1890 - Double Rotating Channel

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1,400,000 tpy Rebar Mill with H.S.D. System 58 95 9439
Double Rotating Channel JOB ITEM 8274.1890
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B - Equipment and Maintenance Manual 00 1
8274.1890 DOUBLE ROTATING CHANNEL
B EQUIPMENT
AND MAINTENANCE
MANUAL
ATTENTION:
Please read carefully the instructions before the machine commissioning is executed. It is the
Customers responsibility to study and understand the contents of this manual. Also to pass
the contained information by a training process to the plant operators and maintenance
personnel to result in acceptable and safe working standards with the equipment.
Images and drawing extracts present in this manual are typical of the machine type and
present an indication from which to understand the accompanying descriptions. For the
actual drawings, please refer to the project specific versions.
JIN-8274 Property of SMS MEER S.p.A; copy and disclosure of this document are prohibited 160115
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B - Equipment and Maintenance Manual 00 2
00 Contents
Chapter Title Pages
1.0 Preface 2
2.0 Safety Recommendations 3
3.0 Technical Data and Drawings 4
4.0 Functions 23
5.0 Maintenance and Use Instructions 14
6.0 Trouble-Shooting 2
7.0 Documentation of the Sub-Suppliers 1
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B - Equipment and Maintenance Manual 1.0 1
1.0 Preface
The double rotating channel system is installed in the continuous rolling mill line to
facilitate the delivery of high-speed bars and rods from the upstream mill equipment onto
the cooling bed grids. Due to the higher speeds of rolling it is not possible to deliver such
bars to the grids by more conventional drop-wall roller table transfer mechanism because
of the available inter-bar gap and the cycle time of the sliders operation.
The rotating channel is a key part of the SMS Meer combined high speed delivery system
(H.S.D.) which comprises:
The conveying channels for the bars.
Pinch rolls
High speed dividing shear
Braking pinch rolls
Tandem arrangements are possible to facilitate greater productivity in cases where the
mill is multi-stranding for bars production.
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In this configuration (see fig. 1 line A and line B) there is the possibility to add a further
device with sliders to allow the alternate discharging of the bars of both the channels on
the first tooth of the grid.
The double rotating channel is installed for the complete length and above the grids of the
cooling bed on cantilevered supports to form a monolithic entity machine to receive and
deliver the bars directly to the grids. The bars are deposited to the grid first notch and are
processed across the cooling bed by cyclical translation of the moving rakes.
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2.0 Safety Recommendations

2.1 General
See Plant Manual A
ATTENTION:
Please read carefully the instructions before the machine is commissioned, handed-over
and operated. It is the customers responsibility to read the following manual and
effectively train and communicate the contained information to all the operational and
maintenance personnel.
2.2 Specific
Attention is drawn to the specific hazards outlined in the text sections of 4.0, 5.0 and
6.0
ATTENTION:
The double rotating channel and its associated equipment is normally automatic in
operation on detection of the arriving bar or according to initiation signals from the
software controlling its activation. In any case, the device and its associated equipment is
initiated by PLC automation and since this is not an intrinsically safe system, beware that
a fault condition (although rare) has the ability to start the associated mechanism drives
or activate the equipment at any time.
The boundary areas and the adjacent underside of the cooling bed are normally totally
open to personnel access. In any case, great care must be exercised when approaching
within hand reach of the equipment and its associated devices moving parts whilst they
are live due to the risk of serious injury.
There are many potential trapping hazards within the incorporated mechanisms which
may be impractical to effectively guard. The operator must ensure that any supplied
guards conform with local or national safety regulations and must risk assess other such
points of perceived danger to identify safe working practices and rules to control access
and to mitigate the dangers.
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ATTENTION CONTD:
The entry axis and the downstream end plane of the rotating channel are both areas
where special consideration and personnel access protocols/controls need to be
considered and enforced due to the proximity of the high-speed conveyed bars and the
associated danger of being struck by the bar whether it is in its normal conveyed axis or
due to a cobble situation.
Be aware that there is no natural safe walking/access area local to the rotating channel -
access to recover material in the channels needs to be risk assessed and controls
implemented e.g. temporary working surfaces, fall restraints etc. to mitigate the possibility
of serious injury due to the risk of trips and falls, falls into pits, falls onto hot surfaces and
falls onto sharp edges.
The operator must execute risk assessment methodology in the establishment of

obligatory safe working rules for approaching close to or working directly on the rotating
channel and associated equipment when both the mill is live and delivering bars or when
it is in a stopped condition. This should include the provision of fail-safe means of
electrical and media isolations of the machines and issuing an appropriate permit to work
whenever access local to the devices would otherwise render risk of the operator being
struck, trapped or ingested into the moving parts should the mechanisms be activated.
The operator must exercise risk assessment on the dangers that any local pits or un-
guarded edges present and mitigate the risk of injury of falls by the provision of secure
guards, fences or temporary means of safe access to the cooling bed/rotating channel
area.
Be aware that the entry pinch rolls or braking rolls, if operated onto an otherwise static
bar e.g. plant stoppage conditions or when the bar is released from an upstream
constraint, can propel the bar forward and present a danger to personnel who may be
working on equipment downstream of the devices.
Be aware of the presence of upstream and downstream equipment which may be live
and operable when personnel are working on or near the rotating channel e.g. during
normal operations. Devices such as the pinch and braking rolls, dividing shear, drop-wall
roller table and moving rakes of the cooling bed equipment present specific additional
hazards to the rotating channel area. These hazards should be taken into account when
developing safe working practices through risk assessment methodology.
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ATTENTION CONTD:
Be aware of the risk of burns when accessing the equipment which will be very hot during
and immediately after its operation and also when recovering any hot material from the
rotating channel or cooling bed area. Be aware to the potential of other personnel e.g.
below and when recovering hot material due e.g. to the presence of the large pit below
the cooling bed working surface.
Also be aware that the local surfaces and specific devices such as pinch rolls, shears,
conveyors, sliders, rakes and grids are likely to be very hot due to heating conduction
and radiation from the hot bars.
SMS Meer declines any responsibility towards injuries to people or damages to

things due to the non-compliance of the above mentioned rules and
recommendations and all other safety cautions outlined in specific sections of
this manual.
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3.0 Technical Data and Drawings

3.1 Designation not applicable
3.2 Mechanical
3.3 Electrical
3.4 Hydraulic not applicable
3.5 Pneumatic
3.6 Water
3.7 Lubrication
3.8 List of Drawings and Drawings
3.2 Mechanical
Serial no. 8274.1891.01

8274.1891.02
Year of construction 2015
Type double rotating channel (double
drum)
Machine handing LH
(Handing refers to bar feeding direction)
Equipment rotating channel

Type double with four channels
Function start-stop
Dimension of the channel (mm) 40-60 mm
Rotating channel total length (m) 102 m
Distance between axis single
rotating channel (mm) 300 mm
Distance between rolling material axis (mm) 160 mm
Dimension of rotating channel drum (mm) 250 mm
Shaft diameter 75 mm
Maximum bar length 96 m
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Rounds dimension dia. min. 8 mm

dia. max. 40 mm
Rolled product speed 45 m/s dia. 8 mm
8,09 m/s dia. 40 mm
Index rotation angle 90
Rotation time 0,51,5 s
Number of drives/channel 2
Gear-motors 8,9 Kw 415 V at 50Hz - with
inverter
- reduction ratio tau i = 1 : 10,4
- transmission direct with coupling
Gearboxes entry rotating channel
Serial no. 8274.1895.01
8274.1895.02
Gearboxes exit rotating channel
Serial no. 8274.1895.03
8274.1895.04
Reduction ratio Tau = 1 : 2.29
3.3 Electrical Electric Manual, chapter E-11.2
Motor List dwg. 2465.E030
3.5 Pneumatic (for pyrometer)
Scheme dwg. 2465.P003

Plant on board dwg. 2465.0204 (pyrometer)
TOP line pressure 6 bar
Working pressure pyrometer 2 bar
Air consumption per unit/cycle (pyrometer) 1 Nm/h
Condition filtered
3.6 Water
Scheme (direct water) dwg. 2465.P001

Board machine dwg. 2465.0203
Water flow capacity for the beams (direct water) 35 + 35 m /hr
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Pressure 2 bar
Scheme (indirect water) dwg. 2465.P002
Board machine dwg. 2465.0203
Water flow capacity for the shaft (indirect water) 20 + 20 +20 + 20 m /hr
TOP Water pressure for the shaft 5 bar
NOTE:
Concerning the water values (temperature, analysis data, etc.) please refer to Plant
Manual A, chapter 3.0 Description of the plant/machine.
3.7 Lubrication Equipment and Maintenance

Manual B - 00, chap. 3.1.2
Type of lubrication
- manual grease KP2K-20, DIN 51502
Centralized double line (grease) Equipment and Maintenance
Manual B - 8274.4015
- on board machine modules: dwg. 75.076.04 - 75.076.05 -
75.076.06
For splash lubricated gearmotors
- oil type PGLP 220 DIN 51502
- oil quantity 4.29 l
For splash lubricated gearbox (exit channel) drive gearbox

- oil type CLP 320 DIN 51502
- oil quantity 35 l
Central supplied drive gearbox (entry channel) Equipment and Maintenance

Manual B - 8274.4003
- on board machine dwg. 75.077.05

- scheme dwg. 2465.N0014
- oil flow 21 l/min
- entry pressure 2,0 bar
- oil type VACUOLINE 525
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3.8 List of Drawings and Drawings
Item Pos. WBS Drawing N Description Pages

3.8.01 8274.1890 2465.0201 General assembly rotating channel (only drawing) 2
3.8.02 8274.1891 75.076.12 Initial module rotating channel CR250 I=300 1
3.8.03 8274.1891 75.076.02 Intermediate module rotating channel CR250 1
I=300
3.8.04 8274.1891 75.076.13 Final module rotating channel CR250 I=300 1
3.8.05 8274.1893 2465.0202 Structure for rotating channel 2
3.8.06 8274.1894 2465.0206 Drive unit rotating channel 1
3.8.07 8274.1895 75.076.07 Gearbox for double rotating channel drive unit 1
(i=1:2.29)
3.8.08 8274.1895 75.076.08 Gearbox drive unit for double rotating channel 1
(i=1:2.29)
3.8.09 8274.1895 75.077.05 Oil lubrication system for gearbox at the entry of 1
rotating channel
3.8.10 8274.1891 75.076.04 Grease lubrication system rotating channel initial 1
module
3.8.11 8274.1891 75.076.05 Grease lubrication system rotating channel 1
intermediate module
3.8.12 8274.1891 75.076.06 Grease lubrication system rotating channel final 1
module
3.8.13 8274.1895 75.076.11 Grease system in rotating channel gearbox at 1
entry side
3.8.14 8274.1893 2465.0203 Water cooling system for rotating channel 1
3.8.15 8274.1895 1827.0041 Limit switches assembly on gearbox for rotating 1
channel CR250 I=300
3.8.16 8274.1895 75.077.07 Electric plant on gearbox at rotating channel entry 1
3.8.17 8274.1895 75.076.10 Electric plant on rotating channel gearbox 1
3.8.18 8274.1893 2465.0204 Pyrometer assembly on rotating channel 1
3.8.19 8274.1893 2465.0205 Photocells assembly on rotating channel 2
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4.0 Functions
4.1 General Functions
4.2 Single Functions
4.1 General Functions
The double rotating channel has the functionality to receive and transfer, by a series of
cyclical rotational indexing movements, the bars to the cooling bed grids. For purpose of
this description the two double rotating channels assemblies are called A1 and A2 for the
line A and B1 and B2 for the line B (see fig.1). Concerning the functional cycles of the
rotating channels with de-synchronization slider refer to the Equipment and Maintenance
Manual 8274.1960 Cooling Bed For Hot-Rolled Product.
Depending on the above deviators adjustments (orientation of the deviators in service at

the 2 cut-to-length shears H.S.D. area), the entrance will correspond to the above chose
line.
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LINE A LINE B
BAR A1 A2 B1 B2
CHANNELS
CHUTE
CHUTE
GRID
SLIDER C1
Fig.1 - Rotating channel assemblies
Its design so far as its on-board channels dimensions and cycle time is optimized to the
mills portfolio of product type and sizes. Its length is dictated by the available length of the
cooling bed. The appropriate dimension channel is rotated to the receiving position/entry
guide pass-line axis.
The cut-to-length bars on both the lines A and B enter in the channels of the device
according to the dual pass-lines of the conveying guides at the entry side and under the
control of the up-stream braking pinch rolls. Each entry-side guide is aligned to the
receiving axis of the A and B sections of the device. The bar completes its deceleration to
zero velocity within the selected on-board receiving channel before the rotational indexing
is initiated and the bar is caused to fall under gravity onto the grid receiving notch or on
the chute of the synchronization sliders.
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LINE A LINE B
B1
A1
C1
Fig. 2 - Bars discharging on the cooling grid
Its indexing angle and cycle time is variable to accordingly meet the frequency
requirements of the delivered bar or bar groups (e.g. slit rolling practices) from the
upstream equipment and so that it meets the desired productivity.
The two rotating channels of each single line rotate in the opposite direction to leave the
bars by means of the chutes (line A) and the synchronization liftable sliders (line B) on the
first tooth of the grid.
The sliders (C1) of line B receive the bars coming from the more external part of the
rotating channel in comparison with the cooling bed. They ensure the
alternate/synchronized discharging of the bars (the device is described on the cooling be
manual).
General operation sequence of the rotating channel line A:
The first bar begins its delivery into the nominated receiving guides of the A1 section
rotating channel.
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1,400,000 tpy Rebar Mill with H.S.D.
H.S.D. System 58 95 9439
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Fig. - Bar entry on the channel A1
After the dividing cut is made at the upstream shear and after the tail of the first bar has
passed fully into the selected guides, the channel
hannel is caused to index-rotate
index so that the
new and free section of guides is now in position to receive the next switched
swit bar to
section A, see fig.1.. Meanwhile the first bar decelerates to-rest
to rest within the first set of
guides due to the sliding frictional contact with the guides surface.
Also after the dividing cut is made - the head of the second bar is switched to the
guides of the entry conveyor which is aligned to the receiving axis of section A2
rotating channel.
Fig. - Bar entry on channel A2 and discharging position A1
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The second bar begins to deliver to the guides of the section A2 2 rotating channel and
the channel similarly index-rotates
index rotates after the bar is fully into the guides.
The third divided bar is diverted into section A1 rotating channel

hannel guides.
Fig. - Bar entry on channel A1

A and discharging position A2
A
Etc., etc.
The indexing angle is selected according to the bar product and guides dimensioning
together with the required/cycle time available. The full indexing angle for the guides to
be positioned correctly for the next bar may be 90 or 180 degrees accordingly. In either
case, the firstt indexing angle is 90 degrees to allow the bar to deposit under gravity
conditions onto the deflector chutes and into the grid notch - a further index of 90
degrees is sometimes then necessary to correctly position the dimensioned guide into
the receiving axis.
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4.2 Single Functions
The rotating channel comprises:
4.2.1 Support Beams and Columns
4.2.2 Rotating Channel Assembly
4.2.3 Deflector Chutes and Static Guide Devices
4.2.4 Stopper Safety Device for Overrun Bars
4.2.5 Drive Group
4.2.6 Cooling System
4.2.7 Guards and Heat Protections
4.2.8 Grease Lubrication System
4.2.9 Entry Interface
4.2.10 Exit Interface
4.2.11 Electrical Controls and Safety Equipment
4.2.12 Valve Bench for Pyrometers
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Fig. - Rotating channel, entry side section
Fig. - Rotating channel, exit side section
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Fig. - Rotating channel with synchronization/discharging device
Specific/Layout Function
4.2.1 Support Beams and Columns

The main longitudinal machinery sections of the rotating channel assembly are mounted in
cantilever-format from a series of columns and short transverse beams which are installed
alongside and outboard of the cooling bed grids. The arrangement provides facilitates
adequate maintenance access to the associated machinery of the cooling bed entry such
as the drop-wall roller table (where installed).
The columns which are constructed in either concrete or from fabricated steel sections are
attached rigidly to the foundation (check the actual project design and provision) - in either
case, the columns provide a rigid platform to mount the associated cantilever beam
members to which the longitudinal supports of the machine are attached.
The beams are accurately aligned and levelled to provide the correct working axis for the
machine via the longitudinal beam members which are mounted with a bolted and
shimmed connection to the cantilever beams.
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4.2.2 Rotating Channel Assembly

The rotating channel comprises:
Longitudinal water-cooled support beams
Tubular driving shafts with mounting/support brackets and bearings
Guiding channel members
Longitudinal water-cooled support beams

The water cooled beams are fabricated and machined in modular sections for attachment
via shimmed and bolted connection to the cantilever supports - the typical module length
is 6 m - check the specifications and layout for the actual dimensioning. The beams are
mounted for the entire length of the rotating channel assembly and above the grids area of
the cooling bed.
Each beam is constructed from hot-rolled hollow and square steel section to facilitate a
torsionally and structurally stiff support and to permit the functionality for the water cooling
- the water fills and is caused to flow through the section via pipe connections to cool and
control the tendency for otherwise high levels of longitudinal expansion of the beam
system.
Each beam is mounted from two flanged connections to the supports and is connected to
the subsequent up-stream and down-stream beam with pins which ensure the axial
alignment of the intersections. Nominal gaps at the beam junctions further facilitate the
requirement of longitudinal expansion.
On the underside of the beams there are typically three machined interfaces for the bolted
connection of the tubular driving shafts supporting brackets. For this reason the final
levelling and axial alignment of the longitudinal beams is critical to the operation of the
rotating channels system.
The beams also serve to support ancillary equipment such as cooling pipes, lubrication
distribution and electrical sensors devices.
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Tubular driving shafts with mounting/support brackets and bearings

The tubular driving shafts facilitate the support to the guide sections which form the
individual guide channels comprising the working parts of the system referenced to the
bars interface.
Each single rotating channel system feature two longitudinal shafts which are
dimensionally and horizontally pitched to each other according to the system requirements
and in particular, the bar product size to be processed. The shafts are mounted from
horse-shoe shaped and machined support brackets which are attached to the water-
cooled beam members with bolted connections.
Fig. - Single rotating channel
Special bearing assemblies to support the shaft are mounted into oblique and split
machined registers within the brackets construction. The split facility allows easy mounting
of the shaft to the supports.
The shafts are machined from thick-wall mechanical tubing and the central hole forms the
gallery for the continuous cooling water flow - each modular section is interconnected to
each other with a high-quality hose connection.
Each modular shafts section is interconnected with the next by virtue of the special
channel guide sections at the shaft to shaft interfaces which are keyed and bolted to the
shafts and provide a rigid muff-type coupling arrangement. The connection method which
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provides the shaft to shaft transmission is by pin-type drive and which permit relative axial
expansion of each modular section (also see later descriptive text).
The bearings which support the shafts in the oblique, split brackets are grease lubricated
anti-friction cylindrical needle type. Special housings with flanges facilitate the connection
of each bearing assembly onto the support bracket. There are typically three support
bearings on each shaft module and the material entry-end bearing is configured as a
locked arrangement whilst the downstream two bearings are mounted in free condition to
allow for thermal expansions.
Each modular shaft assembly is identical excepting the first and last - this is due to the
requirements of the drive group and also the cooling water entry and exit arrangements.
Guiding channel members

The spit type guiding channels are mounted to the shafts on keys and bolts in muff style.
The keys provide the accurate axial alignment of each individual guide section to the other
whilst the bolts provide a rigid clamping action of the guides to the shaft wall. There are
nominal gaps between the guides and at the locations for the support bearings.
The guide channels are manufactured in special cast-iron type material to facilitate
optimum wearing and non-scratching characteristics. Due to the sliding friction condition
with the decelerating bar, the guides are classified as wearing items. There are typically
six sections of guide attached to each shaft module.
The sectional shape of the guide is designed to suit the portfolio of products types and
dimension - the smaller groove dimension in the channels for the smaller products etc.,
etc. The entry end of the guides is flared to allow for the bar flow direction and to ensure
that is no striking conditions to impede the smooth transition of the bar as it passes from
guide to guide.
The first and last split guide sections which are attached to the shaft module are special
types to accommodate the pin-type transmission coupling arrangements. The four
transmission pins of each coupling are installed and fixed with nuts into tapered holes at
the downstream side and are in close sliding-clearance holes on the upstream side to
facilitate any axial thermal expansion conditions.
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ATTENTION:
Beware - there are no guards supplied to the many potential trapping points of the
rotating channel movements itself since such guards are impractical - in any case,
these trapping points are isolated by their position from regular accidental exposure to
the operator.
For access due to operational or maintenance reasons the machine should be
effectively electrically isolated including consideration to isolation of upstream and
downstream machinery which impose dangers whilst working or the channels area.
4.2.3 Deflector Chutes and Static Guide Devices

The static guides are fabricated and curved-shaped devices which surround the upper
inner quadrant part of the single rotating channels. They are attached to the water-cooled
beam with bolted connection and are placed in longitudinal array with one assigned to
each of the channel guides comprising a V configuration. Their function is to provide
containment of the travelling bar such that the bar remains within the channel groove at all
times. As the selected channel index-rotates, it moves away from the constraining
influence of the guides and the bar is free to fall due to gravity from the channel.
The deflector chutes are also supported from the water-cooled beam members and hang
below the rotating channel to provide collection and guidance for the falling bar to find the
grid notch. The bar falls under gravity onto the chute and then slides down the curved or
inclined face of the device to, once again, fall under gravity into the notch. The brackets
support the chutes are attached to machined pads on-board the water-cooled beam.
The chutes themselves are attached to the brackets on pivot pins and a screwed
adjustment device permits articulation of the chute about the pivot connection - in this way
the trajectory of the falling bar can be trimmed by the adjustment devices so that the
accurate delivery to the grids is assured. There is one deflector chute assigned to each
channel guide position.
ATTENTION:
Beware - the adjustments to the devices entails working in close proximity to the rotating
channels and access to the cooling bed - the operator is advised to undertake risk
assessment in the development of safe working practices for the adjustment procedure
including electrical isolations and permits.
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4.2.4 Stopper Safety Device for Overrun Bars

The device is located at the extreme downstream end of the double rotating channel
and serves as a safety device in an emergency overrun situation such as could occur
if e.g.:
The settings of the bar braking device were incorrect

The braking device failed to operate
The dividing shear failed to cut the bar
Software fault e.g. to cut-to-length system
Optical devices fault
An optical sensor views the gap between the last guide and the stopper - if the gap is
blocked by a bar, the rotating channel is inhibited from index-rotation movement until
such times as the situation is manually recovered.
The device serves both lines of the double rotating channel. It is sturdily constructed in
fabricated steel plates and sections to destroy the inertia of the overrun bar and it is
rigidly attached to the foundation
ATTENTION:
Access to the area of the stopper device must be strictly controlled by procedures, protocols
and isolations of the up-stream equipment due to the risk of serious injury should a further
bar de delivered on the cooling bed entry conveyor or in the rotating channel when personnel
are working at the scroll-stopper device. The operator must execute Risk Assessment in the
development of such controls and take into account the likely injury severity should an
accident occur.
4.2.5 Drive Group

The drive group is designed and configured depending on the double rotating channel
system overall length. Shorter systems can be served by a single and separate drive
group for each channel placed at the extreme downstream end - due to torsional
deflections considerations in the hollow shafts, longer systems may need to be served by
drive groups driving each extreme ends of the channels.
The drive group functions to transmit the index-rotation drive necessary for the rotating
channel operation. The drive operates in stop - start mode to satisfy the rotational indexing
movement required for the rotating channel.
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Single drive group placed at downstream end

The motors for each of the double rotating channel drives are installed in staggered array
on a common base-plate but to the foundation. The motors can be optional AC or DC type
- check the actual provision in section 3.0.
The common gear- housing for each of the two separate drives of the double rotating
channel is installed on a base-plate in front of the motors. The gear housing is a fabricated
and machined type. The two exit shafts axis are aligned to the axis of the two hollow
shafts of the rotating channels. The gearbox contains the independent sets of gears for
each channel drive in single reduction format.
The high quality gears and pinion shafts are mounted in anti-friction bearings and the
lubrication system for both gears and bearings is splash-type from the reservoir volume
contained in the housing. The oil-seals of the entry and exit shafts are additionally
lubricated with grease by manual application.
The gearbox exit shafts are hollow type and at the entry side of the housing, the shafts are
extended to facilitate the installation of a rotary coupling necessary to supply the cooling
water to the complete hollow shaft assemblies of the rotating channel - also see 4.2.2.
The transmission couplings installed to the exit shafts of the gearbox and also to the ends
of the hollow shafts of the rotating channel are single-engagement crowned-gear type.
The interfacing connection of the transmission is by special, axially split type tubular
spacer shaft. The axial split provides the functionality to install and access the necessary
water hose linking feed for the water cooling supply to the hollow shafts.
Double tandem drive group placed at both ends

The solution incorporates a separated tandem drive arrangement placed at each extreme
end of the rotating channel assembly to facilitate lower overall torsional deflections in the
hollow shafts during the accelerative and decelerative phases of the power transmission.
The motors for each of the channel drives are vertically flange-mounted to 90 degree
combined bevel/cylindrical gearbox pre-reducers - the horizontal output from the bevel
gearbox is linked with tubular transmission shaft to the entry shaft of the vertically
mounted parallel-axis reduction gearboxes. The motor-bevel drives are mounted on angle
brackets supports to a machined interface on-board the water cooled beams. The shaft
couplings are crowned-gear type single engagement. The lubrication of the gearboxes is
self-contained splash-type.
The main parallel-axis gearboxes are different in detail at the entry end compared to the
exit end - the entry end is a special type to facilitate the passage of the bar through the
gearbox itself whilst the exit end is more conventionally closed construction. See later
details.
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The parallel-axis gearboxes have a common housing for both channel drives and are
shaft-mounted to extensions of the hollow shafts of the rotating channels but are also
mounted on flanged and bolted connection to the end walls of the longitudinal water-
cooled support beams of the channel to counter the torque reaction from the drive.
The gear housing is a fabricated and machined type. The two exit shafts axis are aligned
to the axis of the two hollow shafts of the rotating channels. The gearbox contains the
independent sets of gears for each channel drive in double reduction format. There is an
idling gear on the third shaft axis which has an extension shaft to the outside of the
housing to facilitate the mounting of the four proximity sensor devices. The number of
teeth of the third shaft gear and the output is identical such that the sensors actually also
detect the rotational angular position of the output shafts and therefore the channels
parked positions
The gearbox exit shafts are hollow type and at the appropriate side of the housing, the
shafts are extended to facilitate the installation of a rotary coupling necessary to supply or
exhaust the cooling water to the complete hollow shaft assemblies of the rotating channel
- also see 4.2.2. The gearbox at the entry end has the water exhaust coupling and that of
the exit end has the water supply coupling.
The exit shafts of the parallel axis gearboxes are specially extended type and are
connected to the hollow shafts of the rotating channel with split muff-type rigid couplings -
the axial split provides the functionality to install and access the necessary water coupling
union which is the linking feed for the water cooling connection to the hollow shafts.
The high quality gears and pinion shafts are mounted in anti-friction bearings and for the
exit end parallel axis gearbox, the lubrication system for both gears and bearings is
splash-type from the reservoir volume contained in the housing. The oil-seals of the entry
and exit shafts may be additionally lubricated with grease by manual application (check
the assembly drawing).
For the entry end parallel axis gearbox, the oil lubrication system for the gear-shaft
bearings and gears meshing is by re-circulation from a central system. For the output
shafts and due to the localized double housing design the output bearings to the hollow
shaft are grease fed by the same central system as for the channels hollow shaft support
bearings.
Entry-end parallel axis gearbox

The special feature of the entry-end gearbox is the double housing design local to the exit
shafts. This allows the gears on-board the hollow output shafts to be lubricated normally
by the central re-circulation system whilst the bearings supporting the output shaft gears
are contained within the same housing in separate sealed arrangements and lubricated by
force-fed grease. The housing surrounding the side-walls of the output gears is therefore
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dry and is vented by an opening on the lower part of the housing to permit the free
evacuation of scales from the bars passage through the gear housing.
The gears of the output shafts feature four drilled holes to allow the bar to pass through
the gear-wheel itself - a flared entry guide mounted to the entry side of the housing
ensures the bar passes through the housing with a clearance condition respective of the
hole in the gear - wheels.
The automation ensures that, when parked, the holes axis in the gearwheels aligns in
oblique fashion to the system entry axis (pass-line) of the bars and also to the receiving
axis of the channel guides. The transmission is inhibited to drive when the bar is passing
through the gearbox housing.
ATTENTION:
The high-speed shafts of the drive and the hollow-shafts locations may be equipped with
local guards - check the terms of the contract supply. It is the responsibility of the operator to
check that such guards are required and that they comply with local and national safety
requirements where installed.
Where such guards are installed, the rotating channel should not be operated unless they
are securely in place.
Low-speed including hollow shafts areas - exercise great care when in the proximity of these
devices and when the equipment is live and operable. On no-account should trouble
shooting or intrusive work be undertaken to the shafts or support bearings etc. without an
effective complete isolation of the machine.
Where guards are provided - on no account should the equipment be operated without them
being securely in-place.
4.2.6 Cooling System

The function of the water circuits is to supply cooling conditions to prevent localized
over-heating due to effects of radiation, conduction and convection energy from the
hot bars passing through the rotating channels system. It further functions to critically
limit the effects of longitudinal thermal expansions movements which are seriously
detrimental to the system performance.
Cooling water systems are applied to the sectional box-beam overhead supports and
also to the transmission hollow shafts of the rotating channels. The quality of the water
supply to the box-beams is not critical and is normally supplied from the mill as direct
cooling water circuit whilst that of the shafts cooling is more critical and the
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recommended quality as indirect cooling water circuit and supply volumes must be
strictly respected according to the specifications.
Fig. - Cooling plant on rotating channel scheme; direct water for the channels support
beams cooling, indirect water for the cooling of the transmission shafts line (dwg.
2465.0203).
The water circuit to cool the box beams is normally configured in a number of parallel
circuits - each circuit feeds a number of interconnected box-beams
box in series
connection - check the single-line
single diagram for the actual project situation. Each circuit
has separate entry and exit isolation valves to balance the overall flow distribution.
The headers for the supply and return are mounted on-board on board the cantilevered
supports for effectively short distribution connections to the box beams
be by flexible
hoses.
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Fig. - Water circuit to cool the box beams
The water circuit to cool the hollow shafts of the rotating channel is configured in a
single pass entering the shafts at the downstream end and exiting at the entry end of
the rotating channel system via rotating couplings mounted into the shaft ends and
coupled to the distribution pipe-work with flexible hoses. Isolation valves are provided
at each end to isolate (when required) and to regulate the flow conditions. Flow and
pressure switches are configured to these circuits - see scheme below.
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ATTENTION:
Beware of trapped pressure or accidentally ejected hot water when trouble shooting faults in
the water circuits - take special care that system are de-pressurized before invasive work is
undertaken.
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4.2.7 Guards and Heat Protections

Guards and heat protections are supplied at the locations of the drives and the entry
shafts to the rotating channel - these are attached with bolted connections to the
various supports.
There are no guards supplied to the many potential trapping points of the rotating
channel movements itself since such guards are impractical - in any case, these
trapping points are isolated by their position from regular accidental exposure to the
operator.
ATTENTION:
It is responsibility of the operator to satisfy himself that the guarding devices fully
conform to any national or local safety regulations which may apply at site.
The associated equipment should not be operated without the guarding/heat shield
devices installed - intrusive maintenance to the machines should not be attempted
without full and effective electrical and media isolations.
For instances of trouble-shooting and the associated requirements of removal of any
guards, the operator must ensure the complete training of personnel to the
consequences and danger presented by the guard removals. It is highly recommended
that any damage to safety guarding is properly repaired and with immediate effect.
4.2.8 Grease Lubrication System

The functionality of the lubrication systems is to ensure that the rotating parts operate
efficiently and with minimal frictional contact - also to ensure the equipment has a long
service-life.
A centralized grease distribution system is supplied and installed on-board the water
cooled box beams for means of lubrication the individual support bearings of the
hollow shafts of the rotating channel drive. The system is dual-line type and the
distribution blocks feed the bearings housings entry with solid pipe connections. Loops
formed in the dual-line pipes at the intersections of the support beams ensure the
requirement for thermal expansion movement of the pipes.
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The centralized system feeding the distribution lines may be unique to the rotating
channel or may be part of a general cooling bed area central system - check the
layout and provision. The re-lubrication cycle is initiated by timed interval according to
the energisation and operational use of the rotating channel system. The quantity of
grease injected to the bearings is controlled by the selection of the distributor or by
stroke control at the distributor itself - check the actual type specified in the scope.
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There are other manually applied grease lubrication points - check the machines
assembly and the lubrication schedule detail for the exact located positions and details
of the re-fill volumes and grease type.
Be aware that the over-application of grease to the high and low speed gear-couplings or
rapid injection of grease under high pressure can result in axial forces which can damage
the bearings of the motor and the gearboxes and can cause high axial forces and
displacement of the longitudinal hollow shafts.
4.2.9 Entry Interface

The entry interface to the rotating channel comprises the immediate guides following
the braking pinch rolls system. The guides are established accurately on the entry
pass-lines into the rotating channel.
ATTENTION:
Read the carefully notes in section 2.2 in respect of working on the entry interface equipment
and the possibility of creating downstream dangers.
4.2.10 Exit Interface

The end exit interface is the described scroll-stopper device which arrests the
accidental over-run of bars from the rotating channels. See section 4.2.4.
The main exit interface is that of the cooling bed grids where the bars are deposited
and, critically, the axial alignment conditions of the first notch in respect of the working
axis of the rotating channel.
ATTENTION:
Read the carefully notes in section 2.2 in respect of working on the exit interface equipment
and the possibility of being exposed to upstream dangers.
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4.2.11 Electrical Controls and Safety Equipment

Proximity sensors or encoders are mounted to detect and control the parking
positions of the rotating channels guides axis. These are installed at the location of the
drives - see section 4.2.5 for typical description of location.
The drive is initiated according to the automation and from signals indicating that the
dividing shear has made a cut and the bar has freely passed completely into the
rotating channel - the latter is initiated from the photo-cells mounted at the entry side
and viewing the gaps between the static entry guides and the rotating guides of the
channel.
Similarly mounted photo-cells detect the presence of any overrun bar condition to the
scroll-stopper device - see section 4.2.4.
The control of the drive is critical to reducing the torsional deflections in the hollow
shafts - the deflections, if uncontrolled, can lead to high stresses in the shafts and
axial misalignments to the channels with resultant risk of cobbles. The electrical drive
is set according to the recipe requirements of the controlling software.
The photo-cells are mounted off local brackets from the water-cooled beams.
Additionally to the pyrometers may be configured a device to detect the recovered

temperature in the bar as it reaches the position for discharge to the cooling bed - check
the project provision.
Flow switches are installed at the exit side of the water circuits for the hollow shafts
cooling.
ATTENTION:
Beware of false signals made by accident to the photo-cell equipment by light sources or
accidental blocking of the light-path - such rogue signals can initiate the automation and
present danger.
4.2.12 Valve Bench for Pyrometer

The purge-air for the pyrometers device. The valve bench is mounted locally to the box
beams supports and features isolation valve, 2-way venting type isolator and pressure
regulation unit with manometer. Its function is to provide cooling and purge air to the
containment boxes of the pyrometers to ensure there is clear vision to the viewing gap to
detect the temperature of the bar.
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5.0 Maintenance and Use Instructions

Refer also to Plant Manual A - Instructions for Erection, No-Load Tests and Commissioning
Manual D
5.1 Receiving
5.2 Storage
5.3 Installation
5.4 Handling
5.5 Assembly/Disassembly
5.6 Commissioning
5.7 Every-day Adjustments
5.8 Maintenance (General - Lubrication Instructions)
5.9 Special Checking/Adjustment Procedures
5.10 Special Safety Points and Instructions
5.11 Shutdown and Storage
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5.1 Receiving
Check that there are no obvious damages to the equipment due to packaging or
transportation - report any defects immediately on receipt with photographic evidence of
any damage. Check that the temporary protective plugs applied to any media connections
on the machines are intact and that there is no penetration contamination of water or dirt.
Check that any loose parts are delivered with the main equipment.
5.2 Storage
Store the rotating channel equipment, all associated supports and ancillary equipment on
flat level surfaces preferably in the correct working axis and suitable supported on packs
to avoid bending or twisting deformations.
The equipment, excepting the un-machined structural part should be stored in dry
conditions, preferably indoors or covered adequately with suitable protection sheets to
eliminate water ingress. Do not store in standing water conditions or where the
atmosphere is very humid. Inspect any equipment stored outside at regular intervals to be
sure it is not deteriorating or that temporary coverings are intact and functional. In any
case sensitive equipment such as the motors, gearboxes, couplings, valve bench
components, bearings, machined items such as shafts and gear-motors must be stored in
dry, workshop/warehouse conditions - never in an open environment.
5.3 Installation
Before the Installation

The module lengths of rotating channel assemblies are normally supplied fully pre-
assembled onto the water-cooled support box-beams except for the lower deflector chute
parts. The structural supports are supplied as separate pieces. The remaining parts are
supplied as loose or packaged items. In any case, check the assembly drawings and
assemble any and all loose parts strictly according to the drawing layout and
interconnection connection details.
Before attempting the rotating channels equipment installation, it is necessary to become

fully familiar with the requirement of the installation accuracy so far as critical alignments
and levelling is concerned - it is recommended that a detail discussion is taken with an
SMS specialist before planning or undertaking the work.
A network of interlinked and extremely accurate setting-out datum points for alignments
and levelling is required to avoid e.g. dimensional accumulation errors.
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Check that all the foundations and bolt-hole provisions comply with the engineered
requirements including the drawings of the complete rotating channel layout and also the
cooling bed assembly with respect to the grids locations.
The foundation preparation must be complete and the concrete fully cured to receive the
base-plates/supports/structural elements. Check that the correct elevations and critical
alignments for all the components can be achieved on the foundation. A check to any
installation and assembly drawings must be made.
All the described rotating channel equipment needs to be established and connected
according to drawings datums to ensure the correct inter-functional requirements and
also with the downstream (exit area) and upstream (entry area) equipment.
Immediately prior to installation of the equipment the base-plates any protective coatings
and any protections media on machined interfaces is to be removed and a check made
that all areas are suitably clean to receive the critical pieces. Also check that there are no
foreign particles adhered to the undersides of the equipment to be secured to the base-
plates during the storage/transport phase.
The undersides of the base-plates/supports must be free of oil/grease to ensure a correct

fixation to the concrete and grout. The base-plates/supports must be adequately
supported on steel packs and the bolts to the foundation fully tensioned.
Checks during Installation

Check that the supports aligned positions and critical levels have been set correctly -
particularly that of the mounting interface on the cantilever beams to receive the pre-
assembled rotating channel module assemblies. Where appropriate, ensure that an
allowance for a nominal shim under the gearboxes and motor feet has been made e.g.
future exchange of these components. Check that the accurate alignment of the hubs of
the gear-couplings of the motors to gearboxes and output shafts to the shafts of the
rotating channel has been made within the max. tolerances given in the sub-suppliers
information for the couplings - also that the shaft-ends are aligned before installing the
muff-couplings. Close to perfect alignment will ensure maximum coupling life.
Finally, that welded stop-blocks or suitable alternative are applied to all the designated
feet positions to prevent any movements and future lost alignment conditions.
Check that any other welded stop-blocks on the associated pre-assembled equipment of
the rotating channel have been installed and welded according to the drawing indications.
Make sure that the rotating channel equipment and sub-components been mounted
correctly and that everything corresponds to the assembly drawing. It is necessary to
install the loose components on plants on-board and the pipes/connections to any central
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system or valve bench location (if configured) according to the single-line diagrams and
the assembly drawings.
Make sure that all safety and heat protections have been installed and function correctly.
Refer to special notes 1 below for the base-plates support criticality. It is recommended
that the grouting is not applied to any of the individual supports of the rotating channel
and equipment base-plates until all critical positions and alignments are verified.
Check that all the fluid media piped systems are fully flushed and certified clean before
connection to the T.O.P.s.
Check that any speed regulation devices have been installed in the correct direction for
functionality.
Check that the first-fill lubricants are installed to all the defined positions according to
specification for the lubricant and fill volumes. The gear-type coupling hubs should be pre-
grease packed by hand before the shrouds are bolted together.
Special Note 1. The base-plates, especially for the foundation mounted gearboxes and
motors needs to be established on multiple steel packs/shims to avoid twisting distortions
when the foundation bolts are correctly tensioned.
The rotating channel and associated equipment cannot be operated until all the necessary
grouting (including curing of the grout) of base-plates is completed to a high standard.
Checks after Installation

Check that all piping installed is suitably clean and that there are no external leaks.
After installation and also after one month from machines operation, check that all bolts,
including the foundation bolts, are correctly tensioned.
5.4 Handling
The handling of the rotating channel equipment is normally only that required for off-
loading, storage and installation. Use any provided attachment points and soft slings
wherever there is the risk that surfaces may be damaged or too much pressure will be
exerted to vulnerable parts.
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ATTENTION:
Refer to the drawings information or revert to SMS if there is any doubt about the attachment
points on any of the equipment for correct slinging and handling. Employ the normal good
and safe practices when slinging - in any case, slinging should only be undertaken by trained
operatives and with full information about the mass of the equipment to be slung and also its
centre of gravity/stability.
Be aware of trapping points when handling the equipment into confined positions during its
installation. Unless the handled device has special provisions, check that all attachments
points are fully engaged at all times during lifting/lowering operations.
Refer to the sub-suppliers information for the correct handling points of the gearboxes and
motors. Any eye-bolts should be inspected before every use and also to check that they are
fully engaged to the threaded holes and without any threads damages. Shock loads must not
be applied due to the risk of internally damaging the gearboxes and motors - the feet may be
of cast iron. The guiding channels are manufactured from cast-iron - where necessary,
handle these with care to avoid breakages.
When handling sub-component parts e.g. during invasive maintenance - check the weight of
parts are handle-able or use a lifting device.
Check if the moving parts of the pre-assemble equipment are temporarily blocked for
shipment - remove such blocks in a careful way so as to prevent accidents from devices
moving suddenly and without warning.
5.5 Assembly/Disassembly
Equipment and Maintenance Manual B - 00, chap. 3.2.1
5.5.1 General
Only the modular sections of rotating channel table are supplied pre-assembled - follow
the guidelines for installation. Follow the drawings for the installation assemblies for the
remaining rotating channel equipment
Assembly and disassembly will only be required in the event of abnormal maintenance
situation of equipment failure or wear after prolonged operation. The manufacturers
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drawings and tolerances should be consulted before any work is contemplated and any
parts substituted should be of O.E.M. source and quality. Consult the assembly drawings
and SMS expertise, as necessary, for invasive maintenance or major repair work where
the methods of disassembly or the degree of repair needed to restore functionality are not
clear. Assembly and disassembly of the gearboxes, motors and valve-bench components
and their associated parts is a specialist procedure and should only be entrusted to the
O.E.M. or a repairing specialist.
ATTENTION:
Disassembly and re-assembly are irregular activities and should not be undertaken
without the necessary skills and training due to the risk of damaging the machines and
the risk of injuries.
5.6 Commissioning
ATTENTION:
Be aware that this must be strictly controlled and supervised to avoid danger to
personnel not involved in this process. Special barrier systems and warning notices are
likely to be required and definitive communication to all personnel who may be exposed
to the commissioning area must be made.
Attention - refer to the critical safety points contained in section 2.0 before accessing the
rotating channel equipment and related equipment areas for commissioning and start-up.
Be aware of the inter-related equipment (entry and exit areas) commissioning status and
whether this is live and potentially operable - take such steps as are necessary to
mitigate the risks of injury from the intentional or accidental operation of this equipment.
SMS Meer S.p.A. declines any responsibility towards injuries to persons or damages to
equipment due to the non-compliance of the above mentioned rules and
recommendations.
If any abnormalities occur, the equipment should be immediately stopped for

investigation/corrective action and the appointed SMS Meer Engineer informed.
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The sequence for commissioning and start-up is:
- Verification of all installation completion with full tension to all the bolts and critical
alignments checked and approved by SMS Meer.
- The maximum number of guards or safety barriers are attached in the work area to avoid
Danger to other personnel.
- A check that all the I/O of the PLC are correct at the application points of the valve
benches.
- Full commissioning of the fluids media systems including final connections and
verifications of supplies to the valve bench. This includes the setting and checking the
specified pressures and flows.
- All manual lubrications to be undertaken before any commissioning activity. Refer to the
lubrication section to identify all manual points etc.
- Set the supply pressure on the air pressure regulator for the cooling of the pyrometers.
- Gear-motor/gearbox drives. Wherever possible, with the low-speed coupling opened and
the coupling shrouds stabilised - check for the correct direction of rotation of the output
shaft.
Before proceeding with hot start-up:
- Check the full functionality of the operation from the remote pulpits via the mill
automation system.
- Close the gear-motor low-speed gear-coupling including fully pre-lubricating the teeth
and re-installing the local guards and heat shields.
- Check that the response speed and speed control of the rotating channel indexing
conforms to that of the automation settings.
- Check by simulation that any HMD/photo-cells are working within the required sensitivity
ranges.
- Check that the proximity sensors for the stopping controls/parking positions are set
correctly.
5.7 Every day Adjustments
There are no every-day adjustments required to the equipment of the rotating channel.
The operational speed of the drives, the selection of the appropriate dimension receiving
channel and the sequence for the indexing rotations selected for operation and associated
timers are set within the HMI according to product types and anticipated bar entry speed.
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5.8 Maintenance
5.8.1 General
5.8.2 Lubrication Instructions
5.8.1 General
A preventative approach to maintenance will secure a good operational result and limit
expensive failures.
Where possible and appropriate predictive techniques can also give optimum results e.g.
vibration analysis, thermo-graphic imaging, wear particle analysis in lubrication and fluids
systems etc. The user is strongly advised to research the availability of such techniques
and employ them as appropriate to this equipment.
Wherever possible it is important to establish a quantitative way to establish and record

machine condition - this avoids subjective opinion of condition and allows a proper basis
for trending condition. If this is not possible, it is useful to contain the task of undertaking
machine inspections to a minimum number of fully trained staff.
Establishing data base of records of machine condition is essential as is consulting the

data base to highlight a worsening trend and predicting when a necessary intervention of
adjustment, component exchange etc., is to be planned.
Establishing check sheets for each adopted maintenance routine is essential - in the
design of the check sheet there should be enough prompts of exactly what to check and
record in order to take out any subjectivity - also there should, wherever possible, be
limiting values/conditions stated on the sheets such that immediate action can be taken if
there is a critical non-conformity.
Maintenance should only be carried out by fully trained personnel who are familiar with the
specific equipment.
Critical alarms - it is recommended that critical alarms resulting from field-mounted

transducers are tested by simulation method wherever possible and according to periodic
routines
It is recommended that the maintenance is carried out in a routine manner according to
specific timetable or taking account of equivalent machine operating time. The
recommended frequencies should be adjusted according to local conditions.
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The following is to be regarded as a minimum requirement for preventative maintenance

practice.
For the terms relating to the operating conditions and frequency, please refer to
Equipment and Maintenance Manual B - 00, chapter 3.1.1. The following is a minimum list
of routine planned maintenance which must be considered.
Operating
Equipment Inspection/Test State
Interval
Whole machine Cleaning FE S

Check the parking positions accuracy FE M
Foundation/ bolts Check the tensions FE M
Check the grout condition FE 6M
Fixation bolts/pins general Inspect/check for looseness - re-tension FE 3M
Motors/gear-motors Holding-down bolts tension FE M
Gear reducer body Functioning- abnormal noise FU S
Tension of fixing screws FE S
Possible fluid leakages FE S
Oil levels FE S
Oil condition test FE A
Guards and heat shields Condition/in-place security FU S
Gears Test overall backlash and teeth contacts FE 3M
Inspect teeth conditions FE 3M
Gear and muff couplings Functioning/loose bolts - re-tension FE M
Open and inspect teeth - re-pack FU 6M
grease
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Operating
Equipment Inspection/Test State
Interval
Shaft bearings Check the operating temperature FU T

Check radial clearances FE 6M
Channels guides Visible grooving/wear conditions FE T
Water/grease pipes Possible leakages FU T
Grease supply valves Functioning FU S
Water supply system Pressure and flow FU T
Pressure/flow transducers - test set FE M
points
Rotary couplings External condition/leaks FE S
Beams Possible leakages FU G
Hoses Wear/condition - leakages FE T
Photo-cells Alignment and clean FE S
Pyrometers Alignment and clean FE S
Air-purge/care cooling FE S
Valve bench Condition/settings FE S
Proximity sensors Security/gap settings FE M
Scroll-stopper Anchor bolts tension FE 6M
Internal wear/damages FE 6M
Operation of latching device FE T
Whole machine Cleaning FE S
Anchoring bolts Check the anchoring FE M
Screws Blocking FE M
Gear reducer body Functioning- noise FU S
Tensioning of fixing screws FE S
Possible fluid leakages FE S
Oil level FE S
Joint Functioning FI M
Bearings Check the temperature FU T
Gap FE 6M
Gears Noise FU S
Side gap FE 3M
Rolled product guide Wear FE T
Water/grease pipes Possible leakages FU T
Grease supply valves Functioning FU S
Water line Pressure and flow FU T
Beams Possible leakages FU G
Hoses Wear - leakages FE T
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5.8.2 Lubrication Instructions

For the terms used for the Type of Lubrication, Lubrication Interval, Quantity of Lubricant
and Type of Lubricant, refer to Equipment and Maintenance Manual B - 00, chapter 3.1.2.
All the values indicated in the lubrication schedule are estimates and can vary according
to the work experience.
For the periodical replacement of the lubrication and hydraulic oils refer to
manual B - Contents chapter B - 3.0 General Maintenance Instructions.
For the information concerning the first filling of the devices refer to the
Equipment and Maintenance Manual B - 8274.9220 (where available).
Concerning the lubrication of the materials from trade refer to the Sub-Supplier
catalogue. The note See catalogue refers to the chapter 7.0 of this Equipment
and Maintenance Manual; look at the Sub-Supplier documentation list.
N of points
Part Type of Lubrication Quantity of Type of
N Assembly N Item to be
lubrication interval lubricant lubricant
Item lubricated
01 75.076.12 15A-15B bearings 6x2 C H 0,25 cm 3
04 2465.0206 10A motor/bearings 8 IN Refer to catalogue
05 11A gearboxes (entry/exit 8 F
Refer to catalogue
channel)
06 12A coupling 4x4 IN Refer to catalogue

07 12B coupling 4x4 IN Refer to catalogue
08 75.076.07 --- drive gearboxes (entry 2 U --- 21 l/m 20
channel - lines A end B)
09 75.076.08 --- drive gearboxes (exit 2 F S12 35l 13

channel - lines A end B)
Beware - during re-lubrication and injecting grease by high pressure/high capacity air-
operated equipment to the gear-couplings that jacking forces are not created which can
seriously damage motors and gearboxes bearing and cause axial displacement of the
line-shafts
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5.9 Special Checking/Adjustment Procedures
There are no special checking/adjustment procedures applicable to the rotating channel

equipment. The working speed of the bar entering the entry guide devices and the
channel guides themselves demands that special care and attention to critical alignments
is made if problems such as cobbles are to be averted. Attention is drawn for the need to
routinely check that the parking positions determined by the rotational angular index
movements are accurately set and maintained - also that of the entry guide devices
alignment to the rotary channel is correct
5.10 Special Safety Points and Instructions
Plant Manual A, chapter 2.0
ATTENTION:
Be aware that unless the equipment is properly maintained in accordance with suppliers
minimum recommendations, then failure conditions may precipitate danger to operational
and maintenance staff. Persons undertaking maintenance must be fully trained, assessed
and approved to be competent in the specific tasks. Be aware that the on-board piped
system may contain stored energy. Make any disconnections with care. Be aware that if any
seal are from Viton material; special handling precautions are needed if the seals are burnt
or charred, check the specific recommendations for this material. The user is recommended
to evaluate all media supplies to the equipment under the requirements of COSHH
regulations or equivalent (if applicable) and to train and execute any recommended control
measures. A risk assessed method to undertake the work should always be taken. This
should include the regular tasks and the irregular and maybe unforeseen tasks which may
present themselves. Persons undertaking operational duties must be fully trained, assessed
and approved to be competent in the specific tasks so as not to present unacceptable risks
to themselves or others. Attention is drawn to the nature of the use of the equipment; the
main apparent risks are:
Danger of becoming trapped or struck by moving parts.
Risks from burns or being struck by the red-hot bars during the rolling operations.
Risk of sudden and unexpected movements of the equipment in automatic PLC driven
controls (fault conditions). The user is specifically recommended to adopt strict controls of:
Equipment electrical isolation and permit/certificate procedures.
Stored energy systems which supply the equipment - isolations and permit procedures.
Tasks which may be permitted to be undertaken without general electrical isolation of the
machine and control of stored energy devices.
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Be aware of the parts of the machines which are to be handled without lifting aids. Ensure
that operators or maintenance staff are not exposed due to lack of knowledge or training to
lifting operations which may be instantly or longer term injurious.
Be especially aware of the high risk of scalding during trouble shooting if the water
passages of the shafts become blocked or partially restricted and there is subsequent
steam or hot water conditions within the water passages, hoses and pipes - removal
of hoses/fittings could result in ejection of high velocity of hot water or steam.
Isolation valves should not be installed or retro-fitted to the outlet connection of the
cooling water supplies together with isolation valves on the entry side. This is in case
both valves are accidentally closed and there are trapped water conditions which
result in the danger of steam generation within the roll and fittings.
SMS Meer declines any responsibility towards injuries to people or damages to

things due to the non-compliance of the above mentioned rules and
recommendations.
5.11 Shutdown and Storage
It is recommended to purge the old grease residues from all of the manual application
points and refill with fresh grease. See special note in 5.8.
Re-lubricate all points according to the lubrications instruction list.

Apply protective grease to any adjustable threaded parts (as applicable) if the shutdown is
to be longer than 1 month.
Clean all the areas of the equipment from free scales and water entrapment points to
prevent severe corrosion occurring - re-paint/apply a protective barrier where paint
removal has left surfaces open to oxidation effects.
Shut-off the air supplies.
If there is a risk of freezing conditions, the water in shafts and water-cooled beams and
associated pipes should be purged out using compressed air - leave the connections
vented until it is necessary to re-commission the cooling system. Alternatively, the water
should be kept in active circulation to prevent the risk of freezing provided the ambient
temperature itself does not impose a threat to freezing with active flows conditions.
Move the mechanisms by re-energizing the equipment to prevent seizures or Brinelling
effects to the bearings.
CONTRACT N
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It is recommended to re-energize the machine and operate in manual mode and in

controlled conditions each 1 month of stoppage if this is possible.
Refer to SMS Meer for recommendations if periods of shutdown in excess of 6

months are envisaged.
CONTRACT N
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6.0 Trouble-shooting
ATTENTION:
Be aware that fault/trouble-shooting can result in exceptional hazards. A risk assessed method
to undertake the work should always be taken. Persons undertaking fault finding must be fully
trained, assessed and approved to be competent in the specific tasks so as not to present
unacceptable risks to either themselves or other Workers.
Defect Possible Causes Solutions

Stopping of the machine Lack of electric power to the Check the electric board
motor
Drive couplings broken Replace
Software problem Replace
Software pre-conditions not Resolve
met
Cabling fault Investigate/repair
Broken gears in gearbox Investigate/replace
External influence Investigate/remove source
Excessive temperature on drives Bearings failure Check lubrication
of the machine (max. 55 - 60 C) Check radial/axial clearances
Gears Check lubrication
Check backlash clearances
Heat shields missing Replace
Lack of lubrication Replenish
Abnormal radiance external Remove source
source
Excessive machine Cooling water problem to Restore the cooling
temperatures/high axial shafts or w.c. beams
expansions
Noises or vibrations Loose bolts on gearboxes, Tighten, check critical tensions of
couplings, motors. bolts
Damaged couplings/bolts Investigate/replace
Lack of lubricant Replenish
Muff or low speed couplings Investigate and repair
looseness/wear problems
Misalignments Check and re-align
CONTRACT N
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Defect Possible Causes Solutions

Bearings failure Check clearance/lubrication
Gears damage Check lubrication/check contacts
and backlash
Cobbles Channel angular position Adjust the stopping position
incorrect
Entry guides misaligned Re-align
Timing of the index-rotation Check the electric cycle
incorrect Check the photocell at the entry
of the duct
Premature wear in working parts Neglected lubrication Restore routines
Central system/distributor Recover fault
fault
Incorrect materials Install correct materials
Misalignments Re-align
Manual lubrication Restore routines/correct auto
Seizure of working parts neglected/auto lube fault fault
Incorrect lubricant Change to correct type
CONTRACT N
CHAPTER SHEET REV.

7.0 Documentation of the Sub-Suppliers for the

Erection, the Commissioning and the
Maintenance
* Refer to Components Manual C - 2.0.
Drawing N Item Supplier Description Catalogue N*

2465.0206 10A ABB MOTOR C-2.2.10
11A ROSSI GEARMOTOR C-2.1.21
12A MAINA COUPLING C-2.1.04
12B MAINA COUPLING C-2.1.04
75.076.07 27C DEUBLIN ROTARY COUPLING C-2.5.02
75.076.08 21A ELESA OIL LEVEL C-2.6.03
27C DEUBLIN ROTARY COUPLING C-2.5.02
75.076.04 21A DROPSA FEEDER BLOCK C-2.6.01
1827.0041 30A HT ITALIA PROXIMITY SWITCH C-2.2.01

1890 - Double Rotating Channel

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CONTRACT N

1,400,000 tpy Rebar Mill with H.S.D. System 58 95 9439

Double Rotating Channel JOB ITEM 8274.1890

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8274.1890 DOUBLE ROTATING CHANNEL

Double Rotating Channel JOB ITEM 8274.1890

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Double Rotating Channel JOB ITEM 8274.1890

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The conveying channels for the bars.

High speed dividing shear

Braking pinch rolls

Double Rotating Channel JOB ITEM 8274.1890

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Double Rotating Channel JOB ITEM 8274.1890

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2.0 Safety Recommendations

See Plant Manual A

Double Rotating Channel JOB ITEM 8274.1890

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The operator must execute risk assessment methodology in the establishment of

Double Rotating Channel JOB ITEM 8274.1890

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SMS Meer declines any responsibility towards injuries to people or damages to

Double Rotating Channel JOB ITEM 8274.1890

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3.0 Technical Data and Drawings

3.4 Hydraulic not applicable

3.8 List of Drawings and Drawings

Serial no. 8274.1891.01

Equipment rotating channel

Double Rotating Channel JOB ITEM 8274.1890

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Rounds dimension dia. min. 8 mm

Reduction ratio Tau = 1 : 2.29

3.3 Electrical Electric Manual, chapter E-11.2

Motor List dwg. 2465.E030

3.5 Pneumatic (for pyrometer)

Scheme dwg. 2465.P003

Scheme (direct water) dwg. 2465.P001

Double Rotating Channel JOB ITEM 8274.1890

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3.7 Lubrication Equipment and Maintenance

For splash lubricated gearbox (exit channel) drive gearbox

Central supplied drive gearbox (entry channel) Equipment and Maintenance

- on board machine dwg. 75.077.05

Double Rotating Channel JOB ITEM 8274.1890

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3.8 List of Drawings and Drawings

Item Pos. WBS Drawing N Description Pages

Double Rotating Channel JOB ITEM 8274.1890

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4.1 General Functions

4.2 Single Functions

4.1 General Functions

Depending on the above deviators adjustments (orientation of the deviators in service at

Double Rotating Channel JOB ITEM 8274.1890

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Fig.1 - Rotating channel assemblies

Double Rotating Channel JOB ITEM 8274.1890

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Fig. 2 - Bars discharging on the cooling grid

General operation sequence of the rotating channel line A: