INSTRUCTION MANUAL

.

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
BALL MILLS 70000375-1
Bolted-on lining plates

Erection Instruction




The text refers to the following instruction manuals etc.:

General safety regulations on erection sites
General Instruction. Operation and Maintenance
DucroBar lining for fine grinding chamber
DRAGPEB lining for fine grinding chamber
DUO3 lining for coarse grinding chamber
DUO3 lining for fine grinding chamber
STANEX diaphragm
Separately forwarded erection drawings




32031

70000393
9181
39031
38731
70000373





70000375-1

Edited by: BjIJ Translated by: BjIJ
Approved by: JVi MGN code: B601
Pages:
23

2

Indhold: Side:


1. General information ......................................................................... 4
2. Construction and operating principle ................................................ 5
3. Erection........................................................................................... 6
3.1 Preparations.................................................................................................................... 9
3.2 Fixation.......................................................................................................................... 10
3.3 Lining plates for inlet head (06)..................................................................................... 11
3.4 Shell lining for coarse grinding chamber (1), (8) ........................................................... 11
3.5 Grates and lining plates for stanex diaphragm (app. lll)................................................ 13
3.6 Shell lining for fine grinding chamber (02) .................................................................... 13
3.7 Outlet grate (13) ............................................................................................................ 14
3.8 Wet process mills.......................................................................................................... 15
3.9 Dismantling of worn lining plates................................................................................... 15
4. Operation ...................................................................................... 16
5. Maintenance .................................................................................. 17
Appendix ........................................................................................... 18


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Appendices:


Shell lining types I
Vertical lining and grates. Erection details II
Stanex diaphragm lll


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1. GENERAL INFORMATION

Lining plates are installed inside a ball mill, mainly to protect
the mill body from destructive impact and wear. Further some
of the lining plates are by their shape improving the grinding
efficiency of the mill, and others, i.e. grates for diaphragm and
outlet head, are screening the ground material and preventing
the grinding media from leaving the chambers.

This instruction manual deals with the different types of
bolted-on lining plates and grates used in a ball mill. For
boltless and semi-boltless lining types is referred to separate
instruction manuals.

The high-Chromium alloys used for lining plates and grates
are materials with excellent characteristics in terms of
hardness and wear resistance, whereas the impact resistance
is limited. So because of the relative brittleness of these
materials it is essential that lining plates and especially grates
are handled with care during transportation and erection on
site. The lining plates and grates must never be thrown about
or hurled casually into a pile on top of one another since
impact and pressure loads may cause the plates to crack.
This is especially important for the thinner lining plates and
grates of the fine grinding chamber. Further, grates and lining
plates must not be subject to bending stresses when the bolts
are tightened. However, correctly installed, lining plates and
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 equipment 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.


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grates manufactured from high-Chromium alloys will normally
have a long service life compared to most other materials.


2. CONSTRUCTION AND OPERATING PRINCIPLE

Lining plates and grates are normally cast from wear resistant
high-Chromium alloys, except for the inner lining plates on
inlet head which are subject to heavy impact from the big balls
of the coarse grinding chamber. These inner lining plates are
made in the extremely ductile Manganese steel.

For the different mill types, different shell lining types and
combinations of lining types are used. See appendix I.

Cement mills, type UMS: Step lining (1), bolted or semi-
boltless, is used in coarse grinding chamber and semi-boltless
corrugated lining (2) in fine grinding chamber. The same lining
types can be used in cement- and slurry mills of type UM.

Raw mills, mono-chamber, types TUMS and TMS: Heavy,
bolted classifying lining (3) with step lining (1) closest to the
inlet head. The classifying section is a combination of wave
lining and classifying lining plates. The same lining types can
be used in raw mills types TUM and TM.

Coal mills, mono-chamber, type TM: Light, semi-boltless
classifying lining (4) which is a combination of bolted
classifying plates and boltless Dragpeb-plates, both with
corrugated profile.

Most bolted-on shell lining plates for coarse grinding
chambers are designed to fit to several mill diameters in a
range. For that reason, the contact area at the bottom of the
plates are manufactured with two different radii. So depending
of the actual mill diameter, the contact to the mill shell will be
an area along the centreline of the plate (for the largest mill
diameter in the range) or outside this centre area (for the
smaller mills).



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The vertical lining plates and grates, i.e. lining plates for inlet
head, grates and lining plates for diaphragm and grates or
lining plates for outlet head, are more or less of the same
design in the different mill types. See appendix ll and III. The
main difference is that lining plates and grates for coarse
grinding chamber are of a heavier design than those for fine
grinding chamber due to the impact from the big balls.
Vertical lining plates and grates are normally installed with two
or three bolts and there must be contact to the mill body only
with the contact faces around the bolt holes.

Besides protection of the mill body, the function of the shell
lining is to lift the ball charge sufficiently high to give the
required power uptake. But on the other hand, the lining -at
least in coarse grinding chamber- must not lift the ball charge
too much since this will give higher impact loads on the lining
plates, resulting in crushing and increased wear on lining
plates and balls.

Lining plates and grates for coarse grinding chamber may
normally be used together with balls up to 100mm in diameter.
In fine grinding chamber, the maximum ball size is 60mm.


3. ERECTION

COMMAND:
Directions in instruction No. 32031, General safety
requirements on erection sites have to be obeyed on site.
The instruction must be read by client, erection company and
supervisor before the erection starts.

When the instruction says:
ERECTION CONTROL
it means that the responsible erection chef or supervisor have
to control and accept the erected parts before the erection
can continue.



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SAFETY:
Whenever work is being done inside the mill, on top of the
mill or under the mill, the main motor MUST be de-
energized by switching off the high- voltage switch and
LOCKING it. When the auxiliary drive is engaged, this too
has to be locked. Only the responsible work coordinator/
shift manager must be able to remove the lock.

Due to the safety of the personal there must, during the
whole erection, be stable scaffolding and platforms including
hand rails wherever needed.

Safety helmet and safety shoes must be used on site.
Working gloves are highly recommended when working with
lining plates.
Dust protection masks to be used when necessary (e.g.
during cleaning). Hearing protection to be used whenever
using noisy tools (e.g. grinding machines, jack hammers or
pneumatic keys). When grinding or flame cutting protection
glasses must always be used.

When lining plates are installed there is always a risk that
they, if wrongly handled, are falling down and thereby
represents a danger for injuring of personal. Therefore
measures must to be taken to make all lifts safe.
Weights of grates and lining plates can be found in the parts
lists.

When the mill is turned no personal is allowed inside, on top
of or under the mill.

During the erection of lining plates and grates, the mill can
often become unbalanced (side-heavy). Turning a side-heavy
mill is very critical and the mill must therefore be secured by
use of wires and chain blocks to prevent the mill from rotating
unintentionally. The wires with chain blocks can be bolted to
the mill shell through one or more lining plate boltholes and
anchored to the floor with expansion bolts. Building columns
must not be used for anchoring.



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If the mill is turned by means of the auxiliary drive and this is
equipped with an over-running clutch, the installation of
lining plates must always be done so that the side heaviness
presses in the right direction on the over-running clutch.
Otherwise there is a considerable risk for sudden,
unintentional release of the clutch, with uncontrolled turning of
the mill as result.

For use of electrical tools and working lamps plus General
safety regulations at erection sites see FLS-instruction No.
32031.


IMPORTANT! During handling and erection of the heavy
lining plates and grates, be careful not to drop these parts
onto the unprotected mill shell. Impression marks will
leave stress concentrations so high that there is a
considerable risk for developing of cracks in the
dynamically loaded mill shell.

DO NOT weld or flame-cut on the mill shell since such
damages may also result in developing of cracks.

When lifting the lining plates into the mill through the
manholes, be careful NOT to damage the edge of the
manholes. In order to prevent damages, the edge of the
manhole could be provided with a protection frame made from
wood or angle iron.

In case the mill shell is damaged in some way, it must NEVER
be repaired by welding, but only by careful grinding to obtain a
smooth surface. FLS must be informed before any repairs
are done.

Any superfluous bolt holes in the mill body (shell, slide rings
or mill heads) MUST be closed by means of glued-in conical
rubber plugs. Bolt holes must NEVER be plugged by
welding since such welding will leave stress
concentrations big enough to develop cracks.


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With the exception of welding specifically indicated on
drawings and in instruction manuals no welding, nor repair
welding, must be performed on the mill body unless prior
approval has been obtained from FLS.

Whenever turning the mill during erection of the lining
parts, it is of vital importance to lubricate the mill
bearings to avoid seizure. So the high-pressure oil pumps
must therefore be running during turning.

Whenever the mill is turned during erection, there should be
no loose lining plates inside, since there is a risk for damage
of the mill shell (if unprotected) or lining plates, or plates
might drop out through a manhole

3.1 Preparations
As previously mentioned, it is very important that lining plates
and grates are not subject to major bending stresses when
the bolts are tightened, since the hard but relatively brittle
materials may then crack. So lining plates and grates must
have contact to the support (mill shell, slide rings etc.) only
with the foreseen contact faces around the bolt holes.
So the entire inside surface of the mill body on which the
lining plates and grates are to be fitted must be examined
carefully for irregularities, i.e. weld splashes, too high
convexity of weld seams etc., which may prevent proper
contact between lining plates and mill body. Any such
irregularities must be removed by careful grinding in order to
obtain a smooth surface. Finally the mill must be completely
cleaned for all dirt and waste.

Since many of the lining plates are very heavy, up to approx.
150 kg, it will normally be necessary to install suitable lifting
equipment inside the mill, such as chain blocks, winch, trolley
etc.







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3.2 Fixation
When the lining plates and grates are to be installed, it must be
checked that they are supported only on the contact surfaces
around the bolt holes. If this is not the case, a minor adaption of
the plates can be done by careful grinding. Such grinding must be
done in a manner so as to prevent local heating, which may cause
cracks.
It is especially important for grates and lining plates fixed by
three bolts, that all three contact surfaces are in contact with
the support.

Under no circumstances adaption of lining plates and
grates by means of welding or flame cutting is allowed.

Due to different circumstances such as nominal clearance
between lining plates and grates, casting tolerances and bolt
clearance, there is a risk for rather big gaps between the
plates. In order to distribute the plates evenly on the surface
and to prevent them from twisting, most lining types are
designed with small recesses on the backside. Wherever
possible, the supplied spacer angles must be placed in these
recesses. In case there is still more than 2mm gap after
spacer angles have been inserted, weld on small plate pieces
of different thickness to the angles.

Before mounting of the bolts, check the condition of the
thread of all bolts and nuts and lubricate the thread with oil
and molybdenum disulphide (Molykote or similar) to ensure
minimum friction.

All lining bolts going through the mill body, i.e. with nuts on
the outside, must be installed with special sealing washers to
avoid leakage of material. The sealing washers consist of a
machined washer with increased bore (10), a rubber grommet
(11) inserted in this bore and on top a normal washer (12).
Since the rubber grommet is thicker than the machined
washer, the rubber will be squeezed into the clearance
between bolt and hole when the nut is tightened, thus forming
a seal.

The lining bolts must be tightened to a specified torque, by
means of a torque spanner, and they have to be retightened
until the torque remains constant.


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During the tightening process, the bolts are to be vibrated by
blows from a hammer on the head.
For tightening torques and re-tightening, see drawing No.
3.021665.
Bolts which have the nut inside the mill must be secured by
tack-welding of the nut after the final re-tightening.

3.3 Lining plates for inlet head (06)
The inlet head can be either plane (in mill types UMS, TUMS,
TMS, TUM or TM) or conical (in UM mills). In both cases, the
lining plates are designed with contact faces around the bolt
holes. These faces must be the only contact between the
lining plate and the mill head. In order to distribute the lining
plates evenly on the surface with uniform spaces between the
plates, insert spacer angles (07) wherever possible in the
recesses on the backside of the lining plates. The bolts must
be able to pass freely through the holes and must be parallel
to the mill axis.
The relatively heavy lining plates must be lifted into the mill
through the manhole by means of a small electrical winch or a
chain block. Inside the mill the lining plates can be handled by
pulling/pushing them on steel plate or boards up to the inlet
end. When placed near the inlet head, also use an electrical
winch or chain block to lift the plates up in position. Whenever
the mill is turned during erection, there should be no loose
lining plates inside, since there is a risk for damage of the mill
shell (if unprotected) or lining plates, or plates might drop out
through a manhole.
This paragraph (3.3) is also valid for erection of lining plates
on outlet head in TM mills (fully airswept).

3.4 Shell lining for coarse grinding chamber (1), (8)
For type of shell lining to be used in the relevant mill, see
separate erection drawings for mill and lining. Also for
identifying the different lining patterns and find out where to
install them in the chamber, please study the assembly
drawings.
In case of semi-boltless lining, see separate instruction
manual.



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Fully bolted-on step lining in cement mills (UMS) are normally
supplied with rubber backing (09). Make sure that the
individual rubber plates do not interfere with each other or
fold, since such increased thickness of rubber will result in
improper contact between the lining plates and mill shell. The
plates must lie firmly against the mill shell without tilting.
Otherwise the mill shell or contact face(s) must be adapted by
grinding. Insert spacer angles, wherever possible in the
recesses under the lining plates.
Step lining plates must be installed so that the thin end of the
plate is pointing forward in the direction of rotation of the mill
(05).
In UMS mills, the first row of lining plates at the inlet head is
boltless. This first row is fixed by the outer lining plate on inlet
head and the first bolted-on row on the mill shell. The rubber
plates under the two first rows of lining plates must is
extended to cover the corner (radius R20) of the slide ring. To
prevent the boltless lining plates from moving in
circumferential direction during operation, 70x70mm locking
plates must be placed in the corners between the boltless
plates and the first bolted-on plates. When the bolted rows
have been installed, the boltless plates must be aligned in
both directions in relation to the bolted-on plates and the
supplied shims must be inserted, wherever required, in the
circumferential and longitudinal gaps between the plates. Use
as few and as thick shims as possible and fix them firmly in
the gaps by hammering. (see the lining erection drawing).

Erection control

The last row of bolted-on lining plate at the diaphragm must
be erected only after the outer boltless lining plates (22) of
the Stanex diaphragm have been installed.
The mill has to be turned two or three times in order to erect a
full lining ring. Do not erect too may rings simultaneously,
since the mill will become unbalanced (side-heavy) with the
risk of uncontrolled turning.
The lining plates inclusive rubber backing for the manhole
covers should be installed outside the mill and only lifted into
the mill when needed.



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The fully bolted classifying lining (03) in raw mills, types
TUMS and TMS (and TUM and TM) has no rubber backing
3.5 Grates and lining plates for stanex diaphragm (app. lll)
See separate mill erection drawing and instruction manual
Stanex diaphragm.
Grates (20) and lining plates (21) must not be subject to
bending stresses when the bolts are tightened. Therefore they
must rest only on the surfaces around the bolt holes. This is
especially important for the grates since they are fixed with
three bolts. In case of insufficient contact, it is necessary to
either align with shims or by means of careful grinding so that
all contact faces have full contact with front plate and
supporting plate.
It is important that the grates and lining plates evenly
distributed over the diaphragm surfaces, i.e. with uniform
gaps between them, and that the bolts are perpendicular to
the diaphragm. The grates and lining plates are fixed with
shared, through-going bolts. The bolts holding the grates and
lining plates are partly square head bolts (23) used at the
radial butt joints and partly bolts with conical seating (B-
bolts)(24) used in the central hole in the grates. First the B-
bolts (24) are erected through the grates, diaphragm structure
and one of the holes of the lining plates with washer and nut.
Under the head of the square head bolts a square washer
(25) must be used. However, as the grates do not necessarily
have the same height it may be necessary first to insert half
square steel washer(s) (26) to level out the difference. The
maximum allowable height difference between two adjoining
grates is 0.2 mm. When all the bolts (23 and 24) have been
installed with washer and nut, and the grates and lining plates
are evenly distributed over the diaphragm surface, the bolts
must be tightened to the specified torque (See drawing No.
3.021665). The outer boltless lining plates (22) have to be
erected at the same time as the shell lining in chamber 1.

3.6 Shell lining for fine grinding chamber (02)
Different types of semi-boltless linings for fine grinding
chamber are available, both corrugated and classifying.
For erection of these, see the relevant instruction manual.
However, all the above mentioned precautions to take in
connection with erection of bolted-on lining plates are also
valid for the bolted-on plates of a semi-boltless lining.


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3.7 Outlet grate (13)
The structural parts (supporting plate) (15) for outlet grates
have normally been finish-assembled in the workshop. Before
starting erection of the grates, it must be checked that the
supporting plate has been properly aligned, i.e. is concentric
with the shell and firmly fixed to the web plate of the slide
slide ring. It is extremely important to check now that the
supports for the grates, i.e. the pipes and the flat bars, are
completely flush within the area of each grate, so that the
grates are not subject to bending when the bolts are
tightened.

Erection control

If not done already, adjust the lifters of the supporting plate to
full length.
Before bolting on each grate, it must be checked that all three
contact faces on the backside are in contact with the support.
In case of insufficient contact, it is necessary to adapt the
grate (or support) by careful grinding.
In order to distribute the grates evenly on the surface, with
uniform spaces between the plates, insert spacer angles
wherever possible in the recesses on the backside of the
grates. The bolts must be able to pass freely through the
holes in the grates, in the supporting plate and the slide ring,
and must be parallel to the mill axis.
The bolts holding the grates are partly square head bolts (15)
used at the radial butt joints and partly bolts with conical
seating (B-bolts)(16) used in the central hole in the grates.
First the B-bolts (16) are erected through the grates,
supporting structure and slide ring web plate with sealing
washers and nut. Under the head of the square head bolts a
square washer (17) must be used. However, as the grates do
not necessarily have the same height it may be necessary first
to insert thin half square steel washer(s) (18) to level out the
difference. The maximum allowable height difference between
two adjoining grates is 0.2 mm. When all the bolts (15 and
16) have been installed with sealing washers and nut, the
bolts must be tightened to the specified torque (See drawing
No. 3.021665). The outer boltless lining plates (22) will be
erected at the same time as the shell lining.


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For mills with central drive, sealing washers for the bolts are
not required, but just normal washers, and after final
retightening, the nuts must be secured by tack-welding.

Erection control

3.8 Wet process mills
In principle, lining plates and grates are to be installed in the
same way as for dry process mills. However, as slurry
penetrates under the lining plates and will cause wear and
corrosion on the mill body, it is extremely important that all
lining plates bolted-on to mill shell and heads are installed on
rubber sheet.
Depending on type of semi-boltless lining in fine grinding
chamber, such a lining can either be installed on rubber sheet
or it can be grouted with a cement grout after the erection has
been finished.
All major spacings behind lining plates must be filled with soft
rubber blocks in order to prevent slurry from sliding / rotating,
thus causing wear on the mill body.

3.9 Dismantling of worn lining plates
In worn-out lining plates, the bolt heads are normally so
deformed that it is impossible to dismantle the bolts from the
plates in a normal manner. Since the bolts cannot be re-used
after all, the recommended procedure is to unscrew the nuts
and remove the lining plates without taking out the bolts.
Only if it is impossible to unscrew the nut, it should be
considered to cut off the bolt end with nut by flame-cutting or
with a cutting disc, or by melting away the bolt head by means
of carbon electrodes (air-arc gouging). If the latter methods
are used, utmost care must be taken not to damage the
mill body (shell, slide rings etc.). Cutting scars in the
dynamically loaded mill body will most likely result in
developing of cracks sooner or later. Such scars must be
carefully smoothened by grinding and inspected for cracks
and futher be inspected for cracks in the future twice a year.
DO NOT repair scars or other damages by welding. Also note
that scars and grinding of said can make it very difficult to
seal the boltholes again with new seals.


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For grates and lining plates for Stanex diaphragm and other
lining plates where the nuts have been tack-welded, either the
head or nut has to be melted/cut-out by means of flame-
cutting or air-arc gouging.

NOTE! It is a highly dangerous job to dismantle worn
lining plates, especially semi-boltless liners, since there
is a risk that plates may fall out unintentionally. So ALL
safety precaution must taken to avoid any injuries on
personnel working in or around the mill.
If the worn lining plates are dropped to the floor on top of
each other through the manholes, there is a considerable risk
of flying debris which can be very dangerous. Proper
measures have to be taken to avoid injuries.

When the lining plates have been loosened, it is essential
that the worn lining plates do not drop down on unprotected
mill shell or damage the edges of the manholes when they are
taken out of the mill. Protect the mill body from damages!.


4. OPERATION

Before charging the mill with grinding balls, check that all
lining parts are correctly installed and that the bolts are
tightened with the prescribed torque. Remove tools and other
remains from the erection from the mill.

IMPORTANT!
In order to avoid damage of lining plates and grinding balls,
there MUST always be a suitable amount of materials (clinker
or limestone) in the coarse grinding chamber before charging
the grinding balls and starting the mill. The amount of
materials should be approximately 25% of the weight of the
grinding balls.

It is essential for the lifetime of the lining plates that the mill is
always operated with sufficient material. If the amount is too
small the lining plates and the grinding media will be worn
much too fast and there is a considerable risk of breaking the


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lining plates and the grinding media in the coarse grinding
chamber. When stopping a mill, the feed to the mill should not
be stopped more than 2-3 minutes before.

All lining bolts which have the nuts inside the mill, must be re-
tightened, with torque spanner, first after 2 hours of operation
and then every 12 hours until the torque remains constant.
Then secure the nut by tack-welding. Lining bolts which have
nuts outside the mill body, must be re-tightened, first after 8
hours of operation and then every 12 hours until the torque
remains constant. These nuts must not be tack-welded.

Erection control

Any material/dust leaking from the mill during operation must
be stopped immediately. Besides contamination of the mill
building, leaking material may result in wear of the mill body.


5. MAINTENANCE
For maintenance of mill lining, please refer to General
Instruction. Operation and Maintenance


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Appendix
I
Key to enclosures l
01. Step lining
02. Corrugated lining
03. Classifying lining for coarse grinding chamber
04. Classifying lining for fine grinding chamber
05. Mill direction of rotation






























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I



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II

Key to enclosures ll
06. Lining plates for inlet head
07. Spacer angle
08. Shell lining
09. Rubber backing
10. Machined washer
11. Rubber grommet
12. Normal washer
13. Grates for outlet head
14. Supporting plate
15. Square head bolt
16. B-bolt
17. Square washer
18. Half square washer


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II



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IIl
Key to enclosures lll
20. Grates
21. Lining plates
22. Outer lining plate
23. Square head bolt
24. B-bolt
25. Square washer
26. Half square washer


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IIl

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