O&M Manual XRP 1003

OPERATION & MAINTENANCE
M A N UA L
XRP 1003 BOWL MILL
CUSTOMER M/s DAMODAR VALLEY CORPORATION
PROJECT BOKARO ‘A’ TPP 1X500 MW
Publication NO. HY-BM-019-2013
Rev.00
Date: 06/11/13
C
The copyright on all documents, drawings and other instruments are the
property of Bharat heavy Electricals Limited. These shall not be used without
their express written permission in any form or part thereof for any other
purposes than for which it is sent to receiver.
PUBLICATION NO: HY-BM-019-2013
REV. NO: 00, DATE: 06/11/2013
ISSUED BY
PULVERISERS ENGINEERING
BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM::HYDERABAD
INDIA
Bowl Mill
CONTENTS XRP1003
CONTENTS
Sl.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 bowl mill.......................................................... 5
3.2 Check list of dont’s bowl mill ..................................................... 8
3.3 Principles of operation .................................................................. 10
3.4 Operating parameters ................................................................... 12
3.5 Start up ............................................................................................ 14
3.6 Normal shut down. ....................................................................... 15
3.7 Emergency shut down .................................................................. 15
3.8 Start up after emergency shut down .......................................... 16
3.9 Mill fires ................................................................................................... 17
3.10 Fire extinguishing procedures .............................................................. 19
3.11 Mill rejetcs ...................................................................................... 22
4.0 PULVERISER LUBE OIL SYSTEM ............................................. 23
4.1 Journal ............................................................................................. 23
4.2 Miscellaneous and idle mills ................................................................. 24
4.3 Pulveriser lube oil system operating instructions.............................. 26
4.3.1 Filling with oil ......................................................................................... 26
4.3.2 Oil pump......................................................................................... 27
4.3.3 Oil cooler......................................................................................... 27
4.3.4 Start up ............................................................................................ 28
4.4 Pulveriser lube oil system operating procedure ....................... 29
4.4.1 Temperature measurement…………………………………….. 29
4.4.2 Pressure measurement.................................................................. 29
4.4.3 Level measurement……………………………………………… 29
4.4.4 Flow measurement ........................................................................ 30
4.5 PLOS pre-commissioning checks……………………………… 30
4.6 Pulveriser lube oil system operation…………………………… 30

Bowl Mill
CONTENTS XRP1003
Sl. no. Description page no.

4.7 Mill start permissive conditions from the PLOS…………….. 32
4.8 Alarm’s list……………………………………………………….. 35
5.0 PLANETARY GEAR BOX ............................................................ 34
5.1.1 Measures and checks before start up.......................................... 34
5.1.2 De-preservation of gear unit ........................................................ 35
5.1.3 Flushing .......................................................................................... 35
5.1.4 Oil filling ......................................................................................... 35
5.1.5 Start up ............................................................................................ 38
5.1.6 Shut down ...................................................................................... 39
5.2 Operation ........................................................................................ 40
5.3 General trouble shooting .............................................................. 40
5.4 Inspection ....................................................................................... 43
5.5 Maintenance……………………………………………………… 43
5.6 Repair .............................................................................................. 51
5.7 Lubricants ....................................................................................... 51
5.8 List of equipment........................................................................... 51
5.9 Locking guide lines ....................................................................... 52
5.10 Spare parts stock………………………………………………… 53
6.0 MILL OPTIMIZATION………………………………………… 56
7.0 TROUBLE SHOOTING………………………………………… 58
8.0 PULVERISED COAL SAMPLING ANALYSIS …………….. 63
8.1 Non Iso-kinetic sampling method…………………………….. 63
8.2 Adjustment of fineness…………………………………………. 65
8.3 Mill wear life assessment………………………………………. 69
9.0 MAINTENANCE……………………………………………….. 70
10.0 GENERAL MAINTENANCE………………………………….. 71
10.1 Instruction for interference fit………………………………….. 73
11.0 PREVENTIVE MAINTENANCE………………………………. 75
11.1 Mill clearances…………………………………………………… 75
11.2 Journal spring compression……………………………………. 82
11.3 Checking spring compression…………………………………. 85

Bowl Mill
CONTENTS XRP1003
CONTENTS
Sl.No. Description Page No.
11.4 Inspection task……………………………………………………. 86
12.0 COMPONENT MAINTENANCE ................................................... 88
12.1 General disassembly and re assembly of components……… 88
12.1.1 Planetary gear box withdrawal and reinstallation procedure... 89
12.1.2 Journal cover removal……………………………………………. 93
12.1.3 Discharge valves………………………………………………… 95
12.1.4 Separator body removal………………………………………… 96
12.1.5 Bowl & bowl hub removal………………………………………. 97
12.2 General disassembly and re assembly of other components…. 99
12.2.1 Renewal of bull ring segments…………………………………. 99
12.2.2 Airport ring replacement……………………………………….. 100
12.2.3 Roll removal……………………………………………………… 101
12.2.4 Journal opening frame liner replacement…………………….. 102
12.2.5 Journal head liner assembly replacement……………………… 102
12.3 Journal shaft assembly with double upper journal bearing… 103
12.4 Journal head to journal shaft assembly………………………… 127
12.5 Adjustment of the seal air gap………………………………… 128
13.0 STORAGE AND PRESERVATION…………………………… 131
13.1 Preservation with preservatives………………………………… 131
13.2 Spare roller journal assembly preservation…………………… 132
13.3 Preservation of journal assemblies in mill……………… 133
13.4 Drive couplings…………………………………………………… 133
13.5 Mill discharge valve assembly………………………………… 133
13.7 Mill motor………………………………………………………… 133
13.8 General……………………………………………………………. 133
14.0 SPARES…………………………………………………………………. 134
14.1 Recommended spares list…………………………………… 136

Bowl Mill
CONTENTS XRP1003
LIST OF TABLES
Table Description Page No.
No.
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 For Property Class:5 51
4.a Pre stressing Force For Stud Tensioning For Property Class 40C8 52
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 63
9. Mill performance/fineness record 71
10. Spacer grinding dimensions of Timken 122
11. Spacer grinding dimensions of Torrington 122
12. Pulveriser Journal Lift Load And End Play 123
13. Recommended preservatives for PGB 138

Bowl Mill
CONTENTS XRP1003
LIST OF FIGURES
Fig No. Description
A Bowl 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.
I 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
O 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

Bowl Mill
INTRODUCTION XRP1003
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 1003 Bowl Mill where
X – 3 Phase, 50 Hz Supply,
R – Raymond (Inventor of the mill),
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 ELECTRICALS LIMITED 1

Bowl Mill
TECHNICAL DESCRIPTION XRP1003
2.0 TECHNICAL DESCRIPTION
2.1 MILL TECHNICAL DATA:
Type Of Mill XRP 1003

Total Weight Of Mill ( Including Motor)
in Tons 130
Type Of Load Moderate Shock Load
Mill Capacity( in TPH) 68
Spring rate ( Kg/Cm) 5359
Spring Preload ( in Kg) 9500
Mill Outlet Temperature 66oC – 100 oC
Fineness 70% through 200 mesh
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

ii) High Reliability
iii) Minimum maintenance time required
iv) Wide capacity with good turndown ratio
v) Ability to handle wide range of coals
vi) Quite and less vibration operation

Bowl Mill
2.2 MAJOR ASSEMBLIES:
a) PLANETARY GEAR BOX AND BOWL HUB ASSEMBLY:

Planetary gear box is used to give required torque to the bowl & bowl hub
assembly which is directly mounted and bolted to the gear box top table. The
direction of torque transmission in planetary gear box changed from horizontal to
Vertical. The bowl assembly consists of Bull ring assembly (mounted on the bowl),
Skirt & Scrapper Assembly and vane wheel assembly (attached to the bowl).
b) MILL SIDE AND LINER ASSEMBLY:
The hot primary air for drying and carrying

pulverized coal enters into the mill side and
air inlet housing. The mill side and liner
assembly is insulated internally to prevent
heat loss from primary air to the
atmosphere, or to the gearbox.

Bowl Mill
c) SEPARATOR BODY ASSEMBLY:
The separator body holds the components that give

necessary grinding pressure (journal spring
assembly), journal assembly and also the
components that direct the coarse sized coal
particles back to the bowl for re grinding.
d) ROLLER JOURNAL ASSEMBLY:
The roller assembly consists of journal shaft,

journal bearings, and journal housings, Grinding roll,
journal head, trunion shaft assembly.
.
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.

Bowl Mill
OPERATION XRP1003
3.0 OPERATION:
Pulverization is the method of preparing raw coal for complete burning.

Mechanically pulverizing coal into fine powder enables the pulverized fuel to burn
like an oil or gas in a steam generator, thus allowing more efficient combustion. The
Pulverised coal Transported by hot air and introduced directly into the boiler furnace
zone for combustion.
3.1 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 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.
12. Check that cooling water line is open and cooling water supply present to the mill
lube oil coolers.
13. Check that tramp iron spout valve is open.
14. Check that raw coal bunker outlet gate and/or inlet gate to feeder is/are open.

Bowl Mill
OPERATION XRP1003
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, temperature and pressure to the planetary gear box.
18. Feeder must be started only after the mill has been started and warmed up.
19. Check that there is proper coal flow into the mill (an annunciation for the no coal
flow from raw coal feeder will come when there is no coal flow to the mill)
20. During the initial period and load picking up of the mill check that sufficient
ignition energy is available in the furnace till pulverised fuel from each mill attains
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 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.
B. Normal operation :
1. Check oil flow, temperature and pressure to planetary gear box.
2. Check for proper mill outlet temperature.
3. Check for proper mill air flow.
4. Check for all bearing and oil temperatures.
5. Check for pulverised fuel fineness at routine intervals. Carry out ring-roll setting
and/or classifier setting based on the PF fineness lab results.
6. Check for mill rejects (quality and quantity).
7. Check for status of wear on all wear parts at least once in two months whenever
mill is down for more than one shift.
8. Carry out raw coal analysis at routine intervals.
9. Check level and quality of lube Oil in lube oil tank and journal assemblies regularly.

Bowl Mill
OPERATION XRP1003
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.
C. SHUT-DOWN :
i) During Normal Shut-Down :
1. Cool the mill during and after shut-down.
2. Run the mill for at least 5 minutes until coal is completely emptied before shut
down.
3. Keep cold air regulating damper slightly throttled to approximately 5° after the mill
has stopped.
4. If water freezing weather is present and if mill shut-down is of long duration drain
the water from oil cooler.
ii) During Emergency Shut-Down :
1. If fire in the bunker or in the mill is noticed, take immediate action for putting out
the fire. For quenching these fires in the mill, try the following methods.
(a) Shut the hot air shut off gate, 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

Bowl Mill
OPERATION XRP1003
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 oil 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.
5. Do not start the feeder without ensuring proper ignition energy in the furnace.
6. Do not start the mill without seal air supply.
7. Do not continue operation of mills with high mill outlet temperatures.
8. Do not run the mill continually with abnormal noise, high vibration, or with high
bearing & oil bath temperatures and only one or two spring adjusting stud
deflecting.
9. 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.

Bowl Mill
OPERATION XRP1003
3. Do not use direct flame torch for heating bearing assemblies.
4. Do not leave tools, work pieces, electrodes etc., inside the mill after maintenance
work has been carried out.
5. Do not carry out maintenance work inside the mill without proper personnel safety
equipment.
6. Do not weld on the bowl or any part attached to it unless the welding machine is
grounded to the bowl to prevent arching across bearing assemblies.
7. Do not use 230 volts supply lights, and electrical grinders inside the mill (Use 24 volts
supply for hand lamps as a safety measure).
8. After a mill fire, do not open access door until all symptoms of fire are vanished.
9. Do not weld on high strength non-weldable components of planetary gear box

like bevel pinion shaft, bevel gear wheel etc.
10. Do not interchange bevel pinion shaft and bevel gear wheel. Both these are
matched set. It is recommended to replace them as a set. It is recommended to
carry out maintenance on the gearbox internals only in the presence of
experienced fitters from BHEL or send the gearbox to BHEL works.
11. Do not interchange journal opening covers, even within the same mill. They are
matched with respective journal opening frames of the separator body.
3.3 PRINCIPLES OF OPERATION:
Coal is fed to the center of the pulveriser onto a revolving bowl. Centrifugal force
causes the coal to travel towards the perimeter of the bowl. The coal passes
between the bull ring and the grinding rolls, which impart the pressure necessary for
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

Bowl Mill
OPERATION XRP1003
of the inner cone, then out through the venturi and multiple port outlet assembly. As
the air passes upward around the bowl, it picks up the partially pulverized coal;
particles are carried up through the deflector openings of the classifier. The deflector
blades in the openings cause the coal - air mixture to spin within the inner cone. The
angle of the blades determines the velocity of the spin and the resulting fineness of
the finished product. Coarser pulverised coal particles are returned through the
inside of the inner cone to the bowl for further grinding. Coal that is pulverised to the
desired fineness leaves the pulveriser and enters the fuel piping system.
Any tramp iron or dense and difficult to grind foreign material in the coal feed is
carried over the top of the bowl, where it drops through the air stream and rotating
vanes to the mill bottom. Pivoted scrapers attached, to the lower skirt, sweep the
tramp iron or other material to the tramp iron discharge opening.
The tramp iron spout is fitted with a valve. Under normal operation this valve remains
open and material is discharged into a sealed pyrite hopper. The valve is closed only
while the hopper is being emptied.
DO NOT close the valve on the tramp iron spout to prevent the discharge of rejects.
If the valve is closed for an extended period, material normally discharged will be
retained in the mill side housing and be ground by the scrapers, scraper guards and
holders. This produces excessive wear on these parts and creates a potential fire
hazard.
If coal is discharged into the pyrite hopper, this indicates overfeeding, too little
grinding pressure on the rolls, too low an air flow or too low a pulveriser outlet
temperature. Excessively worn pulveriser parts or improper adjustment can also
cause coal to be discharged. Excessive spillage indicates that a pulveriser is not
functioning properly and steps should be taken as soon as possible to correct the
situation.
The pulveriser operates under positive pressure. A seal air system provides clean air to
a chamber (Labyrinth seal) surrounding the bowl hub to prevent hot air and coal
dust from leaking to the atmosphere. Seal air is supplied to each journal trunnion
shaft to prevent coal dust from entering the journal bearings. Seal air is also supplied
to each spring assembly to keep it free from coal dust.
For good pulveriser performance, the temperature of the coal-air mixture

leaving the classifier should be maintained as high as possible within the safe

Bowl Mill
OPERATION XRP1003
temperature limit for that particular coal. Too high an outlet temperature may lead
to a pulveriser fire.
The safe temperature limit for a given coal depends on the percentage of volatile
matter, moisture and pyrites either individually or a combination of them in the coal.
BHEL pulveriser systems are designed to perform effectively with coals with a wide
range of moisture content and grindability. In order to obtain rated capacity from
the pulveriser, it is necessary to have sufficient hot air entering the pulveriser to dry
the coal, sufficient pressure on the rolls to pulverise it and proper setting of the
classifier deflector vanes to obtain fineness reasonably close to that for which the
pulveriser is designed. Operating experience will help determine the 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.
3.4 OPERATING PARAMETERS:
To meet the safe and optimized mill operating criteria, the following operating
parameters must be established for the given coal
i). MILL AIR FLOW:
Mill should be operated at the design air flow at all loads. Operating at higher air
flow will cause excess wear and upset the performance of classifier etc. If mill is
operated at lower air flow it may result in coal rejects, low bowl differential
pressure, excess fineness, coal settlement etc. The air flow is controlled by the
simultaneous operations of hot and cold air dampers.
ii). MILL OUTLET TEMPERATURE:

For good 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.

Bowl Mill
OPERATION XRP1003
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.
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 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, after carrying out an
optimized spring compression setting, air flow setting and ring roll setting for the mill
iv). MILL CAPACITY:
The capacity of mill depends on the hard groove grindability index, the moisture
content of coal and the pulverised fuel fineness.
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 bowl differential pressure.
c) Low mill outlet temperature.
d) Mill rejects having large amount of coal.

Bowl Mill
OPERATION XRP1003
3.5 START - UP:

Before the pulveriser motor circuit is energized and the pulveriser is run under power
for taking up coal firing. The following items must be checked for
completion/readiness.
1. Pre –Start up checks:
a) Pulveriser / motor coupling alignment.

b) Roll - ring clearance.
c) Lubrication system.
d) Deflector blades setting.
e) Seal air supply adequacy.
f) MDVs and Tramp iron spout valve is in open position.
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 IS STARTED, THE OIL TEMPERATURE
SHOULD BE MAINTAINED BETWEEN 30 C TO 50 C.
5. Open the hot air shut off gate. The control system should adjust the hot and cold
air control dampers to give the proper air flow and allow the pulveriser to warm up
to a temperature range of 60 C to 70 C and exact temperature set point to be
established later, depending upon operating experience with the given coal.
6. Establish the required ignition energy. Then start the feeder with a fairly high feed
rate. When the pulveriser begins to grind, (this is indicated by an increase in the

Bowl Mill
OPERATION XRP1003
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
second and successive mills should be placed in service when the loading on the
operating pulveriser(s) reaches 80%.
3.6 NORMAL SHUT DOWN:

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

manual emergency fuel trip, the mill motor should be tripped immediately.
Stopping the motor should trip the feeder; close the hot air shut off gate and
initiate a minimum inert sequence, if required, provided the mills are equipped with
an inerting system.

Bowl Mill
OPERATION XRP1003
An emergency trip may subject residual fuel in the mills to cause spontaneous
combustion. The unit should be re-fired within a reasonable time (45 minutes) to
clear the mills. If this cannot be done, the mill should be cooled and manually
cleared (see CAUTION).
As a minimum precaution, the mill should be isolated, and all inspection doors
removed / opened to prevent volatile gases from mill entering the furnace.
NOTE: If an inerting system is installed, start the mill steam inerting system for one
minute immediately after shut down and again before opening the
pulveriser inspection doors. The inerting steam line isolation valves must be
properly closed before the mill man hole doors are opened.
CAUTION
A HOT MILL WILL DISTILL COMBUSTIBLE GASES, FROM RESIDUAL COAL. THEREFORE
TAKE PRECAUTIONS WHEN OPENING THE MILL FOR CLEANING.
3.8 START UP AFTER EMERGENCY SHUT DOWN:
After an emergency trip, the mills that were in service will be hot and contain a
considerable amount of partially pulverised coal. The coal should be removed
from the mills one by one quickly to avoid mill fires. The following procedure should
be used.
i) Purge the unit.
ii) Establish ignition energy in the boiler for the mill to be operated.
iii) Check that the mill discharge valves are closed on all mills not in service.
This will prevent hot furnace gases, which will be at higher than normal
pressure upon initial ignition of the coal, from surging down the fuel piping
into the idle pulverisers.

Bowl Mill
OPERATION XRP1003
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.
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 remaining
idle mills should be opened to allow the required minimum cold air flow
through them.
3.9 MILL FIRES:

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

Bowl Mill
OPERATION XRP1003
iii) Excessive Accumulations of Pyrites or Coal on the Mill Bottom or in the Air
inlet to the Mill:
The valve on the tramp iron discharge spout should normally be open to
allow the free discharge of foreign materials into the Pyrites collection
system. The valve may be closed momentarily for the removal of pyrites
from the collecting hopper. Accumulation of debris in the air inlet should be
removed whenever the mill is open for inspection. Scraper and guard
assemblies clearances with mill side liner insulation cover plate shall be re-
set periodically or replaced.
iv) Excessive Accumulations of Coal in Areas above the Bowl:
This condition is usually brought about by lack of maintenance. Worn liners
may allow coal to accumulate in an area faster than the normal air flow
will remove it or to reach areas where it cannot be removed by the normal
air flow. Coal can also be trapped by foreign material bridging a section of
the mill through or over which the coal would normally move.
v) Improper or Unusual Operation:
An accumulation of coal or flammable foreign material is a hazard under

normal operating circumstances, but in most cases this alone does not
cause a fire or puff. Usually some additional improper operating conditions
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

Bowl Mill
OPERATION XRP1003
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.
3.10 FIRE EXTINGUISHING PROCEDURES:
If a mill system fire does occur, perform the following:
a) Regardless of the fire location DO NOT shut down the mill and NEVER open any mill
inspection doors until all evidence of the fire has disappeared.
b) SHUT THE HOT AIR SHUT OF GATE. 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.

Bowl Mill
OPERATION XRP1003
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 DUCT AREA SHOULD BE CLEARED OF ACCUMULATED MILL REJECTS AT
EVERY OPPORTUNITY.
e) Shut off the steam or water being admitted to the system.
f) 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.

Bowl Mill
OPERATION XRP1003
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.
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.
o) Check the oil seals on each journal assembly.
p) Check the journal assembly lubricants and replace them if there is evidence of
carbonizing. Once everything is satisfactory, the mill may be returned to service.
CAUTION
TAKE CARE WHEN OPENING MILL INSPECTION DOORS, THE MILL MAY BE PRESSURIZED.
CHECK THAT THE HOT AND COLD AIR SHUT OFF GATES, THE MILL AND FEEDER SEAL AIR
VALVES AND THE PULVERISERS DISCHARGE VALVES ARE CLOSED. THE MILL MOTOR,
BREAKER SHOULD BE RACKED OUT AND TAGGED. THE PYRITE HOPPER DOOR SHOULD BE
CAREFULLY CRACKED AND THEN COMPLETELY OPENED, CAREFULLY REMOVE THE BOLTS
OF THE INSPECTION DOOR. EYE PROTECTION (GLASS OR FACE SHIELD) IS
RECOMMENDED.
3.11 MILL REJECTS:
Mill has been designed to reject tramp iron, pyrites and other denser and difficult
to grind material. When these come under the roller, the roller lifts up allowing
these to pass under. These are further carried over the edge of the bowl and drop

Bowl Mill
OPERATION XRP1003
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 3 should be rejected. (For coal
bulk density is 1.2 TO 1.6 t/ m3) However sometimes the raw coal is also rejected.
This could happen due to:
i) Over loading of mill.

ii) Improper operation and adjustments.
iii) Worn out parts.
i) Over loading of Mill can be due to:
a) Mill capacity reduction due to

Low grindability index of raw coal.
High fineness.
High moisture.
b) Physical overloading of mill due to feeder problems. (Refer feeder

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 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.

Bowl Mill
OPERATION XRP1003
f) Improper setting of ring-roll gap or higher gap between journal spring

assembly and journal head.
g) Improper mill differential pressure. Increase the same by adding air
restriction rings/ blocks on the airport ring.
iii) Worn out parts:

a) Roller and bull ring segments.
b) Gaps - fill up all voids and gaps between the liners by suitable filler
Compound (for ex. Dum Dum paste).

Bowl Mill
PULVERISER LUBE OIL 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 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.
4.1 JOURNAL
The Roller Journals are lubricated by means of a self-contained circulation system.

The oil level in the shaft is maintained at a point just below the top of the seal and
checked by using a dip stick.
The pumping action of the Roller Bearings circulates oil from the reservoir in the
journal housing to the annular chamber between the Bearings, then into the shaft
bore and through the oil return holes where the cycle is completed. The upper
journal housing is provided with a triple lip type seal to prevent oil leakage. The
journals are kept clean by seal air brought through flexible tubing to holes
provided in the Trunnion shaft and journal head for this purpose. (Refer figure-
11e). This inward moving air prevents dust from getting into the bearings.
The Roller Journals should be filled with the recommended oil (see Lubrication
Schedule-Table-1) through the fill connection at the top of the journal assembly).
Brush or blow any dust/dirt from the top of the Journal Shaft. Remove the cover
and plugs from the journal opening cover and journal shaft. Check the oil level
with a dip stick. Dip stick must touch the bottom. Fill the roller journal with oil to the
level shown on the oil instruction plate attached to the journal opening cover
and tighten the plug (refer Figure.12-e.) Pour the oil steadily to prevent air lock.

Bowl Mill
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.
4.2 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.
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

Bowl Mill
ROLLER JOURNALS OIL QUANTITY AND LEVELS:
MILL SIZE Quantity of lubricant Quantity of lubricant Oil level (in mm) from
per assembly (in litre) per mill (in litre) bottom
XRP- 1003 45 135 810-910
GEAR CASE OIL QUANTITY:
Mill Size Quantity of lubricant per mill

(liters)
XRP- 1003 1100

Bowl Mill
4.3 PULVERISER LUBE OIL SYSTEM OPERATING INSTRUCTIONS
GENERAL CONFIGURATION
The oil supply system described below is used for oil cooling and/or lubrication of a
gear unit (see Vendor‟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.
4.3.1. 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”-section -5).
In all cases, before startup, the gear unit/oil supply system should be filled with oil
(see Operating Instructions” Gear unit” -section -5). 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”- section -5).
Mixing oils of different manufacturers is NOT permissible.
To remove residues of preservatives which can lead to oil foaming, the oil supply
system alone and followed by system together with the gear unit should be flushed
before startup (see Operating Instructions” Gear unit” -section -5).
The oil must then be drained carefully from the oil supply system, the monitors and
the oil compartment in the gear unit while it is hot. It may only be reused as flushing

Bowl Mill
oil. If the flushing oil is to be used in another system, it should first be carefully
purified/filtered.
Fresh oil in accordance with the specification should be used for startup (see
Operating Instructions” Gear unit” -section -5).
Fill the oil supply system tank with oil in accordance with the Operating Instructions”
Lube Oil System”- section -5.
Fill until the specified oil level is reached on the oil level gauge with the pump
stationary (see Operating Instructions” Lube Oil System”- section -5). The pump
should then be started.
Before initial startup of the gear unit, the oil supply system must be run for at least 15
minutes to allow all oil compartments to fill up (see Operating Instructions” Gear
unit” section -5). 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.
4.3.2. Oil pump

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.
4.3.3. OIL COOLER
The water supply connections for the oil cooler should be established by the
operator.
If there is risk of frost and the oil supply system will be out of service for any
considerable time, the cooling water should be drained off.

Bowl Mill
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, filling with oil must be carried out.
2.0 Before startup, check the cooling water circuit!
3.0 Stop valves are to be secured to prevent accidental closure.
Before startup and after repairs and maintenance work, the oil supply system is to
be cleaned thoroughly to remove any impurities. This applies particularly to water
(e.g. rain water and leakage of the cooler) in order to prevent mixture of water and
oil. All pumps, filters and coolers must be suitably bled.
NOTE: The works setting of the pressure relief valves/safety valves carried out at
works may NOT be altered, as it is not used to regulate the pressure and
rate of flow. It is intended ONLY as overload protection!

Bowl Mill
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 (HFC01 AH001) provided in the oil tank keeps the oil temperature in
the required range, provided the pump is ON.
The following instrumentation is provided in the PLOS for interlocks & protection, alarm
and indication.
4.4.1 TEMPERATURE MEASUREMENT:
- Temperature switches 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 Duplex RTD‟s (PT 100) are also provided on the gear box to measure the
temperature of input shaft bearings (2nos.-HFC01 CT 024, 025), the thrust pad bearing
(4 nos.- HFC01 CT 020 TO 023).
- Temperature indicators are provided-
a) One on the oil tank (HFC01 CT 353).

b) One each at the cooler inlet & outlet (HFC01 CT351, 352).
4.4.2 PRESSURE MEASUREMENT:
- Two Pressure Switches (HFC01 CP252, CP253) 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, CP352).
b) One at the cooler outlet (HFC01 CP353).
4.4.3 LEVEL MEASUREMENT:
- Three oil level Switches (HFC01 CL251, CL252, CL253), two for low level (pump trip)
and low level alarm & the other for high level alarm, are provided in the oil tank.
- One oil level gauge (HFC01 CL351) is provided on the oil tank for visual check of “OIL
LEVEL”.
4.4.4 FLOW MEASUREMENT:

Bowl Mill
- Two oil flow transmitters (HFC01 CF151, CF152) are provided in the lube oil line after
cooler assembly.
4.5 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.
4.6 PLOS OPERATION:
Once the lube oil system flushing along with the gear box is completed the same is
declared ready for normal operation.
When the oil temperature in the tank (HFC01 CT254) 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 (HFC01 CT251) the mill is released for start. Below 30 deg. C oil temperature
in the tank (HFC01 CT255) the oil heater (HFC01 AH001) is energized, provided the pump
is in service. The heater is de-energised at the tank oil temperature (HFC01 CT256) of 36
deg.C or when the lube oil pump is stopped.
Charge one of the duplex filters and the oil cooler. Once the permissive conditions are
met with, start the lube oil pump. The lube oil pump can be started either from Local
push button OR from FSSS through a potential free contact & CRT and when pump stop
command is not present, lube oil level is not low (HFC01 CL252 OR CL253) and tank oil
temperature is not low (HFC01 CT254).
The filter change over can be done on line for cleaning the filter element. Cooler
change over can be done on line too.
4.7 MILL START PERMISSIVE CONDITIONS FROM THE PLOS:
THE MILL MOTOR CAN BE ENERGISED ONCE THE FOLLOWING PERMISSIVE CONDITIONS ARE
FULL FILLED.
1.0 Lube oil temperature is adequate (HFC01 CT251 > 30 deg. C)

Bowl Mill
2.0 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).
3.0 Lube oil filter not dirty (DPS-HFC01 CP251 < 2.0 bar)
4.0 Lube oil flow to the gearbox is NOT LOW (HFC01 CF151 OR 152 > 120 LPM).
5.0 Any bearing temperature of Gearbox is within ALARM limits (i.e <75 deg.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. 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.
c. Lube oil temperature after cooler is very high (HFC01 CT253 > 65 deg. C).
d. Lube oil flow to the gearbox is very low (HFC01 CF151 OR 152 < 105 LPM).
PUMP TRIP 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 OR CL253).

- Lube oil temperature in tank is low ( HFC01 CT254 < 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 (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)
- Lube oil pressure after cooler very low
(HFC01 CP253 < 0.5 Bar) (to SOE in DDCMIS)
- Cooler outlet oil temp. very high
(HFC01 CT253 > 65 deg.C) (to SOE in DDCMIS)
- Lube oil flow to gearbox is very low

Bowl Mill
(HFC01 CF 151 OR 152 < 105 LPM) (to SOE in DDCMIS)
4.8 ALARMS LIST:
The following „ALARM‟ signals are provided.
i. Lube oil tank level low (HFC01 CL252 OR CL253).
ii. Lube oil tank level high (HFC01 CL251).
iii. Lube oil flow to gearbox is low (HFC01 CF151 OR 152 < 120 LPM).
iv. Oil temperature after cooler high (HFC01 CT252 > 60 deg. 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 deg. C).
viii. Lube oil pressure after cooler very low (HFC01 CP253 < 0.5 Bar).
ix. Cooler outlet oil temperature very high (HFC01 CT253 > 65 deg.C)
x. Lube oil flow to gearbox is very low (HFC01 CF 151 OR 152 < 105 LPM).
xi. Both lube oil pumps not ON

Bowl Mill
LUBRICATION SCHEDULE EQUIPMENT: BOWL MILL XRP 1003
Sl. Parts to be Recommended Lubricants Type of filling Qty. of Lub. In Frequency of Frequency of Remarks
No. Lubricated IOC HP BP litres/Mill oil observation
check
1 2 3 4 5 6 7 8 9 10
1 Mill Drive Gear Servomesh SP- Parthan AMOCAM External tank 1100 6 Months Once daily check Oil level shall
Housing 320 EP-320 OIL-320 gauges, lines and be maintained
headers in the external
lube oil tank
2 Roller Journals Servomesh SP- Parthan AMOCAM 680 Reservoir cap 135 6 months Check when Level 810 mm
680 EP-680 on journal accessible at to 910 mm
shaft least once in
every 3 months
3 Journal Stop Servogem-3 Lithon-3 MP Grease-3 Grease fitting Fill chamber initially. Lubricate after making Wipe clean all
Bolts adjustments. grease fittings
before and
4 Discharge valve Servogem-3 Lithon-3 MP Grease-3 Grease fitting Grease the shafts and seals initially and every 2 after greasing.
shafts and Seals weeks. Remove
5 Journal Shaft Oil Molykote 33 or equivalent Grease the shafts and seals initially and every excess grease
Seals replacement time.
6 Mill Drive Motor As per Motor Manufacture's Recommendation
7 Drive Coupling Not Required at Disc End Pack completely initially & Every Three months.
( Grid-Disc) ServoGem-3/HTXX of IOC at Grid End Clean Out & Renew the Grease Every three months.
8 Drive Coupling ServoGem HTXX of IOC at Gear End & Grid End Pack completely initially & Every Three months for grid
( if Grid-Gear) end.
Clean Out & Renew the Grease 15 days at gear end.
TABLE -1

Bowl Mill
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 bowl and bowl 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?
- Were all pipes assembled and cleaned according to the assembly instructions?

