Operation and Maintenance Regulation for Finishing Mill

上海重矿冶金设备有限公司 SHANGHAI HEAVY MINING MACHINERY LTD.

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Operation and maintenance regulation

of 150,000 ton / annual

rolling mill line for wire rod

RASHMI, INDIA

上海重矿冶金设备有限公司

SHANGHAI HEAVY MINING MACHINERY LTD

2010.12

Chapter 1. Regulation I. Parameter for equipment

1. Pinch roll before no-twist mill

Diameter of pinch roller: Φ295mm～Φ310mm

Max distance of pinch roller: 335mm

Min distance of pinch roller: 298mm

Motor model: Z4-160-31

Power: 22kw

Voltage: DC 440V

Rotary speed: 1000～2000 r/min

Ratio: 0.963

Rolling speed: 6~12m/s

Cylinder: Φ125x200mm

Working pressure: 0.4～0.63mpa

2. Crop shear

Motor model: ZFQZ-315-081

Power： 112kw；

Voltage： DC 440v；

Rotary speed： 500～1000 r/min

Rotary diameter of blade： 800mm

Ratio： 1

Overlap of blade: 0.25～0.75mm

Rolling speed： ≤15 m/s

Cutting temperature： ≥850 ℃

Cutting section： max Φ17

3. Chopping shear

Motor model： Z4-225-11

Power： 75kw；

Voltage： DC 440v；

Rotary speed： 1000～2000r/min

Distance between centers of

Rotary blade and pinch roller: 443.5mm

Diameter of pitch circle： Φ164mm

Ratio: 1

Distance between centers of

Rotary blade: 250mm

Diameter of pitch circle： 250mm

Ratio: 1

Diameter of piston： Φ160mm

Diameter of piston rod： Φ40mm

Stroke: 40mm

Diameter of rotary blade: 250mm

Overlap of blade: 0.25～0.75mm

Chopping length: 260mm

4. Side looper

Working pressure 0.4 ～0.6 MPa

Diameter of piston Φ130mm

Piston stroke 254 mm

Forming range： 300～600mm

5. Snap shear

Working temperature: ＞850℃

Rolling piece speed： 6～8 m/s

Cylinder diameter & stroke Φ63mm x 70mm

Cylinder working pressure ≥0.4Mpa

6. 8-stand heavy duty no-twist mill

Motor model： Z710-320

Power 1300KW

Voltage： DC 750V

Cascade connection for 2 motors

Roller ring size

N0.1～ N0.3 Φ210.5(max)～Φ189.5(min) x 72 mm

N0.4～ N0.8 Φ158.8(max)～Φ142.91(min) x 62 mm

Rolling torque

Φ200 rolling mill stand M = 2.86 KNm

Φ150 rolling mill stand M = 1.61 KNm

Rolling force

Φ200 rolling mill stand P = 152 KN

Φ150 rolling mill stand P = 107.8 KN

Rolling mill stand type and quantity: 45°top cross 8-stand centralized drive

Cooling water working pressure： 0.5 ～ 0.6 Mpa3

Cooling water consumption： max 30m³/h for each stand

Speed-up gear box：

Ratio for high speed output shaft 0.2866

Ratio for low speed output shaft 0.3503

Ratio for each stands：

Stands No. Ratio No1 Φ200 1.01206818 No2 Φ200 0.80487113 No3 Φ200 0.66878989 No4 Φ150 0.40239947 No5 Φ150 0.32262096 No6 Φ150 0.25726428 No7 Φ150 0.20520449 No8 Φ150 0.16346826

Lubrication： centre oil lubrication

Oil working pressure： 0.35mpa

Oil consumption： 800 l/min

Oil model： Mobil 525

Cleanliness： 10µ

Cooling water for roller：

Working pressure 0.5~0.6mpa；

Water consumption Max.8×30m³/h

Hydraulic system for protecting jacket：

Working pressure 15mpa；

System flow： 20 l/min

Working pressure for load the roller: max22.5mpa

Working pressure for unload the roller: max 60mpa

7. Pinch roll before lying head

Power 55 KW ；

Voltage DC 440v；

Rotary speed 1500 ～3000 r/min

Gear box ratio： 1/4.247

Max pinch force： 3350 N

Cooling water pressure： 0.4～0.6 MPa

Water flow 10 m³/h

Lubrication oil pressure 0.35 MPa

Oil flow： 25L/min

Pressed air pressure： 0.4～0.6 MPa

Air flow： 10 m³/h

8. Lying head

Product size： Φ5.5mm ～ Φ16mm

Diameter of coil Φ1080mm

Max produce speed： 65 m/s

Power ： 90 KW；

Voltage DC 440V；

Ratio ： 1.538

Diameter of cylinder piston： Φ200 mm

Diameter of cylinder piston rod： Φ50 mm

Cylinder stroke： 610 mm

Working pressure： 0.6 MPa

9. Cooling roller table

Roller table driven motor： YTSP132M-4；

Power 7.5KW ；

Rotary speed： 1480 r/min；

Quantity： 7 set；

Ratio： 7

Diameter of roller： Φ120mm

Roller center distance： 295mm

Lifting motor model： Y132M-4；

Power 7.5KW ；

Rotary speed： 1440 r/min

Ratio： 24

Diameter of roller Φ120mm

Push rod motor model： Y112M-6；

Power： 2.2KW ；

Rotary speed 1480 r/min

Diameter of roller： Φ120mm

Roller length： 1450 mm

Line speed of roller table： 0.25～1.5m/s

Drop height between sections 250mm

10. Blower

Motor model： Y2-315M-6；

Power ： 90KW ；

Quantity ： 5 sets

Air volume： max 110000 m³/h

Air pressure： 1900 Pa

Cooling bearing water consumption 1.5～2t/h

Water pressure： 0.2～0.4 MPa

11. Reform station

Inside diameter of coil

collecting device： 1250 mm

Elevating distance： 50 mm

Air cylinder for finger：

Inside diameter of cylinder Φ200mm

Stroke： 320mm

Working pressure： 0.4～0.6 MPa

Hydraulic cylinder： φ40 x φ28mm

Stroke： 290mm

Coil plate lifting motor model： YTSZ280S-6

Power ： 55KW；

Brake torque: 1600 NM

Ratio： I = 27.96

Hydraulic cylinder for coil plate：

Inside diameter of cylinder Φ80mm

Stroke 440mm

Double-support arm spindle

motor model YTSZE200L1-4；

Power ： 30KW

Brake torque 300 NM

12. Coil transport car

Coil transport car motor model： YTSZ225S-8；

Power ： 22KW

Brake torque ： 400 ～ 630 NM

Transport speed： 300 mm/s

Ratio ： I = 9.75

13. Bundling machine

Tying coil motor model： Y100L1-4；

Power ： 2.2KW；

Quantity ： 4台

Driving supporting motor model： Y132S-4；

Power ： 5.5KW

Rotary speed 1480 r/min

Diameter of hydraulic cylinder： φ200mm ；

Stroke： 1700mm

Force ： 40 t ；

Max bundling length： 3650mm ；

Min bundling length： 600mm

14. Coil weighing scale

Hydraulic cylinder： Φ125 xΦ90 mm

stroke： 500mm

weigh range： 0 ～ 2500 Kg

accuracy： ±1 Kg

scale mark： 1 Kg

coil（outside diameter /

inside diameter / thickness） Φ1250/Φ850/Φ1800 mm

max coil weight： 2000 Kg

II. Regulation for operation

1. Pinch roll before no-twist mill

Feature

Pinch roll before no-twist mill located before crop shear, and it pinch the

rolling piece to no-twist mill while normally rolling. It consists of body,

gear shaft, arm and a pair of rollers, and the rollers could adjust by an air

cylinder. The air cylinder controlled by electromagnetic valve.

Function

1) Pinch roll pinch the rolling piece while the crop shear crop the head of

rolling piece by signal send from HMD, it will not release until the rolling

piece be conveyed into block mill.

2) Pinch the rolling piece the whole rolling time

3) Pinch the tail of rolling piece

1.1 Pinch roll’s speed is 100%~120% of rolling piece’s speed, and the

pinch force could adjust according to motor’s output torque. The setting

pinch force make the motor get the max output torque when motor

speed is 10% of rated motor speed.

1.2 It will pinch the rolling piece immediately while accident happens, and

it should release the rolling piece when the problem is solved.

1.3 It could choose whether pinch the rolling piece the whole rolling time

or not when normally rolling.

1.4 It should pinch the head of rolling piece after a time delay when HMD

detect the head of rolling piece.

1.5 It could release the rolling piece after the rolling piece be conveyed into

block mill.

1.6 When the lubrication oil flow detected by oil flow indicator is lower

than 3L/min, the system alarms, and the pinch roller must stop when

alarm last 2 minutes. When the lubrication oil flow detected by oil flow

indicator is lower than 1.5L/min and last 30s, pinch roll must stop

immediately.

