08 Rp-Trouble Shooting

LEARNING MORE ABOUT
ROLLER PRESS
TROUBLE SHOOTING
A TECHNICAL WORKSHOP
CONDUCTED BY
HUMBOLDT WEDAG INDIA-
PROCESS KNOW HOW
1
1. Roller Skewing
2. Managing Vibrations
Trouble Shooting
3. Material Distribution
4. Contents
Lets learn more about the most efficient Grinding Technology-Roller Press 2
Trouble Shooting Overview
I. Roller Skewing
II. Managing Vibrations
III. Material Distribution
IV. Contents
Roller Managing Material
Contents
Skewing Vibrations Distribution
Managing of Roller Skewing
Skewing Normal operation

Main reason:
 Uneven PS distribution Roller 1 Roller 1
because of segregation Fine Material
(serious process problem!)
Coarse Material
Gap distance
Possible consequences
skewing: BIG FORCES Roller 2 Roller 2
 Damage of roller surface
 Damage of gear box Possible consequence: Serious surface damage on the side with big forces
 Short roller lifetime
Detection:
High difference between roller distance
left and right (> 6 mm)
Contents
Managing of Roller Skewing
Measures:
 Decrease hydraulic pressure
 Decrease roller speed (where possible)
 Adjust feed gate position (where possible)
 If skewing continuous: STOP THE PRESS
 Modify entire feeding arrangement if problem persists
Contents
Managing Vibrations
Main reason:
 Too high roller speed
 Too coarse feed
 Too fine feed
 Poor ventilation out of gap
Possible consequences:
 High wear on roller surfaces
 Decreased roller lifetime
 Damage of gearboxes Detection:
Trend vibration measurement
 Poor grinding efficiency
Contents
Managing Vibrations
Measures:
 Decrease hydraulic pressure
 Decrease roller speed
 Adjust feed gate position (where possible)
 If vibration continuous: STOP THE PRESS = > Solve serious process
problem!
Contents
Managing uneven Material Distribution on Rollers
feeder 1 feeder 2
Main reason:
 Bad feeder arrangement Coarse (e.g.
clinker and
Fines (e.g.
(fines go to one side of the gypsum)
returns)
feed bin, coarse to the
other)
Rollers
Contents
Possible consequences:
 Low production
 Reduced life time of roller surface
 Surface break outs and expensive repairs to rollers
 High risk of damaging gear boxes
Material
Detection: Trend
Roller 1 Roller 2
kW
Motor roller 1
coarse fine
Motor roller 2
kW 1 > kW 2
time
Contents
Measures:
 Reduce hydraulic pressure
 Reduce roller speed
 Solve process problems by modifying feed arrangement
Contents
Dosing Gate too much opened

If material becomes
too fine pressue
and kW can start
fluctuating heavily.
Lowering dosing gate
Contents
Contents
1. Excessive Plant Noise Emission in Hydraulic System
2. Abnormal pressure or flow variations and vibrations in Hydraulic System
3. Excessive pressure fluid temperature in Hydraulic System
4. Changes gear noise in Planetary Gear Box
5. Oil leakage, Oil Temperature high/low, Oil mixed with water in Planetary Gear Box
6. Changes in Noise level/Vibration, No torque transmission in Fluid and N-EUPEX

Coupling
7. Not delivering oil, Irregular/low flow, pressure level high of hydraulic pump
8. Pump overheating, valve cone chattering, Motor overheating, hydraulic pump seizes up
9. Other Troubleshooting activities
Contents
1 - Excessive Plant Noise Emission in Hyd. System

Sr. No. Cause Reason Action for correction
1. Cavitaion wear in the pump Pressure fluid too cold Heat pressure fluid to recommended temp.
Pressure fluid viscosity too high Discharge pressure fluid and fill up correct fluid
Vapour formation Reduce working temperature to required level

Feed Pump breakdown Repair or replace feed pump
Pump is running too fast Limit speed to correct velocity
Foam formation or air
2. The pressure fluid level low Refill oil to correct level
entrapped in pressure fluid
Wrong pressure fluid used Fill up correct fluid
Air penetration through shaft seal Replace shaft seal
Insufficient venting Vent the unit
3. Mechanical vibration Defective alignment or loose coup. Re-align or re-tighten
Pipe line vibration Retighten or improve assemblies
4. Pump Worm or damaged Repair or replace
Coupling element defective Replace element
5. Pump drive Damaged Repair or replace
Coupling element defective Replace element
6. Safety- or pr. limiting valve Fluttering Correct setting or replace
Contents
2 - Abnormal pressure or flow variations and vibrations in Hyd. System

1. Cavitaion wear in the pump Pressure fluid too cold Heat pressure fluid to recommended temp.
Excessive pressure fluid viscosity Replace pressure fluid

Vapour formation Lower temperature
Feed Pump breakdown Repair or replace feed pump
Pump is running too fast Limit speed to correct velocity
2. Foam formation or air entrapped The pressure fluid level low Refill oil to correct level
in pressure fluid
Wrong pressure fluid used Fill up correct fluid
Air penetration through shaft seal Replace shaft seal
Electric system faulty Repair / rectify

Insufficient venting Vent the unit
3. Mechanical vibration Defective alignment or loose coupling Re-align or re-tighten
4. Safety valve or pressure limiting shuttering Correct setting or replace

valve
Damaged valve seat Repair or replace
In proper valve seat contact Replace
5. Valves sticking Coating / dirty fluid Replace pressure fluid
Clean valves
Contents
3 – Excessive pressure fluid temp. in Hyd. System

1. Spillage of fluid Wrong pressure setting Correct setting and fill up fluid to correct level
Safety valve mal functioning Replace
Leakage of fluid in between valve mal functioning and leakage of fluid Correct setting, Clean line, locate damage and
2.
delivery & return through Gaskets Repair/Replace Gaskets & Elements
Pressure fluid viscosity too low or too

Replace fluid
high
Insufficient cooling and heat

3. Interruption in cooling water supply Check the water source and rectify fault
dissipation
Deposits in water line / heat exchanger Clean
Increase retention time of cooling water
4. Pump over heated Worn pump Repair / replace
Pressure fluid viscosity too low or too

Replace fluid
high
Contents
4 – Changes gear noise in Planetary Gear Box

1. Damage of gear teeth Contamination of gear box oil Replace the Oil
Entry of foreign material Clean gear box and replace oil
Check gear teeth and repair/replace gear
2. Bearing defective Looseness, pitting on rolling element, Replace

damage of inner race / outer race /
cage
Oil leakage from Seal Replace the seal

bearing temperature high Check oil level, top up if required, check cooling
system
3. Noise / vibration from gear Looseness of fasteners Tighten / Replace damage bolts
unit fasteners
Contents
5 – Oil leakage, Oil Temperature high/low, Oil mixed with water in

Planetary Gear Box
1. Gear unit oily Leakage from seal, housing cover, joints Check and rectify
2. Oil temp. high Oil level too high/low Adjust the oil level
Oil contaminated Replace
Oil cooling system not functioning properly Check heat exchanger/Pipe line&clean if reqd
Clogged filter Clean filter

In proper oil / coolant flow Fully open valves
3. Oil temp. low Cooling water flow high / lower water temp. Reduce cooling water supply
4. Water in oil Damage of heat exchanger tube Repair / Replace
Cooled air coming from machine room ventilator Alter the direction of ventilator air
heating gear unit causing condensation
5. Oil pressure high Pressure relief valve defective or wrongly set Repair/Replace PRV or correct the setting
Oil pipe line chocked Locate blockage and clean pipe

Oil viscosity high Check and fill the correct oil
6. Oil pressure low Filter clogged Clean / replace filter elements
Pressure relief valve defective or wrongly set Repair/Replace PRV or correct the setting
Pump defective Repair/Replace

Oil viscosity low Check and fill the correct oil
7. Oil consm high Leakage in the system Tightened the fittings / replace the seals
Contents
6 – Changes in Noise level/Vibration, No torque transmission in Fluid

and N-EUPEX Coupling
1. Change of Alignment Loosening of gear box mounting bolts Fully tighten
Wear of flexible elements of N-EUPEX

Replace
coupling
Wear of coupling parts Replace
Rectify the source of leakage and top up oil to

2. Coupling temperature high Oil leakage from coupling, oil level low
required level
Sharp increase in oil pressure, higher

3. Coupling failure Replace coupling and fill the oil 80% of total volume
oil level
Fusion of safety plug , over heating or

4. No torque transmission Fill up oil and fit up new plug
high oil level
Contents
7 – Not delivering oil, Irregular/low flow, pressure level high of

hydraulic pump
1. Not delivering oil, Incorrect direction of rotation Correct direction of rotation
irregular / low flow,
pressure level high
Pump not filled, oil seal Fill and bleed pump and suction line
inadequate
Suction line leaking Seal the suction line
Shaft seal leaking Replace seal
Screw plugs leakage Seal and tighten plugs
Suction head excessive / inflow Check suction head/ resistance, increase the line cross suction or
inadequate shorten the length of the line
Suction filter clogged or internals Clean, Replace damage parts
parts worn out
No bleed facility in the delivery line Install by pass line with return line in to the oil tank
Partial flow via pressure relief Machine valve cone or replace

valve, valve cone jamming
Suction & Delivery line clogged Clear clogging or deposits
Contents
7 – Not delivering oil, Irregular/low flow, pressure level high of

hydraulic pump
1. Not delivering oil, Pressure relief valve opening too Set PRV to higher value and replace valve spring
irregular / low flow, early
pressure level high
Air inclusions in circulation system Return lines must enter the tank blow oil level
Inadequate bleeding Lay suction and return connection further apart in the tank
Pump medium frothing Increased bleed area

Volumetric efficiency too Reduce the speed of rotation for high viscous oil
low/viscosity too high
Contents
8 – Pump overheating, valve cone chattering, Motor overheating,

hydraulic pump seizes up
1. Pump seizes up Pump not filled Fill and bleed pump and suction line
Flied seal Inadequate Replace seal
Foreign bodies in pumps Dismantle pump and remove foreign bodies, Replace
damage parts and install filter in suction line
Sized bearing assembly Dismantle pump and repair
2. Motor overheating Power consumption to high Check motor rating, install higher power motor, reduce
RPM
Running on two phases Repair motor or replace fuse
Inadequate cooling In prove cooling air supply
High viscosity of pump medium Heat oil
Motor bearing assembly defective Repair
3. Pump overheating Delivery pressure too high Reduce pressure / increase size of delivery line / reduce
resistances
Speed of rotation too high Reduce RPM
Defective bearing Check Repair / Replace
Over loaded bearing Improve lubrication
Inadequate viscosity of pump medium Reduce Temp
Miss Alignment Align
Stuffing box packing over tightened Slacken stuffing box gland nuts
4. Valve cone chattering Valve spring operating in resonance range Fit new valve spring
Valve cone beating against seat Adjust the opening pressure
Contents
9- Other Troubles and Corrective actions

Sr. No. Fault Reason Action for correction
1 Roller gap too large Roller surface worn out Measure roller surface ,repair if required
No contact pressure Check hydraulic system for proper functioning

Rubber plate worn Replace
Way transmitter setting incorrect Adjust the way transmitter
Material deposits between bearing clean

housings
2 Roller gap too small length of spacer elements not correct Insert spacer of proper length
Way transmitter setting incorrect Adjust the way transmitter
Roller diameter too large Check roller diameter ,set the gap
3 Rollers blocking Foreign bodies in roller gap Remove foreign bodies
Excessive material volume Empty material supply
4 Rollers do not rotate Defective motor Check motor ,repair

Defective fluid coupling Check oil level ,fusible plug
Defective gear box Check/repair
Shrink disc connection loose Check/repair
Contents

5 Deterioration of the Pressure too low Check and correct
flake quality
Roller gap too large or small Check roller surface ,roller wear
Check min roller distance
Dosing of the feed not sufficient Check setting of dosing device and adjust
Material flows besides the rollers Check feeding device for wear, replace worn out parts
Check wear on head walls& lateral walls tips, replace /repair
parts
Check setting of head walls ,correct if required
Spacer elements at the bearings Increase of material volume
come in contact during operation
Reduce the material contact pressure

Check/correct length of spacers
Remove material accretions between the spacer elements
6 Heavy vibration Feed size too large Reduce feed size to admissible value
RP foundation bolts loose Check and tighten foundation bolts
Roller surface damage Check and repair
Roller diameter out of round Check spacer and roller diameter
Contents

Irregular movement of movable
7. Nitrogen reservoir pressure low Check and re-fill
roller
Nitrogen reservoir defective Check N2 reservoir and replace if reqd
8. Hot hydraulic oil Internal leakage in the hydraulic system Check, Repair hydraulic system
Pump running time too long Check / repair pump & Motor
Rapping of the valve in
9. Nitrogen reservoir pressure low Check and fill
reservoir
Nitrogen reservoir defective Check N2 reservoir and replace if reqd
Differential pressure between pressure limit
valve set in hyd. system and adjusted is not Make Correct setting
higher by 20 Bar
Feeding Device gates cannot
10. Material accretion in adjusting area Check and remove
be adjusted
Articulated point jammed Check and lubricate
Guide distorted or jammed Check and repair
11 Material coming out from rollers Sealing plate distorted Check and replace
Flange bolts loose Re-tighten bolts

Sealing roller lining defective Repair
Dust collecting system defective Repair
Any further Question?
25
To get more out of
your cement plant, visit
www.khd.com
26

08 Rp-Trouble Shooting

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LEARNING MORE ABOUT

II. Managing Vibrations

III. Material Distribution

Managing of Roller Skewing

Skewing Normal operation

Managing of Roller Skewing

 Decrease hydraulic pressure

 Decrease roller speed (where possible)

 Adjust feed gate position (where possible)

 If skewing continuous: STOP THE PRESS

 Modify entire feeding arrangement if problem persists

 Too coarse feed

 Too fine feed

 Poor ventilation out of gap

 Decrease hydraulic pressure

 Decrease roller speed

 Adjust feed gate position (where possible)

 If vibration continuous: STOP THE PRESS = > Solve serious process

Managing uneven Material Distribution on Rollers

Managing uneven Material Distribution on Rollers

Managing uneven Material Distribution on Rollers

 Reduce hydraulic pressure

 Reduce roller speed

 Solve process problems by modifying feed arrangement

Dosing Gate too much opened

1. Excessive Plant Noise Emission in Hydraulic System

2. Abnormal pressure or flow variations and vibrations in Hydraulic System

3. Excessive pressure fluid temperature in Hydraulic System

4. Changes gear noise in Planetary Gear Box

6. Changes in Noise level/Vibration, No torque transmission in Fluid and N-EUPEX

9. Other Troubleshooting activities

1 - Excessive Plant Noise Emission in Hyd. System

Vapour formation Reduce working temperature to required level

2 - Abnormal pressure or flow variations and vibrations in Hyd. System

Excessive pressure fluid viscosity Replace pressure fluid

Electric system faulty Repair / rectify

4. Safety valve or pressure limiting shuttering Correct setting or replace

3 – Excessive pressure fluid temp. in Hyd. System

Safety valve mal functioning Replace

Pressure fluid viscosity too low or too

Insufficient cooling and heat

Deposits in water line / heat exchanger Clean

Increase retention time of cooling water

4. Pump over heated Worn pump Repair / replace

Pressure fluid viscosity too low or too

4 – Changes gear noise in Planetary Gear Box

Entry of foreign material Clean gear box and replace oil

Check gear teeth and repair/replace gear

2. Bearing defective Looseness, pitting on rolling element, Replace

Oil leakage from Seal Replace the seal

5 – Oil leakage, Oil Temperature high/low, Oil mixed with water in

Clogged filter Clean filter

Oil pipe line chocked Locate blockage and clean pipe

Pump defective Repair/Replace

6 – Changes in Noise level/Vibration, No torque transmission in Fluid

1. Change of Alignment Loosening of gear box mounting bolts Fully tighten

Wear of flexible elements of N-EUPEX

Wear of coupling parts Replace

Rectify the source of leakage and top up oil to

Sharp increase in oil pressure, higher

Fusion of safety plug , over heating or

7 – Not delivering oil, Irregular/low flow, pressure level high of