Roll Grinder

PURPOSE

• 1.1 To define the standard operating practice for grinding smooth and textured rolls on the roll grinder. Roll grinders are high-precision machines used in steel, aluminium and paper mills to grind rolls to very tight tolerances.

SCOPE

• 2.1 This SOP applies to Production Department.

REFERENCE(S) & ATTACHMENTS

• 3.1 References

  • 3.1.1 In-house

• 3.2 Attachments

  • 3.2.1 Attachments: Production Logbook : SIPL/PDI/005/F01/00

RESPONSIBILITY

• 4.1 Production Department Person

  • 4.1.1 To prepare the SOP.

• 4.2 Production Head

  • 4.2.1 To ensure the training of the SOP to all concerned personnel involved in implementation of the SOP.

  • 4.2.2 To ensure the implementation of the SOP after training.

• 4.3 Quality Assurance Person

  • 4.3.1 To check the SOP and to maintain the original copy of the SOP.

  • 4.3.2 To issue the controlled copy of the SOP and maintain its issuance record. To retrieve the controlled copy of the SOP when it is superseded/obsolete and maintain its record.

• 4.4 QA Head / Plant Head

  • 4.4.1 To approve new or revised SOP.

  • 4.4.2 To ensure the implementation of the defined system.

DISTRIBUTION

• 5.1 Production

DEFINITION(S) & ABBREVIATION(S)

• 6.1 Definitions

  • 6.1.1 Nil

• 6.2 Abbreviations

  • 6.2.1 Nil

PROCEDURE

• 7.1 Standard Operating Practices

  • 7.1.1 Make sure the grinding water is not contaminated.

  • 7.1.2 Make sure the edge-holding lubrication module has a minimum 80% oil level.

  • 7.1.3 Make sure the grinding wheel is properly balanced (with the OEM balancing blocks).

  • 7.1.4 Do a free spin of the wheel on the wheel holder before proceeding with grinding (free spin should be in the range of 100-150 rpm).

  • 7.1.5 The rolls should be properly cooled from the core. Minimum cooling time for the roll: Winter — 24-30 hrs; Summer — 36-48 hrs. Attach the head stock module to the roll and make sure the bolts are properly tightened with the correct torque.

  • 7.1.6 Put the roll on the machine (maintain safety and use proper gear).

  • 7.1.7 Check the before-grinding roll Hardness, Roughness average value, and Camber profile value; record them in the designated place.

  • 7.1.8 Cross-check the given plan GRIT requirement against the attached wheel GRIT size.

  • 7.1.9 Input the data on the UI of the operating panel.

  • 7.1.10 Cross-check the plan and the operating data inputs.

  • 7.1.11 Start the grinding process.

  • 7.1.12 Check that the edge-holding lubrication is working properly.

  • 7.1.13 Make sure the wheel sludge does not choke the drain water tank input.

  • 7.1.14 Change the filter paper after every 06 nos. of work roll and 02 nos. of backup roll grinding.

  • 7.1.15 During the rough cutting process, wipe the roll with the wiper (no bare hands).

  • 7.1.16 No bare-hand contact with the roll surface during grinding.

  • 7.1.17 After grinding, check the Hardness, Roughness average, and Camber profile value and record them in the designated place.

  • 7.1.18 Clean with the wiper; no moisture content should be present on the roll.

  • 7.1.19 Cover the roll with poly film and oil; no foreign particles should be present on the roll during the covering process.

  • 7.1.20 Take down the roll and place it in the finish roll rack.

  • 7.1.21 Remove the head stock module from the roll.

• 7.2 Process Table

----------------------------------------------------------------------- PROCESS TABLE WORK ROLL BACKUP ROLL ----------------------------- -------------------- -------------------- Diameter Max. 230 mm 550 mm

Diameter Min. 210 mm 530 mm

Barrel length 1250 mm 1200 mm

Hardness 100° Shore C 72° Shore C (Approx) (Approx)

Roughness 0.008 - 0.23 µm 0.70 - 0.80 µm

Grinding Time 145 min's 180 min's

Loading / Unloading time 25-30 min's 40-45 min's

Shape 0.01 - 0.10 mm on 0.01 - 0.10 mm on dia. dia. -----------------------------------------------------------------------

• 7.3 Safety Concern

  • 7.3.1 Wear gloves, goggles, helmet and safety shoes.

REVISION HISTORY

+----------------+----------------+----------------+----------------+----------------+----------------+ | Revision No. | 00 | Effective | | CC No. | | | | | Date | | | | +----------------+----------------+----------------+----------------+----------------+----------------+ | Details of revision: New SOP | +-----------------------------------------------------------------------------------------------------+