FLSmidth

ATOX Mill Hydraulic System

© 2008 Eaton Corporation. All rights reserved .

ATOX MILL
HYDRAULIC FUNCTION
HYDRAULIC FUNCTION
HYDRAULIC FUNCTION
HYDRAULIC FUNCTION
HYDRAULIC FUNCTION ­ ACCUMULATOR
HYDRAULIC FUNCTION ­ ACCUMULATOR
HYDRAULIC FUNCTION – SPRING ANALOGY
HYDRAULIC FUNCTION ­ LEAKAGE

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HYDRAULIC FUNCTION – PUMP & PLC

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HYDRAULIC FUNCTION – PUMP & PLC

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HYDRAULIC FUNCTION ­ LIFTING
FULL CIRCUIT
TANK & FILTRATION UNIT

SIGHT
GLASS

WATER
THERMOMETER CONTROL
VALVE WATER STRAINER
PRESSURE
GAUGE

WATER
COOLER EMPTYING
CHECK POINT
VALVE
FILTER
AIR
BREATHER
LEVEL
FILTER
GAUGES
BLOCKED HEATER
BAFFLE DIFFUSER SWITCH
2400 LITRE TANK
SHUT­OFF GEAR
VALVE PUMP
DRAIN VALVE ELECTRIC
FLEXIBLE HOSE MOTOR

FILLING
POINT
TANK & MAIN PUMP

PUMP CASE DRAIN

TEMPERATURE
FLOW TRANSDUCER
METER
LEVEL
SWITCHES
FLEXIBLE SUCTION
FLEXIBLE
HOSE HEATER STRAINER
HOSE

SHUT­
OFF
VALVE
WITH
LIMIT
VARIABLE SWITCH
PISTON
PUMP
ELECTRIC
MOTOR
FLEXIBLE HOSE
CYLINDER & ACCUMULATORS

GAS PRESSURE
SWITCHES

CHECK PRESSURE GAUGE

ORIFICE VALVE CYLINDER

ACCUMULATORS

TO 2 OTHER
CYLINDERS
CONTROL VALVES

DIRECTIONAL VALVES
DIRECTIONAL VALVES

SOLENOID
VALVE

CHECK
VALVE
SOLENOID
VALVE
CHECK
VALVE

ACCUMULATOR
CHECK UNLOADING
DRAIN VALVE
VALVE VALVE
RELIEF
VALVE
SIMPLIFIED CIRCUIT
SIMPLIFIED CIRCUIT

F R F R R
SOLENOID PILOT VALVES

F A R F B R R Bx Bx

Valves 53 & 64 ensure

that the highest pressure
in the system is used as
pilot pressure.
SOLENOID PILOT VALVES ­ LOWERING
SOLENOID PILOT VALVES ­ LIFTING
SOLENOID PILOT VALVES – DECREASING GRINDING PRESSURE
ROLLERS LIFTING
81 82
Y1 Y2

Rollers are lifted off

the grinding bed for mill
start-up to reduce
excessive vibration.
ROLLERS LIFTING
81 82
Y1 Y2

Valve 61 ensures a
minimum pressure in line
A which prevents full
discharge of the
accumulators.
ROLLERS LIFTED
81 82
Y1 Y2

Valve 61 is set to a
pressure 20–30 %
higher than the
accumulator pre-charge
pressure.

Pump remains running while rollers are lifted.

ROLLERS LOWERING
81 82
Y1 Y2

With valve 61 acting as

a counterbalance valve,
the cylinders will lower
at a speed determined
by the pump flow rate.
ROLLERS LOWERING
81 82
Y1 Y2

Valve 61 creates a
counterbalance
pressure in line B to
prevent rapid falling of
the rollers.
ROLLERS LOWERING
81 82
Y1 Y2

When the rollers

contact the grinding
bed, pressure builds up
in line A thus opening
valve 61 fully to relieve
the back pressure in
line B.
ROLLERS LOWERING
81 82
Y1 Y2

The will pump continue

to run until all of the
accumulators are fully
charged to the required
grinding pressure.
ROLLERS LOWERED/ OPERATION
81 82
Y1 Y2

When the accumulators

are charged, the pump
drive motor is switched
off.
ROLLERS LOWERED/ OPERATION: INCREASING GRINDING PRESSURE
81 82
Y1 Y2

To increase grinding
pressure, the pump is
simply switched on …
ROLLERS LOWERED/ OPERATION: INCREASING GRINDING PRESSURE
81 82
Y1 Y2

… which charges the

accumulators further
until the required
pressure is signalled on
the pressure sensor 44.
ROLLERS LOWERED/ OPERATION
81 82
Y1 Y2

The pump drive motor is

then switched off.
ROLLERS LOWERED/ OPERATION ­ REDUCED GRINDING PRESSURE
81 82
Y1 Y2

If a lower grinding
pressure is demanded,
New set point for
pressure sensor 44 is
set.
Y2 energises to open
valve 74 & bleed of oil
from the pressure side.
ROLLERS LOWERED/ OPERATION ­ REDUCED GRINDING PRESSURE
81 82
Y1 Y2

Y2 energises to open
valve 74 & bleed of oil
from the pressure side.
ROLLERS LOWERED/ OPERATION ­ REDUCED GRINDING PRESSURE
81 82
Y1 Y2

Solenoid Y2 de-
energises when the
pressure has dropped to
the required level.
ROLLERS LOWERED/ OPERATION ­ REDUCED GRINDING PRESSURE
81 82
Y1 Y2

A reduction in grinding
pressure could be
required for example if
there is a large lump
size on the grinding bed.
ROLLERS LOWERED/ OPERATION ­ EXCESS PRESSURE RELIEF
81 82
Y1 Y2

Pressure sensor 44
signals the excess
pressure.
Y2 energises to open
valve 74 & bleed of oil
from the pressure side.
ROLLERS LOWERED/ OPERATION
81 82
Y1 Y2

Solenoid Y2 again de-

energises when the
pressure has reduced to
the required level.
EMERGENCY STOP
81 82
Y1 Y2

Valve 56 de-energises
and thus opens at very
low pressure to unload
system pressure during
a power loss or
emergency stop
situation.
MAINTENANCE
81 82
Y1 Y2

65

CAUTION: Open valve

65 to drain
accumulators before
carrying out any
maintenance work on
the system.
PRESSURE SETTINGS

SET POINT P S

The set-point for the

grinding pressure is set
from the Central
Control Room.

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PRESSURE SETTINGS

P S + ΔP 1

SET POINT P S
The pump will charge
the accumulators to P S +
ΔP1 then the pump drive
motor will stop.

Over a period of time,

leakage will cause the
grinding pressure to
drop.
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PRESSURE SETTINGS

P S + ΔP 1

SET POINT P S

P S ­ ΔP 4
When the pressure has
dropped to P S – ΔP4, the
pump is re-started to
charge the
accumulators back to P S
+ ΔP1 when the cycle
repeats.
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PRESSURE SETTINGS

P S + ΔP 1

SET POINT P S

P S ­ ΔP 4

Typically the cycle time

between pump re-starts
should be in the range
10 to 60 minutes.
10 – 60 min
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PRESSURE SETTINGS

P S + ΔP 1

SET POINT P S

P S ­ ΔP 4

The minimum system working pressure should

therefore always be higher than the
accumulator pre-charge pressure to ensure
that the accumulators are never fully emptied.
t
PRESSURE SETTINGS

Y2 P S + ΔP 3

P S + ΔP 1

SET POINT P S

P S ­ ΔP 4
If a build-up of material on
the grinding bed causes the
pressure to rise to P S + ΔP3
then solenoid Y2 energises
to bleed some accumulator
volume to tank.
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PRESSURE SETTINGS

Y2 P S + ΔP 3

P S + ΔP 1

SET POINT P S
Y2 P S ­ ΔP 2

P S ­ ΔP 4

Solenoid Y2 will de-energise

again when the pressure has
dropped to P S – ΔP 2.

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PRESSURE SETTINGS

Y2 P S + ΔP 3

P S + ΔP 1

SET POINT P S
Y2 P S ­ ΔP 2

P S ­ ΔP 4

The pump compensator is

set to a pressure higher
than P S + ΔP 3

t
PRESSURE SETTINGS

Y2 P S + ΔP 3

P S + ΔP 1

SET POINT P S
Y2 P S ­ ΔP 2

P S ­ ΔP 4

And the system relief

valve is set at least 10 bar
higher than the pump
compensator
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CYLINDER DOUBLE ROD SEAL

Normal connection
SEAL LEAKAGE TEST

The drain hose

can be removed
using the quick
release
connections.
SEAL LEAKAGE TEST

The supplied hose

can then be used to
check for seal
leakage from the
inner seal.
CYLINDER DOUBLE ROD SEAL

If leakage is detected,
block the drain line (to
pressurise the outer
seal) until the inner
seal can be replaced.
F. L. Smidth
Atox Mill Hydraulic System

© 2008 Eaton Corporation. All rights reserved .

 F. L. SMIDTH
Atox Mill
Hydraulic System
Steve Skinner
Eaton Fluid Power
Havant, UK
November 2003
1st Revision November 2004
2nd Revision November 2005
3rd Revision January 2006
4th Revision December 2007

5th Revision Marts 2011 By FLSmidth NISM+JOK

© 2004 Eaton Corporation. All rights reserved.