Escolar Documentos
Profissional Documentos
Cultura Documentos
Mantenimiento Mecánico y
Eléctrico de Molinos SAG y de
Title
Bolas
General: This Training Manual is for training purposes, and is only intended to introduce
the student to concepts relating to the operation and use of equipment furnished by
FLSmidth A/S and/or its subsidiaries, affiliates and/or related companies (“FLS”). The
information contained in this Training Manual will not be automatically updated. Unless
otherwise specifically informed by FLS’ trainer (and then only to the extent so informed),
the Training Manual and operational training provided by FLS are not intended to be a
substitution for and are not a substitution for any training required by law, code or
regulation, including but not limited to in the United States MSHA and OSHA. When actually
operating or maintaining equipment furnished by FLS, consult with and utilize the operation,
maintenance and instruction manuals and other documentation furnished for use with such
specific equipment. Further, follow all safety policies and procedures established by your
employer.
Please note that this Training Manual is not a contract or an agreement. This manual and all
training are being provided pursuant and subject to the terms, conditions and other parts of
the contract between FLS and the purchaser of the Training Services. Nothing in this manual
is intended to modify, amend or replace any part of that contract.
The training material is not official project documentation. The training material is never to
supersede the technical documents & drawings delivered with the equipment.
The tag numbers on the training material documents might be different from the actual tag
numbers as the training presentations were complete prior to Factory Acceptance Testing
(“FAT”). The start-up procedures are obtained from the Functional Spec document prior to
FAT and will not be used for system start up. This information is placed in the training
material for reference and for operators to get familiar with such procedures.
This Training Manual is protected by copyright laws. This training manual and the
information contained therein is the property of FLSmidth A/S and is intended solely for the
use of the individual to which it was provided by FLS. No part of this training manual may
be duplicated, disclosed or provided, directly or indirectly, to any third party without the
prior written consent of FLS.
All FLS trademarks used in the Training Manual are trademarks of FLSmidth A/S. All other
trademarks are the property of their respective owners and their use by FLS is for
identification purposes only and does not indicate any affiliation between FLS and the
trademark owner.
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Capacitación de Mantenimiento Mecánico y
Eléctrico de Molinos SAG y de Bolas
Tabla de Contenido
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Mantenimiento
¿Por qué tenemos que realizar tareas de mantenimiento a los
Molinos SAG y de Bolas?
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1
Mantenimiento
El mantenimiento se define como:
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Mantenimiento
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2
Objetivo del Curso
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Detalles Administrativos
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3
Acerca de los Participantes
Nombre
Años de experiencia
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4
Estructura del Curso
Módulos
Módulo 1 – Descripción del Proceso de Molienda Módulo 7-Procedimientos de Trabajo Sistemas de
Lubricación y Auxiliares de los Molinos (Lubricación
Módulo 2- Introducción al Equipo y sus del Molino y Sistema de Engrase)
Sistemas
Módulo 8- Sistemas de Freno
Módulo 3- Sistemas Estructurales de los
Molinos Módulo 9 – Lectura e Interpretación del PID
Sistema de Frenos, identificación de componentes
Módulo 4- Procedimientos de Trabajos en los en campo y variables principales a monitorear.
Molinos
Módulo 10 – Sistema Eléctrico General del Molino.
Módulo 5- Sistemas de Lubricación y Auxiliares
de los Molinos Módulo 11 - Mantenimiento Preventivo en el
Molino y Sistemas Auxiliares
Módulo 6 - Lectura e Interpretación de
Diagramas PID, Análisis de circuitos de Alta y
Baja Presión, Valores Óptimos de Operación del Módulo 12 – Inspecciones Eléctricas
Sistema de Lubricación, Levante y Sistema de Recomendadas
Engrase del Sello del Molino.
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¿PREGUNTAS?
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5
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6
DESCRIPCIÓN DEL
PROCESO DE MOLIENDA
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Objetivos
Al término de este modulo, el participante podrá:
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7
Etapas en el Procesamiento de Mineral
Conminución •Chancado
•Molienda
•Flotación Rougher
Flotación •Flotación Cleaner
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Circuito de Molienda
El circuito de molienda está
diseñado para reducir el
tamaño del mineral que viene
del chancado para
procesamiento en las celdas
de flotación.
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8
Proceso de Conminución
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9
Descripción del Proceso
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Límites de Batería
Los límites de batería del proceso de chancado son los de:
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10
Límites de Batería
Producto
Hidrociclón
Alimentación
Molino SAG
Molino de Bolas
Molino SAG
Molino de Bolas
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id h A/S
A/S. All Ri
Rights
h R Reserved.
d The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Circuito de Molienda
El circuito cuenta con los siguientes equipos:
Molino SAG
Molino de Bolas
Hidrociclones
Bombas
Chancadoras de Pebbles
Zarandas
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11
Datos de los Equipos Principales
Molinos SAG
0310-MLS-0001 y MLS-0002
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12
Circuito de Molienda
El circuito de Molienda está diseñado como un circuito cerrado.
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Circuito de Molienda
Una segunda clasificación sucede en los ciclones, el material que
no cumple con el tamaño requerido, se recircula al molino de
bolas.
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13
Circuito de Molienda
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Circuito de Molienda
Ciclones
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14
Reducción del Tamaño del Mineral
En los molinos, el material se IMPACTO
reduce de tamaño por:
Impacto
Atrición (Fricción)
Trituración
Atrición
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Zona de
Catarata
Zona de
Atrición
Zona de
Impacto
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15
Movimiento de la Carga en el Molino
SAG
Video
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16
Molienda en el Molino de Bolas
En esta etapa el molino de
bolas realiza el trabajo por
medio de atrición.
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VARIABLES EN LA
OPERACIÓN DE LOS
MOLINOS
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17
Parámetros del Proceso Ciclones
PRODUCTO
Alimentación
de agua
Alimentación FLOW
de agua MASS
DENSITY
Molino
SAG Molino de
Bolas
Bomba
Alimentación
de Agua
1. Tph Tanque
2. kWh 5. T80 Tamaño de Transferencia
3. Tamaño de la Alimentación (F80) 6. % Separación
4. Tamaño del Producto ( P80) 7. Peso Específico
8. Densidad del Mineral
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18
Velocidad de Alimentación del Material
Cuando la velocidad de alimentación aumenta, la carga del molino
aumenta.
La velocidad del material debe ser ajustada para mantener una
óptima carga del molino.
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19
Variables que dependen de la Carga
del Molino.
El operador debe tener presente que un cambio en la densidad del mineral también
puede indicar un cambio en la dureza y en la distribución del tamaño de la partícula
para la alimentación.
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20
Distribución del tamaño de partículas
A medida que el tamaño de la alimentación del material
incrementa y la dureza de éste se mantiene constante; el tiempo
de residencia del material en la moledora incrementara para
poder llegar a el tamaño de partículas deseado.
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21
Nivel de la Carga de Bolas
Uno de los elementos más importantes de la molienda es el
adecuado mantenimiento del nivel de la carga de bolas.
Nunca permita que el molino de bolas opere con una carga de bolas mínima. Las
bolas que impacten directamente a los blindajes pueden causar graves daños.
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Nivel de Sonido
Un sonido que es demasiado alto puede indicar contacto de acero
sobre acero (en molino de carga). El daño puede afectar a los
revestimientos, parrillas y bolas.
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22
PARTES Y COMPONENTES
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Objetivos de Aprendizaje
Al termino de este modulo, el participante podrá:
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23
El Circuito de Molienda
Las Bambas cuenta con dos Circuitos de Molienda.
2 Molinos SAG
2 Molinos de Bolas
Ciclones
Zarandas
Circuito de Chancadoras Pebbles
Bombas
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El Molino
Los componentes básicos del Molino son:
Coraza
Pads
Sistema de Alimentación
Sistema de Descarga
Revestimientos
Sistemas de Lubricación y Levante
Impulso Gearless
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24
El Molino
Los molinos SAG (2) y los molinos de bolas (2) cuentan con los
siguientes sistemas los cuales son idénticos:
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25
Chute de Alimentación Molino SAG
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Video
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26
Sello del Chute de Alimentación Molino SAG
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Revestimientos
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27
Chute de Alimentación Molino de Bolas
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28
Los Molinos
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29
COMPONENTES INTERNOS DEL
MOLINO
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30
Componentes Internos
Anillo de Levantamiento
Levantadores de
Pulpa
Cono de Descarga
Placas de Blindaje
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31
Descarga del Molino
Revestimientos
del Trunion Lado
de Descarga
Trommel
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32
Componentes Externos Pernos
Críticos
Cabezal de
Descarga
Salida del
Molino
Coraza
Cojinete
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33
Coraza
La coraza consta de varias
secciones de placas soldadas
y/o apernadas.
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Video
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34
Cojinetes del Molino
Objetivo
Permitir que el molino pueda girar con relación a los pilares de
concreto que lo soportan.
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Trunnion Trunnion
Fuerza de Empuje
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35
Características del Cojinete del Molino
Los cojinetes utilizan aceite que circula a
través de ellos
El molino es soportado por una capa de
aceite entre el cojinete y el trunnion.
Esencialmente no existe fricción entre ellos.
No existe el contacto entre las superficies
metálicas.
Teóricamente tienen vida infinita.
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Mercado
Hidrostático Hidrodinámico
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36
Tipos de Cojinetes
Existen dos tipos principales de Cojinetes:
Hidrodinámicos – La rotación crea el levante
Hidrostáticos – La bomba crea el levante
Hidrodinámico Hidrostático
Aceite
Aceite Aceite
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37
Cojinete Multi Pad Hidrostático
Aceite para elevación contínua
de alta presión
Insertos de bronce
reemplazables
Detectores de temperatura
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Sello Triple
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38
Especificaciones Técnicas
Molinos SAG
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Especificaciones Técnicas
Molinos de Bolas
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39
Componentes del Cojinete Hidrostático
Multi Pad
Cojinete de Bronce
Cojinete de Empuje
Drenado de Aceite
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40
Cojinete Hidrostático Multi Pad
Sensores de Presión de Aceite
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Bloque de Soporte
Pistón
Arandela Esférica
Locknut
Arandela Plana
Espaciador
Anillo Retenedor
Base
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41
Conjunto del Cojinete de Empuje
Cojinete de Empuje
Líneas de
Abastecimiento de
Aceite
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Video
Video
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42
Sello de los Cojinetes
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Video
Sello Triple
Cada lado de los descansos
tiene un sello triple.
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43
Descarga Del Molino SAG
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Trommel
Objetivo
Prevenir que el material de gran tamaño entre en el tanque de
reciclado.
El espiral de avance remueve el material no triturado Trommel
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44
Instalación del Tromel
Video
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45
Descarga Del Molino de Bolas
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46
Especificaciones técnicas.
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¿PREGUNTAS?
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47
Actividad
Escoja el nombre de la parte que corresponde al número.
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fid ti l and
d proprietary
i t tto FLS
FLSmidth
idth and
d iis protected
t t db by copyright
i ht or ttrade
d secrett laws.
Componenteses del
olas
Molino de Bolas
9 2
1 3
Espiral de Retardo
Chute de Alimentación
Pad
Cabezal de Entrada
8 7
Cabezal de Salida
4
Gearless Drive
5
Revestimientos
6
Casco
48
SISTEMA ESTRUCTURAL
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Objetivos de Aprendizaje
Al término de este modulo, el participante podrá:
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49
Revestimientos del Molino y Cabezales
Objetivo:
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Revestimiento del
Cabezal de Carga Placas del Cabezal
de Salida
Anillo de Levantamiento
Levantadores de
Pulpa
Cono de Descarga
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50
Capítulo 2
Descripción del
Molino SAG
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51
Revestimientos del Casco Lado de
la Alimentación
Levantadores Altos
Levantadores Bajos
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Levantadores Altos
Levantadores Bajos
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52
Feed Throat Liner
Filler Ring
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
53
Revestimientos del Cabezal de Carga
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Anillo de Retención
Placa de Descarga
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54
Elevador de Descarga de la Pulpa
Levantador de Pulpa del
Levantador de Pulpa Externo centro
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Placa de Descarga
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55
Anillo de Retención
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Revestimiento de
Descarga Central
Parrillas de Descarga
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56
Elevador de Descarga de la Pulpa
Revestimientos de Descarga
Parrillas de Descarga Central
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
57
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Revestimientos
del Trunnion Lado
de Descarga
Trommel
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58
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015
5 FLSmidth A/S
A/S. All Rights Reserved
Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
59
Capítulo 2
Descripción del
Molino de Bolas
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60
Revestimiento del Casco Zona
Central
61
Los cabezales de
alimentación y de
descarga usan el mismo
tipo de revestimientos.
Trunnion
Liner Outer
Trunnion
Liner Inner
Filler Ring
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Filler Ring
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62
Revestimientos de los Cabezales
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63
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
64
PERNOS EN EL MOLINO
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Pernos en el Molino
Existen dos tipos de Pernos en el Molino
A) De sujeción
B) Críticos
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65
Pernos de Sujeción
Todos aquellos pernos que sujetan los revestimientos u otros
componentes al cuerpo del molino.
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Ejemplos
Torque de Pernos de la Torque de Pernos Trunnion
Pletina Liner
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66
Pernos Críticos
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Pernos Críticos
Los pernos críticos son todos aquellos pernos que se utilizan para
mantener las diferentes piezas que conforman el cuerpo del
molino juntas.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
67
Ejemplos de Pernos Críticos
Pernos Críticos entre
las secciones de la
Coraza
68
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69
Ejemplo de Lista Completa de Pernos
Críticos Molinos SAG
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70
Pernos Críticos
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71
Ejemplos de Pernos críticos
Unión Trommel Adapter y
Unión Trommel Adapter y Trunnion
Trunnion
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Pernos Críticos
Importante
Las convergencias de todas las piezas que unen estos pernos críticos
necesitan estar selladas completamente para evitar fugas de
material.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
72
Procedimientos de Trabajo en Molinos
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Objetivos de Aprendizaje
Al término de este módulo, los participantes podrán:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
73
Herramientas Especiales para el
Mantenimiento de los Molinos
Monitor de Temperatura IR
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Proveedores:
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74
Llaves Dinamométricas Hidráulicas
Descripción Cantidad Comentarios
Llaves 2 Cuerpo principal de la llave de torque. Si
Dinamométricas se requiere más de una llave del
Hidráulicas tamaño entonces se suministra una
llave de cada tamaño. El tamaño de la
llave se basa en la precarga del perno
requerida.
Adaptador HEX 2 El tamaño del adaptador hex depende
del tamaño del perno a ser apretado. Si
mas de un tamaño se requiere entonces
se provee uno de cada tamaño.
Adaptador de Perno 1 Este adaptador le da espacio al cuerpo
principal de la herramienta fuera de la
pestaña cuando no hay suficiente
espacio entre filas de tornillos (sobre
todo en la cabeza del molino para
bombardear con dos filas de tornillos)
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
75
Llaves Dinamométricas Hidráulicas
Conexión de la Adaptador
Manguera HEX Herramienta
Llave /
Herramienta Par de
Reacción
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
76
IR Monitor de Temperatura
Monitor Portátil de Temperatura Infrarrojo (SKF)
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Procedimientos
de Trabajo
T en
Molinos
Moli
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77
Cambio de Deflectores
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Procedimiento de
Trabajo FLS-WI-Mec-59
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78
Cambio de Deflectores (Molino SAG)
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79
Cambio de Deflectores (Molino SAG)
Retirar el deflector con apoyo
del puente grúa y trasladarlo
al lugar de almacenamiento
temporal asignado. Demarcar
el área y continuar.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
80
Cambio de Deflectores (Molino SAG)
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
81
Cambio Trunnion Liners
Procedimiento de
Trabajo FLS-WI-Mec-318
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82
Cambio Trunnion Liners
El procedimiento de cambio debe ser inmediato, es decir una vez
retirado los lifter y placa debe ser reemplazado por los nuevos.
Este procedimiento debe estar de la mano con los giros del molino
programados para los cambios de revestimientos.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
83
Procedimiento Cambio de Paneles del
Trommel
Remover la malla utilizando
desarmador plana y retirar
mallas usadas de esa fila
hacia el exterior.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
84
Cambio del Trommel
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Cambio de Trommel
Quite todo el paso de tuberías
a través del trommel.
Levante ligeramente el
trommel para apoyarlo
mientras se desconecta de la
brida del adaptador.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
85
Cambio de Trommel
Cuando el trommel se ha separado desde el adaptador, hay
que levantar hacia arriba.
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
86
Pernos Críticos
a) Casco
b) Cabezal de carga
c) Muñón de carga
d) Cabezal de descarga
e) Muñón de descarga
f) Adaptador del Trommel
Pernos Críticos
Antes de instalar los sujetadores nuevos, mida la longitud de
cada perno con una resolución de 0,01 mm
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
87
Pernos Críticos
El número grabado deberá estar
fuera del área rectificada de la
cabeza del perno. El área rectificada
de la cabeza del perno típicamente
tiene 25 mm de diámetro.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Seleccione la elongación
máxima correcta y súmela a
la longitud inicial. Ésta es su
longitud de tensión máxima.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
88
Reemplazo de Elementos Críticos de
Fijación
Calibrar la llave
dinamométrica hidráulica a un
valor en el rango medio entre
el mínimo y máximo valor de
precarga.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
89
Medición del Alongamiento
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90
Tabla de Mediciones de Sujetadores
Críticos
Tensión Mínima
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91
Secuencia y Re torque de los Pernos
de Revestimientos
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Consulte el procedimiento del fabricante del revestimiento para conocer los lineamientos de
lubricación. Algunos fabricantes requieren lubricante, mientras que otros no.
La lubricación puede disminuir de manera significativa el apriete requerido en hasta un 50 por
ciento.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
92
Secuencia y Re torque de los Pernos
de Revestimientos
Calibre las llaves percutoras de manera regular para asegurarse
de aplicar el apriete correcto.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
93
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94
SISTEMAS DE LUBRICACIÓN
MOLINOS SAG Y DE BOLAS
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Objetivos de Aprendizaje
Al término de este módulo, el participante podrá:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
95
Sistemas de Lubricación
Cada uno de los Molinos SAG y de Bolas cuentan con el siguiente
Sistema de Lubricación:
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
96
Sistema de Lubricación de los
Cojinetes tipo Pad
Los cojinetes del molino son lubricados por medio de lubricación
hidrostática.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret la
laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
97
Circuito de Acondicionamiento del
Aceite
El aceite acondicionado
asegura la limpieza,
condiciones de temperatura y
así se garantiza el flujo
correcto de aceite hacia los
cojinetes Multi-Pad del
molino.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
98
Sistema de Lubricación- Circuito de
Acondicionamiento
Bombas
Sensores de
Temperatura
Intercambiador
de Calor/
Enfriador
Filtros
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Enfriadores
Filtros
Bombas de
Baja Presión
Hidrostática Lube
System
DWG No. 60097532
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
99
Variables a Monitorear físicamente
Cuando se hace una inspección diaria estas son las variables que
se pueden monitorear
Presión
Temperatura
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Línea de Lubricación AP
Línea de Lubricación AP
Retorno
Retorno
Retorno
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100
Circuito de Alta Presión
Este circuito consiste en:
Bombas de Alta Presión
Divisores de Flujo
Transmisores de Flujo de Alta Presión
Sensores de Flujo de Aceite
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101
Divisores de Flujo y Líneas de
Suministro
Conexión de
Suministro
de Aceite a
los Cojinetes
Manómetros
de Presión
Pantalla
Digital del
Divisores de Flujo de
Flujo Aceite
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
102
Suministro Divisor de
Flujo de los Pads
Bombas de
Alta Presión
Hidrostática Lube
System
DWG No. 60097532
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Cojinetes
Axiales
Suministro al Sistema de
Lubricación de Emergencia Hidrostática Lube
System
DWG No. 60097532
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
103
Variables a Monitorear Físicamente
Cuando se hace una inspección diaria estas son las variables que
se pueden monitorear
Presiones Descansos y
Pads de Empuje
Indicación Local
de Flujo
Temperatura
del Tanque
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Presiones Descansos y
Pads de Empuje cerca
del Molino
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104
Sistema de Lubricación de Emergencia
El sistema de lubricación de
emergencia suministra aceite
a los Pads en caso de pérdida
total de energía.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Acumuladores Manómetros
de Presión
Divisores de Flujo
Válvula de
Descarga
Filtros
Bomba de
Carga
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
105
Sistema de Lubricación de Emergencia
El sistema de Lubricación de
Emergencia se mantiene
cargado con Aceite y solo se
descarga cuando se necesite.
Aceite
Acumuladores
Filtros
Carga de
Acumuladores
P.&I.D. of
Hidrostática Lube
System
DWG No. 60097534
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
106
Variables a Monitorear Físicamente
Transmisores de Presión
En Acumuladores de Nitrógeno
Presión de Descarga
Presión Diferencial
De Filtros
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
107
Lubricación de los Sellos de los
Descansos
Los sellos de goma de triple
labio que se encuentran en
los descansos de alimentación
y de descarga.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Entrada de Lubricante
Sello Triple
Trunnion
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108
Esquema de Lubricación del Sello
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Bomba y Calentador
Manifold de Lubricación
Válvulas Divisoras
Transmisores de Presión
Panel de Control
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109
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110
MÓDULO- 6
LECTURA E
INTERPRETACIÓN DE
DIAGRAMAS PID Y
ANÁLISIS DE CIRCUITOS DE
LUBRICACIÓN
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Unidad Hidráulica
Los molinos se suministran con una unidad de Lubricación
diseñada especialmente para el tamaño, tipo y capacidad del
Molino.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
111
Sistema de Lubricación del Molino
La unidad hidráulica es un sistema que en su conjunto se encarga
de acondicionar y suministrar aceite para los cojinetes Multi-Pad
de los molinos.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
112
Sistema de Lubricación del Molino
La unidad de lubricación existe para:
Lubricar Acondicionar el Aceite
Proteger Al Molino
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Unidad Hidráulica
El objetivo de la Unidad Hidráulica del Molino es crear la presión
de aceite necesaria para generar un “levante” del molino creando
una capa de aceite que evita el contacto entre el Trunnion y el
Pad.
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113
Sistema de Lubricación de Alta Presión
El objetivo de este levante es evitar que el molino gire sin una
película de lubricación.
Evitar el contacto metal con metal con el molino girando es el
objetivo primordial del sistema de lubricación.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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114
Sistema de Lubricación del Molino
Circuito Hidráulico Básico de Lubricación del Molino SAG
MOLINO SAG
Línea de Lubricación AP
Línea de Lubricación AP
Línea de Lubricación AP
Retorno
Retorno
Retorno
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MOLINO de BOLAS
Línea de Lubricación AP
Retorno
Retorno
Retorno
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115
Sistema de Lubricación del Molino
El sistema de lubricación de los molinos SAG y de Bolas se
diseñaron idénticos.
Pese a no requerir la misma capacidad de aceite de lubricación y
acondicionamiento de aceite por el tamaño de los molinos , es
una decisión inteligente desde el punto de vista de
Mantenimiento, partes de repuesto y operación.
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116
Sistema de Lubricación del Molino
Placa de Datos
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Levante Hidrostático
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117
Principales Componentes del
Sistema de Lubricación del Molino
El sistema de Lubricación de los Molinos Consiste en 3 elementos
principales.
Acondicionamiento Circuito de
Tanque de Reserva
de Aceite, Sistema Lubricación de Alta
de Aceite
de Baja Presión. Presión
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Sistema de Lubricación de
Emergencia o Run Down
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118
TANQUE DE RESERVA DE
ACEITE
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119
Tanque de Reserva de Aceite
Dividido de esta forma el aceite regresa del molino, se recibe en
el compartimiento de retorno, se asienta en el compartimiento de
reposo y se envía al compartimiento de aceite acondicionado.
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Compartimiento de
Reposo
Compartimiento de
Retorno
Compartimiento de
Aceite Acondicionado
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120
Tanque de Reserva de Aceite
El dibujo numero 60097532 Pagina-1 muestra el diagrama del
tanque de reserva de aceite así como los circuitos de Alta, Baja
Presión y la instrumentación respectiva.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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121
Tanque de Reserva de Aceite
Compartimiento de
Compartimiento de
Retorno
Aceite Acondicionado
Compartimiento de
Reposo
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SISTEMA DE BAJA
PRESIÓN
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122
Acondicionamiento de Aceite
Sistema de Baja Presión.
El sistema de baja presión se encarga de acondicionar el aceite
mediante bombas, filtros y un intercambiador de calor.
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Acondicionamiento de Aceite
Sistema de Baja Presión.
El acondicionamiento de aceite se realiza en la misma unidad y
prepara el aceite para una correcta lubricación.
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123
Acondicionamiento de Aceite
Sistema de Baja Presión.
El Documento 60097532 hoja-1 muestra el diagrama del circuito
hidráulico de baja presión del molino.
Intercambiador de
Calor
Filtros de Aceite
Bombas de Baja
Presión de Aceite
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Acondicionamiento de Aceite
Sistema de Baja Presión.
El sistema de baja presión consiste en 2 bombas.
Por diseño una de ellas opera normalmente y la segunda actúa
como respaldo (Stand-By)
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124
Acondicionamiento de Aceite
Sistema de Baja Presión.
Bombas de Baja Presión.
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Acondicionamiento de Aceite
Sistema de Baja Presión.
Las bombas de baja presión toman el aceite del compartimiento
de reposo y lo hace circular a través de filtros e Intercambiador
de Calor para regresar al mismo tanque pero al compartimiento
de aceite acondicionado.
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125
Acondicionamiento de Aceite
Sistema de Baja Presión.
Flujo de Aceite en el sistema de baja presión.
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Temperatura
Flujo de Agua de
Enfriamiento
Presión
Presión Diferencial de
Filtros
Flujo
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126
SISTEMA DE ALTA
PRESIÓN
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MOLINO SAG
Línea de Lubricación AP
Línea de Lubricación AP
Retorno
Retorno
Retorno
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127
Circuito de Aceite de Alta Presión
El aceite de Alta presión se inyecta a los Multi-Pad generando un
levante para evitar contacto entre superficies metálicas del
Trunion y el Descanso del Molino.
MOLINO de BOLAS
Línea de Lubricación AP
Línea de Lubricación AP
Línea de Lubricación AP
Retorno
Retorno
Retorno
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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128
Sistema de Lubricación de Alta Presión
Únicamente aceite a alta presión es enviado a los Multi-Pads para
lograr el efecto de levante.
Aceite a Alta presión también es enviado hacia los Pads de
empuje.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Bombas de Alta
Presión
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129
Diagrama Hidráulico del Sistema de
Lubricación de Alta Presión
El diagrama 60097532 Página-3 muestra la continuación del
sistema de lubricación de Alta Presión.
Sistema de Lubricación
De Emergencia
(Run Down)
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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130
Sistema de Lubricación de Alta Presión
Flujo de Aceite en el sistema de Alta Presión.
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131
Instrumentación del sistema de
Lubricación de Alta Presión
El diagrama 69004522 Pagina-3 muestra la continuación del
sistema de lubricación de Alta Presión y sus instrumentos.
Flujo de Aceite
Emergencia
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
SISTEMA DE
LUBRICACIÓN DE
EMERGENCIA
(RUN DOWN)
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132
Instrumentación del sistema de
Lubricación de Emergencia
El circuito Hidráulico de emergencia se muestra en el diagrama
60097532 pagina 2.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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133
Sistema de Lubricación de Emergencia
El sistema de Lubricación de Emergencia consiste en lo siguiente:
Acumuladores de Aceite
Bomba de Carga de Acumuladores
Válvula Solenoide de Descarga
Acumuladores de Aceite
(Precargados con Nitrógeno)
Nitrógeno
Bombas de Carga
de Acumuladores
Aceite
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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134
Sistema de Lubricación de Alta Presión
Flujo de Aceite en el Sistema de Lubricación de emergencia.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Instrumentación Sistema de
Lubricación de Emergencia
Componentes Principales en Diagrama 60097532 hoja-2.
Acumuladores de Nitrógeno
Válvula de Descarga
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135
Instrumentación Sistema de
Lubricación de Emergencia
La instrumentación del circuito esta mostrada en el diagrama
60097532 página 2.
Transmisores de Presión
En Acumuladores de Nitrógeno
Solenoide de Descarga
Presión de Descarga
Presión Diferencial
De Filtros
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136
Sistema de Lubricación de Emergencia
Válvula Solenoide de descarga
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137
Sistema de Lubricación de Emergencia
Acumuladores
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138
Sistema de Lubricación de Emergencia
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SISTEMA DE
LUBRICACIÓN DEL SELLO
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139
Sistema de Lubricación del Engrane
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140
Sistema de Lubricación del Engrane
Tanque Regulador
de Grasa de Presión
Regulador
de Presión
Puntos de Inyección
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Block de
Distribución
Progresivo
Bomba
Almacén de
Grasa
Calentador
Blocks de
Suministro de Aire Distribución
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141
Sistema de Sello de Grasa de los
descansos del molino
Ejemplo de Instalación
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142
PID’S
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Diagramas PID’s
Que son los diagramas PID?
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143
Diagramas PID’s
Diagramas PID significa Piping and Instrumentation Diagram por
sus siglas en inglés.
También son conocidos como C&ID Control and Instrumentation
Diagram.
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Diagramas PID’s
Para la Mina Las Bambas, se tienen dos tipos de Diagramas PID
disponibles:
Diagramas PID de Howard Marten
Diagramas PID de FLSmidth.
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144
Diagramas PID’s
Los diagramas PID de Howard Marten que es el fabricante de la
unidad de Lubricación contienen información de instrumentación
además de datos sobre el sistema hidráulico como capacidades,
flujos, rangos de operación y diseño del equipo.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Diagramas PID’s
Los diagramas PID de FLSmidth están dedicados solo a mostrar
información eléctrica, control e instrumentación como Tags del
Instrumento, Interlocks y Alarmas.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
145
Diagramas PID
La información que un PID nos proporciona
Instrumentación
• Tag del Instrumento
• Tipo de Instrumento
Alarmas
• Señal Ligada a Alarma
• Interlock Ligado a dicha señal
Lazos de Control
• Señales controladas en automático
• Control de una variable
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Tag de Instrumentos
La mejor identificación que puede existir para un equipo eléctrico
o de instrumentación es el Tag.
Este Tag del instrumento es único e identifica al tipo de
instrumento, la variable a monitorear así como todas las alarmas
y ajustes asociados a ella.
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146
Tipos de Instrumentación
Existe un gran numero de tipos de instrumentos en la industria.
En los Molinos y la Unidad Hidráulica, se manejan los siguientes
tipos de instrumentos de acuerdo al dibujo 80023554 Hoja-1.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Ejemplos de Instrumentos
Ejemplo de Instrumentos.
Sensor de Nivel
Alarmas Asociadas
al nivel bajo de
aceite en Tanque
Sensor de Temperatura
Alarmas Asociadas a
la Temperatura de
Aceite en el Tanque
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147
Alarmas
Las Señales que nos proporcionan una alarma en sala de control
son señales críticas para la operación tanto del molino como de la
unidad hidráulica.
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Alarmas
Las alarmas nos proporcionan una alerta para tomar acciones y
controlar la variable que se ha salido de control.
Estas señales están identificadas en los PID
Alarma por
Diferencial de Temperatura
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148
Lazos de Control
Los Lazos de Control son una herramienta utilizada en sistemas
de control e instrumentación para el control automático de una
variable sin ninguna acción del operador.
Proceso
Ajuste Medición
Controlador
Set Point
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Lazos de Control
Los lazos de control existen para proporcionar un apoyo al
operador y realizar funciones de control de ciertas variables que
se consideran críticas dentro de cualquier proceso.
El objetivo de los lazos de control es efectuar un control
automático de la variable sin acción del operador.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
149
Lazos de Control
Existen dos lazos de control en el sistema del molino los cuales
están identificados en el diagrama PID.
Control de flujo de agua de enfriamiento de aceite
Control de temperatura en el Tanque de Aceite
Control de Temperatura
de Aceite en el Tanque
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Lazos de Control
El control de flujo de agua de enfriamiento hacia los
intercambiadores de calor se encarga de mantener una
temperatura controlada a la salida de dichos intercambiadores
antes de que el aceite llegue al tanque.
A mayor temperatura mayor flujo de agua.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
150
Lazos de Control
Elementos del Lazo de Control de flujo de agua de enfriamiento.
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Lazos de Control
El control de temperatura del aceite en el tanque se regula con
calentadores de aceite.
Se utilizan estos calentadores cuando es necesario incrementar la
temperatura del aceite en el tanque.
Un detector de temperatura controla 2 calentadores.
Los calentadores están localizados 2 en el compartimiento de
reposo y 2 en el compartimiento de aceite acondicionado.
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151
Lazos de Control
Elementos del Lazo de Control.
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Lazos de Control
El control de presión de carga de aceite en los acumuladores del
sistema de lubricación de emergencia está controlado mediante
un lazo de control.
El objetivo del lazo de control es mantener presión constante en
los acumuladores.
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152
Lazos de Control
Componentes del Lazo de Control de Presión de aceite en
acumuladores.
Bombas de Carga
De Acumuladores
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DOCUMENTACIÓN
ELÉCTRICA
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153
Documentación Eléctrica
Documentación Disponible
•Instrucciones Generales del Equipo
•Lista de Partes
IOM •Dibujos
•Todas las especialidades
•Componentes Eléctricos
60097532, 60097535, •Componentes Hidráulicos
60097529, 60097536 •Datos de Diseño
Howard Marten PID •Capacidad del Sistema
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Documentación Eléctrica
Documentación Disponible
•Lista de Instrumentos
80024451, 80024452, •Marcas y Modelos de Instrumentos
Capítulo-24 Lista de •Rango de Instrumentos
Instrumentos I/O •Ajuste de Alarma y Corte
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154
Documentación Eléctrica - PID
PID FLS Standard
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
155
Documentación Eléctrica PID
PID FLS Standard
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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156
Documentación Eléctrica PID
PID FLS Standard Unidad de Lubricación
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
157
Documentación Eléctrica PID
PID FLS Standard Sistema de Alta Presión.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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158
Documentación Eléctrica PID
PID Howard Marten Standard unidad de lubricación.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
159
Documentación Eléctrica PID
PID Howard Marten Standard lubricación de emergencia.
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160
Procedimientos de Trabajo en el
Sistema de Lubricación y de Engrase
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Objetivos de Aprendizaje
Al término de este módulo, los participantes podrán:
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161
Calibración de Pads de Molinos
“A”
“B” “D”
“C”
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162
Importancia del Reparto de Carga
Distribución Dinámica de la Presión
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+/- 5% de la Presión
Promedio
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163
Importancia del Reparto de Carga
entre Pads
Ejemplo:
Distribución de la Presión Dinámica
Pad A 5300 kipá
Pad B 5600 kipá
Pad C 5140 kipá
Pad D 5720 kipá
Promedio 5440 kipá
Tolerancia +/- 10% 544 kipá
Rango Min 4896 kipá “A”
Rango Max 5984 kipá
“B” “D”
Conclusión:
Reparto de Carga Dinámico esta “C”
dentro de la tolerancia.
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164
Importancia del Reparto de Carga
La distribución estática del reparto de carga se mide cuando el
molino está parado.
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165
Sistema Hidráulico de Ajuste Lateral
de la Base de los Cojinetes Multi-Pad
Se utiliza para ajustar la posición de la base de los cojinetes
durante el comisionamiento
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diff
Bearing Disch End diff from Bearing Feed End from
Pad P (psi) avg % Pad P (psi) avg %
A 550 -20 E 750 -4
B 700 2 F 800 2
Presiones Estáticas: C 890 30 G 850 9
D 600 -12 H 730 -7
Mientras que los pads del extremo
Paverage 685 Paverage 783
de alimentación comparten la carga
adecuadamente, los pads centrales Pavg +10% 754 Pavg +10% 861
del extremo de descarga están Pavg -10% 617 Pavg -10% 704
severamente sobrecargados.
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166
Importancia del Reparto de Carga en los Pads
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Inspección de Pads
La inspección de los pads se debe verificar si el muñón está
sentado correctamente en los pads (04 de alimentación y 04 de
descarga) esta verificación se debe de realizar con un calibrador
de launas.
167
Inspección de Pads
168
Cambio de Pads
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Cambio de Pads
Equipo Necesario:
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169
Cambio de Pads
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Cambio de Pads
Desconecte la manguera de suministro
de lubricación de la almohadilla de los
cojinetes.
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170
Cambio de Pads
Conecte el sistema auxiliar de
bomba hidráulica al gato
hidráulico de la almohadilla.
Aplique presión hidráulica al
gato hasta que se registre un
ligero movimiento del bloque
de apoyo en el indicador de
cuadrante (0,075 mm).
Cambio de Pads
Continúe levantando el bloque
de apoyo y la almohadilla
utilizando presión hidráulica
auxiliar hasta que pueda
aflojarse el collarín de
bloqueo del gato de la
almohadilla. Afloje
completamente el collarín de
bloqueo en el gato de la
almohadilla.
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171
Cambio de Pads
Baje el gato hidráulico
permitiendo que la almohadilla
de levantamiento se aleje del
muñón.
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Cambio de Pads
Conecte el aparejamiento a
los pernos de argolla en el
bloque de apoyo y retire el
bloque para colocarlo sobre el
soporte de desmontaje con un
extractor portátil o un guinche
de tracción.
Desmonte la almohadilla de
levantamiento de bronce del
cojinete para separarla del
bloque de apoyo.
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172
Cambio de Pads
Rotule las ubicaciones de los
restrictores en la almohadilla
del cojinete.
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173
Cambio de Pads
Instale la almohadilla de
reemplazo sobre el bloque de
apoyo y vuelva a montar los
componentes del conjunto de
bloques en orden inverso a su
desmontaje. Asegúrese de
haber instalado un nuevo aro
tórico de sellado de aceite
entre el buje y el bloque de
apoyo.
Tubos Restrictores
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Cambio de Pads
Aplique un ligero
recubrimiento de aceite para
cojinetes sobre las superficies
del inserto de bronce y el
muñón.
Deslice el conjunto de la
almohadilla del cojinete
nuevamente al interior de la
caja del cojinete hasta que la
base del gato choque con el
borde posterior del conjunto
maquinado.
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174
Cambio de Pads
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Cambio de Pads
Eleve la almohadilla de
levantamiento con su gato y
el sistema hidráulico auxiliar
hasta que la misma entre en
contacto con la superficie de
el trunion del cojinete, y la
presión en el sistema
hidráulico sea igual a aquella
registrada antes de bajar el
conjunto de almohadilla y
bloque de apoyo.
Apriete la contratuerca en el
pistón hasta que descanse
sobre la base del gato.
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175
Cambio de Pads
Arranque el sistema de lubricación de los cojinetes. Observe las
presiones—deben encontrarse dentro de ±10 por ciento entre sí.
(Presiones Estáticas)
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Orificios Satélite
- 1.0 a 1.7 Mpa menos que
en el Orificio Central
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176
Cambio de Pads
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177
Cambio de Pads de Empuje
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178
Cojinete Hidrostático Multi Pad – Ajuste Axial
Bloque de Soporte
Ranura del Cojinete de
Empuje
Cojinete de Empuje
Lainas
Tornillos
Manta de
Aislamiento
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179
Reemplazo de Pads de Empuje
Inspeccione las superficies de
montaje y de apoyo de las
almohadillas de empuje de
bronce de reemplazo. Elimine
las ligeras mellas, rasguños y
rebabas, y pula las superficies
de apoyo según sea requerido
utilizando un paño de esmeril
fino y aceite.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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180
Cojinete Hidrostático Multi Pad – Ajuste Axial
Tornillos Retirados,
Conjunto del Cojinete de Empuje
en posición baja. Lainas
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Ajuste el grosor ensamblado según sea requerido para obtener una holgura de empuje de
entre 0,15 y 0.20 mm entre cada almohadilla de empuje y la superficie de apoyo de la ranura
de empuje tal como se mide con galgas de espesores.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
181
Reemplazo de Pads de Empuje
Retire o añada calzos según sea requerido y asegure que conjunto de los rieles de empuje está
en posición. Registre las mediciones de holgura final.
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182
Procedimientos Sistema de
Lubricación
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183
Cambio de Filtros de Baja Presión
2. Drene el aceite del filtro sucio.
Drene 2-3 Litros de la parte
inferior y después abra la purga
de aire encima del filtro, tenga
cuidado de no dañar el anillo “O”.
3. Remueva el filtro
Anillo O dañado
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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184
Filtros de Ingreso a los Pads
(Interruptores de Flujo)
Estos filtros mandan una
señal al cuarto de control si
están tapados y entran en
bypass.
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
185
Cambio de los Intercambiadores de
Calor
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186
Procedimiento de Cambio de los
Acumuladores de Nitrógeno
Para realizar el cambio, el
acumulador debe presentar
necesariamente baja presión
de gas Nitrógeno en su
manómetro.
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Reemplazar acumulador.
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187
Desmontaje del Blader o Membrana
del Acumulador
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188
Desmontaje del Blader o Membrana
del Acumulador
Desmontar la válvula de aceite retirando la tuerca de fijación,
anillo separador y los elementos de sellado, el anillo de apoyo y
la teórica.
Empujar el conjunto hacia adentro insertando nuestra mano por el
agujero de la parte inferior, una vez dentro retiramos desde el
interior el anillo de retención de válvula. (hace que no salga la
válvula al exterior).
Retirar la válvula de aceite.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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189
Montaje del Blader o Membrana del
Acumulador
Inspeccionar, limpiar y lubricar el interior o fondo del acumulador.
Limpiar el nuevo blader o membrana a insertar.
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190
Montaje del Blader o Membrana del
Acumulador
Colocar los elementos de sellado, anillo de extrusión, junta teórica
y el anillo de apoyo.
Colocar el anillo separador y fijar la tuerca. Y verificar que el
tornillo de purga esté ajustado.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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191
Procedimientos de Mantenimiento
Sistema de Lubricación del Sello
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192
Localizar un Bloqueo en el Divisor
Realice una inspección visual del
sistema. Si no existe ninguna línea
rota, entonces
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Si se encontró bloqueo, la
válvula divisora debe ser
desmontada y limpiada.
193
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194
SISTEMA DE FRENOS
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Objetivos de Aprendizaje
Al termino de este modulo, el participante podrá:
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195
Sistema de Frenos del Molino SAG
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Sistema de Frenos
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196
Componentes del Sistema de Frenos
A) Frenos
B) Sistema Hidráulico
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197
Especificaciones Técnicas del Sistema
de Freno Molinos Bolas
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Caliper Activo
Pernos y
espaciadore
s
Pad
Pastilla
Pad
Caliper pasivo
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198
Flange del Molino donde se montan los
frenos
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Tanque
Filtro
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199
Acumuladores Frenos
Carga de
Acumuladores
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Termómetro
Análogo
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200
MÓDULO-9 SISTEMA DE
FRENOS
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Objetivos de Aprendizaje
Al termino de este modulo, el participante podrá:
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201
Sistema de Frenos
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Sistema de Frenos
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202
Sistema de Frenos
Los principales componentes del sistema de frenos son:
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Sistema de Frenos
Conjunto del sistema de frenos.
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203
Sistema de Frenos
Conjunto del sistema de frenos.
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Sistema de Frenos
Los ensambles del conjunto de frenos están instalados del lado
contrario al impulso principal del Molino.
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204
Sistema de Frenos
El freno tiene funciones principales, tales como:
Detener el molino cuando éste se encuentre en operación normal.
Prevenir la rotación del molino cuando se encuentra en reposo, a ésto
se le conoce como “freno estacionario” o “Parking Break”
Realizar un frenado suave para posicionar el molino.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Sistema de Frenos
El diagrama 80015199 Página-9 del Anexo Eléctrico muestra los
componentes principales del sistema de frenos.
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205
Componentes del Sistema de Frenos
Acumuladores
Tablero Local
Válvulas
Bombas
Freno Freno
Lado Lado
Tanque de Reserva Izquierdo Derecho
Aceite Hidráulico
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Sistema de Frenos
El sistema de frenos está diseñado para frenar de emergencia el
molino trabajando a plena carga en caso de falla en el sistema de
lubricación, falla de energía o en caso de perdida de algún
interlock de protección critico del molino.
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206
Sistema de Frenos
Los conjuntos de freno multi-pinza son un arreglo mecánico -
hidráulico de acción directa aplicado por resorte y liberación
hidráulica de la Marca Svendborg.
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Sistema de Frenos
Componentes del Sistema de Frenos.
Disco de Frenado
207
Sistema de Frenos
Los conjuntos de freno multi-pinza son un arreglo mecánico -
hidráulico de acción directa aplicado por resorte y liberación
hidráulica.
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Sistema de Frenos
Principales componentes del freno.
Conjunto Multi-Pinza
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208
Sistema de Frenos
El freno se aplica mecánicamente mediante la fuerza del resorte
colocado dentro del tornillo de ajuste.
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Sistema de Frenos
El freno aplica la fuerza de frenado o sujeción cuando la presión
del sistema hidráulico se reduce o se retira completamente de la
cámara del pistón.
Esta reducción o ausencia de presión en los pistones del freno
provocan que el resorte actué y genere movimiento del pistón
hacia el disco de frenado.
Sin Presión
Hidráulica
Freno aplicado
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209
Sistema de Frenos
Freno Liberado, con presión en el sistema Hidráulico.
Con Presión
Hidráulica
Freno Liberado
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Sistema de Frenos
Freno aplicado, sin presión en el sistema Hidráulico.
Sin Presión
Hidráulica
Freno Liberado
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210
Sistema de Frenos
Principio Básico de Operación del Freno:
El freno se aplica (cierra) siempre y en todo momento mediante la
fuerza de un resorte de manera mecánica.
No existe presión del sistema Hidráulico durante la aplicación del
freno.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Sistema de Frenos
Principio de Operación del Freno:
El freno se libera (abre) mediante el sistema hidráulico.
Para Liberar el freno se presurizan las líneas de los conjuntos de
frenado contrarrestando la fuerza del resorte liberando el disco de
frenado.
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211
Sistema de Frenos
Principio de Operación del Freno:
La operación del freno se controla mediante la secuencia de 4 válvulas
solenoides.
HV-11609, HV-11610, HV-11612, HV-11616
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Sistema de Frenos
Secuencia de Operación del Freno.
El freno tiene 4 funciones posibles que son controladas con la
combinación de posiciones de las 4 válvulas.
1. Freno en Posición Normal (abierto)
2. Frenado suave (abierto)
3. Frenado normal (cerrado)
4. Frenado Rápido (cerrado)
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212
Sistema de Frenos
1.- Freno Abierto para la operación normal del molino.
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Sistema de Frenos
2.- Frenado suave
Esta opción se conoce también como presión balanceada donde el
flujo de aceite hacia los pistones del freno se hace utilizando un
regulador de presión de aceite.
Esta opción está limitada a únicamente 20 segundos y se utiliza
normalmente para posicionar el molino.
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213
Sistema de Frenos
3.- Frenado Normal, bajo cualquier condición de falla todas las
válvulas deberán estar desenergizadas.
En este tipo de frenado, el aceite retorna al tanque controlando el flujo
y la presión de aceite en su regreso al tanque mediante una placa de
orificio y un regulador de presión.
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Sistema de Frenos
4.- Frenado Rápido.
En este tipo de frenado el aceite retorna al tanque sin ningún tipo de
restricción.
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214
Instrumentación Sistema de Frenos
La instrumentación del sistema de frenos se muestra en el
siguiente diagrama.
Presión
Frenos
Lado
Derecho
Presión
Diferencial
Presión
Presión Sensores
Frenos
Lado
Izquierdo
Temperatura del
Tanque
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Sistema de Frenos
La posición de los frenos es monitoreada todo el tiempo mediante
sensores de posición.
Instalados en total tenemos 24 sensores.
Dichos sensores tienen 2 funciones principales:
Detectar la posición de freno activado o desactivado
Detectar el desgaste de las pastillas del freno
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215
Sistema de Frenos
Ejemplo sensor de posición.
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Sistema de Frenos
Señales de Instrumentación del freno.
Presión del Sistema Presión Diferencial Posición del Freno
Hidráulico de Filtros
Presion Diferencial
del filtro
Válvulas Solenoides
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216
Sistema de Frenos
El diagrama hidráulico se muestra en el dibujo numero 60101752.
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Sistema de Frenos
El sistema del freno tiene un tablero que centraliza las conexiones
y realza funciones básicas de monitoreo.
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217
Sistema de Frenos
El diagrama eléctrico se muestra en el dibujo numero 69004745.
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Sistema de Frenos
El diagrama eléctrico se muestra en el dibujo numero 69004745.
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218
Sistema de Frenos del Molino
Ejemplo de conjunto del sistema de frenos del molino.
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219
Sistema de Frenos del Molino
Ejemplo de Instalacion Sistema de Frenos.
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220
Sistema de Frenos del Molino
Ejemplo del tablero de control del sistema de frenos.
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221
Sistema de Frenos del Molino
Ejemplo de conjunto de válvulas del sistema de frenos.
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222
MÓDULO-10
SISTEMA ELÉCTRICO
GENERAL DEL MOLINO
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Objetivos de Aprendizaje
Al termino de este módulo, el participante podrá:
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223
PANORAMA GENERAL DEL
PROCESO
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Diagrama de Flujo
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224
Diagrama de Flujo
El área de molinos SAG y Molinos de Bolas es el corazón de una
planta concentradora.
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225
Proceso Molino SAG
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226
Equipo Eléctrico en el área de Molinos
Protecciones del Molino SAG.
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227
Equipo Eléctrico en el área de Molinos
Tablero de Control Local
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228
Fuentes de Voltaje de los Molinos
El sistema Gearless, tiene su propia fuente de alimentación y
controles.
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229
Fuentes de Voltaje de los Molinos
Los sistemas de Instrumentación, Tablero de Control, Cajas de
Conexión también se consideran fuentes de voltaje para el molino.
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230
Fuentes de Voltaje de los Molinos
Sala de Control Central, se considera un centro de control y
monitoreo remoto del equipo.
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PRINCIPALES
COMPONENTES ELÉCTRICOS
Y DE INSTRUMENTACIÓN
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231
Introduction al tema
¿Porqué Utilizamos Instrumentación?
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Introduccion al Tema
En el área de Molinos, podemos dividir la instrumentación en dos
grupos:
Instrumentacion de Proceso
• Medición de Flujo
• Peso
• Nivel
• Densidad
• Sonido del Molino
• Potencia del Molino
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232
MEDICION DE VARIABLES CRITICAS
ALIMENTACION FRESCA
RECIRCULACION
AGUA
POTENCIA
VELOCIDAD VIBRACION
POTENCIA
A FLOTACION
CICLONES
AGUA P80
POTENCIA
PRESION DE ENTRADA
A CICLONES
FLUJO
AGUA
DENSIDAD
VELOCIDAD
NIVEL
POTENCIA
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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233
Instrumentación del Molino
La instrumentación del molino propiamente se basa en
temperaturas de los Trunnions y Pads de empuje.
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RTD’s Pads de
RTD’s Entrada
Empuje Lado
Molinos
Derecho
Lado Derecho
Grupo de RTD’s
Lado Descarga
Derecho
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234
Instrumentación del Molino
Mediciones de Temperatura en el Molino SAG.
RTD’s Lado entrada
al molino lado
Izquierdo Grupo de RTD’s
Lado Descarga
Izquierdo
RTD’s Pads de
Empuje Lado
Derecho
RTD’s Pads de
RTD’s Entrada
Empuje Lado
Molinos
Derecho
Lado Derecho
Grupo de RTD’s
Lado Descarga
Derecho
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
235
Instrumentación del Molino
En molinos de gran capacidad, Debido al tamaño de los cojinetes
Multi-Pad para incrementar el nivel de protección del equipo la
temperatura se monitorea en tres puntos diferentes en ambos
lados del molino.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
236
Instrumentación del Sistema Motriz
Las Mediciones de Temperatura en el Pad de empuje (Thrust Pad)
las mediciones estan agrupadas en arreglo de 2 RTD’s.
Temperatura Thrust Pad Lado Derecho
Temperatura Thrust Pad Lado Izquierdo
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RTD en Chumacera
Ejemplo Detalle de Instalación de Sensores
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237
Instrumentación del Molino
Ejemplo de Instalación de RTD’s
RTD en Trunnion
Ejemplo Detalle de Instalación de Sensores
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238
Instrumentación del Molino
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239
INSTRUMENTACIÓN DEL
MOLINO
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240
Sistema de Lubricacion del Molino
El sistema de lubricación acondiciona y suministra aceite de
lubricación para los cojinetes Multi-Pad de los molinos.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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241
Principales Componentes del
Sistema de Lubricación del Molino
El sistema de Lubricacion de los Molinos Consiste en 3 elementos
principales.
Acondicionamiento Circuito de
Tanque de Reserva
de Aceite, Sistema Lubricación de Alta
de Aceite
de Baja Presión. Presión
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Compartimiento de
Compartimiento
o de Reposo
Retorno
Compartimiento de
Aceite Acondicionado
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242
Tanque de Reserva de Aceite
Compartimiento de
Compartimiento de
Retorno
Aceite Acondicionado
Compartimiento de
Reposo
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243
Instrumentación en el Tanque
Detectores de Temperatura
Existen 2 elementos detectores de temperatura en el tanque, uno
monitorea la temperatura en el compartimiento de reposo y el
segundo en el compartimiento de aceite acondicionado.
Los Tags de estos instrumentos son TE-11310 y TE-11312.
Alarmas e Interlocks por temperatura del tanque deberán ser
programados en el sistema de control de acuerdo los valores
expresados en el Anexo C.
Detector de
Temperatura
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Instrumentación en el Tanque
Detectores de Temperatura de Aceite
RTD’s instalados en el Tanque. (ejemplos)
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244
Instrumentación en el Tanque
Detectores de Temperatura de Aceite
RTD’s instalados en el Tanque. (ejemplos)
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Instrumentación en el Tanque
Transmisores de Nivel
Existen 2 Transmisores de Nivel en el tanque de reserva de aceite.
Uno monitorea el nivel del compartimiento de reposo y el segundo
monitorea el nivel del compartimiento de aceite acondicionado.
Los Tags de estos instrumentos son LIT-11305 y LIT-11306.
Alarmas e Interlock por bajo Nivel de aceite deberán ser
programadas en el sistema de control de acuerdo a la tabla del
anexo C.
Transmisores
de Nivel
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245
Instrumentación en el Tanque
Detectores de Nivel de Aceite
El principio de operación del sensor de nivel es mediante presión
diferencial entre la parte alta y la parte baja del tanque.
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Calentadores
de Aceite
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246
Calentadores de Aceite
Existen un total de 4 Calentadores.
2 Calentadores se encuentran en el compartimiento de Reposo y 2
en el compartimiento de aceite acondicionado.
Compartimiento de Reposo:
0310-HXD-001
0310-HXD-002
Compartimiento de Aceite Acondicionado
0310-HXD-003
0310-HXD-004
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Calentadores de Aceite
Los calentadores están instalados en Thermowells a lo largo de la
parte inferior del tanque de aceite.
Thermowells
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247
Calentadores de Aceite
Los calentadores son operados y controlados eléctricamente
mediante los ajustes de temperaturas de un controlador TIC en el
sistema de control.
TIC-11310 Controla los 2 Calentadores del Compartimiento de Reposo
TIC-11312 Controla los 2 Calentadores del Compartimiento de Aceite
Acondicionado.
Para los valores de ajuste del controlador véase la tabla de
Alarmas e Interlocks del Anexo Eléctrico.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Calentadores de Aceite
Ejemplo Calentadores de Aceite
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248
Calentadores de Aceite
Ejemplo Calentadores de Aceite
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Calentadores de Aceite
Los calentadores son de 10 kW. Cada uno y son operados
eléctricamente desde el Centro de Control de Motores de Planta.
Son hechos de cerámica resistente a altas temperaturas.
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249
Acondicionamiento de Aceite
Sistema de Baja Presion.
El Documento 60097532 del Anexo Eléctrico muestra el diagrama
del circuito hidráulico de baja presión del molino.
Intercambiador de
Calor
Filtros de Aceite
Bombas de Baja
Presión de Aceite
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Acondicionamiento de Aceite
Sistema de Baja Presion.
Bombas de Baja Presión.
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250
Acondicionamiento de Aceite
Sistema de Baja Presion.
Las bombas son de 32kW de Capacidad cada una, se operan y
controlan desde el Centro de Control de Motores de Planta.
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Temperatura
Flujo de Agua de
Enfriamiento
Presión
Presión Diferencial de
Filtros
Flujo
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251
Instrumentación del Circuito de Baja
Presión
En los filtros se monitorea la presión diferencial entre la entrada y
la salida de cada filtro para detectar condición de filtro sucio.
El Tag de este instrumento es PDIT-11317
Las señales de Alarma e Interlocks deberán ser implementados en
el sistema de control de planta de acuerdo al Anexo Eléctrico.
Presión Diferencial
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Filtros de Aceite
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252
Instrumentación del Circuito de Baja
Presión
En el sistema de baja presión se monitorean lo siguiente:
Temperatura – Tag TE-11322
Presión – Tag PIT-11325
Flujo – Tag FIT 11324
Transmisor de
Temperatura
Transmisor de Presión
Medición de Flujo
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Lazo de Control
Sensor
De Temperatura
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253
Medición de Flujo en el Circuito de
Baja Presión
La medición de flujo se realiza mediante una placa de orificio y un
Transmisor de presión diferencial.
Placa de Orificio
Indicación de Flujo
calculado mediante
Presión Diferencial
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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254
Sistema de Lubricacion de Alta Presion
El objetivo del sistema de alta presión es crear un “levante” del
molino mediante aceite evitando el contacto entre el Trunnion y
el Pad.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
255
Diagrama Hidráulico del Sistema de
Lubricación de Alta Presión
El diagrama 60097532 Pagina 1 del Anexo Eléctrico, muestra las 3
bombas del sistema de alta presión y las líneas de conducción de aceite.
Bombas de Alta
Presión
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
256
Diagrama Hidráulico del Sistema de
Lubricación de Alta Presión
Las bombas del sistema de Alta presión son de 130kW de
Capacidad, son operadas y controladas desde el Centro de Control
de Motores de Planta.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Flujo de Aceite
Emergencia
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257
Circuito de Aceite de Alta Presion
Para lograr la distribución de aceite anteriormente mencionada, la
unidad de lubricación utiliza divisores de flujo.
Los divisores de flujo están instalados en la unidad de lubricación.
Divisores de Flujo
de Aceite
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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258
Circuito de Aceite de Alta Presion
Ejemplo de instalación de un conjunto completo de divisores de
flujo de aceite.
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259
Transmisores de Flujo de Aceite
Los transmisores de flujo de aceite están instalados en los
divisores de flujo.
El transmisor de flujo es básicamente un sensor de proximidad
que monitorea la velocidad de los engranes internos del divisor de
flujo.
Si los engranes giran, significa que el aceite está fluyendo de
manera correcta y el sensor de velocidad envía la señal de flujo
dependiendo de la velocidad de giro.
Sensor de Flujo de
Aceite
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260
Transmisor de Flujo de Aceite
Señales de Alarma e Interlock deberan ser programados en la sala
de control.
Para valores de ajuste vease la seccion de Interlocks y Alarmas.
Indicación Local
de Flujo
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261
Distribuidores de Aceite
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262
Filtros-Interruptores
Ejemplo de Instalación Filtros-Interruptor
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Filtros-Interruptores
Ejemplo de Instalación Filtros-Interruptor
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263
Transmisores de Presion
Sistema de Alta Presion
En cada una de las líneas de lubricación del sistema de alta
presión se tienen transmisores de presión.
Estos transmisores proporcionan indicación de cada una de las
líneas del Circuito de Alta Presión en el sistema de control.
Alarmas e Interlocks deberán ser implementados en el sistema de
control de acuerdo a los valores del Apéndice A.
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264
Transmisores de Presión
Sistema de Alta Presión
En cada una de las líneas de lubricación del sistema de alta
presión se tienen instalados transmisores de presión.
Estos transmisores proporcionan indicación de cada una de las
líneas del Circuito de Alta Presión en el sistema de control.
Alarmas e Interlocks deberán ser implementados en el sistema de
control de acuerdo a los valores indicados en la tabla de alarmas.
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Transmisores de Presión
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265
Instrumentación del Circuito de Alta
Presión
Filtro-Presión Diferencial
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266
Instrumentación del sistema de
Lubricación de Emergencia
El circuito Hidráulico de emergencia se muestra en el diagrama
60097532 página 2 del Anexo Eléctrico.
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Acumuladores de Aceite
(Precargados con Nitrógeno)
Nitrógeno
Bombas de Carga
de Acumuladores
Aceite
267
Instrumentación Sistema de
Lubricación de Emergencia
La instrumentación del circuito esta mostrada en el diagrama
69004522 pagina 2 del Anexo Eléctrico.
Transmisores de Presión
En Acumuladores de Nitrógeno
Solenoide de Descarga
Presión de Descarga
Presión Diferencial
De Filtros
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268
Temperatura de Aceite Sistema de
Baja Presión
Ejemplo de instalación de transmisores de presión.
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269
Temperatura de Aceite Sistema de
Baja Presión
Ejemplo de instalación de transmisores de presión para el control
de recarga de aceite.
Los valores de ajuste de este transmisor se encuentran en el
Anexo-C
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270
Temperatura de Aceite Sistema de
Baja Presión
Ejemplo de instalación del transmisor de presión diferencial.
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271
Sistema de Lubricación de Emergencia
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272
Panel de Control Local del Sistema de
Lubricacion
El sistema de lubricación del Molino cuenta con un panel local de
control.
Este Panel de Control provee de indicación local del estatus del
sistema, alarmas, indicación de equipo en operación y fuera.
El Panel de Control cuenta con botones de arranque y paro de las
bombas de lubricación.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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273
RANGO DE CALIBRACIÓN
DE INSTRUMENTOS
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Introducción al tema
¿Porqué Utilizamos Instrumentación?
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274
Introduccion al Tema
En el Molino de Bolas, podemos dividir la instrumentacion en dos
grupos:
Instrumentacion de Proceso
• Medición de Flujo
• Peso
• Nivel
• Densidad
• Sonido del Molino
• Potencia del Molino
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Rango de Calibración de
Instrumentos
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275
Introducción al Tema
Todos los instrumentos independientemente de la complejidad y
de su aplicación tendrán los siguientes componentes.
Ejemplo de Medición de Temperatura.
Transmisor
Sensor
Normalmente en
contacto fisico con
el proceso a medir.
Proceso A Ser
medido.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Introducción al Tema
Ejemplo de Instrumentación.
Transmisor
Sensor
Normalmente en
Contacto fisico con
el proceso.
Proceso A ser
medido
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276
Introducción al Tema
Toda la instrumentación para su aplicación tiene que ser ajustada
de acuerdo al Rango especifico requerido por el proceso.
Ver Anexo-D Lista de Instrumentos.
Rango y
Transmisor Convertidor de
4-20 mA.
Sensor Sensor
Normalmente en Tiene que ser
Contacto fisico con adecuado para la
el proceso. aplicación especifica
Proceso
Proceso A ser Instrumento
medido adecuado para el
proceso a medir.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Introducción al Tema
Toda la instrumentación debe tener una identificación especifica
llamado Tag del Instrumento.
Esto hace único a cada instrumento, único en su aplicación,
localización y de igual forma bajo ese Tag se encontrara en la
documentación de referencia para verificar rango, tipo de
instrumento, ajuste, alarmas y corte respectivo si así fuera el
caso.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
277
Introducción al Tema
Toda la información referente a Tag de Instrumentos, ajustes,
calibraciones y protecciones están definidas en los siguientes
documentos:
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Introducción al Tema
Información que nos proporcional el documento Lista de
Instrumentos y Señales.
•Numero de •Tipo de sensor •Identificación única •Área funcional,
Diagrama PID •Tipo de señal del instrumento Molino-A,B, etc
donde se encuentra
el instrumento
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278
Introducción al Tema
Información que nos proporcional el documento Lista de
Instrumentos y Señales.
•Grados oC •Define el umbral en •Si la señal esta
•Presión kPa. el que el instrumento ligada a una alarma
•Distancia mm. va a trabajar. o protección, aquí se
•0 a 100oC. define ese valor.
Unidades de Rango
Ajuste
Ingeniería Instrumento
Tipo de Señal
Modelo del
para el Sistema Fabricante
Instrumento
de Control
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Temperatura de
Trunnions del Molino
Tag de Instrumentos:
TE-1104, A,B,C
Unidades: Grados
Centígrados oC
Rango: 0 – 100 oC
Alarma H: 50 oC
Alarma HH: 55 oC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
279
Rango de Instrumentos Molinos
Mediciones de temperatura en Trunnion Molino SAG lado Salida.
Temperatura de
Trunnions del Molino
Tag de Instrumentos:
TE-1105, A,B,C
Unidades: Grados
Centígrados oC
Rango: 0 – 100 oC
Alarma H: 50 oC
Alarma HH: 55 oC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Temperatura de Pads
de Empuje del Molino
Tag de Instrumentos:
TE-1103, A y B.
Unidades: Grados
Centígrados oC
Rango: 0 – 100 oC
Alarma H: 55 oC
Alarma HH: 60 oC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
280
Rango de Instrumentos Molinos
Medición de Temperatura Trunnion Molino de Bolas.
Temperatura de
Trunnions del Molino
Tag de Instrumentos:
TE-1104, A,B,C
Unidades: Grados
Centígrados oC
Rango: 0 – 100 oC
Alarma H: 50 oC
Alarma HH: 55 oC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Temperatura de Pads
de Empuje del Molino
Tag de Instrumentos:
TE-1103, A y B.
Unidades: Grados
Centígrados oC
Rango: 0 – 100 oC
Alarma H: 55 oC
Alarma HH: 60 oC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
281
Rango de Instrumentos Unidad de
Lubricación
FLSmidth determina las condiciones de diseño de dichas unidades
de lubricación y en conjunto con Howard Marten Co. se especifica
el tipo y capacidad de la unidad de lubricación.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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282
Rango de Instrumentos Unidad de
Lubricación
Sistema de Baja Presión.
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283
Rango de Instrumentos Unidad de
Lubricación
Sistema de Lubricación de Emergencia.
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284
Rango de Instrumentos Unidad de
Lubricación
Ejemplos:
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285
Rangos de Calibración Sistema Baja
Presión
Circuito de Baja Presión
Temperatura TE-11322
Unidades: 0C
Rango: 0 – 1000C
Alarma H: 32 0C
Alarma HH: 41 0C
Presión PIT-11325
Presión Diferencial de
Filtros PDT-11317 Unidades: Kpa o PSI
Rango: 0 – 100 kPA
Unidades: Kpa o PSI Alarma L: 69kPA
Rango: 0 – 500 kPA
Alarma H: 175 kPA
Alarma HH: 310 kPa
Flujo FIT-11324
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
286
Rangos de Calibración Instrumentos
Sistema de Lubricación de Alta Presión
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Flujo de Aceite
Pads Empuje FIT-11544
Unidades LPM
Rango: 0-100 LPM
Alarma L: 83 LPM
Alarma LL: 72 LPM
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287
Rangos de Calibración Instrumentos
Sistema de Lubricación de Alta Presión
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288
Rangos de Calibración Instrumentos
Sistema de Lubricación Emergencia
Transmisores de Presión
En Acumuladores de Nitrógeno
PIT-12405
Presión Diferencial
De Filtros
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INTERLOCK Y ALARMAS
SISTEMA DE
LUBRICACION
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289
Definicion de Interlock
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Definición de Interlock
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290
Interlocks
Tipos de Interlocks
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Interlocks
Tipos de Interlocks
291
Valores de Ajustes de Interlocks
Para cada proyecto FLSmidth entrega un documento llamado
descripción funcional.
En el caso del Proyecto Las Bambas existen 4 documentos
diferentes para los molinos de Bolas y Molinos SAG.
EL contenido de los documentos es idéntico, únicamente cambian
los números de Tags de los Instrumentos y los números de
equipos.
80023554 Molino de Bolas-A
80023555 Molino de Bolas-B
80024451 Molino SAG-A.
80024452 Molino SAG-B
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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292
Set Points de Instrumentación
La segunda parte del documento es el listado de toda la
instrumentación del molino identificado con numero de Tag,
unidades de ingeniería utilizadas, set points y la indicación de si
es Alarma, Interlock o Ambas.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Interlocks
Los interlocks del Molino están listados en la sección H: del
documento de descripción funcional.
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293
Interlocks
Ejemplos
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Interlocks Críticos
Ejemplos
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294
Simbolos de Interlocks
Todos los Interlocks están mostrados en los diagramas de Control
e Instrumentación.
En nuestro caso, Proyecto Las Bambas los interlocks deberán ser
programados en el sistema de control
En los diagramas de Control e Instrumentación, los interlocks
estarán identificados con los siguientes símbolos.
I Interlock Cableado
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Alarma de Presión
Diferencial Filtros
Alarma de Nivel
De Aceite
Alarma de Temperatura
De Aceite
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295
PID Distribución Aceite de Alta Presión
(ejemplo)
Presión de Aceite
Presión Diferencial
Flujo
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Alarma de Presion de
descarga
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296
PID Sistema de Frenos
(ejemplo)
Presión de Acumuladores
Sensores
Nivel de Aceite
Sensores
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297
PID Molino SAG (ejemplo)
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298
Documentación Eléctrica PID
PID FLS Standard
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299
Documentación Eléctrica PID
PID FLS Standard
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300
Documentación Eléctrica PID
PID FLS Standard
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Documentación Eléctrica
Descripción Funcional
Descripción Funcional es un documento creado para explicar el
funcionamiento de los equipos.
Este documento describe con detalle todos los componentes del
sistema del molino y su función dentro del sistema.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
301
Documentación Eléctrica
Descripción Funcional
Ejemplo de Descripción Funcional.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
PARÁMETROS DE
OPERACIÓN DEL SISTEMA
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302
Parámetros de Operación del Sistema
Los parámetros de operación del sistema son entendibles
analizando los valores de alarmas baja, alta de nuestras variables.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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303
Parámetros de Operación del Sistema
Ejemplo del sistema de control Unidad de Lubricación
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304
Parámetros de Operación del Sistema
Ejemplo: Indicaciones de Presión del sistema de Lubricación del
molino.
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
305
Parámetros de Operación del Sistema
Ejemplo: Indicaciones de Presión del sistema de Lubricación del
molino.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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306
DETECCIÓN DE FALLAS
ANÁLISIS DE ALARMAS
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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307
Detección de Fallas y Alarmas
Sin una correcta asignación de rangos de instrumentos y ajustes
las protecciones, interlocks e indicaciones de variables de proceso
serán erróneas.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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308
Detección de Fallas y Alarmas
Ajustes de Alarmas y Puntos de corte.
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309
Detección de Fallas y Alarmas
Ejemplo de una señal fuera de rango.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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310
Ejemplo de un Interlock
Que necesitamos para ver una señal en pantallas del sistema de
control?
Cableado
Conexiones Sistema de
de Equipos
al PLC Control
de Campo
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Ejemplo de un Interlock
Diagramas
Equipo de de Software: Software: Software:
Equipo de
Campo: Alambrado:
Campo: Base de Datos Aplicación del Pantallas del
Cuarto
Señales del Cajas de del Sistema de Sistema de Sistema de
Eléctrico,
Molino Conexión Control Control Control
Subestación,
PLC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
311
Ejemplo de un Interlock
Diagramas de
Equipo de Alambrado: Software: Software: Software:
Campo: Cuartos Base de Datos Aplicacion del Pantallas del
Señales del Electricos, del Sistema de Sistema de Sistema de
Molino Subestacion, Control Control Control
PLC
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
312
Ejemplo de Falla de Interlock
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313
Ejemplo de Falla de Interlock
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314
Ejemplo de Falla de Interlock
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
315
Ejemplo de Falla de Interlock
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PREGUNTAS?
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316
MANTENIMIENTO
PREVENTIVO DE LOS
MOLINOS
Objetivos de Aprendizaje
Al finalizar este módulo el participante podrá:
317
Mantenimiento Preventivo
El propósito del mantenimiento preventivo es el poder “medir” la
condición de el equipo para decidir si el equipo va a fallar en el
futuro y poder tomar decisiones para evitar una falla y las
consecuencias de esta.
Mantenimiento Preventivo
1. Monitoreo del Desgaste
318
MONITOREO DE
DESGASTE
319
La Importancia del Monitoreo de
Desgaste en el Molino.
320
Componentes Internos Molino SAG
Anillo de Levantamiento
Barras elevadoras
de Pulpa
Cono de Descarga
Revestimientos
Revestimientos
321
Tendencia de Desgaste de los
Revestimientos
Inspección aleatoria y
también en un revestimiento
en especial para crear las
tendencias.
S. Banisi, M.
Hadizadeh
322
Medición del Desgaste de los
Revestimientos
Monitorear el perfil de
elevación:
h0
Cuando la altura es menor
que el 50% de la original, es
el momento de cambiar los
revestimientos.
323
Ejemplo de Monitoreo de Desgaste en
los Revestimientos
Límite Operacional
324
Revestimientos de las Tapas
Cuando el espesor es
inferior al 50% del original,
es el momento de cambiar
los revestimientos.
MUESTREO Y ANÁLISIS DE
ACEITE
325
Actividad
Discusión en grupos
10-20 minutos
Importancia de la Lubricación
La Lubricación es una parte importante de la vida operacional de
cualquier molino.
326
Muestreo de Aceite y Lubricación
El aceite puede llegar a ser contaminado por desgaste de los
componentes o partículas de polvo como:
327
Contaminación del Aceite
Las partículas de desgaste:
Fierro (Fe)
Cobre (Cu)
Plomo (Pb)
Estaño (Sn)
Cromo (Cr)
Níquel (Ni)
Metales de Desgaste
• Partículas de desgaste ferroso típicamente
Hierro vienen de las bombas, engranajes, cilindros
o corrosión.
328
Metales de Desgaste
329
Contaminación con Agua
Oxidación
La velocidad de oxidación se duplica por cada 20 º C por encima
de 130 º C
330
Oxidación
Aceite Aceite
Nuevo Oxidado
El aceite se vuelve más oscuro, ya que se oxida. Comparar la muestra
de aceite con una muestra aceite nuevo del mismo grado y marca.
Oxidación
Aceite Aceite
Nuevo Oxidado
331
Tamaño de las Partículas
Contaminantes
El tamaño de
partícula contaminante se
mide en micras. Un micrón es
definido como una
millonésima de un metro,
o 0.000039 pulgadas. La
partícula visible más
pequeña a simple vista es de
40 micras.
31
332
ISO 4406 Código de Contaminación
2 ȝP 5 ȝP 15 ȝP
20/18/16
33
10 5-10
11 10-20
12 20-40
13 40-80
14 80-160
15 160-320
16 320-640
17 640-1300
18 1300-2500
19 2500-5000
20 5000-10,000
21 10,000-20,000
22 20,000-40,000
23 40,000-80,000
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333
Ejemplo ISO 4406
20/18/16
5000 a 1300 a 2500 320 a 640
10,000 partículas partículas
partículas mas grandes mas grandes
mas grandes que 5 micras que 15 micras
que 2 micras
5 ȝm 15 ȝm
18/16
Fluid Conditioning36
334
Sistema Nuevo Antes del Arranque
23/22/20
Sistemas nuevos normalmente no están lo suficientemente limpios para
poner en funcionamiento sin una limpieza amplia.
© 2015 FLSmidth A/S. All Rights Reserved.
37
22/20/18
El aceite nuevo no se filtra en la refinería y no es lo
suficientemente limpio para un sistema hidráulico. Debe ser
filtrado en el sitio antes de ponerlo en el estanque.
© 2015 FLSmidth A/S. All Rights Reserved.
38 Fluid
335
Sistema de Filtrado Típico
20/18/16
La mayoría de los fabricantes de componentes especifican
recuento de partículas de no más grande que lo mostrado.
© 2015 FLSmidth A/S. All Rights Reserved.
39 Fluid
ǃ
14/13/11
La tendencia es que el fluido este más limpio y más limpio. Con el
diseño y el uso adecuado de los filtros de alta eficiencia, la duración
de los componentes se puede ampliar de manera significativa.
© 2015 FLSmidth A/S. All Rights Reserved.
336
Comparación en el Nivel de Limpieza
23/22/20 22/20/18
20/18/16 14/13/11
© 2015 FLSmidth A/S. All Rights Reserved.
42
337
Códigos ISO Sugeridos
Maquinaria Código ISO
Target
Reductores 18/16/13
Fuentes de Contaminación
Contaminantes Incorporados (sistemas nuevos)
338
Muestreo de Aceite
Seguir la tendencia de las partículas contaminantes ayudará a
determinar en las etapas iniciales cualquier problema en los
componentes de las máquinas, por ejemplo: Desgastes en los
bujes, etc.
© 2015 FLSmidth
Smidth A/S
A/S. All Rights Reserved
Reserved.
Ejemplo
Muestreo de Aceite
Ejemplo
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339
Muestreo de Aceite
En caso de encontrar anomalías en las muestras, es importante
tomar una nueva muestra para confirmar y reducir la frecuencia a
la mitad para dar un seguimiento más detallado.
340
Como tomar una muestra de aceite
El sistema debe de estar en operación
3 ) Ajuste la bomba o
dispositivo y ajústela al frasco a
través de la bolsa, hasta llegar
a perforarla
© 2015 FLSmidth A/S. All Rights Reserved.
341
Toma de la muestra en Campo
1) Verificar el nivel de aceite
en el recipiente o tanque
antes de proceder a purgar
el circuito.
Estanque:
Condición general del aceite.
Condición histórica del aceite
Línea de Retorno:
Condición de la maquina en ese
momento
Línea de Drenado:
No da una muestra representativa,
puede permitir que se este
analizando todo el lodo que se
forma en la parte baja del estanque.
No recomendada.
342
Tipos de Puntos de Muestreo
Se pueden tener varios
puntos de muestreo como
ayuda durante búsqueda de
problemas.
Punto Primario
Punto Secundario
Sistema de Freno
Unidad de Lubricación
Línea de Retorno
de los Pads
de los Cojinetes
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343
Sistema de Lubricación de los Pads
Ejemplo de zonas en el
Tanque donde se
pueden tomar
muestras de Aceite
Línea de Retorno
de los Cojinetes
2 puntos
Punto Primario
Compartimiento
Compartimiento
de Retorno
de Reposo Punto Secundario
© 2015 FLSmidth A/S. All Rights Reserved.
RUTINAS DE MANTENIMIENTO
PREVENTIVO EN EL MOLINO
344
Actividad
Discusión en grupo:
A) Diariamente
B) Semanalmente
C) Durante Paros mayores
10-15 minutos
Mensajes de Seguridad
Herramientas
Procedimientos
Peso del Equipo, etc.
345
Inspecciones cuando el Equipo esta
Operando
0LUH(VFXFKH
+XHOD6LHQWD
346
Inspecciones
Es necesario marcar los rangos de operación en las carátulas de
presión y temperatura, las mirillas de aceite, así como asignar
indicativos de tipo de aceites a utilizar, etc.
Sellos Sellos
Desgaste
Pernos Sueltos o
Flojos
Lubricación
•Calidad
•Flujo
•Distribución
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15 FLSmidth A/S
A/S. All Rights Reserved
Reserved.
347
Inspecciones Internas
Condición de los
Revestimientos
Componentes de la
Descarga
Componentes
de la
Alimentación
Cartillas de Inspección
348
Inspecciones Mecánicas D M 6M
R D D
Conjunto del Molino
ł ł ł
D= Diario
Sistema de Lubricación de los Sellos
ł ł ł W= Semanal
M=Mensual
Cojinetes Lado de Alimentación y
Descarga ł ł R= En Operación
D= Fuera de Servicio
Sistema de Lubricación
ł ł ł PM = Mantenimiento
Preventivo
Trommel
ł
Sistema de Freno
ł ł
Sistema de Lubricación de los
Sellos
6
D M M
Conjunto del Molino
6
D M M
Chutes de Alimentación
No hay sonidos extraños
No hay fugas
Superficies externas
Verifique el exterior de los cabezales en busca de signos de fugas
desde los sellos de los pernos del revestimiento.
349
Conjunto del Molino
Pernos /
Tornillería
Fugas de
Material
Temperaturas
Verifique las temperaturas del RTD provenientes del DCS.
Todas las lecturas nominalmente deben ser de 45°C (113°F) y
encontrarse dentro de 5°C (10°F) entre sí
350
Inspecciones Diarias en Operacion
Cojinetes Principales (Empuje)
Flujo de aceite y empuje
Verifique y registre el flujo de aceite de empuje hidraulico en cada una
de las almohadillas.
Con el molino en funcionamiento, las presiones de las almohadillas
deben encontrarse dentro de ±10 por ciento de la presión promedio.
Temperaturas
Verifique las temperaturas del RTD provenientes del DCS.
Todas las lecturas nominalmente deben ser de 45°C (113°F) y
encontrarse dentro de 5°C (10°F) entre sí
351
Inspecciones Diarias– Molino en
Operación
Sistema de Lubricación
Sistema y Frenos
Hidráulico de Levante
Circuito de Alta Presión:
Bombas de Alta Presion
Caudal del Distribuidor
Condiciones Operativas
Presion y flujo del sistema de
alta presion
352
Inspecciones Diarias – Molino en
Operación
Sistema de Freno
Sistema Hidráulico de Frenos
Temperatura de los discos y
calibradores
Verifique la temperatura del
disco y de los conjuntos de
calibradores utilizando un
detector térmico portátil.
Tuberías y mangueras
hidráulicas
353
Inspecciones Mensuales - Molino
Detenido
Conjunto del Molino
Trómel
Superficies del Trómel
Chute de Alimentación
Revestimientos
Sellos del Chute
354
Inspecciones Mensuales- Molino
Detenido
Cojinetes del Lado de Alimentación y Descarga
355
Inspecciones Mensuales– Molino
Detenido
Sistema de Freno
Sistema Hidráulico de Frenos
Condición del Disco
Verifique ambos lados del disco del freno en busca de agrietamiento
por calor y fisuras, y decoloración debido a un calor excesivo.
Filtros
Sujetadores de Montaje
Revise los sujetadores de montaje de la bomba y el motor para
asegurarse de que todos estén apretados, y que no esté roto ni falte
ninguno.
356
Inspecciones Semi-Anuales –Molino
Detenido
Sistema de Lubricación
Sistema de Lubricación
Drenado de Aceite
Limpieza interior y exterior del tanque de Aceite
Condición de los imanes
Enfriadores
Alineación de las Bombas de Alta presión
Acoplamiento de los accionamientos
Pernos Críticos
Conjunto del Molino
Semi-anual
357
Inspecciones Semi-anuales Molino
Detenido
Conjunto del Molino
Pernos de
la Coraza
Ejemplo
Pernos
de las
Tapas
358
Inspecciones Semi-anuales
Cojinetes de Alimentación y Descarga
Cambio de Aceite
Filtro Interno
359
Inspecciones Semi anuales – Molino
Detenido
Sistema de Freno
Funcionamiento de la bomba
¿PREGUNTAS / DUDAS?
360
MODULO-12
PRÁCTICAS y PROCEDIMIENTOS DE
MANTENIMIENTO ELÉCTRICO-
INSTRUMENTACIÓN
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Objetivos de Aprendizaje
Al termino de este modulo, el participante podrá:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
361
PRÁCTICAS DE MANTENIMIENTO
ELÉCTRICO
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
362
Mantenimiento Conceptos Básicos
Algunas de las mejores prácticas de mantenimiento son
aprendidas a lo largo de la operación y el conocimiento de los
equipos.
El mejor mantenimiento que se puede aplicar a los equipos
proviene del personal que día a día esta junto a los equipos.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Ambientales
• Contaminación (Polvo, corrosión, humedad)
• Calor
• Falta de limpieza
Operacionales
• Exceso de arranques consecutivos (Estrés
Eléctrico)
• Mantener el equipo funcionando a su límite.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
363
Mantenimiento
Una fuente confiable para definir que, cuando y como aplicar
mantenimiento proviene del vendedor para asegurar que se
aplique un mantenimiento adecuado y de acuerdo a estándares en
forma y tiempo.
Contactar a un representante de FLS para información de
mantenimiento especifico y reemplazo de partes.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
La implementación de un sistema computarizado, software de
mantenimiento es altamente recomendada.
Coordinación de Recursos, Materiales y la programación de tiempos de
mantenimiento son realizadas en el sistema.
Rutinas de Mantenimiento previenen fallas y paradas de producción
inesperadas.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
364
Mantenimiento
Los manuales IOM de FLS contienen toda la información del
equipo principal y de todos los componentes que formen parte del
suministro.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
Los manuales IOM de FLS contienen toda la información del
equipo principal y de todos los componentes que formen parte del
suministro.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
365
Mantenimiento en la Unidad Hidráulica
Toda la instrumentación y equipo eléctrico de la unidad esta
cableada a través de la Caja de Conexiones montada en la propia
unidad, es importante mantener esta caja cerrada todo el tiempo.
Checar el estado del sello de goma de las cajas de conexiones
cada 6 meses.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
366
Mantenimiento en la Unidad Hidráulica
Mantener siempre la caja cerrada para evitar el ingreso de polvo.
Revisar el estado del sello de goma cada 6 meses.
Sello de Goma
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
367
Mantenimiento en la Unidad Hidráulica
Los motores y bombas instalados en la unidad hidráulica al operar
transmiten vibración a todos los dispositivos instalados en la
unidad.
Para contrarrestar los efectos de esta vibración es recomendable:
Reapretar conexiones cada 6 meses.
Verificar la fijación y estado físico de los instrumentos.
Verificar la fijación y estado físico de Motores.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Resistencias Calefactoras
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368
Mantenimiento CCM y Cargas
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
369
Administración de Mantenimiento
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Administración de Mantenimiento
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370
Administración de Mantención
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
371
Mantenimiento a Motores Eléctricos
La Termografía es una excelente práctica de Mantenimiento.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
372
Mantenimiento Mayor
Retirar el equipo eléctrico delicado e instrumentos antes de un
mantenimiento mayor, esto ayudara a evitar que el equipo sea
dañado durante maniobras de piezas mayores o por personal de
mantenimiento externo no familiarizado con el área y equipos.
Si el retirar instrumentos no es una opción viable, se recomienda
protegerlos adecuadamente.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento a Motores
Limpieza al intercambiador de calor cada 15 a 30 días.
Inspección visual de dispositivos de protección del motor como
sensores de vibración, RTD’s cada turno.
Análisis de Vibraciones a rodamientos cada 45 a 60 días.
Medición física de temperatura cada mes.
Termografia Dispositivos
De
protección
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
373
Mantenimiento a Motores
Inspección de sistema de auto ventilación del motor cada mes.
Mantenerse alerta por cualquier ruido, vibración o golpes
anormales en el motor durante la operación.
Sistema de
autoventilacion
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
374
Mantenimiento a Instrumentación
Las mejores prácticas de Mantenimiento a Instrumentación:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento a Instrumentación
La instrumentación siempre esta definida de acuerdo a las
variables utilizadas en cada proceso.
Buscar siempre la fuente mas confiable para el ajuste de
instrumentos, proceso, fabricante, etc esto implica.
Rango del Instrumento
Ajustes de Alarmas, Alta, Baja, Baja-Baja, Alta-Alta.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
375
Mantenimiento a Instrumentación
Las mejores prácticas de Mantenimiento e Instrumentación:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento a Instrumentación
Las mejores prácticas de Mantenimiento a Instrumentación:
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
376
Mantenimiento a Instrumentación
Las mejores prácticas de Mantenimiento a Instrumentación:
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MANTENIMIENTO
PREVENTIVO Y CHEQUEOS
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Mantenimiento
Un adecuado análisis de numero de piezas de stock siempre es
recomendable.
Sacar ventaja de que son 4 unidades de lubricación idénticas por
cada molino, eso optimiza nuestras refacciones y partes de
repuesto.
No es posible tener una pieza de repuesto de cada equipo pero si
se puede optimizar el numero.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
Sacar ventaja de equipo común de los 4 molinos, equipos, marcas
instrumentos pueden ser optimizables en buena forma.
No es posible tener una pieza de repuesto de cada equipo pero si
se puede optimizar el numero.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
378
Mantenimiento
Un adecuado análisis de numero de piezas de stock siempre es
recomendable.
Sacar ventaja de que son 4 unidades de lubricación idénticas por
cada molino, eso optimiza nuestras refacciones.
No es posible tener una pieza de repuesto de cada equipo pero si
se puede optimizar el numero.
Contratos de Mantenimiento con principales proveedores siempre
trae ventajas en cuanto a las tareas de mantenimiento y
refacciones.
Electrónica de Potencia falla impredecible.
Contrato de calibración de instrumentos con una compañía
externa especializada es muy recomendable.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
Calibración de Instrumento
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Mantenimiento
Instrumento Calibrado
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Mantenimiento
Saber como funciona, como fue instalado, como fue probado nos
da una gran ventaja para la ejecución de mantenimiento.
Entrenamiento es siempre importante.
Identificar partes de repuesto en manuales IOM de FLS.
Termografía ampliamente recomendada
Seguir las recomendaciones del vendedor en cuanto a frecuencia
de mantenimientos y reemplazo
Implementar Horómetros y planear mantenimiento en función de
Horas de operación.
Las mejores inspecciones para disparar mantenimiento provienen
del personal de campo, ellos viven sienten y saben cuando una
maquina requiere revisión
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
380
Mantenimiento
Planear Mantenimiento a Mediano y Largo Plazo, para equipos
principales, Mantenimiento mayor cada 6,12 o hasta 18 meses.
Buscar tecnologías de “Libre Mantenimiento”
Las redes de dispositivos Inteligentes como CCM’s e
Instrumentación aportan grandes beneficios a la ejecución de
mantenimiento
Las redes de dispositivos Inteligentes para CCM’s aportan mucha
información para detectar fallas.
Chequeo y Doblechequeo de señales de Entradas y Salidas es
ampliamente recomendado.
Prueba física y real de Interlocks es siempre recomendable
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
Un adecuado análisis de numero de piezas de stock siempre es
recomendable.
No es posible tener una pieza de repuesto de cada equipo.
Siempre el tener equipos comunes optimiza el numero de piezas
de cambio.
Analizar la posibilidad de tener piezas de repuesto en stock
regional.
Contratos de Mantenimiento con principales proveedores siempre
trae ventajas en cuanto a las tareas de mantenimiento y
refacciones.
Electrónica de Potencia falla impredecible.
Solicitar a Proveedor Sistemas Electrónicos de autocompensación
para minimizar paros de equipos.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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Causas comunes de falla en equipo
eléctrico
Nuestros Check Ups y Rutinas de mantenimiento deberán incluir
siempre actividades que detecten y corrijan fallas de estos tipos:
Medio Ambiente
Vibración
Contaminación (Polvo, corrosión, humedad)
Calor
Falta de limpieza
Operacional
Exceso de arranques consecutivos (Estrés Eléctrico)
Mantener equipo corriendo a su limite de disparo.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento
Una fuente confiable para definir que, cuando, como y donde se
debe hacer mantenimiento proviene del vendedor para asegurar
que se aplique un mantenimiento adecuado y a tiempo.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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Mantenimiento Motor Principal
Termografia Dispositivos
De protección
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
383
Mantenimiento Motor Principal
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
384
Mantenimiento Eléctrico
Exceso de lubricante
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
385
Mantenimiento a la Unidad Hidráulica
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
386
Mantenimiento CCM y Cargas
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© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
387
Mantenimiento Subsistema de Control
Reapriete de Conexiones
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Subsistema de Control
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388
Mantenimiento CCM y Cargas
Los calentadores de aceite son controlados con un controlador de
temperatura.
Cuando la temperatura del aceite alcanza la temperatura deseada
los calentadores deben parar. Asegurarse de que los calentadores
se desconecten.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Administración de Mantenimiento
El mejor control que podemos tener para ejecutar mantenimiento
es contando las horas de operación del equipo.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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Administración de Mantenimiento
Aplicando este sencillo método de conteo de horas en el CCM el
sistema computarizado de administración de mantención puede
generar ordenes de trabajo en función de horas de operación.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Motores Eléctricos
Las mejores practicas de Mantenimiento eléctrico a motores
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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Motores Eléctricos
Termografía es una excelente practica de Mantenimiento
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Motores Eléctricos
Las mejores practicas de Mantenimiento eléctrico a motores
Ajuste correcto de protecciones por sobre corriente instantánea
(Termo magnético)
Ajuste correcto de protección por sobre corriente sostenida (Térmico)
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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Mantenimiento a Motores
Las mejores practicas de Mantenimiento eléctrico a motores
Mantener Motor libre de polvo para permitir un intercambio de
calor adecuado en el motor.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento Instrumentación
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392
Mantenimiento Instrumentación
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mantenimiento Instrumentación
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
393
Mantenimiento Eléctrico-
Instrumentación
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Mantenimiento Eléctrico-
Instrumentación
Fuga
Funciona??
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
394
Mantenimiento Eléctrico-
Instrumentación
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
© 2015 FLSmidth A/S. All Rights Reserved. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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