INSTRUCTION MANUAL .

BALL MILLS 70000393-1

DucroBar lining for fine grinding
compartment

INSTALLATION

In text reference is made to the following

manuals etc.:

General safety regulations at sites of erection 32031

Safety Guards 39521
Cement mill, type UMS. Safety instructions
General instruction manual. Operation and maintenance
Bolted-on lining parts 70000375
STANEX diaphragm 70000373
Separately forwarded erection drawings

VIGERSLEV ALLÉ 77 - 2500 VALBY - DENMARK ‹ 2040 AVENUE C - PA 18017-2188 BETHLEHEM – USA ‹ CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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CONTENTS: PAGE:

1 General notes ................................................................................... 4

2 Construction and operating principle ................................................. 5
3 Installation ........................................................................................ 6
3.1 Initial operations. ............................................................................................................. 9
3.2 Tools required for installation. ....................................................................................... 10
3.3 Adaptation of lining plates. ............................................................................................ 11
3.4 Emptying of mill............................................................................................................. 11
3.5 Diaphragm and outlet grate........................................................................................... 12
3.6 Installation of lining. First third....................................................................................... 13
3.7 Installation of lining. Second third. ................................................................................ 14
3.8 Installation of lining. Last third ...................................................................................... 14
3.9 Installation of lining. Remainder of compartment.......................................................... 15
3.10 Tightening of bolts....................................................................................................... 15
4 Operation ....................................................................................... 16
5 Maintenance ................................................................................... 18
6 Appendices..................................................................................... 20

Edited by: KEl Translated by: JRo Pages:

29
Approved by: JVi MGN code:
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APPENDICES:

Standard DucroBar corrugated lining I

DucroBar classifying lining II

Lining at diaphragm and outlet head III

Tools for installation IV

Installation procedure V
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Note!
The present instruction manual is concerned with the situations
which, according to the experience of FLS, are the most likely to
occur. An exhaustive enumeration of all conceivable situations
which may occur during the installation, operation and
maintenance of the lining cannot be provided.

Consequently, if a situation should arise, the occurrence of which

is not foreseen in the instruction manual, and which the operator
is/or feels unable to handle, we would recommend that FLS is
contacted without undue delay for advice on appropriate action.

1. GENERAL NOTES
The DucroBar lining for the fine-grinding compartment of ball mills is a
semi-boltless lining, the primary purpose of which is to protect the mill
shell against wear and, due to the shape of the lining, to enhance the
grinding efficiency of the mill.
The lining which is made of cast iron with a high chromium content is
extremely wear-resistant, but its impact strength characteristics are
limited due to the high hardness level. For this reason, it is of
paramount importance to ensure that these relatively brittle lining
plates are handled with extreme care in connection with the handling
and installation at site. The lining plates must never be thrown about
or thrown randomly onto a pile atop one another since pressures
resulting from impacting and stress loading may result in breakage of
the plates. This applies particularly to the long and relatively thin bars.
Furthermore, the lining plates must never be subjected to bending
stresses while tightening of the bolts is being carried out.
However, if properly handled and installed the DucroBar lining will
normally have a long service life in comparison with most other types
of linings and materials.
Any minor cracks incurred by the lining plates due to rough handling
may cause the lining plates to crack during operation, resulting in
dislodgement (drop-out) of the plates. This will lead to a situation
where the heavy lining fragments will inflict damage to the remaining
lining plates, and the unprotected mill shell will be subjected to wear
exposure/damage.
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2. CONSTRUCTION AND OPERATING PRINCIPLE

The DucroBar lining for the fine-grinding compartment is available
either as a standard corrugated lining (see Appendix I) or as a
classifying lining (see Appendix II). Whereas the standard corrugated
lining is used together with small grinding media, normally balls with a
diameter of 15-25 mm, the classifying lining is used with balls having a
broader range in terms of diameter, e.g. from dia. 15 to dia. 50 mm.
The operating principle of the classifying lining involves that, during
operation, the largest balls are forcibly driven towards the diaphragm,
i.e. to the feed end of the grinding compartment, so that the smallest
balls will be found near the outlet end of the compartment. This type of
sorting of grinding balls will result in enhanced grinding efficiency.
The corrugated surface of the DucroBar lining will ensure that the mill
charge is lifted to an appropriate level to enable the mill to absorb the
desired power, while simultaneously preventing the charge from sliding
against the lining, which would otherwise result in heavy wear on the
lining and balls.
The standard DucroBar corrugated lining must not be used together
with balls larger than 50 mm, whereas the classifying lining can be
used with balls to a size up to 60 mm.
Both types of lining consist of bolted-on retaining rings (01,02), with
boltless lining plates (rods, 03) fitted between these rings and
tightened by wedging in the circumferential direction. As an additional
safeguard against drop-out of rods, both ends of the rod (03) feature
oblique end faces engaging with points under similar oblique side
faces on the bolted-on retaining ring segments (01, 02). See
Appendices I and II. In the axial direction, the clearance between the
retaining rings and rods must be filled, wherever this can be done, by
means of 70º angle iron intermediates (04) to prevent the rods from
dropping out because of an excessive clearance.
Wedging in the circumferential direction is done by means of
intermediates (05) of different thickness. The shape of these
intermediates corresponds to that of the rods, i.e. they will also be
brought into engagement with a point under the retaining rings,
thereby preventing them from dropping out.
The distance between the bolted-on retaining rings may vary from mill
to mill, but also for the mill in question. In modern mills, the distance
between the retaining rings will normally be 1000 mm. In older mills,
the distance between the rings may be 800 or 750 mm.
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Fixation of the rods at the diaphragm and outlet grate can be done in
different ways, dependent upon the design of the mill. Appendix III
shows different methods. Fig. A and B are the methods most
commonly used for modern UMS-mills. Reference is made to the
specific erection drawing for the method applied in the specific case.

3. INSTALLATION

The directions outlined in instruction manual No. 32031 "General

safety regulations at erection site" must be strictly observed at the site
of erection.
This instruction manual must be scrutinized by the client, the erection
supervisor, the erection contractor and other parties involved before
erection work is started.

SAFETY!
In order to provide a safe working environment for the erection
personnel, it is essential to ensure – regardless of the method
of erection – that stable scaffolding and platforms with railing are
provided around the worksite throughout the erection process.
In connection with the performance of any activities in, on
or under the mill, the main motor, the auxiliary drive or any
other temporary drive mechanism MUST be de-energized
through switching-off and lockout of the high-voltage
circuit breaker. It must only be possible for the supervisor
in charge of operations to cancel the lockout.
Locked safety guards etc. must always be fitted around
rotating parts such as auxiliary drive or any other
temporary drive mechanism.

It it is essential to ensure that there are no persons inside the mill, on or

under the mill prior to initiating any turning operation, given the danger of
structural collapse or exposure to falling parts.
Operators involved in work on mill, or in or around the mill, MUST
wear helmets and safety footwear.
Dust masks should be used to extent deemed necessary (for
example, in connection with clean-up operations) and hearing
protectors must be used by anyone involved in activities inside the
mill building when the mill is in operation or if noise-intensive tools
(such as angular grinders, jackhammer drills or pneumatic spanners)
are used.
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Goggles MUST always be worn by operators involved in grinding and

torch-cutting operations.
Working gloves should be always be used in connection with the
installation of lining plates.
Imbalance of mill (due to mill being side-heavy) will often occur in
connection with the installation or replacement of lining parts.
Therefore, when work is done in or on the mill, safeguards must be in
place to prevent abrupt turning of mill, for instance by means of the
brake on turning gear or through wires fixed between mill shell and
anchor bolts in the floor. When the mill is to be turned in side-heavy
condition, it is of crucial importance to ensure that the mill is fully
controlled at all times and that inadvertent rotation of the mill is
prevented by means of wires and chain blocks.
If during the installation of the lining parts, the mill is to be turned by
means of the auxiliary drive equipped with overrunning claw
coupling, the lining must always be installed so that the side-heavy
mill will always exert a pressure on the coupling in the correct
direction. Otherwise, the risk of the claw coupling being suddenly, and
inadvertently, engaged will be quite substantial, and this will cause
the mill to turn in uncontrolled manner.
The installation of heavy mill parts, such as lining plates, involves risk
of such parts falling down, potentially causing injuries to personnel or
damage to equipment, if improperly handled. Consequently, effective
safeguards are needed to eliminate such risks in connection with the
lifting of heavy parts.
For weights of the mill parts involved, reference is made to the
weights indicated provided in the mill parts list.
For use of power tools and working lamps and other general safety
regulations, reference is made to instruction manual 32031.

Where ERECTION CHECK is specifically called for in the

erection manual, this means that the FLS erection supervisor
must inspect and approve the parts mounted before permission
to proceed with the erection work can be given.

IMPORTANT!
Extreme care is needed when handling and installing the
heavy mill parts in order to avoid a situation where such
parts are dumped or dropped onto the unprotected mill
shell and the slide rings. Indentation marks on the
dynamically stressed mill body is liable to give rise to
crack formations at subsequent point in time.
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Welding as well as torch-cutting operations must never

be performed on the mill shell since this will also give
rise to crack formations.
For example, when lining plates are lifted into the mill through the
manhole of the mill, the utmost care is needed to prevent
damage to the manhole edges. For avoidance of such damage,
the edge of the manhole may be equipped with a protective frame
made of wood or angle irons.
If the mill body is damaged in any way, such damage must NEVER
be repaired by welding, but only through very careful smooth-grinding.
FLS must be notified before such repair work is
undertaken.
In case of bolt holes on the mill body which will not be needed, such
holes must ONLY be closed using conical rubber plugs which must be
glued in place. Redundant bolt holes must never be closed
by welding since such welding will leave stress
concentrations which are so substantial that they will
cause cracking of the mill shell at subsequent point in
time.
With the exception of welding specifically mentioned on
drawings and in instruction manuals, it will not be
acceptable to perform any type of welding or repair
welding on mill body or any other severely stressed mill
components, such as the girth gear.
Whenever turning of the mill is required during the erection process, it
is of the utmost importance to ensure proper lubrication of the
slide shoe bearings to prevent total degradation of the white metal
(seizure). Therefore, the high-pressure pumps MUST always be in
operation while the mill is being turned.
The mill must never be turned if there are any loose parts (such as
lining plates etc.) inside the mill due to the risk of damage to the mill
shell (if unprotected) or the risk of the parts falling out through the
manholes, involving risk of injuries to the operating personnel.
FOR FURTHER INFORMATION, REFERENCE IS MADE TO
THE INSTRUCTION MANUAL MENTIONED ON THE FRONT
PAGE OF INSTRUCTION MANUAL: ”Cement mill, type
UMS. Safety instruction manual”
For the installation of Stanex diaphragm and bolted-on lining plates,
reference is made to separately forwarded instruction manuals.
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3.1 Initial operations

Turn the mill so that the manhole nearest the outlet hole is in bottom
position.
Clean very carefully the inner surface of the mill shell and check for
irregularities such as weld spatter, excessive convexity of welded
seams etc. which may prevent good contact between lining plates and
mill shell. In older mills, it is of particular importance that irregularities
in the form of set cement are removed completely.
In old mills, the mill shell may be affected by wear or corrosion. In
severe cases, it may be necessary to repair the surface by grinding
and subsequent filling-up of the recesses.
FLS should be contacted in such cases.
In connection with the filling-up of recesses, it is very important to use
a material having good bonding characteristics in relation to steel, with
capability of setting to a reasonable level of hardness and being
resistant to temperatures of up to approximately 125°C. Furthermore,
it must have a consistency making it suitable for application, using, for
example, a spatula.
IMPORTANT!
Attempts must not be made under any circumstances to
fill up by welding any worn or corroded areas, since, in
all likelihood, this will cause crack formations on the
mill shell at subsequent point in time.
In connection with the installation of new linings in older mills, it will in
certain cases be necessary to drill some additional bolt holes, most
often around manholes, or existing bolt holes have to be expanded by
drilling to a larger diameter. For such operations, it will be possible to
use drilling machine with a magnet base and an ordinary twist drill.
Existing bolt holes which cannot be used in connection with the new
lining must be plugged, using, for example, conical glued-on rubber
plugs. The holes must never be plugged by welding!
For positioning of new bolt holes and plugging of existing holes,
reference is made to separate erection drawing.
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Sometimes, it may be necessary to blank off a manhole if the lengths

of mill compartments are changed. In such instances, it is essential to
ensure that the blanking-off plate is flush with the inner side of the mill
shell; otherwise, it will not be possible to achieve satisfactory contact
between the lining plates and the mill shell. If the blanking-off plate is
not flush with the mill shell, it may become necessary to either insert
an intermediate between the outer side of the mill shell and the plate
or to increase the height of the blanking-off plate in inward direction,
for example by tack-welding a thin plate to the inner side of the
blanking-off plate.
ERECTION CHECK
3.2 Tools for installation
Normally, the mill will be provided with an auxiliary drive unit to
facilitate turning of the mill when necessary during the erection
process. However, small and older mills may have been supplied
without any auxiliary drive unit, and in such instances the client or the
erection contractor must ensure availability of alternative equipment
for turning the mill, for example a mobile crane.
If such a crane is used, it will be necessary to make one or several
lifting fittings at site; these fittings can be bolted to the mill shell
through existing bolt holes. At least two bolt holes must be used for
fixation of a lifting fitting. A drift punch (mandrel) must never be used
in the bolt holes since the edge of the holes will be deformed, entailing
risk of cracks occurring at the hole at subsequent point in time.
Furthermore, this method is dangerous since the drift
punch may slide outwards, leading to a situation where
the side-heavy mill will turn in uncontrolled manner
while work is in progress in and on the mill. Therefore, it
is very important that the mill is always maintained in its
position by means of wires in order to prevent any
sudden, uncontrolled turning from occurring.
Lifting fittings must NEVER be welded directly to the mill
shell since this may give rise to subsequent crack
formations.
Since many lining plates are very heavy, it will often be necessary to
install appropriate lifting gear inside the mill, for example a pulley or
tackle. For weights of the individual lining plates, reference is made to
the weight indications in the mill parts list.
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The erection irons (20) – shown in Appendix IV – are used for

retention of the boltless lining plates (rods, (03) while the mill is being
turned. In connection with new mills, these erection irons are normally
supplied by FLS together with the lining, but in the case of spare parts
supplies they are manufactured locally, based on drawing
documentation forwarded by FLS. See also separate erection drawing
for application of erection irons.
For compression of the lining rods in connection with the termination
of a ring (belt section), a small hydraulic jack is supplied together with
the above-mentioned erection irons.
Lining bolts must always be tightened to the specified torque, using a
torque spanner which is normally supplied together with the lining.
It is a foregone conclusion that normal hand tools are available at site.
3.3 Adaptation of lining plates.
In case of problems occurring in connection with the installation of
lining, being ascribable either to oversized lining plates or mill shell
inaccuracies, it may become necessary to adapt a number of lining
plates.
This must only be done through careful grinding, without
giving rise to substantial localized heating. Torch-
cutting and welding operations must not be carried out
since they may give rise to subsequent crack
formations.
3.4 Emptying of mill.
Whenever the mill is to be turned during the erection process,
lubrication of the mill bearings is of crucial importance to avoid
total degradation of the white metal (seizure). Therefore, the high-
pressure pumps MUST always be in operation while the mill is being
turned.
For smaller, older mills without high-pressure pumps, the lubrication
rings of the bearings must be manually turned a couple of times in
order to feed a certain amount of oil to the bearings.
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3.5 Diaphragm and outlet grate

See Appendix II and separate instruction manual for Stanex
diaphragm.
Normally, the installation of the DucroBar lining is not commenced until
mounting of the supporting parts (supporting plates) for diaphragm
(10) and outlet grate (11) has been completed. For new mills these
parts are usually shop-fitted in the workshop undertaking the
manufacture of the mill. In UMS-mills, the supporting plate (11) for
outlet grate contributes towards supporting the lining plate (12) at
outlet slide ring (Fig. B). For other methods of retention, as illustrated
in for example Fig. F, the mounting of the supporting plate of the outlet
grate will also be necessary.
Because of the tolerance on the length of the mill shell, the distance
between the last row of bolts of mill shell and the webplate of the slide
ring may become so substantial as to generate an excessive axial
clearance between the rods (03) and retaining ring (01,02) and lining
plate (12) at slide ring. If the clearance is more than 4 mm, it will be
necessary to tack-weld an intermediate plate (14) to the front side of
the supporting plate so that the lining plate (12) is displaced towards
the rods, thereby minimizing the axial clearance. In similar manner,
intermediates can be inserted behind the retaining ring (13) for the
retention method illustrated in Fig. F.
NOTE!
Intermediates or any other parts must never be welded directly to the
slide ring or the mill shell, but only to the supporting plate for outlet
grate.
ERECTION CHECK
The boltless lining plates (12) at the outlet slide ring must be evenly
distributed on the circumference during installation. To prevent
excessive distances between some of the liners, the supplied angle
irons (15) – having a length of 100mm - must be inserted in as many
places as possible. The clearance between the plates must not be
more than 6 mm at any point. To prevent the plates (12) from being
dislocated or falling out when the mill is turned, a number of
provisional plate sections can be fixed by welding to the front side of
the supporting plate (not on mill shell or slide ring!).
Also, to prevent tilting of the plates (12), plate sections (16) can be
fixed by welding in the radial clearances between the supporting plate
(11) and plates (12). These plate sections must remain fitted.
 70000393-1 13

