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Dysfunctions, solutions & optimization

by Paul Wurth

16/10/2013

Maintenance on the example of sinter


coolers by Paul Wurth Umwelttechnik
GmbH
Author: Dipl. Ing. Holger Kassebaum

Belo Horizonte 21 e 22 de Outubro de 2013


Presentation for maintenance conference Brazil 2013

Paul Wurth 2013

The maintenance of castles in the air is an


expensive pleasure.
Edward George Earle Bulwer-Lytton (1803 - 1873)

Born: 25. August 1845 in Schloss Nymphenburg


King of Bavaria 18641886
Died: 13. Juni 1886 in Starnberger See
Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Maintenance
What are the advantages to do
maintenance?
What are the objectives of preventive
maintenance?

Presentation for maintenance conference Brazil 2013

Paul Wurth 2013

Definition of Maintenance

(DIN 31051:2003-06)

Maintenance
Servicing

Inspection

Repair

Improvement

Keep the
target state

Set/review of the
actual state

Restore the
target state

Improve the
target- & actual
state

clean
grease
adjust

measure
check
diagnose

exchange
improve

develop
optimize

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Maintenance Strategies:

Fly to failure
Preventive maintenance
Predictive maintenance
Condition based maintenance

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Aims:
Increase lifetime
Increase operational safety
Less failure
Less downtime
No loss of production
Forward-looking planning costs

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Maintenance means to PW
Service and maintenance manuals
PW inspections and tips on site
Experience for the continuous
development and improvement

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Types of existing Sinter Cooler


Cell rotary cooler

preview

Cup rotary cooler

preview

Cone shaft rotary cooler

preview

Shaft rotary cooler

preview

Linear air cooler

preview

Retractable/Annular cooler

preview

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Possible consequences of a lack of non-compliance with the


servicing and maintenance

Servicing
Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Possible consequences of a lack of non-compliance with the


servicing and maintenance

Servicing
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Paul Wurth maintanance conference

10

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Possible consequences of a lack of non-compliance with the


servicing and maintenance

normal situation

Servicing
Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

11

Possible consequences of a lack of non-compliance with the


servicing and maintenance

Servicing and Inspection


Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

12

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Possible consequences of a lack of non-compliance with the


servicing and maintenance
Correct Situation

Incorrect Situation

correct.

Servicing and Inspection


Paul Wurth 2013

too small.

Presentation for maintenance conference Brazil 2013

13

Possible consequences of a lack of non-compliance with the


servicing and maintenance

3) The rubber is pressed out

2) This creates an angle

1) The wheel presses the rail out of the horizontal

Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

14

Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Possible consequences of a lack of non-compliance with the


servicing and maintenance

Inspection and Repair


Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

15

Possible consequences of a lack of non-compliance with the


servicing and maintenance

Inspection and Repair


Paul Wurth 2013

Presentation for maintenance conference Brazil 2013

Paul Wurth maintanance conference

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Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Experiences and improvements of the Retractable air cooler

Comparison retractable rails


Old

New

- Only the under frame is welded


- Rails can be aligned
- Rails are interchangeable
- Easy mounting
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Presentation for maintenance conference Brazil 2013

17

Experiences and improvements of the Retractable air cooler

Comparison frame of the sinter segment


Old

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New

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Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Experiences and improvements of the Retractable air cooler

Comparison grate frame bearing


Old
Loose bearing

New
Fixed bearing

Loose bearing

Fixed bearing

- Pre turned pipe more accurate bearing


- Easier and more accurate mounting
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Presentation for maintenance conference Brazil 2013

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Experiences and improvements of the Retractable air cooler

Comparison - unlocking
Old

New

- Smaller lever / shaft


- Less machining
- Easy mounting
- Lighter construction

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Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Experiences and improvements of the Retractable air cooler

Comparison - consoles for drive rollers


Old

New

- Maintenance free
- During the operation changeable
- No springs
- Easy mounting
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21

Types of Sinter Cooler


Change of drive rollers during the operation

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Dysfunctions, solutions & optimization


by Paul Wurth

16/10/2013

Thank you for your attention


PAUL WURTH Umwelttechnik GmbH
Grugaplatz 4
D-45131 Essen
www.paulwurth.com

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