Technical Seminar Miami M iami 2013
Miami, September 17 - 19, 2013
Proceedings Convening Networking
E H C S E O L y b ©
Page 2
E H C S E O L y b ©
Page 2
Final programme September 16, 2013
19:00 - 22 22:00
Social ac activity, Lo Location TBD - meet in hotel lo lobby
Septem Sep tember ber 17, 201 2013 3
Tech echnic nical al Semi Seminar nar at Doubl DoubleT eTree ree by Hilt Hilton on Gran Grand d Hotel Hotel Bis Biscay cayne ne Bay Bay
08:30 - 09:00
Registration open: Coffee and networking
09:0 :00 0 - 09.15
Welcome address / opening remarks / Agenda overv rviiew - Perla Ruiz, LOESCHE America, Inc.
09:1 :15 5 - 09:30
Meet the delegates - In Inttroduce yourself to the audience
09:30 - 10:30
Introduction LOESCHE vertical vertical roller mills - Desi Delgado, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
10:45 - 12:00
Process, operation & evaluation of LOESCHE mills mills - Christian-Martin Ruthenberg, LOESCHE GmbH
12:00 - 13:00
Lunch and networking
13:00 - 14:30
Main assembly groups - Peter Lolschou, LOESCHE America, Inc.
14:30 - 14:45
Coffee and networking
14:45 - 15.45
Open discussion
September 18, 2013
E H C S E O L y b ©
08:30 - 09:00
Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:30
Maintenance & procedures - Peter Lolschou, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
Page 3
Final programme 10:45 - 11:45
Main mill gearbox - Desi Delgado, LOESCHE America, Inc.
11:45 - 13:00
Hydraulic Systems: Function & design Part 1- Dirk Grube, LOESCHE GmbH
13:00 - 14:00
Lunch and networking
14:00 - 14.45
Hydraulic Systems: Function & design Part 2- Dirk Grube, LOESCHE GmbH
14:45 - 15:00
Coffee and networking
15:00 - 16:30
Process parameters - Christian-Martin Ruthenberg, LOESCHE GmbH
September 19, 2013
08:30 - 09:00
Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:45
Stabilization of mill in upset conditions - Christian-Martin Ruthenberg, Ruthenberg, LOESCHE GmbH
10:45 - 11:00
Coffee and networking
11:0 :00 0 - 12 12:30
Optimization of gr grinding plants: Upgrades, mo modifications - Desi Delgado, LOESCHE America, Inc.
12:30 - 13:30
Lunch and networking
13:30 - 14:45
World Café - hosted workshops
14:45 - 15:00
Coffee and networking
15:00 - 15:30
World Café summary
15:30 - 15:45
Closing remarks - end of seminar - Perla Ruiz, LOESCHE America, Inc.
E H C S E O L y b ©
Page 4
Organisers Perla Ruiz Project engineer, LOESCHE America, inc.
Desi Delgado Customer Service Manager, LOESCHE America. Inc.
Main activities: • Technical Support for existing plants in the Americas • Office coordinator for new project installation & commissioning supervisors • Inspections and investigations at plant sites
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
email:
[email protected]
email:
[email protected]
In cooperation with LOESCHE Training Center, Germany: Theodora Bruns Head of Training Center, LOESCHE GmbH
Dr Regina Krammer Deputy Head Training Center, LOESCHE GmbH, Germany
Main activities: • Development of blended learning concepts for internal and external use • Business development • Customer service
Main activities: • Development of blended learning concepts for internal and external use • Design of eLearning courses • Knowledge management and communication
email:
[email protected]
email:
[email protected]
Christian-Martin Ruthenberg Technical trainer, LOESCHE GmbH, Germany
E H C S E O L y b ©
Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants email:
[email protected] Page 5
Lecturers Desi Delgado
Christian-Martin Ruthenberg
Customer Service Manager, LOESCHE America. Inc.
Technical trainer, LOESCHE GmbH
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants
email:
[email protected]
email:
[email protected]
Peter Lolschou
Dirk Grube
Field Service Manager, LOESCHE America, inc.
Deputy director Design, LOESCHE GmbH
Main activities: • Technical field services • Customer support • Inspections and investigations at plant sites
Main activities: • Design of hydraulic applications at LOESCHE mills • Coordination of design draftsmen
email:
[email protected]
email:
[email protected]
E H C S E O L y b ©
Page 6
About LOESCHE Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continually advanced and in the meantime is synonymous with LOESCHE GmbH. The key competence of the company is the design and development of individual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first concept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities. In April 2012, LOESCHE GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions. Having taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activities with related products e.g. industrial burners and hot gas generators.
When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the the principle of ‚integrated learning‘ (Blended Learning Concept) with the aid of the latest learning methods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidtate the knowledge so imparted in the best manner possible and with lasting effect.
For more information please refer to: www.loesche.com LOESCHE GmbH Hansaallee 243 D-40549 Duesseldorf Tel.: +49-211-5353-0 Fax: +49-211-5353-500
LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 employees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Russia and P.R. China as well as agents in more than 20 countries.
E H C S E O L y b ©
The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates trainings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.
Page 7
Introduction LOESCHE vertical roller mills by Desi Delgado, LOESCHE America, Inc.
Introduction LOESCHE vertical roller mills
Desi Delgado, Technical Instructor Miami, September 2013
E H C S E O L y b ©
Page 8
Table of contents
Technical Seminar for:
General LOESCHE in
brief
LOESCHE worldwide
History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Welcome!
Pictures
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
2
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
3
E H C S E O L y b ©
Page 9
General
General
LOESCHE in brief
LOESCHE worldwide
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
LOESCHE GmbH
is a privately owned company founded 1906 in Berlin, Germany Certified according to DIN EN ISO 9001 Main shareholder: Dr. Thomas Loesche Management: Dr. Thomas Loesche, Dr. Joachim Kirchmann Employees in Düsseldorf: 400 Employees worldwide: 850 Turnover 2012: Euro 290 millions worldwide
4
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
5
E H C S E O L y b ©
Page 10
General
General
History
History
1906 - Foundation in Berlin 1927 - Invention of the ‚LOESCHE mill‘
1961 - Introduction of the hydropneumatic spring system
1970 - Patented 4-roller mill for raw material grinding
1980 - Patented modular coal mill
2003 - Largest cement mill in the world (capacity 300 t/h), type 3+3
2005 - LOESCHE s latest invention – 6-roller mill for raw material grinding
2006 - 100 years LOESCHE
2008 - Since 1906, LOESCHE has supplied worldwide over 2740 VRMs
2008 - LOESCHE achieved 7442 Blaine in grinding slag
2010 - LOESCHE achieved 6067 Blaine in grinding clinker
2012 – Loesche purchases majority share in ATEC / Greco – Wolrd leader in cement pyro process technology
2010 - Operation of VRM PPC and OPC without water for grinding bed preparation
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
6
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
7
E H C S E O L y b ©
Page 11
General
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
General
8
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
9
E H C S E O L y b ©
Page 12
General
General
History
History Historical VRM design
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
LM-1928
10
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
11
E H C S E O L y b ©
Page 13
General
General
History
History
1970 - Introduction of the Hydropneumatic Spring System
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
12
1970 - Patented 4-Roller Mill
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
13
E H C S E O L y b ©
Page 14
General
Fields of Application
History
Loesche Grinding Plants are mainly used in the following industries
1980 – Patented modular coal mill
Power, Iron, Steel and Cement Industry
Cement Industry
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
14
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Industrial Minerals Industry
Iron and non-ferrous Ores
Grinding plants for Dry-grinding plants the processing of for baryte, betonite, minerals quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
Hot Gas Generator
Hot Gas Generators for all industries Gas, Oil and Coal fired
15
E H C S E O L y b ©
Page 15
Cement Industry
Power, Iron, Steel Industry
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
16
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
17
E H C S E O L y b ©
Page 16
Industrial Minerals Industry
Iron and non-ferrous Ores
Dry-grinding plants for baryte, betonite, quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
18
Grinding plants for the processing of mi nerals and ores
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
19
E H C S E O L y b ©
Page 17
Hot Gas Generator
Mill in Operation
Hot Gas Generators for all industries Gas, Oil and Coal fired
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
20
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
21
E H C S E O L y b ©
Page 18
General
General
Mill structure: LM xx.x+x CS with LSKS xx CS r
Mill structure: LM xx.x RM with LSKS xx
56
2
2
81
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
22
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
23
E H C S E O L y b ©
Page 19
General
General
Mill structure: LMxx.x D with LSKS xx D
Special features of Grinding
Drying
Transportation
Classifying
High flexibility in terms of
24
Products
Recipes
Product properties
Product qualities
all in one machine
Combination of compressive and shear forces for a highly efficient grinding process
Rollers fixed individually in rocker arms without intermediate frame
Hydropneumatic loading of rollers
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
LOESCHE VRMs
Possibility of swinging-out grinding elements for easy maintenance and replacement
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
25
E H C S E O L y b ©
Page 20
General
General
Loesche VRM – Special Features
Fundamentals of Vertical Roller Mills LOESCHE Vertical Roller Mills
Flat grinding table
Large tapered rollers
Combination of compressive and shear forces for comminution
table diameter
Rollers fixed individually in rocker arms without intermediate frame Low masses, low vibration level Hydro-pneumatic loading of rollers
Hydraulic swing-out-device for easy replacement of grinding elements
table diameter table rpm
Grinding velocity
centrifugal force
table diameter 2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
26
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
27
E H C S E O L y b ©
Page 21
General
General
Fundamentals of Vertical Roller Mills
Special features of
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
28
LOESCHE VRMs
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
29
E H C S E O L y b ©
Page 22
General
General
Principle of design: Modular design
Principle of design: Modular design Raw material/coal/petcoke mills
A high interchangeability of parts is gained by modules:
A module consists of:
Roller Rocker arm Pedestal Hydraulic cylinder (inside the pedestal)
2- roller- mill
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
3- roller- mill
30
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
31
E H C S E O L y b ©
Page 23
General
General
RM
Coal
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
32
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
33
E H C S E O L y b ©
Page 24
General
General Comparison grinding technologies Advantages / disadvantages
Coal
Ball mill
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
34
Vertical r oller mill
High pressure r oller p ress
Investment costs (machinery)
+
-
-
Investment costs (building)
-
+
+/-
Operation costs
-
Capacity
-
+
+/-
Change of wear parts
+
+/-
+/-
Noise emission
-
+
+
Flexibility
-
+
+
Fineness
+
+
-
Cement quality 1 daystrength
+
-
-
28 daystrength
-
+
+
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
+
+
+
+
35
E H C S E O L y b ©
Page 25
General
General
Mill structure
Mill structure: Main assembly groups Illustration of a LOESCHE Mill LM 3+3 C/S
The LOESCHE VRM for grinding cement/slag consists primarily of
Raw material feed
Mill
Sogamoso RM
Classifier LSKS M-roller Mill body incl. lining M-rocker arm
Classifier
Mill gearbox
Hydraulic system
S-spring assembly S-rocker arm Table S-roller
M-spring assembly
Mill gearbox Illustration
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Mill drive
36
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Mill stand Illustration
37
E H C S E O L y b ©
Page 26
General
General
Mill structure: Main assembly groups Rocker arm M-roller
M-roller
S-roller
Classifier structure: Main assembly groups Lining
Classifier drive Mill body
Outlet duct Upper housing
Grinding plate
Rocker arm S-roller
Intermediate frame Dam ring
Guide vane Louvre / armour ring
Ring duct
Lower housing Scraper
Table
Pedestal
Classifier rotor Hot gas inlet
Mill gearbox
Classifier grit cone Concrete foundation
Foundation frame
Feed chute
Reject flap Illustration
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
38
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
39
E H C S E O L y b ©
Page 27
Table of contents
Pictures
General LOESCHE in
VRM for cement / slag with product separation in bag house.
