Long-Term Storage: Roll Crusher Rust Prevention & Storage Standards
Proper storage procedures are essential for maintaining roll crushers during extended shutdown periods. Without adequate protection, these valuable machines can suffer from rust, seized components, and electrical degradation. This comprehensive guide covers the complete storage process from shutdown preparation to recommissioning, providing practical solutions for environmental control, corrosion prevention, and maintenance scheduling.
Pre-Storage Preparation Procedures
Thorough preparation is the foundation for successful long-term storage of roll crushers. These initial steps ensure the equipment remains in optimal condition throughout the dormant period.
Complete Equipment Cleaning
Begin with a comprehensive cleaning of all crusher components. Remove all material residues from the crushing chamber using appropriate tools, taking care not to damage roll surfaces or chamber liners. For stubborn deposits, specialized cleaning agents designed for roll crusher maintenance can be used, followed by thorough rinsing and drying.
Pay special attention to hidden areas where material might accumulate, such as between roll teeth or in discharge chutes. Complete removal of processing residues prevents chemical reactions that could accelerate corrosion during storage.
Fluid System Management
Drain all hydraulic fluids and lubricants from the system, as aged oils can contain acidic compounds that damage internal components. Flush hydraulic lines with cleaning fluid to remove any sludge or particulate matter. For gearboxes and bearing housings, consider filling them with preservation oil that provides long-term corrosion protection.
Document the types and quantities of fluids removed for reference during recommissioning. This information ensures the correct products are used when returning the crusher to service.
Environmental Control Strategies
Creating and maintaining the proper storage environment significantly impacts the crusher's preservation. Controlled conditions prevent the most common storage-related damage.
Humidity and Temperature Regulation
Maintain relative humidity between 40-60% to prevent condensation while avoiding excessive dryness that can damage seals. Industrial dehumidifiers with adequate capacity for the storage space should run continuously, with backup units available for redundancy. In cold climates, space heaters maintain temperatures above freezing to protect sensitive components.
Install monitoring devices to track environmental conditions throughout the storage period. Digital loggers can provide historical data that helps troubleshoot any issues that may arise during storage.
Dust and Pest Prevention
Cover the crusher with breathable, anti-static fabric that allows moisture to escape while keeping dust out. Secure all openings, including feed and discharge points, with durable covers that seal tightly. Implement pest control measures appropriate for the storage location, considering both rodents and insects that might nest in or damage equipment.
For electrical components, consider using desiccant bags inside control panels to absorb any residual moisture. These should be checked and replaced periodically according to the manufacturer's recommendations.
Corrosion Protection Methods
Specialized techniques protect the crusher's critical components from rust and degradation during extended storage periods.
Roll Surface Preservation
Apply a high-quality, long-term corrosion inhibitor to all roll surfaces. The product should be viscous enough to remain in place but easy to remove when needed. For toothed rolls, ensure the preservative penetrates between teeth where moisture might accumulate. Store rolls in a position that prevents flat spots from developing on bearing surfaces.
Periodically rotate the rolls (quarter turn every month) to redistribute lubricants and prevent brinelling of bearings. This practice also helps identify any developing issues with rotation before they become serious problems.
Electrical System Protection
Remove batteries from all equipment and store them separately in a climate-controlled environment with periodic charging. Coat electrical contacts and terminals with dielectric grease to prevent oxidation. For control systems, consider using vapor-phase corrosion inhibitors that protect enclosed spaces.
Schedule monthly power-ups of electrical systems to maintain capacitor conditioning and prevent moisture accumulation. These brief activations should be documented along with any observations about system performance.
Scheduled Maintenance During Storage
Regular inspections and maintenance during the storage period ensure the crusher remains in ready-to-operate condition.
Quarterly Preservation Checks
Conduct thorough inspections every three months to assess the condition of all protective measures. Reapply corrosion inhibitors where necessary and check the integrity of all seals and covers. Verify that environmental controls continue to function properly and make adjustments as needed for seasonal changes.
During these inspections, operate all movable components through their full range of motion to prevent seizing. This includes hydraulic cylinders, adjustment mechanisms, and any moving guards or access panels.
Comprehensive Annual Review
Perform an in-depth evaluation annually, including detailed documentation of equipment condition with photographs. Test all safety systems and verify that emergency stop functions remain operational. Replace any desiccant materials and renew vapor corrosion inhibitors as needed.
This annual review should include functional testing of all monitoring systems and a check of all stored spare parts for their preservation status. Consider rotating spare parts into service during seasonal maintenance to verify their condition.
Special Environmental Considerations
Unique storage conditions require customized solutions to address specific challenges.
Coastal Salt Air Protection
In marine environments, additional measures are needed to combat salt-induced corrosion. Apply multiple layers of protective coatings to exposed metal surfaces, using products specifically formulated for saltwater protection. Consider installing sacrificial anodes on the crusher frame to provide cathodic protection.
Increase the frequency of inspections in coastal areas, paying particular attention to electrical components and precision-machined surfaces. More frequent rotation of moving parts may be necessary to prevent salt accumulation in critical interfaces.
Extreme Temperature Solutions
For arctic storage conditions, use low-temperature hydraulic fluids and lubricants that won't thicken excessively in cold weather. Install thermostatically controlled heating elements on critical components like hydraulic reservoirs and bearing housings.
In desert environments, protect rubber components and seals from UV degradation with specialized covers. Increase attention to dust sealing measures and consider more frequent lubrication of exposed mechanisms.
Recommissioning Procedures
Proper restart procedures ensure the crusher returns to service safely and efficiently after extended storage.
Pre-Startup Inspection
Conduct a comprehensive inspection before attempting to restart the crusher. Remove all preservatives and verify that no cleaning residues remain in the crushing chamber. Check all fasteners for proper torque and inspect belts for signs of deterioration.
Test all safety systems and emergency stops to confirm proper operation. Verify that all guards are in place and secure before proceeding with startup procedures.
Gradual System Activation
Begin with the lubrication system, circulating fresh oil through all circuits before applying power to the main drive. For hydraulic systems, cycle all functions several times to purge any air and redistribute seals. Gradually increase operating parameters during initial testing to identify any issues before reaching full operating conditions.
Document all recommissioning steps and any observations about equipment performance. This information provides valuable baseline data for future storage cycles and helps refine preservation procedures.