A STUDY ON

TYPE OF ROLL CRUSHERS MANUFACTURED IN

L&T,KANSBAHAL WORKS

GUIDED BY
DR. MANOJ KUMAR MOHANTY
MANAGER-BUSINESS DEVELOPMENT
SUBMITTED BY-
SHAKTI PRASAD PANDA
REGD. NO.:-15021272
V.S.U.T Burla, Sambalpur,Odisha,
SESSION-10.05.2016 TO 09.06.2016

CERTIFICATE

This is to certify that:-

Mr. Shakti Prasad Panda a student of Production engineering at ​Veer Surendra Sai
University of Technology, Burla,Sambalpur,Odisha ​has undergone a vacation
Training from ​10​th may 2016 to ​9th​ june 2016 ​at LARSEN & TOUBRO LTD.

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KANSBAHAL. During this tenure he was found sincere and very creative. He was
assigned with project on which he worked very smartly and

I am extremely overwhelmed to mention that his performance during

this training period was far ​above the satisfactory level.

DR. MANOJ KUMAR MOHANTY

( MANAGER-BUSINESS DEVELOPMENT)

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 ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude to ​Dr. Manoj Kumar

Mohanty​(Manager Business Development) for providing me with the opportunity
to undertake these project and providing me with all the necessary help for its
completion.

I would also like to thank ()for assisting me in my endeavor and giving me his
support whenever I need it.

I would also like to thank ​Mr. Binoda Pradan for providing me vital data available
about the Roll Crusher

I would like to thank all the workers and supervisors of the Assembly shop and
Fabrication shop for giving me the working knowledge of the various machine and
about the working of the Assembly shop.

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 ​ SHAKTI PRASAD PANDA

CONTENTS

SECTION DESCRIPTION
1 INTRODUCTION​:-
● WHY THIS PROJECT?
● IMPORTANCE OF THE PROJECT

2 ABOUT L&T KBL & PRODUCT

PORTFOLIO
3 STUDY ON EQUIPMENT​:-
● CLASSIFICATION
● APPLICATION
● TYPE OF EQUIPMENT
● IMPORTANT PARTS
● ITS FUNCTION
● HOW IT WORKS

5
 ● ASSEMBLE PROCEDURE
● ERECTION PROCEDURE
● SPARE PARTS
● DIFF. PHOTOS & SCHEMATIC
DIAGRAMS

4 CONCLUSION

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 SECTION-1
INTRDUCTION

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 INTRODUCTION

Roll Crushers are compression type crushers, and were once widely used
in mining. They have, within the last 10 or so years, fallen into dis-favor
among mining and processing companies. The probable reason is because
the large mines require very large crushed product output with minimal
cost, makes the roll crusher uncompetitive. The roll crushers are not nearly
as productive as cone crushers, with respect to volume, and they do have a
little higher maintenance associated with them. Roll crushers do, however,
give a very close product size distribution, and if the ore is not too abrasive,
they do not have high maintenance costs.​

The particles are drawn into the gap between the rolls by their rotating
motion and a friction angle formed between the rolls and the particle, called
the nip angle. The two rolls force the particle between their rotating surface
into the ever smaller gap area, and it fractures from the compressive forces

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presented by the rotating rolls. Some major advantages of roll crushers are
they give a very fine product size distribution and they produce very little
dust or fines. Rolls crushers are effectively used in minerals crushing where
the ores are not too abrasive and they are also used in smaller scale
production mining of more abrasive metal ores, such as gold. Coal is
probably the largest user of roll crushers, currently, though. Coal plants will
use roll crushers, either single roll or double roll, as primary crushers,
reducing the ROM coal. Usually, these crushers will have teeth or raised
forms on the face of the roll. (Roll crushers used for minerals and metal
ores have smooth faced rolls.)

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 SECTION-2
ABOUT L&T KBL & PRODUCTION
PORTFOLIO

10
 ABOUT L&T ,KANSBAHAL WORK

COMPANY​ PROFILE

Larsen & Toubro Limited (L&T) is a technology-driven engineering and

construction organization, and one of the largest companies in India's private
sector. It has additional interests in manufacturing, services and Information
Technology.

A strong, customer-focused approach and the constant quest for top-class quality
have enabled the Company to attain and sustain leadership in its major lines of
business across seven decades.

L&T has an international presence, with a global spread of offices. A thrust on

international business over the last few years has seen overseas earnings growing
to 18 per cent of total revenue. With factories and offices located around the
country, further supplemented by a wide marketing and distribution network,
L&T's image and equity extends to virtually every district of India.

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L&T believes that progress must necessarily be achieved in harmony with the
environment. A commitment to community welfare and environmental
protection constitute an integral part of the corporate.

History

The evolution of L&T into the country's largest engineering and construction
organizations is among the more remarkable success stories in Indian industry. The
company was founded in Bombay (Mumbai) in 1938 by two Danish engineers,
Henning Holck-Larsen and Soren Kristian Toubro - both of whom were strongly
committed to developing India's engineering talent and enabling it to meet the
demands of industry. Beginning with the import of machinery from Europe, L&T
rapidly took on engineering and construction assignments of increasing
sophistication. Today, the company sets engineering benchmarks in terms of scale
and complexity.

