Vertical Roller Mill Maintenance Training FLSVRMOO1Training Manual Disclaimer General: ‘This Training Manual is for training purposes, and is only intended to introduce the student to concepts relating to the operation and use of equipment furnished by P.L.Smidth Inc FLS”). The information contained in this Training Manual will not be automatically updated. Unless otherwise specifically informed by FLS’ trainer (and then only to the extent so informed), the Training Manual and operational training provided by FLS are not intended to be a substitution for and are not a substitution for any training required by law, code or regulation, including but not limited to MSHA and OSHA. When actually operating or maintainin, equipment furnished by FLS, consult with and utilize the operation, maintenance and instruction manuals and other documentation furnished for use with such specific equipment. Further follow all safety policies and procedures established by your employer: Warning: All warnings, cautions, and notes contained in equipment operatis maintenance, and instruction manuals and all jobsite safety policies and procedures established by your employer must be closely adhered to and followed to avoid or minimize the risk of serious personal injury and/or property damage. Please note that this Training Manual is not a contract or an agreement, This manual and all training are being provided pursuant and subject to the terms, conditions and other parts of the contract between FLS and the purchaser of the Training Services. Nothing in this manual is intended to modify, amend or replace any part of that contract. Use of Training Materials This Training Manual and all information that it contains is the proprietary and confidential property of F. L. Smidth, Inc., and is intended solely for the use of the student to whom it is provided by F.L.Smidth Inc. No part of this Training Manual may be duplicate provided, directly or indirectly, to any third party without the prior written consent of F. L ‘Smidth, Inc disclosed orFL DTH Vertical Mill Training Manual TABLE OF CONTENTS Page Fuller Roller Mill for Vertical Grinding 1 FRM - Grinding Table Assembly 34 FRM - Grinding Rollers Assembly 50 Hydro-Pneumatic Spring System 89 Grease Lubrication System 4112 RAR Separator 125 Atox Vertical Roller Mill 130 RAKM - LVT Separator 204 Posimetric Feeder 2 OK Mill 218 OK Mill Roller Assembly 249 Lubrication Unit 253 Tire Segments 255 Rocker Arm Assembly 256 Grease Lubrication System 267 ROKS Separator 302 Rotary Sluice Feeder 314[Eomiorn FRM Vertical Mill for Raw Grinding[Esmorw Vertical Mills Supplied by FLSmidth [Esmiorn Safety[emo [Eomiorn Lockout/Tagout 1, Isolate the Mill from the System Make a plan for your particular system and lock out all equipment affecting the mill Lockout/Tagout 2. Lock out the Mill and Auxiliaries Mill fan Preheater/kiln 1.D. fan Dust collector fan Mill isolation dampers (closed) Hot gas generators Mill feed system Material re-circulation system CO, systems (coal mills) Mill motor Separator Hydraulic System Water spray systems Flap valves Lubrication systems[smiorm Lockout/Tagout 3, Take Confined Space Precautions + Check Oxygen Levels + Check for Combustibles Check for Toxic Gas (CO) + Work in Pairs + Block Open the Mill Door + Ensure Safe Egress Ebmiorm Getting Trapped Inside + If the fan were to start the door would pull shut and the would hold it closed. Block the door open when working inside Account for all persons before closing doors.[emir Pinch Points + Be aware of pinch points when raising or lowering rollers or when turning the table. [smo Hydraulic Safety ‘Accumulator “ + Accumulator will maintain high pressure in the system even after the pumps are stopped. Always bleed down the system manually before performing maintenance.[smo Hydraulic SafetySeparator Feed Inlet Chute Gas inlet Duct [Eomiorn Gas and Material Flow + Raw material enters onto the center of the rotating grinding table where it Is thrown out and ceushed beneath the roller. High velocity gas coming up around the table carries material to the separator and out the exit duct. The hot gas also dries the material Gas and Material outlet Duct Mil Body Gas inlet Duct[bmiorn Mill Feed Proportioning Raw material Bins Sampler GUUG pm ae _ fore Feeder set points [smi Weigh feeders By controlling the speed of the weigh feeders, the proper proportion of materials are put onto the mil feed bet.[emo Seal Bin Airlock [Bsmiorm Wear PartsEsmorm Mill body seal for the grinding roller + Circular seal that is bolted to the racker arm and is held to mill body by mill suction [Esmiorm Roller Swing-out Swing-out —_| Cylinder +The FRM features rollers that swing out for easy maintenance. "[smo Wear Parts + Most mill maintenance al with replacement of the grinding parts. The frequency of replacement will depend on t properties EEsmom Tire Wear — follersi Original Weight 6801.25 ibs Final Weight 1699.76 Ibs 75% material consumed, wear rate lbs per ton of raw meal Produced. Actual wear rate depends on abrasiveness ay material[smiorm Tire Wear + Once the hub becomes exposed it is necessary to change the tires Tire change may also be necessary to maintain the mil's output. Esmiom Tire Wear + When tires become very thin, inspect frequently to detect cracks which can lead to hub exposure.[ismorm Cracked Tire Tires are very hard but also very oritte, This tire after rapid cool-down with the mill water spray [Bsmiomm Tire Removal Hex Nut with Tire nping Ring + With the roller assembly in the swing-out position the tire cen be removed from the hub[Esmiomm FRM Roller Hold-down Studs, Holes for Liting + Remove the nuts from the clamping ring hold down studs. The ring can then be lifted off. [smo Tire Lifting Fixture + Once the clamping ring is removed the tire can be lifted off the hub using the lifting fixture.[Esmiorn Installing Mill Tire it Up So as not to cock the tire on hub. Tire Lifting Fixture + hack TS ting 5+ The new fixture improves on the older 3-hook design Esmiom Table Liners ee = +A ting of table ters conetutes the “gnaing path.Table Liners The segments of the grinding path are made of high chromium cast iron. [smiom Table Liners (underside) + The liner underside is designed to seat flush on the grinding table s bending forces which could[smorm Worn Table Liners + Liners can be worn down to 25% of the original metal. However liners are usually changed before that since the mill production rate goes down with liner wear. Table Liner Installation + Liners are replaced in a complete ring comprised of a number of segments.[emir Table Liner Installation Top surface of table should be swept clean of all rocks, dust other material that would prevent grinding ring segments from setting flat against the outer 2. Grinding ring segments must be pl rim of the table and pushed together leaving two radial gaps 180° apart: 3. Install clamping ring segments and bolts. (Do not fully tighten bolts at this time). + Important: each clamping ring segment must clamp only fone (1) grinding ring segment. [morn Table Liner Installation Never weld lifting eyes ghly brittle + Segments are rigged with stir onto a liner as it will cause crack[Esmiorn Table Liner Installation 4. Inspect the placement of each grinding ring segment to make sure that the clamping ring segment does not contact two grinding ring segments. If contact does occur, rearrange grinding ring segments to add radial gaps. + Recheck for contact after the addition of each gap. + Gaps should be approximately equally spaced and equal in size. Recommended minimum size of gap Is 12 mm (1/2 inch) to allow for removal of backing compound when removing segments. + Use the least number of gaps possible without the clamping ring segments contacting adjacent grinding ring segments. [smo Table Liner Installation + Lay out the ring with even space between the segments,[Esmiorm Table Liner Installation hten clamping ring bolts to specified torque. Torque the bolts again until none of the bolts turn. 5. Fill gaps completely with backing compound. Before pouring backing compound, it is essential the voids which will permit leakage to other areas (particularly below chamfer on outside diameter, and below clamping ring at inside diameter) be plugged with putty. + If the backing compound is allowed to leak, the grinding ring segments will be very difficult to remove. 