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Snap Shear
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8274.1285
00
SHEET
REV.
1
8274.1285 – SNAP SHEAR
B – EQUIPMENT
AND MAINTENANCE
MANUAL
ATTENTION:
Please read carefully the instructions before the machine commissioning is executed. It is the
Customer’s responsibility to study and understand the contents of this manual. Also to pass
the contained information by a training process to the plant operators and maintenance
personnel to result in acceptable and safe working standards with the equipment.
Images and drawing extracts present in this manual are typical of the machine type and
present an indication from which to understand the accompanying descriptions. For the
actual drawings, please refer to the project specific versions.
JIN-8274
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Contents
Chapter
1.0
2.0
3.0
4.0
5.0
6.0
7.0
JIN-8274
CONTRACT N°
58 95 9439
Title
Preface
Safety Recommendations
Technical Data and Drawings
Functions
Maintenance and Use Instructions
Trouble-Shooting
Documentation of the Sub-Suppliers
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Pages
1
2
2
6
13
2
1
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1.0 Preface
The snap shear is located at the entry of the roughing mill in order to provide a separation
of the billet during e.g. during emergency conditions such as when the bar has cobbled in
the mill. The volume of billet material feeding forward to the mill is therefore reduced and
this minimises the risk of the cobbled bar material causing damage to the equipment by
an over-accumulation effect. It further reduces the amount of material that the other
shears within the mill need to process before the bar is cleared from the rolls.
The downstream separated section of billet can often be recovered back to the furnace for
later rolling or ejected from the feeding roller table for subsequent processing.
JIN-8274
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2.0 Safety Recommendations
2.1
General
See Plant Manual A
2.2
Specific
Attention is drawn to the specific hazards outlined in the text sections.
ATTENTION:
The snap shear is normally automatic in operation and can be initiated from remote pulpit
controls or in manual from a local desk on detection of an emergency event or,
alternatively, in a controlled situation. In any case, the snap shear is initiated by PLC
automation and since this is not an intrinsically safe system beware that a fault condition,
although rare, has the ability to operate the snap shear at any time.
The adjacent working area of the snap shear is normally not protected with guarding which
in any way inhibits access to the moving parts of the shear. In any case, and even when
there is no hot billet present, great care must be exercised when approaching within hand
reach of the machines moving parts due to the high risk of serious injury including the risk
of trapping and limb amputation. The operator must execute risk assessment methodology
in the establishment of obligatory safe working rules for approaching close to or working
directly on the snap shear - this should include the provision of fail-safe means of
electrically and pneumatic isolation of the machine whenever access local to the snap
shear would otherwise render risk of the operator being struck or trapped by the moving
parts should the shear be activated.
In the event that any guarding devices are supplied by SMS, it is responsibility of the
operator to satisfy himself that the devices fully conform to any national or local safety
regulations which may apply at site. Under any circumstances such guard devices must
never be removed to gain access to moving parts of the machine without effective media
isolations or the complete training of personnel of the consequences and danger presented
by the guard removals. It is highly recommended that any damage to safety
guarding/containment doors is properly repaired with immediate effect.
Beware - unless the vented isolation valve for shear activation is closed, there is stored
compressed air energy within the cylinder and feeding pipes which can present hazards
including roll activation and sudden venting conditions if the pipes are opened or fail.
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ATTENTION CONT’D:
Specifically, when access into the snap shear housing or locality to the blades operating
area is needed for intervention or maintenance purposes - the vented isolation valve should
be closed and a check made that the air has vented to prevent pneumatic cylinder
actuation. Also be aware that the snap shear blade holders are held in an open condition by
the presence of the compressed air to the annulus side of the cylinder - when the air supply
is isolated and vented it is possible that the blade holders can move and present a serious
hazard. In such situations the blade holders should be prevented from closing by applying a
temporary physical blocking device whenever the vented isolation valve is closed and
access to the proximity of the blades is needed.
Beware that when the blade holders are initiated to open and in case a billet is present - the
action of the blades may move the billet on the roller table and present a hazard to the
operator.
The hot billet radiates significant energy to machine. Beware of the risk of burns caused by
coming into contact with hot surfaces of the machine during short pauses and interventions
during operation.
Refer to any individual specific hazards which may be highlighted in the following sections
of this manual.
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3.0 Technical Data and Drawings
3.2
3.3
JIN-8274
3.1
Designation
3.2
Mechanical
3.3
Electrical
3.4
Hydraulic
3.5
Pneumatic
3.6
Water
3.7
Lubrication
3.8
List of Drawings and Drawings
not applicable
not applicable
not applicable
Mechanical
• Serial no.
• Year of construction
• Type
8274.1285.01
2015
snap shear with pneumatic
driven
• Maximum billet dimension
165x165
(possible 130x130)
• Maximum cutting resistance
(temperature and tensile strength)
• Cylinder data
• Blades Gaps setting data
• Blades bolts grade and dimension
• Blades bolts tensioning torque
80 N/mm²
160/40 stroke 260
10 mm
M20x180 grade 8.8
290 Nm
Electrical
Electric Manual, chapter E-11.2
• Motor List
dwg. 2465.E030
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Item
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Scheme
Plant on board
TOP line pressure
Working pressure
Air consumption/cylinder cycle
dwg. 2465.P003
dwg. 08.045.05
6 bars
5 bars
1 Nm³/h
Lubrication
•
•
•
•
3.8
Snap Shear
Pneumatic
•
•
•
•
•
3.7
CONTRACT N°
58 95 9439
Bushings, joints,
Type of lubrication
Type of grease
Drawing
grease
manual
Mobilith SHC 460
08.045.01
List of Drawings and Drawings
Pos. WBS
Drawing N°
Description
Pages
3.8.01 8274.1285
08.045.01
Pull shear (only engineering)
1
3.8.02 8274.1285
2465.0027
Guards for snap shear (only engineering)
1
3.8.03 8274.1285
08.045.05
Pneumatic system on snap shear (only
1
engineering)
3.8.04 8274.1285
08.045.04
Electric detail on board snap shear (only
1
engineering)
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4.0 Functions
4.1
4.1
General Functions
4.2
Single Functions
General Functions
See also section 1.0.
The snap shear is used to shear the entry billet to the mill in order to control the volume
such as would occur between the stands during a cobbled bar condition. It is also used
where the billet volume entering the mill is deliberately reduced (e.g. trials/start-up’s
conditions), e.g. a short length of billet is allowed to enter the mill and the main body of
billet is retained on the entry roller table.
The shearing force is primarily created from the pulling force in the billet which is engaged
by the driving torque applied to the billet by the work rolls in the first stands. The
pneumatic cylinder only serves to power the blade holders and therefore the blades onto
the billet surface - thereafter the approach angle of the blades to the billet surface together
with the pulling force applied to the billet causes the blades to bite into the billet mass and
cause a progressive cutting action as the billet continues to be pulled by the stands.
Towards the end of the cutting action and when the un-cut cross section of the billet has
substantially reduced, the final severance of the billet from the ongoing piece entering the
stands is by a tension induced failure - the blades gap is therefore not critical.
The blade holders are re-opened by reverse actuation of the pneumatic cylinder.
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Single Functions
The snap shear is composed by:
4.2.1
Machine Housing
4.2.2
Reaction Arms to the 1st Stand
4.2.3
Entry Guide Side-Plates
4.2.4
Upper and Lower Blade Holders with Blades and Connecting Links
4.2.5
Pneumatic Cylinder with Heat Shield
4.2.6
Pneumatic Plant/Valve Bench
Specific/Layout Function
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4.2.1
Machine Housing
The housing is manufactured from fabricated steel sheet and steel profile sections to form
a stiff and single housing entity to contain the cutting forces resulting from the blade
holders operation. Mounted on the fabrication are attachment surfaces and brackets for
the pneumatic cylinder and reaction arms respectively. The critical surfaces which guide
the blade holders and contain the mounting shafts and connecting pins are fully
machined. The integral base plate to the fabricated housing is mounted directly to the mill
foundation with anchor bolts.
4.2.2
Reaction Arms to the 1st Stand
Two pivoting reaction arms (one each side of the shear housing) are mounted in
substantial brackets and lubricated pins. When they are swung in a ‘forward’ direction they
engage (with a very small clearance dimension) to the stand chocks support frame onboard the stand container - locking pins are applied by hand operation to maintain the
arms in the forward presented position. When the billet shearing force is transmitted
through the blade holders and into the housing, the arms form a strut-type brace reaction
onto the stand and thus reduce the bending forces applied to the housing and also, in
turn, minimise the overturning forces of the housing on its foundation. The reaction arms
can be swung backwards to facilitate a clearance condition for exchange of the stand unit.
4.2.3
Entry Guide Side-Plates
Two fabricated steel flared entry guide plates (one each side) are mounted with bolts to
the housing. The nuts for the bolts are located in ‘window’ pockets of the housing to avoid
threaded connections in the frame of the housing itself. The mounted inter-distance
dimension of guide plates is designed to facilitate a generous clearance dimension to the
billet and to ensure that the billet is fully covered by the width of the blades - the guides
also serve to protect against damage from the billet the synchronising linkage of the blade
holders.
4.2.4
Upper and Lower Blade Holders with Blades and Connecting Links
Two substantial fabricated and machined steel blade holders (upper and lower) are
mounted on lubricated pins and bronze bushings into the housing. The blade holders
contain the mounting interface taper-walled slot for the tool-steel blades themselves. Each
of the blade holders rotate in an operation arc of approx. 40 degrees from the open to
closed conditions - in each case the tips of the blades move towards the 1st rolling stand
when the shearing action to the billet is applied. The closed position of the blade holders
is adjusted so that the holders axis is vertical and the blades oppose each other when the
housing is first assembled by the use of stopper bolts. These can be adjusted in later life
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to compensate for normal wear conditions. The upper blade holder has the mounting
interface bracket for a pinned connection to the pneumatic cylinder. The action of the two
blade holders is synchronised so that the blade tips axis coincide onto the billet surface
and eventually to fully oppose each other due to the connection onto the blade holders of
two synchronising connecting links (one each side of the holders). The links connect to
the blade holders with lubricated pins and bronze bushings. Due to the presence of the
synchronising links, the two blade holders are statically balanced. The specially shaped
blades are fitted to the blade holders with bolts which pass through a wedge-block to
rigidly secure the blades. The blades are readily exchangeable in case of wear or
breakages. Limit switch is installed in the cylinder of the actuated device to signal the
open and/or closed condition of the blade holders - the signals are linked to the mill
automation system.
ATTENTION:
Refer to the notes in section 2.0 and 4.2.5 and undertake the task of blade exchange or any
intrusive work within the shear housing with extreme caution and the execution of full safety
measures.
4.2.5
JIN-8274
Pneumatic Cylinder with Heat Shield
The pneumatic actuation cylinder is mounted in vertical axis on trunnion supports to the
top plate of the housing and is protected by a bolted heat shield. The cylinder extends
during actuation of the shearing action due the application of compressed air to the fullbore side of the cylinder. During the opening and stored position phases, the compressed
air is energised to the annulus side of the cylinder. The cylinder rod has an adjustable eye
which connects to the upper blade holder by a pinned connection. The rod length is
adjusted at assembly of the shear such that the cylinder still has a small reserve of stroke
when the blades are in the fully closed condition. This is to ensure that the piston rod is
not tensioned by the very large forces applied by the pulling force of the billet and before
the blade holders reach their physical stopper bolts at the closed position.
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ATTENTION:
Before working on any part of the pneumatic system or the cylinder, refer to the notes in
section 2.0. In any case the three-way venting isolation valve should be in the closed
position and the blade holders blocked from rotation by a temporary means.
4.2.6
JIN-8274
Pneumatic Plant/Valve Bench
A valve bench is provided and mounted to a support which is permanently fixed to the
foundation local to and next to the snap shear. The valve bench provides for the
functionality of the shearing action pneumatic actuation cylinder via compressed air media
supply.
The bench consists of a three-way manual venting-type isolation valve, a combined
filter/pressure regulator, a lubricator and a two-position, five-way solenoid operated
directional control valve (DCV). Additionally pipe or cylinder-mounted adjustable speed
control devices are supplied to regulate the extension and retraction speed of the cylinder
piston rod.
The manual venting isolation valve is used to shut off or restore the air supply to the DCV
- when the valve is closed, the locked air downstream to the valve is vented to
atmosphere. This is a safety feature and avoids partial energisation of the cylinder after
the valve is closed. A locking device can be applied to the valve to prevent accidental reopening.
Additionally, a solenoid operated VIV may be provided - check the project actual supply.
The specific function is automatically disabled by de-energisation of the VIV whenever the
machine is de-selected at the HMI or the local control panel. Pressure switches are
installed which monitor the downstream pressure condition and provide annunciation
signals to the PLC / HMI.
The filter/regulator controls the final quality and the set-pressure of the air which supplies
the DCV for cylinder operation. Refer to the technical specification for the pressure
setting.
The line lubricator provided an oil entrained supply of compressed air to the pneumatic
cylinder. The oil is replenished in the device reservoir manually and the rate of oil transfer
can be regulated on the adjusting screw.
The solenoid operated DCV switches the air supply to either the full bore side of the
cylinder to extend the piston rod and activate the shear or to the annulus side of the
cylinder which has the opposite effect. In its normal, electrically de-energised state, the
DCV supplies compressed air to the annulus side of the cylinder in order to power retract
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the piston rod. When the shear is initiated from the automation system, the DCV receives
an electrical supply to switch the valve to provide compressed air to the full-bore side of
the cylinder.
ATTENTION:
Before working on any part of the pneumatic system, refer to the notes in section 2.0. In
any case the three-way venting isolation valve should be in the closed position.
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5.0 Maintenance and Use Instructions
Refer also to Plant Manual A - Instructions for Erection, No-Load Tests and Commissioning
Manual D
5.1
5.1
Receiving
5.2
Storage
5.3
Installation
5.4
Handling
5.5
Assembly/Disassembly
5.6
Commissioning
5.7
Every-day Adjustments
5.8
Maintenance (General - Lubrication Instructions)
5.9
Special Checking/Adjustment Procedures
5.10
Special Safety Points and Instructions
5.11
Shutdown and Storage
Receiving
ATTENTION:
Handle the equipment by the provided attachment points or sling/support during unloading
in an appropriate way as to not cause damages to the equipment or danger to personnel
involved. The unloading/handling operation should only be carried out by staff trained for
this type of work.
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Equipment and Maintenance
Manual B - 00, chap. 3.3
Before Handling
Check that there are no obvious damages to the equipment due to packaging or
transportation - report any defects immediately on receipt with photographic evidence of
any damage. Check that the temporary protective plugs applied to any media connections
on the machine are intact and that there is no penetration contamination of water or dirt.
Check that any loose parts are delivered with the main equipment.
5.2
Storage
Store the snap shear housing on flat level surfaces preferably in the correct working axis alternatively the machine can be stored horizontally using packing blocks to protect any
vulnerable areas.
The equipment should be stored in dry conditions, preferably indoors or covered
adequately with suitable protection sheets to eliminate water ingress. Do not store in
standing water conditions or where the atmosphere is very humid. In any case sensitive
equipment such as the valve bench components must be stored in dry,
workshop/warehouse conditions - never in open environment.
5.3
Installation
Checks before Installation
Check the foundations and bolt hole provisions comply with the engineered requirements
including the layout drawings of the assembly.
The foundation preparation must be complete and the concrete fully cured to receive the
shear housing. A check that the correct elevations and critical alignments for the blades
axis can be and is achieved on the foundation - check to the layout drawing for critical
dimensions and datum must be made.
The undersides of the housing base-plate must be free of oil/grease to ensure a correct
fixation to the concrete and grout. Also check that there are no foreign particles adhered
to the undersides of the equipment to be secured to the base-plates during the
storage/transport phase.
The snap shear positional relationship to the adjacent stand unit is critical due to the
functionality of the reaction arms - see section 4.2.2. Ensure that the clearance
dimensional tolerance of the arms to the stand can be and is achieved.
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Checks during Installation
In most cases the pneumatic cylinder and shield is likely to have been removed from the
snap shear due to the risk of transportation damage and also the blade holders blocked
from accidental movement. If this is the case, assemble the cylinder onto the shear
housing taking references from the machine assembly drawing to position and connecting
the cylinder to the upper blade holder. Install the shield. Caution - refer to the notes in
section 4.2.5 in checking or setting the piston rod length on the rod-eye. Remove the
temporary blocking system of the blade holders to manipulate the blade holders for
connection to the cylinder piston rod.
The reaction arms are also likely to have been delivered with the shear as loose parts.
Follow the machine assembly drawings to fix these on-board the housing using the
supplied pins.
ATTENTION:
Beware of the free movement of the blade holders once the temporary blocking device is
removed. There is a consequential risk of trapping injury by the movement of the blade
holders - use lifting devices to manipulate the blade holders to the correct position.
The housing base-plate must be adequately supported on steel packs and the bolts to the
foundation fully tensioned.
- Check that the housing has been positioned correctly according to elevation and all
positional requirements.
- Make sure that all units comprising the complete snap shear have been mounted
correctly and that everything corresponds to the layout and assembly drawing.
- Make sure that all safety protections have been installed and function correctly.
- It is recommended that the grouting is not applied to the housing base-plate until all
critical alignments are verified for the complete machine.
- Check that all the fluid media piped systems are fully flushed and certified clean before
connection to the machine T.O.P.’s.
Connect the media pipes from the valve stand to the cylinder referring to the assembly
drawings and single-line diagrams. In particular, check that the speed regulation devices
have been installed in the correct direction for functionality.
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Checks after Installation
• Check that all piping installed is suitably clean and that there are no leaks.
• After 1 shift of operation, re-check that the tension of the blade bolts.
• After one month of machine operation, check that the foundation tie bolts are correctly
tensioned.
5.4
Handling
ATTENTION:
Refer to the drawing information or revert to SMS if there is any doubt about the attachment
points for correct slinging and handling. Employ the normal good and safe practices when
slinging - in any case, slinging should only be undertaken by trained operatives and with full
information about the mass of the equipment to be slung and also its centre of
gravity/stability.
The handling of the shear housing assembly is normally only that required for off-loading,
storage and installation. Use any provided attachment points and soft slings wherever
there is the risk that surfaces may be damaged or too much pressure will be exerted to
vulnerable parts.
5.5
Assembly/Disassembly
Refer to the notes in checks during installation if the shear has been delivered with loose
parts.
Assembly and disassembly of the other components e.g. cylinder, blade holders, reaction
arms etc., will only be required in the event of abnormal maintenance situation due to
equipment wear or failure. The manufacturers drawings and tolerances should be
consulted before any work is contemplated and any parts substituted should be of O.E.M.
source and quality.
Consult the assembly drawings and SMS expertise, as necessary, for invasive
maintenance or major repair work.
JIN-8274
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Commissioning
ATTENTION:
Be aware that this must be strictly controlled and supervised to avoid danger to personnel
not involved in this process. Special barrier systems and warning notices are likely to be
required and definitive communication to all personnel who may be exposed to the
commissioning area must be made.
Attention - refer to the critical safety points contained in section 2.0 before accessing the
snap shear and related equipment areas for Commissioning and start-up.
SMS Meer S.p.A. declines any responsibility towards injuries to persons or damages to
equipment due to the non-compliance of the above mentioned rules and recommendations.
If any abnormalities occur, the equipment should be immediately stopped for
investigation/corrective action and the appointed SMS Meer engineer informed.
The sequence for commissioning and start-up is:
- Verification of all installation completion with full tension to all the bolts and critical
alignments checked and approved by SMS Meer.
- The maximum number of guards or safety barriers are attached in the work area to
avoid danger to other personnel.
- A check that all the I/O of the PLC are correct at the application points of the valve
bench.
- Full commissioning of the fluids media systems including final connections and
verifications of supplies to the valve bench. This includes the setting and checking the
specified pressures and flows.
- All manual lubrications to be undertaken before any commissioning activity.
- Set the supply pressure on the air pressure regulator and fill the lubricator with oil.
- Operate the cylinder movements in manual mode using firstly the manual override on
the DCV and then the local desk controls.
- Set the operation of the speed control for the cylinder piston-rod retraction and
extension. Refer to the single-line diagram for the approx. linear speed setting.
Before proceeding with hot start-up:
- Check the functionality of the DCV operation from the remote pulpits via the mill
automation system.
- Check that the reaction arms engage the adjacent stand unit and the locking pins are
installed.
JIN-8274
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ATTENTION:
Be aware that operation of the device without the reaction arms is the correct position will
lead to equipment failure.
5.7
Every-day Adjustments
There is no every-day adjustment required to the machine.
Attendance is required to manually apply and retract the reaction arms when the stand is
exchanged or groove-changing is taking place.
5.8
5.8.1
JIN-8274
Maintenance (General - Lubrication Instructions)
5.8.1
General
5.8.2
Lubrication Instructions
5.8.3
Blade Changing
General
A preventative approach to maintenance will secure a good operational result and limit
expensive failures.
Where possible and appropriate, predictive techniques can also give optimum results e.g.
vibration analysis, thermo-graphic imaging, wear particle analysis in lubrication and fluids
systems etc. The user is strongly advised to research the availability of such techniques
and employ them as appropriate to this equipment.
Wherever possible it is important to establish a quantitative way to establish and record
machine condition - this avoids subjective opinion of condition and allows a proper basis
for trending condition. If this is not possible, it is useful to contain the task of undertaking
machine inspections to a minimum number of fully trained staff.
Establishing data base of records of machine condition is essential as is consulting the
data base to highlight a worsening trend and predicting when a necessary intervention of
adjustment, component exchange etc., is to be planned.
Establishing check sheets for each adopted maintenance routine is essential - in the
design of the check sheet there should be enough prompts of exactly what to check and
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record in order to take out any subjectivity to the maintenance - also there should,
wherever possible, be limiting values/conditions stated on the sheets such that immediate
action can be taken if there is a critical non-conformity.
Maintenance should only be carried out by fully trained personnel who are familiar with the
specific equipment. It is recommended that the maintenance is carried out in a routine
manner according to specific timetable or taking account of equivalent machine operating
time. The recommended frequencies should be adjusted according to local conditions.
The following is to be regarded as a minimum requirement for preventative maintenance
practice.
For the terms regarding the Operating State and the Interval, refer to Equipment and
Maintenance Manual B - 00, chapter 3.1.1.
JIN-8274
Operating
Equipment
Inspection/Test
Whole machine
Screws/blade bolts
Cleaning
Tightening
FE
FE
S
M
Foundation
bolts/grouting
Shear blades
Reaction arms
Ducts
Protections
Pneumatic plant
Pneumatic cylinders
Solenoid valves
Air line
Air filter
Air line cylinder
Lubricator
Lubrication points
Tension
FE
6M
FE
FE
LA
LA
FE/FU
FE
FE
FE
FU
FE/FU
G
S
----S
S
S
G
S
M
FE
S
Proximity/sensor
devices on the cylinder
Security/functioning
FE
S2
Wear
Free movement by hand
Clearing from eventual foreign parts
Installation
Possible fluid leakages
Function
Function
Pressure and flow
Clogging - cleaning
Check the oil level
Adjustment/functioning
Check all positions are intact/no damages
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Interval
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Lubrication Instructions
For the terms used for the Type of Lubrication, Lubrication Interval, Quantity of Lubricant
and Type of Lubricant, refer to Equipment and Maintenance Manual B - 00, chapter 3.1.2.
All the values indicated in the lubrication schedule are estimates and can vary according
to the work experience.
• For the periodical replacement of the lubrication and hydraulic oils refer to
manual “B - Contents” chapter B - 3.0 “General Maintenance Instructions”.
• For the information concerning the first filling of the devices refer to the
Equipment and Maintenance Manual B - 8274.9220 (where available).
• Concerning the lubrication of the materials from trade refer to the Sub-Supplier
catalogue. The note “See catalogue” refers to the chapter 7.0 of this Equipment
and Maintenance Manual; look at the Sub-Supplier documentation list.
N° Assembly N°
Part Item
Item
N° of points
to be
lubricated
Type of
lubrication
Lubrication
interval
Quantity of
lubricant
Type of
lubricant
01
08.045.01
107
shaft/bush
2x2
IN
S
50
∆
02
“
122
pin/bush
2x2
IN
S
25
∆
03
“
115
shaft/bush
2x2
IN
S4
20
∆
04
“
124
pin/bush
2x2
IN
S2
10
∆
∆ - grease MOBILITH SHC 460
Note:
The re-lubrication intervals must not be over-looked considering the heat exposure of the
machine to the passing billets in rolling operations. Recovery from seizure of the working
bearings and pivot parts is costly and is not an easy operation.
JIN-8274
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Blade Changing
ATTENTION:
Before attempting blade changing the safety notes in sections 2.0, 4.2.4 and 4.2.5 should be
referred to. Specifically the air media to the cylinder is to be vented and the blade holders
temporarily blocked from any possibility of sudden and uncontrolled movement. Beware that
access to change the blades may need to be taken from the feeding device table - permits to
work on and in the proximity of these devices should be taken including electrical and media
isolations. Beware that the parts to be handled are heavy and also the old parts and the
shear parts are likely to be hot. Also see the special caution notes in the descriptive text
below. Blade changing should only be executed by fully trained staff, fully aware of the safety
requirements of the task.
The blades need to be changed only when the condition has deteriorated to a point where
the billet separation is not clean or in cases where the blades may be broken.
The initial blades are installed against a bottom shim - item 105, which is bolted into the
blade holders. This shim is machined during assembly to suit the actual closed condition
dimension of the blades due to tolerances in the manufacture of all the component parts
of the shear. The shim is re-used whenever new standard dimension blades are to be
fitted.
Remove the old blades after de-tensioning the bolts and loosening the grip of the wedge
blocks using a soft-face hammer.
ATTENTION:
The blades are heavy and can cause injury if they are dropped - the upper blade can fall out
of the holder due to gravity once the wedge is freed - hold the blade to prevent this
occurrence and handle it in a controlled manner once it is free.
Once the old blades are removed, it is recommended to fully remove the bolts and the
wedge blocks to clean by hand to remove surface scales/dirt from all the wedge face
surfaces and the bolt threads - on no account are the surfaces of the wedge blocks to be
ground (e.g. hand grinder) or damaged in any way. If the bolt threads are corroded or
damaged it is recommended to renew them with the correct specification parts.
JIN-8274
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Also clean by hand the inner surfaces of the blade holders where the wedge blocks
interact. Check the condition of the threads in the holder for the bolts - use a thread-tap if
necessary to clean the threads to ensure the bolts are installed with minimum friction.
Check that the base shims for the blades are fully tight in the holder - if they are loose,
remove the bolts, clean out the surfaces and re-fit them so they are fully secure.
Lubricate the bolt and bolt hole threads with anti-seize media - copper or aluminium type
to help prevent seizure and since the blades are long lasting in operation.
Installing the lower blade: place the new blade into the holder to contact the correct face the blade is stable in the slot so only needs lateral centralisation to the holder before the
wedge block and bolts are re-fitted. Tension the bolts sequentially with 50% and followed
by 100% of the correct torque value.
Installing the upper blade: loosely refit the wedge block with the bolts to the slot in the
holder - tighten the bolts to advance the wedge block in the slot but only enough so as to
be able to offer in the new blade and allowing for a small sliding clearance.
ATTENTION:
Caution: the blade needs to be held by hand until the bolts are tensioned so that the wedge
grips the blade with a light but adequate pressure to prevent it falling out under gravity.
Strike the blade with a soft hammer so as to cause lateral centralisation in the Holder and
also cause it to fully seat against the base shim plate - check the latter condition with a
‘feeler’ shim of say 0.1mm - the 0.1mm shim should not enter any gap which may exist
between the blade and the base shim. Finally tighten the blade bolts according to the
same method as for the lower blade fixing.
When the blades are fully re-fitted, the shear must be operated by closing the blade
holders in strictly controlled conditions to check for the blade positions and tip gap
dimension according to the drawing references. Note that the blade gap only needs to
satisfy a nominal dimension.
JIN-8274
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Special Checking/Adjustment Procedures
Refer to sections 5.8 for the blade change instructions.
Adjustments when exchanging the pneumatic cylinder or if the stopper bolts for the blade
holders are damaged, exchanged or adjusted for any reason. Refer also to the notes in
section 4.2.5.
The stopper bolts are adjusted to regulate the closed condition of the blade holders and to
ensure the closed axis of the blades is correct and co-incident. It is recommended that if
adjustment or replacement of the bolts is executed - firstly the pneumatic cylinder is
disconnected from the upper blade holder and that holders are then held firmly against the
stopper bolts by temporary means. In this condition and with the piston rod fully extended,
the rod-eye is adjusted on the piston rod so that the connecting pin in the holder becomes
aligned to the rod-eye. Then unscrew the rod eye 1.5 turns off the piston rod so that the
piston rod has to be pushed back into the cylinder a short distance in order to fulfil the
aligned condition of the connecting pin. When this is confirmed, tighten the locking nut
securing the adjusted position of the rod-eye to the piston rod and fully fit the connecting
pin.
Note: if there is any doubt that the piston rode may not be fully extended during this
setting operation, a temporary air supply can be attached to the full bore (upper)
connection of the cylinder to achieve a ‘powered-out’ position of the rod.
Adopt the same procedure principle as above when exchanging the pneumatic cylinder the blade holders should be closed against the stopper bolts to set the rod-eye position on
the piston rod of the cylinder.
JIN-8274
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Special Safety Points and Instructions
See also section 2.0.
Also note the specific hazards and safety recommendation highlighted in each section of
this manual with the words ‘Note’ or ‘Attention’.
ATTENTION:
Be aware that unless the equipment is properly maintained in accordance with suppliers
minimum recommendations, then failure conditions may precipitate danger to operational
and maintenance staff. Persons undertaking maintenance must be fully trained, assessed
and approved to be competent in the specific tasks. Be aware that the on-board piped
system systems may contain stored energy. Make any disconnections with care. Be aware
that if the lip-seals in the gear housings are from Viton material - special handling
precautions are needed if the seals are burnt or charred - check the specific
recommendations for this material. The user is recommended to evaluate all media supplies
to the equipment under the requirements of COSHH regulations or equivalent (if applicable)
and to train and execute any recommended control measures.
A risk assessed method to undertake the work should always be taken. This should include
the regular tasks and the irregular and maybe unforeseen tasks which may present
themselves. Persons undertaking operational duties must be fully trained, assessed and
approved to be competent in the specific tasks so as not to present unacceptable risks to
themselves or others. Attention is drawn to the nature of the use of the equipment - the main
apparent risks are:
Danger of becoming trapped or ingested into the rotating parts.
Risks from burns or being struck by the red-hot bars during the rolling operations.
Risk of sudden and unexpected movements of the equipment in automatic PLC driven
controls (fault conditions). The user is specifically recommended to adopt strict controls of:
Equipment electrical isolation and permit/certificate procedures.
Stored energy systems which supply the equipment - isolations and permit procedures.
Tasks which may be permitted to be undertaken without general electrical isolation of the
machine and control of stored energy devices.
Be aware of the parts of the machines which are to be handled without lifting aids. Ensure
that operators or maintenance staff are not exposed due to lack of knowledge or training to
lifting operations which may be instantly or longer term injurious..
SMS Meer declines any responsibility towards injuries to people or damages to
things due to the non-compliance of the above mentioned rules and
recommendations.
JIN-8274
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Shutdown and Storage
It is recommended to purge the old grease residues from all of the manual application
points and refill with fresh grease.
Re-lubricate all points according to the lubrications instruction list.
Apply protective grease to the threaded parts if the shutdown is to be longer than 1 month.
Clean all the areas of the equipment from free scales and water entrapment points to
prevent severe corrosion occurring - re-paint/apply a protective barrier where paint removal
has left surfaces open to oxidation effects.
Shut-off the air supply and install a temporary blocking device to the blade holders.
It is recommended to re-energise the machine and operate in manual mode and in
controlled conditions each 1 month of stoppage if this is possible.
Refer to SMS Meer for recommendations if periods of shutdown in excess of 6 months are
envisaged.
JIN-8274
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6.0 Trouble-shooting
ATTENTION:
Be aware that fault/trouble-shooting can result in exceptional hazards. A risk assessed method to
undertake the work should always be taken. Persons undertaking fault finding must be fully
trained, assessed and approved to be competent in the specific tasks so as not to present
unacceptable risks to either themselves or other Workers.
Defect
Reaction arms not free
Possible Causes
Seizure in the bushes
Billet does not part or parting
is not clean
Billet does not part
Damaged/severely worn blades
Solutions
Lubricate or remove and
renovate
Change blades
Billet is slipping in the rolls of the
stand
Stop and cut the billet by
flame cutting process
Resolve the fault
Replacement and/or setup
Air leakages in connections to
cylinder
Fault in the functioning cycle
Line pressure switch fault or to
adjust
Electrical problem of DCV
feeding or cleaning
Connection joint break /worn air
pipes
Cylinder internal fault
Cylinder sailings break
Main b. holder bushings
seized
Missing//insufficient lubrication
Connecting link bushings
seized
Missing//insufficient lubrication
Cylinder rod-eye seized to pin
Missing//insufficient lubrication
Blade holders do not
operate:
Initiation fault in automation
No air supply/pressure too
low
Fault with DCV
JIN-8274
Check the cleaning status and/or
replace the DCV
Check the tightening of the
connections and/or replace the
hoses
Change cylinder sailings
Free and re-lubricate
Unlock and/or replace (see the
lubrication cycle)
Free and re-lubricate
Unlock and/or replace (see the
lubrication cycle)
Free and re-lubricate
Unlock and/or replace (see the
lubrication cycle)
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Defect
Fault or setting of speed
controls
Possible Causes
Pressure reducers to be tuned
Solutions
Check the pressure reducers
status and tune or replace them
Blade holders slow/jerky in
operation:
Low pressure and/or insufficient
air flow rate
Increase pressure and/or air flow
rate
Fault or setting of speed
controls
Pressure reducers to be tuned
Check the pressure reducers
status and tune or replace them
Semi seizure in moving parts
---
Restricted air supply
Line pressure switch fault or to
adjust
Cylinder sailings break
Refer to above list and trouble
shoot
Replacement and/or setup
Cylinder fault
JIN-8274
Change cylinder sailings
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7.0 Documentation of the Sub-Suppliers for the
Erection, the Commissioning and the
Maintenance
* Refer to Components Manual C - 2.0.
Drawing N°
Item
08.045.01
25A
08.045.05
21B
08.045.03
JIN-8274
Supplier
Description
Catalogue N°*
Pneumatic cylinder
C-2.1.18
ROSS
Solenoid valve
C-2.4.02
21E
ROSS
FRL
C-2.4.02
21F
SMC
Manual valve
C-2.4.01
21I
ROSS
Solenoid valve
C-2.4.02
30A
HT ITALIA
Proximity switch
C-2.2.01
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