brief
LOESCHE worldwide
History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Pictures
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
40
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
41
E H C S E O L y b ©
Page 28
Pictures
Pictures
10 units of LM 28.2 D Taiwan Power Co. Taichung , Taiwan, 2000
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Ras al Khaimah Arab Emirates LM 60.4 RM
42
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
43
E H C S E O L y b ©
Page 29
Pictures
Pictures
Mill body / scraper / ring duct Mill motor
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Lubrication line and mill gearbox
44
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
45
E H C S E O L y b ©
Page 30
Pictures
Pictures Roller of LM 28.2 D
Louvre ring from above
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Louvre ring from below
46
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
47
E H C S E O L y b ©
Page 31
Pictures
Pictures Buffer
S-roller: rocker arm in working position
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
M-roller: rocker arm in working position
48
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
49
E H C S E O L y b ©
Page 32
Pictures
Hi gh pr es sur e hy dr au li c ho ses
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
Pictures
Hy dr aul ic cy li nd er
Piston (left) and bladder (right) accumulator
50
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
51
E H C S E O L y b ©
Page 33
Pictures
Rotor (without bearing cartridge)
Static flap /guide vane assembly
Thank you for your attention
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
52
2013 Technical Seminar Miami –Introduction to Vertical Roller Mills
53
E H C S E O L y b ©
Page 34
Process, operation, and evaluation of LOESCHE mills by Christian-Martin Ruthenberg, LOESCHE GmbH
Process, operation & evaluation of LOESCHE vertical roller mills Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical S eminar Miami, 2013-09-17
E H C S E O L y b ©
Page 35
Agenda Different
Different LOESCHE mill types Range of application
LOESCHE mill types
LOESCHE VRMs
are mainly used in:
Processes inside a mill
Different process circuits
Cement industry Coal fired power plants Iron making plants with blast furnace injection/ PCI (pulverised coal injection) Minerals and ore industry
Control values Raw material mill
Evaluation of performance
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
2
Clinker & slag mill
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
Coal/petcoke mill
Mineral mill
3
E H C S E O L y b ©
Page 36
Different LOESCHE mill types
Different LOESCHE mill types
Mill structure: LM 56.4 RM with LSKS 88
Differences
56
Feed material Moisture content Grain size distribution Flow characteristics Grindability
.4
88
Illustration extract out of DWG 935021-00-3 LM 69.6 RM Process,operation& evaluationofLoesche vertic alrollermillsRev.A
4
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
5
E H C S E O L y b ©
Page 37
Different LOESCHE mill types
Agenda
Differences
Different LOESCHE mill types Processes inside a mill
Machine
Grinding force (according to grindability) Table speed (centrifugal force) Dam ring (grinding bed) S-rollers (deaeration) Louvre and armour ring (drying)
Different process circuits Control values Evaluation of performance
Illustration extract out of DWG 935021-00-3 LM 69.6 RM Process,operation& evaluationofLoesche vertic alrollermillsRev.A
6
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
7
E H C S E O L y b ©
Page 38
Processes inside a mill
Agenda Different LOESCHE mill types
The LOESCHE VRM combines
Processes inside a mill Grinding
Different process circuits
mill drive, gearbox, table and rollers
Hot gas source: HGG, cooler, gas pre-heater
Control values
Classifying
Drying
Evaluation of performance
Transportation
Transportation
Drying
Gas flow introduced by fan
Classifying
Grinding
LDC / LSKS
in one machine.
Clinker/slag mill Process,operation& evaluationofLoesche vertic alrollermillsRev.A
8
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
9
E H C S E O L y b ©
Page 39
Process circuits
Process circuits
Raw meal grinding plant
Coal grinding plant with external inert gas source
Process,operation& evaluationofLoesche verti calrollermillsRev.A
10
Process,operation& evalu ationof Loesche vertic alrollermillsRev.A
11
E H C S E O L y b ©
Page 40
Process circuits
Agenda
Clinker/slag grinding plant
Different LOESCHE mill types
Damper S (Stack)
Processes inside a mill Different process circuits
Damper R (Recirculation)
Control values Evaluation of performance
Damper Z1 (Fresh air)
Hot gas generator
Process,operation& evaluationofLoesche verti calrollermillsRev.A
12
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
13
E H C S E O L y b ©
Page 41
Mill inlet pressure
Mill differential pressure
Clinker/slag grinding plant
Clinker/slag grinding plant Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
Hot gas generator
14
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
15
E H C S E O L y b ©
Page 42
Mill outlet temperature
Process gas flow
Clinker/slag grinding plant
Clinker/slag grinding plant Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
Hot gas generator
16
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
17
E H C S E O L y b ©
Page 43
Control Values
Agenda Different LOESCHE mill types Raw material
Coal
Inlet pressure
Differential pressure
-
Outlet temperature
Gas flow
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
Clinker
Processes inside a mill Different process circuits Control values Evaluation of performance
18
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
19
E H C S E O L y b ©
Page 44
Evaluation of performance
Process evaluation Clinker/slag grinding plant Damper S (Stack)
Improvements (according to requirements)
Damper R (Recirculation)
Audit Assessment Operation
Damper Z1 (Fresh air)
Construction
Commissioning
Opt imisation
Performance Run Hot gas generator
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
20
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
21
E H C S E O L y b ©
Page 45
Summary Different
LOESCHE mill types
Raw material, coal and clinker/slag mill
Processes inside a mill
Grinding, drying, transport and classifying
Different process circuits
Raw material, coal and clinker/slag mill
Control values
Thank you for your attention
Inlet pressure, differential pressure, outlet temperature and gas volume
Evaluation of performance
Operation, audits and required improvements
Essential knowledge of system, process and relations
Process,operation& evaluationofLoesche vertic alrollermillsRev.A
22
Process,operation& evaluationofLoesche vertic alrollermills Rev.A
23
E H C S E O L y b ©
Page 46
Main assembly groups by Peter Lolschou, LOESCHE America, Inc.
Main Assembly Groups LOESCHE
vertical roller mills
Peter K. Lolschou, Technical Instructor Miami, September 2013
E H C S E O L y b ©
Page 47
Table of contents
Overview CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Example: Bilbao LM 46.2+2 CS Illustration
Q….00-4en_TM_Maintenance Part 1_Rev.E
2
Q….00-4en_TM_MaintenancePart 1_Rev.E
3
E H C S E O L y b ©
Page 48
Overview
Overview
RM
D
Example: Lengerich LM 46.4 RM
Example: Nasice LM 20.2 D Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration 4
Q….00-4en_TM_MaintenancePart 1_Rev.E
5
E H C S E O L y b ©
Page 49
Table of contents
Main assembly groups
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS
Mill body Lining
M-lever sealing
M-roller tire
Table
M-roller
M-rocker arm
Grinding plate
HSLM: Hydraulic system M-roller
Mill stand
HSMS M-roller lubrication* Swinging device*
Grinding bed sprinkler* M-rocker arm bearing lubrication*
* These items are not shown in this illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
6
Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration 7
E H C S E O L y b ©
Page 50
Main assembly groups
Main assembly groups
RM
D Mill body Mill body
Lining Roller tire Roller
Lever sealing
Table
Roller tire
Rocker arm
Grinding plate
Lever sealing
Lining
Roller
Table
Rocker arm Grinding plate
HSLM: Hydraulic system roller
HSLM: Hydraulic system roller
Mill stand
Slide with pneumatic interlock
Mill stand H SM S r ol le r l ub ri ca ti on * G ri nd in g b ed sp ri nk le r* Swinging device* Water injection* Rocker arm bearing lubrication* * These items are not shown in this illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
Water Injection* Swinging device* Rocker arm bearing lubrication* * These items are not shown in this illustration
Illustration 8
Q….00-4en_TM_MaintenancePart 1_Rev.E
Reject box Illustration 9
E H C S E O L y b ©
Page 51
Table of contents
Mill stand - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 2+2 X
X
7
1 2 6 5 4
3
1 Ring duct 2 Gas duct 3 Foundation frame 4 Gearbox baseplate
5 Pedestal (S) 6 Pedestal cpl. 7 Bridge
5 0 6 0 0 0
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
10
Q….00-4en_TM_MaintenancePart 1_Rev.E
11
E H C S E O L y b ©
Page 52
Mill stand - structure
Mill stand - structure
CS 3+3
RM X-X
1
X
X
1
6
6
7
5 5
2
3
X
2
4
X
4
6 9 5 0 0 0
3 3 0 5 0 0 0
1 Bridge with railing 2 Ring duct 3 Gas duct 4 Foundation frame Q….00-4en_TM_MaintenancePart 1_Rev.E
5 Pedestal cpl. 6 Block (for S roller: take-up for swinging device) 7 Gearbox baseplate
1 Ring duct 2 Gasduct 3 Foundation frame
Illustration 12
4 Gearbox baseplate 5 Pedestal cpl. 6 Bridge Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
13
E H C S E O L y b ©
Page 53
Mill stand - structure
Mill stand - function
Foundation frame LM x.3+3 CS
Ring duct – CS, RM, D
The ring duct surrounds the table. Ring duct
The ring duct channels the hot gas into the louvre / armour ring. The ring duct is air-tight by welding.
Access door
The walls are partly hard surfaced to control wear.
The floor of the ring duct is doublewalled to stiffen the design and provide thermal insulation towards the gearbox below.
Foundation frame
Hot gas inlet Ring duct Illustration
Q….00-4en_TM_Maintenance Part 1_Rev.E
14
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
15
E H C S E O L y b ©
Page 54
Table of contents
Table - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS, RM, D The table consists of
Table casting
Clamping ring
Dam ring
Scatter ring (if fitted)
Louvre ring
Armour ring
Scraper
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
16
Q….00-4en_TM_MaintenancePart 1_Rev.E
17
E H C S E O L y b ©
Page 55
Table - structure
Table - structure
CS
RM
7
8
1
1 13
2
14
3
9 9
8
12
2
10
7 3
4 5 11
6
6
4 10 5
Illustration
1 Table casting 2 Armour ring 3 Louvre ring 4 Insulatin g material 5 Bore for discharging foreign bodies 6 Dam ring 7 Scatter ring Q….00-4en_TM_MaintenancePart 1_Rev.E
3 8 5 0 0 0
7 0 6 0 0 0
8 Table bolts 9 Auxiliary equipment 10 Drive pin 11 Scraper 12 Ring duct 13 Cover 14 Clamping ring
1 Roller 2 Armour ring 3 Louvre ring 4 Table casting 5 Ring duct 18
Q….00-4en_TM_MaintenancePart 1_Rev.E
6 Scraper 7 Grinding plate 8 Clamping ring 9 Dam ring 10 Scatter ring
Illustration 19
E H C S E O L y b ©
Page 56
Table - structure
Table - structure
D
1
2
CS
3
Armour ring
Clamping ring
Table without dam ring 4
5
12
10 6
11
9 8
1 Clamping ring 2 Cover plate 3 Table casting 4 Armour ring 5 Louvre ring 6 Scraper Q….00-4en_TM_MaintenancePart 1_Rev.E
7
7 Drive pin 8 Gearbox output flange 9 Sealing air chamber 10 Wear rings 11 Dam ring 12 Scatter ring
3 5 6 0 0 0
Table guard preassembled Casted table Illustration 20
Dam ring
Louvre ring Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
21
E H C S E O L y b ©
Page 57
Table - structure
Table - function
Dam ring – CS, RM, D
Louvre ring - CS, RM, D Louvre ring
The dam ring consists of ring segments stacked / bolted on top of each other and can be adjusted by adding or removing segments.
Generates the initial airlift
Important factors are:
Typical heights are
200 - 350 mm for slag / clinker 60 - 70 mm for limestone (RM) 60 – 100 mm for raw meal / coal
Dam ring
Louvre ring
To have sufficient velocity to avoid excessive reject To have sufficient amount to lift the finer material to the classifier Too high velocity will lift coarse material and create wear on mill lining and classifier Too low velocity will result in excessive reject and a table overload Gas flow ideally is evenly distributed Cover plates fine-tune gas velocity and gas distribution Louvre ring is subject to high wear and needs frequent inspections
Inclination of louvres creates defined vortex and supports material drying
Grinding plates
Different mill sizes have different angles for the louvres Armour ring
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
22
Illustration D Q….00-4en_TM_MaintenancePart 1_Rev.E
23
E H C S E O L y b ©
Page 58
Table of contents
Table - function Armour ring - CS, RM, D
Louvre ring
Acts as protection for mill body
For clinker / slag and raw meal: The hollow area between the inclined plates and the mill housing will fill up with material and act as autogenous wear protection
The armour ring is subject to heavy wear and needs frequent inspections
Armour ring
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
24
Q….00-4en_TM_MaintenancePart 1_Rev.E
25
E H C S E O L y b ©
Page 59
M-roller - structure
M-roller - structure
CS, RM, D
CS
1 12
The M-roller consists of Roller axle Tire Clamping ring Hub Hub cover Taper roller be aring Guard Cylindrical roller bearing Sealing sleeve Cover disc Slip ring sealing
13
2
14
3
4
5
6
7
10
8
11
1 Roller axle 2 Tire 3 Clamping ring 4 Hub 5 Hub cover 6 Cover disc 7 Taper roller bearing Q….00-4en_TM_MaintenancePart 1_Rev.E
9
26
Q….00-4en_TM_MaintenancePart 1_Rev.E
8 Guard 9 Cylindrical roller bearing 10 Sealing sleeve 11 Rocker arm 12 Cover disc 13 Sealing air inlet 14 Slip-ring seal
6 0 5 0 0 0
Illustration 27
E H C S E O L y b ©
Page 60
Roller - structure RM
9
Roller - structure 10
11
12
D
1
10
9 1
2 2
3 11 3
4
4
8
8
7
5
5
7
6 4 8 5 0 0 0
1 Tire 2 Clamping ring 3 Hub cover 4 Cover disc 5 Taper roller bearing 6 Guard ("bell housing")
6
7 Cylindrical roller bearing 8 Slip-ring sealing 9 Cover disc 10 Roller axle 11 Sealing sleeve 12 Hub Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
28
1 Clamping ring 2 Hub 3 Hub cover 4 Cover disc 5 Spherical roller bearing 6 Bell housing Q….00-4en_TM_MaintenancePart 1_Rev.E
1 5 6 0 0 0
7 Sealing sleeve 8 Slip-ring seal cpl. 9 Cylindrical roller bearing 10 Roller axle 11 Oil dipstick Illustration 29
E H C S E O L y b ©
Page 61
Roller - structure
M-roller - structure
RM, CS, D
CS
Seal sizes and gaps
3
Number and location Depending on design: 2 or 3 M-rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting) The position of the M-roller on the table which means the distance to the dam ring can be changed by using the distance ring inserted between the conical sleeve on the rocker arm and the corresponding axle shoulder.
are project dependent!
