Type of Surface

Innovation On Demand
LEARNING MORE ABOUT ROLLER PRESS

MAINTENANCE PRACTICES FOR ROLLER PRESS
A TECHNICAL WORKSHOP CONDUCTED BY
HUMBOLDT WEDAG INDIA-PROCESS KNOW HOW
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Grinding Technology -Roller Press
Roller Press Maintenance
 Safety first for the roller

press
 Roller and it‘s surface
 Hydraulic Check
 Scheduled Checks
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2
Grinding Technology-Roller Press
Safety first for Roller Presses
Principles of Pressing

Grinding Technology-Roller Press 3
The Big Ball
Normal load distribution equal

over width
With single
oversized stone
local overload
damage

4
 Magnet and Metal detector

• Metal pieces
 Over sized Material

(<2 x gap)
• Load peaks on surface

5
Types of surfaces
Hard facing
 2 welded layers of hard facing
 With profiles
ILP interrupted line profiles

 Autogenous wear protection
 Profiles to hold it
 Regularly welding maintenance
Stud lining
 Highest wear protection
 Limits to press force

CHF, Complete Hard Faced Welded Wear Surface
 2 welded layers of hard facing

 Profiles for a better grip
 Normal wear applications
 Maintenance once a year

ILP, Interrupted Line Profile

 Profiles welded to the base
holding the AWP
 Normal to higher wear
applications
 Regularly maintenance

Stud Lining

 Tungsten carbide studs protect
the surface
 Highest wear applications
 Limits to press force
 Repair difficult

Welding
Hardfacing in good condition

Profiles are clearly visible

Welding
Hardfacing height reduced
Time to Weld

Welding
When to weld ? Rule of thumb:

After half the weld thickness:
Complete weld: 4 mm
ILP: 6 mm
How long and How often?

12
General Check of Hydraulic System
 Stop machine
 Relive pressure
• All pressure guages at zero
 Run hydraulic pump in local

• Check pressure at hydraulic unit min 150 bar
 Pressure locally left and right side

• In steps
• Difference in pressure increase shows N2 pressure in accumulators
o Equal on both sides and according to settings
• Reach highest achievable pressure
o Equal on both sides and according to settings

13
General Check of Hydraulic System

 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
• Movement easy possible But you will know
We have a problem
This takes you 10 minutes
Or
Let’s go

14
Maintenance Schedule, Every 24 hrs or daily
Roller press in general-

 Abnormal noise
 Dust deposits
Frame –
 Check gap between the
spacer strips of bearing
housing
 Material accretions in the
gap on the bottom frame
section to be removed

15
Roller support-
 Check bearing temperature
 Check bearing lubrication
 Check internal and external

labyrinth seals for sufficient
lubrication
• 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

16
Hydraulic pressing system-

 Check connections for
tightness
 Check oil pressure
 Central grease
lubrication -
 Observe end indication
for barrel change

17
Maintenance Schedule, Every 1000 hrs
Rollers-
 Wear measurement at the
rollers( wear measurement
with measuring template,
entering the measuring
results into the log of
measuring points)
 Check the surface for break
outs in the wear surface .
Repair of the wear surface if
required.
 Check the roller surfaces,
roller front and profiling,
repair and regenerate the
wear surface

18
Surface Measurements
 Measurement device
part of KHD delivery
 Crossbar mounted
to the roll
 Distance easy to
measure

19
Frame –
 Check bolts of end pieces
 Check bolts of outer guide

Chart 20
20

Feeding device-
 Check the slide
bearing and threaded
bush for lateral wall
support
 Check distance of the
lateral wall with lateral
wall tips to the rollers
front sides
 Check the gate guiding
and lateral wall
suspensions
 Check bellows for
tightness

21
Drive –
 Check tightening
torque of the screw
for the articulated
shaft
 Torque support-
 Check tightening
torques of the screws
gear box holder/gear
box
 Check foundation
fastening

Chart 22
22
 Oil in gearbox
 Cardan shaft
needs Grease

23
Roller support-
 Check fastening bolts or tighten
them
 Scrap off material deposits at
the labyrinths
 Remove deposit from side ways
 Check bolts of the outer guiding.
 Check side ways of the outer
guide.
 Check degree of contamination
of the air filters at the bearing
housings, replace if required.

24

 Check all hydraulic components for
leakages.
 Visual check of the rubber hinge
between the bearing housings of
the floating roller and the frame
end pieces.
 Check filter at the hydraulic set
and at the intermediate tank,
replace ,if required.
 Check the pressing device for
proper functioning.
 Check the pump pressure of
hydraulic system.
25
 Screw setting screw at the

pressure switch system down, until
the cartridge valves respond and
/or interrupt the current supply to
the pressure switch system. In this
case ,the current switch valve must
blow pressure/the hydraulic oil
over the cartridge valves. If in both
cases the cartridge valves do not
drain hydraulic oil into the
balancing tank, contact KHD.

26
Every 9000 hrs or yearly
Roller press in general-

 Complete wear check and cleaning.
 Check all screw union for tight
seating
 Oil change as per list of lubricating
schedule
 Check & fix (50 degree centigrade )
set volume regulating valve for
cooling water.
 Replace all the air cleaners at the
bearing housing/hydraulic set/
intermediate tanks/control
block/guard.

27
If the days come to change the rolls
It was done in
48 hours

28
Roll Exchange

29
Roller Press Technology

30
Roller Press Maintenance
Discussion

31

Type of Surface

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Innovation On Demand

LEARNING MORE ABOUT ROLLER PRESS

Lets aim together to learn more about most efficient

Roller Press Maintenance

 Safety first for the roller

Lets aim together to learn more about the most efficient

Safety first for Roller Presses

Lets aim together to learn more about the most efficient

Safety first for Roller Presses

The Big Ball

Normal load distribution equal

Lets aim together to learn more about the most efficient

Safety first for Roller Presses

 Magnet and Metal detector

 Over sized Material

Lets aim together to learn more about the most efficient

ILP interrupted line profiles

Lets aim together to learn more about the most efficient

CHF, Complete Hard Faced Welded Wear Surface

 2 welded layers of hard facing

Lets aim together to learn more about the most efficient

ILP, Interrupted Line Profile

 Autogenous wear protection

Lets aim together to learn more about the most efficient

 Autogenous wear protection

Lets aim together to learn more about the most efficient

Hardfacing in good condition

Lets aim together to learn more about the most efficient

Hardfacing height reduced

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When to weld ? Rule of thumb:

How long and How often?

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General Check of Hydraulic System

 Run hydraulic pump in local

 Pressure locally left and right side

Lets aim together to learn more about the most efficient

General Check of Hydraulic System

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 24 hrs or daily

Roller press in general-

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 24 hrs or daily

 Check bearing temperature

 Check bearing lubrication

 Check internal and external

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 24 hrs or daily

Hydraulic pressing system-

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 1000 hrs

Lets aim together to learn more about the most efficient

Maintenance Schedule, Every 2000 hrs

Lets aim together to learn more about the most efficient