Training for tensioning

hydraulic system

MPS mills
General Purpose

 Use of Hydraulic system for:

1. Control process
2. Shock absorbing system
3. Adjusting the grinding and nitrogen pressure to increase the
productivity

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Main circuit tensioning unit

central control system

cylinder with position and
pressure feedback
PLC

central hydraulic unit

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Central hydraulic unit

1. Hydraulic unit consisting of

 Oil hydraulic pump
 Filter unit
 Local operation panel
 Measuring equipment
 Valves
 Piping

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Hydraulic cylinder

2. Tensioning cylinder consisting of:

 Piping
 Valves
 Nitrogen accumulators
 Pull rod and cylinder
 Cylinder position indication

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Tension cylinder with bladders

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Control system

3. Control the system by:

 giving start-stop command

 give local permission
 Set points for lifting height during
start up
 Set points for pre tensioning and
operating pressure
 Monitoring
 Valve status
 Shut down system
 Trouble shooting

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Basic function

 The pull rods are each linked to

the corners of the pressure
frame. Each roller is so pressed
by the force of two cylinders

 During the lifting phase of the

rollers, the control system
balances the cylinder position
out, so the pressure frame and
the rollers will be lifted equal.

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Basic pressure Settings

Tension pressure:
Normal (design) and maximum pressure are stated at manual, to be
strictly observed for normal life times
Various specific grinding loads as design standard are available for
Pfeiffer mills, depending on age, size and type (coal, raw, cement).

1. Nitrogen pressure of the bladders p0

2. Pretension pressure p1 = 1,7…1,9 x p0
3. Tension pressure (Grinding) p2 = 1,5….3,0 x p0
4. Prealarm low pressure during grinding pL < 1,3 x po
5. Stop grinding low pressure pLL < 1,15 x p0

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Start with no pressure

 The start of the system begins

with rollers on the grinding table, P0
and no pressure in the system.

 In that condition, the nitrogen

bladder is totally expanded

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Build up pretension pressure

P1 = 1,7…1,9 x p0
 Building up pretension pressure
is necessary, to precharge the
nitrogen accumulators.

 The control parameter in that

step is the pressure p1.

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Lift the cylinders/rollers

 By lifting of the cylinders, the

tension side will be locked, and
the lifting pressure will be built up.

 The control parameter in that step

is the position of the cylinders

TP/ Ne- 08 / 04

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Lowering of the cylinders/rollers

 During lowering, the oil at the

lifting side will be released

 The control parameter in that step

is the lifting pressure

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Grinding

P2 = 1,5…3,0 x p0
 During grinding, the set point of
the grinding pressure will be pL > 1,3 x p0
maintained pLL > 1,15 x p0

 The control parameter in that step

is the tension pressure

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 Optimum Nitrogen pressure p0

N2 Pressure too low, -> Rough

Running

N2 Pressure, OK, ->controlled

roller movement, Efficient
Grinding

N2 Pressure too high, -

>Excessive Roller Movement,
Inefficient Grinding, Rough
Running

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Damping behavior with pressure relation

p0 = Nitrogen pressure, p2 = Tension (operating) pressure

p2/p0 = 1,5 p2/p0 = 2 p2/p0 = 3

soft damping medium damping hard damping

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 Charging of accumulator

charging unit with accessories pressure reducer

adapter pressure charging+ testing unit
reducer
FPU-1

Charging unit
adapter
FPU-1
charging hose

accumulator
nitrogen bottle

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Calibration of the cylinder positions

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Oilflow in Tension Hydraulic

MPS mills
Valve status

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building up pre pressure tension hydraulic

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Lifting pressure until lifting highest cylinder x mm

TP/ Ne- 01 / 05

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Lifting to setpoint cylinder position

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Lifted rollers leveling cylinder positions

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Lowering the Rollers (pressure frame)

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Grinding operation

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Troubleshooting and
maintenance

MPS mills
Trouble Shooting

Filtration

Why we are talking about contamination ?

70-80% of all failures of hydraulic systems

and
up to 45% of all bearing failures
are caused by
contamination of the hydraulic fluid or lubricant

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Trouble Shooting

Why is filtration so important?

• Choosing the optimal solution for filtration is an essential
step to avoid damage due to contamination
• To increase the running time of the unit and consequently
its productivity.
• The development in hydraulics in recent years is essentially
concerned with faster and more precise switching valves.
• Pumps, valves and actuators feature less and less oil
leakage despite the fact that pressure increase in hydraulic.
• This increase in performance can only be obtained by
minimizing the valve clearance in the hydraulic
components.
• Consequently higher requirements and standards are
made with regard to cleanliness in mounting the hydraulic
components and handling the operating fluids.

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Trouble Shooting

Particle Proportions

75
Diameter in µm

Human hair
30

15

5
1
Bearing Fine/coarse
lubrication film particle

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Trouble Shooting

Kinds and Effects - Conclusion

Types of contamination effects

gaseous liquid solid

air water corundum

scales very strongly
rust particles damaging
iron
steel
brass strongly
bronze damaging
aluminum
fabric-base laminate
fibers
seal abrasion
particles of vulcanized weakly
rubber of hoses damaging
lacquer particles
oxidation products
of hydro fluids

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Trouble Shooting

Causes of Gaseous Contamination

 Leakage within the system

 Air suction caused by pump
 Faulty construction of components
 Water in oil
 Used additives
 Mixing of different types of fluids
 Blending of substances containing silicone
 Return above the fluid level
 Determination of tank size

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Trouble Shooting

Consequences of Gaseous Contamination

 Cavitation
 Local oil overheating
 Increased fluid temperature
 Oil aging
 Foaming
 Shortened life-time of filter element
 Leads to unstable regulation behavior
 Reduces the dynamic lubrication film
thickness

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Trouble Shooting

Possible damage in case of Gaseous

Contamination

 Loss of transferable energy

 Noise within pump
 Reduced lubrication capabilities
 Increased operational temperature
 Technical reactions
 Foaming fluids in tank
 Shorter oil and component change
intervals
 Permanent filtration in filter housing

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Trouble Shooting

Preventive measures against Gaseous

Contamination

 Careful breathing of the system

 Fitting of suction pump below fluid level inside the
tank
 Long resting time of fluids in tank (to make sure that
the tank can be breathed).
 Professional mounting of hydraulic pipes
 Avoid mixing different types of oil.

ATTENTION: There are very few filtration techniques to

deal with the contamination!!!!!!

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Trouble Shooting

Types of Liquid Contamination

• Water
• Adding incompatible new oil

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Trouble Shooting

Causes of Liquid Contamination

 Open tank inlets

 Worn out piston rod sealing
 Formation of condensation water due to
extreme temperature changes.
 Leakage in heat exchanger
 Unprofessional machine cleaning
procedures

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Trouble Shooting

Consequences of Liquid Contamination

 Corrosion of metal parts

 Decrease of dynamic viscosity
 Decrease of lubrication film thickness
 Reduction of oil durability
 Changes of oil condition
 Increase of oil aging speed

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Trouble Shooting

Types of Solid Contamination

• Core sand
• Weld splatter
• Fibres
• Scale
• Rust
• Packaging residue
• Paint

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Trouble Shooting

Solid Particle Wear depends on

 Size and form of solid particles

 Flow velocity
 Material of the contamination

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Trouble Shooting

Effects of Solid Contamination

• Increased leakage
• Jamming of pistons and
spools
• Component failure
• Changes in control
characteristics

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Trouble Shooting

Damages on Bearings

10% 10%

20%

35%

5%
20%
solid contamination liquid contamination
oil aging unsuitable lubricant
unsuitable choice of bearing mounting faults

Source: FAG Rolling bearing damage Publ.-Nr.: WL 82 102 / 2 ED

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Trouble Shooting

Effects of Contamination

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Trouble Shooting

Initial Damaging on Bearing

Without starting flush

With starting flush

Starting Operating time

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Trouble Shooting

Preventive Actions Against External Contamination -

Summary

Origins Preventive Action

 Assembly, repairs  System flushing

 Breathing of cont. air  Air breather filter

 Damaged seals on  Control of the seals

pistons and piston rods and eventually
replacement

 Badly sealed tank  Control of the seals

and pipe connections

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Trouble Shooting

Preventive Actions Against Internal Contamination

- Summary

Origins Preventive Action

 Initial contamination  System filling with
of the new oil filtration
 Initial contamination  System flushing with
of the system oil service units
 Particles of paint and  Filtration with internal
oxidation products system filters

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Trouble Shooting

 The hydraulic system is an open

system. Any kind of particles
could damage the system.

 The pictures show the leftovers

of a hydraulic pump, that was
damaged by durst particles

 Golden rule: keep the system

clean

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Trouble Shooting

 Always charge the oil through the

offline filter system

 Keep the tank filter in good condition

 Make regular oil inspection

 When changing the oil, clean the tank

 When opening the pipe circuit, clean

the surrounding and prevent dirt
entering the system.

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Trouble shooting examples

Malfunction of solenoid valve:

• Electrical problems/wire break:

Check power supply

 Malfunctions often caused by dirt

in the oil. Opening and cleaning or
replacing of the damaged valve is
required.

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Trouble Shooting examples

 Due to a cloth forgotten inside a

tube during maintenance, the
system was infiltrated and totally
blocked. As a consequence, the
whole hydraulic system had to be
cleaned totally.

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Trouble shooting examples

 If no replaceable functional parts

are available, repairing is the only
chance to fix.

 keep the hydraulic parts clean

 during maintenance, do not

infiltrate dirt into the system

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Trouble shooting examples

 Problem: one cylinder is not staying

in the position. It even rising without
command.

 Most probably the reason is

contaminated oil with foreign
particles

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

No pressure build-up Pressure relief valve(s) Clean the pressure relief valve(s) or
malfunctioning or with dirt build- replace it/them
up
Pump malfunctioning Replace the pump

Internal leaking Look for source of leaking, remedy it

Improper valve switching Check the valve position according to

the hydraulic circuit diagram and
inspection and testing specification.
Check orifice

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

No pressure shown Pressure gauge and/or pressure Replace pressure switch / pressure
switch malfunctioning gauge
Choker valve closed Open the choker valve

Directional valve not in the right Correct switched position

switched position

Directional valve malfunctioning Check the plug (voltage), replace it if

or with dirt build-up necessary, check for the right pin
assignment; if necessary, clean valve

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

Built-up pressure The setting of the pressure relief Check the setting and correct it, if
too low valves is wrong necessary

Valves leaking, internal leakage Check the valves

Pressure relief valves Check the valves and, if necessary,

set incorrectly, malfunctioning or replace them
with dirt build-up

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

Pressure build-up Valve switched incorrectly, has Check the switched position; clean
insufficient dirt build-up or is malfunctioning valve or replace it. Check the 1.2 mm
orifice in p upstream of the valve

Cylinder leaking Replace piston gasket, if necessary

repair cylinder

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

No pressure present Respective check valves Check routing of lines, connections
leaking, with dirt build-up, against documentation; if necessary
connected wrong or not being correct them; check valve; check
triggered switching sequence

Dirt build-up or malfunction of Check valve switching, remedy leaking;

valves clean or replace valve(s) as necessary

Cylinder leaking Replace piston gasket, if necessary

repair cylinder

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

Pressure values present Directional valve not being Correct switched positon
as specified in hydraulic switched correctly
circuit diagram, no
upward movement Movement electronically Check setting
restricted by position sensor
system

Pressure present, Leaking, dirt build-up or Check the switched position and
however not all cylinders malfunction of valves function of the valves; clean valves or
are moved replace them as necessary
Piston gasket of respective Replace piston gasket
cylinders is defective
Flow divider malfunctioning Check flower divider

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

No or insufficient Malfunction or leaking of valve Check valve switching, remedy leaking,
pressure or in connection with leakage, clean or replace valve(s) as necessary;
dirt check switching sequence
build-up or malfunctioning of
valves
Safety valve of flow divider Replace valve
malfunctioning

Pressure present, Flow-control valve closed Set flow-control valve

however no lower
function
Valve incorrectly switched Check the switched position, and
correct or, if necessary

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Maintenance and repair

Causes of Malfunction - Troubleshooting

Error symptom Possible cause Troubleshooting

No pressure relieved Choker valve closed after Open choker valve
when switching the pressure build-up
facility off
No pressure relieved Valve malfunctioning Check valve
possible when valve is
closed

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bladder damages

 Damages in the accumulators are often created by wrong ratio

between charging pressure, and operation pressure.

 Also abnormal cylinder movement and high mill vibrations will

create damages like broken flow valves and scratches on the
rubber

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www.gpse.de
 Barbarossastraße 50-54
P.O. Box 3080
67618 Kaiserslautern
Phone: ..49-631-4161-0
Fax: ..49-631-4161-290
e-mail: [email protected]
homepage:www.gpse.de

Thank you!