VERTICAL RO

Equipment COAL MILL Equipment Type

Failure Mode Failure Description Causes
Component
Over Load Motor overloading due to 1. High Voltage
mechanical or electrical 2. Process overloading
unbalance

Rotor damage Electrical Unbalance 1. Repeated start/stop

2. Starting current high and
too long
3. Pulsating load

Winding Motor stator winding 1. Loss of motor cooling

failure damage 2. Weak insulation

Mill A Motor

Bearing Motor DE or NDE bearing 1. Lube oil system problem

damage issues 2. Misalignment of motor
shaft.

Wear & Tear Grinding table and Rollers 1)Improper roller to

wornout . Grinding table gap.
2). Abrasive objects
in Coal feed

Grinding
Roller/table
Grinding
Roller/table
Roller Roller worn out 1) Less Hydraulic pressure
damages on spring force .

Vane damage Vanes puntures 1)Abrasion . 2) Vanes

wrongly set and loosness
Classifier
Motor failure Overloading Mill Feed and PA in excess
than rated
Gear teeth Gear teeth broken out 1) Lube oil quality
crack 2) Excessive Mechanical &
thermal stresses 3)
Foundation Bolts looseness

Gear Box
Beairng Gear Box Bearings Issues 1) Lube oil system issues.
damage 2.Misalignmment
3) LO contamination on
Oil seals failures and coal
dust ingress

Pump failure Pumpcomponents issue 1) Impeller worn out

2) Bearing Seized.

Motor failure Motor jam or shorted 1)Motor winding /

Lube oil insulation failed
system 2) Motor Bearing
seized
Filter damage Filter busrt 1) Filter DP switch faulty
2) LO Contanminated

Hydraulic oil Pumpcomponents issue 1) Impeller worn out

pump failure 2) Bearing Seized.

motor failure Motor jam or shorted 1)Motor winding /

Hydraulic insulation failed
system 2) Motor Bearing
seized
Hydraulic
system

filter damage Filter busrt 1) Filter DP switch faulty

2) LO Contanminated
 VERTICAL ROLLER MILL ASSET RCM ASPECTS

VERTICAL ROLLER Make & Model

Effects (Impact) Remedial Actions Detection Parameter /
KPI
Over heating and Trip Control the voltage level by adjusting the Voltage in all three
tap changer and monitor surge arrester phases
healthiness.
Reduce the coal feeding Motor Current three
phases
Winding Temperatures

Mill Delta Pressures

Rotor bar, End ring and 1. Avoid frequent start/stop and OEM Motor Current
lamination damages recommended time delay between start
and stop.
2. Ensure balanced loading of mill motor Motor voltage
and take mill rejection timely
Motor vibration

Over heating and Trip Ensure proper cooling water quality, Winding Temperature
pressure, temperature and flow
balance the voltage in all 3 Phases Voltage Imbalance

Check IR values periodicaly and ensure Cooling water flow

healthiness of winding
Vibration and Motor trip / 1. Ensure proper lube oil pressure and Motor bearing DE
seizure tempeature is maintained at each bearing Temperature
2. Ensure proper lube oil quality as
recommended by OEM is being Motor bearing NDE
maintained by analysiing the lube oil Temperature
samples at regular intervals Lube oil temperature
3. Check alignment of motor shaft and
load side shaft and coupling during the
scheduled maintenace.

Lube oil pressure

Lube Oil Quality

Vibration rise ans trip 1)Inspect the roller surface & dimensions Vibrations Sound
during monthly / regular maintenance and level
repair or change the roller if required.
2) Check no metal or abrasive
objects like pyrites / metal pieces fed in .
Vibration rise ans trip Adjust spring force and gap with Grinding 1) Vibrations. 2)
table regularly with Hydrualic oil pressure . Mill Fineness & UBC

Classifier Performance Ensure proper mill inlet pressure and Mill fineness decrease
reduced classifier speed is set to avoid vane UBC & CO increase
damage

Classifier trip on Motor Ensure Prpoer vanes angle setting and Mill Classifier Current
protection. Mill loading limits.
Vibration increase and trip 1) Gear Lube oil load bearing rating Gear box casing &
and damages analysis. 2) Shaft vibrations
Loading limils and regular checking Gear
teeth flank surface. 3)Gear teeth back
lash error correction with Blue matching
and lapping. 4) Check for alignemnt during
regular maintenace 5) Check
regularly Foundation bolts and Gear Box
casing temperatures.
Gear Box Operating
sound changed to
whistling Lube
Oil analysis

Bearing tempeature and 1) Check LO Pump healthiness to ensure LO pressure

Vibration increase & trip proper lube oil pressure and temperature
are maintained 2) Check the Oil
seals of Gear box 3) Check alignemnt Bearing temperatures
of the Gear train shaft
Vibration

LO quality and
alignment check

LO pump trip and standby Take pump change over regularly and Discharge pressure
Cut in carry out preventive maintenance. Bearing tempeature
Bearing vibration

Motor trip and transient Motor current

loss of LO

Bearing damages on Ensure proper lube oil quality is Filter DP

contanmination maintained. Calibrate the filter DP
regularly for accurate measure of filter DP

LO pump trip and standby Take pump change over regularly and Discharge pressure
Cut in carry out preventive maintenance. Bearing tempeature
Bearing vibration

Motor trip and transient Motor current

loss of LO
Bearing damages on Ensure proper lube oil quality is Filter DP
contanmination maintained. Calibrate the filter DP
regularly for accurate measure of filter DP
Periodicicy Source of Observation Change Type Weightage
Measurement Change
Minute Continuous Value Trend Step Increase 0.4
Measurement
Minute Continuous Value Trend Slow Increase 0.4
Measurement
Minute Continuous Value Trend Gradual Increase 0.1
Measurement
Minute Continuous Value Trend Gradual Increase 0.1
Measurement
Minute Continuous Value Trend Step Increase 0.4
Measurement
Minute Continuous Value Trend Step Increase 0.4
Measurement
Minute Continuous Value Trend Gradual Increase 0.2
Measurement
Minute Continuous Value Trend Step Increase 0.4
Measurement
Minute Continuous Value Trend Slow Increase 0.2
Measurement
local 3 months wise and Inspection Step Increase 0.4
on need. Report
Minute Continuous Value Trend Slow Increase 0.1
Measurement
Minute Continuous Value Trend Slow Increase 0.1
Measurement
Minute Continuous Value Trend Step Increase 0.2
Measurement

Minute Continuous Value Trend slow decrease 0.4

Measurement
Local & once in 3 months Inspection Gradual deterioration 0.2
External Lab Report

Minute Continuous Value trend Gradual deterioration 0.4

Local Measurement Inspection
Local Report
Minute Continuous Value trend Gradual decrease 0.6
Local Measurement Lab Inspection slow increase
Report Report

Local Monthly and on Inspection Gradual deterioration 0.6

need Report

Minute Continuous Value trend Step Increase 0.4

Measurement
Minute Continuous Value trend Step Increase 0.6
Measurement

Local shift wise for Log and Gradual Increase 0.4

soundand LO Inspection
analysis once report
in 3 months

Minute Continous Trend value Step increase 0.4

Measurement
Minute Continous Trend Value Step increase 0.3
Measurement
Minute Continous
Measurement
Local Once in 3 months Lab and Gradual 0.3
and on Need Inspection Deterioration
report

Minute Continuous Trend value Gradual deterioration 0.2

Measurement

local shift wise Log and step increase 0.3

Inspection
report

local shift wise Log and step increase 0.5

Inspection
report

local shift wise Trend value Gradual deterioration 0.2

local shift wise Log and step increase 0.3

Inspection
report
local shift wise Log and step increase 0.5
Inspection
report
Vibration
Mill DP
Mill motor
current