Operation & Maintenance Manual For Fiberizor

OPERATION AND MAINTENANCE MANUAL

FOR

FIBERIZOR
(Dia. 2200 x 2032 Width)

KRANTI S.S.K.LTD
W. O. No. – 4 M.0176

ThyssenKrupp Industries India

 Operation & Maintenance Manual For Fiberizor

CLIENT : KRANTI S.S.K.LTD.

EQUIPMENT : Fiberizor – Dia 2200 x 2032 Width

ORDER NO. : 4M.0176

YEAR OF
MANUFACTURE : 2012

MANUFACTURED BY : ThyssenKrupp Industries India Pvt. Ltd.

Pimpri, Pune - 411018
Fax No : (020) 27425350

NOTE :

This is a general O & M manual for all different types & constructions of Fiberizor
machines being manufactured by us. Some of the items mentioned are optional and supplied
against special order only. The description in the manual will be applied to your equipment
whenever these items are covered in your order.
 Operation & Maintenance Manual For Fiberizor

TABLE OF CONTENTS

TITLE SECTION

INTRODUCTION 1

TECHNICAL DATA 2

GENERAL NOTES 3

DESCRIPTION 4

OPERATION 5

HANDLING, TRANSPORTATION & STORAGE 6

INSTALLATION 7

MAINTENANCE 8

LUBRICATION CHART 9

SPARE PARTS & TOOLS 10

ANNEXURES:

BEARING MOUNTING PROCEDURE I

COUPLING MAINTENANCE &

ALIGNMENT PROCEDURE II

DRAWINGS AND PART LISTS III

Operation & Maintenance Manual For Fiberizor
 Operation & Maintenance Manual For Fiberizor

1.0 INTRODUCTION
Fiberizor is a sturdy and uncomplicated machine for sugar cane preparation prior to milling. It provides
trouble-free service when properly installed and maintained.

This instruction manual is intended to serve as a guide for proper operation and maintenance of fiberizor.

During installation, repair, and maintenance, it is mandatory to observe the local safety and accident
prevention regulations.

The operating personnel should go through this manual and have to familiarise themselves with the
equipment before using.

NOTE:

This is a general O & M manual for all different types & constructions of Fiberizor machines being
manufactured by us. Some of the items mentioned are optional and supplied against special order
only. The description in the manual will be applied to your equipment whenever these items are
covered in your order.
 Operation & Maintenance Manual For Fiberizor

2.0 TECHNICAL DATA

1. Name of the Customer : KRANTI S.S.S.K. LTD

2. Address : At-Kundal,Tal:-Palus,Dist:-Sangli 416309

Maharashtra

3. Work Order No. : 4 M.0176

4. Fiberizor Model. : Dia 2200 mm. x 2032 mm. Width

5. Swing Dia. : Dia 2200 mm

5.1 Rotor Speed : 750 RPM.

6. Anvil type. : 126 deg. Pocketed

7. Bearings. : Spherical Roller Bearings - 23060 CCK/C3/W33

8. Lubrication of Brgs. : Grease lubricated.

9. Coupling. : REXNORD make, Resilient Coupling,

Size-1140T10 & Spacer type resilient 1140T50

10. Drive : 2 x 1000 KW / 750 RPM

10.1 Single drive / Double drive : : Double Drive

11. Floating flap. : Yes

12. G. A. Drawing No. : MP-5440-1/0

Bearing mounting data

Bearing size – 23060 CCK/C3/W33

Withdrawal Sleeve – AOH 3060 G
Bearing Initial Radial Clearance – 0.33 mm – 0.43 mm
Axial Drive-Up – 2.0 mm – 3.0 mm
Reduction in Radial Clearance – 0.13 mm – 0.19 mm
Bearing Final Radial Clearance – 0.20 mm – 0.30 mm
 Operation & Maintenance Manual For Fiberizor
See detail bearing mounting procedure in Annexure -I

3.0. GENERAL NOTES

Following are the important points to watch on fiberizor after installation:

3.1 Proper installation

3.2 Scheduled regular maintenance of hammers. Wear on Hammer Inserts should be checked every week.

3.3 Regular check of following items:

3.3.1 Sudden appearance of vibrations which indicate loss of hammers / replaceable tips.

3.3.2 Check tightness of bolts of hammer tips, hammer axle locking plates.

3.3.3 Lubrication of fiberizor bearing & drive & continuous water flow for water cooling of bearing
housing.

3.3.4 Lubrication of floating flap bearing.

3.4 Every third month, the hardfacing on the Anvil, Floating flap should be checked and if
necessary hard face layers should be built up.
 Operation & Maintenance Manual For Fiberizor

4.0 DESCRIPTION
Fiberizor is a machine for sugar cane preparation prior to milling. It basically comprises of housing
assembly, rotor assembly, rear chute, anvil assembly, deflector plate, floating flap and drive for fiberizor as
applicable and shown in G.A. drawing.
Housing assembly is a fabricated casing in which other components and assemblies are fitted. Housing
plates are provided with stainless steel liners from inside to avoid corrosion / rusting (optional). Two
inspection doors are provided on sidewalls of housing for quick inspection of hammers / hammer inserts, etc.
Housing comprises of several panels for easy of maintenance. All housing panels are held together by
fasteners.

Rotor assembly for fixed hammer fiberizor consists of rotor discs (each off set at 36 deg) to which the
hammers along with inserts are bolted. Hammers are precisely located in the machined pockets of rotor
discs to form a solid mass for striking sugar cane. Hammer inserts are of replaceable type and are fitted to
hammer by screws. This whole assembly of rotor is supported by two precision bearing housings mounted
on pedestals.

Rotor Assembly for swing hammer fiberizor consists of rotor discs (each off- set by 36 deg / 45 deg).
Hammer Axles are assembled in rotor discs and locked at either end by locking plates. Swing Hammers with
single bolt replaceable Hammer Tips are suspended on to the Hammer axles. Bushes protect axle Bores in
Hammers and rotor discs.

Anvil is of pocketed type steel construction for efficient fiberizing of chopped cane. The surface of anvil
coming in contact with cane is hard faced. In case of standard fiberizor anvil envelopes the rotor over
approx. 90 deg circumference. It is supported by spring loaded stud assemblies to absorb shocks. These
assemblies’ help in rejecting a foreign material like a tramp iron piece, thereby avoiding the damage of anvil
and rotor assembly. The gap between Hammer circle and anvil pocket plate can be adjusted with the help of
stud assembly.
In heavy-duty fiberizor pocketed anvil is suspended in the Housing and it envelops the rotor over 126-
deg circumference. Anvil is in two parts hinged together and adjusted independently by stud assemblies. Due
to higher lap angle of the anvil thorough fiberizing action with superior preparation is ensured.

To ensure positive feed of the cane to heavy-duty fiberizor rotor a floating flap is placed over the carrier
in front of fiberizor rotor. The floating flap is hinged in housing side plates and continuously rides over cane
bed, thus ensuring positive feed of compacted cane to the fiberizor rotor. The pressure on cane bed exerted
by floating flap can be adjusted by adjusting the position of counter-weight on the lever arm. The Floating
flap continuously adjusts itself so that it is always compacting with the cane bed over the feed carrier, even
when there are wide variations in feeding pattern.

The gap between hammer circle and floating flap is automatically adjusted to regulate the flow of
chopped cane on to rear chute / anvil. By regulating flow of cane, a cane anvil is formed between floating
flap and carrier in the zone where rotor engages into the cane. Approx.50% to 60% fiberizing takes place in
this zone. Floating flap does not require any drive. However, suitable provision should be made in cane
carrier drive for additional weight of floating flap.
 Operation & Maintenance Manual For Fiberizor
The floating flap seals the air gap over cane bed and thus reduces windage losses, noise and sugar mist
formation. The fiberized cane output from anvil is fed to the rake elevator by deflector plate. Deflector plate
is provided with a pouch that absorbs impact of cane. Deflector plate is lined with an SS liner.
Refer G.A Drawing for general arrangement of parts.

5.0 OPERATION :
The sugarcane from cane carrier is fiberized by the rotating hammers and is carried to rear chute.
Floating flap sets the direction and controls the flow of cane pieces. Cane accumulating on rear chute slide
on to the anvil by gravity action. At the anvil, due to repeated hammering action, the cane pieces open up
completely and turn into fine fibres with almost 85% to 90% of its cells opened. A specially developed-
pocketed design of Anvil ensures that cane is crushed over cane resulting in a better preparation and less
wear of Anvil. The fineness and the output of fibre can be adjusted by altering the gap between anvil bar and
the Hammer circle.

