16RKI006 RKI Preventative Maintenance Programs For Tube, Pipe and Roll Forming Mills (ID 96847)

EMPLOYEE TRAINING AND DEVELOPMENT
Preventative Maintenance Programs

for Tube, Pipe and Roll Forming Mills
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Introduction
At Roll-Kraft, we are committed to excellence in all aspects of tube and pipe tooling and roll forming tool-
ing. This commitment began in 1963 in Willoughby, Ohio when founder and roll tooling maker George
F. Gehrisch started Roll-Kraft in a small house and garage. He had a simple business philosophy that
incorporated understanding his customers needs, and making them the very best roll tooling.
That commitment has endured through the more than 50 years of company success that followed. Today,
the pursuit of our mission to be the most reliable supplier for industries we serve is stronger than ever.
One of the key reasons for our success lies in our long-term commitment to training. Our broad experi-
ence has given us unsurpassed insight into tube and pipe and roll forming tooling processes. We put that
experience and know-how to use around the country through custom-designed training seminars at our
customers facilities. As the next step in our training commitment, this e-book synthesizes our preventative
maintenance best practices into a powerful and highly useful learning tool.
THE E-BOOK IS ORGANIZED IN FIVE CHAPTERS:
1. Profit Pointer for Preventative Maintenance Programs for Tube, Pipe and Rollform Mills
2. Profit Pointer for Tooling Management & Maintenance Programs
3. Roll Tooling Cleaning Procedures
4. Tube and Pipe Tooling Maintenance When to Send Tooling in for a Rework
5. The Importance of a Properly Maintained PM Program for the Tube and Pipe and Roll Forming Industry
Conclusion: FREE Mill Evaluation
We hope you find this e-book informative and helpful. If you have any questions after reading this
e-book, we encourage you to contact us via our website.
Robert A. Sladky, V.P. of Tube Mill Engineering

CHAPTER 1
Profit Pointer for Preventative Maintenance
Programs for Tube, Pipe and Rollform Mills
In this chapter, we focus on the subject of tube, pipe and rollform mill maintenance. The information pro-
vided in this chapter will allow mill operators to develop, or modify, their own maintenance programs to
ensure efficient operation of their mills.
While primarily a tooling manufacturer, Roll-Kraft believes that a properly maintained mill maximizes the
performance of the tooling. Quite often, production problems and poor product quality are blamed on
the tooling when, in fact, a mill problem is to blame. And in most cases, that particular mill problem could
have been prevented if the mill had been properly maintained. Therefore, it is essential to develop and
implement a preventative maintenance program for your mill, if such a program does not exist, to put a
stop to such problems.
Once in place, a preventative maintenance program will yield surprising results. Among the benefits that
you will realize from a properly maintained mill, compared to a neglected mill, are quicker changeovers,
reduced down time and scrap, longer tooling life and higher quality end product.
LUBRICATION
Lubrication is the cornerstone of any mill maintenance program. This is easy to see based simply on the
number of drive shafts and bearings that require grease or oil in a typical tube, pipe or rollform mill. If
these components are not properly lubricated, failure can occur.
For example, more than half of all bearing failures are lubrication related. Most mills are lubricated accord-
ing to a daily or weekly schedule, with the frequency determined by date. It has been the experience of
Roll-Kraft, however, that tube, pipe and rollform mills should be greased according to a schedule based
on service time, such as hours. This is a common practice employed with construction equipment. Service
time can easily be tracked with an hourmeter. If your mill is not equipped with an hourmeter, install one. Be
sure that it is installed on the power side of the mill (for example, connected to the motor drive contactor).
When installed in this manner, the hourmeter will only count down when the mill is running, not sitting idle.
The general mill lubrication guidelines listed below are based on best practices used in the tube, pipe and
rollform industry. Keep in mind that these are guidelines, not specific lubrication intervals applicable to all
mills. For the specific lubrication intervals for your particular mill, contact the mill manufacturer. If the manu-
facturer of your mill is no longer in business, these guidelines can be used as a starting point to develop a
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Program for Tube, Pipe and Rollform Mills
reliable lubrication schedule. Over the course of time, the schedule can be tailored to your specific needs
based on such factors as mill configuration and operating environment.
Always use a high-quality, high-temperature grease when lubricating your mill. Also, a high-quality oil is
recommended for those applications requiring oil, such as gearboxes and oilers.
MILL COMPONENTS
Mill components should be greased every 100 hours. Be sure all grease fittings are serviceable and the
component or bearing is taking grease. Apply grease sparingly. More is not necessarily better. The excessive
grease that flows out of a bearing or component creates a messy environment and is a waste of lubricant.
The following is a list of mill components that require lubrication (your particular mill might not be equipped
with all the components listed; this list excludes AC and DC motors):
Driven stand bearing blocks (inboard and outboard)
Side pass rolls
Entry guide, seam guide, turkshead
Drive shaft universals joints (W style mills)
Upper lead screws for top shaft adjustment
Coolant tank support rollers
Run out table rollers
Looper or Floop accumulators (including pinch roll drive systems)
Payoff reel bearings (greaseable style)
Auxiliary equipment specific to your mill Driven Stand Lubrication Points
WELD ROLLS
Two-roll, ERW design welders should be lubricated every 100 hours
Three-, four-, or five-roll HF (high-frequency) design welders should be lubricated every 12 hours
GEARBOXES
Check the oil level every 100 hours
Check for oil leaks every 100 hours (repair any leaks, as needed)
Change the oil in gearboxes every 2,500 hours
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Program for Tube, Pipe and Rollform Mills
DRIVE LINE COUPLINGS

Grease every 2,500 hours
ELECTRIC MOTOR BEARINGS

This group of components includes AC and DC motors, coolant pump
motors, rotary transformer bearings on ERW welders, fan motors and
hydraulic motors on auxiliary equipment. These bearings should be
greased every 2,500 hours. Apply the grease sparingly, as over-greas-
Rollformer Lubrication Points (typical)
ing will force grease inside the motor housing, which can cause internal
electrical problems.
Rotary Transformers (ERW Welders)

Check the oil level every 100 hours
Change oil every 2,500 hours
MG SETS
Greaseable designs (with grease fittings) should be lubricated every 2,500 hours. For wet bearing cup de-
signs, check the oil level every 100 hours; change the oil every 2,500 hours. Be careful not to over-grease
either design, as excess grease will be forced inside the motor housing, which can cause internal electrical
problems.
CUT-OFF PRESSES
Grease the lube points every 100 hours (lube points are located on the ram swing arms, crankshaft bear-
ings, and sections of the accelerator system). Cut-off presses are often equipped with oil lube systems to
lubricate the die and rail systems. Most oil lube systems include visual reservoirs for checking the oil level.
Check the oil level every 100 hours, or as required, based on usage (some reservoirs might require refilling
before 100 hours). Inspect all oil lines to ensure that each line is (1) properly connected to its connection
point and the connection is not leaking, and (2) not plugged, and oil is flowing through the line. Clean the
oil reservoirs annually, as sludge has a tendency to accumulate in the bottom of the tanks.
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HYDRAULIC ACCELERATOR SYSTEMS

Check oil level every 100 hours
Check for oil leaks every 100 hours
Change oil and filters every 2,500 hours
Driven Stand Lubrication Points (typical)
Rollformer Lubrication Points (typical)
AIR LINE OILERS

Many pneumatic systems are equipped with air line oilers to lubricate the internal components of the
system. Check the oil level every 100 hours, or as required, based on usage. Check the operation of the
oilers to ensure that the correct amount of oil is being delivered throughout the system.
CENTRAL LUBRICATION SYSTEMS

Due to the fact that weld rolls require more lubrication than the rest of the mill, a central lubrication system
is ideal for ensuring proper lubrication of these rolls. A central system is completely separate from the main
system and its use offers many advantages. These include reduced lubrication labor, lubrication usage and
cleanup, as well as increased machine life and productivity. A timer, which is wired to the run circuit of the
mill, lubricates the weld rolls during production, but not when the mill is idle. Central lube systems can also
be utilized in the breakdown and fin sections of the mill.
Preventative Maintenance
Inspect the bearings for roughness and excessive end play
Inspect expansion arbors, linkage and hold-down arms
Inspect turntable bearings and king pin
Inspect all lube points for broken or plugged grease fittings
Inspect brake systems
Inspect all powered components, hydraulic rams, expander, and hold-downs
Check the alignment of the payoff reel with respect to the rest of the mill line
End Welding Equipment Central Lubrication System

Inspect the guide rolls for strip
Inspect the surface condition of the guide rolls
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Inspect the guide roll bearings for roughness and excessive end play
Inspect the hold-down clamps for strip
Inspect the copper back-up plates and clamps (tig weld machines)
Inspect the welding torch traverse system (rails, drive motor, belt, or lead screw)
Inspect all electrical cables and connections
Inspect all air lines, hydraulic lines and gas-shielding lines for leaks
Inspect and clean the power supply; check for proper fan operation
Many firms schedule a semiannual or annual plant shutdown to perform basic inspections, repairs and
upgrades on their equipment, regardless if breakdowns have occurred. These actions ensure that their tube,
pipe and rollform mills continue to operate efficiently and safely. Performing maintenance tasks on such a
regularly scheduled basis is known as Preventative Maintenance (PM).
Tube, pipe and rollform mills are production-oriented machines that require ongoing maintenance to en-
sure reliable and productive operation. Unfortunately, maintenance is often done only when a breakdown
occurs. When maintenance is only performed on an as-needed basis, the mechanical condition of the mill
progressively declines, with the net result being poor product quality.
Outlined below are guidelines for a preventative maintenance program for tube, pipe and rollform mills.
As stated in the Lubrication section, these guidelines are based on best practices used in the industry. Keep
in mind that these are guidelinesnot specific maintenance tasks applicable to all mills. For the specific
maintenance tasks for your particular mill, contact the mill manufacturer.
CLEANUP
Plant shutdowns are especially good times to clean the entire mill. The mill should be cleaned before any
maintenance work is started. A clean mill will make inspection and maintenance work much easier to
perform compared to a mill that is not clean. Many plants use a pressure washer, connected to the coolant
system, to clean the mill. Such a setup does not add any water to the system and can be used for cleaning
the mill at any time.
PAYOFF REEL
Accumulator Floop Style
It is highly recommended that an annual tune-up, performed by the manufacturer, be an integral part of a
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preventative maintenance plan for the accumulator (vertical and horizontal designs).
In addition, the following maintenance tasks should be performed every 2,500 hours:
Inspect all support and turnaround rollers (surface condition of the rollers)
Inspect the roller bearings for roughness and excessive end play
Inspect all chain and gear drives
Inspect all linkages, air lines and hydraulic lines for leaks
Inspect all pneumatic and hydraulic cylinders for leaks
Inspect motors and pumps and the connection couplings (if a DC motor is used, perform the DC
motor maintenance tasks outlined later in this document)
Inspect and clean the DC motor blower (if equipped)
Inspect all sensors and proximity switches
Inspect all guarding
Check alignment of the entry and exit end of the accumulator with respect to the entry end of the
mill and the other auxiliary equipment
Accumulator Looper Style

Inspect all support and turnaround rollers (surface condition of the rollers)
Inspect the roller bearings for roughness and excessive end play
Inspect all support and turnaround rollers and drums in the unit
Inspect the turnaround drums (crown must still be machined into the drums for proper tracking)
Check the alignment of turnaround drums within the framework of the accumulator
Inspect the looper carriage cart, cables, cable winch, (motor and transmission) carriage rollers,
bearings, track and brake
Inspect the framework of the looper assembly for cracked or broken welds
Inspect the pinch roll drive rollers for flatness
NOTE: If your mill is not equipped with a pinch roll drive, it is highly recommended that one be installed.
Pulling the strip through the looper with the mill places a tremendous amount of additional stress on the tool-
ing and the entire drive system. This can cause excessive wear on the tooling (40-50% greater wear rates
compared to mills with pinch roll drives) and drive system components. The net result is poor product quality.
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Inspect the motor and transmission (if a DC motor is used, perform the DC motor maintenance tasks
outlined later in this document)
Inspect the dancer arm and encoders that monitor the free loop of the strip before it enters the mill
Inspect all sensors and E-stop limit switches
Entry Guide
Inspect the guide rolls for wear (guide rolls should be replaced on a regular basis)
Inspect the guide roll shafts for wear
Inspect the guide roll bearings for roughness and excessive end play
Inspect the shaft mounting blocks for excessive play in the gibs
Inspect the lead screws, side-to-side adjustment and height adjustment (if equipped)
Inspect surface smoothness of the horizontal lead-in roller
Inspect the horizontal lead-in bearings for roughness and excessive end play
Check the position of the entry guide; it should be mounted as close as mechanically possible to the
first breakdown; move the unit as required
Check the integrity of the edge trim units (if equipped)
Check the position of the entry guide; it must be centered and at the correct height with respect to
the entry end of the mill
Driven Stands
Inspect O.D. of the driven shafts; allowable undersize wear is .001 per 1.000 O.D. of the shaft
NOTE: When replacing bearings, inspect the bore of the bearing block (for the outside race) and the
bearing journal O.D. (for the inside bearing race). Always preload the bearing to the proper inch pound
rotational drag. Do not preload bearings by feel.
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Inspect the outboard tower bearings for roughness and excessive end play
Inspect outboard tower bearing sleeves for excessive wear; allowable oversize wear is .001 per
1.000 I.D. of the original bore of the outboard sleeve
Check the bearing block fit to the inboard and outboard towers
NOTE: If these bearing blocks do not have grease seals, it is recommended that seals be added. It
should be noted, too, that if seals are installed, a grease relief must be added. The grease relief is
necessary to prevent the seals from blowing out when the bearing block is greased. The grease relief
should be installed on the opposite side of the end caps, opposite from the grease fitting to ensure that
the grease flows through both bearings. If the grease fitting is located in the center of the bearing block,
move it to the end cap.
Verify that the top shaft is parallel to the bottom shaft

Inspect the integrity of the top lead screw adjustment for the top shafts
Inspect the jackscrews if the mills are equipped with Single Point Adjustment (SPA); if equipped with
anti-back lash jackscrews, the proper preload on the bearings must be maintained
Inspect the driven shafts for straightness
Verify the shoulder alignmenttop shaft to bottom shaft and stand-to-stand
Side Pass Stands

Inspect the side pass shafts for wear and indentations from the
bearings
Check the fit of the side pass shafts to the shaft mounting blocks
Inspect the shaft mounting blocks for excessive play in the gibs
Inspect the lead screws and the side-to-side adjustment for loose-
ness; eliminate any backlash
Inspect the integrity of the foundation components, if the height
is adjustable; be sure that the foundation can hold the side pass
stand plumb and upright against the formation forces of the mill during normal mill operation
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Inspect the top tie bars (if equipped); all fasteners and lead screws must be in place
Check the position of the metal line in the side pass stands; the metal line must be at the proper
height and centered with respect to the driven passes per the tooling design and setup chart
Check the position of the side rolls, if brass washers are used
NOTE: Consider switching from brass washers to thrust bearings on the side rolls. Thrust bearings allow the
side rolls to rotate easier, reducing drag on the mill drive. Also, the thrust bearings eliminate the variable
wear on the rolls and brass washers.
Inspect the framework of the side pass stands for coolant; be sure that the coolant can drain proper-
ly from the areas around the shaft mounting blocks
Seam Guide (if applicable)

Seam guide units have multiple designs.
Design 1 Two horizontal rolls set up in the same manner as a side pass stand for guiding the V gap of the
tube to the weld rolls
Design 2 Two horizontal rolls set up in the same manner as a side pass stand with an insulated fin blade
for guiding the V gap of the tube to the weld rolls
Design 3 Insulated fin blade only for guiding the V gap of the tube to the weld rolls
Inspect Design 1 in the same manner as you would a side pass stand, as the configuration is similar. In-
spect Designs 2 and 3 in the same manner as you would a side pass stand, as the configuration is similar,
plus perform the following tasks:
Inspect the insulation on the two halves of the fin blade guide; the fin blades must be completely
insulated from the arbors on which the blades are mounted
Inspect the fin blades for wear
Inspect the bearings on the assembly for roughness and excessive end play
Inspect the in-and-out adjustment for the fin blades
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Weld BoxesERW Type

If your ERW configuration has two bottom weld rolls, follow the guidelines, as outlined for the side
pass stands, for checking the integrity of the unit
If your ERW configuration has live bottom shafts, inspect the bearings for roughness and excessive
end play; be sure the bearings are properly preloaded and the seals are functional; check the
shoulder alignment (the weld rolls must be parallel)
If your ERW configuration has only one bottom weld roll, inspect the shaft, bearings, and shoulder
references for proper integrity
WELD BOXESHF TYPE

Many designs are used for HF (high-frequency) welding. These include (1) two-roll units; (2) flat plate, three-
roll design and (3) three-roll, chuck design. Four- and five-roll units are often used on larger tube and pipe
mills. For two-roll units, follow same guidelines as outlined for the ERW-type weld boxes.
Inspect the flat plate (separate clevises with separate adjustments), three-roll design as follows (these guide-
lines should also be followed for four- and five-roll weld boxes of this design):
Inspect the slides, gibs, and lead screws if the back plate moves up and down, and side to side
Inspect each weld roll clevis for proper integrity (includes the slides, gibs, lead screws, and bored
holes for the weld roll shafts)
Inspect the weld roll shafts for proper O.D. and shoulder referencing for weld roll location
Inspect the three-roll, chuck design (each weld roll is usually individually adjustable) as follows:
Most chuck-style weld boxes are mounted on a flat, intermediate plate; most move up and down,
and some side to side; inspect the slides, gibs, and lead screws
Inspect the chuck; these units should have grease fittings to lubricate the internal scroll; disassemble
the scroll and clean it, then inspect the scroll for excessive wear and end play
Inspect each lead screw in each of the three jaws of the chuck
Inspect each weld roll clevis for proper integrity (includes the slides, gibs, lead screws, and bored
holes for the weld roll shafts)
Inspect the weld roll shafts for proper O.D. and shoulder referencing for weld roll location
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ERW Rotary Transformer

Inspect the bearings for roughness and excessive end play; be sure the bearings are properly pre-
loaded and lubricated
Inspect the insulation between the two top copper electrodes
Inspect the bolt hole threads for the top copper electrodes; replace any stripped-out threads or studs
Inspect the slip rings and brushes
Have a motor shop meg the rotary transformer to verify the integrity of the insulation (no current
should be leaking to the ground)
Inspect all electrical connections, including the connections of the heavy cables to the slip rings
Inspect the motor, transmission and chain drive that rotates the transformer, allowing the copper
electrodes to be trimmed
Inspect the integrity of the trimming unit; a tight unit is a must for smooth trim cuts
Inspect the oil coolant rotary couplings
Inspect all hoses
Inspect the pump, filters and supply tank
MG Set
Have a motor shop meg the generator to verify the integrity of the insulation (no current should be
leaking to the ground)
Inspect the commutator and brushes, as well as all cables and connections
Inspect the coupling between the AC motor and the gen-set
Inspect the AC motor bearings for roughness and excessive end play
Inspect the exciter generator; inspect the coupling (if equipped)
Service the exciter generator annually
HIGH-FREQUENCY (HF) WELDER COMPONENTS

It is highly recommended that an annual tune-up, performed by the manufacturer, be an integral part of a
preventative maintenance program for your welder. These welders are quite complicated and are consid-
ered specialized equipment, requiring service from specially trained technicians. Special test equipment that
you might not have in-house is also required. A tune-up will maintain your equipment in peak condition and
will allow the manufacturer to upgrade it to the latest changes.
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As part of your regular in-house maintenance program, perform the following tasks every 2,500 hours:
Check the distilled water level in the closed loop cooling system; check the system for external and
internal leaks
Check the water for contamination; determine the source of contamination, correct the problem and
recharge the system with clean distilled water
Inspect the heat exchanger for leaks
Inspect the temperature gauges and throttle valves for proper operation
Inspect the pump and motor
Lube the pump motor and pump (if it does not have sealed bearings) annually
Inspect buss bar arms; check the insulation between arms
Inspect the induction coil clamps and clamp fasteners
SCARF STANDS
Two basic scarf stand designs are used: (1) one-piece rotary design, and (2) single- and two-knife design
The maintenance tasks for the rotary design are the following:
Inspect the round cutting tool saddle, as well as the hold-down clamps
Inspect the limit or proximity switches used for rotation change of the unit
Inspect the motor and gearbox; lubricate the motor and gearbox annually
Inspect the bearings, or slip fit, of the rotary unit to the fixed base; lubricate as required
The maintenance tasks for the single- and two-knife design are the following:
Inspect the gibs and slides that incorporate the up-and-down feature of the stand; these areas must
be tight to ensure steady, smooth cuts
Inspect the air cylinders (if equipped) for wear and air leaks
Check the cylinder air line oilers for proper operation and adjustment
Inspect the air cylinder-to-knife mount slide linkage; some units use cams for this purpose; if
equipped with cams, check the integrity of the cams
Inspect scarf knife hold-down clamps and fasteners
Inspect the support rolls, bearings, shafts and lead screw adjustments
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O.D. BEAD WINDING EQUIPMENT (WHERE APPLICABLE)

Inspect the motor and gearbox; lube annually, if the units are greaseable
Inspect the fingers on the back plate
Inspect the bearing for roughness and excessive end play
Inspect the slip clutch
Inspect the end cap/plate (where applicable) that fits over the fingers
Inspect any lead rolls/guides that guide the scrap on the winder
IRONING PASS (WHERE APPLICABLE)

Most of these units are simply an inboard and outboard stand, similar in design to a forming and sizing
stand, but not driven. If your plant is equipped with this style of ironing pass, follow the maintenance tasks
outlined in the Driven Stand section. Some ironing passes are a three-roll design, with an eccentric on the
top roll for pressure. This design is also similar to a forming or sizing stand. If your plant is equipped with
this style of ironing pass, follow the maintenance tasks outlined in the Driven Stand section. In addition,
check the cam, or eccentric, adjustment.
COOLANT TANK AND COOLANT SYSTEM

This is the section between the forming and sizing stands where tube or pipe is cooled.
Inspect all support rollers, bushing/bearings, shafts and support fixtures
Inspect all lube points for broken or plugged grease fittings. If your unit is equipped with a top hold-
down rack of rolls, inspect the rolls in the same manner as the bottom support rolls and the linkage
to the top rack
Inspect the spray nozzles (if equipped); be sure the nozzles are not plugged, or missing
Inspect the valves, drains and overflows
Inspect all flex coolant lines on the mill; be sure all the lines are installed, coolant is flowing through
the lines, the connections are not leaking and coolant is being supplied to each driven, side pass,
weld roll and turkshead
Inspect the coolant pump and motor; lubricate as required
Inspect the pressure and temperature gauges (if equipped)
Inspect and service the filtration system (if equipped); depending on the design of the unit, regular
(daily/weekly) maintenance will be required, as outlined by the manufacturer
Clean the coolant tank, remove all sludge, and discard the material in a proper manner
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TURKSHEAD UNITS
The four basic designs of turkshead units are: (1) single four-roll cluster; (2) double four-roll cluster; (3) two-
roll horizontal; and (4) two-roll vertical. Some units have rotational capabilities for twist control.
Inspect the back plates; these plates slide up and down, side to side
Inspect the lead screws for excessive backlash
Inspect the tooling clevises, including the fasteners, slides and gibs; check for wear on the inside
face; check for wear in the roll shaft bore
Inspect turkshead roll shafts to verify dimensions, O.D. and shoulder location
Check the fit between the turkshead rolls and clevises if brass washers are used
Note: Consider switching from brass washers to thrust bearings on the turkshead rolls. Thrust bearings allow
the turkshead rolls to rotate easier, reducing drag on the mill drive. Also, the thrust bearings eliminate the
variable wear on the rolls and the brass washers.
Inspect the rotary adjustment (where applicable); be sure there is no end play in the assembly
CUT-OFF PRESS
There are several designs of cut-off presses used in the industry, which include: (1) single cut; (2) double cut;
(3) hot saw; (4) cold saw; (5) plasma; and (6) laser. Each design has unique maintenance requirements.
The single and double guillotine cut are the most popular designs; therefore, the generic maintenance tasks
for these two designs will be presented.
Inspect the encoder wheel and its assembly; the wheel should be flat, with no grooves
Inspect the coupling between the encoder wheel shaft and the encoder
Inspect the primary lower bed rails of the die
Inspect the upper rails on the ram
Inspect the links, bearings, and crankshaft of the swinging ram
Inspect the swinging ram for cracks
Inspect the gibs on the die (upper and lower)
Inspect the wear plates and wipers (if equipped)
Inspect the assembly of the die (sleeves and posts, slides, die clamps and all major components)
Inspect the spare dies
Inspect the brake and clutch assembly; adjust per the manufacturers recommendations
Inspect the air, oil and hydraulic lines for leaks
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Inspect the main drive motor bearings for roughness and excessive end play
Inspect the V-belts from the motor to the flywheel
If the accelerator incorporates a DC motor, perform the DC motor maintenance tasks outlined later
in this document
Inspect the accelerator drive system; check the connection shaft from the die assembly to the
accelerator
Inspect the central oil lube system for the die and related press lube points, which include the motor,
pump, reservoir and all lubrication lines
DC DRIVE MOTORS
Consider sending your DC motors to a qualified motor shop for service. The shop will clean, bake out
and meg the motor, dress the commutators, replace the brushes, and reinsulate the armatures and fields, if
needed. They will also check and replace the bearings. If you decide not to send your DC motors out for
service, conduct the following maintenance tasks:
Dress the commutator, as outlined by the tool manufacturer
Inspect the brushes; replace if necessary
Meg the armature and fields to ensure there are no leaks to ground; if either component fails the
test, the motor will have to be sent to a motor shop to be baked out and re-insulated
Inspect blower motors (if equipped); lube the motor and clean the fan blades
If the motor is direct coupled to the transmission, inspect the couplings
If the motor is belt driven, inspect the pulleys and belts
Inspect the motor mount and frame for cracks and looseness
Inspect the tack feedback generators, couplings and mounts
AC DRIVE MOTORS
AC motors are serviced in the same manner as DC motors, with the following exceptions:
There is no commutator to dress
There are no brushes to replace
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TRANSMISSIONS
There are two transmission designs used in the industry. The first is the M style, in which the transmission
is part of the inboard stand. The other design is the universal, in which the gearboxes are mounted on an
intermediate base and connected to the inboard drive stand via universal drive shafts.
The maintenance tasks for the M style transmission are the following:
Perform the tasks outlined in the drive pass section of this document
Pull the covers and inspect the inside of the gearbox
Inspect the bearings and seals; pre-load any bearings that are replaced
Inspect the gearbox vents; the vents must be clear and not plugged
Inspect the worm shaft, worm gear and transfer gears for wear
Inspect the oil transfer system to ensure oil is being delivered to the transfer idle gears for the top
shaft
Inspect the seals and couplings between gearboxes
Inspect the coupling and pulley guards
The maintenance tasks for the universal style transmission, including auxiliary two-, three- and four-speed
designs, are the following:
Inspect the bearings and seals; pre-load any bearings that are replaced
Inspect the worm shaft, worm gear and transfer gears for wear
Inspect the gearbox vents; be sure the vents are clear and not plugged
Inspect the output and input shafts keyways
Inspect the drive shafts, U-joints, spline couplings, and welded tubing between these components
Check the drive shaft timing: floating joint to floating joint, fixed joint to fixed joint; incorrect timing
will result in variable speeds of the driven stands and the tooling installed on those stands
Run out and dump tables (if equipped)

Inspect all carry out rollers
Inspect the shafts for excessive wear
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Inspect the dump feature related components: arms, linkages, cylinders, flag switches or encoders,
and back stop rails
Inspect the accumulation table components: collection rails, stops, conveyor belts, drives
SUMMARY
The importance of regular and preventative maintenance cannot be overemphasized. Remember, a properly
maintained tube, pipe or rollform mill not only extends the service life of the tooling and machinery, but im-
proves overall product quality. To assist our customers with their maintenance tasks, Roll-Kraft offers a full line of
services that include mill evaluation, mill alignment, mill maintenance consulting and in-house training.
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LUB RI CA TI O N CHECKLIST
LUBRICATION CH ECKLISTFOR
F ORTUBE,
TUB E,
PIPE PI PE
AND A N D ROLLMILLS
ROLLFORM F ORM M I LLS
100 HOUR TASKS

Task date
Actual Time
Mill Components (Grease)
Driven stand bearing blocks (inboard)
Driven stand bearing blocks (outboard)
Side roll passes
Entry guide
Seam guide
Turkshead
Driveshaft universal joints (W style mills)
Upper lead screws (top shaft adjustment)
Coolant tank support rollers
Run out table rollers
Looper/Floop accumulator
Payoff reel bearings (greaseable style)
Gearboxes
Check the oil level
Check for oil leaks
Check the oil level
MG Sets
Check the oil level (wet bearing cups)
Cut-off Presses
Grease the lube points
Check the lube system oil level
Hydraulic Accelerator Systems
Check the oil level
Check for oil leaks
Air Line Oilers
Check the oil level
NOTES:
Place maintenance mechanic initials in each box next to the specific task when that task is completed
Task date is the date the lubrication is performed
Actual time is the time interval, in hours, when the task is performed (recommended interval is 100)
Black spaces provided in the Mill Components section is for auxiliary equipment not listed
LUBRICATION CHECKLIST FOR TUBE,
PIPE AND ROLLFORM MILLS
2,500 HOUR TASKS