Bowl Mill
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 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:
 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 mill.
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:
- 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.

Bowl Mill
5.1.3 FLUSHING
General
A clear difference must be made between ”flushing” before the initial startup
and ”flushing” before/ after repair and maintenance work.
Flushing before the initial startup
The purpose of flushing before the initial startup is to minimize the residues of
previously used lubricating oils or preservative oils.
The selected operating lubricating oil shall be used for flushing.
- Put in selected lubricating oil.
- Flushing times: run the oil pump of the lubrication circuit for 6 hours at least
for flushing or the filter is found on visual inspection reasonably clean,
whichever occurs later.
CAUTION
AFTER FLUSHING, DRAIN THE OIL COMPLETELY THROUGH THE OIL DRAIN COCKS ON
THE GEAR UNIT AND THE OIL SUPPLY SYSTEM. THE OIL MAY ONLY BE RE-USED AS
FLUSHING OIL. BEFORE RE-USING IT, THE FLUSHING OIL SHOULD BE FILTERED. THE
FLUSHING OIL CAN BE REUSED FOR A MAXIMUM OF 10 GEAR UNITS.
.
5.1.4 OIL FILLING
After flushing and before the initial startup of the gear unit, the gear unit &Lube
oil system must be filled with fresh oil after parts like pressure gauge,
thermometer, pipes, etc. if supplied separately or which were removed during
transport are 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, oil viscosity and
required oil quantity.

Bowl Mill
PLANETARY GEAR BOX ASSEMBLY
CAUTION
THE OIL LEVEL MARKS ON THE OIL LEVEL INDICATOR OF THE MAIN GEAR UNIT, THE
PAD BEARING OR THE OIL SUPPLY SYSTEM TANK ONLY ARE RELEVANT FOR
DETERMINING THE OIL QUANTITY TO BE FILLED IN.
NOTE: The quantities given on the nameplate of the gear unit are reference values only.
Oil pumps and all oil filling bores marked with special information plates should
be filled with oil before starting-up the gear unit. For this purpose, there is an oil
filling hole on the oil pump or on the pressure pipe or on oil filling hole is marked
with an information plate. Carefully close these oil filling holes so that the oil
pump does not draw in air or that any oil leaks.

Bowl Mill
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 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.
5.1.4.2 Oil quantity

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

Fill in so much oil that the prescribed oil level is reached on the oil level
indicators of the gear unit (see cross section drawing-FIG A) and the oil
supply system tank with the gear unit stationary and the oil pump of the oil
supply system running.
After the pre-run of the oil supply system (see item 5.1.4.1), the gear unit can
be rotated.
c) Oil supply system
The main gear unit is supplied with lubricating and cooling oil by the oil supply
system (see Operating Instruction ”Oil supply system”).
5.1.5 STARTUP
a) Pre-lubrication phase
Before startup, the gear unit should be pre-lubricated by the oil supply
system for 15 minutes at least.
During this phase, anti-friction bearings, axial tilting pad bearings and
toothed systems are adequately supplied with lubricating oil for the initial
startup.

Bowl Mill
b) Initial startup
When all relevant Operating Instructions have been followed, the gear unit
can be started, with the main drive motor for the dry run (no load run).
CAUTION
THE GEAR UNIT MUST RUN ON PART LOAD, IF POSSIBLE, FOR SEVERAL HOURS. IF NO
MALFUNCTIONS ARE DETECTED, THE LOAD CAN BE INCREASED GRADUALLY UP TO
FULL LOAD IN ADEQUATE TIME INTERVALS AND UNDER PERMANENT SUPERVISION.
During this phase, pay special attention to the following:

 Noises
If possible, check the gear unit for abnormal noises (anti-friction bearings) with a
stethoscope in different places during this time.
 Oil leakages
Check all flange connections of the oil pipes for oil leakages and re-seal them, if
necessary!
5.1.6 SHUT-DOWN
- Switch off the drive assembly to shut down the gear unit.
- It is recommended to let the oil supply system run during short interruptions of
operation. For a longer standstill, we recommend to let the oil supply run for
approximately 60 minutes to prevent heat from building up. How ever in case of
sudden standstill, e. g. due to a power failure, there is no danger of damage.
CAUTION
SECURE THE DRIVE ASSEMBLY TO PREVENT ACCIDENTAL SWITCH-ON!
- Close the shut-off valves in the coolant inlet and outlet lines (only for gear units
with oil cooling system). In case of water-oil cooler, drain the water, to avoid
freezing, especially in winter.
- In the case of gear units which are to be operated in a saline environment or

next to salt water the oil supply system must always continue running to avoid
corrosion damages. Moreover the gear unit should be turned every week for 15
minutes by main motor.

Bowl Mill
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, and see TABLE 13
5.2 OPERATION
During operation, the gear unit should be checked for:
- Excessive operating temperature
- Any changes in gear unit noises
- Possible oil leakage at the housing and the shaft seals and
- 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.
Control information:
See Section 4.0, “PLOS Operating Procedure” for control information.
5.3 GENERAL TROUBLESHOOTING

The Trouble Shooting Table lists possible malfunctions, their causes and suggestions
for remedying them. If the cause cannot be determined or there is no facility for
repair with suitable own equipment, it is recommended calling in BHEL for service
fitters.
Note: Malfunctions occurring during the warranty period which necessitate repair of the
gear unit may only be remedied by BHEL service personnel. Even after the warranty
period has elapsed, Customers are recommended to consult BHEL Service Division in
respect of malfunctions for which causes cannot be ascertained clearly.

Bowl Mill
MALFUNCTIONS CAUSES REMEDY
Temperature rise Oil is over aged Check when last oil change was
at bearing points 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 Oil is over aged Check when last oil change was
operating carried out, change oil if necessary.
temperature See Section 10.
Oil filter clogged Clean oil filter, observe the
operating instructions for oil filter
Change oil. See Section 10.
Oil pump defective Check oil pump, replace if
necessary. Observe the operating
instructions for motor oil pump.
Defective cooler Observe operating instructions for
Cooler.
Defective cooling water Check cooling water supply.
Observe Operating Instructions for
supply
cooler.
Gear unit oiled up Insufficient sealing of the Check seals, replace if necessary.
housing Seal joints.
cover or the joints.
Pressure control Oil level too low Check oil level, top up oil if
necessary
trips alarm
Operating temperature See above
too high
Oil filter clogged Clean oil filter
Observe Operating Instructions for oil
Filter.
Volumetric flow Oil too cold Warm up oil
Oil filter clogged Clean oil filter
meter trips alarm
Observe Operating Instructions for oil
filter
Pipes leaking Check pipes, replace if necessary
Temperature at Oil filter clogged Check oil filter for clogging
temperature Oil supply of pad Check the setting of the relief valve
sensor in pad bearing too low
bearing (part 800) monitoring devices Check all monitoring devices.
too high defective.

Bowl Mill
5.4 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
Measures Frequency/ Periods Remarks

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

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

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

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

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

such as couplings. single components.
below:
TABLE-2(Check list for evaluating the condition of PGB lube oil system)
5.5 MAINTENANCE
5.5.1 DESCRIPTION OF MAINTENANCE AND REPAIR WORK
a) 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

Bowl Mill
connection can be provided on the oil drain piping (for example an oil drain
line with isolation valve and end plug).
- The minimum amount required is 1 liter of oil in a clean and for transportation
purposes closeable safety vessel.
- The decrease in oil viscosity should not exceed 10% of the value of the new oil.
- Oil purity must be between 15/13/10 (high availability) and 17/15/12 (normal
availability) according to ISO 4406.
Limit values for oil contamination:
Material Limit content possible source

[ mg/kg ]
Iron (Fe) 40 Internally toothed gear,
cage of a bearing
Chrome (Cr) 4 Rolling bearing, teeth
Aluminum (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 -3(Material–related contamination limit values for lube oil)

Bowl Mill
b) CARRYING OUT OIL CHANGES

Mixing oils of different grades or makes is not permissible. In particular, synthetic
oils shall not be mixed with mineral oils or different synthetic oils. When
changing over from mineral oil to synthetic oil or from synthetic oil with a
particular base to synthetic oil with another base, the gear unit must be
flushed thoroughly with the new oil grade.
CAUTION
WHEN CHANGING THE OIL, THE GEAR UNIT SHOULD ALWAYS BE FILLED WITH
THE OIL GRADE PREVIOUSLY IN USE.
When changing the oil, the gear housing and, the lube oil system must also be
cleaned thoroughly by flushing with oil to remove oil sludge, abraded particles
and residue of old oil. For this purpose, the same oil grade should be used as is
in use for operation of the gear unit. Viscous oils should be warmed
beforehand. Only when all residues have been removed, shall the fresh oil be
poured in.
Note: The oil should be changed directly after shutting off the gear unit while the oil is
still warm.
- Shut down the gear unit by switching off the drive unit.
CAUTION
SECURE THE DRIVE UNIT TO PREVENT ACCIDENTAL STARTUP
.
Affix notice at the switch-on point.
- Place a suitable receptacle under the oil drain cock of the gear unit housing
and the pad bearing room.
- Unscrew the vent plugs of the oil drain cock and drain the oil into the
receptacle.
- The oil shall be drained through the oil drain cocks.

Bowl Mill
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.

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”(Vendor manual)). Suitable
oil grades will be found in the Operating Instructions for lubricants (see TABLE1.0).
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:

Bowl Mill
- 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 -C) 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 LEAKAGE SHOULD BE REMOVED IMMEDIATELY WITH OIL BINDING
AGENT.
.
C) 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.

Bowl Mill
d) CHECKING THE BINDING BOLTS FOR TIGHTNESS
All binding bolts with metric thread according to DIN 13, sheet 20, of property class
5.8 according to DIN 267 should be tightened to the following pre-stressing forces.
Pre- Pre- Tightening

stressing stressing Torque Pre-stressing
Thread Force Force Tigtening Torque ( in Lbft) Device
size (in Newton) ( in Lbf) ( In N-m) ( In Bar)
M 20 71250 16017 256 189
M 24 102500 23042 443 327
M 30 163750 36811 906 668
M 36 238750 53671 1580 1165
M 42 328750 73903 2540 1873
M 48 433120 97365 3830 2825
See the
M 56 599370 134738 6150 4536 Operating
M 64 792500 178154 8940 6593 Instructions of
the
M 72 x 6 1000000 224800 13000 9588
manufacturer
M 80 x 6 1218750 273975 18060 13319 of
M 90 x 6 1593750 358275 26030 19197 the hydraulic
pre-stressing
M 100 x 6 2000000 449600 36120 26638 device
TABLE -4 (Pre-stressing force, tightening torques, pre-stressing device hydraulic)
Note: Unserviceable screws should be replaced by new ones of the same property
class and type.

Bowl Mill
For Studs of Hot Rolled/Forged Carbon Steel Bars, Gr:40C8 – Normalised (

Comparable Standards IS:1570, PART II, Section I-1979 )
Thread Size Pre-stressing Force Pre-Stressing Force (

( in Newtons) in Lbf)
M39 156896 35270
M48 205926 46292
TABLE -4-a (Pre-stressing force required for stud tensioning)
Note: M39 X3 studs are used to fasten PGB & Sole Plate.
M48X 4 studs are used to fasten Bowl Hub to PGB Rotary Table.
Hence, both these studs require the stud tensioning as per the above mentioned table.

Bowl Mill
e) 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.
Measures Frequency Remarks

Cleaning the filter inserts every 4 weeks or if filter element see Operating
is dirty Instructions for the
individual
components
Test oil for water content after approx. 400 service hours / see item 5.5.1
at least once a year
First oil change after start– after approx. 1000 service hours
up or depending on result of oil see item 5.5.1(b)
analysis
Oil analyses every 1000 service hours see item 5.5.1
subsequent oil changes depending on result of see item 5.5.1(b)

oil analysis; (without oil analysis
every 18 months or
60000 operating hours)
Cleaning the air filters every 12 weeks see item 5.5.1(c)
(breather filter)
Checking tightness of Simultaneously with oil change see item 5.5.1(d)

foundation bolts
Carry out complete approx. every 2 years along with see item 5.5.1(e)
inspection of the gear oil change
unit
Maintenance work on the see also Operating

oil–supply unit Instructions for oil
supply unit
Couplings: every 26 weeks see Operating
Instructions for the
individual
components
Maintenance comprises all measures to maintain the desired condition.
TABLE -5 (Maintenance of PGB & lube oil system)

Bowl Mill
5.6 REPAIR
Repair comprises all measures to re-establish the desired condition after a malfunction.
CAUTION
WHEN CARRYING OUT REPAIR WORK USING ELECTRIC WELDING AT ANY POINTS OF
THE UNIT, MAKE SURE THAT THE WELDING CURRENT IS NOT CONDUCTED THROUGH
ANTI-FRICTION BEARINGS OR OTHER MOVING CONNECTIONS AND MEASURING
DEVICES. THEREFORE, THE WELDING CURRENT RETURN CABLE SHOULD BE DIRECTLY
CONNECTED TO THE PART TO BE WELDED.
When replacing components and larger sub-assemblies, make sure that they are
fastened and secured carefully to hoists to avoid hazardous situations.
CAUTION
ONLY USE SUITABLE HOISTS IN PERFECT TECHNICAL CONDITION AND SUSPENSION
DEVICES WITH SUFFICIENT CARRYING CAPACITY! DO NOT STAND OR WORK BELOW
SUSPENDED LOADS
5.7 Lubricants
See TABLE 1.0 for lubricants.
5.8 LIST OF EQUIPMENT

TYPE: KMP SIZE 280/300
Switching and monitoring functions as per:
Lubrication diagram : Figure - N

Gear Unit type: KMP 280/300 : Figure - C
Terminal diagram as per : Erection Manual (Fig 15)

Bowl Mill
TAG.
QUANTITY DESCRIPTION PART-NO. MANUFACTURER
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
Temperature control of the rolling bearings

EL = 95 mm
Connection : G 1/2
100 DIN IEC Kl.B
for rolling bearing part no.
150
> "75" °C : WARNING
> "85" °C : MILL STOP
EL = 230 mm
Connection : G 1/2
100 DIN IEC Kl.B
for rolling bearing part no.
151
> "75" °C : WARNING
> "85" °C : MILL STOP
TABLE-6
5.9 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:

Bowl Mill
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
CAUTION
AFTER SWITCHING OFF THE GEAR UNIT, THE OIL SUPPLY SYSTEM SHOULD TO BE IN
SERVICE, AT LEAST FOR ANOTHER HOUR TO AVOID THE ACCUMULATION OF HEAT.
Note: For further control information, see the Operating Instructions “PLOS Operating
Procedure Section 4.0”.
5.10 SPARE PARTS STOCK

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

Bowl Mill
SPARE PARTS LIST-KMP 280/300

PART
DESCRIPTION QTY WEIGHT(Kg)
NO
0202 Internal Toothed Wheel KMP 280/300 1 St 308.0

0040 Oil level Indicator 1 St 0.2
0044 Ball Cock 1 St 0.6
0048 Ball Cock 1 St 0.6
0056 Air Filter 2St 0.1
0099 Pair Of Mating Bevel Wheels KMP280 1 St 479.0
0100 Bevel Pinion Shaft 1 St 118
0402 Bevel Gear 1 St 237
0123 O-Ring 1 St 0.1
0124 O-Ring 1 St 0.1
0128 Shim Ring,2-Piece 341x440x15S235JR 1 St 7.0
0130 Labyrinth Ring 1 St 10.0
0132 O-Ring 1 St 0.1
0150 Paired Taper Roller Bearings 1 St 34.0
0151 Rolling Contact Bearing 1 St 35.4
0200 Planetary Carrier 1 St
0208 O-Ring 4St 0.1
0214 Adapter Ring 300x340x15 1 St 1.6
0253 Thrust Slide Bearing 1 St 684
0290 Flange (Rotary Table) 1 St 3.085
0300 Planetary Axle 3 St 31.0
0301 Pinion Shaft 1 St 33.5

Bowl Mill
PART DESCRIPTION QTY WEIGHT(Kg)

NO
0302 Gear Wheel 3 St 96.4

0350 Rolling Contact Bearing 3St 28.2
0400 Shaft 195x555 1.6587 1 St 87.5
0399 Coupling Sleeve 1 St 24.4
0428 Shim Ring, 2-Piece 1 St 6.4
0450 Paired Taper Roller Bearings 1 St 21.0
0800 Resistance Thermometer EL=265 4St 0.3
0806 Resistance Thermometer EL=095 1 St 0.2
0808 Resistance Thermometer EL=230 1 St 0.2
TABLE – 7

Bowl Mill
MILL OPTIMIZATION XRP1003
6.0 MILL OPTIMIZATION
PURPOSE:
The purpose of this program is to optimize the mill operation to ensure the rated mill
capacity with required PF fineness and at the same time, the best wear life of grinding
elements and other wear prone areas is achieved.
ADJUSTMENTS:
One or more of the following adjustments may be required for the mill optimization:
1) Area of opening around the bowl for primary air flow to maintain desired differential
pressure across the bowl, with low mill rejects.
2) 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.

Bowl Mill
MILL OPTIMIZATION XRP1003
Procedure:
1) Collect one set of mill readings from Unit Control Room (UCB), raw coal analysis
data, pulverised fuel fineness details, quantity and quality of mill rejects and raw
coal size and grindability index etc.
2) Check and ensure the requirements of raw coal feeder, condition of mill DP
instruments, and primary air flow through the mill and the quantity of raw coal.
The above adjustments may be carried out to maintain the required bowl DP, PF fineness,
quantity & quality of mill rejects and for the said purpose

Bowl Mill
TROUBLESHOOTING XRP1003
7.0 TROUBLESHOOTING
The trouble shooting guide lists Mill Malfunctions generally faced but a large number of the
problems are off shoot of a problem, which has not been take care in time. Mill problems
can be reduced to maximum extent if the Instructions are listed here are followed. If the
malfunction is not clear, we recommend therefore that the specialist personnel of BHEL be
consulted in tracing possible cause.
Instructions:-
1. Maintain proper air flow and mill outlet temperature
2. Do not run the mill with spillage.
3. Change or service labyrinth seal as soon as it fails.
4. Prevent foreign material entry to mill with coal.
5. Check and maintain proper internal clearances regularly.
6. Follow the lubrication chart/schedule.
7. Empty the pyrite hopper periodically.

Bowl Mill
TABLE- 8
Disturbances, Reasons and Remedy
Bowl Mill Troubleshooting Guidelines
PROBLEM PROBLEM CAUSE RECOMMENDATION

Mill Vibration Under Spring Compression too high Reset Spring compression
Load Improper assembly of Bull Ring segments Assemble Properly
Excessive wear of Bowl and extension ring Replace Extension Ring. Build up bowl by weld deposit
Loosening of Separator body bolts Tighten the Separator body bolts.
Roll to Bowl clearance Adjust roll to bowl clearance.
Foreign material in mill Take mill offline and remove foreign material
Mill Coal spillage High Over feeding Reduce feeder speed/ coal feed to mill
Insufficient primary air flow Correct the primary air flow quantity.
Jamming of rolls Attend to worn out seal air skirts. Service the bearings and oil seals
Check and clean seal air supply to journal assembly.
Low Mill outlet temperature Reduce Cold air, increase hot air supply.
Reduce feeder s feed/coal feed to mill.
Worn grinding roll Replace roll/or Ring and adjustment.
Low journal spring Pressure set Increase spring pressure load.
Classifier set for higher fineness Reset classifier Blades towards open position.
High Pulverized fuel Improper setting of classifier Reset the classifier towards open position.
fineness Excess spring compression Reset to the required pressure load.
Improper Method adopted for : Train the manpower.
i. Pulverized Fuel sampling technique
ii. Sieve Analysis
Low Pulverized Fuel Improper setting of classifier Reset classifier Blades towards closure position(max position “5”).
Fineness Improper Alignment of classifier vanes Properly align classifier vanes
High air Flow Repair/ Replace Worn out Parts.

Bowl Mill
Table 8(cont.)
Low Pulverized Fuel Reduce air flow to design value. Excess wear of mill parts
Fineness (cont.) More gap between cone and feed pipe Correct the gap.
More gap between inverted cone and Correct the gap.
classifier cone.
Improper setting of:-
i. Ring Roll clearance
ii. Pressure spring seat- journal head
clearance
Oil Leakage from Mating surface not cleaned properly. Assemble properly.
Flanges Seal compound not applied Apply Gasket eliminator or any suitable sealing compound.
Improper gasket used Use compressed asbestos gasket.
Bolts not properly tightened, threads Tighten properly. Rethread to mark high size bolt.
damage
Lubricating Oil Temp. No cooling water Rectify cooling water supply.
too High Cooler contains air Bleed cooler.
Cooler dirty Replace Cooler,/ Clean or Replace contaminated pipe
bundle.
Lubricating Oil Temp. Gear unit not yet warmed up to operating wait
too Low temperature.
Too much cooling water Reduce cooling water supply.
Lubricating Oil header Filter Clogged Switch over to clean filter and clean filter and clean filter
pressure too Low element.
Pressure limiting valves defective/wrong set Replace Pressure limiting valve if defective.
Suction line blocked Clean suction line.
Pump Aspirating air Check suction line and remedy any leaks.
Lubricating oil temperature too High Check cooler performance.
Oil Viscosity too low Check viscosity and if necessary fill with correct oil.

Bowl Mill
Table 8(cont.)
Lubricating oil Gear unit not yet warmed up to operating Wait, Reduce cooling water flow/ isolate.
pressure too high temperature
Pressure limiting valve wrongly set Correct oil pressure at limiting valve.
Pressure limiting valve defective Repair or replace pressure limiting valve
Lubricating oil lines to and at gear unit Locate blocked line and clean.
blocked
Mill Fire High Mill outlet Temperature Do not exceed mill o/l temp. recommend as per volatile matter
content in coal.
Coal settlement in mill Do not leave coal in idle mill. Remove the coal either manually or
taking the mill in service.
Rapid change in moisture content of coal Keep a close watch at mill outlet temperature.
Putting burning coal in mill Empty the bunker and remove smoldering coal.
Journal Oil Bearing damaged Change bearing.
Contamination Oil contaminated improper oil Change oil as per recommendations
No Bearing clearance Set bearing clearance.
Oil seal damage/ worn out wear sleeve Change them.
Clearly appeared or Pipes dirty(scale, welding residues) Clean pipes.

accumulated filter Abraded particles from gear unit Check gear unit (bearing, tooth systems, alignment)and rectify
residues defects.
Lubricating oil dirty Carry out oil change.
Oil tank dirty Clean oil tank and carry out oil change.

Bowl Mill
Table 8 (cont.)
High Mill outlet Interrupted coal flow Check & take necessary action
temperature Too high air flow, particularly hot air flow Open cold air and reduce hit air keeping air flow to mill
constant.
Fire in mill/ coal fed to mill Check mill/feeder for fires
See that coal flow is optimum(Bowl Differential, feeder speed,
mill motor current)
If this measure are not fruitful and temperature continuous to
rise, isolate mill & spray water to quench fire.
Oil consumption too high Leak in pipes, connections, valves or gear Tighten screws.
unit.
Cooler Leaking Seal cooler or renew cooler element.
Shaft outlets on gear unit leaking Renew seal ring.
Check orifice size and reduce to avoid over flow.

PULVERISED COAL SAMPLING ANALYSIS & Bowl Mill
ADJUSTMENT OF FINENESS XRP1003
8.0 PULVERISED COAL SAMPLING:
Pulverised coal samples should be taken for fineness test periodically and whenever
furnace or pulveriser operation suggests fineness has changed.
In order to obtain repeatable and comparable fineness test results, it is necessary to

maintain the pulveriser and furnace conditions as constant as possible during the
sampling procedure. The pulveriser should be on manual control at or near its full load
rating and should be allowed to settle out for at least 10 minutes before testing starts,
pulverisers with obvious indications of trouble (heavy coal spillage, rumbling) should
not be tested.
8.1 NON-ISOKINETIC SAMPLING METHOD: (For ISO KENITIC SAMPLING refer to O& M manual
of M & W Denmark)
A sampling device, illustrated in Figure – „O‟ is supplied for each installation. The
sampling device consists of a cyclone separator, a sampling jar (receiver) and a
sampling nozzle connected directly or by means of a hose to the cyclone.
Eight aspirating fittings, also shown in Figure „O‟ are furnished with each pulveriser.
These fittings should be installed 90 apart in holes provided in the pulveriser discharge
valves (see mill General arrangement drawing). To utilize the aspirators properly admit
compressed air into the fitting, remove the 2" pipe plug, then reduce the quantity of
compressed air to the minimum necessary to prevent discharge of powdered coal
into the room.
The opening in the end of the sampling nozzle should always point directly towards
upstream while taking the sample. Sample must be taken from all the eight aspirating
fittings provided to get a representative sample.
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%

100 - 2 (Wt. on 50 + on 100)
% though 200 mesh

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

NOTE:
Holes in the inner cone, holes in the deflector vanes or missing deflector vanes can
produce erratic coal fineness test results. Check the calibration of air flow
instrumentation if high air flow is suspected. Improper ring-roll setting, journal spring
compression too would affect the P.F. fineness.
The following publications may be used as references for sampling and sieving
procedures.
Sampling : A.S.ME. P.T.C. 4.2 “Coal Pulverisers” or ISO 9931 for

Isokinetic sampling
Sieving : A.S.T.M.D. 197 “Test for Fineness of Powdered Coal”.
8.2 ADJUSTMENT OF FINENESS:
The degree of coal fineness obtainable with air separation is extremely high, and
within normal limits it is possible to control fineness with considerable exactness.
Fineness of any material is usually measured as the percentage of the material that
will pass through each of a series of test sieves. When a material such as coal is
reduced to fineness to that 95% passes through a 100 mesh sieve, 75% to 85% of it will
pass through a 200 mesh sieve. The percentage passing through the 200 mesh sieve
will depend on the hardness or grindability of the coal. The lower percentage will
apply to harder coals, which have lower grindability. The percentage for more easily
pulverised coals with higher grindability will be closer to the higher value. (Refer to
A.S.T.M. publication 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 –„O‟ 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. If the coal is too coarse when the
deflector handle point is set to “7 or 8”, 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.


FIG-8A SIEVE DITRIBUTION CHART

8.3 MILL WEAR LIFE ASSESSEMENT
The objective of this test is to realize the maximum wear life of grinding element. Attach
wear measurement gauge to journal assy. It is important to hold the gauge securely
against lower journal housing and roller back face to ensure accurate reading as
shown in figure 8B
Fig 8B
Measure the dimension ”x” at various locations 120 degree apart at each locating with equal
spacing and record on data sheet. During service and after the roll removal, reading may be
taken.

Bowl Mill
MAINTENANCE XRP1003
9.0. MAINTENANCE
The Bowl Mill and its auxiliaries require continuous monitoring and periodical maintenance
to ensure reliable operation and availability. Monitoring and Maintenance are required
both during operation and when the unit is at standstill.
Some maintenance works require with the mill at shut down position, while some
maintenance works may be carried out during normal operation of the mill .This
Maintenance Section of O & M manual is divided into three sub-sections :-
MAINTENANCE
GENERAL PREVENTIVE COMPONENT

MAINTENANCE MAINTENANCE MAINTENANCE

Bowl Mill
GENERAL MAINTENANCE XRP1003
10.0 GENERAL MAINTENANCE:
The pulveriser is a rugged machine, designed and built for continuous operation over an
extended period, with minimal wear on the working parts. However iron pyrites and other
abrasive substances in the coal are apt to shorten the life of parts such as the rolls, bull
ring, rotating vanes and scrapers.
Since wear of pulveriser parts depends on many factors that vary from one
installation to another, it is difficult to prescribe a specific routine inspection and
maintenance program. Characteristics of the fuel, operating hours of individual pulverisers,
availability of pulveriser due to unit load demands, and trained maintenance staff
availability are all factors that determine the frequency and scheduling of pulveriser
inspection and maintenance. An effective program can be established only on the basis
of actual plant operating experience. It is therefore imperative that an accurate log be
kept from the beginning, to relate individual pulveriser running time (see NOTE) with
pulveriser performance, plant operating schedules, unit load, outages, inspection reports,
and other associated data.
NOTE:
PULVERISER WEAR IS A FUNCTION OF THE NUMBER OF HOURS A PULVERISER IS
GRINDING COAL, NOT NECESSARILY THE AMOUNT IN TONS OF COAL PULVERISED. A
PULVERISER WILL LAST SOMEWHAT LONGER WHILE OPERATING AT REDUCED
CAPACITIES BUT WILL GRIND MUCH LESS TONNAGE BEFORE PART REPLACEMENT
BECOMES NECESSARY.
Pulveriser part replacement criteria cannot always be defined in advance. They must be
established on the basis of experience and judgment on the part of personnel familiar with
the pulveriser history and performance. The degree, location and pattern of wear soon
become evident and can be handled accordingly. In some cases surfaces can be built
up; in other instances, replacement of the part is more practical. The following list
describes the pulveriser parts normally subject to wear:

Bowl Mill
1. Bull Ring and Rolls:

Reduced pulveriser capacity and increased spillage even after carrying and ring roll
setting periodically are indications of excessive wear requiring part replacement.
Contour templates, made when the equipment is new, may aid in checking the
degree and location of wear as it progresses. In case sand accumulation is
noticed on the bowl which would also stop the mill output, carryout “Mill Purging”
periodically. Stop coal feeding and air supply to mill and run it empty for 5 minutes
till all the sand from bowl is removed by centrifugal action of the rotating bowl.
2. Airport Ring (Figure. 11.d):
Check and maintain a vertical clearance of 5 to 11 mm between the top of

rotating vanes and the bottom of the body liner segment.
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 to improve
the parts wear life.
4. Mill bottom Cover Plates:
Wear can be minimized by maintaining proper support of the scraper blades.

Replace when worn-out.
5. Mill side liners and Air inlet vanes:
Excessive rejects will cause wear on liners and edges of vanes
6. Scrapers:
Bottom edges are most susceptible to wear and should be replaced when
required gaps cannot be maintained with the help of the turn-buckle support.
Maintaining proper support (pins and bushings) helps to minimize wear.

Bowl Mill
7. Mill Discharge Valves:
Excessive clearance in valve flap closed position is an indication of wear. Disc

should be replaced when worn out.
Most of the inspection and repair works inside the pulveriser above the bowl can
be accomplished by removing one journal assembly cover and journal assembly.
Work below the bowl is normally done by entering the mill through the mill side
access door.
CAUTION
WHEN MAINTENANCE IS REQUIRED ON A PULVERISER WHILE THE UNIT IS IN OPERATION,

MAKE SURE THE PULVERISER IS COMPLETELY ISOLATED (DAMPERS, GATES AND VALVES
ARE CLOSED, MOTOR CIRCUIT BREAKERS LOCKED IN OPEN POISTION, AND THE MEANS
FOR OPERATING THIS EQUIPMENT SUITABLY TAGGED) BEFORE ENTERING THE
PULVERISER.
9. Bearings:
Unusual noise and operating temperatures consistently above normal are
indications of impending bearing failure. Bearings should be inspected at the first
opportunity.
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-5 on Planetary Gearbox (Page no 36).
10.1 INSTRUCTIONS FOR INTERFERENCE FIT:
INTERFERENCE FITS:
Where components have been designed with interference fits, it is necessary to heat
and/or cool the mating parts to facilitate assembly.
a) Heating:

Bowl Mill
Heat must be applied uniformly to the entire piece. Acetylene torches with
rosebud tips are not recommended, since heating by this method is not sufficiently
uniform. Heat can best be applied in a commercial type oven. However, it is also
possible to shroud the part in an insulated enclosure and increase the part
temperature with space heaters.
b) Cooling:
Chilling of components can be done in a commercial freezer. It is usually easier to

submerge the part, after providing a protective oil or grease coating, in an ice/salt
bath or to pack the part in dry ice.

Bowl Mill
PREVENTIVE MAINTENANCE XRP1003
11.0 PREVENTIVE MAINTENANCE
Preventive maintenance is conducted to extend the life of the equipment. It involves the
regular inspection, testing and replacement OR repair of equipment and operational
systems.
Preventive maintenance takes proactive approach to the problems before they occur
And also saves money from mill breakdowns.
.
11.1 MILL CLEARANCES
i) INVERTED CONE CLEARANCE
The inverted cone prevents the pulverised coal from by-passing the classifier.
Inverted cone clearance is the perpendicular distance between the inverted
cone and
Fig -11.a

Bowl Mill
the classifier inner cone. The gap between inverted cone and inner cone is
100mm (±5 mm) and the gap between center feed pipe lower and inner
cone is 114mm (±5 mm).If the clearance is too small, bridging of coal between
the inverted cone and the classifier inner cone can occur, which would result
in carry over large coal particles to the boiler furnace leading to other related
problems periodically. If the clearance is too large, the primary air can carry
large particles out of the mill by passing the classifier. This results in poor
pulverised fuel fineness.
ii) GRINDING ROLL-TO-BULL RING SEGMENT CLEARANCE:
The roll-to-ring clearance should be set to 6 to 8 mm parallel for the entire

length of the roll. This clearance setting affects the performance of the mill
upon wear.
Fig -11.b

Bowl Mill
iii) PYRITE SCRAPER CLEARANCE:
The clearance between scraper and insulation cover plate is 13 to 19mm. and
the clearance between scraper guard and insulation cover plate is 10 to 16
mm. Radial Gap between scraper and mill side bottom liner is 25 to 35 mm.
Radial clearance between Labyrinth Seal & Bowl hub is 3 ±0. 5 .
Fig -11.c

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

Bowl Mill
ROLL TO RING CLEARANCE ADJUSTMENT
The most common indications of the need for roll-ring clearance adjustment are
the falling off of pulveriser capacity, rumbling and increased coal spillage.
Adjustment of clearance and/or spring compression should be considered in the
event of any prolonged coal side pulveriser operating difficulties. If difficulties do
not exist, adjustments are not recommended.
The entire journal assembly (Figure) including the roll, pivots about the
center of the trunnion shaft and can be raised or lowered with the journal stop
bolt. As roll and ring wear progress, the first adjustment is to lower the rolls using the
stop bolts. Continue to make stop bolt adjustments until they are no longer
effective.
Trunnion shaft bushings in the trunnion shaft end caps support the trunnion
shaft so that when the end caps are rotated from position 1 to 5, the location of
the center of the trunnion shaft is changed and this alters the position of the entire
journal assembly. The trunnion shaft end caps can be used to make roll-ring
clearance adjustments, once the stop bolt adjustments are no longer effective in
position 1.
Note:- It was advised to run the pulveriser after checking the trunnion end cap
position ( After setting it to "1") in all the six end caps of the three journal assembly
of the same mill. Otherwise it may lead to unnecessary mill vibration followed by
decreased mill performance.
a) To make a roll - ring clearance adjustment with the stop bolt:
i) Slack off the journal stop bolt lock nut. Pulveriser running with empty bowl
and no coal being fed, slowly retract the journal stop bolt until contact
between ring and roll can just be heard or felt with the roll rotating on the
journal shaft assembly. Then turn the stop bolt by one flat with new roll
and segments however for worn out ring rolls-segments stop bolt rotation
by one flat further need not be done .Turn the stop bolt till the high points
of rolls & segments do not touch each other and tighten the journal stop
bolt locknut. Assemble the lock plate and bolt it.
ii) Slack clamp plate stud lock-nuts of journal spring assembly.

Bowl Mill
iii) Keeper shim gap 0.5 mm between the pressure spring seat and journal
head insert and the snug up all clamp plate studs firmly and evenly and
drive the locknuts tight. The pressure spring seat now will be in touch with the
stop journal head insert, remove the shim. This to be repeated for the
remaining two journal spring assemblies.
b) To make a roll-ring clearance adjustment using the trunnion end

caps:
i) Slack clamp plate stud locknuts and retract studs several turns. This frees
the pressure spring assembly inside the spring cup. Loosen the journal
stop bolt lock nut and back out the journal stop bolt until the roll just
touches the rings.
ii) Remove the bolts from both trunnion end caps and slack off the four
journal opening cover bolts adjacent to each end of the trunnion shaft.
Using special box wrenches, rotate both trunnion end caps
simultaneously in the direction indicated by the cast arrow, so that the
numeral '5' lines up with the indicating arrow on the journal cover.
Replace and snug the trunnion end cap bolts. Tighten the cover bolts
and tighten the end cap bolts.
iii) Turn the pulveriser bowl manually through one revolution by hand to make
sure that none of the rolls make contact with any part of the ring. Then
adjust the roll-ring clearance with the stop bolt following steps (a)
above.
Additional adjustments should be made using the journal stop bolt until they are
again no longer effective. When this occurs, it is necessary either to replace the
rolls and bull ring. A ring will usually outlast the rolls.

Bowl Mill
Fig. 11 f Trunnion Shaft End Cap (shows tunnion position)

Bowl Mill
11.2 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).
SPRING PRELOAD SETTING PROCEDURE (Refer Figure 11.e)
1) The spring assembly should be completely assembled per the assembly drawing
except for the “spring stud extension cap, spring stud lock nut keeper hex. hd. cap
screw M52 and keeper washer” if the assembly has just been shipped, remove the
shipping bolt per view “a-a” then install the pipe plug.
2) of the six (6) threaded studs, four (4)must be backed out of the journal spring
housing cover to the dimension indicated in detail “8” for the purpose of wrench
clearance two (2) studs must be removed in the region of one of the cutouts in the
preload fixture (item #2)
3) Slide the spring stud lock nut keeper onto the spring preload stud.
4) Using two (2) hex. hd. cap screws (item #3), fasten the cylinder (item #1) to the
spring preload fixture (item #2) mount the fixture as shown using one (1) hex. nut at
the top, slide there preload stud (item #4) through the cylinder and screw it into
the end of the spring preload stud. Atleast 76 of thread engagement is required.
Screw the nut (item #5) onto the preloaded stud (item #4) with cylinder (item #1)
fully retracted.
5) Slide the spring stud lock nut keeper back off the spring preload stud.
6) use the cylinder (item #1) to draw the spring guide to contact the spring housing
cover, pump the cylinder (item #1) until the pressure guage reads “p” kg/sq. cm.

Bowl Mill
This will compress the spring from the static length using the lock nut wrench (item
#7). Advance the lock nut until it comes in contact with the spring guide.
7) relieve the pump pressure (item #1) to using a magnetic base dial indicator, place
the indicator needle on the flat vertical face of the lock nut 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 start to move as the pressure gauge reads „p”
kg/sq.cm.
8) tighten of loosen the lock nut until this occurs slide the lock nut keeper onto the
spring preload stud causing the keeper to interlock with the lock nut, it may be
necessary to compress the spring just above “p” kg/sq. cm to allow rotation of the
lock nut. the lock nut 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) loctite and install
hex. hd cap screw & keepr washer, torque the hex. cap screw to 75 ft/lbs and
weld hex.hd. cap screw, keeper washer & lock nut keeper together see weld
details
10) Mount the spring stud extension cap.
11) Mount the six (6) hex. nuts onto the adjusting threaded studs.
Refer to the ring to roll procedure before adjusting these studs.
12) pressure (p) = required preload (f/ effective area of jack (a)”
Where f=in kg/ sq. cm, area = in sq cm (refer vendor‟s catalogue)
CAUTION
USING THE SPRING COMPRESSION MEASUREMENT TAKEN, DO NOT ALLOW THE PRESSURE
GAUGE READING TO EXCEED 3000 KG FOR EACH CENTIMETER OF THREAD
ENGAGEMENT. THEN BACK OFF THE SPRING ADJUSTING NUT THE DESIRED AMOUNT OR 6
MM. FOR THE PURPOSE OF ESTIMATION, THE FOLLOWING TABLE GIVES THE SPRING RATE
FOR THE MILL.
Mill Size Spring Rate Spring load to be registered at Pr. gauge in Kg.
( Kg/Cm)
1003 XRP 5359 9500

Bowl Mill
a) SPRING PRELOAD SETTING PROCEDURE (refer Fig No 11.e)

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

Bowl Mill
11.4 INSPECTION TASKS
Reliable operation of the mill will be ensured only if inspections and overhauls are carried
out at regular intervals so that any faults can be detected and corrected before they
result in costly failures. The Bowl mill needs a periodic check to be done on the lubricating
system, mill clearances and other operating parameters of mill.
The spare parts stored for repairs and overhauls should be checked at regular
intervals.
SUGGESTED CHECKLIST FOR MILL PREVENTIVE MAINTENANCE INSPECTION
INSPECTION TASKS
1. Check grinding roll wear depth using the wear measuring gauge and
Record the data. Readings may be taken approximately after every 1000 Hrs
of mill operation.
2. Check roll to bowl clearance, nominal clearance for roll to bowl is 6 to 8
mm. If clearance value is not proper, correct it either by adjusting stop bolt
or by adjusting trunnion end caps.
3. The initial compression setting (9.5 tons) should be checked and if necessary,
the springs should be compressed using the spring compression fixture
supplied, based on mill performance.
4. Check segmented bull ring for wear. Measure with the help of Contour
templates, made when the equipment is new, would aid in checking the
degree and location of wear as it progress.
5. Check and set the air port ring assembly clearances as well as hand facing
the eroded areas.

Bowl Mill
6. Check bowl extension ring and change, if worn out.
7. Check clearance between mill bottom and lower skirt.
8. Maintain the seal air hoses in good condition and replace them
immediately, if got damaged.
9. Make periodical adjustment of the classifier vanes and hence the fineness of
pulverized coal, based on use results.
10. Coupling inspection and greasing if required
12.Check and maintain scraper gap with respect to mill bottom insulation cover
It suggested that, the maintenance staff, based on their experience with the mill in
operation, update the inspection tasks check list and follow the same periodically on
daily, weekly basis. So that the mill availability and performance can be sustained nearly
100%

Bowl Mill
COMPONENT MAINTENANCE XRP1003
12.0 COMPONENT MAINTENANCE
12.1 GENERAL DIS- ASSEMBLY AND RE -ASSEMBLY OF COMPONENTS:
ISOLATION OF THE PULVERISER (Refer fig.1):
It is a good operating practice to isolate the pulveriser, before attempting any

maintenance job, that calls for opening the mill or dismantling its components. To
isolate the mill close the hot gas shut-off gate, the cold gas shut-off gate, the coal line
gate (if provided), the feeder discharge valve (if provided) and open the mill feeder
motor breakers. (Tag and/or lock open).
For most maintenance procedures a complete general disassembly of the bowl mill is
not required. Planetary Gearbox is designed to perform for long time smoothly,
provided the operation guide lines are followed strictly. Periodical cleaning of filter
element and or replacing the same with spare element, keeping a watch on the oil
quality through periodical sampling and testing only are expected to be the normal
maintenance activity. Inspection doors are provided to peep into the gearbox for a
visual check. However, in case the gearbox needs any major maintenance activity to
be done, the same can be drawn out from its place, as per the procedure given
below, and replaced with a spare gearbox. This way the mill can be brought back into
operation within couple of days. 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.

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

motor and the junction box fitted on the gearbox.
5. Remove the skirt assembly including the scrapper assembly from the
bowl/bowl hub. Remove the labyrinth seal assembly.
6. Loosen and remove the holding down studs & nuts (M 48) between bowl hub
and the table top/flange of the gear box. Use hydraulic jacks to loosen the
nuts.
7. Remove the drive coupling guard and disconnect the mill-Motor coupling.
8. Loosen the holding down bolts of the drive motor to the base plate, rig and
remove the motor from its place and keep it in a nearby location, in case no
maintenance work need to be done on it.
9. Install the gear box withdrawal fixture assembly as shown in Figure G.

Bowl Mill
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.
10. 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.
11. 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.
12. Loosen and remove the holding down bolts between gear box and base
plate.
13. Jack and raise the gear box assembly and fix the roller assemblies as shown in
Figure G.
14. Using the pull and lift equipment (2 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.

Bowl Mill
15. Move the gearbox till it clears the air inlet housing assembly. Provide stoppers
below the rollers and remove the pull and lift equipment from the gear box.
16. Using the service crane of the Electrical operated handling system, rig and lift
the gear box, above the Mill maintenance platform, and move it to the Mill
Maintenance day. Place the gear box in a truck and shift it to the workshop.
17. Plug the holding down bolt openings for Planetary gear box and Motor in the
base plate to avoid dirt entry.
12.1.1.b RE-INSTALLING GEARBOX ASSEMBLY:
The gear box assembly is re-installed by sliding it into position under the assembled
pulveriser.
CAUTION
FOR DETAILS ON THE ALIGNMENT, LEVELING AND CLEARANCES TO BE MAINTAINED
DURING GEARBOX RE-INSTALLATION, WITH THE BASE PLATE, MILL SIDE AIR INLET
HOUSING ETC. REFER TO THE SECTION 6 OF THE BOWL MILL ERECTION MANUAL.
1. Ensure that the gear box assembly is positioned such that the input shaft is
facing the Motor side. Lift, move and set the gear box on rollers which are
mounted on gear box withdrawal fixture as shown in Figure G.
CAUTION
BEFORE MOVING THE GEAR BOX, ENSURE THAT THE THRUST PAD BEARING HOUSING
IS FILLED WITH RECOMMENDED LUBRICATING OIL (SERVOMESH SP 320) SO THAT THE
THRUST BEARING IS TOTALLY IMMERSED IN THE OIL.
2. Using the pull and lift equipment, as done previously, slide in the gear box
into position.
3. Jack up the gear box and remove the roller assemblies. Lower the gear box
on to the base plate, after aligning to make the dowel pins entry into gear box
bottom flange.

Bowl Mill
4. Fix the holding down bolts between the gear box and base plate. With The Help
of Stud Tensioning Equipment Pretension the studs between the gear box & The
sole Plate By 16 Tons.
. 5. Lower the bowl & bowl hub assembly on to the table top / flange of the gear
box after ensuring that the keys match with the key slots provided in the bowl
hub.
Note: If required heat the bowl hub with blow torch, to about 100 Deg C with
Uniform torch heating while placing the bowl hub on the gear box for ease of
assembly.
If required, the table/ flange of the Planetary gear box may be rotated by
manually rotating the input shaft. Remove the rigging equipment and the Hoisting
clevis (3no‟s) from the bowl.
6. Fix the holding down studs & nuts between the bowl hub and the table / flange
of the gear box. Pretension the stud to 41,000 Kg load and run down the nut
hand tight.
7. Replace all the components removed in the Planetary gear box withdrawal
procedure (step 5.0 to 10.0) in the reverse order.
8. Torque tighten the gear box holding down bolts to the base plate to 120 Kgm.
9. 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. Fix the Mill-Motor coupling, after checking their alignment, as per procedure, and
replace the guard assembly.
11. Connect the lube oil piping, HT/LT / instrumentation cables to the respective
equipments, which were removed for gear box withdrawal (step no. 3 & 4).
12. Establish power supply and run the gear box lube oil system to ensure that there are
no leakages and also flush the newly assembled gear box till the filter is found
reasonably clear/ clean.
13. Re-install the journal assemblies and the journal opening covers removed for gear
box withdrawal (step no.2).
14. Release the Mill for normal operation.

Bowl Mill
12.1.2 JOURNAL AND COVER REMOVAL SEQUENCE (FIG. 12.a):
Table shows the tasks for replacement of the journal and journal cover assembly from
the bowl mill.
REMOVAL TASKS
1. Disconnect the seal air supply lines from the trunnion shaft and spring assembly
of each journal.
2. Relax the stop bolt lock nut and back out the journal stop bolt until the roll is
resting on the bull ring segments.
3. Release the clamp plate stud locknuts of journal pressure spring assembly
4. Back out the clamp plate studs to remove spring pressure from the journal
head.
5 Rig and remove journal cover and journal assembly.

Bowl Mill
Fig
12.a.
JOC
WITH
JOURNAL PRESSURE SPRING ASSEMBLY

Bowl Mill
12.1.3 DISCHARGE VALVES & MULTIPLE PORT OUTLET ASSEMBLY

REMOVAL(12.b & fig -A)
Table shows the removal tasks for multiport outlet assembly
REMOVAL TASKS
1. Disconnect the purge air piping over the mill discharge valves from the air
supply header.
2. Disconnect electricity and compressed air from the mill discharge valve drivers
and remove the Victaulic / dresser couplings between the coals feed pipes
and the valves.
3. Disconnect Instrument connection
4. Unbolt the multi-port outlet assembly flange and remove the assembly with the
mill discharge valves from separator top.
5 Unbolt and remove the upper center feed pipe.
Fig 12.b. DISCHARGE

VALVES & MULTIPLE PORT
OUTLET ASSEMBLY

Bowl Mill
12.1.4 SEPERATOR BODY REMOVAL (FIGURE. 12.c & FIG-A):
Table shows the removal tasks for separator body.
REMOVAL TASKS
1. Remove the bolts from the flange between the separator body and mill side,
separator body and separator top.
2. Disconnect instrument and other piping, and any other equipment attached
to the separator body and top
3. Remove the entire separator top with deflector assembly, inner cone, feed
pipe and liners from mill separator body and place on suitable place.
4. Remove the separator body with liners from mill side liner assembly and place
on wooden blocks.
SEPARATOR BODY SEPARATOR TOP
Fig 12.c

Bowl Mill
12.1.5 BOWL AND BOWL HUB REMOVAL
After disassembly of the three journal assemblies, the discharge valve and multiple
port outlet assembly, and the separator body, follow the procedure given for
removal of bowl and bowl hub assembly. Table below shows the removal
procedure for bowl and bowl hub.
TASKS
1. Remove the skirt assembly including the scrapper assembly from the
bowl/bowl hub.
2. Remove the labyrinth seal assembly.
3. Remove the bowl and bowl hub insulation cover sheet and the insulation.
4. Loosen and remove the holding down studs & nuts (M 48) between bowl
hub and the table top/flange of the gear box. Use hydraulic jacks to loosen
the nuts.
5. Rig and lift the bowl and bowl hub together using the 3 no‟s of Ratchet lever
type manual handling equipment, suitable slings and eye-bolts, by 65 mm.
6. 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.
7. Alternately, Rig and lift the bowl and bowl hub together using 4 no‟s – 10
tons jacks placed in the mill side air inlet housing and below the bowl hub
flange to free the bowl hub from the gearbox table top/ flange, by 65 mm.
8. Ensure that the bowl hub has cleared the keys provided on the table top/
flange of the gear box.

Bowl Mill
9. Fix suitable size of wooden blocks/ shim plates between the mill side bottom
insulation cover plate and the bowl hub.
10. Lower the jacks such that the bowl and bowl hub assembly load is transferred
to the wooden blocks/ shim plates. Remove the jacks to use them for
gearbox removal.
Fig
12.d. BOWL AND BOWL HUB ASSEMBLY

Bowl Mill
12.2 GENERAL DIS- ASSEMBLY AND RE- ASSEMBLY OF OTHER COMPONENTS:
The following mill components subjected to wear like bull ring segment and journal
rolls are required to renew or replaced periodical intervals based on the inspection
reports and date records. The procedure for renewal of bull ring segment, air port
ring assembly and journal roll are given below:-
12.2.1 RENEWAL OF BULL RING SEGMENTS (Figure 12.d & FIG-H ):
1. For access to the bowl, remove a journal assembly as per disassembly

procedure”Journal Cover and Journal assembly Removal”
2. Unbolt and remove the split clamping ring. Use the jack screws provided to
loosen the ring if necessary. Remove the retaining ring.
3. Remove the old bull ring segments. It may be necessary to air-arc the first
segment into several pieces. When air-arcing, make sure the welding machine
is firmly grounded to the bowl. Exercise care not to cut the bowl.
4. Clean all interior surfaces of the bowl.
5. Install the 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 to hold them in place
against the outer periphery of the bowl as they are being set in place. Refer to
additional instructions on Figure-H
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.

Bowl Mill
12.2.2 AIRPORT RING REPLACEMENT (Figure 11.d):
Air port ring is the part of air port ring assembly. For replacement of airport ring
remove a journal assembly as per table of “Journal Cover and Journal assembly
Removal”. If necessary, remove worn airport ring. The procedure for attaching
new air port ring to bowl is given below:-
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
TECHNICAL POINT
BASED ON MILL PERFORMANCE AND BOWL DELTA „P‟ VALUES ADD AIR RESTRICTION
RINGS ON BODY LINER ASSEMBLY. AIR RESTRICTION PLATES SHALL BE WELDED ON
THE ROTATING WHEEL OUTER SHROUD INNER SURFACE ONE AT A TIME BY WELDING,
IF REQUIRED.

Bowl Mill
12.2.3 ROLL RENEWAL (Fig. 12.e and FIG - J):
After the removing journal opening cover and journal assembly as per
table of journal cover removal procedure, follow the given steps for renewal of
journal roll.
1. Lower the journal assembly until the edge of the roll touches the floor.
Carefully allow the assembly to settle to a horizontal position while further
lowering the hoist.
2. Remove the welded lugs if present holding the roll locknut to the lower
journal housing remove the locknut.
3. After removing the nut lift the assembly to a vertical position and let it rest on
the bottom face of the lower journal housing.
4. Attach a sling around the journal head and apply just enough strain to take
the weight off the bottom face of the lower journal housing. The rigging
should be such that the bottom face remains horizontal.
5. Tap the roll with a brass or lead hammer to knock it off. Do not use a steel
hammer, as it may chip the roll and cause injuries. If the roll cannot be
tapped off, heat it evenly with a torch or roll removal fixture.
TECHNICAL POINT
IF THE ROLL IS HEATED, ALLOW THE LOWER JOURNAL HOUSING TO COOL
BEFORE LOWERING IT INTO A NEW ROLL.
6. When the roll is loose, raise the journal out of the roll and lower it into the new
roll, placed on 100 X 100 mm blocks to permit the lower journal housing to
pass through the roll.
7. Carefully tip the assembly on its side and replace the roll locknut. Drive up
the nut solidly and re-weld the lugs to lock the nut to the housing.
TECHNICAL POINT
BE SURE THE WELDING MACHINE IS GROUNDED TO THE ROLL OR LOWER
HOUSING AND NOT TO THE SHAFT OR JOURNAL HEAD.

Bowl Mill
12.2.4 JOURNAL OPENING FRAME LINER REPLACEMENT (Refer to Fig-L)

After removal of the journal assemblies as per table of “Journal cover and Journal
assembly removal” procedure, follow given below steps for removal of journal
opening frame liner.
1. Remove worn journal opening frame liners.
2. Thoroughly clean journal opening frame where weld plugs are attached to
guarantee a proper weld.
3. Apply RTV sealer to all liner joints. Place liners through on the journal opening
frame with an approximate 3 mm gap between the liners. Secure the journal
frame liners with weld plugs.
4. Apply silicone cement to ceramic plugs and install as shown on the weld plug.
12.2.5 JOURNAL HEAD LINER ASSEMBLY REPLACEMENT:
Table below shows the replacement tasks of journal head liner assembly
TASKS
1. Remove worn journal head liners from journal head liners support.
2. If necessary, wash the tack welds off and remove hex. head screws and
journal head liner assembly.
3. If removed, position journal head liner assembly and secure with hex. head
screws. Tack-weld both sides of screws.
4. Apply RTV sealer to all liner joints. Place liners on journal head liner support
with approximately 3 mm gap between the liners.
5. Secure the liners with weld plugs. Fill weld plug voids with RTV sealer.

Bowl Mill
TECHNICAL POINT
THE JOURNAL HEAD LINER ASSEMBLY SHOULD BE TAGGED AND REINSTALLED TO THE
SAME JOURNAL BECAUSE LINER ASSEMBLY INTERCHANGEABILITY MAY NOT BE
FEASIBLE.
12.3 JOURNAL SHAFT ASSEMBLY WITH DOUBLE UPPER JOURNAL BEARING
The assembly of a pulveriser journal shaft with double upper bearings requires several
distinct steps performed in the proper sequence to assure that proper clearances
are obtained. Proper clearances must be obtained to ensure maximum bearing
life.
1) Establish the upper bearing bench end play by grinding the spacer
supplied with the double bearing.
2) Assemble the upper journal housing subassembly and check the bearing
end play.
3) Assemble the lower journal housing sub-assembly and install the journal roll.
4) Assemble the journal shaft sub-assembly.
5) Assemble journal shaft sub-assembly and journal housing assemblies. Check

the journal assembly bearing end play.
6) Journal Assembly Bearing End-Play
TECHNICAL POINT
THE MEASUREMENTS TAKEN DURING THE ASSEMBLY OF THE BEARINGS MUST BE SO
PRECISE. ALL OF THE COMPONENTS AND MEASURING TOOLS MUST BE AT 70 F, (21C).
IF THIS IS NOT PRACTICAL, THEN THE MEASUREMENTS MUST BE CORRECTED FOR
THERMAL EXPANSION TO 70 F, (21C).

Bowl Mill
1 .Establish Upper Bearing Bench End Play
TASKS
1.1. Measure and record the upper journal housing bearing bore. Use procedure
given in Figure A. Retain data for future reference.
1.2. Grind the bearing spacer.
1.3 Measure and record the spacer length; use procedure given in Figure. 12. B.
SPACER GRINDING CALCULATION
Lateral clearance = (etched on O.D. of Spacer)
Lateral clearance = _________________________
Fit = Average bearing O.D. (Fig. 12.B. - Average housing bore (Fig. 12.A).
Fit = ( ) - ( ) =
Spacer grind value = Lateral clearance - 0.007” - [2.62x (fit)]
Spacer grind value = ( ) -0.007”- [2.62x ( )]
Spacer grind value = __________________________________
1.4 Alternatively use table 10/11 with respect to know the spacer grind value.
Average bore measurement made in step 1.0.
1.5 Measure and record the spacer fixed ground length.
CAUTION
UPPER JOURNAL BEARINGS ARE SUPPLIED IN MATCHED AND SERIALIZED SETS. THE CUPS
AND CONES ARE NOT INTERCHANGEABLE. EACH CUP MUST BE KEPT WITH ITS MATING
CONE. THE BEARING SPACER IS ALSO MATCHED WITH THE CUPS AND CONES AND
SHOULD NOT BE INTERCHANGED WITH OTHER BEARINGS. IF AN ERROR OCCURS IN THE
GRINDING AND AS A RESULT THE BENCH END PLAY IS OUT OF TOLERANCE, THE SPACER
MAY BE REWORKED. ADD MATERIAL TO THE GROUND SURFACE BY WELDING FLAME
SPRAYING OR PLATING AND REGRIND TO THE CORRECT DIMENSION.

Bowl Mill
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 in 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 12.A - Determination of Upper Journal housing Bore Diameters.

Bowl Mill
1. Use a micrometer to measure spacer length “E” at eight locations on 45 intervals
prior to grinding.
2 Record and average readings.
3. Grind the spacer; remove material as per table-10/11.
4. Re-measure ground spacer length, record and average readings.
OIRENTATION DIMENSION E-NEW DIMENSION E-GROUND

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

8
Figure – 12.B Journal Bearing Spacer Length Determination

Bowl Mill
2. Assemble Bearing in Housing and Check End-Play
TASKS
2.1. Install the double bearing in the upper journal housing along with spacer.
2.1.1 Heat the upper journal housing to 80  C to 100  C. For, ease of assembly,
each 0.025 mm of interference requires a 5.5C temperature differential
between the bearing cups and bearing housing.
NOTE:- To facilitate future disassembly coat the O.D of the bearing cups with
Molykote 41 or equal. (If bearings are chilled for insertion coat the bearing
housing bore).
2.2 Install the lower bearing cup squarely in the housing, follow in rapid order and
sequence with the finish ground bearing spacer, the bearing cone
assembly(s)., the second bearing cup, the bearing ring (if so equipped) and
the bearing keeper.
2.3 Insert and torque the bearing keeper bolts to 50 ft lbs. (6.91 kgm) to ensure
that the bearing cup and spacer stack is properly seated.
2.4 Allow the housing and bearings to return to room temperature
3.0 Install bearing keepers and shims
3.1 Using a 0.001” (0.0254mm) feeler gauge, check between the bearing housing
shoulder and the bearing cup to assure the bearing cup is properly seated.
3.2 Relieve tension on the bearing keeper cap screws to finger tight.

Bowl Mill
3.3 Measure the gap between the end face of the housing and the bearing
keeper In four places, reference Figure-12.D. Average the measurements.
3.4 Assemble a shim ack with a total thickness of 0.003” 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.
3.5 Remove cap screws and bearing keeper. Assemble the shim pack to the
Upper housing.
3.6 Replace the bearing keeper.
3.7 Use a thread locking/sealant, reinstall the cap screws and uniformly torque.
TECHNICAL POINT
AS AN ALTERNATE ASSEMBLY METHOD, THE BEARING CUPS AND SPACER MAY BE
CHILLED IN DRY ICE INSTEAD OF HEATING THE BERAING HOUSIN. IF THE CHILLING
METHOD IS USED, THE BEARING CUPS AND CONES AND ROLLER BEARINGS MUST BE
COMPLETELY COATED WITH THE RECOMMENDED JOURNAL OIL IMMEDITELY AFTER
ASSEMBLY TO PPREVENT AFTER ETCHING.

Bowl Mill
1. Use a micrometer to measure the outside diameter of the bearing cups at four
locations 0, 45 , 90, and 135.
2. Record reading in the table below, all dimensions must agree within 0.001” TIR
(0.025mm).
3. Average the dimensions for comparison with bore dimension “B” Fig.12 A.
ORIENTATION BRG. 1 DIMENSION BRG. 2 DIMENSIONS

0
45
90
135
F AVG F11 AVG = F2 AVG =
FAVG= F0 + F45 + F90 + F135

4
Fig. 12.C Journal Bearing Outside Diameter

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

0
90
180
270
GAVG = G0 + G90 + G180 + G270
4
Figure. 12.D. Bearing Keeper Shim Pack.

Bowl Mill
TASKS
4.0 Check upper bearing end play
4.1 Arrange the upper journal housing and bearings in the end play fixture. Refer
to Figure 12.F. A base capable of withstanding a lift load of 4400 lbs. (2000 kg)
must be made available.
4.2 Attach an overhead hoist, a come-along and a direct reading load cell of
approximately 5 ton capacity to the eyebolt of the end play fixture. All
components must be of sufficient capacity to withstand the lift load of
bearing, upper housing assembly given on the Upper Bearing Lift Load and
End Play Table -12.
4.3 Mount three dial indicators as shown in Figure.12. F. Rest the contact buttons
on the top of the housing.
4.4 Rotate the housing at least five revolutions in one direction to seat the bearing
Rollers.
4.5 Zero the dial indicators and mark their position on the housing.
4.6 Raise the housing and bearing cups with the come-along until the load cell
reads the lift load value determined in step 5.2.
4.7 Turn the housing five revolutions in one direction. Return the dial indicators to
their original marked position and record the readings, refer to Figure. 12G.
4.8 Lower the come-along until the load on the housing is released.
4.9 Turn the housing five revolutions in one direction. Return the dial indicators to
their original marked position and record the indicator readings.

Bowl Mill
4.10 If the indicators have returned to zero  0.0005” ( 0.0127 mm) in step 4.9
calculate and record the average indicator reading for step 4.7 on the
worksheet. If the indicators do not return to zero  0.0005”  0.0127) disregard
the average reading.
4.11 Repeat steps 4.5 through 4.10 until at least three average readings are
recorded on worksheet.
4.12 Average the average readings on the worksheet and record. The final value
must be within the end play limits give on the Upper Bearing End Play Table,
Table 12 or the assembly must be reworked.

Bowl Mill
Figure:12. F End play fixture

Bowl Mill
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
H1AVG  + H5AVG
HAVG =
5
Note: Refer to Procedures in Text, steps 4.5 to 4.10 in page: 112
Figure: 12.G Upper Bearing End Play

Bowl Mill
SPACER GRINDING VALUE
HOUSING BORE TIMKEN
INCHES MM INCHES MM
(Range) (Range)
17.9950 - 17.9952 457.013 - 457.079 0.000 0.000
17.9953 - 17.9955 457.080 - 457.087 0.001 0.025
17.9956 - 17.9958 457.088 - 457.094 0.002 0.051
17.9959 - 17.9961 457.095 - 457.102 0.003 0.076
17.9962 - 17.9964 457.103 - 457.110 0.004 0.102
17.9965 - 17.9967 457.111 - 457.117 0.005 0.127
17.9968 - 17.9970 457.118 - 457.124 0.006 0.152
TABLE - 10
SPACER GRINDING VALUE
HOUSING BORE TORRINGTON
INCHES MM INCHES MM
(Range) (Range)
17.9950 - 17.9952 457.013 - 457.079 0.000 0.000
17.9953 - 17.9955 457.080 - 457.087 0.001 0.025
17.9956 - 17.9958 457.088 - 457.094 0.002 0.051
17.9959 - 17.9961 457.095 - 457.102 0.003 0.076
17.9962 - 17.9964 457.103 - 457.110 0.004 0.102
17.9965 - 17.9967 457.111 - 457.117 0.005 0.127
17.9968 - 17.9970 457.118 - 457.124 0.006 0.152
TABLE - 11
Spacer Grinding Dimensions: Double Upper Bearing Journals

(Refer to Figure B)

Bowl Mill
USAGE
When using this table ensure that the upper bearing and upper housing part number match
those listed in the table.
The lift load is used in determining upper bearing end play described in steps 4.1 through
4.12. The results obtained in step 4.12 should be compared with the values for the end play
tolerance given in table 12.
The values given are used in determining journal housing flange gap shims, Step: 10.4 and
Figure 12.L. and journal assembly end play steps 11.6 through 11.14 and Fig 12.M.
UPPER BEARING JOURNAL ASSEMBLY
Mill Size Lift(lb) Load End play (Inches) Tolerance Lift(lb) Load End play „A‟
lbs (Kgs) (mm) lbs (Kgs.) (Inches) (mms.)
963-1003 4000 1814 0.005 - 0.009 0.127 - 0.229 2200 998 0.006 0.152
TABLE -12
Pulveriser Journal Lift load and End Play

Bowl Mill
Assemble the Lower Journal Housing Sub-Assembly
TASKS
6. Grinding Roll with locknut( taper fit connection)
6.1 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.
6.2 Once the taper contact has been verified, press the grinding roll and lower
housing together with 50 tons force.
6.3 Tighten the locknut on the lower housing while maintaining the 50 ton force.
6.4 Spot drill the grinding roll through the set screw holes.
6.5 Install the cone point set screws with Loctite 271 or equal and torque to 50 ft/lbs
(6.9 kg/m).
6.6 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.
7. Assemble the lower journal bearing cup with lower journal housing
7.1 Using procedure on Figures A and measure the lower journal housing bearing
and pilot bores and record the measurements on Figure J. 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).

Bowl Mill
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.
NOTE: - 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.

Bowl Mill
Note:
For Bore determination use procedure Figure 12.A:
For Bearing O.D. use procedure Figure 12.C.
ORIENTATION BRG. BORE PILOT BORE LWR. BRG. CUP

BBL BBU BPL BPU F3 OUTSIDE DIM
0
45
90
135
B0+B45+B90+B135 CB L = CB U = CP L = CPU = F3 AVG =

4
CL  CU DB = DP =
2
F 0 + F 45 + F 90 + F135
F3 AVG =
4
Bearing/Bore Interference = F3 AVG - DB = ___________
Figure 12.J. Lower Journal Housing Bore Dimensions & Interference

Bowl Mill
4. Journal Shaft Sub-Assembly
TASKS
8. Check the journal shaft for straightness and roundness. Measure and record the
information, reference Figure12. K. The shaft must be straight and round with
in 0.001” (0.025 mm).
9.0 Assembly of long spacer shaft journals
9.1 Install the oil seal wear ring.
9.2 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).
9.3 Heat oil seal wear ring in an oven or in oil to 300F maximum.
9.4 Locate oil seal wear ring on journal shaft as shown in the assembly drawing
(either by a given dimension or against a shaft shoulder). Allow wear ring to
cool.
10. Install the upper bearing assembly
10.1 Lubricate the upper journal bearing seat on the journal shaft with standard
journal oil.
10.2 Install one oil seal facing inward into the upper journal housing and then the
remaining two with the lip pointing outward. Coat the seal lips and fill the
cavities between the seals with Molykote 33 or equal.
NOTE: AVOID MARRING THE SHAFT BLENDED RADIUS FINISH OR DAMAGING OIL SEAL
DURING ASSEMBLY
10.3 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).
10.4 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.

Bowl Mill
11. Install the lower journal bearing cone
11.1 Assemble the lower bearing spacer (if applicable) on the journal shaft. The
chamfer on the spacer must clear the shaft fillet.
11.2 Coat the lower bearing seat on the journal shaft with Molykote 41 or equal.
11.3 Check the I.D. of the bearing cone, use procedure Figure A and compare
with shaft measurement 12K, Figure12. K. The interference must be between
0.001” and 0.007” (0.025 to 0.178 mm).
11.4 Heat the bearing cone in an oven or oil bath to 250F (120C) maximum and
install it on the journal shaft.
11.5 Install the bearing keeper and torque cap screws to 100 ft. lbs. (14 kgm).
11.6 Allow bearing to return to room temperature.
11.7 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.
12. Install bearing keeper and shim assembly
12.1 Remove cap screws and journal bearing keeper.
12.2 Measure the gap between the shaft end and the bearing face with a depth
micrometer in four places. Average the readings.
12.3 Prepare a shim pack with a total thickness of 0.076 to 0.127 mm less than the
average gap measured in step 12.2.
12.4 Assemble shim pack, keeper plate, lock plate and screws to the journal shaft.
12.5 Bend the lock plate against the nearest flat on the screws.

Bowl Mill
5. Assemble the Journal Shaft to the Housing Assemblies
TASKS
13 Assemble journal shaft with housing and sub assemblies.
NOTE:- PRIOR TO ASSEMBLY COAT ALL BEARINGS WITH STANDARD JOURNAL OIL
13.1 Install a lifting eye in the end of the journal shaft.
13.2 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.
13.3 Turn the shaft five complete revolutions in one direction.
13.4 Measure the gap between the upper and lower journal housing flanges in
eight places, 45 increments, with feeler gauges. Record the reading,
reference Figure. 12.L. all readings should be alike within 0.003” (0.076 mm).
Average the readings.
13.5 Prepare a shim pack with a thickness equal to the average housing gap
measured in step 13.4 above plus 1/2 the end play of the two row upper
bearing. Fig 12.F, plus value “A" from the assembly end play table, table 12.
Check the shim pack with a micrometer.
13.6 Remove the journal shaft and upper housing assembly (or the upper housing
sub assembly) from the lower housing.
13.7 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.
13.8 Reassemble the lower housing, shaft assembly and upper housing with the
Prepared shim stack. Do not pinch the “O” ring.
13.9 Apply Loctite 277 or equal to the hex socket head cap screw threads. Install
cap screws and torque to assembly specification.

Bowl Mill
6 Journal Assembly Bearing End-Play
TASKS
14 Check journal assembly bearing end play.
14.1 Fasten two rods threaded at their lower ends in the lifting holes in the flange
of the upper journal housing
14.2 Lock the rods with hex nuts.
14.3 Install a dial indicator on each rod. Mark the indicator locations (180 0 apart)
on the top of the journal shaft.
14.4 Rotate the journal five revolutions in one direction and return the dial
indicators to their marked locations.
14.5 Zero the indicators.
14.6 Use a come-along and a five ton load cell, carefully lift the journal shaft to
the lift load given in Table 12.
14.7 Rotate the shaft at least five revolutions in one direction and return the dial
indicators to their original position.
14.8 Record the two indicator readings. Refer to Figure. 12.M.
14.9 Lower the shaft to zero load on the load cell.
14.10 Rotate the journal shaft at least five revolutions in one direction and return
the dial indicators to their original position. Record the indicator readings.
14.11 If both indicators have returned to zero  0.005” ( 0.0127 mm) in step 14.10
average the readings take in step 14.8 and record.

Bowl Mill
14.12 Zero the dial indicators and repeat steps 14.6 through 14.11 until three
average indicator readings, within 0.001” (0.025mm) are obtained.
14.13 Average the three average readings.
14.14 The value obtained in step 14.13 should be 1/2 the end play of the two row
bearing, Figure F. plus value “A” from the Assembly End Play Table, Table 12.
The acceptable tolerance is  0.001” (0.025 mm).
14.15 If the journal assembly end play is not within acceptable limits, disassemble
the housings, and adjust shims (steps 13.3 through 13.9) as required. After
shims are adjusted, recheck journal assembly end play by repeating steps
14.1 through 14.14.
14.16 If the journal assembly end play is within the acceptable limits, remove the
rods installed in step 14.1 and plug the lifting and jack screw holes in the
upper journal bearing with set screws.

Bowl Mill
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 12.K Shaft out of Round and Straightness

Bowl Mill
Orientation 1st TRIAL GAP 2nd TRIAL GAP 3 rd TRIAL

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
Figure12. L. Journal Housing Flange Gap Shim Thickness

Bowl Mill
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 12.M. Journal Assembly End - Play

Bowl Mill
12.4 JOURNAL HEAD TO JOURNAL SHAFT ASSEMBLY
a. Lubricate the threads on the journal shaft with anti-seize compound and install
the lock nut.
b. Slug lock-nut tight using the supplied wrench and a sledge hammer. Scribe the
nut and the head with chalk and strike the wrench with three additional solid
blows of the sledge hammer. If the nut moves less than 3 mm ,it is sufficiently
tight. If the nut moves more than 3 mm the tightening process should be
repeated. Lock the set-screw on the lock nut once it is properly tightened.
c. Stamp the serial number of the journal assembly which is located on the end
of the journal shaft on the journal head for future identification.
Fig.12.e

Bowl Mill
12.5 Adjustment of the Seal Air Gap
ORIENTATION 1st TRIAL 2nd TRIAL 3 rd TRIAL

GAP GAP GAP
0
45
90
135
180
225
270
315
0 + 45+...........315
AVG GAP =
8
Upper Journal Head Skirt Flange Gap
Fig. 12.N. Air Seal Ring Upper Flange Gap
1. Remove cap screws and drop the journal head skirt until it is seated squarely on the
taper of the upper journal housing.
2. Measure the gap between the journal head and the skirt flange in eight places.
Record and average on the work sheet next page.
3. The thickness of the shim stack is equal to the average gap measured in Step 2 minus
twice the desired air gap. The air gap should be 1 mm. Therefore, the shim stack
thickness will be the average gap minus 2 mm.
4. Measure each stack of split shims with a micrometer.
5. Install the split shims between the journal head and the journal head skirt flange. Install
the cap screws and torque them to 13 Kg-m. With Loctite # 242 applied to the
threads.
6. Check the seal air gap between the upper journal housing and the journal head skirt
in eight places. Each measurement should be 1 mm ±0.13 mm.

Bowl Mill
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. 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.

Bowl Mill
STORAGE AND PRESERVATION XRP1003
13.0 STORAGE AND PRESERVATION OF MILL COMPONENTS
When the mill is not operated for more than one week, any one of the following
preservation procedures may be adopted to protect the interior parts of the gear
case like worm shaft, vertical shaft, bearings, worm gear etc.
13.1 PRESERVATION WITH PRESERVATIVE
Before longer storage times, the gear unit should be run with no load with
preservative.
We recommend the preservatives listed in the table below for preservation of the
gear unit:
STORAGE SATBILITY PRESERVATIVE SPECIAL MEASURES

Plug the gear unit air tight,
SERVOMESH SP320 OF
up to 24 months replace air filter with plug
IOC screws (replace before
startup)
SERVOMESH SP320 OF Re-preserve gear unit as up to
more than 24 months 24 months
IOC
TABLE-13 Recommended preservatives for PGB
Internal preservation procedure

- Shut down the gear unit and drain the oil as described in Section “Maintenance
and repair”.
- Fill with preservative up to the upper mark of the oil level indicator through the
ventilation hole or the hole in the inspection cover.
- Close the venting hole or the cover opening, respectively.
- Run the gear unit briefly with no load. To do so, start the oil supply system for a
time minimum 1 hour.
CAUTION
THERE IS A RISK OF SCALDING FROM HOT PRESERVATIVE EMERGING.
WEAR PROTECTIVE GLOVES.

Bowl Mill
- The gear unit must start once. If this is not possible, the gear unit must be rotated
at least 1 revolution on the output flange. This can be done by turning the
input shaft D1 manually.
- Remove the oil drain plug and drain the preservative into a suitable receptacle
and dispose of in accordance with the regulations.
- Replace the oil drain plug.
- Seal labyrinth seals on input shaft and output flange with adhesive tape.
OIL TESTING:
The oil may be tested every 3 months to ensure its properties. Refer PGB section for
oil properties and impurity limits.
13.2 SPARE ROLLER JOURNAL ASSEMBLIES PRESERVATION:
These assemblies shall be stored in closed storage in vertical position (Standing on

roll).The journal assemblies are completely filled with recommended lube oil prior to
shipments from workshops. Oil to be used: Servo Mesh SP 680 of IOC. At site, the
condition of oil, level and leakage if any should be checked periodically. Use Oil Dip
Stick for level measurement.
Prior to commissioning excess oil is to be removed with the help of siphon hand
pump. Retain the recommended oil level in the assembly. Prior to commissioning,
the oil in the journal Assembly is dirty; the same is to be removed with a suction hand
pump. Clean the internals by topping up with a thinner. Fill the assembly with
lubricant SERVOMESH SP 680 OF INDIAN OIL COROPORATION LTD or Equivalent to the
recommended level. Make sure the pipe plug is tightly closed in the journal shaft.
The exterior surface of the journal should be kept reasonably dry and free of any
moisture and other weather condition.
Note:- As a best maintenance practice, the level of oil in each journal assembly is
required to be checked periodically in order to avoid any damage to the bearings
in the journal shaft assembly.

Bowl Mill
13.3 PRESERVATION OF JOURNAL ASSEMBLIES IN THE MILL:

When the mill is out of operation for long period preservation of journal assembly shall
be done by filling the recommended lube oil completely. Prior to taking the mill into
the service the excess oil may be siphoned off.
13.4 DRIVE COUPLINGS:

If uncoupled, pack with a recommended grease and wrap with sheet (plastic). If
coupled, fill with the same recommended grease.
13.5 MILL DISCHARGE VALVES ASSEMBLY:
These valves carry several integrally mounted instrumentation components like

solenoid valves, Limit switches, Electrical cable conduits, Junction Box, Air Cylinders
etc. These assemblies should be stored in fully covered condition with the integrally
mounted instrumentation components protected against moisture and dust.
13.6 INTERIOR AREAS:

The air passages, grinding and classifying areas of the Mill, Mill Discharge Valve,
Reject Hoppers, etc. should be stored under cover and protected as much as
possible. Water should not be allowed to accumulate and stand in or on these parts.
13.7 MILL MOTOR:

Follow manufacturer‟s instructions.
13.8 GENERAL:
All exposed machined surfaces like shaft extensions, threaded or drilled bolt holes,
classifier link mechanisms should be periodically preserved with protective grease or
by such means and covered.
Note: Refer Lubrication Schedule (TABLE-1), for the recommended lubricants

Bowl Mill
SPARES XRP1003
14.0 SPARES
A stock of spares for important replacement and wearing parts is essential for satisfactory
operation and serviceability of the bowl mill at all times. Classification of Bowl Mill spares are
given below:-
BOWL MILL SPARES - CLASSIFICATION

Bowl mill spares can be classified on the given following basis.
1. Long Delivery Items

2. Short Delivery Items
3. Low Value Items
4. High Value Items
5. Fast Wear Items
6. Special Items
LONG DELIVERY ITEMS (DELIVERY 12 TO 18 MONTHS)
This type of items consist following spares
i. Journal Assembly
ii. Lower Journal Housing
iii. Journal Head
iv. Bowl
v. Pressure Spring
vi. Mill Discharge Valve Assy
vii. Motor Coupling
viii. Journal Shaft
ix. Trunnion Shaft
SHORT DELIVERY ITEMS
This type of items consists following spares.
i. Trunnion Shaft end Cap

ii. Bowl Extension ring
iii. Air Seal & Dust Guard Assembly
iv. Seal assembly And Seal Runner Assembly
v. Scraper Assembly
vi. Valve Body & MPO
vii. Inner cone
FAST WEAR OUT ITEMS (DELIVERY 6 TO 12 MONTHS)
This type of items consists following spares:-
i. Grinding Elements Like Rolls & Bull Rings

ii. All Liners Like
 Journal Head Liners
 Separator Liners

Bowl Mill
SPARES XRP1003
 M.D.V. Liners
iii. Oil Seals For Journal Assembly, PGB Assy
iv. Oil Seal Wear Sleeves
v. O Ring
SPECIAL ITEMS
This type of items consist following spares
i. All Fixtures
 Spring Compression Fixture
 Grinding Roll Removal Fixture
ii. Any Items With Specific Scope
iii. Coal Sampling Devices

Bowl Mill
SPARES XRP1003
14.1 RECOMMENDED SPARES LIST
ONE MILL QTY FORMS A SET –REFER O&M MANUAL FOR FIGURE REFERRED HEREIN
SL DESCRIPTION OF PART NO. RECOMMEND UNIT OF FIGUREN

NO OFF PER ED MEASUR O- ITEM
MILL SETS./ 10 EMENT NO
MILLS
A ROLLER JOURNAL ASSEMBLY- FIG
01 GRINDING ROLLS – 50 " (SINTERED 3 30 SET P-03

CARBIDE INSERT TYPE)
02 JOURNAL ASSEMBLY (WITH 3 3 SET FIG R
G.ROLLS & LINERS)
03 JOURNAL BEARING LOWER 3 10 SET P-23
04 JOURNAL BEARING (UPPER) 3 10 SET P-21
05 JOURNAL CAP SCREW LOCK 3 10 SET P-26

PLATE
06 JOURNAL HEAD 3 10 NO‟s P-01
07 JOURNAL HEAD LINERS SET (5- 3 48 SET R-08

TYPES)
08 JOURNAL SHAFT 3 8 SET P-01
09 LOCKNUT (GRINDING ROLL) 3 30 SET P-04
10 O RING OIL SEAL (VAR-07) 3 30 SET P-06
11 OIL SEAL (UP.JR.HSG ASSY) 6 30 SET P-08
12 SHIM SET (UPP JRL HSG) 3 SETS 10 SET P-17
13 SHIM SET (JRL BRG KEEPER) 3 SETS 10 SET P-24
14 SPRING PINS D10x30 6 10 SET P-16
15 TRUNNION SHAFT END CAP 3 10 SET Q-04

(THRUST END)
16 TRUNNION SHAFT END CAP (FREE 3 20 SET Q-05
END)
17 JRNL TRUNNION BUSHING 6 20 SET Q-03
18 TRUNNION BUSHING RETAINER 6 20 SET Q-06
19 THRUST PLATE (THRUST END) 3 10 SET Q-08
20 THRUST PLATE (FREE END) 3 10 SET Q-09
21 CYLINDRICAL PIN D12x60 3 20 SET Q-11
22 HEX.SOC.CAP SCREW M30X230 36 10 SET P-07
23 TRUNNION SHAFT 3 5 SET Q-02

Bowl Mill
SPARES XRP1003
24 PIPE PLUG 2” TS 3 10 SET
25 JOURNAL HEAD LOCK NUT 3 20 SET P-13
26 SHIM SET ( UPP BRG KEEPER) 3 10 SET P-18
27 SEAL WEAR RING 3 5 SET P-09
B MILL DRIVE & BOWL ASSY.
01 BOWL EXN.RING SEGMENT 1 SET 48 SET U-12
02 BOWL HUB CLAMPING RING 1 SET 30 SET U-14
03 BOWL HUB COVER 1 10 SET U-17
04 BULL RING RETAINER RING 1 30 SET U-13
05 BULL RING SEGMENT ASSEMBLY- 1 SET 30 SET FIG H

HICHROME
06 LAYBRINGTH SEAL ASSEMBLY 1 10 SET U-28
07 SKIRT ASSY 1 5 SET U-27
08 SCRAPER 2 30 SET S-03
09 SCRAPER & GUARD ASSY 2 10 SET U-33
10 SCRAPER BUSH 4 40 SET S-12
11 SCRAPER PIN 4 40 SET S-08
12 WEAR PLATE (BOWL HUB COVER) 1 30 SET U-19
C MILL SIDE LINER ASSEMBLY
01 INSULATION COVER PLATE 1 SET 10 SET T-2&3

ASSEMBLY SEGMENTS
02 WEAR PLATES 1 SET 30 SET T-12&13
D SEPARATOR BODY ASSEMBLY
01 SPRING STUD BEARING (WEAR 3 10 SET U-22

SLEEVE)
02 SPRING AIR SEAL CAP 3 4 SET U-25
03 SPRING GUIDE 3 4 SET U-10
04 HIGH TENSILE STUD M39X3-260 18 10 SET U-19
05 HOUSING COVER (WEAR SLEEVE) 3 10 SET U-14
06 SPRING STUD ADOPTER 3 1 SET U-08
07 SPRING PRELOAD STUD 3 1 SET U-07
08 JOURNAL PRESSURE SPRING ASSY 3 1 SET A-08
09 SPRING ORIFICE PLATE 3 1 SET U-24
10 SET OF AIRPORT RING ASSEMBLY 1 SET 20 SET A-13

Bowl Mill
SPARES XRP1003
11 DEFLECTOR BLADES 1 SET 10 SET
12 DEFLECTOR SHAFT BUSHING 1 SET 20 SET E-23
13 INNER CONE ASSEMBLY WITH 1 10 SET A-15

CERAMIC LINER
14 JOURNAL STOP BOLT BUSHING 6 30 SET A-32
15 O-RING OIL SEAL (STOP BOLT) 3 6 SET A-33
16 OUT LET VENTURY ASSEMBLY 1 10 SET A-17
17 OUT LET VENTURY COLLAR 1 10 SET A-28

ASSEMBLY
18 VENTURI VANE (WITH CERAMIC 4 10 SET A-22
LINER
19 DRUM SECTION 1 10 SET A-29
20 CENTER FEED PIPE UPPER 1 4 NO A-20
21 GASKET FOR VICTAULIC 4 10 SET A-34

COUPLING
22 GASKET FOR DRESSER COUPLING 1 10 NO A-21
E MILL DISCHARGE VALVE

ASSEMBLY
01 MDV ASSEMBLY 1 10 NO
01 CERAMIC LINED VALVE BODY 4 10 SET A-19
02 CERAMIC LINED MPO 4 10 SET A-30
02 GASKET FOR FLANGE 1 20 SET A-31
01 SOLENOID VALVES 2 10 SET
02 LIMIT SWITCHES 4 20 SET
03 PNEUMATIC OPERATED POWER 2 20 SET

CYLINDER
G MILL MOTOR COUPLING 1 10 NO.

Bowl Mill
SPARES XRP1003
1.0 PLANETARY GEARBOX: It is recommended to keep one spare gearbox for use in
emergency. The maintenance of gearbox, if required shall be done at Hyderabad
works. However, recommended spares list is provided in the O & M manual PGB
section.
2.0 Recommended spares for lube oil system shall be part of the o&m manual of the lube
oil system vendor. Refer to their o&m manuals for the same.
3.0 It is recommended that the customer should keep one set of total journal assembly
along with grinding rolls 2 sets for replacement in short period there by reducing the
down time of mill.
4.0 One mill quantity forms a set.
5.0 This list is not exhaustive and may change based on coal characteristic,
maintenance practice etc. customer is advised to revise the list based on their
experience at the power station.
6.0 Long term preservation method for Gear Box (10 years):
For long term preservation, example spare Gearbox kept in stores,

the complete Gearbox has to be filled with the recommended Lube oil.
The step-by-step procedure is given below:
6.1 Preparatory work
 The lower drain valve on the gear unit must be tightly sealed with a screw plug
or the handle locked in close position.
 The oil inlet and drain lines must be sealed with blank flanges.
 To tightly seal the labyrinth seal on the input shaft, a sealing cap must be fitted
to the gear unit and sealed as shown in the sketch/ photo below.
 The oil drain of the sealing cap must be tightly sealed with a screw plug.
 The vent in the sealing cap must remain open during the oil filling until the oil
runs over. Then the vent must be sealed with a screw plug.
 The breather assembly fitted to the Gearbox (two numbers) shall be removed
and the opening to be sealed with a screw plug. The breather assembly from
the thrust pad bearing chamber shall be removed only after completion of oil
filling activity and then plugged.
a. Filling with oil
 The oil to be put in must be filtered beforehand with a 25 micron filter gauge.

Bowl Mill
SPARES XRP1003
Note: Re-use and preparation of the recommended lube oil, for normal
operation, after long periods of preservation and storage must be checked up
with the oil manufacturer.
 The gear unit must be filled with oil via the oil drain valve of the thrust pad
chamber. During filling care must be taken that the vent of the “Preservation
cap” fitted at site on the input shaft is not sealed until oil emerges from it. Oil
filling further shall be continued after sealing the cap vent, once oil emerges
from it.
 The rate of filling the oil into the thrust pad bearing chamber shall be such that
oil does not emerge out from its labyrinth seal.
 The Gearbox is considered as „completely filled‟ when the oil emerges from the
thrust pad bearing chamber breather assembly. Now the breather assembly is
removed and screw plug fitted in its place.
 The drain valve of the thrust pad bearing chamber shall be closed and the
handle locked. Seal the end with a screw plug too, after removing the oil supply
line connected to the valve. The labyrinth seal in the thrust pad bearing
chamber shall be sealed with adhesive tape.
Note: a) Clean any oil spillage immediately. Oil leaks, if any, occurring during
filling must be attended to immediately.
b) The gear unit must be inspected for leaks at regular intervals.
 The long term preservation method explained above is suitable for a period of
10 years. After 10 years, the filled oil must be totally replaced following the
above procedure.
 Before starting up the gear unit the preservation oil must be drained off at the oil
drain points on the thrust pad bearing chamber and the gear unit base. The
Preservation cap is to be dismantled and stored for future use. The breather
assemblies have to be installed back in their position and the thrust bearing
housing labyrinth seal adhesive tape shall be removed. Then installation and
start-up of the spare Gearbox must be carried out in accordance with the
Erection/ O&M instruction manuals.
 The quantity of Lube oil required per mill for filling Gearbox top and bottom
chambers together is 1000Liters.
7.0 Long term preservation of Gearbox fitted in mill and put into operation:
For Gearbox which is in operation, in case the unit outage is for long period, the
long term preservation procedure is different. In that case we need to run the
Lube oil system for one hour and then the mill at no load for 15 minutes to ensure
that all the gearbox internals are thoroughly lubricated and oil film applied.
Otherwise, with lube oil system kept in service, the Gearbox input shaft shall be
manually rotated such that the bowl rotates by one complete revolution, at
least. Then the breather assemblies have to be removed and kept in safe place
for re-use. The labyrinth seals of the input shaft and thrust pad bearing chamber
shall be sealed with adhesive tape. This procedure has to be repeated
periodically, till the mill/ gearbox is taken back into operation.

Bowl Mill
SPARES XRP1003
These long term preservation steps have to be taken so that the gear box
components are not exposed to atmospheric conditions and there by avoid
rusting, pitting or other damages for trouble free operation, when put back into
service.
PLANETARY GEARBOX WITH PRESERVATION CAP FOR LONG TERM PRESERVATION
Long Time Preservation Method - Preparation – Fixing of end cap on the input shaft to avoid
oil leakage when the housing is filled with lube oil up to the output flange labyrinth seal

Bowl Mill
SPARES XRP1003

O&M Manual XRP 1003

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OPERATION & MAINTENANCE

CUSTOMER M/s DAMODAR VALLEY CORPORATION

PROJECT BOKARO ‘A’ TPP 1X500 MW

Publication NO. HY-BM-019-2013

PUBLICATION NO: HY-BM-019-2013

REV. NO: 00, DATE: 06/11/2013

BHARAT HEAVY ELECTRICALS LIMITED

Sl. no. Description page no.

BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LIMITED

Fig No. Description

A Bowl Mill cross-section

BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LIMITED 1

2.0 TECHNICAL DESCRIPTION

2.1 MILL TECHNICAL DATA:

Type Of Mill XRP 1003

i) Low power consumption

BHARAT HEAVY ELECTRICALS LIMITED 2

2.2 MAJOR ASSEMBLIES:

a) PLANETARY GEAR BOX AND BOWL HUB ASSEMBLY:

b) MILL SIDE AND LINER ASSEMBLY:

The hot primary air for drying and carrying

BHARAT HEAVY ELECTRICALS LIMITED 3

c) SEPARATOR BODY ASSEMBLY:

The separator body holds the components that give

d) ROLLER JOURNAL ASSEMBLY:

The roller assembly consists of journal shaft,

e) MILL DISCHARGE VALVE ASSEMBLY:

BHARAT HEAVY ELECTRICALS LIMITED 4

Pulverization is the method of preparing raw coal for complete burning.

3.1 CHECKLIST OF “DO‟S” - BOWL MILL

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

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.

13. Check that tramp iron spout valve is open.

BHARAT HEAVY ELECTRICALS LIMITED 5

15. Check that cold air gate is open.

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

2. Check for proper mill outlet temperature.

3. Check for proper mill air flow.

4. Check for all bearing and oil temperatures.

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

8. Carry out raw coal analysis at routine intervals.

BHARAT HEAVY ELECTRICALS LIMITED 6

10. Check for any abnormal sound.

i) During Normal Shut-Down :

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

ii) During Emergency Shut-Down :

BHARAT HEAVY ELECTRICALS LIMITED 7

3.2 CHECK LIST OF “DON‟TS” - BOWL MILL

A. BEFORE START-UP AND OPERATION :

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

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

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

BHARAT HEAVY ELECTRICALS LIMITED 8

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

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

3.3 PRINCIPLES OF OPERATION: