Presentation

On
Maintenance of coal mill and coal feeders

Coal Mill

Coal pulverizer
pulverizer/mill
/mill system: One of the
critical power plant components that is relied
upon to convert the energy stored in coal
into electricity is the coal pulverizer or mill.
mill.

The coal flow is controlled by the feeder,

allowing coal to flow into the pulverizer mill.
mill.

The pulverized coal and air mixture is then

transport to the boiler burner panels.

Coal Mill

Coal pulverisers are essentially volumetric devices .

As the density of coal is fairly constant, are rated in mass units of
tones/hr.

A pulveriser accepts a volume of material to be pulverized which is

dependent on the physical dimensions of the mill and the ability of coal
to pass through the coal pulverizing system.

The common measure of mass in tones enables matching of energy

requirements with available coal properties and mill capacity.

Increased combustible loss can occur if the furnace volume or mill

capacity is less than desirable for a particular coal.

The furnace volume and mill capacity in a specific power station may

dictate the need to purchase coals which are reactive and which can be
ground easily.

Size reduction is energy intensive and generally very inefficient with

regard to energy consumption.

In many processes the actual energy used in breakage of particles is

less than 5% of the overall energy consumption.
consumption.

Coal Mill

The pulverizer receives the raw coal and

reduces it to a very fine, specified size

consist, similar to face powder.(75%
powder.(75%
through 200 Mesh sieve)
There are four primary principles
involved in pulverization:
pulverization:
Drying
Grinding
Circulation
Classification

Drying
The coal that is passing through a
pulveriser is entrained by the use of hot air
usually from the air heater. During the
pulverization process the surface area of
the coal particles increases dramatically
exposing fresh coal to the entrainment air.
air.
The inherent and surface moisture of the
coal is reduced by the exposure to hot air.
(Air heater outlet Temperature :220 deg.
Centrigrate & Mill outlet temperature
90degree )

Grinding

There are three basic types of grinding
grinding::

1. Impaction where the material to be
ground is hit or impacted by an outside
force

2. Crushing where material is forced
between two fixed objects

3. Attrition where material is ground by
rubbing or friction

METHOD OF GRINDING

Circulation

The primary air, is the method of
circulating the coal through the
pulverizer.. Circulating air is also
pulverizer
important in allowing for the removal of
heavy material such as pyrites through
gates, extraneous metal, etc. by
centrifugal force that otherwise might
damage the grinding mechanisms.

Classification
The circulating air is also used to classify
the pulverized coal product prior to
carrying it to the burners.
burners. The classifier,
located on the top of a mill returns the
over--size material back to the pulverizer
over
but allows the properproper-sized material to
pass out of the mill to the burners.
classifiers are critical in providing the
desired quality of pulverized coal with
the desired fineness

The process of Classification

Classification of Pf is the process of separation

of the finer particles from coarser particles

This process ensures the fineness of the fuel
leaving the pulverizer.

As per acceptable standards the fineness of fuel
is 70% passing through 200 mesh( 74 microns
size) for direct fired bituminous coal

Each mill is designed to deliver fuel with a
certain particle size distribution

10

The Static Classifier

A static classifier is a centrifugal separator

The coal air mixture flows through openings guided at a
certain angle to impart spin and induce centrifugal force

The coarser particles impact the circumference, come
out of suspension and fall back into the grinding zone

In addition a change in direction of fuel is given to
separate the still existing coarse particles

Static classifiers are limited to provide 70% fineness of
particles passing 200 mesh

11

Pulverizers:
There are three stages in the pulverizing process of coal
1. Feeding: feeding system controls the fuel feed rate
according to the boiler demand
2. Drying:Hot air through Primary air fan is forced into
the Mill for drying the varying quantities of moisture in coal.
3.Grinding :Grinding is performed by impact,attrition,crushing
with the help of ball and race

Coal pulverization

Roller mill grinding mechanism:

The roller passes over a layer of granular material
Roller compresses granular coal against a moving table
The movement of the roller causes motion between particles
The roller pressure creates compressive loads between particles
Motion under applied pressure within the particle layer causes attrition
which is the dominant size reduction mechanism

Pulveriser coal
recirculation
Design requirement:
optimum fineness for design coals
over the entire pulveriser operating range
rapid response to load changes,
stable and safe operation over the entire load range
continuous service over long
operating periods,
acceptable maintenance
requirements, particularly
grinding elements, over the pulveriser life
ability to handle variations in coal properties
ease of maintenance (minimum number of
moving parts and adequate access)
minimum building volume.

Mills

There are basically four different types of pulverizing mills which are

designed to reduce coal with a top particle size of about 50 mm to the

necessary particle size range.

Ball&Tube Mill, Ball &Race Mill, Bowl Mill & Impact Mill

Each type has a different grinding mechanism and different operating
characteristics.

There are four unit operations going concurrently within the mill body,
coal drying, transport, classification and grinding.

For coal pulverizers the capacity of a mill is normally specified

as tonnes output when grinding coal with a HGI of 50, with a
particle size of 70% less than 75 micron and 1 or 2 % greater
than 300 micron and with a moisture in coal of less than 10%.

A few manufacturers specify 55 instead of 50 with respect to HGI..

This standardization enables selection of an appropriate mill for a specific
duty.

Coal Mills :Ball & Race

Type

Ball & Race, 10.9 E 10

Rated Capacity

45T/Hr. (max)

Rated Power

304 KW.

Speed

33.41 RPM

No in Operation at Boiler MCR with :

Design Coal 4
Worst Coal 5

Max Feed size to mill

75 mm.

Pulverised Fuel size :

75% through 200 mesh

NOMENCLATURE:
583 XRS / 903 XRP Bowl Mills
58,80 Stands for Bowl diameter in inches.
If the number is even then its Shallow Bowl Mill.
If the number is odd then its Deep Bowl
3-Number of Rollers
X- Frequency of Power supply (50 cycles).
R- Raymond Name of the inventor
S- Suction type with Exhauster after mill
P- pressurized type with P.A. FAN before mill

DRESSER COUPLING

MULTIPLE PORT OUTLET ASSY

CENTER FEED PIPE UPPER

SEPARATOR TOP ASSY

OUTLET VENTURI

VENTURI VANE

CENTER FEED PIPE LOWER

INVERTED CONE
INNER CONE
JRNL HD & TRUNN SHAFT ASSY
JOC & SPRING ASSY

INNER CONE PIPE SUPPORT

INNER CONE SPOUT

JOURNAL SHAFT ASSY

SEP. BODY LINER ASSY.
BOWL EXTN RING
AIR PORT RING ASSY
BULL RING ASSY
BOWL RING CLAMPING RING
BOWL & BOWL HUB ASSY
MILL BASE & AIR INLET ASSY
SCRAPER & GUARD ASSY
LABYRINTH SEALS
MOUNTING PLATE & DOWEL PINS

PLANETARY GEAR BOX

SOLE PLATE & DOWEL PINS
MILL PEDESTAL

GEAR BOX PEDESTAL

MANUFACTURER BASE
CAPACITY
MILL TYPE

BASE CAPACITY

703 XRP
763 XRP
783 XRP
803 XRP
883 XRP
903 XRP
1003 XRP
1043 XRP

26.4
33.8
36.5
39.8
51.1
54.1
68.1
72.0

Bowl Mill

Bowl mills are employed to pulverize the prepre-

crushed raw coal to the required fineness before it is

admitted into the boiler furnace for combustion.
combustion. The
mill output can be easily varied, as per the turndown
ratio from its minimum to maximum load.
load. Crushed
raw coal at a controlled rate is fed into the revolving
bowl of the Bowl Mill.
Mill. Centrifugal force feeds the
coal uniformly over the replaceable grinding ring
where independently spun rolls exert the required
grinding pressure. The rolls do not touch the
grinding ring even when the mill is empty.

BOWL MILL
Medium speed vertical mill (40(40-70 RPM)
Conical Grinding rolls 3no.s per mill
The Race will be either deep or shallow

like
saucer covered with liner called Bullring
segment
The Bowl is rotated by a Gearbox have
reducing gear like Worm gear set or
Bevel helical gears

Bowl MillMill- Advantages

Lower power consumption

Reliability

Minimum maintenance

Wide range of capacity

Ability to handle wide variety of coals

Quiet and vibration less operation

28

Bowl & Roll

Raw coal feeders

It is a device for controlling the amount of raw

coal from storage bunker to be fed into the

pulverizer

Feeder designs incorporate maximum particle
size, bulk density of coal, moisture content and
abrasiveness, desired flow rate and degree of
control required.

Feeders for modern power stations are
essentially of two types :
1) Volumetric
2) Gravimetric
31

Volumetric feeders

It is designed to provide for a controlled volume
rate flow of coal

Examples are drag
drag--link type
type,belt
,belt feeders

The bedbed- height of coal can be adjusted at
constant width to control the flow of coal

The feeder speed is varied to maintain the
required velocity of coal through the bed
opening

32

Volumetric feedersfeeders- contd

Volumetric designs does not compensate
for changes in coal bulk density

This results in variations in the energy
input to the pulverizer and ultimately to the
burners

33

Gravimetric Feeders

Control the weight of coal fed

Compensates for changes in bulk density

Provide more precise weight flow rate

35

What are the advantages of

Gravimetric feeders ?
1.Fuel Economy : Savings in coal cost with control of
combustion air.
2.Combustion : Balanced fuel / air ratio ensure a
more complete combustion.
3.Stratification : Coal fed is directly proportional to
fuel demand resulting in less
stratification of combustion air.
4.Safety : Optimum air/fuel ratios reduce the
possibility of furnace upsets during
load changing.

NoX emissions : Accurate control of combustion

air reduces Nox emissions.

Corrosion : Accurately controlled fuel and

Resistance air ratios reduces formation of
sulphates and thereby corrosion

Fuel rate : Coal delivery rate available for

measurement efficiency calculations

Fuel consumption : Actual amount of fuel consumed

per MW available to customer.

Functions of Primary Air

For drying of coal inside mill

To develop a certain air velocity just above the

throat so that only finer coal articles are lifted

upwards and very coarser particles are left
behind

Transportation of segregated coal particles up to
the burner through coal pipes

Quantity of primary air is 15 20% of total
combustion air

39

Requirements of PA

The temperature of primary air should be
sufficient for drying of coal.

Effective drying can be known from the
temperature of coal air mixture leaving the mill
( between 80 100 deg cent)

The volume of primary air should be sufficient to
maintain required fineness of fuel,transport of
fuel to burners and maintain proper colacola- air
ratio.
40

Fineness

Fineness is an indicator of the quality of the pulveriser

action.

Specifically, fineness is a measurement of the percentage of a
coal sample that passes through a set of test sieves usually
designated at 50, 100, and 200 mesh

A 70% coal sample passing through a 200 mesh screen
indicates optimum mill performance.
performance. The mill wear and the
power consumption are increased if the 70% value is
exceeded.. Values lower than 70% mean higher carbon loss
exceeded
and increased fuel consumption.
consumption. In addition, coal retained on
the 50 mesh screen should be in the 1
12% range. Higher
values indicate worn internals or improper settings. Also, the
higher percentages can cause boiler slagging and high
unburned carbon.

Mill Fineness
Decrease in Mill Fineness

Classifier Vane position

Loss of Roller Tension/spring
compression

Ring or Roller Wear

Classifier Vane Wear

Exceeding Mill Capacity

Primary air velocity

Settlement of Coal Particles in a Pipe

Cook and Hurworth suggest that the source of deposits in long

horizontal pulverizedpulverized-coal pipelines is the phenomenon of "roping".

Roping is the segregation of pulverized coal and air with the coal
forming a band traveling along the bottom of the horizontal pipe.
This band of fuel is then slowing down due to wall friction.
It was found that as the air to coal ratio increased, the tendency for
deposition decreased and at values of air/coal > 3.5 and at
conveying velocities of 2222-31m/sec, they could run their test rig free
of deposition.
Unfortunately air/fuel ratios required for grinding mill operation, and
for purposes of the primary mixture injected through the burner,
have much higher coal concentrations so that the use of these lean
concentrations is not practicable.

Factors affecting mill performance

Hard grove index of coal

Moisture content of coal
Primary air pressure
Classifier performance
Size of raw coal
Profile of grinding elements
Pressure applied by springs of grinding
elements
44

Effects on Mill performance

With harder coal the grinding fineness will

decrease
The fraction of coarse particles entering the
classifier will increase
This will result in more recirculation of coal
within the mill
To prevent overloading, the coal input to mill is
to be restricted
Mill power consumption per unit of coal will
increase
Reject will increase
45

Moisture Content

The surface moisture present in coal affects

adversely mill performance

The presence of moisture tends to conglomerate
the finer coal particles which affects grinding
adversely

The mill throughput decreases with an increase
in surface moisture

The mill outlet temperature falls which requires
higher PA temperature for drying of coal

46

Maintenance:

Increase availability

Improve reliability

Increase efficiency

Reduce the downtime / Failure rate of mill.

Smooth operation

Availability of mills for operation /
main deciding plant load factor

What is wearing?
Wear is directly proportional to:

Abrasive substances

Service hours

COAL MILL

TUBE MILL

Indications for maintenance:

Reduced mill capacity

Increase in spillage

Incorrect coal fineness

Noise level

Wearable mill parts:

Grinding rolls
Bull ring segments
Separator body liners
Direction vanes
Bowl extension ring
Scrappers
Mill side liner
Mill discharge valves

Factors responsible for

scheduling maintenance
program and inspection are:

Characteristics of fuel

Operating hour

Availability of mill

Availability of maintenance force

Lets see few common

problems and
troubleshooting.

i) DURING EACH 1000 HRS R/M GREASE INSIDE FABRIC SEAL TO BE CHECKED & SPRING TENSION TO
BE CHECKED.
J) EVERY 6500 HRS TO 7000 HRS OF MILL RUNNING,PUSHROD TO BE FITTED WITH SPACER(3NOS IN
EACH PUSH ROD TO EXTRACT LIFE OF GRINDING ELEMENT)
K) IN CASE OF HIGH VIBRATION OF CLASSIFIER HOUSING & MILL BODY a)CLASSIFIER D-SHAKLE
SUPPORT ARRANGEMENT MUST BE CHECKED FOR FAILURE.b) SCRAPPER PLOUGH TO BE CHECKED.c)
CLASSIFIER SIDE SUPPORT TO BE CHECKED FOR FAILURE.
L) IN CASE OF HIGH REJECT FOLLOWING TO BE CHECKED:a) THROAT GAP (SHOULD BE WITHIN 10-12 MM)
b) RELIEF GATE
c) ENSURING FULL OPEN MDVS DURING MILL RUNNING.
d) CLASSIFIER VANE POSITION( SHOULD BE WITHIN 45 DEGREES WITH RADIALi.e. MIDPOSITION)
M) IN CASE OF NO REJECT FOLLOWING TO BE CHECKED:a) CHECK FOR SCRAPPER PLOUGH DISLOGEMENT
b) CHECK FOR BLOCKAGE OF REJECT SPOUT OR OPENING.(NO AIR FLOW IS EXPECTED FROM SPOUT
IN NO REJECT CONDITION
c) CHECK THE RACK & PINION ARRANGEMENT OF REJECT DOOR.
N) INCASE OF LOW PA FLOW AT MILL LOADED CODITION FOLLOWING TO BE CHECKED:a) CHECK FOR FULL OPENING OF PA TO MILL INLET GUILLOTINE DAMPER( DAMPER OPENS AT 2 & 1/4
TURN FROM CLOSED CONDITION)
b) CHECK FOR POSITION OF MDV FLAP AT FULL OPEN CONDITION.
c) CHECK FOR CLINKER FORMATION IN PF NOZZLES.
d) ASK EI TO CHECK FOR INSTRUMENT CALIBRATION.
e) CHECK THROAT RING GAP & IF THROAT GAP FOUND LESS THAN 10MM INCREASE GAP

O) IN CASE OF ABNORMAL SOUND DUE TO TRAMP IRON PIECE CHECK THE FOLLOWING:a) RELIEF GATE TO BE KEPT IN RAISED POSITION FOR SOMETIME.
b) IF BY RAISING RELIEF GATE PROBLEM IS NOT SORTED THEN GO FOR MILL INTERNAL
INSPECTION.

P) WHEN MILL BALL DIAMETER REACHES 750 MM GO FOR 11 TH BALL INSERTION.ALL BALLS TO BE
KEPT AT
EQUAL DISTANCE BEFORE PUTTING TOP GRINDING RING IN POSITION.

****INCASE OF INSERTION OF BALL WITH HIGHER DIAMETER THAN THE REPLACED ONES A PROFILE
MISMATCH
BETWEEN BALLS & RING TAKES PLACE WHICH PORTENDS BALL BREAKAGE.TO PREVENT THIS
RODAS RAM GAS PRESSURE TO MAINTAINED TO BE 18 KG/CM2 IN ORDER TO EXTEND WEAR PARTS
LIFE
MAKE SURE THAT THE FEEDER IS MADE ON AS SOON AS MILL STARTS.(OPS TO BE INFORMED

Q IN CASE OF BOTTOM RING CRACK OR MILL RUNNING WITH LESS THAN 10 BALLS LOADING GAS &
OIL PRESSURE HAS TO BE REDUCED BY 5 BAR EACH.

MILL PERFORMANCE
FACTORS

P.F. FINENESS

CARBON LOSS

MILL POWER CONSUMPTION

COAL
COAL--AIR RATIO

MILL REJECTS

EFFECTS OF P.F.FINENESS

TOO COARSE

WEAR IN COAL PIPE

SLOWER IGNITION
POOR FIREBALL MIXING
UNSTABLE FLAME FRONT AT LOW LOADS
HIGH CARBON LOSS

TOO FINE

INCREASED WEAR OF PULVERISER

DECREASED PULVERISER OUTPUT

INCREASED POWER CONSUMPTION

1% CHANGE IN FINENESS EQUALS
APPROXIMATELY 1.5% IN CAPACITY

EFFECTS OF COAL AIR RATIO

HIGH AIR FLOW

AFFECTS COAL CLASSIFICATION

REDUCES DISCHARGE OF PYRITES
INCREASES COAL PIPE EROSION
AFFECTS IGNITION POINT
MORE P.A. FAN POWER
CONSUMPTION

LOW AIR FLOW

INCREASES COAL PIPE SPILLAGE

CAUSES DRIFTING IN COAL PIPE AND
ULTIMATE COAL PIPE CHOKING

Troubleshooting:
Problem:: Incorrect coal fineness
Problem
Possible cause:

Uneven deflector blade settings

Worn or damage deflector blades

Low or high spring compression

Grinding process

Problem:: In correct coal fineness

Problem
(Corrective Action)

Calibrate the blades properly.

Inspect repair and /or replace deflector blades
as soon as Possible

Check the compression and change as required.

Inspect repair by patching the holes or replacing
the cone as soon as possible.

Problem:: Noise above bowl

Problem
Possible cause:
cause:

Reject material on bowl

Failed grinding roll

Uneven spring pressure

Heavy reject material

Problem:Noise
Problem
:Noise above bowl
(Corrective Action)

Stop the pulverize inspect & remove the

material.

Stop the pulverize repair or replace the
Journal assembly.

Check the spring pressure and change if
required(250 kg/cm2).

Stop the pulverized and remove the material &
Check the damage.

CAUSES OF MILL REJECTS

LOW AIR VELOCITY

LOW AIR FLOW

AIR BYPASSING

HIGH RE CIRCULATION RATIO

WEAR OF GRINDING ELEMENTS

IMPROPER SETTING OF GRINDING
ELEMENTS

IMPROPER SPRING COMPRESSION

OPERATING MILL WITH HIGHER FINENESS

HIGH MOISTURE COAL/LOW MILL OUTLET
TEMPERATURE

CAUSES OF MILL REJECTS

OVER FEEDING EXCEEDING MILL
CAPACITY

MALFUNCTIONING OF FEEDER OR FEEDER
HINGE GATE

HIGH RPM OF FEEDER

REDUCTION IN MILL CAPACITY

EFFECTS OF REJECTS

REDUCTION IN BOILER EFFICIENCY

DETORIARATION OF DUST GUARD SEAL

OIL CONTAMINATION RESULTING DAMAGE
TO MILL DRIVE COMPONENTS

MILL PLANT REQUIREMENTS

MUST BE ABLE TO HANDLE DESIGN QUANTITY
COAL AND PRODUCE AN ACCEPTABLE
PRODUCT EVEN WITH WORN OUT
COMPONENTS

P.F.MUST BE WITHIN DESIRED GRINDING
RANGE AT ALL STABLE LOADS

WET COAL UPTO DESIGN WETNESS MUST BE
ADEQUATELY DRIED WHILE FULL OUTPUT IS
MAINTAINED

AT NO TIME MUST IT BE NECESSARY TO
OPERATE THE MILLING PLANT IN AN UNSAFE
CONDITION

MILL PLANT CONSTRAINTS

GRINDING LIMIT

GRINDABLITY INDEX

MILL MOTOR CAPACITY

P.F.FALL OUT LIMIT

MIN. VEL. OF COALCOAL-AIR 18 TO 20Kg/s

EROSION LIMIT

1.5 TIMES OF FALL OUT LIMIT

FLAMMABLITY

SAFE AIR/FUEL RATIO 5:1

FLAME STABLITY

MINIMUM THROUGHPUT NOT LESS THAN 50%

ATTEMPERATION

MINIMUM AIR TEMP. CONSTANT

MILL OPERATING WINDOW

LIMITING VALUES
MAX.COAL THROUGHPUT-12Kg/s at 94% < 150 m
STABLITY 0.5*12=6 Kg/s COAL FLOW
EXPLOSION LIMIT AT 5:1 AIR/FUEL RATIO
FAN POWER Wf +Wa =12 + 30.2 + 5 =42.7 Kg/s
FALL OUT - MIN. AIR FLOW -21 Kg/s
EROSION LIMIT - 33 Kg/s
FOR DRYING LIMIT
AT 2900C AIR TEMP. & 24% MOISTURE
= (30.7-30.2)/30.2 =0.017

= AO*(TI-TO)*4.043*10-04/MC*(1+
)
= AO*(290-70)*4.043*10-04/(0.24*1.017)
= 0.36*AO
AO = 2.7 Wf
AIR/FUEL RATIO = 2.7: 1
Wf

AT 2000C AIR TEMP. & 14% MOISTURE

AIR/FUEL RATIO = 4.6: 1

Lets us now focus on

Maintenance Aspects

Overview of maintenance:

Daily maintenance

Weekly maintenance

Shutdown maintenance

Daily maintenance / checks:

Check the gear case oil level ( Daily)

Gear case oil bath temperature

Coal and oil leakages

Weekly checks:

Greasing of spring adjusting bolt

Greasing of journal stop bolt.

Check gear case oil for contamination

Shutdown
(Checks after 66-8 months)

Oil level in journal and its quality(800mm)

All internal clearances

Greasing the gear coupling

Industrial Maintenance program

Preventive maintenance

Package overhaul

Capital overhaul

Isolation of mill:

Hot air shut off gates

Cold air shut off gate

Seal air shut off valves

Mill discharge valve should be closed

Mill and feeder motor breakers are to be
left open.

Disconnect the electricity

Preventive maintenance:

Grinding rolls and bull ring

segments(Clearance 2.52.5-3mm)
Spring gap adjustment between journal head
and head of spring assembly ( Usually in the
range of 0.8~1.0mm.)
Check the spring tension.
Check the condition and height of bowl
extension ring(Approx:90ring(Approx:90-95mm)
Check the Condition of cone (eroded /
Punctured)

Preventive maintenance:

Check the condition of classifier

Check the height and condition of venturi.

Check the sealing arrangement at the
insulation plates (damages due to
temperature difference).

Check the clearance between the
scrapper and insulation plate regularly.

Preventive Maintenance:

Check the condition of oil in gearbox and
level of oil(SP257/1050L)

Flush the oil coolers if required.

Packaged Overhaul:
(wear Packaging)
Replacement of bullring segments:
Procedure:
1.Unbolt clamping rings using jack screws.
2.Remove worn out bull ring segment
3.Clean all interior surface of bowl
4.Install new bull ring segment in numerical
sequence clockwise

Packaged overhaul:
Replace the bullring segments contd..
5.After installing bull ring segments if gap
exists use shims around the periphery.

Packaged Overhaul:
Servicing of journal assembly:
Procedure:

1. Lower the journal assembly (Lower edge

touches floor)
2. Remove the set screw or strips welded
on the roll lock nut
3. Remove the roll lock nut

Servicing of journal assembly:

contd..

4.Lift the assembly by sliding over journal

head assembly
5.If unable to remove use jack and fixture
assembly.

Packaged Overhaul:

Servicing of spring assembly(T624 and
T625 Thrust brg.)
( Hydraulic jack for adjusting spring tension)

Replacement of cone

Replacement of bowl extension ring and
vane assembly

Servicing of all Mechanical seal if required.

Servicing of Worm shaft assembly

Capital overhaul
Disassemble the mill completely..
Go for complete overhaul

Coal mill
Donts:

Do not get in to the mill when the motor is
not isolated and the discharge valves
closed

Do not use steel hammers on rolls

Do not use direct flame torch for bearing
assembly

Donts:

Do not leave in the tools,workpieces inside
the mill.

Do not alter classifier setting ,spring
compression setting, roll ring settings,
ring--roll clearance etc.
ring

Do not carry out maint. Work inside the
mill with out proper personnel safety
equipment

Do not weld on the bowl or any part
attached to it unless the welding m/c is
grounded to the bowl to prevent arcing on
surfaces.

Coal Feeders:

Coal feeder is installed at the bottom of
the coalcoal-bunker

Capacity to supply coal (Range:7.4T/hr 43.6T/hr)

Speed (Range:2.7 RPM 16RPM)

Feed is proportional to change in speed.

Types of coal feeder:

feeder-Drag chain

Volumetric coal feeder
Gravimetric feederfeeder-Belt Type

Maintenance Volumetric
feeder--Drag chain type:
feeder
(Periodic Checks)

Drive chain links.

Drive wheel teeth.
Drive shaft.
Drive shaft bearings.
Drive and driven shaft sprocket and
bearings of the same.

Maintenance Volumetric
feeder--Drag chain type:
feeder

Drag chain link, drag chain link push

plates and drag chain pin links.

Drag chain guide angles.
Top and bottom body liners LHS & RHS.
Guides of the driven shaft.
Thickness of the bed plate.
Load cells.

Maintenance (for both types)

Inspection, repairs or replacement of

gear teeth.
Inspection, repairs or replacement of
gear shaft.
Bearings of gears shafts.
Inspection of geargear-box oil, cleaning of oil
indicators.
Inspection, repairs or replacement of
clutch mechanism.

VOLUMETRIC DRAG LINK CHAIN FEEDER

MAKE: ALSTOM
TOP DECK PLATE LINER THICKNESS =6MM(SS);
TO BE CHANGED IF THICKNESS REDUCES TO 2MM
BOTTOM DECK PLATE LINER THICKNESS
=6MM(SS);

RAIL THICKNESS( TOP & BOTTOM) =12 MM

(HADFIELD PLATE)
TO BE CHANGED IF THICKNESS REDUCES BELOW
5 MM

ONE COMPLETE CHAIN OF FEEDER CONSISTS OF

A) 66 NOS. EN-8 CHAIN LINK WITH TONGUE
B) 66 NOS. EN-8 CHAIN LINK WITHOUT TONGUE
C) 132 NOS EN24 LINK PIN HARDENED TO 45-50 Rc
D) 132 NOS EN45 SPLIT TENSION BUSH
HARDENED TO 32-35 Rc
E) 33 MS FABRICATED DRAG BAR.
F) 132 NOS SPRING STEEL COTTER PIN OF FOUR SIZES EACH(
M6/45;M6/55;M10/45,M10/55)

MAXIMUM ALLOWED FEEDER TRAILING

END GAP= 50MM;
IF END GAP FOUND LESS THAN 50 MM
ADJUST GAP BY
a) REDUCING ONE PAIR OF CHAIN LINK.
b) RENEW CHAIN COMPLETELY IF TIME
PERMITS.
FREE LENGTH OF TENSION SPRING TO BE
CHECKED(AFTER RELEASING TENSION FROM SPRING)
& IF FOUND LESS THAN 280MM SPRING TO
BE REPLACED.
MAXIMUM COMPRESSED SPRING LENGTH ALLOWED=255265MM ON BOTH SIDES.
NO LOAD AMPS OF FEEDER VARIES FROM
6.5 TO 7.2 AMPS.
COAL BED HEIGHT AS PER OPS REQUIREMENT MAY BE
ADJUSTED FROM 200MM TO 300MM BY
ADJUSTMENT OF HEIGHT OF REGULATING
GATE ABOVE TOP PLATE.

TROUBLE SHOOTING
PROBLEM
FEEDER STALLED
WITH SHEAR
PIN SHEARED

FEEDER STALLED
WITH SHEAR
PIN NOT SHEARED

PROBABLE CAUSE

1) FOREIGN MATERIAL MAY COME IN

ISOLATION

1) ELECTRICAL

BETWEEN LINER PLATE & DRAG BAR

2) ROD GATES SHUT
2) LINER PLATE AFTER THICKNESS
3) BOTTOM BYPASS
REDUCTION MAY STICK WITH DRAG
BAR.
DOOR OPEN.
3) LARGE SIZED COAL LUMP MAY STICK 4) ONE BLANK PLATE
IN DE SPROCKET
TO BE PLACED AT
4) TRAILING END SPROCKETS MAY
CENTRAL COAL
TOUCH
CHUTE
WITH END COVER PLATE.
OPENING OF FEEDER

1) FOREIGN MATERIAL MAY COME IN

1) ELECTRICAL WITH
BETWEEN LINER PLATE & DRAG BAR
LOCAL FEEDER
2) LARGE SIZED COAL LUMP MAY STICK SELECTION
IN DE SPROCKET
IN REVERSE MODE.
3)ELECTRICAL OVERLOAD SETTING
INCORRECT

SOLUTION
1) CHECK TENSIONING SPRING
LENGTHS
ON BOTH SIDE(N &S) & IF FOUND
EQUAL
EMPTY FEEDER BY LOCAL RUNNING
MANUALLY
REPACE SHEARED PIN
& RUN FEEDER LOCALLY
& IF NOLOAD AMPS
FOUND OK & INTERNAL
MEMBERS OK RELEASE
FEEDER.OTHERWISE CHANGE
THE DAMAGED MEMBER
2) IF CHAIN LINK FOUND UNEQUAL
OR
FEEDER TRIPS DURING LOCAL
RUNNING
MANUAL EMPTY FEEDER.

TRY LOCALLY TO RUN THE

FEEDER IN REVERSE MODE
FOR FEW SECONDS.IF IT RUNS
SELECT FEEDER IN FORWARD
MODE & RUN FEEDER LOCALLY
& FOUND OK RELEASE THE FEEDER

THANK YOU !!!