Manual for wear measurements of Polycom rollers for

• new installed rollers (“zero measurement”) and

• rollers in operation (wear progress and roller history).
Manual for wear measurement of HPGR rollers
Purpose: a) The circumferential measurements provide absolute data of the actual
roller size including the autogenous wear protection (profiling and material
between profiling). It is needed to derive information about concavity of each
roller and to compare roller diameters.
b) The distance wear measurements provide relative data (distance be-
tween measuring bar and profiling and roller base material). It is needed to
evaluate the wear progress of the roller profiling and the roller base material.
c) Both measurements, together with the visual inspection report are
needed to plan maintenance jobs, e.g. intermediate profile welding, new zig-
zag profiling or grinding of exposed roller shoulders (removal of concavity)
and to record the success of such maintenance jobs.
d) The measurement histories are needed to derive the HPGR specific
wear rates. Maintenance stopps become more plannable and the roller life-
time prognosis becomes more precise.

Time effort: 1 hours (for circumferential measurement incl. reporting).

1 - 2 hours (for additional distance measurement incl. reporting).

Frequency: Before and after maintenance actions (or as recommended by tk IS).

Activities: Circumferential measurement

1. Stop roller press.
2. Open housing doors
(recommended: Not earlier than 2 hours after stoppage).
3. Roughly clean complete roller surface (by air blasting or broom)
4. Follow circumferential measurement procedure
(as explained in this manual for each roller completely).
5. Report
(Fill in form sheet “POLYCOM roll body wear measurement report”).
Send your report to: rollers.tkis@thyssenkrupp.com.
6. Receive feedback
(Review and Comments by dedicated tk IS HPGR specialists).

Circumferential measurement procedure

Throw a measuring tape over the roll body, catch the loose end and bring
both ends together. Make sure the tape is wrapped tight and precicely around
the circumference.
Start with the measurement on drive-side and measure
on 5 positions (position 2, 4, 6, 8, 10 of the form sheet).
Keep measuring tape ends in both hands together until
all measurements are done.

Fill in the circumference in the form

sheet “POLYCOM roll body wear
measurement report”. The diameter
is calculated automatically.

Send your report and receive feedback.

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November 2016
 Activities: Distance wear measurement
1. Stop roller press.
2. Open housing doors
(recommended: Not earlier than 2 hours after stoppage).
3. Metal blanc clean roller surface in the measure bar area
(e.g. by steel brush or needle hammer)
4. Follow distance wear measurement procedure
(as explained in this manual for each roller completely).
Best practice: First measurement in 0° reference position (roll body
stamping field) and second measurement in 180° position (opposite side).
5. Report
(Fill out form sheet “POLYCOM roll body wear measurement report”).
Send your report to: rollers.tkis@thyssenkrupp.com.
6. Receive feedback
(Review and comments by dedicated tk IS HPGR specialists).

Distance wear measurement procedure

Install measuring bar. Make sure, the measuring bar is always installed in the same position
(to compare several measurements and derive wear rates later).

The 0° position for the first measurement should be in the area of the stamping field.

Begin measurement on drive side. For each measuring position, measure the distance of
measuring bar to roll body base material (deepest point) and the distance to profiling (highest
point). To avoid measuring errors, make sure to keep 90° angle between measurement bar
and roll body surface.

Fill in your measurements for 0°and

180°positions in the form sheet
“POLYCOM roll body wear measure-
ment report”.

Send your report and receive feedback.

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 Tipps and best practice

Calculate measuring positions:

Type in roller width in the form sheet (cell M15) to get measuring position (from drive end):

Measurement position 1 is always on drive side:

Find 0° and 180° measuring position and mark it with welding spots:
The stamping field is always on the non-drive side (this is always
the lower diameter of the conical inner bore of the roll body).
At the time of the first intermediate profiling, mark the 0° position
with one welding spot and the 180° position with two spots.
For the determination of 180° position, fix the measuring tape on
the roll body surface and turn the roller until you measure ½ of
the total circumference.

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