Hazard Identification and Risk Assessment in Roller Mill – Case Study

Roller Mills are used to grind or crush plastic, ore, grain into fine particles for usage in various industries such as chemical industry, glass fiber industry and coal industries. During the operation, the roller mills are subjected to failures due to high vibrations, low roller pressure, low Mill pressure and higher wear of grinding tools.  These kinds of failures are a greater threat for the Roller milling industry as the respective material production is affected. To overcome this issue, Risk Based Maintenance (RBM) approach and Failure Mode Effective Analysis (FMEA) is employed in the industry taken for study. Risk Based Maintenance helps in reducing the failure rate that is happening in machines and the resulting breakdown are managed with establishing action priorities. FMEA mainly deals with the estimation of risk caused by the unexpected failures due to components of the roller mill and the probability with which the failures occur is determined by Risk Priority Number (RPN). The results of this study helps to find the maintenance activity needed to be taken at the highest priority for the roller mill. The priority order thus made is based on the risk level that helps in reducing the overall risk of the equipment.