The bolted-on type of retaining ring (13) at the outlet head (Fig. F) is
often mounted on the supporting plate of the outlet grate by means of
T-head bolts (17). First, these bolts are placed in the hole of the
retaining ring, and the retaining ring can then be mounted using a
special tool attached to the bolt end, turning/pulling the T-head bolt to
its proper position on the supporting plate. The notch in the threaded
end of the bolt indicates the direction on the bolt head. It is very
important to ensure that the bolt head is correctly
positioned relative to the hole in the supporting plate,
i.e. at right angles to the hole, since, otherwise, the
retaining ring will fall off.
3.6 Installation of lining. First third.
With the manhole at the outlet end in lowermost position, the operation
is started by mounting the lining rods (03) in the belt section nearest
the outlet grate by pushing the rods under the lining plate (12) at the
outlet slide ring (UMS-mills). The rods must be absolutely parallel to
the mill axis. Gradually as the rods are fitted, the bolted-on retaining
ring segments (01,02) must be mounted at the other end of the rods.
The individual retaining ring segments must be centered exactly above
the bolt holes in the mill shell and must be flush in the circumferential
direction. Mount, wherever possible, the supplied angle irons,
25x25x3, in the recesses at the end of the retainer ring segments. This
must be done to prevent excessive movements of the segments during
operation. DO NOT FORGET to check constantly the axial clearance
of the rods. If the clearance is more than 4mm, the supplied 70° angle
irons (04) must be fitted in the recess at one end of the rods. If the
clearance is still more than 4mm, it will be necessary to tack-weld a
thin plate to the angle iron in order to reduce the clearance as much
as possible. If the rod cannot be accommodated due to inadequate
space, i.e. if the rod is too long or if the distance between the last row
of bolts and the outlet slide ring is too short, it will be necessary to
grind off - exercising due caution - some of the 5mm high crusts at one
end of the rod.
NOTE! Orientation of classifying retaining rings to be
such that the oblique face is pointing towards the mill
inlet. See Appendix II and separate erection drawing.
Lining plates are mounted on about one-third of the circumference
(Fig. A in Appendix V). The bolts for the retaining ring must be
provided with sealing discs (07). On older mills, the size of the bolt
holes in the mill shell may be larger than actually required, and in such
cases a combined guide bushing and sealing disc must be used (see
separate erection drawing).
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Bolts must not be inserted in the retaining ring segments at the ends
of the mounted area since these bolt holes must be used for the
bolting-on of erection irons (20) for retention of the rods (03) when the
mill is turned.
In the second-but-last belt section before the outlet head, rods (03)
and retaining ring segments (01,02) must also be mounted on about
one-third of the circumference.
The lining plates (08) must be mounted on each side of the manhole in
the belt section with manhole. The plates must be mounted so that
they are absolutely parallel to the axis, and the bolts must be equipped
with sealing discs (07).
The erection irons (20) must be mounted so that the pressure screws
(21) force the rods together, preventing them from being dislocated or
falling out when the mill is turned (see Appendices IV and V as well as
separate erection drawing for application of erection irons).
3.7 Installation of lining. Second third.
The mill must now be turned through 1/3 revolution. DO NOT
FORGET the lubrication of bearings! There must never be
any persons or heavy parts in or on the mill while the mill is being
turned. The lining parts for the next one-third of the mill circumference
in the two belt sections nearest the outlet end must be mounted as
described in sub-section 3.6, again terminating the operation by
means of erection irons (20). See Fig. B in Appendix V.
ERECTION CHECK
3.8 Installation of lining. Last third.
Again, the mill must be turned 1/3 revolution so that the last unlined
part of mill shell is now facing downwards. See Fig. C in Appendix V.
The rods (03) must be fitted in their proper positions, with the
exception of the last rod. The entire lining section must be forced
lightly together, using the small jack – included in the supply – placed
in the last opening. Place a steel plate between jack and rods in order
to distribute the pressure exerted on the rods. Then determine the
exact distance between the contact faces of the rods. If the distance is
more than 235mm, a three-wave rod (25) must be used along with
intermediate plates (05) in order to fill out the last gap. If there is
inadequate space to accommodate the three-wave rod, a normal rod
should be used along with intermediate plates (05) for filling out the
gap. Simultaneously with the measuring of the distance, it must also
be checked that the distance is the same across the two sets of
contact faces, i.e. whether the rods are positioned in parallel. If not,
compensation is needed by welding on a thin plate at one end of one
or several intermediate plates.
 70000393-1 15

The intermediate plates must not be mounted together between two

rods, but must be distributed so that there is only one intermediate for
each of the last rods ahead of the location where the belt section is
terminated. Furthermore, it will always be necessary to use as few
intermediate plates as possible, i.e. 10 mm thick intermediates should
primarily be used. The last rod in a belt section must be well
tensioned, and, therefore, a lead hammer must be used to position the
rod axially. It will be easier to introduce the last rod if a thick
intermediate plate (05) can be fitted on either side of the rod.
Finally, the erection irons (20) must be dismantled, and the normal
lining plates with sealing discs must be fitted in the last retaining ring
segments.
3.9 Installation of lining. Remaining part of compartment.
The remaining belt sections in the fine-grinding compartment must be
mounted in the same way as described above. No more than two belt
sections should be mounted at a time; otherwise, there is a risk of the
mill getting overly side-heavy.
If there are two manholes diametrically opposite one another, the
installation of lining is started from both sides of the one manhole
which is facing downwards. From this point, work is carried on towards
the second manhole. This involves risk of having to use two rods with
a three-wave pattern (25) in this belt section.

The last belt section to be terminated must be lying next to a belt

section with a manhole so that the manhole area can be used to
hammer the final rod into position.
ERECTION CHECK
3.10 Tightening of bolts.
All lining bolts must be tightened to the specified torque level, which is
450 Nm for M30x2-bolts. A torque spanner must be used for this
purpose. During tightening-up operation, the bolt must be impacted by
using a hammer to apply blows to the bolt head.
16 70000393-1

Prior to the mounting of bolts, it is essential to check the condition of

the thread on all bolts and nuts and the threads must be lubricated
with machine oil containing molybdenum disulphide additives
(Molycote or similar grade) in order to minimize friction.
For tightening-up of other bolt sizes and of bolts where the nut is
located inside the mill, reference is made to separate erection
drawing.
After the mill has been put into operation, the bolts must be re-
tightened until the torque remains constant; the first time after 8 hours
of operation and then for every 12 hours of operation.
ERECTION CHECK

4. OPERATION
Prior to grinding media being charged to the fine-grinding
compartment, it must be checked that the lining has been installed in
correct manner, that all bolts have been tightened to the specified
torque level, and that all erection tools and other items used during the
installation procedure have been removed from the mill. Presence
of heavy foreign objects in the mill may lead to the
destruction of the lining after a short period of
operation.

ERECTION CHECK
Close all manholes, except one manhole which must be placed in top
position; this manhole must be used for the charging the grinding
media. Do not charge all the balls through the same manhole, but
distribute the grinding balls to both ends of the compartment. Do not
forget to mount the manhole covers (09) with the supplied rubber
packings. The tightening torque for the bolts for covers, M42x3: 1200
Nm
The compartment must be filled with the specified quantity of grinding
media. The full quantity of grinding balls is not normally charged into
new mills at the initial stage. Hence it will be possible to adjust the
composition of balls during the running-in of the mill. To safeguard the
mill gear unit, the mill must not under normal circumstances be
operated at less than 80% of its installed power.
 70000393-1 17

In the fine-grinding compartment of the mill, the largest balls must be

charged through the manhole nearest the diaphragm and the smallest
balls through the manhole nearest the outlet end. This is of particular
importance in grinding compartments featuring a classifying lining
since there will normally be a greater difference between the largest
and the smallest size of balls. If the largest balls are located at the
outlet end of the mill, this will have a negative effect on the grinding
efficiency.
NOTE! Balls in sizes larger than 50 mm must never be used
together with the standard DucroBar corrugated lining. If a classifying
lining is installed, balls in size up to 60 mm can be used.
Close the last manhole.
Check that all tools and other erection parts have been removed from
the upper side of the mill and that any wires which have been used for
fixing the mill during the erection process have been dismantled.
ERECTION CHECK
During operation, the mill must be checked for tightness, i.e. to ensure
that there is no leakage of material at bolts and manholes. Also,
listening must be done to determine whether there are any abnormal
sounds indicative of drop-out of lining plates or heavy foreign elements
in the charge load.
If any irregularities are observed, the mill must be
stopped immediately and an inspection must be
conducted.
After the mill has been in operation during a period of approximately 8
hours, all lining bolts must be re-tightened to the specified tightening
torque. See sub-section 3.10.
One of the manholes must be turned in the top position and opened.
The entire lining must be carefully inspected for cracks and dislodged
lining plates and any other irregularities. In order to allow an inspection
of that part of the lining which is hidden under the charge load, it will
be necessary to reclose the manhole, and to turn the mill through
180°, subsequently opening another manhole.
For every 12 hours of operation, the lining bolts must be re-tightened
until the tightening torque remains constant. During this process, an
inspection of the lining should be conducted.
It is of crucial importance to the service life of lining and grinding
media that the mill is always operated with an appropriate amount of
material in the compartment. A too small quantity will lead to
premature wear of the lining plates and grinding balls. In connection
with any shutdown of mill, the feed to the mill should not be stopped
more than 2-3 minutes prior to such stoppage.
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5. MAINTENANCE
Alter all lining bolts have been re-tightened until the specified torque
level remains constant, the lining does not require any particular
maintenance. However, the lining plates must be checked, on a
regular monthly basis, for wear, cracks and dislodgement. The
wear, or the residual thickness, on the single lining patterns must be
measured and recorded on an ongoing basis to allow an assessment
of the residual service life to be made, so that a new lining can be
ordered at an early stage. In principle, the lining can be used up to the
point of lining breakage or wear-through occurring. In case of lining
plate breakage and if a part of the plate has dropped out, it is of the
utmost importance to locate the fragments in the charge load;
otherwise such fragments will damage the other lining plates in the
compartment. Furthermore, the unprotected zone of the mill body will
be subjected to wear exposure/damage, involving risk of subsequent
crack formations. So, gradually as the lining parts are being worn
down, the inspection intervals should be narrowed or the lining should
be replaced before the mill body sustains damage.
For a full-scale inspection of the entire lining to be conducted, it will be
necessary to close the mill and to turn it through 180º in order to
inspect that part of the lining which was previously hidden under the
charge load in the mill.
Dismantling of worn lining parts.
The bolt head in the worn-out lining plates will normally be deformed to
such an extent that it will not be possible to dismantle the bolts from
the plates in normal manner. Since the bolts cannot be re-used, we
would recommend that the nut is screwed off, with subsequent
removal of the entire lining plates with the embedded bolt.
 70000393-1 19

Only if it is impossible to unscrew the nut, consideration should be

given to the option of cutting off the bolt end with the nut by means or
torch cutting or with a cutting disc, or by melting away the bolt head by
means of carbon-arc cutting. If any of the latter methods are used, this
must be done with the utmost caution in order not to
damage the mill shell! Cutting scars on the dynamically stressed
mill shell will inevitably give rise to crack formations at some
subsequent point in time. Such scars must be carefully smoothened by
grinding, and inspected for cracks, and henceforth crack inspections
must be conducted twice a year. Scars or any other damage sustained
must NEVER be repaired by welding! Attention is also drawn to the
fact that scars and grinding of scars will make it difficult to reseal the
bolt hole by means of new sealing discs.
IMPORTANT! Dismantling of worn-out linings is
extremely dangerous work, particularly the semi-boltless
linings, given the risk of sudden dislodgement and fall-
out of lining plates. It is therefore essential to ensure
that ALL necessary precautions are taken to avoid
injuries to personnel carrying out work in and around the
mill.
If worn lining plates are thrown through the manhole, landing on top of
one another on the floor, there is a major risk of stray steel splinters
and debris flying about. This is a dangerous situation, entailing
significant risk of eye injuries, and, therefore, the necessary
precautions must be taken to avoid injuries.
After the lining bolts have been relaxed, it is very important that the
plates are not allowed to fall down directly onto the unprotected mill
shell or causing damage to the manhole edges when they are removed
from the mill. Therefore, the mill shell must be adequately
protected to avoid damage to shell!
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6. APPENDICES

Appendix I
01 Retaining ring, standard corrugated lining
03 Boltless lining plate (rod)
04 70 o angle iron
05 Intermediate
06 25x25x3 mm angle iron
07 Sealing discs
08 Lining plates at manhole
09 Manhole cover
70000393-1 21

I
22 70000393-1

Appendix II
02 Retaining ring, classifying lining
03 Boltless lining plate (rod)
04 70 o angle
05 Intermediate
06 25x25x3 mm angle iron
07 Sealing discs
08 Lining plate at manhole
09 Manhole cover
70000393-1 23

II
24 70000393-1

Appendix III

10 Supporting parts for diaphragm

11 Supporting plate for outlet grates
12 Lining plate at outlet slide ring
13 Retaining ring at outlet head
14 Intermediate plate
15 Angle iron
16 Plate sections
17 T-head bolt
70000393-1 25

III
26 70000393-1

Appendix IV

01 Retaining ring
03 Boltless lining plate (rod)
20 Erection iron
21 Pressure screw
22 Jack
70000393-1 27

IV
28 70000393-1

Appendix V

05 Intermediate
25 boltless lining plate with three-wave pattern (rod)
70000393-1 29