KSRM Bar Revamping Project

Operation and Maintenance Manual

Hydraulic Equipment

Design Xu Yi
Check Yang Yong
ApproveLuo Xinhua

WISDRI Engineering & Research Incorporation Limited

Hot Rolling Business Branch
Jan, 2017
1. Hydraulic Equipment
1.1 General
KSMR bar revamping project includes hydraulic equipment as follows: No.2
hydraulic systems of cooling bed area and collection area, a total of two sets. The

No.2 hydraulic system of cooling bed area includes one hydraulic pump station (use
old), 6 hydraulic valve stands (including 2 use old); collection area includes one
hydraulic pump station, and 9 hydraulic valve stands(including 2 use old).

1.2 Operation and Maintenance

1.2.1 Requirements of Operation
1Start the pumps
Pumps should be started by operating personnel. If the duty worker want to start
the pumps, he must notify dispatch and in accordance with his instructions, hit the box
from remote position to local, the system must confirm to be correct before the start.
The requirements to start
a The temperature must be above 20;
b The temperature must be below 65;
c The level of oil tank must be higher than "low low level"
d No emergency stop signal;
e The suction valve of pump is opened;
f No filter alarm signal.
Cooler and heater:
Heater:
a The temperature is below 35 , start the heater;
b The temperature is above 40 , stop heating;
Cooler:
a The temperature is above 50 , start cooling;
b The temperature is below 40 , stop the cooler.
When pumps are need to use, start the circulation pump and then start the main
pumps. After startup, check whether the pump pressure satisfy the technical standard,
or the pumps are working properly, without abnormal sounds and vibration, if it
appear, immediately shut them down, and notify the scheduling in time, execute the
arrangement from him.
Fill out the log.
2) Stop the pumps:
Pumps should be stopped by operating personnel. If the duty worker want to stop
the pumps, he must notify dispatch and in accordance with his instructions, hit the box
from remote position to local, and should stop the main pumps and then stop the
circulation pump.
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It should be carefully confirmed after the pumps stop, to ensure that the
equipment does have stopped running.
The master control button should be switched to the locked status.
Fill out the log.
1.2.2 Requirements of Maintenance
1) The oil depot should be clean and free from empty oil drums, rags and other
debris, flammable and explosive materials are strictly prohibited, instruments should
be complete and clean, easy to adjust and reading, all kinds of equipment should be
clean, the sump should be discharge timely, clean up.
2) Regularly check the oil level, temperature, pressure whether in the normal
range, oil should be at a high level, the oil temperature should be between 35 ~ 50 ,
not exceed 55 in summer.
3)Regularly check the oil situation by visual method, the oil in the tank should
not be color (white, black) and has no foam , observe whether the catchment has
water, if has open the drain valve in time to let it go, at the same time find out the
reason and solve it. Do oil quality testing if necessary.
4) All pumps, motors, piping, valve stands, valves, etc. should be firmly fixed, no
loose bolts, functions are complete and properly, there should be no leakage of
hydraulic equipment.
5) Check whether the filter is clogged, if the differential pressure indicator alarm,
replace the filter element immediately.
6) The seals of pipe fittings, hose connections, and valves should use flexible
material, silk and linoleum are not allowed to use, cleaning pipes, valves, tanks, etc.
should use lint-free cloth or special paper.
7) Hydraulic cylinders, hydraulic motor bolts should be no loose, solid and
reliable, can move in place, bearing and earrings should be flexible.
8) Records should be true , accurate and clear.
1.2.3 Safety Requirements
1) No smoking inside the depot, maintenance personnel is forbidden to bring fire
into the depot.
2) In the depot if maintenance need to use fire, it must go through the relevant
fire work permits, fire extinguisher should be complete, the inflammable and
explosive materials should be clean, safety precautions and safety monitoring should
be ready.
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3) If maintenance needs to remove barricades and other security facilities,

recover them after the maintenance.
4) The site should be promptly cleaned, no fire and no theft.
5) Before the stop or start the media system, operation and maintenance
personnel should be in a safe position.
6) The non-staff people in and out of the depot should be registered.
7) When cleaning the tank should pay attention to ventilation and have someone
care.
8) Increasing the hydraulic cylinder pressure should be strictly in accordance
with regulations, pressure must not exceed 1.5 times the working pressure, when
increasing pressure should pay attention to personal safety.
9) When doing operation and maintenance work, all personnel should be in a
secure location.