FS F.L.SMIDTH INSTRUKTIONER INSTRUCTIONS —_INSTRUCTIONS ANWEISUNGEN INSTRUCCIONES —INSTRUGOES. 38501-01 726) BALL MILLS Preventive mainteanance Examination of fatigue-stressed mill components MGN:B Enclosure: Unidan mill with trunnion 38500-01-1 Unidan mill with welded-in slide rings 38500-01-I1 Tirax mill with slide ring and gear rim 38500-01-111 Mill head, cast, conical and mild steel head 38500-01-1V Manhole, modern and old-type 38500-01-v Trunnion, modern, old-type and tight-fitting bolts 38500-01-VI Slide ring, cast and welded type 38500-01-VI1 Gear rim 38500-01-VIII Grinding of weld 38500-01-Ix Contents: Page 2 __GENERAL 2. ___MOST STRESSED WELDED SEAMS AND COMPONENTS 3 CHECKING INTERVALS 3 TESTING METHODS 4 5. INSPECTION AND REPAIR 8 5.1 Mill tube (manhole/bolt holes/circular seams) 5.2 Trunnion/mill head/tight-fitting bolts 5.3 Slide ring 5.4 Gear rim and flange KEY TO SKETCHES 16 N=PR _ FLSMIDTH & CO. A/S, VIGERSLEV ALLE 77, DK.2500 VALBY, DENMARK38501-01 2 NOTE The present instruction manual is concerned with the situations which, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during the erection/operation/maintenance of the plant/machine/equipment cannot be provided. Consequently, if a situation should arise, the oc- currence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate ac- tion. GENERAL The ball mill is a dynamically loaded structure con- sisting of welded sheet material and cast parts of different thicknesses which are exposed to alteran- ting stresses. The alternating stresses result as the individual mill components undergo a varying and operation-con- ditioned state of stress per revolution. Experience has shown that the risk of crack forma- tion in fatigue-stressed structures depends on the Preventive maintenance and on avoiding to subject them to damages which will result in future fatigue cracks. Periodical checking and maintenance of welded seams and heavily loaded components, both visually and by means of non-destructive methods are, therefore, an absolute must for maintaining a high mill run fac- tor.38501-01 3 2, MOST STRESSED WELDED SEAMS AND COMPONENTS The following welds and components are subjected to the highest stresses: 1. The circular welded seams (1) at the transition between mill tube (2) and mill head (3), and the longitudinal and circular welded seams (5) in the mill tube. See Enclosures I & III. 2, Around manholes (6) and bolt holes (7) in the mill tube. See Enclosure v. 3. Trunnion (8) and mill head (3). See Enclosures Iv & VI. 4, Tight-fitting bolts and tight-fitting bolted joint (4) between trunnion and mill head. See Enclosure VI. 5. Slide rings (9A & 9B). See Enclosures 11 and VII. » IIE 6. For side-drive mills: Gear rim (10) and the welds (11A & 11B) between flange and mill tube. See Enclosures III & VIII. CHECKING INTERVALS An annual inspection is adequate when starting up the mill once per 24 hours. In case of more frequent mill start-ups (e.g. due to Power failure, feed failure or similar reasons), the mill is subjected to additional loads due to the thermal stresses and deformations. Frequent inspec- tions may therefore be required. Since it is not possible to specifiy "accurate" inspection intervals38501-01 4 in such cases, it is required to contact FLS - PSS so that the actual operating condition can be clari- fied and suitable inspection intervals be agreed u- pon. It is, of course, very important to folllow up on all suspicions concerning mechanical defects so that they are repaired as soon as possible. More frequent inspections may be required in connec- tion with repair welding or repair of inflicted da- mages. For inspection methods, refer section 4, 4. TESTING METHODS 4.4 Visual checking Visual checking of welded seams and machine compo- nents is the most simple and also the most important checking method. Make the initial check without cleaning the welds of dirt and rust, because it will then often be easier to spot a crack, if any. After the initial visual check, clean the surface of the welded seam and the machine component thorough- ly. When checking subsequently, note that irregularities on the surface may resemble cracks. It is recommended that the cleaned areas are also tested with dye penetrant (PT) or Magnetoflux (MT). If you are in doubt, also check by ultrasonic test~ ting (UT).38501-01 5 4.2 NDT testing Satisfactory testing requires equipment of approved manufacture. Please note that the described examinations must be made at a suitably low mill temperature so that the mentioned test media/contact agents are not damaged. 4 Testing with dye penetrant (PT) Dye penetrant is a vividly coloured (red) fluid which, when applied to a metallic surface, penetra- tes into a crack, if any, and makes it clearly vi- sible on the surface by means of a "developer". Procedure: 1. Clean the surface of grease, dust, oxide scales and other impurities. 2. Apply an even layer of dye penetrant to the cleaned area. 3. Give the penetrant time to penetrate into the crack. A period of 10 minutes is sufficient at a temperature of 0 - 60°C. Adhere to the instruc- tions on the can. 4. Carefully remove all excess liquid. Use the supplied solvent. The dye penetrant must not be "flushed off", but must be dried off with a clean cloth. 5. Apply an even thin layer of developer when the surface is dry. The developer is a strongly absorbing white pow- der suspended in a volatile solvent.38501-01 6 6. When the solvent has evaporated, a crack is clearly visible as a red line on white back- ground. In case of very deep cracks, the liquid can penetra- te so deep that it cannot be seen after application of the developer. Therefore, make sure that suffi- cent dye penetrant is applied. At temperatures below 0°C it is required to heat the sheet with gas or electric heat before applying the liquid. NOTE: If the crack is filled with oil or other kinds of grease, this method cannot be applied and one of the other mentioned methods must be adpoted. For further information, refer ISO 3879 - 1977. 4.2.2 Magnetoflux testing (MT) Magnetoflux testing (MT) is a method for detecting surface cracks or cracks immediately below the sur- face. Cracks up to 3 mm below the surface are detec- table. MT requires an electromagnet with 90° phase shift capable of applying a magnetic field intensity of between 2400 and 4000 A/m (30-50 Oersted) to the blank. Accessory iron powder in spray bottle or in aqueous solution may be used. To facilitate the examination, a fast-drying, white contrasting colour, preferably in spray bottle, should be available. This method is applicable on cracks filled with grease and other impurities.38501-01 7 Procedure: 1. Clean the surface of grease, dust and other im- purities. Make sure during cleaning that the surface around a crack, if any, is not "dama- ged", because otherwise it may be difficult to see the crack when the magnet field is applied later. 2. To facilitate the examination, spray a fast- drying white contrast colour on the area to be examined. 3. When the colour has dried, cover the area to be examined with a ferro-magnetic indicator (magne- tic powder). Subsequently apply a magnet field to the area in at least two directions, as closely as possible perpendicular to each other. The indicator will now concentrate as a line where the crack is located, and in this manner even very small surface cracks and defects re- veal themselves. For further information, see ASTM E 709 or DIN 54130. Ultrasonic testing (UT) If the MT and PT examinations have not revealed any defects, but there is a suspicion that there are in- ternal defects or it is required to know the crack depth prior to repair, UT may be applied. UT necessitates an instrument operating according to the pulse-echo method including sound probes. That is, 2 (2.25) and 4 MHz standard (normal) sound probe, 924 and #10 mm, and 45° and 70° angle probes in standard and miniature probes.38501-01 8 The contact agent is technical glycerine (connecting jelly) or wall paper paste (metylcellulose glue). Other media may also be used, such as oil or cup grease. UT should also be applied to the area after major weld repair jobs. Clean the area to be examined so that it is clean and smooth and so that the sound probes can be moved "freely" without encountering weld splashes, loose oxide scales, rust or other impurities. A UT with 2 (2.25) and 4 MHz standard and 45° and 70° angle probes in standard and miniature probes will normally be sufficient. Crack examinations should only be made by experien- ced technicians holding a certificate, possibly in co-operation with a local ultrasonic testing company or FLS. INSPECTION AND REPAIR Si Mill tube, (manhole/bolt holes/circular seams) The tendency to crack formations is influenced by the general conditon of the mill. Therefore it is important, at regular intervals, to check the mill tube for wear, that is check the mill tube sheet thickness and to examine the lining to make sure that it is intact and protected against wear and impacts from the grinding media.38501-01 9 This is particularly important for wet-process mills in which wear and corrosion may occur below the li- ning plates and result in serious wear problems un- less all hollow spaces behind the lining plates are filled out with rubber sheet and possibly sponge rubber. If a mill has operated without lining plates on part of the tube, or a wet-process mill has operated with "rotating slurry", the mill tube will more or less be worn off in the place concerned. This does not necessarily mean that the mill tube will crack here, because the stress level is not the same in all pla- ces of the mill tube. If mill tube wear has been ascertained, it must be avoided to fill up the worn areas by welding, be- cause this will most probably result in crack forma- tions in the mill tube. Moreover, this may result in mill tube deformations and consequent eccentricity of slide ring/trunnion and possibly the gear rim. The worn area may possibly be filled with a suitable two-component material to provide a good joint face for the lining plates. ‘The area must be checked for cracks frequently. In serious cases, involving cracks, it may be required to replace part of the mill tube. The risk of crack formations around welds is higher than in the actual parent metal. Therefore it is im- portant to inspect the welds so that any crack ini- tiation can be ascertaind and subsequently be re- paired as soon as possible.38501-01 10 This applies particuarly to the two circular welds (1) between mill head and mill tube, see Enclosures I, III & IV, and to some degree the longitudinal and circular welds (5) "inside" the actual mill tube. Around manholes (6) and bolt holes (7) in the mill tube, see Enclosure Vv, stress concentrations are created which increase the risk of crack formations in the mill tube. Consequently it is important that bolt holes and manholes and the surrounding areas are inspected and checked to the possible extent at regular intervals. In case of leaks at the old riveted cast manhole frames, see Enclosure V, these must not be fastened by welding, because this will result in crack forma- tions. The best method for sealing the frame is to caulk the frame closely along the mill tube or, if the frame has come off completely, to dismount it and re-rivet it followed by caulking of the edge. When closing holes in the mill tube, e.g. due to change of lining type, this must not be done by wel- ding in a steel plug, because this method results in crack formations. Instead use conical rubber plugs which must be glued into the hole from the inside. If inspection reveals even small cracks, these must, of course, be carefully repaired. (For repair, see below). It is particularly important to inspect the areas which have cracked previously and been weld-repaired subsequently, because there is an increasing risk of crack formations here.38501-01 qi In case of repeated problems in a given area it may be required to replace an area or a complete sheet section. A repair weld must always be ground absolutely flush with the mill tube, because this will improve fati- gue strength substantially and contribute to avoid new cracks. MT and UT are recommended for inspecting the afore- mentioned areas. Repair If inspection reveals a crack, it must be decided which repair method is to be applied. If the crack is sufficiently small, it is best to grind it off. If it is possible to grind or mill the crack off without reducing the wall thickness by more than 3-5 mm or by max. 10% of the sheet thickness, and at the same time obtain a smooth ground surface with a minimum radius of 15 mm without core prints, this must be considered as satisfactory. If the crack is bigger than described above it must be welded and it is recommended to do this job assi- sted by a welding specialist from FLS. 5.2 Trunnion (8), mill head (3) and tight-fitting bolts (4 Cracks in trunnions (8) may occur in the large roun- ding between the cylindrical section and the big flange or on the actual journal, see Enclosure VI, but cracks may also occur in other places on the trunnion.38501-01 12 Cracks in mill heads (3) may occur in the area loca- ted around the weld connecting mill tube and mill head and around tight-fitting bolts, see Enclosures IV & VI, but cracks in other places of the mill head, e.g. at holes and lining bolts, may also oc- cur. Cracks in trunnion and mill head may occur if "un- authorized" welds have been made, such as welding of nuts, scoop device and various fittings. Also burns from energization of an electrode or from wel- ding cables with a hole in the insulation may give rise to cracks. Damages may also occur if nuts and bolts are cut off with cutting blowpipe in connection with the repla- cement of lining plates and when dismounting the worn lining in trunnions by blowpipe cutting. Dama- ges in connection with blowpipe cutting will defini- tely result in crack formations at a later time. Da- maged areas must be ground smooth and polished to have an even rounding as transition as soon as pos- sible. If the lining in the cylindrical section of the trunnion is not cast with concrete, and for wet-pro- cess mills with Latex cement as specified, material may slide round in the hollow space between lining and trunnion and result in wear. Under adverse cir- cumstances this may cause crack: formations in the trunnion. Since trunnions and mill heads are heavy-loaded com- ponents, they must be checked at regular intervals. The best way to do this is to thoroughly clean and degrease the aforementioned areas and check them vi- sually and subsequently with MT. If in doubt or if there is a well-founded suspicion that there are cracks, checking with UT is required.38501-01 13 Cracks in trunnion and outlet head can be repaired in two ways. If the crack is discovered in due time and is sufficiently small, it can be ground off. There must be no stress risers and the transition must be made smooth with a minimum radius of 15 mm. If there is a small crack, it must be measured and marked and kept under observation until repair can be carried out. In case of a large crack, which is possibly through- going, weld repair is required immediately. Cracks in trunnion and mill head can normally be welded, but this is a specialist's job and it is re- commended only to make repairs assisted by an FLS welding specialist. Except for small repairs, such repairs must be con- sidered as temporary, and to ensure stable mill ope- ration it is recommended to order a new trunnion or mill head immediately. Tight-fitting bolt joints between trunnion and mill head must be checked for loose and torn tight-fit~- ting bolts and that they are tightened to the speci- fied torque. Loose bolts may cause bolt heads to break and that the mill head cracks between the tight-fitting bolt holes. The best way to inspect tight-fitting bolts is to apply UT from the end of the bolt, see Enclosure vi. As for the mill tube, holes in trunnion/mill head which are not used because of changed type of 1i- ning, must be plugged with conical rubber plugs and Nor, as is often done, by welding steel plugs into the holes, since this results in crack formations.38501-01 14 5.3 Slide rings (9) Slide rings (9A & 9B), Enclosure IX, must, on the same lines as the other fatigue-stressed mill compo- nents, be inspected regularly to detect any crack formation in due time and to be able to make an ap- propriate and fast weld repair. As concerns welded, welded-in slide rings (9B), the welds between slide path and web plate and particu- larly between slide path and mill tube (1) must be checked. The tight-fitting bolted joint of bolted slide rings must be checked in the same manner as for trunnion/ mill head. Like trunnions and mill heads, the slide rings must also be protected against wear and other damages. Do not repair-weld on slide rings without previous agreement with FLS. 5.4 Gear _rim (10) and flange (11) On side-drive mills the gear rim and flange for the gear rim are exposed to varying stresses and may therefore be subjected to crack formations, see En- closure VIII. To prolong the service life it is important not to damage gear rim and flange which may result in future crack formations. The circular welds connecting flange and mill tube are one of the areas which should be checked regu- larly.38501-01 15 If a minor crack is found it must be observed close- ly until repair can be carried out. For welding procedure, please contact FLS If a more serious crack is concerned, the mill must be stopped immediately and repair be carried out. It is recommended to contact FLS and to make the repair assisted by an FLS welding specialist so as to avoid deformation of the mill tube and runout of flange and gear rim. A careful visual inspection must be made of gear rim and pinion tooth flanks and tooth roots to ensure that wear and any pittings do not develop into cracks or gear rim and pinion rupture. The gear rim ribs and transitions to the cylindrical section must likewise be examined for cracks. It is important that the bolted joint between gear vim and flange has been made as specified in the assembly documentation and has not been tightend up harder than specified. All bolts must be positioned in free holes and never be replaced by tight-fitting bolts. The reason for this is that high thermal stresses will be created due to different thermal expansions between gear rim and flange which consequently can- not slide in the bolted joint. This may give rise to crack formations in the weld between flange and mill tube, in the actual gear rim or in the bolts assemb- ling the gear rim halves. For the same reason there must be no gear rim align- ment shims and wedges in the circular clearance (12) between flange top and recess in the gear rim. See Enclosure VIII.38501-01 16 "Unauthorized" welds and traces after cutting with blowpipe on flange and mill tube must be removed by grinding and polishing of the damaged area, because such damages may otherwise result in cracks. Should problems with cracks arise at the gear rim flange, it is possible to increase the fatigue strength considerably by grinding smooth the welded transition at the mill tube and in this way possibly avoid new cracks altogether. See Enclosure IX. :___KEY TO SKETCHES 01 Circular seam between mill head/slide ring and mill tube 02 Mill tube 03 Mill head (3A: Cast, conical mill head) (3B: Plane, mild steel head) 04 Tight-fitting bolt joint 05 Welded seams (Circular and longitudinal) in mill tube 06 Manhole (GA: Modern type) (6B: Old type with riveted frame) 07 Bolt holes 08 Trunnion Modern type) Old type) Cast, bolted type) Welded, wedled-in type) 09 Slide ring 10 Gear rim 11 Weld between gear rim flange and mill tube, (11a: Old type) (11B: Modern type) 12 Clearance between flange and recess in gear rim 13 Hard alloy milling cutter 14 Grinding discLainie oO 38500-01-Ira, OD [Ki38500-01-IV38500-01-V(jp 4e ZL z © fe) ® ae by |38500-01-VIT38500-01-Ix