Assembly instructions

Intermediate Diaphragm

© by Christian Pfeiffer Intermediate diaphragm

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 Copyright 

CHRISTIAN PFEIFFER MASCHINENFABRIK GmbH

A-8940 Liezen, Austria/A-8940

Copyright , incl. component parts.

All rights, incl. those of the translation reserved. This
document must neither be revised, duplicated nor disclosed
to third parties in any way, whatsoever, neither in part nor in
total nor by using electronic systems, without CPB’s prior
written approval./

ADDRESS
CHRISTIAN PFEIFFER MASCHINENFABRIK GmbH
Werkstrasse 5
A-8940 Liezen, Austria/A-8940

Tel. ++43 (0) 3612 / 270 - 215

Telefax ++43 (0) 3612 / 270 - 589

© by Christian Pfeiffer Intermediate diaphragm

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Content

1. Safety instructions

1.1 The 10 comandements of security

1.2 Additional safety instructions
1.3 Specific safety instructions

2. Technical description of the intermediate diaphragm

3. Assembly of the intermediate diaphragm

3.1 General
3.2 Assembly operation
3.3 Assembly of tear off bolts
3.4 General guidelines for assembly welding

4. Assembly tools

5. Assembly staff

5.1 Preconditions for respect of the assembly duration

5.2 Working method
5.3 Assembly duration

6. Spare parts

© by Christian Pfeiffer Intermediate diaphragm

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1. Safety instructions

1.1 The ten commandments of safety

1. Please support all efforts for a safe and healthy working environment.

2. Always act conscientious and with great attention when your personal and others safety is concerned.

3. Check regularly all safety equipments and the complete tools with regard to completeness, safe
function and handling.

4. Inform yourselves and others about risks which are related to your work in order to avoid efficiently
any risk.

5. In order to avoid any injuries to persons and to machines, inform yourselves about risks and safety
matters if you have the feeling that your knowledge is not sufficient.

6. Always bear in mind risk of injuries and accidents before starting a new job. Develop reasoned safety
measures in order to protect yourselves and others. Check these security measures regularly and
carry out necessary improvements immediately.

7. Warn others of possible risks and damage if you are about to perform risky works or generate risk of
accidents.

8. Pay attention to modifications of the work conditions and the work procedures and adapt immediately
to the new situation.

9. Accidents, risky actions and dangerous conditions and processes which have almost led to accidents
must be communicated immediately to the superintendent. Please do not assume someone else will
do this! Please do not take any narcotics, strong medicine etc, and do not dring when operating a
machine or performing maintenance works on a machine resp. prohibit any narcotic and alcohol
intake during the working time.

10. Keep your working environment clean. Tools and aids must be collected after use and stored in the
designated area.

© by Christian Pfeiffer Intermediate diaphragm

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1.2 Additional safety instructions

All emergency telephone codes must be communicated to the assembly staff and deposit near to the
phone.

In case of physical injury, attend to the injured person and call immediately a doctor or another
paramedic.

All accidents must immediately be communicated to the superintendent.

For lifting heavy charges (above 25 kg) only use certified lifting devices with corresponding charges.

When lifting charges bend knees and lift with legs.

Never stand under lifted charges and check all lifting devices before use with regard to damages and
sufficient lifting capacity.

In order to avoid injuries. always use individual safety equipment.

Never modify or remove safety and accident prevention devices and keep in operation safe condition.

Maintenance works have to performed in switched off mode and secured against unintentional
start-up of machine (block main switch).

For your safety always wear a protective headgear

Depending on the working conditions noise can be generated in the

working area which makes the wearing of an ear protection
necessary.

Depending on the working conditions, hazard by dust can make the

wearing of a protective mask necessary.

Protect your eyes with protective glasses to avoid injuries by dust

and flying particles.

© by Christian Pfeiffer Intermediate diaphragm

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1.3 Specific safety instructions

For specific operational phases and maintenance works as well as eliminating mal functions go sure
that:

- the operating personnel has been informed before beginning special operations and
maintenance works;
- the machine/plant is completely shut down for maintenance and repair work, locking the
principal control elements resp. removing the ignition key and attaching a warning sign to the
main switch;
- only suitable and technically perfect lifting gear and suspension systems with adequate lifting
capacity are used;
- for carrying out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms;
- you never use machine parts as a climbing aid;
- you always tighten any screwed connections that have been loosened during maintenance and
repair;
- any safety devices removed for set-up, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work;
- all consumables and replaced parts are disposed of safely and with minimum environmental
impact.

© by Christian Pfeiffer Intermediate diaphragm

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2. Technical description of intermediate diaphragm

The high quality requirements on product as well as on the mill internal equipment have formed the
process technological and mechanical design development of this intermediate diaphragm.

The PFEIFFER Intermediate Diaphragm can be adjusted and controlled according to the special
requirements of the grinding process.

This is possible due to a system for material flow control integrated in the diaphragm centre.

All diaphragm components can be brought into the mill either through the manhole or the inlet trunnion
bearing. In the mill, all segments of the support structure are carefully bolted and welded, thus avoiding
wear by movement in the support structure.

The intermediate diaphragm mainly consists of

- the MONOBLOC support structure with curved lifters

- the diaphragm centre with integrated material flow control system
- the slotted plates made of special Pfeiffer steel, heat treated provided with slots, and central
pieces and if necessary with filling pieces
- the backside plates made of special Pfeiffer steel, heat treated throughout, and central pieces
and if necessary the filling pieces
- all bolts with accessories, welding electrodes and special socket wrenches (for tear off bolts)
which are necessary for assembly

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3. Assembly of the intermediate diaphragm

3.1 General

All parts of the intermediate diaphragm (e.g. fastening ring, steel plate etc.) are marked with figures.
Their sequence and correspondence with the before mounted elements must be observed.

Before starting assembly you should make sure that all parts according to the parts list are available
and are lying before the mill tube.

For a perfect assembly operation it is absolutely necessary that the mill tube can be turned.

Before starting the assembly of the intermediate diaphragm, 1 - 2 rows before and behind the
diaphragm have to be disassembled. The ovality of the mill tube has to be checked and if necessary to
be corrected to assure a perfect fit of the fastening ring of the intermediate diaphragm.

The mill tube must be cleaned before starting the assembly.

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3.2 Assembly operation

(all pictures and illustrations of this assembly instructions must not correspond with the actual design oft he diaphragm. Only the
supplied assembly drawing is binding).

3.2.1 Fastening ring

The fastening rings segments are fixed with the

assembly cover plates to the mill tube for later
adjustment.
The arrangement of the cover plate must be chosen to
assure a full seating. After this, proceed in the
same way with all fastening material segments
according to the markings on the parts
.

Take care that a full seating of the cylindrical part of the fastening ring segment on the mill tube is
ensured.
A regular alignment of the rims of the fastening ring segments is necessary.

The fastening material of the cover plates is

corresponding to the fastening material of the tie
pieces. Please refer to the drawings for more
information.

© by Christian Pfeiffer Intermediate diaphragm

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3.2.2 Steel plate

The steel structure has to be assembled according to the sequences marked on the fastening ring and
the steel plate and as well the arrangement on the drawing

Bolt the steel plate segments with the tear off bolts and the accessories (please refer to assembly
drawing for number and sizes) for later adjustment of the single segments.

The steel plate segments are provided with swages in

the outer area of the fastening ring for bolting.

In case the diaphragm is designed with filling pieces,

the outer area of the steel plate is provided with through
holes for the tear off bolts for fastening of the filling
pieces.

If drillings of the steel plate do not correspond to those

of the fastening ring, because the mill tube is not
perfectly round, only trim the drilling in the fastening
ring.

Adjust the steel plate segments, tighten the tear off

bolts and tear off the square heads.

Finally fix the steel plate with the fastening ring by welding.

Assembly cover plates are replaced against the remaining tie pieces.

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3.2.3 Lifters

Bolt the lifters according the markings on the parts with the tear off bolts and the accessories (number
and sizes according to the assembly drawing) to the steel plate for later adjustment.

Schaufel

Adjust the lifters and tighten the tear off bolts and tear off the square heads.

© by Christian Pfeiffer Intermediate diaphragm

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3.2.4 Steel plate cross and ring cover plate

Put one segment of the ring cover plate into the hollows
of the rims and secure against dropping out.
.

Steel plate cross segment

Ring cover plate segment

The arrangement of the steel plate cross segments is indicated on the assembly drawing. The steel plate
cross segments are provided with swages for fastening of the tear off bolts with the accessories (number
and size are indicated in the assembly drawing) on the fastening ring resp. the segment of the ring cover
plate.
The steel plate cross segments must be bolted for later adjustment.

Further to this, through holes in the outer area of the steel plate cross must remain free - if required -for
the fastening of the filling pieces and as well in the inner area for fastening of the central pieces.

Thereafter put the remaining segment of the ring cover plate into the lifters and bolts to the steel plate
cross segments for later adjustment of each segment.

The same procedure will be performed between the steel plate cross and the fastening ring.

