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INSTRUCTION MANUAL .

OK mill 70003294
Operation and maintenance 2.0
Safety instructions

The text refers to the following instruction


manuals etc.:

OK mill for clinker; Operation and maintenance 70001089

Hydraulic installations 19871

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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Contents: Page:

General information. ....................................................................................... 3


Visual inspection during operation. ................................................................. 4
Maintenance inside the mill. ............................................................................ 4
Handling of heavy parts................................................................................... 5
Hydraulic system. ............................................................................................ 6
Lubrication systems......................................................................................... 6

Edited by: LRJe Translated by: Pages:


Approved by: LuP MGN code: B 400 6
Deleted: 48
70003294-1.0 3

General information

NOTE !

The present instruction manual is concerned with the situations


which, according to the experience of FLS, are the most likely to
occur. An exhaustive enumeration of all conceivable situations
which may occur during the erection, operation and maintenance of
the OK mill cannot be provided.

Consequently, if a situation should arise, the occurrence of which is


not foreseen in the instruction manual, and which the operator is/or
feels unable to handle, we would recommend that FLS is contacted
without undue delay for advice on appropriate action.

Before any maintenance work is carried out, read this instruction,


the safety instructions for the entire process module, the safety
instructions for the entire cement plant and the cement mill
maintenance instruction manual.
The fact that the OK mill is a remotely operated machine integrated
in a larger process module means that special procedures for safe
maintenance must be worked out by the manager responsible for
plant safety, taking into account the entire process module.
Always ensure that workers carrying out maintenance work on the
OK mill are skilled in the type of work they are performing and that
they have been given the necessary instructions concerning the
special precautions to be applied when working with large
machinery.
The mill is equipped with warning, prohibiting and mandatory signs
which cover all normally occurring risks that could not be
eliminated by conventional means, through the use of guards, rails
etc.
Safety precautions required when working with dangerous tools like
disc grinders, welding machines, blowtorches etc. are foreseen to be
part of normal site safety procedures and this aspect is outside the
scope of the present instruction manual.
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Visual inspection during operation

During operation, visual inspection must be restricted to safe areas.


Never dismantle doors, guards or rails during operation.
During operation, hot air or exhaust gases are utilized for heating
the mill. Attention is drawn to the fact that temperatures of mill
housing and air spouts can be very high.
When entering the space for the gear unit below the mill during
operation, be aware of the following.
During operation, the air pressure inside the mill is lower than the
atmospheric pressure, thereby preventing outflow of cement dust
from the mill. However a small spillage rate of particles may occur
at the location where the table enters the mill housing. Clean up the
spillage on a regular basis. Goggles must be worn to prevent eye
damage.
The mill motor and feed system are noisy machines. Ear protection
equipment must be used to prevent damage to hearing.

Maintenance inside the mill

Prior to dismantling of any doors and guards, make sure that the
following equipment has been stopped and interlocked to prevent
starting: Mill main motor, mill fan, hydraulic system, all feeding
equipment and heat generator, if any. The power supply for the
above-mentioned equipment must be effectively locked by means of
padlocks in the Motor Control Centre (MCC) to prevent inadvertent
starting of the motors. The supervisor in charge of the maintenance
team undertaking work inside the mill must keep the key for the
lock. The padlocks must remain fitted until all personnel have left
the mill and all doors and guards have been re-mounted.
The manager responsible for plant safety must work out safe
maintenance procedures to prevent inadvertent starting.
Given the dusty environment inside the mill, anyone entering the
mill must be wearing a face shield and goggles.
If exhaust gases are utilized for heating the mill, it is essential to
ensure that the mill is vented to normal O2, CO and CO2 level prior
to entry into the mill. The mill must be vented while personnel are
carrying out work inside the mill.
In connection with entry into the mill, attention is drawn to the fact
that cooling of the mill is a lengthy process, and that the
temperatures of the surfaces inside the mill can be very high.
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When entering the mill, due caution is needed to step across the
nozzle ring opening and the material built up between the air guide
cone and the mill housing. There is a distinct risk of tripping;
therefore, the manager in charge of plant safety aspects must
notify the operating personnel of the attendant hazard.
The interior of mill vertical mills often have hot accumulated
material inside separator cone, feed sluice etc. this can dislodge and
create dangerous situations; so proper inspection and precautions
must be taken to avoid any hazard before entering the mill.
When work is done inside the mill, one person must be assigned to
perform surveillance function outside the mill, ensuring that any
undetected gases will not cause suffocation of the persons working
inside the mill.
When it is necessary to do maintenance with the rollers in raised
position, make sure that the rollers are locked mechanically in the
upper position. This is done by mounting the Safety Clamp on top of
the roller stopper shaft, lower the rollers so mechanical contact are
achieved between roller stopper and Safety Clamp and roller stopper
shaft.
Changing of wear segments on the grinding rollers is done with the
rollers in raised position. Removal of the segments will lead to
imbalance of the roller. Undesirable turning of the roller must be
prevented, see operation and maintenance instruction manual
70001089.

Handling of heavy parts

During maintenance it may become necessary to handle heavy


equipment. Handling of heavy parts may involve hazards but is
foreseen to be a normal procedure for personnel carrying out
maintenance work at a cement plant and this aspect is outside the
scope of the present instruction manual
Before handling heavy parts from the OK mill, read the operation
and maintenance instruction manual 70001089.
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Hydraulic system

Prior to performing any maintenance work on the hydraulic system,


read the data and safety data sheet from the oil supplier.
The hydraulic system is equipped with accumulators. Before
dismantling any part of the system, make sure that the pressure in
the entire hydraulic system has been reduced to zero bar.
Before dismantling any part of the hydraulic system, make sure that
the power supply has been turned off and locked out in the MCC.
Following the reassembly of the system, a pressure test must be
conducted as described in the general instruction manual 19871 for
hydraulic systems.

Lubrication systems

Prior to performing any maintenance work on the lubrication


systems, read the data and safety data sheet from the lubricant
supplier.
Before dismantling any part of the lubrication systems, be sure that
the power supply has been turned off and locked out in the MCC.
Following the reassembly of the system, a pressure test must be
conducted as described in the general instruction manual 19871 for
hydraulic systems.

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