SECTION 3 - HP PULVERIZER MAINTENANCE

TABLE OF CONTENTS

TITLE TAB NO.

GENERAL MAINTENANCE ----------------------------------------------------------------- 1 GENERAL DISASSEMBLY ----------------------------------------------------------------- 2 GENERAL REASSEMBLY ------------------------------------------------------------------- 3 COMPONENT SERVICING ------------------------------------------------------------------ 4 COMPONENT LUBRICATION AND MAINTNEANCE SCHEDULES ------------ 5

This page intentionally left blank.

i

SECTION 3 - HP PULVERIZER MAINTENANCETAB 1. GENERAL MAINTENANCE

CONTENTS TAB 1

TITLE PAGE NO.

INTORDUCTION ------------------------------------------------------------------------------------------------ 1

GENERAL MAINTENANCE ----------------------------------------------------------------------------------- 2

INTERFERENCE FITS ----------------------------------------------------------------------------------------- 4

Heating ------------------------------------------------------------------------------------------- 4

Chilling ------------------------------------------------------------------------------------------- 4

GENERAL MAINTENANCE

ii

This page intentionally left blank.

1

TAB 1. GENERAL MAINTENANCE

INTRODUCTION

The following tabs of the manual have been prepared to serve as a guide in maintaining DOOSAN Pulverizers. They do not cover all possible variations in equipment nor provide solutions for special problems which may arise. If additional information is required, however, DOOSAN or its representatives may be contacted. It must be recognized that no amount of written instructions can replace intelligent thinking and reasoning by maintenance personnel and boiler operators, especially under unpredictable conditions. It is the responsibility of the maintenance person or operator to become completely familiar with the equipment covered in this manual, along with the pertinent control and auxiliary equipment. Maintenance of controls and auxiliary equipment associated with the pulverizer but not provided by DOOSAN is the sole responsibility of the owner/operator and his maintenance and operating personnel. For most maintenance procedures, access to all internal wear parts can be made through the three journal openings or the separator body and millside access doors. To facilitate maintenance on the drive components, the gearbox assembly is removable. This is accomplished by disconnecting the bowl assembly from the gearbox, lifting the bowl assembly within the separator body and allowing the gearbox to slide out from under the millside assembly. Once the gearbox is removed from under the pulverizer, it may be disassembled in a clean environment. If only a quick inspection of the gearbox is required, inspection doors provided in the side of the gearbox can be used. Refer to the instructions provided by the gearbox manufacturer. When it is necessary to inspect, repair, or replace wear parts and drive components of the pulverizer, the procedures described in the following sections may be used as a guide for removal and reinstallation of individual pulverizer components. Review the Bowl Mill Cross Section drawing E-PLVE-0528 for orientation and location of major components. Detailed procedures covering the repair of major sub-assemblies can be found in SECTION 5. PULVERIZER ACCESSORIES of this manual.

GENERAL MAINTENANCE

2

GENERAL MAINTENANCE

The pulverizer is a rugged machine, designed and built for continuous operation over an extended period, with minimal wear on the working parts. However, iron pyrites and other abrasive substances in the coal (ex. ash composition, silica, sand) will shorten the life of parts such as the rolls, bull ring, separator body liners, vane wheel liners, and scrapers. Since wear of pulverizer parts depends on many factors that vary from one installation to another, it is difficult to prescribe a specific routine inspection and maintenance program. Characteristics of the coal, operating hours of individual pulverizers, availability of pulverizers due to unit load demands, and availability of maintenance personnel are all factors that determine the frequency and scheduling of pulverizer inspections and maintenance. An effective program can be established only on the basis of actual plant operating experience.

NOTE: During the initial operating period, the pulverizers should be inspected at regular intervals not greater than 3 months apart. This interval should be maintained until sufficient operating experience indicates otherwise. Pulverizer components must be inspected for general condition as outlined in this manual.

It is, therefore, imperative that an accurate log be maintained on each pulverizer from initial installation, to relate individual pulverizer running time with pulverizer performance, plant operating schedules, unit load, outages, inspection reports, and other associated data.

NOTE: Pulverizer wear is a function of the number of hours a pulverizer is grinding coal, not necessarily the amount (in tons) of coal pulverized. While operating at reduced capacities, a pulverizer will last somewhat longer, but will grind much less tonnage before it becomes necessary to replace parts. WARNING: WHEN MAINTENANCE IS REQUIRED ON A PULVERIZER WHILE THE UNIT IS IN OPERATION, MAKE SURE THE PULVERIZER IS MECHANICALLY AND ELECTRICALLY ISOLATED. FOLLOW ALL PLANT SAFETY PROCEDURES.

Pulverizer part replacement criteria cannot always be defined in advance. They must be established on the basis of experience and judgment on the part of personnel familiar with the pulverizer history and performance along with plant maintenance outage schedules. The degree, location, and pattern of wear will soon become evident and can be handled accordingly.

GENERAL MAINTENANCE

3

In some cases wear surfaces can be built up ; in other instances, replacement of the part is more practical. The following is a list of the pulverizer parts normally subject to wear :

1. Bull Ring and Rolls

Reduced pulverizer capacity and increased spillage are indications of excessive wear. Contour templates, made when the equipment is new, may aid in checking the degree and location of wear as it progresses.

2. Separator body Liners, and Vane Liner Assemblies

Some pulverizers are supplied with ceramic or other types of internal liners, their degree of wear will vary considerably from one installation to another and sometimes between pulverizers at the same plant. Individual liners must be replaced when thinning and holes indicate excessive wear.

NOTE: Protective compounds use to fill liner joints and attachment holes must be completely renewed if ther is a possibility that liner joints and attachments will be exposed before the next inspection. To prevent loss of liners all attachment fasteners showing evidence of wear must be replaced.

3. Vane Wheel Replace vane wheel segments and/or air restriction segments if excessively worn.

4. Bowl Extension Ring

The ring should be replaced when worn excessively. 5. Air Inlet Vanes

Excessive rejects will cause wear on edges of vanes. Replace or rebuild if excessively worn.

6. Scrapers and scraper wear plates

Wear plates are most susceptible to wear and can be replaced with unworn side upside down.

CAUTION : When maintenance is required on a pulverizer while the unit is in operation, make sure the pulverizer is completely isolated before entering it. Close the dampers, gates and valves ; isolate the fire suppression system and motor circuit breakers ; ensure that the means for operating this equipment is suitably tagged.

Most inspection and repair work inside the pulverizer above the bowl can be accomplished by removing one journal opening cover and on journal shaft assembly. Work below the bowl can usually be done through the pulverizer millside access door(s).

CAUTION : When welding on a bowl, roll or any part of the pulverizer, the welding machine should be grounded to the component being welded in order to prevent racing across bearings in the gear case or journals.

GENERAL MAINTENANCE

4

7. Bearings

Unusual noise and operating temperatures consistently above normal are indications of impending bearing failure. Bearings should be inspected at the first opportunity.

8. Gearbox

These components usually give long, trouble-free service. However, failure of other components can accelerate their wear. Refer to manufactures instructions for additional information.

INTERFERENCE FITS Where components have been designed with interference fits, it is frequently necessary to heat and/or cool the mating parts to facilitate assembly. HEATING Heat must be applied uniformly to the entire piece. Acetylene torches with rosebud tips are not recommended, since heating by this method is not sufficiently uniform. Heat can best be supplied in a commercial type oven or an oil bath. However, it is also possible to shroud the part in an insulated enclosure and increase the part temperature with space heaters, or stress relieving blankets. A two (2) hour minimum for heating is recommended. CHILLING Components can be chilled in a commercial freezer. They may also be chilled in a dry ice and alcohol bath, -40℃ or by packing in dry ice. Before submerging a part in a chilling bath, it should be coated with a thin layer of grease. Components should be chilled for a minimum of 3 hours. After the part is removed from the chilling process, be sure wipe off any condensation that might have occurred.

i

SECTION 3 - HP PULVERIZER MAINTENANCETAB 2. GENERAL DISASSEMBLY

CONTENTS TAB 2

TITLE PAGE NO.

ISOLATION OF THE PULVERIZER ------------------------------------------------------------------------ 1

JOURNAL OPENING COVER REMOVAL ---------------------------------------------------------------- 2

JOURNAL TILT OUT ------------------------------------------------------------------------------------------- 3

JOURNAL ASSEMBLY REMOVAL ------------------------------------------------------------------------ 5

JOURNAL ROLL AND SHAFT ASSEMBLY REMOVAL --------------------------------------------- 6

JOURNAL HEAD REMOVAL ---------------------------------------------------------------------------------- 8

BOWL AND BOWL HUB LIFTING -------------------------------------------------------------------------- 9

GEARBOX ASSEMBLY REMOVAL --------------------------------------------------------------------- 11

Figure.1 ----------------------------------------------------------- XHP 1103Pulverizer

GENERAL MAINTENANCE

ii

This page intentionally left blank.

1

TAB 2. GENERAL DISASSEMBLY

ISOLATION OF THE PULVERIZER

CAUTION : Use procedures adopted by your plant, locks, tags, log notes, etc., to ensure that gates, valves, dampers, pumps, motors and fire suppression systems associated with an isolated pulverizer are not inadvertently operated while a pulverizer is opened for inspection or maintenance. CAUTION : If the pulverizer contains coal, ensure that the gearbox drive shaft has been blocked to prevent rotation of the bowl before entering the pulverizer.

1. To isolate the pulverizer, close the hot air shutoff gate, the cold air shutoff gate, the pulverizer discharge valves, the coal line gates (if provided), the vent air and seal air shutoff valves, and the feeder discharge valve (if provided).

2. Open the pulverizer and feeder motor breakers. 3. Disconnect the pulverizer motor coupling at the gearbox. 4. Isolate, lock shut, and tag inoperative applicable fire suppression systems. 5. Ensure that pulverizer is depressureized by opening a millside access door.

GENERAL DISASSEMBLY

2

JOURNAL OPENING COVER REMOVAL(Refer to TAB 6 )

The journal opening cover and journal spring assembly is normally removed as a unit. 1. Disconnect the seal air supply lines from the trunnion shafts and journal spring

assembly. Refer to drawings E-PLVE-0528, D-GP-9955 and SE-110-01608. Remove the trunnion shaft air riser and plug the seal air header opening.

2. Lower the journal so the grinding rolls is resting on the bowl by removing the stop bolt nut and fasteners.

3. Remove the key 4. Remove the stop bolt 5. Remove the O-ring

CAUTION : The journal opening cover and journal spring assembly weighs approximately 3.79 Ton and must be adequately rigged to ensure safe handling. NOTE : To prevent the journal opening cover from titling and to ensure a vertical lift it may be necessary to rig to the journal spring assembly as well as the lifting holes in the journal opening cover

6. Center the crane directly above the journal opening. Rig the journal

opening cover for removal using the two lifting holes provided in the top edge of the cover. Take up a slight load on the lift rigging.

7. Remove the hex head cap screws that secure the journal opening cover to the

separator body.

8. Remove the journal opening cover and move it the convenient storage area.

GENERAL DISASSEMBLY

3

JOURNAL TILT OUT

NOTE : Unless otherwise stated, refer to Fig. 1 on E-PLVE-0539 when using the following procedure.

1. Remove journal opening cover. 2. Secure the journal tilt out bracket to the separator body journal cover opening with

hex head cap screws and to the separator top lifting lug with a shaft, washers and cotter pins. Install the safety bracket loosely to the journal cover opening with hex head cap screws.

3. Turn the journal stop bolt to lift the grinding roll from the bull ring. Rotate the roll until

the 1-1/2 in. tapped holes on top of the journal housing are at 12 O'clock (refer to drawing no. (D-94-1748).

4. Remove existing set screws and install lug using hex head cap screws. 5. Remove journal head cover plate and set it aside.

NOTE : If maintenance will be performed on the journal shaft assembly then consideration should be given to pumping oil out of the bearing housing.

6. Remove the oil fill pipe, replace the pipe plug in the journal shaft to prevent oil leakage.

7. Attach the cable to lug and tilt out bracket as shown on Fig. 1 of E-PLVE-0539.

CAUTION : Ensure that the crane is correctly positioned for a vertical line of pull.

CAUTION : During the next step the cable will go slack and then tighten as the journal falls outward when its center of gravity passes over the top of the pivot point. Always stand clear during this operation. Do not exceed 9.0 MT of pull.

8. SLOWLY raise the cable vertically until there is a minimum distance between the tilt

- out lug connection and the active sheave (Position 2, Fig. 1, of E-PLVE-0539) 9. After the journal falls outward, SLOWLY lower the cable and tilt out lug to position 3.

The journal assembly should contact and rest on the safety bracket. 10. Install hex head cap screws and washers through the safety bracket and into the

journal head, tighten all screws per B-GP-2175 to lock the journal in the tilted

GENERAL DISASSEMBLY

4

position. This will prevent the journal from falling into or out of the mill when the tilt rigging is removed.

11. Remove the tilt out rigging and tilt out bracket.

GENERAL DISASSEMBLY

5

JOURNAL ASSEMBLY REMOVAL

If pulverizer repairs will be extensive or if the bowl will be removed from the gearbox, it may be advantageous to remove the journal assemblies completely. If access to the pulverizer is only for the purpose of inspection or minor maintenance, then removing only the journal roll and shaft assembly may be sufficient. (Refer to Journal Roll and Shaft Assembly Removal, Page 6).

1. Remove the journal opening cover and spring assembly. 2. Tilt out the journal assembly.

CAUTION : The journal assembly weighs approximately 9.20 MT, trunnion shafts weigh approximately 146 kg each. All must be adequately rigged to ensure safe handling.

3. Remove all of the grinding roll keeper bolts and the keeper plates. Refer to Drawing

SE-GP-6646 and install the grinding roll removal lug. The hex head cap screws should be installed through the inner bolt circle into the journal housing. Torque fasteners (10) to 6.9 kg-m.

CAUTION : The overhead crane must support the journal assembly at all times during the removal procedure.

4. Make sure that the scribe line on the lug faces into the center of the mill. Install a

wire rope through the removal lug and attach to an overhead crane [10 MT minimum capacity]. The wire rope sling must clear the classifier door opening when loaded.

CAUTION : The crane must provide support for the journal assembly during the entire removal procedure.

5. Attach the sling to an overhead crane positioned above the center of the door

opening. Take up slack.

NOTE : The sling and/or crane cable must not contact the separator body when the journal assembly is being lifted out of the separator body opening.

6. Remove the safety bolts from the journal head. 7. Remove the cap screws from the trunnion shaft end caps, the use jacking bolts in

the threaded holes to remove the trunnion shafts from the journal head. 8. When the trunnion shafts clear the journal head, swing the journal assembly clear of

the classifier body.

GENERAL DISASSEMBLY

6

9. Move the assembly to convenient work area. 10. Inspect the trunnion shaft bushings. 11. Store the trunnion shafts until required for reassembly.

JOURNAL ROLL AND SHAFT ASSEMBLY REMOVAL

If repairs are required on the journal shaft assembly only, or less access to the separator body is required, it may be easier to remove the journal roll and shaft assemblies and leave the journal heads in place. The procedure and equipment arrangement are explained in the following text.

NOTE : For the following procedures, refer to drawings D-94-1747 and D-94-1748 unless otherwise stated.

1. Remove the journal opening cover and spring assembly. 2. Remove the journal head cover plate and the journal oil fill plug and pipe assembly.

Remove the pipe plug from the assembly and replace the plug in the end of the journal shaft assembly.

NOTE : If maintenance is to be performed upon the journal shaft assembly then consideration should be given to pumping approximately 49 liter of oil out of the bearing housing at this time. Refer to "Journal Oil Removal Procedures",.Maintenance Tab 4 COMPONENT SERVICING

3. Install journal head safety brackets and perform the Journal Tilt Out procedure.

CAUTION : The journal roll and shaft assembly weighs approximately 5.8 MT and must be adequately rigged to ensure safe handling.

4. Remove all of the grinding roll keeper bolts and the keeper plates. Refer to Drawing

SE-GP-6646 and install the grinding roll removal lug (Item 5). The hex head cap screws should be installed through the inner bolt circle into the journal housing. Torque fasteners (Item 10) to 6.9 kg-m.

CAUTION : The overhead crane must support the journal assembly at all times during the removal procedure.

5. Make sure that the scribe line on the lug faces into the center of the mill. Install a

wire rope through the removal lug and attach to an overhead crane [7.5 MT minimum capacity]. The wire rope sling must clear the classifier door opening when loaded.

GENERAL DISASSEMBLY

7

6. Attach the sling to and overhead crane positioned above the center of the door

opening. Take up slack. NOTE : The chain sling and crane cable must not contact the separator body when the journal roll and shaft assembly is lifted out of the separator body journal opening.

7. Remove the journal skirt.

NOTE : Some journals are equipped with journal head liners. If supplied, they must be removed at this time. The journal head liners are custom fit during assembly and some liners may not be interchangeable. It is imperative that each liner be identified and marked so that it can be reinstalled in the SAME position from which it was removed.

8. Remove the journal shaft flange bolts. 9. Lift the journal roll and shaft assembly clear of the journal head and swing assembly

out of the separator body journal opening. Move it to a convenient work area.

GENERAL DISASSEMBLY

8

JOURNAL HEAD REMOVAL If, after the journal roll and shaft has been removed, it is necessary to remove the journal head the following procedures may be used.

NOTE : Refer to drawing D-PLVD-0823. CAUTION : The journal head weighs approximately 2.6 MT, trunnion shafts weigh approximately 146 kg each and must be adequately rigged to ensure safe handling.

1. Install two(2) 1-1/4 in. eyebolts in the head flange 180°apart. 2. Install a chain shackle in each eyebolt and attach a chain sling. 3. Attach the chain sling to an overhead crane positioned above the center of the

journal opening. Take up slack. CAUTION : The crane must provide support for the journal head during the entire removal procedure.

4. Remove the safety bolts from the journal head. 5. Remove the cap screws from the trunnion shaft end caps and use jacking bolts to

remove the trunnion shafts from the journal head. 6. When the trunnion shafts clear the journal head, swing the head clear of the

classifier body. 7. Move the journal head to a convenient work or storage area. 8. Inspect the trunnion shaft bushings. 9. Store the trunnion shafts until required for reassembly.

GENERAL DISASSEMBLY

9

BOWL AND BOWL HUB LIFTING

In order to access the gearbox for major maintenance, it must be removed from under the mill. The bowl and bowl hub assembly must be lifted clear of the gearbox to do this.

NOTE : Refer to drawing SC-GP-8255 and SE-110-01595.

1. Remove the three journal opening covers. 2. Tilt out all journal assemblies. 3. Remove all journal assemblies. 4. Open the millside access doors.

NOTE : Before disassembly, verify that each piece is identified and match marked.

5. Remove the scraper assemblies and move them to the outer edge of the millside. 6. Disassemble the components of the bowl hub air seal ring and bowl hub liners. Use

care not to damage the lower surface of the air seal ring.

7. Disassemble the air seal packing gland and packing. Transfer parts to clean, safe storage area.

8. Remove the bolt protection piece and cap plates. 9. Start the lubrication oil system and turn the bowl by hand until one of the 1 in. hex

socket head cap screws (located in the bowl extension ring) is positioned at the center line of each journal opening. Refer to drawing SD-110-01596.

10. Remove that cap screw and adjacent cap screws on each side, for a total of three

at each opening. 11. Install bowl hoist clevis and bowl hoisting frame hook at each journal opening.

Refer it drawing SC-GP-8255. 12. Disassemble the bolts that secure the vane wheel segments to the bowl hub and

remove the vane wheel segment. Mark each segment as it is removed so that it can be installed in the same location.

13. Remove torque nuts and then remove all 8 studs from the hub.

CAUTION : The bowl hub, vane wheel and bowl assembly weighs approximately 17.98 MT and must be adequately rigged to ensure safe handling.

GENERAL DISASSEMBLY

10

14. Attach three chain blocks or come-alongs [each with a 15 MT minimum capacity] to

the tilt-out lug and the bowl hoisting clevis (refer to drawing SC-GP-8155). 15. Lift the bowl, bowl hub assembly approximately 50 mm. Stabilize the bowl hub

assembly with screw jacks or cribbing. 16. Remove the gearbox.

GENERAL DISASSEMBLY

11

GEARBOX ASSEMBLY REMOVAL

NOTE : Reference drawings E-PLVE-0528 ans SC-GP-8255.

1. Remove three (3) journal opening covers and journal spring assemblies. 2. Remove the Three (3) journal assemblies. 3. Lift the bowl and bowl hub assembly as described above. 4. Isolate the lubrication system and disconnect the oil lines from the gearbox. Cap or

cover all openings to keep the system clean. 5. Disconnect the wiring from the bearing thermocouples, and from the other

monitoring equipment on the gearbox. Mark and secure the wiring.

6. If not previously done, remove the coupling guard and disconnect the drive coupling. 7. Remove fasteners securing the pyrite hopper to millside, pyrite valves and pyrite

hoppers. 8. Remove the hex head cap screws that secure the gearbox to its sole plate. Also

remove the dowel pins that align the gearbox. 9. Place the gearbox removal rails on cribbing or a steel frame built up from the floor.

Ensure that top of the rails are flush with the gearbox sole plate, then attach to the sole plate, see drawing SC-110-1359.

10. Slide the gearbox onto the rails.

CAUTION : The gearbox weighs approximately 17.0 MT and must be adequately rigged to ensure safe handling.

11. Once the gearbox is out from under the pulverizer, it may be moved to a

maintenance area for disassembly. 12. If a replacement gearbox will not be installed immediately, build a steel or wood

crib capable of supporting the weight of the bowl and bowl assembly under the bowl hub. The height of the crib should be set so that when the bowl and bowl hub assembly is placed on it, the assembly will be at approximately the same height it was before disassembly.

13. Lower the bowl and bowl hub assembly onto the cribbing. Stabilize the bowl hub

assembly with screw jacks or cribbing, If necessary, remove the lift rigging to provide access to the interior of the pulverizer.

Refer to the manufacturer's instructions for further information about the gearbox.

GENERAL DISASSEMBLY

12

Figure.1 XHP 1103Pulverizer

i

SECTION 3 - HP PULVERIZER MAINTENANCETAB 3. GENERAL REASSEMBLY

CONTENTS TAB 3

TITLE PAGE NO.

GEARBOX ASSEMBLY INSTALLATION ----------------------------------------------------------------- 1

BOWL HUB TO GEARBOX ASSEMBLY ----------------------------------------------------------------- 3

AIR SEAL INSTALLATION AND CLEARANCE ---------------------------------------------------------- 4

SECURING GEARBOX TO SOLE PLATE --------------------------------------------------------------- 5

SCRAPER AND GUARD ASSEMBLY --------------------------------------------------------------------- 5

BOWL HUB INSTALLATION ------------------------------------------------------------------------- 6

PULVERIZER LUBRICATION SYSTEM REASSEMBLY -------------------------------------------- 6

JOURNAL HEAD ASSEMBLY INSTALLATION -------------------------------------------------------- 7

JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION ---------------------------------- 9

JOURNAL OPENING COVER AND SPRING ASSEMBLY --------------------------------------- 10

SEAL AIR -------------------------------------------------------------------------------------------------------- 12

PULVERIZER MOTOR --------------------------------------------------------------------------------------- 12

PREPARATION FOR A RETURN TO SERVICE ------------------------------------------------------ 13

GENERAL MAINTENANCE

ii

This page intentionally left blank.

1

TAB 3. GENERAL REASSEMBLY

GEARBOX ASSEMBLY INSTALLATION

The gearbox assembly is installed by sliding it into position under the assembled pulverizer. Special fixtures should be provided to assist in this procedure.

NOTE: Refer to drawings T04019-PV-A003, E-PLVE-0528, SD-110-01594, C-GP-7389, and SC-110-1359 unless stated otherwise. For the gearbox and lube system preparation and handling procedures, refer to instructions in the gearbox manufacturers instruction manual.

1. Attach the gearbox removal rails to the sole plate. Place the rails on cribbing as required to level them with the top of the gearbox sole plate.

WARNING: THE PULVERIZER GEARBOX WEIGHS APPROXIMATELY 17 MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

NOTE: Prior to installing the gearbox under the pulverizer, check that two dowel pins are installed in the gearbox output adapter. Use Loctite RC 680 and install the pins so that they protrude 15.2 mm, ± 0.4 mm. NOTE: If the same gearbox is being reinstalled on the same sole plate, and if perfect alignment of the original holes can be achieved, the same size dowel pins may be used. However, it is permissible (and possibly easier) to re-drill and ream the holes at the old location and install 6.3 mm larger diameter dowel pins.

If a new or different gearbox assembly is installed under a pulverizer, it will be necessary to drill new dowel pin holes in the gearbox mounting flange and the sole plate. These must be located at least 15.24 cm away from the original dowel pin (or existing) holes and diametrically opposed.

NOTE: If a new or different gearbox is installed, perform step 2; if re-installing the same gearbox, skip to step 3.

2. As necessary, drill two 34 mm pilot holes 180° apart in the gearbox bottom flange. Pilot holes should be at least 152.4 mm away from existing holes and diametrically opposed.

GENERAL REASSEMBLY

2

NOTE: The gearbox must be positioned adjacent to the pulverizer foundation, oriented with the input drive shaft facing toward the motor location.

3. Assure that the gearbox removal rails are clean, apply a light film of grease, and set the gearbox assembly on the fixture.

4. Lift the bowl, bowl hub assembly as required to clear the gearbox. a. If previously removed, reinstall a bowl hoist clevis at each journal opening. Refer

to drawing SC-GP-8255. b. Rig three 10 MT minimum capacity each chain block or come alongs to the bowl

hub assembly hoist clevis.

WARNING: THE BOWL, BOWL HUB, AND VANE WHEEL ASSEMBLY WEIGHS APPROXIMATELY 17.9 MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

c. Lift the bowl as required to clear the gearbox.

5. Remove the bowl hub assembly support cribbing. 6. Slide the gearbox assembly into position under the millside. Check that the gearbox

bolt holes line up with the tapped holes in the sole plate and the old dowel pin (if to be reused).

7. Install the washers and cap screws which secure the gearbox to the gearbox sole plate (hand tight with Fel-Pro C5-A anti-seize compound or equal).

8. Remove the gearbox removal rails. 9. Install the gearbox millside adjustment blocks on the sole plate. Refer to drawing C-GP-7389

GENERAL REASSEMBLY

3

BOWL HUB TO GEARBOX ASSEMBLY

1. Ensure that the mating surfaces of the bowl hub and the gearbox adapter are

clean.

NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified.

CAUTION: Ensure that the upper reservoir of the gearbox is full of oil to the level indicated on its sight glass before turning the gearbox shaft.

2. The input shaft of the gearbox may be turned by hand to get the dowel pins in the output adapter to line up with the dowel pin holes in the bowl hub.

3. When aligned, lower the bowl hub assembly onto the gearbox assembly. Be sure that the pins are properly engaged and that the hub is firmly seated on the gearbox output adapter.

4. Clean the threads of the eight 2" studs that secure the bowl hub to the gearbox. 5. Apply Loctite 277 to lower 76 mm of thread opposite stud hex. head. 6. Install studs so that thread engagement into the output plate is 101.6 mm, + 1.5

mm, - 0.0 mm. 7. Clean the top of the bowl hub flange and apply anti-seize compound to the

protruding end of the studs.

NOTE: Clean the internal threads of the torque nuts, check that all jack bolts supplied with the nuts have been removed, cleaned and lubricated with an approved lubricant to ensure proper jackbolt performance upon re-installation. Install jack bolts in the tension nut so they are flush with the bottom of the nut. NOTE: For torquing procedures refer to the SUPERBOLT® Multi-Jackbolt Tensioner instructions with the vendor equipment.

8. Install the hardened washers supplied with the torque nuts. 9. Install and snug the torque nuts by hand; the nut body should contact the

hardened washer. 10. Remove the chain hoists and bowl hub hoisting fixtures. 11.Tension the studs (tighten the torque nuts). Refer to Note 6 on drawing E-

PLVE-0528. 12. Check the upper air seal clearance before doweling the gearbox to the sole plate.

GENERAL REASSEMBLY

4

AIR SEAL INSTALLATION AND CLEARANCE

NOTE: The following steps refer to drawings SD-110-01597 and E-PLVE-0528. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified. CAUTION: Ensure that the upper oil reservoir of the gearbox has been filled with the recommended oil, to the centerIine of the gauge glass before turning the gearbox input shaft (by hand) during air seal setting.

1. Use the drive adjustment blocks and center the gearbox and bowl hub assembly to the millside within 0.010" (0.254 mm). For this initial setting, measure from the packing ring bore in the millside to the outside diameter of the bowl hub.

2. Install the rings of pecking and the packing gland. Install and torque fasteners. 3. Install the gearbox thermocouples (if previously removed). 4. Install the sections of expanded metal screen to the millside guard supports. A

ssemble with nuts, washers, and cap screws. 5. Reconnect all thermocouples, oil lines, and instrument wiring. 6. Check coupling alignment.

GENERAL REASSEMBLY

5

SECURING THE GEARBOX TO SOLE PLATE

NOTE: Refer to drawing E-PLVE-0528 unless otherwise stated. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified.

Secure the gearbox to the sole plate only after the coupling alignment has been set and confirmed. 1. Remove the bolts which hold the gearbox to the sole plate. Coat each bolt with anti-

seize compound, then install and torque. 2. Mount a drilling rig above each of the dowel pin holes in the gearbox mounting

Flange. 3. Drill and ream to oversize for new dowel pins or using the 34 mm diameter holes in

the gearbox flange as pilots, drill and ream two holes into the sole plate, 38.1 mm, -0.026 mm ~ -0.0038 mm to a depth of 139.7 mm.

4. Lubricate the dowel pins with Molykote GN-Paste, or an equivalent, and press fit the dowel pins into the reamed holes.

5. Remove the gearbox adjustment blocks and retain for use on next gearbox installation.

6. Verify coupling alignment, secure the coupling, and install the coupling guard.

SCRAPER AND GUARD ASSEMBLY

NOTE: The following steps refer to drawings E-PLVE-0528 and SD-110-01597 unless otherwise stated. NOTE: Apply thread locking sealant to all threads and torque all fasteners per B-GP-2175 unless otherwise specified.

1. Install the two scraper assemblies on the bowl hub. 2. Set the clearance between scraper wear plate and millside bottom plates to 9.7

mm, ± 6.3 mm.

CAUTION: Ensure that the upper reservoir of the gear box is full of oil to the level indicated on its sight glass before turning the gearbox shaft.

3. Rotate the bowl and recheck the gap, along the radius, in at least eight places, once for each millside bottom plate. Check the gaps at the highest point on each wear plate.

GENERAL REASSEMBLY

6

BOWL HUB INSTALLATION

NOTE: The following steps refer to drawings E-PLVE-0528 and SD-110-01597 unless otherwise stated. NOTE: Apply anti-seize compound to all fasteners and torque all fasteners per B-GP-2175 unless otherwise specified.

1. Wrap bowl hub insulation, around the bowl hub. 2. Re-install the bowl hub liners using bolts and plain washers through the clips at the

top of the liners. 3. Torque all bolts.

PULVERIZER LUBRICATION SYSTEM REASSEMBLY

NOTE: Refer to gearbox and lube oil system manufacturers instruction manual for details.

NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified.

1. Connect the wiring to the gearbox thrust bearing thermocouples. 2. Remove the caps and covers that were applied to keep the system clean from the

oil supply and return piping and gearbox. 3. Clean and assemble the flanges. 4. Fill the oil tank to operating level with the recommended oil. 5. Start the lube system pump to fill the oil supply and return lines, the thrust bearing

reservoir, and the gearbox. Check for system leaks. 6. Refill the oil tank reservoir to operating level. 7. Place the lubrication system back into service.

GENERAL REASSEMBLY

7

JOURNAL HEAD ASSEMBLY INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-94-1747, D-94-1748, and C-GP-7711 unless otherwise stated. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified. WARNING: JOURNAL HEAD LIFTING EYEBOLTS MUST BE DROP FORGED STEEL SHOULDER PATTERN AND RATED FOR 3.0 MT WORKING LOAD CAPACITY. WARNING: THE JOURNAL HEAD WEIGHS APPROXIMATELY 2.5 MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

1. With the journal head assembly laying flange side up, remove the trunnion shafts and install two 1-1/4" lifting eye bolts 180° apart in the head flange.

2. Install a chain shackle in each eyebolt and attach a chain sling. Rig the chain sling to an overhead crane. Take up the slack.

WARNING: TRUNNION SHAFTS WEIGH APPROXIMATELY 146 KG EACH AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

3. Place a trunnion shaft near each side of the journal opening. 4. Lift the head and remove the journal head cover plate. 5. Position the journal head in the separator body journal opening and align with the

trunnion shaft openings. 6. Slide a 366cm or longer "all thread" rod through the separator body trunnion shaft

openings and the journal head. 7. Coat the surfaces of the trunnion shafts liberally with anti-seize compound.

NOTE: If alignment is perfect, trunnion shafts may slide into position without performing steps 13 through 15.

8. Lift each shaft and slide it over the all thread rod and into its separator body opening. Start the end of each trunnion shaft into the journal bushing retainers.

9. Remove the pipe plug from the seal air opening in the trunnion shaft end plate.

GENERAL REASSEMBLY

8

CAUTION: Maintain alignment of all components during the next few steps to prevent components from binding.

10. Slide a backing plate on each end of the all thread rod. Thread two hex nuts on one end of the all thread rod and one heavy duty hex nut on the other end.

11. Securely lock the two hex nuts together at one end of the all thread rod and tighten the nut on the other end.

12. Use an air impact wrench on the double nutted end of the rod. Use a wrench, as necessary, to hold the single heavy hex nut. Then slowly turn the rod to tighten the heavy hex nut and pull the trunnion shafts into place.

13. When trunnion shafts are fully inserted, align the bolt holes and secure the trunnion shaft end plates to the trunnion shafts and separator body with Iubricated, hex head cap screws. Torque the bolts per drawing B-GP-2175.

14. Disconnect the rigging and remove the eyebolts. 15. Install the journal roll and shaft assembly.

GENERAL REASSEMBLY

9

JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-94-1747, D-94-1748, D-PLVD-0823, E-PLVE-0539, D-110-01604 and SC-GP-6646 unless otherwise stated. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified. WARNINGS: THE JOURNAL ROLL AND SHAFT ASSEMBLY WEIGHS APPROXIMATELY 5.8 MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

1. Move the journal roll and shaft assembly adjacent to the mill. 2. Remove the grinding roll keeper bolts and keeper plates. Install the grinding roll

removal lug. Torque all fasteners.

WARNING: THE OVERHEAD CRANE MUST SUPPORT THE JOURNAL SHAFT ASSEMBLY AT ALL TIMES DURING THE INSTALLATION PROCEDURE.

NOTE: The slings and crane cable must not contact the separator body when the journal roll and shaft assembly is lifted into position.

3. Clean the mating surfaces of the journal head assembly and the journal shaft flange.

NOTE: To ensure correct assembly, one hole in the shaft flange is offset 0.50" (12.7 mm).

4. Set the journal roll and shaft assembly in position on the journal head assembly. Rotate shaft to align the holes in the journal shaft flange with the tapped holes in the journal head.

5. Apply thread locking compound and install hex socket head cap screws. Tighten fasteners in the sequence shown on drawing D-94-1747, Section "A-A."

6. Install the journal head skirt and torque fasteners per drawing B-G P-2175.

NOTE: Journals are equipped with journal head liners. As some liners may not be interchangeable, it is imperative that each liner be identified and marked so that it can be re-installed on the same journal.

7. Re-install the journal head liner assembly and torque fasteners per drawing B-BP-2175.

GENERAL REASSEMBLY

10

8. Remove the grinding roll removal lug. Reinstall the grinding roll keeper plates and

bolts. Torque the fasteners.

9. Tilt in the journal assembly to return the roll to the bowl

WARNING: STAND CLEAR OF THE JOURNAL DURING THE TILT-OUT PROCEDURE. AS THE JOURNAL APPROACHES TOP DEAD CENTER, THE JOURNAL WILL TEND TO FALL OUT OF THE PULVERIZER SINCE THE CENTER OF GRAVITY IS PASSING THROUGH THE TOP OF ROTATION

JOURNAL OPENING COVER AND SPRING INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-GP-9955, D-GP-8580 , E-GP-8101 and B-GP-3960 unless otherwise stated. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified WARNING; THE JOURNAL OPENING COVER ASSEMBLY WEIGHS APPROXIMATELY 2.6 MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE HANDLING. USE LIFTING HOLES PROVIDED.

1. Loosen the spring position adjusting stud nuts and studs. 2. Retract the spring assembly until only 2.54 cm of the assembly is protruding from

the inside of the journal opening cover. Snug the inner nuts on the studs to maintain the position of the spring assembly.

3. Rig to lift the journal opening cover using the top lifting holes. 4. Ensure that the journal stop bolt is through the journal door. The flat edges of the

stop bolt should be in the operating position, parallel to the sides of the cover. The stop bolt keyway should be facing approximately 45° from the top of the cover.

5. The nut should be threaded onto the stop bolt until the stop bolt keeper plate can just be installed and engage the keyway (stop bolt in the full inward position). Hand tighten the cap screws into the stop bolt nut and keeper plate.

6. Clean the mating surfaces of the journal opening frame and journal opening cover and coat them with Felt-Pro C5-A anti-seize compound or equal.

7. Hoist the journal cover and spring assembly into position away from the separator body, but aligned with the journal opening. Position the cover so the "mushroom head" of the stop bolt is higher than the slot in the journal head arm. Carefully move the cover inward, then downward, to engage the stop bolt in the journal head slot.

8. Align the cover bolt holes with the journal opening bolt holes and install all journal cover bolts. Torque per drawing B-GP-2175.

GENERAL REASSEMBLY

11

9. Remove the keeper plate socket cap screws and stop bolt nut/washer cap screws.

Retract the stop bolt using the stop bolt nut until the "mushroom head" is fully seated in the journal head slot.

10. Install the stop bolt keeper plate bolts hand tight. Final stop bolt setting will be made later when ring-to-roll clearance is set.

11. Check the journal spring compression; refer to Pulverizer Component Servicing, "Journal Spring Preloading Procedure” for instructions.

NOTE: Steps 12 and 13 can only be performed when the pulverizer is operational.

12. Set the roll-to-bowl ring clearance. Refer to Pulverizer Component Servicing for procedures.

13. Adjust the journal spring to journal head clearance. Refer to Pulverizer Component Servicing, Journal Spring Position for procedures.

14. Reconnect the seal air system piping.

GENERAL REASSEMBLY

12

SEAL AIR

NOTE: Refer to drawings E-PLVE-0528 and SE-110-01608 unless otherwise stated. NOTE: Apply pipe thread sealant to all threaded joints at assembly. NOTE: Apply anti-seize compound to all threads and torque all fasteners per B-GP-2175 unless otherwise specified.

1. Replace the seal air piping removed in the disassembly procedures. 2. Replace the male portion of a 2-1/2" pipe nipple on the trunnion shaft end plate at

each journal and a pipe plug in the other end plate. Ensure that the male portion of the 2-1/2" pipe nipple on the rigid piping meets the female portion at the trunnion shafts.

3. If removed, replace the male portion of a 1-1/2" pipe nipple at the top of each journal spring housing. Ensure that the male portion of the 1-1/2" pipe nipple on the rigid piping meets the female portion of 1 -1/2” 90° elbow. Tighten all fittings.

PULVERIZER MOTOR

If the pulverizer motor was removed, or a new motor is installed, use the following procedure as a guide for installation. The pulverizer motor may be in place on its sole plate. When the gearbox has been secured on its sole plate and air seal clearances have been set, the installation of the pulverizer motor and coupling can be completed.

NOTE: Refer to motor and coupling manufacturer's instructions for mounting and alignment recommendations.

GENERAL REASSEMBLY

13

PREPARATION FOR A RETURN TO SERVICE

1. Check motor rotation. (This must be performed before the motor/gearbox coupling is assembled.)

2. Assemble the motor/gearbox coupling. 3. Install the coupling guard. 4. Clean out the pulverizer. Remove tools, lights, etc. 5. Close and secure doors and inspection plates. 6. Install the miliside inspection door insulation covers.

NOTE: For steps 7 and 8, reference procedures in "Pulverizer Component Servicing."

7. Ensure that the roll to-ring clearance has been adjusted. 8. Ensure that the clearance between the journal spring and journal head has been

adjusted. 9. Start up and test the lubrication oil system. Repair leaks and add oil as necessary.

10. Use plant procedures to remove the pulverizer from isolation. Remove the tags, unlock switches, close the pulverizer motor breaker, etc.

11. Use plant procedures to remove the feeder from isolation. Remove tags, unlock switches, close the feeder motor breaker, etc.

12. Open the hot air shin off gate, the cold air shut off gate, the mill discharge valves, the Coal pipe gates, the vent air and seal air shut off valves, and the feeder discharge valves (if provided).

13. Check that the pulverizer fire suppression system is operative. 14. Return the pulverizer to service. Refer to the Pulverizer Operating Procedures for

additional information.

GENERAL REASSEMBLY

14

This page intentionally left blank.

i

SECTION 3 - HP PULVERIZER MAINTENANCETAB 4. COMPONENT SERVICING

CONTENTS TAB 4

TITLE PAGE NO. Bull Ring Segment Replacement ---------------------------------------------------------------------- 1 Vane Wheel Servicing ----------------------------------------------------------------------------------- 3 Liner Installation Using Weld Plugs -------------------------------------------------------------- 4 Equipment Required ------------------------------------------------------------------------------------------ 4 Welding Specification - Manual Insert Gas Welding (MIG) ------------------------------------------ 4 Welding Specification - Stick Weld, Manual Metal Arc Process ---------------------------------- 4 Application of Weld Plugs ----------------------------------------------------------------------------------- 4 Installation of Tiles and Liners - General --------------------------------------------------------------- 5 Trouble Shooting - Large Gaps Between Tile ------------------------------------------------------- 6 Trouble Shooting - Tile is Cracking -------------------------------------------------------------------- 6 Trouble Shooting - Welds Not Fusing ------------------------------------------------------------------ 6 Liner Replacement ---------------------------------------------------------------------------------------- 7 General -------------------------------------------------------------------------------------------------------- 7 Separator Body Liners -------------------------------------------------------------------------------------- 7 Journal Lubrication ------------------------------------------------------------------------------------ 7 Journal Assembly ----------------------------------------------------------------------------------- 7 Journal Stop Bolt ------------------------------------------------------------------------------------- 9 Journal Trunnion Shafts ------------------------------------------------------------------------------ 9 Major Adjustment -------------------------------------------------------------------------------------------------------------------- 10 Journal Spring Assembly Preload Procedure -------------------------------------------------------- 10 Ring to Roll Gap ------------------------------------------------------------------------------------------- 11 Spring Assembly to Journal Head Gap ------------------------------------------------ 13 Component Maintenance ----------------------------------------------------------------------------- 14 Journal Opening Cover Removal and Installation --------------------------------------------- 14 Journal Oil Replacement ------------------------------------------------------------------- 15 Journal Oil Seal Replacement ----------------------------------------------------------------------- 16 Journal Bearing End Play Checking --------------------------------------------------------------- 18 Journal Bearing Replacement------------------------------------------------------------------------- 19 Journal Shaft Assembly Removal ------------------------------------------------------- 19 Journal Shaft Assembly Disassembly ------------------------------------------------------- 20 Journal Shaft Assembly Reassembly ------------------------------------------------------- 21 Journal Shaft Assembly Reinstallation -------------------------------------------------- 24 Grinding Roll Replacement--------------------------------------------------------------------- 26 Trunnion Bushing and Seal Replacement --------------------------------------------------------- 28 Journal Spring Assembly Rebuild--------------------------------------------------------------- 29 Spring Assembly Disassembly ------------------------------------------------------------------ 29 Spring Assembly Reassembly --------------------------------------------------------------------- 30

COMPONENT SERVICING

ii

This page intentionally left blank.

1

TAB 4. COMPONENT SERVICING

Bull Ring Segment Replacement

NOTE: The following steps refer to drawings SD-110-01596 and D-66-754 unless otherwise stated.

NOTE: Apply anti-seize compound to all fasteners and torque all fasteners per drawing B-GP-2175 unless otherwise noted.

1. Isolate the pulverizer. 2. Open the millside access doors. 3. Open the separator body access doors. 4. To provide access to the bowl, remove at least one journal opening cover and journal

roll and shaft assembly as described in General Disassembly. 5. Unbolt and lower the vane wheel segments into the millside.

NOTE: The two hex socket set screws installed in each bowl extension ring segment. These can be used as jacking bolts during the removal process. Cut or break tack welds on end shims as needed.

6. Unbolt and remove the bowl extension ring segments. 7. Remove the old bull ring segments. 8. If undamaged, leave the bull ring clamping ring in place. If damaged, unbolt and

remove the bull ring clamping ring. 9. Clean all interior surfaces of the bowl. 10. Replace any damaged components.

NOTE: If the bull ring clamping ring was not removed, skip steps 11 through 14.

11. Install one of the bull ring clamping ring segments. a. Apply Loctite 271 to the hex socket head cap screws for that segment. b.Insert the hex socket head cap screws and washers and torque each screw to 34.5

kg-m (338 Nm), one half of the value specified on SD-110-01596 c. Torque the cap screws again to the full value, 69 kg-m (676 Nm).

12. Repeat step 11 until all of the bull ring clamping ring segments are fastened in place. 13. In the same order that, the screws were torqued in step 11, repeat the torquing

procedure to verify that the socket head cap screws are torqued to the specified value, 69 kg-m (678 Nm).

NOTE: Bull ring segments are numbered for sequential installation. Segment 1 is keyed to the bowl.

If ribbed segments are used, they should be spaced at approximately equal angular increments. Ensure that no two ribbed segments are spaced exactly 120° apart.

COMPONENT SERVICING

2

14. Arrange the bull ring segments on the bowl in numbered sequence starting with the

keyed segment number 1 and proceeding clockwise. 15. Push the segments downward into the bowl as far as possible against the clamping

ring and firmly butt them against each other.

NOTE: Bull ring segment shims should be inserted at points equally spaced around the perimeter of the bowl with no more than one shim between segments. DO NOT install shims adjacent to a ribbed segment. Total shim thickness in a complete ring should not exceed 25.4 mm.

16. Bull ring segment shims may be added or removed to make a tight fit. Drive segments counterclockwise to ensure contact before gauging and fitting the final shim.

17. Upper surfaces of adjacent bull ring segments should match within 1.5 mm. Mis-match around the entire perimeter of the bowl must not exceed 3.0 mm.

NOTE: If original bowl extension ring segments are reused, any shims or weld material left on them must be removed prior to re-installation.

18. Position the bowl extension ring segments on the bowl. When they are properly

seated, (metal-to-metal contact) a 0.038 mm feeler gauge should not fit between the bowl extension ring segments and bowl at the bowl outside diameter. Additionally, none of the bull ring segments should touch the bowl extension ring.

19. Install and torque the hex socket head cap screws for a bowl extension ring segment. a. Apply Loctite 271 to the screws. b. Install the hex socket head cap screws and washers and torque to 34.5 kg-m (338

Nm), one half of the value specified on drawing SD-110-01596. c. Torque the cap screws again to the full value 69 kg-m (676 Nm)

20. Repeat step 19, a to c until all of the bowl extension ring segments are fastened in place. Check clearance per step 18.

21. In the same order that the screws were torqued in step 19 c, repeat the torquing procedure to verify the socket head cap screws are torqued to the specified value, 69 kg-m (676 Nm).

22. Replace the hex socket head set screws, after applying anti-seize lubricant. Screws should be flush to two turns below the surface of the bowl extension ring. Stake the at two places for each screw.

23. Starting with any one bull ring segment, measure the gap between the center of the bull ring segment and the bowl extension ring.

24. Select bull ring segment end shims so that the thickness of the shim pack will be 0.00 to 0.38 mm less than the measured gap. Use the minimum number of shims possible.

25. Drive the shims into the gap between the center of the bull ring segment and the bowl extension ring.

CAUTION: During all welding procedures, ground each component individually as close as possible to the point of weld to prevent damage to any bearings.

26. Bend the shims back until they contact the bowl extension ring. Tack weld them in place. Refer to drawing D-66-754.

27. Replace the vane wheel segments.

COMPONENT SERVICING

3

28. Use anti-seize lubricant and install and torque the bolts attaching the segments to the bowl extension ring to 41.5 kg-m (407 Nm). Torque all other bolts per drawing B-GP-2175. Tack weld washers and bolts to the support lugs after installation.

CAUTION: Before turning the gearbox input shaft by hand, ensure that the upper oil reservoir of the gearbox has been filled with the recommended oil to the centerline of the gauge glass.

29. Reinstall the journal roll and shaft assemblies and journal opening covers. Vane Wheel Servicing

NOTE: The following steps refer to drawings E-PLVE-0528 and SD-110-01596, unless otherwise stated.

1. To provide access to the bowl, remove a journal opening cover and tilt out all journal

assemblies. 2. Open the millside access doors. 3. Inspect the body liner segment, air restriction segment, and vane wheel segments. 4. Remove and replace body liner segment and air restriction ring segment as necessary.

If new vane wheel segments will not be installed, new wing tips may be installed by welding them to the wheel vanes.

5. Replace worn vane wheel segments as follows: a. Break tack welds and remove cap screws and washers from vane wheel support

lugs. b. Remove the bolt protection piece by carefully grinding or burning out. c. Unbolt and remove worn vane wheel segments. d. Fit a new vane wheel segment and install and hand tighten the hex head cap

screws and plain washers holding the segment to the bowl extension ring. Do not torque the screws at this time.

e. Apply anti-seize lubricant to the hex head cap screws then attach the vane wheel support lugs to the bowl with the screws and plain washers.

f. Position and weld the support lugs to the vane wheel segments. Torque he support lug cap screws per B-GP-2175 then tack weld the Washers and screws to the support lugs.

g. Remove the vane wheel segment cap screws, apply anti-seize lubricant, reinstall and torque them to 41.5 kg-m (407 Nm).

CAUTION: Before turning the gearbox input shaft by hand, ensure that the upper oil reservoir of the gearbox has been filled with the recommended oil to the centerline of the gauge glass.

6. Reweld the bolt protection piece removed in step 5.b. Maintain the gap of 5 mm

between body liner segment and vane wheel segment shown on drawing E-PLVE-0528. Ensure that the gearbox hydrodynamic bearing is properly lubricated then manually turn the gearbox input shaft to rotate the bowl. Re-check gap at 45˚ intervals.

7. Tilt in the journal assemblies and reinstall the journal opening covers.

COMPONENT SERVICING

4

Liner Installation Using Weld Plugs

The following procedures cover installation of liners that cannot be directly welded to the pulverizer

NOTE: The pulverizers at your installation may not have all liner variations covered in these instructions.

Equipment Required

The following equipment and materials will be required: 1. MIG or Electric Arc Welder. 2. Masonry saw (Clipper trademark SM 300 or equivalent) for ceramic liners. 3. Diamond blade (Selker Bay State M-1 Bar 500 mm diameter, 2150 RPM or

equivalent) for ceramic liners. 4. Solvent (if required) such as toluene, zylene, or acetone. 5. Weld Plugs.

NOTE: Item 6 and 7 are sent complete from shop in a single unit container.

6. RTV Adhesive Sealant. 7. Duromar HAR Filler. Other fill materials such at Moldit D, Nordback, or Devcon Martek may be required to fill voids between and adjacent to installed tiles. See notes on reference drawings.

Welding Specification - Manual Insert Gas Welding (MIG)

1. Follow standards of the American Welding Society (AWS). 2. Wire rod size: 0.045" diameter. 3. Wire type: AWS-ASTM E605-E or similar. 4. Voltage requirement: 20 to 24 volts. 5. Amperage requirements 180 to 230 amps. 6. Gas rate: 10 CFH.

Welding Specification - Stick Weld, Manual Metal Arc Process 1. Follow standards of the American Welding Society. 2. Electrode: 3/32" or 1/8" diameter E-6011, E-6012 or E-6013; 3/32" diameter E-7014 or

E-7018. 3. Amperage-set near maximum amperage recommended by the electrode manufacturer.

Application of Weld Plugs

Procedures excerpted from drawing B-GP-3843. WARNING: DURING ALL WELDING PROCEDURES, GROUND EACH COMPONENT INDIVIDUALLY AS CLOSE AS POSSIBLE TO THE POINT OF WELD. IF THE WELD IS ON A PART WHICH ROTATES, GROUND THE WELDING EQUIPMENT TO THE ROTATING PART TO PREVENT DAMAGE TO ANY BEARINGS.

COMPONENT SERVICING

5

NOTE: Hold a short arc to float molten flux to the top of the weld. Fill weld plug 1/3 to 1/2 full. Do not overfill.

The following welding procedures are taken verbatim from Section 4.21, 'Plug Welds' of the American Welding Society Structural Welding Code D 1.1. These procedures should be adhered to during the installation of any weld plugs.

1. "For welds to be made in the flat position, each shall be deposited around the root of

the joint and then deposited along a spiral path to the center of the hole, fusing and depositing a layer of weld metal in the root and bottom of the joint. The arc is then carried to the periphery of the hole and the procedure is repeated, fusing and depositing successive layers to fill the hole to the required depth. The slag covering the weld metal should be kept molten until the weld is finished. If the arc is broken or the slag is allowed to cool, the slag must be completely removed before restarting the weld.

2. "For welds to be made in the vertical position, the arc is started at the root of the joint at the lower side of the hole and is carried upward, fusing into the face of the inner plate and to the side of the hole. The arc is stopped at the top of the hole, the slag is cleaned off, and the process is repeated on the opposite side of the hole. After cleaning slag from the weld other layers should be similarly deposited to fill the hole to the required depth."

3. "For welds to be made in the overhead position, the procedure is the same as for the flat position, except that the slag should be allowed to cool and should be completely removed after depositing each successive bead until the hole is filled to the required depth."

Installation of Tiles and Liners - General

1. Clean the metal surfaces thoroughly. The surface must be free of dirt, dust, oil, rust, or scale. Clean with solvent. Sandblast or grind if required.

2. Scribe lines to be used as guides to assure proper layout of tiles. 3. The application of the tile should begin with the bottom or lower course. Proper

alignment at this stage is critical. Misalignment here will be compounded as additional courses of tile are added.

4. Trial fit the tiles; note location of excessive gaps between tiles and mating parts. Trim tile as required to ensure a snug fit.

NOTE: The purpose of the adhesive sealant cement is to secure the tile to the steel, and to provide a solid back-up by filling the void between the tile and steel. Too much cement will make the weld plug welding difficult (or impossible) and reduce the cohesive properties of the product.

5. Using the adhesive sealant cartridge in a caulking gun, apply a thin coat (bead) of adhesive e to the back of the ceramic tile. Use a thicker coating in areas observed with excessive gaps Do not apply the adhesive near the weld plug hole. The eventual weld must not be contaminated with t e adhesive.

6. After the first course of tile is in place and properly aligned, weld plugs should be inserted and welded. Use the recommended welding procedure.

CAUTION: During all welding procedures, ground each component individually as close as possible to the point of weld. The welds should be made as quickly as possible so that a minimum amount of heat is

COMPONENT SERVICING

6

transferred to the liners. Excessive heat will cause the liners to crack.

7. Continue the attachment of successive courses of tiles. Maintain a check on alignment with scribed lines. Close adherence to the piece mix in each course count is essential to minimize openings between tiles. Each piece of tile has a number 1 or 2 embossed on the wear surface. Any special cut pieces are also marked for identification. Welding of metal plugs other than the first course as described in step 6 can be done after all the tiles have been cemented in place.

8. It may be necessary to cut the last piece of tile in each course. 9. If the closing tile/liner is ceramic, a masonry saw and diamond blade will be required.

10. Open joints should not exceed 1/16" and should be filled with the adhesive sealant (silicone) cement, such as RTV Sealer, troweled flush with the surface of the liner.

NOTE: RTV Sealer and Duromar HAR requires approximately 24 hours to cure completely, however, both set up rapidly (approximately 1/2 hour).

11. Fill the weld plug holes with Duromar HAR and trowel flush with the surface of the liner.

Trouble Shooting - Large Gaps Between Tile

Possible cause and remedies are as follows: 1. Improper piece mix - check drawing for proper count and mix. 2. Improper alignment - check scribed alignment lines and correct as required. 3. First (bottom) course has been installed improperly - check against the print provided. 4. Improperly fabricated liners - check print provided.

Trouble Shooting - Tile is Cracking

Possible cause and remedies are as follows: 1. Too much heat - use smaller diameter welding rod. Decrease weld puddle and fill.

Trouble Shooting - Welds Not Fusing

Possible cause and remedies are as follows 1. Area contaminated - burn cement away by heating above 371 °C. 2. Surface scale - clean by grinding or sandblasting

COMPONENT SERVICING

7

Liner Replacement

General

NOTE: Refer to the specific segment for reference illustrations and drawings.

Individual tiles and liners held in place with weld plugs can be replaced as follows: 1. Remove the damaged or worn tile/liner. 2. Clean the metal seating surface, grind off the old weld plugs. 3. Fit the new tile/liner in the area voided by the original. Maintain a clearance of 3 mm

between liners 4. Secure the new liner with adhesive and weld plugs. See "Application of Weld Plugs." 5. After all damaged liners have been replaced, fill the weld plug holes with Duromar

HAR and the spaces between the liners with RTV Sealer. Trowel all surfaces flush.

CAUTION: Protrusions or sharp breaks between liners can cause eddies and coal/airflow disturbances which will accelerate to wear on the adjoining tiles.

Separator Body Liners

NOTE: The following steps refer to drawing SE-110-01598, unless otherwise stated.

1. To provide access to the liners, remove the journal opening covers and tilt out the

journal assemblies.

NOTE: Individual liners can be replaced per Liner Replacement. If it becomes necessary to install or replace an entire liners, use the steps below.

2. Install the bottom row of liners starting at the right end. Maintain 105.6 mm, +0.0 mm,

- 3.0 mm clearance from the bottom flange of separator body and allow 3 mm between the liners. At the left end, the liners should be trimmed to overhang the left end liner. Install weld plugs and weld.

3. Fill all the weld plug holes with Duromar HAR filler and trowel flush. 4. Fill all the gaps between liners with RTV Sealer. 5. Close up the pulverizer by tilting in the journals and replacing the journal opening

covers as described in the General Reassembly Procedures.

Journal Lubrication

Journal Assembly Each of the three journal assemblies has a self-contained oil bath lubrication system. Refer to Figure 1. The journals are shipped completely filled with the recommended lubricant in order to protect the bearings and internal surfaces. Prior to operation, the oil level in each installed journal must be adjusted to its proper level for operation. Determine the proper level by using the oil dip stick, measuring from the bottom of the oil reservoir. If the customer will use a different brand of oil for

COMPONENT SERVICING

8

replacement or make up, replace the oil with customer-supplied lubricant prior to start up.

NOTE: The journal oil level must be checked periodically (at least once every 6 months).

CAUTION: Do not overfill the journal assembly oil reservoir. Too much oil may damage the oil seals.

Notes: 1. A lubricant is acceptable only if the acceptance criteria of the most recent

AGMA Standard for Industrial Enclosed Gear Drives (250.0 X) and the above specifications are met.

2. EP additives such as molybdenum disulfide, borate, lead napthanates, chlorides, sulfurized esters, etc., are not recommended.

3. Absolutely no water-based or water-containing lubricants are recommended for service anywhere in the pulverizer.

4. Change oil in new or rebuilt journals after 400 hours of pulverizer operation. Thereafter, oil changes should be scheduled every 6 months or when oil analysis shows signs of breakdown. Drain the oil while warm. At each oil change, flush the journal assembly oil prior to refilling to the proper oil level.

5. Toward the end of an oil change interval, an oil analysis by a qualified laboratory is recommended. Test results will indicate the remaining lubricant service life.

6. If a pulverizer fire occurs, journal oil should be changed or analyzed by a qualified laboratory for degradation before returning the pulverizer to service.

7. Do not mix oil brands or grades.

Figure 1

COMPONENT SERVICING

9

Journal Stop Bolt

Lubricant : Heat resistant multipurpose NLGI#2 extreme pressure Lithium based grease with

a 375°F minimum drop point, Molykote #33, Dow Corning #33 or Mobilith #AW2.

Fitting : Grease fitting on the end of each (3) stop bolt Frequency : Grease initially and after every adjustment

Figure 2

Journal Trunnion Shafts

Lubricant: Heat resistant multipurpose NLGI#2 extreme pressure Lithium based grease with a 375°F minimum drop point, Molykote #33, Dow Corning #33 or Mobilith #AW2.

Fitting: Grease fitting on the end of each (6) trunnion shaft Frequency: Grease initially and every 6 months

Figure 3

COMPONENT SERVICING

10

Major Adjustments

Journal Spring Assembly Preload Procedure

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE RE-MOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTE: The following steps refer to drawings D-GP-8580 and E-GP-8101, unless otherwise stated. This procedure can be performed in the maintenance shop or with the spring assembly mounted on the pulverizer. NOTE: The HP 1103 pulverizer spring rate is 5,357 kg/cm and the commissioning preload is 13608 kg or 2.54cm of spring deflection. Preload may vary depending on final pulverizer adjustments. NOTE: The Journal Spring Assembly Preload Tools referred to in this procedue are supplied by Doosan.

1. The journal spring assembly should be completely assembled

except for the spring stud extension cap, spring stud key, and connecting fasteners.

2. Measure the extension of the six positioning studs per dimension "A" on drawing E-GP-8101. All six studs should be extended from the spring housing cover the same amount to within 0.06". If this condition does not exist, the studs should be adjusted to achieve this requirement.

3. Mount the hydraulic cylinder onto the preload fixture using fasteners.

4. Install the spring preload fixture onto the journal spring assembly.

NOTE: The fixture should be installed providing access to the cotter pin. It may be necessary to rotate the preload stud or the preload fixture.

5. Using the hand pump, extend the hydraulic cylinder until it is

approximately 12.7 mm from full retraction. 6. Remove the cotter pin. 7. Install the preload stud, threading it onto the journal pressure

spring stud until it bottoms out. Install the stud washer and hex nut.

WARNING: TO PREVENT POSSIBLE INJUYRY OR DAMAGE TO EQUIPMENT, DO NOT STAND OR WORK IN LINE WITH THE SPRING ADJUSTING STUD WHILE HYDRAULIC PRESSURE IS BEING APPLIED.

COMPONENT SERVICING

11

8. Preload the spring by pressurizing the hydraulic cylinder to 2,350 psi, + 100 psi (from table of drawing E-GP-81 01 -p/n GP-8101-A.) The pressure is based on an effective hydraulic cylinder area for (P/N GP-369-A) of 12.73 sq. in. . Note if during commissioning a different spring preload is used then the pressure would need to be adjusted : [pressure {PSI} = preload {Ibs} / 12.73 {in2 (hydraulic cylinder area)}].

9. Use the locknut wrench to advance the adjustment castle nut until it contacts the spring stud adapter. If the slots in the castle nut do not align with the cotter pin hole in the journal spring preload stud, back off the nut, a quarter turn maximum, until the slot aligns with the hole.

10. Relieve the hydraulic cylinder pressure. 11. Check the preload by reapplying the hydraulic pressure and

recording the pressure at which the nut begins to move away from the spring stud adapter. The nut should begin to move within + 150 psi of the set value (2,350 psi). A dial indicator can be used to monitor this movement. If no movement is detected, repeat steps 8 and 9.

12. Release the hydraulic pressure and remove the preload adjusting stud, hydraulic cylinder and preload fixture.

13. Install the cotter pin and spring housing cover. 14. Set the roll-to-ring clearance. (Refer to detailed procedure) 15. Set journal spring to journal head clearance. (Refer to detailed

procedure)

Ring to Roll Gap The following procedure uses the journal stop bolt to set the roll-to-ring clearance and must be performed before the journal spring assembly to journal head clearance is set.

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1 . The following steps refer to drawing E-PLVE-0528. 2. Apply anti-seize compound to all fasteners and torque all fasteners

per drawing B-GP-2175 unless otherwise noted. 3. The pulverizer must be 100% operational before this procedure can be

done. NOTE: The HP 1103 pulverizer commissioning ring to roll gap is four flats. This value may vary depending on final pulverizer adjustments.

1. Open at least one pulverizer separator body access door and clean the

bowl. Vacuum out any residual coal from the bowl. 2. Back out the journal spring adjusting studs 25.4 mm (refer Dwg D-GP-8580) in

order to provide additional clearance between the journal spring assembly and the journal head.

3.Working with one journal at a time, remove the stop bolt nut fasteners and retract the stop bolt nut until the journal roll rests on the bowl.

COMPONENT SERVICING

12

NOTE: To ensure that the stop bolt does not rotate during this process, be sure that the key and stop bolt keeper plate remain in position.

4. Mark the back face of the roll at the contact point between the bowl and roll. Label this point "1 ".

5. Raise the roll by turning the stop bolt nut 2 flats 6. Find the high spot on the roll by turning the roll through one full

revolution. If the roll turns through one complete revolution, skip to Step 8.

7. If the roll cannot be turned through one full revolution, mark the contact point with the bowl and label "2" and repeat Step 5. Continue this procedure (5, 6, 7, etc.) until the highest point is found on the roll.

8. After the roll can be turned through one full revolution, turn the roll so that the high point of the roll (highest number) is at the 6 o'clock position.

9. Turn the stop bolt nut two complete revolutions inward in order to raise the roll away from the bowl.

10. Repeat Steps 3 through 9 for the remaining journals. 11. Once journal adjustments are complete, remove any foreign

material from the bowl area and close the separator body access doors.

12. Place the pulverizer lube oil system in operation and start the pulverizer. If any roll is still in contact with the bowl, raise the roll slightly.

13. Working with one roll at a time, lower the roll (via the stop bolt nut) until till the first indication of contact with the bowl. Stop at first indication of contact.

14. Immediately raise the roll via the stop bolt nut four flats (one revolution with 4 threads per inch thread) of the stop bolt nut.

15. Repeat Steps 13 through 14 for the remaining journals. Stop and isolate the pulverizer.

16. Secure the stop bolt nut by installing the four fasteners between the nut and stop bolt keeper plate. If the holes in the nut and keeper plate do not line up, turn the stop bolt nut clockwise (raise the roll slightly) so that they can be installed.

17. If not previously done, set journal spring compression. (Refer to detailed procedure)

18. Set journal spring assembly to journal head clearance. (Refer to detailed procedure)

19. Close the separator body access doors.

COMPONENT SERVICING

13

Spring Assembly to Journal Head Gap

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED.

CAUTION: This procedure is used to prevent the spring from exerting pressure on the stop bolt. This step is performed only after the springs have been preloaded and the roll-to-ring clearance has been set. NOTES: 1. The following steps refer to drawings D-GP-8580, and E-GP-

8101. 2. Apply anti-seize compound to all fasteners and torque all

fasteners per drawing B-GP-2175 unless otherwise noted. NOTE: The HP 1103 pulverizer commissioning spring assembly to journal head gap is 0.0625"(1.6mm). This value may vary depending on final pulverizer adjustments.

1. Open the separator body access door(s). Vacuum out any residual coal

from the bowl. 2. Verify that nothing is wedged under the grinding rolls by turning each by

hand. If they do not turn, either the ring to roll gap is not correctly set or there is residual material under the roll.

3. Using two opposite spring adjusting studs, move the spring assembly into the mill until there is a 1.6mm gap between the spring stud face and the journal head as shown on drawing E-GP-8101. A 1.6mm shim should be used to ensure that this gap is maintained.

4. Adjust all 6 spring adjusting studs so that they make contact with the spring stud adapter. Verify that all 6 studs are positioned correctly by measuring the stud length extending from the spring housing cover. The stud length extending should be the same within 1.6mm.

5. Remove the 1.6mm shim and verify the gap. 6. Torque the spring position adjusting nuts per drawing B-GP-2175. 7. Set the spring position on the other two journals. 8. Close the separator body access door(s).

COMPONENT SERVICING

14

Component Maintenance

Journal Opening Cover Removal and Installation

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED.

NOTES: 1. The following steps refer to drawing E-PLVE-0528. 2. Apply anti-seize compound to all fasteners and torque all

fasteners per drawing B-GP-2175 unless otherwise noted.

Removal

1. Open the separator body access doors. 2. Remove the seal air piping from the spring assembly. 3. On the back end of the spring assembly, there are eight studs. Back

them out 25.4mm in order to provide additional clearance between journal spring assembly and journal head . This clearance is required during the reinstallation process.

4. Lower the journal so the grinding rolls is resting on the bowl by removing the stop bolt nut and fasteners.

5. Remove the key. 6. Remove the stop bolt . 7. Remove the O-Ring. 8. Rig the journal opening cover thru the two holes in the top. A choker

around the end of the spring assembly with come-along up to the crane hook for balance may be used. Take up the slack on the crane.

9. Remove the fasteners and cover.

Installation 1. Grease the frame of the separator body with Molykote #33 or

Mobilith #AW2. 2. Rig the journal opening cover. Thru the two holes in the top. A

choker around the end of the spring assembly with come-along up to the crane hook for balance may be used. Install the journal opening cover with fasteners.

3. Grease the O-Ring with Molykote #33 or Mobilith #AW2 and install it in the groove.

4. Install the journal stop bolt. Be sure not to damage the O-Ring which is in the cover with the threads of the stop bolt.

5. Install the key. 6. Apply anti-seize compound (Fel-Pro #C5A or Molykote #41) to the

threads of the stop bolt. 7. Apply Molykote #33 or Mobilith #AW2 to the face of the stop bolt

COMPONENT SERVICING

15

nut. 8. Install the stop bolt nut. 9. Reset the ring to roll gap. (Refer to detailed procedure) 10. Reset the spring assembly to journal head gap. (Refer to detailed

procedure) 11. Close the separator body access doors.

Journal Oil Replacement

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1. It is recommended that the oil in journals be changed with the

journal warm. This will facilitate draining and removal of contaminates.

2. Refer to Journal Lubrication System section of this manual for oil specifications and service recommendations.

3. The journal must be in its normal installed position to perform the following procedure.

4. The area around the oil fill pipe acts as an air plenum for the journal oil seal and bearing seal air system. Failure to keep this area clean will reduce the life of the oil seal and subsequently cause early failure of the journal bearing(s).

5 . The following steps refer to drawing D-GP-9955, D-94-1748 and D-PLVD-0823 unless otherwise noted

1. Open the separator body access doors. 2. Remove the journal opening cover inspection hole cover and gasket item

on Dwg D-GP-9955. 3. Remove the journal head cover plate items on Dwg D-PLVD-0823 4. Remove the 1-1/4" pipe plug from the oil fill pipe Dwg D-94-1748. 5. Oil may be siphoned from a journal through the oil fill plug in order to

adjust oil level or continue with the following procedure to drain a journal.

WARNING: EXERCISE CAUTION WHEN THE DRAIN PLUG IS FIRST REMOVED, WARM OIL COULD BE DISCHARGED IF THE JOURNAL OIL LEVEL IS HIGHER THAN RECOMMENDED.

6. Rotate the grinding roll three revolutions by hand to mix the oil and stop it

with the drain plug at its highest possible position, near the top of the roll. This will be above the normal oil level.

7. Assemble a section of flexible hose to a 1" pipe nipple. Provide an oil receiver, bucket or large pan, with a capacity of more than 13 gallons (50 liter) in the pulverizer bowl.

8. Remove the 1" drain plug, be ready to insert and secure the pipe nipple and hose.

9. Ensure that the hose end is directed into the oil receiver then rotate the roll to place the drain at the lowest position.

COMPONENT SERVICING

16

10. When oil is completely drained, rotate the roll 1/4 turn clockwise. 11. Add to the journal thru the 1" pipe nipple, one quart (approx. 1 liter) of

journal oil, see Pulverizer Lubricants section for oil specification. 12. Ensure that the hose end is directed into the oil receiver then rotate the roll

to place the drain at the lowest position. 13. When completely drained, remove the hose and nipple and replace the

drain plug. 14. Refill the journal with new oil. Refer to Pulverizer Lubrication section for the

oil specification and quantity. 15. Install the 1-1/4" pipe plug in the oil fill pipe. 16. Clean the mating surfaces of the journal head and cover plate, apply RTV

sealer, and install the plate. 17. Install the journal opening cover inspection hole cover and gasket. 18. Close the separator body access doors.

Journal Oil Seal Replacement

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1. It is recommended that the oil in journals be changed when

the oil seals are changed. 2. Refer to Journal Lubrication System section of this manual for

oil specifications and service recommendations. 3. This procedure is based upon having the journal in its normal

installed position. If additional workspace is required, tilt out the journal and replace the seals with the journal in the vertical position.

4. The area around the oil fill pipe and oil seal keepers act as an air plenum for the journal oil seal and bearing seal air. Failure to keep these areas clean will reduce the life of the oil seal and subsequently cause early failure of the journal bearing(s).

5. The following steps refer to drawing D-94-1747 unless otherwise noted

6. Apply anti-seize compound to all fasteners and torque all fasteners per drawing B-GP-2175 unless otherwise noted.

Journal oil seals should be replaced during a Journal Bearing Replacement procedure, however, if there is evidence of oil leakage, the oil seals can be replaced without removing the journal assembly from the pulverizer.

1. Drain the oil from the journal using the Journal Assembly Oil

Replacement Procedure, steps 1 thru 13. 2. Remove the journal head liner assembly. Set it down on the bowl. 3. Remove the journal skirt assembly.

COMPONENT SERVICING

17

NOTES: 1. The following steps refer to drawing D-94-1748 unless otherwise

noted 2. Apply anti-seize compound to all fasteners and torque all fasteners

per drawing B-GP-21 75 unless otherwise noted.

4. Remove the oil seal keeper . 5. Remove the oil seal access cover. 6. Cut the three oil seals and remove them from the upper journal housing

cover. 7. Rotate the journal and inspect the seal wear ring. If excessively scored,

replacement should be considered. 8. Coat the upper journal housing cover oil seal bore with a small amount of

Molykote 33 or Mobilith #AW2 grease. 9. Pack the new oil seals with Molykote 33 or Mobilith #AW2 grease. Slide

the first seal into the journal housing cover with the lip facing the journal roll. Be sure to glue the ends of the seal together using the procedure and adhesive supplied with the oil seal.

10. Slide the second and third oil seals into the journal housing cover with the lip facing out. Be sure to glue the ends of the seal together using the procedure and adhesive supplied with the oil seal. Also be sure to pack the region around the seals with Molykote 33 or Mobilith #AW2 grease.

11. Ensure by inspecting through an access cover that oil seal splits are staggered (at least 60° apart) and match end to end without overlap.

12. Apply Loctite Sealant 515 to the oil seal access covers and replace them. Lubricate and torque the access cover fasteners per B-GP-2175.

13. Replace the seal keeper. Install and torque the bolts per B-GP-2175. NOTES: 1. The following steps refer to drawing D-94-1747 unless

otherwise noted 2. Apply anti-seize compound to all fasteners and torque all fasteners

per drawing B-GP-2175 unless otherwise noted.

14. Replace the journal skirt. Install and torque the bolts per B-GP-2175.

15. Replace the journal head liner assembly. 16. Complete the remaining steps of the Journal Assembly Oil

Replacement Procedure, steps 14 thru 18.

COMPONENT SERVICING

18

Journal bearing end play checking

Journal bearing end play should be checked at two to three year intervals or anytime an oil sample analysis shows evidence of metal contamination (manganese, nickel, chromium).

NOTE: Refer to drawings D-94-1748 and C-GP-7711 unless otherwise noted.

NOTE: Journal bearing end play can be checked with the journal assembly in the tilt-out position or the journal roll and shaft assembly can be removed and placed on a temporary foundation.

1. Remove the journal opening cover and tilt out the journal assembly. 2. Ensure that the journal is secured to the tilt out bracket. 3. Remove the lower journal housing cover. 4. Remove two keeper bolts 180° apart and install eyebolts to the full depth

of the full depth of the threads. Ensure that the shoulders of the eyebolts are flush with the roll keeper plate surface.

5. Install a chain shackle in each eyebolt and attach a chain sling. The sling when loaded must clear the journal opening and allow the roll to be rotated.

6. Rig a chain fall to an 'overhead crane centered above the journal opening. Attach a sling, and load cell.

7. Mount a dial indicator on the journal housing with the indicator needle resting on a machined face of the bearing inner race.

8. Rotate the roll several times to be sure that the bearings are properly seated. Zero the indicator and mark the location of the indicator needle on the housing.

9. Use the chain fall to apply a load of 6.44 MT. ("Lift Load with Roll", tabulated on P/N GP-7711-B on drawing C-GP-7711) to the journal housing roll assembly.

10. Rotate the roll several times to be sure the bearings are properly seated. Realign the indicator needle with the mark on the journal housing and record then reading.

11. Lower the roll until there is no load on the load cell. Rotate the housing several time to seat the bearings. Line up the indicator needle with the mark on the housing. If the reading is within 0.013 mm the original zero setting, the measurement is considered accurate.

12. Repeat steps 8 through 11 until two accurate measurements are obtained.

13. Average the readings and compare the results to the maximum allowable in the table.

14. If the measured end lay is less than the maximum allowable 0.13mm then the journal may be returned to service for the next six month interval.

15. If the measured end pay is greater than the maximum allowable 0.13mm, then the bearing internal clearance must be reset. Refer to the Journal Shaft Disassembly Procedure.

NOTE: If the bearing end play was out of specification and will be reset, it should be set to the specification 0.03 to 0.08mm loose.

COMPONENT SERVICING

19

16. If the bearing end-play was acceptable, tilt in the journal assembly. 17. Check and re-establish the journal oil level, 343 to 394 mm measured

on the oil dip stick. 18. Re-install the journal opening cover.

Journal Bearing Replacement

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1. The following steps refer to drawing, D-94-1747. 2. Apply anti-seize compound to all fasteners and torque all

fasteners per drawing B-GP-2175 unless otherwise noted. 3. It is not necessary to remove the grinding roll from the journal

hosing to replace the journal bearings. If the roll is worn and needs replacement, it can be replaced as per the procedure in another section of this manual.

This procedure is best performed if the journal shaft assembly is removed from the mill and taken to a maintenance shop. This procedure can be performed with the journal shaft assembly still attached to the journal head, which is still in the mill. If it is done on the mill, cleanliness and accuracy of the bearing set-up may be compromised. Journal Shaft Assembly Removal 1. Open the separator body access doors. 2. Remove the journal opening cover. 3. Drain the oil from the journal assembly using the procedure in the section of

this manual titled Journal Assembly Oil Replacement. 4. Remove the oil fill pipe and fittings. Plug the oil fill port in the journal shaft

with the pipe plug 5. Tilt out the journal. (Refer to detailed procedure and fixture supplied by

Doosan) Be sure that the safety lug is properly installed and secured to the journal assembly and separator body frame.

6. Remove the journal head liner assembly. 7. Remove the journal skirt assembly.

NOTES: The following steps refer to drawing D-94-1748 unless otherwise noted. Apply anti-seize compound to all fasteners and torque all fasteners per drawing B-GP-2175 unless otherwise noted.

8. Remove the grinding roll keeper and grinding roll key. 9. Install the grinding roll removal lug supplied by Doosan; ensure that the

COMPONENT SERVICING

20

bolts thread into the journal housing, not the grinding roll. Refer to drawing E-GP-6646. The scribe line on the removal lug must face into the center of the mill. Torque the bolts to 6.9 kg-m.

10. Install a wire rope sling through the grinding roll removal lug.

NOTE: The sling and crane cable must not contact the journal opening frame when the journal assembly is lifted.

11 . Attach the rope sling to the overhead crane positioned above the center of the grinding roll. Take up the slack.

12. After removing the fasteners holding the journal shaft assembly to the journal head, Dwg D-94-1747 item 25, lift the journal shaft assembly off the journal head and take it to a maintenance facility.

Journal Shaft Assembly Disassembly

NOTE: Fabricate a foundation plate and mount it on the floor in a maintenance area. This foundation plate (supporting platform) will be used for journal shaft disassembly as well as journal bearing endplay checking. It must be capable of withstanding a lift load of 6,441 kg without movement. The plate should be at least three inches thick, have a thru center hole which is 435mm in diameter and have equally spaced holes 1.250"-7 UNC tap on 508mm DBC. The plate should be at least 914mm OD or square. A rim around the plate to retain oil is recommended. Refer to Dwg C-GP-7711 (flanged shaft design)

1. Secure the shaft assembly to the foundation plate. 2. Unbolt and remove the lower journal housing cover. Discard the O-Ring. 3. Unbolt the oil seal keepers and remove them. 4. Remove and discard the three oil seals. As the seals are removed, some

residual oil may spill; be prepared for clean up. 5. Unbolt and remove the two journal housing liners. 6. Unbolt the upper journal housing cover and let it slide down to rest on the

seal wear ring. When the O-ring seal loosens, some residual oil may spill; be prepared for clean up. Discard the O-Ring.

7. Continue disassembly of the journal shaft by unbolting and removing the journal bearing keeper, cap screw lock plate, and bearing keeper shims.

NOTE: The inner race of the upper and lower journal bearings was a line to line / loose fit at original installation on the journal shaft.

8. Using a suitable puller, remove the inner race of the lower journal bearing

from the journal shaft. 9. Attach lifting equipment, eyebolts and sling, to the journal housing. Lift the

journal housing off the journal shaft. The upper and lower bearing outer races will remain inside the journal housing.

10. Using a suitable puller, remove the inner race of the upper bearing and spacer from the journal shaft.

11. Lift off the upper journal housing cover . 12. Using a suitable puller, remove the seal wear ring from the journal shaft.

COMPONENT SERVICING

21

NOTE: The outer races of the upper and lower journal bearings are a tight fit at original installation in the journal housing.

13. Use a suitable puller to remove the upper and lower bearing cup

assemblies from the journal housing. 14. Clean and inspect all components to determine required replacements.

Journal Shaft Assembly Reassembly

NOTE: Do not use split oil seals when rebuilding a journal assembly. Use only solid oil seals.

1. Slide over the shaft the three solid oil seals and set them down on the

flange. Be sure that the two closest to the large flange have the lips pointing towards the flange and the one farthest away from the flange has the lip pointing away from the flange. See Figure 4

Figure 4

2. Heat the new oil seal wear ring (10) to 250°F(121℃) and slide it into position on the journal shaft (5). The oil seal wear ring must be firmly seated against the shaft step before it cools.

3. Apply Loctite Sealant 515 to the oil seal access cover (20) and mount the oil seal access cover to the upper journal housing cover (15).

4. Set the upper journal housing cover (15) down over the journal shaft

(5) and block it up so that the end of the journal housing cover (15) is at the same elevation as the end of the oil seal wear ring (10). See Figure 5.

COMPONENT SERVICING

22

Figure 5

5. Grease the O-Ring with Molykote #33 and set in the upper journal housing

cover grove. 6. Slide the journal bearing spacer over the journal shaft with the chamfer side

against the shoulder. 7. Slide the inner race assembly for the upper bearing onto the journal shaft. It

should rest firmly against the bearing spacer.

NOTE: It may be necessary to heat the bearing cone assembly prior to installation. Do not exceed 200°F (93℃).

8. Chill the two tapered roller bearing outer races down to at least -60°F(-

51℃). Install both races in the journal housing and clamp them in place until the housing and race temperatures reach equilibrium.

CAUTION: To prevent damage to the bearing, exercise care when positioning the bearing cup on the rollers.

9. Lower the journal housing assembly onto the journal shaft.

NOTE: It may be necessary to heat the bearing cone assembly prior to installation. Do not exceed 200°F (93℃).

10. Install the inner race assembly of the lower tapered roller bearing on the

journal shaft. 11. Attach the bearing keeper to the end of the journal shaft. Hand tighten the

bolts. 12. When the component temperatures are equal, rotate the journal housing at

least five times in each direction to seat the bearing rollers. 13. Remove the bearing keeper and use a depth micrometer to measure the

gap between the end of the shaft and the edge of the lower bearing cone.

COMPONENT SERVICING

23

14. Assemble a shim set 0.00 ~ 0.05mm more than the measured gap. 15. Install the shims, bearing keeper, and the lock plate, and torque the

fasteners per B-GP-2175.

NOTE: The following steps refer to drawings C-GP-7711, unless otherwise stated.

16. Install two eyebolts 180° apart on the bearing housing (holes are 1”-8

UNC), attach chain shackles and a chain sling. (Note the lift load to be 14,200 lbs(6,441 kgf).

17. Center a crane over the roll and shaft assembly and attach a chain fall, shackle, sling and load cell.

18. Install three dial indicators onto the bearing keeper plate. Rest the indicator needles on the machined surface of the journal housing.

19. Rotate the roll several times to be sure that the bearings are properly seated. Zero the indicators.

20. Number and mark the location of each indicator on the journal housing. 21. Rotate the journal housing five times and return to original indicator

positions. If all indicator readings do not return to zero, repeat step.

NOTE: If fixtures other than eyebolts, shackles, and chain slings are used in this procedure, add twice their weight to the recommended lift loads.

22. Using the chain fall, apply a lift load of 14,200 lb(6,441 kgf) ("Lift Load with

Roll", tabulated as P/N GP-771 1-B on drawing C-GP-771 1) to the journal housing assembly. (Apply a lift load of 10,300 lb(4,672 kgf) if the roll has been removed.)

23. Rotate the housing several times to be sure the bearings are properly seated. Align the indicators at their original positions, record the indicator readings, and average them.

24. Release the load on the journal housing assembly and rotate the housing several times to seat the bearings. Line up the indicators with their original marks. All indicator readings must return to zero.

25. Repeat steps 19 through 24 five times and calculate the average of the averages. This average should be between 0.03mm and 0.08mm, the recommended initial endplay for new bearings. If the averaged readings are out of specification, add or subtract shims as necessary and repeat the bearing endplay check, steps 11 through 15. When the measured endplay falls within the indicated range, remove the equipment used for checking, and proceed with the journal shaft reassembly.

26. Grease the lower journal housing cover O-ring with Molykote 33 or Mobilith #AW2 grease. Install the O-ring and the lower journal housing cover.

27. Replace pipe plugs in the lower journal housing cover using pipe sealant. Lubricate and replace set screws in tapped holes; stake four places.

NOTE: If the roll was removed, install a new roll per the "Grinding Roll Renewal" procedures.

28. Remove the journal shaft from the foundation plate and turn the journal

assembly over so that the lower journal housing cover is sitting on the floor. Verify that the O-ring is properly positioned between the upper journal housing and housing cover.

COMPONENT SERVICING

24

29. Fasten the upper journal housing cover to the journal housing. 30. Add to the journal assembly the journal oil thru the port in the end of the

journal shaft. See the section titled Pulverizer Lubrication for additional detailed information.

31. Coat the journal housing cover upper seal bore with a small amount of Molykote 33 or Mobilith #AW2 grease.

32. Pack the oil seals with Molykote 33 or Mobilith #AW2 grease. 33. Slide the first seal into the bore with the lip facing into the bore. Slide the

second and third oil seals into the bore with the lip facing out. 34. Install the oil seal keeper. 35. Position and fasten both halves of the journal housing liner to the journal

housing. Install the remaining bolts through the journal housing cover into the journal housing.

36. Install the grinding roll key.

Journal Shaft Assembly Reinstallation

37. Turn the journal shaft assembly over (weight is 12500 lbs(5.8 MT).) so that the large flange is down and install the grinding roll removal lug, ensure that the bolts thread into the journal housing, not the grinding roll. Refer to drawing E-GP-6646.

NOTE: There is an offset hole in the bolt pattern, which fastens the journal shaft assembly to the journal head. Be sure that the offset holes are aligned.

38. Set the journal shaft assembly down on the journal head. Be sure to align

the offset bolt hole. 39. Using a hydraulic torque wrench, pump and drive and torquing pattern

shown in Figure 6, torque the fasteners to 235 kg-m using a three step sequence of 1.38 kg-m, 138 kg-m and 235 kg-m.

40. Remove the roll removal lug and install the roll keeper plates. 41. Install the journal skirt. 42. Install the journal head liner assembly. 43. Tilt in the journal assembly. 44. Remove the access cover on the back side of the journal head. 45. Remove the pipe plug in the end of the journal shaft and check the oil

level. Add or subtract oil as necessary. See the Pulverizer Lubrication section of this manual for additional information. Reinstall the oil fill pipe and fittings and reinstall the access cover.

46. Reinstall the journal opening cover. (Refer to detailed procedure) 47. Reset the ring to roll gap. (Refer to detailed procedure) 48. Reset the spring assembly to journal head gap. (Refer to detailed

procedure) 49. Close the separator body access doors.

COMPONENT SERVICING

25

Figure 6

COMPONENT SERVICING

26

Grinding Roll Replacement

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1. The following steps refer to drawing D-94-1748, and SE-GP-

6646 2. Apply anti-seize compound to all fasteners and torque all

fasteners per drawing B-GP-2175 unless otherwise noted.

This procedure can be performed with the journal assembly in the tilt-out position on the pulverizer, or the journal roll and shaft assembly can be removed to a convenient work area.

1. Open the separator body access doors. 2. Remove the journal opening covers (Refer to detailed procedure) 3. Tilt out the journal. Be sure that the safety lug is properly installed and

secured to the journal assembly and separator body frame. 4. Remove the grinding roll keeper and grinding roll key refer to Dwg D-94-

1748. 5 . Install the grinding roll removal lug, ensure that the bolts thread into the

grinding roll, not the journal housing. Refer to drawing E-GP-6646. The scribe line on the removal lug must face into the center of the mill. Torque the bolts to 6.9 kg-m.

6. Install a wire rope sling through the grinding roll removal lug.

NOTE: The sling and crane cable must not contact the journal opening frame when the journal roll is lifted.

7. Attach the rope sling to the overhead crane positioned above the center of

the grinding roll. Take up the slack.

WARNING: THE GRINDING ROLL SHOULD NOT BE HEATED ABOVE 300°F(148℃). CIRCUMFERENTIAL TEMPERATURE GRADIENTS SHOULD BE MINIMIZED. NOTE: The entire roll must be heated evenly all the way through to permit its removal. Use a contact pyrometer or similar device to measure the temperature of the grinding roll surface. Temperature variations around the perimeter of the roll must not exceed 10°F(5℃).

8. Heat the grinding roll with a stress relieving blanket or similar device;

monitor the temperature.

NOTE: As the roll expands due to heating, it should lift off the journal housing.

COMPONENT SERVICING

27

9. As the temperature of the roll approaches 200°F(93℃), apply a slight load

on the rigging. Maintain a constant heat for approximately 45 to 60 additional minutes to insure that the roll is heated throughout.

10. Once the roll breaks free and lifts clear of the housing, move it away from the pulverizer to a suitable area to cool.

NOTE: Allow the journal bearing housing to cool before installing a

new roll. NOTES: 1. If schedule permits, the journal bearing end play should be

checked at this time. Refer to the Journal Bearing Replacement Procedure for information.

2. If schedule permits, the journal oil and seals should be replaced. See the appropriate sections of this manual for the procedures.

11. Clean the mating surfaces of the journal housing and the bore of the new

roll. 12. Install the grinding roll removal lug on the new roll.

NOTE: The entire roll must be evenly heated throughout to allow installation. Use a contact pyrometer or similar device to measure the surface temperature. Temperatures around the perimeter of the roll must vary by less than 10°F(5℃).

13. Install the grinding roll key and torque the hex socket head screws to 42.8

kg-m. 14. Use a stress relieving blanket or similar device to heat the new grinding

roll. Monitor the roll temperature; it should not exceed 200°F(93℃).. 15. Lift the roll and carefully lower it onto the journal housing. Ensure that the

keyway on the roll is in line with the key on the journal housing. 16. Verify that the back face of the roll seats completely on the housing. 17. Remove the wire rope sling and grinding roll removal lug. Immediately

install the grinding roll keeper plates and keeper bolts. Torque the keeper bolts to 42.8 kg-m.

18. Allow the roll and journal housing to cool to near ambient.

NOTE: If the journal roll and shaft assembly was removed to a maintenance area for this procedure, it may be reinstalled on the journal head at this time.

19. Tilt in the journal as per the Journal Tilt-out Procedure. 20. Check and re-establish the journal oil level. See the section on Pulverizer

Lubrication for details. 21. Install the journal opening covers. (Refer to detailed procedure) 22. Close the separator body access doors. 23. Set the ring to roll gap. (Refer to detailed procedure) 24. Adjust the spring assembly to journal head gap. (Refer to detailed

procedure)

COMPONENT SERVICING

28

Trunnion Bushing and Seal Replacement

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE OPENING THE ACCESS DOORS. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED.

NOTES: 1. The following steps refer to drawing, D-94-1747 2. Apply anti-seize compound to all fasteners and torque all fasteners per drawing B-GP-2175 unless otherwise noted.

1. Using the journal shaft assembly removal procedure found in another

section of this manual, remove the journal shaft assembly.

NOTES: 1. The following steps refer to drawing D-PLVD-0823 unless otherwise noted. 2. Apply anti-seize compound to all fasteners and torque all fasteners per drawing B-GP-2175 unless otherwise noted.

2. With the journal head in the tilted out position, install three equally spaced

eye bolts into the holes that were securing the journal shaft assembly to the journal head. Using the maintenance crane, lift up slightly on the journal head to take its weight off the trunnion bushings. Be sure that the crane chain / cable is not dragging on the face of the journal opening frame.

3. Remove the trunnion end plates. 4. Pull out the trunnion shafts, and remove and dispose of the O-Rings. 5. Lift the journal head out of the mill and place it on the floor on timbers. 6. Remove the two trunnion bushing retainers and remove and dispose of the

0-Rings. 7. Remove the trunnion bushings . 8. After cleaning the bore of the journal head and bore and OD of the

trunnion bushings, install them into the journal head with anti-seize compound on the OD of the bushing.

9. Install the trunnion bushing retainers. 10. Lubricate and install the O-Rings with molykote #33 or Mobilith #AW2 in

the trunnion bushing retainer. 11. After cleaning the trunnion shafts, lubricate and install the O-Rings . 12. Set the journal head back in position in the mill. Be sure to install the

retaining bracket under the journal head. 13. Lubricate the OD of the trunnion shafts with molykote #33 or Mobilith

#AW2 and reinstall them. Be sure that the end of the shaft with the pipe plug in it is installed inboard.

14. Install the trunnion end plates. Be sure that the grease fitting in the trunnion end plate lines up with the grease hole in the trunnion shaft.

15. Grease the trunnion assembly. 16. Reinstall the journal shaft assembly using the journal shaft assembly

reinstallation procedure found in an earlier section of this manual.

COMPONENT SERVICING

29

Journal Spring Assembly Rebuild

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED. NOTES: 1 . The following steps refer to drawing D-GP-8580, and E-GP-

8101. 2. Apply anti-seize compound to all fasteners and torque all

fasteners per drawing B-GP-2175 unless otherwise noted. 3. Before reassembling of the journal spring, clean and coat

internals with Molykote Metal Protector. Take care not to coat mating surfaces, threads, plated or bearing surfaces.

This procedure is best performed if the spring assembly is removed from the mill to a maintenance shop. This procedure can be performed with the spring assembly still assembled to the mill. However, cleanliness and accuracy of the bearing set-up may be compromised. Spring Assembly Disassembly 1. Open the separator body access doors. 2. Uncouple the pipe nipple at the spring housing and remove the seal air

piping at the spring assembly. 3. Release the tension on the spring position adjusting stud nuts and retract the

spring position adjusting studs at least 2.0". 4. Remove the spring stud extension cap.

WARNING: IT IS ADVISABLE TO RELEASE THE SPRING PRESSURE BEFORE THE ASSEMBLY IS REMOVED FROM THE JOURNAL OPENING COVER. USE EQUIPMENT SUPPLIED FOR JOURNAL SPRING PRELOAD. REFER TO DRAWING E-GP-8101.

5. Bolt the hydraulic cylinder to the spring preload fixture. 6. Remove the spring stud cotter pin and thread the preload adjusting

stud into the journal pressure spring preload stud to the full depth of the preload stud threads.

7. Attach the preload fixture to the spring assembly; be sure to align a side opening of the fixture with the cotter pin hole in the spring preload stud.

8. Using the hand pump, extend the hydraulic cylinder until it is within 1/2" of full extension.

9. Install the flat washer and lock nut, and hand tighten with a wrench. The nut must thread completely onto the adjusting stud.

NOTE: The HP 1103 pulverizer spring rate is 5,357kg/cm and the commissioning preload is 13,608 kg. Preload may vary depending on final pulverizer adjustments.

10. Use the hydraulic pump and extend the hydraulic cylinder to apply pressure

COMPONENT SERVICING

30

to the spring. 11. Pump the hydraulic cylinder pump until the pressure gauge exceeds "P",

165.2 kg/cm2 (2,350 psi )(from the table on drawing GP-8101, P/N GP-8101-A) and the spring adjusting castle nut is free.

12. Remove the spring stud cotter pin and back off the spring adjusting castle nut 2.0".

13. Slowly release the hydraulic pressure on the cylinder. The spring adjusting castle nut should be loose after the hydraulic pressure is released. If-not, repeat the process until the spring stud lock nut is fully loosened.

14. Remove the spring preload adjusting fixture. 15. Provide support to the spring assembly and rig for removal. 16. Remove the eight cap screws holding the spring assembly to the door. 17. Using the overhead crane, apply some lift, and slide the spring housing

out of the journal opening cover. Move the spring assembly to a work area. 18. With spring assembly on its side (shop floor or bench), remove the spring

air seal cap and the spring orifice plate. Inspect the orifice plate for wear. 19. Using a fixture or cribbing, stand the spring assembly on the inboard face

of the spring housing flange. 20. Remove spring housing cover. 21. Install an eyebolt into the end of the spring stud and lift the spring stud,

spring adjusting nut, spring stud adapters, and the journal pressure spring out of the spring housing.

22. Sequentially, remove the adjusting nut , spring stud adapter, spring, and the second spring stud adapter from the spring stud .

23. Remove the retaining ring and the spring stud bearing . 24. Remove the spring stud bearing from the spring hosing cover. 25. Clean and inspect all components to determine required replacements. Spring Assembly Reassembly 26. Stand the spring housing on end so the inboard end of the housing is up.

Chill and insert a spring stud bearing into the spring housing. Lock in place with the retaining ring.

27. Flip the spring housing 180° so that the outboard end is now up. Use a fixture or cribbing to support the spring housing (by the flange) 6.0" above the floor.

28. Chill and insert the second spring stud bearing into the spring housing cover.

29. Assemble onto the spring preload stud; the spring stud adapter, the spring , the second spring stud adapter, the spring housing cover and the spring stud adjusting nut.

30. Install an eyebolt in the end of the spring preload stud. Carefully lift the assembly and lower it into the spring housing. Take care when guiding the preload stud through the lower bronze bushing.

31. Install the spring housing cover cap screws, lubricate, and torque per drawing B-GP-21 75.

32. Turn the spring housing on its side, and install the spring orifice plate and spring air seal cap. Torque the socket head cap screws per drawing B-GP-21 75.

33. When ready to mount the spring assembly in the journal opening cover, coat the bore of the journal opening cover and mating faces with Molykote #33 grease.

34. Rig to lift the spring assembly. Lift and guide the spring assembly into the journal cover. Locate the spring assembly and install the eight cap screws.

COMPONENT SERVICING

31

Torque the cap screws per drawing B-GP-2175. 35. Set journal spring compression. (Refer to detailed procedure) 36. Set the roll-to-ring clearance. (Refer to detailed procedure) 37. Set journal spring to journal head clearance. (Refer to detailed procedure) 38. Reinstall the seal air piping and spring stud extension cap. 39. Close the separator body access doors.

COMPONENT SERVICING

32

This page intentionally left blank.

i

SECTION 3 - HP PULVERIZER MAINTENANCETAB 5. COMPONENT LUBRICATION AND MAINTENANCE

SCHEDULES

CONTENTS TAB 5

TITLE PAGE NO.

1. PULVERIZER MAINTENANCE SCHEDULES ---------------------------------------------- 1 2. PULVERIZER LUBRICATION SCHEDULES --------------------------------------------- 3

GENERAL MAINTENANCE

ii

This page intentionally left blank.

1

1. PULVERIZER MAINTNEANCE MAINTENANCE SCHEDULE

ITEM REFERENCE ONCE/SHIFT 3 MONTHS 6 MONTHS 12 MONTHS OTHER

Lubrication System Check oil storage tank level Level gauge ◆ Check oil storage tank temperature 30 to 60 °C ◆ Check oil supply temperature 35 to 60 °C ◆ Check oil supply pressure 0.9 kgf/cm ² Min. ◆ Check oil supply flow 173 Liter/min Min. ◆ Check cooling water supply temperature 44°C Max. ◆ Check oil filter differential pressure 2 Bar Max. ◆ Check oil filter clean indicator Indicator ◆ Check for oil leaks Visual ◆

Change oil ◆ Change oil filter ◆ Or as required Oil Analysis ◆

Planetary Gearbox Check upper housing oil level Level Gauge ◆ Check for oil leaks Visual ◆ Check gearbox general condition Visual ◆ Check for any abnormal noise or vibration ◆ Clean / regrease input shaft labyrinth seal ◆

Pyrites Rejects Collection Check inlet gate normally open Visual ◆ Check for normal reject flow Visual ◆ Check hopper reject level Visual ◆

Pulverizer Body (All Housing – External) Check pressure tap purge air flow (3 points) Gauge Column ◆ Check general condition Visual ◆ Check for any abnormal noise or vibration

Coal Discharge Gate Valves Check / adjust body packing ◆

2

ITEM REFERENCE ONCE/SHIFT 3 MONTHS 6 MONTHS 12 MONTHS OTHER

Grinding Elements Check roll journal bearing oil level Dip Stick ◆ Change roll journal oil ◆ Oil Analysis ◆ Check roll journal spring compression Procedure ◆ Check clearance spring to journal head arm Procedure ◆ Check / reset ring to roll clearance Procedure ◆ Replace grinding rolls > 5,500 Hours Re place grinding roll bearings 10 Years Overhaul roll journal springs 10 Years Replace bull ring segments > 5,500 Hours

Pulverizer Internals Inspect millside inlet duct screen ◆ Check / adjust pyrite scrapers ◆ Inspect vane wheel support brackets Procedure ◆ Inspect bowl hub insulation covers ◆ Inspect millside pressure taps ◆ Check bull ring segments wear condition ◆ Check vane wheel wear condition ◆ Check separator body liners ◆ Check inner cone ceramic tile condition ◆ Inspect separator body pressure tap ◆ Check mill outlet thermowells for wear ◆ Inspect / clean water spray nozzles ◆ Check grinding roll wear condition ◆ Check/ adjust deflector blades ◆ Inspect journal and journal head liners ◆ Inspect journal spring stud orifice plate ◆

General

Check / retorque gearbox mounting bolts ◆ Check drive coupling alignment ◆ Check / recalibrate all instruments ◆

2. PLVERIZER LUBRICATION SCHEDULES

1. A LUBRICANT IS ACCEPTABLE ONLY IF THE ACCEPTANCE CRITERIA OF THE MOST RECENT AGMA STANDARD

FOR INDUSTRIAL ENCLOSED GEAR DRIVES # 250.OX AND THE ABOVE SPECIFICATIONS ARE MET. 2. EP ADDITIVES SUCH AS MOLYBDENUM DISULFIDE, BORATES, LEAD NAPTHANATES, CHLORIDES, SULFURIZED

ESTERS, ETC. ARE NOT RECOMMENDED. CONSULT EQUIPMENT MANUFACTURER FOR EXCEPTIONS NOT LISTED.

3. ABSOLUTELY NO WATER BASED OR WATER CONTAINING LUBRICANTS ARE RECOMMENDED FOR SERVICE

ANYWHERE IN THE PULVERIZER. 4. DRAIN THE GEAR CASE JUST AFTER THE EQUIPMENT HAS BEEN SHUT DOWN, WHILE LUBRICANT IS WARM. THIS

AIDS IN A MORE COMPLETE REMOVAL OF THE DETERIORATED OIL AND ACCOMPANYING CONTAMINANTS. 5. CHANGE OIL IN NEW OR REBUILT JOURNALS AFTER 400 TO 1000 HOURS OF PULVERIZER OPERATION. DRAIN THE OIL

WHILE IT IS WARM. EACH OIL CHANGE, FLUSH THE ASSEMBLY WITH NEW JOURNAL OIL PRIOR TO REFILLING IT TO THE PROPER OPERATING LEVEL.

6. TOWARD THE END OF A CHANGE INTERVAL, AN OIL ANALYSIS BY A QUALIFIED INDEPENDENT LAB IS RECOMMENDED. TEST RESULTS WILL INDICATE THE REMAINING LUBRICANT SERVICE LIFE AND THE GENERAL CONDITION OF BEARINGS AND GEARS.

7. IF A PULVERIZER FIRE OCCURS. JOURNAL OIL SHOULD BE CHANGED OR ANALYZED BY A QUALIFIED INDEPENDENT LAB

FOR DEGRADATION BEFORE PUTTING THE PULVERIZER BACK INTO SERVICE. 8. MOBIL OIL LUBRICANTS LISTED, CUSTOMER TO SUPPLY AND RECORD IF DIFFERENT. 9. DO NOT MIX OIL BRANDS OR GRADES. 10. OIL TO BE APPROVED BY GEAR BOX ASSEMBLY VENDOR

LUBRICANT SPECIFICATIONS 1,3 QUANTITY OF LUBRICANT REQUIRED

VISCOSITY HP PULVERIZER SIZE

CTS SSU LUBRICANT

SERVICE AGMA NUMBER

ISO VISCOSITY

GRADE 40°C 100°C 100°'F 212°F

POUR POINT °F

EP TYPE ADDITIVE

TYPE OF FITTING

963-1103

CHANGE 6FREQUENCY

OF OBSERVATION

REMARKS

LITERS / (GALLONS) APPROXIMATE. REFER TO GEAR BOX MANUFACTERS INSTRUCTIONS

FOR SPECIFIC RECOMMENDATIONS 6EP,1 320 268- 352

21.8 26.4

1505- 1840

108 129

+10 MAX.

SULFUR PHOSPHORUS 2

PULVERIZER PLANETARY GEAR BOX

ASSEMBLY 10

NAME OF CUSTOMER'S LUBRICANT 8,9 MOBIL GEAR #632

OIL. TANK RESERVOIR

FILL PIPE 1030 (265)

9 TO12 MONTHS 4,6,9

ONCE DAILY CHECK GAUGES, UNES AND HEADERS

SHIPPED WITH PRESERVATIVE OIL FLUSH AND FILL WITH OPERATING OIL BEFORE START-UP. SEE MANUFACTURERS INSTRIJCIIONS CHECK TEMPERATURE, PRESSURE, FILTER FLOWSAND OIL LEVEL DAILY. MAKE INITIAL OIL CHANGE AFTER 1000 HOURS OF OPERATION

OIL FOR STORAGE, LITERS/(GALLONS) APROXIMATE

86.5(23)

OIL FOR OPERATION LITERS (GALLONS) APPROXIMATE

49(13)

COLD (21°C/70°F) OIL LEVEL ,MILLIMETERS

343 TO 394

HOT (82°C/180°F) OIL LEVEL, MILLIMETERS

8 EP 1 680 612- 748

32.1- 41.1

3261- 3988

155- 191

+20 MAX

SULFUR PHOSPIN DRUS 9JOURNALS

NAME OF CUSTOMER’S LUBRICANT MOBILGEAR 8,9 MOBILGEAR #636

RESERVOIRCAP ON

JOURNALSHAFT

394 TO 445

9 TO 12 MONTHS 4,6,9

CHECK WHEN ACCESSIBLE; AT LEAST EVERY 3 MONTHS

AT ASSEMBLY EACH JOURNAL IS FILLED WITH AN OIL SUITABLE FOR SERVICE. CHECK THAT THE ASSEMBLY REMAINS FULL DURING STORAGE TO PREVENT POSSIBLE DAMAGE TO THE JOURNAL OIL SEALS, REMOVE OIL TO THE RECOMMENDED COLD 21°C(70°F) LEVEL PRIOR TO START-UP OF THE PULVERIZER. CONFIRM THE OIL LEVEL IN THE INSTALLED POSITION

USE A HEAT RESISTING MULTI-PUROPOSE NGLI 82 EXTREME PRESSURE LITHIUM GREASE WITH A 375°F MINIMUM DROPPING POINT

CLASSSIFIER VANE SHAFT

AND GEAR BOX LABYRINTH

SEALS NAME OF CUSTOMER'S LUBRICANT MOSILUX 8,9 MOBILGEAR #EP2

GREASE FITTINGS

OUTPUT SEALS - AT INITIAL ASSEMBLY AND DURING REBUILDS INPUT SHAFT SEALS - AT INITIAL ASSEMBLY AND EVERY 2 MONTHS

WIPE ALL GREASE FITTINGS BEFORE AND AFTER GREASING