Hp963 Pulverizer Installation, Operation and Maintenance

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ABB CE HP963 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 Componenes.......................... Part 2
Installation Procedures ............................................................................ Part 3
HP PULVERIZ OPERATION ............................................................................. TAB II
Principles of Operation ............................................................................ Part 1
Pulverizer OperatingProcedures ............................................................. 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
HP PULVERIZER ILLUSTRATIONS ............................................................... TAB IV
ENGINEERING DRAWINGS ............................................................................ TAB V
Contract Drawings .................................................................................. Part 1

Pulverizer Drawings ............................................................................... Part 2
Maintenance Tool Drawings ................................................................... Part 3
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ABB CE TYPE HP963 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
INTRODUCTION ..................................................................................................... 3-1

PULVERIZER COMPONENTS ....................................................................................... 3-1
GENERAL ASSEMBLY .......................................................................................... 3-4
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING ......... 3-6
Pulverizer ...................................................................................................... 3-6
Motor ............................................................................................................. 3-8
MILLSIDE AND LINER ASSEMBLY ..................................................................... 3-9
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY ................................... 3-10
SEPARATOR BODY ............................................................................................ 3-11
SEPARATOR TOP ASSEMBLY ......................................................................... 3-13
MILL DISCHARGE VALVES AND MULTIPLE PORT OUTLET ASSEMBLY ....... 3-14
OUTLET VENTURI AND VANES ASSEMBLY ................................................. 3-14
INNER CONE WITH LINERS ............................................................................. 3-15
JOURNAL OPENING COVER WITH SPRING .................................................. 3-16
GEARBOX ASSEMBLY INSTALLATION ........................................................... 3-16
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION ...................... 3-19
SECURING THE GEARBOX .............................................................................. 3-21
CLEARANCE AIR SEAL ..................................................................................... 3-21
PULVERIZER MOTOR ........................................................................................ 3-22
JOURNAL INSTALLATION ................................................................................. 3-23
Journal Assembly Installation ................................................................... 3-23
Journal Head Assembly Installation ....................................................... 3-25
Journal Roll And Shaft Assembly Installation ..................................... 3-26
TRUNNION SHAFT,JOURNAL SPRING SEAL AIR ......................................... 3-28
FEED AND FUEL PIPING ASSEMBLY ............................................................ 3-29
DISCHARGE VALVE LIMIT SWITCH SET-UP ................................................. 3-29
CONTROLS .......................................................................................................... 3-29
FINAL ADJUSTMENTS: JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE, JOURNAL SPRING POSITION . 3-30
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TABLE OF CONTENTS
PULVERIZER DESCRIPTION Part 1
TITLE PAGE NO.

PULVERIZER DESCRIPTION ................................................................. 1-1
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LIST OF FIGURES
TITLE FIGURE NO.
HP Pulverizer .......................................................................................... 1-1

HP Pulverizer Coal and Air Flow ...................................................... 1-2
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PART 1 - PULVERIZER
DESCRIPTION
PULVERIZER DESCRIPTION
ABB Combustion Engineering 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:
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, its liners and air inlet (Refer to Figure 1－1) 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. deflector liners and separator top with attached
deflector assemblies and the inner cone and classifier, contain the
material after it is pulverized. The separator body, deflector liners 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
1-1
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7. The outlet venturi and 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 ABB CE 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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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 ................................. .......................................... 2-4
Component Storage ..................................................................................... 2-4
GEARBOX ASSEMBLY ......................................................... ................... 2-4
OUTLET VENTURI AND FEED PiPE ASSEMBLY, MULTIPLE PORT
OUTLPT AND OUTLET PLATE ............................. .......................... 2-4
MILLSIDE AND SEAL AIR HEADER ASSEMBLY .......... .......................... 2-4
SEPARATOR BODY ASSEMBLY ........................ ..................................... 2-5
JOURNAL HEAD AND TRUNNION SHAFT ASSEMBLY .......................... 2-5
JOURNAL OPENING COVER ASSEMBLY ............................................... 2-5
SEPARATOR TOP ASSEMBLY ................................................................ 2-5
PULVERIZER DISCHARGE VALVE/MULTIPLE PORT OUTLET
ASSEMBLY ...................................................................................... 2-5
INNER CONE OR INNER CONE AND CERAMIC LINER ASSEMBLY ..... 2-6
JOURNAL SHAFT ASSEMBLY ................................................................. 2-6
GEARBOX LUBRICATION UNIT, OIL COOLERS, GEAR BOX
ACCESSORIES, OIL HEATERS ...................................................... 2-6
SOLE PLATES AND MOUNTING PLATES ............................................... 2-6
MISCELLANEOUS FASTENERS .............................................................. 2-7
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY .... ......................... 2-7
SEAL AIR SYSTEM PIPING ............................................................. ........ 2-7
CENTER FEED PIPE UPPER AND INVERTED CONE ....... ..................... 2-7
COUPLING ASSEMBLY ............................................................................ 2-7
LUBE OIL PIPING ..................................................................................... 2-7
MOTOR COUPLING GUARD, BOWL HUB CLEARANCE, AIR SEAL AND
GUARD, COAL SAMPLING FITTINGS, THERMOWELLS,
BULL RING SHIMS .... ...................................................................... 2-7
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TABLE OF CONTENTS (Continued)
PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTSPART 2
TITLE PAGE NO.
DIFFERENTIAL PRESSURE CONTROLLER .............. ...................... 2-7

BOWL HUB UPPER AND LOWER SKIRTASSEMBLIES,SCRAPER AND
GUARD ASSEMBLIES, AND JOURNAL SKIRT ASSEMBLIES 2-8
WATER PIPING AND NOZZLE ASSEMBLIES .............. .................... 2-8
INNER CONE CERAMIC LINERS ..................................................... 2-8
MOTORS ............................................................................................ 2-8
BOWL HUB HOISTING FIXURES, JOURNAL TILT-OUT COMPONENTS,
GEARBOX ALIGNMENT FIXTURES .. .................................... 2-8
COAL SAMPUNG DEVICE, OIL DIP STICK, SPECIAL TOOLS ... ..... 2-8
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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.
NOTE
Components, when received, should be stored in accordance

with ABB Combustion Engineering's, Mechanical Design Sta-
ndard Number 18-79 (Index No. 11.5.1).
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.
USE CARE W HEN HA NDLING ASSEMBLIES WHICH

C O N T A I N C E R A M I C L I N E R S . TH E L I N E R S M A Y
CRA CK I F A N A S SEMBLY IS HANDLED ROUGHLY
NOTE
Cosmoline No. 1058 (E.F. Houghton & Co., Valley Forge, PA)
and grease are used many places for preservation. These
coatings must be maintained during the storage period. When
the component is being readied for assembly, the
Cosmoline/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 pe-
riods 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. Outlet venturi and vane assembly E
2. Millside and seal air header assembly E

3. Separator body assembly E
4. Journal head and trunnion shaft assembly C
5. Journal opening cover assembly C
6. Separator top assembly E
7. Inner cone (and ceramic liner) assembly E
8. Journal shaft assembly C
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MAJOR SUBASSEMBLIES (continued) Storage Type
(Minimum)
9.Gear box lubrication unit C
10.Gear box assembly (Refer to Manufacturer's instructions) C
11.Bowl, bowl hub, and vane wheel assembly E
12.Mill discharge valve and multiple port outlet assembly C
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. Seal air components (pulverizer and discharge valve) C
15. Center feed pipe - upper E
16. Inverted cone E
17. Bowl hub clearance air seal and guard C
18. Bowl hub upper and lower skirt assemblies C
19. Scraper and guard assemblies C
20. Mill motor coupling C
21. Miscellaneous fasteners B
22. Motor coupling guard C
23. Lube oil piping C
24. Water piping and nozzle assemblies C
25. Gear box accessories C
26. Journal skirt assemblies C
27. Differential pressure controller B
28. Thermowells C
29. Aspirating (coal sampling fittings C
30. Bull ring shims (extra) C
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TOOLS AND FIXTURES
Storage Type
(Minimum)
31. Coal sampling device B
32. Oil dip stick B
33. Special tools B
34. Bowl hub hoisting fixtures C
35. Journal tilt-out components C
36. Spring preload components B
37. Gearbox alignment fixtures C
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 instr-
uctions.
OUTLET VENTURI AND FEED PIPE ASSEMBLY.MULTIPLE PORT OUTLET

AND OUTLET PLATE (Storag Type E)
Place the components on timbers with the axis of the feed pipe horizontal.
Coat all exposed machined surfaces and the threaded holes with CosmoIine
No. 1058. Plug tapped holes with plastic tapered plugs. Securely cover the
assemblies with clear heavy gauge plastic.
EXERCISE CARE WHEN HANDLING THESE ASSEMBLIES.

ROUGHHANDLING MAY CARACK CERAMICLINERS.
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.
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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 HEAD AND TRUNNION SHAFT ASSEMBLY

(Storage Type C)
Store the assembly on timbers. Coat all of the exposed machined surfaces,
including tapped holes with Cosmoline No. 1058. Plug all of the tapped
holes with tapered plugs.
JOURNAL OPENING COVER 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.
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.
PULVERIZER DISCHARGE VALVE/MULTIPLE PORT OUTLET

ASSEMBLY (Storage Type C)
Place the assembly on timbers with the multiple port outlet plate facing
down. Coat all of the exposed machined surfaces, including tapped holes,
with Cosmoline No. 1058. Plug all of the tapped holes with tapered plugs.
Securely cover the assembly with a clear heavy gauge plastic.
CAUTION
EXERCISE CARE WHEN HANDLING THIS ASSEMBLY.

ROUGH HANDLING CAN DAMAGE THE CERAMIC LIN-
ERS ON THE MULTIPORT OUTLET ASSEMBLY
2-5
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ABB CE TYPE HP963 PULVERIZERS - INSTALLATION

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INNER CONE OR INNER CONE AND CERAMIC LINER SSEMBLY

(Storage Type E)
Place this assembly on timbers with the large diameter down. No other
preservation is required.
IF CERAMIC LINERS ARE INSTALLED, USE CARE IN

HANDLING TO PREVENT CRACKING LINERS.
JOURNAL SHAFT ASSEMBLY (Storage Type C)
Place the assembly vertically on timbers, stand on the base of the lower
journal housing. Check that each journal shaft assembly is completely filled
with the recommended oil. 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, every 4th one. Run a 1/4 in. tube down the journal shaft until it
bottoms on the lower journals housing. Close the end of the tub 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
completly 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 Lubricating Specifications in the Pulverizer Operations section of
this Instruction Manual.
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.
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 CAU-

SE ANY OF THE PLATES TO BEND
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MISCELLANEOUS FASTENERS (Storage Type B)
Store these components on metal shelving. No other preservation is

required.
BOWL,BOWL HUB 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.
SEAL AIR SYSTEM 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 UPPER AND INVERTED CONE (Storage Type E)
Place the components on timbers. Coat the machined flanges with

Cosmoline No. 1058. Coat bolt holes with grease.
COUPLING ASSEMBLY (Storage Type C)
Store the coupling on metal shelving. Preserve per the vendor's require
ments.
LUBE OIL PIPING (Storage Type C)
Same as gear box lubrication system.
MOTOR COUPLING GUARD, BOWL HUB (CLEARANCE, AIR SEAL

AND GUARD. COAL SAMPLING FITFINGS. THERMOWELLS. BULL
RING SHIMS (Storage Type C)
Store these components on metal shelving. No other preservation is req-

uired.
DIFFERENTIAL PRESSURE CONTROLLER (Storage Type B)
Store these components on metal shelving. No other preservation is req-

uired.
2-7
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BOWL HUB UPPER AND LOWER SKIRT ASSEMBLIES. SCRAPER

AND GUARD ASSEMBLIES. AND JOURNAL SKIRT 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.
WATER PIPING AND NOZZLE ASSEMBLIES (Storage Type C)
Store the components on pallets or metal shelves. 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.
MOTORS (Storage Type B)
When supplied, motors should be stored on pallets or timbers and preserved

per vendor's specifications.
BOWL HUB 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.
COAL SAMPLING DEVICE. OIL DIP STICK. SPECIAL TOOLS (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
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TABLE OF CONTENTS
INSTALLATION PROCEDURES PART 3
TITLE PAGE NO.
INTRODUCTION ..................................................................................... ........... 3-1

PULVERIZER COMPONENTS............................................................................. 3-1
SUB-ASSEMBLI ES .................................................................................. 3-1
LOOSE PARTS ......................................................................................... 3-2
TOOLS ...................................................................................................... 3-3
GENERAL ASSEMBLY ...................................................................................... 3-4
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING .......... 3-6
Pulverizer ...................................................................................................... 3-6
Motor ............................................................................................................. 3-8
MILLSIDE AND LINER ASSEMBLY ................................................................... 3-9
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY .................................... 3-10
SEPARATOR BODY ........................................................................................ 3-11
SEPARATOR TOP ASSEMBLY ...................................................................... 3-13
MILL DISCHARGE VALVES AND MULTIPLE PORT OUTLET ASSEMBLY ... 3-14
OUTLET VENTURI AND VANES ASSEMBLY ................................................ 3-14
INNER CONE WITH LINERS ........................................................................... 3-15
JOURNAL OPENING COVER WITH SPRING ................................................. 3-16
GEARBOX ASSEMBLY INSTALLATION ......................................................... 3-16
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION ........................ 3-19
SECURING THE GEARBOX ............................................................................ 3-21
CLEARANCE AIR SEAL .................................................................................. 3-21
PULVERIZER MOTOR ..................................................................................... 3-22
JOURNAL INSTALLATION .............................................................................. 3-23
Journal Assembly Installation ................................................................... 3-23
Journal Head Assembly Installation .......................................................... 3-25
Journal Roll And Shaft Assembly Installation .......................................... 3-26
TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ........................................ 3-28
FEED AND FUEL PIPING ASSEMBLY ............................................................ 3-29
DISCHARGE VALVE LIMIT SWITCH SET-UP ................................................. 3-29
CONTROLS ..................................................................................................... 3-29
FINAL ADJUSTMENTS, JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE, JOURNALSPRING POSITION ....... 3-30
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ABB CE TYPE HP963 PULVERIZERS - INSTALLATION

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PART 3 - INSTALLATION
PROCEDURES
INTRODUCTION
The pulverizer described in this manual is too large to be shipped asse-

mbled.
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.
TO PREVENT POSS IBLE EQUIPMENT FAILURE-

S,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
D RA W I NG B - GP - 21 75 LOCA TE D W I TH THE TOOL
DRAWINGS
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 controlsbe retained in
storage and be installed on the pulverizers just prior to [not more than six (6)
months before] unit commissioning.
PULVERIZER COMPONENTS
SUB-ASSEMBLIES
The normal subassemblies are:
1. Millside, liner and seal air header assembly.
2. Bowl, bowl hub and vane wheel assembly,
3-1
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ABB CE TYPE HP963 PULVERIZER -INSTALLATION

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3. Separator body assembly.
4. Inner cone and spout segment assembly.
5. Outlet venturi and vanes assembly.
6. Separator top assembly.
7. Journal head and trunnion shaft assembly.
8. Journal shaft assembly.
9. Journal opening cover assembly,
10. Gearbox assembly.
11. Gearbox lubrication system.
12. Mill discharge valve and multiple port outlet assembly.
MAJOR PULVERIZER COMPONENTS ARE KEYED OR MATCH

MARKED TO ENSURE PROPER ORIENTATION OF THE AIR
INLET, JOURNAL OPENINGS AND FUEL PIPES. EACH COMP-
ONENT lS IDENTIFIEDWITH A SERIAL NUMBER TAG. USE
CARE TO INSTALLTHE CORRECT SERIAL NUMBERED PUL-
VERIZER AND ITS COMPONENTS AT THE LOCATION IND-
ICATED ON THE CONTRACT DRAWINGS.
LOOSE PARTS
The following items may be bundled Or boxed and are normally shipped
unassembled:
13. Clearance Air Seal and guard components.
14. Inner cone support pipes,
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15. Center feed pipe- upper.
16. Center feed pipe -lower.
17. Seal air piping.
18. Discharge valve air header and piping
19. Seal air header valves.
20. Motor coupling.
21. Motor coupling guard.
22. Sole plates and mounting plates.
TOOLS
23. Coal sampling device.

24. Bowl hub hoisting tools
25. Gearbox alignment tools.
26. Gearbox removal rail kit.
27. Hydraulic stud tensioner (bowl/gearbox),
28. Journal tilt-out components.
29. Journal spring preload procedure.
30. Oil dipstick (for journals).
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),
3-3
20
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_________________________________________________________
those fasteners which must meet special tighten ing requirements are identi-
fied on the engineering drawings and in the text.
TORQUE VALUES SPECIFIED ON ENGINEERING DRAWINGS

AND IN THE TEXT SHOULD NOT BE EXCEEDED.
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 EQUI-
PMENT. LIFTING EQUIPMENT, CRANES, CHAIN FALLS, COME
ALONGS, CHAIN AND WIRE ROPE SLINGS, ETC. MUST BE ADE-
QUATELY 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.

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.
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
COMP ONE NTS ARE INSTALLE D AT THE L OCATION INDI-
CATED ON THE CONTRACT DRAWING K3922.00 AND
K3923.00.
3-4
21
________________________________________________________

________________________________________________________
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
(4) to six (6) 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 millside and seal air header assembly.
3. Place bowl hub upper and lower skirt and scraper and guard
assemblies in the millside (DO NOT remove preservative coatings).
4. Build up cribbing from the sole plate and place bowl, bowl hub and
vane wheel assembly inside the millside.
5. Install the separator body assembly.
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.
6. Place the inner cone (and liners) inside the separator body.
7. Slide the inverted cone up the center feed pipe of the outlet venturi
and vane assembly. Secure the cone temporarily with the set screws.
8. Place the inverted cone and outlet venturi and vane assembly inside
the inner cone.
9. Install the separator top assembly.
10. Assemble the mill discharge valves and multiport outlet plate to the
separator top
11. Assemble the outlet venturi and vane assembly to the multiple port
outlet plate.
12. Assemble the inner cone to the classifier drum.
13. Install the center feed pipe (upper).
14. Temporarily install the journal opening cover assemblies.
15. Close and secure the millside and separator body doors
16. Seal all remaining openings with waterproof covering
3-5
22
________________________________________________________

________________________________________________________
The balance of the erection procedure will be delayed until about six months
prior to unit commissioning.
17. Remove the journal opening cover assemblies.
18. Lift the bowl, bowl hub and vane wheel assembly and remove cribbing.
19. Install the gearbox.
20. Assemble bowl hub to gearbox, install bowl hub skirts and scraper and
guard assemblies.
21. Align components, set air seal clearances.
22. Secure and dowel gearbox.
23. Install journal heads and trunnion shafts.
24. Install journal shaft assemblies with rolls.
25. Tilt-in journal assemblies.
26. Install journal cover assemblies.
27. Set/check spring compression.
28. Install gearbox lubrication system.
29. Install pulverizer motor, check rotation, assemble coupling.
30. Install instrumentation and controls equipment.
31. Set roll-ring and spring to journal head clearances.
32. Check all equipment, close pulverizer and energize for operation.
SOLE PLATE AND

MOUNTING PLATE
ALIGNMENT AND GROUTING
Pulverizer
NOTE
The following steps refer to Drawings K3922.00 AND
K3923.00 unless other Stated.
NOTE
For recommendations concerning the grouting of sole
plates,see ABB CE Design Standard 27-68(index 6.26)
1. Prepare the foundation for grouting per Design Standard 27-68
3-6
23
_______________________________________________________

_______________________________________________________
THE GEAR BOX SOLE PLATE WEIGHS APPROXI-

MATELY 2383 kg THE MOUNTING PLATES
APPROXIMATELY 1483 Kg EACH ALL MUST BE
ADEQUATELY RIGGED TO INSURE SAFE
HANDLING.
2. Degrease and sand blast 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. Setthe gearbox sole plate on the foundation. Use shims to set the elevation.
The tapped holes for the gearbox removal fixture must face away from the
pulverizer motor location.
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 K3922.00 and K3923.00.
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 (0.12 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,
9. After the grout has cured,ensure that all holes through the sole Plate are
cleaned of grout.Tension the anchor bolts to 69388 kgf the value specified on
the Foundation Loads drawing K3922.00 AND K3923.00 using a hydraulic
stud tensioner.
THE MOUNTING PLATES WEIGH APPROXIMATELY

2 3 8 2 K G E A C H , B O T H MU S T B E A D E Q UA T -
ELY RIGGED TO INSURE SAFE HANDLING.
25
3-7
_______________________________________________________

_______________________________________________________
NOTE
The fixed mounting plate with the round dowel pin hole should be
located on the north foundation pier under the pulverizer air inlet (to
the right 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 K3922.00 and K3923.00 .
11. Align the mounting plate with the sole plate as follows (refer to drawing K3922.00 and
K3923.00);
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. (0.12 mm) and parallel to the sole
plate surface within 0.010 in. (0.25 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. Refer to
K3922.00 and K3923.00 for details.
NOTE
Motor sole plate location is shown on drawing K3922.00 and

K3923.00. Rough in the motor sole plate to the dimensions
given. Shim as required.
26
3-8
27
_______________________________________________________

_______________________________________________________
MILLSIDE AND LINER
ASSEMBLY
NOTE
The following steps refer to drawings k3858.4.0 and
k3734.9.0 unless otherwise stated.
TO ENSURE THAT THE AIR SEAL RING INNER SEG-

MENTS 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.
THE MILLSIDE AND LINER ASSEMBLY WEIGHS AP-

PROXIMATELY 17160kg AND MUST BE ADEQUATELY
RIGGED TO INSURE SAFE HANDLING.
1. Remove the millside and liner assembly from its shipping rig and clean
the bottom surface of its feet.
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 K3922.00
AND K3923.00 .
2. Apply a very thin coat of light oil or anti-seize compound to the top sur-
face of the millside mounting plates.
3. Fill the slot in the millside mounting plate (sliding) approximately 1/3 full
with a general purpose grease.
28
3-9
29
_______________________________________________________

_______________________________________________________
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 and liner 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 Ar-
rangement drawing K3922.00 and K3923.00 .
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 69388 kgf the value specified on the
pulverizer foundation drawing K3922.00 and K3923.00 using a hydraulic
stud tesioner.
11. Place the scraper and guard assemblies in the millside. DO NOT remove
their preservative coatings at this time.
12. Partially disassemble the bowl hub skirt assemblies and place in the
millside. Ensure that all exposed machined surfaces are preserved with
protective coatings for long term storage.
BOWL, BOWL HUB AND

VANE WHEEL ASSEMBLY
NOTE
The following steps refer to Drawings K3740.6.0
unless otherwise stated.
THE BOWL HUB, BOWL AND VANE WHEEL AS-

SEMBLY WEIGHS APPROXIMATELY 14538kg
A N D MU ST BE AD EQU AT EL Y R IGGED
TO ENSURE SAFE HANDLING.
1. Erect a steel or wooden crib on the gearbox sole plate underneath the
millside assembly. It must be capable of supporting the weight of the
bowl hub, bowl and vane wheel assembly. The height of the crib should
be such that when the bowl hub, bowl and vane wheel assembly is
placed on it, the top of the vane wheel will be 2.0 in. (50.8 mm) below
the top of the millside upper flange.
30
3 - 10
31
________________________________________________________
ABB CE TYPE HP963 PULVERIZER-INSTALLATION

________________________________________________________
2. Install the hoist clevis (bowl hub lifting lugs) from the maintenance tools
on the bowl at 120° intervals. Reference tool drawing KF3740.5.0 Rig
and hoist the bowl hub, bowl, and vane wheel assembly into the millside
assembly and place it on the cribbing. Use screw type jacks in at least
three places at 120 ° intervals around the perimeter of the bowl to
stabilize it in the millside.
SEPARATOR BODY
NOTE
The following steps refer to drawings K3740.5.0

THE SEPARATOR BODY ASSEMBLY WEIGHS AP-

PROXIMAT EL Y 16509kg AND MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE HAN -
DLING
1. Remove the separator body assembly from its shipping rig and place it
on blocks approximately 18 in. (457 mm) high 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).

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
K3922.00 and K3923.00.
NOTE
Match the Vee notches on the mating flanges of the sep-
arator body and millside to ensure proper component align-
ment.
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 - 11
29
________________________________________________________

________________________________________________________
NOTE
Remove the retaining lugs and back out the journal stop bolts
to install the separator body to millside fasteners. It may be
necessary to completely remove the journal stop bolt bushings
to access some of the separator body fasteners.
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.
THE INNER CONE WITH LINERS WEIGHS

APPROXIMATELY 1613 kg AND MUST BE ADEQ-
UATELY RIGGED TO ENSURE SAFE HANDLING.
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.
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.
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 lower feed pipe of the outlet venturi and
vanes assembly, small end up, (toward the venturi) .
6. Place the outlet venturi and vanes assembly inside the inner cone.
3 - 12
30
________________________________________________________

________________________________________________________
SEPARATOR TOP
ASSEMBLY
THE SEPARATOR TOP ASSEMBLY WEIGHS APPROX-

I M ATE L Y 1 169 2 kg AND M US T BE ADEQUATEL Y
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 K3740.13.0 .

ENSURE PROPER ORIENTATION OF THE AIR INLET,
JOURNAL OPENINGS AND FUEL PIPES. EACH COMP-
ONENT HAS A TAG WITH THE PULVERIZER SERIAL
NUMBER. USE CARE TO ENSURE THAT THE CORR-
ECT SERIAL NUMBERED PULVERIZER AND ITS COM-
PONENTS ARE INSTALLED AT THE LOCATION INDI-
CATED ON THE CONTRACT DRAWING K3922.00 AND
K3923.00.
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.
31
3 - 13
________________________________________________________

________________________________________________________
MiLL DISCHARGE VALVES
AND MULTIPLE PORT
OUTLET ASSEMBLY
NOTE
Reference drawings K3922.2.0 .unless otherwise stated.
THE PULVERIZER DISCHARGE VALVES AND MUL-

TIPLE PORT OUTLET PLATE WEIGH APPROXIMATELY
4953 kg (2.7 MT) AND MUST BE ADEQUATELY RIGGED
1. Clean the entire bottom surface of the multiple port outlet plate including the
clearance and tapped holes and the flange for the center feed pipe.
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. Align the scribe lines next to the offset bolt holes on the mill discharge valve
assembly and the separator top.
4. Bolt the mill discharge valve, multiple port outlet assembly to the separator top
with hex head cap screws, torque per B-GP-2175
OUTLET VENTURI AND

VANES ASSEMBLY
THE OUTLET VENTURI AND VANES ASSEMBLY WEIGHS

PROXIMATELY 1119 kg (0.45MT) IT MUST BE ADEQUATELY
REGGED TO ENSURE SAFE HANDLING.
3 - 14
32
________________________________________________________

________________________________________________________
1. Rig through the center feed pipe opening and lift the venturi and vane assembly into
position under the outlet plate assembly.
2. Align scribe lines for proper orientation then secure with hex head cap screws
through the inner bolt circle of the multiple port outlet assembly. Torque fasteners
per B-GP-2175.
3. Working from inside the pulverizer install hex head cap screws around the perimeter
of the venturi and vane assembly, torque per B-GP-2175.
4. Clean the flanges on the upper feed pipe.
5. Position the upper feed pipe above the multiple port outlet plate and secure with hex
head cap screws. Torque fasteners per B-GP-2175.
INNER CONE WITH LINERS
If not previously done, install the ceramic liners in the inner cone.
THE INNER CONE WITH CERAMIC LINERS WEIGHS

AP P R O X I M AT E L Y 1 6 1 3 k g AND M US T BE AD-
EQUATELY 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-217 5.
2. Install the inner come pipe supports
3. The clearance between the inner cone and lower feed pipe should be checked. The
perpendicular distance between the inner cone liners and pipe should be 4.5 in.
(114.3 mm)
4. The inverted cone should be moved down the center feed pipe to obtain a clearance
of 3 in. (76.2 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.
3 - 15
33
________________________________________________________