Task date
Actual Time
Drive Line Couplings
Lubricate
Electric Motor Bearings (Grease)
AC motors
DC motors
Coolant pump motor
Rotary transformer (ERW welders)
Fan motors
Hydraulic motors
Gearboxes
Check the oil level
Check the oil level
MG Sets
Check the oil level (wet bearing cups)
Lubricate (greaseable designs)
Hydraulic Accelerator Systems
Change oil
Change oil filter
NOTES:
Place maintenance mechanic initials in each box next to the specific task when that task is completed
Task date is the date the lubrication is performed
Actual time is the time interval, in hours, when the task is performed (recommended interval is 100)
Black spaces provided in the Mill Components section is for auxiliary equipment not listed
CHAPTER 2
Profit Pointer for Tooling Management
& Maintenance Programs
A properly employed tooling management and maintenance program will go a long way toward improv-
ing your overall performance. The first step is to create individual files for each set of tooling in your shop.
These files contain all the necessary information required to maintain your tooling in top condition.
Many shops have a difficult time starting and maintaining a tooling management program. However, it is
really not that complicated as you will see by reading through the following steps. Firms that have estab-
lished such a program have accurate control over their tooling costs and needs. They are able to predict
tooling wear and schedule rework and production accordingly. By continually monitoring your tooling with
such a program, your tube and pipe production will operate more efficiently at a lower net cost.
II. STARTING YOUR FILE

A separate file should be set up for every set
of tooling in your shop. This is true for partial
sets, as well as complete sets. The following
items should be included:
Prints of the Tooling Setup Chart
Rework records
Rim clearance sheets
Tooling inspection reports
Rework cost record sheet
Lets examine each of these six items to under-
stand their importance in your tooling mainte-
nance program.
III. PRINTS OF THE TOOLING

Figure 1 is a typical tube roll print. As in any
manufacturing operation, the print lists much of the basic information about the process, in addition to the
dimensional data of the tooling itself. For a particular tubing size, all of the prints, from the entry table to
the exit, should be included in the file. The prints will list information that is helpful during setup, along
with the following: gauge range, rim clearances, tube size, roll width, roll O.D., keyway size, bore size,
spacer length, and metal line of weld and side rolls. Bearing make and model numbers are also listed if
bearings are required on the mill.
IV. TOOLING SETUP CHART

Your setup chart includes all the specifications required to properly set up your tube mill. Roll-Kraft includes
24
a laminated setup chart (see Figure 2) with each

set of tooling that it supplies. Adjusting your mill
according to the data listed on the chart (rim
clearance, tube size, spacer length, etc.) will
ensure that every pass, driven and idle, will
properly form the strip as it advances through the
mill. Settings, identifications and specifications for
auxiliary equipment should also be included on
the setup chart.
V. REWORK RECORD
This record tells the history of your tooling. The
most important data is the tooling size (1) new;
(2) before rework; and (3) after rework. Figure
3 illustrates a typical rework record as provided
by Roll-Kraft. Revisions made to the tooling will
also be recorded on this sheet. This would include such items as replacement of severely damaged rolls,
rechroming and side grinding. These modifications will affect the readjustment of the mill when the tooling is
reinstalled. The information taken from this record is used to: readjust the mill to maintain the bottom or met-
al line; make shims for universal stands; lower side roll stands; calculate rpm for mills with multiple drives;
and make new spacers for rolls that have been side ground.
VI. RIM CLEARANCE SHEETS

Record rim clearance before the tube is run out of
the mill at the end of every run. By plotting this data
on the Rim Clearance Sheet (see Figure 4), you will
be able to determine if the setup was maintained
through the entire run. As the tooling wears, you
should see an even decrease in rim clearances. If
this decrease is not even throughout the mill, one or
more passes may be adjusted incorrectly. Studying
the data on the rim clearance sheet should enable
you to pinpoint the passes where the problems
exist. Left uncorrected, tube quality suffers and roll
life between reworks is diminished. An additional
25
benefit of this chart is using recorded data

to assist in mill setup the next time that
particular size of tubing is being run. Simply
put, you start up where you left off. If setup
was maintained during the last run, the
clearances of each pass as recorded can
be used for setup, thereby saving setup time
and reducing expensive scrap.
VII. TOOLING INSPECTION REPORTS

Another important element of a well-man-
aged tooling maintenance program is con-
sistent data from your own tooling inspec-
tion. Tooling should be inspected between
each run with measurements, notes and
comments recorded on an inspection report
similar to that shown in Figure 5. While
you can be as thorough as you wish with
your inspection, one parameter that must be
measured and recorded is the throat diam-
eter of each roll. As with the rim clearance
data, throat diameter measurements can be
analyzed to determine whether a particular
pass (or passes) is working too much. Throat
diameter wear should be progressive, in the
same manner as rim clearances. Excessive
reduction in throat diameter indicates an
overloaded pass. A similar reduction in rim
clearance will be seen for that specific pass
on the rim clearance sheet as well. Identify-
ing abnormal wear through the use of your
tooling inspection reports enables you to
confirm and correct problem areas before
the next run.
26
VIII. REWORK COST RECORD

The final form recommended by Roll-Kraft
for your tooling maintenance program is the
rework cost record (see Figure 6). This form
lists which tooling has been reworked; (1)
when the rework was done; (2) the footage
obtained; and (3) the cost of the rework.
Analyzing this data will show you the actual
cost of reworking your tooling and allow
you to predict product footage and when
the tooling will require rework. The rework
cost record has many obvious benefits.
It will clearly show the additional cost of
unexpected rework of overloaded passes.
To bring overloaded tooling back to spec
requires special rework and increases total
cost. Using tooling beyond the recommend-
ed rework point not only results in excessive
tooling wear and the subsequent increase in special rework costs; it decreases the tooling life as well.
Overloaded tooling adversely affects the quality of the tube and increases the amount of scrap. The data
can be further analyzed to determine the actual manufacturing costs per foot of tube. This detailed informa-
tion is invaluable when establishing budgets and projecting production levels.
SUMMARY
A properly organized maintenance file is of the utmost importance in managing your tooling efficiently.
When all data is collected and analyzed, it becomes possible to accurately predict rework schedules. This
ensures smoother production, faster setup, longer tooling life, a higher quality product and greater cost
efficiency. In todays fast-paced global market, keeping pace is an achievement in itself. Implementing a
tooling management and maintenance program allows you to step out ahead of your competition and set
the pace!
27
CHAPTER 3
Roll Tooling Cleaning Procedures
In order for roll tooling to function properly, its necessary to ensure that your tooling and mill are free of
excess grease, oil, dirt and other substances that can affect performance. In this chapter, we will provide
some cleaning dos and donts, along with some standard cleaning procedures.
CLEANING THE TOOLING

At Roll-Kraft, we recommend using cleaning tanks that are serviced by companies such as Safety-Kleen to
remove grease, oil, dirt and other contaminants from the rolls as they come in. There are even higher-end
cleaning processes, such as ultrasonic cleaning and hot water detergent pressure washers (similar to large
and powerful dishwashers) that can get the job done as well.
To begin, the tooling is normally wiped down dry with rags so that it is not slippery. Many of our customers
will polish their tooling to remove pick-up. While there is some benefit to this, care absolutely must be taken
not to damage the rolls. No matter how skilled you are at polishing, or how carefully you remove material
when you polish, any cleaning of the tooling will wear down that tooling to some degree. In this regard,
cleaning is a bit of an art. Do not use materials such as aggressive sandpaper to polish the tooling; your
tooling may look spectacular as a result, but its likely youll ruin the roll in the process by changing the
contour and flaring it out. Well say it again: Cleaning must be done carefully.
For polishing purposes, you can use a Scotch-Brite padScotch-Brite will not score the surface of the
hardened roll tooling, but it will successfully remove the light pick-up that can be found on the roll tooling.
There are times when there is heavier pick-up on the tooling. In these cases, we recommend using nothing
more aggressive than 150 grit emery cloth. If you can remove that pick-up using a finer grit such as 240,
that really is best. In fact, thats what we use to finish the rolls here at Roll-Kraft. If you use a more aggres-
sive emery cloth, then you will probably create scratches that will only lead to more pick-up.
VERY IMPORTANT: Do not attempt to clean tooling while the mill is running. Tooling should only be cleaned
when it is removed from the mill for a change-over.
CLEANING THE MACHINE ACCEPTABLE PROCEDURES AND CLEANERS

If you utilize mills that run coolant on their tooling, you can hook up a pressure washer to the coolant lines
and use that to clean the tooling/mill as it is running. Using coolant from the mill does not add any water
to the coolant system so as to dilute it.
For mills that run dry with no coolant (like most roll formers do), we recommend simple common sense when
wiping down excessive grease that may ooze out of the bearing blocks. To that end, we recommend using
29
cleaners such as Simple Green to clean the rest of the mill components when the mill is down and not run-
ning. Simple Green will cut the grease; its environmentally friendly; and its available at many retail stores.
Additionally, for those mills that incorporate coolant, it wont upset the chemical balance of the concentra-
tion. Fresh water is fine, but it wont do much to cut the grease on the mill. And, if you use just water, it will
likely dilute the concentration of the coolant. We do not recommend using petroleum solvents, as they are
not environmentally friendly. While petroleum solvents may cut grease effectively, they will contaminate and
upset the chemical balance of the coolant.
In situations where you get flaking of material, paint or other substances from the product line as it is being
formed, it can be cleaned using an industrial vacuum after the mill is shut down.
BASIC POLISHING PROCEDURES

Below are some basic polishing procedures we recommend, along with accompanying photos.
Properly line up the roll on the This picture shows pick-up on the Use emery cloth - 150 grit, and
machine. roll. wrap it around a back-up bar.
Polish the roll with even strokes, Use emery cloth 240 grit, and Polish the roll with even strokes,
back and forth on the contour, with wrap it around a back-up bar. back and forth on the contour, with
150 grit to remove the pick-up. 240 grit to remove any scratches.
30
Add very little oil to the rag. Very slowly polish the roll with Finished polished roll.
even strokes back and forth to
bring out the luster.
31
CHAPTER 4
Tube and Pipe Tooling Maintenance
When to Send Tooling in for a Rework
How will I know when my tube and pipe tooling needs to be sent in for rework? The answer can be
summed up in one word: performance. Obviously, the goal is to send in the tube and pipe tooling for re-
work before it can no longer perform as needed. Performance factors include the ability to hold tube size,
straightness and product quality.
Each producer needs to establish a threshold for when their tube and pipe tooling needs to be sent in
for rework. Some may earmark footage as a threshold. The only way this method is useful is if the same
gauge and the same type of material are run day after day. However, most companies run a wide variety
of gauges and material types. The heavier gauges and more abrasive materials will wear the tooling more
quickly than their lighter gauge counterparts.
There are several roll dimensions that can be checked for wear that will give you this threshold. When tool-
ing needs to be reworked, this threshold needs to be incorporated with the production mill reports which, in
turn, can be used to monitor the toolings performance.
Which of these dimensions will indicate when a roll set needs to be reworked? One dimension alone will
not answer this question. The throat diameter, condition of the contour, and bore and face wear are all
areas to look at collectively.
One primary dimension to check is the throat di-

ameter (along with tracking rim clearances), which
can be used for the next setup. This dimension
is normally measured by using a blade or ball
micrometer.
Another wear indicator is the contour (radius) of

the roll. Why the contour? The throat diameter
could have a minimal wear of only .001; yet you
could have a contour problem where the sides of
the radius are blown open or flared out. This
condition would necessitate a rework because of
the inability to hold ovality on a round tube size.
There may also be some pits or nicks in the con-
tour that are causing unacceptable marking.
33
Tube and Pipe Tooling Maintenance
When to Send Tooling in for a Rework
Contour inspection is a good way to see if the tooling has been set up and used properly. For example, if
the contour is worn on one side more than the other, this indicates that something might have been wrong in
the setup of the tooling, or there may be a mill alignment problem. Disc gauges and templates are the most
common devices used to check roll contours for wear.
The bores and faces of the tooling are also important

attributes to monitor. An excessively worn bore may cause
issues on the mill that could lead to damage to the O.D.
of the driven shaft. If you have this movement going on
between the O.D. of the shaft and the I.D. of the roll, the
faces of the roll will become worn along with the spacers.
This will start to affect the alignment of the tooling on the
driven shafts. These problems can be remedied by chrome
plating then grinding the bore, side grinding the affected
faces back to the original dimensions, and manufactur-
ing new spacers to make up the difference in width. The
general rule for bore wear is for every inch of bore you
are allowed .001 wear. For example, wear on a 2.000
bore should not exceed .002. Any bore exceeding this general rule should be chrome plated, or the roll
should be replaced (depending on which option is more cost effective).
Once you start a maintenance program for inspecting the tooling between runs, it is simple to establish a
threshold that will fit your operation. As you document these inspection measurements as we have outlined
in this article (and your quality standards for finished tube or pipe get to within 90% of your maximum allow-
34
able tolerance mandated by the quality standards set by your customers), you can then establish a threshold
for sending us your tooling for rework.
Once established, you can then predict how much life is left in any roll set at any point in time, eliminating
the guesswork of when to send your tooling to us for rework.
A proper tooling maintenance program will ensure maximum tooling life, minimize costly downtime, and
produce a top-quality end product.
35
CHAPTER 5
The Importance of a Properly Maintained PM Program
for the Tube, Pipe and Roll Forming Industry
In the tube, pipe and rollform industry, just like any

other industry with machinery, a properly maintained
preventative maintenance (PM) program will help pre-
vent issues from arising that will cause machine failure
and downtime.
However, all too often, we find our best intentions

of maintaining a formal PM program can go astray
and quickly fall into crisis management mode, where
the equipment or machine is only fixed when it totally
breaks down.
This is usually because we feel the pressure of produc-

tion pushing the envelope of our available time to do
proper PMs on the equipment.
Unfortunately, this type of practice can cost us much more in the long run, and many times, breakdowns can
happen at the most inopportune time when production is very demanding.
There are two things you will never get back:

The opportunity.after it is missed
The time..after it is gone.
So how do we get a proper PM program in place, and how do we keep it maintained?
37
The Importance of a Properly Maintained PM Program
for the Tube, Pipe and Roll Forming Industry
Lets go over some key points to achieve this goal:
Outline the needs and requirements of the equipment you need to maintain
From that list above, outline the frequency of the maintenance that needs to be performed; for exam-
ple, grease the machine every 100 hours, change oil in the gear boxes every 2,500 hours, etc.
Create a check-off list for the required PM so nothing is missed
Conduct an audit every so often to ensure the boxes on the check-off list are not just being crossed
off without the required areas actually being checked or serviced
Schedule regular intervals for the PM program so your sales/production can work around this time
frame. This would be no different than working around a holiday or a plant shutdown
Stick to your guns in regard to maintaining your PM program. If you even let one excuse interrupt
this plan, it can quickly lead to a breakdown in your entire program, and ultimate failure of the
same
Numerous studies have shown that a properly maintained PM program does pay off in the long
and short term of any operation that depends upon machinery to produce its product
38
Conclusion
FREE Mill Evaluation:
We Will Operate On Your Tube Mill, Pipe Mill, or Roll Forming Mill On-Site
If you are having issues with production but cant pinpoint the exact problem, why not contact Roll-Kraft
and get an unbiased opinion? Just ask about our free tube mill, pipe mill, or roll forming mill evaluations.
Here is how to receive a free mill evaluation: Start by sending us a detailed description (video, audio,
and/or written) of the specific area you would like us to evaluate.
Our professional hands on technicians will evaluate all the equipment of your mill operation. You
will receive a detailed written report outlining all the particulars of the findings, along with resulting
recommendations.
Use our contact form to request more information about our free initial mill evaluation.
On-Site Mill Evaluation

In addition to our free mill evaluations, we also offer on-site mill evaluations. On-site evaluations really
make an impression with your staff, confirming you are serious about producing quality tube, pipe, and
rollform products. Our technicians will tell you exactly where you are currently doing a great job, in addi-
tion to pointing out any areas that could be improved. We have been doing training and evaluations for
over 30 years and understand the sensitive nature of bringing someone in to talk about improvements. Your
staff will be in good hands with Roll-Kraft.
Visit us at www.roll-kraft.com or call us at 888.953.9400 to learn more about how you can take your
tube and pipe or roll forming mill operations to the next level.

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EMPLOYEE TRAINING AND DEVELOPMENT

Preventative Maintenance Programs

THE E-BOOK IS ORGANIZED IN FIVE CHAPTERS:

2. Profit Pointer for Tooling Management & Maintenance Programs

3. Roll Tooling Cleaning Procedures

Conclusion: FREE Mill Evaluation

Robert A. Sladky, V.P. of Tube Mill Engineering

DRIVE LINE COUPLINGS

ELECTRIC MOTOR BEARINGS

Rotary Transformers (ERW Welders)

HYDRAULIC ACCELERATOR SYSTEMS

AIR LINE OILERS

CENTRAL LUBRICATION SYSTEMS

End Welding Equipment Central Lubrication System

Accumulator Looper Style

Verify that the top shaft is parallel to the bottom shaft

Side Pass Stands

Seam Guide (if applicable)

Weld BoxesERW Type

WELD BOXESHF TYPE

ERW Rotary Transformer

HIGH-FREQUENCY (HF) WELDER COMPONENTS

O.D. BEAD WINDING EQUIPMENT (WHERE APPLICABLE)

IRONING PASS (WHERE APPLICABLE)

COOLANT TANK AND COOLANT SYSTEM

Run out and dump tables (if equipped)

100 HOUR TASKS

2,500 HOUR TASKS

II. STARTING YOUR FILE

III. PRINTS OF THE TOOLING

IV. TOOLING SETUP CHART

a laminated setup chart (see Figure 2) with each

VI. RIM CLEARANCE SHEETS

benefit of this chart is using recorded data

VII. TOOLING INSPECTION REPORTS

VIII. REWORK COST RECORD

CLEANING THE TOOLING

CLEANING THE MACHINE ACCEPTABLE PROCEDURES AND CLEANERS

BASIC POLISHING PROCEDURES

One primary dimension to check is the throat di-

Another wear indicator is the contour (radius) of

The bores and faces of the tooling are also important

In the tube, pipe and rollform industry, just like any

However, all too often, we find our best intentions

This is usually because we feel the pressure of produc-

There are two things you will never get back:

So how do we get a proper PM program in place, and how do we keep it maintained?

Lets go over some key points to achieve this goal:

On-Site Mill Evaluation

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