2
4,5
1 Fixing ring 2 Sealing ring 3 O-ring 4 Sealing set 5 Spiral spring ring Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration 30
Q….00-4en_TM_MaintenancePart 1_Rev.E
31
E H C S E O L y b ©
Page 62
Roller - structure
Roller - structure
RM
D
Number and location
Number and location
Depending on design: 2 , 4 or 6 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
Depending on design: 2 , 3, 4 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
Q….00-4en_TM_MaintenancePart 1_Rev.E
32
Q….00-4en_TM_MaintenancePart 1_Rev.E
33
E H C S E O L y b ©
Page 63
Table of contents
M-rocker arm – structure CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Q….00-4en_TM_Maintenance Part 1_Rev.E
1
2 9
X 3 10 4 11 8
X
12 5
13 6 14
7
8 0 5 0 0 0
1 Rocker arm 8 Clamping sleeves 2 Clamping sleeves 9 Fork 3 Roller axle 10 Central lever 4 Cylindrical roller bearing (locating bearing) 11 Bearing block on pedestal 5 Ring 12 Cylindrical roller bearing (floating bearing) 6 Pedestal 13 Flange centring sleeve Illustration 7 Pivot point of spring-assembly cylinder 14 Rocker-arm axle 34
Q….00-4en_TM_MaintenancePart 1_Rev.E
35
E H C S E O L y b ©
Page 64
Rockerr arm – struc Rocke structure ture 11
RM
Rockerr arm – struc Rocke structure ture
X-X
D
X 1 10
1
2
3
12
15
2
13
4
3 14
5
6
6
4
7 8
9
5
13
6
10
8
12 9
14
11 10
7
X
Illustration
1 transport lug 8 Fixed bearing 2 Taper pin connection 9 Pivot point of spring assembly cylinder 3 Lever 10 Clamping sleeve connection 4 Flange sleeve connection with oil connection 11 Sealing air connection 5 Axle 12 Taper sleeve 6 Floating bearing 13 Roller shaft 7 Fork 14 Clamping sleeve connection Q….00-4en_TM_MaintenancePart 1_Rev.E
2 5 6 0 0 0
1 Clamp with taper sleeve 9 Sealing air connection 2 Hood 10 Fork 3 Clamping sleeve connection 11 Journal 4 Rocker arm clamp 12 Bearing block 5 Seal 13 Fixed bearing 6 Rocker arm 14 Mounting for hydropneumatic spring assembly 7 Hub 15 Cover Illustration 8 Floating bearing
3 2 0 1 0 0
36
Q….00-4en_TM_MaintenancePart 1_Rev.E
37
E H C S E O L y b ©
Page 65
Table of contents
Grinding Grind ing parts – funct function ion
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand stand - CS, RM, RM, D Table - CS, RM, RM, D Roller – CS, RM, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide Sli de – D Pneumatic Pneum atic interlock interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, RM, D Seal Air – CS, RM, RM, D Water injection injection - RM, D Grinding bed sprinkler sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Q….00-4en_TM_Maintenance Part 1_Rev.E
CS Grinding plate:
38
Depending on the material the grinding plate can be hard-faced by expert companies 8 to12 times Wear reference measurements are needed Replacement / re-welding frequency is predicted by wear measurements Recommended max. wear before welding is app. 35 mm Typical wear rate for clinker / slag is 6 – 8 g/t product; about 2 to 3 g/t for limestone Rollers run on outside of the grinding path
Q….00-4en_TM_Maintenance Part 1_Rev.E
39
E H C S E O L y b ©
Page 66
Table of contents
M-lever sealing - structure RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand stand - CS, RM, RM, D Table - CS, RM, RM, D Roller – CS, RM, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide Sli de – D Pneumatic Pneum atic interlock interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, RM, D Seal Air – CS, RM, RM, D Water injection injection - RM, D Grinding bed sprinkler sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Q….00-4en_TM_Maintenance Part 1_Rev.E
1
2
X 3
3
11
X
A
A
10
4 9
A-A
5
2 12
8 7 13
6
1 Sealing bar (secured to the mill body) 2 Mill body 3 Sealing cap 4 Wear ring 5 Armour ring 6 Lining plate 7 Sealing bar (secured to the mill body) 40
Q….00-4en_TM_MaintenancePart 1_Rev.E
3 5 8 0 0 0
8 Seal 9 Sealing bar (secured to the rocker arm) 10 Rocker arm 11 Seal 12 Sealing bar (secured to the mill body) 13 Seal Illustration 41
E H C S E O L y b ©
Page 67
Lever sealing sealing - struc structure ture
M-lever sealing - structure
D
CS, RM Flange for cover door
Seals:
Cover door Sealing flanges around box mounted on shaft (moving (moving with with roller) roller)
Shaft mounted box Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
42
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
43
E H C S E O L y b ©
Page 68
Lever sealing - structure
Table of contents
D
Lever sealing
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
44
Q….00-4en_TM_MaintenancePart 1_Rev.E
45
E H C S E O L y b ©
Page 69
HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
CS, RM, D
CS M-spring assembly
The hydraulic system M-roller consists of:
M-spring assembly
Hydraulic cabinet HSLM
Ring pipeline with pressure transmitter
Connecting pipeline
Bladder accumulator
For systems with counter pressure: Piston accumulator
Hydraulic cylinder
For CS, D: Buffer
Hydraulic cabinet HSLM
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
46
Q….00-4en_TM_MaintenancePart 1_Rev.E
47
E H C S E O L y b ©
Page 70
HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
RM
CS HSLM power unit M-spring assembly
Buffer
Hydraulic cabinet HSLM Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration 48
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
49
E H C S E O L y b ©
Page 71
HSLM: hydraulic system M-roller - structure CS, RM, D Bladder accumulator
HSLM: hydraulic system M-roller - structure Piston accumulator for systems with counter pressure
N2
Oil
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
50
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
51
E H C S E O L y b ©
Page 72
Table of contents
HSMS: roller lubrication - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
The HSMS roller lubrication consists of
Hydraulic cabinet HSMS Connecting pipeline LM lubrication line
Seal air inlet
Vent line
Oil level
Inlet line / Outlet line
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
52
Q….00-4en_TM_MaintenancePart 1_Rev.E
53
E H C S E O L y b ©
Page 73
HSMS: roller lubrication - structure
HSMS: roller lubrication - function
CS, RM
CS, RM M-roller Tank
Heater
Cooler
Suction pump
Oil filter
Pressure pump
Pressure line Suction line
Pipelines are connected to rollers by hoses (roller movement) If oil is too cold, the pressure pump is outrunning the suction pump and the roller will be overfilled If the oil is too hot, the internal sealings of the roller may be damaged In normal operation the suction pump capacity is higher = always some oil runs from tank Suction pump is started first, several minutes later the pressure pump The circulation starts / stops with app. 30 minutes delay to the feed to allow the rollers to heat up and cool down
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
54
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
55
E H C S E O L y b ©
Page 74
HSMS: roller lubrication - data
Table of contents
CS, RM
Example
Oil type is project dependent
Oil Type and Quantity ISO VG 320 (see lubrication list)
Pump capacity Suction pump 30% higher capacity than pressure pump
Interlocked oil temperature limits in return / suction line T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps
Interlocked tank oil temperature limits T < 15 C - - - no start of pumps T < 55 C - - - start heater in tank T > 60 C - - - stop heater in tank T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps
Q….00-4en_TM_MaintenancePart 1_Rev.E
56
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Q….00-4en_TM_MaintenancePart 1_Rev.E
57
E H C S E O L y b ©
Page 75
M-rocker arm bearing lubrication - structure
M-rocker arm bearing lubrication - function
CS, RM, D
CS, RM, D
The M-rocker arm bearing lubrication consists of (depending on mill size)
grease pump lubrication lines grease distributors leading to the rocker arm floating and locating bearings
Rocker arm bearings
The connections from rocker arm to hydraulic cylinders are manually greased
The connection on top and bottom of hydraulic cylinders are manually greased
Rocker arm pivot point
Hydraulic cylinder pivot point Q….00-4en_TM_MaintenancePart 1_Rev.E
(depending on size)
M-rocker arm bearing lubrication ensures maximum bearing service life. Grease pump pumps grease from reservoir into outlets Each outlet is connected to a distribution unit that has equal outlets The outlets of each distributor are connected to pipelines to greasing points All pipelines are mounted in protected corners and therefore difficult to reach
Illustration CS 58
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
59
E H C S E O L y b ©
Page 76
M-rocker arm bearing lubrication - function
Table of contents
CS
The control system will start the pump when the mill feed is started The pump will run for 5 minutes, time is adjusted during commissioning Then the pump shuts down for 55 minutes, time is adjusted during commissioning As long as the mill is running the pump starts every runtime-hour Commissioning will ensure that the pump / distributors convey the proper amount of grease into the proper grease point The system will alarm if there is a problem with the grease flow, level or pump 8 hours after the initial alarm, the mill will shut down if the system is not corrected
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
60
Q….00-4en_TM_MaintenancePart 1_Rev.E
61
E H C S E O L y b ©
Page 77
Slide – structure
Slide – function
D
D Slide with pneumatic interlock
The slide cpl. ensures that the mill is shut off in a dust- and gastight state within tenable limits when foreign bodies are removed and in the event of reject material. It is usually located between the outlet hopper of the mill ring duct and the reject box.
Reject box
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
62
Q….00-4en_TM_MaintenancePart 1_Rev.E
63
E H C S E O L y b ©
Page 78
Table of contents
Pneumatic interlock – structure D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
1 2
15
3
4
9
11 13
6
14
10 12
5
8
7
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
64
Q….00-4en_TM_MaintenancePart 1_Rev.E
65
E H C S E O L y b ©
Page 79
Table of contents
Reject box – function D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Q….00-4en_TM_Maintenance Part 1_Rev.E
66
The reject box is a welded round container with a torispherical head which is anchored on the mill floor. The reject box is erected underneath the mill ring duct and connected to this duct via an inlet hopper. A shut-off device (slide) is inserted between the box inlet funnel and connecting flange. The end face of the reject box incorporates a large door with a seal and several quick-release locks. Foreign bodies and reject material from the mill is collected in the reject box. When the door is opened, the reject box can be emptied with a shovel
Q….00-4en_TM_MaintenancePart 1_Rev.E
67
E H C S E O L y b ©
Page 80
Table of contents
Mill body - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
RM X 1
2
X
3
4 7 9 5 0 0 0
1 Cover 2 Mill body 3 Pointer 4 Mill door Illustration
Q….00-4en_TM_Maintenance Part 1_Rev.E
68
Q….00-4en_TM_MaintenancePart 1_Rev.E
69
E H C S E O L y b ©
Page 81
Mill body - structure
Mill body – structure Mill door – CS, RM, D
M-roller cover
S-roller cover
Mill door
Doors with quick-release covers are provided for inspection of the mill interior. It is not allowed to access the mill without following all safety procedures.
Lining plates Central air flap (project specific) Illustration CS
Q….00-4en_TM_MaintenancePart 1_Rev.E
70
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
71
E H C S E O L y b ©
Page 82
Table of contents
Lining - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 1
X 2
3
4
X
5
1 Mill body (top view) 2 S-cover lining 3 Lining plates
8 3 6 0 0 0
4 M-cover lining 5 Mill door lining
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
72
Q….00-4en_TM_MaintenancePart 1_Rev.E
73
E H C S E O L y b ©
Page 83
Lining - structure
Table of contents
RM
3
2
1 2
2
2
2
9 9 5 0 0 0
1 Cast lining plates 2 Wear-resistant steel plates 3 Mill body
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
74
Q….00-4en_TM_MaintenancePart 1_Rev.E
75
E H C S E O L y b ©
Page 84
Sealing air – structure
Sealing air – structure
RM
RM
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
76
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
77
E H C S E O L y b ©
Page 85
Sealing air and cleaning air – structure
Sealing air and cleaning air – structure
D
D
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
78
Illustration Q….00-4en_TM_MaintenancePart 1_Rev.E
79
E H C S E O L y b ©
Page 86
Table of contents
Water injection - structure RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration D Q….00-4en_TM_Maintenance Part 1_Rev.E
80
Q….00-4en_TM_MaintenancePart 1_Rev.E
81
E H C S E O L y b ©
Page 87
Water injection - structure
Water injection - function
RM, D
RM, D
The water piping connected to the pump aggregate is split into several feed pipes. The feed pipes end at the distribution pipes at the mill upper housing flange. Each distribution pipe is connected to spray nozzles via flexible hoses. The spray nozzles are screwed into the pipes which are flanged to the upper housing. The nozzles are arranged so they spray water between the rollers. The nozzle switchover point is at the lower characteristic curve range so that large pressure surges can be avoided (see also "Characteristic curve sheet: pumps + nozzle").
Illustration D Q….00-4en_TM_MaintenancePart 1_Rev.E
82
Q….00-4en_TM_MaintenancePart 1_Rev.E
83
E H C S E O L y b ©
Page 88
Table of contents
Grinding bed sprinkler - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Plant water system supplies water to the pump Pump pumps water into pipeline to mill, excess water returns to plant system Water is split into pipelines, one injection per M-roller Injection lances distribute water across grinding path Compressed air supplied to purge lances (avoids dribbling into stopped mill)
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
84
Q….00-4en_TM_MaintenancePart 1_Rev.E
85
E H C S E O L y b ©
Page 89
Grinding bed sprinkler - structure
Grinding bed sprinkler - structure
CS, RM
CS, RM 1
2
8 9
10
7
6 3 5
Q….00-4en_TM_MaintenancePart 1_Rev.E
4
1 Grinding r oller
6 Orifice p late
2 Tire
7 Compressed-air line
3 Grinding p late
8 Grinding c hamber
4 Table casting
9 Pipe holder
5 Water line
10 Sprinkler pipe
8 1 5 0 0 0
Illustration CS 86
Illustration CS Q….00-4en_TM_MaintenancePart 1_Rev.E
87
E H C S E O L y b ©
Page 90
Table of contents
Swinging Swin ging device – struct structure ure CS, RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand stand - CS, RM, RM, D Table - CS, RM, RM, D Roller – CS, RM, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide Sli de – D Pneumatic Pneum atic interlock interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, RM, D Seal Air – CS, RM, RM, D Water injection injection - RM, D Grinding bed sprinkler sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
HSAV Pump unit
Illustration Q….00-4en_TM_Maintenance Part 1_Rev.E
88
Q….00-4en_TM_MaintenancePart 1_Rev.E
89
E H C S E O L y b ©
Page 91
Swinging Swing ing device – funct function ion
Table of contents
CS, RM, D
The swinging device serves to swing out/in the rollers
A
B
1
6
2
3
5
4
Q….00-4en_TM_MaintenancePart 1_Rev.E
1 Gr Grind inding ing rol rolle ler, r, sw swung ung out
4 Hy Hydra draul ulic ic pum pump p uni unit, t, HS HSA AV
2 Hy Hydraulic cylinder
5 Pe Pedestal
3 Jo Joint se seating
6 Gr Grinding ro roller, sw swung in in
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, RM, D Roller – CS, RM, RM, D Rockerr Arm – CS, RM, Rocke RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication Lubrication – CS, RM, D Slide Sli de – D Pneumatic Pneum atic interlock interlock – D Reject box – D Mill body - CS, RM, RM, D Lining - CS, RM, RM, D Seal Air Air – CS, RM, RM, D Water injection injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 90
Q….00-4en_TM_MaintenancePart 1_Rev.E
91
E H C S E O L y b ©
Page 92
Classifier Class ifier - struc structure ture
Classifier Clas sifier - struc structure ture LSKS Classifier drive Outlet duct
The classifier consists of
Upper housing
Classifier drive* Intermediate frame
Classifier lubrication line*
Guide vane
Upper housing with outlet duct and support for classifier drive* Lower housing with static guide vane*, lining* and feed chute
Lower housing
Rotor* with rotor blades* and bearing cartridge* Grit cone*
Classifier rotor
Classifier grit cone
Feed chute
* These items are not shown in this illustratio illustration n Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration
92
Q….00-4en_TM_MaintenancePart 1_Rev.E
93
E H C S E O L y b ©
Page 93
Classifier Class ifier - struc structure ture
Classifier Clas sifier - struc structure ture
LSKS ZD
LDC
Upper bearing
Classifier drive
Classifier Drive Outlet duct
Upper housing
Lower bearing Feed chute
Rotor shaft Rotor with removable rotor blades
Lower housing Intermediate frame Guide vane
Intermedi ate shaft Classifier grit cone
Stiff support pipes towards lower housing hold lower end of bearing cartridge in position (no swinging)
Classifier grit cone
Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
Rotor
Illustration
94
Q….00-4en_TM_MaintenancePart 1_Rev.E
95
E H C S E O L y b ©
Page 94
Classifier - structure
Classifier drive - structure
LSKS ZD power plant
LSKS for CS, RM Feed chute
Classifier drive consists of Classifier motor Classifier gearbox (speed monitor, temperature probes) Classifier lubrication with instrumentation (temperature, oil flow, speed monitor, …) Coupling, coupling guard, supports, hoses, etc.
Outlet duct
Upper housing Classifier drive
Classifier motor
Classifier lubrication
Rotor Coupling guard
Lower housing
Reservoir
Coupling Classifier gearbox
Guide vane
Bell housing
Classifier grit cone Illustration
Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration
96
Q….00-4en_TM_MaintenancePart 1_Rev.E
97
E H C S E O L y b ©
Page 95
Classifier drive - structure
Classifier drive - structure Classifier gearbox lubrication system
D Classifier drive consists of Classifier motor Grease pump
4 5
1
6
7
2
is a circular or splash lubrication that needs a certain rpm of the rotor to s upply sufficient lubrication (never idle rotor) Temperature (PT100): Oil temperature < 0 C classifier drive stop Oil temperature > 85 C warning signal to control station Oil temperature > 90 C classifier drive stop
3
14 8
Resistance thermometer
13
Oil reservoir
Cooling water inlet
Pump
9 12
1 Sealing air connection 2 Cover 3 Castellated disc 4 Multi-V pulley, bearing cartridge 5 Labyrinth ring 6 Proximity switch 7 Power belts Q….00-4en_TM_MaintenancePart 1_Rev.E
11
8 Multi-V pulley, motor 9 Guard 10 Motor 11 Console 12 Classifier upper housing 13 Inspection cover
9 5 0 1 0 0
10
RM/CS Not existing for coal
Illustration
98
Q….00-4en_TM_MaintenancePart 1_Rev.E
Illustration
99
E H C S E O L y b ©
Page 96
Lining – structure LSKS Lining
Thank you for your attention
Lining in the classifer upper housing
Q….00-4en_TM_MaintenancePart 1_Rev.E
100
Q….00-4en_TM_Maintenance Part 1_Rev.E
101
E H C S E O L y b ©
Page 97
Maintenance & procedures by Peter Lolschou, LOESCHE America, Inc.
Maintenance & Procedures LOESCHE
vertical roller mills
Peter K. Lolschou, Technical Instructor Miami, September 2013
E H C S E O L y b ©
Page 98
Table of Contents
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
M-Roller – Maintenance Work CS Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
2
Q…-01-4en_TM_MaintenancePart 2_Rev.B
3
E H C S E O L y b ©
Page 99
Roller – Maintenance Work
Roller – Maintenance Work
RM
D
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
Illustration RM Q…-01-4en_TM_MaintenancePart 2_Rev.B
Illustration D 4
Q…-01-4en_TM_MaintenancePart 2_Rev.B
5
E H C S E O L y b ©
Page 100
M-Roller – Maintenance Work
Roller – Maintenance Work
CS
RM
Minimum gap between M-roller and table
Minimum gap between M-roller and table
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The adjustment has to be checked weekly:
Buffer
Lift rollers – thread buffer out 3 revolutions – set minimum 10 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 10 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The monitoring has to be checked weekly: Lift rollers – set minimum 10 mm plate under roller – lower rollers – calibrate the monitoring – lift rollers – extract 10 mm plates – repeat the procedure with different plates. The monitoring will drift with wear. The grinding efficiency will deteriorate over time.
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
Illustration 6
Q…-01-4en_TM_MaintenancePart 2_Rev.B
7
E H C S E O L y b ©
Page 101
Roller – Maintenance Work
M-Roller – Maintenance Work
Coal
CS
Minimum gap between Roller and table
Bearing Replacement
Roller tires are highly chrome-alloyed, wear resistant but brittle Metal to metal contact between rollers and table must be avoided
It is strongly recommended to have experienced personnel and correct tools.
5 mm
A minimum gap of 5 mm is adjusted for monitoring The adjustment has to be checked weekly: Lift rollers – thread buffer out 3 revolutions – set 5 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 5 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
Buffer
Remove inner cover plate Loosen inner rings Pump high pressure oil into grooves of bearing seats using the delivered handpump Remove taper roller bearing Remove inner and outer rings and distance sleeves Remove cylindrical roller bearing by using a hydraulic jack
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
8
Q…-01-4en_TM_MaintenancePart 2_Rev.B
9
E H C S E O L y b ©
Page 102
Roller – Maintenance Work
Roller – Maintenance Work
Coal Bearing Replacement
RM Bearing Replacement
Q…-01-4en_TM_MaintenancePart 2_Rev.B
10
Q…-01-4en_TM_MaintenancePart 2_Rev.B
11
E H C S E O L y b ©
Page 103
M-Roller – Maintenance Work
Roller – Maintenance Work
CS/RM
Coal
Exchange of M-roller
Exchange of roller
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
- It is recommended to have a Loesche expert on site for supervision Remove M-roller covers (seal and cover) Disconnect seal air and (if needed) lubrication hoses Install blind plugs to avoid oil loss into breather (and open bores for hoses) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Remove blind plugs from oil lubrication connections Re-install seal air and oil lubrication hoses Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
Q…-01-4en_TM_MaintenancePart 2_Rev.B
It is recommended to have a Loesche expert on site for supervision 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
12
Remove roller covers (seal and cover) Disconnect PT100 (Temperature sensor) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Re-install PT100 Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
Q…-01-4en_TM_MaintenancePart 2_Rev.B
13
E H C S E O L y b ©
Page 104
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller
Exchange of M-roller
4. Install swing-out devices (all parts)
1. Remove roller covers (seal and cover) 2. Disconnect seal air and (if needed) for RM: lubrication hoses 3. Install blind plugs to avoid oil loss into breather (RM: and open bores for hoses)
pins to fix transistion to rocker arm
Swing-out transition for rocker arm
1
2/3
Pin to fix cylinder to foundation eye-bolt connection hoses: HSAV Pump unit - cylinder
HSAV pump unit (functional, filled with oil)
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
14
pin to fix transition to cylinder shaft Maintenance cylinder (functional)
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
15
E H C S E O L y b ©
Page 105
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller tire
Illustration
6. Swing roller out of mill
Locking pin(s) Rocker arm shaft
Exchange of M-roller 5. Remove locking pins 6. Swing roller out of mill To swing-out the M-roller (S-roller similar):
Extend the maintenance cylinder shaft fully using the mobile hydraulic cart Attach shaft to swing-out transition part at rocker arm
Remove the locking pins (1 per side)
Use the hydraulic cart to move the maintenance cylinder shaft back in
The roller will then pivot at the common pivot pin as it swings into the vertical / maintenance position
Q…-01-4en_TM_MaintenancePart 2_Rev.B
Illustration 16
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
17
E H C S E O L y b ©
Page 106
Table of Contents
M-Roller – Maintenance Work Exchange of M-roller 7. Roller removal
Open outer shaft cover and loosen / take out bolts of outside clamp ring (at bottom of roller when swung-out) Install lifting eye bolts (original delivered) Install manual hydraulic jack under shaft and press roller shaft out of rocker arm seat Do not use force of crane to loosen roller assembly (either rocker arm or crane could break) Once lose the roller assembly is lifted off using a crane and the lifting eye bolts
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
18
Q…-01-4en_TM_MaintenancePart 2_Rev.B
19
E H C S E O L y b ©
Page 107
Swinging Device – Film
Swinging Device – Maintenance Work CS, RM, D
Proper dismounting and mounting of taper pin- and flanged sleeve connection of rocker arm - fork connection is important.
Intervals:
Flanged sleeve
The hydraulic cylinder has to be stored vertically.
Taper pin connection
Swinging device
check completeness and function of all auxiliary-parts prior to use of auxiliary parts.
Maintenance: change oil vent off air of swing out cylinder clean tank
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
20
Q…-01-4en_TM_MaintenancePart 2_Rev.B
21
E H C S E O L y b ©
Page 108
Table of Contents
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Grinding Parts – Maintenance Work CS, RM, D
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
22
Q…-01-4en_TM_Maintenance Part 2_Rev.B
23
E H C S E O L y b ©
Page 109
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
1
1
CS, RM, D
2
2
Back of roller ca. 10 mm
X
X
Front of roller
3 4 2 5 0 0 0
3
1 Tire profile ruler 2 Tire 3 Hub Q…-01-4en_TM_Maintenance Part 2_Rev.B
Illustration 24
Illustration Q…-01-4en_TM_Maintenance Part 2_Rev.B
25
E H C S E O L y b ©
Page 110
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
CS, RM, D Grinding plate
Roller tire
Wear Measurement
Using a template, wear has to be measured approximately weekly or as needed The measurements have to be recorded and used to predict when welding or exchange of the grinding parts is required Maximum recommended wear before rewelding: 30 mm
Maximum recommended wear before exchanging: according to contract For Clinker / slag and coal: Do not forget to re-adjust buffers Roller measurement tool as per drawing
Table = “straight edge” with markers
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
26
Tire profile ruler
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
27
E H C S E O L y b ©
Page 111
Grinding Parts – Maintenance Work
1
Grinding Parts – Maintenance Work Picture1 : new M-roller tire Picture 2: M-Roller tires in the range of re-welding Picture 3: limit of re-weldable wear
Pictures 4, 5 and 6 show M-Roller tires beyond rewelding
6 5
Tire exchange imminent Picture 7 shows a tire at the breaking point
3
4 7 2
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
28
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
29
E H C S E O L y b ©
Page 112
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM
CS, RM
Welding procedures for roller tires and grinding plate
To be performed by experienced welding company
Needs specialised equipment (automatic welding head, large welding gear)
Will be done inside the mill with all parts installed
The table is turned by means of an auxiliary drive for welding the grinding plate
The tires are turned by the table or by separate drives for each roller
It is critical for both procedures to set-up the we lding ground properly, not to damage bearings and gears. Generally, when welding the grinding plate or tires check for
Grinding plate set tight and all clamping bolts torqued
Tires set tight and all clamping bolts torqued
Tires are not broken or cracked in any spot
Tires and grinding plate should be built back up to the original profile App. 8 to 12 re-weldings are possible
Welding in an external workshop is also possible after dismounting all grinding parts Illustration
Q…-01-4en_TM_MaintenancePart 2_Rev.B
30
Q…-01-4en_TM_MaintenancePart 2_Rev.B
31
E H C S E O L y b ©
Page 113
Table of Contents
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Table – Maintenance Work Auxiliaries table – CS, RM, D
Hydraulic jack
Table support
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
32
Q…-01-4en_TM_MaintenancePart 2_Rev.B
33
E H C S E O L y b ©
Page 114
Table – Maintenance Work
Table – Maintenance Work
CS, RM
Effects of dam ring height on production and quality – CS, RM, D
Visual check
Armour ring wear
Dam ring wear
Louvre ring / Cover plates wear
The grinding plates wear out which may increase the effective height of the dam ring. It might be necessary to weld on / exchange the grinding plates or adjust the dam ring height to keep a constant mill performance. Changing the dam ring height is used to achieve the following effects: Stabilization of mill operation (vibration control) Optimization of specific power consumption Optimization of product fineness (rough tuning)
Clamping ring wear and tightness of bolts
Table seal wear and tear
Illustration CS
Intervals:
Visual check weekly
Repair / retighten as needed
Change / re-weld grinding plates as needed
Change / re-weld louvre / armour ring as needed
Roller / table wear measurement every 3 months
For clinker / slag: stop buffer adjustment every 3 months
Shift intervals according to the specific „wear behavior“ of the mill
Q…-01-4en_TM_MaintenancePart 2_Rev.B
The following results will be achieved: Improved product fineness (dam ring higher) Improved specific power consumption (dam ring lower)
34
The optimum dam ring height will be determined during commissioning.
Q…-01-4en_TM_MaintenancePart 2_Rev.B
35
E H C S E O L y b ©
Page 115
Table of Contents
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
HSMS: roller lubrication – maintenance work CS, RM Visual check: Tank oil levels Tank oil temperatures Flow in suction line sight glasses Indication of pressure / suction gauges Leaks along all pipelines / hoses Temperature of oil from / to rollers Connection at rollers tight Filter dirty indication (if provided)
Intervals: Visual checks daily Filter clogged weekly, if no indication is provided Oil samples of each tank unit every 3,500 Rth (Runtime-hours) Oil change as needed / per manual (see lubrication list) During oil change open tank units and clean oil sludge thoroughly
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
36
Q…-01-4en_TM_MaintenancePart 2_Rev.B
37
E H C S E O L y b ©
Page 116
Table of Contents
HSMS: roller lubrication – maintenance work CS, RM Lubrication list
Q…-01-4en_TM_MaintenancePart 2_Rev.B
Project dependent
38
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Q…-01-4en_TM_MaintenancePart 2_Rev.B
39
E H C S E O L y b ©
Page 117
Table of Contents
Rocker Arm – Maintenance Work CS, RM, D Axle
Rocker arms - visual check: Grease supply of 3+1 bearings Condition of grease pump Cracks in casted rocker arm Tightness of all bolts Seal air supply Condition / adjustment of buffers Condition of shaft sealing box (inside)
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Maintenance / Interval: Visual checks inside / outside (weekly) Check seal air labyrinths (every 6 monthls) Check bearing clearance (annually) Change / re-weld labyrinths as needed Change bearings as needed Re-tighten / re-seal / repair as needed
Rocker arm bearings
Hydraulic spring assembly
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
40
Q…-01-4en_TM_MaintenancePart 2_Rev.B
41
E H C S E O L y b ©
Page 118
M-Rocker Arm Bearing Lubrication – Maintenance Work
M-Rocker Arm Bearing Lubrication – Maintenance Work
CS
CS
Project dependant
Visual check: Lid of grease tank tightly closed (auto system) Grease tank full (auto system, lubrication list on next slide) Leaks at pump unit (auto system) Grease pipelines intact (auto & manual systems) Grease leaks at pipelines, distributors or bearings (auto & manual systems)
Intervals: Visual checks daily Supply the 12 manual grease points with grease according to documentation (lubrication list) daily (lubrication list)
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
42
Q…-01-4en_TM_MaintenancePart 2_Rev.B
43
E H C S E O L y b ©
Page 119
Table of Contents
M-Lever Sealing – Maintenance Work CS, RM, D
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
M-lever sealing
Visual check: attachment bolts of lever sealing parts wear of lever sealing parts proper adjustment of gaskets and bellows check flanges between rocker arms and mill body for tightness
Maintenance: change worn parts
Intervals: visual check weekly change worn parts according to actual wear shift interval according to the specific „wear behaviour“ of the mill
Illustration CS Q…-01-4en_TM_MaintenancePart 2_Rev.B
44
Q…-01-4en_TM_MaintenancePart 2_Rev.B
45
E H C S E O L y b ©
Page 120
Table of Contents
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
HSLM: hydraulic system M-roller - function CS, RM, D : With counter pressure The M-rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the M-rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. For CS, D: A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.
Operating pressure
Counter pressure
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
46
Q…-01-4en_TM_MaintenancePart 2_Rev.B
47
E H C S E O L y b ©
Page 121
HSLM: hydraulic system M-roller - function
HSLM: hydraulic system M-roller - function
D: Without counter pressure
Function of accumulators
Gas valve
The rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. A stop buffer on the rocker arm prevents the t ires from coming into direct contact with the grinding plates.
Shell
The accumulators act as shock absorbers and as a system pressure equalizer Standard charge: 50% of expected operation oil pressure, exact values to be adjusted during commissioning (>30% ; < 70%) Nitrogen pressure can only be measured with oil pressure completely drained
Bladder
Oil valve
Oil Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
48
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
49
E H C S E O L y b ©
Page 122
HSLM: hydraulic system M-roller – Maintenance Work
HSLM: hydraulic system M-roller – Maintenance Work
Lubrication instructions
Lubrication instructions
Q…-01-4en_TM_MaintenancePart 2_Rev.B
50
Q…-01-4en_TM_MaintenancePart 2_Rev.B
51
E H C S E O L y b ©
Page 123
Table of Contents
HSLM: hydraulic system M-roller – Maintenance Work Filtration skid / Filling cart
Loesche delivered a cart with an oil pump and a filter unit to ensure that only properly filtered oil is filled or topped up into the Hydraulic Tank. This cart is to be used during normal maintenance. Typical filter size < 25 micron (e.g. 10)
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
52
Q…-01-4en_TM_MaintenancePart 2_Rev.B
53
E H C S E O L y b ©
Page 124
Table of Contents
Lining – Maintenance Work CS, RM, D Inspection and replacement The lining has to be checked for wear regularly. Worn plates can be replaced / exchanged with equally shaped less worn plates be replaced by a new plates Severe and premature wear can be adjusted by louvre ring cover placement review of the design of the armour ring inclination (Loesche involvement recommended)
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
CS
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
54
Q…-01-4en_TM_MaintenancePart 2_Rev.B
55
E H C S E O L y b ©
Page 125
Table of Contents
Water injection – Maintenance Work RM, D Visual check: Inspect the nozzles for wear and contamination Protect hoses from physical damage The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight.
M-Roller - CS, RM, D
Swinging Device - CS, RM, D
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Repair: Replace nozzles if necessary Replace hoses if necessary After repair work screwed fittings should be resealed with hemp or sealing tape The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight.
Intervals: Visual checks every 6 months Repair if necessary
Q…-01-4en_TM_MaintenancePart 2_Rev.B
56
Q…-01-4en_TM_MaintenancePart 2_Rev.B
57
E H C S E O L y b ©
Page 126
Mill stand - Maintenance Work
Mill stand - Maintenance Work
CS, RM, D
Ring duct – CS, RM, D
Visual check:
Condition and tightness of bolts of bearing caps Condition of weldings
Oil accumulations or material chunks on concrete foundation
Wear at scraper supports should be repaired with hard-faced welding
Condition of anchor bolts
Condition of gearbox attachment bolts
Interval: weekly
Inspections can be carried out through the ring duct access door (confined space)
Check torque
The scrapers should be checked regularly for wear and secure mounting The lower housing is subject to heavy wear and may be hardfaced or lined with Densit
Interval: yearly
Superbolt system Q…-01-4en_TM_MaintenancePart 2_Rev.B
Hydraulic tension system
Illustration 58
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
59
E H C S E O L y b ©
Page 127
Table of Contents
Classifier – Maintenance Work
M-Roller - CS, RM, D
LSKS
Swinging Device - CS, RM, D
Visual check:
Grinding Parts: roller tires, grinding plate - CS, RM, D
Table – CS, RM, D
HSMS: roller lubrication - CS, RM
M-Rocker Arm - CS, RM, D
M-Rocker Arm Bearing Lubrication - CS, RM, D
M-Lever sealing - CS, RM, D
HSLM: hydraulic system M-roller - CS, RM, D
Lining – CS, RM, D
Water Injection – RM, D
Mill Stand – CS, RM, D
Reject Box – D
Classifier
Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Intervals: Visual checks every week as needed or as in manual
Illustration Q…-01-4en_TM_MaintenancePart 2_Rev.B
60
Q…-01-4en_TM_MaintenancePart 2_Rev.B
61
E H C S E O L y b ©
Page 128
Classifier – Maintenance Work
Classifier – Maintenance Work
LSKS Visual check:
LSKS Project dependent Project dependent
Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Intervals: Visual checks every week as needed or as in manual
Click to open Illustration
Q…-01-4en_TM_MaintenancePart 2_Rev.B
62
Q…-01-4en_TM_MaintenancePart 2_Rev.B
63
E H C S E O L y b ©
Page 129
Rotor – Maintenance Work
Rotor – Maintenance Work
LSKS
LSKS Guide vanes and rotor blades The guide vanes are not adjustable.
Exchange of rotor blades
The guide vane position has a direct impact on the product quality and classifier efficiency
If visual inspection reveals wear / tear on rotor blades – exchange is necessary
Static guide vanes and rotor blades need to be inspected frequently for wear, tear and position since these parts are directly responsible for product fineness and quality
1. Unbolt and extract locking rings (upper/lower end of blades at inside) 2. Pull blades out of guide-slots
Illustration
3. Insert new blades into guide slots 4. Bolt down locking rings and secure bolts by tack welding Exchange blades in pairs 180 degrees opposite of each other OR re-balance rotor upon first start
Illustration
Q…-01-4en_TM_MaintenancePart 2_Rev.B
Illustration
64
Q…-01-4en_TM_MaintenancePart 2_Rev.B
65
E H C S E O L y b ©
Page 130
Rotor – Maintenance Work
Rotor – Maintenance Work LSKS
LSKS
Static
Exchange of Bearing Cartridge
Rotor clearance
Project dependent
1. Secure rotor by chain-falls to upper housing (ceiling)
Visual check • wear • imbalance
2. Dismount classifier gearbox (as complete unit using a crane), pulling gearbox vertical upwards off coupling
Interval every 6 months for more details, please see in manual
3. Disconnect automatic grease system and instrumentation from bearing cartridge 4. Unbolt flange cartridge – upper housing 5. Unbolt flange cartridge – rotor 6. Use crane to pull old cartridge out off classifier
Dynamic
7. Use crane to insert new cartridge into classifier 8. Re-assemble in reverse order
Illustration
Q…-01-4en_TM_MaintenancePart 2_Rev.B
Illustration
66
Q…-01-4en_TM_MaintenancePart 2_Rev.B
67
E H C S E O L y b ©
Page 131
Rotor – Maintenance Work LSKS
Grease lubrication of bearing cartridge: Grease reservoir with level sensor Continuous low level alarm will trip the system after X hours (usually 8 hours) Single outlet grease pump Grease splitter (50:50) 2 lines into (upper / lower bearing) Pump runs for 10 minutes, shuts down for 50 minutes and restarts as long as classifier is running
Thank you for your attention
The bearing temperature is monitored continually by temperature sensors Grease type KPF 2 G 20 or comparable Amount: 8 Liter in pump reservoir, 2 kg in bearing cartridge and pipelines Illustration
Q…-01-4en_TM_MaintenancePart 2_Rev.B
68
Q…-01-4en_TM_Maintenance Part 2_Rev.B
69
E H C S E O L y b ©
Page 132
Mechanical design and maintenance: Mill Gearbox by Desi Delgado, LOESCHE America, Inc.
Mechanical Design and Maintenance Mill gearbox
Desi Delgado, Technical Instructor Miami, September 2013
E H C S E O L y b ©
Page 133
Table of contents
Gearboxes Selection of Gearboxes for LOESCHE Mills
Mill gearbox Gearboxes
Rated Power of Mill Drive
Type of Gearbox
< ~350 kW
Bevel-Helical; 2-/3-Stages
Maintenance
< ~2.000 kW
Bevel-Planetary; 2-Stages
Gearbox internals
> ~2.000 kW
Bevel-Helical-Planetary; Bevel-Planetary-Planetary; 3-Stages
Sub-suppliers Coupling Gearbox lubrication
Q….-03-4en_TM_Maintenance Part 3_Rev.A
2
Q….-03-4en_TM_Maintenance Part 3_Rev.A
3
E H C S E O L y b ©
Page 134
Gearbox
Gearbox
Bevel-Planetary-Gearbox with 2-stage Reduction
Bevel-Helical-Planetary-Gearbox with 3-stage Reduction
Output Flange
Thrust Bearing
Planetary Stage
Input Shaft
Gear Coupling Bevel-Gear Stage
Housing
HelicalGear Stage
FLENDER KMP Q….-03-4en_TM_MaintenancePart 3_Rev.A
4
Q….-03-4en_TM_Maintenance Part 3_Rev.A
FLENDER KMPS
5
E H C S E O L y b ©
Page 135
Gearbox
Gearbox
Bevel-Planetary-Gearbox with 3 stage Reduction
Loesches Strategy of Mill and Drive Sizes
FLENDER KMPP Q….-03-4en_TM_MaintenancePart 3_Rev.A
6
Q….-03-4en_TM_Maintenance Part 3_Rev.A
7
E H C S E O L y b ©
Page 136
Table of contents
Gearbox Unification Concept for CRM and C/S-mills
Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
Q….-03-4en_TM_MaintenancePart 3_Rev.A
8
Q….-03-4en_TM_MaintenancePart 3_Rev.A
9
E H C S E O L y b ©
Page 137
Mill gearbox
Mill gearbox
Sub-suppliers
Sub-suppliers
Sub-suppliers approved by LOESCHE
CMD, France
Flender (Siemens), Germany, Bocholt
Formosa Heavy Industries (Licence of M/s Renk), Taiwan,
Keller, Germany, St. Augustin
Maag (FLS), Swiss
Moventas, Germany, Wuppertal
Renk (MAN) / Renk-Maag, Germany, Augsburg
Seisa (SHI), Japan
Q….-03-4en_TM_MaintenancePart 3_Rev.A
10
CMD, France rating up to 1.500kW Smaller gearboxes Bevel-Helical, planetary Flender, Bocholt(HQ), rating 200 kW up to 7.000 kW Voerde (machining, assembly) Germany
Keller Siegburg, Germany
rating 200 kW up to 1.500 kW
Maag, Winterthur, Swiss (HQ)
rating … up to 5.400 kW
Moventas, Wuppertal Germany
rating 200 kW up to 1.500 kW
Renk, Augsburg, Germany
rating up to 5.400 kW
Seisa, Osaka Japan
rating 450 kW up to 4.500 kW
Q….-03-4en_TM_Maintenance Part 3_Rev.A
11
E H C S E O L y b ©
Page 138
Table of contents
Mill gearbox Sub-suppliers
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
Q….-03-4en_TM_MaintenancePart 3_Rev.A
12
Q….-03-4en_TM_MaintenancePart 3_Rev.A
13
E H C S E O L y b ©
Page 139
Mill gearbox
Gearbox
Coupling
Coupling
Different types
High flexible couplings: Flender Flexible couplings: Bolt type:
- ELPEX ENG …
Flender
- RUPEX RWN …, RUPEX-APEX
Elastic RUPEX coupling, Type RAK
Q….-03-4en_TM_MaintenancePart 3_Rev.A
14
Q….-03-4en_TM_MaintenancePart 3_Rev.A
15
E H C S E O L y b ©
Page 140
Mill gearbox
Mill gearbox
Coupling
Coupling RUPEX
ELPEX
Q….-03-4en_TM_MaintenancePart 3_Rev.A
16
Q….-03-4en_TM_MaintenancePart 3_Rev.A
17
E H C S E O L y b ©
Page 141
Table of contents
Mill gearbox gearbox - Coup Coupling ling
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
Q….-03-4en_TM_MaintenancePart 3_Rev.A
18
Q….-03-4en_TM_MaintenancePart 3_Rev.A
19
E H C S E O L y b ©
Page 142
Mill gearbox
Mill gearbox – Gearbox Lubrication
Gearbox lubrication
Always included in the scope of supply of gearbo x suppliers Usually consists of:
Low pressure pump,
Filter,
oil cooler (water/air)
HP-pumps,
Instrumentation pressure transmitter, RTD‘s flow meter, and gauges (temperature, pressure, flow indicator), heating device, oil container
Signals of instruments are interlocked in PLC
Certain sequences and paramaters must be adhered to
Project dependent Q….-03-4en_TM_MaintenancePart 3_Rev.A
20
Q….-03-4en_TM_MaintenancePart 3_Rev.A
21
E H C S E O L y b ©
Page 143
Table of contents
Mill gearbox – Gearbox Lubrication
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
Project dependent Q….-03-4en_TM_MaintenancePart 3_Rev.A
22
Q….-03-4en_TM_MaintenancePart 3_Rev.A
23
E H C S E O L y b ©
Page 144
Mill gearbox
Mill gearbox
Maintenance
Maintenance
On-site check
Gearbox removal procedure overview Please have expert on site
An annual check should be completed b y the gearbox supplier
High vibration / severe torque variations to be avoided
Check for the mill operation data, maintenance
Illustrations
Maintenance drive
Visual check, oil level, leaks, abnormal noise, oil filter, oil level check and oil analysis, History of oil analysis and oil exchanges
Q….-03-4en_TM_MaintenancePart 3_Rev.A
24
Q….-03-4en_TM_MaintenancePart 3_Rev.A
25
E H C S E O L y b ©
Page 145
Mill gearbox
Mill gearbox
Maintenance
Maintenance Condition monitoring
Gearbox handling/lifting
vibrations, temperature, pressure, torque, speed, … data collection, filtering, storage, analyzing
Signals analog or digital
(optional) limit settings, filter settings, trigger settings, …
Modem / COM Server/ Internet Router storage, analysis, trend…
data
computer
Q….-03-4en_TM_MaintenancePart 3_Rev.A
26
Q….-03-4en_TM_MaintenancePart 3_Rev.A
messages
SMS e-mail FAX
27
E H C S E O L y b ©
Page 146
Table of contents
Mill gearbox Maintenance
Mill gearbox
Condition monitoring
Mill gearbox 4xT
Sub-suppliers
a a
Coupling
a
Gearbox lubrication
Lubrication oil inlet T
n
T
M
Δp
Main Filter
a T
p
Δp
Maintenance
Maintenance Filter
Gearbox internals
T T
a
MINI
8Ch.
MIDI 13 Ch. a: M: n: p: T:
acceleration (vibratio n) torque speed pressure t emp er atu re
Q….-03-4en_TM_MaintenancePart 3_Rev.A
Gearbox KMPP
MAXI 19 Ch.
28
Q….-03-4en_TM_MaintenancePart 3_Rev.A
29
E H C S E O L y b ©
Page 147
Gearbox
Gearbox
Lubrication
On Stock
Q….-03-4en_TM_MaintenancePart 3_Rev.A
30
Q….-03-4en_TM_Maintenance Part 3_Rev.A
31
E H C S E O L y b ©
Page 148
Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
Q….-03-4en_TM_MaintenancePart 3_Rev.A
32
Q….-03-4en_TM_MaintenancePart 3_Rev.A
33
E H C S E O L y b ©
Page 149
Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
Q….-03-4en_TM_MaintenancePart 3_Rev.A
34
Q….-03-4en_TM_MaintenancePart 3_Rev.A
35
E H C S E O L y b ©
Page 150
Mill gearbox Gearbox internals
Thank you for your attention
Q….-03-4en_TM_MaintenancePart 3_Rev.A
36
Q….-03-4en_TM_Maintenance Part 3_Rev.A
37
E H C S E O L y b ©
Page 151
Hydraulic systems: Function & design by Dirk Grube, LOESCHE GmbH
The hydraulic systems at LOESCHE mills Overview Dirk Grube Technical Seminar Miami, 2013
E H C S E O L y b ©
Page 152
Agenda
Hydraulic Hydrau lic systems - overvi overview ew
1. Hydraulic systems 2. Hydropneumatic spring system - HSLM 3. Roller lubrication lubrication unit - HSMS 4. Hydraulic for support roller - HSSW 5. Swin Swinging ging out device - HSAV 6. Fill unit unit - HSBF
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
2
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
3
E H C S E O L y b ©
Page 153
Hydraulic application and their power unit nomenclature
Hydraulic systems - different types
Nomenclature for all application are similar!
LM …CS HSLM with counterpressure Hydropneumatic spring system
HSSW Hydraulic positioning devicefor theS-roller
LM …RM HSLM with counterpressure Hydropneumatic spring system
Hydraulicsystems in
LOESCHE mills:
Example:
HSMS Roller lubrication system
HSLM 1000/45/2 HSLM is the abbreviation for the German: [H [Hydraulik ydrauliks schrank LOESCHE Mühle]
LM …D HSMS
Roller lubrication system
HSLM with counterpressure Hydropneumatic spring system
HSAV
HSBF
Swinging out device
Filling n g andfilter unit
design & functionRev.A
HSLM without counterpressure Hydropneumatic spring system
HSMS is the abbreviation for the German: [H [Hydraulik ydrauliks schrank Mahlwalzen Schmierung] HSSW is the abbreviation for the German: [H [Hydraulik ydrauliks schrank Support Walzen] HSAV is the abbreviation for the German: [H [Hydraulik ydrauliks schrank Ausschwenk Vorrichtung] HSBF is the abbreviation for the German: [H [Hydraulik ydrauliks schrank Befüll Filtriereinheit]
4
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
5
E H C S E O L y b ©
Page 154
Hydropneumatic spring system
Hydropneumatic spring system – design & position
Assembly groups
HSLM, ring and connection pipeline: Hydropneumatic spring system Connecting pipeline
HSLM
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
Ring pipeline
Spring assembly
6
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
7
E H C S E O L y b ©
Page 155
Roller lubrication system
HSMS – hydraulic plan
roller lubrication system
HSMS
Hydraulicsystems in
LOESCHE mills:
connecting pipe line
design & functionRev.A
lubrication line
roller
8
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
9
E H C S E O L y b ©
Page 156
Mill hydraulic – system for S-roller
HSSW – hydraulic plan
Hydraulic system S -roller
connecting pipe line
HSSW
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
S- springassembly
10
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
11
E H C S E O L y b ©
Page 157
HSAV and swinging cylinder
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
HSBF
12
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
13
E H C S E O L y b ©
Page 158
Agenda 1. Hydropneumatic spring system – components – overview 2. Hydraulic cylinder 3. Rod head and clamping nut
The hydropneumatic spring ass. group in LOESCHE mills
4. Piston and bladder accumulator
Components Dirk Grube Technical Seminar Miami, 2013
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
2
E H C S E O L y b ©
Page 159
Hydraulic system – hydropneumatic spring system
Hydropneumatic spring system – function (1) Damping the system (2) Induce grinding force
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
3
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
4
E H C S E O L y b ©
Page 160
Hydropneumatic spring system
Hydropneumatic spring system – design
Assembly groups
Spring assembly Hydropneumatic spring system Connecting pipeline
HSLM
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
Ring pipeline
Spring assembly
5
Hydraulic cylinder
Rod head
Clamping nut
Bladder accumulator
Piston accumulator
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
6
E H C S E O L y b ©
Page 161
Hydropneumatic spring system – design
Hydropneumatic spring system – design
Hydraulic cylinder
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
Clamping nut and rod head
7
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
8
E H C S E O L y b ©
Page 162
Hydropneumatic spring system – design
Hydropneumatic spring system – design
Piston accumulator
Bladder accumulator
N2
Oil
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
9
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
10
E H C S E O L y b ©
Page 163
Agenda 1. Hydraulic system with counter pressure 2. Function
The hydropneumatic spring system in LOESCHE mills Function (with counter pressure) Dirk Grube Technical Seminar Duesseldorf, 2013-07-25
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
2
E H C S E O L y b ©
Page 164
Hydraulic system with counter pressure
Hydraulic system with counter pressure LM …CS HSLM with counterpressure Hydropneumatic spring system
HSMS
HSSW
Roller lubrication system
Hydraulic positioning device forthe S-roll er
LM …RM HSLM with counterpressure Hydropneumatic spring system
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
3
Hydraulicsystemsin
LOESCHE mills:
LM …D HSMS
Roller lubrication system
HSLM with counterpressure Hydropneumatic spring system
HSAV
HSBF
Swinging out device
Filli ngand filter unit
design & functionRev.A
HSLM without counterpressure Hydropneumatic spring system
4
E H C S E O L y b ©
Page 165
Hydropneumatic spring system – working pressure
Hydropneumatic spring system – with counter pressure Operating mode
Movie roller Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
5
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
Movie rod head 6
E H C S E O L y b ©
Page 166
Hydropneumatic spring system – with counter pressure
Hydropneumatic spring system – design & position HSLM, ring and connection pipeline:
Hydraulicsystems in LOESCHE mills: design & functionRev.A
7
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
8
E H C S E O L y b ©
Page 167
HSLM hydraulic scheme – with counter pressure
The hydropneumatic spring system in LOESCHE mills Diagram spring stiffness and roller force Dirk Grube Technical Seminar Duesseldorf, 2013-07-26
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
9
E H C S E O L y b ©
Page 168
Agenda
Hydropneumatic spring system – diagrams Diagram spring stiffness and load per roller
1. Diagram: roller force with counter pressure 2. Diagram: spring stiffness with counter pressure
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
2
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
3
E H C S E O L y b ©
Page 169
Hydropneumatic spring system – load per roller
Hydropneumatic spring system – spring stiffness
Design and life time calculated for 100 % of roller force.
Stiffness with too high counterpressure
~3,8
ca. 55 %
~2,2
Stiffness increased by too high counterpressure of 25 bar (against 15 bar) by + 74 %! Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
4
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
5
E H C S E O L y b ©
Page 170
Hydropneumatic spring system – spring stiffness
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
Hydropneumatic spring system – spring stiffness
6
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
7
E H C S E O L y b ©
Page 171
Hydropneumatic spring system – load per roller
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
Hydropneumatic spring system – load per roller
8
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
9
E H C S E O L y b ©
Page 172
Hydropneumatic spring system – load per roller
E R U S S E R P G N I K R O W
FW = 60% FW = 55%
Hydropneumatic spring system – load per roller
R E L L O R R E P D A O L
E R U S S E R P G N I K R O W
FW = 60% FW = 55%
FW = 30%
FW = 30%
COUNTERPRESSURE
COUNTERPRESSURE
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
R E L L O R R E P D A O L
10
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
11
E H C S E O L y b ©
Page 173
Hydropneumatic spring system – load per roller
FW = 70%
E R U S S E R P G N I K R O W
FW = 55%
The hydropneumatic spring system in LOESCHE mills
R E L L O R R E P D A O L
Coal mills - HSLM with counter pressure and not counter pressure
Dirk Grube Duesseldorf, 2013-07-26
COUNTERPRESSURE
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
12
E H C S E O L y b ©
Page 174
Agenda
Hydropneumatic spring system
1. Hydraulic system HSLM with counter pressure 2. Hydraulic system HSLM without counter pressure
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
2
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
3
E H C S E O L y b ©
Page 175
Hydraulic system HSLM at coal mills - different types
Hydropneumatic spring system – with counter pressure Operating mode
LM …D HSLM with counterpressure Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
Movie roller Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
4
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
Movie rod head 5
E H C S E O L y b ©
Page 176
Hydropneumatic spring system – without counter pressure
HSLM with counter OR not counter pressure 1. In coal mills in normal case hydraulic system HSLM with counter pressure is not necessary. But it can be an option. 2. Hydraulic system HSLM with counter pressure is necessary if part load operating at coal mills is a customer‘s requirement. (frequently power plants and steel plants are aware to operate in part load)
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
6
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
7
E H C S E O L y b ©
Page 177
Decrease working pressure for part load
Trend operation trends for counter pressure system 100
100
90
90
] r a b 80 [ e r u s s 70 e r P / e 60 t n o C 50 & g n i 40 t a r e p O 30 g n i k r o 20 W 10
80 70
] m m [ d 50 e b g n i 40 d n i r G 30 60
10 0 0
10
20
30
40
50
Mill Load [%]
8
Grinding bed
20
0
Hydraulicsystemsin LOESCHE mills: design & functionRev.A
Operating pressure
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
60
70
80
90
100 h]
9
E H C S E O L y b ©
Page 178
Increase counter pressure additional for part load
Trend operation trends for counter pressure system 100
100
90
90
] r a b 80 [ e r u s s 70 e r P / e 60 t n o C 50 & g n i 40 t a r e p O 30 g n i k r o 20 W 10
80 70
] m m [ d 50 e b g n i 40 d n i r G 30 60
0 10
20
30
40
50
Mill Load [%]
design & functionRev.A
10
Grinding bed
10
0
LOESCHE mills:
Conter pressure
20
0
Hydraulicsystems in
Operating pressure
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
60
70
80
90
100 h]
11
E H C S E O L y b ©
Page 179
Comparison of trends
HSLM scheme with counter pressure operation trends forcounterpressure system
100
100
90 ] r a b 80 [ e r u s s 70 e r P / 60 e t n o C 50 & g n i t a 40 r e p O 30 g n i k r 20 o W 10
90 80 70 ] 60 m m [ d 50 e b g n i 40 d n i r G 30
Operatingpressure
Grindingbed
20 10
0
0 0
10
20
30
40
50
60
70
80
90
100
Mill Load [%]
h]
operation trends forcounterpressure system 100
100
90 ] r a b 80 [ e r u s s 70 e r P / 60 e t n o C 50 & g n i t 40 a r e p O 30 g n i k r 20 o W 10
90 80 70 ] 60 m m [ d 50 e b g n i 40 d n i r G 30
Grindingbed
10 0 0
10
20
30
40
50 Mill Load [%]
LOESCHE mills:
Conter pressure
20
0
Hydraulicsystems in
Operatingpressure
design & functionRev.A
60
70
80
90
100 h]
12
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
13
E H C S E O L y b ©
Page 180
HSLM scheme without counter pressure
Thank you for your attention
Hydraulicsystems in
LOESCHE mills:
design & functionRev.A
14
Hydraulicsystemsin
LOESCHE mills:
design & functionRev.A
15
E H C S E O L y b ©
Page 181
Process parameters by Christian-Martin Ruthenberg, LOESCHE GmbH
Process parameter of LOESCHE vertical roller mills Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical S eminar Miami, 2013-09-17
E H C S E O L y b ©
Page 182
Agenda
Processes inside a mill
Processes inside a mill Process Parameters Dependencies Examples
Transportation
Classifying
Drying
Grinding
Summary
Clinker/ slagmill Processparameter_Rev.1
2
Processparameter_Rev.1
3
E H C S E O L y b ©
Page 183
Processes inside a mill
Processes inside a mill Flow
Transportation Flow
Drying Temperature
Classifying Speed
Pressure
Constantly controlled & stable
Grinding Pressure
Consistent product
Temperature
Speed
Processparameter_Rev.1
4
Processparameter_Rev.1
5
E H C S E O L y b ©
Page 184
Agenda
Process Parameters Pressure
Processes inside a mill
Process Parameters
Dependencies
Examples
Mill inlet vs. Outlet (dp mill) Filter inlet vs. Outlet (dp filter) Working and counter pressure (grinding force) Compressed air
Summary
Flow
Processparameter_Rev.1
6
Temperature Material Reject Gas Water (Fuel) Product
Processparameter_Rev.1
Mill outlet gas Material Water Product
7
E H C S E O L y b ©
Page 185
Agenda
Dependencies
Processes inside a mill Process Parameters
Temperature
Dependencies Examples Summary Pressure
Speed
Flow
Processparameter_Rev.1
10
Processparameter_Rev.1
11
E H C S E O L y b ©
Page 186
Examples - Filter
Processparameter_Rev.1
Examples - Hopper
12
Processparameter_Rev.1
13
E H C S E O L y b ©
Page 187
Examples - Hopper
Clinker/slag grinding plant Damper S (Stack)
Damper R (Recirculation)
Damper Z1 (Fresh air) Minimum value
Max value
Limestone hopper level
6.85 m
10.23 m
Rawmill body vibration
7.81 mm/s
14.24 mm/s
Rawmill motor power
4536 kW
5490 kW
Processparameter_Rev.1
Hot gas generator
14
Processparameter_Rev.1
15
E H C S E O L y b ©
Page 188
Agenda
Summary
Processes inside a mill
Processes inside a mill
Process Parameters
transport, grinding, drying and classifying
Dependencies Process parameters
Examples
Summary
flow, pressure, temperature and speed
Dependencies
flow, pressure, temperature and speed
Examples
Processparameter_Rev.1
16
filter and hopper
Processparameter_Rev.1
17
E H C S E O L y b ©
Page 189
Thank you for your attention
Process parameter_Rev.1
18
E H C S E O L y b ©
Page 190
Stabilization of mill in upset conditions by Christian_Martin Ruthenberg, LOESCHE GmbH
Stabilization in upset condition
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
E H C S E O L y b ©
Page 191
Agenda
Upset condition = Vibration
Upset condition = Vibration
Gas volume
Water sprinkling
Unstable grinding bed Immediate measures & root causes Most common causes
Mill body vibration Stabilizationin upsetcondition_Rev.1
2
Stabilizationin upset condition_Rev.1
3
E H C S E O L y b ©
Page 192
Upset condition = Vibration Unstable grinding bed
Upset condition = Vibration Unstable grinding bed Changes in feed material
Unstable Conditions
Feed material
Process & Operation
Maintenance
Moisture Grain size Grindability Temperature Foreign material …
Process & Operation
Classifier speed Grinding force Gas flow Water sprinkling …
Maintenance
Stabiliz ationin upsetcondition_Rev.1
4
Dam ring, support ring Roller and grinding plates Scrapers Water sprinkling …
Stabiliz ationin upsetcondition_Rev.1
5
E H C S E O L y b ©
Page 193
Upset condition = Vibration Unstable grinding bed
Agenda Upset condition = Vibration
Caused by too coarse or too fine material
Unstable grinding bed Immediate measures & root causes Most common causes
Grain size distribution
Stabiliz ationin upsetcondition_Rev.1
6
Stabilizationin upset condition_Rev.1
7
E H C S E O L y b ©
Page 194
Immediate measures & root causes
Agenda Upset condition = Vibration
For fast response: Water sprinkling Working pressure Classifier speed
Unstable grinding bed
Immediate measures & root causes
Most common causes
Vibration
Stabilizationin upset condition_Rev.1
Apply immediate measure
Solve root cause
Reverse immediate measure
8
Stabilizationin upset condition_Rev.1
9
E H C S E O L y b ©
Page 195
Most common causes
Most common causes - feed
Feed
Operation
Wear
Lumps
Memory
Roller & table
Segregation
Interpretation
Dam ring
Source: Loesche report(KN Swain OCL 2007-03-14)
Lumps > 150 mm = 56 pieces Lumps > 120 mm < 150 mm = 76 pieces Hand gloves = 6 pieces Gunny bags = 4 pieces Cotton waste = 200 gram Number of stoppage due to star feeder = 0 Stabilizationin upsetcondition_Rev.1
10
Stabilizationin upset condition_Rev.1
11
E H C S E O L y b ©
Page 196
Most common causes - wear
Thank you for your attention
Stabilizationin upsetcondition_Rev.1
12
Stabilizationi n upsetcondition _Rev.1
13
E H C S E O L y b ©
Page 197
Optimization of grinding plants: Upgrades, modifications by Desi Delgado, LOESCHE America, Inc.
Optimization of Grinding Plants: Modifications, Upgrades & Audits Type: clinker / slag, raw meal, coal Desi Delgado, Technical Instructor Miami, September 2013
E H C S E O L y b ©
Page 198
Modifications / Upgrades
Modifications
Upgrades
Audits / Optimization
Modifications / Upgrades
Justification can be quantified
Production increase
Energy Savings
Decreased downtime
…
Justification not easily quantified
Ease of maintenance / Operation
Replace obsolete / difficult to source components
Q….-03-4en_TM_Maintenance Part 3_Rev.A
2
Achieve optimum product quality
Provide more control / insight of mill system (instrumentation / sensors / advanced control) …
Q….-03-4en_TM_MaintenancePart 3_Rev.A
3
E H C S E O L y b ©
Page 199
Examples - Modification
Examples - Modification
Roller position indicators (Linear Transducers)
Roller position indicators (Linear Transducers)
Q….-03-4en_TM_MaintenancePart 3_Rev.A
4
Provide actual roller position information as opposed to simply High, Low, ETC Can be used to see if material is evenly distributed Can see if breakouts or foreign materials are in the mill by observing periodic oscillation Small investment for the amount of insight provided
Q….-03-4en_TM_MaintenancePart 3_Rev.A
5
E H C S E O L y b ©
Page 200
Examples - Modification
Examples - Modification
Updated Design (i.e. Rod Head)
Old Design
Q….-03-4en_TM_MaintenancePart 3_Rev.A
Updated Design (Grinding Elements)
MMC
New Design
6
Q….-03-4en_TM_Maintenance Part 3_Rev.A
Ductile Hardfaced
7
E H C S E O L y b ©
Page 201
Examples - Modification
Examples - Modification
G 20Mn5
Facial side protected
Highest Forces
Q….-03-4en_TM_Maintenance Part 3_Rev.A
Main wear area
V 100 Mo
8
Q….-03-4en_TM_MaintenancePart 3_Rev.A
9
E H C S E O L y b ©
Page 202
Examples - Modification
• Ductile Iron core accepts welding easier • Less Risk of cracking • Longer Wear life compared to Hi Chrome • Harder Materials can be applied to areas of less wear • Profile tracking and optimal Manufacturing Q….-03-4en_TM_Maintenance Part 3_Rev.A
Examples - Modification Chromium Alloy
Ductile Iron w/ Hardfacing
Metal Matrix Composite
Cost
“X”
“X” – “X + 50%”
“X + 100%-150%
Life
1
1.5
2
Re-Weldable
Yes but difficult
Yes
NO
• Hardfacing required • Risk in cracking
10
Q….-03-4en_TM_MaintenancePart 3_Rev.A
11
E H C S E O L y b ©
Page 203
Examples - Upgrade
Examples - Upgrade
High Efficiency Classifier Classifier Type LKS
Q….-03-4en_TM_Maintenance Part 3_Rev.A
Classifier Type LSKS
12
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
13
E H C S E O L y b ©
Page 204
Examples - Upgrade
Examples - Upgrade
Improved velocity profile
v1
<
V new v2new
Enlarged classifying zone
v2
= V old ⋅ 85% =
v2old (new geometry) v2
Modified shape v1
Reduced pressure drop across the mill Less gas volume Increase of classifying efficiency
• • •
Q….-03-4en_TM_MaintenancePart 3_Rev.A
14
Q….-03-4en_TM_MaintenancePart 3_Rev.A
Enhanced classifier efficiency and less power consumption of classifier Less fines in the material rejected by rotor Better stability of grinding bed leads to better grinding efficiency 15
E H C S E O L y b ©
Page 205
Loesche Classifier
Loesche Classifier
From LKS to LSKS
From LKS to LSKS
LM 30.4 (Quebec)
Achieved Results (Examples): LM 32.4 (Höver) Production Increase
21 %
Power Saving
> 1,5 kWh/t
Fineness
Before 1.48
0.41
% R 0.090
11.04
11.78
15,5 %
Production Increase (Material B)
22,5 %
LM 30.4 (Aslan 2)
After
% R 0.200
Production Increase (Material A)
Production Increase
8,5 %
Power Saving
> 1,5 kWh/t
Fineness
Before
% R 0.200
2.1
LM 38.4 (Hereke) Production Increase
16,3 %
Power Saving
0,6 kWh/t
Q….-03-4en_TM_MaintenancePart 3_Rev.A
After 0.7
LM 27.2 (Isparta)
16
Production Increase
18,8 %
Power Saving
1,5 kWh/t
Q….-03-4en_TM_MaintenancePart 3_Rev.A
17
E H C S E O L y b ©
Page 206
Examples - Upgrade
Larger Rollers
Modifications
Increase Roller diameter Can increase the throughput Of the mill.
Q….-03-4en_TM_Maintenance Part 3_Rev.A
18
Q….-03-4en_TM_MaintenancePart 3_Rev.A
Upgrades
Audits / Optimization
19
E H C S E O L y b ©
Page 207
Audits & Optimization
Internal Personnel
Carried out by Internal, OEM or Independent consultant Compare Actual/Measured/Historical/Benchmarks Should be carried out periodically or after major events
Audits & Optimization
Detailed Equipment knowledge Industry references and experiences
Major overhauls / equipment modifications Changes in feed material Changes in product
Knowledge of upgrade and improvements available Costs Availability
Maximization of availability and reliability Maximization of the operational and functional safety Minimization of unplanned repairs Increase of the operational lifetime
Q….-03-4en_TM_Maintenance Part 3_Rev.A
Independent Consultant
Historical Knowledge of installed equipment
Ideally audits will help to:
OEM
Product/Project support Range of General Knowledge Bias
20
Q….-03-4en_TM_Maintenance Part 3_Rev.A
21
E H C S E O L y b ©
Page 208
Audits & Optimization
Audits & Optimization Example
Example visual inspections:
Visual inspections leakages, damages, etc. Check of the filling pressure of the hydraulic accumulator smooth and stable operation
Oil- and grease pipes leakages Expansion joints damages At coal mills level of the rejectbox
Q….-03-4en_TM_MaintenancePart 3_Rev.A
22
Q….-03-4en_TM_Maintenance Part 3_Rev.A
23
E H C S E O L y b ©
Page 209
Audits & Optimization
Audits & Optimization
Sampling for oil analysis
Alternative: Installation of an Online Condition Monitoring System
Oil sensor at the lubrication system continuous monitoring of all relevant parameters
Q….-03-4en_TM_Maintenance Part 3_Rev.A
24
Q….-03-4en_TM_Maintenance Part 3_Rev.A
25
E H C S E O L y b ©
Page 210
Audits & Optimization
Trouble-free operation
Wear measurement at the grinding parts
Wear measurement at the grinding parts
Measurement at the grinding plate Ideal
Not Ideal
•
Fixed reference point
• No Fixed reference point
•
Consistent measurements
• Inconsistent measurements
Q….-03-4en_TM_MaintenancePart 3_Rev.A
Measurement at the roller tyres Ideal
26
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Not Ideal
27
E H C S E O L y b ©
Page 211
Trouble-free operation
Audits
Wear measurement at the grinding parts
Process Audit
Regularly record of the wear
Process Audit – Field measurements Measurement of
pressure
temperature
O2-content
power consumption of the components
Volume flow
etc.
at the different measuring points
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
28
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
29
E H C S E O L y b ©
Page 212
Audits
Audits
Process Audit
Process Audit
Comparison of the hand measurement with the values in the CCR
Scope of work Execution of hand measurements at the complete grinding plant
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
30
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
31
E H C S E O L y b ©
Page 213
Audits & Optimization
Audits & Optimization
Process Audit
Summary
Results Evaluation of the results with regard to stated targets
Mechanical Audit:
Summary of the findings and a detailed overview of measurements In the event of a deviation necessary actions should be defined and planned
Process Audit:
Information about the mechanical condition of the grinding plant
Information about the process parameters of the grinding plant
Identify wear zones
Identify optimization potentials / Bottle Necks
New adjustment based on current state
New adjustment to the target state
Spare parts / Repair strategy and planning
Results: Written recommendations for operation and maintenance Historical records to benchmarking Reference point for future operation / scenarios Reduce unplanned down time Increase of the plant efficiency
Q….-03-4en_TM_MaintenancePart 3_Rev.A
32
Q….-03-4en_TM_MaintenancePart 3_Rev.A
33
E H C S E O L y b ©
Page 214
Audits & Optimization Process Optimization
Audits & Optimization - Plant Optimization Process Optimization
Example: Adjustment of working pressure
At parameter changes one has to:
working pressure = f (output)
Adjust the control loops
working pressure [bar]
Readjustment of alarms/setpoints (if necessary)
High pressure High
power consumption
Unstable behaviour
Low pressure Low
capacity
output [%] Q….-03-4en_TM_MaintenancePart 3_Rev.A
34
Q….-03-4en_TM_MaintenancePart 3_Rev.A
35
E H C S E O L y b ©
Page 215
Audits & Optimization - Plant Optimization
Audits & Optimization - Plant Optimization
Process Optimization
Summary 110%
Example - Adjustment of classifier speed
No Audits
100% 90%
Mech. Failure` 80%
60%
Grinding is too fine
Unnecessary increase of wear
Decrease of plant performance
Baseline Knowledge Spare Parts Mechanical Condition Plant Efficiency Plant availability
70%
Product fineness is adjusted by classifier speed
50% 1
2
3
4
5
6
7
Cont. loss of efficiency
8
9
10
Loss of personnel / Knowledge 11
110%
12
13
14
15
14
15
16
17
18
19
20
21
22
23
24
Audits
100%
90%
Change of the relation between volume flow and classifier speed
80%
Savings at the mill fan
70%
Mech. Failure` Identified and corrected Baseline Knowledge
Mid Campaign Optimization Loss of knowledge and training
Spare Parts 60%
Mechanical Condition Plant Efficiency Plant availability
50% Q….-03-4en_TM_MaintenancePart 3_Rev.A
36
1 2 3 enancePart 4 5 3_Rev.A 6 Q….-03-4en_TM_Maint
7
8
9
10
11
12
13
16
17
18
19
20
21
22
23
24 37
E H C S E O L y b ©
Page 216