Machine manual

en-22468.007-C

Water injection system type

OP for QUADROPOL® roller
mill

Code word

Order number

POLYSIUS Order Code (POC)

Technical Data Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

en-22468.007-C
Machine manual Contents
Water injection system type OP for QUADROPOL® roller mill

Contents

1 Technical Data........................................................................................ 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-4
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for test run.........................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Safety instructions....................................................................................7-1
7.2 Inspection.................................................................................................7-3
7.3 Maintenance.............................................................................................7-3
7.4 Trouble shooting.......................................................................................7-4
7.5 Repair....................................................................................................... 7-5
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers' documentation...................................................................9-1

en-22468.007-C
Machine manual Technical Data
Water injection system type OP for QUADROPOL® roller mill 1

1 Technical Data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Specifications of the intended use

See machine manual of the roller mill .........................................No.

Basic data
Year of manufacture............................................................................
Required water flow rate max. ...................................................m3/h
Water quality clean process water from plant water supply system

Valves and fittings

Flowmeter (1.4)
Type.....................................................................................................
Solenoid valve (7)
Type.....................................................................................................
Motorised control valve (8)
Type.....................................................................................................
Flowmeter (9)
Type.....................................................................................................
Machine manual Safety
Water injection system type OP for QUADROPOL® roller mill 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 Be sure to comply with the safety regulations when working on
the water injection system in the roller mill.
 The machine is exclusively intended for injecting water into
the roller mill. The water to be injected must at least
correspond to the quality specified in the section Technical
data.
 Any use other than the intended use is forbidden. POLYSIUS AG
is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner's own risk.
 The intended use also includes observance of the machine
manual and compliance with the maintenance instructions.

Transport and assembly

 All transport instructions in this machine manual refer
exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting gear and load-carrying equipment
which is in serviceable order and has a sufficient load-bearing
capacity.
 Never work under a suspended load.

Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour occur that
are relevant to safety, shut the machine down immediately.
 Hearing protectors must be worn during operation of the mill.
Safety Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

Maintenance
 Be sure to also comply with the safety instructions in the
operating manual and in the machine manual for the roller mill
and in the subsupplier's documentation.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances to clean the machine.
 You have to obtain the written permission of the plant manager
before you start with work inside the machine, and you must
shut down the plant section in which the machine is installed.
 Make absolutely sure that all machines, motors and the
material flow whose operation might endanger persons or
equipment are switched off and safeguarded against restarting
for the entire duration of the maintenance work.
 Switch off the power supply to the electrical components
before beginning any maintenance work.
 Make absolutely sure that all parts of the machine have come
to a complete standstill before you remove any protection
devices or open any covers.
 After shutting down the grinding table drive wait until it has
come to a complete standstill. Reverse rotation of the grinding
table up to ¼ of a full rotation is possible.
 The plant management must ensure that all moving parts are
protected against accidental contact.
 Before performing any work on the machine, make absolutely
sure that there is no danger of suffering burns when touching
the machine, and before opening any inspection and service
covers, make absolutely sure that there is no longer any hot
material inside the machines.
 Make absolutely sure that all piping is depressurised.
 Make absolutely sure that no hot gas can enter the interior.
 Remove all incrustations, loose wear protection lining and
other materials that could fall down or slide down.
 Only use 24 volt lamps to illuminate the interior of the
machine.
 Directly after the machine has been shut down, you are only
allowed to enter the interior wearing a breathing apparatus
with independent ventilation.
Machine manual Safety
Water injection system type OP for QUADROPOL® roller mill 3

 Cold shock due to excessive temperature differences must be

avoided, as it could cause stress cracks in the roller tyres.
 You are not allowed to enter the interior without breathing
apparatus until you have sufficiently purged it with fresh air.
Make absolutely sure that there is sufficient oxygen inside the
machine.
 When work is being performed inside the machine, make
absolutely sure that fresh air is supplied continuously (by
injection or suction), so that the inhaled air remains free of
noxious constituents. Aeration with pure oxygen is forbidden.
 When work is carried out in the roller mill, a large amount of
dust has to be expected, so make sure that dust protection
masks are worn.
 For repair work to be carried out inside the plant sections you
have to install auxiliary platforms, if necessary. These auxiliary
platforms must be of stable design.
 The hydraulic system has been specially designed for the
supplied machine and must therefore not be used for any other
machine without the express consent of POLYSIUS AG.
 Only use hydraulic oil that complies with the requirements.
 Make absolutely sure that the hydraulic piping is depressurised
before disconnecting it.
 Never use the pumps of the hydraulic system to empty or fill
the oil tank.
 If you drain hydraulic oil at operating temperature, you risk
scalding yourself.
 Only use pure nitrogen and never oxygen for filling the piston
accumulators.
Flame cutting, grinding or welding work
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
Safety Machine manual
4 Water injection system type OP for QUADROPOL® roller mill

● In particular, never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding track and the roller tyres, as
these points may become starting points of cracks. Never connect earthing
cables to these components either.
Machine manual Safety
Water injection system type OP for QUADROPOL® roller mill 5

Conclusion of maintenance work

● After having finished all maintenance work, check all joints and connections
for leaks.
● Remount all protection devices when maintenance work has been finished.
Make absolutely sure that no persons are inside the plant component before
you properly close the inspection and service covers.
 Check that all signs are complete and distinctly legible. Mount
new signs if necessary.
Machine manual Components and mode of functioning
Water injection system type OP for QUADROPOL® roller mill 1

3 Components and mode of functioning

The water is injected into the roller mill and sprayed onto the
grinding table and in front of the grinding rollers via injection
pipes.

Water with the required water pressure is taken from the process
water supply system and fed to the injection lances. The mounted
valves and fittings measure and control the water flow rate to be
injected.

3.1 Components
NOTE
Some details of the drawings in this manual may not be
identical with the drawings supplied under the contract.

The water injection system essentially consists of:

 the valves and fittings
 the injection pipes
Components and mode of functioning Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

Items shown in the drawings

1 Injection pipes
1.1 Pipe
1.2 Hose
1.3 Through-way valve
1.4 Flowmeter
7 Solenoid valve
8 Motorised control valve
9 Flowmeter
W Water supply
Machine manual Components and mode of functioning
Water injection system type OP for QUADROPOL® roller mill 3

Figure 1
Components and mode of functioning Machine manual
4 Water injection system type OP for QUADROPOL® roller mill

3.2 Mode of functioning

The water is injected into the roller mill via four injection pipes
(1). Each of the four injection pipes (1) has its own supply pipe
(1.1). A flowmeter (1.4) with upstream through-way valve (1.3) is
installed in each of the four pipes (1.1). This enables individually
adjustable water injection before each roller.

The pipe cross section depends on the maximum water flow rate
to be injected. The water pressure has to be at least 5 bar.

The water injection control system is integrated into the electric

control system of the grinding plant and both systems have to be
coordinated and checked prior to commissioning.

Water is supplied from the process water supply system.

The solenoid valve (7) stops a possible water flow in the case of
grinding plant stoppage.

The water quantities for the injection pipes (1) are controlled via
the motorised control valve (8), the flowmeter (9) measures the
water quantity.
Machine manual Transport and assembly
Water injection system type OP for QUADROPOL® roller mill 1

4 Transport and assembly

4.1 Transport and storage instructions

The valves and fittings are already mounted on the water tank for
transportation to the plant.

The injection pipes (1) are supplied individually and the piping
(1.1) to be laid on site is supplied loose.

Make absolutely sure that suitable lifting equipment is employed

for lifting all the parts from the transport vehicles and
transferring them to the storage facilities.

When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against moisture, soiling and
damage. Never place the parts directly on the ground.

4.2 Assembly

General notes
The following assembly instructions do not detail the individual
steps for assembling the units, but rather give an overview of the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.

NOTE
It is a prerequisite of our warranty that the final assembly and
the assembly inspection are undertaken by an assembly
specialist from POLYSIUS AG.

We recommend that the assembly work is supervised from start

to finish by an assembly specialist from POLYSIUS AG.
A prerequisite for correct performance of the work is that the
tools and appliances to be used and the assembly personnel to be
employed are carefully selected.
Transport and assembly Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

CAUTION
If you carry out electric welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring
devices, in order to prevent damage to these parts.
Always directly connect the welding current return lead to the
part being welded.
Never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding track and the
roller tyres, as these points may become starting points of
cracks.
Never connect earthing cables to these components either.

Sequence of assembly
Mount the injection pipes (1) in accordance with the drawings in
section 9.1 Technical drawings.

NOTE
The water piping must be free from metal chips and dirt
particles. The piping must be flushed prior to installation.
Ensure absolute cleanliness, especially during final assembly of
the water piping.

The connection to the customer's process water supply system is

realised via the water supply system.
Machine manual Lubrication
Water injection system type OP for QUADROPOL® roller mill 1

5 Lubrication

CAUTION
Ensure that the environment is not polluted when lubricants are
stored, used and disposed of and carefully observe the relevant
national legislation for the protection of the environment when
handling lubricants.

Lubrication chart

Figure 2

Lubrication points

No. Qty. Designation Comment

1 1 Motorised control valve See manufacturer’s

documentation
Machine manual Preparation for test run
Water injection system type OP for QUADROPOL® roller mill 1

6 Preparation for test run

NOTE
It is a prerequisite of our warranty that the first test run is
carried out in the presence of specialists from POLYSIUS AG
and in accordance with their instructions.

6.1 Checks prior to the test run

Check all plant sections in accordance with the list below after
having completed the assembly work and prior to the first test
run. Make absolutely sure that all material remnants, tools and
assembly appliances have first been carefully removed.
 Is the water supply system installed and is sufficient water
available in the required quality?
 Have all fittings, valves, piping etc. been installed to ensure
correct functioning?
 Are all fittings, valves and monitoring devices functioning
properly?
 Have the connecting flanges and pipe joints been screwed on
tightly?
 Have all electric motors been connected correctly?
Has the direction of rotation been checked?

6.2 Setting and adjustment

The water injection control system is integrated into the electric

control system of the grinding plant and must be checked and set
during commissioning in accordance with the operating
conditions of the mill.
Machine manual Maintenance
Water injection system type OP for QUADROPOL® roller mill 1

7 Maintenance

7.1 Safety instructions

CAUTION
The noise level in the machine building can exceed 90 dB(A).
Your hearing could be harmed.
Wear hearing protectors.

DANGER
The machine is hot.
You could be seriously injured or killed.
I. Wear the prescribed protective clothing.
II. Wait until the mill has cooled down before starting the
maintenance work.

WARNING
There are rotating components at the machine.
You could suffer severe injuries.
Do not enter the areas cordoned off during operation of the
machine.

WARNING
Open doors can move suddenly and without warning.
You might be crushed.
Secure open doors against unintentional closing.

WARNING
Material can fall out.
You could be seriously injured or killed.
Stay at an adequate distance.

DANGER
There are hot inert gases in the grinding compartment.
You could be seriously injured or killed.
I. Make absolutely sure that there are no remaining hot gases in
the roller mill and that any hot gases can enter the interior.
II. Wear the prescribed protective clothing.
III. Wait until the mill has cooled down before starting the
maintenance work.
Maintenance Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

DANGER
The mill feed material in the mill can fall down or give way.
You could be buried alive or sink into the material.
I. Make absolutely sure that there are no coatings of mill feed
material in the mill and in the inlet.
II. Make absolutely sure that the material has an adequate bearing
capacity or suitably cover the material.

WARNING
Suspended loads
You could be seriously injured or killed.
Never work under a suspended load.

Note
After having completed the maintenance work, you must check the
machine/plant again in accordance with the section Checks prior to the
test run.
Machine manual Maintenance
Water injection system type OP for QUADROPOL® roller mill 3

7.2 Inspection

No. Work to be performed Frequency Comments

1 General visual inspection for leaks of Daily

and damage to the
 valves and fittings
 piping
2 Check the injection pipes (1). Monthly Only on
stationary and
shut down roller
mill
3 Check the valves and fittings. Weekly In accordance
with the
manufacturer's
instructions

7.3 Maintenance

CAUTION
If the water injection system is shut down due to danger of
freezing, be sure to drain the water (see 1.4 Repair).

No. Work to be performed Frequency Comments

1 Maintenance work on the valves and In accordance

fittings with the
manufacturer's
instructions
2 Check and repair the paint coat of Annually
 the valves and fittings
 the piping
Maintenance Machine manual
4 Water injection system type OP for QUADROPOL® roller mill

7.4 Trouble shooting

The most important functions of the water injection system are

monitored by the electric control system of the grinding plant
during operation.

If there are problems with these functions, an alarm is triggered

and/or the water injection system and the grinding plant are
stopped.

Fault Cause Elimination

No water in No water supply Check by customer

the injection pipe (1) from the plant network
The solenoid valve (7) Repair in accordance
does not open. with the manufacturer's
instructions.
The motorised control Repair in accordance
valve (8) with the manufacturer's
does not open. instructions.
The injection pipes (1) Clean the injection
are clogged up. piping.
Break of the pipe (1.1) Repair the pipe.
The electric control Repair the electric
system is faulty. control system.
The flowmeter (9) is Repair in accordance
faulty. with the manufacturer's
instructions.
The flowmeter (1.4) is Repair in accordance
faulty. with the manufacturer's
instructions.

Consult the subsuppliers' documentation for additional

information on faults, their causes and their elimination.
Machine manual Maintenance
Water injection system type OP for QUADROPOL® roller mill 5

7.5 Repair

Switch off the power supply to all electrical components before

beginning any repair work.
Ensure absolute cleanliness at all times during the repair work in
order to prevent dirt from entering the bearings, the drives or
other sensitive parts of the machine or plant.
Do not remove or open any covers or protection devices before all
rotating parts have come to a complete standstill.

NOTE
After having finished all repair work, check all joints and
connections for leaks.
Only use suitable hoisting gear and load-carrying equipment
which is in serviceable order and has a sufficient load-bearing
capacity.
Never work under a suspended load.

Emptying the entire water injection system

 Change over the water injection control system from
"automatic" to "manual operation" in the control room.
 The motorised control valves (8) must be opened with the
"more/less pushbutton". The "local" motorised control valve
indicates the degree of opening.
 Remove the flexible water hoses at the injection pipes (1) in
order to ensure that the water can better flow away through the
piping.

Repair work on the valves and fittings

CAUTION
The piping is subjected to a pressure.
The plant may suffer damage due to water spurting out. Check
whether all piping is depressurised and make sure that the
water injection system is switched off and safeguarded against
restarting.

Mount the valves and fittings so that they are free of stresses and
installed in accordance with their flow direction.
Please refer to the manufacturers' documentation for the repair
work on the valves and fittings.
Maintenance Machine manual
6 Water injection system type OP for QUADROPOL® roller mill

Note
After having completed the maintenance work, you must check the
machine/plant again in accordance with the section Checks prior to the
test run.
Tools and auxiliary equipment
No special tools are required for repair work on the machine.
However, you may need torque wrenches of a bigger size than
normal.

Whether or not you need auxiliary equipment, such as scaffolds

or hoists, depends on the operating conditions in your plant.
Machine manual Spare parts
Water injection system type OP for QUADROPOL® roller mill 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG wants to make spare part enquiries and spare part order
placements as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the speediest and most trouble-free manner.
Please copy the title page and the page with the corresponding table. Complete
the columns for quantity and units. Mark the parts you require with a cross in the
column Order or in the column Enquiry. Send the title page and the table to the
POLYSIUS AG spare parts department.
If the table refers to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
Spare parts Machine manual
2 Water injection system type OP for QUADROPOL® roller mill

Figure 3
Machine manual Spare parts
Water injection system type OP for QUADROPOL® roller mill 3

Code word: Order number: POC:

Item Designation Qty. Unit Order Enquiry

1.2 Hose with hose clips 1 Set(s)

1.3 Through-way valve 4 Piece(s)

1.4 Flowmeter 4 Piece(s)

7 Solenoid valve 1 Piece(s)

8 Motorised control valve 1 Piece(s)

9 Flowmeter 1 Piece(s)
Machine manual Appendix
Water injection system type OP for QUADROPOL® roller mill 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of
this folder.

Designation Drawing no.

Assembly drawing

9.2 Subsuppliers' documentation

Solenoid valve

Motorised control valve

Flowmeter