These fibres improves mill feeding considerably, as 85 to 90% of cells are opened.

NOTES:

[1] Before starting the fiberizor for the first time after installation, and there after before
starting every season, ensure that the anvil pockets are filled and compacted with dry
baggase. This avoids accumulation of fresh cane in the pockets, which decomposes and
builds bacteria in the due course of time. This also facilitates easy cleaning of anvil at the
end of season.
[2] During the operation / working, uniform loading of the cane & uniform cane bed height on
cane carrier is to be ensured to avoid choking of cane just before entering the fiberizor. In
order to increase the capacity the cane carrier speed is to be suitably increased so that
cane bed height does not increase abnormally.
 Operation & Maintenance Manual For Fiberizor

6.0 HANDLING, TRANSPORTATION AND STORAGE:

6.1 Handling:
Various sub-assemblies of the fiberizor are generally despatched separately. While handling
rotor assembly, ensure that the lifting rope does not damage the bearings & other machined surfaces.
Rope slings should be placed directly around shaft with suitable packing.
The anvil assembly, side panels of housing, rear chute, deflector plate & floating flap should be properly
protected before lifting by rope to avoid their distortion.

6.2 Transportation:
During transportation, ensure that sub-assemblies are firmly fixed / anchored by giving braces
supports to avoid any deformation.

6.3 Storage:
For long storage, ensure that sub-assemblies/components are protected from sun/rain. Bearings
& machined surfaces is properly lubricated & rust preventive / paint is applied. Ensure that the sub-
assemblies/components are supported on wooden sleepers on firm and horizontal ground.

Rotor assembly, if supported on bearings, should be rotated through 90 deg. every fifteen days to
prevent fretting corrosion at bearing rollers.
 Operation & Maintenance Manual For Fiberizor

7.0 INSTALLATION:
In the following, a brief description of the procedure to be followed during installation is outlined:

7.1 Check the fiberizor for possible damages during transit Advise carriers of any damage.
7.2 For maintaining the dimensions specified in G.A. & Installation drawings:
7.2.1 Mount the two bearing support pedestals on the foundations using shims to level them off and
obtain the required elevation. Tighten the foundation bolt and nuts. After levelling, the top of
pedestals should be at the same height within (+/-) 0.5 mm and each top of pedestal should be
level. Half grouting of pedestals can be carried out in this condition.
7.2.2 Mount housing supports along with lower plates on the foundation and tighten the foundation
bolt nuts after levelling.
7.2.3 Lower the rotor assembly complete with bearings and bearing housings but without hammers on
pedestals. (For bearing mounting see Annexure I)

IMPORTANT: Suitably lubricate the bearings-(ref. lubrication chart in section 9 in this manual)
before closing bearing housing. For mist lubricated or oil lubricated brgs. some oil should be applied
to bearing initially through oil / mist inlet holes.

Install the locating rings in fixed bearing housing. Align the rotor with dimensions specified in G.A. drawing
using shims as required under the drive.
After alignment, the following conditions should be satisfied with the foundation bolts and the bearing
anchor bolts fully tightened.

a) The rotor shaft should be in level : (+/-) 0.5 mm

b) The rotor centred within the housing : (+/-) 1.5 mm
c) The clearance between hammer tips and conveyor slat should be:- 40 (+/-) 5 mm (Uniform along
width)
d) The rotor should rotate freely when propelled by hand.

Grout under the bearing support pedestals. Any packing plates, shims used for levelling should be
permanently grouted. For positioning packing plates under the pedestal please ref. Fig.1 for
guidelines.

7.2.4 Install the anvil. There should be no interference between anvil and the sidewalls of housing. The
anvil must be free to swing within its support bearings. If there be some interference in places due to
distortion during transit, these local interference’s can be removed by pulling the housing plate at the
required place(s) by the judicial use of pull jacks, wedges etc. Adjust the clearance between anvil pocket
plates and Hammer tip circle as shown in G.A. drawing and guidelines given below:

Type of Anvil Clearance at fibre / Cane inlet Clearance at fibre outlet

126 deg 150 - 180 20
90 deg 65 - 85 22
 Operation & Maintenance Manual For Fiberizor
7.2.5 Install the deflector plate located below the rotor by bolting it to the side plates.
Check the clearance between the deflector plate and

(a) The hammer tips; this should be 20 (+/-) 2 mm

(b) The cane carrier slats; this should be 30 (+/-) 5 mm
(c) Tighten the bolts.

CAUTION : The location of deflector plate is critical. ThyssenKrupp Industries should be consulted
if the location of the conveyor head shaft and / or the fiberizor rotor is / are changed for any reason.

7.2.6 Install rear chute and also the rest of housing components such as floating flap, top, front and rear
plates, cross beams, etc. and bolt them.

7.2.7 Bolt the housing to the conveyor skirt-boards.

7.2.8 Complete all site welds indicated in drawings

a. Sealing angle between cane carrier and fiberizor housing.
b. Housing support to suit the position of cane carrier column.

7.2.9 Install flywheel and the coupling half of fiberizor on rotor shaft. Also install spacer between the
flywheel & coupling half to ensure that flywheel does not move axially.

7.2.10 Align the coupling half on the prime mover with the fiberizor coupling half within (+/-) 0.02 mm
both for the axial and angular misalignment. Coupling maintenance and alignment procedure is
given in detail as per Annexure -II.

7.2.11 In all cases the specified min. gap between coupling halves and shaft ends should be maintained.

7.2.12 It is necessary to carry out static balancing of bare rotor initially and dynamic balancing by
vibration method in running condition before assembly of hammers. After balancing of rotor,
vibration at bearings should be limited within 25 x 10 -3mm amplitude (i.e.2A = 50 x 10 -3mm).

IMPORTANT: Please refer hammer replacement / assembly procedure in sect. 8.5

before mounting the hammers.

7.2.13 Fixed Hammers: Mount all hammers, three bolts are provided for each hammer. Nuts along
with lock nuts should be tightened with torque wrench to 711 Nm. (For 8.8 grade M24 blots &
nuts.). Hardened washers provided should be used to avoid damage to disc while tightening.

7.2.14 Ensure that hammer seats completely in the pocket and that there is no gap between seating
surface of hammer and rotor disc after tightening the bolts. This check should be done with feeler
gauge.

7.2.15 Swing Hammers: Swing hammers are assembled with Hammer Axles and end locking plates are
bolted at either end.

7.2.16 After hammer assembly, run the rotor at rated speed (RPM) and record vibrations at the
bearings. Vibrations should be within 50 microns amplitude (i. e. 2A = 100 microns)
 Operation & Maintenance Manual For Fiberizor
7.2.17 Install floating flap and set the gap of approx.250 mm. between floating flap and hammer circle as
mentioned in G.A. Drg. Locate & fix the stopper for lever so that minimum gap between
floating flap and carrier slat is set as indicated in G. A. Drawing.

8.0 MAINTENANCE:
As such the fiberizor requires little maintenance. However it needs a planned maintenance to obtain
optimum performance during season.
The key to success is the regularity of the maintenance. It is always better to perform a little work on the
hammers and index the Hammer Inserts in time, thus maintaining the quality of fiberizing all the time, rather
than wait until the hammer inserts are too far-gone and have, therefore, to be replaced. The best preventive
maintenance work schedule on a fiberizor is as follows:

8.1 Rotor Assembly

Hammers at each opportunity (say a downtime of 30 minutes or more) check the tightness of the
hammer fixing bolts.
The combination of shocks and corrosion (due to the low PH of sugar juices) have a tendency to slacken the
hammers. It is good practice to have the following items near at hand, in constant readiness at all times:
a) A spare set of hammers, nuts, bolts and washers.
b) Hammer Tips with bolts and washers.
c) A spanner and a ratchet wrench to suit the size of hammers, nuts, bolts and washers.

When a slack hammer is detected, the three nuts are further tightened.

Hammer Inserts - The hammer inserts are the only parts of a fiberizor, which wear rapidly. The wear of the
tips depend on type of cane (fibre), extraneous matters and damage depends on stones, iron etc. It is
necessary to study & monitor the wear / damage pattern of tips periodically say every week, so as to
determine when to index tips & replace after both the edges are used.

Hammer inserts are fixed on hammer arm by a single M24x2 (fine pitch) 8.8 Gr. H.T. bolt and a
H.T.C-45 material hardened washer. Torque required for correct tightening 600 Nm.

Hammer arms are permanently fixed in rotor disc and normally they do not require replacement.
hammer arm is hard faced in few areas where wear can occur over a prolonged period of time. If hardfacing
is worn out then it should be re-deposited. The recommended electrode is eutectrode 700 L&T make or
equivalent.

If due to lack of maintenance, the hammers have worn too much, then they can be salvaged by building
up with ordinary mild-steel electrodes and finished off with two layers of hard facing electrodes. Ideally,
two layers of hardfacing overlay should be laid on. The first layer is somewhat diluted by the parent metal,
the second layer is pure hardfacing. A third layer would be a waste of money and time, as it would make the
overlay too brittle. Hammer insert is a high wear component and is hard faced with a special alloy and
process. Inserts should be indexed / replaced after wear. We do not recommend rebuild-up of hammer
inserts.
 Operation & Maintenance Manual For Fiberizor
Note: While changing the hammer inserts, it is to be noted that the insert on the opposite side of same
rotor disc is also to be changed to maintain the balancing of the rotor.
For Swing Hammer rotor assembly the bushes in Axle bores of hammers and rotor discs shall be
inspected for wear / damage after every season and if necessary replaced.

Hammer Axles / Locking plates shall be inspected for wear periodically. Any steps formed on the axles
shall be ground smooth before re-assemble. If axles are bent, then it shall be straightened for easy
assembly or shall be replaced, if necessary.

IMPORTANT: Before using arc welding, for any reason, on the rotor, the following precaution must
be taken, otherwise the bearings might be permanently damaged.
The precaution is to avoid the welding currents from passing from the bearing inner race to the
bearing outer race by way of the rollers of the bearings. These currents might cause pitting at the
bearing surfaces, thereby, causing irreparable damage. The idea, therefore, is to provide a better and
alternate path for the welding currents. This is achieved preferably by connecting the ground (or
earth) connection of the welding set to any one of the rotor hammers / rotor discs. Alternatively, the
ground connection of the welding set and rotor may both be connected to the nearest available
structural steel.

8.2 Anvil

The anvil does not require more than a once-a-year repair by hardfacing at the tip of each pocket plate.
The hardface building procedure is same as that of hammer arm building.

Electrode for hardfacing : Eutectrode 700 L&T make or equivalent.

After about two seasons it may be necessary to replace S.S.304 liner on leading edge of 126 deg. anvil.

8.3 Bearings

The bearing will run normally fairly hot. A bearing temperature of 60 deg. C. is not excessive. A
common mistake is to over lubricate grease-lubricated bearings. This practice will certainly cause the
bearings to heat up; in case of over-heating due to excess grease lubrication, the fault can be rectified,
during operation, by removing the drain plug and allowing the hot-melted grease to run out and then
replacing the plug. However where labyrinth seals are provided, the excess grease flows out through seals
and this grease should not be replaced.
In all cases, the bearing manufacturers' recommendation should be followed regarding lubrication but, as a
guide, in the case of grease-lubricated bearings, one shot of the suitable grease from a grease gun, once
every two weeks is adequate. (Ref. lubrication chart in section 9 for further details).In the case of oil-
lubricated bearings, it is necessary to fill the oil upto the required level. The quality of the oil should be
inspected frequently and, in case of cloudiness or discoloration, the oil should be drained out, the bearings
flushed and replenished. For operation and maintenance of any other forced / centralised lubrication system
for bearings, provided with fiberizor, refer manual supplied by the manufacturer, given separately.

8.4 Vibrations

Occasionally, one or several hammers may be lost. The fiberizor has an extremely hard work to perform
and at times heavy pieces of tramp iron may go through the machine. The pivoted anvil is designed to reject
these pieces of tramp iron with minimum damage to the machine.Further more, as an extra precaution
against heavy damage, the fiberizor is designed in such a way that the expensive items such as the shaft and
 Operation & Maintenance Manual For Fiberizor
hubs will never break; instead, the easily replaceable items (the hammers) will act as a "fuse" and will give
way rather than the others.However, in cases of loss of hammers, the rotor may become unbalanced to the
extent that vibrations will be noticed. These vibrations cause no great harm immediately (unless they are
excessive) but will tend to cause one or both bearings to heat up. They may also tend to loosen the bearing
Hsg. fixing bolts. It is advisable, therefore, to stop the machine at the earliest opportunity, to inspect the
rotor and to perform the necessary change and / or to replace the hammers.

8.5. Hammer Assembly And Replacement

8.5.1. Procedure
Before assembling the hammers on the bare rotor, the rotor shall be dynamically balanced without hammers
and hammer axles (hammer axles only for swing hammer type rotors) as per G6.3 of IS:1940-1;2003 (or
the standard / grade mentioned in the drawing) at rotor speed, mentioned in the drawing.

8.5.2. The basic requirement of Assembly of hammers.

(1) - In case of 8 rows rotor, hammers placed diametrically opposite to each other, should be of equal
weight (within ±25gms)
- In case of 6 rows rotor, 3 hammers in one plane should be of equal weight (within ±25 gms.)
- In case of 10 rows rotor, 5 hammers in one plane should be of equal weight (within ±25 gms.)

(2) - In case of 8 rows rotor, hammers in opposite rows balance each other. Maximum difference in
weight between any two opposite rows i.e. between 1-5, 2-6, 3-7 and 4-8 shall no be more than
150 gms. (i.e. ± 75 gms.)
- In case of 6 rows rotor, sum of weights of 3 rows at 120o i.e. between 1-3-5, 2-4-6 shall be
within 150 gms. (i.e. ± 75 gms.)
- In case of 10 rows rotor, sum of weights of 5 rows at 72o i.e. between 1-3-5-7-9, 2-4-6-8-10 shall
be within 150 gms. (i.e. ± 75 gms.)

(3) - Dynamic balancing due to residual unbalance is kept to minimum.

Hammers are individually weighed and hammer no. & weight is punched on each hammer. Records of
hammer no. v/s weights are arranged in ascending order w. r. t weight

Assign sr.no.1,2,3... to these sorted out records.

Sr. Nos. shown in tables of hammer arrangement refers to these Sr. Nos. of sorted out records.

If necessary position of the hammers can be changed or the hammers can be ground or hard-faced welded, in
order to bring the difference in weight within specified limits.
The maximum weight difference is mentioned as 150gms in all the cases, however it should be kept as low
as possible, since minimum difference in weight will ensure better dynamic balancing.
When the system is rotated, each unbalance hammer could set up a rotating centrifugal force, which tends to
rock the shaft on its bearing causing dynamic unbalance. Hence unbalanced plane are placed adjacent to
each other thus minimising Dist. "A" between them and minimising dynamic unbalance (see fig.-1)
 Operation & Maintenance Manual For Fiberizor

FIG – 1

8.5.3. [A] Rotors with 8 rows of hammers ( see fig. 2 )

Fig. 2
Here the hammers are arranged in staggered manner, i.e. in each plane there shall be 4 hammers.
Row 1st 2nd Middle n-1th nth sum of
no. plan plane plane plane plane rows
e

1 1 - i - 8 w1

2 - 9 - 16 - w2

3 3 - i-2 - 6 w3

4 - 11 - 14 - w4
 Operation & Maintenance Manual For Fiberizor
5 2 - i-1 - 7 w5

6 - 10 - 15 - w6

7 4 - i-3 - 5 w7

8 - 12 - 13 - w8

Example of Hammer Balancing:

Listing 1 satisfies the condition that opposite rows should weigh equal (within 150 gms). However,
hammers on opposite arms are not in balance. This is simplified method i.e. only static balance is achieved.
Listing 2 satisfies above condition of static balancing. In this case unbalance weights are equal and 180°
apart, system is statically balanced about rotor axis. However, when the system is rotated, each unbalanced
hammer could set up a rotating centrifugal force, which tends to rock the shaft on its bearings causing
dynamic unbalance.

Listing 3 shows optimum way of assembling hammers without disturbing balancing of the rotor. Unbalance
planes are placed adjacent to each other thus minimising dist. “A” (see fig.1) between them and minimising
dynamic unbalance.

Listing – 1
Unbalance Row 1 Row 5 Unbalance
20.00a 20.00aa
19.60b 19.90bb 0.3
19.80c 19.90cc 0.1
19.50d 19.80dd 0.3
0.6 20.00e 19.40ee
0.2 20.20f 20.00ff
19.80g 20.30gg 0.5
0.4 20.40h 20.00hh
Total 159.30 159.30
weight

Listing – 2
Unbalance Row 1 Row 5 Unbalance
19.60b 19.80c 0.2
19.40ee 19.50d 0.1
20.00a 20.00aa
19.80g 19.80dd
19.90cc 19.90bb
20.00c 20.00ff
0.2 20.20f 20.00hh
0.1 20.40h 20.30gg
Total 159.30 159.30
weight

Listing – 3
Unbalance Row 1 Row 5 Unbalance
20.00a 20.00aa
 Operation & Maintenance Manual For Fiberizor
19.80g 19.80dd
19.90cc 19.90bb
20.00c 20.00ff
19.60b 19.80c 0.2
0.2 20.20f 20.00hh
0.1 20.40h 20.30gg
19.40ee 19.50d 0.1
Total 159.30 159.30
weight

All weights are in kg. Number of hammers in a row depends on rotor width.What is shown in Listing 1
above is a random sample and is not optimum in balancing even though the total row weights are within
tolerance. The hammers should be rearranged as shown in Listing 3. With this arrangement dynamic
unbalance is kept to the minimum.

8.5.3 [B] Rotors with 6 rows of hammers (see fig. 3)

Fig. 3
Here the hammers are arranged in staggered manner, i.e. in each plane there shall be 3 hammers, as
indicated in table below.

Row 1st 2nd Middle n-1th nth sum of

no. plane plane plane plane plane rows

1 1 - i - 6 w1

2 - 7 - 12 - w2

3 2 - i-1 - 5 w3
 Operation & Maintenance Manual For Fiberizor
4 - 8 - 11 - w4

5 3 - i-2 - 4 w5

6 - 9 10 - w6

Balancing of hammers is achieved by arranging the hammers in similar way as mentioned in the
Listing –1, Listing – 2, Listing – 3, so as to minimise the dynamic unbalance.

8.5.3 [C] Rotors with 10 rows of hammers ( see fig. 4 )

Here the hammers are arranged in staggered manner, i.e. in each plane there shall be 5 hammers, as
indicated in the table below.

Row 1st plane 2nd Middle n-1th nth sum of

no. plane plane plane plane rows
1 1 - I - 10 w1
2 - 11 - 20 - w2
3 2 - i-1 - 9 w3
4 - 12 - 19 - w4
 Operation & Maintenance Manual For Fiberizor
5 3 - i-2 - 8 w5
6 - 13 - 18 - w6
7 4 - i-3 - 7 w7
8 - 14 - 17 - w8
9 5 - i-4 - 6 w9
10 - 15 - 16 - w10

Balancing of hammers is achieved by arranging the hammers in similar way as mentioned in the Listing -
1, Listing - 2, Listing – 3, so as to minimise the dynamic unbalance.

9.0 LUBRICATION CHART

Project: - KRANTI S.S.S.K. LTD
Order No. – 4 M.0176

Sr.No Location Type of Lubrication First fill Re-lubrication

. (Indian Oil or Qty Interval/Qty
Equiv.)
1 Rotor Bearing MoS2 grease Or Lithium 7 kg for Replace every two
Grease Lubrication Base Grease. both months.
bearings
2 Floating flap Bearing Servogem EP2
Spring Feed Lubricator
(Bush Bearing) 0.8 kg
55cc Capacity
3 Resilient Coupling Ref. Suppliers Manual
 Operation & Maintenance Manual For Fiberizor

10.0 SPARE PARTS AND TOOLS

We recommend that following spare parts and tools should be kept handy.

10.1 Description Quantity

10.1.1 Hammers 1 Set (145 nos.)

10.1.2 Hammer Inserts 2 Sets (290 nos.)

10.1.3 Bolts & C45 Hardened washers 2 Sets (290 nos.) for hammers

10.1.4 Main bearings 2 Nos.

10.1.5 Bolts, nuts & washers 1 Set for housing.

10.1.6 Hammer & Disc bushes 1 Set

10.2. Tools

10.2.1 Ring spanners and box for hammer bolts M24 1 No. each

10.2.2 Ratchet wrench for hammer nuts M24 1 No.

10.2.3 Allen-key for hammer inserts M16 1 No.

10.2.4 Torque wrench upto 1000 Nm capacity 1 No with suitable sockets for
M24, M20, M16 bolts.
 Operation & Maintenance Manual For Fiberizor

ANNEXURE-I

BEARING MOUNTING PROCEDURE

 Operation & Maintenance Manual For Fiberizor

BEARING MOUNTING PROCEDURE

MOUNTING & REMOVAL OF BEARING WITH WITHDRAWAL SLEEVE BY

HYDRAULIC METHOD

Large forces are required to mount bearings of higher sizes (more than 200mm shaft dia.) on
withdrawal sleeves. With the hydraulic method oil is injected between the mating surfaces, the
friction between the surfaces is overcome and the mounting forces are essentially reduced.
To permit mounting and dismounting by hydraulic method larger size withdrawal sleeves feature oil
ducts. Drg. No.: R.Q14.200.20.16.0(3) shows the details of mounting & removal of bearing on
withdrawal sleeve using oil injection method and hydraulic nut (P.No.1), pressure ring (P.No.3),
lock nut (P.No.4).For mounting & removal of bearing on withdrawal sleeve without using oil
injection method then withdrawal nut (P.No.2) to be used.

A] Procedure for mounting of bearing :-

1. Check bearing initial clearance and record. Stand the bearing on a clean work surface and rotate
inner ring few times. Initial radial internal clearance is measured on the upper most rollers using
feeler gauge.

2. Coat bearing sleeves and shaft seating surfaces with lubricating oil.

3. Mount bearing on withdrawal sleeve up to maximum possible distance.

4. Mount hydraulic nut (P.No.1) on to the threading of withdrawal sleeve, so that there is a
positive gap (more than axial drive-up) between hydraulic nut & inner race of bearing. Its
annular piston abuts the pressure ring (P.No.3). The lock nut (P.No.4) to be positioned so that
it will abut pressure ring.

5. Connect the hoses to oil injection pumps as shown in Drg.No R.Q14.200.20.16.0(3)

 Operation & Maintenance Manual For Fiberizor
6. Inject oil with Pump-1 under pressure in the hydraulic nut to push bearing tightly upon the
sleeve.

7. Simultaneously both pumps are operated alternately to slowly push the withdrawal sleeve. Inject
high pressure oil with oil injection Pump-2, between surface of withdrawal sleeve & shaft as
well as between sleeve & bearing bore, to form an oil film. This oil film separates the mating
surfaces & appreciably reduces friction between them & expands the inner race of bearing.
Pumping oil into hydraulic nut by the Pump-1 displaces hydraulic nut axially along with the
withdrawal sleeve.

8. Ensure the final clearance and axial drive-up as given in bearing mounting data in Section
–2

The general data (table - 1) giving the values of initial clearance, axial drive-up, reduction
in clearance & final clearance is enclosed for reference.

9. Relieve hydraulic pressure on the bearing inner race and wait till all oil is drained back to pump
and bearing grips firmly on the withdrawal sleeve. Hydraulic nut pressure shall be relieved only
after Pump-2 oil is fully drained. Otherwise bearing will slide back.

10. Once again check bearing clearances and repeat above procedure if necessary.

B] Procedure for removal of Bearing :-

1. Mount the hydraulic nut on to the threading of withdrawal sleeve so that its annular piston
abuts the inner race of bearing.

2. Inject the high pressure oil with Pump-2, between surface of shaft & withdrawal sleeve to
form an oil film. This oil film separates the mating surfaces & appreciably reduces friction
between them & expands the inner race of bearing.

3. Inject the oil with Pump-1 in the hydraulic nut by separate pump, so that hydraulic nut
along with withdrawal sleeve get displaced away from the bearing & the bearing can be
removed from shaft very easily.
 Operation & Maintenance Manual For Fiberizor

ANNEXURE-II

COUPLING MAINTENANCE

&

ALIGNMENT PROCEDURE

(Refer Supplier’s Manual attached)

 Operation & Maintenance Manual For Fiberizor

ANNEXURE-III

DRAWING & PARTLIST

 Operation & Maintenance Manual For Fiberizor

PART LIST

Refer – KRANTI S.S.S.K. LTD

G. A. Drawing. MP-5440-1/0

Item No. Description Qty.

1 Housing Assembly 1x

2 Rotor Assembly 1x

3 Anvil Assembly 1x

4 Floating Flap Assembly 1x

5 Pedestal for Rotor Assembly 2x

6.a Bearing Housing Assembly - SDS 3060 2x

(1 No. Fixed + 1 No. Loose)

6.b Bearing for Rotor Assembly - 23060 CCK/C3/W33 2x

7.a Foundation Bolt M24 x 500 long 8x

7.b Foundation Bolt M42 x 1300 long 12x

 Operation & Maintenance Manual For Fiberizor
8 Coupling Guard for spacer type coupling 1x

9 Coupling for gurad for resilient coupling 1X