Three Roll Mill Services

TRM FIELD SERVICES:

KMC has servicemen available for field service throughout the world. These servicemen regularly do emergency repairs, routine annual maintenance trips, and mill disassembly/reassembly for Roll Set Jobs and Roll Set Switches. In this type of service trip, the customer is charged on a portal-to-portal basis from New York.

KMC also has prescheduled service trips (PSTs) to the West Coast, Midwest, Southeast, and Texas. On these trips, our service team normally consists of four or five servicemen, and our teams are domiciled in appropriate cities as required. On a PST, the customer is charged as if the KMC shop is in the domicile city. On a PST the customer does not pay for airfare and travel time to the domicile city.
- The manager of the KMC TRM Department (Rich Condon) regularly visit the PST Domicile Cities. These trips are sales/inspection trips required to organize our service trips, as well as doing plant inspections. If done in conjunction with a PST, there is no charge for a KMC Inspection Trip. The customer will receive a written Three Roll Mill Inspection Report, a written Plan of Attack, and written Proforma Invoices for the work that Rich recommends.

MILL REPAIR PROGRAMS:

ROLL SET JOB PROGRAM:
- In this case, the TRM is disassembled by the customer, and the roll set is sent into the KMC shop for work. Upon receipt, the roll set is disassembled, inspected and a detailed Proforma Invoice is prepared. The Roll Set is then remanufactured, reassembled, and sent back to the customer. (A more complete discussion regarding this program can be obtained by clicking on the link above.) The roll set is normally at KMC for approximately 8 weeks, and the mill is normally down for approximately 10 to 11 weeks.

ROLL SET SWITCH PROGRAM:
- In this case, KMC ships a remanufactured roll set to the customer. Once received at the customer's site, the TRM is disassembled, the existing roll set is removed, the remanufactured roll set is installed, and the mill is reassembled and tested. (A more complete discussion regarding this program can be obtained by clicking on the link above.) If a KMC service team is used to switch out the roll sets, the TRM is normally down for approximately 5 days.

MODIFIED ROLL SET JOB PROGRAM:
- In this case, the customer sends the entire TRM into the KMC shop for work. The TRM is disassembled, inspected, and a detailed Proforma Invoice is prepared. A Roll Set Job is then accomplished, and the mill is reassembled and tested. The mill is normally at KMC for approximately 8 weeks and the mill is normally down for approximately 12 to 13 weeks.

MILL REMANUFACTURE PROGRAM:
- In this case, the customer sends the entire mill into the KMC shop for work. The TRM is disassembled, inspected and a detailed Proforma Invoice is prepared. The TRM is then remanufactured and tested. (A more complete discussion regarding this program can be obtained by clicking on the link above.) The mill is normally at KMC for approximately 14 weeks and the mill is normally down for approximately 16 to 18 weeks.

MILL SWITCH PROGRAM:
- In this case, KMC remanufactures a TRM and sends it to the customer, and the customer’s existing TRM is returned to KMC in trade, with the customer paying round trip freight. A MILL SWITCH can be for an identical TRM, or it can be for a different size TRM, or for a TRM with many more repeatability options. For a TRM that needs roll grinding, and is not ANSI 2017 compliant, a MILL SWITCH is a very logical path forward. Also, with a MILL SWITCH, downtime is only a day or two.

APRON PROGRAM:
- Customers have a number of choices when it comes to the repair of an apron. The simplest choice is the APRON SWITCH. In this case, a remanufactured apron is sent to the customer, and once installed, the existing apron is sent back to the KMC shop. With an APRON SWITCH, the TRM is down for only a few minutes. With the APRON REMANUFACTURE, the customer sends the apron to the KMC shop for work. The apron is remanufactured and sent back to the customer for reinstallation. In this case, the apron will be at the KMC shop for approximately 3 to 4 weeks, and the mill will be down approximately 5 to 6 weeks. KMC also manufactures new aprons for all TRMs.

ENDPLATE PROGRAM:
- In years past, the normal procedure would be for the customer to send a set of endplates to the KMC shop, for a “rebore”. The rebore consisted of cutting off the tIp of the existing endplate, machining the endplate to accept a new oversize tIp casting, attaching the new tip casting, and then machining the endplates for the correct roll diameter and bevel measurements. With a rebore, the endplates would typically be at the KMC shop for 2 to 3 weeks.
- Since 2000, the standard program is an “ENDPLATE SWITCH”. With an ENDPLATE SWITCH, the customer supplies the roll diameter and bevel measurements. KMC manufactures and invoices for a new set of endplates, and the new set of endplates is shipped to the customer. The customer removes the existing set of endplates and installs the new set of endplates on the TRM. The existing set of endplates are sent back to the KMC shop. If the existing set of endplates are “reboreable”, then KMC will issue a credit, only charging for the rebore price. If the endplates are worn, or too small to be replaced, then the customer is charged for a new set of endplates. With an ENDPLATE SWITCH, the TRM will only be down for one day.

Note:

1) The customer is responsible for roundtrip freight on the set of endplates.

2) Endplates for Day or Lehmann TRMs are designed to ride on the roll bevels. These endplates require “hand fitting”. KMC servicemen who are experts in this process. It normally takes 2 to 5 hours to do this fitting.Endplates for Day or Lehmann TRMs are designed to ride on the roll bevels. These endplates require “hand fitting”.