Pulverizer Maintenance Guide

Volume 3: Ball/Tube Mills

Technical Report

Effective December 6, 2006, this report has been made publicly available in accordance
with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export
Administration Regulations. As a result of this publication, this report is subject to only
copyright protection and does not require any license agreement from EPRI. This notice
supersedes the export control restrictions and any proprietary licensed material notices
embedded in the document prior to publication.
Pulverizer Maintenance Guide
Volume 3: Ball/Tube Mills
1010443

Final Report, March 2006

EPRI Project Manager

A. Grunsky

ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1395 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA
800.313.3774 ▪ 650.855.2121 ▪ askepri@epri.com ▪ www.epri.com
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH
INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE
ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)

WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR
SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR
INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL
PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S
CIRCUMSTANCE; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER

(INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE
HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR
SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD,
PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Electric Power Research Institute (EPRI)

NOTE
For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or
e-mail askepri@epri.com.

Electric Power Research Institute and EPRI are registered service marks of the Electric Power
Research Institute, Inc.

Copyright © 2006 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS

This report was prepared by

Electric Power Research Institute (EPRI)

Fossil Maintenance Applications Center (FMAC)
1300 W.T. Harris Boulevard
Charlotte, NC 28262

Maintenance Management and Technology (MM&T)

1300 W.T. Harris Boulevard
Charlotte, NC 28262

Principal Investigator
S. Parker

This report describes research sponsored by EPRI.

The report is a corporate document that should be cited in the literature in the following manner:

Pulverizer Maintenance Guide, Volume 3: Ball/Tube Mills. EPRI, Palo Alto, CA: 2006.
1010443.

iii
REPORT SUMMARY

The Pulverizer Maintenance Guide, Volume 3: Ball/Tube Mills provides fossil plant personnel
with current maintenance information on ball/tube mills from different manufacturers. This guide
will assist a plant in improving the maintenance of their pulverizer mills.

Background
This is the third guide produced for pulverizer mills; it is preceded by:
• Pulverizer Maintenance Guide, Volume 1: Raymond Bowl Mills (EPRI report 1005061)
• Pulverizer Maintenance Guide, Volume 2: B&W Roll Wheel™ Pulverizers (EPRI report
1009508)
Two Electric Power Research Institute (EPRI) groups, Fossil Maintenance Applications Center
(FMAC) and Maintenance Management and Technology (MM&T), sponsored this guide.

Objectives
• To identify preventive and predictive maintenance practices for ball/tube mills
• To assist plant maintenance personnel in the identification and resolution of ball/tube mill
equipment problems

Approach
A Technical Advisory Group (TAG) was formed that consisted of pulverizer equipment owners
from EPRI FMAC and MM&T members. There are five manufacturers’ mills covered in this
report. The manufacturers are Allis-Chalmers, Foster Wheeler, Kennedy Van Saun, Riley Power
Inc., and Stein Industrie. Input was solicited for the current maintenance issues for the ball/tube
mills. An extensive search of industry and EPRI information was conducted to provide relevant
information for this guide.

Results
This guide includes general information on the ball/tube mill function in the coal-handling
process, the operation and safety of the ball/tube mill, and the performance testing of the mills.
The technical description, failure modes, troubleshooting, and predictive and preventive
maintenance sections are the main sources of information in the guide. A preventive maintenance
(PM) basis was also developed for the guide. This guide covers the coal pulverizer system from
the feeder to the pulverizer outlet.

v
EPRI Perspective
The maintenance of the ball/tube mills affects the availability and reliability of the operating
unit. The efficiency of the mill in providing the desired coal and air mixture to the furnace has
increased cost consequences with the addition of NOx controls. Repairs and modifications to the
mill will ensure that the mills operate reliably.

Keywords
Pulverizer mill
Ball mill
Tube mill
Maintenance
Reliability
Troubleshooting

vi
ABSTRACT

The pulverizer mill is a critical component in a coal-fired power plant. As the age of the mill
increases, the maintenance costs required for continued operation also increase. With the
addition of NOx controls, the efficiency of the unit is affected to a greater degree by the air
quantity and fineness of the coal-air mixture going to the furnace.

Monitoring critical dimensions and parameters on the mill makes sure that the mill is functioning
correctly. Performing routine preventive inspections and anticipating component replacements
ensures that the maintenance activities are planned activities and not the cause of forced outages.

This guide covers several ball/tube mill manufacturers. It is intended to improve the maintenance
practices and reliability of the equipment.

vii
ACKNOWLEDGMENTS

This report was produced by the Electric Power Research Institute (EPRI) Fossil Maintenance
Applications Center (FMAC), Maintenance Management and Technology (MM&T), and the
following members of the Technical Advisory Group (TAG). EPRI would like to thank these
individuals for their participation in the preparation and review of the report:

TAG Members:
Name EPRI Member Utility/Location
Robert Baca Salt River Project/Coronado
J. Corie Biggs Hoosier Energy/Merom
Jesse Billings Hoosier Energy/Merom
Mark Breetzke Eskom/Kendal
Marlize Dreyer Eskom/Arnot
Chris Du Toit Eskom/Tutuka
Wolf Hahn Eskom/Tutuka
Scott Hall Salt River Project/Coronado
Andre Van Heerden Eskom/Lethabo
Ken Isaacson Salt River Project/Coronado
Mahomed Jhetam Eskom/Majuba
Ken Johnson Salt River Project/Coronado
Robert Jones Wisconsin Energies/Corporate Office
Ken McDonald Hoosier Energy/Merom
Mce Matanda Eskom/Kendal
Hennie Pretorius Eskom/Matimba
Russell Tarr Eskom/Corporate Office
Christo Van Wyk Eskom/Matimba
Manufacturers:
Dan Smith Riley Power Inc.

EPRI and the TAG were supported in their efforts to develop this guide by:
Sharon Parker Industry Consultant

ix
CONTENTS

1 INTRODUCTION ................................................................................................................. 1-1

1.1 Background............................................................................................................... 1-1
1.2 Approach................................................................................................................... 1-2
1.3 Organization.............................................................................................................. 1-3
1.4 Key Points................................................................................................................. 1-4

2 GLOSSARY......................................................................................................................... 2-1

3 SYSTEM APPLICATION ..................................................................................................... 3-1

3.1 Coal Handling System............................................................................................... 3-1
3.2 Coal Characteristics .................................................................................................. 3-5
3.3 Coal Pulverizer Mills.................................................................................................. 3-7
3.4 Environmental Regulations ....................................................................................... 3-9

4 TECHNICAL DESCRIPTION – GENERAL .......................................................................... 4-1

5 TECHNICAL DESCRIPTION – ALLIS-CHALMERS............................................................ 5-1

5.1 Inlet/Outlet Boxes...................................................................................................... 5-4
5.2 Rotating Shell, Liners, and Balls................................................................................ 5-7
5.3 Trunnion Bearings..................................................................................................... 5-9
5.4 Classifier ..................................................................................................................5-15
5.5 Drive Motor ..............................................................................................................5-17
5.6 Gearbox Unit............................................................................................................5-23
5.7 Girth Gear and Pinion Shaft .....................................................................................5-29
5.8 Power-Sonic Mill Conditioning System .....................................................................5-33
5.9 Technical Specification List ......................................................................................5-35

6 TECHNICAL DESCRIPTION – FOSTER WHEELER .......................................................... 6-1

6.1 Conveyor Assembly .................................................................................................. 6-4

xi
 6.1.1 Conveyor Support Assembly ............................................................................ 6-6
6.2 Drum Assembly......................................................................................................... 6-8
6.2.1 Double-Wave Liners ........................................................................................6-10
6.2.2 Double-Size, Double-Wave Access Doors.......................................................6-12
6.2.3 Flight Bars .......................................................................................................6-12
6.2.4 Grinding Balls ..................................................................................................6-12
6.3 Conveyor Shaft Bearing and Seal ............................................................................6-13
6.4 Trunnion Main Bearing and Dust Seal......................................................................6-14
6.5 Gearing ....................................................................................................................6-16
6.5.1 Pinion Bearings ...............................................................................................6-17
6.6 Trunnion Tube..........................................................................................................6-18
6.7 Classifier ..................................................................................................................6-20
6.7.1 Classifier Reject Damper .................................................................................6-20
6.7.2 Adjustable Blade Classifier ..............................................................................6-21
6.7.3 M-Type Classifier.............................................................................................6-23
6.7.4 Dynamic Classifier...........................................................................................6-24
6.8 Exhausters ...............................................................................................................6-27
6.9 Lubrication Systems.................................................................................................6-28
6.9.1 Cardwell Lubrication System ...........................................................................6-28
6.9.2 Farval Lubrication System ...............................................................................6-30

7 TECHNICAL DESCRIPTION – KENNEDY VAN SAUN....................................................... 7-1

8 TECHNICAL DESCRIPTION – RILEY POWER INC. .......................................................... 8-1

8.1 General Description .................................................................................................. 8-1
8.2 System Components................................................................................................. 8-4
8.2.1 Feeder.............................................................................................................. 8-5
8.2.2 Crusher-Dryer................................................................................................... 8-6
8.2.3 Rotating Drum or Barrel.................................................................................... 8-7
8.2.4 Grinding Ball Makeup ....................................................................................... 8-8
8.2.5 Classifier........................................................................................................... 8-9
8.2.6 Shutoff Valves .................................................................................................8-10
8.2.7 Speed Reducer Gearbox .................................................................................8-10
8.2.8 Clutch ..............................................................................................................8-12
8.3 Systems ...................................................................................................................8-15

xii
 8.3.1 Primary Air System..........................................................................................8-15
8.3.2 Seal Air System ...............................................................................................8-16
8.4 Modifications ............................................................................................................8-17
8.4.1 Trickle Valve Addition ......................................................................................8-17
8.4.2 Trunnion Air Seal Redesign.............................................................................8-18
8.4.3 Mill Conditioning System Upgrade...................................................................8-19
8.4.4 Hydrodynamic Slide Shoe Bearing Conversion................................................8-19
8.4.5 Crusher-Dryer Crusher Block...........................................................................8-21

9 TECHNICAL DESCRIPTION – STEIN INDUSTRIE............................................................. 9-1

9.1 General Description .................................................................................................. 9-1
9.2 Systems .................................................................................................................... 9-5
9.2.1 Coal Inlet System ............................................................................................. 9-5
9.2.2 Primary Air System........................................................................................... 9-6
9.2.3 Seal Air System ................................................................................................ 9-8
9.2.4 Lubrication Oil Systems .................................................................................... 9-9
9.2.5 Drive System ...................................................................................................9-13
9.2.6 Blow-Down System .........................................................................................9-14
9.2.7 Ball Loading System........................................................................................9-14

10 OPERATION AND SAFETY – ALLIS-CHALMERS..........................................................10-1

10.1 Operations...........................................................................................................10-1
10.2 Fire Protection .....................................................................................................10-2

11 OPERATION AND SAFETY – FOSTER WHEELER ........................................................11-1

11.1 General Operation ...............................................................................................11-1
11.2 Operation Indications...........................................................................................11-3
11.3 Startup Procedures..............................................................................................11-4
11.4 Fire Detection System .........................................................................................11-6
11.5 Fire Protection .....................................................................................................11-7

12 OPERATION AND SAFETY – KENNEDY VAN SAUN.....................................................12-1

12.1 Load Changes .....................................................................................................12-1
12.2 Fuel Oil Support...................................................................................................12-2
12.3 Blocked Fuel Pipe................................................................................................12-3
12.4 Wet Coal .............................................................................................................12-4

xiii
 12.5 Mill Stripping........................................................................................................12-5
12.6 Cold Startup ........................................................................................................12-6

13 OPERATION AND SAFETY – RILEY POWER INC. ........................................................13-1

13.1 General Operation ...............................................................................................13-1
13.2 Control System....................................................................................................13-2
13.3 Handling Ball Charge...........................................................................................13-8
13.4 Primary Air Damper Operation.............................................................................13-8
13.5 Seal Air System .................................................................................................13-11
13.6 Feeder Calibration .............................................................................................13-12
13.7 Instrumentation Settings ....................................................................................13-13
13.8 Fire Detection ....................................................................................................13-15
13.9 Fire Protection ...................................................................................................13-17

14 OPERATION AND SAFETY – STEIN INDUSTRIE...........................................................14-1

14.1 Layup ..................................................................................................................14-1
14.2 Fire Protection .....................................................................................................14-2

15 PERFORMANCE ..............................................................................................................15-1
15.1 Fineness..............................................................................................................15-1
15.2 Grindability ..........................................................................................................15-2
15.3 Moisture ..............................................................................................................15-2
15.4 Capacity ..............................................................................................................15-3

16 FAILURE MODES ............................................................................................................16-1

16.1 Abrasion ..............................................................................................................16-1
16.2 Erosion ................................................................................................................16-3
16.3 Failed Components .............................................................................................16-4

17 TROUBLESHOOTING......................................................................................................17-1
17.1 Allis-Chalmers .....................................................................................................17-1
17.2 Foster Wheeler....................................................................................................17-5
17.3 Kennedy Van Saun..............................................................................................17-7
17.4 Riley Power Inc....................................................................................................17-9
17.5 Stein Industrie ...................................................................................................17-10

xiv
18 PREDICTIVE MAINTENANCE .........................................................................................18-1
18.1 Vibration Analysis ................................................................................................18-3
18.2 Oil Analysis..........................................................................................................18-3
18.3 Condition-Based Maintenance – Kennedy Van Saun ........................................18-12
18.4 Condition Based Maintenance – Stein Industrie ................................................18-15

19 PREVENTIVE MAINTENANCE ........................................................................................19-1

19.1 Allis-Chalmers .....................................................................................................19-1
19.1.1 Inspection Criteria ........................................................................................19-2
19.1.2 External Mill Inspection.................................................................................19-3
19.1.3 Internal Mill Inspection..................................................................................19-6
19.1.4 Classifier Inspection .....................................................................................19-7
19.1.5 Drive Train Inspection ..................................................................................19-9
19.1.6 Shell and Trunnion Liner ............................................................................19-10
19.1.7 Trunnion Bearing Insert Replacement ........................................................19-11
19.1.8 Girth Gear Replacement.............................................................................19-13
19.1.9 Gearbox Rebuild ........................................................................................19-18
19.1.10 Miscellaneous Equipment...........................................................................19-22
19.1.11 Equipment Lubrication List .........................................................................19-22
19.2 Kennedy Van Saun............................................................................................19-24
19.2.1 Pinion, Girth Gear, and Lubrication System................................................19-25
19.2.2 Reversing the Worm Gear..........................................................................19-25
19.3 Riley Power Inc..................................................................................................19-27
19.3.1 Feeder........................................................................................................19-27
19.3.2 Crusher-Dryer ............................................................................................19-28
19.3.3 Inlet/Outlet Box and Air Seals.....................................................................19-31
19.3.4 Mill Liners ...................................................................................................19-31
19.3.5 Ball Charge ................................................................................................19-32
19.3.6 Speed Reducer Gearbox............................................................................19-33
19.3.7 Drive Train..................................................................................................19-38
19.3.8 Driveshaft ...................................................................................................19-44
19.3.9 Lubrication Heat Exchanger .......................................................................19-46
19.3.10 Classifier ....................................................................................................19-47
19.3.11 Primary Air Fan and Ductwork....................................................................19-48
19.3.12 Coal Shutoff Valves....................................................................................19-49

xv
 19.3.13 Lubrication Schedule ...................................................................................19-49
19.3.14 Spare Parts ..................................................................................................19-50
19.3.15 Example Preventive Maintenance Inspections ............................................19-51
19.4 Stein Industrie .....................................................................................................19-51
19.4.1 Preventive Maintenance Tasks....................................................................19-53
19.4.2 Inspection Tasks..........................................................................................19-58
19.4.3 Pinion and Girth Gear Replacement ............................................................19-61

20 PREVENTIVE MAINTENANCE BASIS..............................................................................20-1

20.1 Background ...........................................................................................................20-1
20.2 Failure Locations, Degradation Mechanisms, and PM Strategies ........................20-2
20.3 PM Tasks and Their Degradation Mechanisms ....................................................20-9
20.4 PM Template.......................................................................................................20-14

21 REFERENCES ...................................................................................................................21-1

A KEY POINTS......................................................................................................................... A-1

B TRANSLATED TABLE OF CONTENTS .............................................................................. B-1

日本語 (Japanese) ............................................................................................................... B-2

Español (Spanish) .............................................................................................................. B-19

xvi
LIST OF FIGURES

Figure 3-1 A Typical Coal Handling System Diagram from Unloading to the Plant .................. 3-2
Figure 3-2 A Typical Coal Handling System Diagram from Plant to Unit Bunkers.................... 3-3
Figure 3-3 Foster Wheeler Ball Mill ......................................................................................... 3-8
Figure 3-4 Fuel-Bound Nitrogen Evolution to NOx ..................................................................3-10
Figure 5-1 Allis-Chalmers Ball/Tube Mill Outline ..................................................................... 5-2
Figure 5-2 Inlet/Outlet Box ...................................................................................................... 5-4
Figure 5-3 Mill Sealing Arrangement ....................................................................................... 5-6
Figure 5-4 Ball Charge Hopper ............................................................................................... 5-8
Figure 5-5 Trunnion Bearing Low-Pressure Lubrication System.............................................5-10
Figure 5-6 Manual High-Pressure Jacking Pump ...................................................................5-13
Figure 5-7 Static Classifier .....................................................................................................5-15
Figure 5-8 Mill Drive Motor .....................................................................................................5-17
Figure 5-9 Barring Gear Unit ..................................................................................................5-19
Figure 5-10 Barring Coupling .................................................................................................5-21
Figure 5-11 Barring Brake......................................................................................................5-22
Figure 5-12 Gearbox Unit.......................................................................................................5-23
Figure 5-13 Gearbox Output Coupling ...................................................................................5-25
Figure 5-14 Gearbox Lubrication System ...............................................................................5-26
Figure 5-15 Gear Teeth Lubrication .......................................................................................5-27
Figure 5-16 Mill Outline ..........................................................................................................5-30
Figure 5-17 Girth Gear Lubrication System ............................................................................5-31
Figure 5-18 Power-Sonic Mill Conditioning System................................................................5-33
Figure 6-1 Foster Wheeler Ball Mill Diagram........................................................................... 6-1
Figure 6-2 Air/Coal Flow Diagram ........................................................................................... 6-2
Figure 6-3 Flight Ribbon Conveyor Assembly ......................................................................... 6-5
Figure 6-4 Flight Ribbon Spring Support Assembly................................................................. 6-6
Figure 6-5 Conveyor Support Assembly.................................................................................. 6-6
Figure 6-6 Conveyor Removal with the Eight-Spoke Design ................................................... 6-8
Figure 6-7 Complete Drum Assembly ..................................................................................... 6-9
Figure 6-8 End Casting ..........................................................................................................6-10
Figure 6-9 Double-Wave Liners .............................................................................................6-11
Figure 6-10 Double-Size, Double-Wave Access Door ............................................................6-12

xvii
Figure 6-11 Ball Wear Rates ..................................................................................................6-13
Figure 6-12 Conveyor Bearing Modification ...........................................................................6-13
Figure 6-13 Original Bearing Assembly..................................................................................6-14
Figure 6-14 New Design Bearing ...........................................................................................6-15
Figure 6-15 Trunnion Seal .....................................................................................................6-16
Figure 6-16 Pinion and Bull Gear Assembly...........................................................................6-17
Figure 6-17 Roller Bearings ...................................................................................................6-18
Figure 6-18 Classifier Trunnion Tube .....................................................................................6-19
Figure 6-19 Original Scroll-Type Classifier .............................................................................6-20
Figure 6-20 Classifier Reject Dampers...................................................................................6-21
Figure 6-21 Adjustable Classifier ...........................................................................................6-22
Figure 6-22 Classifier Comparison .........................................................................................6-22
Figure 6-23 Adjustable Classifier Fineness Improvement.......................................................6-23
Figure 6-24 M-Type Classifier ................................................................................................6-24
Figure 6-25 Dynamic Classifier ..............................................................................................6-25
Figure 6-26 Exhauster Diagram .............................................................................................6-27
Figure 6-27 Exhauster Spider ................................................................................................6-28
Figure 6-28 Cardwell Lubrication System...............................................................................6-29
Figure 6-29 Farval Lubrication System...................................................................................6-30
Figure 7-1 Kennedy Van Saun Mill System ............................................................................. 7-2
Figure 7-2 Kennedy Van Saun Mill Components..................................................................... 7-3
Figure 8-1 Riley Power Chain-Driven Ball/Tube Mill System ................................................... 8-2
Figure 8-2 Riley Power Gear-Driven Ball/Tube Mill System..................................................... 8-3
Figure 8-3 Drum-Type Feeder................................................................................................. 8-5
Figure 8-4 Crusher-Dryer ........................................................................................................ 8-6
Figure 8-5 Mill with Pinion/Ring Gear Drive Set....................................................................... 8-8
Figure 8-6 Static Classifier ...................................................................................................... 8-9
Figure 8-7 Speed Reducer Gearbox ......................................................................................8-11
Figure 8-8 Clutch Assembly ...................................................................................................8-13
Figure 8-9 Rotorseal ..............................................................................................................8-15
Figure 8-10 Clutch Air Control System ...................................................................................8-15
Figure 8-11 New Trickle Valve Design ...................................................................................8-18
Figure 8-12 Trunnion Air Seal Designs ..................................................................................8-19
Figure 8-13 Hydrodynamic Slide Shoe Bearing......................................................................8-20
Figure 8-14 Thrust Bearing ....................................................................................................8-21
Figure 9-1 Stein Industrie Tube Mill......................................................................................... 9-2
Figure 9-2 Detailed View of the Stein Industrie Tube Mill ........................................................ 9-3
Figure 9-3 Mill Airflow.............................................................................................................. 9-7
Figure 9-4 High- and Low-Pressure Lubricating Oil System ...................................................9-10

xviii
Figure 10-1 Mobile Gas Bottle Unit ........................................................................................10-3
Figure 10-2 Permanently Installed Carbon Dioxide Fire Protection System............................10-4
Figure 11-1 Fire Detection Sensor Head ................................................................................11-7
Figure 12-1 Wet Coal Operation ............................................................................................12-4
Figure 13-1 Riley Power Operation Diagram..........................................................................13-4
Figure 13-2 Motor Power Versus Product Charge..................................................................13-5
Figure 13-3 Mill Parameters Using Product Charge Control...................................................13-5
Figure 13-4 Effects of Reduced Ball Charge ..........................................................................13-6
Figure 13-5 Water Spray System Nozzle Locations .............................................................13-18
Figure 16-1 Pulverizer Component Failure Frequency ...........................................................16-1
Figure 18-1 Early Warning for Pulverizer Failure....................................................................18-2
Figure 19-1 Link-Belt Single-Gear Reducer..........................................................................19-34
Figure 19-2 Link-Belt Double-Gear Reducer ........................................................................19-35
Figure 19-3 Link-Belt Triple-Gear Reducer...........................................................................19-36

xix
LIST OF TABLES

Table 1-1 Conversion Factors ................................................................................................. 1-2

Table 5-1 Alarm Conditions for the Power-Sonic Mill Conditioning System ............................5-34
Table 5-2 Data for Allis-Chalmers Mills ..................................................................................5-35
Table 9-1 Normal Lubrication Oil Pressure Values.................................................................9-12
Table 9-2 Mill Lubrication Systems.........................................................................................9-13
Table 10-1 Ball Replacement Tasks.......................................................................................10-2
Table 11-1 Shutting Down One Side of a Double-End Mill .....................................................11-2
Table 11-2 Normal Operation Checks ....................................................................................11-4
Table 11-3 Initial Mill Preparation for Startup .........................................................................11-4
Table 11-4 Charging the Mill for Startup.................................................................................11-5
Table 11-5 Placing the Mill in Service ....................................................................................11-6
Table 11-6 Procedures for Fire Extinguishing in the Foster Wheeler Mill................................11-8
Table 11-7 Emergency Shutdown Procedures for the Foster Wheeler Mill.............................11-9
Table 11-8 Recommended Procedures for Shutting Down the Foster Wheeler Mill Filled
with Coal ........................................................................................................................11-9
Table 12-1 Tasks for Stripping the Mill ...................................................................................12-5
Table 12-2 Cold Startup Tasks...............................................................................................12-6
Table 13-1 Coal Feeder Calibration Tasks ...........................................................................13-12
Table 13-2 Sample Riley Mill Instrumentation Parameters ...................................................13-13
Table 13-3 Sample Equipment Parameters..........................................................................13-14
Table 13-4 Fire Detection Temperature Sensor Locations ...................................................13-16
Table 15-1 Standard Screen Dimensions...............................................................................15-1
Table 16-1 Abrasive Wear Coefficients ..................................................................................16-3
Table 16-2 Allis-Chalmers Failure Components .....................................................................16-4
Table 17-1 Troubleshooting for Allis-Chalmers Mills ..............................................................17-1
Table 17-2 Troubleshooting Chart for Foster Wheeler Mills....................................................17-5
Table 17-3 Troubleshooting Chart for Kennedy Van Saun Mills .............................................17-7
Table 17-4 Troubleshooting Chart for the Chain-Driven or Gear-Driven Riley Power Ball
Mills................................................................................................................................17-9
Table 17-5 Troubleshooting for Stein Industrie Mills.............................................................17-10
Table 18-1 Particle Count Range Numbers............................................................................18-5
Table 18-2 Elements in Oil Additive Package.........................................................................18-9

xxi
Table 18-3 Kennedy Van Saun Mill Components for Lubrication Program ...........................18-13
Table 18-4 Condition-Based Monitoring Values at Majuba Power Station ............................18-16
Table 18-5 Monitored Conditions at Majuba Power Station..................................................18-19
Table 18-6 Condition Monitoring Instrumentation for Majuba Power Station ........................18-20
Table 18-7 Scheduled Condition Monitoring at Majuba Power Station .................................18-24
Table 19-1 External Mill Inspection Tasks ..............................................................................19-4
Table 19-2 Internal Inspection Tasks .....................................................................................19-6
Table 19-3 Classifier Inspection Tasks...................................................................................19-8
Table 19-4 Mill Drive Train Inspection Tasks..........................................................................19-9
Table 19-5 Shell and Trunnion Liner Replacement Tasks ....................................................19-10
Table 19-6 Trunnion Bearing Insert Replacement Tasks......................................................19-12
Table 19-7 Girth Gear Replacement Tasks ..........................................................................19-14
Table 19-8 Gearbox Rebuild Tasks......................................................................................19-19
Table 19-9 Equipment Lubrication List .................................................................................19-23
Table 19-10 Inspection Tasks for Pinion, Girth Gear, and Lubrication Systems ...................19-25
Table 19-11 Tasks for Reversing the Gearbox Worm Gear..................................................19-26
Table 19-12 Wear Liner Replacement..................................................................................19-32
Table 19-13 Speed Reducer Gearbox Oil Capacities ...........................................................19-33
Table 19-14 Triple-Speed Reducer Gearbox Disassembly Tasks ........................................19-37
Table 19-15 Clutch Inspection Tasks ...................................................................................19-40
Table 19-16 Chain Repair Tasks..........................................................................................19-41
Table 19-17 Driven Sprocket Removal and Reinstallation Tasks .........................................19-42
Table 19-18 Driveshaft Replacement Tasks.........................................................................19-44
Table 19-19 Heat Exchanger Inspection Tasks....................................................................19-46
Table 19-20 Lube Oil Heat Exchanger Replacement Tasks .................................................19-47
Table 19-21 Classifier Preventive Maintenance Tasks .........................................................19-48
Table 19-22 Lubrication Schedule........................................................................................19-49
Table 19-23 Riley Power Recommended Spare Parts .........................................................19-50
Table 19-24 Feeder Inspection Tasks for the 7000 Operating Hour Interval.........................19-53
Table 19-25 Preventive Maintenance Tasks ........................................................................19-54
Table 19-26 Inspection Tasks for the 5500 Operating Hour Interval.....................................19-59
Table 19-27 Inspection Tasks for the 18-Month Interim Inspection.......................................19-60
Table 19-28 Inspection Tasks for the Nine-Year General Overhaul......................................19-61
Table 19-29 Replacement Tasks for the Pinion and Girth Gear ...........................................19-61
Table 20-1 Failure Locations, Degradation Mechanisms, and PM Strategies for
Ball/Tube Mills ................................................................................................................20-4
Table 20-2 PM Tasks and Their Degradation Mechanisms for Ball/Tube Mills .....................20-10
Table 20-3 PM Template for the Ball/Tube Mills...................................................................20-15

xxii
1
INTRODUCTION

The purpose of this guide is to provide information for ball/tube mills. The information is
intended to provide a comprehensive maintenance guide for plant maintenance personnel. This
guide should assist plant maintenance personnel in the identification and resolution of pulverizer
equipment problems.

1.1 Background

Maintenance costs on pulverizers are a significant part of a plant’s maintenance budget. The loss
of pulverizer availability results in operational impacts from load reduction, NOx control
difficulties, and an increased heat rate. Pulverizer failures increase demands on maintenance
crews to perform reactive maintenance, which directly affects scheduled work and crew
utilization and effectiveness.

Most pulverizers in service today are at least 25 years old, and many are being maintained with
smaller maintenance crews that have a limited amount of experience. Equipment age, technician
knowledge, operational practices, and dated monitoring techniques have impacted pulverizer
performance in various stations. These issues and others prompted the development of a series of
comprehensive maintenance guides for pulverizers.

With input from utility members, it was decided to produce three maintenance guides. The
selection of the mill types was determined from survey information submitted from member
utilities. The three maintenance guides are:
• Pulverizer Maintenance Guide, Volume 1: Raymond Bowl Mills (EPRI report 1005061),
August 2004
• Pulverizer Maintenance Guide, Volume 2: B&W Roll Wheel™ Pulverizers (EPRI report
1009508), December 2004
• Pulverizer Maintenance Guide, Volume 3: Ball/Tube Mills (EPRI report 1010443),
March 2006

Two Electric Power Research Institute (EPRI) groups, the Fossil Maintenance Applications
Center (FMAC) and Maintenance Management and Technology (MM&T), sponsored this guide.

1-1
Introduction

1.2 Approach

The proposed guide content and schedule was sent to the EPRI-member coal-fired plants in
January 2005. Input for the guide and participation in a Technical Advisory Group (TAG) was
then solicited.

The TAG for the guide consisted of 16 utility members and one manufacturer representative. The
TAG members provided input for the guide, reviewed the first draft, and provided comments.

An extensive search of existing EPRI guides and industry literature was conducted during the
development of this guide. Because many sources of information were used in the compilation of
this guide, it was decided to use a reference system for the appropriate sections. The use of
reference numbers in brackets is used at the beginning of sections and after the titles on tables
and figures to denote where the majority of information in that section was obtained. The
numbers and corresponding references are listed in the Section 21 of this guide.

The following conversion factors in Table 1-1 should be used to convert from English to
Standard International units of measurement.

Table 1-1
Conversion Factors

Parameter English Units to Standard Standard International Units to

International Units English Units
2 2 2 2
Area 1 in = 6.45 cm 1 cm = 0.155 in
2 2 2 2
1 ft = 929 cm 1 cm = 0.001 ft
3 3
Flow 1 ft /min = 28.317 liter/min 1 liter/min = 0.0353 ft /min
3 3
1 ft /sec = 28.317 liter/sec 1 liter/sec = 0.0353 ftp. /sec
-4
Energy 1 Btu = 2.9307 x 10 kwh 1 kwh = 3412 Btu
-4
1 Btu = 1055 Joules 1 Joule = 9.48 x 10 Btu

Length 1 inch = 0.0254 m 1 m = 39.37 inch

1 inch = 2.54 cm 1 cm = 0.3937 inch
1 inch = 25.4 mm 1 mm = 0.03937 inch
-6
1 inch = 25,400 µm (micron) 1 µm = 39.37 x 10 inch

1 ft = 0.3048 m 1 m = 3.28 ft
1 ft = 30.48 cm 1 cm = 0.0328 ft
1 ft = 304.8 mm 1 mm = 0.00328 ft
-6
1 ft = 304,800 µm (micron) 1 µm = 3.28 x 10 ft

1-2
 Introduction

Table 1-1 (cont.)

Conversion Factors

Parameter English Units to Standard Standard International Units to

International Units English Units

Pressure 1 psi = 6.89 kPa 1 kPa = 0.145 psi

1 psi = 0.006895 mPa 1 mPa = 145 psi
psig = psi gauge
psia = psi absolute

Temperature ºF = 1.8 (ºC) + 32 ºC = (ºF-32)/1.8

Torque 1 ft-lb = 1.356 N-m 1 N-m = 0.738 ft-lb

Weight 1 oz. = 28.35 g 1 g = 0.0353 oz
1 lb. = 0.454 kg 1 kg = 2.2 lb
1 U.S. ton = 2000 lbs. = 0.907 1 metric ton = 1000 kg = 1.1 U.S.
metric tons tons

Velocity 1 in/sec = 2.54 cm/sec 1 cm/sec = 0.394 in/sec

1 ft/sec = 0.3048 m/sec 1 m/sec = 3.28 ft/sec

Volume 1 gal = 3.78 liter 1 liter = 0.264 gal

-4
1 gal = 3785 milliliters 1 milliliter = 2.642 x 10 gal

1.3 Organization

This guide is organized into the following sections:

1. Introduction – Background, approach, organization, and key points
2. Glossary
3. System Application – Coal-handling system, coal characteristics, coal pulverizer mills, and
environmental regulations
4. Technical Description – General
5. Technical Description – Allis-Chalmers
6. Technical Description – Foster Wheeler
7. Technical Description – Kennedy Van Saun
8. Technical Description – Riley Power Inc.
9. Technical Description – Stein Industrie
10. Operation and Safety – Allis-Chalmers
11. Operation and Safety – Foster Wheeler

1-3
Introduction

12. Operation and Safety – Kennedy Van Saun

13. Operation and Safety – Riley Power Inc.
14. Operation and Safety – Stein Industrie
15. Performance – Fineness, coal grindability, moisture, and capacity
16. Failure Modes – Abrasion, erosion, and failed components
17. Troubleshooting – Allis-Chalmers, Foster Wheeler, Kennedy Van Saun, Riley Power Inc.,
and Stein Industrie
18. Predictive Maintenance – Vibration analysis, oil analysis, and condition-based maintenance
19. Preventive Maintenance – Allis-Chalmers, Kennedy Van Saun, Riley Power Inc., Stein
Industrie, inspection criteria, and inspection tasks
20. Preventive Maintenance Basis Component Module – Background, failure locations,
preventive maintenance (PM) tasks, and PM templates
21. References
Appendix A – Key Points Summary
The words mill and pulverizer are used interchangeably in this guide.

1.4 Key Points

Throughout this guide, key information is summarized in key points. Key points are bold lettered
boxes that highlight information covered in the text.

The primary intent of a key point is to emphasize information that will allow individuals to act
for the benefit of their plant. EPRI personnel who reviewed and prepared this guide selected the
information included in these key points.

The key points are organized into three categories: Human Performance, O&M Costs, and
Technical. Each category has an identifying icon to draw attention to it when quickly reviewing
the guide. The key points are shown in the following way:

Human Performance Key Point

Denotes information that requires personnel action or consideration in order to
prevent personal injury, equipment damage, and/or improve the efficiency and
effectiveness of the task.

O&M Cost Key Point

Emphasizes information that will result in overall reduced costs and/or an increase
in revenue through additional or restored energy production.

1-4
 Introduction

Technical Key Point

Targets information that will lead to improved equipment reliability.

The Key Points Summary section (Appendix A) of this guide contains a listing of all key points
in each category. The listing restates each key point and provides a reference to its location in the
body of the report. By reviewing this listing, users of this guide can determine if they have taken
advantage of key information that the writers of this guide believe would benefit their plants.

1-5
2
GLOSSARY

AGMA – American Gear Manufacturer Association.

balls – Balls are composed of hardened carbon steel, high-chrome steel, or forged chrome-
molybdenum and are 3/4–2 1/2 inches in diameter. The balls are also called cylpebs.

ball mill – A ball mill is a low-speed mill (10–20 rpm) that uses the grinding action of steel balls
in a rotating horizontal cylinder or drum. If the diameter of the drum is greater than the length of
the drum, then the mill is called a ball mill.

barr – Barr means to rotate or turn the mill.

base capacity – Base capacity is the amount of coal the mill will process using a coal with a
grindability index of 50 and a final product fineness of 70% passing through a 200-mesh screen.

bituminous coal – Bituminous coals are the largest group of coals available. The name of
bituminous is derived from the fact that when heated, the coal is reduced to a cohesive, binding,
sticky mass. The volatile matter is complex and high in heating value. These coals burn easily in
pulverized form. Bituminous coals can be further classified as high-volatile, medium-volatile and
low-volatile coals. Bituminous coals are typically composed of 65% carbon, 32% volatiles, and
3% water.

capacity – Capacity is the measured output of the pulverizer in pounds of coal per hour.

Cardwell lubrication system – For the Foster Wheeler ball mills, the Cardwell lubrication
system supplies lubricating oil to the trunnion tube journal bearings.

classifier (dynamic) – The dynamic classifier is a rotating vane assembly for the separation of
coal particles.

classifier (scroll) – The scroll classifier directs the coal and airflow upward, over, and down a
curved plate surface. The heavier particles drop down and do not exit the classifier.

coal mill – A coal mill is a machine that reduces the size of coal particles, dries the coal,
classifies the coal, and transports the coal to the boiler piping. A coal mill is also called a coal
pulverizer.

2-1
Glossary

coal pulverizer – A coal pulverizer is a machine that reduces the size of coal particles, dries the
coal, classifies the coal, and transports the coal to the boiler piping. A coal pulverizer is also
called a coal mill.

conveyor – The conveyor assembly admits the primary air and coal flow into the drum. The
conveyor assembly resides in the trunnion tube and is connected to the drum. It consists of an
inlet air screen, an air tube, a flight ribbon with chains, and spokes.

cylpebs – Cylpebs are another name for the balls in a ball/tube mill.

crusher-dryer – The crusher-dryer is equipment used to reduce the coal particles by hammer
action and to provide drying before the coal material enters the rotating drum.

double-ended mill – A double-ended mill is a ball mill that admits coal into the drum at both
ends of the drum.

drum – The drum is a rotating steel cylinder where the balls crush the coal.

exhauster – For the Foster Wheeler ball mills, the exhauster is a six-blade paddle wheel located
at the discharge of the ball mill.

Farval lubrication system – For the Foster Wheeler ball mills, the Farval lubrication system
supplies oil to the pinion and bull gear that turn the drum.

feeder – A feeder supplies coal at a metered rate to the pulverizer. Feeders can be gravimetric or
volumetric in design.

fineness – Fineness is the measured particulate size distribution of pulverized product as

determined by standard screens. A standard fineness is 70% passing through a 200-mesh screen.

fires – Fires consist of the active and ongoing combustion of coal and/or debris in the pulverizer.

flight ribbon – In the Foster Wheeler ball mills, the flight ribbon is a spiral metal ribbon with
chains attached to the outside of the air tube. As the drum rotates, the flight ribbon also rotates
and coal is fed into the drum.

gravimetric feeder – The gravimetric feeder weighs material on a length of belt between two
fixed rollers located in the feeder body. The gravimetric feeder compensates for variations in
bulk density due to moisture, coal size, and other factors. The gravimetric feeder provides a more
precise weight flow rate of coal to the pulverizers than the volumetric feeder.

grindability – Grindability is a measure of the ease that a coal can be pulverized when compared
with other coals. The higher grindability index indicates a coal that is easier to grind.

2-2
 Glossary

Hardgrove grindability – The Hardgrove grindability index is based on the use of the
Hardgrove grindability machine. Grindability is determined by the amount of new material that
will pass through a 200-mesh screen.

ignition support – Ignition support is the addition of supplemental oil or gas for startup and low-
load stabilization of the fire in the boiler.

inerting substance – An inerting substance is deficient in active properties. The substance lacks
the usual or anticipated chemical or biological action. For fire fighting, the inerting substance can
be carbon dioxide, water, or steam.

inertant – An inertant substance is noncombustible, nonreactive, and incapable of supporting

burning with the contents of the system being protected.

lignite – Lignite coal is brown in color, has a laminar structure, and remnants of woody fibers
may be apparent. They are high in volatile matter and moisture content, but are low in heating
value. Lignite coal typically contains 38% carbon, 19% volatiles, and 43% water.

loss on ignition (LOI) – Loss on ignition is the weight percentage of combustibles in fly ash
based on American Society for Testing and Materials (ASTM) test standard D-3174-04,
“Standard Test Method for Ash in the Analysis Sample of Coal and Coke from Coal.” LOI is a
measure of all components (including carbon) that are volatized by the heat applied during the
ASTM test procedure.

lubrication system – The lubrication system for the gearbox is external to the pulverizer and
performs the pumping, filtering, heating, and cooling of the oil for the gearbox.

moisture – Moisture is the amount of water retained by the coal and is expressed as a percentage
of a coal sample’s weight. Moisture reduces the mill capacity since it takes time for the hot air to
dry the coal for grinding.

Mw – Mw is the abbreviation for the unit of power called megawatts or 106 watts.

NOx – NOx is an abbreviation for all combinations of nitrogen and oxygen. Typically, NOx as a
combustion product in a power plant is 90% NO and 10% NO2.

PF – PF is the abbreviation for pulverized fuel.

PRB – PRB is the abbreviation for Powder River Basin coal.

primary air – Primary air is the air required for the drying and transport of the pulverized coal
through the pulverizer and into the boiler.

pyrite – Pyrite can mean any material that is rejected from the mill. Pyrites are actually a
compound of iron and sulfur, FeS2, found in coal.

2-3
Glossary

seal air system – The seal air system supplies sealing air to the trunnion bearings in order to
prevent contaminants from entering the bearing area.

single-ended mill – A single-ended mill is a ball mill that admits coal into the drum from one
end only.

spokes – The spokes center and support the conveyor assembly inside the trunnion tubes.

sub-bituminous coal – Sub-bituminous coals are brownish black or black, and are typically
composed of 45% carbon, 25% volatiles, and 30% water. PRB coal is a sub-bituminous coal.

tramp iron – Tramp iron is any metal that enters the pulverizer with the coal, such as nuts, bolts,
scrap steel, tools, and so on.

trickle valve – In the Riley Power ball mills, a trickle valve is used to keep the flow of rejected
coal particles and air flowing from the classifier to the ball mill.

trunnion tube – A trunnion tube is an integral part of the drum end castings. The drum is
supported through the bearings that support the trunnion tubes.

tube mill – A tube mill is a low-speed mill (10–20 rpm) that uses the grinding action of steel
balls in a rotating horizontal cylinder or drum. If the diameter of the drum is less than the length
of the drum, then the mill is called a tube mill.

vertical spindle mill – Vertical spindle mills are medium-speed pulverizer mills with a vertical
shaft that turns the grinding table. Vertical spindle mill designs include bowl mills, ring roll
mills, and ring and ball mills.

volumetric feeder – Volumetric feeders deliver coal at a uniform controlled rate based on
volume. Some examples of volumetric feeders are drag, table, pocket, apron, and belt.

2-4
3
SYSTEM APPLICATION

In a coal-fired power plant, the fuel handling system consists of the following functions:
• Delivering the coal
• Unloading the coal
• Weighing the coal
• Initial crushing of the coal
• Conveying the coal to an active pile and/or into the plant
• Unloading the coal into bunkers or silos for each unit
• Metering feeders and the control of the coal into the coal mills
• Moving the pulverized coal and primary air for entry into the boiler

The fuel handling system can be divided into two systems: the coal handling system and the coal
pulverizing system. The coal handling system, general coal characteristics, coal pulverizer mills,
and environmental regulations are included in this section.

3.1 Coal Handling System

In a coal-fired power plant, the coal handling system provides the following functions:
• Unloads the coal from railroad cars, dump trucks, barges, ships, and so on
• Weighs the coal being received into the plant
• Transports (typically by conveyor belts) the coal from the unloading site to the crushing
equipment, to an active coal pile or inside the plant, to bunkers or silos, and then to the coal
feeders
• Crushes the coal so it can be moved by a conveyor system into the plant. The equipment used
to crush the coal may be located before or after the coal goes to the active coal pile and
before the coal is moved into the plant.
• Separates tramp iron from the incoming coal
• Stores coal in bunkers or silos to provide an adequate supply of coal to the plant if a
malfunction of the coal handling equipment should occur. The bunkers are sized to store a
12–24 hour or more supply of coal.

3-1
System Application

Figures 3-1 and 3-2 show typical one-line diagrams of the coal handling system.

Figure 3-1
A Typical Coal Handling System Diagram from Unloading to the Plant
(Courtesy of SCANA McMeekin Station Units 1 and 2)

3-2
 System Application

Figure 3-2
A Typical Coal Handling System Diagram from Plant to Unit Bunkers
(Courtesy of SCANA McMeekin Station Units 1 and 2)

For stations with railroad delivery of coal, the railroad cars are capable of holding 70–110 tons of
coal. It is necessary to weigh the coal in each railroad car. This can be done using electronic
scales on the track to weigh the car full, weigh the car empty, and then subtract to find the weight
of the unloaded coal. Also, the coal can be weighed on a scale below the unloading area grating
or on belt scales along the conveyor.

A locomotive or mechanical puller is used to position the cars directly over the unloading
hoppers. The cars can be unloaded from the bottom doors with car shakers to loosen the coal
3-3
System Application

from the cars. The cars can also be turned upside down in a rotary dumper. From the unloading
hoppers, the coal is transported to the crushers, where the coal is broken into smaller, finer
particles. Coal sampling equipment is positioned near the conveyor belt to remove samples of
uncrushed coal for testing.

Typically, crushers are motor-driven equipment that use rolling rings or ring hammers to reduce
the chunks of coal to less than 1-in. pieces. The crushed coal is then placed on a series of
conveyor belts. They are propelled by a drum that is belt driven from a speed reducer gearbox
and a motor. The belt rests on idlers that are evenly spaced under the belt.

These belts transport the coal to the active storage pile. Coal is temporarily stored on an active
storage pile before being transported into the plant. Coal from the active storage pile gravitates
into the active storage reclaim hopper. A vibrator feeder or variable-speed rotary feeder is
located at the discharge of the hopper. Variable-speed rotary feeders provide improved control of
the feed rate. The coal falls onto the conveyor and is transported into the plant.

For economic or environmental reasons, many plants burn more than one type of coal. Coals
with various sulfur contents or other characteristics may be blended to achieve the most effective
mixture. Each type of coal is stored in separate piles and reclaimed at specific rates in order to
achieve the desired blend. Reclaim conveyors under each pile release the coal onto the main
conveyor that transports the coal into the plant.

In the plant, the coal travels beneath a magnetic separator. This device pulls out any metal
material that can be attracted by a magnet, such as iron or steel. The transfer conveyor then
unloads the coal onto a conveyor with a movable tripper device. The tripper device is positioned
over each silo or bunker. Some plants use a cascade system of conveyors instead of a moveable
tripper. The coal then flows to a coal silo (circular shape with conical outlet) or a coal bunker
(rectangular shape with a pyramidal outlet).

The outlet from the silo or bunker is usually equipped with a fully enclosed slide gate. The slide
gate can be manually operated or motor operated. There is usually one silo or bunker for each
feeder and one feeder for each pulverizer mill. The coal moves through the silo or bunker,
through the feeder, and then enters the pulverizer.

Because of the strict regulations concerning fugitive dust emissions and the explosive nature of
coal dust, dust control is required on the coal handling system. The dust control systems may
inject a water/chemical mixture at different points along the coal path. The dust control system
may also use water to cover the surface of the coal on the belt. Other types of dust control
include transfer chutes that are designed to direct the coal onto the belt at the same speed and
angle of the belt in order to minimize dust creation. Additional control is obtained by using dry
fogging systems or dust collectors.

Some very dusty coals may require the addition of air-supported conveyors in place of the more
conventional idler-supported conveyors. The air-supported conveyors use a cushion of low-
pressure air to support the belts and are totally enclosed on the load side to reduce any dust
creation.

3-4
 System Application

3.2 Coal Characteristics

Coal [1] is classified by the rank or degree of transformation of the original plant material to
carbon. The ranks of coal containing the most carbon to the coal containing the least amount of
carbon are:
• Anthracite
• Bituminous
• Sub-bituminous
• Lignite

A continuous gradation occurs between these ranks. Anthracite, bituminous, and sub-bituminous
coals are known as black coals. Lignite is known as brown coal.

In addition to carbon, coals contain hydrogen, oxygen, nitrogen, and sulphur. Low-rank coals
contain small amounts of carbon and large amounts of hydrogen and oxygen. High-rank coals
contain large amounts of carbon (higher heating value) and small amounts of hydrogen and
oxygen. High-rank coals require the finest grinding and are usually ground in ball mills.

Anthracite is the highest ranked coal and is composed of low-volatile matter (less than 10%) and
high carbon content (~90%). Anthracite has a semi-metallic luster and is capable of burning
without smoke. It is used primarily for heating homes and in gas production. The main producers
of anthracite include South Africa, China, Vietnam, Germany, and the United Kingdom.

Bituminous coals are the largest group of coals available. The word bituminous is derived from
the fact that when heated, the coal is reduced to a cohesive, binding, sticky mass. The volatile
matter is complex and high in heating value. These coals burn easily in pulverized form.
Bituminous coals can be further classified as high-volatile, medium-volatile, and low-volatile
coals. The major producers of bituminous coals are China, the United States, India, South Africa,
Australia, Russia, Poland, Ukraine, Kazakhstan, Indonesia, Germany, and the United Kingdom.

Sub-bituminous coals are dull and dark brown to black in color. The quality of the coal ranges
from soft and crumbly to bright, jet black, with a hard, strong texture. Sub-bituminous coals are
used for power generation and industrial processes. These coals have typical moisture levels
between 10–30% and a carbon content between 71–77%.

Lignite coals are dark brown to black in color with low organic maturity. They are high in
volatile matter and moisture content (>45%), with low carbon/energy content as compared to
high-rank coals such as anthracite. Because of the high moisture content and relatively low
calorific value, lignite is usually consumed close to where it is mined.

There are seven coal producing regions in the United States:

• Eastern – Pennsylvania, Rhode Island, Virginia, North Carolina, Ohio, Kentucky, West
Virginia, Tennessee, and Alabama. This region has the largest deposit of high-grade
bituminous and semi-bituminous coals.

3-5
System Application

• Interior – Mississippi Valley, Illinois, Texas, and Michigan. Bituminous coals with a lower
value and a higher sulfur content than the eastern region are found in the interior regions of
the United States.
• Gulf – Alabama, Mississippi, Louisiana, Arkansas, and Texas. The lowest value coals are
found in this region. The coals are lignites with moisture content as high as 55% and heating
values below 4000 Btu/lb.
• Northern Great Plains – North Dakota, South Dakota, Wyoming, and Montana. The
Dakotas have lignite deposits. Wyoming and Montana have bituminous and sub-bituminous
coals.
• Rocky Mountain – Montana, Wyoming, Utah, Colorado, and New Mexico. Coals in this
region range from lignite to sub-bituminous and high-grade bituminous to anthracite.
• Pacific Coast – Washington, Oregon, and California. The coals in this region range from
sub-bituminous to bituminous to anthracite.
• Alaska – The coal reserves in Alaska are estimated to be 15% bituminous and 85% sub-
bituminous and lignite.

Powder River Basin (PRB) coal is a sub-bituminous coal. The PRB is a 12,000–14,000-ft-deep
depression filled with sediments eroded from land uplifted during the formation of the Rocky
Mountains. The PRB is located in Montana and Wyoming between the Bighorn Mountains and
the Black Hills. PRB coal has an average heating value around 8500 Btu/lb. The most attractive
quality of PRB coal is its low sulfur content. With an average of about 0.3% sulfur, most of the
coal meets the environmental compliance requirements for utility boilers without scrubbers.

Coal from the eastern region of the United States is a high-sulfur bituminous coal. Typical coal
costs for PRB coal per ton are about 23% less than eastern bituminous coals. However, it takes
about 113 lbs of PRB coal to equal the same energy content of 80 lbs of eastern coal. This means
that it takes 30% more PRB coal to equal the energy content of eastern coal.

Coal prices were stable for many years in the United States. Recent years have seen market
forces changing and the cost of coal increasing. High petroleum and natural gas prices, increased
coal exports, the depletion of accessible coal veins in the eastern region of the country, fuel
switching, and higher transportation costs are some market forces that are influencing the price
of coal.

The Clean Air Act Amendments (CAAA) of 1990 have required utilities to reduce sulfur
emissions. Methods of compliance include flue gas desulfurization, fuel switching, fuel blending,
and emission allowance trading. For the fuel blending, some utilities are blending the PRB coals
with the eastern coals to meet air quality requirements.

A common area of significant concern with fuel blending is the pulverizer grinding capacity with
PRB coal or coal blends. PRB coals typically have a reduced heating value and higher moisture
content compared to eastern coals. Because of the higher moisture content in PRB coal, a higher
level of mill coal drying is required.

3-6
 System Application

Mill grinding capacity requirements depend on the PRB blend ratio, the maximum boiler load
required, and the amount of reserve mill capacity desired. For example, a plant may relax its
normal requirement of attaining full load with five of six mills in service, as long as full load can
be attained using PRB coals with six mills. However, if maintaining full load capacity with five
mills in service is required, then mill capacity upgrades may be necessary.

Inadequate mill drying capacity will result in lower than normal mill outlet temperatures. This
can occur because of higher coal mass flow rates, higher coal moisture content, and capacity
limitations of the hot, primary air supply system. Lower acceptable mill outlet temperature
requirements for PRB coals may offset the hot, primary air drying requirements to some extent.
However, in general practice, an increase in primary airflow has been associated with the use of
PRB coals. If the primary airflow requirements are sufficiently high, the velocities in the coal
piping can increase significantly and erosion problems can occur.

Specific pulverizer-related issues that should be evaluated when burning PRB coals include:
• Mill grinding capacity and fineness requirements
• Coal drying capacity requirements (primary air/fuel ratio)
• Primary air (PA) fan capacity, fan discharge pressure, and air temperature
• Feeder discharge pluggage and cleaning practices for PRB coal
• Mill fire protection, carbon dioxide or steam inerting, water wash systems, water fogging
nozzle installation at the air inlet, and coal dust dampening/removal for explosion prevention
to work in conjunction with carbon dioxide inerting system
• Mill fire detection system (carbon monoxide detection)
• Coal pipe line velocities and potential long-term erosion
• Mill outlet temperatures (possible reduction from ~150ºF to approximately
130–135ºF for PRB coals to offset some of the increased primary air requirements)

For additional information on coals in the United States, the following EPRI guides can be
referenced:
• Effects of Coal Quality on Power Plant Performance and Costs, Volumes 1–4 (EPRI report
CS-4283)
• Coal Quality Information Book, Volumes 1–2 (EPRI report GS-7194)

3.3 Coal Pulverizer Mills

The purpose of a pulverizer mill is to:

• Reduce the coal to small particles by grinding for better combustion
• Dry the coal
• Classify the particle size of the coal leaving the mill
• Transport the coal from the classifier to the boiler burners

3-7
System Application

There are several styles of pulverizer mills. They are:

• Ball/tube mills – Ball/tube mills are low-speed machines that grind the coal with steel balls
in a rotating horizontal cylinder. If the diameter of the cylinder is greater than the length of
the cylinder, then the mill is called a ball mill. If the length of the cylinder is greater than the
diameter of the cylinder, then the mill is called a tube mill. For the mills covered in this
guide, the terms ball and tube are used interchangeably.
• Vertical spindle mills – Vertical spindle mills are medium-speed pulverizer mills with a
vertical shaft that turns the grinding table. Vertical spindle mill designs include bowl mills,
ring roll mills, and ring and ball mills.
• Impact mills – Impact mills are high-speed impact machines that use beater wheels to crush
the coal.

The mills covered in this report are ball/tube mill designs. For the purpose of this guide, the
ball/tube will be called ball mills or the manufacturer designation. Some of the manufacturers of
the ball mills are Allis-Chalmers, Foster Wheeler, Kennedy Van Saun, Riley Power Inc., and
Stein Industrie.

Figure 3-3 is a diagram of the coal pulverizer system for the Foster Wheeler ball mill.

Figure 3-3
Foster Wheeler Ball Mill [2]

3-8
 System Application

Coal is fed from a bunker or silo to a coal feeder. A feeder supplies and meters the coal going to
the pulverizer mill. One or more feeders are provided for each pulverizer. The feeders can be
volumetric or gravimetric designed and are typically driven by induction motors.

Coal flows from the feeder through a spiral ribbon conveyor mounted on the outside of the drum
trunnion tube. Coal can be fed through one (single-ended) or both (double-ended) ends of the
drum.

Hot air is supplied from the boiler secondary air system through a forced draft or primary air fan
and flows into the drum through the inside diameter of the trunnion tube.

The drum is a large cylinder with integral trunnions bolted to each end of the drum. One journal
bearing supports each trunnion. The drum is rotated through the pinion and drive gears coupled
to a mill motor. The journal bearings, the pinion, and the drive gears are lubricated by a pumped
supply of oil. The alignment of the journal bearings, the pinion, and the drive gears is critical for
reliable operation.

The drum contains steel balls and rotates slowly (10–20 rpm). The rotation causes the balls to
cascade over each other and crush the coal between the balls. The drum has steel liners that are
made of a harder material than that of the steel balls.

Hot air flows out of the drum and dries the incoming coal. After the coal is ground, the coal
flows into the classifier that allows smaller size particles to pass through and larger size particles
to return to the drum. The pulverized coal and air mixture flows from the mill outlet to the boiler
burners.

The earlier designed mills are operated in negative pressure with an exhauster fan located at the
discharge of the classifier. The coal and air particles flow through the exhauster fan and into the
boiler piping. The newer designed ball mills are operated in positive pressure supplied by a
primary air fan located upstream of the mill.

3.4 Environmental Regulations

The CAAA of 1990 established lower NOx emission rates for utility boilers [3]. Because NOx
formation is largely dependent on how the fuel is combusted, the efforts to reduce NOx emissions
have focused on modifying the combustion process.

NOx includes NO, NO2, and N2O formations during combustion. Three primary sources for the
formation of NOx are:
• Thermal NO – Thermal NO is the oxidation of molecular nitrogen (N2) to form NO. The
triple-bonded N2 requires significant energy for oxidative attack and occurs only at high
temperatures. Thermal NO accounts for approximately 20–30% of the final NOx emissions.
• Prompt NO – Prompt NO describes the hydrocarbon radical attack of N2 to form-fixed
nitrogen compounds (NHx, XCN) that can subsequently react to form NO. Prompt NO
accounts for approximately 5–10% of the final NOx emissions.

3-9
System Application

• Fuel NO – Fuel NO is the oxidation of fuel-bound nitrogen in the coal to NOx compounds.
Typically, fuel-bound nitrogen will evolve as an amine or cyano compound and will be
oxidized to NO or reduced to N2. Fuel NO accounts for approximately 60–70% of the final
NOx emissions.

Figure 3-4 shows how the fuel-bound nitrogen evolves to form either NOx pollutants or nitrogen
gas. Char is the combustible residue remaining after the destructive distillation of coal.

Figure 3-4
Fuel-Bound Nitrogen Evolution to NOx [4]

The amount of NOx formed when coal burns is a function of the nitrogen content of the coal, the
flame temperature, the amount and distribution of air during combustion, and the flame structure.
Three technologies used for reducing the NOx formed are low-NOx burners, the addition of
overfire air, and selective catalytic reductions (SCRs). The addition of SCRs involves adding a
catalyst bed in the boiler flue gas that converts the NOx leaving the boiler.

Low-NOx burners control the mixture of fuel and air to create larger and more branched flames,
reduce peak flame temperatures, and lower the amount of NOx formed. The improved flame
structure also improves burner efficiency by reducing the amount of oxygen available in the
hottest part of the flame.

In principle, there are three activities in a conventional low-NOx burner: combustion, reduction,
and burnout. In the first stage, the combustion occurs in a fuel-rich, oxygen-deficient zone where
the NOx is formed. In the reduction stage, hydrocarbons are formed and react with the already
formed NOx. In the burnout stage, internal air staging completes the combustion. Additional NOx

3-10
 System Application

is formed in the burnout stage; however, the additional NOx can be minimized by an air-lean
environment.

Low-NOx burners can be combined with overfire air technologies that create two stages for
combustion. This requires a primary and a secondary source of combustion air. The secondary
air nozzles are located above the burners. This system results in a more complete burnout of the
fuel and the formation of N2 rather than NOx.

The operation of low-NOx burners tends to increase the unburned carbon in the ash. Unburned
carbon can occur in both the bottom ash and fly ash. Loss on ignition (LOI) is a weight
percentage of all the components (including carbon) in fly ash. With NOx control, the LOI for
tangentially fired furnaces increases an average of 2% and for a wall-fired furnace the LOI
increases 3–5%.

O&M Cost Key Point

The increases in LOI from NOx combustion control the increase in the heat rate.
The average industry loss is 12 Btu/kWh per 1% change in unburned carbon. This
increase in LOI creates a need for greater fineness. Some units have increased
fineness from 70% passing through a 200-mesh screen to 75–80% passing through
a 200-mesh screen and 99–99.5% passing through a 50-mesh screen. The increase
in fineness settings requires more work from the pulverizer.

In other words, the increase of LOI in the boiler increases the heat rate for the unit. In order to
offset the heat rate increase, the mill is required to perform more work. Performing more work
for the given amount and type of coal can increase the maintenance costs for the mill.

3-11
4
TECHNICAL DESCRIPTION – GENERAL

The ball/tube mill [3] is designed for hard, highly abrasive coal materials and for some very soft
coals. Ball mills are used widely in countries where high-ash, abrasive coals are available, such
as China, India, and South Africa. Typical availabilities of the ball mills in the 95% range are
common.

In the technical description, Sections 5–9, there are five manufacturers of ball/tube mills that are
covered. The manufacturers are:
• Allis-Chalmers
• Foster Wheeler
• Kennedy Van Saun
• Riley Power Inc.
• Stein Industrie

In general, the main components of the ball/tube mill are:

• Feeder – The feeder provides the raw coal in a measured amount.
• Crusher/Dryer – In one style mill, a hammer-type crusher and hot air dryer are used to
reduce the coal size and dry the coal before it enters the drum.
• Balls – Steel balls ranging in size from 1.2–2.4 in. (30–60 mm) are located in the drum. As
the mill is rotated, the balls crush the coal in the drum.
• Drum – The rotating tube or drum ranges in size up to 33 ft (10 m) long and 20 ft (6 m) in
diameter.
• Liners – Liners are steel plates fastened to the inside of the drum to form a replaceable,
protective layer for the drum.
• Classifier – The classifier regulates the fineness of the pulverized coal leaving the mill and
entering the piping to the boiler.
• Mill motor – The mill motor is the electrical motor that connects to the drive system that
turns the drum.
• Drive system – The drive system connects to the motor and consists of a reduction gearbox
and clutch that drives the pinion and girth gear in order to rotate the drum.

4-1
Technical Description – General

Technical Key Point

If the diameter of the drum is greater than the length of the drum, then the mill is
called a ball mill. If the length of the drum is greater than the diameter of the drum,
then the mill is called a tube mill. The terms ball and tube are used interchangeably
in this guide.

Ball mills have a large footprint in a power plant. Because of the large rotating drum and the
weight of the steel balls, there is a large dynamic loading that requires extensive mill
foundations.

The noise level for the ball mill is relatively high. An acoustic cover is sometimes required over
the mill in order to reduce the noise to an acceptable level.

The power requirement for turning the drum is high, with most of the power used for lifting the
ball weight. The power requirement is essentially constant as the mill loading is decreased. The
power requirement for a ball mill is about twice the requirement for that of a vertical spindle
mill. For this reason, the ball mill is regarded as the least efficient type of mill with respect to
grinding.

Ball mills contain large quantities of coal that can be released to the boiler piping if a sudden
increase of coal is needed. This stored quantity is not affected by a temporary coal feed blockage.
However, the large quantity of coal available is a disadvantage if the coal contains a fire. For this
reason, the airflow is limited for this type of mill. The limited airflow makes this mill unsuitable
for high-moisture coals.

The time needed to start a ball mill and place the mill in service is in the 30-minute range. For
comparison, the vertical spindle mill require about 5–7 minutes to place a mill in service.

For a ball mill operation, the grinding action is ball-against-ball with a cushioning layer of coal
between the balls. The tumbling, grinding action of the balls is generated by the rotation of the
drum. As the mill speed increases, the grinding action increases until a critical rotational speed is
reached. At the critical rotational speed, the balls are held against the drum by centrifugal force
and the grinding stops. Mills are usually operated in the range of 65–80% of the critical
rotational speed.

The grinding process of the coal in the drum begins with the larger diameter balls impacting and
crushing the coal. The smaller balls do the fine grinding by rubbing the coal between the balls
and the liner.

Initially, the balls were made of forged, high-carbon steel, heat-treated to a Brinell hardness of
550–560. Many of the balls now consist of a high-chrome material. The rate of wear on the balls
depends on the abrasiveness of the coal. As the balls wear, new balls are added to maintain
grinding efficiency.

4-2
 Technical Description – General

The drum liners require replacement after an interval of 20,000–30,000 operating hours.
Replacing the drum liners requires an extended outage. To keep the drum liner from wearing, the
liner material should be harder than the ball material. Using a softer ball material causes a higher
ball wear rate. There is no provision for removing tramp iron or other foreign material after it has
entered the drum.

Ball mills cannot be operated for lengthy times without coal in the mill. The rotation of the
cylinder creates heat in the ball charge, and the small amount of coal in the cylinder can ignite.
When the mills are shut down with coal still in them, provisions are made for the mill to be
turned slowly or intermittently to cool the coal.

Sections 5–9 contain a technical description of the following manufacturers’ ball mills:
• Allis-Chalmers
• Foster Wheeler
• Kennedy Van Saun
• Riley Power Inc.
• Stein Industrie

4-3
5
TECHNICAL DESCRIPTION – ALLIS-CHALMERS

The information in this section was provided by the Eskom Lethabo Power Station in South
Africa. The station has six units with six mills per unit for a total of 36 mills at the station. The
unit layout has three mills located on each side of the boiler.

Figure 5-1 shows the outline of the Allis-Chalmers ball/tube mill.

5-1
Technical Description – Allis-Chalmers

Figure 5-1
Allis-Chalmers Ball/Tube Mill Outline
(Courtesy of Lethabo Power Station)

5-2
 Technical Description – Allis-Chalmers

Each tube mill is supported by trunnion bearings. The mill is rotated by the mill drive motor via
the reduction gear unit, pinion shaft, and girth gear. A barring drive is provided that can be
coupled to the mill drive motor when required.
The coal is supplied to the ball/tube mill from two stock volumetric coal feeders that discharge
coal through raw coal chutes into the mill inlet ductwork.
The ball/tube mill is hot-air swept and arranged for double-ended operation. At each end of the
ball/tube mill is an inlet box that allows the coal and heated primary air to pass into the mill shell
through the trunnion throats. The double-ended operation causes the air stream within the mill to
circulate as if a dividing wall were present inside the rotating shell.
The grinding of the coal is achieved by the rotational movement of the mill shell that causes a
charge of hardened steel balls to rise up and cascade down on the coal and pulverize it. The
charge of steel balls is fed into the mill through one of the inlet boxes and conveyed to the
classifiers above the mill ends by the heated primary air. The mill inlet and outlet boxes are
contained in one housing that also contains the mill sealing arrangement.
The pulverized coal fineness is achieved by the static classifiers that reject the oversize particles.
Under design load conditions with an established ball charge and coal level, the average
throughput of five mills in operation is 19.62 kg/second per mill. Of this throughput, 99% of the
pulverized coal will pass through a 300-micron screen and a minimum of 70% will pass through
a 75-micron screen.
The pulverized coal is contained within the mill by a seal air system consisting of one 100%
capacity seal-air fan and ductwork supplying pressure at 17.7 kPa. The seal air system maintains
a seal at the mill head extension. Seal air is also piped to the coal feeders in order to prevent hot
air from escaping into the bunker supplying coal to the feeder. A separate seal air system is
provided for the girth gear in order to prevent any entrance of pulverized coal into the gearing.
The level of coal in the mill is controlled by a Power-Sonic mill conditioning system. The system
uses measurements of the mill motor power drawn and the noise produced by the grinding
process in order to generate a trimming signal for the coal feeder speed controllers. The noise
increment is sensed by a transducer located on the mill acoustic housing.
A dip tube system is provided as a standby to the mill conditioning system. The dip tube system
uses a differential pressure measurement from the probes fitted on the inlet/outlet boxes to
control the mill coal level. Changeover from the mill conditioning system to the dip tube system
is a manual operation.
Equipment for the Allis-Chalmers mills is discussed in this section. Also, a technical
specification list for the equipment is included. The equipment consists of:
• Inlet/outlet boxes
• Rotating shell, liners, and balls
• Trunnion bearings
• Classifier

5-3
Technical Description – Allis-Chalmers

• Drive motor
• Gearbox unit
• Power-Sonic mill conditioning system

5.1 Inlet/Outlet Boxes

Figure 5-2 shows the inlet/outlet box.

Figure 5-2
Inlet/Outlet Box
(Courtesy of Lethabo Power Station)

5-4
 Technical Description – Allis-Chalmers

Integral inlet/outlet boxes are located at each end of the mill and provide the following functions:
• An inlet for the coal and primary air into the mill
• An outlet for the pulverized coal to the classifiers
• An inlet for ball addition
• A housing for the bypass damper for the primary air bypass
• A sealing interface for the pulverized coal between the rotating and fixed structure
• A mounting point for the dip tube system
• An access point for entry into the mill

The inlet/outlet boxes are a steel fabrication with selected surfaces fitted with replaceable liners.
A division plate extends from the center line of the fabrication and carries the dip tubes. The
division plate pulverized coal side and the outlet box casing are tiled using 6-mm and 12-mm
high alumina content ceramic tiles, respectively.

A hinged access door is located on the underside of the inlet section. A yoke clamping
arrangement is provided to ensure a good seal. The 200-mm ball charge pipe from the ball
charge hopper is fed into the upper section of the inlet side of the box.

A coarse rejects return pipe from the classifier is also connected to the inlet side of the box. This
return pipe is equipped with an integral trickle valve that allows the return of oversized coal
particles to the mill inlet while preventing the backflow of primary air.

A bypass damper is provided between the inlet and outlet side of each inlet/outlet box. The
damper blade is mounted 7° off the vertical line toward the outlet side of the box on a shaft
supported by bearings at either end. The bearings are external to the inlet/outlet box. An
operating range of 49.5° travel toward the outlet side of the box is provided from the closed
position. The drive for each bypass damper is provided by an electrical actuator.

The bypass dampers for each pair of inlet/outlet boxes per mill are controlled in parallel as a
function of the control system.

Technical Key Point

The bypass dampers accomplish three functions:
• Assist in maintaining the minimum pulverized coal and air velocity in the piping
• Assist in increasing the flow of drying, hot air during periods when the coal is wet
• Allow the mill to operate at lower loads

A sealing arrangement is fitted to the mill side of the inlet/outlet boxes. Sealing is achieved by a
pad seal on the inlet/outlet box bearing against a mill head extension. The pad seal maintains its
contact with the mill head extension by steel spring fingers. The cavity formed behind the pad
seal is supplied with seal air in order to maintain a pressure greater than the interior pressure of
the mill.

5-5
Technical Description – Allis-Chalmers

The sealing arrangement is provided with three spare pad seals that are located on extended
securing bolts and protected by a pad seal shroud. The spare location permits the fitting of a new
pad seal without removing the inlet/outlet box from the end of the mill. Figure 5-3 shows the
sealing arrangement.

Figure 5-3
Mill Sealing Arrangement
(Courtesy of Lethabo Power Station)

The dip tube system provides a standby level measuring system for the mill conditioning system.
The dip tube system consists of two lengths of 15-mm piping mounted horizontally on the
division plate with one pipe above the other. The mill end of the two pipes is open ended. A
removable end extension is provided for the lower-pipe probe to facilitate the removal of the
inlet/outlet box for mill maintenance. The removable end is designed for easy replacement and
has a thick wall for extra wear life. The other end of the two pipes is connected through isolating
valves to a pressure differential transmitter.

5-6
 Technical Description – Allis-Chalmers

The pipes are located on the inlet side of the division plate, and a half-tube section cover is
welded over them for protection. A continuous supply of purge air from the station instrument air
supply is passed through the pipes to prevent blockage.

5.2 Rotating Shell, Liners, and Balls

The mill shell is a fabricated steel cylinder supported by trunnion bearings at each end in order to
allow rotation of the mill in a horizontal plane. The mill is driven by a girth gear that is bolted to
the driving end of the mill shell.

The shell liners perform two functions. The first function is to protect the mill shell from wear.
The second function is to raise the grinding medium to a high angle in order to assist in the
grinding action. In order to achieve the second function, the liners are contoured to prevent
slippage of the grinding medium.

There are two types of liners, a single-hole liner and double-hole liner. Single-hole liners are
provided for the location at the end of each alternate row to offset the gap pattern. The liners are
secured through the mill shell using a full nut and locknut. The sealing between the full nut face
and the shell is achieved using a silicon washer seated in a retainer cup. Liners are manufactured
from high-chrome iron material or Roq-Last.

The trunnion ends of the mill shell are equipped with liners that are similarly secured to the
liners in the shell. A filler ring is inserted between the trunnion end liner and the shell liner.
Sealing between the trunnion throat liner and trunnion end liner is achieved using three
asbestos/graphite packing rings. Trunnion throat and trunnion end liners are designed to protect
the trunnion ends and should be replaced when worn.

Technical Key Point

As the liner contour wears, the grinding medium begins to slip. This slippage leads
to a lowering of efficiency in the grinding action because the grinding medium
cannot be raised to a high angle. As slippage continues, the wear will accelerate.
Replacement of liners is recommended when the minimum thickness is reached.
The rate of wear of the liners can be predicted based on the grade of coal being
ground and the experience gained from inspections.

Whenever the mill is opened for inspection, the liners should be examined for wear and
breakage. It is important that broken liners be replaced immediately.

The impact of the ball charge and the coal being ground tends to loosen the liner bolts. Loose
bolts allow the coal to work between the liner and the shell, making bolt tightening impossible.
Looseness also causes impacting and breakage of bolts.

A hole (normally sealed with a blanking plate) is provided in the shell. The hole is provided in
order to remove the ball charge and coal from the mill if there is an emergency shutdown
followed by a long outage. Figure 5-4 shows the ball charge hopper.

5-7
Technical Description – Allis-Chalmers

Figure 5-4
Ball Charge Hopper
(Courtesy of Lethabo Power Station)

One ball charge hopper per mill is provided for charging the mill with the required quantity of
50-mm steel balls (cylpebs). Each hopper consists of an upper and lower section. The upper
section is capable of storing 1 metric ton of steel balls. A top loading cover is fitted to the upper

5-8
 Technical Description – Allis-Chalmers

section and secured by three swing bolts. A worm gear, operated by an extended spindle, is used
to open the lower charging door. An access door, located in the lower section, facilitates
inspection of the lower charging door seal. It is important that the lower charging door seal be
maintained in good condition so that there is no leakage of pulverized coal.

Because of the grinding action of the balls, ball replacement is required frequently. Ball charging
can be carried out during milling operation. The replenishment ball charge is provided in 850-kg
barrel loads. Special trolleys are provided for transporting the barrels. When released, the ball
charge drops rapidly through the 200-mm bore piping, through the inlet/outlet box, and into the
mill.

5.3 Trunnion Bearings

The mill trunnion bearings are journal bearings that support the shell on both sides of the
trunnion. The mill trunnion bearings are fitted with babbitted rocker inserts. Cooling is achieved
by passing 0.46 liters/second of cooling water at 310 kPa pressure through the coils in the liner
inserts. The bearings are designed for an oil-wedge principle of operation.

The two mill trunnion bearings are provided with an independent, self-contained lubrication
system. These systems are identical and ensure that the mill trunnions are floated on a film of oil
and are adequately lubricated during mill operations.

In oil-wedge bearings, the journal is stationary and comes in contact with a section of the bearing
surface. A wedge clearance exists on either side of the contact area. Before rotation of the drum,
high-pressure oil is used to raise the rotor journal clear of the bearing surface. The high-pressure
oil is introduced through an oil opening in the bottom center of the bearing insert. As the journal
starts to rotate, oil is drawn into the clearance to form an oil wedge that is forced under the
journal. As the rotation continues, the journal becomes completely supported on a film of oil.
The high-pressure lubrication is then stopped.

To provide an oil wedge in the mill trunnion bearings, an oil bucket arrangement is used with a
combined high- and low-pressure lubrication system. The oil bucket arrangement consists of four
buckets spaced at 90° intervals around the journal. As the mill journal rotates, the oil buckets
scoop up oil from the sump in the trunnion housing and discharge it onto the journal surface.
This action helps to maintain the wedge of lubricant between the journal and the bearing surface.
The oil buckets do not provide adequate lubrication alone for the trunnion bearings. This is
provided by the low-pressure lubrication system.

Figure 5-5 shows the low-pressure lubrication system.

5-9
Technical Description – Allis-Chalmers

Figure 5-5
Trunnion Bearing Low-Pressure Lubrication System
(Courtesy of Lethabo Power Station)

5-10
 Technical Description – Allis-Chalmers

Each low-pressure oil system consists of an electric heater, pump, filters, and a water-cooled oil
cooler. The low-pressure oil system provides a continuous flow of filtered and temperature-
controlled oil through a distribution manifold onto the trunnion bearings. Under normal
operation, the low-pressure oil system also provides the oil supply for the high-pressure jacking
oil pump.

The oil temperature is maintained at 30°C by an in-line electric heater and a water-cooled oil
cooler. If the oil temperature falls below 30°C, the mill start control is inhibited. The low-
pressure pump delivers oil at 680 kPa to one of two filter paths through a three-way valve.
Differential pressure across the filters is monitored, and a warning signal is initiated if an
excessive differential exists. Check valves on the outlet side of the filters are fitted in order to
prevent a backflow in the filter that is not being used.

From the filter, the oil passes through a water-cooled oil cooler. In the event of a reduction in the
flow rate or a pressure build-up in the oil cooler, the flow switch initiates a signal to the mill
control that automatically shuts down the mill.

From the oil cooler, the low-pressure oil divides into two paths. One path passes oil to the supply
side of the high-pressure pump, and the other path passes oil to the bearing housing. At the
bearing housing, the oil passes through a distribution manifold inside the top of the bearing cap,
over the bearing journal, and into the bearing sump.

The low-pressure pump is a twin-cam rotor and is driven by a flange-mounted electric motor.
The pump delivers oil at 0.38 liters/second to the trunnion bearing lubrication system.

The pump consists of a rotor with two cams phased at 90° and supported at each end by roller
bearings. In addition, a rolling element bearing is fitted at the non-drive end to locate the rotor
within the pump body. A rocker arm, center plate, and a set of check valves are fitted to provide
a pressurizing non-return pumping operation. Sealing is achieved at the non-drive end by an O-
ring and an end cap. Sealing is achieved at the drive end by an oil seal. The rotor extends from
the drive end of the pump body and is keyed to the drive coupling.

Each filter unit is flange mounted and designed to permit a continuous flow of filtered (75-µm)
oil. The filter element is paper, and sealing is achieved using O-rings. In the event of filter
blockage, a visual color-coded indicator operates automatically, and a full-flow bypass opens at
17.3 kPa differential pressure.

The oil is cooled by a water-cooled, four-pass oil cooler. The cooler is mounted on a common
bedplate with the high- and low-pressure oil system components. The tube bundle consists of a
number of copper-nickel, 6.3-mm diameter tubes fixed at 57-mm intervals by segmented brass
baffle plates. The tube bundle is housed in a brass shell. This arrangement provides 4.98 m2 of
outside cooling tube surface area.

The water connections are made through an end bonnet bolted to the end hub. Sealing is
achieved using an asbestos-neoprene bonded gasket. At the opposite end of the cooler, sacrificial
anodes are fitted to protect the cooling tubes.

5-11
Technical Description – Allis-Chalmers

A high-pressure oil system consists of a high-pressure jacking pump and a manual, standby high-
pressure jacking pump. The high-pressure oil system provides the initial trunnion lift through a
supply oil hole in the bottom bearing insert. The lift of the trunnion is critical during startup,
inching (slow shell rotation), and shutdown.

The high-pressure jacking pump takes suction from the low-pressure oil system. A low-pressure
bypass line is provided in order to maintain the oil supply in the event of a failure in the low-
pressure oil system.

A manual, high-pressure jacking pump is connected into the high-pressure oil discharge line. The
manual pump is provided for use when the mill is being inched or there is a failure in the high-
pressure oil system. The manual pump is isolated from the oil supply line by a non-return check
valve.

The high-pressure jacking oil pump is a gear-type pump driven by a flange-mounted electric
motor. The advantages of using a gear-type pump is low noise operation, large suction, and
pressure zones resulting in small filling and displacement fluid velocities.

The manual, high-pressure jacking pump (shown in Figure 5-6) is mounted on the side of the
mill trunnion bearing.

5-12
 Technical Description – Allis-Chalmers

Figure 5-6
Manual High-Pressure Jacking Pump
(Courtesy of Lethabo Power Station)

5-13
Technical Description – Allis-Chalmers

The pump is provided as an emergency facility in the event of a failure in the high-pressure oil
system. The pump is a reciprocating piston type operated by oscillating the handle through an arc
of approximately 40°. This oscillating movement drives a gear segment that is meshed with a
rack on the pump piston, causing the piston to reciprocate. The pump piston is double-acting in
the bore. The discharge per stroke of the pump is 7.5 ml. When in operation, the pump draws oil
from the integral 2.8 liter reservoir. The reservoir is fitted with a fine mesh filter screen. It is
important that an external fresh supply of clean oil is available when using the pump in order to
maintain the level in the oil reservoir.

Two-piece piston ring seals are fitted to prevent oil leakage from the trunnions. The piston rings
are grease-lubricated and connected by piping to a charging point on the side of the trunnion
housing. The trunnion housing is used as a mounting point for an emergency, manual, high-
pressure pump that is provided for each trunnion. The trunnion bearing temperatures are
monitored.

5-14
 Technical Description – Allis-Chalmers

5.4 Classifier

Figure 5-7 shows the static classifier.

Figure 5-7
Static Classifier
(Courtesy of Lethabo Power Station)

5-15
Technical Description – Allis-Chalmers

Each mill is provided with two static classifiers. The classifiers are hung by spring supports and
located above the respective inlet/outlet boxes. Each classifier consists of a fabricated outer cone,
an inner cone, 16 directional vanes, a segmented discharge chamber, an inverted control cone,
and a coarse rejects return pipe leading back to an inlet/outlet box. A flanged top cover is
provided to facilitate access to the inside of the classifier for maintenance.

The directional vanes are adjustable, and the optimum setting is determined during
commissioning by coal fineness tests. Once the directional vanes are set, they should be regarded
as fixed vanes. The inverted control cone that controls the flow pattern within and the rate of
reject flow from the inner cone is preset and not adjustable.

A mixture of primary air and pulverized coal enters the bottom of the classifier between the inner
and outer cones. At the top of the inlet section of the classifier, the mixture enters the inner cone
through the directional vanes. The oversized particles in the inner chamber are flung outward by
centrifugal force. By nature of their weight, the coal particles fall down the slope of the inner
cone into the coarse rejects return pipe. At the same time, the mixture of air and fine particles
passes upward into the discharge piping.

When sufficient coal accumulation has built up in the rejects return pipe, the trickle valve opens.
This opening permits the rejects to discharge against the existing differential pressure into the
mill through the inlet/outlet box. The rejects are then reground. The differential pressure closes
the trickle valve.

5-16
 Technical Description – Allis-Chalmers

5.5 Drive Motor

Figure 5-8 shows the mill drive motor.

Figure 5-8
Mill Drive Motor
(Courtesy of Lethabo Power Station)

The mill drive motor is a horizontal foot-mounted, induction cage motor fitted with a top-
mounted air-to-air heat exchanger. The rotor is double-ended to provide an output drive to the
mill gear and an input connect point for the mill barring gear.

The stator frame is a fabricated steel box construction. The stator core is formed by high-
permeability steel laminations pre-built on a mandrel and then welded to steel clamping
members to form a core pack. The stator winding high-tension coils are formed from rectangular
copper strips that are pre-insulated with polyester enamel and a layer of film-backed mica tape.
The main insulation is provided by mica glass taping applied as a number of half-lapped layers.
The coils are fitted into open slots in the stator core packs that are then closed with resin-bonded
fabric slot wedges. The end windings are securely blocked and braced.

The rotor core is built from laminations that are keyed to a steel shaft and clamped between two
end plates to form a rigid mass. Impellers, secured to the rotor shaft on the inner side of the
bearings, circulate air within the motor frame through the windings. At the non-drive end, the
rotor shaft carries an outer impeller that draws in ambient air and directs it through the heat
exchanger tubes.

The rotor shaft is supported by two external foot-mounted, split-sleeve bearings located at both
ends of the shaft. The bearing shells are spherically seated in the pedestal housing and bearing

5-17
Technical Description – Allis-Chalmers

cover. The housing is made of cast iron and pinned in order to assist in heat dissipation. The
bearing shells are made of steel and lined with white metal. Floating labyrinth seals are fitted,
and an external water flinger is provided. Each bearing is self-lubricated by a system that uses a
central loose oil ring to pick up oil from the reservoir in the pedestal housing and deposit the oil
onto the shaft journal as it rotates. A window on the side of each pedestal housing permits visual
checking of the oil level in the reservoir. A provision is made on each of the pedestal housings
for fitting thermocouples in order to monitor the temperature of the bearings. The bearings are
insulated from the motor frame by insulation packers and sandwiched under the pedestal feet.
Insulated jacking blocks are provided at the pedestal feet to assist in the accurate alignment of
the pedestals.

Anti-condensation heaters are fitted on each side of the stator core. The 714-watt heaters are
supplied with 240-volt voltage through a separate terminal box on one exterior side of the motor
casing.

The motor and bearings are mounted on a sub-base plate that is secured to the floor by eight
foundation bolts. Each of the mounting points has a 30-mm thick square pad fitted to the
underside that is set into the grouting during installation.

The mill drive coupling consists of two steel hubs that are keyed to the gear unit input shaft and
the motor shaft. The mill drive motor coupling is a smaller version of the gear unit output
coupling. The hubs are connected by a segmented grid spring in order to form a resilient
coupling. The grid spring segments fit into grooves machined in the peripheries of the hubs. The
assembly is packed with grease and enclosed in two half covers that are bolted together.

Figure 5-9 shows the barring gear unit.

5-18
 Technical Description – Allis-Chalmers

Figure 5-9
Barring Gear Unit
(Courtesy of Lethabo Power Station)

The barring gear unit is provided to rotate the tube mill and gear unit for maintenance and
inspection purposes. The barring drive is connected through a special coupling to the mill motor
shaft that is double-ended. The barring gear consists of a double-reduction gear unit, a motor
drive, and an electromagnetic brake on the barring drive motor coupling. All units are mounted
on a common bedplate.

5-19
Technical Description – Allis-Chalmers

The double-reduction worm gear unit provides the barring drive to the mill drive motor. The first
reduction case is made of cast iron. The unit consists of an over-driven worm shaft and worm
wheel supported by rolling element bearings. The first reduction wheel is keyed onto the second
reduction worm. The first reduction unit is fitted with a fan and cowl for cooling purposes. The
assembly of the first reduction unit is bolted onto the input side of the second reduction unit.

The second reduction case is also made of cast iron. The unit consists of an under-driven worm
shaft with a worm wheel mounted on a special output shaft for the barring coupling. The shafts
are supported by rolling element bearings.

The first and second reduction casings have self-contained lubrication systems, each having
separate filling, draining, ventilation, and level indication facilities. Lubrication of the gears and
bearings is achieved by oil bath and splash. Oil seals are provided for shaft extensions.

An oil level plate provides the indication of a correct oil level for the first reduction casing. A
dipstick located in a tube on the outside of the casing gives the indication of the oil level in the
second reduction casing.

Figure 5-10 shows the barring coupling.

5-20
 Technical Description – Allis-Chalmers

Figure 5-10
Barring Coupling
(Courtesy of Lethabo Power Station)

The barring coupling drive uses two half-bevel gears. The driven-half gear is located on the shaft
extension of the mill drive motor. The driving half, along with the operating mechanism, is
located on the output section of the double-reduction worm gear unit.

5-21
Technical Description – Allis-Chalmers

The two coupling halves are engaged by rotating the engagement nut, causing it to move toward
the driven-half coupling. The movement of the engagement nut toward and away from the
driven-half coupling is affected by a square thread drive. The thread drive is a male, fixed-square
thread that is cut on an extended stub of the special oil catcher located on the worm gear unit.

An interlock system is used to prevent the barring gear motor and the mill drive motor from
being operated at the same time. The interlock system is initiated by two limit switches that
function respectively as a main motor interlock and a barring motor interlock. When the coupling
is engaged, the main motor interlock switch is set so that the main motor is turned off. At the
same time, the locking catch is moved from the locked position, permitting the barring motor to
be operated. If the engagement nut is screwed fully back and the locking catch is set in the
locking position, the barring motor is turned off, and the main motor can be operated.

Figure 5-11 shows the barring brake.

Figure 5-11
Barring Brake
(Courtesy of Lethabo Power Station)

The barring brake is provided to positively brake and hold the barring gear drive during
maintenance events. When applied, the brake has a remaining torque of 163 N-m on the cone
ring input coupling of the barring gear unit. The brake is spring-applied, electrically released,
and incorporates a hand-release mechanism. The brake shoes are fiber lined and self-aligning.
A welded-steel hinged cover protects the complete magnet assembly against dust and damage.

5-22
 Technical Description – Allis-Chalmers

5.6 Gearbox Unit

Figure 5-12 shows the gearbox unit.

Figure 5-12
Gearbox Unit
(Courtesy of Lethabo Power Station)

5-23
Technical Description – Allis-Chalmers

The mill gearbox unit is a single-reduction, double-helical unit that transmits the drive from the
mill drive motor to the mill pinion shaft. The output shaft from the gearbox unit is connected to
the mill pinion shaft by a grid spring coupling. The gearbox unit is mounted on a separate base
plate and is completely encased by an acoustic hood.

The gearbox unit case consists of two flanged half casings bolted together at midheight, with the
alignment of the two half casings being achieved by four suitably spaced dowels. On the top of
the top half casing is a removable inspection cover and four eyebolts that are used for lifting the
top half casing only. Four lugs are provided on the bottom half casing that are used for lifting the
complete gearbox unit.

Other components fitted to the gearbox case are a sump drain plug and a labyrinth seal cover.
The seal cover is packed with grease in order to protect the gearbox case from the entry of
pulverized coal.

The double-helical gears are mounted together to form a single-reduction output drive. The input
and output shafts are supported by double-row, tapered roller bearings. On the output shaft the
double-helical wheel is both pressed and keyed to the output shaft.

Figure 5-13 shows the gearbox output coupling.

5-24
 Technical Description – Allis-Chalmers

Figure 5-13
Gearbox Output Coupling
(Courtesy of Lethabo Power Station)

The gearbox unit output coupling consists of two steel hubs that are keyed to the gearbox unit
output shaft and pinion shaft, respectively. The hubs are connected together by segmented grid
springs to form a resilient coupling. The grid springs fit into grooves machined in the peripheries
of the hubs. The assembly is packed with grease and enclosed in two half covers that are bolted
together.

Figure 5-14 shows the gearbox lubrication system.

5-25
Technical Description – Allis-Chalmers

Figure 5-14
Gearbox Lubrication System
(Courtesy of Lethabo Power Station)

The mill gearbox lubrication system consists of a two pump arrangement, a filter, an oil cooler,
and instrumentation components. The system is mounted on top of the lubricating oil supply
tank. The pumps draw oil from the oil tank and discharges the oil at 140-kPa pressure to the mill
gearbox. The oil then flows to the internal oil distribution fittings.

The two pump arrangement is designed to have one pump on-line and one pump in standby
mode. At startup, the discharge oil pressure of the duty pump is monitored. If the discharge oil
pressure fails to reach 140 kPa after 10 seconds, the standby pump is automatically started.

5-26
 Technical Description – Allis-Chalmers

Lubricating oil is drawn from the oil tank through a suction line and is circulated at 140-kPa
pressure through a filter and an oil cooler. From the oil cooler, the oil passes to the gearbox
through piping. Oil enters the gearbox casing through a flanged connection and is distributed to
the bearings of both shafts and gear teeth. Figure 5-15 shows the gear teeth lubrication.

Figure 5-15
Gear Teeth Lubrication
(Courtesy of Lethabo Power Station)

5-27
Technical Description – Allis-Chalmers

The supply to the gear teeth is passed through spray nozzles. Restrictors are fitted within the
gearbox distribution lines to ensure that each lubrication point receives the correct quantity of oil
at 140-kPa pressure. Four spray nozzles provide an oil flow of 1.12 liters per second to the gear
teeth. The input shaft bearings are provided with 0.25 liters per second of oil flow and the output
shaft bearings are provided with 0.07 liters per second of oil flow.

Two pressure gauges are used, one before the filter and one after the cooler. The first gauge
indicates the pressure of the oil leaving the pump and also indicates the cleanliness of the filter or
cooler. The second gauge indicates the oil pressure entering the gearbox unit.

Three spring-controlled relief valves are used in the system. One relief valve acts as a safety
valve if the filter becomes blocked. Another relief valve serves as a cooler bypass and normally
operates during the early stages of operation when the oil is cold and the resistance to flow
through the cooler is high. The relief valve acts as a safety valve if a total blockage of the cooler
occurs. The third relief valve acts as a pressure regulator and is set to maintain the specified
working pressure of the gear unit at the normal working oil temperature.

A pressure switch is located in the oil cooler discharge pipe. This switch is connected in the
starting circuit of the mill drive motor. The starting circuit ensures that the drive motor will not
start until the oil pressure has risen above 80 kPa and will trip the motor when the oil pressure
falls below 50 kPa.

A dial-type thermometer, fitted in the delivery pipe at the exit from the cooler, indicates the
temperature of the oil being supplied to the spray nozzles and bearings in the gearbox unit. A
flow indicator with an alarm indicating a low-flow condition is also connected in this line.

A manually operated drain valve, fitted directly downstream of the oil pumps, facilitates rapid
system and tank draining into suitable containers. The remainder can be drawn off by the drain
plug provided.

The oil pumps are gear pumps driven by electric motors through flexible, gear-type couplings.
Each pump consists of two intermeshing rotors that operate in rolling element bearings. The top
rotor shaft extends from the pump body and is keyed to the flexible drive coupling. One oil seal
is located in a housing attached to the drive-end cover and provides sealing for the drive shaft. O-
rings, located in the covers at each end of the pump, provide sealing for the pump body.

Oil entering the inlet port in the pump body is drawn around the space between the body and the
rotor teeth and is discharged through the outlet port on the opposite side of the body.

The oil filter is a biplex filter designed to permit a continuous flow of filtered oil when one of the
filter baskets is removed for cleaning. The filter body consists of twin chambers located on each
side of the main valve where the two filter baskets are located. The main valve directs the flow
of oil through the filter and is operated by a handle that is pinned to the valve spindle at the top
of the filter body. With the handle in the central position (in line with the inlet and outlet
flanges), the flow of oil passes through both filter baskets. When the handle is positioned over

5-28
 Technical Description – Allis-Chalmers

one of the two basket chambers, the filter basket under the handle is the only one in use. The
other basket may be removed for maintenance.

A cover on top of each chamber is secured by two wing nuts and provides access for the removal
of the filter baskets. A drain plug is provided at the bottom of each chamber.

The oil enters the filter chamber at its head and flows down through one of the filter baskets,
depending on the position of the handle and out through the sides of the basket. Particles of
foreign matter in the oil are retained within the basket forming a layer of sediment at the base of
the basket.

The oil cooler is an oil/water heat exchanger consisting of a tube stack with two headers at each
end. One header is for the shell pass fluids, and the other header is for the tube pass fluids. Both
headers are contained in a steel tube. The tube stack consists of stainless steel tubes sealed at
both ends under compression using elastomer seals that allow for expansion. A similar
arrangement seals each tube and shell pass header to the end cap and shell, respectively.

The oil cooler is provided with a special set of pressure plates and tensioning bolts in order to
ensure that the shell pass of the cooler remains sealed when the tube pass is opened for
inspection or maintenance.

Oil enters the cooler at one end through the shell header and is directed over the tubes by
segmented baffles separated by distance pieces. The distance pieces ensure uniform flow and the
elimination of hot spots. Cooling water enters the unit through the tube header at the oil outlet
end and, after passing through the tubes, is discharged from the tube header at the oil inlet end.
This opposed flow ensures maximum cooling at the oil outlet.

The oil pressure switch is a bellows-operated switch electrically connected to close on rising
pressure and open on falling pressure. Adjustment of the operating point can be made by a screw
driver adjustment located at the top of the switch. An adjusting screw for altering the differential
is accessible by removing the cover of the switch.

5.7 Girth Gear and Pinion Shaft

The girth gear and pinion shaft transmit the torque to rotate the mill shell. The pinion shaft gear
wheel and girth gear ring are enclosed by a girth guard. The pinion shaft is supported by two
bearings. A large inspection door is provided in the girth guard adjacent to the pinion shaft gear
wheel.

The girth guard seal is achieved on the rotating interface using a Teflon seal strip fixed in a radial
groove and bearing against the girth gear wheel side flat surface. The seal strip is maintained in
contact with the gear side by a light radial spring that is adjustable. The sealing arrangement is
needed to prevent the ingress of pulverized coal into the girth gear guard enclosure. The girth
gear seal air system also keeps the pulverized coal contamination out of the enclosure. Figure 5-
16 shows the location of the girth gear and girth guard.

5-29
Technical Description – Allis-Chalmers

Figure 5-16
Mill Outline
(Courtesy of Lethabo Power Station)

The two pinion shaft bearings are spherical roller bearings. The bearing adjacent to the mill gear
unit coupling is a stationary bearing. The other bearing is free to float in the housing. Both
bearings are packed with grease for lubrication purposes.

Each mill is provided with a girth gear seal air system that supplies an air pressure of 0.5 kPa to
the girth gear enclosure. The air pressure is required to assist the girth gear seal and to prevent
contamination of the girth gear lubricant.

The air supply is provided by a motor-driven, radial-bladed fan located adjacent to the ball mill
on the ground level. The fan is fitted with a twin inlet facility, each inlet having an isolating ball
valve and air filter.

The air supply is piped to the girth gear guard through 100-mm diameter piping with a section of
rubber hose fitted at the mill end of the piping.

A schematic of the girth gear lubrication system is shown in Figure 5-17.

5-30
 Technical Description – Allis-Chalmers

Figure 5-17
Girth Gear Lubrication System
(Courtesy of Lethabo Power Station)

The girth gear is lubricated by a four-nozzle spray lance arrangement that is supplied with
lubricant from a pneumatic pumping system. The spray lance is attached to the girth side of the
girth gear teeth. The spraying is carried out in intervals, the frequency being controlled by a
timer control circuit. The quantity of lubricant is metered by a piston displacement within a
distributor block.

5-31
Technical Description – Allis-Chalmers

The pneumatic pumping system consists of the following:

• Pneumatic pump
• Air service unit containing a pressure switch, filter, regulator, lubricators, and solenoid valve
• Four-nozzle spray lance
• Control panel with timer
• Lubricant distributor with cycle counter
• Air lubricator at pump motor

The air supply is connected to a pressure switch on the side of the air service unit. The air supply
passes through a filter, a regulator, and a lubricator to a solenoid valve. The solenoid valve is
controlled by the timer. When the solenoid valve is open, air flows to the spray lance and the air
pump. The lubricant supply is provided from a standard commercial container where the air
pump is mounted. The air pump maintains a supply of lubricant from the container to the
distributor block. The flow of air through the spray lances clears the nozzles and atomizes the
lubricant at the nozzles when it is supplied from the distributor. After lubricating the gear teeth,
residue lubricant collects in a drip tray under the gearing.

The girth gear lubrication system has a heating system that improves the pumping ability of the
lubricant during times of low-ambient temperatures. The heating system contains trace heating
elements and cartridge heater elements controlled from independent temperature controllers. The
trace heating tape is wrapped around the grease pump outlet piping and controlled by a Danfoss-
manufactured controller. The cartridge heater is fitted into an aluminum manifold and mounted
between the distribution block and the mill casing. The cartridge heater is controlled by using a
Brainchild-manufactured temperature controller.

One of the distributor sections contains a piston with an external indicator pin that trips a contact
for each displacement of the distributor piston. The contact circuit causes a pulse to be recorded
by the cycle counter fitted to the distributor. When the preset number of pulses has been reached,
the control circuit closes the air solenoid valve and stops the pump action. The pump remains
stopped until a preset time delay expires. The system then repeats the operation.

The system is provided with alarm functions as follows:

• Loss of supply voltage or an open circuit in the air pressure switch circuit causes an interlock
relay to disable the system.
• Loss of air pressure or excessive pumping time initiates a visible and audible alarm, stops the
cycle timer, and disables the system.
• Excessive pump time that may be caused by lubricant leakage or pumping from an empty
lubricant container shuts off the air solenoid valve.

5-32
 Technical Description – Allis-Chalmers

The girth gear lubricating pump is an air-driven pump mounted on top of a standard 180-kg
lubricant drum. The pump requires an air pressure of 500 kPa to operate. The pump consists of a
top-mounted controlling air motor and a long pump tube assembly designed to reach the bottom
of the supply drum.

Operating air enters the motor valve body and is directed by a ported piston into the cylinder
under the operating piston. The operating piston is attached by connecting rods to a lower piston
at the bottom of the pump tube. As the lower piston rises, the upper ball is held on its seat, and
the lower ball is lifted off its seat due to the ingress of the lubricant.

When the piston rod reaches the top of its travel, the ported piston then redirects the operating air
to the top of the operating piston, causing it to move downward. As the operating piston moves
downward, the lower ball is forced onto its seat, and because of the pressure buildup, the upper
ball is lifted. This allows the pressurized lubricant to pass out of the discharge port and into the
outlet supply line to the distributor block.

5.8 Power-Sonic Mill Conditioning System

Figure 5-18 shows a line diagram of the Power-Sonic mill conditioning system

Figure 5-18
Power-Sonic Mill Conditioning System
(Courtesy of Lethabo Power Station)

5-33
Technical Description – Allis-Chalmers

Under normal operating conditions, the coal level in each mill is controlled by a mill
conditioning system. The system is provided to maintain the coal level in the mill for the various
operating conditions including moisture content, size of coal, and so on. The system primarily
uses a measurement of power drawn by the mill motor along with a measurement of the noise
generated by the grinding process in order to produce a composite error signal. The error signal
is then passed to the coal feeder speed controllers.

The system consists of a power transducer, a sonic transducer, a control cabinet, and a control
panel. One control cabinet houses the individual control circuitry for three ball mills. The power
transducer monitors the power used by the mill drive motor when driving the rotation of the mill.
The sonic transducer monitors the noise generated by the grinding action of the balls in the mill.

The mill shell and girth gear are enclosed by an acoustic housing. The sonic transducer for the
mill conditioning system is mounted on the side of the acoustic housing, 1700 mm above ground
level and 600 mm from the access door edge towards the center of the mill.

The power control circuit provides the major control path for the mill conditioning system.
A signal representing mill motor power is generated by the power transducer. The signal is
processed and passed to the power meter, the low-power alarm, and the power set point. With
this set point, a power error signal is generated that is then passed through a summation network
where both the sonic inputs and the mill load demand signals are compared. From the signal
summator, a composite error signal is derived and passed on to the coal feeder speed controllers.

A signal proportional to the grinding noise is generated by the sonic transducer. The signal is
amplified, filtered, and passed to a sonic meter, a sonic alarm, a sonic-swamp set point, and a
sonic-trim set point. When the sonic intensity exceeds the sonic-swamp set point, the signal
triggers a comparator to affect the power error signal. This action forces the composite error
signal to indicate to the controller that the product charge is out of range or on the low side. The
low limit is used to provide a fixed reference for the power control circuit when the swamping
circuit is not triggered.

Table 5-1 shows the alarm conditions for the Power-Sonic mill conditioning system

Table 5-1
Alarm Conditions for the Power-Sonic Mill Conditioning System
(Courtesy of Lethabo Power Station)

Mill Condition Alarm Output

Low-Power High-Sonic

Normal operation within control range Normal Normal

Mill starting to overload – high product charge Alarm Normal

Mill is reducing the product charge and indications are Normal Alarm
moving toward the stripping range or loss of a feeder in
the control range
Mill in stripping range and almost void of product charge Alarm Alarm

5-34
 Technical Description – Allis-Chalmers

From Table 5-1, a high-sonic alarm condition indicates a low-product charge. If the ball charge
weight has not been maintained, then the following symptoms appear:
• At rated high-load output, the mill becomes unstable because of the inability to grind the
required throughput because of insufficient ball charge.
• At lower outputs permitted by reduced ball charges, the system initiates a low-power alarm
because the power is lower than the alarm set point.
• A reduced ball charge drops the stripping point power down below the control setting and the
high-sonic alarm is initiated. This is because the controller attempts to increase power to the
set value by reducing the coal feed to the mill.

5.9 Technical Specification List

Data for the Allis-Chalmers mill are listed in Table 5-2.

Table 5-2
Data for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Equipment/System Parameter Technical Data

Mill shell Diameter 4267-mm
Length 5790-mm
Maximum ball charge Weight 97,000-kg
Initial ball charge Size 20% – 60-mm balls
80% – 40-mm balls
Make-up ball charge Size 60-mm balls
Trunnion bearings Type Babbitted rocker type insert with
individual lubrication system
Trunnion bearing cooling Type Water-cooled coils in inserts
Water flow rate 0.46 liters/second
Pressure 810 kPa
Drive gear Type Single-helical pinion shaft and girth gear

Ratio 10,071:1
Pinion shaft Size 614.5-mm outside diameter
Number of teeth 28 teeth
Girth gear Size 5820.3-mm outside diameter
Number of teeth 282 teeth
Rotating mill Speed 15.7 rpm

5-35
Technical Description – Allis-Chalmers

Table 5-2 (continued)

Data for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Equipment/System Parameter Technical Data

Girth gear seal air fan, single Size 228-mm diameter
inlet
Speed 2800 rpm
Pressure 0.5 kPa
Girth gear seal air fan motor Voltage 380 volt
Type 3-phase
Frequency 50 Hz
Frame KDY 71
Girth gear lubrication system Type Four-nozzle lance with spray valves
Pressure 400 kPa
Voltage 110 volts AC
Mill trunnion bearing Operating pressure – 20.7 mPa
lubrication system high pressure
Relief valve setting 31 mPa
Low pressure 680 kPa
Oil temperature 30°C
Oil flow rate 0.38 liters/second
Minimum oil flow rate 0.125 liters/second
Oil reservoir capacity 2.8 liters
High oil temperatures 60°C auto start high-pressure pump,
82°C auto trip mill
Gearbox unit Weight of gearbox 13,000 kg
without oil
Input speed 985 rpm
Output speed 158,871 rpm
Acoustic hood Size 2400 mm by 1810 mm by 1180 mm
Lining material 30 mm
thickness
Gearbox lubrication system Tank capacity 675 liters
Oil tank temperature 54°C
Oil spray temperature 48°C
Operating pressure 140 kPa

5-36
 Technical Description – Allis-Chalmers

Table 5-2 (continued)

Data for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Equipment/System Parameter Technical Data

Pump Type Gear
Flowrate 1.76 liters/second
Pump motor Power rating 4 kW
Voltage 380 volt
Type Three-phase
Frequency 50 Hz
Frame DX112MD
Speed 1,425 rpm
Filter Size 119 microns
Cooler Water flow rate 0.9 liters/second
Pressure drop 157 kPa
Pressure switches Settings Closes on rising pressure of 80 kPa
Opens on falling pressure of 50 kPa
Relief valves Settings 350–360 kPa, 300 kPa, 154 kPa
Flow meter Size 2 in.
Mill drive motor Enclosure CACA
Cooling Air
Shaft length 3.700 mm double-ended
Supply 3300 volt, Three-phase, 50 Hz
Output 1550 kW
Speed 993 rpm
Insulation Class F
Weight 9.75 metric tons
Bearings Lubrication Loose ring
Winding Temperature alarms 120°C alarm, 130°C trip
Bearing bushing Temperature alarms 85°C alarm, 90°C trip
Bearing sump Temperature alarms 75°C alarm, 80°C trip
Motor/gear coupling Manufacturer Falk
Type T10
Size 170T
Weight 443 kg
Coupling gap 6 mm

5-37
Technical Description – Allis-Chalmers

Table 5-2 (continued)

Data for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Equipment/System Parameter Technical Data

Barring gear unit Gear ratio 1st gear – 4.875:1
2nd gear – 30.5:1
Total reduction – 148,687:1
Input speed 1460 rpm
Output speed 9819 rpm
Barring speed 0.157 rpm
Bearings Ball race
Weight 1900 kg
Input coupling Type Heavy-duty cone ring
Size 03
Coupling gap 3 mm
Output coupling Type Special CUD14 barring coupling
Coupling gap 6-mm
Barring gear drive motor Frame size D180L
Enclosure TEFC
Supply 380 volt, Three-phase, 50 Hz
Speed 1460 rpm
Barring gear brake Size 203-mm diameter
Supply 380 volt, Three-phase, 50 Hz
Retaining torque 163 N-m

5-38
6
TECHNICAL DESCRIPTION – FOSTER WHEELER

The Foster Wheeler ball/tube mill system [5] consists of a single- or double-feed system that
delivers coal to a large rotating drum partially filled with hardened steel balls. The ball/tube mills
can process up to 70 tons/hour of coal.

The following is a description of a negative pressure Foster Wheeler ball mill. When charged
with approximately 50 tons of forged steel balls of 7/8-in., 1-1/4-in., and 2-in. diameter, the
Foster Wheeler ball mills are capable of grinding 83,000 lbs of coal per hour with a pulverized
coal fineness of 70% through a 200-mesh screen and 98.5% through a 50-mesh screen. This is
based on 10% maximum raw coal moisture and a coal grindability of not less than 55 on the
Hardgrove scale.

Figure 6-1 shows a diagram of the Foster Wheeler ball mill. The pulverized fuel system can be a
single- or double-feed system. The system described here is comprised of two raw coal feeders
and motors, one ball mill pulverizer and motor, two classifiers, two exhausters and motors, two
distributors, interconnecting raw coal and fuel piping, and all related dampers and controls.

Figure 6-1
Foster Wheeler Ball Mill Diagram [2]

6-1
Technical Description – Foster Wheeler

During operation, two table-type feeders provide coal to each end of the mill. Each feeder has a
single discharge and supplies coal into one end of the mill. The rotating table of the feeder is
driven by a 1-horsepower, two-speed, squirrel-cage induction motor. The flow of coal from the
feeder table is regulated by the position of an adjustable shear plate. An access door with a glass
observation window permits inspection of the feeder table and shear plate. The access door
facilitates removal of any foreign material that may interfere with feeder operation.

Raw coal flows from the feeders in a pipe through the classifier. The raw coal is mixed with
coarse rejects drawn out from the classifiers. The coal is then carried into the mill by the spiral
ribbon conveyors that rotate with the mill. Figure 6-2 shows the air/coal flow diagram for the
Foster Wheeler ball mill.

Figure 6-2
Air/Coal Flow Diagram [6]

After the 1960s, ball mills were designed for pressure operation and supplied with a primary air
fan; the exhauster fan was removed. The primary air fan supplies air to the mill inlet. Preheated
air is taken from the secondary air duct downstream of the air heaters and enters the mill from
both ends through a centrally located air tube. This preheated air is called primary air and is used
to carry pulverized coal through the pulverizer to the classifiers, exhausters, and fuel piping to
the boiler. The desired air temperature is achieved by blending the hot primary air with cold
tempering air through an adjustable damper arrangement upstream of the pulverizer.

A 700-horsepower, 327-rpm, 4160-volt, squirrel-cage induction motor drives each mill through
two flexible couplings to a herringbone pinion and gear. The mill is rotated at a speed of

6-2
 Technical Description – Foster Wheeler

approximately 18 rpm. The mill motor is protected by a low-voltage auxiliary relay, current
overload relays, and ground relays.

As the drum rotates and coal is fed into the mill, the balls and coal are carried up on the
periphery of the drum. The balls and coal then cascade toward the mill axis and the coal is
ground. The pulverized coal and air leave the mill through the annular space between the air inlet
tube and the mill trunnion tube.

Technical Key Point

There is no tramp iron removal system. The mill is designed to grind the raw coal
and foreign matter together. Considerable amounts of pyrites will accelerate the
wear rates of the grinding media.

The flow of primary air transports the ground coal to the classifiers. There may be one or two
classifiers that receive the coal and air mixture exiting the drum. With two classifiers, each
classifier receives the coal and air mixture from one end of the drum.

Each classifier separates coarse particles from the mixture of primary air and fuel leaving the
mill, allowing only the fine particles to continue on to the exhauster. The heavy particles fall and
are separated by centrifugal force as the fuel mixture passes over the baffle plate. The coarse
particles are mixed with the raw coal being fed into the classifier and are returned to the mill for
further grinding by the spiral ribbon conveyor. The differential pressure across the classifier is
the primary indication of mill output.

Before the 1960s, Foster Wheeler-manufactured ball mills were negative pressure mills equipped
with exhauster fans. The exhauster fans are located at the discharge of the mill and provide
suction pressure for the mill. The primary air and fuel exit the classifier and are drawn through
the exhauster inlet elbow and into the exhauster. A coal distributor is located on the exhauster
outlet to distribute fuel uniformly to the piping that leads to the boiler.

The exhauster is essentially a six-bladed paddle wheel that receives the fuel mixture at the center
of the wheel and discharges the fuel mixture at the periphery of the blades. The exhauster pulls
air through the mill to pick up the coal and discharges the coal/air mixture to the boiler burners.

The exhauster is driven by a 200-horsepower, 1165-rpm, 4160-volt, squirrel-cage induction

motor. The maximum fuel flow capacity of one exhauster is approximately 85,000 lbs per hour.

Mill suction should be maintained at approximately 2 in. of water negative pressure. This is
necessary to ensure proper functioning of the feeder controller. If the mill suction is low, then the
differential signal will be low. This will cause the feeder to operate continuously and fill the
pulverizer with coal. If the mill suction is too high, the air leakage will be too great, and the coal
level in the mill will be reduced.

6-3
Technical Description – Foster Wheeler

From the discharge of the exhauster, a distributor box distributes the coal/air mixture to the fuel
piping that leads to the boiler burners. The shape of the distributor box assists the distributor
dampers in dividing the coal equally among the burners. Normally, when the distributor dampers
are set, it is not necessary to make any changes. The burner shutoff valves are located at the
discharge side of the distributor box. The burner shutoff valves enable the operator to take any
burner or burners out of service without affecting the operation of the other burners.

The output of the pulverized fuel system depends on the airflow through the mill. The airflow is
regulated by the position of the exhauster output control damper located in the exhauster inlet
elbow.

This section covers the technical description for the Foster Wheeler ball mill on the following
components/systems:
• Conveyor assembly
• Drum assembly
• Trunnion main bearings
• Gearing
• Trunnion tube
• Classifier
• Exhauster
• Lubrication systems
• Seal air system

6.1 Conveyor Assembly

Figure 6-3 shows the flight ribbon conveyor assembly. The conveyor assembly consists of an
inlet air screen, an air tube, a flight ribbon with chains, and spokes. The conveyor assembly
resides inside the trunnion tube and is connected to the drum.

6-4
 Technical Description – Foster Wheeler

Figure 6-3
Flight Ribbon Conveyor Assembly [2]

The primary air flows through an inlet screen, through the air tube, and into the drum. The coal is
fed from the piping through the classifier and onto the flight ribbon. The flight ribbon is a spiral
metal ribbon attached to the outside of the air tube. There are chains attached between the spiral
ribbons. As the drum rotates, the flight ribbon rotates, and coal is fed into the drum. Attached to
the drum end of the conveyor assembly, a ring with spokes keeps the air tube centered in the
trunnion tube and the drum.

A number of changes have occurred in the conveyor assembly when compared to the original
design provided on older units. The following changes have occurred from the original design:
• The flight ribbons have additional supports that reduce the possibility of breakage.
• The flight ribbon supports on the drum end are not fixed. The new standard support is a type
of spring support that provides some flexibility when objects such as tramp iron, pyrites, or
other objects become wedged in the flight ribbons.
• The screen at the mill end of the air tube is now located at the inlet elbow end of the air tube.
The new location for the screen reduces damage to the screen due to balls and other debris
getting tangled in the screen.
• A reject ribbon is welded inside the air tube. This reject ribbon kicks the balls and other
debris back into the mill before it reaches the screen at the other end of the air tube.

6-5
Technical Description – Foster Wheeler

6.1.1 Conveyor Support Assembly

The flight ribbon spring support assembly is shown in Figure 6-4.

Figure 6-4
Flight Ribbon Spring Support Assembly [2]

The redesigned conveyor support systems have had two major upgrades in order to provide
increased reliability. Figure 6-5 shows the conveyor support assembly.

Figure 6-5
Conveyor Support Assembly [2]

6-6
 Technical Description – Foster Wheeler

The first upgrade was to add four spokes to the assembly for a total of eight spokes. The use of
eight spokes reduces the loading on the individual spokes and decreases the load transferred to
the remaining spokes if one spoke breaks.

The second upgrade includes spokes that are not threaded. This reduces the chance of stress
concentrations and cyclic-fatigue failures. The spoke material has also been upgraded. Finally,
the hole in the reject liner that the spoke fits in has a sleeve insert that keeps the spoke tight in
the reject liner hole.

For earlier designs, a significant amount of time was spent in aligning the air tube after the
spokes were cut out or removed. It is critical for the air tube to be precisely centered in the mill,
or the spokes will fail after some period of time. The original design has the air tube centered and
the ring and spokes welded into position. With the redesign, a fixed ring and its spokes remain in
position, and the air tube is bolted into the ring. When the conveyor needs repair or replacement,
the air tube is easily removed from the ring, but the ring and spokes can remain in position.
When the air tube is reinstalled, it is bolted back into the ring, and alignment is not required.
Figure 6-6 shows the conveyor removal with the eight-spoke ring design.

6-7
Technical Description – Foster Wheeler

Figure 6-6
Conveyor Removal with the Eight-Spoke Design [2]

6.2 Drum Assembly

The pulverizer drum assembly consists of two cast-iron end castings bolted to a rolled-steel plate
cylinder. The ends are cast with integral trunnions, and the entire assembly is supported at each
end by large, self-aligning, water-cooled, babbitted bearings. Flight bars are bolted to the end

6-8
 Technical Description – Foster Wheeler

castings. Flight bars are designed to direct debris and small grinding balls back into the drum.
Figure 6-7 shows the complete drum assembly.

Figure 6-7
Complete Drum Assembly [2]

O&M Cost Key Point

It is less expensive and more time efficient to purchase the complete drum
assembly instead of having the end castings and drum shell plate assembled on site.

The drum assembly shell plate is pre-drilled for the installation of liners, and the end castings are
finished machined.

The end castings enclose the drum shell and provide the rotating bearing surfaces when the drum
assembly is seated in the trunnion bearing. Figure 6-8 shows an end casting.

6-9
Technical Description – Foster Wheeler

Figure 6-8
End Casting [2]

The castings are susceptible to long-term failure from cyclic fatigue and notch effect if the
routine maintenance procedures, such as flight bar replacement and ball charge reclassification,
are not regularly completed.

6.2.1 Double-Wave Liners

The drum liners are designed to lift and tumble the ball charge as the drum is rotated. Foster
Wheeler has standardized double-wave liners for the grinding drum on all of the new mills.
Figure 6-9 shows the double-wave liners.

6-10
 Technical Description – Foster Wheeler

Figure 6-9
Double-Wave Liners [2]

The primary benefits of the double-wave liners are:

• Reduced maintenance – This design eliminates the need to align separate wedge bars and
liners.
• Improved efficiency – An improvement in mill performance and coal fineness
characteristics is typically noted because wedge bar systems can rarely be maintained to the
design specification.
• Liner longevity – The double-wave liners last longer than the old wedge bar and liner
system.
• Ease of installation – Compared to the wedge bar and liner system, the labor required to
install the double-wave liners is 30% less because there are fewer parts and no required liner
adjustments are necessary (each liner automatically bolts into position).
• Increased durability – In the older system when the wedge bars were worn, there was a
degradation of mill performance because of the loss of the original lift profile. The original
wedge bars had a hardness of 300 BRN (Brinell hardness number). The wedge bars would
wear more rapidly than the liners and needed to be replaced more often. The double-wave
liners have a hardness of 600 BRN. Additionally, as the double-wave liner wears, the contour
remains the same for the life of the liner without loss of mill performance.
• Reduced inventory – A typical wedge bar and liner design can require as many as 14
different patterns. The typical double-wave design uses only six different patterns (assuming
the double-size, double-wave access door replaces the original access door).

The improved double-wave liners can be installed when the wedge bars are scheduled for
replacement or during the next liner replacement outage.

6-11
Technical Description – Foster Wheeler

6.2.2 Double-Size, Double-Wave Access Doors

In response to requests for larger access doors for the ball mills, Foster Wheeler is producing
double-size, double-wave access doors. The original door can be retained with the larger door
providing additional access, or the larger door can be installed over the original door, resulting in
fewer liner patterns. Figure 6-10 shows a double-size, double-wave access door.

Figure 6-10
Double-Size, Double-Wave Access Door [2]

6.2.3 Flight Bars

Between the trunnion tube and drum end casting is a gap where debris and small grinding balls
can get lodged. Over time, this debris can wear grooves at the most critical area of the end
casting. The resulting wear and stress concentration eventually causes the end casting to fail.
Bolted to the end casting are flight bars that are designed to push the small grinding balls and
debris back into the drum. If the flight bars are worn out or missing, they should be replaced. The
flight bar material has been upgraded in order to improve wear and abrasion properties.

6.2.4 Grinding Balls

Foster Wheeler has standardized high-chrome grinding balls for the grinding media. The
increased cost of the steel-forged balls is offset by longer wear life properties. The material of
the high-chrome balls matches the high-chrome, double-wave liner material. Foster Wheeler
recommends the reclassification of balls every three years or at some reasonable cycle. The
largest ball size is usually 2.5 in. in diameter, while the smaller ball size ranges from 0.75–1 in.
in diameter.

Figure 6-11 shows the wear rates on the forged-steel, carbon-molybdenum, and high-chrome
balls for different grindability coals.

6-12
 Technical Description – Foster Wheeler

Figure 6-11
Ball Wear Rates [2]

6.3 Conveyor Shaft Bearing and Seal

The bearing and stuffing seal in the inlet elbows is used to support the outboard end of the ribbon
conveyor assembly. The latest design uses an air-cooled roller bearing in an internally braced
inlet elbow. Figure 6-12 shows the conveyor bearing modification.

Figure 6-12
Conveyor Bearing Modification [2]

6-13
Technical Description – Foster Wheeler

This upgrade has three advantages over the old design and the advantages are:
• The bearing is air-cooled to extend the operating life.
• A labyrinth seal is included in the bearing support enclosure. The cooling air provides a
purging action that keeps coal particles away from the bearing.
• The internally braced inlet elbow provides adequate stiffness to the bearing support and
eliminates the need for the old pipe support.

Because of the close machining tolerances required for this modification, it is difficult to
accurately locate the new bearing and seal in the field, as well as install the internal support in
the elbow area. For these reasons, new elbows are normally purchased with the modification.

If there is a need to replace the inlet elbows because of fire damage or mill puffs, then this
modification would be an improvement from the current design. If the existing elbows are in
good condition, then the elbows can be retrofitted during a future outage.

6.4 Trunnion Main Bearing and Dust Seal

The trunnion main bearing assembly supports the drum end casting and consists of the main
bearing, thermocouples, and spring-loaded dust seals. Figure 6-13 shows the original bearing
assembly.

Figure 6-13
Original Bearing Assembly [2]

6-14
 Technical Description – Foster Wheeler

The trunnion bearing has been modified to be used in the driven or the non-driven end of the
drum casting. The new design bearing is shown in Figure 6-14.

Figure 6-14
New Design Bearing [2]

The thermocouples protrude into the babbitted bearing surface at the 4 o’clock position. These
thermocouples provide the operators with a high-temperature alarm in the event of possible
bearing distress.

The spring-loaded dust seals are self-adjusting so that the outboard gap between the trunnion and
the oil retainer is sealed. This prevents coal dust and other contaminants from entering the lube
oil.

The ball mills with exhausters installed before the 1960s may leak coal dust during mill
excursions. In this design, the exhausters provide a negative pressure operation in the drum. The
loss of drum level or control problems can cause the mill to go from negative to positive pressure
operation, and coal dust may leak out of the drum. Figure 6-15 shows the trunnion seal.

6-15
Technical Description – Foster Wheeler

Figure 6-15
Trunnion Seal [2]

Ball mills supplied after the 1960s use a positive pressure system that uses a primary air fan to
pressurize the mill. To prevent coal dust from blowing out between the end casting and
trunnions, a trunnion dust seal arrangement was added. Seal air, at a pressure that is slightly
higher than the mill pressure, is provided to a trunnion seal chamber. During operation, the seal
air is introduced to prevent coal from escaping through the clearance between the rotating drum
and the trunnion. Spring-loaded mechanical seals, consisting of a steel ring attached to the
pulverizer trunnion and a flexible gasket attached to the classifier, keep the seal air contained.
This trunnion seal area is vented to the lower-pressure classifier in order to remove any coal fines
that migrate there during operation. A plow, rotating with the trunnion, stirs up the coal to ensure
that it is removed through the scavenging vent system. The modification for the dust seals is
available for the negative pressure mills.

6.5 Gearing

The Foster Wheeler ball mill drive system consists of gearboxes, couplings, support rings,
inching drives, pinions, and bull gear assemblies. Bull gears are available as either cast or
fabricated alloy steel materials. Pinions are available as carburized and ground, forged-alloy steel
material. Figure 6-16 shows the pinion and bull gear assembly.

6-16
 Technical Description – Foster Wheeler

Figure 6-16
Pinion and Bull Gear Assembly [2]

6.5.1 Pinion Bearings

The original babbitted pinion bearings required a large amount of maintenance. It is possible to
convert the babbitted pinion bearings to roller bearings. Figure 6-17 shows the new roller
bearings.

6-17
Technical Description – Foster Wheeler

Figure 6-17
Roller Bearings [2]

The roller bearings have several advantages:

• The lubrication system used for the old babbitted pinion bearings is not required. This
reduces maintenance costs, power consumption, and the chance for bearing failures.
• The roller bearings can be mounted in split pillow blocks. This facilitates the flipping of the
pinion gear to operate on the unused side of the pinion teeth. The pillow blocks do not
require removal from the foundation sole plates, and this eliminates the need to realign the
pinion gear.

6.6 Trunnion Tube

The classifier trunnion tube is the part of the classifier housing that extends through the trunnion
and into the drum. As originally designed, a thorough inspection and replacement of the flight
bars is difficult. An access door in the trunnion tubes is now provided for inspections and flight
bar replacement. Figure 6-18 shows the new classifier trunnion tube.

6-18
 Technical Description – Foster Wheeler

Figure 6-18
Classifier Trunnion Tube [2]

The lower portion of the inside of the trunnion tube is protected from wear by replaceable steel
liner plates. The liner plates can be supplied in different grades of steel for corrosion and erosion
protection.

6-19
Technical Description – Foster Wheeler

6.7 Classifier

The original scroll-type classifier is shown in Figure 6-19.

Figure 6-19
Original Scroll-Type Classifier [6]

There are several options or upgrades from the original design scroll-type classifier. The
options/upgrades are:
• Classifier reject damper
• Adjustable blade
• M-type classifier
• Dynamic classifier

6.7.1 Classifier Reject Damper

The classifier reject damper [2] is an on-line adjustable device used to optimize the return flow
path of large coal particles from the classifier to the mill’s raw feed inlet conveyor. Proper
adjustment minimizes and/or eliminates bypassing of the large particle sizes (greater than or
equal to 50 mesh). Figure 6-20 shows the classifier reject dampers.

6-20
 Technical Description – Foster Wheeler

Figure 6-20
Classifier Reject Dampers [2]

If the ball mill performance has been optimized and coal fineness still requires minor adjustment
in order to assist with the reduction of NOx and unburned carbon, then these dampers can
provide the desired results. A 3–5% increase in fineness is the expected range of improvement
for these reject dampers.

6.7.2 Adjustable Blade Classifier

The modification for an adjustable blade classifier consists of substituting a static classifier with
adjustable inlet vanes. This classifier is similar to a cyclone-type classifier with the inlet area
around the circumference and fitted with adjustable vanes. The primary air and coal/air mixture
is centrifuged by the dual scroll before exiting the mill. Figure 6-21 shows the adjustable
classifier.

6-21
Technical Description – Foster Wheeler

Figure 6-21
Adjustable Classifier [6]

Figure 6-22 shows the original classifier and the static classifier with adjustable inlet vanes.

Figure 6-22
Classifier Comparison [6]

6-22
 Technical Description – Foster Wheeler

Figure 6-23 shows the fineness improvement with the adjustable classifier.

Figure 6-23
Adjustable Classifier Fineness Improvement [6]

6.7.3 M-Type Classifier

The Foster Wheeler M-type classifier is similar to the static classifier used on vertical shaft mills.
It offers a higher coal fineness output for the same coal flow as the original ball mill classifier.
Additionally, the coal fineness can be controlled by the use of movable vanes that can be
adjusted while the mill is operating. Depending on the coal piping configuration, the M-type
classifier may also provide a better coal flow balance among the burners. Figure 6-24 shows an
M-type classifier.

6-23
Technical Description – Foster Wheeler

Figure 6-24
M-Type Classifier [2]

6.7.4 Dynamic Classifier

The dynamic classifier is designed to improve the coal classification from the static, cyclone-
type classifier. Using the dynamic classifier improves the pulverizer capacity, coal fineness
distribution, and fineness control. The M-type classifier can be directly converted into a dynamic
classifier and results in minimal changes to the existing hardware and components. The dynamic
classifier consists of:
• An outer housing with coal distribution control vanes
• A vertical rotor assembly
• A ring of fixed, flow-directing vanes
• A reject hopper
• A modular shaft and bearing assembly
• A drive system, complete with a drive belt, sprockets, an ac electric motor, and a variable-
frequency inverter drive

6-24
 Technical Description – Foster Wheeler

Figure 6-25 shows a dynamic classifier for the ball mills.

Figure 6-25
Dynamic Classifier [2]

On horizontal ball mills, the classifier can be either close-coupled to the mill discharge or
mounted from the above elevation floor and connected to the mill discharge through a short
transition pipe.

The dynamic classifier rotor design is similar to a radial flow fan. The rotor consists of a central
conical hub that is encircled by a ring of vertically-mounted, evenly spaced blades. The blades
are held in place by several stabilizing rings and a lower-support ring. The support ring is
directly attached to the conical hub. Each stabilizing ring is attached to the hub by spokes. The
rotor and stationary vane ring are manufactured from abrasion-resistant steel plate. After
fabrication, the rotor is dynamically balanced.

The rotor assembly is bolted to the lower end of the main drive shaft. The drive shaft is hollow to
provide a central passage for the coal feed pipe. The shaft is constructed from forged steel and is
supported by a pair of anti-friction roller bearings.

The bearing housings are designed with multiple fittings for periodic grease lubrication.
Labyrinth seals retain grease in the bearing housings, and pressurized seal air is introduced into
the bearing housing cavities in order to protect the bearing from coal dust contamination.
Thermocouples or resistance temperature detectors (RTDs) are supplied for the temperature
monitoring of each bearing.

6-25
Technical Description – Foster Wheeler

The bearing and shaft assembly is a modular unit. The rotor is driven by an ac, inverter-duty
motor. The motor is connected to the rotor by a set of sprockets and a drive belt with teeth. The
motor is bolted to a base on the top of the classifier housing. The drive sprocket is connected to
the motor shaft using a bushing. The driven sprocket is bolted to the top of the rotor shaft and
supports a labyrinth seal. The labyrinth seal seals the annular space between the coal feed pipe
and the rotor shaft. Surrounding the rotor is a ring of fixed, static vanes. The vanes direct the air
and coal particles into the classification zone between the static vanes and the rotor. The lower
end of the static vane ring is attached to a reject cone that directs rejected material back to the
coal conveyor.

The cylindrical classifier housing is constructed from carbon steel plate and is fitted with an
ellipsoidal-shaped roof. The roof has a flanged opening for the installation of the rotor, shaft, and
bearing assembly. All major sub-assemblies are flanged and piloted for ease of assembly and
maintenance. The drive bearings and shaft assembly can be removed without removing the rotor
when servicing of the bearings is required.

The operation of the dynamic classifier starts as the pulverized coal/air mixture enters the
classifier and flows through the annulus between the outer periphery of the classifier static vane
ring and the outer housing. The mixture passes through the ring of fixed vanes and is directed
into the rotor. Here, the coal particles are segregated by size as the rotor imparts an outward
force proportional to the rotor speed. The higher the rotor speed, the finer the outgoing coal
particle fineness.

Heavier or larger coal particles that cannot accelerate through the rotor lose their speed and are
returned to the coal conveyor by the reject cone and the hopper assembly. When the weight of
the rejects in each hopper is sufficient, the hopper swing flap opens, and the rejected material is
directed to the coal conveyor entering the mill drum.

The speed of the rotor is controlled by a variable-speed drive motor. The motor can be set to vary
automatically as a function of coal flow or airflow. The typical speed range of the rotor is
between 75 and 150 rpm. As the rotor speed increases, a larger quantity of coal particles is
rejected to the conveyor for further size reduction. The overall higher separation efficiency of the
dynamic classifier means that a lower percentage of large particles are discharged by the mill,
and a lower percentage of small particles are retained in the mill.

The small coal particles exit the mill by passing through the discharge divider and into each coal
pipe by coal distribution vanes. The vanes are made of abrasion-resistant steel. The vanes are
independent from one another, manually adjusted, and locked into position.

6-26
 Technical Description – Foster Wheeler

6.8 Exhausters

An exhauster diagram is shown in Figure 6-26.

Figure 6-26
Exhauster Diagram [5]

The exhauster assembly contains a housing fan (spider) and a motor to drive the fan. Exhauster
fans and wear liners in the housing can be replaced if necessary. Figure 6-27 shows the exhauster
spider.

6-27
Technical Description – Foster Wheeler

Figure 6-27
Exhauster Spider [2]

6.9 Lubrication Systems

There are two lubrication systems for the Foster Wheeler ball mill. The first system is called the
Cardwell lubrication system and supplies oil and starting lifting hydraulic pressure to the
trunnion bearings. The second system is the Farval lubrication system and supplies oil to the
pinion and bull gear that turns the drum.

6.9.1 Cardwell Lubrication System

The Cardwell lubrication system for the trunnion bearing consists of a main oil reservoir with an
80-gallon capacity, an auxiliary oil reservoir with a 25-gallon capacity, a low-pressure pump, a
high-pressure pump, strainers, filters, relief valves, and interconnecting tubing.

The low-pressure pump feeds both trunnion bearings and the high-pressure pump and supplies
oil for lubrication of the bearings. The high-pressure pump is a hydraulic lift pump used to lift
the trunnions off the bearings during start up.

Figure 6-28 shows the Cardwell lubrication system.

6-28
 Technical Description – Foster Wheeler

Figure 6-28
Cardwell Lubrication System [5]

The low-pressure pump, the high-pressure pump, and the mills are interlocked in a starting
sequence.

6-29
Technical Description – Foster Wheeler

An integral control system monitors the output of the oil pump and switches to the standby pump
if necessary. Isolation valves allow for the replacement of pumps and filters without shutting
down the system. Integration of the lubrication system and plant controls ensures that:
• The trunnions are lifted before the mill is started.
• The lubricating mode is changed when the mill starts.
• The mill will trip if the lubrication system fails.

6.9.2 Farval Lubrication System

The Farval lubrication system provides lubrication to the gear system that turns the mill. It is
controlled by a system timer that is interlocked to the mill motor switchgear breaker. Figure 6-29
shows the Farval lubrication system.

Figure 6-29
Farval Lubrication System [5]

6-30
 Technical Description – Foster Wheeler

The time clock starts each cycle of lubrication by energizing a solenoid-operated, air-control
valve on the air-control panel. A pre-set air pressure of 40 psi is applied to the air-operated
pumping unit that delivers lubricant from the supply drum to the spray valve panel through the
hydraulic reversing valve.

As the lubricant enters one of the two supply lines leading to the dual-line measuring valves, the
measuring pistons force a predetermined quantity of lubricant through the valve discharge lines
to the spray control valves and nozzles. Here, the air stream atomizes the lubricant and blows it
onto the gear surface. The air supply pressure to the spray valve is set at 80 psi.

After all measuring valves have discharged the predetermined quantity of lubricant, the pressure
flows through one of the two return lines to actuate the pistons at the hydraulic reversing valve
and shuts down the system. The movement of flow-directing pistons in the reversing valve
automatically relieves the pressure in the line that was last pressurized and sets up the proper
porting to direct lubricant to the opposite supply line when the time clock starts the next cycle.

The lubricator may be hand-tripped by loosening the thumb nut on the spraying cycle control
dial until it is loose on the shaft and then turning the star wheel clockwise.

6-31
7
TECHNICAL DESCRIPTION – KENNEDY VAN SAUN

The Kennedy Van Saun mills for the Kendal Power Station of Eskom in South Africa consist of
30 air-swept ball mills. The mills are 15 ft, 5 in. in diameter and 22 ft, 1 in. in length from flange
to flange. The mill speed is 14.88 rpm. The mill motor supplies power for each mill and the
power requirement is 1.85 MW.

Figure 7-1 shows the Kennedy Van Saun mill system.

7-1
Technical Description – Kennedy Van Saun

Figure 7-1
Kennedy Van Saun Mill System
(Courtesy of Kendal Power Station)

The Kennedy Van Saun mill components are shown in Figure 7-2.

7-2
 Technical Description – Kennedy Van Saun

Figure 7-2
Kennedy Van Saun Mill Components
(Courtesy of Kendal Power Station)

The following are components of the mills:

• Feeder discharge boxes made of welded steel fabrication with ceramic lining on the
discharge side and chrome-iron lining on the feed plate.
• Trunnion sleeve made of chrome-moly steel with helical flights.
• Ball charge hopper made of fabricated steel.
• Gear reducer consisting of a single-stage reduction helical gear.
• Falk Steel flex couplings for low speed and high speed.
• Gear reducer and bearing-forced lubrication system – The lubrication system is located on
top of the steel oil tank. Oil is circulated under pressure by a gear pump and driven by a 4-kw
motor at 1450 rpm. Oil is drawn from the oil tank by the pump and is fed to a dual-basket oil
filter. The oil is then passed to a tube oil cooler. The oil is conveyed through piping to the
mill drive reducer gear case and drive pinion bearings. The reducer gear case has an internal
oil distributor.

The lubrication system includes three pressure relief valves for bypassing the filters and the
cooler and to acts as a pressure regulator. Pressure switches, thermometers, flow indicators,

7-3
Technical Description – Kennedy Van Saun

pressure gauges, and thermostats are used for system control and monitoring. Sensor
switches activate alarms in the event of malfunction or failure.
• Ring gear and lubrication system – The lubrication system is an air-operated, automatic gear
spray system. Supplied at a constant pressure, air is filtered, regulated, and lubricated. The air
then passes through a solenoid valve that is energized from an electrical switchboard timer.
The air operates a 40:1 ratio pump that delivers grease from either a 50- or 180-kg standard
grease container to a progressive single-line distributor. The grease then goes to the spray
nozzles where the grease is air atomized and sprayed onto the pressure side of the gear teeth.
The system continues to operate until a pre-selected number of operating cycles is completed.

An alarm system provides visual and audible alarms on low air pressure, high pressure in the
nozzle line, and excessive pumping time. Under alarm conditions, the electrical switchboard
will automatically shut down the lubrication system. If the condition is not corrected, the ball
mill will automatically be shut down.
• Barring (or rotating) gear – The barring gear is driven by the mill motor and produces a
barring speed of 0.15 rpm. The barring gear system consists of a worm reducer driven by a
18.5-kW, 1460-rpm motor. A 203-mm diameter magnetic brake and brake drum is fitted
between the motor and reducer. A gear-type coupling is fitted between the worm reducer
low-speed shaft and one end of a double-ended electric motor shaft.
• Ball charge – An initial ball charge for each mill consists of 124,989-kg of high-carbon, heat-
treated, forged steel balls with a nominal Brinell hardness of 600, composed of 60-mm, 50-
mm, 40-mm, and 30-mm balls.
• Twin cone classifiers – The classifiers are made of all welded steel plate construction. The
classifiers consist of a manually operated vane set, an inlet and outlet connection, two
inspection ports, an inner and outer cone, a set of deflector vanes, a conical-shaped top with
four 203-mm. inspection ports, ceramic tiles on the high-wear surfaces, and a reject line. The
reject line has a cut-off gate and lining in the sloped area going to the mill feed box.
• Silencer housing – The housing consists of a steel angle frame, 3-mm cover sheets, insulation
to meet 85 db(a) specification, an access door, and an inspection hole with cover.
• Piping ducts – The piping ducts consist of ducts from the feeder outlet valves to the mill feed
connections, from the mill discharge connections to the classifier inlet connections, and from
the classifier reject connections to the feed box reject return connections.
• Ball charge hopper – The ball charge hopper is supplied with an isolation valve and chute
from the hopper to the mill feed/discharge box.
• Mill bypass damper assemblies.
• Seal air fans – The seal air fans deliver 5.29-m3/second airflow at 38°C at an elevation of
1615 m. The design discharge pressure is 12.93 kPa, and the suction pressure is -0.25 kPa.
The air fans include an inlet silencer with a filter, a 120-Mw motor, acoustic dampening to
achieve 85 db at a 3-m sound power level, gear-type coupling, and ductwork from the seal air
fan to the various mill components.

7-4
8
TECHNICAL DESCRIPTION – RILEY POWER INC.

Riley Power Inc. is part of the Service Business Unit of Babcock Power Inc. Riley Power Inc.
was previously called the Riley-Stoker Corporation.

This section covers a general description, components, systems, and modifications for the Riley
Power ball/tube mill.

8.1 General Description

The Riley Power ball/tube mill [7–9] is a cylindrical, low-speed grinding mill designed for high-
capacity grinding of coals ranging from anthracites to low-rank sub-bituminous and lignites.
Grinding capacities range from 20,000–300,000 lbs of coal per hour.

The Riley Power mill systems that are currently offered are gear-driven, double-feed, and
double-discharge systems. There are also chain-driven units in service. The ball/tube mill is
characterized by the size of the rotating drum, specifically the inside diameter and the length.
The mill consists of a steel barrel lined with cast alloy liners, partially filled with hardened steel
balls.

Coal, mixed with heated primary air, enters each end of the mill from a crusher-dryer or directly
from a feeder. With a crusher-dryer, the size of the steel balls is smaller than a mill without a
crusher-dryer. Figure 8-1 shows a typical Riley Power chain-driven ball/tube mill system.

8-1
Technical Description – Riley Power Inc.

Figure 8-1
Riley Power Chain-Driven Ball/Tube Mill System [7]

Figure 8-2 shows the outline of the ball/tube mill system with trunnion bearings and gear drive.

8-2
 Technical Description – Riley Power Inc.

Figure 8-2
Riley Power Gear-Driven Ball/Tube Mill System [8]

Coal flows from the feeders to the crusher-dryers, which are installed at the inlets to the mill, the
crusher-dryer performs the primary crushing process. Hot primary air is introduced in the
crusher-dryer and evaporates most of the surface moisture in the coal. A reduction in the coal
size in the crusher-dryers results in lowering the power requirements of the mill.

Primary air conveys the coal from the crusher-dryer to the mill drum. Pre-crushed and partially
dried coal and preheated air (primary air reduced in temperature after going through the crusher-
dryer) enters the rotating drum through the mill inlet box located at each end of the drum. The
mill drum is connected to the mill inlet/outlet boxes by pressurized air seals. As the mill rotates,
the balls and coal are lifted by the corrugated shape of the liners. The balls and coal then cascade
down the drum and pulverize the coal by impact and attrition.

The pulverized coal and primary air leave the drum through the outlet box, and the coal goes to
the external centrifugal classifiers. Fine coal particles exit the classifier through the shutoff
valves into the coal piping for transport to the boiler burners. Classifier rejects are returned to the
mill for further grinding through the coarse particle return pipe. The classifiers reduce
overgrinding and control the coal fineness.

8-3
Technical Description – Riley Power Inc.

The rotating drum is driven by the mill motor, speed reducer gearbox, air clutch reducer, and
chain drive assembly or pinion/ring gear set. The rotating drum is supported by two spherical
roller bearings or by two oil film trunnion bearings.

Temperature detectors are installed on all bearings associated with the mill system. These
temperature detector readings, the load cell readings from the thrust roller assembly, the clutch
air pressure, and the oil pressures are all monitored by the mill alarm system for safe operation of
the mill.

In order to grind and deliver the coal efficiently, the amount of coal in the mill must be
accurately controlled, which is accomplished by the Power-Sonic mill conditioning system. This
system uses a measurement of the noise made by the grinding process, sensed by a microphone
located on the mill silencer housing, and a measurement of the mill motor power to generate a
signal proportional to raw coal demand. This signal and a feed-forward signal from the
combustion controls determine the feeder speed.

The chain-driven ball mill is supplied with 24 temperature detectors. Nineteen temperature
detectors are located on the mill drive bearings, four are on the speed reducer, and one is in the
chain oil bath.

Some characteristics of this type of mill are:

• The grinding balls can be replaced while the mill is in service.
• Mill liners require replacement up to a 10-year interval, depending on fuel abrasiveness.
• Each mill end has a feeder and crusher-dryer set that may be taken out of service without
taking the mill out of service.
• Coal fineness of 99% or higher through 50-mesh screen and 80% or higher through 200-
mesh screen can be achieved.

The mill is completely enclosed in a sound insulation housing in order to reduce the noise of mill
operation. Access doors are provided on both sides of the housing for maintenance access.

8.2 System Components

The Riley Power ball/tube mill system consists of the following components:
• Feeder
• Crusher-dryer
• Rotating drum/barrel
• Grinding balls
• Classifier
• Shutoff valve

8-4
 Technical Description – Riley Power Inc.

• Speed reducer gearbox

• Clutch
• Chain drive

8.2.1 Feeder

The feeder supplied for the Riley ball mills can be a gravimetric or volumetric feeder. A Riley
Power drum-type volumetric feeder is shown in Figure 8-3.

Figure 8-3
Drum-Type Feeder [9]

The feeder consists of the following components:

• Rotating drum
• Adjustable leveling apron
• Apron liner
• Wiper blade
• Shearing pin device
• Seal air connections
• Feeder housing

8-5
Technical Description – Riley Power Inc.

• Speed reducer
• Isolation gate valve with manually operated handwheel

The feeder has a housing that contains a rotating feed drum that delivers a measured amount of
coal to the crusher-dryer and is designed with eight longitudinal arc-shaped pockets. This drum
is fabricated from an alloy metal that is non-magnetic and corrosion resistant.

An adjustable leveling apron covers the discharge side of the drum to level the coal in the
pockets and to ensure uniform delivery with each drum revolution. A spring attached to the
apron shaft allows the leveling apron to swing out and pass larger objects or foreign materials.

An adjustable apron liner at the rear of the drum acts as a seal to prevent fine coal particles from
leaking down behind the drum. Below and behind the drum is a revolving wiper that is
synchronized with the drum to clear the drum pockets of remaining coal. Through gearing, the
wiper is timed to clean each drum pocket with each revolution of the drum.

A shearing pin device is provided to prevent damage to the feeder and drive mechanism when
foreign objects jam or obstruct the drum. A variable speed motor is used to drive the feeder.
Speed changes may be accomplished manually or automatically by the control mechanism.

The feeder is pressurized from the primary air system. When a feeder is pressurized, sealing air
is provided to prevent infiltration of coal dust into the shaft bearings.

8.2.2 Crusher-Dryer

The crusher-dryer is designed to feed partially dried, granulated coal and primary air to the mill.
The crusher-dryer is a pressurized, constant-speed, swing hammer-type coal crusher that operates
with hot primary air for drying the coal. There are typically two crusher-dryers supplied for each
mill. A crusher-dryer is shown in Figure 8-4.

Figure 8-4
Crusher-Dryer [9]

8-6
 Technical Description – Riley Power Inc.

The crusher-dryer is mounted on a base plate and is driven by a constant-speed induction motor
through a self-aligning coupling. The shaft is supported by double-row roller bearings. Forced-
feed lubrication is provided to maintain a low bearing temperature.

Raw coal and preheated air enter the hammer circle where the coal is crushed by impact between
the hammers and breaker plate. The crusher section is equipped with six rotors that have evenly
spaced hammers mounted on each rotor. Each hammer is cast and secured to the rotor disc with a
pin. An adjustable crusher block assembly is located below the breaker plate to allow in-service
adjustments to maintain crushing efficiency.

The lubrication system consists of two oil pumps, a cartridge filter, a gravity oiler, an oil bath air
filter, a check valve, a needle valve, a pressure gauge, and an overflow sight glass.

The crusher-dryer is equipped with an air seal connection mounted on each side of the crusher-
dryer where the shaft enters the housing. The purpose of the air seal arrangement is to prevent
coal/air leakage from the crusher-dryer. Seal air requirements to each connection are
approximately 30 scfm per seal or 60 scfm per crusher-dryer at a pressure of 10 in. water gauge
above the static pressure existing at the crusher-dryer inlet. A 2-in. pipe connection is provided at
each seal for the seal air piping.

The normal inlet air temperature for the crusher-dryer is between 450°F and 700°F with a
maximum air temperature of 900°F. The rotational speed of the crusher-dryer is 900 or 1200 rpm
depending on the size.

8.2.3 Rotating Drum or Barrel

The rotating drum or barrel contains the coal and balls that grind the coal. The drum is a
cylindrical steel barrel with welded steel heads and integral steel roller tires or large trunnion
bearings on each end of the mill barrel. At the ends of the barrel are welded boxes through which
the coal/air mixture passes into the mill barrel and out of the mill barrel. The mill barrel is
connected to these inlet/outlet boxes by a set of lubricated air seals at each end of the mill barrel.
Seal airflow behind the seal prevents any coal/air mixture leakage from the seal into the plant.

For the chain-driven ball/tube mills, the roller tires rotate on trunnion support rollers and support
the mill barrel. The support roller assemblies consist of a pedestal base, a support assembly,
bearing housing, and roller. There are four assemblies on each mill.

The thrust roller assembly is used to hold the mill drum or barrel in place axially. The drive end
of the drum is positioned between the thrust rollers to restrict the axial movement of the mill
during operation. The clearance between the sides of the mill barrel and the two thrust rollers
should be 0.010 in. ± 0.005 in.

A load cell (strain gauge) is connected to the roller assembly and wired to the mill alarm system.
The load cell monitors any excessive load put on the thrust roller assembly that could move the
barrel. Detection of excessive barrel movement by the load cell activates an alarm. Limit

8-7
Technical Description – Riley Power Inc.

switches are positioned on the thrust roller assembly. They are connected to the alarm and trip
the circuitry whenever a severe radial movement of the barrel is detected.

A multi-strand roller chain is used to rotate the barrel. The assembly consists of a sprocket
assembly on the outside of the barrel, a drive sprocket on the drive shaft, and an idler sprocket
for chain adjustment. The drive shaft and idler shaft are supported by pillow block bearing
assemblies. The roller chain is lubricated by an oil bath system.

For the gear-driven ball/tube mills, a single helical gearing is used for the drive arrangement. A
high-speed induction motor and speed reducer supply the power. A direct-drive, low-speed
synchronous motor and coupling may be furnished.

Trunnion bearings are the ball-and-socket type, have easily removable babbitted bearing sockets,
and are water cooled.

A high-pressure, motor-driven oil pump is provided for each main bearing to float the mill
trunnions on the bearing surfaces before the start-up cycle. Oil is continually circulated to the
bearings when the mill is operating.

The ring gear assembly is equipped with an automatic spray lubrication system.

The mill barrel is shown in Figure 8-5.

Figure 8-5
Mill with Pinion/Ring Gear Drive Set [9]

8.2.4 Grinding Ball Makeup

Riley Power Inc. recommends specific ball sizes and ratios of each ball size for ball/tube mills
with and without crusher-dryers.

8-8
 Technical Description – Riley Power Inc.

The ball-charging hopper enables makeup ball charges to be added to the mill during operation
and without mill service interruption. Balls may be added to an operating mill by closing the
hopper outlet valve on the ball charging hopper and filling the hopper with balls. The cover
should then be latched securely in place and the stop valve opened to allow the balls to enter the
mill. This procedure is then repeated until the required addition to the ball charge is complete.

8.2.5 Classifier

The classifiers for the Riley Power ball/tube mills can be static or dynamic.

8.2.5.1 Static Classifier

The static centrifugal classifier ensures that the coal is accurately sized, uniformly mixed, and
evenly distributed to all boiler burners in service. Oversized coal particles are returned to the
mill. Thermocouples are installed to monitor classifier exit temperatures.

The static centrifugal classifier consists of an outer cone, an inner cone equipped with adjustable
vanes, a segmented discharge cylinder, and a coarse return pipe with an integral trickle valve.
The trickle valve is a self-closing door mechanism that allows the return of oversized coal
particles to the mill inlet while preventing the backflow of primary air.

A mixture of primary air and pulverized coal enters the bottom of the classifier between the inner
and outer cones where a rotational spin is imparted to the mixture by fixed vanes. At the top of
the inlet section of the classifier, the mixture swings around and enters the inner cone through the
adjustable control vanes. Classifier discharge fineness can be altered by adjustment of these
control vanes. The forced rotation of the mixture into the discharge chamber provides substantial
uniformity in particle fineness and density leaving the classifier.

In the inner chamber, the oversized particles fall downward into the coarse return pipe leading
back to the mill. When the accumulation in the coarse return pipe becomes heavy enough, the
counterbalanced door opens to permit the contents to be discharged against the existing pressure
differential and into the mill inlet for regrinding.

The efficient classification of coal size is accomplished by the swirling effects imparted on the
coal/air mixture within the centrifugal classifier.

The static classifier is shown in Figure 8-6.

8-9
Technical Description – Riley Power Inc.

Figure 8-6
Static Classifier [7]

8.2.5.2 Dynamic Classifier

To achieve better coal fineness and increase mill capacity, a dynamic classifier is an option. The
Riley Power dynamic classifier for ball/tube mills consists of a set of stationary vanes and a set
of rotating vanes (cage) located within the stationary set. The rotating cage is driven by a
variable-speed drive motor. Adjusting the speed of the rotating cage can change the intensity of
the centrifugal force field to achieve fineness control and high efficiency of classification. For
the mill equipped with a dynamic classifier, zero residue on a 50-mesh screen can be obtained at
a fineness of 80% passing through a 200-mesh screen.

8.2.6 Shutoff Valves

Isolating the mill from the burner is done by the coal shutoff valves that are designed to be
installed in each coal supply line to the burners of a pulverized coal-fired furnace. These valves
can be equipped with remote operating devices, either pneumatic cylinders or electric motors,
that receive signals to open or close the valves from the burner management system.

The coal shutoff valve is installed in the vertical run of coal piping just above the classifier outlet
so when closed, the coal/airflow is completely stopped.

8.2.7 Speed Reducer Gearbox

The speed reducer gearbox between the mill and the mill motor is shown in Figure 8-7.

8-10
 Technical Description – Riley Power Inc.

Figure 8-7
Speed Reducer Gearbox [7]

The Food Machinery Corporation Link-Belt parallel-shaft speed reducer uses helical gears that
experience a lateral thrust on each shaft. The parallel-shaft reducer can be a single-, double-, or
triple-gear reducer. Adjustments made with shims enable the use of ball and roller bearings at the
bearing retainers. The intermediate- and high-speed shaft bearings are adjusted correctly when
they have 0.005–0.015-in. of lateral play.

The speed reducer is equipped with an oil bath lubrication system. The oil bath system for the
speed reducer and the chain case has individual pumps driven by the same motor. The clutch is

8-11
Technical Description – Riley Power Inc.

air-actuated from the plant air supply system. The air is introduced through the rotorseal into the
unused end of the reducer output shaft.

8.2.8 Clutch

The neoprene rubber and cord actuating tube is contained within a steel rim that is drilled for
mounting to the driving component. As air pressure is applied to the air-actuating tube, the tube
inflates, forcing the friction shoe assemblies uniformly against the drum that is attached to the
driven component. The friction shoe assemblies consist of friction blocks attached to aluminum
backing plates and are guided by torque bars that are secured to side plates. As actuating air is
exhausted, release springs and centrifugal force ensure positive engagement. The torque flow is
from the driving shaft, through the element mounting component, through the rim/side plate
structure, through the torque bars to the backing plates and friction material, where the torque is
transmitted, and through the friction couple to the components mounted on the driven shaft
(clutch drum and drum mounting component). The air-actuating tube automatically compensates
for friction shoe wear, eliminating the need for adjustment. Centrifugal force and release springs
ensure total disengagement of the friction shoes from the drum at the moment the air is expelled.
Power is transmitted from the friction shoes through the torque bars to the side plates of the
assembly. The maximum recommended air pressure is 150 psi. The clutch assembly is shown in
Figure 8-8.

8-12
 Technical Description – Riley Power Inc.

Figure 8-8
Clutch Assembly [7]

The clutch carrier is mounted on the reducer shaft that has a drilled air passage for supplying air
to the clutch. The clutch drum hub is mounted on the ball mill drive sprocket shaft. Bore
diameters are machined to provide a standard interference fit when installed on the shafts. The
interference is a maximum of 0.0005 in. for each inch of shaft diameter.

8-13
Technical Description – Riley Power Inc.

Plant-supplied compressed air is passed through an air amplifier system to the air receiver and
distributed under flow control conditions to the clutch arrangement. The air amplifier system
consists of the following items:
• Air amplifier
• Solenoid air valve
• Flow control valve
• Flow switch
• Relief valve
• Pressure gauge
• Filter
• Regulator with gauge
• Check valve
• Air cock
• Gate valve
• Oil pump and filter with cooler set
• Oil pump motor
• Two hydraulic pumps
• Sight glasses
• Heat exchanger for the reducer
• Heat exchanger for the chain reservoir
• Strainer
• Valve
• Pressure gauge
• Needle valve
• Gate valve
• Pressure switch

The rotorseal is a positive seal for introducing air under pressure into a rotating shaft. The
rotorseal operates continuously or intermittently at high speeds in either direction. It is flange
mounted to the machinery shaft or assembly. The rotating seal of the rotorseal is established by a
lapped surface on the rotating carbon seal that is held against the lapped surface of the stationary
shaft by spring pressure. The high-quality lapped finish of the contacting surfaces and the
applied contact pressure ensure a good seal from the stationary member to the rotating member.
Air can pass through the bore of the stationary shaft and through the bore of the rotating seal into
the clutch assembly. Figure 8-9 shows the rotorseal.

8-14
 Technical Description – Riley Power Inc.

Figure 8-9
Rotorseal [7]

An air control system for the clutch is shown in Figure 8-10.

Figure 8-10
Clutch Air Control System [7]

8.3 Systems

The following systems are used in the Riley Power ball/tube mill:
• Primary air system
• Seal air system

8.3.1 Primary Air System

The primary air system consists of ductwork and dampers from primary air fans and air
preheaters. The function of a primary air system is to convey the coal at a desired temperature to
the boiler burners. This is accomplished by the position of various dampers for the control of the
temperature, flow, and air velocity.

In a cold primary air system, air from the atmosphere is moved by the primary air fan to a
tempering air header, through the air preheater, and then to the hot air duct.

In a hot primary air system, the primary air fan receives tempering air from the cold air duct and
hot primary air from the secondary air ducts. The temperature of the coal/air mixture at the
classifier outlet is maintained at the desired value by the movement of the tempering air dampers
and the hot air dampers. Both dampers are butterfly-type dampers and are used for their tight
closing feature.

8-15
Technical Description – Riley Power Inc.

When the supplied coal is very wet and the action of the tempering air damper and hot air
damper is not sufficient to maintain the required classifier exit temperature, the bypass damper is
used. The bypass damper allows a portion of the primary air to go around the mill and to enter
back into the classifier discharge.

The flow of coal from the mill to the boiler burners is controlled by modulation of the rating
damper.

8.3.2 Seal Air System

The coal dust is contained within the mill system by automatic modulation of the seal air
dampers. The seal air fans take suction from the tempering air duct, through an inlet filter box,
and then deliver the suction to the seal air header. Each mill system has its own seal air
differential pressure controller. This controller maintains a constant differential between the
pressure in the seal air header and the pressure at the mill inlet. If seal air pressure is lost, the mill
will trip.

The sealing air system prevents coal dust leakage into and from the components of the ball/tube
mill system by providing a positive flow of sealing air. Seal air is provided to the feeder, the
feeder discharge isolation gate, and the crusher-dryer in order to prevent coal dust from
damaging bearings and other rotating parts outside the coal stream. It also maintains a seal at the
mill trunnion air seals (connection of mill barrel to inlet/outlet boxes), which prevents coal dust
leakage into the plant’s environment.

Seal air is forced from the discharge side through a transformation section, into the connecting
pipe section, and to the discharge header. Air from the discharge header flows to the main
distribution branches and then to each individual piece of equipment. Each branch section of the
air distribution system is designed on the basis of the specific seal air requirements of the
equipment. A solenoid-operated butterfly valve is located before each mill sub-system and
modulates in response to the mill differential pressure.

The seal air fan is typically provided by Buffalo Forge Company. The fan has a flanged inlet and
outlet, independent pedestals with sole plates, variable-inlet vanes, an inlet screen, a housing
split for wheel removal, sleeve bearings, outlet dampers, a housing drain and access door,
bearing thermocouples, bearing seals, and a coupling guard.

The seal air fans are generally located adjacent to the ball/tube mill system for accessibility.
These single-width, single-inlet fans have a cleanout door that includes both a housing drawer
and a coupling guard.

The seal air fan is a booster fan that draws air from the tempering air duct, through the filter box,
and supplies the required seal air to the various pieces of equipment. One fan is necessary to
meet operating requirements. The second fan serves as a 100% backup unit.

8-16
 Technical Description – Riley Power Inc.

8.4 Modifications

Riley Power Inc. has introduced several modifications [8] to the ball/tube mill. The
modifications covered in this section are the trickle valve addition, trunnion air seal re-design,
the mill conditioning system upgrade, the hydrodynamic slide shoe bearing conversion, and the
crusher-dryer crusher block.

8.4.1 Trickle Valve Addition

The addition of a trickle valve is used in the classifying process. In order for the classifying
process to operate successfully, a smooth flow of coal particle rejects should occur from the
classifier back to the drum. Also, the primary air should not flow from the mill to the classifier
through the reject line. A trickle valve is similar to a check valve and is installed to keep the flow
of rejected coal particles and air flowing in one direction, from the classifier to the drum. The
valve opens as the rejected coal pressure increases above the primary air pressure from the mill.
In general, the valve moves continuously from the open and closed position during normal
operation.

The actual rejects flow rate is dependent upon coal properties and primary air pressure changes
during operation. A new design trickle valve with an adjustable counterweight controls the
rejects level above the valve for various operating conditions. The new trickle valve design
consists of the valve housing with flanged connections to the rejects pipe, a valve plate, a valve
shaft with an external indicator, shaft support bearings, and an adjustable counterweight. The
new trickle valve design is shown in Figure 8-11.

8-17
Technical Description – Riley Power Inc.

Figure 8-11
New Trickle Valve Design [8]

8.4.2 Trunnion Air Seal Redesign

Pressurized air seals are needed between the rotating mill and the mill inlet/outlet boxes. These
seals prevent leakage of coal dust or air from the mill. The old seal design was a lip-seal design,
and the new seal design uses a self-tightening pad seal arrangement. The new design seal
improves the seal distribution with an enlarged air chamber, a longer service life, and a higher
tolerance for surface irregularities in the mill head extension. Figure 8-12 shows the old and new
trunnion air seal designs.

8-18
 Technical Description – Riley Power Inc.

Figure 8-12
Trunnion Air Seal Designs [8]

8.4.3 Mill Conditioning System Upgrade

A Riley Power Power-Sonic mill conditioning system was developed in the 1970s to control the
total coal inventory in the mill by using the measurements of two mill variables. One variable is
obtained by comparing the coal inventory to the mill power (kW input) required for the mill
motor to rotate the mill barrel. The second variable is the sonic level (sound) of the steel balls
colliding with each other and with the mill liners. This sonic level is also related to the amount of
coal inventory in the mill.

Riley Power recently upgraded the Power-Sonic mill conditioning system design by adding an
Allen-Bradley programmable logic controller-based system with a control setup display. The
display allows the operator to adjust parameters and setpoints for various applications. The new
design is compatible with a digital control system and capable of peak display and recording.

8.4.4 Hydrodynamic Slide Shoe Bearing Conversion

Merom Generating Station of Hoosier Energy installed a hydrodynamic slide shoe bearing for
the mill drum. The bearing assembly consists of the bearing housing, bearing segments, and an
oil supply. Figure 8-13 shows the hydrodynamic slide shoe bearing.

8-19
Technical Description – Riley Power Inc.

Figure 8-13
Hydrodynamic Slide Shoe Bearing
(Courtesy of Hoosier Energy – Merom Generating Station)

The two identically designed segments are mounted on the bearing seat in the bearing housing.
The bearing shoe is supported on the bearing base through the axial bearing that permits gyratory
movement.

The thrust bearing is hydrodynamically lubricated. The lubricating oil is distributed through
annular grooves in the segments. Figure 8-14 shows the thrust bearing.

8-20
 Technical Description – Riley Power Inc.

Figure 8-14
Thrust Bearing
(Courtesy of Hoosier Energy – Merom Generating Station)

The lubrication system for the bearings consists of a high-pressure pump and motor, a low-
pressure pump and motor, a thrust pump, backup pumps and motors, an oil cooler, a filter, and
associated piping. The high-pressure pump provides the lift for the main shaft at a maximum
pressure of 3000 psi. The low-pressure pumps provide bearing lubrication. Each pump provides
their lubrication at a pressure of 225 psi.

The control system will not allow the mill to start until the pumps have been operational at least
3–5 minutes. After the mill has started, the high-pressure pump will operate for another minute,
and then it will shut down. The low-pressure pump and thrust pump operate continuously with
the mill operating. If insufficient flow is detected, then the backup pumps will begin operation.

8.4.5 Crusher-Dryer Crusher Block

Riley Power Inc. has introduced modifications to the crusher-dryer with a limited float crusher
block. The purpose of the crusher block assembly is to maximize the effect of the swing
hammers in reducing the size of coal passing through the crusher-dryer. As the swing hammers
and crusher block wear during their service life, the adjustable crusher block can be repositioned

8-21
Technical Description – Riley Power Inc.

to maintain the proper gap between the swing hammer tips and block to achieve maximum size
reduction. The original design resulted in excessive float between the adjustment screw and the
crusher block. The excessive float prevented the block from being accurately withdrawn to
maintain the proper gap after impact with the rotating swing hammers. The end result was less
than optimum coal size reduction. The latest design features a modified adjustment mechanism
that substantially reduces crusher block float. This permits the crusher block to be precisely
positioned with respect to the rotating swing hammers. The crusher components provide uniform
wear across the width of the crusher block. Riley Power Inc. conducts regular wear tests to
determine the most wear-resistant materials.

8-22
9
TECHNICAL DESCRIPTION – STEIN INDUSTRIE

This section covers the ball/tube mills found in the Eskom Matimba Power Station, Majuba
Power Station, and the Tutuka Power Station.

The tube milling plant is composed of the following:

• Tube mill bunkers and hoppers
• Coal feeder system
• Tube mill pulverizing system
• Tube mill primary air system
• Tube mill sealing air supply

The following topics are included in this section:

• General description
• Systems

9.1 General Description

The coal pulverizing system is comprised of five identical pressurized tube mill assemblies per
boiler unit. Four tube mills are normally used when the boiler is operated at the maximum
continuous rating. The fifth tube mill is kept in reserve and used when one of the four running
tube mills is taken out of service.

Each tube mill supplies pulverized coal to six burners in the boiler. Each group of six burners is
arranged in a row on the same level, three in the front wall and three in the rear wall. Mill 1
supplies pulverized coal to the bottom row of burners. Each successive row above the bottom
row is supplied by mills 2–5, with mill 5 supplying the top row.

Figure 9-1 shows the arrangement of the Stein Industrie tube mill. A more detailed view of the
Stein Industrie tube mill is shown in Figure 9-2.

9-1
Technical Description – Stein Industrie

Figure 9-1
Stein Industrie Tube Mill
(Courtesy of Majuba Power Station)

9-2
 Technical Description – Stein Industrie

Figure 9-2
Detailed View of the Stein Industrie Tube Mill
(Courtesy of Tutuka Power Station)

9-3
Technical Description – Stein Industrie

Overland conveyors supply graded raw coal to the tube mill bunkers, which stores raw coal to be
used by the tube mill. Each bunker supplies only one tube mill. The conical, steel bunker directs
the coal through two hoppers attached to the bottom of each bunker. Coal is fed by gravity into
two raw-coal feeders that work in conjunction with the bunker and hoppers. Each raw-coal
feeder supplies one end of one tube mill. The amount of coal fed to the tube mill depends on the
unit load. As the unit load increases, the speed of the raw-coal feeders increases, and more coal is
supplied to the tube mill.

Each feeder feeds coal through the coal and primary air mixing box, where it is mixed with
heated primary air. The heated primary air raises the temperature of the coal and dries it, making
the coal easier to pulverize. If the pulverized coal is warm, it will be closer to the coal
combustion temperature.

Hot primary air is taken from the hot air leg of the combustion air system, after the air heater.
The primary air passes through a hot air control damper and into the hot and cold primary air
mixing box. Cold tempering primary air is tapped from the cold air leg of the combustion air
system and passes through the tempering air control damper into the hot and cold primary air
mixing box. The tempering air control damper provides cold air to mix with the hot air to
produce the mill outlet temperature.

The tempered air then passes through a quick-closing isolating damper to the primary air inlet
piping, bypass piping, and purge air piping. The primary air inlet piping is the main inlet into the
tube mill. The primary air conveys the pulverized coal from the mill to the boiler burners. The
bypass piping feeds the primary air into the raw coal and primary air mixing boxes to dry and
raise the temperature of the coal prior to pulverizing. The purge air piping feeds the primary air
to the pulverized coal ductwork after the classifier to maintain a pulverized coal flow of not less
than 20 m/second. The velocity of 20 m/second prevents the pulverized coal from settling in the
ductwork.

The raw coal falls down the raw-coal chute into the mill coal inlet, where the screw conveyor
feeds it into the tube mill. Inside the tube mill, the raw coal mixes with the forged chrome-
molybdenum steel balls (cylpebs). Monobloc liners, attached to the inside of the mill body, lift
the coal and cylpebs when the tube mill is turned. The falling action of the coal and cylpebs
pulverizes the coal. Primary air, fed into both ends of the tube mill, lifts and conveys the
pulverized coal out of the tube mill, through the classifiers, and to the boiler burners.

The tube mill is driven through a girth gear fitted onto its circumference in order to provide the
maximum torque. An electric motor and reduction gearbox provide the main drive to the drive
pinion gear. Slow movement, normally barring or inching, of the tube mill is achieved through
an auxiliary drive system.

Because of the mass of the tube mill (~120 tons), a high degree of friction occurs at its turning
points. To overcome this, oil is pressure-fed to the journal bearings, also known as trunnion
bearings. An oil film is created in which the tube mill journals (trunnions) can turn.

9-4
 Technical Description – Stein Industrie

Cylpebs are added, when required, to maintain the pulverizing efficiency of the tube mill. A ball
feed mechanism, located adjacent to the raw-coal feeders, introduces new cylpebs to enter the
drive end of the tube mill with the raw coal.

Pulverized coal passes from the tube mill to the classifier, which classifies the size of the coal
particles. Heavier coal particles drop out of the pulverized coal stream and return to the tube mill
through the rejects line for finer pulverization. The finer pulverized coal particles continue
through the coal ducts to the boiler burners.

A carbon dioxide fire protection system is incorporated within the tube mill. Carbon dioxide can
be fed into the tube mill to extinguish any fire.

9.2 Systems

This section covers the following systems for the Stein Industrie tube mill:
• Coal inlet system
• Primary air system
• Seal air system
• Lubrication systems
• Drive system
• Blowdown system
• Ball loading system

9.2.1 Coal Inlet System

The coal inlet system from the feeder to the mill is composed of a continuous chain fitted with
flights and moved in an enclosed steel trough. The steel trough has a rectangular cross section.
The chain/scraper conveyor slides along the casing bottom and conveys the coal. The conveyor
is guided around the end station shaft by a non-toothed idler. The reverse run of the chain is
supported by a central guide rail above the coal being conveyed. The coal is extracted from the
bunker by the upper returning chain. The coal then drops to the lower bottom of the adapter
trough. The coal is transported by the lower chain toward the outlet at the terminal end.

The chain is pulled by a rotating toothed wheel. The toothed wheel is driven by a 380-V motor
through a variable-speed gearbox in order to control the coal level in the mill on the coupling
connecting the toothed wheel and the variable-speed gearbox. A shearing pin is fitted to protect
the feeder. If any foreign matter such as steel pieces or rocks enter the feeder chain and wedge
between the flights, the foreign matter will break the shearing pin and not the feeder chain or
flights.

The variable-speed gearbox speed for the feeder can be adjusted manually.

9-5
Technical Description – Stein Industrie

9.2.2 Primary Air System

Primary air is taken from the hot and cold air (tempering air) ducts from the primary air fans.
Each duct is equipped with control dampers that are controlled by the mill outlet temperature
control system. The mill outlet temperature is set from the unit control desk.

After the hot and cold air are mixed, the air goes through the quick-close damper. The ductwork
is then divided into four lines. Two lines go to the drive-end side of the mill and the other two
lines go to the non-drive-end side of the mill.

One line on each side supplies the mill directly with primary air through a control damper. This
damper controls the amount of airflow entering the mill for transporting the pulverized fuel to
the burners. A flow transmitter is installed on these lines to give a flow reading in the unit
control room.

The other two lines are for bypassing the mill. These lines, located on each side of the mill, have
a bypass control damper on each line. This damper controls the amount of air through the coal
pipes and mixing box. A flow transmitter is installed to measure the flow.

Each bypass line is again divided into two lines. One line is for direct connection to the coal
pipes through an isolating damper. The purpose of this bypass air line on the coal pipes is to
maintain the velocity in the coal pipes as constant as possible during load changes. It is also used
for the purging of the coal lines.

The other line is connected to the mixing box through an isolating damper. The purpose of this
line is to dry and increase the coal temperature before it enters the mill.

Figure 9-3 displays the airflow through the mill.

9-6
 Technical Description – Stein Industrie

Figure 9-3
Mill Airflow
(Courtesy of Tutuka Power Station)

9-7
Technical Description – Stein Industrie

9.2.3 Seal Air System

As the pulverized coal is conveyed in an air stream, it tends to leak from the tube mill through
the air gaps between the rotating and stationary parts of the mill. Seal air, at a greater pressure
than the primary air, is used to prevent the coal-laden primary air from escaping and damaging
sensitive equipment and machined surfaces.

Cold air is taken from the tempering air duct and is boosted by a sealing air fan. Therefore, seal
air is at a slightly higher pressure than primary air. Seal air is used to contain the pulverized coal
at the following points:
• Ball feed mechanism delivery tube
• Both hot air box stuffing boxes
• Both conveyor body seal air boxes
• Trunnion
• Girth gear

Seal air is also fed to the hinges of the coal level detector on both raw-coal feeders. The seal air
prevents coal dust from getting into the detector and causing it to jam or stick.

The girth gear surrounding the tube mill is supplied by its own seal air system. The seal air
system prevents coal dust and pulverized coal from getting to the machined surfaces of the girth
gear, the pinion gear, and the lubricating system.

The seal air system is composed of four different lines from the trunnion seal air system and the
girth gear seal air system.

In the trunnion seal air system, the seal air is supplied by the seal air fan that receives air from
the tempering air duct through a hand-isolating damper. Two lines, one for each side of the mill,
ensure a seal between the rotating parts of the mill and the stationary parts.

A control damper controls the seal air pressure. Limit switches are installed to indicate whether
the damper is open or closed.

The seal air pressure will increase or decrease as the pressure inside the mill increases or
decreases. The seal air pressure must be higher than the primary air pressure inside the mill.

Two lines supply seal air upstream of the seal air control damper. One line goes to the coal
feeder to keep the coal detection flaps clean. The other line goes to the ball loading for sealing
purposes.

On the girth gear seal air system, a separate seal air fan is installed at ground level. This fan
receives air through an air filter from the atmosphere. It delivers the air to the girth gear
enclosure to prevent any dirt from entering the gear system. This occurs by pressurizing the
enclosure above atmospheric pressure.

9-8
 Technical Description – Stein Industrie

9.2.4 Lubrication Oil Systems

There are several lubrication systems for this mill. The systems are:
• Turbo lubrication system – The turbo lubrication system is divided into three
compartments: the oil return, preparation, and working oil.
• Low-pressure sprinkle system – The purpose of the low-pressure sprinkle system is to
sprinkle oil on top of the mill bearings and to supply the working oil compartment of the oil
tank with clean oil. The sprinkle oil acts mainly as a cooling medium for the bearings.

The two mill bearings support the mill trunnion and the bearing ball and socket support. If
any of the bearing temperatures reach 80°C, the mill will trip. A warning alarm in the unit
control room will indicate when the bearing temperatures reach 60°C.

The low-pressure oil pump receives oil from the preparation compartment through a suction
filter that is located inside the tank. At the pump discharge, a safety valve is installed that
operates at a pressure of 1 MPa. The oil from the pump discharge returns to the oil return
compartment.

From the pump, the oil flows through an oil/water cooler. A control valve on the water inlet
controls the oil cooler oil outlet temperature in conjunction with the three heaters inside the
oil tank. If the differential pressure increases, the two filters on the low-pressure system can
be changed over manually by a three-way valve.

After the filters, the lines split into two sections, and some of the oil flows through an orifice
at a rate of 40 liters/minute to the working oil compartment of the oil tank. This flow ensures
suction to the high-pressure pump. The rest of the oil flows to the drive-end and non-drive-
end bearings of the mill at a rate of more than 21 liters/minute and is sprayed on top of the
bearings. An alarm will sound in the unit control room if the flow drops to 21 liters/minute.

The maximum oil temperature at the low-pressure pump outlet is 55°C. The minimum oil
temperature for low-pressure pump operation is 20°C. The high alarm oil temperature is set
at 56°C, and the oil heater will stop at 45°C. The low-pressure pump will not start if the oil
temperature is less than 19°C. Figure 9-4 shows the low-pressure lubricating oil system.

9-9
Technical Description – Stein Industrie

Figure 9-4
High- and Low-Pressure Lubricating Oil System
(Courtesy of Tutuka Power Station)

• High-pressure oil system – The high-pressure oil system receives oil from the working oil
compartment of the oil tank. This system consists of three motors and eight pumps. Four of
the pumps supply jacking oil, two pumps supply thrust oil to the mill, and two pumps supply
oil for the ball and socket lubrication. The jacking oil causes the bearings to float and
prevents metal-to-metal contact.

Two jacking oil pumps and one thrust oil pump are driven by one electrical motor for the
drive-end side of the mill. The same arrangement is installed for the non-drive-end side of the
mill with the exception of the thrust oil going only to the drive-end side.

Two ball and socket pumps (positive displacement) are driven by one electrical motor.

The jacking oil is supplied to the drive-end and non-drive-end bearings by four lines. Two
lines go to the drive-end and two lines go to the non-drive-end side bearings. Each of these
lines is equipped with a pressure gauge, a non-return valve, and a safety valve that operates at
8 mPa.

The thrust bearing oil line provides oil to the thrust bearing. The mill girth gear teeth are
fitted at an angle, and when the gear is turned by the motor, a thrust movement occurs toward
the drive end. To counteract this movement, thrust oil is supplied in order to prevent damage
to the mill bearings and seals.

9-10
 Technical Description – Stein Industrie

The oil to the mill thrust bearing is supplied by two lines, each equipped with a pressure
gauge, a non-return valve, and a safety valve. The safety valve operates at 8.9 MPa. This oil
is supplied to the drive-end side only.
The ball and socket oil is supplied to the drive-end and non-drive-end bearings by one motor
and two pumps. Each line is equipped with a pressure gauge, a non-return valve, and a safety
valve. The safety valve operates at 8 MPa.
A sump is installed at the bottom of the drive-end and non-drive-end bearings. From this
sump, the oil flows back to the oil return compartment of the oil tank by gravity. The oil from
the safety valves on the oil lines also drains to the oil return compartment of the oil tank.
• Gearbox oil system – The main speed gearbox oil system uses oil pumped from the gearbox
through a filter back to the gearbox top. The oil then passes over the gears and the lubricating
oil cooler. The lines are composed of two filters, one in service and one on standby.
Each filter is equipped with a differential pressure gauge over the filter with a maximum
difference of 50 kPa. A pressure gauge, temperature gauge, and flow meter are installed in
the line and located after the pump. At the pump, a safety valve is installed that will return
the oil back to the gearbox.
Inside the gearbox, a cooler that is fitted with a control valve on the water outlet line controls
the temperature of the oil. At the gearbox, high- and low-level switches are installed to warn
against high or low oil level.
• Girth gear lubrication system – In the girth gear lubrication system, grease is pumped from
a grease drum by an air-operated pump and is used as a lubricating medium on the girth gear.
Air from the service air range is supplied at a constant pressure through an air filter, a
regulator with a pressure gauge, and an air lubricator to a normal two-three-way solenoid
valve. The solenoid valve is energized by the interval timer, allowing clean oil and air at the
correct pressure to pass to the air-operated grease pump. A separate air line goes to the spray
lance (nozzle) for the atomizing of the grease.
The air-operated grease pump discharges the lubricant through a pressure gauge to the single-
line distributor. From the distributor, the grease is discharged to the five spray nozzles at the
girth gear.
The pump continues to operate until a pre-selected number of operating cycles have been
completed. The number of cycles is determined by a timer in the control box. The timer gets
a signal from a counting switch next to the block. Because there is air flowing through the
nozzles, the lubricant is atomized and delivered onto the girth gear teeth. If this system fails
to operate, an alarm will sound after 10 minutes. The mill will trip after 30 minutes of the
system failure.
• Main motor lubrication system jacking system – The main motor bearings use ring
lubrication. Because the oil rings do not work when the mill is on barring, there is no
lubrication on the bearing. To prevent damage to the bearings, a Hytec lubrication system is
used to ensure sufficient lubrication of the bearings and remove the hot oil from the sumps
for cooling.

9-11
Technical Description – Stein Industrie

Oil is drawn from the tank through a suction filter by two pumps. A bypass is fitted to the
filter in order to allow the oil to bypass the filter when it becomes dirty. A vacuum gauge
fitted before the pump allows monitoring of the suction pressure. This is an indication of the
filter condition.

Pump A discharges the oil through a cooler back to the tank. No cooling water is connected
to the cooler because of low ambient temperature. Pump B discharges the oil to the forced
feed and jacking system.

The forced feed lubrication system is used under normal working conditions. Oil is
discharged by the pump through a discharge filter to the directional control valve. The filter
is supplied with a spring-loaded non-return valve. The valve acts as a bypass in the event of a
blocked filter. In the forced feed mode of operation, the directional control valve is
deenergized.

Oil flows through the directional control valve out of port A and to the mill motor bearings.
A pressure relief valve is located in the bearing supply line to control the oil pressure at
2 MPa. Oil from the bearings returns to the tank by gravity.

The jacking system is used when the mill motor is started or when the mill is on barring. In
this mode of operation, the directional control valve is energized. Oil flows through the
directional control valve out of port B and to the mill motor jacks. The jacks lift the shaft
clear of the bearings.

When the directional control valve is deenergized, the forced feed system is in operation. Oil
expelled from the jacks flows back to the tank through port T of the directional control valve.
A pressure relief valve is located in the oil supply line to the jacks. The relief valve opens at a
pressure of 4 MPa.

Table 9-1 shows the normal operating oil pressure values.

Table 9-1
Normal Lubrication Oil Pressure Values
(Courtesy of Tutuka Power Station)

Lubrication System Parameter Value

Low-pressure System pressure 5–6 Bar or 500–600 kPa

High-pressure Jacking oil pressure 80 Bar or 8 MPa

Ball and socket oil pressure 30 Bar or 3 MPa

Thrust bearing oil pressure 15 Bar or 1.5 MPa

Main motor bearings Suction pressure 0 kPa

Discharge pressure with mill on-line 2 MPa

Discharge pressure with mill off-line 4 MPa

Recirculating oil pressure through cooler 300 kPa

9-12
 Technical Description – Stein Industrie

Table 9-2 shows the mill lubrication systems for the Tutuka Power Station.

Table 9-2
Mill Lubrication Systems
(Courtesy of Tutuka Power Station)

Lubrication Manufacturer Lubricant Lubricant Filtration Bearing

System Type Volume Type

Main David Brown British 445 liters Vokes Rolling

gearbox Model 360X535 Petroleum (E238L/62982) element
CRS (BP) Energol 17 micron
GRXP 150 nominal at
61 liters/minute
Inching Citroën Messian BP Energol 145 liters None Rolling
gearbox GRXP 150 element
Main lube Stein Industrie BP Energol 1315 liters EPE 40 micron All white
oil tank Turbolub HL 460 nominal at metal
17 liters/minute

Mill main Hytec BP Energol 45 liters Hydac 10 micron All white

motor lube THB 32 nominal at metal
oil tank 60 liters/minute

9.2.5 Drive System

The mill drive system consists of a 380-V motor for the barring or inching rotation and a main
drive motor (3.3 kV).

The main mill motor is provided with two tail shafts. At the drive-end side of the mill, the tail-
end shaft is connected to the main speed gearbox. On the other tail-end shaft, the barring motor
is connected by a gearbox. The barring motor is used to drive the mill and the main motor at a
very slow speed when the mill is off-line.

Technical Key Point

Barring is performed when the mill needs to be cooled down. Inching of the mill is
performed during maintenance periods and allows the precise positioning of the
mill drum inspection door.

The gearbox contains a free wheel system that uncouples the low-speed barring gear when the
mill is on-line. A safety device will trip the mill when the free wheel system is not operating
correctly.

The barring motor is provided with an electromagnetic brake. The purpose of the brake is to lock
the mill when barring is stopped at a certain position for maintenance. The shoes of the brake can
be released locally by a padlock lever. The lever position is monitored by limit switches.

9-13
Technical Description – Stein Industrie

9.2.6 Blow-Down System

To prevent the lines and probes from blockage and from a malfunction of the automatic controls,
a blow-down line is installed. Station air is used to clear any blockage of the instruments. The
system works automatically.

When the blow-down system is in operation, the drive-end and then the non-drive-end side
probes will be purged. After 1 hour, the program will start the purge program again.

It is important to know that the mill controls on the side where purging is performed will be
frozen during the purge period on the set point that existed before the purging.

9.2.7 Ball Loading System

Additional grinding media must be introduced into the mill. The wear of the balls depends on the
quality of the coal. Less abrasive coal allows the balls to remain in service for a longer time. The
mill must be loaded with balls whenever the power output decreases.

A square ball container is lifted onto a platform located above the ball loading system. The
loading system consists of a hopper, a quick-opening gate, a lock chamber, and a slow-opening
gate.

When the balls are loaded, the quick-opening gate is opened. The balls are then dropped into the
lock chamber, and the quick-opening gate is closed. The slow-opening gate is then opened so
that the balls drop gently into the mill through the fuel inlet line. The two gates are fitted to
prevent air and coal from blowing into the plant during ball loading.

The feed trunnion includes a screw feeder that drives the balls toward the inside of the mill drum.
The line of the ball loading system consists of pins specifically located in order to reduce the
speed of the falling balls. The mill must be on-line or at least on barring before the ball loading
can be performed.

9-14
10
OPERATION AND SAFETY – ALLIS-CHALMERS

This section (courtesy of Lethabo Power Station) covers the operations and fire protection for the
Allis-Chalmers ball/tube mills.

10.1 Operations

Before starting the mill, the low-pressure trunnion bearing lubrication system is operated to
ensure that the oil temperature has reached 21°C. The high-pressure jacking pump is then started
to raise the oil pressure in order to lift the trunnion clear of the bearing. After the mill has started,
the high-pressure jacking pump stops after 5 minutes, leaving the low-pressure system to provide
lubrication.

When the mill shuts down, the high-pressure pump starts an automatic cycle operation of
5 minutes on and 30 minutes off until the cycle is manually stopped. The cycling operation is
required until the mill shell has cooled to ambient temperature and all mill contractions have
ceased.

If the high-pressure jacking pump fails during a mill shutdown, the manual jacking pump is used.
A suitable operating cycle for the manual jacking pump is a minimum of 60 seconds pumping
every 30 minutes for the period when the high-pressure pump jacking would normally be
operating.

10-1
Operation and Safety – Allis-Chalmers

Table 10-1 lists the tasks for ball replacement.

Table 10-1
Ball Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

1. Barricade the lifting area.

2. Lower the cross beam with the mill ball hoist.

3. Use the cross beam chains to attach the ball drum and ensure tightness.

4. Load the mill ball drum onto the mill ball trolley and unhook the cross beam chains.

5. Pull the trolley to the selected mill ball hopper.

6. Verify the hopper is the correct unit and mill.

7. Open the mill ball hopper top door.

8. Discharge the balls into the hopper.

9. Close the top hopper door.

10. Use the bottom hopper valve spindle to discharge the balls into mill.

11. Close the bottom hopper valve when completed.

12. Remove the trolley and cross beam.

13. Clear the lifting area.

10.2 Fire Protection

If a fire in the mill or classifier occurs, it will be extinguished with carbon dioxide. Centrally
located at the fire fighting station are two mobile trailers. Figure 10-1 shows a mobile gas bottle
unit.

10-2
 Operation and Safety – Allis-Chalmers

Figure 10-1
Mobile Gas Bottle Unit
(Courtesy of Lethabo Power Station)

Each trailer is provided with carbon dioxide gas bottles. One trailer is located at the non-drive
end and the other trailer is located at the drive-end side of the mill. The gas trolleys will be
connected by quick fit couplings to the existing purge pipework on the mills. The existing
shutoff valves at the trolley and the shutoff valves on the purge pipework on the mill are to be
opened. During purging, the carbon dioxide flows out of the bottles through the flexible hose,
into the mill pipework, and into the mill. After purging both trailers, the mill shutoff valves
should be closed, and the carbon dioxide bottles should be refilled.

A permanently installed carbon dioxide fire protection system is shown in Figure 10-2.

10-3
Operation and Safety – Allis-Chalmers

Figure 10-2
Permanently Installed Carbon Dioxide Fire Protection System
(Courtesy of Lethabo Power Station)

10-4
11
OPERATION AND SAFETY – FOSTER WHEELER

The operational and safety aspects for the Foster Wheeler mills [5] include the following topics:
• General operation
• Operation indications
• Startup procedures
• Fire detection system
• Fire protection

11.1 General Operation

The double-ended ball/tube mill [3] can be operated as two mills with each end of the mill
serving a different set of boiler burners. In this way, six single-ended mills can be replaced with
three larger, double-ended mills. The advantage of using fewer mills is compared to the
increased complexity of operating the larger mills.

There are problems in balancing the flow of air and coal from the double-ended mills. The dual
supply and discharge of the coal and air requires a complicated control system to overcome any
imbalance problems. At low load, the instabilities of the coal/airflow can be avoided by shutting
down one side of the mill. The following conditions are possible with a double-ended mill:
• Double-end startup
• Single-end startup
• Single-end operation
• Double-end operation
• Adding double-end operation while operating in single-end operation
• Shutting down double-end operation and operating in single-end operation
• Shutdown of double-end operation
• Shutdown of single-end operation

Because of the many different operating modes, the airflow for each mode must be changed. The
control system dictates damper adjustments for each flow requirement.

11-1
Operation and Safety – Foster Wheeler

The mill operating system [3] can control the:

• Coal flow to the mill
• Air inlet temperature
• Airflow through the mill
• Classifier settings

Technical Key Point

The ideal proportion of the weight of the balls to the weight of the coal is between
six and seven. This means that for every 330 lbs of coal in the mill, there should be
2205 lbs of balls to effectively pulverize the coal. If the proportion of coal in the
mixture is too low, the balls will strike each other and grind against the cylinder. If
the proportion of coal in the mixture is too high, the coal will tend to flow into the
feed scrolls.

The output of coal from the mill is controlled by the airflow through the mill. The airflow
required to transport the coal mixture to the boiler is greater than the airflow required in the
cylinder. Therefore, some of the airflow bypasses the mill. At low load, most of the air bypasses
the mill.

A mill control system varies the rate of coal flow in order to maintain a constant level in the mill.
During startup, the mill sounds very loud as the balls are contacting each other. During full load
operation, the coal level is monitored using differential pressure sensors.

Table 11-1 lists the operating tasks for the shutting down for one side of a mill.

Table 11-1
Shutting Down One Side of a Double-End Mill [3]

Tasks

1. Decrease the coal feed on both ends to below 60%.

2. Stop the drive-end coal feeder.

3. Close the drive-end raw coal gate valve.

4. Set the classifier temperature control to single-end operation.

5. Close the drive-end primary air damper and bypass damper.

6. Close the damper to the drive-end pre-drying chamber.

7. Open the cold purge air damper to the pulverized coal lines.

8. Purge the pulverized coal lines for 10 minutes.

9. Close the purge air damper.

11-2
 Operation and Safety – Foster Wheeler

As the drive-end primary air and bypass air dampers are closed, the flow settings of the
corresponding dampers for the other side of the mill are automatically increased to keep the total
airflow through the mill constant. After shutdown of the drive-end coal feeder, the mill level is
controlled by varying the input of the remaining coal feeder. The control system ensures that
temperatures and transport velocities remain within critical limits.

The operation [2] of the classifier is controlled through a programmable, variable-frequency

drive (VFD) controller. The controller accepts an external 4-20 milliamp (mA) signal for motor
speed control purposes and provides a 4-20 mA motor speed feedback signal. A remote alarm
signal is generated whenever the controller trips and/or is operating outside of the normal
operating parameters. The controller also typically incorporates an override feature to allow for
remote, manual speed control of the classifier. Programming of the controller is lock-out
protected and typically has a self-diagnostic capability while displaying fault causes.

11.2 Operation Indications

For the negative pressure Foster Wheeler ball mill, the temperature of the coal/air mixture
leaving the mill should be 150–160ºF. Temperatures higher than 160ºF could result in a fire in
the mill. Opening the tempering air damper allows cooler air to flow into the mill and reduces the
exiting coal/air temperature.

The coal/air temperature leaving the mill should not be below 140ºF except during startup.
Coal/air temperatures below 140ºF may result in an unstable ignition of the coal and could
require the addition of fuel oil in the boiler. Low coal/air temperatures also mean that the coal is
not being properly dried and may result in plugged coal piping.

Excessive moisture content in the coal will result in the need for a higher classifier differential
for a given steam flow. A higher classifier differential can be obtained by adjusting the exhauster
loading signal bias. Excessive moisture may also cause the fuel level control lines to become
plugged more frequently.

Normal mill and feeder operation, including mill level gauges, mill amperage, and coal/air mix
temperatures, provide a good indication of the coal level in the mill. Variation of the normal
relationship between the high- and low-level lines indicates a problem. The problem is usually
plugged mill level control lines which would need to be blown out.

Foster Wheeler provides a purge system to prevent coal from entering the mill level sensing
lines. This purge system is needed on pressurized mills and may be applicable to mills with
exhausters. Positive pressure operation of the mill during mill swings can cause the sensing lines
to become plugged.

The basic idea for the purge system is to supply air at a slight pressure to each of the sensing
lines in order to prevent the coal from entering the lines. Because the mill level controls are
based on differential pressure, the added air pressure is nullified when measuring the differential
pressure. When properly calibrated, the mill controls read the correct differential pressure.

11-3
Operation and Safety – Foster Wheeler

Differences of 0.5–1 in. between the high- and low-level lines are normal assuming the low level
line is not below 1 in. Mill motor amperage will normally be between 114 and 116 amps.

The shear arm on the feeder table is adjusted to keep the feeders on slow speed approximately
90% of the time. The shear plate arm position is not usually changed. When a mill is operated at
more than one-half load using one feeder, instead of two, the shear plate arm should be adjusted
to a larger opening.

Table 11-2 lists the normal operation checks for the negative pressure Foster Wheeler ball mill.

Table 11-2
Normal Operation Checks [5]

Operational Tasks

1. Check the feeders periodically to see that coal is flowing. When a feeder is off, check to
ensure that coal is not flowing through this feeder, as this would plug the mill with coal.
2. Visually inspect the mill for any coal that is spilling because of loose liner bolts.

3. Visually inspect all lubricated parts.

4. Check to see that the air supply pressure to the Farval pump is approximately 40 psi.
The atomizing air supply should be a minimum of 80 psi.
5. Change the strainer scraper five or six turns each shift to clean the strainer on the
Cardwell lubrication system.

6. Check to see that oil is flowing through the sight glass to the trunnion bearings.

11.3 Startup Procedures

Three tables are listed for the startup procedures for a negative pressure Foster Wheeler ball mill.
Table 11-3 lists the initial preparation tasks, Table 11-4 lists the tasks for charging the mill, and
Table 11-5 lists the tasks for placing the mill in service.

Table 11-3
Initial Mill Preparation for Startup [5]

Operational Tasks

1. In cold weather, energize the strip heaters in the Cardwell tank a few hours before the
mill is to be used.
2. Check the lubrication of the mill gear and pinion, all motor bearings, all exhauster
bearings, and the air tube bearings. Check the oil level in Cardwell reservoir tank.

3. Turn on the cooling water to the mill trunnion bearings.

4. Close the purge damper, the output damper, and the mill hot air shutoff damper.

5. Open the inspection plate at the outside end of the air inlet tube.

11-4
 Operation and Safety – Foster Wheeler

Table 11-3 (continued)

Initial Mill Preparation for Startup [5]

Operational Tasks

6. Purge the mill level control lines. Check the oil level in the Farval barrel.

7. Check the Farval nozzles for spraying.

8. Open the burner-switching valve above the exhauster to be used for charging the mill
and place a 3-in. plug in the coal pipe.

9. Place the burner cleanout plugs in the burner that is used for charging the mill. Set the
feeder shear plates to 50% open.
10. Check all controls for proper settings.

11. Check that the following dampers are closed: mill suction, tempering air damper,
capacity dampers, and exhauster purge dampers.

Table 11-4
Charging the Mill for Startup [5]

Operational Tasks

1. Open the auxiliary air damper cover plates to 35–40% open.

2. Start the exhauster that is selected for startup.

3. Open the purge damper.

4. Open the output damper approximately 20%.

5. Adjust the mill suction to approximately 2 in. of negative water pressure. If the mill
suction is too high, open the auxiliary air damper enough to reduce the suction to the
desired level. If the suction is too low, start closing the auxiliary air damper. If this fails,
start closing the output damper.
6. Start the low-pressure mill lube oil pump, wait 5 seconds, then start the high-pressure
lube oil pump.
7. Start the mill 20 seconds after the high-pressure pump is started.

8. Turn off the high-pressure pump after the mill has reached operating speed.
9. Open the bunker coal gate.

10. Start the feeders.

11. Feed coal to the mill by operating the feeder intermittently 1 minute on and 2 minutes off.
12. NOTE: Be careful not to feed too much raw coal to the mill. The mill will not grind the
coal if it is fed too fast. When the first coal level indication appears, (0.2–0.3 in.),
discontinue operating the feeder until the level stabilizes.

13. If necessary, feed more coal until the low level line shows 1–1.2 in. When the level has
reached this point, as indicated by low level line gauge, the mill may be placed in service

11-5
Operation and Safety – Foster Wheeler

Table 11-5
Placing the Mill in Service [5]

Tasks

1. Close the auxiliary air damper of the exhauster to be placed in service.

2. Open the mill suction control damper about 10%.

3. Check to see that all plug cocks in the coal pipe are closed.

4. Open the burner shutoff valve.

5. Open the hot air shutoff damper wide and hold open until the damper has latched.
6. Readjust the mill suction damper to give 2 in. negative water pressure in the mill.
Place the mill suction damper control on automatic as soon as two burners are in
service on that mill, or as soon as possible thereafter.

7. The output damper must first be closed manually at the output damper control
station.
8. The purge damper is then opened by a control switch.

9. The output damper is then reopened manually approximately 20% at the output
damper control station.
10. The hot air mill suction shutoff damper is then opened by a reset pushbutton.

11. NOTE: The mill suction shutoff damper is tripped closed automatically when both
purge dampers are closed, regardless of how the purge damper closes.
12. The purge damper can be closed with the operation of the respective control
switches and operation is below minimum exhauster differential.
13. NOTE: The operation of dampers is identical for all mills and exhausters. Damper
open means open to fuel flow.
14. Place the feeders on automatic as soon as possible. At least two burners should be
in service on any one mill.
15. Adjust the mill output damper for the desired output and place this damper control
on automatic.
16. Open the auxiliary air damper, as required, to give enough exhauster discharge
pressure to keep the burners from plugging with coal. The minimum exhauster
discharge pressure should be 5 in.

17. Close the inspection plate at the outside end of the mill air inlet tube.

11.4 Fire Detection System

The fire detection system designed by Foster Wheeler is normally set up to detect a spark or
flame in the classifier area. The system is based on the detection of light emissions in the visible
to near infrared spectrum. A standard system contains sensor head assemblies, a junction box at
each mill, an interface enclosure with a power supply, a computer, a monitor, and a printer. A
fire detection sensor head assembly is shown in Figure 11-1.

11-6
 Operation and Safety – Foster Wheeler

Figure 11-1
Fire Detection Sensor Head [2]

Holes are cut and mounting brackets are welded to the mill housing at the appropriate locations.
A mounting flange, including dual-quartz sight glasses, is bolted to the mounting bracket sealing
the mill. The sensor head is quick-coupled to the mounting flange.

Electronic circuitry responds to minute currents generated when light is present in the visible to
near infrared spectrum. The resulting signal is reviewed by a microprocessor system. As each
head is polled for data, the corresponding microprocessor communicates with the control system.
Only the corresponding head assembly that matches the address sent by the control system will
respond with data.

Every 15 minutes, the control system commands all the assemblies to enter the self-test mode by
turning on light-emitting diodes within the sensor head. The control system sequentially polls
each head for the self-test data and notifies the user of any sensor problems.

11.5 Fire Protection

The National Fire Protection Association (NFPA) now requires that ball mills be provided with a
means of inerting inside the mill during a trip. Although older mills may not be equipped with
this safeguard, it is recommended that ball mills be retrofitted with an inerting system, especially
if highly volatile fuels are being used.

11-7
Operation and Safety – Foster Wheeler

Human Performance Key Point

The NFPA identifies two areas of protection for ball mills. The two areas are
preventing an explosion (inerting) and extinguishing a fire.

The inerting process introduces a vapor medium (steam, nitrogen, or carbon dioxide) that lowers
the oxygen concentration to prevent an explosion. This will also reduce the intensity of or
extinguish any existing fire. The use of the inerting system is intended for out-of-service
equipment and would not be effective for an operating mill, even at the minimum airflow
through the mill. Therefore, the inerting concept should only be used when the pulverizer is out
of service.

Extinguishing a fire is primarily accomplished with water. In addition to extinguishing the fire, it
is necessary to remove the ignition source so that a dust or gaseous explosion does not occur.

Foster Wheeler offers a steam inerting system that is skid-mounted with one skid per ball mill.
The associated steam piping to the skid and the ball mill are typically provided by the plant.
The steam supply for the inerting system is in the 50–100 psig pressure range and between
0 and100°F of superheat temperature.

Table 11-6 lists the procedures required when a fire is detected in the negative pressure ball mill.

Table 11-6
Procedures for Fire Extinguishing in the Foster Wheeler Mill [5]

1. Stop the exhauster(s). This should automatically stop the mill and feeders.

2. Allow sufficient time for the pulverized coal in suspension to settle, approximately 5–10
minutes. Flood the mill by allowing a low-velocity stream of water to flow into the feeder until
the water runs out the bottom of the trunnion. The mill should then be turned over for
approximately 5 minutes to thoroughly mix the water and coal. The remainder of the system
should then be carefully inspected and any existing fires should be extinguished. A carbon
dioxide (CO2) extinguisher can be readily adapted to the mill.

3. Fires in the pulverized coal system cause coke formations on the inside of the fuel piping,
distributors, and burners. If the coke deposits are not removed, they may cause future fires.
The thorough cleaning of these parts following a fire is necessary to prevent future fires.
4. Blow out the mill level lines immediately after a mill has been flooded and after all fires have
been extinguished.
5. Water and coal may wash back into these lines and deposit a layer of silt that would be
difficult to remove. Blow out the level lines frequently until the coal in the mill has dried.
6. To dry the mill after it has been flooded, the equipment and dampers should be set up for
normal operation with the exception that no coal is fed to the mill. The unit should be
operated until the hot air flowing through the mill and the heat generated by the cascading
ball charge has evaporated all the moisture in the mill.
7. When the mill is dry, the presence of coal at the burners will appear.

11-8
 Operation and Safety – Foster Wheeler

Table 11-7 lists the emergency shutdown procedures for the negative pressure Foster Wheeler
ball mill.

Table 11-7
Emergency Shutdown Procedures for the Foster Wheeler Mill [5]

1. Close the exhauster output damper. In case of extreme emergency, omit this step.
2. Trip the exhausters. The tripping of both exhausters should automatically trip the mill, both
feeders, and the hot air shutoff damper.
3. If after tripping the exhausters, the mill, feeders, and hot air shutoff damper do not
immediately trip, manually trip the mill, feeders, and hot air shutoff damper.
4. Trip the mill low-pressure lube oil pump.

5. Close the burner switching valves.

6. Remove the coal conduit plugs, burner front plugs, and blow out if necessary.

Circumstances may necessitate shutting down a mill filled with coal. Table 11-8 lists the
recommended procedures that should be used when shutting down the mill filled with coal.

Table 11-8
Recommended Procedures for Shutting Down the Foster Wheeler Mill Filled with Coal [5]

1. Lower the fuel level in the mill to a point where the ball charge is no longer covered with
coal. Mill fuel level gauges will indicate almost 0 in. while maintaining a mill suction pressure
of 2 in. This should be done in all cases except emergency shutdown.

2. The mill should be started up and turned over several revolutions every hour in order to
prevent the coal in the mill from igniting due to spontaneous combustion.
3. Check the mill to ensure that no dormant fires have started before turning the mill over.
Fires may be detected by the odor of burning coal at the feeder inspection door and the
inspection hole on the air tube, or by visual inspection through the inspection hole on the air
tube.

11-9
12
OPERATION AND SAFETY – KENNEDY VAN SAUN

The Eskom Kendal Power Plant has Kennedy Van Saun ball mills. The following topics are
covered in this section:
• Load changes
• Fuel oil support
• Blocked fuel pipe
• Wet coal
• Mill stripping
• Cold startup

12.1 Load Changes

During normal operation, the load is met with four mills in service, but it is possible to operate
with three and a half mills in service. The one-half mill is a ball mill with only single-end
operation.

When increasing the load from 586–686 MW with three and a half mills in service, the single-
end operation should be changed to double-end operation at 586 MW. If three mills are in
service, then the fourth mill should be started at 586 MW.

For the load range of 486–586 MW, the normal operation in this load range can be achieved with
three, three and a half, or four mills.

When reducing load to the 386–486 MW load range with four mills in service, the top mill
should be changed to single-end operation at 486 MW. With three and a half mills in service, one
of the double-ended mills should be shut down at 386 MW. With three mills in service, the top
mill should be changed to single-end operation no later than 386 MW. The single-end operation
mills should be changed to a double-end operation at 386 MW when increasing the load in the
386–486 MW load range with two and a half mills in service.

When operating in the load range of 300–386 MW, normal operation in this load range is with
two and a half mills in service.

12-1
Operation and Safety – Kennedy Van Saun

12.2 Fuel Oil Support

Should any mill fuel flow fall to 34% in double-end operation or 20% in single-end operation,
the affected mill master must be placed in manual mode, and oil must be added for the affected
burner. Should the oil addition not be available, the mill demand should be increased to maintain
the fuel flow above 30% in double-end operation or 15% in single-end operation. The oil
addition can be safely removed when the fuel flow on that mill is above 38% in double-end
operation or 23% in single-end operation and the mill is stable.

Human Performance Key Point

Fuel flow of the mill feeding the lower burner elevation should not drop below
45%. Fuel oil should be added on the bottom mill in service if the fuel flow drops
below 45% and is not stable.

The ignition of coal on the lower burner elevation mill in service could become unstable at low-
fuel flow if the bottom mill is not supported by an adjacent mill.

When shutting down, stripping the mill of fuel, or working on the mill controls on any lower
burner elevation mill, fuel oil support must be inserted on that elevation and on the next burner
elevation mill upward.

The two mills that feed the bottom boiler burner levels may not be started or stopped without
fuel oil support. In order to save fuel oil when starting these mills, the mills should be pre-
warmed.

Pre-warming the mill is accomplished by opening the hot mill primary air isolation gate and both
mill outlet gates at the back panel. The hot air control damper should then be opened to a
maximum of 20 kg/second of airflow through the mill. The mill outlet temperature should be
monitored, and when the outlet temperature exceeds 80°C, the dampers can all be closed, and the
mill started normally. If any instability occurs while warming the mill during this process, the
primary air on the mill should be shut down as soon as possible.

Pre-warming should not be done if the unit load is less than 486 MW. When starting the mill in
an emergency situation, the mill does not have to be pre-warmed.

Any mill can be changed from double-end operation to single-end operation or from single-end
operation to double-end operation without fuel oil support, provided that all of the following
conditions are satisfied:
• The unit load must be above 386 MW.
• There must be at least three mills in service in either single- or double-end operation.
• There must be at least two mills in service below the corresponding boiler burner level. The
two mills do not have to be the mills supplying the burner level directly below the mill being
changed, but can be the mills for a lower burner elevation.

12-2
 Operation and Safety – Kennedy Van Saun

If the above criteria are not met, then it is necessary to add fuel oil before the mill is changed in
operation.

During the change from single-end operation or double-end operation, it is important to monitor
the drive-end mill outlet gate run time. If after 70 seconds, the appropriate limit switch has not
been made, an attempt can be made to change back to the previous selection. If the limit has not
been made within 80 seconds, the mill will trip.

When changing a mill from double-end operation to single-end operation, the mill bias will
automatically be set to minus 40%. When starting a mill in single-end operation, the mill bias
must be manually set to minus 40% except during startup conditions.

12.3 Blocked Fuel Pipe

Human Performance Key Point
If a blocked coal pipe is discovered, every effort should be made to correct this
defect as soon as possible. Continued mill operation with a blocked coal pipe is
not allowed for more than 14 days.

As soon as the blocked fuel pipe is discovered, operating personnel will complete an “out of
normal” notification and tag the associated mill at the mill motor. The pipe should be isolated
and cleaned as soon as possible.

If the blocked fuel pipe is on the drive-end side, the mill should be changed to single-end
operation as soon as possible, and the pipe should be blanked off for cleaning. If required, the
mill can then be returned to double-end operation and operated with seven of the eight fuel pipes
in service.

If the blocked fuel pipe is on the non-drive-end side, the mill will have to be shut down as soon
as possible, and the pipe will need to be blanked off for cleaning. While the pipe cleaning occurs,
the mill can be returned to service and safely operated with the one pipe blanked off.

If a second blocked fuel pipe occurs on the same mill and the blocked pipes are on the same end
of the mill, then:
• If the blocked pipes are on the drive-end side, the mill can be changed to single-end operation
to allow for the blanking and cleaning of the blocked fuel pipes. The mill may be returned to
double-end operation only when one of the pipes has been cleaned and the blank removed.
• If the blocked pipes are on the non-drive-end side, the mill must be shut down immediately
to allow for the isolation of the affected pipes. The mill may be returned to service when one
of the pipes has been cleaned and the blank removed.
• If one pipe on both ends of the mill is blocked, then the mill must either be shut down
immediately or changed to single-end operation to allow for the immediate cleaning of one of
the pipes to continue. If selected for single-end operation, the mill may be operated with one
blocked fuel pipe for a maximum of 14 days.

12-3
Operation and Safety – Kennedy Van Saun

The pulverized fuel trapped in the blocked fuel pipe does occasionally begin burning. This
causes the pipe surface temperatures to increase dramatically to over 200°C. Because the fuel
sediment is compact, the combustion proceeds slowly with only the exposed surface of the
sediment burning. The ash layer that remains and the combustion gases reduce the availability of
oxygen for continued combustion.

When blocked fuel pipes are found to be burning, the pipes should be left to burn out and cool.
Additional blanks should be put in place on both ends of the burning pipe to limit the ingress of
more oxygen. Without additional oxygen, the combustion process will not continue, and the heat
will dissipate. Once the combustion has ceased, the remaining ash and pulverized fuel can be
cleaned out from the pipe.

12.4 Wet Coal

Operation with wet coal can be identified by comparing the mill demand versus the inlet
temperature according to the following graph in Figure 12-1.

Figure 12-1
Wet Coal Operation
(Courtesy of Kendal Power Station)

If a mill is operating with wet coal, the following actions should be taken:
• The affected mill bias must be set to minus 40%.
• The mill power must be monitored. Should the mill power drop significantly by more than
80 kW, the feeders must be stopped immediately and the mill stripped empty.

12-4
 Operation and Safety – Kennedy Van Saun

• When the hot air control damper opens fully, the mill differential pressure is in alarm values,
and the mill fails to maintain primary airflow, it is an indication of partial blocking of the
feed box with wet coal. The affected mill feeders must be stopped immediately. If the
primary airflow does not return to normal values but continues to decrease, then the mill
must be shut down immediately.
• Oil support on mills feeding the lower burner elevations will require fuel support.
• The maximum number of mills should be put in service depending on the permissible load
contract.

12.5 Mill Stripping

Mill stripping is emptying the mill of coal. If the level instrumentation indicates that there is coal
in the mill when the mill is empty, then the instruments should be recalibrated.

Table 12-1 lists the tasks for stripping the mill.

Table 12-1
Tasks for Stripping the Mill [Kendal-Kennedy Van Saun Mills]

Tasks

Note: The mill should be in service for at least three hours before the stripping process begins.

1. Initiate oil support on burner where required.

2. Shut down the feeders.

3. Place the mill master in manual and at 53%.

4. When the mill level has reached a steady state (~10 minutes), monitor the mill power until it
is constant at 1360 kW. The mill is assumed to be empty.

5. Place the mill master at the 40% setting. For the mill supplying the lower burner elevation,
the mill master should be set at 50%.
6. Check the primary airflow. The airflow should be 42.5 kg/second.

7. Set the bypass dampers to 100% open.

8. The mill level should be checked for 0% indication.

9. Turn off both seal air fans to trip the mill.

10. After the mill trips, return both seal air fans to normal operation (one fan operating and one
fan in standby).
11. Open the drive-end and non-drive-end mill outlet gates.

12. The primary airflow should be at 42.5 kg/second and the bypass dampers set to 100%
open.

13. The level instrumentation can now be set to 100% indication.

12-5
Operation and Safety – Kennedy Van Saun

Table 12-1 (continued)

Tasks for Stripping the Mill [Kendal-Kennedy Van Saun Mills]

Tasks

14. Return the mill to the normal shutdown position. All pressure switches should be reading
zero.
15. Restart the mill but do not load the mill. Recheck the zero position of the level
instrumentation.
16. After the instrumentation is calibrated, then the mill can be shut down for an internal
inspection.

12.6 Cold Startup

After a major outage, it is necessary for the mills to go through a cold startup. The tasks for a
cold startup are shown in Table 12-2.

Table 12-2
Cold Startup Tasks
(Courtesy of Kendal Power Station)

System Tasks

Trunnion high-pressure Fill the lube oil tank.

lube oil system
Set the high-pressure lube oil system pressure relief valve to lift at
15 MPa.

Place the lube oil tank heaters in service and verify that the
temperature is within the indicated range.
Check the lube oil tank level alarm.
Check the lube oil temperature alarm.

Check the lube oil pressure alarm.

Trunnion low-pressure Verify the LP lube oil flows to be 20 liters/min.
(LP) lube oil system
Check the LP lube oil flow alarm.

Check the LP lube oil pressure alarm.

Pinion lube oil system Fill the pinion lube oil tank.

Check the pinion lube oil flow low alarm.

Check the oil pressure low alarm to be <100 kPa.

12-6
 Operation and Safety – Kennedy Van Saun

Table 12-2 (continued)

Cold Startup Tasks
(Courtesy of Kendal Power Station)

System Tasks

Mill motor lube oil Fill the mill motor lube oil tank.
system
Verify the oil pressure relief valve setting to be 10 MPa.
Verify the oil pressure setting to be 3.5 mPa.
Check the oil pressure alarms to be <3.0 mPa and <1.5 mPa.
Perform the mill lift test and record the results.
Clean all lube oil filters after the pressure/flow adjustments.
Mill feeders Change the feeder switchgear setting to remote.
Ensure the feeders internal lighting is available.
Perform the feeder belt training.
Check the clean out conveyors chain tension.
Check the feeders. No coal on belt switch.
Check the clean out conveyors shearing pin broken alarm.
Ensure the ball loading hoppers door is lock-fitted.
Mill dampers Check the hot air isolating damper stroke.
Check the cold air isolating damper stroke.
Check the hot air control damper stroke.
Check the cold air control damper stroke.
Check the drive-end bypass damper stroke.
Check the non-drive-end bypass damper stroke.
Check the drive-end mill outlet damper stroke.
Check the non-drive-end mill outlet damper stroke.
Check the drive-end feeder outlet damper stroke.
Check the non-drive-end feeder outlet damper stroke.
Check the drive-end reject gate stroke.
Check the non-drive-end reject gate stroke.
Seal air fans Balance and test both of the seal air fans.
Check the seal air pressure to be >10 kPa and the differential pressure
from the drive-end and non-drive-end to be 1 kPa.
Check the seal air pressure alarm.
Check the seal air system for leaks.

12-7
Operation and Safety – Kennedy Van Saun

Table 12-2 (continued)

Cold Startup Tasks
(Courtesy of Kendal Power Station)

System Tasks

Mill barring and Place the mill on barring and check the girth gear spray patterns.
protection devices
Check the bearing alarms for 60°C.

Check the mill motor bearing alarms for 80°C.

Simulate the trunnion lube oil pressure to be low and check the mill trip.

Check the mill seal air trip.

Check the mill motor bearing temperature trip.

Check the mill bearing temperature trip.

Check the girth gear spray trip.

Check the mill outlet gate open limit lost trip.

12-8
13
OPERATION AND SAFETY – RILEY POWER INC.

The following topics are covered in this section:

• General operation
• Control system
• Handling ball charge
• Primary air damper operation
• Seal air system
• Feeder calibration
• Instrumentation settings
• Fire detection
• Fire protection

13.1 General Operation

During normal operation, the ball/tube mill temperature monitoring is accomplished through the
mill alarm system. The system monitors the mill bearing temperatures and the oil temperature to
the reducer and chain case, alarming and tripping when these temperatures increase beyond their
predetermined set points.

The most commonly monitored pressures are:

• The seal air differential that protects the shafts and bearings of rotating parts from coal dust
and prevents coal dust leakage from the mills, crusher-dryers, and feeders
• The mill differential that gives the operator an indication of fuel flow
• The classifier to furnace differential, a measure of coal line velocity, the maintenance of
which protects against coal line layout
• Primary air system pressures that give an indication of the system’s overall condition
• The pressure exerted on the thrust rollers is transmitted by the load cell to the mill alarm
system. This pressure should be monitored, as it warns the operators that the mill barrel is not
in alignment. Excessive pressure will set off the alarm, and corrective action must be taken
immediately.

13-1
Operation and Safety – Riley Power Inc.

For flow indication, the operator makes continual reference to the following flow indications:
• Coal flow measurement is made in two ways. The mill differential is an indication of the
amount of coal/air leaving the mill and, therefore, is used as the total fuel signal that is being
sent to the combustion control system. This differential is also useful when trying to maintain
equal fuel flow from all mills in service. The coal flow determined from the feeder counters
is an essential tool used to determine when to add balls to the mill and when to check
hammers in the crusher-dryers. These values are helpful when calculating the amount of coal
fed to the system over time.
• The oil flow to the chain case and reducer oil baths is monitored through the mill alarm
system. Periodic inspections are necessary to ensure that this system is functioning properly
and that an adequate supply of oil is maintained.

The coal charge is an inventory of coal in a mill. The proper inventory is measured by a
combination of sound (dB) and power (kW) values that are fed into the Power-Sonic mill
conditioning system.

Trending the classifier exit temperature provides the early warning of a fire present in the mill
system and also whether there is proper drying of the coal in order to ensure ignition at the boiler
burners.

Detailed startup procedures are available from the Riley Power Service Guide for:
• Ball/tube mill startup procedure with steam inerting
• Startup of ball/tube mill containing a coal inventory using steam inerting
• Operation of double-ended ball/tube mill with one feeder out of service
• Operation with burners out of service
• Normal ball/tube mill shutdown procedure with steam inerting
• Steam inerting procedure following a ball/tube mill trip

13.2 Control System

The Power-Sonic mill conditioning system includes a kilowatt transducer, a sonic transducer,
and a kilowatt set point control station with sound decibels, kilowatt meters, and interconnecting
multi-conductor cables.

Through this equipment, the system maintains control of the total coal inventory in the mill by
using measurements of two mill variables. One variable is obtained by comparing the coal
inventory to the mill power required for the mill motor to rotate the mill barrel. The second
variable is the sound or sonic level of the steel balls colliding with each other and with the mill
liners. This variable is also related to the amount of coal inventory in the mill.

From these variables, an error signal is generated by which the system directs the feeder speed
controller calling for either an increase or a decrease in the feed rate.

13-2
 Operation and Safety – Riley Power Inc.

The power required to rotate the mill barrel is related to the total balls plus the coal inventory
weight. With the ball inventory traction being held reasonably constant, the power input becomes
a function of the coal inventory. As the coal is fed into an empty rotating mill that is holding just
the balls, the power input to the mill motor increases with the coal inventory. The incoming coal
eventually fills the void between the colliding balls resulting in a decreased sound level. When
this condition is reached, the combined inventory bulk density and power input are at a
maximum peak power.

Further addition of coal decreases the bulk density by forcing the balls apart, swelling the
inventory, and displacing its center of gravity toward the mill axis. This reduces the power input
despite increasing the total weight. Maximum grinding efficiency is obtained near the peak
power requirement.

The region where power increases with increasing coal inventory is called the stripping range of
the kW curve. The region where power decreases with additional coal inventory is called the
operating or control range of the kW curve. It is necessary to operate with a mill that has a coal
reserve in it so the mill system can respond to sudden increased demand on output without
waiting for additional new coal to be fed into the mill for pulverization. The ball/tube mill is
operated in the control range of the operating range of the kW curve. Thus, a kW set point is
selected in this range, and the mill feeders automatically reposition on a change in mill load to
satisfy this set point.

The second control factor is the sonic function (sound level in dB versus coal inventory). Sonic
intensity increases as the coal inventory decreases. This is caused by the steel balls making direct
contact with each other when the coal is moving toward the stripping range of the sonic curve.
This portion of the sonic curve indicates that there is not enough coal in the mill to fill the voids
between the steel balls.

The control strategy of the Riley Power ball mill is shown in Figure 13-1.

13-3
Operation and Safety – Riley Power Inc.

Figure 13-1
Riley Power Operation Diagram (Riley Power Service Guide)

The rate of the airflow is controlled in response to a mill output or fuel demand signal. The coal
feeder rate is controlled by the feeder speed controller in response to the error signal generated
by the mill conditioning system. This error signal is generated in response to three signals
representing the mill motor power, the sonic (sound level) intensity of the mill, and the mill
output of the fuel demand signal.

When the mill is operating at the rated capacity, the coal feeder rate is primarily controlled by a
signal representing the power consumed by the mill motor. When the mill is operating above
rated capacity, the coal feeder rate is controlled by signals from the mill motor power and the
sonic intensity of the mill. When the mill is operating below rated capacity, the coal feeder rate is
controlled by the mill motor power and by the mill output demand signal.

The control strategy is based on maintaining the weight of the coal charge in the mill rather than
the coal level at the ends of the mill. The power needed to rotate the mill drum is related to the
total charge weight of the coal and balls. Therefore, if the ball weight is held constant, the power
required is a function of the coal charge weight. Restoration of ball charge weight from wear at
10-day intervals should maintain the coal charge to mill motor power relationship within
practical limits. This is achieved by adding steel balls without taking the mill out of service.

13-4
 Operation and Safety – Riley Power Inc.

The maximum grinding efficiency is obtained at the peak power requirement. However, it is
desirable to maintain a reserve capacity in the mill to supply sudden required output increases
without waiting for additional coal to be added and pulverized. For this reason, the control
system is set to maintain a product charge in excess of that existing at peak power. Figure 13-2
shows the desired control point.

Figure 13-2
Motor Power Versus Product Charge [7]

The control system uses motor power as the primary input. The drum sound level (Riley Power
Inc. calls this sonics) and feed forward input is used as input to the power control. The power
controller operates on a full-range output of less than 5% change in motor power. Figure 13-3
shows the response characteristics of the mill parameters using the product charge control.

Figure 13-3
Mill Parameters Using Product Charge Control [7]

13-5
Operation and Safety – Riley Power Inc.

From these parameters it can be seen that as the demand on the mill is increased, the total
product charge increases, the motor power decreases, the sound level decreases, then remains
constant and begins to increase with higher loads, and the product level remains steady and
increases with higher loads.

The alarm outputs are:

• Normal operation – no alarms
• High product charge – low power alarm only
• Low product charge – high sonics alarm only
• Low-low product charge – low power alarm and high sonics alarm

The high sonics alarm condition indicates low product charge. If the ball charge weight falls
below the control range value, three events can occur:
• At rated, high-load output, the mill will become unstable due to the inability of the mill to
grind the required throughput because of inadequate ball charge.
• At lower outputs, the system will alarm at low power, because the power is now lower than
the alarm set point.
• The reduced ball charge will lower the power required below the control setting. The high
sonic alarm will be activated as the controller attempts to increase power to the set value by
reducing the feed rate to the mill.

Figure 13-4 shows the effects of reduced ball charge.

Figure 13-4
Effects of Reduced Ball Charge [7]

13-6
 Operation and Safety – Riley Power Inc.

During normal mill operation, the Power-Sonic mill conditioning system maintains the coal
product charge weight as determined by the motor power set point and the feed forward signals.
Control may be switched to the Power-Sonic mill conditioning system after initial startup as soon
as the motor power reaches its peak.

If a loss of one of the mill feeders occurs, the sonic signal will indicate a stripped (empty)
condition, and the other feeder will go to full-open operation. If the second feeder does not
operate in a short time, the load on the mill should be reduced.

The control system can provide stable mill operation when the coal is wet. With a moderately
wet coal, the reduced charge provides greater air volume for drying. With a very wet coal, the
coal can build up in the ducts between the mill and the feeder and block the flow into the mill.
However, the lower level of product in the mill tends to prevent this situation.

The effects of moisture content in the coal charge to the mill power is as follows:
• Over 12% moisture, the mill power is 10–15% below normal operating input and steady.
• For 8–12% moisture, the power increases and becomes very erratic as the drying process
proceeds.
• For 2–8% moisture, swinging decreases and power drops to an empty mill value.

The effect of excessive moisture on the mill operation is evident by rapidly swinging current
indications on the mill motor.

If a mill upset occurs because of an interruption of coal feed from the source to the feeders, the
controls should be changed to a manual operation. The manual operation should maintain a
constant mill motor current reading until the normal coal supply resumes. Then the control
system can be returned to an automatic mode. A change in the voltage to the mill motor will not
affect the operation of the Power-Sonic mill conditioning system. Unless the coal is of very poor
quality or very wet, the mill motor set point should not require changing.

When removing a mill from service, the control system is placed in manual, and the mill is
stripped of coal by the operator.

Delivering the coal in measured amounts is accomplished by the drum-type coal feeders, which
receive a signal from the Power-Sonic mill conditioning system and by the modulation of the
rating dampers. The feeders consist of a housing containing a rotating drum that delivers a given
volume of coal and provides a seal against the backflow of primary air into the bunkers. A
variable-speed transmission drives the feeder, changing its speed when the signal from the
conditioning system indicates the need.

13-7
Operation and Safety – Riley Power Inc.

13.3 Handling Ball Charge

The ball charge hopper permits makeup ball charges to be added to the mill during operation and
without mill service interruption. Balls may be added to an operating mill by closing the hopper
outlet valve on the ball-charge hopper and filling the hopper itself with balls. The cover should
then be latched securely in place and the stop valve opened to allow the balls to enter the mill.
This procedure is then repeated until the required addition to the ball charge is complete.

The charging frequency for each mill should be approximately one or two 2000-lb drums every
10 days. The outside dimensions of a 55-gallon drum are approximately 23.75-in. outside
diameter × 35-in. long. The common method of storing these drums is on end, although some are
stored on their side. The storage area is usually located on a different level from that of the mill
ball-charge hopper. The drum is transported to the charging hopper by truck. Once the drum has
been oriented over the charging hopper, cut a small flap on the drum to control the flow of balls
to the charging hopper.

The ball charge is added through a 2-ft, 10.5-in. × 2-ft, 10.5-in. opening in the concrete floor
covered by 0.25-in. checkered cover plate of 1-in. thick grating. The ball charge hopper flange is
recessed below floor level and is centered in the opening. The hopper door cover is 2-ft, 4-in. in
diameter and is bolted to the hopper flange with eight eye bolts that extend 1.5 in. above the
flange. The transporting truck must be able to straddle the opening, or the drum must be
maneuvered so that one edge is over the charging hopper opening so that the flap can be cut in
the drum to control the flow of balls to the charging hopper. When the drum is being emptied, its
lowest point should be a minimum of 3 in. and a maximum of 24 in. above floor level.

The truck used to move the drums must have load bearing wheels of the largest type possible and
not less than 1.5-in. wide. The truck must be able to move over grating usually spaced with 1-in.
wide openings. The heavy 2000-lb load dictates that the wheels should be of steel or hard
synthetic composition that is oil resistant. The wheels should have a non-marking tread. It is
suggested that any equipment that tilts the drum by chain or cable, which would allow such a
load to swing, must also be able to drop this load on a base of safe transportation to the charging
hopper. The use of four-wheel vehicles as opposed to three-wheel vehicles is suggested for the
same reason.

The trucking vehicle must be small enough to be put on an elevator and light and maneuverable
enough to be handled by one or two people. A means of lifting the truck and drum by crane
would be required if elevators were not available.

13.4 Primary Air Damper Operation

Delivering the coal and maintaining its temperature requires the interaction of the many dampers
and controls in the primary air system that performs three functions. The functions are
temperature control, flow control, and velocity control.

For temperature control in a cold primary air system, air from the atmosphere is taken by the
primary air fan and discharged to a tempering air header, through the air preheater to the hot air

13-8
 Operation and Safety – Riley Power Inc.

duct. In a hot primary air system, the primary air fan draws tempering air from the cold air duct
and hot primary air from the secondary air duct discharging the hot air to an individual mill
system.

The temperature of the coal/air mixture at the classifier outlet is maintained at the desired value
by the manipulation of the tempering air dampers and the hot air dampers. This temperature is
necessary to ensure proper handling and ease of combustion while minimizing the effects of wet
coal on crusher-dryers, ductwork, and ill inlets. The tempering air dampers and hot air dampers
have a fixed relationship to one another. This relationship helps maintain a stable primary air
pressure through the load range, calming the system’s response. Both dampers are butterfly-type
dampers, selected for their tight closing feature.

When coal is supplied that is so wet that the action of the tempering air damper and hot air
damper is not sufficient to maintain the required classifier exit temperature, a wet coal override
comes into action with the bypass damper.

For flow control, the flow of coal from the mill to the burners is controlled by modulation of the
rating damper. This louver-type damper acts on demand from the boiler master through the fuel
master, controlling the flow of primary air to the mill system. The amount of coal flowing to the
burners is proportional to the amount of air flowing through the mill. The mill differential is the
value used to measure the flow through the mill.

At periods of low load or wet coal, some of the primary air delivered to the system through the
rating damper is bypassed around the mill.

For velocity control, the coal-laden air stream in the coal pipes to the furnace must be maintained
at a certain velocity or the coal particles will drop out of suspension. The coal can collect in the
coal pipe, form a barrier to flow, and create a fire hazard in the pipe or at the burner. Another
problem is the unbalanced heat input to the furnace.

The bypass damper performs two functions. It helps to maintain the coal/air velocity above the
minimum values at low loads, and it helps to increase the flow of drying air during periods when
wet coal is being supplied.

The classifier to furnace differential pressure is a measure of coal/air velocity. The bypass
damper’s controller reacts to this differential when it approaches a minimum value. When this
value drops during operation, primary airflow will lower due to the movement of the rating
damper, and the bypass damper will begin to open. This causes some of the air supplied to
bypass the mill to join the coal/air mixture leaving the mill, lowering the mill differential. The
rating damper, in response, will open slightly to regain the required mill differential. Variable
relationship between the bypass damper and the rating damper will then exist, at low loads. The
bypass damper enables the mill to operate at low loads.

The bypass damper also assists the temperature control system when wet coal exists. The bypass
damper will begin to open if the coal is so wet that, with the hot air damper wide open and
tempering air damper completely closed, the classifier exit temperature falls below 150°F. This

13-9
Operation and Safety – Riley Power Inc.

causes the mill differential to decrease and the coal flow from the mill to drop. Sensing the drop,
the rating damper will open more, delivering more primary air to the system than is required for
coal transport. This added air contains additional heat that is used to dry the wet coal.

The sequence of operation for the primary air fan dampers is as follows:
• The primary air fan inlet dampers are closed when the primary air fan is not operating.
Although the seal air fan draws its supply from the ducts served by these fans, there is
enough leakage by the damper to allow sufficient air quantities to cool and clean the flame
scanners.
• The inlet damper remains closed while the primary air fan is started, and is opened only after
the isolating dampers have been opened and the fan is up to speed. Thereafter, the inlet
damper is modulated to satisfy the hot air header pressure set point and is placed on
automatic control.
• The system isolation dampers that are in the cold air and hot air ducts from each fan prevent
backflow into an idle system while the other system is in service. The system isolation
dampers are opened after starting a primary air fan.
• Before starting a ball/tube mill, the tempering air damper should be fully opened and the hot
air damper closed. The hot and tempering air dampers are set to maintain the classifier exit
temperature at its normal set point.

Technical Key Point

The mill system’s rating and bypass dampers control the fuel flow responding to
the demand signal from the combustion controls. The mill bypass dampers operate
in a fixed relationship to the mill rating damper over the entire demand signal range
of the combustion control system.

These dampers are characterized so the coal pipe velocity will decrease moderately with a
decreasing mill load to a predetermined minimum value for proper coal transport.

At mill startup, open the bypass dampers and follow the procedures outlined in the Riley Power
Service Guide. Increase the mill load by opening the rating damper while simultaneously closing
the bypass damper.

The rating damper is in the primary air duct downstream of where the hot and tempering air
blend. When all the burners serviced by the mill are in service, place the rating and bypass
damper in automatic. The bypass damper is integral with the mill inlet/outlet box. The rating
damper responds to fuel demand. The bypass damper responds to the rating damper position to
maintain a required air/fuel ratio over the loading range of the mill.

A manual bypassing or proportional adjustment of both the rating and bypass dampers will
increase the level of primary airflow and will be used during conditions of extremely wet coal
operation.

13-10
 Operation and Safety – Riley Power Inc.

13.5 Seal Air System

The seal air system is placed in operation before starting the first forced-draft fan. Seal air
pressure is required as a permissive to begin the purge sequence of the boiler. This pressure must
be maintained during the operation of the ball/tube mill system. Loss of the seal air pressure will
result in a master fuel trip.

In order to isolate the operating fan from the backup fan, the power-operated butterfly valve
located in the discharge side of the backup fan is placed in the closed position. The inlet side
manual damper to the backup fan is placed in the open position. A system shutdown of the
operating fan would result in the automatic opening of the backup fan discharge damper and the
automatic starting of the fan. The inlet damper to the idle fan should always remain in the open
position, except during isolation of the fan for maintenance.

The sealing air to the mill trunnion arrangement confines the coal dust within the mill system.
Replace the trunnion seal if the required pressure drop cannot be maintained. Sealing air is also
provided to the feeder discharge gate to restrict a backflow of hot air from the primary air system
into the feeder and bunker when a feeder or feeders are out of service. Except for the mill, each
piece of equipment has its own manual control damper valve located in the seal line.

The mill damper modulates to control and to maintain a constant differential between the
pressure in the seal air header and the pressure at the mill inlet. Maintaining the selected set point
is accomplished by the use of a single-element control loop using a differential controller
interlocked with each mill. Alarm settings are established to monitor the seal air pressure in the
seal air system.

The differential controller must be released to the combustion controls before starting the
primary air fan. The seal air system then remains on automatic control during the operation of
the boiler and the ball/tube mill system.

13-11
Operation and Safety – Riley Power Inc.

13.6 Feeder Calibration

Table 13-1 shows the tasks for coal feeder calibration.

Table 13-1
Coal Feeder Calibration Tasks [7]

Calibration Tasks

1. Remove the feeder from service. Allow the feeder to cool.

2. Open the access doors for inspection. Remove the shear pin from the drive socket or from the
shear pin alarm coupling to permit rotation of the feeder pinion shaft, feed drum, and pocket
wiper, using the hand crank. Note: Eight crank revolutions equals one drum revolution of the
feeder.
3. Rotate the feed drum by hand-cranking at least one complete revolution to determine the
condition and operation of the drum pocket wiper, leveling apron, functional revolution counter,
and so on. Set the leveling apron-to-drum clearance at 1/16 in. maximum, and correct any
mechanical deficiencies prior to calibration.
4. After placing and securing sample chutes prepared for calibration through the crusher access
door, open raw coal spout gates above feeder. Rotate the feed drum by hand cranking through
at least two revolutions to establish uniform coal flow from bunker to feeder, and to determine
and verify sample acquisition procedure.

5. Calibrate the feeder in terms of pounds of coal per revolution. This is done by rotating the feeder
drum by hand exactly eight complete revolutions, catching coal on and removing same from the
catch chutes during the feeder rotation. The coal should be immediately transferred to a 55-
gallon steel drum for weighing on an appropriate scale. Weigh the full 55-gallon drum and
determine the coal weight per cubic foot (55 gal. = 7.353 cu. ft)

6. Immediately after removing the coal from the chute for weighing, rotate the feeder one revolution
to obtain additional coal from which a sample for size and moisture content should be obtained
and sent to the lab for analysis. The laboratory is to determine the approximate analysis,
grindability, higher heating value in Btu/lb, and relay information to the persons doing the
calibration to those keeping records in the plant.

7. In the event that the coal cannot be weighed within a reasonable time after depositing in the
steel drums, the drums should be capped or covered in order to prevent the loss of moisture and
to prevent a subsequent error in determining the results.
8. For other coals, calibration can be done simply by determining coal weight per cu. ft and
calculating the ratio of weight per cu. ft to determine the new pounds of coal per drum revolution.
Samples should be sent to the laboratory for results. Recalibration can be done for each
different coal source or for the same source of coals to have a plot for average values of lb
coal/drum revolution and records kept.
9. The following date is provided to help in the test: Feeder drum size is 17.75-in. diameter and 30-
in. long. The approximate lb/rev. is 105. This varies with raw coal size and moisture content. The
number of steel drums of 55-gallon capacity required for eight feeder revolutions is four.

13-12
 Operation and Safety – Riley Power Inc.

13.7 Instrumentation Settings

Table 13-2 lists the various parameters for the mill instrumentation.

Table 13-2
Sample Riley Mill Instrumentation Parameters [7]

Equipment Alarm Setting Trip Setting

Feeder No coal N/A

Chain oil temperature – high 185°F 200°F

Mill bearings temperature – high 200°F 220°F

Gear reducer bearings temperature – high 225°F 240°F

Gear reducer oil temperature – high Varies 200°F

Mill inlet temperature – high Varies N/A

Mill outlet temperature – high 110°F N/A

Mill end pressure differential – high 14-in. W.G. N/A

Mill seal air pressure differential – high and low 22-in. W.G. N/A
12-in. W.G.
Clutch air pressure – low 90 psig N/A

Mill displacement load cell weight 10,000 lbs 1/4-in. movement

(16,000 lbs)
Classifier exit temperature – high Varies N/A

Classifier to burner differential pressure – low Field determined N/A

Mill motor power – low Field determined N/A

Mill sonics – high Field determined N/A

13-13
Operation and Safety – Riley Power Inc.

Typical operating parameters are shown in Table 13-3.

Table 13-3
Sample Equipment Parameters [7]

Equipment Parameter Value

Mill drum speed 16.3 rpm

Mill capacity 151,140 lbs/hr

Crusher-dryer inlet temperature – normal 450–700°F

Crusher-dryer inlet temperature – maximum 900°F

Crusher-dryer seal airflow Approximately 450 #/hr

Crusher-dryer rotating speed 900 rpm

Crusher-dryer bearings operating temperature range – normal 150–170°F

Crusher-dryer bearings operating temperature – maximum 190°F

Crusher-dryer bearings – normal vibration limit 3-4 mills displacement

Feeder capacity, bituminous coal 133,800 lbs/hr

Feeder capacity, sub-bituminous coal 120,400 lbs/hr
Feeder shaft speed – maximum 21–25 rpm
Feeder shaft speed – minimum 0.73 rpm

Feeder motor shaft output speed – maximum 1700 rpm

Feeder reducer and wiper speed – minimum 5.8 rpm

Feeder reducer and wiper speed – maximum 170 rpm
Feeder available speed variation ratio 29:3:1

Feeder drum size, diameter 17.75 in. outside diameter

Feeder seal airflow 45 scfm

Chain water recirculation inlet temperature 85°F

Chain water recirculation temperature rise 32°F

Chain water recirculation inlet pressure 40 psi

Chain water recirculation pressure rise 0.08 psi

Chain water recirculation flow rate 3 gpm at 85°F

Chain oil recirculation inlet temperature 190°F

Chain oil recirculation temperature drop 15°F

Chain oil recirculation flow rate 15 gpm at 85°F

Chain oil recirculation outlet pressure <15 psi

13-14
 Operation and Safety – Riley Power Inc.

Table 13-3 (continued)

Sample Equipment Parameters [7]

Equipment Parameter Value

Chain oil recirculation pressure drop 3.75 psi

Reducer water recirculation inlet temperature 85°F

Reducer water recirculation temperature rise 9°F

Reducer water recirculation inlet pressure 40 psi

Reducer water recirculation flow rate 6 psi

Reducer water recirculation pressure drop 3.8 psi

Reducer oil recirculation inlet temperature 180°F

Reducer oil recirculation temperature rise 20°F

Reducer oil recirculation flow rate 3.6 gpm at 85°F

Reducer oil recirculation outlet pressure <50 psi

Reducer oil recirculation pressure drop 8 psi

13.8 Fire Detection

Inspections of the system should be performed on a regular basis for evidence of fires. Peeling
paint, hot spots, and/or glowing or discolored surfaces can all be signs of a fire. Abnormal
temperature differences and/or excursions can indicate a fire is present in the mill system.

The recommended method of ensuring a startup without incident is to completely strip the mill
of coal upon shutdown.

If the system has been tripped with a coal charge in it, it must be physically inspected for the
evidence of fire before startup. The following inspection sequence is recommended:
• Examine the area above the coal level in the bunker supplying the mill for smoke, odor, or
other indications of fire. Carbon monoxide or methane gas detection systems can be used to
detect combustion.
• Inspect the external surface of the downspouts between the bunker and feeders and the feeder
housings for hot areas that may indicate an internal fire.
• Inspect the top of the feeder housings and the top of the classifier housings.
• Inspect the surface areas of the crusher-dryer housings, the mill inlet/outlet boxes, the mill
bypass dampers, the classifier inlet ducts, the coarse rejects pipe, the trickle valve housing,
and the coal lines from the classifiers to the burners.

13-15
Operation and Safety – Riley Power Inc.

Table 13-4 lists the temperature sensor locations for fire detection.

Table 13-4
Fire Detection Temperature Sensor Locations [7]

Location Number of Sensors Required Temperature Range (°F)

Single-Ended Mill Double-Ended Mill

Hot Primary Air Fan 1 1 0–700

Discharge

Hot Primary Air 1 1 0–700

Header
Cold Primary Air Fan 1 per fan 1 per fan 0–700
Discharge

Cold Primary Air Duct 1 1 (2 when damper 0–700

After Mill Rating is < 6 ft from duct
Damper split)
Mill Inlet 1 2 0–500 with crusher-dryer,
0–700 without crusher-dryer

Mill Discharge 1 2 0–300

Classifier Exit 1 2 0–300

An active fire anywhere in the mill system will usually cause abnormal temperature differences
and/or excursions of the mill inlet, outlet, or classifier exit temperatures that cannot be accounted
for by occurrences such as a sudden change in coal moisture, faulty control of primary air
temperature or flow, or a sudden stoppage or decrease of raw coal feed into the mill.

For mills with one classifier, the continuously recorded exit temperature can identify fires by
indicating rates of temperature rise and abnormally high temperatures. For double-ended mills
with two classifiers, the two continuously recorded exit temperatures, in addition to indicating
rates of temperature rise and abnormally high temperatures can isolate fires by identifying the
differences between classifier exit temperatures. It is rare, but possible, for fires to exist
simultaneously in both ends of the mill.

When a fire is detected anywhere in the mill system, the system should be taken out of service by
simultaneously activating the water deluge system and the ball/tube mill system emergency trip.

After a fire is extinguished, conduct a thorough inspection and repair any fire-damaged
equipment. Remove any agglomerated coal, coke, deposits, or other debris remaining after the
fire is extinguished. Close all inspection ports and all access doors except those at the mill ends.
Completely vent the mill with the air fans.

Thoroughly remove any debris from the inlet/outlet boxes manually. Proceed to remove slurry by
pumping it through trunnions. Remove all material down to the top of the ball charge. An

13-16
 Operation and Safety – Riley Power Inc.

intermittent spray application at reduced pressure adjacent to the pump hose inlet in slurry may
be required to assist in pumping if dry pulverized coal pockets are encountered. Any odor of
burning coal detected inside the mill after the removal of coal down to the top of the ball charge
may indicate hot, unburned coal remaining in the mill. Continue spraying and pumping slurry
until all evidence of the fire disappears. It is recommended that further removal of slurry be
accomplished by inserting a pipe into the bottom of the ball charge and pumping until suction is
completely lost. Check the trunnion seal air local header loops for flooding and drain if needed.

13.9 Fire Protection

If ignition occurs anywhere in a ball/tube mill system, a continued flow of hot air and fuel past
the ignition source results in a rapid downstream spread of fire that is both damaging and
dangerous. For this reason, fire control and extinguishing procedures must be initiated
immediately upon detection of fire at any location in the system.

The basic method of extinguishing fires in a ball/tube mill system is the application of water
spray directly to the fire to quench it, plus an additional spray application to the mill interior to
prevent accidental or spontaneous ignition of the pulverized coal in and above the ball charge.

A fire fighting system should be installed for each ball mill system. Water spray nozzles should
be installed in the 10 system locations as shown in Figure 13-5.

13-17
Operation and Safety – Riley Power Inc.

Figure 13-5
Water Spray System Nozzle Locations [7]

The system should be permanently piped, have a remote manual activation switch in the control
room, and should be activated on both ends of the system. Care should be taken to ensure that
water leaks into the system cannot occur. Unintentional activation should not occur. The valve
that directly supplies water to the deluge system should be automatically regulated in order to
avoid overflooding the mill system.

13-18
 Operation and Safety – Riley Power Inc.

Deposits of unground or pulverized coal anywhere in the system between the feeder discharge
and the boiler furnace are potentially dangerous and should be minimized. Raw or pulverized
coal accumulations exposed to air above normal operating temperatures can spontaneously
ignite.

The probability of ignition is lowest with anthracite or low-volatile bituminous coals, but
increases with both volatile and sulfur content coals. Midwestern U.S. bituminous, western sub-
bituminous, and lignite coals, in that order, are increasingly prone to oxidation and self-ignition
under the previously described conditions.

System equipment maintenance involving welding or torch cutting may cause fires, especially
following an emergency shutdown that has prevented the usual system purge.

Emergency hot shutdown of a mill system containing a coal charge can also cause a fire. This
could occur within two hours or within even a shorter period for the more readily ignitable coals.

The practice of feeding hot coal into an operating mill system from a smoldering or active raw
coal bunker fire is dangerous and should not be done.

Fires can also be caused by operating at higher than normal temperatures.

13-19
14
OPERATION AND SAFETY – STEIN INDUSTRIE

This section covers the mill layup and fire protection of the Stein Industries ball/tube mills.

14.1 Layup

If the mill will be out of service or on standby for a period of 60 days or longer, then certain
preservation tasks should be performed on the mill. The following are the equipment and tasks to
be performed:
• Mill bunkers – The mill bunkers will not be able to hold the same coal for a period of more
than six weeks. A full spontaneous combustion test should be performed.
• Mill barring or rotation – The mills should be rotated every 14 days for a period of at least
1 hour. A mill checksheet is completed and any problems with the rotation are corrected.
• Main bearing lubrication system (turbo lube system) – The lubrication system should be
operating at all times except when maintenance is being performed on the system.
• Gearbox lubrication system – The gearbox lubrication system should be operating when the
rotation or barring occurs, but not operating when the mill is off-line.
• Girth gear greasing system – The girth gear greasing system should be operated when the
mill is being rotated, but not operated when the mill is off-line.
• Girth gear seal air fan – The girth gear seal air fan should be operated when the mill is
being rotated, but not operated when the mill is off-line.
• Trunnion seal air system – One seal air fan should be operated when the mill is being
rotated while the other fan should be tested for operation. The seal air regulating damper
should be placed on manual and reduced to 10% flow in order to prevent the fan motors from
experiencing high amperage.
• Air system – The control air and service supply lines should remain open with the purge air
systems on automatic operating mode.
• Dampers – All mill dampers should be operated for one full cycle every 60 days. The
primary air isolation damper can not be operated if there are other mills in operation.
• Feeders – Feeders should be operated in the test mode every 60 days for one full revolution
of the belt.

14-1
Operation and Safety – Stein Industrie

14.2 Fire Protection

After a mill is taken out of service, the mill is put on barring until the internal ball load and fuel
has cooled down to prevent internal combustion. When the mill barring is stopped, the mill outlet
temperatures should be checked for a temperature rise. The mill should be checked for any
hotspots or discolored areas. It must also be checked for the smell of sulfur that would indicate
combustion.

If a major temperature rise exists, it will be necessary to inject carbon dioxide. Before the carbon
dioxide trailer is started, the following should occur:
• Ensure the trunnion seal air fan is shut down.
• Ensure the girth gear seal air fan is shut down.
• Shut down the compressed air purge of differential pressure level control.
• Ensure the mill is off barring.

The carbon dioxide system is activated by the following actions:

• Position the carbon dioxide trailer about two meters from the control panel to ensure the
hoses are uncoiled completely.
• Connect the two quick-acting couplings from the trailer hoses to the control panel.
• On the female coupling, pull back the spring-loaded outer sleeve and push the male coupling
firmly into the mating piece. Release the sleeve and pull hard on the hose to ensure the hose
is firmly coupled.
• If you do not need to inject carbon dioxide into the mill body, move the mill body valve bar
to the closed position to allow injection to the classifiers only.
• Open the carbon dioxide cylinders isolating valve levers to allow injection into the
classifiers.
• Empty the top three cylinders first. The top three cylinders are for cooling down the mill and
to reduce the oxygen level.
• If the fire still exists, discharge the remaining four cylinders at a continuous flowrate over a
period of 40 minutes.
• After the cylinders have been discharged, close the cylinder valves and wait five minutes for
any residual gas to clear the hosepipe.
• Disconnect the coupling and remove the trailer and cylinders from the mill area.
• Recharge the cylinders.

14-2
15
PERFORMANCE

Acceptance testing for mills is performed according to the American Society of Mechanical
Engineers (ASME), Performance Test Code (PTC) 4.2, Coal Pulverizers, 2003. Other testing
may be performed as part of an overall boiler test or to determine if maintenance or adjustments
are needed. The following are parameters that affect mill performance:
• Fineness
• Grindability
• Moisture
• Capacity

15.1 Fineness

Fineness is an indication of the quality of the pulverizer action. Fineness is defined as the
measured particulate size distribution of pulverized product as determined by standard screens.
Specifically, fineness is a measurement of the percentage of a coal sample that passes through a
set of test screens usually designated at 50, 100, and 200 mesh. Table 15-1 shows the standard
screen dimensions.

Table 15-1
Standard Screen Dimensions

Mesh In. Microns

20 0.0331 840

30 0.0234 595

40 0.0165 420

50 0.0117 297

60 0.0098 250

100 0.0059 149

140 0.0041 105

200 0.0029 74

325 0.0017 44

400 0.0015 37

15-1
Performance

A standard fineness is 70% passing through a 200-mesh screen. The coal retained on the 50-
mesh screen should be in the 1–2% range.

There are two standards that are used in sampling and fineness testing. The standards are the
ASME PTC 3.2-1054- Solid Fuels and the American Society of Testing Materials (ASTM) D
197 (1980) - Sampling and Fineness Test of Pulverized Coal.

Tutuka Power Station samples and tests the coal for fineness every 3500 operating hours.

15.2 Grindability

Grindability indicates the ease that coal can be ground. A higher grindability number indicates
coals that are easier to pulverize. Grindability is not just a matter of hardness. Coal of the same
hardness can have a range of different grindability indexes because of other constituents such as
moisture. Also, materials that are fibrous, sticky, or plastic can be difficult to grind.

One test procedure is the Hardgrove Machine Method to determine the Hardgrove Grindability
Index. This procedure is described in ASTM D 409 – Method of Test for Grindability of Coal by
Hardgrove Machine Method. The grindability is determined by the amount of new material that
will pass through a 200-mesh screen. A 50-gram air-dried coal sample, sized to less than 16
mesh and greater than 30 mesh, is placed in the Hardgrove machine with eight 1-in. steel balls. A
weighted race is placed on the balls, and the machine is turned for 60 revolutions. The resultant
coal size is then compared to an index and a value assigned from the index.

Another test procedure is the bond ball mill work index (BMWI) that was developed for use in
the minerals industry to determine the grindability of ores. The bond BMWI work index models
continuous grinding in a horizontal ball mill. It was devised as a feature of the bond method for
sizing ball mills. A standard cylindrical test mill is loaded with balls of a designated diameter
and weight. The coal is air-dried and screened over a No. 6-mesh screen. The sample is then
placed into the mill and rotated 100 times at a speed of 70 rpm. The product is then screened
over a 200-mesh screen. Fresh sample coal is added to the oversized coal, and the mixture is then
retested. Using the screening process, the number of mill revolutions required to give a product
containing 28.6% passing through 200-mesh sieve and 71.4% (250% of 28.6) oversize is
estimated. The process is continued until a constant value is obtained for the mass of undersize
coal produced per mill revolution. This value is called the grindability (G).

Correlations between the Hardgrove Grindability Index and the bond BMWI have been
developed.

15.3 Moisture

Moisture content in the coal can influence grindability for sub-bituminous and lignite coals. The
surface moisture plus inherent moisture influence the amount of drying needed and the air inlet
temperature. Coal moisture is highly variable and depends more on coal type than on the amount

15-2
 Performance

of water introduced after mining. Moisture may be present in the geological deposit or may be
surface moisture that is introduced during handling, transport, processing or storage.

Moisture found in the coal ranges from levels of 2% for Appalachian bituminous to 40% for
lignites. Brown coals can range up to 70%. Moisture in coal is determined according to the
procedures in ASTM D3302-02a – Standard Test Method for Total Moisture in Coal.

15.4 Capacity
The following is an example of a performance improvement project with the mills. The Arnot
Power Station of Eskom was initially designed to produce 350 MW. The ball mills are Stein
Industrie mills that are serviced by Alstom. Three mills producing 54 tons/hour of pulverized
coal were required to produce the 350 MW. To perform maintenance on one mill, it was
necessary to reduce the load on the unit to 280 MW. It was decided to derate the unit to a
nominal 320 MW.
The station investigated the feasibility of operating two mills and achieving the full load of
320 MW. It was decided to increase the ball volume from 17–21%, which is equivalent to 80
tons of balls total. This was done over a six to eight month period. As a result, the motor mill
current increased from 260 to 310 amps. The current trip is set at 340 amps, which is 110% of
the load. A safe minimum air to fuel ratio is 1:5, and the minimum primary air velocity is 18
m/second.

It was necessary to modify the classifiers to achieve the desired fineness. The following
modifications were performed:
• A reject box with a loose sealing flap door was added to stop the coarse pulverized coal from
bypassing the classifier vanes.
• Every second classifier vane was removed to eliminate the blocking of vanes by foreign
objects.
• The Vortex finder was reintroduced to improve fineness.
• The feed chute was covered to stop the raw coal from entering the classifier before it was
milled.

The conclusions of the test were that two mills could produce 330 MW with an acceptable
fineness. It was necessary to operate an additional primary air fan in order to allow more boiler
control. The ability to operate the unit at full load with only two mills allowed a spare mill for
maintenance work and produced the power with considerable savings to the plant.

EPRI is currently looking at pulverizer performance issues to include the impact of blending
coals, mill control, and particle size distribution measurement.

15-3
16
FAILURE MODES

Information from earlier studies of pulverizer components is noted below.

The failure of the pulverizer components can be shown as the relative frequency of component
failures [10]. Figure 16-1 shows the frequency of pulverizer component failures.

Figure 16-1
Pulverizer Component Failure Frequency [10]

A discussion of failure mechanisms is given and an excerpt is provided from EPRI report CS-
5935 [11]. Failure modes analysis is defined by failure mechanisms and recommended action to
reduce or eliminate the failure mechanisms. Failure mechanisms for the pulverizer mills include
erosion and three types of abrasion.

16.1 Abrasion

The three types of abrasion are:

• Gouging abrasion – Gouging abrasion is a heavy plastic deformation of a surface by hard
mineral fragments under heavy pressure or an impact causing deep surface grooving or
gouging and the removal of relatively large wear debris particles. Examples of gouging
abrasion are seen in jaw crushers and hammer mills.

16-1
Failure Modes

• High-stress grinding abrasion – High-stress grinding abrasion is a three-body process

caused by mineral fragments under sufficient contact stress to cause the scratches in the
contacted surface. Examples of high-stress grinding abrasion are found in pulverizers and
ball mills.
• Low-stress scratching abrasion – Low-stress scratching abrasion is the wear by cutting or
plowing of mineral fragments under contact stress below their crushing strength. Examples
of low-stress scratching abrasion are found in coal chutes, sand pump impellers, and screens.

In coal pulverization, 5–20% of the material being crushed is abrasive mineral. A large part of
the power in coal pulverization is used to crush coal. Coal is not abrasive by itself. The minerals
in coal that are the most abrasive are quartz and pyrite. These minerals in the coal cause a less
severe, high-stress grinding abrasion than the minerals alone. Because of the cushioning effect of
coal powder, the size and shape of the mineral particles found in coal influence the severity of
the abrasion process.

Abrasion involves the sliding of particles under normal load over a surface. The abrasion rate is
influenced by the particle hardness and the normal load of the abrasive medium. The removal of
material during the abrasive wear process can occur by cutting or plowing. The cutting process is
more efficient and results in severe wear.

The probability of cutting by abrasive particles increases with the sharpness and the angularity of
the particles. Therefore, quartz particles crushed in a mineral processor are more aggressive than
rounded sand particles sliding over a metal surface. The angle of attack by each individual
abrasive particle determines whether cutting will occur. This cutting occurs when the angle
between the leading facet and the plane of sliding reaches a critical value. The critical angle for
cutting is influenced by metal alloy properties. For example, the critical angle for the cutting
abrasion of nickel is 60–70º.

One of the parameters that influence abrasion resistance is the quantity of carbides in the metal
part. Some materials that contain massive carbides are Ni-Hard, high-chromium cast iron, and
Stellite. The Ni-Hard and high-chromium white cast iron materials are considered to be the most
resistant to mineral abrasion in high-stress grinding abrasion conditions.

Alloying elements are important in the design of abrasion resistant alloys. Carbon content is the
most effective parameter in abrasion control. As the carbon content increases, abrasion resistance
increases. Increasing silicon content will significantly improve fracture toughness in a cast
material. Molybdenum, in quantities up to 1%, will improve abrasion resistance with no
discernable effect on toughness. Usually an increase in abrasion resistance is accompanied by a
decrease in toughness.

High-chromium cast iron materials are used for improved abrasion resistance. These alloys have
a variety of compositions to choose from. The alloy could be selected on the basis of optimizing
required toughness, hardenability, corrosion resistance, and abrasion resistance. In comparing
wear coefficients for several materials having wear data available, the values shown in Table
16-1 have been obtained.

16-2
 Failure Modes

Table 16-1
Abrasive Wear Coefficients [10]

Material Wear Coefficient

-4
High-Chrome Cast Iron (18 Cr, 2 Mo) 1.2 × 10
-4
Ni-Hard (3C, 4Ni, 2Cr) 1.5 × 10
-4
Stellite No. 6 hardfacing 2.4 × 10
-4
Star J (Stellite) hardfacing 5.4 × 10
-3
1090 Steel (Rockwell C hardness 55) 8.0 × 10

16.2 Erosion

Erosion by mineral particles picked up in the air stream carrying pulverized coal through the
mill, classifier, and transport pipe is a recognized problem. The erosion process is more selective
than the abrasive wear and tends to remove metal in localized areas.

Erosion can produce holes in steel liners and deep depressions in large section cast parts. A
localized attack is typical of erosive damage because of the sensitivity of the material removal
rate to the angle of impingement and the impingement velocity.

The following parameters affect erosion rates:

• Velocity – Erosion rates increase exponentially with velocity. For ductile materials, the
exponent is about 2.3; for brittle materials, the exponent ranges between 1.4 and 5.
• Impingement angle – Maximum erosion rates occur at 30º for ductile materials and at 90º
for brittle materials.
• Particle size – Erosion rates increase with particle size up to a critical size. Particle sizes
larger than the critical size do not increase the erosion rate. For very small particles, all
materials act like ductile materials. EPRI studies have determined that pyrite particles above
the 200-micron size cause pronounced damage [11].
• Particle hardness – Hard particles relative to the surface being eroded are more aggressive.
EPRI studies have determined that mill wear is primarily dependent on the quartz content
and, to a lesser extent, the pyrite content of the coal. In general, the damaging effect of quartz
is about two to three times that of pyrite [11].
• Material structure – Single-phase materials improve erosion resistance with increasing
hardness. Multiphase materials are insensitive to hardening.

The approach to erosion control requires using wear-resistant material mechanical properties for
a predicted impingement angle. There has been success in the industry using ceramic materials.
Ceramics are ideal for erosion corrosion conditions because of their inertness in the corrosive
environment and their ability to handle low impingement angle erosion.

16-3
Failure Modes

16.3 Failed Components

Table 16-2 lists the components, failure, cause of failure, and the corrective action for the Allis-
Chalmers mills.

Table 16-2
Allis-Chalmers Failure Components
(Courtesy of Lethabo Power Station)

Components Damage Cause Of Damage Corrective Action

Acoustic hood Bent/damaged Aging/incorrect Repair

assembly

Feed tube Erosion/deformed Misalign/ageing Replace/align

Bypass damper Worn/bent Wear Repair

Bypass damper shaft Worn/bent Wear Replace/repair

Bypass damper pillar Worn Wear Refurbish

blocks
Reject flap valve Hole/deformed Wear Replace

Division plate Erosion/deformed Wear Repair/replace

Slope liners inlet box Worn/cracked Wear/impact Replace

Slope liners outlet box Worn/cracked Wear/impact Replace

Slope liner bolts Loose/missing Vibration Replace/tighten

Square to round seal Leaking/damaged Wear Repair

Classifier outer cone Hole/erosion Wear Repair

Classifier inner cone Hole/erosion Wear Repair

Classifier inverted cone Worn/misaligned Wear/incorrect Repair/align

assembly
Classifier vanes Worn Wear Repair/replace

Reject wear sleeve Hole/erosion Wear Replace

Reject pipe bend Worn/hole Wear Replace

Ball loading pipe bend Damaged/hole Impact/wear Repair/replace

Ball loading hopper Leaking/deformed Impact/jammed Repair/clear

16-4
17
TROUBLESHOOTING

This section consists of troubleshooting tables for the ball/tube mills provided by Allis-
Chalmers, Foster Wheeler, Kennedy Van Saun, Riley Power Inc., and Stein Industrie.

17.1 Allis-Chalmers

Table 17-1 lists the symptoms, possible causes, and actions for troubleshooting the Allis-
Chalmers mills.

Table 17-1
Troubleshooting for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Symptoms Causes Actions

Gearbox Lubrication System

High oil Spray nozzles in gearbox unit Remove spray nozzles and piping, flush,
temperature blocked and clear.
Filter unit dirty Clean filters.
Cooler not functioning properly. Check cooling water flow. The minimum
flowrate is 0.88 liters/second.
Blocked cooler Clean cooler.
Pump over-heating Check pump and motor speed (1425 rpm).
Inspect and repair pump.
Low oil pressure Pressure relief valves set too low Reset relief valves.
Leakage in system Check system for leaks and repair.
High oil temperature Verify temperature indication and operation
of cooler.
Oil pump worn Repair pump
Pump not operating at rated speed Check pump and motor speed (1425 rpm).
Inspect and repair pump.
Vibration Air in suction line Check gear unit oil level and add oil as
needed.
Pump-motor misalignment Check coupling alignment.
Worn or loose pump bearings Rebuild pump.
Piping exerting forces on pump Re-align piping.

17-1
Troubleshooting

Table 17-1 (continued)

Troubleshooting for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Symptoms Causes Actions

Trunnion Bearing Lubrication System

High oil Filter unit dirty – associated with Change filter unit.
temperature high low pressure pump pressure
Cooler not functioning properly Check cooling water flow when oil
temperature is above 30°C. Clean cooler.
Low-pressure pump overheating Check low-pressure pump and motor speed
(1410 rpm). Inspect pump and rebuild if
needed.

Low oil flow Check flow rate to be 0.38 liters/second.

Low jacking oil Regulating pressure relief valve set Reset relief valve to 31 mPa.
pressure too low
Leakage in system Check system for leaks and repair.

High oil temperature Verify temperature indication and operation

of cooler.
Jacking oil pump worn Repair pump.

Pump not operating at rated speed Check pump and motor speed.
Vibration Air in suction line Check bearing sump oil level and add oil as
needed.
Pump-motor misalignment Check coupling alignment.

Worn or loose pump bearings Rebuild pump.

Piping exerting forces on pump Realign piping.

Power-Sonic Mill Conditioning System

Power or sound Defective meter Replace meter.

meters inoperative
Loose terminal Tighten all terminal connections.

Defective cable Repair or replace cable.

No system output Repair main electronics.

Power set point or Defective potentiometer or switch Install new potentiometer or switch.
read/set switch
inoperative Loose or defective cable Tighten or repair cable.

Main electronic system defective Repair main electronics.

Feeder speed controller defective Repair or replace speed controller.

17-2
 Troubleshooting

Table 17-1 (continued)

Troubleshooting for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Symptoms Causes Actions

Power-Sonic Mill Conditioning System (continued)

Mill tends to Incorrect power set point Adjust power set point.
overfill
Incorrect sound set point Adjust sound set point.

Incorrect feed forward set point Adjust feed forward set point

Incorrect output polarity Change switch.

Incorrect feed forward input polarity Change switch.

Defective electronic system Repair or replace electronics.

Defective feeder speed controller Repair or replace speed controller.

Mill tends to empty Low ball charge Replenish ball charge.

Incorrect power set point Adjust power set point.

Incorrect feed forward set point Adjust feed forward set point.

Incorrect output polarity Change switch.

Defective electronic system Repair or replace electronics.

Defective feeder speed controller Repair or replace speed controller.

High sound alarm Defective relay Repair or replace relay.

inoperative
Defective electronic system Repair or replace electronics.

Defective or incorrect wiring to Repair or replace wiring.

terminal block
Incorrect high sound set point Adjust high sound set point setting.

Low power alarm Defective relay Repair or replace relay.

inoperative
Defective electronic system Repair or replace electronics.

Defective or incorrect wiring to Repair or replace wiring.

terminal block
Incorrect low power set point Adjust power set point.

Mill does not Incorrect feed forward set point Adjust feed forward set point.
change coal level
with output Incorrect feed forward gain setting Adjust feed forward gain setting.
demand

17-3
Troubleshooting

Table 17-1 (continued)

Troubleshooting for Allis-Chalmers Mills
(Courtesy of Lethabo Power Station)

Symptoms Causes Actions

Power-Sonic Mill Conditioning System (continued)

No ± 15-volt on No input power Connect power and turn on as appropriate.

PCB
Blown fuse Replace fuse.
PCB not located correctly in Insert PCB correctly.
connector.
Defective transformer Replace transformer.
Defective regulator Replace regulator.
Defective transistor Replace transistor.
Power input has Defective input switch Replace switch.
no effect on output
Defective IC in system Replace IC.
Switch S4 open Close switch S4.
Inputs holding output high or low Correct other inputs.
Feed forward input Look for power input in previous Look at previous fault.
has no effect on fault
output.
Set switch between positions. Set switch to correct position.
Sound input has Look for power input in previous Look at previous fault.
no effect on fault
output.
Defective filter Replace filter.
Filter not tuned to correct frequency Tune filter.
Input has no effect Set switch between positions. Set switch to correct position.
on output
Defective IC Replace IC.
Defective output transistors Replace output transistors.
No output from No input to transducer Check connection to transducer.
power transducer
No input power to amplifier Connect correct input to terminals.
terminals or input out of range
Defective transducer Replace transducer.
No output from Microphone input clogged Clear microphone area.
sound transducer
No input power Connect ± 15-volt dc from main electronics.
Defective IC Replace IC.
Defective microphone Replace microphone.

17-4
 Troubleshooting

17.2 Foster Wheeler

Table 17-2 shows a troubleshooting chart for the operation of a negative pressure Foster Wheeler
ball mill.

Table 17-2
Troubleshooting Chart for Foster Wheeler Mills [5]

Problem Possible Causes

Loss of pulverized coal Mill level control lines may be plugged or leaking.

Coal feeder may be plugged.

Feeder motor may be stopped, burned out, or have blown fuses.

Feeder rotating table is binding.

Coal feed pipe to the mill is plugged.

Mill is plugged or overloaded with raw coal.

Mill is receiving coal faster than it can be ground.

Classifier settings are too fine.

Coal ribbon conveyor is not working.

Pulverized coal is spilling out The mill level control lines may be plugged or leaking.
of the mill
The feeder is operating continuously on manual.

The automatic feeder controller is malfunctioning.

Dry, fine coal is spilling off the feeder rotating table into the mill.

The liner bolts on the liner plates are loose.

The mill is receiving coal faster than it can be ground.

The mill suction pressure is lost or the mill is being pressurized.

The fuel level block is excessively worn.

Exhauster is tripped The exhauster has been accidentally tripped.

There is a loss of one or more forced draft or induced draft fans

There is a loss of voltage for the exhauster motor.

The exhauster overload trip has been activated.

Mill is tripped The mill is accidentally tripped.

There is a loss of exhausters, forced draft or induced draft fans.

There is a loss of voltage for the mill motor.

The mill motor overload trip is activated.

17-5
Troubleshooting

Table 17-2 (continued)

Troubleshooting Chart for Foster Wheeler Mills [5]

Problem Possible Causes

Feeder is tripped The feeder is accidentally tripped.

There is a loss of exhausters, forced draft or induced draft fans.

There is a feeder motor overload trip. There are problems with the
thermal heaters in the circuit.

The feeder motor fuses are activated.

The feeder rotating table is binding.

The dampers are tripped There is a loss of exhausters, forced draft or induced draft fans.

The dampers are accidentally closed.

There is a loss of exhauster differential.

The air operated pistons or air solenoid valves are not operating
properly.

Bearing (mills, exhausters, or Bearing vibration is too high.

feeders) temperatures are too
high There is a loss of lubricant in the bearings.

The lubricant supply lines are plugged.

The lubrication system is not operating.

The lubricant type is incorrect.

There is a failure of the bearing wear parts.

Mill gear and pinion damage There is misalignment between the gear and pinion.

The Farval lubricator is not operating.

There is coal or foreign material on the gear surface.

There is excessive loading on the gear teeth.

17-6
 Troubleshooting

17.3 Kennedy Van Saun

Table 17-3 lists the problems, possible causes, and actions for the Kennedy Van Saun ball/tube
mills.

Table 17-3
Troubleshooting Chart for Kennedy Van Saun Mills
(Courtesy of Kendal Power Station)

Problem Possible Cause Actions

Low primary Low airflow <37.5 Check the cold air and hot air damper control. If the
airflow Kg/second primary airflow does not increase, change the damper
control to manual and open the damper to clear the
alarm/trip. Note: There is one minute to trip the mill.
Faulty primary airflow Establish which transmitter is faulty. Select the cold air
transmitter and hot air dampers to manual to restore airflow. Contact
the instrumentation and controls group.

High mill motor Closed auxiliary cooling Open the auxiliary cooling valves to >30 L/minute flowrate.
stator winding return valve Contact maintenance group. Change to spare mill.
temperature
Overloading mill motor Check motor current to be <203 amps. Reduce the mill
load.

Bearing temperature Check the rate of change of the bearing temperature and
tracks the winding the stator winding temperature. Contact maintenance. If
temperature the rate of change indicates a trip condition, shutdown the
mill.
Too high or too low Determine proper values for mill motor voltage/current.
motor voltage/current Increase voltage and decrease current on the mill motor.
readings
Failed instrument Verify thermocouple reading. Contact the instrumentation
and controls group.

Oil support Tripped both feeders Establish oil support. Start feeders in the automatic mode.
required
Mill motor just started Verify oil support. Ensure alarm clears three minutes after
the mill starts.
Low fuel flow <38% Establish oil support. Stop the loading program. Increase
the output setpoint by 10 Mw. Change the loading
program to automatic. Ensure fuel flow increases.

17-7
Troubleshooting

Table 17-3 (continued)

Troubleshooting Chart for Kennedy Van Saun Mills
(Courtesy of Kendal Power Station)

Problem Possible Cause Actions

High mill bearing Low oil level Verify oil level. Monitor bearing temperatures. If needed,
temperature add oil and inspect for leaks.
Faulty thermocouple Determine which thermocouple is faulty. Replace
thermocouple. Monitor bearing vibration.

High load on motor Verify motor amps are <203 amps. Lower mill level to
normal.
Failed bearing Check rate of change of bearing temperature on plant
instrumentation. If rate is high, shut down mill. Contact
maintenance personnel.

Incorrect oil ring Check oil ring operation. Inform maintenance personnel.
operation Shut down mill.
Lack of oil Shut down mill. Inform maintenance personnel.

Low cooling water to oil Check auxiliary cooling flow to be ≥30 L/min. If not, shut
cooler down mill. Contact maintenance personnel.
Low seal air Broken/leaking impulse Try to contain leak. Start standby mill.
pressure line to transmitter

Ruptured seal air Shut down mill. Start standby mill. Inform appropriate mill.
ductwork
Faulty instrumentation Try to repair instrument. Start standby mill.

Tripped seal air fan Ensure standby seal air fan motor starts automatically or
motor manually. Investigate reason for seal air fan motor trip.
Contact appropriate personnel.
Blocked suction filters Investigate and correct blocked filters. Contact appropriate
personnel.

Abnormal mill Low mill level at -1 Investigate feeder operation. Monitor mill level.
coal level
Low mill level at -2 Mill motor will trip at 35% in shutdown program. Monitor
mill level.
High mill level at +1 Check feeder speeds. Remove control from automatic to
manual. Reduce speed and place back in automatic.
Monitor mill level.
Faulty card Change feeder control to manual. Add oil support to
burners. Monitor mill level.

17-8
 Troubleshooting

17.4 Riley Power Inc.

Table 17-4 lists the problems and possible causes for the chain-driven Riley Power ball/tube
mills.

Table 17-4
Troubleshooting Chart for the Chain-Driven or Gear-Driven Riley Power Ball Mills [7]

Problem Possible Causes

Speed Reducer Gearbox

Overheating Overloading – Load exceeds capacity of reducer.

Improper lubrication – Insufficient oil level, oil level too high, bent or
missing oil wipers, clogged air passages, wrong grade of oil, forced
lubrication, and oil cooling system on high speed drives may be
clogged
Noise and vibration Loose foundation bolts

Bearings failed from wear and overloading

Excessively worn gears from overloading

Insufficient oil

Loose parts from excessive shock loads

Excessively high speeds

Excessive end play in low Worn bearings from exposure to an abrasive substance
speed shaft or excessive radial
motion in high speed shaft
Excessive backlash or slack Worn gear or loose parts. Backlash is greater in double- and triple-
reduction units.

Oil leakage Leakage between housing and cover, too much oil, clogged breather

17-9
Troubleshooting

17.5 Stein Industrie

Table 17-5 lists the alarms, possible causes, and operator actions for the Stein Industrie ball/tube
mills.

Table 17-5
Troubleshooting for Stein Industrie Mills
(Courtesy of Tutuka Power Station)

Alarm Possible Causes Operators Action

High motor and Mill motor drive-end and non-drive-end
bearing temperatures bearing temperature high on video
Oil leaks Check for oil leaks.
Incorrect oil level Check oil level. Add oil if needed.
Contaminated oil Sample and test oil.
High inlet oil temperature Check cooling water flow.
Check filter differential pressure.
Change filter if required.
Motor/gear misalignment Check alignment.
Worn bearings Inspect bearings.
Motor overheated Check motor winding temperature.
Thermocouple faulty Check for loose connections and
check thermocouple.
Alarm value >60°C
Trip value >80°C
Mill motor winding temp high on video

Motor overloaded Reduce mill load.

Worn bearings Inspect bearings.
Gearbox oil level low Check oil level and add oil if needed.
Low-supply voltage Check equipment.
Faulty measuring equipment Alarm value >120°C
Low/High Primary Air Faulty dampers Check dampers at normal working
Inlet Flow position.
Mill blocked Verify mill inlet or outlet differential
pressure and coal level normal.
Faulty pressure control of PA fans Verify PA fans on automatic and PA
fan outlet pressure is normal.
Damaged expansion joints Verify pipework is in good condition

Faulty measuring equipment Check equipment.

17-10
 Troubleshooting

Table 17-5 (continued)

Troubleshooting for Stein Industrie Mills
(Courtesy of Tutuka Power Station)

Alarm Possible Causes Operators Action

Low primary air Faulty dampers Verify dampers are open in plant.
bypass flow during
mill startup Damaged pipework Verify pipework is in good condition.

Faulty measuring equipment Check equipment.

Faulty startup program Check startup program.

High bearing Bearing temperature on the drive-end

temperature and non-drive-end high on video

Damaged bearings Inspect bearings.

Hot air leaks onto bearings Inspect for hot air leaks.

High-oil temperature Check cooling water flow.

Blocked filter Check filter differential pressure and

change filters if needed.

Oil leaks Check for oil leaks.

Faulty lube oil pressure control valves Check control valves.

Faulty measuring equipment Check equipment

Alarm value >60°C
Trip value >80°C

Low oil flow spray Blocked filters Check filter differential pressure and
change-over filter if needed.

Damaged pipework Check for oil leaks.

Lube oil pump faulty Check pump coupling.

Faulty measuring equipment Check equipment.

Contaminated oil Sample and analyze oil.

Low lube oil temperature Check in on cooling water flow to

increase oil temperature.
Check temperature control on cooling
water system.
Trip value <21 liters/second after 60
seconds.

Orifice plate wear Check size.

17-11
Troubleshooting

Table 17-5 (continued)

Troubleshooting for Stein Industrie Mills
(Courtesy of Tutuka Power Station)

Alarm Possible Causes Operators Action

Faulty lube oil level Mill oil tank level low/ high. Mill
reduction oil tank level low/high on
video.
Oil leaks Check for any oil leaks.
Tank temperature low/high Verify tank temperature to be normal
>35°C and <65°C.
Contaminated oil Sample and test oil.
Operating error Purify oil if necessary. Check oil in
sight glass. Add or drain oil if needed.
Faulty measuring equipment Check equipment.
Faulty mill gear wheel No grease Verify grease drum level is correct.
lubrication
No air supply Verify air supply.
No electrical supply Verify electrical supply is energized.
Faulty timer Check timer.
Pump faulty Inspect pump.
Loss of girth gear seal air fan Verify fan is on-line.
Alarm after 10 minutes.
Trip after 30 minutes.
Faulty seal air system Seal air fan tripped Verify fan is on-line.
Faulty dampers Verify dampers in plant are open.
Verify control damper actuator is intact.
Air leaks Check for air leaks in piping.
Faulty measuring equipment Check equipment.
Trip mill after 15 seconds.
Faulty feeder Shearing pin broken Verify shearing pin is intact.
Feeder tripped Check switch gear.
Bunker empty Verify coal level in bunker to be
correct.
Coal flow blocked/hang-up Verify coal in feeder and clear hang-up
if needed.
Faulty measuring equipment Check equipment.

17-12
18
PREDICTIVE MAINTENANCE

Predictive maintenance philosophy assumes that the pulverizer equipment will deteriorate and a
partial or complete loss of function will occur. Predictive maintenance monitors the condition or
performance of plant equipment through various technologies. The data are obtained, analyzed,
trended, and used to predict equipment failures. When equipment failure timing is known, then
actions can occur to prevent or delay failure. This allows equipment reliability to remain high.

Predictive maintenance is accomplished by integrating all available data in order to predict the
impending failure of equipment. This process depends on the ability to recognize undesirable
operating conditions as measured by diagnostic equipment. This process allows equipment to
continue operating in an undesirable condition while it is being monitored until maintenance can
be scheduled.

Early warning can be broken into catastrophic failure or minor failure and deterioration. These
can be further broken into maintenance or operations effects and to actual costs. Figure 18-1
shows the effects of early warning for pulverizer equipment failure.

18-1
Predictive Maintenance

Figure 18-1
Early Warning for Pulverizer Failure [12]

Some advantages of detecting equipment problems early include:

• Reduced catastrophic failure rate – This rate is reduced by diagnosing equipment
conditions and taking action before the equipment fails.
• Reduced forced outage rate – By detecting equipment problems early, the inspection and
repairs can be performed during scheduled outage time and not during a forced outage.
• Increased inspection/overhaul interval – The inspection and overhaul interval can be
increased by knowing the equipment condition and not basing the interval on elapsed time
alone.
• Reduced maintenance outage length – The time to perform inspection and repairs is
reduced when adequate planning for the outage can occur. This can include having the
correct parts and tools on site, the labor force planned, the isolation tags requested, and so on.

One of the main predictive maintenance tasks is the measurement and estimation of wear. This
applies to drum liner wear and ball wear. Other areas of wear are on the inlet and outlet ducts and
pipes.

The main technologies used in predictive maintenance are vibration analysis, oil analysis, and
thermography. This section covers the vibration analysis and oil analysis.

18-2
 Predictive Maintenance

Thermography may be used on the mill motors to detect overheating, loose connections, and so
on. For more information on thermography for use on motors, see Electric Motor Predictive
Maintenance Program (EPRI report TR-108773-V2) [13].

Thermography may also be used on the gear teeth to detect misalignment or areas of high
temperature that can eventually lead to lubrication breakdown.

18.1 Vibration Analysis

Vibration readings should be taken on the trunnion tube bearings and the pinion and bull gears.
The recommended frequency of taking vibration readings on the gearing is a three to six month
interval depending on the operation of the mill.

Some general guidelines on interpreting vibration data are given in this section. If the dominant
frequency is one times the operating speed (1 × rpm), then the vibration could be caused by an
unbalance, a misalignment, or a bent shaft. If the dominant frequency is two times the operating
speed (2 × rpm), then the vibration can be caused by looseness or misalignment. Multiple values
of the operating speed indicate vibration caused by bearing or gear problems.

Identifying the specific details of the bearings and gears, such as the number of rollers in the
bearings, the number of teeth on the gears, and the individual gear speed, allows the measured
high frequencies to be used as a diagnostic tool for the bearings or gears. For example, a bearing
with 18 rollers on a shaft rotating at 1800 rpm would have a characteristic frequency of 540 hertz
(1800 rpm/60 seconds per minute × 18 rollers).

The mill motor vibration should be checked on a quarterly basis. The horizontal and vertical
vibration readings should be taken on the inboard and outboard bearings. Axial vibration
readings should be taken on the outboard bearing. The vibration amplitude and phase readings
should be trended. High axial vibration readings could be the result of a coupling problem or
misalignment between the motor and gearbox.

18.2 Oil Analysis

Technical Key Point
Lubricant testing is recommended for several reasons. These include:
• To study the condition (wear) of the machine being lubricated. If there is a
problem with the lubricant, there is a strong possibility that the machine will
need maintenance.
• To determine if the lubricant is meeting the specifications

18-3
Predictive Maintenance

There are numerous lubricant tests that can be performed on an oil sample. The task is to perform
the minimum tests that produce the condition of the oil and the condition of the machine. The
first and most crucial step in lubricant testing is to get a representative sample.
Recommendations for taking samples are to:
• Take the sample when the system is stabilized, not before or just after makeup lubricant has
been added.
• Take the sample ahead of filters so that contaminants are still in the lubricant.
• Put the oil sample in a suitable, clean, well-labeled container.
• Take the sample using a consistent method. Take the sample from the same location and
under the same operating conditions.
• Ensure that contaminants from the component do not enter the sample.

It is recommended that the bearing lubricating oil sample be taken and analyzed every 6 months
for the Riley ball/tube mills.

A general discussion of lubricant testing is given in this section. The following are laboratory
tests [14] performed on oil samples.
• Particle count (International Standards Organization (ISO) 4405, 4406) – Particles have
long been recognized as the main cause of failure in hydraulics and rotational machinery.
Particles are also a leading indicator of a machine’s condition. Since all contaminants in the
oil are counted as particles, the particle count includes wear particles, soot, dirt, and other
contaminates. This test provides information on lubricant cleanliness.

As oil cleanliness becomes more important, particle counters have taken on an increasingly
important role in maintenance strategies. Most particle counters use light or infrared energy
to illuminate individual particles and are referred to as optical particle counters.
The ISO Solid Contaminant Code (ISO 4406:99) is probably the most widely used method
for representing particle counts (number of particles/milliliter) in lubricating oils and
hydraulic fluids. The current standard employs a three-range number system. The first range
number corresponds to particles larger than 4 microns, the second range number for particles
larger than 6 microns, and the third for particles larger than 14 microns. As the range
numbers increment up by one digit, the associated particle concentration roughly doubles. A
typical ISO Code for a turbine oil would be ISO 17/15/12.
Particle counts can be obtained manually using a microscope or by an automatic instrument
called a particle counter. There are many different types of automatic particle counters used
by oil analysis laboratories. There are also a number of different portable and online particle
counters on the market. The performance of these instruments can vary considerably
depending on the design and operating principle.

18-4
 Predictive Maintenance

Table 18-1 shows the particle count range numbers and the corresponding number of particles.

Table 18-1
Particle Count Range Numbers [15]

Number of Particles per Milliliter Sample

Greater Than Up To and Range

Including Number (R)

80,000 160,000 24

40,000 80,000 23

20,000 40,000 22

10,000 20,000 21

5,000 10,000 20

2,500 5,000 19

1,300 2,500 18

640 1,300 17

320 640 16

160 320 15

80 160 14

40 80 13

20 40 12

10 20 11

5 10 10

2.5 5 9

1.3 2.5 8
0.64 1.3 7

0.32 0.64 6

0.16 0.32 5

0.08 0.16 4

0.04 0.08 3

0.02 0.04 2

0.01 0.02 1

18-5
Predictive Maintenance

• Fourier transform infrared analysis (FTIR) – The FTIR monitors the chemical
composition of the oil in certain key wavelengths. The infrared absorption spectrum of a
lubricant furnishes a means of fingerprinting organic compounds and functional groups. Test
results are trended, and quantitative and qualitative determinations can be made. Infrared
analysis is often used for identifying additives and their concentrations, reaction products,
and contamination by organic materials in used lubricants. Oxidation (carboxylic acids and
esters), nitrate esters, water, soot, and glycol can be quantified.
• Spectrometric analysis/Emission spectroscopy/Rotrode filter spectroscopy (RFS) –
Elemental analysis is performed in accordance with atomic emission spectroscopy (AES). A
specific volume of lubricant is energized using an electrical arc. The light frequencies and
intensities are measured and reported in parts per million of various elements. Elemental
analysis is useful for identifying contamination, confirming additive content, and indicating
system wear. The following elements are analyzed: Fe, Cr, Al, Pb, Sn, Cu, Ag, Ni, Na, V,
Cd, Ti, Mo, Ca, Ba, P, Zn, B, K, Mg, and Si.
• Additive package condition – Additives present in a lubricant improve and strengthen the
performance characteristics of the lubricant. Chemically active additives are able to interact
with metals and form a protective film with the metallic components present in the
machinery.

The designer of the additive package must ensure that the additives will not produce
unacceptable side effects. If an additive is present in excessive levels or interacts in an
unsatisfactory manner with other additives that are present, it can be detrimental to the
equipment. Over a period of time additive packages can deplete, leaving machinery
unprotected, and vulnerable to failure.
The additives in a lubricant can also be referred to as the performance package. Some of the
more commonly used additives include:
– Anti-foam agents – Almost every lubricant foams to some extent due to the agitation and
aeration that occurs during operation. Air entrainment due to the agitation encourages
foam formation. The presence of some detergent and dispersant additives tends to
promote foam formation. Foaming increases oxidation and reduces the flow of oil to the
bearings. In addition, foaming may cause abnormal loss of oil through orifices.
Anti-foam agents are used to reduce the foaming tendencies of the lubricant. Foam
inhibitors may be added to a lubricant in service if a foaming problem is detected. The
lubricant and equipment manufactures should be consulted before adding foam inhibitors.
The foaming characteristics of lubrication oils are tested per the ASTM D892 standard.
The test makes a determination of the foaming characteristics of lubricating oils at a
specific temperature. The test results monitor the foaming tendency and stability of the
foam.
– Anti-wear and EP additives – Both anti-wear and extreme-pressure (EP) additives form
a protective layer on metal parts by decomposition and absorption. Anti-wear additives
function in moderate environments of temperature and pressure while EP additives are
effective in the more extreme environments.

18-6
 Predictive Maintenance

Molybdenum disulfide and graphite additives are a special form of anti-wear additives
known as anti-seize agents. They form a protective layer on the metal parts by deposition
of the graphite or molybdenum disulfide. Anti-seize agents work independent of
temperature and pressure.
Typical applications include engine oils, transmission fluids, power steering fluids, and
tractor hydraulic fluids. EP additives are common in gear oils, metalworking fluids, and
some hydraulic fluids.
– Dispersants – The purpose of this additive is to suspend or disperse harmful products
within the lubricant. Thus, the additive neutralizes the effect of these products. Harmful
products include contaminates such as dirt, water, fuel, and process material, and lube
degradation products such as sludge, varnish, and oxidation products.
Typical applications include diesel and gasoline engine oils, transmission fluids, power
steering fluids, and in some cases gear oils.
– Detergents – Detergents, like dispersants, are blended into lubricants to remove and
neutralize harmful products. In addition, detergents form a protective layer on the metal
surfaces to prevent deposition of sludge and varnish. In engines, this can reduce the
amount of acidic materials produced.
A detergent’s protective ability is measured by the total base number or the reserve
alkalinity. The metallic basis for detergents includes barium, calcium, magnesium and
sodium. Typical applications for detergent additives are primarily diesel and gasoline
engines.
– Friction modifiers – Friction modifiers are lubricant additives blended with the base
stock to enhance the oil’s natural ability to modify or reduce friction. Friction modifiers
reduce wear, scoring, and noise.
Typical applications include gasoline engine oils, automatic transmission oils, power
steering fluids, metalworking fluids, and tractor hydraulic fluids.
– Anti-oxidants – Anti-oxidants, also known as oxidation inhibitors, interfere with the
oxidation process by chemically converting oxidation products to benign products. In
addition, some oxidation inhibitors interact with the free catalytic metals (primarily
copper and iron) to remove them from the oxidation process. Almost all modern
lubricants contain anti-oxidation additives in varying degrees.
Lubricants for extreme operating conditions such as diesel and gasoline engines, for high-
temperature situations, and for applications that involve high lubricant agitation require
higher levels of anti-oxidants than other lubricants.
– Pour point depressants – The pour point is the lowest temperature that a lubricant will
flow. In order to obtain flow of oil at low temperature (fluidity), pour depressants are
added to the lubricating oil to lower the pour point. These additives tend to inhibit the
formation of wax at the low temperatures. In many formulations, especially those
containing viscosity improvers, supplemental pour depressants are not needed since other
additives also have pour point depressant properties.

18-7
Predictive Maintenance

Typical applications include diesel and gasoline engine oils, transmission fluids, tractor
fluids, hydraulic fluids, and circulation fluids.
– Rust and corrosion inhibitors – Rust and corrosion are the result of the attack on the
metal surfaces by oxygen and acidic products, and are accelerated by the presence of
water and impurities. Rust and corrosion inhibitors work by neutralizing acids and
forming protective films. These inhibitors must work in the lubricant and on surfaces
above the liquid level.
The rust preventing characteristics are tested per the ASTM D665 standard. The test
evaluates the ability of inhibited mineral oils to aid in preventing the rusting of ferrous
parts should water become mixed with the lubricant.
Typical applications include engine oils, gear oils, metalworking fluids, and greases.
– Viscosity index improvers – Mineral lubricants tend to lose their lubricating ability at
high temperatures due to viscosity reduction. Viscosity improvers are added to a lubricant
to retain satisfactory lubricating capabilities at the higher temperatures. At low
temperatures the viscosity characteristics of the base stock prevail while at high
temperatures the viscosity improver maintains the viscosity at satisfactory levels.
In addition to these additives, there are numerous other ones such as dyes to mark lubricant
types, seal-swell agents to counteract the adverse effect of other additives on seals, and
biocides to retard or prevent bacterial growth. Additive packages are proprietary information,
and lubricant manufacturers do not offer detailed information on the additives present in their
products.
There are, however, several laboratory tests available to determine additive depletion or loss
in a lubricant. It is important to monitor your additive package through laboratory tests.
When your additive package depletes, your lubricant’s performance decreases, and your
equipment is left unprotected.

18-8
 Predictive Maintenance

Common elements found in lube oil additives are shown in Table 18-2.

Table 18-2
Elements in Oil Additive Package [16]

Common Elements Additive Function

Barium Detergent or dispersant

Boron Extreme-pressure

Calcium Detergent or dispersant

Copper Anti-wear additive

Lead Anti-wear additive

Magnesium Detergent or dispersant

Molybdenum Friction modifier

Phosphorus Corrosion inhibitor, anti-wear

Silicon Anti-foaming

Sodium Detergent or dispersant

Zinc Anti-wear or anti-oxidant

• Viscosity testing (ASTM D445) – Viscosity is one of the most important characteristics of
an oil because it ensures that the proper film strength is present to minimize metal-to-metal
contact and machine wear. Viscosity is a factor in the formation of lubricating films under
both thick and thin film conditions. It affects heat generation in bearings, cylinders, and
gears. It governs the sealing effect of the oil and the rate of consumption or loss. It
determines the ease with which machines may be started in cold conditions. For any piece of
equipment, the first essential for satisfactory results is to use oil of proper viscosity to meet
the operating conditions.

If the viscosity is too low, the oil may not have the necessary film strength required to
maintain a proper oil film. An inadequate oil film results in excessive wear. A decrease in
viscosity may indicate contamination with a solvent or fuel or with lower grade viscosity oil.
If the viscosity is too high, additional fluid friction is generated. This increases the operating
temperature of the bearings and increases the rate of oxidation.
A change in viscosity over time can indicate oxidation, shearing, the presence of
contamination, and additive depletion. However, in most cases, an out-of-specification
viscosity value indicates the use of an incorrect oil or the addition of an incorrect oil during
refilling of the reservoirs.
Viscosity testing is performed to characterize a fluid’s flow/resistance to flow at a given
temperature. Almost all industrial lubricating oils are specified by the International Standards
Organization (ISO) viscosity grade system. The system specifies standard viscosities at 40°C

18-9
Predictive Maintenance

from 2 Centistokes (cSt) to 460 cSt. The most common viscosity grades for bearing
applications are 32, 46, 68,100,150, and 220 cSt. To meet the specifications of the ISO
viscosity grade system, oils must be within ± 10% of the viscosity grade from the lube oil
suppliers.
From the ASTM D445/446 standard, kinematic viscosity is measured by adding a small
portion of sample oil to a calibrated capillary tube viscometer in a temperature-controlled
bath. The time it takes the fluid to flow between two fixed points in the viscometer is
measured and then compared to the standard. From this, viscosity is calculated and reported
in centistokes.
• Total Acid Number (TAN) (ASTM D664 and D974) – Acidity indicates the extent of
oxidation of a lubricant and its ability to neutralize acids from exterior sources such as
combustion gases. The acidity of lubricants is measured by the amount of potassium
hydroxide required for neutralization (mg KOH/g), and the resultant number is called the
TAN. The additives in most new oils contribute a certain TAN or acidity. Therefore, it is
critical to determine and monitor changes from the new oil reference. An increase in TAN
may indicate lube oxidation or contamination with an acidic product. A severely degraded
lubricant indicated by a high TAN may be very corrosive.
• Total Base Number (TBN) (ASTM D4739, D664, D974, and D2896) – The TBN is
determined by titration of a known substance, such as HCl, in order to determine an unknown
quantity. Weighed samples are titrated using an automatic titration system. TBN of a used
lubricant is a measurement of its ability to neutralize the acid using basic buffers.
• Crackle test/Karl Fischer water test (ASTM D-4928 and D1744) – Water in a lubricant
not only promotes corrosion and oxidation, but also may form an emulsion having the
appearance of a soft sludge. In many bearing applications, even a small amount of water can
be detrimental, especially in journal bearing applications where the oil film thickness is
critical. Some of the major causes of water in the oil include seal leaks, heat exchanger leaks,
and condensation. The sources of these leaks must be identified if the reoccurrence of this
problem sis to be prevented.

The purpose of the crackle test is to monitor the lubricant for water contamination. Since the
presence of water can cause accelerated oxidation, corrosion, and excessive wear, it is
essential that the oils are monitored for water.
In the crackle test, a drop of oil from an eyedropper is placed on a hot plate, heated to 100°
C, and monitored for the characteristic crackle that occurs as water explodes into steam. This
test is a simple, go-no go test that indicates either a positive or negative for the presence of
water. If the drop of oil crackles, it indicates that at least 0.1% water or greater is present.
The lab will report this as a “positive” test. Typically, a Karl Fisher test is then performed to
quantify the amount of water.
The Karl Fisher test is a quantitative measure of moisture in oil, reported in parts per million,
or as a percentage. Per the ASTM D1744 standard, a fixed amount of water reactive reagent
is added to a mixture of sample and solvent to achieve a pre-selected electric response. The
instrument calculates the amount of water present based on the amount of reagent required.

18-10
 Predictive Maintenance

• Smells – EPRI has been working with Cyrano Sciences to develop a library of composite
smells of lube oils, both for new oil fingerprinting and additive concentration and also for
used oil degradation without ever having to sample the equipment.

The technology consists of individual thin-film carbon-black polymer composite detectors

configured into an array. The collective output of the array is used to identify an unknown
vapor using standard data analysis techniques. The sensor array, along with data analysis
algorithms, forms the main components of the electronic nose. The output from the device is
an array of resistance values as measured between each of the two electrical leads for each of
the detectors in the array. When the detector is exposed to vapors, the polymer matrix acts
like a sponge and swells while absorbing the vapors.
Moreover, for well-defined applications, the polymers used in the detector array can be
chosen to maximize chemical differences between target compounds to increase the
discrimination power of a smaller array. This underscores the power of Cyrano Sciences’
polymer composite sensor technology because it is not reliant on any particular polymer type
or limited to a particular set of polymers. Additionally, the simplicity of reading resistance
values and the low cost of materials of the detectors makes this an ideal technology for a
low-cost, hand-held electronic nose.
By establishing a library of the composite smells of oxidized oils in different degrees of
oxidation, a library can be established that will allow for a quick check of a sample using the
electronic nose to determine what state of degradation the oil is in. Because of the desire to
concentrate the vapors in an available headspace, the vented areas of storage drums and
operating equipment reservoirs become the ideal location to perform in situ analysis of the
condition of the lubricants. Without ever sampling the oil from equipment or drums, an
evaluation of the vapors present in the headspace can provide important information about
the condition of the lubricating oil present.
• Flash Point (ASTM D92) – Flash point indicates the presence of highly volatile and
flammable materials in a relatively nonvolatile or nonflammable material. An example is an
abnormally low flash point on a test specimen of engine oil that can indicate fuel
contamination. The lubricant sample temperature is raised at a constant rate as the flash point
is approached. At specified intervals, a small test flame is passed across the cup containing
the sample. The lowest temperature that the application of the test flame causes the vapors
above the surface of the liquid to ignite is determined as the flash point.
• Oxidation Stability Test (ASTM D2272) – This was formerly called the rotating bomb
oxidation test. The test is used to assess the remaining oxidation test life of in-service
lubricants. The test lubricant, water, and a copper catalyst coil contained in a covered glass
container are placed in a pressure vessel equipped with a pressure gage. The vessel is charged
with oxygen to a pressure of 620 kPa, placed in a constant-temperature oil bath set at 150°C,
and rotated axially at 100 rpm at an angle of 30° from the horizontal. The number of minutes
required to reach a specific drop in gage pressure is the oxidation stability of the test sample.
• Demulsibility (ASTM D1401-96) – The test provides a guide for determining the water
separation characteristics of oils subject to water contamination and turbulence. A 40-ml
sample and 40-ml of distilled water are stirred for 5 minutes at 54°C in a graduated cylinder.

18-11
Predictive Maintenance

The time required for the separation of the emulsion thus formed or volumes of water, oil,
and emulsion remaining after 30 minutes is recorded.
• Pour Point (ASTM D97) – The pour point is the determination of the lowest temperature
that a petroleum product may be used if fluidity is necessary to the application. After
preliminary heating, the petroleum sample is cooled at a specified rate and examined at
intervals of 3ºC for flow characteristics. The lowest temperature that movement of the
specimen is observed is recorded as the pour point.
• Foam Test (ASTM D892-95) Sequence I, II, III – The test determines the foaming
characteristics of lubricating oils at specified temperatures. The foam test is a means of
empirically rating the foaming tendency and the stability of the foam. A defined volume of
air is forced through a set volume of sample lubricant at a specified temperature. The
resulting volume of foam is measured.
• Cone Penetration of Lubricating Grease (ASTM D 217) – This test measures the
consistency of grease. Harder grease will have a low National Lubricating Grease Institute
(NLGI) rating number such as 00 or 1. Most industrial greases penetrate in the 265–295
ranges and have a NLGI rating of 2.

A measured amount of grease sample is placed under a cone apparatus. The cone is attached
to a gauge that measures from 85–475 gradations on the apparatus. The cone is dropped into
the grease sample from a specified height and for a specified time. The measured amount that
the cone penetrates into the grease is the cone penetration.
• Dropping Point of Lubricating Greases (ASTM D566) – This test is a determination of the
maximum operating temperature of grease. A grease sample is heated in the dropping point
apparatus. The point at which the grease starts separating and the oil drops out of the
apparatus is the dropping point. The temperature is measured in degrees Celsius.
• Percent Sediment in Lubricating Oils – This test is an excellent determination of sediments
suspended in lubricating oil. Excessive amounts of sediments can impede oil capability and
can clog filters.

18.3 Condition-Based Maintenance – Kennedy Van Saun

(Courtesy of Kendal Power Station)

The following pertains to the condition-based maintenance program on the Kennedy Van Saun
ball/tube mills at the Kendal Power Station.

Vibration readings are taken monthly on all mill components. Historical data are captured for
monitoring the critical components like the girth gear, the pinion gear, and the main gearbox.

Oil samples from the motor oil tank and trunnion bearing oil tank are tested for viscosity, water
content, total acid number, spectrometric analysis, and wear particle concentration.

Table 18-3 lists the components that are included in the lubrication program.

18-12
 Predictive Maintenance

Table 18-3
Kennedy Van Saun Mill Components for Lubrication Program

Equipment Component for Lubrication

Trunnion bearings Lube oil tank motor bearings

Lube oil tank

Mill main gearbox Lube oil tank

Labyrinth seals

Lube oil tank motor bearings

High-speed coupling

Low-speed coupling

Mill pinion bearings

Mill drive motor bearings Lube tank

Lube oil tank motor bearings

Barring gear unit Motor

Perigrip brake (pivots)

Gearbox

Coupling (Hand wheel)

Girth gear Spray

Lubricator on control air system

Seal air fans Motor bearings

High speed coupling

Fan bearings

Mill isolation valve (non-drive-end and Bushings for air cylinder

drive-end)
Pin on fulcrum

Glands on valve

Lubricator on control air

Classifier reject isolation valve (non- Bushings for air cylinder

drive-end and drive-end)
Pin on fulcrum

Glands on valve
Lubricator on control air

Reject flap gate

18-13
Predictive Maintenance

Table 18-3 (continued)

Kennedy Van Saun Mill Components for Lubrication Program

Equipment Component for Lubrication

Control damper Actuator

Links/fulcrums

Drive-end reject shutoff gates control

air

Ball charge hopper control air Glands (2)

isolation valve
Pin

Lubricator on control air

Hot primary air control damper Gearbox worm

Actuator

Cold air isolator Gear motor

Gearbox
Metro-flex isolator

Stock Volumetric Feeders:

Belt drive conveyor Motor bearings

Eddy current coupling

Gearbox worm

Cleanout conveyor Motor bearings

Gearbox worm

Belt head pulley (DE [2], NDE [1])

Chain head pulley (DE [2], NDE [1])

Head support rollers (2)

Tension pulley

Booster pulley

Impact rollers (13)

Belt take-up pulley

Belt take-up
Chain take-up

18-14
 Predictive Maintenance

Table 18-3 (continued)

Kennedy Van Saun Mill Components for Lubrication Program

Equipment Component for Lubrication

Feeder inlet gate – Bunker outlet Gearbox handwheel and chain

Shaft end cap
Drive-end bearing housing
Valve body (1 roller per side)
Position indicator
Feeder outlet gate – Air/coal valve Valve
Valve actuator
Shaft end cap
Drive-end bearing housing
Limitorque main gear case
Zerk fitting in housing cover
Geared limit switch
Motor bearings

18.4 Condition Based Maintenance – Stein Industrie

(Courtesy of Matimba and Majuba Power Stations)

Matimba Power Station has placed many of the ball/tube mill components on a condition-based
maintenance program. For example, the trunnion seal air fan motors are monitored and repaired
based on their condition.

Vibration readings are taken once a month for the mill drive train (main motor and gearbox), the
girth gear, and the pinion. Vibration readings are taken every two months for the hot seal air fan
and the cold seal air fan.

The following equipment is monitored for temperature readings monthly:

• Girth gear and pinion tooth flank
• Pinion bearing
• Lubrication system motors for the Turbolub, Hytec, and main gearbox and girth grease
systems
• Hot and cold seal air fan motors
• Feeder belt drive gearbox and motors
• Main motor winding temperatures (every two months).

18-15
Predictive Maintenance

Oil samples are taken every six months for the main gearbox, motors and annually for the
auxiliary gearbox.

The following equipment is rotated or replaced based on the condition of the equipment:
• Main gearbox
• Screw conveyor – 40,000 operating hours life
• Girth gear – 90,000 operating hours life
• Mill liners – rotations at 35,000 operating hours and replacements at 65,000 operating hours
• Melroth gasket

The following discussion pertains to the condition-based monitoring program for the Majuba
Power Station. A history of all wearing or eroding parts should be established to monitor the rate
of wear or erosion. After the history has been established, any drastic change must be
investigated.

The system is running in an acceptable state if no faults are found during condition monitoring
checks by the operational or maintenance personnel and all temperatures and pressure are
correct. A potential failure mode is an operating condition that may lead to failure if allowed to
continue. The potential failure modes for equipment are listed in all relevant tables in this
section. Table 18-4 shows the system parameters that are monitored.

Table 18-4
Condition-Based Monitoring Values at Majuba Power Station

System Parameter Value

Raw-coal feeder Chain speed 0.34 rpm,

0.741 m/minute
minimum
3.47 rpm,
7,562 m/minute
maximum
Drive motor speed 1,445 rpm

Reduction gearbox – input 1,445 rpm

Reduction gearbox –output 17.89 rpm

Reduction gearbox – reduction ratio 80.76:1

Inverter speed reduction ratio 10:1

18-16
 Predictive Maintenance

Table 18-4 (continued)

Condition-Based Monitoring Values at Majuba Power Station

System Parameter Value

Main bearing Low-pressure system – cooling oil flow 7 liters/minute

lubrication
system Low-pressure system – cooling oil temperature 40°C

Low-pressure system – oil differential pressure 100 kPa

High-pressure system – pump supply pressure 150 kPa

High-pressure system – pump outlet pressure 7 MPa

High-pressure system – thrust pump outlet pressure 4 MPa

Oil tank level 1,750 mm (1,800 liters)

Drive train Mill speed 16.2 rpm

Mill motor speed 991 rpm

Main reduction gearbox – input 991 rpm

Main reduction gearbox – output 123.8 rpm

Main reduction gearbox – reduction ratio 8:1

Number of teeth on drive pinion gear 30

Number of teeth on girth gear 234

Main reduction Oil quantity 270 liters

gearbox
lubrication Oil temperature 45°C
system
Oil pressure 300 kPa
Oil flow rate 80 liters/minute

Oil differential pressure 100 kPa

Girth gear Pump delivery 40:1

lubrication
system Grease temperature Ambient temperature

Main motor Flooding oil pressure 1.5 MPa

lubrication
system Jacking oil pressure 20 MPa

Oil flow rate per bearing 4.3 liters/minute

Oil differential pressure 100 kPa

18-17
Predictive Maintenance

Table 18-4 (continued)

Condition-Based Monitoring Values at Majuba Power Station

System Parameter Value

Mill air system Primary air collector – air temperature 245°C

Primary air collector – air pressure 10 kPa

Direct hot air box – air temperature 245°C

Direct hot air box – air pressure 10 kPa

Direct hot air box – airflow 28 kg/second

Bypass piping – air temperature 245°C

Bypass piping – air pressure 10 kPa

Bypass piping – airflow 28 kg/second,

32 kg/second maximum
Purge air piping – air temperature 245°C

Purge air piping – air pressure 2.63 kPa

Purge air piping – airflow 8.2 kg/second

Air inlet/outlet differential pressure 3 kPa

Seal air sub- Fan suction pressure 9 kPa

system
Fan discharge pressure 14 kPa
3
Fan airflow 8,000 m
3
Fan air density 1,083 kg/m

Seal air pressure at air boxes 11.2 kPa

Seal air to mill air differential pressure 1.5 kPa

First fan differential pressure 1.15 kPa

Second fan differential pressure 1.2 kPa

Condition monitoring covers the following:

• Continuous remote operational monitoring using alarm sensors
• Scheduled condition monitoring

The conditions listed in Table 18-4 are monitored by the operating staff in the control room.
These indications are checked locally by operational staff on the local alarm panel or directly on
the local sensors at the equipment. All the alarm-based checks are listed in Table 18-5.

18-18
 Predictive Maintenance

Table 18-5
Monitored Conditions at Majuba Power Station

Operating Performance Parameter Acceptance Potential Failure

Criteria Modes

Trunnion bearing drive-end/non-drive-end <60 °C >60 °C

temperature

Main motor bearing temperature <85 °C >85 °C

Mill primary air/pulverized fuel duct purge >1.0 kg/s <1.0 kg/s
airflow

Drive-end/non-drive-end outlet primary air

temperature – Low >75 °C <75 °C
High <90 °C >90 °C

Burner pulverized fuel duct supply pressure

>2.5 kPa <2.5 kPa
Low
<4.5 kPa >4.5 kPa
High

Seal air/primary air differential pressure >5 kPa <5 kPa

Mill non-drive-end/drive-end inlet primary air >4.5 kPa <4.5 kPa

pressure

Mill quick-closing damper position >100% <100%

Duplex filter differential pressure <160 kPa >160 kPa

Burner pulverized fuel duct supply temperature

Low >75 °C <75 °C
High <100 °C >100 °C

A list of condition monitoring instruments supplied by Stein Industrie and a description of their
particular function and location are given in Table 18-6. The instrumentation covers the raw-coal
feeder, the mill air system, the seal air system, and the mill main motor.

18-19
Predictive Maintenance

Table 18-6
Condition Monitoring Instrumentation for Majuba Power Station

Instrumentation Description Working Point at the

Maximum Continuous Rating

Raw-Coal Feeder

Speed transmitter monitoring speed of raw-coal feeder 3.3 m/minute (96.53%)

Current transmitter monitoring current drawn by feeder motor Load dependent

Limit switch monitoring coal level 200 mm

Inductive pick-up monitoring feeder rotation stall monitor 3.3 mm

Limit switch monitoring single gate slide damper position 100%

Limit monitor monitoring speed - control frequency inverter 3.3 m/minute

Current transducer monitoring main drive motor kW indication 1.508–1.660 kW

Limit switch (barring) monitoring electrohydraulic brake position Disengaged

Limit switch (inching) monitoring electrohydraulic brake position Engaged

Centrifugal switch monitoring auxiliary gearbox speed 50 r/minute

Thermocouple monitoring trunnion drive-end/non-drive-end 55°C

bearing

Thermocouple monitoring main drive motor bearing 70°C

Thermocouple monitoring main drive motor winding 100°C

Thermocouple (fire detection) monitoring tube mill classifier 75°C

temperature

Flow switch monitoring trunnion bearing NDE oil flow - connected 20–25 liters/minute
to flow transducer (SM1 supplied)

Flow switch monitoring trunnion bearing DE oil flow - connected 20–25 liters/minute
to flow transducer (SM1 supplied)

Flow switch monitoring main reduction gearbox oil flow 90 liters/minute

Low -level switch monitoring trunnion bearing oil reservoir level 1.450 liters

Low-level switch monitoring main reduction gearbox oil level 245 liters

Local sight glass monitoring trunnion bearing oil reservoir level 750 mm

Differential pressure switch monitoring trunnion bearing low- 100 kPa

pressure differential pressure

Pressure switch monitoring trunnion bearing high-pressure pump 100 kPa

inlet pressure

Pressure switch monitoring trunnion bearing non-drive-end 2–4 MPa

lubrication pressure

18-20
 Predictive Maintenance

Table 18-6 (continued)

Condition Monitoring Instrumentation at Majuba Power Station

Instrumentation Description Working Point at the

Maximum Continuous Rating

Raw-Coal Feeder

Pressure switch monitoring trunnion bearing drive-end lubrication 2–4 MPa

pressure

Differential pressure switch monitoring reduction gearbox filter 100 kPa

differential pressure

Pressure switch monitoring trunnion bearing thrust face 1–4 MPa

lubrication pressure

Local pressure gauge displaying trunnion bearing cooling low 250 kPa
pressure oil pressure

Local pressure gauge displaying trunnion bearing inlet pressure 150 kPa

Local pressure gauge displaying trunnion bearing non-drive-end 3 MPa

lubrication pressure

Local pressure gauge displaying trunnion bearing drive-end 3 MPa

lubrication pressure

Local pressure gauge displaying tube mill reduction gearbox 100 kPa
lubrication pressure

Local pressure gauge displaying trunnion bearing thrust face 1.5 MPa
lubrication pressure

Temperature sensor controlling trunnion bearing lubrication 40°C

Temperature switch controlling trunnion bearing oil reservoir 40°C

heater

Temperature switch controlling trunnion bearing oil tank 40°C

temperature interlock

Temperature switch controlling trunnion bearing oil tank 40°C

temperature

Temperature switch monitoring trunnion bearing high pressure 40°C

Temperature switch monitoring reduction gearbox oil 60°C

temperature

Local temperature gauge displaying trunnion bearing oil reservoir 40°C

temperature

Local temperature gauge displaying reduction gearbox inlet 60°C

temperature

Level switch monitoring mill main motor lube oil tank level 80 liters

Sight glass displaying mill main motor lube oil tank level 80 liters

18-21
Predictive Maintenance

Table 18-6 (continued)

Condition Monitoring Instrumentation at Majuba Power Station

Instrumentation Description Working Point at the

Maximum Continuous Rating

Pressure switch monitoring mill main motor jacking oil pressure 10 MPa

Pressure switch monitoring mill main motor jacking oil pressure 10 MPa

Pressure switch monitoring mill main motor jacking oil pressure 10 MPa

Pressure switch monitoring mill main motor flooding oil pressure 600 kPa

Pressure switch monitoring mill main motor flooding oil pressure 600 kPa

Pressure switch monitoring mill main motor flooding oil pressure 600 kPa

Differential pressure switch monitoring mill main motor filter 20 kPa

differential pressure

Local pressure gauge displaying mill main motor lube oil 20 MPa
pressure

Local pressure gauge displaying mill main motor lube oil filter 20 kPa
differential pressure

Local pressure gauge displaying mill main motor flooding oil 600 kPa
pressure

Temperature switch monitoring mill main motor lube oil 50°C

temperature -

Temperature switch monitoring mill main motor lube oil 50°C

temperature

Temperature switch monitoring mill main motor lube oil 50°C

temperature

Local temperature gauge displaying mill main motor lube oil 50°C
temperature

Mill Air System

Primary air collector pressure measurement - connected to 10 kPa

differential pressure transducer

Resistance thermal device, monitoring primary air collector 245°C

temperature measurement

Venturi measuring purge air piping flow 2.93 kg/second

Venturi measuring bypass piping non-drive-end flow 8.8 kg/second

Venturi measuring direct piping drive-end flow 19 kg/second

Venturi measuring direct piping non-drive-end flow 19 kg/second

Venturi measuring direct piping drive-end flow 19 kg/second

18-22
 Predictive Maintenance

Table 18-6 (continued)

Condition Monitoring Instrumentation at Majuba Power Station

Instrumentation Description Working Point at the

Maximum Continuous Rating

Direct piping non-drive-end pressure measurement 8 kPa

Direct piping drive-end pressure measurement 8 kPa

Resistance thermal device measuring direct piping non-drive-end 245°C

temperature

Resistance thermal device measuring direct piping drive-end 245°C

temperature

Tapping point for drive-end hot air box differential pressure 10 kPa

Tapping point for non-drive-end hot air box differential pressure 10 kPa

Seal Air System

Tapping point for seal air differential pressure 15.4 kPa

Connection to pressure transmitter showing differential pressure 10 kPa

between drive-end hot air box primary air and main seal air
piping

Connection to pressure switch showing differential pressure 10 kPa

between non-drive-end hot air box primary air and main seal air
piping

Mill Main Motor

Type-K thermocouple monitoring drive-end bearing temperature ±75°C

Type-K thermocouple monitoring non-drive-end bearing ±75°C

temperature

Resistance temperature device monitoring U-phase winding ±140°C

temperature

Resistance temperature device monitoring W-phase winding ±140°C

temperature

Resistance temperature device monitoring V-phase winding ±140 °C

temperature

Resistance temperature device monitoring U-phase winding ±140 °C

temperature - connected to SM1 instrumentation

Resistance temperature device monitoring W-phase winding 140°C

temperature

Resistance temperature device monitoring V-phase winding 140°C

temperature

All scheduled (time-related) condition-based maintenance tasks are listed in Table 18-7.

18-23
Predictive Maintenance

Table 18-7
Scheduled Condition Monitoring at Majuba Power Station

Equipment Condition Monitored Acceptance Potential Scheduled

Criteria Failure Monitoring
Modes Interval

Conveyor bearings Check temperature <10°C >10°C one month

increase.
No vibration Vibration
Check for vibration.
Drive pinion bearing Check temperature <10°C >10°C one month
drive-end/non-drive-end increase.
No Vibration Vibration
Check for vibration.
Main reduction gearbox Check temperature <10°C >10°C one month
bearing increase.
No Vibration Vibration
Check for vibration.
Auxiliary reduction Check temperature <10°C >10°C one month
gearbox bearing increase.
No Vibration Vibration
Check for vibration.
Mill main motor Check for vibration. <2.8 mm/s rms >2.8 mm/s one month
bearings rms
Check temperature <10°C
increase. <10°C
Mill and seal air system Check gland for leaks. No leaks Leaks one month
dampers
Check for damaged No damage Damage
cables.
Secure Loose
Check for loose
mounting. No leaks Leaks

Check for air duct leaks.

Seal air fan bearings Check for vibration. No vibration Vibration one month
Check temperature <10°C >10°C
increase.
Seal Air Check airflow. Slight increase Marked one month
increase

Raw-coal feeder Check chain tension >30 mm <30 mm 200 hours

bearings adjuster gap.
<1 mm >1 mm
Check clamping plate
distance between either
side.

18-24
 Predictive Maintenance

Table 18-7 (continued)

Scheduled Condition Monitoring at Majuba Power Station

Equipment Condition Monitored Acceptance Potential Scheduled

Criteria Failure Monitoring
Modes Interval

Main Seal Air Fan Check for leaks: No leaks Leaks three months
Outlet seal, inlet seal, No cracks or Cracks
and shaft seal. corrosion corrosion
Check fan for cracks or No cracks, Not secure
corrosion. secure
Vibration
Check bearing plummer No vibration >4 mm/
block bases for cracks second
and security.
Check fan alignment.

Raw-coal feeder Check temperature <10°C >10°C 800 hours

bearings increase.
No vibration Vibration
Check for vibration.

Electrohydraulic Brake Check brake shoe >1–3 mm <1–3 mm 100

adjustment. operations

Mill main motor Check desiccator Blue Pink one year

crystals for motor
dampness. Secure Loose

Check fixing bolts, Tight Loose

couplings, and guards.
Check electrical
connections.

Quick-close damper Check gland for leaks. No leaks Leaks one year

At Tutuka Power Station, the manufacturer recommended oil change intervals for the mill main
lubrication system, the main reduction gearbox, the inching gearbox, and the mill main motor
lubrication system of 4000 operating hours. This means that each mill would require a full
lubricant service twice a year.

The station decided to use condition-based monitoring of the oil to determine the interval of
lubricating oil changes. The following practices were adopted:
• Lubricant sampling and analysis was conducted between 1500 and 1750 operating hours.
• Modifications were made to the existing shaft sealing arrangement to eliminate points of
contaminant ingress.

18-25
Predictive Maintenance

• Additional lubricant sampling and analysis was conducted based on vibration analysis and
other plant monitoring parameters.
• Blockage of lube oil filters was investigated quickly.
• Lubricants with moisture contamination were replaced.

Because of these lubrication system practices, the current average interval for oil changes is
39,450 operating hours. The change from the manufacturer-recommended interval of 4,000
operating hours to 39,450 operating hours has realized cost savings to the plant. There have been
no forced outages from lubricant failures, but the plant has been unavailable because of severe
lubricant contamination.

Tutuka Power Station has a well-equipped, on-site oil laboratory that is used primarily to test
lubricants for basic parameters such as viscosity, moisture content, and acid number on a routine
basis. The on-site laboratory is used for first-line investigations and has a very fast turnaround
time for testing.

An independent, off-site oil analysis laboratory was contracted to provide the in-depth oil testing
and analysis. The off-site laboratory was selected based on the offerings of testing available, the
repeatability of test results, the reliability of analysis, and rapid turnaround times. The following
lubricant tests are performed by an off-site testing laboratory:
• Viscosity at 40°C in centistokes (cSt)
• Total acid number in mg KOH/g
• Water content in parts per million (ppm)
• Solid Contamination Code from ISO (International Standards Organization) 4406 –
Hydraulic Fluid Power – Fluids –Methods for Coding the Level of Contamination by Solid
Particles
• Elemental analysis by atomic emission spectroscopy
• Additive package condition
• Fourier transform infrared analysis
• Wear debris analysis

18-26
19
PREVENTIVE MAINTENANCE

This section includes the PM information for the ball/tube mills manufactured by Allis-
Chalmers, Kennedy Van Saun, Riley Power Inc., and Stein Industrie.

Human Performance Key Point

There are three areas of work that are critical to performing maintenance on the
mills. The areas are temporary lighting, lifting and rigging practices, and temporary
scaffolding.

It should be noted that temporary lighting should be installed when working in and around the
mill. Generally, the environment is dark, and the black color of the coal makes the environment
even darker.

When lifting components, it is very important to know the weight of the components so that the
appropriate lifting devices can be used. In some of the tables in this section, the weight of the
components is given. Using the correct device to lift the components prevents personnel injury.

In a number of areas around the mill, it is necessary to access manholes, dampers, or piping.
Temporary scaffolding should be inspected prior to use.

19.1 Allis-Chalmers

Information in this section was provided by Eskom’s Lethabo Power Station. There are several
tables that list the inspection tasks for the mill components. The following tables cover:
• External inspection
• Internal inspection
• Classifier inspection
• Drive train inspection
• Shell and trunnion liner replacement
• Trunnion bearing insert replacement
• Girth gear replacement
• Gearbox rebuild

19-1
Preventive Maintenance

• Miscellaneous equipment
• Equipment lubrication list

Before the tables are presented, the general layout of the Lethabo Power Station is given. Entry
to the interior of the ball mill is through an access door in one of the two inlet/outlet boxes.
Externally, access to the milling plant equipment can be achieved using low scaffolding.

The primary air piping and ducting above the ball/tube mill is supported by constant load
supports enabling disconnect from the inlet/outlet boxes without additional support being
provided.

The inlet/outlet boxes require support platforms when withdrawing them from the mill trunnions.
This support is also required when relocating the inlet/outlet boxes to align the mill sealing
arrangement.

A special jacking cradle is provided to facilitate limited upward movement of each ball/tube mill
for maintenance purposes such as bearing changes. A portable hydraulic system consisting of a
power pack with four lifting cylinders is used under the lifting cradle to raise the mill evenly.
The system is designed to extend and retract the lifting cylinders at the same time, but individual
cylinder control is not provided. The system is protected by an overload trip switch in the
electrical circuit and by pressure relief valves in the hydraulic circuit. Each cylinder is fitted with
a safety valve that locks the cylinder in the event of a power or hydraulic hose failure during
operation.

19.1.1 Inspection Criteria

The following inspections should be performed every 3000 operating hours:

• Seal air fan system – impeller, bearings, breather, coupling, springs, foundation bolts,
trunnion air seal, and trunnion vent valve
• Ball charge hopper
• Trunnion lube oil system – sight glass, filters, strainer, flexible hoses, oil cooler, sample
points, and oil pump
• Gearbox lube oil system – oil pumps, filters, oil cooler, flexible pipe, bypass regulating
valve, and drain valve
• Girth gear lube system – lubricators, air supply line water trap, air regulator, flexible hoses,
spray bar distribution block and pump, nozzles distribution block and overhaul pump,
flexible pipe, air filter, and seal air fan
• Dampers – secondary air, primary air, isolation, hot air, tempering air, bypass, rating, and
core air

19-2
 Preventive Maintenance

• Feeders – screens, tension pulley bearings and bushings, main conveyor drive pulley, main
drive coupling, conveyor main drive gearbox, gearbox oil level, inspection windows, main
conveyor belt and joint, conveyor tensioning unit, suspended support roller, support idlers
and bearings, impact idlers and bearings, rubber scraper and bushings, feeder casing, door
seals, inspection cover seals, and feeder profile bar height
• Cleanout conveyor system – drive sprocket, heat and tail sprocket, chain and links, first and
second reduction gearbox, drive adaptor coupling, and tensioning unit
• Drive train alignment – mill motor to gearbox, gearbox to pinion gear, barring gear to
motor, drive motor magnetic center, pinion bearing clearances, trunnion bearing insert wear,
reduction gearbox internal condition
• Mill motor heat exchanger – remove, clean, and replace
• Classifiers – vanes and inverted cone
• Motors – mill drive, gearbox lube oil pump, mill girth gear seal air fan, mill barring gear,
trunnion pump, feeder conveyor drive, secondary air damper, bypass damper actuator ,
primary air isolating damper, seal air fan damper actuator, primary air rating damper, hot air
damper, tempering air damper, seal air fan, and core air fan

In addition, the following inspections should occur annually:

• Pinion gear – Remove, clean, and reinstall.
• Girth gear – Verify axial and radial run-outs, root clearance, backlash, gear contact, and
alignment.

19.1.2 External Mill Inspection

Table 19-1 lists the inspection tasks for an external mill inspection.

19-3
Preventive Maintenance

Table 19-1
External Mill Inspection Tasks
(Courtesy of Lethabo Power Station)

Equipment Tasks

Ball charge Check around hopper flanges and access doors for air leaks.
hopper
Check the status of the ball charge and confirm the storage of replenishment
balls.
Ensure operability of the operating extending spindle for the lower charging door.
Check the 200-mm ball-charge piping for damage.
Classifier Check around the flanges and top cover for leakage of coal. Check the spring
hanger supports for damage.
Check the outer cone for deterioration.
Check the coarse rejects pipe for leakage and deterioration.
Primary air Check the expansion joints and flanges for leakage and deterioration.
ductwork
Check the fixed and spring hanger supports for damage.
Check the ductwork for deterioration.
Inlet/Outlet Check the mill sealing arrangement for leakage.
boxes
Check the inlet/outlet boxes and ductwork for deterioration.
Note: Discolored areas of paint may indicate internal hot spots or fires. It is
recommended any discolored areas be repainted.
Check around the flanges and access doors for leakage.
Check the service supply connections to the inlet/outlet boxes for leakage.
Rotating mill Check the acoustic housing for damage and deterioration.
Check the acoustic housing for external noise level.
Check the trunnion bearings for overheating.
Check that the power and sound transducers are in normal operating limits.
Check the trunnion piston ring sealing system and add grease as needed.
Check that all drive coupling guards are secure.
Trunnion Check the oil levels in each trunnion sump and add oil as needed.
bearing
lubrication Check the lubricating systems for leakage.
system Check the low-pressure (680 kPa) readings on each lubrication system.
Check the cooling water supply flow rates (0.46 liters/second).
Check the oil temperatures on each system (30–60°C).

19-4
 Preventive Maintenance

Table 19-1 (continued)

External Mill Inspection Tasks
(Courtesy of Lethabo Power Station)

Equipment Tasks

Trunnion Check the oil filter color indicators with coding as follows:
bearing
lubrication Green - Full filtration, bypass closed.
system Green/Red - Change element, full filtration but bypass valve is starting to open.
(continued)
Red - Element change overdue, partial filtration, bypass valve is opening.
Check low press pumps for unusual noise and heat.
Gearbox unit Check the gearbox unit for unusual noise and vibration.
and lubrication
system Check the gearbox unit acoustic housing for damage and deterioration.
Check the acoustic housing for external noise level.
Check the oil level and add oil as needed.
Check the oil temperature (48–54°C) and pressure (140 kPa)
Check the system for leakage.
Check the input and output coupling guards for security.
Check the cooling water supply flow rates (0.9 liters/second).
Girth gear Check the lubricant level in the supply drum.
lubrication
system Check the air pump, panel, and piping for leakage.
Check that the air supply pressure is above the minimum required (400 kPa).
Cleanout the residue from the drip tray under the gearing.
Confirm that all spray lances are providing lubricant over the girth gear.
Girth gear seal Check the fan bearings for unusual heat and noise.
air system
Check that both fan inlet filters have no obstructions.
Check the fan discharge pressure (0.5 kPa).
Check the flexible air supply piping for leakage.
Check around the girth gear guard for air leaks.
Motor and Check that the motor cooling air inlet and outlet have no obstruction.
barring gear
Check the motor air temperatures (<110°C).
Check the oil level in the motor bearings.
Check that the bearing oil temperatures are in the normal range (<80°C).
Check the oil level in the barring gear unit.
Check that the barring coupling engagement handwheel is not obstructed and is
correctly in the engaged or disengaged position

19-5
Preventive Maintenance

19.1.3 Internal Mill Inspection

Table 19-2 lists the internal inspection tasks for the Allis-Chalmers mill.

Table 19-2
Internal Inspection Tasks
(Courtesy of Lethabo Power Station)

Equipment Tasks

Disassembly Wear appropriate safety equipment at all times.

Observe safety precautions. Use gas monitor at all times.

Grease drums to be removed to prevent contamination.

Clean acoustic hood, chutes, and pinions.

Install access ladders at all mill doors.

Miscellaneous Repair or replace trunnion division plates.

during
disassembly Renew reject flaps and wear sleeves where identified.
Repair mill bypass dampers and shafts. Set open and close stops on actuator.

Replace feedtubes where needed.

Measure grinding media levels.

Shell liners Measure the thickness of the shell liners using an ultrasonic thickness tester.

The measurements should be taken in the trough of the liner contour and on the
crest.

Measure the thickness of the end inner and outer liners.

Examine the trunnion throat liners for wear.

Record the measurements to establish a rate of wear.

The high-chrome iron liners are 25-mm thick initially and should be replaced when
worn to 18-mm thickness. The Roq-last liners can be used until completely worn
through. When these liner plates are between 2- to 3-mm thick, then replacement
should be considered.

Shell liner bolts Check the tightness of all liner bolts. Tighten the liner bolts to 750 N-m.
When using new liners, the liner bolts must be retightened within the first eight
hours of full load operation. A second retightening must be performed within the
first week of full load operation.

19-6
 Preventive Maintenance

Table 19-2 (continued)

Internal Inspection Tasks
(Courtesy of Lethabo Power Station)

Equipment Tasks

Trunnion Remove the small access cover on the top of the trunnion bearing cap at each
bearing insert end of the mill.
Measure the distance between the trunnion journal and the outer face of the
access cover hole using a steel rule.

Compare this measurement with previous measurements. When the

measurement has increased by 2 mm, the trunnion seal should be checked.
When the measurement has increased by 6 mm, the bearing insert should be
replaced.
General Repair inlet and outlet boxes for ceramic tile installation, if needed.

Remove and replace bottom coal gates.

Repair reject pipe bends.

Inspect and replace tiles in the mill.

Inspect and repair tiles for the reject wear sleeves.

Retile the mill outlet boxes if needed.

Outside the Check all coupling bolts for tightness.

Drum
Check all hold down bolts for security.

Check all piping brackets for security.

Check all concrete foundation platforms and surrounding areas for cracking and
deterioration.
Assembly Remove all tools and debris from mill.

Replace grease drums.

Replace girth gear grease system.

Close mill doors.

Remove access ladders from mill doors.

Clean outer mill area from tools and debris.

19.1.4 Classifier Inspection

Table 19-3 lists the tasks for inspecting the classifier.

19-7
Preventive Maintenance

Table 19-3
Classifier Inspection Tasks
(Courtesy of Lethabo Power Station)

Tasks
1. Open inspection plug on classifier roof.
2. Remove side inspection covers.
3. Inspect inner cone for blockage.
4. Inspect inverted cone.
5. Inspect vanes for blockage.
6. Record findings.
7. Close inspection plugs and covers.
8. Open classifier by removing the pipe bend on top of the classifier. Move bend sideways to allow
access and anchor in position.
9. Inspect vanes and shafts for wear.
10. Inspect all lined surfaces for wear. Measure the thickness of the liners using an ultrasonic
thickness tester. Record the thickness readings to establish a rate of wear.
11. Inspect classifier roof for wear.
12. Inspect unlined surfaces for wear and deterioration. Small areas can be strengthened by
welding plate patches externally.
13. Inspect inverted cone for position and wear.
14. Inspect thermocouple pockets for wear.
15. Mark repairs and record findings.
16. Perform ultrasonic thickness test on inner cone. Record findings.
17. Repair classifier inner cones using the window repair method. Open the inspection covers on
the outer cone before welding. Repairs to be welded from inside of cone and ground flat on the
outside.
18. Inspect tiles on classifier inner cones.
19. Inner cones to have tiles replaced from the outside of the inner cone. Open inspection covers on
outer cone to ensure draft for welding. Rough grind area to be repaired before applying tiles to
ensure bonding.
20. Replace inspection covers.
21. Perform final inspection of repairs.
22. Inspect sealing surfaces and clean.
23. Inspect gasket and lightly grease.
24. Remove scaffold and tools from inner cone.
25. Ensure no tools or debris are dropped in inner cone.
26. Close pipe bend.

19-8
 Preventive Maintenance

19.1.5 Drive Train Inspection

Table 19-4 lists the tasks for inspecting the mill drive train.

Table 19-4
Mill Drive Train Inspection Tasks
(Courtesy of Lethabo Power Station)

Tasks

1. Clean and inspect mill pinion gear for destructive pit marks.

2. Remove, clean, and inspect grid couplings.

3. Open, clean, and inspect pinion bearings.

4. Re-pack pinion bearings with grease and close bearings.

5. Replace all oil filters.

6. Replace all breathers.

7. Open gearbox cover, disconnect coupling, and inspect.

8. Check and correct the drive train alignment.

9. Clean and inspect bearing engagement nut.

10. Inspect gearbox oil level.

11. Inspect gear brake drum linings.

12. Inspect gear motor coupling.

13. Drain drive motor bearing oil and inspect bearings.

14. Clean motor bearing oil cavity and level sight glass. Replace sight glass when stained or
damaged.
15. Lubricate and replace grid couplings.

19-9
Preventive Maintenance

19.1.6 Shell and Trunnion Liner

Table 19-5 shows the tasks for replacing the shell and trunnion end liners.

Table 19-5
Shell and Trunnion Liner Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

1. Remove the ball charge from the mill using a vacuum device or remove manually.

2. Remove the mill acoustic housing.

3. Remove the inlet/outlet boxes.

4. Position and support a runway beam through the center of the mill shell end and through the
ends to give clearance for lowering the liners onto a trolley.
5. Install portable air extraction and supply equipment inside the mill.

6. Install portable lighting inside the mill.

7. Install a communication system between the inside and outside of the mill.
8. Arrange for the barring gear to be available.

Note: When turning the mill, the trunnion bearing jacking oil system or manual jacking pumps must be
used. The mill gearbox lubrication system should be in operation.
Note: The liner bolts, nuts, and seal washers are not to be reused but replaced with new items. The seal
washer retainers can be reused. As the old bolts are removed, they should be put in bags for disposal.
9. Starting at a point well below the level of the portable runway beam, remove the shell liner bolts.

10. As each liner is released, use rigging attachments and raise the liner up and out of the shell
along the portable runway beam.
11. Remove all liners that are accessible using the lifting arrangement.

12. Remove the securing bolts from the trunnion end liners and filler ring that can be reached and
move the bolts out of the mill.
13. When all the liners that can be reached are removed from the shell, raise and remove all tools
and equipment from inside the bottom of the shell.

14. Using the barring gear, the manual jacking pumps, and the gearbox lubrication system, rotate
the mill to the next working position.
15. Repeat the procedure to remove the shell liners, trunnion liners, and securing bolts.

16. Clean the inside of the shell and inspect for corrosion and erosion.

Note: New liners should be interchangeable within the type of liner. The weights of the new liners are:
Trunnion end liner - inner = 174 kg, trunnion end liner outer = 184 kg, filler ring = 70 kg, 2-hole shell liner
= 114 kg, 1-hole shell liner = 57 kg.
17. Fit new filler ring segments, new filler ring bolts, nuts, seal washers, and original seal washer
retainers to the lower working area of the trunnion ends.

19-10
 Preventive Maintenance

Table 19-5 (continued)

Shell and Trunnion Liner Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

Note: The liner bolts should not be finally tightened until all the gaps between the liners have been
equalized.
18. Fit new trunnion end outer liners using new attachment pieces. Check each liner against the
trunnion inner face for rocking. If more than 2.5 mm of rocking is present, the liner should be
adjusted to fit.

19. Fit new trunnion end inner liners using new attachment pieces. Check each liner against the
trunnion inner face for rocking. If more than 2.5 mm of rocking is present, the liner should be
adjusted to fit.
20. Fit new shell liners and attachment pieces. The shell liners consist of the single-hole and
double-hole types that allow the offset gaps.
Note: Shell liner rock should be checked. Only the lip around the liner edges should be in contact with
the shell.
21. Rotate the mill with the barring gear until all the liners are installed.

22. Check and equalize the gaps between the liners.

23. Tighten the liner bolts to 750 N-m using a torque wrench.

24. Remove all tools from the inside of the mill shell.

25. Remove the portable runway beam, air extraction equipment, portable lighting, and
communication system.
26. Replace the inlet/outlet boxes.

27. Replace the acoustic housing.

28. Return the mill to service.

19.1.7 Trunnion Bearing Insert Replacement

Table 19-6 lists the tasks for replacing a trunnion bearing insert.

19-11
Preventive Maintenance

Table 19-6
Trunnion Bearing Insert Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

1. Attach a flexible hose to the drain valve on the trunnion bearing base sump.

2. Open the drain valve and drain the oil into an appropriate container.

3. Shut the drain valve and remove the flexible hose.

4. Disconnect the oil supply pipe from the bearing cp.

5. Plug the oil supply piping to prevent ingress from dirt.

6. Disconnect the grease supply pipes to the upper halves of the two sealing rings.

7. Remove the nuts, washers, and bolts securing the bearing cap. Then remove the tapered dowel
pins.
8. Fit eye bolts in the two rapped holes in the bearing cap.

9. Attach lifting slings to the eye bolts and remove the bearing cap using the hoists attached to the
mill runway beams.
10. Remove and discard the gasket.

11. Disconnect the cooling water supply and return hoses from the bearing insert.

12. Disconnect the high-pressure jacking oil supply hose from the bearing insert. Plug the system
side of the pipe to prevent the ingress of dirt. Release the pipe clamps.
13. Disconnect the resistance temperature detector from the bearing insert.

14. Remove the retainer plates, deflector plate, and felt from the bearing insert.

15. Fit the eye bolts in the ends of the bearing insert. Attach slings to the eyebolts and lift the
bearing insert using hoists attached to the mill runway beams.
Note: It is important that cleanliness standards be maintained during assembly to prevent the ingress of
foreign material into the trunnion bearing lubrication system.

16. Fit eye bolts in the tapped holes in the sides and ends of the new bearing insert.
17. Lightly oil the trunnion surface.

18. Attach slings to the eyebolts on the side of the bearing insert.

19. Lift the bearing insert and lower the bearing onto the trunnion surface.
20. Rotate the insert around the trunnion surface until the insert is in the correct position in the
bearing housing. Remove all eyebolts.

21. Using the hydraulic jacks, lower the mill carefully into the bearings.

22. Check the oil wedge clearance by inserting a 0.5-mm thick feeler gauge. The sum of the depths
of penetration of the feeler gauge on both sides of the bearing should be an average of 200 mm.
23. Fit the retainer plates, deflector plate, felt, and clamps. Adjust the felt so that it is in contact with
the trunnion.

19-12
 Preventive Maintenance

Table 19-6 (continued)

Trunnion Bearing Insert Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

24. The retainer plate on the deflector plate side of the bearing should be adjusted with shims if
necessary to ensure that it contacts the bearing housing. The retainer plate on the other side of
the bearing should be adjusted with shims to give a clearance between 1.5–7.8 mm. After the
retainer plate is adjusted, tighten the retainer plate securing bolts to 2,650 N-m.
25. Re-connect the resistance temperature detector to the bearing insert.

26. Remove the plug from the system side of the jacking oil supply hose and re-connect the pipe to
the bearing insert. Fit the pipe clips and tighten to 22 N-m.
27. Install a new gasket on the bearing housing. Lift the bearing cap and lower the cap into position
on the bearing housing.

28. Fit the taper dowel pins and secure the bearing cap with the bolts, washers, and nuts. Tighten
the bolts to 185 N-m.
29. Reconnect the grease pipe to the upper halves of the sealing rings and fill the lubricating system
with grease. The initial grease charge is 3.5-kg followed by 0.1-kg six times hourly for 20 hours.
After 20 hours, add 0.5-kg every second week or when leakage is detected.
Note: The gap between the sealing rings and bearing cap should be 0.1–2.2 mm maximum.

30. Remove the plug from the system side of the lubricating oil pipe and reconnect the pipe to the
bearing cap.

31. Record the bearing clearances.

32. Carry out an inspection of the drive pinion and gear to check alignment.

33. Refit the input/output box.

34. Open one of the hand-hold covers and replenish the oil level in the bearing housing. Use a
funnel or a hand pump to transfer oil from the container to the bearing.
35. Close the hand-hold cover.

19.1.8 Girth Gear Replacement

Table 19-7 lists the tasks to replace the girth gear.

19-13
Preventive Maintenance

Table 19-7
Girth Gear Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

Disassembly

1. Remove sections of the acoustic housing from the drive-end of the mill for access to the girth
gear.
2. Remove the four top half sections of the girth gear guard.

3. Remove the ball charge from the mill using a vacuum device or remove ball charge manually.
4. Rotate the mill using the barring gear until the split line of the girth gear halves is horizontal.

Note: When turning the mill, the trunnion bearing jacking oil system or manual jacking pumps must be
used. The mill gearbox lubrication system should be in operation.
5. Remove the mill drive pinion assembly.

6. Using a system of pulleys, slings, and winches, secure the mill to prevent rotation.

7. Remove the split pins, locknuts, and nuts from the girth gear split joint alignment bolts.

8. Remove the parallel stud bolts and drive out the fitted taper stud bolts.

9. Drive out the split taper bushings from the taper stud bolt holes. Ensure that match markings on
the stud bolts, taper bushings, and corresponding holes are clearly visible.

10. Attach slings to the girth gear top half and support the weight (8000 kg) of the gear with the aid
of hoists attached to the runway beam.
11. Remove the locknuts, nuts, and bolts securing the girth gear half to the mill head.

12. Lift the girth gear half clear of the mill.

13. Rotate the mill 180° so that the remaining girth gear half is on the top position of the mill.

14. Secure the mill to stop any rotation.

15. Attach slings to the girth gear top half and support the weight (8000 kg) of the gear with the aid
of hoists attached to the runway beam.
16. Remove the locknuts, nuts, and bolts securing the girth gear half to the mill head.

17. Lift the girth gear half clear of the mill.

New Girth Gear Installation

18. Inspect the new girth gear halves and remove any burrs, grease, paint, and protective coatings
from the machined surfaces.

19. Ensure that all centering bolts for adjusting radial alignment have been fitted before mounting
the gear halves.
20. Inspect the mill head flange and remove all burrs, grease, and paint from the gear mating
surface.

21. Check that all mill shell flange bolts are correctly tightened.

19-14
 Preventive Maintenance

Table 19-7 (continued)

Girth Gear Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

22. Check all connecting bolts for damage and compatibility with nuts.

23. Check tapered bolts and bushings for damage and compatibility with nuts.

24. Attach slings to the girth gear half and lift the gear half into position. Install the gear half with
every third bolt connected to the mill head flange. Ensure that the true face marking on the girth
gear is facing toward the mill drive.
25. Rotate the mill so that the gear half is on the bottom half of the mill.

26. Check the clearance bolt assembly by inserting a clearance bolt from the top of the split into one
of the clearance holes located nearest the outside diameter of the gear half. If the bolt passes
completely through the hole, proceed with mounting the other gear half.
Note: If the bolt does not pass completely through the hole because of interference at the inside rim
diameter of the gear, all clearance bolts must be inserted into this half before assembly.
27. Attach slings to the remaining girth gear half and raise the gear half into position. Ensure that
the true face marking is on the correct side.
28. Draw the girth gear half against the mounting flange with three bolts. Do not fully tighten bolts
until after alignment of the gear halves.
29. Insert the stud bolts and draw together the ring gear halves. Do not fully tighten the bolts until
the correct match marks of the stud bolts and holes are verified.
30. Coat the internal and external surfaces of the split tapered bushing with Coppercoat and insert
the tapered bushing into the hole. Place the flange of the tapered bushing at the top of the
flange seated against the counterbore. Ensure the correct match marking of the tapered bushing
and holes.

31. Insert the tapered alignment bolt into the tapered bushing with the small end down. Ensure the
correct match marking of the tapered bolts and holes.
32. Place a washer and nut on the small end thread and tighten with a torque spanner wrench to
3,343 N-m.

33. Place a washer and nut on the large end thread of the tapered bolt and tighten with a torque
spanner to 2522 N-m. Fit the large end locknut and tighten.
34. Check the torque at the small end of the tapered bolt, fit the locknuts, and tighten.

35. Repeat steps 30–-34 of these tasks for the remainder of the alignment bolts. Tighten the parallel
alignment bolts to 5865 N-m.
36. Check the joint true face alignment with a straight edge and feeler gauges. The true face
alignment should be within 0.076 mm.

37. Tighten all stud bolts and adjust to give equal lengths on either side of the joint.

19-15
Preventive Maintenance

Table 19-7 (continued)

Girth Gear Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

38. Heat shrink the clearance bolts into place. Place nuts on the bottom of the clearance bolts and
adjust the bolts so that equal amounts of bolt length extend out both sides. After adjusted,
remove the nut from the bottom, making sure that the nut can be easily removed. Slip the bolt
out of the hole so that the unthreaded portion is completely exposed. Do not damage the
threads. Heat the unthreaded portion uniformly to a temperature of 234°C above ambient
temperature. Check the temperature every three or four minutes with a surface pyrometer or
Tempilstik. Make sure the bolts are heated evenly and that the torch is not held too close to the
bolts. Do not heat above the specified temperature. After heating, replace the bolt quickly and
put the nut on and tighten by sledging. Lock nuts should then be put on and tightened.
Note: Do not fit split pins until the final alignment is complete.

Note: The gear is now ready to be aligned for axial wobble and radial runout.

Note: Joint tighteners should prevent an entry of 0.0381-mm feeler gauge.

39. Reinstall the mill drive pinion assembly.

Note: Pinion shaft seals should be set to fit as snug as possible.

Girth Gear Alignment

Note: Suitable gear alignment data sheets should be developed based on the original installation
records.

40. Insert all flange bolts and finger-tighten the bolts.

41. Adjust the gear centering screws to position the girth gear on the shell flange to obtain a uniform
gap between the gear flange inside diameter and the shell flange outside diameter.

42. Tighten every third flange bolt snug.

43. Mark the girth gear in 12 equal positions starting at the split line of the gear and number 1 to 12.

Note: Box axial wobble and radial runout test should be made at the same time. Four dial indicators are
required. The gauge used for radial runout should be fitted with a large mushroom button.

44. For radial runout, place the indicator mushroom squarely against the top land of the gear teeth
and set the indicator to zero.
45. Rotate the gear so that each of the numbered stations is brought under the indicator.

Note: If the indicator does not return within 0.05 mm of zero after one revolution, the readings must be
repeated as the dial may have moved or the gear is not properly located.
46. Record the readings of the indicator at each of the 12 locations and determine the amount and
location of the largest positive runout.

47. Rotate the mill so that the point of largest positive runout is in the 12 o’clock position.

48. Back off the centering screws on the top half of the gear to the amount of correction required.

49. Back off the flange bolts and allow the gear to settle back on the centering screws under its own
weight.

19-16
 Preventive Maintenance

Table 19-7 (continued)

Girth Gear Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

50. Tighten all flange bolts to secure the gear in position.

51. Tighten all centering screws into contact with the gear.

52. Continue taking runout readings and make corrections until the maximum runout is 0.608-mm is
obtained. Record the final runouts.

53. For axial wobble, place two indicators against the trunnion journal face and one against the gear
face.
54. Rotate the mill and take a reading at 12 positions.

Note: The axial wobble is the algebraic difference between the readings. If the axial wobble is greater
than 0.608 mm, then the mill manufacturer should be consulted.
55. Tighten all the gear securing bolts to the correct torque of 5,865 N-m. Check the full
circumference with a feeler gauge ensuring full contact between the gear face and shell flange
face.

56. Back off the centering screws and secure with Locktite.

57. Check the gear teeth contact marking and backlash by rotating the gear to a position that the
point of maximum runout is in contact with the pinion.

58. Ensure that the gear can not rotate.

59. Tighten the pinion against the gear in the direction of normal rotation.

60. Check the contact and backlash clearance on both sides of the pinion and gear with feeler
gauges. The backlash is 2.79-mm maximum and 2.54-mm minimum measured at 20°C ambient
temperature.
Note: Contact and clearance should be made at four points that are 90° apart. If the gear and pinion axis
are parallel, the contact and backlash will be the same on either end of the tooth. If not, shimming of the
pinion may be necessary and should not affect the drive alignment.
Assembly

61. Replace the girth gear guard by joining the segments of the guard from the markings.

62. Seal all guard flange joints with RTV sealant.

63. Screw all the air seal adjusting screws down, then back off five full turns for the initial setting.

64. Replace the acoustic housing.

65. Replace the ball charge.

66. Check the gear teeth contact marking with the full ball charge in the mill and record the
readings. If the contact is not correct, then the gear may require shimming.
Note: If any shimming of the pinion was performed, the alignment of the pinion to the gearbox and the
gearbox to the motor coupling must be checked and realigned.

19-17
Preventive Maintenance

Table 19-7 (continued)

Girth Gear Replacement Tasks
(Courtesy of Lethabo Power Station)

Tasks

Mill Startup

67. During startup of the mill, the following must be monitored for the first 48 hours of operation:

• Final alignment of the girth gear to pinion by using a strobe light

• Vertical and horizontal vibration readings on the drive train

• Temperatures across the pinion and girth gear measured at three places. If a temperature
difference of >10°C between any one of the measured values occurs, the mill should be
shut down and the alignment checked.

• Girth gear guard air seal checked for clearance at the normal operating conditions

19.1.9 Gearbox Rebuild

Table 19-8 lists the tasks for rebuilding the mill gearbox unit.

19-18
 Preventive Maintenance

Table 19-8
Gearbox Rebuild Tasks
(Courtesy of Lethabo Power Station)

Tasks

Note: The component weights are:

Acoustic hood = 494 kg, complete main gear unit = 13,000 kg, main gear unit casing = 4400 kg, output
coupling = 1420 kg, input coupling = 443 kg, input shaft assembly without the coupling = 415 kg, output
shaft assembly without the coupling = 5080 kg.
Disassembly

1. Remove the coupling halves from the input shaft and the output shaft.

2. Remove the dowels, nuts, and bolts from the casing.

3. Remove the studs, nuts, and locknuts from the bearing housings.
4. Remove the setscrews and screws from the top half of the input shaft end cover and oil catcher.

5. Attach the lifting devices to the four lifting lugs on the top half casing and with a straight lift, raise
the top half casing carefully and remove. The approximate weight of the top half casing is
2000 kg.
Disassemble Pinion Shaft

6. Remove the setscrews from the bottom half of the input shaft end cover and oil catcher.
Remove the end cover.
7. Disconnect the flanged joint and remove the oil spray nozzle piping.

8. Protect the shaft and attach lifting devices around the shaft on both sides of the double helical
pinion. Raise the assembly carefully. The weight of the pinion shaft is 415 kg.

9. Remove the labyrinth cover from the oil catcher. Remove the oil seals and slide off the oil
catcher.
10. Remove the keeper plate from the non-drive-end of the shaft and the locknut from the drive-end.

Disassemble Output Shaft Assembly

11. Remove the screws from the bottom half of the output shaft end cover and oil catcher. Remove
the end cover from the assembly.
12. Protect the shaft and attach the lifting gear around the shaft on either side of the wheel. Raise
the assembly carefully.
13. Remove the labyrinth cover from the oil catcher. Remove the oil seals and slide off the oil
catcher.
14. Remove the keeper plate from the non-drive-end of the shaft. Remove the lock plate, setscrew,
and washer from the locknut. Remove the locknut.
15. Remove both bearings from the shaft.

16. Remove the distance piece.

17. If required, remove the complete wheel center and wheel rim from the output shaft using a
hydraulic press.

19-19
Preventive Maintenance

Table 19-8 (continued)

Gearbox Rebuild Tasks
(Courtesy of Lethabo Power Station)

Tasks

Clean and Inspect

18. Clean all removed components for inspection. Clean the gear case.

19. Examine the gears for cracked or broken teeth. If there is damage on the gears, then both gears
should be replaced.

20. Examine the bearings for damaged rollers or races. Replace bearings if needed.
21. Examine the internal lubrication piping, restrictors, and nozzles for damage or blockage.

22. Examine the shafts for cracking, damage, and wear. If wear is found on the shaft bearing
surfaces from inner race creep, the seating scan be machined slightly undersize, plated with
chromium, and reground to the correct size.
Assemble Output Shaft

23. If it was necessary to remove the complete wheel center and wheel rim from the shaft, then
perform the following tasks:

• Grease the mating surfaces of the wheel and the shaft.

• Fit the key to the shaft.

• Ensure the helix is correct and press the complete wheel center and wheel rim onto the
shaft until it makes solid contact with the shaft should using a 60-metric ton hydraulic press.

24. Fit the distance piece ensuring the piece makes contact with the final wheel.

25. Prepare the bearings by heating in an oil bath not to exceed 121°C.

26. Fit the bearings to the shaft ensuring a solid fit against the shaft end distance piece and shaft
shoulder.

27. Fit the keeper plate onto the short end of the shaft and secure with setscrews and spring
washers. Lock the setscrews with wire.
28. Fit the bearing locknut and secure with the lock plate, setscrew, and washer.

29. Attach the lifting devices to the shaft on both sides of the wheel and lift the assembly. The
weight of the shaft assembly is 5080 kg.
30. Lower the assembly into the bottom half gear casing. Set the bearings carefully into the bearing
housings to avoid damage.

31. Position the output shaft to maintain 925 mm from the shaft end to the center line of the gear
unit.
32. Fit the end cover and oil catcher. Ensure the oil slots coincide with those in the gear casing.

33. Check that the bearing axial end float is between 0.81–1.13 mm.

34. Fit the new oil seals and spacer. Pack the cavity with grease. Fit the labyrinth cover.

19-20
 Preventive Maintenance

Table 19-8 (continued)

Gearbox Rebuild Tasks
(Courtesy of Lethabo Power Station)

Tasks

Assemble Input Shaft

35. Prepare the bearings by heating them in an oil bath not to exceed a temperature of 121°C.
Ensure that the oil is clean.
36. Fit the bearings to the shaft ensuring they are in close contact with against the shaft shoulder.

37. Fit the keeper plate to the short end of the shaft with setscrews and spring washers. Lock the
setscrews with wire.
38. Fit the bearing locknut and lock washer.

39. Protect the shaft and attach the lifting devices around the shaft on both sides of the pinion. The
shaft assembly weight is 415 kg. Lift the assembly.
40. Lower the assembly into the bottom half gear casing. Set the bearings carefully into the bearing
housings to avoid damage.

41. Position the input shaft to maintain 825 mm from the shaft end to the center line of the gear unit.

42. Apply blue dye to the pinion teeth and roll the gears under light load to ensure the input shaft is
centered. Check that the teeth make contact over 80% of the meshing line.
43. Fit the end cover and oil catcher. Ensure the oil slots coincide with those in the gear casing.

44. Check that the bearing axial end float is between 0.498–0.675 mm.

45. Fit the oil seals and spacer. Pack the cavity with grease. Fit the labyrinth cover.

Assemble the Top Half Casing

46. Ensure that the top and bottom half casing mating surfaces are clean.
47. Apply a thin layer of jointing compound to the top and bottom half casing mating surfaces. Fit
new brown paper packing. (0.15-mm thick).

48. Fit the oil spray nozzle piping and re-connect at the flanged joint. Secure bolts with steel wire.

49. Attach the lifting devices to the four lifting lugs on the top half casing. The casing weight is
approximately 2000 kg. Position the top half casing over the bottom half casing and lower the
top half casing carefully into position.

50. Insert the dowels to center the top half casing.

51. Fit the studs, nuts, and locknuts to the bearing housings.

52. Fit the nuts and bolts to the casing joint.

53. Fit the screws to the top half of the output shaft end cover.

54. Fit the screws to the top half of the input shaft end cover.

55. Fit the coupling halves to the input shaft and output shaft.

19-21
Preventive Maintenance

19.1.10 Miscellaneous Equipment

The sealing air fan system uses a single fan during operation, leaving the second as a backup
source. This arrangement provides an opportunity to alternate the usage of the fans and allows
for a scheduled maintenance program. The inlet filter boxes must be cleaned periodically, with
filters being replaced or cleaned as operation conditions dictate.

All dampers must be lubricated and operated to order to ensure that the shafts are free to rotate in
the bearing assemblies. Linkages and controls must be free in the entire range of movement. The
dampers in the air system are integral with the boiler control system.

All damper valves must be checked for leaks and operated periodically for ease in shutting and to
determine if replacement parts are needed. All supports, internal and external, should be
inspected periodically to ensure their integrity. Any evidence of corrosion or erosion should be
recorded and repaired.

19.1.11 Equipment Lubrication List

Table 19-9 lists the equipment that requires lubrication.

19-22
 Preventive Maintenance

Table 19-9
Equipment Lubrication List
(Courtesy of Lethabo Power Station)

Equipment Component

Girth gear seal air fan Intermediate bearings

Mill drive motor Bearings

Trunnion Bearings

Low-pressure pump motor

High-pressure pump motor

Piston ring seal

Seal air fan Bearing box

Drive motor bearing

Coupling

Feeder Belt take-up pulley

Belt take-up screws

Cleanout conveyor take screw

Inlet span rollers

Tension roller shaft

Tension roller pivot

Support roller (suspended)

Belt drive shaft

Cleanout conveyor shaft

Belt paddle switch shaft

Belt drive motor counter shaft

Cleanout conveyor motor booster roller

Idle rollers

Reducer gearbox Belt drive-MVF 150 P

Cleanout conveyor

Inlet valves Operating shaft

Gate rollers

Actuator adaptors

Position indicators

19-23
Preventive Maintenance

Table 19-9 (continued)

Equipment Lubrication List
(Courtesy of Lethabo Power Station)

Equipment Component

Outlet valves Operating shaft

Gate rollers

Actuator adaptors

Position indicators

Primary and FD fans Lube oil Pump – Motor bearing

Jacking oil pump – Motor bearing

Lubricating oil tank

Motor bearing

Vane control actuators (Siemens Linkage)

Gearbox

PF isolating dampers Isolating dampers gearbox

(Babcock)
Bypass dampers Siemens Linkage ball joints
actuator
Automatic mill ball loading Conveyor grease points
machine
Air line mist spray

Milling plant gear unit David Brown gear unit

Input Coupling

Output coupling

Mill gear unit labyrinth

Barring gear unit First and second reduction cases

Output gearing

Girth gear and pinion shaft Girth gear spray grease pump

Girth gear spray air service unit

Pinion shaft bearing

19.2 Kennedy Van Saun

This section (Courtesy of Kendal Power Station) includes tables for the inspection of the pinion,
girth gear, and lubrication systems and for reversing the worm gear.

19-24
 Preventive Maintenance

19.2.1 Pinion, Girth Gear, and Lubrication System

Table 19-10 lists the tasks for inspecting the pinion, girth gear, and the lubrication systems.

Table 19-10
Inspection Tasks for Pinion, Girth Gear, and Lubrication Systems
(Courtesy of Kendal Power Station)

Tasks

1. Ask operations about oil leaks and overheating conditions during operation. Check the
condition of the pinion gear seals and lantern rings.

2. Inspect the clearances between the stuffing box and pinion shaft (19 mm).

3. Check the stuffing box alignment measured at 4 places.

4. Check the mounting bolts torque for the pinion mounting bolts (2700 N-m) and the pinion
bearing pedestal bolts (4200 N-m)

5. Inspect the pinion bearing. Remove the old grease and replace with new grease.

6. Check the backlash using lead wire readings. The contact and backlash average should be
>1.964 mm and <7.856 mm.

7. Check the contact pattern using Prussian blue. Parallel and center patterns covering 80% tooth
load surface should be recorded.

8. Check the girth gear lubrication system for train 1 and 2.

9. Clean the drip trays and surrounding area.

10. Service the girth gear spray pumps to deliver 15 MPa.

11. The girth gear spray pumps air supply lubricators should be filled with oil.

Girth Gear Distribution Blocks and Nozzles

12. Unblock the strainers, distribution blocks, nozzles, and piping.

13. Ensure there is a 2-mm gap between the moving plunger and the proximity switch.

14. Simulate the lube spray distribution and ensure the spray is uniform across the tooth flank.

15. Verify the girth gear sealing arrangement is intact with no air leaks.

19.2.2 Reversing the Worm Gear

Table 19-11 lists the tasks for reversing or flipping the gearbox worm gear.

19-25
Preventive Maintenance

Table 19-11
Tasks for Reversing the Gearbox Worm Gear
(Courtesy of Kendal Power Station)

Tasks
1. Remove gearbox coupling guards, housings, and coupling springs on both high- and low-speed
sides.
2. Remove mounting bolts and pipework.
3. Secure flange holes.
4. Lift out gearbox from mill using approved crane and rigging hardware.
5. Transport the gearbox from the mill area into a workshop area.
6. Remove both couplings.
7. Remove all bolts and nuts and lift the top casing half.
8. Remove the two M20 dowels from the casing joint.
9. Remove the three top half bolts on the input line end cover and oil catcher.
10. Remove the oil spray lance at the flanged joint.
11. Lift out the pinion shaft by using suitable slings on both sides of the bearings.
12. Remove the labyrinth cover from the oil catcher and slide off the oil seals.
13. Remove the keeper plate at the non-drive-end side from the shaft and the locknut on the drive-
end side.
14. Pull off both bearings, inspect the bearings, and replace if necessary.
15. Using suitable slings on both sides of the bearings, lift the output shaft assembly straight up.
16. Clean the casing halves and ensure the casing is dry.
17. Inspect the pinion and output shaft gears for high wear, pitting, damage and so on.
18. Record findings by using a camera.
19. Turn the gears 180° and reinstall the complete assembly into the bottom casing.
20. Adjust input bearing bench endplay to 0.26–0.42 mm.
21. Adjust input bearing mounting endplay to 0.05–0.21 mm.
22. Adjust output bearing bench endplay to 0.50–0.75 mm.
23. Adjust output bearing mounted endplay to 0.13–0.39 mm.
24. Reassembly of gearbox is the reverse of the disassembly procedure.
25. Install gasket onto center joint and refit the top half of the gearbox.
26. Fit nuts and bolts on center joint and tighten to correct torque specifications.
27. Refit mill reduction gearbox into mill drive train.
28. Align gearbox.

19-26
 Preventive Maintenance

19.3 Riley Power Inc.

The PM information in this section [7] covers the PM inspection criteria and tasks associated
with the following components/issues:
• Feeder
• Crusher-dryer
• Inlet/outlet boxes and air seals
• Mill liners
• Ball charge
• Speed reducer gearbox
• Drive train
• Driveshaft
• Classifier
• Lubrication heat exchanger
• Primary air fan and ductwork
• Coal shutoff valves
• Lubrication schedule
• Spare parts
• Example PM inspections

19.3.1 Feeder

The PM tasks for the feeder include the following:

• Grease bearings monthly. This includes the drum shaft bearing, the wiper shaft bearing, the
release apron shaft bearing, the shear pin sprocket assembly, and the conveyor pulley shaft.
• Apply a light oil (SAE #40) weekly to the roller chain drive.
• Flush and refill the transmission gear reducer every six months with AGMA #8 compound.
• Check wiper blades for wear once every six months.
• Check the release apron gap (1/16 in.), the adjustable apron gap (1/32 in. ±1/64 in.), and the
wiper blade gap (between 1/8–1/4 in.) every six months.
• Inspect all wearing parts once a year for excessive wear.
• Inspect counter linkage monthly to prevent loosening of parts.

19-27
Preventive Maintenance

There should be a 1/16-in. clearance between the tip of the leveling apron and the drum. This
clearance can be obtained by adjusting the external support under the leveling apron arm. A
minimum clearance is necessary for the adjustable apron plate. Loosen the holding screws, move
the apron liner forward until it touches the drum rib, retract it slightly for a tolerance of 1/32 in.
±1/64 in., and tighten the holding screws. Recheck by rotating the drum one full revolution.

The wiper blades should have 1/4-in. maximum and 1/8-in. minimum clearance at the inlet and
outlet points for moving through the drum pockets to ensure maximum cleaning. After adjusting
the wiper blades, revolve the drum by hand to make sure the wiper blades pass through all the
pockets without interference. A maximum 10% pocket loss from teeth tip to pocket bottom is the
allowable limit.

19.3.2 Crusher-Dryer

On a monthly schedule, the hammer-to-crusher block clearance should be reset to a clearance of

1/8 in. This procedure is done with the crusher-dryer in service and no doors on the crusher-dryer
open. To adjust the clearance requires the following actions:
• Loosening the locknuts on the crusher block adjusting screws
• Turn each crusher block adjusting screw1/4 turn clockwise until a ticking noise is heard
• Back off each crusher block adjusting screw one full turn counterclockwise and retighten the
locknuts, thereby securing the crusher block adjusting screws

Change the crusher-dryer lube oil annually. The lube oil has a viscosity of 225 Saybolt Seconds
Universal (SSU) at 100°F and a Society of Automotive Engineers (SAE) rating of 20. It is
recommended to flush the entire lube oil system before changing the oil. This is accomplished by
adding a solvent with no greater than 5% by volume of the total quantity of used oil in the
reservoir. This can be done while the crusher-dryer is in a normal operating mode. Allow the
crusher-dryer to operate normally with the solvent-oil mixture for a 24-hour period but not more
than 36 hours. The lube oil system is then drained and filled with new oil.

Clean the oil filter element periodically. The filter element can be cleaned with the crusher-dryer
in service. Using the handle at the top of the filter housing, make one complete turn of the filter
element. In addition, remove the plug at the bottom of the filter sump housing to drain the filter
annually.

The grids, swing hammers, and crusher block of the crusher-dryer can be removed and replaced
easily through the front access door that is located above the adjustable crusher block. Removal
of this door exposes the back of the breaker plate and frame assembly. Remove the breaker plate
support rods, and with the help of an overhead lifting device, withdraw the breaker plate from the
crusher. Remove the breaker frame assembly holding bolts. The breaker frame assembly can
then be removed. Then, remove the adjustable crusher block and inspect the solid grids and
hammers.

19-28
 Preventive Maintenance

Swing hammers can be worn to within 1.5 in. of the shank opening as measured from the side
with the least wear of the hammer before replacing. Grids can be worn through one-half of the
thickness.

The swing hammers can be easily removed after the cotter pin, that holds the swing hammer pins
in position, has been removed. Each swing hammer pin may be slid out through the hand hole
provided in the crusher-dryer housing. The swing hammers are matched and wired in balanced
pairs, and care must be taken to install these hammers diametrically opposite each other to
maintain the balance of the crusher-dryer. The adjustable crusher block should be set for 1/4–
1/2-in. clearance from the hammers before starting the crusher-dryer. Refasten the breaker plate,
the frame assembly and the front access door. Refasten any other access doors that were
removed.

To remove the bearings from the shaft, support the weight of the crusher-dryer shaft on a sling or
blocking, remove the bearing housing end cover along with the shaft coupling and any other
obstructions. Remove the bearing lock nut and lock-washer. Then, using the bearing removal nut
furnished with the crusher-dryer tools, loosen and extract the tapered adapter sleeve, and remove
the bearing from the housing.

To install a new bearing, visually inspect the bearing seat to ensure that the machined finish is
not scratched or marred. Make a similar visual inspection of the housing base. The housing base
and the mounting surface must be flat. Place the bearing housing on the sole plate, check for any
unevenness or distortion, and correct any irregularities. Wipe the inside of the bearing housing
and the shaft with a clean, lint-free, lightly oiled rag, remove the bearing from the wrapping, and
place it in the housing. Do not remove the oil-soluble protective coating from the bearing. Place
the housing and the bearing on the shaft with tapered sleeve lightly pushed into position. Make
sure that the inside flinger, the collar, and the end cover are already in place.

Pay close attention to cleanliness in handling these bearings, especially during installation.
Clean, lint-free rags and hand protection should be used when cleaning the bearing housing and
shaft. Be careful to keep dirt and corrosive chemicals from coming in contact with the polished
surfaces.

Do not remove new bearings from their carton or wrapper until they are required to be mounted
on the crusher-dryer shaft. Before replacing the bearing, all the parts and tools necessary for the
complete assembly and disassembly of the shaft should be available.

With the bearing partially assembled on the shaft, and the weight of the crusher-dryer rotor and
shaft supported by a sling or block so that the bearing has no load, and after properly centering
the rollers in the outer race, the unmounted initial clearance between the rollers and the outer
race can be determined by the use of feeler gauges. The allowable range for unmounted initial
clearance is 0.0031–0.0043 in. The outer race should be lifted, and the clearance measured. Keep
the bearing assembly covered.

When tightening the bearings, clean the threads on the shaft and in the locknut. Dirt on the
threads may cause damage by galling. Apply a very light coating of Molykote to the shaft

19-29
Preventive Maintenance

threads, to the faces of the tapered sleeve, and to the lock nut that meets during assembly.
Position the tapered sleeve in the bearing. Run the locknut up to a hand-tight position. Tighten
the nut further with a light spanner wrench or by tapping with a hammer and drift. Maintain a
steady force on the locknut with the spanner wrench. Hold a heavy punch parallel to the shaft
with the end against the locknut face. Hit the punch with an 8-lb hammer. The impact on the nut
drives the sleeve inward if the nut is kept firmly against the sleeve. This is achieved by
maintaining a steady pressure on the spanner wrench.

Continue tightening in the above manner until the desired reduction in bearing unmounted
internal clearance is obtained.

During field disassembly or assembly, the crusher weight should be removed from the bearing
by jacking underneath the shaft next to the bearing so that the lower rollers are free to turn.

Always tighten the locknut. Never release tension to obtain the correct internal clearance. Should
it become necessary to release tension because of over-tightening, use the sleeve removal nut,
and begin the tightening process again.

Care must be used during the tightening operation as the races and adaptor are hard and brittle,
and it is important that no chips or dirt enter the bearing or housing.

If the bearing assembly is too loose, the adaptor may creep or turn in the shaft. Both the shaft and
bearing would be damaged beyond repair before corrective action could be taken. Consequently,
it is extremely important that the crusher-dryer shaft bearing adaptor sleeve and inner race be
even and free from dirt or grit. The locknut should be rigid in position and retained by the lock
washer. By driving the tapered sleeve by the locknut and reducing the internal clearance between
the rollers and the outer race, a definite tightness is set up between the inner bearing race and the
shaft sleeve. It is important that the allowable minimum reduction is obtained.

Assemble the remaining bearing parts, such as covers and so on. Avoid unnecessary hammering
or rough handling when assembling bearing parts.

Bearing housing covers and flingers must be assembled with proper clearance. There should be
approximately a 1/16-in. longitudinal clearance between the flingers and cover in order to allow
for shaft expansion. The flingers must not rub on the housing cover, and there should be equal
clearance around the entire circumference of the flinger. This equal clearance should be
maintained when the housing is bolted to the pedestal, and care should be taken when bolting the
housing to avoid housing distortion, as the bearing outer race must float in the housing. Tight fit
or distortion of the bearing housing that restricts the movement of the outer race causes the
bearing to overheat and become damaged.

The parts that need to be replaced the most frequently in the crusher-dryer section are solid
grinds, swing hammers, and crusher block and breaker plates. The design of the machine enables
these parts to be easily replaced without removing the housing.

19-30
 Preventive Maintenance

19.3.3 Inlet/Outlet Box and Air Seals

The mill inlet/outlet boxes are normally not a high-maintenance item. However, a few routing
items should be checked periodically. These items include:
• The bypass damper, which should move freely, and the shaft bearing should be lubricated at
regular intervals.
• The foundation bolts, which should be checked and tightened as required.
• The inlet/outlet boxes, which should be checked for distortion from overheating caused by
fires in the mill system. This could cause binding of the bypass damper or misalignment with
the mill head extension causing damage to the air seal.

The inlet/outlet air seals should be inspected and greased monthly according to the lubrication
schedule. There are two grease fittings on the perimeter of the seal at each end of the mill.

These seals should be replaced when excessive leakage occurs and the preset mill/seal air
differential cannot be maintained. With the mill rotating, stand at the end of the mill, and listen
for rubbing noises in the area of the mill inlet/outlet box seal sleeve. If rubbing noises are heard,
the air seals should be inspected and repaired.

Visually inspect the air seal for leaking coal dust. If coal dust is observed leaking from the area
of the air seals, verify that the seal air pressure is approximately 15 psig. Open the ring header air
piping drain valve to blow out any water.

The following should be performed when inspecting the air seals:

• Remove the existing seal and visually inspect the seal lip before cleaning.
• If the seal lip appears undamaged and pliable, carefully clean the seal using rags and mineral
spirits (do not damage seal lip). If the cleaned seal has a satisfactory sealing lip, it may be
reused.
• If the seal lip is damaged or hardened, it must be replaced.
• Inspect the sealing surface of the mill head extension for signs of wear and grooving. Replace
the mill head extension if wear and grooving is significant, as this will prematurely wear out
the new seal and/or a poor seal will result.
• Lubricate the new seal immediately while rotating the mill.
• If the new air seals are still leaking, it may be necessary to replace the sealing gasket or seal
sleeve.

19.3.4 Mill Liners

The mill liner bolts must be kept tight to prevent coal dust leakage from the mill barrel and to
keep the liners secured to the mill barrel. These bolts should be checked annually and tightened
as required. Check the Riley Power Service Guide for specific torque values for these liner bolts.

19-31
Preventive Maintenance

Table 19-12 lists the tasks for replacing the wear liners.

Table 19-12
Wear Liner Replacement
(Courtesy of Hoosier Energy - Merom Generating Station)

Wear Liner Replacement Tasks

1. Remove the ball charge using a vacuum truck.

2. Disconnect and remove the drive chain.

3. Block the mill to prevent the mill from rotating.

4. Unbolt and remove a row of liners at the bottom of the mill. Take each liner out of the mill with
slings.

Note: To prevent damage to the mill bearings and drive train, the mill must be rotated in the normal
direction of rotation.

5. Unblock the mill and rotate it 180° using the rigging, then reblock the mill.

Note: The wear liners should be removed and installed one row at a time, alternating across quadrants
or 90°of the mill.

6. Inspect the mill board liner for wear and repair if needed.

7. Install one row of new liners into position in the bottom of the mill.

8. Lubricate the threads of the liner bolts and nuts using Molykote.

9. Install the bolts, rubber washers, retainers, and nuts. Do not install the lock nuts at this time.
Tighten the nuts to 170 ft-lbs for the shell liners or to 400 ft-lbs for the head or throat liners.

10. Unblock the mill and rotate it 180°. Then re-block the mill. Install the new liners one row at a time
alternating between 90° of mill.

11. When all new liners are installed, rotate the mill 10–12 revolutions.

12. Tighten the liner nuts.

13. Install and connect the drive chain.

14. Load the ball charge and return the mill to service for 30–60 minutes.

15. Retighten the liner nuts and install the lock nuts.

Note: The liner nuts should be retightened after one month of operation.

19.3.5 Ball Charge

At the annual mill inspection, a visual check of the ball charge size distribution should be made.
For mills without the crusher-dryers, the ball charge should show a uniformly graded size
distribution with approximately 25% of the ball charge in sizes between 1.5-in. and 2.5-in. in
diameter and the remaining balls between 0.75-in. and 1.5-in. There are non-spherical geometric
wear patterns, in the smaller sizes.

19-32
 Preventive Maintenance

19.3.6 Speed Reducer Gearbox

The approximate oil capacities for the speed reducer gearbox are shown in Table 19-13.

Table 19-13
Speed Reducer Gearbox Oil Capacities [7]

Single- Oil Capacity Double- Oil Capacity Triple- Oil Capacity

Reduction (gallons) Reduction Type (gallons) Reduction Type (gallons)
Type HS HD, HDS HT, HTS

400 0.50 1000, 1028 2.5 1000, 1028 2.5

500 0.75 1300, 1350 4 1300, 1350 3.5

600 1 1500, 1566 6 1500, 1566 5.5

700, 800 2 1650, 1700, 1750 7.5 1650, 1700, 1750 6.5

900,1000 3.5 2000, 2050, 2100 13 2000, 2050, 2100 11.5

1100,1200 5.5 2250, 2300, 2350 20 2250, 2300, 2350 18

1300,1400 9.5 2450, 2500 29 2450, 2500 24

1500,1600 14 2900, 2950, 3000 41 2900, 2950, 3000 34

1800 18 3400, 3450, 3500 46 3400, 3450, 3500 38

1900, 2000 26 4100, 4150, 4200 76 4100, 4150, 4200 64

2400, 2500 45 4900, 4950, 5000 150 4900, 4950, 5000 130

3200, 3300 65 6200, 6250, 6300 240 6200, 6250, 6300 200

19-33
Preventive Maintenance

Figure 19-1 shows the single-gear reducer.

Figure 19-1
Link-Belt Single-Gear Reducer [7]

19-34
 Preventive Maintenance

Figure 19-2 shows the double-gear reducer.

Figure 19-2
Link-Belt Double-Gear Reducer [7]

19-35
Preventive Maintenance

Figure 19-3 shows the triple-gear reducer.

Figure 19-3
Link-Belt Triple-Gear Reducer [7]

Table 19-14 lists the disassembly tasks for the triple-speed reducer gearbox.

19-36
 Preventive Maintenance

Table 19-14
Triple-Speed Reducer Gearbox Disassembly Tasks [7]

Disassembly Tasks
1. Note: Never remove the housing without disconnecting the motor and ensuring that the motor
cannot start. The gears are retained in the bottom housing by their weight only. Drain the oil
completely from the housing or to a point below the bore of the lowest bearings.
2. Remove the cap screws that fasten the bearing retainers to the housing cover. Loosen the
fastening retainers to the housing base.
3. Remove the oil dipstick.
4. Remove the taper pins in the housing cover flange that positions the cover on the base.
5. Remove the cap screws that fasten the housing cover to the base.
6. Break the bond between the cover and base by tightening jack screws at both ends of the
housing cover flanges.
7. Attach eyebolts and a sling to remove the cover.
Removing the flexible coupling:
8. Unfasten and separate the coupling halves.
9. With the housing cover removed, vertically lift the shaft assembly out of the housing. Be careful
not to damage the parts.
10. The couplings halves can be repaired or replaced without disturbing the foundation or alignment
of the speed reducer or the mill motor.
Removing the high speed shaft and supporting bearings:
11. Remove the key from the high-speed shaft projection. The key can be unseated by making an
indentation in the end of the key with a center punch and tapping the punch with a hammer.
12. Remove the cap screws that fasten the high-speed bearing retainers to the housing base.
13. To prevent the sharp keyseat edges from causing damage to the seals, slide the high-speed
bearing retainer with the oil off the shaft.
14. Lift the high-speed shaft with the bearings from the housing as one piece. Be sure to use
softeners when lifting to prevent damage to the parts. Remove the bearings from the high-speed
shaft with a bearing ring puller.
15. Lift the low-speed pinion shaft with the intermediate gear from the housing as one piece.
C-clamps can be used to fasten the sides of the intermediate gear in lifting.
16. Remove the retaining rings from the intermediate pinion shaft. Remove the retaining rings from
the housing bore.
17. Remove the intermediate integral pinion shaft by pushing on the end of the shaft so it slides
through the gear and out the opposite bearing bore. The bearing located on the side from which
the shaft was pushed will separate, leaving the outer race in the housing bore. The inner and
outer races of the bearing on the opposite side will remain on the end of the shaft as it is pushed
through the bearing bore.
18. Clean housing joints and use an acceptable sealing compound on all the metal-to-metal parts
when reassembling.
Note: For assembly, the intermediate- and high-speed shaft bearing are adjusted correctly when they
give 0.005–0.015 in. lateral play. The end float should be adjusted at normal room temperature.

19-37
Preventive Maintenance

19.3.7 Drive Train

There are several components in the drive train that require periodic maintenance. Some of the
components are the rotorseal, the clutch, the speed reducer, the oil conditioning system, the drive
chain and sprocket, the idler shaft bearings and sprocket, the mill tires and trunnion rollers, the
thrust rollers and bearings, and the trunnion shaft bearings.
• Rotorseal – Four or five drops of light machine oils should be applied every three months
through the oil hole sealed with the pipe plug. Leaks in the air lines or in the rotorseal should
be repaired as needed.
• Clutch – Areas to inspect on the clutch include:
– The condition of the friction surface of the drum. If the drum surface is badly grooved or
worn, the surface may be remachined. The minimum drum diameter is given in the Riley
Power Service Guide.
– The condition of the friction shoe assemblies. If friction linings are glazed, this condition
can be corrected by sanding the friction lining to remove the glaze. Linings that have
been worn to minimum allowable thickness should be replaced.
– The condition of the rubber tube. If there are air bubbles or signs of ply separation on the
tube, the tube must be replaced.
– Oil or grease on the friction surface. If oil or grease accidentally gets on a clutch
actuating element, the oil or grease should be wiped off with a cloth dampened with
gasoline or naphtha, and then wiped dry. If friction shoes have been contaminated, they
should be removed and cleaned. For light contamination, Fuller’s earth media may be
used to remove grease or oil from the friction-lining surface. If the lining is saturated with
oil or grease, a solvent should be used to degrease the lining. A cloth dampened with the
solvent may be used to wipe the grease off the lining, or the friction shoe assembly may
be dipped into the solvent. Severely saturated linings may have to be replaced.
– Friction shoes that do not retract:
o Inspect the quick-release valve. Contamination of the quick-release valve may not
permit complete air exhausting of the tube and will not allow the shoes to retract
properly.
o Inspect the release springs. If the release springs are broken, the shoes will not retract
properly and should be replaced.
o If the element is exposed to severe contamination, a deposit may form that can
prevent the friction shoes from retracting. The friction shoes should be removed, and
the deposits should be cleaned off.
o Inspect the rubber for hardening of the actuating tube. If hardening occurs, then the
rubber resists proper friction shoe retraction. The tube should be replaced.

19-38
 Preventive Maintenance

Due to environmental conditions in the ball tube mill operations, the clutches can be
subjected to contamination from dust. This mill dust is usually very abrasive and tends to
shorten the life of the clutch components. Sealing air may be provided to the clutch
housing to eliminate dust contamination of the clutch components.

Technical Key Point

Excessive accumulation of dust deposits within clutch elements can eventually
restrict shoe retraction during clutch disengagement, resulting in dragging and
overheating. Protective shielding or total enclosure is recommended to keep the
dust out, and if it is not provided, the clutches must be inspected frequently (every
three months) to ensure normal shoe release.

The clutch should be de-energized briefly each month in order to maintain the flexibility
of the rubber tube.
To effectively clean the clutch elements, it is necessary to completely dismantle them.
The removal of the friction shoes is also necessary to ensure a thorough cleaning. With a
vacuum cleaner or an air hose, remove the dust deposits from all of the components. In
most instances, it is not necessary to remove the clutch drums for this operation.
Regularly scheduled inspection of the friction lining is important in order to determine
when replacement is necessary. Do not exceed the limits of liner wear because the rivets
or screw heads will score the drum and release spring breakage can occur.
The clutch air system should be inspected at regular intervals for possible leakage and
contamination of the air filter, which should be repaired and replaced as required. The air
receivers should also be drained periodically in order to remove any condensate
accumulation.
Instructions for replacing the clutch friction shoes, the lining, and the actuating tube are given
in the Riley Power Service Guide.

Table 19-15 lists the tasks for inspecting the clutch.

19-39
Preventive Maintenance

Table 19-15
Clutch Inspection Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Tasks

1. Unbolt the clutch enclosure. Rig and remove the clutch enclosure.

2. Visually inspect the clutch friction surfaces (shoe linings and drum) for oil or grease. If a small
amount of oil or grease is found on the shoe friction lings, the linings should be cleaned using
solvent and rags. If the linings are saturated with oil or grease, the linings should be replaced.

3. Visually inspect the friction shoe assemblies for damage and excessive wear. Glaze on the shoe
friction linings can be removed by sanding. If the thickness of the lining is 3/8 in. or less, the
lining should be replaced.
4. Visually inspect the clutch drum for damage and excessive wear. Measure the drum diameter in
several locations to determine the amount of wear. The maximum allowable drum wear
diametrically is 1/4 in.
5. Visually inspect the clutch rubber tube for air bubbles or other signs of ply separation.

6. Remove all tools from the clutch area. Rig, install, and bolt the clutch enclosure.

• Speed reducer – The speed reducer is lubricated by an oil bath, and the oil is supplied by the
oil conditioning system. This oil bath should be full at all times.
• Oil conditioning system – The oil conditioning system supplies oil to the chain bath and
speed reducer, and should be serviced annually. The heat exchangers should be disassembled
and cleaned, and the suction oil strainers should be cleaned during the annual outage. At six
month intervals, the oil filter elements should also be replaced.
• Drive chain and sprocket – Monthly visual examinations of the chain drive should be made
to ensure that adequate lubrication, chain alignment, and adjustments are maintained. An oil
level sight gauge is mounted outside the silence housing to allow monitoring of the oil level
in the chain case. The chain case oil level should be kept full at all times. The chain tension
should ensure that the sag of the lower strand is approximately 4 in. from the horizontal.
Adjustments, if necessary, are made by lowering the idler sprocket and relocking the jack
screws in place. Make sure the chain is lined up on the sprockets and rides correctly to
prevent unusual and premature wear of this equipment.

The chain must be kept lubricated during outages to prevent rust from forming and damaging
the chain rollers. This can be accomplished by the periodic rotation of the mill during the
outage period and drawing the chain through its oil bath.
Chain case seals should be replaced if oil leakage develops. Oil leakage creates a cleanliness
problem that can be hazardous to personnel inspecting and servicing the equipment.

19-40
 Preventive Maintenance

Table 19-16 lists the tasks for repairing a break in the drive chain.

Table 19-16
Chain Repair Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Chain Repair Tasks

1. Remove the back access door of the chain case. Locate the break in the chain.

2. Isolate the mill.

3. Drain oil from the chain case.

4. Remove the chain tensioning covers (Plexiglas and steel on sides). Remove the top tensioning
device covers on both sides.

5. Install the jacking device above both tensioning idler bearings. Check the “out of service” chain
position before jacking out the idler bearings. Measure/count the threads on the idler tensioning
pad for the “as found” condition on both sides. Record the findings.

6. Use the jacking device to remove the idler bearings.

7. Loosen the jamb and tensioning nuts to relieve pressure from the chain. Cut the chain case as
needed for access to the broken chain segments.

8. Install small steel chokers on the chain on the bottom side of the break. Attach a come-along to
the steel on the back of the mill. Pull the slack out of the bottom of the chain to allow
replacement of the breaker segments.

9. Have personnel clean the chain case components while the chain repair is being performed.
Remove the sealant and gaskets from the cover. Grind components out of the chain case.

10. Remove the pins from the links to be replaced. Replace one link at a time. Drive the new link in
as the old link is removed. The new link is installed in the opposite direction of the broken link.
Repeat until all the broken links are replaced.

11. Allow slack in the chain. Remove the rigging from the chain. The slack in the chain should be 4-
in. sag ±1/2 in.

12. Weld repair the chain case.

13. Verify the level of the idler shaft. Verify the jamb nuts are tight.

14. Complete cleaning the openings, remove the jacking devices, and reseal covers and doors.

15. Reinstall the door on the backside of the mill.

16. Install the chain break glass rod.

17. Remove the mill isolation tags.

Table 19-17 lists the tasks for removing and reinstalling the driven sprocket.

19-41
Preventive Maintenance

Table 19-17
Driven Sprocket Removal and Reinstallation Tasks
(Courtesy of Hoosier Energy - Merom Generating Station)

Tasks for Sprocket Removal and Re-Installation

Safety requirements: Full protection must be worn when working on the upper levels of the mill. Burn
permits are needed for any cutting or welding. When rotating the mill barrel, the barrel must be locked
down by rigging to prevent rotation. When the barrel is rotated manually, all personnel and equipment
must be clear of the barrel. The welding ground procedure must be used for any welding done on the
ball mill.
Removal of Sprocket Segments:

Note: Three segments can be removed for each roll of the mill. The lubrication and lift oil pumps must be
in service when rotating the mill manually. Manual rotating is accomplished by using two 1-1/2-ton come-
alongs. When removing and replacing sprocket segments, it is easier to perform this task from the top of
the mill.

1. Use a cutting torch to remove the bolt keepers from the segment bolts and the washers from the
dowel keepers
2. Fabricate a slide hammer on a 5/8-in. solid stock rod and tack weld to the dowel pin.

3. Remove the dowel pin by hammering and cut the pin from the slide hammer rod.

4. Grind off the slide hammer rod and move to the next pin.

5. Mark the sprocket segments by stamping so the segments can be replaced in the same order as
the segments are removed.

6. Insert a 3/4-in. eye bolt in the sprocket segment and connect with a 1-in. wide by 2- or 3-ft long
nylon choker to the mobile crane hook.
7. Remove the bolts from the segment. Remove the sprocket segment. If the sprocket segment will
not come loose, then a straight torch can be used to cut the nut off under the sprocket segment.

8. Move all sprocket segments to a laydown area. Clean the segments and inspect all surfaces for
burrs and damage. If necessary, grind the mounting surfaces of the segments.
Oil Seal Replacement:

9. Cut off the segment bolt nuts and grind the surface. A cutting torch can be used on the nuts.

10. Cut out the oil seal plate. Leave a lip for welding on the new oil seal.

11. Overlay the new oil seal to the lip of the old seal. Tack weld and check the fit.

12. Seal weld the new oil seal into place. The material is carbon steel. Use the proper welding
procedure.
Installing the Segment Nuts:

13. Position the nuts by inserting the centering hole apparatus into the bolt hole. Make sure the
apparatus has shoulder sleeves on the bolt.
14. Screw on the nut and tack weld the nut. Use the proper welding procedure.

15. Remove the apparatus and weld the nut solid around the nut. Continue to the next nut. There
are 90 nuts total.

19-42
 Preventive Maintenance

Table 19-17 (continued)

Driven Sprocket Removal and Reinstallation Tasks
(Courtesy of Hoosier Energy - Merom Generating Station)

Tasks for Sprocket Removal and Re-Installation

Install the Sprocket Segments:

16. Inspect each segment for burrs.

Note: It is recommended that the segments be installed from the top of the mill barrel. Three segments
can be installed before the barrel is rotated. Each time the barrel is rotated, the barrel should be locked
into place with come-alongs to secure the barrel.
17. Using the threaded hole in the center of the segment, attach an eye bolt shackle to a 1-in. wide
by 2- or 3-ft long nylon choker to the crane hook. Lift the segment into place on the top of the
mill.

18. Fabricate two 1-1/2-in. rod coupling nuts for each side of the segment. Install a 30- or 36-in. long
all thread rod into the rod couplings.
19. Using a heavy piece of channel (3/8-in. thick, 4-in. wide, 36-in. long) as a strong back, jack the
ends of the segment into place with 10-ton hydraulic jacks.

20. Align the dowel pins and install the dowel on each end first, leaving 1/8 in. of dowel sticking out,
then install the bolts (six per segment).
21. Hold the opposite end of the segment down while jacking the other end into place. Use a 3/4-ton
come-along and a 3-ft steel choker around the segment through the hand holes under the ribs,
and pull down.

22. After the segment is in place, the dowels and bolts are in place, tighten the bolts snug with a
1-1/2-in. combination wrench. Move to the next segment until all segments are installed. Tighten
the segments to 1495 ft-lbs.
23. Using the weld grounding procedure, weld the washer onto the dowel pins and the mill rib. Weld
all bolt keepers and dowel washers.
24. Remove all rigging. Reinstall the chain. Set the chain tensioner.

25. Close up the oil casing covers.

26. Reinstall the lagging.

• Idler Shaft Bearings and Sprocket – The idler shaft bearings require monthly lubrication.
Refer to the lubrication recommendations in the Riley Power Service Guide.
When raising or lowering the idler shaft sprocket, its horizontal alignment with the chain is
very important. Premature and uneven wear can result if the idler sprocket is not properly
aligned.
• Mill Tires and Trunnion Rollers – The mill tires and trunnion rollers should be inspected
periodically to check for uneven tire/roller wear. If uneven wear exists, the mill must be
realigned according to the Riley Power Service Guide.
• Thrust Rollers and Bearings – The thrust rollers are set with the proper clearances during
the installation of the mill. The mill end thrust is monitored through the load cell attached to

19-43
Preventive Maintenance

the thrust roller assembly and alarms if the end thrust increases beyond the alarm point
(usually 10,000 lbs). An end thrust alarm is indicative of mill barrel misalignment and should
be corrected immediately as outlined in the Riley Power Service Guide.

The thrust rollers require periodic adjustment back to the 0.010–0.005 in. clearance as they
wear into the tire. Inspections and adjustments should be monthly during the wear-in period.
Excessive wear, as with frequent alarms, is caused by mill misalignment and should be
corrected immediately.
The thrust roller bearings should be cleaned and repacked during the annual outage.

19.3.8 Driveshaft

The driveshaft bearings are pillow block bearings that should be cleaned and repacked during the
annual outage. The operating records for the bearing should be checked with the highest
operating temperature bearing for inspection. The bearing metal thermocouples and vibration
detectors should be removed, and the grease supply tubing should be removed from the bearing
cap. The bearing cap can then be unbolted, the rigging hardware can then be attached, and the
bearing cap can be removed. The bearing can now be inspected and replaced if needed. Refer to
the lubrication schedule in the Riley Power Service Guide.

Table 19-18 lists the tasks for replacing the driveshaft.

Table 19-18
Driveshaft Replacement Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Driveshaft Replacement Tasks

Note: The mill must be rotated in the normal direction of rotation. Verify the chain is lined up and located
correctly in the sprocket teeth.

Caution: The mill motor must be tagged out.

Mill Shaft, Drive Chain, and Sprocket Removal:

1. Remove grease lines from the mill housing and bearings.

2. Remove thermocouples and instrumentation.

3. Remove water lines to chain spray cooler.

4. Remove doors. Remove the necessary sections of mill housing to access the upper chain case.
Use 15/16-in. socket for the divider strips. Use a torch for removal of the frame above the case.
Mark the bolts and place in a bag.

5. Drain oil from the idler tensioner housing.

6. Remove the upper chain case housing. Mark the bolts and place in a bag.

7. Remove the covers on the tensioner housing. Use a 9/16-in. socket and adjustable wrench to
remove the flexible hose. Mark the bolts and place in a bag.

19-44
 Preventive Maintenance

Table 19-18 (continued)

Driveshaft Replacement Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Driveshaft Replacement Tasks

8. Raise the idler sprocket to the maximum adjustable height to relax the chain tension. Remove
the top cover on the tensioner. Install a special pallet on top for the hydraulic jack. Measure the
thread length exposed on the lower tension rod. Loosen nuts on both tension rods at the bottom
by installing horseshoe plates at the bottom and pressing the tension off with the hydraulic jack
at the top.

9. Disconnect the chain at the drive sprocket.

10. Using rigging equipment, position the chain to gain access to the idler and drive shafts.

11. Remove the housing for the clutch assembly. Unhook the air supply pipe.

12. Remove the clutch assembly. Remove the left connecting bolts, holding the hub to the
driveshaft. Remove the right bolts holding the outer hub to the gearbox hub. Remove enough
bolts on the left side at the rear of the outer hub to allow removal past the driveshaft. Mark the
bolts and place in a bag. Remove the clutch assembly using rigging apparatus and mobile
crane.

13. Before removing the driveshaft, take the following readings: Tight wire to sprockets, face-to-face
dimension on the hubs at four points, and the run out on the hubs at four points.

14. Remove the driveshaft bearing caps and mark the location.

15. Attach rigging for the driveshaft removal.

16. Remove the driveshaft.

17. Clean all areas in preparation for reinstallation.

Installation and Alignment:

18. Apply rigging and lift the new driveshaft into position above the bearing housings. Slowly lower
the new driveshaft into the bearing housings. Remove the rigging.

19. Install the bearing caps and tighten the bolts.

20. Align the driveshaft in the bearings. Pre-load the center bearing to 0.006 in. total. Use powdered
graphite to ease the preload. The axial movement is 0.017 in. for each 0.001 in. of preload.
Install a tight wire through the driven sprockets and align within 0.060 in. Perform four face-to-
face readings on the clutch. The readings should be within 0.00025 in. Take four rim runout
readings. The runout should be 0.0005 in. Remove the driveshaft. Install the bearing caps and
tighten the bolts.

21. Remove the driveshaft. Install a tight wire in the center bearing with the east and west bearings
with caps on and bolts tightened. Reinstall the driveshaft. Pre-load the center bearing to 0.0040–
0.0055-in. range total using powder graphite to ease the preload. Replace the bearing caps and
tighten the bolts.

22. Install the clutch assembly.

23. Reconnect the chain.

24. Reset the idler shaft tension chain. Use a level on the idler sprocket.

19-45
Preventive Maintenance

Table 19-18 (continued)

Driveshaft Replacement Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Driveshaft Replacement Tasks

25. Lock the tension rods and remove the jacks and special plates.

26. Replace all tension covers. Install the chain case cover. Install the mill housing and clutch
housing.

27. Install the water lines to the chain spray cooler.

28. Install the thermocouples and instrumentation.

29. Fill the case with oil (Mobil DTE Extra Heavy)

30. Clear isolation tagging.

19.3.9 Lubrication Heat Exchanger

Table 19-19 lists the tasks for inspecting the lubrication heat exchanger.

Table 19-19
Heat Exchanger Inspection Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Inspection Tasks

1. External inspection of the heat exchanger shell includes examination for dents in the shell,
extruded or damaged gaskets, corrosion, damaged flanges, bonnets, hub, and tube sheets,
stress marks in the shell, signs of a previous repair, and shell bulge.

2. Internal inspection should include draining the shell completely and inspecting the heat
exchanger to determine the extent of cleaning needed. Detection of severe fouling or corrosion
of the tubes and/or bonnets may require further disassembly.

3. If further disassembly of the heat exchanger is needed, visually inspect the tube ends for
thinning, anodes for wear (if applicable), damage to the nozzle threads on the tube and shell
side, and erosion of the tubes under the shell side nozzle.

Note: Signs of any damage may be an indication of high velocity, particle entrainment in the
fluid, or a corrosive environment. Depending on the severity of the damage, the heat exchanger
may require replacement.

4. Clean the inside of the tubes with a rotary brush driven by an air or electric rotating tool. The use
of nylon brushes is recommended because metal brushes or bristles will break the protective
film, scratch the metal surfaces, and accelerate corrosion. After brushing, the tubes should be
flushed with clean water to remove loosened dirt and scale.

5. Before assembly of the heat exchanger, the shell side should be pressure tested to verify the
integrity of the tubes and all joints.

6. Clean the bonnets as required and reassemble to the heart exchanger. New gaskets are
required for assembly. Use of oiled gaskets is acceptable. Perform a pressure test on the tube
side at the specified test pressure with air under water.

19-46
 Preventive Maintenance

Table 19-20 lists the tasks for replacing the lube oil heat exchanger.

Table 19-20
Lube Oil Heat Exchanger Replacement Tasks
(Courtesy of Hoosier Energy – Merom Generating Station)

Heat Exchanger Replacement Tasks

Note: The following tasks are for replacing the lube oil heat exchanger with the mill on-line. The cold
start bypass valve, heat exchanger lube oil inlet and outlet ball valves, and the cooling water inlet and
outlet isolation ball valves will need to opened and closed during the online heat exchanger replacement.
The replacement should occur when the ambient temperature is low since no cooling of the oil will take
place during the time (~2 hours) of the replacement.

Caution: The minimum oil pressure on the low-pressure system is 10 psi and the thrust shoe pressure
system is 4 psi. When the oil pressure drops below these pressure settings, the mill will trip. The bearing
pad alarm temperature is 160°F and trip temperature is 165°F. These pressure and temperature
indications should be monitored during the heat exchanger replacement.

1. Remove the 2-in. diameter inlet and outlet oil lines.

2. Remove the inlet and outlet water lines.

3. Remove the fittings on the inlet and outlet on the top of the cooler.

4. Remove the four bolts from the base.

5. Remove the cooler and install a new cooler.

6. Set up two electric fans on the outside of the mill housing to blow air across the bearing surfaces
on each end of the drum.

7. Disconnect the oil and water lines from the heat exchanger. Remove the heat exchanger.

8. Install the new heat exchanger. Connect the oil and water lines. Leave the fitting loose at the oil
inlet isolation ball valve so the air can be purged out of the heat exchanger and oil lines.

9. Purge the air from the heat exchanger. Tighten the fitting at the oil inlet.

10. Remove the air fans.

19.3.10 Classifier

Classifier vanes require the most maintenance attention in the classifier. These vanes impart the
swirling effect to the coal/air mixture that results in an erosive effect on the vanes. The erosion
tends to be more prevalent at the top edge as a result of the design flow pattern.

The trickle valve is not an integral part of the classifier assembly; however, the trickle valve can
cause problems in the operation of the mill. A deformed, missing, or sticking trickle valve may
prevent coarse coal from returning to the mill or allow air and coarse coal to bypass the vane
arrangement.

Table 19-21 lists the PM tasks for the classifier.

19-47
Preventive Maintenance

Table 19-21
Classifier Preventive Maintenance Tasks [7]

Preventive Maintenance Tasks

1. Remove the classifier from service and isolate from the system.
2. Remove the bolted cover on the top of the classifier.

3. Inspect the vanes for erosion and excessive movement. The vanes should be replaced if the
erosion or other physical effects are severe.
4. Inspect the internal services for abnormal wear or metal failure.

5. Investigate any area of coal buildup.

6. Inspect the deluge system and clean the nozzles from any coal pluggage.

7. Inspect the classifier exit thermocouple. Replace and/or calibrate as needed.

8. Inspect the trickle valve and associated coarse return pipe for deformation, sticking, and so on.

9. Document all conditions in the classifier.

19.3.11 Primary Air Fan and Ductwork

The cold primary air fans draw ambient air and forces it through the air preheater into the
system. The inlet silencers and screens must be cleaned periodically or fan capacity will be
reduced. The shaft, damper, and drive motor bearings must be assured of receiving the proper
lubrication. The drive coupling should be inspected for general condition and wear.

All dampers should be lubricated and worked to ensure the shafts are free to rotate in the
bearings. Linkages and controls must be free in the entire range of movement. The dampers in
the air system are integral in the control of the boiler, and their maintenance schedule must be
adhered to rigidly. Inspect the mating seating surfaces of these dampers to ensure good contact
and make sure the damper blades are neither warped nor improperly positioned on their shafts.

Inspect all supports, internal and external, to ensure their integrity, and record and deal with any
evidence of corrosion or erosion as required. Also check the position of any spring hangers,
noting and correcting any problems.

Inspect all expansion joints for evidence of cracks or tears that can result from cyclic stress or
uneven expansion. Repair these leaks early, either by welding or by a partial or full replacement
of the expansion joint.

An accumulation of debris (fly ash, coal, and so on) in the bottom convolutions of these joints is
a major cause of failure. Remove these accumulations at every opportunity.

19-48
 Preventive Maintenance

19.3.12 Coal Shutoff Valves

Exercise the shutoff valve once a month for several cycles to ensure proper functioning of the
unit. During the annual outages, disassemble the valve, wire-brush the parts to remove the oil
lubricant and coal deposits, and apply Molykote spray. Reassemble and grease the valve, but do
not use any grease on the valve sealing surface.

19.3.13 Lubrication Schedule

Table 19-22 shows the lubrication schedule for the Riley Power ball mills.

Table 19-22
Lubrication Schedule [7]

Component Number of Bearing Type Lube Lubrication Lubrication

Bearings Quantity Frequency Specification

Trunnion support 4 Sleeve Grade II

grease

Trunnion support 16 Pillow block 1 oz. Monthly Grade II

roller bearings (main grease
bearings

Drive shaft bearings 3 Pillow block 1 oz. Monthly Grade II

grease

Idler shaft bearings 2 Rolling element As needed Monthly Grade II

grease

Thrust roller 2 Rolling element 0.3 oz. Monthly Grade O

grease

Drive chain case 205 gallons Change at six EP 75

months. Add as
needed.

Oil conditioning Change at six

system filters months or as
required

Rotorseal 4–5 drops Add monthly Light machine

oil

Air seals (inlet/outlet Add monthly as Type M-77

boxes) required Molykote

19-49
Preventive Maintenance

19.3.14 Spare Parts

Table 19-23 lists the recommended spare parts for 1–5 ball mills. Merom Generating Station
stocks a complete clutch and gearbox assembly. The complete assembly allows for a faster
response time when changing these components because of a component failure.

Table 19-23
Riley Power Recommended Spare Parts [7]

Spare Parts Quantity

Reducer high-speed pinion gear 1

Reducer high-speed bearings 2

Reducer high-speed thrust bearings or 2 or 1

Spare reducer complete with coupling half and clutch spider

Reducer high-speed coupling 1

Clutch element assembly 1

Clutch drum 1

Clutch rotorseal with coupling and hose 1

Clutch solenoid valve 1

Clutch flow control valve 1

Clutch air regulator 1

Clutch air amplifier 1

Trunnion roller with bearings and seals 1

Thrust roller assemblies 2

Drive sprocket segments 3, 2–14 teeth, 1–15 teeth

Drive shaft bearings with seals 3

Drive shaft chain case seals 2

Idler shaft chain case seals 2

Felt chain case seals 2

Chain – 62.5-ft length 1

30 gpm oil pump 1

5 gpm oil pump 1

Oil filter elements 12

2 hp motor for oil pump 1

Motor coupling for 5 gpm oil pump 1

Motor coupling for 30 gpm oil pump 1

19-50
 Preventive Maintenance

19.3.15 Example Preventive Maintenance Inspections

The Merom Generating Station has the following PM inspections:

• Inspect the motor coupling every two years.
• Clean and inspect the heat exchangers annually.
• Replace the air drive amplifier annually.
• Inspect the gearbox annually.
• Inspect the chain case, gear reducer, and lube oil skip pump annually.
• Inspect the air seal, clutch, bearings, and heat exchangers annually.
• Replace the heat exchanger every two years.
• Lubricate the driveshaft, idler shaft, and gear reducer seal monthly.

The drive chain oil reservoir holds approximately 215 gallons of EP oil. The oil filter should be
replaced every 750 hours of operation. The oil should be changed every 2500 hours of operation.

The oil level on the speed reducer gearbox should be checked weekly and oil added if needed.
The grease seals should be purged monthly and grease added to all of the couplings. Take an
oil/grease sample for testing every two months. Change the oil every 6 months or 2500 operating
hours. Change the grease at the seals at the same time as the oil change.

19.4 Stein Industrie

This section contains the following items:

• Feeder inspection tasks for the 7000-hour interval
• Preventive maintenance tasks
• Inspection tasks for a 5500-hour interval
• Inspection tasks for an 18-month interval
• Inspection tasks for a nine-year general overhaul
• Replacement tasks for the pinion and girth gear

As an example, the following is the maintenance strategy for the Stein Industrie mills at the
Matimba Power Plant:
• One mill at a time is planned for off-line maintenance. The mill will not be scheduled off-line
unless the remaining mills are providing reliable operation.
• Mills on the same unit cannot be scheduled for planned maintenance within the same week.
• The screw conveyor replacement outages are scheduled during a unit outage.
• Liner rotations and liner replacements are performed during unit outages.

19-51
Preventive Maintenance

The following are components and their maintenance strategies:

• Mill drum liner wear – The cylindrical, conical, and oblique liners have to be rotated and
replaced. The drum liners are used for 35,000 operating hours and then rotated. After
rotation, the liners are used for an additional 30,000 operating hours. After the resultant
65,000 operating hours, the liners are replaced.
• Screw conveyors – A new design screw conveyor was installed starting in 1999. The
modification was made in the inlet area from 110 × 12 mm to 120 × 12 mm, and a third liner
was added to the hot air tube. As a result, the life of the screw conveyor was extended from
22,500 to 30,000 operating hours. The wear rate is monitored during the 5500-hour operating
hour inspection intervals, while the screw conveyors are typically replaced at six-year
intervals. Rubbing of the flights on the liners will increase the wear rate on the liners and
shorten the life of the liners.
• Classifier inlet piping – Visual inspections and thickness measurements are made during
each unit outage. Repairs are also performed at the same time.
• Feeders – For Matimba Power Station, feeder inspections are performed at 5500 operating
hour intervals and any repairs are completed at that time. A general overhaul is scheduled
every nine years. The scope of the general overhaul is to inspect all bearings, the gearbox, the
clutch, and the motor. The feeder level bar height should be inspected during the general
overhaul.

For the Tutuka Power Station, the feeder is inspected at an interval of 7000 operating hours.
Tables 19 through 24 list the feeder inspection tasks.

19-52
 Preventive Maintenance

Table 19-24
Feeder Inspection Tasks for the 7000 Operating Hour Interval
(Courtesy of Tutuka Power Station)

Tasks

1. Open inspection door on feeder and make sure it is safe to work on feeder.

2. A chain block must be used to pull the chain. The crane should not be used.

3. The return idlers should be checked for correct nuts and tightness.

4. The feeder bar heights should be checked. Clean the feeder bar and base plate. Measure the
distance between the bottom of the feeder bar and the base plate of the coal feeder on the left
hand side of the feeder bar. This distance should be perpendicular to the bottom of the feeder
bar and parallel to the feeder bar. Measure the same distance in the middle and on the right
hand side of the feeder bar. Record the measurements.

5. Inspect the general condition of the feeder bar assembly for wear, holes in body, and so on.

6. Check the general condition of the pedestal bearings.

7. Check the feeder speed. Check the motor frequency versus feeder speed. Check for 5 Hz at
80 rpm and 24 Hz at 360 rpm for the short and long feeders.

8. All bent flights should be straightened.

9. The chain should be tensioned to clear the guide shoe by ± 3 mm.

10. Inspect and replace the feeder shaft seals if needed.

11. Clean the classifiers.

• Couplings – The mill motor-to-gearbox coupling was originally a gear coupling that required
regreasing. The 5500 operating hour interval was too long because the lubricant experienced
soap separation and coupling failure. The couplings are being replaced with spring couplings.
• Electrical motors – The motors include the main bearing oil pumps, the main motor bearing
oil pump, the main gearbox lubrication oil pump, the girth gear grease pump, the seal air fan,
and the feeder. These motors are inspected and cleaned every 18 months with a general
overhaul at nine years.
• Girth gear and pinion gear – Inspection of the girth and pinion gears to detect cracks,
broken teeth, pitting, wear, and so on should be performed every 18 months and during the
general overhaul. Any problems found during inspections should be monitored until the next
repair outage. Repairs should be made for tooth flank relief, pitting removal, sharp edges, and
crack removal. The expected life of the girth gear is 90,000 operating hours, and then the
gear is turned or flipped. A new pinion gear is used with the turned girth gear.

19.4.1 Preventive Maintenance Tasks

Table 19-25 lists the PM activities for the Stein Industrie ball mills at the Majuba Power Station.

19-53
Preventive Maintenance

Table 19-25
Preventive Maintenance Tasks
(Courtesy of Majuba Power Station)

Tasks Frequency
(Operating Hours)
Pulverized fuel sampling Annual
Airflow checks Every 3 years
Mill load line checks Annual
Internal inspections:
Ball charge measurement 5000
Liner wear measurement 10,000
Screw conveyor wear measurement 10,000
Wind box liner wear measurement 10,000
Trunnion tube liner wear measurement 10,000
Reject chute clack box inspection 5000
Classifier inspection:
Chinese hat position 5000
Vane position 5000
Wear 10,000
Feeder inspections:
Liner wear 10,000
Flights condition 5000
Feeder calibration 5000
Level bar height 5000
Power transducers calibration check Annual
Electric ear calibration Annual
Ball wear rate calculations Monthly
Ball loading Daily
Mill operating hours Monthly
Operating conditions – temperatures, power, damper positions Daily
Oil analysis 5000
Vibration monitoring performed by:
Maintenance Monthly
Performance Every three months
Girth gear condition monitoring Every two weeks

19-54
 Preventive Maintenance

Table 19-25 (continued)

Preventive Maintenance Tasks
(Courtesy of Majuba Power Station)

Tasks Frequency
(Operating Hours)
Raw-coal feeder:
Clamping Plate – Measure distance between either side 200
Scraper chain – Check chain tension 200
Head and tail section bearings – Change grease for first time 200
Head and tail section bearings – Greasing 200
Head and tail section bearings – Check vibration and temperature 800
Head and tail section bearings – Change bearing grease routinely 4000
Single-gate slide damper – Change grease on spindle for first time 800
Single-gate slide damper – Change grease on drive gear for first time 8000
Single-gate slide damper – Grease the spindle and drive gears 4000
Double-gate slide damper – Change spindle grease routinely 800
Double-gate slide damper – Change drive gear grease routinely 8000
Double-gate slide damper – Grease both gearboxes and bearing pedestals Annual
Liners – Inspect liner 6000 to 7000
Reduction gearbox and drive gears – Change oil for first time 10,000
Reduction gearbox and drive gears – Change oil routinely 25,000
Drive arrangement – Check gear backlash 15,000
Mill body liners:
Mill Liners – Change liners 28,000 to 40,000
Conveyor body liners – Change liners 28,000 to 40,000
Mill conveyor bearing:
Bearings – Change grease for first time 500
Bearings – Change grease routinely 8000
Bearings – Grease routinely 2000
Bearings – Check vibration and temperature Monthly
Girth gear and drive pinion:
Drive pinion bearings – Check vibration and temperature Monthly
Drive pinion bearings – Lubricate bearings 2000
Drive pinion bearings – Change bearing grease for first time 800
Drive pinion bearings – Change bearing grease routinely 8000
Drive pinion and girth gear – Clean 8000
Drive pinion and girth gear – Check backlash 40,000
Drive pinion and girth gear – Check contact marks 40,000
Grease drum – Replenish As required

19-55
Preventive Maintenance

Table 19-25 (continued)

Preventive Maintenance Tasks
(Courtesy of Majuba Power Station)

Tasks Frequency
(Operating Hours)
Main reduction gearbox:
Bearings – Check vibration and temperature Monthly
Gearbox oil – Change oil first time 500
Gearbox oil – Change oil routinely 4000 to 8000
Gearbox oil – Oil sampling and testing 8000
Gearbox oil – Check oil level 500
Air breather – Change 6 months
Oil cooler – Clean Annual
Labyrinths – Grease 800
Gears and bearings – Inspect and repair 150,000
Main reduction gearbox high-speed coupling:
High-speed coupling – Inspect coupling pins 5000 to 10,000
Main reduction gearbox low-speed coupling:
Low-speed coupling – Perform routine greasing 2000
Low-speed coupling – Change grease 2 years
Low-speed coupling – Inspect coupling grid members 2 years
Auxiliary Reduction Gearbox:
Gearbox oil – Change oil for first time 500
Gearbox oil – Check oil level 500
Labyrinths – Grease routinely 800
Gearbox oil – Sample and test oil 4000
Gearbox oil – Change oil 4000 to 8000
Breather – Change 6 months
Bearings – Check vibration and temperature Monthly
Gears and bearings – Inspect 25,000
Auxiliary reduction gearbox low-speed coupling:
Low-speed coupling – Inspect coupling pins 6 months
Electrohydraulic brake:
Brake pads – Inspect 100 operations
Brake pads – Change As required
Fluid drive coupling:
Coupling bolts – Inspect 6 months
Coupling oil – Change oil 8000 or Annual

19-56
 Preventive Maintenance

Table 19-25 (continued)

Preventive Maintenance Tasks
(Courtesy of Majuba Power Station)

Tasks Frequency
(Operating Hours)
Electromagnetic brake:
Friction disk – Check wear Monthly
Mill main motor:
Lubricating oil system – Change oil 10,000
Lubricating oil system – Sample and test oil 10,000
Motor bearings – Check vibration and temperature Monthly
Desiccator – Check for dampness Annual
Fixing bolts – Check tightness Annual
Electrical connections – Check tightness Annual
Main bearing oil lubrication system:
Oil – Change oil 12,000
Oil – Sample and test oil 12,000
Duplex oil filter – Clean As required
Oil cooler – Clean During outage
Fire protection system:
Carbon dioxide bottles – Check pressure Weekly
Carbon dioxide bottles – Change As required
Bursting disks – Change As required
Ball feed mechanism:
Slide gate – Grease spindle 500
Mill air system:
Air system dampers – Inspect Monthly
Gland – Check for leaks Monthly
Cables – Check for damage Monthly
Mountings – Check for security Monthly
Ducting – Check for leaks Monthly
Quick-close damper – ball and socket – Change grease 3 months
Quick-close damper – hydraulic actuator – Sample and test oil Annual
Quick-close damper – hydraulic actuator – Change oil 2 years
Quick-close damper – hydraulic actuator – Check oil seals 2 years
Classifier – Inspect liners During outage

19-57
Preventive Maintenance

Table 19-25 (continued)

Preventive Maintenance Tasks
(Courtesy of Majuba Power Station)

Tasks Frequency
(Operating Hours)
Main seal air sub-system:
Fan bearings – Check vibration and temperature Monthly
Fan bearings – Inspect 3 months
Fan bearings – Grease routinely 2000
Fan bearings – Change grease 10,000
Sub-system flow test points – Check flow Monthly
Fan coupling guard – Inspect 3 months
Fan ducting – Inspect 3 months
Fan shaft seal – Inspect 3 months
Fan casing – Inspect 6 months
Fan shaft – Inspect 6 months
Fan coupling alignment – Inspect 6 months
Fan coupling tire – Inspect 6 months
Fan plummer blocks – Inspect 6 months

19.4.2 Inspection Tasks

At the Matimba Power Station, there are several types of inspections and intervals for mill
inspections. The first type is the 5500 operating hour inspection based on equipment experience
and failure investigations. The interim repair occurs every 18 months. There is also a partial
overhaul at four and a half years. The last inspection is the general overhaul that is scheduled for
a nine-year interval.

19-58
 Preventive Maintenance

Table 19-26 shows the inspection tasks for the 5500 operating hour interval.

Table 19-26
Inspection Tasks for the 5500 Operating Hour Interval
(Courtesy of Matimba Power Station)

System or Area Inspection Task

for Inspection

General Check the damper positions.

Inspect the splitter boxes.

Classifier Inspect the classifier.

Verify the classifier vane angle settings.

Feeder Inspect the volumetric feeders.

Verify the feeder speed versus actual belt speed.

Girth gear Check girth gear pattern with the stroboscope.

Check the oil spray pattern for the girth gear.

Clean the mill driven train.

Disassemble the high and low speed couplings.

Inspect the girth gear grease system.

Lubrication Inspect the main gearbox lubrication oil system.

systems
Inspect the main motor lubrication system – Hytec.

Inspect the main bearing lubrication system – Turbolub.

Mill internals Inspect the mill liner profiles.

Verify the ball filling degree versus the power readings.

Inspect the screw conveyor bearing and stuffing box.

Inspect the mill screw conveyor on both ends of the mill.

Inspect the pipe thermocouple protection rod.

Seal air system Inspect the cold and hot seal air fan couplings and bearings.

19-59
Preventive Maintenance

Table 19-27 lists the tasks for the interim inspection and repairs every 18 months.

Table 19-27
Inspection Tasks for the 18-Month Interim Inspection
(Courtesy of Matimba Power Station)

System or Area Inspection Task

for Inspection

General Perform a pre-shutdown inspection.

Perform a mill barring function test.

Inspect the mill ball loading gates inspection and repair.

Perform a general mill cleaning.

Perform a general mill inspection.

Open and close all mill doors.

Install and inspect mill mix box door.

Classifier Inspect, clean, and repair the classifier.

Refurbish raw coal chute.

Inspect epoxy wear protection on classifier pipe.

Inspect the mixing box.

Inspect and repair the wear on the top cover.

Dampers Inspect and service the cold air regulation damper.

Inspect and service the hot air regulation damper.

Inspect and service the isolating damper.

Test the primary air and bypass dampers.

Feeder Inspect the bunker slide gates and liners.

Gearbox Perform main gearbox internal inspection and oil system service.
Girth gear Inspect the girth gear and pinion condition.

Mill internals Perform a mill internal inspection.

Inspect the mill screw conveyor on both ends of the mill.

Seal air system Inspect the seal air ducts.

Table 19-28 lists the tasks for the general overhaul of the Stein Industrie ball mills. These tasks
are in addition to the 18-months and 5500 operating hour inspection tasks. The general overhaul
is scheduled for a nine-year interval.

19-60
 Preventive Maintenance

Table 19-28
Inspection Tasks for the Nine-Year General Overhaul
(Courtesy of Matimba Power Station)

System or Area Inspection Task

for Inspection

Classifier Adjust vanes and perform thickness measurements.

Dampers Inspect the primary air isolation damper gearbox.

Inspect and service the primary regulating damper.

Inspect and service the bypass regulation damper.

Inspect and repair the purge air isolating damper.

Feeder Perform volumetric feeder major service.

Girth gear Perform girth gear and pinion inspection and repairs.

Lubrication Drain and clean the main bearing lubrication system – Turbolub
systems
Mill internals Perform mill internal inspection.

19.4.3 Pinion and Girth Gear Replacement

Table 19-29 lists the tasks for the replacement of the pinion and girth gear on the Alstom Stein
Industrie mills at the Arnot Power Station.

Table 19-29
Replacement Tasks for the Pinion and Girth Gear
(Courtesy of the Arnot Power Station)

Tasks

1. Remove the soundhood panel top section and pinion section.

2. Remove the girth gear seal air fan pipe and girth gear guard top section and pinion section.

3. Clean all flange bolts on the girth gear and loose all the bolts.

4. Clean all the girth gear mounting bolts on station 1/10 and 5/6. Loosen and remove the
mounting bolts
5. Position the first section of the girth gear. Install lifting and rigging equipment. Remove all
flange bolts. Lift the girth gear.

6. Rotate and clean the first section of the girth gear mounting face and the flange face
station 1 to 5 and 6 to 10.
7. Erect the first girth gear section onto the mill and install the flange bolts.

8. Rotate the mill 180° and remove the second section of the girth gear.

19-61
Preventive Maintenance

Table 19-29 (continued)

Replacement Tasks for the Pinion and Girth Gear
(Courtesy of the Arnot Power Station)

Tasks

9. Rotate and clean the second section of the girth gear mounting face and the flange face
station 1 to 5 and 6 to 10.
10. Erect the girth gear second section onto the mill and install the flange bolts.

11. Tighten the girth gear mounting bolts on station 1/10 and 5/6.

12. Perform runout checks on the girth gear alignment. Tighten all flange bolts.
13. Remove the pinion from the base plate and clean the base plate.

14. Install the new pinion and check the backlash and contact with the girth gear.

15. Install the pinion guard, girth gear guard, and the seal air pipe.

16. Install the soundhood panel at the pinion side and girth gear top section.

17. Align the low speed side of the reduction gearbox to the pinion coupling.

18. Align the main motor to the reduction gearbox high-speed side.

19. Align the auxiliary reduction gearbox to the main motor coupling.

20. Align the auxiliary motor to the auxiliary reduction gearbox coupling.

21. Grease and close all couplings. Install safety guards.

22. Clean area around the mill and drive train.

19-62
20
PREVENTIVE MAINTENANCE BASIS

It is the intent of this section to establish a PM Basis document for the ball/tube mills.

20.1 Background

Many power plants are in the process of reducing PM costs and improving equipment
performance by matching PM tasks with the functional importance of the equipment. For this to
succeed, utilities require information on the most appropriate tasks and task intervals for the
important equipment types, while accounting for the influences of functional importance, duty
cycle and service conditions.

An early approach to optimizing the PM activities was the use of reliability centered
maintenance (RCM). RCM was developed in the 1960s by the commercial airline industry to
apply reliability concepts to maintenance and the design of maintenance programs. The RCM
approach to preventing equipment failure is to perform maintenance tasks that are specifically
aimed at preventing component failure mechanisms from occurring. Many nuclear power plants
used the RCM process to improve their PM programs.

In 1991, the Nuclear Regulatory Commission issued 10 CFR 50.65, Requirements for
Monitoring the Effectiveness of Maintenance at Nuclear Power Plants, also called the
Maintenance Rule. In brief, the Maintenance Rule required the nuclear power plants to develop a
reliability and availability monitoring program for the systems, structures, and components
considered to be within the scope of the rule. The monitoring part of the rule included
determining the effectiveness of the maintenance performed on the components. In addition, the
Maintenance Rule required the utility to evaluate industry operating experience and to use that
experience when modifying the maintenance program. When maintenance practices have been
changed, the most common action is to modify the PM tasks for the components.

Initially, PM tasks were assigned based on vendor recommendations and plant experience. In
modifying or optimizing the PM tasks, one vital piece of information was missing - the time to
failure for the components. Because the time to failure was not known, it was difficult to justify
the PM task intervals. Also missing was the understanding of the factors that influence the
progression of the degradation mechanisms for the component.

20-1
Preventive Maintenance Basis

As a result of the need to comply with the Maintenance Rule and to optimize the PM tasks for
more effective maintenance, the PM Basis project was proposed by EPRI. The PM Basis
objective was to:
• Provide a summary of industry experience that the PM tasks and task intervals were based on
• Establish the relationship between the degradation mechanism, the progression of the
mechanisms to failure, and the opportunities available to discover the failure mechanisms
before component failure occurred

During the 1996-1998 timeframe, 39 PM Basis documents were developed for major
components in the nuclear power plants. The components included various style valves,
switchgear, motor control centers, motors, pumps, compressors, HVAC (heating, ventilation and
air conditioning) components, inverters, batteries, relays, heat exchangers, turbines, transformers,
and instrumentation and control (I&C) components. The PM Basis documents can be found in
Preventive Maintenance Basis Volume 1–38 (EPRI report TR-106857) [17].

Currently, there are over 73 component types in an electronic PM database. The database can be
accessed by logging onto www.epri.com, searching for Preventive Maintenance Database
Version 5.1.1 (EPRI report 1010919) [18]. The product can be downloaded from www.epri.com;
however, it is best to order the CD from the EPRI Orders and Conferences Center at 1-800-313-
3774 (press 2).

Although the fossil power plants do not have the same regulatory requirements as the nuclear
power plants, the establishment of the PM Basis for critical components provides valuable
information for the optimization of the maintenance program.

The next step in the development of this PM Basis document is an additional review with plant
personnel. The PM tasks are further analyzed for criticality, condition monitoring options, and
other parameters before being added to the EPRI PM database.

The information used in the development of the PM Basis was gathered from the manufacturer,
industry literature, and input from utility maintenance personnel. The following is a description
of the tables generated by the PM Basis document.

20.2 Failure Locations, Degradation Mechanisms, and PM Strategies

The information for the mills can be contained in several tables. Table 20-1 lists the failure
locations of the pulverizer. The first table (Table 20-1) contains the:
• Failure locations – A list of the most common components
• Degradation mechanisms – The cause of the component failing at the specified failure
location
• Degradation influence – Aspects of the environment, plant operations, maintenance, or
design that cause the initiation of degradation processes or can affect how rapid the
degradation progresses

20-2
 Preventive Maintenance Basis

• Degradation progression – Whether the degradation progress is present most of the time
(continuous) or whether it would not normally be present but might exist or initiate in a
haphazard (random) way
• Failure timing – The relevant time period that the component would be free from failure
• Discovery opportunity – Reasonable, cost-effective opportunities for detecting the failure
mechanism
• PM strategy – The choice of PM tasks that can discover the failure mechanism

20-3
Preventive Maintenance Basis

Table 20-1
Failure Locations, Degradation Mechanisms, and PM Strategies for Ball/Tube Mills

Failure Location Degradation Degradation Degradation Failure Timing Discovery PM Strategy

Mechanism Influence Progression Opportunity
Grinding balls Cracking Coal level too Random Random Operator checks Operator checks
low
Chain drive Broken sprocket Lack of Random Random Visual inspection, Visual inspection,
lubrication Operator checks Operator checks
Classifier – Scroll Wear Normal use Continuous Based on amount Visual inspection, Visual inspection,
type, if present of coal processed Fineness Test Performance test
Foreign Material Random Random Visual inspection Visual inspection
Classifier – Blade wear Normal use Continuous Based on amount Visual inspection, Visual inspection,
Adjustable or of coal processed Fineness Test Performance test
dynamic, if present
Cone wear Normal use Continuous Based on amount Visual inspection, Visual inspection,
of coal processed Fineness test Performance test
Cone impact Foreign Material Random Random Visual inspection Visual inspection
damage
Classifier trickle Stuck open or Foreign Material Random Random Visual inspection, Visual inspection,
box, if present closed Operator checks Operator checks
Will not close Wear Continuous Continuous Visual inspection Visual inspection
fully
Clutch Slipping Wear Continuous Continuous Visual inspection Visual inspection
Insufficient air Random Random Operator checks Operator checks
Crusher-dryer, if Broken swing Wear Continuous Continuous Visual inspection Visual inspection
present hammers
Failed bearings Contamination Random Random Vibration analysis, Vibration analysis,
Visual inspection Visual inspection

20-4
 Preventive Maintenance Basis

Table 20-1 (continued)

Failure Locations, Degradation Mechanisms, and PM Strategies for Ball/Tube Mills

Failure Location Degradation Degradation Degradation Failure Discovery PM Strategy

Mechanism Influence Progression Timing Opportunity
Airflow dampers Stuck Wear Continuous Continuous Operator checks, Operator checks,
Visual inspection Visual inspection
Controls failure Random Random Calibration, Operator Calibration, Operator
checks checks
Drum/trunnion High temperature Improper Random Random Oil analysis, Operator Oil analysis,
bearings lubrication type checks Operator checks
Insufficient Random Random Operator checks Operator checks
lubricant
Oil cooling system Random Random Operator checks Operator checks
clogged
High vibration Wear Continuous Continuous Vibration analysis, Oil Vibration analysis,
analysis Oil analysis
Drum liners Thinning Wear Continuous Continuous Visual inspection Visual inspection
Broken wedge Wear Continuous Continuous Visual inspection Visual inspection
bolts
Foreign material Random Random Visual inspection Visual inspection
Exhauster, if Bearing wear Age Continuous Months to Vibration analysis, Vibration analysis,
present years Visual inspection Visual inspection
Lack of lubrication Random Random Check oil level, Operations check,
Vibration analysis Vibration analysis
Lubrication Random Random Oil analysis, Seal Air Oil analysis,
contamination System check Operations check
Vibration Continuous Random Vibration analysis, Oil Vibration analysis,
analysis Oil analysis
Bearing housing Fan vibration Continuous Continuous Vibration analysis, Vibration analysis,
wear Visual inspection Visual inspection

20-5
Preventive Maintenance Basis

Table 20-1 (continued)

Failure Locations, Degradation Mechanisms, and PM Strategies for Ball/Tube Mills

Failure Degradation Degradation Degradation Failure Discovery PM Strategy

Location Mechanism Influence Progression Timing Opportunity

Exhauster, if Fan blade wear Normal use Continuous Months to Visual inspection, Visual inspection,
present - years Vibration analysis, Fan Vibration analysis,
continued Tests Performance test

Foreign Material Random Random Fineness Test, Visual Performance test, Visual
inspection, Vibration inspection, Vibration
analysis analysis

Fan housing Normal use Continuous Random Visual inspection Visual inspection
wear
Foreign material Random Random Visual inspection Visual inspection

Loose or broken Coal erosion, Random Random Visual inspection, Visual inspection,
fan shaft fatigue Vibration analysis Vibration analysis

Feeder - Leaking seals Age Continuous Continuous Operations check, Operations check, Visual
Visual inspection inspection
Gearbox drive

Feeder - Failed bearings Contamination Random Random Oil analysis Oil analysis
Bearings

Feeder - Belt Incorrect coal Wear Continuous Continuous Calibration, Visual Calibration, Visual
table flow inspection inspection

Feeder Obstruction Foreign material Random Random Calibration, Visual Calibration, Visual
inspection inspection

Wear Normal use Continuous Years Calibration, Visual Calibration, Visual

inspection inspection

Belt wear, if Age Continuous Years Calibration, Visual Calibration, Visual

applicable inspection inspection

Feeder controls Inaccuracy Controls failure Random Random Calibration Calibration

20-6
 Preventive Maintenance Basis

Table 20-1 (continued)

Failure Locations, Degradation Mechanisms, and PM Strategies for Ball/Tube Mills

Failure Degradation Degradation Degradation Failure Discovery PM Strategy

Location Mechanism Influence Progression Timing Opportunity
Girth gear and Misalignment Wear Continuous Years Vibration analysis, Vibration analysis,
pinion Visual inspection Visual inspection
Gear damage Lack of Random Random Vibration analysis, Vibration analysis,
lubrication Operator checks Operator checks
Contamination Random Random Vibration analysis, Oil Vibration analysis, Oil
analysis analysis
Inlet/outlet box Ribbon wear Age Continuous Continuous Visual inspection Visual inspection
Broken ribbon Foreign material Random Random Visual inspection Visual inspection
Mill motor High temperature Insufficient Random Random Operator checks Operator checks
bearing
lubrication
Lubrication Random Random Oil analysis, Visual Oil analysis, Visual
contamination inspection inspection
Oil cooler not Random Random Operator checks Operator checks
functioning
Faulty Random Random Operator checks, Operator checks,
thermocouple Calibration Calibration
Low voltage Random Random Operator checks Operator checks
High load Random Random Operator checks Operator checks
Speed reducer Overheating Improper Random Random Oil analysis, Operator Oil analysis, Operator
gearbox lubrication type checks checks
Insufficient Random Random Operator checks Operator checks
lubricant
Oil cooling Random Random Operator checks Operator checks
system clogged

20-7
Preventive Maintenance Basis

Table 20-1 (continued)

Failure Locations, Degradation Mechanisms, and PM Strategies for Ball/Tube Mills

Failure Location Degradation Degradation Degradation Failure Discovery PM Strategy

Mechanism Influence Progression Timing Opportunity

Speed reducer Failed bearings Wear Continuous Continuous Vibration analysis, Vibration analysis,
gearbox - Visual inspection Visual inspection
continued
Insufficient Random Random Operator checks Operator checks
lubricant

Lubrication Random Random Oil analysis, Visual Oil analysis, Visual

contamination inspection inspection

High vibration Loose foundation Random Random Operator checks, Operator checks,
bolts Vibration analysis Vibration analysis

Worn gears Continuous Continuous Visual inspection Visual inspection

Loose parts Random Random Vibration analysis, Vibration analysis,

Visual inspection Visual inspection

Pitted and galled Incorrect Random Random Oil analysis Oil analysis
gears lubrication

20-8
 Preventive Maintenance Basis

20.3 PM Tasks and Their Degradation Mechanisms

Table 20-2 contains the PM tasks and intervals. The PM tasks and the degradation mechanisms
are listed from the previous table. The corresponding PM task interval is then given for each
applicable PM task.

20-9
Preventive Maintenance Basis

Table 20-2
PM Tasks and Their Degradation Mechanisms for Ball/Tube Mills

Component Location/Degradation PM Task and Interval

Calibration Oil Operator Performance Vibration Visual
Analysis Checks Testing Analysis Inspection
1–2 years 6 months Daily Monthly 3–6 6 months
– 1 year months – 1 year
Grinding balls Cracking X
Chain drive Broken sprocket X X
Classifier - Scroll type, Wear/normal use X X
if present
Wear/foreign material X
Classifier - Adjustable Blade wear X X
or dynamic, if present
Cone wear X X
Cone impact damage X
Classifier trickle box, if Stuck open or closed X X
present
Will not close fully X
Clutch Slipping/wear X
Slipping/insufficient air X
Crusher-dryer, if Broken swing hammers X
present
Failed bearings X X
Airflow dampers Stuck/wear X X
Stuck/controls failure X X
Drum/trunnion bearings High temperature/improper X X
lubrication
High X
temperature/insufficient
lubricant

20-10
 Preventive Maintenance Basis

Table 20-2 (continued)

PM Tasks and Their Degradation Mechanisms for Ball/Tube Mills

Component Location/ Degradation PM Task and Interval

Calibration Oil Operator Performance Vibration Visual
Analysis Checks Testing Analysis Inspection
1–2 years 6 months Daily Monthly 3–6 6 months
– 1 year months – 1 year
Drum/trunnion bearings High temperature/oil cooling X
- continued system clogged
High vibration X X
Drum liners Thinning X
Broken wedge bolts/wear X
Broken wedge bolts/foreign X
material
Exhauster, if present Bearing wear X X
Bearing wear/lack of X X
lubrication
Bearing wear/ lubrication X X
contamination
Bearing wear/vibration X X
Bearing housing wear X X
Fan blade wear/normal X X X
Fan blade wear/foreign X X X
material
Fan housing wear/normal X
use
Fan housing wear/foreign X
material
Loose or broken fan shaft X X

20-11
Preventive Maintenance Basis

Table 20-2 (continued)

PM Tasks and Their Degradation Mechanisms for Ball/Tube Mills

Component Location/ Degradation PM Task and Interval

Calibration Oil Operator Performance Vibration Visual

Analysis Checks Testing Analysis Inspection
1–2 years 6 months Daily Monthly 3–6 6 months
– 1 year months – 1 year

Feeder - Leaking seals X X

Gearbox drive
Feeder - Bearings Failed bearings X

Feeder - Belt, if Incorrect coal flow X X

applicable
Obstruction X X

Wear X X

Belt wear, if applicable X X

Feeder controls Inaccuracy X

Girth gear and pinion Misalignment X X

Gear damage X X

Gear damage X X

Inlet/outlet box Ribbon wear X

Broken ribbon X

Mill motor High X

temperature/insufficient
bearing lubricant
High temperature/lubrication X X
contamination

20-12
 Preventive Maintenance Basis

Table 20-2 (continued)

PM Tasks and Their Degradation Mechanisms for Ball/Tube Mills

Component Location/ Degradation PM Task and Interval

Calibratio Oil Operator Performance Vibration Visual
n Analysis Checks Testing Analysis Inspection
1–2 years 6 months – Daily Monthly 3–6 months 6 months
1 year – 1 year
Mill motor (continued) High temperature/oil cooler X
not functioning
High temperature/faulty X X
thermocouple
High temperature/low X
voltage
High temperature/high load X
Speed reducer gearbox Overheating/improper X X
lubrication type
Overheating/insufficient X
lubricant
Overheating/oil cooling X
system clogged
Failed bearings/wear X X
Failed bearings/insufficient X
lubricant
Failed bearings/lubrication X X
contamination
High vibration/loose X X
foundation bolts
High vibration/worn gears X
High vibration/loose parts X X
Pitted and galled gears X

20-13
Preventive Maintenance Basis

20.4 PM Template

The following describes the information contained in the PM template shown in Table 20-3.

The PM template summarizes the program of tasks and task intervals for the equipment type.
Each plant should base their program on the manufacturer recommendations and their own
history of equipment performance. The PM template can serve as a beginning for development
of a PM program for the equipment with changes added from feedback as the program is
implemented.

Columns labeled 1–8 in the PM template list the 8 sets of conditions for the ball/tube mills. Each
column corresponds to the combined choices of critical or non-critical equipment, high or low
duty cycle, and severe or mild service conditions. Time intervals for the performance of each
task are entered at the intersections of the task rows and columns 1–8.

The definitions of template application conditions are:

• Critical
Yes – Functionally important, that is, risk significant, required for power production,
safety related, or other regulatory requirement

No – Functionally not important, but economically important, that is, for any of the
following reasons: high frequency of resulting corrective maintenance, more
expensive to replace or repair than to do preventive maintenance, has a high potential
to cause the failure of other critical, or economically important equipment.

• Duty Cycle
High – Frequently cycled or partially loaded during the greater part of its operational
time

Low – Fully loaded during the greater part of its operation time

• Service Condition
Severe – High or excessive humidity, excessive temperatures (high/low) or
temperature variations, excessive environmental conditions (that is, salt, corrosive,
spray, steam, low quality suction air), high vibration.

Mild – Clean area (not necessarily air conditioned), temperatures within OEM
specifications, normal environmental conditions.

PM tasks – The PM tasks provide a cost-effective way to intercept the causes and mechanisms
that lead to degradation and failure. The PM tasks can be used to develop a complete PM
program or to improve an existing program. These tasks are intended to complement and not to
replace the PM recommendations given by the manufacturer. A brief description of the PM tasks
follows the PM Template.

20-14
 Preventive Maintenance Basis

Table 20-3
PM Template for the Ball/Tube Mills

Conditions 1 2 3 4 5 6 7 8

Critical: Yes X X X X
No X X X X
Duty Cycle: High X X X X
Low X X X X

Service Condition: Severe X X X X

Mild X X X X

PM Tasks Frequency Interval

Calibration 1–2 years 1–2 years 1–2 years 1–2 years 2 years 2 years 2 years 2 years
Oil analysis 6 months 6 months 6 months 6 months 1 year 1 year 1 year 1 year

Operator checks Daily Daily Daily Daily Daily Daily Daily Daily

Performance testing Monthly Monthly Monthly Monthly 2 months 2 months 2 months 2 months
Vibration analysis 3 months 3 months 3 months 3 months 6 months 6 months 6 months 6 months

Visual inspection 3000 hrs 3000 hrs 3000 hrs 3000 hrs 1 year 1 year 1 year 1 year

20-15
Preventive Maintenance Basis

The following is a brief description of PM tasks used in the PM Template.

• Calibration – Calibration of pulverizer equipment includes the setting and verification of
instruments and components. Instruments include thermocouples, RTDs (Resistance
Temperature Detectors), pitot tubes, pressure gauges, and so on. The calibration of
components includes setting the clearances/tolerances for the mill inlet/outlet boxes,
classifier blades, trickle valves, feeders, and so on. The frequency for calibration can be time
based or initiated based on equipment condition. For example, if mill fineness testing
indicates a drop in performance, then adjusting the classifier blades should be performed.
New on-line monitoring techniques may trigger an instrument that needs calibration.
• Oil analysis – Oil analysis is very valuable predictive maintenance technology in detecting
problems in equipment before failure occurs. For the ball/tube mills, oil samples should be
taken and analyzed for the speed reducer gearbox, mill motor bearings, trunnion/drum
bearings, chain drive oil reservoir, and so on. Samples should be analyzed for water and
particle contamination and oil properties. The results of the oil analysis can alert personnel
that bearings are failing and plans can be made to monitor the operation of the equipment,
take more frequent samples, or shut the equipment down.
• Operations check – Operations check includes an external visual inspection of the mills,
listening for noises, smelling for smoke, checking temperatures, checking pressures, and so
on.
• Performance testing – Performance testing includes fineness testing, airflow tests, fan tests,
and so on. Fineness testing is especially important with the mills to determine the efficiency
or effectiveness of the mill.
• Vibration analysis – Vibration analysis on rotating equipment is very valuable in detecting
bearing problems before the bearings fail. Vibration analysis is recommended for the speed
reducer gearbox, trunnion/drum bearings, mill motor bearings, and so on.
• Visual inspection – A visual inspection is an internal inspection of mill components to
determine their condition. Components to be inspected include classifier blades, classifier
cone, inlet/outlet box ribbon conveyor, trickle valve, shut-off valves, drum liner and wedge
bolts, speed reducer gearbox, girth and pinion gears, feeders, crusher-dryers, and so on.
Inspections include taking physical measurements, ultrasonic thickness checks, non-
destructive testing, general condition assessment, wear areas, foreign material/debris, and so
on.

20-16
21
REFERENCES

1. Guidelines for Evaluating the Impact of Powder River Basin (PRB) Coal Blends on Power
Plant Performance and Emissions. EPRI, Palo Alto, CA: 1996. TR-106340.
2. Foster Wheeler Ball Mill Upgrades and Features, July 2003, http://parts.fwc.com/ballmills.
3. David H. Scott, “Coal Pulverizers – Performance and Safety,” International Energy Agency
Coal Research, London, England. June 1995.
4. Pulverizer and Fuel Delivery Guidelines. EPRI, Palo Alto, CA: 2004. 1009490.
5. Allegheny Power, Armstrong Station Unit #1 Pulverized Coal System (description for
training purposes).
6. J. Garcia-Mallol, K. McCarthy, J. Fernandez, P. Ventin, P. Yague, and J. Martinez, “Hard-
Coal Burnup Increase with Adjustable Static Classifier for Ball Mill,” Power-Gen
International Conference, Orlando, FL, November 14–16, 2000.
7. “Riley Power Service Guide Steam Generating Equipment for Hoosier Energy Rural Electric
Cooperative, Inc., Merom Station Units 1 and 2,” Merom, IN, 1981.
8. Q. Lin and C. Peterson, “Coal Pulverizer Design Upgrades to Meet the Demands of Low
NOx Burners,” Electric Power 2004, Baltimore, MD, March 30–April 1, 2004.
9. Internet web site http://www.babcockpower.com
10. Component Failure and Repair Data for Coal-Fired Power Units. EPRI, Palo Alto, CA:
1981. AP-2071.
11. Evaluation of Coal Pulverizer Materials. EPRI, Palo Alto, CA: 1988. CS-5935.
12. On-Line Predictive Condition Monitoring System for Coal Pulverizers. EPRI, Palo Alto, CA:
2003. 1004902.
13. Electric Motor Predictive Maintenance Program. EPRI, Palo Alto, CA: 1999. TR-108773-V2.
14. Predictive Maintenance Guide Primer Revision. EPRI, Palo Alto, CA: 2003. 1007350.
15. Lubrication Guide: Revision 3. EPRI, Palo Alto, CA: 2001. 1003085.
16. Lana Robin, “Improving the Life and Capabilities of Lubricants,” Maintenance Technology,
May 1999. http://www.pdma.com.
17. Preventive Maintenance Basis, Volumes 1–38. EPRI, Palo Alto, CA: 1998. TR-106857.
18. Preventive Maintenance Basis Database, Version 5.1.1. EPRI, Palo Alto, CA: 2004.
1010919.

21-1
A
KEY POINTS

Human Performance Key Point

Denotes information that requires personnel action or consideration in order to
prevent personal injury, equipment damage, and/or improve the efficiency and
effectiveness of the task.

Section Page Key Point

11.5 11-8 The NFPA identifies two areas of protection for ball mills. The two areas are
preventing an explosion (inerting) and extinguishing a fire.
12.2 12-2 Fuel flow of the mill feeding the lower burner elevation should not drop below 45%.
Fuel oil should be added on the bottom mill in service if the fuel flow drops below
45% and is not stable.

12.3 12-3 If a blocked coal pipe is discovered, every effort should be made to correct this
defect as soon as possible. Continued mill operation with a blocked coal pipe is not
allowed for more than 14 days.
19.0 19-1 There are three areas of work that are critical to performing maintenance on the
mills. The areas are temporary lighting, lifting and rigging practices, and temporary
scaffolding.

O&M Cost Key Point

Emphasizes information that will result in overall reduced costs and/or an increase
in revenue through additional or restored energy production.

Section Page Key Point

3.4 3-11 The increases in LOI from NOx combustion control the increase the heat rate. The
average industry loss is 12 Btu/kWh per 1% change in unburned carbon. This
increase in LOI creates a need for greater fineness. Some units have increased
fineness from 70% passing through a 200-mesh screen to 75–80% passing through
a 200-mesh screen and 99–99.5% passing through a 50-mesh screen. The increase
in fineness settings requires more work from the pulverizer.
6.2 6-9 It is less expensive and more time efficient to purchase the complete drum assembly
instead of having the end castings and drum shell plate assembled on site.

A-1
Key Points

Technical Key Point

Targets information that will lead to improved equipment reliability.

Section Page Key Point

4.0 4-2 If the diameter of the drum is greater than the length of the drum, then the mill is
called a ball mill. If the length of the drum is greater than the diameter of the drum,
then the mill is called a tube mill. The terms ball and tube are used interchangeably in
this guide.

5.1 5-5 The bypass dampers accomplish three functions:

• Assist in maintaining the minimum pulverized coal and air velocity in the piping
• Assist in increasing the flow of drying, hot air during periods when the coal is wet
• Allow the mill to operate at lower loads
5.2 5-7 As the liner contour wears, the grinding medium begins to slip. This slippage leads to
a lowering of efficiency in the grinding action because the grinding medium cannot be
raised to a high angle. As slippage continues, the wear will accelerate. Replacement
of liners is recommended once the minimum thickness is reached. The rate of wear of
the liners can be predicted based on the grade of coal being ground and the
experience gained from inspections.

6.0 6-3 There is no tramp iron removal system. The mill is designed to grind the raw coal and
foreign matter together. Considerable amounts of pyrites will accelerate the wear
rates of the grinding media.
9.2.5 9-12 Barring is performed when the mill needs to be cooled down. Inching of the mill is
performed during maintenance periods and allows the precise positioning of the mill
drum inspection door.
11.1 11-2 The ideal proportion of the weight of the balls to the weight of the coal is between six
and seven. This means that for every 330 lbs of coal in the mill, there should be
2205 lbs of balls in order to effectively pulverize the coal. If the proportion of coal in
the mixture is too low, the balls will strike each other and grind against the cylinder. If
the proportion of coal in the mixture is too high, the coal will tend to flow into the feed
scrolls.
13.4 13-10 The mill system’s rating and bypass dampers control the fuel flow responding to the
demand signal from the combustion controls. The mill bypass dampers operate in a
fixed relationship to the mill rating damper over the entire demand signal range of the
combustion control system.
18.2 18-3 Lubricant testing is recommended for several reasons. These include:
• To study the condition (wear) of the machine being lubricated. If there is a
problem with the lubricant, there is a strong possibility that the machine will need
maintenance.
• To determine if the lubricant is meeting the specifications
19.3 19-37 Excessive accumulation of dust deposits within clutch elements can eventually restrict
shoe retraction during clutch disengagement, resulting in dragging and overheating.
Protective shielding or total enclosure is recommended to keep the dust out, and if it is
not provided, the clutches must be inspected frequently (every three months) to
ensure normal shoe release.

A-2
B
TRANSLATED TABLE OF CONTENTS

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF

WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI).
NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY
PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH
RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM
DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED
RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS
SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE, (IV) THAT ANY TRANSLATION FROM THE
ENGLISH-LANGUAGE ORIGINAL OF THIS DOCUMENT IS WITHOUT ERROR; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING
ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF
THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS
DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN
THIS DOCUMENT.

THE TRANSLATION OF THIS DOCUMENT FROM THE ENGLISH-LANGUAGE ORIGINAL HAS BEEN PREPARED WITH
LIMITED BUDGETARY RESOURCES BY OR ON BEHALF OF EPRI. IT IS PROVIDED FOR REFERENCE PURPOSES ONLY
AND EPRI DISCLAIMS ALL RESPONSIBILITY FOR ITS ACCURACY. THE ENGLISH-LANGUAGE ORIGINAL SHOULD BE
CONSULTED TO CROSS-CHECK TERMS AND STATEMENTS IN THE TRANSLATION.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Electric Power Research Institute (EPRI)

B-1
Translated Table of Contents

レポートの概要

目的
• ボール/チューブミルのための予防および予知保全方法を明らかにすること

• ボール/チューブミル装置問題を明らかにして解決して、プラント保全の人員を助け
ること

B-2
 Translated Table of Contents

目次

1はじめに.................................................................................................................................. 1-1

1.1背景 ................................................................................................................................. 1-1

1.2アプローチ ...................................................................................................................... 1-2

1.3構成 ................................................................................................................................. 1-3

1.4キーポイント................................................................................................................... 1-4

2用語......................................................................................................................................... 2-1

3システム.................................................................................................................................. 3-1

3.1石炭の取扱いシステム .................................................................................................... 3-1

3.2石炭の特性 ...................................................................................................................... 3-5

3.3石炭の微粉化ミル............................................................................................................ 3-7

3.4環境の規則 ...................................................................................................................... 3-9

4技術的な記述–一般 ................................................................................................................. 4-1

5技術的な記述– ALLIS-CHALMERS ...................................................................................... 5-1

5.1入口/出口ボックス........................................................................................................... 5-4

5.2回転シェル、ライナーおよびボール............................................................................... 5-7

5.3トラニオンベアリング .................................................................................................... 5-9

5.4分類機 ........................................................................................................................... 5-15

5.5駆動モーター ................................................................................................................ 5-17

B-3
Translated Table of Contents

5.6変速機ユニット ............................................................................................................. 5-23

5.7ガースギヤおよびピニオンシャフト............................................................................. 5-29

5.8パワーソニックミル調節システム ................................................................................ 5-33

5.9技術仕様のリスト.......................................................................................................... 5-35

6技術的な記述–FOSTER-WHEELER....................................................................................... 6-1

6.1コンベヤーアセンブリ .................................................................................................... 6-4

6.1.1コンベヤーサポートアセンブリ .............................................................................. 6-6

6.2ドラムアセンブリ............................................................................................................ 6-8

6.2.1ダブルウェイブライナー ....................................................................................... 6-10

6.2.2ダブルサイズ、ダブルウェイブアクセスドア....................................................... 6-12

6.2.3フライトバー ......................................................................................................... 6-12

6.2.4粉砕ボール............................................................................................................. 6-12

6.3コンベヤーの軸受およびシール .................................................................................... 6-13

6.4トラニオンの主要なベアリングおよびダストシール.....................................................6-14

6.5伝動装置 ........................................................................................................................ 6-16

6.5.1ピニオンベアリング .............................................................................................. 6-17

6.6トラニオンの管 ............................................................................................................. 6-18

6.7分類機 ........................................................................................................................... 6-20

6.7.1分類機のリジェクトダンパー ............................................................................... 6-20

6.7.2調節可能な刃の分類機........................................................................................... 6-21

6.7.3 Mタイプ分類機 ..................................................................................................... 6-23

6.7.4ダイナミック分類機 .............................................................................................. 6-24

6.8排気装置 ........................................................................................................................ 6-27

B-4
 Translated Table of Contents

6.9潤滑油システム ............................................................................................................. 6-28

6.9.1 Cardwellの潤滑油システム................................................................................... 6-28

6.9.2 Farvalの潤滑油システム....................................................................................... 6-30

7技術的な記述–KENNEDY VAN SAUN .................................................................................. 7-1

8技術的な記述–RILEY POWER株式会社................................................................................. 8-1

8.1概説 ................................................................................................................................. 8-1

8.2システムコンポーネント................................................................................................. 8-4

8.2.1送り装置 .................................................................................................................. 8-5

8.2.2粉砕機ドライヤー ................................................................................................... 8-6

8.2.3回転ドラムまたはバレル ......................................................................................... 8-7

8.2.4粉砕ボール............................................................................................................... 8-8

8.2.5分類機...................................................................................................................... 8-9

8.2.6遮断弁.................................................................................................................... 8-10

8.2.7減速変速機............................................................................................................. 8-10

8.2.8 クラッチ............................................................................................................8-12

8.3システム ........................................................................................................................ 8-15

8.3.1一次空気システム.................................................................................................. 8-15

8.3.2シール空気システム .............................................................................................. 8-16

8.4改造 ............................................................................................................................... 8-17

8.4.1逆流抑制（トリクル）弁の付加 ............................................................................ 8-17

8.4.2トラニオンの空気シールの設計変更 ..................................................................... 8-18

8.4.3ミル調節システムアップグレード......................................................................... 8-19

8.4.4流体力学のスライドシューベアリング変更 .......................................................... 8-19

B-5
Translated Table of Contents

9技術的な記述–STEIN INDUSTRIE ........................................................................................ 9-1

9.1概説 ................................................................................................................................. 9-1

9.2システム .......................................................................................................................... 9-4

9.2.1石炭入口システム.................................................................................................... 9-5

9.2.2一次空気システム.................................................................................................... 9-5

9.2.3シール空気システム ................................................................................................ 9-6

9.2.4潤滑油システム ....................................................................................................... 9-7

9.2.5 駆動システム ....................................................................................................... 9-12

9.2.6排出システム ......................................................................................................... 9-13

9.2.7ボールのローディングシステム ............................................................................ 9-13

10運転および安全– ALLIS-CHALMERS ............................................................................... 10-1

10.1運転 ............................................................................................................................. 10-1

10.2防火 ............................................................................................................................. 10-2

11運転および安全–FOSTER-WHEELER ............................................................................... 11-1

11.1運転の概要 .................................................................................................................. 11-1

11.2運転指示値 .................................................................................................................. 11-3

11.3起動プロシージャ........................................................................................................ 11-4

11.4火検出システム ........................................................................................................... 11-6

11.5防火 ............................................................................................................................. 11-7

12運転および安全–KENNEDY VAN SAUN .......................................................................... 12-1

12.1ロード変更 .................................................................................................................. 12-1

12.2燃料サポート............................................................................................................... 12-2

12.3ブロックされた燃料管 ................................................................................................ 12-3

B-6
 Translated Table of Contents

12.4湿った石炭 .................................................................................................................. 12-4

12.5ミルストリッピング .................................................................................................... 12-5

12.6冷態起動 ...................................................................................................................... 12-6

13運転および安全–RILY POWER株式会社.............................................................................13-1

13.1運転の概要 .................................................................................................................. 13-1

13.2制御システム............................................................................................................... 13-2

13.3ボール供給取扱い........................................................................................................ 13-7

13.4一次空気のダンパー運転............................................................................................. 13-8

13.5シール空気システム .................................................................................................. 13-11

13.6送り装置のキャリブレーション ................................................................................ 13-12

13.7計器の設定 ................................................................................................................ 13-13

13.8火災探知 .................................................................................................................... 13-15

13.9防火 ........................................................................................................................... 13-17

14運転および安全–STEIN INDUSTRIE ................................................................................. 14-1

14.1 長期停止時の対策 ...................................................................................................... 14-1

14.2防火 ............................................................................................................................. 14-2

15パフォーマンス................................................................................................................... 15-1

15.1微粉の細かさ............................................................................................................... 15-1

15.2 粉砕性 ........................................................................................................................ 15-2

15.3湿気 ............................................................................................................................. 15-2

15.4容量 ............................................................................................................................. 15-3

16故障モード .......................................................................................................................... 16-1

16.1摩耗 ............................................................................................................................. 16-1

16.2腐食 ............................................................................................................................. 16-3

B-7
Translated Table of Contents

16.3機器の故障 .................................................................................................................. 16-4

17トラブルシューティング .................................................................................................... 17-1

17.1 Allis-Chalmers ........................................................................................................... 17-1
17.2 FOSTER WHEELER .................................................................................................. 17-5
17.3KENNEDY VAN SAUN ............................................................................................... 17-7

17.4RILEY POWER株式会社 ..............................................................................................17-9

17.5 STEIN Industrie ....................................................................................................... 17-10

18予知保全.............................................................................................................................. 18-1

18.1振動分析 ...................................................................................................................... 18-3

18.2油分析 ......................................................................................................................... 18-3

18.3状態監視保全–KENNEDY VAN SAUN ..................................................................... 18-12

18.4状態監視保全–STEIN Industrie ................................................................................ 18-15

19予防保全.............................................................................................................................. 19-1
19.1 Allis-Chalmers ........................................................................................................... 19-1

19.1.1点検基準 .............................................................................................................. 19-2

19.1.2ミルの外部点検 ................................................................................................... 19-3

19.1.3ミルの内部点検 ................................................................................................... 19-6

19.1.4分類機の点検 ....................................................................................................... 19-7

19.1.5駆動機構のトレインの点検 ................................................................................. 19-9

19.1.6シェルおよびトラニオンライナー..................................................................... 19-10

19.1.7トラニオンベアリングインサート取替 ............................................................. 19-11

19.1.8ガースギヤ取替 ................................................................................................. 19-13

19.1.9変速機の改造 ..................................................................................................... 19-18

19.1.10様々な装置....................................................................................................... 19-22

B-8
 Translated Table of Contents

19.1.11装置の潤滑油のリスト..................................................................................... 19-22
19.2KENNEDY VAN SAUN ............................................................................................. 19-24

19.2.1ピニオン、ガースギヤおよび潤滑油システム................................................... 19-25

19.2.2ワームギヤの逆転.............................................................................................. 19-25

19.3RILEY POWER株式会社 .......................................................................................19-27

19.3.1送り装置 ............................................................................................................ 19-27

19.3.2粉砕機ドライヤー ............................................................................................. 19-28

19.3.3入口/出口ボックスおよび空気シール ................................................................ 19-31

19.3.4ミルライナー ..................................................................................................... 19-31

19.3.5ボール供給......................................................................................................... 19-32

19.3.6減速変速機......................................................................................................... 19-33

19.3.7トレイン駆動 ......................................................................................................19-38

19.3.8ドライブシャフト.............................................................................................. 19-44

19.3.9潤滑油の熱交換器.............................................................................................. 19-46

19.3.10分類機.............................................................................................................. 19-47

19.3.11一次空気ファンおよびダクト.......................................................................... 19-48

19.3.12石炭の遮断弁 ................................................................................................... 19-49

19.3.13潤滑スケジュール............................................................................................ 19-49

19.3.14予備品.............................................................................................................. 19-50

19.3.15予防保全点検 ................................................................................................... 19-51

19.4STEIN Industrie ........................................................................................................ 19-51

19.4.1予防保全タスク ..................................................................................................19-53

19.4.2点検タスク..........................................................................................................19-58

19.4.3ピニオンおよびガースギヤ取替 .........................................................................19-61

B-9
Translated Table of Contents

20予防保全の基礎................................................................................................................... 20-1

20.1背景 ............................................................................................................................. 20-1

20.2故障の位置、劣化メカニズムおよびPM戦略 .............................................................. 20-2

20.3 PMタスクおよび劣化メカニズム ............................................................................... 20-9

20.4 PMテンプレート ...................................................................................................... 20-14

21参照..................................................................................................................................... 21-1

Aキーポイント......................................................................................................................... A-1

B-10
 Translated Table of Contents

図のリスト

図3-1荷降ろしからプラントまでの典型的な石炭取扱い系統図 ............................................... 3-2

図3-2プラントからユニットバンカまでの典型的な石炭取扱いの系統図 ................................. 3-3

図3-3 FOSTER WHELLERチューブミル.................................................................................. 3-8

図3-4燃料に含まれる窒素の窒素化合物への変化 ................................................................... 3-10

図5-1 Allis-Chalmersのボール/チューブミルの概要 ................................................................. 5-2

図5-2入口/出口ボックス ........................................................................................................... 5-4

図5-3ミルのシーリング配置 ..................................................................................................... 5-6

図5-4 ボール供給のホッパー ................................................................................................... 5-8

図5-5トラニオンベアリングの低圧潤滑システム ................................................................... 5-10

図5-6手動高圧ジャッキングポンプ ........................................................................................ 5-13

図5-7 静的な分類機................................................................................................................. 5-15

図5-8ミル駆動機構モーター .................................................................................................. 5-17

図5-9バーリングギヤユニット................................................................................................ 5-19

図5-10バーリングカップリング.............................................................................................. 5-21

図5-11バーリングブレーキ..................................................................................................... 5-22

図5-12変速機ユニット ............................................................................................................ 5-23

図5-13変速機出力カップリング.............................................................................................. 5-25

図5-14変速機潤滑油システム ................................................................................................. 5-26

図5-15ギヤ歯の潤滑油 ............................................................................................................ 5-27

図5-16ミルの概要 ................................................................................................................... 5-30

図5-17ガースギヤ潤滑油システム .......................................................................................... 5-31

図5-18パワーソニックミルの調節システム............................................................................ 5-33

B-11
Translated Table of Contents

図6-1FOSTER WHEELチューブミルの図 ................................................................................ 6-1

図6-2空気/石炭の流れ図 ........................................................................................................... 6-2

図6-3フライトリボンのコンベヤーアセンブリ ........................................................................ 6-5

図6-4フライトリボンのばねサポートアセンブリ ..................................................................... 6-6

図6-5コンベヤーサポートアセンブリ ....................................................................................... 6-6

図6-6 8スポーク設計のコンベヤーの取り外し ......................................................................... 6-8

図6-7完全なドラムアセンブリ.................................................................................................. 6-9

図6-8端の鋳造部品.................................................................................................................. 6-10

図6-9ダブルウェイブライナー................................................................................................ 6-11

図6-10ダブルサイズ、ダブルウェイブアクセスドア ............................................................. 6-12

図6-11ボールの摩耗率 ............................................................................................................ 6-13

図6-12コンベヤーベアリング改造 .......................................................................................... 6-13

図6-13オリジナルベアリングアセンブリ ............................................................................... 6-14

図6-14新設計のベアリング..................................................................................................... 6-15

図6-15トラニオンのシール..................................................................................................... 6-16

図6-16ピニオンおよびブル・ギヤアセンブリ ........................................................................ 6-17

図6-17ローラ軸受 ................................................................................................................... 6-18

図6-18分類機のトラニオンの管.............................................................................................. 6-19

図6-19オリジナルのスクロールタイプ分類機 ........................................................................ 6-20

図6-20分類機のリジェクトダンパー ..................................................................................... 6-21

図6-21調節可能な分類機 ........................................................................................................ 6-22

図6-22分類機の比較................................................................................................................ 6-22

図6-23調節可能な分類機の適合性（フィットネス)の改善 ..................................................... 6-23

図6-24Mタイプ分類機............................................................................................................. 6-24

図6-25ダイナミック分類機..................................................................................................... 6-25

図6-26排気装置の図表 ............................................................................................................ 6-27

図6-27排気装置のスパイダー ................................................................................................. 6-28

図6-28 Cardwellの潤滑油システム ......................................................................................... 6-29

B-12
 Translated Table of Contents

図6-29 Farvalの潤滑油システム ............................................................................................. 6-30

図7-1KENNEDY VAN SAUN Millシステム................................................................................ 7-2

図7-2KENNEDY VAN SAUN Millの構成部................................................................................ 7-3

図8-1RILEY POWERのチェーン駆動のボール/チューブミルシステム.................................... 8-2

図8-2RILEY POWERのボール/チューブミルシステム ............................................................. 8-3

図8-3ドラム型送り装置 ............................................................................................................ 8-5

図8-4 粉砕機ドライヤー .......................................................................................................... 8-6

図8-5ピニオン/リングギヤ駆動機構セット付きのミル............................................................. 8-8

図8-6分類機 .............................................................................................................................. 8-9

図8-7減速変速機 ..................................................................................................................... 8-11

図8-8クラッチアセンブリ....................................................................................................... 8-13

図8-9 ロータシール................................................................................................................. 8-15

図8-10クラッチ空気制御システム .......................................................................................... 8-15

図8-11新逆流抑制（トリクル)弁デザイン .............................................................................. 8-18

図8-12トラニオンの空気シール設計 ...................................................................................... 8-19

図8-13流体力学のスライドシューベアリング ........................................................................ 8-20

図8-14スラスト・ベアリング ................................................................................................. 8-21

図9-1STEIN Industrieのチューブミル....................................................................................... 9-2

図9-2 STEIN Industrieのチューブミルの詳細鳥瞰図 ................................................................ 9-3

図9-3ミルの空気流れ ................................................................................................................ 9-6

図9-4高圧、低圧の潤滑油システム .......................................................................................... 9-9

図10-1移動式ガス容器ユニット.............................................................................................. 10-3

図10-2恒設二酸化炭素の防火システム ................................................................................... 10-4

図11-1火災探知センサーヘッド.............................................................................................. 11-7

図12-1湿り石炭運転................................................................................................................ 12-4

図13-1RILEY POWER運転の図表 .......................................................................................... 13-4

図13-2モーター出力対生産性 ................................................................................................. 13-5

図13-3プロダクト制御によるミルパラメータ ........................................................................ 13-5

B-13
Translated Table of Contents

図13-4ボール供給減少の効果付き .......................................................................................... 13-6

図13-5水スプレーシステムノズルの位置 ............................................................................. 13-18

図16-1 微粉化装置の機器故障頻度 ......................................................................................... 16-1

図18-1微粉化装置の故障に対する早期警報............................................................................ 18-2

図19-1リンクベルト単一ギヤ減速機 .................................................................................... 19-34

図19-2リンクベルトダブルギヤ減速機 ................................................................................. 19-35

図19-3リンクベルト三重ギヤ減速機 .................................................................................... 19-36

B-14
 Translated Table of Contents

テーブルのリスト

テーブル1-1換算率.................................................................................................................... 1-2

テーブル5-1パワーソニックミルの調節システムのアラーム条件.......................................... 5-34

テーブル5-2 Allis-Chalmersのミルのデータ ........................................................................... 5-35

テーブル9-1正常な潤滑油の油圧値 ........................................................................................ 9-11

テーブル9-2ミルの潤滑油システム ........................................................................................ 9-12

テーブル10-1ボールの取替タスク .......................................................................................... 10-2

テーブル11-1ダブルエンドのミルの一方を停止 .................................................................... 11-2

テーブル11-2通常運転時の点検.............................................................................................. 11-4

テーブル11-3起動のための最初のミルの準備 ........................................................................ 11-4

テーブル11-4起動のためのミルチャージング ........................................................................ 11-5

テーブル11-5ミルの運転開始 ................................................................................................. 11-6

テーブル11-6 FOSTER WHEELERミルでの消火プロシージャ ............................................. 11-8

テーブル11-7 FOSTER WHEELERミルの緊急停止プロシージャ ......................................... 11-9

テーブル11-8石炭の入ったFOSTER WHEELERミルを停止する為の推薦手順......................11-9

テーブル12-1ミルストリップのタスク ................................................................................... 12-5

テーブル12-2冷態起動タスク ................................................................................................. 12-6

テーブル13-1給炭機のキャリブレーションタスク ............................................................... 13-12

テーブル13-2ミルの計器パラメータ .................................................................................... 13-13

テーブル13-3典型的な装置パラメータ ................................................................................. 13-14

テーブル13-4火災探知の温度センサの位置.......................................................................... 13-16

テーブル15-1標準スクリーン寸法 .......................................................................................... 15-1

テーブル16-1研摩の摩耗係数 ................................................................................................. 16-3

B-15
Translated Table of Contents

テーブル16-2 Allis-Chalmers故障部品 .................................................................................... 16-4

テーブル17-1 Allis-Chalmersミルのトラブルシューテ-ィング............................................... 17-1

テーブル17-2 FOSTER WHEELERミルのトラブルシューテ-ィングの図 ............................. 17-5

テーブル17-3 KENNEDY VAN SAUN Millsのトラブルシューテ-ィングの図 ......................... 17-7

テーブル17-4 RILEY POWERのチューブミルのトラブルシューテ-ィングの図.................... 17-9

テーブル17-5STEIN Industrieミルのトラブルシューテ-ィング............................................ 17-10

テーブル18-1粒子カウントのレンジ番号 ............................................................................... 18-5

テーブル18-2油の追加パッケージのエレメント .................................................................... 18-9

テーブル18-3潤滑油プログラムのためのKENNEDY VAN SAUN Mill構成 ........................... 18-13

テーブル18-4 Majuba発電所の状態監視の値........................................................................ 18-16

テーブル18-5 Majuba発電所で状態監視されたパラメータ条件 ........................................... 18-19

テーブル18-6 Majuba発電所の状態監視用の計器 ................................................................ 18-20

テーブル18-7 Majuba発電所の状態監視スケジュール ......................................................... 18-24

テーブル19-1外部ミルの点検タスク ...................................................................................... 19-4

テーブル19-2内部点検タスク ................................................................................................. 19-6

テーブル19-3分類機の点検タスク .......................................................................................... 19-8

テーブル19-4ミル駆動機構トレインの点検タスク ................................................................. 19-9

テーブル19-5シェルおよびトラニオンライナー取替タスク ................................................ 19-10

テーブル19-6トラニオンベアリングインサート取替タスク ................................................ 19-12

テーブル19-7ガースギヤ取替タスク .................................................................................... 19-14

テーブル19-8変速機の改造タスク ........................................................................................ 19-19

テーブル19-9装置の潤滑油リスト ........................................................................................ 19-23

テーブル19-10ピニオン、ガースギヤおよび潤滑油システムのための点検タスク .............. 19-25

テーブル19-11変速機のワームギヤの逆転タスク ................................................................ 19-26

テーブル19-12摩耗ライナーの取替 ...................................................................................... 19-32

テーブル19-13減速変速機油容量.......................................................................................... 19-33

テーブル19-14三重速度減速変速機の分解タスク ................................................................ 19-37

テーブル19-15クラッチの点検タスク .................................................................................. 19-40

B-16
 Translated Table of Contents

テーブル19-16チェーン修理タスク ...................................................................................... 19-41

テーブル19-17運転されたスプロケットの取り外しおよび再設置タスク............................. 19-42

テーブル19-18ドライブシャフト取替タスク........................................................................ 19-44

テーブル19-19熱交換器の点検タスク .................................................................................. 19-46

テーブル19-20潤滑油の熱交換器の取替タスク .................................................................... 19-47

テーブル19-21分類機予防保全タスク .................................................................................. 19-48

テーブル19-22潤滑油スケジュール ...................................................................................... 19-49

テーブル19-23RILEY POWERの推薦予備品 ........................................................................ 19-50

テーブル19-24送り装置の7000作動時間間隔点検タスク ..................................................... 19-53

テーブル19-25予防保全タスク ............................................................................................. 19-54

テーブル19-26 5500作動時間間隔の点検タスク .................................................................. 19-59

テーブル19-27 18ヶ月の暫時点検タスク ............................................................................. 19-60

テーブル19-28 9年の汎用分解検査のための点検タスク ...................................................... 19-61

テーブル19-29ピニオンおよびガースギヤの取替タスク...................................................... 19-61

テーブル20-1ボール/チューブミルのため故障位置、劣化メカニズムおよびPM戦略20-4

テーブル20-2ボール/チューブミルのためのPMタスク及び劣化メカニズム ........................ 20-10

テーブル20-3ボール/チューブミルのためのPMテンプレート.............................................. 20-15

B-17
Translated Table of Contents

RESUMEN DEL REPORTE

Objetivos
• Para determinar las prácticas de mantenimiento preventivas y proféticas para los molinos de
bola/tubo
• Para asistir al personal de mantenimiento de la planta en la identificación y la resolución de
problemas de equipos de molinos de bola/tubo

B-18
 Translated Table of Contents

CONTENIDOS

1 INTRODUCCIÓN .................................................................................................................. 1-1

1.1 Antecedentes ................................................................................................................. 1-1
1.2 Aproximación ................................................................................................................. 1-2
1.3 Organización ................................................................................................................. 1-3
1.4 Puntos Dominantes ....................................................................................................... 1-4

2 GLOSARIO............................................................................................................................ 2-1

3 USO DE SISTEMAS ............................................................................................................ 3-1

3.1 Sistema de Manejo del Carbón ..................................................................................... 3-1
3.2 Características del Carbón ............................................................................................ 3-5
3.3 Molinos de Pulverizador de Carbón .............................................................................. 3-7
3.4 Reglas Ambientales ...................................................................................................... 3-9

4 DESCRIPCIÓN TÉCNICA- GENERAL ................................................................................ 4-1

5 DESCRIPCIÓN TÉCNICA-ALLIS CHALMERS ................................................................. 5-1

5.1 Cajas de Entrada/Salida ................................................................................................ 5-4
5.2 Granada, Forros, y Bolas Rotadoras ............................................................................. 5-7
5.3 Cojinetes del Muñón ...................................................................................................... 5-9
5.4 Clasificador ................................................................................................................. 5-15
5.5 Motor Impulsador ........................................................................................................ 5-17
5.6 Unidad de la Caja de Engranajes ................................................................................ 5-23
5.7 Engranaje de la Circunferencia y Árbol del Piñón ....................................................... 5-29
5.8 Sistema de Condicionamiento del Molino Poder-Sonic .............................................. 5-33
5.9 Lista de Especificación técnica ................................................................................... 5-35

6 DESCRIPCIÓN TECNICA DE RODADOR FOSTER ......................................................... 6-1

6.1 Asamblea del Transportador ......................................................................................... 6-4

B-19
Translated Table of Contents

6.1.1 Asamblea de Apoyo del Transportador ................................................................. 6-6

6.2 Asamblea del Tambor ................................................................................................... 6-8
6.2.1 Forros de Doble-Agite .......................................................................................... 6-10
6.2.2 Puertas de Acceso Doble-Talla, Doble-Agita ....................................................... 6-12
6.2.3 Barras del Vuelo .................................................................................................. 6-12
6.2.4 Bolas que Esmerilan ............................................................................................ 6-12
6.3 Cojinete y Sello del Árbol del Transportador ............................................................... 6-13
6.4 Cojinete del Muñón y Sellos Principales del Polvo ..................................................... 6-14
6.5 Engranaje .................................................................................................................... 6-16
6.5.1 Cojinetes del Piñón .............................................................................................. 6-17
6.6 Tubo del Muñón .......................................................................................................... 6-18
6.7 Clasificador ................................................................................................................. 6-20
6.7.1 Amortiguador de Rechazo del Clasificador ......................................................... 6-20
6.7.2 Clasificador Ajustable de la Pala ......................................................................... 6-21
6.7.3 Clasificador Tipo-M............................................................................................... 6-23
6.7.4 Clasificador Dinámico .......................................................................................... 6-24
6.8 Ventiladores ................................................................................................................ 6-27
6.9 Sistemas Lubricantes .................................................................................................. 6-28
6.9.1 Sistema Lubricante de Cardwell .......................................................................... 6-28
6.9.2 Sistema lubricante de Farval ............................................................................... 6-30

7 DESCRIPCION TECNICA DE KENNEDY VAN SAUN ........................................................ 7-1

8 DESCRIPCIÓN TECNICA - RILEY POWER INC.................................................................. 8-1

8.1 Descripción General ...................................................................................................... 8-1
8.2 Componentes del Sistema ............................................................................................ 8-4
8.2.1 Alimentador ........................................................................................................... 8-5
8.2.2 Trituradora-Secante ............................................................................................... 8-6
8.2.3 Tambor o Barril Rotante ........................................................................................ 8-7
8.2.4 Bolas que Esmerilan .............................................................................................. 8-8
8.2.5 Clasificador ............................................................................................................ 8-9
8.2.6 Válvulas de Cierre ............................................................................................... 8-10
8.2.7 Caja de Engranajes que Reducen la Velocidad .................................................. 8-10
8.2.8 Embrague ............................................................................................................ 8-12

B-20
 Translated Table of Contents

8.3 Sistemas ..................................................................................................................... 8-15

8.3.1 Sistema de Aire Primario ..................................................................................... 8-15
8.3.2 Sistema de Sello de Aire ..................................................................................... 8-16
8.4 Modificaciones ............................................................................................................. 8-17
8.4.1 Adición de la Válvula del Chorrito ........................................................................ 8-17
8.4.2 Reajuste del Sello de Aire del Muñón ................................................................. 8-18
8.4.3 Mejora de Condicionamiento del Sistema del Molino .......................................... 8-19
8.4.4 Conversión hidrodinámica del Cojinete del Zapato de la Placa .......................... 8-19

9 DESCRIPCIÓN TECNICA- STEIN INDUSTRIES ................................................................. 9-1

9.1 Descripción General ...................................................................................................... 9-1
9.2 Sistemas ....................................................................................................................... 9-4
9.2.1 Sistema de la Entrada del Carbón ......................................................................... 9-5
9.2.2 Sistema de Aire Primario ....................................................................................... 9-5
9.2.3 Sistema del Sello de Aire ...................................................................................... 9-6
9.2.4 Sistemas de Aceite de Lubricación ....................................................................... 9-7
9.2.5 Sistema de Impulsión .......................................................................................... 9-12
9.2.6 Sistema de la Purga ............................................................................................ 9-13
9.2.7 Sistema del Cargamento de la Bola .................................................................... 9-13

10 OPERACIÓN Y SEGURIDAD– ALLIS-CHALMERS ....................................................... 10-1

10.1 Operaciones .............................................................................................................. 10-1
10.2 Protección Contra los Incendios ................................................................................ 10-2

11 OPERACIÓN Y SEGURIDAD-RODADOR FOSTER ....................................................... 11-1

11.1 Operación General .................................................................................................... 11-1
11.2 Indicaciones de la Operación .................................................................................... 11-3
11.3 Procedimientos de Lanzamiento ............................................................................... 11-4
11.4 Sistema de Detección de Fuego ............................................................................... 11-6
11.5 Protección Contra los Incendios ................................................................................ 11-7

12 OPERACIÓN Y SEGURIDAD– KENNEDY VAN SAUN .................................................. 12-1

12.1 Cambios de Carga .................................................................................................... 12-1
12.2 Apoyo de Gasolina y Aceite ...................................................................................... 12-2
12.3 Tubo de combustible bloqueado ................................................................................ 12-3
12.4 Carbón Mojado .......................................................................................................... 12-4

B-21
Translated Table of Contents

12.5 El Estropeado del Molino .......................................................................................... 12-5

12.6 Lanzamiento río ......................................................................................................... 12-6

13 OPERACIÓN Y SEGURIDAD – RILEY POWER INC…………………. ............................ 13-1

13.1 Operación general ..................................................................................................... 13-1
13.2 Sistema de Mando .................................................................................................... 13-2
13.3 Manejo de Carga de la Bola ...................................................................................... 13-7
13.4 Operación Primaria del Amortiguador del Aire .......................................................... 13-8
13.5 Sistema de Sello de Aire .......................................................................................... 13-11
13.6 Calibración del Alimentador .................................................................................... 13-12
13.7 Fijaciones de la Instrumentación ............................................................................. 13-13
13.8 Detección de Fuego ................................................................................................ 13-15
13.9 Protección Contra los Incendios .............................................................................. 13-17

14 OPERACON Y SEGURIDAD– STEIN INDUSTRIES ........................................................ 14-1

14.1 Periodo de Parada .................................................................................................... 14-1
14.2 Protección Contra los Incendios ................................................................................ 14-2

15 FUNCIONAMIENTO ......................................................................................................... 15-1

15.1 Fineza ....................................................................................................................... 15-1
15.2 Habilidad de Esmerilar .............................................................................................. 15-2
15.3 Humedad ................................................................................................................... 15-2
15.4 Capacidad ................................................................................................................. 15-3

16 MODOS DE FALLO ......................................................................................................... 16-1

16.1 Excoriación ................................................................................................................ 16-1
16.2 Erosión ...................................................................................................................... 16-3
16.3 Componentes fallados .............................................................................................. 16-4

17 LOCALIZANDOR DE AVERÍAS ...................................................................................... 17-1

17.1 Allis-Chalmers ........................................................................................................... 17-1
17.2 Rodador Foster ......................................................................................................... 17-5
17.3 Kennedy Van Saun ................................................................................................... 17-7
17.4 Power Riley Inc........................................................................................................... 17-9
17.5 Industrias Stein ........................................................................................................ 17-10

B-22
 Translated Table of Contents

18 MANTENIMIENTO PROFÉTICO....................................................................................... 18-1

18.1 Análisis de la Vibración ............................................................................................. 18-3
18.2 Análisis del Aceite ..................................................................................................... 18-3
18.3 Acondicionado Basado en Mantenimiento Kennedy Van Saun ............................... 18-12
18.4 Acondicionado Basado en Mantenimiento Stein Industrie ....................................... 18-15

19 MANTENIMIENTO PREVENTIVO .................................................................................... 19-1

19.1 Allis-Chalmers ........................................................................................................... 19-1
19.1.1 Consideraciones de Inspección ......................................................................... 19-2
19.1.2 Inspección Externa del Molino ........................................................................... 19-3
19.1.3 Inspección Interna del Molino ............................................................................ 19-6
19.1.4 Inspección del Clasificador ................................................................................ 19-7
19.1.5 Inspección del Tren de Expulsión....................................................................... 19-9
19.1.6 Forro de la Granada y del Muñón .................................................................... 19-10
19.1.7 Repuesto de la Pieza Inserta en el Cojinete del Muñón .................................. 19-11
19.1.8 Repuesto del Engranaje de la Circunferencia ................................................. 19-13
19.1.9 Reconstrucción de la Caja de Engranajes ...................................................... 19-18
19.1.10 Equipo Misceláneo ........................................................................................ 19-22
19.1.11 Lista del Equipo de Lubricación ..................................................................... 19-22
19.2 Kennedy Van Saun ................................................................................................. 19-24
19.2.1 Piñón, Engranaje de la Circunferencia, y Sistema Lubricante ........................ 19-25
19.2.2 Invirtiendo el Engranaje del Tornillo Sin Fin .................................................... 19-25
19.3 Riley Power Inc......................................................................................................... 19-27
19.3.1 Alimentador ..................................................................................................... 19-27
19.3.2 Trituradora-Secante ......................................................................................... 19-28
19.3.3 Entrada/Sellos de la Caja y del Aire de la Salida ............................................ 19-31
19.3.4 Forros del Molino ............................................................................................. 19-31
19.3.5 Carga de la Bola .............................................................................................. 19-32
19.3.6 Caja de Engranajes Reductora de Velocidad .................................................. 19-33
19.3.7Tren de Impulso................................................................................................. 19-38
19.3.8 Eje del Motor ................................................................................................... 19-44
19.3.9 Cambiador de Calor en la Lubricación ............................................................ 19-46
19.3.10 Clasificador .................................................................................................... 19-47
19.3.11 Ventilador y Canalización Primaria del Aire .................................................. 19-48

B-23
Translated Table of Contents

19.3.12 Válvulas de Cierre del Carbón ....................................................................... 19-49

19.3.13 Horario de la Lubricación ............................................................................... 19-49
19.3.14 Piezas de Repuesto ...................................................................................... 19-50
19.3.15 Inspecciones del Mantenimiento Preventivo del Ejemplo ............................. 19-51
19.4 Industrias Stein ........................................................................................................ 19-51
19.4.1 Tareas del mantenimiento preventivo ............................................................. 19-53
19.4.2 Tareas de la Inspección .................................................................................. 19-58
19.4.3 Repuesto del piñón y del Engranaje de la Circunferencia ............................... 19-61

20 BASES DEL MANTENIMIENTO PREVENTIVO ............................................................... 20-1

20.1 Fondo ........................................................................................................................ 20-1
20.2 Situaciones de la Falla, Mecanismos de la Degradación, y Estrategias del P.M. ..... 20-2
20.3 Tareas del P.M. y sus Mecanismos de la Degradación ............................................ 20-9
20.4 Patrón del P.M. ........................................................................................................ 20-14

21 REFERENCIAS ................................................................................................................ 21-1

A PUNTOS DOMINANTES .................................................................................................... A-1

B-24
 Translated Table of Contents

LISTA DE FIGURAS

Figura 3-1 Un Diagrama Típico del Sistema de Tramitación del Carbón de Descargar a
la Instalación .................................................................................................................... 3-2
Figura 3-2 Un Diagrama Típico del Sistema de Tramitación del Carbón de la Instalación
a las Casamatas de la Unidad ......................................................................................... 3-3
Figura 3-3 Fomenta el Molino de la Bola del Rodador ............................................................ 3-8
Figura 3-4 Combustible Limita la Evolución del Nitrógeno a NOx ......................................... 3-10
Figura 5-1 Allis-Chalmers/el Esquema del Molino del Tubo .................................................... 5-2
Figura 5-2Caja de Salida/Entrada ............................................................................................ 5-4
Figura 5-3 Colocación del Sello en el Molino........................................................................... 5-6
Figura 5-4 Tolva de la Carga de la Bola ................................................................................... 5-8
Figura 5-5 El Muñón que Soporta el Sistema Lubricante de Baja Presión ........................... 5-10
Figura 5-6 Bomba Manual que Alza Con el Gato de Alta Presión.......................................... 5-13
Figura 5-7 Clasificador Estático .............................................................................................. 5-15
Figura 5-8 Motor Impulsor del Molino .................................................................................... 5-17
Figura 5-9 Salvo Unidad del Engranaje ................................................................................. 5-19
Figura 5-10 Salvo el Acoplamiento ........................................................................................ 5-21
Figura 5-11 Salvo Freno ........................................................................................................ 5-22
Figura 5-12 Unidad de la Caja de Engranajes ...................................................................... 5-23
Figura 5-13 Acoplamiento del Rendimiento de la Caja de Engranajes .................................. 5-25
Figura 5-14 Sistema de Lubricación de la Caja de Engranajes .............................................. 5-26
Figura 5-15 Lubricación de los Dientes del Engranaje ........................................................... 5-27
Figura 5-16 Escape del Molino ............................................................................................... 5-30
Figura 5-17 Sistema Lubricante del Engranaje de la Circunferencia...................................... 5-31
Figura 5-18 Sistema de Condicionamiento del Molino Poder-Sonic....................................... 5-33
Figura 6-1 Diagrama del Molino de la Bola del Rodador ......................................................... 6-1
Figura 6-2 Organigrama del Aire/Carbón.................................................................................. 6-2
Figura 6-3 asamblea del transportador de la cinta del vuelo de .............................................. 6-5
Figura 6-4 Asambleas de Apoyo del Muelle de la Cinta del Vuelo……………………………….6-6
Figura 6-5 Asamblea de Apoyo del Transportador ................................................................... 6-6
Figura 6-6 Retiro del Transportador con Ocho-Habló Diseño ................................................. 6-8
Figura 6-7 Termina la Asamblea del Tambor .......................................................................... 6-9
Figura 6-8 Fin de la Fundición .............................................................................................. 6-10

B-25
Translated Table of Contents

Figura 6-9 Figuras de Doble Agite………………………………………………………………….6-11

Figura 6-10 Puerta de Acceso Doble-Talla, Doble-Agita ...................................................... 6-12
Figura 6-11 Regímenes del Desgaste de la Bola ................................................................... 6-13
Figura 6-12 Modificación del Cojinete del Transportador ....................................................... 6-13
Figura 6-13 Conjunto de Cojinetes Original............................................................................ 6-14
Figura 6-14 Nuevo Diseño de Cojinete................................................................................... 6-15
Figura 6-15 Sello del Muñón................................................................................................... 6-16
Figura 6-16 Asamblea del Piñón y Asamblea del Engranaje de Bull ..................................... 6-17
Figura 6-17 Cojinetes de Rodillo............................................................................................. 6-18
Figura 6-18 Tubo Clasificador del Muñón............................................................................... 6-19
Figura 6-19 Clasificador Original Tipo Desfile ....................................................................... 6-20
Figura 6-20 Amortiguadores del Rechazo del Clasificador..................................................... 6-21
Figura 6-21 Clasificador Ajustable .......................................................................................... 6-22
Figura 6-22 Comparación del Clasificador.............................................................................. 6-22
Figura 6-23 Mejoría Ajustable de la Fineza del Clasificador.................................................. 6-23
Figura 6-24 Clasificador Tipo M.............................................................................................. 6-24
Figura 6-25 Clasificador Dinámico.......................................................................................... 6-25
Figura 6-26 Diagrama del Ventilador ...................................................................................... 6-27
Figura 6-27 Ventilador Araña.................................................................................................. 6-28
Figura 6-28 Sistema Lubricante Cardwell .............................................................................. 6-29
Figura 6-29 Sistema Lubricante Farval .................................................................................. 6-30
Figura 7-1 Sistema de Molino Kennedy Van Saun .................................................................. 7-2
Figura 7-2 Componentes del Molino Kennedy Van Saun......................................................... 7-3
Figura 8-1 Bolas de Poder Riley/Sistema Chain-Driven del Molino del Tubo……...……………8-2
Figura 8-2 Bolas de Poder Riley/Sistema del Molino del Tubo……………………………………8-3
Figura 8-3 Alimentador Tipo Tambor ........................................................................................ 8-5
Figura 8-4 Trituradora-Secante................................................................................................. 8-6
Figura 8-5 Molino con la Impulsión del Engranaje del piñón/Anillo Fijado ............................... 8-8
Figura 8-6 Clasificador.............................................................................................................. 8-9
Figura 8-7 Caja de Engranajes Reductor de Velocidad.......................................................... 8-11
Figura 8-8 Asamblea de Embrague ........................................................................................ 8-13
Figura 8-9 Sello del Rotor ...................................................................................................... 8-15
Figura 8-10 Sistema de Mando del Aire del Embrague .......................................................... 8-15
Figura 8-11 Nuevo Diseño de la Válvula del Chorrito............................................................. 8-18
Figura 8-12 Diseños del Sello del Aire del Muñón .................................................................. 8-19
Figura 8-13 Cojinete Hidrodinámico del Zapato de la Placa................................................... 8-20
Figura 8-14 Cojinete de Tracción............................................................................................ 8-21
Figura 9-1 Molino del Tubo de Stein Industrie .......................................................................... 9-2
Figura 9-2 Opinión Detallada del Molino del Tubo de Stein Industrie ...................................... 9-3

B-26
 Translated Table of Contents

Figura 9-3 Circulación de Aire del Molino ................................................................................. 9-6

Figura 9-4 Sistema de Aceite Lubricador de Alta y Baja Presión ............................................. 9-9
Figura 10-1 Unidad Movible de la Botella del Gas.................................................................. 10-3
Figura 10-2 Sistema de Protección Contra el Fuego por Dióxido de Carbono
Permanentemente Instalado ........................................................................................... 10-4
Figura 11-1 Sensor de Temprana Detección de Fuego.......................................................... 11-7
Figura 12-1 Operación de Carbón Mojado ............................................................................. 12-4
Figura 13-1 Diagrama de Operación de Riley Power ............................................................. 13-4
Figura 3-12 Poder del Motor Comparado con Carga del Producto ....................................... 13-5
Figura 13-3 Parámetros del Molino Usando Mando de la Carga del Producto ...................... 13-5
Figura 13-4 Efectos de la Carga Reducida de la Bola ........................................................... 13-6
Figura 13-5 Localización de la Boquilla del Sistema de Aerosol de Agua............................ 13-18
Figura 16-1 Componente de Frecuencia de Falla del Pulverizador ...................................... 16-1
Figura 18-1 Detección Temprana de Fallas en el Pulverizador ............................................. 18-2
Figura 19-1 Reductor de Único-Engranaje del Eslabón-Cinturón......................................... 19-34
Figura 19-2 Reductor de Doble-Engranaje del Eslabón-Cinturón ........................................ 19-35
Figura 19-3 Reductor de Triple-Engranaje del Eslabón-Cinturón ....................................... 19-36

B-27
Translated Table of Contents

LISTA DE TABLAS

Tabla 1-1 Factores de Conversión............................................................................................ 1-2

Tabla 5-1 Condiciones de la Alarma para el Sistema de Condicionamiento del Molino a
Poder-Sonic ................................................................................................................... 5-34
Tabla 5-2 Datos de los Molinos de Allis-Chalmers ................................................................ 5-35
Tabla 9-1 Valores Normales de la Presión del aceite de Lubricación .................................... 9-11
Tabla 9-2 Sistemas de Lubricantes del Molino ....................................................................... 9-12
Tabla 10-1 Tareas del Reemplazo de Bola ............................................................................ 10-2
Tabla 11-1 Cerrando un Lado de un Molino de Doble-Extremo ............................................ 11-2
Tabla 11-2 Operación Normal Verifica ................................................................................... 11-4
Tabla 11-3 Preparación Inicial del Molino para el Arranque ................................................... 11-4
Tabla 11-4 Carga el Molino para el Lanzamiento .................................................................. 11-5
Tabla 11-5 Colocando el Molino en Servicio ......................................................................... 11-6
Tabla 11-6 Procedimientos para el Extintor en el Molino Foster del Rodador ....................... 11-8
Tabla 11-7 Procedimientos del Paro de Emergencia para el Molino Foster del Rodador ..... 11-9
Tabla 11-8 Recomendación de los Procedimientos para Cerrar el Molino Foster del
Rodador Lleno de Carbón ...............................................................................................11-9
Tabla 12-1 Tareas para Estropear el Molino ......................................................................... 12-5
Tabla 12-2 Tareas de Arranque Frío ...................................................................................... 12-6
Tabla 13-1 Tareas de la Calibración del Alimentador de Carbón ......................................... 13-12
Tabla 13-2 Parámetros de la Instrumentación del Molino .................................................... 13-13
Tabla 13-3 Parámetros Típicos del Equipo........................................................................... 13-14
Tabla 13-4 Situaciones del Sensor de Temperatura de la Detección de Fuego .................. 13-16
Tabla 15-1 Dimensiones Estándar de la Pantalla................................................................... 15-1
Tabla 16-1 Coeficientes Abrasivos del Desgaste ................................................................... 16-3
Tabla 16-2 Componentes de la Falla de Allis-Chalmers ........................................................ 16-4
Tabla 17-1 Localizador de Averías para los Molinos de Allis-Chalmers ................................ 17-1
Tabla 17-2 Carta de Localización de Averías para los Molinos Foster de Rodador .............. 17-5
Tabla 17-3 Carta de Localización de Averías para Molinos Kennedy Van Saun ................... 17-7
Tabla 17-4 Carta de Localización de Averías para los Molinos de Bola de Poder de Riley ... 17-9
Tabla 17-5 Localización de Averías para los Molinos de Stein Industrie ............................. 17-10
Tabla 18-1 Conteo de Partículas de Alcance de Números ..................................................... 18-5
Tabla 18-2 Elementos en Empaques de Adictivos de Aceite ................................................ 18-9

B-28
 Translated Table of Contents

Tabla 18-3 Componentes de Molinos Kennedy Van Saun para el Programa de

Lubricación ................................................................................................................... 18-13
Tabla 18-4 Vigilancia Basada-Acondicionada de Válvulas en la Central Eléctrica de
Majuba ......................................................................................................................... 18-16
Tabla 18-5 Condiciones Vigiladas en la Central Eléctrica de Majuba .................................. 18-19
Tabla 18-6 Instrumentación de Vigilancia de Condiciones para la Central Eléctrica de
Majuba .......................................................................................................................... 18-20
Tabla 18-7 Vigilancia de Condición Programada en la Central Eléctrica de Majuba............ 18-24
Tabla 19-1 Tareas Externas de Inspección del Molino .......................................................... 19-4
Tabla 19-2 Tareas de Inspección Internas ............................................................................. 19-6
Tabla 19-3 Tareas de Inspección del Clasificador .................................................................. 19-8
Tabla 19-4 Tareas de Inspección del Tren de Impulsión del Molino ...................................... 19-9
Tabla 19-5 Tareas de Reemplazo del Forro de la Granada y del Muñón............................. 19-10
Tabla 19-6 Tareas del Reemplazo de la Pieza Inserta en el Cojinete del Muñón ................ 19-12
Tabla 19-7 Tareas del Reemplazo del Engranaje de la Circunferencia ............................... 19-14
Tabla 19-8 Tareas de Reconstrucción de la Caja de Engranajes ........................................ 19-19
Tabla 19-9 Lista de Lubricación de Equipos......................................................................... 19-23
Tabla 19-10 Tareas de Inspección para el Piñón, el Engranaje de la Circunferencia, y
los Sistemas Lubricantes ............................................................................................. 19-25
Tabla 19-11 Tareas para Invertir el Engranaje de Tornillo sin fin de la Caja de
Engranajes ................................................................................................................... 19-26
Tabla 19-12 Repuesto del Forro del Desgaste ..................................................................... 19-32
Tabla 19-13 Capacidades de Aceite de la Caja de Engranajes del Reductor de
Velocidad ...................................................................................................................... 19-33
Tabla 19-14 Tareas de Desmontaje de la Caja de Engranajes del Reductor de la Triple-
Velocidad ...................................................................................................................... 19-37
Tabla 19-15 Tareas de la Inspección del Embrague ............................................................ 19-40
Tabla 19-16 Tareas de Reparación de Cadena.................................................................... 19-41
Tabla 19-17 Tareas de Retiro y de la Reinstalación del Piñón Impulsor .............................. 19-42
Tabla 19-18 Tareas de Reemplazo del Eje del Motor .......................................................... 19-44
Tabla 19-19 Tareas de Inspección del Cambiador de Calor ............................................... 19-46
Tabla 19-20 Tareas de Reemplazo Aceites Lubricantes del Cambiador de Calor ............... 19-47
Tabla 19-21 Tareas de Mantenimiento Preventivo del Clasificador ..................................... 19-48
Tabla 19-22 Horario de Lubricación...................................................................................... 19-49
Tabla 19-23 Piezas de Repuesto Recomendadas por Riley Power ..................................... 19-50
Tabla 19-24 Tareas de Inspección del Alimentador para el Intervalo de Operación de
7000 Horas.................................................................................................................... 19-53
Tabla 19-25 Tareas de Mantenimiento Preventivo ............................................................... 19-54
Tabla 19-26 Tareas de Inspección para el Intervalo de Operación de 5500 Horas.............. 19-59
Tabla 19-27 Tareas de Inspección para la Inspección del Interino de 18 Meses ................ 19-60
Tabla 19-28 Tareas de Inspección para el Reacondicionamiento General de 9 Años ........ 19-61

B-29
Translated Table of Contents

Tabla 19-29 Tareas del Reemplazo para el Piñón y el Engranaje de Circunferencia ......... 19-61
Tabla 20-1 Localizaciones de Fallas, Mecanismos de Degradación, y Estrategias de PM
para Molinos de Tubo/Bola .............................................................................................20-4
Tabla 20-2 Tareas de P.M. y sus Mecanismos de Degradación para los Molinos de
Bola/Tubo ..................................................................................................................... 20-10
Tabla 20-3 Patrón de PM para el Molino de Bola/Tubo....................................................... 20-15

B-30
Export Control Restrictions The Electric Power Research Institute (EPRI)
Access to and use of EPRI Intellectual Property is granted with The Electric Power Research Institute (EPRI), with major locations in
the specific understanding and requirement that responsibility Palo Alto, California, and Charlotte, North Carolina, was established
for ensuring full compliance with all applicable U.S. and in 1973 as an independent, nonprofit center for public interest
foreign export laws and regulations is being undertaken by energy and environmental research. EPRI brings together members,
you and your company. This includes an obligation to ensure participants, the Institute’s scientists and engineers, and other leading
that any individual receiving access hereunder who is not a experts to work collaboratively on solutions to the challenges of electric
U.S. citizen or permanent U.S. resident is permitted access power. These solutions span nearly every area of electricity generation,
under applicable U.S. and foreign export laws and delivery, and use, including health, safety, and environment. EPRI’s
regulations. In the event you are uncertain whether you or members represent over 90% of the electricity generated in the
your company may lawfully obtain access to this EPRI United States. International participation represents nearly 15% of
Intellectual Property, you acknowledge that it is your EPRI’s total research, development, and demonstration program.
obligation to consult with your company’s legal counsel to
determine whether this access is lawful. Although EPRI may Together...Shaping the Future of Electricity
make available on a case-by-case basis an informal
assessment of the applicable U.S. export classification for
specific EPRI Intellectual Property, you and your company
acknowledge that this assessment is solely for informational
purposes and not for reliance purposes. You and your
company acknowledge that it is still the obligation of you and
your company to make your own assessment of the applicable
U.S. export classification and ensure compliance accordingly.
You and your company understand and acknowledge your
obligations to make a prompt report to EPRI and the
appropriate authorities regarding any access to or use of EPRI
Intellectual Property hereunder that may be in violation of
applicable U.S. or foreign export laws or regulations.

Program:
© 2006 Electric Power Research Institute (EPRI), Inc. All rights reserved.
Fossil Maintenance Applications Center
Electric Power Research Institute and EPRI are registered service marks of
the Electric Power Research Institute, Inc.

Printed on recycled paper in the United States of America 1010443

ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1395 • PO Box 10412, Palo Alto, California 94303-0813 USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com