Rollerpress

maintenance

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Rollerpress Maintenance
• Principals of pressing
• Safety first for the press
• Roller and it‘s surface
• Bearing system
• Hydraulic and Controls
• Drive
• Replacement work

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Pricipals of Pressing

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Principals of pressing

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 The big ball
Normal load distribution
equal over width

With single
oversized stone

local overload
damage

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Safety first
even with Rollerpresses
• Magnet and Metaldetector
– Metal pieces
• Over sized Material
(<2 x gap)
– Load peaks on surface

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Roller and it‘s surface
• Ridged Rollers
– Pressforces
• Longlasting Surface
– Pressforces
– Wear protection

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

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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 ILP Interrupted line profile
• Autogenous wear
protection
• Profiles welded to the
base holding the AWP
• Normal to higher wear
applications
• Regularly maintenance

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Stud lining

• Autogenous wear
protection
• Tungsten carbide studs
protect the surface
• Highest wear applications
• Limits to press force
• Repair possible

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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Welding
Rule of thumb:
When to weld ?
After half the weld thickness
Complete weld 4mm
ILP 6mm

How often and How long

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Welding on site

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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Welding specifications
material specifications

• See the Documentaion

• See the KHD Specifications

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Bearing system
• 4 cylindrical rolls

• Skewing with the

bearing housing

• Stationary seals

• Oil lubsystem

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Oil lubrication system
Double filter
Cooler
Heater for startup
PLC control

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Grease the outside protection
•Grease needs to
cover the
seal gap ring opening

•Grease needs to
•come out
to clean the seal

•If Grease is getting

liquid
seal may be damaged

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 What to check
Oil lubrication

Oil leaks
every day

Oil flow
every day

Oil level at tank

every week

Oil quality
every month

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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Spherical roller bearing
grease lubricated
Quantity
distributor
control counts

Quality
environmental
contamination

Skewing of the
bearing housing

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Spherical roller bearing
Skewing checked
Fixed side key
Loose side bearing and attachment piston

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Hydraulics and safe guards

Accumulator
Spring

Safety valve

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Rolcox control system

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 What to check @ the Hydraulic
• Stop machine
• Relive pressure
• All pressure gages at zero
This takes you 10 minutes
• 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 But you will know
• Pressure should not decrease
• Check pressure reading in rollcox
• Check position of both rolls, We have a problem
• bearing touches stops, bearing distance must be equal
• Gaps left and right in Rolcox must be equal and according to settings
• Relive pressure Or
• Both sides must relive pressure to zero
• Push rolls/bearing housings apart
• Movment easy possible Let’s go

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Shaft mounted
Drive Gearboxes
Separate torque
arms
Hydraulic shrink
disc
Cardan shaft
Coupling fluid or
rubber

Maintenance:
Oil in gearbox

Cardan shaft needs

Grease

Bolt torque

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

 Maintenance schedule
• Daily or 20 h:
– Walk the machine and lubrication room
check leaks or noises
• Weekly or 100 h:
– Stop the machine
check hydraulic, oil lubrication, oil filling hydraulic, oil lubrication, gearboxes
check 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

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site

If the days come to change the rolls

It was done in
2 or 48 h

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 your

Rollerpress

Maintenance conference 16.–18.11.02 at Rajashree Malkhed site