Space for stamping (Review and validation status):

Project Name:
LEPCL 660 MW CFPP, Karachi
Owner’s Name:
LUCKY ELECTRIC POWER COMPANY LIMITED

Owner’s Engineer:
FICHTNER GMBH & CO KG

EPC Contractor:

SEPCOIII ELECTRIC POWER CONSTRUCTION CORPORATION., LTD.

EPC Contractor’s Engineer:

POWERCHINA HEBEI ELECTRIC POWER DESIGN & RESEARCH
INSTITUTE CO., LTD.

Revision history
Rev. Date Created by Checked by Approved by Description
A 14.05.2020 Dangel Kendel Erlenbusch First Issue

Description of the latest revision

Cross checked by
Department Name Date
E-ME
Participant

ALSTOM SWISS OWNED TECHNOLOGY

Customer’s Document Code: L E P C L - 1 0 - H F C - M D C - 2 0 0 8 0 3 - P 0 1 - A

Scale Other Document Code (if any)
A4
Responsible dept. Created by Checked by Approved by Format
E-ME Dangel Kendel Erlenbusch A4
Originator Document Type Project Document Code
Note of Applicability QML/10/M/HFC068-2FS/GS/303
Document title, Subtitle Document Status
Released
ALSTOM SWISS OWNED TECHNOLOGY
Mill N260.34S Originator Document Code
Operation and Maintenance C-000083_00068_7303
Rev. Date Lang. Sheet
Manual A 14.05.2020 EN 1/76
© ALSTOM and /or its Affiliates. All rights reserved.
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CONTENT
1 FOREWORD 5
2 SAFETY INSTRUCTIONS 8
2.1 Duty of care for the operator 8
2.2 Safety Notes and Signs 8
2.3 General Safety Instructions 9
2.4 Personnel Selection and Qualification 10
2.5 Special Safety Notes 10
2.6 Hints and Notes 11
3 RANGE OF APPLICATIONS 11
3.1 Technical Data 12
3.2 Document code 12
3.2.1 Originator Document Code 13
3.2.2 Project Document Code 13
4.1 Register of Mill Subassemblies 14
4.2 Design of the Beater Wheel Mill N 260.34 S 15
4.2.1 General Information 16
4.2.2 Assembly 18
4.2.3 Overview 19
5 COMPONENTS 20
5.1 Down Shaft Connection with Slide Gate 20
5.2 Mill Door 21
5.3 Mill Housing 22
5.4 Intermediate Piece 23
5.5 Box-type Classifier 24
5.6 Beater Wheel 25
5.7 Double Bearing 26
5.8 Mill Drive Train 27
5.8.1 Gear Box (Geared variable speed coupling) 27
5.8.2 Motor 28
5.8.3 Connection couplings 28
5.9 Foundation 29
6 MILL OPERATION 30
6.1 First Commissioning of Mill 30
6.2 Mill Start-up 30
6.3 Mill Operation 31
6.4 Mill Shut down 31
7 WORKING ON THE MILL 32

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7.1 Down Shaft Connection with Slide Gate 32
7.2 Mill Door 36
7.2.1 Opening the Mill Door 37
7.2.2 Closing the Mill Door 37
7.3 Mill Housing 38
7.4 Intermediate Piece 39
7.5 Classifier 40
7.6 Beater Wheel 41
7.7 Beater Wheel with Fastening Device 41
7.8 Double Bearing 41
7.9 Double Bearing Lubrication 43
7.10 Beater Wheel Mounting Device 44
7.11 Double Bearing Mounting Device 44
7.12 Balancing Device 44
7.13 Lifting Devices and Crane Runway over the Mill Drives 44
8 MAINTENANCE 45
8.1 Cleaning and Lubrication 45
8.2 Lubricant list 46
8.3 Inspection and Maintenance 47
8.3.1 Down Shaft Connection with Slide Gate 48
8.3.2 Mill Door 49
8.3.3 Mill Housing 49
8.3.4 Intermediate Piece 49
8.3.5 Classifier 49
8.3.6 Beater Wheel 49
8.3.7 Double Bearing 50
8.3.8 Gear Box (Geared Variable Speed Coupling) 50
8.3.9 Connection Couplings 50
8.3.10 Mill Motor 50
8.3.11 Balancing Device 50
8.3.12 Foundation with Mounting Parts 50
8.3.13 Beater Wheel Mounting Device 50
8.3.14 Double Bearing Mounting Device 50
8.4 Repair Works 51
8.4.1 Down Shaft Connection with Slide Gate 51
8.4.2 Mill Door 52
8.4.3 Mill Housing 52
8.4.4 Intermediate Piece 54
8.4.5 Box-Type Classifier 54
8.4.6 Beater Wheel 54
8.4.7 Double Bearing 57
8.4.8 Beater Wheel Mounting Device 60
8.4.9 Double Bearing Mounting Device 60
8.4.10 Balancing Device 60
8.4.11 Foundation with Mounting Parts 60
9 HANDLING MALFUNCTIONS 61

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9.1 Possible Malfunctions 61
10 Activities at Mill 63
10.1 Inspection of wear situation 63
10.2 Dismounting of the beater wheel 63
10.3 Mounting of the beater wheel 65
11 Activities in Maintenance Workshop 66
11.1 Lifting Works 66
11.2 Cleaning 66
11.3 Dismantling of the wear parts 67
11.4 Replacement of the wear parts 67
11.5 Balancing 67
12 Tools 68
12.1 Device for beater wheel servicing 68
12.2 Hydraulic Aggregate 68
12.3 Mill Door Moving Device 69
12.4 Beater Wheel Balancing Device 70
12.5 Suggestion for Storage Area 70
13 ATTACHMENTS AND INDEXES 71
13.1 Drawing List 71
13.1.1 Subassembly 060 DIMENSION SHEETS AND DRAWINGS 71
13.1.2 Subassembly 350 Arrangement 71
13.1.3 Subassembly 354 Mill Foundation 71
13.1.4 Subassembly 355 Foundation 71
13.1.5 Subassembly 357 Special tools 71
13.1.6 Subassembly 360 Mill housing 71
13.1.7 Subassembly 361 Foundation Frames 72
13.1.8 Subassembly 362 Mill door 72
13.1.9 Subassembly 363 Intermediate Piece 72
13.1.10 Subassembly 364 Down shaft connection 72
13.1.11 Subassembly 365 Classifier 72
13.1.12 Subassembly 367 Double Bearing 72
13.1.13 Subassembly 368 Drive 72
13.1.14 Subassembly 369 Beater Wheel 73
13.1.15 Subassembly 377 Water Supply 73
Aggregates, Armatures and Instruments 73
13.1.16 Subassembly 357 devices 73
13.1.17 Subassembly 362 Mill Door 73
13.1.18 Subassembly 363 Intermediate piece 74
13.1.19 Subassembly 364 Down Shaft Connection 74
13.1.20 Subassembly 365 Box-Type Classifier 75
13.1.21 Subassembly 367 Double Bearing 75
13.1.22 Subassembly 368 Gear Box 75
13.2 Protocols 76

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1 FOREWORD
The plant is built reliable and according to the state of the art. Nevertheless, disturbances of the plant
and impairments to other machinery and equipment of the operator or dangers to life and limb of the
operating personnel or third parties may occur, if the plant is not operated by technically qualified and
specially trained personnel and/or if the plant is used improperly or is not used as prescribed.

1. For the operation and maintenance of the plant described below, it is therefore assumed that
the plant is operated and maintained only by well-trained and authorized personnel who
furthermore know this operation manual - hereinafter referred to as "operation manual" - in
detail and comply with and have access to this operation manual at all time.

The supplier assumes that the plant is subject to a proper operation. Further, the supplier
supposes that any operator's errors and improper operations resulting in damages to the
plant as well as intentional or negligent damages will be avoided or eliminated, if they already
exist.

A proper operation requires the permanent supervision of the plant, so that any changes,
(including changes of the operating behavior) which risk impairing the safety, are immediately
reported to the supervisory personnel to be cut off. The operator ensures that the plant is
always operated in perfect condition.

Reconstruction or modifications of the plant must be agreed with the plant manufacturer for
safety reasons. Furthermore, for safety reasons only spare parts which are identical to the
original parts or have been purchased from spare parts suppliers acceptable to the
manufacturer may be used. Otherwise, the operator is not liable for damages within the
scope of warranty obligation.

It is not admissible that safety devices are wholly or partly short-circuited or shut down.

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 5/76
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 2. In principle, during the operation and maintenance of the plant, besides from the conditions
imposed by the licensing authorities, the as amended relevant national statutory provisions,
as well as the relevant regulations as amended must be followed.
In particular:
• The corresponding Directives V European Standards (EN), Standards of the
International Standard Organization (ISO), as well as German industry standards
• The general accident prevention regulations
• The applicable special accident prevention regulations
• The instructions for operation and the accident prevention regulations laid down by
the operator
• The federal water acts
• Device Safety Act
• Steam Boiler Code
• Federal Emission Control Law
• The technical regulations for:
• Steam Boiler DIN EN 12952-9
• Pulverized coal combustion for steam boilers (TRD413)
• Pressure equipment Directive 97/23/EG
• Flammable liquids
• Vd TÜV, VDE etc.

In addition, the practical instructions given to the operating personnel by the supplying firms /
companies / manufacturers and the operator's manuals issued by the supplying firms /
companies / manufacturers are applicable.
3. The present operation manual has been designed as an all-out instruction for the operation
and routine maintenance in compliance with the requirements in point 1 and 2. It is not an
instruction for the installation, assembling / disassembling or repair of the plant.
4. The supplier reserves the right to amend or supplement the operation manual, if new
operational experience makes this necessary.
The operator is requested to inform the supplier of any new operating results so that such
experience can be generally used in future.

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 6/76
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 5. The operation manual handed to the operator should be carefully treated und updated during
the whole operating time of the plant. In particular, single sheets of the operation manual
should not be removed.

It is recommended to perform training courses with the operating personnel on the basis of
the available operation manual in regular intervals, evaluate any cases of damage and
malfunctions and to elaborate necessary operating manuals for the trained operating
personnel.

The data, drawings and other specifications included in this operation manual are confidential
proprietary information of the supplier. This information delivered by the supplier according to
the contractual provisions to the operator and the relevant operating personnel of the plant is
strictly confidential and for the exclusive purpose of the operation and maintenance of the
plant.

No license is granted for the manufacture of spare parts or construction of the plant, unless
otherwise explicitly agreed in the contractual provisions. The contents of these operating
instructions shall be neither copied nor made available to third parties without approval of the
supplier in writing.

Notes:
Some of images in this manual my differ from the original in detail, just for reference.

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 7/76
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2 SAFETY INSTRUCTIONS

2.1 Duty of care for the operator

The beater wheel mill is constructed and built within the framework of a risk assessment and some
carefully chosen harmonized standards as well as technical specifications. It conforms to the
technological standard and provides the highest security standard during operation. This standard can
only be guaranteed if all required measures are taken by the operator. It is the operator’s duty of care
to plan, manage and implement the measures.

2.2 Safety Notes and Signs

The safety notes listed in the following are used in this operation manual to inform and warn its reader of any
possible danger of injury or life during working operations or operation of the mill. These notes will also instruct
the reader during working operations to avoid plant parts being damaged, as well as in the consequences of not
taken these notes into account.

Attention: The plant or plant parts might be damaged.

Warning: Risk of injury or life for the operating personnel.

Risk of falling

Hot surface

Danger of entrapment

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 Do not touch!

Electrical hazard !

2.3 General Safety Instructions

The operator must make sure that:

• the plant is only used as intended by the supplier
• the plant is only operated in proper functional condition and the special safety features are
regularly checked
• required PPE (personal protective equipment) for the operating, maintenance and repairing
staff is on hand and used anytime.
• the entire operation manual is available in proper, readable condition at the plant’s place of
action
• only qualified and authorized staff is operating, maintaining and repairing the plant
• the personnel are regularly trained concerning working safety and environmental protection
and is made familiar with this operation manual, especially with its safety instructions
• Arbitrary changes which have an impact on the operational safety are prohibited
• the mill is only operated in the conditions defined in the contract of delivery
• The mill is fully determined to its area of application, defined in the technical data. Every other
usage is infringement of use for intended purpose and only the operator is liable in case of
damage of the plant or plant parts.
• The safety warning signs at the mill must be installed by the operator according to the warning
notices in the O&M manual.
• All safety notes and warnings on the machine must not be removed and be visible and
readable at any time.

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 9/76
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2.4 Personnel Selection and Qualification

Only trained and instructed personnel is authorized to operate the mill. The personnel
must be familiar with the operation manual and refer to it concerning all necessary working
steps. The particular authorizations for the operating personnel must be defined
unmistakably by the operator of the plant

Furthermore, the operations named in the following need special qualifications:

Maintenance and Repair: Only personnel with particular professional training are authorized for these
operations.

2.5 Special Safety Notes

Be aware of the following dangers during operations on the mill:

Surfaces or mill parts that have not cooled out sufficiently. Do not touch!

Risk of fire due to glowing embers when opening access doors or the mill door improperly.

Danger of entrapment when opening or closing the mill door and the down shaft slide
gate.

Risk of falling when working on higher located mill parts.

Electrical hazard

Originator Project Document Code Rev. Date Lang. Sheet

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Especially during maintenance and repair work as well as the shut-down of the mill, the operator is
responsible for seeing that substances with negative impact on the ground water are not
contaminating the soil or entering the canalization. The substances must be collected in appropriate
containers, stored, transported and disposed.

2.6 Hints and Notes

Following these Hints and Notes eases the mounting and demounting procedure!

3 RANGE OF APPLICATIONS

The intended purpose of the beater wheel mill N 260.34S is the milling and drying of raw brown coal.
The mill provides the function of the drying gas intake as well as the transport of the pulverized fuel,
mixed with the carrier gas.
The coal enters the mill door via the down chute. Simultaneously the beater wheel draws hot flue
gas which serves as drying and carrier gas for the pulverized fuel. Grinding and drying occurs
simultaneously by means of impact and friction between the coal and the beater plates, until the
pulverized fuel is fine enough to be transported by the carrier gas out of the mill.
The beater wheel mill is equipped with a classifier. The classifier sorts out the milled product
according to its fineness. Sufficiently milled material is carried out via the dust pipes. Insufficient
milled material is transported back into the mill via the oversize return.
Operating conditions:
The mills must be operated with lignite within the contractual coal range. See Document
QML_10_B_H----2FS--_DO_001. Impurities in the coal such as metal pieces, stones etc. are not
admissible.
The beater wheel mill is operated with a pressure upstream mill of –6 to –8 mbar and a pressure
downstream mill of -/+2 mbar.
The temperature downstream mill measures 125°C to 200°C during normal operation (max. 240°C).
The mill is equipped with Gear Box (variable speed hydraulic coupling).

Originator Project Document Code Rev. Date Lang. Sheet

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3.1 Technical Data

Beater wheel mill N 260.34 S

Mill with box-type Classifier

High moisture coal mill Outer diameter: beater wheel Ø=3.4 m
Volume flow 260,000 m³/h

Raw coal throughput max. 95 t/h design coal

Ejected mixture of carrier gas and pulverized fuel Max. 260.000 m³/h
Operation speed 440 - 540 1/min
Classifier temperature 125-200 °C
Design Clockwise design / Counter-clockwise design

Clockwise (CW) design Left Housing Right Housing Counter-clockwise (CCW) design
Outlet Outlet

Direction of Rotation:
Beater Wheel

Beater wheel outer diameter 3,400 mm

Beater wheel inner diameter 2,300 mm
Clear width 850 mm
Moment of inertia 32.465 Kg/m²
Mill weight with drive aggregates approx., ca. 148.000 kg

3.2 Document code

There are three different document codes used for the same documents:
• Originator Document Code
• Project Document Code
• Customer’s Document Code
Originator Document Code and/or Project Document Code are used as document ID, please see below
numbering rules for these two codes:

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 12/76
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3.2.1 Originator Document Code

C-000083/00 350 – 0 0 0 1
Project type
Project Number
Product classification
Subassembly, see subassembly Register
Document type

0 – Drawing
2 – Parts List
7 – Specification
Document No°

3.2.2 Project Document Code

QML/10/M/HFC350-2FS/DD/001

Subassembly, see subassembly Register

Document type
DD – Drawing
EA - Arrangement Drawing
EI - Erection Instruction
ER – Engineering Report

BQ – Part List
GS – Specification

Document No°

Originator Project Document Code Rev. Date Lang. Sheet

ALSTOM QML/10/M/HFC068-2FS/GS/303 A 14.05.2020 EN 13/76
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4.1 Register of Mill Subassemblies

Description Subassembly
Dimension sheets ........................................................................................................................... 060
Specification ................................................................................................................................... 068
Mill arrangement drawing ............................................................................................................... 350
Mill foundation................................................................................................................................. 354
Special mill parts............................................................................................................................. 355
Special tools ................................................................................................................................... 357
Mill housing ..................................................................................................................................... 360
Foundation frames .......................................................................................................................... 361
Mill door with undercarriage ........................................................................................................... 362
Intermediate piece .......................................................................................................................... 363
Down shaft connection with slide gate ........................................................................................... 364
Classifier ......................................................................................................................................... 365
Double bearing with beater wheel fastening device, lubrication, cooling ....................................... 367
Gear Box with variable speed coupling .......................................................................................... 368
Beater wheel, rotor ......................................................................................................................... 369
Cooling water supply ...................................................................................................................... 377
Motor ............................................................................................................................................... 390

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4.2 Design of the Beater Wheel Mill N 260.34 S

Fig.: Beater wheel mill

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 4.2.1 General Information
The beater wheel mill is named after its technology: A wheel is installed on the interior of the mill.
This wheel rotates with relatively high speed and pulverizes the coal by crushing it at the beater
plates.

8.60 m Platform
6.652 m Platform

4
1
6.20 m Platform

3.80 m Platform
2
9
6
1.40 m Platform
7

16
3

15

Fig.: Overview of the beater wheel mill (view 1)

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 5

11
13
1

8 4
10 9

12 2
14

3
7

16

15

Fig.: Overview of the beater wheel mill (view 2)

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4.2.2 Assembly
The beater wheel mill consists of the following subassemblies:
1. Down shaft with hydraulic slide gate (subassembly 364)
2. Mill door which is mobile for maintenance (subassembly 362)
3. Mill housing (subassembly 360)
4. Intermediate piece (subassembly 363)
5. Classifier (subassembly 365)
6. Beater wheel (subassembly 369)
7. Foundation frame for the double bearing, the gear coupling and the motor (subassembly 361)
8. Double bearing with lubrication (subassembly 367)
• Bearing of the shaft
• Equipped with self-aligning roller bearing (beater wheel side)
• Equipped with self-aligning roller bearing (coupling side)
• Lubrication and cooling of the roller bearings via circulating oil lubrication and cooling
water
9. Hydrodynamic gear coupling for speed adjustments (subassembly 368)
10. Mill motor (subassembly 390)
11. geared connection coupling between the double bearing and the variable speed-gear
coupling (subassembly 368)
12. geared connection coupling between the variable speed-gear coupling and the motor
(subassembly 368)
13. Coupling guard: double bearing/variable speed-gear coupling (subassembly 368)
14. Coupling guard: variable speed-gear coupling/motor (subassembly 368)
15. Foundation with spring element and visco damper (subassembly 354)
16. Cooling water supply (subassembly 377)

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4.2.3 Overview

4.2.3.1 Direction of Rotation of the Beater Wheel Mill

ALSTOM provides two designs of the beater wheel mill: clockwise and counter-clockwise design.
In the clockwise designed mill, the beater wheel rotates clockwise and the housing outlet is on the
left side. In the counter-clockwise designed mill, the beater wheel rotates counter clockwise and the
housing outlet is on the right side.

Clockwise mill design Counter-clockwise mill design

Fig.: Direction of rotation of the beater wheel mill

4.2.3.2 Determine the terms: front, back, right, left

“Front” is determined as the direct view on the mill door. Accordingly, the term “back” refers to the
opposite side on which the mill drive is located. “Right” refers the right side of the mill when looking
from the “Front” of the mill and "left" refers to the left side.

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 5 COMPONENTS
5.1 Down Shaft Connection with Slide Gate Sealing:
Recirculation Shaft

Housing Slide Valve

Hydraulic Cylinder Frame

Slide Valve
Schi
Plate/Cover eber
platt
e

Slide Valve
Refractory Sealing Plate/Cover
Hydraulic Cylinder Sealing Edge:
Cylinder
Mill door

Fig.: Down shaft connection with slide valve

This welding construction consists of mild steel and heat resisting steel. The down shaft connection
has refractory setting for better thermal insulation.
The down shaft features of a hydraulic control unit to operate the hydraulic cylinders for maintenance
purposes.
The mobile hydraulic aggregate is located on the zero level.
The crossing of the hydraulic pipes from the mill housing towards the down shaft connection is
worked out with heat-resistant pipes, to compensate tolerances caused by construction and heat
expansion.
The hydraulic control unit is equipped with a parallel lifting device to guarantee parallel lifting of the
sealing cylinder at the down shaft.
Seals between the down shaft housing and the sealing cylinder, as well as between the sealing
cylinder and the mill door, provide compensation for expansion/deflection due to high temperatures.
The slide valve plates are designed for the defined load of deposit and falling refractory and slag.

Originator Project Document Code Rev. Date Lang. Sheet

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5.2 Mill Door

Sealing edge down shaft connection

Conveying gas
recirculation

Housing

Hub shield

Support brackets

Ladder

Undercarriage

Submersible collar

Fixing spindles
Fig.: Mill door

The mill door welding construction consists of mild steel and the hub shield welding construction
consists of heat resistant steel. The mill door has refractory setting for better thermal insulation.
Armor plates are located in the wear area of the mill door. Screw connections allow easy exchange
and maintenance.
The mill door is located on an undercarriage, which allows moving the mill door in required positions
for maintenance with the respective devices (e. g. maintenance vehicle).
Fixing spindles lock the mill door in the required position when operating to unload the wheel
bearings. The mill door carries the hub shield, which provides wear protection of the hub disk and
distributes the coal along the beater plates via distribution plates. That is why the hub shield is
worked out with wear plates manufactured of wear resistant material.
Adjustable support brackets provide adjustment of the doors towards the housing and guarantee
leakage-free fitting in the sealing towards the mill housing. The flange sealing to the mill door
towards the sealing cylinder adjusts according to the position of the mill door.
Furthermore, the mill is equipped with a conveying gas recirculation for regulation of the mill
temperature. Coarse particles, which are sorted out by the classifier, are taken back for further
grinding by the beater wheel through the oversize return duct (conveying gas recirculation) which
connects the hopper of the intermediate piece with the mill door.

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5.3 Mill Housing
Cover: Circumferential
Armoring

Corner
Armor
Side Wall
Upper Armoring
Part
Beater wheel
retaining
device
Scaffold Spiral and
openings Armoring
Lower
Part
Attachment of
the mill door Frame

Grating cover for

cooling

Guide

Fig.: Mill housing

The beater wheel is located in the mill housing, which consists of an upper part, a lower part and a
base frame. Main feature for the grinding process, besides the beater wheel, is the spiral.
The mill housing welding construction consists of mild steel. The corner armor and the wear areas
are equipped with wear-resistant armoring. The corner armor plates are sealed with a cover. After
removing the cover, the plates can be exchanged one by one. The circumferential armors consist of
bars which can be mounted or demounted via the circumferential armor covers. Manufacturing
tolerances can be adjusted with less dense fitting parts.
The mill housing is equipped with an access door for inspection and maintenance of the beater
wheel and the spiral. Scaffold openings in the upper part carry the scaffold tubes for the mounting of
an inner scaffold up to the PF-duct.
A removable cover of the housing rear wall allows mounting and demounting of the double bearing
via the housing.
The housing frame foundation is equipped with guides to regulate a defined heat expansion during operation.

The mill design features a radial arrangement of the housing wall towards the beater plates of the
beater wheel, circulating in the mill housing. This special design is a significant approach to the high
safety standard of the mill housing.

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5.4 Intermediate Piece
Armoring
Armor Adjustment Drive
bars

Riser Shaft

Access
Openings
for Hopper
Maintenance

Scaffold
Openings

Oversize Return Support: Hopper

Sealing: Mill Door Slide Valve

Fig.: Intermediate Piece

The welding construction consists of mild steel.
The intermediate piece consists of two components. The first component is the riser shaft. The riser
shaft guides the material flow from the mill housing into the classifier.
The second component is the hopper. The hopper guides coarse particles, sorted out by the
classifier, via the oversize-return back into the mill door for further grinding.
The wear area of the intermediate piece is equipped with armor plates/ bars.
The armor bars can be exchanged via the access openings in the intermediate piece.
Scaffold openings can carry scaffold connecting pieces for scaffolding the inside of the intermediate
piece up to the PF duct.
The oversize return can be adjusted to operating conditions with a slide valve. The slide valve is
operated by an electronic adjustment drive.
While operation of the mill, the slide valve should be opened completely every 3-4 hours for a short
period of time, to avoid a possible accumulation of coal in the lower part of the hopper.
The oversize return is closed for maintenance with the slide valve. This provides higher safety for
maintenance works. The connection to the mill door is sealed.

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 5.5 Box-type Classifier

Classifier Vanes
Drive: Classifier
Vanes

Firefighting port

g flap

Scaffold Openings

Firefighting flap
(both sides)

Access Door

Fig.: Box-type classifier

The welding construction consists of carbon steel.

The fineness of the grinded material is controlled by the adjusted angle of the classifier vanes. The
vanes can be adjusted manually with handwheels.
Sufficiently grinded material is guided via the classifier outlet into the dust pipes. Insufficiently
grinded material is guided back through the hopper for further grinding.
The wear area of the classifier is equipped with armor plates. The classifier has access doors for
maintenance and scaffold openings for carrying scaffold connection pieces.
Firefighting
The event of fire is detected by excessive classifier temperature.
For firefighting a dedicated port is provided.
Further, the classifier is equipped with firefighting flaps (preserved for water firefighting system).

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5.6 Beater Wheel

Beater Plates
Hub Disk

Retaining
Strip Ring
Disk
Fin Bar

Armor
Sheet

Fig.: Beater Wheel

Components, which require special strength (hub disk, ring disk, fin bars, fin bar screws, beater
plate) consists of heat resistant material and are designed for rough operation conditions such as
high temperature and centrifugal forces. The strength design is based on the latest operation
experiences in our plants.
The beater wheel is mounted in an overhung position on the double bearing shaft. This allows quick
exchange and availability of the beater wheel.
Maintenance of the beater wheel and the exchange of worn out beater plates, armor plates and
retaining strips takes place at the workshop.
The back side of the hub disk is equipped with ventilation strips and a cover disk to establish a
ventilation effect. This prevents dust from entering the gap between the hub and the housing ring
and diminishes the wear in this area.

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 5.7 Double Bearing Local Thermometer
Fixed bearing

Housing
Filling and Ventilation
Filter Remote Thermometer
Fixed bearing
Local Thermometer
Loose bearing

Remote Thermometer
Loose bearing
Cone carrying
the beater
Double Bearing
wheel
Shaft
Oil flow throttle

Oil flow meter

Speed Sensor

Oil filter
Junction box
Lubrication
pump (2x)
cooler
Cooling water Oil Level switch and Meter
supply

Fig.: Double Bearing

The double bearing carries the beater wheel, which is mounted in an overhung position. The bearing
housing consists construction consists of welded steel cast parts and sheet plates.
The shaft, carrying the beater wheel and the connection coupling, is adapted to operation conditions
and manufactured of heat resistant material. The bearings and the lubrication supplies are chosen in
collaboration with our high reputed bearing suppliers. Preferentially self-aligning roller bearings are
used to comply with the operation conditions.
The double bearing is equipped with a splash and circulating lubrication, which provides the required
lubrication for the self-aligning roller bearings at all times. Oil levels, oil flow and bearing
temperatures are continuously measured and controlled by the operating personnel. Furthermore,
the shaft speed is registered via the proximity switch. The lubrication system is equipped with an oil
pump, heat exchanger and an oil filter and consists of reliable components. It is easy to access and
to maintain. Cooling water provides cooling of the lubrication system. The design pressure is 16 bar
(oil side) and 10 bar (water side). The double bearing is ventilated and if necessary, filled with oil via
the filling and ventilation filter.
The inclined arranged bottom plate forms a sump and guides the oil towards the draining valves.
The shaft passages on the beater wheel and drive side are equipped with labyrinth seals, catching
the oil ejected by the shaft and guide it back into the bearing. Furthermore, a sealing ring on the

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beater wheel side counteracts the suction effect caused by the negative pressure in the housing.
Both of these measures prevent oil leakage.
The double bearing is located on the bearing frame. That means, the bearing is fixed sideways and
a twist of the double bearing due to malfunction during operation is not possible.
It can be positioned lengthwise on the frame and be mounted and demounted via the mill housing
with a special device for maintenance purposes.

5.8 Mill Drive Train

5.8.1 Gear Box (Geared variable speed coupling)

For details see O&M manual QML_10_M_HFC368NARA_EI_003.

Applicable

Radial hub

Fig.: Gear Box

The geared variable speed coupling regulates the beater wheel speed. It is a reliable and high-
quality aggregate provided by NARA. The coupling is equipped with all required instruments for a
high availability, such as oil level, oil flow, oil pressure and temperature measurements. It transfers
the power of the motor without any wear to the beater wheel in the following way:
• Between drive machine and geared variable speed coupling via a connection coupling
• Between primary and secondary wheel hydrodynamic via the oil
• Between primary and secondary shaft via the bevel gear with a conversion into slow
• Between geared variable speed coupling and double bearing via a connection coupling

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The beater wheel speed is adjusted via a scoop tube control without any intermediate steps.
The power of the drive motor is transmitted via the primary wheel (function: pump) onto the oil. The
oil is accelerated in the primary wheel and the mechanical energy is transformed into flow energy.
The secondary wheel (function: turbine) absorbs the flow energy and converts it back into
mechanical energy. This energy is then transmitted onto the double bearing/beater wheel.
If the oil temperature exceeds 160°C because of malfunction during operation, the safety screws in
the coupling melt and oil is ejected into the housing of the geared variable speed coupling. The
coupling empties, the torque transmission is interrupted and the mill is shut down.

5.8.2 Motor
The mill motor is a 3-phase induction motor.
Please find all relevant data in motor supplier’s documents
(drawing list No. QML_10_M_HFC390TECO_DL_001).

5.8.3 Connection couplings

Fig.: Connection Coupling

5.8.3.1 Geared connection coupling SSM 400 -

double bearing / variable speed coupling
The geared coupling is a reliable, flexible and low-maintenance coupling.
See O&M manual QML_10_M_HFC368NARA_EI_003.

5.8.3.2 Geared Connection coupling SAM 280 - variable speed-gear coupling / motor
The NARA coupling is a reliable, flexible and low-maintenance coupling.
See O&M manual QML_10_M_HFC368NARA_EI_003.

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5.9 Foundation

The mill foundation is a concrete block worked out with reinforcement steel. It is located on spring
elements and visco dampers, which provide damping of the dynamic load on the foundation caused
by the beater wheel, or malfunctions during the mill operation. This special design prevents the
surrounding aggregates from swinging, here especially the steel construction and the pressure parts.
Anchor boxes manufactured with specially designed tubes are embedded in the mill foundation.
Mill components are fixed with T-head bolts located in the anchor boxes.
Furthermore, rails for moving the mill door are embedded in the foundation and the zero level. The
frames of each subassembly on the foundation are grouted with non-shrinking concrete to guarantee
supporting surfaces.
In case of earthquake, excessive movements of the block are cushioned by rubber plates.

Check bolt tightness of the anchor screws from time to time.

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6 MILL OPERATION

Please refer to the following documents:

• Erection Instruction Beater Wheel Mill, QML_10_M_HFC068--FS_GS_301, Mill is
assembled, filled with fluids, motor connected and checked.
• QML_10_B_H----2FS--_DM_160, Firing Design – System Description, section 8.3
• functional group, coal burner QML_10_B_HHA--2CSE-_LO_061
• Boiler operation manual

6.1 First Commissioning of Mill

The following steps must be accomplished before the mill start-up:

• A leak test with 200 bar has been carried out on all hydraulic components except the
hydraulic cylinders (to be done before first mill start-up)
• All access doors of the feeder and the mill must be closed
• The mill must be connected
• Checking of the oil level in the double bearing, the variable speed coupling and the motors
is confirmed
• Function check of connected instruments is confirmed
• Direction of rotation check of the motors and the gears is confirmed
• Position the classifier vanes and the oversize return slider on operating position

6.2 Mill Start-up

The mill is started via the start-up program in the functional group "mill". All auxiliary aggregates are
started according to the step sequence.
For details about functional group, please consult QML_10_B_HHA--2CSE-_LO_061
Among other criteria, the following steps must be accomplished before the individual mill start-up
• All access doors of the feeder and the mill must be closed
• The down shaft connection is closed, hot gas connection is tightened.
• The dampers at the outlet side are opened
• The safety conditions from boiler and furnace must be implemented
• The supply of coal is available.
• Feeders are tightened, functionable.
• Checking of the oil level in the double bearing, the variable speed coupling and the motors
is confirmed (remote measurements or local)
• Function check of connected instruments is confirmed

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6.3 Mill Operation

The following data are automatically monitored during the mill operation according to the P&ID
drawings QML_10_B_-----CSE--_FD_023, QML_10_M_HFC368NARA_FD_001,
QML_10_M_HFC367NHSG_FD_001.
Monitoring the temperature and pressure upstream and downstream the mill, motor flow, bearing
and winding temperatures, oil temperatures, oil pressure, oil levels, oil flow speed, speed and filter
pollution.
The mill must be checked regularly by the operating personnel during operation, especially:
• the smoothness of the operation conditions of the mill
• for leakage such as dust or air leakage of the mill
• for leakage of the oil systems
• the oil level and the oil flow of the auxiliary aggregates
• the differential pressure of oil filters at the lubrication aggregates
• the water supplies
• for leakage (false air and coal) of the mill feeder (access doors, cover, etc./armoring
screws)

6.4 Mill Shut down

The mill is shut down according to the functional group. The “out-program” of the mill is started. The
auxiliary aggregates are shut down according to the step sequence.

The mill must be cooled down for at least 8 hours after the mill shut down in order to lower the
temperature of the mill parts. Then the mill door is opened according to the instructions for
maintenance or repair work.
Temperatures at the surfaces should be checked by a portable thermometer to confirm cooling
period. Max. outer surface temperature allowed is 60 °C.

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7 WORKING ON THE MILL

Surfaces or mill parts may be hot. Do not touch!

Open all maintenance doors and door locks carefully. Make sure the mill is safety
cool down and free of hot surfaces for mill inspection.

For any inspection, maintenance and repair work inside the mill, the local
regulations for work shall be followed.

7.1 Down Shaft Connection with Slide Gate

C-000083/00 364-0001
Operation Manual of the hydraulic aggregate: QML_10_M_HFC357—2FS--GS_321

Because of safety and technical reasons, opening the mill for maintenance or repair work requires
the disconnection of the flue gas recirculation shaft and the mill door.

Check the upper part of the flue gas recirculation head and the flue gas
recirculation duct via the sight opening for slag caking before shutting-down
the mill. If existing, remove the slag with special devices such as air jets. The
slag is ejected via the beater wheel mill and the steam generator during mill
operation. Not checking for caking is a danger to life because the slide valves
are not designed for the heavy load of falling slag caking.

Position the mobile hydraulic aggregate in front of the mill. Connect the identical labeled hydraulic
hoses and hydraulic pipes via the quick release couplings. Open all ball valves (mill side) at the
hydraulic pipes. Position the selection switch on position 2: down shaft.
Press the “lift” button on the hydraulic aggregate until the sealing cylinder (1) has reached the
highest position (see fig. below).

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 If the extension of the cylinders is asynchronous, manually correction at the
slower cylinder is required to avoid damage of plant parts.

Ventilate the system via the hydraulic cylinders if necessary. Check the oil amount in the hydraulic
aggregate and refill oil if required.
Releasing the button "lift" stops the synchronous extension. Position the selector switch on the
respective position and re-press the "lift" button. The faster cylinder will retract. The synchronous
extension can be continued when the faster cylinder has reached the level of the slower cylinder.
When both cylinders are in their final position the automatic lifting adjustment takes place. For this
reason, the button must be pressed until the lifting adjustment is accomplished (approx. 2-3 sec.)
and all cylinders have reached their final position.
Position the selection switch on position 1 "slide valve”. Press the button "close slide valve” until the
slide valve covers (2) are closed.
Visual check: Gap between the slide valve top covers smaller than 5 mm.
Position the selection switch on position 2 “down shaft”. Press the button “lower”. The sealing
cylinder (1) is lowered by its own weight on the slide gate. The sealing cylinder must have contact
over the whole circumference to the slide valves.

The motor pump is shutdown during the lowering procedure!

The lowering speed is adjusted via the knurled screw on the throttle valve. Turning the screw
clockwise accelerates the lowering speed and vice versa.

If the extension of the cylinders is asynchronous, manually correction at the faster cylinder
is required to avoid damage of plant parts.

Releasing the button "lift" stops the synchronous extension. Position the selector switch on the
respective position and re-press the "lift" button. The faster cylinder will retract on the same level
than the slower cylinder. The synchronous extension can be continued until both cylinders have
reached their final position.
Before disconnecting of the quick release couplings, all ball valves at the hydraulic pipes must be
closed to establish a pressure-free connection of the quick release couplings.
The hydraulic hoses are separated via the quick release coupling from the hydraulic pipes. Remove
the hydraulic aggregate.

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 2
1
2

Fig.: Down shaft connection with open slide valve

Gap max. 5 mm

Fig.: Down shaft connection with closed slide valve

After maintenance and repair work on the mill, the recirculation shaft, the mill door and the mill
housing are re-connected. The sealing point on the connection flange of the mill door must be
cleaned carefully to guarantee the sealing function.
Connect the similar labeled hydraulic hoses and hydraulic pipes via the quick release couplings.
Open all ball valves at the hydraulic pipes.
Position the selection switch on position 2: down shaft.
Press the "lift" button on the hydraulic aggregate until the sealing cylinder (1) has reached the
highest position.

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 If the extension of the cylinders is asynchronous, manually correction at the
slower cylinder is required to avoid damage of plant parts.

Releasing the button "lift" stops the synchronous extension. Position the selector switch on the
respective position and re-press the "lift" button. The faster cylinder will retract. The synchronous
extension can be continued when the faster cylinder has reached the level of the slower cylinder.
When both cylinders are in their final position the automatic lifting adjustment takes place. For this
reason, the button must be pressed until the lifting adjustment is accomplished (approx. 2-3 sec.)
and all cylinders have reached their final position.

Position the selection switch on position 1 ”slide valve”.

Press the button "open slide valve” until the slide valve covers (2) are opened.

Visual check: the slide valve covers must be fully retracted.

Falling slag or ash deposit may have impact on the free movement of the slide
valve.
Impaired slide gates because of malfunctions must be supported with mechanical
devices (e.g. grip hoist). Inspect the slide gates for falling ash or slag in the closed
mill carefully. A second inspection is done via the access door (drive side) on the
mill housing. Open the mill door and remove the disposal of the mill door or on
the mill housing if necessary.

Position the selection switch on position 2 “down shaft”.

Press the button “lower”. The sealing cylinder (1) is lowered by its own weight on the mill door.

The motor pump is shutdown during the lowering procedure!

The lowering speed is adjusted via the knurled screw at the throttle valve. Turning the screw clock-
wise accelerates the lowering speed and vice versa.

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 If the extension of the cylinders is asynchronous, manually correction at the faster cylinder
is required to avoid damage of plant parts.

Releasing the button "lift" stops the synchronous extension. Position the selector switch on the
respective position and re-press the "lift" button. The faster cylinder will retract on the same level
than the slower cylinder. The synchronous extension can be continued until both cylinders have
reached their final position.
All ball valves at the hydraulic pipes are closed. All ball valves at the hydraulic pipes must be closed
to establish a pressure-free connection of the quick release couplings. The hydraulic hoses are
separated via the quick release coupling from the hydraulic pipes. If it is not possible to disconnect
the couplings, please press the button “releasing pressure” at the hydraulic aggregate. Remove the
hydraulic aggregate.
Please read the instruction and maintenance manual of the supplier of the hydraulic aggregate
QML_10_M_HFC357—2FS--GS_321, C-000083_00357_7321.

7.2 Mill Door

C-000083/00 362- 0001

The sealing point on the connection flange of the mill door must be clean-swept to guarantee the
sealing function.

Before starting work requiring the opening or moving of the mill door, the beater
wheel mill must be shut down and fully cooled down (minimum 8 hours cooling
down time).

Open the door locks carefully (360_0002 Pos.18; 360_0003 Pos.11)! Deposits of
coal possible, danger of fire!
Do not remain in the cruising range of the mill door!
For the upper door locks use a mobile platform.

Open the down shaft (chapter 7.1 down shaft connection with slide gate).

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7.2.1 Opening the Mill Door

Open the door locks carefully! Deposits of coal possible, danger of fire! Do not remain
in the cruising range of the mill door!

For the upper door locks use a mobile platform.

• Clean the rails in the mill foundation and on the zero level. Remove foreign matters if
existing.
• Unload the support spindles. Move the door in maintenance position using the mill door
shifting device. Pay attention to the trailing cable / hydraulic hose (use hose through guide –
C-000083_00354_0014).
• Closing the Mill Door
• Clean the sealing point on the connection flange of the mill door to guarantee the sealing
function.
• Move the mill door in operating position using the mill door shifting device. Lubricate, close
and secure all door locks. For the upper door locks use a mobile platform.
• The correct sealing of the mill door in the housing sealing must be checked in detail and
confirmed using a protocol.
• Unload the mill door wheels with support spindles. Close the down shaft connection
(chapter down shaft connection with slide gate).
• The sealing on the sealing cylinder in the sealing of the mill door must be checked in detail
und confirmed using the protocol (C-000083_00350_7330).
• The sealing on the mill housing in the sealing of the mill housing must be checked in detail
und confirmed using the protocol (C-000083_00350_7321).

7.2.2 Closing the Mill Door

• Clean the sealing point on the connection flange of the mill door to guarantee the sealing
function.
• Move the mill door in operating position using the mill door shifting device. Lubricate, close
and secure all door locks. For the upper door locks use a mobile platform.
• The correct sealing of the mill door in the housing sealing must be checked in detail and
confirmed using a protocol.
• Unload the mill door wheels with support spindles. Close the down shaft connection
(chapter down shaft connection with slide gate).
• The sealing on the sealing cylinder in the sealing of the mill door must be checked in detail
und confirmed using the protocol (C-000083_00350_7321).

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7.3 Mill Housing

C-000083/00 360-0001

Pressure spindle

Securing
screw

Retaining clip

Fig.: Access door with interlock

Release the securing screw and then both pressure spindles and the studs of both clamps to open
the access door at the classifier. Open the access doors about 10° until it meets the retaining clip.
The opened access door in combination with the opened mill door is used for ventilating and cooling
of the mill.

Open the door locks carefully. Make sure the mill is safety cooled down.
In the unlikely event of coal dust deposit- deflagration cannot be excluded.

Remove the stud of the retaining clip and turn over the retaining clip to open the mill door
completely.

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 Fig.: Corner armor door

Remove the screw connection of the side and end cover in order to exchange the corner armors. The
side covers for the exchange of the circumferential armors are mounted with 4 screws.

7.4 Intermediate Piece

C-000083/00 363-0001
The cover plates in the armor bar area can be removed after unscrewing the tommy screws and
clamps.
Scaffold openings for scaffold tubes in the upper mill part and the riser shaft provide the possibility for
scaffolding platforms in the intermediate piece on the side of the riser shaft. Remove the covers for
this purpose.
The platform (3.8 m) on the backside of the housing and the platform above (6.2 m) provides access
to the intermediate piece.

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7.5 Classifier

C-000083/00 365-0001

Release both pressure spindles and the studs of both clamps to open the access door. Open the
access door about 10° until it meets the retaining clip. Remove the stud of the retaining clip and turn
over the retaining clip to open the access door completely.

Fig.: Access door with interlock

Scaffold openings for scaffold tubes provide the possibility to enter the classifier. Remove the covers
for this purpose. The platform (8.6 m) on the backside of the mill provides access to the classifier.

Mount the scaffold over the riser shaft bottom-up to provide access to the hopper (inside of the mill). The hopper
walls provide support for the scaffold.

Weld-on special retaining units to guarantee safe working procedures (Remove the retaining units after the
maintenance work to prevent dust deposit).

Open the door locks carefully. Make sure the mill is safety cooled down.
In the unlikely event of coal dust deposit- deflagration cannot be excluded.

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7.6 Beater Wheel

C-000083/00 369-0001
Pay attention to unbalanced mass or start-up noises during operation.
See also Chapter 10.1 in this manual

7.7 Beater Wheel with Fastening Device

C-000083/00 367-0055
Torque moment for screws: 1800 Nm / gap 0 mm (Priority: gap 0).
All M48 screws at the fastening device should be fastened with the same torque.

Gap
Spalt 0
0

Fig.: Beater wheel fastening device

7.8 Double Bearing

Attention rotating parts! Do not touch!

C-000083/00 367-0001

C-000083/00 367-0042
Two oil drain valves 1 and a filling and ventilation filter 2 are provided for the oil exchange. The oil
level is supervised via two oil level gauges 3 before and during the filling via the filling and ventilation
filter and three float switches 4 (2 for minimum oil level / 1 for maximum oil level during operation.
Three bimetallic dial thermometer 5 and two resistance thermometers 6 supervise the roller bearing temperature.
The bearing is adjusted on the bearing frame towards the mill housing via the adjustment screws 13.

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 6
2

5
6

1
1
3

Fig.: Double bearing

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 1
0

1
1

4 8

1
2

7 9

Fig.: Double bearing lubrication

7.9 Double Bearing Lubrication

Use skin protection emulsion!

C-000083/00 367-0040
The two self-aligning roller bearings (fixed bearing and floating bearing) are supplied with the required
oil amount via the pump aggregate 7. The oil in the double bearing is pumped towards the consumers
via one duplex filter 8, a heat exchanger 9 and flow monitors 10 as well as a throttle valves 11.
The pollution if the double in-line filter 8 is supervised by the differential pressure indicator 12 (included
in the filter).

The oil amount towards the floating bearing (coupling side) is set via the throttle valve 11 on 10 l/min.
A flow monitor 10 indicates the oil amount. The oil amount towards the fixed bearing (beater wheel
side) is set on approx. 18 l/min, according to the difference of the oil amount in the pump. A flow
monitor 10 indicates the oil amount in the pipes towards the fixed bearing.

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7.10 Beater Wheel Mounting Device

The Beater Wheel must be mounted and dismounted by a mounting device on a vehicle.

7.11 Double Bearing Mounting Device

The Double Bearing must be mounted and dismounted by a mounting device on a vehicle.

7.12 Balancing Device

C-000083/00 357-0090
Place the beater wheel with the proper fitted balancing stud carefully on the support rollers of the
balancing device to avoid damages on the roller bearings of the support rollers.

7.13 Lifting Devices and Crane Runway over the Mill Drives

The crane runway with the lifting devices over the mill drives serves for the exchange of gear box
and motor.

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8 MAINTENANCE

Surfaces or mill parts may be hot. Do not touch!

The safety warning signs for hot surfaces must be placed by the operator
on all surfaces of the mill which may be hot!

8.1 Cleaning and Lubrication

(Time interval and amount: see chapter 8.2 lubrication plan)

Down-shaft connection with slide gate Spray the inner parts of the clamping device with a
lubricant or a preservative agent.
Mill door Lubricate the lubrication points at the supports and
at the axis of the undercarriage wheels at the latest
after the mill cleaning.
Double bearing Two manual valves are provided for the oil
exchange. The drains are closed with plugs. Use
the filling and ventilation filter to fill in the new oil.
Use a filter for filling in the oil. Fill oil in both
chambers of the double bearing up to the middle of
the oil gauge. Start with the chamber on the drive
side. Please find the information for the filter, the
heat exchanger and the pump in a separate
operation manual.
Housing Lubricate the hinges of the access doors
Intermediate piece Lubricate the actuating drive of the oversize return
according to the separate operation manual
Classifier Lubricate the hinges of the access doors
Variable speed-gear coupling See separate operation manual
Mill motor See separate operation manual
Balancing device Spray the support disks with thin fluid corrosion
protection regularly. Lubricate the swivel socket
regularly
Beater wheel mounting device / Double Clean the rails of the slider before every usage.
bearing All hinges, cylindrical joints, thread spindles,
conical seats and hydraulic cylinders as well as all
screw connections must be cleaned and lubricated
regularly.
Beater wheel mounting vehicle See separate operation manual from supplier

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8.2 Lubricant list

Operation time/hours check Amount Lubricant list Annotations

weekly after mill after yearly lubricant
cleaning 1200
hours
exchange
to do
• • Oil level double bearing 350GS399

• • Oil level down shaft 130 l

350GS399
hydraulic system
• • Support spindle of the 2g
350GS399
mill door undercarriage
• • mill door wheel axis 2g 350GS399
• • Screw plugs mill
350GS399
housing
• • • Access doors housing/
intermediate piece/ 350GS399
classifier
• Adjustment drive:
350GS399
oversize return
• • Oil filling double 300 l Exchange period can
be extended
bearing according to the
350GS399 analysis and the
approval by the oil
supplier.
• • geared variable speed 1000 l Exchange period can
be extended
coupling according to the
350GS399 analysis and the
approval by the oil
supplier.
• • Oil filling down shaft 32 l 350GS399 Exchange period can
be extended
hydraulic system according to the
analysis and the
approval by the oil
supplier.
• Balancing device 350GS399 monthly
swivel socket
• Balancing device 350GS399 monthly
support disks
• Clamping device down 350GS399 monthly
shaft connection
• Beater wheel and 350GS399 With every beater
wheel exchange
double bearing shaft
cone
• Beater wheel 350GS399
anchorage screws

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8.3 Inspection and Maintenance

In general:

• Note all findings of wear and damage in a table

• Replace all damaged or disabled parts (sealing, wear parts)
• Damaged refractory or other parts than wear parts must be repaired or replaced
professionally. Follow the hints of the manufacturer for preparing and working with parts.
Consult the manufacturer if findings on the parts are unusual.

Danger of entrapment!

Surfaces or mill parts may be hot. Do not touch!

!

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8.3.1 Down Shaft Connection with Slide Gate

C-000083/00 364-0001

Roller pulleys

L-profile segment
Sealing
Sealing cylinder
Clamping device

Fig.: Down shaft connection with detail

Check the refractory of the down shaft connection housing and of the down shaft connection sealing
cylinder for wear and damage, at latest during boiler rest. The sealing of the down shaft connection
housing and of the down shaft connection sealing cylinder must be checked for wear. If the sealing
is not fitting correctly, check the spring elements of the clamping device for correct movement and
repair or adjust during the mill operation if necessary. The L-profile segments for fixing the sealing
must not touch each other and the gap should measure 20 mm. The roller and guide pulleys have
lifetime lubrication.
Visible oil leakage on the hydraulic cylinders indicates a damaged sealing of the piston rod. When
the piston sealing is leaking (indicated by tilt of the sealing cylinder during lifting or lowering
process), the leakage oil is guided via the leakage oil pipe to the tank of the hydraulic aggregate.
Check the hydraulic hoses and the screw connection for leakage and make sure they are in
undamaged condition.

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8.3.2 Mill Door

C-000083/00 362-0001
Check the refractory, the armoring and the fixation elements of the armoring for wear, damage or
distortion when working on the mill. Replace or repair if necessary. The hub shield anchorage and
the arms of the hub shield must be checked for wear. Make sure the sealing of the down shaft
connection sealing cylinder is in undamaged condition and fits correctly on the sealing edges of the
down shaft connection cylinder.

8.3.3 Mill Housing

C-000083/00 360-0001
Check the sealing of the submersible collar for wear and make sure it fits correctly on the sealing
edges of the mill door submersible collar. Also check the sealing of the access doors and of the side
armor covers for wear and make sure the fit correctly. Check the armor plates and armor bars and
the fixation of the armor plates and bars. Replace or repair if necessary.

8.3.4 Intermediate Piece

C-000083/00 363-0001
Make sure the sealing edges fit correctly and check the sealing of the access openings for wear.
Check the adjustment drive according to its operation manual. Check the armoring and the fixation
elements of the armoring for wear, damage or distortion when working on the mill. Replace or repair
if necessary.

8.3.5 Classifier

C-000083/00 365-0001
Make sure the sealing edges of the access doors fit correctly and check the sealing of the access
doors for wear. Makes sure the expansion joint is working correctly and check for wear. Check the
armoring and the fixation elements of the armoring for wear, damage or distortion when working on
the mill. Replace or repair if necessary.

8.3.6 Beater Wheel

C-000083/00 369-0001
Check the screws for fin bar according to the inspection protocol C-000083/00 369-7265 with every
beater plate exchange. Note the results in the protocol. The cone of the hub disk must be checked
visually with every beater wheel exchange. Measure the gap between the beater wheel and the mill
housing and note the result in the protocols C-000083/ 00 350-7360.

Determine the weight of the demounted beater wheel once a year.

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8.3.7 Double Bearing

C-000083/00 367-0001, -0040, -0042

Check the oil levels regularly via the oil level gauges. Make sure the thermometer, the flow monitors
and the differential pressure indicator in the lubrication system is in undamaged condition, as well as
the flow monitor in the cooling water recirculation. Check the oil pipes, the water pipes, the heat
exchanger, the double filtering screen and the lubrication pump for leakage regularly.

8.3.8 Gear Box (Geared Variable Speed Coupling)

C-000083/00 350-0001 Pos.9

Please find all information in the separate operation manual from NARA
(QML_10_M_HFC368NARA_EI_003).

8.3.9 Connection Couplings

C-000083/00 350-0001 Pos. 11, 18

The condition of the coupling elements must be detected every month. Please find further
information in the separate operation manual (QML_10_M_HFC368NARA_EI_003).

8.3.10 Mill Motor

C-000083/00 350-0001 Pos. 8

Please find all information in the separate operation manual.

8.3.11 Balancing Device

C-000083/00 357-0090
Makes sure the support rollers can move freely.

8.3.12 Foundation with Mounting Parts

C-000083/00 354-0002
Check the visco damper for leakage and the condition of the spring elements annually. Make sure
the corrosion protection of the visco damper and the spring elements are in undamaged condition.

8.3.13 Beater Wheel Mounting Device

Makes sure the hydraulic hoses are in undamaged condition and check the hydraulic system for
leakage before every usage.

8.3.14 Double Bearing Mounting Device

Please find all information in a separate operation manual

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8.4 Repair Works

In general:
• Note all findings of wear and damage in a table
• Replace all damaged or disabled parts (sealings, wear parts, fixation parts…)

• Damaged refractory or other parts than wear parts must be repaired or replaced professionally. Follow
the hints of the manufacturer for preparing and working with parts. Consult the manufacturer if findings
on the parts are unusual.

8.4.1 Down Shaft Connection with Slide Gate

C-000083/00 364-0001

The boiler must be out of commission!

Replace damaged refractory of the down shaft connection housing and of the down shaft connection
sealing cylinder, at latest during boiler rest. Check the sealing (down shaft connection housing/down
shaft connection sealing cylinder) for wear and replace it if necessary.
If the sealing on the down shaft connection housing is not fitting correctly in the down shaft
connection housing, check the spring element of the clamping device for free movement and
release, clean and lubricate them if required. Adjust the tension force using the adjusting screw. The
L-profile segments for fixation of the sealing must not touch each other and the gap should measure
20mm.

The roller and guide pulleys have lifetime lubrication and must not be cleaned with water!

Replace leaking hydraulic cylinders.

Adjust the tilt of the sealing cylinder when lifting or lowering using the hydraulic aggregate (see also
separate operation manual: Neumeister C-000083_00357_7321). Replace damaged hydraulic
hoses and re-screw leaking screw connections.

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8.4.2 Mill Door

C-000083/00 362-0001
Replace worn-out, damaged or distorted armoring of the mill door and the submersible collar.
Check the refractory for damage and replace it if necessary.
Refer to the manufacturer’s operation manual when preparing or working with the supplied parts.
Check the anchorage of the hub shield and repair or replace if necessary.
Remove all deposits and impurities of the down shaft connection sealing before closing. Replace the
sealing if it is worn-out or damaged. Replace damaged thermocouples and their wear protection.
Use an adaptable scissor platform if necessary.

8.4.3 Mill Housing

C-000083/00 360-0001

Working above the mill axis requires scaffolding of the mill housing for safety reasons and
protection of the double bearing (additional cover) shaft.

Replace worn-out, damaged or distorted armoring. Replace damaged or worn-out seals in the
access doors and covers.

8.4.3.1 Corner Armor

Fig.: Corner Armor

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Open the corner armor access door. The corner armor plates are mounted staggered via straps and
can be mounted/demounted one by one. The armors are hooked into a rail. The rail and a stopper
provide the positioning of the armors.

Attention: The end pieces have different shape than the other ones and serve as fitting
parts.

8.4.3.2 Upper Circumferential Armoring

Open the cover lid next to the side armor door. Replace the upper circumferential armors via the
nearest access door.

Pay attention during installation or deinstallation of the circumferential armor bars

in the upper mill housing. The armor bars are only retained by the square bars of
the side wall armor plates. Secure the armor bars (of the circumferential armoring)
during installation or deinstallation against falling down!

8.4.3.3 Circumferential Armoring

Remove the arranged covers of the spiral areas in the side walls to exchange the circumferential
armors.

The longer circumferential armors are carried by the wall of the mill housing in
the area of these covers. The armors support the upper located armor bars. For
this reason, the lower bar can only be removed when all armor bars located
above are already demounted. The demounting takes place from up to down,
the mounting vice versa. The end parts are fitting parts.

The armors are pushed through the opening located on the opposite side in the mill housing.

8.4.3.4 Side Armors

The side armors are screwed from the outside of the housing. Armors in the sump area and in the
area of the housing armor rings are screwed from the inside.

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8.4.4 Intermediate Piece

C-000083/00 363-0001

Works on the intermediate piece require scaffolding of the intermediate piece.

Remove all cover lids to exchange the armor bars. The armors are exchanged in sections. The side
armors are screwed on the outer side of the housing.
Replace worn-out or damaged sealings.

8.4.5 Box-Type Classifier

C-000083/00 365-0001

Working on the classifier requires scaffolding of the classifier.

The armors are screwed from the outside of the housing. Exchange the armors via the access door.
Replace worn-out or damaged seals.
Refer to the separate operation manual of the manufacturer when working, especially securing the
actuator.

8.4.6 Beater Wheel

C-000083/00 369- 0001

The exchange of the beater plates, retaining straps, armor sheets, wear rings and of the wear plate
takes place in the workshop. Conditions for a successful exchange are a clean and dust-free beater
wheel.

Pay attention to the direction of rotation of the beater wheel

according to the mill.

Measure the gap between inner/outer beater plates, beater plate/retaining strip, retaining strip/armor
sheet according to the assembly drawing C-000083/00 369- 0001 and note the results in a protocol.
Measure the gap between beater wheel and mill housing after the mounting of the beater wheel in the
mill. Record all results in the protocols C-000083/00 350-7360.
The cone of the hub disk must be clean and free from grease. Spread Molykote Powder Z before the
mounting of the beater wheel.

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 Do not use paste!

Beater plate exchange and, if required, exchange of the retaining strip (according to its wear
state):
Demount the following parts:

Part no – drawing 369-0001 / Description Annotation

369-0051
Parts 29 Cover disk
Parts 20 Hexagon bolt M 20 x 120
Parts 8 Retaining strip of the hub disk
Parts 9 Retaining strip of the ring disk
Parts 21 Hexagon bolt M 20 x 105
Parts 6 Armor sheet of the hub disk
Parts 7 Armor sheet of the ring disk

After these preliminary works the outer and inner beater plate can be swiveled out.
The mounting of the replaced parts takes place in reversed order.

Take in account the torque moments of the screws.

Exchanging the armor sheets:

Demount the following parts:
Part – drawing 369-0001 / 369- Description Annotation
0051
Parts 29 Cover disk
Parts 21 Hexagon bolt M 20 x 105
Parts 6 Armor sheet of the hub disk
Parts 7 Armor sheet of the ring disk

The mounting of the replaced parts takes place in reversed order.

Take in account the torque moments of the screws

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Exchange of the ventilation disk:

Drawing 369-0001 / 369-0051

• Remove: Parts 25, Cylindrical Head Screw M 16 x 40

• Remove: Part 14, Ventilation disk

Pay attention to the direction of rotation of the beater wheel according to the mill
design.

The hub disk cone must be free from grease and in undamaged condition.
Clean the cone and spread Molykote Powder Z before the mounting of the beater wheel. Measure
the gap between the beater wheel and the mill housing after the mounting of the beater wheel in the
mill. Record the result in the protocol C-000083/00 350-7360.

Side armor
Retaining Bars

Beater plates
(inner and outer)

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8.4.7 Double Bearing
C-000083/00 367-0001

Bearing noises indicate damages on the outer or inner ring, the retainer or the roller element. An exact analysis
requires an oscillation measurement. Demount the double bearing using the double bearing mounting device.

Exchange of the roller bearing

This work takes place only in the work shop.

Preconditions:
• Demounted cover / Protect the opening from dust and contaminations
• Drain the oil- before the demounting of the double bearing
• Dispose the oil according to the environmental regulations
Demount the following parts:
Fixed bearing side:
Part – drawing 367-0001 Description Annotation
Part 46 Hexagon head screw M 6 X 20
Part 16 Clamp ring: fixed bearing
Part 14 Intermediate ring: fixed bearing
Part 40 Hexagon head bolt M 24 X 100
Part 4 Bearing Cover Use the lifting screw
Part 18 Labyrinth ring: fixed bearing
Part 45 Countersunk screw M 8 x20
Part 9 Oil guide plate 1
Floating bearing side:
Part – drawing 367-0001 Description Annotation
Part 46 Cylindrical head screw M6x20
Part 17 Clamp ring: floating bearing side
Part 15 Intermediate ring: floating bearing side
Part 41 Hexagon bolt M 20 x 60
Part 5 Bearing cover Use the lifting screw
Part 19 Labyrinth ring: floating bearing
Partition wall: oil chamber Detail G:
(drawing 367-0001) Hexagon bolt M10 x 25, Cap nut M10
Sheet, Sealing
Elastic coupling half See O&M Manual of elastic
coupling

After the preliminary works the double bearing shaft can be pulled together with the roller bearing
and the bushes out of the bearing housing in direction of the fixed bearing.

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Assembling the bearing shaft / bearing housing:
The Assembling takes place in reversed order. Use lubricants and make sure no component is
damaged to guarantee an undisturbed mill operation.
Demounting the fixed bearing with fixed bearing bush:
Demount the following parts:
Part – drawing 367-0001 Description Annotation
Part 46 Hexagon bolt M 6 X 20
Part 16 Clamping ring - fixed bearing
Part 14 Intermediate ring - fixed bearing
Part 40 Hexagon head bolt M 24 X 100
Part 4 Bearing cap- fixed bearing Use the lifting screw
Part 18 Labyrinth sealing
Part 37 Cab screw M16 x 40
Part 26 Feather key
Part 47 Hexagon bolt M16 x 30
Parts 42 Hexagon bolt M 16 x 35
Part 12 Splash Collar – Fixed Bearing
Part 30 Lock Nut with Retaining Clip Unscrew only about a ¼
turn – securing the bearing
in axial direction
Parts 45 Countersunk screw M 8 x 20
Part 9 Oil guide plate
Part 20 Bush

Attention: the outside located oil guide plate fixes the roller bearing in the fixed
bearing bush.

Use the hydraulic mounting kit to force off the roller bearing (with bush). After removing Lock Nut with Retaining
Clip (part 30, the bush (part 20) and the feather key (part 26), pull off the roller bearing with bush from the double
bearing shaft.

Take the roller bearing out of the fixing bearing bush after removing the outer oil guide plate.

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Demounting the floating bearing with floating bearing bush:
Demount the following parts:
Part – drawing 367-0001 Description Annotation
Part 46 Cylindrical head screw M6x20
Part 17 Clamp ring: floating bearing side
Part 15 Intermediate ring: floating bearing side
Part 41 Hexagon bolt M 20 x 60
Part 5 Bearing cover Use the lifting screw
Part 19 Labyrinth sealing
Parts 43 Hexagon bolt M 10 x 25
Part 13 Splash Collar - Floating Bearing
Part 50 Hexagon bolt M10 x 20
Part 34 Circlip
Part 33 Lock nut with Retaining Clip Unscrew only about a ¼ turn
– securing the bearing in
axial direction
Parts 44 Hexagon bolt M 8 x 20
Part 11 Oil guide plate
Part 23 Bush 2

Use the hydraulic mounting kit to force off the roller bearing (with bush). After removing the lock nut with retaining
clip (part 6), the bush 2 (part 23) and the feather key (part 25), pull off the roller bearing with bush from the
double bearing shaft.
Take the roller bearing out the roller bearing bush after removing the retaining ring.

Mounting the roller bearing with fixed bearing bush:

Mount the following parts:
Part – drawing 367-0001 Description Annotation

Part 20 Bush 1 – Fixed Bearing

Part 30 Lock nut Retaining Clip Unscrew with several turns

(away from the bearing hub)
Part 47 Hexagon bolt M 16 x 30

Push the roller bearing, mounted in the fixing bearing bush, on the double bearing shaft. Adjust the
bearing clearance using the hydraulic nut. Refer to the bearing clearance table 367-7292. Make sure
the lock nut with retaining clip secured.

Shaft nuts, located on both side can only be tightened for securing! No loosening!

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Mounting the roller bearing with floating bearing bush:
Mount the following parts:
Part – drawing 367-0001 Description Annotation
Part 23 Bush 2
Part 33 Lock nut Retaining Clip Unscrew with several turns
(away from the bearing hub)
Part 34 Circlip
Part 49 Hexagon bolt M 8 x 16
Push the roller bearing, mounted in the floating bearing bush, on the double bearing shaft. Use the
hydraulic nut according to the manufacturer’s operation manual.
Adjust the bearing clearance using the hydraulic nut. Refer to the bearing clearance table 367-7292.
Make sure the lock nut with retaining clip secured.
Clean the cone and spread Molykote Powder Z before the mounting.

8.4.8 Beater Wheel Mounting Device

Please find all information in an operation manual from the supplier

8.4.9 Double Bearing Mounting Device

Check the winch according to the manufacturer operation manual. The sliding surfaces must be
sprayed with thin fluid corrosion protection on a regular basis to avoid corrosion.

8.4.10 Balancing Device

C-000083/00 357-0090
The support rollers must be sprayed regularly with thin fluid corrosion protection. Lubricate the swivel
socket regularly.

8.4.11 Foundation with Mounting Parts

C-000083/00 354-0002
Check the visco damper regularly for leakage, intact corrosion protection and make sure they are in
undamaged condition.
Check the corrosion protection of the spring elements for wear and damage.
Accomplish functional test according to the separate operation manual of the supplier.

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9 HANDLING MALFUNCTIONS

Observe the following points to avoid injury of the operating personnel or damaging plant
parts when handling malfunctions or disorders:

• Only qualified personnel is allowed to repair or remove malfunctions on the plant

• Secure the plant against accidentally start-up by disconnecting the beater wheel mill
• Obey the SAFETY INSTRUCTIONS in chapter 2 at all times

9.1 Possible Malfunctions

Malfunction Cause Handling the malfunction

Mill is not running smooth increasing wear of the beater exchange the beater plates
wheel
defective visco damper exchange the visco mass
lost wear part (beater wheel/pre- shut-down the mill and replace
beater) the wear part
loose hub of the beater wheel shut-down the mill and check the
beater wheel hub on the shaft
cone, adjust if necessary
Re-work the cone of the hub/
shaft if necessary
Heavier damages of the surface
require professional welding
repair with mechanical
treatment
loose/already damaged self check the bearings
aligning roller bearings of the Make an oscillation measurement
double bearing and replace the bearing if
necessary
attention: take into account the
long time of delivery and
make sure there are
bearings on reserve

Sliding noises on the rear wall of Armor screws are too long Exchange screws
the housing loose armor sheets on the housing re-screw armor sheets attachment
rear wall screws
Dust leakage sealing is not braced correctly re-brace the sealing
sealing is damaged or worn-out Exchange sealing
Exceeding temperature on refractory damage shut-down the mill
isolated parts (down shaft repair the refractory
connection/mill door)

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 bearing temperature > oil flow is too low shut-down the mill
double bearing check the lubrication system
switch the oil filter
check the oil flow
supervise the temperature
clean the affected filter chamber
Replace the lubrication pump if
necessary
bearing damage shut-down the mill
check the roller bearings
differential pressure on the filter> filter element is clogged switch filter and change the
clogged filter element
Oil flow is too low Throttle valve is closed Re-adjust throttle valve
Oil pump is defect Check pump/motor, repair if
necessary
Oil level is too low not enough oil in the system refill oil
Leakage shut-down the lubrication pump for
a short term and repair the leakage
(supervise the bearing temperature
when the temperature is exceeding
shut down the mill and repair the
pipes)
pipe rupture shut-down the lubrication pump for
a short term and repair the leakage
(supervise the bearing temperature
when the temperature is exceeding
shut down the mill and repair the
pipes)
Oil level too high pipe rupture in the heat exchanger Disconnect the water supply for a
short term and replace the heat
exchanger (make an oil analysis to
check the water content in the oil,
drain the complete oil and refill
with new oil if necessary)
Abnormal speed of the drive unit is defect check the variable speed-gear
beater wheel coupling/mill motor and repair if
necessary
check the condition of the
connection couplings.
running/operating noises damaged roller bearings Analysis via oscillation
• outer ring measurement; replace roller
• inner ring bearing if necessary
• bearing cage attention: take into account the
• roller element long time of delivery and make
sure there are bearings on reserve

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10 Activities at Mill
10.1 Inspection of wear situation

Inner Beater plate close to end of

wear life. Replacement of wear
parts requested.

10.2 Dismounting of the beater wheel

This section needs to be updated when the selection of the device has been done

Install the retaining bars

C-000083_00357_0045 Beater wheel retaining device
Detach the beater wheel fixation. Attention, heavy parts!

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 Mill door removed (outside sketch)
Beater wheel loaded on device

Beater wheel in working position

on shaft

1. Device comes along, centering with brackets (detail, zoom)

2. Device shifts towards wheel

3. Pulling cylinder tips up

4. Bolts 8x connect wheel with cylinder

5. Hydraulic Cylinder takes wheel over

Safety advice: keep clear of danger area

6. Device withdraws with wheel connected

Danger of entrapment!

7. Wheel is lowered into holding brackets

8. Device lifts and drives away

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10.3 Mounting of the beater wheel

Disc Spring compensates thermal

expansion of cone seating

Checklist:
• Cone of shaft and hub must be cleaned by sandpaper
• Shaft of double bearing must be rubbed with powder acc. manual
• Wheel must be placed at shaft in correct position
• Gap 0,0 mm between wheel and shaft must be checked
• Gap ~ 1,0 mm of spring box must be checked before assembly
• Screw of fastening device prepared by Molykote
• Segments of fastening device must be placed without lubricant
• Screws of fastening device fixed by using electrical torque wrench
• Used starting torque min 1.100 Nm, max 1.500 Nm
• Gap 0,0 mm of spring box after assembly must be checked
• Gap 0,0 mm between shaft and hub must be checked again
• Screws must be fixed by metal strip

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11 Activities in Maintenance Workshop

11.1 Lifting Works

Lifting of beater wheel must be done either using chains or steel cables. All lifting devices hilfsmittel
must be approved and released for application by authority. When using cables, it is important, to
protect the cables against sharp edges of beater plates or ring disc.

Admissible weight for lifting must be considered. Dimensions and weights can be found in document
068-7324 (lifting arrangement of static components beater wheel mill) or in drawings and part lists.

Take care of sharp edges when attaching loads!

Do not stand or work under suspended loads!

11.2 Cleaning

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11.3 Dismantling of the wear parts

11.4 Replacement of the wear parts

Retaining Strips

Weld Sealing Stripes with no Gap

Beater Plates

11.5 Balancing

The wheels are delivered balanced without wear parts. For installation of new beater plates, the
same shall be installed in pairs of similar weight. After installing the new beater plates, the wheel
must be balanced, using the balancing device. See 12.4

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12 Tools

12.1 Device for beater wheel servicing

For dismantling /Mounting of the beater wheel with its weight and size a special device is requested.
Depending on the maintenance strategy two options are available.
Maintenance trailer:)
• needs additional traction vehicle
• Operates hydraulically
• Different devices for vehicle available
• Also used for double bearing maintenance
• Must be operated only on sustainable ground floor

Self-driving maintenance vehicle

• no additional device needed

12.2 Hydraulic Aggregate

→ Mobile Unit (1 Piece)

→ Used to operate
hydraulic cylinders at
the gate valve
→ Operates hydraulic
moving device of the
mill door to give access
to beater wheel

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 Ports for hydraulic operation of gate
valve

12.3 Mill Door Moving Device

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12.4 Beater Wheel Balancing Device

• The wheel shall be lifted by the crane

• Install the temporary mill shaft

12.5 Suggestion for Storage Area

Storage area in boiler house

for housing wear parts

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13 ATTACHMENTS AND INDEXES
13.1 Drawing List

13.1.1 Subassembly 060 DIMENSION SHEETS AND DRAWINGS

C-000083_00060_0001 Mill dimension sheet N 260.34 S

C-000083_00060_0004 Mill platform arrangement Mill N 260.34 S

13.1.2 Subassembly 350 Arrangement

C-000083_00350_0001 Mill assembly drawing

13.1.3 Subassembly 354 Mill Foundation

C-000083_00354_0002 Foundation with Anchorage Elements

C-000083_00354_0003 Foundation - Anchorage rails
C-000083_00354_0004 Foundation - Guide for mill housing
C-000083_00354_0005 Foundation - Anchorage drive frame
C-000083_00354_0007 Foundation - Anchorage double bearing frame
C-000083_00354_0008 Foundation - Anchorage mill housing
C-000083_00354_0009 Foundation - Edge guard foundation
C-000083_00354_0010 Foundation - Ceiling joint
C-000083_00354_0012 Fastening disc for double bearing frame
C-000083_00354_0013 Socket
C-000083_00354_0014 Hose Through Guide
C-000083_00354_0016 Stopper

13.1.4 Subassembly 355 Foundation

C-000083/00 355-0001 Anchorage rails 0 m floor level

13.1.5 Subassembly 357 Special tools

C-000083_00357_0045 Beater wheel retaining device

C-000083_00357_0068 Beater Wheel Maintenance Device
C-000083_00357_0075 Trestle Beater Wheel
C-000083_00357_0083 Mill Door shifting device
C-000083_00357_0085 Hub Shield mounting device
C-000083_00357_0090 Balancing device

13.1.6 Subassembly 360 Mill housing

C-000083_00360_0001 Mill housing assembly

C-000083_00360_0002 Mill housing upper part
C-000083_00360_0003 Mill housing lower part
C-000083_00360_0060 Armoring Assembly

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13.1.7 Subassembly 361 Foundation Frames

C-000083_00361_0001 Double Bearing frame

C-000083_00361_0003 Motor frame
C-000083_00361_0005 Gear frame

13.1.8 Subassembly 362 Mill door

C-000083_00362_0001 Mill door – Assembly

C-000083_00362_0040 Armoring general view
C-000083_00362_0060 Hub shield
C-000083_00362_0070 Resistance thermometer mounting

13.1.9 Subassembly 363 Intermediate Piece

C-000083_00363_0001 Intermediate piece assembly

C-000083_00363_0030 Intermediate piece armoring – assembly
C-000083_00363_0060 Downshaft hydraulic pipes

13.1.10 Subassembly 364 Down shaft connection

C-000083_00364_0001 Downshaft connection

C-000083_00364_0007 Down shaft – hydraulic pipes

13.1.11 Subassembly 365 Classifier

C-000083_00365_0001 Classifier assembly

C-000083_00365_0028 Armoring general view

13.1.12 Subassembly 367 Double Bearing

C-000083_00367_0001 Double bearing – Assembly

C-000083_00367_0040 Double bearing lubrication
C-000083_00367_0042 Measuring instruments
C-000083_00367_0053 Double Bearing attachment
C-000083_00367_0054 Double Bearing rotational speed measurement
C-000083_00367_0055 Beater wheel attachment assembly

13.1.13 Subassembly 368 Drive

C-000083_00368_0001 Overview of shaft ends

C-000083_00368_0002 Shims
C-000083_00368_0021 Coupling guard double bearing
C-000083_00368_0031 Coupling guard motor

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13.1.14 Subassembly 369 Beater Wheel

C-000083_00369_0001 Beater wheel – Assembly CW mills HFC 20 + 40 + 60 + 80

C-000083_00369_0051 Beater wheel – Assembly CCW mills HFC 10 + 30 + 50 + 70

13.1.15 Subassembly 377 Water Supply

C-000083_00377_0001 Cooling water interface – CW Mill

C-000083_00377_0002 Cooling water interface – CW Mill

Aggregates, Armatures and Instruments

13.1.16 Subassembly 357 devices

13.1.16.1 Hydraulic aggregate

KKS-No: HFC00AX001
Drawing number + Pos.: 357_0050
Manufacturer: Neumeister Hydraulic
Description: gear-type pump aggregate,
AA009 D040 L00060 V506024 T270S
Movable hydraulic aggregate
Documentation: 357_7321

13.1.16.2 Mill door shifting cylinder

KKS-No: NA
Drawing number + Pos.: 357_0083
Manufacturer: Neumeister
Description: Double acting hydraulic cylinder 209-40151
Documentation: 357_7321

13.1.17 Subassembly 362 Mill Door

13.1.17.1 Resistance Thermometer (Thermal Coupling)

KKS-No: HFC10CT611 / HFC10CT612
Drawing number + Pos.: 362-0001 Pos.11; 362_0070 Pos. 1
Manufacturer: Chongqing Chuanyi
Description: WRKK2-2512
Documentation: NA

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13.1.18 Subassembly 363 Intermediate piece

13.1.18.1 Actuator

KKS-No: HFC10AA110
Drawing number + Pos.: 363-0001 Pos. 3
Manufacturer: EUBA
Description: Type B4
Documentation: 363_7323

13.1.18.2 Electric actuator

KKS-No: HFC10AA110
Drawing number + Pos.: 363-0001 Pos. 3
Manufacturer: AUMA
Description: SA 07.2
Documentation: 363_7323

13.1.19 Subassembly 364 Down Shaft Connection

13.1.19.1 Double acting hydraulic cylinder (slide gate)

KKS-No: HFC10AA011; HFC10AA012

Drawing number + Pos.: 364-0001 Pos. 6
Manufacturer: Neumeister
Description: DZL 63 N 36-1830 GE UK-2RS
Documentation: C-000083_00364_7321

13.1.19.2 Double acting hydraulic cylinder (sealing cylinder)

KKS-No: HFC10 AS011; HFC10 AS012

HFC10 AS013; HFC10 AS014
Drawing number + Pos.: C-000083/00 364-0001 Pos. 7
Manufacturer: Neumeister
Description: DZL 63 N 36-520 GE UK-2RS
Documentation: C-000083_00364_7321

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13.1.20 Subassembly 365 Box-Type Classifier

13.1.20.1 Manual Drive (worm gearbox)

KKS-No: HFC10AS521, HFC10AS522

Drawing number + Pos.: C-000083/00 365-0052 Pos. 2
Manufacturer: EMG
Description: WORM GEARBOX,
Type GS125.3-180-F10-DCD + scale ring
Documentation: C-000083_00365_7325

13.1.21 Subassembly 367 Double Bearing

13.1.21.1 Double Bearing

KKS-No: 10HFC11
Drawing number + Pos.: 350-0001 Pos. 10
Manufacturer: NGC
Description: NA
Documentation: 367NHSG_FD_001

13.1.22 Subassembly 368 Gear Box

13.1.22.1 Gear Box (geared Variable Speed Coupling)

KKS-No: HFC10AS001
Drawing number + Pos.: 350-0001 Pos. 9
Manufacturer: NARA
Description: Type R 750 B 4G NGC 750T1R
Documentation: 368NARA_DL_001

13.1.22.2 Connecting coupling Input (motor / gear box)

KKS-No: NA
Drawing number + Pos.: 350-0001 Pos. 18
Manufacturer: NARA
Description: SAM 280
Documentation: 368NARA_DL_001

13.1.22.3 Elastic coupling (gear box / double bearing)

KKS-No: NA
Drawing number + Pos.: 350-0001 Pos. 11

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Manufacturer: NARA
Description: SSM 400
Documentation: 368NARA_DL_001

13.2 Protocols

C-000083/00 350-7308 Alignment of Double Bearing

C-000083/00 350-7309 Position Mill Housing – Double Bearing

C-000083/00 350-7321 Mill Door Alignment + Setting

C-000083/00 350-7328 Report - Beater Wheel installation

C-000083/00 350-7337 Drive Train Alignment Double Bearing and Gear Box

C-000083/00 350-7338 Drive Train Alignment Gear Box and Motor

C-000083/00 350-7360 Alignment of Mill Housing Clearances

C-000083/00 350-7361 Gap Beater Wheel – Corner Armor

C-000083/00 367-7292 Double bearing – Shaft and bearing installation measurement

C-000083/00 369-7260 Graphical balancing and installation of webs

C-000083/00 369-7261 Installation of Beater Plates

C-000083/00 369-7262 Gaps at shoulder pads

C-000083/00 369-7263 Installation of webs

C-000083/00 369-7264 Inspection Report Beater Wheels

C-000083/00 369-7265 Record sheet for checking the web screws

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