rp maintenance

8/8/2019 RP Maintenance

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Maintenance conference 16.18.11.02 at Rajashree Malkhed site

Rollerpress

maintenance


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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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Pricipals of Pressing

Videoclip


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Principals of pressing


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The big ball

Normal load distributionequal over width

With singleoversized stone

local overload

damage


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Safety first

even with Rollerpresses Magnet and Metaldetector

Metal pieces

Over sized Material

(


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Roller and its surface

Ridged Rollers

Pressforces

Longlasting Surface

Pressforces

Wear protection


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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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Hardfacing

2 welded layers of

hardfacing

Profiles for a better grip

Normal wear applications

Maintenace once a year


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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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Stud lining

Autogenous wear

protection

Tungsten carbide studsprotect the surface

Highest wear applications

Limits to press force Repair possible


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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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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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Welding on site


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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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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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Bearing system

4 cylindrical rolls

Skewing with the

bearing housing

Stationary seals

Oil lubsystem


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Oil lubrication systemDouble filter

Cooler

Heater for startu

PLC control


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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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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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Spherical roller bearing

Roll skews in bearing

Bearing housing is

guided by an

inner key


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grease lubricatedQuantity

distributor

control counts

Qualityenvironmental

contamination

Skewing of the

bearing housing


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Skewing checkedFixed side keyLoose side bearing and attachment iston


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Hydraulics and safe guards

Accumulator

S ring

Safety valve


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Rolcox control system


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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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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 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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It was done in2 or 48 h

If the days come to change the rolls


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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

rp maintenance

Documents