OPERATION & MAINTENANCE MANUAL XRP 1003 BOWL MILL CUSTOMER | NTPC LIMITED provect | RIHAND SUPER THERMAL POWER PROJECT, Stage-IIl, UNIT-V,VI, 2X500 MW Bharat Heavy Electricals Limited LiL Ramachendrapuram- Hyderabad Publication NO. HY-BM- 008-2013 Rev.00 Date: 25/05/13© The copyright on all documents, drawings and other instruments are the property of Bharat heavy Electricals Limited. These shall not be used without their express written permission in any form or part thereof for any other purposes than for which it is sent to receiver. PUBLICATION NO: HY=BM- 008-2013 REV. NO: 00, DATE: 25/05/2013 ISSUED BY PULVERISERS ENGINEERING BHARAT HEAVY ELECTRICALS LIMITED RAMACHANDRAPURAM::HYDERABAD INDIABow! Mill CONTENTS XRP1003, CONTENTS SI.No. Description Page No. 1.0 INTRODUCTION 1 2.0 TECHNICAL DESCRIPTION 2 2.1 Mill Technical Data 2 2.2 Major assemblies... 3 3.0 OPERATION. - 5 3.1 Check list of do’s bow! mill 5 3.2 Check list of dont’s bow! mill 8 3.3 Principles of operation. 10 34 Operating parameters. . ssn 12 35 Start up. “4 3.6 Normal shut down. 15 3.7 Emergency shut down ov 15 38 Start up after emergency shut down 16 39 Mill fires. v7 3.10 Fire extinguishing procedures 19 3.11 Mill rejetes 2 4.0 PULVERISER LUBE OIL SYSTEM 4 4A Journal san 4 4.2 Miscellaneous and idle mills 25 4.3 Pulveriser lube oil system operating instructions, a 43.1 Filling with oil a 43.2. Oil pump.... 2B 433 Oilcooler. 29 434 — Start up. 29 44 Pulveriser lube oil system operating procedUte.....nsnno 30 44.1 Temperature measurement. 30 44.2 Pressure measurement. 31 443 Level measurement. 31 444 Flow measurement. 31 45 PLOS pre-commissioning checks... cosseeeennnenne 31 4.6 Pulveriser lube oil system operation. ....cssssssesseesssseeense 33 BHARAT HEAVY ELECTRIGALS LIMITEDBow! Mill CONTENTS XRP1003, sl.no. Description page no. 4.7 Mill start permissive conditions from the PLOS......... oo 3 48 Alarm’s list... . oe 35 5.0 PLANETARY GEAR BOX. 97 5.1.1 Measures and checks before statt Up..nsnnnnnnnnnnnne 9 5.12 De-preservation of gear unit soo sn 39 513 Flushing 39 SAA OF1fIILING onimnnnnnnnnnninnnnnnninnanninninnnnn 39 BAS Start Upson 2 5.1.6 Shut down 8 5.2 Operation. 44 5.3 General trouble shooting... 44 54 Inspection... ov - “ 46 55 Maintenance 47 56 Repai 53 57 Lubricants... 54 58 List of equipment. 54 59 Locking guide lines. 56 5.10 Spare parts stock. 58 6.0 MILLOPTIMIZATION 60 7.0 TROUBLESHOOTING ....cscssssessssessssseennseen 2 8.0 PULVERISED COAL SAMPLING ANALYSIS..... . 66 8.1 Non Iso-kinetic sampling method.....sssssessssseesssseeeee 66 8.2 Adjustment of fineness. 68 83 Mill wear life assessment. - . n2 9.0 MAINTENANCE. 3 10.0 GENERAL MAINTENANCE. 4 10.1 Instruction for interference fit. 7 11.0 PREVENTIVE MAINTENANCE. ..secsssssesssssesssseessseeene 78 111 Mill clearances... 7B 11.2 Journal spring compression. 85 11.3 Checking spring compression 89 BHARAT HEAVY ELECTRIGALS LIMITEDcomes oa CONTENTS SI.No. Description Page No. 11.4 Inspection task. 90 120 COMPONENT MAINTENANCE. 2 12.1 General disassembly and re assembly of components... 2 12.1.1 Planetary gear box withdrawal and reinstallation procedure. % 12.1.2 Journal cover removal. 98 121.3 Discharge valves...ssssessssesssseesseeenseseens 100 12.14 — Separator body removal 101 12.1.5 Bowl & bowl hub removal 102 122 General disassembly and re assembly of other components... 105 12.2.1 Renewal of bull ring segments......cssesesssseeusseeenseeees 105 12.22 Airport ring replacement. 106 12.23 Roll removal. 107 12.24 Journal opening frame liner replacement. 108 1225 Journal head liner assembly replacement. 109 123. Journal shaft assembly with double upper journal bearing. 0 124 Journal head to journal shaft assembly......sesssseeessee 135 125 Adjustment of the seal air gap. 136 13.0 STORAGE AND PRESERVATION. 138 13.1 Preservation with preservatives. 138 13.2. Spare roller journal assembly preservation. 139 13.3. Preservation of journal assemblies in mill. 140 13.4 Drive couplings. 140 135 Mill discharge valve assembly. 140 137 Mill motor. 140 138 — General 140 140 SPARES. 141 14.1 Recommended spares list....... cecseneesnsee 143 BHARAT HEAVY ELECTRIGALS LIMITEDBow! Mill CONTENTS are LIST OF TABLES Table Description Page No. _N 1. Lubrication schedule 36 2. Check list for evaluating the condition of PGB lube oil system 46 3. Material-related contamination limit values 48 4. Pre-stressing force, tightening torques. 82 5. Maintenance of PGB lube oil system 53 6. List of equipment KMP size-300 55 7. Spare part list by KMP 280/300 58 8 Disturbances, reasons and remedy 6 9. Mill performance/ fineness record 7 10. Spacer grinding dimensions of Timken 123 11. Spacer grinding dimensions of Torrington 123 12. Pulveriser Jounal Lift Load And End Play 124 13. Recommended preservatives for PGB 139 BHARAT HEAVY ELECTRIGALS LIMITEDBowl Mill CONTENTS XRP1003. Fig Description No. A Bow! Mill cross-section B Bowl Mill General Arrangement Drawing c Planetary gear box assembly D Mill foundation drawing E Deflector Control Assembly F Removal and Weight of Mill Parts G Gear box withdrawal procedure H Bull ring segment assy. 1 Tightening Torque for Fasteners J Roll Removing Fixture K Special Tools L Journal opening frame liner assembly M Protective Seal Application (17 deg tilt) venturi vane N Pulveriser Lube Oil System Scheme ° PF Sampling Arrangement P Journal shaft assembly Q Journal head and trunnion shaft assembly R Journal assembly s Scrapper assembly T Mill side housing and Base assembly U Journal pressure spring assembly BHARAT HEAVY ELECTRIGALS LIMITED7a Bow! Mill PEA — INTRODUCTION XRP1003 1.0 INTRODUCTION Bow! 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 bow! 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 bow 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 @ 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 Bow! 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 1003 Bow Mill where X~3 Phase, 50 Hz Supply, R— Raymond (Inventor of the mil), P — Pressurized, 100 ~ 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 ELECTRIGALS LIMITED 7TECHNICAL DESCRIPTION Bow! Mill XRP1003 2.0 TECHNICAL DESCRIPTION 24. MILL TECHNICAL DATA: Total Weight Of inTons ‘Type Of Load ‘Mill Capacity( in TPH) Spring rate ( Kg/Cm) Spring Preload (in Ks) Mill Qutlet Temperature. Fineness XRP 1003, 130 Moderate Shock Load 60.9 5359 9500 66°C-90°C ‘70% through 200 mesh Note: The given mill pacity is for design coal ie for Total Moisture = 20% & Hard Groove Index( HGI}= 55 The Bowl mill is one of the most advanced designs of coal pulveriser presently manufactured by BHEL. It posses the following advantages over other type of pulverisers i) Low power consumption ji) High Reliability ii) Minimum maintenance time required iv) Wide capacity with good tumdown ratio v) Ability to handle wide range of coals vi) Quite and less vibration operation BHARAT HEAVY ELECTRICALS LIMITEDBow! Mill TECHNICAL DESCRIPTION XRP1003 2.2 MAJOR ASSEMBLIES: a) PLANETARY GEAR BOX AND BOWL HUB ASSEMBLY: Planetary gear box is used to give required torque to the bow! & bow! hub assembly which is directly mounted and bolted to the gear box top table. The direction of torque transmission in planetary gear box changed from horizontal to Vertical. The bow! assembly consists of Bull ring assembly (mounted on the bowl), Skit & Scrapper Assembly and vane wheel assembly (attached to the bow). b) MILL SIDE AND LINER ASSEMBLY: | The hot primary air for drying and carrying Pulverized coal enters into the mill side and air inlet housing. The mill side and liner assembly is insulated intemally to prevent heat loss from primary air to the atmosphere, or to the gearbox. BHARAT HEAVY ELECTRICALS LIMITEDBow! Mill TECHNICAL DESCRIPTION XRP1003 c) SEPARATOR BODY ASSEMBLY: ‘The separator body holds the components that give necessary grinding pressure(journal spring assembly), journal assembly and also the components that direct the coarse sized coal particles back to the bow! for re grinding, d) ROLLER JOURNAL ASSEMBLY: ‘The roller assembly consists of journal shaft, journal bearings, and journal housings, Grinding roll, journal head, trunion shaft assembly. a e) MILL DISCHARGE VALVE ASSEMBLY: ‘The mill discharge valve assembly consists of four multiport outlet and mill discharge valves mounted on the multiport outlet plate. Air cylinders operate the flaps in the mill discharge valves. Solenoid valves and limit switches are provided to effect and indicate the open or close position of the flap. This assembly does the distribution of pulverised fuel into four pipes and also it isolates the mill from boiler when required, BHARAT HEAVY ELECTRICALS LIMITED a7) Bowl Mill OPERATION ar 3.0 OPERATION: 34 Pulverization is the method of preparing raw coal for complete burning, Mechanically pulverizing coal into fine powder enables the pulverized fuel to burn like an oll or gas in a steam generator, thus allowing more efficient combustion. The Pulverised coal Transported by hot air and introduced directly into the boiler furnace zone for combustion. CHECKLIST OF “DO'S” - BOWL MILL Before start up: 1. Check lubrication with reference to proper level and cleanliness of lubricants. 2. Check sufficient raw coal in the raw coal bunker. 3. Check for proper operation of mill discharge valves, hot air shut off gate, hot air damper and cold air damper and seal air system. 4, Check that all three roller journal pressure springs are compressed to the same spring pre-load of 9.5 tons to start with and further adjustment as per given Coal (HGI)Hard groove 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. BHARAT HEAVY ELECTRICALS LIMITED 3Bow! Mil OPERATION aed 12, 13. 14. 15. 16. 17. 18. 19. 20. 24 Check that cooling water line is open and cooling water supply present to the mill lube oil coolers. Check that tramp iron spout valve is open. Check that raw coal bunker outlet gate and/or inlet gate to feeder is/are open. Check that cold air gate is open. Check that adequate primary air pressure is available in the hot air header. After the mill lube system has been started at least 15 minutes before, check up the oil low, temperature and pressure to the planetary gear box. Feeder must be started only after the mill has been started and warmed up. Check that there is proper coal flow into the mill (an annunciation for the no coal flow from raw coal feeder will come when there is no coal flow to the mill) 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 attzins self sustained combustion. 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 (cilicoal) elevation is cut in until the furnace draft has stabilized, to avoid any surging back of furnace gases into the coal laden pulverisers in case of furnace pressurisation. This procedure should be employed until all such coal laden pulverisers are either taken into regular service or emptied completely. Normal operation : Check cil flow, temperature and pressure to planetary gear box. Check for proper mill outlet temperature. Check for proper mill air flow. Check for all bearing and oil temperatures. BHARAT HEAVY ELECTRICALS LIMITED e7) Bow! Mill OPERATION XRP1003 Check for pulverised fuel fineness at routine intervals. Carry out ring-roll setting and/or classifier setting based on the PF fineness lab results, Check for mill rejects (quality and quantity) Check for status of wear on all wear parts at least once in two months whenever mill is down for more than one shift. Carry out raw coal analysis at routine intervals. Check level and quality of lube Oil in lube oil tank and journal assemblies regula. 