7. After the mill start up, torque the clamping ring bolts once a week for the next two months. Make sure to check to see if any of the bolts move when torquing [Esmorm Table Liner Installation + Lay out the clamping ring with one clamping segment for ‘one liner segment.[omiorn Table Liner Installation 8. Then torque the clamping ring bolts once a month. Make sure to check to see if any of the bolts move when torquing. 9. Inspect the backing compound between the liner plates once a month and install new backing compound if the existing backing compound wears out. EEsmom Table Liner Installation + Clamping ring segments must not overlap liners. 2[Esmiorn Table Liner Installation + NOTE: ~ Its very important that the spacing between the liners are filled with epoxy material to avoid any dust fill the gap and eventually wear out the liners or table. ~ Inorder to apply the epoxy, fill the bottom end with a non adhesive paste and pour the epoxy on top, Failing to use the paste will bond the liner with the table and will be extremely difficult to remove Lemon Table Liner InstallationPemorn Table Liner Installation + Make sure the clamping ring fits solidly against the liner. emorn Table Liner Installation + Lightly spray WD-40 lubricant or similar the threats then install the clamping ring bolts and torque to specification (2800Nm) 2Emir Grinding segments Installation + Ahnydraulic wrench is used for tightening the dam ring bolts to specified torque (2800 Nm) Esmom Checking Table Profi + The wear profile is measured with this template. mu 6[emir Tire wear gauge [emo Tire Wear PatternEsmorm Hard facing Table and Rollers te rms ss + Table liners and roller tires may be hard faced instead of replacing, [ismiorm Hard facing + Chromium carbide flux-cored welding wire. + Hard facing can reduce wear up to 50%, + Hard facing can be performed a little at a time during routine mill stops, without swing out the rollers.[Esmiorn Table Hard facing + Hard facing the table can be done without swinging out the rollers [smiorm Table Hard facingsmo Table Hard facing + A frequency regulated drive is used for rotating the gearbox during table welding [Esmiorn Table Hard facing + Table liners can be welded as much as 25 times. Wear life is, typically doubled when comparing hard facing with the original casting. 3[Esmorn Roller Hard facing + Due to the localized wear pa hardfacing may be economically applied. This is particularly true when grinding difficult materials such as blast furnace slag. [morn Roller Hard facing plied with gas shielded automatic wire feed equipment, welding across the segment gaps. Re-surfacing Up to 10 times is possible.[Esmiorn Roller Hard facing + The rollers are turned by a geared frequency drive motor. Deposit rates of 10-15 kg/h per gun can be expected. [Esmiorn Roller Hard facing WN bh Ls + Checking the roller shape with a template. 9[Esmiorn Grinding Table Assembly [smiorn Grinding Table Assembly Mounting Studs WE[Esmiorn Grinding Table Installation + The top of the mill reducer is cleaned and studs are prepared. [smo Grinding Table Installation + The grinding table is rigged and leveled so as to ensure the two circular keys will engage properly.[emo Installation of the Table [bmiorn Grinding Table Installation + The grinding t[smo Grinding Table Installation + The table studs are stretched to a specified tension using @ hydraulic tool. [Esmiorm Hydraulic Bolt Tensioning Tool[emo Dam Ring + The dam ting height is critical to mill performance little height will result in mill vibration, too much result in decreased grinding efficiency. Too wil [smo Dam Ring Dam Ring J Table Liner[Esmiorn Ring Canal Duct Grinding — Table + The ring canal duct brings hot gas for drying around the outside of the grinding table. The scraper removes material that has fallen through the louver ring[Bmiorn Table assembly Ebmiorm Ring Canal + Inspecting the seal between the ring canal and the grinding table Clearances must be held to less than 2 mm or 5/64".[smo Table Scraper Check scrapers for looseness and wear. Install new wear plates as required, EEsmiom Table scrapers[Bsmiorn Table scrapers + Note, the splits should be welded and polished after the rings have been installed [Eemiorn Louvre Ring + The louvre ring has different thickness wear plates at different locations. This is done to achieve a uniform air flow around the mill table.[emo Louvre ring - Inserts Emiom Louvre Ring S| rng canal duct The louvre ring channels the hot gas from evenly around the mill table, imparting direction as the separator rotation.[smiorm Louvre Ring + The louvre ring is subject to abrasive wear from the high velocity gas stream. Repair as required with weld overlay plate. g Velocity (mis) (% Fresh Feed) (%) + Note that the higher the velocity, the lower the rejects However, the wear rate inside the mill will increase 4 times with a 2 X increase in velocity 45[smiorn Louvre Ring Installation oy + The louvre ring is supplied in segments. [Esmiorm Louvre Ring Installation + The gments are held in place with temporary clips and clearance between adjustments are made to achieve @ minimal ring and table. The ring is then welded in place.[mim Louvre Ring Ebmiom Nozzle Ring + The nozzle ring directs gas flow toward the center of the mill Wear rate can be significant due to the high velocity of the material/gas stream. Ee eel[Esmiorm Nozzle Ring + The nozzle ring is heavy cast steel to resist wear. The segments rest in place and are held only by clips. The space hind the ring will be fil [Esmiorm Reducer Removal Hydrauli Reducer 5) Hydraulic jack(s) an¢ fixtures are supplied to lift and support the grinding table. The reducer can then be slid out. Larger mills use 4 jacks to lift the table at the support stands. Le TSEEsmiom Reducer Removal Emo Finite Element Analysis + Computer analysis of table stresses resulted in stron: lighter and cheaper table designs. In this image the ri indicates areas of highest stress. “9Grinding Roller Assembly emo Grinding roller[Esmiom Grinding Roller Assembly [Esmiorm Grinding Roller[Esmiorn Removal of Roller Assembly Caution! Do Not Use Tire Lifting Fixture for Roller Removal aay + The roller axle is pressed out of the tapered rings in the jocker arm socket using a hydraulic Jack. Esmorm ifting of Roller + sling Supplied byFLs[smo Roller Removal [Esmiorm Lifting of Grinding Roller Broken Lifting Eyes Stretched Lifting Eye Caution! Apply lift evenly to avoid damage to lifting eyes, 53[smiorn Grinding Roller Bearings Pixed Bearing Bearing [Esmiomm Roller Bearings —_ = = =p Free Bearing Fixed Bearingsmo Roller Bearings Spacer Ring 4 2 | | ad + The double tapered roller bearing must be preloaded to a specific amount. This is accomplished by adjusting the thickness of the spacer ring. [Esmorm Bearing Preload Procedure olal Indicators —_ { + After installing a new bearing the roller is stood on end and two dial indicators are placed to measure the axial play in the assembly. 5[smo Bearing Preload Procedure = Rotate the roller shaft to make sure the indicators are readir correctly. Lift the roller by the shaft and take readings. After setting the roller down again, make sure the indicators read Bearing Preload Procedure oF * the axle end play plus the preload amount "2" (see assembly drawing for "2" value),[mom Grinding Roller Lubrication Return Supply Oil Lever * Oil is pumped into the roller assembly. A suction pump sucks out the oil through the return line and maintains the oil level. [iar prea rr [Esmiorn Roller Lube Connections Breather Ret ‘Supply sr[Esmiorn Roller Lubrication = Each roller is lubricated with a water-cooled circulating lube system: [smiorm Roller Lubrication System + A pressure pump pumps ail into t pulls it out and sends it thru a fiemo Roller Circulating Oil Unit ia + For handy reference, enclose @ copy of the schematic in plastic and paste it on the inside of the cabinet door.[smiorn Roller Lubrication System + Pressure and vacuum gages monitor the si lines and the filter condition. ply and return Grinding Roller Oil Seal Bellville Washers Rotatin Sealing Cove Sy[smiorm Grinding Roller Oil Seal [smo Grinding Roller Seal Critical Dimension + If the dimension is to great the seal will leak. IF the dimension is too small the seal will wear out. 6[tion Grinding Roller Oil Seal L J\ : Rocker Arm Assembly |[Eomorn Rocker arm assembly [Eemorn Rocker arm assemblyEmon Two Piece Rocker Arm arm allows the fhout disturbing t mor Roller Swing-Out Swing-Out + After disengaging the lever from the fork, a special hydra wing-out the roller to a horizo[smiorn Rocker Arm one Pin Spherical Roller Bearing (both ses) Thrust Plate (one side only) Cylinder ‘connection morn Rocker Arm Assemblyemo Rocker Arm Bearings [smorn Rocker Arm roller axle is pressed into tapered rings in the socket,[emir Rocker Arm Tapered Rings + The tapered rings hold the axle tight inside the rocker arm socket. Esmiom Rocker Arm Swing-out + The roller can be swung out after the mill body cover plate is removed, the rocker is separated and the swing-out cylinder is connected. o[Esmiorn Rocker Arm - Pins and Clamping bushing [Esmiorm Swing out ‘Swing out cylinder Portable hydraulic unit[Esmiorn Spring suspension assembly [Esmiom Rocker Arm Swing-out + The cone pin holds the rocker arm lever onto the fork. ooEEsmiom Rocker Arm Swing-out aya Cie aac + The cone pin fits into the sleeve, whic the rocker arm lever. is inserted into [Eomiorm Rocker Arm Swing-out Apply MoS, Paste ie pin must be removed to separate the rocker arm jm the fork.[smiorn Rocker Arm Swing-out ra Tapered Sleeve hack Screws + After disengaging the cone pins the tapered sleeves on the rocker arm shaft need to be loosened. Three jack screws are provided. [smo Rocker Arm Swing-out + The swing-out cylinder is installed. Adjust the speed control valves to control cylinder speed. Make sure all air is stroked out of the cylinder before swinging out. n[smiorn Rocker Arm Swing-out + Start the pump and swing the roller out. Be careful when th roller passes top dead center as the reversing load may cau! the roller to lurch if there is air in the hydraulic system, [Esmiorn Swing-out Portable Power Unit Pump Directional Valve i Tank: Hoses Oil Level Switch Filter[Esmiors Spring Suspension with Hydraulic Cylinder [smior Joint head[Esmorm Hydraulic cylinder [smo Installing Roller In Rocker Arm ft. Make sure the[bmiorm Installing Roller In Rocker Arm + The roller is lifted with a chain rig (do not use the tire lifting hook). Make sure each lifting eye is equally loaded as the eye can tear out under excessive load [Eomiorn Installing Roller In Rocker Arm + The assembly is lowered into the rocker arm socket.[Eomiorn Installing Roller In Rocker Arm + The roller shaft is installed so that the pin lines up with the slot, This ensures that the oil holes in the roller shaft are orrectly oriented. [mio Installing Roller In Rocker Arm + The bottom ring is installed on the shaft. Make sure the shaft 0.D and ring I.D. are clean and oil free.[bmiorn Installing Roller In Rocker Arm + The plate is installed and the bolts are tightened to specified torque. This results in the axle shaft being wedged tightly inside the taper rings. [Esmorm Installing Roller In Rocker Arm + The tapered rings hold the axle tight inside the rocker arm socket,EEsmiomm Rocker Arm Lubrication [smo Auxiliary Equipment[emiorm Grease Lubrication System + Rocker arm spherical bearings + Rocker arm thrust plates + Cylinder rod connecting bearings + Separator upper and lower bearings * + Use NLGI no. 2 grease + Separator bearings require hi- temperature synthetic grease + The pump cabinet sends grease to a local distribution manifold for each roller. 79[smo Grease Lubrication System From Pump Divider Plugged Indicator [smiorn ivider Valve Block Operation lubricant from[morn Water Spray Systems + Mill body water spray system Used for controlling mill exit temperature (approximately 80°C) + Table spray system ¥ Used for stabilizing grinding bed to eliminate high mill vibrations. [smo Mill Body Spray Water System + The mill body spray is used for controlling mill exit temperature. A high-pressure multistage centrifugal pump is used, The pump requires filtration to 25 microns, (Ne aEEsmiorm EEsmiorn Mill Body Water Spray Nozzle Mill Body Water Spray Nozzle e which lets when the[smiorm Table Spray System LTO center + The table spray system is used for stabilizing grinding bed to eliminate high mill vibrations, This table spray pipe is protected with concrete where it crosses the louver ring Ee TTY [Esmiorm Table Spray System + This table spray piping comes in alongside the feed chute, thereby avoiding the high velocity, abrasive gas stream at the louver ring.[smiorn Table Spray System + This table spray system consists of a control valve and flow meter. Plant wat equi [smiorm Mill Body Liners + Ceramic tiles prevent mill body wear[mor Ceramic Tiles + Tiles have an embedded washer which is plug welded to the mill body. After welding the hole is closed with a ceramic plug, [Esmior Feed Chute q + The feed chute is lined with replaceable steel plates Make sure the chute places the feed material exactly in the center of the grinding table.10TH Vibration Transmitter alien TESS on transmitter is installed on the mil in when the material bed shutdown point are programmed into the Pl body. Vibration and [emo Preventive Maintenance[Esmiorn Daily Inspection Items + Listen for vibrations + Listen for unusual noises + Listen for air leakage + Look for oil leakage + Look for material leakage + Check grease system indicators + Check filter differential switches + *Feel” the Swing Lever motion [iismiorn Periodic Inspection Items + Items not visible during operation + Feed Chute + Feeder + Air Guide Cone = Dam Ring + Scatter Ring + Nozzle Ring = Measure and record table and tire Wear segment wearInspection Items + Bottom Casing + Bottom Casing Liners + Table to Bottom + Scraper Liner + Cylinde + Joint Red Clamping Nut + Joint Rod Spherical Bearing + Joint Rod Cylindrical Bearing dic Inspection Items Mill Body to Swing Lever Seals-Adjust 2: equired Look for wear of Roller Shaft Boss Cover Look for wear of Sealing Rubber Keep Corner Pieces adjusted Separator Guide Veins Return Cone Rotor Rotor Seal Plates Outlet DuctHydro-pneumatic Spring System [Esmiorn Hydro-Pneumatic Spring System The hydraulic cylinder gives grinding force. The accumulator provides shock absorption, a[smo Hydro-Pneumatic Spring System As the roller rides up on the bumpy material bed, oll Is forced out of the cylinder into th mulator. The nitrogen in the bladder is ng a spring effect. [smom Hydro-Pneumatic Spring Syste Pump Operating Pressure Pressure check Valve The pump fills the system to the desired pressure. The check valve keeps th during the normal g sssure locked in, The pump is not running ding mode,[Ebmiorn Hydro-Pneumatic Spring System + The central control room puts in the grinding pressure set point and the PLC sends a signal to the MCC to start and stop the Pump as required to maintain the pressure. [Esmiorn Mill with Roller Lift Circuit © Free Flow + When pump flow is directed to the bottom of the cylinder the roller raises. Oil from the top of the cylinder is forced into the accumulator. The free flow valve is closed during raising, er[smo Hydro-Pneumatic Spring System oan @—— Clamping Nut Hydraulic, pein YW - Bottom of cylinder Accumulator (AV units only) Emm Hydro-Pneumatic Spring System Hydraulie Cylinder Hydro-pneumatic Accumulator lio[mir Cylinder Rod Flanged Connection This mill features a flanged connection instead of a clamping nut to join the two-piece cylinder rod. [Esmorm Hydro-Pneumatic Spring System 93[bmiorm Hydro-Pneumatic Spring System On this mill accumulators are mounted directly on the cylinder. [smo Hydraulic Cylinder[mo Piston Seals Seals are replaced when leakage is detected. Piston Seal Replacement Replacing the piston seals,[smiorm Hydro-pneumatic Accumulators Esmom Bladder Accumulator Avord high Nowe rates it could foree the[emir Accumulator Charging Nitrogen Bottle ‘Accumulator + Accumulators are pre-charged with nitrogen gas to 80% of the hydraulic grinding pressure. Caution! Use only dry nitrogen. Never use oxygen or air as an explosion could occur. [smo Accumulator Charging Kit + Note: nitrogen bottle fittings have right hand thread. The pressure reducer is needed if the nitrogen bottle pressure is greater than the accumulator maximum working pressure 97[smiorn Accumulator Charging System hydraulic pressure must be zero when charging 2. Charge with nitrogen only ~ no air or oxy 3. Charge to 80% ¢ nding pressure Allow nitrogen to enter slowly so as not to cause freezing of the rubber bladder 5. Check nitrogen pressure after temperature has stabilized. 