________________________________________________________
JOURNAL OPENNING COVER

WITH SPRING
THE JOURNAL OPENING COVER WITH SPRING

W E I G H A P P R O X I M A T E L Y 4 7 6 6 k g AN D
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, 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.
GEARBOX ASSEMBLY
INSTALLATION
The gearbox assembly is installed by sliding it into position under the

assembled pulverizer. Special fixtures are provided to assist in this
procedure.
Ref erence drawing KF3740.6.0 and the gearbox vendor's instruction

manual for detailed preparation and handling.
NOTE
Prior to installing the gearbox under the pulverizer check

that two dowel pins (38.1 mm DIA) are installed in the
gearbox output adapter. Use Loctite RC 680 and install the
pins so that they protrude 0.600 in. ±0.015 in. (15.24 mm
±0.38 mm).
34
3 - 16
________________________________________________________

________________________________________________________
THE PULVERIZER GEARBOX WEIGHS APPROXIMATELY

11000 kg AND MUST BE ADEQUATELY RIGGED TO
ENSURE SAFE HANDLING.
1. Remove the journal opening cover assemblies and move them to a

convenient storage area.
2. Install gearbox removal rails. Reference drawing, KF3740.6.0 Place the

rails on cribbing as required to raise them to the level of the gearbox sole
plate.
3. Coat the removal rails with a light film of lubricant. Set the gearbox
assembly on the rails. The gearbox must be positioned adjacent to the
pulverizer foundation, oriented with the driven end toward the motor lo-
cation.
4. Refer to tool drawing KF3740.5.0 Install the bowl hoisting frame hooks to
the top of the journal openings. Attach three bowl extension ring hoist
clevis at 120° intervals on the bowl at the journal opening centerlines.
5. Attach three chain hoists (5MT) minimum capacity each to the journal
opening frame hooks and the bowl hub, bowl and vane wheel assembly
hoist clevis.
THE BOWL HUB, BOWL AND VANE WHEEL

ASSEMBLY WEIGHS APPROXIMATELY 14538 kg
AND MUST BE ADEQUATELY RIGGED TO
6. Lift the bowl hub, bowl and vane wheel assembly [approximately 2 in.
(50.4 mm)] until the vane wheel shroud just touches the intermediate and
deflector liners. The hub must clear the cribbing.
7. Remove the cribbing.
8. Slide the gearbox assembly into position over its sole plate. Check that
the gearbox bolt holes line up with the tapped holes in the sole plate
then remove the gearbox removal rails.
9. Install the drive adjustment blocks on the sole plate.refer to KF3740.4.0 .
10.Use the adjustment blocks and center the gearbox assembly to the
millside within 0.010 in. (0.25 mm). For this initial setting, measure from
the seal ring bore in the millside to the outside diameter of the bowl hub.
35
3 - 17
36
________________________________________________________

________________________________________________________
11. Coat the fasteners which secure the gearbox to the gearbox sole plate
with Fel-Pro CS-A anti-seize compound or equal and Install them hand
tight.
NOTE
The following steps refer to drawings K3736.7.0
unless stated otherwise.
ENS URE THAT THE UPPER RESERVOIR OF THE

GEARBOX IS FULL OF OIL TO THE CENTERLINE OF
THE OIL SIGHT GLASS [APPROXIMATELY 88 GALLON
(330 L)], BEFORE TURNING THE GEARBOX SHAFT.
12. Clean the mating surfaces of the bowl hub and gearbox and apply a
light coating of anti-seize lubricant.
13. The input shaft of the gearbox must be turned by hand to get the dowel
pins to line-up with the dowel pin holes.
14. Lower the bowl hub. 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 adapter.
15. Remove the bowl hub cover wear plate and bowl hub cover from the
bowl hub.
16. Apply thread locking sealant (Loctite) to the first two inches of the (8-
M48) studs that hold the bowl hub to the gearbox. Install studs so that
thread engagement into the output plate is 67mm.
17. Apply anti-seize compound to the protruding studs then install the
washers and hex nuts. Snug the nuts with a slugging wrench.
18. Remove the chain hoists and bowl hub hoisting fixtures.
19. Using a hydraulic stud tensioner KF3740.3.0 tension each stud to

12,000 lbs.Refer to drawing K3922.00 and K3923.00.
20. Repeat step 19. to 90,000 lbs.
21. Repeat step 19. to 120,000 lbs.
22. Apply RTV sealer (PIN 2226) between the bowl hub cover and the the
bowl hub. Replace the access covers (refer to Figure 7 and drawing
K3740.6.0)torque fasteners per B-GP-2175.
3 - 18
37
________________________________________________________

________________________________________________________
BOWL HUB SKIRTS AND
INNER AIR SEAL
INSTALLATION
NOTE
The following steps refer to K3740.7.0 and

Figures 5 and 6, unless otherwise stated
ENSURE THAT THE UPPER OIL RESERVOIR OF THE

GEARBOX HAS BEEN FILLED WITH THE
RECOMMENDED OIL, TO THE CENTERLINE OF THE
GUAGE GLASS , BEFORE TURNING THE GEARBOX
INPUT SHAFT (BY HAND) DURING SKIRT INSTALLATION
AND AIR SEAL SETTING.
NOTE
Skirt segments are match marked in sets and segments are not
interchangeable. Dowel pins at the centerline of the ribs of the
segments ensure their alignment. ,
NOTE
Apply anti-seize compound to all fasteners and torque all
fasteners per B-GP-2175 unless otherwise specified.
1. Clean the mating surfaces of the upper skirt assembly and the bowl hub
and apply a light film of anti-seize lubricant. Using match marks, as-
semble the quarter sections of the upper skirt. Fasten them together
and to the bowl hub using the fasteners supplied with the skirts.
2. Clean the surfaces of the mill bottom on which the air seal ring
assembly will seat. Install the air seal ring segments into the mill bottom
without the shims, hand tighten the fasteners.
USE CARE IN PERFORMING THE FOLLOWING STEPS, DO

NOT DAMAGE THE UPPER SURFACE OF THE AIR SEAL
RING SEGMENTS.
3. Clean the mating surfaces of the upper and lower skirt assembly. Align
and fasten together three quarter sections of the lower skirt leaving
out one section that does not hold a scraper assembly.
38
3 - 19
39
________________________________________________________

________________________________________________________
4. Install two set screws in each quarter section of the lower skirt and use
them to jack up the skirt section until the gap between the lower skirt
flange and the mill bottom cover plates is0.50 in.+O.06 in.- 0.0 in.
(12.70 mm + 1.52 mm - 0.00 mm). This establishs the scraper to mill
bottom clearance.
5. Measure the gap between the upper and lower skirt flange.
6. Select shims from the shim pack which are equal to 0.06 in. (1.5 mm)
less than the gap.
7. Install the shims and fasten the three quarter sections of the lower skirt
assembly to the upper skirt.
8. Measure the gap between the lower skirt assembly and mill bottom
cover plates. It should be 0.50 in. to 0.62 in. (12.7 mm to 15.7 mm). Re-
shim, if required.
9. Remove the jack screws from the lower skirt.
NOTE
Removal and reinstallation of lower skirt sections will be
required during Steps 10. through 16.
10. measure the gap between the lower skirt and the inner air seal ring.
11. Select shims from the air seal shim pack to raise the air seal ring and
provide a clearance of 0.5~1.6mm.
12. Reposition the gearbox, if necessary, to obtain acceptable clearances at

30° intervals around the perimeter of the skirt (refer to C-GP-4756).
13. Ensure that the gearbox upper oil reservoir is filled to operating level
with oil. Turn the gearbox input shaft by hand to advance the bowl about
120°
14. Remeasure the skirt to air seal ring clearance. If consistent, 0.0625 in.
±0.005 in (1.587 mm ±0.127 mm) match mark and disassemble the
air seal and shims.
15. Reinstall the shim pack and reassemble the air seal ring in the same
order that it was removed. Apply RTV-106 to the joints. Apply antiseize
compound to the fasteners and torque per B-GP-2175.
16. Install the remaining skirt shim pack selected in step 5. Align and install
the last quarter section of the lower skirt. Lubricate and torque fasteners
per B-GP-2175.
17. Reconfirm the skirt to air seal ring clearance. Refer to Steps 13. and 14.
18. Attach the scraper and guard assemblies to the lower skirt. Verify
clearance of 0.31 in. ± O.06 in. (7.8 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).
3 - 20
40
________________________________________________________

________________________________________________________
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 step 11. of 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 the 1.33 in. (33.78 mm) diameter holes in the
gearbox flange as pilots, drill and ream two holes into the sole plate,
1.5000 in. ± 0.0005 in. (38.100 mm ±0.0127 mm) to a depth of 4.50 in.
(114.3 mm).
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.

CLEARANCE AIR SEAL
NOTE
The clearance air seal and guard assembly can be in-

stalled 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.
NOTE
The following steps refer to drawings K3740.16.0 AND K3740.17.0 .
1. Clean the surface of the mill bottom on which the seal ring assembly
will seat.
2. Pay close attention to match marks, loosely attach the clearance seal
ring segments to the mill bottom.
3. Hand tighten bolts. Align match marks and trial fit butt joints, maximum
clearance of 0.010 in.
4. Disassemble the seal. Apply anti-seize lubricant to the fasteners.
5. Reassemble the seal in the same order and apply RTV 106 (PIN -2227
or equal) to the butt joints.
6. Position the seal ring assembly to provide a gap around the bowl hub
which does not vary by more than ±0.003 in. (±0.08 mm).
7. Start the lubrication oil system and rotate the bowl hub. Check that the
gap every 90° is within the ±0.003 in. (±0.08 mm) tolerance.
3 - 21
41
________________________________________________________

________________________________________________________
8. Once the gap is set, torque the hex head cap screws per drawing B-GP-
2175.
9. Use bolts, washers and nuts to assemble the four screen sections in
place and to the millside guard supports.
PULVERIZER MOTOR
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 pulv-
erizer motor and coupling can be completed.
NOTE
Refer to motor manufacturer's instructions for their mounting

recommendations.
NOTE
The following steps refer to K3922.00 and K3923.00unless 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 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), re-shim 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.
3. Grout the motor sole plate, reference ABB CE Design Standard 27-68
(Index 6.26). 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 indi-
cator. Check maximum angular runout and maximum clearance. Use
additional shims under the motor as required.
42
3 - 22
43
________________________________________________________

________________________________________________________
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 and trunnion assembly and journal shaft
assembly the descriptions below deal with the installation of the journal
assembly and then installation of the journal assembly components.
NOTE
Each journal assembly, K3740.4.0 ,is supplied as three (3)
subassemblies and several loose parts with attaching
hardware.
Journal Assembly
Installation
For tools and components used in this procedures refer to Figure 13 and
drawings K3740.4.0 .
AN OVERHEAD CRANE MUST SUPPORT THE JOURNAL

COMPONENTS AT ALL TIMES DURING THE INSTALLATION
PROCEDURE.
THE JOURNAL ASSEMBLY WEIGHS APPROXIMATELY

8 2 1 0 k g AN D M U S T B E AD E Q U ATE L Y R I GGE D TO
1. Move the complete journal assembly adjacent to the journal opening at

the pulverizer.
2. Remove the retaining lugs and back out the journal stop bolts.
Reference the Separator Body Assembly drawing K3740.5.0
TRUNNION SHAFTS WEIGH APPROXIMATELY 265kg EACH

AND MUST BE ADEQUATELYRIGGED TO ENSURE SAFE
HANDLING.
3. Place each trunnion shaft near the appropriate side of the journal
opening.
44
3 - 23
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________________________________________________________
4. Remove the journal head cover plate.
5. Remove two (2) grinding roll keeper bolts 180° apart and install two
eyebolts to the full depth of the threads. Ensure that eyebolt shoulders
contact the keeper plates.
6. Install a chain shackle in each eyebolt and attach a chain sling.
7. Rig and lift the journal assembly into position in the separator body
journal opening.
8. Carefully align the journal head with the trunnion shaft openings in the
separator body.
9. Install the journal head to separator body safety tilt out bracket and
torque the bolts.
10. Slide a 0.8 to 1 in. x 120 in. (20-25mm x 3100 mm) all thread rod
through the trunnion shaft openings and the journal head.
11. Remove the pipe plugs from the seal air openings in the trunnion shafts.
12. Ensure that the dowel pins are secure in each trunnion shaft. Coat the
mating surfaces of the thrust plates and shafts with anti-seize
compound and slide the thrust plates onto the trunnion shafts.
13. Ensure that the "thrust end" and "free end" trunnion shafts are on the
correct side of the journal head then lift each shaft and slide it over the
allthread rod and into its separator body opening.
14. Ensure that the numeral 1 on the end of each shaft is in the 12 O'clock
position and start the end of each trunnion shaft into the journal bushing
retainers.
MAINTAIN ALIGNMENT OF ALL COMPONENTS DURING

THE NEXT FEWS TEPS TO PREVENTTHEM FROM BIN-
DING.
15. Slide a backing plate on each end of the all thread rod. Thread two hex
nuts on one end of the all thread rod and one heavy duty hex nut on the
other end.
16. Securely lock the two hex nuts at the end of the rod and tighten the nut
on the other end.
45
3 - 24
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________________________________________________________
THE NUMERAL ONE ON THE TRUNNION SHAFT END

CAPS MUST BE IN THE SAME RELATIVE POSITION,
I.E., BOTH AT 12 O'CLOCK, OR SHAFTS WILL BIND IN
THE TRUNNION BUSHINGS AS THEY ARE DRAWN IN-
TO POSITION.
17. Use an air impact wrench on the double nutted end of the rod. Slowly
turn the rod to tighten the heavy hex nut and pull the trunnion shafts and
thrust plates into place.
18. When fully inserted, turn the trunn ion shafts together until the numberal
1 on the end caps is in the 12 O'clock position. Secure the trunnion
shafts to the separator body with lubricated, hex head cap screws.
Torque the bolts per drawing B-GP-2175
19. Ensure that the journal assembly is supported by the tilt out safety
bracket. Disconnect the rigging and remove the chain sling and eyebolts.
20. Reinstall the grinding roll keeper bolts and torque per B-GP-2175.
21. Use the Journal Tilt In Procedure to return the roll into the bowl. See
MAINTENANCE PROCEDURES and eference drawing KF3740.8.0 .
Journal Head Assembly

Installation
NOTE
Refer to Figure 13 and drawing K3740.4.0 .
TRUNNION SHAFTS WEIGH APPROXIMATELY 265 kg

EACH AND MUST BE ADEQUATELy RIGGED TO
1. With the journal head assembly laying flange side up, remove the
trunnion shafts and thrust plates, install two M30 eye bolts 180ºapart in
the head flange.
46
3 - 25
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________________________________________________________
THE JOURNAL HEAD WEIGHS APPROXIMATELY 1550

k g AN D M U S T B E AD E Q U ATE L Y RI GGE D TO
3. Rig the chain sling to an overhead crane positioned above the center of
the door opening. Take up slack.
4. Place each trunnion shaft near the appropriate side of the journal
opening and remove the pipe plugs from the seal air openings.
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. Continue with steps NO TAG through of the Journal Assembly Ins-

tallation.
9. Ensure that the journal head is supported by the tilt out safety bracket,
disconnect the rigging, remove the eyebolts and proceed to install
the journal rolland shaft assembly.
Journal Roll And Shaft
Assembly Installation
NOTE
Refer to Figure 13 and Drawing K3740.4.0 .
1. Move the journal roll and shaft assembiy adjacent to the mill. Remove
two (2) of the grinding roll keeper bolts 180º apart and install two (2)
eyebolts to the full depth of the threads.
THE JOURNAL ROLL AND SHAFT ASSEMBLY MUST

BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.
47
3 - 26
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________________________________________________________
THE OVERHEAD CRANE MUST SUPPORT THE JOUR-

NAL SHAFT ASSEMBLY AT ALL TIMES DURING THE
INSTALLATION PROCEDURE.
3. 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.
4. Clean the mating surfaces of the journal head assembly and the journal
shaft flange.
NOTE
To ensure correct assembly, one hole is offset 0.50 in. (12.7 mm).
5. 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.
6. Install hex socket head cap screws using thread locking compound.
Torque fasteners in the sequence and steps shown on drawing
K3740.4.0 .Section "A-A".
a. 1.35kgm (13.5 Nm)

b. 135kgm (1350 Nm)
c. 230.3kgm (2303 Nm)
7. Install the journal head skirt, torque fasteners per drawing B-GP-2175.
8. Ensure that the journal tilt out safety bracket is properly installed then
disconnect the crane and remove the chain sling and eyebolts.
Reinstall the grinding roll keeper bolts. Torque the fasteners.
9. Use the journal tilt in procedure to return the roll into the bowl.
10. Install the journal opening cover and spring assemblies.
48
3 - 27
49
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________________________________________________________
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 drawingsK3734.9.0 .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.
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.
NOTE
Pipe sealant with teflon [Loctite PST]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.
3 - 28
50
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________________________________________________________
FEED AND FUEL PIPING
ASSEMBLY
1. Clean the mating flanges and install the upper feed pipe coupling. Use
anti-seize compound on the flanges and fasteners.
2. Install the remaining section of the feed pipe.
3. Connect the fuel piping to the mill discharge valves.
4. Install the discharge valve air header and piping assembly per
K3736.16.0 Connect the seal air piping.
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 K3922.2.0 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.
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.
51
3 - 29
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________________________________________________________
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.
AFTER ADJUSTMENTS ARE COMPLETED ENSURE

THAT ALL TOOLS AND DEBRIS HAVE BEEN RE-
MOVED FROM INSIDE THE PULVERIZER.
1. Set the journal spring proload at all three journals. Reference proce-
dures in HP PULVERIZER - MAINTENANCE, Section 4, MAJOR AD
JUSTMENTS, 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 PULV-
ERIZER 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.
52
3 - 30
53
________________________________________________________
ABB CE TYPE HP963 PULVERIZER-OPERATION

________________________________________________________
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 ...................................................................................... 2-3
EMERGENCY SHUTDOWN ............................................................................... 2-4
START-UP AFTER EMERGENCY SHUTDOWN ............................................... 2-6
PULVERIZER FIRES . ........................................................................................ 2-6
COAL PULVERIZER FIRE FIGHTING PROCEDURE ........................................ 2-8
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 . ...................................................................................................3-6
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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54
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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
-i-
55
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________________________________________________________
PART1-PRINCIPLES OF
OPERATION
GENERNAL
ABB CE 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 (refer 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.
1-1
56
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________________________________________________________
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 sy-
stems, 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.
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 three-stage
classification process (refer to Figure 1-2).
1. The first stage of classification takes place just above bowl level. Sta-
tionary 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 mom-
entum and fall out of the air stream.
3. After this, the mixture is passed around a vertical “dip- tube” called
the venturi collar. Further classification takes place, and the desired
fineness level is achieved.
The heavier coal particles separated by the deflector blades and venturi col-
lar 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.
57
1-2
________________________________________________________

________________________________________________________
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.
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 te-

mperature 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 pulverizerwith the outlet temperatu reabove 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.
58
1-3
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________________________________________________________
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
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."
59
1-4
60
61
62
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TABLE OF CONTENTS
PULVERIZER OPERATING PROCEDURES PART 2
TITLE PAGE NO.
INITIAL START-UP .......................................................................................... 2-1

NORMAL SHUTDOWN . ................................................................................... 2-3
EMERGENCY SHUTDOWN ............................................................................. 2-4
START-UP AFTER EMERGENCY SHUTDOWN ............................................. 2-6
PULVERIZER FIRES ....................................................................................... 2-6
COAL PULVERIZER FIRE FIGHTING PROCEDURE ...................................... 2-8
PULVERIZER TROUBLESHOOTING (TABLE 2-1) ........................................ 2 -12
63
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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.
64
2-1
65
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________________________________________________________
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 and
c heck t o en sur e an oil supply to the bearing
sprays.
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 ope-
r a t i ng t e mp er at u r e f or 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 ret-
urned to its set point value.
9. Check the furnace to ensure that coal fires are established and stable.
10. Inciease the coal feed when the pulverizer outlet temperature has re-
turned to the set point.
2-2
66
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________________________________________________________
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.
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℃).
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 re-
duce 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℃)
2-3
67
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________________________________________________________
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.
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.
68
2-4
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A HOT PULVERIZER WILL DISTILL COMBUSTIBLE

GASES.FROM RESIDUAL COAL. THEREFORE USE
CARE WHE N OP E NI NG THE PULVERIZE R FOR
CLEANING AFTER AN EMERGENCY TRIP.
I F AN I NE RTI NG S Y S TE M I S I NS TAL LED, 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.
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.
4. Remove all but the four corner bolts from an inspection door. Back off
the corner bolts three or four turns and rap the flange to break the seal.
Remove the bolts and the door. Open the other inspection and millside
doors as required for access.
5. A f t er t ak i ng t h e ne cessar y pr e ca utions, manuall y cl ean the

pulverizer.
2-5
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START-UP AFTER
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
pulveri zers 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.
2-6
63
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________________________________________________________
3. Exces-sive 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 failu re 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.
2-7
64
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________________________________________________________
IF A PULVERIZER SYSTEM FIRE DOES OCCUR, RE-

GARDLESS 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,

AL L P ERSONNEL NOT ACTIVELY FIGHTING THE
FIRE SHOULD BE CLEARED FROM THE PULVERIZER
BAY, AIR DUCTS AND FEEDER DECK AREA.
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
operating) 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
2-8
65
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________________________________________________________
NOTE
Nozzles are provided on the separator top, millside and air

inlet duct. It is recommended that the nozzl es 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
f u e l f e e d o r d i st ur b an y de posi t of co mb ust i bl e
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.
USE CARE WHEN OPENING PULVERIZER INSPEC-

TION DOORS. CHECK THAT THE HOT AND COLD AIR
SHUTOFF GATES, THE PULVERIZER AND FEEDER
SEAL AIR VALVES AND THE PULVERIZER DIS-
CHARGE VALVES ARE CLOSED.
THE PYRITES HOPPER DOOR SHOULD BE CARE-

FUL LY CRACKED AND THEN COMPLETELY
OPENED.
EYE PROTECTION (GLASSES OR FACE SHIELD)

SHOULD BE WORN WHEN CRACKING OPEN THE IN-
SPECTION DOORS. THE PULVERIZER MAY BE PRES-
"SURIZED AND THERE IS A POSSIBILITY OF A DIS-
CHARGE OF HIGH PRESSURE GAS AND COAL DUST.
66
2-9
________________________________________________________

________________________________________________________
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.
P RI OR TO E NTE RI NG THE P UL V ERIZE RVERIFY

THAT IT HAS BEEN COMPLETELY PURGED FTOXIC
GASES AND THAT NO POCKETS OF SMOLDERING
FUEL STILL EXIST.
USE CARE WHEN CLEANING A PULVERIZER MANU-

ALLY. ROLL PRESSURE ON COAL MOUNDED IN THE
BOWL CAN CAUSE THE BOWL TO ROTATE UNEX-
PECTEDLY. TO PREVENT THE BOWL FROM ROTAT-
ING INSTALL AN "A" FRAME RESTRAINT ON THE
PULVERIZER DRIVE COUPLING.
2 - 10
67
68
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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.
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.
2 - 11
69
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________________________________________________________
Table 2 - 1 -Pulverizer Troubleshooting
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Reduced Leak in lubricating system Inspect for oil leaks and
Lubricating Oil repair as requfl, ired.
Pressure Oil pump worn Repair or replace pump at
first opportunity
Dirty oil filters Clean or replace primary/
oil being used.
Oil viscosity low secondary filters
High oil temperature/wrong
Pulverizer Pulverizer fire See Fire Fighting Proce dures
Outlet Hot air damper mallunction Close hot air gate, shut
Temperature- down mill, repair as required.
High Cold air damper mallunction Open cold air damper
manually, shut down mill,
repair as required.
Feeder mallunction/feed Shut down mill, repair as
pipe plugged required.
Outlet thermocouple Verify readings and repair/
mallunction replace as required.
Pulverizer Extremely wet coal in Reduce feed rate to main
Outlet pulverizer(s) rain outlet temperature.
Temperature- Hot air gate not open Check gate position and
Low repair as required.
Hot or cold air damper Shut down mill and repair
mallunction as required.
Low primary air temperature Reduce feed rate.
Low air flow Recalibrate airflow control system.
Pulverizer Overloaded pulverizer or Reduce feed rate to pulv
Motor wet coal erizer, check feeder
Amperage - calibration. Check coal
High hardness.
Excessive coal fineness Adjust classifier blades (open).
Excessive grinding force Check spring compression
and reset as required.
Motor mallunction Test motor
No coal entering pulverizer Check feeder and feed pipe
for blockage.
Pulverizer One or more journals Shut down mill. repair as
Motor seized required.
Amperage - Reduced coal to pulverizer Check feeder operation and/
Low or plugging.
Motor coupling or shaft Shut down mill and repair as
breakage required.
Bowl Overloaded pulverizer Reduce feed rate to pulv

Differential erizer, check feeder calibra
Pressure - tion. Check coal hardnessAdjust
High Excessive fineness. classifier blades.(open)
Plugged pulverizer Check purge air and clean
pressure tap(s). pressure taps as required.
Excessive mill airflow. Check airflow control system.
Insufficient open area Remove one vane wheel air
around the bowl. restriction ring.
70
2 - 12
71
________________________________________________________
ABB CE TYPE HP963 PULVERIZER - OPERATION

________________________________________________________
Table 2 - 1 - Pulverizer Troubleshooting
PROBLEM POSIBLE CAUSE CORRECTIVE ACTION

Bowl Reduced coal flow to mill Check feeder operation and/
Differential or plugging.
Pressure - Low Plugged pressure tap/leak Check purge air and clean
pressure taps as required.
Low mill airflow Check airflow control system.
No Coal to Coal pipe blockage Shut off the feeder. Checkthe
Coal Nozzle(s) (prolonged blockage can pulverizer airflow. Tap
lead to fires) on the piping. If still not
clear, remove and clean as
necessary.
Blocked feeder, center feed Check and clear the feeder
pipe or, low airflow or center feed pipe. Check
operation of the primary air
controldampers.
Blocked orifice or riffle Shut down the pulverizer
distributor, if installed and isolate. 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 Calibrate the deflector
calibration blades.
Worn or damaged deflector Inspect, repair and/or re-
blades place as soon as possible.
Incorrect inverted cone Reduce clearance by 1/2"
position or to a minimum of 3".
Holes worn through inner Inspect, patch/replace cone
cone or liners or liners as required.
Noise: Above Reject material on bowl Stop the pulverizer. Inspect
the Bowl and 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 re-
the Bowl pair or replace as required.
Broken air vane(s) Stop the pulverizer and re-
pair or replace as required.
Noise: Gear Bearing or gear damage Stop the pulverizer. Inspect
Housing the components.
Damage to the pulverizer Repair or replace worn items
gears or bearings gears or bearings as
required.Test oil and
replace as required.
Oil Leak - Dirty labyrinth seal lShut down mill, clean seal
Horizontal groves.
Drive Shaft
High Gear Low water flow to oil cooler Increase water flow and
Housing Oil check cooler.
Temperature Oil cooler plugging Check and clean oil cooler
as soon as possible.
Low oil level Check level and add oil as
required. Check for leaks.
72
2 - 13
________________________________________________________
ABB CE TYPE HP963 PULVERIZER - OPERATION

________________________________________________________
Table 2 - 1 - Pulverizer Troubleshooting
PR()BLEM POSSIBLE CAUSE CORRECTIVE ACTION

