883BakreswarO&amp M WithFigures

OPERATION
AND
MAINTENANCE
BOWL MILL-XRP 883
CUSTOMER :
WBPDCL, BAKRESWAR
2X210 MW UNIT IV & V
Bharat Heavy Electricals Limited

Ramachandrapuram, Hyderabad - 502 032.
Publication No. HY-BM-01-2008

Rev. 00
Date: 31/01/2008
©
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 the receiver.
2007
PUBLICATION No: HY-BM-01-2008
Rev. No: 00
Date: 31/01/2008
ISSUED BY
PULVERISERS ENGINEERING
BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM :: HYDERABAD
INDIA
CONTENTS Bowl Mill
XRP 883
CONTENTS
Sl. No. Description Page No.
1.0 INTRODUCTION ................................................................................... 1
2.0 IMPORTANT INSTRUCTIONS............................................................ 2
3.0 PROTECTION AND PRESERVATION OF MILL COMPONENTS 8
3.1 Planetary Gear Box........................................................................ 8
3.2 Spare Roller Journal Assembly Preservation ............................ 8
3.3 Preservation of Journal Assemblies in the Mill........................ 8
3.4 Drive Couplings ............................................................................ 8
3.5 Mill Discharge Valve Assembly .................................................. 9
3.6 Interior Areas. ................................................................................ 9
3.7 Mill Motor....................................................................................... 9
3.8 General............................................................................................ 9
4.0 SETTING UP OF BOWL MILL ............................................................. 10
5.0 LUBRICATION ....................................................................................... 12
5.1 General............................................................................................ 12
5.2 Pulveriser Lube System ................................................................ 12
5.3 Journals ........................................................................................... 12
5.4 Miscellaneous & Idle Mills........................................................... 13
6.0 PULVERISER LUBE OIL SYSTEM OPERATING PROCEDURE ... 15
7.0 LUBRICATION SCHEDULE ................................................................ 20
8.0 OPERATION ........................................................................................... 21
8.1 Principles of Operation................................................................. 21
8.2 Operating Parameters................................................................... 23
8.3 Start-up ........................................................................................... 25
8.4 Normal Shut-down ....................................................................... 27
8.5 Emergency Shut-down…………………………………………... 27
8.6 Start-up After Emergency Shut-down ....................................... 28
8.7 Mill Fires…………………………………………………………... 29
8.8 Mill Rejects ..................................................................................... 34
8.9 Adjustment of Fineness…………………………………………. 36
8.10 Pulverised Coal Sampling............................................................ 38
BHARAT HEAVY ELECTRICALS LIMITED I

CONTENTS Bowl Mill
XRP 883
Sl. No. Description Page No.

9.0 MAINTENANCE.................................................................................... 41
9.1 General Maintenance .................................................................... 41
9.2 Mill Clearances .............................................................................. 46
9.3 Journal Spring Compression........................................................ 47
9.4 General Disassembly .................................................................... 51
9.5 General Reassembly...................................................................... 59
9.6 Other Components Disassembly and Reassembly................... 59
9.7 Double Upper Journal Bearing Assembly Procedures ............ 65
10.0 MILL OPTIMIZATION ................................................................ 94
11.0 PLANETARY GEAR BOX & LUBE OIL SYSTEM 95
OPERATING INSTRUCTIONS…………………………………
11.1 Measures Before Startup………………………………………. 95
11.2 Operation………………………………………………………….. 100
11.3 General Troubleshooting………………………………………… 102
11.4 Gear Box Lube Oil System Flushing…………………………… 104
11.5 List Of Equipment………………………………………………… 111
11.6 Pulveriser Lube System ................................................................ 113
11.7 Disturbances, Reasons and Remedy…………………………. 115
11.8 Spare Parts Stock…………………………………………………. 118
BHARAT HEAVY ELECTRICALS LIMITED II

CONTENTS Bowl Mill
XRP 883
LIST OF ILLUSTRATIONS
Fig. No. Description
1. Bowl Mill Cross-section
2. Bowl Mill General Arrangement Drawing
3. Mill Performance /Fineness Record
4. Planetary Gear Box Assembly
5. Journal Assembly
6. Air Port Assembly
7. Mill foundation Drawing
8. Bowl & Bowl Hub Assembly
9. Spring Preload Procedure
10. Deflector Control Assembly
11. Arrangement of Sampling Equipment
12. Removal and Weight of Mill Parts
13. Gear Box Withdrawal Procedure
14. Bull Ring Segments Assembly
15. Bowl Mill Lube oil Piping Arrangement
16. Tightening Torque for Fasteners
17. Roll Removing Fixture
18. Grinding Roll Wear Measurement Gauge
19. Journal Pressure Spring Assembly
20. Sieve Distribution Chart
21. Special Tools
22. Journal Shaft Assembly
23. Journal Head and Trunnion Shaft Assembly
24. Journal Opening Frame Liner Assembly
25. Protective Seal Application (17 deg tilt) venturi vane
26. Pulveriser Lube Oil System Scheme
BHARAT HEAVY ELECTRICALS LIMITED III

Introduction Bowl Mill
XRP 883/903
1.0 INTRODUCTION
Bowl mills are employed to pulverize the pre-crushed raw coal to the required
fineness before it is admitted into the boiler furnace for combustion. The operating
characteristics of bowl mills make it the best mill available for the direct firing system
of the coal. The best features of all the pulverisers have been incorporated in the
design of the bowl mill. The mill output can be easily varied, as per the turndown ratio
from its minimum to maximum load and it will operate for long periods without
mechanical problems or stoppages for cleaning, oiling or adjusting.
Crushed raw coal at a controlled rate is fed into the revolving bowl of the Bowl
Mill. Centrifugal force feeds the coal uniformly over the replaceable grinding ring
where independently spun rolls exert the required grinding pressure. The rolls do not
touch the grinding ring even when the mill is empty. Therefore the Bowl Mill operates
silently without the rumble that is characteristic of the mills in which there is metallic
contact between the grinding elements.
This mill is designated as XRP 903 Bowl Mill where
X – 3 Phase, 50 Hz Supply,
R – Raymond (Inventor of the mill),
P – Pressurized,
90 – Nominal dia. of the Bowl (inches)
3 – Number of the Grinding Rolls.
The mill works in a pressurized atmosphere as the primary air fan is placed in
the system ahead of the mill and hence will be designated as XRP mill.
The instructions contained in this manual give an outline of the correct

methods and procedures for installation. The contents in this manual have been
compiled and checked by experts in this field. Every possible care has been taken to
ensure the contents are accurate. It must be recognized that no amount of written
instructions can replace intelligent thinking and reasoning on the part of the operating
and maintenance staff.
BHARAT HEAVY ELECTRICALS LIMITED 1

Important Instructions Bowl Mill
XRP 883/903
2. IMPORTANT INSTRUCTIONS
CHECKLIST OF “DO’S” - BOWL MILL
A. Before start up :
1. Check lubrication with reference to proper level and cleanliness of

lubricants.
2. Check sufficient raw coal in the raw coal bunker.
3. Check for proper operation of mill discharge valves, hot air shut off gate,
hot air damper and cold air damper and seal air system.
4. Check that all three roller journal pressure springs are compressed to the
same spring pre-load of 8.0 tons to start with and further adjustment as
per Coal Hardgrove Index.
5. Check for proper ring-roll setting.
6. Check that all classifier vanes are open to the same extent.
7. Check that all flange joints and packing are properly placed and
adequately tightened.
8. Check that no boiler trip condition exists.
9. Check sufficient ignition energy is available in the furnace.
10. Check that mill discharge valve is in open condition.
11. Check that all seal air valves to mill are open and seal air supply present at
adequate pressure.
12. Check that cooling water line is open and cooling water supply present to
the mill lube oil coolers.

XRP 883/903
13. Check that tramp iron spout valve is open.
14. Check that raw coal bunker outlet gate and/or inlet gate to feeder is/are
open.
15. Check that cold air gate is open.
16. Check that adequate primary air pressure is available in the hot air header.
17. After the mill lube system has been started at least 15 minutes before,
check up the oil flow and pressure to the planetary gear box.
18. Feeder must be started only after the mill has been started and warmed
up.
19. Check that there is proper coal flow into the mill (an annunciation for the no
coal will come when there is no coal flow to the mill, if a no coal flow alarm
is provided).
20. During the initial period and load picking up of the mill check that sufficient
ignition energy is available in the furnace till pulverised fuel from each mill
attains self sustained combustion.
21. During a relight-up of the unit, after a unit trip out, ensure that the
discharge valves of all non operating coal laden pulverisers are closed
whenever a fresh fuel (oil/coal) elevation is cut in until the furnace draft has
stablised, to avoid any surging back of furnace gases into the coal laden
pulverisers in case of furnace pressurisation. This procedure should be
employed until all such coal laden pulverisers are either taken into regular
service or emptied of their content.
B. Normal operation :
1. Check oil flow and pressure to planetary gear box.
2. Check for proper mill outlet temperature.

XRP 883/903
3. Check for proper mill air flow.
4. Check for all bearing and oil temperatures.
5. Check for pulverised fuel fineness at routine intervals. Carry out ring-roll
setting and/or classifier setting based on the PF fineness lab results.
6. Check for mill rejects (quality and quantity).
7. Check for status of wear on all wear parts at least once in two months
whenever mill is down for more than one shift.
8. Carry out raw coal analysis at routine intervals.
9. Check level and quality of lube Oil in lube oil tank and journal assemblies
regularly.
10. Check for any abnormal sound.
11. Check for any air or pulverized coal leakage and attend to them promptly.
12. Check for hot air leakage through the Labyrinth seals. This indicates
trouble with the Labyrinth Seal or inadequate seal air pressure/ supply.
C. SHUT-DOWN :
i) During Normal Shut-Down :
1. Cool the mill during and after shut-down.
2. Run the mill for at least 5 minutes until coal is completely emptied.
3. Keep cold air regulating damper slightly throttled to approximately 5° after

the mill has stopped.
4. If water freezing weather is present and if mill shut-down is of long duration

XRP 883/903
drain the water from oil cooler.
ii) During Emergency Shut-Down :
1. If fire in the bunker or in the mill is noticed, take immediate action for
putting out the fire. For quenching these fires in the mill, try the following
methods.
(a) Shut the hot air shut off gate, place the feeder on manual control
and continue feeding coal at a high rate without overloading the mill.
(b) If fire is not put out by the above, water or steam may be admitted
into the milling system. The mill must be kept running, with the feeder
stopped, for several minutes till all the signs of fire are gone.
2. If a fire exists completely through the mill and fuel piping, clear all
personnel from the area surrounding the mill, its associated feeder and fuel
piping. Shut off the feeder and allow the mill to clear itself all the fuel.
Maintain a flow of cold air through the mill until all evidence of fire has
disappeared and the mill is cold, then shut-down and isolate the mill.
3. When a fire has been extinguished and the mill has cooled, stop the mill,
open inspection doors carefully and thoroughly clean the interior of the
mill of any accumulation including coal water slurry. Check lubricants for
evidence of carbonizing. Check all parts where the fire has occurred for
any damage, especially the O Rings & Oil seals.
CHECK LIST OF “DON’TS” - BOWL MILL
A. BEFORE START-UP AND OPERATION :
1. Do not start the mill without ensuring proper lubrication, cooling water
supply to the oil coolers.
2. Do not start the mill with discharge valve closed.

XRP 883/903
3. Do not start the feeder without the mill running in warmed up condition.
4. Do not start the feeder without ensuring proper ignition energy in the
furnace.
5. Do not start the mill without seal air supply.
6. Do not continue operation of mills with high mill outlet temperatures.
7. Do not run the mill continually with abnormal noise, high vibration, or with
high bearing & oil bath temperatures and only one or two spring adjusting
stud deflecting.
8. Do not start the feeder without checking ring-roll clearance of the mill.
B. MAINTENANCE :
1. Do not Open any of the Manhole Doors to get into the mill for
maintenance without ensuring that driving motor has been isolated, mill
discharge valve is closed (if the boiler is in operation), and the mill is
isolated from the air side as well as raw coal side.
2. Do not use steel hammers directly on grinding rolls and bull ring
segments.
3. Do not use direct flame torch for heating bearing assemblies.
4. Do not leave tools, work pieces, electrodes etc., inside the mill after
maintenance work has been carried out.
5. Do not carry out maintenance work inside the mill without proper personnel
safety equipment.
6. Do not weld on the bowl or any part attached to it unless the welding
machine is grounded to the bowl to prevent arching across bearing
assemblies.

XRP 883/903
7. Do not use 230 volts supply lights, and electrical grinders inside the mill
(Use 24 volts supply for hand lamps as a safety measure).
8. After a mill fire, do not open access door until all symptoms of fire are
vanished.
9. Do not weld on high strength non-weldable components of planetary gear

box like bevel pinion shaft, bevel gear wheel etc.
10. Do not interchange bevel pinion shaft and bevel gear wheel. Both these
are matched set. It is recommended to replace them as a set. It is
recommended to carry out maintenance on the gearbox internals only in
the presence of experienced fitters from BHEL or send the gearbox to
BHEL works.
11. Do not interchange journal opening covers, even within the same mill.
They are matched with respective journal opening frames of the separator
body.

Protection And Preservation Bowl Mill
of Mill Components XRP 883/903
3. PROTECTION AND PRESERVATION OF MILL COMPONENTS
STORAGE AND PRESERVATION OF MILL COMPONENTS
When the mill is not operated for more than a week, any one of the following
preservation procedures may be adopted to protect the interior parts of the planetary
gear box.
3.1 PLANETARY GEAR BAX:
Refer to Planetary Gear Box section.
3.2 SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:
These assemblies shall be stored in closed storage in vertical position (Standing on

roll).The journal assemblies are completely filled with recommended lube oil prior to
shipments from workshops. Oil to be used: Servo Mesh SP 680 of IOC. At site, the
condition of oil, level and leakage, if any, should be checked periodically. Use Oil Dip
Stick for level measurement.
Prior to commissioning, excess oil is to be removed with the help of siphon hand
pump. Retain the recommended oil level in the assembly. Prior to commissioning, if
the oil in the journal Assembly is dirty, the same is to be removed with a suction hand
pump. Clean the internals by topping up with a thinner. Fill the assembly with
lubricant SERVOMESH SP 680 OF INDIAN OIL COROPORATION LTD or
Equivalent to the recommended level. Make sure the pipe plug is tightly closed in the
journal shaft. The exterior surface of the journal should be kept reasonably dry and
free of any moisture and other weather condition.
3.3 PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL:
When the mill is out of operation for long period preservation of journal
assembly shall one by filling the recommended lube oil completely. Prior to
taking the mill into the service the excess oil may be siphoned off.
3.4 DRIVE COUPLINGS:
If uncoupled, pack with a recommended grease and wrap with sheet (plastic). If
coupled, fill with the same recommended grease.

Protection And Preservation Bowl Mill
of Mill Components XRP 883/903
3.5 MILL DISCHARGE VALVES ASSEMBLY:
These valves carry several integrally mounted instrumentation components like

solenoid valves, Limit switches, Electrical cable conduits, Junction Box, Air Cylinders
etc. These assemblies should be stored in fully covered condition with the integrally
mounted instrumentation components protected against moisture and dust.
3.6 INTERIOR AREAS:
The air passages, grinding and classifying areas of the Mill, Mill Discharge Valve,
Reject Hoppers, etc. should be stored under cover and protected as much as
possible. Water should not be allowed to accumulate and stand in or on these parts.
3.7 MILL MOTOR:
Follow manufacturer’s instructions.
3.8 GENERAL:
All exposed machined surfaces like shaft extensions, threaded or drilled bolt holes,
classifier link mechanisms should be periodically preserved with protective grease or
by such means and covered.
Note: Refer Lubrication Schedule (Section 7.0), for the recommended lubricants.

Setting Up of Bowl Mill Bowl Mill
XRP 883/903
4.0 SETTING UP OF BOWL MILL
Prior to operating the pulveriser with its electric motor for the first time,
i) Recheck the shaft coupling alignment.
ii) Ensure removal of the pipe plug and replace it with breather vent assembly on
the gearbox. Also, remove the tape provided as part of preservation on gear
box output flange and input shaft.
iii) Set the spring compression (see “journal spring compression”, (Figure 9)).
Then set the rolls and spring, location as follows :
NOTE:
To prevent undue stress on pulveriser components, spring compression on all
three journals should check within 450 Kgs.
a) Check to make sure that the bull ring segments are properly seated and
tightened in the bowl (Figure 14) (Clamping ring sockets head cap screws
should be torqued to 43 Kgm.
b) The trunnion end caps thrust and free should be turned so that numeral “1”
lines up with indicating arrow on the journal cover.
c) Refer Fig. 9 unlock the clamp plate studs by turning the clamp plate stud
locknuts counter-clockwise then retract the studs several turns. This frees the
spring assembly inside the spring cup.
d) Turn the pulveriser bowl through one revolution by hand to make sure that
none of the rolls make contact with any part of the ring. If any roll contacts the
bowl, screw in the journal stop bolt to provide roll-ring clearance. Jog the
pulveriser motor under power to check rotation.
e) Run the pulveriser with no feed. Turn each journal stop bolt counter clockwise
until contact between ring and roll can just be heard or felt. Slowly continue

Setting Up of Bowl Mill Bowl Mill
XRP 883/903
turning the stop bolts counterclockwise until the grinding roll turns freely on its
shaft. This ensures locating of the true high spot of roll-ring contact. Turn the
stop bolt clockwise until the contact just stops. Continue turning one more flat
clockwise. Tighten the journal stop bolt lock screw and assemble the locking
plate and bolt.
f) Draw up all clamp plate studs firmly and evenly and drive the locknuts tight.
Ensure there is no spring force on the roll by having 0.5 mm gap between
Journal Head Insert and spring stud insert, but as soon as material enters the
bowl and the roll starts to lift the springs come into action.
Set the deflector blades as per the following procedure for controlling pulverized fuel
fineness (ref Fig 10)
1. Loosen screws on all deflector link levers.
2. Disconnect all connected rods from the link levers. Do not remove control lever.
Set the pointer position to no. 5 on the scale and lock in position with handle nut.
3. Adjust the length of each connecting rod so that the bearing ends fix over the
deflector shaft and tighten the hex nuts. Reassemble the connecting rods to the
link levers with the cylindrical pin & split pin / bolts & nuts.
4. Measure distance from the tip of any one of the deflector blades set in step 3 to
the clockwise top edge of blade opening in the inner cone drum section.
(117±2mm)
5. Use a wrench on top of the deflector shaft to set all remaining deflector blades to
the measurement taken in the above steps Hold the blade while tightening screw.
6. Adjust the control lever pointer position depending upon the P F fineness results.

Lubrication Bowl Mill
XRP 883/903
5.0 LUBRICATION
5.1 GENERAL:
With the exception of the Roller Journals the Pulveriser is completely

lubricated from the external lube oil system. The Pulveriser lube oil system and piping
is constructed so that oil can be circulated to the planetary gear and its bearings at
the required location and flow back to the lube oil tank while the mill is in operation.
The journal assembly is filled with oil and internal circulation takes place as the roller
assembly rotates around its axis. Recommended lubricant specifications are given in
the lubrication schedule in this chapter.
5.2 PULVERISER LUBE SYSTEM :
Refer to Planetary Gear Box Section.
5.3 JOURNALS:
The Roller Journals are lubricated by means of a self-contained circulation
system. The oil level in the shaft is maintained at a point just below the top of
the seal and checked by using a dip stick.
The pumping action of the Roller Bearings circulates oil from the reservoir in
the journal housing to the annular chamber between the Bearings, then into
the shaft bore and through the oil return holes where the cycle is completed.
The upper journal housing is provided with a triple lip type seal to prevent oil
leakage. The journals are kept clean by seal air brought through flexible tubing
to holes provided in the Trunnion shaft and journal head for this purpose.
(Refer Figure. 22 & 23). 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.

XRP 883/903
Check the oil level with a dip stick. Dip stick must touch the bottom. Fill the
roller journal with oil to the level shown on the oil instruction plate attached to
the journal opening cover and tighten the plug (refer Figure.23.) 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 the oil seals have seated properly) a
normal interval of inspection, at least once in every three months and/ or when
the opportunity presents itself, can be initiated. When checked, if the oil
shown signs of contamination, or a laboratory test indicates oil break down, it
should be changed.
To change oil, siphon out the old oil and add new oil to bring the oil back up to
the level. Do this repeatedly until the oil is clear.
5.4 MISCELLANEOUS & IDLE MILLS:
The Deflector Regulators and Journal Stop Bolts should be greased as per
recommended Bowl Mill Lubrication schedule.
The Mill to Motor Coupling should be lubricated according to the

manufacturer’s recommendations (given in the lubrication schedule).
The Journal Trunnion Bushings are made of rubber and require no lubrication.

XRP 883/903
BOWL MILL OIL COOLER - COOLING WATER REQUIREMENT PER MILL IN

LITRES / MINUTE AT 32°C WATER TEMPERATURE
Recommended Inlet Pressure : 4.5 Kg/cm2.

Pressure Drop in Cooler : 0.7 Kg/cm2.
Water quantity per cooler : 15 m3/hr
ROLLER JOURNALS OIL QUANTITY AND LEVELS:
MILL SIZE Quantity of Quantity of Oil level (in mm)

lubricant per lubricant per mill from bottom
assembly (in litre) (in litre)
XRP- 903 80 240 840-940
GEAR CASE OIL QUANTITY:
Mill Size Quantity of lubricant per mill

(liters)
XRP- 903 1100

Lube Oil System Bowl Mill
Operating Procedure XRP 883/903
6.0 PULVERISER LUBE OIL SYSTEM OPERATING PROCEDURE
The Pulveriser lube oil system (PLOS) consists of a lube oil tank, 2x100 % Screw
pumps & motors, duplex basket filter, oil coolers etc. Lube oil pump capacity is 150
LPM. Filtered and cooled oil, to the required temperature range of 30 to 50 deg C, is
supplied to the gearbox thrust pad bearing, input shaft bearings and gears. The
return line from the gear box is connected to the tank. Two electrical heaters (HFC01
AH301) provided in the oil tank keep the oil temperature in the required range,
provided the pump is ON.
The following instrumentation is provided in the PLOS for interlocks & protection,
alarm and indication.
1.0 TEMPERATURE MEASUREMENT:
- Temperature switches with RTD’s (PT 100) provided in the lube oil system -
a) Three No.’s on the lube oil tank (HFC01 CT254, CT255, CT256).
b) Three No.’s at the cooler outlet (HFC01 CT251, CT252, CT253).
- Six No.’s RTD’s (PT 100) are also provided on the gear box to measure the
temperature of input shaft bearings (2nos.-HFC01 CT 022, 023), the thrust pad
bearing (4 nos.- HFC01 CT018 TO 021).
- Temperature indicators are provided-
a) One on the oil tank (HFC01 CT 353).

b) One each at the cooler inlet & outlet (HFC01 CT351, 352).
2.0 PRESSURE MEASUREMENT:
- Two Pressure Switches (HFC01 CP252, 253) are provided in the lube oil line,
after the oil cooler assembly.
- A differential pressure switch (HFC01 CP251) is provided across the oil filter unit
for alarm. A differential pressure indicator (local- HFC01 CP354) is also provided.
- Pressure indicators are provided-

a) One each at the filter inlet and outlet (HFC01 CP351, 352).
b) One at the cooler outlet (HFC01 CP353).
3.0 LEVEL MEASUREMENT:
- Two oil level Switches (HFC01 CL251, 252), one for low level (pump trip) and the
other for high level alarms, are provided in the oil tank.
- Two oil level gauges (HFC01 CL351) are provided on the oil tank for visual check
of “OIL LEVEL”.
4.0 FLOW MEASUREMENT:
- Two oil flow switches cum indicators (HFC01 CF251, CF252) are provided in the
lube oil line after cooler assembly.
PLOS : PRE-COMMISSIONING CHECKS:
1. Ensure electrical connections to MOTOR & Instruments, if any.
2. All the flanges in the system are tightly fastened.
3. Ensure valves position, which are to be kept open.
4. Avoid air pockets while priming the system.
5. Maintain oil level in the tank to the required level after priming the lube oil system.
6. Start & stop the Motor to check the direction of rotation of pump and Motor.
Ensure correct direction as shown on the pump.
7. Start the Motor and allow the system to run for 4 hours (trial run cum system
flushing operations).
8. Run the system with the required oil pressure at cooler outlet.
NOTE: 1) Avoid dry running of the pump as it results in seizer of moving parts.
2) The relief valve at the pump outlet is factory set at 10 bars.

PLOS OPERATION:
Once the lube oil system flushing along with the gear box is completed the same is
declared ready for normal operation.
When the oil temperature in the tank (HFC01 CT254) is greater than 10° C the lube
oil pump is permitted to start and at oil temperature value greater than 30° C at the
cooler outlet (HFC01 CT251) the mill is released for start. Below 30° C oil
temperature in the tank (HFC01 CT255) the oil heater (HFC01 AH301) is energized,
provided the pump is in service. The heater is de-energised at the tank oil
temperature (HFC01 CT256) of 36° C or when the lube oil pump is stopped.
Charge one of the duplex filters and the oil cooler. Once the permissive conditions
are met with, start the lube oil pump. The lube oil pump can be started either from
Local push button OR from FSSS through a potential free contact & CRT and when
pump stop command is not present, lube oil tank level is not low (HFC01 CL252) and
tank oil temperature is not low (HFC01 CT254).
The filter change over can be done online for cleaning the filter element. Cooler
change over too can be done online.
MILL START PERMISSIVE CONDITIONS FROM THE PLOS:
THE MILL MOTOR CAN BE ENERGISED ONCE THE FOLLOWING

PERMISSIVE CONDITIONS ARE FULL FILLED.
Lube oil temperature is adequate (HFC01 CT251 > 30° C)
Lube oil Pump ‘ON’ for more than 60 sec.’s and Lube oil pressure at cooler outlet is
NOT LOW (HFC01 CP252 > 0.8 bar).
Lube oil filter not dirty (DPS-HFC01 CP251 < 2.0 bar)
Lube oil flow to the gearbox is NOT LOW (FS-HFC01 CF251 > 120 LPM).
Any bearing temperature of Gearbox is within ALARM limits (i.e. <75° C).

AUTOMATIC MILL TRIP CONDITIONS FROM PLOS:
THE MILL IS TRIPPED IF ANY ONE OF THE FOLLOWING CONDITIONS ARE

PRESENT.
a. When both lube oil pumps are not ‘ON’ for more than 2 sec.
b. Control power supply OFF for more than 2 sec.
c. Lube oil pump ‘ON’ and lube oil pressure (HFC01 CP253 < 0.5 bar) after cooler is
very low, with a time delay of 15 seconds.
d. Lube oil temperature after cooler is very high (HFC01 CT253 > 65° C).
e. Lube oil flow to the gearbox is very low (FS-HFC01 CF252 < 105 LPM).
PUMP STOP CONDITIONS:
1.0 The lube oil pump stops/ shall be stopped when any one of the following
conditions are acknowledged or satisfied.
- Lube oil level in tank is low (HFC01 CL252).

- Lube oil temperature in tank is low ( HFC01 CT254 < 10° C)
- Pulveriser OFF for more than 60 minutes and pump stop push bottom actuated.
STAND-BY PUMP START CONDITIONS:
1. The running pump is ‘ON’ for more than 60 seconds and discharge pressure at
pump outlet is low (HFC01 CP252 < 0.8 bar), the standby pump to start.
2. When Pump-1 (Main) fails to start on giving start command, after 10 sec. time
delay, the stand by pump to start.
OUTPUT CONTACTS PROVIDED:
- Pulveriser Start Permissive ( to FSSS)

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

ALARMS LIST:
The following ‘ALARM’ signals are provided.
i. Lube oil tank level low (HFC01 CL252).
ii. Lube oil tank level high (HFC01 CL251).
iii. Lube oil flow to gearbox is low (HFC01 CF251 < 120 LPM).
iv. Oil temperature after cooler high (HFC01 CT252 > 60° C).
v. Any lube oil pump ON for more than 60 sec. and Oil Pressure after cooler low
(HFC01 CP252< 0.8 bar).
vi. Lube oil filter dirty (HFC01 CP251 > 2.0 bar).
vii. Lube oil temperature in tank very low (HFC01 CT254 < 10° C).

7.0 LUBRICATION SCHEDULE EQUIPMENT: BOWL MILL XRP 903
Sl. Parts to be Recommended Lubricants Type of Qty. of Lub. Frequency of Frequency of Remarks
No. Lubricated filling In litres/Mill oil observation
IOC HP BP
check
1 2 3 4 5 6 7 8 9 10
1 Mill Drive Gear Servomesh Parthan AMOCAM External tank 1100 6 Months Once daily Oil level shall be
Housing SP-320 EP-320 OIL-320 check gauges, maintained in
lines and the external lube
headers oil tank
2 Roller Journals Servomesh Parthan AMOCAM 680 Reservoir 240 6 months Check when Level 840 mm to
SP-680 EP-680 cap on accessible at 940 mm
journal shaft least once in
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 after
4 Discharge valve Servogem-3 Lithon-3 MP Grease-3 Grease Grease the shafts and seals initially and every 2 greasing.
shafts and Seals fitting weeks. Remove excess
5 Drive coupling Servogem-2 Grease Pack completely initially and every 3 months. grease
(BIBBY / GEAR) fitting Clean out & renew grease every year.
6 Journal Shaft Oil Molykote 33 or equivalent Grease the shafts and seals initially and every
Seals replacement time.
7 Mill Drive Motor As per Motor Manufacture's Recommendation

Operation Bowl Mill
XRP 883/903
8.0 OPERATION
8.1 PRINCIPLES OF OPERATION:
Coal is fed to the center of the pulveriser onto a revolving bowl. Centrifugal
force causes the coal to travel towards the perimeter of the bowl. The coal
passes between the bull ring and the grinding rolls, which impart the pressure
necessary for grinding. The partially ground coal moves outward and over the
edge of the bowl.
Heated air enters the mill side housing below the bowl and is directed upward
around the bowl outside diameter and separator body annulus, by the rotating
vanes. It continues upward and into the deflector openings in the classifier at
the top of the inner cone, then out through the venturi and multiple port outlet
assembly. As the air passes upward around the bowl, it picks up the partially
pulverized coal; particles are carried up through the deflector openings of the
classifier. The deflector blades in the openings cause the coal - air mixture to
spin within the inner cone. The angle of the blades determines the velocity of
the spin and the resulting fineness of the finished product. Coarser pulverised
coal particles are returned through the inside of the inner cone to the bowl for
further grinding. Coal that is pulverised to the desired fineness leaves the
pulveriser and enters the fuel piping system.
Any tramp iron or dense and difficult to grind foreign material in the coal feed is
carried over the top of the bowl, where it drops through the air stream and
rotating vanes to the mill bottom. Pivoted scrapers attached, to the lower skirt,
sweep the tramp iron or other material to the tramp iron discharge opening.
The tramp iron spout is fitted with a valve. Under normal operation this valve
remains open and material is discharged into a sealed pyrite hopper. The
valve is closed only while the hopper is being emptied.

Operation Bowl Mill
XRP 883/903
DO NOT close the valve on the tramp iron spout to prevent the discharge of
rejects. If the valve is closed for an extended period, material normally
discharged will be retained in the mill side housing and be ground by the
scrapers, scraper guards and holders. This produces excessive wear on these
parts and creates a potential fire hazard.
If coal is discharged into the pyrite hopper, this indicates overfeeding, too
little pressure on the rolls, too low an air flow or too low a pulveriser outlet
temperature. Excessively worn pulveriser parts or improper adjustment can
also cause coal to be discharged. Excessive spillage indicates that a pulveriser
is not functioning properly and steps should be taken as soon as possible to
correct the situation.
The pulveriser operates under positive pressure. A seal air system provides
clean air to a chamber (Labyrinth seal) surrounding the bowl hub to prevent
hot air and coal dust from leaking to the atmosphere. Seal air is supplied to
each journal trunnion shaft to prevent coal dust from entering the journal
bearings. Seal air is also supplied to each spring assembly to keep it free from
coal dust.
For good pulveriser performance, the temperature of the coal-air mixture

leaving the classifier should be maintained as high as possible within the safe
temperature limit of the particular coal. Too high an outlet temperature may
lead to a pulveriser fire. Typically, Bituminous coals may tolerate temperatures
to 70° C. Sub-bituminous coals may become troublesome with pulveriser
outlet temperatures exceeding 65° C.
Environmental conditions may cause changes that result in a lower pulveriser

outlet temperature. A pulveriser may be operated at a temperature below 65°
C, provided there is no loss in capacity, coal spillage or high motor current. An
outlet temperature below 60° C may not dry the coal sufficiently.

Operation Bowl Mill
XRP 883/903
BHEL pulveriser systems are designed to perform effectively with coals with a
wide range of moisture content and grindability. In order to obtain rated
capacity from the pulveriser, it is necessary to have sufficient hot air entering
the pulveriser to dry the coal, sufficient pressure on the rolls to pulverise it
and proper setting of the classifier deflector vanes to obtain fineness
reasonably close to that for which the pulveriser was designed. Operating
experience will help determine the pulveriser’s optimum conditions for a given
coal.
CAUTION
PULVERISER OUTLET TEMPERATURE IN EXCESS OF 95° C COULD RESULT

IN PULVERISER FIRES. REFER TO “PULVERISER FIRES”. THE CONTROL
SYSTEM SHOULD AUTOMATICALLY CLOSE THE HOT AIR SHUTOFF GATE IF
THE PULVERISER OUTLET TEMPERATURE RISES TO 95°C.
8.2 OPERATING PARAMETERS:
Operating experience will help to determine the pulveriser’s optimum

conditions for a given coal.
i) Mill Air Flow:
Mill should be operated at the design air flow at all loads. Operating at
higher air flow will cause excess wear and upset the performance of
classifier etc. If mill is operated at lower air flow it may result in coal
rejects, low bowl differential pressure, excess fineness, coal settlement
etc. The air flow is controlled by the simultaneous operations of hot and
cold air dampers.

Operation Bowl Mill
XRP 883/903
ii) Mill Outlet Temperature:
For good pulveriser performance, the temperature of coal air mixture

leaving the classifier should be maintained as high as possible within
the safe temperature limit of the coal being ground. Too high an outlet
temperature may lead to a pulveriser fire. When grinding coal with a
volatile content below 30% on “as received” basis, the mil outlet
temperature of 75° C to 80° C is recommended. When grinding coal
with higher volatile content, the mill outlet temperature should be
maintained between 65° C and 75° C. If a high volatile coal with high
sulphur content the maximum safe operating temperature may be as
low as 65° C.
Environmental conditions may cause changes that result in lower

pulveriser outlet temperature. A pulveriser may be operated at a
temperature below 65° C provided there is no loss in capacity, coal
spillage, high bowl differential pressure, or high motor current. The
outlet temperature below 60° C may not dry the coal sufficiently. Mill
outlet temperature is controlled by simultaneous operation of cold and
hot air dampers.
iii) Pulverised Fuel Fineness:
The degree of pulverised coal fineness required depends upon the

volatile content of coal and the furnace size. This is specified for each
unit. Operating the mills at higher fineness increases the wear rate and
reduces capacity of the mill. The fineness can be controlled by
operating the classifier vanes.
Note: See pulverised coal sampling and adjustment of fineness

sections also.

Operation Bowl Mill
XRP 883/903
iv) Mill Capacity:
The capacity of mill depends on the hard groove grindability index,

the moisture content of coal and the pulverised fuel fineness
output required.
Note: If low calorific value of coal is used, the amount of coal required
is more. Thus mill capacity against quantity of steam generated
decreases.
The indications of mill overloading are the following, out of which one or
more indication may be present during mill overloading.
a) High mill motor current.
b) High bowl differential pressure.
c) Low mill outlet temperature.
d) Mill rejects having large amount of coal.
8.3 START - UP:
1. Before the pulveriser motor circuits are energized and the pulveriser is run
under power, the following items must be checked:
a) Pulveriser / motor coupling alignment.

b) Roll - ring clearance.
c) Lubrication system.
d) Deflector blades setting.
e) Seal air supply adequacy.
f) MDVs and Tramp iron spout valves are in open position.

Operation Bowl Mill
XRP 883/903
2. Check the oil level in the journals and in the lube oil tank and gear housing.
Make sure the shut off valves in the lubrication system are open both on oil
side and cooling water side.
3. Open all coal line valves and/ or gates and the cold air shut off gate.
4. Start the pulveriser lubrication system. Check that adequate oil pressure
and flow is established to the bearings and gears in gear box with the
help of the instrumentation provided in the lube oil lines.
Note:
The lube oil pump must be running at least for 15 minutes before giving a
pulveriser start permissive.
After the pulveriser is started, the oil temperature should be maintained at

approximately 50° C or less.
5. Open the hot air shut off gate. The control system should adjust the hot and
cold air control dampers to give the proper air flow and allow the pulveriser to
come up to normal operating temperature of 60° C to 77° C and exact
temperature to be established later, depending upon operating experience with
the available coal.
6. Establish the required ignition energy. Then start the feeder with a fairly high
feed rate. When the pulveriser begins to grind, (this is indicated by an increase
in the motor amps.) reduce the feed rate to the desired setting (minimum feed
rate on the first pulveriser). Increase the feed rate as unit load is increased.
The second and successive mills should be placed in service when the loading
on the operating pulveriser(s) reaches 80%.

Operation Bowl Mill
XRP 883/903
8.4 NORMAL SHUT DOWN:
If possible cool the mill before shutting it down.
i) Close the mill hot air regulator damper and hot air shut off gate and cold
air damper should be opened to maintain 100 percent air flow.
ii) Continue feeding coal till the mill outlet temperature reaches 50° C.
Then stop the feeder.
iii) Run the mill for another few minutes till it becomes empty and then shut
down.
iv) Cold air damper should be throttled to approximately 5° open after the
mill stops. A minimum air flow must be maintained through the mill at all
times.
Chances of mill fire would be reduced if the above steps are followed.
v) When the pulveriser is shut down for any length of time in cold weather,
it is advisable to drain the water from the lube oil coolers. If for any
reason ice has formed in the tubes, a careful examination should be
made before starting up to make sure that the tubes have not ruptured
allowing cooling water to contaminate the oil.
8.5 EMERGENCY SHUT DOWN:
On loss of furnace ignition or another condition that requires an automatic or

manual emergency fuel trip, the mill motor should be tripped immediately.
Stopping the motor should trip the feeder; close the hot air shut off gate and

Operation Bowl Mill
XRP 883/903
initiate a minimum inert sequence, if required, provided the mills are equipped
with an inerting system.
An emergency trip may subject residual fuel in the mills to cause spontaneous
combustion. The unit should be re-fired within a reasonable time (45 minutes)
to clear the mills. If this cannot be done, the mill should be cooled and
manually cleared (see CAUTION).
As a minimum precaution, the mill should be isolated, and all inspection doors
removed / opened to prevent volatile gases from mill entering the furnace.
CAUTION:
A HOT MILL WILL DISTILL COMBUSTIBLE GASES, FROM RESIDUAL

COAL. THEREFORE TAKE PRECAUTIONS WHEN OPENING THE MILL
FOR CLEANING.
NOTE: If an inerting system is installed, start the mill steam inerting system
for one minute immediately after shut down and again before
opening the pulveriser inspection doors. The inerting valves must be
properly closed before the doors are opened.
8.6 START UP AFTER EMERGENCY SHUT DOWN:
After an emergency trip, the mills that were in service will be hot and contain a
considerable amount of partially pulverised coal. The coal should be removed
from the mills one by one quickly to avoid mill fires. The following procedure
should be used.
i) Purge the unit.
ii) Establish ignition energy in the boiler for the mill to be operated.

Operation Bowl Mill
XRP 883/903
iv) Check that the mill discharge valves are closed on all mills not in
service. This will prevent hot furnace gases, which will be at higher than
normal pressure upon initial ignition of the coal, from surging down the
fuel piping into the idle pulverisers.
iv) Open mill discharge valve on the mill to be cleared.
v) Hot air shut off gate should remain CLOSED. Open cold air damper and
establish 100% air flow through the mill to transport the coal.
vi) Start the mill and leave it on for several minutes to remove all coal. If
mill is to be kept in service start the feeder before mill is empty. Then
open the hot air shut off gate and modulate hot air damper to bring the
mill for normal operating temperature.
vii) Repeat (ii) to (vi) above for all mills containing coal. When mills have
been emptied and/ or placed back in service, the discharge valves of
any of the idle mills should be opened to allow the required minimum
cold air flow.
8.7 MILL FIRES:
Causes:
The usual causes of pulveriser fires are:
i) Excessive Mill Outlet Temperatures:
Do not permit the mill outlet temperature to exceed 95° C regardless of

the material being pulverised.

Operation Bowl Mill
XRP 883/903
ii) Foreign Material such as Paper, Bags, Straw, Wood and Excelsior
collection in the inner Cone and other points in the Mill:
These materials do not pulverise readily and therefore should be kept

out of the raw fuel supply. When they get into the system, they collect
and may catch fire. Each time the mill is opened for any reason, remove
any such debris from air inlet, inner cone, bowl or other areas.
iii) Excessive Accumulations of Pyrites or Coal on the Mill Bottom or

in the Air inlet to the Mill:
The valve on the tramp iron discharge spout should normally be open to
allow the free discharge of foreign materials into the Pyrites collection
system. The valve may be closed momentarily for the removal of pyrites
from the collecting hopper. Accumulation of debris in the air inlet should
be removed whenever the mill is open for inspection. Scraper and
guard assemblies should not be allowed to wear excessively.
iv) Excessive Accumulations of Coal in Areas above the Bowl:
This condition is usually brought about by lack of maintenance. Worn

liners may allow coal to accumulate in an area faster than the normal air
flow will remove it or to reach areas where it cannot be removed by the
normal air flow. Coal can also trapped by foreign material bridging a
section of the mill through or over which the coal would normally move.
v) Improper or Unusual Operation:
An accumulation of coal or flammable foreign material is a hazard under

normal operating circumstances, but in most cases this alone does not
cause a fire or puff. Usually some additional improper operating
conditions must initiate the trouble. For instance, if a mill is operated
with low air flow, higher mill inlet temperatures are necessary to
maintain the set outlet temperatures. The air flow may be so low that

Operation Bowl Mill
XRP 883/903
additional coal settles out of the air stream. This condition can result in
more heat, less coal movement and a potential for fire.
Another example would be failure to close the hot air gate when there is
reason to believe an operating condition may have allowed a fire to
start. Such a condition could be a sluggish damper drive mechanism or
a sluggish damper control system, coupled with a substantial and rapid
change in coal moisture.
An example of unusual operation would be running coal through a mill

from a bunker that is known to be on fire. Of course extreme care must
be taken while doing this. Everything possible must be done to make
feeding continuous at a moderate to heavy rate.
INDICATIONS:
The two most common indications of a fire in a milling system are:
a) A high or rapidly increasing mill outlet temperature without other cause.
b) Paint peeling from the mill and/ or piping.
FIRE EXTINGUISHING PROCEDURES:
If a mill system fire does occur, perform the following:
a) Regardless of the fire location DO NOT shut down the mill and NEVER open
any mill inspection doors until all evidence of the fire has disappeared.

Operation Bowl Mill
XRP 883/903
b) SHUT THE HOT AIR SHUT OF GATE. Pulveriser outlet temperature in excess
of 95° C could result in “Mill fires”. The control system should automatically
close the hot air shutoff gate if the pulveriser outlet temperature rises to 95° C.
c) Place the feeder on manual control and continue feeding coal at a high rate
without overloading the mill.
Closing the hot air gate will frequently extinguish the fire, but if the mill
temperature continues to rise:
d) Cool the mill by admitting steam or water.
NOTE : On pressurised mill where the air ducts and mill feeders are sealed, it is
recommended that spray nozzles be installed in the mixing air ducts
and mill centre feed pipe so they may be used to admit water or steam
to the milling system. The nozzles can be permanently piped to a supply
system with suitable valves or they can be equipped with some type of
quick disconnect coupling to allow connection to portable water supply
hoses.
CAUTION:
FIRES UNDER THE BOWL USUALLY DO NOT CONTRIBUTE TO ABOVE

BOWL FIRES OR EXPLOSIONS UNLESS SOMETHING IS ALLOWED TO
VIOLENTLY DISPERSE THEM, SUCH AS A SUDDEN SLUG OF WATER.
THE MOST EFFECTIVE WAY OF TREATING THEM IS TO CONTINUE
RUNNING THE MILL WITH COLD AIR UNTIL THE FIRE GOES OUT. THE
MILL AIR INLET SHOULD BE CLEARED AT EVERY OPPORTUNITY.
AFTER THE MILL OUTLET TEMPERATURE HAS DROPPED AND ALL

SIGNS OF FIRE ARE GONE,

Operation Bowl Mill
XRP 883/903
e) Shut off the steam or water being admitted to the system.
f) Stop the feeder.
g) Run the mill for several minutes to completely purge the system and to reduce
the possibility of accumulation of water.
CAUTION
WHEN A FIRE HAS BEEN EXTINGUISHED AND THE MILL HAS COOLED, STOP
THE MILL OPEN THE INSPECTION DOORS (SEE WARNING) AND
THOROUGHLY CLEAN THE INTERIOR OF THE MILL OF ANY
ACCUMULATIONS, INCLUDING ANY COAL WATER SLURRY. USE CARE WHEN
CLEANING A BOWL MILL MANUALLY.
IF IT BECOMES OBVIOUS FROM PEELING PAINT AND CHANGE IN COLOUR

THAT A FIRE EXISTS COMPLETELY THROUGHOUT THE MILL AND FUEL
PIPING AND THE PRECEDING METHODS OF COMBATING THE FIRE HAVE
BEEN INEFFECTIVE.
h) Clear all personnel from the area surrounding the mill and its associated
feeder and fuel piping.
i) Shut off the feeder and allow the mill to clear itself of fuel.
j) Maintain a flow of cold air through the mill until all evidence of fire has
disappeared and the mill is cold.
k) Shut down and isolate the mill.
l) Open all inspection doors (see WARNING) and hand hole covers.

Operation Bowl Mill
XRP 883/903
m) Inspect the mill interior and check the separator body, inner cone, upper and
lower mill sides and feeder.
n) Clean where necessary.
NOTE : After any fire or mill puff, the entire milling system from the feeder to the
fuel nozzles, including the coal feeder mill air inlet duct, coal pipes,
internal coal nozzles and tilt mechanism should be checked for possible
damage and cleanliness. Repeat and clean as necessary. Be sure to
remove any accumulations of coal or coke.
o) Check the oil seals on each journal.
p) Check the lubricants and replace them if there is evidence of carbonizing.

Once every thing is satisfactory, the mill may be returned to service.
WARNING:
TAKE CARE WHEN OPENING MILL INSPECTION DOORS. THE MILL MAY BE
PRESSURIZED. CHECK THAT THE HOT AND COLD AIR SHUT OFF GATES,
THE MILL AND FEEDER SEAL AIR VALVES AND THE PULVERISERS
DISCHARGE VALVES ARE CLOSED. THE MILL MOTOR, BREAKER SHOULD
BE RACKED OUT AND TAGGED. THE PYRITE HOPPER DOOR SHOULD BE
CAREFULLY CRACKED AND THEN COMPLETELY OPENED, CAREFULLY
REMOVE THE BOLTS OF THE INSPECTION DOOR. EYE PROTECTION (GLASS
OR FACE SHIELD) IS RECOMMENDED.
8.8 MILL REJECTS:
Mill has been designed to reject tramp iron, pyrites and other denser and
difficult to grind material. When these come under the roller, the roller lifts up
allowing these to pass under. These are further carried over the edge of the
bowl and drop through the mill side air inlet housing. Then, scrapped by

Operation Bowl Mill
XRP 883/903
scrappers through tramp iron spout to pyrite hopper, from where they are
periodically removed. Any material having a bulk density above 1.7 tons/ m3
should be rejected. (For coal it is 1.2 TO 1.6 t/ m3) However some times the
raw coal is also rejected.
This could happen due to:
i) Over loading of mill.
ii) Improper operation and adjustments.
iii) Worn out parts.
i) Over loading of Mill can be due to:
a) Mill capacity reduction due to
Low grindability index of raw coal.
High fineness.
High moisture.
b) Physical overloading of mill due to feeder problems. (Refer feeder

supplier’s manual)
ii) Improper Operation and Adjustments:
a) Lower air flow - Operate at design air flow.

b) Low mill outlet temperature - Modulate hot and cold air dampers to
improve mill outlet temperature. After full adjustment if still

Operation Bowl Mill
XRP 883/903
temperature cannot be maintained above 65° C reduce the coal

feed rate.
c) Journal spring pressure too low - Check and set the journal springs
as detailed under maintenance section.
d) Jamming or breaking of journal springs.
e) Jamming of roll; all rolls should rotate freely on an empty bowl.
f) Improper setting of ring-roll gap or higher gap between journal spring

assembly and journal head.
g) Improper mill differential pressure. Increase the same by adding air

restriction rings/ blocks on the airport ring.
iii) Worn out parts:
a) Roller and bull ring segments.
b) Gaps - fill up all voids and gaps between the liners by suitable filler
compound.
8.9 ADJUSTMENT OF FINENESS:
The degree of coal fineness obtainable with air separation is extremely high,
and within normal limits it is possible to control fineness with considerable
exactness.
Fineness of any material is usually measured as the percentage of the

material that will pass through each of a series of test sieves. When a material
such as coal is reduced to fineness to that 95% passes through a 100 mesh

Operation Bowl Mill
XRP 883/903
sieve, 75% to 85% of it will pass through a 200 mesh sieve. The percentage
passing through the 200 mesh sieve will depend on the hardness or
grindability of the coal. The lower percentage will apply to harder coals, which
have lower grindability. The percentage for more easily pulverised coals with
higher grindability will be closer to the higher value. (Refer to A.S.T.M.
publication D-409:”Grindability of Coal by the Hardgrove Machine Method”).
When 95% or less passes through the 100 mesh sieve, the spread or
difference between the percentages of coal passing through the two sieves will
be 15 to 20 percentage points. As fineness increases, or for softer coals, the
spread decreases. For example, when fineness is increased to 90% passing
through a 200 mesh sieve, the difference is only about 9 percentage points
between the two sieves. With the same adjustments on the pulveriser, different
degrees of fineness will be obtained with different coals.
If a result is reported showing over 25 percentage points difference, a careful

recheck should be made with particular emphasis on the sampling procedure
used (see “pulverised coal sampling”).
It should be remembered that with increasing fineness there is a decrease in

the capacity of the pulveriser in tons per hour and an increase in the power
required per ton of pulverised coal.
The fineness is adjusted by moving the deflector handle(s) on the separator

top. When the handle point is set on “O”, the deflector vanes are at their
maximum opening, producing minimum fineness. As the handle is moved to
higher numbers on the scale, the deflector blades close and fineness
increases. See Figure 10 for deflector blade set up.
The fineness for which the pulverising equipment and system were designed is
given in the contract. If the coal is finer than necessary when deflector handle
point is set on “O”, the handle should be reset to allow for a greater blade
opening. If deflector blades are radial and the fineness is still too high, then
there is the possibility that the spring force on the journals should be reduced.

Operation Bowl Mill
XRP 883/903
If the coal is too coarse when the deflector handle point is set on “10”, the
spring force may have to be increased.
For this purpose the needs to be stopped and spring compression fixture used
for reducing or increasing spring compression. The spring compression will be
less when the grinding elements are new. Later on, for getting the desired
fineness, the spring compression can be increased by opening the mill. Other
reason for low fineness is large gap between grinding roll and bull ring
segments. For adjusting this gap, two mechanisms are provided in the mill.
The gap can be adjusted by stopping the mill and adjusting the stop bolt
results in lowering the grinding rolls. In case this does not become effective,
the cam arrangement provided on the trunnion end cap shall be used. For this
stop the mill and turn the end caps to lower the grinding rolls. It should be
ensured that both, the right and left side end cap numbers are same at the
arrow point.
With the above, the fineness and output can be achieved near the end
of the grinding element guaranteed wear life too.
8.10 PULVERISED COAL SAMPLING:
Pulverised coal samples should be taken for fineness tests periodically and
whenever furnace or pulveriser operation suggests fineness has changed.
In order to obtain repeatable and comparable fineness test results, it is

necessary to maintain the pulveriser and furnace conditions as constant as
possible during the sampling procedure. The pulveriser should be on manual
control at or near its full load rating and should be allowed to settle out for at
least 10 minutes before testing starts, pulverisers with obvious indications of
trouble (heavy coal spillage, rumbling) should not be tested.
NON-ISOKINETIC SAMPLING METHOD:
A sampling device, illustrated in Figure 11 is supplied for each installation.

The sampling device consists of a cyclone separator, a sampling jar (receiver)
and a sampling nozzle connected directly or by means of a hose to the
cyclone.

Operation Bowl Mill
XRP 883/903
Eight aspirating fittings, also shown in Figure 11 are furnished with each
pulveriser. These fittings should be installed 90° apart in holes provided
in the pulveriser discharge valves (see mill General arrangement drawing).
To utilize the aspirators properly admit compressed air into the fitting, remove
the 2" pipe plug, then reduce the quantity of compressed air to the minimum
necessary to prevent discharge of powdered coal into the room.
The opening in the end of the sampling nozzle should always point directly
towards upstream while taking the sample. Sample must be taken from all the
eight aspirating fittings provided to get a representative sample.
The content of the sampling jar(s) should be placed on a heavy sheet of paper
or plastic and thoroughly mixed by lifting the corners to roll the coal back and
forth along one diagonal and then along the other diagonal. The sample should
then be coned, quartered and remixed until it is reduced to approximately 150
grams. Fifty grams of this sample should then be placed on the top screen of
nested 50 mesh, 100 mesh and 200 mesh sieves. The sieves should be
shaken on a Ro-tap or similar shaker for a total of 15 minutes. After 5 and 10
minutes stop the shaker, remove the collecting pan, brush the bottom of the
200 mesh sieve and discard the contents of the pan.
After 15 minutes the amount of coal left on each of the sieves is individually
weighed and fineness is calculated as per the following example.
Sample Calculation Example
% on 50 mesh
( 2 x Wt. on Sieve) 2 x 0.5 = 1.0%
% through 100 mesh 100 - 2 (0.5 + 4.4) = 90.2%

Operation Bowl Mill
XRP 883/903
100 - 2 (Wt. on 50 + on 100)
% though 200 mesh

100 - 2 (Wt. on 50+on 100+on 200) 100 - 2 (0.5 + 4.4 + 9.9) = 70.4%
Fineness determination from the same example by the same operator using the
same sieves should check within one percent on all screen sizes.
A record of pulveriser performance and fineness result, similar to that shown on

Figure 3, should be kept for each pulveriser. A drop off in pulveriser performance can
thus be detected and corrective measure taken.
One method of validating fineness test results is to use a Rosinrammler sieve

distribution chart (see Figure-20). When the fineness test results, such as those in
the example given above, are plotted for the particular coal, the lines should be
closely parallel or coincide.
If the fineness test results do not form a straight line, the sample sampling technique,
or equipment (see NOTE) should be checked. If there are large variations in the
amount of coal on the 50 mesh sieve, check the pulveriser for a very high air flow or
a hole in the inner cone. If air flow is normal, the pulveriser should be shut down and
inspected at the first opportunity. Check for wear patterns, holes in the inner cone
and other indications of unusual wear.
NOTE:
Holes in the inner cone, holes in the deflector vanes or missing deflector vanes
can produce erratic coal fineness test results. Check the calibration of air flow
instrumentation if high air flow is suspected. Improper ring-roll setting, journal
spring compression too would affect the P.F. fineness.
The following publications may be used as references for sampling and sieving
procedures.

Operation Bowl Mill
XRP 883/903
Sampling : A.S.ME. P.T.C. 4.2 “Coal Pulverisers” or ISO 9931 for Isokinetic
sampling
Sieving : A.S.T.M.D. 197 “Test for Fineness of Powdered Coal”.

Maintenance Bowl Mill
XRP 883/903
9.0 MAINTENANCE
9.1 GENERAL MAINTENANCE :
The pulveriser is a rugged machine, designed and built for continuous

operation over an extended period, with minimal wear on the working parts.
However iron pyrites and other abrasive substances in the coal are apt to
shorten the life of parts such as the rolls, bull ring, rotating vanes and
scrapers.
Since wear of pulveriser parts depends on many factors that vary from one
installation to another, it is difficult to prescribe a specific routine inspection
and maintenance program. Characteristics of the fuel, operating hours of
individual pulverisers, availability of pulveriser due to unit load demands, and
maintenance force availability are all factors that determine the frequency and
scheduling of pulveriser inspection and maintenance. An effective programme
can be established only on the basis of actual plant operating experience. It is
therefore imperative that an accurate log be kept from the beginning, to relate
individual pulveriser running time (see NOTE) with pulveriser performance,
plant operating schedules, unit load, outages, inspection reports, and other
associated data.
NOTE:
PULVERISER WEAR IS A FUNCTION OF THE NUMBER OF HOURS A PULVERISER IS
GRINDING COAL, NOT NECESSARILY THE AMOUNT IN TONS OF COAL PULVERISED.
A PULVERISER WILL LAST SOMEWHAT LONGER WHILE OPERATING AT REDUCED
CAPACITIES BUT WILL GRIND MUCH LESS TONNAGE BEFORE PART REPLACEMENT
IS NECESSARY.
Pulveriser part replacement criteria cannot always be defined in advance.

They must be established on the basis of experience and judgment on the part
of personnel familiar with the pulveriser history and performance. The degree,

XRP 883/903
location and pattern of wear soon become evident and can be handled
accordingly. In some cases surfaces can be built up; in other instances,
replacement of the part is more practical. The following list describes the
pulveriser parts normally subject to wear:
1. Bull Ring and Rolls:
Reduced pulveriser capacity and increased spillage are indications of

excessive wear. Contour templates, made when the equipment is new, may
aid in checking the degree and location of wear as it progress.
2. Airport Ring (Figure. 6):
Maintain a vertical clearance of 5 to 10 mm between the top of rotating vanes

and the bottom of the body liner segment.
3. Bowl Extension Ring:
The ring should be replaced when worn excessively.
NOTE: Items 2 & 3: Periodic inspection for wear and hard facing to be done.
4. Mill bottom Cover Plates:
Wear can be minimized by maintaining proper support of the scraper blades.

Replace when worn.
5. Mill side liners and Air inlet vanes:
Excessive rejects will cause wear on liners and edges of vanes.

XRP 883/903
6. Scrapers:
Bottom edges are most susceptible to wear and should be replaced after wear.
Maintaining proper support (pins and bushings) helps to minimize wear.
7. Mill Discharge Valves:
Excessive clearance in closed position is an indication of wear. Disc should be

replaced after wear.
Most inspection and repair work inside the pulveriser above the bowl can be
accomplished by removing one journal assembly cover and journal assembly.
Work below the bowl can usually be done through the mill side access door.
CAUTION
WHEN MAINTENANCE IS REQUIRED ON A PULVERISER WHILE THE UNIT IS IN

OPERATION, MAKE SURE THE PULVERISER IS COMPLETELY ISOLATED
(DAMPERS, GATES AND VALVE ARE CLOSED, MOTOR CIRCUIT BREAKERS
LOCKED OPEN, AND THE MEANS FOR OPERATING THIS EQUIPMENT
SUITABLY TAGGED) BEFORE ENTERING THE PULVERISER.
WHEN WELDING ON THE BOWL OR A PART ATTACHED TO IT. THE WELDING

MACHINE SHOULD BE GROUNDED TO THE BOWL TO PREVENT ARCING
ACROSS THE VERTICAL SHAFT BEARINGS.
9. Bearings:
Unusual noise and operating temperatures consistently above normal are

indications of impending bearing failure. Bearings should be inspected at the
first opportunity.

XRP 883/903
10. Planetary Gearbox:
Planetary gearbox components usually give long, trouble-free service. Proper

lubrication and its parameters, avoiding entry of large size extraneous
materials into the mill are to be taken care off during operation. For more
details refer to the Section-11 on Planetary Gearbox.
NOTE:
1. INTERFERENCE FITS:
Where components have been designed with interference fits, it is frequently

necessary to heat and/or cool the mating parts to facilitate assembly.
Heating:
Heat must be applied uniformly to the entire piece. Acetylene torches with
rosebud tips are not recommended, since heating by this method is not
sufficiently uniform. Heat can best be applied in a commercial type oven.
However, it is also possible to shroud the part in an insulated enclosure and
increase the part temperature with space heaters.
Cooling:
Chilling of components can be done in a commercial freezer. It is usually

easier to submerge the part, after providing a protective oil or grease coating,
in an ice/salt bath or to pack the part in dry ice.
2 ROLL - RING CLEARANCE:
The most common indications of the need for roll-ring clearance adjustment
are the falling off of pulveriser capacity, rumbling and increased coal spillage.
Adjustment of clearance and/or spring compression should be considered in

XRP 883/903
the event of any prolonged coal side pulveriser operating difficulties if

difficulties do not exist, adjustments are not recommended.
The entire journal assembly (Figure 5) including the roll, pivots about the
center of the trunnion shaft and can be raised or lowered with the journal stop
bolt. As roll and ring wear progress, the first adjustment is to lower the rolls
using the stop bolts. Continue to make stop bolt adjustments until they are no
longer effective.
Trunnion shaft bushings in the trunnion shaft end caps support the trunnion
shaft so that when the end caps are rotated from position 1 to 5, the location of
the center of the trunnion shaft is changed and this alters the position of the
entire journal assembly. The trunnion shaft end caps can be used to make roll-
ring clearance adjustments after the stop bolt adjustments are no longer
effective.
To make a roll - ring clearance adjustment with the stop bolt:
1. Slack off the journal stop bolt lock nut. With the pulveriser running but no coal
being fed, slowly retract the journal stop bolt until contact between ring and roll
can just be heard or felt. Then turn the stop bolt in half flat with new roll and
segments (turn the stop bolt till the high points of in-service rolls & segments
do not touch each other) and tighten the journal stop bolt locknut. Assemble
the lock plate and bolt it.
2. Slack clamp plate stud lock-nuts of journal spring assembly.
3. Snug up all clamp plate studs firmly and evenly and drive the locknuts tight.
The pressure spring seat now bears with only slight force on the journal head
arm. This to be repeated for the remaining two journal spring assemblies.

XRP 883/903
To make a roll-ring clearance adjustment using the trunnion end caps:
4. Slack clamp plate stud locknuts and retract studs several turns. This frees the
pressure spring assembly inside the spring cup. Loosen the journal stop bolt
lock nut and back out the journal stop bolt until the roll just touches the rings.
5. Remove the bolts from both trunnion end caps and slack off the four journal
opening cover bolts adjacent to each end of the trunnion shaft. Using special
box wrenches, rotate both trunnion end caps simultaneously in the direction
indicated by the cast arrow, so that the numeral '5' lines up with the indicating
arrow on the journal cover. Replace and snug the trunnion end cap bolts.
Tighten the cover bolts and tighten the end cap bolts.
6. Turn the pulveriser through one revolution by hand to make sure that none of
the rolls make contact with any part of the ring. Then adjust the roll-ring
clearance with the stop bolt following steps 1, 2 and 3 above.
Additional adjustments should be made using the journal stop bolt until they are again
no longer effective. When this occurs, it is necessary either to replace the rolls and
bull ring. A ring will usually outlast the rolls.
9.2 MILL CLEARANCES:
1. Vertical gap between body liner segment and rotating vane 5 to10 mm
segment of air port assembly.
2. Gap between inverted cone and inner cone. 75 mm
3. Gap between center feed pipe lower and inner cone. 100 mm
4. Vertical gap between scraper and insulation cover plate. 16 to19mm
5. Vertical gap between skirt and insulation cover plate. 19 to21mm

XRP 883/903
6. Vertical gap between scraper guard and insulation cover 10 to16mm

plate.
7. Radial gap between scraper and mill side bottom liner. 25 to 35mm
8. Radial clearance between Labyrinth Seal & Bowl Hub 0.3+ 0..05
- 0.05
9.3 JOURNAL SPRING COMPRESSION:
The spring compression must be set before the pulveriser is placed in service.
The initial compression setting (8.0 tons) should be checked and if necessary,
the springs should be compressed using the spring compression fixture
supplied. If some coal or load characteristic causes poor operation changing
the spring compression should be considered.
To prevent undue stress on pulveriser components, spring compression on the

three journals in one pulveriser should check within 450 Kg.
The most common reasons (and action) for changing spring compression are:
1. Rough operation at low loads (reduce the compression).
2. High or unstable power consumption (increase the compression).
3. Vibration at high loads (increase the compression).

XRP 883/903
SPRING PRELOAD SETTING PROCEDURE:
1. The spring assembly should be completely assembled except for the spring
stud extension cap, spring stud locknut keeper Hex. Hd. cap screw M52 and
keeper washer.
2. Of the six threaded studs, four must be backed out of the journal spring
housing cover to the dimension indicated in detail “B”. For the purpose of
wrench clearance, two studs must be removed in the region of one of the
cutouts in the preload fixture (item 2).
3. Slide the spring stud locknut keeper on to the spring preload stud.
4. Using two Hex. Hd. cap screws (item 3), fasten the cylinder (item1) to the
spring preload fixture (item 2) mount the fixture as shown using one nut at the
top. Slide the preload stud (item 4) through the cylinder and screw it into the
end of the spring preload stud. At least a thread engagement of 76 mm is
required. Screw the nut (item 5) on to the preload stud (item 4) with the
cylinder (item 1) fully retracted.
5. Slide, back off the spring stud locknut keeper from the spring preload stud.
6. Use the cylinder to draw the spring guide. To contact the spring housing cover
pump the cylinder (item 1) until the pressure gauge reads “P” ± 100 P.S.I. This
will compress the spring “X” from the static length. Using the locknut wrench
(item 7) advance the locknut until it contacts the spring guide.
7. Relieve the pump pressure (item 1) to 1000 P.S.I. using a magnetic base dial
indicator. Place the indicator needle on the flat vertical face of the locknut and
zero the indicator. Pump the cylinder pressure up to “P” P.S.I. again and check
the preload by making sure the indicator just starts to move (about 0.2 mm) as
the pressure gauge reads “P” P.S.I.

XRP 883/903
8. Tighten or loosen the locknut until this occurs. Slide the lock nut keeper onto
the spring preload stud causing the keeper to interlock with the locknut. It may
be necessary to compress the spring just above “P” P.S.I. to allow rotation of
the locknut. The locknut should be rotated a maximum of 1/8 of a turn. Slide
the keeper into position and relieve the cylinder pressure.
9. Remove the preload stud (item 4) and preload fixture (item 2), and install Hex.
Hd. cap screw & keeper washer. Torque the Hex. Hd. cap screw to 75 ft-lbs
and weld Hex. Hd. cap screw, keeper washer & locknut keeper together.
10. Mount six Hex. nuts onto the adjusting threaded studs. Refer to the ring to roll
setting procedure before adjusting these studs.
11. The spring compression should be checked whenever time permits to ensure
near equal loading all the three springs.
12. The spring compression can be adjusted, by stopping the mill, to get the
desired pulverized coal fineness or mill output, especially when the grinding
elements are worn out.
CAUTION:
USING THE SPRING COMPRESSION MEASUREMENT TAKEN, DO NOT ALLOW

THE PRESSURE GAUGE READING TO EXCEED 3000 KG FOR EACH
CENTIMETER OF THREAD ENGAGEMENT. THEN BACK OFF THE SPRING
ADJUSTING NUT THE DESIRED AMOUNT OR 6 MM.
FOR THE PURPOSE OF ESTIMATION, THE FOLLOWING TABLE GIVES THE

SPRING RATE FOR THE MILL.

XRP 883/903
Mill Size Spring Rate Spring load to be registered at Pr. gauge in Kg.
(in Kg/Cm)
903 XRP 5357 8000
CHECKING SPRING COMPRESSION (Refer Figure. 9):
It is normally necessary to open the pulveriser in order to check spring compression,

but it should be run for 5 minutes with no feed to clear itself of coal.
Check the new setting by releasing the hydraulic force, using the dial indicator and
reapplying the hydraulic force, noticing the pressure gauge reading when the
indicator has moved about 0.2 mm. If more than 6mm, compression is to be moved,
release all the hydraulic force, back off the mounting nut another 6mm and repeat the
above as many times as required.
NOTE:
1. Hand movement of the spring adjusting nut may be difficult. In order to turn the
same under these circumstances, use spanner wrench.
2. Check the ram area of Hydraulic cylinder written on the each Hydraulic
cylinder and multiply the same with pressure gauge reading to get the required
hydraulic load in tons applied on spring assembly.
3. Amount of compression in mm depends on the spring rate.

XRP 883/903
9.4 GENERAL DISASSEMBLY (Figure 1):
ISOLATION OF THE PULVERISER:
It is a good operating practice to isolate the pulveriser, before attempting any

maintenance job, that calls for opening the mill or dismantling its components.
To isolate the mill close the hot gas shut-off gate, the cold gas shut-off gate,
the coal line gate (if provided), the feeder discharge valve (if provided) and
open the mill feeder motor breakers. (Tag and/or lock open).
For most maintenance procedures a complete general disassembly of the bowl

mill is not required. Planetary Gearbox is designed to perform for long time
smoothly, provided the operation guide lines are followed strictly. Periodical
cleaning of filter element and or replacing the same with spare element,
keeping a watch on the oil quality through periodical sampling and testing only
are expected to be the normal maintenance activity. Inspection doors are
provided to peep into the gearbox for a visual check. However, in case the
gearbox needs any major maintenance activity to be done, the same can be
drawn out from its place, as per the procedure given below, and replaced with
a spare gearbox. This way the mill can be brought back into operation within
couple of days. This, in turn, first requires removal of all three hydraulic loading
system cylinders with their accumulators, the three journal opening covers and
journal assemblies. Next, the body block off liner of air port ring assembly and
the bowl extension ring segment assembly is dismantled and the bowl and
bowl hub are separated from the turn table of the gearbox and raised by 65
mm using suitable tools and tackles.
PLANETARY GEARBOX WITHDRAWAL & REINSTALLATION PROCEDURE:

(Ref: Figure 13)

XRP 883/903
WITHDRAWAL OF GEAR BOX ASSEMBLY:
The Planetary gearbox will be removed towards the drive motor side. The step
by step procedure for withdrawal and replacement of Planetary gearbox, in
case required, is as explained below:
Isolate the Mill and lock the Mill motor and lube oil pump motors.
The journal assembly and journal opening cover shall be removed as per
sequence.
OR
Tilt the journal assembly and journal opening cover in situ, after removing the
fasteners holding the journal opening cover to the journal opening frame and
the trunnion bushing flange.
Disconnect and remove the lube oil piping, both inlet and outlet side from the
gear box, till the withdrawal path is clear. Plug the openings to avoid any dirt
entry.
Disconnect the HT / LT and instrument cable connections made to the drive

motor and the junction box fitted on the gearbox.
Remove the skirt assembly including the scrapper assembly from the
bowl/bowl hub. Remove the labyrinth seal assembly.
Loosen and remove the holding down studs & nuts (M 48) between bowl hub
and the table top/flange of the gear box. Use hydraulic jacks to loosen the
nuts.
Remove the drive coupling guard and disconnect the mill-Motor coupling.

XRP 883/903
Loosen the holding down bolts of the drive motor to the base plate, rig and
remove the motor from its place and keep it in a nearby location, in case no
maintenance work need to be done on it.
Install the gear box withdrawal fixture assembly as shown in Figure 13.
Loosen the bolts and remove the body block off liner of the Air port ring
assembly, fastened to the bracket welded to separator body. In case the
journal block off liner is provided, the same may be gas cut and removed.
Remove the bowl extension ring fastened to the bowl.
Rig and lift the bowl and bowl hub together using the 3 no’s of Ratchet lever
type manual handling equipment, suitable slings and eye-bolts, by 65 mm. The
bowl hub shall clear the keys provided on the table top/flange of the gear box.
Fix the Hoisting clevis (3 no’s) to the M24 tapped holes made in the top
surface of the flange of the bowl, at 120° apart.
Note: If required use jacks in the mill side air inlet housing to free the bowl hub
from the gearbox table top/ flange.
Alternately, Rig and lift the bowl and bowl hub together using 4 – 10 tons jacks
placed in the mill side air inlet housing to free the bowl hub from the gearbox
table top/ flange, by 65 mm. The bowl hub shall clear the keys provided on the
table top/ flange of the gear box. Fix suitable size of wooden blocks/ shim
plates between the mill side bottom insulation cover plate and the bowl hub.
Lower the jacks such that the bowl hub assembly load is transferred to the
wooden blocks/ shim plates. Remove the jacks for lifting the gear box as
explained below.
Loosen and remove the holding down bolts between gear box and base plate.
Jack and raise the gear box assembly and fix the roller assemblies as shown
in Figure 13.

XRP 883/903
Using the pull and lift equipment (2 no’s), one to hold and allow the gear box
movement slowly from the rear end, and the other one to pull the gear box out,
from the input shaft end, between the concrete piers on to the rails.
Caution:
Gear box removal fixture rails are roller guides only and will not support the
gear box across large depressions, trenches made in the floor, with out
providing additional support.
Move the gearbox till it clears the air inlet housing assembly. Provide stoppers
below the rollers and remove the pull and lift equipment from the gear box.
Using the service crane of the Electrical operated handling system, rig and lift
the gear box, above the Mill maintenance platform, and move it to the Mill
maintenance bay. Place the gear box in a truck and shift it to the workshop.
Plug the holding down bolt openings for Planetary gear box and Motor in the
base plate to avoid dirt entry.
RE-INSTALLING GEARBOX ASSEMBLY:
The gear box assembly is re-installed by sliding it into position under the
assembled pulveriser.
Caution: For details on the alignment, leveling and clearances to be

maintained during gearbox re-installation, with the base plate, mill side air inlet
housing etc. refer to the Section 6 of the Bowl Mill erection Manual.
1.0 Ensure that the gear box assembly is positioned such that the input shaft is
facing the Motor side. Lift, move and set the gear box on rollers which are
mounted on gear box withdrawal fixture as shown in Figure 13.

XRP 883/903
Caution: Before moving the gear box, ensure that the thrust pad bearing
housing is filled with recommended lubricating oil (Servomesh SP 320) so that
the thrust bearing is totally immersed in the oil.
Using the pull and lift equipment, as done previously, slide in the gear box into
position.
Jack up the gear box and remove the roller assemblies. Lower the gear box on
to the base plate, after aligning to make the dowel pins entry into gear box
bottom flange.
Fix the holding down bolts between the gear box and base plate; hand tight
them.
Lower the bowl & bowl hub assembly on to the table top / flange of the gear
box after ensuring that the keys match with the key slots provided in the bowl
hub.
Note: If required heat the bowl hub with blow torch, to about 100 Deg C with
uniform torch heating while placing the bowl hub on the gear box for ease of
assembly.
If required, the table/ flange of the Planetary gear box may be rotated by
manually rotating the input shaft. Remove the rigging equipment and the
Hoisting clevis (3no’s) from the bowl.
Fix the holding down studs & nuts between the bowl hub and the table / flange
of the gear box. Pretension the stud to 41,000 Kg load and run down the nut
hand tight.
Replace all the components removed in the Planetary gear box withdrawal
procedure (step 5.0 to 10.0) in the reverse order.

XRP 883/903
Torque tighten the gear box holding down bolts to the base plate to 120 Kgm.
Rig and place the drive motor in its place, after removing the gear box removal
fixture assembly. Fix the holding down bolts between the Motor and the base
plate. Torque tighten them to 150 Kgm.
10.0 Fix the Mill-Motor coupling, after checking their alignment, as per
procedure, and replace the guard assembly.
Connect the lube oil piping, HT/LT / instrumentation cables to the respective
equipments, which were removed for gear box withdrawal (step no. 3 & 4).
Establish power supply and run the gear box lube oil system to ensure that
there are no leakages and also flush the newly assembled gear box till the
filter is found reasonably clear/ clean.
Re-install the journal assemblies and the journal opening covers removed for
gear box withdrawal (step no.2).
14.0 Release the Mill for normal operation.
JOURNAL AND COVER REMOVAL SEQUENCE (FIG. 19):
1. Disconnect the seal air supply lines from the trunnion shaft at each
journal.
2. Relax the stop bolt lock nut and back out the journal stop bolt until the roll
is resting on the bull ring segments.
3. Release the clamp plate stud locknuts of journal pressure spring

assembly and back out the clamp plate studs to remove spring pressure
from the journal head.

XRP 883/903
4. Rig and remove journal cover and journal assembly.
DISCHARGE VALVES & MULTIPLE PORT OUTLET ASSEMBLY

REMOVAL (FIG-1)
5. Disconnect the purge air piping over the mill discharge valves from the air
supply header. Disconnect electricity and compressed air from the mill
discharge valve drivers and remove the victualic/ dresser couplings
between the coal feed pipes and the valves. Disconnect Instrument
connection.
6. Unbolt the multi-port outlet assembly flange and remove the assembly
with the mill discharge valves from separator top. Unbolt and remove the
upper center feed pipe.
SEPERATOR BODY REMOVAL (FIGURE. 1):
7. Remove the bolts from the flange between the separator body and mill
side, separator body and separator top.
8. Disconnect instrument and other piping, and any other equipment

attached to the separator body and top. Then remove the entire
separator body and separator top with deflector assembly, inner cone,
feed pipe and liners from mill side.
BOWL AND BOWL HUB REMOVAL (FIG. 4, 8 AND 13):
Once the three journal assemblies, the discharge valve and multiple port
outlet assembly, and the separator body have been removed, the bowl
can be removed from the vertical shaft.
Remove the skirt assembly including the scrapper assembly from the
bowl/bowl hub. Remove the labyrinth seal assembly.

XRP 883/903
Loosen and remove the holding down studs & nuts (M 48) between bowl
hub and the table top/flange of the gear box. Use hydraulic jacks to
loosen the nuts.
Rig and lift the bowl and bowl hub together using the 3 no’s of Ratchet
lever type manual handling equipment, suitable slings and eye-bolts, by
65 mm. The bowl hub shall clear the keys provided on the table
top/flange of the gear box. Fix the Hoisting clevis (3 no’s) to the M24
tapped holes made in the top surface of the flange of the bowl, at 120°
apart.
Note: If required use jacks in the mill side air inlet housing to free the
bowl hub from the gearbox table top/ flange.
Alternately, Rig and lift the bowl and bowl hub together using 4 – 10 tons
jacks placed in the mill side air inlet housing to free the bowl hub from the
gearbox table top/ flange, by 65 mm. The bowl hub shall clear the keys
provided on the table top/ flange of the gear box. Fix suitable size of
wooden blocks/ shim plates between the mill side bottom insulation cover
plate and the bowl hub. Lower the jacks such that the bowl hub assembly
load is transferred to the wooden blocks/ shim plates. Remove the jacks
for lifting the gear box as explained below.

XRP 883/903
9.5 GENERAL RE-ASSEMBLY:
Separator Body Reassembly:
Reinstallation of the separator body is the reverse of the disassembly procedures.

See “Separator Body Removal”.
Discharge valve and Multiple Port Outlet Installation:
Reinstallation of the discharge valve and multiple port outlet assembly is the reverse
of the disassembly procedures. See “Discharge valve and Multiple Port Outlet
Assembly Removal”.
Journal cover and Journal Assembly Reassembly:
Reinstallation of the journal covers and journal assemblies is the reverse of the
disassembly procedures. See “Journal cover and Journal Assembly Removal “. Look
for the match marks on journal opening covers and journal opening frames on the
separator body.
NOTE:
CHECK SPRING COMPRESSION AND SET THE ROLL-RING CLEARANCE (SEE

“ROLL-RING CLEARANCE”). UPON REASEMBLY REMOVE THE TRUNNION
SHAFT END CAPS WITH BUSHINGS AND RETAINER. USING AN ANTI-SEIZE
COMPOUND LUBRICATE BETWEEN THE TRUNNION SHAFT AND BUSHING TO
PREVENT COAL LEAKS.
9.6 OTHER COMPONENT DISASSEMBLY AND REASSEMBLY:
RENEWAL OF BULL RING SEGMENTS (Figure 14):
1. For access to the bowl, remove a journal assembly as per disassembly

procedure “Journal Cover and Journal Assembly Removal”.
XRP 883/903
2. Unbolt and remove the split clamping ring. Use the jack screws provided to
loosen the ring if necessary. Remove the retaining ring.
3, Remove the old bull ring segments. It may be necessary to air-arc the first
segment into several pieces. When air-arcing, make sure the welding machine
is grounded to the bowl. Exercise care not to cut the bowl.
4. Clean all interior surfaces of the bowl.
5. Install the new bull ring segments in numerical sequence, starting with the No.
1 keyed segment and working clockwise. Use narrow wooden wedges
between the bowl hub and the inner (small) end of the segments of hold them
in place against the outer periphery of the bowl as they are being set in place.
Refer to additional instructions on Figure 14.
When installing the last segment, it may be necessary to insert a portable jack
between the segments to open the gap as much as possible.
If a gap remains when the last segment is installed, shims from the shims
package should be inserted between the segments at points equally spaced
around the periphery of the bowl.
6. When all segments are in place, remove the wooden spacer wedges and
install a new retainer ring.
7. Replace the split clamping ring and hold down bolts. Tighten the bolts securely
and evenly at the same time, making sure that the segments are well seated in
the bowl and are back hard against the inside diameter of the bowl rim.

XRP 883/903
AIRPORT RING REPLACEMENT (Part of Air Port Assembly. Refer to Figure 6):
1. For access to the bowl, remove a journal assembly as per disassembly

procedure “Journal Cover and Journal Assembly Removal”.
2. If necessary, remove worn airport ring.
3. Attach new airport ring to bowl as follows:
a) Measure the distance between Bowl OD & mill side ID.

b) Check all mill side wall liners are in proper position.
c) Align and weld new extension ring with bowl.
d) Use two bolts of bowl and bowl extension ring to hold each segment of
rotating vanes in position (of air port assembly). Fix a pointer and by
rotating the bowl, level all the vanes in one plane. Tighten the bolts.
e) Select the highest segment of vane assembly and put a distance piece
of thickness 8mm on the outer ring to fix the position of body liner
segments. Tack-weld the same to the separator body shell.
f) Repeat the procedure for the rest of the segments of body liners, to
complete the circle, taking the reference of the same segment of
rotating vane assembly.
g) Once again check the clearance between vane assembly and body
liners by rotating the bowl. It should be within the limit of 8±3mm.
h) Lock the position of vane assembly and body liners with lock plate
temporarily, to avoid distortion during full welding.
i) Weld all tack weld joints in sequence i.e. diagonally opposite positions
and in small pass. Welding rod to be used is E7018 with pre-heating.
Also peening of welds is necessary.
j) After full welding, allow it to cool down.
k) Tack weld vane assembly inner ring with body of bowl from bottom.
l) Remove temporary lock plate (Refer ‘h’).
m) Check the welding and check free rotation of complete assembly.

XRP 883/903
Note: Based on mill performance and Bowl delta ‘P’ values add air restriction
rings on body liner assembly, air restriction plates on the rotating wheel
outer shroud inner surface(by welding). Further if required, provide
journal block off plates as per the procedure given below:
n) Fix up the three journal block off plates, above body liner, to the ID of
separator body shell, keeping a vertical clearance of about 20±5mm
from the top of the bowl extension ring. The position of these plates is to
be decided by taking into consideration the direction of air flow. To
support block off plates on body liner fabricate two gusset (support
bracket) and weld them at two ends.
JOURNAL OPENING FRAME LINER REPLACEMENT (Refer to Figure 24):
1. For access to the liners, remove the journal assemblies as per disassembly
procedure “Journal cover and Journal assembly removal”.
2. Remove worn journal opening frame liners.
3. Thoroughly clean journal opening frame where weld plugs are attached to
guarantee a proper weld.
4. Apply RTV sealer to all liner joints. Place liners through on the journal opening
frame with an approximate 3 mm gap between the liners. Secure the journal
frame liners with weld plugs.
5. Apply silicone cement to ceramic plugs and install as shown on the weld plug.
JOURNAL HEAD LINER ASSEMBLY REPLACEMENT:
1. Remove worn journal head liners from journal head liners support.

XRP 883/903
NOTE:
THE JOURNAL HEAD LINER ASSEMBLY SHOULD BE TAGGED AND REINSTALLED TO THE
SAME JOURNAL BECAUSE LINER ASSEMBLY INTERCHANGEABILITY IS UNLIKELY.
2. If necessary, wash the tack welds off and remove hex. head screws and
journal head liner assembly.
3. If removed, position journal head liner assembly and secure with hex. head
screws. Tack-weld both sides of screws.
4. Apply RTV sealer to all liner joints. Place liners on journal head liner support
with an approximate 3 mm gap between the liners. Secure the liners with weld
plugs. Fill weld plug voids with RTV sealer.
ROLL RENEWAL (Fig. 5 and 18):
1. Remove journal opening cover and journal assembly as per disassembly

procedure “Journal Assembly Removal”.
2. Lower the journal assembly until the edge of the roll touches the floor.
Carefully allow the assembly to settle to a horizontal position while further
lowering the hoist.
3. Remove the welded lugs if present holding the roll locknut to the lower journal
housing remove the locknut.
4. After removing the nut lift the assembly to a vertical position and let it rest on
the bottom face of the lower journal housing.
5. Attach a sling around the journal head and apply just enough strain to take the
weight off the bottom face of the lower journal housing. The rigging should be
such that the bottom face remains horizontal.

XRP 883/903
6. Tap the roll with a brass or lead hammer to knock it off. Do not use a steel
hammer, as it may chip the roll and cause injuries. If the roll cannot be tapped
off, heat it evenly with a torch or roll removal fixture.
NOTE:
IF THE ROLL IS HEATED, ALLOW THE LOWER JOURNAL HOUSING TO COOL

BEFORE LOWERING IT INTO A NEW ROLL.
7. When the roll is loose, raise the journal out of the roll and lower it into the new
roll, placed on 100 X 100 mm blocks to permit the lower journal housing to
pass through the roll.
8. Carefully tip the assembly on its side and replace the roll locknut. Drive up the
nut solidly and re-weld the lugs to lock the nut to the housing.
NOTE:
BE SURE THE WELDING MACHINE IS GROUNDED TO THE ROLL OR LOWER HOUSING NOT
TO THE SHAFT OR JOURNAL HEAD.
JOURNAL BEARING INSPECTION OR REPLACEMENT (Fig 5 and 22):
Removal journal assembly from the pulveriser as per dis-assembly procedure

“Journal cover and Journal Assembly Removal”. Refer double upper journal bearing
assembly procedure as per clause 9.7.

XRP 883/903
9.7 DOUBLE UPPER JOURNAL BEARING ASSEMBLY PROCEDURE
1. SCOPE:
This section covers standard assembly procedure for double upper bearing
journals.
2. CONTENT:
a) Establish Upper Bearing Bench End Play :
Measure the upper journal housing bore.

Grind the bearing spacer.
b) Assemble Bearing in Housing and Check End-Play:
Install the double bearing in the upper journal housing.

Install bearing keepers and shims.
Check upper bearing end play.
c) Assemble the Lower Journal Housing Sub-Assembly:
Grinding roll with locknut (taper fit connection)

Install the lower journal bearing cup.
d) Journal Shaft Sub-Assembly:
Check shafts straightness and roundness.

Assembly of long spacer shaft journals
Install the oil seal wear ring.
Install the upper bearing assembly.
Install the lower journal bearing cone.
Install bearing keeper and shim assembly.
e) Assemble the Journal Shaft to the Housing Assemblies, Check Journal

Assembly End-Play:
Journal shaft and housing sub-assemblies

Check journal assembly bearing end play.

XRP 883/903
TABLES:
Spacer Grinding Dimensions, 883-1003 Pulverisers - Table 1
Pulverisers Journal lift load and End Play - Table 2
FIGURES :
Determination of bore diameters - Figure A
Journal Bearing Spacer length determination - Figure B
Journal Bearing Outside Diameter - Figure C
Bearing Keeper Shim Pack - Figure D
Torque Specification Chart - Figure E
End Play Fixture - Figure F
Upper Bearing End Play - Figure G
Lower Journal housing bore dimensions & Interference - Figure J
Shaft out of Round and Straightness - Figure K
Journal Housing Flange Gap Shims - Figure L
Journal Assembly End Play - Figure M
Journal Head Skirt Flange Gap - Figure N

XRP 883/903
The assembly of a pulveriser journal shaft with double upper bearings requires
several distinct steps performed in the proper sequence to assure that proper
clearances are obtained. Proper clearances must be obtained to ensure maximum
bearing life.
I) Establish the upper bearing bench end play by grinding the spacer
supplied with the double bearing.
II) Assemble the upper journal housing subassembly and check the
bearing end play.
III) Assemble the lower journal housing sub-assembly and install the
journal roll.
IV) Assemble the journal shaft sub-assembly.
V) Assemble journal shaft sub-assembly and journal housing assemblies.

Check the journal assembly bearing end play.
NOTE:
EXTRA SETS OF THE FIGURES IN THIS SECTION SHOULD BE AVAILABLE TO

RECORD MEASUREMENTS, READINGS AND SETTINGS MADE. THESE MAY
BE RETAINED FOR AN EQUIPMENT MAINTENANCE HISTORY.
CAUTION:
BECAUSE THE MEASUREMENTS TAKEN DURING THE ASSEMBLY OF THE

BEARINGS MUST BE SO PRECISE, ALL OF THE COMPONENTS AND
MEASURING TOOLS MUST BE AT 70° F, (21°C). IF THIS IS NOT PRACTICAL,
THEN THE MEASUREMENTS MUST BE CORRECTED FOR THERMAL
EXPANSION TO 70° F, (21°C).

XRP 883/903
CAUTION:
UPPER JOURNAL BEARINGS ARE SUPPLIED IN MATCHED AND SERIALIZED SETS.

THE CUPS AND CONES ARE NOT INTERCHANGEABLE. EACH CUP MUST BE KEPT
WITH ITS MATING CONE. THE BEARING SPACER IS ALSO MATCHED WITH THE
CUPS AND CONES AND SHOULD NOT BE INTERCHANGED WITH OTHER BEARINGS.
IF AN ERROR OCCURS IN THE GRINDING AND AS A RESULT THE BENCH END PLAY
IS OUT OF TOLERANCE, THE SPACER MAY BE REWORKED. ADD MATERIAL TO THE
GROUND SURFACE BY WELDING FLAME SPRAYING OR PLATING AND REGRIND TO
THE CORRECT DIMENSION.
I. ESTABLISH UPPER BEARING BENCH END PLAY:
1.0 Measure and record the upper journal housing bearing bore. Use procedures
and Figure. A. Retain data for future reference.
2.0 Grind the bearing spacer.
2.1 Measure and record the spacer length; use procedure Figure. B.
SPACER GRINDING CALCULATIONS
Lateral clearance = (etched on O.D. of Spacer)
Lateral clearance = _________________________
Fit = Average bearing O.D. (Fig. B. - Average housing bore (Fig. A).
Fit = ( ) - ( ) =
Spacer grind value = Lateral clearance - 0.007” - [2.62x (fit)]
Spacer grind value = ( ) -0.007”- [2.62x ( )]
Spacer grind value = __________________________________

XRP 883/903
2.2 Refer the average bore measurement made in step 1.0, grind the
spacer.
2.3 Measure and record the spacer ground length.
CAUTION:
THE BEARING, SPACER AND HOUSING ARE NOW A MATCHED SET. THE
BEARING AND SPACER ARE NOT INTERCHANGEABLE WITH OTHER
HOUSINGS.
II. ASSEMBLE BEARING IN HOUSING AND CHECK END PLAY:
3.0 Install the double bearing in the upper journal housing along with spacer.
3.1. Heat the upper journal housing to 80 ° C to 100 ° C.

For, ease of assembly, each 0.025 mm of interference requires a 5.5°C temperature
differential between the bearing cups and bearing housing.
To facilitate future disassembly coat the O.D of the bearing cups with Molykote 41 or
equal. (If bearings are chilled for insertion coat the bearing housing bore).
NOTE:
AS AN ALTERNATE ASSEMBLY METHOD, THE BEARING CUPS AND SPACER

MAY BE CHILLED IN DRY ICE INSTEAD OF HEATING THE BEARING
HOUSING. IF THE CHILLING METHOD IS USED, THE BEARING CUPS, CONES
AND ROLLER BEARINGS MUST BE COMPLETELY COATED WITH THE
RECOMMENDED JOURNAL OIL IMMEDIATELY AFTER ASSEMBLY TO
PREVENT WATER ETCHING. THE ASSEMBLY SEQUENCE IS THE SAME, SEE
STEPS 3.2 AND 3.4.
3.2 Install the lower bearing cup squarely in the housing, follow in rapid
order and sequence with the finish ground bearing spacer, the bearing
cone assembly(s)., the second bearing cup, the bearing ring (if so
equipped) and the bearing keeper.

XRP 883/903
3.3 Insert and torque the bearing keeper bolts to 50 ft lbs. (6.91 kgm) to
ensure that the bearing cup and spacer stack is properly seated.
3.4 Allow the housing and bearings to return to room temperature

.
4.0 Install bearing keepers and shims:
4.1 Using a 0.001” (0.0254mm) feeler gauge, check between the bearing
housing shoulder and the bearing cup to assure the bearing cup is
properly seated.
4.2 Relieve tension on the bearing keeper cap screws to finger tight.
4.3 Measure the gap between the end face of the housing and the bearing
keeper in four places, reference Figure-D. Average the measurements.
4.4 Assemble a shim pack with a total thickness of 0.003” to 0.005” (0.0762
mm to 0.127 mm) less than the gap measured in step 4.3. Check
thickness of the shims with a micrometer.
4.5 Remove cap screws and bearing keeper. Assemble the shim pack to
the upper housing.
4.6 Replace the bearing keeper.
4.7 Use a thread locking/sealant, reinstall the cap screws and uniformly
torque.
5.0 Check upper bearing end play.
5.1 Arrange the upper journal housing and bearings in the end play fixture.
Refer to Figure F.

