2 Product BA 35011

PRODUCT STANDARD STD NO.

Rev No. 5
TD-106-1

PULVERISERS
Form No.
Rev No 01
HYDERABAD Page 1 of 6

HPMS SYSTEM( SINTERCAST) FOR BOWL MILLS

1. GENERAL:

This specification governs the procurement of grinding elements consisting of Insert

type centrifugally cast Rolls in Sintercast metallurgy, Sintercast bull ring segments
and air port ring assembly from M/s. AIA Engg. Ltd. only as per the MOU for
BHEL supplied Bowl mills.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
It must not be used directly or indirectly in any way detrimental to the interest of the company.

2. MATERIAL CODE : Ref. Sheet 5 of 6

3. QUANTITY/ MILL
1) 3 nos. of centrifugally cast inserted grinding rolls in Sintercast metallurgy.
2) 1 set of Sintercast Bull ring segments.
3) Air port ring assly.
4. GRINDING ROLL:

The overall dimensions of the grinding roll shall be as per BHEL Drawings. The
COPYRIGHT AND CONFIDENTIAL

supplier shall submit the Production drawings to BHEL for approval.

The hardness of inserts shall be measured on surface of any one insert per roll and
hardness shall be in the range of 59-66 RC. The grinding rolls shall be of composite
construction with hard inserts embedded in SG iron. Insert shall be formed primarily
of chromium carbides in highly wear resistant mass. This mass shall be integral part
of high chrome iron having following Chemical composition:

C = 2.3-3.4 %, Cr = 18.0-27.0 %, Mo= 0.5-1.3 %

Mn = 0.5-1.5 %, Si = 1.0 % max., Ni-0.3-1.3%, S-0.1% max, P-0.1% max

The Chemical composition of SG iron

C- 3.2-3.5%,Si-2.5-3.0%, Mn-0.3% max. Mg-0.04-0.07%
The above Chemical Composition does not absolve the supplier from guarantee
responsibility.

The Rolls shall be offered for examination after removal of outside scales.

The Heat treatment procedure shall be established by the vendor and shall be
indicated in Quality Plan.

Revisions: Prepared: Approved: Date:

MVRM JGK 08.01.07
Refer to record of revisions:
 Product BA35011
Rev No. 5
TD-106-1
PRODUCT STANDARD STD no.

Form No.
PULVERISERS Rev No. 01
HYDERABAD Page 2 of 6

5. BULL RING SEGMENT ASSLY:

The Dims of segments shall be as per BHEL Drgs and supplier shall submit the
production drawings to BHEL for approval.
Bull Ring segments shall be of composite construction, formed primarily of
chromium carbides in highly wear resistant mass. This mass shall be integral part of
high chrome iron having following Chemical composition:
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
It must not be used directly or indirectly in any way detrimental to the interest of the company.

C = 2.3 –3.4 %, Cr = 18.0-27.0 %, Mo=0.5 – 1.3 %, Mn = 0.5-1.5 %

Si = 1.0 % max.,Ni-0.3-1.3%, S- 0.1% max, P- 0.1% max.
The hardness shall be checked on the working surface of bullring segments at
random on four segments per set .The Hardness of segment shall be 59-66 RC.

The above Chemical Composition does not absolve the supplier from guarantee
responsibility.
The Heat treatment procedure shall be established by the vendor and shall be
indicated in Quality Plan.
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6. AIR PORT RING ASSEMBLY:

The selection of material and Design of air port ring is left to discretion of the supplier.
The design of the air port ring is such that it shall not interfere with any of the existing
Mill components. The drgs shall be submitted to BHEL for approval before
Manufacturing. Any modifications during performance guarantee shall be carried out
by the supplier at customers work.

7. MICRO STRUCTURE

Microstructural examination shall be carried out at 200 X magnifications on

1) One insert selected at random from batch of 3 sets of rolls.

2) One segment selected at random from three sets of bullring segments.
(One set means complete requirement of one mill)
Microstructure shall consist of discontinuous network of primary carbides in
martensitic matrix.

8. VISUAL AND DIMENSIONAL INSPECTION

8.1 The overall dimension of the grinding roll shall be as per approved drawing.

8.2 For Grinding Rolls: Extremely hard structure and composite construction causes
Revisions:cracks and other discontinuities to occurPrepared: Approved: Date:
in the inserts ofJGK
MVRM
the rolls and08.01.07
are not
harmful to the functioning of the part. The inserts may show cracks and other
Refer to record of revisions:
 Product BA35011
Rev No. 5
TD-106-1
PRODUCT STANDARD STD no.

Form No.
PULVERISERS Rev No. 01
HYDERABAD Page 3 of 6

discontinuities at unpredictable locations and in unpredictable numbers and are

acceptable.

8.3 For Bull Ring Segments: Extremely hard structure and composite construction
causes cracks and other discontinuities to occur in the castings and are not harmful
to the functioning of the part. The castings may show cracks and other
discontinuities at unpredictable locations and in unpredictable numbers and are
acceptable.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
It must not be used directly or indirectly in any way detrimental to the interest of the company.

8.4 The bullring segments shall be assembled in check bowl. After assembling of the
segments, final gap should not be more than 20 mm. The drawing for the check
Bowl and the arrangement for segment assembly on check bowl shall be furnished
to BHEL for approval.
8.5 The number of segments i.e. Plain, Half, Quarter, Keyed & Shim for each size of
the mill shall be shown on check bowl drg. However, additional shims/ segment to
fill the gap upto 20 mm shall be supplied which may be required at site during
assembly.
9. GUARANTEES:
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9.1 Wear Life: The wear life guarantee to be given as per the indent/ purchase
order.
9.2 The supplier shall give back to back guarantee for wear life of grinding
elements.
9.3 The supplier shall take into consideration that Indian coal could contain hard to
grind extraneous Materials.
9.4 Consistency in mill output to minimum 90% of capacity and pulverized fuel
fineness.
9.5 No increase in motor current at maximum mill output comparing with
conventional mills ( for the spares)
9.6 No mill internals / components are required to be changed/modified.
9.7 Consequential damages / loss of any component/ system due to installation of
HPMS system shall be borne by the supplier.
9.8 Failure due to manufacturing defects of HPMS system shall be replaced and
installed immediately.
9.9 All other technical and delivery conditions shall be as per the agreed MOU.
9.10 Supplier to confirm supply of grinding elements in the guarantee test period of
the project.
10. INSPECTION AT SUPPLIERS WORK
Tests and inspection are to be conducted in the presence of BHEL/ customer
representatives as per approved Quality plan. The representatives shall have free access
at all times while the work on the contract being performed. The supplier shall offer
Revisions: Prepared: Approved: Date:
him all reasonable facilities without chargeMVRM
to satisfy the later
JGK
that the items are
08.01.07
conforming to this specification.
Refer to record of revisions:
 Product BA35011
Rev No. 5
TD-106-1
PRODUCT STANDARD STD no.

Form No.
PULVERISERS Rev No. 01
HYDERABAD Page 4 of 6

11. TEST CERTIFICATE:

All the rolls shall be identified with a serial number punched. The Bull ring segments
set shall be numbered by paint for each set. Supplier shall supply 3 copies of Test
certificates with following information for rolls and bull ring segments.
1. BHEL order number
2. Supplier’s reference and name.
3. Heat no./ Roll no.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

4. Results of chemical analysis, Hardness Test and all other tests

It must not be used directly or indirectly in any way detrimental to the interest of the company.

5. Drawing no.
6. Consignment/ Identification no.
12. ACCESSORIES

12.1 Wear measurement gauge for project site, fasteners, hard facing electrodes and any
other consumables required shall be supplied by the supplier.

13. DOCUMENTS:
COPYRIGHT AND CONFIDENTIAL

13.1 3 Copies of test certificates are to be provided.

13.2 The quality plan shall be submitted for the approval of BHEL. The inspection
will be at the suppliers works by BHEL / Customer representatives/any other
approved inspection agency.

14. PACKING:
All components are to be suitably packed set wise to prevent Corrosion and damage
during transit. Machined/ Ground surfaces shall be properly protected with suitable
anti-corrosive compound. Each package shall be legibly marked with following
information.
1. BHEL Order No.
2. Consignment/ Identification No.
3. Roll No./ Set No.
4. Casting No.
5. Weight in Kg
6. Suppliers Name
15 SUPERVISION & SERVICES:
15.1 Supervision for Erection and commissioning.
15.2 Mill performance shall be monitored for the guaranteed period and supplier
shall visit the site periodically and record the grinding elements wear life along
Revisions: with BHEL/ CUSTOMER. Prepared: Approved: Date:
15.3 Supplier shall associate during capacityMVRMtest on mills, if any, 08.01.07
JGKat each project.
Refer to record of revisions:
 Product BA35011
Rev No. 5
TD-106-1
PRODUCT STANDARD STD no.

Form No.
PULVERISERS Rev No. 01
HYDERABAD Page 5 of 6

TABLE FOR MATERIAL CODE

Var No. Mill Type Item Description Matl. Code

1. 623 XRP Grinding rolls 28” (3 pcs/ set) BA9735011018

2. 623 XRP Bull ring segment set BA9735011026
3. 623 XRP Air port ring assly. BA9735011034
803 XRP BA9735011042
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

4. Grinding rolls 37” (3 pcs/ set)

803 HHP
It must not be used directly or indirectly in any way detrimental to the interest of the company.

803 XRP BA9735011050

5. Bull ring segment set
803 XRP BA9735011069
6. Air port ring assly.
7. 803 HP Grinding rolls 46” (3 pcs/ set) BA9735011077
803 HP BA9735011085
8. Air port ring assly.
803 HHP
803 HHP BA9735011093
COPYRIGHT AND CONFIDENTIAL

9. Bull ring segment set

803 HP
10. 883 XRP Grinding rolls 43” (3 pcs/ set) BA9735011107
11. 883 XRP Bull ring segment set BA9735011115
12. 883 XRP Air port ring assly. BA9735011123
13. 703 HP Grinding rolls 42” (3 pcs/ set) BA9735011131
14. 703 HP Bull ring segment set BA9735011140
15. 703 HP Air port ring assly. BA9735011158
16. 703 XRP Grinding rolls (3 pcs/ set) BA9735011166
17. 703 XRP Bull ring segment set BA9735011174
18. 703 XRP Air port ring assly. BA9735011182
19. 663 XRP Grinding rolls (3 pcs/ set) BA9735011190
20. 663 XRP Bull ring segment set BA9735011204
21. 663 XRP Air port ring assly. BA9735011212
22. 1003 XRP Grinding rolls 50” (3 pcs/ set) BA9735011220
23. 1003 XRP Bull ring segment set BA9735011239
24. 1003 XRP Air port ring assly. BA9735011247
25 1003 XRP Grinding Roll – 50” BA9735011255
26 883 XRP Grinding Rolls 43” BA9735011263
27 1103 XRP Grinding rolls 62” (3 pcs/ set) BA9735011271
28 1103 XRP Bull ring segment set BA9735011280
Revisions: Prepared: Approved: Date:
29 1103 XRP Air port ring assly. MVRM BA9735011298
JGK 08.01.07
Refer to record of revisions:
 Product BA35011
Rev No. 5
TD-106-1
PRODUCT STANDARD STD no.

Form No.
PULVERISERS Rev No. 01
HYDERABAD Page 6 of 6

RECORD OF REVISION

REV. DATE REVISION DETAILS REVISED APPROVED

NO
01 20.2.07 Chemical composition, Visual inspection,
microstructure, wear life guarantee and
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

bull ring segment clauses modified. Aman MVRM

It must not be used directly or indirectly in any way detrimental to the interest of the company.
COPYRIGHT AND CONFIDENTIAL

Revisions: Prepared: Approved: Date:

MVRM JGK 08.01.07
Refer to record of revisions: