Van Hanh May Nghien Xi Mang

Mill with Classifier

Operating Instructions

LOESCHE Mill with Classifier

Type: LM 63.3+3 CS with LSKS 107 CSr

Project: P09961 Codeword: Tan Truong Clinker

Date of issue: 2011-07-09 / gu

Document No: P09961-M10X00.980 en Rev. A Original Operating Instructions


 Copyright by LOESCHE GmbH Hansaallee 243 D-40549 Düsseldorf Federal Republic of Germany Phone: +49 (0)211 5353-0 Fax: +49 (0)211 5353-500 E-mail: [email protected] Internet: www.loesche.com

2

P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH


Table of Contents List of Tables .................................................................................................................8 List of Figures................................................................................................................9 1

Liability and warrant conditions ........................................................................11

1.1

Intended use.............................................................................................................. 12

1.2

Reasonably foreseeable misuse ............................................................................... 14

2

About the instruction manual ............................................................................15

2.1

Subject matter of this instruction manual................................................................... 15

2.2

Plant identification ..................................................................................................... 16

2.3

Reference documents ............................................................................................... 16

2.4

Explanation of symbols used to identify text.............................................................. 16

2.5

Signal words .............................................................................................................. 17

2.6

Pictorial symbols........................................................................................................ 18

2.7

Conversion table........................................................................................................ 21

2.8

Abbreviations ............................................................................................................. 22

3

Safety ...................................................................................................................23

3.1

Obligations of the operator ........................................................................................ 23

3.2

Obligations of personnel ............................................................................................ 23

3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

Safety instructions for specific operating phases....................................................... 24 Transport ....................................................................................................................24 Assembly ....................................................................................................................24 Commissioning ...........................................................................................................24 Operation....................................................................................................................25 Maintenance ...............................................................................................................25

3.4 3.4.1 3.4.2

Safety requirements .................................................................................................. 26 Organisational issues .................................................................................................26 Requirements of personnel ........................................................................................26

3.5 3.5.1 3.5.2 3.5.3 3.5.4

Information about specific types of risk...................................................................... 27 Risks posed by electrical energy ................................................................................27 Risks posed by hydraulic and pneumatic energy .......................................................27 Risks posed by harmful gases, vapours and dusts ....................................................27 Risks posed by vibration and noise ............................................................................27

3.6

Duties of the operator ................................................................................................ 28

3.7

Safety checks ............................................................................................................ 29

3.8

Interfaces at the roller grinding mill............................................................................ 30

3.9

Operating and hazardous areas ................................................................................ 31


3


3.10

Shutdown procedure ..................................................................................................32

3.11 3.11.1 3.11.2 3.11.3 3.11.4

Safety instructions for the roller grinding mill components .........................................33 Safety instructions pertaining to the LOESCHE mill................................................... 33 Safety instructions pertaining to the classifier ............................................................33 Safety instructions pertaining to the hydraulic systems.............................................. 34 Safety instructions pertaining to the swinging device................................................. 35

3.12

Installed safety systems .............................................................................................36

4

Technical Data .....................................................................................................41

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

Technical Data, LOESCHE roller grinding mill ...........................................................41 Production data, LOESCHE roller grinding mill.......................................................... 42 Electrical data.............................................................................................................42 Water injection............................................................................................................43 Sealing air supply .......................................................................................................43 Ambient data ..............................................................................................................43 Coating and choice of colours .................................................................................... 44

4.2

Technical Data, LOESCHE mill..................................................................................44

4.3

Technical Data, classifier ...........................................................................................45

4.4 4.4.1 4.4.2 4.4.3

Technical Data, hydraulic system...............................................................................46 Hydraulic cabinet HSLM.............................................................................................46 Hydraulic cabinet HSSW ............................................................................................47 Hydraulic cabinet HSMS ............................................................................................ 47

4.5 4.5.1 4.5.2

Technical Data, swinging device ................................................................................48 Hydraulic cabinet, HSAV ............................................................................................48 Swinging device cpl....................................................................................................49

5

Description of the machine ................................................................................50

5.1 5.1.1

Overview of the roller grinding mill .............................................................................50 Functional description ................................................................................................51

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.8.1 5.2.8.2 5.2.9 5.2.10 5.2.11 5.2.12 5.2.12.1 5.2.13 5.2.14 5.2.15

LOESCHE mill............................................................................................................53 Mill stand cpl...............................................................................................................54 Mill body cpl................................................................................................................57 Lining cpl. ...................................................................................................................59 Grinding bed sprinkler cpl........................................................................................... 60 Table cpl.....................................................................................................................62 LM drive......................................................................................................................65 Grinding parts cpl. ...................................................................................................... 66 Roller (M) cpl. .............................................................................................................67 Roller rotation monitor cpl. .........................................................................................69 Slip-ring sealing cpl. ...................................................................................................70 Rocker arm (M) cpl..................................................................................................... 71 Lever sealing (M) cpl. .................................................................................................73 Rocker arm monitor (M) cpl........................................................................................ 75 Roller (S) cpl...............................................................................................................77 Roller rotation monitor (S) cpl.....................................................................................79 Rocker arm (S) cpl. ....................................................................................................80 Lever sealing (S) cpl...................................................................................................81 Rocker arm monitor (S) .............................................................................................. 82

4



5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10

Swinging device......................................................................................................... 84 Swinging the grinding roller ........................................................................................84 Swinging the support roller .........................................................................................85 Preparatory work for swinging out ..............................................................................86 Swinging-out process .................................................................................................86 Swinging-in process ...................................................................................................87 Lubrication line cpl......................................................................................................88 Seal-air piping.............................................................................................................89 Sealing air monitoring cpl. ..........................................................................................90 Vibration monitoring cpl. .............................................................................................91 Name plate .................................................................................................................92

5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7

Hydraulic system of the grinding roller....................................................................... 93 Hydraulic spring assembly - mode of operation..........................................................95 Spring characteristic ...................................................................................................96 Working pressure (spring stiffness) – hydraulic bladder accumulator ........................96 Counterpressure function ...........................................................................................98 Roller relief pressure (RRP) – partial load operation ..................................................98 Functions of hydropneumatic spring assembly system ..............................................99 Service functions ......................................................................................................101

5.5 5.5.1 5.5.2

Hydraulic system of the support roller ..................................................................... 102 Mode of operation.....................................................................................................103 Functions of hydraulic positioning device .................................................................103

5.6 5.6.1 5.6.2 5.6.2.1 5.6.2.2 5.6.2.3 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7

Design and construction of the classifier ................................................................. 105 Classifier housing cpl................................................................................................106 Rotor cpl. ..................................................................................................................107 Upper bearing cpl. ....................................................................................................108 Lower bearing cpl. ....................................................................................................108 Classifier temperature sensor cpl. ............................................................................109 Classifier lining cpl....................................................................................................110 Classifier upper housing lining cpl. ...........................................................................111 Classifier drive cpl. ...................................................................................................112 Classifier lubrication line cpl. ....................................................................................113 Name plate ...............................................................................................................114

6

Transport ...........................................................................................................115

6.1

Scope of supply ....................................................................................................... 115

6.2 6.2.1 6.2.1.1 6.2.1.2 6.2.1.3 6.2.1.4 6.2.2

Delivery and packaging ........................................................................................... 115 Transport sketches ...................................................................................................116 Standard transport sketches for the LOESCHE Milll ................................................116 Standard transport sketches for the classifier...........................................................121 Standard transport sketches for the hydraulic cabinets............................................124 Standard transport sketch for the swinging device ...................................................124 Weight of the components ........................................................................................125

6.3

Checking the delivery status.................................................................................... 127

6.4

Interim storage of supplied parts ............................................................................. 127

6.5 6.5.1 6.5.2

Transport to the installation site............................................................................... 128 Crane transport.........................................................................................................128 Transport with a fork-lift truck ...................................................................................128


5


6.6

Disposal of the packaging ........................................................................................129

6.7

Joining parts on the construction site .......................................................................129

7

Installation .........................................................................................................130

7.1

Installation reference documents .............................................................................130

7.2

Description of the assembly sequence.....................................................................131

8

Commissioning .................................................................................................132

8.1 8.1.1 8.1.2 8.1.3 8.1.4

Cold start-up.............................................................................................................132 Requirements ...........................................................................................................132 Applicable documents .............................................................................................. 132 Extent of cold start-up ..............................................................................................133 Cold start-up sequence ............................................................................................134

8.2

Warm start-up...........................................................................................................135

8.3

Commissioning the hydraulic system .......................................................................136

8.4

Commissioning the hydraulic positioning device for support rollers (S) ...................136

8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5

Starting the mill when unfilled or filled ......................................................................137 Master rollers (M) .....................................................................................................137 Support rollers (S) ....................................................................................................138 Shutting down the mill during normal operation .......................................................138 Emergency Stop.......................................................................................................138 On-site operation......................................................................................................138

9

Operation ...........................................................................................................139

9.1 9.1.1

Local control panels .................................................................................................140 Operation..................................................................................................................140

9.2 9.2.1 9.2.2

Operating modes......................................................................................................140 Local operation......................................................................................................... 140 Automatic mode .......................................................................................................141

9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6

Switching the grinding plant on and off ....................................................................141 Switching the plant on .............................................................................................. 141 Starting the grinding circuit.......................................................................................141 Start sequence .........................................................................................................142 Operating the grinding plant .....................................................................................143 Switching the plant off .............................................................................................. 144 Unlocking the Emergency Stop functions................................................................. 145

9.4 9.4.1 9.4.2

Failure of power supplies .........................................................................................145 Switching the plant off in the event of a power failure .............................................. 145 Switching the plant off in the event of a hydraulic-system failure............................. 145

9.5

Electrical engineering ...............................................................................................146

10

Troubleshooting ................................................................................................147

10.1

11 6

Customer service .....................................................................................................150

Maintenance.......................................................................................................151 P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH


11.1

General notes on maintenance works ..................................................................... 151

11.2

Inspection ................................................................................................................ 153

11.3

Cleaning .................................................................................................................. 154

11.4 11.4.1 11.4.2 11.4.3 11.4.4 11.4.5 11.4.5.1 11.4.6 11.4.6.1 11.4.7 11.4.7.1 11.4.7.2 11.4.7.3 11.4.7.4 11.4.7.5 11.4.8 11.4.8.1 11.4.8.2 11.4.9 11.4.9.1 11.4.10 11.4.11 11.4.12 11.4.13 11.4.14 11.4.15 11.4.16 11.4.17 11.4.18

Maintenance ............................................................................................................ 156 Lubrication ................................................................................................................156 General maintenance information for assemblies and machines .............................157 Maintenance: Mill stand cpl. .....................................................................................158 Maintenance: Mill body cpl. ......................................................................................159 Maintenance: Table cpl. ...........................................................................................160 Auxiliary equipment: table cpl...................................................................................163 Maintenance: Rocker arms.......................................................................................167 Auxiliaries: Rocker arm (M) cpl.................................................................................169 Maintenance: Roller..................................................................................................172 Auxiliaries: Roller (M) cpl. .........................................................................................175 Auxiliaries: Roller (S) cpl. .........................................................................................178 Auxiliary equipment: lifter cpl. ...................................................................................179 Auxiliary equipment: tyre profile ruler cpl..................................................................182 Auxiliaries: Oil drain device cpl. ................................................................................183 Maintenance: Spring assembly cpl. ..........................................................................185 Auxiliaries: Spring assembly (M) cpl.........................................................................187 Auxiliaries: Spring assembly (S) cpl. ........................................................................188 Maintenance: Hydraulic accumulators......................................................................190 Auxiliary equipment: Fill and test unit cpl..................................................................193 Maintenance: Hydraulic cabinets..............................................................................194 Maintenance: LM-Drive ............................................................................................196 Maintenance: Gearbox lubrication unit .....................................................................197 Maintenance: Central lubrication unit .......................................................................198 Maintenance: Sealing air system..............................................................................199 Maintenance: Piping system.....................................................................................200 Maintenance: Swinging device .................................................................................200 Maintenance: Grinding bed sprinkler cpl. .................................................................201 Maintenance: Classifier ............................................................................................202

11.5

Checks after maintenance work .............................................................................. 204

12

Spare parts ........................................................................................................205

13

Decommissioning, dismantling and disposal ................................................ 206

13.1

Qualifications of dismantling personnel ................................................................... 206

13.2

Requisite conditions for dismantling ........................................................................ 206

13.3

Carrying out dismantling and disposal..................................................................... 207

14

Supplier documentation ...................................................................................208

Index ........................................................................................................................... 209


7


List of Tables Tab. 1: Conversion factors ......................................................................................................................... 21 Tab. 2: Abbreviations used......................................................................................................................... 22 Tab. 3: Shutdown procedure ...................................................................................................................... 32 Tab. 4: Characteristic data, LOESCHE roller grinding mill......................................................................... 41 Tab. 5: Limit dimensions, LOESCHE roller grinding mill ............................................................................ 41 Tab. 6: Production data, LOESCHE roller grinding mill.............................................................................. 42 Tab. 7: Electrical data ................................................................................................................................. 42 Tab. 8: Water injection................................................................................................................................ 43 Tab. 9: Sealing air....................................................................................................................................... 43 Tab. 10: Ambient data ................................................................................................................................ 43 Tab. 11: Characteristic data, LOESCHE mill.............................................................................................. 44 Tab. 12: Characteristic data, classifier ....................................................................................................... 45 Tab. 13: Characteristic data, hydraulic cabinet HSLM ............................................................................... 46 Tab. 14: Characteristic data, hydraulic cabinet HSSW .............................................................................. 47 Tab. 15: Characteristic data, hydraulic cabinet HSMS............................................................................... 47 Tab. 16: Characteristic data, swinging device............................................................................................ 48 Tab. 17: Characteristic data, hydraulic cabinet HSAV ............................................................................... 48 Tab. 18: Characteristic data, swinging device cpl. ..................................................................................... 49 Tab. 19: Roller grinding mill, transport weights of components ............................................................... 126 Tab. 20: Fault, Cause, Remedy table....................................................................................................... 149 Tab. 21: Function checks, inspection intervals......................................................................................... 153 Tab. 22: Cleaning intervals....................................................................................................................... 155 Tab. 23: Maintenance table, mill stand..................................................................................................... 159 Tab. 24: Maintenance table, mill body...................................................................................................... 159 Tab. 25: Maintenance table, table ............................................................................................................ 162 Tab. 26: Maintenance table, rocker arm................................................................................................... 168 Tab. 27: Maintenance table, roller ............................................................................................................ 174 Tab. 28: Maintenance table, spring assembly.......................................................................................... 186 Tab. 29: Maintenance table, bladder accumulator ................................................................................... 191 Tab. 30: Maintenance table, hydraulic cabinet......................................................................................... 195 Tab. 31: Maintenance table, LM drive ...................................................................................................... 196 Tab. 32: Maintenance table, gearbox lubricating unit............................................................................... 197 Tab. 33: Maintenance table, central lubricating unit................................................................................. 198 Tab. 34: Maintenance table, sealing air system ....................................................................................... 199 Tab. 35: Maintenance table, swinging device .......................................................................................... 200 Tab. 36: Maintenance table, grinding bed sprinkler ................................................................................. 201 Tab. 37: Maintenance table, classifier ...................................................................................................... 203

8



List of Figures Fig. 1: LOESCHE roller grinding mill, assembly groups overview ............................................................. 12 Fig. 2: LOESCHE roller grinding mill interfaces, schematic sketch............................................................ 30 Fig. 3: LOESCHE roller grinding mill overview........................................................................................... 50 Fig. 4: Flow of grinding material through mill, pictorial representation....................................................... 51 Fig. 5: LOESCHE Mill, assembly overview ................................................................................................ 53 Fig. 6: Mill stand cpl.................................................................................................................................... 54 Fig. 7: Mill body cpl..................................................................................................................................... 57 Fig. 8: Lining cpl. ........................................................................................................................................ 59 Fig. 9: Grinding bed sprinkler cpl................................................................................................................ 60 Fig. 10: Table cpl. ....................................................................................................................................... 62 Fig. 11: LM drive cpl., schematic sketch .................................................................................................... 65 Fig. 12: Roller (M) cpl. ................................................................................................................................ 67 Fig. 13: Roller rotation monitor cpl. ............................................................................................................ 69 Fig. 14: Slip-ring sealing cpl. ...................................................................................................................... 70 Fig. 15: Rocker arm cpl. ............................................................................................................................. 71 Fig. 16: Lever sealing cpl............................................................................................................................ 73 Fig. 17: Rocker arm monitor cpl. ................................................................................................................ 75 Fig. 18: Roller (S) cpl.................................................................................................................................. 77 Fig. 19: Roller rotation monitor (S) cpl., schematic sketch......................................................................... 79 Fig. 20: Rocker arm (S) cpl......................................................................................................................... 80 Fig. 21: Lever sealing (S) cpl...................................................................................................................... 81 Fig. 22: Rocker arm monitor (S) cpl. .......................................................................................................... 82 Fig. 23: Swinging the grinding roller ........................................................................................................... 84 Fig. 24: Swinging the roller (S) ................................................................................................................... 85 Fig. 25: Sealing air system ......................................................................................................................... 89 Fig. 26: Sealing air monitoring cpl. ............................................................................................................. 90 Fig. 27: Vibration monitoring cpl., schematic sketch .................................................................................. 91 Fig. 28: Name plate .................................................................................................................................... 92 Fig. 29: Interplay, working pressure/counterpressure system.................................................................... 95 Fig. 30: Diagram: Spring stiffness .............................................................................................................. 97 Fig. 31: Spring assembly (S) cpl. ............................................................................................................. 102 Fig. 32: Classifier, assembly overview ..................................................................................................... 105 Fig. 33: Classifier housing cpl., schematic sketch.................................................................................... 106 Fig. 34: Rotor cpl. ..................................................................................................................................... 107 Fig. 35: Upper bearing cpl. ....................................................................................................................... 108 Fig. 36: Lower bearing cpl. ....................................................................................................................... 108 Fig. 37: Schematic sketch of classifier temperature sensor, cpl. ............................................................. 109 Fig. 38: Classifier lining cpl....................................................................................................................... 110 Fig. 39: Classifier upper housing lining cpl............................................................................................... 111 Fig. 40: Classifier drive cpl. ...................................................................................................................... 112 Fig. 41: Schematic sketch of the classifier lubrication line, cpl. ............................................................... 113 Fig. 42: Name plate .................................................................................................................................. 114 Fig. 43: Transport sketch, foundation frame............................................................................................. 116 Fig. 44: Transport sketch, pedestal (left fig.), gearbox baseplate ............................................................ 116 Fig. 45: Transport sketch, bridge.............................................................................................................. 117 Fig. 46: Transport sketch, ring duct.......................................................................................................... 117 Fig. 47: Transport sketch, table (left fig.), gas duct .................................................................................. 118 P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

9


Fig. 48: Transport sketch, mill body.......................................................................................................... 118 Fig. 49: Transport sketch, cover ............................................................................................................... 119 Fig. 50: Transport sketch, rocker arm (M) (left fig.), rocker arm (S)......................................................... 119 Fig. 51: Transport sketch, roller (M) (left fig.), roller (S) ........................................................................... 120 Fig. 52: Transport sketch, foot-bridges..................................................................................................... 120 Fig. 53: Transport sketch, classifier upper housing.................................................................................. 121 Fig. 54: Transport sketch, classifier lower housing .................................................................................. 121 Fig. 55: Transport sketch, frame............................................................................................................... 122 Fig. 56: Transport sketch, grit funnel ........................................................................................................ 122 Fig. 57: Transport sketch, Rotor ............................................................................................................... 123 Fig. 58: Transport sketch, motor console ................................................................................................. 123 Fig. 59: Transport sketch, hydraulic cabinets........................................................................................... 124 Fig. 60: Transport sketch, cylinder swinging device................................................................................. 124 Fig. 61: Grinding plate segment alignment............................................................................................... 161 Fig. 62: Auxiliary equipment: table cpl...................................................................................................... 163 Fig. 63: Support cpl................................................................................................................................... 165 Fig. 64: Flange-sleeve connection............................................................................................................ 169 Fig. 65: Taper-pin connection................................................................................................................... 170 Fig. 66: Auxiliary equipment: roller (M) cpl. .............................................................................................. 175 Fig. 67: Auxiliary equipment: roller cpl., roller bearing removal................................................................ 176 Fig. 68: Auxiliary equipment: roller (S) cpl................................................................................................ 178 Fig. 69: Lifter cpl. ...................................................................................................................................... 179 Fig. 70: Changing the tire ......................................................................................................................... 180 Fig. 71: Tire profile ruler cpl...................................................................................................................... 182 Fig. 72: Oil drain device (M) cpl................................................................................................................ 183 Fig. 73: Oil drain device cpl. ..................................................................................................................... 184 Fig. 74: Dismantling the spring pin ........................................................................................................... 188 Fig. 75: Assembling the spring pin ........................................................................................................... 189

10


LOESCHE Mill with Classifier Liability and warrant conditions

1

Liability and warrant conditions Our "General terms and conditions of sale and delivery" apply. Warranty and liability claims for material damage and personal injury will not be accepted if they can be attributed to one or more of the following causes: – Failure to use the machine as intended (see chapter "1.1 Intended use", on page 12) – Improper mounting, putting into operation, running and maintenance of the machine – Operation of the machine when safety switching devices are defective or when safety relays and protective devices have been improperly fitted or are not in perfect working order – Non-compliance with the information in the instruction manual with regard to the transportation, storage, assembly, commissioning, operation, maintenance and repair of the machine – Unauthorised changes to the design and structure of the machine – Unauthorised technical modifications (e.g. drive ratios, output and/or speed) – Failure to monitor machine parts which are prone to wear – Improperly completely repairs – Catastrophes attributable to extraneous causes and force majeure – Deployment of untrained personnel


11


1.1

Intended use 38

1 2

37 3

4

5

36 35

34 33 32 31 30 29 28 27

6

26

7

25

8

24

9

23

10

22

11

21

12 13

20 19 17

14

18

15

001219

16

Fig. 1: LOESCHE roller grinding mill, assembly groups overview

12



Key 1 Classifier drive cpl. 2 Classifier platform cpl. 3 4 5 6 7 8 9 10 11 12 13

Raw material inlet Star feeder Hydraulic oil supply, support rollers Sealing air pipeline cpl. Lever sealing (M) cpl. Roller (M) cpl. LM lubrication line Roller rotation monitor (M) cpl. Rocker arm monitoring (M) cpl. Rocker arm (M) cpl. Mill stand cpl.

14 Spring assembly (M) cpl. 15 Ring pipeline cpl./ Connecting pipeline cpl. 16 LM-drive cpl. 17 Hydraulic oil supply, grinding rollers 18 Swinging device 19 Table cpl. 20 Grinding parts cpl. 21 Roller (S) cpl. 22 Lever sealing (S) cpl. 23 Rocker arm monitoring (S) cpl. 24 Roller rotation monitor (S) cpl. 25 Rocker arm (S) cpl. 26 Spring assembly (S) cpl.

27 Lining cpl. 28 Mill body cpl. 29 Classifier housing cpl. 30 Rotor support cpl. 31 Lining cpl. 32 Lower bearing cpl. 33 Guide vane carrier cpl. 34 Rotor 35 Upper bearing cpl. 36 Classifier upper housing lining cpl. 37 Finished material outlet 38 Classifier lubrication line cpl.

The LOESCHE roller grinding mill serves exclusively to grind grinding stock in accordance with the specifications given in the chapter "Technical Data“. The grinding stock is fed to the roller grinding mill in metered amounts via a conveyor. The grinding process is generated by pressure and friction under the effect of a hydropneumatic roller spring assembly. The ground stock is thrown outwards by centrifugal force and carried by the gas flow to the classifier. The finished product passes through the classifier with the desired fineness, is discharged and dispatched for further use. This LOESCHE roller grinding mill is intended for commercial use and was developed, designed and constructed solely for this purpose.

WARNING Personal and/or machine damage! This machine is intended solely for the purpose described above. Any other use or modification of the machine without the written consent of the manufacturer is deemed unacceptable. The manufacturer accepts no liability for damage resulting from such use. The risk is borne solely by the operator. The machine may only be put into operation if the superior system in which it is being installed complies with regulations and once there is an assurance that all safety switching devices have been assembled and are fully functional.

Intended use also includes observation of the manufacturer's instructions regarding the assembly, disassembly and reassembly, commissioning, operation and maintenance (inspection, servicing, repair) of the roller grinding mill.

Note on application of the EC Directive EMC 2004/108/EEC: According to DIN EN 61000-6-4 (Generic standards - Emitted interference for industrial environments) the machine may not be used in residential, business or industrial areas or in small businesses unless it also satisfies the standard DIN EN 61000-6-3 (Emitted interference).


13


1.2

Reasonably foreseeable misuse Use of the roller grinding mill to grind materials contaminated by packaging materials is prohibited. It is not permitted to operate the roller grinding mill without the metal separator connected upstream.

14


LOESCHE Mill with Classifier About the instruction manual

2 2.1

About the instruction manual Subject matter of this instruction manual This instruction manual describes all necessary tasks and activities relating to the machine. These include transportation, assembly, operation, troubleshooting and maintenance. A separate document describes the electrical equipment and the electrical installation work. It also features the corresponding drawings. The instruction manual contains information which is important for the safe, correct and efficient running of the machine. Observation of this information will help to prevent risks, avoid repairs and downtimes as well as increase the reliability and service life of the machine(s). This instruction manual must be supplemented with information derived from applicable national regulations governing accident prevention and the protection of the environment. The instruction manual must be read and used by everyone charged with working with/on the machine. The instruction manual must be available and accessible at all times in the machine's place of use. ● You must read this instruction manual before using the machine(s). Compliance with the safety instructions is mandatory. ● You must also comply with the binding regulations in force in the country of use with regard to accident prevention and acknowledged rules for safe and proper working. The tasks described in this instruction manual are listed in such a way as to be understood – in the chapters Control and Operation by an instructed person, – in the chapters Transportation, Erection and Assembly, Maintenance, Fault/Cause/Rectification by a skilled worker. The chapters Transportation, erection and Assembly, Maintenance, Fault/Cause/Rectification are intended for skilled workers only. Tasks described in this chapter may only be carried out by skilled workers. Instructed person A person who has been instructed or trained by a skilled worker in the tasks assigned to him/her and the potential hazards of improper operation, in addition to the necessary safety devices and safety measures. Skilled worker A skilled worker is a person who, by combining his or her specialist training, knowledge and experience with awareness of applicable standards, is able to assess the tasks with which or he she has been assigned and identify potential hazards (definition based on EN 60204-1). The figures in this manual have been provided for illustrative purposes only. The specific drawings supplied with each purchase are your primary source of reference.


15

LOESCHE Mill with Classifier About the instruction manual 2.2

Plant identification The information in this instruction manual applies only to the machine whose type designation is give on the title page. The name plate containing the machine data is attached to the machine (for position, see Technical Drawings). For all enquiries, it is important to specify correctly: – the designation – the type designation This is the only way of ensuring that your enquiry is dealt with quickly and correctly.

2.3

Reference documents Additional documents should be referred to in conjunction with this instruction and installation manual; please refer to the list in the  superordinated main table of contents. We do not accept liability for damage due to non-compliance with the information in this instruction manual. The scope of the product includes this manual and all associated reference documents. ● Should ownership of the product be transferred, this instruction manual, along with all associated reference documents, must be handed over to the new owner.

2.4

Explanation of symbols used to identify text Symbol identifying a list of items – In the text, each item in a standard list is preceded by a dash. Symbol identifying an instruction ● Instructions describing actions to be carried out are preceded by bullet points. Actions must be completed in the sequence described. Symbol identifying separate documents  The opened book indicates additional separate documents. Cross-references Cross-references are links either to a section of text in this instruction manual or to another document. In the case of cross-references to a section of text, either the chapter, a figure number or a page number will be indicated. In the case of cross-references to another document, a document name, a drawing number or a document number will be indicated (e.g. see  supplier documentation).

16



2.5

Signal words DANGER Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING Indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, COULD result in minor or moderate injury.

NOTICE Indicates a hazardous situation which, if not avoided, COULD result in property damage.

Note Indicates useful or additional information for easy and safe usage of the machine(s) and the manual.


17


2.6

Pictorial symbols Please note the following symbols which have been used in the manual to identify safety information: Safety symbols comprise a warning triangle and a symbol against a yellow background. In the instruction manual, the following symbols have been used to identify risks to personal safety: DANGER Direct risk to life and limb!

DANGER Toxic substances!

DANGER Risk of electrocution!

DANGER Risk of falling!

DANGER Explosive materials!

DANGER Suspended loads!

CAUTION Hot surfaces!

18



CAUTION Risk of tripping!

WARNING Risk of injuries to the hands!


19


Other signs: NOTICE Possible risk to machine!

Note Useful information and special notes.

Note on environmental care! Useful information and special notes:

Switching symbol prompts the user to interrupt the power supply.

Lock symbol prompts the user to lock a switch state.

Book symbol Notice to additional documents

20



2.7

Conversion table The following conversion factors can be used to convert metric values into US units: Convert from

into

Multiply by

mm

inch

0.3937

inch

mm

25.4

m

ft

3.208084

ft

m

0.30479

m2

ft2

10.76391

2

cm

in

2

0.155

cm3

in3

0.061

l

gal (US)

0.264178

kg

lbs

2.204622

lbs

kg

0.45359

t

lbs

2204.622

lbs

t

0.0004536

kN

lbf

224.809

kW

HP

1.34

daN/cm2

lbf/in2

lbf/in

2

14.50378 2

daN/cm

0.06895

bar

psi

14.50378

psi

bar

0.06895

m/s

ft/s

3.28084

Nm

lbf ft

0.7375

°C

°F

1.8 x °C+32

°F

°C

(°F-32)/1.8

t/m2

lbs/ft2

204.8

2

m /t

2

ft /lbs

0.04882

Tab. 1: Conversion factors


21


2.8

Abbreviations The following abbreviations are used in this manual: Abbreviation

Stands for

HSLM

Hydraulic cabinet LOESCHE mill

HSMS

Hydraulic cabinet grinding roller lubrication

HSSW

Hydraulik cabinet support-roller

HSAV

Hydraulic cabinet swinging-out device

HSBF

Hydraulic cabinet filling unit (optional)

M-... or (M)

Master-... (e. g. M-roller, rocker arm (M), etc.)

S-... or (S)

Support-... (e. g. S-roller, spring assembly (S), etc.)

PPE

Personal protective equipment

Fig.

Figure

Tab.

Table

Tab. 2: Abbreviations used

22


LOESCHE Mill with Classifier Safety

3

Safety The machine has been designed and built in accordance with the state of art and acknowledged safety engineering practice. However, its use can pose risks to the life and limb of its user and/or third parties. There is also the potential for damage to the machine or other equipment and property. No changes, additions or conversions may be made to the machine without the manufacturer's approval. This also applies to welding on load-bearing parts. Written permission must be obtained from the manufacturer for all conversion work.

3.1

Obligations of the operator The operator is obliged: – Only to use trained personnel equipped with personal protective equipment who are familiar with the fundamental regulations governing occupational safety and accident prevention and have been instructed in the running and operation of the machine. – Only to use personnel who have read the safety chapter and the safety instructions in this instruction manual and have signed a declaration indicating their understanding of their content. – To have personnel undergo annual instruction in occupational safety and accident prevention – To comply with legal requirements regarding operational safety and reliability – To carry out regular checks to ensure that personnel are working in a way which exhibits an awareness of safety

3.2

Obligations of personnel All persons charged with working on/with the machine are obliged: – To comply with the fundamental regulations governing occupational safety and accident prevention – To read the safety chapter and the safety instructions in this instruction manual and sign a declaration indicating their understanding of their content – To comply with the safety instructions in the supplier documentation – To keep all safety and hazard instructions on the machine in a legible condition – To keep transport routes clear and free from obstacles


23


3.3 3.3.1

Safety instructions for specific operating phases Transport – – – – –

– 3.3.2

Assembly – – – –

– 3.3.3

Only use a suitable transport vehicle with sufficient load-bearing capacity. Secure the load safely. Use designated rigging points. When loading equipment, only use lifting devices and load-bearing equipment with sufficient load-bearing capacity. Designate a competent banksman for lifting operations. Machine parts must only be lifted properly and with lifting devices as per the specifications in the instruction manual (rigging points for load-bearing equipment, etc.). Use safe lifting devices bearing the CE mark.

Secure the areas in which work will be taking place to prevent unauthorised access. Co-ordinate assembly work with all companies involved. Ensure that all auxiliary equipment used (e.g. ladders) is safe. Risk of falling! When carrying out assembly work overhead, use ladders/scaffolding and working platforms which have been tested for safety. Do not use machine parts as a means of accessing overhead locations! Do not conduct welding current through bearings!

Commissioning Make sure that – prior to powering up machines, these cannot pose a risk of potential injury. – the safety instructions pertaining to cold start-up and the supplier documentation are read, digested and followed. – working areas are protected. – edges are made safe. – all auxiliary equipment used (e.g. ladders or safety harnesses) is safe. Risk of falling! – ear defenders are worn in the event of noise pollution in excess of 85 dB(A). – hazardous areas are closed off to unauthorised persons. – prior to the test run, an acoustic signal is issued to warn personnel if a startup test is only possible with the safety devices inactive. – the main switch is turned off during necessary retrofit or adjustment operations and that machines are secured against unintentional poweringup. – the activities during commissioning are carried out by qualified skilled personnel only. – safety distances are observed. – machine parts are not used as a means of accessing overhead locations. – safety devices are removed only when the machine is at a standstill. – a warning is given before safety devices are shut down for start-up work, and that immediately after this work is completed these safety devices are reinstalled are restarted.

24


LOESCHE Mill with Classifier Safety 3.3.4

Operation – –

– – – 3.3.5

Prior to power-up, check that this cannot pose a risk of personal injury. Check the machine at least once per shift for any visible external evidence of damage and check that safety switching devices are in perfect working order. If you detect a problem, stop the machine immediately and rectify the cause. Only operate the machine if all safety switching devices are in place and fully operational. Do not switch off or remove exhaustion devices or ventilation equipment when the machine is running. In the event of malfunctions, stop and secure the machine immediately. Have the causes of such problems rectified immediately.

Maintenance – – – – –

– – –

– – – – –

– – –

– –

Carry out prescribed setting, maintenance and inspection work at the required intervals. Inform operators before starting service and maintenance work. Stop the infeed of materials. Seal off the area in and around which work will be carried out. The machine must be stopped and disconnected from the voltage supply prior to commencing cleaning, service and maintenance work. Secure the machine to prevent restarting. Lock the main switch and remove the key. Affix a sign warning against restarting. Depressurise pneumatic, vapour pressure and hydraulic equipment and let off any remaining pressure. Secure all system components and operating media (e.g. compressed air and hydraulics) upstream and downstream of the machine to prevent accidental starting. Use suitable arresting devices to lock moving parts. When replacing larger components, rig and secure them carefully to lifting devices. Do not stand or work under suspended loads. Check that all screwed union connections are tight. Once maintenance work is complete, check that all safety switching devices are in working order. When carrying out assembly work overhead, use ladders/scaffolding and working platforms which have been tested for safety. Do not use machine parts as a means of accessing overhead locations! Safety harnesses to protect against falling must be worn when carrying out maintenance work overhead. There must be no evidence of soiling, oil, grease, snow and ice on handles, steps, railings, resting places, platforms, ladders, etc. Any machine parts which are not in perfect working order must be replaced immediately. Only original spare and wear parts may be used. If third-party products are used, we cannot guarantee that they will have been designed and built to provide the requisite levels of performance and safety. Ensure that all auxiliary equipment used (e.g. ladders) is safe. Risk of falling Use safe lifting devices bearing the CE mark.


25


3.4

Safety requirements – – – – – –

–

– 3.4.1

Organisational issues – –

–

– – – – – 3.4.2

The operator must provide suitable personal protective equipment. The instruction manual must be supplemented by additional instructions including information about supervision and reporting duties taking account of individual operating conditions, e.g. with regard to how work is organised, operational sequences, the deployment of personnel, etc. Personnel working on or with the machine must tie back long hair and must not wear loose clothing or jewellery (including rings). Non-compliance with this requirement could result in injuries due to becoming suspended from or dragged into the machine. Check safety switching devices regularly to ensure that their inspections are up to date, see chapter “3.12 Installed safety systems”on page Seite 36. Make sure that you are aware of the possible means of reporting and fighting fires. Specify the type of fire-extinguishing equipment to be used. Provide information about where fire extinguishers are located and how to use them. Provide instructions for emergency procedures.

Requirements of personnel – – – – –

26

The machine's safety switching devices are described in chapter “3.12 Installed safety systems”on page Seite 36. Maintain the requisite safety clearances specified. The fitting of any part components for safety switching devices resourced by the operator is solely his or her responsibility. Isolating or non-isolating safety switching devices might be required in addition to those supplied with the machine. Safety switching devices must not be removed until after the machine has been stopped and secured against restarting. Before taking safety switching devices out of service (e.g. for maintenance work), issue warnings accordingly and replace such devices or put them back into service immediately on completion of this work. Safety switching devices must also be checked prior to operation being resumed. Safety switching devices must be checked regularly to ensure that they are in full working order. Inspection intervals and procedures must be complied with and logged, see chapter “3.12 Installed safety systems”on page Seite 36. Comply with the safety instructions in the supplier documentation.

Only personnel who have undergone training and instruction may work on the machine. Relevant experience is required for work involving each of the assembly, operation, refurbishing, maintenance and service of the machine. Make sure that only personnel authorised to do so work on the machine. Personnel must wear personal protective equipment. The supervisor must check that this requirement is met. Responsibilities in respect of the assembly, operation, refurbishing, maintenance and service of the machine must be clearly defined. P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

LOESCHE Mill with Classifier Safety – 3.5 3.5.1

Information about specific types of risk Risks posed by electrical energy –

–

– –

– 3.5.2

– –

–

–

Depressurise system sections and pressure lines (hydraulic, compressed air) to be opened in the context of repairs prior to starting work. Only personnel with specialist knowledge and experience of hydraulics are permitted to work on hydraulic equipment. Hydraulic and compressed air lines must be laid and assembled correctly. Do not mix up connections! Valves and fittings and the length and quality of flexible hoses must meet requirements. All lines, hoses and couplings must be checked regularly for leaks and visible evidence of external damage. Damage must be made good immediately. Leaks can lead to injuries and fires. Even if there is no visible evidence of a defect which might pose a risk to safety, hydraulic flexible hoses must be replaced at regular intervals.

Risks posed by harmful gases, vapours and dusts –

– –

– 3.5.4

Only skilled electricians working in compliance with correct electrical engineering practice are permitted to work on electrical installations and equipment. Be aware of the possibility of damage affecting electrical equipment and carry out regular inspections accordingly. Risk due to loose connections and scorched cables. This problem must be rectified immediately. The switching cabinet must be kept locked at all times. Access must only be permitted to authorised personnel who are in possession of a key or tool. When working on live parts, seek the assistance of a second person who, in the event of an emergency, will be able to activate the emergency stop or main switch to disconnect the voltage supply. In the event of faults affecting the power supply, the machine must be shut down immediately.

Risks posed by hydraulic and pneumatic energy –

3.5.3

Personnel undergoing training on the machine must be under the permanent supervision of an experienced worker.

Harmful gases, vapours and/or dusts can escape when covers are open. Ensure that adequate ventilation (a means of exhaustion might be required) is provided. A dust mask must be worn when cleaning the inside of the classifier housing. Express permission must be obtained prior to carrying out any welding, firing or grinding work. The machine must be cleaned of any dust and flammable substances prior to commencing such work. Fire and explosion risk! Observe any applicable national regulations when working in confined spaces.

Risks posed by vibration and noise – –

During operation, any sound insulation devices on the machine must be activated. Wear personal hearing protection as prescribed.


27


3.6

Duties of the operator Note In the EEA (European Economic Area) it is compulsory to observe the national implementation of the framework directive (89/391/EEC), the associated individual directives and in particular Directive (89/655/EEC) covering the minimum health and safety requirements pertaining to the use of work materials and equipment by employees in the workplace (the latest version thereof in each case). In Germany the Ordinance on Industrial Safety and Health of October 2002 must be observed (implementation of the above-mentioned directive in national law). The operator must obtain the local type approval and adhere to the conditions associated therewith. The operator must also adhere to the local statutory provisions governing – the safety of personnel (accident-prevention regulations) – the safety of work equipment and materials (protective equipment and maintenance) – the disposal of products (waste legislation) – the disposal of materials (waste legislation) – cleaning (cleaning agents and disposal) – environmental-protection conditions CAUTION Risk of burns due to contact with hot surfaces! Before operating the plant, the operator must ensure that the insulation and protective coverings are fitted on hot machine parts.

Connections Before operating the plant, the operator must ensure that the local regulations (e.g. for electrical connection) are observed during installation and start-up operations if these operations are carried out by the operator himself.

Lighting The operator must ensure that the machine is adequately and uniformly illuminated in all areas. An illuminance level of 300 lux is recommended in the operating area (maintenance value; ASR 7/3 applicable in Germany).

28



3.7

Safety checks The following safety checks are carried out by the manufacturer before the machine leaves the factory: 1. Airborne noise measurement in accordance with the Machinery Directive, Annex 1 (item 1.7.4/f) 2. Check and inspection in accordance with DIN EN 60204-1:2007-06 – Inspection to verify compliance of the electrical equipment with the technical documentation – Continuous connection of the protective conductor system – Insulation resistance tests – Voltage tests – Protection against residual voltages – Function tests – Verification test – The functions of the electrical equipment, particularly those affecting safety and protective measures, have been tested. Note The roller grinding mill contacts the building's steel frame at several positions. This ensures earthing and that a connection exists to the building’s equipotential bonding.


29


3.8

Interfaces at the roller grinding mill

4 1 4 6

2

2

4

4

3

000501

5

Fig. 2: LOESCHE roller grinding mill interfaces, schematic sketch Key 1 Finished material outlet 2 Inspection opening 3 Process air inlet

4 Access platform 5 Hydraulik system 6 Grinding material inlet

Further interfaces not shown (observe mill installation diagram): – Outgoing-air discharge – Compressed-air supply – Seal-air supply – Electrical supply – Control elements

30



3.9

Operating and hazardous areas For the operator the areas on the switching cabinet and control desk (central control room) and on the local control panel are operating areas For the purpose of carrying out refurbishing, cleaning, maintenance and repair work the immediate area around the machine and the interior of the machine are hazardous areas. Only skilled personnel adhering to the safety regulations are permitted to work in the hazardous areas. DANGER The hazardous area for maintenance and repair work stretches roughly 1 m around the machine or component assembly. The swinging range of the switching-out device of the rollers and the swinging range of the opening switching-cabinet doors must also be taken into consideration. ● Keep the area around the machine free of objects. ● Observe the local safety regulations is the installation diagram is altered by the customer. Electrical current! ● Beware of the hazards due to electrical current when handling the machine. Current is applied ahead of the main switch or maintenance switch even in the "0" position. ● Perform the shutdown procedures (see Chapter 4.5) before carrying out cleaning, maintenance and repair work.


31


3.10 Shutdown procedure Shutdown procedure It is essential to observe the following shutdown procedure prior to cleaning, maintenance or repair work (by skilled personnel only). 1. Run the machine empty This takes approx. 60 minutes. 2. Shut off the process gas supply 3. De-energise the machine: ● Switch the mains isolator (main switch) on the switching cabinet to "0“. ● Make sure that no voltage is applied. ● Short-circuit and earth/ground the plant. ● Secure the main switch against anauthorised turning on with a padlock. 4. Shut off the pneumatic system: ● Close the stop valve. ● Check whether the plant is depressurised. ● Secure the stop valve against reopening. 5. Shut off the hydraulic system: ● Switch off the hydraulic unit. ● Check whether the system is depressurised. ● Secure the hydraulic unit against switching on again. 6. Shut off the seal-air supply: ● Close the stop valve. 7. Close the opened electrical cabinets when cleaning so as to prevent the ingress of water, steam or dust. Failure to comply with this instruction results in danger to life and limb. Tab. 3: Shutdown procedure

32



3.11 Safety instructions for the roller grinding mill components 3.11.1 Safety instructions pertaining to the LOESCHE mill The following safety instructions must be observed in particular: ● In the case of large mills, it is not permitted to remain in the mill pedestal ("mill stand" assembly) during grinding operation. Accident hazard! ● Make sure that the mill motor cannot be started before entering the grinding chamber. ● Persons are not permitted to remain either in the grinding chamber or in the area of the rollers during the roller swinging-out and swinging-in processes. ● The hydraulic accumulators of the roller spring assembly are covered in the country of manufacture by an inspection interval of 2 years. The operator must ensure that the hydraulic accumulators are operated in accordance with the statutory provisions of the country of erection. ● Carry out maintenance work on the hydraulic system only after the system is depressurised and if necessary has been completely drained. ● Open inspection doors/covers only when the plant has been shut down and is in the rest state. ● To prevent accidents resulting from falls, use safety belts during maintenance work which calls for the platform to be disassembled. ● During all maintenance and inspection work observe the statutory accidentprevention regulations of the relevant country of erection.

3.11.2 Safety instructions pertaining to the classifier The following safety instructions must be observed in particular: ● Observe the statutory accident-prevention regulations of the relevant country of erection during all maintenance and inspection work. ● Open the inspection covers of the classifier and the classifier drive only after stopping all the rotating parts of the classifier and LOESCHE mill. ● Secure the drives against unauthorised turning on, e.g. with a padlock. ● Install the safety devices properly before starting up the machine. ● Make sure that the interior of the classifier is adequately ventilated during maintenance work.


33


3.11.3 Safety instructions pertaining to the hydraulic systems The following safety instructions must be observed in particular: ● The hydraulic cabinet may only be used for the purpose intended by the manufacturer. ● The limits specified by the manufacturer for the ratio of hydraulicaccumulator operating pressure to fill pressure must not be over- or undershot. ● When filling the accumulator with the necessary gas filling pressure the correction factor for the ambient temperature, specified by the manufacturer, must be considered! (see technical information hydraulic system). ● The pressure-limiting valves (6...) set by the manufacturer in the HSLM must not be altered (see Technical Documents for Hydraulic System). ● The quality, cleanliness and operational viscosity of the hydraulic medium are crucial to determining the operational safety and reliability, economy and service life of the machine. ● Make sure that the LOESCHE hydraulic scheme is available in the hydraulic cabinet. ● Make sure that communication between the workers on or in the mill and the hydraulic-cabinet operator is possible and is practised during safety-related work. ● Make sure during maintenance work (local operation of the hydraulic cabinets) that there are no persons remaining in the area of the rollers when the latter are being raised or lowered. Accident hazard! Lay spacers underneath when the rollers are raised. ● Carry out maintenance work on the hydraulic system only after the system is depressurised and has been completely drained. ● Use only nitrogen (N2) to refill the hydraulic accumulators. Oxygen or air may cause an explosion when combined with oil! The nitrogen (N2) purity has to be at last 99,995 %, filtered < 3 µm. ● Use exclusively the original filling unit to fill the hydraulic accumulators. Observe the information in the hydraulic scheme. ● Change filters only after you have made sure that the pump motor cannot be started. ● Use only the specified hydraulic oil in accordance with LOESCHE recommendations. The cleanliness class of the hydraulic oil used should meet the requirements of ISO 4406 19/17/14 at the very least.

34



3.11.4 Safety instructions pertaining to the swinging device The following safety instructions must be observed in particular: ● Do not remain in the swinging range of the rollers while they are being swung out and in. ● When a complete roller is removed from the rocker arm, the latter must remain coupled with the hydraulic swinging-out cylinder. This prevents the rocker arm from also being raised when the roller axle is pulled upwards by frictional locking in the conical clamping sleeves and from springing back as soon as the axle is free. Accident hazard! ● Do not use the hydraulic cylinders without the line-break retainers. ● Ensure that personnel are adequately protected during all operations where the rollers are swung in and out. ● To prevent accidents resulting from falls, use safety belts during maintenance work which calls for the platform to be disassembled. ● Check the high-pressure hoses for damage prior to each use. Replace these hoses if necessary. Use only high-pressure hoses of the required pressure stage. ● Use only the specified hydraulic oil in accordance with LOESCHE recommendations. The cleanliness class of the hydraulic oil used should meet the requirements of ISO 4406 19/17/14 at the very least.


35


3.12 Installed safety systems DANGER Direct risk to life and limb! It is strictly forbidden to override safety systems or change their method of operation. The operator must ensure that unauthorised persons (not including operating and maintenance personnel) are allowed to access the operating area. Risk of electrocution! ● Secure the maintenance switch through the use of a padlock after it has been switched off before you begin with commencing refurbishing, maintenance, overhaul or cleaning work. Electrical cabinets can only be opened using a special key. The special key may only be issued to one authorised person. ● Ensure that doors/flaps on electrical cabinets are only opened by specialist personnel for maintenance purposes and troubleshooting, and otherwise remain closed and locked.

Operating and maintenance personnel will be trained by LOESCHE GmbH personnel at the plant operation location. If you have any questions or are uncertain of anything, please contact LOESCHE GmbH.

Note This operating manual is a component of the equipment and must always be accessible to operating personnel. All safety information contained therein must be observed.

36



The safety systems fitted must be checked at regular intervals using suitable inspection methods (see following table).

Inspection intervals

Inspection methods

d

=

daily

w

=

weekly

V

=

visual check

m

=

monthly

F

=

function check

¼y

=

quarterly

M

=

measurement

½y

=

half yearly

y

=

annually

The grinding plant is equipped with the following safety systems: Mains isolator

Inspection

(Main switch or maintenance switch) Interval The machine is connected to the power supply or y disconnected from it by activating the main switch or the maintenance switch. These switches are located at the electro cabinet. Further separation facilities are: – Pneumatics → pressure relief, – Hydraulics → pressure equalisation valve, – Sealing air → stop valve.

Method F

Emergency stop system

Inspection

The machine is equipped with several emergency stop systems. The machine is put into a safe operating state immediately when the emergency stop switch is pressed. The location and effect of the emergency stop switch is determined by the owner. Emergency stop switches may be located: – on the switching cabinet (superordinated system) – on the mill (activates interlock overall system) – on the classifier (activates interlock overall system) – on the sealing air fan (activates interlock overall system) – on the grease pump (emergency stop pump, maintenance switch)

Interval

Method

M

F


37


Plant control

Inspection

The plant control is carried out internally with a 5Interval core cabling system, 3-phase, with loadable MP and y separate earth cable jacketed with GREEN/YELLOW colouring.

Metal separation

S, F, M

Inspection

A metal detector with ferrous metal separation in the Interval raw coal feed prevents metal parts which might M cause sparks entering the grinding chamber.

38

Method

Method F

Resting places and railings

Inspection

In order to guarantee secure walking routes and standing locations for operating and maintenance personnel, appropriate areas on the machine have been secured using platform and guardrail equipment.

Interval

Method

½y

V, F

Contact protection

Inspection

Piping carrying heat, in addition to machine parts which heat up, are provided with insulation or protective coverings on site to prevent burns.

Interval

Method

M

V, F

Vibration monitoring

Inspection

A vibration pickup is mounted above the upper housing mill door to monitor how the mill runs ("vibration monitoring cpl." according to the drawing). As soon as the indicator (in the measuring cabinet) exceeds a preset value, the normal shutdown process is initiated for grinding plant.

Interval

Method

M

F



Sealing air monitor

Inspection

The sealing air operational system is monitored by a Interval pressure monitor to prevent foreign bodies from m getting into the system. The entire plant is shut down if the pressure drops below the permissible value.

Method FC

Overload protection

Inspection

The electric motors are equipped with overload protection to protect the machine against overheating or overloading.

Interval

Method

½y

F, M

Inspection door

Inspection

The mill has been fitted with a bolted door to allow carrying out of inspection, maintenance, cleaning and repair work.

Interval

Method

½y

V, F

Roller rotation monitor

Inspection

Rotation of the rollers is monitored by means of Interval sensors. Irregularities (speed fluctuations, stoppage) m are signalled in the control room.

Rocker arm monitor

Method FC

Inspection

Stop buffers or proximity switches at the rocker arm Interval limit its swivel range. So, direct metal contact between rollers and grinding track is prevented. The Y position of the rocker arm with lifted rollers is monitored electronically.

Method V, F

Hydraulic monitoring

Inspection

The hydraulic system is fitted with control lamps which signal or prevent an unprogrammed fall in hydraulic pressure.

Interval

Method

M

F


39


40

Temperature monitor, rotor bearings

Inspection

Each of the classifier rotor bearings is monitored by a temperature sensor with two independent measuring points. In the event of the permissible temperatures being exceeded, the signal from the sensors will generate an alarm in the central control room.

Interval

Method

m

FC, M

Classifier outlet temperature monitoring

Inspection

Two independent temperature sensors in the classifier gas duct exit measure the gas temperature. Exceeding the limit values defined during initial start-up leads to an alarm being displayed in the central switch room or intervention in the process control.

Interval

Method

½y

F, M

Lubricating system fill level monitoring

Inspection

A lubrication compound dispensing vessel is installed on the automatic lubrication pump. The fill level in the container is monitored by a fill level monitor (min; MinMin).

Interval

Method

M

F


LOESCHE Mill with Classifier Technical Data

4 4.1

Technical Data Technical Data, LOESCHE roller grinding mill Note The materials/media needed for operation of the machine in compliance with its intended use are procured and used by the its operator. Proper handling of these materials/media and the associated risks are the sole responsibility of the operator. The operator must draw up a set of instructions for dealing with risks and disposal instructions for operating and maintenance personnel. The information in the safety data sheets issued by the manufacturer(s) of the material and media must be observed.

Characteristic data, LOESCHE roller grinding mill Year of construction

Tan Truong Clinker

Order/project number

P09961

Password

2011

Tab. 4: Characteristic data, LOESCHE roller grinding mill

Dimensions and weight, LOESCHE roller grinding mill Height

approx. 23.8 m

Width

approx. 15.6 m

Depth

approx. 19.0 m

Total weight consisting of: – LOESCHE mill – Classifier – Hydraulic cabinets – Swinging device

approx. 919,318 kg

Tab. 5: Limit dimensions, LOESCHE roller grinding mill


41


4.1.1

Production data, LOESCHE roller grinding mill Designation

OPC

PLC

Quick Cement

Clinker

95%

68%

86%

Gypsum

5%

5%

5%

Limestone

-

20%

9%

Puzzolana

-

7

-

Raw material mix

Raw material grain size before LOESCHE mill

100% < 100 mm 90% < 70 mm

Material moisture (average)

0.46% H2O

2.36% H2O

Grinding-stock quality

No metallic filings permitted, solvent-free

Throughput

280 t/h

255 t/h

320 t/h

Product grain size

3,300 cm²/g

4,200 cm²/g

3,200 cm²/g

Product moisture

1.06% H2O

≤ 0.3% H2O

Tab. 6: Production data, LOESCHE roller grinding mill

For details, please see  "Delivery contract". 4.1.2

Electrical data Designation

Unit

Value

Operating voltage

V  5%

230/400

No. of phases

Ph / PE

3

Neutral conductor

Current-carrying N (in the plant)

Protective conductor

Separate PE (yellow/green)

Frequency

Hz + 2%

50

Protection class

min. IP 55

Installation specifications

in accordance with BS

Insulation class

F to B

Lighting

VAC

230

Control voltage

VAC

230

Control voltage

VDC

24

Analogue output signals

mA

4-20

kVA

approx. 110

Power supply Installed power Tab. 7: Electrical data

42



DANGER Risk of electrocution! In the case of machines with a matching transformer, it is absolutely essential if altering the network configuration or the earthing/grounding principle to consult the machine manufacturer. Incorrect installation may result in electronic components being destroyed (caused by overcurrent and overvoltage). The specified voltages must be observed without fail.

4.1.3

Water injection Water injection Delivery rate

7.5 m³/h

Pressure

6 bar

Tab. 8: Water injection

4.1.4

Sealing air supply Only sealing air which is free from foreign substances (e.g. dust, oil, steam, gases and similar ) may be used. Sealing air Volume

2,060 m³/h

Pressure drop

26 bar

Tab. 9: Sealing air

4.1.5

Ambient data Ambient data (foundry atmosphere) Lower limit temperature

+10 °C

Upper limit temperature

+40 °C

Switching cabinet/Control desk

max. 40 °C

Humidity

max. 80%

Noise level (ear defenders)

LPA < 75 dB (A)

Tab. 10: Ambient data


43


4.1.6

Coating and choice of colours Note Coating is carried out on the basis of the LOESCHE QS - corrosion-protection plan no. 4.Q09961-2609/01. The data sheets for the assemblies concerned are included in the technical documentation

4.2

Technical Data, LOESCHE mill Characteristic data, LOESCHE mill Machine type

LM 63.3+3 CS

SAP no. mill

10242593

Machine drawing

043691-00-0

Dimension sheet

M927230-00-1

Machine weight (per mill)

approx.773.410 kg

Motor power

7,300 kW

Table speed

max. 21.30 min-1

Tab. 11: Characteristic data, LOESCHE mill

Mill type-designation LM

63

.3

+3

CS Clinker / Slag Number of support rollers Number of grinding rollers Table nominal diameter [dm] LOESCHE Mill

44



4.3

Technical Data, classifier Characteristic data, classifier Machine type

LSKS 107 CS r

SAP no. classifier

10242594

Machine drawing

101334-00-3

Dimension sheet

M956607-00-2

Machine weight per classifier

approx. 134,875 kg

Motor power

500 kW

Nominal reduction rate

i = 16.0

Rotor speed

37-92 min-1

Tab. 12: Characteristic data, classifier

Classifier type-designation LSKS

107

C

S

r right-hand rotation Slag Clinker Classifier nominal diameter [dm] LOESCHE bar cage classifier


45


4.4 4.4.1

Technical Data, hydraulic system Hydraulic cabinet HSLM Characteristic data, hydraulic cabinet HSLM Machine type

HSLM 2200/120/2

SAP number

10242504

Machine drawing

see manufacturer's documentation

Dimension sheet

M932581-00-3

Machine weight

approx. 1,500 kg

LOESCHE hydraulic scheme

917850-00-0

Tab. 13: Characteristic data, hydraulic cabinet HSLM

Hydraulic cabinet-designation HSLM

2200

/120

/2 Number of pumps Delivery rate [l/m] Tank volume [l] Hydraulic cabinet LOESCHE mill

46



4.4.2

Hydraulic cabinet HSSW Characteristic data, hydraulic cabinet HSSW Machine type

HSSW 200/3-3

SAP no.

10242581

Machine drawing


Dimension sheet

M932596-00-3

Machine weight

approx. 530 kg


917830-00-1

Tab. 14: Characteristic data, hydraulic cabinet HSSW

Hydraulic cabinet-designation HSSW

200

/3

-3 Number of pumps Delivery rate [l/m] Tank volume [l] Hydraulic cabinet support roller

4.4.3

Hydraulic cabinet HSMS Characteristic data, hydraulic cabinet HSMS Machine type

HSMS 1350/10-6/3

SAP number

10242543

Machine drawing


Dimension sheet

M932589-00-3

Machine weight

approx 1,085 kg

LOESCHE lubrication scheme

917860-00-2

Tab. 15: Characteristic data, hydraulic cabinet HSMS

Hydraulic cabinet-designation HSMS

1350

/10

-6

/3 Number of pumps Delivery rate [l/m] Intake capacity [l/m] Tank volume [l] Hydraulic cabinet grinding-roller lubrication


47


4.5

Technical Data, swinging device Characteristic data, swinging device SAP number

10255933

Machine drawing

021818-00-3

Machine weight

approx. 7,925 kg

Tab. 16: Characteristic data, swinging device

The swinging device consists of − Machine "Hydraulic cabinet HSAV" − Assembly "Swinging device cpl." 4.5.1

Hydraulic cabinet, HSAV Characteristic data, hydraulic cabinet HSAV Machine type

HSAV 125/50

SAP number

10257248

Machine drawing


Machine weight

approx. 295 kg


932634-00-2

Tab. 17: Characteristic data, hydraulic cabinet HSAV

Hydraulic cabinet-designation HSAV

125

/50 Delivery rate [l/m] Tank volume [l] Hydraulic cabinet swinging-out device

48



4.5.2

Swinging device cpl. Characteristic data, swinging device cpl. SAP number

10257581

Machine drawing

053716-00-0

Machine weight

approx. 7,630 kg

Hydraulic-cylinder type

Ø380/170-3200

Hydraulic-cylinder drawing


Tab. 18: Characteristic data, swinging device cpl.

Hydraulic cylinder-designation Ø380

/170

-3200 Cylinder stroke [mm] Cylinder-rod diameter [mm] Cylinder-piston diameter [mm]


49

LOESCHE Mill with Classifier Description of the machine

5 5.1

Description of the machine Overview of the roller grinding mill

1

2 3

000500

4

Fig. 3: LOESCHE roller grinding mill overview Key 1 Classifier 2 LOESCHE mill

50

3 LM drive 4 Hydraulic system



5.1.1

Functional description

1

13 11

2

3

12

3

5 10

4

9

7

6

000876

8

Fig. 4: Flow of grinding material through mill, pictorial representation Key 1 Grinding material inlet via air lock 2 Classification of material in classifier 3 Material is carried by hot gas to classifer 4 Material rejected by classifier 5 Grinding material drops through chute onto centre of table 6 LM drive drives table 7 Reject material

8 9 10 11 12 13

Hot gas inlet Scrapers push reject material into reject funnel Hot gas flows through louvre ring Material is intercepted by hot gas flow Rollers grind material Finished material outlet

The LOESCHE roller grinding mill for grinding clinker/slag consists primarily of – the feed material gate; – the mill; – the classifier; – the mill gearbox with clutch and drive motor; – hydraulic control and lubrication cabinets for the rollers. The individual machines are assembled into a "roller grinding mill" functional unit or interconnected by pipes.


51

LOESCHE Mill with Classifier Description of the machine The grinding material is dumped through an air gate into the feeding chute on the classifier. Gravity forces it centrally onto the table, which is set into rotatory motion by an electric motor and the mill gearbox. The centrifugal force acting on the table delivers the grinding material to the rollers. The grinding material is crushed between the respective master roller and the grinding route by pressure and friction under the influence of the hydropneumatic roller spring assembly system. A support roller for preparing the grinding bed is located upstream of the master roller in each case. Crushed grinding material is discarded via the table edge into the area of the louvre ring. There it is interecepted by the air flow which is drawn in through the mill and the classifier to carry and classify the grinding material. Material already crushed to final fineness exits the LOESCHE cement mill together with the air flow via an outlet fitting on the classifier. Oversized material is rejected by the classifier and redirected via a directing cone to the table to be crushed again. Grit which is neither intercepted by the rollers for crushing nor routed by the air flow to the classifier falls through the louvre ring into the ring duct surrounding the table and from there directed via a reject hopper to the external reject handling system.

52



5.2

LOESCHE mill 1 14

2 3 4

13

5 6 7

12

8

9 10

000502

11

Fig. 5: LOESCHE Mill, assembly overview Key 1 Mill body 2 S roller 3 M roller 4 S spring assembly, positioning device 5 S rocker arm 6 M arm seal 7 M rocker arm

8 9 10 11 12 13 14

M sprain assembly Swinging device Mill stand Ring / connecting pipelines LM drive Table Lining

The following describes the individual complete assemblies of the machine in detail.


53


5.2.1

Mill stand cpl. X-X 8

1

7

5

9

2 3

X 6

5

001138

X

4

Fig. 6: Mill stand cpl. Key 1 Railing 2 Bridge 3 Ring duct 4 Anchoring rods 5 Foundation frame

6 7 8 9

Gas duct with funnel Pedestal cpl. Support block Gearbox baseplate

Structure The "Mill stand cpl.“ is a combined cast/welded construction whose foundation frame is mounted in a reinforced concrete foundation using foundation bolts. Foundation frame The foundation frame is a supporting structure made of wide-flanged girders. The frames support the pedestals and the mill gearbox via the gearbox baseplate. The foundation frame is divided into one main part and an additional part for transport purposes. The prefabricated structural elements are welded together on site to form one unit. Suitable anchoring points must be provided for aligning the parts. Gearbox baseplate The gearbox baseplate is a precise supporting surface for the mill gearbox and connects this to the lower housing. It is aligned using jackscrews. A balancing mass is provided between gearbox baseplate and foundation frame so that the physical weight of the gearbox and table can be transferred into the foundation across its whole area. Gearbox foot flange, gearbox baseplate and foundation frames are fixed together with gearbox mounting bolts. In addition, the gearbox foot flange is directly supported by the foundation frame via driving wedges.

54



Pedestals The pedestals for the mill stand are located symmetrically around the mill centre. They are aligned, bolted and welded to the foundation frame. The pedestals are a combination of cast and welded construction. A bearing block containing the cam follower bearings with 2 bearing housings is welded onto a box carrier made of sheet metal. Sheet metal plates welded into the pedestal increase its torsional resistance. A mounting housing for the M (Master) buffer to the M rocker arm is welded in below the bearing block. It transfers the forces acting on the buffer to the steel construction of the M pedestal. The pedestal incorporates heavy welded plates with bores to which the cylinders of the M spring assembly are linked. The mounting for the swinging-out device for the roller/rocker arm unit is located on the outside of the pedestal. The pedestal has doors which seal off the assembly opening for the hydraulic cylinders of the M spring assembly. Bridges The bridges are box girder structures. They are inserted between the pedestals at bearing block height, bolted to them and welded to form a torsionally-stiff ring structure. The bridges contain a nonslip stud or checkered plate floor and form the mill platform together with the railings. Railing DANGER Risk of falling! Platform components must be removed from the pedestals before swinging out the rollers. ● Always use safety belts when dismantling the platforms and carry out the following maintenance work. The railings are welded to the bridges to form the mill platform on site. Platform components on the pedestals can be dismantled to allow the rollers to be swung out. Access to the platform is possible via the building or a separate access. Ring duct The ring duct is a gas-tight sheet steel housing which is supported on the pedestals and bridges via a flanged connection. The floor of the ring duct is double-walled to provide heat insulation. As an option, the ring duct can be wholly or partially jacketed with a wearresistant lining.


55


Gas duct The gas ducts are welded to form a gas-tight sheet steel housing together with the ring duct. The floor of the gas duct is made to form a slide which allows foreign bodies to fall out of the mill stand. As an option, the gas duct can be wholly or partially jacketed with a wear-resistant lining. Reject flap The reject hopper in the gas duct leads to a chute which is closed off by a flap. The flap is hinged so that it closes itself due to self-weight and mill vacuum pressure.

Function The mill stand housing has two functions: – The mill base supports the milling tools and power transmission elements via the pedestals. In addition to this, it guides the hot gases to the louvre ring, which is located in the upper section of the ring duct. The hot gases flow to the gas duct via the ring duct into the mill. In the ring duct, the hot gas distributes itself around the table neck and flows evenly through the louvre ring into the grinding chamber. – Foreign bodies and grinding material parts which fall through the louvre ring into the ring duct are pushed by scrapers on the table into the floor opening of a gas duct and then fall out of the reject opening.

56



5.2.2

Mill body cpl. X 4

1

X 1

2

3

2

001139

4

Fig. 7: Mill body cpl. Key 1 Cover (rocker arm-roller unit (S)) 2 Cover (rocker arm-roller unit (M)) 3 Mill body 4 Door

Structure The mill body is a welded structure. The cylindrical housing is welded to the mill stand. The housing is made in 2 parts for transportation if necessary. The housing halves then have prepared areas for welds at the sweeping point. The two halves, which are kept dimensionally stable by welded-in struts, are welded to each other during assembly. The mill body contains large passage openings for swinging the M and S rollers in and out. These openings are closed off by covers which are bolted to the housing. The passage openings for the rocker arms in the mill body are sealed by sealing systems (see "Rocker arm seal" assemblies). M roller covers The M roller covers are a steel plate/welded construction and bolted to the mill body. The M rocker arm collar reaches into the grinding chamber through an opening in the cover recess. The rocker arm passage is sealed with the "Lever sealing (M) cpl.". S roller covers The S roller covers seal the openings for the S rocker arm passages. In the upper area the covers are supported against the mill body.


57

LOESCHE Mill with Classifier Description of the machine Articulated lugs for accommodating hydraulic cylinders ("Spring assembly (S) cpl.") are located here. Lugs with integrated joints are located at the lower end of the S roller covers. These comprise hollow journals which are guided in bearing blocks. The bearing blocks are welded to the bridges during assembly at the construction site. Equalising rings can be used to align the bearing points exactly and to provide distortion-free welding. Mill door Two doors with quick-release locks are provided to inspect the interior of the mill.

Function The mill body has the following functions: – forming a grinding chamber which encloses the dust/gas mixture between table and classifier and guides it; – closing off the rocker arm passages in the housing; – supporting the forces from the S roller systems via the integriated S covers; – supporting the classifier, which is welded to the LM body flange.

58



5.2.3

Lining cpl. X

1

2

3

4

X

001140

5

Fig. 8: Lining cpl. Key 1 Mill body 2 Lining plates 3 Lining, cover of rocker arm-roller unit (S) 4 Lining, cover of rocker arm-roller unit (M) 5 Lining, mill door

Structure and function The interior of the mill body is protected against wear by blast jet and impacts by highly wear-resistant steel plates. The plates are plug-welded to the mill body. They are applied in a specific, prescribed arrangement, which is shown in the "Lining cpl." drawing.


59


5.2.4

Grinding bed sprinkler cpl.

X

1 2

3 4 5

8

7

X

6

001302

3 4 5

Fig. 9: Grinding bed sprinkler cpl. Key 1 Grinding roller 2 Support roller 3 Compressed-air line 4 Water line

5 6 7 8

Grinding aid supply Tire Grinding plate Sprinkler pipe

Structure and function The grinding bed sprinkler is a piece of auxiliary equipment which can be used to influence the properties of the grinding bed. It has been demonstrated in many plants for clinker and blast furnace slag comminution that a water sprinkler helps to stabilise the grinding bed significantly, thereby enabling the mill to run more smoothly. Water is introduced ahead of each grinding roller as closely as possible above the grinding bed. The amount of water is so small that it has only a negligible effect on the mill's heat balance and is of no process engineering significance. As an option, a liquid grinding aid can be added to the water.

60



The effect of the grinding bed sprinkler is greater the close the water is introduced ahead of the grinding rollers. On the other hand, there is a risk of the hot grinding rollers being destroyed if they come into direct contact with cold water. NOTICE Possible tire damage! ● Position the grinding bed sprinkler as indicated in the drawing so as to prevent the tires from being destroyed by temperature stress (see "Grinding bed sprinkler cpl.“ drawing). A hose connects the water line to the sprinkler pipe. The sprinkler pipe can be released from the pipe holder for servicing and pulled out of the grinding chamber. Orifice plates are installed in the water lines ahead of the connecting hose. The orifice plates increase the pressure in the water lines and ensure flawless pump delivery and uniform distribution of the water volume to the sprinkler pipes. The openings in the sprinkler pipes can be freed of deposit build-ups and residual water blown out of the pipes by means of compressed air blasted through additional lines. If the mill is to be operated for an extended period without the grinding bed sprinkler, the complete pipe holder can be removed and the opening in the mill body sealed with the cover provided.

Delivery and flow rate The orifice plate is designed in such a way that the upper flow rate limit value (see assembly drawing) is achieved at max. pump capacity. It is possible to alter the range of the effective flow rate (see supplier's documentation) by using a different orifice plate size.


61


5.2.5

Table cpl.

1

9

2

3

10

4 5 6

7 001148

8

4

Fig. 10: Table cpl. Key 1 Clamping ring 2 Cover 3 Cover 4 Table casting 5 Ring duct

6 7 8 9 10

Scraper Mill gearbox Louvre ring Armour ring Dam ring

Structure Table casting The table casting is a heavy cast rotational body which is fixed via screw bolts to the drive flange on the LM gearbox. The drive torque is transferred from the gearbox via the bolted connections and 2 or 4 drive pins onto the base body. The horizontal top side of the table casting is lined using the grinding plate and forms the grinding route. Bores can be provided as an option in the grinding plate and the table casting. Unwanted iron parts can be discharged through these bores. The table works as an anvil due to its large weight and its material properties. Alternating loads are absorbed by the rollers. Dynamic loading is only partially transferred to the gearbox axial bearings. Grinding plate and clamping ring The highly wear-resistant grinding plate, which is divided into segments, is the grinding route lining. The segments are cylindrically ground around their outside diameter so that they contact the table casting collar perfectly. The segments are tensioned between inside and outside table collars using the clamping ring clamping piece and bolts. 62



Dam ring The dam ring is bolted from above onto the outside table casting collar. The dam ring height determines the layer thickness (grinding bed) of the grinding material on the table. A high grinding bed leads to high energy consumption within the mill without correspondingly increasing the milling effect. For this reason, the dam ring height should be kept as low as possible. A lower dam ring retains less grinding material on the table and the grinding material quantity flung off by centrifugal force puts more load on the louvre ring. The dam ring height is selected to match the application when the mill is shipped. Despite this, it may be necessary to adjust the height during initial start-up. The dam ring comprises a solid basic ring with turned collar for centring on the table collar. A pack of flat steel rings is screwed to the basic ring bolted to the table. It is possible by removing or adding flat steel rings to adjust the overall height of the dam ring over the grinding plate. Note In order to guarantee perfect milling, the rollers should be located as close as possible to the dam ring wear ring!

Scatter ring (if fitted) The scatter ring is a metal ring divided into segments. It distributes the milled material thrown off the by the dam ring and guides it to the louvre ring. It covers the wide air gap between the outside diameter of the table and the inner louvre ring jacket ring. In doing so, it forms a long, narrow gap which causes a high airflow resistance together with the flat ring on the inside diameter of the louvre ring. For this reason, the primary gas flows against the lower resistance caused by the louvre ring into the LM upper housing. If the mill does not have a separate scatter ring, the specially designed dam ring acts as a scatter element. Louvre ring A segmented louvre ring is fixed stationary around the table. The exterior of the louvre plates is protected against wear by a lining shell. Each segment can be flexibly aligned. This enables the gap between the segments to be minimised. This means that undesirable bypass flow of the gas with increased wear is avoided. Bypass flow adjacent to this is prevented by the temperature-resistant insulation material which is plugged between the louvre ring segments and the ring duct. The louvre ring directs the primary gas flowing out of the ring duct from above and, due to the inclined location of the louvres, causes the necessary grinding material particle circulation in the grinding chamber. Armour ring The segmented armour ring causes the extension of the external jacket ring from the louvre ring. It also supports the primary gas guidance away from the upper section wall. Individual armour ring segments are each bolted to a louvre ring segment. P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

63


Scraper Foreign bodies and grinding material particles which have fallen through the louvre ring or the grinding route openings against the primary gas flow are collected on the floor of the ring duct. During operation, or when the mill starts, the particles are caught by the scrapers and pushed to the reject hopper in the gas entrance of the LM lower housing.

Function The main function of the table is to support the grinding bed and to transfer the forces caused by the rollers into the gearbox located below, and to transfer the torque from the drives into the grinding zone. Together with the ring duct, the table forms a ring-shaped chamber from which the primary gas flows into the grinding chamber via the louvre ring. The table is the second milling tool inside the mill in addition to the rollers.

64



5.2.6

LM drive

1

2

3

4

5

000519

6

Fig. 11: LM drive cpl., schematic sketch Key 1 Mill gearbox 2 Coupling 3 Mill motor

4 Motor frame 5 Motor base frame 6 Coupling guard

Structure and function The mill motor drives the table via the rubber-elastic coupling and the mill gearbox. The table is bolted directly to the gearbox output flange. The mill motor is supported by the motor frame, which is bolted and pinned to the motor base frame set in concrete after the mill motor is aligned to the mill gearbox. The coupling guard ensures that rotating parts cannot be accidentally touched during grinding operation. If damaged, the mill gearbox can, after removal of the mill motor (with motor frame) and raising of the table, be pulled out under the mill for removal on socalled tracks, which are welded on the motor base frame set in concrete. Note Refer to the separate gearbox documentation for information on installation, operation and maintenance of the mill gearbox.


65


5.2.7

Grinding parts cpl. Setup and function The "Grinding parts cpl." assembly consists of the grinding plate (functional part of the "Table cpl." assembly) and the tires for the rollers (M) and (S). Grinding plate The grinding plate is the mill grinding route lining. It comprises a wear-resistant casting. The grinding plate is divided into segments whose surface-ground contact faces rest flat on the table. The segments are clamped between the inner and outer table collars. M tire The rollers are crushing tools and are therefore subject to wear. A tire is used as a wear part. The tire is a highly wear-resistant casting and is formed as a single-component ring with tapered runway. Refer to the drawing "Roller (M) cpl." for the type of tire mounting. S tire The S rollers are used to prepare the grinding bed. They operate with low specific pressure and theoretically exert no sliding movement on the grinding bed. The tire comprises a wear-resistant casting. The non-profiled surface has a working width which is adapted to the M roller. Refer to the drawing "Roller (S) cpl." for the type of roller mounting. Wear Grinding plate The grinding plate is brittle on account of its structure. If a segment cracks as a result of mechanical or thermal stresses, it does not have to be replaced immediately. However, fragments of a segment must not creep upwards and create holes in the grinding track. Cracked grinding plate segments are usually wedged by the penetration of grinding material so firmly against each other that they do not have to be replaced before the normal wear time has elapsed. It is not planned to replace the grinding plate at regular intervals. Wear usually occurs in a limited area. Here the grinding plate can be relined by means of build-up welding. Lining is performed using mobile welding equipment (see separate manufacturer's documentation) inside the mill. The grinding plate does not need to be removed. Experience shows that rewelding has to be performed at the latest when the wear recess has reached a maximum depth of 10 mm. M tire The M tire is subject to wear in a ring-shaped area. In this case, as with the grinding plate, regular relining by means of build-up welding (see above) is provided for. S tire Rolling wear of the S tires is minimal on account of their function as preparation rollers.

66



5.2.8

Roller (M) cpl.

16

4

1

15

2

3

14

5

13

6 7 8

12 9

11

001147

10

Fig. 12: Roller (M) cpl. Key 1 Hub 2 Guard 3 Axle 4 Cover disc with ring 5 Dipstick 6 Distance ring 7 Slip ring sealing 8 Sealing sleeve

9 Cylindrical roller bearing 10 Distance sleeves 11 Hub cover 12 Cover disc 13 Cover 14 Spherical roller bearing 15 Sleeve 16 Clamping ring

Number and location Depending on the design, the mill is fitted with two or three M rollers, each of which is clamped in a rocker arm. The M rollers are spaced equidistant from each other and are held with a marginal axial inclination to the horizontal grinding route in the zero setting. Bearings Each M roller runs in a cylindrical roller bearing located on the rocker arm side and in a dual-row taper roller bearing on the hub cover side. Whereas the cylindrical roller bearing takes up only radial forces, the taper roller bearing transfers both radial and axial forces. Both bearings are supported against each other using distance sleeves and clamped using the hub cover and sealing sleeve bolts.


67


Note The achievable bearing service life is very much dependent on: – the way the mill is operated – the use of perfectly functioning lubricants – sufficient lubrication – observance of the stipulated operating temperature for the mill.

Lubrication The roller bearings are generally lubricated by circulating oil, whereby pumps in the HSMS hydraulic cabinet supply the oil. A radial bore in the hub ensures a constant minimum M roller oil level (see "Hydraulic cabinet HSMS" instruction manual). Seals Each M roller is fitted with different seals: –

Sealing gas seals The roller bearings are under atmospheric pressure. Since this is higher than the pressure in the grinding chamber, no dust can penetrate the bearings. (See "Sealing air piping cpl." instruction manual).

–

Mechanical seals The roller bearing space is protected by mechanical seals against the dust atmosphere in the mill: An O-ring seals the hub cover against the hub. The rotating roller parts are sealed against the fixed axle via a slip-ring system (see "Slip-ring seal cpl." instruction manual).

Roller settings The position of the M roller on the table (distance to dam ring) can be changed using a ring. This ring is inserted between the conical sleeve on the rocker arm and the corresponding axle shoulder. Note Only fit this ring for making roller settings if the roller is touching the dam ring along its internal diameter (see drawing information).

68



Wear NOTICE Possible tire damage! The clamping surfaces on the tires and hubs are manufactured with very tight tolerances. The use of imprecisely manufactured tires leads to increased danger of breakage and destruction of the cone seat! The rollers are crushing tools and are therefore subject to wear. A tire is used as a wear part. The tire is a highly wear-resistant casting and is formed as a single-component ring with tapered runway. It is pulled over the roller hub using a clamping ring with tee-head bolts, disc springs and nuts. The disc springs accept push points which affect the bolts. The hub is protected against wear by blast jet by a revolving bell housing in wear-resistant material. A removable protection plate is optionally connected to the bell housing. This protects the rocker arm seal against wear by blast jet. 5.2.8.1

Roller rotation monitor cpl.

1

2 3

000536

4

Fig. 13: Roller rotation monitor cpl. Key 1 Protected feed line 2 Proximity switch 3 Connecting screw (slip-ring seal - hub)

4 Roller

Rotation monitoring of the roller takes place using a proximity switch, and is therefore contactless. The proximity switch is guided through the rocker arm with the help of a tube, and is given its pulses by the screws which connect the slip-ring seal with the rotating hub. P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

69


5.2.8.2

Slip-ring sealing cpl.

5

1

4

3

000507

2

Fig. 14: Slip-ring sealing cpl. Key 1 Sealing ring (rotating) 2 Roller axle 3 Sliding ring

4 O-ring 5 Thrust ring (fixed)

The slip-ring seal holds the lubricant in the mill roller bearing space. For this purpose, the rotating mill parts are sealed via the slip-ring system against the fixed axle.

70



5.2.9

Rocker arm (M) cpl. 1

2

9

X 3 10 4

11

8

X

12

5

13

6

14

000508

7

Fig. 15: Rocker arm cpl. Key 1 Rocker arm 2 Clamping sleeves 3 Roller axle 4 Cylindrical roller bearing (locating bearing) 5 Ring 6 Pedestal 7 Pivot point of spring-assembly cylinder

8 Clamping sleeves 9 Fork 10 Central lever 11 Bearing block on pedestal 12 Cylindrical roller bearing (floating bearing) 13 Flange centring sleeve 14 Rocker-arm axle

Structure The mill is fitted with M rocker arms which are each hinged on a bearing block on the LM lower housing. Two or three M rocker arms are symmetrically arranged in relation to the mill centre. Each M rocker arm consists of a central lever, fork, axle and radial and axial bearings in the LM lower housing bearing block. The central lever is shrunk onto the axle. The upper part of the lever contains the seat opening for the roller axle which is fixed using tapered sleeves at right angles to the lever axis. The fork grips the lever from both sides. This is also fixed to the axle using tapered flange centring sleeves. Screwed and bolted connections transfer any torque occurring (see "Rocker arm (M) cpl." drawing). Each fork side wall is pulled against the central lever using bolts. Torque is either transferred via the surface friction between fork and lever or via a taper P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

71

LOESCHE Mill with Classifier Description of the machine pin connection on each fork side wall (see also "LM auxiliary equipment: Rocker arm cpl."). The bottom end of the fork is formed as a box and is completed by one or two straps with transverse drillhole. This is where the cylinder(s) on the hydropneumatic spring assembly are hinged. An armoured sealing cap to seal off the rocker arm opening in the mill body is bolted onto the face of the rocker arm collar (see "Lever sealing (M) cpl." assembly). Bearings The M rocker arm shaft is supported in two bearing housings in the pedestal bearing block. Spherical roller bearings, in which the rocker arm shaft is hinged, take up radial forces. Changing axial thrust is taken up by fixed thrust washers. Any impact force occurring on the bearing housing bolts during mill operation is relieved via friction in disc springs. Lubrication All lubrication points are lubricated with grease. All lubrication bores are sealed by grease nipples during transportation and arm installation. After mill assembly all the lubrication bores are connected to a central grease lubrication system (see "Lubrication line cpl." assembly). A specification of the heavy-duty lubricating greases is contained in the maintenance table.

Function The M rocker arm transmits the forces caused by the double-acting hydraulic cylinder onto the rollers and the grinding bed. The hydraulic cylinders are hinged on the bottom end of the M rocker arm by joint pins. Hydraulic cylinder and M rocker arm a located so that the bearing reaction forces are always transmitted into the pedestals. Separation of the central lever from the fork allows the roller (M) to be swung out without having to dismantle the fork and spring assembly cylinder. Sealing air is fed into the ring gap between roller axle and M rocker arm via a drillhole with connecting unions on the top of the lever. This prevents dust penetrating the roller bearings (see also "Sealing air system"). A geometrically adapted sealing box seals the M rocker arm against the mill body (see also "Lever sealing cpl." assembly).

72



5.2.10 Lever sealing (M) cpl. 1 3

2

X

10

X

3

9

Y 8

Y 3 4

7

000509

5 6

Fig. 16: Lever sealing cpl. Key 1 Sealing bar (secured to the mill body) 2 Mill body 3 Sealing cap 4 Sealing bar (secured to the mill body) 5 Seal

6 7 8 9 10

Sealing bar (secured to the rocker arm) Sealing bar (secured to the mill body) Seal Rocker arm Seal

Design The "Lever sealing (M) cpl." assembly consists of moved parts mounted on the rocker arm and static parts which are bolted to the mill body. a) Moved parts The components fixed to the rocker arm (M) are: – the sealing cap with side wall lining, – the armour ring, – the upper lining plate on the sealing cap and the lower sealing segment which is bolted to the sealing cap, – the armour ring bolted to the sealing cap.


73

LOESCHE Mill with Classifier Description of the machine b) Static parts The static parts are bolted to the cover and the mill body: – an upper and lower sealing channel which match the moved sealing segments with their curves, – 2 right-hand and 2 left-hand "side walls" (angled strips), – various rubber and sheet strips which are bolted to the sealing segments.

Function The rubber and sheet strips can be readjusted using longitudinal holes up to the moved parts (sealing caps). The same applies to the sealing segments and angled strips. Tight and long labyrinth gaps are formed between the moved and static parts using the adjustable strips. They prevent dust penetrating the external sealing strips. The fabric-reinforced rubber sealing strips can be cut out of used rubber conveyor belts. To keep leak air entry into the mill as low as possible, special corner seals have been bolted to the sealing caps and upper housing cover to seal off the right angled corners.

74



5.2.11 Rocker arm monitor (M) cpl.

8 7 6 5 4

2

1 3

4

X 6

5

8 2

1

000510

A

Fig. 17: Rocker arm monitor cpl. Key 1 Rocker arm 2 Bearing block 3 Flange centring sleeve 4 Holder

5 6 7 8

Encoder Displacement sensor Guard plate Holder

Structure and function The rocker arm monitor cpl. continuously monitors the up and down movements of the rocker arm. A reference mark sensor is attached to the moving rocker arm. This is moved over a transducer in a constant distance (dimension A, see drawing information). The transducer is statically mounted to the bearing block of the pedestal. The transducer and reference mark sensor are protected by a common cover. Note For more information about the transducer and reference mark sensor, please refer to the manufacturer documentation.


75


Adjusting the rocker arm monitor cpl. NOTICE Possible risk to the machine! Incorrect or faulty adjustments of the rocker arm monitor cpl. can lead to damage of the machine! The rocker arm monitor cpl. must be adjusted: – after the initial installation – after the pivoting procedure of the rollers and – after replacing the transducer, the reference mark sensor or their holders.

The checking of the dimension A (see drawing information) and the determination of the measuring points for the roller positions "Roller too deep" and "Roller raised" are part of the adjustment. This means: Roller too deep

The roller position falls below the position of the minimally required grinding bed thickness.

Roller raised

The roller is in the highest position possible (cylinder end stop)

Both positions are shown by signals in the central central control room. Grinding bed thickness The measuring range of the grinding bed thickness is limited by the measuring points of both roller positions "Roller too deep" and "Roller raised". The position of the reference mark sensor in relation to the transducer changes with the changing of the pivoting angle of the rocker arm. The position signal is converted into a value in the evaluation unit which directly specifies the grinding bed thickness. The value is displayed in the central central control room.

76



5.2.12 Roller (S) cpl.

2 4 1

5 3 6 7 8 9

16

10

15 14 11

13

001367

12

Fig. 18: Roller (S) cpl. Key 1 Rocker arm (S) 2 Angle ring 3 Slip-ring seal 4 Wear ring 5 Sealing sleeve 6 Tire 7 Hub 8 Roller axle

9 Clamping ring 10 Hub cover 11 Cover disc 12 Spherical roller bearing 13 Guard 14 Cylindrical roller bearing 15 Flanged connection 16 Tube bundle

Structure Depending on the design, the mill is equipped with two or three S-rollers. The rollers are each permanently connected to an S-rocker arm. The S-rollers are positioned between the M-rollers. In the zero setting the conical working surface is parallel to the horizontal grinding route. In order to achieve as clean a rolling effect as possible, the inclined roller axle and the vertical table axle meet in the working plane.


77


Bearings Each S-roller runs in a cylindrical roller bearing located on the rocker arm side and in a spherical roller bearing on the hub cover side. Whereas the cylindrical roller bearing takes up only radial forces, the spherical roller bearing transfers both radial and axial forces. The axial forces are generated by the inclined arrangement of the S-roller in relation to the table.

Seals Each S-roller is fitted with different seals. – Sealing gas seal The non-contact sealing gas seal prevents the roller bearing assembly from being contaminated by dust from the grinding chamber (see "Sealing air system cpl." instruction manual). The roller bearing assembly is under atmospheric pressure via a filter and bores. Since this is higher than the pressure in the grinding chamber, no dust can penetrate the bearings. –

Mechanical seals The roller bearing space is protected by mechanical seals against the dust atmosphere in the mill. An O-ring seals the hub cover against the hub. The sealing sleeve is bolted to the hub using sealing compound. The rotating components of the roller are sealed off against the fixed axle via a slip-ring system.

Roller settings The S-roller is not a grinding roller, but rather a preparation roller. Its function is to compress, i.e. prepare, the ventilated and inhomogeneous grinding bed of feed material and re-circulating material for the subsequent grinding roller (Mroller). The working level of the S-roller is therefore significantly higher than that of the M-roller. There are two possible ways of selecting the position of the S-roller above the table surface: – by adjusting the buffer spindle of the S-buffer, whereby the S-rocker arm is mechanically adjusted to a desired height with the S-roller; – with the aid of the S-hydraulics by positioning with a hydraulic cylinder.

Lubrication The roller bearings are lubricated in the oil bath. Refer to the lubricant table for oil quantity and oil quality.

78



Wear The S-rollers are used to prepare the grinding bed. They operate with low specific pressure and theoretically exert no sliding movement on the grinding bed. Rolling wear is therefore minimal. –

Tire The S-tire is part of the "Grinding parts cpl." assembly and is described in the instruction manual under the same name.

–

S-tire fastening The S-tire has two cylindrical seats of different sizes on the S-hub. The tire is clamped with the aid of a bolted clamping ring against a flat hub collar surface.

–

Bell housing / guard Depending on the S-roller design, the hub is protected against wear by blast jet by a rotating bell housing or guard made of wear-resistant material.

5.2.12.1 Roller rotation monitor (S) cpl.

1

2

6

X

3

5

X

7

6

5

4

000535

7

Fig. 19: Roller rotation monitor (S) cpl., schematic sketch Key 1 Rocker arm (S) 2 Roller (S) 3 Hub cover 4 Shaft

5 Cam disc 6 Proximity switch 7 Hood

The rotating S roller drives a shaft. The shaft is guided longitudinally by the roller axle and the rocker arm. A cam disc is attached to the shaft outside the mil. The pulses of the rotating cam disc are recorded by a proximity switch.


79


5.2.13 Rocker arm (S) cpl. X

13

X

11 1

12

11

3

2

14

4 5

15

10 9

16

8 7

001368

6

Fig. 20: Rocker arm (S) cpl. Key 1 Mill body 2 Rotation/swing axle 3 Guard 4 Flanged joint 5 Oil dipstick tip 6 Roller (S) 7 Tube bundle 8 Rocker arm (S)

9 Plate 10 Jib 11 Oil dipstick 12 Stop spindle 13 Positioning device 14 Bush 15 Axle 16 Sealing air connection

Structure The S rocker arm is a welded construction. It is mounted in the upper housing cover. The cross-struts are provided with sleeve bearing bushes for this purpose and form the swivel joints with the axle bolts secured in the upper housing. On the side projecting into the mill the S roller is secured by means of a flanged fitting. A tube bundle flanged on the S roller, which is guided outwards by the rocker arm, provides a connection with the roller interior for oil filling and checking and rotation monitoring. The reverse side of the S rocker arm has a jib, which serves as the articulated point of the S assembly hydraulic cylinder and to accommodate the stop spindle.

80



Function The function of the S rocker arm is to: – secure the S roller so that it swivels, – support the S roller resiliently on the S buffer and to maintain it at a defined minimum distance above the grinding route, – direct into the S roller additional hydraulic forces from the effect of the hydraulic cylinder acting at the top on the S rocker arm, – seal the S rocker arm/roller unit via a flanged sealing shield on the housing passage (see also "Arm seal (S) cpl." assembly). Sealing air is supplied through the hollow journals into the annular gap between the roller axle and S rocker arm, which serves to seal the rocker arm/roller internally against penetration by dust into the roller bearings. For this purpose the transport protection cover must be replaced at the planned connection point by the sealing air connection piece (see "Sealing air system" instruction manual). 5.2.14 Lever sealing (S) cpl. 1

A

2 3

5

000512

4

Fig. 21: Lever sealing (S) cpl. Key 1 Rocker arm (S) 2 Clamping ring 3 Seal 4 Clamping frame 5 S-cover at mill body

Design The "Lever sealing (S) cpl." assembly is composed of moving parts fitted to the S-rocker arm and of stationary parts bolted to the mill body. a) Moving Parts A rounded ring is welded to the rocker arm (S) The bellows is clamped between this ring and another one with the aid of bolts. These parts are sealed with sealing compound (e. g. silicon) against the rocker arm (S).


81

LOESCHE Mill with Classifier Description of the machine b) Stationary Parts A frame made of flat steel bars attaches the bellows to the mill body with bolts.

Function The flexible bellows seales the opening in the mill body for the moving rocker arm (S). 5.2.15 Rocker arm monitor (S) X 1

Y

X

4

2 Y

5

A

6

001141

3

Fig. 22: Rocker arm monitor (S) cpl. Key 1 Rocker arm (S) 2 Cover 3 Cover of the rocker arm-roller unit (S)

4 Holder 5 Transducer 6 Displacement sensor

Structure and function The rocker arm monitor cpl. continuously monitors the up and down movements of the S rocker arm. A position sensor is mounted on the moving S rocker arm. This sensor is guided at a constant distance (dimension A, see drawing information) via a displacement sensor. The displacement sensor is statically secured to the cover of the mill body. The displacement and position sensors are protected by a common body. Note Please refer to the manufacturer's documentation for further information on the displacement and position sensors.

82



Adjusting the rocker arm monitor (S) cpl. NOTICE Possible risk to the machine! Incorrect or poor adjustment of the rocker arm monitor (S) cpl. may result in damage to the machine! The rocker arm monitor (S) cpl. must be adjusted: – after initial assembly – after the rollers have been swung in, and – after replacing the displacement sensor, the position sensor or their holders. Adjustment involves checking dimension A (see drawing information) and determining the measuring points for the roller positions "roller too low“ and "roller raised“. Position meanings: Signal

Meaning

Roller too low

The roller position drops below the position of the minimum required grinding bed thickness.

Roller raised

The roller is in the highest possible position (cylinder end stop).

Both positions are indicated by signals in the central control room. Grinding bed thickness The measuring range of the grinding bed thickness is limited by the measuring points of the two roller positions "roller too low" and "roller raised“. The position of the position sensor in relation to the displacement sensor changes as the swivel angle of the S rocker arm changes. The position signal is converted in the evaluator unit into a value which specifies the grinding bed thickness directly. The value is displayed in the central control room.


83


5.3

Swinging device

5.3.1

Swinging the grinding roller

A

B 1 6

2

3

5

000540

4

Fig. 23: Swinging the grinding roller Key 1 Grinding roller, swung out 2 Hydraulic cylinder 3 Joint seating

84

4 Hydraulic cabinet, HSAV 5 Pedestal 6 Grinding roller, swung in



5.3.2

Swinging the support roller

A

B

1

7

2

3 4

5

000541

6

Fig. 24: Swinging the roller (S) Key 1 Roller (S), swung out 2 S cover on mill body 3 Positioning device blocked with auxiliary equipment 4 Hydraulic cylinder

5 Hydraulic cabinet HSAV 6 Joint seating 7 Roller (S), swung in

The grinding parts of the LOESCHE mill can be quickly changed with the hydraulic swinging device. The roller is swung out of the mill body and the rocker arm supported with a hydraulic cylinder. Tire and grinding plate are freely accessible after swinging out. For swinging the lower rod end of the hydraulic cylinder is connected to joint seating. The piston rod incorporates a fork element with pin, which is engaged in a strap on the rocker arm. The hydraulic cylinder is equipped with non-return valves with restriction at both ends. Quick-release coupling facilitate the connection of maximum-pressure hoses. The couplings can be opened under pressure without the loss of oil. The supply system, the HSAV, consists of a frame with an oil tank and pump mounted on top, a manually actuated control valve, an electrical control box, two maximum-pressure hoses for connecting with the swinging cylinder and an electrical cable for connecting the pump motor to the mains power supply. The valve control lever is used to preselect the working direction of the hydraulic cylinder and to switch on the pump. The pump runs for as long as the slide is actuated. The cylinder must be filled with oil when the piston is retracted. The tank must not be filled completely as oil displaced by the piston flows back and requires a volume reserve.


85

LOESCHE Mill with Classifier Description of the machine 5.3.3

Preparatory work for swinging out For grinding roller ● Release the taper pin and flange sleeve connections between the arm and fork of the "Rocker arm cpl." assembly (see also "LM auxiliaries cpl." assembly). ● Screw off and remove the cover from the mill body. ● If fitted, remove the 2-part protection plates for the roller cpl. For roller (S) ● Block the hydraulic cylinder of the positioning device with auxiliary equipment. ● Detach the hydraulic hoses from the hydraulic cylinder. ● Detach the S cover from the mill body. Further for grinding roller and roller (S) ● Remove any platforms in the rocker arm swinging area. ● In the case of oil circulating lubrication, have a collecting container ready for oil from the roller. ● Close the vent bore on the roller. ● Suspend the rod end bearing of the hydraulic cylinder from the joint seating of the pedestal (grinding roller) or from the foundation (roller (S)) and secure. ● Move the HSAV to the hydraulic cylinder. ● Attach the two hydraulic hoses of the HSAV with their quick-release couplings to the corresponding cylinder connections. ● Connect the HSAV via the mains cable to the mains supply. ● Actuate the control lever and extend the piston rod. The control lever switches the pump motor on and off. During commissioning or after changing a seal, move the piston back and forth to vent the cylinder. ● Extend the piston rod up to the rod end bearing of the rocker arm. ● Connect the fork end of the piston rod with the pin to the rocker arm rod end bearing. ● Secure the pin with a split pin.

5.3.4

Swinging-out process ●

Place the hand lever of the control valve in the "Swing out" position until the pump motor runs. The pump motor is switched off when the control lever is in the centre position. ● Hold the valve lever in the working position until the axle of the swung-out roller is vertical.

86



Note When it is released, the valve lever returns automatically to the "0" position. To avoid uncontrolled movements, the oil flow is braked by throttle check valves in the hydraulic cylinder. These are set by the hydraulic cylinder supplier to their minimum values. Make sure when resetting that the oil flow does not become too high so that the fuses in the hydraulic cylinder do not operate unintentionally. The rocker arm moves downwards to its end position, which is limited by a mechanical stop. ●

Move the valve lever to the "0" position; the pump motor switches off.

The hydraulic system is protected by an overflow valve which is an integral part of the pump unit. The HSAV has a motor circuit-breaker with bimetal tripping device. 5.3.5

Swinging-in process The swinging-in process happens in reverses sequence to the swinging-out process. Place the control valve in the "Swing in" position here. The swinging-in process is concluded when the rocker arm has assumed its normal working position.


87


5.3.6

Lubrication line cpl. This assembly comprises the oil lines of the recirculating oil lubrication system for the rollers (M) and the grease lines for the rocker arms (M). Design and function Oil lines The oil lines are installed in accordance with the "Lubrication line cpl." assembly drawing between the connecting line of the HSMS hydraulic cabinet and grinding rollers. Refer to the assembly drawing or lubrication scheme for identification of the pipe connections. Connection is established to the roller axle via hoses, permitting free adjustability both during mill operation while the rocker arm (M) is moving and during the swinging-out operation. Note Subsequent reductions in the pipe cross-sections may result - particularly in the return line to the tank - in impaired lubrication system operation. Grease lines The grease lines are installed in accordance with the "Lubrication line cpl." assembly drawing between one or more motor-driven lubrication pumps (see parts list for number) and the respective lubrication points. These include the radial and thrust bearings of the rocker arms (M). Piston distributors with force control ensure that grease is distributed precisely to the lubrication points. Fault-free operation of the piston distributors is only guaranteed when all the outlets to the consumers are connected.

88



5.3.7

Seal-air piping 8

1

2

7

3 4

5

000515

6

Fig. 25: Sealing air system Key 1 Grinding chamber 2 Rotating parts of roller (M) 3 Grinding chamber 4 Rotating parts of roller (S)

5 6 7 8

Fixed parts of roller (S) Fixed parts of roller (M) Sealing air Sealing air pipe

Structure and function In order to prevent the roller bearings and the slip-ring seal of the M and S rollers being damaged by dust from the grinding chamber, the very tight annular gap between the wear ring of the rollers and the wear ring of the M or S rocker arm is pressuresed with sealing air. This air is supplied through the sealing air pipe which surrounds the LM upper housing. The sealing air pipe enters through an upper bore at the M rocker arm. In the case of the S rocker arm, the sealing air is routed from the side into the rocker arm. In the case of both rocker arm types, the sealing air then flows through the rocker arm past the slip-ring seal and through the sealing air gap into the grinding chamber. The sealing air gap is structurally determined by the difference in the diameters of the two wear rings. It cannot be adjusted.


89


5.3.8

Sealing air monitoring cpl.

5

1

2

3

000854

4

Fig. 26: Sealing air monitoring cpl. Key 1 Sealing air pipe 2 Sensor, pressure transducer 3 Ball valve

4 Mill body 5 Classifier

Structure and function CAUTION Overpressure! Escaping compressed air may cause injuries. ● Replace the pressure transducer only with the valve closed! Sealing air is used in the roller and rocker arm assemblies and in the drive of certain classifiers (see the corresponding chapters) to prevent the ingress of dust into the bearings. The sealing air monitor causes an alarm if the sealing air supply is disturbed. The sealing air stream is monitored by an electronic pressure transducer. If the pressure in the sealing air system is too high or too low, an alarm will be set off. A ball valve situated between the air stream and the sensor allows the sensor to be exchanged whilst the mill is in operation. Under normal circumstances the valve must be kept in the open position.

90



5.3.9

Vibration monitoring cpl.

1

2 3

X

000517

4

Fig. 27: Vibration monitoring cpl., schematic sketch Key 1 Mill body 2 Electrical cable 3 Holder 4 Vibration pickup Dimension X, see drawing "Vibration monitoring cpl."

Vibration evaluation of the mill is performed in accordance with VDI Guideline 2056. The LOESCHE roller grinding mill must be classified into Group "D". Recorded in this group are machines which are rigidly mounted and bring about non-compensatable mass actions. For Group "D" there are no evaluation scales on account of the non-compensatable mass actions. The mill is therefore classified as an alternative in Group "G", where rigidly mounted machines (on heavy foundations) are recorded with only revolving masses.

Structure and function In order to monitor mill operation a vibration pickup is mounted above the mill door on the body in accordance with the drawing "Vibration monitoring cpl.". The vibration pickup measures the movements of the body in the horizontal direction (mm/s). What is indicated is not foundation vibrations, which are to be evaluated directly in accordance with VDI Guideline 2056. Instead, a significantly increased vibration velocity over the foundation vibration is signalled at the height of the mill door. The measured values converted from mechanical into electrical signals are directed via a cable to a contact instrument in the measuring cabinet abd then indicated by the instrument. The grinding plant's normal shutdown procedure is initiated as soon as the indication exceeds a preselected value.


91


001302

5.3.10 Name plate

Fig. 28: Name plate

The name plate is attached to the outside of the LOESCHE mill. It is located on the mill stand. Information on the name plate: – Type – Serial number – Year of construction – Order number – Manufacturer

92



5.4

Hydraulic system of the grinding roller The grinding tools in the LOESCHE roller grinding mill are the table and the grinding rollers. The table is fitted with a horizontal grinding route and is driven at constant speed. While in raw meal dry grinding plants the feed material is ground with all the rollers, a distinction is made in clinker/slag grinding plates between the master roller (M roller, also roller (M)) and the support roller (S roller, also roller (S)). The two roller types differ in design and size, based on their respective function. They are located in pairs opposite the table. The M rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force; the grinding material is merely prepared by the S rollers by way of low contact pressure on the grinding bed. The pressing force of the M rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. The grinding clearance of the S rollers above the grinding route is adjusted with the hydraulic positioning device. A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.

Structure and function Spring assembly cpl. Every M roller in the mill is fitted with a spring assembly. These consist, depending on the mill type, of one or two hydraulic cylinders which are connected to the M rollers via the rocker arm. The hydraulic cylinders are each fixed as a hinge by the rod end bearing to the LM lower housing and fixed to the rocker arms with a rod head. Hydraulic cabinet HSLM The HLSM hydraulic cabinet provides the supply system for the hydropneumatic mill roller spring assembly. Please see the separate manufacturer's documentation for detailed information about the HLSM setup. Ring/connecting pipeline cpl. The oil supply system (hydraulic cabinet) and the hydropneumatic spring assembly for the mill are connected to each other via a pipe system. The crosssectional areas stated in the drawing must be observed for each pipe. Welded pipes are descaled and conserved at manufacture by pickling, and must be protected by hermetic sealing of the flange against corrosion and the penetration of dirt until final assembly.


93


NOTICE Possible risk to the machine! If the piping is laid in a foundation duct, its top surface must be painted with oilresistant paint to prevent damage to the concrete. A drain fitted to the duct ensures that leaked oil and water can flow away during cleaning work.

Hydraulic bladder accumulator A bladder accumulator consists of a liquid and a gas section with a bladder as a gas-proof separating element. The liquid components around the bladder are connected to the hydraulic circuits so that if the pressure increases the bladder accumulator is filled, which compresses the gas. If the pressure reduces, the compressed gas expands again and displaces the accumulated pressurised liquid into the circuit. Hydraulic piston accumulator A piston accumulator consists of a liquid and a gas section with a piston as a gas-proof separating element. The gas side is pre-filled with nitrogen. The liquid components around the bladder are connected to the hydraulic circuits so that if the pressure increases the piston accumulator takes in fluid, which compresses the gas. If the pressure reduces, the compressed gas expands again and displaces the accumulated pressurised liquid into the circuit. Hydraulic cylinder The hydraulic cylinder construction can be seen from the separate manufacturer's documentation. Stop buffer cpl. WARNING Heavy machine parts. Possible loss of body parts! ● Remaining in the vicinity of moving parts belonging to systems transmitting grinding power is not permitted for safety reasons. ● Use shims of sufficient thickness between roller and table in order to prevent unintentional lowering of the rollers. ● Use suitable auxiliary equipment, such as e.g. rods, to place the metal plates under the rollers. The stop buffer consists of the welded housing, the adjustable spindle and the pretensioned elastomer for absorbing impacts. The housing is bolted to the pedestal in the LM lower housing. The spindle can be readjusted in accordance with the wear on the grinding parts. Adjustment is performed by inserting a 10 mm plate under the rollers on the empty table. The spindle is secured from the outside against subsequent rotation during operation. If wear arises on the grinding parts, it is necessary to check the spindle adjustment in good time as otherwise the stop buffer will be subjected to unnecessarily frequent load from striking by the fork. 94



5.4.1

Hydraulic spring assembly - mode of operation

A

B 1

11

2

10 3

4

A

A 5

9

12

6

8

G

G

000537

7

Fig. 29: Interplay, working pressure/counterpressure system

The hydraulic cylinders (4) are connected to the working pressure system (10) on the piston rod side (12) and the counterpressure system (9) on the piston side (7). A: During mill operation, the rollers are raised by the grinding material lying on the table. In doing so, the rocker arms are deflected. The pistons (6) in the hydraulic cylinders move upwards and displace oil (3) from the working pressure system into the hydraulic bladder accumulator (11). The nitrogenfilled accumulator bladder (1) in the bladder accumulators is compressed by the inflowing oil. At the same time the counterpressure system works on the piston side of the hydraulic cylinder. In the case described above, oil is pressed by nitrogen pressure (5) out of the hydraulic piston accumulator (8) back into the piston side of the hydraulic cylinder. B: If the grinding rollers roll into a "grinding bed valley" the process is reversed. Oil is pressed out of the hydraulic bladder accumulator in the working pressure system into the piston rod side of the hydraulic cylinder. At the same time, oil is displaced out of the piston side of the hydraulic cylinder into the hydraulic piston accumulator. The rollers continually make vertical movements in a certain working range (2) due to the unevenness of the grinding bed. The processes described above alternate continuously. To run the mill in and shut it down it is possible to raise the rollers hydraulically from the grinding bed. Due to varying resistance in the hydraulic system, the rollers do not raise simultaneously but one after the other. Their movement is limited mechanically at the top. Once all rollers have reached their top end position this condition is signalled electrically.


95

LOESCHE Mill with Classifier Description of the machine Once the rollers are raised it is possible to start a mill in in its filled condition. The mill motor must apply around 40% of its nominal torque when starting a filled mill. The residual milled material on the table is ground extremely quickly when the rollers are lowered. Lowering the rollers takes place with a delay after switching on the material feed. For this reason, the grinding bed sets itself up slowly. The required motor torque slowly increases to 100%. Full load operation is achieved at around 30 seconds in this process. A stop buffer prevents metallic contact between the roller tires on the grinding roller and the grinding plates if the milled goods feed to the mill is interrupted and the rollers are not hydraulically raised in time. The permissible lowest point of the rollers is electrically monitored. 5.4.2

Spring characteristic The hydropneumatic spring system together with the HSLM hydraulic cabinet allows the roller force to be adapted to the grinding material being processed, and to keep the grinding bed thickness constant within tight limits. It consists of two separate systems, the so-called working system, which provides the piston rod side with pressure and the counterpressure system, which provides the piston side with pressure. Regulation normally takes place depending on the current milling task. Diagram: Roller spring stiffness Please see the documentation parts list for the hydraulic cabinet for the drawing number of the "Diagram: Roller spring stiffness". Diagram: Roller force Please see the documentation parts list for the hydraulic cabinet for the drawing number of the "Diagram: Roller force".

5.4.3

Working pressure (spring stiffness) – hydraulic bladder accumulator Spring characteristic The spring characteristic, in other words the spring stiffness, can be selected by setting the ratio between the hydraulic working pressure p2 and the nitrogen filling pressure in the hydraulic bladder accumulator p1 . The roller stiffness can even be changed within certain limits during the operation without changing the nitrogen filling pressure. The following applies: the gas spring becomes stiffer the lower the filling pressure and the higher the working pressure. Exact adjustment of the spring characteristic is performed by LOESCHE personnel. The "Diagram: Roller spring stiffness" states the limits which must be observed. Procedure The "Diagram: Roller spring stiffness" displays the roller stiffness cwf (= spring stiffness related to the rollers) via the nitrogen (accumulator bladder) filling pressure p1. The different hydraulic working pressures p2 or the roller forces FW are displayed as parameters.

96



[kN/mm]

Description of the machine

8,0 7,0

A

6,0

cwf

5,0

3

4

4,0 3,0

p2

2,0

1 1,0

2

0,0

20,0

40,0

60,0

80,0

120,0 [bar]

000538

p1

100,0

Fig. 30: Diagram: Spring stiffness Key cwf p1 p2 A

Spring stiffness of the roller Charging pressure of the hydraulic accumulator Operating pressure Operating range

Please note: p1max = 0.8 * p2min p1min = 0.25 * p2max Sequence: 1. Selection of working pressure p2 (depending on "Diagram: Roller force" (see documentation parts list "HSLM")) 2. Selection of accumulator filling pressure p1 within operating area 3. Form intersection with vertical on bladder accumulator filling pressure and p1 working pressure p2 4. Determine intersection horizontal on roller stiffness cwf and read off relevant roller stiffness The roller stiffness states by how much the force increases if the roller is deflected by 1 mm.


97


The smaller the difference between p2 and p1, the softer the spring. This means that the force increase for a soft spring is low if the roller is deflected. The maximum p1 pressure of the nitrogen filling in the accumulator may not exceed 80% of the operating pressure p2, otherwise the rubber bladder may be destroyed.

5.4.4

Counterpressure function Introduction The hydraulic cylinders are downstream of piston-side piston accumulators. These ensure a harmonic sequence of oil exchange (due to roller movement) during mill operation in this location. Procedure The function of the piston accumulator system requires a so-called counterpressure on the cylinder piston side. The counterpressure should be kept at a low level in order to counteract the spring characteristics of the pistonsided working pressure as little as possible. It must, however, always be greater than 0.7 Mpa (7 bar). Adjusting the hydraulic counterpressure p4 takes place depending on the nitrogen filling pressure p3 in the piston accumulator. NOTICE Possible risk to the machine! The nitrogen filling pressure 3 in addition to the piston accumulator counterpressure p4 may only be set within a range of  10 % of the values stated in the "Diagram: Roller spring stiffness"! During mill operation, the piston accumulator piston must be moving in the central range of the piston accumulator stroke (guide value).

5.4.5

Roller relief pressure (RRP) – partial load operation General If necessary, the facility is provided to operate the mill with roller relief. A pre-requirement for partial load operation is the installation of a roller rotation monitor (see chapter "5.2.8.1 Roller rotation monitor cpl." on page 69). It must be ensured that the roller is turning during mill operation. Procedure In principle, the working pressure is regulated for higher load ranges and the counterpressure is held at a low constant level. The commissioning engineer will set the working system so that regulation of the roller force is possible from 100% down to around 50%. 100% working pressure (roller force) is the necessary pressure to achieve maximum milled product performance, and it varies with the job characteristics. If, however, a lower roller force than 50% is required (partial load) the working pressure is kept at its minimum value and the counterpressure is increased. This means that the effective working pressure (and therefore the roller force) remains reduced.

98



5.4.6

Functions of hydropneumatic spring assembly system WARNING Heavy machine parts. Possible loss of body parts! ● Remaining in the vicinity of moving parts belonging to systems transmitting grinding power is not permitted for safety reasons. ● Use shims of sufficient thickness between roller and table in order to prevent unintentional lowering of the rollers. ● Use suitable auxiliary equipment, such as e.g. rods, to place the metal plates under the rollers.

NOTICE Possible damage to machine caused by improper operation! ● Ensure that the LOESCHE hydraulic scheme (drawing "Scheme: Hydraulics“) is available in the HSLM.

Note Operation of the HSLM must be carried out by at least one instructed person who has been instructed or trained by a specialist in the tasks assigned to him and the possible hazards of improper operation, in addition to the necessary safety devices and safety measures.

(For valve settings, see "Scheme: Hydraulics" in the HSLM) Oil supply to the hydraulic system takes place by the pump unit. Pump run-up is only necessary during mill operation if leakage losses which could lead to pressure drops need to be compensated. The HSLM outfeed pipes are fitted with a pressure monitor in the hydraulic cabinet. a) Increasing (raising) the working pressure The working pressure setpoint and the regulation characteristics can be preselected in the control engineering system. During the operation, the pump runs automatically until the stated setting has been reached. The pump is stopped as soon as the higher pressure is achieved. b) Reducing (lowering) the working pressure The working pressure setpoint and the regulation characteristics can be preselected in the control engineering system. Please check whether the ratio between the nitrogen filling pressure and the hydraulic working pressure is within the permitted tolerance using the spring diagram. If necessary, the nitrogen filling pressure must be corrected. This is only permissible when the mill is at a standstill and the working pressure has been completely relieved.


99


c) Increasing (raising) the counterpressure The counterpressure setpoint and the regulation characteristics can be preselected in the control engineering system. A valve closes once the higher pressure has been reached. d) Reducing (lowering) the counterpressure The counterpressure setpoint and the regulation characteristics can be preselected in the control engineering system. A valve closes as soon as the lower pressure has been reached. e) Raising the rollers When in automatic operating mode, a solenoid valve is switched to the required position in accordance with the hydraulic scheme. The process is carried out by pressing the "Raise rollers" button when operating on-site. The pump unit starts automatically and continues to run until all rollers have reached their top end position, which is monitored by the proximity switch on the rocker arms. After this, the pump unit is switched off automatically. While the rollers are being raised, the working pressure value is increased. Safety valves ensure that the maximum permissible system pressure cannot be exceeded. As an alternative, oil can be fed from the working pressure side to the counterpressure side through a valve when the rollers are being raised. This can take place depending on time or pressure. These settings will be made by a LOESCHE engineer during commissioning. f) Keep rollers raised (automatic operation) If, due to leaks in the hydraulic system, one or more rollers leave their top end position, the pump unit is started automatically in accordance with the "Raise rollers" process. g) Lowering rollers (automatic operation) The oil flows from the counterpressure system back to the tank until the counterpressure has been reached. The lowering speed of the rollers will be determined by the LOESCHE commissioning engineer. h) Reducing pressure If the entire hydraulic system needs to be brought down to atmospheric pressure, for example during accumulator filling pressure measurement or during maintenance work, the hydraulic system must be enabled for "on-site operation". The regulating function is out of action. Once the stopcock has been opened manually (in accordance with the function tables on the hydraulic scheme) the oil will flow back to the tank. i) Bypass filtering The tank contents can be circulated automatically through the filter at specified intervals by this regulation (in addition to normal main flow filtering). Operationally-caused pump starts have priority compared with bypass filtering.

100



5.4.7

Service functions a) Nitrogen pressure test in accumulator The nitrogen pressure in the bladder accumulators can be checked with this function. b) Keeping the rollers raised during service operation Raise rollers automatically. "On-site operation" released by control room. The regulating function is out of action. The stopcocks must be in the preset setting in accordance with the hydraulic scheme tables when the rollers are raised.


101


5.5

Hydraulic system of the support roller

1 6

5

4

2

000539

3

Fig. 31: Spring assembly (S) cpl. Key 1 Mill body 2 Roller (S) 3 Rocker arm (S)

4 Stop buffer 5 Hydraulic cylinder 6 Cover (S)

Design and function The function of the hydraulic positioning device of the rollers (S=Support) is to maintain the S rollers at a preselected distance (working height) from the table grinding plate during mill operation. The following assemblies are required for this purpose: – Spring assembly (S) cpl. of mill (hydraulic cylinder, stop buffer) – Roller rotation monitor (S) cpl. of mill – Connecting pipeline cpl. of mill – Hydraulic cabinet HSSW Hydraulic cylinder See separate manufacturer's documentation

102



Stop buffer The stop buffer serves to absorb impacts. The buffer unit comprises the bracket, the elastomer and the adjustable spindle. Spindle adjustment is performed by inserting a plate under the S roller on the grinding route. Here the spindle is bolted from the outside to the S roller rocker arm. This adjustment ensures that there is no metallic contact between the S roller and the grinding plate. The adjustment must be checked in good time if the grinding parts are worn. Connecting pipeline cpl. Pipelines connect the HSSW hydraulic cabinet to the hydraulic cylinders of the S rollers. Hydraulic cabinet HSSW ... The HSSW hydraulic cabinet provides the supply system for the hydraulic positioning device of the S rollers. Please see the separate manufacturer's documentation and the HSSW .... hydraulic scheme for detailed information about the HSSW setup. 5.5.1

Mode of operation The S rollers are adjusted during mill operation individually to a distance above the metallic grinding route with the aid of the hydraulic positioning device. The intention is for the S rollers to be rotated without slip by friction with the grinding material and thereby for the grinding bed to be prepared for subsequent crushing under the grinding rollers. The height is dependent on the respective grinding material and is determined during start-up. The height can be measured by means of stroke monitoring. Deviations from this working height can occur during normal operation (see also HSSW ... hydraulic scheme) under the following conditions: – Foreign bodies in the grinding material – Grinding bed too high – Oil leaks in the hydraulic system.

5.5.2

Functions of hydraulic positioning device WARNING Heavy machine parts. Possible loss of body parts! ● Remaining in the vicinity of moving parts belonging to systems transmitting grinding power is not permitted for safety reasons. ● Use shims of sufficient thickness between roller and table in order to prevent unintentional lowering of the rollers. ● Use suitable auxiliary equipment, such as e.g. rods, to place the metal plates under the rollers.


103


NOTICE Possible damage to machine caused by improper operation! ● Ensure that the LOESCHE hydraulic scheme (drawing "Scheme: Hydraulics HSSW …“) is available in the hydraulic cabinet HSSW.

Note Operation of the HSSW must be carried out by at least one instructed person who has been instructed or trained by a specialist in the tasks assigned to him and the possible hazards of improper operation, in addition to the necessary safety devices and safety measures. (For valve settings, see "Scheme: Hydraulics" in the HSLM) a) Raising the S roller The S roller is raised after the control valve is switched and the pump is started. The oil displaced from the other cylinder chamber flows via the adjustable flow restrictor, the valve and the filter back into the tank. b) Holding the S roller at the top Hold the control valve in position 1. The pump only has to be started if the S roller lowers due to an oil leak. c) Lowering the S roller The S roller is lowered after the control valve is switched and the pump is started. The oil displaced from the other cylinder chamber flows via the adjustable flow restrictor, the valve and the filter back into the tank. d) Controlling the S roller in Service mode "On-site operation" enabled by the control room. The regulating function is out of action. The S roller can be raised or lowered using the button integrated in the HSSW hydraulic cabinet.

104



5.6

Design and construction of the classifier

1 9

8

7 2

6 5 3

000787

4

Fig. 32: Classifier, assembly overview Key 1 Classifier drive cpl. 2 Classifier platform cpl. 3 Lining cpl. 4 Guide vane cpl. 5 Rotor cpl.

6 7 8 9

Classifier housing cpl. Classifier upper housing lining cpl. Name plate Classifier platform cpl. (classifier drive)

The following describes the individual complete assemblies of the machine in detail.


105


5.6.1

Classifier housing cpl.

12 1 10 11

9

8

2

7

6

3 5

000789

4

Fig. 33: Classifier housing cpl., schematic sketch Key 1 Classifier upper housing 2 Chute 3 Shock blower 4 Grit funnel 5 Support tube 6 Support block for bracking pipes.

7 8 9 10 11 12

Classifier lower housing Deflector ring Guide vane carrier Frame Attachment point for uncoupling rotor Inspection cover

Structure and function The "classifier housing cpl." assembly comprises the static parts of the classifier: The classifier lower housing is welded or bolted to the mill body. One or two feeding chutes for the grinding material is/are integrated in the side of the classifer lower housing. Two chutes serve to feed dry and moist grinding material separately. They can additionally be equipped with shock blowers. These remove any deposited material from the chutes by means of intermittently escaping compressed air. The grit funnel with support pipes is mounted in the classifier lower housing. Flat bars in the grit funnel reduce the swirling rate of the grit, thereby reducing wear. 106


LOESCHE Mill with Classifier Description of the machine Four passages are provided in the classifier lower housing to support the lower rotor bearing. Support blocks are welded to the appropriate points on the outside for mounting the bracing pipes (see also "Rotor support cpl." drawing). The frame rests on the upper flange of the classifier lower housing. It accommodates the guide vane carrier. Sectional rings are also attached in the immediate vicinity to seal off the rotor and prevent coarse particles. The classifier upper housing rests on the upper flange of the frame. An inspection cover in the classifier upper housing enalbes this area to be inspected and accessed. The classifier upper housing directs and guides the dust/gas flow. It supports the upper bearing with the suspended rotor and the drive unit. The outlet connection on the classifier upper housing is connected to the overall grinding plant. 5.6.2

Rotor cpl.

1 6

2 3

4

000735

5

Fig. 34: Rotor cpl. Key 1 Upper bearing 2 Rotor 3 Assembly kit (comprising turnbuckle, shackle, sling chain) 4 Blades


5 Rotor support cpl. 6 Rotor cpl. 7 Lower bearing (not shown)

107


5.6.2.1

Upper bearing cpl.

1 9

2

8 3 6

7

5

000736

4

Fig. 35: Upper bearing cpl. Key 1 Plug 2 Bore for the temperature sensor 3 Feed of the lubrication line 4 Seal gap 5 Sealing ring

5.6.2.2

6 7 8 9

Bolt for aligning the rotor Axial spherical roller bearing Sealing ring Shaft

Lower bearing cpl.

1 9 2 3 5

4

8 7

6

000737

5

Fig. 36: Lower bearing cpl. Key 1 Axle 2 Seal gap 3 Sealing ring 4 Bearings 5 Temperature sensor position

108

6 7 8 9

Cover Washer Plug Connection lubrication line



Structure and function The direction of rotation of the rotor is determined by the swirl generated by the louvre ring and the alignment of the guide vanes or guide flaps in the classifier. The "Upper bearing cpl." is centred by the classifier upper housing and is screwed to the rotor. The mounting ring supplied with the machine is welded to the classifier upper housing using the flat bar ring once the rotor has been aligned. Attached to the rotor underside is the "Lower bearing cpl." which centres the rotor on the underside via the "Rotor support cpl.". The four bracing pipes of the "Rotor support cpl." can be adjusted in length inside and are prestressed on the outer side of the classifier lower housing. The shaft inside of the upper bearing as well as the axle inside the lower bearing are guided in roller bearings and lubricated with grease. The lubricant is supplied via two separate lines (see "Classifier lubrication cpl." assembly). The roller bearing temperature can be monitored continuously with a temperature sensor (available as an optional extra). 5.6.2.3

Classifier temperature sensor cpl.

6

1

2

3

000741

4 5

Fig. 37: Schematic sketch of classifier temperature sensor, cpl. Key 1 Upper bearing 2 Temperature sensor for upper bearing 3 Lower bearing

4 Temperature sensor for lower bearing 5 Power supply line (see electrical documentation) 6 Power supply line (see electrical documentation)

Structure and function Each of the classifier rotor bearings is monitored by a temperature sensor with two independent measuring points. In the event of the permissible temperatures being exceeded, the signal from the sensors will generate an alarm in the central control room.


109


5.6.3

Classifier lining cpl.

1

2

3

4

000786

5

Fig. 38: Classifier lining cpl. Key 1 Lining on classifier lower housing 2 Lining on bracing pipes 3 Lining on support pipes

4 Lining on shock blowers 5 Lining on chute

Structure and function The inside of the classifier lower housing is armored. The wear protection can consist eg. of metal or ceramic. If a shock blower is connected to the chute , the feed side requires additional protect ion with lining shells. The outside of the chute and the area of the incident air flow has to be protected with wear-restistant lining shells. The supports of the grit funnel and the bearing cartridge as well as the connecting pipeline of the shock blower ha ve to be protected against wear with angular lining sheets. The area of the incident air flow around the grit funnel can be protected with wear-restistant material eg. ceramics.

110



5.6.4

Classifier upper housing lining cpl.

1

4 A

A-A

A

3

000788

2

Fig. 39: Classifier upper housing lining cpl. Key 1 Ceramic lining on classifier upper housing 2 Ceramic lining on braces

3 Ceramic lining on inspection cover 4 Ceramic lining on classifier upper housing

The classifier upper housing with outlet connection as well as parts of the bearing cartridge can be optionally equipped with a special lining to protect against wear (see  parts list „Classifier lining cpl.“).


111


5.6.5

Classifier drive cpl. 1

3

2

11

10

9 8 4 6 7

000548

5

Fig. 40: Classifier drive cpl. Key 1 Gearbox 2 Coupling 3 Motor 4 Console 5 Classifier upper housing 6 Coupling guard

7 8 9 10 11

Bearing cartridge / upper bearing Coupling Bell housing Proximity switch Castellated disc

Structure and function The gearbox is supported by a bell housing which is centred and secured on the bearing cartridge or the upper bearing housing of the "rotor cpl." assembly. Once the gearbox has been aligned with the rotor shaft, it is pinned to the bell housing as showing in the drawings. An elastic coupling transmits torque from the gearbox to the rotor shaft. The electric motor and its support console are aligned with the gearbox input shaft during assembly. The console is then welded to the classifier upper housing as indicated in the drawings. There is also an elastic coupling between the motor and the gearbox. The coupling is protected by a coupling guard. The rotation of the rotor is monitored. This is achieved using a fixed proximity switch and a castellated disc which turns with the rotor shaft. The rotor speed is adapted to meet the dust grain size requirements of the material to be classified. This is achieved steplessly by adjusting the motor frequency; such changes can be made during active operation of the classifier.

112



5.6.6

Classifier lubrication line cpl.

1

3

4

000549

5

2

Fig. 41: Schematic sketch of the classifier lubrication line, cpl. Key 1 Bearing cartridge 2 Dispensing vessel 3 Grease pump unit

4 Lubrication line 5 Distributor

Structure and function The classifier lubrication line lubricates the two roller bearings in the "bearing cartridge cpl." assembly (in the case of larger classifiers there are two separate assemblies, "upper bearing cpl." and "lower bearing cpl."). The lubrication pump and its grease container are attached to a mounting plate on the classifier upper housing on the classifier platform (classifier drive) or towards the top of the classifier lower housing. The arrangement of components and the route of the lubrication line will vary from one machine to another; please refer to the corresponding assembly drawings for information. A single lubrication line runs from the pump outlet to a distributor to which the two lubrication lines for the upper and lower bearings are connected. The filling level in the dispensing vessel is usually monitored. If it sinks under a specific level, this is signaled in the control room. The running time of the pump and the required grease volume are specified in "Lubrication scheme: Classifier lubrication line".


113


Name plate

001302

5.6.7

Fig. 42: Name plate

The name plate is attached to the outside of the classifier. It is located on the classifier upper housing and can be accessed from the classifier platform. Information on the name plate: – Type – Serial number – Year of construction – Order number – Manufacturer

114


LOESCHE Mill with Classifier Transport

6 6.1

Transport Scope of supply The scope of supply consists of: – LOESCHE roller grinding mill LM 63.3+3 CS with LSKS 107 CSr with auxiliary equipment, safety equipment and hydraulic installations, material feeding unit – Instruction manual – Technical documentation – Separate manufacturer's instruction manuals The precise and detailed scope of supply can be found in the order confirmation. Note The detailed  assembly documentation will be provided to the operator together with the machine.

6.2

Delivery and packaging LOESCHE will provide information concerning the scope of supply prior to the delivery. The notification will provide information concerning the following points: – the delivery date – the number and type of transport units – kind of delivery (train, truck, ship) – necessary tools for unloading The transport units are accompanied by package lists that contain information concerning the content of the transport units, the weight, and the assembly status.


115


6.2.1 6.2.1.1

Transport sketches Standard transport sketches for the LOESCHE Milll

g

Foundation frame

5960

5305

3550

680

3550

680

680

680

3550

001137-1

5814

4500

4410

Fig. 43: Transport sketch, foundation frame

Pedestal cpl., gearbox baseplate 4 Ringschrauben DIN 580-M56

140

° . 45 min

EYE BOLT anneau de levage

3530 3200

4070

4150

VRBS 16t (4x)

4 8.5 4150

500

001137-2

4500

6840

900

Fig. 44: Transport sketch, pedestal (left fig.), gearbox baseplate

116



Bridge

X VRBS 6,7t (4x)

2700

2700

11118

750

725

° . 45 m in

2972 1500

X

2700

3 5,5

001137-3

2700

Fig. 45: Transport sketch, bridge

Ring duct Ø8470

3 min

5,5

Trennlinie Cutting Line ligne de démarcation

001137-4

2420

° . 45

VRBS 6,7t (6x)

Fig. 46: Transport sketch, ring duct


117


Table, gas duct

X 4040

3181 min . 45

Ø6650

°

Ø4300

X 2945

2600

800 700

001137-5

2605 1896

3 4

VRBS 4t (4x)

Fig. 47: Transport sketch, table (left fig.), gas duct

Mill body X 3

X

Ø8920

Trennlinie CUTTING LINE ligne de démarcation

001137-6

4100

VRBS 6,7t (6x)

4930

4350

5,5

Fig. 48: Transport sketch, mill body

118



Cover X

X

580

2650

001137-7

1615

3995

4210

X

X

3770

Fig. 49: Transport sketch, cover

Rocker arm (M), rocker arm (S) 1120

Y

X 3325 2440

3065

2070

X

5065

Y

2590

001137-8

Ø922

Fig. 50: Transport sketch, rocker arm (M) (left fig.), rocker arm (S)


119


Roller Transport TRANSPORT transport

Transport

3600

1860

TRANSPORT transport

Ø2900

3 Ringschrauben DIN 580-M42

3 Ringschrauben DIN 580-M100x6

INSTALLATION installation

Eye Bolt anneau de levage

Eye Bolt anneau de levage

Einbau

INSTALLATION installation

001137-9

Einbau

Ø1944

Fig. 51: Transport sketch, roller (M) (left fig.), roller (S)

Foot-bridges 3 4 min

. 45

° . 45

mi n

130

VRBS 4t (2x)

130

°

2980 500

500

500 VRBS 4t (2x)

3 4

1990

001137-10

910

820

500

Fig. 52: Transport sketch, foot-bridges

120



6.2.1.2

Standard transport sketches for the classifier

Classifier upper housing X

4000

4360

X

ca. 7780

001136-1

Ø6870

Fig. 53: Transport sketch, classifier upper housing

Classifier lower housing X X

Ø8720 Ø ca. 10450

001136-2

7350

Ø 8100

Fig. 54: Transport sketch, classifier lower housing


121


Frame X

350

X

Ø 8100

001136-3

Ø8100

Fig. 55: Transport sketch, frame

Grit funnel X

Ø1120

Ø7520

001136-4

6025

X

Fig. 56: Transport sketch, grit funnel

122



Rotor X

Ø6600

001136-5

ca. 4300

X

Fig. 57: Transport sketch, Rotor

Motor console

1260

1030

X

X

001136-6

1000

Fig. 58: Transport sketch, motor console


123


6.2.1.3

Standard transport sketches for the hydraulic cabinets

HSLM, HSMS and HSSW HSMS

HSSW

2000

1300

2000

1300

1880

1100

1000

000797

2200

2200

HSLM

Fig. 59: Transport sketch, hydraulic cabinets

Standard transport sketch for the swinging device

430

6.2.1.4

001136-7

4575

Fig. 60: Transport sketch, cylinder swinging device

124



6.2.2

Weight of the components

Assembly / Transport unit

Weight per transport Centre of unit gravity

Attachment points

Lifting gear

Foundation frame

approx. 21,960 kg

Centre

as per dwg.

Crane with lifting accessories

Gearbox baseplate

approx. 15,300 kg

Centre

as per dwg.


Pedestal cpl.

approx. 43,220 kg

Off-centre

as per dwg.


Support cpl.

approx. 1,205 kg

Off-centre

as per dwg.


Bridges

approx. 9,660 kg

Off-centre

as per dwg.


Ring duct

approx. 17,325 kg

Centre

as per dwg.


Gas duct

approx. 6,305 kg

Off-centre

as per dwg.


Gas duct

approx. 5,320 kg

Off-centre

as per dwg.


Gearbox

see manufacturer's specifications

Off-centre

Transport lugs


Table

approx. 97,150 kg

Centre

as per dwg.


Mill body

approx. 19,780 kg

Centre

Transport lugs


Cover, left

approx. 5,105 kg

Off-centre

as per dwg.


Cover, right

approx. 3,140 kg

Off-centre

as per dwg.


Rocker arm (M) cpl.

approx. 37,675 kg

Off-centre

Transport lugs


Rocker arm (S) cpl.

approx. 2,200 kg

Off-centre

Transport lugs


Spring assembly cylinder (M)

approx. 2,300 kg

Centre

Transport lugs


Spring assembly cylinder (S)

approx. 415 kg

Centre

Transport lugs


Roller (M) cpl. with tire

approx. 43,560 kg

Centre

Transport lug


Roller (S) cpl. with tire

approx. 6,510 kg

Centre

Transport lug


LOESCHE mill 63.3+3 CS


125


Assembly / Transport unit

Weight per transport Centre of unit gravity

Attachment points

Lifting gear

Hydraulic unit - HSLM

approx. 1,500 kg

Centre

Transport lugs


Hydraulic unit - HSMS

approx. 1,085 kg

Centre

Transport lugs


Hydraulic unit - HSSW

approx. 530 kg

Centre

Transport lugs


Grit funnel

approx. 11,035 kg

Centre

Transport lugs


Classifier lower housing

approx. 25,365 kg

Centre

Transport lugs


Frame

approx. 6,075 kg

Centre

Transport lugs


Rotor incl. blades

approx. 19,790 kg

Centre

Transport lugs


Classifier upper housing

approx. 12,060 kg

Centre

Transport lugs


Chute

approx. 785 kg

Off-centre

Transport lugs


Chute

approx. 430 kg

Off-centre

Transport lugs


Guide vane carrier incl. guide vanes

approx. 895 kg

Off-centre

Transport lugs


Bearing, upper

approx. 3,645 kg

Centre

as per dwg.


Bearing, lower

approx. 900 kg

Centre

as per dwg.


Classifier drive cpl.

approx. 4,645 kg

Off-centre

as per dwg.


approx. 2,800 kg

Centre

Transport lugs


Hydraulic cabinets

Classifier LSKS 107 CS r

Swinging device Hydraulic cylinder

Tab. 19: Roller grinding mill, transport weights of components

126



6.3

Checking the delivery status The machines and the equipment made by LOESCHE are thoroughly inspected and packaged prior to their dispatch, but damage cannot be excluded during the transport. Transport units will be delivered to the construction site on transport pallets. The following checks also apply to the supply of spare and replacement parts. Incoming inspection ● Check the incoming goods for completeness using the delivery note! ● Check the incoming goods for signs of damage (visual inspection)! Procedure in the event of complaints or damaged goods ● Immediately contact the last carrier! Complain to them about the damage. ● Keep the packaging (so that it can be checked by the carrier or used to return the goods). Packaging for returning goods If parts are damaged to such an extent that they must be returned to the manufacturer, please contact LOESCHE GmbH. ● Please package the machine parts or transport units in such a way that there is no risk of further damage during the transport. Packaging for transport by lorry For the transport by lorry, the transport units are placed on suitable transport pallets, fastened, and secured with lifting accessories.

6.4

Interim storage of supplied parts The freight packaging of the machine and of the spare and replacement parts is designed for 3 months of storage as of the day of delivery. Bearings and similar parts are also preserved for this period. The following storage conditions apply to all of the parts: – Closed and dry room with a room temperature of + 5° C to + 40 °C. – The maximum relative air humidity must not exceed 80 % (noncondensing). Other requirements may be stated on the package lists. In order to avoid long periods of storage, we recommend storing the supplied machines and parts near the assembly location and providing a warehouse container or similar for small parts. ● Please place desiccants into the electrical and operating cabinets.


127


6.5

Transport to the installation site DANGER Overturning parts! ● Please refer to the information concerning the centre of gravity in the transport sketches and on the machine parts! ● If necessary, secure the transport units with suitable lifting accessories prior to the transport. Only specialised personnel is authorised to transport the goods. The local conditions must be taken into consideration. ● Secure the transport units so that they cannot overturn after the removal of the freight packaging. ● Take the weight of the transport unit (see the package list) into consideration for the transport.

6.5.1

Crane transport In order to lift the goods with a crane, the operator must provide suitable crane types, load-bearing equipment, and lifting gear. Please fulfil the following requirements: – The crane must be suitable for the weight of the transport unit. – The operator must be authorised to operate the crane. ● Fasten the lifting accessories (e.g. load-bearing equipment, belts, multipoint suspension gear, chains) to the transport unit only at the specified lifting points.

NOTICE Possible risk to the machine! ● Use only the lifting points that are specified in the transport sketches. Avoid any lateral application of force to these points. ● 6.5.2

Use the existing lifting points for the transport of the electrical equipment.

Transport with a fork-lift truck Please fulfil the following requirements: – The fork-lift truck must be suitable for the weight of the transport unit. – The driver must be authorised to drive the fork-lift truck. ● Move the forks of the fork-lift truck between or under the bars of the transport pallet or transport unit. The forks must protrude on the other side. ● Lift the transport unit up and transport it.

128



6.6

Disposal of the packaging The operator is responsible for the correct disposal of the packaging. ● Dispose of the packaging in accordance with the national rules and regulations.

6.7

Joining parts on the construction site NOTICE Possible risk to the machine! ● Do not damage the mill when performing welding or grinding work above the mill. Beware of flying sparks. ● During welding, place the earth electrode as close to the welding point as possible and not near shaft ends or bearings. ● Please refer to the reference documents  Q900024-00-4 "Welding of parts made of ferritic material" and  Q900560-00-4 "Quality assurance guideline for the production".


129

LOESCHE Mill with Classifier Installation

7

Installation It is always preferable to have the machine installed by a specialist engineer from LOESCHE GmbH. If you choose to have the machine installed by a specialist assembly company, that company must provide personnel with experience in the assembly of heavy industrial machinery. The work of the assembly companies involved must be carefully co-ordinated. The area in and around which the machine is to be assembled and installed must be sealed off. The figures used in the description which appears below are for illustrative purposes only. The drawings, installation diagrams and the plant layout included in the scope of supply must be referred to when assembling and installing the machine. The customer must provide the various lifting devices and tools, load-bearing equipment, lifting gear, racks and supporting structures required for assembly and installation. The assembly sequence will vary depending on local conditions on site. These include the available space, the load-bearing capacities of floors, the availability of power points, etc. Solid and even foundations are vital to achieving the best installation and assembly results with regard to angularity, evenness and dimensional accuracy. It is equally important when assembling and installing system components on the corresponding machine. The assembly and installation reports for these system components must be inspected before the assembly and installation of the classifier can commence, in order that their integrity can be verified. ● Check the structure of the building/foundation to ensure that it is able to support the load of the machines and ensure that any additional support necessary has been put in place. ● Keep the routes leading to the area in which the machines are being assembled and installed clear in order that the process of assembling the machines will not be hindered. Note These mounting instructions, including the instructions and guidelines they contain, serve solely as a supplement to the drawings and must only be used in conjunction with them.

7.1

Installation reference documents Note The LOESCHE-Mill LM 63.3+3 CS with LSKS 107 CSr and its assembly groups may be found in the customer’s parts list (see technical documents).

130


LOESCHE Mill with Classifier Installation

7.2

Description of the assembly sequence Note More detailed information for assembly you will find in the speratly delivered document  "assembly instruction", which is part of the delivery to the grinding plant.


131

LOESCHE Mill with Classifier Commissioning

8

Commissioning

8.1

Cold start-up Note Cold start-up can only be carried out or monitored by a LOESCHE commissioning engineer, who is normally an electrotechnician or electrotechnical engineer with procedural knowledge. The following is merely a brief summary of the complex procedures for commissioning a LOESCHE mill.

Definition of the term cold start-up Cold start-up is the term used for initial start-up of a plant without feeding the goods to be milled. 8.1.1

Requirements In order to commence cold start-up, the mechanical and electrical fitting work must be completed and the fitting acceptance protocol must be signed.

8.1.2

Applicable documents The following documents must be taken into account for carrying out cold startup. 1. LOESCHE documentation: – Fitting instructions – Documentation for electrical equipment – Start-stop sequences – Interlocking diagrams – Hydraulic schemes – Lubrication instructions – List of electrical consumers – Instrument list – UM datasheets (machine monitoring) – UP datasheets (process control) – Protocols, checklists, forms – Drawings 2. Supplier's documentation The LOESCHE company accepts absolutely no liability for damages which are caused by non-observance of this manual for cold start-up and all further applicable documentation.

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8.1.3

Extent of cold start-up If possible, commissioning should ideally take place in the opposite direction to material flow. For the most part, however, the sequence of commissioning is determined by which plant components are already finally assembled and electrically connected. During cold commissioning each individual plant component is first started up. The commissioning engineer here must check in each case whether all the stipulated preconditions are satisfied. Preconditions applicable to every plant component: – The plant component is mechanically correctly installed – The plant component is electrically connected – The plant component is pre-filled with the required media In addition, it is necessary for different plant components to satisfy different preconditions, which are always listed in the relevant chapter on cold commissioning. The commissioning engineer monitors the tests carried out by customer personnel and, if necessary, the rectification of any faults occurring. He/she also logs the test results. After this, plant components are matched to each other in groups using sequence tests. The cold run for the entire plant is then carried out for calibration and for the presetting of process variables and controlled process variables. The cold run also includes heating up the plant using the hot gas source. Material is not fed in during this phase. The results of the cold run are logged by the commissioning engineer. After the successful completion of sequence tests and the cold run itself, cold commissioning is deemed to be completed. The plant is handed over to the commissioning engineer who is to perform hot commissioning together with the protocols of the idle running test and the testing of the start/stop sequences and interlockings.


133


8.1.4

Cold start-up sequence DANGER Wide range of hazards! ● Secure hazard areas with safety devices or, if necessary, blocking off! ● Sound an acoustic warning signal before starting any drives!

NOTICE Possible risk to machine! ● Before starting any drive, always ensure that no other plant components can be damaged!

The cold start-up of individual plant components normally follows a particular scheme: 1. The commissioning manager checks the correct mechanical assembly of components. 2. The commissioning manager checks that components are correctly electrically connected. 3. The commissioning manager checks the control system hardware and software in accordance with the LOESCHE interlocking diagram. 4. The commissioning manager sets the time delays (timer) and values for warning or alarm in the hardware and software in agreement with the LOESCHE UM and UP datasheets. 5. The commissioning manager checks that all lubricants have been filled up in accordance with the LOESCHE lubricant list. 6. The commissioning manager carries out signal tests (I/O checks) on the relevant electrical consumers and instruments. 7. The commissioning manager ensures that motors are rotating in the right direction. 8. The commissioning manager parameterises the instruments in accordance with the LOESCHE and supplier documentation. 9. The commissioning manager checks interlocking in accordance with the LOESCHE interlocking diagram. 10. The commissioning manager checks whether motors are coupled to the associated machines using supplier documentation. 11. The commissioning manager tests the function and interlocking of appropriate components during a trial run. 12. If the relevant components have been commissioned, the commissioning manager carries out a function and trial run (sequence test) on the component groups. 13. Once all component groups have been commissioned, the commissioning manager carries out a cold run for the entire plant in accordance with the LOESCHE starting sequence. This start includes heating up the system with the hot gas producer or another hot gas source. Material is not fed in.

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LOESCHE Mill with Classifier Commissioning 14. The commissioning manager checks the sequential and processing into locks in accordance with LOESCHE documentation. 15. The commissioning manager runs the entire plant down in accordance with the LOESCHE stop sequence. 16. The commissioning manager tests the emergency stop sequence in accordance with the LOESCHE emergency stop sequence diagram. 8.2

Warm start-up Note Hot commissioning can only be carried out or monitored by a qualified LOESCHE commissioning engineer, who is normally an electrical engineer or a mechanical engineer with process engineering knowledge.

Definition Hot commissioning is the term used for initial start-up of a plant including feeding the raw material to be ground. It follows on in the LOESCHE sequence diagram at the point where cold commissioning was concluded: With material feed. Hot commissioning is divided into the following phases: 1. First warm-up 2. Plant stop 3. First inspection 4. Optimisation phase 5. Performance verification test 6. Verification of reliability 7. Performance run 8. Handover to the operator

Objectives The objectives of hot commissioning are 1. integrating the LOESCHE mill with classifier and the customer's scope of supply into the normal operational sequence of the grinding plant. 2. achieving stable grinding operation. 3. achieving the contractually warranted product qualities. 4. achieving the contractually warranted product quantities. 5. achieving the contractually warranted values.

Preconditions To be able to begin hot commissioning, it is necessary to satisfy the following conditions: – The plant cold run has been successfully completed and the necessary protocols and reports have been drawn up, signed and handed over in accordance with the LOESCHE overview of protocols, reports and drafts for commissioning. P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

135

LOESCHE Mill with Classifier Commissioning – –

–

–

– – – –

– 8.3

All the plant components are in full working order, ready for operation and safe in accordance with the supplier's documentation. The operator makes available feed material in/of sufficient quantity and quality so that the start of hot commissioning is not delayed and measurement results are not negatively influenced. The operator makes available further consumables required such as e.g. electric current, water, air, hot gases, oil, lubricant, fuel, etc. in/of sufficient quantity and quality so that the start of hot commissioning is not delayed and measurement results are not negatively influenced. The operator makes available sufficiently qualified and experienced personnel so as to ensure 24-hour operation. The operator must also make available standby personnel for repairs. The operator makes available all the required tools, vehicles, machines and spare parts. The operator ensures that measurements and settings can be carried out on all plant components. All protective devices are adjusted, in proper working order and ready for operation. The LOESCHE commissioning engineer is knowledgeable about the plant documentation such as e.g. heat balances, spring stiffness, layouts and settings. The operator warrants the fault-free functioning of its scope of supply by means of written release.

Commissioning the hydraulic system Commissioning is performed in this order: ● Check the position of the hand valves in the hydraulic system in accordance with the drawing "Scheme: Hydraulic HSLM ..." and "Scheme: Hydraulic HSSW ...". ● Check electrical monitors and locks in accordance with the electrical documentation. ● Fill the hydraulic accumulators with nitrogen. The filling pressure is determined during commissioning by the LOESCHE running-in engineer. Leaded safety valves (6....) in the HSLM hydraulic cabinet must be examined for undamaged lead seals. ● Fill the overall hydraulic system with prescribed oil up to the upper tank marking - including pipelines and cylinders. ● Clean the overall hydraulic system with flushing oil. ● Adjust the proximity limit switches on the rocker arms in accordance with the "Rocker arm monitor cpl." drawing (see mill parts list). These limits switches are mounted on each rocker arm. ● Bleed the hydraulic system several times until the system is completely gasfree. ● Preserve the piston rods of the hydraulic cylinders on the S rollers.

8.4

Commissioning the hydraulic positioning device for support rollers (S) When commissioning the mill and when making important changes to the grinding material composition, it is necessary to determine the correct working height for the support rollers by testing. The aim is to minimise the vibration velocity of the mill in order to ensure safe and fault-free machine operatioin. The following measures, which are carried out during commissioning by the LOESCHE running-in engineer, are required:

136


LOESCHE Mill with Classifier Commissioning ●

Raising or lowering of the support rollers in 5 - 10 mm increments until their swinging range is covered. The initial height of the support roller is freely preselected. ● Noting down of the values of support roller speed and relative mill vibration velocity (measured on the mill body) in a table for each working height. ● Raising or lowering of all the S rollers in the same direction at the same time during measurement. After measurement the LOESCHE running-in enginerr adjusts for Automatic mode the working height for the S rollers at which the mill vibrations are minimal. The throttle valves are adjusted and checked by the LOESCHE running-in engineer during commissioning. They influence the lowering and raising speed of the support rollers. The LOESCHE running-in engineer adjusts the throttle valves in such a way that the pressure reducer valve does not open during the normal raising operation (see "Hydraulic scheme HSSW ...“). 8.5 8.5.1

Starting the mill when unfilled or filled Master rollers (M) After the hydropneumatic spring assembly system of the rollers is electrically enabled, the following processes occur automatically in accordance with the electrical sequence plan. The respective position of the hand and solenoid valves is set out in the function table in the drawing "Scheme: Hydraulic HSLM ...". The rollers are raised until a mechanical stop is reached (the end of movement is determined by limitation of the piston stroke on the cylinder cover). After all the rollers have reached their upper position, the relevant pump motor is switched off by the proximity switches. Note While the pistons move out of the cylinder when the rollers are raised, the pressure in the working pressure and counterpressure systems rises in relation to the set pressure as long as the solenoid valve(s) is/are not activated. The regulating function is out of action while the rollers are raised or lowered. The higher working pressure or counterpressure can be read off at the relevant pressure gauges (see drawing "Scheme: Hydraulic HSLM ..."). If, while the rollers are raised, a pressure loss occurs in the system, e.g. due to leakage oil, one or more rollers move downwards. The respective high-pressure pump starts automatically to counteract this. It runs until the switching point of the upper proximity switch is reached again. During the "Lower rollers" process the rollers move downwards in response to the force of gravity and the additional force of the gas cushion in the accumulators onto the table. The regulating function is out of action while the rollers are being lowered. In order to ensure that the rollers are immersed slowly into the grinding bed as they are lowered, the return oil to the tank is routed via an adjustable flow restrictor. The relevant preconditions for activating the individual processes can also be taken from the sequence diagram in the LOESCHE electrical documentation.


137

LOESCHE Mill with Classifier Commissioning 8.5.2

Support rollers (S) The processes of the hydraulic positioning device of the support rollers also take place in parallel to the M rollers after electrical enabling, whereby the respective position oif the hand and solenoid valves can be taken from the table featured in the drawing "Scheme: Hydraulic HSSW ...". The relevant preconditions for activating the individual processes can also be taken from the sequence diagram in the LOESCHE electrical documentation.

8.5.3

Shutting down the mill during normal operation If the mill is to be stopped, transportation of the grinding material is shut down. The mill motor can be deactivated with a delay if after a few rotations the grinding material still on the table has been thrown off as a result of centrifugal force. When the supply of material is interrupted, the hydraulic pressure is usually switched over in the hydropneumatic spring assembly system to the piston side of the spring assembly cylinders, which causes the master rollers to be lifted off the table. The process runs in the same way when the S rollers are raised.

8.5.4

Emergency Stop In the event of an emergency stop or a power failure, both the master rollers and the support rollers remain in contact with the grinding material. It takes max. one rotation to brake the table.

8.5.5

On-site operation In the event of maintenance work enabling is performed for "on-site operation" by the control room. The regulating function is out of action. The rollers can then be raised at the HSLM and HSSW hydraulic cabinets, whereby the pumps are started on site.

138


LOESCHE Mill with Classifier Operation

9

Operation DANGER Accident hazard! The plant may only be operated by skilled personnel who are qualified and have been trained to do so.

NOTICE Possible risk to machine! ● Check before starting production that there are no objects (e.g. tools, residual materials or similar) in the machines, units and piping

Note It is essential when operating the individual machines to observe the relevant information and specifications provided in the separate instruction manuals The individual machines can be operated in the Manual or Set-up mode from the local control panels (determined by the operator). The machines are operated within the framework of the function of the overall system (higher-level control room) in Automatic mode and controlled from the central control room.


139


9.1 9.1.1

Local control panels Operation The following control elements can be located on the local control panel (determined by the operator): 1. Maintenance switch (rotary switch), optional The component is connected to or disconnected from the power supply by actuating the maintenance switch. DANGER Accident hazard! If the maintenance switch is switched off for the performance of cleaning, maintenance and repair work, it must be mechanically secured against unintentional switching on through the use of a padlock. 2. Emergency Stop button (red palm button switch), optional The complete grinding plant is brought to a safe operating state when this button is actuated. The Emergency Stop button can be released again by pulling or turning counterclockwise/clockwise. 3. On (green illuminated pushbutton), optional The control system is switched on when this button is actuated; lights up permanently after switching on.

9.2 9.2.1

Operating modes Local operation For the performance of refurbishing, maintenance and repair work all the electrical drives can be switched over from their local control points to Manual mode and thereby operated. (Determined by the operator) This may occur only after consultation with the responsible plant operator and is permitted only when the plant is stopped. The plant fails complete when switched over from Automatic mode to Local mode during operation. All the designated locks must be activated for Local mode so as to ensure that the individual machines are protected. Process-relevant locks are partially deactivated. In Local mode the operator bears the responsibility for operating individual components of the plant. Operation of individual components and of machine or plant components may only be performed by experienced and specially trained persons, taking into account potential effects on persons and plant components.

140



9.2.2

Automatic mode In normal operation the complete plant is operated in Automatic mode. The complete plant is controlled and monitored here from the central control room. NOTICE Possible risk to the machine! Operation of the complete plant is permitted for production only in Automatic mode! All the designated locks must always be activated. This guarantees the protection of persons and of the individual machines and prevents longer plant stoppages on account of damaged machines.

9.3 9.3.1

Switching the grinding plant on and off Switching the plant on Before starting the grinding plant, especially after a longer stoppage, inspect the complete plant to ensure that all openings and access doors in the grinding circuit are closed, tools have been removed and auxiliary scaffolding and platforms have been disassembled. Also check: – Stop cocks ahead of the transducers opened, all measurements ready for operation, 0 point and measuring ranged adjusted and checked – Start up all the shut-off devices in the mill lube-oil circuit – Check the oil level in the mill gearbox and after an inspection, correcting if necessary – Oil level in the gearbox of the grinding-stock feeder OK – Oil level at the bearing block of the mill blower OK – Before starting after an extended stoppage, run all the flap drives locally once. Check external "OPEN" / "CLOSED" end position to ensure operational reliability – The shut-off devices of the mill hydraulic system are in the operating position in accordance with the hydraulic scheme – Grinding stock present in the feeder, layer height > min.

9.3.2

Starting the grinding circuit If scheduled by the operator, it is possible after commissioning is completed to start the complete plant by actuating the corresponding button (Master Start/Stop - Start button). The individual sequences are started automatically as soon as the start conditions are satisfied. Independently of the above, however, the operator can start the grinding plant in individual steps as follows:


141


9.3.3

Start sequence Auxiliary units "ON" The lube-oil pump of the mill gearbox should remain in operation in winter in order to keep the lube-oil circuit at an operating temperature of min. 15° C. Note The lube-oil temperature must be > 15° C before the mill is started.

The group is started by actuating the corresponding button (Mill auxiliary drives). The following functions are executed with this command: – Lube-oil pump of mill gearbox ON, coolant on standby – Note: If the oil temperature rises to > 30°C, a control valve in the coolant line opens automatically – Classifier drive ON – Mill hydraulic system ON, "Raise rollers“ Start "Warm-up" Starting of the flap program (different depending on the plant circuit) Start "Mill motor" Requirement: – All the rollers are in the "Top Position“ When the corresponding button (Mill motor) is actuated, the mill motor is started. Note The list of limit values containing the setting parameters and operating data for the grinding plant is created during commissioning(IBN) depending on the raw material Start "Grinding operation" Requirement: – Grinding operation is started by actuating the corresponding button (Mill material feed). Program sequence: – The gas volume ahead of the mill approaches the start setpoint value – Start of the grinding-stock feeder with the start setpoint value; see list of limit values – Lowering of the grinding rollers after start of material feed; waiting time, see list of limit values. When the back pressure has reached the setpoint value, the grinding plant is properly in grinding mode.

142


LOESCHE Mill with Classifier Operation Automatic pressure control becomes active after a short waiting period. The feeder speed can be increased in several increments while observing the mill outlet temperature. If this start is implemented fully automatically, the different moisture of the feed material must be taken into consideration. In other words, 2 start sequences must be developed where necessary for summer and winter operation. 9.3.4

Operating the grinding plant The grinding plant is in stable grinding mode after the start sequence is completed and the setpoint value for the feeder speed has been reached. All the control loops are in Automatic mode. If a "warning" is issued, the operator must react accordingly and re-establish a normal operating state through appropriate manual interventions. In hazardous situations the grinding plant must be powered down in case of doubt. (Change of setpoint values, rotational speeds, flap positions...). The essential control loops and principles for constant grinding operation are described in the following. Monitoring of differential pressure over mill The differential pressure over mill is a value calculated from the measured pressure after mill and the measured pressure before mill. The differential pressure rises as the feed quantity increases. Furthermore, a change in grindability from easy to hard at a constant working pressure is manifested in a rise in the pressure loss over mill. The limit value for the differential pressure must be set accordingly. Max. setpoint value, see list of limit values. Note When the plant resistance rises above the setpoint value, sufficient internal material circulation in the mill is no longer guaranteed on account of an inadequate gas volume through the mill. Consequences: – The grinding plant becomes increasingly unsteady, vibrations increase – There is an increased incidence of rejects – The setpoint gas volume can no longer be achieved. Control of temperature after mill The gas temperature is set during commissioning depending on the residual moisture in the finished stock. The temperature is measured in the classifier outlet of the grinding plant. In situations in which an automatic correction of deviations from the setpoint value is not possible, limit monitors send signals to the central control room. In the interests of guaranteeing machine safety, an alarm is issued or an intervention is made in the process control system (detailed structrure, see electrical documentation). Note During grinding drying the setpoint value for temperature control after mill must not be < 80° C, as otherwise sufficient drying of the grinding stock is no longer guaranteed.


143


Measuring the air flow after filter A constant air flow through the mill is an essential requirement for stable grinding operation and consistent product quality. The minimum gas volume is determined among other things by the amount of reject material obtained. Increasing the gas volume has negative effects on the kWh demand of the mill blower and on wear in the mill. The setpoint value for the gas volume is specified by the operator, the gas volume is maintained by the swirl flap or by the variable speed of the mill blower. Product quality Comminution is dependent on: – Feed quantity – Total gas volume – Working pressure – Classifier speed – Feed moisture of the grinding stock The level of the working pressure has a direct influence on the product quantity / quality. Reducing the working pressure results in the case of a high feed quantity in a rise in the differential pressure over mill and in the case of extreme changes in increased rejection of grinding stock via the louvre ring into the reject boxes. The classifier speed should, on account of the required grinding fineness, be adjusted to the currently measured product fineness. 9.3.5

Switching the plant off Intentional powering down of the grinding plant is performed by actuating the corresponding button (Master Start/Stop - Stop button). Material feed is automatically stopped. The stop sequence is explained in detail in the electrical documentation. The mill motor runs on to ensure that the grinding table is emptied to the greatest possible extent. The grinding plant can be started up from this state during the next start by the operator. If an extended grinding-plant stoppage is scheduled (> 1 week), the following plant components can be shut down by the operator. – Stop - gearbox lubrication – Stop – HSLM (See electrical documentation). Note Gearbox lubrication should wherever possible remain in continuous operation in the winter months.

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9.3.6

Unlocking the Emergency Stop functions The Emergency Stop function is unlocked after the cause has been eliminated at the Emergency Stop button. Acknowledgement of the Emergency Stop indication is performed from the central control room (for details, see electrical documentation).

9.4 9.4.1

Failure of power supplies Switching the plant off in the event of a power failure The following plant components are protected by an uninterruptible power system against failure for 30 minutes: – Plant control system (SPC), optional – Plant visualisation, optional – Gas analysis (if provided), (exception: tracing) In the event of an extended power failure (> 30 min), the operator must supply the above-mentioned safety-relevant plant components with power by means of a separate power supply (e.g. diesel generator). When electrical power is restored, the plant must be returned to its basic setting and restarted.

9.4.2

Switching the plant off in the event of a hydraulic-system failure When hydraulic pressure is restored, the plant component or if necessary the plant must be returned to its basic setting and restarted.


145


9.5

Electrical engineering Note The operation, function and mode of action of the grinding plant can be found in the separate  "Electrical documentation" which is included in supply with the grinding plant.

146


LOESCHE Mill with Classifier Troubleshooting

10 Troubleshooting DANGER Accident hazard! The facts and notes to "faults, causes and troubleshooting" mentioned in this instruction are described in a way, that it can be understood by trained skilled personnel (see definition chapter Requirements of personnel on page 26 " in: – electricity / electronics – mechanics / maintenance The adequate tools and test equipement has to be allocated to the trained and skilled personnel. Specially before all maintenance and repair work essentially the shutdown procedure has to be operated (see chapter 3.10). If the measures mentioned above end in failure, please contact LOESCHE GmbH. Faults are indicated by means of colour-coding on the process flow screen in the control room. Alarm indications appear in plain text and include information about which components have been affected. A distinction is drawn between process faults and machine-specific faults. Intervention - by trained skilled personnel only - is required to rectify the machine-specific faults listed below. Should investigations into a fault identify a need for maintenance and repair work, the shutdown procedure for the machine (see "Maintenance on page 151") or the higher-level control will need to be followed prior to such work commencing. You will find information about troubleshooting purchased components in the separate manufacturer's instructions, see  "Supplier documentation".


147


Fault

Cause

Remedy

Main switch/maintenance switch set to "0".

Switch the main switch/maintenance switch on.

Overcurrent protection triggered

Request skilled worker for fault rectification

Emergency Stop button pressed

Determine and rectify cause, and unlock Emergency Stop button, cancel Emergency Stop

Sealing air pressure too low/sealing air exhausted.

Identify the cause and restore the sealing air system to working order

Lubrication system fault indication; insufficient or no lubrication compound available

Top up with lubricant

Strong vibrations

Feed pieces too great

Reduce feed pieces to permissible value

Mill resistance increases

Armour ring worn

Replace armour rings

Blocked roller

Check bearing

Unsteady mill operation

Dam ring worn

Replace dam ring

Increased temperature at grinding rollers

Oil level in roller too low!

Check oil level

Oil is overaged

If necessary, top up with oil Check when last oil change was carried out

Bearing faulty

Check bearing, replace if necessary

Oil discharge at grinding rollers

Slip-ring seal faulty

Check slip-ring seal, replace if necessary (in pairs)

Heavy discolouration by microscopic floating particles in oil

Sliding rings worn

Replace sliding rings (in pairs)

Sealing air pressure too high

Sealing air system is fouled

Clean the sealing air system

Sealing air pipes are damaged, e.g. kinked

Replace defective pipes

Sealing air seal in the roller is fouled

Clean the roller sealing gap Check the sealing air gap in the roller

Sealing air system is leaking

Locate and seal leaks

Mill Control will not power up.

Machine shuts down; fault indications in the control room

Sealing air pressure too low

Wear ring, roller/rocker arm, worn Replace wear rings if sealing air gap too large Shortened switch-on intervals of pump in HSLM

Working pressure drops too quickly

Check piston seals in hydraulic cylinder, replace if necessary Check valves in cabinet

148



Fault

Cause

Remedy

Connection between arm and fork (pin connection and screws) not released

Check connection, release if necessary

Bearing faulty


Swing-out cylinder cannot be moved


Swinging device Roller cannot be swung out

Increase pressure or check condition of line-break fastener Classifier Classifier running unsteadily; vibrations

Rotor; blade faulty

Check classifier rotor; replace parts if necessary

Increased temperature at classifier drive

Fault at bearings/drive Oil loss

Check bearings/drive Check oil level

Specific fault indications are shown via the control system in the control room of the higher-level system. Tab. 20: Fault, Cause, Remedy table


149


10.1 Customer service Should you require further information, please contact our customer service team directly: LOESCHE GmbH Hansaallee 243 40549 Düsseldorf Germany Tel.: +49 (0)211 5353-0 Fax: +49 (0)211 5353-500 e-mail: [email protected]

150


LOESCHE Mill with Classifier Maintenance

11 Maintenance 11.1 General notes on maintenance works The standard "DIN 31051, Fundamentals of maintenance" divides maintenance works into the sectors – inspection – cleaning – service/preventive maintenance

DANGER Accident hazard! The chapter Maintenance/Cleaning is intended for skilled workers only. Maintenance, cleaning and repair work may only be carried out by skilled personnel.

Skilled worker A person who, by combining his or her specialist training, knowledge and experience with awareness of applicable standards, is able to assess the tasks with which or he she has been assigned and identify potential hazards. Definition in accordance with EN 60204-1.

Note Operating and maintenance personnel will be trained by LOESCHE GmbH personnel at the machine installation site. If any questions or uncertainties arise, please contact LOESCHE GmbH. To ensure fault-free operation, it is absolutely vital that the machine will be cleaned and serviced at regular intervals. ● Record all maintenance work completed in a maintenance logbook. ● Record the operating hours of bearings and components subject to particular wear. During operation, the machine is subject to vibrations which can cause screwed/bolted and clamp connections to come loose. ● To prevent damage, check the machine at regular intervals (recommended interval for single-shift operation 6 months) for loose connections. Note ● Refer to the external manufacturer instruction manuals for information on servicing / cleaning the individual bought-in components (especially motors and gearboxes).


151


General hazards associated with maintenance, cleaning and lubrication

DANGER Accident hazard! ● Before carrying out cleaning, maintenance and repair work, it is absolutely essential to follow the shutdown procedures (see Chapter "Shutdown procedure Page 32“). ● Before carrying out burning and welding work, obtain the necessary approvals. When carrying out welding work, always observe the applicable safety regulations. ● Hydraulic accumulators are pressure vessels and must be pressure-tested at regular intervals in accordance with the regulations of the technical inspection authorities. Operation of hydraulic accumulators is subject to mandatory reporting in most countries. Strict compliance is required! ● When carrying out cleaning and maintenance work, open the inspection covers only after the plant has been run empty and shut down. Duration of emptying, see Chapter "Shutdown procedure Page 32 ● Do not use any sharp objects or tools for cleaning which are not expressly intended for this purpose. ● Observe the data and useful life intervals of hydraulic connections and hydraulic hoses so as to be able to carry out in good time the prescribed replacements. Explosive materials Oxygen or air can cause explosions in connection with oil. ● Only nitrogen gas may be used to fill up the rubber bladder in the accumulator or in the piston accumulator.

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11.2 Inspection Component

Interval for one-shift operation d

w

m

Main switch

¼y

½y

1y

C

X

Emergency Stop button

X

Locks on cabinets

X

Check cables for tight seating

X

Setting values on circuit-breaker

X

Buttons on electrical switching cabinet and local control panels

X X

X

Check all plug, screwed and clamp connections for tight seating, retightening if necessary

X

Pneumatic system; check set air pressure on maintenance unit

X

Check pressure at maintenance unit, adjust if necessary

X

Hydraulic unit; check set hydraulic pressure on hydraulic unit

X

Tab. 21: Function checks, inspection intervals

Key d w m y C

daily weekly monthly yearly Clean when openend

The intervals are calculated for one-shift operation (8 hours/working day 12 months/year).


153


001382

11.3 Cleaning

Cleaning work is performed only on the outer areas of the machine. DANGER Work involves a high danger potential! Danger to life and limb ● Observe the shutdown procedures (see Ch. "Shutdown procedure Page 32“) before starting cleaning, maintenance and repair work.

NOTICE Possible risk to the machine! ● Do not use any sharp objects or tools for cleaning which are not expressly intended for this purpose.

General cleaning instructions: ● Regularly clean all areas of the machine (well swept). ● Dispose of material remnants, cleaning waste and cleaning materials in an environmentally compatible manner. ● Clean the filters of the compressed-air system on a regular basis. Cleaning is carried out according to the filter manufacturers' instructions. ● At the beginning of maintenance/repair work clean the machine, connections and screwed joints to remove oil, fuel or care products. Do not use any aggressive cleaning agents. Use fluff-free cleaning cloths. ● Before cleaning the machine with water or a steam jet (high-pressure cleaner) or other cleaning agents, cover/tape closed all openings into which water/steam/cleaning agents are not permitted to enter for safety and/or functional reasons. Electric motors and switching cabinets are at particular risk. ● Make sure when cleaning the machine hall that temperature sensors of the fire alarm and extinguishing systems do not come into contact with hot cleaning agents. The extinguishing system could otherwise be set off. ● Remove all covers and taping after cleaning.

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LOESCHE Mill with Classifier Maintenance ●

After cleaning check all the fuel, engine oil and hydraulic oil lines for leaks, loosened connections, abrasion and damage. Rectify identified defects immediately.

Note ● When carrying out cleaning work, following the information and instructions provided in external  instruction manuals and corresponding  in-house instructions.

Activity

Interval

Make sure that cooling fins of electric motors are not clogged by dirt so as to prevent the risk of motor overheating; clean if necessary.

m

Clean switches, buttons and information plates/signs on switching cabinets and control panels (on the outside) with a fluff-free cloth (plates/signs that are no longer legible must be replaced).

y

Keep all access routes, steps and platforms free of dirt on a regular basis and if necessary eliminate any existing slipping hazards.

d

Dispose of material remnants, cleaning waste and cleaning materials on a regular basis in an environmentally compatible manner. Tab. 22: Cleaning intervals

The intervals are calculated for one-shift operation (8 hours per working day 12 months per year). Key d m y

daily monthly yearly


155


11.4 Maintenance

001381

11.4.1 Lubrication

NOTICE Possible risk to the machine! ● Use only lubricants which are featured in the  LOESCHE lubricants list. – – – – – – –

–

– –

–

–

156

All lubrication points are lubricated with grease. Follow the notes and instructions in the lubricant tables when carrying out lubrication tasks. The lubrication points on the plant must be regularly lubricated with the aid of appropriate lubrication tools. On larger mills all the lubrication bores are connected to a central grease lubrication system. The lubrication intervals must be determined by the operator on the basis of the operating hours to be performed by the plant. All lubrication bores are sealed by grease nipples during transportation. The piston and piston rods in the hydraulic cylinders are lubricated automatically by the hydraulic oil (oil change in accordance with maintenance table). On larger raw meal and clinker/slag grinding plants the roller bearings are lubricated by the HSMS (see parts lists or delivery contract). Refer to the lubricant table for oil quantity and oil quality. When lubricating gearboxes, follow the instructions in the separate manufacturer instruction manuals. Mechanical damage to pipes must be repaired immediately. Hoses must be checked on a regular basis as to their good condition and if necessary replaced. The grease containers of the lubrication pumps must be regularly refilled with the grease specified in the lubricant table. The cover of the grease container must be sealed tight to prevent dust from getting into the container. The rod head and hydraulic cylinder roller bearings are kneaded full of grease. Re-greasing the bearing takes place using a hand grease gun on the grease nipples at long periods in accordance with the maintenance table. Since the bearings are moved through small pivoting angles, grease consumption is low. The grease has a long useful life.



001380

11.4.2 General maintenance information for assemblies and machines

These abbreviations are used in the following maintenance instructions: Key I d w m M W Y OH

Interval daily weekly monthly Months Weeks Years Operating hours

MP M E

Maintenance personnel Mechanic Electrician

OC O S

Operating condition In operation Stoppage

Table of Contents – Maintenance Maintenance: Mill stand cpl. .............................................................................158 Maintenance: Mill body cpl. ..............................................................................159 Maintenance: Table cpl. ...................................................................................160 Maintenance: Rocker arms ..............................................................................167 Maintenance: Roller .........................................................................................172 Maintenance: Spring assembly cpl...................................................................185 Maintenance: Hydraulic accumulators .............................................................190 Maintenance: Hydraulic cabinets .....................................................................194 Maintenance: LM-Drive ....................................................................................196 Maintenance: Gearbox lubrication unit.............................................................197 Maintenance: Central lubrication unit ...............................................................198 Maintenance: Sealing air system .....................................................................199 Maintenance: Piping system ............................................................................200 Maintenance: Swinging device.........................................................................200 Maintenance: Grinding bed sprinkler cpl..........................................................201 Maintenance: Classifier ....................................................................................202


157


11.4.3 Maintenance: Mill stand cpl. DANGER Risk of falling! ● Wear protective gear during maintenance work with disassembly of platform parts. ● Cordon off danger areas from unauthorized persons ●

● ● ● ● ● ●

Tighten bolts on bearing cap immediately after commissioning. Repeat the process after 8 operating hours and then secure bolt heads in accordance with drawing information. Retighten hex nuts inside and outside the pedestals and then weld after around 100 mill operating hours in accordance with drawing information. Retighten hex bolts and gearbox foot flanges after around 24 operating hours and secure in accordance with gearbox documentation. Check driving wedges (if fitted) for secure seating after around 24 hours, knock in again if required and weld lightly together. Keep (reject) flaps closed during operation to prevent leak air ingress into the mill. Check (reject) flaps for good seating on edges and check reject chute, align if necessary. Check (reject) flap seals for correct functioning, replace if necessary.

Ring duct - Scraper Inspection can be carried out through the inspection openings in the gas duct or ring duct. ● Replace worn scrapers. ● Remedy signs of wear on the scraper rods by hard-facing with hard electrodes. Component

Description

I

MP

OC

Mill stand

Check pedestal welded seams

6M

M

Op

Check welded seams on bridges

6M

M

Op

Check welded seams on bearing blocks

6M

M

Op

Check bolted connections for completeness

6M

M

Op

Check bolted connections for tight fitting

6M

M

Op

Inspect for rust formation

12 M M

Op

Check gas duct

12 M E

S

Check seal air piping

6M

M

S

Check bolted connections on seal air piping

6M

M

Op

Check expansion joints for damage and sealtightness

6M

M

Op

158



Component

Description

I

MP

OC

Ring duct

Check surface coatings, look for rust formation

6M

M

S

Check for holes

3M

M

S

Check for damage and wear

3M

M

S

Check scrapers for damage and wear

3M

M

S

Check distance between scrapers and ring duct floor, correct

3M

M

S

Tab. 23: Maintenance table, mill stand

11.4.4 Maintenance: Mill body cpl. ●

● ●

The "0" setting of the grinding roller can be set on a scale on the rocker arm using a fixable pointer on the mill body cover. To do this, the rollers need to be in the lowest position. When the mill is operating, the scale moves relative to the fixed pointer. Both the median grinding bed thickness and the thickness variation can be read off. After a certain operating duration, the indicator gives information about the grinding roller wear condition. Ensure that the door seals are replaced in time to prevent leak air entry. Inspect the lining plates regularly for wear. Heavily damaged plates can be replaced by less worn plates or new ones.

Component

Description

I

MP

OC

Mill body

Check the mill body for holes

6M

M

Op

Check surface coatings, look for rust formation

6M

M

Op

Check bolted connections for completeness and tight fitting

6M

M

Op

Check that all weld seams are continuous

6M

M

Op

Check connected piping and tubing for damage and sealtightness

6M

M

Op

Check all connected electrics

12 M E

S

Check rubber seals for damage and wear

6M

M

S

Check measuring points for blockage

6M

M

Op

Check expansion joints for damage and sealtightness

6M

M

Op

Check linings for damage and wear

6M

M

Op

Check distance between adjusting screw and sensor

6M

E

Op

Door monitoring

Tab. 24: Maintenance table, mill body


159


11.4.5 Maintenance: Table cpl. NOTICE Damage hazard for mill parts ● Strong currents are produced during electrical welding work, which can damage sensitive components. ● The earth must be connected immediately next to the welding location during all welding work on the grinding plant to avoid bearing damage. It is also important to connect the earthing cable to the gearbox (see gearbox manufacturer's documentation). Damage hazard for grinding plates and table! ● Doing operation, the table casting achieves steady state temperatures of over 100 °C. Once the mill has been switched off, do not open reject flaps and mill doors immediately. ● Allow the table to cool down to around 60 °C before opening the grinding plant to avoid thermal tension and crack formation in the table due to exposure to cold air. ● Do not use liquids to accelerate this process!

Grinding plate The grinding plate material is very brittle. Cracked grinding plate segments must, however, only be replaced if pieces have broken off which cause holes in the milling route. The intended lifetime is normally achieved by wedging any cracked grinding plate parts. ● You should replace the grinding plate at the latest if the mill throughput performance has fallen below that given in a guarantee data. Replacing the grinding plates is not necessary if the tires are only worn. NOTICE Possible risk to the machine! Only one clamping ring segment per grinding plate segment (see figure)! Falsely fitted clamping rings lead to insufficient fixing of the grinding plate segments. Wear to the table collar or grinding plate segment breakage can result. Ensure the clamping ring is correctly assembled.

160



X X 1

2

000623

3 4 Fig. 61: Grinding plate segment alignment Key 1 Table casting 2 Grinding plate 3 Clamping ring 4 Correct alignment (1 clamping ring segment for 1 grinding plate segment)

●

When hard-facing the grinding plates in the mill, observe the operating manual for the mobile welding equipment (see manufacturer's documentation).

Amour ring ● If segments have varying levels of wear, rearrange the segments to avoid damage to the primary gas flow and any consequential damages. This increases the armour ring lifetime considerably. Scatter ring (applies only to appropriate LM version) The scatter ring should have a small a gap as possible to the appropriate counter ring on the louvre ring. ● To reduce the mill power consumption, remove the relevant scatter ring segment and align it if it has been deformed by the presence of foreign bodies and scrapes across the rings. ● If necessary, you can set the ring a little higher by fitting washers to avoid contact with the louvre ring. Dam ring Constant dam ring height around the entire table circumference is a basic requirement for smooth mill running.


161


You should even out unevenness and dents which occur due to wear or contact with foreign bodies as quickly as possible. If items are worn, the entire metal ring wearing insert can be burnt out and replaced by a new flat iron ring (see also "Work instructions: Assembly of dam edge", whose number is in the parts list. If the effective dam ring height has become larger due to wear to the grinding parts at around half way through the mills and effective service life, the dam ring height can be reduced to the initial effective height in order to achieve the original specific power consumption (kWh/t) as closely as possible.

Louvre ring Individual louvre ring segments can be replaced. Segments with varying wear can be exchanged with one another. The component lifetime will be increased by such evening out. ● To remove a segment, burn two short strips of metal which are welded to the ring duct and the segment out. When inserting new segments, locate them so that the gap between the segments is as small as possible, and fix each segment with new metal strips to the ring duct. Component

Description

I

MP

OC

Table

Check that all weld seams are continuous

6W

M

S

Clamping ring


6W

M

S

Check fixing bolts for completeness

6W

M

S

Check bolt retainers for damage

6W

M

S

Grinding plate

Check segments for damage and wear

6W

M

S

Amour ring

Check segments for correct alignment and fixing

6W

M

S


6W

M

S

Check segments for correct alignment and fixing

6W

M

S


6W

M

S

Wear ring


6W

M

S

Scatter ring


6W

M

S


6W

M

S


6W

M

S

Louvre ring

Tab. 25: Maintenance table, table

162



11.4.5.1 Auxiliary equipment: table cpl. Removing / installing the table

1.

2. 1 9 8

10

A-A

7 6

14

2

5

13 3 2

A 12 4

A

000857-1

11

Fig. 62: Auxiliary equipment: table cpl. Key 1 Hand lever pump 2 Distance holder 3 Ring duct 4 Through-passage for support 5 Gearbox output flange 6 Support pipe 7 Hydraulic jack

8 Table 9 Table in raised state 10 Table in operating state 11 Gearbox 12 Support cpl. 13

For the purpose of installing and removing the mill gearbox, the table is released from the gearbox cover flange, then raised and supported. Before the table is removed, the rollers must be raised and mechanically secured or swung out (see following note on safety).


163


DANGER Heavy, moving machine parts! The rollers must be swung out if a mechanical securing device which locks the rollers in the raised position is not provided. It is not permitted to hold the rollers in the top position with the aid of the spring assembly hydraulic system. Direct risk to life and limb by possible failure of the hydraulic system with rollers lifted!.

a)

Removal

DANGER Suspended loads! Damaged supports can break. ● Check that the supports are in perfect condition prior to use. No persons are permitted to remain in the ring duct or in the grinding chamber while the table is moving. It is not permitted to stand under the supported table after the gearbox has been removed. ● Fence off the hazardous area without fail. ● Ensure that arrangements are made between employees. ● ●

● ● ● ● ● ●

Clean the entire ring duct. Raise the rollers and secure them mechanically using the corresponding auxiliary equipment (see above). Swing out the rollers if a mechanical securing device is not provided. Accident hazard (see above). Mount the support rings on the ring duct. Remove the cover, if fitted, from the centre of the table. Remove the table bolts. Flange on the hydraulic jack(s) that is/are part of the auxiliary tools after inserting intermediate supports in the table. Extend the jack(s) with the supplied hand lever pumps. Make sure that the table is raised uniformly. Repeat the procedure until the distance holders can be inserted between the table and the gearbox cover flange. Depending on the type of construction, the ring may have to be removed from the table seal beforehand. Observe the information provided in the "Table cpl." drawing for this purpose.

Note ● Position the distance holders next to the jack supports (see drawing "Auxiliaries: table cpl."). This ensures that the distance holders are evenly distributed around the edge of the table. ●

164

Uniformly lower the table onto the distance holders.



–

Mounting the supports

1 2

3

4

8 5

6

000860

7

Fig. 63: Support cpl. Key 1 Upper support section 2 Ring duct 3 Guide piece 4 Retaining rod

5 6 7 8

Lower support section Mounting plate Foundation frame Bolt connection between support pipes

The supports are slid into each other when delivered and stored. ● Separate the support parts. –

Mounting the upper support section ● Remove the covers from the mounting hatches in the ring duct

Note The positions of the mounting hatches are shown in the drawing "Auxiliaries: table cpl.". ● ●

Bolt the guide piece to the ring duct Slide the upper support section through the guide piece and lock it with the retaining rods


165


–

Mounting the lower support section ● Remove the guard plates from the welded-on mounting plates on the mill foundation.

Note The positions of the mounting plates are shown in the drawing "Mill stand cpl.".

●

Position the lower support section on the mounting plate, align it and bolt it hand-tight

–

Connecting upper and lower support sections ● Release the upper support section from the retaining fixture ● Lower the upper section onto the lower support section ● Bolt both flange plates ● Tighten down the fixing bolts on the foot plate of the lower support section ● Mount the remaining supports in the same way

–

Lowering the table ● Raise the table uniformly with the hydraulic jacks. Remove all the distance holders. ● Uniformly lower the table onto the supports. ● After supporting the table, remove the hydraulic jack(s). Remove the gearbox.

b) Installation of the tabel ● Proceed in reverse order when reassembling the table. ● The locating bores on the underside of the table must be positioned exactly over the driving pins. ● Lower the table without tilting in the gearbox cover flange. ● Tighten and secure the table bolts in accordance with the construction drawing "Table cpl.".

166



11.4.6 Maintenance: Rocker arms Rocker arm (M) cpl. ● When replacing rollers, observe the location of the separating slits in the tapered sleeves in accordance with construction drawing "Rocker arm cpl.". The clamping connection between fork and axle must be tight during operation. Even minimum play in this clamping connection leads to immediate deflection of the fork drillhole and the danger of fork breakage. ● Lubricate all bearing locations continuously since lubrication interruption leads to seizure of the bearing seats (see operating manual "Lubrication line cpl."). ● When transporting the rocker arm, use lifting brackets. They are included in delivery and shown on the assembly drawings. ● If a transparent hose is fitted to the rocker arm, check it for leaking oil. This can run from the sealing air chamber down to the M rocker arm axle. If leaking oil is found, check the roller slip-ring seal. ● Replace the stop plate at the bottom end of the fork if it becomes deformed due to regular contact with the spring buffer. Rocker arm (S) cpl. Plain bearings are provided with solid lubricant for lifetime. In fact no further greasing is required. ● check the fastening screws of the axle pins for being tight during periodical inspections of the mill. Lever Sealing (M) cpl. ● Ensure there is a narrow gap between standing and moving parts. ● Always support the rubber strips on both sides with metal strips. The rubber strip should protrude past the metal strips by maximum 2 mm. Larger protrusion means excessive working in the rubber and the danger of breakage due to fatigue. ● If the armour ring becomes worn, replace it in good time to protect the sealing air seals from becoming worn externally. ● Carry out regular checks for wear on the highly wear-resistant lining plates on the sealing cap; replace them early before basic body components of the sealing cap can be affected. Lever Sealing (S) cpl. Because the S rocker arm is only moved relatively infrequently, major wear is not expected on the lever sealing. ● Replace a boot if worn.


167


Rocker arm monitor cpl. ● Before swinging out the rollers, disassemble the rocker arm monitor cpl. ● Fix and adjust the rocker arm monitor cpl. after swinging the rollers back in (in this case, please refer to Chapter "Adjusting the rocker arm monitor cpl.“ in this manual). ● Check electrical connections regularly and check rocker arm monitor bolts for tight fitting. ● Check the distance spacing A (see chapter "Rocker arm monitor cpl.“) regularly. Component

Description

I

MP

OC

Rocker arm

Check for damage

6M

M

S


6M

M

S

Retighten fixing bolts if necessary

6M

M

S

Check gland box for wear and tight connection

3M

M

S

Check whether the roller bearings are tightly in position

12 M M

S

Check bearing play

24 M M

S

Check lubrication level, correct

1W

M

S

Check sealing air gap to mill body

6M

M

S

Lever Sealing

Check for minimum distance to rocker arm

6M

M

S

Buffer


3M

M

S

Rocker arm monitor

Check correct functioning of proximity sensor

6M

E

S

Check fixing of proximity sensor

6M

E

S

Check electrical connections

12 M E

S

Tab. 26: Maintenance table, rocker arm

168



11.4.6.1 Auxiliaries: Rocker arm (M) cpl. Installing/removing the rocker arms Before swinging out the rollers, it is necessary to release or remove the following connections: – Flange-sleeve connection between fork and axle – Taper-pin connection of arm and fork Note See also construction drawing "Rocker arm cpl.".

1 2 3 4

5 001143

6

Fig. 64: Flange-sleeve connection Key 1 Flange sleeve 2 Jacking screw 3 Axle 4 Clamping sleeve 5 Rocker-arm fork


169


9

1 2

8 3 4 5

6

000528

7

Fig. 65: Taper-pin connection Key 1 Rocker-arm fork 2 Connecting screw 3 Cover 4 Disc springs (removed !) 5 Hexagon screw + washer

6 7 8 9

Taper pin Cover screw Sleeve Central arm of rocker arm

Disassembly WARNING Heavy, moving machine parts! If you do not follow the instructions, there is danger of acute injuries and machine parts can not be assembled. ● Depressurise the hydraulic system prior to disassembly. ● Release the connecting screws only after separating the taper-pin connection. a) Remove the taper pin ● Release the cover screws and remove the cover ● Remove the disc springs ● Reinstall the cover with cover screws ● Twist the hexagon screw with washer into the taper pin until the taper pin is released from the sleeve ● Unscrew the cover and remove the taper pin and sleeve ● Slacken but do not remove the connecting screws between fork and arm b) Remove the flange-sleeve connection ● Release and remove the fixing screws 170


LOESCHE Mill with Classifier Maintenance ● ● ●

Insert the jacking screws until the flange sleeve is released Withdraw the flange sleeve up to the bearing block Remove the connecting screws between fork and arm

Assembly Note 

Ensure conditions of absolute cleanliness and use assembly grease during assembly operations

a) Insert the connecting screws between fork and arm hand-tight b) Establish the flange-sleeve connection ● Remove the jacking screws without fail ● Prior to assembly degrease all the seating surfaces and treat with anitcorrosion agent ● Firmly tighten the flange sleeve using the fixing screws c) Establish the taper-pin connection ● Slide the sleeve with slot downwards into the bore for arm and fork ● Tighten the connecting screws to the torque specified in the drawing "Rocker arm cpl.“ ● Guide the taper pin into the sleeve ● Lay the disc springs on the taper pin and tighten the cover and cover screws up to the stop


171


11.4.7 Maintenance: Roller NOTICE Component breakage hazard! ● All parts must be regularly checked for radiation or impact abrasion and must be replaced if necessary. ● Repair welding may only be carried out in consultation with the manufacturer as far as possible.

S-roller When the S roller is removed, it is swung out together with the mill body cover (see "Swinging device cpl." assembly). Note Only in case of clamping sleeve connection! Observe during assembly the drawing information on the position of the slits in the conical sleeves. The slit in the taper sleeve must be caulked gas-tight with lead in accordance with the design drawing ("Rocker arm (S) cpl.") so that no sealing gas can escape or so that no dust can enter.

172

●

Check the slip-ring seal regularly (see "Slip-ring seal cpl.")

●

Oil level - check using the oil dispstick supplied The dipstick features 2 markings. The lower marking applies to new grinding parts, the upper marking to worn grinding parts. Top up oil to the upper marking no later than after 3000 operating hours.

●

Checking the roller bearings 1. Close off the drill hole in the roller axle to prevent oil discharging from this area 2. Bring the S roller into the vertical position using the swinging device 3. Remove the hub cover, check the bearings 4. When you refit the hub cover, you must always fit a new O-ring. You may only use cast O-rings in accordance with the parts list specifications. 5. Tighten the cover bolts in accordance with information in the drawing and secure the bolts. 6. The inspection cover in the hub cover can be opened to enable the spherical roller bearing to be inspected occasionally. Make sure when reattaching the cover that it is adequately sealed and secured.



M-roller ● Ensure the mill is running smoothly (tight closing of sliders and flaps in gas piping; dam ring height...). ● Ensure the dam ring height remains at the same height above the milling route around its whole circumference ● Set the roller force in accordance with the spring diagram ● Check the effectiveness of sealing air sealing by placing the flat of your hand on the drillholes leading outwards from the sealing cap through the rocker arm. Your hand must be noticeably sucked in if the sealing function is correct. If this is not the case, either the gap between the sealing sleeve and the sealing cap on the rocker arm has become too large due to wear, or the sealing cap has become soiled with dust on the inside. ● In the first case, the 2-part rings on the sealing sleeve which form the rinsing air gap must be replaced; In the second case, these spaces should be cleaned out as quickly as possible by removing the complete rollers, otherwise there is serious danger of damage to the roller bearings. ● Removing the roller 1 Swing the roller out of the mill together with the rocker arm 2 Release the clamping sleeves in accordance with the "Auxiliary equipment cpl." instruction manual 3 When reassembling, note the location of the slits in the conical clamping sleeves in accordance with the drawing 4 Caulk the slits in the taper sleeve in accordance with the group drawing ("Rocker arm (M) cpl.") gas tight with lead so that no sealing gas can escape or so that no dust can enter. ● Checking the roller bearings: 1 Close off the sealing air drill hole in the roller axle in accordance with information on the drawing to prevent oil discharging from this area. 2 Bring the roller into the vertical position using the swinging-out device. 3. Remove the hub cover, check the bearings 4. When you refit the hub cover, you must fit a new O-ring in each case. You may only use cast O-rings in accordance with the parts list specifications. 5. Tighten the cover bolts in accordance with information in the drawing and secure the bolts.


173


Slip-ring seal (M- and S-rollers) NOTICE Possible risk to machine! ● Note limit temperature! Exceeding the contractually agreed limit temperature for the male leads to hardening of the elastomer O-rings and therefore to early failure of the seal. The slip-ring seal is a wear part, and therefore leads to be replaced regularly (at the latest before each major change) to avoid damage to the roller bearings due to leakage. The condition of the slip-ring seal can only be checked indirectly. When the rollers are swung out, the oil runs downwards out of the roller bearing space through the central drillhole in the axle. If the drained-off oil has heavy colouring due to microscopic suspended particles, it is possible that the slip-ring seal is worn. ● In this case, disassemble the rollers and check the condition of the slip ring. ● Slip rings should only be replaced as pairs. Tire A tire profile ruler has been supplied with the "Auxiliary equipment cpl." assembly for checking roller tire wear. You can find information about setting it up and using it in the chapter "Auxiliary equipment: Tire profile ruler". ● When hard-facing the roller tire, observe the instruction manual for the mobile welding equipment (see manufacturer's documentation). Component

Description

I

MP

OC

Tire


6W

M

S


6W

M

S

Check for ease of rotation

6W

M

S

Check distance between roller and milling route, adjust if necessary

6W

M

S

Check distance between tire and wear ring

6W

M

S

Check oil level and top up if necessary

6W

M

S

Check for oil leakages

6W

M

S

Check guard for damage, wear and correct fixing

6W

M

S

Check to see whether material is located between guard and roller axle

6W

M

S

Check to see whether sealing air gaps are blocked

6W

M

S

Roller axle

Tab. 27: Maintenance table, roller

174



11.4.7.1 Auxiliaries: Roller (M) cpl.

1

2

30°

30°

9 8

10

3

7 5 001142

6

4

Fig. 66: Auxiliary equipment: roller (M) cpl. Key 1 Roller (M) 2 Eye bolt 3 Rocker arm (M) 4 Block (see swinging device cpl.) 5 Hand pump

6 7 8 9 10

Hydraulic jack Support Claw ring Distance ring Ring

Disassembly/assembly of the roller a) Disassembly To dismantle the rollers, in other words to pull the rollers out of the rocker arm, lifting eye nuts and/or eye bolts are provided. Please see the drawing entitled "Auxiliaries: roller cpl." for details. ● swing out rollers ● screw eyebolts into hub cover ● loosen and remove fixing bolts on roller axle ● bolt ring onto claw ring ● bolt hydraulic pressing cylinder into ring ● use hand lever pump from spammer assembly aids to press roller axle out of rocker arm ● use crane to pull rollers out of lever.


175


b)

Assembly

Note 

Clean clamping sleeve bracing surfaces and treat with roller bearing lubricant to prevent fretting corrosion



Align notches on front face of roller axle in accordance with drawing "Roller cpl."



Caulk slots in taper sleeve in accordance with drawing "Rocker arm cpl." with lead

● ● ●

Refitting generally takes place in reverse sequence. The roller should be fixed in a position stated on drawing "Roller cpl.". If a temperature sensor is fitted, see "Roller temperature monitoring cpl." operating manual.

1

5 2

4

000855

3

Fig. 67: Auxiliary equipment: roller cpl., roller bearing removal Key 1 Hand pump 2 Hub 3 Roller axle with bearing

176

4 Jacking screw 5 Bearings



Removing the roller bearings A so-called hydraulic brace is provided to facilitate removal of the roller bearings from the roller. ● Pump highly viscous oil into the channels in the roller bearing seat using the hand lever pump which is required for disassembling the table and roller. The oil expands the bearing seat in its hub, which simplifies disassembling the bearing. ● To disassemble the bearings, connect a hose with the appropriate bore hole in the hub. This is normally plugged with a threaded plug (see drawing "Roller cpl."). ● Screw bolts into the hub bores to press the roller bearings out of the bearing seats.


177


11.4.7.2 Auxiliaries: Roller (S) cpl.

1 max. 30°

2 3

000785

4

Fig. 68: Auxiliary equipment: roller (S) cpl. Key 1 Hand pump 2 Upper roller bearing 3 Hub 4 Lower roller bearing

Disassembly of roller bearings A so-called hydraulic brace is provided to make disassembling the roller bearings from the roller easier. ● Pump highly viscous oil into the channels in the roller bearing seat using the hand lever pump which is required for disassembling the table and roller. The oil expands the bearing seat in its hub which simplifies disassembling the bearing. ● To disassemble the bearings, connect a hose with the appropriate bore hole in the hub. This is normally plugged with a threaded plug (see drawing "Roller cpl.").

178



11.4.7.3 Auxiliary equipment: lifter cpl.

1

6

2 5 3

001145

4

Fig. 69: Lifter cpl. Key 1 Chain 2 Hook 3 Holder

4 Hub 5 Tire 6 Lug at holder

The tire is raised for installation or removal with the lifter and hoisting gear. The load-bearing capacity corresponds to the weight of a new tire.


179


Changing the tire DANGER Lifted loads! Misuse may lead to danger for life due to falling loads. ● Check that the lifter is in perfect condition prior to use. ● Do not under any circumstances exceed the lifter's maximum load-bearing capacity (see drawing "Lifter cpl."). ● Use the lifter only to transport the tire. ● It is not permitted to raise the roller with the lifter. ● Do not stay under lifted loads The roller tire and the hub are designed with a small clearance so that assembly and dismantling can be easily accomplished. On assembly, the roller tire must have at least the same temperature as the hub. If this is not the case, the tire may be gently warmed with a soft flame or heating blankets in the area of the cylindrical seat until it has attained a temperature of 30° to 40°C above that of the hub.

3 4 6

1

5

001366

2

Fig. 70: Changing the tire Legende 1 Tire 2 Clamping ring 3 Tee head bolt

180

4 Disc spring 5 Nut 6 Flat bar



Dismantling ● Swing the roller with rocker arm out of the mill ● Release the nuts of the tee-head bolts ● Remove the tee-head bolts and roller clamping ring ● Release the tire from the hub. To do so, heat the tire evenly over its entire circumference by 30 ° to 40 °C with a weak flame or a heating blanket ● Remove the now loosened tire from the hub with the lifter

Assembly If necessary, warm the cylindrical seat of the tire as described above. The assembly of the tire is accomplished in the reversed sequence like the dismantling. ● Tighten finally disc spring up to block ● Turn back nut by 40 ° and secure it with flat bar


181


11.4.7.4 Auxiliary equipment: tyre profile ruler cpl.

1

X

2

4

10

4

001144

X

3 Fig. 71: Tire profile ruler cpl. Key 1 Profile ruler 2 Tire 3 Hub 4 Holder

●

Check the wear of the grinding parts in accordance with the maintenance schedule so as to be able to provide clear statements about the anticipated service life and to provide comparisons of the grinding-stock and wear-part quality during replacement. Comparable measurements can be performed with the tire profile ruler. ● Mount the tire profile ruler as shown in the drawing "Tire profile ruler cpl.". ● Adjust the ruler during the first measurement to a distance of approx. 10 mm to the tire surface. This distance vary slightly on new tires on account of the unfinished-casting tolerance. The actual distance when new must be noted down and subracted from the respective profile (tread) depths. ● Document the measured values. Note We recommend our pre-printed  form 3.F 1158 for documenting and evaluating the measurement results.

182



11.4.7.5 Auxiliaries: Oil drain device cpl. Oil drain device for the grinding roller

X 5

7

X

7

6 5

4

3

1

001146

2

Fig. 72: Oil drain device (M) cpl. Key 1 Roller swung in 2 Oil drain hose 3 Sealing nipple 4 Roller swung out

5 Plug 6 Adaptor 7 Quick-release coupling

During the swinging-out movement of the roller, the oil, intended for the lubrication of the roller bearings, returns through the breather bore of the roller axle. The swinging-out procedure should be slow enough to give the oil sufficient time, even at low temperatures and high viscosity, to flow to the rear end of the roller axle. Conversion Sequence: ● Disconnect the two hoses from the rear end of the roller axle. ● Remove all three adapters. ● Install the new adapter with sealing ring, the two fittings and the self-sealing coupling into the upper right hand tapped hole. ● Seal the two remaining holes with plugs and sealing rings. P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

183


● ●

After swinging-out the roller, fit the selfsealing coupling onto the oil suction hose (larger diameter) and connect to the previously fitted coupling on the axle. Whilst the oil flows away to the tank the upper left plug must be removed to allow air to replace the oil. Watch the oil level in the sight class of the HSMS. When it ceases to rise the bulk of the oil will have been drained from the roller.

Note More information can be seen in the drawing "Oil Drainage cpl.".

Oil drain device for the support roller

1 2 3

000526

4

Fig. 73: Oil drain device cpl. Key 1 Slide 2 Roller axle 3 Transparent hose 4 Collecting container

When the roller is swung out, the oil which lubricates the roller bearings flows back through the central bore of the roller axle. ● Remove the wet air filter. ● Install the adaptor and the gate valve. ● Install the slide with a transparent hose. The oil return flow can be observed through the hose. ● Feed the hose into a collecting container of sufficient size. The size of the collecting container can be determined using the LOESCHE lubricant table. ● Swing out the roller slowly so that the oil, even at low temperatures and with high viscosity, has sufficient time to flow to the end face of the roller axle. ● Refill the mill with the drained oil or with fresh oil prior to start-up. 184



11.4.8 Maintenance: Spring assembly cpl. WARNING Hydraulic overpressure! Possible serious injuries ● To prevent accidents, any maintenance work on a hydraulic system may only be carried out once the oil pressure has been completely relieved.

Lubrication The rod head and hydraulic cylinder roller bearings are kneaded full of grease. Re-greasing the bearing takes place using a hand grease gun on the grease nipples at long periods in accordance with the maintenance table. The piston and piston rods in the hydraulic cylinder are lubricated automatically by the hydraulic oil. The maintenance table also applies to oil changes in this case. Leaked oil Lubricant replacement takes place according to the information in the maintenance table. Leaked oil from the piston rod-sided working space which flows past the piston seals is automatically transported back into the tank via the piston-sided cylinder space by piston movements. If leaked oil quantities become too large, this can be seen in the shortened switch-on intervals used by the high-pressure pump because the working pressure is dissipated very quickly. In this case, the seals need to be replaced on the piston. Leaked oil in the piston rod movement area of the cylinder is visible from outside and points to wear in the sleeve gaskets. Couplings ● Check all hose, tube and flanged couplings regularly. Since the hydraulic piping is subject to pulsating pressure, it is possible that some couplings will loosen during operation. ● Always retighten loosened couplings immediately. Hoses ● Check hoses in the cylinder area, especially after fitting work, for external damage or ageing cracks. Replace them if necessary. Hydraulic accumulator The hydraulic accumulator is supplied with a gas filling pressure of 1 MPa (=10 bar) so that the oil valve located in the floor can be closed safely and so that the oil chamber is protected against the penetration of foreign bodies. You can find more information in the separate HSLM operating manual. Hydraulic cylinder The hydraulic system needs to be depressurised before carrying out any maintenance work on the hydraulic cylinder. Once the covers have been removed from the mill stand, the bolts can be pulled out of the hydraulic P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH

185

LOESCHE Mill with Classifier Maintenance cylinder. After this, take the bolts out of the rod head in a similar manner, uncouple the hydraulic piping and dismantle the hydraulic cylinder. Please see the manufacturer's documentation for more information. Roller bearings If there is bearing damage to the rod head or a rod end bearing on the hydraulic cylinder, the corresponding bearing bolts must be drawn. The spherical roller bearing seat on the bolts should be treated with roller bearing lubricant when replacing bearings so that removing the bolt is made easier. Otherwise, roller bearings are maintenance-free. Component

Description

I

MP

OC

Piping

Check fixings

6M

M

S

Check for rust and surface damage

6M

M

S

Check connections for tight seating and safety

6M

M

S

Check fittings for tight seating and sealtightness

6M

M

S

Check hoses for wear

6M

M

S

12 M M

S

Check rod head seals

6M

M

S

Check leakage oil container, empty if necessary

1W

M

S

Check bearing fixing bolts for tight seating

12 M M

S

Check bearing play

24 M M

S

Lubricate bearing

1W

M

S

Check base eye

6M

M

S

Check clamping nut bolts for completeness and tight seating

6M

M

S

Check boot for tight seating

6M

M

S

Check boot for damage

6M

M

S

Lubricate rod head

1M

M

S

Hydraulic cylinder Check fixings

Tab. 28: Maintenance table, spring assembly

186



11.4.8.1 Auxiliaries: Spring assembly (M) cpl. WARNING Hydraulic overpressure! Direct risk to life and limb ● To prevent accidents, all maintenance works are only permitted when the hydraulic system (HSLM) is depressurised! Crushing hazard! The tasks described pose a potential crushing hazard between the springassembly cylinder and the pedestal or the mill stand. ● Ware personal protective equipment. ● Ensure that there is a sufficient spacing.

NOTICE Possible risk to the machine! ● Observe the drawing "Auxiliary eqpt.: spring assembly, cpl." without fail in order to avoid personal injury and/or machine damage. ● Make sure when using spindles that the collar nut is correctly aligned during removal and installation. ● Before the clamping nut is reassembled, the spring rod has to be extended with the provided auxiliary to the dimension given in the drawing.

The work sequences of disassembly and assembly of the bolts, rod heads and the hydraulic cylinders are described step by step in the detailed drawings "Aux.: Spring Assembly (M); cpl.".


187


11.4.8.2 Auxiliaries: Spring assembly (S) cpl. The pins for connecting the hydraulic cylinders of the S spring assemblies to the S rocker arms and the covers of the mill body can be easily removed and installed using the auxiliary equipment. Note The spindle used as a tension or thrust rod should be treated with grease prior to use so as to ensure smooth handling.

Dismantling

1

2 3

5

000529

6

4

7

Fig. 74: Dismantling the spring pin Key 1 Rocker arm (S) 2 Bell housing 3 Collar nut 4 Spindle

5 Disc 6 Spring pin 7 Hand pump

In the event of roller bearing damage and when dismantling the hydraulic cylinder, the pins must be pulled out of the respective bores. The seat of the spherical roller bearing on the pin can be hydraulically expanded using the oil injection expansion method: ● Remove the discs with the bolts which are located in the pin at the end face. ● Connect the hand pump (included in the delivery specification) via a hose to the pin at one end. ● Then force the pin out of the bores using the supplied device. Support the procedure hydraulically with the hand pump.

188



Assembly

000530

3

Fig. 75: Assembling the spring pin Key 3 Collar nut turned!

The pin is reassembled with the same device, with the collar nut inserted on the other side.


189


11.4.9 Maintenance: Hydraulic accumulators Mineral oils release certain quantities of gases which can discharge from the mill during operation. Since this air bubble formation can lead to damage to hydraulic components, the hydraulic system needs to be regularly vented after initial start-up (monthly). The gas quantity is operationally and medium-dependent. For this reason, the intervals between venting measures must be adapted to the operating conditions. Measuring connections located in several locations around the hydraulic system are used for venting (e.g. cylinder, accumulator etc. - see assembly drawings). The venting process must be carried out until gas-free oil discharges! Technical monitoring of pressure tank Hydraulic accumulators are pressure tanks and must be subjected to a pressure test at regular intervals, which must be carried out in accordance with the relevant regulations for the country of use by a technical monitoring body. In most countries, monitoring of pressure accumulators and equipment operated with pressure accumulators is prescribed. This must be carefully observed.

Bladder accumulator For mill operation, the bladder accumulator is filled with nitrogen from standard steel bottles with the help of a special filling device which is included in delivery. The filling pressure can be read off from the pressure gauge fitted to the filling unit. As delivered, the accumulators are normally filled with sufficient nitrogen filling pressure so that the rubber bladder fills up the entire steel enclosure, in other words is lying in close contact with the enclosure and closes the oil-sided mushroom valve. This prevents penetration of dirt into the hydraulic working space in the accumulator. You must ensure that the gas valve is sealed off via the shut-off cap belonging to the accumulator. The gas valve alone does not seal off sufficiently tightly. Filling up with gas DANGER Explosive materials! Only nitrogen gas (N2) has to be used to fill up the rubber bladder in the accumulator or in the piston accumulator. The nitrogen gas (N2) purity has to be at last 99,995 %, filtered < 3 µm. Oxygen or air could cause explosions in connection with oil.

190



Setting the valve (for N2 filling pressure checked and N2 pressure increase) To check the correct nitrogen filling level both for the hydraulic bladder accumulator and the hydraulic piston accumulator, it is absolutely imperative that the pressure on the oil side is completely vented. For this purpose: ● set the main switch to the "manual operation" position", ● open the stopcock in accordance with the function table on "Scheme: hydraulic HSLM ...". If this rule is not observed, the incorrect N2 pressure will be displayed or filled up. In addition to this, the accumulator bladder can be destroyed. Checking interval for controlling gas filling pressure After initial start-up, the gas pre-filling pressures in the bladder accumulator must be checked at regular intervals and corrected if necessary. – After the 1st week; – After the 4thweek; – After the 3rd month; – Half-yearly. Component

Description

I

MP

OC

Bladder accumulator

Check pressure, refill with NITROGEN (N2) if necessary (see above)

3M

M

S

Check bladder sealtightness

12 M M

S

Check to see that connections are tight and correctly positioned

12 M M

S

Check bottle for tight seating and correct position

12 M M

S

Check bottle for rust damage and wear

12 M M

S

Check to see that valve is secured, tightly seeded and undamaged

12 M M

S

Tab. 29: Maintenance table, bladder accumulator


191


Piston accumulator Filling of the top piston accumulator with nitrogen takes place in a similar manner. For more information, see manufacturer's documentation for the "Spring assembly cpl." assembly in the mill. It is possible that gas losses can occur due to operational conditions at the piston accumulators, and on the other hand oil can be transported to the gas side by the piston movement. For this reason, the following checks should be carried out at regular intervals: Checking the gas pre-filling pressure in the piston accumulator: – if there is a pressure loss of ≥ 30 % of the original filling pressure, only one refilling is necessary. – if there is a pressure increase of ≥ 30 % of the original filling pressure, there is a danger that oil is present in the gas-side accumulator space Checking procedure: 1 Vent the gas completely using the fill and test unit. Open the valve screw by 1.5 turns. 2 Remove the fill and test unit. 3 Fit a plastic hose (provided by customer) over the gas valve body. Put the free end in a collecting trough (provided by customer). 4 Press the "Raise rollers" button on the hydraulic cabinet. If the pump is running, the accumulator piston will be moved upwards and presses the oil out of the gas-side space. 5 Remove hose, fit fill and test unit and refill the accumulator with gas again (see chapter "4.3 Filling the hydraulic accumulator"). 6. Checking intervals: – After the 1st week; – After the 2nd week; – After the 4th week; – monthly; – After the 6thmonth - half yearly.

192



11.4.9.1 Auxiliary equipment: Fill and test unit cpl. DANGER Explosive materials! ● Only nitrogen gas (N2) may be used to fill up the rubber bladder in the accumulator or in the piston accumulator. Oxygen or air can cause explosions in connection with oil.

This device is a combined item of auxiliary equipment for filling the bladder and piston accumulators with nitrogen and a measuring instrument. The gas pressure in the hydraulic accumulators can be measured with the aid of the fill and test unit. Filling and gas-pressure measurement may only be carried out after the oil pressure has been reduced (see supplier's instruction manual).

Note The fill pressure of the bladder accumulators must be selected in correct relation to the hydraulic working pressure. Refer to the "Diagram: spring stiffness" for the permissible limit values (see documentation parts list "HSLM").


193


11.4.10 Maintenance: Hydraulic cabinets WARNING Hydraulic overpressure! Possible serious injuries ● To prevent accidents, any maintenance work on a hydraulic system may only be carried out once the oil pressure has been completely relieved.

Hydraulic oil ● Use only the specified hydraulic oil in accordance with LOESCHE recommendations. The cleanliness class of the hydraulic oil used should meet the requirements of ISO 4406 19/17/14 at the very least. ● Observe the specified oil change intervals. ● Always fill the hydraulic system using a suitable filtering system (which meets the specified cleanliness class) with fresh oil.

Component

Description

I

Hydraulic cabinet

Check for damage

12 M M

Op

Check for rust and surface damage

12 M M

Op

Function check

12 M M

Op

Check for easy running

6M

M

Op

Check oil level and correct if necessary

3M

M

S

Check oil quality, replace if necessary

6M

M

S

Check all connections for tight seating

6M

M

Op

Check filter for deposits and damage

6M

M

S

Replace filter

6M

M

S


3M

M

Op

Check warm start-up

3M

M

Op

Check correct fixings

3M

M

S

Lubricate bearing

3M

M

S

Check cooling air connection for cleanliness

3M

M

S


12 M E

S

Function check

12 M M

Op

Check for leaks

12 M M

Op

Check for damage

12 M M

Op

Check 0 point when depressurised

12 M M

S

Pump

Motor

Pressure gauge

194

MP

OC



Component

Description

Solenoid valve 7.x Function check

Valve 5.x

I

MP

OC

12 M M

Op

Check for tight seating

12 M M

Op

Check for damage

12 M M

Op


12 M E

Op

Function check

12 M M

Op

Check for tight seating

12 M M

Op

Check for damage

12 M M

Op


12 M E

Op

Tab. 30: Maintenance table, hydraulic cabinet


195


11.4.11 Maintenance: LM-Drive NOTICE Possible risk to the machine! Strong currents are produced during electrical welding work, which can damage sensitive components. The earth must be connected immediately next to the welding location during all welding work on the grinding plant to avoid bearing damage. It is also important to connect the earthing cable to the gearbox (see gearbox manufacturer's documentation).

Component

Description

I

MP

OC

Motor


6M

M

Op

Check warm start-up

6M

M

Op

Check fan

12 M M

S


12 M E

Op

Lubricate bearing

6M

M

Op

Check motor fixing

3M

M

Op

Check slip ring for wear

12 M E

S

Check carbon brushes for wear, replace if necessary

12 M E

S

Check rectifier for wear

12 M E

S


6M

M

Op

Check temperature

6M

M

Op

Check oil level and top up if necessary

3M

M

S

Check coupling for wear, check alignment

6M

M

S

Check electrical connections to the thermoelement connected

12 M M

S

Check clearance X (gearbox output flange to gearbox housing)

12 M M

S

Check all connected pipes and hoses for damage

6M

M

S

Check all connected tubes and hoses for tight seating

6M

M

Op

Gearbox

Tab. 31: Maintenance table, LM drive

196



11.4.12 Maintenance: Gearbox lubrication unit

Component

Description

I

MP

OC

Low pressure pump

Function check

3M

M

Op

Check for easy and constant operation

3M

M

Op

Check for leaks

3M

M

Op

Check connections are tight

3M

M

Op

Check for leaks

6M

M

Op

Check filter for deposits and damage

6M

M

S

Function check

3M

M

Op

Check for easy and constant operation

3M

M

Op

Check for leaks

3M

M

Op


3M

M

Op

Check for ease of movement

12 M M

Op

Check for warm running

12 M M

Op

Check ventilation grille

12 M M

S

Lubricate bearing

3M

M

S


12 M E

S

Check motor fixing

12 M M

S

Function check

12 M M

Op

Check for leaks

12 M M

Op

Check 0 point when depressurised

12 M M

S

Temperature monitoring

Function check

12 M M

Op

Pressure switch

Function check

6M

M

Op

Check for leaks

6M

M

Op

Check piping fixings for sealtightness

6M

M

Op


12 M E

S

Function check

6M

M

Op

Check for leaks

6M

M

Op

Check piping connections for tight seating

6M

M

Op


12 M E

S

Check for damage and sealtightness

6M

M

S


6M

M

S

Filter High-pressure pump

Pump motors

Pressure gauge

Flow meter

Expansion joint

Tab. 32: Maintenance table, gearbox lubricating unit


197


11.4.13 Maintenance: Central lubrication unit ● ● ●

If there is mechanical damage to the pipes, rectify this immediately. Check hoses regularly for good condition. Replace them if necessary. Fill up the grease container in the lubrication pump regularly with the grease specified in the lubrication table. Ensure that the grease container cover is closed tightly to prevent penetration of dust.

Component

Description

I

MP

OC

Lubrication unit

Check lubrication lines for sealtightness

6M

M

Op


6M

M

Op

Check hoses for damage

6M

M

Op

Check lubrication points for sufficient supply

1M

M

Op

Function check

3M

M

Op

Check pump delivery rate

3M

M

Op

Check fill level of lubricant container, refill if necessary

6M

M

Op

Check for damage

6M

M

Op

Check the sealtightness of all connections

1M

M

Op

Check for leaks

3M

M

Op

Check the sealtightness of the gland box or slip ring

3M

M

Op


3M

M

Op


3M

M

S

Check motor fixing

3M

M

S

Lubricate bearing

3M

M

S

Check cleanliness of cooling air inlet

3M

M

S


12 M E

S

Lubrication pump unit

Motor

Tab. 33: Maintenance table, central lubricating unit

198



11.4.14 Maintenance: Sealing air system The pressure in the sealing air system is monitored by the "sealing air monitoring" unit. It triggers an alarm if there are irregularities in the sealing air flow. Possible causes for an alarm and the measures for rectification are described in the "Sealing air monitoring cpl." operating manual. ● Check the wear rings by remeasuring the diameter for wear if the rollers are disassembled during major inspections. ● Replace worn wear rings otherwise the sealing air gap will be too large. The resulting insufficient "sealing air sealing" can lead to the entry of foreign bodies and to subsequent damage to the roller bearings or the slip-ring sealing. Component

Description

I

MP

OC

Fan

Check for smooth operation

1M

M

Op

Check connections for damage and tightness

1M

M

S

Check fan grill for existence and fixing

1M

M

S

Check absorber elements for wear

6M

M

S

Check shaft cover plate for existence and fixing

1M

M

S

Check silencer for damage

3M

M

S

Lubricate bearing

3M

E

S


12 M E

Op

Check warm start-up

12 M E

Op

Clean grills

12 M E

S


12 M E

S

Check motor fixing

12 M E

S

Check for damage and fastening

3M

S

Motor

Coupling

M

Tab. 34: Maintenance table, sealing air system


199


11.4.15 Maintenance: Piping system WARNING Hydraulic overpressure! Possible serious injuries ● To prevent accidents, any maintenance work on a hydraulic system may only be carried out once the oil pressure has been completely relieved. ● ● ●

Maintenance on the piping is restricted to checks for sealtightness. Sealing of compression joints must take place in accordance with the manufacturer's instructions. If new welded piping is used, this must be de-burred and de-scaled and preserved immediately after cleaning. Test pressure: 210 bar, 2 hours!

11.4.16 Maintenance: Swinging device NOTICE Possible risk to machine! ● After use, hang up the hydraulic cylinder vertically or deactivate it. Otherwise the piston weight can permanently deform the sleeve gaskets which leads to lack of sealtightness. ● ● ● ●

Before swinging out, always check the bolts and joint seatings for damage and rust pocks. Do not disconnect the swinging cylinder from the roller during roller dismantling Protect the hydraulic cylinder and its piston rod from external damage. Keep high-pressure hoses in a place where they cannot be damaged. Only use hoses with a burst pressure of more than 200 bar.

Component

Description

I

Cylinder

Function check

12 M M

Op

Check for leaks

12 M M

Op

Function check

12 M M

Op

Check hydraulic oil fill level, refill if necessary

12 M M

S

Check hoses and connections for damage and sealtightness

12 M M

S/Op

HSAV

MP

OC

Tab. 35: Maintenance table, swinging device

200



11.4.17 Maintenance: Grinding bed sprinkler cpl. ●

● ● ●

Check the sprinkler pipes regularly for damage and free drillholes. They can be pulled from the outside out of the pipe holder for this purpose. If this is not possible, the pipe must be inspected inside the mill and if necessary repaired. Deposit build-ups should be removed if necessary. If replacement is necessary, the pipe can be cut through at the end of the pipe holder where necessary and the remainder pulled from the outside out of the holder. Protect the water hoses against mechanical damage. Replace them if necessary. Reseal the screw connections after repairs with sealing tape or hemp. Regularly check the pipe holders on the mill body for tight fitting.

Component

Description

I

MP

OC

Grinding bed sprinkler

Check sprinkler pipes for damage

1M

M

S

Check sprinkler pipes for free drillholes

1M

M

S

Check hoses for damage and sealtightness, replace if necessary

3M

M

S

Check pipe holders for tight seating

3M

M

S

Tab. 36: Maintenance table, grinding bed sprinkler


201


11.4.18 Maintenance: Classifier ● ●

● ●

●

●

●

● ●

●

Carry out regular visual checks of the machine for early detection of any possible damage. Checked all screwed/bolted connections regularly for secure seating. Treat all bolted threads with corrosion protection to prevent fretting corrosion and corrosion. Always remove deposits of grinding material from rotating parts immediately. Carry out regular checks on the lining (not standard) the blades and the guide vanes for wear. The covers in the classifier upper and lower housings should be opened or removed to carry out visual checks. In the case of large classifiers with accessible rotors, worn blades and guide vanes should be replaced from the inside of the rotor. The blades should be partially disassembled in order to replace the guide vanes. In the case of smaller, non-accessible classifiers, either the rotor or the guide vanes or the guide vane support segments must be lowered into the interior of the mill in order to replace worn blades and guide vanes. In both cases, the multiple-part grit funnel must be removed and if necessary the rollers swung out. If the blades are replaced, the rotor should be checked for sufficient balance. To do this, the blades are weighed individually and sorted so that each 2 strips of similar weights are mounted in opposing positions. When maintaining the bearings, ensure that the rotary shaft seal has the correct installation position in accordance with information on the drawings. During inspections, carry out regular checks to see that there is a sufficient grease collar on the rotary shaft seal on the rotor bearings. This will ensure that the bearing is lubricated sufficiently. When replacing the guide vane supports, ensure that the nuts are secured with tack welds after tightening.

Exchange of the classifier guide vanes, large classifier Dismantling ● Remove the inspection cover in the upper body of the classifier to gain access to the inside of the rotor. ● Grind off the tack-welds which secure the nuts ● Remove the screws on the guide vanes ● Remove the guide vanes from their carriers

Assembly The assembly of the guide vanes is accomplished in the reversed sequence to that of the dismantling. ● Tighten the screws of the guide vanes to the torque quoted in the drawing "Guide vanes cpl.". ● Secure the nuts with a tack-weld. ● Reinstall and secure the blades of the rotor. Rhombic hardfacing can slow down further wear on slit guide vane supports.

202



Component

Description

I

MP

OC

Housing


6M

M

B

Check paint finish for damage

6M

M

B

Check outside for rust

6M

M

B

Check weld seams are continuous

6M

M

B


6M

M

S

Check lubricant level and top up if necessary

6M

M

S

Check bearing play

6M

M

S

Check alignment and fastening

6M

M

S

Check for wear

6M

M

S

Check blades for damage and wear

6M

M

S

Check for imbalance

12 M M

B


3M

M

S

Check bolted connections

6M

M

S

Remove deposits

6M

M

S


6M

M

B


6M

M

B

Check lubricant level and top up if necessary

1M

M

S

Change lubricant

12 M M

S

Check for leaks

12 M M

S

Check thickness of coupling discs

6M

M

S

Check alignment

6M

M

S

Check fastening

6M

M

S


3M

M

B


3M

M

B

Check fastening

3M

M

S

Lubricate bearing

3M

M

S

Check cleanliness of cooling air inlet

3M

M

S


12 M E

S

Bearing cartridge

Guide vane Rotor Grit funnel

Gearbox

Coupling (clutch)

Motor

Tab. 37: Maintenance table, classifier


203


001383

11.5 Checks after maintenance work

●

● ● ● ● ● ●

Carry out a visual inspection in the electrical switching cabinet. Check: – the wiring for kinks, abrasions and burns, – the covers and insulation for damage, – the switching cabinet doors for ease of movement. Check if the protection conductor connections are tight. Make sure the repair work has actually been completed. Make sure that there are no tools in the machine and carry out a function test of the machine. Remove all tolle that you used for the maintenance work Carry out a function check of all the assemblies in Set-up mode and Manual mode. After checking and replacing spare parts and wearing parts, check the functionality of the installed safety systems (see Chapter "Installed safety systems Page 36").

When all the functions are fault-free, the machine is handed over to the operator.

204


LOESCHE Mill with Classifier Spare parts

12 Spare parts We expressly point out those spare parts and accessories which are not supplied by us were also not examined by us and released. The installation and / or use of such products may therefore affect the constructive given characteristics of your machine in a negative manner. For damage caused by the use of non-original parts and non-original equipment parts, the liability of the company LOESCHE GmbH is excluded. We recommend using only original LOESCHE spare parts for your own safety. Standard parts may be purchased from specialized dealers. Please refer to the  spare parts lists for information concerning the spare parts. Order information In order to avoid mistakes when ordering spare parts, please state the drawing number and the item number or send in a sample of the required spare part.


205

LOESCHE Mill with Classifier Decommissioning, dismantling and disposal

13 Decommissioning, dismantling and disposal 13.1 Qualifications of dismantling personnel Only (skilled) personnel who have undergone the requisite instruction/training are permitted to dismantle the machine in accordance with the instruction manual. Specialist skilled personnel need to be deployed for certain specialist areas, e.g. hydraulics and electrical engineering. 13.2 Requisite conditions for dismantling ● ● ● ● ● ● ● ● ●

You must run the machine completely empty (or, if it is part of a plant, as far as necessary) prior to dismantling. Remove general evidence of soiling. Components soiled with hazardous substances will need to be cleaned thoroughly. Set the main switch to "OFF" and lock it in this position. Disconnect the machine from the power supply and secure to prevent reconnection. Disconnect the machine. Depressurise pressurised components and connecting pipelines at the designated points. Allow components and connecting pipelines to cool down. Seal the connections on removing the lines. Release components under tension, such as springs and similar.

Collection of hazardous substances Used oils and operating supplies (drilling fluid, propellants, etc.) can contain hazardous substances. Clean components soiled with hazardous substances prior to disassembly. ● Collect used oil, grease and other harmful substances in containers and have them disposed of properly in compliance with legal requirements.

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LOESCHE Mill with Classifier Decommissioning, dismantling and disposal

13.3 Carrying out dismantling and disposal If the machine comprises a variety of recyclable materials or materials which need to be disposed of separately, dismantle the machine on this basis if at all possible. ● Dismantle the machine into units/pieces which can easily be transported. ● Dismantle the machine on the basis of the different materials which need to be separated. Compliance with legal requirements is mandatory! The machine must be disposed of in compliance with applicable laws and ordinances. Parts soiled with hazardous substances must be marked accordingly prior to shipment. ● Separate materials for disposal in material groups. – Dispose of metal parts as scrap steel – Dispose of non-ferrous metals for metal recycling – Dispose of plastics and compounds for plastic recycling – Dispose of electric/electronic parts as special waste

Note European law governing hazardous substances EU directives state that the owner of machinery which has come into contact with hazardous substances (acids, lye, solutions, etc.) shall be responsible for its disposal in an appropriate manner or for issuing an expert declaration in relation to the transportation of such machinery.


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LOESCHE Mill with Classifier Supplier documentation

14 Supplier documentation Note The general documentation contains a list of supplier documentation in table format. Each entry has an inventory code and is accompanied by a folder number for cross-referencing purposes, e.g. in the event of maintenance being required.

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Index Abbreviations................................................... 22 Assembly ................................................. 24, 131 Assembly instruction...................................... 132 Assembly Instructions.................................... 131 Assembly sequence ...................................... 132 Automatic mode............................................. 142 Auxiliaries Oil drain device cpl. .................................... 184 Rocker arm (M) cpl. .................................... 170 Roller (M) cpl. ............................................. 176 Roller (S) cpl............................................... 179 Spring assembly (M) cpl............................. 188 Spring assembly (S) cpl. ............................ 189 Auxiliary equipment Fill and test unit cpl..................................... 194 lifter cpl. ...................................................... 180 table cpl. ..................................................... 164 tyre profile ruler cpl..................................... 183

B Bladder accumulator...................................... 191 Book symbol .................................................... 20

C Checking the delivery status.......................... 128 Classifier drive cpl. ........................................ 112 Classifier housing cpl..................................... 106 Classifier lining cpl......................................... 110 Classifier lubrication line cpl. ......................... 113 Classifier outlet temperature monitoring.......... 40 Classifier temperature sensor cpl.................. 109 Classifier upper housing lining cpl................. 111 Classifier, design and construction................ 105 Cleaning......................................................... 155 cold start-up..................................................... 24 Cold start-up .................................................. 133 Cold start-up sequence ................................. 135 Commissioning ........................................ 24, 133 Contact protection ........................................... 38 Conversion table.............................................. 21 Counterpressure function ................................ 98 Customer service........................................... 151


D Decommissioning .......................................... 207 Delivery ......................................................... 115 Diagram: Spring stiffness ................................ 96 Disassembly .................................................. 207 Dismantling.................................................... 207 dismantling personnel, qualifications ............ 207 Disposal................................................. 207, 208

E Electrical engineering .................................... 147 Emergency stop system .................................. 37 Extent of cold start-up ................................... 134

F Faults............................................................. 148 Functional description ..................................... 51

G General maintenance information for assemblies and machines............................................ 158 Grinding bed sprinkler cpl. .............................. 60 Grinding parts cpl. ........................................... 66

H Hazardous areas ............................................. 31 Hydraulic monitoring........................................ 39 Hydraulic oil................................................... 195 Hydraulic system, grinding roller ..................... 93 Hydraulic system, support roller.................... 102

I Inspection ...................................................... 154 Inspection door................................................ 39 Installation ..................................................... 131 Instructed person............................................. 15 Instruction manual, notes ................................ 15 Intended use.................................................... 12

209


J

N

Joining parts on the construction site ............ 130

Name plate ........................................ 16, 92, 114

L

O

Leaked oil ...................................................... 186 Lever sealing (M) cpl. ...................................... 73 Lever sealing (S) cpl. ....................................... 81 Liability and warrant conditions ....................... 11 Lighting ............................................................ 28 Lining cpl.......................................................... 59 LM drive ........................................................... 65 Local control panels....................................... 141 Local operation .............................................. 141 Lock symbol..................................................... 20 LOESCHE mill ................................................. 53 Lubricating system fill level monitoring ............ 40 Lubrication ..................................................... 157 Lubrication line cpl. .......................................... 88

oil cleanliness class ....................................... 195 Operating and maintenance personnel ........... 36 Operating areas............................................... 31 Operating the grinding plant .......................... 144 Operation................................................. 25, 140 Operator, Duties of the .................................... 28 Operator, Obligations of the ............................ 23 Organisational issues ...................................... 26 Overload protection ......................................... 39

M Machine Description ........................................ 50 Mains isolator................................................... 37 Maintenance .................................... 25, 152, 157 Central lubrication unit................................ 199 Classifier ..................................................... 203 Gearbox lubrication unit.............................. 198 Grinding bed sprinkler cpl........................... 202 Hydraulic accumulators .............................. 191 Hydraulic cabinets ...................................... 195 LM-Drive ..................................................... 197 Mill body cpl. ............................................... 160 Mill stand cpl. .............................................. 159 Piping system ............................................. 201 Piston accumulator ..................................... 193 Rocker arms ............................................... 168 Roller .......................................................... 173 Sealing air system ...................................... 200 Spring assembly cpl. .................................. 186 Swinging device.......................................... 201 Table cpl. .................................................... 161 Maintenance works........................................ 152 Metal separation .............................................. 38 Mill body cpl. .................................................... 57 Mill stand cpl. ................................................... 54 Misuse, foreseeable......................................... 14

210

P Packaging...................................................... 115 Packaging, disposal ...................................... 130 Personnel, Obligations .................................... 23 Personnel, Requirements................................ 26 Pictorial symbols.............................................. 18 Plant control..................................................... 38 Plant identification ........................................... 16

R Reference documents ..................................... 16 Reference documents, installation ................ 131 Resting places and railings ............................. 38 Risks, electrical energy ................................... 27 Risks, harmful gases, vapours and dusts ....... 27 Risks, hydraulic and pneumatic energy .......... 27 Risks, vibration and noise ............................... 27 Rocker arm (M) cpl.......................................... 71 Rocker arm (S) cpl........................................... 80 Rocker arm monitor......................................... 39 Rocker arm monitor (M) cpl............................. 75 Rocker arm monitor (S) ................................... 82 Roller (M) cpl. .................................................. 67 Roller (S) cpl.................................................... 77 Roller grinding mill, interfaces ......................... 30 Roller relief pressure ....................................... 98 Roller rotation monitor ..................................... 39 Roller rotation monitor (S) cpl.......................... 79 Roller rotation monitor cpl. .............................. 69 Rotor cpl. ....................................................... 107 P09961-M10X00.980 en Rev. A The copyright for this document and all appendices is reserved by LOESCHE GmbH


S Safety............................................................... 23 Safety checks .................................................. 29 Safety instructions Classifier....................................................... 33 Hydraulic systems ........................................ 34 LOESCHE mill .............................................. 33 Operating phases ......................................... 24 Roller grinding mill components ................... 33 Swinging device............................................ 35 Safety requirements ........................................ 26 Safety systems ................................................ 36 Scope of supply ............................................. 115 Seal-air piping.................................................. 89 Sealing air monitor........................................... 39 Sealing air monitoring cpl. ............................... 90 Shutdown procedure ....................................... 32 Signal words .................................................... 17 Skilled worker .......................................... 15, 152 Slip-ring seal.................................................. 175 Slip-ring sealing cpl. ........................................ 70 Spare parts .................................................... 206 Specific types of risk........................................ 27 Standard transport sketches Classifier..................................................... 122 Hydraulic cabinets ...................................... 125 LOESCHE Mill ............................................ 116 Swinging device.......................................... 125 Start sequence .............................................. 143 Storage, supplied parts.................................. 128 Supplier documentation................................. 209 Swinging device............................................... 84 Swinging the grinding roller ............................. 84 Swinging the support roller .............................. 85 Switching symbol............................................. 20 Switching the grinding plant on and off ......... 142 Switching the plant off ................................... 145


Symbols........................................................... 16

T Table cpl.......................................................... 62 Technical Data ................................................ 41 Ambient data ................................................ 43 Classifier....................................................... 45 Coating and colours ..................................... 44 Electrical data............................................... 42 Hydraulic system .......................................... 46 LOESCHE mill.............................................. 44 LOESCHE roller grinding mill....................... 41 Production data ............................................ 42 Sealing air supply......................................... 43 Swinging device ........................................... 48 Water injection.............................................. 43 Temperature monitor, rotor bearings .............. 40 Transport ................................................. 24, 115 Crane.......................................................... 129 Fork-lift truck............................................... 129 Transport sketches........................................ 116 Transport, installation site ............................. 129 Troubleshooting............................................. 148 Type approval.................................................. 28

U Unlocking the Emergency Stop functions ..... 146

V Vibration monitoring ........................................ 38 Vibration monitoring cpl................................... 91

W Warm start-up................................................ 136 Weight ........................................................... 126

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Van Hanh May Nghien Xi Mang

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