L&T's signature of excellence is evident on:

India's first indigenous hydrocracker reactor

Oil and gas platform projects executed to global benchmarks
The world's largest continuous catalyst regeneration reactor

12
 The simultaneous execution of clean fuel projects at eight refineries around
India
The world's biggest fluid catalytic cracking regenerator
The world's biggest fluid catalytic cracking regenerator
The world's biggest fluid catalytic cracking regenerator
The world's longest product splitter
Asia's highest viaduct - built for the Konkan Railway
The world's longest LPG pipeline
The world's longest cross country conveyor
Building an international class football stadium in 260 days

Engineering & Construction – Projects

L&T's engineering & construction track record consists of successful

implementation of turnkey projects in major core and infrastructure sectors of
Indian industry. L&T has integrated its strengths in process technology, basic and
detailed engineering, equipment fabrication, procurement, project management,
erection, construction and commissioning, to offer single-point responsibility
against stringent delivery schedules. Strategic alliances with world leaders enable

13
L&T to access technical know-how and execute process-intensive large-scale
turnkey projects to maintain its leadership position.

L&T's core competencies in engineering include highly qualified and experienced

personnel from various disciplines, state-of-the-art 2-D and 3-D CAD facilities
with sophisticated plant design systems and basic engineering capabilities. L&T is
the only Indian EPC company pre-qualified for executing large, process-intensive
projects for oil & gas, refinery, petrochemical and fertilizer sectors.

Heavy Engineering
L&T is acknowledged as one of the top five fabrication companies in the world,
with engineering and manufacturing capabilities that are among the most sought
after in industry. Operating at the high end of the technological spectrum, L&T has
led Indian industry in introducing new processes, products and materials in
manufacturing. L&T also has the logistics capabilities of fabricating and supplying
over-dimensional equipment to tight delivery schedules. L&T's
globally-benchmarked workshops are located in Mumbai, Hazira, Baroda and
Kansbahal.

Construction

14
ECC - the Engineering Construction & Contracts Division of L&T is India's largest
construction organization. Many of the country's prized landmarks - its exquisite
buildings, tallest structures, largest industrial projects, longest flyovers, highest
viaducts, longest pipelines … have all been built by L&T. L&T's leading edge
capabilities cover every discipline of construction - civil, mechanical, electrical and
instrumentation. L&T has also expanded its focus to the Middle East, South East
Asia, Russia, CIS, Mauritius, African and SAARC countries. L&T is also
developing markets for its construction services in the Indian Ocean rim countries,
Africa and Latin America.

Electrical & Electronics

L&T is a major international manufacturer of a wide range of electrical and
electronic products and systems. In the electrical segment, the Company is India's
largest manufacturer of low tension switchgear, and is rapidly establishing itself in
international markets. Its products are widely sold in markets in Europe and
Australia. Recently, L&T set up a new manufacturing base for high-end air circuit
breakers in China. L&T also manufactures custom-engineered switchboards for
industrial sectors like power, refineries, petrochemical, cement, etc. In the
electronic segment, L&T offers a wide range of meters and provides complete

15
control and automation systems for diverse industries. Medical equipment and
systems manufactured by L&T include advanced ultrasound scanners and patient
monitoring systems.

Information Technology
Larsen & Toubro Infotech Limited, a 100 per cent subsidiary of L&T, offers
comprehensive, end to end software solutions and services with a focus on
Manufacturing, BFSI and Communications & Embedded Systems. It provides a
cost cutting partnership in the realm of offshore outsourcing, application
integration and package implementation. Leveraging the heritage and domain
expertise of the parent company, its services encompass a broad technology
spectrum, catering to leading international companies across the globe. It leverages
the L&T parentage to also provide services in the embedded intelligence and
e-Engineering space.

Machinery & Industrial Products

L&T manufacturers, markets and provides service support for critical construction
and mining machinery - surface miners, hydraulic excavators, aggregate crushers,
loader backhoes and vibratory compactors.

16
 

Larsen & Toubro limited - Kansbahal Business Unit

Kansbahal Business Unit (L&T-KBU) is an autonomous strategic business unit

under the aegis of company’s Machinery & Industrial Products Division of Larsen

17
& Toubro Limited. The unit is located in Sundargarh district of Orissa, India, about
25 KM from Rourkela township in State Highway #10.

This Kansbahal unit is primarily into manufacturing of capital-intensive industrial

equipment in four product categories, i.e., Crushing Systems, Pulp & Paper, Steel
plant, Windmills and Cast products. The unit had an annual turnover of Rs.300
Crores (Aprox.) in 2015-16.

Kansbahal Business Unit – The Setup

Kansbahal Business unit is an autonomous integrated manufacturing unit of L&T

with its own design, marketing and manufacturing setup in addition to other
support services such as Personnel, Finance, Administration, Township etc.

Product Group :

The complete business in Kansbahal is divided along product verticals into product
groups to facilitate focus on product-market segment. Each product group is
structured as a miniature Strategic Business Unit acting as a single window

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interface with the customer having overall responsibility for organizational
performance and customer satisfaction in respective product-market segment. The
Product Groups are responsible for marketing, sales, project management,
customer relationship management, after sales & services etc. Further in order to
achieve greater flexibility and continuity in the business, for all major customers
there are Key Account Managers’ acting as their contact point with the
organization – assuming different roles as different point of order cycle –
marketing manager to project manager to service manager. The Key account
managers’ are part of the Product Groups.

