Cement mill-2 Inlet Slide shoe bearing inspection work

Preparatory jobs:

1. Grinding media unloading (1st and 2nd chambers)

2. Scaffolding arrangement at mill inlet slide ring area.
3. Zugad preparation for slide shoes blue matching on slide ring
4. Both the torsion shafts dismantling work
5. Zugad preparation for mill lifting

Spare parts required:

 Rubber lip seals, felt seals of the bearing

 Guide rails
 Rubber packing for the guards
 Molykote grease

Slide shoe bearing dismantling procedure:

 Dismantle the cables from thermal sensors and proximity sensors

 Dismantle the felt/rubber seals on both sides of the bearing.
 Dismantle the top section & guards of the inlet slide ring
 Oil & water hoses to be dismantled. Cooling water to be drained from
bearings.
 The guide rails on each side of the slide shoes & oil pans must be removed
 Stationary inlet has to be removed
 Outlet felt seal, top expansion joint of the outlet side has to be removed
 Dismantle outlet slide ring seals, girth gear guard felt seals.
 When the mill is lifted, it is very important to check that pinions are
capable of turning freely.
 The mill end is lifted by means of two hydraulic jacks between the saddle
and a sufficiently sturdy block-up arrangement on the inner side of the
bearing foundation.
 The saddle must be placed as close to the bearing foundation as possible
 Blocks of the hard wood must be placed over the entire area of the saddle
and the mill shell(65-70mm holes to be drilled on the hard wood at lining
bolts area)
  The saddle to be placed under the mill, with all supports and jacks in
position.
 After the tools for dismantling the slide shoe have been placed on the bed
plate, the mill must be lifted to extent needed to ensure that the ball
segment of the slide shoe is only just clear of the ball socket(min.42mm)
 The hydraulic jacks must be locked and oil pressure from the jacks must be
relieved.

Dismantling tools fixing procedure:

 Clean the threaded holes on the bedplate and mount the supports of the
tools.
 Mount the jacks and the cross beams on the supports, the height must be
adjusted so that the hardwood intermediate on the three caterpillar rollers
make contact with the slide shoe.
 Check that both cross beams are horizontally positioned and that the
working length of the jacks is sufficient to lift the slide shoe with ball
segment clear the ball socket of the bearing.
 The eye bolts must be fitted carefully in the two large threaded holes at
each end of the slide shoe.
 To prevent the uncontrolled movement of the slide shoe on the cross
beams during the operation, the slide shoe must be effectively secured
through a wire from the eye bolts at the ends of the slide shoe attached to
bolts on the mill shell or fixed points in the building.
 The slide shoe can now be lifted clear to the base part of the bearing using
the four jacks of the tools with simultaneous adjustment.
 The slide shoe is to be pulled out of the bearing with full controllability of
the movement by easing off the wire ropes.
 When the slide shoe has been disengaged fully from the bearing, wedges
must be placed under one of the three “caterpillar rollers” while the
strapping arrangement must be adapted so that the slide shoe can be lifted
away.
 Scrapping and blue matching of the slide shoes
 The Slide shoe bearing rollers cleaning and rotating 90 degrees.
Mounting of slide shoe :

 The mounting of a slide shoe in the slide shoe bearing corresponds exactly
to the dismantling procedure applied for the slide shoe, only in reversed
sequence.
 At final mounting stage, the slide shoe and slide ring must be cleaned very
carefully and lubricated using the EP 460 oil.
 The ball segment and socket must also be cleaned and lubricated with
molykote or a similar lubricant.
 When the mill is lowered down towards the slide shoes, it must be possible
for the shoes to move freely to their proper position after the slide ring. If
necessary, this can be ensured by reducing the height of the two lower
most jacks, subsequently removing the two uppermost caterpillar rollers.
 In this way, the slide ring will first get into contact with the slide shoe at
the upper end and it will lose contact with the support when the mill is
lowered.
 Just before the mill is lowered completely, the bronze guide rails of the
slide shoes must be mounted so that the slide shoe, and on the movable
slide shoes, the components on the rollers match the slide ring.
 The bolts of the guide rails must not be tensioned to the specified torque
level until the mill has been lowered to its exact position in the slide shoes.
 After ensuring that the mill is in exact position all the guide rails bolts is to
be torque to the specified value.
 Oil pans, oil and water hoses are to be connected.
 After ensuring that there is no leakages in oil and water hoses joints, all the
guards has to be fixed by keeping the rubber packing and sealant at joints.
 Before the mill is put into operation a final inspection must be made of the
lubrication system and water cooling system of the bearing, checking also
that all hose connections are tight.
 Cables, thermal sensors, proximity sensors are to be connected.
 Girth gear guard felt packing, outlet slide ring guard seals to be fixed
 Torsion shafts are to be connected
 Outlet felt packing and expansion joint has to be fixed.
 Scaffoldings and jugads have to be removed from position
 Grinding media has to be loaded.
CEMENT MILL-1 LIFTING SIDE RAW MILL-1 PRESSING SIDE
GEAR BOX EP-320 OIL GEAR BOX EP-320 OIL

CEMENT MILL-2 LIFTING SIDE CEMENT MILL-2 PRESSING SIDE

GEAR BOX EP-320 OIL GEAR BOX EP-320 OIL

Tweanty thousend
O,
GEOCHEM MIDDLE EAST

PLOT # TP/010305

TECHNO PARK DUBAI - UAE

PHONE NO :048867400
 Date: 03/4/2012

To
The Deputy Chief Engineer ( Mech )
Pioneer Cement Industries L.LC,
Ras Al Khaimah.
U.A.E

Sub: Oil samples

Dear sir,

With reference to our phone call, we send the oil samples for following equipments.

Oil sample taken for following equipment Date:03-04-2012

Sr Oil grade Tank
no Description/ Identification (Total) capacity Date of sample

1 Cement mill -1 Inlet HLPC EP 460 OIL 420 liters 03/04/2012

2 Cement mill -1 outlet HLPC EP 460 OIL 420 liters 03/04/2012

3 Cement mill -2 Inlet HLPC EP 460 OIL 420 liters 03/04/2012

4 Cement mill -1 outlet HLPC EP 460 OIL 420 liters 03/04/2012

5 Raw mill-1 inlet EP 460 OIL 420 liters 03/04/2012

6 Raw mill-1 out let EP 460 OIL 420 liters 03/04/2012

7 Raw mill-2 out let EP 460 OIL 420 liters 03/04/2012

8 RAW MILL-2 Lifting SIDE EP 320 OIL 440 liters 03/04/2012

NOTE: 1). Foam testing 500ml sample.

With Best Regards,

G.Aayavaru Reddy,

Sr.Engineer (Mech).
 Main Group 13-BALL MILL,ROLLER PRESS AND ACCESSORIES
Sub Group 08-OSEPA
Sub-Sub Group 01-OSEPA
Item Description CERAMIC TILE (LINING)
Item
SIZE : 6X100X150MM MATEARIAL:85% AL2 O3, TILE WITH STAND TEMP :180 DEG
Specification

Status REJECTED
Remarks Rejected due to Group not Correct

Main Group 13-BALL MILL,ROLLER PRESS AND ACCESSORIES

Sub Group 08-OSEPA
Sub-Sub Group 01-OSEPA
Item Description CERAMIC TILE (LINING)
Item
SIZE : 6X100X100MM MATEARIAL:85% AL2 O3, TILE WITH STAND TEMP :180 DEG
Specification

Status REJECTED
Remarks Rejected Due to Group Not matched
Main Group 13-BALL MILL,ROLLER PRESS AND ACCESSORIES
Sub Group 08-OSEPA
Sub-Sub Group 01-OSEPA
Item Description CERAMIC TILE (LINING)
Item Specification SIZE : 6X25X150MM MATEARIAL:85% AL2 O3, TILE WITH STAND TEMP :180 DEG

Status REJECTED
Remarks Rejected due to Group Not matched

Main Group 13-BALL MILL,ROLLER PRESS AND ACCESSORIES

Sub Group 08-OSEPA
Sub-Sub Group 01-OSEPA
Item Description WHITE RTV SILICONE (ADHESIVE)
Item Specification WITH STAND TEMP :180 DEG

Status REJECTED
Remarks Rejected Due not Group Not matched