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 supply, pressure and flow. ‘SHUT-DOWN : During Normal Shut-Down 1 2, D 1 Cool the mill during and after shut-down. Run the mill for at least 5 minutes until coal is completely emptied before shut down. Keep cold air regulating damper slightly throttled to approximately 5* after the mill has stopped, If water freezing weather is present and if mill shut-down is of long duration drain the water from oil cooler. uring Emergency Shut-Down : 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. BHARAT HEAVY ELECTRICALS LIMITED 77) Bow! Mill OPERATION XRP1003 (2) Shut the hot air shut off gate, place the feeder on manual control and continue feeding coal at a high rate without overloading the mil. (0) _Iffire 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 til all the signs of fire are gone. 2. Ifa fire exists completely through the mill and fuel piping, clear all personnel from the area surrounding the mill, ts 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. Use in emergency firefighting water to quench the fire 3. When a fire has been extinguished and the mill has cooled, stop the mill, open inspection doors carefully and thoroughly clean the interior of the mill of any accumulation including coal water slurry. Check lubricants for evidence of carbonizing. Check all parts where the fire has occurred for any damage, especially the O Rings & Oil seals, 3.2 CHECK LIST OF “DON'TS” - BOWL MILL A. BEFORE START-UP AND OPERATION 1. Don't start the mill, if any permissive, inter locks or protection is found not ‘working/by passed. 2 Do not start the mill without ensuring proper lubrication, cooling water supply to the oll coolers, 3. Do not start the mill with discharge valve closed. 4. Do not start the feeder without the mill running in warmed up condition. BHARAT HEAVY ELECTRICALS LIMITED a7) Bow! Mill OPERATION XRP1003 5. Donot start the feeder without ensuring proper 1 energy in the furnace. 6. Donot start the mill without seal air supply. 7. Donot continue operation of mills with high mill outlet temperatures. 8 Do not run the mill continually with abnormal noise, high vibration, or with high bearing & oil bath temperatures and only one or two spring adjusting stud deflecting. 9. Donot start the feeder without checking ring-roll clearance of the mil 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. Donot use steel! hammers directly on grinding rolls and bull ring segments. 3. Donot 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 bow! or any part attached to it unless the welding machine is grounded to the bowl to prevent arching across bearing assemblies. 7. Do not use 230 volts supply lights, and electrical grinders inside the mill (Use 24 volts supply for hand lamps as a safety measure). 8 After a mill fro, do not open access door until all eymptome 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. BHARAT HEAVY ELECTRICALS LIMITED o7) Bowl Mill OPERATION ar 3.3 10. Do not interchange bevel pinion shaft and bevel gear wheel. Both these are matched set. Itis recommended to replace them as a set. It is recommended to carry out maintenance on the gearbox intemals 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. 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 bow. Heated air enters the mill side housing below the bow! and is directed upward around the bow! 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 bow, 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 bow 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 {ramp iron or other material to the tramp iron discharge opening. BHARAT HEAVY ELECTRICALS LIMITED 707) Bowl Mill OPERATION ar The tramp iron spout is fitted with a valve. Under normal operation this valve remains open and material is discharged into a sealed pyrite hopper. The valve is closed only while the hopper is being emptied. DO NOT close the valve on the tramp iron spout to prevent the discharge of rejects, If the valve is closed for an extended period, material normally discharged will be retained in the mill side housing and be ground by the scrapers, scraper guards and holders. This produces excessive wear on these parts and creates a potential fire hazard. If coal is discharged into the pyrite hopper, this indicates overfeeding, too litle Grinding pressure on the rolls, too low an air flow or too low a pulveriser outlet temperature. Excessively wor 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 bow! 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 coalair mixture leaving the classifier should be maintained as high as possible within the safe temperature limit for that particular coal. Too high an outlet temperature may lead to a pulveriser fire, ‘The safe temperature limit for a given coal depends on the percentage of volatile ‘matter, moisture and pyrites either individually or a combination of them in the coal. BHEL pulveriser systems are designed to perform effectively with coals with a wide range of moisture content and grindabilty. In order to obtain rated capacity from the pulveriser, i is necessary to have sufficient hot air entering the pulveriser to dry the BHARAT HEAVY ELECTRICALS LIMITED 7ri Bowl Mill OPERATION ar coal, sufficient pressure on the rolls to pulverise it and proper setting of the classifier deflector vanes to obtain fineness reasonably close to that for which the pulveriser is designed. Operating experience will help determine the 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 3.4 OPERATING PARAMETERS: To meet the safe and optimized mill operating criteria, the following operating parameters must be established for the given coal '), MILL AIR FLOW: Mil should be operated at the design air flow at all loads. Operating at higher air flow will cause excess wear and upset the performance of classifier etc. If mill is operated at lower air flow it may result in coal rejects, low bowl differential pressure, excess fineness, coal settlement etc. The air flow is controlled by the simultaneous operations of hot and cold air dampers. ii). MILL OUTLET TEMPERATURE: For good pulveriser performance, the temperature of coal air mixture leaving the classifier should be maintained as high as possible within the safe temperature limit for 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 mill 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 55° C and 65° C. If a high volatile coal has high sulphur content then also the maximum safe operating temperature may be as low as 60°C. BHARAT HEAVY ELECTRICALS LIMITED @ri Bowl Mill OPERATION ar Environmental conditions (rainy seasons) 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 bow! 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. il, PULVERISED FUEL FINENESS: The degree of pulverised coal fineness required depends upon the volatile content of coal and the furnace size. This is specified for each unit. Operating the mills at higher fineness increases the wear rate and reduces capacity of the mill. The fineness can be controlled by operating the classifier vanes, after carrying out an optimized spring compression setting, air flow setting and ring roll setting for the mill iv), MILL CAPACITY: The capacity of mill depends on the hard groove grindabilty index, the moisture content of coal and the pulverised fuel fineness. TECHNICAL POINT IF LOW CALORIFIC VALUE OF COAL IS USED, THE AMOUNT OF COAL REQUIRED BY THE STEAM GENERATOR IS MORE, THUS MILL CAPACITY IN TERMS OF HEAT INPUT. TO STEAM GENERATOR DECREASES, The indications of mill overloading are the following, out of which one or more indication may be present during mill overloaded condition: a) High mill motor current. b) High bow! differential pressure. cc) Lowmill outlet temperature. d) Mill rejects having large amount of coal. 5 START - UP: Before the pulveriser motor circuit is energized and the pulveriser is run under power for taking up coal firing. The following items must be checked for completion/readiness. BHARAT HEAVY ELECTRICALS LIMITED 3ri Bowl Mill OPERATION ar Pre —Start up checks: a) Pulveriser / motor coupling alignment. b) Roll - ring clearance. ©) Lubrication system. d) Deflector blades setting, ©) Seal air supply adequacy. f) - MDVs and Tramp iron spout valve is in open position. 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, ‘Temperature and Flow is established to the bearings and gears in gear box with the help of the instrumentation provided in the lube oil lines. TECHNICAL POINT ‘THE LUBE OIL PUMP MUST BE RUNNING AT LEAST FOR 15 MINUTES BEFORE GIVING ‘A PULVERISER START PERMISSIVE. AFTER THE PULVERISER 1S STARTED, THE OIL, TEMPERATURE SHOULD BE MAINTAINED BETWEEN 30° CTO 50°C. 5. Open the hot air shut off gate. The control system should adjust the hot and cold air control dampers to give the proper air flow and allow the pulveriser to warm up to a temperature range of 60° C to 70° C and exact temperature set point to be established later, depending upon operating experience with the given coal. ©. Establish the required ignition energy. Then start the feeder with a fairly high feed rate. When the pulveriser begins to grind, (this is indicated by an increase in the motor amperes.) reduce the feed rate to the desired setting (minimum feed rate on the first pulveriser). Increase the feed rate as per unit load demand. The BHARAT HEAVY ELECTRICALS LIMITED 4ri Bowl Mill OPERATION ar second and successive mills should be placed in service when the loading on the ‘operating pulveriser(s) reaches 80%. 3.6 NORMAL SHUT DOWN: If possible coo! the mill before shutting it down, ji) 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 til the mill outlet temperature reaches 50° C. Then stop the feeder. iil) Run the mill for another few minutes till it becomes empty and then shut down. iv) Cold air damper should be throttled to approximately 5° open after the mill stops. A minimum quantity of cold air flow must be maintained through the mill at all times. NOTE:- Chances of mil fire would be reduced if the above steps are followed, v) When the pulveriser is shut down for any length of time in cold weather, it Is advisable to drain the water from the lube oil coolers. If for any reason ice has formed in the tubes, a careful examination should be made before Starting-up to make sure that the tubes have not ruptured allowing cooling water to contaminate the oil, 3,7 EMERGENCY SHUT DOWN: On loss of furnace ignition or another condition that requires an automatic or manual emergency fuel trip, the mill motor should be tripped immediately. ‘Stopping the motor should trip the feeder; close the hot air shut off gate and initiate a minimum inert sequence, if required, provided the mills are equipped with an inerting system. BHARAT HEAVY ELECTRICALS LIMITED %7) Bowl Mill OPERATION ar 3.8 ‘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 lear 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. Nor! an inerting system is installed, start the mill steam inerting system for ‘one minute immediately after shut down and again before opening the pulveriser inspection doors. The inerting steam line isolation valves must be properly closed before the mill man hole doors are opened. CAUTION A HOT MILL WILL DISTILL COMBUSTIBLE GASES, FROM RESIDUAL COAL. THEREFORE TAKE PRECAUTIONS WHEN OPENING THE MILL FOR LEANING. 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. ) Purge the unit ii) Establish ignition energy in the boiler for the mill to be operated, iil) 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. BHARAT HEAVY ELECTRICALS LIMITED 76Bow! Mil OPERATION aed 39 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. v) Start the mill and leave it ‘ON’ for several minutes to remove all coal. If mill is to be kept in service start the feeder before mill is empty. Then open the hot air shut off gate and modulate hot air damper to bring the mill to normal operating temperature. vil) Repeat (ji) to (vi) above for all mills containing coal. When mills have been ‘emptied and/ or placed back in service, the discharge valves of remaining idle mills should be opened to allow the required minimum cold air flow through them, MILL FIRES: Causes: ‘The usual causes of pulveriser fires are: i) ii) Excessive Mill Outlet Temperatures: Do not permit the mill outlet temperature to exceed 95° C regardless of the material being pulverised. 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. Excessive Accumulations of Pyrites or Coal on the Mill Bottom or in the Air inlet to the Mi BHARAT HEAVY ELECTRICALS LIMITED 7Bow! Mil OPERATION aed iv) wy ‘The valve on the tramp iron discharge spout should normally be open to allow the free discharge of foreign materials into the Pyrites collection system. The valve may be closed momentarily for the removal of pyrites from the collecting hopper. Accumulation of debris in the air inlet should be removed whenever the mill is open for inspection. Scraper and guard assemblies clearances with mill side liner insulation cover plate shall be re- set periodically or replaced. Excessive Accumulations of Coal Areas above the Bowl: This condition is usually brought about by lack of maintenance. Worn liners may allow coal to accumulate in an area faster than the normal air flow will remove it or to reach areas where it cannot be removed by the normal air flow. Coal can also be trapped by foreign material bridging a section of the mill through or over which the coal would normally move. 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 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 BHARAT HEAVY ELECTRICALS LIMITED 8ri Bowl Mill OPERATION ar 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) b) Aniigh or rapidly increasing mill outlet temperature without other cause. Paint peeling from the mill and or piping. 3.10 FIRE EXTINGUISHING PROCEDURES: Ifa mill system fire does occur, perform the following: a) b) °) 4) Regardless of the fire location DO NOT shut down the mill and NEVER open any mill inspection doors unti all evidence of the fire has disappeared. 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. Place the feeder on manual control and continue feeding coal at a high rate without overloading the mil, Closing the hot air gate will frequently extinguish the fire, but if the mill temperature continues to rise: Cool the mill by admitting steam or water. BHARAT HEAVY ELECTRICALS LIMITED 79v7 Bow! Mill OPERATION Sarina NOTE: On pressurised mill where the air ducts and mill feeders are sealed, it is e) f) 9) hy 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 DUCT AREA SHOULD BE CLEARED OF ACCUMULATED MILL REJECTS AT EVERY OPPORTUNITY. Shut off the steam or water being admitted to the system. Stop the feeder. 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, Clear all personnel from the area surrounding the mill and its associated feeder and fuel piping. ‘Shut off the feeder and allow the mill to clear itself of fuel. BHARAT HEAVY ELECTRICALS LIMITED 20ri Bowl Mill OPERATION a 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. 1) Open all inspection doors (see WARNING) and hand hole covers. 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 the checks and be sure to remove any accumulations of coal or coke. ©) Check the oil seals on each journal assembly. ) Check the journal assembly lubricants and replace them if there is evidence of carbonizing. Once everything is satisfactory, the mill may be retumed to service. CAUTION TAKE CARE WHEN OPENING MILL INSPECTION DOORS, THE MILL MAY BE PRESSURIZED. CHECK THAT THE HOT AND COLD AIR SHUT OFF GATES, THE MILL AND. FEEDER SEAL AIR VALVES AND THE PULVERISERS DISCHARGE VALVES ARE CLOSED. THE MILL MOTOR, BREAKER SHOULD BE RACKED OUT AND TAGGED. THE PYRITE HOPPER DOOR SHOULD BE CAREFULLY CRACKED AND THEN COMPLETELY OPENED, ‘CAREFULLY REMOVE THE BOLTS OF THE INSPECTION DOOR. EYE PROTECTION (GLASS (OR FACE SHIELD) IS RECOMMENDED. BHARAT HEAVY ELECTRICALS LIMITED a7) Bowl Mill OPERATION ar 31 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 bow! and drop through the mill side air inlet housing. Then, scrapped by scrappers through tramp iron spout to pyrite hopper, from where they are periodically removed. Any ‘material having a bulk density above 1.7 tons/ m* should be rejected. (For coal bulk density is 1.2 TO 1.6 tm’) However sometimes the raw coal is also rejected. This could happen due to: 1) Over loading of mill. li) 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 stil temperature cannot be maintained above 65° C reduce the coal feed rate, BHARAT HEAVY ELECTRICALS LIMITED @Bow! Mil OPERATION aed ii ¢) Journal spring pressure too low - Check and set the journal springs as detailed under maintenance section. 4d) Jamming or breaking of journal springs. ) Jamming of rol; all rolls should rotate freely on an empty bowl. ) Improper setting of ring-roll gap or higher gap between journal spring assembly and journal head. 9) Improper mill differential pressure. Increase the same by adding air restriction rings/ blocks on the airport ring. Wor out parts: a) Roller and bull ing segments, b) Gaps - fil up all voids and gaps between the liners by suitable filler Compound (for ex. Dum Dum paste). BHARAT HEAVY ELECTRICALS LIMITED 3rym Bow! Mill E777] PuveriseR Luse oll sysTEM XRP1003 4.0 PULVERISER LUBE OIL SYSTEM 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 oll 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. 44 JOURNAL The Roller Journals are lubricated by means of a self-contained circulation system, The oll 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 oll return holes where the cycle is completed. The upper journal housing is provided with a triple lip type seal to prevent oil leakage. The joumals are kept clean by seal air brought through flexible tubing to holes provided in the Trunnion shaft and journal head for this purpose. (Refer figure- 11e). This inward moving air prevents dust from getting into the bearings. ‘The Roller Journals should be filled with the recommended oil (see Lubrication ‘Schedule-Table-1) through the fill connection at the top of the journal assembly). Brush or blow any dustidirt from the top of the Journal Shaft. Remove the cover and plugs from the journal opening cover and journal shaft. Check the oil level with a dip stick. Dip stick must touch the bottom. Fill the roller journal with oil to the level shown on the oil instruction plate attached to the journal opening cover land tighten the plug (refer Figure.12-e.) Pour the oil steadily to prevent air lock. ‘BHARAT HEAVY ELECTRICALS LIMITED 2Bow! Mil PULVERISER LUBE OIL SYSTEM xRP1003 42 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 andi 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. MISCELLANEOUS & IDLE MILLS: ‘The Deflector Regulators and Journal Stop Bolts should be greased as per recommended Bow! 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, ‘BHARAT HEAVY ELECTRICALS LIMITED 2v7 Bow! Mill i PULVERISER LUBE OIL SYSTEM XRP1003 BOWL MILL OIL COOLER - COOLING WATER REQUIREMENT PER MILL IN LITRES / MINUTE AT 32°C WATER TEMPERATURE Recommended Inlet Pressure 4.5 Kglom, Pressure Drop in Cooler 2 0.7 Kglom?, Water quantity per cooler 15 mir 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- 1003 45 135 810-910 GEAR CASE OIL QUANTITY: Mill Size ‘Quantity of lubricant per mill XRP- 1003 1100 ‘BHARAT HEAVY ELECTRICALS LIMITED 26rym Bow! Mill E777] PuveriseR Luse oll sysTEM XRP1003 4.3. PULVERISER LUBE OIL SYSTEM OPERATING INSTRUCTIONS GENERAL CONFIGURATION ‘The oil supply system described below is used for oll cooling andor lubrication of a gear unit (see Vendor's “O&M Manual of Lube Oil System’) The oil supply system has been subjected to an exhaustive trial run. The oll 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 ofthe oil supply system. A filter is provided in the oil circuit for filtration of the circulating oil. The quantity of heat generated by losses, which is not dissipatable by convection, is dissipated by means of a cooler. Filtered and re-cooled oil is then passed back to the gear unit via a pressure line. The modules described above are mounted on the oil reservoir of the oil supply system. 4.3.4. 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'-section -5).. In all cases, before startup, the gear unit/ol supply system should be filed with oil (see Operating Instructions” Gear unit’ -section -6). After filing, the filler openings should be properly reclosed and sealed. Only oil in accordance with the specification should be used (see Operating Instructions" Gear unit section -5). Mixing cils of different manufacturers is NOT permissible. To remove residues of preservatives which can lead to oil foaming, the oil supply system alone and followed by system together with the gear unit should be flushed before startup (see Operating Instructions” Gear unit’ -section -5). ‘BHARAT HEAVY ELECTRICALS LIMITED avm Bow! Mil Oi PULVERISER LUBE OIL SYSTEM XRP1003 ‘The oll must then be drained carefully from the oll 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 oll is to be used in another system, it should first be carefully purifiedifitered. Fresh oil in accordance with the specification should be used for startup (see Operating Instructions” Gear unit” -section -6). Fill the oil supply system tank with oll in accordance with the Operating Instructions" Lube Oil System’- section -6. Fill until the specified oil level is reached on the oil level gauge with the pump stationary (see Operating Instructions” Lube Oil System’- section -6). The pump should then be started. Before initial startup of the gear unit, the oil supply system must be run for at least 18 minutes to allow all oil compartments to fill up (see Operating Instructions” Gear unit” section -5). Stop the oil supply system again after wards and correct the oll 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. 43.2. Oil pump Low-pressure oll 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, 4.3.3, OIL COOLER ‘The water supply connections for the oll cooler should be established by the operator. ‘BHARAT HEAVY ELECTRICALS LIMITED 2Bvm Bow! Mil affa PULVERISER LUBE OIL SYSTEM XRP1003 If there is risk of frost and the oil supply system will be out of service for any considerable time, the cooling water should be drained off. ‘The special Operating Instructions for oil coolers should be observed from O&M Manual of Lube Oil system of vendor. 4.3.4 STARTUP 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, filing with oil must be carried out. 2.0 Before startup, check the cooling water circuit! 3.0 Stop valves are to be secured to prevent accidental closure. Before startup and after repairs and maintenance work, the oil supply system is to be cleaned thoroughly to remove any impurities. This applies particularly to water (e.g, rain water and leakage of the cooler) in order to prevent mixture of water and cil. All pumps, fiters and coolers must be suitably bled. NOTE: The works setting of the pressure relief valvesisafety valves carried out at works may NOT be altered, as it is not used to regulate the pressure and rate of flow, Its intended ONLY as overload protection! ‘BHARAT HEAVY ELECTRICALS LIMITED 2vi Bow! Mil Oi PULVERISER LUBE OIL SYSTEM XRP1003 4.4 PULVERISER LUBE OIL SYSTEM OPERATING PROCEDURE The Pulveriser lube oil system (PLOS) consists of a oil tank, 2x100 % ‘Screw pump & motor, basket filter, oil cooler etc. Lube oil pump capacity is 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. A heater (HFCO1 AHO01) provided in the oil tank keeps the oil temperature in the required range, provided the pump is ON. The following instrumentation is provided in the PLOS for interlocks & protection, alarm and indication. 4.4.1 TEMPERATURE MEASUREMENT: RTD's (Duplex PT 100) with temperature transmitter shall be provided in the lube oil system - a) Two No. on the lube oil tank (HFCO1 CT153, CT154). b) Two No.’s at the cooler outlet (HFCO1 CT1S1, CT152). Six No.’s RTD’s (Duplex PT 100) with temperature transmitter are also provided on the gear box to measure the temperature of input shaft bearings (2nos-HFCOL CT (024, 025), the thrust pad bearing (4 nos.- HFCO1 CT020 TO 023). ‘Temperature gauges are provided- a) One on the oil tank (HFCO1 CT 353), b) One each at the cooler inlet & outlet (HECO1 CT351, 352), 4.4.2 PRESSURE MEASUREMENT: ‘Two Pressure transmitters (HFCO1 CP1S1, 152) are provided in the lube oil line, after the oil cooler assembly. A differential pressure switch (HFCO1 CP251) is provided actoss the oil filter unit for alarm. An optical differential pressure indicator (local-HFCO1 CP3S4) is also provided. ‘BHARAT HEAVY ELECTRICALS LIMITED 30vi Bow! Mil Oi PULVERISER LUBE OIL SYSTEM XRP1003 Pressure Gauges are provided- 4) One each at the filter inlet and outlet (HFCO1 CP351, 352). ) One at the cooler outlet (HFCO1 CP353). 4.4.3. LEVEL MEASUREMENT: Two oil level Transmitters are provided in the oil tank (HFCO1 CL1S1, 152) and used in 1V2 logie for oil level low - pump trip & oil level low alarm, and also for oil level high alarm. One oil level gauge (HFCO1 CL351) is provided on the oil tank for visual check of “OIL LEVEL”. 4.4.4 FLOW MEASUREMENT: Two oil flow transmitters (HFCO! CF1S1, 152) are provided in the lube oil line after cooler assembly. 45 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. ‘BHARAT HEAVY ELECTRICALS LIMITED cyvi Bow! Mil affa PULVERISER LUBE OIL SYSTEM XRP1003 4.6 PULVERISED LUBE OIL SYSTEM 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 CT153 OR CT154) is greater than 10 deg. C the lube oil pump is permitted to start and at oil temperature value greater than 30 deg. C at the cooler outlet (HFCO1 CT151 OR 152) the mill is released for start. Below 30 deg. C oil temperature in the tank (HFCO1 CT153 OR CT154) the oil heater (HFCO1 AHO01) is energized, provided the pump is in service. The heater is de-energised at the tank oil temperature (HFC01 CT153 OR CT154) of 36 deg.C or when the lube oil pump is stopped. Charge one of the duplex filters and the oil cooler. Once the permissive conditions are met with, start the lube oil pump. The lube oil pump can be started either from Local push button OR from FSSS through remote push button and when pump stop command is not present, lube oil level Is not low (HFCO1 CL151 OR CL152) and tank oil temperature is not low (HFCO1 CT153 OR CT 154), The filter change over can be done on line for cleaning the fitter element. Cooler change over can be done on line too. 4,7 MILL START PERMISSIVE CONDITIONS FROM THE PLOS: THE MILL MOTOR CAN BE ENERGISED ONCE THE FOLLOWING PERMISSIVE CONDITIONS ARE FULL FILLED. 1.0 Lube oil temperature is adequate (HFC01 CT151 OR 152 > 30 deg. C) 2.0LP Pump ‘ON’ for more than 15 minutes and Lube oil pressure at cooler outlet is adequate (HFC01 CP151 OR 152 > 0.8 bar). 3.0 Lube oil filter not dirty (DPS-HFCO1 CP251 < 2.0 bar) 4.0 Lube oil flow to the gearbox is adequate (FT-HFC01 CF 151 OR 152 > 120 LPM). Any bearing temperature of Gearbox is within ALARM limits (ie <75 deg.C). ‘BHARAT HEAVY ELECTRICALS LIMITED @vi Bow! Mil affa PULVERISER LUBE OIL SYSTEM XRP1003 AUTOMATIC MILL TRIP CONDITIONS FROM PLOS: THE MILL IS TRIPPED IF ANY ONE OF THE FOLLOWING CONDITIONS ARE PRESENT. a) When both lube oil pumps are not ‘ON’ for more than 2 sec. b) Lube oil pump ‘ON’ and lube oil pressure (HFCO1 CP151 OR 152 < 0.5 bar) after cooler is very low, with a time delay of 15 seconds. c) Lube oll temperature after cooler is very high (HFCO1 CT151 OR 152 > 65 deg. C). 4) Lube oil flow to the gearbox is very low (FT-HFC01 CF151 OR 152 < 105 LPM), with time delay of 5 seconds. PUMP STOP CONDITIONS: ‘The lube oil pump stops’ shall be stopped when any one of the following conditions are acknowledged or satisfied. a) Lube oil level in tank is low (HFCO1 CLI151 OR CL152), b) Lube oil temperature in tank is low ( HFCO1 CT153 OR CT1S4 < 10 deg. 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 (HFCO1 CP1SI OR 152 < 0.8 bar), the standby pump to star. 2. When Pump-1 (Main) fails to start on giving start command, after 10 se delay, the stand by pump to start time ‘The running pump tripped on fault, immediately the stand-by pump to start QUTPUT CONTACTS PROVIDED: - Pulveriser Start Permissive ( to FSSS) = Pulveriser Stop Command (to FSSS) - Start lube of! pump (to motor starter) = Stop lube oil pump (to motor starter) = Both lube oil pumps not ON (to SOE in DDCMIS) ‘BHARAT HEAVY ELECTRICALS LIMITED 33vi Bow! Mil affa PULVERISER LUBE OIL SYSTEM XRP1003 4,8 ALARMS LIST: The following ‘ALARM’ signals are provided. i. Lube oil tank level low (HFCO1 CL151 OR CL152).. ii, Lube oil tank level high (HFCO1 CL1S1 OR CL1S2). iii, Lube oil flow to gearbox is low (HFCO1 CF1S1 OR 152 < 120 LPM) iv. Oil temperature after cooler high (HFCO1 CT 151 OR CT152 > 60 deg. C). v. Any lube oil pump ON for more than 60 sec. and Oil Pressure after cooler low (HFCO1 CP1SI OR CP152 < 0.8 bar). vi, Lube oil filter dirty (HFCO1 CP251 > 2.0 bar) vii. Lube oil temperature in tank low (HFCO1 CT1S3 OR CT154< 10 deg. C). ‘BHARAT HEAVY ELECTRICALS LIMITED a4oe G3LINM STVORILOSTA AAWBH LVEVHE batev. 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Mill gw PLANETARY GEAR BOX XRP1003 5.0 PLANETARY GEAR BOX 5.1 PLANETARY GEAR BOX OPERATING INSTRUCTIONS 5.1.1. MEASURES AND CHECKS BEFORE START UP Measures before startup Warranty shall only be given if the initial startup was carried out by BHEL specialists or by specialists of the plant engineer after prior consultation with BHEL. Note: Any attempt to make the drive move will be regarded as startup! Especially in case of maintenance work on the mill where the mill is rotated and the gear unit rotates, too, the Operating Instructions should be observed. Checks before startup After the assembly and before the first cold dry run, check all drive parts and remove all residues of material, tools and assembly aids. The oil supply system function is tested before delivery. Before the dry run of the mill, the electric interlock between oil supply and mill drive motor should be checked. Keep the shut-off valves on the cooling water side open. Before a dry run of the mill, check the electric interlock between gear unit and mill drive motor. Furthermore, the complete drive should be checked according to the following check list: ~ Was the foundation made properly? Are the foundation bolts tightened securely? ~ Are the foundation bolts of the main gear unit tightened according to the Specifications? = Is the gear unit pinned properly? ~ Is the milling bow! and bow! hub 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 of gear unit removed? BHARAT HEAVY ELECTRIGALS LIMITED 36Bow! Mill gw PLANETARY GEAR BOX XRP1003 - 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? Pay special attention to the flange connections of the suction pipe. When air enters, the oll 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 ol. = 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: > Was the function of the interlock checked according to the interlocking diagram on the description (see Section -4"PLOS Operating Procedure")? > Are the flow controls, pressure switches and temperature sensors set to the correct values and were they checked for proper function? > Is the cooling water inlet/outlet line isolation valves open? For further checks, see the Operating Instructions of couplings, motors, oil supply system and mil. 5.1.2. 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 BHARAT HEAVY ELECTRIGALS LIMITED 7Bow! Mill PLANETARY GEAR BOX SEO ~ 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. 5.1.3. FLUSHING General ‘A clear difference must be made between “flushing” before the initial startup and “lushing’ before! after repair and maintenance work. Flushing before the initial startup The purpose of flushing before the intial startup is to minimize the residues of previously used lubricating oils or preservative oils. The selected operating lubricating oil shall be used for flushing, ~ Putin selected lubricating oil. = Flushing times: run the oil pump of the lubrication circuit for 6 hours at least for flushing or the filter is found on visual inspection reasonably clean, whichever ocours 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 10 GEAR UNITS, .4 OIL FILLING After flushing and before the initial startup of the gear unit &Lube oil system must be filled with fresh oil after parts like pressure gauge, thermometer, pipes, etc. if supplied separately or which were removed during the gear unit transport are re-installed. For the oil to be used see the Operating Instructions on lubricants (See the data sheet (see Table 1.0) for information on oil grade, cil viscosity and required oil quantity. BHARAT HEAVY ELECTRIGALS LIMITED 38worn Bow! Mill ofa PLANETARY GEAR BOX XRP1003 PLANETARY GEAR BOX ASSEMBLY BHARAT HEAVY ELECTRIGALS LIMITED 39Bow! Mill PLANETARY GEAR BOX Sari a ‘CAUTION ‘THE OIL LEVEL MARKS ON THE OIL LEVEL INDICATOR OF THE MAIN GEAR UNIT, ‘THE PAD BEARING OR THE OIL SUPPLY SYSTEM TANK ONLY ARE RELEVANT FOR DETERMINING THE OIL QUANTITY TO BE FILLED IN. NOTE: The quantities given on the nameplate of the gear unit are reference values only. Oil pumps and all oil filing bores marked with special information plates should be filed with oil before starting-up the gear unit. For this purpose, there is an ol filing hole on the oil pump or on the pressure pipe or on oll filing hole is marked with an information plate. Carefully close these oll filing holes so that the oll pump does not draw in ar or that any oil leaks. 5.1.4.1. Filling the oil The gear unit can be filled with oil in different ways dependent on the equipment of the oil supply system. = The oil to be put in must be filtered beforehand or on filling with a filter of nominal gauge 25 1m (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. 5.1.42. Oil quantity a) Oil quantity for flushing For flushing, the gear unit & piping the tank of the oil supply system should be filled with just just sufficient quantity of oil to run the oil pump of the oil supply system for this purpose, Depending on the gear unit, this oll quantity can be between 50 % and 60 % of the total oil filling quantity. b) Oil quantity for the initial startup, Fill in so much oil that the prescribed oil level is reached on the oil level indicators of the gear unit (see cross section drawing-FIG A) and the oil BHARAT HEAVY ELECTRIGALS LIMITED %