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HP1003 Coal Pulverizer

Installation & Operation And


Maintenance Manual

Shanghai Heavy Machinery Plant Co., Ltd.


Shanghai, China
15,05, 2012
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SHMP Co.,Ltd.
HP1003 PULVERIZER
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INSTALLATION,OPERATION AND MAINTENANCE

TABLE OF CONTENTS
HP PULVERIZER INSTALLATION ................................................. TAB I
Pulverizer Description ........................................................... Part 1
Protection and Preservation of Pulverizer Components.......... Part 2
Installation Procedures .......................................................... Part 3
HP PULVERIZER OPERATION ..................................................... TAB II
Principles of Operation .......................................................... Part 1
Pulverizer Operating Procedures .......................................... Part 2
Lubrication Systems .............................................................. Part 3
Pulverized Coal Fineness - Adjustment and Testing ............. Part 4
HP PULVERIZER MAINTENANCE .................................................. TAB III
General Maintenance Procedures ........................................ Part 1
General Disassembly ............................................................ Part 2
General Reassembly ............................................................. Part 3
Pulverizer Component Servicing ........................................... Part 4
ENGINEERING DRAWINGS ........................................................ TAB IV
Contract Drawings ................................................................. Part 1
Maintenance Tool Drawings .................................................. Part 2
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SHMP Co.,Ltd.
HP1003 PULVERIZER - INSTALLATION
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TABLE OF CONTENTS

PULVERIZER DESCRIPTION PART 1

PULVERIZER DESCRIPTION ............................................................................... 1-1

PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS PART 2

INTRODUCTION ..................................................................................................... 2-1


GENERAL STORAGE REQUIREMENTS ............................................................. 2-2
Storage Types ............................................................................................. 2-2
Minimum Storage Requirements ............................................................... 2-2
Component Storage ..................................................................................... 2-4

INSTALLATION PROCEDURES PART 3

INTRODUCTION ..................................................................................... ........... 3-1


PULVERIZER COMPONENTS............................................................................. 3-2
SUB-ASSEMBLI ES .................................................................................. 3-2
LOOSE PARTS ......................................................................................... 3-2
TOOLS ...................................................................................................... 3-3
GENERAL ASSEMBLY ...................................................................................... 3-4
DETAILED ASSEMBLY PROCEDURE ............................................................... 3-5
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING ...... 3-5
Pulverizer ................................................................................................. 3-5
Motor ........................................................................................................ 3-6
GEARBOX ASSEMBLY INSTALLATION ...................................................... 3-7
MILLSIDE ASSEMBLY .................................................................................. 3-7
BOWL AND VANE WHEEL ASSEMBLY ....................................................... 3-8
SEPARATOR BODY ..................................................................................... 3-9
SEPARATOR TOP ASSEMBLY .................................................................. 3-10
INNER CONE AND CERAMIC LINER ASSEMBLY ...................................... 3-11
MILL DISCHARGE VALVES AND
MULTIPLE PORT OUTLET ASSEMBLY ................................................. 3-11
JOURNAL OPENING COVER AND SPRING ASSEMBLY ........................... 3-12
INNER AIR SEAL AND SCRAPER INSTALLATION .................................... 3-12
SECURING THE GEARBOX ....................................................................... 3-12
SEAL AND GUARD ASSEMBLY ................................................................. 3-13
PULVERIZER MOTOR, COUPLING AND GUARD ...................................... 3-13
JOURNAL INSTALLATION ......................................................................... 3-14
TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ................................... 3-15
DISCHARGE VALVE LIMIT SWITCH SET-UP ............................................ 3-16
CONTROLS ................................................................................................. 3-17
FINAL ADJUSTMENTS, JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE,
JOURNAL SPRING POSITION ...................................................................... 3-17
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TABLE OF CONTENTS

PULVERIZER DESCRIPTION Part 1

TITLE PAGE NO.


PULVERIZER DESCRIPTION ................................................................. 1-1
___________________________________________

LIST OF FIGURES
TITLE FIGURE NO.

HP Pulverizer .......................................................................................... 1-1


HP Pulverizer Coal and Air Flow ...................................................... 1-2

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HP1003 PULVERIZER - INSTALLATION
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PART 1 - PULVERIZER
DESCRIPTION

PULVERIZER DESCRIPTION

Shanghai heavy machinery plant co.ltd. (SHMP for short) has developed a series
of pulverizers which grind and dry coal in power plants through out the world. The
grinding surface in the pulverizer resembles a deep dish or bowl. Therefore the
name"Bowl Mill" has been adopted to refer to this piece of equipment.

The Pulverizer consists of the following components: (refer to figure 1-1)

1. The “gearbox”, which is driven by an electric motor, is directly connected to


the bowl hub. A planetary gear arrangement provides the proper reduction
between the motor and the bowl hub to obtain the desired bowl speed.

2. The “millside and air inlet” surround the bowl and the bowl hub and support the
separator body. Air for transporting and drying the coal enters through the air
inlet, and is directed upward around the bowl.

3. The "bowl" is the table upon which the coal is crushed. Material to be ground is
admitted to the pulverizer and deposited near the center of the rotating bowl.

4. The “vane wheel assembly”, which is attached to the bowl, manages the
coal/air mixture within the grinding zone of the pulverizer by uniformly
distributing the transport air through the bowl O.D. and inner cone/ separator
body annulus.

5. Three independent, spring loaded “journal assemblies” are suspended from


the separator body and overhang the bowl. The journal assembly rolls are free
to rotate, and do so, when the coal being pulverized fills the space between
them and bowl.

6. The “separator body and separator top” with attached deflector assemblies and
the inner cone and classifier, contain the material after it is pulverized. The
separator body and separator top direct the material and transport air up
through the deflector assemblies where larger particles of material are
separated from the transport air and returned to the bowl for further grinding

7. The multiple port outlet assembly separates the flow of material and transport
air into four separate, equal streams.

8. The pulverizer discharge valve assembly is mounted on top of the multiple


port outlet assembly. The four valves, which make up the assembly, are used
to isolate the pulverizer from an operating furnace during a unit start-up and
when the idle pulverizer contains coal. They are also used (in conjunction with
coal line valves) to isolate the pulverizer for maintenance.

The illustrations used in the pulverizer manual are included to supplement and
clarify written information, the components pictured are typical of those used on
the SHMP HP Series of pulverizers. They may not picture all of the pulverizer
parts as they actually exist on your equipment. The value of the descriptive
material, however is not affected in any way.

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Figure 1-1 HP Pulverizer


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HP1003 PULVERIZER - INSTALLATION
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Figure 1-2 HP Pulverizer Coal and Air Flow


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TABLE OF CONTENTS

PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS PART 2

TITLE PAGE NO.

INTRODUCTION .................................................................................................. 2-1


GENERAL STORAGE REQUIREMENTS ........................................................ 2-2
Storage Types ............................................................................................. 2-2
STORAGE TYPE B ................................................................................... 2-2
STORAGE TYPE C ................................................................................... 2-2
STORAGE TYPE E ................................................................................... 2-2
Minimum Storage Requirements ................................................................. 2-2
MAJOR SUBASSEMBLIES .......................................................... ............. 2-2
BOXED OR BUNDLED ITEMS ... ............................................................... 2-3
TOOLS AND FIXTURES ................................. .......................................... 2-3
Component Storage ..................................................................................... 2-4
GEARBOX ASSEMBLY ......................................................... ................... 2-4
MILLSIDE AND SEAL AIR HEADER ASSEMBLY .......... ........................... 2-4
SEPARATOR BODY ASSEMBLY ........................ ..................................... 2-4
JOURNAL ASSEMBLY ............................................................................. 2-4
JOURNAL OPENING COVER AND SPRING ASSEMBLY ....................... 2-5
SEPARATOR TOP ASSEMBLY ................................................................ 2-5
INNER CONE AND CERAMIC LINER ASSEMBLY ................................... 2-6
BOWL AND VANE WHEEL ASSEMBLY .... .............................................. 2-6
GEARBOX LUBRICATION UNIT, OIL COOLERS, GEAR BOX
ACCESSORIES, OIL HEATERS ............. ......................................... 2-6
MILL DISCHARGE VALVE AND MULTIPLE PORT
OUTLET ASSEMBLY ....................................................................... 2-6
CLASSIFIER ADJUSTING PLATFORM .................................................... 2-6
PYRITE HOPPER ..................................................................................... 2-6
SOLE PLATES AND MOUNTING PLATES ............................................... 2-7

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TABLE OF CONTENTS (Continued)

PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS PART 2

TITLE PAGE NO.

MISCELLANEOUS FASTENERS .............................................................. 2-7


SEAL AIR PIPING ............................................................. ........................ 2-7
CENTER FEED PIPE AND INVERTED CONE ....... .................................. 2-7
MILL MOTOR COUPLING AND COUPLING GUARD ................................ 2-7
LUBE OIL PIPING ..................................................................................... 2-7
SEAL AND GUARD, THERMOWELLS, BULL RING SHIMS .................... 2-7
DIFFERENTIAL PRESSURE CONTROLLER
AND MILL INSTRUMENTATION .............. ........................................ 2-7
SCRAPER AND GUARD ASSEMBLIES .................................................... 2-8
INNER CONE CERAMIC LINERS .................................. ........................... 2-8
ELECTRICAL EQUIPMENT ................................................................... ... 2-8
ADHESIVES,SEALANTS AND LUBRICANTS .................................... .... 2-8
OIL DIP STICK, SPRING PRELOADING COMPONENTS,
WRENCH AND TENSIONER, GRINDING ROLL REMOVAL FIXTURE,
GEARBOX REMOVAL RAIL ARRANGEMENT ............................. ... 2-8
BOWL HOISTING FIXURES, JOURNAL TILT-OUT COMPONENTS,
GEARBOX ALIGNMENT FIXTURES .. ........................................... 2-8

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HP1003 PULVERIZER - INSTALLATION
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PART 2 - PROTECTION AND
PRESERVATION OF
PULVERIZER COMPONENTS

INTRODUCTION

The pulverizer is too large to be shipped assembled. As a result, it is broken


down into many subassemblies and loose components. If pulverizer com-
ponents will require field storage (for up to two years), the following specifi-
cations should be followed.

The coatings, oils and plugs referred to in these procedures are initially
applied in the shop. They should be checked and maintained in the field as
required.

CAUTION: USE CARE WHEN HANDLING ASSEMBLIES WHICH


CONTAIN CERAMIC LINERS. THE LINERS MAY CRACK IF AN
ASSEMBLY IS HANDLED ROUGHLY

NOTE: Antirust or grease are used in many places for preservation.


These coatings must be maintained during the storage period. When
the component is being readied for assembly, the antirust/grease must
be removed with a petroleum based solvent.

NOTE: Plastic tapered plugs, plastic tapered caps, plastic pipe thread
protectors, plastic valve flange protectors and plastic web sleeving are
used in many locations. They are made of low density polyethyiene
unless otherwise specified.

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GENERAL STORAGE
REQUIREMENTS

Storage Types
Three types of storage must be employed when storing pulverizer
components.

STORAGE TYPE B

Store indoors within an insulated building, upon a concrete slab or metal


pallet shelving. The space shall include lighting and environ- mental
controls for heating.

STORAGE TYPE C

Store in weather-tight indoor areas with no provision for heating and


with natural lighting. Floors may be compacted earth. Material shall be
stacked off the floor upon dunnage with sufficient room for visual
inspection. Provision to add heating, if required, during certain periods
shall be included.

STORAGE TYPE E

Consists of field storage of components positioned on dunnage, so as to


provide for drainage, inspection and maintenance. Protective coatings,
seals and caps shall remain in placed and be maintained. Provisions to
add covering, when dictated by the local environment, shall be included.

Minimum Storage
Requirements
MAJOR SUBASSEMBLIES

The storage type for each of the normal major subassemblies is as


follows:
Storage Type
(Minimum)
1. Gear Box Assembly (Refer to Manufacturer's Instructions) C
2. Millside and Seal Air Header Assembly E
3. Separator Body Assembly E
4. Journal Assembly C
5. Journal Opening Cover and Spring Assembly C
6. Separator Top Assembly E
7. Inner Cone (and Ceramic Liner) Assembly E
8. Bowl and Vane Wheel Assembly E
9. Gear Box Lubrication Unit C
10. Mill Discharge Valve and Multiple Port Outlet Assembly C
11. Classifier Adjusting Platform E
12. Pyrite Hopper E

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BOXED OR BUNDLED ITEMS

The storage type for the following items, which may be bundled or boxed, is
as follows:
Storage Type
(Minimum)
13. Sole Plates, and Mounting Plates C
14. Miscellaneous Fasteners B
15. Seal Air Piping C
16. Center Feed Pipe E
17. Inverted Cone E
18. Mill Motor Coupling C
19. Motor Coupling Guard C
20. Lube Oil Piping C
21. Seal and Guard Assembly C
22. Thermowells C
23. Bull Ring Shims (extra) C
24. Differential Pressure Controller B
25. Mill Instrumentation B
26. Scraper and Guard Assemblies C
27. Gear Box Accessories C
28. Electrical Equipment B
29. Adhesives, Sealants and Lubricants B

TOOLS AND FIXTURES


Storage Type
(Minimum)
30. Oil Dip Stick B
31. Spring Preloading Components B
32. Wrench and Tensioner B
33. Grinding Roll Removal Fixture B
34. Gearbox Removal Rail Arrangement B
35. Bowl Hoisting Fixtures C
36. Journal Tilt-out Components C
37. Gearbox Alignment Fixtures C

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Component Storage

GEARBOX ASSEMBLY (Storage Type C)

The gear box assembly is to be placed on timbers and preserved as per


vendor's specifications. Refer to VENDOR'S MANUAL for detailed
instructions.

MILLSIDE AND SEAL AIR HEADER ASSEMBLY (Storage Type E)

Place the assembly on timbers. Coat all of the exposed machined surfaces.
including tramp iron spout flange, air inlet flange, millside access door
flanges, tapped and dowel pin holes with Cosmoline No. 1058. Plug all of the
tapped and dowel pin holes with tapered plugs.

SEPARATOR BODY ASSEMBLY (Storage Type E)

Place the assembly on timbers and orient it as if it is installed on the


pulverizer. Support must be to the lower flange, not the deflector liners which
protrudes below the lower flange. Coat all of the exposed machined surfaces,
including tapped holes and the access door flange faces with Cosmoline No.
1058. Plug all of the tapped holes with tapered plugs. Cap the pipe with a pipe
thread protector.

JOURNAL ASSEMBLY (Storage Type C)

Place the assembly vertically on timbers and stand on the base of the lower
journal housing. Check that each journal assembly is completely filled with the
recommended oil, see “HP PULVERIZER LUBRICANT SPECIFICATIONS”.
Check periodically for leakage at the oil seal. An oil-filled journal assembly is
permanently protected.

At three-month intervals, an oil sample should be taken from representative


journals. Run a 1/4" (6.35 mm) tube down the journal shaft until it bottoms on
the lower journal housing. Close the end of the tube to extract a column of oil.
If there is evidence of water, drain the oil and replace it with new oil. If
contamination is found in any one assembly, then all assemblies should be
inspected. After inspection, the journals should be refilled completely and
capped. At this time, all journal shafts should be turned one revolution.

Before any pulverizer is placed into service, the excess oil must be removed
from the journals (siphon or pump) and the correct level established per the
Pulverizer Lubrication Specifications in the Pulverizer Operations section of
this Instruction Manual.

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IF INSTALLED AND BEING STORED IN PULVERIZER

Though it is not the supplier’s recommendation to install and then store the
journals for an extended period it can be done. If the journals were left full of
oil there is a potential that the oil could leak out past the seals as the journals
are now in their operating orientation. Thus it is recommend that some of the
oil be drained out so the journals have oil at their operating level (which
means the level is lower than the seals).

On three month intervals all journals rolls should be rotated to re-coat the
bearings and check for any oil leaks. A sample of oil should be taken on one
journal in each mill and checked for water as noted below.

Note make sure that journal stop bolt is adjusted to raise rolls off the grinding
table -thus permitting the roll to be turned as well as not putting additional
weight on the gearbox thrust bearing.

JOURNAL OPENING COVER AND SPRING ASSEMBLY (Storage Type C)

Store the assembly on timbers with the face which mates with the separator
body pointing down. Coat all of the exposed machined surfaces, including
access cover faces with Cosmoline No. 1058. Coat the exposed portions of
the hydraulic cylinder retaining studs with Cosmoline and cover them with
Web Sleeving. Do not twist assembly during storage.

CAUTION: ENSURE THAT THE WEIGHT OF THE STACK DOES


NOT CAUSE ANY OF THE JOURNAL OPENING COVER TO BEND.

SEPARATOR TOP ASSEMBLY (Storage Type E)

Place the assembly on timbers with the Separator Top Assembly/Separator


Body Assembly flange pointing down. Coat all of the exposed machined
surfaces, including tapped holes with Cosmoline No. 1058. Plug all of the
tapped holes with tapered plugs. Liberally apply a general purpose grease to
the linkage which is located on the top of the assembly. Grease the pivot
points of the Deflector Shaft Assemblies. Securely cover the assembly with a
heavy gauge clear plastic to prevent rain from washing the grease off of the
linkage.

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HP1003 PULVERIZER - INSTALLATION
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INNER CONE AND CERAMIC LINER SSEMBLY (Storage Type E)

Place this assembly on timbers with the large diameter down. No other
preservation is required.

CAUTION: IF CERAMIC LINERS ARE INSTALLED, USE CAREIN


HANDLING TO PREVENT CRACKING LINERS.

BOWL AND VANE WHEEL ASSEMBLY (Storage Type E)

This assembly is to be placed on timbers and oriented as if it was installed


in the pulverizer. Coat the exposed machined surfaces including tapped
holes and dowel pin holes with Cosmoline No. 1058. Plug the tapped holes
with tapered plugs.

Build a wooden crib over the top of the bowl and cover the assembly with
clear heavy gauge plastic. Secure the plastic so that it will not fall off or be
blown away by the wind. The crib should be constructed so that any rain
which falls on top of the plastic will drain off the side of the assembly and
not be caught in the bowl.

GEARBOX LUBRICATION UNIT, OIL COOLERS, GEAR BOX ACCES-


SORIES. OIL HEATERS (Storage Type C)

The lubrication system must be placed on timbers or pallets. Refer to


VENDOR'S MANUAL for detailed instructions.

MILL DISCHARGE VALVE AND MULTIPLE PORT OUTLET


ASSEMBLY (Storage Type C)

Store the Discharge valve and multiple port outlet system on pallets or
metal shelving. Plug all open pipes with plastic plugs and install plastic
flange protectors of all flanges.

CLASSIFIER ADJUSTING PLATFORM (Storage Type E)

Place the assembly on timbers and orient as if it was installed on the


pulverizer.Do not twist assembly during storage.

PYRITE HOPPER (Storage Type E)

Place the assembly on timbers and orient as if it was installed on the


pulverizer.Do not twist assembly during storage.

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SOLE PLATES AND MOUNTING PLATES (Storage Type C)

Place the sole plates on timbers. They may be stacked no more than six (6)
high. Coat the machined surfaces, including tapped and dowel' pin holes with
Cosmoline No. 1058. Plug the tapped and reamed dowel pin holes with
tapered plugs.

CAUTION: ENSURE THAT THE WEIGHT OF THE STACK DOES


NOT CAUSE ANY OF THE PLATES TO BEND.

MISCELLANEOUS FASTENERS (Storage Type B)

Store these components on metal shelving. No other preservation is required.

SEAL AIR PIPING (Storage Type C)

Stack components on timbers or pallets. Seal the ends of the piping, hoses
and fittings which make up the system with the appropriate type of plug or
cap.

CENTER FEED PIPE AND INVERTED CONE (Storage Type E)

Place the components on timbers. Coat the machined flanges with Cosmoline
No. 1058. Coat bolt holes with grease.

MILL MOTOR COUPLING AND COUPLING GUARD (Storage Type C)

Store the coupling and coupling guard on metal shelving. Preserve per the
vendor's requirements.

LUBE OIL PIPING (Storage Type C)

Store the lube oil piping on pallets or metal shelving.

SEAL AND GUARD. THERMOWELLS. BULL RING SHIMS (Storage Type C)

Store these components on metal shelving. No other preservation is required.

DIFFERENTIAL PRESSURE CONTROLLER AND MILL


INSTRUMENTATION (Storage Type B)

Store these components on metal shelving. Plug all open pipes with plastic
plugs and install plastic flange protectors of all flanges.

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SCRAPER AND GUARD ASSEMBLIES (Storage Type C)

Store these components on metal shelving, timbers or pallets. Application of


general purpose grease to pivot pointswill ensure rust protection, but it must
be washed off with solvent prior to pulverizer start-up. Coat the exposed
machined surfaces including the tapped holes with Cosmoline No. 1058.

Plug all tapped holes with tapered plugs.

INNER CONE CERAMIC LINERS (Storage Type C)

When shipped separately, these components are to be stored on pallets or


metal shelving. No other preservation is required.

ELECTRICAL EQUIPMENT (Storage Type B)

Store these components on pallets or metal shelving. Plug all open pipes with
plastic plugs and install plastic flange protectors of all flanges.

ADHESIVES,SEALANTS AND LUBRICANTS (Storage Type B)

Store these components on pallets or metal shelving.

OIL DIP STICK, SPRING PRELOADING COMPONENTS,


WRENCH AND TENSIONER, GRINDING ROLL REMOVAL FIXTURE,
GEARBOX REMOVAL RAIL ARRANGEMENT (Storage Type B)

Store these components on metal shelving. Coat the exposed machined


surfaces including tapped holes with Cosmoline No. 1058. Plug and cap all of
the holes and ends of fittings with tapered caps.

BOWL HOISTING FIXTURES. JOURNAL TILT-OUT


COMPONENTS,GEARBOX ALIGNMENT FIXTURES (Storage Type C)

Store the components on pallets or metal shelves. Coat exposed machined


surfaces including any tapped holes with Cosmoline No. 1058. Plug all tapped
holes with tapered plugs.

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TABLE OF CONTENTS

INSTALLATION PROCEDURES PART 3

TITLE PAGE NO.

INTRODUCTION ..................................................................................... ........... 3-1


PULVERIZER COMPONENTS............................................................................. 3-2
SUB-ASSEMBLI ES .................................................................................. 3-2
LOOSE PARTS ......................................................................................... 3-2
TOOLS ...................................................................................................... 3-3
GENERAL ASSEMBLY ...................................................................................... 3-4
DETAILED ASSEMBLY PROCEDURE ............................................................... 3-5
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING ...... 3-5
Pulverizer .................................................................................................. 3-5
Motor ......................................................................................................... 3-6
GEARBOX ASSEMBLY INSTALLATION ....................................................... 3-7
MILLSIDE ASSEMBLY ................................................................................... 3-7
BOWL AND VANE WHEEL ASSEMBLY ....................................................... 3-8
SEPARATOR BODY ...................................................................................... 3-9
SEPARATOR TOP ASSEMBLY .................................................................. 3-10
INNER CONE AND CERAMIC LINER ASSEMBLY ...................................... 3-11
MILL DISCHARGE VALVES AND
MULTIPLE PORT OUTLET ASSEMBLY .................................................. 3-11
JOURNAL OPENING COVER AND SPRING ASSEMBLY ........................... 3-12
INNER AIR SEAL AND SCRAPER INSTALLATION .................................... 3-12
SECURING THE GEARBOX ....................................................................... 3-12
SEAL AND GUARD ASSEMBLY ................................................................. 3-13
PULVERIZER MOTOR, COUPLING AND GUARD ...................................... 3-13
JOURNAL INSTALLATION .......................................................................... 3-14
TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ................................... 3-15
DISCHARGE VALVE LIMIT SWITCH SET-UP ............................................ 3-16
CONTROLS ................................................................................................. 3-17
FINAL ADJUSTMENTS, JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE, JOURNAL SPRING POSITION ...... 3-17

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PART 3 - INSTALLATION
PROCEDURES

INTRODUCTION

Since the pulverizer described in this manual is too large to be shipped


assembled.These installation instructions provide a sequence for assembling
the normal subassemblies.

Special site conditions may allow for more or less subassembly of


components. All required fasteners, sealants and lubricants are shipped loose.

Pulverizers are frequently assembled in place early in the erection sequence,


sometimes prior to the erection of the building steel. It is recommended that
gearboxes, lubrication systems, journals and all controls be retained in
storage and be installed on the pulverizers just prior to [not more than six (6)
months before] unit commissioning.

CAUTION: TO PREVENT POSSIBLE EQUIPMENT FAILURES,


ENSURE THAT THE CORRECT BOLTS (LENGTH AND GRADE)
ARE USED IN PROPER LOCATIONS DURING THE ASSEMBLY
PROCEDURES. TORQUE ALL FASTENERS TO THE VALUES
INDICATED IN TEXT, ON DRAWINGS OR ON DRAWING B-GP-2175
LOCATED WITH THE TOOL DRAWINGS. BE SURE THAT THE
PROPER TYPE OF THREAD LUBRICANT, FOR EXAMPLE ANTI-
SEIZE COMPOUND OR LOCTITE, IS USED ON EACH FASTENER.
INFORMATION ON THE TYPE OF LUBRICANT TO BE USED IS
FOUND ON THE DRAWING WHERE THE FASTENER IS CALLED
OUT.

NOTE: As components are brought to the site for assembly the mating
machined surfaces must be cleaned and prepared for welding. Bolted
joints should be cleaned and greased or a light film of oil should be
applied.

WARNING: The application of rigging is the responsibility of the


erector or user. Exercise care when handling components to prevent
injury to personnel or damage to equipment. Lifting equipment, jacks,
cranes, chain falls, come-alongs, chain, and wire rope slings, etc. Must
be adequately sized to support the loads being lifted. The weight of
each component, which will be lifted, can be found in the Bill of
Materials on the contract drawings.

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PULVERIZER
COMPONENTS

SUB-ASSEMBLIES

The normal subassemblies are:

1. Millside and Seal Air Header Assembly.


2. Bowl and Vane Wheel Assembly.
3. Separator Body Assembly.
4. Inner Cone (and Ceramic Liner) Assembly.
5. Separator Top Assembly.
6. Journal Assembly.
7. Journal Opening Cover and Spring Assembly.
8. Gear Box Assembly.
9. Gearbox Lubrication System.
10. Mill Discharge Valve and Multiple Port Outlet Assembly.

CAUTION: MAJOR PULVERIZER COMPONENTS ARE KEYED OR


MATCH MARKED TO ENSURE PROPER ORIENTATION OF THE
AIR INLET, JOURNAL OPENINGS AND FUEL PIPES. EACH
COMPONENT lS IDENTIFIEDWITH A SERIAL NUMBER TAG. USE
CARE TO INSTALLTHE CORRECT SERIAL NUMBERED
PULVERIZER AND ITS COMPONENTS AT THE LOCATION
INDICATED ON THE CONTRACT DRAWINGS.

LOOSE PARTS

The following items may be bundled or boxed and are normally shipped
unassembled:

1. Sole Plates and Mounting Plates


2. Miscellaneous Fasteners
3. Center Feed Pipe
4. Mill Motor Coupling and Coupling Guard
5. Lube Oil Piping
6. Seal Air Piping
7. Journal Shaft liner
8. Pulverizer Instrumentation
9. Mill Adhesives and Sealants (Loctite, Anti-Seize Compound, etc.)
10. Inner Cone Support Pipes

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TOOLS
1. Bowl hoisting tools
2. Gearbox alignment tools.
3. Gearbox removal rail kit.
4. Hydraulic stud tensioner (bowl/gearbox).
5. Journal tilt-out components.
6. Journal spring preload procedure.
7. Oil dipstick (for journals).
8. Grinding Roll Removal Application
9. Journal Limited Spanner

As components are brought to the site for assembly their mating machined
surfaces must be cleaned and a light film of oil should be applied. Unless
instructed otherwise, bolts and nuts, cap screws, and studs should be
lubricated and tightened securely per B-GP-2175 (Refer to tool drawings).

those fasteners which must meet special tighten ing requirements are
identified on the engineering drawings and in the text.

