SUPPORT & GUIDENCE – MR. P.

SHARMA (HEAD)

M UPADYAY (SR.ENGG) - POWER MECH A KUMAR (LEAD ENGINEER) – MPL

 R KUMAR (ENGG) – POWER MECH

MAITHON POWER LTD

INDEX
1) MILLTECHNICAL SPECIFICATIONS

2) MILL MILE STONE ACTIVITIES

3) DISMANTLING PROCEDURE

4) INSPECTION OF ALL MILL COMPONENTS

i) DEFECTS

ii) OBSERVATIONS

5) ASSEMBLY PROCEDURE

6) MILL OVERHAULING CHECKLIST

7) NEW SPARES & CONSUMABLES USED

8) MAN POWER ENGAGED.

MILL TECHNICAL SPECIFICATIONS:-

TYPE OF MILL : XRP 1003

MILL BASE CAPACITY (T/HR) : 61.0

MOTOR SPEED (RPM) : 895

TOTAL WEIGHT OF MILL (T) :130

(Including Motor)

TYPE OF LOAD : Moderate shock load

ROTATING WEIGHT OFMILL : 22.88

SPRING RATE (Kg/cm) : 5359

SPRING PRE LOAD (Kg) : 9500

MILL OUTLET TEMP RANGE : 65OC-90OC

AIR FLOW : 102 (T/Hr)

FINENESS : 70 % through 200 Mesh

 PLANNING SHEET
SL No. DESCRIPTION 28.07.13 29.07.13 30.07.13 31.07.13 1.07.13 2.07.13 3.07.13

1 Journal opening cover              

bolts removal and shifted
to 3.5 meter mill floor

2 R.J shaft Assy and              

grinding roll assembly
removal and shifted to 0
meter
3 Lock nut removal from              
R.J.Assy.

4 Grinding roll removal            

from R.J.Assy. and old
Clamping ring and bull
ring segment dismantling
5 Journal head removal              
from R.J.Assy. , R.J.Assy.
Oil Drain

6 New bull ring segment              

fitting and Clamping ring
fitting.

7 R.J. Shaft Assy.              

Dismantling

8 R.J. Assy bearing              

inspection, Alignment
checking, oil seal
inspection , o ring
inspection, float checking
and box- up.
9 Journal head hard-facing              
work and Journal head
liner repairing work ,
assembled with
R.J.Assymbly
10 New Grinding roll fitting              
with R.J. shaft Assembly.,
Gr.roll Lock-nut fitting &
tightening
11 R.J.Assymbely with              
grinding rolls and journal
head final fitting, Check
nut tightening.
12 Lifting of R.J. shaft -            
Journal head assembly
and shifting to 3.5 Mtr
Floor. and journal
opening cover door box-
up
13 Airport assembly              
repairing , Bowl extension
ring repairing and hard
facing work
14 Bottom insulation plate              
inspection work and
repairing.

15 Upper skirt and dam ring              

dismantling and removal

16 Labyrinth seal (upper and              

lower) dismantling and
removal work for
checking.
17 Labyrinth seal (upper and              
lower) Assembly work
and Dam ring and Upper
skirt insulation fitting and
final box - up.
18 Inner cone and outer              
cone inspection,
Venturycoller, Classifier
Vanes, MPO and MDV
inspection and
rectification as required.
19 Checking of Roller and              
spring setting, roll to
bowl, scraper and
insulation cover plate
clearance etc.
20 Radial gap between              
scrapper and mill side
liner, Gear-box oil
replacement, if required.
21 Motor to gear box              
alignment

22 Final box - up and Permit              

return, Inter -locks &
protection checking &
trial run
MILE STONE ACTIVITES

 TOTAL RUNNING HOURS OF Mill-2BWAS 8172 HR.

 ABOVE 7500 RUNNING HOURS HIGH REJECTION COMING IN MILL

REJECTION

 MILL TAKEN FOR THE OVERHAULING AND PTW ISSUED: 28.08.2013

 MILL DISMANTLE STARTED : 28.08.2013

 MILL INTERNAL AND EXTERNAL INSPECTION:29.08.2013

 ROLLER AND MILL INTERNAL RECTIFICATION DONE: 29.08.2013-

01.09.2013.

 MILL ASSEMBLE STARTED :02.09.2013

 MILL BOX UP AND PTW RETURNED: 03.09.2013

 MILL TRAIL RUN TAKEN: 03.09.2013

MILL DISMANLTLE PROCEDURE:

Chain blocks arrangement were done for the Mill dismantle purpose.
MILLJ1-J3 Roller journal cover and RollerJournalAssembly were removed one by one with the help of
chain block.

Roller removed and shifted at “0” meter. Roller chuck nut opened and journal head dismantle done.
Grinder lock nut opened and grinder removed from the roller Assembly. Journal Roller oil was drained.
And upper bearing housing dismantles and cleaning done.J1/J2/J3 Trunnion bush dismantle done.

Damaged Bull ring segments and clamping ring were removed from the position. Damaged Airport
assembly damaged portion cutting done. Lowerskirt scrappers Assembly dismantle done. Insulation
plate, upperand lower labyrinth seal dismantle done.

INSPECTION OF ALL MILL COMPONENTS

DEFECTS & OBSERVATOINS:-

1. Mill inspection done and found all grinding roller was heavily worn-out condition.

2. Bull ring segment were worn out in condition.

3. Clearance between scraper plate and bottom insulationplate is not within the limits.

4. Found Gap more between the Radial clearance between labyrinth seal & bowl hub

5. Vertical gap between rotating vanswheel of airport assembly is more.

6. Inspection done of Bowl Extension ring found worn out in condition.

7. Found All J1/J2/J3 Journal head liner assembly found worn out in condition.

8. Grinding Roll J1/J2 Lock nut found heavily worn out in condition.

9. Bottom Insulation plate inspection done found worn out in condition.

10. Scrapper block Assembly found worn out condition.

Defects &Findings Pictures

J1 Roller found Worn out condition More than 70-80 MM

J2 Roller found Worn out condition More than 70-80 MM

J3 Roller found Worn out condition More than

80-90 MM
Journal Head J1 hard facing done with hard facing
electrodes to prevent the damage of journal head.

Journal Head J2 hard facing done with hard facing

electrodes to prevent the damage of journal head.

Journal Head J3 hard facing done with hard facing

electrodes to prevent the damage of journal head.
 J1/J2/J3 Liner Assembly is in damaged in condition.

Journal Head J3 hard facing done with hard facing

electrodes to prevent the damage of journal head.

Clamping ring and bull ring segments were heavily worn

out condition.
 New bull ring segments, clamping ring were replaced
with new. Extension bowl ring hard facing done.

Vane wheel hard facing done with hard facing done and
vane wheel bolts were replaced with new.

AirportAssembly damaged in condition.

 Airport Assembly was welded with new.

Locking arrangement done for roller lock nut and hard

facing done.

Roller liner Assembly repairing and hard facing done.

 Graphite Rope replacement done for the upper and
lower Labyrinth seal.

Bottom insulation plate hard facing work done

Damaged clamping ring.

MILL ASSEMBLY PROCEDURE:

All journal Rollers oil 250ltrs (Servo mesh SP-680) replacement was done. All three journal head liner
Assembly were repairing done by patching 10 MM plate by welding ,and All three journal head hard
facing was done.

Bull ring segment and clamping ring found damage same were replacement with new.clampping ring
hard facing was done.

Airport assemblywere cut and replaced with 20 mm plate welding done. Bowl extension ring, hub liner
and clamping ring hard facing was done.

J1/J2 /J3 roller Alignment done and float was set roller is J1: 0.13 and J2:0.14 and J3:0.12.

After assembled roller assembly with the help of chain block fitting done in position and all the journal
cover J1-J3 were fixed back. All rollers gap was adjusted by manually gap were 6 mm. All rollers spring
gap was adjusted to J1; J2 & J3 was 1 mm, 1 mm & 1 mm respectively

J1/J2/J3 Trunnion bush inspection done for all the journal head, found O.K, Greasing and Assemble
done.Upper& lower labyrinth seal rope replacement &insulation filling done on the bottom insulation
plate,and insulation plate fitting done. And dam ring fitting, insulation filling, Skirt and scrapper
assembly fitting was done and tie rod, bridge ring fitting & welding had done. Mill Alignment done,
Alignment readings were follow as:Axial & Radial Is Max: 0.05. Distance piece fitting, coupling done.
And Gear coupling greasing done. Mill box up done. RO returned.

VIBRATION READING WERE TAKEN DURING THE TRAIL

NO LOAD CONDITION:

MOTOR
Unit G/B
Date NDE DE
(RMS)
H V A H V A

03.09.2013 MM/SEC 0.85 0.38 0.51 0.94 0.59 0.86 0.68

LOAD CONDITION at 40 ton/hr.

 MOTOR
Unit
Date NDE DE G/B
(RMS)
H V A H V A

04.09.2013 MM/SEC 2.43 1.12 2.88 2.73 2.02 2.83 4.79

SAFETY ASPECTS:

 Barication done at 3.5 mtr after cutting handrail and midrail for lowering &
lifting the roller assembly.
 JSA prepared and Discussed with workers.
 Use proper PPE’s while working.
 Conduct the TBT for workmen before starting the work.
 Close supervision by PMPL safety persons.
 Inspect the lifting tools and tackles before it is using in the job.

 Over hauling Check list – Mill – 2B

OVERHAULING MAINTENANCE CHECK LIST

EQUIPMENT
UNIT: #2 PTW No: 28.08.2013
NAME: Mill – 2B
 PTW
PTW SCHEDULE
28.08.2013 CLOSING 03.09.2013
DATE: DATE: Sep-2013 DATE:

SL No. DESCRIPTION Value Mill- Mill – 2B REMARKS

2B( Before ( After
Over Over
hauling hauling

Check grinding roll wear depth

0 to 70 Above80 All the three no. Rolls
1 using the wear measurement Nil
mm mm replaced by new one
gauge

Roller setting and

2 Check roll to bowl clearance 6 to 8 mm 10mm 6 mm stopper bolt setting
done

3 Spring compression setting 9.5 tons 9.5 tons 9.5 tons Found O.K

New Bull Ring Segment

set replaced
0 to 70 Above 70
4 Check Bull ring segment Found o.k
mm mm

Two no. scrapper shoe

Clearance between scraper and 13 to 19 above 25
5 15.0 mm were replaced with
insulation cover plate mm mm
new.

Clearance between scraper guard 10 to 16 above 20

6 15.0 mm hard facing work done
and insulation cover plate mm mm

Radial gap between scraper and 25 to 35

7 30.0 mm 25.0 mm Found O.K
mill side liner mm

New Graphite rope

Radial clearance between labyrinth
8 0.3 mm 4mm 0.2 mm replace in labyrinth seal
seal & bowl hub
upper and lower.

Airport Assembly was

Vertical gap between liner segment
5 to 11 replaced with 20 MM
9 and rotating vans segment of air 20 mm 6.0 mm
mm plate. Hard facing done
port assembly
for the vanes.

Gap between inverted cone and

10 100 mm 100 mm 100 mm Found O.K
inner cone
 Gap between centre feed pipe
11 114 mm 114 mm 114 mm Found O.K
lower and inner cone

Normal /
12 Inspection of Bowl Extension ring worn out Normal Hard facing done
worn out

Repairing done for the

Normal /
13 Journal head liner assembly worn out normal All the 3 no’s liner
worn out
assembly.

Normal /
14 Journal shaft assembly Normal Normal Found O.K
worn out

Normal / 02 No. lock nut were

15 Grinding Roll Lock nut worn out Normal
worn out replaced with new.

Normal / Hard facing done in top

16 Journal head worn out Normal
worn out body

normal /
17 Condition of Classifier Vanes Normal Normal Found O.K
missing

Normal / hard facing and

18 Vane wheel worn out Normal
worn out patching done

Normal /
19 Venturi and venture collar Normal Normal Found O.K
worn out

Normal /
22 Insulation plate worn out Normal Hard facing done
worn out

Normal /
23 Inspection of Mill Discharge valves normal Normal Found O.K
worn out

Inspection of Multiple port outlet Normal /

24 Normal Normal Found O.K
Assembly worn out

NEW SPARES USED

 All the three no. Grinding Rolls replaced with new.

 New Bull Ring Segment set replaced

 Clamping ring set replaced with new.

  Two no. Scraper shoe werereplaced with new.

 Upper and lower labyrinth seal graphite rope were replaced with new

 Oil seal 9 no’s for All journal roller assembly.

 Roller lock nut 2 no’s were replaced with new.

Consumable Used:

Welding electrode (7018) 4mm : 30 packets

Welding electrode (7018) 3.15mm : 24 packets

Grinding wheel (7”) : 08Nos.

Grinding wheel (4”) : 10Nos.

Emery wheel (4”) : 6 No’s

LPG : 1 No’s

Oxygen gas : 05 No’s

Diesel : 35 Lit.

Molykote : 1KG

Hard facing –Make L&T 4MM : 55 KG (supplied by MPL)

Manpower Engaged:

SL.No Designation Manpower engaged Manpower engaged

(Day shift) (Night shift)

1 Engineer 1 1

2 Supervisor 1 1

3 Forman 1 1
 4 IBR Welder 0 0

5 Fitter 1 1

6 Grinder 1 1

7 Welder 3 2

8 Gas cutter 1 1

9 Hydra operator 1 1

10 Rigger 04 02

11 Helper 03 02

TOTAL 17 13

TOTAL MANPOWER 30 No’s

REPORT PREPARED BY:-

Manish - Powermech