If drillings of the steel plate cross do not correspond to those of the fastening ring, only trim the drillings in
the fastening ring.

Adjust all parts, tighten firmly and tear off the square heads of the tear off bolts.

In order to avoid erosion by circulating material, the fastening ring should be sealed with a sealing cord
between steel plate resp. steel plate cross and mill tube (please refer to drawing).

© by Christian Pfeiffer Intermediate diaphragm

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3.2.5 Welding

General Guidelines for Assembly Welding – please refer to point 3.4

Welding consumables are necessary for the welding works. Quantity, types and technical data are
indicated on the drawing:

- Weld the lifters with the steel plate and steel plate cross and fastening ring.

- Weld the fastening ring on the points of impact and as well weld the rim segments of the fastening
ring with the steel plate and the steel plate cross.

- Weld the segment of the steel plate on the points of impact (only 2nd compartment side).

- Secure all nuts against loosening by welding with the bolt pins.

weld

After welding grind off projecting welding seams as well as the remnants of the torn off square heads of
the tear off bolts on the front side of the steel plate and the steel plate cross, so that the backside lining
plates and the central pieces have a smooth surface.

© by Christian Pfeiffer Intermediate diaphragm

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3.2.6 Filling pieces and backside plates

Number of filling pieces as well as quantity of fastening material are indicated on the assembly drawing.

filling pieces

backside plates
Start with the assembly of the filling pieces.
Sequence of assembly from outside to inside.

Assembly of tear off bolts, please refer to point 3.3.

Tighten tear off bolts and tear off the square heads.

Tear off bolts with accessories for

fastening of the plates
(conical plugs are necessary only for the last not
easily reachable plates)

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3.2.7 Central pieces and material flow control

Bolt the segment of the material flow control with the tear off bolts and the accessories (number and size
according to assembly drawing) on the central pieces. Bolt the central pieces with bolted material flow
control segment with tear off bolts and accessories (number and sizes according to assembly drawing)
considering the markings on the steel plate.

Make sure that the guide plates of the material flow control are connected to the long lifters.

Weld the segments of the material flow control together.

Tighten the tear off bolts and tear off the square heads with the special socket wrench.

Illustration without backside plates

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3.2.8 Filling pieces, slotted plates and central pieces

Number of the filling pieces and the central pieces as well as the number of the fastening material are
indicated on the assembly drawing

Filling
pieces

Slotted plates

Central pieces

Start the assembly with the filling pieces.

Sequence of assembly form outside to inside.

Assembly of tear off bolts, please refer to point 3.3.

Tighten tear off bolts and tear off the square heads.

Tear off bolts with accessories for

fastening of the plates
(conical plug are necessary only for the last not
easily reachable plates)

© by Christian Pfeiffer Intermediate diaphragm

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3.2.9 Protection grate

Bolt the protection grate halves by the hex. bolts and the safety disks on the holding of the material flow
control.
.

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3.3 Assembly of tear-off bolts

It is absolutely necessary to tighten tear-off bolts until the square heads tear off.

To tear off the square heads the following tools can be used:
- long-handled wrench
- impact wrench
- slugging wrench

It is important that the square head is torn off. The square head should not be knocked off or burned
off. When tightening the bolts the following minimum torques must be reached:
M20 550 Nm
M22 700 Nm
M24 800 Nm
M30 1000 Nm

Care must be taken not to impact the square head at an angle.

When using an impact wrench special care must be taken that:

- a special socket has to be attached to the impact wrench. The thinner square of this socket has
to fit the square of the tear-off bolt.
- the impact wrench should only work in clockwise direction.
- The dead weight of the impact wrench should not cause any force working on the square
head at an angle.

Setting time of the two-component adhesive is twenty minutes. Bolts must be completely tightened
within these twenty minutes.

If bolts are not tightened within twenty minutes the following problems will occur:
- The nut is fixed to the bolt and can no longer be tightened.
- The square head tears off before reaching the necessary torque.

Consequence is:
Slotted or backside plates are not properly fastened to the support structure. This results in mill
operation with loose and vibrating plates. At the same time the risk of breakage and damage to the
bolt holes of the support structure is increased.

© by Christian Pfeiffer Intermediate diaphragm

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© by Christian Pfeiffer Intermediate diaphragm
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3.4 General Guidelines for Assembly Welding

1. The welder should have the requested qualifications according to EN 287-1. If qualified welders
are not available, manual skill and qualification have to be checked before starting manufacture
by corresponding test welding.

2. Filler metal
Only weld vacuum packed electrodes. Open electrode parcels must be welded within 6 hours. If
electrodes are not packed or stored correspondingly, it must be redried according to producer’s
instructions. Certificate of producer according to EN 10204-2.2 has to be delivered by the
supplier (analysis).

3. In case of temperatures lower 10°C it is advisable to preheat the welding grooves with a burner,
if possible.
If during welding condensate arises, in any case preheat with a burner resp. dry the seams with
a burner before starting welding.

4. By experience endangered welding and seam points must be checked, if possible, after
finalization of welding by PT or MT. Fissures or lacks of fusion generally must be ground out or
jointed out or rewelded.

5. Setting of welding seams

All welding grooves and metal front sides must be set by a welding seam. A simple overlap
seam resp. welding seam of small cross-section is not allowed.
Grind by hand a corresponding welding groove.

6. Generally grind out and weld out final crater fissures.

It is not allowed to overweld final crater fissures.

7. Undercuts and groove cross-falls

Undercuts up to 0,95 x t rest metal thickness are admissible. But the notches must be round out
in the limit area 0,95 x t by grinding. Larger undercuts must be cleared by welding out.
Grind too large groove cross-falls as they cause additional fatigue notch.
See norm EN 25817
Further too important groove cross-falls can indicate a too small welding current (take care for
lack of fusion).

8. Welding sequence:
During welding sequence consider the dimension and bulkyness of the work piece, so that an
ideal welding sequence only up to a point is possible!

Proposal:
After introduction of assembly parts like ring segments, backside parts, lifters and cross parts
tack the lifter diaphragm.
The tacking length should be at least 5 cm lg.

Generally:
1. at first totally weld the root
2. then weld out

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 a) back side welding:
The backside shall be welded in parallel operation i.e. it must be welded left and right
resp. above and below. If possible start welding works from the centre.

Cracked weld tackers and root fissures must be welded out or jointed out, if necessary.
Overwelding is not allowed.

b) The lifter- and cross piece weldings have to be made in sequence. It is not meaningful
to determine an exact sequence of welding due to bulkyness of piece. But in any case
the parallel welding operation should be maintained to prevent unequal diaphragm
shrinks and shiftings.

c) Finally make the circumferential seams in the outer diaphragm area. Maintain parallel
welding operation (or in quadrants).

9. Make the indications of welding seam dimension according to drawing. Control cross-sections
at work piece. Utilize the multiple layer welding (stringer bead).
Single-run pendulum welding on butt seam and hollow seam is not allowed.

a = until 6 mm ..............1 layer

a = 7 - 10 mm .............. 3 layers

Further take care for sufficient welding gap in the grooves (rim distance) to keep low the shrink
strains in the seam cross-sections

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4. Assembly tools
Assembly of diaphragms

- El. Welding equipment

- Hand-tools
- Wrench from 8 - 42 mm
- Hand-hammer
- Screw driver with accessories
- Sledge-hammer
- Bevel cut with accessories
- Impact wrench with accessories
- Socket-spanner, Set of 13 - 42 mm
- Cable-extension
- Halogen-exciter with transformer
- Hand drilling machine with accessories

5. Assembly staff

5.1 Preconditions for respect of the assembly duration

Preparation of assembly for mill diaphragms

- Remove the grinding balls from the mill

- The old diaphragm must be completely disassembled including the old diaphragm structure
- The mill must be clean
- Two rows of the mill shell lining before and behind the intermediate diaphragm must be
completely disassembled
- All parts supplied from CPB for the intermediate and/or discharge diaphragm must be
stored near the mill
- Tools according to tool list must be available and ready for function

5.2 Working method

- in 2 shifts à 12 hours or in 3 shifts à 8 hours

- our supervisor is generally working 10 hours/day

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5.2 Assembly duration

Days of assembly staff / There from

shift welders

Ø 2,00m – 2,60m 5 4 3

Ø 2,80m – 3,40m 6 5 3

Ø 3,60m – 4,20m 7 6 4

Ø 4,40m – 5,00m 8 6 4

6. Spare parts

In case of spare parts order please always indicate:

• CPB-Order number
• Technical item according to spare parts drawing
• Descriptions out of the spare parts lists
• Quantity of the parts to be delivered

Spare parts must correspond to the technical requirements determined by the manufacturer.
This can always be assured in case original spare parts are ordered!

Address:

Christian Pfeiffer Maschinenfabrik GmbH

Sudhofer Weg 110-112
59269 Beckum, Germany

Internet: www.christianpfeiffer.net
E-Mail: office@christianpfeiffer.de

Telefon: +49 2521 849 00

Telefax: +49 2521 849 123

© by Christian Pfeiffer Intermediate diaphragm

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