1.7 When the lubrication oil pressure detected by pressure gauge is lower

than 0.25Mpa, system alarms, and the pinch roll must stop when the

alarm last 2 minutes. When the lubrication oil pressure detected by

pressure gauge is lower than 0.15MPa and last 30s, pinch roll must stop

immediately.

1.8 When the pressed air pressure detected by pressure gauge is lower than

0.35Mpa, system alarms, and pinch roll must stop when the alarm last 2

minutes.

1.9 Vulnerable part list:

No. description type / model drawing No. / standards material Qty remarks

1 entrance duct HC2010-004 Q235 1 piece welded part

2 exit duct HC2010-005 Q235 1 piece welded part

3 ogalloy HC2010-002-16 iron-base 2 pieces

No. description type / model drawing No. / standards material Qty remarks

6 liner HC2010-002-34 ZQA19-4 4 pieces

7 roller HC2010-002-54 45/alloy 2 pieces

8 sealing ring HC2010-002-56 Fluoro-rubber 2 pieces

9 joint bearing UG30 GB304-64 3 pieces product

10 sealing ring PD70x95x12 HG4-696-67 1 piece product

11 bearing 46211 Φ55xΦ100x21 GB293-64 4 pieces product

12 O ring d=3.1 L=6900 GB1235-76 rubber 1-2 1 piece product

13 O ring Φ70x3.1 GB1235-76 rubber 1-2 4 pieces product

15 O ring Φ165x3.1 GB1235-76 rubber 1-2 4 pieces product

17 nozzle ZG3/4 PZ86908 2 pieces product

18 pressure relief valve PJ-L25-51 1 piece product

19 electromagnetic valve AC220V 25D2-25-L1 1 piece product

20 one-way throttle valve LA-L25-L1 2 pieces product

21 triple unit 398-293 1 piece product

2. Crop shear Feature

Crop shear located between pre-finishing mill and block mill, it using for

rolling piece’s head cut, rolling piece’s tail cut and accident cut. Crop shear

adopt rotary structure and driven by a 112Kw motor through gear coupling

without mechanical braking. Two blades assemble on two parallel shafts

which connected by a pair of gears. The gear ratio is 1:1, and that makes

the two shafts as same rotary speed but reverse rotary direction. The blades

overlap and cut the rolling piece once a cycle driven by motor through the

gear coupling. After cutting, the shaft hold in the prepare position

controlled by proximity switch and the location detector on motor.

2.1 Crop shear could operate automatic or manually.

Manual: controlled by operator press buttons

Automatic: controlled by computer for non-link cut and accident cut

2.2 The blades hold the prepare position at 90°in coordinates, when get

the cut signal, the blades start clockwise rotary and speed-up to the

cutting speed according to the rolling speed. The rolling speed about

6 ～ 12 m/s is detected from the exit of pre-finishing mill, and the

cutting speed could add a adjustable overspeed to the rolling speed.

Blades depart from rolling piece before it get 30°in coordinates, then

start braking by motor. Blades go to the prepare position with creeping

speed (motor rotary speed about 50～60 rpm) with precision ±1°.

2.3 There are an oil flow indicator and a pressure gauge for the crop shear

to ensure the normally lubrication. It will alarm while the oil flow and

oil pressure are lower than the setting value.

2.4 Rolling piece’s head cutting

While HMD detect the rolling piece’s head, the pulser which located

between duct and pinch roll starts to work. When the pulse counter

achieves the setting value, the HMD send the signal to crop shear, and

the crop shear starts the cutting period. When blades cut the rolling

piece, the blades' speed is 5～20％ faster than the rolling speed and

adjustable. After the rolling piece’s head is cut, the rolling piece goes

into the switcher which located after crop shear. The switcher is on the

“crop position” before the rolling piece head into the block mill through

side looper. As soon as rolling piece enter into the block mill, the

switcher turn to the “chop position” and get ready for chopping if the

accident happens. While the rolling piece tail depart from pinch roll and

rolling normally, switcher turn back to “crop position” and ready for cut

the rolling piece’s tail and cut next rolling piece’s head.

2.5 Rolling piece’s tail cutting

While HMD detect the rolling piece’s head, the pulser which locate

between duct and pinch roll starts work. When the pulse counter

achieves the setting value, the HMD send the signal to crop shear, and

the crop shear starts the cutting period. When blades cut the rolling

piece, the blades’ speed is equal the rolling speed even slower than the

rolling speed. The switcher is on the “crop position” and the cut off

piece being guided to the chute.

2.6 Accident cut

Accident cut start by detecting system automatic or manual. The cut

speed should 5～15％ faster than rolling speed while accident cut, and

the switcher should turn to the “chop position” and ensure guide the

rolling piece to the chopping shear. It should set the cut speed by pulpit

when manual setting.

2.7 Non-link cut

There is a button in the local box that could act the non-link cut when

permissible. It could finish once cut period after press the button once,

and the cut speed is set by pulpit. This function is for test run usually.

2.8 Installation and adjustment for crop shear

2.8.1 Installation: It should follow technical requirement on drawings and

listed standards:

(1) Metallurgical mechanical equipment installation and acceptance

check standard – General: YBJ201-83

check standard - Hydraulic, pneumatic and lubrication system:

YBJ207-85

check standard – rolling equipment: YB9249-93

The crop shear installation precision adopt class I

(4) The installation of electrical equipment on crop shear should follow

the national standards or profession standards.

2.8.2 Adjustment: the adjust must after equipment installed completely

and acceptance check qualified. The adjustment should follow the

drawing and list requirement:

(1) The gap between two blades should in 0.2 ～ 0.25 mm, and the

overlap of two blades should less than 0.75 mm. It should adjust the

gear backlash of gear first, then adjust the gap to 0.2 ～ 0.25 mm by

regrinding the washer. The overlap of blades should adjust by

regrinding the blade and adding washer.

(2) The adjustment for entrance and exit guide plate should ensure the

rolling piece enter and exit crop shear smoothly.

(3) Each rotary part should act smoothly, and could adjust the bearing

gap if necessary.

(4) It should ensure the oil distribution system distribute the oil to each

lubrication point with right flow, and make sure there is no jamming

and leakage.

(5) Driven the crop shear several cycles manually, and make sure that

the blades not crash.

2.9 Examination

location aim part / place state period way

box body leakage seal place working each shift Human’s eye

bearing working bearing working each shift hear voice and

measure the temperature

lubrication pipes

pressure and leakage

pressure gauge and pipes working each shift human’s eye

blade wear blade’s edge unworking each shift Human’s eye

blade gap between blades unworking each shift feeler gauge

blade loose or not bolt unworking each shift human’s eye

location aim part / place state period way

gear wear tooth face unworking half a year human’s eye

2.10. Vulnerable parts list

No. description model / specification

drawing No./ standard material Qty remarks

1 blade HB2100-007-04R 5cr5WM。Vsi

2 pieces

2 bearing 3053720 Φ100xΦ165x52 GB288-87 4

pieces product

3 sealing B170x200x15 GB9877.1-88 rubber I-1 3 pieces product

4 bearing 240308 Φ150xΦ225x75 NTN 2

pieces product

5 bearing 3003130 Φ150xΦ225x56 GB288-87 2

pieces product

6 sealing B22x40x7 GB9877.1-88 rubber I-1 1 piece product

3. Switcher

Feature

Switcher located after crop shear and guides the rolling piece to side looper

while normally rolling and guide to chopping shear while accident happens.

Switcher consists of switcher body and air cylinder.

3.1 Switcher has two working positions, one is “crop position”, and another

is “chop position”, and switch position by a change valve. The rolling

piece will be guided to side looper while switcher is on “crop position”,

and will be guided to chopping shear while switcher is on “chop

position”. There are two proximity switches to detect the switcher’s

working position.

3.2 Vulnerable part list：

No. description model / specifications material quantity remarks

1 bearing 311 Φ55xΦ120x29 1 product

2 bearing 314 Φ70xΦ150x35 1 product

3 air cylinder JB160x80-S 1 product

4 scraper seal FA80x90x6.3 1 product

5 one-way throttle valve LA-L20-L1 2 product

6 electromagnetic valve 25D2-20-L1 1 product

7 triple-unit 399-283 product

8 muffler (M27x2) X5-L20-L1 2 product

4. Chopping shear

Feature

Chopping shear chop the rolling piece while accident happens after

chopping shear on rolling line. Chopping shear consist of shear body and

motor. Three blades on both the blade base, that makes 3 cut while the shaft

run a cycle. The pinch roll on chopping shear driven by shaft through belt,

and pinch act by air cylinder.

4.1 Chop the rolling piece come from crop shear while accident happens.

4.2 Three blades on both the blade base, that makes 3 cut while the shaft

run a cycle. The pinch roll on chopping shear driven by shaft through

belt, and pinch act by air cylinder.

Chopping length: 260mm

Diameter of rotary blade: 380mm

4.3 Pulpit, MMI and local box near CT could control chopping shear, and

should have list functions

a. Pinch roll on chopping shear start button with lamp

b. Pinch roll on chopping shear stop button with lamp

c. Chopping shear start button with lamp

d. Chopping shear start bottom with lamp

4.4 Control and interlock

Chopping shear could operate automatic or manually.

Manual: controlled by operator press button

Automatic: controlled by computer with non-link cut and accident cut

4.4.1 Control

In manual model, chopping shear start by pressing the start button and

stop by pressing the stop button. The cutting speed is controlled by the

“speed-up / stop / speed-down” knob.

In automatic model, chopping shear start by pressing the start button

and will not stop while rolling. The cutting speed is same as the crop

shear’s cutting speed, which means cutting speed is faster 5-15% than

the rolling speed.

4.4.2 Interlock

A. When the lubrication oil pressure is lower than 0.3Mpa, the system

alarms, and block mill must stop when alarm last 2 minutes. When

the lubrication oil pressure is lower than 0.25Mpa and last 30s, block

mill must stop immediately.

B. When the lubrication oil flow is 0 and last 30s, block mill must stop.

C. When the pressed air pressure is lower than 0.3Mpa, system alarms,

and block mill must stop when alarm last 2 minutes. When the

pressed air pressure is lower than 0.25Mpa and last 30s, block mill

must stop immediately.

4.5、Vulnerable part list：

No. description model / specifications Qty material drawing No. /

standard remarks

1 blade 6 5Cr5WMoVSi HB2200-024R

2 sealing PD125x60x4 2 JB2600-80 product

3 O ring Φ210x7 2 JB/ZQ4224-86 product

4 bearing 3053222

Φ110xΦ200x69.8

2 GB288-87 product

5 bearing 53518 Φ90xΦ160x40

2 GB288-87 product

6 air cylinder Φ160xS40 1 JB1448-74 product

7 belt B-13700mm 6 GB11544-89 product

8 bearing 53516 Φ80xΦ140x33

4 GB288-87 product

9 O ring Φ140x5 4 rubberⅠ-4 GB3452.1 product

11 O ring Φ170x6 4 rubberⅠ-4 JB/ZQ4224-86 product

12 O ring Φ160x5 2 rubberⅠ-4 GB3452.1 product

15 signaler YXG-20 0.5KW

1 GB/ZQ4596-86 product

16 indicator GZQ-10 2 GB/ZQ4597-86 product

17 one-way throttle valve

LA-L10-S1 2 product

18 electromagnetic valve

K25D-10 1 product

19 muffler XS-L10-L1 2 product

20 triple-unit 399-253 1 product

5. Side looper

Feature

Side looper located between crop shear and block mill, it could provide

non-tension or micro-tension for rolling, and also provide a buffer space for

rolling piece. Looper consist of form roller, guide roller, looper body and

loop scanner, the looper acted by air cylinder and controlled by loop

scanner. Form roller has two positions, one is working position, and

another is unworking position. Rolling piece could go through the looper

straight while the form roller is on unworking position. Form roller will

cross the rolling line when turn to working position from unworking

position, and make rolling piece form a loop. The loop will be formed

while the rolling piece’s head into the block mill with right speed setting.

5.1 Form roller control

The form roller be controlled by signal send from detector at upstream

(such as looper scanner, HMD), and it should set the advance. The

automation system sends the delay signal according to the rolling speed.

Form roller could also controlled manual with “reach” and “regain”

button.

Form roller must stay at the unworking position until rolling piece’s

head into the block mill, it must turn to working position immediately

while the rolling piece’s head into the block mill. Form roller must stay

at the unworking position while accident happens at looper.

Form roller must stay at the working position until the rolling piece’s

tail depart from the block mill, and must turn to the unworking position

immediately while rolling piece’s tail depart from the block mill. It may

cause the loop fall down, rolling piece enter the guide after looper

overlapped and accident if form roller turn to unworking position while

rolling piece still in block mill.

5.2 Forming automatic control

Forming controlled by loop scanner and loop adjuster, loop scanner

detects the forming situation and generate location signal. This location

signal is compared with the base valve in the loop adjuster and get

deviation signal, and the deviation signal be transformed to speed signal.

Controlled by the speed signal, rolling speed be adjusted to make the

forming as a setting value.

5.3、 Vulnerable part list：

No. description quantity material drawing No. remarks

1 air cylinder 1 HC3001-021

2 roller assembly (1) 2 HC3001-034

4 form roller assembly 1 HC3001-036

7 one-way throttle valve 2 KLA-L25 product

8 electromagnetic valve 1 K25D2-25 product

9 muffler 2 FXS-L25 product

10 triple-unit 1 398-293 product

11 nozzle 2 Q235A HC3001-041-01

6. Snap shear

Feature

Snap shear located after the side looper. It will cut off the rolling piece

when block mill or equipment after block mill failure to prevent rolling

piece into the block mill. It also prevents the rolling piece into the block

mill for safety when protecting jacket for block mill is open. Snap shear

have two blades and the cutting acted by air cylinder. There is a spring in

the cylinder for cutting in case of non-pressure and a proximity switch in

the cutting position.

6.1 Control and operation

Snap shear could work manually by pulpit and local box or automatic.

In manual model, snap shear cut by press “close” button and release by

press “open” button.

6.2 Interlock

6.2.1 Snap shear must not open while any of list situation happens when

automatic model.

(1). Main motor for block mill is power off.

(2). Block mill lubrication system is failure.

(3). Air-oil lubrication system for entrance guide is failure.

(4). Protecting jacket for block mill is open.

(5). There is no flow of cooling water for roller or low pressure of

cooling water for roller.

(6). Protection jacket for laying head is open.

6.2.2 Snap shear could open while the all list situation are satisfied.

(1). Protecting jacket for block mill is closed.

(2). Oil lubrication system for block mill is working normally.

(3). Air-oil lubrication system is working normally.

(4). Main motor for block mill is working normally.

(5). The situation of coiling water for roller is normal.

(6). Block mill is working normally, cobble detector is normal.

(7). Pinch roll before laying head and laying head are working normally.

(8). The “open” button be pressed.

6.2.3 Snap shear will stop when any of list situations happens when

automatic model:

(1). The “close” button be pressed.

(2). Main motor for block is stop or the rotary speed is slower than 200

(3). The motor for lubrication shut off suddenly or the pressure of oil is

(4). Pinch roll before laying head is stop.

(5). The situation of cooling water for roller is abnormal.

(6). Protecting jacket for block mill is open.

(7). Accident happens in block mill.

(8). Block mill is abnormal.

(9). The cooling roller table is stop.

6.3 Interlock to other equipment

6.3.1 Protecting jacket for block mill must not open until the snap shear is

close. Snap shear must not open until protecting jacket for block mill

is close.

6.3.2 Protecting jacket for laying head must not open until the snap shear

is close. Snap shear must not open until protecting jacket for laying

head is close.

6.3.3 The form roller in looper must stay the unworking position when

the snap shear is close.

6.3.4 The extractor must not eject the billet from the furnace when the

snap shear is close.

6.4 Control

While the accident happens at downstream in automatic model, the

chopping shear should chop the rolling piece and the snap shear should

cut the rolling piece. It should follow list process:

6.4.1 Snap shear must not close until chopping shear works.

6.4.2 Snap shear could close after chopping shear works 2s later. And this

time is adjustable.

6.4.3 Above process suit for manual model while press the “close” button

meanwhile HMD detect the rolling piece.

6.5 Vulnerable part list：

No. description Qty material Drawing No. remarks

1 Air cylinder 1 HC3002-008

2 Blade 2 5Cr5WMoVSi HC3002-013

3 ogalloy 4 Iron-base HC3002-024

4 electromagnetic valve 1 25ZVD-L15-L1 product

5 Muffler 2 XS-L15-L1 product

6 Triple-unit 1 398-263 product

7. Block mill

Feature

Rolling piece be rolled by 8 stands heavy duty no-twist mill (Block mill)

from Φ13~Φ20 to product Φ5.5~Φ12. The design speed is 60m/s and the

guarantee speed is 50m/s.

These central driven 8 stands adopt 45° top cross structure, them consist of

3 stands of Φ200 which roller ring’s dimension is Φ210.5 / Φ189.5 ×

72mm and 5 stands of Φ150 which roller ring’s dimension is Φ158.75 /

Φ142.91 × 62mm. The last 2 stands of Φ150 are high speed stand. Block

mill consist of 8 stands, speed-up gear box, base plate, gear coupling, water

fender, protecting jacket and so on. The stands consist of gear boxes and

bevel gear boxes, and the roller is cantilever structure.

7.1 Feature for structure

7.1.1 Block mill consist of 3 stands of Φ200 and 5 stands of Φ150, and

that reinforce the intensity.

7.1.2 The last 2 stands of Φ150 are super-high speed stand, could increase

the exit speed and the guarantee speed could achieve 50m/s.

7.1.3 Stands adopt 45°top cross structure, which increase the stability

and decrease the equipment’s weight, and that make the operation and

maintenance easier.

7.1.4 The neighbor stands arrange 90°(perpendicular) to each other,

which makes the no-twist rolling.

7.1.5 The roller adopt cantilever structure, and using the taper sleeve to

fix the roller ring in the shaft end. The gear box using eccentric

mechanism which has oil-film bearing and roller shaft to adjust the

roller gap.

7.1.6 Bevel gear box consist of body, driving shaft, bevel gear pair, and

synchronous gear pair. All gears are hard tooth gear with grade 5

precision to ensure the stable working in high speed.

7.1.7 Gear box and bevel gear box are connected with bolts. During

assembling, insert the head of bevel gear box to the gear box, make

sure two heads and two roller shaft gears mesh with each other.

7.1.8 By using the thrust bearing, could settle the roller shaft’s axial float

problem and ensure the dimensional precision of product

7.1.9 Adjustment of roller gap is realized with a screw bar with left and

right screw-thread, which will make the eccentric mechanisms rotate

in different direction, and the roller gap will change by the eccentric

movement of the eccentric mechanism relative to the rolling line, and

the location of the original rolling line and the guide are maintained.

7.1.10 The roller ring is made of tungsten carbide, and it is connected to

the shaft of roller through the taper sleeve. It should be reload with

special hydraulic tool, which makes the reload process easy and fast.

7.2 Assembling and test run

Rolling stand and other parts assemble at manufactory, it should follow

the standard YB/T036.18－92 and technical requirement on drawings.

Them will not allow to leave the factory until them pass the no-load test

7.2.1 Preparation

1) Clean the parts, remove the dirty and rust, dredge the pipes and holes,

coat with rust preventative oil.

2) Check the dimensional tolerance of fitting parts.

3) Prepare the measures and tools.

4) Mark the each stand’s number on because of the different ratio.

7.2.2 Stand assembling

1) bevel gear box

The assembling of bevel gear and shaft suggest adopt the pressing fit

because of the small range of interference and the disassembling

suggest adopt extracting. Adjust the contact pattern and backlash

carefully while installing the bevel gear. Increasing contact pattern

and suitable backlash will extend the gear’s life.

2) Oil-film bearing assembling

Heat the eccentric sleeve to 120℃, cool the bearing bush to -80℃ in

dry ice or liquid nitrogen.

Correspond the separation line of bearing bushes with the mark line

on the eccentric sleeve, and align the oil hole on bearing bush and oil

hole on the eccentric sleeve..

Push the bearing bushes into the eccentric sleeve with the guiding of

taper guide sleeve.

Check the alignment of oil hole on the bearing bush and oil hole on

the eccentric sleeve, make sure there is no damage on bearing

bushes.

3) Rolling bearing assembling in stands

The rolling bearing used in gear box and bevel gear box are all high

speed bearing made by MRC. The assembling of rolling bearing and

shaft suggesting the different temperature method.

The rolling bearing on roller shaft is thrust ball bearing, its backlash

should be 0.012~0.038 mm to guarantee the rolling product’s quality.

4) Assembling and disassembling the roller ring

It should using assembly tools with 22.5MPa pressure for

assembling the roller ring.

It should using disassembly tools with <60MPa pressure for

disassembling the roller ring.

5) Other

There must no beating to the shaft shoulder and end of baffle ring

which using for axial locating while assembly.

It should adjust the axial compressing suitably for sealing ring in the

roller’s neck area, make sure not too tight cause the damage of the

sealing ring and not too loose cause leakage.

All lubrication pipes should be firm and will not be crashed by the

rotary parts. The lubrication pipes must lubricate the gears and

bearings well.

It should check the list dimensions and satisfy the requirements after

assembling

Φ200 stand Φ150 stand

A 836.6±0.08 836.6±0.08

B 432±0.06 380±0.012

C、D C≠D：<0.1mm

7.2.3 Block mill assembling

1) Assembling order

Install the base plate, speed-up gear box and main motor on their

position.

Install the No.1 – No.8 stands on the their position.

Install the coupling between motor and speed-up gear box, coupling

between speed-up gear box and No.7 stand, coupling between

speed-up gear box and No.8 stand and couplings between each

stands. Adjust the location accurately of main motor, speed-up gear

box and stands, then fasten all parts.

Install the water fender and buffer box.

Install the cobble detecting device.

Install the protecting jacket for block mill.

Install the pipes for oil lubrication, hydraulic system and cooling

water.

2) Guarantee after assembling

Gradient of coupling’s both ends should less than 1/2000, radial

displacement should less than 0.06mm. The long shaft’s proper

alignment on whole length should less than 0.08mm after couplings

between stands be installed.

The displacement of the center line should less than Φ0.1mm for

neighbor stand, and should less than Φ0.3mm for whole stands.

7.2.4 No-load test run for single stand

1) It should driven by human’s hand firstly for each stand and speed-up

gear box after assembling, and make sure all parts run smoothly. The

adjustment of roller gap should flexible.

2) Each stand install on the base plate and connect with test run motor

after hand driving. The rotary speed of stand’s input shaft is 1000

r/min and last for 3 hours after all lubrication pipes be connected.

Check the joggling voice of gear, the contact pattern and backlash,

the temperature rise of oil-film bearing, and the leakage situation of

sealing places.

3) The roller should be cooled by cooling water while test run.

4) To make sure the lubrication oil volume is ~100 L/min，oil pressure is

0.35MPa, filter precision is 10μ and oil temperature is ~38℃ for

each stand.

5) Speed-up gear box connect with test run motor after hand driving.

The rotary speed of input shaft is 1000 r/min and last for 3 hours

after all lubrication pipes be connected. Check the joggling voice of

gear, the contact spot and backlash, the temperature rise of oil-film

bearing, and the leakage situation of sealing places.

6) To make sure the lubrication oil volume is ~200 L/min，oil pressure is

speed-up gear box.

7.2.5 No-load test run for block mill

It should run no-load test run after block mill assembling.

1) Necessary condition for block mill’s test run

All oil lubrication points get oil supply according to the requirement

of pressure, oil flow, temperature, cleanliness, and oil grade.

Apply lubrication grease on each coupling

Apply lubrication grease on all lubrication surfaces

Supply cooling water onto the roller.

Close protecting jacket while the test run.

2) Scheme of test run

Test run procedure: start manual operation first, then switch to auto

mode; stepping movement before continuous movement; low speed

running at first, then switch to middle speed and high speed.

No-load test run of the equipment should last for 4 hours

continuously for min.

Equipment and components should shuttle 5~10 times in stroke

range.

Adjustment region should be tested 5 times each for min.

3) Requirement for test run

Rotary speed of the speed-up gear box’s input shaft should be 1000

r/min during the test run.

Vibration strength of the block mill should be lower than 4.5mm/s.

Noise level should be lower than 85dB (checked at 10m length of the

block mill).

Temperature rise of each rolling bearing should be lower than 40 , ℃

and the highest temperature of each rolling bearing should not

exceed 80 .℃

There should be no oil leakage and water penetration.

7.3 Operation before DC motor start

7.3.1 Check the signals of lubrication system, cooling system, electrical

system, pneumatic system and so on. Check the pressure, flow,

temperature, cleanliness, oil grade, oil situation of lubrication system.

7.3.2 Apply lubrication grease on each coupling

7.3.3 Apply lubrication grease on all lubrication surfaces

7.3.4 Supply cooling water onto the roller.

7.3.5 Check the grooves’ abrasion and adjust them.

7.3.6 Make sure all guides clean, check the guide roller’s rotary situation.

7.3.7 Make sure the guides’ center line correspond with the rolling line.

7.3.8 Check the situation of cooling water for groove and nozzle’s

position.

7.3.9 Check the function of control system.

7.3.10 Check the alarm system, controlled by the pulpit.

7.3.11 Check the hydraulic system, and the interlock function to other

equipment.

7.3.12 Check the operation of cooling water system.

7.3.13 Check the leakage. (oil lubrication system, cooling water system,

hydraulic system, grease lubrication system and so on)

7.3.14 Make sure the parameters’ setting follow the rolling schedule list.

7.3.15 DC motors could adjust speed in cascade model. The rolling speed

is accordant with the setting.

7.3.16 Protecting jacket is safe and trustworthy. It is close while rolling.

After all mentioned operations be done, the DC motor could start.

7.4 Operation while running

7.4.1 Stepping movement before continuous movement; low speed

7.4.2 Make sure the tension situation is normal, and check the situation of

cascade control and motor’s current.

7.4.3 Make sure the vibration intensity of block mill should ≤ 4.5mm/s.

7.4.4 Check the situation of rollers and guides, adjust the guides’ center

correspond with the rolling line.

7.4.5 Make sure the roller’s axial and radial adjustment smoothly.

7.4.6 Make sure the grooves and guides be cooled well.

7.4.7 There must no leakage and infiltration in joints, pipes and sealing

places.

7.4.8 The noise must ≤ 85dB (10m far away).

7.4.9 The temperature rise must ≤ 40℃, and the max temperature must

≤ 80℃

7.4.10 Check the situation of oil lubrication and air-oil lubrication every

1~2 hours.

7.4.11 It should stop the cooling water supply before stop the equipment

and stop the supply of oil lubrication and air-oil lubrication after

equipment been stopped 5 minutes.

7.5 Vulnerable part list

7.5.1、Φ200 gear box(HB3111-000)

No. Description model/material Qty Drawing No. remark

1 Half bushing of oil-film bearing 172050JA Load-bearing end 6 MRC

2 Half bushing of oil-film bearing 172050KA Unload-bearing end 6 MRC

3 Half bushing of oil-film bearing 172050A Load-bearing end 6 MRC

4 Half bushing of oil-film bearing 172050B Unload-bearing end 6 MRC

5 Protecting sleeve 2Gr13 6 HB3111-022

6 O ring Oil resistant and high-temperature

resistant rubber Ⅲ-2 6 GB3452.1-82

7 Sealing ring Oil resistant and high-temperature

resistant rubber Ⅲ-2 12 HB3111-037

8 O ring 25×3.55 Oil resistant and high-temperature

11 washer Oil resistant rubber asbestos plate

3 HB3111-0012

12 Damping washer Product 12 HB3111-011

13 Sealing 38×56×12 Oil resistant and high-temperature

resistant rubber Ⅲ-2 6

7.5.2、Φ150 gear box(HB3112-000)

No. description Model/material Qty Drawing No. remarks

1 Half bushing of oil-film bearing 172050E Load-bearing end 10 MRC

2 Half bushing of oil-film Unload-bearing 10 MRC

No. description Model/material Qty Drawing No. remarks

bearing 172050FB

3 Half bushing of oil-film bearing 172050A Load-bearing end 10 MRC

4 Half bushing of oil-film bearing 172050BB Unload-bearing 10 MRC

5 Cover (protecting sleeve) ZG1Cr17Ni2 10 HB3112-001

7 Reinforce sealing ring assembly 10 GB9877.1-88

8 Sealing ring Oil resistant and high-temperature

resistant rubber Ⅲ-2 10 HB3112-019

9 O ring 140.6×2.2 Oil resistant and high-temperature

10 O ring 88.9×2.2 Oil resistant and high-temperature

11 Asbestos pad Oil resistant rubber asbestos plate

5 HB3112-022

12 Washer assembly 20 HB3112-010

7.5.3、couplings between stands

No. description material Qty Drawing No. remark

1 coupling (1) assembly 6 HB3115-000

2 coupling (2) assembly 1 HB3116-000

3 coupling (3) assembly 1 HB3116-000A

7.5.4、Stand

No. description Model/material Qty Drawing No. remark

1 Entrance duct(1) Welded part 1 HB3117-001

No. description Model/material Qty Drawing No. remark

2 Exit duct(1) Welded part 2 HB3117-018-03

3 Exit duct(2) Welded part 2 HB3117-018-06

4 Guide duct(1) 16Mn 1 HB3117-018-01-01

5 Guide duct (2) 16Mn 1 HB3117-018-01-02

6 Guide duct (3) 16Mn 1 HB3117-018-01-07

7 Guide duct (4) 16Mn 1 HB3117-018-01-08

8 Lower guide duct(1) QT600-3 1 HB3118-005

9 Upper guide duct (1) QT600-3 1 HB3118-006

10 Lower guide duct (2) QT600-3 1 HB3118-009

11 Upper guide duct (2) QT600-3 1 HB3118-008

12 Hose unit 25Ⅰ-1100 A 8 JB1885-77 cooling

13 Hose unit 38Ⅲ-1800 8 JB/T6142.1-92 lubrication

14 Hose unit 25Ⅲ-2000 8 JB/T6142.1-92 lubrication

15 Pressure gauge YX-100 21 lubrication

16 Pressure gauge switch KF-L8/20E 21 lubrication

17 Hydraulic cylinder C25ZB100/70 2 Protecting jacket

18 Proximity switch YB-D-C20L 2 Protecting jacket

19 bearing XQZD-050 8 0-1MPaDC24V Protecting jacket

7.5.5、Speed-up gear box

No. description Model/material Qty Drawing No./ standard remark

1 Rolling bearing 6226 2 SKF

2 Rolling bearing N128VAA 4 ROIIWay

3 Rolling bearing QJ234N2 1 SKF

4 Rolling bearing NU234EC 1 SKF

No. description Model/material Qty Drawing No./ standard remark

5 Rolling bearing NU1040 1 SKF

6 Rolling bearing NU228EC 2 SKF

7 Rolling bearing QJ228N2 1 SKF

8 O ring 38.7x2.65 1 GB3452.1-82 butadiene-nitrile rubber

9 Pressure relief valve PJ-25-S1 1 pneumatic

10 Electromagnetic valve 22JD-25-Wx1 1 pneumatic

8. Pinch roll before laying head and laying head

Feature

Pinch roll before laying head and laying head located after the cooling

water box. Rolling piece be pinched into the laying head by pinch roll

before laying head and be laid onto the cooling roller table as Φ1080mm

coils by laying head’s movement.

Pinch roll before laying head and laying head are independent equipments

to another. Pinch roll before laying head located before the entrance of

laying head.

The pinch rollers are cantilever structure, and arranged horizontally.

Rolling piece could be pinched and released by upper roller and lower

roller acted by a pneumatic cylinder through a link mechanism. The rollers

are driven by a DC motor through a gear box. The open width for rollers is

adjustable, and the body of pinch roll is welded. The gears, oil-film

bearings and high-speed rolling thrust bearing are lubricated by centralized

lubrication. While normally working, the pinch roller always rotary with

the speed set according to the rolling technology. Pinch roll could pinch the

rolling piece’s head, rolling piece’s tail and the rolling piece whole the time

according to the rolling technology.

Laying head is inclined 10°to horizontal. It consists of laying pipe which

fixed on the rotary hollow shaft unit and transmission unit. The hollow

shaft unit is driven by DC motor through a pair of bevel gears. The laying

pipe rotary with setting speed and lay the coils out with satisfied size.

Rotary hollow shaft unit consist of hollow shaft and pipe support

assembly which used to fix the laying pipe. Hollow shaft is driven through

bevel gear. There has sleeve unit between the hollow shaft and duct which

in the hollow shaft, the sleeve unit could cool the duct and prevent the heat

from rolling piece to the bearings on the hollow shaft.

The gear box is welded structure, the gears and bearings which in the gear

box are lubricated by centralized lubrication.

Protecting jacket of laying head is outside of the pipe support assembly. It

is barrel structure and incline 10°to horizontal same as the laying head.

The upper part could open by hydraulic cylinder when change the laying

pipe. But the upper part must close when normally working.

It should do the static balancing test first for the rotary hollow shaft unit

and parts which assembled on the rotary hollow shaft. According the test

result, adjust the balance of shaft assembly. Then do the dynamic balancing

test with rotary speed 2000r/min, the precision of dynamic balance should

≥ grade G2.5. Do the test run after equipment assembling. Measure the

vibration at the front bearing cover and the back bearing cover, make sure

the vibration both are ≤ 5mm/s.

After the adjustment, weld the stop dog on the base plate to keep the laying

head’s gear box.

8.1 Assembling and test run

Pinch roll before laying head and laying head assemble at manufactory,

it should follow the standard JB/T5000.10-1998, standard

JB/T5000.11-98 and technical requirement on drawings. Them will not

allow to leave the factory until them pass the no-load test run.

8.1.1 Preparation

1) Clean the parts, remove the dirty and rust, dredge the pipes and holes,

coat with rust preventative oil.

2) Check the dimensional tolerance of fitting parts.

3) Prepare the measures and tools.

8.1.2 Assembling

1) Bevel gear assembling

The assembling of bevel gear and shaft suggest adopt the pressing fit

consider of the small range of interference, and the disassembling

suggest adopt extracting.

Adjust the contact area and backlash carefully while installing the

bevel gear. Increasing contact pattern and suitable backlash will

extend the gear’s life. The backlash should be Cn=0.30~0.592mm,

and the contact pattern should ≥ 75%.

2) Oil film bearing assembling for upper roller

Heat the shaft sleeve of upper roller to 120℃, and cool the bearing

bush to -80℃ with dry ice or liquid nitrogen.

Correspond the separation line of bearing bushes with the mark line

on the eccentric sleeve, and align the oil hole on bearing bush and oil

hole on the eccentric sleeve..

Push the bearing bushes into the eccentric sleeve with the guiding of

taper guide sleeve.

Check the alignment of oil hole on the bearing bush and oil hole on

the eccentric sleeve, make sure there is no damage on bearing

bushes.

3) Rolling bearing assembling

The rolling bearing be used in gear box made by FAG, MRC, SKF.

The assembling of rolling bearing and shaft suggesting the different

temperature method.

The rolling bearing on roller shaft for pinch roll is thrust ball bearing,

its backlash should be 0.012~0.038 mm to guarantee the rolling

product’s quality. The axial float should ≤0.05mm, and the radial

runout should≤0.08mm.

8.1.3 Assembling and disassembling the roller

1) It should using assembly tools with 22.5MPa pressure for assembling

the roller ring.

2) It should using disassembly tools with <60MPa pressure for

disassembling the roller ring.

3) It should use the special tool for assembling and disassembling.

8.1.4 Other

1) There must no beating to the shaft shoulder and end of baffle ring

which using for axial locating while assembly.

2) It should adjust the axial compressing suitably for sealing ring in the

upper roller’s neck area, make sure not too tight cause the damage of

the sealing ring and not too loose cause leakage.

3) All lubrication pipes should be firm and will not be crashed by the

rotary parts. The lubrication pipes must lubricate the gears and

bearings well.

8.1.5 No-load test run

1) It should driven by human’s hand firstly after assembling, and make

sure all parts run smoothly. The adjustment of roller gap should

flexible.

2) The rotary speed are 1500 r/min for pinch roll and laying head both,

and last for 3 hours after all lubrication pipes be connected. Check

the joggling voice of gear, the contact pattern and backlash, the

temperature rise of oil-film bearing, and the leakage situation of

sealing places.

3) The roller should be cooled by cooling water while test run, and the

water flow should ≥ 6.75Ton/h

4) To make sure the lubrication oil volume is ~50 l/min，oil pressure is

pinch roll and laying head both.

8.1.6 No-load test run

It should run no-load test run after pinch roll before laying head and

laying head assembling.

1) Necessary condition for test run

All oil lubrication points get oil supply according to the requirement

of pressure, oil flow, temperature, cleanliness, and oil grade.

Apply lubrication grease on each coupling

Apply lubrication grease on all lubrication surfaces

Supply cooling water onto the roller.

Close protecting jacket while the test run.

2) Scheme of test run

Test run procedure: start manual operation first, then switch to auto

mode; stepping movement before continuous movement; low speed

No-load test run of the equipment should last for 4 hours

continuously for min.

Equipment and components should shuttle 5~10 times in stroke

range.

Adjustment region should be tested 5 times each for min.

3) Requirement for test run

Rotary speed of the pinch roll before laying head and laying head

should be 1500 r/min during the test run.

Vibration intensity of the block mill should be lower than 5mm/s.

Noise level should ≤ 85dB (checked at 10m far away from

equipment). (noise level should ≤ 105dB at 1m far away from

equipment)

Temperature rise of each rolling bearing should be lower than 40 , ℃

and the highest temperature of each rolling bearing should not

exceed 80 .℃

There should be no oil leakage and water penetration.

8.2、Vulnerable part list

8.2.1. Vulnerable part list for pinch roll before laying head（HC4100-000）

No. description Qty Material / specific Drawing No. Remark

1 O ring 87.5×2.65 4 SF7433 GB3452.1-82 2 O ring 185×3.55 1 HN7443 GB3452.1-82 3 O ring 132×3.55 1 HN7443 GB3452.1-82 4 O ring 30×2.65 1 JM7443 GB3452.1-82 5 6″ oil-film bearing 2 Product 7381651 MRC 6 6″ oil-film bearing 2 product 7381652 MRC 7 Reinforce sealing

B90.120.12 1 SN7443 GB9877.1-88

8 Electromagnetic valve

2 23JD-24V Product

9 Pressure relay 1 HED10A-20/5 Product 10 Cooling nozzle 2 HC4100-006-05R Welded part

8.2.2. Vulnerable part list for laying head（HC4200-001）

No. description Qty Material / specific Specific / drawing

Remark

1 O ring 1 515X7 Oil resistant rubber GB3452.1-82 2 Rubber plate 1

2.5X280X500 Oil resistant rubber

plate GB5574-85

3 O ring 1 307X7 RubberⅠ-1 GB3452.1-82

4 O ring 2 95X2.65 RubberⅠ-1 GB3452.1-82

5 O ring 1 487X7 Oil resistant rubber GB3452.1-82

6 O ring 1 307X7 Oil resistant rubber GB3452.1-82

7 Sealing 1 PG85X110X12 Oil resistant rubber JB7600-80

8 O ring 1 175X5.3 Oil resistant rubber GB3452.1-82

9 O ring 2 60X3.1 RubberⅠ-4 JB/ZQ4433-86

10 O ring 1 Φ106x2.65 neoprene Product

11 O ring 1 Φ400x5.30 neoprene Product

12 Bearing 1 568906 FAG 400x500x46

13 Bearing 1 N226EC SKF 130x230x40

14 Bearing 2 7040MPUA FAG 200x310x51

15 Reinforce

sealing

1 110x140x15 Product

16 Sealing 1 GVA002000 NBR 180x15x25

17 Reinforce

sealing

2 GSC30130 NBR 130x160x15

18 O ring 1 25x2.5 NBR GB3452.1-82

19 spring 6 65 Mn HC4200-001-47 Nonstandard part

8.2.3. Vulnerable part list for protecting jacket for laying head

（HC4100-000）

description Qty Material / specific Drawing No. /

standard

Remark

1 Pneumatic cylinder

QGBⅡ

1 200x610-MP2 Product

2 Bearing 30E 1 8x38x45 FZ1360 Product

3 Joint bearing 1 GE45DS GB9163-90 Product

4 Bearing 60G 2 7x70x60 FZ1360 Product

5 One way throttle valve 2 KCA-L20 (pneumatic) Product

9. Cooling roller table

Feature

The chain type cooling roller table convey the coils to reform station. It

could use the standard cooling model and retarded cooling model to cool

the coil.

Standard cooling model: faster convey speed with blowers;

Retarded cooling model: slower convey speed without blower.

This chain type cooling roller table adopt standard cooling model, and

convey the Ф1200mm～Ф1250mm coil formed by laying head to the

reform station uniformly.

By adjusting the air volume and quantity of blowers, cool the coil to get

coil which satisfy the requirement.

The 7 sections are entrance section (1 set), main cooling section (5 sets)

and exit section (1 set).

Each section driven by a VVVF motor independently through chain.

Each section’s roller could adjust speed independently.

The rollers supported by bearing supports.

The entrance section which next the laying head supported by an elevator

with motor. The angle of rake of roller table could adjust by elevation of

elevator, to get the suitable form of coil. The elevation stroke is 200mm,

and be controlled by 2 sets of proximity switch which located at the highest

position and lowest position to prevent damage by incorrect operation.

There are 2 steps in main cooling section, the step height is 250mm. The

step makes the coil’s tensile strength uniformity.

There have a independent blower with motor for both 1st and 4th section in

main cooling section.

There have 3 independent blowers with motor for 2ed and 3rd section.

There has no blower for 5th section (retarded cooling zone)

Blowers connect to cooling roller table through air chambers.

The exit section which before reform station has wheels and is supported

by rails. The exit section could traverse that driven by a pushing rod with

motor to adjust the distance between end of exit section and coil collecting

device’s center. The traversing stroke is ±150mm. The side aprons which

on the exit section could align the coil’s center and the roller table’s center,

to ensure the coil fall into the coil collecting device smoothly.

The coil pressing device located at the end of exit section could make sure

the coil fall into the coil collecting device horizontally. A proximity switch

connected with the signal rod on cantilever could send the signal of coil’s

head and tail coming.

9.1 Preparation

9.1.1 Make sure all lubrication points be lubricated

9.1.2 Make sure all proximity switches work normally

9.1.3 Make sure all reducers’ oil level are normal.

9.1.4 Make sure the coil pressing device has suitable distance to rollers.

It will not allow running the rollers until mentioned requirements are

satisfied.

9.1.5 Start run the rollers after the signal ring ( long-time ) in jogging

model. It will restart after everything is normal.

9.1.6 Check the function of all electric equipments, make sure they are

same as the instruction. Make sure the order of action is correct. Make

sure all interlock and self-lock are effective.

9.1.7 Make sure each section’s convey speed is satisfy the requirement

and match for each other. Send the signal after check.

9.1.8 Make sure all lubrication points on blower are lubricated well.

Make sure the rotary direction of motor for blower is correct. Adjust

the air volume and quantity of blower according to the requirement of

technical process.

9.2 Vulnerable part list for cooling roller table

9.2.1、Vulnerable part list (1)

No. description Drawing No. Qty Material Remark

1 Bearing 6308-2LS SM1002.2.1.1.00 8 Φ40×Φ90×23

2 Bearing support SM1002.2.1.1.00 58 Cast steel

3 SM1002.2.1.2.00 112

4 SM1002.2.1.3.00 100

5 SM1002.2.1.4.00 56

Bearing support

SM1002.2.1.5.00 28

Cast steel

7 SM1002.2.1.3.00 8

8 Bearing with

support SM1002.2.1.5.00 6 Assembly

9 SM1002.2.1.3.00 8

10 Bearing with

support SM1002.2.1.5.00 6 Assembly

11 Bearing with support UCP205 SM1002.2.1.5.00 2 Product

12 Roller chain 12A-Ⅰ-42 SM1002.2.1.3.00 12 Product

With transition

13 Roller chain 08B-Ⅰ-43 SM1002.2.1.1.00 29 Product

With transition

14 Roller chain 08B-Ⅰ-46 SM1002.2.1.5.00 8 Product

With transition

15 Roller chain 12A-Ⅰ-50 SM1002.2.1.5.00 6 Product

With transition

chain 16 SM1002.2.1.2.00 56

17 SM1002.2.1.3.00 48

Roller chain 12A-Ⅰ-52

SM1002.2.1.4.00 28

Product With transition

No. description Drawing No. Qty Material Remark

19 SM1002.2.1.5.00 8

20 SM1002.2.1.2.00 56

21 SM1002.2.1.3.00 50

22 SM1002.2.1.4.00 28

Roller

SM1002.2.1.5.00 14

Welded part

No. description Drawing No. Qty material remark

1 Roller SM1002.2.1.1.00 29 QT500-7

2 SM1002.2.1.3.00 4

3 Roller

SM1002.2.1.5.00 2 Welded part

4 Roller SM1002.2.1.3.00 4 Welded part

7 Alignment roller SM1002.2.1.3.00 12 QT500-7

10. Reform station

Feature

(1) Coil collecting device after cooling roller table consist of upper barrel

body, lower barrel body, nose cone, fingers and hydraulic supporting

device. The nose cone is inside of the barrel. The hydraulic supporting

device is used for support the nose cone, and the fingers are used for hold

the coils.

Coil collecting device collect the coil and store for a short time, and it will

provide a buffer time for transportation.

(2) Coil plate assembly consist of elevation device, main support

assembly, transmission device, idler assembly, coil plate acted by hydraulic

cylinder, chain wheel, chain and so on.

Coil plate collect the coil come from coil collecting device, while get the

“full of coil” signal, coil plate descend to the unload position with fast

speed.

(3) Double arm spindle receive the coil and transport from vertical

position to horizontal position by the two arms which are perpendicular.

The rotary shaft is 45°to horizontal, and this make one arm move from

vertical to horizontal and another arm move form horizontal to vertical

while shaft rotate half-cycle.

(4) Transport car consist of coil basket device, elevation device, car

assembly, base assembly and towline.

Transport car transport the coil from double arm spindles to hook, and the

car’s lifting by hydraulic and moving by motor.

10.1 Operation for coil collecting device

10.1.1 make sure all lubrication points get lubricated well.

10.1.2 Make sure all oil, air, electric lines are correct and smooth.

10.1.3 Make sure all oil pipes, air pipes and electric wires are fastening,

and the function is same as the introduction.

10.1.4 Make sure the equipment’s action is same as design.

10.1.5 A group of fingers hold the coils, they will retract when coil is full

and will not stretch out until the collected coils all unload. All fingers

are linked and acted by an air cylinder. The nose cone could go up and

down acted by 3 sets of hydraulic cylinder for rotary action of double

arm spindles.

10.2 Operation for coil plate assembly

10.2.1 Make sure all chains could work normally.

10.2.2 Make sure the elevating device could elevate smoothly without tilt.

10.2.3 Make sure the coil plate could open and close smoothly.

10.2.4 Make sure the hydraulic cylinder could work normally.

10.2.5 Make sure all oil pipes and joints are tight without damage.

10.2.6 Make sure all chains are lubricated well.

10.2.7 Make sure the braker could work well.

10.2.8 Make sure all electric parts all work well.

10.2.9 Make sure the idler mesh well with chain.

10.3 Operation for double arm spindle

10.3.1 Make sure all lubrication points get lubricated well.

10.3.5 Make sure the interlock could work well.

10.3.6 The two arms are perpendicular.

10.3.7 The rotary shaft is 45°to horizontal, and this make one arm move

from vertical to horizontal and another arm move form horizontal to

vertical while shaft rotate half-cycle.

10.4 Operation for transport car

10.4.1 Make sure all lubrication points get lubricated well.

10.4.5 Make sure the interlock could work well.

10.4.6 Operation must follow the instruction.

10.4.7 The arm spindle, transport car and hook must not interfere with

each other.

10.5 Vulnerable part list

10.5.1 Vulnerable part list (1)

1 Coil collecting device SM1002.2.3

2 Block SM1002.2.3.1.00 3 42CrMo

3 Sleeve SM1002.2.3.1.00 6 ZCuAl10Fe3

5 Cushion SM1002.2.3.1.00 6 H62

6 Joint bearing GE40ES SM1002.2.3.1.00 10 Φ40/Φ62-28

7 Angle contact ball bearing SM1002.2.3.1.00 12 Assembly

No. description Drawing No. Qty material remark Φ125×Φ70-24

9 Cushion SM1002.2.3.1.00 2 H62

10 Joint bearing GEG50E SM1002.2.3.1.00 1 Φ50/Φ90-56

11 Double arm spindle assembly SM1002.2.3

12 Wear resistant plate SM1002.2.3.2.2.00 3 QT420-12

15 Coil plate assembly SM1002.2.3

16 Wear resistant plate SM1002.2.3.3.00 4 40CrMnMo

17 Bearing 32026X/DF SM1002.2.3.3.00 2

18 Cushion SM1002.2.3.3.00 2 Asbestos plate

19 Cushion SM1002.2.3.3.00 2 Q235-A

20 Bearing 6313 SM1002.2.3.3.00 8

21 Bearing 6313 SM1002.2.3.3.00 8

22 Bearing 22214E SM1002.2.3.3.00 4

1 Transport car SM1002.2.3

2 Wear resistant plate SM1002.2.3.4.1.00 2 16Mn

4 Bearing with

support (GB/T7810-1995)

SM1002.2.3.4.1.00 4 UCFLU313

7 Bush SM1002.2.3.4.1.00 2 ZCuAl10Fe3

8 Bush SM1002.2.3.4.1.00 4 ZCuAl10Fe3

9 Bearing NUTR40 SM1002.2.3.4.1.00 12 Product

10 Bearing NUTR25 SM1002.2.3.4.1.00 8 Product

11 Eccentric shaft SM1002.2.3.4.1.00 4 45

12 Roller shaft SM1002.2.3.4.1.00 4 Welded part

13 Bush SM1002.2.3.4.2.00 8 ZCuAl10Fe3

14 Shaft sleeve SM1002.2.3.4.2.00 2 Seamless pipe 20

15 Bearing GE70ES SM1002.2.3.4.2.00 1 Product

16 Bearing with

SM1002.2.3.4.2.00 2 UCP322

17 Bearing with

SM1002.2.3.4.2.00 2 UCP322

18 Bearing 23122CC/W33 SM1002.2.3.4.3.00 1 Product

19 Bearing 23022CC/W33 SM1002.2.3.4.3.00 1 Product

20 Bearing NH2210 SM1002.2.3.4.3.00 4 Product

21 Bearing 32015 SM1002.2.3.4.3.00 8 Product

22 Wheel SM1002.2.3.4.3.00 4 45

11. Bundling machine

Feature

Bundling machine compact the coil come from the reform station, tie the

coil, and bundle the coil.

Bundling machine consist of base assembly, compact device and

supporting roller device. Base assembly is welded structure and fixed on

the ground. Compact device consist of support, hydraulic cylinder, wheel

and car. The wheel is support by the base assembly and the shaft which

fixed on the car through rolling bearing. Supporting roller device which

fixed on the ground consist of gearmotor, roller and support.

Supporting roller device should not work until compact device is not

working, and compact device should not work until the supporting roller

device is not working.

After the coil convey to bundling machine by crane, tying device works

when it get the signal send by the compactor, and compactor will not stop

compacting until the coil be compacted. After the coil be bundled manually,

compactor release, and the crane take the compacted coil away when get

the signal sent by compactor.

11.1 Operation

11.1.1 Make sure all lubrication points all get well lubricated, and

hydraulic system is normal.

11.1.2 Adjust the position of proximity switch according to the traverse

speed.

11.1.3 Make sure all function and action are same as instruction, the order

of action is correct, the interlock and self lock are effective.

No. Description Drawing No. Qty material remark

SM1002.2.4.1.00 1 1

Hydraulic cylinder CD250E200/125-1525A10/02C

GDMA SM1002.2.4.2.00 1 With collar

SM1002.2.4.1.00 2 2 Cooper sleeve

SM1002.2.4.2.00 2 ZCuAl10Fe

3 Gearmotor YCJ132-75-Y100L1-4-B3-Ⅰ SM1002.2.4.1.00 1 2.2KW

4 Gearmotor YCJ132-75-Y100L1-4-B8-Ⅰ SM1002.2.4.1.00 1 2.2KW

5 Gearmotor YCJ132-75-Y100L1-4-B3-Ⅲ SM1002.2.4.1.00 1 2.2KW

6 Gearmotor YCJ132-75-Y100L1-4-B8-Ⅲ SM1002.2.4.1.00 1 2.2KW

SM1002.2.4.1.00 4 7 Wheel

SM1002.2.4.2.00 4 45

SM1002.2.4.1.00 8 8 Bearing NJ1026

SM1002.2.4.2.00 8 130/200-33

9 Gearmotor YCJ180-66-Y132S-4-B3-Ⅰ SM1002.2.4.4.00 1 Motor

132S-4

10 Chain 20A-1-44 SM1002.2.4.4.00 2 Product

11 Bearing 22214CC/W33 SM1002.2.4.4.00 4 70/125×31

12 Bearing NUTR40 SM1002.2.4.4.00 4

12. Coil weighing scale

Feature

The coil weighing scale will weigh the coil and print the label, and the

label will be hang on the coil manually.

Coil weighing scale consist of base plate and coil support unit. The welded

structure base plate is fixed on the ground. The coil support unit is

connected with base plate through link mechanism and bearing with

support. There is a set of weigh device assembled on the coil support unit.

The weight get by weigh device send to the label printer as signal, and print

out on label.

After crane take the coil to the weigh position, coil support elevate and hold

the coil by elevation hydraulic cylinder acting. When the coil non-contact

with the hook, weigh device works. After get the weight, the coil support

descend to the unworking position and send signal, hook take the coil away

from weigh position.

Interlock: The coil must not move out until coil support finish the period of

elevating, descending and weighing. The coil support must not elevate and

weigh until the coil stop at the weighing position stability.

12.1 Operation

12.1.1 Make sure all lubrication points all get well lubricated, and

hydraulic system is normal.

12.1.3 Make sure all function and action are same as instruction, the order

of action is correct, the interlock and self lock are effective.

12.1.4 Make sure the weighing system is precise.

No. Description Drawing No. Qty Material Remark

1 JMX-3 weighing module SM1002.2.5 4 Product

2 Bearing with support UCP216 SM1002.2.5 4 Product

3 Bearing with support UCP213 SM1002.2.5 2 Product

4 Hydraulic cylinder

HSGK-125/90E2511-500×952

SM1002.2.5 1 Φ125×Φ90-500

5 Spherical hinge collar GA45 SM1002.2.5 2 M45×1.5,L1=105

6 Spherical hinge collar GA45 SM1002.2.5 2 M45×1.5LH,L1=105

7 Bearing 6010-Z SM1002.2.5 4 Φ50×Φ80-16

III． Regulation for shifting of duty

1. Operator on duty should resume duty ahead of time for handover work

with operator off-duty at post, to comprehend the condition of running

equipments and report to relevant department if abnormal condition

discovered.

2. After taking over the duty, the operator should start patrol inspection on

the equipments which he is in charge of, and make the record. To request

electrician or mechanical workers for eliminating the hidden trouble if

discovered.

3. The job of duty shift covers tracking the defection development of

running equipments, to acknowledge the fault solved on last shift, to check

the bearing temperature, lubrication system, and all the instruments and

signal which are connected with operation control room and etc.

Chapter 2. General maintenance regulation 1. Daily maintenance

Daily maintenance is important for normally working, and the maintenance

items and frequency see the list.

No. Maintenance item Each shift

Each day

Each week

Each month

Each quarter

Each half of year

1 Leakage（pipe, joint place, sealing place for rotary shaft）

2 Tightening of fastener （bolt, nut）

3 Lubrication for gear and bearing（oil pressure, valve） √

4 Reliability for electrical element, pressure switch √

5 Mesh of gear（wear、contact pattern）

6 Wear of rolling bearing, shaft sleeve √

7 Washing for filter, vent hood √

8 Washing for coupling √

9 Wear of important part, vulnerable part √

10 Pressure of oil, air-oil, air √

11 Pressure of hydraulic oil √

12 Wear of entrance duct, exit duct √

13 Cleaning off scale, dust √

14 Crosshead of universal spindle √

15 Vibration and temperature rise of motor and reducer √

2. Daily maintenance schedule

2.1 General maintenance guide

Clean all spare parts, remove the rust and grease, paint the rust

preventative oil, mark the label and store. The important parts such as

oil film bearing, gear and rolling bearing should pay more attention.

Remove the rust preventative oil before using

2.2 Make sure there is no crack and scuffing on sealing parts, clean them

with clear water to prevent distortion.

2.3 Keep the oil and grease clean, and make sure there is no pollution when

sealed store.

2.4 Read the drawings and technical files before replacing, make sure the

new parts have the same precision of fit tolerance as the old parts.

3. Principle of daily maintenance

It is important to set up a reasonable maintenance schedule. It will know

the condition of equipments well if check the equipments follow the

maintenance schedule, and that make the maintenance easier and the solve

faster. Meanwhile the maintenance record could provide data to improve

the operation and maintenance, to make the equipment work better.

4. Maintenance

4.1 Make sure the condition of equipment, sealing parts and lubrication

points are well. Make sure the electrical cabinet, electrical elements,

current, voltage are normal, sensitive and reliable. Solve the anomaly

immediately if discovered.

4.2 Make sure the condition of equipment, sealing parts and lubrication

points for stands and reducers are well. Solve the anomaly immediately

if discovered. The sealing ring on mill roll should be changed when

change the mill roll. The slight leakage is allowed. It must change all

sealing parts when maintenance.

4.3 It should wrap the pipes for lubrication and hydraulic system with

plastic film to seal the oil hole. Keep the oil hole of pipes without

pollution especially the pipes for oil film.

4.4 Each shift must be done

4.4.1 Each shift must check the lubrication points once, make sure no

leakage on joints.

4.4.2 Each shift must check the oil level of reducer.

4.4.3 Each shift must clean the equipments.

4.4.4 Each shift must clean equipment’s round.

4.4.5 Each shift must check the electrical elements, signal, and proximity

switch.

4.4.6 Each shift must lubricate the transmission part manually.

4.4.7 Each shift must lubricate the lubrication points which are not

centralized grease lubrication manually.

4.4.8 Each shift must check the condition of fastener

4.4.9 Each shift must make the record, and make sure the equipment

work normally.

4.5 Matters need attention of safety for maintenance

4.5.1 The operation and maintenance must executed by trained staff.

4.5.2 The operator and maintainer must cooperate when maintenance,

repair and cleaning. The power must shut off before maintenance,

repair and cleaning. The power switch must can be touched by related

operator only.

4.5.3 It must under the professional’s supervise if the equipment need to

run when solving the problem of mechanical or electrical.

4.5.4 It must shut and unload all valves before maintain the hydraulic

and lubrication system.

4.5.5 It should collect the tools and used parts to avoid lost after

maintenance.

4.5.6 Make sure there is no people in the unsafe zone when restart the

equipment after maintenance. The operator must follow the command

to start the equipment.

5. Institution for oil testing and replacing

5.1 The oil used in the lubrication station should be replaced according the

quality which tested periodically.

5.2 The replacement for oil tank should according the result of test, and

follow the standard for oil’s quality.

5.3 It should test the oil if find the oil’s quality go bad or water in oil. (test

in the middle of tank)

5.4 The test result for oil should be record immediately.

5.5 The new oil should purchase ahead of time.

5.6 The oil to be fill into the tank must pass through 3 grades of filter. The

filters must be clean periodically.

6. Periodical maintenance

6.1 Check the fasteners, lubrication points and electrical equipments

thoroughly and periodically. Solve the problem if discovered.

6.2 Maintain the equipment as minor repair periodically, it includes

changing the worn bearings, worn parts, broken electrical elements,

cleaning the pipes and inside body of equipment.

6.3 Check and replace the lubrication oil and hydraulic oil for equipment

periodically.

6.4 It should follow standard and requirement to disassemble, clean and

reassemble the equipment. Make the record of maintenance.

7. Major repair (overhaul)

7.1 The major repair must follow the technical standard and regulation. The

motors, hydraulic system, lubrication system, pneumatic system must

shut down when major repair.

7.2 Make sure there is no leakage after replacing the instruments for

hydraulic system, lubrication system and pneumatic system. Make sure

the electrical wiring for instruments are correct. The new pipes must

clean especially the pipes for filter system.

7.3 It should do the AC voltage withstand test and insulation test for

transformer, insolating switch of high voltage switch cabinet, oil switch,

control cabinet and high voltage line. The test should follow the

technical standard and regulation for major repair.

7.4 It should replace the oil, sealing parts, worn bearings, gears, shafts,

chains and rollers in major repair. Check and replace the proximity

switches and electrical elements. Maintain and replace the motors,

reducers and couplings.

Operation and Maintenance Regulation for Finishing Mill

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