Derang Jitpl-O&m Manual - xrp1103-1 Mill

OPERATION & MAINTENANCE
M A N UA L
XRP1103 BOWL MILL
CUSTOMER
PROJECT
M/s JINDAL INDIA THERMAL POWER LTD

AT DERANG, ANGUL, ORISSA
2x600MW TPP
Publication NO. HY-BM-007-2014

Rev.00
Date: 03/06/2014
The copyright on all documents, drawings and other instruments are the
property of Bharat heavy Electricals Limited. These shall not be used without
their express written permission in any form or part thereof for any other
purposes than for which it is sent to receiver.
PUBLICATION NO:
HY-BM-007-2014
REV. NO: 00, DATE: 03/06/2014
ISSUED BY
PULVERISERS ENGINEERING
BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM::HYDERABAD
INDIA
1.0.
1.0
INTRODUCTION
Bowl Mill
XRP1103
INTRODUCTION ................................................................................................................................... 1
2.0 TECHNICAL DESCRIPTION ........................................................................................................................ 2

2.1 MILL TECHNICAL DATA: ............................................................................................................................... 2
2.2 MAJOR ASSEMBLIES: .................................................................................................................................. 3
3.0 OPERATION: ............................................................................................................................................ 5
3.1
CHECKLIST OF DOS - BOWL MILL........................................................................................................... 5
3.2 CHECK LIST OF DONTS - BOWL MILL ......................................................................................................... 8

3.3 PRINCIPLES OF OPERATION: ....................................................................................................................... 9
3.4
OPERATING PARAMETERS: ................................................................................................................... 12
3.5 START - UP: ................................................................................................................................................. 13

3.6
NORMAL SHUT DOWN: ......................................................................................................................... 14
3.7
EMERGENCY SHUT DOWN: ..................................................................................................................... 14
3.8
START UP AFTER EMERGENCY SHUT DOWN: ....................................................................................... 15
3.9
MILL FIRES: ............................................................................................................................................ 16
3.10 FIRE EXTINGUISHING PROCEDURES: ...................................................................................................... 17

3.11
4.0
MILL REJECTS: ....................................................................................................................................... 19

PULVERISER LUBE OIL SYSTEM ............................................................................................................. 5
4.1
JOURNAL ................................................................................................................................................. 5
4.2
MISCELLANEOUS & IDLE MILLS: .............................................................................................................. 6
4.3 PULVERISER LUBE OIL SYSTEM OPERATING INSTRUCTIONS ....................................................................... 8

TABLE -1......................................................................................................................................................... 14
5.0 PLANETARY GEAR BOX ........................................................................................................................... 15
5.1 PLANETARY GEAR BOX OPERATING INSTRUCTIONS ................................................................................. 15
5.2
OPERATION ......................................................................................................................................... 20
5.3 GENERAL TROUBLESHOOTING .................................................................................................................. 21

5.4 INSPECTION .............................................................................................................................................. 23
TABLE-2 (Check list for evaluating the condition of PGB lube oil system) ....................................................... 23
5.5 MAINTENANCE ......................................................................................................................................... 24
TABLE -3 (Materialrelated contamination limit values for lube oil) .............................................................. 25
TABLE -4 (Pre-stressing force, tightening torques, pre-stressing device hydraulic) ......................................... 29
TABLE -5 (Maintenance of PGB lube oil system)............................................................................................. 30
5.6 REPAIR ...................................................................................................................................................... 31
5.7 LUBRICANTS ............................................................................................................................................. 31
1.0.
INTRODUCTION
Bowl Mill
XRP1103
5.8 LIST OF EQUIPMENT ................................................................................................................................. 31

TABLE - 6 ........................................................................................................................................................ 32
5.9
LOCKING GUIDELINES .............................................................................................................................. 32
5.10 SPARE PARTS STOCK................................................................................................................................ 33

6.0 MILL OPTIMIZATION .............................................................................................................................. 36
7.0 TROUBLESHOOTING ............................................................................................................................... 38
TABLE- 8......................................................................................................................................................... 39
8.0
8.1
PULVERISED COAL SAMPLING: ........................................................................................................... 43

NON-ISOKINETIC SAMPLING METHOD: (For ISO KENITIC SAMPLING refer ............................................ 43
to O& M manual of Vendor, if applicable) ........................................................................................................ 43

8.2
ADJUSTMENT OF FINENESS: ................................................................................................................. 45
8.3 MILL WEAR LIFE ASSESSEMENT ................................................................................................................ 49

9.0. MAINTENANCE........................................................................................................................................ 50
10.0 GENERAL MAINTENANCE: ...................................................................................................................... 51
10.1 INSTRUCTIONS FOR INTERFERENCE FIT: ................................................................................................... 53
11.0
11.1
PREVENTIVE MAINTENANCE............................................................................................................... 55
MILL CLEARANCES ................................................................................................................................. 55
11.3 CHECKING SPRING COMPRESSION (Refer Figure. 11.f): ......................................................................... 67

11.4
INSPECTION TASKS ................................................................................................................................ 68
12.0 COMPONENT MAINTENANCE .............................................................................................................. 70

12.1 GENERAL DIS-ASSEMBLY AND RE-ASSEMBLY OF COMPONENTS: .......................................................... 70
12.1.1 PLANETARY GEARBOX WITHDRAWAL & REINSTALLATION PROCEDURE .......................................... 70
(Ref: Figure G) ............................................................................................................................................... 70
12.1.2 JOURNAL AND COVER REMOVAL SEQUENCE (FIG. 12.a): ............................................................... 74
12.1.3 DISCHARGE VALVES & MULTIPLE PORT OUTLET ASSEMBLY REMOVAL ............................................ 76
(Fig. 12.b & Fig.-A) ........................................................................................................................................ 76
12.1.4 SEPERATOR BODY REMOVAL (Fig. 12.C & Fig-A): ............................................................................ 77
12.1.5 BOWL AND BOWL HUB REMOVAL ................................................................................................. 78
12.2 GENERAL DIS-ASSEMBLY AND RE-ASSEMBLY OF OTHER COMPONENTS: ............................................. 80
12.2.1 RENEWAL OF BULL RING SEGMENTS (Figure 12.d & FIG-H): ............................................................. 80
12.2.2 AIRPORT RING REPLACEMENT (Figure 11.d): ................................................................................... 80
12.2.3 ROLL RENEWAL (Fig. 12.e and FIG-J): ............................................................................................... 81
12.2.4 JOURNAL OPENING FRAME LINER REPLACEMENT (Fig-L) ................................................................ 82
12.2.5 JOURNAL HEAD LINER ASSEMBLY REPLACEMENT: ......................................................................... 83
12.3 JOURNAL SHAFT ASSEMBLY WITH DOUBLE UPPER JOURNAL BEARING ................................................ 83
SPACER GRINDING CALCULATION .................................................................................................................. 85
TABLE -12 ....................................................................................................................................................... 96
1.0.
INTRODUCTION
Bowl Mill
XRP1103
12.4 JOURNAL HEAD TO JOURNAL SHAFT ASSEMBLY ................................................................................... 108

12.5 Adjustment of the Seal Air Gap ............................................................................................................... 109
13.0 STORAGE AND PRESERVATION OF MILL COMPONENTS ..................................................................... 111
13.1 PRESERVATION WITH PRESERVATIVE ................................................................................................... 111
TABLE-13 Recommended preservatives for PGB ........................................................................................ 111
13.2
SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:...................................................................... 112
13.3 PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL: ..................................................................... 112

13.4
DRIVE COUPLINGS: .............................................................................................................................. 112
13.5
MILL DISCHARGE VALVES ASSEMBLY: ................................................................................................. 112
13.6
INTERIOR AREAS: ................................................................................................................................. 113
13.7
MILL MOTOR: ...................................................................................................................................... 113
13.8
GENERAL: ............................................................................................................................................ 113
13.9 LONG TERM PRESERVATION OF THE PLANETARY GEAR BOX: ................................................................ 113
14.0 SPARES ............................................................................................................................................... 118
14.1 RECOMMENDED SPARES LIST .............................................................................................................. 120
Bowl Mill
XRP1103
CONTENTS
LIST OF DRAWINGS
Fig
No.
A
B
C
D
E
F
G
H.
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
Description
Bowl Mill cross-section
Bowl Mill General Arrangement Drawing
Planetary gear box assembly
Mill foundation drawing
Deflector Control Assembly
Removal and Weight of Mill Parts
Gear box withdrawal procedure
Bull ring segment assy.
Tightening Torque for Fasteners
Roll Removing Fixture
Special Tools
Journal opening frame liner assembly
Protective Seal Application (17 deg tilt) venturi vane
Pulveriser Lube Oil System Scheme
PF Sampling Arrangement
Journal shaft assembly
Journal head and trunnion shaft assembly
Journal assembly
Scrapper assembly
Mill side housing and Base assembly
Journal pressure spring assembly
Bowl & Bowl Hub Assembly
1.0.
1.0
INTRODUCTION
Bowl Mill
XRP1103
INTRODUCTION
Bowl mills are employed to pulverize the pre-crushed raw coal to the required fineness
before it is admitted into the boiler furnace for combustion. The operating characteristics of
bowl mills make it the best mill available for the direct firing system of the coal. The best
features of all the pulverisers have been incorporated in the design of the bowl mill. The mill
output can be easily varied, as per the turndown ratio from its minimum to maximum load
and it will operate for long periods without mechanical problems or stoppages for cleaning,
oiling or adjusting.
Crushed raw coal at a controlled rate is fed into the revolving bowl of the Bowl Mill.
Centrifugal force feeds the coal uniformly over the replaceable grinding ring where
independently spun rolls exert the required grinding pressure. The rolls do not touch the
grinding ring even when the mill is empty. Therefore the Bowl Mill operates silently without
the rumble that is characteristic of the mills in which there is metallic contact between the
grinding elements.
This mill is designated as XRP 1103 Bowl Mill where
X 3 Phase, 50 Hz Supply,
R Raymond (Inventor of the mill),
P Pressurized,
104 Nominal dia. of the Bowl (inches)
3 Number of the Grinding Rolls.
The mill works in a pressurized atmosphere as the primary air fan is placed in the system
ahead of the mill and hence will be designated as XRP mill.
The instructions contained in this manual give an outline of the correct methods and
procedures for installation. The contents in this manual have been compiled and checked
by experts in this field. Every possible care has been taken to ensure the contents are
accurate.
It must be recognized that no amount of written instructions can replace
intelligent thinking and reasoning on the part of the operating and maintenance staff.
2.0.
2.0
Bowl Mill
XRP1103
TECHNICAL DATA
TECHNICAL DESCRIPTION
2.1 MILL TECHNICAL DATA:
TYPE OF MILL
XRP 1103
MILL BASE CAPACITY(T/Hr)*
78.5 (Design Coal)
MOTOR SPEED(RPM)
990
TOTAL WEIGHT OF MILL(T)
170
(including motor)
TYPE OF LOAD
Moderate Shock Load
ROTATING WEIGHT OF MILL(T)
22.88
SPRING RATE(Kg/cm)
5359
SPRING PRE LOAD(Kg)
9500
MILL OUTLET TEMPERATURE RANGE
65C -90C
AIR FLOW (T/Hr)
136
FINENESS *
70% Through 200 Mesh

98% Through 50 Mesh
The capacity for bituminous/ sub-bituminous coal having hard grove index (HGI) as
45 and Total Moisture as 12%.
The Bowl mill is one of the most advanced designs of coal pulverisers presently
manufactured by BHEL. It possess the following advantages over other type of pulverisers
i)
Low power consumption
ii)
High Reliability
iii)
Minimum maintenance time required
iv)
Wide capacity with good turndown ratio
v)
Ability to handle wide range of coals
vi)
Quite and less vibration operation
2.0.
2.2
TECHNICAL DATA
Bowl Mill
XRP1103
MAJOR ASSEMBLIES:
a)
PLANETARY GEAR BOX AND BOWL

HUB ASSEMBLY:
Planetary gear box is used to give

required torque to the bowl & bowl hub
Assembly which is directly mounted
and bolted to the gear box top table.
The direction of torque transmission in
planetary gear box changed from
horizontal
to
vertical.
The
bowl
assembly consists of Bull ring assembly

(mounted
on
the
bowl),
Skirt
&
Scrapper Assembly and vane wheel

assembly (attached to the bowl).
b) MILL SIDE AND LINER ASSEMBLY:

The hot primary air for drying and
carrying pulverized coal enters into the
mill side and air inlet housing. The mill
side and liner assembly is insulated
externally to prevent heat loss from
primary air to the atmosphere, or to the
gearbox.
2.0.
Bowl Mill
XRP1103
TECHNICAL DATA
c) SEPARATOR BODY ASSEMBLY:

The
separator
body
holds
the
components that give necessary

grinding
pressure
(journal
spring
assembly), journal assembly and also

the components that direct the
coarse sized coal particles back to
the bowl for re grinding.
d) ROLLER JOURNAL ASSEMBLY:

The roller assembly consists of journal
shaft,
Journal bearings, and journal
housings, Grinding roll, journal head,
trunion shaft assembly.
.
2.0.
TECHNICAL DATA
Bowl Mill
XRP1103
e) MILL DISCHARGE VALVE ASSEMBLY:

The mill discharge valve assembly
consists of four multiport outlet and mill
discharge valves mounted on the
multiport outlet plate. Air cylinders
operate the flaps in the mill discharge
valves.
Solenoid
valves
and
limit
switches are provided to effect and

indicate the open or close position of
the flap. This assembly does the
distribution of pulverised fuel into four
pipes and also it isolates the mill from
boiler when required
3.0.
3.0
OPERATION
Bowl Mill
XRP1103
OPERATION:
Pulverization is the method of preparing raw coal for complete burning.
Mechanically pulverizing coal into fine powder enables the pulverized fuel to burn
like an oil or gas in a steam generator, thus allowing more efficient combustion. The
Pulverised coal Transported by hot air and introduced directly into the boiler furnace
zone for combustion.
3.1
A.
CHECKLIST OF DOS - BOWL MILL

Before start up :
1.
Check lubrication with reference to proper level and cleanliness of lubricants.
2.
Check sufficient raw coal in the raw coal bunker.
3.
Check for proper operation of mill discharge valves, hot air shut off gate, hot air
damper and cold air damper and seal air system.
4.
Check that all three roller journal pressure springs are compressed to the same
spring pre-load of 9.5 tons to start with and further adjustment as per given Coal
Hargrove Index (HGI).
5.
Check for proper ring-roll setting.
6.
Check that all classifier vanes are open to the same extent.
7.
Check that all flange joints and packing are properly placed and adequately
tightened.
8.
Check that no boiler trip condition exists.
9.
Check sufficient ignition energy is available in the furnace.
10.
Check that mill discharge valve is in open condition.
11.
Check that seal air valve to mill is open and seal air supply present at adequate
pressure.
12.
Check that cooling water line is open and cooling water supply present to the mill
lube oil coolers.
13.
Check that tramp iron spout valve is open.
14.
Check that raw coal bunker outlet gate and/or inlet gate to feeder is/are open.
3.0.
OPERATION
Bowl Mill
XRP1103
15.
Check that cold air gate is open.
16.
Check that adequate primary air pressure is available in the hot air header.
17.
After the mill lube system has been started at least 15 minutes before, checkup the
oil flow, temperature and pressure to the planetary gear box.
18.
Feeder must be started only after the mill has been started and warmed up.
19.
Check that there is proper coal flow into the mill (an annunciation for the no coal
flow from raw coal feeder will come when there is no coal flow to the mill)
20.
During the initial period and load picking up of the mill check that sufficient ignition
energy is available in the furnace till Pulverised fuel from each mill attains selfsustained combustion.
21.
During a relight-up of the unit, after a unit trip out, ensure that the discharge valves
of all non-operating coal laden pulverisers are closed whenever a fresh fuel
(oil/coal) elevation is cut in until the furnace draft has stabilized, to avoid any
Surging back of furnace gases into the coal laden pulverisers in case of furnace
pressurization.
This procedure should be employed until all such coal laden
pulverisers are either taken into regular service or emptied completely.
B.
Normal operation :
1.
Check oil flow, temperature and pressure to planetary gear box.
2.
Check for proper mill outlet temperature.
3.
Check for proper mill air flow.
4.
Check for all bearing and oil temperatures.
5.
Check for Pulverised fuel fineness at routine intervals. Carry out ring-roll setting
and/or classifier setting based on the PF fineness lab results.
6.
Check for mill rejects (quality and quantity).
7.
Check for status of wear on all wear parts at least once in two months whenever
mill is down for more than one shift.
8.
Carry out raw coal analysis at routine intervals.
3.0.
OPERATION
Bowl Mill
XRP1103
9.
Check level and quality of lube oil in lube oil tank and journal assemblies regularly.
10.
Check for any abnormal sound.
11.
Check for any air or pulverized coal leakage and attend to them promptly.
12.
Check for hot air leakage through the Gland packing seal. This indicates trouble
with the Labyrinth Seal and or Gland packing seal or inadequate seal air supply,
pressure and flow.
C.
SHUT-DOWN :
i)
During Normal Shut-Down :

1.
Cool the mill during and after shut-down.
2.
Run the mill for at least 5 minutes until coal is completely emptied before shut down.
3.
Keep cold air regulating damper slightly throttled to approximately 5 after the mill
has stopped.
4.
If water freezing weather is present and if mill shut-down is of long duration drain the
water from oil cooler.
ii)
During Emergency Shut-Down :

1.
If fire in the bunker or in the mill is noticed, take immediate action for putting out the
fire. For quenching these fires in the mill, try the following methods.
(a)
Shut the hot air shut off gate, and supply 100% cold air flow to mill; place the
feeder on manual control and continue feeding coal at a high rate without
overloading the mill.
(b)
If fire is not put out by the above, water or steam may be admitted into the
milling system. The mill must be kept running, with the feeder stopped, for
several minutes till all the signs of fire are gone.
3.0.
2.
OPERATION
Bowl Mill
XRP1103
If a fire exists completely through the mill and fuel piping, clear all personnel from
the area surrounding the mill, its associated feeder and fuel piping. Shut off the
feeder and allow the mill to clear itself all the fuel. Maintain a flow of cold air through
the mill until all evidence of fire has disappeared and the mill is cold, then shut-down
and isolate the mill. Spray emergency firefighting water into the mill to quench the
fire.
3.
When a fire has been extinguished and the mill has cooled, stop the mill, open
inspection doors carefully and thoroughly clean the interior of the mill of any
accumulation including coal water slurry. Check lubricants for evidence of
carbonizing. Check all parts where the fire has occurred for any damage,
especially the O Rings & Oil seals.
3.2 CHECK LIST OF DONTS - BOWL MILL
A.
B.
BEFORE START-UP AND OPERATION :

1.
Dont start the mill, if any permissive, inter locks or protection is found not working/by
passed.
Do not start the mill without ensuring proper lubrication, cooling water supply to the
oil coolers.
3.
Do not start the mill with discharge valve & tramp iron valve closed.
4.
Do not start the feeder without the mill running and in warmed up condition.
5.
Do not start the feeder without ensuring proper ignition energy in the furnace.
6.
Do not start the mill without seal air supply.
7.
Do not continue operation of mills with high mill outlet temperatures.
8.
Do not run the mill continually with abnormal noise, high vibration, or with high
bearing & oil bath temperatures and only one or two roll indicators moving.
9.
Do not start the feeder without checking ring-roll clearance of the mill.
MAINTENANCE :
3.0.
OPERATION
Bowl Mill
XRP1103
1.
Do not Open any of the Manhole Doors to get into the mill for maintenance without
ensuring that driving motor has been isolated, mill discharge valve is closed (if the
boiler is in operation), and the mill is isolated from the air side as well as raw coal
side.
2.
Do not use steel hammers directly on grinding rolls and bull ring segments.
3.
Do not use direct flame torch for heating bearing assemblies.
4.
Do not leave tools, work pieces, electrodes etc., inside the mill after maintenance
work has been carried out.
5.
Do not carry out maintenance work inside the mill without proper personnel safety
equipment.
6.
Do not weld on the bowl or any part attached to it unless the welding machine is
grounded to the bowl to prevent arching across bearing assemblies.
7.
Do not use 230 volts supply lights, and electrical grinders inside the mill (Use 24 volts
supply for hand lamps as a safety measure).
8.
After a mill fire, do not open access door until all symptoms of fire are vanished.
9.
Do not weld on high strength non-weldable components of planetary gear box like
bevel pinion shaft, bevel gear wheel etc.
10.
Do not interchange bevel pinion shaft and bevel gear wheel. Both these are
matched set. It is recommended to replace them as a set. It is recommended to
carry out maintenance on the gearbox internals only in the presence of
experienced fitters from BHEL or send the gearbox to BHEL works.
11.
Do not interchange journal opening covers, even within the same mill. They are
matched with respective journal opening frames of the separator body.
3.3
PRINCIPLES OF OPERATION:
Coal is fed to the center of the pulveriser onto a revolving bowl. Centrifugal force
causes the coal to travel towards the perimeter of the bowl. The coal passes
between the bull ring and the grinding rolls, which impart the pressure necessary for
3.0.
OPERATION
Bowl Mill
XRP1103
grinding. The partially ground coal moves outward and over the edge of the bowl.
Heated air enters the mill side housing below the bowl and is directed upward
around the bowl outside diameter and separator body annulus, by the rotating
vanes. It continues upward and into the deflector openings in the classifier at the top
of the inner cone, then out through the venturi and multiple port outlet assembly. As
the air passes upward around the bowl, it picks up the partially pulverized coal;
particles are carried up through the deflector openings of the classifier. The deflector
blades in the openings cause the coal - air mixture to spin within the inner cone. The
angle of the blades determines the velocity of the spin and the resulting fineness of
the finished product. Coarser Pulverised coal particles are returned through the
inside of the inner cone to the bowl for further grinding. Coal that is Pulverised to the
desired fineness leaves the pulveriser and enters the fuel piping system.
Any tramp iron or dense and difficult to grind foreign material in the coal feed is
carried over the top of the bowl, where it drops through the air stream and rotating
vanes to the mill bottom. Pivoted scrapers attached, to the lower skirt, sweep the
tramp iron or other material to the tramp iron discharge opening.
The tramp iron spout is fitted with a valve. Under normal operation this valve remains
open and material is discharged into a sealed pyrite hopper. The valve is closed only
while the hopper is being emptied.
DO NOT close the valve on the tramp iron spout to prevent the discharge of rejects.
If the valve is closed for an extended period, material normally discharged will be
retained in the mill side housing and be ground by the scrapers, scraper guards and
holders. This produces excessive wear on these parts and creates a potential fire
hazard.
If coal is discharged into the pyrite hopper, this indicates overfeeding, too little
grinding pressure on the rolls, too low an air flow or too low a pulveriser outlet
temperature. Excessively worn pulveriser parts or improper adjustment can also
cause coal to be discharged. Excessive spillage indicates that a pulveriser is not
functioning properly and steps should be taken as soon as possible to correct the
situation.
The pulveriser operates under positive pressure. A seal air system provides clean air
to a chamber (Labyrinth seal) surrounding the bowl hub to prevent hot air and coal
dust from leaking to the atmosphere. Seal air is supplied to each journal trunnion
shaft to prevent coal dust from entering the journal bearings. Seal air is also supplied
to each spring assembly to keep it free from coal dust.
10
3.0.
Bowl Mill
XRP1103
OPERATION
For good pulveriser performance, the temperature of the coal-air mixture

leaving the classifier should be maintained as high as possible within the safe
temperature limit for that particular coal. Too high an outlet temperature may lead
to a pulveriser fire.
The safe temperature limit for a given coal depends on the percentage of volatile
matter, moisture and pyrites either individually or a combination of them in the coal.
BHEL pulveriser systems are designed to perform effectively with coals with a wide
range of moisture content and grindability. In order to obtain rated capacity from
the pulveriser, it is necessary to have sufficient hot air entering the pulveriser to dry
the coal, sufficient pressure on the rolls to pulverise it and proper setting of the
classifier deflector vanes to obtain fineness reasonably close to that for which the
pulveriser is designed. Operating experience will help determine the pulverisers
optimum conditions for a given coal.
CAUTION
PULVERISER OUTLET TEMPERATURE IN EXCESS OF 95 C COULD RESULT IN PULVERISER FIRES.
REFER TO PULVERISER FIRES. THE CONTROL SYSTEM SHOULD AUTOMATICALLY CLOSE THE
HOT AIR SHUTOFF GATE IF THE PULVERISER OUTLET TEMPERATURE RISES TO 95C.
11
3.0.
3.4
OPERATION
Bowl Mill
XRP1103
OPERATING PARAMETERS:
To meet the safe and optimized mill operating criteria, the following
operating parameters must be established for the given coal
i). MILL AIR FLOW:
Mill should be operated at the design air flow at all loads. Operating at higher air
flow will cause excess wear and upset the performance of classifier etc. If mill is
operated at lower air flow it may result in coal rejects, low bowl differential pressure,
excess fineness, coal settlement etc. The air flow is controlled by the simultaneous
operations of hot and cold air dampers.
ii). MILL OUTLET TEMPERATURE:
For good pulverizer performance, the temperature of coal air mixture leaving
the classifier should be maintained as high as possible within the safe temperature
limit of the coal being ground. Too high a outlet temperature may lead to a
pulverizer fire. When grinding coal with a volatile content below 25% on an as
received basis, the mill outlet temperature of 75C to 80C is recommended. If a
high volatile coal is also a high sulphur coal, the maximum safe operating
temperature may be as low as 65C. When grinding coal with higher volatile
content, more than 25%, the mill outlet temperature should be maintained
between 55C to 60C.
Environmental conditions may cause changes that result in lower pulverizer
outlet temperature. A pulverizer may be operated at a temperature below 65C
provided there is no loss in capacity, coal spillage, high bowl differential pressure,
or high motor current. The outlet temperature below 55C may not dry the coal
sufficiently. Mill outlet temperature is controlled by simultaneous association of cold
and hot air dampers.
iii). PULVERISED FUEL FINENESS:
The degree of Pulverised coal fineness required depends upon the volatile
content of coal and the furnace size. This is specified for each unit. Operating the
mills at higher fineness increases the wear rate and reduces capacity of the mill.
The fineness can be controlled by operating the classifier vanes, after carrying out
an optimized spring compression setting, air flow setting and ring roll setting for the
mill
iv). MILL CAPACITY:
The capacity of mill depends on the hard groove grindability index, the moisture
content of coal and the pulverised fuel fineness.
12
3.0.
Bowl Mill
XRP1103
OPERATION
TECHNICAL POINT
IF LOW CALORIFIC VALUE OF COAL IS USED, THE AMOUNT OF COAL REQUIRED BY

THE STEAM GENERATOR IS MORE. THUS MILL CAPACITY IN TERMS OF HEAT INPUT TO
STEAM GENERATOR DECREASES.
The indications of mill overloading are the following, out of which one or more
indication may be present during mill overloaded condition:
a)
b)
c)
d)
High mill motor current.

High bowl differential pressure.
Low mill outlet temperature.
Mill rejects having large amount of coal.
3.5 START - UP:

Before the pulveriser motor circuit is energized and the pulveriser is run under power
for
taking
up
coal
firing.
The
following
items
must
be
checked
for
completion/readiness.
1. Pre Start up checks:
2.
a)
Pulveriser / motor coupling alignment.
b)
Roll - ring clearance.
c)
Lubrication system.
d)
Deflector blades setting.
e)
Seal air supply adequacy.
f)
MDVs and Tramp iron spout valve is in open position.
Check the oil level in the journals and in the lube oil tank and gear housing. Make
sure the shut off valves in the lubrication system are open both on oil side and
cooling water side.
3.
4.
Open all coal line valves and/ or gates and the cold air shut off gate.
Start the pulveriser lubrication system. Check that adequate oil pressure,
temperature and flow is established to the bearings and gears in gear box with
the help of the instrumentation provided in the lube oil lines.
TECHNICAL POINT
THE LUBE OIL PUMP MUST BE RUNNING AT LEAST FOR 15 MINUTES BEFORE GIVING A
PULVERISER START PERMISSIVE. AFTER THE PULVERISER IS STARTED, THE OIL TEMPERATURE
SHOULD BE MAINTAINED BETWEEN 30 C TO 50 C.
5.
Open the hot air shut off gate. The control system should adjust the hot and cold
air control dampers to give the proper air flow and allow the pulveriser to warm up
13
3.0.
OPERATION
Bowl Mill
XRP1103
to a temperature range of 60 C to 70 C and exact temperature set point to be

established later, depending upon operating experience with the given coal.
6.
Establish the required ignition energy. Then start the feeder with a fairly high feed
rate. When the pulveriser begins to grind, (this is indicated by an increase in the
motor amperes.) reduce the feed rate to the desired setting. Increase the feed
rate as per unit load demand. The second and successive mills should be placed
in service when the loading on the operating pulveriser(s) reaches 80%.
3.6
NORMAL SHUT DOWN:

If possible cool the mill before shutting it down.
i)
Close the mill hot air regulator damper and hot air shut off gate and cold
air damper should be opened to maintain 100 percent air flow.
ii)
Continue feeding coal till the mill outlet temperature reaches 50 C. Then
stop the feeder.
iii)
Run the mill for another few minutes till it becomes empty and then shut
down.
iv)
Cold air damper should be throttled to approximately 5 open after the mill
stops. A minimum quantity of cold air flow must be maintained through the
mill at all times.
NOTE: - Chances of mill fire would be reduced if the above steps are followed.
v)
When the pulveriser is shut down for any length of time in cold weather, it is
advisable to drain the water from the lube oil coolers. If for any reason ice
has formed in the tubes, a careful examination should be made before
starting up to make sure that the tubes have not ruptured allowing cooling
water to contaminate the oil.
3.7
EMERGENCY SHUT DOWN:

On loss of furnace ignition or another condition that requires an automatic or
manual emergency fuel trip, the mill motor should be tripped immediately.
Stopping the motor should trip the feeder; close the hot air shut off gate and
initiates a minimum inert sequence, if required, provided the mills are equipped
with an inerting system.
14
3.0.
Bowl Mill
XRP1103
OPERATION
An emergency trip may subject residual fuel in the mills to cause spontaneous
combustion. The unit should be re-fired within a reasonable time (45 minutes) to
clear the mills. If this cannot be done, the mill should be cooled and manually
cleared (see CAUTION).
As a minimum precaution, the mill should be isolated, and all inspection doors
removed / opened to prevent volatile gases from mill entering the furnace.
NOTE: If an inerting system is installed, start the mill steam inerting system for one
minute immediately after shut down and again before opening the
pulveriser inspection doors. The inerting steam line isolation valves must be
properly closed before the mill manhole doors are opened.
CAUTION
A HOT MILL WILL DISTILL COMBUSTIBLE GASES, FROM RESIDUAL COAL. THEREFORE
TAKE PRECAUTIONS WHEN OPENING THE MILL FOR CLEANING.
3.8
START UP AFTER EMERGENCY SHUT DOWN:

After an emergency trip, the mills that were in service will be hot and contain a
considerable amount of partially pulverised coal. The coal should be removed
from the mills one by one quickly to avoid mill fires. The following procedure should
be used.
i)
Purge the unit.
ii)
Establish ignition energy in the boiler for the mill to be operated.
iii)
Check that the mill discharge valves are closed on all mills not in service.
This will prevent hot furnace gases, which will be at higher than normal
pressure upon initial ignition of the coal, from surging down the fuel piping
into the idle pulverisers.
iv)
Open mill discharge valve on the mill to be cleared.
v)
Hot air shut off gate should remain CLOSED. Open cold air damper and
establish 100% air flow through the mill to transport the coal.
vi)
Start the mill and leave it ON for several minutes to remove all coal. If mill
is to be kept in service start the feeder before mill is empty. Then open the
hot air shut off gate and modulate hot air damper to bring the mill to normal
operating temperature.
15
3.0.
vi)
OPERATION
Bowl Mill
XRP1103
Repeat (ii) to (VI) above for all mills containing coal. When mills have been
emptied and/ or placed back in service, the discharge valves of remaining
idle mills should be opened to allow the required minimum cold air flow
through them.
3.9
MILL FIRES:
Causes:
The usual causes of pulveriser fires are:
i)
Excessive Mill Outlet Temperatures:

Do not permit the mill outlet temperature to exceed 95 C regardless of the
material being pulverised.
ii)
Foreign Material such as Paper, Bags, Straw, Wood and Excelsior collection
in the inner Cone and other points in the Mill:
These materials do not pulverise readily and therefore should be kept out
of the raw fuel supply. When they get into the system, they collect and may
catch fire. Each time the mill is opened for any reason, remove any such
debris from air inlet, inner cone, bowl or other areas.
iii)
Excessive Accumulations of Pyrites or Coal on the Mill Bottom or in the Air

inlet to the Mill:
The valve on the tramp iron discharge spout should normally be open to
allow the free discharge of foreign materials into the Pyrites collection
system. The valve may be closed momentarily for the removal of pyrites
from the collecting hopper. Accumulation of debris in the air inlet should
be removed whenever the mill is open for inspection. Scraper and guard
assemblies clearances with mill side liner insulation cover plate shall be reset periodically or replaced.
iv)
Excessive Accumulations of Coal in Areas above the Bowl:

This condition is usually brought about by lack of maintenance. Worn liners
may allow coal to accumulate in an area faster than the normal air flow
will remove it or to reach areas where it cannot be removed by the normal
air flow. Coal can also be trapped by foreign material bridging a section
of the mill through or over which the coal would normally move.
v)
Improper or Unusual Operation:

An accumulation of coal or flammable foreign material is a hazard under
normal operating circumstances, but in most cases this alone does not
cause a fire or puff. Usually some additional improper operating conditions
16
3.0.
OPERATION
Bowl Mill
XRP1103
must initiate the trouble. For instance, if a mill is operated with low air flow,
higher mill inlet temperatures are necessary to maintain the set outlet
temperatures. The air flow may be so low that additional coal settles out of
the air stream. This condition can result in more heat, less coal movement
and a potential for fire.
Another example would be failure to close the hot air gate when there is
reason to believe an operating condition may have allowed a fire to start.
Such a condition could be a sluggish damper drive mechanism or a
sluggish damper control system, coupled with a substantial and rapid
change in coal moisture.
An example of unusual operation would be running coal through a mill from
a bunker that is known to be on fire. Of course extreme care must be taken
while doing this. Everything possible must be done to make feeding
continuous at a moderate to heavy rate.
INDICATIONS:
The two most common indications of a fire in a milling system are:
3.10
a)
A high or rapidly increasing mill outlet temperature without other cause.
b)
Paint peeling from the mill and/ or piping.
FIRE EXTINGUISHING PROCEDURES:
If a mill system fire does occur, perform the following:

a)
Regardless of the fire location DO NOT shut down the mill and NEVER open any
mill inspection doors until all evidence of the fire has disappeared.
b)
SHUT THE HOT AIR SHUT OF GATE AND OPEN COLD AIR CONTROL DAMPER.
Pulveriser outlet temperature in excess of 95 C could result in Mill fires. The
control system should automatically close the hot air shutoff gate if the pulveriser
outlet temperature rises to 95 C. At the same time the cold air control damper
should get open command to supply 100% design air flow to the mill.
17
3.0.
c)
Bowl Mill
XRP1103
OPERATION
Place the feeder on manual control and continue feeding coal at a high rate
without overloading the mill.
Closing the hot air gate will frequently extinguish the fire, but if the mill temperature
continues to rise:
d)
Stop the feeder as well as supply of Cold air to Mill and cool the mill by admitting
steam or water.
NOTE : On pressurised mill where the air ducts and mill feeders are sealed, it is
recommended that spray nozzles be installed in the mixing air ducts and
mill center feed pipe so they may be used to admit water or steam to the
milling system. The nozzles can be permanently piped to a supply system
with suitable valves or they can be equipped with some type of quick
disconnect coupling to allow connection to portable water supply hoses.
CAUTION
FIRES UNDER THE BOWL USUALLY DO NOT CONTRIBUTE TO ABOVE BOWL
FIRES OR EXPLOSIONS UNLESS SOMETHING IS ALLOWED TO VIOLENTLY DISPERSE
THEM, SUCH AS A SUDDEN SLUG OF WATER. THE MOST EFFECTIVE WAY OF
TREATING THEM IS TO CONTINUE RUNNING THE MILL WITH COLD AIR UNTIL THE FIRE
GOES OUT. THE MILL AIR INLET DUCT AREA SHOULD BE CLEARED OF
ACCUMULATED MILL REJECTS AT EVERY OPPORTUNITY.
e)
Shut off the steam or water being admitted to the system.
f)
Run the mill for several minutes to completely purge the system and to reduce the
possibility of accumulation of water.
CAUTION
WHEN A FIRE HAS BEEN EXTINGUISHED AND THE MILL HAS COOLED, STOP THE MILL
OPEN THE INSPECTION DOORS (SEE WARNING) AND THOROUGHLY CLEAN THE INTERIOR
OF THE MILL OF ANY ACCUMULATIONS, INCLUDING ANY COAL WATER SLURRY. USE CARE
WHEN CLEANING A BOWL MILL MANUALLY.
IF IT BECOMES OBVIOUS FROM PEELING PAINT AND CHANGE IN COLOUR THAT A FIRE
EXISTS COMPLETELY THROUGHOUT THE MILL AND FUEL PIPING AND THE PRECEDING
METHODS OF COMBATING THE FIRE HAVE BEEN INEFFECTIVE.
g)
Clear all personnel from the area surrounding the mill and its associated feeder
and fuel piping.
h)
Shut off the feeder and allow the mill to clear itself of fuel.
18
3.0.
i)
OPERATION
Bowl Mill
XRP1103
Maintain a flow of cold air through the mill until all evidence of fire has disappeared
and the mill is cold.
j)
Shut down and isolate the mill.
k)
Open all inspection doors (see WARNING) and hand hole covers.
l)
Inspect the mill interior and check the separator body, inner cone, upper and lower
mill sides and feeder.
m)
NOTE:
Clean where necessary.

After any fire or mill puff, the entire milling system from the feeder to the fuel
nozzles, including the coal feeder mill air inlet duct, coal pipes, internal coal
nozzles and tilt mechanism should be checked for possible damage and
cleanliness. Repeat the checks and be sure to remove any accumulations
of coal or coke.
n)
Check the oil seals on each journal assembly.
o)
Check the journal assembly lubricants and replace them if there is evidence of
carbonizing. Once everything is satisfactory, the mill may be returned to service.
CAUTION
TAKE CARE WHEN OPENING MILL INSPECTION DOORS, THE MILL MAY BE PRESSURIZED.
CHECK THAT THE HOT AND COLD AIR SHUT OFF GATES, THE MILL AND FEEDER SEAL AIR
VALVES AND THE PULVERISERS DISCHARGE VALVES ARE CLOSED. THE MILL MOTOR,
BREAKER SHOULD BE RACKED OUT AND TAGGED. THE PYRITE HOPPER DOOR SHOULD BE
CAREFULLY CRACKED AND THEN COMPLETELY OPENED, CAREFULLY REMOVE THE BOLTS
OF THE INSPECTION DOOR. EYE PROTECTION (GLASS OR FACE SHIELD) IS
RECOMMENDED.
3.11
MILL REJECTS:
Mill has been designed to reject tramp iron, pyrites and other denser and difficult
to grind material. When these come under the roller, the roller lifts up allowing these
to pass under. These are further carried over the edge of the bowl and drop
through the mill side air inlet housing. Then, scrapped by scrappers through tramp
19
3.0.
Bowl Mill
XRP1103
OPERATION
iron spout to pyrite hopper, from where they are periodically removed. Any
material having a bulk density above 1.7 tons/ m3 should be rejected. (For coal
bulk density is 1.2 TO 1.6 t/ m3) However sometimes the raw coal is also rejected.
This could happen due to:
i)
Over loading of mill.
ii)
Improper operation and adjustments.
iii)
Worn out parts.
i)
Over loading of Mill can be due to:

a) Mill capacity reduction due to low grindability index of raw coal, high
fineness, high moisture.
b) Physical overloading of mill due to feeder problems. (Refer feeder
suppliers manual)
ii)
Improper Operation and Adjustments:

a) Lower air flow - Operate at design air flow.
b) Low mill outlet temperature - Modulate hot and cold air dampers to
improve mill outlet temperature.
After full adjustment if still
temperature cannot be maintained above 65 C reduce the coal

feed rate.
c) Journal spring pressure too low - Check and set the journal springs as
detailed under maintenance section.
d) Jamming or breaking of journal springs.
e) Jamming of roll; all rolls should rotate freely on an empty bowl.
f) Improper setting of ring-roll gap or higher gap between journal spring
assembly and journal head.
g) Improper mill differential pressure. Increase the same by adding air
restriction rings/ blocks on the airport ring.
iii)
Worn out parts:

a)
Roller and bull ring segments.
b)
Gaps - fill up all voids and gaps between the liners by suitable filler
Compound (for ex. Dum Dum paste).
20
4.0
4.0
PULVERISER LUBE OIL SYSTEM
Bowl Mill
XRP1103
GENERAL:
The Pulveriser gear box (planetary) is completely lubricated from the external lube
oil system. The Pulveriser lube oil system and piping is constructed so that oil can be
circulated to the planetary gear and its bearings at the required location and flow back
to the lube oil tank while the mill is in operation.
The journal assembly is filled with oil and internal circulation takes place as the roller
assembly rotates around its axis when the mill is in operation and loaded. Recommended
lubricant specifications are given in the lubrication schedule in this chapter.
4.1
JOURNAL
The Roller Journals are lubricated by means of a self-contained circulation
system. The oil level in the shaft is maintained at a point just below the top of the
seal and checked by using a dip stick.
The pumping action of the Roller Bearings circulates oil from the reservoir in
the journal housing to the annular chamber between the Bearings, then into the
shaft bore and through the oil return holes where the cycle is completed. The upper
journal housing is provided with a triple lip type seal to prevent oil leakage. The
journals are kept clean by seal air brought through flexible tubing to holes provided
in the Trunnion shaft and journal head for this purpose. (Refer figure-11e). This
inward moving air prevents dust from getting into the bearings.
The Roller Journals should be filled with the recommended oil (see
Lubrication Schedule Table-1) through the fill connection at the top of the journal
assembly. Brush or blow any dust/dirt from the top of the Journal Shaft. Remove the
cover and plugs from the journal opening cover and journal shaft. Check the oil
level with a dip stick. Dip stick must touch the bottom. Fill the roller journal with oil
to the level shown on the oil instruction plate attached to the journal opening
cover and tighten the plug (refer Figure.12-e.) Pour the oil steadily to prevent air
lock.
During initial operation, the opening between the Journal Head Skirt and
the upper journal housing should be inspected frequently (approximately weekly)
for evidence of any oil leakage.
4.0
Bowl Mill
XRP1103
If no leakage is observed (indicating that the oil seals have seated properly)
a normal interval of inspection, at least once in every three months and/ or when
the opportunity presents itself, can be initiated. When checked, if the oil shown
signs of contamination, or a laboratory test indicates oil break down, it should be
changed.
To change oil, siphon out the old oil and add new oil to bring the oil back
up to
4.2
the level. Do this repeatedly until the oil is clear.
MISCELLANEOUS & IDLE MILLS:

The Deflector Regulators and Journal Stop Bolts should be greased as per
recommended Bowl Mill Lubrication schedule.
The Mill to Motor Coupling should be lubricated according to the
manufacturers recommendations (given in the lubrication schedule).
The Journal Trunnion Bushings are made of rubber and require no lubrication
4.0
Bowl Mill
XRP1103
BOWL MILL OIL COOLER - COOLING WATER REQUIREMENT PER MILL IN

LITERS / MINUTE AT 32C WATER TEMPERATURE
Recommended Inlet Pressure
4.5 Kg/cm2.
Pressure Drop in Cooler
Water quantity per cooler
0.7 Kg/cm2.
20 m3/hr.
ROLLER JOURNALS OIL QUANTITY AND LEVELS:

MILL SIZE
Quantity of lubricant
Quantity of lubricant
Oil level (in mm)
per assembly (in liters)
per mill (in liters)
from bottom
85
255
810-910
XRP- 1103
GEAR CASE OIL QUANTITY:
Mill Size
Quantity of lubricant per mill

(liters)
XRP- 1103
1600
4.0
Bowl Mill
XRP1103
4.3 PULVERISER LUBE OIL SYSTEM OPERATING INSTRUCTIONS

GENERAL CONFIGURATION
The oil supply system described below is used for oil cooling and/or lubrication of
a gear unit (see Vendors O&M Manual of Lube Oil System). The oil supply system
has been subjected to an exhaustive trial run. The oil supply is ensured by means of
two pump assemblies, one of which acts as a standby pump. The pump draws the oil
from the oil reservoir of the oil supply system.
A filter is provided in the oil circuit for filtration of the circulating oil. The quantity of
heat generated by losses, which is not dissipatable by convection, is dissipated by
means of a cooler. Filtered and re-cooled oil is then passed back to the gear unit via
a pressure line. The modules described above are mounted on the oil reservoir of the
oil supply system.
4.3.1. FILLING WITH OIL
The following provisions are recommendations based on long years of experience.
Responsibility for the oil grade lies with the manufacturer of the oil and the operator
of the system has to ensure satisfactory state of the oil grade (see Lubrication
schedule Table 1).
In all cases, before startup, the gear unit/oil supply system should be filled with oil
(see operating instructions Planetary Gear box Section-5). After filling, the filler
openings should be properly reclosed and sealed.
Only oil in accordance with the specification should be used (see Lubrication
schedule Table 1).
Mixing oils of different manufacturers is NOT permissible.
To remove residues of preservatives which can lead to oil foaming, the oil supply
system alone and followed by system together with the gear unit should be flushed
before startup (see operating instructions Planetary Gear box Section-5).
The oil must then be drained carefully from the oil supply system, the monitors and
the oil compartment in the gear unit while it is hot. It may only be reused as flushing
4.0
Bowl Mill
XRP1103
oil. If the flushing oil is to be used in another system, it should first be carefully purified/
filtered.
Fresh oil in accordance with the specification should be used for startup (see
operating instructions Planetary Gear box Section-5).
Fill the oil supply system tank with oil in accordance with the Operating Instructions
Planetary Gear box- Section-5.
Fill until the specified oil level is reached on the oil level gauge with the pump
stationary (see Operating Instructions Planetary Gear box- Section-5). The pump
should then be started.
Before initial startup of the gear unit, the oil supply system must be run for at least 15
minutes to allow all oil compartments to fill up (see Operating Instructions Planetary
Gear box- Section-5). Stop the oil supply system again afterwards and correct the
oil level if necessary.
All pipes, screw unions and flanges should be tightened, this applying particularly to
suction lines (to prevent air being drawn into the system). Leaks should be resealed.
4.3.2.
Oil pump
Low-pressure oil pumps are only permissible for one direction of rotation. The
direction of rotation of motors must be same as the direction of rotation arrow on the
pump.
4.3.3. OIL COOLER

The water supply connections for the oil cooler should be established by the operator.
If there is risk of frost and the oil supply system will be out of service for any
considerable time, the cooling water should be drained off.
The special Operating Instructions for oil coolers should be observed from O&M
Manual of Lube Oil system of vendor.
4.3.4 STARTUP
4.0
Bowl Mill
XRP1103
Before starting up the oil supply system, check that the requirements in accordance
with these Operating Instructions and the requirements in accordance with the gear
unit Operating Instructions have been fulfilled.
CAUTION
1.0 Before startup, filling with oil must be carried out.
2.0 Before startup, check the cooling water circuit!
3.0 Stop valves are to be secured to prevent accidental closure.
Before startup and after repairs and maintenance work, the oil supply system is to be
cleaned thoroughly to remove any impurities. This applies particularly to water (e.g.
rain water and leakage of the cooler) in order to prevent mixture of water and oil. All
pumps, filters and coolers must be suitably bled.
NOTE: The works setting of the pressure relief valves/safety valves carried out at works
may NOT be altered, as it is not used to regulate the pressure and rate of
flow. It is intended ONLY as overload protection!
4.4
PULVERISER LUBE OIL SYSTEM OPERATING PROCEDURE
The Pulveriser lube oil system (PLOS) consists of a oil tank, 2x100 % Screw pump & motor,
basket filter, oil cooler etc. Lube oil pump capacity is 250 LPM. Filtered and cooled oil, to
the required temperature range of 30 to 50 deg C, is supplied to the gearbox thrust pad
bearing, input shaft bearings and gears. The return line from the gear box is connected to
the tank. A heater (HVA AH001) provided in the oil tank keeps the oil temperature in the
required range, provided the pump is ON.
The following instrumentation is provided in the PLOS for interlocks & protection, alarm and
indication.
4.4.1 TEMPERATURE MEASUREMENT:
-
Temperature switches are provided in the lube oil system a) Three No.s on the lube oil tank (HVA CT103, CT104, CT105).
b) Three No.s at the cooler outlet (HVA CT100, CT101, CT102).
Six No.s RTDs (Duplex PT 100) are also provided on the gear box to measure the
temperature of input shaft bearings (2nos.-HFC01 CT 024, 025), the thrust pad bearing
(4 nos.- HFC01 CT 020 TO 023).
Temperature indicators are provided-
10
4.0
Bowl Mill
XRP1103
a) One on the oil tank (HVA CT 502).

b) One each at the cooler outlet & inlet (HVA CT500, 501).
4.4.2 PRESSURE MEASUREMENT:
-
Two Pressure Switches (HVA CP101, CP102) are provided in the lube oil line, after the
oil cooler assembly.
A differential pressure switch (HVA CP100) is provided across the oil filter unit for alarm.
A differential pressure indicator (local- HVA CP503) is also provided.
Pressure indicators are provideda) One each at the filter inlet and outlet (HVA CP500, CP502).
b) One at the cooler outlet (HVA CP501).
4.4.3 LEVEL MEASUREMENT:

-
Two oil level Switches (HVA CL100, CL101), one for high level alarms and the other for
low level (pump trip), are provided in the oil tank.
One oil level gauge (HVA CL500) is provided on the oil tank for visual check of OIL
LEVEL.
4.4.4 FLOW MEASUREMENT:

-
Two oil flow switches cum point indicators (HVA CF100, CF101) are provided in the lube
oil line after cooler assembly.
4.5 PLOS PRE-COMMISSIONING CHECKS:

a. Ensure electrical connections to MOTOR & Instruments, if any.
b. All the flanges in the system are tightly fastened.
c. Ensure valves position, which are to be kept open.
d. Avoid air pockets while priming the system.
e. Maintain oil level in the tank to the required level after priming the lube oil system.
f.
Start & stop the Motor to check the direction of rotation of pump and Motor. Ensure
correct direction as shown on the pump.
g. Start the Motor and allow the system to run for 4 hours (trial run cum system flushing
operations).
h. Run the system with the required oil pressure at cooler outlet.
NOTE: a) Avoid dry running of the pump as it results in seizer of moving parts.
b) The relief valve at the pump outlet is factory set at 6.0 bar.
11
4.0
Bowl Mill
XRP1103
4.6 PLOS OPERATION:

Once the lube oil system flushing along with the gear box is completed the same is
declared ready for normal operation.
When the oil temperature in the tank (HVA CT103) is greater than 10 deg. C the lube oil
pump is permitted to start and at oil temperature value greater than 30 deg. C at the
cooler outlet (HVA CT100) the mill is released for start. Below 30 deg. C oil temperature in
the tank (HVA CT104) the oil heater (HVA AH001) is energized, provided the pump is in
service. The heater is de-energised at the tank oil temperature (HVA CT105) of 36 deg.C
or when the lube oil pump is stopped.
Charge one of the duplex filters and the oil cooler. Once the permissive conditions are
met with, start the lube oil pump. The lube oil pump can be started either from Local push
button OR from FSSS through a potential free contact & CRT and when pump stop
command is not present, lube oil level is not low (HVA CL101) and tank oil temperature is
not low (HVA CT103).
The filter change over can be done on line for cleaning the filter element. Cooler change
over can be done on line too.
4.7 MILL START PERMISSIVE CONDITIONS FROM THE PLOS:
THE MILL MOTOR CAN BE ENERGISED ONCE THE FOLLOWING PERMISSIVE CONDITIONS ARE
FULL FILLED.
a) Lube oil temperature is adequate (HVA CT100 > 30 deg. C)
b) LP Pump ON for more than 15 minutes and Lube oil pressure at cooler outlet is
adequate (HVA CP101 > 0.8 bar).
c) Lube oil filter not dirty (DPS-HVA CP100 < 2.0 bar)
d) Lube oil flow to the gearbox is NOT LOW (FS-HVA CF100 > 200 LPM).
e) Any bearing temperature of Gearbox is within ALARM limits (i.e <75 deg.C).
4.8 AUTOMATIC MILL TRIP CONDITIONS FROM PLOS:
THE MILL IS TRIPPED IF ANY ONE OF THE FOLLOWING CONDITIONS ARE PRESENT.
a) When both lube oil pumps are not ON for more than 2 sec.
b) Lube oil pump ON and lube oil pressure (HVA CP102 < 0.5 bar) after cooler is very
low, with a time delay of 15 seconds.
c) Lube oil temperature after cooler is very high (HVA CT102 > 65 deg. C).
d) Lube oil flow to the gearbox is very low (FS-HVA CF101< 175 LPM).
12
4.0
Bowl Mill
XRP1103
4.9 PUMP TRIP CONDITIONS:

The lube oil pump stops/ shall be stopped when any one of the following conditions are
acknowledged or satisfied.
a) Lube oil level in tank is low (HVA CL101).
b) Lube oil temperature in tank is low ( HVA CT103 < 10 deg. C)
c) Pulveriser OFF for more than 60 minutes and pump stop push bottom actuated.
4.10 STAND-BY PUMP START CONDITIONS:
a) The running pump is ON for more than 60 seconds and discharge pressure at
pump outlet is low (HVA CP101< 0.8 bar), the standby pump to start.
b) When Pump-1 (Main) fails to start on giving start command, after 10 sec. time
delay, the stand by pump to start.
c) The running pump trips on fault, the stand-by pump to start immediately.
4.11 OUTPUT CONTACTS PROVIDED:
a)
b)
c)
d)
e)
Pulveriser Start Permissive ( to FSSS)

Pulveriser Stop Command ( to FSSS)
Start lube oil pump
(to motor starter)
Stop lube oil pump
(to motor starter)
Both lube oil pumps not ON (to SOE in DDCMIS)
4.12 ALARMS LIST:

The following ALARM signals are provided.
a) Lube oil tank level low (HVA CL100).
b) Lube oil tank level high (HVA CL101).
c) Lube oil flow to gearbox is low (HVA CF100 < 200 LPM).
d) Oil temperature after cooler high (HVA CT101 > 60 deg. C).
e) Any lube oil pump ON for more than 60 sec. and Oil Pressure after cooler low
(HVA CP101 < 0.8 bar).
f)
Lube oil filter dirty (HVA CP100 > 2.0 bar).
g) Lube oil temperature in tank very low (HVA CT103< 10 deg. C).
NOTE: The Alarm and Trip set points arising from Boiler Auxiliaries instrumentation, like the
Mill bearing temperatures or Mill motor bearing temperatures etc., the same are taken
care of separately in FSSS logic.
13
Bowl Mill
XRP1103

LUBRICATION SCHEDULE
EQUIPMENT: BOWL MILL XRP 1103

TABLE -1
Recommended Lubricants
Sl.
No.
Parts to be
Lubricated
Mill Drive
Gear Housing
Servomesh
SP-320
3
4
5
6
7
IOC
HP
BP
4
Parthan
EP-320
5
AMOCAM
OIL-320
Type of
filling
Qty. of Lub.
In litres/Mill
Frequency of
oilcheck
Frequency of
observation
9
Once daily check
gauges, lines and
headers
External
tank
1600
Check when
accessible at
255
6 months
least once in
every 3 months
Fill chamber initially. Lubricate after making
adjustments.
Grease the shafts and seals initially and every 2
weeks.
Roller
Journals
Servomesh
SP-680
Parthan
EP-680
AMOCAM
680
Journal Stop
Bolts
Discharge
valve shafts
and Seals
Journal Shaft
Oil Seals
Mill Drive
Motor
Drive
Coupling
( Grid-Disc)
Drive oupling
( if GridGear)
Servogem3
Lithon-3
MP Grease3
Reservoir
cap on
journal
shaft
Grease
fitting
Servogem3
Lithon-3
MP Grease3
Grease
fitting
Molykote 33 or equivalent
6 Months
Grease the shafts and seals initially and every

replacement time.
Remarks
10
Oil level shall be
maintained in the
external lube oil
tank
Level 810 mm to
910 mm
Wipe clean all

grease fittings
before and after
greasing. Remove
excess grease
As per Motor Manufacture's Recommendation

Not Required at Disc End
ServoGem-3/HTXX of IOC at Grid End
Pack completely initially & Every Three months. Clean Out & Renew
the Grease Every three months.
ServoGem HTXX of IOC at Gear End & Grid End
Pack completely initially & Every Three months for grid end. Clean
Out & Renew the Grease 15 days at Gear end.
14
5.0.
PLANETARY GEAR BOX
Bowl Mill
XRP1103
5.0 PLANETARY GEAR BOX

5.1 PLANETARY GEAR BOX OPERATING INSTRUCTIONS
5.1.1
MEASURES AND CHECKS BEFORE START UP

Measures before startup
Warranty shall only be given if the initial startup was carried out by BHEL specialists
or by specialists of the plant engineer after prior consultation with BHEL.
Note: Any attempt to make the drive move will be regarded as startup! Especially in case
of maintenance work on the mill where the mill is rotated and the gear unit
rotates, too, the Operating Instructions should be observed.
Checks before startup
After the assembly and before the first cold dry run, check all drive parts and
remove all residues of material, tools and assembly aids.
The oil supply system function is tested before delivery. Before the dry run of the
mill, the electric interlock between oil supply and mill drive motor should be
checked. Keep the shut-off valves on the cooling water side open.
Before a dry run of the mill, check the electric interlock between gear unit and
mill drive motor.
Furthermore, the complete drive should be checked according to the following
check list:
- Was the foundation made properly?
- Are the foundation bolts tightened securely?
- Are the foundation bolts of the main gear unit tightened according to
the specifications?
- Is the gear unit & motor pinned and clamped properly?
- Is the milling bowl and bowl hub mounted properly?
- Were the directions of rotation of motor and gear unit checked?
- Were the adhesive tapes on the labyrinth seals of gear unit removed?
- Were all pipes assembled and cleaned according to the assembly instructions?
15
5.0.
-
PLANETARY GEAR BOX
Bowl Mill
XRP1103
Are the pipes and tubes mounted and arranged correctly?

CAUTION
MAKE ABSOLUTELY SURE THAT THE OIL FEED PIPES ARE CLEAN AS ANY
CONTAMINATIONS IN THE PIPES WOULD BE LED THROUGH THE GEAR UNIT
BEFORE THEY CAN BE CAUGHT IN THE FILTER OF THE OIL SUPPLY SYSTEM,
RESULTING IN BEARING DAMAGE
- Were the pipe and tube connections checked for leaks?

Pay special attention to the flange connections of the suction pipe. When air
enters, the oil tends to foam.
- Does the oil in the oil container (tank of the oil supply system or the gear unit,
respectively) show little foam on the surface? A thin layer of foam of approx. 3
... 4 mm (0.120.16 inch) on the surface is permissible.
When foam develops, check all suction pipe connections. If necessary,
contact the manufacturer of the oil.
- Is the oil container filled with oil up to the respective marks?
- Is the pad bearing filled with oil up to the mark?
- The oil level may be checked while the oil supply system is running and the gear
unit is stationary.
- Are all monitoring devices connected according to the circuit
diagram?
- Was the function of the oil supply tested?
- Were test reports made on the following measurements?
Was the function of the interlock checked according to the interlocking diagram on
the description (see Section - 4.4 PLOS Operating Procedure)?
Are the flow controls, pressure transmitters and temperature sensors set to the correct
values and were they checked for proper function?
Is the cooling water inlet/ outlet line isolation valves open?
For further checks, see the Operating Instructions of couplings, motors, oil supply system and
mill.
5.1.2
De-preservation of the gear unit

For de-preservation of the gear unit, remove all preservative coatings by runningin oil by means of flushing. The following work and flushing times are required:
-
Install the breathers according to the cross section drawing.
Remove the adhesive tape from the labyrinth seal of the input shaft and the
output flange.
16
5.0.
5.1.3
Bowl Mill
XRP1103
PLANETARY GEAR BOX
FLUSHING
General
A clear difference must be made between flushing before the initial startup
and flushing before/ after repair and maintenance work.
Flushing before the initial startup
The purpose of flushing before the initial startup is to minimize the residues of
previously used lubricating oils or preservative oils.
The selected operating lubricating oil shall be used for flushing.
-
Put in selected lubricating oil.
- Flushing times: run the oil pump of the lubrication circuit for 6 hours at least for
flushing or the filter is found on visual inspection reasonably clean, whichever
occurs later.
CAUTION
AFTER FLUSHING, DRAIN THE OIL COMPLETELY THROUGH THE OIL DRAIN COCKS ON
THE GEAR UNIT AND THE OIL SUPPLY SYSTEM. THE OIL MAY ONLY BE RE-USED AS
FLUSHING OIL. BEFORE RE-USING IT, THE FLUSHING OIL SHOULD BE FILTERED. THE
FLUSHING OIL CAN BE REUSED FOR A MAXIMUM OF 8 GEAR UNITS.
.
5.1.4
OIL FILLING
After flushing and before the initial startup of the gear unit, the gear unit & Lube
oil system must be filled with fresh oil after parts like pressure gauge, thermometer,
pipes, etc. if supplied separately or which were removed during transport are reinstalled.
For the oil to be used see the Operating Instructions Lubrication Schedule Table 1
for information on oil grade, oil viscosity and
required oil quantity.
17
5.0.
PLANETARY GEAR BOX
Bowl Mill
XRP1103
PLANETARY GEAR BOX ASSEMBLY
CAUTION
THE OIL LEVEL MARKS ON THE OIL LEVEL INDICATOR OF THE MAIN GEAR UNIT, THE
PAD BEARING OR THE OIL SUPPLY SYSTEM TANK ONLY ARE RELEVANT FOR
DETERMINING THE OIL QUANTITY TO BE FILLED IN.
NOTE: The quantities given on the nameplate of the gear unit are reference values only.
Oil pumps and all oil filling bores marked with special information plates should
be filled with oil before starting-up the gear unit. For this purpose, there is an oil
filling hole on the oil pump or on the pressure pipe or on oil filling hole is marked
with an information plate. Carefully close these oil filling holes so that the oil pump
does not draw in air or that any oil leaks.
5.1.4.1 Filling the oil
The gear unit can be filled with oil in different ways dependent on the equipment
of the oil supply system.
-
The oil to be put in must be filtered beforehand or on filling with a filter of

nominal gauge 25 m (0.0010 inch).
18
5.0.
PLANETARY GEAR BOX
Bowl Mill
XRP1103
- The oil supply system is equipped with a tank and the oil is to be filled-in through
the oil tank of the oil supply system.
5.1.4.2 Oil quantity
a)
Oil quantity for flushing

For flushing, the gear unit & piping the tank of the oil supply system should be
filled with just sufficient quantity of oil to run the oil pump of the oil supply
system for this purpose. Depending on the gear unit, this oil quantity can be
between 50 % and 60 % of the total oil filling quantity.
b) Oil quantity for the initial startup

Fill in so much oil that the prescribed oil level is reached on the oil level
indicators of the gear unit (see cross section drawing-FIG A) and the oil supply
system tank with the gear unit stationary and the oil pump of the oil supply
system running.
After the pre-run of the oil supply system (see Section 4.7), the gear unit can
be rotated.
c) Oil supply system
The main gear unit is supplied with lubricating and cooling oil by the oil supply
system (see Section 4.6).
5.1.5
STARTUP
a) Pre-lubrication phase
Before startup, the gear unit should be pre-lubricated by the oil supply system
for 15 minutes at least.
During this phase, anti-friction bearings, axial tilting pad bearings and toothed
systems are adequately supplied with lubricating oil for the initial startup.
b) Initial startup
When all relevant Operating Instructions have been followed, the gear unit
can be started, with the main drive motor for the dry run (no load run).
CAUTION
THE GEAR UNIT MUST RUN ON PART LOAD, IF POSSIBLE, FOR SEVERAL HOURS. IF NO
MALFUNCTIONS ARE DETECTED, THE LOAD CAN BE INCREASED GRADUALLY UP TO
FULL LOAD IN ADEQUATE TIME INTERVALS AND UNDER PERMANENT SUPERVISION.
19
5.0.
PLANETARY GEAR BOX
Bowl Mill
XRP1103
During this phase, pay special attention to the following:

Noises
If possible, check the gear unit for abnormal noises (anti-friction bearings) with a
stethoscope in different places during this time.
Oil leakages
Check all flange connections of the oil pipes for oil leakages and re-seal them, if
necessary!
Measure the vibration at the gear box input shaft end
5.1.6
SHUT-DOWN
-
Switch off the drive assembly to shut down the gear unit.
It is recommended to let the oil supply system run during short interruptions of
operation. For a longer standstill, we recommend to let the oil supply run for
approximately 60 minutes to prevent heat from building up. However in case of
sudden standstill, e. g. due to a power failure, there is no danger of damage.
CAUTION
SECURE THE DRIVE ASSEMBLY TO PREVENT ACCIDENTAL SWITCH-ON!
-
Close the shut-off valves in the coolant inlet and outlet lines (only for gear units with
oil cooling system). In case of water-oil cooler, drain the water, to avoid freezing,
especially in winter.
In the case of gear units which are to be operated in a saline environment or next
to salt water the oil supply system must always continue running to avoid corrosion
damages. Moreover the gear unit should be turned every week for 15 minutes by
main motor.
Note:
During longer periods of outage the gear box has to be flushed for one hour and to
be turned for 15 minutes, weekly. If it is to remain out of service for longer than six
months, fill it with preservative, and see Section-13 Storage & Preservation,
TABLE 13, Page - 143.
5.2
OPERATION
During operation, the gear unit should be checked for:
- Excessive operating temperature
- Any changes in gear unit noises
- Possible oil leakage at the housing and the shaft seals and
20
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX
- Correct oil level (see also Section Startup).

Note: To check the oil level, the gear unit should be shut off and the oil pump of the
lubrication circuit of the oil supply system should be running.
The oil level should be between the two marks on the oil level indicator. If the oil
level is below the lower mark of the oil level indicator, top up oil if necessary.
CAUTION
IF IRREGULARITIES ARE DETECTED DURING OPERATION OR IF A PRESSURE
TRANSMITTER, A TEMPERATURE TRANSMITTER OR A VOLUMETRIC FLOW TRANSMITTER
IN THE OIL SUPPLY SYSTEM INITIATES AN ALARM AND LATER ON A TRIP SIGNAL, THE
DRIVE ASSEMBLY SHOULD BE SHUT OFF IMMEDIATELY.
Control information:
See Section 4.4, PLOS Operating Procedure for control information.
5.3 GENERAL TROUBLESHOOTING
The Trouble Shooting Table lists possible malfunctions, their causes and
suggestions
for remedying them. If the cause cannot be determined or there is no facility for repair
with suitable own equipment, it is recommended calling in BHEL for service fitters.
Note: Malfunctions occurring during the warranty period which necessitate repair of the gear
unit may only be remedied by BHEL service personnel. Even after the warranty period
has elapsed, Customers are recommended to consult BHEL Service Division in respect
of malfunctions for which causes cannot be ascertained clearly.
MALFUNCTIONS
CAUSES
Oil is over aged
Temperature rise
at bearing points
Oil pump defective

Bearing(s) defective
Oil is over aged
Excessive
operating
temperature
Oil filter clogged
Oil pump defective
REMEDY
Check when last oil change was carried out,
change oil if necessary. See Section 5.5-b
Maintenance.
Check oil pump, replace if necessary.
Observe the operating instructions for motor
oil pump.
Call in BHEL service. Check bearing(s),
replace if necessary.
Check when last oil change was carried out,
change oil if necessary See Section 5.5-b
Maintenance.
Clean oil filter, observe the operating
instructions for oil filter,
Change oil, if necessary. See Section 5.5-b
Maintenance.
Check oil pump, replace if necessary.
Observe the operating instructions for motor
oil pump.
21
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX

Defective cooler
Defective cooling water
Gear unit oiled

up
Pressure control
trips alarm
supply
Check cooling water supply. Observe

Operating Instructions for cooler.
Insufficient sealing of the

housing Cover or the joints.
Check seals, replace if necessary.

Seal joints.
Breather assembly
clogged
Clean it
Oil temperature is < 300C
Heat the Oil
Oil level too low in tank

Operating temperature
too high
Check oil level, top up oil if necessary

See above-Excessive Operating
Temperature
Clean oil filter, Observe Operating
Instructions for oil Filter.
Warm up oil
Clean oil filter
Observe Operating Instructions for oil filter
Check pipes, replace if necessary
Oil filter clogged

Volumetric flow
meter trips alarm
Temperature at
temperature
sensor in pad
bearing
(part
800) too high
Oil too cold

Oil filter clogged
Pipes leaking
Oil filter clogged
Oil level of pad bearing
housing is too low
Monitoring
devices
defective.
Increase
in
grinding
pressure or leaking of
labyrinth seals hot air flow
from mill side sir inlet
housing to the gearbox top
table
Damage to gear teeth
Changes in gear
noise
Oil foams
Water in oil
Observe operating instructions for Cooler.
Bearing backlash too high

or too low
Bearing defective
Water in oil
Oil too cold. De-foaming
agent used up
Unsuitable oils mixed up
Air being sucked at pump
suction zone
Cooler leaky
Condensation
Fault in oil-supply
system
Check oil filter for clogging

Check the setting of the pump/ system relief
valves.
Check all monitoring devices.
Analyze and check milling parameters.
Attend to the labyrinth seal leakages.
Call in BHEL service

-Check all toothed components and replace
any damaged parts
-Adjust bearing play
-Replace defective bearings
Test the oil; change if necessary
Attend to pump seals
Replace cooler
Change oil. Reduce water content in oil by
heating
Consult operating instructions for oil-supply
system. Call in BHEL/Vendor service.
22
5.0.
5.4
Bowl Mill
XRP1103
PLANETARY GEAR BOX
INSPECTION
The inspection comprises all measures to determine and evaluate the actual condition.
It is recommended to use a check list. A suggested check list is given below:
TABLE-2 (Check list for evaluating the condition of PGB lube oil system)
Measures
General visual check for
cracks,
leaks
&
damages
Visual check of the flank
condition for damage
Check the oil filter of the
oil supply system for
clogging.
Frequency/ Periods
Every 4 weeks
Check the instruments

installed on site (oil
temperatures, pressures
& flow)
every 4 weeks
Check the oil-carrying

pipes for leaks.
weekly
Check the oil level on

the oil level indicators on
the oil supply system.
weekly
Check
- for external noises
- the temperature
-the protective
equipment.
every 4 weeks
Check the attachments

such as couplings.
annually
Remarks
Every 4 weeks
every 4 weeks
visual indication, see also

Operating Instructions for oil
supply system.
See also Operating Instructions

for oil supply system
See Operating Instructions for

single components.
23
5.0.
5.5
Bowl Mill
XRP1103
PLANETARY GEAR BOX
MAINTENANCE
a) Maintenance Measures:
Measures
Frequency/Periods
Remarks
Clearing the filter elements
Every 4 weeks or when
See operating instructions
filters are dirty
for individual components
Testing
oil
for
water
content
First time after approx. 400

operating
hours
then
See item 5.5.1
once per year atleast

First
&
subsequent
oil
Depending on analysis of
See item 5.5.1 (b)
change after start-up
oil carried out
Oil analysis
Every 1000 operating hours
See item 5.5.1
Subsequent oil changes
Depending on result of oil
See item 5.5.1(b)
analysis;
(without
oil
analysis every 18 months or

60000 operating hours)
Checking of air filter
Every 12 weeks
See item 5.5.1(c)
Checking tightness of base
Every 12 weeks
See item 5.5.1(d)
Every 2 years
See item 5.5.1(e)
bolts
Carrying
out
complete
inspection of gear unit

Maintenance work on the
oil supply system
oil
supply
system
of
vendor
Check Couplings
Every 26 weeks

for individual components
24
5.0.
b)
Bowl Mill
XRP1103
PLANETARY GEAR BOX
Examining oil for water content / making of oil analysis
Detail information on examining the oil for water content or on making of oil analysis
can be obtained from the lubricant manufacturer or from BHEL service department.
- The oil sample for an oil analysis has to be taken downstream the gearbox in the
drain line of the lubrication system while the system is running. A suitable
connection can be provided on the oil drain piping (for example an oil drain line
with isolation valve and end plug).
- The minimum amount required is 1 liter of oil in a clean and for transportation
purposes closeable safety vessel.
- The decrease in oil viscosity should not exceed 10% of the value of the new oil.
-
Oil purity must be between 15/13/10 (high availability) and 17/15/12 (normal
availability) according to ISO 4406.
Limit values for oil contamination:

Material
Limit content
possible source
[ mg/kg ]
Iron
(Fe)
40
Internally toothed gear, cage of a bearing
Chrome
(Cr)
Rolling bearing, teeth
Aluminum (Al)
Oil pump bearing
Copper
(Cu)
cage of a bearing
Lead
(Pb)
Axial thrust slide bearing, pump bearing
Tin
(Sn)
Axial thrust slide bearing, pump bearing
(Ni)
Teeth
(Zn)
10
(Si)
20
Cement dust or other environmental factors
0.10 %
Condensed water; water oilcooler defective
Nickel
Zinc
Silicon
Water (H2O)
Zincbased primer. Is sometimes used as an

additive. In this case please contact BHEL.
TABLE -3 (Materialrelated contamination limit values for lube oil)

c)
CARRYING OUT OIL CHANGES

Mixing oils of different grades or makes is not permissible. In particular, synthetic
oils shall not be mixed with mineral oils or different synthetic oils. When changing
over from mineral oil to synthetic oil or from synthetic oil with a particular base
to synthetic oil with another base, the gear unit must be flushed thoroughly with
the new oil grade.
25
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX
CAUTION
WHEN CHANGING THE OIL, THE GEAR UNIT SHOULD ALWAYS BE FILLED WITH
THE OIL GRADE PREVIOUSLY IN USE.
When changing the oil, the gear housing and the lube oil system must also be
cleaned thoroughly by flushing with oil to remove oil sludge, abraded particles
and residue of old oil. For this purpose, the same oil grade should be used as is
in use for operation of the gear unit. Viscous oils should be warmed beforehand.
Only when all residues have been removed, shall the fresh oil be poured in.
Note:
The oil should be changed directly after shutting off the gear unit while the oil is still
warm.
-
Shut down the gear unit by switching off the drive unit.
CAUTION
SECURE THE DRIVE UNIT TO PREVENT ACCIDENTAL STARTUP
.
Affix notice at the switch-on point.
- Place a suitable receptacle under the oil drain cock of the gear unit housing
and the pad bearing room.
-
Unscrew the vent plugs of the oil drain cock and drain the oil into the
receptacle.
The oil shall be drained through the oil drain cocks.
26
5.0.
PLANETARY GEAR BOX
Bowl Mill
XRP1103
Detailed illustrations of the gear unit will be found in the drawings in the gear unit
documentation.
Note:
Dispose-off the old oil according to the regulations on environmental protection.
CAUTION
THERE IS A RISK OF SCALDING FROM THE HOT OIL EMERGING. WEAR PROTECTIVE
GLOVES.
Note:
Screw in the screw plugs of the oil drain cocks.
Data such as oil grade, oil viscosity and quantity of oil required should be taken from
the Lubrication Schedule (see TABLE1).
The gear unit can be filled with oil in various ways, depending on the set-up of the oil supply
system. The suggested method is as given below:
- The fresh recommended lube oil shall be filtered with a suitable strainer/ filter
of nominal gauge 25 m (0.0010 inch) before or while filling into the lube oil
tank.
-
From the lube oil supply system the oil is filled into the gear box through a filter
of nominal gauge 25 m (0.0010 inch).
Fill in so much oil that the specified oil level on the oil level indicators of the
gear unit (see Figure - C) and the oil supply system is reached with the gear
unit stationary and the oil pump of the oil supply system running.
27
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX

CAUTION
ANY OIL LEAKAGE SHOULD BE REMOVED IMMEDIATELY WITH OIL BINDING

AGENT.
.
d)
CLEANING THE AIR FILTER
Every 12 weeks or when the air filter (breathing filter) is clogged, heavily.
Unthread the filter and clean it with petroleum benzine or similar

detergents.
CAUTION
BE EXTREMELY CAREFUL WHEN CLEANING WITH COMPRESSED AIR. WEAR SAFETY

GLASSES!
e)
Reinstall the dry air filter.
CHECKING THE BINDING BOLTS FOR TIGHTNESS

All binding bolts with metric thread according to DIN 13, sheet 20, of property class 5.8
according to DIN 267 should be tightened to the following pre-stressing forces.
28
5.0.
f)
Bowl Mill
XRP1103
PLANETARY GEAR BOX
CHECKING THE BINDING BOLTS FOR TIGHTNESS

All binding bolts with metric thread according to DIN 13, sheet 20, of property class 5.8
according to DIN 267 should be tightened to the following pre-stressing forces.
Thread size
Prestressing
Force
(in
Newton)
Prestressing
Force
( in Lbf)
Tigtening Torque
( In N-m)
M 20
71250
16017
256
189
M 24
102500
23042
443
327
M 30
163750
36811
906
668
M 36
238750
53671
1580
1165
M 42
328750
73903
2540
1873
M 48
433120
97365
3830
2825
M 56
599370
134738
6150
4536
M 64
792500
178154
8940
6593
M 72 x 6
1000000
224800
13000
9588
M 80 x 6
1218750
273975
18060
13319
M 90 x 6
1593750
358275
26030
19197
M 100 x 6
2000000
449600
36120
26638
Tightening
Torque
( in Lbft)
Pre-stressing
Device
( In Bar)
See the
Operating
Instructions of
the
manufacturer
of
the hydraulic
pre-stressing
device
TABLE -4 (Pre-stressing force, tightening torques, pre-stressing device hydraulic)

Note:
Unserviceable screws should be replaced by new ones of the same property

class and type.
29
5.0.
g)
Bowl Mill
XRP1103
PLANETARY GEAR BOX
COMPLETE GEAR UNIT INSPECTION

The gear unit inspection should be entrusted to BHEL Service Division as by virtue
of vast experience, technicians can most reliably assess whether and which part
of the gear unit need to be replaced.
Maintenance comprises all measures to maintain the desired condition.
Measures
Cleaning the filter inserts
Test oil for water content
First oil change after startup
Oil analyses
subsequent oil changes
Cleaning the air filters
(breather filter)
Checking tightness of
foundation bolts
Carry out complete inspection
of the gear unit
Frequency
Every 4 weeks or if filter element is
dirty.
after approx. 400 service hours /at
least once a year
after approx. 1000 service hours or
depending on result of oil analysis
every 1000 service hours
depending on result of
oil analysis; (without oil analysis
every 18 months or
60000 operating hours)
see item 5.5.1

see item 5.5.1(b)
see item 5.5.1
see item 5.5.1(b)
every 12 weeks
see item 5.5.1(c)
every 12 weeks
see item 5.5.1(d)
Every 2 years
see item 5.5.1(e)
Maintenance work on the oil

supply unit
Couplings:
Remarks
see Operating
Instructions for the
individual components
every 26 weeks
See Operating
Instructions for oil supply
unit
see Operating
Instructions for the
individual components
TABLE -5 (Maintenance of PGB lube oil system)
30
5.0.
5.6
Bowl Mill
XRP1103
PLANETARY GEAR BOX
REPAIR
Repair comprises all measures to re-establish the desired condition after a malfunction.
CAUTION
WHEN CARRYING OUT REPAIR WORK USING ELECTRIC WELDING AT ANY POINTS OF
THE UNIT, MAKE SURE THAT THE WELDING CURRENT IS NOT CONDUCTED THROUGH
ANTI-FRICTION BEARINGS OR OTHER MOVING CONNECTIONS AND MEASURING
DEVICES. THEREFORE, THE WELDING CURRENT RETURN CABLE SHOULD BE DIRECTLY
CONNECTED TO THE PART TO BE WELDED.
When replacing components and larger sub-assemblies, make sure that they are
fastened and secured carefully to hoists to avoid hazardous situations.
CAUTION
ONLY USE SUITABLE HOISTS IN PERFECT TECHNICAL CONDITION AND SUSPENSION
DEVICES WITH SUFFICIENT CARRYING CAPACITY! DO NOT STAND OR WORK BELOW
SUSPENDED LOADS
5.7
LUBRICANTS
See Lubricating Schedule TABLE 1.0 for lubricants.
5.8
LIST OF EQUIPMENT
TYPE: KMP SIZE 350
Switching and monitoring functions as per:
Lubrication diagram
Gear Unit type: KMP 350
Figure - N
Terminal diagram Gear box as per
Figure - C
:
Figure- W
31
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX
TABLE - 6
QUANTITY
DESCRIPTION
PARTNO.
MANU
FACTU
RER
TAG. NO.
Temperature element
Duplex PT100
Resistance thermometer
EL =280 mm
HFC01 CT020
Connection : G A
HFC01 CT021
4
Precision resistor : Double PT 100 DIN
800
BHEL
HFC01 CT022
IEC 60751
HFC01 CT023
Four-wire circuit from Terminal box
Degree of protection : IP 65
> 75 C : WARNING
> 85 C : MILL STOP
Temperature control of the rolling bearings
Temper x is adjusted to: Actual temperature (after approx.. 100 Operational
hours)
+15 K: WARNING
+20 K: MILL STOP
However, not above 1000C
x1 = T(act) + 15 K= .,x2 = T (act) +20 K
Temperature element
Duplex PT100
EL = 140 mm
Connection : G A
1
806
BHEL
HFC01 CT024
IEC 60751
Four-wire circuit from Terminal box
for rolling bearing part no. 150
> "x1" C : WARNING
> "x2" C : MILL STOP
Temperature element
Duplex PT100
EL = 230 mm
Connection : G A
1
808
BHEL
HFC01 CT025
IEC 60751
Four-wire circuit from terminal box
for rolling bearing part no. 151
> "x1" C : WARNING
> "x2" C : MILL STOP
5.9
LOCKING GUIDELINES
The mill motor should be released if the following conditions are met:
32
5.0.
PLANETARY GEAR BOX
Temperature of pad bearing (800)
Bowl Mill
XRP1103
< 75 C
Temperature of bearings (806 / 808) < x1 C

A warning should be output if one of the following conditions is met:
Temperature of pad bearing (800) > 75 C
Temperature of bearings (806 / 808) > x1 C
The mill motor should be stopped if one of the following conditions is met:
Temperature of pad bearing (800) > 85 C
Temperature of bearings (806 / 808) > x2 C
CAUTION
AFTER SWITCHING OFF THE GEAR UNIT, THE OIL SUPPLY SYSTEM SHOULD TO BE IN
SERVICE, AT LEAST FOR ANOTHER HOUR TO AVOID THE ACCUMULATION OF HEAT.
Note:
For further control information, see the Operating Instructions PLOS Operating
Procedure Section 4.4.
5.10 SPARE PARTS STOCK

A stock of the most important replacement and wearing parts is essential for
satisfactory operation and serviceability of the gear unit at all times.
Please
use the Spare Parts List for ordering spare parts.

For further information, see the Spare Parts Drawing contained in the Spare Parts List.
Only original replacement parts supplied by BHEL are covered by the warranty.
Note:
Attention is drawn expressly to the fact that replacement parts and accessories not
supplied by BHEL have not been tested or approved by BHEL. Installation and/or use
of such products can therefore under certain circumstances alter the structurally
specified properties of the gear unit and can as a result impair active and/or passive
safety. BHEL accept no liability of any sort for damage caused by the use of
replacement parts and accessories which are not original BHEL; their use will
invalidate warranty in every respect.
33
5.0.
Bowl Mill
XRP1103
PLANETARY GEAR BOX
Please note that special production and supply specifications frequently exist for
individual components and that BHEL always supply replacement parts in
accordance with the state of the art and the latest legal requirements.
The relevant data should be stated when ordering replacement parts:
SPARE PARTS LIST-KMP 350
PART NO
DESCRIPTION
QTY
WEIGHT(Kg)
0318
PLUG
1St
0.4
0040
Oil level Indicator
1 St
0.2
0045
Ball Cock
1 St
1.4
0046
Ball Cock
1 St
1.4
0056
Air Filter
2St
0.1
0099
Pair Of Mating Bevel Wheels
1 St
1105.0
0100X
Bevel Pinion Shaft
1 St
170
0402X
Bevel Gear
1 St
722
0123
O-Ring
1 St
0.1
0124
O-Ring
1 St
0.1
0128
Shim Ring,2-Piece 341x440x15S235JR
1 St
10.0
0130
Labyrinth Ring
1 St
6.5
0291
COUPLING RING
1St
80.0
0150
Paired Taper Roller Bearings
1 St
50.0
0151
Rolling Contact Bearing
1 St
43.5
0200
Planetary Carrier
1 St
1340.0
0208
O-Ring
6St
0.1
0286
O-Ring
1 St
0.1
0252
1 St
92.5
0253
Thrust Slide Bearing
1 St
972.0
0290
Flange (Rotary Table)
1 St
4280.0
0300
Planetary Axle
3 St
62.1
0301
Pinion Shaft
1 St
1.0
34
5.0.
PART NO
Bowl Mill
XRP1103
PLANETARY GEAR BOX
DESCRIPTION
QTY
WEIGHT(Kg)
0302
Gear Wheel
3 St
162.0
0350
3St
61.0
0400
Shaft 195x555 1.6587
1 St
110.0
0390
Coupling Sleeve
1 St
25.0
0428
Shim Ring, 2-Piece
1 St
7.0
0450
Paired Taper Roller Bearings
1 St
29.4
0451
1 St
11.7
0800
Resistance Thermometer EL=265
4St
0.3
0806
1 St
0.1
0808
1 St
0.2
Parts belongs to the sub assembly. Hence the sub assembly must be replaced complete.
TABLE 7
35
6.0.
6.0
MILL OPTIMIZATION
Bowl Mill
XRP1103
MILL OPTIMIZATION
PURPOSE:
The purpose of this program is to optimize the mill operation to ensure the rated mill capacity
with required PF fineness and at the same time, the best wear life of grinding elements and
other wear prone areas is achieved.
ADJUSTMENTS:
One or more of the following adjustments may be required for the mill optimization:
1)
Area of opening around the bowl for primary air flow to maintain desired differential
pressure across the bowl, with low mill rejects.
2)
Vary the journal spring compression value to achieve the required mill output, fineness
and mill rejection level.
3)
Ring-roll clearance to reduce high bed formation on the bowl and to reduce rejection
rate. If required change the Trunnion end cap position too.
Note: Mill needs to be stopped for a short while for the above (Point 3) work, but it
gives better fineness and mill output.
4)
Spring seat gap to ensure equal load on bowl by spring assemblies.
5)
Classifier blade position to maintain Pulverised fuel fineness.
6)
Height of the venturi collar to maintain the desired pulveriser fuel fineness and
differential pressure across the bowl.
7)
Inverted cone gap to maintain the Pulverised fuel fineness.
36
6.0.
MILL OPTIMIZATION
Bowl Mill
XRP1103
Procedure:
1)
Collect one set of mill readings from Unit Control Room (UCB), raw coal analysis data,
Pulverised fuel fineness details, quantity and quality of mill rejects and raw coal size
and grindability index etc.
2)
Check and ensure the requirements of raw coal feeder, condition of mill DP
instruments, and primary air flow through the mill and the quantity of raw coal.
The above adjustments may be carried out to maintain the required bowl DP, PF fineness,
quantity & quality of mill rejects and for the said purpose.
37
7.0
TROUBLESHOOTING
Bowl Mill
XRP1103
7.0 TROUBLESHOOTING
The trouble shooting guide lists Mill Malfunctions generally faced but a large number of the
problems are off shoot of a problem, which has not been take care in time. Mill problems can
be reduced to maximum extent if the Instructions are listed here are followed. If the
malfunction is not clear, we recommend therefore that the specialist personnel of BHEL be
consulted in tracing possible cause.
Instructions:1. Maintain proper air flow and mill outlet temperature
2. Do not run the mill with spillage.
3. Change or service labyrinth seal as soon as it fails.
4. Prevent foreign material entry to mill with coal.
5. Check and maintain proper internal clearances regularly.
6. Follow the lubrication chart/schedule.
7. Empty the pyrite hopper periodically.
38
Bowl Mill
XRP1103
TROUBLESHOOTING
TABLE- 8
Disturbances, Reasons and Remedy
Bowl Mill Troubleshooting Guidelines
PROBLEM
Mill Vibration Under

Load
PROBLEM CAUSE
Spring Compression too high
Improper assembly of Bull Ring segments
Excessive wear of Bowl and extension ring
Loosening of Separator body bolts
Roll to Bowl clearance
RECOMMENDATION
Reset Spring compression
Assemble Properly
Replace Extension Ring. Build up bowl by weld deposit
Tighten the Separator body bolts.
Adjust roll to bowl clearance.
Foreign material in mill
Take mill offline and remove foreign material
Over feeding
Insufficient primary air flow
Reduce feeder speed/ coal feed to mill

Correct the primary air flow quantity.
Attend to worn out seal air skirts. Service the bearings and oil seals
Check and clean seal air supply to journal assembly.
Reduce Cold air, increase hot air supply.
Reduce feeder speed.
Replace roll/or Ring and adjustment.
Increase spring pressure load.
Reset classifier Blades towards open position.
Reset the classifier towards open position.
Reset to the required pressure load.
Jamming of rolls
Mill Coal spillage High
High Pulverized fuel

fineness
Low Pulverized Fuel

Fineness
Low Mill outlet temperature

Worn grinding roll
Low journal spring Pressure set
Classifier set for higher fineness
Improper setting of classifier
Excess spring compression
Improper Method adopted for :
i.
Pulverized Fuel sampling technique
ii.
Sieve Analysis
Improper setting of classifier
Improper Alignment of classifier vanes
High air Flow
Train the manpower.

Reset classifier Blades towards closure position(max position 5).
Properly align classifier vanes
Repair/ Replace Worn out Parts.
Table 8(cont.)
39
Bowl Mill
XRP1103
TROUBLESHOOTING
Table 8 (cont.)
Low Pulverized Fuel

Fineness (cont.)
Oil Leakage from Flanges
Lubricating Oil Temp. too

High
Lubricating Oil Temp. too
Low
Lubricating Oil header

pressure too Low
Reduce air flow to design value.

More gap between cone and feed pipe
More gap between inverted cone and classifier
cone.
Improper setting of:i.
Ring Roll clearance
ii. Pressure spring seat- journal head
clearance
Mating surface not cleaned properly.
Seal compound not applied
Improper gasket used
Bolts not properly tightened, threads damage
No cooling water
Cooler contains air
Excess wear of mill parts

Correct the gap.
Cooler dirty
Replace Cooler,/ Clean or Replace contaminated pipe bundle.
Gear unit not yet warmed up to operating

temperature.
Too much cooling water
Filter Clogged
Pressure limiting valves defective/wrong set
Suction line blocked
Pump Aspirating air
Lubricating oil temperature too High
Oil Viscosity too low
Correct the gap.
Assemble properly.
Apply Gasket eliminator or any suitable sealing compound.
Use compressed asbestos gasket.
Tighten properly. Rethread to mark high size bolt.
Rectify cooling water supply.
Bleed cooler.
Check whether heaters are working
Reduce cooling water supply.
Switch over to clean filter and clean filter and clean filter element.
Replace Pressure limiting valve if defective.
Clean suction line.
Check suction line and remedy any leaks.
Check cooler performance.
Check viscosity and if necessary fill with correct oil.
NOTE: Also refer to Sec: 5 on Planetary Gear Box

40
Bowl Mill
XRP1103
TROUBLESHOOTING
Lubricating oil
pressure too high
Gear unit not yet warmed up to operating

temperature
Pressure limiting valve wrongly set
Pressure limiting valve defective
Lubricating oil lines to and at gear unit
blocked
High Mill outlet Temperature
Mill Fire
Journal Oil
Contamination
Coal settlement in mill

Rapid change in moisture content of coal
Putting burning coal in mill
Bearing damaged
Oil contaminated improper oil
No Bearing clearance
Oil seal damage/ worn out wear sleeve
Pipes dirty(scale, welding residues)
Clearly appeared or
accumulated filter
residues
Abraded particles from gear unit

Lubricating oil dirty
Oil tank dirty
Wait, Reduce cooling water flow/ isolate.

Correct oil pressure at limiting valve.
Repair or replace pressure limiting valve
Locate blocked line and clean.
Do not exceed mill o/l temp. Recommend as per volatile matter
content in coal.
Do not leave coal in idle mill. Remove the coal either manually or
taking the mill in service. Remove accumulated mill rejects from air
duct and mill side housing, periodically.
Keep a close watch at mill outlet temperature.
Empty the bunker and remove smoldering coal.
Change bearing.
Change oil as per recommendations
Set bearing clearance.
Change them.
Clean pipes.
Check gear unit (bearing, tooth systems, alignment)and rectify
defects.
Carry out oil change.
Clean oil tank and carry out oil change.
41
Bowl Mill
XRP1103
TROUBLESHOOTING
Interrupted coal flow
Check & take necessary action
Too high air flow, particularly hot air flow
Open cold air and reduce hit air keeping air flow to mill
constant.
Fire in mill/ coal fed to mill
Check mill/feeder for fires

See that coal flow is optimum(Bowl Differential, feeder speed,
mill motor current)
If this measure are not fruitful and temperature continuous to
rise, isolate mill & spray water to quench fire.
High Mill outlet

temperature
Oil consumption too high
Leak in pipes, connections, valves or gear

unit.
Cooler Leaking
Shaft outlets on gear unit leaking
Tighten screws.
Seal cooler or renew cooler element.
Renew seal ring.
Refer to BHEL-Pulv.Engg. division for solution.
42
8.0. PULVERISED COAL SAMPLING

ANALYSIS & ADJUSTMENT OF FINENESS
8.0
Bowl Mill
XRP1103
PULVERISED COAL SAMPLING:

Pulverised coal samples should be taken for fineness test periodically and whenever
furnace or pulveriser operation suggests fineness has changed.
In order to obtain repeatable and comparable fineness test results, it is necessary to
maintain the pulveriser and furnace conditions as constant as possible during the
sampling procedure. The pulveriser should be on manual control at or near its full load
rating and should be allowed to settle out for at least 10 minutes before testing starts,
pulverisers with obvious indications of trouble (heavy coal spillage, rumbling) should not
be tested.
8.1
NON-ISOKINETIC SAMPLING METHOD: (For ISO KENITIC SAMPLING refer

to O& M manual of Vendor, if applicable)
A sampling device, illustrated in Figure O is supplied for each installation. The
sampling device consists of a cyclone separator, a sampling jar (receiver) and a
sampling nozzle connected directly or by means of a hose to the cyclone.
Eight aspirating fittings, also shown in Figure O are furnished with each pulveriser. These
fittings should be installed 90 apart in holes provided in the pulveriser discharge valves
(see mill General arrangement drawing). To utilize the aspirators properly admit
compressed air into the fitting, remove the 2" pipe plug, then reduce the quantity of
compressed air to the minimum necessary to prevent discharge of powdered coal into
the room.
The opening in the end of the sampling nozzle should always point directly towards
upstream while taking the sample. Sample must be taken from all the eight aspirating
fittings provided to get a representative sample. Sampling probe should be moved in
and out at a uniform speed
The content of the sampling jar(s) should be placed on a heavy sheet of paper or
plastic and thoroughly mixed by lifting the corners to roll the coal back and forth along
one diagonal and then along the other diagonal. The sample should then be coned,
quartered and remixed until it is reduced to approximately 150 grams. Sample should
be heated in an oven to mill outlet temperature value, before sieving. Fifty grams of this
43

Bowl Mill
XRP1103
sample should then be placed on the top screen of nested 50 mesh, 100 mesh and 200
mesh sieves. The sieves should be shaken on a Ro-tap or similar shaker for a total of 15
minutes. After 5 and 10 minutes stop the shaker, remove the collecting pan, brush the
bottom of the 200 mesh sieve and discard the contents of the pan.
After 15 minutes the amount of coal left on each of the sieves is individually weighed
and fineness is calculated as per the following example.
Sample Calculation
Example
% on 50 mesh
( 2 x Wt. on Sieve)
2 x 0.5 = 1.0%
% through 100 mesh
100 - 2 (0.5 + 4.4) = 90.2%
100 - 2 (Wt. on 50 + on 100)

% though 200 mesh
100 - 2 (Wt. on 50+on 100+on 200)
100 - 2 (0.5 + 4.4 + 9.9) = 70.4%
Fineness determination from the same example by the same operator using the same
sieves should check within one percent on all screen sizes.
A record of pulveriser performance and fineness result, similar to that shown on TABLE-9,
should be kept for each pulveriser. A drop off in pulveriser performance can thus be
detected and corrective measure taken.
One method of validating fineness test results is to use a Rosin rammler sieve distribution
chart (see Figure-8A). When the fineness test results, such as those in the example given
above, are plotted for the particular coal, the lines should be closely parallel or coincide.
If the fineness test results do not form a straight line, the sample sampling technique, or
equipment (see NOTE) should be checked. If there are large variations in the amount of
coal on the 50 mesh sieve, check the pulveriser for a very high air flow or a hole in the
inner cone. If air flow is normal, the pulveriser should be shut down and inspected at the
first opportunity. Check for wear patterns, holes in the inner cone and other indications of
unusual wear.
44

Bowl Mill
XRP1103
NOTE:
Holes in the inner cone, holes in the deflector vanes or missing deflector vanes can
produce erratic coal fineness test results. Check the calibration of air flow instrumentation
if high air flow is suspected. Improper ring-roll setting, journal spring compression too
would affect the P.F. fineness.
The following publications may be used as references for sampling and sieving
procedures.
Sampling
A.S.ME. P.T.C. 4.2 ------ for non iso-kinetic method or

ISO 9931 for ----------- Isokinetic sampling
Sieving
8.2
A.S.T.M.D. 197 Test for Fineness of Powdered Coal.
ADJUSTMENT OF FINENESS:
The degree of coal fineness obtainable with air separation is extremely high, and within
normal limits it is possible to control fineness with considerable exactness.
Fineness of any material is usually measured as the percentage of the material that will
pass through each of a series of test sieves. When a material such as coal is reduced to
fineness to that 95% passes through a 100 mesh sieve, 75% to 85% of it will pass through
a 200 mesh sieve. The percentage passing through the 200 mesh sieve will depend on
the hardness or grindability of the coal. The lower percentage will apply to harder coals,
which have lower grindability. The percentage for more easily pulverised coals with
higher grindability will be closer to the higher value. (Refer to A.S.T.M. publication D409:Grindability of Coal by the Hardgrove Machine Method).
When 95% or less passes through the 100 mesh sieve, the spread or difference between
the percentages of coal passing through the two sieves will be 15 to 20 percentage
points. As fineness increases, or for softer coals, the spread decreases. For example,
when fineness is increased to 90% passing through a 200 mesh sieve, the difference is
only about 9 percentage points between the two sieves. With the same adjustments
on the pulveriser, different degrees of fineness will be obtained with different coals.
If a result is reported showing over 25 percentage points difference, a careful recheck
should be made with particular emphasis on the sampling procedure used (see
Pulverised coal sampling).
45

Bowl Mill
XRP1103
It should be remembered that with increasing fineness there is a decrease in the

capacity of the pulveriser in tons per hour and an increase in the power required per
ton of Pulverised coal.
The fineness is adjusted by moving the deflector handle(s) on the separator top. When
the handle point is set on 0, the deflector vanes are at their maximum opening,
producing minimum fineness. As the handle is moved to higher numbers on the scale,
the deflector blades close and fineness increases. See Figure E for deflector blade
set up.
The fineness for which the pulverising equipment and system were designed is given in
the contract. If the coal is finer than necessary when deflector handle point is set on
0, the handle should be reset to allow for a greater blade opening. If deflector blades
are radial and the fineness is still too high, then there is the possibility that the spring
force on the journals should be reduced. If the coal is too coarse when the deflector
handle point is set on 10, the spring force may have to be increased.
For this purpose the mill needs to be stopped and spring compression fixture used for
reducing or increasing spring compression. The spring compression will be less when the
grinding elements are new. Later on, for getting the desired fineness, the spring
compression can be increased by opening the mill. Other reason for low fineness is
large gap between grinding roll and bull ring segments. For adjusting this gap, two
mechanisms are provided in the mill. The gap can be adjusted by stopping the mill and
adjusting the stop bolt results in lowering the grinding rolls. In case this does not become
effective, the cam arrangement provided on the Trunnion end cap shall be used. For
this stop the mill and turn the end caps to lower the grinding rolls. It should be ensured
that both, the right and left side end cap numbers are same at the arrow point.
With the above, the fineness and output can be achieved near the end of the
grinding element guaranteed wear life too.
46

Bowl Mill
XRP1103
Note: Note down the mill parameters before and after PF sampling to ensure that the
parameters were maintained more or less constant.
47

Bowl Mill
XRP1103
Fig. 8A Sieve Distribution Chart
48

Bowl Mill
XRP1103
8.3 MILL WEAR LIFE ASSESSEMENT

The objective of this test is to realize the maximum wear life of grinding element. Attach
wear measurement gauge to journal assy. It is important to hold the gauge securely
against lower journal housing and roller back face to ensure accurate reading as
shown in figure 8B
Fig 8B
Measure the dimension x at various locations 120 degree apart at each locating with equal
spacing and record on data sheet. During service and after the roll removal, reading may be
taken.
49
9.0.
Bowl Mill
XRP1103
MAINTENANCE
9.0. MAINTENANCE
The Bowl Mill and its auxiliaries require continuous monitoring and periodical maintenance to
ensure reliable operation and availability. Monitoring and Maintenance are required both
during operation and when the unit is at standstill.
Some maintenance works require with the mill at shut down position, while some
maintenance works may be carried out during normal operation of the mill. This Maintenance
Section of O & M manual is divided into three sub-sections:-
MAINTENANCE
GENERAL
MAINTENANCE
PREVENTIVE
MAINTENANCE
COMPONENT MAINTENANCE
50
10.0 GENERAL MAINTENANCE
Bowl Mill
XRP1103
10.0 GENERAL MAINTENANCE:

The pulveriser is a rugged machine, designed and built for continuous operation over an
extended period, with minimal wear on the working parts. However iron pyrites and other
abrasive substances in the coal are apt to shorten the life of parts such as the rolls, bull ring,
rotating vanes and scrapers.
Since wear of pulveriser parts depends on many factors that vary from one
installation to another, it is difficult to prescribe a specific routine inspection and
maintenance program. Characteristics of the fuel, operating hours of individual pulverisers,
availability of pulveriser due to unit load demands, and trained maintenance staff
availability are all factors that determine the frequency and scheduling of pulveriser
inspection and maintenance. An effective program can be established only on the basis of
actual plant operating experience. It is therefore imperative that an accurate log be kept
from the beginning, to relate individual pulveriser running time (see NOTE) with pulveriser
performance, plant operating schedules, unit load, outages, inspection reports, and other
associated data.
NOTE:
PULVERISER WEAR IS A FUNCTION OF THE NUMBER OF HOURS A PULVERISER IS
GRINDING COAL, NOT NECESSARILY THE AMOUNT IN TONS OF COAL PULVERISED. A
PULVERISER WILL LAST SOMEWHAT LONGER WHILE OPERATING AT REDUCED
CAPACITIES BUT WILL GRIND MUCH LESS TONNAGE BEFORE PART REPLACEMENT
BECOMES NECESSARY.
Pulveriser part replacement criteria cannot always be defined in advance. They must be
established on the basis of experience and judgment on the part of personnel familiar with
the pulveriser history and performance. The degree, location and pattern of wear soon
become evident and can be handled accordingly. In some cases surfaces can be built up;
in other instances, replacement of the part is more practical. The following list describes the
pulveriser parts normally subject to wear:
I) Bull Ring and Rolls:

51
Bowl Mill
XRP1103
Reduced pulveriser capacity and increased spillage even after

carrying and ring roll setting periodically are indications of excessive wear requiring
part replacement. Contour templates, made when the equipment is new, may aid
in checking the degree and location of wear as it progresses. In case sand
accumulation is noticed on the bowl which would also stop the mill output, carryout
Mill Purging periodically. Stop coal feeding and air supply to mill and run it empty
for 5 minutes till all the sand from bowl is removed by centrifugal action of the
rotating bowl.
II) Airport Ring (Figure. 11.d):
Check and maintain a vertical clearance of 5 to 11 mm between the top of
rotating vanes and the bottom of the body liner segment.
III) Bowl Extension Ring:
The ring should be replaced when worn excessively.
NOTE: Items 2 & 3: Periodic inspection for wear and hard facing to be done to improve
the parts wear life.
IV) Mill bottom Cover Plates:
Wear can be minimized by maintaining proper support of the scraper blades.
Replace when worn-out.
V) Mill side liners and Air inlet vanes:
Excessive rejects will cause wear on liners and edges of vanes
VI) Scrapers:
Bottom edges are most susceptible to wear and should be replaced when required
gaps cannot be maintained with the help of the turn-buckle support. Maintaining
proper support (pins and bushings) helps to minimize wear.
52
Bowl Mill
XRP1103

VII) Mill Discharge Valves:
Excessive clearance in valve flap closed position is an indication of wear. Disc should
be replaced when worn out.
Most of the inspection and repair works inside the pulveriser above the bowl can be
accomplished by removing one journal assembly cover and journal assembly. Work
below the bowl is normally done by entering the mill through the mill side access
door.
CAUTION
WHEN MAINTENANCE IS REQUIRED ON A PULVERISER WHILE THE UNIT IS IN OPERATION,
MAKE SURE THE PULVERISER IS COMPLETELY ISOLATED (DAMPERS, GATES AND VALVES
ARE CLOSED, MOTOR CIRCUIT BREAKERS LOCKED IN OPEN POISTION, AND THE MEANS
FOR OPERATING THIS EQUIPMENT SUITABLY TAGGED) BEFORE ENTERING THE
PULVERISER.
VIII) Bearings:
Unusual noise and operating temperatures consistently above normal are
indications of impending bearing failure. Bearings should be inspected at the first
opportunity.
IX) Planetary Gearbox:
Planetary gearbox components usually give long, trouble-free service. Proper
lubrication and its parameters, avoiding entry of large size extraneous materials into
the mill are to be taken care off during operation. For more details refer to the
Section-5 on Planetary Gearbox.
10.1 INSTRUCTIONS FOR INTERFERENCE FIT:

INTERFERENCE FITS:
Where components have been designed with interference fits, it is necessary to heat
and/or cool the mating parts to facilitate assembly.
53

a)
Bowl Mill
XRP1103
Heating:
Heat must be applied uniformly to the entire piece. Acetylene torches with rosebud
tips are not recommended, since heating by this method is not sufficiently uniform.
Heat can best be applied in a commercial type oven. However, it is also possible to
shroud the part in an insulated enclosure and increase the part temperature with
space heaters.
b)
Cooling:
Chilling of components can be done in a commercial freezer. It is usually easier to
submerge the part, after providing a protective oil or grease coating, in an ice/salt
bath or to pack the part in dry ice.
54
11.0. PREVENTIVE MAINTENANCE

11.0
Bowl Mill
XRP1103
PREVENTIVE MAINTENANCE
Preventive maintenance is conducted to extend the life of the equipment. It involves the
regular inspection, testing and replacement OR repair of equipment and operational
systems.
Preventive maintenance takes proactive approach to the problems before they occur
And also saves money from mill breakdowns.
.
11.1
MILL CLEARANCES
i)
INVERTED CONE CLEARANCE

The inverted cone prevents the Pulverised coal from by-passing the classifier.
Inverted cone clearance is the perpendicular distance between the inverted
cone and the classifier inner cone.
Fig -11.a
The gap between inverted cone and inner cone is 100mm (5 mm) and the
gap between center feed pipe lower and inner cone is 114mm (5 mm).If the
clearance is too small, bridging of coal between the inverted cone and the
55
Bowl Mill
XRP1103
classifier inner cone can occur, which would result in carry over large coal
particles to the boiler furnace leading to other related problems periodically. If
the clearance is too large, the primary air can carry large particles out of the
mill by passing the classifier. This results in poor Pulverised fuel fineness.
ii)
GRINDING ROLL-TO-BULL RING SEGMENT CLEARANCE:

The roll-to-ring clearance should be set to 4 to 6 mm parallel for the entire length
of the roll in new condition. This clearance setting affects the performance of
the mill upon wear.
Fig -11.b
iii) PYRITE SCRAPER CLEARANCE:

The clearance between scraper and insulation cover plate is 13 to 19mm. and
the clearance between scraper guard and insulation cover plate is 10 to 16
mm. Radial Gap between scraper and mill side bottom liner is 25 to 35 mm.
Radial clearances between Labyrinth Seal & Bowl hub is 0.25 to 0.75 mm.
56
Bowl Mill
XRP1103
Fig -11.c
iv)
AIR PORT RING CLEARANCES

Vertical Gap between body liner segment and rotating vane segment of Air
Port assembly is between 5 to 11 mm. Figure 11.d shows the clearance
57
Bowl Mill
XRP1103
CROSS SECTION OF AIR PORT RING ASSEMBLY

Fig -11.d
ROLL TO RING CLEARANCE ADJUSTMENT

The most common indications of the need for roll-ring clearance adjustment are the
falling off of pulveriser capacity, rumbling and increased coal spillage. Adjustment
of clearance and/or spring compression should be considered in the event of any
prolonged coal side pulveriser operating difficulties. If difficulties do not exist,
adjustments are not recommended.
58
Bowl Mill
XRP1103
The entire journal assembly (Figure - P) including the roll, pivots about the
center of the Trunnion shaft and can be raised or lowered with the journal stop bolt.
As roll and ring wear progress, the first adjustment is to lower the rolls using the stop
bolts. Continue to make stop bolt adjustments until they are no longer effective.
Trunnion shaft bushings in the Trunnion shaft end caps support the Trunnion
shaft so that when the end caps are rotated from position 1 to 5, the location of the
center of the Trunnion shaft is changed and this alters the position of the entire
journal assembly. The Trunnion shaft end caps can be used to make roll-ring
clearance adjustments, once the stop bolt adjustments are no longer effective in
position 1.
a) To make a roll - ring clearance adjustment with the stop bolt:
I) Slack off the journal stop bolt lock nut. Pulveriser running with empty bowl and
no coal being fed, slowly retract the journal stop bolt until contact
between ring and roll can just be heard or felt with the roll rotating on the
journal shaft assembly. Then turn the stop bolt by one flat with new roll and
segments however for worn out ring rolls-segments stop bolt rotation by
one flat further need not be done .Turn the stop bolt till the high points of
rolls & segments do not touch each other and tighten the journal stop bolt
locknut. Assemble the lock plate and bolt it. Repeat the same on
remaining two journal assemblies.
ii)
Slack clamp plate stud lock-nuts of journal spring assembly.
iii) Keep a shim of 0.5-1.0 mm thick between the pressure spring seat and journal
head insert and the snug up all clamp plate studs firmly and evenly and
drive the locknuts tight. The pressure spring seat now will be in touch with
the stop journal head insert, remove the shim. This to be repeated for the
remaining two journals spring assemblies.
59
Bowl Mill
XRP1103
b) To make a roll-ring clearance adjustment using the Trunnion end caps:

Note:
.
When a new grinding elements (rolls and bull ring segments)

are fitted in the mill, the trunnion shaft end cap should be
positioned one position prior to numeral 1, by rotating in the
opposite direction to the arrow marking made on the end cap
face. Once the mill has operated for 1000 hours and wear in
the grinding elements sets in there by increasing the gap
between the rolls, the Trunnion shaft end cap is to be brought
back to its original envisaged position, i.e numeral 1 lines up
with indicating arrow on the journal opening cover (JOC). This
is done to avoid mill vibrations and other related damages in
case the rolls are touching each other during mill operation.
i) Slack clamp plate stud locknuts and retract studs several turns. This
frees the pressure spring assembly inside the spring cup. Loosen the
journal stop bolt lock nut and back out the journal stop bolt until the roll
just touches the rings.
ii)
Remove the bolts from both Trunnion end caps and slack off the four
journal opening cover bolts adjacent to each end of the Trunnion shaft.
Using special box wrenches, rotate both Trunnion end caps
simultaneously in the direction indicated by the cast arrow, so that the
numeral '5' lines up with the indicating arrow on the journal cover.
Replace and snug the Trunnion end cap bolts. Tighten the cover bolts
and tighten the end cap bolts.
iii)
Turn the pulveriser bowl manually through one revolution by hand to
make sure that none of the rolls make contact with any part of the ring.
Then adjust the roll-ring clearance with the stop bolt following steps (a)
above.
Additional adjustments should be made using the journal stop bolt until they are
again no longer effective. When this occurs, it is necessary either to replace the rolls
and bull ring. A ring will usually outlast the rolls.
60
Bowl Mill
XRP1103
Fig. 11 e) Trunnion Shaft End Cap (shows Trunnion position)
61
Bowl Mill
XRP1103
11.2 JOURNAL SPRING COMPRESSION

The spring compression must be set before the pulveriser is placed in service. The
initial compression setting (9 or 10 tons) should be checked and if necessary, the
springs should be compressed using the spring compression fixture supplied. If some
coal or load characteristic causes poor operation changing the spring compression
should be considered.
To prevent undue stress on pulveriser components, spring compression on the three
journals in one pulveriser should check within 450 Kg.
The most common reasons (and action) for changing spring compression
are:
a)
1.
Rough operation at low loads (reduce the compression).
2.
High or unstable power consumption (increase the compression).
3.
Vibration at high loads (increase the compression).
SPRING PRELOAD SETTING PROCEDURE (Refer Figure. 11. f):

i) The spring assembly should be completely assembled except for the spring
stud extension cap, spring stud locknut keeper Hex. Hd. cap screw (M52)
and keeper washer.
ii)
Of the six threaded studs, four must be backed out of the journal spring
housing cover to the dimension indicated in detail B. For the purpose
of wrench clearance, two studs must be removed in the region of one of
the cutouts in the preload fixture (item 2).
iii)
Slide the spring stud locknut keeper on to the spring preload stud.
iv)
Using two Hex. Hd. cap screws (item 3), fasten the cylinder (item1) to the
spring preload fixture (item 2) mount the fixture as shown using one nut
at the top. Slide the preload stud (item 4) through the cylinder and screw
it into the end of the spring preload stud. At least a thread engagement
62
Bowl Mill
XRP1103
of 76 mm is required. Screw the nut (item 5) on to the preload stud (item

4) with the cylinder (item 1) fully retracted.
v)
Slide, back off the spring stud locknut keeper from the spring preload
stud.
vi)
Use the cylinder to draw the spring guide. To contact the spring housing
cover pump the cylinder (item 1) until the pressure gauge reads P 10
kg/Sq. cm. This will compress the spring X from the static length. Using
the locknut wrench (item 7) advance the locknut until it contacts the
spring guide.
vii)
Before carrying out the journal spring compression initial setting (F Kgs),
ensure that the required information/ data is available to calculate and
arrive at the hydraulic cylinder oil pressure (P Kg/ Sq.Cm) to be
maintained in the pressure gauge, to achieve the desired result. For this
one should have a complete set of hydraulic kit in good working
condition, the pressure gauge calibration checked and the hydraulic
jack RAM area (A Sq.Cm) is available based on the make and model.
Otherwise contact Pulverizer Engineering Dept. at R.C.Puram unit. The
formula to arrive at the required oil pressure to be set is P = F/ A Kg/Sq.Cm.
Example: For Hydraulic kit make of M/s VANKOS, with model no.
RCHO30/75, the hydraulic jack RAM area is 89.55 Sq.Cm. Suppose the
initial spring compression setting is 10 tons (10, 000 Kgs), then the oil
pressure to be maintained would work out to be as follows:
Hydraulic oil pressure (P) = 10, 000/ 89.55 = 111.70 kg/Sq. cm.
viii)
Relieve the pump pressure (item 1) to 70 kg/Sq. cm using a magnetic base

dial indicator. Place the indicator needle on the flat vertical face of the
locknut and zero the indicator. Pump the cylinder pressure up to P
kg/Sq. cm. again and check the preload by making sure the indicator just
starts to move (about 0.2 mm) as the pressure gauge reads P kg/Sq. cm.
ix)
Tighten or loosen the locknut until this occurs. Slide the lock nut keeper onto
the spring preload stud causing the keeper to interlock with the locknut. It
may be necessary to compress the spring just above P kg/Sq. cm. to
allow rotation of the locknut. The locknut should be rotated a maximum
of 1/8 of a turn. Slide the keeper into position and relieve the cylinder
pressure.
63

x)
Bowl Mill
XRP1103
Remove the preload stud (item 4) and preload fixture (item 2), and install
Hex. Hd. cap screw & keeper washer. Torque the Hex. Hd. cap screw to
75 ft-lbs and weld Hex. Hd. cap screw, keeper washer & locknut keeper
together.
xi)
Weld a locking plate (L-plate) between the stud lock nut keeper and screw
of the journal spring assembly, after performing the journal spring
compression setting. This would ensure that the spring stud lock nut would
not get disturbed from its place; otherwise it would change the spring
compression setting value during mill operation.
xi)
Mount six Hex. nuts onto the adjusting threaded studs. Refer to the ring to roll
setting procedure before adjusting these studs.
xii)
The spring compression should be checked whenever time permits to ensure

near equal loading all the three springs.
xiii)
The spring compression can be adjusted, by stopping the mill, to get the
desired pulverized coal fineness or mill output, especially when the
grinding elements are worn out.
64
Bowl Mill
XRP1103
07.
LOCK NUT WRENCH
06.
WASHER 43 MM
05.
NUT M42
04.
PRE LOAD ADJ. STUD
03.
SCREW HEX. CAP M12

X 40
02
.SP. PRE LOAD FIXTURE

ASSY
01.
HYD
CYLINDER
AND
PUMP SET
ITEM
DESCRIPTION
NO
Fig -11.f
65
Bowl Mill
XRP1103
CAUTION
USING THE SPRING COMPRESSION MEASUREMENT TAKEN, DO NOT ALLOW THE PRESSURE
GAUGE READING TO EXCEED 3000 KG FOR EACH CENTIMETER OF THREAD ENGAGEMENT.
THEN BACK OFF THE SPRING ADJUSTING NUT THE DESIRED AMOUNT OR 6 MM. FOR THE
PURPOSE OF ESTIMATION, THE FOLLOWING TABLE GIVES THE SPRING RATE FOR THE MILL.
Mill Size
XRP 1103 -
Spring
Rate
( Kg/Cm)
Spring load to be registered at Pr. gauge in Kg.
5359
9500
1103
66

11.3
Bowl Mill
XRP1103
CHECKING SPRING COMPRESSION (Refer Figure. 11.f):

It is normally necessary to open the pulveriser in order to check spring compression,
but it should be run for 5 minutes with no feed to clear itself of coal.
Note: Carryout steps i) to vi) as per Spring preload setting procedure (Refer to
11.2.a).
Check the existing setting by applying the hydraulic force up to 70 Kg/Sq.Cm
pressure and then fix the dial indicator as well as set it to 0 on the dial, and increase
the hydraulic force further, noticing the pressure gauge reading, till the indicator has
moved to about 0.2 mm on the dial. At this point, the pressure gauge reading will
give the existing spring load set value. If the set value is to be reduced loosen the
locknut. If more than 6mm compression is to be moved, release all the hydraulic
force, back off the lock nut keeper another 6mm and repeat the above as many
times as required.
NOTE:
1.
Hand movement of the spring adjusting nut may be difficult. In order to turn the
same under these circumstances, use spanner wrench.
2. Check the ram area of Hydraulic cylinder written on the each Hydraulic cylinder and
multiply the same with pressure gauge reading to get the required hydraulic load in
tons applied on spring assembly.
3. Amount of compression in mm depends on the spring rate.
67

11.4
Bowl Mill
XRP1103
INSPECTION TASKS
Reliable operation of the mill will be ensured only if inspections and overhauls are carried
out at regular intervals so that any faults can be detected and corrected before they result
in costly failures. The Bowl mill needs a periodic check to be done on the lubricating system,
mill clearances and other operating parameters of mill.
The spare parts stored for repairs and overhauls should be checked at regular intervals.
SUGGESTED CHECKLIST FOR MILL PREVENTIVE MAINTENANCE INSPECTION
INSPECTION TASKS
1. Check grinding roll wear depth using the wear measuring gauge and
Record the data. Readings may be taken approximately after every 1000
Hrs. of mill operation.
2. Check roll to bowl clearance, nominal clearance for roll to bowl is 4 to 6
mm. If clearance value is not proper, correct it either by adjusting stop bolt
or by adjusting Trunnion end caps.
3. The initial compression setting (9.5 tons) should be checked and if necessary,
the springs should be compressed using the spring compression fixture supplied,
based on mill performance.
4. Check segmented bull ring for wear. Measure with the help of Contour
templates, made when the equipment is new, would aid in checking the
degree and location of wear as it progress.
5. Check and set the airport ring assembly clearances as well as hand facing
the eroded areas.
6. Check bowl extension ring and change, if worn out.
7. Check clearance between mill bottom and lower skirt.
8. Maintain the seal air hoses in good condition and replace them immediately,
if got damaged.
9. Make periodical adjustment of the classifier vanes and hence the fineness of
pulverized coal, based on use results.
10. Coupling inspection, alignment check and greasing if required

11. Check and maintain scraper gap with respect to mill bottom insulation cover
68
Bowl Mill
XRP1103
It is suggested that, the maintenance staff, based on their experience with the mill
in operation, update the inspection tasks check list and follow the same periodically on
daily, weekly basis. So that the mill availability and performance can be sustained nearly
100%
69
12.0. COMPONENT MAINTENANCE
12.0
12.1
Bowl Mill
XRP1103
COMPONENT MAINTENANCE
GENERAL DIS-ASSEMBLY AND RE-ASSEMBLY OF COMPONENTS:
ISOLATION OF THE PULVERISER (Refer fig.1):
It is a good operating practice to isolate the pulveriser, before attempting any
maintenance job, that calls for opening the mill or dismantling its components. To isolate
the mill close the hot gas shut-off gate, the cold gas shut-off gate, the coal line gate (if
provided), the feeder discharge valve (if provided) and open the mill feeder motor
breakers. (Tag and/or lock open).
For most maintenance procedures a complete general disassembly of the bowl mill is
not required. Planetary Gearbox is designed to perform for long time smoothly, provided
the operation guide lines are followed strictly. Periodical cleaning of filter element and
or replacing the same with spare element, keeping a watch on the oil quality through
periodical sampling and testing only are expected to be the normal maintenance
activity. Inspection doors are provided to peep into the gearbox for a visual check.
However, in case the gearbox needs any major maintenance activity to be done, the
same can be drawn out from its place, as per the procedure given below, and replaced
with a spare gearbox. This way the mill can be brought back into operation within couple
of days.
12.1.1 PLANETARY GEARBOX WITHDRAWAL & REINSTALLATION PROCEDURE

(Ref: Figure G)
12.1.1.a WITHDRAWAL OF GEAR BOX ASSEMBLY:
The Planetary gearbox will be removed towards the drive motor side. The step by step
procedure for withdrawal and replacement of Planetary gearbox, in case required, is
as explained below:
1.
Isolate the Mill and lock the Mill motor and lube oil pump motors.
2.
The journal assembly and journal opening cover shall be removed as per
sequence. OR Tilt the journal assembly and journal opening cover in situ, after
70

removing the
Bowl Mill
XRP1103
fasteners holding the journal opening cover to the journal
opening frame and the Trunnion bushing flange.

3.
Disconnect and remove the lube oil piping, both inlet and outlet side from the
gear box, till the withdrawal path is clear. Plug the openings to avoid any dirt
entry.
4.
Disconnect the HT / LT and instrument cable connections made to the drive

motor and the junction box fitted on the gearbox.
5.
Remove the skirt assembly including the scrapper assembly from the bowl/bowl
hub. Remove the labyrinth seal assembly.
6.
Loosen and remove the holding down studs & nuts (M56) between bowl hub
and the table top/flange of the gear box. Use hydraulic jacks to loosen the nuts.
7.
Remove the drive coupling guard and disconnect the mill-Motor coupling.
8.
Loosen the holding down bolts of the drive motor to the base plate, rig and
remove the motor from its place and keep it in a nearby location, in case no
maintenance work need to be done on it.
9. Install the gear box withdrawal fixture assembly as shown in Figure G.

Loosen the bolts and remove the body block off liner of the Airport ring assembly,
fastened to the bracket welded to separator body. In case the journal block off
liner is provided, the same may be gas cut and removed. Remove the bowl
extension ring fastened to the bowl.
10.
Rig and lift the bowl and bowl hub together using the 3 nos of Ratchet lever
type manual handling equipment, suitable slings and eye-bolts, by 65 mm. The
bowl hub shall clear the keys provided on the table top/flange of the gear box.
Fix the hoisting clevis (3 nos) to the M24 tapped holes made in the top surface
of the flange of the bowl, at 120 apart.
Note: If required use jacks in the mill side air inlet housing to free the bowl hub from
the gearbox table top/ flange.
71

11.
Bowl Mill
XRP1103
Alternately, Rig and lift the bowl and bowl hub together using 4 no.s of 10 tons
jacks placed in the mill side air inlet housing to free the bowl hub from the
gearbox table top/ flange, by 65 mm. The bowl hub shall clear the keys provided
on the table top/ flange of the gear box. Fix suitable size of wooden blocks/ shim
plates between the mill side bottom insulation cover plate and the bowl hub.
Lower the jacks such that the bowl hub assembly load is transferred to the
wooden blocks/ shim plates.
Remove the jacks for lifting the gear box as
explained below.
12.
Loosen and remove the holding down bolts between gear box and base plate.
13.
Jack and raise the gear box assembly and fix the roller assemblies as shown in
Figure G.
14.
Using the pull and lift equipment (2 nos), one to hold and allow the gear box
movement slowly from the rear end, and the other one to pull the gear box out,
from the input shaft end, between the concrete piers on to the rails.
CAUTION
GEAR BOX REMOVAL FIXTURE RAILS ARE ROLLER GUIDES ONLY AND WILL NOT
SUPPORT THE GEAR BOX ACROSS LARGE DEPRESSIONS, TRENCHES MADE IN THE
FLOOR, WITH OUT PROVIDING ADDITIONAL SUPPORT.
15.
Move the gearbox till it clears the air inlet housing assembly. Provide stoppers
below the rollers and remove the pull and lift equipment from the gear box.
16.
Using the service crane of the Electrical operated handling system, rig and lift
the gear box, above the Mill maintenance platform, and move it to the Mill
Maintenance day. Place the gear box in a truck and shift it to the workshop.
17.
Plug the holding down bolt openings for planetary gear box and Motor in the
base plate to avoid dirt entry.
12.1.1.b RE-INSTALLING GEARBOX ASSEMBLY:

The gear box assembly is re-installed by sliding it into position under the assembled
pulveriser.
72
Bowl Mill
XRP1103
CAUTION
FOR DETAILS ON THE ALIGNMENT, LEVELING AND CLEARANCES TO BE MAINTAINED
DURING GEARBOX RE-INSTALLATION, WITH THE BASE PLATE, MILL SIDE AIR INLET
HOUSING ETC. REFER TO THE SECTION 6 OF THE BOWL MILL ERECTION MANUAL.
1. Ensure that the gear box assembly is positioned such that the input shaft is
facing the Motor side. Lift, move and set the gear box on rollers which are
mounted on gear box withdrawal fixture as shown in Figure G.
CAUTION
BEFORE MOVING THE GEAR BOX, ENSURE THAT THE THRUST PAD BEARING HOUSING
IS FILLED WITH RECOMMENDED LUBRICATING OIL (SERVOMESH SP 320) SO THAT THE
THRUST BEARING IS TOTALLY IMMERSED IN THE OIL.
2. Using the pull and lift equipment, as done previously, slide in the gear box into
position.
3. Jack up the gear box and remove the roller assemblies. Lower the gear box on
to the base plate, after aligning to make the dowel pins entry into gear box
bottom flange.
4. Fix the holding down bolts between the gear box and base plate; hand tight
them.
5. Lower the bowl & bowl hub assembly on to the table top / flange of the gear box
after ensuring that the keys match with the key slots provided in the bowl hub.
Note:
If required heat the bowl hub with blow torch, to about 100 Deg C with
uniform torch heating while placing the bowl hub on the gear box for ease of
assembly.
If required, the table/ flange of the planetary gear box may be rotated by manually
rotating the input shaft. Remove the rigging equipment and the Hoisting clevis
(3nos) from the bowl.
6. Fix the holding down studs & nuts between the bowl hub and the table / flange
of the gear box. Pretension the stud to 61,100 Kg loads and run down the nut
hand tight.
73
Bowl Mill
XRP1103
7. Replace all the components removed in the Planetary gear box withdrawal
procedure (step 5.0 to 10.0) in the reverse order.
8. Torque tighten the gear box holding down bolts to the base plate to 391 Kgm.
9. Rig and place the drive motor in its place, after removing the gear box removal
fixture assembly. Fix the holding down bolts (M42) between the Motor and the
base plate. Torque tighten them to 259 Kgm.
10. Fix the Mill-Motor coupling, after checking their alignment, as per procedure,
and replace the guard assembly.
11. Connect the lube oil piping, HT/LT / instrumentation cables to the respective
equipment which were removed for gear box withdrawal (step no. 3 & 4).
12. Establish power supply and run the gear box lube oil system to ensure that there
are no leakages and also flush the newly assembled gear box till the filter is found
reasonably clear/ clean.
13. Re-install the journal assemblies and the journal opening covers removed for
gear box withdrawal (step no.2).
14. Carry ring roll setting during mill no-load run and release the Mill for normal
12.1.2
operation.
JOURNAL AND COVER REMOVAL SEQUENCE (FIG. 12.a):
Table shows the tasks for replacement of the journal and journal cover assembly from
the bowl mill.
REMOVAL TASKS
1.
Disconnect the seal air supply lines from the Trunnion shaft and spring
assembly of each journal.
2.
Relax the stop bolt lock nut and back out the journal stop bolt until the roll is
resting on the bull ring segments.
3.
Release the clamp plate stud locknuts of journal pressure spring assembly
4.
Back out the clamp plate studs to remove spring pressure from the journal
head.
Rig and remove journal cover and journal assembly.
74
Bowl Mill
XRP1103
Fig 12.a. JOC WITH PRESSURE SPRING ASSEMBLY
75
Bowl Mill
XRP1103
12.1.3 DISCHARGE VALVES & MULTIPLE PORT OUTLET ASSEMBLY REMOVAL

(Fig. 12.b & Fig.-A)
Table shows the removal tasks for multiport outlet assembly
REMOVAL TASKS
1.
Disconnect the purge air piping over the mill discharge valves from the air
supply header.
2.
Disconnect electricity and compressed air from the mill discharge valve
drivers and remove the Victaulic / dresser couplings between the coals feed
pipes and the valves.
3.
Disconnect Instrument connection
4.
Unbolt the multi-port outlet assembly flange and remove the assembly with
the mill discharge valves from separator top.
5 Unbolt and remove the upper center feed pipe.
5. Unbolt Venturi Assembly and lower it down
Fig 12.b. DISCHARGE VALVES & MULTIPLE PORT OUTLET ASSEMBLY
76
Bowl Mill
XRP1103
12.1.4 SEPERATOR BODY REMOVAL (Fig. 12.C & Fig-A):

Table shows the removal tasks for separator body.
REMOVAL TASKS
1. Remove the bolts from the flange between the separator body and mill
side, separator body and separator top.
2. Disconnect instrument and other piping, and any other equipment attached
to the separator body and top. Make adequate slinging facility ready.
3. Remove the entire separator top with deflector assembly, inner cone, feed
pipe and liners from mill separator body and place on suitable place.
4. Remove the separator body with liners from mill side liner assembly and
place on wooden blocks.
SEPARATOR BODY
SEPARATOR TOP
Fig 12.c
77

12.1.5
Bowl Mill
XRP1103
BOWL AND BOWL HUB REMOVAL

After disassembly of the three journal assemblies, the discharge valve and multiple
port outlet assembly, and the separator body, follow the procedure given for
removal of bowl and bowl hub assembly. Table below shows the removal procedure
for bowl and bowl hub.
TASKS
1. Remove the skirt assembly including the scrapper assembly from the
bowl/bowl hub.
2. Remove the labyrinth seal assembly.
3. Remove the bowl and bowl hub insulation cover sheet and the insulation.
4. Loosen and remove the holding down studs & nuts (M 52) between bowl
hub and the table top/flange of the gear box. Use hydraulic jacks to loosen
the nuts.
5. Rig and lift the bowl and bowl hub together using the 3 nos of Ratchet lever
type manual handling equipment, suitable slings and eye-bolts, by 65 mm.
6. Alternately, Rig and lift the bowl and bowl hub together using 4 nos 10
tons jacks placed in the mill side air inlet housing and below the bowl hub
flange to free the bowl hub from the gearbox table top/ flange, by 65 mm.
7. Ensure that the bowl hub has cleared the keys provided on the table top/
flange of the gear box.
8. Fix suitable size of wooden blocks/ shim plates between the mill side bottom
plate and the bowl hub.
9. Lower the jacks such that the bowl and bowl hub assembly load is
transferred to the wooden blocks/ shim plates. Remove the jacks to use
them for gearbox removal.
78
Bowl Mill
XRP1103
Fig 12.d. BOWL AND BOWL HUB ASSEMBLY
79
12.2
Bowl Mill
XRP1103
GENERAL DIS-ASSEMBLY AND RE-ASSEMBLY OF OTHER COMPONENTS:

The following mill components subjected to wear like bull ring segment and journal
rolls are required to renew or replaced periodical intervals based on the inspection
reports and date records. The procedure for renewal of bull ring segment, airport
ring assembly and journal roll are given below:-
12.2.1 RENEWAL OF BULL RING SEGMENTS (Figure 12.d & FIG-H):

1. For access to the bowl, remove a journal assembly as per disassembly
procedure Journal Cover and Journal assembly Removal
2. Unbolt and remove the split clamping ring. Use the jack screws provided to loosen
the ring if necessary. Remove the retaining ring.
3. Remove the old bull ring segments. It may be necessary to air-arc the first segment
into several pieces. When air-arcing, make sure the welding machine is firmly
grounded to the bowl. Exercise care not to cut the bowl.
4. Clean all interior surfaces of the bowl.
5.
Install the bull ring clamping ring segments. Install the Bowl extension ring
segments. Then install the new bull ring segments in numerical sequence starting
with the axle-1 keyed segment and working clockwise.
When installing the last segment it may be necessary to insert a portable jack to
open the gap as much as possible. If the gap remains when the last segment is
installed, shims from the shims package should be inserted between the segments
at points equally space around the periphery of the bowl. Then drive end shim,
between the bull ring segments and bull ring clamping ring segments. Tack weld
end shims to bull ring clamping ring.
12.2.2 AIRPORT RING REPLACEMENT (Figure 11.d):

Airport ring is the part of airport ring assembly. For replacement of airport ring
remove a journal assembly as per table of Journal Cover and Journal assembly
Removal. If necessary, remove worn airport ring. The procedure for attaching new
airport ring to bowl is given below:a)
Measure the distance between Bowl OD & mill side ID.
80
Bowl Mill
XRP1103
b)
Check all mill side wall liners are in proper position.
c)
Align and weld new extension ring with bowl.
d)
Use two bolts of bowl and bowl extension ring to hold each segment of
rotating vanes in position (of airport assembly). Fix a pointer and by rotating
the bowl, level all the vanes in one plane. Tighten the bolts.
e)
Select the highest segment of vane assembly and put a distance piece of
thickness 8mm on the outer ring to fix the position of body liner segments. Tackweld the same to the separator body shell.
f)
Repeat the procedure for the rest of the segments of body liners, to complete
the circle, taking the reference of the same segment of rotating vane
assembly.
g)
Once again check the clearance between vane assembly and body liners by
rotating the bowl. It should be within the limit of 83mm.
h)
Lock the position of vane assembly and body liners with lock plate temporarily,
to avoid distortion during full welding.
i)
Weld all tack weld joints in sequence i.e. diagonally opposite positions and in
small pass. Welding rod to be used is E7018 with pre-heating. Also peening of
welds is necessary.
j)
After full welding, allow it to cool down.
k)
Tack weld vane assembly inner ring with body of bowl from bottom
TECHNICAL POINT
BASED ON MILL PERFORMANCE AND BOWL DELTA P VALUES ADD AIR RESTRICTION
RING SEGMENTS, WHICH ARE SUPPLIED LOOSE, ON BODY LINER ASSEMBLY BY WELDING.
12.2.3 ROLL RENEWAL (Fig. 12.e and FIG-J):
After the removal of journal opening cover and journal assembly as per table of
journal & cover removal sequence procedure (Ref. 12.1.2), follow the steps given
below for renewal of journal roll.
1.
Lower the journal assembly until the edge of the roll touches the floor.
Carefully allow the assembly to settle to a horizontal position while further
lowering the hoist.
2.
Remove the 12 Nos of holding screws connecting the grinding roll to housing.
81

3.
Bowl Mill
XRP1103
After removing journal screws lift the journal head to a vertical position and let
it rest on the bottom face of the lower journal housing.
4.
Attach a sling around the journal head and apply just enough strain to take
the weight off the bottom face of the lower journal housing. The rigging should
be such that the bottom face remains horizontal.
5.
Tap the roll with a brass or lead hammer to knock it off. Do not use a steel
hammer, as it may chip the roll and cause injuries. If the roll cannot be tapped
off, heat it evenly with a torch or roll removal fixture.
TECHNICAL POINT
IF THE ROLL IS HEATED, ALLOW THE LOWER JOURNAL HOUSING TO COOL
BEFORE LOWERING IT INTO A NEW ROLL.
6.
When the roll is loose, raise the journal out of the roll and lower it into the new
roll, placed on 100 X 100 mm blocks to permit the lower journal housing to pass
through the roll.
7.
Carefully tip the assembly on its side and replace screws connecting roll to
lower journal housing. Apply a Torque of 30 Kg-m on screws while tightening.
TECHNICAL POINT
BE SURE THE WELDING MACHINE IS GROUNDED TO THE ROLL OR LOWER
HOUSING AND NOT TO THE SHAFT OR JOURNAL HEAD.
12.2.4 JOURNAL OPENING FRAME LINER REPLACEMENT (Fig-L)
After removal of the journal assemblies as per table of Journal cover and Journal
assembly removal procedure, follow given below steps for removal of journal
opening frame liner.
1.
Remove worn journal opening frame liners.
2.
Thoroughly clean journal opening frame where weld plugs are attached to
guarantee a proper weld.
82

3.
Bowl Mill
XRP1103
Apply RTV sealer to all liner joints. Place liners through on the journal opening
frame with an approximate 3 mm gap between the liners. Secure the journal
frame liners with weld plugs.
4.
12.2.5
Apply silicone cement to ceramic plugs and install as shown on the weld plug.
JOURNAL HEAD LINER ASSEMBLY REPLACEMENT:

Table below shows the replacement tasks of journal head liner assembly
TASKS
1.
Remove worn journal head liners from journal head liners support.
2.
If necessary, wash the tack welds off and remove hex. head screws and
journal head liner assembly.
3.
If removed, position journal head liner assembly and secure with hex. head
screws. Tack-weld both sides of screws.
4. Apply RTV sealer to all liner joints. Place liners on journal head liner support
with approximately 3 mm gap between the liners.
5.
Secure the liners with weld plugs. Fill weld plug voids with RTV sealer.
TECHNICAL POINT
THE JOURNAL HEAD LINER ASSEMBLY SHOULD BE TAGGED AND REINSTALLED TO THE
SAME JOURNAL BECAUSE LINER ASSEMBLY INTERCHANGEABILITY MAY NOT BE
FEASIBLE.
12.3
JOURNAL SHAFT ASSEMBLY WITH DOUBLE UPPER JOURNAL BEARING

The assembly of a pulveriser journal shaft with double upper bearings requires several
distinct steps performed in the proper sequence to assure that proper clearances
are obtained. Proper clearances must be obtained to ensure maximum bearing life.
83

1)
Bowl Mill
XRP1103
Establish the upper bearing bench end play by grinding the spacer
supplied with the double bearing.
2)
Assemble the upper journal housing subassembly and check the bearing
end play.
3)
Assemble the lower journal housing sub-assembly and install the journal roll.
4)
Assemble the journal shaft sub-assembly.
5)
Assemble journal shaft sub-assembly and journal housing assemblies. Check

the journal assembly bearing end play.
6)
Journal Assembly Bearing End-Play
TECHNICAL POINT
THE MEASUREMENTS TAKEN DURING THE ASSEMBLY OF THE BEARINGS MUST BE SO
PRECISE. ALL OF THE COMPONENTS AND MEASURING TOOLS MUST BE AT 70 F, (21C).
IF THIS IS NOT PRACTICAL, THEN THE MEASUREMENTS MUST BE CORRECTED FOR
THERMAL EXPANSION TO 70 F, (21C).
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1 .Establish Upper Bearing Bench End Play
TASKS
1.1. Measure and record the upper journal housing bearing bore. Use procedure
given in Figure 12.A. Retain data for future reference.
1.2. Grind the bearing spacer.
1.3 Measure and record the spacer length and bearing O.D.; use procedure given
in Figure. 12.B.
SPACER GRINDING CALCULATION
Lateral clearance = (etched on O.D. of Spacer)
Lateral clearance = _________________________
Fit = Average bearing O.D. (Fig. 12.B.) - Average housing bore (Fig.
12.A).
Fit = (
) - (
) =
Spacer grind value = Lateral clearance - 0.178 - [2.62x (fit)] mm

Spacer grind value = (
Spacer grind value =
1.4
) - 0.178 - [2.62x (fit)] mm

__________________________________mm
Measure and record the spacer fixed ground length.
CAUTION
UPPER JOURNAL BEARINGS ARE SUPPLIED IN MATCHED AND SERIALIZED SETS. THE CUPS
AND CONES ARE NOT INTERCHANGEABLE. EACH CUP MUST BE KEPT WITH ITS MATING
CONE. THE BEARING SPACER IS ALSO MATCHED WITH THE CUPS AND CONES AND
SHOULD NOT BE INTERCHANGED WITH OTHER BEARINGS. IF AN ERROR OCCURS IN THE
GRINDING AND AS A RESULT THE BENCH END PLAY IS OUT OF TOLERANCE, THE SPACER
MAY BE REWORKED. ADD MATERIAL TO THE GROUND SURFACE BY WELDING FLAME
SPRAYING OR PLATING AND REGRIND TO THE CORRECT DIMENSION.
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1. Use dial bore to

determine
bore
dimensions.
2. Measure at two
depths, 1/4A and
3/4A,
on
45
increments,
A
equals the bearing
length or bore depth
whichever is smallest.
3 Record readings,
BU and BL in the table
below.
All
measurements must agree within 0.0254 mm TIR.
4.
Average the upper, lower and total bore dimension Cu, CL. The average reading D
must meet blue print specification that is base dimension + 0.051/0.000 mm.
ORIENTATION
BU UPPER DIMNS.
BL LOWER. DIMNS.
CU
CL
AVERAGE
O
45
90
135
B0 + B45+ B90+ B135
4
CU +CL
2
Figure 12.A - Determination of Upper Journal housing Bore Diameters.
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Figure 12.B Journal Bearing Spacer Length Determination

1.
Use a micrometer to measure spacer length E at eight locations on 45 intervals
prior to grinding.
2
Record and average readings.
3.
Grind the spacer; remove material as per calculation (Ref. page 112).
4.
Re-measure ground spacer length, record and average readings.

OIRENTATION
DIMENSION E-NEW
DIMENSION E-GROUND
0
45
90
135
180
225
270
315
E. AVG..
AVG =
2.
ENEW =
EGROUND =
E0 + E45 + E90 +E135 + E180 + E225 + E270 + E315

8
Assemble Bearing in Housing and Check End-Play
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TASKS
2.1.
Install the double bearing in the upper journal housing along with spacer.
2.1.1 Heat the upper journal housing to 80 C to 100 C. For, ease of assembly, each
0.025 mm of interference requires a 5.5C temperature differential between
the bearing cups and bearing housing.
NOTE: - To facilitate future disassembly coat the O.D of the bearing cups with
Molykote 41 or equal. (If bearings are chilled for insertion coat the bearing
housing bore).
2.2 Install the lower bearing cup squarely in the housing, follow in rapid order and
sequence
with the finish ground bearing spacer, the bearing cone
assembly(s)., the second bearing cup, the bearing ring (if so equipped) and
the bearing keeper.
2.3
Insert and torque the bearing keeper bolts to 6.91 kgm to ensure that the
bearing cup and spacer stack is properly seated.
2.4
Allow the housing and bearings to return to room temperature
3.0 Install bearing keepers and shims

3.1 Using a 0.0254 mm feeler gauge, check between the bearing housing shoulder
and the bearing cup to assure the bearing cup is properly seated.
3.2 Relieve tension on the bearing keeper cap screws to finger tight.
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3.3 Measure the gap between the end face of the housing and the bearing keeper
In four places, reference Figure-12.D. Average the measurements.
3.4 Assemble a shim ack with a total thickness of 0.0762 mm to 0.127 mm less than
the gap measured in step 4.3. Check thickness of the shims with a micrometer.
3.5 Remove cap screws and bearing keeper. Assemble the shim pack to the
Upper housing.
3.6 Replace the bearing keeper.
3.7 Use a thread locking/sealant, reinstall the cap screws and uniformly torque.
TECHNICAL POINT
AS AN ALTERNATE ASSEMBLY METHOD, THE BEARING CUPS AND SPACER MAY BE
CHILLED IN DRY ICE INSTEAD OF HEATING THE BEARING HOUSING. IF THE CHILLING
METHOD IS USED, THE BEARING CUPS AND CONES AND ROLLER BEARINGS MUST BE
COMPLETELY COATED WITH THE RECOMMENDED JOURNAL OIL IMMEDIATELY AFTER
ASSEMBLY TO PPREVENT WATER ETCHING.
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1.
Use a micrometer to measure the outside diameter of the bearing cups at four
locations 0, 45 , 90, and 135.
2.
Record reading in the table below, all dimensions must agree within TIR 0.025 mm.
3.
Average the dimensions for comparison with bore dimension B Fig.12 A.
ORIENTATION
BRG. 1 DIMENSION
BRG. 2 DIMENSIONS
F1 AVG =
F2 AVG =
0
45
90
135
F AVG
F AVG = F0 + F45 + F90 + F135

4
Fig. 12.C Journal Bearing Outside Diameter
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Bowl Mill
XRP1103
1.
Measure clearance between the bearing housing and bearing keeper with a feeler
gauge at four locations.
2.
Record measurements in table below:
3.
Calculate average clearance measurement.

ORIENTATION
DIMENSION G
0
90
180
270
GAVG = G0 + G90 + G180 + G270
4
Figure. 12. D. Bearing Keeper Shim Pack.
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TASKS
4.0 Check upper bearing end play
4.1 Arrange the upper journal housing and bearings in the end play fixture. Refer
to Figure 12.F. A base capable of withstanding a lift load of 2000 kg must be
made available.
4.2 Attach an overhead hoist, a come-along and a direct reading load cell of
approximately 5 ton capacity to the eyebolt of the end play fixture. All
components must be of sufficient capacity to withstand the lift load of bearing,
upper housing assembly given on the Upper Bearing Lift Load and End Play
Table -12.
4.3 Mount three dial indicators as shown in Figure.12. F. Rest the contact buttons
on the top of the housing.
4.4 Rotate the housing at least five revolutions in one direction to seat the bearing
Rollers.
4.5 Zero the dial indicators and mark their position on the housing.
4.6 Raise the housing and bearing cups with the come-along until the load cell
reads the lift load value determined in step 5.2.
4.7 Turn the housing five revolutions in one direction. Return the dial indicators to
their original marked position and record the readings, refer to Figure. 12G.
4.8 Lower the come-along until the load on the housing is released.
4.9 Turn the housing five revolutions in one direction. Return the dial indicators to
their original marked position and record the indicator readings.
4.10 If the indicators have returned to zero 0.0127 mm in step 4.9 calculate and
record the average indicator reading for step 4.7 on the worksheet. If the
indicators do not return to zero 0.0127 discard the average reading taken.
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4.11 Repeat steps 4.5 through 4.10 until at least three average readings are
recorded on worksheet.
4.12 Average the average readings on the worksheet and record. The final value
must be within the end play limits give on the Upper Bearing End Play Table
(Table 12) or the assembly must be reworked.
93
Figure:12. F
Bowl Mill
XRP1103
End play fixture
94
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Trial
Indicator
Indicator Readings
No Load
Lifted
No Load
HA
A
1
HAVG =
HB
HC
HA
HB
HC
HA
HB
HC
HA
HB
HC
HA
HB
HC
H1AVG
AVG. Readings
Lifted Position
H1 AVG. = HA+HB+HC
3
H2 AVG =
H3AVG =
H4AVG =
H5AVG =
+ H5AVG
5
Note: Refer to Procedures in Text, steps 4.5 to 4.10 in page: 120

Figure: 12.G
Upper Bearing End Play
95
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USAGE
When using this table ensure that the upper bearing and upper housing part number match
those listed in the table.
The lift load is used in determining upper bearing end play described in steps 4.1 through 4.12.
The results obtained in step 4.12 should be compared with the values for the end play
tolerance given in Table 12.
The values given are used in determining journal housing flange gap shims, Step: 13.5 and
Figure 12.L. and journal assembly end play steps 13.6 through 13.14 and Fig 12.M.
UPPER BEARING
Mill Size
XRP 1003 1103
JOURNAL ASSEMBLY
Load
End play
Load
End play A
(Kgs)
(mm)
(Kgs.)
(mm)
2000
0.127 - 0.229
998
0.152
TABLE -12
Pulveriser Journal Lift load and End Play
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2. Assemble the Lower Journal Housing Sub-Assembly
TASKS
5.
Grinding Roll with taper fit connection.
5.1 Use Prussian blue to determine the contact pattern between the lower housing
taper and the grinding roll taper. There must be at least 80% contact between
the mating tapers and any no contact zones must not exceed 10 of arc.
Modify the roll to achieve proper contact.
5.2 Once the taper contact has been verified, press the grinding roll and lower
housing together with 50 tons force.
5.3 Tighten the locknut on the lower housing while maintaining the 50 ton force.
5.4 Spot drill the grinding roll through the set screw holes.
5.5 Install the cone point set screws with Loctite 271 or equal and torque to 6.9 kg/m.
5.6 Use a pipe thread sealant, install the 1 hex socket pipe plug in the oil drain hole
in the lower housing and stake in two places.
6.
Assemble the lower journal bearing cup with lower journal housing
6.1 Using procedure on Figure 12.A measure the lower journal housing bearing and
pilot bores and record the measurements on Figure 12.J. Take measurements at
the top and bottom of each bore. All the measurements for a given bore must
be alike within 0.0254 mm T.I.R. (Calculate the average bore diameter).
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Bowl Mill
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6.2
Measure the O.D. of the lower journal bearing cup, reference procedures on
Figure C. Record on Figure-J.
6.3
Calculate the bearing housing interference F 3 AVG minus DB. It must be

between 0.025 mm and 0.180 mm.
6.4
Coat the lower journal housing bearing bore with Molykote 41 or equal.
6.5
Chill the lower bearing cup in dry ice or liquid nitrogen and install in lower
housing.
NOTE: - AS THE BEARING CUP RETURNS TO NORMAL TEMPERATURE WIPE DRY AND
COAT WITH JOURNAL OIL TO PREVENT WATER ETCHING.
6.6 After the cup has returned to room temperature, check beneath the cup with a
feeler gauge to assure proper seating. A 0.025 mm feeler gauge must not fit
between the bearing cup and the housing backing shoulder.
98
Bowl Mill
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Note:
For Bore determination use procedure Figure 12.A:
For Bearing O.D. use procedure Figure 12.C.
ORIENTATION
BRG. BORE
BBL
PILOT BORE
BBU
BPL
BPU
LWR. BRG. CUP

F3 OUTSIDE DIM
0
45
90
135
B0+B45+B90+B135
CB L =
CB U =
CP L =
CPU =
F3 AVG =
CL CU
2
DB =
DP =
F3 AVG =
F 0 + F 45 + F 90 + F135
4
Bearing/Bore Interference = F3 AVG - DB = ___________
Figure 12.J. Lower Journal Housing Bore Dimensions & Interference
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4. Journal Shaft Sub-Assembly

TASKS
7. Check the journal shaft for straightness and roundness. Measure and record the
information, reference Figure12. K. The shaft must be straight and round with in
0.025 mm.
8.0 Assembly of long spacer shaft journals
8.1
Install the oil seal wear ring.
8.2
Measure the I.D. of the oil seal wear ring, compare with shaft O.D.
measurements. The interference must be between 0.102 to 0.28 mm.
8.3
Heat oil seal wear ring in an oven or in oil to 150C maximum.
8.4
Locate oil seal wear ring on journal shaft as shown in the assembly drawing
(either by a given dimension or against a shaft shoulder). Allow wear ring to
cool.
9.
Install the upper bearing assembly
9.1 Lubricate the upper journal bearing seat on the journal shaft with standard
journal oil.
9.2 Install one oil seal facing inward into the upper journal housing and then the
remaining two with the lip pointing outward. Coat the seal lips and fill the
cavities between the seals with Molykote 33 or equal.
NOTE: AVOID MARRING THE SHAFT BLENDED RADIUS FINISH OR DAMAGING OIL
SEAL DURING ASSEMBLY
9.3 Assemble the upper bearing and housing on the journal shaft. A clearance of
0.051 to 0.102 mm should exist between the shaft and the upper bearing.
9.4 Slip the journal bearing sleeve (long spacer) onto the journal shaft. The bearing
spacer is marked so that the slots are assembled toward the lower bearing.
100
10.
Bowl Mill
XRP1103
Install the lower journal bearing cone
10.1 Assemble the lower bearing spacer (if applicable) on the journal shaft. The
chamfer on the spacer must clear the shaft fillet.
10.2 Coat the lower bearing seat on the journal shaft with Molykote 41 or
equal.
10.3 Check the I.D. of the bearing cone, use procedure Figure 12.A and compare
with shaft measurement Figure12. K. The interference must be between 0.025
to 0.178 mm.
10.4 Heat the bearing cone in an oven or oil bath to 120C maximum and install it
on the journal shaft.
10.5 Install the bearing keeper and torque cap screws to 14 kgm.
10.6 Allow bearing to return to room temperature.
10.7
Check with a feeler gauge to assure proper seating of the bearing. A 0.025
mm feeler gauge must not fit between the bearing spacer and cone or the
shaft and cone.
11.
Install bearing keeper and shim assembly
11.1 Remove cap screws and journal bearing keeper.

11.2 Measure the gap between the shaft end and the bearing face with a depth
micrometer in four places. Average the readings.
11.3 Prepare a shim pack with a total thickness of 0.076 to 0.127 mm less than the
average gap measured in step 11.2.
11.4 Assemble shim pack, keeper plate, lock plate and screws to the journal shaft.
11.5 Bend the lock plate against the nearest flat on the screws.
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Bowl Mill
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5. Assemble the Journal Shaft to the Housing Assemblies

TASKS
12
Assemble journal shaft with housing and sub-assemblies.
NOTE:- PRIOR TO ASSEMBLY COAT ALL BEARINGS WITH STANDARD JOURNAL OIL
12.1 Install a lifting eye in the end of the journal shaft.
12.2
On journal shafts with the long spacer, lower the shaft and upper housing
assembly without the O ring & the spring pins into the lower housing and
seat the lower bearing cone in its cup.
12.3 Turn the shaft five complete revolutions in one direction.

12.4 Measure the gap between the upper and lower journal housing flanges in eight
places, 45 increments, with feeler gauges. Record the reading, reference
Figure. 12. L. all readings should be alike within 0.076 mm. Average the
readings.
12.5
Prepare a shim pack with a thickness equal to the average housing gap
measured in step 12.4 above plus 1/2 the end play of the two row upper
bearing. Fig 12.F, plus value A" from the assembly end play table (Table 12).
Check the shim pack with a micrometer.
12.6
Remove the journal shaft and upper housing assembly (or the upper housing
sub assembly) from the lower housing.
12.7 Install the O ring in the upper housing groove and grease lightly with Molykote
33 or equal. Install the spring pins in the lower housing.
12.8
Reassemble the lower housing, shaft assembly and upper housing with the
prepared shim stack. Do not pinch the O ring.
12.9
Apply Loctite 277 or equal to the hex socket head cap screw threads. Install
cap screws and torque to assembly specification.
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Journal Assembly Bearing End-Play

TASKS
13
Check journal assembly bearing end play.
13.1 Fasten two rods threaded at their lower ends in the lifting holes in the flange of
the upper journal housing
13.2 Lock the rods with hex nuts.
13.3 Install a dial indicator on each rod. Mark the indicator locations (180 0 apart) on
the top of the journal shaft.
13.4 Rotate the journal five revolutions in one direction and return the dial indicators
to their marked locations.
13.5 Zero the indicators.
13.6 Use a come-along and a five ton load cell, carefully lift the journal shaft to the
lift load given in Table 12.
13.7
Rotate the shaft at least five revolutions in one direction and return the dial
indicators to their original position.
13.8 Record the two indicator readings. Refer to Figure. 12.M.

13.9 Lower the shaft to zero load on the load cell.
13.10 Rotate the journal shaft at least five revolutions in one direction and return the
dial indicators to their original position. Record the indicator readings.
13.11 If both indicators have returned to zero 0.0127 mm in step 13.10 average the
readings take in step 13.8 and record.
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13.12 Zero the dial indicators and repeat steps 13.6 through 13.11 until three average
indicator readings, within 0.025 mm are obtained.
13.13 Average the three average readings.
13.14 The value obtained in step 13.13 should be 1/2 the end play of the two row
bearing, Figure 12.F. plus value A from the Assembly End Play Table (Table
12). The acceptable tolerance is 0.025 mm.
13.15 If the journal assembly end play is not within acceptable limits, disassemble the
housings, and adjust shims (steps 12.3 through 12.9) as required. After shims
are adjusted, recheck journal assembly end play by repeating steps 13.1
through 13.14.
13.16 If the journal assembly end play is within the acceptable limits, remove the rods
installed in step 13.1 and plug the lifting and jack screw holes in the upper
journal bearing with set screws.
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Shaft Outside Diameter Measurements. Use a Micrometer.

ORIENTATION
L.R. BRG. SEAT

K
UPP. BRG. SEAT

L
SEAL RING SEG

N
0
45
90
135
AVG =
0 + 45 + 90 + 135
4
Shaft straightness measurements, mount shaft on live centers & use a dial indicator to check
at K, L, M & N. Dial indicator reading should not vary more than 0.025 mm for out of round.
ORIENTATION
0
45
90
135
180
225
270
315
Figure 12.K Shaft out of Round and Straightness
105
Bowl Mill
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A
UPPER JOURNAL HOUSING FLANGE GAP

Orientation
1st TRIAL GAP
2nd TRIAL GAP
3 rd TRIAL
GAP
0
45
90
135
180
225
270
315
AVG.
Shim Pack = AVG Gap +
SHIM PACK = (
Bearing end play,Step 4.12

2.
)+(
)+(
+ End play ' A' Table - 12
SHIM PACK = ( ) mm
Figure12. L. Journal Housing Flange Gap Shim Thickness
106
Bowl Mill
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TRIAL
INDICATOR
INDICATOR READINGS
No Load
HA
HB
HA
HB
HA
HB
HA
HB
HA
B
1
Lifted
AVG. READINGS
No. Load
LIFTED POSITION
H1 AVG =
HA + HB
2
H2 AVG =
H3 AVG =
H4 AVG =
H5 AVG =
HB
H AVG + H AVG +H AVG + H4 AVG + H5 AVG

HAVG =
=
5
Note: Refer to Procedure in text, Step 13.0
Permitted Assembly End Play =
Bearing End Play, Step 4.12

2
+ (End Play A Table 12)
HAVG = Permitted Assembly End Play 0.025 mm

(
) =(
)+(
) 0.025 mm
If HAVG is not within 0.025 mm of the permitted assembly end play, the journal housing flange
gap shims should be readjusted.
Figure 12.M. Journal Assembly End - Play
107
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12.4 JOURNAL HEAD TO JOURNAL SHAFT ASSEMBLY

a.
Lubricate the threads on the journal shaft with anti-seize compound and install
the lock nut.
b.
Slug lock-nut tight using the supplied wrench and a sledge hammer. Scribe the
nut and the head with chalk and strike the wrench with three additional solid
blows of the sledge hammer. If the nut moves less than 3 mm, it is sufficiently
tight. If the nut moves more than 3 mm the tightening process should be
repeated. Lock the set-screw on the lock nut once it is properly tightened.
c. Weld a locking plate (L-Plate) between the lock nut and journal shaft,. This
would ensure that the stud lock would get disturbed from its place.
d.
Stamp the serial number of the journal assembly which is located on the end of
the journal shaft on the journal head for future identification.
Fig.12.e
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12.5 Adjustment of the Seal Air Gap
ORIENTATION
1st TRIAL
2nd TRIAL
3 rd TRIAL
GAP
GAP
GAP
0
45
90
135
180
225
270
315
0 + 45+...........315
AVG GAP =
8
Upper Journal Head Skirt Flange Gap
Fig. 12.N.
Air Seal Ring Upper Flange Gap
1.
Remove cap screws and drop the journal head skirt until it is seated squarely on the
taper of the upper journal housing.
2.
Measure the gap between the journal head and the skirt flange in eight places. Record
and average on the work sheet next page.
3.
The thickness of the shim stack is equal to the average gap measured in Step 2 minus
twice the desired air gap. The air gap should be 1 mm. Therefore, the shim stack
thickness will be the average gap minus 2 mm.
4.
Measure each stack of split shims with a micrometer.
5.
Install the split shims between the journal head and the journal head skirt flange. Install
the cap screws and torque them to 13 Kg-m, With Loctite # 242 applied to the threads.
6.
Check the seal air gap between the upper journal housing and the journal head skirt in
eight places. Each measurement should be 1 mm 0.13 mm.
Clean all the mating machined surfaces with copper wire brush and apply a thin film
of oil. Place the three Journal Assemblies together with Grinding Roll, Trunnion Shaft and End
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Caps through the Separator Body Journal Opening. Install the Roller Journal Assembly by
carefully lowering it through the Journal Opening in the Separator Body. Bolt up the Trunnion
shaft End caps on to the Journal opening frame on either side. This will partially support the
Trunnion shaft ends, Bring in the match marked journal opening cover and assemble on to
the separator body. The Trunnion end caps should be turned so that the numeral "-1" lines up
with the indicating arrow on the Journal opening cover.
Tighten all bolts connecting separator body and Journal Opening Cover. DO NOT
INTERCHANGE THE JOURNAL OPENING COVERS AS THESE HAVE BEEN MATCH MACHINED WITH
THE SEPARATOR BODY. Draw up tight the other bolts connecting the Trunnion Shaft End Caps
and the Journal Opening Cover. Proceed with the remaining setting up of ring roll clearance
and spring compression as described elsewhere in this manual.
110
13.0. STORAGE AND PRESERVATION OF MILL

COMPONENTS
Bowl Mill
XRP1103
13.0 STORAGE AND PRESERVATION OF MILL COMPONENTS

When the mill is not operated for more than one week, any one of the following
preservation procedures may be adopted to protect the interior parts of the gear case
like worm shaft, vertical shaft, bearings, worm gear etc.
13.1 PRESERVATION WITH PRESERVATIVE
Before longer storage times, the gear unit should be run with no load with preservative.
We recommend the preservatives listed in the table below for preservation of the gear
unit:
STORAGE SATBILITY
up to 24 months
more than 24 months
PRESERVATIVE
SPECIAL MEASURES
SERVOMESH SP320 OF
Plug the gear unit air tight,

replace air filter with plug
screws (replace before startup)
Re-preserve gear unit as up to
24 months
IOC
SERVOMESH SP320 OF
IOC
TABLE-13 Recommended preservatives for PGB

Internal preservation procedure
- Shut down the gear unit and drain the oil as described in Section Maintenance
and repair.
-
Fill with preservative up to the upper mark of the oil level indicator through the
ventilation hole or the hole in the inspection cover.
Close the venting hole or the cover opening, respectively.
Run the gear unit briefly with no load. To do so, start the oil supply system for a
time minimum 1 hour.
The gear unit must start once. If this is not possible, the gear unit must be rotated
at least 1 revolution on the output flange. This can be done by turning the input
shaft D1 manually.
Remove the oil drain plug and drain the preservative into a suitable receptacle
and dispose of in accordance with the regulations.
Replace the oil drain plug.
Seal labyrinth seals on input shaft and output flange with adhesive tape.
111

COMPONENTS
Bowl Mill
XRP1103
OIL TESTING:
The
CAUTION
oil
THERE IS A RISK OF SCALDING FROM HOT PRESERVATIVE EMERGING.

WEAR PROTECTIVE GLOVES.
may
be
tested every 3 months to ensure its properties. Refer PGB section for oil properties and
impurity limits.
13.2
SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:

These assemblies shall be stored in closed storage in vertical position (Standing on
roll).The journal assemblies are completely filled with recommended lube oil prior to
shipments from workshops. Oil to be used: Servo Mesh
SP 680 of IOC. At site, the
condition of oil, level and leakage if any should be checked periodically. Use Oil Dip
Stick for level measurement.
Prior to commissioning excess oil is to be removed with the help of siphon hand pump.
Retain the recommended oil level in the assembly. Prior to commissioning, the oil in
the journal Assembly is dirty; the same is to be removed with a suction hand pump.
Clean the internals by topping up with a thinner. Fill the assembly with lubricant
SERVOMESH SP 680 OF INDIAN OIL COROPORATION LTD or Equivalent to the
recommended level. Make sure the pipe plug is tightly closed in the journal shaft. The
exterior surface of the journal should be kept reasonably dry and free of any moisture
and other weather condition.
13.3
PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL:

When the mill is out of operation for long period preservation of journal assembly shall
be done by filling the recommended lube oil completely. Prior to taking the mill into
the service the excess oil may be siphoned off.
13.4
DRIVE COUPLINGS:
If uncoupled, pack with a recommended grease and wrap with sheet (plastic). If
coupled, fill with the same recommended grease.
13.5
MILL DISCHARGE VALVES ASSEMBLY:

These valves carry several integrally mounted instrumentation components like
solenoid valves, Limit switches, Electrical cable conduits, Junction Box, Air Cylinders
112

COMPONENTS
Bowl Mill
XRP1103
etc. These assemblies should be stored in fully covered condition with the integrally
mounted instrumentation components protected against moisture and dust.
13.6
INTERIOR AREAS:
The air passages, grinding and classifying areas of the Mill, Mill Discharge Valve,
Reject Hoppers, etc. should be stored under cover and protected as much as
possible. Water should not be allowed to accumulate and stand in or on these parts.
13.7
MILL MOTOR:
Follow manufacturers instructions.
13.8
GENERAL:
All exposed machined surfaces like shaft extensions, threaded or drilled bolt holes,
classifier link mechanisms should be periodically preserved with protective grease or
by such means and covered.
Note: Refer Lubrication Schedule (TABLE-1), for the recommended
Lubricants.
13.9 LONG TERM PRESERVATION OF THE PLANETARY GEAR BOX:

If a spare gearbox is procured by customer than the following steps has to be followed
for preserving the gear box efficiently.
The step-by-step procedure is given below:
Preparatory work:
i.
The lower drain valve on the gear unit must be tightly sealed with a screw plug
or the handle locked in close position.
ii.
The oil inlet and drain lines must be sealed with blank flanges.
iii.
To tightly seal the labyrinth seal on the input shaft, a sealing cap must be fitted
to the gear unit and sealed as shown in the sketch/ photo below.
iv.
The oil drain of the sealing cap must be tightly sealed with a screw plug.
v.
The vent in the sealing cap must remain open during the oil filling until the oil
runs over. Then the vent must be sealed with a screw plug.
113

COMPONENTS
vi.
Bowl Mill
XRP1103
The breather assembly fitted to the Gearbox (two numbers) shall be removed
and the opening to be sealed with a screw plug. The breather assembly from
the thrust pad bearing chamber shall be removed only after completion of oil
filling activity and then plugged.
a.
i.
Filling with oil

The oil to be put in must be filtered beforehand with a 25 micron filter gauge.
Note: Re-use and preparation of the recommended lube oil, for normal operation,
after long periods of preservation and storage must be checked up with the oil
manufacturer.
ii.
The gear unit must be filled with oil via the oil drain valve of the thrust pad chamber.
During filling care must be taken that the vent of the Preservation cap fitted at site
on the input shaft is not sealed until oil emerges from it. Oil filling further shall be
continued after sealing the cap vent, once oil emerges from it.
iii. The rate of filling the oil into the thrust pad bearing chamber shall be such that oil
does not emerge out from its labyrinth seal.
iv. The Gearbox is considered as completely filled when the oil emerges from the
thrust pad bearing chamber breather assembly. Now the breather assembly is
removed and screw plug fitted in its place.
v. The drain valve of the thrust pad bearing chamber shall be closed and the handle
locked. Seal the end with a screw plug too, after removing the oil supply line
connected to the valve. The labyrinth seal in the thrust pad bearing chamber shall
be sealed with adhesive tape.
Note: Clean any oil spillage immediately. Oil leaks, if any, occurring during filling
must be attended to immediately.
vi. The gear unit must be inspected for leaks at regular intervals.
vii. The long term preservation method explained above is suitable for a period of 10
years. After 10 years, the filled oil must be totally replaced following the above
procedure.
114

COMPONENTS
Bowl Mill
XRP1103
viii. Before starting up the gear unit the preservation oil must be drained off at the oil
drain points on the thrust pad bearing chamber and the gear unit base. The
Preservation cap is to be dismantled and stored for future use. The breather
assemblies have to be installed back in their position and the thrust bearing housing
labyrinth seal adhesive tape shall be removed. Then installation and start-up of the
spare Gearbox must be carried out in accordance with the Erection/ O&M
instruction manuals.
ix. The quantity of Lube oil required per mill for filling Gearbox top and bottom
chambers together is 1000Liters.
Long term preservation of Gearbox fitted in mill and put into operation:
For Gearbox which is in operation, in case the unit outage is for long period, the long
term preservation procedure is different. In that case we need to run the Lube oil
system for one hour and then the mill at no load for 15 minutes to ensure that all the
gearbox internals are thoroughly lubricated and oil film applied. Otherwise, with lube
oil system kept in service, the Gearbox input shaft shall be manually rotated such
that the bowl rotates by one complete revolution, at least. Then the breather
assemblies have to be removed and kept in safe place for re-use. The labyrinth seals
of the input shaft and thrust pad bearing chamber shall be sealed with adhesive
tape. This procedure has to be repeated periodically, till the mill/ gearbox is taken
back into operation.
These long term preservation steps have to be taken so that the gear box
components are not exposed to atmospheric conditions and there by avoid rusting,
pitting or other damages for trouble free operation, when put back into service.
PLANETARY GEARBOX WITH PRESERVATION CAP FOR LONG TERM PRESERVATION
115

COMPONENTS
Bowl Mill
XRP1103
Long Time Preservation Method - Preparation Fixing of end cap on the input shaft to
avoid oil leakage when the housing is filled with lube oil up to the output flange
labyrinth seal
116

COMPONENTS
Bowl Mill
XRP1103
117
14.0. SPARES
Bowl Mill
XRP1103
14.0 SPARES
A stock of spares for important replacement and wearing parts is essential for satisfactory
operation and serviceability of the bowl mill at all times. Classification of Bowl Mill spares are
given below:BOWL MILL SPARES - CLASSIFICATION
Bowl mill spares can be classified on the given following basis.
i.
Long Delivery Items
ii.
Short Delivery Items
iii.
Low Value Items
iv.
High Value Items
v.
Fast Wear Items
vi.
Special Items
LONG DELIVERY ITEMS (DELIVERY 12 TO 18 MONTHS)

This type of items consist following spares
i.
Journal Assembly
ii.
Lower Journal Housing
iii.
Journal Head
iv.
Bowl
v.
Pressure Spring
vi.
Mill Discharge Valve Assy
vii.
Motor Coupling
viii.
Journal Shaft
ix.
Trunnion Shaft
118
14.0. SPARES
Bowl Mill
XRP1103
SHORT DELIVERY ITEMS

This type of items consists following spares.
i.
Trunnion Shaft end Cap
ii.
Bowl Extension ring
iii.
Air Seal & Dust Guard Assembly
iv.
Seal assembly And Seal Runner Assembly
v.
Scraper Assembly
vi.
Valve Body & MPO
vii.
Inner cone
FAST WEAR OUT ITEMS (DELIVERY 6 TO 12 MONTHS)

This type of items consists following spares:i.
Grinding Elements Like Rolls & Bull Rings
ii.
All Liners Like
Journal Head Liners
Separator Liners
M.D.V. Liners
iii.
Oil Seals For Journal Assembly, PGB Assy.
iv.
Oil Seal Wear Sleeves
v.
O Ring
SPECIAL ITEMS
This type of items consist following spares
i.
All Fixtures
Spring Compression Fixture
Grinding Roll Removal Fixture
ii.
Any Items With Specific Scope
iii.
Coal Sampling Devices
119
Bowl Mill
XRP1103
14.0. SPARES
14.1
RECOMMENDED SPARES LIST
ONE MILL QTY FORMS A SET REFER O&M MANUAL FOR FIGURE REFERRED HEREIN:
SL
DESCRIPTION OF PART
NO
NO.
OFF
PER
MILL
RECOMMEND
ED
SETS./ 8 MILLS
UNIT OF
MEASUR
EMENT
FIGUREN
O- ITEM
NO
ROLLER JOURNAL ASSEMBLY- FIG
01
24
SET
P-08
SET
FIG R
03
GRINDING ROLLS 62 " (SINTERED

CARBIDE INSERT TYPE)
JOURNAL ASSEMBLY (WITH G.ROLLS
& LINERS)
JOURNAL BEARING LOWER
SET
P-02
04
JOURNAL BEARING (UPPER)
SET
P-01
SET
P-14
NOs
Q-02
42
SET
R-04
SET
P-09
02
05
06
07
08
JOURNAL CAP SCREW LOCK PLATE

JOURNAL HEAD
JOURNAL HEAD LINERS SET
TYPES)
JOURNAL SHAFT
(5-
09
HEX. Head SCREW M 36 x110
24
SET
P-10
10
O RING OIL SEAL (VAR-07)
24
SET
P-17
11
OIL SEAL (UP.JR.HSG ASSY)
24
SET
P-24
12
SHIM SET (UPP JRL HSG)
3 SETS
SET
P-18
13
SHIM SET (JRL BRG KEEPER)
3 SETS
SET
P-12
14
SPRING PINS D10x30
SET
P-19
15
SET
Q-03
20
SET
Q-10
17
TRUNNION SHAFT END CAP (THRUST

END)
TRUNNION SHAFT END CAP (FREE
END)
JRNL TRUNNION BUSHING
20
SET
Q-04
18
TRUNNION BUSHING RETAINER
20
SET
Q-09
19
THRUST PLATE (THRUST END)
SET
Q-05
20
THRUST PLATE (FREE END)
SET
Q-08
21
CYLINDRICAL PIN D12x80
20
SET
Q-07
22
HEX.SOC.CAP SCREW M30X300
36
SET
P-22
16
23
TRUNNION SHAFT
SET
Q-01
24
PIPE PLUG 2 TS
SET
Fig Q
25
JOURNAL HEAD LOCK NUT
20
SET
P-28
120
Bowl Mill
XRP1103
14.0. SPARES
26
SHIM SET ( UPP BRG KEEPER)
SET
P-18
27
SEAL WEAR RING
SET
P-21
28
AIR SEAT RING UPPER
SET
Q-16
29
AIR SEAL RING SHIM SET
SET
Q-17
MILL DRIVE & BOWL ASSY.
01
BOWL EXN.RING SEGMENT
1 SET
42
SET
V-18
02
BOWL HUB CLAMPING RING
1 SET
24
SET
V-13
03
BOWL HUB COVER
SET
V-08
05
1 SET
24
SET
V- 17
06
BULL RING SEGMENT ASSEMBLYHICHROME

LAYBRINGTH SEAL ASSEMBLY
SET
V-27
07
SKIRT ASSY
SET
V-20
08
SCRAPER
24
SET
S-03
09
SCRAPER & GUARD ASSY
SET
V-22
10
SCRAPER BUSH
33
SET
S-12
11
SCRAPER PIN
33
SET
S-08
12
WEAR PLATE (BOWL HUB COVER)
24
SET
V-11
SET
U-36
02
SPRING STUD BEARING (WEAR

SLEEVE)
SPRING AIR SEAL CAP
SET
U-58
03
SPRING GUIDE
SET
U-18
04
HIGH TENSILE STUD M39X3-260
18
SET
U-33
05
HOUSING COVER (WEAR SLEEVE)
SET
U-29
06
SPRING STUD ADOPTER
SET
U-16
07
SPRING PRELOAD STUD
SET
U-15
08
JOURNAL PRESSURE SPRING ASSY
SET
A-08
09
SPRING ORIFICE PLATE
SET
U-57
10
SET OF AIRPORT RING ASSEMBLY
1 SET
20
SET
A-13
11
DEFLECTOR BLADES
1 SET
SET
12
DEFLECTOR SHAFT BUSHING
1 SET
20
SET
E-23
SET
A-15
D
01
13
SEPARATOR BODY ASSEMBLY
INNER CONE ASSEMBLY WITH

CERAMIC LINER
121
Bowl Mill
XRP1103
14.0. SPARES
14
JOURNAL STOP BOLT BUSHING
24
SET
A-32
15
O-RING OIL SEAL (STOP BOLT)
SET
A-33
16
OUT LET VENTURY ASSEMBLY
SET
A-17
17
SET
A-28
SET
A-22
19
OUT LET VENTURY COLLAR

ASSEMBLY
VENTURI VANE (WITH CERAMIC
LINER
DRUM SECTION
SET
A-29
20
CENTER FEED PIPE UPPER
NO
A-20
21
GASKET FOR VICTAULIC COUPLING
SET
A-34
22
GASKET FOR DRESSER COUPLING
NO
A-21
MILL DISCHARGE VALVE ASSEMBLY
18
01
MDV ASSEMBLY
NO
01
CERAMIC LINED VALVE BODY
SET
A-19
02
CERAMIC LINED MPO
SET
A-30
02
GASKET FOR FLANGE
20
SET
A-31
01
SOLENOID VALVES
SET
02
LIMIT SWITCHES
20
SET
20
SET
NO.
03
G
PNEUMATIC OPERATED POWER

CYLINDER
MILL MOTOR COUPLING
i.
PLANETARY GEARBOX: It is recommended to keep one spare gearbox for use in
NOTE:emergency. The maintenance of gearbox, if required shall be done at Hyderabad

works. However, recommended spares list is already provided.
ii.
Recommended spares for lube oil system shall be part of the O & M manual of the
lube oil system vendor. Refer to their O & M manuals for the same.
iii.
It is recommended that the customer should keep one set of total complete
journal assembly for replacement in short period there by reducing the down time
of mill.
iv.
One mill quantity forms a set.
v.
This list is not exhaustive and may change based on coal characteristic,
maintenance practice etc. customer is advised to revise the list based on their
experience at the power station.
122
%

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&3;0
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OPERATION & MAINTENANCE

M/s JINDAL INDIA THERMAL POWER LTD

Publication NO. HY-BM-007-2014

REV. NO: 00, DATE: 03/06/2014

2.0 TECHNICAL DESCRIPTION ........................................................................................................................ 2

CHECKLIST OF DOS - BOWL MILL........................................................................................................... 5

3.2 CHECK LIST OF DONTS - BOWL MILL ......................................................................................................... 8

OPERATING PARAMETERS: ................................................................................................................... 12

3.5 START - UP: ................................................................................................................................................. 13

NORMAL SHUT DOWN: ......................................................................................................................... 14

EMERGENCY SHUT DOWN: ..................................................................................................................... 14

START UP AFTER EMERGENCY SHUT DOWN: ....................................................................................... 15

MILL FIRES: ............................................................................................................................................ 16

3.10 FIRE EXTINGUISHING PROCEDURES: ...................................................................................................... 17

MILL REJECTS: ....................................................................................................................................... 19

MISCELLANEOUS & IDLE MILLS: .............................................................................................................. 6

4.3 PULVERISER LUBE OIL SYSTEM OPERATING INSTRUCTIONS ....................................................................... 8

5.3 GENERAL TROUBLESHOOTING .................................................................................................................. 21

5.8 LIST OF EQUIPMENT ................................................................................................................................. 31

LOCKING GUIDELINES .............................................................................................................................. 32

5.10 SPARE PARTS STOCK................................................................................................................................ 33

PULVERISED COAL SAMPLING: ........................................................................................................... 43

to O& M manual of Vendor, if applicable) ........................................................................................................ 43

ADJUSTMENT OF FINENESS: ................................................................................................................. 45

8.3 MILL WEAR LIFE ASSESSEMENT ................................................................................................................ 49

11.3 CHECKING SPRING COMPRESSION (Refer Figure. 11.f): ......................................................................... 67

INSPECTION TASKS ................................................................................................................................ 68

12.0 COMPONENT MAINTENANCE .............................................................................................................. 70

12.4 JOURNAL HEAD TO JOURNAL SHAFT ASSEMBLY ................................................................................... 108

SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:...................................................................... 112

13.3 PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL: ..................................................................... 112

DRIVE COUPLINGS: .............................................................................................................................. 112

MILL DISCHARGE VALVES ASSEMBLY: ................................................................................................. 112

INTERIOR AREAS: ................................................................................................................................. 113

MILL MOTOR: ...................................................................................................................................... 113

GENERAL: ............................................................................................................................................ 113

BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LIMITED

It must be recognized that no amount of written instructions can replace

BHARAT HEAVY ELECTRICALS LIMITED

2.1 MILL TECHNICAL DATA:

MILL BASE CAPACITY(T/Hr)*

78.5 (Design Coal)

TOTAL WEIGHT OF MILL(T)

Moderate Shock Load

ROTATING WEIGHT OF MILL(T)

SPRING PRE LOAD(Kg)

MILL OUTLET TEMPERATURE RANGE

AIR FLOW (T/Hr)

70% Through 200 Mesh

Low power consumption

Minimum maintenance time required

Wide capacity with good turndown ratio

Ability to handle wide range of coals

Quite and less vibration operation

BHARAT HEAVY ELECTRICALS LIMITED

PLANETARY GEAR BOX AND BOWL

Planetary gear box is used to give

assembly consists of Bull ring assembly

Scrapper Assembly and vane wheel

b) MILL SIDE AND LINER ASSEMBLY:

BHARAT HEAVY ELECTRICALS LIMITED

c) SEPARATOR BODY ASSEMBLY: