MATERIAL SPECIFICATION NOTE

Centrifugally Cast Inserted Grinding Rollers in Improved / Sintercast

metallurgy
BRIEF DESCRIPTION:
You shall have to Design, Manufacture & Supply of the Centrifugally Cast Inserted
Grinding Rollers (1 Set = 3 Nos.) in the Improved / Sintercast metallurgy for all Coal
Mills of 500 MW to the Presently installed & in service. The specified inserted
Grinding Rollers must be Suitable for Worst Coal Analysis mentioned here under and
Guaranteed for 8000 Running Hours.
Ultimate Analysis:
% By Weight.
Moisture. 15.00
Ash. 40.00
Carbon. 33.05
Hydrogen. 2.49
Sulphur. 0.30
Oxygen (diff.). 7.69
Nitrogen. 0.68
Higher Heating Value Kcal / kg. 3300
Grind ability Index HGI. 50
Centrifugally Cast Inserted Grinding Rollers in Improved / Sintercast metallurgy for
Coal Mills of 500 MW shall be manufactured by Centrifugal Casting Machine. It
should be of Composite Construction with ceramic padded Hard Insert Embedded in
centrifugally cast SG Iron. Hard Inserts shall be formed Primarily of Chromium
Carbides embedded with ceramic in Highly Wear Resistant Mass.

A. PROCESS / PROPERTY REQUIREMENTS:

i. REFERENCE STANDARD AND DEVIATIONS:
The Indian Standard IS: 4771-1985 shall be Reference Standard (Ref, Std.) for All
Purposes, except Chemical Composition and Hardness unless otherwise
mentioned.
Chemical Composition and Hardness are modified as iii mentioned below
ii. CASTING PROCESS:
Centrifugally Cast inserted Grinding Rollers in the Improved / Sintercast
Metallurgy are to be manufactured by Centrifugal Casting Process.
iii. CHEMICAL COMPOSITION:
The Chemical Composition of Centrifugally cast Inserted Grinding Rollers in the
Improved / Sintercast Metallurgy shall be in the Range of:
Carbon (C) 2.3 - 3.4 %.
Chromium (Cr) 18 - 27 %.
Molybdenum (Mo) 0.3 -2.5 %.
Nickel 0.3-1 %
Manganese (Mn) 1.5 % max.
Silicon (Si) 1.0 % max.
Sulphur & Phosphorous-0.1% max
The Indian Standard IS: 1865 shall be Reference Standard (Ref, Std.) for SG Iron.
Respectively Chemical Composition of S.G. iron of the Centrifugally Cast
Inserted Grinding Rollers in the Improved / Sinter cast Metallurgy shall be in the
Range of:
 Carbon (C) 3.2 - 3.5 %.
Magnesium (Mg) 0.04 – 0.07 %.
Manganese (Mn) 0.3 % max.
Silicon (Si) 2.5 % max.
The above Chemical Composition does not absolve you from Guarantee
Responsibility. You shall have to submit the ‘Laddle’ Analysis of Each heat the
Rollers to GSECL.
HARDNESS:
The Hardness of Centrifugally Cast Inserted Grinding Rollers in the Improved /
Sintercast Metallurgy shall be in range of 60 to 66 HRC. The Hardness shall have
to be measured on Minimum Three Insert per Roller. Hardness of spheroidal
graphite iron material shall be 180 BHN min.
iv. MICROSTRUCTURE:
Test Coupons shall be cast with each set of Inserts. Test coupons shall be
identified with Roll numbers which shall be heat treated with corresponding rolls
Microstructure Examination shall be carried out at 200 X magnification.
Microstructure shall consist of discontinuous network of primary Carbides in the
matrix of Martensite. There shall be one sample per 3 sets of rolls for checking
v. HEAT TREATMENT:
The roller shall be suitably Heat Treated for achieving required hardness &
microstructure.
vi. VISUAL INSPECTION
This being very hard structure and composite construction, which causes cracks and
other discontinuities in the inserts, these are not harmful for functioning parts. The
inserts may show cracks and other discontinuities to occur at unpredictable location
and unpredictable numbers which are acceptable.
RESIDUAL MAGNETISM:
All Centrifugally Cast Inserted Grinding Rollers in the Improved / Sintercast
metallurgy shall be free from Any Type of (Residual) Magnetism.

RED – OXIDE / PAINT:

Red-Oxide shall be applied only after final inspection.
QUALITY ASSURANCE MEASURES:

STAGE INSPECTION:
It will be essential that you shall have to keep GSCEL informed about their
production schedule 15 days in advance. (Particularly Pouring, Heat - Treatment) so
that GSECL can arrange Stage Inspection. You need not discontinue your
Production schedule because of Absence of GSECL’s Representative unless it is to
be instructed or agreed upon.
“FIRST SAMPLE” STAGE INSPECTION:
It will be essential for you to get All Stages inspected for the First Sample of Inserts
& Grinding Roller by GSECL’s Representative. Therefore, You shall arrange for
Necessary Advance Intimations to GSECL for this Purpose.

‘SAMPLE APPROVAL’:
In Addition to the Stage Inspections, it will be essential for you to submit First
Sample of centrifugally cast inserted grinding roller in Sinter cast / improved
metallurgy to GSECL Site and obtain ‘Sample Approval’ for Commencement of
 Bulk Production.

‘IDENTIFICATION MARK’:
It will be essential that all centrifugally cast inserted grinding roller in Sinter cast /
improved metallurgy have Clear-Cut Identification’ for Traceability to their Heat,
Heat Treatment Batch, your Name. Painting / punching is allowed for Identification
Marks. (it should be such that it remains a Present at the time of Supply)

IDENTIFICATION STATEMENT:
You shall have to submit a Statement, along with Supply of Rollers regarding the list
of Centrifugally Cast Inserted Grinding Rollers in Improved / Sintercast Metallurgy
along with their Identification Marks and Details about Heat, Heat Treatment Batch
they belongs to.

CHEMICAL ANALYSIS:
Party should pour the button sample for Spectro analysis and should arrange the
spectro analysis in presence of GSECL representative and should preserve the
sample.

CROSS VERIFICATION OF SAMPLES:

Some of these submitted button Samples will be tested of GSECL end. In case the
Result of Any button Sample tested at GSECL end & if it differs significantly
with the reported Chemical Analysis submitted by the party , the Entire Supply
will be rejected.

HARDNESS TESTING:
REPORT:
You shall have to submit a list of all Rollers and their All Measures Hardness
Values (All Readings of All Three Locations and Not Average), along with Supply
of the Rollers.

HARDNESS LOCATIONS:
All Hardness ‘Indentations’ shall be left as they are. All Hardness Locations
(where Measurement is made) shall leave to be encircled with suitable Paint such
that they are apparent at the time of Supply.

MICROSTRUCTURAL EXAMINATION:
REPRESENTATIVE SAMPLES:
You shall have to arrange preparation of Suitable ‘Representative’ (Separately
Cast and simultaneously Heat Treated) Samples for Micro Structural
Examination, representing at least 10 % of Total Number of Grinding Rollers
and get them examined for their Microstructure. (Refer: clause A (iv))
REPORT:
You shall have to submit a list of Roller whose Representative Samples are
examined for their Microstructure

VARIFICATION SAMPLES:
You shall have to submit to GSECL, Minimum Half Number of Samples
examined as above for Microstructure, along with Proper Identification
(indication the Grinding Rollers they represent) at the time of Supply of the
 Grinding Rollers for Verification at GSECL End.
DOCUMENTS/ CERTIFICATES TO BE SUBMITTED WITH SUPPLY:
Chemical Analysis of 100 % quantity
Hardness Report 100% quantity
Microstructure Report 10% quantity

PERFORMANCE GUARANTEE for HPMS/MPSP System:

The Criteria of The Performance Guarantee for each set of centrifugally cast
inserted grinding rollers in Sintercast / improved metallurgy, Compatible High
chrome Bull Ring segments and rotating Airport Ring Assembly shall be as
follow.
(1) Guarantee: Life of Grinding Rolls and Bullring Segments ( in set) : 8000 hrs.
The life of Airport ring assembly should be 16000 hrs

• For Grinding rollers and Bullring segments ,free replacement if wear is more
than 50mm on roller and 30 mm on Bullring Segments before logging 4000 hrs
and prorata recovery between 4001 to 7999 hrs.

• For airport ring assembly, free replacement if fails before logging 8000 hrs.
Prorata recovery between 8001 to 15999 hrs.
• The mill output should not fall below 57 +/- 5% TPH for the coal composition
specified above. The rejection of mill should be less than 0.7%. These
parameters should be measured at Full Load of the Unit during Guaranteed
8000 Running Hours for coal characteristics specified above
You shall have to agree for the following Standard Conditions: If the Product fails prior to
50% of the Guarantee Life, it shall be replaced Free of Cost and if the Product fails after 50%
but before 100% of the Guaranteed Life, then Pro Rate Rebate shall be given in terms of
Supplying Equivalent Number of Grinding Rollers, Compatible High chrome Bull Ring
segments and rotating Airport Ring Assembly for the Shortfall Hours Life by the Party. This is
applicable for One Time for Particular A/T. You shall have to submit performance Bank
guarantee of 10% of total order value for the centrifugally cast inserted grinding rollers in
Sintercast/ improved metallurgy , Compatible High chrome Bull Ring segments and rotating
Airport Ring Assembly
S/d
Supdt. Engineer(Met)
GSECL, WTPS.