CAUTION: TORQUE VALUES SPECIFIED ON ENGINEERING


DRAWINGS AND IN THE TEXT SHOULD NOT BE EXCEEDED.

WARNING: THE APPLICATION OF RIGGING IS THE


RESPONSIBILITY OF THE USER. CARE MUST BE USED WHEN
HANDLING COMPONENTS TO PREVENT INJURY TO PERSONNEL
OR DAMAGE TO EQUIPMENT. LIFTING EQUIPMENT, CRANES,
CHAIN FALLS, COME ALONGS, CHAIN AND WIRE ROPE SLINGS,
ETC. MUST BE ADEQUATELY SIZED TO SUPPORT THE LOADS
BEING LIFTED.

Drawings dealing with the following equipment and procedures are included
with the Tool Drawings. Tools to perform these procedures may not be
supplied.

1. Gear Box Removal Rail Arrangement.


2. Journal Bearing End Play Arrangement.
3. Journal Grinding Roll Removal Application.
4. Sole Plate Stud Tensioning.

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GENERAL ASSEMBLY

The installation sequence assumes a normal stack up of the preassembled


pulverizer components on a prepared foundation. Detailed assembly
recommendations follow this General Assembly.

CAUTION: MAJOR PULVERIZER COMPONENTS ARE KEYED TO


ENSURE PROPER ORIENTATION OF THE AIR INLET, JOURNAL
OPENINGS AND FUEL PIPES. EACH MAJOR COMPONENT HAS A
TAG WITH THE PULVERIZER SERIAL NUMBER. USE CARE TO
ENSURE THAT THE CORRECT SERIAL NUMBERED PULVERIZER
AND ITS COMPONENTS ARE INSTALLED AT THE LOCATION
INDICATED ON THE CONTRACT DRAWING K7038.00.

It is presumed that major pulverizer components will be "stacked up" and


protected while the balance of the plant is erected around them. Then four to
six months before unit start-up, just prior to unit/equipment commissioning,
the remaining components will be installed.

1. Install and grout the gearbox sole plates and millside mounting plates.
2. Install the gearbox.
3. Install millside and seal air header assembly.
4. Place scrapers in the millside (DO NOT remove preservative coatings).
5. Place the bowl and vane wheel assembly inside the millside and on the
gearbox.
6. Install the separator body assembly.
7. Place the inner cone and ceramic liners inside the separator body.
NOTE: Inner cone liners may be installed on the inner cone before it is
placed in the separator body. If this is done use care in handling the
inner cone and liner assembly to prevent breakage of the liners.

8. Slide the inverted cone up the center feed pipe. Secure the cone
temporarily with the set screws.
9. Install the separator top, inner cone and center feed pipe.
10. Assemble the mill discharge valves and multiport outlet on separator top.
11. Assemble the inner cone to the classifier drum.
12. Install the planetary gearbox lubrication system.
13. Install pulverizer motor, check rotation, assemble coupling.
14. Install the seal and scrapers.
15. Install journal assembly.
16. Install journal opening cover and spring assembly with stop bolt.
17. Install the seal air piping.
18. Install the mill instrumentation.

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19. Set-up the mill including the spring preload, ring to roll gap and spring
assembly to journal gap.
20. Flush the planetary gearbox and lubrication system.
21. Commission the mill.

DETAILED ASSEMBLY
PROCEDURE

SOLE PLATE AND


MOUNTING PLATE
ALIGNMENT AND
GROUTING

Pulverizer

NOTE: The following steps refer to Drawings K7038.00 unless other Stated.

1. Prepare the foundation for grouting.

WARNING: THE GEARBOX SOLE PLATE WEIGHS


APPROXIMATELY 2760kg THE MOUNTING PLATES
APPROXIMATELY 1363 Kg EACH ALL MUST BE ADEQUATELY
RIGGED TO ENSURE SAFE HANDLING.

2. Degrease and sandblast the surfaces of the gear box sole plate, millside
mounting plate (fixed) and millside mounting plate (sliding) which will
contact the grout.

3. Plug all of the tapped and dowel pin holes through the machined surfaces
of the gearbox sole plate, millside mounting plate (fixed) and millside
mounting plate (sliding), so that when they are grouted the grout will not
plug the holes.

4. Settle gearbox sole plate on the foundation. Use shims to set the
elevation.

5. Install the four hex nuts with washers on the sole plate anchor bolts (hand
tight with anti- seize compound or light oil).

6. Position the gearbox sole plate,refer to drawing K7038.00.

7. Level and flatten the gearbox sole plate by adding and/or subtracting
shims and snugging the anchor bolt nuts. There is a region of the
gearbox sole plate that is under cut, neglect this region. The plate should
be level within 0.015 in. (0.38 mm) and flat within 0.005 in (0.127 mm).

8. Grout the gearbox sole plate. Be sure that there are no air Pockets in
the grout and that the region around the outside diameter of each
anchor bolt cup is full of grout.

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9. After the grout has cured, ensure that all holes through the sole Plate are
cleaned of grout. Tension the anchor bolts to the value specified on the
Foundation Loads drawing K7038.00 using a hydraulic stud tensioner.

WARNING: THE MOUNTING PLATES WEIGH APPROXIMATELY


1363 KG EACH, BOTH MUST BE ADEQUATELY RIGGED TO
ENSURE SAFE HANDLING.

NOTE: The fixed mounting plate with the round dowel pin hole should be
located on the south foundation pier (to the left side of the motor when facing
the pulverizer).

10. Place the two millside mounting plates on the foundations, use shims to
set the elevation, refer to drawing K7038.00 .

11. Align the mounting plate with the sole plate as follows (refer to drawing
K7038.00);

a.) Lines through reference points A-B on the sole plate, and through
points E-F and J-K on the mounting plates must be collinear within
0.030 in. (0.76 mm).

b.) Lines through reference points C-D on the sole plate and through
points G-H and L-M on the mounting plates must be parallel within
0.030 in. (0.76 mm).

12. Mounting plate surfaces to be aligned within 0.005 in. (0.127 mm) and
parallel to the sole plate surface within 0.010 in. (0.254 mm).

13. Grout the two millside mounting plates. Be sure that there are no air
pockets in the grout and that the region around the outside of each
anchor bolt cup is full of grout.

14. After the grout has cured, remove the nuts and washers from the mounting
plate anchor bolts. Ensure that all of the through holes in the mounting
plates are opened up and cleaned out.

15. Clean the top surfaces of the gearbox sole plate and mounting plates so
that they are free of any rust, grout, or any other contaminates. Apply a
light coat of oil to prevent future rusting.

Motor

The motor sole plates should be installed similarly to the pulverizer sole plates.
But, as the motor, motor sole plate and its anchor bolts are not in supply
scope of SHMP, the detailed installation procedure please refer to the
demand of manufacturer.

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GEARBOX ASSEMBLY
INSTALLATION

Reference drawing and the gearbox vendor's instruction manual for detailed
preparation and handling.

WARNING: THE PULVERIZER GEARBOX WEIGHS


APPROXIMATELY 14086 kg (WITHOUT OIL) AND MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

Using the lifting instructions provided by the planetary gearbox supplier, set
the planetary gearbox on its sole plate and secure it with fasteners. Finger
tight, do not torque these fasteners at this time. Be sure that the input shaft is
pointing towards the motor.

NOTE: If the gearbox is delayed to deliver to site due to its


correspondingly long manufacturing cycle, it is recommended to install
other assemblies first. The installation of gearbox can refer to its
reassembly procedure and per drawing KF7006.7.0.

MILLSIDE AND LINER


ASSEMBLY

NOTE: The following steps refer to drawings K7038.5.0 unless


otherwise stated.

CAUTION: TO ENSURE THAT THE AIR SEAL RING INNER SEGMENTS


ARE NOT DAMAGED DURING THE ERECTION OF THE PULVERIZER,
THEY SHOULD BE REMOVED FROM THE MILLSIDE AND STORED WITH
OTHER LOOSE COMPONENTS. MARK THEM ADEQUATELY TO ENSURE
THAT THEY WILL BE REINSTALLED IN THE PULVERIZER FROM WHICH
THEY WERE REMOVED.

CAUTION: THE MILLSIDE ASSEMBLY WEIGHS APPROXIMATELY


15537kg AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

1. Remove the millside assembly from its shipping rig and clean the bottom
surface of its feet.

CAUTION: MAJOR PULVERIZER COMPONENTS ARE KEYED TO


ENSURE PROPER ORIENTATION OF THE AIR INLET, JOURNAL
OPENINGS AND FUEL PIPES. EACH COM-PONENT HAS A TAG
WITH THE PULVERIZER SERIAL NUMBER. USE CARE TO
ENSURE THAT THE COR-RECT SERIAL NUMBERED PULVERIZER
AND ITS COMPONENTS ARE INSTALLED AT THE LOCATION
INDICATED ON THE CONTRACT DRAWING K7038.00.

2. Apply a very thin coat of light oil or anti-seize compound to the


top sur-face of the millside mounting plates.

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3. Fill the slot in the millside mounting plate (sliding) approximately 1/3 full
with a general purpose grease.

4. Remove the two pipe plugs from the half couplings which are on the
millside feet.

5. Grease a dowel pin with general purpose grease and install it in the dowel
pin hole on the fixed millside mounting plate. The pin should be inserted
approximately half of its length.

6. Ensure appropriate rigging, hoist the millside assembly over the


foundation and lower it onto the millside mounting plates. The fixed dowel
pin should engage the hole in the millside foot. This should locate the air
inlet according to the information on the contract Bowl Mill Arrangement
drawing K7038.00 .

7. Pivot the millside around the fixed dowel pin until a second dowel pin can
be installed through the hole in the other millside foot into the slot in the
sliding mounting plate.

8. Reinstall the two pipe plugs into the half coupling on the millside feet.

9. Install the anchor bolt nuts with washers. Use light oil on the threads.

10. Tension the millside anchor bolts to the value specified on the pulverizer
foundation drawing K7038.00 using a hydraulic stud tesioner.

11. Place the scraperassemblies in the millside. DO NOT remove their


preservative coatings at this time.

BOWL AND VANE


WHEEL ASSEMBLY

NOTE: The following steps refer to Drawings K7006.9.0 unless


otherwise stated.

CAUTION: THE BOWL AND VANE WHEEL ASSEMBLY WEIGHS


APPROXIMATELY 14555kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

1. Check the top of the planetary gearbox and verify that the two drive dowel
pins are installed as per the planetary gearbox assembly drawing.

2. Install the supplied bowl hub lifting lugs (per drawing KF7006.8.0) on the
bowl and vane wheel assembly at 120˚ intervals. This will require that 6
(2 at each location) bowl extension ring to bowl fasteners be temporarily
removed. Rig and hoist the bowl and vane wheel assembly into the
millside and onto the gearbox. Be sure that the bowl hub is resting firmly
on top of the gearbox and on top of both the dowel pins (one dowel pin is
offset).

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3. Install the studs and nuts and preload the studs as per the procedure on
drawing K7038.00 note8. Remove the bowl lifting lugs. Reinstall the 6
bowl extension ring to bowl washers and fasteners which were removed
and torque them (Loctite must be used). Note after installing the last
bowl and vane wheel assembly the lifting lugs and fasteners are to be
repackaged and stored in the mill maintenance tools box.

SEPARATOR BODY
ASSEMBLY

NOTE: The following steps refer to drawings K7006.8.0(A) unless


otherwise stated.

CAUTION: THE SEPARATOR BODY ASSEMBLY WEIGHS


APPROXIMATELY 18011kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING

1. Remove the separator body assembly from its shipping rig and place it on
blocks with the bottom flange down. Be sure that the separator body is
resting on its flange, not the deflector liners. Clean the top flange of the
millside and bottom flange of the separator body (including the tapped
and clearance holes).

CAUTION: MAJOR PULVERIZER COMPONENTS ARE KEYED TO


ENSURE PROPER ORIENTATION OF THE AIR INLET. JOURNAL
OPENINGS AND FUEL PIPES. EACH COMPONENT HAS A TAG
WITH THE PULVERIZER SERIAL NUMBER. USE CARE TO
ENSURE THAT THE CORRECT SERIAL NUMBERED PULVERIZER
AND ITS COMPONENTS ARE INSTALLED AT THE LOCATION
INDICATED ON THE CONTRACT DRAWING K7038.00 .

NOTE: Match the mating flanges of the separator body and millside to
ensure proper component alignment.

2. Apply a light coat of high temperature anti-seize compound to the millside


flange and the bottom flange of the separator body. Rig and lift the
separator body assembly into position on the millside. Center the
separator body on the millside.

3. Bolt the separator body to the millside with hex head cap screws using
Fel-Pro C5-A anti-seize com pound (or equal) and torque the fasteners to
the value specified on B-GP-2175.

4. Place the inner cone assembly inside the separator body assembly.
Support it approximately vertical with the small diameter down. Ensure
that the cone access door opening is in line with a separator body access
door.

WARNING: THE INNER CONE WITH LINERS WEIGHS


APPROXIMATELY 3100 kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

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NOTE: Tne ceramic liners may be installed in the inner cone before it
is placed in the separator body. Refer to "HP Pulverizer Maintenance
Procedures", Pulverizer Component Servicing. Use care in handling
the lined cone to prevent liner breakage

WARNING: SUPPORTS MUST ENSURE THAT THE CONE IS


STABLE AND IT IS SAFE FOR WORK TO BE PERFORMED INSIDE
THE CONE.

5. Install the inverted cone on the center feed pipe, small end up.

SEPARATOR TOP
ASSEMBLY

WARNING: THE SEPARATOR TOP ASSEMBLY WEIGHS


APPROXIMATELY 18069 kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

1. Remove the separator top assembly from its shipping rig. Clean the top
flange of the separator body and bottom flange of the separator top as-
sembly including the tapped and clearance holes. Refer to K7038.7.0.

CAUTION: MAJOR PULVERIZER COMPONENTS ARE KEYED TO


ENSURE PROPER ORIENTATION OF THE AIR INLET. JOURNAL
OPENINGS AND FUEL PIPES. EACH COMPONENT HAS A TAG
WITH THE PULVERIZER SERIAL NUMBER. USE CARE TO
ENSURE THAT THE CORRECT SERIAL NUMBERED PULVERIZER
AND ITS COMPONENTS ARE INSTALLED AT THE LOCATION
INDICATED ON THE CONTRACT DRAWING K7038.00 .

NOTE: One smaller diameter hole, between two larger holes in the
separator top flange, keys the separator top to the separator body.
This hole fits over a hex socket head cap screw located in the
separator body flange at the centerline of journal number one.

2. Insert the hex socket head cap screw which aligns the separator top to the
separator body at the center line of journal number one.

3. Apply a light coat of high temperature anti-seize compound to the top


flange of the separator body.

4. Lift the separator top into position on the separator body, use the small
hex socket head cap screw to assure proper orientation.

5. Bolt the separator top to the separator body with hex head cap screws.
Use Fel-Pro C5-A anti-seize compound (or equal) and torque the
fasteners per B-GP-2175.

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INNER CONE AND
CERAMIC LINER
ASSEMBLY

If not previously done, install the ceramic liners in the inner cone.

WARNING: THE INNER CONE WITH LINERS WEIGHS


APPROXIMATELY 3100 kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

1. Lift the inner cone up to the inner cone drum section. Ensure that the cone
access door is in line with a separator body access door then install hex
head cap screws, plain washers and nuts. Torque per B-GP-2175.

2. Install the inner cone pipe supports

3. The clearance between the inner cone and center feed pipe should be
checked. The perpendicular distance between the inner cone liners and
pipe should be 114 mm.

4. The inverted cone should be moved down the center feed pipe to obtain a
clearance of 76 mm measured perpendicular to the inner cone liners. Set
screws will hold the inverted cone in position for initial operation. After
coal fineness tests have confirmed that the adjustment is correct, weld
the inverted cone to the feed pipe.

MiLL DISCHARGE VALVES


AND MULTIPLE PORT
OUTLET ASSEMBLY

NOTE: Reference drawings K7038.9.0 .unless otherwise stated.

WARNING: THE PULVERIZER DISCHARGE VALVES AND


MULTIPLE PORT OUTLET ASSEMBLY WEIGHS APPROXIMATELY
2612kg AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

1. Clean the entire bottom surface of discharge valves including the


clearance and tapped holes.

NOTE: Hex head cap screws hold the discharge valve assembly to the
separator top. A scribe line between valves should be used to assure proper
alignment.

2. Clean the top flange of the separator top including the tapped holes. Apply
a light coat of high temperature anti-seize compound to the flange. Lift
the discharge valve assembly onto the separator top.

3. Bolt the mill discharge valve, multiple port outlet assembly to the
separator top with hex head cap screws, torque per B-GP-2175

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JOURNAL OPENNING
COVER AND
SPRING ASSEMBLY

WARNING: THE JOURNAL OPENING COVER AND SPRING


ASSEMBLY WEIGHS APPROXIMATELY 3537kg AND MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

1. Clean mating surfaces of the separator body and the journal opening
cover assemblies.

2. Coat these surfaces with a light coat of high temperature anti-seize


compound.

3. Temporarily install the journal opening covers, secure with hex head cap
screws.

At this point, the major components of the pulverizer, except the journals,
gearbox lubrication system and motor, have been erected on the foundation.
Additional assembly and set up of components will depend upon their
availability. It is recommended that all openings on the pulverizer, pulverizer
discharge valves and feed pipe be covered with waterproof protective
coverings (plywood sheets and plastic film) and the balance of pulverizer
erection/installation be delayed until approximately six months before start up,
nearer to unit commissioning.

INNER AIR SEAL AND


SCRAPER INSTALLATION

1. Reassemble the inner air seal ring in the same order that it was removed.
Verify clearance of 0.5mm±0.25mm between inner air seal ring and
bowl. Apply RTV-106 to the joints. Apply antiseize compound to the
fasteners and torque per B-GP-2175.

2. Attach the scraper assemblies to the bowl. Verify clearance of 8mm±


1.5mm between the scraper and the mill bottom cover plates. Torque hex
socket head cap screws to 136 ft .lb. (184 Nm).

SECURING THE
GEARBOX

The gearbox can be secured to the sole plate only after the inner air seal
clearance has been set and confirmed.

1. The fasteners holding the gearbox to the sole plate were installed hand
tight in the "Gearbox Assembly Installation" procedure. Torque per B-GP-
2175.

2. Mount a drilling rig above each dowel pin hole in the gearbox assembly
mounting flange. Using theφ34 mm diameter holes in the gearbox flange
as pilots, drill and ream two holes into the sole plate to the diameter of
φ40mmH7.

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3. Lubricate the dowel pins with Molycote GN-Paste, or an equivalent, and
press fit into the gearbox/sole plate.

4. Remove the gearbox adjustment blocks.

SEAL AND GUARD


ASSEMBLY

NOTE:The seal and guard assembly can be installed any time after
the pulverizer is erected and the lubrication oil system is available or
the oil supply in the upper gearbox reservoir allows the gearbox input
shaft to be turned by hand. But the seal ring should be installed before
the gearbox installation.

NOTE:The following steps refer to drawings K7006.10.0 .

1. Adjust the seal ring to ensure that the gap between its dimension φ1350
and bowl is uniform.

2. Apply studs with sealant Loctite and tighten them. Fix packing gland
around the bowl per matching mark.

3. Put the packing into the seal ring, tighten nuts and press packing with
packing gland.

4. Install sharp pointed pins.

PULVERIZER MOTOR
COUPLING AND GUARD

The pulverizer motor may be set in place on its sole plate after the sole plate
is installed. When the gearbox has been secured, the installation of the
pulverizer motor, coupling and guard can be completed.

NOTE:Refer to motor manufacturer's instructions for their mounting


recommendations.

NOTE:The following steps refer to K7038.00 unless otherwise stated.

1. Place the pulverizer motor on the motor sole plate. Using steel shims
near each of the four corners of the motor, level the motor, and align the
coupling. Reference coupling manufacturer's alignment procedures.
Place a machinist’s level on machined motor surfaces in several places.
Check the levelness in two directions 90° apart, until the motor is level in
every position checked. If motor shim requirement is greater than 0.25 in
(6.35 mm), reshim the motor sole plate.

2. Make the angular alignment of the motor and the shafts as close as
possible. Offset in both the vertical and horizontal directions should be
within 0.005 in. (0.127 mm) total indicator reading.

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3. Grout the motor sole plate. Make sure grout hugs the bottom of the sole
plate and fills any keying openings.

4. When grout has cured, proceed with mill to motor coupling alignment.

5. Check motor rotation before assembling the coupling.

NOTE : The coupling halves are rigid, therefore it is necessary to


move the motor to obtain the required clearance between the coupling
flanges. and when properly aligned the radial faces of the coupling will
be parallel. Refer to manufacturer's instructions for explicit coupling
alignment instructions.

6. Measure the clearance between the coupling flanges using a dial


indicator. Check maximum angular runout and maximum clearance. Use
additional shims under the motor as required.

7. Anchor the motor and recheck the alignment.

8. Recheck the clearance between the coupling flanges to insure that no


change has occurred then dowel the motor to its sole plate.

9. Install the coupling guard.

JOURNAL
INSTALLATION

The journal assemblies may be installed in the pulverizer as assemblies or as


components, that is journal head, trunnion assembly and journal shaft
assembly, the descriptions below deal with the installation of the journal
assembly. And the installation procedure of journal head, trunnion assembly
and journal shaft assembly please refer to general reassembly in HP
pulverizer maintenance.

NOTE : Each journal assembly, K7006 ( A ) .12.0, is supplied as


three subassemblies and several loose parts with attaching hardware.

For tools and components used in this procedures refer to drawings


K7006(A).12.0, KF7006.4.0, K7006.8.0(A).

WARNING: An overhead crane must support the journal components


at all times during the installation procedure.

WARNING: The journal assembly approximately weighs 7362kg and


must be adequately rigged to ensure safe handling.

1. Remove the journal opening cover from the separator body.

2. Remove the thrust plates, fasteners and pipe nipple from the separator
body.

3. Pull the trunnion shafts out approximately 1.38”(35mm). Do not exceed


1.50”(38.1mm).

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WARNING: Trunnion shafts weigh approximately 148kg each and


must be adequately rigged to ensure safe handling.

4. Temporarily install the safety bracket (according to drawing KF7006)


using fasteners.

5. Lift the journal assembly and install it in the separator body. The large
arm of journal head should be pointing down and be outside the journal
opening frame as depicted on drawing KF7006.4.0. Slide the trunnion
shafts in and engage the pilots with the journal head. Be sure that they
are fully seated and not riding up on the jack screws. Fasten, finger tight
at this point, the trunnion shafts to the journal head.

6. Fasten the journal assembly to the safety bracket with fasteners.

7. Remove the rigging holding the journal assembly.

8. Torque the journal head to trunnion shaft fasteners using the supplied
torque wrench to the value shown on drawing K7038.00.

9. Grease the thrust plate faces, reinstall them with fasteners and pipe
nipple removed previously from the separator body.

10. Center the journal tilt-out bracket assembly on the journal opening frame,
and secure it with fasteners. Install lug, shackle and wire rope cable.

11. Tilt in the journal assembly using the Journal Tilt-In Procedure.

TRUNNION SHAFT,
JOURNAL SPRING
SEAL AIR

After the pulverizer has been erected, the journals and journal spring
assemblies are in place the balance of the seal air piping can be installed. The
seal air piping consists of the seal air header which is supplied with the
millside and the individual piping runs that go to the trunnion shafts and the
journal springs. The piping to the bowl hub is built into the millside.

NOTE : The following steps refer to drawings K7038.8.0 . unless


otherwise stated.

NOTE : All pipe supports will be cut to length and welded to the
separator body at assembly. All pipes must be cut to length and
threaded as required at assembly.

CAUTION: TO PREVENT DAMAGE TO BEARINGS, ETC. GROUND


THE WELDING MACHINE DIRECTLY TO THE MILLSIDE OR
SEPARATOR BODY NEAR THE WELD BEING MADE WHEN
INSTALLING BRACKETS.

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NOTE:Pipe sealant with teflon must be applied to all pipe threads at


assembly.

1. Cut, thread and clean the pipe as necessary and assemble the rigid
sections of the seal air piping for the trunnion shafts, and journal springs
startin at the millside seal air header. Be sure to apply thread sealant to
all the pipe threads.

2. Locate the pipe supports for the rigid piping and weld to the separator
body.

3. Secure the seal air piping to the pipe supports with U-bolts. Tack weld the
U-bolt hex nuts.

4. Assembly the flex hoses, elbows and unions to each of the journal spring
housings. Note that one pipe plug on each housing remains in place.

5. Connect the seal air header to the seal air system, install controls as
required.

DISCHARGE VALVE
LIMIT SWITCH SET-UP

The discharge valve limit switches are installed and set up in the shop. If after
the discharge valves are installed the set up does not function properly, check
the switches as follows:

NOTE : The following steps refer to drawing K7038.9.0 unless


otherwise stated. Air pressure to the valve operating cylinders is
required.

1. With both limit switches finger tight on the mounting bracket and the
valve in the closed position, set angle "A" on the open limit switch to 90º
±4°.

2. Open the valves and adjust the open limit switch by moving it vertically
until angle “B”is 70°,+0°,-5°.Secure the open limit switch. Set
angle “C”to 10°±3°.

CAUTION: DO NOT FORCE THE LIMIT SWITCH.

3. Close the valves (must be 100% tight against the valve seat). Place a
small piece of 12 gauge shim material between the limit switch trip stud
and the limit switch operating lever of the closed limit switch(gap “D”).
Slide the closed limit switch as far to the right as possible, to the end of
the operating lever travel.

4. Secure the closed limit switch. Remove the shim.

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CONTROLS

1. Install the remaining temperature, pressure, differential pressure, etc.,


controls to the mill.

2. Check the control systems and verify that they are functioning properly.

FINAL ADJUSTMENTS,
JOURNAL SPRING
PRELOADING PROCEDURE,
JOURNAL ROLL-RING
CLEARANCE,
JOURNAL SPRING POSITION

When the pulverizer can be run, that is the pulverizer lubricating systems are
installed and operational, motor wired and checked for rotation and pulverizer
controls installed and checked out, then the final adjustments prior to actual
operation can be performed.

CAUTION: AFTER ADJUSTMENTS ARE COMPLETED ENSURE


THAT ALL TOOLS AND DEBRIS HAVE BEEN REMOVED FROM
INSIDE THE PULVERIZER.

1. Set the journal spring proload at all three journals. Reference procedures
in HP PULVERIZER - MAINTENANCE, Section 4, MAJOR
ADJUSTMENTS, Journal Spring Proloading Procedure.

2. Set the journal roll to bowl ring clearance at all three journals. Reference
procedures in HP PULVERIZER - MAINTENANCE, Section 4, MAJOR
ADJUSTMENTS, Journal Roll- Ring Clearance, steps 1 through 8.

3. Set the clearance between the journal spring stud insert and the journal
head insert at all three journals. Reference procedures in HP
PULVERIZER - MAINTENANCE, Section 4, MAJOR ADJUSTMENTS,
Journal Spring Position, steps 1 through 8.

4. Remove all tools and debris from the pulverizer.

5. Close and secure all access doors.

6. Refer to HP PULVERIZER - OPERATION.

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TABLE OF CONTENTS

PRINCIPLES OF OPERATION PART 1

GENERAL .......................................................................................................... 1-1


IMPROPER PULVERIZER OPERATION ........................................................... 1-3

PULVERIZER OPERATING PROCEDURES PART 2

INITIAL START-UP ............................................................................................ 2-1


NORMAL SHUTDOWN ...................................................................................... 2-2
EMERGENCY SHUTDOWN ............................................................................... 2-4
START-UP AFTER EMERGENCY SHUTDOWN ............................................... 2-5
PULVERIZER FIRES . ........................................................................................ 2-5
COAL PULVERIZER FIRE FIGHTING PROCEDURE . ....................................... 2-7
PULVERIZER TROUBLESHOOTING (TABLE 2-1) ......................................... 2-10

LUBRICATION SYSTEMS PART 3

SYSTEM DESCRIPTIONS ................................................................................. 3-1


Journal Lube Systems ............................................................................ 3-1
Gearbox Lube System ................................................................................ 3-1
GEARBOX LUBE SYSTEM OPERATION ............................................................ 3-5
Start-up ....................................................................................................... 3-5
Shutdown . ................................................................................................... 3-5

PULVERIZED COAL FINENESS ADJUSTMENT AND TESTING PART 4

ADJUSTMENT OF FINENESS .......................................................................... 4- 1


PULVERIZED COAL FINENESS TESTING ...................................................... 4- 2
Location .................................................................................................. 4- 2
Pulverizer Loading ................................................................................. 4- 2
Equipment ............................................................................................... 4- 2
Taking a Pulverized Coal Sample .......................................................... 4- 3
Sieving ..................................................................................................... 4- 4

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TABLE OF CONTENTS

PRINCIPLES OF OPERATION PART 1

TITLE PAGE NO.

GENERAL .......................................................................................................... 1-1


IMPROPER PULVERIZER OPERATION ........................................................... 1-3

________________________________________________________

LIST OF FGURES

TITLE FIGURE NO.

HP Pulverizer .................................................................................................... 1-1


HP pulverizer Coal and Air Flow ........................................................................ 1-2

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PART1-PRINCIPLES OF
OPERATION

GENERNAL

SHMP HP pulverizers are used in central power stations to reduce the size of
the incoming raw coal to a fineness that will efficiently burn in a furnace.

The maximum capacity of a pulverizer is dependent on the following:

1. Pulverizer size

2. Raw coal properties - Hardgrove index and moisture level

3. Pulverized coal fineness - % thru 200 mesh.

The raw coal (≤1-1/2″dia.) is fed Into a rotating bowl via a center feed pipe
(ref er to Figure 1-1 ). The rate of coal feed is normally determined
automatically by a combustion control system, taking into account the MW
demand on the unit, coal quality, and the number of pulverizers in service.
Centrifugal force causes the coal in the bowl to move radially outward,
building up a bed of coal on the grinding ring.

The bed of coal passes under pivoted grinding assemblies called journals.
Here, spring produced loads are imparted to the coal by the rotating rolls. Size
reduction takes place in the localized area between the grinding ring (called
the bullring) and journal roll through a process know as attrition or friction
grinding. The radial and circumferential movement of the coal carries the
crushed coal up over the edge of the bowl into the path of a transport medium.

The transport medium, typically hot air, has three primary functions:

1. It supplies the dynamics necessary within the pulverizer to classify the


coal (control coal fineness).

2. The heated air aids the grinding process by partially drying the coal as it
is reduced in size.

3. It is responsible for transporting the pulverized coal from the pulverizer to


the furnace.

As the coal is continuously reduced in size, the smaller/lighter particles are


swept from the bowl by the gaseous transport medium, hot air.

Transport air is normally supplied by primary air (P.A.) fans located up stream
of the pulverizers. However, In some cases it is provided by individual
exhausters located downstream of the pulverizers. In both systems, the air
is admitted below the pulverizer bowl into an area known as the millside.
The millside is at a positive gauge pressure if the transport air is supplied
by a P.A. fan or at a negative gauge pressure if the transport air is supplied
by an exhauster.

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From the millside, the air flows upward around the outside diameter of the
rotating bowl. Vanes attached to the bowl (called the vane wheel) change the
air flow to a vertical direction. The smaller/lighter particles of coal at the edge
of the bowl are carried upwards in the air steam, dense, difficult to grind
foreign material falls through the air stream into the millside.

Above the bowl, the lighter airborne coal particles undergo a two-stage
classification process (refer to Figure 1-2).

1. The first stage of classification takes place just above bowl level.
Stationary air deflectors mounted on the separator body cause the
heaviest coal particles to abruptly change direction, they loose
momentum and are returned directly to the bowl for further size reduction.

2. The lighter particles are carried by the transport medium to the separator
top where the second stage of classification occurs. Here curved
adjustable vanes (deflector blades) impart a cyclonic motion to the
coal/air mixture again causing the heavier particles to lose momentum
and fall out of the air stream, and the desired fineness level is achieved.

The heavier coal particles separated by the deflector blades return to the mill
bowl grinding zone by sliding down the inside of the inner cone.The cone
separates the pulverizer's “turbulent” flow area from the classified particles.
The absence of turbulence in this area allows gravity to return these particles
to the bowl.

An inverted cone is positioned inside of the inner cone to reduce the velocity
of the transport medium entering the inner cone through .the cone spout and
ensure that the heavier coal particles are not prevented from returning to the
bowl.

The exiting coal/air mixture passes through a venturi where the mixture is first
concentrated, and then expanded to obtain an even coal/air distribution in
each fuel pipe. The fuel piping carries the coal/air mixture to the furnace ,
where the combustion process takes place.

The difficult to grind foreign material which falls through the air stream into the
mil/side is moved by scraper assemblies, attached to the bowl hub skirt to
anopening in the millside floor. The rejected foreign material enters the pyrite
system.

The reject material usually consists of rock found as over or under burden in
the coal seam and/or parts of the machinery used in the mining or coal
processing operations. It is io the users advantage to minimize the quantity of
this type of material entering the pulverizer.

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IMPROPER PULVERIZER
OPERATION
There are both correct and incorrect ways to operate a pulverizer. Listed
below are incorrect and hazardous operating conditions which should be
avoided.

1. Excessive coal spillage - this is a hazardous situation, coal can plug the
pyrites discharge chute thus allowing a coal build up in the millside and
increasing the potential for a pulverizer fire.

2. Operating a pulverizer for an extended period of time with outlet


temperature below specification - this is hazardous as the coal may not
be properly dried and will plate out inside the pulverizer and in the fuel
piping. Fuel pipe plugging and pulverizer or fuel pipe fires can result.

3. Operating a pulverizer with the outlet temperature above specification -


this is hazardous because high outlet temperatures can drive volatile
gases from the fuel thus increasing the fuel's potential to ignite. The
control system should automatically close the hot air shutoff gate if the
pulverizer outlet temperature rises to 20°F (11 ℃) above the specified
outlet temperature (refer to “Pulverizer Fires” section).

Table 2.1 Pulverizer Discharge Temperatures

COAL TYPE TEMPERATURE


Hi-Volatile Bituminous A 180°F (82℃)
Hi-Volatile Bituminous B
Hi-Volatile Bituminous C 170°F (77℃)
Subbituminous A
Subbituminous B
Subbituminous C 150°F (65℃)
Lignite

4. Operating a pulverizer with reduced airflow (below specification) - this is


hazardous as velocity in the fuel pipes may not be adequate to maintain
the pulverized coal in suspension. If coal settles it can cause fuel pipe
plugging and fires.

5. Operating a pulverizer with airflow above specification -this is considered


less then optimal, the higher airflow will increase internal wear in the fuel
pipe and pulverizer. It can also cause a reduction in the pulverized coal
fineness.

6. Operating a pulverizer with the pyrite discharge gate closed - this is


hazardous because it prevents the discharge of rejects. When the gate is
closed for extended periods of time, material normally discharged will be
retained in the millside. The scraper assemblies can be severely
damaged and the potential for a pulverizer fire is increased

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7. Inadequate warm up of the pulverizer prior to feeding coal - this is
hazardous as moist coal may plate out on the "cold" internals of the
pulverizer and fuel piping. This increases the potential for a fire to occur
in the milling system. See "Initial Start-up" procedure.

8. Inadequate cool down of pulverizer prior to shutting off coal flow - this is
hazardous as temperatures may exceed a safe limit for the remaining
coal/air mixture, this increases the likelihood of a pulverizer or coal pipe
fire/puff to occur. See "Normal Shutdown" procedure.

9. Operating a pulverizer with too high an output fineness -this is considered


less then optimal as increased fineness results in lower pulverizer
capacity and higher pulverizer motor power consumption. See
"Adjustment of Fineness."

10. Operating a pulverizer with too low an output fineness - this is considered
less then optimal as low pulverized coal fineness will adversely affect
furnace operation. See "Adjustment of Fineness."

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Figure 1-1 HP Pulverizer


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Figure 1-2 HP Pulverizer Coal and Air Flow


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TABLE OF CONTENTS

PULVERIZER OPERATING PROCEDURES PART 2

TITLE PAGE NO.

INITIAL START-UP .......................................................................................... 2 - 1


NORMAL SHUTDOWN . ................................................................................... 2 - 2
EMERGENCY SHUTDOWN ............................................................................. 2 - 4
START-UP AFTER EMERGENCY SHUTDOWN ............................................. 2 - 5
PULVERIZER FIRES ....................................................................................... 2 - 5
COAL PULVERIZER FIRE FIGHTING PROCEDURE ...................................... 2 - 7
PULVERIZER TROUBLESHOOTING (TABLE 2-1) ........................................ 2 -10

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PART 2 - PULVERIZER
OPERATING PROCEDURES

INITIAL START-UP

1. Before the pulverizer motor circuits are energized and the pulverizer is
run under power, all start permissives must be met. Refer to the controls
manufacturers instructions for start permissive interlocks.

2. Prior to starting the pulverizer, the following items should be checked:

a. Ensure that the pulverizer/motor coupling has been properly aligned


and connected and that the input shaft of the planetary gearbox can
be rotated by hand.

b. Confirm that the classifier blades were calibrated (adjusted internally


to the correct opening) and that the control levers are set in the
correct position, initial set point "3".

c. Ensure that the oil level in each journal assernbly is at the


recommended dip stick level.

d. Ensure that all personnel are clear of the pulverizer and all access
doors are securely fastened.

e. Ensure that the pyrite shutoff valve is open.

f. Ensure that an air flow path has been established through the
puIverizer and that all coal line valves and/or gates and the cold air
shutoff gate are open.

g. Ensure that cooling water flow to the lube oil cooler is established.
The water supply temperature should be maintained between
113°- 130°F (45°- 55℃)

3. Establish seal air to the journals. journal springs and bowl hub air seal.

4. Ensure that oil flow to the upper and lower gearbox bearings is
established and that the upper oil reservoir has filled with oil. Refer to the
controls manufacturer's - Lube Oil System Controls for interlocks. .(Use
visual indicators for verification.)

5. Start the pulverizer.

NOTE:During the initial start up of the pulverizer (commissioning) or


after replacing the thrust bearing pads, (before feeding coal to the
pulverizer) use a digital indicator wired to the gearbox RTDs to
compare the hydrodynamic thrust bearing temperatures with the lube
oil supply temperature. The hydrodynamic bearing temperatures
should stabilize at 18 ° to 36 ° F (10 ° to 20℃) above the oil inlet
temperature. If the temperature does not stabilize, stop the pulverizer
a n d c h e c k t o ensure an oil supply to the bearing sprays.

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6. Open the hot air shutoff gate. The pulverizer air control system should
adjust the hot and cold air dampers to provide the proper air flow and
bring the pulverizer up to its selected outlet temperature.

NOTE:The pulverizer should be maintained at its normal operating


temperature for a minimum of 15 minutes before feeding coal. Normal
operating temperature is 150 °F to 170 ° F (65℃ to 82℃) depending
upon operating experience with the available coal. The pulverizer must
be warmed so that the coal begins to dry as soon as it enters the
pulverizer. This warm-up procedure reduces the potential for coal pipe
plugging and promotes more stable coal ignition.

7. Establish ignition energy.

NOTE:Ignition energy can be ignitors, oil guns, gastorches or


adjacent proven pulverizers. The system controls establish the
parameters, refer to the control manufacturers instructions.

8. Start the coal feeder.

NOTE:With the feeder control in manual and set at minimum, coal


will automatically be fed at a rate equal to 25% of the pulverizer's
rated capacity. The feed rate should not be increased until the
pulverizer outlet temperature has returned to its set point value.

9. Check the furnace to ensure that coal fires are established and stable.

10. Increase the coal feed when the pulverizer outlet temperature has
returned to the set point.

NOTE:Coal feed can be increased in increments to the feed rate


required to support unit load increases. The second and successive
pulverizers should be placed in service when the loading on the
operating pulverizer(s) reaches 80%.

11. When the coal feed rate of a pulverizer has been increased to match
system demand, the feeder control should be placed on automatic.

NORMAL SHUTDOWN

NOTE:During a normal shutdown, the pulverizer should be cooled to


below normal operating temperature and be emptied of coal. The
recommended cool-down temperature prior to stopping the pulverizer
is 120°F (50℃).

1. Reduce the pulverizer load by reducing the feeder speed to minimum.

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NOTE:This can be done by biasing the feeder control or by placing
the feeder control in manual mode. Reduce the feed rate in 10%
increments. At each reduced coal flow, the pulverizer outlet
temperature should be allowed to return to the set point value before
the coal feed is reduced further. Pulverizer air flow should be
maintained on automatic control.

NOTE:Observe the pulverizer outlet temperature, do not allow the


temperature to exceed the set point value by more than 15°F (8℃).

CAUTION: IGNITION ENERGY MUST BE AVAILABLE TO ENSURE


COAL STREAM IGNITION STABILITY.

2. When the feed rate is at minimum, close the hot air shutoff gate to
reduce the pulverizer outlet temperature.

NOTE:The cold air damper should automatically open to maintain


the required air flow.

3. Stop the feeder after the pulverizer has cooled to approximately 120°
F(50℃)

4. Run the pulverizer a minimum of 10 minutes to clear the bowl of coal.

NOTE:Low motor current can be used as an indication that grinding


has ceased.

5. Stop the pulverizer.

6. Throttle the cold air damper to approximately 5% open to allow a small


flow of air through the pulverizer for purging and cooling. The pulverizer
discharge valves (and coal pipe valves) should remain open.

NOTE:The minimum position of the cold air damper should be at an


automatic stop established during initial unit start- up (commissioning).
A minimum cooling air flow must be maintained through the pulverizer
at all times.

7. The lube oil system should continue in service.

NOTE:If a lube oil system must be shut down for any length of time
in cold weather when the associated pulverizer is out of service, it is
advisable to shut off the cooling water and drain the water from the oil
cooler. If ice has had an opportunity to form in the tubes, a careful
examination should be made before starting up to make sure that the
tubes have not ruptured, allowing cooling water to contaminate the oil.

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EMERGENCY
SHUTDOWN

On loss of furnace ignition or if some other condition should arise which ne-
cessitates an automatic or manual emergency fuel trip, the pulverizer motor
should be stopped immediately. Stopping the pulverizer motor should trip the
feeder, and close the hot air shutoff gate.

An emergency trip subjects residual fuel in the pulverizer to conditions which


may cause spontaneous combustion. It is strongly recommended that an
automatic system be provided to render the pulverizer inert whenever the
pulverizer is tripped under load. The recommended inerting media is steam.

A pulverizer that has been tripped under load should be cooled to ambient
temperature. Then open the pulverizer and manually clean out the coal.

WARNING : A HOT PULVERIZER WILL DISTILL COMBUSTIBLE


GASES. FROM RESIDUAL COAL. THEREFORE USE CARE WHEN
OPENING THE PULVERIZER FOR CLEANING AFTER AN
EMERGENCY TRIP.

IF AN INERTING SYSTEM IS INSTALLED, THE INERTING VALVES


MUST BE PROVEN CLOSED BEFORE THE DOORS ARE OPENED.
USE EXTREME CARE WHEN OPENING THE INSPECTION DOORS,
BECAUSE THE PULVERIZER MAY BE PRESSURIZED. EYE
PROTECTION IS RECOMMENDED.

PURGE THE PULVERIZER OF COMBUSTIBL GASES AND /OR


INERTING MEDIUM BEFORE ENTERING FOR CLEANING

WARNING:ROLL PRESSURE ON COAL MOUNDED IN THE BOWL


COULD CAUSE THE BOWL TO ROTATE UNEXPECTEDLY WHEN
IT IS BEING CLEANED.TO PREVENT THIS FROM HAPPENING,
INSTALL AN "A" FRAME RESTRAINT ON THE PULVERIZER DRIVE
COUPLING.

1. Check that the hot and cold air shutoff gates, the discharge valves and
the pulverizer and feeder seal air valves are closed.

2. Use procedures established by your plant to ensure that the pulverizer


motor and feeder motor are deenergized and secured, breakers are
opened and tagged.

NOTE:Put on a face shield or goggles before performing the next


steps. Some coal dust and debris will discharge from around the door,
therefore, eye protection is recommended.

3. Carefully crack open the pyrites hopper door, then open it completely.

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5. After taking the necessary precautions, manually clean the pulverizer.

START-UP AFTER
EMERGENCY
SHUTDOWN

After any pulverizer trip under load, the pulverizers must be cooled to
ambient temperature, opened. and the coal manually removed. The
pulverizer can then be restarted using normal start-up procedures.

NOTE:As a precaution, upon start-up after an emergency trip, close


the discharge valves of all pulverizers not in service.This will prevent
hot furnace gases, at the higher than normalpressure caused by the
initial ignition of coal, from surging down the fuel piping into the
idlepulverizers.

Restart all pulverizers, one at a time, as soon as possible. Run each


pulverizer a minimum often minutes to ensure that any residual coal
which was not manually removed is air swept from the pulverizer.

NOTE:When pulverizers are back in service with the unit load


stabilized and all pulverizers have been restarted to remove residual
coal, the discharge valves of any idle pulverizers should be opened to
allow the required minimum air flow.

PULVERIZER FIRES

The two most common indications of a fire in a pulverizing system are:

1. A high or rapidly increasing pulverizer outlet temperature without other


cause, or

2. Paint peeling from the pulverizer and/or fuel piping.

The usual causes of pulverizer fires are:

1. Excessive pulverizer temperatures. Do not allow the pulverizer outlet


temperature to exceed the specified outlet temperature by more than
20°F (11℃).

2. Foreign material such as paper, rags, straw, wood and excelsior


collecting in the inner cone and other points in the pulverizer. These
materials do not pulverize readily and therefore should be kept out of the
raw fuel supply. When they get into the system, they collect and may
catch fire. Each time the pulverizer is opened for any reason, remove all
foreign materials from the air inlet, inner cone, bowl, etc.

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3. Excessive accumulations of pyrites or coal on the mill bottom or in the air
inlet to the pulverizer. The valve on the tramp iron discharge spout
should be open to allow the free discharge of foreign materials into the
pyrites collection system. The valve may be closed momentarily for the
removal of pyrites from the collecting hopper. Accumulations of debris in
the air inlet should be removed whenever the pulverizer is open for
inspection. Scraper and guard assemblies should not be allowed to wear
excessively.

4. Excessive accumulations of coal in areas above the bowl. This condition


is usually brought about by lack of maintenance. Worn liners may allow
coal to accumulate in an area faster than the normal air flow will remove
it or to reach areas where it cannot be removed. Coal can also be
trapped by foreign material bridging a section of the pulverizer through or
over which the coal would normally move, i.e. an obstruction on top of a
liner cover plate.

5. Improper or unusual operation. Accumulations of coal or flammable


foreign material are a hazard under normal operating circumstances, but
in most cases they do not of themselves cause fires or puffs. Usually
some additional improper operating condition must initiate the trouble.
For instance, if a pulverizer is operated with low air flow, higher
pulverizer inlet temperatures are necessary to maintain the set outlet
temperature. The air flow may be low enough to allow additional settling
out of cqal from the air stream. These conditions can result in more heat,
less coal movement and potential trouble.

Another example would be failure to close the hot air gate when there is
reason to believe an operating condition may have allowed a fire to start.
Such a condition could be a sluggish damper drive mechanism or a
sluggish damper control system coupled with a substantial and rapid
change in coal moisture.

An example of unusual operation would be running coal through a


pulverizer from a bunker that is known to be on fire. Of course, extreme
care must be taken while doing this. Everything possible must be done to
ensure that coal feed is continuous at a moderate to heavy rate.

6. Feeder hot air. When the feeders use hot air, it is important to close the
feeder hot air valve whenever there is a possibility that the feeder will be
stopped for longer than 3 minutes with coal in it.

WARNING : IF A PULVERIZER SYSTEM FIRE DOES OCCUR,


REGARDLESS OF THE FIRE LOCATION, DO NOT SHUT DOWN
THE PULVERIZER AND NEVER OPEN ANY PULVERIZER
INSPECTION DOORS UNTIL ALL EVIDENCE OF THE FIRE HAS
DISAPPEARED AND THE PULVERIZER IS COOLED TO AMBIENT
TEMPERATURE.

DURING ANY FIRE EXTINGUISHING PROCEDURE, ALL


PERSONNEL NOT ACTIVELY FIGHTING THE FIRE SHOULD BE
CLEARED FROM THE PULVERIZER BAY, AIR DUCTS AND
FEEDER DECK AREA.

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NOTE: A pulverizer fire is not eminently dangerous. As long as
pulverizer operating conditions are stable and normal, risk of an
explosion is minimal. Once a pulverizer fire has been detected, the fire
extinguishing procedure should be followed carefully and expediently.

COAL PULVERIZER
FIRE FIGHTING
PROCEDURE

Pulverizer fires are detected by high pulverizer outlet temperatures [tem-


peratures more than 20°F (11 ℃) above the specified outlet (normal operat-
ing) temperature]. Pulverizer outlet temperature detection devices should
monitor and alarm when the outlet temperature reaches a set point value.
This alerts operators to the potential presence of a fire.

1. At first indication of a fire, close the hot air shutoff gate and open the cold
air damper to 100% Continue feeding coal at a rate equal to or above the
feed rate that existed just prior to the fire. Use care not to overload the
pulverizer.

NOTE: Closing the hot air shutoff gate will frequently extinguish the
fire, if the pulverizer temperature continues to rise, it will be necessary
to cool the pulverizer by admitting water.

2. Close the pyrite hopper isolation valve.

3. Introduce water through the nozzles provided on the air inlet, millside
and separator top

NOTE: Nozzles are provided on the separator top, millside and air
inlet duct. It is recommended that the nozzles be connected to a
permanent piping system and water supply with suitable valving.

4. Continue to feed coal and water until the pulverizer outlet temperature
has dropped and all signs of fire are gone.

NOTE: Water should be admitted in such quantity and at such


location(s) as not to cause hang-up or interruption of the fuel feed or
disturb any deposit of combustible material.

5. Shut off the water supply.

6. Stop the coal feed.

7. Run the pulverizer for several minutes to purge the system of


accumulated coal and water.

8. Stop the pulverizer. Isolate the pulverizer by closing all gates and valves,
cold air shutoff valve, seal air valves, coal pipe shutoff valves, etc.

9. Use plant procedures, isolate the pulverizer and feeder motors, open
breakers and tag.

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WARNING : USE CARE WHEN OPENING PULVERIZER
INSPECTION DOORS. CHECK THAT THE HOT AND COLD AIR
SHUTOFF GATES, THE PULVERIZER AND FEEDER SEAL AIR
VALVES AND THE PULVERIZER DISCHARGE VALVES ARE
CLOSED.

THE PYRITES HOPPER DOOR SHOULD BE CAREFULLY


CRACKED AND THEN COMPLETELY OPENED.

WARNING : EYE PROTECTION (GLASSES OR FACE SHIELD)


SHOULD BE WORN WHEN CRACKING OPEN THE INSPECTION
DOORS. THE PULVERIZER MAY BE PRES"SURIZED AND THERE
IS A POSSIBILITY OF A DISCHARGE OF HIGH PRESSURE GAS
AND COAL DUST.

WARNING:PRIOR TO ENTERING THE PULVERIZER, IT MUST BE


COMPLETELY PURGED TO ENSURE A BREATHABLE
ATMOSPHERE.

10. The pulverizer should be opened, inspected and its contents (coal)
removed. Entry into the pulverizer will be made through the inspection
doors in the separator body and through the millside doors. The following
procedure is to be followed when opening these or any other inspection
door in the pulverizing system.

a. Ensure that the pulverizer has been isolated and the motor
breaker has been racked out and tagged.

b. Ensure that all door attachment lugs or nuts are present and
tightened down. visual only)

c. Onthedoortobeopened, removeallbutthecornernutsorlugs, Then


back off the corner attachment lugs halfway.

d. Crack the door free with a crowbar or jar it Loose with a


hammer.When the seal breaks sore e coal dust will discharge
from around.the door.

e. Remove the corner lugs or nuts completely.

f. Remove or open the door.

CAUTION: PRIOR TO ENTERING THE PULVERIZERVERIFY THAT


IT HAS BEEN COMPLETELY PURGED FTOXIC GASES AND THAT
NO POCKETS OF SMOLDERING FUEL STILL EXIST.

WARNING : USE CARE WHEN CLEANING A PULVERIZER


MANUALLY. ROLL PRESSURE ON COAL MOUNDED IN THE BOWL
CAN CAUSE THE BOWL TO ROTATE UNEXPECTEDLY. TO
PREVENT THE BOWL FROM ROTATING INSTALL AN "A" FRAME
RESTRAINT ON THE PULVERIZER DRIVE COUPLING.

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11. Upon satisfactory inspections of the following areas for evidence of fire or
smoldering products of coal or coke, clean up can take place.

a. Fuel pipe

b. Millside

c. Separator body

d. Inner cone and classifier.

CAUTION: PULVERIZERS SHOULD NOT 'BE RESTARTED WITH


COAL ON THE BOWL.

NOTE: After any fire or pulverizer puff, the entire pulverizing system
from the feeder to the fuel nozzles (the coal feeder, pulverizer,
pulverizer air inlet duct, coal pipes, riffle distributors, Internal coal
nozzles, tilt mechanism, etc.) should be checked for possible damage
and cleanliness. Repair and clean as necessary. Be sure to remove
any accumulations of coal or coke.

12. Check the lubricants and replace them if there is evidence of cadc.
onizing.

13. After coal has been removed from the bowl and millside and the
pulvenzer has been thoroughly cleaned and repaired as required, it can
be restarted. Use normal start-up procedures.

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Table 2 - 1 Pulverizer Troubleshooting

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION


Reduced Leak in lubricating system Inspect for oil leaks and repair as
Lubricating Oil required.
Pressure Oil pump worn Repair or replace pump at first
opportunity
Dirty oil filters Clean or replace primary/ secondary
filters
Oil viscosity low High oil temperature/wrong oil
Pulverizer Pulverizer fire See Fire Fighting Procedures
Outlet Hot air damper malfunction Close hot air gate, shut down mill,
Temperature repair as required.
High Cold air damper malfunction Open cold air damper manually, shut
down mill, repair as required.
Feeder malfunction/feed pipe Shut down mill, repair as required.
plugged
Outlet thermocouple malfunction Verify readings and repair/replace as
required.
Pulverizer Extremely wet coal in pulverizer(s) Reduce feed rate to maintain outlet
Outlet temperature.
Temperature Hot air gate not open Check gate position and repair as
Low required.
Hot or cold air damper malfunction Shut down mill and repair as required.
Low primary air temperature Reduce feed rate.
Low air flow Recalibrate airflow control system.
Pulverizer Overloaded pulverizer or wet coal Reduce feed rate to pulverizer, check
Motor feeder calibration. Check coal
Amperage - hardness.
High Excessive coal fineness Adjust classifier blades (open).
Excessive grinding force Check spring compression and reset as
required.
Motor malfunction Test motor
Pulverizer No coal entering pulverizer Check feeder and feed pipe for
Motor blockage.
Amperage - One or more journals seized Shut down mill. repair as required.
Low Reduced coal to pulverizer Check feeder operation and/ or
plugging.
Motor coupling or shaft breakage Shut down mill and repair as required.
Bowl Overloaded pulverizer Reduce feed rate to pulverizer, check
Differential feeder calibration. Check coal hardness
Pressure - Excessive fineness. Adjust classifier blades.(open)
High Plugged pulverizer pressure tap(s). Check purge air and clean pressure
taps as required.
Excessive mill airflow. Check airflow control system.
Insufficient open area around the Remove one vane wheel air restriction
bowl. ring.
Bowl Reduced coal flow to mill Check feeder operation and/or
Differential plugging.
Pressure – Plugged pressure tap/leak Check purge air and clean pressure
Low taps as required.
Low mill airflow Check airflow control system.

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Table 2 - 1 - Pulverizer Troubleshooting

PROBLEM POSIBLE CAUSE CORRECTIVE ACTION


No Coal to Coal pipe blockage (prolonged Shut off the feeder. Check the
Coal Nozzle(s) blockage can lead to fires) pulverizer airflow. Tap on the piping. If
still not clear, remove and clean as
necessary.
Blocked feeder, center feed pipe or, Check and clear the feeder or center
low airflow feed pipe. Check operation of the
primary air controldampers.
Blocked orifice or riffle distributor, Shut down the pulverizer and isolate.
if installed Inspect, clean and repair or replace
the riffie or orifice.
Incorrect Coal Classifier blades set wrong Open/close as required.
Fineness Classifier blades out of calibration Calibrate the deflector blades.
Worn or damaged deflector blades Inspect, repair and/or replace as soon
as possible.
Incorrect inverted cone position Reduce clearance by 1/2" or to a
minimum of 3".
Holes worn through inner cone or Inspect, patch/replace cone or liners
liners as required.
Noise: Above Reject material on bowl Stop the pulverizer. Inspect and
the Bowl remove the material.
Failed grinding roll Stop the pulverizer. Repair or replace
the journal assembly.
Uneven spring pressure Check the spring pressure and
change, if required.
Heavy reject material Stop the pulverizer. Remove the
material and check for damage.
Noise:Below Broken scraper assembly Stop the pulverizer and repair or
the Bowl replace as required.
Broken air vane(s) Stop the pulverizer and repair or
replace as required.
Noise: Gear Bearing or gear damage Stop the pulverizer. Inspect the
Housing components.
Damage to the pulverizer gears or Repair or replace worn items gears or
bearings bearings as required.Test oil and
replace as required.
Oil Leak-Horizontal Dirty labyrinth seal Shut down mill, clean seal groves.
Drive Shaft
High Gear Low water flow to oil cooler Increase water flow and check cooler.
Housing Oil Oil cooler plugging Check and clean oil cooler as soon as
Temperature possible.
Low oil level Check level and add oil as required.
Check for leaks.
Rough Running Inadequate coal bed depth Increase coal flow, check feeder
Pulverizer calibration /line plugging
Excessive grinding force Reduae spring compression or
hydraulic pressure.
Incorrect ring to roll Reset ring to roll clearance
Over grinding Adjust classifier (open)
Insufficient raw coal feed size Increase size of raw coal feed

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Table 2 - 1 - Pulverizer Troubleshooting

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION


High Bearing Bearing failure Check for noise immediately.
Temperature(s) Low oil level Check level and add oil as required.
Oil cooler malfunction Check cooling water temperature and
flow.
No Oil in Oil Plugged manifold or supply AIlow time for oil to warm up after
Flow Indicator(s) line(s) pulverizer start-up. Stop pulverizer,
isolateline(s) and clean out.
Oil pump failure Stop pulverizer; drain gear housing oil
and replace pump.
Coal Spillage Pulverizer overloaded
From Tramp 1. Excessive raw coal feed 1. Reduce the feed rate to the
Iron Spout pulverizer.
a. Check feeder calibration.
b. Check coal hardness.

2. Excessive coal fineness 2. Adjust classified blades(open).


Worn grinding rolls or bull ring Reset the roll to ring clearance.
Replace the rolls, and / or bull ring.
Adjust spring compression.

Inadequate grinding force check /increase spring compression


or recalibrate hydraulic system
pressure.

Rolls not rotating a.Shut down and open the pulverizer,


(at start up) check the rolls for rotation, remove
any foreign material and / or repair /
replace the journal assembly.
b.Warm up the pulverizer for a longer
period of time.
c.Check journal for proper viscosity of
oil.
d.Increase size of raw coal feed.

Low air velocity across the bowl Check air flow control for
proper operation.

Excessive open area around the Add an additional vane wheel air
bowl restriction ring.

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TABLE OF CONTENTS

LUBRICATION SYSTEMS PART 3

TITLE PAGE NO.

SYSTEM DESCRIPTIONS (Refer to Figures 3-1 and 3-2) ............................. 3 - 1


Journal Lube Systems ............................................................................... 3 - 1
Gearbox Lube System ............................................................................... 3 - 1
LUBRICATION OF THE MAIN DRIVE GEARS AND BEARINGS ............ 3 - 1
EXTERNAL LUBE OIL SYSTEM ............................................................. 3 - 1
LUBE OIL SKID ....................................................................................... 3 - 2
Flow Switch .................................................................................... 3 - 2
Heat Exchanger (Oil Cooler) .......................................................... 3 - 2
Lube Oil Filters ............................................................................... 3 - 3
Lube Oil Pump ............................................................................... 3 - 3
Gauges .......................................................................................... 3 - 3
Switches ......................................................................................... 3 - 4
Relief Valve .................................................................................... 3 - 4
Heaters .......................................................................................... 3 - 4
GEARBOX LUBE SYSTEM OPERATION ....................................................... 3 - 5
Start-up ....................................................................................................... 3 - 5
Shutdown ....................................................................................................... 3 - 5

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PART3-LUBRICATION
SYSTEMS

SYSTEM DESCRIPTIONS
(Refer to Figures 3-1
and 3-2)

There are two separate types of lubricating systems on a pulverizer, the


journal lube systems and the gearbox lube system

Journal Lube Systems

Each of the three journal assemblies has a self-contained oil bath lubrication
system. The journals are shipped over filled with the recommended lubricant
(see oil tag on journal). The oil level in each journal reservoir must be
checked and adjusted after the journals have been installed and before the
pulverizer is started-up. Determine the proper level by using the oil dip stick,
measure from the bottom of the oil reservoir. If the customer will use a
different brand of oil for replacement or make up, the oil should be replaced
with customer supplied lubricant prior to start up.

NOTE: The journal oil level must be checked periodically (at least
once every 6 months).

CAUTION: DO NOT OVER FILL THE JOURNAL ASSEMBLY OIL


RESERVOIR. TOO MUCH OIL MAY DAMAGE THE OIL SEALS.

Gearbox Lube System

The second lubricating system is for the gearbox assembly. It is a


combination of oil bath and sprays with provisions for external cooling and
filtering. An oil pump driven by an electric motor supplies the required
circulation. (Refer to vendor instructions elsewhere in this manual for detailed
information.)

LUBRICATION OF THE MAIN DRIVE GEARS AND BEARINGS

The gearbox is supplied with pressurized oil, from an external lube oil system.
Each bearing is provided with an individual oil supply, spray nozzles, or flood
lubrication. Cooled oil is sprayed onto the hydrodynamic bearing, the oil is
retained in a reservoir to submerge the hydrodynamic bearing in an oil bath.
The oil level in the reservoir is kept constant via over flow dams.

EXTERNAL LUBE OIL SYSTEM

An electric motor drives the oil pump that is mounted on the external lube oil
tank. Oil is discharged to duplex type filters and then through an oil cooler
where excess heat is dissipated.

A relief valve, installed between the pump and filter, provides protection from
over pressurization and also allows for oil recirculation during heat up of the
lube oil system.

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For warm up after an extended shutdown or during cold weather, a
thermostatically controlled heater is installed in the bottom of the lube oil tank.

Check valves, installed at the filter outlet and a vented loop in the supply line
prevents oil from draining out of the hydrodynamic bearing reservoir back to
the lube oil tank when the oil pump is turned off. The valves also allow work to
be performed on the lube oil pump without draining the oil from the gearbox.
Pressure gauges, thermometers, oil level and oil flow indicators provide visual
indications of lube oil system conditions.

Pressure switches, level switches, and temperature sensors provide for both
audible and visual alarms. Signals from these switches are used by the
control systems to establish pulverizer start-up permissives and can cause a
pulverizer shutdown if the condition which initiated the alarm condition is not
corrected.

The controls (time delays, interlocks, relays) which are used in conjunction
with the switches are described in a separate part of the manual. Basically,
the control logic (in conjunction with the various switches) provides interlocks
between the pump, heaters, filter, and the sensors for oil level, oil temperature
and oil pressure to aid in proper operation of the lubrication system. This
ensures adequate lubrication of the pulverizer gearbox. However, routine
operator inspections must also be performed to assure proper operation of the
lube system components.

LUBE OIL SKID

The following paragraphs describe the components associated with the lube
oil tank. For detailed information refer to the vendor's instructions elsewhere
in this manual.

Flow Switch

The flow switch is located on the oil supply pipe at the outlet from the cooler.
It actuates an alarm if oil flow to the gearbox is low.

Heat Exchanger (Oil Cooler)

The lube oil system is designed to have the heat exchanger operating at all
times. The heat exchanger, supplied with each lube oil system, is sized to
remove all the excess heat generated within the gearbox. Heat generated is
due to inefficiency of the gearing, bearing friction and the lube oil pump. Heat
also comes from the hot primary air to the pulverizer which is conducted down
through the bowl hub to the gear case.

The heat exchanger continually removes heat from the system to insure an
acceptable oil viscosity for protection of the bearings and gears. The heat
exchanger is sized to remove this heat based on a maximum water inlet
temperature and minimum specified water flow. A valve should be installed by
the customer on the water supply side of the heat exchanger to regulate the
water flow. Instrumentation must be supplied (by the customer) to monitor the
water inlet and outlet temperatures. Based on the water temperature and oil
temperature, the water flow should be adjusted to maintain a steady oil
temperature exiting the heat exchanger, approximately 104°F (40℃).

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The following are possible causes of excess cooling water and/or oil
temperatures. These items should be checked and corrected as required if
temperatures exceed the recommended values.

1. Insufficient quantity of cooling water (increase flow). Check valve to


insure that water is flowing through the heat exchanger.

2. Temperature of water at cooler inlet above maximum allowable (reduce


temperature).

3. Low oil level in oil tank (refill promptly).

4. Tank heater thermostat not properly adjusted (reset the thermostat).

5. Scale formation in heat exchanger (increase water flow if possible). If oil


temperature normalizes, clean heat exchanger (per manufacturer's
instructions) at first opportunity.

6. Breakdown of lubricant or foaming (change oil).

NOTE: The first oil change should take place after 1000 hours of
operation. If the oil cannot be periodically analyzed then it should be
changed every 18 months or after approximately 6,000/8,000 hours of
operation (reference gearbox vendor's manual).

In cold weather, a slight flow of water should always be allowed to pass


through the heat exchanger to prevent water from freezing in the exchanger.

Lube Oil Filters

A .duplex oil filter is installed. Each filter is equipped with a differential pres-
sure indicator to show the cleanliness of the elements. If the elements are not
maintained and become clogged continued operation will result in a high
differential pressure alarm and, if not corrected, a low oil pressure trip of the
pulverizer. A three-way and check valves ensure isolation of the inactive filter
for servicing.

Lube Oil Pump

The external lube pump is used to pump oil into the gearbox. The constant
volume pump can be operated if the pulverizer motor is off. The resultant oil
pressure is dependent on oil temperature, viscosity, line sizes, spray nozzle
diameter and restrictions such as the filter and heat exchanger.

Gauges

Oil pressure gauges are located between the pump outlet and filter, between
the filter and heat exchanger and after the heat exchanger. These are used to
verify the pump outlet pressure and the pressure drops across the filter and
heat exchanger.

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Temperature gauges are located on the oil tank and after the heat exchanger.
These gauges indicate the temperature of the oil supply in the tank and to the
bearings.

Switches

A level switch is installed in the oil tank to provide an indication of an


adequate oil level.

A differential pressure switch is provided across the filters to indicate the


cleanliness of the operating filter element.

A pressure switch is provided after the heat exchanger to assure that


adequate oil pressure is present.

A flow switch is provided after the heat exchanger to assure adequate oil flow
to the gears and bearings.

Relief Valve

A relief valve is located at the pump outlet and routes oil back to the tank This
valve is set to open during certain phases of operation. Oil can flow through
this valve continuously.

Heaters

The oil h eater located in the bottom of the oil tank is used to warm the oil and
satisfy the oil temperature start permit when the pulverizer is off. The heater
has an integral thermostat which will shut the heater off when the oil
temperature exceeds a preset value. If the pulverizer and heater have been
off for a long time and the ambient conditions are very cold, it can take
several hours to warm the oil in the tank.

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GEARBOX LUBE
SYSTEM
OPERATION

A control system is provided to ensure adequate lubrication of gearbox com-


ponents. Refer to "Lubrication System Instrumentation and Controls"
elsewhere in the manual for details. Typically the system operates as follows:

Start-up

1. Ensure that the oil level and temperature in lube oil tank is satisfactory.

2. Satisfy all lube system start permits as required by the controls logic.

3. Start the lube oil pump.

4. After lube system is operating, check the oil flow, oil temperature and oil
pressure.

NOTE: In general, the heat exchanger is required when the pulverizer


ls operating and the lube oil heater ls required when the pulverizer is
off. They should not be used at the same time, as they have opposing
functions.

CAUTION: ASSURE THAT THERE IS ADEQUATE OIL IN THE


UPPER GEARBOX RESERVOIR (HYDRODYNAMIC THRUST
BEARING) PRIOR TO STARTING THE PULVERIZER.

5. After the pulverizer is running, adjust the water flow to the heat
exchanger as necessary to maintain the proper oil supply temperature.

6. Periodically check oil flow, oil temperature and oil pressure.

Shutdown

NOTE: When the pulverizer is in operation, the lube oil system must
not be shut down. If it is, the pulverizer will be automatically tripped.

1. After a pulverizer has been shut down, the lube system should be allowed
to run, filtered, heated oil will continue to lubricate the bearings and
maintain the pulverizer ready for instant restart.

2. Once the pulverizer has cooled enough to enter for maintenance, the
customer may elect to shut down the lube system.

3. If the pulverizer is shut down for a long time and the customer has
elected to shut down the lube system. the gearbox bearings and gears
should be lubricated per the lay up procedure (see vendor's manual) or
the lube system can be run for three hours every two months.

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TABLE OF CONTENTS

PULVERIZED COAL FINENESS ADJUSTMENT AND TESTING PART 4

TITLE PAGE NO.

ADJUSTMENT OF FINENESS .................................................................................... 4 - 1


PULVERIZED COAL FINENESS TESTING ................................................................. 4 - 2
Location ............................................................................................................ 4 - 2
Pulverizer Loading ........................................................................................... 4 - 2
Equipment ........................................................................................................ 4 - 2
Taking a Pulverized Coal Sample .................................................................... 4 - 3
Sieving .............................................................................................................. 4 - 4
PREPARING THE PULVERIZED COAL SAMPLE .................................. 4 - 4
SIEVING THE COAL SAMPLE ................................................................ 4 - 4

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PART 4 - PULVERIZED
COAL FINENESS
ADJUSTMENT
AND TESTING

ADJUSTMENT OF
FINENESS

A wide range of lineness levels can be obtained with the air separation
concept of classification utilized in HP pulverizers. The deflector blade
(external adjustment) mechanism allows for on-line coal fineness adjustment
which is both accurate and trouble free.

The size distribution of any particulate sample is measured as the percentage


of the material passing through a series of test sieves. For pulverized coal,
the percent of sample passing through 50, 100, and 200 mesh sieves is the
current industry standard. The proper method of taking and sieving a
pulverized coal sample is described below in "Pulverized Coal Sampling" and
"Pulverized Coal Fineness Testing".

The fineness level for which the pulverizing system was designed is specified
in the contract documents. From experience (based on coal type and furnace
design), it has been determined that this level of fineness will provide
acceptable furnace operation with regards to the percent of unburned carbon,
emissions, efficiency, and slagging. It is possible, however, that a higher level
of fineness may be required to achieve the furnace performance goals.
Conversely, it is also possible that lower than specified fineness will result in
acceptable furnace operation. In either case, adjustments should be made
and fineness should be set at the lowest level which will result in acceptable
furnace performance.

Pulverizer fineness is adjusted by moving the control lever(s) on the separator


top. The lever(s) is attached by link rods to multiple deflector blades within the
pulverizer separator top. When the lever is set on "0" the deflector blades are
in their most open position. This will result in the lowest fineness level
obtainable. Adjusting the lever(s) to a higher position number (0 ⇒ 10), closes
the deflector blades resulting in higher fineness levels.

If the fineness of the coal is too coarse and the lever(s) is set on its highest
effective position (may not be "10"), other pulverizer adjustments will be
required (see Trouble Shooting Chart). If the coal fineness is too high and the
lever(s) is set on "0" then the deflector blades can be reindexed (reset to a
more open position) (refer to "HP Pulverizer Maintenance - Pulverizer
Component Servicing, Classifier Deflector Blade Replacement"). Other
pulverizer adjustments may be required as well (refer to Trouble Shooting
Chart).

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PULVERIZED COAL
FINENESS TESTING

This procedure describes the sampling and testing parameters recommended


by SHMP. Coal sampling procedures should use good sampling technique
and consistent sampling locations.
Location

The location where a pulverized coal sample in taken has a definite effect on
the coal fineness result. It is recommended that all samples be taken at the
recommended location, just above the discharge valve in coal dust pipe.
These locations should be equipped with aspirated fittings that will allow for
proper sam pl ing without expelling coal dust into the atmosphere.

Pulverizer Loading

In order to obtain fineness test results that can be compared between


pulverizers and are repeatable, it is necessary that pulverizer and furnace
conditions be maintained at set levels while the coal samples are being
obtained. Unit load should be high enough that the pulverizer being sampled
can be placed on manual control at or near its full load rating during the
testing period. The pulverizer should be allowed to operate at that level for
about ten minutes before taking the sample.If there is a pulverizer or unit
upset during the testing peried, the coal sample should be discarded. New
samples should be obtained later.

NOTE: Other pulverizers in the system may be left on automatic


control to accommodate small swings In unit load.

Since pulverizer performance is different at varying loads coal fineness test


should always be run at the same pulverizer loading, that is, coal fineness
samples taken at a sixty percent pulverizer loading should not be compared
with samples taken at eighty-five percent pulverizer loading.

Pulverizers with obvious indications of trouble (heavy coal spillage, rumbling,


etc.) should not be tested until problems are corrected.

Equipment

Pulverized coal samples should only be taken with an powdered coal


sampling device . It is recommended to use a large cyclone collector
equipped with a thin wall sampling nozzle (probe). It is important that the
cyclone and the sampling nozzle be in an "as new" condition. Dents. Leaking
seams, and/or a damaged sampling nozzle tip can have an effect on the
fineness of the sample and will give incorrect results. The sampling nozzle
must be long enough for the tip to reach across the full diameter of the coal
pipe at the sampling location. Repair or replace the equipment as necessary
to ensure accurate fineness test results.

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Taking a Pulverizer
Coal Sample

Prior to taking a sample, lt is good practice to warm up the cyclone and the
sampling nozzle. This can be done by placing the sampling device on top of
the pulverizer for 5 to 10 minutes. Warming of the sampling device will help
prevent plugging as It will reduce the potential for plating of coal inside the
cyclone. During the winter or in cold environments, it may be necessary to
insulate the cyclone. This can be done by wrapping the cyclone with cork,
foam rubber, or fiber glass insulation.

The aspirated fittings on the coal pipes should be working properly before
attempting to take coal samples. Proper operation means that the aspirati ng
air pressures can be adjusted (equalized with the pressures in the coal pipe
being sampled) so that air flow is neither into or out of the coal pipe.

Taking a pulverized coal sample is a simple operation, but care must be


exercised to do it properly.

1. Turn on the air supply to the aspirated fitting and remove the pipe plug.

2. Throttle the air supply valve until coal just "puffs" from the fitting. Then
open the air supply valve slightly until a pressure balance is achieved.

NOTE: Traverse the coal pipe in a continuous stroke. The traverse


should be performed as smooth as possible for a set time (such as 30
sec., 15 sec. in and 15 sec. out). The time of the traverse for each
sampling location should be the same. This can be accomplished by
using a watch or counting during the traverse.

3. Take the coal sample by inserting the sampling nozzle through the
aspirated fitting with the opening in the end of the probe pointed into the
coal flow.

NOTE: The total time used to take the coal sample will have an effect
on the quantity of coal collected in the collection jar(s). A sufficient
quantity of coal must be collected to perform the fineness test and/or
any other test that is required (such as a moisture test). Ensure that
equal quantities of coal are obtained from each of the coal pipes
sampled.

When sampling, fill the mason jar to no more than the half or three-quarter
level (1/2-3/4 qt). If the quantity of coal over fills the jar, the sample should be
discarded and the test repeated with shorter traverse times. If an insufficient
quantity of coal is obtained, then the traverse tim e per aspirated fitting should
be increased.

4. Tap the cyclone gently to shake any coal that adheres to the inside of the
cyclone into the jar. This coal must be included in the sample.

NOTE: It may be necessary to use a separate collection jar for each


coal pipe or sampling point.

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HP1003 PULVERIZER-OPERATION
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5. Seal the collection jar or place the coal sample in a sealed, air tight
plastic bag(s) until required for analysis.

Sieving

NOTE: The following is excerpted and revised from the ASME and
ASTM Procedures. If time ls available, the ASTM and ASME
procedures may be used.

PREPARING THE PULVERIZER COAL SAMPLE

NOTE: The proper procedures for performing a fineness test is to air


dry the pulverized coal sample prior to sieving. Since this is time
consuming it may not be practical when a fast turn around of fineness
data is required.

Mix the total fineness sample (all samples taken from a pulverizer during one
test) thoroughly.

1. Empty the sample jar(s) onto a large sheet of plastic, rubber, or glazed
paper.

2. Roll the sample by raising one corner of the sheet and then the other to
cause the coal to roll over itself at least 50 times.

3. Roll the sample into a cigar shape.

4. Using a small spatula, take samples at regular intervals and weigh out 50
grams on a balance type scale capable of 0.1 gram accuracy.

5. Place the remaining sample in an air tight container for future testing.

The sample should be saved until the results of the sieving operation are
obtained. If results are questionable, resieving or resampling may be
necessary.

SIEVING THE COAL SAMPLE

NOTE: If a moisture test will be performed, then one half of the gross
sample should be placed in an air tight container after the
rolling/mixing procedure has been completed.

NOTE: Some coals that are high in moisture content will ball up on the
50 mesh sieve. This is an indication that the coal is too wet and it must
be dried before sieving. Drying can be accomplished by placing the
coal in an appropriate drying oven as outlined In the ASTM and ASME
procedures.

Prepare a stack of three sieves (50 mesh, 100 mesh, 200 mesh) with the 50
mesh on top, and the 200 mesh on the bottom. The sieves should be thorough
ly cleaned prior to use by brushing and tapping, or by blowing low pressure air
through them. Place a catch pan on the bottom of the stack. Provide a tight
fitting cover for the top.

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1. Place the pulverizer coal sample that was previously weighed out in the
top sieve.

NOTE: A "Rotap" type shaker is recommended. The mechanical


shaker must be capable of producing a rotary motion of the sieves and
vibrating the sieves by means of a suitable tapping device. A machine
that just vibrates the sieves is not adequate.

2. Install the cover and place the stack in a "Rotap"or equivalent machine.

3. Shake the sample for 5 minutes.

4. Remove the sieves and brush the bottom of the 200 mesh sieve
with a 1" stiff bristle brush so that all of the 200 mesh coal falls into
the pan.

5. Weigh and record the weight of the contents of the pan.

6. Discard the contents from the pan then reassemble the pan with the
sieve stack and place it back on the shaker.

7. Shake the remaining sample for two additional 5 minute periods, re-
peating steps 4. and 5. the cleaning and weighing procedures.

NOTE: If the contents of the pan after the last shake is more than 0.2
grams, then the 5 minute shaking procedure should be repeated until
there is less than 0.2 grams in the pan. Add the weights of all samples
discarded.

To ensure that results are correct, the balance of the sample must be weighed
after shaking is completed to determine the quantity of coal tllat was +50
mesh, +100 mesh and +200 mesh. This is accomplished in the following
manner:

1. Remove the cover and the 50 mesh sieve from the stack.

2. Brush the bottom of the 50 mesh sieve over the 100 mesh sieve so that
any —50 coal is included in the 100 mesh sample. Rap the sieve lightly
with the brush handle to get all of the coal out of the sieve.

3. Weigh and record the weight of the contents of the 50 mesh sieve.

4. Repeat this procedure, steps 2. and 3.,for the 100 mesh and 200 mesh
sieves.

The weight of coal from each sieve is then added to the weight of coal from
the previous sieve(s). These weights are then used to calculate the coal
fineness as follows:

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Sieve Weight on Calculations Calculations Fineness

Mesh Sieve(g) %+(Mesh) %-(Mesh)


50 "x"=0.5 "X"x 2 = 1.0 100-1.0= 1.0%(+50)
99.0%(-50)

100 "Y"=5.2 ("X"+"Y") x 2 = 11.4 100 -11.4= 88.6%(-100)

200 "Z"=10.9 ("X"+"Y"+"Z") x 2 = 31.2 100 -31.2= 68.8%(-200)

The total weight of the sample weighed plus the weight of the —200 mesh
coal (coal through the 200 mesh sieve) should total 48.5 to 51.5 grams. If the
total weight is not within this range, the test should be rerun. Pulverizer
Performance and Coal Fineness should be recorded for future reference. A
suggested form is shown in Figure 4-1.

To check the validity of the test, the results should be plotted on a


RoslinRammler sieves chart. If the fineness results do not plot on or close to a
straight line, then the equipment or sampling procedures should be checked.

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UNIT DESIGNATION

Rated Steam Flow, Ib/hr:tonnes/hr ________________________________________________________________

PuIverizer Designation____________________Rated Capacity _______________________________ Ib/hr :I/min

DATE

TIME

STEAM FLOW Ib/hr

CLASSIFIER SETTING

INITIAL SPRING COMPRESSION in:mm

JOURNAL HYDRAULIC LOADING psig:bar

ECCENTRIC POSITION NUMBER

HOT AIR DUCT PRESSURE in. H20: bar

COLD AIR DUCT PRESSURE in. H20: bar

PULVERIZER INLET PRESSURE in. H20: bar

BOWL DELTA P. in. H20: bar

PULV. DISC. PRESSURE OR in. H20: bar

PULV./FURNACE DELTA P in. H20: bar

FURNACE PRESSURE In. H20: bar

PRIMARY AIR FLOW

PULVERIZER AMPS (Rated_______ )

PULVERIZER OUTLET TEMPERATURE °F: ℃

FEED RATE Ib/hr:Kg/hr

ESTIMATED REJECT RATE GPM:I/min

SERVICE HOURS SINCE LAST ROLLS _____________ _ _ _ ____ _ _ ____ _ _ ____ _ _ ____ _ _ _ _

REPLACEMENT RING

COAL GRINDABILITY (Hargrove Number)

FINENESS % ON 50 MESH SCREEN

% THRU 100 MESH SCREEN

% THRU 200 MESH SCREEN

COMMENTS: (Facts pertinent to fineness results)

Figure 4 - 1, Suggested Pulverizer Performance/Coal Fineness Record

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TABLE OF CONTENTS

GENERAL MAINTENANCE PROCEDURES PART 1

TITLE PAGE NO.

GENERAL MAINTENANCE ......................................................................................... 1 - 1


Interference Fits ............................................................................................... 1 - 3

GENERAL DISASSEMBLY PART 2

INTRODUCTION ......................................................................................................... 2-1


ISOLATION OF THE PULVERIZER ............................................................................ 2-2
OPENING AN ACCESS DOOR ................................................................................... 2-2
JOURNAL OPENING COVER REMOVAL ................................................................... 2-3
JOURNAL TILT OUT ................................................................................................... 2-3
JOURNAL ASSEMBLY REMOVAL ............................................................................. 2-5
JOURNAL ROLL AND SHAFT ASSEMBLY REMOVAL ............................................. 2-6
JOURNAL HEAD REMOVAL ....................................................................................... 2-7
BOWL AND BOWL HUB LIFTING .............................................................................. 2-7
GEARBOX ASSEMBLY REMOVAL ............................................................................ 2-9

GENERAL REASSEMBLY PART 3

GEARBOX ASSEMBLY INSTALLATION . ................................................................... 3-1


BOWL AND VANE WHEEL INSTALLATION .............................................................. 3-3
INNER AIR SEAL INSTALLATION6 ............................................................................ 3-3
SEAL AND GUARD INSTALLATION .......................................................................... 3-4
ASSEMBLY OF THE PULVERIZER LUBRICATION SYSTEM ................................... 3-5
JOURNAL ASSEMBLY INSTALLATION ..................................................................... 3-5
JOURNAL HEAD ASSEMBLY INSTALLATION . .......................................................... 3-6
JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION ..................................... 3-7
JOURNAL TILT IN ....................................................................................................... 3-8
JOURNAL OPENING COVER AND SPRING INSTALLATION .................................... 3-9
ASSEMBLY OF TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ....................... 3 - 10
PULVERIZER MOTOR .............................................................................................. 3 - 10
PREPARATION FOR A RETURN TO SERVICE ....................................................... 3 - 11

PULVERIZER COMPONENT SERVICING PART 4

BULL RING SEGMENT REPLACEMENT ................................................................... 4-1


VANE WHEEL SEGMENT AND AIR RESTRICTION RING REPLACEMENT ............. 4-3
GRINDING ROLL RENEWAL ...................................................................................... 4-4
JOURNAL BEARING END PLAY CHECKING ............................................................. 4-7

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TABLE OF CONTENTS (continued)

PULVERIZER COMPONENT SERVICING (continued) PART 4

TITLE PAGE NO.

JOURNAL BEARING REPLACEMENT ....................................................................... 4-8


Journal Shaft Disassembly .............................................................................. 4-9
Journal Shaft Reassembly Procedures ......................................................... 4 - 10
JOURNAL OIL SEAL REPLACEMENT ..................................................................... 4 - 13
JOURNAL OIL CHECKING PROCEDURES . ............................................................. 4 - 14
JOURNAL SPRING SERVICING ............................................................................... 4 - 15
Journal Spring Disassembly ......................................................................... 4 - 15
Journal Spring Reassembly .......................................................................... 4 - 17
CLASSIFIER DEFLECTOR BLADE REPLACEMENT ............................................... 4 - 18
MAJOR ADJUSTMENTS .......................................................................................... 4 - 19
Roll-ring Clearance ........................................................................................ 4 - 19
Journal Spring Preloading Procedure .......................................................... 4 - 20
Journal Spring Position ................................................................................. 4 - 22
Discharge Valve Limit Switch Set-up ............................................................ 4 - 23
PULVERIZER LINER INSTALLATION PROCEDURES USING WELD PLUGS ........ 4 - 23
Equipment Required ...................................................................................... 4 - 23
Welding Specification .................................................................................... 4 - 24
Application of Weld ,Plugs ............................................................................ 4 - 24
Installation of Tiles - General ........................................................................ 4 - 25
Trouble Shooting ........................................................................................... 4 - 26
LINER REPLACEMENT (GENERAL) ........................................................................ 4 - 27
Installation Procedures for Inner Cone Liners ............................................. 4 - 27
Installation of Inner Cone Spout Segments .................................................. 4 - 28
Installation/Replacement Procedures for Separator Body Liners ............... 4 - 28

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TABLE OF CONTENTS

GENERAL MAINTENANCE PROCEDURES PART 1

TITLE PAGE NO.

GENERAL MAINTENANCE ........................................................................................... 1-1


Interference Fits ................................................................................................. 1-3
HEATING ................................................................................................... 1-3
CHILLING ................................................................................................... 1-3

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PART 1 - GENERAL
MAINTENANCE
PROCEDURES

GENERAL
MAINTENANCE

The pulverizer is a rugged machine, designed and built for continuous


operation over an extended period, with minimal wear on the working parts.
However, iron pyrites and other abrasive substances in the coal will shorten
the life of parts such as the rolls, bull ring, deflector liners, intermediate liners,
vane wheel liners, millside liners, inner cone liners and scrapers.

Since wear of pulverizer parts depends on many factors that vary from one
installation to another, it is difficult to prescribe a specific routine inspection
and maintenance program. Characteristics of the coal, .operating hours of
individual pulverizers, availability of pulverizers due to unit load demands,
and availability of maintenance personnel are all factors that determine the
frequency and scheduling of pulverizer inspections and maintenance. An
effective program can be established only on the basis of actual plant
operating experience. It is, therefore, imperative that an accurate log be
maintained on each pulverizer from initial installation, to relate individual
pulverizer running time (see NOTE) with pulverizer performance, plant
operating schedules, unit load, outages, inspection reports and other
associated data.

NOTE: Pulverizer wear is a function of the number of hours a


pulverizer is grinding coal, not necessarily the amount, in tons, of coal
pulverized. While operating at reduced capacities a pulverizer will last
somewhat longer, but will grind much less tonnage before it becomes
necessary to replace parts.

Pulverizer part replacement criteria cannot always be defined in advance.


They must be established on the basis of experience and judgment on the
part of personnel familiar with the pulverizer history and performance. The
degree, location and pattern of wear will soon become evident and can be
handled accordingly. In some cases wear surfaces can be built up; in other
instances, replacement of the part is more practical. The following list
describes the pulverizer parts normally subject to wear:

1. Bull Ring and Rolls

Reduced pulverizer capacity and increased spillage are indications of


excessive wear. Contour templates, made when the equipment is new, may
aid in checking the degree and location of wear as it progresses.

2. Deflector Liners, Intermediate Liners, and Vane Liner Assemblies

Some pulverizers are supplied with ceramic or other types of internal Iiners,
their degree of wear Will vary considerably from one installation to another
and sometimes between pulverizers at the same plant. Individual liners must
be replaced when thinning and holes indicate excessive wear.

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3. Vane Wheel

Maintain a clearance of 1/2 in.±1/8 in. (12.7 mm :±3.2 mm) between the top
of the vane wheel adjustable shroud and the bottom of the intermediate and
deflector liners. Replace shroud when adjustments can no longer be made.
Replace vane wheel segments and/or air restriction segments if excessively
worn.

4. Bowl Extension Ring

The ring should be replaced when worn excessively.

5. Pulverizer Bottom Cover Plates

Replace cover plates when worn. Wear can be minimized by maint- aining
proper support of the scraper blades.

6. Millside Liners and Air Inlet Vanes

Excessive rejects will cause wear on liners and edges of vanes. Replace or
rebuild if excessively worn.

7. Scrapers

Bottom edges are most susceptible to wear and can be built up with welding
material. Maintaining proper support (pins and bushings) helps to minimize
wear.

8. Pulverizer Discharge Valves

Excessive clearance in closed position is an indication of wear. Disc outside


diameter can be built up by welding and remachining.

Most inspection and repair work inside the pulverizer above the bowl can be
accomplished by removing one journal opening cover and one journal shaft
assembly. Work below the bowl can usually be done through the pulverizer
millside access door(s).

WARNING: WHEN MAINTENANCE IS REQUIRED ON A


PULVERIZER WHILE THE UNIT IS IN OPERATION, MAKE SURE
THE PULVERIZER IS COMPLETELY ISOLATED (DAMPERS, GATES,
FIRE SUPPRESSION SYSTEMS, AND VALVES CLOSED, MOTOR
CIRCUIT BREAKERS LOCKED OPEN, AND THE MEANS FOR
OPERATING THIS EQUIPMENT SUITABLY TAGGED) BEFORE
ENTERING THE PULVERIZER.

CAUTION: WHEN WELDING ON A BOWL, ROLL OR ANY PART OF


THE PULVERIZER, THE WELDING MACHINE SHOULD BE
GROUNDED TO THE COMPONENT BEING WELDED IN ORDER TO
PREVENT ARCING ACROSS BEARINGS IN THE GEAR CASE OR
JOURNALS.

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9. Bearings
Unusual noise and operating temperatures consistently above normal are
indications of impending bearing failure. Bearings should be inspected at the
first opportunity.

10. Gearbox

These components usually give long, trouble-free service. However, failure of


other components can accelerate their wear.

Interference Fits

Where components have been designed with interference fits, it is frequently


necessary to heat and/or cool the mating parts to facilitate assembly.

HEATING

Heat must be applied uniformly to the entire piece. Acetylene torches with
rosebud tips are not recommended, since heating by this method is not
sufficiently uniform. Heat can best be supplied in a commercial type oven or
an oil bath. However, it is also possible to shroud the part in an insulated
enclosure and increase the part temperature with space heaters, or stress
relieving blankets. A 2 hour minimum for heating ls recommended.

CHILLING

Components can be chilled in a commercial freezer. They may also be chilled


in a dry ice and alcohol bath (—40°F,—40℃) or by packing in dry ice. Before
submerging a part in a chilling bath, it should be coated with a thin layer of
grease. Components should be chilled for a minimum of 3 hours.

1-3
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TABLE OF CONTENTS

GENERAL DISASSEMBLY PART 2

TITLE PAGE NO.

INTRODUCTION ........................................................................................................................... 2-1


ISOLATION OF THE PULVERIZER .............................................................................................. 2-2
OPENING AN ACCESS DOOR ..................................................................................................... 2-2
JOURNAL OPENING COVER REMOVAL .................................................................................... 2-3
JOURNAL TILT OUT .................................................................................................................... 2-3
JOURNAL ASSEMBLY REMOVAL ............................................................................................... 2-5
JOURNAL ROLL AND SHAFT ASSEMBLY REMOVAL ............................................................... 2-6
JOURNAL HEAD REMOVAL ........................................................................................................ 2-7
BOWL AND BOWL HUB LIFTING5 .............................................................................................. 2-7
GEARBOX ASSEMBLY REMOVAL ................................................................................................ 2 - 9

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PART 2 - GENERAL
DISASSEMBLY

INTRODUCTION

This section of the manual has been prepared to serve as a guide in


maintaining HP Pulverizers. It does not cover all possible variations in
equipment nor provide solutions for special problems which may arise. Should
additional information be required,SHANGHAI HEAVY MACHINERY PLANT
Co.Ltd (SHMP) should be contacted.

It must be recognized that no amount of written instructions can replace in-


telligent thinking and reasoning by maintenance personnel and boiler op-
erators, especially under unpredictable conditions. It is the responsibility of the
maintenance person or operator to become completely familiar with the
equipment covered in this manual, along with the pertinent control and aux-
iliary equipment.

Maintenance of controls and auxiliary equipment associated with the pul-


verizer but not provided by SHMP is the sole responsibility of the
owner/operator and their maintenance and operating personnel.

For most maintenance procedures a complete general disassembly of the


pulverizer is not required. Access to all internal wear parts can be made
through the three journal opening covers or the separator body and m illside
access doors. To facilitate maintenance on the drive components, the gear-
box assembly is removable. This is accomplished by disconnecting the bowl
assembly from the gearbox, lifting the bowl assembly within the separator
body and allowing the gearbox to slide out from underthe millside assembly.
Once the gearbox is removed from under the pulverizer, access to the drive
components is through the gearbox access cover. Refer to the instructions
provided by the gearbox manufacturer.

The following text provides procedures for removal and installation of the
individual pulverizer components necessary to permit the inspection and
maintenance of the wear parts and drive components of the pulverizer.
Illustrations depict a sequence for disassembly and assembly. Review the
Bowl Mill Cross Section (drawing K7038.00) for orientation and location of
major components. Detailed procedures covering the repair of major
subassemblies can be found in other sections of this manual.

2-1

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ISOLATION OF THE
PULVERIZER

WARNING: USE PROCEDURES ADOPTED BY YOUR PLANT,


LOCKS, TAGS, LOG NOTES, ETC., TO ENSURE THAT GATES,
VALVES, DAMPERS, PUMPS, MOTORS AND FIRE SUPPRESSION
SYSTEMS ASSOCIATED WITH AN ISOLATED PULVERIZER ARE
NOT INADVERTENTLY OPERATED WHILE A PULVERIZER IS
OPENED FOR INSPECTION OR MAINTENANCE.

BEFORE ENTERING THE PULVERIZER, ENSURE THAT THE


GEARBOX DRIVE SHAFT IS BLOCKED TO PREVENT ROTATION
OF THE BOWL, ESPECIALLY IF THE PULVERIZER CONTAINS
COAL.

1. To isolate the pulverizer close the hot air shutoff gate, the cold air shutoff
gate, the pulverizer discharge valves, the coal line gates (if provided),
the vent air and seal air shutoff valves, and the feeder discharge vaive (if
provided).

2. Open the pulverizer and feeder motor breakers.

3. Disconnect the pulverizer motor coupling at the gearbox and block it from
rotating.

4. Isolate, lock shut, and tag inoperative applicable fire suppression


systems.

5. Ensure that pulverizer is depressurized by opening a millside and/or a


separator body access door.

OPENING AN
ACCESS DOOR

NOTE: Put on a face shield or goggles before performing the next


steps. Some coal dust and debris may discharge from around the door,
therefore, eye protection is recommended.

1. Carefully crack open the pyrites hopper door, then open it completely.

2. Remove all but the four corner bolts/nuts from an inspection door.

3. Back off the corner bolts/nuts three or four turns and rap the flange to
break the seal.

4. Remove the bolts/nuts and the door.

5. Open the other inspection and millside doors as required for access.

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JOURNAL OPENING
COVER REMOVAL

The journal opening cover and spring assembly is normally removed as a unit.

1. Disconnect the seal air supply lines from the trunnions hafts and journal
spring assembly. Refer to drawing K7038.8.0 Remove the trunnion shaft
air riser and plug the seal air header opening.

2. Remove the hex head cap screws from the stop bolts ,refer to
K7006.13.0 Section "A - A" and remove the lock bar and retaining lugs.
Back out the journal stop bolts until the roll is resting on the bowl.

3. Equally loosen the eight hex nuts that retain the spring assembly on the
studs. If there is any pressure on the spring assembly, it will back out of
the journal cover. Stop loosening the nuts when no movement is evident.

WARNING: THE JOURNAL OPENING COVER & SPRING


ASSEMBLY WEIGHS APPROXIMATELY 3537KG AND MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

4. Center the crane directly above the journal opening. Rig the journal
opening cover for removal using the two lifting holes provided in the top
edge of the cover. Take up a slight load on the lift rigging.

5. Remove the hex head cap screws that secure the journal opening cover
to the separator body.

6. Remove the journal opening cover and spring assembly. Move it to a


convenient storage area.

JOURNAL TILT OUT

NOTE: Refer to drawing K7038.00 for clearances required on


KF7006.4.0 when using the following procedure unless otherwise
stated.

1. Remove the journal opening cover and spring assembly.

2. Insert the top "shoe" of the journal tilt out bracket [Approximately 300 kg]
into the bracket above the separator body journal cover opening.

3. Secure the journal tilt out bracket to the separator body journal cover
opening with hex head cap screws.

4. Install the safety bracket loosely to the journal cover opening with hex
head cap screws.

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5. Check the trunnion shaft end caps and replace the trunnion shaft bolts
(refer to drawing K7006.8.0(A) )

6. Turn one journal stop bolt to lift the grinding roll from the bull ring. Rotate
the roll until the M36 tapped holes on top of the journal housing are at 12
O'clock (refer to drawing KF7006.4.0 )

7. Remove existing set screws and install lug using hex head cap screws .

8. Remove journal head cover plate and set it aside.

NOTE: If maintenance will be performed on the journal shaft assembly


then consideration should be given to pumping oil out of the bearing
housing.

9. Remove the oil fill pipe. Place the pipe plug in the journal shaft to
prevent oil leakage.

10. Remove the shaft from the lower beams of the tilt out bracket. Attach
snatch block to an overhead crane, thread the cable over the snatch
block sheave.

CAUTION: ENSURE THAT THE CRANE IS CORRECTLY


POSITIONED FOR A VERTICAL LINE OF PULL.

11. Attach the cable to lug and tilt out bracket as shown on drawing
KF7006.4.0.

WARNING: STAND CLEAR OF THE JOURNAL AND TILT OUT


ASSEMBLY DURING A TILT OUT PROCEDURE.

WARNING: AS THE SNATCH BLOCK IS LIFTED, THE CABLE WILL


GO SLACK AND THEN TIGHTEN WHEN THE JOURNAL FALLS
OUTWARD AS ITS CENTER OF GRAVITY PASSES OVER THE TOP
OF THE TRUNNION SHAFT (PIVOT POINT). LIFTING SHOULD
STOP ONCE THE CABLE GOES SLACK.

12. SLOWLY raise the snatch block vertically until the distance between the
tilt lug connection and the active bracket sheave reaches a minimum
(Position 2, drawing KF7006.4.0 )

13. After the journal fails outward, SLOWLY lower the snatch block and tilt
out lug to position 3. The journal head should contact and rest on the
safety bracket.

14. Install hex head cap screws and washers, brough the safety bracket and
into the journal head, tighten all screws per B-GP-2175 to lock the journal
in the tilted position. This will prevent the journal from falling into or out of
the mill when the tilt rigging is removed.

15. Remove the tilt out rigging and tilt out bracket.

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JOURNAL ASSEMBLY
REMOVAL

If pulverizer repairs will be extensive, it may be advantageous to completely


remove the journal assemblies. if access to the pulverizer is only for the
purpose of inspection or minor maintenance, then removing only the journal
roll and shaft assembly may be sufficient. (Refer to Journal Roll and Shaft
Assembly Removal, Page 2 - 6)

1. Remove the journal opening cover.

2. Tilt out the journal assembly.

3. Remove two grinding roll keeper bolts 180° apart and install two eye
bolts to the full depth of the threads. Ensure that the eyebolt flange rest
securely against the journal keepers.

WARNING: THE JOURNAL ASSEMBLY WEIGHS


APPROXIMATELY 7362Kg , TRUNNION SHAFTS WEIGH
APPROXIMATELY 148Kg EACH. ALL MUST BE ADEQUATELY
RIGGED TO ENSURE SAFE HANDLING.

WARNING: THE OVERHEAD CRANE MUST SUPPORT THE


JOURNAL ASSEMBLY AT ALL TIMES DURING THE REMOVAL
PROCEDURE.

4. Install a chain shackle in each eye bolt and attach a chain sling. The sling
should be parallel to and must clear the separator body journal opening
when loaded.

5. Attach the chain sling to an overhead crane positioned above the center
of lhe door opening. Take up slack.

NOTE: The chain sling and crane cable must not contact the
separator body when the journal assembly is being lifted out of the
separator body opening.

6. Remove the safety bolts from the journal head.

7. Remove the cap screws from the trunnion shaft end caps.

8. Use jacking bolts in the threaded holes to remove the trunnion shafts
from the journal head.

9. As the trunnion shafts clear the journal head, remove the thrust plates
and swing the journal assembly clear of the classifier body.

10. Inspect the trunnion shaft bushings.

11. Move the journal assembly to a convenient work area.

12. Store the trunnion shafts and thrust plates until required for reassembly.

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JOURNAL ROLL AND
SHAFT ASSEMBLY
REMOVAL

If repairs are required on the journal shaft assembly only, or less access to the
separator body is required, it may be easier to remove just the journal roll and
shaft assemblies and leave the journal heads in place. The procedure and
equipment arrangement are explained in the following text.

NOTE: For the following procedures, refer to drawing K7006(A).12.0


Unless otherwise stated.

1. Remove the journal opening cover.

2. Remove the journal head cover plate and the journal oil fill plug and pipe
assembly. Remove the pipe plug from the assembly and replace the plug
in the end of the journal shaft assembly.

NOTE: If maintenance is to be performed upon the journal shaft


assembly then consideration should be given to pumping oil out of the
bearing housing at this time.

3. Install the journal head safety brackets and perform the Journal Tilt Out
procedure, Page 2 - 3.

4. Remove eight grinding roll keeper bolts and install eight screws to the full
depth of the threads. Grinding roll removal lug should be flush with the
roll keeper surface.

WARNING: THE JOURNAL ROLL AND SHAFT ASSEMBLY MUST


BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING. THE
OVERHEAD CRANE MUST SUPPORTTHE JOURNAL ROLL AND
SHAFT ASSEMBLY AT ALL TIMES DURING THE REMOVAL
PROCEDURE.

5. Install a chain shackle in grinding roll removal lug and attach a chain
sling. The sling should be parallel to and must clear the separator body
journal opening when loaded.

6. Attach the chain sling to an overhead crane positioned above the center
of the journal opening. Take up slack.

NOTE: The chain sling and crane cable must not contact the
separator body when the journal roll and shaft assembly is lifted out of
the separator body journal opening.

7. Remove the journal skirt.

NOTE: Some journals are equipped with journal head liners. If supplied, they
must be removed at this time. The journal head liners are custom fit during
assembly and some liners may not be interchangeable. It is imperative that
each liner be identified and marked so that it can be reinstailed on the same
journal from which it was removed.

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8. Remove the journal shaft flange bolts.

9. Lift the journal roll and shaft assembly clear of the journal head. Swing
the assembly out of the separator body journal opening and move it to a
convenient work area.

JOURNAL HEAD
REMOVAL

If, after the journal roll and shaft has been removed, it is necessary to move
the journal head the following procedures may be used.

NOTE: Refer to drawing K7006(A).12.0.

WARNING: THE JOURNAL HEAD WEIGHS APPROXIMATELY


1500Kg, TRUNNION SHAFTS WEIGH APPROXIMATELY 148Kg
EACH. ALL MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

1. Install two M36 eyebolts in the head flange 180° apart.

2. Install a chain shackle in each eyebolt and attach a chain sling.

3. Attach the chain sling to an overhead crane positioned above the center
of the journal door opening. Take up slack.

CAUTION: THE CRANE MUST PROVIDE SUPPORT FOR THE


JOURNAL HEAD DURING THE ENTIRE REMOVAL PROCEDURE.

4. Remove the safety bolts from the journal head.

5. Remove the cap screws from the trunnion shaft end caps.

6. Use jacking bolts to remove the trunnion shafts from the journal head.

7. When the trunnion shafts clear the journal head, remove the thrust plates
and swing the head clear of the classifier body.

8. Inspect the trunnion shaft bushings.

9. Move the journal head to a convenient work or storage area.

10. Store the trunnion shafts and th rust plates until required for reassembly.

BOWL AND BOWL HUB


LIFTING

In order to access the gearbox for major maintenance, it must be removed


from under the mill. The bowl and bowl hub assembly must be lifted clear of
the gearbox to do this.

NOTE: Refer to drawing KF7006.8.0.


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1. Remove the three journal opening covers.

2. Tilt out all journal assemblies, refer to Page 2 - 3.

3. Remove all journal assemblies, refer to Page 2 - 5.

4. Open the millside access doors.

NOTE: Before disassembly, verify that each piece is identified and


match marked. Skirt assemblies are fabricated as a set and segments
are not interchangeable.

5. Remove the scraper assemblies and move them to the outer edge of the
millside.

6. Disassemble the components of the bowl hub air seal (Refer to drawings
K7038.00. Use care not to damage the upper surface of the inner air
seal ring.

7. Remove the seal and guard assembly (refer to drawing K7006.10.0 ).

NOTE: Clearances must be reestablished when the seal and guard


assembly is reinstailed. Ensure that each piece is match marked prior
to its removal, this will significantly aid in reinstallation and adjustment.

8. Start the lubrication oil system and turn the bowl by hand until one 1 in.
hex socket head cap screw located in the bowl extension ring is
posirioned at the center line of each journal opening.

9. Remove that cap screw and adjacent cap screws on each side, for a total
of three at each opening.

10. Install bowl lifting lugs and bowl lifting frame lug at each journal opening.
Refer to drawing KF7006.8.0 .

11. Loosen the bolts that secure the vane wheel adjustable shroud (refer to
drawing K7006.9.0) to the vane wheel segments. Lower the adjustable
shroud segments as far as possib e to provide adequate clearance for
lifting the bowl.

12. Remove the hex socket head cap screws that secure the bowl hub cover
wear plate to the bowl hub and remove the cover wear plate.

13. Install the stud tensioner on one of the studs that secures the bowl hub
assembly to the gearbox. Release the tension on each stud in turn, use
the sequence shown on Section of Drawing K7038.00. Tension the studs
to the values indicated and loosen the hex nut in steps until all are loose.
Remove the nuts and then remove all 8 studs from the hub.

a. Tension studs first round to 90,000 lbs (40824kg).

b. Tension studs second round to 120,000 lbs (54432kg).

WARNING: THE BOWL AND VANE WHEEL ASSEMBLY WEIGHS


APPROXIMATELY 14555Kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

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14. Attach three chain hoists or come alongs [each with a 5MT minimum
capacity] to the journal opening frame lugs and the bowl lifting lugs, refer
to drawing KF7006.8.0.

15. Lift the bowl and vane wheel assembly until the vane wheel shroud just
touches the intermediate and deflector liners [approximately 2 in. (50
mm)]. Stabilize the bowl hub assembly with screw jacks or cribbing.

16. Remove the gearbox

GEARBOX ASSEMBLY
REMOVAL

1. Remove three journal opening covers and springs, refer to Page 2 - 3.

2. Remove the three journal assemblies, refer to Page 2 - 5.

3. Lift the bowl and bowl hub assembly, refer to Page 2 - 7.

4. Disconnect and remove the pyrite hopper.

5. Isolate the lubrication system and disconnectthe oil lines from the
gearbox. Cap or cover all openings to keep the system clean.

6. Disconnect the wiring from the bearing thermocouples, and from the
other monitoring equipment on the gearbox. Mark and secure the wiring.

NOTE: Reference drawing K7038.00 .The gearbox will be removed


away from the motor or driven end.

7. If not previously done, remove the coupling guard and disconnect the
drive coupling.

8. Remove the hex head cap screws that secure the gearbox to its sole
plate.

9. Remove the dowel pins that align the gearbox.

10. Place the gearbox removal rails on cribbing or a steel frame built up from
the floor.Ensure that top of the rails are flush with the sole plate,then
attach to the sole plate,see drawing KF7006.7.0 .

11. Slide the gearbox onto the rails.

WARNING: THE GEARBOX WEIGHS APPROXIMATELY 14086kg


AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

12. Once the gearbox is out from under the pulverizer,it may be moved to a
maintenance are for disassembly.

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13. If a replacement gearbox will not be installed immediately,build a steel
or wood crib capable of supporting the weight of the bowl and vane wheel
assembly,approximately 14555kg under the bowl hub.The height of the
crib should be set so that when the bowl hub,bowl and vane wheel
assembly is placed on it ,the assembly will be at approximately the same
height it was before disassembly.

14. Lower the bowl and vane wheel assembly onto the cribbing.

15. Stabilize the bowl hub assembly with screw jacks or cribbing. If
necessary ,remove the lift rigging to provide access to the interior of the
pulverizer.Refer to vendor supplied instructions for gearbox maintenance
procedures.

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TABLE OF CONTENTS

GENERAL REASSEMBLY PART 3

TITLE PAGE NO.

GEARBOX ASSEMBLY INSTALLATION ........................................................................................ 3 - 1


BOWL AND VANE WHEEL INSTALLATION ................................................................................... 3 - 3
INNER AIR SEAL INSTALLATION .................................................................................................. 3 - 3
SEAL AND GUARD INSTALLATION ............................................................................................... 3 - 4
ASSEMBLY OF THE PULVERIZER LUBRICATION SYSTEM ........................................................ 3 - 5
JOURNAL ASSEMBLY INSTALLATION ......................................................................................... 3 - 5
JOURNAL HEAD ASSEMBLY INSTALLATION ............................................................................... 3 - 6
JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION .......................................................... 3 - 7
JOURNAL TILT IN ........................................................................................................................... 3 - 8
JOURNAL OPENING COYER AND SPRING INSTALLATION ........................................................ 3 - 9
ASSEMBLY OF TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ........................................... 3 - 10
PULVERIZER MOTOR ................................................................................................................... 3 - 10
PREPARATION FOR A RETURN TO SERVICE ............................................................................ 3 - 11

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PART 3 - GENERAL
REASSEMBLY

GEARBOX ASSEMBLY
INSTALLATION

The gearbox assembly is installed by silding it into position under the


assembled pulverizer special fixtures are used to assist in this procedure.
Reference drawing KF7006.7.0 and gearbox vendor instruction manual for
details on preparation and handling.

NOTE: Prior to installing the gearbox under the pulverizer, ensure that
two dowel pins are installed in the gearbox output adapter. Use Loctite
RC680 and install the pins so that they protrude 0.600 in .±0.015 in
(15.24mm±0.38mm). Refer to K7038.00.

WARNING: THE PULVERIZER GEARBOX WEIGHS


APPROXIMATELY 14086kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

NOTE: If a new or different gearbox assembly is installed under a


pulverizer, it will be necessary to drill new dowel pin holes in the
gearbox mounting flange and sole plate .These must be located at
least 6 in.(153mm) away from the original dowel pin holes.

If the same gearbox is being reinstalled and if perfect alignment of the


original holes can be achieved, the same size dowel pins may be
used.However,it is permissible(and possibly easier)to re-drill and ream
the holes at the old location and install larger diameter [+1/4
in.(6.35mm)] dowel pins.

If installing a new or different gearbox perform steps 1and 2 ,if reinstalling the
same gearbox skip to step 3.

1. As necessary,drill two 1.33in.(33.8 mm) pilot holes 180 ° apart in the


gearbox bottom flange. Pilot holes should be at least 6 in.(153mm) away
from existing dowel pin holes.

2. Attach the gearbox removal rails to the gearbox sole plate opposite the
pulverizer motor location.Support them on cribbing or a steel framework
at the level of the gearbox sole plate.Reference KF7006.7.0.

3. If the gearbox removal equipment is still in place,assure that it is clean,


apply a light film of oil and set the gearbox assembly on the fixture.The
gearbox must be positioned adjacent to the pulverizer foundation,oriented
with the driven end nearest the motor location.

4. Attach three chain hoists or come-alongs[(5MT) minimum capacity each]


to the journal opening frames and the bowl and vane wheel assembly
(Refer to KF7006.8.0 ).

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WARNING: THE BOWL AND VANE WHEEL ASSEMBLY WEIGHS
APPROXIMATELY 14555Kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

5. Lift the bowl and vane wheel assembly until the vane wheel shroud just
touches the intermediate and deflector liners.

6. Remove the bowl hub assembly support cribbing.

7. Slide the gearbox assembly into position under the millside. Check that
the bolt holes line up with the tapped holes in the sole plate.

8. Install the washers and cap screws which secure the gearbox to the
gearbox sole plate (hand tight with Fel-Pro C5-A anti-seize compound or
equal)

9. Remove the gearbox removal fixture.

10. Install the gearbox millside adjustment blocks on the sole plate.Refer to
KF7006.7.0.

CAUTION: ENSURE THAT THE UPPER RESERVOIR OF THE


GEARBOX IS FULL OF OIL TO THE LEVEL INDICATED ON
ITSSIGHT GLASS BEFORE TURNING THE GEARBOX SHAFT.

11. Ensure that the mating surfaces of the bowl hub and the gearbox adapter
are clean then apply a light coating of anti-size lubricant.

12. The input shaft of the gearbox may be turned by hand to get the dowel
pins in the output adaptor to line up with the dowel pin holes in the bowl
hub. When aligned, lower the bowl and vane wheel onto the gearbox
assembly. Be sure that the pins are properly engaged and that the hub is
firmly seated on the gearbox output adaptor.

13. Apply thread locking sealant to the first two inches (50.8mm) of the 8 –
M48. studs that hold the bowl hub to the gearbox. Install studs so that
thread engagement into the output plate is2.50 in. +0.06 in. -0.00 in (63.5
mm +1.52 mm -0.00 mm). Refer to drawing K7038.00.

14. Install the hex nuts with washers (apply anti-seize compound) and snug
the nuts with a slugging wrench.

15. Using a hydraulic stud tensioner KF7006.3.0 , tension each stud to


90,000Ibs (40824kg). Reference drawing K7038.00. for the
recommended numerical sequence.

16. Repeat step 15. to 120,000 lbs (54432kg).

17. Remove the bowl and vane wheel hoisting fixtures.

18. Apply RTV sealer between the bowl hub cover plate lower and the bowl
hub. Install hex socket cap screws and torque to 75 ft lb (963 Nm).

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19. Apply RTV sealer (PIN -2226) between the bowl hub cover and the cover
plate lower (refer to Figure 7). Install hex socket cap screws and torque to
75 ft lb (963 Nm).

20. Use the drive adjustment blocks (refer to drawing KF7006.6.0 ), shift the
gearbox to align the dowel holes of the reinstailed gearbox or center the
gearbox assembly to the millside within 0.010 in. (0.25 mm). For this
setting, measure from the seal air ring bore in the millside to the outside
diameter of the bowl hub.

21. Set the air seal clearance before dowelling the gearbox to the sole
plate. Refer to " Air Seal Installation" Page 3 - 3.

22. Mount a drilling rig above each of the dowel pin holes in the gearbox
mounting flange.

23. Drill and ream oversize for new dowel pins or using the 34 rnm pilot holes
in the gearbox flange, drill and ream 40mmH7 holes into the sole plate to
a depth of 4.50 in. (114.3 mm).

24. Lubricate the dowel pins with Molykote GN-Paste, or an equivalent, and
press fit the dowel pins into the reamed holes.

25. Torque the fasteners holding the gearbox to the gearbox sole plate per B-
GP-2175.

BOWL AND VANE


WHEEL INSTALLATION

1. Install the bowl assembly to the gearbox per steps 11. thru 19. of the
"Gearbox Assembly Installation" procedure, Page 3 - 1.

2. Remove the bowl hub hoisting fixtures.

3. Position the vane wheel adjustable shroud segments as indicated on


drawing K7006.9.0. Set the shroud to separator liner clearance to 0.50 in.
±0.12 in. (12.7 m m ±3.05 m m) then tighten the bolts that secure the
vane wheel adjustable shroud to the vane wheel segments per B-GP-
2175.

Continue the reassembly of the pulverizer by setting the inner air seal
clearance.

INNER AIR SEAL


INSTALLATION

NOTE: The following steps refer to drawings K7038.00 and K7038.5.0.

NOTE: Apply anti-seize compound to all fasteners and torque all


fasteners per B-GP-2175 unless otherwise specified.

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1. Clean the surfaces of the mill bottom on which the inner air seal
assembly will seat. Install the air seal ring segments into the mill bottom
without the shims. Hand tighten the fasteners.

2. Refer to K7038.00 measure the gap between the bowl hub and the inner
air seal ring.

NOTE: It may be necessary to reposition the gearbox (refer to


KF7006.7.0 ) to obtain acceptable clearances at 30 ° intervals
around the perimeter of the skirt. Removal and reinstallation of skirt
sections will be required.

3. Select shims from the shim pack to raise the air seal ring and provide a
clearance of 0.5 mm ± 0.25 mm.

4. Disassemble sections of the seal. Apply anti seize compound to the


fasteners

5. Install the shim pack and reassemble the seal section in the same order
that it was removed. Apply RTV-106 to the joints and torque the fasteners
per B-GP-2175.

6. Rotate the bowl and repeat steps 4 and 5 for the six sections of the inner
air seal.

7. Attach the scraper and guard assemblies to the bowl hub. Verify
clearance of 8 mm ±1.5 mm between the scraper and the mill bottom
cover plates. Torque hex socket head cap screws to 136 ft .lb. (184 Nm).

SEAL AND GUARD


INSTALLATION

This procedure can be performed after the inner air seal clearance has been
set and the gearbox has been doweled to its sole plate.

NOTE: The seal and guard assembly can be installed if the upper
reservoir of the gearbox is full of oil or the lube oil system is available.

NOTE: The following steps refer to drawings K7006.10.0 unless


otherwise stated.

1. Adjust the seal ring to ensure that the gap between its dimension φ1350
and bowl is uniform.

2. Apply studs with sealant Loctite and tighten them. Fix packing gland
around the bowl per matching mark.

3. Put the packing into the seal ring, tighten nuts and press packing with
packing gland.

4. Install sharp pointed pins.

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ASSEMBLY OF THE
PULVERIZER
LUBRICATION
SYSTEM

NOTE: Refer to Gearbox and Lube Oil System manufacturers' In-


struction Manuals for details.

1. Reconnect the wiring to the bearing thermocouples, the monitoring


equipment and to the heaters on the gearbox.

2. Remove covers and connect the supply and return oil lines to the
gearbox.

JOURNAL ASSEMBLY
INSTALLATION

This prclcedure should be used if the journal head and journal shaft
assemblies were removed from the pulverizer as a unit. If they were removed
separately refer to "Journal Head Assembly Installation", Page 3 – 6 and to
"Journal Roll And Shaft Assembly Installation", Page 3 - 7 for procedures.

For tools and components used in this procedures refer to drawing


K7006(A).12.0 .

WARNING: AN OVERHEAD CRANE MUST SUPPORT THE


JOURNAL ASSEMBLY AT ALL TIMES DURING THE INSTALLATION
PROCEDURE.

WARNING: THE JOURNAL ASSEMBLY WEIGHS


APPROXIMATELY 7362kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

WARNING: TRUNNION SHAFTS WEIGH APPROXIMATELY 148kg


EACH AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

1. Remove the journal opening cover from the separator body.

2. Remove the thrust plates, fasteners and pipe nipple from the separator
body.

3. Pull the trunnion shafts out approximately 1.38”(35mm). Do not exceed


1.50”(38.1mm).

4. Temporarily install the safety bracket (according to drawing KF7006)


using fasteners.

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5. Lift the journal assembly and install it in the separator body. The large
arm of journal head should be pointing down and be outside the journal
opening frame as depicted on drawing KF7006.4.0. Slide the trunnion
shafts in and engage the pilots with the journal head. Be sure that they
are fully seated and not riding up on the jack screws. Fasten, finger tight
at this point, the trunnion shafts to the journal head.

6. Fasten the journal assembly to the safety bracket with fasteners.

7. Remove the rigging holding the journal assembly.

8. Torque the journal head to trunnion shaft fasteners using the supplied
torque wrench to the value shown on drawing K7038.00.

9. Grease the thrust plate faces, reinstall them with fasteners and pipe
nipple removed previously from the separator body.

10. Center the journal tilt-out bracket assembly on the journal opening frame,
and secure it with fasteners. Install lug, shackle and wire rope cable.

11. Tilt in the journal assembly using the Journal Tilt-In Procedure.

JOURNAL HEAD
ASSEMBLY
INSTALLATION

NOTE: Refer to drawing K7006(A).12.0.

1. With the journal head laying flange side up, install two M36 eye bolts
180° apart in the head flange.

WARNING: THE JOURNAL HEAD WEIGHS APPROXIMATELY


1500kg AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

2. Install a chain shackle in each eyebolt and attach a chain sling.

3. Rig the chain sling to an overhead crane positioned above the center of
the separator body journal opening. Take up slack.

4. Place the thrust and trunnion shafts near the appropriate side of the
journal opening. Remove the pipe plugs from the seal air opening.

5. Attach the journal head Tilt Out safety bracket to the separator body.

6. Lift the head and remove the journal head cover plate.

7. Position the journal head in the separator body journal opening. Align the
trunnion shaft openings and bolt the journal head to the safety bracket.
Torque the safety bracket bolts.

8. Secure the trunnion shafts to the separator body with hex head cap
screws. Lubricate and torque the bolts per drawing B-GP-2175.

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9. Ensure that the journal head is supported by the tilt out safety bracket,
disconnect the rigging.

10. Rremove the eyebolts and proceed to install the journal roll and shaft
assembly.

JOURNAL ROLL AND


SHAFT ASSEMBLY
INSTALLATION

NOTE: Refer to drawing K7006(A).12.0.

1. Move the journal roll and shaft assembly adjacent to the mill.

2. Remove eight of the grinding roll keeper bolts and install eight screws to
the full depth of the threads. Ensure that the grinding roll removal lug
contact the grinding roll keeper plates.

WARNING: THE JOURNAL ROLL AND SHAFT ASSEMBLY MUST


BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

3. Install a chain shackle in grinding roll removal lug and attach a chain
sling.

WARNING: THE OVERHEAD CRANE MUST SUPPORT THE


JOURNAL SHAFT ASSEMBLY AT ALL TIMES DURING THE
INSTALLATION PROCEDURE.

4. Attach the chain sling to the the overhead crane. Take up slack.

NOTE: The slings and crane cable must not contact the separator
body when the journal roll and shaft assembly is lifted into position.

5. Clean the mating surfaces of the journal head assembly and the journal
shaft flange.

NOTE: To ensure correct assembly, one bolt hole in the journal shaft
is offset 13 mm.

6. Set the journal roll and shaft assembly in position on the journal head
assembly. Align the holes in the journal shaft flange with the tapped holes
in the journal head.

7. Install hex socket head cap screws using thread locking compound.
Torque fasteners in the sequence and steps shown on drawing
K7006(A).12.0 Section "A-A".

8. Install the journal head skirt, torque fasteners per drawing B-GP-2175.

NOTE: If journal head liners were supplied, they should be replaced at


this time.

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9. Ensure that the journal Tilt Out safety bracket is properly installed then
disconnect the crane and rein ove the chain sling and eyebolts. Reinstall
the grinding roll keeper bolts. Torque the fasteners.

10. Use the Journal Tilt In procedure to return the roll into the bowl.

JOURNAL TILT IN

1. Insert the top "shoe" of the journal tilt out bracket into the bracket
above the separator body journal opening.

2. Secure the journal tilt out bracket assembly to the separator body journal
opening with hex head cap screws.

3. Remove set screws and attach the tilt out lug to the journal housing.

4. Ensure that the shaft removed from the lower beams of the tilt out bracket
for the tilt out procedure is replaced.

5. Center the crane directly over the separator body journal opening and
attach the snatch block.

6. Thread the cable through the snatch block and sheaves as shown on
drawing KF7006.4.0. Attach it tothe tilt out bracket and to the lug on the
journal housing. Take up slack.

7. Remove the hex head cap screws and plain washers that lock the journal
head to the safety bracket in the tilted position. If necessary, lift the
journal slightly with the overhead crane to asist in loosening the safety
bracket cap screws.

WARNING: STAND CLEAR OF THE JOURNAL AND TILT OUT


ASSEMBLY DURING A TILT IN PROCEDURE.

WARNING: AS THE SNATCH BLOCK IS LIFTED, THE CABLE WILL


GO SLACK AND THEN TIGHTEN WHEN THE JOURAL FALLS INTO
THE MILL AS ITS CENTER OF GRAVITY PASSES OVER THE TOP
OF THE TRUNNION SHAFT (PIVOT POINT). LIFTING SHOULD
STOP ONCE THE CABLE GOES SLACK.

8. Slowly lift the snatch block with the overhead crane until the center of
gravity of the assembly passes over the center of rotation. When the
cable goes slack and then goes tight again, stop lifting and begin lowering
the journal assembly into the pulverizer. Continue lowering until the
grinding roll rests on the grinding ring or the journal head contacts a stop
bolt.

9. Remove the cable. the tilt out bracket and the safety bracket.

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10. Replace the set screws in the roll after removing the tilt out lug. Stake the
set screws at four places.

11. Install the oil fill pipe and check oil level with the dip stick. Add or remove
oil as required to obtain the correct oil level, 15 to 17 inches (381 to 432
mm) on the oil dip stick, Replace the oil fill pipe plug.

CAUTION: THE AREA AROUND THE OIL FILL PIPE IS THE AIR
PLENUM FOR THE JOURNAL SEAL AIR. FAILURE TO KEEP THIS
AREA CLEAN CAN REDUCE THE LIFE OF THE OIL SEALS AND
WILL CONTRIBUTE TO SUBSEQUENT FAILURE OF THE JOURNAL
BEARINGS.

12. Vacuum clean the area in the journal head around the oil fill pipe.

13. Replace journal head cover plate. Toique cap screws per B-GP-2175.

14. Reinstall the journal opening cover and spring assembly.

JOURNAL OPENING
COVER AND SPRING
INSTALLATION

NOTE: The following steps refer to K7006.13.0 ,unless otherwise


stated.

1. Loosen the eight outer nuts which position the spring assembly on the
mounting studs.

2. Retract the spring assembly until only 1 in. of the assembly is protruding
out of the journal opening cover. Snug the inner nuts on the studs to
maintain the position of the spring assembly.

WARNING: THE JOURNAL OPENING COVER WEIGHS


APPROXIMATELY 3537Kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

3. Rig to lift the journal opening cover use the top lifting holes.

4. Clean the mating surfaces of the separator body and journal opening
cover and coat them with anti-seize compound.

5. Lift the jjourrnal cover into position on the separator body and secure it
with hex head cap screws.

6. Check the journal spring compression, refer to "Journal Spring


Preloading Procedure" in the HP Pulverizer - Maintenance, Part 4
instruction for procedures.

NOTE: Steps 7. and 8. can only be performed when the pulverizer is


operational. Refer to "Component Servicing" Maintenance - Part 4
instructions for procedures.

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7. Set the roll to bowl ring clearance.

8. Adjust the journal spring/journal head clearance.

9. Reconnect the seal air system.

ASSEMBLY OF
TRUNNION SHAFT,
JOURNAL SPRING
SEAL AIR

Refer to drawing K7038.8.0

1. Replace the trunnion shaft air riser and reconnect the seal air piping to
the trunnion shaft and journal springing.

2. Apply pipe thread sealant and replace pipe plug in the trunnion shaft.

PULVERIZER MOTOR

If the pulverizer motor was removed, or a new motor is installed, use the
following procedure as a guide for installalion.

The pulverizer motor may be in place on its sole plate. When the gearbox has
been secured on its sole plate and air seal clearances have been set the
installation of the pulverizer motor and coupling can be completed.

NOTE: Refer to motor and coupling manufacturer's instructions for


their mounting and alignment recommendations.

NOTE: The following steps refer to K7038.00 unless otherwise stated.

1. Place the pulverizer motor on the motor mounting plate. Use steel shims
near each of the four corners of the motor to level the motor. and align
the coupling as close as possible, Place a machinist level on machined
motor surfaces in several places. Check the level in two directions 90°
apart. The motor must be level at every position checked.

2. Make the angular alignment of the motor and the shafts as close as
possible. Offset in both the vertical and horizontal directions should be
within 0.005 in. (0.127 mm) total indicator reading.

3. Check motor rotation before assembling the coupling.

NOTE: The coupling halves are rigid, therefore it is necessary to move


the motor to obtain the required clearance between the coupling
flanges. Clearance between the motor and gearbox shafts is 1200mm
and when properly aligned the radial faces of the coupling will be
parallel. Refer to manufacturer's instructions for explicit coupling
alignment instructions.

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4. Measure the clearance between the coupling flanges using a dial


indicator. Check maximum angular runout and maximum clearance. Use
additional shims under the motor as required
5. Tighten the motor hold down bolts and recheck the alignment.
6. Recheck the clearance between the coupling flanges to insure that no
change has occurred then dowel the motor to its sole plate.
7. Install the coupling guard. Reference drawing K7038.00.
8. Install the coupling guard.

PREPARATION FOR A
RETURN TO SERVICE

1. Check motor rotation. (This must be accomplished before the motor


and gearbox coupling spacer is installed.)

2. Install the motor/gearbox coupling spacer.

3. Install the coupling guard.

4. Clean out the pulverizer. Remove tools, lights, etc.

5. Close and secure doors and inspection plates.

6. Start-up and test the lubrication oil system. Repair leaks and add oil as
necessary.

7. Use plan procedures to remove the pulverizer from isolation. Remove


the tags, unlock switches, close the pulverizer motor breaker, etc.

NOTE: For steps 8. and 9. reference procedures in "Pulverizer


Component Servicing".

8. Adjust the roll to ring clearance.

9. Adjusttheclearancebetweenthejournalspringandjournal headinsert.

10. Use plant procedures to remove the feeder from isolation. Remove tags,
unlock switches, close the feeder motor breaker, etc.

11. Open the hot air shut off gate, the cold air shut off gate, the mill
discharge valves, the coal pipe gates (if provided), the vent air and seal
air shut off valves and the feeder discharge valves (if provided).

12. Check that the fire suppression system(s)is operative.

13. Refer to Pulverizer Operation part of this manual for additional


information.

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TABLE OF CONTENTS

PULVERIZER COMPONENT SERVICING PART 4

TITLE PAGE NO.

BULL RING SEGMENT REPLACEMENT ........................................................................................ 4 - 1


VANE WHEEL SEGMENT AND AIR RESTRICTION RING REPLACEMENT .................................. 4 - 3
GRINDING ROLL RENEWAL ........................................................................................................... 4 - 4
JOURNAL BEARING END PLAY CHECKING ................................................................................. 4 - 7
JOURNAL BEARING REPLACEMENT .............................................................................................. 4 - 8
Journal Shaft Disassembly ....................................................................................................... 4 - 9
Journal Shaft Reassembly Procedures ................................................................................... 4 - 10
JOURNAL OIL SEAL REPLACEMENT ............................................................................................ 4 - 13
JOURNAL OIL CHECKING PROCEDURES .................................................................................... 4 - 14
JOURNAL SPRING SERVICING ...................................................................................................... 4 - 15
Journal Spring Disassembly ..................................................................................................... 4 - 15
Journal Spring Reassembly ...................................................................................................... 4 - 17
CLASSIFIER DEFLECTOR BLADE REPLACEMENT ..................................................................... 4 - 18
MAJOR ADJUSTMENTS ................................................................................................................. 4 - 19
Roll-ring Clearance .................................................................................................................... 4 - 19
Journal Spring Preloading Procedure ...................................................................................... 4 - 20
Journal Spring Position ............................................................................................................ 4 - 22
Discharge Valve Limit Switch Set--up ...................................................................................... 4 - 23
PULVERIZER LINER INSTALLATION PROCEDURES USING WELD PLUGS ............................... 4 - 23
Equipment Required .................................................................................................................. 4 - 23
Welding Specification ................................................................................................................ 4 - 24
MANUAL INSERT GAS WELDING - MIG ............................................................................ 4 - 24
STICK WELD - MANUAL METAL ARC PROCESS ............................................................. 4 - 24
Application of Weld Plugs ......................................................................................................... 4 - 24
Installation of Tiles - General .................................................................................................... 4 - 25
Trouble Shooting ....................................................................................................................... 4 - 26
LARGE GAPS BETWEEN TILE ........................................................................................... 4 - 26
TILE IS CRACKING ............................................................................................................. 4 - 26
WELDS NOT FUSING ......................................................................................................... 4 - 26
LINER REPLACEMENT (GENERAL) ............................................................................................... 4 - 27
Installation Procedures for Inner Cone Liners ......................................................................... 4 - 27
Installation of Inner Cone Spout Segments ............................................................................. 4 - 28
Installation/Replacement Procedures for Separator Body Liners ........................................... 4 - 28

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PART 4 - PULVERIZER
COMPONENT SERVICING

BULL RING SEGMENT


REPLACEMENT

NOTE: The following steps refer to drawing K7006.9.0 unless


otherwise stated.

1. To provide access to the bowl, remove at least one journal opening cover
and journal roll and shaft assembly as described in the HP
PULVERIZER- MAINTENANCE, General Disassembly Procedures, Part
2.

2. Open the millside and separator body access doors.

3. Unbolt and lower the vane wheel segments into the millside. Reference
drawing K7006.9.0

4. Unbolt and remove the bowl extension ring segments. The two hex socket
set screws installed in each segment can be used as jacking bolts during
the removal process. Cut or break tack welds on end shims as needed.

5. Remove the old bull ring segments.

6. If undamaged, leave the bull ring clamping ring in place. If damaged,


unbolt and remove the bull ring clamping ring. The hex socket set screws
provided in each segment can be used as jacking bolts during the
removal process.

7. Clean all interior surfaces of the bowl.

8. Inspect the bull ring filler key and bull ring stop key. If damaged, replace
them.

NOTE: If the bull ring clamping ring was not removed, skip steps 9.
through 12.

9. Install one of the bull ring clamping ring segments. Apply Loctite 271 to the
hex socket head cap screws for that segment. Insert and torque each
screw to 345 Nm, (1/2 of the value specified on K7006.9.0 ). Torque
them again to the full value, 690 Nm.

10. Repeat step 9. until all of the bull ring clamping ring segments are
fastened in place.

11. In the same order that the screws were torqued in step 9., repeat the
torquing procedure to verify that the socket head cap screws are torqued
to the specified value, 690 Nm.

12. Replace the hex socket head set screws, use anti-seize lubricant. Screws
should be flush to two turns below the surface of the bull ring clamping
ring. Stake them, two places at each screw.

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NOTE: Bull ring segments are numbered for sequential installation.

13. Arrange the bull ring segments on the bowl in numbered sequence
starting with the keyed segment No. 1 and proceeding clockwise.

NOTE: Bull ring segment shims should be inserted. at points equally


spaced around the perimeter of the bowl. No more than one shim
between segments. Total shim thickness should not exceed 1 in. (25.4
mm).

14. Push the segments downward into the bowl as far as possible and firmly
butt them against each other. Bull ring segment shims may be added or
removed to make a tight fit. Drive segments counterclockwise to ensure
contact before gauging and fitting the final shim.

15. Upper surfaces of adjacent bull ring segments should match within 0.06
in. (1.5 mm). Mismatch around the entire perimeter of the bowl must not
exceed 0.12 in. (3.0 mm).

NOTE: If the old bowl extension ring segments are reused, any shims
or tack weld material left on them must be removed prior to installation.

16. Position the bowl extension ring segments on the bowl. When they are
properly seated a 0.0015 in. (0.038 mm) feeler gauge should not fit
between the bowl extension ring segments and bowl at the bowl outside
diameter. Additionally, none of the bull ring segments should be touching
the bowl extension ring

17. Apply Loctite 271 to the hex socket head cap screws for a bowl extension
ring . Install and torque the bolts to 345Nm, (1/2 of the value specified on
K7006.9.0 )Torque them again to the full value, 690Nm.

18. Repeat step 17. until all of the bowl extension ring segments are fastened
in place. Check clearance per step 16.

19. In the same order that the screws were torqued in step 17., repeat the
torquing procedure to verify the socket head cap screws are torqued to
the specified value, 690 Nm.

20. Replace the hex socket head set screws, use anti-seize lubricant. Screws
should be flush to two turns below the surface of the bowl extension ring.
Stake them, two places at each screw.

21. Starting with any one bull ring segment, measure the gap between the
center of the bull ring segment and the bowl extension ring.

22. Select bull ring segment end shims so that the thickness of the shim pack
will be 0.000 in. to 0.015 in. (0.00 mm to 0.38 mm) less than the
measured gap. Use the minimum number of shims possible. Drive the
shims into the gap between the center of the bull ring segment and the
bowl extension ring.

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NOTE: Various types of replacement bull rings are available, cast
segment, weld overlay segment and solid weld overlay. Shim
requirements vary as follows:

No. of shim Location of shims


ocations per on segment
segment
Cast Segments 1 Centerline
Weld Overlay One at each end and
Segments 3 one at centerline
Solid Weld Overlay Equally spaced at 15°
Ring 24 increments

CAUTION: DURING ALL WELDING PROCESSES, GROUND EACH


COMPONENT INDIVIDUALLY AS CLOSE AS POSSIBLE TO THE
POINT OF WELD.

23. Bend the shims back until they contact the bowl extension ring. Tack
weld them in place. (refer to drawing K7006.9.0 )

24. Replace the vane wheel segments. Reference drawing K7006.9.0 .

25. Use anti-seize lubricant and torque the bolts attaching the segments to
the bowl extension ring to 300 ft lb (407 Nm). Torque all other bolts per
drawingB-GP-2175 Tacik weld washers and bolts to the support lugs after
installation.

26. Reset clearance of adjustable shroud to 0.50 in. +-0.12 in. (12.70 mm
+-3.05 mm). Ensure that the gearbox hydrodynamic bearing is properly
lubricated then manually turn the gearbox input shaft to rotate the bowl.
Check clearances at 45° increments.

27. Reinstall the journal roll and shaft assemblies and journal opening covers
as described in the HP PULVERIZER - MAINTENANCE, "General
Reassembly Procedures", Part 3.

VANE WHEEL SEGMENT


AND AIR RESTRICTION
RING REPLACEMENT

NOTE: The following steps refer to drawings K7006.9.0 unless


otherwise stated.

NOTE: After inspection of components, if only the air restriction rings


require replacement, perform steps 1. through 3. and step 5. If vane
wheel segments require replacement, perform steps 1.,2.,4. and 5.

1. To provide access to the bowl, remove the journal opening cover and tilt
out a journal assembly as described in the HP PULVERIZER -
MAINTENANCE, "General Disassembly Procedures", Part 2. Open the
millside doors.

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2. Inspect the air restriction rings, adjustable shroud and vane wheel seg-
ments.

NOTE: The correct quantity of air restriction rings was determined


during pulverizer commissioning. The number of rings required should
change only if there is a major change in the coal being ground.

3. Remove worn air restriction rings as necessary. If new vane wheel


segments will not be installed, new air restriction rings may be installed
by tack welding them to the wheel vanes

4. Replace worn vane wheel segments as follows:

NOTE: Refer to drawing K7006.9.0.

a. Break tack welds and remove cap screws and washers from vane wheel
support lugs.

b. Unbolt and remove worn vane wheel segments.

c. Fit a new vane wheel segment, install and hand tighten the hex head
cap screws and plain washers holding the segment to the bowl
extension ring. Do not torque the screws at this time.

d. Apply anti-seize lubricant to the hex head cap screws then attach the
vane wheel support lugs to the bowl with the screws and plain washers.

e. Position and weld the support lugs to the vane wheel segments. Torque
the support lug cap screws per B-GP-2175 then tack weld the washers
and screws to the support lugs.

f. Remove the vane wheel segment cap screws, apply anti-seize lubricant,
reinstall and torque them to 300 ft. lb. (407 Nm).

g. If three air restriction rings were removed from the old vane wheel
assembly, install three rings on the new assembly. Tack weld them to
the wheel vanes.

5. Adjust the clearance between the vane wheel and the adjusting ring of
separator body to 8 mm ± 1 mm. Ensure that the gearbox hydrodynamic
bearing is properly lubricated then manually turn the gearbox input shaft
to rotate the bowl. Recheck clearances at 45° intervals

6. Tilt in the journal assemblies and reinstall the journal opening covers as
described in the HP PULVERIZER - MAINTENANCE, "General Rea-
ssembly Procedures", Part 3.

GRINDING ROLL
RENEWAL

This procedure can be performed with the journal assembly in place in the
pulverizer or the journal roll and shaft assembly can be removed to a
convenient work area.
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NOTE: If the journal roll and shaft assembly are removed for this
procedure, the shaft must be mounted on a foundation similar to the
one pictured in reference drawing.

NOTE: The following steps refer to drawing K7006(A).12.0 unless


otherwise stated.

1. Remove the journal opening cover and tilt out the journal assembly as
described in the HP PULVERIZER- MAINTENANCE, "General
Disassembly Procedures", Part 2.

NOTE: If the schedule permits, take a sample of the journal lubricating


oil for analysis.

2. Ensure that the tilt out safety bracket is properly installed.

3. Remove the grinding roll keeper bolts, keeper plates and grinding roll key.

WARNING: THE GRINDING ROLL WEIGHS APPROXIMATELY


1740Kg. RIGGING MUST BE ADEQUATE TO SUPPORT THE ROLL
AND APPLY THE FORCE REQUIRED FOR THE ROLL REMOVAL.

4. Install two 1 in. eyebolts in the grinding roll 180° apart. Insert to the full
depth of the roll threads and ensure that the eyebolt shoulder is flush with
the roll surface.

5. Install a chain shackle in each eyebolt and attach a chain sling.

6. Attach the chain sling to an overhead crane positioned above the center of
the door opening, take up slack.

CAUTION: THE GRINDING ROLL SHOULD NOT BE HEATED


ABOVE 200 ° F (94 ℃ ). CIRCUMFERENTIAL TEMPERATURE
GRADIENTS SHOULD NOT EXCEED 25°F (14℃).

7. Heat the grinding roll with a stress relieving blanket or similar device,
monitor the temperature. The entire roll must be heated evenly all the
way through to permit its removal. Use a contact pyrometer or similar
device to measure temperatures of the grinding roll surface.
Temperatures around the perimeter of the roll must vary by less than
25°F (14℃).

CAUTION: IF THE ROLL IS TAPPED FROM BELOW TO HELP


REMOVE IT, A BRASS OR LEAD HAMMER MUST BE USED. DO
NOT USE A STEEL HAMMER, AS IT MAY CHIP THE ROLL AND
CAUSE INJURY.

8. As the temperature of the roll approaches 200°F (94℃), apply a slight


load on the rigging. Maintain a constant heat for approximately 45 to 60
additional minutes to insure that the roll is heated through. As the roll
expands it should lift off the journal housing. When clear move the roll
away from the pulverizer to a suitable area to cool.

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NOTE: Allow the journal bearing housing to cool before installing a
new roll.

NOTE: If schedule permits, the journal bearing end play should be


checked at this time. Refer to 'Journal Bearing End Play Checking",
Page 4 - 7.

9. Clean the mating surfaces of the journal housing and the roll bore.

10. Lubricate the surface of the journal housing with a thin film of lubricant
such as Molykote 41 to prevent rust and possible future difficulties with
roll disassembly.

11. Install the roll lifting equipment on the new roll.

12 Use a stress relieving blanket or sirn ilar device to heat the new grinding
roll. Monitor the roll temperature it should not exceed 200°F (94℃). The
entire roll must be evenly heated through to allow installation. Use a
contact pyrometer or similar device to measure the temperature around
the grinding roll perimeter. Circumferential temperature gradient should
not exceed 25°F (14℃).

13. Install the grinding roll key, torque bolts per B-GP-2175.

14. Lift the roll and carefully lower it onto the journal housing. Ensure that the
key way on the roll is in line with the key on the journal housing.

15. Verify that the back face of the roll has completely seated on the housing.

16. Remove the roll lifting equipment and immediately install the grinding roll
keeper plates and keeper bolts. Torque the keeper bolts to 50 ft lb (67.8
Nm).

17. When temperature of the roll and journal housing normalizes, approxi-
mately 15 minutes, torque the keeper bolts to 310 ft lb (420 Nm).

18. Reheat the roll to 200°F (94℃) as in step 12. When temperature has
been reached and maintained for approximately 45 minutes, retorque the
keeper bolts to 310 ft. lbs (420 Nm).

19. Allow the roll and journal housing to cool to near ambient.

NOTE: If the journal roll and shaft assembly was removed to a


maintenance area for this procedure, it should be reinstalled on the
journal head at this time.

20. Tilt In the journal assembly as described in the HP PULVERIZER -


MAINTENANCE, "General Reassembly Procedures", Part 3.

21. Check and re-establish the journal oil level, 15 to 17 inches (381 to 432
mm) on the oil dip stick.

22. Reinstall the journal opening cover as described in the "General Rea-
ssembly Procedures".
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JOURNAL BEARING
END PLAY CHECKING

NOTE: Reference drawing K7006(A).12.0 and C-GP-7711 Journal


bearing end play can be checked with the journal assembly in the tilt
out position or the journal roll and shaft assembly can be removed and
placed on a temporary foundation per reference drawing.

Steps 6. though 13. cover a checking procedure that can be used in


either location. Steps 1. through 23. presume that the procedure is
performed in place on the pulverizer.

1. Tilt out the journal and ensure that the journal is properly supported on
the tilt out safety bracket.

2. Remove the journal tilt out lug from the journal housing.

3. Remove two keeper bolts 180° apart and install eyebolts to the full
depth of the threads. Ensure that the shoulders of the eyebolts are flush
with the roll keeper plate surface.

4. Install a chain shackle in each eyebolt and attach a chain sling. The sling
when loaded must clear the classifier journal opening and allow the roll to
be rotated.

5. Rig a chain fall to an overhead crane centered above the journal opening.
Attach a sling, and load cell.

6. Mount a dial indicator on the journal head with the indicator needle
resting on the back face of the journal housing.

7. Rotate the roll several times to be sure that the bearings are properly
seated. Zero the indicator and mark the location of the indicator needle
on the housing.

8. Use the chain fall to apply a load of 4070kgf (39890N)(the "lift load with
roll" tabulated ) to the journal housing/roll assembly.

9. Rotate the roll several times to be sure the bearings are properly seated.
Realign the indicator needle with the mark on the journal housing and
record the reading.

10. Lower the roll until there is no load on the load cell. Rotate the housing
several times to seat the bearings. Line up the indicator needle with the
mark on the housing. If the reading is within 0.0005 in. (0.013 mm) of the
original zero setting the measurement is considered accurate.

11. Repeat steps 7. through 10. until two accurate measurements are
obtained.

12. Average the readings and compare the results with those in the table.

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13. If the measured end play is within specification [<0.005 in. (0.127 mm)]
then the journal may be returned to service for the next six month
interval without inspecting the lower bearing or resetting the bearing end
play.

14. If the measured end play is out of specification [>0.005 in. (0.127 mm)]
the lower bearing should be checked for wear.

15. Remove the lower journal housing cover, the journal bearing keeper plate
and the shims.

16. Using a suitable puller, remove the inner race of the lower bearing and
inspect the bearing rolls for pitting or wear. If the bearing is damaged,
replacement is necessary. Refer to the "Journal Bearing Replacement"
procedure, Page 4 - 10 for further instructions.

17. If the lower bearing is not damaged, replace the bearing inner race.
Install the journal bearing keeper and cap screws hand tight.

18. Rotate the journal housing five complete turns in each direction to reseat
the bearings.

19. Remove the caps screws and bearing keeper. Use a depth micrometer to
measure the gap between the end of the shaft and the edge of the lower
bearing cone.

20. Assemble and install a shim set that measures 0.002 in. (0.051 mm)
more than the measured gap.

21. Install the journal bearing keeper, the screw lock plate and cap screws.
Torque the fasteners per B-GP-2175.

NOTE: If the bearing end play was out of specification and will be
reset, it should be set to the 'as new' specification [0.0005 in to 0.0025
in (0.0127 mm to 0.0635 mm) loose].

22. Repeat steps 4. through 13. and steps 17. through 21.

23. After a satisfactory setting has been achieved [0.0005 to 0.0025 in


(0.0127 mm to 0.0635 mm)], grease the lower journal cover O-ring with
Molykote #33 grease. Install the O-ring and the lower journal cover.
Torque the fasteners per B-GP-2175.

JOURNAL BEARING
REPLACEMENT

1. Remove the journal opening cover and tilt out the journal assembly as
described in the "General Disassembly Procedures".

2. Check journal bearing end play (reference "Journal Bearing End Play
Checking", Page 4 - 7)

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WARNING: THE JOURNAL ROLL AND SHAFT ASSEMBLY WEIGHS
APPROXIMATELY 2612Kg AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING. THE OVERHEAD CRANE MUST
SUPPORT THE JOURNAL ROLL AND SHAFT ASSEMBLY AT ALL
TIMES DURING THE REMOVAL PROCEDURE.

3. If bearing inspection indicates that bearing replacement is required re-


move the journal shaft assembly as described in the "General Disas-
sembly Procedures".

4. Move the journal shaft assembly to the maintenance area.

Journal Shaft
Disassembly

NOTE: Fabricate and mount a foundation plate to the floor in a


maintenance area. This foundation plate will be used for journal shaft
disassembly as well as journal bearing end play checking.

NOTE: The following steps refer to drawing K7006(A).12.0.

1. Fasten the journal shaft to the floor mounted foundation plate.

NOTE: Ensure that a container large enough to hold the journal oil,
approximately 10 gallons (38 liters) is positioned under the drain.

2. If the oil was not previously drained from the journal, remove the pipe
plugs from the upper and lower journal housing covers and drain the oil.

3. Replace the pipe plugs.

NOTE: It is not necessary to remove the roll to replace the journal


bearings. If the roll will not be removed then proceed to step 5.

4. Refer to "Grinding Roll Renewal", Page 4 – 4 steps 3. through 8. for roll


removal.

CAUTION: IF THE ROLL IS REMOVED, ALLOW THE JOURNAL


HOUSING TO COOL SUFFICIENTLY BEFORE CONTINUING
DISASSEMBLY.

5. Unbolt and remove the lower journal housing cover.

6. Unbolt the oil seal keeper and move it to the side.

7. Unbolt the upper journal housing cover and let it slide down to rest upon
the seal wear ring. When the O-ring seal loosens, some residual oil may
spill, be prepared for clean up.

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8. Continue disassembly of the journal shaft by unbolting and removing the
journal bearing keeper, cap screw lock plate and bearing keeper shims.

9. Using a suitable puller, remove the inner race of the lower journal bearing
from the journal shaft.

WARNING: THE JOURNAL HOUSING AND ROLL ASSEMBLY MUST BE


PROPERLY RIGGED FOR SAFETY. IF ROLL IS REMOVED SUBTRACT.

10. Attach lifting equipment, eyebolts and chain sling, to the journal housing.
Lift the journal housing off the journal shaft. The upper and lower bearing
cups will remain inside the journal housing.

11. Using a suitable puller, remove the upper bearing cone assembly and
spacer from the journal shaft.

12. Lift off the upper journal housing cover and the oil seals.

13. If inspection reveals a need for replacement, use a suitable puller to re-
move the seal wear ring from the journal shaft.

14. Use a suitable puller to remove the upper and lower bearing cone as-
semblies from the journal housing.

15. Inspect all components to determine required replacements.

Journal Shaft
Reassembly
Procedures

Reassembly the journal shaft assembly as follows:

NOTE: Refer to the journal shaft assembly drawing K7006(A).12.0


for the following steps.

1. If replacement is required, heat the new oil seal wear ring to 250°F
(121 ℃) and slide it into position. Ensure that it is firmly seated against
the shaft step before it cools.

2. Apply Loctite Sealant 515 to the oil seal access covers and mount the oil
seal access covers to the upper journal housing cover. Apply thread
locking sealant [Loctite 222]to the fasteners and torque per B-GP-2175.

3. Coat the journal housing cover upper seal bore with a small amount of
Molykote 33 grease.

4. Pack the oil seals with Molykote 33 grease.

5. Slide the first seal into the bore with the lip facing into the bore. Slide the
second and third oil seals into the bore with the lip facing out.

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6. Lower the upper journal housing cover with the oil seals over the journal
shaft. Slide the oil seals down over the oil seal wear sleeve. Allow the
cover to rest on the oil seal wear sleeve.

7. Slide the journal bearing spacer over the journal shaft with the chamfer
side against the shoulder.

8. Grease the O-ring with Molykote 33 grease and install it in the


groove of the upper journal housing cover.

9. Slide the bearing cone for the upper bearing onto the journal shaft. It
should rest firmly against the bearing spacer.

NOTE: It may be necessary to heat the bearing cone prior to instal-


lation. Do not exceed 200°F (93℃).

10. Chill the two tapered roller bearing cups down to at least -60°F (-51℃).
Install both cups in the journal housing and clamp them in place until the
housing and cup temperatures reach equilibrium.

CAUTION: TO PREVENT DAMAGE TO THE BEARING, EXERCISE


CARE WHEN POSITIONING THE BEARING CUP ON THE ROLLERS.

11. Lower the journal housing assembly onto the journal shaft.

12. Install the cone of the lower tapered roller bearing on the journal shaft.

NOTE: It may be necessary to heat the bearing cone prior to instal-


lation. Do not exceed 200°F (93℃).

13 Attach the bearing keeper to the end of the journal shaft. Hand tighten
the bolts.

14. When the component temperatures are equal, rotate the journal housing
at least five times in each direction to seat the bearing rollers.

15. Remove the bearing keeper and use a depth micrometer to measure the
gap between the end of the shaft and the edge of the lower bearing cone.

16. Assembly a shim set 0.000 in. to 0.002 in. (0.00 mm to 0.05 mm) more
than the measured gap.

17. Install the shims, bearing keeper and lock plate and torque the fasteners
per B-GP-2175.

NOTE: The following steps refer to drawings K7006(A).12.0 unless


otherwise stated.

18. Install two eyebolts 180° apart on the bearing housing, attach chain
shackles and a chain sling.

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NOTE: Tools similar to those illustrated on drawing may be fabricated
for use in this procedure, rather than using eyebolts, shackles and
chain slings.

19. Center a crane over the roll and shaft assembly and attach a chain fall,
shackle, sling and load cell.

20. Install three threaded rods into the bearing keeper plate and mount a dial
indicator on each rod. Rest the indicator needles on the lower face of the
journal housing.

21. Rotate the roll several times to be sure th'at the bearings are properly
seated. Zero the indicators.

22. Number and mark the location of each indicator on the journal housing.

23. Rotate the journal housing five times, return to original indicator positions.
All indicator readings should return to zero. If not repeat step 21.

24. Using the chain fall, apply a lift load to the journal housing assembly of
4070Kgf (39890N) if the roll is mounted or 2497Kgf(24470N) if the roll
has been removed.

25. Rotate the housing several times to be sure the bearings are properly
seated. Align the indicators at their original positions, record the indicator
readings and average them.

26. Release the load on the journal housing assembly and rotate the housing
several times to seat the bearings. Line up the indicators with their original
marks. All indicator readings must return to zero.
27. Repeat steps 21. through 26. five times and calculate the average of the
averages. This average should be between 0.0005 in. and 0.0025 in
(0.0127 mm and 0.0635 mm), the recommended initial end play for new
bearings.

28. If the averaged readings are out of specification, repeat steps 13.
through 17.

29. When the measured end play fails within the indicated range, remove the
checking equipment and proceed with the journal shaft reassembly.

30. Grease the lower journal housing cover O-ring with Molykote 33 grease.
Install the O-ring and the lower journal housing cover. Torque the
fasteners per B-GP-2175.

31. Replace pipe plugs in the lower journal housing cover using pipe
sealant Lubricate and replace set screws in tapped holes, stake four
places.

NOTE: If the roll was removed proceed with step 32. otherwise go to
step 33.

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32. Install a new roll per steps 7. through 19. of the "Grinding Roll Renewal"
procedures, page.4 - 5

33. Remove the journal shaft from the foundation plate and turn the journal
assembly over so that the lower journal housing cover is sitting on the
floor. Verify that the O-ring is properly positioned between the upper
journal housing and housing cover.

34. Fasten the upper journal housing cover to the journal housing with two
bolts.

35. Position and fasten both halves of the journal head liner to the journal
housing. Install the remaining bolts through the journal housing cover into
the journal housing. All bolts are to be torqued per B-GP-2175.

36. Install the oil seal keeper and torque the bolts per B-GP-2175..

37. Fill the journal shaft assembly with oil to the proper level for operation or
to 11 in. (279.4 mm) from the top of the shaft for storage.

38. Install the rebuilt journal roll and shaft assembly onto the journal head
using the procedures "Journal Roll and Shaft Assembly Installation" in the
"General Reassembly" procedures Part of this manual.

JOURNAL OIL SEAL


REPLACEMENT

NOTE: The following steps refer to drawing K7006(A).12.0.

Journal oil seals should be replaced during a Journal Bearing Replacement


procedure, however, if there is evidence of oil leakage the oil seals can be
replaced without removing the journal assembly from the pulverizer.

1. Remove the journal opening cover per the "GeneraIDisassembly"


procedures.

2. Drain or siphon the oil [approximately 10 gallons (38 L)] from the journal.

3. Tilt out the journal assembly. Support the journal assembly on the safety
bracket. Ensure that the safety bracket bolts are tightened securely.

4. Remove the journal skirt assembly and the oil seal keeper (2 segments).

5. Remove the oil seal access covers.

6. Cut the oil seals and remove them from the upper journal housing cover.

7. Rotate the journal and inspect the seal wear ring. If excessively scored,
replacement should be considered.

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8. Coat the upper journal housing cover oil seal bore with a small amount of
Molykote 33 grease.

9. Pack the new, split oil seals with Molykote 33 grease. Slide the first seal
into the journal hnusinc cover with the lip facing the journal roll.

10. Slide the second and third oil seals into the journaJ housing cover with
the lip facing out.

11. Ensure by inspecting through an access cover that oil seal splits match
end to end and do not overlap.

12. Apply Loctite Sealant 515. to the oil seal access covers and replace
them. Lubricate and torque the access cover fasteners per B-GP-2175.

13. Replace the seal keeper ( 2 segments ). Install and torque the bolts
per B-GP-2175.

14. Replace the journal skirt ( 2 segments ). Install and torque the bolts
per B-GP-2175.

15. Tilt in the journal assembly,

16. Ensure that oil drain plugs are in place then fill the journal assembly with
the correct oil to the proper level. Check the oil level [15 in. and 17 in.
(380 mm and 430 mm)] on the oil dip stick.

17. Clean the area around the oil fill pipe then replace the journal head
cover plate.

18. Replace the journal opening cover.

19. Reset the roll-ring clearance and journal spring position before returning
the pulverizer to service.

JOURNAL OIL CHECKING


PROCEDURES

NOTE: The journal must be in its normal installed position to perform


the following procedure. Refer to and drawing K7006(A).12.0.

CAUTION: THE PULVERIZER MUST BE SHUT DOWN AND


PROPERLY ISOLATED BEFORE THE INSPECTION HOLE COVER
IS REMOVED.

1. Remove the journal opening cover inspection hole cover and gasket.

2. Remove the journal head cover plate.

3. Remove the 1 1/4 in. pipe plug from the oil fill pipe.

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4. Using the dip stick, check that the oiI level is between 15in. and 17in.
(380 mm and 430 mm). Add or remove oil to adjust the oil level.

NOTE: Refer to lubrication chart in this manual for oil specifications


and service recommendations.

5. Replace the pipe plug and check that the area around the oil fill pipe is
clean.

NOTE: The area around the oil fill pipe acts as an air plenum for the
journal oil seal and bearing seal air. Failure to keep this area clean will
reduce the life of the oil seal and cause subsequent early failure of the
bearing.

6. Clean the mating surfaces of the journal head and cover plate, apply RTV
sealer and install the cover plate. Torque bolts per B-GP-2175.

7. Install the journal inspection hole cover and gasket. Torque bolts.

JOURNAL SPRING
SERVICING

Journal Spring
Disassembly

WARNING: THE JOURNAL SPRING ASSEMBLY WEIGHS


APPROXIMATELY 3537KG AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

NOTE: The following steps refer to drawings KF7006.2.0


K7006.13.0 unless otherwise noted.

1. Disconnect the seal air piping from the spring housing.

2. Check to be sure there is a minimum gap of 0.060 in. (1.52 mm) between
the journal head insert and the spring adjusting stud insert. Lower the
journal via the stop bolts, if necessary, to obtain .this gap.

3. Loosen the four outboard heavy hex nuts (one per mounting stud) which
secure the spring housing flange to the mounting studs.

CAUTION: IF SPRING WILL BE COMPLETELY DISASSEMBLED IT


IS ADVISABLE TO RELEASE THE SPRING PRESSURE BEFORE
THE ASSEMBLY IS REMOVED FROM THE JOURNAL OPENING
COVER. USE EQUIPMENT SUPPLIED FOR JOURNAL SPRING
PRELOAD. REFER TO DRAWING KF7006.2.0

4. Using two diagonal inboard heavy hex nuts, evenly pull the spring
housing from the journal opening cover bore a distance equal to the
spring set preload compression plus 0.50 in. (12.7 mm).

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For example:
The HP1003 pulverizers spring rate is 15000 lb/in (2627N/mm) and the
recommended preload is 6810Kgf (66738N).
For a spring with a spring rate (K) of 15000lb/in (268110Kgf/m operating at a
preload of 6810Kgf (66738N) calculate the distance to extract the housing as
follows:

Preload(lbs) Preload(N)
+0.50in. = "X"in. OR: +12.7mm = "X"mm
Spring Rate (lb/in.) Spring Rate(N/mm)

15000lbs 66738N
+0.50in. = 1.5in. oR: +12.7mm = 38.1mm
15000lb/in. 2627N/mm

5. Snug by hand the four outboard heavy hex nuts against the spring hous-
ing flange.

6. Bolt the hydraulic cylinder to the spring preload fixture.

7. Remove the spring extension cap and thread the preload adjusting stud
into the journal pressure spring preload stud to the full depth of the
preload stud threads.

8. Attach the preload fixture (reference drawing KF7006.2.0)to the spring


assembly, be sure to align a side opening of the fix'ture with the key way
in the spring preload stud.

9. Use the hydraulic pump and extend the hydraulic cylinder the distance
calculated in Step 4. install the flat washer and lock nut, and hand tighten
with a wrench. The nut must thread completely onto the adjusting stud.

10. Pump the hydraulic cylinder until the pressure gauge reads 'P' PSI (see
Table on Drawing. KF7006.2.0) and the spring stud lock nut is free.

11. Remove the spring stud key and back off the spring stud lock nut a dis-
tance equal to that calculated in step 4.

12. Slowly release the hydraulic pressure on the cylinder. The spring stud
lock nut should be loose after the hydraulic pressure is released. If not,
repeat the process until the spring stud lock nut is fully loosened.

13. Remove the spring preload adjusting fixture.

14. Remove the four outboard heavy hex nuts from the mounting studs.

15. Using the lifting hole in the spring housing flange, lift up on the housing
and slide housing out of the journal opening cover.

16. With spring assembly on its side (shop floor) remove the spring air seal
cap and the spring orifice plate. Inspect the orifice plate for wear. Discard
if wear is 0.125 in. (3.175 mm) or greater.

17. Use a fixture or cribbing, stand spring assembly on inboard face of spring
housing flange.

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18. Remove cap screws from spring housing cover. Install an eyebolt into the
end of the spring stud and lift the spring stud, spring housing cover, and
the spring lock nut out of the spring housing.

19. Sequentially, remove the lock nut, spring housing cover, spring, and
adapter plate from the spring stud.

20. Inspect the bronze bushings in the spring housing and spring housing
cover for wear. If worn, replacement is required:

a. Remove the internal retaining ring from the spring housing.

b. Remove the bushings by using the threaded holes in the bushing


face to pull the bushings from the housings.

Disassembly is now complete.

Journal Spring
Reassembly

NOTE: Before reassembling the journal spring, clean and coat


internals with Molykote metal protector.

Take care not to coat mating surfaces, threads, plated or bearing


surfaces.

NOTE: The following steps refer to drawings KF7006.2.0, K7006.13.0


unless otherwise noted.

1. Stand the housing on end so the inboard end of the housing is up. Chill
and insert the spring stud bearing into the spring housing, ensure that
removal threads face outward. Lock in place with the retaining ring.

2. Flip the spring housing 180° so that the outboard end is now up. Use a
fixture or cribbing to support the spring housing, by the flange, 5 in. (130
mm) off the floor.

3. Chill and insert the second spring stud bearing into the spring housing
cover.

4. Assemble onto the spring preload stud; the spring stud adapter, spring,
spring housing cover and the spring stud locknut.

5. Install an eyebolt in the end of the spring preload stud. Lift the assembly
and lower it into the spring housing. Take care when guiding the preload
stud through the lower bronze bushing.

6. Install the spring housing cover cap screws and torque per drawing B-GP-
2175.

7. Turn the spring housing on its side, and install the spring orifice plate and
spring air seal cap. Torque the socket head cap screws per drawing B-
GP-2175.

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8. When ready to mount the spring assembly in the journal opening cover,
coat the O-ring in the journal opening cover with Molykote 33 and the
spring opening with anti-seize lubricant.

NOTE: Studs must be installed in the journal opening cover to be used


as guides when installing spring assembly.

CAUTION: DURING INSTALLATION THE STUDS ARE TO BE USED


AS GUIDES ONLY. DO NOT ALLOW THE FULL WEIGHT OF THE
SPRING ASSEMBLY TO REST ON THE STUDS UNTIL THE
ASSEMBLY IS FULLY INSERTED IN THE JOURNAL OPENING
COVER AND THE RETAINING HEX NUTS ARE THREADED ONTO
THE STUDS.

9. Install the spring assembly in the journal opening cover. Do not torque
nuts at this time.

NOTE: The journal spring compression can be set before the journal
cover and spring assembly is mounted on the pulverizer. However, the
procedure may be easier to perform with the cover and spring in place.

10. Set journal spring compression. (Refer to "Major Adjustments -Journal


Spring Preloading Procedure".)

11. Set the roll to ring clearance. (Refer to"Major Adjustments - Roll-ring
Clearance".)

12. Set journal spring insert to journal head insert clearance. (Refer to "Major
Adjustments - Journal Spring Position".)

13. Reconnect the seal air piping.

CLASSIFIER
DEFLECTOR BLADE
REPLACEMENT

NOTE: The following steps refer to drawing K7038.7.0 unless


otherwise noted.

1. To provide access to the classifier, remove at least one journal opening


cover and tilt out the journal assembly as described in the General Dis-
assembly Procedures.

2. Open the separator body access door and remove the inner cone access
door to gain access to the inside of the classifier assembly.

3. Loosen the star wheels and lock nuts on the control levers. Move the
levers to position 5 on the quadrant segment and tighten the lock nuts.

4. Loosen the M8 clamping bolt at the end of the deflector link lever.

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5. From inside the classifier cone rotate the deflector blade for access to the
counter sunk screws. Break tack welds and remove screws.

6. Install new defector blade with screws, washers and nuts. Torque the
nuts to 10 ft ib (13.56 Nm) and tack weld.

7. Ensure that new blade clears the deflector support,and inner cone drum
flange by 0.06 in. (1.52 mm).

8. Measure the distance from the top of the blade to the edge of the dru/n
opening and adjust to 3.7 in. 94 mm). Tighten the ' M8 clamping bolt at
the end of the deflector link lever.

NOTE: If more than one blade is to be replaced a block of wood or a


metal bar 3.7 in. (94mm) long may be used as guide to set the blade
opening.

9. After setting the clearance on all defector blades, loosen the star wheel
and lock nut on the control arm and move the pointer back and forth
between 0 and 10 to ensure free movement.

10. Set the pointer at position 3 and tighten the lock nut and star wheel.

11. A fineness test will be required when the mill is placing back into
operation.

MAJOR ADJUSTMENTS

Roll-ring Clearance

The following procedure uses the journal stop bolts to set the roll-ring
clearance and must be performed before the journal spring assembly to
journal head clearance is set.

NOTE: The pulverizer must be 100% operational before this


procedure can be done.

NOTE: The following steps refer to Drawing K7006.8.0(A) unless


otherwise stated.

WARNING: DURING THE PERFORMANCE OF THIS PROCEDURE


(STEP 1. THROUGH 4.), THE PULVERIZER MUST BE ISOLATED.
THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST
BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE
OPEN.

1. Open one pulverizer separator body access door.

2. Remove the hex head bolts, lock bars and retaining lugs from all journal
stop bolts. Disassemble the retaining lugs from the lock bars.

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3. Retract the stop bolts until all journal rolls rest on the bowl.

4. use one stop bolt at each journal to raise the roll. Check to ensure a
clearance of at least 1/2 in. (12.7mm) between the rolls and bull ring
segments.

5. Ensure that personnel are outside the pulverizer, close the access door.
Close the motor breaker.

6. Place the lube oil system in service and start the pulverizer motor.

7. With the pulverizer running, but no coal being fed, slowly retract a stop bolt
at each journal until contact between the ring and roll can just be heard or
felt.

8. Turn the stop bolt in one half flat.Turn the second stop bolt at each journal
in until it contacts the journal head.

9. Install the lock bars on the stop bolts.

10. Secure the stop bolts with the retaining lugs. cap screws and washers.
Torque fasteners per B-GP-2175.

11. Stop the pulverizer motor.

12. If not previously done, set journal spring compression. (Refer to "Major
Adjustments- Journal Spring Preloading Procedure".)

13. Set journal spring insert to journal head Insert clearance. (Refer to "Major
Adjustments - Journal Spring Position".)

Journal Spring
preloading Procedure

NOTE: The following steps refer to KF7006.2.0 unless otherwise


stated.

1. The journal spring assembly K7006.13.0 should be completely as-


sembled except for the spring stud extension cap, spring stud key and
connecting fasteners.

NOTE: For initial or reassembly preloading, the spring stud should be


rotated to ensure that the key way will line up with an opening in the
preloading fixture after its attachment (see drawing KF7006.2.0). For
resetting the preload in the field, the preloading fixture may be rotated
so one of its openings is in line with the existing key way location.

2. Screw the preloading adjusting stud into the journal pressure spring
preload stud to the full depth of the preload stud threads.

3. Screw the spring stud locknut onto the journal pressure spring preload
stud as tightly as possible by hand. Use the locknut wrench to ensure
maximum starting engagement with the stud.

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4. Fasten the hydraulic cylinder to the spring preload fixture with hex head
cap screws.

5. Mount the preload fixture on the spring housing cover and secure it with
hex head cap screws. Ensure that the preload stud key way stays aligned
with an opening in the fixture.

6. With the hydraulic cylinder fully retracted, install a plain washer and
heavy hex nut onto the adjusting stud.

WARNING: TO PREVENT POSSIBLE INJURY OR DAMAGE TO


EQUIPMENT DO NOT STAND OR WORK IN LINE WITH THE
SPRING ADJUSTING STUD WHILE HYDRAULIC PRESSURE IS
BEING APPLIED.

7. Pump the hydraulic pump until the pressure gauge reads "P" psi (see
Table on drawing KF7006.2.0 +0.7MPa This should compress the spring
"X" inches (see Table) from the static length. Using the wrench, advance
the lock nut until it contacts the spring housing cover.

8. Reduce the pump pressure to 3.5 MPa.

9. Place the indicator needle of a magnetic dial indicator on one of the flat
vertical faces of the spring stud lock nut and zero the indicator. Pump the
hydraulic pump until the pressure again reaches 'P' psi. The dial indicator
should show movement up to a maximum 0.005 in. (0.127 mm) when the
cylinder pressure is at 'P'+0.7MPa If stud movement exceeds 0.005 in.
(0.127 mm) advance the lock nut.

10. Repeat steps 8.and 9. until the dial indicator shows movement of less
than 0.005 in. (0.127 mm).

11. It may be necessary to compress the spring just above this setting to
allow the lock nut to be rotated a maximum of 1/8 of a turn to align the
nearest lock out slot with the spring stud key way.

12. Insert spring stud key and secure it by torquing hex socket head cap
screws to 37 ft. lb. (50 Nm).

13. Release the hydraulic pressure and remove the preload adjusting stud
and hydraulic cylinder assembly.

14. Install the spring stud extension cap. Secure the cap by torquing hex
socket head cap screws to 37 ft. lb. (50.16 Nm).

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Journal Spring Position

NOTE: The following steps refer to drawing K7006.13.0 unless


otherwise stated.

NOTE: This procedure must be done after the springs have been
preloaded and the roll-ring clearance has been set.

WARNING: DURING THE PERFORMANCE OF THIS PROCEDURE


THE PULVERIZER MUST BE ISOLATED. THE COAL PIPE GATES
AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE
PULVERIZER MOTOR BREAKER MUST BE OPEN.

1. Open one separator body access door.

2. Ensure that the journal spring assembly is reinstalled on the journal cover
per steps 8. and 9. of the Journal Spring Reassembly procedures.

3. Loosen the four heavy hex nuts between the journal opening cover and
the journal spring assembly flange. Place a 0.06 in. (1.52 mm) shim over
the end of the spring stud insert. Using two diagonal stud nuts, push the
spring assembly into the pulverizer until the shim on the end of the spring
stud insert contacts the journal head insert, Back off one nut.

4. With the spring assembly position established, adjust one of the hex nuts
between the journal opening cover and the spring assembly flange until it
just contacts the spring assembly flange. Torque the opposing hex nut to
100 ft. lb. (135.6 Nm).

5. Remove the 0.06 in. (1.52 mm) shim from the spring stud insert.

NOTE: Apply Loctite #277 to the stud for all hex nuts prior to final
torquing.

6. Adjust the other three hex nuts between the journal cover and the spring
assembly flange until they contact the flange. Torque the opposing three
hex nuts to 500 ft. lb. (677.9 Nm).,

7. Loosen the original two hex nuts. Adjust the hex nut between the cover
and the flange to contact the flange. Torque the opposing hex nut to 500
ft. lb. (677.9 Nm).

8. Use a feeler gauge to recheck the gap between the spring stud insert and
the journal head insert to be 0.06 in. (1.52 mm).

9. Set the spring position on all three journals.

10. Ensure that personnel and tools are outside the pulverizer, close the ac-
cess door.

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Discharge Valve
Limit Switch Set - up

The limit switches on each discharge valve are set up as follows:

NOTE: The following steps refer to K7038.9.0 unless otherwise stated.

1. With both limit switches mounted finger tight on the mounting bracket
and the discharge valve in the closed position, set angle 'A' on the open
limit switch

2. Open the valves and adjust the open limit switch. Secure the open limit
switch.

WARNING: DO NOT FORCE THE LIMIT SWITCH.

3. Close the valves. Place a small piece of 12 gauge (2.77 mm) shim
material between the limit switch trip stud and the limit switch operating
lever of the closed limit switch (gap 'D'). Slide the closed limit switch as
far to the right as possible, to the end of the operating lever travel.

4. Secure the closed limit switch to the bracket. Remove the shim.

PULVERIZER LINER
INSTALLATION
PROCEDURES USING
WELD PLUGS

NOTE: The following procedures cover installation of optional ceramic


and other nonweldable liners.

Equipment Required

The following equipment and materials will be required:

1. MIG or Electric Arc Welder (see Welding Specifications).

2. Masonry saw (Clipper trademark SM 300 or equivalent).

3. Diamond Blade (Selker Bay State M-1 Bar 20 in. diameter, 2150 RPM or
equivalent).

4. Solvent (if required) such as toluene, zylene or acetone.

5. Weld Plugs.

NOTE: Items 6 and 7 are sent complete from shop in a single unit
container.

6. RTV Adhesive Sealant.

7. Duromar HAR Filler.

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Other fill materials such at Moldit D. Nordback or Devcon Martek may be
required to fill voids between and adjacent to installed tiles, see notes on
reference drawings.

Welding Specification

MANUAL INSERT GAS WELDING – MIG

1. Follow standards of the American Welding Society

2. Wire rod size - 0.045 in. diameter

3. Wire type - AWS-ASTM E605-e or similar

4. Voltage requirements - 20-24 volts

5. Amperage requirements- 180-230 amps

6. Gas rate-10CFH

STICK WELD - MANUAL METAL ARC PROCESS

1. Follow standards of the American Welding society

2. Electrode - 3/32 in. or 1/8 in. diameter - E-6011, E-6012 or E-6013, 3/32
in. diameter - E-7014 or E-7018

3. Amperage - set near maximum amperage recommended by the elec-


trode manufacturer

Application of
Weld Plugs

NOTE: Hold a short arc to float molten flux to the top of the weld. Fill
weld plug 1/3 to 1/2 full. Do not over fill.

The following welding procedures are taken verbatim from Section 4.21, 'Plug
Welds' of the American Welding Society Structural Welding Code D 1.1
These procedures should be adhered to during the installation of any weld
plugs.

1. 'For welds to be made in the flat position, each shall be deposited around
the root of the joint and then deposited along a spiral path to the center of
the hole, fusing and depositing a layer of weld metal in the root and
bottom of the joint. The arc is then carried to the periphery of the hole
and the procedure is repeated, fusing and depositing successive layers to
fill the hole to the required depth. The slag covering the weld metal
should be kept molten until the weld is finished. If the arc is broken or the
slag is allowed to cool, the slag must be completely removed before
restarting the weld.'

4 - 24
Page 122 of 130
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SHMP Co.,Ltd.
HP1003 PULVERIZERS - MAINTENANCE
________________________________________________________
2. 'For welds to be made in the vertical position, the arc is started at the root
of the joint at the lower side of the hole and is carried upward, fusing into
the face of the inner plate and to the side of the hole. The arc is stopped
at the top of the hole, the slag is cleaned off, and the process is repeated
on the opposite side of the hole. After cleaning slag from the weld other
layers should be similarly deposited to fill the hole to the required depth.'

3. 'For welds to be made in the overhead position, the procedure is the


same as for the flat position, except that the slag should be allowed to
cool and should be completely removed after depositing each successive
bead until the hole is filled to the required depth.'

Installation of Tiles
- General

1. Clean the metal surfaces thoroughly. The surface must be free of dirt,
dust, oil, rust or scale. Clean with solvent. Sandblast or grind if required.

2. Scribe lines to be used as guides to assure proper layout of tiles.

3. The application of the tile should begin with the bottom or lower course.
Proper alignment at this stage is critical. Misalignment here will be
compounded as additional courses of tile are added.

4. Trial fit the tiles, note location of excessive gaps between tiles and mat-
ing parts. Trim tile as required to ensure a snug fit.

NOTE: The purpose of the adhesive sealant cement is to secure the


tile to the steel, and to provide a solid back-up by filling the void
between the tile and steel. Too much cement will make the weld plug
welding difficult (or impossible) and reduce the cohesive properties of
the product.

5. Using the adhesive sealant cartridge in a caulking gun, apply a thin coat
(bead) of adhesive to the back of the ceramic tile. Use a thicker coating
in areas observed with excessive gaps. Do not apply the adhesive near
the weld plug hole. The eventual weld must not be contaminated with the
adhesive.

6. After the first course of tile is in place and properly aligned, weld plugs
should be inserted and welded. Use the recommended welding procedure.
Refer to Page 4 - 29.

CAUTION: THE WELDS SHOULD BE MADE AS QUICKLY AS


POSSIBLE SO THAT A MINIMUM AMOUNT OF HEAT IS
TRANSFERRED TO THE LINERS. EXCESSIVE HEAT WILL CAUSE
THE LINERS TO CRACK.

4 - 25
Page 123 of 130
________________________________________________________
SHMP Co.,Ltd.
HP1003 PULVERIZERS - MAINTENANCE
________________________________________________________
7. Continue the attachment of successive courses of tiles. Maintain a check
on alignment with scribed lines. Close adherence to the piece mix in each
course count is essential to minimize openings between tiles. Each piece
of tile has a number 1 or 2 embossed on the wear surface. Any special
cut pieces are also marked for identification. Welding of metal plugs
other than the first course as described in Step 6. can be done after all
the tiles have been cemented in place.

8. It may be necessary to cut the last piece of ceramic tile in each course.

9. The last piece, closing tile, should be cut to fit the opening. A masonry
saw and diamond blade are required.

10. Open joints should not exceed 1/16 in. (3.17 mm) and should be filled
with the adhesive sealant (silicone) cement, such as RTV Sealer, trow-
eled flush with the surface of the liner.

NOTE: RTV Sealer and Duromar HAR requires approximately 24


hours to cure completely, however, both set up rapidly (approximately
1/2 hour).

11. Fill the weld plug holes with Duromar HAR and trowel flush with the sur-
face of the liner.

Trouble Shooting

LARGE GAPS BETWEEN TILE

Possible cause and remedies are as follows:

1. Improper piece mix - check drawing for proper count and mix.

2. Improper alignment-check scribed alignment lines and correct as


required.

3. First (bottom) course has been installed improperly - check against the
print provided.

4. Improperly fabricated liners - check print provided.

TILE IS CRACKING

1. Possible cause and remedies are as follows:

2. Too much heat - use smaller diameter welding rod. Decrease weld
puddle and fill.

WELDS NOT FUSING

Possible cause and remedies are as follows:

1. Area contaminated- burn cement away [700°F (371 ℃)]

2. Surface scale - clean by grinding or sandblasting.

4 - 26
Page 124 of 130
________________________________________________________
SHMP Co.,Ltd.
HP1003 PULVERIZERS - MAINTENANCE
________________________________________________________
LINER REPLACEMENT
(GENERAL)

NOTE: Refer to the specific segment, i.e. inner cone, venturi vane,
etc., for reference illustrations and drawings.

Individual ceramic tiles and other liners held in place with weld plugs can be
replaced as follows:

1. Remove the damaged or worn tile/liner.

2. Clean the metal seating surface, grind off the old weld plugs.

3. Fit the New tile/liner in the area voided by the original. Maintain a clear-
ance of 0.12 in. (3 mm) between liners.

4. Secure the new liner with adhesive and weld plugs. See 'Application of
Weld Plugs', Page 4-26.

5. After all damaged liners have been replaced, fill the weld plug holes with
Duromar HAR and the spaces between the liners with RTV Sealer.
Trowel all surfaces flush.

CAUTION: PROTRUSIONS OR SHARP BREAKS BETWEEN LINERS


CAN CAUSE EDDIES AND COAL/AIR FLOW DISTURBANCES
WHICH WILL ACCELERATE WEAR ON THE ADJOINING TILES.

Installation Procedures
for Inner Cone Liners

NOTE: Reference Ceramic wear tiles and weld plugs are supplied per
Drawing K7038.6.0.

1. Reference the preceding procedures 'Application of Weld Plugs' and


'Installation of Tiles -General' for weld plug and liner application.

2. To provide access, remove journal opening covers and tilt out journal
assemblies as described in the General Disassembly Procedures.

3. Remove the inner cone access door.

4. Clean the inside cone surface thoroughly. This surface must be free of
dirt, dust, oil, rust or scale. Clean with solvent. Sandblast or grind if
required.

5. Scribe concentric lines (parallel circles) at 12 in. (304.8 mm) increments,


up the inside slope of the cone. These circles will be parallel with each
other and perpendicular to the vertical center line of the cone. These
lines will be used as guides to assure proper layout of tiles.

4 - 27
Page 125 of 130
________________________________________________________
SHMP Co.,Ltd.
HP1003 PULVERIZERS - MAINTENANCE
________________________________________________________
6. Install tile beginning at the small end (bottom) of the cone. Proper
alignment at this stage is critical,allow approximately 0.12 in.(3mm) be
tween tiles. Misalignment here will be compounded as additional courses
of tile are added.

7. Install and weld the weld plugs in the first course of tile before proceeding
further.

8. Use a Masonry saw with diamond blade to cut the last piece of tile in-
stalled in each course (ring). The course count provided on the reference
drawing is based on no dimensional variation between the steel of the
cone and the tiles. From a practical standpoint this is never the case.

NOTE: When arranging tiles on the inner cone access door they
should be positioned so that the door can be removed after tile
installation is completed.

9. Install the balance of the tiles.

10. Install and weld the weld plugs in the ether courses of tile.

11. Replace the inner cone access door

12. Tilt-in the journal assemblies and replace the journal opening doors as
described in the General Reassembly Procedures.

Installation of Inner Cone


Spout Segments

NOTE: Reference Drawing K7038.6.0.

After the inner cone liners are in place, install the ceramic spout segments.
1. Position the ceramic spout segments around the inner cone to check fit.

2. Locate and install the six weld studs.

3. Place spout segments over the weld studs.

4. Apply thread locking sealant and tighten the stud nuts at each segment
per Drawing B-GP-2175.

5. Insert weld plugs and weld.

6. Fill weld plug holes and space between segments with RTV Sealer,
trowel smooth.

Installation/Replacement
Procedures for Separator
Body Liners

NOTE: The following steps refer to drawing K7006.8.0(A) unless


otherwise stated.

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Page 126 of 130
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SHMP Co.,Ltd.
HP1003 PULVERIZERS - MAINTENANCE
________________________________________________________
1. To provide access to the liners, remove the journal opening covers and
tilt out the journal assemblies as described in the General Disassembly
Procedures.

NOTE: Individual liners can be replaced per Liner Replacement, Page


4 - 27. If it becomes necessary to install or replace an entire deflector
assembly use the steps below.

2. If damaged or worn remove the deflector liner support plate.

3. Center the new deflector liner support plate between the journal openings.
The lower edge should be positioned 2.5in.+0.25in./-0.00in.
(63.5mm+6.3mm/-0.0 mm) below the separator body flange. Fillet weld
the support plate to the separator body on both ends and across the top.

4. Install the deflector side (right end) liner. Allow 0.12 in. (3.0 mm) between
the liner and the separator body, the lower face of the liner should be
flush with the lower edge of the support plate. Install weld plugs and
weld.

5. Install the deflector side (left end) liner. The front faces of the liner should
set back 0.12 in. (3.0 mm) from the front edge of the liner support plate.
Trim if necessary to provide 0.12 in. (3.0 mm) clearance from the
separator body. Insert weld plugs and weld.

6. Scribe a horizontal line at the break line between the lower and middle
tile, along the long edges of the tile.

7. Install the bottom row of liners starting at the right end. Allow 0.12 in. (3.0
mm) between the liners. At the left end the liners should be trimmed to
overhang the left end liner by 0.25 in. (6.4 mm) Install weld plugs and
weld.

8. The middle and top rows of deflector liners should be installed using the
procedures in Step 7.

9. After all three sets of deflector liners have been installed, install the in-
termediate liners starting at the left end. Maintain 0.12 in. (3.0 mm) gap
between the liners. Trim the right intermediate liner as required. Insert
weld plugs and weld.

10. Fill all the weld plug holes with Duromar HAR filler and trowel flush.

11. Fill all the gaps between liners with RTV Sealer.

12. Close up the pulverizer by tilting in the journals and replacing the journal
opening covers as described in the General Reassembly Procedures.

4 - 29
Page 127 of 130
HP PULVERIZER LUBRICANT SPECIFICATION

QUANTITY OF
LUBRICANT SPECIFICATIONS 1.4 LUBRICANT
FREQUENCY
LUBRICATIN TYPE OF REQUIRED OIL CHANGE
OF REMARKS
G ASSEMBLY ISO FITTING CYCLE
AGMA EP TYPE INSPECTION
VISCOSITY HP963~1003
NUMBER ADDITIVE
GRADE
SULFUR- SHIIPPED WITH PRESERVATIVE
5EP1 320 1000L
PHOSPHOR OIL .FLUSH AND FILL WITH CUSTOMER’S
( APPROXIMATE)
DAILY CHECK OIL BEFORE START UP. FOLLOW
PULVERIZER OIL TANK REFER TO GEARBOX
SIX MONTHS GAUGES, VENDOR’S SPECIFICATION. CHECK
PLANETARY RESERVOIR MANUFACTURER’S
NAME OF CUSTOMER’S LUBRICANT (NOTE 4, 6, 9) PIPES AND TEMPERATURE, PRESSURE, FILTER,
GEARBOX FILL PIPE INSTRUCTION FOR
(NOTE 8, 9, 10) HEADER FLOWS AND OIL LEVEL DAILY.MAKE
SPECIFIC
IINIATAIL CHANGE OIL CHANGE AFTER
RECOMMENDATIONS
2000~4000 HOURS OF OPERATION.
OIL CAPACITY FOR AT ASSEMBLY EACH JOURNAL IS FILLED
SULFUR- STORAGE: 90L ANALYZE AT 6 WITH THE OIL SUITABLE FOR SERVICE,
8EP1 680 CHECK
PHOSPHOR OIL CAPACITY FOR MONTHS CHECK THAT THE ASSEMBLY REMAINS
WHEN
RESERVOIR OPERATION: 45.4L INTERVAL. (NOTE FULL DURING STORAGE .TO PREVENT
ACCESS
CAP ON 5, 7, 9) CHANGE POSSIBEL DAMAGE TO THE JOURNAL OIL
JOURNAL INTO MILL ;
JOURNAL AT ONE YEAR OR SEALS, REMOVE OIL TO THE
AT LEAST
NAME OF CUSTOMER’S LUBRICANT SHAFT COLD OIL LEVEL WHEN ANALYSIS RECOMMENDED
EVERY
(NOTE 8, 9, 10) (21℃):381~432mm SHOWS COLD LEVEL (21°C) PRIOR TO START-UP
MONTH
DEGRADATION OF THE PULVERIZER. CONFIRM THE OIL
LEVEL IN THE INSTALLE POSITION.

Page 128 of 130


NOTES:

1. ALL THE LUBRICANTS CAN MEET THE REQUIREMENTS OF ABOVE


TECHNICAL PARAMETERS AS LONG AS THEY ACCORD WITH THE LATEST
ACCEPTANCE CRITERION OF AGMA ABOUT INDUSTRIAL CLOSE GEAR
TRANSMISSION #250.0X.

2. IT IS NOT RECOMMENDED TO USE MOLYBDENUM BISULFIDE, BORATE,


CHLORIDE AND SULFIDE ESTER AS EP TYPE ADDITIVE.

3. IT IS NOT RECOMMENDED TO USE WATER-BASED OR HYDRATED LUBRICANT


FOR ANY MILL COMPONENT.

4. IF THE LUBRICATING OIL IS TO BE REPLACED, IT IS BETTER TO DRAIN OIL


STILL HOT IN GEARBOX AS SOON AS THE MILL IS STOPPED, SO THAT THE
DETERIORATED OIL WITH SUNDRIES MIXED IN IT CAN BE THOROUGHLY
DRAINED AWAY.

5. LUBRICANT IN JOURNAL SHOULD BE REPLACED AFTER MILL HAS BEEN


OPERATING FOR 400 HOURS AND SHOULD BE DRAINED AWAY WHEN IT IS
STILL HOT. WHEN REPLACING OIL IN JOURNAL, IT SHOULD BE FLUSHED
WITH NEW LUBRICANT FIRST, AND THEN FILL LUBRICANT TO THE CORRECT
OIL LEVEL.

6. WHEN CLOSING TO OIL CHANGE CYCLE, IT IS RECOMMENDED TO INVITE AN


INDEPENDENT AND CERTIFICATED LABORATORY TO ASSAY OIL SAMPLE,
AND THE RESULT OF ASSAY WILL TELL HOW LONG THE LUBRICANT CAN
STILL BE USED AND THE GENERAL SITUATION OF BEARINGS AND GEARS.

7. IF PULVERIZER FIRE HAS OCCURRED, BEFORE THE PULVERIZER GOES INTO


OPERATION AGAIN, THE LUBRICANT IN JOURNAL MUST BE REPLACED OR
THE OIL SAMPLE MUST BE ASSAYED BY AN INDEPENDENT AND
CERTIFICATED LABORATORY TO CONFIRM WHETHER THE LUBRICANT HAS
BEEN DETERIORATED.

8. THIS SHOULD BE PROVIDED AND RECORDED BY USER.

9. DO NOT CONFUSE THE LUBRICANT BRAND WITH VISCOSITY GRADE. IF THE


LUBRICANT’S BRAND NAME CHANGED, IT IS SUGGESTED TO DRAIN THE
ORIGINAL OIL AND FLUSH THOROUGHLY TO PREVENT INCOMPATIBILITY.

10. THE LUBRICANT MUST BE CONFIRMED BY MANUFACTURER OF GEARBOX.

Page 129 of 130


TIGHTENING TORQUE FOR FASTENERS (DRAWING B-GP-2175)

Material
Torque(Nm)
5.6 8.8 10.9 12.9
Screw/bolt
M8 10 20 29 35
M10 20 40 55 65
M12 30 70 95 115
M16 75 165 235 280
M20 150 325 460 550
M24 260 560 790 950
M27 380 820 1150 1370
M30 520 1100 1550 1850
M33 700 1500 2100 2500
M36 900 1920 2700 3200
M42 1420 3000 4300 5000
M45 1750 3700 5200 6200
M48 2100 4500 6200 7500
M56 3300 7000 9000 11000
M64 6500 12765 17950 21545

Note: According to the request of the assembly drawing apply sealant correspond to screw thread

Page 130 of 130