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Training Mechanical maintenance of the roller mill Polysius Headquarters Germany High drying capacity Grinding, drying and separating in only one unit Compact arrangement Low energy requirement Proven wear protection Does not necessarily need a proper mill building
Page Training THALOFA Roller mill – THALOFA Mechanical maintenance of the roller mill Training Polysius Headquarters / Germany 19 May – 13 June 2008 Page Training THALOFA Roller mill – THALOFA Page Training THALOFA Roller mill – THALOFA Raw Mill Assemblies - Feed chute Mill housing Grinding roller pair Confining air Grinding table Tie rods & hydraulic system Mill main drive & auxiliary drive SEPOL Separator Water injection Roller pair Dismounting device Page Roller mill – THALOFA SEPOL Hoist carrier Upper housing Hoist Roller pair Drive Lower housing Grinding path Nozzle ring Tie rods Page Training THALOFA Roller mill – THALOFA Feed Chute Page Training THALOFA Roller mill – THALOFA Feed Chute with chute optimised Page Material Training THALOFA Roller mill – THALOFA Coarse Feed Valve Hot gas Hot gas outlet Hot gas inlet Page Training THALOFA Roller mill – THALOFA Coarse Feed Valve Overload coupling (as example) Type Syntex 50 TD1 Rotex GS48/50 Overload torque set when being delivered 180 Nm (as example) Page 10 Training THALOFA Roller mill – THALOFA Coarse Feed Valve Scraper jammed Wear on top of the sealing strips Wear inside the housing Page 11 Training THALOFA Roller mill – THALOFA Feed Chute Mill housing Page 86 Training THALOFA Roller mill – THALOFA Separator SEPOL Setting and adjustment Basic setting of the guide vanes with the adjusting device Basic setting of the rotor blades Training THALOFA Page 87 Roller mill – THALOFA Maintenance - separator Inspection No Work to be performed Frequency Check for abnormal noises daily Check of the bolted connections every weeks Check of the antifriction bearings including the every weeks labyrinth seals for sufficient supply of lubricant every 1000 operating hours Check for wear - of the wear plates (1.14), if installed - of the rotor (2.3) - of the rotor blades (2.6) General check of the separator for leaks every weeks Remarks Training THALOFA Page 88 Roller mill – THALOFA Maintenance - separator Servicing No Work to be performed Frequency Remarks Replacement of the wear plates (1.14) in the housing as required if installed Replacement or rehabilitation of the - rotor blades (2.6) - guide vanes (1.9) as required Maintenance work at the drive unit consult separate machine manual Page 89 Training THALOFA Roller mill – THALOFA Fault Maintenance - separator Cause Im b a la n c e in th e s e p a to r r o to r b la d e s ( ) a r e w o r n o u t Rectification in s ta ll n e w r o to r b la d e s c le a n th e r o to r n o n - - u n ifo r m c a k in g s a t th e ro to r (2 ) r e p a ir th e s u p p o r t fo r th e lo w e r b e a r in g u n it s u p p o r t fo r th e lo w e r b e a r in g u n it is d e fe c tiv e S o u n d a t th e u p p e r o r lo w e r b e a r in g u n it ( o r ) th e b e a r in g s u n its ( o r ) a r e in s u ffic ie n tly s u p p lie d w ith lu b r ic a n t la b y r in th r in g ( 3 ) is d e fe c tiv e th e la b y r in th s e a ls a r e in s u ffic ie n tly s u p p lie d w ith lu b r ic a n - c h e c k th e lu b r ic a tio n p ip e s - r e lu b r ic a te th e b e a r in g u n its r e p la c e th e la b y r in th r in g - c h e c k th e lu b r ic a tio n p ip e s - r e lu b r ic a te th e la b y r in th se a l Page 90 Fault T h e m a te r ia l to b e s e p a te d is to o c o a r s e o r to o fin e Training THALOFA Roller mill – THALOFA Maintenance - separator Cause Rectification th e r o to r s p e e d is n o t c o r r e c t re s e t th e ro to r s p e e d in c o r r e c t a d ju s tm e n t o f th e g u id e v a n e s r e s e t th e g u id e v a n e s Training THALOFA Page 91 Roller mill – THALOFA Inspection Maintenance - separator drive No Work to be performed Frequency General visual check for - cracks - leaks - damage every weeks Check for abnormal noises at the - electric motor (1) - gear unit (3) daily Check of the temperatures at the - electric motor (1) - gear unit (3) daily Inspection work on - electric motor (1) - gear unit (3) Remarks According to manufacturer’s instructions Training THALOFA Page 92 Roller mill – THALOFA Maintenance - separator drive Inspection No Work to be performed Frequency Check of oil level in gear unit (3) every weeks Check of - the coupling (2) - the connecting element (6) Remarks According to manufacturer’s instructions Training THALOFA Page 93 Roller mill – THALOFA Maintenance - separator drive Servicing No Work to be performed Frequency Remarks Servicing work on gear unit (3) According to manufacturer’s instructions Servicing work on electric motor (1) According to manufacturer’s instructions If the torsional clearance at the coupling (2) as required is too large, the coupling packs have to be replaced According to manufacturer’s instructions Servicing work on connecting element (6) According to manufacturer’s instructions Page 94 Training THALOFA Roller mill – THALOFA Fault G e a r u n it ( ) g e ts to o h o t S p e e d o f e le c tr ic m o to r ( ) c a n n o t b e a d ju s te d E le c tr ic m o to r ( ) g e ts to o h o t Maintenance - separator drive Cause Rectification N o t e n o u g h o il in g e a r u n it S p e e d c o n tr o l d e fe c tiv e - E le c tr ic m o to r o v e r lo a d e d - D u s t a n d d ir t p a r tic le s in c o o lin g s y s te m T o p u p o il o r c h a n g e o il R e p a ir s p e e d c o n tr o l in a c c o r d a n c e w ith m a n u fa c tu r e r ’s in s tr u c tio n s - S e e m a c h in e m a n u a l o f S E P O L s e p a to r - C le a n c o o lin g s y s te m o f e le c tr ic m o to r Page 95 Training THALOFA Roller mill – THALOFA Water spray system Items in the drawings Injection pipes 1.1 Piping 1.2 Hose 1.3 Straight way valve 1.4 Water meter (horizontal) 1.5 Water meter (vertical) 2.0 Water tank 2.1 Shut off valve (water supply) 2.2 Drain valve 2.3 Float switch Change over filter 4.0 Motor pump unit 4.1 Motor 4.2 Coupling 4.3 Overflow valve 4.4 Drain plug Contact pressure gauge Drain and vent valves Solenoid valve Motorised control valve for injection pipe Flow meter for injection pipe 10 Pressure gauge for injection pipes Training THALOFA Page 96 Roller mill – THALOFA Lifting device Separator Roller pair Feed Chute Main drive Mill housing Grinding table Page 97 Training THALOFA Roller mill – THALOFA Lifting device Page 98 Training THALOFA Roller mill – THALOFA Lifting device Dismantling of a roller pair in progress Page 99 Training THALOFA Roller mill – THALOFA Lifting device 2.1 Two mounting hoist beams, internal 2.2 Mounting hoist beam, external 2.3 Lifting apparatus 2.4 Safety stops 2.5 Fish plates 2.6 Compressed - air hose Page 100 Technologieforum Mühlentechnik [...]... 6.14 Safety pin Training THALOFA Roller mill – THALOFA Mill housing Nozzle ring Page 16 Roller pair Mill housing Training THALOFA Roller mill – THALOFA Feed Chute Page 17 Training THALOFA Roller mill – THALOFA Roller Pair Page 18 Training THALOFA Roller mill – THALOFA Roller Pair Page 19 Training THALOFA Roller mill – THALOFA Roller Pair Basic data (as example) Outside diameter of grinding rollers 2650... Delta Pressure Metal detector to separate particles of the oil Page 29 Training THALOFA Roller mill – THALOFA Roller Pair Recording of the wear on the roller tyres Page 30 Training THALOFA Roller mill – THALOFA Roller Pair Page 31 Training THALOFA Roller mill – THALOFA Roller Pair Maximum wear on roller tyres To prevent breakage of the roller tyres, the specified maximum limit values „S2” = 150 mm must... Page 32 Training THALOFA Roller mill – THALOFA Roller Pair Recording of the wear on the roller tyres Page 33 Training THALOFA Roller mill – THALOFA Roller Pair Force application to the roller pair units Force application to the roller pair is determined by the position of the hooks relative to the roller unit axis Experience has shown that shifting the hooks influences the wear pattern on the roller. .. installation of the roller pair units, the oil probes must be re-calibrated and checked for proper functioning Page 36 Training THALOFA Roller mill – THALOFA Roller Pair Replacement of the roller tire Lay the roller pair unit horizontally on its side Remove the nuts from studs (26) and force off the clamping ring (27) by means of the forcing screws The roller tire can now be lifted off If the roller tire... 8 Roller body 36.1 Cover 9 Inner bearing cover 10 Air chamber cover 11 Radial shaft seal 12.1 Hose pipe for radial shaft seal Page 22 Training THALOFA Roller mill – THALOFA Roller Pair Confining air system P Page 23 Training THALOFA Roller mill – THALOFA Roller Pair Confining air system Page 24 Training THALOFA Roller mill – THALOFA Roller Pair Confining air system view Page 25 Training THALOFA Roller. .. system view Page 25 Training THALOFA Roller mill – THALOFA Roller Pair Confining air Page 26 Training THALOFA Roller mill – THALOFA Roller Pair Confining air system Rotating part Static part Positive air pressure to avoid dust penetration Page 27 Training THALOFA Roller mill – THALOFA Roller Pair Oil circulation system Page 28 Training THALOFA Roller mill – THALOFA Roller Pair Oil circulation system Filter... direction 80 mm Page 35 Training THALOFA Roller mill – THALOFA Roller Pair Turning roller pair units around Remove the roller pair units, turn them around through 180° outside of the roller mill and re-install them into the roller mill When the roller pair units have been turned around, definitely make sure that the hooks are in the same position relative to the roller unit axis (both in magnitude and direction)...Page 12 Training THALOFA Roller mill – THALOFA Mill housing Mill doors Page 13 Training THALOFA Roller mill – THALOFA Mill housing Rubber seal Mill doors Page 14 Training THALOFA Roller mill – THALOFA Mill housing Page 15 POSITIONS FOR THE NOZZLE RING 6.1 Cover box 6.2 Nozzle ring segment 6.3 Cover plate 6.4 Carrier 6.5 Nozzle... the roller body (8) and cannot be pulled off by means of customary fitting tools, the roller tire may also be sprung off In this case proceed as follows: Locally heat up the roller tire (25) by means of a welding torch, Then cool the heated areas with water (quenching) 25 Polysius personnel must be present at the first time Page 37 Training THALOFA Roller mill – THALOFA Roller Pair Sequence of Roller. .. Repair) Page 20 Training THALOFA Roller mill – THALOFA Roller Pair Components • • • • • • • Roller carrier Shaft Bearing tension cover Roller bearing Roller body Clamping ring Roller tyre Page 21 Training THALOFA Roller mill – THALOFA Roller Pair Item No relating to the roller pair unit 1 Roller carrier 13 Outer bearing cover 2 Axle 14 Bearing cover plate 2.3 Spring type straight pin 25 Roller tyre 3