belt sealing system of the BWR is missing. Install missing belt sealing system for proper dust control during operation. 3.18 Control Cabin: Control cabin, complete replacement is recommended. 3.19 Power / Control Cable Reels: Power cable reels are showing normal operation at this time.

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3.20 Lubrication: Verify that lubrication of all bearings, pivot and balancing points, hinges, etc on the entire equipment is completed so grease is visible at the separation line between bearing and bearing housing for proper dust protection. Replenish ALL antifriction bearing grease every 6 months. 3.21 Painting: Paint surface shows cracks and peeling over many areas of the structure.
All areas that are showing signs of corrosion and paint damage need to be sandblasted, primer coated and painted in accordance with the painting specifications for steel structures of the bridge BW Reclaimer.

This action should be incorporated into the machines routine maintenance. If maintenance personnel identify areas where paint damage occurred such areas should be repaired at once. Additionally, the affected areas should be cleaned and repaired as a part of the routine maintenance program. Efforts should be made to keep material spillage from accumulating. Addressing the repair issues listed above will bring the machine back to its best performance and will help in reducing maintenance. We will be glad to assist in any way with mechanical, structural, electrical repairs or modifications to bring your equipment back to peak operating performance. If you have any questions regarding the above recommendations, please feel free to contact us. Best regards,
GEORGE E. MOREA MECHANICAL, SERVICE ENGINEER
THYSSENKRUPP ROBINS, INC. 7730 EAST BELLEVIEW AVE. # 404 GREENWOOD VILLAGE, CO. 80111-5820 USA PH: 303-793-2636 FAX: 303-770-2153 E-MAIL: mailto:george.morea@thyssenkrupp.com

ThyssenKrupp Robins, Inc.

A company of ThyssenKrupp Engineering

www.thyssenkrupprobins.com

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Bridge BWR Spherical Bearing A side. Bridge BWR Spherical Bearing B side.

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Bridge BWR Spherical Bearing A side. Bridge BWR Spherical Bearing A side Immediate bearing and mounting hardware replacement required. Both sides.

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Bridge BWR Spherical Bearing A side Immediate bearing and mounting hardware replacement required. Both sides. Bridge BWR Spherical Bearing A side Immediate bearing and mounting hardware replacement required. Both sides.

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Bridge BWR Spherical Bearing A side Immediate bearing and mounting hardware replacement required. Both sides. Bridge BWR Spherical Bearing A side Immediate bearing and mounting hardware replacement required. Both sides.

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Bridge BWR Spherical Bearing B side Immediate bearing and mounting hardware replacement required. Both sides. Bridge BWR Spherical Bearing B side Immediate bearing and mounting hardware replacement required. Both sides.

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Bridge BWR Spherical Bearing B side Immediate bearing and mounting hardware replacement required. Both sides. Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition.

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Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition. Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition.

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Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition. Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition.

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Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition. Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition.

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Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition. Bridge BWR Structural damage related to equipment over-skew and spherical bearing condition.

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Bridge BWR End frame A pin wear / Replace. (Same for B side) Bridge BWR End frame A pin wear / Replace. (Same for B side)

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Bridge BWR Immediate replacement of both chain tension equalizer beams and pins required. Bridge BWR Immediate replacement of the vertical & horizontal pins of the carriage center frame is required. Both sides.

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Bridge BWR Immediate replacement of the vertical & horizontal pins of the carriage center frame is required. Both sides. Bridge BWR Immediate replacement of the vertical & horizontal pins of the carriage center frame is required. Both sides.

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Bridge BWR Various locations, handrails and stairs damaged, missing structural bolts. Repair / replace. Bridge BWR Various locations, handrails and stairs damaged, missing structural bolts. Repair / replace.

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Bridge BWR Various locations, handrails and stairs damaged, missing structural bolts. Repair / replace. Bridge BWR Rail cleaner frame bent; touching the wheel. Repair / replace.

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Bridge BWR Bucket Wheel frame. Bridge BWR Immediate replacement of both BW ring girder, splice plates and structural mounting hardware, required.

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Bridge BWR Immediate replacement of both BW ring girder, splice plates and structural mounting hardware, required. Bridge BWR Immediate replacement of both BW ring girder, splice plates and structural mounting hardware, required.

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Bridge BWR Replace all BW cell corroded liners to prevent further corrosion of the wheel frame. Bridge BWR Replace all BW cell corroded liners to prevent further corrosion of the wheel frame.

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Bridge BWR Replacement of both BW frames inner rails together with structural mounting hardware, required. Bridge BWR Replacement of both BW frames inner rails together with structural mounting hardware, required.

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Bridge BWR Replacement of both BW frames inner rails together with structural mounting hardware, required. Bridge BWR Replacement of both BW frames side guide rails together with structural mounting hardware, required.

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Bridge BWR Replacement of both BW frames side guide rails together with structural mounting hardware, required. Bridge BWR Replace worn side guide rollers of the BW frame.

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Bridge BWR Replace worn supporting rollers of the BW frame. Bridge BWR Replace worn supporting rollers of the BW frame.

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Bridge BWR New BW drive chain. Bridge BWR Adjust tension and sprocket alignment, both BW drive chains equally to prevent premature chain wear.

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Bridge BWR Verify and correctly adjust by matching the distance between the centerline of sprockets and chains. Bridge BWR Replace worn BW drive chain sprockets

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Bridge BWR Immediate installation of missing skirt-board along the entire length of the conveyor, both sides, required. Bridge BWR Immediate installation of missing skirt-board along the entire length of the conveyor, both sides, required

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Bridge BWR Replace corroded wear liner plate along the loading chute of the conveyor. Bridge BWR Install missing rollers, clean spillage along the conveyor to prevent roller damage and belt misalignments.

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Bridge BWR Install primary belt cleaner, both head pulley of the conveyor Bridge BWR Head chute B, Repair / replace corroded head chute.

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Bridge BWR Head chute A, Repair / replace corroded head chute. Bridge BWR Travel drive A.

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Bridge BWR Travel drive A, replace re-tension secondary drive chain. Bridge BWR Travel drive A, tension equalizer needs more lubrication.

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Bridge BWR Travel drive A drive sprocket position in relation to the drive shaft. (See below picture for reference) Bridge BWR Immediate repairs / alignment required for the B travel drive main drive sprocket and chain.

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Bridge BWR Immediate repairs / alignment required for the B travel drive main drive sprocket and chain. Bridge BWR Immediate repairs / alignment required for the B travel drive main drive sprocket and chain.

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