6. Adjust charge pressure to allow for difference betwee ambient and operating temperature: x ambient temp + 273°C operating temp + 2 [smo Bladder Accumulator Charge Limits Maximum charge = 90% of system hydraulic pressure Minimum charge = 25% of system hydraulic pressure Above 90% the bladder can become damaged from chafing on the ant! Below 25% the bladder can become damaged from folding a ure whenever changes are made tothe grinding pressA hydraulic cabinet contains the pump, filters an valves that control the spring system operation [emir Hydraulic Cabinet + Solenoid operated directional valves control the system: 6S lowers the rollers, 85 controls the free-flow valve, 5S reduces operating pressure.Esmiorn Hydraulic Cabinet 4S directs flow to either the top of cylinder or bottom of cylinder line. 1S and 2S are used for mills with two circuits (one fo and 3, one for rollers 2 and 4). [smo Free-Flow Valve The free-flow valve is a pilot operated check valve mounted in the cylinder bottom to tank line. The valve eloseetd s open during normal grindin 100EEsmiorn Hydraulic Cabinet Filter maintenance is of utmost importance to any hydraulic system, [Esmorn Maintenance Panel A local maintenance panel allows pump start/stop, increasing / decreasing operating pressure, and roller raising/lowering 101[emiorm Mill with AVD Circuit irdder [| ume Operating Accumulator e AVD (Advanced Vibration Dampening) uses accumulators on the cylinder bottom. The valve block diverts flow to the cylinder bottom during a high mill vibration event Emm Piston Accumulator Piston accumulators are used on AVD systems, connected to the part of the hydraulic cylinEsmom Piston Accumulator [smiorm Piston Accumulator wit + The accumulator is pre-charged with nitrogen, usually to 200-300 PSI 103[ismiorn Roller Mill AVD Spring System + Logic type (pilot operated) check valve: ~ Ifthere is no pressu Controlled flow is from A to B or B to A If there is pressure on the auxiliary port, the valve is closed on the auxiliary port, the valve is [Esmiorn Roller Mill AVD Spring System Solenoid designation re letters T = TOP of CYLINDER CYLINDER PUMP TO CYLINDER[Esmiorn Roller Mill AVD Spring System There are three basic functions of the hydraulic unit Raise rollers Lower rollers Operate (grind) [smo Roller Mill AVD Spring SystemEbmiom Hydraulic Unit for AVD Circuit + This hydraulic unit features two identical systems, one for rollers 1 and 3, the other for rollers 2 and 4. [omorn Valve Block for AVD Circuit + Flow to the top and bottom of the cylinders is controlled by the cartridge valves in the valve block m1Grease Lubrication System [smom Grease Lubrication System + Rocker arm spherical bearing + Rocker arm thrust plates + Cylinder rod connecting bearings | + Separator upper and lower bearings Use NLGI no, 2 grease * Separator bearings require hi-temperature synthetic grease[Esmior Grease Lubrication System Grease pump with reservoir [smiorm Grease Lubrication System From Pump Plugged Line Indicators cycle Switch 13[morn Divider Valve Block Operation +The divider valve block distributes lubricant fram the pump to the various lube points Wale fica ubricant from inlet ee pascageway, shawn in. red, is Connected to the left-hand end of Pistons 8 and C and to the right hand end of Piston A. Application of pressure through the inlet Pistons 8 and C in thelr right-hand positions, while ‘moving Piston "A from right. to left. forcing. the lubricant. in this cylinder. chamber into the passages. shown in blue and discharging this known 2 the bearing connected to Outlet No[smo Valve position 2 Lubricant from the inlet. Tata passageway, shown in red, is connected to the left-hand end of Piston C and to the right-hand end of Pistons A and B. Application of pressure through the inlet passageway, therefore, "locks Pistons A and C in their respective positions, while moving Piston B. from right to left - forcing the known and measured amount of lubricant in this cylinder chamber into the passages shown in blue and discharging this known and measured amount of lubricant to the bearing connected to Outlet No 2 [smo Lubricant from =the inlet passageway, shown in red, is connected to the right-hand end of Pistons A, B and C. Application of pressure through the inlet passageway, therefore, "locks Pistons A and B in the left-hand position, while moving Piston C from right to left - forcing the known and measured amount of lubricant in this cylinder chamber Into the passages shown in blue and discharging this known and measured amount of lubricant to the bearing connected to Outlet No 3[Esmiorn Valve position 4 Lubricant from the passageway, shown in connected to the right-hand Pistons B and C and to the left hand end of Piston A, Application of pressure through the _inle passageway, therefore, “locks Pistons B and C in their left-hand positions, while moving Piston A from left to right - forcing t known and measured amount o} lubricant in this cylinder cham into the passages shown in blui and discharging nown ani measured amount of lubricant to the bearing connected to Outlet No Valve position 5 Lubricant from — the -—_inlet oD passageway, shown in red, is connected to the right-hand end of Piston C and to the left-hand end of Pistons A and B. Application of pressure through the _ inlet passageway, therefore, “locks Pistons A and C in their respective positions, while moving Piston B from left to right - forcing the known and measured amount of lubricant in this cylinder chamber into the passages shown in blue discharging this known and \easured amount of lubricant to the bearing connected to Outlet No 6,[smom Valve position 6 verraccren WBinier Lubricant from — the _—_inlet passageway, shown in red, is connected to the left-hand end of Pistons A, B and C. Application of pressure through the inlet passageway, therefore, "locks" Pistons A and B in the right-hand position, while moving Piston C from left to right - forcing the known and measured amount of lubricant in this cylinder chamber into the passages shown in blue ‘and discharging this known and measured amount of lubricant to the bearing connected to Outlet No Esmiorm Main drive AssemblyEmiorm 3D Cut of Mill Drive Planetary Gear Type WPU[Esmiorn Desing Concept of Mill Drive Planetary Gear Type WPU for Roller Mills 19[mir Distribution of forces Roller ill wu Gearbox WPU- Gear Range[smiorn Bevel gear with roller bearings [Esmiorn WPU-274 - Section view, lubrication[Zsmiorn Instrumentation panel ~ Double oil filter Lubrication unit High pressure Low pressure pumps pump oil cooler Eismorn Planetary stage Material Alloyed stee! Heat treatment Case-hardened Toothing quality Q4andas - >25 Service factor AGMAPlanet axis White metal pared [bmorn Axial thrust bearing Tilting pads hydrostatic and hydrodynamic lubricated va[Esmorn Protocol Sc bevel wheel[emiorn RAR Separator [Eemiorn RAR-CFV Separator + High efficiency separation with cage type rotor enclosed by guide vanes, + Vertical feed to prevent wet or sticky material from clogging the entrance to the mill + Fines are not returned to the mill Selection of wear protection, for best balance between cost and endurance a5EEsmorn Force balance that determines separation in RAR separator FRM With central feed[smiom Variable speed Brie | Reject Hopper Rejects Mixed With Raw Feed from Mill [smiorn Central feed pipe liners on top section where the material enters and can impact walls of pipe Raw feed Sy Liners need to 7) be inspected and maintained regularly ver[Esmiorn - , Wear items In the RAR-CFV Top seal of arrangement bearing arrangement ue 180mm diameter <—_1. Ball Bearing (2) Lower seal of bearing arrangement Split seals are used to Split seal (2) allow replacement And O-ing without removal of bearing arrangement Each bearing is monitored with a resistance temperature detector (RTD) Bearing temperature measurement (RTDs)[smo Air velocity though mill housing + The air velocity should always be accelerating, thus preventing pre-classification in the mill housing. + Increase work done by separator + Reduces pre-classification + Reduces mill gas flow requirement + Reduces material throughput under the rollers + Stabilizes grinding bed + Increases grinding efficiency [ismiorn RAR-CFV Wear plates and liners + Guide vanes - chromium carbide hardfaced plate bolt on wear liners + Ceramic tle lining in housing + Feed pipe ~ stainless steel top section lined with chromium carbide hardfaced liners bottom section with AR 235 liners 129[Bsmiorn ATOX Vertical Roller Mill Ebmiorm Vertical mills Gsmiorn fo Gsmiorn cd @ cuoe praia sc wocscre IYThe first ATOX mill was intcoduced in1920 In 1922 "ATOX” was registered fon the market + Around 1980 2 new concept for the ATOX mill was developed and introduced to the market More than 130 ATOX mills have been sold Esmorm Atox Raw Mill Size 50[mor [bmiorn Atox Raw Mills - Type 45[smo ATOX Coal Mill [smiorn ATOX Coal Mills - Operating Experience ‘capacity: Up to around 70 t/h Anthracite, pet-coke, normal bituminous coal and lignite Feed moisture up to 25 % Final product from < 3 9 to > 20 % on 2 90 mm sieveEEsmom ATOX Mill - Basic Concept + Adjustable dam ring + Adyus The three cyl rigidly connecte centerpiece The grinding table has 3 hor Grinding track encircles by le nozzle ring [smo ATOX Mill - Basic Concept roller assembly is. kept centered on the grinding table and prevented from rotating by three torque rods The grinding pressure is exerted hydraulically through three pull rods attached to the outer end of each roller shat[smiom ATOX Mill Concept - Advantages +The grinding track is horizontal and the center of gravity for the roller system can only move vertically =» All impact forces and dynamic reactions are only vertical and thus easy to accommadate The extremely low mass of the roller suspension system means low inertia and thereby low dynamic forces Concept - Advantages + Due to a patented toe-in of the rollers, the roller bearings are only : exposed to well defined radial toads, and - due to the low mass Of the suspension system - only to ‘very small inertial forces in case of vibrations. {: 135[smom ATOX Mill Concept - Advantages Segmented wear parts for both rollers and table allow use of the most wear res materials without isk crackin Roller segment reversed enabling high material Esmiorn ATOX Mill Concept - Advantages When the wear segments of an AATOX mil are wearing the whole aa Higher oF thick segments than in mills, wi Thicker wear segmentEEomiorn ATOX Mii Concept - Advantages Rollers with larger diameter + Permit a proportional thicker and less critical grinding bed being less sensitive to uneven wear and less entical concerning foreign bodies in the mill feed Allow a proportional coarser feed, which reduces the requirements on pre crushing [Esmiorm ATOX Mill Concept - Advantages Easy starting procedure: + The rollers are lifted hydraulic: + No auxiliary drive required lly before start + Less demand on the mill motor - it starts with no load + Hydraulic system designed to eliminate pressure chocks and to permit a very easy and smooth startEEsmiorm ATOX Mill Concept - Advantages Unrestricted airflow under the grinding table + Low pressure loss and unrestricted air distribution to the 360 nozzle ring + The standard ATOX mill can handle also the extra amount of gas required by specially wet or easy to grind materials without having to go to oversized mill housing - only the nozzle ring and the separator must be adapted to the higher airflow Easy to fit into a constricted Minimum cost of civil work[smiom Atox Mill for grinding sh of raw materials Ey i v Circulation of material ¥ VE EEsmiorn Atox Raw Mill, 3 fan system[Eomiorn Atox Mill [Esmiorn Hydraulic tension system[smo Hydraulic tension system Pre-charged hydraulic Accumulator w/nitrogen [Emiorn Stroke limiting assembly sleeve at pall red salEemiom Grinding bed measuring Lomo Hydraulic accumulator w/nitrogen “Automotive” valve type[morn Double Rod Seal Heat to 250 deg. C ‘And use mounting tape Insertion into cylinder[smo Instrumentation + Instrumentation +L top position indicator \ Le ana + 1 layer thickness metering + Mechanical support for pistons: + Required during maintenance + with lifted rollers -[Ebmiorn Hydraulic Pump Station. [Ebmiorn Hydraulic tools for bolt tensioning 145[smo Torque rod assembly[smiorn Improvements to Original Design + The axial thrust bearing has been changed from pure hydrostatic bearing to more simple and reliable submerged hydrodynamic/semi-hydrostatic bearing with supplementary high pressure oil supply. + The design arinding pressure has been increased from {600 kN/m? to 800 kN/m? for increased mill capacity. [Eemiorm Gi ding Roller Configuration 470 + Larger roller bearings (due to Increased grinding pressure) + Improved sealing system Lubrication changed from grease to oll lubrication with continuous oil fitering and conditioning[brome Y-Profile Grinding Table Present —— smo Tension Rods Original[smiorn Wear protection parts ) Stainless steel lining in chute ‘Stee! ining in mill housing Roller hub wear cover: Chromium carbide & composite plate 4) Joint nea wear cover: chromium carbide & composite plate. 5) Nozzle ring air guide cone: Chromium carbide & composite plate. Gry Wear protection parts 65) Dam ring top: Hardox 400, 7) Bottom plate: Densit ining 8) Torque rod wear cover: Steet 9) Seating alr pipe: Chromium carbide & composite plate. 10) water carbide & composite plate ction pipe: Chromium 41) Sluice: Rubber lined with wear resistant liner & Hardox vanes 9[Esmiorn FLS RAR Separator Material recirculation - Vibration conveyorsmiom Grinding Table ‘Scraper for rejects 151[smo Scraper and table seal adjustments + + ——+" even as possible other wise it will be worn out by the scrape! Bsmiomm Scraper and table seal adjustments oT ring needs adjusted bet sealing under the table[smiorn f & Nozzle ring morn Nozzle Ring ||[Esmiorm Dam Ring configurations[smiorm Watei jection system [Eomiorn Joint head connections[Esmiorn Wear protection emir Separator reject pipe[morn oe a Wear protection [smo Roller lubrication eyemo Grinding Roller Lubrication al hub bores: Eemiorm Grinding Roller Lubrication[smo Hydraulic nut for spherical bearing: + Adjustment of bearing + Removal of sleeve [ismiorm Cavity for sealing air Grease of seals ~Emo Preventive maintenance schedule for lubrication system king[smiom Differential pressure Pipe at air inlet duct [Bsmiorm Coal Mill Gear Pump Station. 161[smo Coal mill - Feed screw, external Coal mill - Feed screw, internal discharge[bmiorm Coal mill - Densit wear protection of mill shell emo Wear segments for rollers and table ‘+ How long time will they last? + Difference between roller & table segments? ‘+ When to rotate or replace? + Can I refurbish? + Depends of operation experience more than actual wear depth. + Record the wear profile using the supplied tools for estimating actual life time. + Compare wear with operation performance 163[Eomiorn Ebon Wear profile on Tire segments + Ni Hard Tire segments on a Coal Mill, wear is on tt outside 164[smior Wear profile on Tire segments ae Emir Holding Clampsao Refurbishing of wear segments + The wear rates differ from 0.2 to 20 g/tor + Tal le segments wears more than roller segments 00h g/ton (desired life time 1 + 3) Slag mills: 10-12 9/ton for slag mills without hard-facing ifetimes down to 3000-6000 hours 0.5 % free iron is normal (0.1% more gives + 1) Raw mills - content of quartz in mill feed may reduce the life Consider to install iron removal equipment at recirculation system [Esmiorn Refurbishing of wear segments Cladding as opposed to fusion bonding + Automated welding equipment + 2-4 welding heads ( each of 8 kg/hour) + Up toa total af 2000 kg No grindi or preheating required Consider down time and cost savings[smiorm Tire Segments Replacement Segmented wear parts for both rollers and table allow use of the most wear resistant materials without risk of cracking Roller segments can be reversed enabling high material utilisation to be achieved also in case of [Esmiorn Gismorm ==> Wear measurement and trend 167[Esmiorm Wear measurement on tire segments f eM Wear measurement on tire segments Gap Represents negative wear on the face of the tire[smo Wear measurement on table liners [Esmiorn Wear measurement on table liners Gap Represents negative wear on the table liners 169smo Welding of roller segments [smiorm Welding of grinding tableEmon Replacement of Roller Station - X \ th N\ [Esmiorn Replacement of Roller Station = = fie = ta ta Boogie Structural support[smiorm Replacement of Roller Station [smo Replacement of Roller Station Dismount all bolts that are fastening the center piece Dismount all bolts that fasten to theEmo Replacement of Roller Station Start the hydraulic system for the pressure for the grinding table, Open the ins ion ( big ) doors for taking the grinding roller outside, It is necessary to ng the dismountes roller to the workshop for dismounting all systems inside the roller [Esmiorn Dismantling the rollers inside the mill body 173[smo Dismounting of sealing air rings ¢ Esmiorm Dismantling the roller[bmior Dismantling the roller (Continued) The grinding roller must be positioned in a vecticl position, Dismount the top cover for ai sealing Dismount the cover for ol sealing Dismantling the roller sTo dismount the conical piece in the spherical bearing, turn the clamp backwards and set it against the bearing inner race to push the sleeve out,— Dismantling the rollerare) fi ccm | Dismount the hardened seal Coan the shaft before rings emounting al pieces Note: The rings can not be reused since in order to take them out they have to be heated up. [Esmiorn Remounting all pieces; Assembly of bearings, shaft and hub. Check that the hub interior is clean If possible, mount the bearings in the hub by heating latter to 120°C above ambient and bearing temperatures. I heating Is not possible, apply the following alternative method Use a mixture of dry ice and alcohol to cool down the spherical roller bearing (45) and the outer race of the cylindrical ralier bearing (43). The temperature must not drop below minus 50°C + Hub temperature to be approx. plus 20°C. ww[ismorn Remounting all pieces; Assembly of bearings, shaft and hub remove the condensed water resulting from the temperature equalization. Bearings must be smeared thoroughly with rust-proofing to eliminate any risk of rust formations Place hub that itis possible to insert the outer race for bearing 43), the outer spacer ring (44) and roller bearing (45) into the hut See encl, 10 Remounting all pieces; Assembly of bearings, shaft and hub + If bearings (45) and (43) have identical outside diameters, it may be :seful to temporarily mount cover (54). Then place the hub with the pen side upwards and mount hearings and spacer ring so that they cen plac Note! If the roller bearings are provided with lubrication groove and the outer race is perforated by lubrication channels, these must be plugged to enable future hydraulic dismantling of the bearings[smo Remounting all piece: and hub Assembly of bearings, shaft Sealing alr and oil channels to be thoroughly cleaned with dry and clean compressed alr Place the shaft in upright position, standing on its flange. Apply corrosion-inhibiting grease, e.g Never Seez, to the shaft at points where bearings and rings are to be located, Mount sealing air ring ($2) on the shaft [smo and hub Remounting all pieces; Assembly of bearings, shaft + Mount the wear rings (55) and (42) and inner race of cylindrical roller bearing (43) on the shaft. + Mounting is done by heating the pparts to 120°C above the ambient temperature, where after the parts are lowered down over the shat 179emo Remounting all pieces; Assembly of bearings, shaft and hub + Mount the inner bearing spacer ring (44 king screw (35) prevents the ring from turning relative to the shaft ecial grease, Klluber NOSOL UTA 4 or similar grease, to be applied to the outer ace an shaft seals (61 + Place the shaft seals in bearing cove 54). Do not forget spacer ring (73) [smiom Remounting all pieces; Assembly of bearings, shaft and hub z, omplet a a ae CA st pt nd wear ring rot overloaded. { L that the shaft seals do not slide 1 over the rear edge of the slide aim] ngLsmiorm Mounting of hub on shaft Mounting 1s done by towering the hub The hub with bearings mus Remounting the roller *To remount the sleeve, set the hydraulic nut against the clamp and apply hydraulic force to set back in place. 181[smo Mounting of hub on shaft [smo Mounting of hub on shaft[more Mounting of hub on shaft ‘Mount the hydraulic equipment 0 ismanting bushing ae well a= on the Hydraulic pressure to be applied to the tismanting bushing (46) Tun the shaft unt ie hasbeen spherical rlier bearing are centered ‘Forcing on the shaft to be started as apply pressure to the hyaraulc nut Mounting of hub on shaft 25 Service factor AGMA, 201[smiorn Slide bearing White metal pared a \ Planet axis [Bsmiorn Axial thrust bearing Tilting pads hydrostatic and hydrodynamic lubricatedEEsmiom Protocol bevel wheelEEsmiorm Coal Mill System RAKM-LVT separator | morn RTKM/RAKM Separator very fine grinding of e.g. Petcok Design eliminates deposits of coal di ignition c 2 withstand explosion pr bar tream transport simplifies lay out[smior RAKM SEPARATOR FOR COAL Variable Speed Brive \_ Fines Rotor Guide Vanes Reject Hopper [smior RAKM-LVT Bearing Arrangement Angular Contact Bearing (2) Deep Groove Ball BearingEsmiom RAKM-LVT Separator - Wear Plates and Liners Guide vanes ~ Hardox 500 bolt on wear liners Rotor - vertical blades of Hardox 400 Outlet section housing - Densit Inside surface of reject cone - Densit Separator Maintenance[mom Separator Shaft Assembly [emo Lower Bearing This bearing was damaged by using the wrong grease, Use only approved high-temperature synthetic grease[Esmiorn Separator Drive parator Is driven with a variable frequency drive motar connected to a right angle reducer [smiom Reducer Lube System ow Tank Flowmeter Cooler This reducer has a circulating oll system with filtration and costing ll Pump[smior Reducer Shaft Seal ‘which requires regular greasing Reducers with vertical shafts often have an oil seal Esmorm Reducer Couplings Input Shaft Coupling laser alignment equipment Output Shaft Coupling + Coupling alignment should be checked with precisionTH Separator Bearing RTD’s | RTD vies ey Each bearing is monitored with a resistance temperature detector (RTD Posimetric Feeders[smior Feeder principles + This feeder readily handles materials having an extraordinary range of characteristics regardless of whether wet, dry, lumpy, sticky, abrasive or granular. Virtually immune to jams, it will, for example, feed dry, light particles at 1,200 pounds per hour or heavy, sticky minerals at 1,800 tons per hour with absolute consistency. Its reliability is so great that it eliminates any need for an operator standing by to clear pluggage. Additionally, the feeder does not agitate nor degrade the material in any way, [Esmiorn Types of feeder an[smo Principles of operation is feeder is a striking example of how simplicity of design can yield superior results, both in performance gains and equipment upkeep. The genius of this concept lies in the way it takes advantage of the bridges that bulk solid material tends to form. In most equipment, material bridging causes problems, In the Posimetric Feeder, controlled bridging is the basis of more unifor more reliable, and more accurate feeding ~ in machine with only a single moving part and which, in most applications, is nearly free of wear. [Esmiorn Principles of operation The feeder consi ts of @ circular, rotating chamber or duct, confined within @ housing, When confined within an enclosed space, most bulk material tends to bridge, or lock up, against the outer walls, filling the entire space, The Posimetric Feede takes advantage of that fact by deliberately causing the material to continuously lock up at the feed point within the duct, and to continuously unlock at the discharge point.EEsmiorm Coal Feeders Improved Productivity and Less Down Time with Posimetric Feeding of Coal Pulverizers and Raw Mill Feeding + Reduced wear and maintenance + Reduced excess oxygen + Reduced unburned carbon (LOT) [smiorn Posimetric feeder ‘Zone 1 - Consolidation Feed material consolidates locks up at 8 constant density as meenters the duct! 213[mor Zone 4 ~ Active Discharge Scraper ensures 100% of the ‘material is discharged Zone [smorn The Secret of its Accurate and Steady Feed Rate lock up + The volume of this material lock up/transport section between the feed and discharge points, about 180° of arc, is fixed. In effect, this duct section serves as a container of known dimensions even though it is open at each end. This means that each rotation can only carry a fixed amount of material, regardless of moisture content, entirely confined by material 215smo The Secret of its Accurate and Steady Feed Rate It will not feed partial amounts because a than full sectio does not permit material lock up, and it can not feed amount greater than the lock up section. As a result, the displacement of the duct lock up section, and therefore feed rate accuracy, is trolled as surely as if using a bucket. There are no fluctuations, over whatever time span you might wish to + In addition, lock up enables the walls of the duct to literally carry thi material gently along; the material has no sliding motion relative to those walls and therefore produces only negligible wear. For sticky materials, a fixed plate above the discharge point gives it an assist Low Speed, Low Wear Rotation speed is surprisingly slow, ally from 1/2 to 10 rpm, depending on the application + Typ nergy demand is also low because the mass of locked up material helps to turn the duct, much as a waterwheel is turned by the falling water, except no paddles are needed. Typically, a 200-tph feeder only needs a 3-hp motor; a S00-tph feeder only requires 10 hp. This also contributes to long life of all drive components because the entire feeder is subjected to minimal stress. In addition, the Posimet jer acts as a seal agai downstream suction or pressure.[smiorm Maintenance advantages + Its single moving part, the duct, is only exposed to nominal abrasion and has routinely provided many years of service before even a token amount of wear is apparent + As for preventive maintenance, the Posimetric Feeder only + requires occasional visual inspection and, at extended + Intervals, greasing of bearings, + In short, the maintenance burden is minimal [smior PLC Based Controller It interfaces with the feeder system display for contin indication of: feeder status, Including rotation speed and delivery rate, with alarms or faults clearly aisplayed. 27=< OK Mill [smo Finish grinding of Cement i and Slag 7[morn Modern Design Features Improved Product Quality Excelent Mechanical Reliability Reduced Maintenance Costs ~ Better Operating Efficiency [Esmiotm Clinker feed to \y the a Product and air mill through the rotary air lock Hot air to the nozzle leaving the separator 219[smo OK cement mill function Clinker are forced to the edge of the grinding table r and under the rollers by centrifugal forces [smo OK cement mill Function ine articles ited by the ai 1. Stage separation of ground clinke Coarse particles falling through the nozzle ring[mim 2 Main causes of wear grinding parts due to age caused by air blast Wear on grinding parts + Wear on the grinding parts are caused by the extreme pressure in the grinding zone. voided, dealing with it part of normal maintenance procedures![Esmiorn Grinding force The pressure in the grinding zone is generated by the force from the hydraulic cylinder. le Mor [smo Pressure Distribution in Grinding Bed 28emo Typical wear profile on OK cement mill EEsmorm Wear on grinding parts must be monitored and reported on a regular basis![emo Measuring wear on table [Esmiorm Checking Table Profile 25[smorm Measu g wear on roller Measuring wear on roller[smo Keep Track of Changes in a centralized location and accessible for anyone to plan and follow up. [smo [emir It is time to act on worn grinding parts whe + Production has reached an insatisfactory low level + Mill operation becomes unstable due to vibrations zremo Pressure Distribution [Esmiorm Roll Segments + Typical wear on working surface[Esmorm Measure wear Example: + After 8811 hours operation. Total 1,1 gr/t + OK 33-4 San Miguel. Blended cement [smorm Segment Replacement 29emo Tire segments replacement Clesance Mssurenst Plot ; + The matir should be cleaned thoroughly. Che tire on the top and/or bote surface of the tire segment and t for match marking of the m surfaces. + Match mark the bearing housing, side liner and clamp plates at each tire segment location. Emon Tire segments replacement Apply red paint (or any similar substance) to the inside bottom) surfaces of the tire segment. + Mount the tire segment onto the bearing housing by using the tire lifting assembly 20[Ebmiorm Tire segments replacement + Rotate the tire segment approximately 20mm = 30min (0.7874" - 1.810") in both circumferential directions on the twaring housing, tx check for contact condition, ~ GHEE Have a sninimuft BOM contact area; target is more than 70% contact area between (transferred red paint areas) inside surface of tire and contact surface of bearing housing. Esmiom Tire segments replacement Assemble the side liners (aty. sarees 8) to the bearing housing with the smaller bolts. Tighten the small bolts to the specified torque Tension to S63kN (typical hydraulic tensioner HTA 90 at (G7MPa= G7Obar which includes 2 factor of 1.075 K-factor for clastic deformation) 2a[smiorm Tire segments replacement with a dial indicator that 059") Assemble each side liner and che dimension "A", in the radial dire of each liner. + Align each side liner with the bearing housing so that all of the bolt holes are in alignment. Before tightening the small bolts, insert the long clamping studs (nut on one end) through the bearing housing to hold the liner in place, nis within 0.15mm (0. [smo Tire segments replacement f + Assemble each tire segment earing housing in orde tire number (match mark on top and/or bottom surface), with tire clamp and clamping stud Lift the tire by using the lifting assembly, chain hoist or wire rope. lon the tire segment on the bearing housing by hitting the outside surface with a rubber hammer. Make sure there is no clearance (gap) between the surfaces of the tire segment and the bearing housing Assemble the tire clamp to the bearing housing with all bolt holes aligned. Make sure there is positive contact between the tire clamp, tire segment and the bearing housing[emo Tire segments replacement + Temporarily assemble the side liner, tire segment and tire clamp using the clamping studs. First, tighten the center clamping stud to the specified tension (Refer to grinding roller shop assembly drawing for value). Make sure that there is no clearance between the tire, bearing housing side liner and tire clamp. Psmorn Tire segments replacement + After completion of adjustment, tighten the remaining two studs in the order shown to the specified Assemble the remaining tire segments in the same manner Make sure there is no gap between all the contact surfaces of the components. Install caps aRer all clamping studs have been tightened to the proper tension 233[smiorw Installation of Table Liners [ismiorm Installation of Table Liners D Mount the table segments according to assembly drawing assuring full contact between ‘segment and table. This could also be done outside the mil before erecting the table fon the gearbox. Verify iting capabilities prior to using this method.[smiorn Installation of Table Line: + a) Start with placing one table track (segment) on the table. +b) Tighten the damping bolts from left to right (seen from the inside) to half the specified value. Then fully tighten bolts assuring that the segments stay in contact, with the table. Check with feeler gauge [smo Installation of Table Liners ©) Mount next track against the first and clamp as in b) 4) Mount all tracks and adjust thickness of table track spacer. Weld in spacer. See procedure for machining spacer on Grinding Table Assembly 11 drawing[smiorn OK Mill Table Liners The ta ring. The 5 mented clamping le liners are held in place with a ween the liners is filled with epoxy. [smo Dam Ring This dam ring Is constructed with weld overlay plate. The dam ring das th erformance and cement quality should be properly ins ight of the ring can affect mill[morn Louver Ring and Nozzle Ring carries the ground material up to the separator controls carrying velocity +The louver ring and nozzle ring create a swirling air stream which The louver ring [smiorn Nozzle Ring + The nozzle ring directs air flow towards the mill center. The louver ring open area can be adjusted for optimum velocity 2a[Esmiorm Hardfacing the table es [Esmiom Hardfacing the table Hardfacing the table can be done without lifting out the rollers by utilising a “swan neck welding gun[smorn Hardfacing rollers + Hardfacing of roller segments are usually done two at a time inside the mill. The rollers are turned by a geared frequency drive motor Deposit rates of 10-15 kg/h per gun can be expected [smo Hardfacing the table[smorn a) To swing the roller: Dismount the housing cover. b) Remave the tapered pins ©) Swing out cylinder. morn Roller swing in - outEsmorm Roller swing in - out + Extend the roller stopper, to make contact with the spring box. + Raise the roller slightly, to remove the wooden block (prepared for prevention of metal contact) + Dress the assembly part for roller swing-in. [smiorm Roller swing in - out Gnd oses ones tLe peal SS ries[emir Roller Assembly removal [smorm OK Mill Video[smior Wear caused by air blast Air at high velocity mixed with clinker / slag can be compared with sand blasting, it is highly abrasive! + Wear by air blast has been minimized through the design, but it can not be completely avoided! [emiorm Wear caused by air blast OWear-Goni Ww Wind cuts are very common cause of damaged steel in Cement, Raw and Coal mills. It is important to understand the wear type to be able to address the issues ADTEC ~ Process related Material related. ~ Age related.[smo Rock box to reduce impact wear welded mill housing fla Feed chute for ~~ dinker lined with \ chromium carbide Bottom casing with Juct and reject, [smo Feed Chute Liner Protection[Bsmiorm Mechanic al Stopper ‘Support Mechanical Stopper ‘Support ImprovedReduces by Emr Table Seal Design Based on proven Atox table es Seal castings and plate ring } era provide a close proximity abyrinth[smiorm Table Scrapper clearance wx [smo Dam Ring Dam Ring height is Aprox. 120mm 4.724") Ff === Il_+[Esmorn Nozzle Ring + The nozzle ring directs the air stream away from the rollers to reduce wi [Eomorn Nozzle Ring LAM So \ 1! LUAVIS SZ Fully adjustable area Optimized differential pressure and material flows + Maximum operating stability 248[Eemorn OK Mill Nozzle Ring [smo Roller assembly 249[smiorn Roller wear protection Air tight housing ,, Seal to prevent o turbulence Hardfaced plates to protect from air blast [Esmiorn Mill Housing Seal No shang pats, no inherent leakage poi ith the changes n sng leverEmo Grinding Roller Assembly ‘Tapered Rings Breather oil Level \aes Supply 7s Ratan Double Cylindrical lier Beatinos Pre-loaded Tapered Roller bextinnos One Lubrication Unit for Each Roller Lubrication Unit + Located Next to Mill Base 282Oil tank Cert 8 =D) sep Gsm Lubrication Unit, Tank Equipment Air filtee—»57 [Level ‘witeh Sight glass Thermome ern - Heating at element a Temperatu re transducer =, aGismorm Lubrication U , Supply Line Pressure » relief valye 7 Supply pump an x! ; / i ‘oil cooler Manometers ) | Oil filter Flow meter Esmiorn Lubrication Unit, Return Line ( Oil filter / Pressure 7 relief vaive 2 Sight glass o { (GN N~valve for Manometers( oll filing Return , pumpEEsmorn Tire Segments The grinding roller has replaceable tire segments. Most wear takes place on one side, but the segments can be reversed. [smorm Roller in Maintenance Po: To change tire segments the roller is swung out into the maintenance position. 255[smiom Tire Segment Lifting Tool _ Lifting Eye Tire Toot smn Individual tire segments are handled with a special lifting tool Ebmorn Rocker Arm Assembly Rocker Arm er |, oot Tapered fe Free L = Rocker Arm =<" Thrust Arrangeme Fork ra A two-piece rocker arm fork and lever arrangement allows for swing-out without disturbing the hydraulic system[smorn Rocker Arm Assembly After disconnecting the rocker arm lever from the fork, the roller can be swung out for maintenance using the hydraulic swing-out cylinder Esmorm Rocker Arm Assembly The rocker arm lever and fork are joined by a tapered pin and sleeve. ar[smiorm Tapered Pin and Sleeve “a [omorn Swing-Out Cylinder The flow control valves on either end of the swing-out cylinder control the swing-out speed,[smiom Mechanical Stop ‘A mechanical stop prevents the roller from contacting the grinding table [smo Mechanical Stop The stop is adjusted as the tires and table liners wear down to in a minimum bed ickness. 259I Stop Adjustment The mechar stop prevents the roller, under full hydraulic pressure, from going below 6 mm above the table, Emon Spring Stop The disc spring cartridge provides a spring with extremely high spring force and minimal spring compression. 200Eemiorm Rocker Arm Seal Good sealing where the rocker arm goes through the mill body is essential to keep false air out of the grinding system, [smiorm Reject Scraper Inspect the rejects scrapers for tightness and wear. A loose scraper can cause a lot of damage to the ring canal.[Eomiorm The roller lubrication system has 3 functions: + Lubricating + Cleaning + Cooling [smiorn Rat 32%, _ Grinding Roller "ao Ga Lubrication System Close coupled. Reduced piping. Reduced flow losses. One lube unit per roller = no cross contamination[smior Roller Bearing Lubrication “4. Oil Vent when stoppedEEsmiorm Oil filling through the air filter is not necessary! EEemiomm Dirty maintenance should be avoided![Esmiorn Fulcrum shaft bearings Radiat ] bearings Axial bearing [Esmiorn Grease Fulcrum shaft lubricatjon Stee! bushing radial bearing port \ on 3 futerum shart Bronze bushing with solid 285smo Tension Spring System Connect the hydraulic cylinder to the joint rod in accordance A by [smo Tension Spring System Adjust the hydraulic eylind ) Align the connecting flange 0 the Joint head and tighten ) Mount sealing bellow bed depth indicator re n ,[smom The slide bearings are lubricated by an automatic grease lubrication unit [Esmiorn Grease He lubrication i unit Tank with wet Tevel esilly tg switch Switch a eeaahil _> Grease Sutlet for re pump each i | pressure i rere ter elle 267emo Hydraulic Cylinder and Joint Pin Assembly + Cylindrical pin design for improved fit 2 [smiom Cylinder end bearings Spherical steel =) bearing Bronze bushing with solid £ lubricant inserts bronze bearing ~ “Bronze rings Grease port with solid 268[smorm Hydraulic cylinder located in the mill base [smior Hydraulic cylinder Heavy duty seals with large clearance between steel parts 269Hydraulic Cylinder With Joint Head real plain bearing Easy to dismantle fan[smior Accumulator Pre charge System + Easier accumulator pre charge checking adjustment [emir Grinding pressure and Nitragen pre filing values. OK 33-4 ‘theddalitonsadOPUIStOTS! lela] |elelel =![smo Grinding pressure and Nitrogen pre filling values OK 33-4 with @Suiter decunulaters EEsmiorm Grinding Aid System 4 os | adhe[smorm Mill Water Injection [Esmiom Maintenance ToolsDTH Table Jacking Arrangement MAAG WPU Planetary Gearbox[smoemiom A key point for getting high availability on the gear box is correct lubrication! The gear is supplied with an automatic lubrication unit controlled by a local control panel. fe lubrication unit has 2 circuits: pre High pre sure circuit circuit[smiorn Low Pressure Circuit Functions + Lubricating gear wheels and bearings + Cleaning the oil + Cooling the gearbox during operation + Heating the gearbox during start up [smiorn TI! ‘Oil cooler i a as ~ oll filter | pea ! ~ Low & pressure pumpEsmiom High pressure circuit function: ‘Lubricating the thrust bearings High i Pressure —~ i pump . i oeEsmorn Supervision of gear box condition during operation ‘Temperatures Pressures Oil level [smorn Temperature F measuring points pay] Jhrust pad 20[morn Pressure measuring points [smiorn Oil level[emiorn Reject Chute and Conveyor ‘Material that falls through the louver ring is swept into the chute by the reject scrapers. The conveyor brings it to an elevator which puts it back into the mill for further grinding, Wear Protectionsmo Wear Protection The feed chute is lined with weld overlay plate. The mill body is liner with replaceable AR plate Emo Roller Wear Protection i The roller has weld overlay plate for wear protection where the roller crosses the high velocity air stream at the nozzle ring.Gismiorn Mill Drives > Planetary Drives > Thrust Bearing > Bevel Helical Drives > Lubrication Systems > Couplings > Maintenance and Inspection Thrust Beai Babbitte d Thrust oi Spray Pipe The thrust pads, mounted on ball and socket joints, accommodate the effects of hydrodynamic lubrication. sprayed into the space between the bearing and plate. Ball and Socket Mount tilt to Oil is 283