2015

Roller #4 Seal Problem

Submitted by:
Inspection Team Members

Under supervision:
Eng. Ashraf Fahmi
Preventive Maintenance Manger

March 24 M.Gamal
[Type the company name]
2/5/2015
 Table of content
1.Introduction Page 3

2. Maintenance history Page 3

3. Problem Description Page 3

4. Problem Evaluation Page 6

5. Bearings Check Page 7

5-1. Visual inspection Page 7

5-2. Roller Lubrication Oil Analysis Page 9

6. Conclusion Page 9

7. Recommendation Page 9

Inspection Dept. Page 2 of 10

 1. Introduction
We faced a technical problem at the latest overhauling for roller no.4, this report represent a clarification for this
problem. We hope to help us by a technical support.

2. Maintenance history
Before describe the problem I like to illustrate the maintenance history for roller no.4.
At October 2012
The roller bearings have been replaced.
The mechanical seal has been replaced.
At October 2013
The seal has been replaced due to leakage at the contact surface between the sealing cover and roller
hub flange Fig2.1.

Fig 2.1

3. Problem Description

During seal replacement at October.2013 we checked the distance between the thrust collar and the sealing
cover X Fig 3.1 before dismantle the old seal and it was 18.00 mm.

We started to erect the new seal following FULLER company instructions step by step, and everything was
normal, until we measured the distances X, Y and W Fig3.1 to calculate Z, The results are listed in the table
below Table 3.1.

Inspection Dept. Page 3 of 10

 Fig 3.1

Dimension Position 0 Position 90 Position 180 Position 270 Average

W 21 21 21 21 21
Trial 1

X 18 18 18.7 18.7 18.35

Y 20 20 20 20 20
Z (Actual) = 21.00 + 18.35 + 20.00 = 59.35 mm
W 21 21 21 21 21
Trial 2

X 18.3 18.15 18 18.2 18.1625

Y 20 20 20 20 20
Z (Actual) = 21.00 + 18.1625 + 20.00 = 59.1625 mm

Table 3.1

So, According to FULLER Company instructions the final value of Z is not accepted Fig3.2 and we need machining
at surface A.

Fig 3.2
So we had a confusion which is how the old seal didnt need any machining and the new one needs machining, In
addition to we have replaced roller seals many times before and no one needed machining.

Inspection Dept. Page 4 of 10

 We decide to make an illogical action; it was rotating the roller shaft when the roller was seated on its end as
shown at Fig3.3.

Fig 3.3
We repeated measurement and the result was a surprise, the results are listed in the table below Table 3.2.

Position Position
Dimension Position 0 Position 90 Average
180 270
W 21 21 21 21 21
Trial 1

X 13.4 13.15 13.1 13.5 13.29

Y 20 20 20 20 20
Z (Actual) = 21.00 + 13.29 + 20.00 = 54.29 mm
W 21 21 21 21 21
Trial 2

X 13.3 13.4 13.2 13.3 13.3

Y 20 20 20 20 20
Z (Actual) = 21.00 + 13.3 + 20.00 = 54.3 mm

Table 3.1

So, According to FULLER Company instructions, Z value is with in tolerance Fig 3.4.

Fig 3.4

According to the final result we proceed to erect the seal to the final step

Inspection Dept. Page 5 of 10

 4. Problem Evaluation

First let us assume that the distance X before rotating the roller shaft is X1 and after shaft rotating is X2 and for
the old seal is X0.

Returning to the roller assembly, we will find that the thrust collar is fixed with the roller shaft and the seal cover
is fixed with the roller hub, So the difference between X1 and X2 represent axial clearance (axial play) at the
assembly, appeared when the roller shaftwith the thrust cover-moved towards the sealing cover during rotation
of the shaft Fig 4.1

Note:-
The rotation of the shaft is an important action when adjusting bearing preload to guarantee that the bearings
are fully seated.

Fig 4.1
It supposes that there is no axial clearance at the assembly because the
assembly is under preload, means an axial interference between rollers and
raceways such that there is no measurable axial shaft movement when axial
force is applied in both directions while oscillating or rotating the shaft.

If we have a looseness at the assembly (Axial End play) Fig 4.2, bearings will
not be stiff enough to resist the axial load from grinding process which will
cause bearings to fail.

Actually bearings status until now is very good according to the regular
check.

Fig 4.2
Inspection Dept. Page 6 of 10
 5. Bearings Check
During raw mill operation from October 2013 until now many inspection programs has been executed as follows.

5.1 Visual inspection

1. At October 2013 shutdown

Bearings have been inspected visually and they are in good conditions Fig 5.1.
No existence for chips at roller housing and Supply filter enclosure.

Fig 5.1
2. At February 2014
Bearings have been inspected visually and they are in good conditions Fig 5.2.
No existence for chips at roller housing and Supply filter enclosure.

Fig 5.2
Inspection Dept. Page 7 of 10
 3. At October 2014
Bearings have been inspected visually and they are in good conditions Fig 5.3.
No existence for chips at roller housing and Supply filter enclosure.

Fig 5.3

1. At February 2015
Bearings have been inspected visually and they are in good conditions Fig 5.4.
No existence for chips at roller housing and Supply filter enclosure.

Fig 5.4

Inspection Dept. Page 8 of 10

 5.2 Roller Lubrication Oil Analysis

1. At January 2014

The oil sample has been analyzed by SHELL CO. and the result was as mentioned below:
The amount of water contamination is too high. The spectrometry shows satisfactory wear levels for this
equipment. Check and eliminate the source of the water contamination.

2. At November 2014

The oil sample has been analyzed by MANTRAC CO. and the result was as mentioned below:
The Sample test results all indicate that the equipment/vehicle and lubricant are both performing within
normal working limits.

3. At November 2014

The oil sample has been analyzed by SHELL CO. and the result was as mentioned below:
The Sample test results all indicate that the equipment/vehicle and lubricant are both performing within
normal working limits. Please continue normal operation and review again at the next scheduled sample.

Note:-
At February 2015 the roller has been checked for ships through the return line for the lubrication oil.

6. Conclusion

1. Theoretically the difference between X1 and X2 translated to axial play at the bearing assembly which
conflict with engineering logic and reality since roller bearings are in good condition.
2. Fortunately the roller bearings until now are in good condition, so we cant complete with this risk.

7. Recommendation

1. First of all we must prepare the spare roller, not only for this situation.
2. Measure the end play of the roller bearings after dismantling the roller to make sure that the bearing
under preload or not.
3. According to the end play value the correction will be done:-

End play = 0

No correction action needed.

Inspection Dept. Page 9 of 10

 End play > 0

Proposal A: replace the roller completely.

Proposal B: its forbidden to make a preload for old bearing (used bearing) this matter is a recommendation from
Eng. Ahmed Salah bearing specialist SKF company, so we recommend adjusting the play to be zero or + (0.05 to
0.1) mm to reduce impact severity, and roller elements sliding motion.

The ideal operating bearing setting is near zero to maximize bearing life time; so we need bearings to be set with
small endplay (yellow range) instead of high end play (red range) at the assembly to reach the desired near zero
setting at operating temperature when mounted as a compromised solution. Fig 6.1

Fig 6.1

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