XRP 883/903
A base capable of withstanding a lift load of 4400 lbs. (2000 kg) must be
provided.
5.2 Attach an overhead hoist, a come-along and a direct reading load cell of
approximately 5 ton capacity to the eyebolt of the end play fixture. All
components must be of sufficient capacity to withstand the lift load for
your bearing, upper housing assembly given on the Upper Bearing Lift
Load and End Play Table -2.
5.3 Mount three dial indicators as shown in Figure. F. Rest the contact
buttons on the top of the housing.
5.4 Rotate the housing at least five revolutions in one direction to seat the
bearing rollers.
5.5 Zero the dial indicators and mark their position on the housing.
5.6 Raise the housing and bearing cups with the come-along until the load
cell reads the lift load value determined in step 5.2.
5.7 Turn the housing five revolutions in one direction. Return the dial
indicators to their original position and record the readings, refer to
Figure. G.
5.8 Lower the come-along until the load on the housing is released.
5.9 Turn the housing five revolutions in one direction. Return the dial
indicators to their original position and record the indicator
readings.
5.10 If the indicators have returned to zero ± 0.0005” (± 0.0127 mm) in step
5.9 calculate and record the average indicator reading for step 5.7 on
the worksheet. If the indicators do not return to zero ± 0.0005”

XRP 883/903
± 0.0127) disregard the average reading.
5.11 Repeat steps 5.5 through 5.10 until at least three average readings are
recorded on worksheet.
5.12 Average the average readings on the worksheet and record. The final
value must be within the end play limits give on the Upper Bearing End
Play Table, Table 2 or the assembly must be reworked.
III ASSEMBLE THE LOWER JOURNAL HOUSING SUB-ASSEMBLY:
6.1 Grinding roll with locknut (taper fit connection).
6.1.1 Use prussian blue to determine the contact pattern between the
lower housing taper and the grinding roll taper. There must be at
least 80% contact between the mating tapers and any “no
contact” zones must not exceed 10° of arc. Modify the roll to
achieve proper contact.
6.1.2 Once the taper contact has been verified, press the grinding roll
and lower housing together with 50 tons force.
6.1.3 Tighten the locknut on the lower housing while maintaining the 50
ton force.
6.1.4 Spot drill the grinding roll through the set screw holes.
6.1.5 Install the cone point set screws with Loctite 271 or equal and
torque to 50 ft/lbs. (6.9 kgm).
6.1.6 Use a pipe thread sealant, install the 1” hex socket pipe plug in
the oil drain hole in the lower housing and stake in two places.

XRP 883/903
7.0 Install the lower journal bearing cup.
7.1 Using procedure on Figures A and measure the lower journal housing
bearing and pilot bores and record the measurements on Figure A.
Take measurements at the top and bottom of each bore. All the
measurements for a given bore must be alike within 0.001” (0.0254
mm) T.I.R. (Calculate the average bore diameter).
7.2 Measure the O.D. of the lower journal bearing cup, reference
procedures on Figure C. Record on Figure-J.
7.3 Calculate the bearing housing interference F3 AVG minus DB. It must
be between 0.001” and 0.007” (0.025 mm and 0.180 mm).
7.4 Coat the lower journal housing bearing bore with Molykote 41 or equal.
7.5 Chill the lower bearing cup in dry ice or liquid nitrogen and install in
lower housing.
CAUTION:
AS THE BEARING CUP RETURNS TO NORMAL TEMPERATURE WIPE DRY

AND COAT WITH JOURNAL OIL TO PREVENT WATER ETCHING.
7.6 After the cup has returned to room temperature, check beneath the
cup with a feeler gauge to assure proper seating. A 0.001” (0.025 mm)
feeler gauge must not fit between the bearing cup and the housing
backing shoulder.
IV. JOURNAL SHAFT SUB-ASSEMBLY:

XRP 883/903
8.0 Check the journal shaft for straightness and roundness. Measure and record
the information, reference Figure K. The shaft must be straight and round with
0.001” (0.025 mm).
9.0 Assembly of long spacer shaft journals.
9.1 Install the oil seal wear ring.
9.11 Measure the I.D. of the oil seal wear ring, compare with shaft O.D.
measurements. The interference must be between 0.004” and 0.011”
(0.102 to 0.28 mm).
9.1.2 Heat oil seal wear ring in an oven or in oil to 300°F maximum.
9.1.3 Locate oil seal wear ring on journal shaft as shown in the assembly
drawing (either by a given dimension or against a shaft shoulder). Allow
wear ring to cool.
9.2 Install the upper bearing assembly.
9.2.1 Lubricate the upper journal bearing seat on the journal shaft with
standard journal oil.
9.2.2 Install one oil seal facing inward into the upper journal housing
and then the remaining two with the lip pointing outward. Coat
the seal lips and fill the cavities between the seals with Molykote
33 or equal.
CAUTION:

XRP 883/903
AVOID MARRING THE SHAFT BLENDED RADIUS FINISH OR DAMAGING THE

OIL SEAL DURING ASSEMBLY.
9.2.3 Assemble the upper bearing and housing on the journal shaft. A
clearance of 0.002” to 0.004” should exist between the shaft and
the upper bearing (0.051 to 0.102 mm).
9.2.4 Slip the journal bearing sleeve (long spacer) onto the journal
shaft. The bearing spacer is marked so that the slots are
assembled toward the lower bearing.
9.3 Install the lower journal bearing cone.
9.3.1 Assemble the lower bearing spacer (if applicable) on the journal
shaft. The chamfer on the spacer must clear the shaft fillet.
9.3.2 Coat the lower bearing seat on the journal shaft with Molykote 41
or equal.
9.3.3 Check the I.D. of the bearing cone, use procedure Figure A and
compare with shaft measurement K, Figure K. The interference
must be between 0.001” and 0.007” (0.025 to 0.178 mm).
9.3.4 Heat the bearing cone in an oven or oil bath to 250°F (120°C)
maximum and install it on the journal shaft.
9.3.5 Install the bearing keeper and torque cap screws to 100 ft. lbs.
(14 kgm).
9.3.6 Allow bearing to return to room temperature.

XRP 883/903
9.3.7 Check with a feeler gauge to assure proper seating of the

bearing. A 0.001” (0.025 mm) feeler gauge must not fit between
the bearing spacer and cone or the shaft and cone.
9.4 Install bearing keeper and shim assembly.
9.4.1 Remove cap screws and journal bearing keeper.
9.4.2 Measure the gap between the shaft end and the bearing face
with a depth micrometer in four places. Average the readings.
9.4.3 Prepare a shim pack with a total thickness of 0.076 to 0.127 mm

less than the average gap measured in step 9.4.2.
9.4.4 Assemble shim pack, keeper plate, lock plate and screws to the
journal shaft.
9.4.5 Bend the lock plate against the nearest flat on the screws.

XRP 883/903
V. ASSEMBLE THE JOURNAL SHAFT TO THE HOUSING ASSEMBLIES,

CHECK JOURNAL ASSEMBLY END PLAY:
10.0 Journal shaft and housing sub-assemblies.
NOTE:
PRIOR TO ASSEMBLY COAT ALL BEARINGS WITH STANDARD JOURNAL OIL.
10.1 Install a lifting eye in the end of the journal shaft.
10.2 On journal shafts with the long spacer, lower the shaft and upper
housing assembly without the “O” ring & the spring pins into the lower
housing and seat the lower bearing cone in its cup.
10.3 Turn the shaft five complete revolutions in one direction.
10.4 Measure the gap between the upper and lower journal housing flanges
in eight places, 45° increments, with feeler gauges. Record the reading,
reference Figure. L. all readings should be alike within 0.003” (0.076
mm). Average the readings.
10.5 Prepare a shim pack with a thickness equal to the average housing gap
measured in step 10.4 above plus 1/2 the end play of the two row upper
bearing. Fig F, plus value “A" from the assembly end play table, table 7.
Check the shim pack with a micrometer.
10.6 Remove the journal shaft and upper housing assembly (or the
upper housing sub assembly) from the lower housing.
10.7 Install the “O” ring in the upper housing groove and grease lightly with
Molykote 33 or equal. Install the spring pins in the lower housing.
10.8 Reassemble the lower housing, shaft assembly and upper housing with
the prepared shim stack. Do not pinch the “O” ring.
XRP 883/903
10.9 Apply Loctite 277 or equal to the hex. socket head cap screw
threads. Install cap screws and torque to assembly drawing
specifications
11.0 Check journal assembly bearing end play.
11.1 Fasten two rods threaded at their lower ends in the lifting holes in the
flange of the upper journal housing.
11.2 Lock the rods with hex nuts.
11.3 Install a dial indicator on each rod. Mark the indicator locations (1800
apart) on the top of the journal shaft.
11.4 Rotate the journal five revolutions in one direction and return the dial
indicators to their marked locations.
11.5 Zero the indicators.
11.6 Use a come-along and a five ton load cell, carefully lift the journal shaft
to the lift load given in Table 2.
11.7 Rotate the shaft at least five revolutions in one direction and return the
dial indicators to their original position.
11.8 Record the two indicator readings. Refer to Figure. M.
11.9 Lower the shaft to zero load on the load cell.
11.10 Rotate the journal shaft at least five revolutions in one direction and
return the dial indicators to their original position. Record the indicator
readings.

XRP 883/903
11.11 If both indicators have returned to zero ± 0.005” (± 0.0127 mm) in step
11.10 average the readings take in step 11.8 and record.
11.12 Zero the dial indicators and repeat steps 11.6 through 11.11 until three
average indicator readings, within 0.001” (0.025mm) are obtained.
11.13 Average the three average readings.
11.14 The value obtained in step 11.13 should be 1/2 the end play of the two
row bearing, Figure F. plus value “A” from the Assembly End Play
Table, Table 2. The acceptable tolerance is ± 0.001” (±0.025 mm).
11.15 If the journal assembly end play is not within acceptable limits,
disassemble the housings, and adjust shims (steps 10.3 through 10.9)
as required. After shims are adjusted, recheck journal assembly end
play by repeating steps 11.1 through 11.14.
11.16 If the journal assembly end play is within the acceptable limits, remove
the rods installed in step 11.1 and plug the lifting and jack screw holes
in the upper journal bearing with set screws.

XRP 883/903
TABLE - 1A
SPACER GRINDING VALUE

HOUSING BORE TIMKEN
INCHES MM INCHES MM
(Range) (Range)
15.9950 - 15.9952 406.273 - 406.279 0.000 0.000
15.9953 - 15.9955 406.280 - 406.287 0.001 0.025
15.9956 - 15.9958 406.288 - 406.294 0.002 0.051
15.9959 - 15.9661 406.295 - 406.302 0.003 0.076
15.9962 - 15.9664 406.303 - 406.310 0.004 0.102
15.9965 - 15.9967 406.311 - 406.316 0.005 0.127
15.9968 - 15.9970 406.317 - 406.324 0.006 0.152
TABLE - 1B
SPACER GR. VALUE
HOUSING BORE TORRINGTON
INCHES MM INCHES MM.
(Range) (Range)
15.9950 - 15.9952 406.273 - 406.279 0.000 0.00
15.9953 - 15.9954 406.280 - 406.284 0.001 0.025
15.9955 - 15.9956 406.285 - 406.289 0.002 0.051
15.9957 - 15.9958 406.290 - 406.294 0.003 0.076
15.9959 - 15.9960 406.295 - 406.299 0.004 0.102
15.9961 - 15.9962 406.300 - 406.305 0.005 0.127
15.9963 - 15.9964 406.306 - 406.310 0.006 0.152
15.9965 - 15.9966 460.311 - 406.315 0.007 0.127
15.9967 - 15.9968 406.316 - 406.320 0.008 0.203
15.9969 - 15.9970 406.321 - 406.324 0.009 0.229
Spacer Grinding Dimensions: Double Upper Bearing Journals

(Refer to Figure 2)

XRP 883/903
USAGE
When using this table ensure that the upper bearing and upper housing part number
you are working with match those listed in the table.
The lift load is used in determining upper bearing end play described in steps 5.1
through 5.12. The results obtained in step 5.12 should be compared with the values
for the end play tolerance given.
The values given are used in determining journal housing flange gap shims, Step:
10.4 and Figure L. and journal assembly end play steps 11.6 through 11.14 and
Figure M.
TABLE 2
UPPER BEARING (Refer to Fig-5) JOURNAL ASSEMBLY

Mill Size Lift Load End play Tolerance Lift(l Load End play ‘A’
(lb.) (Kgs (Inches) (mm) b) (Kgs.) (Inches) (mms.)
lbs ) lbs
883-943 4000 1814 0.005 - 0.009 0.127 - 0.229 2200 998 0.006 0.152
Pulveriser Journal Lift load and End Play

Bowl Mill
Maintenance
XRP 883/903
1. Use dial bore to determine bore dimensions.
2. Measure at two depths, 1/4A and 3/4A, on 45° increments, a equals the
bearing length or bore depth which ever is smallest.
3 Record readings, BU and BL on the table below. All measurements must agree
within 0.001” TIR (0.0254 mm TIR).
4. Average the upper, lower and total bore dimension Cu, CL. The average
reading D must meet blue print specification that is base dimension + 0.002” /
0.000”. (+0.051/0.000mm)
ORIENTATION BU UPPER DIMNS. BL LOWER. DIMNS. AVERAGE

O°
45°
90°
135°
B0 + B45 + B90 + B135 CU CL
4
CU + CL
2
Figure A - Determination of Bore Diameters.

Bowl Mill
Maintenance
XRP 883/903
1. Use a micrometer to measure spacer length “E” at eight locations on 45°

intervals prior to grinding.
2 Record and average readings.
3. Grind the spacer; remove material per table-1.
4. Re-measure ground spacer, record and average readings.
OIRENTATION DIMENSION E-NEW DIMENSION E-GROUND

0°
45°
90°
135°
180°
225°
270°
315°
E. AVG.. ENEW = EGROUND =
E0 + E45 + E90 + E135 + E180 + E225 + E270 + E315

AVG =
8
Figure - B Journal Bearing Spacer Length Determination

Bowl Mill
Maintenance
XRP 883/903
1. Use a micrometer to measure the outside diameter of the bearing cups at four
locations 0°, 45° , 90°, and 135°.
2. Record reading on the table below, all dimensions must agree within 0.001”
TIR (0.025mm).
3. Average the dimensions for comparison with bore dimension “D” Fig. A.
ORIENTATION BRG. 1 DIMENSION BRG. 2 DIMENSIONS

0°
45°
90°
135°
F AVG F11 AVG = F2 AVG =
F 0 + F 45 + F 90 + F 135
FAVG=
4
Fig. C Journal Bearing Outside Diameter

Bowl Mill
Maintenance
XRP 883/903
1. Measure clearance between the bearing housing and bearing keeper with a
feeler gauge at four locations.
2. Record measurements on table below:
3. Calculate average gap measurement.
ORIENTATION DIMENSION “G”

0°
90°
180°
270°
G 0 + G 90 + G180 + G 270
GAVG =
4
Figure. D. Bearing Keeper Shim Pack.

Bowl Mill
Maintenance
XRP 883/903
Figure: F End play fixture

Bowl Mill
Maintenance
XRP 883/903
Trial Indicator Indicator Readings AVG. Readings

No Load Lifted No Load Lifted Position
A HA H1 AVG. = HA+HB+HC
3
1 B HB
C HC
A HA H2 AVG =
2 B HB
C HC
A HA H3AVG =
3 B HB
C HC
A HA H4AVG =
4 B HB
C HC
A HA H5AVG =
5 B HB
C HC
H 1AVG + + H5AVG
HAVG =
5
Note: Refer to Procedures in Text, steps 5.5 to 5.10
Figure: G Upper Bearing End Play

XRP 883/903
Note:
For Bore determination use procedure Figure A:
For Bearing O.D. use procedure Figure C.
ORIENTATION BRG. BORE PILOT BORE LWR. BRG. CUP

B
B
L
B
B U B
P
L
P
B U F3 OUTSIDE DIM
0°
45°
90°
135°
B0+B45+B90+B135 B
C L=
B
C U=
P
C L = C U=
P
F3 AVG =
4
CL + CU B
D =
P
D =
2
F 0 + F 45 + F 90 + F135
F3 AVG =
4
Bearing/Bore Interference = F3 AVG - DB = ___________
Figure J. Lower Jrnl. Housing Bore Dimns. & Interference.

XRP 883/903
Shaft Outside Diameter Measurements. Use a Micrometer.
ORIENTATION L.R. BRG. SEAT UPP. BRG. SEAT SEAL RING SEG
K L M N
0°
45°
90°
135°
0 + 45 + 90 + 135
AVG =
4
Shaft straightness measurements, mount shaft on live centers & use a dial indicator
to check at K,L,M & N . Dial indicator reading should not vary more than 0.001”
(0.025mm) for out of round.
ORIENTATION K L M N
0°
45°
90°
135°
180°
225°
270°
315°
Figure K Shaft out of Round and Straightness

XRP 883/903
Orientation 1st TRIAL 2nd TRIAL 3 rd TRIAL

GAP GAP GAP
0°
45°
90°
135°
180°
225°
270°
315°
0 + 45+.........135
AVG =
8
UPPER JOURNAL HOUSING FLANGE GAP
Bearing end play, Step 5.12

Shim Pack = AVG Gap + + End play ' A' Table - 2
2.
SHIM PACK = ( )+( )+( )
SHIM PACK = ( ) mm
Figure L. Journal Housing Flange Gap Shim Thickness.

XRP 883/903
TRIAL INDICATOR INDICATOR READINGS AVG. READINGS

No Load Lifted No. Load LIFTED POSITION
1 A HA HA + HB
H1 AVG =
2
B HB
2 A HA H2 AVG =
B HB
3 A HA H3 AVG =
B HB
4 A HA H4 AVG =
B HB
5 A HA H5 AVG =
B HB
H AVG + H AVG + H AVG + H4 AVG + H5 AVG
1 2 3
HAVG = =
5
Note : Refer to Procedure in text, Item 12.0
Bearing End Play, Step 5.12

Permitted Assembly End Play = + (End Play ‘A’ Table 2)
2
HAVG = Permitted Assembly End Play ± 0.001 “
( ) = ( )+( ) ± 0.001”
If HAVG is not within ± 0.001” of the permitted assembly end play, the journal housing
flange gap shims should be readjusted.
Figure M. Journal Assembly End - Play.

XRP 883/903
Journal Head to Journal Shaft Assembly
1. Lubricate the threads on the journal shaft with anti-seize compound and install
the lock nut.
2. Slug lock-nut tight using the supplied wrench and a sledge hammer. Scribe the
nut and the head with chalk and strike the wrench with three additional solid
blows of the sledge hammer. If the nut moves less than 3 mm ,it is sufficiently
tight. If the nut moves more than 3 mm the tightening process should be
repeated. Lock the set-screw on the lock nut once it is properly tightened.
3. Stamp the serial number of the journal assembly which is located on the end of
the journal shaft on the journal head for future identification.
Adjustment of the Seal Air Gap
ORIENTATION 1st TRIAL 2nd TRIAL 3 rd TRIAL

GAP GAP GAP
0°
45°
90°
135°
180°
225°
270°
315°
0 + 45+...........315
AVG GAP =
8
Upper Journal Head Skirt Flange Gap
Fig. N. Air Seal Ring Upper Flange Gap

XRP 883/903
1. Remove cap screws and drop the journal head skirt until it is seated squarely on
the taper of the upper journal housing.
2. Measure the gap between the journal head and the skirt flange in eight places.
Record and average on the work sheet next page.
3. The thickness of the shim stack is equal to the average gap measured in Step 2
minus twice the desired air gap. The air gap should be 1 mm. Therefore, the
shim stack thickness will be the average gap minus 2 mm.
4. Measure each stack of split shims with a micrometer.
5. Install the split shims between the journal head and the journal head skirt flange.
Install the cap screws and torque them to 13 Kg-m. With Loctite # 242 applied to
the threads.
6. Check the seal air gap between the upper journal housing and the journal head
skirt in eight places. Each measurement should be 1 mm ±0.13 mm.
Clean all the mating machined surfaces with copper wire brush and apply a
thin film of oil. Place the three Journal Assemblies together with Grinding Roll,
trunnion Shaft and End Caps through the Separator Body Journal Opening. Install the
Roller Journal Assembly by carefully lowering it through the Journal Opening in the
Separator Body. Remove long rod along with fastening plates and nuts for securing
the Trunnion Shaft and 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.
Tighten all bolts connecting separator body and Journal Opening Cover. DO
NOT INTERCHANGE THE JOURNAL OPENING COVERS AS THESE HAVE BEEN
MATCH MACHINED WITH THE SEPARATOR BODY. Draw up tight the other bolts
connecting the Trunnion Shaft End Caps and the Journal Opening Cover. Proceed
with the remaining setting up of ring roll clearance and spring compression as
described elsewhere in this manual.

Mill Optimization Bowl Mill
883/903 XRP
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 for the mill optimization:
1) Area of opening around the bowl for primary air flow to maintain desired
differential pressure across the bowl, with low mill rejects.
2) Height of the venturi collar to maintain the desired pulveriser fuel fineness and
differential pressure across the bowl.
3) Vary the journal 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. If required change the trunnion end cap position too.
Note: Mill needs to be stopped for a short while for the above (Point 5) work,
but it gives better fineness and mill output.
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.

Planetary Gear Box Bowl Mill
883/903 XRP
11.0 Planetary Gear Box & Lube Oil System Operating Instructions
11.1 Measures before startup
Warranty shall only be given if the initial startup was carried out by BHEL
specialists or by specialists of the plant engineer after prior consultation with
BHEL.
Note: Any attempt to make the drive move will be regarded as startup!
Especially in case of maintenance work on the mill where the mill is rotated and the
gear unit rotates, too, the Operating Instructions should be observed.
11.1.1 Checks before startup

After the assembly and before the first cold dry run, check all drive parts and remove
all residues of material, tools and assembly aids.
The oil supply system function is tested before delivery. Before the dry run of
the mill, the electric interlock between oil supply and mill drive motor should
be checked.
Keep the shut-off valves on the cooling water side open.
Before a dry run of the mill, check the electric interlock between gear unit and mill
drive motor.
Furthermore, the complete drive should be checked according to the following check
list:
- Was the foundation made properly?
- Are the foundation bolts tightened securely?
- Are the foundation bolts of the main gear unit tightened according to the
specifications?
- Is the gear unit pinned properly?
- Is the milling bowl mounted properly?
- Were the directions of rotation of motor and gear unit (see direction of rotation
arrow) checked?
- Were the adhesive tapes on the labyrinth seals removed?
- Were all pipes assembled and cleaned according to the assembly instructions?
Caution: Make absolutely sure that the oil feed pipes are clean as any
contaminations in the pipes would be led through the gear unit before they can be
caught in the filter of the oil supply system!
- Are the pipes and tubes mounted and arranged correctly?

- Were the pipe and tube connections checked for leaks?

883/903 XRP
Pay special attention to the flange connections of the suction pipe. When air enters,
the oil tends to foam.
- Does the oil in the oil container (tank of the oil supply system or the gear unit,
respectively) show little foam on the surface? A thin layer of foam of approx. 3 ... 4
mm (0.12–0.16 inch) on the surface is permissible.
When foam develops, check all suction pipe connections. If necessary, contact the
manufacturer of the oil.
- Is the oil container filled with oil up to the respective marks?
- Is the pad bearing filled with oil up to the mark?
- Are all monitoring devices connected according to the circuit diagram?
- Was the function of the oil supply tested?
- Were test reports made on the following measurements:
¾ Was the function of the interlock checked according to the interlocking
diagram on the description (see Section 6”PLOS Operating Procedure”)?
¾ Are the flow controls, pressure switches and temperature sensors set to the
correct values and were they checked for proper function?
¾ Is the cooling water inlet/ outlet open?
For further checks, see the Operating Instructions of couplings, motors, oil supply
system and mill.
11.1.2 De-preservation of the gear unit

For de-preservation of the gear unit, remove all preservative coatings by running-in
oil by means of flushing.
The gear unit is preserved with Rustop 286. The following work and flushing times
are required:
- Install the breathers according to the cross section drawing.
- Remove the adhesive tape from the labyrinth seal of the input shaft and the output
flange.
11.1.3 Flushing
11.1.3.1 General
A clear difference must be made between ”flushing” before the initial startup and
”flushing” before/ after repair and maintenance work.
11.1.3.2 Flushing before the initial startup
The purpose of flushing before the initial startup is to minimize the residues of
previously used lubricating oils or preservative oils.
The selected operating lubricating oil shall be used for flushing.
- Put in selected lubricating oil.
- Flushing times: run the oil pump of the lubrication circuit for 6 hours at least for
flushing or the filter is found reasonably clean, which ever occurs later.
Caution: After flushing, drain the oil completely through the oil drain cocks on the
gear unit and the oil supply system. The oil may only be re-used as flushing oil.

883/903 XRP
Before re-using it, the flushing oil should be filtered. The flushing oil can be
reused for a maximum of 8 gear units.
11.1.4. Oil filling
Caution: After flushing and before the initial startup of the gear unit, the gear unit &
Lube oil system must be filled with oil after parts like pressure gauge, thermometer,
pipes, etc. if supplied separately or which were removed during transport are re-
installed.
For the oil to be used see the Operating Instructions on lubricants (see Section 7.0).
See the data sheet (see Section 7.0) for information on oil grade, oil viscosity and
required oil quantity.
Caution: The oil level marks on the oil level indicator of the main gear unit, the pad
bearing or the oil supply system tank only are relevant for determining the oil quantity
to be filled in.
The quantities given on the nameplate of the gear unit are reference values only.
Oil pumps and all oil filling bores marked with special information plates should be
filled with oil before starting-up the gear unit. For this purpose, there is an oil filling
hole on the oil pump or on the pressure pipe or on oil filling hole is marked with an
information plate. Carefully close these oil filling holes so that the oil pump does not
draw in air or that any oil leaks.
1 Oil drain of gear unit 4 Oil level of pad bearing

2 Oil drain of pad bearing 5 Air filter of gear unit
3 Not applicable 6 Air filter of pad bearing

883/903 XRP
Detailed illustrations of the gear unit will be found in the drawings in the gear unit
documentation.
11.1.4.1 Filling the oil
The gear unit can be filled with oil in different ways dependent on the equipment of
the oil supply system.
- The oil to be put in must be filtered beforehand or on filling with a filter of nominal
gauge 25 µm (0.0010 inch).
- The oil supply system is equipped with a tank and the oil is to be filled-in through the
oil tank of the oil supply system.
11.1.4.2 Oil quantity

11.1.4.2.1 Oil quantity for flushing
For flushing, the gear unit & piping the tank of the oil supply system should be filled
with sufficient quantity of oil to run the oil pump of the oil supply system for this
purpose. Depending on the gear unit, this oil quantity can be between 50 % and 100
% of the total oil filling quantity.
11.1.4.2.2 Oil quantity for the initial startup
Fill in so much oil that the prescribed oil level is reached on the oil level indicators of
the gear unit (see cross section drawing) and the oil supply system tank with the
gear unit stationary and the oil pump of the oil supply system running.
After the pre-run of the oil supply system (see item 4.1), the gear unit can be rotated.
11.1.4.3. Oil supply system
The main gear unit is supplied with lubricating and cooling oil by the oil supply system
(see Operating Instruction”Oil supply system”).
11.1.4.4. Startup
11.1.4.4.1 Pre-lubrication phase
Before startup, the gear unit should be pre-lubricated by the oil supply system for 15
minutes at least.
During this phase, anti-friction bearings, axial tilting pad bearings and toothed
systems are adequately supplied with lubricating oil for the initial startup.
11.1.4.4.2 Initial startup
When all relevant Operating Instructions have been followed, the gear unit can be
started.
Caution: The gear unit must run on part load, if possible, for several hours. If a part
load is not possible, the gear unit can also be run without load. If no malfunctions are
detected, the load can be increased gradually up to full load in adequate time
intervals and under permanent supervision.
During this phase, pay special attention to the following:

a) Noises

883/903 XRP
If possible, check the gear unit for abnormal noises (anti-friction bearings) with a
stethoscope in different places during this time.
b) Oil leakages
Check all flange connections of the oil pipes for oil leakages and re-seal them, if
necessary!
11.1.5. Shut-down
- Switch off the drive assembly to shut down the gear unit.
Caution: Secure the drive assembly to prevent accidental switch-on!
- We recommend to let the oil supply system run during short interruptions of
operation. For a longer standstill, we recommend to let the oil supply run for
approximately 60 minutes to prevent heat from building up. In case of sudden
standstill, e. g. due to a power failure, there is no danger of damage.
- Close the shut-off valves in the coolant inlet and outlet lines (only for gear units with
oil cooling system). In case of water-oil cooler, drain the water, to avoid freezing,
especially in winter.
- In the case of gear units which are to be operated in a saline environment or next to
salt water the oil supply system must always continue running to avoid corrosion
damages. Moreover the gear unit should be turned every week for 15 minutes by
main motor.
Note: During longer periods of outage the gear box has to be flushed for 3 hours and
to be turned for 15 minutes, weekly. If it is to remain out of service for longer than six
months, fill it with preservative, see item 5.1.
11.1.5.1 Preservation for prolonged shut-down

11.1.5.1.1 Preservation with preservative
Before longer storage times, the gear unit should be run with no load with
preservative.
We recommend the preservatives listed in the table below for preservation of the
gear unit:
Storage stability Preservative Special measures
up to 24 months SERVOMESH SP320 OF Plug the gear unit air tight,

IOC. replace air filter with plug
screws (replace before
startup)
more than 24 months SERVOMESH SP320 OF Re-preserve gear unit as up
IOC. to 24 months
Table 7.0: Preservation measures when using mineral oil
11.1.5.1.1.1 Internal preservation procedure

883/903 XRP
- Shut down the gear unit and drain the oil as described in Section”Maintenance and
repair”.
- Fill with preservative up to the upper mark of the oil level indicator through the
ventilation hole or the hole in the inspection cover.
- Close the venting hole or the cover opening, respectively.
- Run the gear unit briefly with no load. To do so, start the oil supply system for a time
minimum 1 hour.
- The gear unit must start once. If this is not possible, the gear unit must be rotated at
least 1 revolution on the output flange. This can be done by turning the input shaft D1
manually.
- Remove the oil drain plug and drain the preservative into a suitable receptacle and
dispose of in accordance with the regulations.
Caution: There is a risk of scalding from hot preservative emerging. Wear protective
gloves.
- Replace the oil drain plug.
- Seal labyrinth seals on input shaft and output flange with adhesive tape.
11.1.5.1.1.2 Internal preservation by oil filling

- Alternatively to 11.1.5.1.1.1 the gear unit can be filled with operating oil up to the
top.
- For any further details on required measures please contact BHEL.
11.2 Operation
During operation, the gear unit should be checked for:

- Excessive operating temperature
- Any changes in gear unit noises
- Possible oil leakage at the housing and the shaft seals
and
- Correct oil level (see also Section ”Startup”).
Note: To check the oil level, the gear unit should be shut off and the oil pump of the
lubrication circuit of the oil supply system should be running.
The oil level should be between the two marks on the oil level indicator. If the oil level
is below the lower mark of the oil level indicator, top up oil if necessary.
Caution: If irregularities are detected during operation or if a pressure switch, a

temperature switch or a volumetric flow switch in the oil supply system initiates an
alarm and later on a trip signal, the drive assembly should be shut off immediately.
The cause of the malfunction should be determined with the aid of the Trouble
Shooting Table.

883/903 XRP
The Trouble Shooting Table lists possible malfunctions, their causes and suggestions
for remedying them.
If the cause cannot be determined or there is no facility for repair with suitable own
equipment, we recommend calling in BHEL for service fitters .
Control information:
See Section 6, “PLOS Operating Procedure” for control information.

883/903 XRP
11.3 General troubleshooting
Note: Malfunctions occuring during the warranty period which necessitate repair of
the gear unit may only be remedied by BHEL service personnel.
Even after the warranty period has elapsed, Customers are recommended to consult
BHEL Service Division in respect of malfunctions for which causes cannot be
ascertained clearly.
Malfunctions Causes Remedy

Temperature rise at Oil is over aged Check when last oil change
bearing points was carried out, change oil if
necessary. See Section 10.
Oil pump defective Check oil pump, replace if

necessary. Observe the
operating instructions for motor
oil pump.
Bearing(s) defective Call in BHEL service. Check

bearing(s),replace if necessary.
Excessive operating Oil is over aged Check when last oil change
temperature was carried out, change oil if
necessary. See Section 10.
Oil filter clogged Clean oil filter, observe the

operating instructions for oil
filter
Oil extremely contaminated Change oil. See Section 10.

necessary. Observe the
operating instructions for motor
oil pump.
Defective cooler Check cooler, replace if
necessary.
Defective cooling water supply. Observe operating instructions

for Cooler.
Check cooling water supply.
Observe Operating Instructions
for cooler.

883/903 XRP
Malfunctions Remedy Causes

Gear unit oiled up Insufficient sealing of the Check seals, replace if
housing necessary.
cover or the joints. Seal joints.
Pressure control trips Oil level too low Check oil level, top up oil if
alarm necessary

necessary
Operating temperature too high See above
Oil filter clogged Clean oil filter

for oil Filter.
Volumetric flow Oil too cold Warm up oil
meter trips alarm
Oil filter clogged Clean oil filter
for oil filter
Pipes leaking Check pipes, replace if

necessary
Temperature at Oil filter clogged Check oil filter for clogging

temperature sensor
in pad bearing (part Oil supply of pad bearing too Check the setting of the relief
800) too high low valve
Monitoring devices defective. Check all monitoring devices.

883/903 XRP
11.4 GEAR BOX LUBE OIL SYSTEM FLUSHING
1. General
Servicing comprises all measures for maintaining and re-establishing the desired
condition as well as for determining and evaluating the actual condition of technical
devices of the system.
In this sense, servicing is a comprehensive generic term which can be divided into
the three areas of inspection, maintenance including lubrication, and repair.
Note: All maintenance and repair work should be carried out with due care and only
by thoroughly trained personnel.
The instructions to “Safety instructions” in Erection manual Planetary Gear Box
Section should be observed.
Caution: Before carrying out maintenance, repair or other work on the gear unit, the
operator of the system should make sure that the drive motor is secured to prevent
an accidental startup. Furthermore, the operator shall refer to the relevant
regulations to prevent accidents at the place of installation.
2. Flushing
2.1 General
Principally, a difference should be made between ”flushing” before the initial startup
and ”flushing” before/after repair and overhaul work.
2.2 Flushing before/after repair/overhaul work
Flushing before or after repair/overhaul work is intended to remove contaminations

(coal fowling, oil foam, abraded particles).
To enhance the flushing effect, use suitable Detergent System Cleaner to desolve
residues or reduce coagulated substances.
The selected operating lubricating oil should be used, later on, for oil flushing.
- Put in flushing oil/ recommended lube oil.
- Flushing time: run the oil pump of the lubrication circuit for 6 hours at least for
flushing or till the filter is found reasonably clean, which ever occurs later.
Caution: After flushing, drain the oil completely through the oil drain cocks on the
gear unit and the oil supply system. The oil may only be re-used as flushing oil.
Before re-using it, the flushing oil should be filtered. The flushing oil can be reused for
a maximum of 8 gear units.

883/903 XRP
3. Inspection
The inspection comprises all measures to determine and evaluate the actual
condition. It is recommended to use a check list. A suggested check list is given
below:
Measures Frequency/ Periods Remarks

Check the oil filter of the oil every 4 weeks visual indication, see also
supply system for Operating Instructions for
clogging. oil supply system.
Check the instruments every 4 weeks

installed on site (oil
temperatures & pressures)
Check the oil-carrying weekly

pipes for leaks.
Check the oil level on the weekly See also Operating

oil level indicators on the Instructions for oil supply
oil supply system. system
Check every 4 weeks

- for external noises
- the temperature
- the protective equipment.
Check the attachments annually see Operating Instructions

such as couplings, for single components.

883/903 XRP
4. Maintenance
Maintenance comprises all measures to maintain the desired condition.
Measures Frequency Remarks

Cleaning the filter every 4 weeks or if filter see Operating
inserts element is dirty Instructions for the
individual components
Test oil for water after approx. 400 service hours see item 4.1.1
content / at least once a year
First oil change after after approx. 1000 service see item 4.1.2
start–up hours or depending on result
of oil analysis
Oil analyses every 1000 service hours see item 4.1.1
subsequent oil depending on result of see item 4.1.2

changes oil analysis; (without oil
analysis every 18 months or
7.0 000 operating hours)
8.0
Cleaning the air filters every 12 weeks see item 4.1.3
(breather filter)
Checking tightness of Simultaneously with oil change see item 4.1.4

foundation bolts
Carry out complete approx. every 2 years along see item 4.1.5
inspection of the gear with oil change
unit
Maintenance work on see also Operating

the oil–supply unit Instructions for oil supply
unit
Couplings: every 26 weeks see Operating

Instructions for the
individual components

883/903 XRP
4.1 Description of maintenance and repair work
4.1.1 Examining oil for water content / making of oil analysis
Detail information on examining the oil for water content or on making of oil analysis
can be obtained from the lubricant manufacturer or from BHEL service department.
- The oil sample for an oil analysis has to be taken downstream the gearbox in
the drain line of the lubrication system while the system is running. A suitable
connection can be provided on the oil drain piping (for example an oil drain
cock).
- The minimum amount required is 1 liter of oil in a clean and for transportation
purposes closeable safety vessel.
- The decrease in oil vicosity should not exceed 10% of the value of the new oil.
- Oil purity must be between 15/13/10 (high availability) and 17/15/12 (normal
availability) according to ISO 4406.
- Limit values for oil contamination:
Material Limit content possible source

[ mg/kg ]
Iron (Fe) 40 Internally toothed girth gear, teeth, cage of a
bearing
Chrome (Cr) 4 Rolling bearing, teeth
Aluminium (Al) 4 Oil pump bearing
Copper (Cu) 4 cage of a bearing
Lead (Pb) 6 Axial thrust slide bearing, pump bearing
Tin (Sn) 2 Axial thrust slide bearing, pump bearing
Nickel (Ni) 2 Teeth
Zinc (Zn) 10 Zinc–based primer. Is sometimes used as an
additive. In this case please contact BHEL.
Silicon (Si) 20 Cement dust or other environmental factors
Water (H2O) 0,10 % Condensed water; water oil–cooler defective
Table: Material–related contamination limit values
4.1.2 Carrying out oil changes

Caution: When changing the oil, the gear unit should always be filled with the oil
grade previously in use. Mixing oils of different grades or makes is not permissible.
In particular, synthetic oils shall not be mixed with mineral oils or different synthetic
oils. When changing over from mineral oil to synthetic oil or from synthetic oil with a
particular base to synthetic oil with another base, the gear unit must be flushed
thoroughly with the new oil grade.

883/903 XRP
When changing the oil, the housing and, the oil cooling system must also be cleaned
thoroughly by flushing with oil to remove oil sludge, abraded particles and residue of
old oil. For this purpose, the same oil grade should be used as is in use for operation
of the gear unit. Viscous oils should be warmed beforehand. Only when all residues
have been removed, shall the fresh oil be poured in.
Note: The oil should be changed directly after shutting off the gear unit while the oil is
still warm.
- Shut down the gear unit by switching off the drive unit.
Caution: Secure the drive unit to prevent accidental startup.
Affix notice at the switch-on point.
- Place a suitable receptacle under the oil drain cock of the gear unit housing and the
pad bearing room.
- Unscrew the vent plugs of the oil drain cock and drain the oil into the receptacle.
- The oil shall be drained through the oil drain cocks.
1 Oil drain of gear unit 4 Oil level of pad bearing

2 Oil drain of pad bearing 5 Air filter of gear unit
3 Not Applicable 6 Air filter of pad bearing
Detailed illustrations of the gear unit will be found in the drawings in the gear unit
documentation.
Note: Dispose off the old oil according to the regulations on environmental protection.
Caution: There is a risk of scalding from the hot oil emerging.

Wear protective gloves.
- Screw in the screw plugs of the oil drain cocks.

883/903 XRP
Note: Check the condition of the seal washer (the seal washer is vulcanised onto the
screw plug); use a new screw plug, if necessary.
Note: Data such as oil grade, oil viscosity and quantity of oil required should be taken
from the rating plate (see Section 1”Technical data”).
Suitable oil grades will be found in the Operating Instructions for lubricants (see
Section 7.0).
The gear unit can be filled with oil in various ways, depending on the set-up of the oil
supply system. The suggested method is as given below:
- The fresh recommended lube oil shall be filtered with a suitable strainer/ filter of
nominal gauge 25 µm (0.0010 inch) before or while filling into the lube oil tank.
- From the lube oil supply system the oil is filled into the gear box through a
filter of nominal gauge 25 µm (0.0010 inch).
- Fill in so much oil that the specified oil level on the oil level indicators of the gear
unit (see Figure 4) and the oil supply system is reached with the gear unit stationary
and the oil pump of the oil supply system running.
Caution: Any oil escaping should be removed immediately with oil binding agent.
4.1.3 Cleaning the air filter

Every 12 weeks or when the air filter (breathing filter) is clogged, heavily.
Unthread the filter and clean it with petroleum benzine or similar detergents.
Caution: Be extremely careful when cleaning with compressed air.
Wear safety glasses!
Reinstall the dry air filter.
4.1.4 Checking the binding bolts for tightness

883/903 XRP
All binding bolts with metric thread according to DIN 13, sheet 20, of property
class 5.8 according to DIN 267 should be tightened to the following pre-
stressing forces.
Thread Pre- [lft Tightening [ft lbs] Pre-stressing

size stressing x104] Torque device
force [ Nm ] p hydraulic [ bar
[N] ]
M 20 71250 16,0 256 189

see the Operating
M 24 102500 23,0 443 327 Instructions of the
M 30 163750 36,8 906 668 manufacturer of
M 36 238750 53,7 1580 1165 the hydraulic
M 42 328750 73,9 2540 1873 pre-stressing
M 48 433120 97,4 3830 2825 device.
M 56 599370 134,7 6150 4536
M 64 792500 178,2 8940 6593
M 72 x 6 1000000 224,8 13000 9588
M 80 x 6 1218750 274,0 18060 13319
M 90 x 6 1593750 358,3 26030 19197
M 100 x 6 2000000 449,6 36120 26638
Table: Pre-stressing force, tightening torques, pre-stressing device p hydraulic
Note: Unserviceable screws should be replaced by new ones of the same property
class and type.
4.1.5 Complete gear unit inspection
The gear unit inspection should be entrusted to BHEL Service Division as by virtue of
vast experience, technicians can most reliably assess whether and which part of the
gear unit need to be replaced.
5. Repair
Repair comprises all measures to re-establish the desired condition after a

malfunction.
Caution: When carrying out repair work using electric welding at any points of the
unit, make sure that the welding current is not conducted through anti-
friction bearings or other moving connections and measuring devices.

883/903 XRP
Therefore, the welding current return cable should be directly connected to

the part to be welded.
When replacing components and larger sub-assemblies, make sure that they are
fastened and secured carefully to hoists to avoid hazardous situations.
Caution: Only use suitable hoists in perfect technical condition and suspension
devices with sufficient carrying capacity!
Do not stand or work below suspended loads!
6. Lubricants
See Section 7.0 for lubricants.
11.5 LIST OF EQUIPMENT
TYPE: KMP SIZE 280/300
Switching and monitoring functions as per:
Lubrication diagram : Figure 26

Gear Unit type: KMP 280 : Figure 4
Terminal diagram as per : Erection Manual (Fig 15)
Qantity Description Part-No. Manufacturer Tag. No.

4 Resistance thermometer 800 FLENDER
EL = 315 mm
Connection : G 1/2
Precision resistor : Double
PT 100 DIN IEC Kl.B
Four-wire circuit from
head
Degree of protection : IP
65
> 75 °C : WARNING
> 85 °C : MILL STOP

883/903 XRP
Temperature control of the rolling bearings

EL = 95 mm
Connection : G 1/2
PT 100 DIN IEC Kl.B
Four-wire circuit from head
Degree of protection : IP 65
for rolling bearing part no.
150
> "75" °C : WARNING
> "85" °C : MILL STOP
EL = 230 mm
Connection : G 1/2
PT 100 DIN IEC Kl.B
Four-wire circuit from head
Degree of protection : IP 65
for rolling bearing part no.
151
> "75" °C : WARNING
> "85" °C : MILL STOP
Locking guidelines
The mill motor should be released if the following conditions are met:
Temperature of pad bearing (800) < 75 °C

Temperature of bearings (806 / 808) < 75 °C
A warning should be output if one of the following conditions is met:
Temperature of pad bearing (800) > 75 °C

Temperature of bearings (806 / 808) > 75 °C
The mill motor should be stopped if one of the following conditions is met:
Temperature of pad bearing (800) > 85 °C

Temperature of bearings (806 / 808) > 85 °C

883/903 XRP
Caution! After switching off the gear unit, the oil supply system should at least for
another hour to avoid the accumulation of heat.
Caution! For further control information, see the Operating Instructions “PLOS
Operating Procedure Section 6”.
11.6 PULVERISER LUBE OIL SYSTEM
General configuration
The oil supply system described below is used for oil cooling and/or lubrication of a
gear unit (see supplier’s “O&M Manual of Lube Oil System”).
The oil supply system has been subjected to an exhaustive trial run.
The oil supply is ensured by means of two pump assemblies, one of which acts as a
standby pump.
The pump draws the oil from the oil reservoir of the oil supply system.
A filter is provided in the oil circuit for filtration of the circulating oil.
The quantity of heat generated by losses, which is not dissipatable by convection, is
dissipated by means of a cooler.
Filtered and re-cooled oil is then passed back to the gear unit via a pressure line.
The modules described above are mounted on the oil reservoir of the oil supply
system.
1. Filling with oil

The following provisions are recommendations 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 reclosed and sealed.
Only oil 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”).

883/903 XRP
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 carefully
purified.
Fresh oil in accordance with the specification should be used for startup (see
Operating Instructions” Gear unit”).
Fill the oil supply system tank with oil in accordance with the Operating Instructions”
Lube Oil System”.
Fill until the specified oil level is reached on the oil level gauge with the pump
stationary (see Operating Instructions” Lube Oil System”). The pump should then be
started.
Before initial startup of the gear unit, the oil supply system must be run for at least 15
minutes to allow all oil compartments to fill up (see Operating Instructions” Gear
unit”). Stop the oil supply system again after wards and correct the oil level if
necessary.
All pipes, screw unions and flanges should be tightened, this applying particularly to
suction lines (to prevent air being drawn into the system). Leaks should be resealed.
2. Oil pump
Caution: Low-pressure oil pumps are only permissible for one direction of rotation.
The direction of rotation of motors must agree with the direction of rotation
arrow on the pump.
3. Oil cooler
The water supply connections for the oil cooler should be established by the
customer/operator.
If there is risk of frost and the oil supply system will be out of service for any
considerable time, the cooling water should be drained off.
The special Operating Instructions for oil coolers should be observed from O&M
Manual of Lube Oil system supplier.

883/903 XRP
4. Startup
Before starting up the oil supply system, check that the requirements in accordance
with these Operating Instructions and the requirements in accordance with the gear
unit Operating Instructions have been fulfilled.
Caution: 1.0 Before startup, filling with oil must be carried out.
2.0 Before startup, check the cooling water circuit!
3.0Stop valves are to be secured to prevent accidental closure.
Before startup and after repairs and maintenance work, the oil supply system is to be
cleaned thoroughly to remove any impurities. This applies particularly to water (e.g.
rain water and leakage of the cooler) in order to prevent mixture of water and oil.
All pumps, filters and coolers must be suitably bled.
Caution: The works setting of the pressure relief valves/safety valves carried out by
us at our works may NOT be altered, as it is not used to regulate the
pressure and rate of flow. It is intended ONLY as overload protection!
11.7 Disturbances, Reasons and Remedy
1. General
The malfunctions listed below are only intended as points of reference for
troubleshooting. With such a complex system, all other modules must always be
included in troubleshooting. If the cause of the malfunction is not clear, we
recommend therefore that the specialist personnel of BHEL be consulted in tracing
possible causes.
2. Possible malfunctions
Disturbance Reasons Remedy

Lubricating oil temperature No cooling water Rectify cooling water supply
too high Too little cooling water Increase cooling water supply
Cooling water too hot
Cooler contains air Bleed cooler
Cooler dirty Replace cooler

Clean or replace contaminated
pipe bundle.

883/903 XRP
Lubricating oil temperature Gear unit not yet warmed Wait

too low up to operating temperature
Too much cooling water Reduce cooling water supply

Cooling water too cold
Lubricating oil pressure too Filter clogged Switch over to clean filter and
low clean or replace filter and filter
element
Pressure limiting valve Correct oil pressure at

wrongly set pressure limiting valve
Pressure limiting valve Repair or replace pressure

defective limiting valve
Suction line blocked Clean suction line
Pump aspirating air Check suction line and remedy

any leaks
Lubricating oil temp too high check cooler performance.
Oil viscosity too low Check viscosity and if

necessary fill with correct oil
Pump defective Switch over to standby pump,

Pump drive defective repair or replace defective
pump
Lubricating oil pressure too Gear unit not yet warmed Wait
high up to operating temperature
Pressure limiting valve Correct oil pressure at limiting

wrongly set valve
Pressure limiting valve Repair or replace pressure

defective limiting valve
Lubricating oil lines to and Locate blocked line and clean

at gear unit blocked
Oil viscosity too high Check viscosity and if

necessary fill with correct oil

883/903 XRP
Clearly apparent or Pipes dirty Clean pipes

accumulated filter residues (scale, welding residues)
Abraded particels from gear Check gear unit (bearings,

unit tooth systems, alignment) and
rectify defects
Lubricating oil dirty Carry out oil change
Oil tank dirty Clean oil tank and carry out oil
change
Abraded particles from Switch over to standby pump,

defective pump repair or replace defective
pump
Oil consumption too high Leak in pipes, connections, Tighten screws
valves or gear unit Reseal
Shaft outlets on gear unit Renew seal rings

leaking
Cooler leaking Seal cooler or renew cooler

element
Filter leaking Seal filter
Oil tank leaking Seal oil tank

883/903 XRP
11.8. Spare parts stock
A stock of the most important replacement and wearing parts is essential for
satisfactory operation and serviceability of the gear unit at all times.
Please use the Spare Parts List for ordering spare parts.
For further information, see the Spare Parts Drawing contained in the Spare Parts
List.
Only original replacement parts supplied by BHEL are covered by the warranty.
Caution: Attention is drawn expressly to the fact that replacement parts and
accessories not supplied by BHEL have not been tested or approved by
BHEL. Installation and/or use of such products can therefore under certain
circumstances alter the structurally specified properties of the gear unit and
can as a result impair active and/or passive safety. BHEL accept no liability
of any sort for damage caused by the use of replacement parts and
accessories which are not original BHEL; their use will invalidate warranty
in every respect.
Please note that special production and supply specifications frequently exist for
individual components and that BHEL always supply replacement parts in
accordance with the state of the art and the latest legal requirements.
The following data should be stated when ordering replacement parts:
SPARE PARTS LIST-KMP 280/300
PART QTY. DESCRIPTION WEIGHT REMARKS

NO. (Kg’s)
G* 0202 1 ST INTERN.TOOTHED GEAR 308,0
WHEEL KMP 280
E 0040 1 ST OIL LEVEL INDICATOR 0,2

E 0044 1 ST BALLCOCK 0,6
E 0048 1 ST BALLCOCK 0,6
E 0056 2 ST AIR FILTER 0,1
G 0099 1 ST PAIR OF MATING BEVEL 479,0
WHEELS KMP 280 i=4,
G* 0100 1 ST BEVEL PINION SHAFT 118,0
G* 0402 1 ST BEVEL GEAR 237,0
E 0123 1,07 O-RING 0,1
M
E 0124 1 ST O-RING 0,1

883/903 XRP
E 0128 1 ST SHIM RING, 2-PIECE 7,0

341X440X15 S235JR
E 0130 1 ST LABYRINTH RING 10,0
E 0132 1 ST O-RING 0,1
E 0150 1 ST PAIRED TAPER ROLLER 34,0
BEARINGS
E 0151 1 ST ROLLING CONTACT BEARING 35,4
G 0200 1 ST PLANETARY CARRIER 800,0
E 0208 4 ST O-RING 0,0

E 0214 1 ST ADAPTER RING 300X340X15 1,6
E 0253 1 ST THRUST SLIDE BEARING 684,0
G 0290 1 ST FLANGE (Rotary Table) 3.085,0
E 0300 3 ST PLANETARY AXLE 31,0
E 0301 1 ST PINION SHAFT 33,5
G 0302 3 ST GEAR WHEEL 96,4
E 0390 1 ST COUPLING SLEEVE 24,4
E 0400 1 ST SHAFT 195X555 1.6587 87,5
E 0428 1 ST SHIM RING, 2-PIECE 6,4
E 0450 1 ST PAIRED TAPER ROLLER 21,0
BEARINGS
E 0800 4 ST RESISTANCE THEMOMETER 0,3
EL=265
EL=095
EL=230

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OPERATION

BOWL MILL-XRP 883

Bharat Heavy Electricals Limited

Publication No. HY-BM-01-2008

BHARAT HEAVY ELECTRICALS LIMITED I

Sl. No. Description Page No.

BHARAT HEAVY ELECTRICALS LIMITED II

BHARAT HEAVY ELECTRICALS LIMITED III

The instructions contained in this manual give an outline of the correct

BHARAT HEAVY ELECTRICALS LIMITED 1

CHECKLIST OF “DO’S” - BOWL MILL

1. Check lubrication with reference to proper level and cleanliness of

2. Check sufficient raw coal in the raw coal bunker.

5. Check for proper ring-roll setting.

8. Check that no boiler trip condition exists.

9. Check sufficient ignition energy is available in the furnace.

10. Check that mill discharge valve is in open condition.

BHARAT HEAVY ELECTRICALS LIMITED 2

13. Check that tramp iron spout valve is open.

15. Check that cold air gate is open.

1. Check oil flow and pressure to planetary gear box.

2. Check for proper mill outlet temperature.

BHARAT HEAVY ELECTRICALS LIMITED 3

3. Check for proper mill air flow.

4. Check for all bearing and oil temperatures.

6. Check for mill rejects (quality and quantity).

8. Carry out raw coal analysis at routine intervals.

10. Check for any abnormal sound.

i) During Normal Shut-Down :

1. Cool the mill during and after shut-down.

3. Keep cold air regulating damper slightly throttled to approximately 5° after

4. If water freezing weather is present and if mill shut-down is of long duration

BHARAT HEAVY ELECTRICALS LIMITED 4

drain the water from oil cooler.

ii) During Emergency Shut-Down :

CHECK LIST OF “DON’TS” - BOWL MILL

A. BEFORE START-UP AND OPERATION :

2. Do not start the mill with discharge valve closed.

BHARAT HEAVY ELECTRICALS LIMITED 5

5. Do not start the mill without seal air supply.

6. Do not continue operation of mills with high mill outlet temperatures.

3. Do not use direct flame torch for heating bearing assemblies.

BHARAT HEAVY ELECTRICALS LIMITED 6

9. Do not weld on high strength non-weldable components of planetary gear

BHARAT HEAVY ELECTRICALS LIMITED 7

3. PROTECTION AND PRESERVATION OF MILL COMPONENTS

STORAGE AND PRESERVATION OF MILL COMPONENTS

3.1 PLANETARY GEAR BAX:

Refer to Planetary Gear Box section.

3.2 SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:

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

3.3 PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL:

3.4 DRIVE COUPLINGS:

BHARAT HEAVY ELECTRICALS LIMITED 8

3.5 MILL DISCHARGE VALVES ASSEMBLY:

These valves carry several integrally mounted instrumentation components like

3.6 INTERIOR AREAS:

3.7 MILL MOTOR: