The finishing mill unit of our high-speed wire rod plant utilizes a 45° top-crossing cantilever design from Danieli, commissioned in 2015 for producing Φ5.5-Φ16mm wire rod. This 8-stand unit reaches maximum speeds of 116m/s. Initial operation revealed persistent issues including roll box water ingress, TC ring cracking, and locking device jams, significantly impacting production. A dedicated team was established to address these challenges.
Common Accident Analysis and Solutions
1.1 Roll Box Water Ingress
Root Causes:
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Excessive clearance between outer oil thrower ring and panel, allowing high-pressure cooling water entry
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Deformed panels from installation damage or operational incidents
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Incompatible materials in double-lip seals causing premature aging
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Insufficient compressed air pressure failing to maintain effective sealing
Solutions:
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Standardize installation protocols for panel flatness and joint surfaces
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Implement grinding treatment for panel contact surfaces
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Prohibit metal tools during assembly to prevent damage
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Verify seal integrity and proper interference fit during installation
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Upgrade seal materials for improved oil resistance and temperature tolerance
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Maintain compressed air pressure within specified ranges with regular pipe cleaning
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Establish assembly standards and regular spare parts replacement schedules
1.2 Roll Ring Fragmentation
Accident Analysis:
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Improperly locked roll rings causing relative rotation and frictional heat generation
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Insufficient cooling water pressure and flow leading to elevated temperatures
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Thermal shock from sudden cooling of high-temperature roll rings
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Internal manufacturing defects in roll rings
Preventive Measures:
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Standardize roll ring installation with clean, oil-free interfaces
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Regular measurement of taper dimensions for cones and shafts
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Maintain adequate cooling water pressure with alarm systems
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Implement natural cooling for heat-affected roll rings
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Replace with new roll rings for urgent production requirements
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Regular nozzle cleaning to prevent blockages
Through systematic implementation of these measures, the high-speed wire rod plant has significantly improved equipment reliability and reduced production interruptions, establishing a foundation for stable operation and consistent product quality.