34 MER Auxiliaries

Auxiliaries in Grinding Systems
© Holcim Group Support Ltd 2009

Generic flow sheet of a grinding system
2
Agenda
• Extraction and dosing equipment

 Vibrators
 Weigh belt feeders, etc.
• Mechanical and pneumatic conveying equipment
 Bucket elevators
 Belt conveyors
 Chutes (not covered)
 Continuous pneumatic pumps, two chamber pumps, air lifts, etc.
• Fans, blowers and compressors
• Dampers, gates, airlocks and valves
• Bag house and nuisance filters
• Heat generation equipment (open)
• Lubrication systems (open)
• Hydraulic equipment (open)
• Water injection equipment (open)
• Magnetic separator, metal detectors (open)
• etc.
3
Bucket Elevator, Types
• Types of bucket elevator Fig. 3: Example
round link chain
 Belt bucket elevator bucket elevator
 Round link chain bucket elevator
 Central chain bucket elevator
Fig. 1: Example belt

bucket elevator
Fig. 2: Example central

chain bucket elevator
Fig. 4: Example Fig. 5: Example

central chain bucket double central chain
elevator bucket elevator 4
Walk by inspection and downtime PMR’s
Walk by inspection Inspection of belt
bucket elevator
Inspection of round Inspection of round

chain bucket elevator chain bucket elevator
9
Typical damages
11
Measuring belt hardness
Analog Digital
Order new belt by hardness 85 Shore A
Replace when it reaches 90 Shore A 12

Bucket elevator chain wear measurement
• Average pitch elongation as wear indicator

• Average pitch = (xn- y) / n
• Wear [%] = (avg. pitchafter – avg. pitchbefore) / avg. pitchbefore x 100
= (avg. pitchafter / avg. pitchbefore - 1) x 100
13
Bucket elevator chain wear measurement
• Measurement of one double link

• Accurate measurement of double
links by using a caliper gauge
• Measuring the length
over two bushings
• Analysis of measurements
Chain type Ø (mm)

Bush Ø Bolt
(mm)
X50
(mm)
Xmax
(mm)
For the chain AU 01 37 25 180 183
type installed in AU 06 53,8 36,35 235,6 239,6
the respective
AU 13 58,8 39,7 240,6 244,6
conveyor,
AU 15 66,5 44,53 248,3 252,3
please refer to
AU 01.1 38 20 180,5 183
the general
AU 02.1 45 27 199,9 202,4
arrangement
AU 06.1 58 36,3 239,8 243,8
drawing
AU 13.1 63 39,7 245,3 249,8
AU 15.1 71 44,5 253,3 257,8
14
Why preventive maintenance???
18
Belt conveyors - maintenance / repair (1/4)
• Spillages Tensioning weight blocked
Return belt passing through spillage
19
• Wear parts are exchanged too

late
• Emergency repairs (partial
repairs) are not completed
within the next stop by a perfect
revision
Belt junction with

20
Clamps
• Insufficient Preventive Maintenance
 Roller, pulleys, conveyor belts, chute skirting
 Cablings, Electrical Installations
Misalignment of belt
21
• Insufficient regular routine inspections at conveyor
systems.
• Control of condition for conveyor belt, roles, pulleys,
brakes, return barriers, clamping stations, chute,
chute rubber
• Oil level checks, tightness controls with gear
• Lubricants
22
Pneumatic Transport Systems - Objectives
Maintenance of pneumatic transport systems is

intended to be a comprehensive training
package for all technical staff within our group
companies.
It provides the basic maintenance requirements
for pneumatic transport systems.
23
Pneumatic Transport Systems - components
Material Conveyed
Solids Feeder
Conveying Pipe
Air Supply Gas-Solids

Equipment Separator
Material Conveyed
27
Screw Pump - Operation
Material
Material
Moved to Material
Forced-in
Mixing Enters
against
Chamber Screw
pressure of
conveying
air
Material Conveying Air

Transporte Enters Screw
d Pump 30
Screw Pump Components
Supply Air
V-Belt Drive
System and Motor
Mixing
Picture: The Claudius Peters X-
Chamber Pump
Discharge Line
Pressure
31
Gauge
Most Common Problem Areas
• There are three areas of the screw pump system
that cause the majority of the maintenance issues.
 End Bearing Damage
 Screw Wear
 Flapper Valve Seating
35
End Bearings
• Contamination is the leading cause of bearing damage.
• Careful attention must be paid to the bearing seals,
particularly on the edges of the material.
• Wear and heat can reduce the effectiveness of the seal. In
order to help this, lubrication and purge air pressure is
needed.
• The discharge bearing is particularly susceptible to
contamination due to the force of the conveying air
36
Internal Wear of System
• Due to the abrasiveness of the material and the
velocity of the air, wear can be a problem.
• Careful attention to wear rates on screw and barrel
bushings is required.
• Ensure air supply is shut off when the pump is
empty to avoid unnecessary wear.
Three Barrel
Bushings
Screw
Pump
System 38
Batch System
• A batch system ( “pressure vessel” or “pressure
tank” system) is used for pneumatic conveying of
pulverized material, particularly raw meal and
cement.
• The batch system transports material by alternately
filling and emptying on a fixed cycle.
42
Principle Cycle of a Batch system
1. Filling 2. Pressurizing
4. Venting 3. Conveying
43
Air Lift System
Transport
Pressure Line
Relief or Vent Material
Feed
Material
Column
Internal
Conveying Pipe
Nozzle
Aeration
Floor
Supply
47
Air
Fans - Types
Radial fan
Axial fan
55
Typical problems in fans
57
Main causes
• Operation and process causes:
 Speed of the fan above or below design parameters
 Operation near critical speed.
 High system resistance (drop pressure)
 Changes in gas flow density.
 False air
 High moisture or sticky particles content in gas flow
• Mechanical causes:
 Imbalance, inlet miss adjustment, ducts or vanes malfunction
 Bearings, coupling or motor
 Fixation and cracks
 Lubrication
 Resonance
 Deformation and high temperature damage
58
Preventive activities
• Adequate startup and stop procedures
• Adjust control settings and alarms
• Reduce false air inlet
• Reduce drops of pressure (vanes, ducts, joints, etc)
• Proper lubrication
• Preventive maintenance
59
Recommended PMR’s
• Walk by inspections
Check that all guards and covers are securely fastened.

 Pay attention to any abnormal noise or vibration.
 Measure temperature of bearing housings.
 Inspect bearing seal for leaks
 Inspect fan for abnormal noise
 Lubrication and inspection of oil levels
• Downtime PMR’s
 Vibration measurements (misalignment, unbalance,
looseness, resonance, bearing condition, etc.)
 Inspect for excessive wear (housing, seals, impeller, ducts,
blades, etc)
 Perform pressure measurements
 Impeller cleaning and coating
60
Vibration measurements
#
Location Direction Parameter
Horizontal Vertical Axial Bearing Vibration(mm/s,
(gSE, SPM) RMS)
1 Motor, NDE X X X
2 Motor, DE X X X
3 Motor, DE X X
4 Motor, DE X X
5 Fan, DE X X X
6 Fan, DE X X
7 Fan, DE X X
8 Fan, DE X X X
9 Fan, DE X X 61
Dampers, gates, airlocks and valves
• Tripple gate
62
Dampers, gates, airlocks and valves
• Shut off damper
63
Bag house and nuisance filters

Daily Maintenance
• Check pressure drop

• Monitor gas flow rate
• Observe stack outlet, visually otr with continuous
monitor
• Monitor cleaning cycle, pilot lights or meters on control
panel
• Check compressed air on pulse-jet baghouses
• Monitor discharge system; make sure dust is removed if
needed
• Walk through bag house inspection to check for
abnormal visual conditions
68
Weekly Maintenance
• Check all moving parts on discharge system and screw

conveyor bearings
• Check damper operation, bypass and isolation
• Spot check bag tensioning on reverse air and shaker bags
• Check compressed air lines including line oilers and filters
• Blow out U-tube manometer or Photo helic gauge lines
• Check accuracy of temperature gauges
• Check cleaning sequence to see that all valves are seating
properly
• Check drive components on fan
69
Monthly Maintenance
• Spot check bag connection condition

• Check all moving parts on shaker baghouses
• Check fan for corrosion and blade wear
• Check all hoses and clamps
• Spot check for bag leaks and holes with Dye
• Inspect bag house structure for corrosion
70
Quarterly Maintenance
• Thoroughly inspect the bags

• Check ducts for dust buildup
• Observe damper valves for proper seating
• Check gaskets on all doors
• Inspect paint on bag house
• Calibrate opacity monitor if required
• Inspect baffle plate for wear
71

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Auxiliaries in Grinding Systems

© Holcim Group Support Ltd 2009

• Extraction and dosing equipment

Fig. 1: Example belt

Fig. 2: Example central

Fig. 4: Example Fig. 5: Example

Inspection of round Inspection of round

Order new belt by hardness 85 Shore A

Replace when it reaches 90 Shore A 12

• Average pitch elongation as wear indicator

= (avg. pitchafter / avg. pitchbefore - 1) x 100

• Measurement of one double link

Chain type Ø (mm)

Return belt passing through spillage

• Wear parts are exchanged too

Belt junction with

Maintenance of pneumatic transport systems is

Air Supply Gas-Solids

Material Conveying Air

• Adequate startup and stop procedures

• Adjust control settings and alarms

• Reduce false air inlet

• Reduce drops of pressure (vanes, ducts, joints, etc)

 Pay attention to any abnormal noise or vibration.

 Measure temperature of bearing housings.

 Inspect bearing seal for leaks

 Inspect fan for abnormal noise

 Lubrication and inspection of oil levels

• Shut off damper

© Holcim Group Support Ltd 2009

• Check pressure drop

• Check all moving parts on discharge system and screw

• Spot check bag connection condition

• Thoroughly inspect the bags

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