Rough Running Inadequate coal bed depth Increase coal flow, check
Pulverizer feeder 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
High Bearing Bearing failure Check for noise and iImmediately.
Temperature(s) Check level and add oil as
Low oil level required.
Check cooling water tem-
Oil cooler mallunction perature and flow.
No Oil in Oil Plugged manifold or supply AIlow time for oil to warm up
Flow line(s) after pulverizer start-up.
Indicator(s) Stop pulverizer, isolate
line(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
Iron Spout the pulverizer.
a. Check feeder calibration.
b. Check coal hardness.
2. Excessive coal fineness 2. Adjust classified blades
(open).
Worn grinding rolls or bull Reset the roll to ring
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 Shut down and open the
(at start up) pulverizer, check the rolls
for rotation, remove any
foreign material and / or
repair / replace the journal
assembly.
Warm up the pulverizer for
a longer period of time.
Check journal for proper
viscosity of oil.
Increase size of raw coal
feed.
Low air velocity across the Check air flow control for
bowl proper operation.
Excessive open area Add an additional vane

around the bowl wheel air restriction ring.
73
2 - 14
74
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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 - 2
EXTERNAL LUBE OIL SYSTEM ............................................................. 3 - 2
LUBE OIL SKID ....................................................................................... 3 - 2
Flow Switch .................................................................................... 3 - 3
Heat Exchanger (Oil Cooler) .......................................................... 3 - 3
Lube Oil Filters ............................................................................... 3 - 4
Lube Oil Pump ............................................................................... 3 - 4
Gauges .......................................................................................... 3 - 4
Switches ......................................................................................... 3 - 4
Relief Valve ................................................................................... 3 - 4
Heaters .......................................................................................... 3 - 5
GEARBOX LUBE SYSTEM OPERATION ....................................................... 3 - 5
Start-up ....................................................................................................... 3 - 5
Shutdown ...................................................................................................... 3 - 6
_________________________________________________________
LIST OF FIGURES
TITLE FIGURE NO.
Typical Journal Asembly - Lubrication and Seal Air ......................................... 3 - 1

HP Pulverizer Lubrication Specifications ......................................................... 3 - 2
-i-
72
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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).
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.)
3-1
73
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LUBRICATION OF THE MAIN DRIVE GEARS AND BEARINGS
The gearbox is supplied with pressurized oil, 38 gpm at 100 psig, 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 hydro-
dynamic bearing, the oil is retained in a reservoir to submerge the hydrody-
namic 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, approximately 160 gal (605L) capacity. 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.
For warm up after an extended shutdown or during cold weather, a therm-

ostatically 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 tem-
perature 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.
74
3-2
75
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________________________________________________________
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℃).
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.
3-3
76
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________________________________________________________
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.
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 ade-

quate 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 ade-
quate 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.
3-4
77
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________________________________________________________
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.
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 pulv-

erizer 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.
ASSURE THAT THERE IS ADEQUATE OIL IN THE UP-

PER GEARBOX RESERVOIR (HYDRODYNAMIC
THRUST BEARING) PRIOR TO STARTING THE PULV-
ERIZER.
5. After the pulverizer is running, adjust the water flow to the heat ex-
changer as necessary to maintain the proper oil supply temperature.
6. Periodically check oil flow, oil temperature and oil pressure.
3-5
78
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________________________________________________________
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.
3-6
79
80
80
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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 ................................................................ 4-5
_________________________________________________________
LIST OF FIGURES
TITLE FIGURE NO.
HP Pulverizer - Deflector Blade Mechanism ................................................................... 4-1

HP Pulverizer- Powdered Coal Sampling Device and Fittings ......................................... 4-2
Rolling a Coal Sample .................................................................................................... 4-3
Coal Sample Shape . ...................................................................................................... 4-4
Selecting the Coal Sample ............................................................................................. 4-5
Weighing the Coal Sample ............................................................................................. 4-6
Shaking the Coal Sample ............................................................................................... 4-7
Brushing the Screens ..................................................................................................... 4-8
Suggested Pulverizer Performance / Coal Fineness Record ........................................... 4-9
Sieve Distribution Chart ................................................................................................ 4-10
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PART 4 - PULVERIZED COAL
FINENESS ADJUSTMENT
AND TESTING
ADJUSTMENT OF FINENESS
A wide range of linen ess levels can be obtained with the air separation con-
cept of classification utilized in ABB CE pulverizers. The deflector blade (ex-
ternal adjustment) mechanism (Figure 4-1 ) 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 pro-vide
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
(Figure 4-1 ). This 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 re-
quired (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 pu-
lverizer adjustments may be required as well (refer to Trouble Shooting Chart).
82
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PULVERIZED COAL
FINENESS TESTING
This procedure describes the sampling and testing parameters recommended

by ABB Combustion Engineering. 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 the valve body.
These eight (8) locations should be equipped with aspirated fittings that will
allow for proper sampling without expelling coal dust into the atmosphere.
Pulverizer Loading
In order to obtain fineness test results that can be compared between pulv-
erizers and are repeatable, it is necessary that pulverizer and furnace condi-
tions 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 pe-
riod. The pulverizer should be allowed to operate at that level for about ten
minutes before taking the sample.If there is a pulverize ror 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, rum-

bling, etc.) should not be tested until problems are corrected.
Equipment
Pulverized coal samples should only be taken with an ABB CE powdered

coal sampling device as shown in Figure 4-2. This is a large cyclone collec-
tor 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.
83
4-2
84
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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 ex-
ercised 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 f or 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 ef-
fect 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.
85
4-3
________________________________________________________

________________________________________________________
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.
5. Seal the collection jar or place the coal sample in a sealed, air tight plas-
tic 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 SAMPLF
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 (Figure 4-3).
3. Roll the sample into a cigar shape (Figure 4-4 ).
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 (Figure 4-5
and 4-6).
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 nec-
essary.
86
4-4
87
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________________________________________________________
SIEVING THE COAL SAMPLF
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.
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
(Figure 4-7).
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 (Figure 4-8).
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
88
4-5
________________________________________________________
ABB CE TYPE HP963 PULVERIZERS - OPERATION

________________________________________________________
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:
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 4-9.
To check the validity of the test, the results should be plotted on a RoslinRammler
sieves chart (Figure 4-10). If the fineness results do not plot on or close to a straight
line, then the equipment or sampling procedures should be checked.
89
4–6
90
91
92
93
94
95
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 - 9, Suggested Pulverizer Performance/Coal Fineness Record
96
97
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ABB CE TYPE HP963 PULVERIZERS - MAINTENANCE

________________________________________________________
TABLE OF CONTENTS
GENERAL MAINTENANCE PROCEDURES PART 1
TITLE PAGE NO.
GENERAL MAINTENANCE ......................................................................................... 1 - 1

Interference Fits ............................................................................................... 1 - 4
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 .............................................. 2-7
JOURNAL HEAD REMOVAL ....................................................................................... 2-8
BOWL AND BOWL HUB LIFTING ............................................................................... 2-9
GEARBOX ASSEMBLY REMOVAL .......................................................................... 2 - 11
GENERAL REASSEMBLY PART 3
GEARBOX ASSEMBLY INSTALLATION ..................................................................... 3-1

BOWL HUB, BOWL AND VANE WHEEL INSTALLATION ........................................... 3-4
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION6 .................................. 3-4
CLEARANCE AIR SEAL INSTALLATION ................................................................... 3-6
ASSEMBLY OF THE PULVERIZER LUBRICATION SYSTEM .................................... 3-7
JOURNAL ASSEMBLY INSTALLATION7 ................................................................... 3-7
JOURNAL HEAD ASSEMBLY INSTALLATION8 .......................................................... 3-9
JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION9 .................................. 3 - 10
JOURNAL TILT IN10 ................................................................................................. 3 - 11
JOURNAL OPENING COVER AND SPRING INSTALLATION ................................... 3 - 13
ASSEMBLY OF TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ........................ 3 - 14
PULVERIZER MOTOR ............................................................................................... 3 - 14
PREPARATION FOR A RETURN TO SERVICE ........................................................ 3 - 15
PULVERIZER COMPONENT SERVICING PART 4
BULL RING SEGMENT REPLACEMENT .................................................................... 4-1

VANE WHEEL SEGMENT AND AIR RESTRICTION RING REPLACEMENT ............... 4-4
GRINDING ROLL RENEWAL ...................................................................................... 4-5
JOURNAL BEARING END PLAY CHECKING ............................................................. 4-8
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TABLE OF CONTENTS (continued)
PULVERIZER COMPONENT SERVICING (continued) PART 4
TITLE PAGE NO.
JOURNAL BEARING REPLACEMENT ............................................................... 4- 10

Journal Shaft Disassembly ..................................................................... 4- 11
Journal Shaft Reassembly Procedures .................................................. 4- 12
JOURNAL OIL SEAL REPLACEMENT .............................................................. 4- 15
JOURNAL OIL CHECKING PROCEDURES . ...................................................... 4- 17
JOURNAL SPRING SERVICING ........................................................................ 4- 18
Journal Spring Disassembly ................................................................... 4- 18
Journal Spring Reassembly .................................................................... 4- 20
CLASSIFIER DEFLECTOR BLADE REPLACEMENT ........................................ 4- 22
MAJOR ADJUSTMENTS ................................................................................... 4- 23
Roll-ring Clearance ................................................................................. 4- 23
Journal Spring Preloading Procedure ................................................... 4- 24
Journal Spring Position .......................................................................... 4- 25
Discharge Valve Limit Switch Set-up ..................................................... 4- 27
PULVERIZER LINER INSTALLATION PROCEDURES USING WELD PLUGS .. 4- 28
Equipment Required ............................................................................... 4- 28
Welding Specification ............................................................................. 4- 28
Application of Weld ,Plugs ..................................................................... 4- 29
Installation of Tiles - General .................................................................. 4- 30
Trouble Shooting .................................................................................... 4- 31
LINER REPLACEMENT (GENERAL) ................................................................. 4- 31
Installation Procedures for Inner Cone Liners ...................................... 4- 32
Installation of Inner Cone Spout Segments ........................................... 4- 33
Installation/Replacement Procedures for Separator Body Liners ........ 4- 34
PULVERIZER LINER INSTALLATION/REPLACEMENT .................................... 4- 35
Outlet Venturi Vanes . .............................................................................. 4- 35
Outlet Plate . ............................................................................................. 4- 35
PULVERIZER LINER INSTALLATION PROCEDURES USING LINER BOLTS .. 4- 36
Multiport Outlets ..................................................................................... 4- 36
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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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ABB CE TYPE HP963 PULVERIZER - MAINTENANCE

________________________________________________________
PART 1 - GENERAL
MAINTENANCE
PROCEDURES
GENERAL MAINTENANCE
The pulverizer is a rugged machine, designed and built for continuous op-
eration 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 oper-
ating experience. It is, therefore, imperative that an accurate log be main-
tained 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 ca-
pacities 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,
r epl ace me nt of t he p ar t i s m or e pr a ct i c al . The f ol lowing list de
scribes the pulverizer parts normally subject to wear:
1-1
101
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________________________________________________________
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 Ii-
ners, their degree of wear Will vary considerably from one installation to
another and sometimes between pulverizers at the same plant. Indi-
vidual liners must be replaced when thinning and holes indicate exce-
ssive wear.
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.
102
1-2
103
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________________________________________________________
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).
WHEN MAINTENANCE IS REQUIRED ON A PULVE-

RIZER 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 EN-
TERING THE PULVERIZER.
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.
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.
1-3
104
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________________________________________________________
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.
1-4
105
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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 ................................................................ 2-7
JOURNAL HEAD REMOVAL ........................................................................................................ 2-8
BOWL AND BOWL HUB LIFTING5 ............................................................................................... 2-9
GEARBOX ASSEMBLY REMOVAL .............................................................................................. 2 - 11
-i-
102
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ABB CE TYPE HP963 PULVERIZER -MAINTENANCE

________________________________________________________
PART 2 - GENERAL
DISASSEMBLY
INTRODUCTION
This section of the manual has been prepared to serve as a guide in main-
taining ABB CE 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 gearbox
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 K3922.00 and K3923.00) for orientation and
location of major components. Detailed procedures covering the repair of
major sub-assemblies can be found in other sections of this manual.
2-1
103
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________________________________________________________
ISOLATION OF THE
PULVERIZER
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. Ope 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 sys-
tems.
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.
Open the other inspection and millside doors as required for access.
2-2
________________________________________________________
104
________________________________________________________
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 K3734.9.0 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 Figure 9
and ]K3740.5.0 Section "D - D" 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 four hex nuts (Refer to Figure 11) that retain the
spring assembly on the studs. If there is any pressure on the spring as-
sembly, it will back out of the journal cover. Stop loosening the nuts when
no movement is evident.
THE JOURNAL OPENING COVER & SPRING ASSEM-

BLY WEIGHS APPROXIMATELY 4766KG AND MUST
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 K3922.00 AND K3923.00 for

clearances required and Fig. 1 on KF3740.8.0 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 (Item 3) [Approxi-
mately 550 lb (250 kg)] into the bracket above the separator body journal
cover opening.
2-3
105
________________________________________________________

________________________________________________________
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.
5. Check the trunnion shaft end caps and verify that the numerals 1 are
positioned at 12 O'clock. If they are in any other position, remove the
trunnion shaft bolts and simultaneously rotate the trunnion shafts to
position the numerals 1 at 12 O'clock. Replace the trunnion shaft bolts
(refer to drawing K3740.4.0 )
6. Turn one journal stop bolt to lift the grinding roll from the bull ring. Rotate
the roll until the M24. tapped holes on top of the journal housing are at 12
O'clock (refer to drawing K3740.4.0 )
7. Remove existing set screws and install lug (item [55 ) using hex head cap
screws (item 6).
8. Remove journal head cover plate and set it aside.
NOTE
If maintenance will be performed on the journal 'shaft as-

sembly 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 pre vent
oil leakage.
10. Remove the shaft from the lower beams of the tilt out bracket. Attach
snatch block to an overhead crane, thread the cableover the snatch block
sheave.
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 Fig. of KF3740.8.0
2-4
106
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________________________________________________________
STAND CLEAR OF THE JOURNAL AND TILT OUT AS-

SEMBLY DURING A TILT OUT PROCEDURE.
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, Fig. 1, of KF3740.8.0 )
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 (items 8,9,10,11,)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.
JOURNAL ASSEMBLY
REMOVAL
If pulverizer repairs will be extensive, it may be advantageous to completely

remove the journal assemblies, refer to Figures 12 and 13. I!f 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 - 7)
1. Remove the journal opening cover.
2. Tilt out the journal assembly.
3. Remove two (2) grinding roll keeper bolts 180° apart and install two (2) eye
bolts to the full depth of the threads. Ensure that the eyebolt flange rest
securely against the journal keepers.
2-5
107
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________________________________________________________
THE JOURNAL ASSEMBLY WEIGHS APPROXI-

MATELY 8210Kg , TRUNNION SHAFTS WEIGH
APPROXIMATELY 265Kg EACH. ALL MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

NAL ASSEMBLY AT ALL TIMES DURING THE RE-
MOVAL PROCEDURE.
4. Install a chain shackle in each eye bolt and a[tach 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 c, verhead crane positioned above the

center of lhe door opening. Take up slack.
NOTE
The chain sling and crane cable must not contact the sepa-
rator body when the journal assemb!y 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 requ ired for reassembly
2-6
108
.________________________________________________________

________________________________________________________
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 Figure 12 and drawing

K3740.4.0 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 two (2) grinding roll keeper bolts 180° apart and install two (2)
eyebolts to the full depth of the threads. Eyebolt flanges should be flush
with the roll keeper surface.
THE JOURNAL ROLL AND SHAFT ASSEMBLY MUST

HANDLING. THE OVERHEAD CRANE MUST
SUPPORTTHE JOURNAL ROLL AND SHAFT ASSEMBLY
AT ALL TIMES DURING THE REMOVAL PROCEDURE.
5. Install a chain shackle in each eyebolt and attach a chain sling. The sling
should be parallel to and must clear the separator body journal opening
when loaded.
2-7
109
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________________________________________________________
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.
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 K3740.4.0
THE JOURNAL HEA D W EIGHS APPROXIMATELY

1550Kg), TRUNNION SHAFTS WEIGH APPROXIMATELY
265Kg EACH. ALL MUST BE ADEQUATELY RIGGED TO
1. Install two (2) M30 eyebolts in the head flange 180° apart.
2-8
110
________________________________________________________

________________________________________________________
3. Attach the chain sling to an overhead crane positioned above the center of
the journal door opening. Take up slack.
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 drawingKF3740.5.0 .
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.
2-9
111
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________________________________________________________
6. Disassemble the lower bowl hub skirt assembly on drawing K3922.00 and
K3923.00 from bowl hub skirt to provide access to the bowl hub air seal.
Set the quarter sections of the lower skirt near the mill sides.
NOTE
Clearances must be reestablished when the skirt air seal is

reinstailed. Match marking each piece prior to its removal
will significantly aid in reinstallation and adjustment.
7. Disassemble the components of the bowl hub skirt air seal (Refer to Figure
1 and drawings K3922.00 and K3923.00. and K3858.4.0 Use care not to
damage the upper surface of the inner air seal ring.
8. Remove the clearance seal guard (refer to Figure 4 and drawing

K3740.16.0 AND K3740.17.0 ).
NOTE
Clearances must be reestablished when the clearance seal

assembly is reinstailed. Ensure that each piece is match
marked prior to its removal, this will significantly aid in
reinstallation and adjustment.
9. Remove the six(6) segments of the clearance air seal and transfer Parts to
a clean, safe storage area. Use care not to damage surfaces that mate to
the bowl hub.
10. 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.
11. Remove that cap screw and adjacent cap screws on each side, for a total
of three at each opening.
12. Install bowl hoist clevis and bowl hoisting frame hook at each journal
opening. Refer to drawing KF3740.5.0 .
13. Loosen the bolts that secure the vane wheel adjustable shroud (refer to F
gure 8 and drawing K3740.6.0 ) to the vane wheel segments. Lower the
adjustable shroud segments as far as possib e to provide adequate
clearance for lifting the bowl.
NOTE
Reference Figure 7 and drawing K3740.6.0 .

14. 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.
112
2 - 10
113
________________________________________________________

________________________________________________________
15. Remove the hex socket head cap screws that secure the bowl hub cover
plate to the bowl hub and remove the cover plate.
16. 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 K3922.00 AND K3923.00.
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 120,000 lbs (162 700 N).
b. Tension studs second round to 90,000 lbs (122 025 N).
c. Tension studs third round to 12,000 lbs (16 270 N).
THE BOWL HUB, VANE WHEEL AND BOWL ASS-

EMBLY WEIGHS APPROXIMATELY 600Kg (6MT) AND
MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.
17. Attach three chain hoists or come--alongs [each with a 5MT minimum
capacity] to the journal opening frame hooks and the bowl hoisting clevis,
refer to drawing KF3740.5.0
18. Lift the bowl hub, 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.
19. Remove the gearbox
GEARBOX ASSEMBLY
REMOVAL
1. Remove three (3) journal opening covers and springs, refer to Page 2 - 3.
2. Remove the three (3) journal assemblies, refer to Page 2 - 5.
3. Lift the bowl and bowl hub assembly, refertO Page 2 - 9.
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.
114
2-11
________________________________________________________

________________________________________________________
NOTE
Reference drawing K3922.00 AND K3923.00 .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 KF3740.6.0 .
11. Slide the gearbox onto the rails.
THE GEARBOX WEIGHS APPROXIMATELY 11000

kg AND MUST BE ADEQUATELY RIGGED TO
12. Once the gearbox is out from under the pulverizer,it may be moved to a
maintenance are for disassembly.
13. If a replacement gearbox will not be installed immediately,build a steel

or wood crib capable of supporting the weight of the bowl hub,vane
wheel and bowl assembly,approximately 6000kg(6MT) 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 hub,vane wheel,and bowl 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.
115
2 - 12
116
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________________________________________________________
TABLE OF CONTENTS
GENERAL REASSEMBLY PART 3
TITLE PAGE NO.
GEARBOX ASSEMBLY INSTALLATION ......................................................................................... 3 - 1

BOWL HUB, BOWL AND VANE WHEEL INSTALLATION ............................................................... 3 - 4
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION ......................................................... 3 - 4
CLEARANCE AIR SEAL INSTALLATION ........................................................................................ 3 - 6
ASSEMBLY OF THE PULVERIZER LUBRICATION SYSTEM ......................................................... 3 - 7
JOURNAL ASSEMBLY INSTALLATION .......................................................................................... 3 - 7
JOURNAL HEAD ASSEMBLY INSTALLATION ............................................................................... 3 - 9
JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION ......................................................... 3 - 10
JOURNAL TILT IN .......................................................................................................................... 3 - 11
JOURNAL OPENING COYER AND SPRING INSTALLATION ....................................................... 3 - 13
ASSEMBLY OF TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ............................................ 3 - 14
PULVERIZER MOTOR ................................................................................................................... 3 - 14
PREPARATION FOR A RETURN TO SERVICE ............................................................................. 3 - 15
--i--
117
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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 KF3740.6.0 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 K3922.00
AND K3923.00.
THE PULVERIZER GEARBOX WEIGHS APPROXI-

MATELY 11000kg AND MUST BE ADEQUATELY
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 remistalled 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.
118
3–1
119
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________________________________________________________
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 KF3740.6.0 .
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,bowl hub and vane wheel
assembly (Refer to KF3740.5.0 ).
THE BOWL,BOWL HUB AND VANE WHEEL

ASSEMBLY WEIGHS APPROXIMATELY 14538Kg
AND MUST BE ADEQUATELY RIGGED TO
5. Lift the bowl,bowl hub 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

KF3740.4.0 .
ENSURE THAT THE UPPER RESERVOIR OF THE

GEARBOX IS FULL OF OIL TO THE LEVEL INDICATED
ON ITSSIGHT GLASS [APPROXIMATELY 50 GAL(188l)]
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.
120
3-2
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________________________________________________________
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, bowl hub 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 (2)inches (50.8mm) of the 8 -
M24. 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 zone F- 3 drawing K3922.00 AND
K3923.00.
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 KF3740.3.0 , tension each stud to

12,000Ibs (53379N). Reference drawing K3922.00 AND K3923.00. for
the recommended numerical sequence.
16. Repeat step 15. to 90,000 lbs (400 340 N).
17. Repeat step 15. to 120,000 lbs (533 787 N).
18. Remove the bowl, bowl hub and vane wheel hoisting fixtures.
19. 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 (102 Nm).
20. 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 (102 Nm).
21. Use the drive adjustment blocks (refer to drawing KF3740.4.0 ), 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.
22.. Set the bowl hub skirt / air seal clearance before dowelling the gearbox to
the sole plate. Refer to "Bowl Hub Skirts and Air Seal Installation" Page 3
-4
23. Mount a drilling rig above each of the dowel pin holes in the gearbox
mounting flange.
24. Drill and ream oversize for new dowel pins or using the 1.33 in.
(33.78 rnm) pilot holes in the gearbox flange, drill and ream 1.5000 in.
±0.0005in. (38.100mm±0.012mm) holes into the sole plate to a depth of
4.50 in. (114.3 mm).
25. Lubricate the dowel pins with Molykote GN-Paste, or an equivalent, and
press fit the dowel pins into the reamed holes.
121
3-3
122
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________________________________________________________
26. Torque the fasteners holding the gearbox to the gearbox sole plate per B-
GP-2175.
BOWL HUB, BOWL AND
VANE WHEEL INSTALLATION
1. Install the bowl assembly to the gearbox per steps 11. thru 20. 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 K3740.6.0 . 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 installing the bowl hub skirts
and setting the inner air seal clearance.
BOWL HUB SKIRTS AND

INNER AIR SEAL
INSTALLATION
, NOTE
The following steps refer to Figures 5 and 6 and drawings

K3922.00 AND K3923.00 and K3858.4.0 ,
NOTE
Skirt segments are match marked in sets, segments are

not interchangeable. Dowel pins at the center of each seg-
ment's end flange ensures their proper alignment. In this
procedure the dowel pins should be temporarily removed
from the lower skirts as it will be necessary to disassemble
and reassemble them several times.
NOTE
Apply anti-seize compound to all fasteners and torque all

fasteners per B-GP-2175 unless otherwise specified.
1. If the upper skirt was removed, use the match marks to align the quarter
sections of the upper skirt assembly and fasten them together and to the
bowl hub using the fasteners supplied with the skirts
3-4
123
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________________________________________________________
2. 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.
3. Clean the mating surfaces of the upper and lower skirt assemblies. Align
and fasten together three quarter sections of the lower skirt leaving out
one section that does not hold ascraper assembly.
4. Install two set screws in each quarter section of the lower skirt and use
them to jack up the skirt section until the gap between the lower skirt
flange and the insulation cover segments is 0.50 in.+O.06 -0.00 in. (12.7
mm +1.52 mm -0.00 mm). This setting establishes the scraper blade to
mill bottom clearance.
5. Measure the gap between the upper and lowers kirt flange and select a
shim pack which is equal to 0.06 in. (1.52 mm) less than the gap.
6. Install the shims and fasten the three quarter sections of the lower skirt
assembly to the upper skirt.
7. Measure the gap between the lower skirt assembly and insulation cover
segments. It should be between 0.50 in. and 0.62 in. (12.70 m m to 15.75
mm). Add or remove shims, as required to.obtain the desired clearance.
8. Remove the jack screws from the lower skirt.
NOTE
The pulverizer bowl must be rotated to allow the inner air

seal shims to be installed in quarter sections. The upper oil
reservoir must be filled to operating level or the lube oil
system must be available so that the bowl can be rotated
9. Refer to K3922.00 AND K3923.00measure the gap between the lower

skirt and the inner air seal ring.
NOTE
It may be necessary to reposition the gearbox (refer to

KF3740.4.0 ) to obtain acceptable clearances at 30 °
intervals around the perimeter of the skirt. Removal and
reinstallation of skirt sections will be required.
10. Select shims from the shim pack to raise the air seal ring and provide a
clearance of 0.0625 in.± 0.005 in. (1.587 mm ± 0.127 mm).
11. Install the shim pack under the air seat ring. Reassemble the lower skirt
and check the air seal clearance.
12. Disassemble a quarter section of the seal. Apply anti seize compound to
the fasteners
124
3-5
125
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________________________________________________________
13. 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.
14. Rotate he bowl and repeat steps 12. and 13. for the four sections of the
inner air seal.
15. Install the remaining shim pack selected in step 5. Align and install the
last quarter section of the lower skirt.
16. Reconfirm the lower skirt to inner air seal ring clearance. Refer to step 9.
17. Attach the scraper and guard assemblies to the lower skirt. Verify
clearance of 0.31 in. ± 0.06 in. (7.87 mm ± 1.52 mm) between the
scraper and the mill bottom cover plates. Torque hex socket head cap
screws to 136 ft .lb. (184 Nm).
CLEARANCE AIR SEAL

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 clearance air 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 Figure 4 and drawings

K3740.16.0 AND K3740.17.0 and K3922.00 AND
K3923.00 unless otherwise stated.
1. Clean the surface of the mill bottom on which the seal ring assembly will
seat.
2. Loosely attach the clearance seal ring assembly to the mill bottom.
3. Hand tighten bolts. Align match marks and trial fit butt joints.
4. Disassemble the seal. Apply anti-seize lubricant to the fasteners
5. Reassemble the seal in the same order and apply RTV 106 or equal to
the butt joints.
6. Position the seal segments to provide an equal gap around the hub [±
0,003 in. (±0.076 mm)].
7. Start the lubrication oil system and rotate the bowl hub. Check that the
gap every 90° is within the 0.003 in (0.076 mm) tolerance
126
3-6
________________________________________________________

