Increased life of Ceramic embedded rolls with weld buttoning

Success story about the increased life of Ceramic embedded rolls with weld buttoning

Wearresist team was called by a cement plant for VRM roller buttoning on 29/01/2020.
After joint Inspection, maximum wear was observed up to 45 mm depth and width was observed around 45 mm on the periphery of rollers in the grinding zone.

Challenge for WRTPL :

The customer gave the challenge to increase the wear life and it should run up to 2000 hrs. The buttoning of ceramic rollers as also rebuilding of VRM table with flux core wires was to be done parallel in total time of 37 hrs which was very challenging.

Solution :

WRTPL took the challenge and offered than the revolutionary XL-CC 880 electrodes. The total system offered was as under:

XL-CC880 -Unique technology electrode which is extremely successful on VRM application.
XL-SPL – High UTS dissimilar steel joining electrode for buffer layers.
XL- CT2013 – Complex Chromium Carbide tubular electrode for build up.
XL-CC 65 – Complex Chromium Carbide electrode for final layers other than critical 45 mm
width for economics.

Equipment & procedure :

4 welding rectifiers of 600 amps with all accessories.
Make scaffolding around all the three rolls so that it was
Convenient for the welders to weld the buttons on the rollers. Open VRM slave roller door so that both the jobs of buttoning & rebuilding could be smoothly done as it was required from safety perspective.
In one shift, three welders were deputed for all three rolls for 12 hrs shift. Welding was continued round the clock.

Reading taken on 18/02/2020

MR1	MR2	MR3
41 mm	43 mm	44 mm
43 mm	44 mm	42 mm
41 mm	49 mm	43 mm

Observation of inspection after running of 400 hrs :

After inspection of the rollers it was observed that maximum wear on MR1 & MR3 rollers is 3 mm and on MR2 roller is 5 mm.

Key benefits due to increased life of ceramic embedded rolls with weld buttoning :

After running 611 hours of the VRM ,the rollers performance is as under:

Getting smooth wear and minimum wear on VRM table
Increase in TPH
Before buttoning 200 TPH
After buttoning 207 TPH
Vibration level minimized
Before buttoning 7 mm/sec
After buttoning 5 mm/sec

Above case study addresses the concern of top management about reclamation of key spares rather then buying new. This approach is economical and technically superior for the society.

The solution in terms of repair and reclamation aware society to adapt better metallurgical upgrades and innovative processes to improve the availability of the plant and machinery.

Overall, this thereby reduces the downtime losses and operational costs resulting into absolute improvement of the bottom line for the organization.