Professional Documents
Culture Documents
Intermediate Diaphragm
ADDRESS
CHRISTIAN PFEIFFER MASCHINENFABRIK GmbH
Werkstrasse 5
A-8940 Liezen, Austria/A-8940
1. Safety instructions
3.1 General
3.2 Assembly operation
3.3 Assembly of tear off bolts
3.4 General guidelines for assembly welding
4. Assembly tools
5. Assembly staff
6. Spare parts
1. Please support all efforts for a safe and healthy working environment.
2. Always act conscientious and with great attention when your personal and others safety is concerned.
3. Check regularly all safety equipments and the complete tools with regard to completeness, safe
function and handling.
4. Inform yourselves and others about risks which are related to your work in order to avoid efficiently
any risk.
5. In order to avoid any injuries to persons and to machines, inform yourselves about risks and safety
matters if you have the feeling that your knowledge is not sufficient.
6. Always bear in mind risk of injuries and accidents before starting a new job. Develop reasoned safety
measures in order to protect yourselves and others. Check these security measures regularly and
carry out necessary improvements immediately.
7. Warn others of possible risks and damage if you are about to perform risky works or generate risk of
accidents.
8. Pay attention to modifications of the work conditions and the work procedures and adapt immediately
to the new situation.
9. Accidents, risky actions and dangerous conditions and processes which have almost led to accidents
must be communicated immediately to the superintendent. Please do not assume someone else will
do this! Please do not take any narcotics, strong medicine etc, and do not dring when operating a
machine or performing maintenance works on a machine resp. prohibit any narcotic and alcohol
intake during the working time.
10. Keep your working environment clean. Tools and aids must be collected after use and stored in the
designated area.
All emergency telephone codes must be communicated to the assembly staff and deposit near to the
phone.
In case of physical injury, attend to the injured person and call immediately a doctor or another
paramedic.
For lifting heavy charges (above 25 kg) only use certified lifting devices with corresponding charges.
Never stand under lifted charges and check all lifting devices before use with regard to damages and
sufficient lifting capacity.
Never modify or remove safety and accident prevention devices and keep in operation safe condition.
Maintenance works have to performed in switched off mode and secured against unintentional
start-up of machine (block main switch).
For specific operational phases and maintenance works as well as eliminating mal functions go sure
that:
- the operating personnel has been informed before beginning special operations and
maintenance works;
- the machine/plant is completely shut down for maintenance and repair work, locking the
principal control elements resp. removing the ignition key and attaching a warning sign to the
main switch;
- only suitable and technically perfect lifting gear and suspension systems with adequate lifting
capacity are used;
- for carrying out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms;
- you never use machine parts as a climbing aid;
- you always tighten any screwed connections that have been loosened during maintenance and
repair;
- any safety devices removed for set-up, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work;
- all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
The high quality requirements on product as well as on the mill internal equipment have formed the
process technological and mechanical design development of this intermediate diaphragm.
The PFEIFFER Intermediate Diaphragm can be adjusted and controlled according to the special
requirements of the grinding process.
This is possible due to a system for material flow control integrated in the diaphragm centre.
All diaphragm components can be brought into the mill either through the manhole or the inlet trunnion
bearing. In the mill, all segments of the support structure are carefully bolted and welded, thus avoiding
wear by movement in the support structure.
3.1 General
All parts of the intermediate diaphragm (e.g. fastening ring, steel plate etc.) are marked with figures.
Their sequence and correspondence with the before mounted elements must be observed.
Before starting assembly you should make sure that all parts according to the parts list are available
and are lying before the mill tube.
For a perfect assembly operation it is absolutely necessary that the mill tube can be turned.
Before starting the assembly of the intermediate diaphragm, 1 - 2 rows before and behind the
diaphragm have to be disassembled. The ovality of the mill tube has to be checked and if necessary to
be corrected to assure a perfect fit of the fastening ring of the intermediate diaphragm.
(all pictures and illustrations of this assembly instructions must not correspond with the actual design oft he diaphragm. Only the
supplied assembly drawing is binding).
Take care that a full seating of the cylindrical part of the fastening ring segment on the mill tube is
ensured.
A regular alignment of the rims of the fastening ring segments is necessary.
The steel structure has to be assembled according to the sequences marked on the fastening ring and
the steel plate and as well the arrangement on the drawing
Bolt the steel plate segments with the tear off bolts and the accessories (please refer to assembly
drawing for number and sizes) for later adjustment of the single segments.
Finally fix the steel plate with the fastening ring by welding.
Assembly cover plates are replaced against the remaining tie pieces.
Bolt the lifters according the markings on the parts with the tear off bolts and the accessories (number
and sizes according to the assembly drawing) to the steel plate for later adjustment.
Schaufel
Adjust the lifters and tighten the tear off bolts and tear off the square heads.
Put one segment of the ring cover plate into the hollows
of the rims and secure against dropping out.
.
The arrangement of the steel plate cross segments is indicated on the assembly drawing. The steel plate
cross segments are provided with swages for fastening of the tear off bolts with the accessories (number
and size are indicated in the assembly drawing) on the fastening ring resp. the segment of the ring cover
plate.
The steel plate cross segments must be bolted for later adjustment.
Further to this, through holes in the outer area of the steel plate cross must remain free - if required -for
the fastening of the filling pieces and as well in the inner area for fastening of the central pieces.
Thereafter put the remaining segment of the ring cover plate into the lifters and bolts to the steel plate
cross segments for later adjustment of each segment.
The same procedure will be performed between the steel plate cross and the fastening ring.
If drillings of the steel plate cross do not correspond to those of the fastening ring, only trim the drillings in
the fastening ring.
Adjust all parts, tighten firmly and tear off the square heads of the tear off bolts.
In order to avoid erosion by circulating material, the fastening ring should be sealed with a sealing cord
between steel plate resp. steel plate cross and mill tube (please refer to drawing).
Welding consumables are necessary for the welding works. Quantity, types and technical data are
indicated on the drawing:
- Weld the lifters with the steel plate and steel plate cross and fastening ring.
- Weld the fastening ring on the points of impact and as well weld the rim segments of the fastening
ring with the steel plate and the steel plate cross.
- Weld the segment of the steel plate on the points of impact (only 2nd compartment side).
- Secure all nuts against loosening by welding with the bolt pins.
weld
After welding grind off projecting welding seams as well as the remnants of the torn off square heads of
the tear off bolts on the front side of the steel plate and the steel plate cross, so that the backside lining
plates and the central pieces have a smooth surface.
Number of filling pieces as well as quantity of fastening material are indicated on the assembly drawing.
filling pieces
backside plates
Start with the assembly of the filling pieces.
Sequence of assembly from outside to inside.
Bolt the segment of the material flow control with the tear off bolts and the accessories (number and size
according to assembly drawing) on the central pieces. Bolt the central pieces with bolted material flow
control segment with tear off bolts and accessories (number and sizes according to assembly drawing)
considering the markings on the steel plate.
Make sure that the guide plates of the material flow control are connected to the long lifters.
Tighten the tear off bolts and tear off the square heads with the special socket wrench.
Number of the filling pieces and the central pieces as well as the number of the fastening material are
indicated on the assembly drawing
Filling
pieces
Slotted plates
Central pieces
Bolt the protection grate halves by the hex. bolts and the safety disks on the holding of the material flow
control.
.
It is absolutely necessary to tighten tear-off bolts until the square heads tear off.
To tear off the square heads the following tools can be used:
- long-handled wrench
- impact wrench
- slugging wrench
It is important that the square head is torn off. The square head should not be knocked off or burned
off. When tightening the bolts the following minimum torques must be reached:
M20 550 Nm
M22 700 Nm
M24 800 Nm
M30 1000 Nm
Setting time of the two-component adhesive is twenty minutes. Bolts must be completely tightened
within these twenty minutes.
If bolts are not tightened within twenty minutes the following problems will occur:
- The nut is fixed to the bolt and can no longer be tightened.
- The square head tears off before reaching the necessary torque.
Consequence is:
Slotted or backside plates are not properly fastened to the support structure. This results in mill
operation with loose and vibrating plates. At the same time the risk of breakage and damage to the
bolt holes of the support structure is increased.
1. The welder should have the requested qualifications according to EN 287-1. If qualified welders
are not available, manual skill and qualification have to be checked before starting manufacture
by corresponding test welding.
2. Filler metal
Only weld vacuum packed electrodes. Open electrode parcels must be welded within 6 hours. If
electrodes are not packed or stored correspondingly, it must be redried according to producer’s
instructions. Certificate of producer according to EN 10204-2.2 has to be delivered by the
supplier (analysis).
3. In case of temperatures lower 10°C it is advisable to preheat the welding grooves with a burner,
if possible.
If during welding condensate arises, in any case preheat with a burner resp. dry the seams with
a burner before starting welding.
4. By experience endangered welding and seam points must be checked, if possible, after
finalization of welding by PT or MT. Fissures or lacks of fusion generally must be ground out or
jointed out or rewelded.
8. Welding sequence:
During welding sequence consider the dimension and bulkyness of the work piece, so that an
ideal welding sequence only up to a point is possible!
Proposal:
After introduction of assembly parts like ring segments, backside parts, lifters and cross parts
tack the lifter diaphragm.
The tacking length should be at least 5 cm lg.
Generally:
1. at first totally weld the root
2. then weld out
Cracked weld tackers and root fissures must be welded out or jointed out, if necessary.
Overwelding is not allowed.
b) The lifter- and cross piece weldings have to be made in sequence. It is not meaningful
to determine an exact sequence of welding due to bulkyness of piece. But in any case
the parallel welding operation should be maintained to prevent unequal diaphragm
shrinks and shiftings.
c) Finally make the circumferential seams in the outer diaphragm area. Maintain parallel
welding operation (or in quadrants).
9. Make the indications of welding seam dimension according to drawing. Control cross-sections
at work piece. Utilize the multiple layer welding (stringer bead).
Single-run pendulum welding on butt seam and hollow seam is not allowed.
Further take care for sufficient welding gap in the grooves (rim distance) to keep low the shrink
strains in the seam cross-sections
5. Assembly staff
Ø 2,00m – 2,60m 5 4 3
Ø 2,80m – 3,40m 6 5 3
Ø 3,60m – 4,20m 7 6 4
Ø 4,40m – 5,00m 8 6 4
6. Spare parts
• CPB-Order number
• Technical item according to spare parts drawing
• Descriptions out of the spare parts lists
• Quantity of the parts to be delivered
Spare parts must correspond to the technical requirements determined by the manufacturer.
This can always be assured in case original spare parts are ordered!
Address:
Internet: www.christianpfeiffer.net
E-Mail: office@christianpfeiffer.de