________________________________________________________
8. Once the gap is set, torque the hex head cap screws per drawing B- GP-
2175.
9. Assemble the four screen sections in place and attach to the guard sup-
ports.
ASSEMBLY OF THE
PULVERIZER LUBRICATION
SYSTEM
NOTE
Refer to Gearbox and Lube Oil System manufacturers'
Instruction 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 assem-
blies were removed from the pulverizer as a unit. If they were removed
separately refer to "Journal Head Assembly Installation", Page 3 - 9and to
"Journal Roll And Shaft Assembly Installation", Page 3 - 10 for procedures.
For tools and components used in this procedures refer to Figure 13 and
drawing K3740.4.0 .
AN OVERHEAD CRANE MUST SUPPORT THE JOUR-

NAL ASSEMBLY AT ALL TIMES DURING THE INSTAL-
LATION PROCEDURE.
THE JOURNAL ASSEMBLY WEIGHS APPROXI-

MATELY 8210kg AND MUST BE ADEQUATELY RIGGED
1. Move the complete journal assembly adjacent to the journal opening at

the pulverizer.
127
3-7
128
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________________________________________________________
T R UN N I O N S H AF TS WE I G H AP P ROX I M ATE L Y
2 6 5 k g E A C H A N D M U S T B E A D E Q U AT E L Y
2. Place the thrust and free trunnion shafts near the appropriate side of the
journal opening.
4. Remove two (2) grinding roll keeper bolts 180° apart and install two eye-
bolts to the full depth of the threads. Ensure that eyebolt shoulders con-
tact the keeper plates.
6. Rig to an overhead crane and lift the journal assembly into position in the
separator body journal opening.
7. Carefully align the journal head with the trunnion shaft openings in the
separator body.
8. nstall the journal head to separator body safety tilt out bracket and torque
the bolts.
9. Slide a 0.8 to 1 in-x120in.(20 to25mmx3100mm)allthreadrod through the

separator body trunnion shaft openings and the journal head.
10. Remove the pipe plug from the seal air opening in the trunnion shaft.
11. Ensure that the dowel pins are secure in each trunnion shaft. Coat the
mating surfaces of the thrust plates and shafts with anti-seize compound
and slide the thrust plates onto the trunnion shafts.
12. Ensure that the "thrust end" and "free end" trunnion shafts are on the
correct side of the journal head then lift each shaft and slide it over the all
thread rod and into its separator body opening.
13. Ensure that the numeral 1 on the end of each shaft is in the 12 O'clock
position and start the end of each trunnion shaft into the journal bushing
retainers.
MAINTAIN ALIGNMENT OF ALL COMPONENTS DUR-

ING THE NEXT FEW STEPS TO PREVENT THEM FROM
BINDING.
14. Slide a backing plate on each end of the all thread rod. Thread two hex
nuts on one end of the rod and one heavy duty hex nut on the other end.
3-8
129
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________________________________________________________
15. Securely lock the two hex nuts at the end of the rod and tighten the nut
on the other end.
THE NUMERAL ONE ON THE TRUNNION SHAFT END

CAPS MUST BE IN THE SAME RESTIVE POSITION, I.E.,
BOTH AT 12 O'CLOCK, OR SHAFTS WILL BIND IN THE
TRUNNION BUSHINGS AS THEY ARE DRAWN INTO
POSITION.
16. Use an air impact wrench on the double nut end of the rod. Slowly turn
the rod to tighten the heavy hex nut and pull the trunnion shafts and thrust
plates into place.
17. When fully inserted, turn the trunnion shafts until the numeral 1 on the
end caps is in the 12 O'clock position. Secure the trunnion shafts to the
separator body with hex head cap screws. Lubricate and torque the bolts
per drawing B-GP-2175
18. Ensure that the journal assembly is supported by the tilt out safety
bracket. Disconnect the rigging and remove the chain sling and eyebolts.
19. Reinstall the grinding roll keeper bolts and torque per B-GP-2175.
20. Use the Journal Tilt In procedure, Page 3 - 11 to return the roll into the
bowl.
21. Check the oil level in the journal. Replace the pipe plug and the journal
head cover plate.
JOURNAL HEAD ASSEMBLY

INSTALLATION
NOTE
Refer to Figure 13 and drawing K3740.4.0 .
1. With the journal head laying flange side up, install two M30 . eye bolts
180° apart in the head flange.
THE J OURNA L HE A D W E I GHS A P PROXIMATELY

900kg (0.9MT) AND MUST BE ADEQUATELY RIGGED TO
3-9
130
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________________________________________________________
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 free end 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. Continue with steps 9. through 17. of the "Journal Assembly Installa-

tion", Page 3 - 7.
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 Figure 13 and Drawing K3740.4.0 .
1. Move the journal roll and shaft assembly adjacent to the mill.
2. Remove two (2) of the grinding roll keeper bolts 180 ° apart and
install two (2) eyebolts to the full depth of the threads. Ensure that the
eyebolt flanges contact the grinding roll keeper plates.
THE JOURNAL ROLL AND SHAFT ASSEMBLY MUST BE

ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

NAL SHAFT ASSEMBLY AT ALL TIMES DURING THE
INSTALLATION PROCEDURE.
4. Attach the chain sling to the the overhead crane. Take up slack.
3 - 10
131
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________________________________________________________
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 0.50 in. (12.7 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 f asteners i n the sequence and steps shown on drawing
K3740.4.0 . 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.
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. Trunnion eccentrics should have the numeral 1 at the 12 O'clock position

with safety bracket bolted to the journal head and separa-
tor body.
NOTE
Referto Fig. 2 on drawing KF3740.8.0 for item numbers.
2. Insert the top "shoe" of the journal tilt out bracket into the bracket above
the separator body journal opening.
3 - 11
132
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________________________________________________________
3. Secure the journal tilt out bracket assembly to the separator body journal
opening with hex head cap screws.
4. Remove set screws and attach the tilt out lug to the journal housing.
5. Ensure that the shaft removed from the lower beams of the tilt out
bracket for the tilt out procedure is replaced.
6. Center the crane directly over the separator body journal opening and
attach the snatch block ,,
7. Thread the cable through the snatch block and sheaves as shown on
Figure 2 of KF3740.8.0 . Attach it tothe tilt out bracket and to the lug on
the journal housing. Take up slack.
8. 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.
STAND CLEAR OF THE JOURNAL AND TILT OUT AS-

SEMBLY DURING A TILT IN PROCEDURE.
AS THE SNATCH BLOCK IS LIFTED, THE CABLE WILL

GO S L ACK AND THE N TIGHTE N WHEN THE JOUR
NAL FALLS INTO THE MILL AS ITS CENTER OF GRAV
ITY PASSES OVER THE TOP OF THE TRUNNION SHAFT
( P I V O T P O I N T) . L I F TI N G S H O U L D S TOP ONCE
THE CABLE GOES SLACK.
9. 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 lower-
ing 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.
10. Remove the cable. the tilt out bracket and the safety bracket.
11. Replace the set screws in the roll after removing the tilt out lug. Stake the
set screws at four (4) places.
133
3 - 12
134
________________________________________________________

________________________________________________________
12. 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.
THE AREA AROUND TI IE 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 SUBSE-
QUENT FAILURE OF THE JOURNAL BEARINGS.
13. Vacuum clean the area in the journal head around the oil fill pipe.
14. Replace journal head cover plate. Toique cap screws per B-G P-2175.
15. Reinstall the journal opening cover and spring assembly.
JOURNAL OPENING COVER

AND SPRING INSTALLATION
NOTE
Thefollowing stepsreferto Figure 11 and K3740.3.0 ,unless

otherwise stated.
1. Loosen the four outer nuts which position the spring assembly on the
mounting studs.
2. Retract the spring assembly until on ly 1 in. of the assembly is protruding

out of the journal opening cover. Snug the inner nuts on the studs to
maintain the position o'f the spring assembly.
THE JOURNAL OPENING COVER WEIGHS APPROXI-

MATELY 4766Kg AND MUST BE ADEQUATELY
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 Felt-Pro No. C5-A anti-seize compound or
equal.
5. Lift the jjourrnal cover into position on the separator body and secure it
with hex'iead cap screws.
135
3 - 13
136
________________________________________________________

________________________________________________________
6. Check the journal spring compression, refer to "Journal Spring
PrelOading Procedure" in the HP Pulverizer - Maintenance, Part 4 in-
struction for procedures.
NOTE
Steps 7. and 8. can only be performed when the pulverizer

is operational. Refer to "Component Servicing" Mainte-
nance - Part 4 instructions for procedures.
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
1. Replace the trunnion shaft air riser and reconnect'the seal air piping to
the trunnion shaft and journal springhe
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 man ufacturer's instructions for

their mounting and alignment recommendations.
NOTE
The following steps refer to K3922.00 AND K3923.00 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
3 - 14
137
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________________________________________________________
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 align-
ment instructions.
4. Measure the clearance between the coupling flanges using a dial indi-
cator. 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 K3922.00 AND K3923.00
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.
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.
3 - 15
138
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________________________________________________________
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 dis-
charge 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 informa-
tion.
139
3 - 16
140
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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 - 4
GRINDING ROLL RENEWAL ........................................................................................................... 4 - 5
JOURNAL BEARING END PLAY CHECKING .................................................................................. 4 - 8
JOURNAL BEARING REPLACEMENT ............................................................................................ 4 - 10
Journal Shaft Disassembly ..................................................................................................... 4 - 11
Journal Shaft Reassembly Procedures ................................................................................... 4 - 12
JOURNAL OIL SEAL REPLACEMENT ............................................................................................ 4 - 15
JOURNAL OIL CHECKING PROCEDURES ..................................................................................... 4 - 17
JOURNAL SPRING SERVICING ...................................................................................................... 4 - 18
Journal Spring Disassembly ..................................................................................................... 4 - 18
Journal Spring Reassembly ...................................................................................................... 4 - 20
CLASSIFIER DEFLECTOR BLADE REPLACEMENT ...................................................................... 4 - 22
MAJOR ADJUSTMENTS .................................................................................................................. 4 - 23
Roll-ring Clearance .................................................................................................................... 4 - 23
Journal Spring Preloading Procedure ...................................................................................... 4 - 24
Journal Spring Position ............................................................................................................ 4 - 25
Discharge Valve Limit Switch Set--up ....................................................................................... 4 - 27
PULVERIZER LINER INSTALLATION PROCEDURES USING WELD PLUGS ................................ 4 - 28
Equipment Required .................................................................................................................. 4 - 28
Welding Specification ................................................................................................................ 4 - 28
MANUAL INSERT GAS WELDING - MIG ............................................................................. 4 - 28
STICK WELD - MANUAL METAL ARC PROCESS .............................................................. 4 - 29
Application of Weld Plugs ......................................................................................................... 4 - 29
Installation of Tiles - General .................................................................................................... 4 - 30
Trouble Shooting ....................................................................................................................... 4 - 31
LARGE GAPS BETWEEN TILE ........................................................................................... 4 - 31
TILE IS CRACKING ............................................................................................................. 4 - 31
WELDS NOT FUSING .......................................................................................................... 4 - 31
LINER REPLACEMENT (GENERAL) ............................................................................................... 4 - 31
Installation Procedures for Inner Cone Liners ......................................................................... 4 - 32
Installation of Inner Cone Spout Segments ............................................................................. 4 - 33
Installation/Replacement Procedures for Separator Body Liners ........................................... 4 - 34
PULVERIZER LINER INSTALLATION/REPLACEMENT .................................................................. 4 - 35
Outlet Venturi Vanes .................................................................................................................. 4 - 35
Outlet Plate, ................................................................................................................................ 4 - 35
PULVERIZER LINER INSTALLATION PROCEDURES USING LINER BOLTS ................................ 4 - 36
Multiport Outlets ........................................................................................................................ 4 - 36
-i-
141
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________________________________________________________
PART 4 - PULVERIZER
COMPONENT SERVICING
BULL RING SEGMENT

REPLACEMENT
NOTE
The following steps refer to Figure 7, and drawing

K3740.6.0 ,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 PULV-
ERIZER- MAINTENANCE, General Disassembly Procedures, Part 2.
2. Open the mill-side and separator body access doors.
3. Unbolt and lower the vane wheel segments into the millside. Reference
drawing K3740.6.0
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 250 ft lb (339 Nm), (1/2 of the value specified on )K3740.6.0 ).
Torque them again to the full value, 500 ft lb (678 Nm).
4-1
142
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________________________________________________________
10. Repeat step 9. until all of the bull ring clamping ring segments are fas-
tened 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, 500 ft lb (678 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.
NOTE
Bull ring segments are numbered for sequential installation.
NOTE
Ribbed segments should be spaced at approximately equal

angular increments. Ensure that no two ribbed segments
are spaced exactly 120" apart.
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 ram).
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 ram). Mismatch around the entire perimeter of the bowl must not
exceed 0.12 in. (3.0 ram).
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 be-
tween 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
4-2
143
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________________________________________________________
17. Apply Loctite 271 to the hex socket head cap screws for a
bowl extension ring . Install and torque the bolts to150 ft lb (200Nm),
(1/2 of the value specified on K3740.6.0 )Torque them again to the
full value, 300 ft lbs (400Nm).
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, 300 ft lbs(400 Nrn).
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 mrn to 0.38 rnrn) 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.
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
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 K3740.6.0 )
144
4-3
145
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________________________________________________________
24. Replace the vane wheel segments. Reference drawing K3740.6.0 .
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 drawinglB-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 Figure 8 and drawings K3740.6.0
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, per-
form 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 - MAIN-
TENANCE, "General Disassembly Procedures", Part 2. Open the millside
doors.
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 seg-
ments will not be installed, new air restriction rings may be installed by
tack welding them to the wheel vanes
4-4
146
________________________________________________________

________________________________________________________
4. Replace worn vane wheel segments as follows:
NOTE
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-GP2175 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. Position the adjustable shroud to provide a clearance of 0.50 in. ± 0.12

in. (12.7 mm ± 3.05 mm) between the shroud and the separator body.
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 con-
venient work area.
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.
147
4-5
148
________________________________________________________

________________________________________________________
NOTE
The f ollowing steps ref er to Figure 12 and drawing

K3740.4.0 unless otherwise stated.
1. Remove the journal opening cover and tilt out the journal assembly as
described in the HP PULVERIZER- MAINTENANCE, "General Disas-
sembly Procedures", Part 2.
NOTE
If the schedule permits, take a sample of the journal lubri-
cating 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.
THE GRINDING ROLL WEIGHS APPROXIMATELY

900Kg(0.9MT). RIGGING MUST BE ADEQUATE TO
SUPPORT THE ROLL AND APPLY THE FORCE RE-
QUIRED 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.
6. Attach the chain sling to an overhead crane positioned above the center
of the door opening, take up slack.
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. Tempera-
tures around the perimeter of the roll must vary by less than 25°F (14℃).
149
4-6
150
________________________________________________________

________________________________________________________
IF THE ROLL IS TAPPED FROM BELOW TO HELP RE-

MOVE 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.
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 - 8.
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)
4-7
151
________________________________________________________

________________________________________________________
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 rein-
stalled 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".
JOURNAL BEARING END

PLAY CHECKING
NOTE
Reference Figure 12 and drawing K3740.4.0 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.
152
4-8
153
________________________________________________________

________________________________________________________
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 rest-
ing 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 iswithin 0.0005 in. (0.013 rmm) of the
original zero setting the measurement is considered accurate.
11. Repeat steps 7. through 10. until two accurate measurements are ob-
tained.
12. Average the readings and compare the results with those in the table.
13. I( the measured end play is within specification [<0.015 in. (0.381 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 [>0.015 in. (0.381 m m)]
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. In-
stall 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.
4-9
154
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________________________________________________________
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 (0.01 27 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.
JOURNALBEARING
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 - 8)
THE JOURNAL ROLL AND SHAFT ASSEMBLY WEIGHS

APPROXIMATELY 2900Kg(2.9MT) 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.
4 - 10
155
________________________________________________________

________________________________________________________
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 Figure 12 and drawing

K3740.4.0
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 - 5steps 3. through 8. for roll

removal.
IF THE ROLL IS REMOVED, ALLOW THE JOURNAL

HOUSING TO COOL SUFFICIENTLY BEFORE CON-
TINUING 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.
4 - 11
156
________________________________________________________

________________________________________________________
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.
THE JOURNAL HOUSING AND ROLL AS SEMBLY

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 Figure 12 and the journal shaft assembly drawing

K3740.4.0 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.
4 - 12
157
________________________________________________________

________________________________________________________
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.
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
installation. 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.
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
installation. 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 (5) times in each direction to seat the bearing rollers.
158
4 - 13
159
________________________________________________________

________________________________________________________
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 drawingsK3740.4.0

18. Install two eyebolts 180° apart on the bearing housing, attach chain
shackles and a chain sling.
NOTE
Tools similar to those illustrated on drawing

may be fabricated for use in this procedure, rather than us-
ing 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. 4-
160
14
161
________________________________________________________

________________________________________________________
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.
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

K3740.4.0
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.
162
4 - 15
163
________________________________________________________

________________________________________________________
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.
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.
164
4 - 16
165
________________________________________________________

________________________________________________________
JOURNALOILCHECKING
PROCEDURES
NOTE
The journal must be in its normal installed position to perform

the following procedure. Refer to Figures 11.12 and 13 and
drawing K3740.4.0
THE PULVERIZER MUST BE SHUT DOWN AND PROP-

E RL Y I S OLATE D BE FORE THE INSPECTION HOLE
COVER IS REMOVED.
1. Remove the journal opening cover inspection hole cover and gasket.
3. Remove the 11/4 in. pipe plug from the oil fill pipe.
4. Usingthedipstick, checkthattheoiIlevelisbetween 15in. and17in.
(380 mm and 430 mm). Add or remove oil to adjust the oil level.
NOTE
Refer to lubrication chart (Figures 3-2)in the Operations

part of this manual for oil specifications and service recom-
mendations.
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.
166
4 - 17
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________________________________________________________
JOURNAL SPRING
SERVICING
Journal Spring Disassembly
THE JOURNAL SPRING ASSEMBLY WEIGHS AP-

PROXIMATELY 900 KG ( 0 . 9M T) AND M UST BE
ADEQUATELY RIGGED TO ENSURE SAFE HAN-
DLING.
NOTE

KF3740.2.0 K3740.3.0 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.
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 SUP-
PLIED FOR JOURNAL SPRING PRELOAD. REFER TO
DRAWING KF3740.2.0
167
4 - 18
168
________________________________________________________

________________________________________________________
4. Using two diagonal inboard heavy hex nuts, evenly pull the spring hous-
ing from the journal opening cover bore a distance equal to the spring set
preload compression plus 0.50 in. (12.7 mm).
For example:
The HP963 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 KF3740.2.0)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.KF3740.2.0) 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.
4 - 19
169
170
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________________________________________________________
17. Use a fixture or cribbing, stand spring assembly on inboard face of spring
housing flange.
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 in-

ternals with Molykote metal protector.
Take care not to coat mating surfaces, threads, plated or
bearing surfaces.
~
NOTE

KF3740.2.0, K3740.3.0 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.
171
4 - 20
172
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6. Install the spring housing cover cap screws and torque per drawing
B-GP-21 75.
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.
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.
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 jour-

nal cover and spring assembly is mounted on the pulv-
erizer. 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.
173
4 - 21
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CLASSIFIER DEFLECTOR
BLADE REPLACEMENT
NOTE
The following steps refer to Figures 14 and 15 and drawing
K3740.13.0 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.
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 to3.7 in. 94 mm). Tighten the ' M8 clamping bolt at
the end of the deflector link lever.
NOTE
If more than on e 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 be-
tween 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 placeiii back into opera-
tion.
175
4 - 22
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MAJOR ADJUSTMENTS
Roll-ring Clearance
The following procedure uses the journal stop bolts to set the roll-ring clear-
ance and must be performed before the journal spring assembly to journal
head clearance is set.
NOTE
The pulverizer must be 100% operational before this pro-
cedure can be done.
NOTE
The following steps refer to Figure 9 and Drawing
DURING THE PERFORMANCE OF THIS PROCEDURE

(STEPS 1. THROUGH 4.), THE PULVERIZER MUST BE
ISOLATED. THE COAL PIPE GATES AND COLD AND
HOT AIR GATES MUST BE CLOSED AND THE PULV-
ERIZER 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.
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.
4 - 23
155
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________________________________________________________
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 Figure 9 and KF3740.2.0 un-

less otherwise stated.
1. The journal spring assembly K3740.3.0 should be completely assembled

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 KF3740.2.0). 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.
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.
4 - 24
156
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________________________________________________________
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 KF3740.2.0 +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).
Journal Spring Position

NOTE

NOTE
This procedure must be done after the springs have been

preloaded and the roll-ring clearance has been set.
4 - 25
157
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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.
4 - 26
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ABB CE HP963 PULVERIZERS - MAINTENANCE

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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 Figure 17 and K3922.2.0 un-

less 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.
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.
4 - 27
159
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________________________________________________________
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.
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
4 - 28
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________________________________________________________
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 electrode

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.'
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.'
4 - 29
161
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________________________________________________________
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 com-
pounded 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 re-
duce 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.
THE WELDS SHOULD BE MADE AS QUICKLY AS POS-

SIBLE SO THAT A MINIMUM AMOUNT OF HEAT IS
TRANSFERRED TO THE LINERS. EXCESSIVE HEAT
WILL CAUSE THE LINERS TO CRACK.
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.
4 - 30
162
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________________________________________________________
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 re-

quired.
3. First (bottom) course has been installed improperly - check against the
print provided.
4. Improperly fabricated liners - check print provided.
TILE IS CRACKING
Too much heat - use smaller diameter welding rod. Decrease weld puddle and
fill.
WELDS NOT FUSING
1. Area contaminated- burn cement away [700°F (371 ℃)]

,
2. Surface scale - clean by grinding or sandblasting.
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:
4 - 31
163
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________________________________________________________
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.
PROTRUSIONS OR SHARP BREAKS BETWEEN LIN-

ERS CAN CAUSE EDDIES AND COAL/AIR FLOW DIS-
TURBANCES WHICH WILL ACCELERATE WEAR ON
THE ADJOINING TILES.
Installation Procedures for

Inner Cone Liners
NOTE
Reference Figure 14. Ceramic wear tiles and weld plugs

are supplied per Drawing K3740.14.0 A 5% overage is
shipped with each set.
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 re-
quired.
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.
6. Install tile beginning at the small end (bottom) of the cone. Proper align-
ment at this stage is critical,allow approximately 0.12 in.(3mm) be-
4 - 32
164
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________________________________________________________
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 proceed-
ing 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 Figure 14 and Drawing K3740.14.0
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.
4 - 33
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________________________________________________________
Installation/Replacement Pro-
cedures for Separator Body
Liners
NOTE

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 - 31. 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.
4 - 34
166
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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.
PULVERIZER LINER
INSTALLATION/
REPLACEMENT
NOTE
Reference the procedures 'Application of Weld Plugs'

P a g e 4 - 2 9 and 'I nst al l a t i on o f Ti l es - Ge ne ra l '
Page 4 - 30 for weld plug and liner application.
Outlet Venturi Vanes
Worn vane liners can be replaced on the outlet venturi and vanes assembly.
1. Remove old liners and clean surfaces.
2. Apply adhesives and position liners on the upper side of the outlet venturi
vanes. Ensure that the top corner of the liner is in line with the top corner
of the vane.
3. Insert and weld the weld plugs.
4. Fill over weld plugs and around perimeter of liners with Nordback, Dev-
con Martek, Duromar HAR or similar filler.
Outlet Plate,
Worn outlet plate liners can be replaced as follows:
1. Remove old liners and clean surfaces.
2. Apply adhesives and position the new liner on the outlet plate.
3. Insert and weld the weld plugs.
4. Fill over the weld plugs with Duromar HAR filler.
5. Fill gaps around the tiles with Moldit D
4 - 35
167
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ABB CE TYPE HP963 PULVERIZERS - ILLUSTRATIONS

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TABLE OF CONTENTS
TITLE FIGURE NO.
Foreword
General Arrangement Illustration
Millside and Liner Assembly .................................................................................... ......... 1
Millside Air Inlet & Vanes .................................................................................................. 2
Millside Inspection Door Assembly .......................................................................... ......... 3
Clearance Air Seal and Guard Assembly ................................................................ .......... 4
Bowl Hub and Skirt Assembly ........................................................................................... 5
Scraper and Guard Assembly ................................................................................. .......... 6
Bowl and Bull Ring Assembly ................................................................................. .......... 7
Vane Wheel Assembly ...................................................................................................... 8
Separator Body and Journal Stop Assembly ........................................................... .......... 9
Separator Body Liners ............................................................................................ .......... 10
Journal Opening Cover and Spring Assembly ......................................................... .......... 11
Journal Shaft Assembly .......................................................................................... .......... 12
Journal Head and Trunion Shaft Assembly ............................................................ ........... 13
Separator Top and Inner Cone Assembly .......................................................................... 14
Control Lever Assembly .................................................................................................... 15
Center Feed Pipe, Multiport Outlet and Venturi ...................................................... .......... 16
Discharge Valve with Cover .............................................................................................. 17
Discharge Valve with Liners and Air Cylinder .................................................................... 18
-i-
168
________________________________________________________
ABB CE TYPE HP963 PULVERIZERS - ILLUSTRATIONS

________________________________________________________
FOREWORD
The illustrations in this part of the manual are typical of the components sup-
plied by Shanghai Heavy Machinery Plant. The parts supplied with your pulv-
erizers may not be exactly as pictured.
Components are pictured in the order in which they would be assembled or

disassembled. This should help maintenance personnel to visualize and plan
for component maintenance.
169
170
170

Hp963 Pulverizer Installation, Operation and Maintenance

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ABB CE HP963 PULVERIZER

INSTALLATION,OPERATION AND MAINTENANCE

Contract Drawings .................................................................................. Part 1

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

PULVERIZER DESCRIPTION PART 1

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

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

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

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

PULVERIZER DESCRIPTION Part 1

TITLE PAGE NO.

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

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

ABB Combustion Engineering has developed a series of pulverizers which

The Pulverizer consists of:

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

5. Three independent, spring loaded journal assemblies are suspended

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

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

The illustrations used in the pulverizer manual are included to

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS PART 2

TITLE PAGE NO.

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

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

TABLE OF CONTENTS (Continued)

PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTSPART 2

TITLE PAGE NO.

DIFFERENTIAL PRESSURE CONTROLLER .............. ...................... 2-7

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

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

Components, when received, should be stored in accordance

USE CARE W HEN HA NDLING ASSEMBLIES WHICH

Plastic tapered plugs, plastic tapered caps, plastic pipe thread

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

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

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

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

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

2. Millside and seal air header assembly E

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

10.Gear box assembly (Refer to Manufacturer's instructions) C

11.Bowl, bowl hub, and vane wheel assembly E

12.Mill discharge valve and multiple port outlet assembly C

BOXED OR BUNDLED ITEMS

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

GEARBOX ASSEMBLY (Storage Type C)

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

OUTLET VENTURI AND FEED PIPE ASSEMBLY.MULTIPLE PORT OUTLET

EXERCISE CARE WHEN HANDLING THESE ASSEMBLIES.

MILLSIDE AND SEAL AIR HEADER ASSEMBLY (Storage Type E)

ABB CE TYPE HP963 PULVERIZER - INSTALLATION

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

JOURNAL HEAD AND TRUNNION SHAFT ASSEMBLY

JOURNAL OPENING COVER ASSEMBLY (Storage Type C)

SEPARATOR TOP ASSEMBLY (Storage Type E)

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

PULVERIZER DISCHARGE VALVE/MULTIPLE PORT OUTLET

EXERCISE CARE WHEN HANDLING THIS ASSEMBLY.

ABB CE TYPE HP963 PULVERIZERS - INSTALLATION

INNER CONE OR INNER CONE AND CERAMIC LINER SSEMBLY

IF CERAMIC LINERS ARE INSTALLED, USE CARE IN