Presentation On Maintenance of coal mill and coal feeders

Maintenance:
 Increase availability  Improve reliability  Increase efficiency  Reduce the downtime / Failure rate of mill.  Smooth operation  Availability of mills for operation /
main deciding plant load factor

What is wearing?
Wear is directly proportional to:

 Abrasive substances  Service hours

COAL MILL

TUBE MILL

Indications for maintenance:

 Reduced mill capacity  Increase in spillage  Incorrect coal fineness  Noise level

Wearable mill parts:

       
Grinding rolls Bull ring segments Separator body liners Direction vanes Bowl extension ring Scrappers Mill side liner Mill discharge valves

Factors responsible for scheduling maintenance program and inspection are:

 Characteristics of fuel  Operating hour  Availability of mill  Availability of maintenance force

Lets see few common problems and troubleshooting.

Troubleshooting:
Problem: Problem: Incorrect coal fineness Possible cause:  Uneven deflector blade settings  Worn or damage deflector blades  Low or high spring compression  Grinding process

Problem: Problem: In correct coal fineness

(Corrective Action)

 Calibrate the blades properly.  Inspect repair and /or replace deflector blades
as soon as Possible  Check the compression and change as required.  Inspect repair by patching the holes or replacing the cone as soon as possible.

Problem: Problem: Noise above bowl

Possible cause: cause:

 Reject material on bowl  Failed grinding roll  Uneven spring pressure  Heavy reject material

Problem:Noise Problem:Noise above bowl

(Corrective Action)

 Stop the pulverize inspect & remove the

material.  Stop the pulverize repair or replace the Journal assembly.  Check the spring pressure and change if required(250 kg/cm2).  Stop the pulverized and remove the material & Check the damage.

Lets us now focus on Maintenance Aspects

Overview of maintenance:
 Daily maintenance  Weekly maintenance  Shutdown maintenance

Daily maintenance / checks:

 Check the gear case oil level ( Daily)  Gear case oil bath temperature  Coal and oil leakages

Weekly checks:
 Greasing of spring adjusting bolt  Greasing of journal stop bolt.  Check gear case oil for contamination

Shutdown (Checks after 6-8 months) 6 Oil level in journal and its quality(800mm)  All internal clearances  Greasing the gear coupling

Industrial Maintenance program

 Preventive maintenance  Package overhaul  Capital overhaul

Isolation of mill:
 Hot air shut off gates  Cold air shut off gate  Seal air shut off valves  Mill discharge valve should be closed  Mill and feeder motor breakers are to be
left open.  Disconnect the electricity

Preventive maintenance:
 Grinding rolls and bull ring    
segments(Clearance 1-1.5mm) 1Spring gap adjustmen(Between journal head and head of spring assembly) Check the spring tension. Check the condition and height of bowl extension ring(Approx:90-95mm) ring(Approx:90Check the Condition of cone (eroded / Punctured)

Preventive maintenance:
 Check the condition of classifier  Check the height and condition of venturi.  Check the sealing arrangement at the
insulation plates (damages due to temperature difference).  Check the clearance between the scrapper and insulation plate regularly.

Preventive Maintenance:
 Check the condition of oil in gearbox and
level of oil(SP257/1050L)  Flush the oil coolers if required.

Packaged Overhaul: (wear Packaging)

Replacement of bullring segments: Procedure: 1.Unbolt clamping rings using jack screws. 2.Remove worn out bull ring segment 3.Clean all interior surface of bowl 4.Install new bull ring segment in numerical sequence clockwise

Packaged overhaul:
Replace the bullring segments contd.. 5.After installing bull ring segments if gap exists use shims around the periphery.

Packaged Overhaul:
Servicing of journal assembly: Procedure:

1. Lower the journal assembly (Lower edge

touches floor) 2. Remove the set screw or strips welded on the roll lock nut 3. Remove the roll lock nut

Servicing of journal assembly: contd..

4.Lift the assembly by sliding over journal head assembly 5.If unable to remove use jack and fixture assembly.

Packaged Overhaul:
 Servicing of spring assembly(T624 and
T625 Thrust brg.) ( Hydraulic jack for adjusting spring tension)  Replacement of cone  Replacement of bowl extension ring and vane assembly  Servicing of all Mechanical seal if required.  Servicing of Worm shaft assembly

Capital overhaul
Disassemble the mill completely.. Go for complete overhaul

Coal mill Donts:

 Do not get in to the mill when the motor is
not isolated and the discharge valves closed  Do not use steel hammers on rolls  Do not use direct flame torch for bearing assembly

Donts:
the mill.  Do not alter classifier setting ,spring compression setting, roll ring settings, ringring-roll clearance etc.  Do not carry out maint. Work inside the mill with out proper personnel safety equipment  Do not weld on the bowl or any part attached to it unless the welding m/c is grounded to the bowl to prevent arcing on surfaces.

 Do not leave in the tools,workpieces inside

Coal Feeders:
 Coal feeder is installed at the bottom of
the coal-bunker coal Capacity to supply coal (Range:7.4T/hr 43.6T/hr)  Speed (Range:2.7 RPM 16RPM)  Feed is proportional to change in speed.

Types of coal feeder:

 Volumetric coal feeder  Gravimetric feeder-Drag chain feeder-

Maintenance Gravametric feederfeederDrag chain type: (Periodic Checks)

    
Drive chain links. Drive wheel teeth. Drive shaft. Drive shaft bearings. Drive and driven shaft sprocket and bearings of the same.

Maintenance Gravametric feederfeederDrag chain type:

 Drag chain link, drag chain link push     
plates and drag chain pin links. Drag chain guide angles. Top and bottom body liners LHS & RHS. Guides of the driven shaft. Thickness of the bed plate. Load cells.

Maintenance (for both types)

 Inspection, repairs or replacement of    
gear teeth. Inspection, repairs or replacement of gear shaft. Bearings of gears shafts. Inspection of gear-box oil, cleaning of oil gearindicators. Inspection, repairs or replacement of clutch mechanism.