Mill Bearings and Lubrication (TST)

Mill Bearings and Lubrication
Objectives
To know the types of bearing systems on tube mills

To understand the lubricating system for the bearings
To be able to assess condition of the bearing system
2
Holcim Group Support Ball Mill Bearings and Lubrication 27.09.2019/TST
Agenda
 Design
 General
 Bearing Lubrication Systems
 QCE standards for bearings and tires
 PMRs
 Inspections
 Troubleshooting
 Bearing Replacement
3
Mill Bearings
 The following pictures shows the two main bearing types
Slide Shoe Bearings Trunnion Bearings

(e.g. in Combination with Central Drive) (e.g. in Combination with Pinion Drive)
4
Mill with Slide Shoe Bearings
Thrust
Bearing
(axial)
Slide Shoe
Slide Shoe Bearings (radial)
in Combination with DMGH Drive
(Flender Combiflex)
5
Mill with Slide Shoe Bearings
Slide Shoe
Double Slide Shoe Bearings

in Combination with DMGH Drive
(Flender Combiflex) Fixed Adjustable
Support Support
6
Adjustment of Slide Shoe Bearings
Static bearing shoe

Adjustable bearing shoe
Pre setting of adjustable bearing shoes by manual check at pressure gauges

(5 bar difference is tolerated)
Final adjustment according to bearing temperature during operation

(3 °C temperature difference between each bearing shoe within one mill side is tolerated)
Set points: Slide Shoe Temperature: 75°C  Alarm 80° C  Mill stop
7
Alarm Settings
Trunnion bearings
•70°C Alarm , 75°C Mill stop
Trunnion bearings without temperature device, have to be checked by
Pyrometer directly on the trunnion shaft surface during mill operation
• Changing of oil 1 time a year

Pinion bearings
• 60° Alarm, 65°C mill stop
Bearings without temperature device, have to be checked by
Pyrometer directly on the pinion shaft
•Changing of oil 1 time a year
•Vibrations in horizontal, axial and vertical direction up to 7,1 mm/s are tolerated
Slide Shoe bearings

 75° Alarm, 80°C mill stop
8
Slide Shoe Bearing
Swivel Hydraulic
Slide Shoe Lock Nut
Bearing Cylinder
Thrust
Bearing
Housing
Pressure Port Base Frame

9
Lubrication Principle
 For both, trunnion and slide shoe system the basics are
the same
 Oil is used to lubricate the surface between the rotating
parts and the fixed foundations
10
Trunnion Bearing
White Metal
Spherical
Calotte
Bearing
Housing
11
Lubrication System
Low Pressure
High Pressure
12
Components of the Lubrication System
7 6
8
9 5
8 3 4
2
2 2
7 5 3 12
1 1
2 3
11
10
10
13
Components of the Lubrication System
1. Low Pressure Pump
2. Check Valve
3. Pressure Relief Valve
4. Recirculating Valve for Heating Up
5. Filter system with differential pressure gauge
6. Oil Cooling, heat exchange system
7. Flowmeter
8. Temperature Sensor
9. Water/Glycol Heat Exchanger for Bearing
10. Pressure Sensor
11. Tank Heater with Temperature Control
12. High Pressure Pump
14
Comparison
Slide Shoes Trunnion

Disadvantage Advantage
No limitation in mill size Well known design

No complicate casting required Lower bearing surface speed  less
Simpler design of outlet diaphragm heat generation due to friction in oil film
Big openings allow higher gas flow
Need precise adjustment work High stressed area in the transition

(especially with 4 shoes per side) between trunnion and wall
very sensitive for inadequate  (risk for cracks)
lubrication Gas temperature affects bearing temp
15
The Two Main Problems with Trunnion Bearings
 Lack of Lubrication:
 Metal to metal contact
 Heat generation and melting of the White Metal
 Hydro Dynamic Fatigue:

 Oil gets pressed into micro structure of the White Metal
 The high oil pressure forms microscopic cracks
 The cracks grows and connect to each other
 Peaces of White Metal break out  Bearing Failure
Note: The Hydro Dynamic Effect is increased by:

 High porosity of the White Metal casting
 High specific bearing pressure (heavy Mill / Small Bearing)
 Run out on Trunnion  Oil film pressure peaks
16
Damaged Trunnion Bearing
Cracked White
Metal Layer
Heavy Breakouts due to Hydro Dynamic Effect

17
Quality Control of Equipment - Bearing
 A final inspection after manufacturing of a new bearing

should include the following:
 Visual inspection
 Ultrasonic test and hammer test of bonding
 White Metal thickness measurement
 Dye penetration test of borders
 Surface roughness test
 Hardness Test
 Curve radius and other Dimensions
 Review of documents and certificates
18
Measuring Play in Trunnion Bearing
 The play for trunnion bearings is crucial for a proper
lubrication film between the trunnion and the bearing
Value for a 120°
bearing
For a 180° bearing
b = 710 mm  x1 & x3
b = 910 mm  x2 & x4
Without Load Full Load
Ø b Without load Fully loaded
Trunnion 120° Bearing X1 X2 X3 X4
Example: 1350 200 0,6 0,3 0,3 0,2
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Bearing Replacement - General
 The mill must be lifted and
secured in place to allow the
bearing to be removed
 Using the overhead crane, slide

out the bearing with a nylon strap.
Keep tight as you pull it away
 Check the bearing “play”

when installing, and scrape
to supplier recommendation
as necessary
20
Bearing Replacement - General
 Check that there is sufficient

axial clearance between liner
and trunnion
21
Extra Slides
22
Example of Operational Settings
23
Gaps at trunnion bearing (bearing clearance)
Check with
feeler gauge
about 1/3
Running-in side
Surface of main contact
Without load With load
Holcim Group Support

1. The bearing bush is KP supply supplied by client
2. The diameter of the trunnion is ........................ mm.
3. The trunnion bearing of floating bearing fixed bearing has been changed
4. The following dimensions have been checked on ...............
The dimensions have been checked in with load without load
Prior to scraping After scraping

Running-in Running-out Running-in Running-out
side side side side
Test run: *) rated size see data on attached page

Ball Mill Bearings and Lubrication
after hrs
Bearing temp.
Client:
Signature
Ball mill: Gaps at trunnion bearings
Krupp Polysius: Code word/ Client:

Signature
Place:
24
27.09.2019/TST
Date: Polysius
Gaps at trunnion bearing (bearing clearance)
Trunnion bearing with load
Installed with full

mill load
Trunnion bearing without load
Surface of main contact.

About 90 % of contact
should be achieved.
Holcim Group Support

Rated dimensions
Trunnion bearing without load Trunnion bearing with load
Trunnion bearing Ø
Test run: after 8 hrs of operation the bearing temperatures should be stabilised
Bearing temperatures: alarm at 70 °C

Ball Mill Bearings and Lubrication
shut-down at 75 °C in normal case

Deviations of the values mentioned above only with the agreement of the mill department
Client:
Signature
Ball mill: Gaps at trunnion bearings
Enclosure
Krupp Polysius: Code word/ Client:
Signature
Place:
25
27.09.2019/TST
Date: Polysius
Trunnion Bearing
26
Slide Shoe System
Slide
Shoe
Lubrication
System
27
Trunnion Bearing
28

Mill Bearings and Lubrication (TST)

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Mill Bearings and Lubrication (TST)

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Formati disponibili

Mill Bearings and Lubrication

To know the types of bearing systems on tube mills

 The following pictures shows the two main bearing types

Slide Shoe Bearings Trunnion Bearings

Double Slide Shoe Bearings

Static bearing shoe

Pre setting of adjustable bearing shoes by manual check at pressure gauges

Final adjustment according to bearing temperature during operation

• Changing of oil 1 time a year

Slide Shoe bearings

Pressure Port Base Frame

Slide Shoes Trunnion

No limitation in mill size Well known design

Need precise adjustment work High stressed area in the transition

 Hydro Dynamic Fatigue:

Note: The Hydro Dynamic Effect is increased by:

Heavy Breakouts due to Hydro Dynamic Effect

 A final inspection after manufacturing of a new bearing

For a 180° bearing

 Using the overhead crane, slide

 Check the bearing “play”

 Check that there is sufficient

Holcim Group Support

2. The diameter of the trunnion is ........................ mm.

4. The following dimensions have been checked on ...............

The dimensions have been checked in with load without load

Prior to scraping After scraping

Test run: *) rated size see data on attached page

Krupp Polysius: Code word/ Client:

Installed with full

Trunnion bearing without load

Surface of main contact.

Holcim Group Support

Trunnion bearing without load Trunnion bearing with load

Bearing temperatures: alarm at 70 °C

shut-down at 75 °C in normal case

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