Training Hyd System in Cement Industri

Hydraulic System
Maintenance Department
December 2008
By : Hydraulic team
Tujuan
 Mengerti dasar operasi Hydraulic di semen industri

 Mengerti permasalaan di Hydraulic system di semen
Industri
 Memahami Trouble shooting hydraulic di semen
industri
2
Holcim Indonesia Training Hydraulic 06.07.21
Hydraulic
Production Hydraulic Mechanical Instrumentation

Control
operation system. System device
1. Production 1. Step operation 1. Optimalization1.Alignment 1. Calibration

process
2. Parameter 2. Interlock system 2. Calibration 2. Mechanical 2. Optimalization

process design
3. Trouble
3. Optimalization 3. Mechanical
shooting
Drawing
Integrated System
Optimalization Production Process

3
RAW MILL
 Operating Mode
1. Lifting Cylinder
2. Keep rollers in top position
3. Lowering rollers
4. Mill in operation
5. Increase pressure
6. Decrease pressure
4
Control Sensors
Top position
Lifting pressure > 45 bar Proximity switch X1: On

Operating press : 50 bar Pressure switch : P1 > 45 bar
Pressure transmitter :
Lifting pressure < 10 bar Proximity switch Y1 : off
Operating Pressure = 40 bar Pressure switch P2 : off

Bottom position Pressure transmitter :
5
Lifting Roller
Syarat :
a. Tidak ada oli di jalur piston side yang ketangki
b. Tidak ada oli di jalur rod side yang ke tangki
c. Oli mengalir ke area piston side
d. Proximity top position on
e.Lifting pressure > 45 bar
 Pump : ON
 MV : Operating
 4S : ON
 5S : OFF
 6S : ON
 8S : OFF
6
Lifting Roller
680 liter Reservoir
11
6
FR M
PB PA 9
12
P A
7
T B
4S
P A
T B
P B P B P B
PC
T A T A T A
5S 8S 6S
x x x
A
16
26
B
14
13
85
P 23 22
I
15
7
Increase operating pressure in top position
Syarat :
a. Tidak ada oli di jalur piston side yang ke tangki
b. Tidak ada oli di jalur rod side yang ke tanki
c. Oli mengalir ke area rod side
d. Operating pressure = 50 bar ( Pressure transmiter )
 Pump : ON
 MV : Operating
 4S : OFF
 5S : OFF
 6S : ON
 8S : OFF
8
680 liter Reservoir
11
6
FR M
PB PA 9
12
P A
7
T B
4S
P A
T B
P B P B P B
PC
T A T A T A
5S 8S 6S
x x x
A
16
26
B
14
13
85
P 23 22
I
15
Increase Pressure
in top position
9
Keep Rollers in top position
Syarat
1. Tidak ada penambahan oli di piston side dan rod side
2. Tidak ada oli diarea piston dan rod side yang mengalir ke tangki
3. Proximity top position on
4.Lifting pressure > 45 bar.
5.Operating pressure = 50 bar
 Pump : OFF
 MV : Operating
 4S : OFF
 5S : ON
 6S : ON
 8S : OFF 10
Keep rollers in 680 liter Reservoir
top position 11
6
FR M
PB PA 9
12
P A
7
T B
4S
P A
T B
P B P B P B
PC
T A T A T A
5S 8S 6S
x x x
A
16
26
B
14
13
85
P 23 22
I
15
11
Lowering Rollers
* 20 detik setelah charging material

Syarat :
1. Oli yang berada di piston side dibuang pelan-pelan ke tanki
2. Tidak ada oli yang di rod side mengalir ke tanki
3. Tidak ada penambahan oli di rod side
4. waktu untuk proses lowering roller = 20 detik
 Pump : OFF
 MV : Operating
 4S : OFF
 5S : ON
 6S : OFF
 8S : OFF
12
Lowering rollers
680 liter Reservoir
11
6
FR M
PB PA 9
12
P A
7
T B
4S
P A
T B
P B P B P B
PC
T A T A T A
5S 8S 6S
x x x
A
16
26
B
14
13
85
P 23 22
I
15
13
Increase Pressure saat operasi
Syarat :
1. Actual pressure < setting pressure
2. Oli di piston side mengalir ke tanki
3. Tidak ada oli di rod side yang ke tangki
4. Penambahan pressure di rod side
 Pump : ON
 MV : Operating
 4S : OFF
 5S : ON
 6S : OFF
 8S : ONc
14
Increase Pressure
680 liter Reservoir
11
6
FR M
PB PA 9
12
P A
7
T B
4S
P A
T B
P B P B P B
PC
T A T A T A
5S 8S 6S
x x x
A
16
26
B
14
13
85
P 23 22
I
15
15
Process Sensors
Top position
Operating Pressure Pressure transmitter
Bottom position
16
Coal Mill
Operating mode
 Mill in operation
 Increase operating pressure
 Decrease operating pressure
 Swing in/out rollers
17
Coal Mill
Reservoir
P
I
P A
T B
 Increase operating pressure
Syarat :
1. Actual pressure < Set pressure
2. Oli mengalir ke area rod side
1. Pump ON
2. Solenoid ON
18
Coal Mill
Reservoir
P
I
P A
 Decrease operating pressure T B
Syarat :
1. Actual pressure > setting pressure.
2. Oli di area rod side menalir ke
tangki
1. Pump OFF
2. Solenoid OFF
19
Coal Mill
Reservoir
 Mill in operation P
I
P A
T B
Syarat :
1. Actual pressure = Setting
pressure
2. Tidak ada oli diarea rod side
yang ke tangki.
1. Pump OFF
2. Solenoid ON
20
PRE-GRINDER
Operating mode
 Roller Up
 Roller up Complete
 Roller Down
 Increase pressure.
 Decrease pressure
21
Process Sensors
Top position
Lifting roller Proximity switch top = on
Operating Pressure Proximity switch top = off

Proximity switch bottom = off
Bottom position Pressure transmitter
22
PRE-GRINDER
Roller Up
Syarat :
1. Tidak ada oli yang ke tanki di jalur piston side
2. Tidak ada oli di jalur rod side yang ke tanki
3. Oli mengalir ke area piston side
 Pump : ON
 SOL 1 : OFF
 SOL 2 : ON
 SOL 3 : OFF
 SOL 4 : OFF
23
Pre-grinder (Roller Up)
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
24
PRE-GRINDER
Roller Up Complete
 Syarat :
1. Tidak ada oli di piston side dan rod side yang ke tangki
2. Tidak ada penambahan oli di piston side dan rod side
3. Proximity top position on
 Pump : OFF
 SOL 1 : OFF
 SOL 2 : OFF
 SOL 3 : OFF
 SOL 4 : OFF
25
Pre-grinder ( Roller up complete )
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
26
PRE-GRINDER
Rollers Down
* 30 detik setelah charging
 Syarat :
1. Oli yang berada di piston side dibuang ke tanki secara berlahan.

2. Tidak ada oli diarea rod side yang ke tangki.
3. Waktu untuk roller down adalah 30 detik
 Pump : OFF
 SOL 1 : ON
 SOL 2 : OFF
 SOL 3 : OFF
 SOL 4 : OFF
27
Pre-grinder ( Roller down )
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
28
PRE-GRINDER
Increase Pressure saat operasi
Syarat :
1. Actual pressure < Setting pressure.
2. Oli mengalir ke area rod side.
3. Oli di area piston side mengalir ke tangki
 Pump : ON
 SOL 1 : ON
 SOL 2 : OFF
 SOL 3 : OFF
 SOL 4 : ON
29
Pre-grinder (Increase Pressure )
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
30
PRE-GRINDER
Normal operation :
Syarat :
1.Actual pressure = setting pressure
2.Tidak ada oli di area rod side yang ke tangki.
3.Oli di area piston side mengalir ke tangki.
 Pump : OFF
 SOL 1 : OFF
 SOL 2 : OFF
 SOL 3 : OFF
 SOL 4 : ON
31
Pre-grinder (Normal operation)
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
32
PRE-GRINDER
Decrease Pressure :
1.Actual pressure > setting pressure
2. Oli di area rod side di buang ke tangki
3.Oli diarea piston side di buang ke tangki
 Pump : OFF
 SOL 1 : OFF
 SOL 2 : OFF
 SOL 3 : ON
 SOL 4 : ON
33
Pre-grinder (Decrease Pressure )
SOL 1 A B SOL 2
P T
P
=
SOL 3
SOL 4
B A B A
T P T P
v
70 K
140 K
34
35
36

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Hydraulic System

 Mengerti dasar operasi Hydraulic di semen industri

Production Hydraulic Mechanical Instrumentation

1. Production 1. Step operation 1. Optimalization1.Alignment 1. Calibration

2. Parameter 2. Interlock system 2. Calibration 2. Mechanical 2. Optimalization

Optimalization Production Process

Lifting pressure > 45 bar Proximity switch X1: On

Lifting pressure < 10 bar Proximity switch Y1 : off

Operating Pressure = 40 bar Pressure switch P2 : off

* 20 detik setelah charging material

Operating Pressure Pressure transmitter

 Increase operating pressure

 Decrease operating pressure T B

Lifting roller Proximity switch top = on

Operating Pressure Proximity switch top = off

1. Oli yang berada di piston side dibuang ke tanki secara berlahan.

2. Oli mengalir ke area rod side.

3. Oli di area piston side mengalir ke tangki

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