Innovation On Demand
LEARNING MORE ABOUT ROLLER PRESS
MAINTENANCE PRACTICES FOR ROLLER PRESS
A TECHNICAL WORKSHOP CONDUCTED BY
HUMBOLDT WEDAG INDIA-PROCESS KNOW HOW
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Grinding Technology -Roller Press
Innovation On Demand
Roller Press Maintenance
Safety first for the roller
press
Roller and it‘s surface
Hydraulic Check
Scheduled Checks
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Grinding Technology-Roller Press
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Safety first for Roller Presses
Principles of Pressing
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Safety first for Roller Presses
The Big Ball
Normal load distribution equal
over width
With single
oversized stone
local overload
damage
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Grinding Technology-Roller Press
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Safety first for Roller Presses
Magnet and Metal detector
• Metal pieces
Over sized Material
(<2 x gap)
• Load peaks on surface
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Grinding Technology-Roller Press
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Types of surfaces
Hard facing
2 welded layers of hard facing
With profiles
ILP interrupted line profiles
Autogenous wear protection
Profiles to hold it
Regularly welding maintenance
Stud lining
Highest wear protection
Limits to press force
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CHF, Complete Hard Faced Welded Wear Surface
2 welded layers of hard facing
Profiles for a better grip
Normal wear applications
Maintenance once a year
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ILP, Interrupted Line Profile
Autogenous wear protection
Profiles welded to the base
holding the AWP
Normal to higher wear
applications
Regularly maintenance
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Stud Lining
Autogenous wear protection
Tungsten carbide studs protect
the surface
Highest wear applications
Limits to press force
Repair difficult
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Welding
Hardfacing in good condition
Profiles are clearly visible
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Welding
Hardfacing height reduced
Time to Weld
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Welding
When to weld ? Rule of thumb:
After half the weld thickness:
Complete weld: 4 mm
ILP: 6 mm
How long and How often?
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Grinding Technology-Roller Press
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General Check of Hydraulic System
Stop machine
Relive pressure
• All pressure guages at zero
Run hydraulic pump in local
• Check pressure at hydraulic unit min 150 bar
Pressure locally left and right side
• In steps
• Difference in pressure increase shows N2 pressure in accumulators
o Equal on both sides and according to settings
• Reach highest achievable pressure
o Equal on both sides and according to settings
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Grinding Technology-Roller Press
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General Check of Hydraulic System
Leave system pressurized
• Pressure should not decrease
• Check pressure reading in rollcox
• Check position of both rolls,
• bearing touches stops, bearing distance must be equal
• Gaps left and right in Rolcox must be equal and according to settings
Relive pressure
• Both sides must relive pressure to zero
Push rolls/bearing housings apart
• Movement easy possible But you will know
We have a problem
This takes you 10 minutes
Or
Let’s go
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Grinding Technology-Roller Press
Innovation On Demand
Maintenance Schedule, Every 24 hrs or daily
Roller press in general-
Abnormal noise
Dust deposits
Frame –
Check gap between the
spacer strips of bearing
housing
Material accretions in the
gap on the bottom frame
section to be removed
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 24 hrs or daily
Roller support-
Check bearing temperature
Check bearing lubrication
Check internal and external
labyrinth seals for sufficient
lubrication
• Grease needs to cover the
seal gap ring opening
• Grease needs to come out
to clean the seal
• If Grease is getting
liquid seal may be damaged
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 24 hrs or daily
Hydraulic pressing system-
Check connections for
tightness
Check oil pressure
Central grease
lubrication -
Observe end indication
for barrel change
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Rollers-
Wear measurement at the
rollers( wear measurement
with measuring template,
entering the measuring
results into the log of
measuring points)
Check the surface for break
outs in the wear surface .
Repair of the wear surface if
required.
Check the roller surfaces,
roller front and profiling,
repair and regenerate the
wear surface
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Surface Measurements
Measurement device
part of KHD delivery
Crossbar mounted
to the roll
Distance easy to
measure
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Frame –
Check bolts of end pieces
Check bolts of outer guide
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Chart 20
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Feeding device-
Check the slide
bearing and threaded
bush for lateral wall
support
Check distance of the
lateral wall with lateral
wall tips to the rollers
front sides
Check the gate guiding
and lateral wall
suspensions
Check bellows for
tightness
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Drive –
Check tightening
torque of the screw
for the articulated
shaft
Torque support-
Check tightening
torques of the screws
gear box holder/gear
box
Check foundation
fastening
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Chart 22
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 1000 hrs
Oil in gearbox
Cardan shaft
needs Grease
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 2000 hrs
Roller support-
Check fastening bolts or tighten
them
Scrap off material deposits at
the labyrinths
Remove deposit from side ways
Check bolts of the outer guiding.
Check side ways of the outer
guide.
Check degree of contamination
of the air filters at the bearing
housings, replace if required.
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 2000 hrs
Hydraulic pressing system-
Check all hydraulic components for
leakages.
Visual check of the rubber hinge
between the bearing housings of
the floating roller and the frame
end pieces.
Check filter at the hydraulic set
and at the intermediate tank,
replace ,if required.
Check the pressing device for
proper functioning.
Check the pump pressure of
hydraulic system.
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Grinding Technology-Roller Press
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Maintenance Schedule, Every 2000 hrs
Hydraulic pressing system-
Screw setting screw at the
pressure switch system down, until
the cartridge valves respond and
/or interrupt the current supply to
the pressure switch system. In this
case ,the current switch valve must
blow pressure/the hydraulic oil
over the cartridge valves. If in both
cases the cartridge valves do not
drain hydraulic oil into the
balancing tank, contact KHD.
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Grinding Technology-Roller Press
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Every 9000 hrs or yearly
Roller press in general-
Complete wear check and cleaning.
Check all screw union for tight
seating
Oil change as per list of lubricating
schedule
Check & fix (50 degree centigrade )
set volume regulating valve for
cooling water.
Replace all the air cleaners at the
bearing housing/hydraulic set/
intermediate tanks/control
block/guard.
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Grinding Technology-Roller Press
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If the days come to change the rolls
It was done in
48 hours
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Grinding Technology-Roller Press
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Roll Exchange
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Grinding Technology-Roller Press
Innovation On Demand
Roller Press Technology
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Grinding Technology-Roller Press
Innovation On Demand
Roller Press Maintenance
Discussion
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Grinding Technology-Roller Press 31
