Erection Manual For FRP 943 BOWL MILL PDF

GUIDELINES FOR ERECTION
XRP 943 BOWL MILL
CUSTOMER
ADHUNIK POWER & NATURAL RESOURCES LTD.

ADHUNIK POWER 2X270 MW
Publication NO.HY-BM-007-2011
Rev.00
Date: 30.03.2011
C
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-007-2011

REV. NO: 00, DATE: 30/03/2011
ISSUED BY
PULVERISERS ENGINEERING
BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM::HYDERABAD
INDIA
BOWL MILL
XRP 943
TABLE OF CONTENTS
Sl.No Description Page
1 Introduction 5
2 Precautions For Mill Erection 6
3 Protection & Preservation Of Mill 7

Components
4 Preparation For Erection 9
5 Grouting Instructions 12
6 Installation 18
7 Lubrication 31
8 Setting-up Bowl Mill 36
9 Motor Installation, Coupling Mounting, 41

Alignment And Assembly Procedure
10 Mill Optimization 48
11 Planetary Gear Box – KMP280 49
BHARAT HEAVY ELECTRICALS LIMITED 1

BOWL MILL
XRP 943
LIST OF ILLUSTRATIONS
BOWL MILL CROSS SECTION FIG.1
LEVEL & GROUTING PROCEDURE FIG. 2
AIRPORT ASSEMBLY FIG. 3
BULL RING ASSEMBLY FIG. 4
INNER CONE SPOUT SEGMENT ASSEMBLY FIG. 5
TIGHTENING TORQUE FOR FASTENERS FIG. 6
CLASSIFIER ASSEMBLY FIG. 7
SPRING COMPRESSION PROCEDURE FIG. 8
SPECIAL TOOLS FIG. 9
PROTECTIVE SEAL APPLICATION FIG. 10
EQUIPMENT ALIGNEMENT RECORD (FORM-A) FIG. 11
EQUIPMENT ALIGNEMENT RECORD (FORM-B) FIG. 12
LUBE OIL LOCATION FIG. 13
MILL MOTOR COUPLING FIG. 14
WIRING DIAGRAM – GEAR BOX RTDS FIG. 15

BOWL MILL
XRP 943
LIST OF ERECTION DRAWINGS
Sl.no Description Drawing no.
1 G.A. OF XRP 943 BOWL MILLS. 00062085885

2 BOWL AND BOWL HUB ASSEMBLY 16118801407
3 PLANETARY GEARBOX LUBE OIL SYSTEM PIPING 16118801416
4 JOURNAL LINER ASSEMBLY 06108800510
5 MILL SIDE AND LINER ASSEMBLY 06128800802
6 JOURNAL OPENING COVER ASSLY. 06138800806
7 MILL DISCHARGE VALVE (MULTIPLE PORT) ASSLY. 06148800515
8 COAL SAMPLING PLATFORM ASSLY. 06188800567
9 SCRAPER MAINTENANCE PLATFORM 06180000661
10 SCHEME FOR EXT. LUBE OIL SYSTEM 16119085943
11 FOUNDATION PLAN FOR XRP 903 BOWL MILLS. 00061085886
12 JOURNAL SHAFT ASSEMBLY 16108801019
13 JOURNAL HEAD & TRUNNION SHAFT ASSLY. 16108801022
14 SPRING PRE-LOAD PROCEDURE. 16188801069
15 JOURNAL ASSEMBLY. 16108801027
16 SEAL AIR ASSEMBLY 16188801409
17 SERVICE AIR LINE FITTINGS 16140001255
18 SEPARATOR BODY ASSLY. 06138800698
19 JOURNAL HEAD LINERS 26108802067
20 JOURNAL HEAD LINER ASSEMBLY 26108802068
21 CLASSIFER ASSEMBLY 06138800805
22 MILL FOUNDATION FASTENERS ASSLY. 26198802709
23 LEVELLING AND GROUTING PROCEDURE 26198002431
24 GEARBOX FOUNDATION FASTENER 26190002626
25 LEVELLING AND GROUTING PROCEDURE-PGB 26190002634
26 BUTT. VALVE & ACTUATOR AIR LINE. 36148802080

BOWL MILL
XRP 943
Sl.no Description Drawing no.
27 STUD ASSEMBLY-MILL FOUNDATION 36198802976

28 STUD ASSEMBLY-PGB FOUNDATION 36198802978
29 PLANETARY GEARBOX ASSEMBLY 06118800707
30 MILL HANDLING ARANGEMENT XRP943 16189001569

BOWL MILL
INTRODUCTION XRP 943
1.0 INTRODUCTION
Bow l mills are employed to pulverize the pre-crushed raw coal to the
required f ineness before it is admitted into the boiler f urnace for
combustion. The operating characteristics of bow l mills make it the best
mill available for the direct firing system of the coal. The best f eatures of
all the pulverisers have been incorporated in the design of the bow l mill.
The mill out put can be easily varied, as per the turn-dow n ratio from its
minimum t o maximum load and it w ill operate for long periods w ithout
mechanical problems or stoppages f or cleaning, oiling or adjusting.
Crushed raw coal at a controlled rate is fed into the revolving bow l of the
Bow l Mill. Centrif ugal force feeds the coal uniformly over the replaceable
grinding ring w here independently spun rolls exert the required grinding
pressure. The rolls do not touch the grinding ring even w hen t he mill is
empty. Therefore the Bow l Mill operates silently w ithout t he rumble that
is characteristic of mills in w hich there is metallic contact bet w een the
grinding elements.
The mill w orks in a pressurised atmosphere as the primary air is placed in
the system ahead of t he mill and hence w ill be designated as XRP mill.
The instructions cont ained 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 f ield. Every possible
care has been taken to ensure t he contents are accurate. It must be
recognized that no amount of w ritten instructions can replace intelligent
thinking and reasoning on the part of the erectors, especially w hen coping
w ith unforeseen conditions faced at t he sit e.
The illustrations included in this manual are typical of the mills

manufactured by Bharat Heavy Electricals Limited. How ever, the erector
must refer to the draw ings and documents supplied w ith individual
contract for actual construction and t he applicable part numbers, before
taking up the erection activity of the mill.

BOWL MILL
PRECAUTIONS XRP 943
2.0 PRECAUTIONS FOR MILL ERECTION
Mill components have to be stored.
Inform Engineering Department for any deviation/ abnormalities
Look for proper orientation as given in the Project Drawings.
Look for better alignments.
Erection Mill Sub-assemblies looking for correct match marks.
Read instructions for better preservation of Mill Drive Assembly at site.
Ensure proper tightening of connecting fasteners.
Cover the classifier vane mechanism and Mill discharge valve assembly to protect
from falling bodies during erection
Trouble free operation of the product must be the aim.
Follow Safety Regulations at all levels.
Observe proper gap between pipe ends of victualic couplings.
Note the clearances between the stationary and the rotating parts
CAUTION :
The mill has been shipped from the factory with a preservative oil coating of in the
gear housing. If the mill gears are turned for any reason while the mills are in storage,
the preservative oil coating must be re-established. (Refer Bowl Mill Preservation
Procedure)

BOWL MILL
PROTECTION & PRESERVATION XRP 943
3. PROTECTION AND PRESERVATION OF MILL COMPONENTS
CAUTION:
Labyrinth gaps in the planetary gear box at Top flange and Bevel Pinion
Shaft locations have been closed w ith tape. Ensure tape during during
storage at site
STORAGE AND PRESERVATION OF MILL COMPONENTS
The Bowl mill assemblies after reaching site are stored for extended periods before
Erection and Commissioning. The Bowl mill assemblies contain many precision
components and should be carefully stored and preserved during storage and erection.
The following method of preservation should be adopted during site storage and
erection.
MILL DRIVE AND BOWL ASSY:
PLANETARY GEAR BOX:
Please refer Gear Box installation instruction, Chapter 11
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 works. Oil to be used: Servo Mesh SP 680 of M/s. Indian Oil
Corporation. 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, if any, is to be removed with the help of siphon /
hand pump. Retain the recommended oil level in the assembly. Prior to
commissioning, if the oil in the journal assembly is found 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 away from other weather conditions.

BOWL MILL
PROTECTION & PRESERVATION XRP 943
DRIVE COUPLINGS:
If uncoupled, pack with recommended grease and wrap with sheet (plastic). If
coupled, fill with the recommended grease.
MILL DISCHARGE VALVES ASSEMBLY:
These valves carry several integrally mounted instrumentation components like

solenoid valves, Limit switches, Electrical cable conduits, Junction Box, Air
Cylinders etc. These assemblies should be stored in fully covered condition with the
integrally mounted instrumentation components protected against moisture and dust.
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 from all weather
conditions. Water should not be allowed to accumulate and stand in or on these
parts.
GENERAL:
All exposed machined surfaces like shaft extensions, threaded or drilled bolt holes,
classifier link mechanism etc. should be periodically preserved with protective grease
or by such means and covered. Mounting Plates, Foundation Fasteners etc. are sent
from Manufacturing works with a preservative coating. Check and renew the
preservative wherever necessary. Ensure that no heavy components are stacked on Air
Port Assembly, Lube oil system components and other mill components.
External lube oil system and its instrument cabinet should be stored under cover.

PREPARATION FOR BOWL MILL
MILL ERECTION XRP 943
4.0 PREPARATION FOR ERECTION :
The follow ing details shall be thoroughly studied w ith respect to the
individual contract requirements regarding size, range, application and
scope of supply w ith reference to the product.
i) Milling Plant Project

ii) Bow l Mill General Arrangement
iii) Bow l Mill Foundation Plan
iv) Mill Plant Flooring Plan
v) Scope of supply and w orks by BHEL and Customer
vi) Shipping Lists w ith connected Erection Draw ings
All the despatch-able units, received at Site, shall be properly

identified w it h respect to Documents and Draw ings. Any short
supply or damaged item shall be immediately intimated to the
concerned agencies. Critical Assemblies, containing bearings
(Planetary Gear Box, Bow l & Bow l Hub Assembly, Grinding Roll and
Journal Assembly ), shall be stored under temporary cover to
protect against severe w eather conditions, at t he location of
erection.
The exposed machined surfaces and threaded portions leave

the factory w ith prot ective preservatives. During on site storage,
these preservative coatings shall be re-established, if necessary.
Plan for Tools and Tackles, Rigging and Handling Facilities

required for the installation of Bow l Mills. Special attention may be
paid to the size, shape and w eight of the components as w ell as
the space limitations w hile proceeding w ith the installation.
Special Tools are supplied along w it h t he Mills. (Refer Figure. 9).
It is to be ensured that the foundation fasteners, sleeves and

connected materials are available at site prior to casting of
concrete pedestal for Mill.

After the concret e pedestal is cast and set, visually inspect

the foundation f or st rength and soundness of concrete. Check for
cracks, holes, exposed steel reinforcement etc. Especially pay
attention to check for any left out w ooden shuttering materials.
The fittings, around t he foundation, should be firm. Do not cut off
the exposed ends of reinforcement as long as they are w ell w ithin
the stipulated height of concrete pedestal. This may offer a good
bonding betw een the mounting plate and concrete pedestal.
Concrete foundation pier checking should be done w it h

respect to axes of boiler as show n in t he Mill foundation and layout
plans. The disposition of Mill foundation bolt holes, and Mill Motor
foundation pocket holes should be checked. The elevation of
foundation should be checked w ith respect to Boiler columns.
Chipping of concrete shall be done, if necessary, to the correct
elevation, indicated on the contract foundation draw ing.
The permissible t olerances in the f oundation is given in t he Table.
PERMISSIBLE TOLERANCES IN THE FOUNDATION
AREA TOLERANCE
IN MM
Tolerance in the cent er line of Mill w ith respect to
Boiler Axes ± 5
Tolerance in the elevation of concrete foundation
w ith respect to draw ing ± 10
Tolerance in the cent er line of foundation bolt hole
w ith respect to foundation center line ± 2
Tolerance in diagonals of bolt hole centers max. 5
Tolerance in the dept h of f oundation hole centers ± 10
Grouting gap t o be maintained betw een mounting 40± 10
plate and foundation
(Refer Contract Draw ing for Bow l Mill foundation for deviations
permitted)
NOTE :
Ensure that all sub-assemblies, that form part of a Mill, are properly
identified w it h match marks before erection. Special attention is
draw n to Journal Opening Covers (JOC) and Separator Bodies,
since the trunnion bores are machined together and marked.
Check for JOC match marks before bringing them from the st ore-
yard and ascertain that match marks tally w ith the match marks on
the Separator Body (Journal Opening Frame).

BOWL MILL
GROUTING XRP 943
5. GROUTING INSTRUCTIONS :
5.1 INTRODUCTION :
This instruction covers materials and methods that shall be used for
grout ing structural st eel and machine base plates.
5.2 GROUT THICKNESS :

Space provided for grouting shall not be less than 30 mm or more than
50 mm.
5.3 GROUTING MATERIALS :
5.3.1 Grouting Compounds :

The preferred grout ing materials shall be a Standard flow able, non-
shrinkable like CONBEXTRA GP2 or equivalent grout mortar. This should
be a ready-to-use grout that contains a non-catalyzed metallic aggregate
for use at flow able, pump-able or damp pack consistency to produce a
hardened grout completely free of both vertical and horizontal shrinkage.
Since the grout requires only the addition of w ater, the required
consistency is easily controlled.
CONBEXTRA GP2 is supplied as a ready to use dry pow der requiring only
the addition of w ater to produce a free flow ing non-shrink grout w hich
w ill maintain its original volume during curing. The material is a mixture
of specially processed cement w ith carefully graded fine aggregate.
Additives impart controlled expansion characteristics and reduce the
w ater necessary to produce fluidity. The very low w ater/cement ratio
ensures very high early strength, particularly at low temperatures. The
aggregate grading is designed t o aid unif orm mixing, minimize segregation
and bleeding w hilst assisting t he flow characteristics.
5.3.2
Sand and cement grout may be used as an alternate, but not preferred.
Consistency of this material is important for proper placement.

BOWL MILL
GROUTING XRP 943
a) For spaces of 25 mm or greater, use t he follow ing mixture:

- One part Portland cement 45 Kg (Approximately)
- Tw o parts clean, w ell graded sand 90 Kg
(Approximately)
- 25 Litres maximum of clean w ater.
b) For spaces less than 25 mm, use t he follow ing mixture.
- One part Portland Cement 45 Kg (Approximately)
- One part clean w ell graded sand 45 Kg
(Approximately)
- 20 litres maximum of clean w ater.
c) Add 20 Kg of 6 to 10 mm size stone chips (clean and
graded) to 50 Kg of " SHRINKKOMP-N" w ith 8 litres of
w ater. Mix enough grout f or t he space to be grouted.
(or)
d) Add 50 Kg of ordinary Portland Cement w ith 45 Kgs. of
" FERROGROUT" , 45 Kgs. of clean dry sand, 75 Kgs. of
stone chips of 6 t o 10 mm size (clean and graded) using
about 10 Liter of w ater. Mix enough grout for the space to
be grouted.
NOTE:
i) Sand, as specified above, shall conform to specifications for
aggregate for masonary mortar as per any available Indian
Standard. Gradation may be modified as necessary to obtain
proper w orkability.
ii) Sand and cement grout proportions shall be basically as
described above. How ever based on results of tests on fresh
and hardened grout prior t o beginning w ork, the proportions
can vary slightly. The w ater content shall be the minimum
necessary for proper placement but in no case more than
specified above. When permitted to stand until setting takes
place, grout shall neither bleed nor segregate. Suitable
admixture know n to have no injurious effects on t he steel or
the concrete, may be used in sand and cement grout to
increase w orkability and t o decrease shrinkage.

BOWL MILL
GROUTING XRP 943
iii) Full Cement Grout is prohibited.
5.4 FOUNDATION PREPARATION

i) All loose concrete and defective areas shall be removed from
the foundation by brush, hammering, chipping or any ot her
means. Surface of t he foundation must be rough.
ii) Surfaces of the foundation and base plat es must be free of
oil, grease and dirt . Grease and oil may be removed by using
a strong caustic solution. Surfaces shall be flushed
thoroughly w ith clean w ater after using a caustic solution
and dried immediately by blow ing air.
iii) Surface of the foundation shall be w ell saturated w ith w ater
for several hours prior to grouting depending upon the grout
mortar.
Surface of the f oundations shall be w ell saturated w ith w ater
for approximately 6 hours prior t o grouting In case of sand
and cement grout.
Dry foundations w ill draw w ater out of freshly placed grout
and seriously affect physical characteristics of the grouting
material.
Water or any debris shall be kept out of foundation bolt
sleeves. Sleeves shall be covered w ith Bitumastic sealing
packing or equivalent before soaking foundation w ith w ater.
iv) Restraints shall be of adequate strengt h and built up to

produce a head in the grout material to permit a continuous
flow of grout. Build strong, tight restraint, braced so that
they w ill not leak or buckle under w eight of flow able grout .
a) Restraint shall be soaked w ith w ater or coated w ith a
resin to prevent w ater removal from t he grout.
b) Construction must provide adequat e clearance
betw een restraint and base plate so t hat grouting
material can be w orked into place properly.

BOWL MILL
GROUTING XRP 943
5.5 MIXING AND APPLICATION OF GROUT:

i) Mixing of grout should take place as near as possible to t he
equipment to be grouted. All necessary tools and materials
should be available to mix and handle grout. For producing
grout of a given consistency, paddle-type mortar mixers or
revolving drum concrete mixer or any suitable mechanical
mixer can be used. DO NOT MIX BY HAND.
ii) The dry GROUT MORTAR should be ready to use as it
comes from the package and only require mixing w ith clean
w ater.
Mix the dry grout w ith no more w ater than needed to
achieve the required consistency. For placing in w ater,
w ater shall be placed in t he mixer first . The grout shall be
added to the w ater.
a) Estimate for Plastic Consistency: The correct
proportion should be arrived as per the
recommendations of t he grout manufacturer.
b) Estimate for Flow able Consistency. The correct
proportion should be arrived as per the
recommendations of t he grout manufacturer.
Do not mix more grout mortar than can be placed in
approximately 10 minutes.
iii) SAND AND CEMENT GROUT shall be mixed dry, then

thoroughly mixed w it h w ater and allow ed to stand f or some
time lesser than the initial setting time. The mortar boxes or
other containers, used to hold t he grout, shall be covered to
prevent the loss of w ater.
After the grout stands for some time, remix thoroughly
w ithout adding w ater and place grout .
iv) Grouting materials shall be retempered w ith w ater once
mixed.

BOWL MILL
GROUTING XRP 943
v) Temperature of material is important. A temperature of 30°

C material w ill set quickly; below 30° C material w ill set
slow ly. Strength gain w ill be affected by temperature.
When temperatures are considerably above or below 3 0° C,
cooling or heating may be required to obtain the desired
results.
vi) For most base plate applications, place grout from one side
only to assure complete filling of the space to be grouted
and to avoid entrapping air.
vii) 12 mm or 25 mm link chain or stiff w ire w ith a loop or steel
strap shall be pulled back through t he grout betw een the
foundation and base plate to properly distribute t he grout
and remove air pockets. Do not over w ork strapping action.
viii) Apply grout w ithin 21 days of putt ing the mill and base plate
on f oundation.
5.6 LEVELLING AND GROUTING PROCEDURE -:

i) Engage jacking bolts to mounting plates such that t he bolts
protrude by about 38 mm on the side coming in contact w ith
the grout.
ii) Place the mount ing plates on t he foundat ion.
iii) Move the mounting plates around such t hat the mill center
line is oriented correctly relative to nort h-south direction.
iv) Install the tw o hex nuts w it h w ashers on the anchor bolts
and finger tight. (Wit h anti-seize compound or light oil)
v) Level the mount ing plates using the jacking bolts. Flatness to
be w ithin 0.13 mm/M and level w ithin 0.38mm/M.
vi) Plates of size 5x75x75 supplied can be either embedded in
the concrete or kept properly on the concrete for supporting
the jacking bolts.
5.7 CURING, FINISHING OR TRIMMING OF GROUT SHOULDERS:

i) All grout must be cured but does not require vertical
confinement t o develop f ull strength.

BOWL MILL
GROUTING XRP 943
a) Grout shoulders or extra projections may be either

finished or left in place depending upon t he size and
location. If desired, grout shoulders may be cut or
trimmed flush or at an angle.
b) Regardless of shoulder treatment, never remove
restraints or cut grout below level of underside of bed
plate until the grout has hardened sufficiently that it
can not be penetrated by a pointed mason' s trow el.
ii) Immediate prevention of rapid w ater loss from grout should
be accomplished by carefully pouring w ater (pending) over
exposed grout in restraints or grout holes just as soon as
grout t hickness and t urns dull (about 20 minutes). Pounding
w ater should be replenished as necessary until grout is to be
finished or trimmed. Follow grout manufacturer' s
instructions.
iii) As soon as the finished grout w ill not be marred by its
application, provide long term curing as suggested by the
grout mortar manufacturer.
5 .8 IMPORTANT NOTES:
i) Manufacturer' s published data on mixing grout material shall
be follow ed in order t o obtain desired results.
ii) Grout placement in or around anchor bolts, sleeves, base
plates etc., shall be governed by cont ract draw ings and / or
vendor' s instructions.
iii) In the type of leveling (Packer/Wedges/Leveling Screw s)
method t o be adopted for Mill Base / Mill Base Plate, follow
contract draw ings and use t he appropriate material supplied
for this purpose.

BOWL MILL
INSTALLATION XRP 943
6. INSTALLATION
6.1 CONSTRUCTION (REFER FIGURE – 1):
The pulverizer described in this manual is too large to be dispatched in

assembled condition. These installation instructions cover a step by step
sequence for assembling the normal sub-assemblies. Special site conditions
may allow for more or less subassembly of components (refer to figures).
6.1.1 The normal sub-assemblies are:
1. Planetary Gear Box Assembly’

2. Bowl and Bowl Hub Assembly
3. Mill Side and Liner Assembly
4. Separator Body Assembly
5. Mill Discharge Valve Assembly
6. Roller Journal Assembly
7. Venturi Collar and Venturi Vane,
8. Instruments for temperature measurement of shaft bearings
9. Centre Feed Pipe
10. Mill Motor Coupling
11. Sole Plates and Mounting Plates
12. Foundation fasteners
13. Lubrication System
6.1.2 The following items may be bundled or boxed but are shipped
unassembled.
1) Sole Plate and Mounting Plates

2) Spring preload components

BOWL MILL
3) Grinding Roll removal fixture

4) Seal Air Assembly
5) Center Feed Pipe & Inverted Cone
6) Coupling Assembly
7) Coupling Guard
8) Lube Oil System and Piping
9) Coal Sampling Device & Fittings
10) Bull Ring Assembly
11) Air Port Assembly
12) Special Tools
13) Inner cone & Inner Cone Spout segment
For 943 XRP Pressurised Mills PGMAs are – 61 – XXX:
1) Roller Journal Assembly : 61-088

2) Mill Drive and Bowl Assembly : 61-188
3) Mill Side and Liner Assembly : 61-288
4) Separator Body Assembly : 61-388
5) Mill Discharge Valve Assembly : 61-488
6) Electrical Motor, Coupling and : 61-788
7) Foundation Fasteners for Mill : 61-988
8) Commissioning Spares : 61-988
9) Seal Air & Special Tools : 67-400
10) General : 00-600
11) Foundation Plan : 00-610
12) General Arrangement : 00-620
a) MILL DRIVE AND BOWL ASSEMBLY : PGMA 61-188:

(REFER FIGURE-1 and Erection Drawing No.: 1-61-188-01407)
Mill Drive and Bowl Assembly consists Planetary Gear Box and Bowl &
Bowl Hub assembly. Planetary gear box consists of the bevel pinion
shaft, bevel gear shaft, sun gear, planetary gears, stationary ring gear
and output flange etc. Lubricant is maintained in the external lube oil
tank. Gear box in spray lubricated by means of lubrication system and
internal piping provided. Filtered and cooled oil is supplied to the gear
box.
The Bowl and bowl hub assembly consists of Bowl, Bowl Hub, Bull
Ring Assembly, Skirt and Scraper Assembly (Attached to the Bowl
Hub), Labyrinth seals etc.

BOWL MILL
b) MILL SIDE AND LINER ASSEMBLY – PGMA 61-288

(REFER FIGURE-1 and Erection Drawing No.: 0-61-288-00802)
The Hot Primary Air, required for drying and carrying pulverized coal,
enters the Mill in Mill side and air inlet housing. The Mill side and Liner
Assembly is insulated to prevent heat loss from primary air to the
atmosphere. Mill side housing also acts as mill base on which other
components like separator body, separator top, Mill Discharge Valve
Assembly etc. are supported
c) SEPARATOR BODY ASSEMBLY – PGMA 61 – 388

(REFER FIGURE-1 & FIGURE-7 and Erection Drawing No.: 0-61-388-
00698)
The separator body assembly consists of Journal Pressure Spring
Assemblies, Classifier Assembly, Air Port Assembly and Journal
opening frame liners.
d) ROLLER JOURNAL ASSEMBLY – PGMA 61 – 088

(REFER FIGURE-1 and Erection Drawing No.: 0-61-088-00510, 1-61-
088-01019, 1-61-088-01022, 1-61-088-01027, 2-61-088-02067, 2-61-
088-02068)
The Roller Assembly consists of Journal Shaft, Journal Bearings,

Journal Housings, Grinding Roll, Journal Head and Trunnion Shaft
Assembly. Three roller assemblies are there in a Mill. Lube oil in the
Journal Assembly provides Oil Lubrication for the Bearings.
e) MILL DISCHARGE VALVE ASSEMBLY – PGMA 61-488

(REFER FIGURE-1and Erection Drawings No.: 0-61-488-00515 & 3-
61-488-02080)
The Mill Discharge Valve Assemblies consists of four Multiple port

outlet and Mill Discharge Valves mounted on the multiple port 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.
f) Venturi Collar and Ceramic Lined Venturi Vane and the venturi portion
of the center feed pipe form the venturi outlet of the Mill. (PGMA 61-
388).
g) Ceramic Liners on the classifier cone are provided to prevent wear and
puncture on the classifier cone (PGMA 61-388).

BOWL MILL
h) The Mill and Motor are coupled together by a flexible coupling. (Gear
Type & Bibby Type combination) for effecting the transmission from the
motor to the Mill (PGMA 61-788)
6.2 During the installation of the Mill Base and other parts, if the feeder
floor has not been completed, the Mill parts should be adequately
protected from damage due to falling of heavy pieces, debris etc., from
above by installing firm anchored sheet covers. Also the Separator Top
Classifier link mechanism should not be used for climbing up the mill.
6.3 BOWL MILL INSTALLATION (SUGGESTED SEQUENCE )
6.3.1 GENERAL :
Clean all the mating machined surfaces or parts with copper wire brush
and apply a thin film of oil before assembly. Be sure that all bolts and nuts,
cap screws etc., are torque tightened. They should be torqued to the torque
values given in the erection drawings. Otherwise they should be torqued as
per Table (Figure-06). All torque values are based on lubricated threads.
(Apply Molykote grease for all assembly & disasembly fasteners of major sub-
assemblies).
6.3.2 MILL DRIVE AND BOWL ASSEMBLY AND MILLSIDE & LINER
ASSEMBLY:
Mill Drive and Bowl assembly consists of Planetary Gear Box

Assembly and Bowl & Bowl Hub Assembly.
Sole Plate, Base Plate (Fixed and Sliding), Dowel Pins (Stationary and
Sliding), Connecting Fasteners, Bull Ring Assembly and Pipe Assembly for
planetary gear box and lube oil system respectively are sent as loose
despatchable units (DU's).
NOTE: For more information on Planetary Gear Box refer Planetary Gear
Box installation instructions, chapter no. 11.
Planetary Gear box, Bowl & Bowl Hub and Air Inlet Housing installation :
1. Ensure foundation dimensions and levels as per drawings and

erection chack lists.

BOWL MILL
2. Ensure the level of sole plate with the help of jacking screws. Level
within 0.4 mm TIR and flatness to 0.1mm/M. Fasten the anchor
bolts.
3. Ensure the alignment /level of Mounting plate with respect to the

sole plate with the help of jacking screws.
4. Install the dowel pins in the sole plate.
5. Ensure placement of gear box on sole plate as per “ Planetary Gear

Box installation Instruction” and snugly tighten the foundation bolts.
6. Ensure alignment of gear box between the two piers and gear box
horizontal input shaft parallality with the motor center line.
7. Install the dowel pins in the Mounting plates of Air Inlet Housing.
8. Place the Air Inlet Housing and ensure concentricity respect to Gear
Box within TIR 0.25 mm and level alignment with respect to bowl
hub flange and sole plate within TIR 0.38 mm. Ensure the tramp
iron opening and air inlet duct opening orientation as per the GA
drawing before placement.
9. Pour operating oil (Servomesh SP 320 of IOC or equivalent) in the

top chamber of the gear box through the beather vent hole till the oil
reaches the level gauge full mark prior to further assembly
activities. This would require about 200 liters of oil. This is to ensure
lubrication of thrust pads.
10. Ensure assembly of bowl hub on the rotary table (flange of

planetary gear box) and tighten the holding down nuts. The step in
the bowl hub may be heated to about 100 Deg C with uniform torch
heating while placing the bowl hub on the gear box for ease of
assembly. Remove the Lower Skirt to get an access to the holding
nuts and studs of Bowl Hub.
11. Grout the Mounting plates of Air Inlet Housing and sole plate of
gear box.
12. Tighten the foundation bolts of air inlet housing.
13. Ensure torque tightening of the holding down bolts between Bowl
Hub and Gear Box to 41 tones with the stud tensioning equipment.
14. Ensure assembly completion of Labyrinth seal assembly, bowl hub

skirt and Scraper guard assemblies in the sequence.

BOWL MILL
Weld turn buckle assembly to Scraper Bracket and Bowl Hub Heat
Shield to maintain verticle clearance
15. Ensure assembly of bull ring segments, bowl extension ring and air
port ring assembly on to the bowl.
CAUTION
Ensure the orientation as per the General Arrangement drawing General

Arrangement (GA) drawing and match marks and serial numbers.
6.3.3 SEPARATOR BODY ASSEMBLY : (REF. Erection Drawing No0-61-

388-00806, 0-61-388-00698, 2-61-388-00805, )
6.3.4 Center feed pipe (Lower) with outlet venturi, outlet venturi collar,
Venturi Vane with Ceramic Liners, Ceramic lined Inner Cone, Center
Feed Pipe (Upper), Separator Top with Classifier vanes Assembly,
inverted cone, inner cone spout segments, Journal opening cover with
journal spring assembly, Air Port Assembly, Dresser Coupling,
connecting fasteners have been sent as loose DU's.
1) Install Separator body assembly on mill side air inlet housing and
fasten with connecting bolts.
2) Install Air port ring assembly. Attach rotating vane wheel segment to
bowl, by connecting it to bowl and bowl extension ring.
3) Weld body liner segments, journal block off assembly variant 01 and
variant 02 to separator body.
4) Restriction plate, restriction ring segment inner and restriction ring
segment outer may be welded later as required depending on the flow
parameters.
5) Supplier’s representative will visit site in assisting installation of air port
ring assembly based on the erection agency requirement.
6.3.5 BULL RING SEGMENT ASSEMBLY : (REF. FIG. 4)
1) Clean the interior surfaces of the bowl.
2) Install the new set of bull ring segments in the numerical sequence,
starting with the No. 1 keyed segment and continuing in increasing
numerical sequence working clockwise around the bowl. As they are
installed, keep all segments radial by sight close together and firmly

BOWL MILL
back against the bowl. Use of wooden blocks and wedges jammed
between the toes of the segments and the bowl hub clamping ring guide
boss is recommended.
Note: about 180 from the key-way there will be two adjacent segments
each having an arrow pointing to their adjoining sides painted on the
upper segment surface, indicating a shim may be required to be placed
at that location. The thickness of the shim (either 3 mm or 6 mm ) will also
be painted on the same general area.
3) To install the last segment, open the gap between the next to last and
keyed segment to the fullest extent possible. To do this it will probably be
necessary to use a jack. As pressure is applied the segments should be
rapped with a hammer to assure as snug a fit as possible. If the gap left
is more than 3mm, depending on the measured gap, use half/quarter
segments or additional shims supplies as loose with the set.
4) If it is impossible to fit the last segment into the gap, remove the shim
mentioned in the note in step-2. This should give enough of space to allow
assembly of the last segment. If there is more than a 3mm gap remaining
after assembling the last segment, insert as shim or shims from the pack
provided. It is not necessary to get a fit tighter than can reasonably be
gotten with the shims in 3mm thickness increments. also, it is not
necessary to spread up to 3mm final gap, between segments.
5) Remove the wooden blocks/wedges used to hold the segments against

the bowl and install the retainer ring.
6) Replace the clamping ring and snug the hold-down bolts while bringing the
segment back against the bowl extension ring. When the assembly is
firmly seated, alternately drive the bolts and rap the clamping ring
heavily with a sledge or jackhammer (using a striker plate). A hold down
bolt torque of 43 kg-m is required (the bolts are good for 140 Kg-m) as the
retainer ring deforms to increase contact with the number of tightening
passes necessary to get and maintain the required 43 Kg-m torque.
7) After the pulveriser has been grinding coal for 150 to 200 hours. Inspect
the bull ring. If gap of less than 12.5mm has opened up between any of
the segments, recheck the bolt torque, the pulveriser can then be put back
into service. If the gap is more than 12.5mm slack the clamping ring
section over the gap so that additional shims can be added.
8) To add shims, carefully remove the material from the gap between the
segments with a tool . Do not put fingers or hands between segments.
Insert the size and number of shims necessary to close the gap to within

BOWL MILL
3mm. Do not attempt to spread the remaining gap. Retighten the

clamping ring bolts to a torque of 43 Kg-m.
6.3.6 Inner Cone, Separator Top Assembly
1) Place the inner cone with ceramic liners assembly inside the separator
body assembly. Support it such that small diameter is down and the cone
is approximately vertical.
2) Remove the separator top assembly from its shipping rig. Clean the top
flange of the separator body and the bottom flange of separator top
including tapped and clearance holes.
3) Insert the small hex socket head cap screw to align the separator top to
the separator body at the center line of journal number one.
4) Lift the separator top into position on the separator body. Use the small
hex socket head cap screw to ensure proper orientation. Bolt the
separator top to the separator body with hex head screws.
5) When the separator body and top are secured, arrange rigging to hoist the
inner cone with ceramic liner into position against the inner cone drum
section. Check the position of the cone access door to make sure it
agrees with the markings on the separator top ( One of the separator body
man hole and inner cone man hole shall be in line).
6) Bolt the inner cone to the inner cone drum section with hex head cap
screws, hex nuts and plain washers.
6.3.7 MILL DISCHARGE VALVES AND VENTURI ASSEMBLIES: (Refer

Figure 1 & Erection Drawing 0-61-488-00515)
WARNING:
THE PULVERISER DISCHARGE VALVES AND MULTIPLE PORT
OUTLET WEIGH APPROXIMATELY 3055 Kg AND MUST BE
ADEQUATERLY RIGGED TO ENSURE SAFE HANDLING.
1) Remove the outlet venture and vane assembly from its shipping rig.
Clean the top flanges including the clearance and tapped holes.
2) The Mill Discharge Valves together with multiple port outlet plate
shipped together should be cleaned with copper wire brush and
assembled with venturi outlet collar assembly.
3) Slide the inverted cone onto the feed and inner cone, secure it with the
set screws (temporarily).
4) Look out for the offset hole for correct placement. Four numbers of
venturi vane (with venturi vane liners) should be assembled in position
with the venturi outlet collar. For welding of protective seal to the
venturi, refer Protective Seal Application-Figure:10.
5) Assemble 4 studs of size M12x60 in the Centre Feed Pipe Lower (with
venturi outlet). Lift and insert the centre feed pipe lower (with venturi

BOWL MILL
outlet) with lifting facility into the classifier cone, before assembling of
the Mill Discharge Valve with Separator Body Assembly.
6) Clean the entire top and bottom surface of the multiple port outlet plate,
including the clearance and tapped holes, and the flange on the centre
feed pipe-upper.
7) Bolt the outlet venturi and vane assembly to the multiple port outlet
plate assembly with hex head screws. Fixing screws of outlet venturi
collar to M. P. O. plate should not project beyond the MPO plate.
8) Lift the assembly which comprises of Mill Discharge Valve, Multiple
Port Outlet Plate, Outlet Venturi Collar Assembly, Venturi Vane with
Venturi Vane Liner and place in position on the separator top in the
correct location to match with the arrangement drawings and key plans
to couple with fuel pipes.
9) Then lift the centre feed pipe lower (with outlet venturi) and position by
rotating the centre feed pipe lower by hand such that the 4 studs go
into the free hole, size of 14, which is in the multiple port outlet plate
and assemble with nuts. Using M16 x 160 size bolts and nuts,
assemble the Mill Discharge Valve Assembly, with the centre feed pipe
lower as per drawing. Then remove the 4 studs and nuts and replace
with the proper fasteners of size M12x60 in these 4 positions. While
lifting the centre feed pipe lower, care should be taken to avoid any
damage to ceramic liners of the classifier cone.
10) Place the centre feed pipe upper in position and bolt with multiple port
outlet plate with proper fasteners.
NOTE:
HEX HEAD SCREWS HOLD THE MILL DISCHARGE VALVE
ASSEMBLY TO THE SEPARATOR TOP. ONE BOLT HOLE IS OFFSET BY
25 MM AND HAS A SCRIBE LINE BESIDE IT TO ENSURE PROPER
ALIGNMENT OF THE VALVES, WITH RESPECT TO THE PULVERISED
COAL PIPES.
11) Align the scribe lines next to the offset bolt holes in the discharge valve
assembly and the separator top.
12) Bolt the discharge valve assembly to the separator top with hex head
screws.
13) The inverted cone shall be moved down the center feed pipe lower to
obtain a clearance of 75 mm measured as shown in Fig. 1. Weld the
inverted cone to the center feed pipe as shown after final adjustment.
14) The clearance between the inner cone and center feed pipe lower
should be checked. The perpendicular distance between the inner
cone and the center feed pipe lower shall be 110 mm. (Refer Fig. 1)
15) Install the inner cone spout segments.

BOWL MILL
16) Weld the Center feed pipe coupling connecting piece to feed pipe from
feeder. Check the circularity of the ends and assemble the Dresser
Coupling.
6.3.8 JOURNAL ASSEMBLY (FIGURE-1 and Erection Drawing No.:0-61-

088-00510, 1-61-088-01019, 1-61-088-01022, 1-61-088-01027, 2-61-
088-02067, 2-61-088-02068:
Journal Head To Journal Shaft Assembly.
1. Closely inspect both tapered surfaces for dents, high spots, burrs, etc.
remove and blend imperfections as necessary with a file and / or
emery cloth. Remove any filing or sanding debris.
2. Strike the journal head with a mallet to ensure proper seating.
3. Lubricate the threads on the journal shaft with anti-seize compound and
install the lock nut.
4. Slug lock-nut tight using the wrench, supplied as part of special tool kit
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.
5. Install anti-rotation pin and the M16 grub screw over the anti-rotation pin.
Adjustment of The Seal Air 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.

BOWL MILL
6. Check the seal air gap between the upper journal housing and the
journal head skirt in eight places. Each measurement shall be within 1
mm ±0.13 mm .
7. 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 Caps through the Separator Body
Journal Opening Frame. Install the Roller Journal Assembly by carefully
lowering it through the Journal Opening Frame in the Separator Body.
Remove the long rod along with fastening plates and nuts used for
securing the Trunnion Shaft End caps during transport. 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.
8. 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 setting up of ring
roll clearance and spring compression as described in chapter 8 of this
manual.
6.4 The roller Journal Assembly positions, the air inlet orientation, the
multiple port outlet orientation must be kept up as indicated in the
contract General Arrangement drawing. Counter check that the relative
locations of air inlet and roller Journal Assembly locations are maintained
as per the requirement and are compatible with the handling
arrangement provided for the contract.
6.5 ASSEMBLY OF SEAL AIR PIPING(REF. Erection Drawings No. 1-61-

890-01569& 1-61-400-01255)
After the pulverizer proper is erected and the journal and spring
assemblies are in place, the seal air piping shall be installed. The seal air
assembly is made of two major components, the seal air header and the
seal air piping to the trunnion shafts and journal spring assemblies. The
illustrations in this manual are typical. Refer to the contract drawings for
hanger locations and the orientation of seal air inlet.
Note: All pipes and nipples must be cut and threaded to suit at assembly.

BOWL MILL
Note: All pipes must be cleaned after cutting and threading. Also, a swab or
sponge must be drawn through the bore if the inside diameter of the pipe has
been oil coated by the supplier.
Note: All pipe threads must have pipe sealant with teflon ( Loctite PST or an
equivalent) applied at assembly.
6.5.1 Cut, thread, clean and apply pipe sealant to the piping as necessary
and assemble the seal air piping as shown in erection drawings
referred above.
6.5.2 If the journal assemblies are not installed, cap the ends of the pipes
going to the trunnion shafts for protection until the journal assemblies
are installed.
Note: Ground the welding machine directly to the mill side housing or the
separator body.
6.5.3 Remove caps from seal air pipe. Cut and install the seal air hose to the
trunnion shafts, vertical shaft seal assembly and seal air pipe to the
spring assemlies. Use two hose clamps at each end.
6.5.4 Use a plywood cover or blind flange to protect the seal air header inlet
until the seal air pipe has been run up to the pulverizer
6.5.5 Connect the seal air lines to the discharge valve per Erection drawing.
6.6 ASSEMBLY OF MDV APPROACH PLATFORM (Erection Drawing 0-

61-888-00567)
6.6.1 Assemble MDV Approach platform on separator top and attach ladder
to it.
6.6.2 The ladder position can be suitably altered at site as required.
6.6.3 Fixing of floor grills should be such that the cut edges of load bearing
bars should rest on item no.03
6.6.4 The splice plate (item 11) can be bent if necessary at site.
6.6.5 Item no 04 is sent in running meters, should be cut suitably at site.
6.6.6 Cut item 01 to a length 400 mm at ladder seating place.
6.7 CLEARANCES:
The following clearances should be checked during erection of the Mill

and suitable rectification work carried out if necessary.

BOWL MILL
a) Vertical gap between body liner : 5 to 10 mm

Segment and rotating vane wheel
Segment of airport assy
(Refer Figure:3)
b) Gap between Inverted cone and : 75 mm

Inner cone
(Refer Figure:1)
c) Gap between center feed pipe lower : 110 mm

And inner cone (Refer Figure:1)
d) Vertical gap between journal block off : 20 mm

assembly (style 1 & 2) with bowl extension
ring top
d) Radial gap between air port ring deflector & : min 10 mm
Mill side liner
6.8 Fill any voids left out due to poor fit between, behind or around the
liners with foster foam sealing compounded or an equivalent.
6.9 Assemble the pipe from the feeder to the centre feed pipe upper by a
dresser coupling, Pulverized fuel pipes from the Mill to the boiler by
victaulic couplings and the primary air duct to the Mill side and Air inlet
flange by fasteners. Cooling water piping connection to the oil cooler to
be given. Connect Fire Extinguishing nozzles in the mill side and air
inlet with steam line and centre feed pipe upper with clarified water .
Electrical connections for the Mill Motor, Limit Switches and Solenoid
Valves, Instrument and service air connection to the mill discharge
valves and other areas to be connected as per the Contract Drawing.

BOWL MILL
LUBRICATION XRP 943
7 LUBRICATION
7.1 GENERAL:
Note: The External Lube Oil System should be installed after the civil and
welding work of feeder floor is complete. This is to avoid damage to the
instruments. Install the system just before commissioning.
External Lube Oil system supplies filtered and cooled oil to the gear
box, which is sprayed onto the gear teeth and supplied to the bearings by
means of internal piping provided.
7.2 LUBE OIL SYSTEM INSTALLATION:
Refer to Planetary Gear Box installation chapter no.
7.3 ROLLER JOURNALS:
The Roller Journals are lubricated by means of a self-contained

circulation system (Refer Erection drawing no.: 1-61-088-01027). The oil level
in the shaft is maintained at a point just below the top of the seal when the mill
is idle.
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 erection drawing no 1-61-088-01022.
This inward moving air prevents dust from getting into the bearings.
The Roller Journals should be filled with the recommended oil (See:
Lubrication Schedule) 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. 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 leakage. If no leakage is observed (indicating that

BOWL MILL
LUBRICATION XRP 943
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 shows signs of
contamination, or a Laboratory Test indicates oil breakdown, it should
be changed.
To change oil, siphon out the old oil and add new oil to bring the oil
back upto the level. Do this repeatedly until the oil is clear.
7.4 MISCELLANEOUS:
The deflector Regulators, Journal Stop Bolts should be greased as per

recommended Bowl Mill Lubricants Schedule.
The Mill to Motor Coupling should be lubricated according to the

Manufacturer's recommendations (Given in the Lubricants Schedule.)
The Journal Trunnion Bushings are made of rubber and require no

lubrication.
7.5 IDLE MILLS:
Because of the use of auxiliary fuels or other reasons, Mill may be out
of service for periods longer than a month. If this occurs, the Mills should be
run for a five minutes period once a week without material being fed. This will
aid in preventing corrosion.
If the out of service period is going to be or becomes longer than

several months, refer to Chapter - 3: (Protection and Preservation of Mill
Components.)

BOWL MILL
LUBRICATION XRP 943
7.6 BOWL MILL OIL COOLER - COOLING WATER REQUIREMENT :
Recommended Inlet Pressure : 4.5 Kg/cm²
Pressure Drop in Cooler : 0.7 Kg/ cm²
Water Quantity per MIll : 15 m³/hr

BOWL MILL
LUBRICATION XRP 943
7.7 LUBRICATION SCHEDULE

EQUIPMENT: BOWL MILL XRP 943 with PGB
Sl. Parts to be Recommended Lubricants Type of Qty. of Frequency Frequency of Remarks
No. Lubricated IOC HP BP filling Lub. In of oil observation
litres/Mill check
1 2 3 4 5 6 7 8 9 10
1 Mill Drive Gear Servomesh Parthan AMOCAM External 1100 6 Months Once daily Oil level shall
Housing SP-320 EP-320 OIL-320 tank check gauges, be maintained
lines and in the external
headers lube oil tank
2 Roller Journals Servomesh Parthan AMOCAM 680 Reservoir 135 6 months Check when Level 830 mm
SP-680 EP-680 cap on accessible at to 930 mm
journal least once in
shaft every 3
months
3 Journal Stop Servogem-3 Lithon-3 MP Grease-3 Grease Fill chamber initially. Lubricate after making Wipe clean all
Bolts fitting adjustments. grease fittings
before and
4 Discharge valve Servogem-3 Lithon-3 MP Grease-3 Grease Grease the shafts and seals initially and after greasing.
shafts and fitting every 2 weeks. Remove
Seals excess grease
5 Drive coupling Servogem-2 Grease Pack completely initially and every 3 months.
(BIBBY / /HTXX fitting Clean out & renew grease every year.
GEAR)
6 Mill Drive Motor As per Motor Manufacture's Recommendation

BOWL MILL
LUBRICATION XRP 943
7.8 ROLLER JOURNALS OIL QUANTITY AND LEVELS
Quantity of
Quantity of lubricant
Mill Size lubricant per Mill Oil Level (in mm)
per assembly (in litre)
(in litre)
883/943 45 135 830-930
XRP

BOWL MILL
SETTING - UP XRP 943
8 SETTING-UP BOWL MILLS :
8.1 Prior to operating the Pulverizer w ith its electric for the first time.
a) Check the shaft coupling alignment.
b) Check if the external lube oil tank is filled to the required
level w ith the recommended lube oil.
8.2 2 numbers of breather vents for shipped loose. These are to be

installed on t o t he inspection doors of gear box after removing the
plugs provided t herein.
8.3 Check to make sure the Bull Ring segment s are properly seated and
tightened in the bow l. Clamping ring socket head cap screw s
should be torqued to 43 Kgm. The Roller lock nut should be snug
on the bottom face of the roll (if necessary, tighten w it h a Wrench)
and w eld lock bar betw een lock nut and low er Journal Housing.
8.4 Turn t he Pluveriser Bow l through one revolution by hand t o make

sure that none of the rolls make contact w ith any part of the Bull
Ring assembly. If any roll contacts t he Bull Ring Assembly, screw
in the journal stop bolts to provide the required roll/ring clearance.
Jog the pulveriser motor under pow er to check direction of
rotation. Make sure the input shaft turns clockw ise w hen view ed
from non-drive end of motor and bow l clockw ise w hen view ed
from above.
8.5 Set the Deflector Blades that cont rol t he product fineness per the
Instructions given in Figure: 7.
8.6 JOURNAL SPRING COMPRESSION :
The spring compression must be set before the pulveriser is

placed in service. The initial compression settings may be
determined by previous experience or, if there is no previous
experience, the springs should be compressed to 8.5 tons. If the
type of coal or load characteristic causes poor operation, changing
the spring compression value/load should be considered.

BOWL MILL
NOTE :
To prevent undue st ress on Pulverizer components, spring
compression on the three journals in one Pulverizer should check
w ithin 700 Kgs.
The most common reasons for checking (and changing)

spring compression values are :
i) Rough operation at low loads. (Reduce the compression).
ii) High or unstable pow er consumption. (Increase the

compression).
iii) Vibration at high loads (Increase the compression).
iv) If there has been a pulverizer fire.
v) On a regular basis w hen there has been any overhaul.
Method of adjust ing spring compression and procedure for

checking compression are described below .
8.7 CHECKING SPRING COMPRESSION (REFER FIGURE : 8)
SETTING THE SPRING COMPRESSION
a) The spring assembly should be completely assembled as per

the assembly draw ing except for the spring stud extension
cap, spring stud lock nut keeper, hex head screw M52 and
keeper w asher. If the assembly has been shipped, remove
the shipping bolt per view " A -A" then inst all the pipe plugs.
b) Of the six(6) threaded studs, four (4) must be backed out of
the journal spring housing cover to t he dimension indicated

BOWL MILL
in detail " B" . For the purpose of w rench clearance, tw o (2)

studs must be removed in the region of one of the cutouts in
the preload fixture
c) Slide the spring st ud locknut keeper ont o the spring preload
stud.
d) Using tw o (2) hex hd cap screw s (item 3), fasten the
cylinder (item 1) to the spring preload fixt ure (item 2) mount
the fixture as show n using one (1) nut at the top. Slide the
pre-load st ud Item 4) through the cylinder and screw it int o
the end of the spring preload stud. At least 76mm of thread
engagement is required. Screw the nut (it em 5) onto the pre-
load stud (item 4) w it h the cylinder (1) fully retracted.
e) Slide the spring stud locknut keeper back off the spring
preload st ud.
f) Use the cylinder (it em 1) to draw the spring guide. To
contact the spring housing cover pump the cylinder (item 1)
until the pressure gauge reads " P" psi ± 7 Kg/Cm². This w ill
compress the spring " X" from the static length. Using the
locknut w rench (item 7) advance the locknut until it contacts
the spring guide.
CHECKING SPRING COMPRESSION
g) Relieve the pump pressure (item 1) to 70 Kg/Cm². Using a

magnetic base dial indicator. Place the indicator needle on
the flat vertical face of the locknut and zero the indicator.
Pump t he cylinder pressure upt o " P" . Kg/Cm². Again check
the preload by making sure t he indicator just starts to move
(about 0.2 mm) as the pressure gauge reads " P" Kg/Cm².
h) Tighten or loosen the lock nut until this occurs. Slide the
locknut keeper onto the spring preload stud causing the
keeper to interlock the locknut. It may be necessary to
compress the spring just above " P" Kg/Cm² to allow rotation
of the lock nut . The locknut should be rotated a maximum of

BOWL MILL
1/8 th of a turn. Slide the keeper into position and relieve the
cylinder pressure.
i) Remove the preload stud (item 4) and preload fixture (item

2) and install hex head cap screw s and keeper w asher.
Torque the hex hd cap screw to 10.4 Kg-m and w eld hex
head screw , keeper w asher & lock nut keeper together
j) Mount t he spring st ud extension cap.
k) Mount six (6) hex nuts onto t he adjusting threaded studs.

Refer to the ring-roll procedure before adjsting t hese studs.
DECREASING RESSURE SPRING SET VALUE:
CAUTION :
Using the spring compression measurement taken, do not
allow the pressure gauge reading to exceed 2000 Kg. for each
centimeter of thread engagement. Back off the spring adjusting nut
by desired amount or 6 mm.
For the purpose of estimation, t he follow ing table gives the

spring rate for XRP 943 bow l mill.
Mill Size Spring Spring load to be registered at Pressure

Rate gauge in Kg
(kg/cm)
943 XRP 5002 8500
Check the new setting by releasing the hydraulic force, using the dial
indicator and reapplying t he hydraulic force, noticing t he pressure gauge
reading w hen t he indicator has moved about 0.62 mm. If more than 6
mm, compression is to be removed, release all the hydraulic f orce, back
off the mount ing nut another 6 mm and repeat the above as many times
as required.

BOWL MILL
NOTE :
Hand movement of t he spring adjusting nut may be difficult.
In order to t urn the same, use spanner w rench.
INCREASING PRESSURE SPRING SET VALUE:
l) If compression is to be increased, operate the Hydraulic

Hand Pump until the desired f orce as read on the pressure
gauge is obtained but in no case should t he distance
betw een the spring adjusting nut and pressure spring clamp
exceed 6 mm. If the spring force desired is more than that
obtained in 6 mm, the spring adjusting nut should be run
dow n t o the pressure spring clamp, t he puller pressure
released the stud mounting nut run int o again contact and
pressure adjusting nut and puller pressure reapplied as
described above, repeating the same procedure as many
times as necessary.
m) Release the hydraulic pressure. Remove the lock nut (12),
retainer nut (11), puller (07) and f ixture (01), stud extension
(03) and stud mounting nut (02).
n) Replace the pressure spring lock nut. Loosen the High tensile
studs if compression has been decreased.
o) Replace the spring support cover and adjust the High tensile
studs t o lock the pressure spring clamp.
p) Replace the spring extension cap and t he stud lock nuts
(Hex. Nut M-30) and drive them tight.
q) After final setting of the spring compression, lock the spring
adjusting nut (as show n in Erection Draw ing 0 -61-300-
00176) by w elding clamps.

MOTOR INSTALLATION, COUPLING BOWL MILL
ALIGNMENT AND ASSEMBLY XRP 943
9 MOTOR INSTALLATION, COUPLING, MOUNTING,

ALIGNMENT AND ASSEMBLY PROCEDURE :
9.1 Positioning and aligning motors and rotating equipment.
9.2 POSITIONING MOTOR :
i) Foundation bolts in f oundation shall be inspected prior to t he

placement of base plate/base frame or equipment on the
foundation.
a) Foundation bolt locat ions and corresponding holes in

base plate/base frame and equipment shall be checked
to ensure t hat all components match.
b) Foundation bolts shall be checked for elevation and
position using an established bench mark.
c) Foundation bolts shall be straight and plumb.
d) Foundation bolts shall be inspected f or damaged
threads. Dies may be run over foundation bolts to
clean up threads w hich are dirty.
e) Foundation bolt sleeves shall be clean. All loose
concrete, w ater or ot her debris shall be removed.
f) Foundation bolts shall be firmly anchored in
foundation.
g) Foundation bolts, w hich are damaged or improperly
located, shall be repaired or replaced.
NOTE: Any alteration as a corrective measure on base plate

or foundation bolts t o accommodate foundation bolts t hat are not
in the proper position, shall be taken up, only after obtaining prior
approval of Pulveriser Engineering Department.
ii) Foundation shall be inspected for soundness, roughness and

cleanliness (free of dirt and debris) prior t o grout ing.

iii) Shipping inst ructions, Manufacturer' s installation draw ings

and specifications f or equipment and motor shall be checked
for lifting, moving and protection procedures.
a) Motor may be overstressed, pulled out of the line or
broken if lifted or moved in an improper manner.
b) Motor may be damaged if protection and preservation
procedures are not carried from storage to final
positioning. Heaters on motors, lubrication of bearings
and shafts, electrical connections, etc., require
protection.
iv) If shims are used, STEEL SHIMS shall be used under all
equipment and motors. Contract draw ings and/or
specifications shall be checked for shim requirements.
v) Clearance betw een foundation bolts and bolt holes shall be

checked after placement of the equipment to be sure there is
no binding or distortion.
Foundation bolts shall be inspected to determine if any
damage occurred w hile the equipment w as being placed.
9.3 SHIMS AND PACKER PLATES :
i) Shims for final alignment and/or replacement of motors.

Motor shall have at least one full bearing shim betw een the
motor base and or base plate. Minimum thickness of this
shim shall be 3 mm.
ii) Shims/packers for elevating, leveling and support of mot ors.

Steel shims/packers shall be placed on each side of
foundation bolts to properly support t he motor f rom t he
foundation. Steel shims shall also be used, w here required,
to prevent distortion, bending, breaking leveling to, of motor
base plates and supports.

a) Steel shims/packers shall be placed on each side of

the foundation bolts located at minimum distance of 6
mm from the foundation bolt sleeve or 6 mm from
foundation bolts w ithout sleeves.
Shims may extend out to w it hin 12mm of the edge of
the sole or base plate. Minimum w idth for these shims
shall be 25 mm.
b) Steel shims do not need to be removed for grout ing
unless otherw ise specified. If specification or draw ing
requires removal of shims after grouting, leveling shall
be done w ith the use of w edges in combination w ith
steel shims (to facilitate removal). Grout must be
patched in area w here shims w ere removed.
9.4 COUPLING : (Ref Figure 14)
The Bow l Mill input shaft is connected to the electric motor by

means of triple crow ned gear type flexible coupling on the gear
side and spring grid t ype (bibby type) resilient flexible coupling on
the motor side. Refer to t he cont ract draw ing for type and size
details of t he coupling. Check up the dimensions of t he coupling
bore and ensure t hat the correct coupling half is mounted on t o the
mill Shaft, Mot or Shaft.
9.4.1 GEAR TYPE COUPLING :
A) MOUNTING :
The coupling half is heated in an oil bath. The soaking
temperature should be around 120° C. Please see that t his
temperature is w ithin the flash point of t he heating oil used. The
coupling must be soaked for a sufficient period so as to obtain
enough expansion w hich w ill allow easy sliding of t he coupling half
on to the shaft. Approximate soaking time is in the order of 20 -30
minutes.

B) ALIGNMENT : ( Refer FQP check list and log sheets)
i) Equipment and motors that have been placed shall be

leveled to required elevation and position (as per
General Arrangement(GA) & Foundation Draw ings).
ii) The electric motor shall be positioned using the

electric center indicated on the mot or as reference.
Electric motors w it hout an electric center mark shall
be positioned using the mechanical center. The mid
position betw een extremes of the rot or end play shall
be considered the mechanical center.
iii) Coupling alignment and t olerances :

Misalignment measurements.
a) Radial alignment : Provide tw o dial gauges, both
on the same side (i.e. for example: base on gear
box shaft side and the dial on the motor side)
but at 180 degree opposite t o each ot her at a
distance r-25 mm from the centre. Rotate bot h
shafts together and t ake readings at 90 degrees
interval. The difference in the respective
position values w ould give the radial alignment,
eliminating the effect of any run-out on the
coupling surface. Radial alignment shall be
achieved w ithin 0.05 mm.
b) Axial Alignment: Provide tw o dial gauges, both
on the same side (i.e. for example: base on gear
box shaft side and the dial on the motor side)
but at 180 degree opposite to each other.
Rotate both shafts t ogether and take readings
at 90 degrees interval. The difference in the
respective position values w ould give the radial
alignment, eliminating the effect of any face-out

on t he coupling surf ace. Radial alignment shall

be achieved w ithin 0.05 mm.
(Refer Figure : 11 & 12).
C) ASSEMBLY : (Figure 14)
After alignment of motor and mill shaft , coat hub and sleeve
bearings w it h grease. Slide the sleeves over hubs. Position spacer
betw een Mill and Motor Shafts. Then insert gasket and bolt sleeves
and spacer together. Tighten bolts unif ormly.
Remove the tw o grub screw s on the coupling sleeves and
grease through one hole using a grease gun, until grease comes out
of the other hole. Reassemble the grub screw s.
9.4.2 BIBBY RESILIENT FLEXIBLE COUPLING:
A) MOUNTING :
Coupling hubs are heated in an oil bath. The soaking
temperature should be around 120° C. Please see that t his
temperature is w ithin the flash point of t he heating oil used. The
coupling must be soaked for a sufficient period so as to obtain
enough expansion w hich w ill allow easy sliding of t he coupling hub
on to the shaft. Approximate soaking time is in the order of 20 -30
minutes. The coupling hub is removed from the bath after soaking.
The bore and the step, w here Spacer-1 w ill seat, are w iped clean.
Spacer-1 is placed in position in the coupling hubs and mounted on
the mill and motor shafts. Spacer-2 and Spacer-3 are assembled
together and then mounted on t he coupling hub (w orm shaft side).
B) ALIGNMENT : (Refer FQP Check list & log sheets)

Alignment w ill be obtained by moving one of the machines
to be coupled (usually the mot or).

Check that the faces of t he half couplings parallel, w it h the

help of feelers introduced betw een the Spacer and coupling
hub on the mot or shaft, at four points at 90 interval.
Check coincidence of axes w ith a small rule placed on
the outer t oot h surface in the same four points.
The axial gap of half coupling is 3 mm. The axial play
allow ed is 0.05mm. The Radial misalignment allow ed is 0.2 mm.
C) ASSEMBLY :
POSITIONING OF SPRINGS :
Fill up the grooves and t he space betw een hubs w ith

grease and position the spring, one segment at a time,
beginning w it h one of the end segment s and introducing
gradually the f ollow ing ones w ith t he help of a hammer.
FASTENING UP OF THE COVERS :

Once the springs have been put into position, finish
filling up w ith grease. Bring the cover in position and
assemble w ith Spacer - 2.
a) LUBRICATION :
Refer Lubrication Schedule (Chapter 7.8)
9.5 GROUTING AND DOWELING :

Grouting and Dow eling of motors shall be done w ithin 21
days of putting the Motor and Base Plate on foundation.
- Motor shall be grouted as per Grouting Inst ructions. (Chapter
No. - 5)
- Motor, requiring dow eling as per draw ing or specifications,
shall be dow eled to t he base plate / base frame.

Tw o dow els shall be used for each item unless ot herw ise
specified. Dow els shall be installed in diagonal corners of t he Motor
near a hold dow n bolt .
The maximum distance, from the edge of the dow el hole to
the edge of a hold dow n bolt, nut and w asher, shall be 12mm.
Tapered, removable dow els shall be used unless otherw ise
specified.

BOWL MILL
MILL OPTIMIZATION XRP 943
10.0 MILL OPTIMIZATION
Purpose:
The purpose of this programme 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 while carrying out
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) Height of the venturi collar to maintain the desired pulveriser fuel

fineness and differential pressure across the bowl.
3) Vary the Spring compression value to achieve the required mill output,
fineness and mill rejection level.
4) Classifier blade position to maintain pulverised fuel fineness.
5) Ring-roll clearance to reduce high bed formation on the bowl and to

reduce rejection rate.
6) Spring seat gap to ensure equal load on bowl by spring assemblies.
7) Inverted cone gap to maintain the pulverised fuel fineness.
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, primary air flow through the mill and the quantity of
raw coal.
3) The above adjustments may be carried out to maintain the required

DP, PF fineness, quantity & quality of mill rejects and for the said
purpose.

BOWL MILL
PLANETARY GEAR BOX XRP 943
11.0 PLANETARY GEARBOX – KMP280
Contents
1. Technical data
Technical data
2. General notes
Introduction
General scope of application
3. Safety notes
Precautions
Work-safety instructions
4. Handling and storage
Handling and storage
5. Technical description
General
Housing
Toothed components
Bearings
Lubrication
Sealing
6. Installation (Assembly)
General assembly instructions
Installation conditions
Preparation of the gear unit assembly
Gear unit assembly
Assembly instructions for attachments
Technical Data
Type: KMP
Size: 280
Year built: 2005
Motor power: 425 kW
Required power: 410 kW
Actual ratio: 23.376
Input speed: 1000 1/min
Output speed: 42.78 1/min
Weight (without oil filling): 10000 kg
Heaviest component weight: 3808 kg
Overall dimensions l x b x h: 2350 x 1750 x 1450 mm
Internal preservation: 12 months from March 2006

BOWL MILL
Lubrication: hydrodynamic lubrication

Oil quantity of gear unit: 1100 liters l
Oil viscosity: ISO VG 320
Oil grade: SERVOMESH SP 320 OF IOC OR EQUI.
Measuring surface sound pressure level (LpA): 85 dB (A)
Ambient temperature: +5 ... +50 °C
SECTION-2
Contents
1. Introduction
2. General scope of application
1. Introduction
The Operating Instructions must be read, understood in all respects and
observed by those persons who are responsible for use of the
PLANETARY GEARBOX,
Only familiarization with the Operating Instructions will prevent
malfunction of the product and ensure trouble-free operation. It is
important, therefore, that the persons actually responsible should be
familiar with theses Operating Instructions.
Careful study of these Operating Instructions before handling the product
and before startup is essential, as no liability is accepted for damage and
malfunctions resulting from non-compliance of these Operating
Instructions.
Note: BHEL reserves the right to amend these Operating Instructions
where rendered necessary by improvement of the products.
2. General scope of application

The product is intended for the scope of application as specified in the
Technical Data.

BOWL MILL
SECTION-3
Contents
1. Precautions
2. Work-safety instructions
1. Precautions
”Caution” will be found at passages in these Operating Instructions which
are especially important to keep the guidelines, regulations, instructions
and correct work procedures and to avoid damage to and destruction of
the machine and/or other parts of the plant.
2. Work-safety instructions
The following work-safety instructions should be followed carefully:
The gear unit is constructed in accordance with the state-of-the-art
technology and is reliable. However, this gear unit can represent danger
when it is used improperly by untrained personnel or not used as
prescribed.
Unauthorized modifications which impair the reliability are not
permissible. This also applies to guards which are fitted for protection
against accidental contact.
The gear unit may only be used and operated within the conditions
specified in the contract of performance and supply.
The gear unit is designed only for the range of application specified in
the technical data. Any further use is regarded as improper use. The
manufacturer cannot be held responsible for any resulting damage; the
risk lies with the user.
Use as prescribed also means to follow the instructions on assembly,
disassembly and reassembly, startup, service and repair as prescribed
by the manufacturer.
Every person dealing with the assembly, disassembly and reassembly,
startup, operation and service (inspection, maintenance, repair) of the
gear unit should have read the Operating Instructions and especially the
”Safety instructions” and observe them in all respects in order to:
– Prevent hazard to life and limb of the user and third persons.
– Ensure the reliability of the gear unit, and
– Prevent failure and environmental pollution due to incorrect
handling.
The gear unit may only be operated, serviced and repaired by
authorized, trained and properly instructed personnel.

BOWL MILL
The persons responsible for assembly, disassembly and reassembly,

startup, operation and service should be appointed clearly determined to
avoid any uncertainties with the safety aspect in mind.
Any work procedure impairing the reliability of the gear unit should be
avoided.
The operating personnel have to inform the person responsible about
any changes of the gear unit affecting the safety.
The user is obliged to operate the gear unit in perfect condition only.
The drive unit should be shut off at once if changes of the gear unit are
detected during operation, such as for example increased operating
temperature or changes in gear unit noises.
The operator should make sure that the place of installation of the gear
unit is clean and clearly laid out by giving the respective instructions and
carrying out checks.
Unauthorized modifications and changes carried out by the operator or a
person instructed by him impairing the reliability of the gear unit is not
permissible.
All work on the gear unit may only be carried out when it is stationary.
The drive unit must be secured to prevent accidental startup (e.g. by
locking the key switch or by removing the fuses in the power supply). A
notice should be displayed at the switch-on point stating that work is in
progress on the gear unit.
Rotating parts, such as couplings, gear wheels or belt drives, must be
protected by means of suitable guards to prevent accidental contact.
Remove any protective parts only with the gear unit stationary and
locked.
Before startup after repair works, make sure that all protective devices
are mounted.
Follow the manufacturer’s instructions when using solvents.
Observe the regulations on environmental protection when draining oil.
When installing the gear unit in other units or systems, the manufacturer
of the unit or system is obliged to incorporate the requirements, notes
and descriptions contained in these Operating Instructions in his own
Operating Instructions.
Notes attached to the gear unit, such as for example rating plate,
direction of rotation arrows, etc., must be observed. They must be kept
free from paint and dirt. Missing plates must be replaced.
Observe the relevant regulations on labor safety and environmental
protection for handling, assembly and disassembly, operation as well as
maintenance and repair.
The carrying capacity of the hoists to be installed and used must at least
correspond to the weight of the heaviest component (including attached
parts) for a split gear unit housing or the total weight of the gear unit in
case of a one-piece gear unit.
In any cases, the local safety rules and regulations for the prevention of
accidents apply to the operation of the gear unit.

BOWL MILL
SECTION-4
Contents

1.1 Handling
1.2 Storage
1.3 Preservation

1.1 Handling
Only use hoists and load suspension devices with sufficient carrying
capacity for handling.
The gear unit is already assembled when delivered.
Options (such as e.g. pipes and fittings) are packed separately.
Caution:
1.0 When handling the gear unit, exercise special care to avoid damage
due to the use of force or careless loading and unloading. The gear unit
may only be handled using the lifting eyes on the gear unit housing. Use
shackles to attach the slings to the lifting eyes.
2.0 In order to prevent damages to the housing and the output flange by
turning of the transport rope, wood blocks are to be inserted.
3.0 Never lift the output flange of the gear unit.
Detailed illustrations of the gear unit will be found in the drawings in the
gear unit documentation.
1.2 Storage
The gear unit should be stored in a protected place in its position of use
and with a suitable cover.
Caution: If stored in the open, the gear unit should be covered with
special care and it should be ensured that neither moisture nor foreign
matter is allowed to collect on the gear unit.
1.3 Preservation
The gear unit is provided with internal preservation and the free shaft
ends with a protective coating.
Note: Unless agreed to the contrary by contract, we warrant the internal
preservation for a warranty period of 12 months and the preservation of

BOWL MILL
the free shaft ends for one of 12 months. The period of validity starts on
the date of delivery of the gear unit.
In case of prolonged intermediate storage (> 12 months), it is advisable
to check the internal as well as external preservation and to renew them
if necessary (see Section 7 ”Startup”).
The external coating is resistant to weak acids and alkalis, oils and
solvents. It is seawater-resistant, tropic-proof and heat-resistant up to
140 °C / 284 °F.
The labyrinth seals on the input shaft and the output flange are sealed
additionally with adhesive tape.
Caution: The adhesive tape must not be removed until immediately
before start-up of the gear unit, because after this the internal
preservative takes no longer effect. In case the start up of the gear unit
will not take place after removing the tape, follow the preservation
instructions (see section 7 “Start-up”). If necessary the preservation must
be renewed.
SECTION-5
Contents
1. General
2. Housing
3. Toothed components
4. Bearings
5. Lubrication
5.1 Hydrodynamic lubrication
6. Sealing
1. General
The vertical mill drive type KMP is a bevel gear planetary gear unit with
triple power transmission path for driving a vertical mill.
High axial forces are generated during the milling process which are
transmitted into the foundation via the gear unit housing.

BOWL MILL
2. Housing
The gear unit is either made from steel (welded design).
The perfect proportion of bearing diameter and supporting housing walls
provides for extremely low specific bending stresses and deformations.
The strong ribbing of the housing provides for a high rigidity which is
especially important for the reliability and life of the thrust bearing.
The strong ribbing of the housing also subdivides the wall surfaces
resulting in an excellent noise damping.
For checking the gear wheels and the pad bearing, inspection holes are
provided.
3. Toothed components
The bevel gear set is case-hardened and has a cyclo-palloid HPG or
ground gearing. The sun gear and the planetary gears are protuberance
hubbed, case-hardened and the tooth flanks are ground. The internal
ring gear is made from high-alloy tempering steel. The tooth flanks are
hub-milled or shaper-cut.
The load distribution is realized by means of a self-adjusting sun gear
which is connected to the bevel gear shaft by means of a double-jointed
toothed coupling.

BOWL MILL
4. Bearings
All shafts are mounted in anti-friction bearings. For compensating the
high axial forces from the bevel gears, taper roller bearing kits are used.
Roller bearings are used for the other bearing points.
The planetary carrier is linked rigidly with the output flange and runs with
high precision in radial bearing and the axial tilting-pad thrust bearing.
A tilting-pad thrust bearing located in the upper part of the housing
compensates for the high axial forces. The bearing is designed for
hydrodynamic lubrication and has a low specific surface load.
All pads are mounted on ball pieces so that they can be adjusted freely
in each level. The elastic deformation of the ball thrust pieces
compensates for processed tolerances and housing deformations.
Thus, the percentage contact area is 100 %.
All pads have a perfect length-to-width ratio and a support offset in the
direction of rotation. The tilt is adjusted according to the load and thus an
optimum lubricating film is achieved.
Fresh oil is supplied through spray pipes located between the pads. In
case of a failure of the oil supply system, the bearings remain under oil
as the overflow lies above the sliding surface.
The anti-friction metal used for coating shows good emergency running
properties and high static and dynamic strength. The temperature is
monitored by means of temperature sensors with the sensors lying
underneath the anti-friction metal coat.
5. Lubrication
Lubrication and cooling are provided by a continuous oil circulation from
a separately installed oil supply system. For a KMP 280 size planetary
gearbox hydrodynamic lubrication method is adopted for the axial tilting-
pad slide bearing.
For low ambient temperatures, the oil has to be preheated. Submerged
heaters are installed in the oil container.
The oil is drawn in by the oil pump, cleaned in the double-switch filter
which is equipped with a visual and electric contamination indicator, and
is then cooled in the cooler and directed to the lubricating points. The oil
flow is divided by valves or orifices for lubricating the gear wheels and
the pad bearing.
Volume flow, pressure and temperature are continuously monitored by
monitoring devices.
Compensators are provided in the piping system to avoid vibration and
compensate for heat expansions.
6. Sealing
The input shaft and the output flange are sealed with labyrinth seals. Air
filters are provided on the housing for pressure compensation.

BOWL MILL
SECTION-6
Contents
1. General assembly instructions

2. Installation conditions
2.1 Dimensions and weights
2.2 Lifting devices
3. Preparation of the gear unit assembly
3.1 Foundation
4. Gear unit assembly
5. Assembly instructions for attachments
5.1 Mounting of the piping
5.2 Adjustment of the pipes on site
5.2.1 Pickling
5.3 Mounting of the couplings
5.4 Mounting the motor
5.5 Mounting separately delivered attachments
6. Preservation for Prolonged Period
1. General assembly instructions

When handling the gear unit, follow the instructions in Section - 4.
Observe the safety instructions in Section - 3 for the assembly.
Assembly should be carried out by specialized personnel with extreme
care.
Right at the planning stage, it should be ensured that there is adequate
space around the gear unit for assembly and subsequent care and
maintenance.
Make sure that the oil can be drained and that the air supply is sufficient.
It must be possible to check the inside parts through the inspection cover
openings.
Upstream and downstream machines should be arranged accordingly.
2.1 Dimensions and weights

Data of the gear unit in assembled state (see Section 1”Technical data”).
2.2 Lifting devices
Before commencing the assembly, adequate hoists must be available.

BOWL MILL
The carrying capacities of the hoists to be installed should at least be

sufficient for the gear unit weight (for details see Section 1 ”Technical
data”).
Caution: Lifting devices must only be attached to the gear unit at the
marked points (see also Section - 4 ”Handling and Storage”).
3. Preparation of the gear unit assembly

Remove the packing from the gear unit before installing it in the mill.
Remove the adhesive tapes from the labyrinth seals only before the
startup.
Caution: The input shaft of the gear unit may only be rotated during the
assembly when the pad bearing room is filled with oil up to the mark.
Caution: Clean the contact surfaces of gear unit and foundation.
3.1 Foundation
Caution: It is of major importance that the mounting surface of the gear

unit is level as the contact pattern of the gearing and the percentage
contact area of the thrust bearing are dependent on this factor.
All points of the mounting surface of the gear unit must be between two
imaginary parallel planes with a distance of 0.1 mm / 1 m.

BOWL MILL
The permissible deviation of the mounting surface of the gear unit from
the horizontal plane is 0.2 mm / 1 m.
4. Gear unit assembly

The gear unit should be installed in the mill according to the special
instructions refer Section 5.
Caution: The gear units are approved for one direction of rotation only.
The direction of rotation of the motor must correspond with the direction
of rotation arrow on the gear unit input shaft.
5. Assembly instructions for attachments

Caution: When mounting the attachments, observe the special Operating
Instructions for the attachments.
5.1 Mounting of the piping
The external lube oil system is supplied in three basic subassemblies.

The balance of the components are shipped loose
1) Mill Drive Lubrication unit consisting of pump, motor,
filter,cooler,Instrumentation console and oil storage tank etc.
2) Loose pipes, flanges, bends, support materials and fasteners etc.
3) Flexible metallic hoses
NOTE: For the following steps, refer to the erection drawing

no.1-61-188-01416/Figure 15. Also refer to Section-7 for details
on the Lube oil system installation
5.1.1 The pipes have to be cut to size as per the site rooting. Weld the
bends and flanges to the pipes. Use TIG welding for the root weld
between pipes and the bends. Trial assembly of the pipes shall be
done according to the drawings with lube oil system and gear box.
Blank flanges and plugs shall be removed before hand.
5.1.2 Dismantle the piping and carry out acid pickling. An inhibited
hydrochloric acid solution of 15% is required for pickling.
Acid Pickling Procedure

Plug the lower ends of the pipes.
Fill pickling solution into the pipe. Duration of action: 1 hour.
After draining the pipe, it should be filled with a neutralizer (ammonia
solution of 3 % to 5 %).
Neutralization duration: 15 minutes.
Then, thoroughly flush the pipe with flushing oil (Servomesh SP 320 of
IOC ). Flushing duration: 30 minutes min.

BOWL MILL
Caution: If the pipes are not mounted directly, they should be preserved
properly.
5.1.3 The interior of all pipes and fittings must be free of all foreign
matter before assembly.
5.1.4 The flange connections are metal to metal joints and appropriate
sealing material should be used.
Caution: The pipes must not be twisted. The pipes should be supported
with brackets according to the drawing.
5.1.5 Unless otherwise noted, torque all hex head screws and apply
thread locking sealant to all fasteners
5.1.6 Fasteners used with gasket connection are to have lock washers
only. No thread locking sealant shall be used.
5.1.7 It may be necessary to shift the lube oil system assembly to
prevent strain on the flanged components.
Assemble the rest of the piping and fittings as per drawing No. 1-61-188-
01416.
5.2 Mounting the motor

The drive motor should be aligned exactly with the center axis of the
input shaft of the gear unit and should be secured in this position.
Caution: When mounting the motor, observe the special Operating

Instruction for the motor.
Note: The life of the shafts, bearings and couplings depend to a large
extent on the precise alignment of the shafts with each other.
5.3 Mounting separately delivered attachments
All separate parts with threaded connection should be sealed with Loctite
572 or equivalent.
Any separately supplied fittings, the tapped holes of which in the gear
unit are closed with plugs, should be installed according to the supplied
drawings.
Caution: The special Operating Instructions of the separately supplied
attachments should be observed.
Electric monitoring devices should be connected according to terminal
diagrams, equipment lists and the special Operating Instructions.

BOWL MILL
6. Preservation for prolonged period

6.1 Preservation with preservative
Before longer storage times, the gear unit should be run with no load
with preservative.
Recommended preservatives are listed in the table below for
preservation of the gear unit:
Storage Preservative Special measures

stability
up to 12 Servomesh SP 320 of Plug the gear unit
months IOC or Equiv. airlight,
replace air filter
with plug
screws (replace
before startup)
more than 12 Servomesh SP 320 of Re-preserve gear

months IOC or Equiv. unit as up to 12
months
Table 7.1: Preservation measures when using mineral oil
6.1.1 Internal preservation procedure
Fill with preservative up to the upper mark of the oil level indicator
through the ventilation hole or the hole in the inspection cover. Allow the
oil to flow to the gearbox internals. However, restrict the level of oil in the
Gearbox housing up to the input shaft only. Close the venting hole on the
cover opening. Rotate the gear unit at least 1 revolution on the output
flange, while filling the oil by overflow in the gearbox housing. This can
be done by turning the input shaft manually.
Caution: Seal labyrinth seals on input shaft and output flange with
adhesive tape.
SECTION 7
PULVERISER LUBE OIL SYSTEM

BOWL MILL
Contents
1. Technical data
Technical data
2. General notes
Introduction
General scope of application
3. Safety notes
Cautionary Instructions
Industrial Safety instructions
Packing
Extent of Disassembly
Handling
Storage
5. Technical description
General configuration
6. Assembly
General Notes
Installation conditions
Installation
Final operations
7. Startup
Filling with oil
Oil pump
Oil cooler
Technical data
Weight (without oil filling):

1180 kg
Overall dimensions l x b x h: 2192 x 1800 x 1585 mm
Pump delivery: 150 l/min
Oil quantity: 1100 LTRS.
Oil viscosity: see operating instructions or
rating plate of the ”gear unit”
Oil grade: SP 320 OF IOC OR EQUIV.
Ambient temperature: +5 .. +50 °C
Supply voltage: 3 x 380...420V (IEC 38)
Supply frequency: 50Hz
Drawing no. Lubrication Diagram: 1-61-190-85943
Drawing no. (Terminal Wiring Plan): Vendor supplied drawing.

BOWL MILL
SECTION-B
Contents
1. Introduction
The Operating Instructions must be read, understood in all respects and
observed by those persons who are responsible for use of the
PLANETARY GEARBOX.
Only familiarization with the Operating Instructions will prevent
malfunction of the product and ensure trouble-free operation. It is
important therefore that the persons actually responsible should be
familiar with theses Operating Instructions.
Careful study of these Operating Instructions before handling the product
and before startup is essential, as no liability will be accepted for damage
and malfunctions resulting from non-compliance of these Operating
Instructions.
SECTION-C
Contents
1. Cautionary instruction
2. Industrial Safety instructions
1. Cautionary instruction
This ”Caution:” instruction will be found in places where special caution is
to be observed, in order that the guidelines, rules, instructions and
correct sequence of
operation are observed, and that damage and destruction of the machine
and/or other system components is prevented.
2. Industrial Safety instructions

The following Industrial Safety instructions should be specially observed:
The oil supply system is constructed in accordance with the state of the
art technology and safe in operation. This oil supply system may
however give rise to hazards if it is used improperly or subjected to use
for which it was not intended by untrained personnel.
Every person engaged in installation, dismantling and reassembly,
startup, operation and maintenance (inspection, servicing, repair) of the
oil supply system MUST have read and understood the complete
Operating Instructions, in particular the ”Safety” Operating Instructions.

BOWL MILL
The oil supply system is intended for the scope of application specified in
the Technical Data.
Any usage over and above this will be considered as improper use. The
manufacturer accepts no liability for damage resulting there from the risk
will be borne solely by the user.
Proper usage will also be taken to include observance of the installation,
dismantling and reassembly, startup, operating and maintenance
instructions specified by the manufacturer.
The oil supply system may only be operated, serviced and repaired by
authorized, trained and suitable instructed personnel.
Screwed pipe connections, flanged joint and monitoring devices may be
undone as long as the system is under pressure. First, pumps have to be
switched off, and aggregates under pressure have to be released.
Any mode of operation which adversely affects the safety of the oil
supply system is to be prohibited.
The operator has to inform the user of the system immediately of any
changes occurring in the oil supply system which adversely affect its
safety.
The user is obliged at all times to operate the oil supply system only
when it is in satisfactory condition.
The user MUST ensure cleanliness and unimpeded view at the place of
installation of the oil supply system by means of suitable instructions and
inspections.
Unauthorized conversion and modifications which adversely affect the
safety of the oil supply system are NOT permitted.
All work on the oil supply system MUST be carried out only when it is
stationary.
Before commencing work on the oil supply system, its drives and
ancillary equipment MUST be secured to prevent accidental switch-on.
Before restarting after repairs, it should be checked that all safety
devices are fitted.
Safety devices may only be removed when stationary, with the oil supply
system secured.
The manufacturer’s instructions on the application of solvents should be
observed.
When draining oil, environmental protection requirements should be
observed.
The loadability of the lifting gear to be installed must be at least that of
the heaviest component weight (see Operating Instructions, ”Technical
Data”).
In ALL cases, operation of the oil supply system will be subject to the
local safety and accident prevention rules.

BOWL MILL
SECTION-D
Contents
1. Extent of disassembly
2. Handling
3. Storage
1. Extent of disassembly
The oil supply system is shipped in assembled state.
(Weight see section 1 ”Technical Data”)
2. Handling
Caution: Special care should be exercised when handling the oil supply
system to prevent damage due to the effect of force or careless loading
and unloading.
Ropes or chains are to be used for handling the oil supply system. Attach
only to the base frame or the oil container. Ensure that the ropes do not
damage fittings and oil lines. A lifting beam will therefore be necessary
for protection. The lengths of the ropes should be such that the base
frame or the oil container is suspended horizontally.
3. Storage
When the shipping packing is removed, the oil supply system must be
stored on site in a clean, dry area.
The oil supply system is to be properly covered to prevent penetration of
dust and moisture.
It must be ensured that temperature fluctuations in the place of storage
do not lead to condensation forming in the oil supply system.
It must be ensured that no external damage can occur!
The openings are sealed with plugs or wooden flanges.
The preservation is adequate for normal shipping conditions and a period
of 12 months until startup takes place (storage in dry rooms).
If storage is to exceed 12 months, it is essential to consult the unit.
The external paint coating is resistant to weak acids, alkalis, oils,
solvents, seawater, tropical conditions and temperatures up to 140 °C /
284 °F.

BOWL MILL
SECTION-E
Contents
1. General configuration
1. General configuration
The oil supply system described below is used for oil cooling and/or
lubrication of a gear unit (see Section 1 ”Technical Data”).
The oil supply system has been subjected to an exhaustive trial run in
conjunction with the gear unit and tested in accordance with the order
data.
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.

BOWL MILL
SECTION-F
Contents
1. General Notes
3. Installation
4. Final operations
When planning space layout (e.g. planning carried out by customer),
ensure that there is sufficient space around the oil supply system to
permit unimpeded assembly and repair work. Machines installed
upstream and downstream of the oil supply system should be located
accordingly.
The load carrying capacity of hoists to be installed and used must at
least be
adequate for the data of the oil supply system; see Section 1 ”Technical
Data”.
Installation of the oil supply system must be carried out on a level, firm
and rigid foundation. Ensure that the oil can be drained off and that there
is sufficient air supply for the motors. The valves and wearing parts must
be readily accessible and permit easy inspection.
The permissible deviation of the installation surface of the oil supply
system from the horizontal is 2 mm/1 m (0.08”/40”); if necessary, shims
should be used.
2. Installation
Erect the lube oil unit at the location indicated on the General
Arrangement drawing and Foundation drawing. Drain the preservative oil
from gearbox assembly, if any. Remove the plugs on the gearbox
assembly from the supply oil flange, return oil flange, return pipe flange
and the discharge flange.
For handling of the oil supply system, see Section 4 ”Handling and
Storage”.
Packing and shipping protection devices should be removed before
installation. Carry out a visual check for shipping damage and
contamination. In the case of shipping damage, see Section 4 ”Handling
and Storage”.
All preserved flange surfaces should be cleaned with a solvent, e.g.
benzine.
Observe environment protection requirements.

BOWL MILL
Connecting lines are supplied loose.

The interfaces are provided with suitable flanges and gaskets..
Compensators (flexible hoses) should be used for vibration insulation
and to compensate for linear expansion. Provide supports to the piping
suitably.
After pipe installation, the lines should be flushed thoroughly. Ensure that
the pipes are pickled. Use TIG welding for the root welding.
Electrical connections of motors and monitors should be carried out in
accordance with terminal drawings, equipment lists and specifications.
Check voltage and circuits.
The sealing plugs and wooden flanges should be removed and the pipe
fit tings supplied loose installed in the system in accordance with
lubrication diagram and drawings (see Section 1 ”Technical Data”).
Parts supplied loose with threaded connection should be sealed with
Loctite 572 or equivalent after thorough cleaning.
4. Final operations
After installing the oil supply system, all visible screw fastenings should
be checked for tightness and tightened if necessary.
Fit all safety devices necessary.
SECTION-G
Contents
1. Filling with oil

2. Oil pump
3. Oil cooler
1. Filling with oil

The following provisions are recommended based on long years of
experience. They are given however without any responsibility on the
part of the gear unit manufacturer. 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 Operating Instructions
”Gear unit”).
In all cases, before startup, the gear unit/oil supply system should be
filled with oil (see Operating Instructions ”Gear unit”). After filling, the filler
openings should be properly re-closed and sealed.

BOWL MILL
Only oils in accordance with the specification should be used (see

Operating Instructions ”Gear unit”).
Mixing oils of different manufacturers is NOT permissible.
To remove residues of preservatives which can lead to oil foaming, the
oil supply system together with the gear unit should be flushed before
startup (see Operating Instructions ”Gear unit”).
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 oil. If the flushing oil is to be used in another
system, it should first be filtered.
Fresh oil in accordance with the specification should be used for startup
(see Operating Instructions ”Gear unit”).
Fill the oil supply system with oil in accordance with the Operating
Instructions ”Gear unit” via the gear unit resp. the oil container. Filling
can be carried out with an auxiliary oil pump. Ensure that no dirt is
allowed to enter the oil circuit.
Fill until the specified oil level is reached on the oil level gauge on the
container with the pump stationary (see Operating Instructions ”Gear
unit”). The pump should then be started. Once the complete system is
prime, the oil level in the container would fall and should be replenished
to the normal operating level.

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GUIDELINES FOR ERECTION

XRP 943 BOWL MILL

ADHUNIK POWER & NATURAL RESOURCES LTD.

PUBLICATION NO: HY-BM-007-2011

Sl.No Description Page

2 Precautions For Mill Erection 6

3 Protection & Preservation Of Mill 7

8 Setting-up Bowl Mill 36

9 Motor Installation, Coupling Mounting, 41

BHARAT HEAVY ELECTRICALS LIMITED 1

BOWL MILL CROSS SECTION FIG.1

LEVEL & GROUTING PROCEDURE FIG. 2

AIRPORT ASSEMBLY FIG. 3

BULL RING ASSEMBLY FIG. 4

INNER CONE SPOUT SEGMENT ASSEMBLY FIG. 5

TIGHTENING TORQUE FOR FASTENERS FIG. 6

CLASSIFIER ASSEMBLY FIG. 7

SPRING COMPRESSION PROCEDURE FIG. 8

SPECIAL TOOLS FIG. 9

PROTECTIVE SEAL APPLICATION FIG. 10

EQUIPMENT ALIGNEMENT RECORD (FORM-A) FIG. 11

EQUIPMENT ALIGNEMENT RECORD (FORM-B) FIG. 12

LUBE OIL LOCATION FIG. 13

MILL MOTOR COUPLING FIG. 14

WIRING DIAGRAM – GEAR BOX RTDS FIG. 15

BHARAT HEAVY ELECTRICALS LIMITED 2

LIST OF ERECTION DRAWINGS

Sl.no Description Drawing no.

1 G.A. OF XRP 943 BOWL MILLS. 00062085885

BHARAT HEAVY ELECTRICALS LIMITED 3

Sl.no Description Drawing no.

27 STUD ASSEMBLY-MILL FOUNDATION 36198802976

BHARAT HEAVY ELECTRICALS LIMITED 4

The illustrations included in this manual are typical of the mills

BHARAT HEAVY ELECTRICALS LIMITED 5

2.0 PRECAUTIONS FOR MILL ERECTION

Mill components have to be stored.

Inform Engineering Department for any deviation/ abnormalities

Look for proper orientation as given in the Project Drawings.

Look for better alignments.

Erection Mill Sub-assemblies looking for correct match marks.

Read instructions for better preservation of Mill Drive Assembly at site.

Ensure proper tightening of connecting fasteners.

Trouble free operation of the product must be the aim.

Follow Safety Regulations at all levels.

Observe proper gap between pipe ends of victualic couplings.

BHARAT HEAVY ELECTRICALS LIMITED 6

3. PROTECTION AND PRESERVATION OF MILL COMPONENTS

STORAGE AND PRESERVATION OF MILL COMPONENTS

MILL DRIVE AND BOWL ASSY:

PLANETARY GEAR BOX:

Please refer Gear Box installation instruction, Chapter 11

ROLLER JOURNAL ASSEMBLIES:

These assemblies shall be stored in closed storage in vertical position (Standing on

BHARAT HEAVY ELECTRICALS LIMITED 7

MILL DISCHARGE VALVES ASSEMBLY:

These valves carry several integrally mounted instrumentation components like

BHARAT HEAVY ELECTRICALS LIMITED 8