MANUFACTURING SETUP : THE MANUFACTURING SETUP OF THE

COMPANY PRIMARILY COMPRISES METAL WORKING SHOP
(FABRICATION SHOP), FOUNDRY, MACHINING SHOP, ASSEMBLY SHOP &
QUALITY ASSURANCE

● Fabrication Shop :This shop primarily is into metal cutting (gas cutting,
shearing etc.), joining (welding, brazing, soldering etc.) and manufacturing of

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 basic structure of an equipment. The material handled is plain carbon steel,
stainless steel, alloyed steel and copper.
● Foundry :It is the only in-house foundry in L&T. The foundry specializes
in iron castings. The basic grades manufactured are Grey Iron, Spheroidal Grey
Iron, medium alloyed iron and High alloyed Iron.
● Machine Shop :The shop primarily caters to in-house requirement of
machining for fabricated items as well as castings. The shop has machines for
carrying out a series of operations such as turning, boring, milling, facing,
drilling etc. The layout of shop is primarily functional oriented.
● Assembly :This shop is the primarily equipment building shop, where
precision assembly of the equipment is carried out. The shop has expertise in
bearing assemblies, dynamic balancing, hydraulic/pneumatic circuits etc.
Components / sub-assemblies manufactured or procured are assembled and
tested here before dispatch of the equipment.
● Quality Assurance :To ensure that the customer gets the right quality of
material each time and every time, the organization has a separate quality
assurance setup which is independent of the manufacturing shops. The quality
assurance department is under the direct control of unit head and is equipped

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 for performing all types of testing for raw material to process to assembly &
trail run of the equipment.

For coordination of flow of information & material between shops there is a

planning department, which is responsible for job routing, creating job
completion schedule, production planning and sub-contracting (outsourcing).

● Engineering, Design & Research Centre (EDRC) : The engineering, design and
research center at Kansbahal is responsible for engineering of the products,
development of new products, carrying out improvement in the existing
products and application related research primarily for crushing.

The department is equipped with the latest state of art technology including
softwares for stress analysis, 2D, 3D & solid modeling, digitalization of drawings,
etc.

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The department also has a pool of engineers and draughtsman not associated
with any product group – providing the additional support to the product group
depending on engineering load in the product group.

● Purchase : The purchase volume is not substantially high and the supplier base
for most of the product groups is common to the organization. To have smooth
flow of procured goods, the purchase function was restructured into two parts :
the indigenous procurement, imported procurement and vendor development
cell. Each product group is also empower to buy there project specific required
items as and when required.

● Administration : As the unit is located in a remote location, the setup has a full
fledged township including health center, club, market place, water &
sewerage treatment plant, transportation etc. for its employees. The complete
management of township is under the administration department, which looks
after the up keeping of the township & area in and around the factory.

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In addition to the above, the unit also has a personnel department and finance
department, which performs the normal function of a personnel department and
finance department respectively.

Kansbahal Business Unit – Historical Perspective

Kansbahal Business Unit started its operation in 1963 as Utkal Machinery Limited
(UTMAL), as a joint venture between three German Companies – Voith,
Guttehofnungshute (GHH) & Koppers and L&T, with each partner holding 25%
stake in the organization. The german partners supplied the technology for
equipment building in addition to process capabilities whereas L&T provided the
market expertise, acting as the marketing partner for the company.

The unit was set up to manufacture equipment for the paper and steel sector,
which were then being imported. The prime objective of floating the company

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was to participate in building of Rourkela Steel Plant, being built during the period
with German collaboration.

For building up of equipment, an integrated workshop was built comprise of

various facilities including metal fabrication, foundry, machining and assembly
including testing and quality facilities. Further, considering the remote location of
the place, a housing colony with all facilities was built adjacent to the workshop
for the employees of the company.

With passage of time and limited business opportunity in steel and paper sector,
the company diversified its product portfolio entering into new business areas -
Crushing Systems, Bulk Material Handling and Specialised Cast Products.

Over the period of time with changing government policies and restricted
business opportunities two of the three German partners – GHH & Koppers in mid
70s divested their stake in favour Larsen & Toubro Limited resulting in L&T
becoming the majority stakeholder of 75% and balance 25% with Voith. In order

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to have access to technology a separate collaboration agreement was entered
into with GHH.

During this period, UTMAL retained its identity as a separate company with Larsen
& Toubro Limited as its marketing agent. The company continued to develop
specialized products for steel sector and helping various steel plants in
indigenization of their equipment.

In 1982, the unit was merged with Larsen & Toubro Limited and became an
integral part of the company. The 25% stake, which Voith was holding in UTMAL,
was converted into L&T’s share at a suitable ratio.

With change in the ownership pattern of UTMAL, the workshop merged with
marketing & project division’s for similar products forming a separate business
group. The business group was organized along the product verticals – Steel,
Paper, Material Handling, Crushing & Cast products with each product vertical a
profit center with common manufacturing facilities. The manufacturing facility
operated as a cost center for division with the sole responsibility of building
product in accordance with requirement of the division.

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With walking away of the technology partners, the company’s access to
technology for Steel Making (GHH & Koppers) was limited which restricted the
business opportunities available and in order to keep the show running, the
company started moving towards manufacturing of equipment based on
customer design serving as jobbing shop transformation from a specialized
product company to job shop.

With falling performance of the unit, in the early 90s the division was restructured
to regain business focus with thrust on project business. The division was
reorganized into four strategic business units :

➢ Steel & Metallurgical

➢ Pulp & Paper
➢ Bulk Material Handling
➢ Mineral Dressing & Processing

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Each of these strategic business units were separate profit center with their
manufacturing needs being served by Kansbahal, which was a cost center for the
division.

With  liberalization  over  the decade, the product and capability differentiation between 

the  company’s  offering  vis-à-vis  competition  reduced  drastically  and  the performance 
of  the  division  started  showing  a  rapid  decline  with  question  of  survival  becoming  a 
key issue.

In 1999, the division was dismantled and Kansbahal was made into separate profit
center with mandate to focus on unit equipment business. A new setup was
created with marketing and customer relationship management being for the first
time brought down to Kansbahal. The unit continued with the same product
portfolio but additional onus of managing the business brought focus in the
organization. Improvement in organization performance to improve cost
competitiveness became the buzz word.

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Kansbahal Business Unit – The New Millenium

With entry into the new millennium and increasing competitive pressure, forced
the organization to have a relook at its product portfolio. A thorough analysis of
the product portfolio was carried out and based on the overall assessment of
capability, market potential, competition, value creation and profitability, it was
decide to vacate two business lines – Steel Plant and Bulk Material Handling, and
concentrate of Crushing Systems, Pulp & Paper, Wind Mill Components & Cast
Products.

a. Crushing Systems : The crushing product range includes Impactors, Roll

Crushers, Jaw Crushers, Feeder Breakers, Wobblers etc. for different
applications such as crushing of limestone, coal, aggregates, bauxite and other
minerals. The equipment offered by the company under this product portfolio
comes in a series of models based on the capacity and configuration.
Impactors are manufactured in technical association with Hazemag EPR,
Germany and Roll Crushers in association with TJ Gundlach & Co., USA.

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b. Pulp & Paper Eqpt : The unit offers an exhaustive range of Pulp & Paper
equipment in technical association with Voith Paper, Germany. This product
portfolio includes a complete range of equipment for manufacturing of pulp &
paper starting from raw material handling to finishing line. The unit has
capability of offering products for manufacturing of different grades of paper
using different raw materials. The equipment offered are suitable for high
production capacity.

c. Wind Mills : In this sector, the product manufactured are parts of

windmill (primarily Nacelle parts) to the design of Windmill suppliers. The
company has exclusive tie-up with one designer & manufactures only one
model of windmill to cater to the requirement of Indian market. The order for
these windmill components is on a rolling basis for available capacity.

d. Cast Products : The cast product business is basically of jobbing nature

with the company manufacturing iron castings to cater to various sectors such

29
 as windmill, thermal power plant, coal crushing, cement, paper, steel etc. The
products can be primarily classified into two categories : Wear/abrasion
resistant castings and Spheroidal Graphite Iron Castings.

The castings are basically manufactured as per the design and specification of
customer comprising of OEM and end users. It involves large variety in terms
of shape and size with the manufacturing process primarily remaining same.

Manufacturing Facility in L&T, Kansbahal works-

ENGINEERING DESIGN & RESEARCH​- A team of highly qualified and experienced

engineers,equipper with up-to-date sophisticated design tools, carry out basic
design and detailed engineering.

FABRICATION​- Fabrication shop having a covered area of 9760 sq. mt. with
maximum gantry height of 16m,can handle upto 100 tons-single piece.68
LRSI-qualified welder deal with a veriety of materials such as carbon steel, low
alloy steel,ss type 304/316/321, Nickel alloy(Nicrofer) etc.- upto a maximum weld
thickness (for test joint) of 150mm. Dished ends of petal construction-formed
upto 50mm thickness(max).

MACINE DESCRIPTION MAXIMUM CAPACITY

CNC Profile cutting X-5.26M,Y-25M & Thickness-300mm
Portable Pug Cutting Thickness-50mm (MS)

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Plasma cutting Thickness-60mm (SS)
Shearing 10mm X 2100mm
Rolling/Bending 100mm X 700mm & ID=3M
Folding 4mm X 2500mm
Hydraulic Press 500T
Column & Boom(Submerged Arc) Arc Travel:6M X 4.5m
Rotator/Positioner 50T/10T
Shot Blasting unit Size-9.9M X 8.2M X 11.6M
Stree Relieving furnace Size-7M X 6.4M X 8M
MACHINING​-Equipped with a wide range of machines for turning,boaring,cylinder
grinding and planing of complex welder structures/castings/forging.

MACHINE DESCRIPTION MAXIMUM CAPACITY

Horizontal Floor Boring(CNC & Sp. Dia
conventional) 203mm,X-10M,Y-5M,Z-2.2M,Job
wt:100T
Table size:4m x 4m,Job wt:80T
Horizontal Table Borer(CNC & Sq. dia 130mm,job wt.:10T
Conventional)
Vertical lathe Table Dia:4.77M,job wt.:100T
Facing Lathe Dio:3m x length:10m
Grinding Dia:2.5m x length:10m
Double Column Plano Milling Planing size:6m x 2m x 1.6m
CNC Lathe Dia.:600mm x length :3m
CNC Turning Centre Swing over carriage:570mm
ASSEMBLY​- With core strengths in the field of Hydraulics and piping,bearing
assembly,shrink fitting, dynamic balancing, vibration analysis and field balancing,

31
fixturing and template development, we carry out assembly,pre-shipment
performance and functional testing of electrically, hydraulically and mechanically
operated equipment.

MACHINE DESCRIPTION MAXIMUM CAPACITY

Dynamic Balancing Job wt:18T
Field Balancing & Vibration Analyser Rotor wt.>3kg.,50-100000 rpm
CNC pipe Bending 65mm O/D X 6mm W/T
Orbital Pipe Welding 76mm dia
Hydraulic press 50T
Hydraulic Power Pack 400 kg/cm2
FOUNDRY​-1.​Moulding- Continous Mixer, Sand plant, Reclaimation unit, Dust
extraction unit, Cylinder moulding pits, Pit moulding stations.

2.​Melting- 5 nos medium frequency induction furnace. Batch capacity 0.5-6 T. 1

no. 5T electric arc furnace 1 to 16 T induction furnace.

3​.Heat treatment​- Oil and furnaces, having PID ,Auto programmer and control.
Water and oil quenching facilities.

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 SECTION-3
STUDY ON EQUIPMENT

33
34
 CLASSIFICATION
The Roll Crusher shall be classified as follows.

● Classification Depends Upon the Roll Surface​:- Depending upon the type of
roll surface, a roll crushed may be of smooth, beaded, spoked or corrugated
roll type.
1. Smooth roll crusher​:- A crushing machine here the roll or roll surfaces
are smooth.
2. Beaded roll crusher​:- A crushing machine where the roll surface is
beaded.
3. Spiked or toothed roll crusher​:- A crushing machine where the roll
surface is composed of spikes or teeth(of different shapes and sizes
based on individual manufacturer design), made up by combination of
circular ring or longitudinal curved sectors carrying such spikes or teeth.
4. Corrugated roll crusher​:- A crusher machine where the roll surface is
corrugated. It can comprise of one corrugated and one smooth roll
surface or both the roll surface corrugated.

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(Smoot roll crusher) (Spiked or toothed roll crusher)

36
● Classification Depends Upon Number of Rotating Rolls​:- Depending upon
the number of rolls, the crusher may be single, double or triple.
1. Single roll crusher​:- A crusher having a single roll which rotates towards
a stationary surface. The roll or rolls may be made up of crushing rings
of different shapes and sizes based on individual design and on the
specific application. The stationary surface may be plain or of tooted
design, staraight or curved.
2. Double Roll Crusher​:- A crusher having two-rolls rotating towards each
other.
3. Triple roll crusher​:- A crusher having rotating roll (of same or different
diameter) so arranged that material to be crusher passes between one
set of two such roll at one time or is composed of single and double roll
crusher.

(Single Roll Crusher) (Double Roll Crusher)

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 (Triple roll crusher)

● Classification Depends upon number of Stage​:-

1. Single stage Roll crusher​:- In a single stage roll crusher 2 roll create a
stage and rotating towards each other.
2. Double stage Roll crusher​:- In double stage roll crusher 4 roll create 2
stage. After the material was crushed in first stage and then it was
crushed in 2​nd​ stage.

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 (Double stage roll crusher)

APPLICATION

39
Roll crusher use in following installation​:-

● SORTING PLANTS OF MINES

(for crushing ore)

● COAL MINES

(for crushing coal and waste)

● CEMICAL PLANTS

(for crushing lime, coal, coke ,rock salt ,etc.)

● SEMI TING PLANTS

(for crushing sintered ore and cinder)

● COAL-FUEL POWER PLANT

(for crushing coal)

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● REFINERIES

(petroleum coke)

● ALUMINUM INDUSTRY

41
 TYPE OF ROLL CRUSER MANUFACTURED

● SINGLE STAGE ROLL CRUSHER​:-

NAME OF MACHINE DIAMETER OF ROLL LENGTH OF ROLL

3030S 15” 30”

4040S 24” 40”

4060S 24” 60”

4080S 24” 80”

“S” Stands for Single stage

● DOUBLE STGE ROLL CRUSHER​:-

NAME OF MACHINE DIAMETER OF ROLL LENGTH OF ROLL
3030D 15” 30”
4040D 24” 40”

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 4060D 24” 60”
4080D 24” 80”
“D” Stands for Double stage

● BREAKER​:-
NAME OF BREAKER

60” SA Breaker

80” SA Breaker

60” SA Breaker

80” SA Breaker

IMPORTANT PART, ITS FUNCTION & HOW IT WORKS

● Name of The Parts​:-

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1. Base Frame
2. Bearing(Antifriction bearing)
3. Shafts
4. Housing
5. Roll (Type of roll, Roll material, Hard facing)
6. Drive Unit & Gear Box
7. Nitrol Control System
8. Lubrication
9. Ring feder
10. Roll gape adjustment and safety device
11. Feeding device and discharge chutes

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1. BASE FRAME​:-

Frames are heavy welded structures with bearing mounted surfaces. Lifting
eyes are provided for safe handling. A flanged, drilled discharge opening
enables connection to the chutework.

It shall serve the purpose of supporting the roll, housing,

adjustment assembly, and the drive motor/prime movers. Secondly it shall
also serve the purpose of locating floating roll parallel to the axis of fixed
roll.

It shall consist of an adequately strong fabricated steel frame made out

of rolled steel section.

45
(BASE FRAME)

(BASE FRAME)

46
​2.​Bearing (Antifriction Bearing)​:-

Regarding of crusher series, all main shaft bearing are double row,
spherical, self-aligning roller bearings, designed for specified running life.

Rolls are supported on the antifriction bearing through stub shafts made of
alloy steels.

​Antifriction Bearing:-
A machine element that permits free motion betweenmoving and fixed parts. Antifrictional
bearings are essential tomechanized equipment; they hold or guide moving machine parts
and minimize friction and wear.

In its simplest form, a bearing consists of a cylindrical shaft, called a journal, and a mating
hole, serving as the bearingproper. Ancient bearings were made of such materials aswoo
d stone, leather, or bone, and later of metal. It soon becameapparent for this type of bearin
g that a lubricant would reduce both friction and wear and prolong the useful life of thebea
ring. Petroleum oils and greases are generally used for lubricants, sometimes containing s
oap and solid lubricants suchas graphite or molybdenum disulfide, talc, and similar subst
ances.

47
(BEARING)

48
3. SHAFT(Stub Shaft)​:-

Shafts for all models are heat treated alloy steel, designed to
transmit the required torque and withstand the required with normal
crushing.

49
 (STUB SHAFT)

4. HOUSING​:-

50
 For easy removal, the housing is split into 4 to 8 section, depending on
the model and options selected.

Replaceable housing liners of wear resistant steel are available in all

models for use in application where abrasive materials are present in
the feed.

The purpose of cover is to minimize dust nuisance and is to guide the

feed material into te roll cavity through side lines, whill shall also
minimize spillage.

The cover shall consist of number of suitably welded section fitted with
at least two numbers inspection window. The section shall be bolted
together to permit easy dismantling during maintenance. The cover shall
be suitabley secured to the base frame by means of rapid lock
mechanism.

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 (ROLL SRUSHER HOUSING)

5. ROLL ​:-

Roll are providing in 30”, 24” and 13”- 16” diameter as standard. Large
or smaller diameter as standard. Large or small diameter are available
for varied application.

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Roll and tooth design on any of the roll are provided as best suited to
the application hether hot or cold, wet or dry, abrasive or non-abrasive,
sticky or not, large or small feed, clean washed or run-of-mine material.
Coupling-mounted roll can be replaced without the need to dissemble
the main drives, secondary drives or gear boxes.

Roll material​:-

Rolls are manufactured from may materials:alloy steel, with or with out
hard facing, Manganese steel, Ni-hard, Hi-Chrom iron,
Chrome-Molybdenum and Stainless steel.

Various tooth configuration are avilable: Hook, Grab, Continous,

Interrupated, Pyramid, Triangular, Round or spike.

Type of Roll​:-
1. Chisel Tooth Roll + Grab
2. Pocket Tooth Roll
3. Hook Tooth Roll + Grab
4. Heringbone Tooth Roll

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Hard facing Operation​:-
Hard facing is a metalworking process where harder or tougher material is applied to a
base metal. It is ​welded​ to the base material, and generally takes the form of
specialized electrodes for ​arc ​welding​ or filler rod for ​oxyacetylene​ and​ ​TIG​ welding.
Powder metal alloys are used in (PTA) also called Powder plasma welding system
and ​Thermal spray​processes like HVOF, Plasma spray, Spray and Fuse, etc.
Hardfacing may be applied to a new part during production to increase ​its ​wear
resistance​, or it may be used to restore a worn-down surface. Hardfacing by arc welding
is a surfacing operation to extend the service life of industrial components,
pre-emptively on new components, or as part of a maintenance program. The result of
significant savings in machine down time and production costs has meant that this

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process has been adopted across many industries such as ​Steel​,
Cement, ​Mining​, ​Petrochemical​, Power, Sugar cane and Food. According to the results
of an experimental study, the SMAW (​Shielded Metal Arc Welding​) and the GMAW
(​Gas Metal Arc Welding​) hardfacing processes were effective in reducing the wear on
the mouldboard ploughshare. With the SMAW and GMAW hardfacing processes, the
life span of the ploughshare was increased approximately 2 times
Extensive work in research has resulted in the development of a wide range of alloys
and ​welding procedures​. The optimum alloy selection is made considering the
component service conditions and feedback of the service performance.
For each industrial application and wear phenomena, there is a welding electrode to
provide wear resistance.
Hardfacing can be deposited by various welding methods:
● Shielded Metal Arc Welding (SMAW)
● Gas Metal Arc Welding (GMAW), including both gas-shielded and open arc welding
● Oxyfuel Welding (OFW)
● Submerged Arc Welding (SAW)
● Electroslag Welding (ESW)
● Plasma Transferred Arc Welding (PTAW), also called Powder Plasma welding
system
● Thermal spraying
● Cold polymer compounds
● Laser Cladding
● Hardpaint

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Commonly applied materials include cobalt-based alloys (such as ​stellite​), nickel-based
alloys, ​chromium carbide​ alloys and ​NOREM​. Hardfacing is sometimes followed by hot
stamping to refinish the part or add color or instructional information to the part. Foils or
films can be used for a metallic look or other protection.

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57
6. DRIVE UNIT& GEAR BOX:-
The drive to roll crusher will be such that all the rolls will be
individually driven or through suitable gears or pneumatic tyres.
The prime mover may be an electric motor, flame proof or
nonflame proof as per requirement.
Power development and transmitted by the poer unit shall be
adequate for the duty to be performed. The power unit shall
conform to relevant Indian standard.

For Single Stage:-

The crusher is provided with one drive design of rolls.
The Motor Pulley is directly mounted on the motor shaft through
key whereas the driven pulley is mounted on the roll shaft through
Ring Feeder locking assemblies.

For Double Stage:-

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 In double stage roll crusher the motor is connected with the lower
fixed roller and the fixed roll transmit motion to movable roll by a
gear system. Upper stage roll are connected with lower by belt.

(DRIVE UNIT)

GEAR BOX:-

There are 4 gear one driving gear one driven gear and 2 idler gear. Driving gear
connect with fixed roll and driven gear connected with movable roll. The power

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transmission to driven gear through idel gear. Idel gear are connected with each
other through a plate fixing the axis on the plate.

The geare transmit poer inside a gear box. Gear box has a oil level indicator. Oil
helps to lubrication of gear. Gear connected with the stub shaft with taper lock.

(COMPOUND GEARTRAIN ) (GEAR BOX)

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61
7. NITROL CONTROL SYSTEM​:-

A control system is a device, or set of devices, that manage , commands,

directs or regulate the behavior of other of other devices or system.

The adjustable roll can be set independently to the desired

position by Hydraulic cylinder. The hydraulic cylinder operate with
hydraulic oil on one side and inert gas (nitrogen) on other side. The roll
position can be changed either by pumping more oil through a and
pump draining out oil tank. The inert gas on the other side of the
cylinder acts as a spring that allow the adjustable roll to move back to
allow tramp iron/ un-crushable material to pass through.

Benefits of NITROL CONTROL system​:-

1. Allows you to set the proper roll pressure needed for your crushing
operation.
2. Offers up to 5” roll relief for passing foreign material.
3. Adjustable pressure from 100 PSI to 1000 PSI.
4. Easy to adjust for various crushing needs.
5. Reduces vibration and wear on gear box.
6. Can withstand greater crushing forces.
7. Prevent screw and nut adjustment freeze-up.

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 (Hydraulic Cylinder)

8. LUBRICATION​:-

The crusher are provided with two bulk-head lubrication points

located in front of the crusher. Semi-automatic and automatic
lubrication systems are also available.

The crusher is equipped with a point to point lubrication system

for greasing main bearing and its labyrinths. The requirement of
grease for various lubrication points is given below.

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 1. Main Bearing​:-

There are 4 main bearing on the crusher. The bearing are double
row spherical roll bearing mounted in machined cast steel bearing
blocks and sealed with labyrinth schedule. Labyrinth rings should
be lubricated every 8 hours of operation to provide dust entry to
bearing.

2. Adjustment ant alignment assembly​:-

All the linkage where rotation is there between two links are
provided with grease nipples. These points to be lubricated with
1kg of grease every 1000hrs. Of operation to permit free
movement. Recommended grease SERVOGER3 of IOC.

3. GEAR BOX​:-

Quantity of oil for gear box 30 liter

Type of oil Servo mesh SP 320 or

equivalent

​OIL LEVEL​:-

The oil level should be visible through the oil level indicator
. provided on the casing.

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4. HYDRAULIC HAND PUMP​:-

Quantity of oil 13 liters

Type of oil Servo system 68 of IOC

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(Lubrication Point)

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67
9. RINGFEDER LOCKING ASSEMBLIES​:-

The RINGFEDER LOCKING ASSEMBLY is a keyless shaft-hub

connector providing mechanically the same characteristics as a shrink
fit. It is, however, easily adjustable and removable thus facilitating
assembly and disassembly. Since torque is transmitted by contact
pressure and friction between functional surfaces, condition of
contact surfaces and proper tightening of the locking screws are of
great importance.

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(RINGFEDER LOCKING ASSEMBLIES)

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10. ROLL GAPE ADJUSTMENT AND SAFETY DEVICE​:-

The roll gap shall be adjusted by moving the floating roll

either towards or away from the stationary roll. This setting shall be
adjustable by means of operation a hand wheel or similar device so
located to permit easy operation. The adjustment shall be possible by
keeping the floating roll axis parallel to the fixed roll axis.

The roll crusher shall be equipped with a safety device for

protecting the crusher against any occasional uncrushable material
entering the crusher. This shall be achieved by providing either a
shear pin or a breaker bolt or spring loading attachment, hic yield.

Heavy duty roll crusher shall be provided with either single or

combination of truncated cone springs or both annual springs
ensuring damped recoil; or with hydraulic springs. Soon after
removal of uncrushable foreign matter, the spring shall regain
original prefixed position.

The above two arrangements, that is roll gap adjustment or

overload safety shall be either grouped together in one device or
arranged separately.

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11. ​Feeding device and discharge chutes​:-

Feed Chute​:-

In order to obtain the maximum through- put capacity of the crusher,

the feed chute should satisfy the following conditions.

● The feed conveyor should run perpendicular to the length of

the roll.
● A minimum drop of 2000mm should be provided between the
feed convey or discharge and the top of the crusher feed
chute.
● The sealing arrangement between the feed chute and the top
of the crusher to be provided.

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 ● The feed chute should be self-supporting type i.e, THE WEIGHT
OF FEED CHUTE SHOULD NOT BE TRANSFERRED TO MACHINE.

Discharge Chute​:-

Discharge chute should be so designed that material does not build up

at the discharge of crusher. Maintain a clearance of minimum 2000mm
between bottom of base frame and top of conveyor.

ASSEMBLE PROCEDURE

​Assemble Sequence​:-

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 ● tatic balancing of the roll and hub welding
● Stub shaft fitting and checking
● Bearing assemble with roll
● Side frame fitting with Base frame
● Coupling Half shrink fitting with Alignment shaft
● Alignment shaft and crank arm fitting with side frame
● Hydraulic piping arrangement
● Tooth rolls fitting with Base frame and Hopper fitting with side
frame
● Clamping Bracket fitting with base frame.
● Roll alignment with sliding plate fitting and Stopper plate
welding.
● Lubrication arrangement for Rolls.
● Roll removal rail mounting bracket setting and welding.
● Drible chute and slot closure assemble .
● Ensure free rotation of roll

Detailed Activities of Gear Box casing & Gear Box Assemble​:-

● Gear Box casing dressing & drilling with back plate as per drive
requirement.
● Side plate lapping with gear box back plate
● Gear box casing assemble
● Preparatory work of Gear box assemble.
1. Gear plate bush fitting

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 2. Bearing fitting on gear plates
3. Brg. Fitting on idler gear
4. Taper lock bush blue contact with drive gear
5. Drive gear with taper lock bush fitting with roll at a TT of
540Nm.
6. Idler gear fitting with gear plate assemble with gear pin

ERECTION PROCEDURE

CRUSHER ERECTION​:-

The erection of the machine should be carried out in the following steps.

Important​:-

1. Foundation Plan​:-

The foundation plan should be in accordance it the foundation drawing.

2. Feed and discharge cut fixing​:-

When attaching a feed and discharge chute, bolt to the hopper and channel
extending concrete base respectively using the holes providing on the
hopper flange. Welding to the crusher may cause distortion, resulting in
failure of the moving parts.

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 Chutes should be self supported units not dependent on te crusher for
support.

3. Maintenance area​:-

In the event of future maintenance on your crusher (changing gear box

parts, roll and bearing) 1500 mm minimum clear area all around the
crusher.

The erection to be done in following steps​:-

A. 1. Check that the foundation plane is made as per the drawing furnished.
2. Place the crusher over the foundation. Install the foundation but do not
tighten them.
3. Check the alignment of the machine.
4. Level the machine. Leveling should be checked at bearing housing pad.
Standard shims can be employed at foundation bolts as required. The
shims should be tack welded with base frame after is leveled.
5. Fine grout (non shrinkable type) to be done. In case of civil foundation.
6. Foundation bolts to be tightened lightly
7. After curing of the fine grout, the levels should be checked again.
8. Tighten the foundation bolts completely
9. Assemble the flywheel sheave on the main drive shaft
B. Erection of drive arrangement​:-
1. Check the foundation plane for the drive arrangement

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 2. Place the slide rails, make sure that the side rails are parallel to each
other and to the axis of crusher. The relative position of slide rail with
respect to machine to be maintained.
3. Level the slide rail. The height of slide rail top with respect to machine
axis should be maintained.
4. Shim provided for leveling should be tack welded with slide rail base.
5. Foundation bolts to be inserted in position and tightened lightly.
6. Provide non-shrinkable type fine grout under slide rail in leveled
condition.
7. After curing of fine grout the levels should be checked again.
8. Tighten the foundation bolts.
9. Place the motor over the slide rails.
C. Installation of other loose items​:-

Install the hose, nitrogen pressure regulator and other items of hydraulic
adjustment assembly send loose.

D. Chute​:-

Feed Chute​:-

In order to obtain the maximum through- put capacity of the crusher,

the feed chute should satisfy the following conditions.

● The feed conveyor should run perpendicular to the length of

the roll.

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 ● A minimum drop of 2000mm should be provided between the
feed convey or discharge and the top of the crusher feed
chute.
● The sealing arrangement between the feed chute and the top
of the crusher to be provided.
● The feed chute should be self-supporting type i.e, THE WEIGHT
OF FEED CHUTE SHOULD NOT BE TRANSFERRED TO MACHINE.

Discharge Chute​:-

Discharge chute should be so designed that material does not build up

at the discharge of crusher. Maintain a clearance of minimum 2000mm
between bottom of base frame and top of conveyor.

E. Maintenance facilities​:-

in order to provide proper maintenance to the crusher and its drive,

sufficient space should be allocated. The minimum space required for
maintenance purpose is sown in g.a with drive drawing.

Important​:-

rotate drive shaft a minimum of once per week while crusher is not being
operated to distribute lubrication to the bearings and prevent possible
corrosion.

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78
 SPARE PARTS

List of spare parts​:-

Sl. No. Description Qty.

1 Drive gear 2

2 Idler gear 2

3 Taper lock busing 2

4 Gear plate 4

5 Fixed bearing assy. 2

6 Bearing for idler gear 4

7 Bearing for gear plate 4

8 Fiber waser for drive 4

gear

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9 Fiber washer for idler 4
gear

10 Gear box stub shaft 2

11 Main drive shaft 1

12 Gib head key 2

13 Alignment shaft 1

14 Slise bar 2

15 Hyd. And pump 1

16 Hose assly. With 1

adapters

17 Pipe connector with 1

check valve

18 Hydro-pnumatic 2
cylinder

19 N2 pressure regulator 1

20 Locking assembly 2

21 8v- Belts 1 set

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81
 SECTION-4
​

​CONCLUSION

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83
 CONCLUSION

A detailed study on ROLL CRUSHER was done under the expert

guidance of ​Dr. Manoj Kumar Mohanty and various members of Assembly
shop. Starting with the parts, function and uses of the machine. The various
along with observation were recorded and the report was prepared.

REFERENCES

● Operation & Maintenance Manual for roll crusher

● Catalogue, Assembly shop, L&T Kansbahal Works
● Wikipedia
● Google Image

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