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8/8/2019 RP Maintenance
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Rollerpress
maintenance
8/8/2019 RP Maintenance
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Rollerpress Maintenance
Principals of pressing
Safety first for the press
Roller and its surface Bearing system
Hydraulic and Controls
Drive
Replacement work
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Pricipals of Pressing
Videoclip
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Principals of pressing
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
The big ball
Normal load distributionequal over width
With singleoversized stone
local overload
damage
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Safety first
even with Rollerpresses Magnet and Metaldetector
Metal pieces
Over sized Material
(
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Roller and its surface
Ridged Rollers
Pressforces
Longlasting Surface
Pressforces
Wear protection
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Types of surfaces
Hardfacing 2 welded layers of hard facing
With profiles
ILP interrupted line profiles
Autogenous wear protection Profiles to hold it
Regulary welding maintenance
Stud lining
Highest wear protection
Limits to press force
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Hardfacing
2 welded layers of
hardfacing
Profiles for a better grip
Normal wear applications
Maintenace once a year
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
ILP Interrupted line profile
Autogenous wear
protection
Profiles welded to thebase holding the AWP
Normal to higher wear
applications
Regularly maintenance
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Stud lining
Autogenous wear
protection
Tungsten carbide studsprotect the surface
Highest wear applications
Limits to press force Repair possible
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Which type is the best for you ?
complete Hardfacing Clinker, Raw materials,
Yearly welding in shutdown
ILP interrupted line profiles
Clinker, Raw materials, Slag
Profiles holding the autogenous wear protection
Regularly maintenance welding
Stud lining Slag, minerals, ores
Highest wear protection
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Welding
How often and How long
When to weld ?Rule of thumb:
After half the weld thickness
Com lete weld 4mm
ILP 6mm
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Welding on site
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Repair welding
main subjects Get help/specialist if you feel uncomfortable Welding machine, gas, electrodes/wire, maintenance drive
Earthing device @ roll water cooling flange
Prepartion Gauching /grinding surface till
surface is solid and crack free
Preheating 150 C
Complete: complete roll from underneath
ILP: local Welding
Buffer layer
Hardfacing or Profiles
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Welding specifications
material specifications
See the Documentaion
See the KHD Specifications
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Welding Checks
After preparation Crack free solid surface
During welding process
Normal welding supervision
Amps, Volts, weld form, flow, temperature
Check for cracks after each welded layer
After welding
Check for cracks Check diameter, roundness, conicality
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Bearing system
4 cylindrical rolls
Skewing with the
bearing housing
Stationary seals
Oil lubsystem
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Oil lubrication systemDouble filter
Cooler
Heater for startu
PLC control
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Grease the outside protection
Grease needs to
cover the
seal ga ring o ening
Grease needs to
come out
to clean the seal
If Grease is getting
liquid
seal may be damaged
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
What to check
Oil lubrication
Oil leaks
every day
Oil flowevery day
Oil level at tank
every week
Oil quality
every month
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Spherical roller bearing
Roll skews in bearing
Bearing housing is
guided by an
inner key
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Spherical roller bearing
grease lubricatedQuantity
distributor
control counts
Qualityenvironmental
contamination
Skewing of the
bearing housing
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Spherical roller bearing
Skewing checkedFixed side keyLoose side bearing and attachment iston
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Hydraulics and safe guards
Accumulator
S ring
Safety valve
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Rolcox control system
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
What to check @ the Hydraulic Stop machine
Relive pressure All pressure gages at zero
Run hydraulic pump in local Check pressure at hydraulic unit min 150 bar
Pressure localy left and right side In steps
Difference in pressure increase shows N2 pressure in accumulators Equal on both sides and according to settings
Reach highest achivable pressure Equal on both sides and according to settings
Leave system pressurized Pressure should not decrease
Check pressure reading in rollcox
Check position of both rolls,
bearing touches stops, bearing distance must be equal
Gaps left and right in Rolcox must be equal and according to settings
Relive pressure Both sides must relive pressure to zero
Push rolls/bearing housings apart Movment easy possible
This takes you 10 minutes
But you will know
We have a roblem
Or
Lets go
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
DriveShaft mounted
Gearboxes
Separate torquearms
Hydraulic shrinkdisc
Cardan shaft
Coupling fluid orrubber
Maintenance:
Oil in gearbox
Cardan shaft needs
Grease
Bolt torque
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Maintenance schedule Daily or 20 h:
Walk the machine and lubrication roomcheck leaks or noises
Weekly or 100 h: Stop the machine
check hydraulic, oil lubrication, oil filling hydraulic, oil lubrication, gearboxescheck visually the roller surfaces complete for damages
Biweekly or 250 h:
Weekly check+ Wear measurement ( decide when to weld next time)
Monthly or 1000 h: Biweekly check
Wear measurement with documentation
Oil quality checks
Lubricate cardan shaft
Yearly: Exchange oils
Check bolt torque of frame, torque arm and its support, cardan shaft
Check hydraulic shrink disc
Tighten all hydraulic and oil pipe fittings
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
It was done in2 or 48 h
If the days come to change the rolls
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Maintenance conference 16.18.11.02 at Rajashree Malkhed site
Rollerpress technology
Have the manual at hand
Inspect the press daily
Have a detailed maintenance plan
Get help when you are uncomfortable
Keep an eye on yourRollerpress