WRITE UP ON 14 TPH BOWL MILL WITH CONVERTOR HEAD

THE MILL CONSISTS OF THE FOLLOWING MAJOR ASSEMBLIES:

A) PLANEATRY GEAR BOX ASSEMBLY WITH EXTERNAL LUB OIL

SYSTEM.

B) BOWL HUB, BOWL AND VANE WHEEL ASSEMBLY

C) MILL SIDE ASSEMBLY

D) SEPARATOR BODY & TOP CLASSIFIER (DYMANIC) ASSEMBLY

E) ROLLER JOURNAL ASSEMBLY.

F) CONVERTER HEAD ASSLY.

G) TRAMP IRON & SPOUT VALVE ASSEMBLY.

H) PYRITE HOPPER & ISOLATION GATE VALVE ASSEMBLY.

A) MILL DRIVE ASSEMBLY WITH EXTERNAL LUB OIL SYSTEM

i) MILL DRIVE ASSEMBLY:

Mill drive assembly consists of planetary gear box, which reduces the motor speed
to the speed of the bowl. The input shaft of the planetary gear box is coupled to
the motor by a flexible coupling.

The planetary gear box assembly is coupled to the bowl assembly through bowl
hub by means of high tensile bolts. High abrasive wear resistant material bullring
segments are assembled on the bowl. The velocity of the primary air around the
bowl can be adjusted to the optimum so that foreign material, pyrites and stones
are rejected out of the mill. This optimizes the pressure drop across the bowl.

The planetary gearbox is forced lubricated with the help of External lube oil
system.

ii) EXTERNAL LUBE OIL SYSTEM:

The system consists of lube oil pump & motor, oil filter, oil cooler (one set on line
and one set as stand-by), flow indicators, relief valves, instrumentation rack,
mounted on a skid. The lube oil system takes care of the lubrication requirement of
bearings of the planetary gear box.

The lube oil system shall be mode ON before the mill is started. Even after the
pulveriser is shut down the system is kept ON to continue filtering and cooling of

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 oil. During long outage of the mill also, the lube oil system is run for short duration
to lubricate the bearings as part of preservation practice.

B) BOWL HUB, BOWL & VANE WHEEL ASSEMBLY :

This assembly is coupled to the mill drive assembly, after completion of mill side
and assembly. Bull ring segments made of high abrasive wear resistant material are
assembled on the bowl. The velocity of the primary air can be adjusted to the
optimum so that foreign material, pyrites and stones are rejected out of the mill.
The vane wheel permits primary air flow all round the bowl which would result in
more uniform flow inside the mill at a lower pressure value near mill inlet. This
reduces the pressure drop across the bowl to the optimum value and hence, saving
in power consumption with lesser wear rate.

C) MILL SIDE ASSEMBLY:

This assembly is coupled to the mill drive assembly, after completion of mill side
and assembly. Bull ring segments made of high abrasive wear resistant material are
assembled on the bowl. The velocity of the primary air can be adjusted to the
optimum so that foreign material, pyrites and stones are rejected out of the mill.
The vane wheel permits primary air flow all-round the bowl which would result in
more uniform flow inside the mill at a lower pressure value near mill inlet. This
reduces the pressure drop across the bowl to the optimum value and hence, saving
in power consumption with lesser wear rate.

D) SEPARATOR BODY & SEPARATOR TOP ASSEMBLY:

The separator body assembly houses Roller journal assembly and Hydraulic
loading System. The Hydraulic loading System/Spring is mounted on the
journal opening cover of the separator body assembly. Hydraulic loading
System exerts the required grinding force on to the roller journal assembly for
crushing the coal. These Hydraulic loading System are provided one on each of
the roller journal assembly. Uniformly distributed hot air flow is provided all
around the bowl through vane wheel assembly. Powdered coal is lifted up by
this up - coming air stream and carried to the stationary classifier (assembled
inside separator top) mounted on the top of the separator body.

The dynamic classifier assembly consists of rotary classifier blades. The rotary
blades impart spin to the coal air mixture. The heavier particles are thrown out
of the stream and returned to the bowl for further grinding by sliding back on
the inner-surface of the classifier cone. The classified product enters the
discharge outlet assembly which then directs the Pulverised coal towards the
intake pipe leading to the bag filters.

E) ROLLER JOURNAL ASSEMBLY(Spring/Hydraulic):

The grinding force from the hydralic loading/Spring assembly is transmitted
through the Journal assembly on to the coal on the bowl. When coal comes

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 between the Roller and the Bull ring assembly, the roller assembly lifts using
the force by hydralic loading system. There is no metal to metal contact between
the Roller and Bull ring assembly when the Bowl is empty. The Roller assembly
can be raised or lowered by means of stop bolt arrangement. The Roller
assembly moves up and down on the Bowl depending on the coal bed, between
the Roller and Bull ring assembly. The Roller assembly oscillates up and down
about the trunnion shaft, which is supported on rubber bushings in the separator
body. The journal assembly is having a tilt out feature for maintenance ease.

F) CONVERTER HEAD ASSEMBLY:

This assembly is mounted over the Separator Top for collection of Pulverised
coal. It is ceramic lined for longer life.

G) TRAMP IRON & SPOUT VALVE ASSEMBLY:

Tramp iron, pyrites and stones in the raw coal, being heavy fall through the
openings in the vane wheel assembly fixed to the bowl, into the mill side and
liner assembly. This is scraped and dumped into the pyrite hopper assembly
through the tramp iron and spout valve, by means of scraper assemblies, which
are fitted to the bowl hub heat shield and rotating along with it. The tramp iron
spout valve is normally kept open to tramp iron and pyrites in the mill side
assembly to fall into the pyrite hopper assembly. Since the mill is pressurized,
whenever the pyrite hopper is to be emptied the tramp iron and spout valve has
to be closed to prevent hot primary air leakage into the atmosphere.

H) PYRITE HOPPER ASSEMBLY:

This assembly is a storage bin for the tramp iron, stones and pyrites. The tramp
iron valve has to be closed whenever pyrite hopper is periodically emptied of its
contents to the reject handling system.

*****

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 RECOMMENDED SPARES FOR 2 YEARS OPERATION

SL DESCRIPTION TOTAL UNIT OF

NO NO. MEASUREMENT

01 GRINDING ROLL 6 NOS.

02 BULLRING SEGMENT ASSLY. 2 SET

03 SCRAPPER AND GUARD ASSLY. 2 NOS.

04 LINERS WITH BRACKETS AND 2 NOS.
FASTENERS
05 OIL SEAL AND O RINGS 2 SET
06 BOWL EXTENSION RING SEGMENTS 2 SET
NOTE: ONE SET MEANS ONE-MILL QUANTITY.

COMMISSIONING SPARES

SL DESCRIPTION QTY/
NO MILL

01 OIL SEAL SOLID JOURNAL ASSEMBLY 3

02 GASKET FOR INSPECTION COVER 2
03 GASKET (THRUST BEARING CAP) 2
04 GASKET (BEARING HOUSING) 2
05 O RING (O RING LOWER RADIAL BEARING HOUSING 1
COVER)
06 JOURNAL STOP BOLT 3
07 INSPECTION COVER GASKET - MILL BASE 2

08 LUBE OIL SYSTEM FILTER ELEMENT 4

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 SPECIAL TOOLS AND TACKLES

SL DESCRIPTION QTY/
NO. PROJECT

01 BOWL & BOWL HUB HOISTING FIXTURE 1 NO’s.

02 JOURNAL GRINDING ROLL LIFTING LUG 1 NO’s.
03 JOURNAL ROLL HYDRALIC LAODING ADJUSTMENT 1 NO’s.
04 PLANETARY GEARBOX ALIGNMENT ADJUSTING BLOCKS 1 SET’s.
05 JOURNAL TILT OUT APPLICATION & FIXTURE 1 NO’s.
06 JOURNAL STOP BOLT WRENCH 1 NO’s.
07 HYDRALIC TORQUE WRENCH 1 NO’s.
08 HYDRALIC STUD TENSIONER 1 NO’s.
09 OIL DIP STICK 1 NO’s.
10 ANCHOR BOLT TEMPLATE 1 NO.
11 TRUNNION SHAFT ECCENTRIC ADJUSTMENT TOOL 1 NO’s.
12 GEARBOX WITHDRAWAL FIXTURE 1 NO.

INITIAL FILL OF LUBRICANTS / MILL

Sl. No. DESCRIPTION QTY. OF LUBRICANTS

PER MILL (IN LITRES)
01 ROLLER JOURNAL ASSEMBLY 240

02 GEAR BOX 1610

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 UTILITY REQUIREMENTS

1) STEAM QUALITY PER MILL FOR MILL INERTING

OPERATION 13, 300 KGS/ HR.
NOTE :- THE STEAM FOR INERTING WILL BE FROM THE AUXILIARY STEAM
HEADER (PRESSURE 16 ATA, TEMP. 230 °C)

ALTERNATELY, NITROGEN GAS CAN BE USED FOR INERTING

2) WATER QUANTITY REQUIRED PER MILL FOR OIL COOLER

AT 32C COOLING WATER TEMPERATURE
NOTE:- A) RECOMMENDED INLET PRESSURE = 4.5 KGS/CM²

B) PRESSURE DROP IN COOLER = 0.5 KGS/CM²

C) WATER QTY PER MILL IN m3/HR = 15

(1 Standby+1
Working)

D) LOCATION OF TP = NEAR MILL

E) TAP DETAILS = INLET AND

OUTLET
NB 50

F) WATER QUALITY = CLEAN AND

FILTERED
WATER OR
DM WATER
Note: Additional Water is required in case of Hydraulic loading system is considered.

3) SERVICE WATER FOR MILL FIRE FIGHTING

(INTERMITTENT) = 7.5 TPH

4) COMPRESSED INSTRUMENT AIR/ MILL

APPLICATION = b) REJECT HOPPER PNEUMATIC OPERATED
(INTERMITTENT gate valves (2 no’s/ mill), 03.5 NM3/ operation
REQUIREMENT) for each valve

AIR PRESSURE = 7 KGS / CM²

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