bowl mill

CUSTOMER GVK LIMITED GOINDWAL TPP 2X270MW

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-0 36-2011 REV. NO: 00, DATE: 11/08/2011

ISSUED BY

PULVERISERS ENGINEERING BHARAT HEAVY ELECTRICALS LIMITED RAMACHANDRAPURAM::HYDERABAD INDIA

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-0 36-2011 REV. NO: 00, DATE: 11/08/2011

ISSUED BY

PULVERISERS ENGINEERING BHARAT HEAVY ELECTRICALS LIMITED RAMACHANDRAPURAM::HYDERABAD INDIA

BOWL MILL XRP 883

TABLE OF CONTENTS Sl.No

Description

Page

1

Introduction

5

2

Precautions For Mill Erection

6

3

7

4

Protection & Preservation Of Mill Components Preparation For Erection

5

Grouting Instructions

12

6

Installation

18

7

Lubrication

31

8

Setting-up Bowl Mill

36

9

Motor Installation, Coupling Mounting, Alignment And Assembly Procedure Mill Optimization

41

Planetary Gear Box – KMP280

49

10 11

BHARAT HEAVY ELECTRICALS LIMITED

9

48

1

BOWL MILL XRP 883

LIST OF ILLUSTRATIONS BOWL MILL CROSS SECTION

FIG.1

LEVEL & GROUTING PROCEDURE

FIG. 2

AIRPORT ASSEMBLY

FIG. 3

BULL RING ASSEMBLY

FIG. 4

INNER CONE SPOUT SEGMENT ASSEMBLY

FIG. 5

TIGHTENING TORQUE FOR FASTENERS

FIG. 6

CLASSIFIER ASSEMBLY

FIG. 7

SPRING COMPRESSION PROCEDURE

FIG. 8

SPECIAL TOOLS

FIG. 9

PROTECTIVE SEAL APPLICATION

FIG. 10

EQUIPMENT ALIGNEMENT RECORD (FORM-A)

FIG. 11

EQUIPMENT ALIGNEMENT RECORD (FORM-B)

FIG. 12

LUBE OIL LOCATION

FIG. 13

MILL MOTOR COUPLING

FIG. 14

WIRING DIAGRAM – DIAGRAM – GEAR BOX RTDS

FIG. 15


2

BOWL MILL XRP 883

LIST OF ERECTION DRAWINGS Sl.no

Drawing no.

Description

1

00062085754

G.A. OF XRP 883 BOWL MILLS.

2

16118801407

BOWL AND BOWL HUB ASSEMBLY

3

16110001416

PLANETARY GEARBOX LUBE OIL SYSTEM PIPING

4

06108800510

JOURNAL LINER ASSEMBLY

5

06128800802

MILL SIDE AND LINER ASSEMBLY

6

26138802927

SEPARATOR BODY ASSLY

7

06148800515

MILL DISCHARGE VALVE (MULTIPLE PORT) ASSLY.

8

06188800567

COAL SAMPLING PLATFORM ASSLY.

9

06180000661

SCRAPER MAINTENANCE PLATFORM

10

16119085924

SCHEME FOR EXT. LUBE OIL SYSTEM

11

00061085755

FOUNDATION PLAN FOR XRP 903 BOWL MILLS.

12

16108801019

JOURNAL SHAFT ASSEMBLY

13

16108801022

JOURNAL HEAD & TRUNNION SHAFT ASSLY.

14

16188801069

SPRING PRE-LOAD PROCEDURE.

15

16108801027

JOURNAL ASSEMBLY.

16

16188801409

SEAL AIR ASSEMBLY

17

16140001255

SERVICE AIR LINE FITTINGS

18

16148000521

WIRING DIAGRAM

19

16189001527

MILL HANDLING SYSTEM DRAWING

20

06138800805

SEPARATOR ASSLY.

21

06138800806

JOC ASSEMBLY

22

26108802067

JOURNAL HEAD LINERS

23

26108802068

JOURNAL HEAD LINER ASSEMBLY

24

26138802710

SEPARATOR TOP ASSEMBLY

25

36148802080

BUTT. VALVE & ACTUATOR AIR LINE.

26

26198802819

MILL FOUNDATION FASTENER ASSY


3

BOWL MILL XRP 883

27 28 29 30 31 32 33

36198802976 26198002431 26198802820 36190003310 26190002634 16188801059 26110002985

STUD ASSEMBLY( MILL FOUNDATION) LEVELLING AND GROUTING PROCEDURE GEARBOX FOUNDATION FASTENER ASSLY FOUNDATION FASTENER ASSLY (GEAR BOX) LEVELLING AND GROUTING PROCEDURE FIXTURE FOR BEARING ENDPLAY ARRANGMENT SEALING ARRANGEMENT


4

INTRODUCTION

1.0

BOWL MILL XRP 883

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 turn-down 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 mills in which there is metallic contact between the grinding elements. The mill works in a pressurised atmosphere as the primary air 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 erectors, especially when coping with unforeseen conditions faced at the site. The illustrations included in this manual are typical of the mills manufactured by Bharat Heavy Electricals Limited. However, the erector must refer to the drawings and documents supplied with individual contract for actual construction and the applicable part numbers, before taking up the erection activity of the mill.


5

PRECAUTIONS

2.0

BOWL MILL XRP 883

PRECAUTIONS FOR MILL ERECTION

Mill components have to be stored. Inform Engineering Department for any deviation/ abnormalities Look for proper orientation as given in the Project Drawings. Look for better alignments. Erection Mill Sub-assemblies looking for correct match marks. Read instructions for better preservation of Mill Drive Assembly at site. Ensure proper tightening of connecting fasteners. Cover the classifier vane mechanism and Mill discharge valve assembly to protect from falling bodies during erection Trouble free operation of the product must be the aim. Follow Safety Regulations at all levels. Observe proper gap between pipe ends of victualic couplings. Note the clearances between the stationary and the rotating parts

CAUTION :

The mill has been shipped from the factory with a preservative oil coating of in the gear housing. If the mill gears are turned for any reason while the mills are in storage, the preservative oil coating must be re-established. (Refer Bowl Mill Preservation Procedure)


6

PROTECTION & PRESERVATION

3.

BOWL MILL XRP 883

PROTECTION AND PRESERVATION OF MILL COMPONENTS

CAUTION: Labyrinth gaps in the planetary gear box at Top flange and Bevel Pinion Shaft locations have been closed with tape. Ensure tape during during storage at site STORAGE AND PRESERVATION OF MILL COMPONENTS

The Bowl mill assemblies after reaching site are stored for extended periods before Erection and Commissioning. The Bowl mill assemblies contain many precision components and should be carefully stored and preserved during storage and erection. The following method of preservation should be adopted during site storage and erection. MILL DRIVE AND BOWL ASSY: PLANETARY GEAR BOX :

Please refer Gear Box installation instruction, Chapter 11

ROLLER JOURNAL ASSEMBLIES : Preservation:

These assemblies shall be stored in closed storage in vertical position (Standing on roll).The journal assemblies are completely filled with recommended lube oil prior to shipments from works. Oil to be used: Servo Mesh SP 680 of M/s. Indian Oil Corporation. At site, the condition of oil, level and leakage if any should be checked periodically. Use Oil Dip Stick for level measurement. Prior to commissioning excess oil, if any, is to be removed with the help of siphon / hand pump. Retain the recommended oil level

in the assembly. Prior to

commissioning, if the oil in the journal assembly is found dirty, the same is to be removed with a suction hand pump. Clean the internals by topping up with a thinner. Fill the assembly with lubricant SERVOMESH SP 680 OF INDIAN OIL COROPORATION LTD or Equivalent to the recommended level. Make sure the pipe plug is tightly closed in the journal shaft. The exterior surfac e of the journal should be kept reasonably dry and free of any moisture and away from other weather conditions.


7

PROTECTION & PRESERVATION

BOWL MILL XRP 883

DRIVE COUPLINGS :

If uncoupled, pack with recommended grease and wrap with sheet (plastic). If coupled, fill with the recommended grease. MILL DISCHARGE VALVES ASSEMBLY:

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

The air passages, grinding and classifying areas of the Mill, Mill Discharge Valve, Reject Hoppers, etc. should be stored under cover and protected from all weather conditions. Water should not be allowed to accumulate and stand in or on these parts. GENERAL:

All exposed machined surfaces like shaft extensions, threaded or drilled bolt holes, classifier link mechanism etc. should be periodically preserved with protective grease or by such means and covered. Mounting Plates, Foundation Fasteners etc. are sent from Manufacturing works with a preservative coating. Check and renew the preservative wherever necessary. Ensure that no heavy components are stacked on Air Port Assembly, Lube oil system components and other mill components. External lube oil system and its instrument cabinet should be stored under cover.


8

PREPARATION FOR MILL ERECTION

4.0

BOWL MILL XRP 883

PREPARATION FOR ERECTION :

The following details shall be thoroughly studied with respect to the individual contract requirements regarding size, range, application and scope of supply with reference to the product. i)

Milling Plant Project

ii)

Bowl Mill General Arrangement

iii)

Bowl Mill Foundation Plan

iv)

Mill Plant Flooring Plan

v)

Scope of supply and works by BHEL and Customer

vi)

Shipping Lists with connected Erection Drawings All the despatch-able units, received at Site, shall be properly

identified with respect to Documents and Drawings. Any short supply or damaged item shall be immediately intimated to the concerned agencies.

Critical Assemblies, containing bearings (Planetary Gear

Box, Bowl & Bowl Hub Assembly, Grinding Roll and Journal Assembly ), shall be stored under temporary cover to protect against severe weather conditions, at the location of erection. The exposed machined surfaces and threaded portions leave the factory with protective preservatives. During on site storage, these preservative coatings shall be re-established, if necessary. Plan for Tools and Tackles, Rigging and Handling Facilities required for the installation of Bowl Mills. Special attention may be paid to the size, shape and weight of the components as well as the space limitations while proceeding with the installation.

Special Tools are

supplied along with the Mills. (Refer Figure. 9). It is to be ensured that the foundation fasteners, sleeves and connected materials are available at site prior to casting of concrete pedestal for Mill.


9


BOWL MILL XRP 883

After the concrete pedestal is cast and set, visually inspect the foundation for strength and soundness of concrete. Check for cracks, holes, exposed steel reinforcement etc.

Especially pay attention to

check for any left out wooden shuttering materials. The fittings, around the foundation, should be firm. Do not cut off the exposed ends of reinforcement as long as they are well within the stipulated height of concrete pedestal.

This may offer a good bonding between the

mounting plate and concrete pedestal. Concrete foundation pier checking should be done with respect to axes of boiler as shown in the Mill foundation and layout plans. The disposition of Mill foundation bolt holes, and Mill Motor foundation pocket holes should be checked. The elevation of foundation should be checked with respect to Boiler columns. Chipping of concrete shall be done, if necessary, to the correct elevation, indicated on the contract foundation drawing. The permissible tolerances in the foundation is given in the Table. PERMISSIBLE TOLERANCES IN THE FOUNDATION AREA

TOLERANCE IN MM

Tolerance in the center line of Mill with respect to Boiler Axes Tolerance in the elevation of concrete foundation with respect to drawing Tolerance in the center line of foundation bolt hole with respect to foundation center line Tolerance in diagonals of bolt hole centers max.

±10

Tolerance in the depth of foundation hole centers

±10

Grouting gap to be maintained between mounting plate and foundation

±5

±2 5

40±10

(Refer Contract Drawing for Bowl Mill foundation for deviations permitted)


10


BOWL MILL XRP 883

NOTE : Ensure that all sub-assemblies, that form part of a Mill, are properly identified with match marks before erection. Special attention is drawn to Journal Opening Covers (JOC) and Separator Bodies, since the trunnion bores are machined together and marked.

Check for JOC

match marks before bringing them from the store-yard and ascertain that match marks tally with the match marks on the Separator Body (Journal Opening Frame).


11

BOWL MILL XRP 883

GROUTING

5.

GROUTING INSTRUCTIONS :

5.1

INTRODUCTION :

This instruction covers materials and methods that shall be used for grouting structural steel and machine base plates. 5.2

GROUT THICKNESS :

Space provided for grouting shall not be less than 30 mm or more than 50 mm. 5.3

GROUTING MATERIALS :

5.3.1 Grouting Compounds : The preferred grouting materials shall be a Standard flow able, non-shrinkable like CONBEXTRA GP2 or equivalent grout mortar. This should be a ready-touse grout that contains a non-catalyzed metallic aggregate for use at flow able, pump-able or damp pack consistency to produce a hardened grout completely free of both vertical and horizontal shrinkage.

Since the grout

requires only the addition of water, the required consistency is easily controlled. CONBEXTRA GP2 is supplied as a ready to use dry powder requiring only the addition of water to produce a free flowing non-shrink grout which will maintain its original volume during curing.

The material is a mixture of

specially processed cement with carefully graded fine aggregate. Additives impart controlled expansion characteristics and reduce the water necessary to produce fluidity.

The very low water/cement ratio ensures very high early

strength, particularly at low temperatures. The aggregate grading is designed to aid uniform mixing, minimize segregation and bleeding whilst assisting the flow characteristics. 5.3.2 Sand and cement grout may be used as an alternate, but not preferred. Consistency of this material is important for proper placement.


12

GROUTING

a)

b)

c)

BOWL MILL XRP 883

For spaces of 25 mm or greater, use the following mixture: -

One part Portland cement 45 Kg (Approximately)

-

Two parts clean, well graded sand 90 Kg (Approximately)

-

25 Litres maximum of clean water.

For spaces less than 25 mm, use the following mixture. -

One part Portland Cement 45 Kg (Approximately)

-

One part clean well graded sand 45 Kg (Approximately)

-

20 litres maximum of clean water.

Add 20 Kg of 6 to 10 mm size stone chips (clean and graded) to 50 Kg of "SHRINKKOMP-N" with 8 litres of water. Mix enough grout for the space to be grouted. (or)

d)

Add 50 Kg of ordinary Portland Cement with 45 Kgs. of "FERROGROUT", 45 Kgs. of clean dry sand, 75 Kgs. of stone chips of 6 to 10 mm size (clean and graded) using about 10 Liter of water. Mix enough grout for the space to be grouted.

NOTE: i)

Sand, as specified above, shall conform to specifications for aggregate for masonary mortar as per any available Indian Standard. Gradation may be modified as necessary to obtain proper workability.

ii)

Sand and cement grout proportions shall be basically as described above. However based on results of tests on fresh and hardened grout prior to beginning work, the proportions can vary slightly.

The water content shall be the minimum

necessary for proper placement but in no case more than specified above.

When permitted to stand until setting takes

place, grout shall neither bleed nor segregate.

Suitable

admixture known to have no injurious effects on the steel or the concrete, may be used in sand and cement grout to increase workability and to decrease shrinkage. iii)

Full Cement Grout is prohibited.


13

BOWL MILL XRP 883

GROUTING

5.4

FOUNDATION PREPARATION i)

All loose concrete and defective areas shall be removed from the foundation by brush, hammering, chipping or any other means. Surface of the foundation must be rough.

ii)

Surfaces of the foundation and base plates must be free of oil, grease and dirt. Grease and oil may be removed by using a strong caustic solution.

Surfaces shall be flushed thoroughly

with clean water after using a caustic solution and dried immediately by blowing air. iii)

Surface of the foundation shall be well saturated with water for several hours prior to grouting depending upon the grout mortar. Surface of the foundations shall be well saturated with water for approximately 6 hours prior to grouting In case of sand and cement grout. Dry foundations will draw water out of freshly placed grout and seriously affect physical characteristics of the grouting material. Water or any debris shall be kept out of foundation bolt sleeves. Sleeves shall be covered with Bitumastic sealing packing or equivalent before soaking foundation with water.

iv)

Restraints shall be of adequate strength and built up to produce a head in the grout material to permit a continuous flow of grout. Build strong, tight restraint, braced so that they will not leak or buckle under weight of flowable grout. a)

Restraint shall be soaked with water or coated with a resin to prevent water removal from the grout.

b)

Construction must provide adequate clearance between restraint and base plate so that grouting material can be worked into place properly.

5.5

MIXING AND APPLICATION OF GROUT: i)

Mixing of grout should take place as near as possible to the equipment to be grouted.

All necessary tools and materials

should be available to mix and handle grout. BHARAT HEAVY ELECTRICALS LIMITED

For producing 14

BOWL MILL XRP 883

GROUTING

grout of a given consistency, paddle-type mortar mixers or revolving drum concrete mixer or any suitable mechanical mixer can be used. DO NOT MIX BY HAND. ii)

The dry GROUT MORTAR should be ready to use as it comes from the package and only require mixing with clean water. Mix the dry grout with no more water than needed to achieve the required consistency.

For placing in water, water shall be

placed in the mixer first. The grout shall be added to the water. a)

Estimate for Plastic Consistency: The correct proportion should be arrived as per the recommendations of the grout manufacturer.

b)

Estimate

for

Flow

able

Consistency.

The

correct

proportion should be arrived as per the recommendations of the grout manufacturer. Do not mix more grout mortar than can be placed in approximately 10 minutes. iii)

SAND AND CEMENT GROUT shall be mixed dry, then thoroughly mixed with water and allowed to stand for some time lesser than the initial setting time. The mortar boxes or other containers, used to hold the grout, shall be covered to prevent the loss of water. After the grout stands for some time, remix thoroughly without adding water and place grout.

iv)

Grouting materials shall be retempered with water once mixed.

v)

Temperature of material is important. A temperature of 30° C material will set quickly; below 30° C material will set slowly. Strength gain will be affected by temperature. When temperatures are considerably above or below 30° C, cooling or heating may be required to obtain the desired results.

vi)

For most base plate applications, place grout from one side only to assure complete filling of the space to be grouted and to avoid entrapping air.

vii)

12 mm or 25 mm link chain or stiff wire with a loop or steel strap shall be pulled back through the grout between the foundation


15

BOWL MILL XRP 883

GROUTING

and base plate to properly distribute the grout and remove air pockets. Do not over work strapping action. viii)

Apply grout within 21 days of putting the mill and base plate on foundation.

5.6

LEVELLING AND GROUTING PROCEDURE -: i)

Engage jacking bolts to mounting plates such that the bolts protrude by about 38 mm on the side coming in contact with the grout.

ii)

Place the mounting plates on the foundation.

iii)

Move the mounting plates around such that the mill center line is oriented correctly relative to north-south direction.

iv)

Install the two hex nuts with washers on the anchor bolts and finger tight. (With anti-seize compound or light oil)

v)

Level the mounting plates using the jacking bolts. Flatness to be within 0.13 mm/M and level within 0.38mm/M.

vi)

Plates of size 5x75x75 supplied can be either embedded in the concrete or kept properly on the concrete for supporting the jacking bolts.

5.7

CURING, FINISHING OR TRIMMING OF GROUT SHOULDERS: i)

All grout must be cured but does not require vertical confinement to develop full strength.

a)

Grout shoulders or extra projections may be either finished or left in place depending upon the size and location.

If desired, grout shoulders may be cut or

trimmed flush or at an angle. b)

Regardless

of

shoulder

treatment,

never

remove

restraints or cut grout below level of underside of bed plate until the grout has hardened sufficiently that it can not be penetrated by a pointed mason's trowel. ii)

Immediate prevention of rapid water loss from grout should be accomplished by carefully pouring water (pending) over exposed


16

GROUTING

BOWL MILL XRP 883

grout in restraints or grout holes just as soon as grout thickness and turns dull (about 20 minutes). Pounding water should be replenished as necessary until grout is to be finished or trimmed. Follow grout manufacturer's instructions. iii)

As soon as the finished grout will not be marred by its application, provide long term curing as suggested by the grout mortar manufacturer.

5 .8

IMPORTANT NOTES: i)

Manufacturer's published data on mixing grout material shall be followed in order to obtain desired results.

ii)

Grout placement in or around anchor bolts, sleeves, base plates etc., shall be governed by contract drawings and / or vendor's instructions.

iii)

In the type of leveling (Packer/Wedges/Leveling Screws) method to be adopted for Mill Base / Mill Base Plate, follow contract drawings and use the appropriate material supplied for this purpose.


17

INSTALLATION 6.

BOWL MILL XRP 883

INSTALLATION

CAUTION: Start up guard and lifting spacer is provided between the lower bearing and radial bearing housing cover (assembled at the bottom of vertical shaft assembly). This prevents damage to vertical shaft thrust bearing during transit. It should be removed during coupling mounting, preservation or any other erection activity requiring rotation of bowl. 6.1

CONSTRUCTION (REFER FIGURE – 1):

The pulverizer described in this manual is too large to be dispatched in assembled condition. These installation instructions cover a step by step sequence for assembling the normal sub-assemblies. Special site conditions may allow for more or less subassembly of components (refer to figures). 6.1.1 The 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

normal sub-assemblies are:

Planetary Gear Box Assembly’ Bowl and Bowl Hub Assembly Mill Side and Liner Assembly Separator Body Assembly Mill Discharge Valve Assembly Roller Journal Assembly Venturi Collar and Venturi Vane, Instruments for temperature measurement of shaft bearings Centre Feed Pipe Mill Motor Coupling Sole Plates and Mounting Plates Foundation fasteners Lubrication System

CAUTION Major pulverizer components are keyed to ensure proper orientation of the Air Inlet, Journal Openings and fuel pipes. Each component is identified with a serial number tag. Use care to install the correct serial numbered pulverizer and its components at the location indicated on the contract drawings. 6.1.2 The following items may be bundled or boxed but are shipped unassembled. 1) 2) 3)

Sole Plate and Mounting Plates Spring preload components Grinding Roll removal fixture


18

BOWL MILL XRP 883

INSTALLATION 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)

Seal Air Assembly Center Feed Pipe & Inverted Cone Coupling Assembly Coupling Guard Lube Oil System and Piping Coal Sampling Device & Fittings Bull Ring Assembly Air Port Assembly Special Tools Inner cone & Inner Cone Spout segment

F o r 9 0 3 X R P P re s s u r i s e d M i l l s P G M A s a r e – 61 – XXX:

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)

Roller Journal Assembly Mill Drive and Bowl Assembly Mill Side and Liner Assembly Separator Body Assembly Mill Discharge Valve Assembly Electrical Motor, Coupling and Foundation Fasteners for Mill Commissioning Spares Seal Air & Special Tools General Foundation Plan General Arrangement

: : : : : : : : : : : :

61-088 61-188 61-288 61-388 61-488 61-788 61-988 61-988 67-400 00-600 00-610 00-620

a)

MILL DRIVE AND B OWL A SSEMBLY : PGMA 61-188:

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


19

INSTALLATION b)

BOWL MILL XRP 883

MILL SIDE AND LINER ASSEMBLY – PGMA 61-288

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

d)

SEPARATOR BODY ASSEMBLY – PGMA 61 – 388 (REFER FIGURE-1 & FIGURE-7 and Erection Drawing No.: 0-61-38800805) The separator body assembly consists of Journal Pressure Spring Assemblies, Classifier Assembly, Air Port Assembly and Journal opening frame liners. R O L L E R J O U R N A L A S S E M B L Y – PGMA 61 – 08 8

(REFER FIGURE-1 and Erection Drawing No.: 0-61-088-00510, 1-61088-01019, 1-61-088-01022, 1-61-088-01027, 2-61-088-02067, 2-61088-02068) The Roller Assembly consists of Journal Shaft, Journal Bearings, Journal Housings, Grinding Roll, Journal Head and Trunnion Shaft Assembly. Three roller assemblies are there in a Mill. Lube oil in the Journal Assembly provides Oil Lubrication for the Bearings. e)

MILL DISCHARGE VAL VE ASSEMBLY – PGMA 61-488

(REFER FIGURE-1and Erection Drawings No.: 0-61-488-00515 & 361-488-02080) The Mill Discharge Valve Assemblies consists of four Multiple port outlet and Mill Discharge Valves mounted on the multiple port outlet plate. Air Cylinders operate the flaps in the Mill Discharge Valves. Solenoid Valves and Limit Switches are provided to effect and indicate the open or close position of the flap. f)

Venturi Collar and Ceramic Lined Venturi Vane and the venturi portion of the center feed pipe form the venturi outlet of the Mill. (PGMA 61388).

g)

Ceramic Liners on the classifier cone are provided to prevent wear and puncture on the classifier cone (PGMA 61-388).


20

INSTALLATION

BOWL MILL XRP 883

h)

The Mill and Motor are coupled together by a flexible coupling. (Gear Type & Bibby Type combination) for effecting the transmission from the motor to the Mill (PGMA 61-788)

6.2

During the installation of the Mill Base and other parts, if the feeder floor has not been completed, the Mill parts should be adequately protected from damage due to falling of heavy pieces, debris etc., from above by installing firm anchored sheet covers. Also the Separator Top Classifier link mechanism should not be used for climbing up the mill.

6.3

BOW L MILL INSTAL LA TION (SUGGESTED SEQUENCE )

6.3.1 G E N E R A L : Clean all the mating machined surfaces or parts with copper wire brush and apply a thin film of oil before assembly. Be sure that all bolts and nuts, cap screws etc., are torque tightened. They should be torqued to the torque values given in the erection drawings. Otherwise they should be torqued as per Table (Figure-06). All torque values are based on lubricated threads. (Apply Molykote grease for all assembly & disasembly fasteners of major subassemblies). 6.3.2 MILL DRIVE AND BOWL ASSEMBLY AND MILLSIDE & LINER ASSEMBLY:

Mill Drive and Bowl assembly consists of Planetary Gear Box Assembly and Bowl & Bowl Hub Assembly. Sole Plate, Base Plate (Fixed and Sliding), Dowel Pins (Stationary and Sliding), Connecting Fasteners, Bull Ring Assembly and Pipe Assembly for planetary gear box and lube oil system respectively are sent as loose despatchable units (DU's). NOTE: For more information on Planetary Gear Box refer Planetary Gear Box installation instructions, chapter no. 11.

Planetary Gear box, Bowl & Bowl Hub and Air Inlet Housing installation : 1.

Ensure foundation dimensions and levels as per drawings and erection chack lists.


21

INSTALLATION

BOWL MILL XRP 883

2.

Ensure the level of sole plate with the help of jacking screws. Level within 0.4 mm TIR and flatness to 0.1mm/M. Fasten the anchor bolts.

3.

Ensure the alignment /level of Mounting plate with respect to the sole plate with the help of jacking screws.

4.

Install the dowel pins in the sole plate.

5.

Ensure placement of gear box on sole plate as per “ Planetary Gear Box installation Instruction” and snugly tighten the f oundation bolts.

6.

Ensure alignment of gear box between the two piers and gear box horizontal input shaft parallality with the motor center line.

7.

Install the dowel pins in the Mounting plates of Air Inlet Housing.

8.

Place the Air Inlet Housing and ensure concentricity respect to Gear Box within TIR 0.25 mm and level alignment with respect to bowl hub flange and sole plate within TIR 0.38 mm. Ensure the tramp iron opening and air inlet duct opening orientation as per the GA drawing before placement.

9.

Pour operating oil (Servomesh SP 320 of IOC or equivalent) in the top chamber of the gear box through the beather vent hole till the oil reaches the level gauge full mark prior to further assembly activities. This would require about 200 liters of oil. This is to ensure lubrication of thrust pads.

10.

Ensure assembly of bowl hub on the rotary table (flange of planetary gear box) and tighten the holding down nuts. The step in the bowl hub may be heated to about 100 Deg C with uniform torch heating while placing the bowl hub on the gear box for ease of assembly. Remove the Lower Skirt to get an access to the holding nuts and studs of Bowl Hub.

11.

Grout the Mounting plates of Air Inlet Housing and sole plate of gear box.

12.

Tighten the foundation bolts of air inlet housing.

13.

Ensure torque tightening of the holding down bolts between Bowl Hub and Gear Box to 41 tones with the stud tensioning equipment.

14.

Ensure assembly completion of Labyrinth seal assembly, bowl hub skirt and Scraper guard assemblies in the sequence.


22

INSTALLATION

BOWL MILL XRP 883

Weld turn buckle assembly to Scraper Bracket and Bowl Hub Heat Shield to maintain verticle clearance 15.

Ensure assembly of bull ring segments, bowl extension ring and air port ring assembly on to the bowl.

CAUTION Ensure the orientation as per the General Arrangement drawing General Arrangement Arrangement (GA) drawing and match marks and serial numbers. n umbers.

(REF. Erectio n Drawi ng No 2-61- 2-61- 6.3.3 SEPARATOR BODY ASSEMBL Y : (REF. 388-02710, 0-61-388-00698, 0-61-388-00724, )

6.3.4 Center feed pipe (Lower) (Lower) with outlet venturi, outlet venturi collar, Venturi Vane with Ceramic Liners, Ceramic lined Inner Cone, Center Feed Pipe (Upper), Separator Top with Classifier vanes Assembly, inverted cone, inner cone spout segments, Journal opening cover with journal spring assembly, Air Port Assembly, Dresser Coupling, connecting fasteners have been sent as loose DU's. 1) 2) 3) 4)

5)

Install Separator body assembly on mill side air inlet housing and fasten with connecting bolts. Install Air port ring assembly. Attach rotating vane wheel segment to bowl, by connecting it to bowl and bowl extension ring. Weld body liner segments, journal block off assembly variant 01 and variant 02 to separator body. Restriction plate, restriction ring segment inner and restriction ring segment outer may be welded later as required depending on the flow parameters. Supplier’s representative representative will visit site in assisting installation of air port ring assembly based on the erection agency requirement.

FIG. 4) 6.3.5 BUL L RING SEGMENT ASSEMBLY : (REF. FIG.

1) Clean the interior surfaces of the bowl. 2) Install the new set of bull ring segments in the numerical sequence, starting with the No. 1 keyed segment and continuing in increasing numerical sequence sequence working clockwise clockwise around around the bowl. As they are installed, keep keep all segments segments radial by sight close together and firmly BHARAT HEAVY ELECTRICALS LIMITED

23

INSTALLATION

BOWL MILL XRP 883

back against the bowl. Use of wooden blocks and wedges jammed between the the toes of the segments and the bowl hub clamping ring guide boss is recommended. Note: Note: about 180 from the key-way there will be two adjacent segments each having an arrow pointing to their adjoining sides painted on the upper segment surface, indicating a shim shim may be be required to be placed at that location. The thickness of the shim (either 3 mm or 6 mm ) will also be painted on the same general area. 3) To install the last segment, open the gap gap between the next to last and keyed segment to the fullest extent possible. possible. To do this it will probably probably be necessary to use use a jack. As pressure is applied the segments should should be rapped with with a hammer to assure as snug a fit as possible. possible. If the gap left left is more than 3mm, depending on the measured gap, use half/quarter segments or additional shims supplies as loose with the set. 4) If it is impossible to fit the last segment into the gap, remove the shim mentioned in the note in step-2. This should give enough of space to allow assembly of the last segment. If there is more than a 3mm gap remaining after assembling the last segment, insert as shim or shims from the pack provided. It is not not necessary to get a fit tighter than can can reasonably be gotten with the shims in 3mm thickness increments. also, it is not necessary to spread up to 3mm 3mm final gap, between segments. 5) Remove the wooden blocks/wedges blocks/wedges used to hold the segments against the bowl and install the retainer ring. 6) Replace the clamping clamping ring and snug snug the hold-down bolts bolts while bringing the segment back back against the bowl extension ring. ring. When the assembly is firmly seated, alternately drive the bolts and rap the clamping ring heavily with a sledge or jackhammer (using a striker striker plate). A hold down bolt torque of 43 kg-m is required (the bolts are good for 140 Kg-m) as the retainer ring deforms to increase increase contact contact with the number of tightening tightening passes necessary to get and maintain the required 43 Kg-m torque. 7) After the pulveriser has been grinding coal for 150 to 200 hours. Inspect the bull ring. If gap of less than 12.5mm has opened up between any of the segments, recheck the bolt torque, the pulveriser can then be put back into service. service. If the gap is more than 12.5mm slack the clamping ring section over the gap so that additional shims can be added. added. 8) To add shims, carefully remove remove the material from the gap between the segments with a tool . Do not put fingers or hands between segments. BHARAT HEAVY ELECTRICALS LIMITED

24

INSTALLATION

BOWL MILL XRP 883

Insert the size and number number of of shims necessary to close the gap gap to within 3mm. Do not attempt to spread the remaining gap. Retighten the clamping ring bolts to a torque of 43 Kg-m.

6.3.6 Inner Cone, Separator Top Assembly 1) Place the inner cone with ceramic liners assembly inside the separator body assembly. Support it such that small diameter is down and the cone is approximately vertical. 2) Remove the separator top assembly from its shipping rig. Clean the top flange of the separator body and the bottom flange of separator top including tapped and clearance holes. 3) Insert the small hex socket socket head cap screw to align the separator to to the separator body at the center line of journal number one. 4) Lift the separator top into position on on the separator body. body. Use the small hex socket head cap screw to ensure proper orientation. Bolt the separator top to the separator body with hex head screws. 5) When the separator body and top are secured, arrange arrange rigging to hoist the inner cone with ceramic liner into position against the inner cone drum section. Check the position of the cone access access door to make sure it agrees with the markings on the separator top ( One of the separator body man hole and inner cone man hole shall be in line). 6) Bolt the inner cone to the inner cone drum section with hex head cap screws, hex nuts and plain washers. (Refe r 6.3.7 MILL DISCHARGE VAL VES AND VENTURI ASSEMBLIES: (Refer Figu re 1 & Erectio n Draw ing 0-61-4 0-61-48888-0051 00515) 5)

WARNING: THE PULVERISER DISCHARGE VALVES AND MULTIPLE PORT OUTLET WEIGH APPROXIMATELY 3055 Kg AND MUST BE ADEQUATERLY RIGGED TO ENSURE SAFE HANDLING. 1) 2)

3) 4)

Remove the outlet venture and vane assembly from its shipping rig. Clean the top flanges including the clearance and t apped holes. The Mill Discharge Valves together with multiple port outlet plate shipped together should be cleaned with copper wire brush and assembled with venturi outlet collar assembly. Slide the inverted cone onto the feed and inner cone, secure it with the set screws (temporarily). Look out for the offset hole for correct placement. Four numbers of venturi vane (with venturi vane liners) should be assembled in position with the venturi outlet collar. For welding of protective seal to the venturi, refer Protective Seal Application-Figure:10.


25

INSTALLATION 5)

6)

7)

8)

9)

10)

BOWL MILL XRP 883

Assemble 4 studs of size M12x60 in the Centre Feed Pipe Lower (with venturi outlet). Lift and insert the centre feed pipe lower (with venturi outlet) with lifting facility into the classifier cone, before assembling of the Mill Discharge Valve with Separator Body Assembly. Clean the entire top and bottom surface of the multiple port outlet plate, including the clearance and tapped holes, and the flange on the centre feed pipe-upper. Bolt the outlet venturi and vane assembly to the multiple port outlet plate assembly with hex head screws. Fixing screws of outlet venturi collar to M. P. O. plate should not project beyond the MPO plate. Lift the assembly which comprises of Mill Discharge Valve, Multiple Port Outlet Plate, Outlet Venturi Collar Assembly, Venturi Vane with Venturi Vane Liner and place in position on the separator top in the correct location to match with the arrangement drawings and key plans to couple with fuel pipes. Then lift the centre feed pipe lower (with outlet venturi) and position by rotating the centre feed pipe lower by hand such that the 4 studs go into the free hole, size of 14, which is in the multiple port outlet plate and assemble with nuts. Using M16 x 160 size bolts and nuts, assemble the Mill Discharge Valve Assembly, with the centre feed pipe lower as per drawing. Then remove the 4 studs and nuts and replace with the proper fasteners of size M12x60 in these 4 positions. While lifting the centre feed pipe lower, care should be taken to avoid any damage to ceramic liners of the classifier cone. Place the centre feed pipe upper in position and bolt with multiple port outlet plate with proper fasteners.

NOTE: HEX HEAD SCREWS HOLD THE MILL DISCHARGE VALVE ASSEMBLY TO THE SEPARATOR TOP. ONE BOLT HOLE IS OFFSET BY 25 MM AND HAS A SCRIBE LINE BESIDE IT TO ENSURE PROPER ALIGNMENT OF THE VALVES, WITH RESPECT TO THE PULVERISED COAL PIPES. 11) 12) 13)

14)

Align the scribe lines next to the offset bolt holes in the discharge valve assembly and the separator top. Bolt the discharge valve assembly to the separator top with hex head screws. The inverted cone shall be moved down the center feed pipe lower to obtain a clearance of 100 mm measured as shown in Fig. 1. Weld the inverted cone to the center feed pipe as shown after final adjustment. The clearance between the inner cone and center feed pipe lower should be checked. The perpendicular distance between the inner cone and the center feed pipe lower shall be 115 mm. (Refer Fig. 1)


26

INSTALLATION 15) 16)

BOWL MILL XRP 883

Install the inner cone spout segments. Weld the Center feed pipe coupling connecting piece to feed pipe from feeder. Check the circularity of the ends and assemble the Dresser Coupling.

6.3.8 JOURNAL ASSEMBL Y (FIGURE-1 and Erectio n Drawi ng No .:0-61- 088-00510, 1-61-088-01019, 1-61-088-01022, 1-61-088-01027, 2-61- 088-02067, 2-61-088-02068:

Journal Head To Journal Shaft Assembly. 1.

2.

3. 4. 5.

6.

Closely inspect both tapered surfaces for dents, high spots, burrs, etc. remove and blend imperfections as necessary with a file and / or emery cloth. Remove any filing or sanding debris. Lower the journal head onto the journal shaft ensuring that the antirotation pin in the head and the key slot in the shaft are properly aligned. Strike the journal head with a mallet to ensure proper seating. Lubricate the threads on the journal shaft with anti-seize compound and install the lock nut. Slug lock-nut tight using the wrench, supplied as part of special tool kit and a sledge hammer. Scribe the nut and the head with chalk and strike the wrench with three additional solid blows of the sledge hammer. If the nut moves less than 3 mm ,it is sufficiently tight. If the nut moves more than 3 mm the tightening process should be repeated. Lock the setscrew on the lock nut once it is properly tightened. Install anti-rotation pin and the M16 grub screw over the anti-rotation pin.

Adjustment of The Seal Air Gap 1. 2. 3.

4. 5.

Remove cap screws and drop the journal head skirt until it is seated squarely on the taper of the upper journal housing. Measure the gap between the journal head and the skirt flange in eight places. Record and average on the work sheet next page. 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. Measure each stack of split shims with a micrometer. 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.


27

INSTALLATION

BOWL MILL XRP 883

6.

Check the seal air gap between the upper journal housing and the journal head skirt in eight places. Each measurement shall be within 1 mm ±0.13 mm .

7.

Clean all the mating machined surfaces with copper wire brush and apply a thin film of oil. Place the three Journal Assemblies together with Grinding Roll, trunnion Shaft and End Caps through the Separator Body Journal Opening Frame. Install the Roller Journal Assembly by carefully lowering it through the Journal Opening Frame in the Separator Body. Remove the long rod along with fastening plates and nuts used for securing the Trunnion Shaft End caps during transport. Bolt up the trunnion shaft end caps on to the Journal opening frame on either side. This will partially support the Trunnion shaft ends. Bring in the match marked journal opening cover and assemble on to the separator body. The Trunnion end caps should be turned so that the numeral "1" lines up with the indicating arrow on the Journal opening cover.

8.

Tighten all bolts connecting separator body and Journal Opening Cover. DO NOT INTERCHANGE THE JOURNAL OPENING COVERS AS THESE HAVE BEEN MATCH MACHINED WITH THE SEPARATOR BODY. Draw up tight the other bolts connecting the Trunnion Shaft End Caps and the Journal Opening Cover. Proceed with the setting up of ring roll clearance and spring compression as described in chapter 8 of this manual.

6.4 The roller Journal Assembly positions, the air inlet orientation, the multiple port outlet orientation must be kept up as indicated in the contract General Arrangement drawing. Counter check that the relative locations of air inlet and roller Journal Assembly locations are maintained as per the requirement and are compatible with the handling arrangement provided for the contract. 6.5 ASSEMB LY OF SEAL A IR PIPING(REF. Erection Dr awin gs No . 1-61- 400-01255& 1-61-88801527 )

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


28

INSTALLATION

BOWL MILL XRP 883

Note: All pipes must be cleaned after cutting and threading. Also, a swab or sponge must be drawn through the bore if the inside diameter of the pipe has been oil coated by the supplier. Note: All pipe threads must have pipe sealant with teflon ( Loctite PST or an equivalent) applied at assembly. 6.5.1 Cut, thread, clean and apply pipe sealant to the piping as necessary and assemble the seal air piping as shown in erection drawings referred above. 6.5.2 If the journal assemblies are not installed, cap the ends of the pipes going to the trunnion shafts for protection until the journal assemblies are installed.

Note: Ground the welding machine directly to the mill side housing or the separator body. 6.5.3 Remove caps from seal air pipe. Cut and install the seal air hose to the trunnion shafts, vertical shaft seal assembly and seal air pipe to the spring assemlies. Use two hose clamps at each end. 6.5.4 Use a plywood cover or blind flange to protect the seal air header inlet until the seal air pipe has been run up to the pulverizer 6.5.5 Connect the seal air lines to the discharge valve per Erection drawing. 6.6 ASSEMBLY OF MDV APPROACH PLATFORM (Erection Drawing 061-888-00567) 6.6.1 Assemble MDV Approach platform on separator top and attach ladder to it. 6.6.2 The ladder position can be suitably altered at site as required. 6.6.3 Fixing of floor grills should be such that the cut edges of load bearing bars should rest on item no.03 6.6.4 The splice plate (item 11) can be bent if necessary at site. 6.6.5 Item no 04 is sent in running meters, should be cut suitably at site. 6.6.6 Cut item 01 to a length 400 mm at ladder seating place.

6.7

CLEARANCES:

The following clearances should be checked during erection of the Mill and suitable rectification work carried out if necessary.


29

BOWL MILL XRP 883

INSTALLATION a)

Vertical gap between body liner Segment and rotating vane wheel Segment of airport assy (Refer Figure:3)

: 5 to 10 mm

b)

Gap between Inverted cone and Inner cone (Refer Figure:1)

: 75 mm

c)

Gap between center feed pipe lower And inner cone (Refer Figure:1)

: 110 mm

d)

Vertical gap between journal block off assembly (style 1 & 2) with bowl extension ring top Radial gap between air port ring deflector & Mill side liner

: 20 mm

d)

: min 10 mm

6.8

Fill any voids left out due to poor fit between, behind or around the liners with foster foam sealing compounded or an equivalent.

6.9

Assemble the pipe from the feeder to the centre feed pipe upper by a dresser coupling, Pulverized fuel pipes from the Mill to the boiler by victaulic couplings and the primary air duct to the Mill side and Air inlet flange by fasteners. Cooling water piping connection to the oil cooler to be given. Connect Fire Extinguishing nozzles in the mill side and air inlet with steam line and centre feed pipe upper with clarified water . Electrical connections for the Mill Motor, Limit Switches and Solenoid Valves, Instrument and service air connection to the mill discharge valves and other areas to be connected as per the Contract Drawing.


30

LUBRICATION

7

LUBRICATION

7.1

GENERAL:

BOWL MILL XRP 883

Note: The External Lube Oil System should be installed after the civil and welding work of feeder floor is complete. This is to avoid damage to the instruments. Install the system just before commissioning. External Lube Oil system supplies filtered and cooled oil to the gear box, which is sprayed onto the gear teeth and supplied to the bearings by means of internal piping provided. 7.2

LUBE OIL SYSTEM INSTALLATION: Refer to Planetary Gear Box installation chapter no.

7.3

ROLLER JOURNALS:

The Roller Journals are lubricated by means of a self-contained circulation system (Refer Erection drawing no.: 1-61-088-01027). The oil level in the shaft is maintained at a point just below the top of the seal when the mill is idle. The pumping action of the Roller Bearings, circulates oil from the reservoir in the Journal Housing to the annular chamber between the Bearings, then into the shaft bore and through the oil return holes where the cycle is completed. The Upper Journal Housing is provided with a triple liptype seal to prevent oil leakage. The journals are kept clean by seal air brought through flexible tubing to holes provided in the Trunnion Shaft and Journal Head for this purpose. Refer erection drawing no 1-61-088-01022. This inward moving air prevents dust from getting into the bearings. The Roller Journals should be filled with the recommended oil (See: Lubrication Schedule) through the fill connection at the top of the Journal Assembly. Brush or blow any dust/dirt from the top of the Journal Shaft. Remove the cover and plugs from the Journal opening cover and Journal Shaft. Check the oil level with a dip stick. Dip stick must touch the bottom. Fill the roller journal with oil to the level shown on the oil instruction plate attached to the journal opening cover and tighten the plug. Pour the oil steadily to prevent air lock. During initial operation, the opening between the Journal Head Skirt and the Upper Journal Housing should be inspected frequently (approximately weekly) for evidence of any leakage. If no leakage is observed (indicating that BHARAT HEAVY ELECTRICALS LIMITED

31

LUBRICATION

BOWL MILL XRP 883

the oil seals have seated properly) a normal interval of inspection, at least once in every three months and/or when the opportunity presents itself, can be initiated. When checked, if the oil shows signs of contamination, or a Laboratory Test indicates oil breakdown, it should be changed. To change oil, siphon out the old oil and add new oil to bring the oil back upto the level. Do this repeatedly until the oil is clear. 7.4

MISCELLANEOUS:

The deflector Regulators, Journal Stop Bolts should be greased as per recommended Bowl Mill Lubricants Schedule. The Mill to Motor Coupling should be lubricated according to the Manufacturer's recommendations (Given in the Lubricants Schedule.) The Journal Trunnion Bushings are made of rubber and require no lubrication. 7.5

IDLE MILLS:

Because of the use of auxiliary fuels or other reasons, Mill may be out of service for periods longer than a month. If this occurs, the Mills should be run for a five minutes period once a week without material being fed. This will aid in preventing corrosion. If the out of service period is going to be or becomes longer than several months, refer to Chapter - 3: (Protection and Preservation of Mill Components.)


32

BOWL MILL XRP 883

LUBRICATION

7.6

BOWL MILL OIL COOL ER - COOLING WATER REQUIREMENT :

Recommended Inlet Pressure

:

4.5 Kg/cm²

Pressure Drop in Cooler

:

0.7 Kg/ cm²

Water Quantity per MIll

:

15 m³/hr


33

BOWL MILL XRP 883

LUBRICATION

7.7 LUBRICATION SCHEDULE EQUIPMENT: BOWL MILL XRP 883 with PGB Sl. No.

Parts to be Lubricated

Recommended Lubricants IOC

HP 3

Type of filling

BP

1

2

5

6

1

Mill Drive Gear Housing

Servomesh SP-320

Parthan EP-320

AMOCAM OIL-320

External tank

1100

2

Roller Journals

Servomesh SP-680

Parthan EP-680

AMOCAM 680

Reservoir cap on journal shaft

135

3

Journal Stop Bolts

Servogem-3

Lithon-3

MP Grease-3

4

Discharge valve shafts and Seals

Servogem-3

Lithon-3

MP Grease-3

5

Drive coupling (BIBBY / GEAR)

6 7

8

Frequency of observation

Remarks

10

6 Months

Once daily check gauges, lines and headers

Oil level shall be maintained in the external lube oil tank

6 months

Check when accessible at least once in every 3 months

Level 830 mm to 930 mm

Grease fitting

Fill chamber initially. Lubricate after making adjustments.

Grease fitting

Grease the shafts and seals initially and every 2 weeks.

Wipe clean all grease fittings before and after greasing. Remove excess grease

HTXX

Grease fitting

Pack completely initially and every 3 months. Clean out & renew grease every year.

Worm Shaft Oil Seals

Molikote 33 or equivalent

Grease fitting

Grease the shafts and seals initially and every 1 month.

Mill Drive Motor

As per Motor Manufacture's Recommendation

34

7

Frequency of oil check

9


4

Qty. of Lub. In litres/Mill

BOWL MILL XRP 883

LUBRICATION

7.7 LUBRICATION SCHEDULE EQUIPMENT: BOWL MILL XRP 883 with PGB Sl. No.

Parts to be Lubricated

Recommended Lubricants IOC

HP 3

Type of filling

BP 4

5

Qty. of Lub. In litres/Mill 7

8

Frequency of observation

Remarks

1

2

9

10

1

Mill Drive Gear Housing

Servomesh SP-320

Parthan EP-320

AMOCAM OIL-320

External tank

1100

6 Months

Once daily check gauges, lines and headers

Oil level shall be maintained in the external lube oil tank

2

Roller Journals

Servomesh SP-680

Parthan EP-680

AMOCAM 680

Reservoir cap on journal shaft

135

6 months

Check when accessible at least once in every 3 months

Level 830 mm to 930 mm

3

Journal Stop Bolts

Servogem-3

Lithon-3

MP Grease-3

Grease fitting

Fill chamber initially. Lubricate after making adjustments.

4

Discharge valve shafts and Seals

Servogem-3

Lithon-3

MP Grease-3

Grease fitting

Grease the shafts and seals initially and every 2 weeks.

Wipe clean all grease fittings before and after greasing. Remove excess grease

5

Drive coupling (BIBBY / GEAR)

HTXX

Grease fitting

Pack completely initially and every 3 months. Clean out & renew grease every year.

6

Worm Shaft Oil Seals

Molikote 33 or equivalent

Grease fitting

Grease the shafts and seals initially and every 1 month.

7

Mill Drive Motor

As per Motor Manufacture's Recommendation


6

Frequency of oil check

34

LUBRICATION

7.8

BOWL MILL XRP 883

ROLL ER JOURNALS OIL QUANTITY AND LEVELS

Mill Size 883/903 XRP

Quantity of lubricant per assembly (in litre) 45

Quantity of lubricant per Mill (in litre) 135

Oil Level (in mm) 830-930

LUBRICATION

7.8

BOWL MILL XRP 883

ROLL ER JOURNALS OIL QUANTITY AND LEVELS

Mill Size 883/903 XRP

Quantity of lubricant per assembly (in litre) 45


Quantity of lubricant per Mill (in litre) 135

Oil Level (in mm) 830-930

35

SETTING - UP

BOWL MILL XRP 883

8

SETTING-UP BOWL MILLS :

8.1

Prior to operating the Pulverizer with its electric for the first time. a)

Check the shaft coupling alignment.

b)

Check if the external lube oil tank is filled to the required level with the recommended lube oil.

8.2

2 numbers of breather vents for shipped loose. These are to be installed on to the inspection doors of gear box after removing the plugs provided therein.

8.3

Check to make sure the Bull Ring segments are properly seated and tightened in the bowl. Clamping ring socket head cap screws should be torqued to 43 Kgm. The Roller lock nut should be snug on the bottom face of the roll (if necessary, tighten with a Wrench) and weld lock bar between lock nut and lower Journal Housing.

8.4

Turn the Pluveriser Bowl through one revolution by hand to make sure that none of the rolls make contact with any part of the Bull Ring assembly. If any roll contacts the Bull Ring Assembly, screw in the journal stop bolts to provide the required roll/ring clearance. Jog the pulveriser motor under power to check direction of rotation. Make sure the input shaft turns clockwise when viewed from non-drive end of motor and bowl clockwise when viewed from above.

8.5

Set the Deflector Blades that control the product fineness per the Instructions given in Figure: 7.

8.6

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


36

BOWL MILL XRP 883

SETTING - UP

NOTE : To prevent undue stress on Pulverizer components, spring compression on the three journals in one Pulverizer should check within 700 Kgs. The most common reasons for checking (and changing) spring compression values are : i)

Rough operation at low loads. (Reduce the compression).

ii)

High

or

unstable

power

consumption.

(Increase

the

compression). iii)

Vibration at high loads (Increase the compression).

iv)

If there has been a pulverizer fire.

v)

On a regular basis when there has been any overhaul. Method of adjusting spring compression and procedure for checking compression are described below.

8.7

CHECKING SPRING COMPRESSION (REFER FIGURE : 8) SETTING THE SPRING COMPRESSION a)

The spring assembly should be completely assembled as per the assembly drawing except for the spring stud extension cap, spring stud lock nut keeper, hex head screw M52 and keeper washer. If the assembly has been shipped, remove the shipping bolt per view "A-A" then install the pipe plugs.

b)

Of the six(6) threaded studs, four (4) must be backed out of the journal spring housing cover to the dimension indicated in detail


37

SETTING - UP

BOWL MILL XRP 883

"B". For the purpose of wrench clearance, two (2) studs must be removed in the region of one of the cutouts in the preload fixture c)

Slide the spring stud locknut keeper onto the spring preload stud.

d)

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) nut at the top. Slide the pre-load stud Item 4) through the cylinder and screw it into the end of the spring preload stud. At least 76mm of thread engagement is required. Screw the nut (item 5) onto the pre-load stud (item 4) with the cylinder (1) fully retracted.

e)

Slide the spring stud locknut keeper back off the spring preload stud.

f)

Use the cylinder (item 1) to draw the spring guide. To contact the spring housing cover pump the cylinder (item 1) until the pressure gauge reads "P" psi ± 7 Kg/Cm². This will compress the spring "X" from the static length. Using the locknut wrench (item 7) advance the locknut until it contacts the spring guide.

CHECKING SPRING COMPRESSION g)

Relieve the pump pressure (item 1) to 70 Kg/Cm². Using a magnetic base dial indicator. Place the indicator needle on the flat vertical face of the locknut and zero the indicator. Pump the cylinder pressure upto "P". Kg/Cm². Again check the preload by making sure the indicator just starts to move (about 0.2 mm) as the pressure gauge reads "P" Kg/Cm².

h)

Tighten or loosen the lock nut until this occurs. Slide the locknut keeper onto the spring preload stud causing the keeper to interlock the locknut. It may be necessary to compress the spring just above "P" Kg/Cm² to allow rotation of the lock nut. The locknut should be rotated a maximum of 1/8 th of a turn. Slide the keeper into position and relieve the cylinder pressure.


38

BOWL MILL XRP 883

SETTING - UP

i)

Remove the preload stud (item 4) and preload fixture (item 2) and install hex head cap screws and keeper washer. Torque the hex hd cap screw to 10.4 Kg-m and weld hex head screw, keeper washer & lock nut keeper together

j)

Mount the spring stud extension cap.

k)

Mount six (6) hex nuts onto the adjusting threaded studs. Refer to the ring-roll procedure before adjsting these studs.

DECREASING RESSURE SPRING SET VALUE: CAUTION : Using the spring compression measurement taken, do not allow the pressure gauge reading to exceed 2000 Kg. for each centimeter of thread engagement. Back off the spring adjusting nut by desired amount or 6 mm. For the purpose of estimation, the following table gives the spring rate for XRP 883 bowl mill. Mill Size

883 XRP

Spring Rate

Spring load to be registered at Pressure

(kg/cm)

gauge in Kg

5002

8500

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 0.62 mm. If more than 6 mm, compression is to be removed, release all the hydraulic force, back off the mounting nut another 6 mm and repeat the above as many times as required. NOTE : Hand movement of the spring adjusting nut may be difficult. In order to turn the same, use spanner wrench. BHARAT HEAVY ELECTRICALS LIMITED

39

SETTING - UP

BOWL MILL XRP 883

INCREASING PRESSURE SPRING SET VALUE: l)

If compression is to be increased, operate the Hydraulic Hand Pump until the desired force as read on the pressure gauge is obtained but in no case should the distance between the spring adjusting nut and pressure spring clamp exceed 6 mm. If the spring force desired is more than that obtained in 6 mm, the spring adjusting nut should be run down to the pressure spring clamp, the puller pressure released the stud mounting nut run into again contact and pressure adjusting nut and puller pressure reapplied as described above, repeating the same procedure as many times as necessary.

m)

Release the hydraulic pressure. Remove the lock nut (12), retainer nut (11), puller (07) and fixture (01), stud extension (03) and stud mounting nut (02).

n)

Replace the pressure spring lock nut. Loosen the High tensile studs if compression has been decreased.

o)

Replace the spring support cover and adjust the High tensile studs to lock the pressure spring clamp.

p)

Replace the spring extension cap and the stud lock nuts (Hex. Nut M-30) and drive them tight.

q)

After final setting of the spring compression, lock the spring adjusting nut (as shown in Erection Drawing 0-61-300-00176) by welding clamps.


40

MOTOR INSTALLATION, COUPLING ALIGNMENT AND ASSEMBLY

9

MOTOR INSTALLATION, COUPLING, MOUNTING, ALIGNMENT AND ASSEMBLY PROCEDURE :

9.1

Positioning and aligning motors and rotating equipment.

9.2

POSITIONING MOTOR : i)

BOWL MILL XRP 883

Foundation bolts in foundation shall be inspected prior to the placement of base plate/base frame or equipment on the foundation. a)

Foundation bolt locations and corresponding holes in base plate/base frame and equipment shall be checked to ensure that all components match.

b)

Foundation bolts shall be checked for elevation and position using an established bench mark.

c)

Foundation bolts shall be straight and plumb.

d)

Foundation bolts shall be inspected for damaged threads. Dies may be run over foundation bolts to clean up threads which are dirty.

e)

Foundation bolt sleeves shall be clean. All loose concrete, water or other debris shall be removed.

f)

Foundation bolts shall be firmly anchored in foundation.

g)

Foundation bolts, which are damaged or improperly located, shall be repaired or replaced.

NOTE:

Any alteration as a corrective measure on base plate or

foundation bolts to accommodate foundation bolts that are not in the proper position, shall be taken up, only after obtaining prior approval of Pulveriser Engineering Department.

ii)

Foundation shall be inspected for soundness, roughness and cleanliness (free of dirt and debris) prior to grouting.


41

BOWL MILL XRP 883

MOTOR INSTALLATION, COUPLING ALIGNMENT AND ASSEMBLY iii)

Shipping instructions, Manufacturer's installation drawings and specifications for equipment and motor shall be checked for lifting, moving and protection procedures. a)

Motor may be overstressed, pulled out of the line or broken if lifted or moved in an improper manner.

b)

Motor may be damaged if protection and preservation procedures are not carried from storage to final positioning. Heaters on motors, lubrication of bearings and shafts, electrical connections, etc., require protection.

iv)

If shims are used, STEEL SHIMS shall be used under all equipment and motors. Contract drawings and/or specifications shall be checked for shim requirements.

v)

Clearance between foundation bolts and bolt holes shall be checked after placement of the equipment to be sure there is no binding or distortion. Foundation bolts shall be inspected to determine if any damage occurred while the equipment was being placed.

9.3

SHIMS AND PACKER PLATES : i)

Shims for final alignment and/or replacement of motors. Motor shall have at least one full bearing shim between the motor base and or base plate. Minimum thickness of this shim shall be 3 mm.

ii)

Shims/packers for elevating, leveling and support of motors. Steel shims/packers shall be placed on each side of foundation bolts to properly support the motor from the foundation. Steel shims shall also be used, where required, to prevent distortion, bending, breaking leveling to, of motor base plates and supports. a)

Steel shims/packers shall be placed on each side of the foundation bolts located at minimum distance of 6 mm


42


BOWL MILL XRP 883

from the foundation bolt sleeve or 6 mm from foundation bolts without sleeves. Shims may extend out to within 12mm of the edge of the sole or base plate. Minimum width for these shims shall be 25 mm. b)

Steel shims do not need to be removed for grouting unless otherwise specified. If specification or drawing requires removal of shims after grouting, leveling shall be done with the use of wedges in combination with steel shims (to facilitate removal). Grout must be patched in area where shims were removed.

9.4

COUPLING : (Ref Figure 14) The Bowl Mill input shaft is connected to the electric motor by means of triple crowned gear type flexible coupling on the gear side and spring grid type (bibby type) resilient flexible coupling on the motor side. Refer to the contract drawing for type and size details of the coupling. Check up the dimensions of the coupling bore and ensure that the correct coupling half is mounted on to the mill Shaft, Motor Shaft.

9.4.1 GEAR TYPE COUPLING : A)

MOUNTING : The coupling half is heated in an oil bath. The soaking

temperature should be around 120° C. Please see that this temperature is within the flash point of the heating oil used. The coupling must be soaked for a sufficient period so as to obtain enough expansion which will allow easy sliding of the coupling half on to the shaft. Approximate soaking time is in the order of 20-30 minutes.

B)

ALIGNMENT : ( Refer FQP check list and log sheets)


43

MOTOR INSTALLATION, COUPLING ALIGNMENT AND ASSEMBLY i)

BOWL MILL XRP 883

Equipment and motors that have been placed shall be leveled to required elevation and position (as per General Arrangement(GA) & Foundation Drawings).

ii)

The electric motor shall be positioned using the electric center indicated on the motor as reference. Electric motors without an electric center mark shall be positioned using the mechanical center. The mid position between extremes of the rotor end play shall be considered the mechanical center.

iii)

Coupling alignment and tolerances : Misalignment measurements. a)

Radial alignment : Provide two dial gauges, both on the same side (i.e. for example: base on worm shaft side and the dial on the motor side) but at 180 degree opposite to each other at a distance R25mm from the centre. Rotate both shafts together and take readings at 90 degrees interval. The difference in the respective position values would give the radial alignment, eliminating the effect of any run-out on the coupling surface. Radial alignment shall be achieved within 0.05 mm.

b)

Axial Alignment: Provide two dial gauges, both on the same side (i.e. for example: base on worm shaft side and the dial on the motor side) but at 180 degree opposite to each other. Rotate both shafts together and take readings at 90 degrees interval. The difference in the respective position values would give the radial alignment, eliminating the effect of any face-out

on the coupling surface. Radial alignment shall be achieved within 0.05 mm. (Refer Figure : 11 & 12). BHARAT HEAVY ELECTRICALS LIMITED

44


C)

BOWL MILL XRP 883

ASSEMBLY : (Figure 14) After alignment of motor and mill shaft, coat hub and sleeve

bearings with grease. Slide the sleeves over hubs. Position spacer between Mill and Motor Shafts. Then insert gasket and bolt sleeves and spacer together. Tighten bolts uniformly. Remove the two grub screws on the coupling sleeves and grease through one hole using a grease gun, until grease comes out of the other hole. Reassemble the grub screws. 9.4.2 BIBBY RESILIENT FLEXIBLE COUPLING: A)

MOUNTING : Coupling hubs are heated in an oil bath. The soaking

temperature should be around 120° C. Please see that this temperature is within the flash point of the heating oil used. The coupling must be soaked for a sufficient period so as to obtain enough expansion which will allow easy sliding of the coupling hub on to the shaft. Approximate soaking time is in the order of 20-30 minutes. The coupling hub is removed from the bath after soaking. The bore and the step, where Spacer-1 will seat, are wiped clean. Spacer-1 is placed in position in the coupling hubs and mounted on the mill and motor shafts. Spacer-2 and Spacer-3 are assembled together and then mounted on the coupling hub (worm shaft side). B)

ALIGNMENT : (Refer FQP Check list & log sheets) Alignment will be obtained by moving one of the machines to be coupled (usually the motor).


45


BOWL MILL XRP 883

Check that the faces of the half couplings parallel, with the help of feelers introduced between the Spacer and coupling hub on the motor shaft, at four points at 90 interval. Check coincidence of axes with a small rule placed on the outer tooth surface in the same four points. The axial gap of half coupling is 3 mm. The axial play allowed is 0.05mm. The Radial misalignment allowed is 0.2 mm. C)

ASSEMBLY : POSITIONING OF SPRINGS : Fill up the grooves and the space between hubs with grease and position the spring, one segment at a time, beginning with one of the end segments and introducing gradually the following ones with the help of a hammer. FASTENING UP OF THE COVERS : Once the springs have been put into position, finish filling up with grease. Bring the cover in position and assemble with Spacer - 2.

a)

LUBRICATION : Refer Lubrication Schedule (Chapter 7.8)

9.5

GROUTING AND DOWELING : Grouting and Doweling of motors shall be done within 21 days of putting the Motor and Base Plate on foundation. -

Motor shall be grouted as per Grouting Instructions. (Chapter No. - 5)

-

Motor, requiring doweling as per drawing or specifications, shall be doweled to the base plate / base frame.


46


BOWL MILL XRP 883

Two dowels shall be used for each item unless otherwise specified. Dowels shall be installed in diagonal corners of the Motor near a hold down bolt. The maximum distance, from the edge of the dowel hole to the edge of a hold down bolt, nut and washer, shall be 12mm. Tapered, removable dowels shall be used unless otherwise specified.


47

MILL OPTIMIZATION

10.0

BOWL MILL XRP 883

MILL OPTIMIZATION

Purpose: The purpose of this programme is to optimize the mill operation to ensure the rated mill capacity with required PF fineness and at the same time, the best wear life of grinding elements, and other wear prone areas is achieved. Adjustments: One or more of the following adjustments may be required while carrying out the mill optimization 1)

Area of opening around the bowl for primary air flow to maintain desired differential pressure across the bowl, with low mill rejects.

2)

Height of the venturi collar to maintain the desired pulveriser fuel fineness and differential pressure across the bowl.

3)

Vary the Spring compression value to achieve the required mill output, fineness and mill rejection level.

4)

Classifier blade position to maintain pulverised fuel fineness.

5)

Ring-roll clearance to reduce high bed formation on the bowl and to reduce rejection rate.

6)

Spring seat gap to ensure equal load on bowl by spring assemblies.

7)

Inverted cone gap to maintain the pulverised fuel fineness.

Procedure 1)

Collect one set of mill readings from Unit Control Room (UCB), raw coal analysis data, pulverised fuel fineness details, quantity and quality of mill rejects and raw coal size and grindability index etc.

2)

Check and ensure the requirements of raw coal feeder, condition of mill DP instruments, primary air flow through the mill and the quantity of raw coal.

3)

The above adjustments may be carried out to maintain the required DP, PF fineness, quantity & quality of mill rejects and for the said purpose.


48

PLANETARY GEAR BOX

11.0

BOWL MILL XRP 883

PLANETARY GEARBOX – KMP280

Contents 1. Technical data Technical data 2. General notes Introduction General scope of application 3. Safety notes Precautions Work-safety instructions 4. Handling and storage Handling and storage 5. Technical description General Housing Toothed components Bearings Lubrication Sealing 6. Installation (Assembly) General assembly instructions Installation conditions Preparation of the gear unit assembly Gear unit assembly Assembly instructions for attachments Technical Data

Type: Size: Year built: Motor power: Required power: Actual ratio: Input speed: Output speed: Weight (without oil filling): Heaviest component weight: Overall dimensions l x b x h: Internal preservation:


KMP 280 2005 425 kW 410 kW 23.376 1000 1/min 42.78 1/min 10000 kg 3808 kg 2350 x 1750 x 1450 mm 12 months from March 2006

49

PLANETARY GEAR BOX

BOWL MILL XRP 883

Lubrication: hydrodynamic lubrication Oil quantity of gear unit: 1100 liters l Oil viscosity: ISO VG 320 Oil grade: SERVOMESH SP 320 OF IOC OR EQUI. Measuring surface sound pressure level (LpA): 85 dB (A) Ambient temperature: +5 ... +50 °C

SECTION-2 Contents 1. Introduction 2. General scope of application 1. Introduction The Operating Instructions must be read, understood in all respects and observed by those persons who are responsible for use of the PLANETARY GEARBOX, Only familiarization with the Operating Instructions will prevent malfunction of the product and ensure trouble-free operation. It is important, therefore, that the persons actually responsible should be familiar with theses Operating Instructions. Careful study of these Operating Instructions before handling the product and before startup is essential, as no liability is accepted for damage and malfunctions resulting from non-compliance of these Operating Instructions. Note: BHEL reserves the right to amend these Operating Instructions where rendered necessary by improvement of the products. 2. General scope of application The product is intended for the scope of application as specified in the Technical Data.


50

PLANETARY GEAR BOX

BOWL MILL XRP 883

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


51

PLANETARY GEAR BOX

BOWL MILL XRP 883

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

52

PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-4 Contents

1. Handling and storage 1.1 Handling 1.2 Storage 1.3 Preservation 1. Handling and storage 1.1 Handling Only use hoists and load suspension devices with sufficient carrying capacity for handling. The gear unit is already assembled when delivered. Options (such as e.g. pipes and fittings) are packed separately. Caution: 1.0 When handling the gear unit, exercise special care to avoid damage due to the use of force or careless loading and unloading. The gear unit may only be handled using the lifting eyes on the gear unit housing. Use shackles to attach the slings to the lifting eyes. 2.0 In order to prevent damages to the housing and the output flange by turning of the transport rope, wood blocks are to be inserted. 3.0 Never lift the output flange of the gear unit.

Detailed illustrations of the gear unit will be found in the drawings in the gear unit documentation. 1.2 Storage The gear unit should be stored in a protected place in its position of use and with a suitable cover. Caution: If stored in the open, the gear unit should be covered with special care and it should be ensured that neither moisture nor foreign matter is allowed to collect on the gear unit. 1.3 Preservation The gear unit is provided with internal preservation and the free shaft ends with a protective coating. Note: Unless agreed to the contrary by contract, we warrant the internal preservation for a warranty period of 12 months and the preservation of


53

PLANETARY GEAR BOX

BOWL MILL XRP 883

the free shaft ends for one of 12 months. The period of validity starts on the date of delivery of the gear unit. In case of prolonged intermediate storage (> 12 months), it is advisable to check the internal as well as external preservation and to renew them if necessary (see Section 7 ”Startup”). The external coating is resistant to weak acids and alkalis, oils and solvents. It is seawater-resistant, tropic-proof and heat-resistant up to 140 °C / 284 °F. The labyrinth seals on the input shaft and the output flange are sealed additionally with adhesive tape. Caution: The adhesive tape must not be removed until immediately before start-up of the gear unit, because after this the internal preservative takes no longer effect. In case the start up of the gear unit will not take place after removing the tape, follow the preservation instructions (see section 7 “Start-up”). If necessary the preservation must be renewed.

SECTION-5 Contents

1. General 2. Housing 3. Toothed components 4. Bearings 5. Lubrication 5.1 Hydrodynamic lubrication 6. Sealing 1. General The vertical mill drive type KMP is a bevel gear planetary gear unit with triple power transmission path for driving a vertical mill. High axial forces are generated during the milling process which are transmitted into the foundation via the gear unit housing.


54

PLANETARY GEAR BOX

BOWL MILL XRP 883

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


55

PLANETARY GEAR BOX

BOWL MILL XRP 883

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


56

PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-6 Contents

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

1. General assembly instructions When handling the gear unit, follow the instructions in Section - 4. Observe the safety instructions in Section - 3 for the assembly. Assembly should be carried out by specialized personnel with extreme care. 2. Installation conditions Right at the planning stage, it should be ensured that there is adequate space around the gear unit for assembly and subsequent care and maintenance. Make sure that the oil can be drained and that the air supply is sufficient. It must be possible to check the inside parts through the inspection cover openings. Upstream and downstream machines should be arranged accordingly. 2.1 Dimensions and weights Data of the gear unit in assembled state (see Section 1”Technical data”). 2.2 Lifting devices Before commencing the assembly, adequate hoists must be available.


57

PLANETARY GEAR BOX

BOWL MILL XRP 883

The carrying capacities of the hoists to be installed should at least be sufficient for the gear unit weight (for details see Section 1 ”Technical data”). Caution: Lifting devices must only be attached to the gear unit at the marked points (see also Section - 4 ”Handling and Storage”).

Detailed illustrations of the gear unit will be found in the drawings in the gear unit documentation. 3. Preparation of the gear unit assembly Remove the packing from the gear unit before installing it in the mill. Remove the adhesive tapes from the labyrinth seals only before the startup. Caution: The input shaft of the gear unit may only be rotated during the assembly when the pad bearing room is filled with oil up to the mark. Caution: Clean the contact surfaces of gear unit and foundation. 3.1 Foundation Caution: It is of major importance that the mounting surface of the gear unit is level as the contact pattern of the gearing and the percentage contact area of the thrust bearing are dependent on this factor. All points of the mounting surface of the gear unit must be between two imaginary parallel planes with a distance of 0.1 mm / 1 m.


58

PLANETARY GEAR BOX

BOWL MILL XRP 883

The permissible deviation of the mounting surface of the gear unit from the horizontal plane is 0.2 mm / 1 m. 4. Gear unit assembly The gear unit should be installed in the mill according to the special instructions refer Section 5. Caution: The gear units are approved for one direction of rotation only. The direction of rotation of the motor must correspond with the direction of rotation arrow on the gear unit input shaft. 5. Assembly instructions for attachments Caution: When mounting the attachments, observe the special Operating Instructions for the attachments. 5.1 Mounting of the piping The external lube oil system is supplied in three basic subassemblies. The balance of the components are shipped loose 1) Mill Drive Lubrication unit consisting of pump, motor, filter,cooler,Instrumentation console and oil storage tank etc. 2) Loose pipes, flanges, bends, support materials and fasteners etc. 3) Flexible metallic hoses NOTE: For the following steps, refer to the erection drawing no.1-61-188-01416/Figure 15. Also refer to Section-7 for details on the Lube oil system installation 5.1.1 The pipes have to be cut to size as per the site rooting. Weld the bends and flanges to the pipes. Use TIG welding for the root weld between pipes and the bends. Trial assembly of the pipes shall be done according to the drawings with lube oil system and gear box. Blank flanges and plugs shall be removed before hand. 5.1.2 Dismantle the piping and carry out acid pickling. An inhibited hydrochloric acid solution of 15% is required for pickling. Acid Pickling Procedure Plug the lower ends of the pipes. Fill pickling solution into the pipe. Duration of action: 1 hour. After draining the pipe, it should be filled with a neutralizer (ammonia solution of 3 % to 5 %). Neutralization duration: 15 minutes. Then, thoroughly flush the pipe with flushing oil (Servomesh SP 320 of IOC ). Flushing duration: 30 minutes min.


59

PLANETARY GEAR BOX

BOWL MILL XRP 883

Caution: If the pipes are not mounted directly, they should be preserved properly. 5.1.3 The interior of all pipes and fittings must be free of all foreign matter before assembly. 5.1.4 The flange connections are metal to metal joints and appropriate sealing material should be used. Caution: The pipes must not be twisted. The pipes should be supported with brackets according to the drawing. 5.1.5 Unless otherwise noted, torque all hex head screws and apply thread locking sealant to all fasteners 5.1.6 Fasteners used with gasket connection are to have lock washers only. No thread locking sealant shall be used. 5.1.7 It may be necessary to shift the lube oil system assembly to prevent strain on the flanged components. Assemble the rest of the piping and fittings as per drawing No. 1-61-18801416. 5.2 Mounting the motor The drive motor should be aligned exactly with the center axis of the input shaft of the gear unit and should be secured in this position. Caution: When mounting the motor, observe the special Operating Instruction for the motor. Note: The life of the shafts, bearings and couplings depend to a large extent on the precise alignment of the shafts with each other. 5.3 Mounting separately delivered attachments All separate parts with threaded connection should be sealed with Loctite 572 or equivalent. Any separately supplied fittings, the tapped holes of which in the gear unit are closed with plugs, should be installed according to the supplied drawings. Caution: The special Operating Instructions of the separately supplied attachments should be observed. Electric monitoring devices should be connected according to terminal diagrams, equipment lists and the special Operating Instructions.


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PLANETARY GEAR BOX

BOWL MILL XRP 883

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

Storage stability up to 12 months

Preservative

Special measures

Servomesh SP 320 of IOC or Equiv.

Plug the gear unit airlight, replace air filter with plug screws (replace before startup)

more than 12 months

Servomesh SP 320 of IOC or Equiv.

Re-preserve gear unit as up to 12 months Table 7.1: Preservation measures when using mineral oil

6.1.1 Internal preservation procedure Fill with preservative up to the upper mark of the oil level indicator through the ventilation hole or the hole in the inspection cover. Allow the oil to flow to the gearbox internals. However, restrict the level of oil in the Gearbox housing up to the input shaft only. Close the venting hole on the cover opening. Rotate the gear unit at least 1 revolution on the output flange, while filling the oil by overflow in the gearbox housing. This can be done by turning the input shaft manually. Caution: Seal labyrinth seals on input shaft and output flange with adhesive tape.

SECTION 7 PULVERISER LUBE OIL SYSTEM


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PLANETARY GEAR BOX

BOWL MILL XRP 883

Contents 1. Technical data Technical data 2. General notes Introduction General scope of application 3. Safety notes Cautionary Instructions Industrial Safety instructions 4. Handling and storage Packing Extent of Disassembly Handling Storage 5. Technical description General configuration 6. Assembly General Notes Installation conditions Installation Final operations 7. Startup Filling with oil Oil pump Oil cooler

Technical data

Weight (without oil filling): 1180 kg Overall dimensions l x b x h: Pump delivery: Oil quantity: Oil viscosity:

2192 x 1800 x 1585 mm 150 l/min 1100 LTRS. see operating instructions or rating plate of the ”gear unit” Oil grade: SP 320 OF IOC OR EQUIV. Ambient temperature: +5 .. +50 °C Supply voltage: 3 x 380...420V (IEC 38) Supply frequency: 50Hz Drawing no. Lubrication Diagram: 1-61-190-85924 Drawing no. (Terminal Wiring Plan): Vendor supplied drawing.


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PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-B Contents

1. Introduction The Operating Instructions must be read, understood in all respects and observed by those persons who are responsible for use of the PLANETARY GEARBOX. Only familiarization with the Operating Instructions will prevent malfunction of the product and ensure trouble-free operation. It is important therefore that the persons actually responsible should be familiar with theses Operating Instructions. Careful study of these Operating Instructions before handling the product and before startup is essential, as no liability will be accepted for damage and malfunctions resulting from non-compliance of these Operating Instructions. SECTION-C Contents

1. Cautionary instruction 2. Industrial Safety instructions

1. Cautionary instruction This ”Caution:” instruction will be found in places where special caution is to be observed, in order that the guidelines, rules, instructions and correct sequence of operation are observed, and that damage and destruction of the machine and/or other system components is prevented. 2. Industrial Safety instructions The following Industrial Safety instructions should be specially observed: The oil supply system is constructed in accordance with the state of the art technology and safe in operation. This oil supply system may however give rise to hazards if it is used improperly or subjected to use for which it was not intended by untrained personnel. Every person engaged in installation, dismantling and reassembly, startup, operation and maintenance (inspection, servicing, repair) of the oil supply system MUST have read and understood the complete Operating Instructions, in particular the ”Safety” Operating Instructions.


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PLANETARY GEAR BOX

BOWL MILL XRP 883

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


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PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-D Contents

1. Extent of disassembly 2. Handling 3. Storage

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


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PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-E Contents

1. General configuration

1. General configuration The oil supply system described below is used for oil cooling and/or lubrication of a gear unit (see Section 1 ”Technical Data”). The oil supply system has been subjected to an exhaustive trial run in conjunction with the gear unit and tested in accordance with the order data. The oil supply is ensured by means of two pump assemblies, one of which acts as a standby pump. The pump draws the oil from the oil reservoir of the oil supply system. A filter is provided in the oil circuit for filtration of the circulating oil. The quantity of heat generated by losses, which i s 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 r eservoir of the oil supply system.


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PLANETARY GEAR BOX

BOWL MILL XRP 883

SECTION-F Contents

1. General Notes 2. Installation conditions 3. Installation 4. Final operations

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


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PLANETARY GEAR BOX

BOWL MILL XRP 883

Connecting lines are supplied loose. The interfaces are provided with suitable flanges and gaskets.. Compensators (flexible hoses) should be used for vibration insulation and to compensate for linear expansion. Provide supports to the piping suitably. After pipe installation, the lines should be flushed thoroughly. Ensure that the pipes are pickled. Use TIG welding for the root welding. Electrical connections of motors and monitors should be carried out in accordance with terminal drawings, equipment lists and specifications. Check voltage and circuits. The sealing plugs and wooden flanges should be removed and the pipe fit tings supplied loose installed in the system in accordance with lubrication diagram and drawings (see Section 1 ”Technical Data”). Parts supplied loose with threaded connection should be sealed with Loctite 572 or equivalent after thorough cleaning.

4. Final operations After installing the oil supply system, all visible screw fastenings should be checked for tightness and tightened if necessary. Fit all safety devices necessary. SECTION-G Contents

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

1. Filling with oil The following provisions are recommended based on long years of experience. They are given however without any responsibility on the part of the gear unit manufacturer. Responsibility for the oil grade lies with the manufacturer of the oil and the operator of the system has to ensure satisfactory state of the oil grade (see Operating Instructions ”Gear unit”). In all cases, before startup, the gear unit/oil supply system should be filled with oil (see Operating Instructions ”Gear unit”). After fi lling, the filler openings should be properly re-closed and sealed.


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PLANETARY GEAR BOX

BOWL MILL XRP 883

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


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