03-Φ5 - 5mx8 - 8m Overflow Ball Mill Manual－ENGLISH

Φ5.5m × 8.
8m Overflow Ball Mill
Installation Operation and Maintenance Manual
for VALE BRUCUTU Project
MACHINE PART OF BALL MILL
CITIC Heavy Industries CO., LTD
2010-05-17
1
Φ5.5×8.8m Ball Mill Installation Operation and Maintenance Manual
Contents
1. General Information
1.1 Users' guide
1.2 Confidentiality Declaration
1.3 Liability
1.4 Safety regulation
2. Handling and Storage
2.1 Handling
2.2 Storage conditions
2.3 Storage period
2.4 Unpack checking and acceptance
3. Product Summary
3.1 Product performance and application
3.2 Meaning of product model
3.3 Applicable product standard
3.4 Suitable working condition and environment
3.5 Product size and technical parameters
3.6 Summary of the primary structure for the product
4. Equipment installation
4.1 Installation instruction
4.2 Preparation before installation
4.3 Installation sequence
4.4 Installation of the main bearings
4.5 Installation of the shell assembly
4.6 Installation of main bearing lubricating system and related electrical part
4.7 Installation of gear
4.8 Installation of pinion assembly
4.9 Installation of gear guard
4.10 Installation of reducer, coupling, main motor and slow drive system
4.11 Installation of other parts
4.12 Recheck
4.13 Cleaning and perfecting installation site, touch-up of equipment, etc.
5. Test Run
5.1 Preparation and check before test run
5.2 Components test run
5.3 Dynamic monitoring of pinion temperature
5.4 System test run
6. Normal Operation and Service
6.1 Start and stop of the mill
CITIC Heavy Industries Co., LTD P.R. China 206 Jianshe Road Luoyang
www.citichmc.com or www.citic-hic.com Page 2 of 91
6.2 Normal operation
7. Maintenance and Repair
7.1 Mill lubrication and grease seal
7.2 Shell assembly
7.3 Main bearing
7.4 Driving part
7.5 Others
8. Maintenance, Common Faults & Removal
8.1 Control principle
8.2 Maintenance contents
8.3 Cautions in maintenance
8.4 Maintenance plan
8.5 Maintenance of main bearing
8.6 Maintenance of lubricating system
8.7 Maintenance of mill driving system
8.8 Maintenance of units at feed and discharge end
8.9 Common faults handling
Appendix 1 Tightening of Bolts
1. Bolt Installation Method
2. PreTightening Torque Value of the Unmarked Bolts
3. Recheck
Appendix 2 Record of Test Run
1. General Information
1.1 Users' guide
The sections in this manual are compiled according to the installation sequence of
the mill. Before installing the mill, the whole content of this manual shall be read and
understood, so as to ensure a successful installation. The content of this manual
includes installation, commissioning and operation, mill maintenance, and additional
information for safe operation.
The storage, handling, transport, commissioning, operation and maintenance of
the equipment shall comply with the requirements of this manual. Before using the
equipment, the relevant personnel shall read and understand the content of this manual,
so as to ensure correct, effective and safe operation. This manual shall be regarded as
a part of the equipment and preserved properly.
This equipment shall be only operated by trained operators and supervisors. The
owner and any person who takes charge of the equipment must ensure the equipment
is operated only by those qualified people.
The operators will need to understand all the functions and all the safety warning
messages of the equipment. All operators will take part in the training, in order to
know how to deal with any emergencies that may arise. The installation, operation
and maintenance of this equipment shall be only performed by those trained and
appointed personnel, and any non trained personnel should not operate this equipment,
otherwise, personal injury or equipment damage may arise.
Pay special attention to the bold letters in this manual except titles.
1.2 Confidentiality Declaration
This Manual, and the information contained within is confidential to CITIC HIC
and must not be used, copied or disclosed (manually or electronically) in whole or
part without the expressed written permission of CITIC HIC.
The information in this manual is owned by CITIC HIC only, and is issued for
customer use only.
1.3 Liability
CITIC HIC reserves the right to alter this information as required.
This manual is for reference use only. As CITIC HIC cannot predict all the
conditions that may occur during installation and operation of this equipment, this
manual does not include all possible technical and safety information.
The composition and configuration of the grinding system is not determined by
CITIC HIC, hence we have nothing to do with this. But our company's sales staff and
product application engineers will help you to make decision at all times.
CITIC HIC will not take any responsibility for any personnel injury, equipment
damage or property loss caused by the improper operation and maintenance of the
equipment that is in violation of the requirements of this manual.
1.4 Safety regulation
The design and manufacture of this equipment conforms to safety standards, and
is safe under the correct operation conditions. If the equipment is not operated
correctly, not used for suitable application, or operated by unqualified personnel, the
equipment has the potential to cause injury.
In view of the safety for your personnel, please read this manual carefully, and get
to know the purpose, limit and relevant potential danger of this equipment.
The dangers caused by the following conditions are very serious:
Incorrect operation or being operated by unqualified operator;
Not comply with the requirement in relevant specification;
Incorrect installation;
Failure of power supply;
Severe maintenance fault;
Change the data and operational parameters;
Use of irregular spare parts;
Exceptional accident;
Others.
Appoint the persons in charge of start, operation and maintenance, and ensure the
equipment is to be operated only under the safe working condition.
Operators shall fix all equipment damages or modifications that may harm the
equipment in a timely manner that falls within their scope of duty; otherwise, they
must inform those conditions to the relevant personnel immediately.
Non qualified personnel and visitors shall be kept behind safety guarding/fencing
away from the equipment.
Ensure the carrying capacity must be sufficient to bear the weight of the
equipment when lifting at site.
Signs or labels related to product safety shall be checked and cleaned regularly. If
they cannot be identified within a reasonable distance, they shall be replaced.
Before each start, all the safety mechanisms must be checked, and all the
protection devices must be ensured to be in good condition. If there is an idle/fault
condition found on any safety device, the device must be replaced; if the faulty device
cannot be replaced immediately, the equipment must be stopped.
Before starting the equipment, clear all possible dangerous items that may harm
the operators.
Before guards or cover plate is opened, and starting maintenance, ensure the
equipment to be fully stopped and locked in avoidance of accidental start (lockout or
warning sign on the main switch).
The components and safety mechanism of the equipment shall not be removed,
modified or bypassed.
This equipment shall not be used in dangerous circumstances.
The working area shall be provided with good lighting.
The working site shall be kept clean, because obstacle may harm your safety. All
the guide plates on the equipment must be kept clean, because the dust on them may
cause serious wear or fire.
If the feed system is blocked, stop the equipment and lock it to prevent accidental
start, after all the moving parts are fully stopped, take measures to remedy the fault.
Before switching off the equipment, the control voltage must be cut off, and the
equipment must be locked in order to prevent the accidental switch-on (there is
lockout or warning sign on the main switch).
The equipment shall not be started under any emergency condition.
Only after the power is off, the equipment is stopped and the safety measures are
taken, can the maintenance, cleaning and disassembly of the equipment be performed.
The equipment shall be provided with good and sufficient maintenance, such as
lubrication and adjustment, but the maintenance shall not be performed whilst the
equipment is operating.
The daily record of work shall be kept, so as to record any faults and their
solutions.
Protective guards (guard rail) have to be provided to protect personnel. Guards
must be correctly installed in place when the equipment is in operation. Warning signs
should be posted to warn personnel of any potential hazard.
During maintenance for any device under pressure, the pressure shall be relieved
first. When relieving the pressure, the device shall not face toward any person, and
before the pressure is completely relieved, the pressure-bearing device shall not be
pressed or moved.
After the initial installation, if the user makes modifications to the equipment, the
information in the manual shall be upgraded.
When starting the equipment ensure there are no maintenance personnel that are
still working on the equipment. The equipment should be switched off and use locking
device to lock the main switch so as to prevent accidental start.
Electrical equipment must be properly earthed, and personnel working with
electrical equipment should follow standard electrical safety precautions.
If welding is to be done around the mill, the welded piece must be earthed. DO
NOT use the ground point of system. Elelctirc current is not allowed through the
mill system. Bearings on motors, pumps, etc., can be easily damaged by incorrect
earthing during welding.
Lifting apparatus must be adequately capable to lift, and its operating condition
checked before lifting. Areas for lifting must be clearly marked and kept clear
during lifting and handling. Warning bells and/or sirens are recommended to alert
personnel at site during lifting.
2. Handling and Storage

2.1 Handling
2.1.1 The lifting and transport for the product shall be performed according to the
requirement of GB191-90.
2.1.2 The lifting lugs on the heads and shell are only used for lifting their own
body; they cannot be used for lifting the entire shell assembly.
2.1.3 The eye bolt on the pinion bearing seat is only used for lifting the bearing
seat itself, it cannot be used for lifting the entire pinion assembly.
2.1.4 During lifting, the machined surface of the equipment shall be protected
from impact, the equipment shall be protected from deformation, and the packaging
shall not be damaged.
2.2 Storage conditions
2.2.1 The packed goods shall be stored in a dry warehouse with good ventilation.
2.2.2 If the area of the warehouse is sufficient, the packed goods shall not be
stacked; if stacking is required, the upper package's weight shall not exceed 1.5-1.8
times of the lower package's weight, and the upper package's dimension shall be equal
to or smaller than the lower package's dimension.
2.2.3 No packaging shall be placed or stacked upside down or tilted, and the
symbols on the packages shall be put in positions that are easy to observe.
2.2.4 The packages for electrical instruments, lubrication equipment and their
spare parts shall not be stacked or placed upside down; they must be stored in a dry
house.
2.2.5 Uncoated goods shall be stored in the open or in the warehouse with regard
to their precision and protection level. The parts or components that need mounting on
site shall not be stacked or damaged.
2.2.6 If the equipment needs to be stored in the open, the rain-proof and
rust-proof packing must be checked to see if it is in good condition. Additional
rain-proof, anti-rust and anti-theft measures shall be taken to protect the equipment.
2.3 Storage period
Before leaving the factory, the mill is applied with the anti-rust oil which has a
life of 12 months. If this period is exceeded, or during this period the packages is
subjected to serious rain, flood or other corrosions, the packages shall be opened and
the contained goods shall be checked, then repack them with anti-rust protection.
2.4 Unpack checking and acceptance
After the equipment arrives on site, the open-package inspection shall be
performed within 15 days, user shall inform the inspection date to the manufacturer
10 days prior to the inspection, the open-package inspection shall be performed by the
two parties together, and then a detailed record of open-package inspection shall be
signed by the two parties.
After the goods arrive at the appointed station, if there is damaged package
discovered, user shall inform the manufacturer immediately, ask the transport
department for the transport accident record within 10 days, and report the case to the
local insurance company. The manufacturer will appoint some personnel to go to the
site and make detailed inspection record with the user.
3. Product Summary
3.1 Product performance and application
The ball mill is used to pulverize the ore or other material after the use of crushers,
AG or SAG Mills, the purpose is to obtain finer particle product. The ball mill is
widely applied to many industries, such as mineral concentration, metallurgy,
construction, and chemical industry, etc. It has many advantages such as high
reliability, high adaptability, and high capacity, etc.
3.2 Meaning of product model
φ5.5×8.8 m overflow ball mill
│ └── length of shell (m)
└──── inside diameter of shell (m)
3.3 Applicable product standard
The performance of this mill shall conform to the standard JB/T1406-93 Ball Mill
and Rod Mill. The delivery acceptance shall be performed according to
Q/HM1006-2002 General Acceptance Rules for Ball Mill and Rod Mill.
3.4 Suitable working condition and environment
3.4.1 Installation condition: indoors
3.4.2 Ambient temperature: 10～40℃
3.4.3 Elevation: 950m
3.4.4 Working duty: continuous
3.5 Product size and technical parameters
Basic technical parameters of product
ITEM DATA UNIT VALUE
1 SHELL DIAMETER mm 5500
2 SHELL LENGTH mm 8800
3
3 EFFECTIME VOLUME m 203
4 MATERIAL t 117
MAX LOAD
BALL t 284(30%)
5 MILL WORKING SPEED r/min 13.62
ASYNCHRONOUS MODEL No YRKK1000-8
6 MOTOR POWER kW 4500
SPEED r/min 896
VOLTAGE kV 13.2
7 REDUCER MODEL No MDSSI-875
RATIO 4.529
8 MODEL No H4SH13
INCHING POWER kW 37
RATIO i 202
SPEED r/min 5.87
SHELLSPEED r/min 0.089
3.6 Summary of the primary structure for the product
3.6.1 Structural composition
This equipment consists of the following: feed trolley, main bearing, shell
assembly, liners, gear, pinion assembly, trommel screen, reducer, main motor, slow
speed driving unit, couplings, jacking device and lubrication, electric control and
automation system etc. And in order to raise the mill operation rate, it is equipped
with liner manipulator and bolt press, hydraulic torque wrench.
3.6.2 Working principle
The equipment is driven by an asynchronous motor, which drives the reducer,
pinion shaft, girth gear, then makes the shell rotate.
When the shell rotates, the grinding media - steel balls inside the shell will rotate
together under the function of friction and centrifugal force and to be lifted to a
certain level, then fall or drop with a certain linear speed. The ore is crushed and
ground under the impact of falling balls, also under pressing and grinding function
between balls as well as between ball and mill liner. When material (slurry) is passing
through the trommel screen, the larger size material and crushed balls are screened,
and slurries enter into next process.
3.6.3 Feed trolley part
The feed trolley is composed of feed chute, trolley body and top feeding pipe that
can be opened and closed. The feed chute is of welded structure, anti-wear steel plate
inside. The trolley body is to provide support to the feed chute to facilitate removing
feed trolley rapidly at maintenance. The top feeding pipe can be opened and closed,
which is convenient to release the feed trolley from mill or connect them.
3.6.4 Shell assembly and liners
The Shell Assembly is the main component of the mill. The end covers (including
trunnion) are connected to the shell, composing the grinding space. There are liners
inside the shell and both feed and discharge heads in order to prevent excessive wear
of the heads and shell. The shell liner are wave-shaped in the cross-section. The heads
liner is fitted with lifters. All liners have to be fixed by bolts. There is a rubber
backing between the shell liners and shell as well as between head liners and heads.
The rubber backing is used to relieve the impact of the steel balls on the mill shell, it
also aides the installation of the liners. At the Feed End, there is a rubber ring seal
secured by a metal clamping ring to prevent the slurry flowing out.
The feed & discharge trunnions are fitted with bush lined with rubber plate to
prevent any wear to the internal surface of the trunnions.
The shell is bended with thick steel plate and welded, flanges on both ends. The
flange is of L type structure, making the weld avoid stress peak area. The automatic
welding process is adopted. The shell is stress relieved by annealing after welding.
The machined flanges and end covers are connected by rabbet joint.
The mill shell is divided into three sections along the length for the need of
transportation, and located with rabbet between two sections, connected by high
strength bolts. To prevent deformation, the shell is supported by inner frame during
machining and the frame is kept to the site. This will both ensure the dimensions and
facilitate field assembly. There are lifting lugs inside and outside the shell to help
transportation and installation.
The end cover and shell end flange after finish machining are fitted by rabbet to
ensure the alignment of the whole assembly. The casting is heat-treated to relieve
stress before machining. There is lug for each end cover to facilitate transportation
and installation.
The shell and end cover are the key parts of mill. Make FEA on their strength and
rigidity. Determine the reasonable wall thickness according to the stress distribution
and optimize the structure at the stress concentration area, making the structure tight
and proper.
Before installing the mill liner, grind and clean where there is no rubber liner at
the shell, end cover support and lifting lug when delivery, and make the rubber liner
fit well at site.
3.6.5 Main bearing
The main bearings are used to support the rotating part of the mill and the
bearings at feed and discharge end are of the same structure. The main bearings are
static sliding bearings, main bearing bush adopting two imported 120º copper alloy
bearing liner, and each copper liner with two high pressure oil pockets. The high
pressure oil is always supplied by the lubricating station before the mill starts and
during its operation, the oil enters the pocket through by-pass motor, automatically
makes static oil film compensation and ensures the oil film thickness keep steady.
This supplies continuous static oil film for the mill operation, ensures the journal and
copper liner totally non-contact, hence greatly reduce the start load of mill, and reduce
the impact to the driving part of mill, as well as avoid the copper bush scrape and
prolong its service life.
The pressure indicator of high pressure line can be used to indirectly reflect the
mill load during mill operation. When the mill stops, the high pressure oil still makes
the journal floating. The journal gradually stops in the copper bush, which will not
make the copper bush scrape.
It is waist drum shape linear contact between main bearing bush body and
bearing housing, which has good aligning function. The bearing can automatically
make adjustment to solve the distortion by the temperature, load or installation error
of the shell, and ensure normal operation.
There is platinum resistor on each main bearing to monitor on line the hollow
shaft temperature. When the temperature exceeds the specified limit value, the main
motor automatically stops. To compensate the mill length change possibly due to the
temperature, the fit size of feed journal and bearing bush along width has a difference
of 30mm, allowing some axial play of journal on the bearing bush (the play is related
to the actual installation adjustment).
The adjustable 3-tongue seal is used on both ends of main bearing, and equipped
with automatically sealing grease system. The timely and rationed grease feeding can
prevent internal thin oil leakage and external dust ingress, also reduce the working
strength of operators. After several years operation of the main bearing, the copper
bush wears, making the hollow shaft lower down. Then the bolt at seal press head of
main bearing can be used to make adjustment, keeping the sealing gap between seal
ring and journal even.
Main bearing type - static sliding bearing
Self-aligning mode - waist drum shape and cylindrical surface
Bearing diameter - Φ2800mm
Bearing width - 650mm
Bearing bush material - Sn-Pb copper alloy
Seal type - adjustable 3-tongue rubber seal
Base plate - with adjusting stud
3.6.6 Driving unit

The driving unit comprises the gear, pinion shaft set, gear housing, reducer,
coupling and guard hood, etc. The gear and pinion of this mill are made of alloy steel,
helical gear meshing. It has the characteristics of work steady, impact low, and service
life long. The automatic grease spraying lubrication is adopted, supplying oil at set
time and quantity, forming the oil film of certain thickness on gear surface. This
lubrication method has good effect, it reduces the working strength of operators and
oil consumption. The rolling bearings on pinion shaft set are supplied oil by the low
pressure oil system of static bearing lubrication station and made thin oil lubrication,
with the automatic greasing system supplying grease to the seal places on both sides
of bearing at set time.
The gear is of half-split structure, and the pinion shaft is a solid forging, totally
symmetrical. Both of them can be used with surface reversed.
The gear and pinion are protected by the guard made in several sections. There
forms the seal chamber between the guard and section installed on gear side to
prevent oil leakage and dust ingress. There is an inspection door on the side of guard
facilitating stop for check. There is draining outlet on the bottom of gear guard for
cleaning or removing residual oil. The guard is also fitted with infrared temperature
measuring device to monitor the temperature of pinion shaft teeth.
As the gear guard is too huge, it may be not rigid enough after installation at
site, hence at least two fixed points need to be added on top of the guard
according to the field condition.
Gear spray lubrication system: The system consists of lubricating oil pumps, air
source control cabinet components, nozzle components, distributor, pipes and
accessories. Air source control components consist of pressure control valve,
containing gauge, solenoid valves, pressure switches, lubricator, and air filters. If the
device does not follow the preset number of work cycles, the control system will
provide a fault signal. The system also consists of a purge timer control, lubrication
after cleaning the nozzles in order to avoid nozzle clogging. The client must provide
clean dry air (0.4 ~ 0.8Mpa). This system is made pipe laying and field installation by
the client.
The main reducer is of parallel shaft reducer supplied by FLENDER. The
reducer has its own thin oil lubrication station for circulating lubrication and cooling.
Refer to the separate instruction manual of the reducer for detail performance
parameters.
3.6.7. Foundation part
The relative position and elevation of anchor bolts for each part are given in this
section, also the load on them; and mill foundation bolts and relevant embedded parts
(bolts and embedded parts supplied by the user) are also included here.
Refer to the related contents in INSTALLTION for the foundation preparation
and equipment installation & adjustment.
3.6.8 Low-speed driving device
This machine is provided with a low-speed driving device supplied by
FLENFDER. The low-speed driving device is composed of motor, coupler,
parallel-axes reducer, clutch etc., and it has a mounting base plate and a lubrication
pump. This device is used for mill maintenance and lining replacement. When the mill
is stopped over 4 hours, the material inside the shell may be agglomerated. Use
low-speed driving device to turn the mill before starting the motor, so as to make the
material unconsolidated. The low-speed driving device has its own brake and
bidirectional clutch.
Special case: When using without low-speed driving device, take measures
to prevent the mill shell from off-centering. If the weight exceeds its extreme
position, the mill shell will fall rapidly by its gravity, and will endanger the
maintenance personnel.
When starting the low-speed driving device, the main motor shall not be
connected; when the main motor is working, the low-speed driving device shall not be
connected. There are mechanical and electrical interlock devices provided between
them.
Note: before starting the low-speed driving device, the lubrication pump
shall be started first to jack up the sleeve shaft, in order to prevent the bearing
shell from abraded.
Provide a key interlocked switch, to prevent the low-speed driving motor from
closing during the main motor is working.
For the detailed performance parameters of low-speed driving device, please see
the relevant documents of FLENDER.
3.6.9 Jacking device
The jacking device is composed of hydraulic oil pump station, balance valve,
jack, bracket, and control unit etc. When stopping the mill for maintenance, place the
jacking device under the mill shell to jack it up, in order to facilitate the inspection
and maintenance. When the maintenance is finished, drop the mill shell, during this,
the pressure must not be relieved rapidly, it shall be relieved step by step to make the
mill shell drop slowly.
A set of hydraulic jacking device includes: two brackets, four hydraulic jacks, a
mobile hydraulic station and a control unit. The four jacks shall act synchronously, the
jacking speed is 20～30mm/min. Under the load condition, the synchronism shall not
be less than 99%.
Note: When the mill shell is jacked up to the required height, the mill shell
and jacks shall be supported firmly immediately, in order to prevent any
accident.
3.6.10 Lubrication system
This mill selects a thin oil lubrication station to lubricate the mill main bearing
and pinion bearing. The lubrication station is composed of high-pressure oil supply
system and low-pressure oil supply system. Through the distribution motor, The
high-pressure oil is supplied equally to the four hydraulic fluid chamber of the mill
main bearing, to float and lubricate the sleeve shaft. Through the distribution motor,
the low-pressure oil supply system supplies the oil to the pinion bearing.
The lubrication station is provided with indication or monitoring for oil pressure,
temperature, flow, level, pressure differential etc. So the protection for overpressure,
underpressure, overtemperature, flow cut-out of the system can be realized. For the
detailed information, please see the manual of hydraulic unit.
3.6.11 Low-tension electrical control system
The low-tension electrical control system includes: oil pump motor control for
the main bearing thin oil lubrication station, control and indication for the heating and
cooling of lubrication oil tank, measurement and indication for every parameters of
lubrication station, low-speed drive control, measurement and indication for the
temperature of main bearing, temperature measurement and indication for the main
motor and pinion shaft set, etc. The electrical control system has audible-visual alarm
and indication, it can give main motor control and indicate the value of each
measuring point, in addition, the alarm value and stop value of each measuring point
can be preset.
The low-tension electrical control system can also give interlocking contact
signal. Single machine operation is carried out through the start and stop buttons on
the control panel, the terminals for remote operation are reserved.
For detailed information, please see the manual of low-tension electrical control
system.
3.6.12 Others
For the detailed information of main motor system, grease splash lubricating
system, main reducer, low-speed driving device, lining board manipulator and bolt
press, hydraulic jack system etc., please see their respective instructions.
4 Equipment erection
4.1 Erection instruction
Thanks for selecting the grinding mill system of CITIC HIC. This equipment has
the advantages of high reliability and suitability, convenient service and maintenance
etc.
Please read this manual carefully, it will help you correctly erect, operate and
service the equipment. Erection is a very important procedure for the normal running
of the mill. The specific erection method and sequence shall be determined through
consultation of erection company, user and supplier, and the erection shall be
performed according to the relevant specifications and equipment drawings. Correct
erection can reduce the wear and damage of related components, effectively increase
the service life of equipment, and optimize the serviceability of equipment.
4.2 Preparation before erection
Before erection, suitable erection tools shall be prepared. Erection personnel
shall read the relevant documents and drawings carefully, and keep the weight and
size of each part firmly in mind.
4.2.1 Erection tools
Following is the common tools for mill erection. Erection company shall prepare
them, CITIC HIC will not supply them. The standard lifting tools and handling tools
shall be provided by engineering company or erection company, they are not listed in
the following list.
-- High-precision optical level (Precision of 0.08mm/m or equivalent)
-- Electronic theodolite
-- Level (Precision of 0.4mm/m) Length of 150mm/200mm/300mm.
-- Frame level (Precision of 0.05 mm/m, 200×200)
-- Bar level
-- Feeler gauge, Length of 75mm - 100mm, thickness of 0.04mm - 1mm; Length
of 300mm, thickness of 0.05mm - 0.6mm.
-- Dial gauge and magnet base, at least 4 sets.
-- Stainless steel bevel gauge, one edge length of 0.6m, one edge length of 1.2m,
one edge length of 1.8m, 100mm width for the 1.8m straight edge.
-- Outside micrometer，Length of 150mm - 450mm, precision of 0.025 mm.
-- Stainless steel gasket, thickness of 0.05mm - 0.75mm, the quantity depends on
the size of mill.
-- Steel wire，diameter of 0.5mm.
-- Plummet, weight of 0.3 kg - 0.35 kg.
-- Locating pin for mounting mill shell and end cap.
-- Band tape，measuring range of 30m.
-- Square
-- Galvanizer
-- File
-- Mark pen
-- Hydraulic torque wrench
-- All kinds of wrench
-- Red lead oxide
-- Infrared thermoscope (within 200℃)
-- Others
4.2.2 Foundation
The foundation shall be prepared well before the equipment erection.
The mill must be erected on the sturdy reinforced concrete foundation. The grade
of concrete shall be heightened with the increasing of the erection height of the mill.
Bottom surface area and volume of the foundation shall be designed by professionals
according to the maximum load and allowable bearing capacity on the foundation.
User or its appointed contractor has the responsibility to construct the suitable
foundation. Because of the complexity of site soil structure, comprehensive condition
analysis shall be done in order to make correct design. The foundation shall be
integral structure, it shall extend to the position below the two main bearings, pinion
bearing, motor base and other driving parts.
The foundation of mill is not allowed to connect with the foundation of
workshop wall, there shall be at least 400 - 500mm gap retained between the both
foundations. The gap shall be filled with flagstone, in order to prevent the vibration
due to mill operation from influencing the foundation of building.
After the construction of equipment foundation, its strength shall conform to the
design requirement. After all the templates are removed, the foundation shall be
subjected to the acceptance. Position, dimension and quality of the equipment
foundation shall conform to the requirement of GB - Construction and Acceptance
Specification for the Reinforced Concrete Engineering, and the acceptance document
or record shall be preserved. Oil dirt, rubble, mud, water on the foundation surface
and in the foundation bolts holes shall be cleared; threads and nuts of foundation bolts
shall be protected well.
The height mark of top surface of foundation shall be 50 - 100mm lower than the
height mark of bottom surface of equipment base plate, so that the secondary base
plate can be used between the two surfaces to make adjustment (the distance can be
determined according to relevant specifications). If without special requirement, the
overall dimension of foundation surface shall be at least 100mm larger than the
overall dimension of equipment.
Before embedding the bolt bushing, check the position according to the
foundation drawing. Protection covers shall be used on the bolt bushing in order to
prevent the foreign matter from dropping into the foundation bolt holes.
Before secondary grouting, the foundation surface to be subjected to the
secondary grouting must be shovelled into a spongy surface by use of steel flat shovel.
The diameter of each pit shall be 30 - 50mm, the distance between the pits shall be
about 150mm (Note: no pit for the position of horizontal secondary base plate). Notch
shall be shovelled at the edges of foundation in order to make the secondary grouting
firmer. If there is any oil dirt, use aqueous caustic to clear it, then spray water on
foundation surface to make the concrete become water saturation. Prevent the water
and other foreign matter from getting into the foundation bolt bushing.
After acceptance of the foundation, the centre targets and reference points shall
be set according to Fig.1. As shown in drawing, No.1 and 2 centre targets are used to
control the longitudinal center line of ball mill shell; No.3 and 4, No.5 and 6 centre
targets are used to control the center lines of the two main bearing seats; No.7 and 8
centre targets are used to control the center line of pinion shaft and reducer low-speed
shaft; No.9 and 10 centre targets are used to control the center line of motor and slow
driving reducer. The centre target can be made of angle steel, its interior angle shall be
welded with round steel fluke. The centre target shall be embedded into the
foundation surface, and it had better be welded onto the foundation reinforcement, its
surface shall be little lower than the foundation surface in order to avoid collision. The
reference point shall be located at the position easy to measure the height mark, its
height mark shall be measured based on the factory zero point. The reference point
can be made of Ø20mm snapped rivet, and it shall be welded onto the foundation
reinforcement. The top of the reference point shall be 30 - 50mm lower than the
foundation surface, make a round pit around the reference point and cover it with a
steel plate in order to avoid collision.
Fig. 1 Reference point and centre target drawing

According to the dimension shown in drawing, use precise theodolite to mark the
longitudinal and horizontal center lines of the mill and the driving device, after the
center lines are determined, the center points shall be stamped on the center plates,
their diameter shall not exceed 1mm. Use red paint around the center points to mark
them for the convenience of protection and application. Use precise level gauge to
measure the heights of height marks, and then record them.
4.3 Erection sequence
Following are necessary procedures for erection, for more detailed requirement
about erection see the follow-up sections. During erection, all the data to be recorded
shall be recorded as actual values, these erection data can provide record of original
dimension and tolerance, which can be used as the reference and basis for the
maintenance and dispute settlement.
4.3.1 First step: Erection of main bearing
4.3.2 Second step: Erection of mill shell
4.3.3 Third step: Erection of main bearing lubrication system and related
electrical parts
4.3.4 Fourth step: Erection of bull gear
4.3.5 Fifth step: Erection of pinion shaft set
4.3.6 Sixth step: Erection of gear cover
4.3.7 Seventh step: Erection of reducer, low-speed driving system, main motor
system
4.3.8 Eighth step: Erection of other parts, including feed part, feed inlet and
discharge outlet of mill shell, lining part, hood, other electrical parts etc.
4.3.9 Ninth step: Recheck
4.3.10 Tenth step: Clean and complete the erection site, repair the paint of
equipments.
The above sequence is only for reference. To improve the erection efficiency or
for other reasons, the erection steps can be adjusted or carried out in parallel
according to the actual condition.
4.4 Erection of main bearing
Erection of main bearing shall be performed according to the main bearing
erection drawing. The main bearing is hydrostatic bearing, which is provided with
120° copper alloy bearing shell. During running, the high-pressure oil from
lubrication station will hold up the mill, the oil film will prevent the copper shell from
contacting with the metal of trunnion, so as to avoid wearing. If without oil film, the
mill must be stopped immediately.
4.4.1 Acceptance for the foundation
a. Check the surface of foundation and remove all the oil dirt, rubble, mud and
water if any. Check that if there are pits shovelled on surface of foundation for the
secondary grouting, if not shovel them according to 4.2.2. Spray water on foundation
surface to make it water-saturated.
b. Before erection the height reference points shall be determined, and according
to fig.1 the center line of mill shell shall be marked (by use of points No.1 and 6), and
the center line of both main bearings shall be marked (by use of points No. 2 and 10,
No.4 and 8).
Record the distance between the two center lines of both main bearings, and
after assembly of mill shell measure the actual distance between the two
trunnions. If the two distances are different, construction shall be continued
according to the actual distance provided that the approval of relevant parties is
obtained. Note: this is very important, ignore this may lead to rework.
c. After the strength of foundation is up to 75%, and the foundation has passed
the acceptance, the erection can be carried out.
4.4.2 Foundation bolt
Remove all the rust and oil dirt on the foundation bolt, coat the threads with oil
to prevent rusting, and check the matching condition of bolt and nut. After locating
the foundation bolt, use template to support it firmly and then fill the packing into the
buried bushing.
The displacement error of foundation bolt shall be within 1 - 2mm, and the
verticality error shall be within 1/1000mm.
Washer must be added under the nut of foundation bolt. Use locking apparatus to
lock the foundation bolt. Spring washer or double nut can be used.
4.4.3 Erection of base plate
4.4.3.1 Erection of secondary base plate
The base plate of this mill adopt secondary base plate (flat iron shim) levelling
method. All the secondary base plate shall be grouted at the specified positions
(specific size and requirement see drawing of foundation part), they will be used as
the flatness and levelness reference for the erection of base plates. The distance
between every two adjacent secondary base plates shall be 300 - 800mm. Place two
secondary base plates at the position of each foundation bolt.
a. When erecting the secondary base plate, the anti-rust oil on surface of it shall
be removed, and the horizontal mortar pile under the plate shall adopt fine stone
concrete. The raw material used for preparing horizontal mortar pile shall conform to
the GB - Construction and Acceptance Specification for the Reinforced Concrete
Engineering (Revised Edition), the cementing material shall adopt non-shrinking
cement, in order to ensure the contact area of secondary base plate and concrete can
be up to 75%. The weight and operating load will be transferred to the foundation
through the secondary grouting layer but not the secondary base plate. We
intentionally reduce the quantity and size of secondary base plate in order to increase
the area of secondary grouting layer. The adjusting wedge shall be removed after
finishing the adjustment.
b. Before erecting the secondary base plate, make the top surface of foundation
rough in order to ensure good contact between horizontal mortar pile and concrete
foundation. Remove all the foreign matter on concrete foundation. Determine the
positions for the secondary base plate and mark them, drill bolt mounting hole
according to the instruction of Fig.2 (a), and fill epoxy resin adhesive into the hole,
then insert the full thread bolt and screw on the bottom nut, at last mount the
secondary base plate. During the solidification of epoxy resin, keep the correct
position of secondary base plate. Once the epoxy resin is fully solidified, screw on the
top nut, adjust the nut to let the secondary base plate reach the required height and
levelness. To reach suitable base plate height, adjusting shim can be used between
base plate and secondary base plate. After adjustment, the top surface of secondary
base plate shall be little lower than the required height mark. The top surface of
secondary base plate shall be horizontal in both two directions, the levelness of each
secondary base plate shall be within 0.1mm.
c. After the acceptance of secondary base plate, the template shall be applied
according to (b) and (c) of Fig.2 (b is top view, c is side view). The template can be
made of plywood or similar material. Use silicon resin or secondary grouting material
to pre-seal the gap between template bottom and foundation, then carry out the
grouting work. The mortar pile shall be tamped, any clearance is not allowed.
d. After solidification of 24 hours, remove template and top nut, and grind off the
emerged part of bolt to ensure the flatness of top surface. Before erecting the main
base plate, the secondary base plate shall be subjected to maintenance of 48 hours,
during this period, any collision or vibration is not allowed.
4.4.3.2 Erection of main base plate
a. Before erecting the main base plate, remove all the anti-rust oil and rust on
every machined surface, clear up the burr, and remove the paint on the contact surface
with secondary base plate if any.
b. Take the foundation bolt hole as the basis, mark the center line of main base
plate. Use precision level gauge to measure the top surface height of each piece of
secondary base plate and record the value, at the same time measure the thickness
differences of main base plates and record them.
c. Place three groups of temporary adjusting wedge on the foundation surface
(their positions according to the actual condition), the thickness of shim on each
secondary base plate shall be determined according to the required design height of
top surface of main base plate. Use shims as few as possible to make the base plate
reach the required height.
If possible, the shims shall be made according to the following thickness (mm):
0.05, 0.08, 0.1, 0.12, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.5, 0.75, 1, 2 etc.
The shims shall be made of stainless steel sheet, galvanized iron sheet and
soft metal is not allowed.
d. The adjusting shim shall fully contact with the main base plate. Use feeler
gauge to check from side, and gently knock the shim from side, the shim shall not be
loose.
e. After adjustment, the levelness error of main bearing base plate shall not
exceed 0.08mm/m, and the middle part shall be higher than edge part, concave middle
part is not allowed.
f. Mark the longitudinal and horizontal center lines on surface of main bearing
base plate, they will be used as the datum line for erection spotting, their limit error is
±1.5mm.
Note: The center distance between two main bearings base plate shall
conform to the requirement of design drawing or equipment document, but after
the assembling the mill shell and end caps the actual dimension sometimes is
deviated from the design dimension, under this situation the construction shall be
continued according to the actual dimension after approval of relevant parties is
obtained. Ignore this may lead to rework.
g. The machined surfaces on the two main bearing base plates shall be in a same
horizontal plane. During erection use level gauge to measure the levelness, the height
differential of two base plates shall not exceed 0.08mm/m, and the feed side shall be
higher than the discharge side.
h. Spotting for the longitudinal and horizontal center lines
According to Fig.1, take No.1 and No.2 center targets as datum, spot the
longitudinal centers of main base plate, to make the four center points and the two
points on the targets in a same straight line, the error shall not exceed ±1.0mm. Take
No.3 and 4, No.5 and 6 four center targets as datum to spot the horizontal center line,
its error shall not exceed ±1.0mm. The parallelism error of horizontal center lines of
two main base plate shall not exceed 0.08mm/m. The horizontal distance between two
main base plates shall be measured by means of using spring balance to apply 5kg
pulling force on steel tape. To verify the parallelism of horizontal center lines of two
main base plates, measure and take two points with same dimension on each
horizontal center line of the two main base plates, then measure the diagonals of these
four points to make comparison. The distance and height data shall be well recorded
according to Fig.3.
i. After the adjustment of main bearing base plate is finished, Screw on the
foundation bolt nut.
4.4.3 Erection of main bearing seat
a. Completely clean the top surface of main bearing base plate and the bottom
surface of bearing seat, remove all the burrs and oil dirt, do not apply any lubricating
grease. The bearing seat and the main bearing base plate shall be contacted evenly, the
local gap around the contact face shall not exceed 0.1mm, the length of each
non-contact part shall not exceed 100mm, and the total length of non-contact parts
shall not exceed 1/4 of the circumference of contact face. Otherwise, grinding is
needed.
b. Preliminary spotting for bearing seat
Put the bearing seat on the main bearing base plate. Determine the marks of mill
longitudinal and horizontal center lines on the top flange and saddle of the bearing
seat, use punching pin to make small but clear marking hole (P-P and L-L in Fig.4).
K1, K2, K3, K4, N1, N2, N3, N4 shall be marked on P-P with same distance to the
center, (K1-K2) and (K3-K4) reaching a equal dimension can ensure the two bearing
seats are parallel, and to ensure the bearing seats are perpendicular to the mill center
line, the distance of (K1-K4) and (K2-K3) must be equal, the maximum permissible
error is ±0.4, that is:
(K1-K2) = (K3-K4) = F±0.4, (K1-K4) = (K2-K3) ±0.4.
The center line L-L shall coincide with the mill center line (a long steel wire can
be used for simulation), and shall coincide with the center line of main bearing base
plate. Fix the seat of discharge side first and then adjust the seat of feed side. Tighten
the bolt of bearing seat after adjustment. All the previous records shall be reviewed
prior to any necessary adjustment being performed in the future.
c. Install the bearing shell assembly (including shell and step brass) onto the
bearing seat, and spot the center line of bearing shell assembly and bearing seat.
Adjust the clearance between clamp plate and step brass according to the requirement
of main bearing assembly drawing, and then tighten the clamp plate. Take the
horizontal center line as reference, use optical level to adjust the two bearings to make
them reach a same height.
The step brass is vulnerable, protect it with care.
d. Final adjustment of bearing
Once the mill shell is located, the final adjustment of bearing must be performed.
After the mill trunnion is installed into the bearing, measure the clearance between the
trunnion and the step brass, the clearance shall conform to the following requirement
(see Fig.4):
A1+C1=B1+D1, E1+G1=F1+H1, A2+C2=B2+D, E2+G2=F2+H2
The maximum permissible error is 0.08mm/m, but the error shall be kept to the
minimum limit.
Use square to correct the center line of bearing shell and bearing seat, so as to
make their coincidence error within 0.75mm.
There is manhole set on bottom the bearing seat. When checking the parallelism
of step brass and trunnion shoulder, the measurement from bottom is also needed, this
value shall be same to the measuring value from top.
Before no load running of mill, check the clearance between step brass and
trunnion shoulder meet the requirement through the manhole on bottom of bearing
seat, check two points for each side.
The correction of bearing is very important. Correct erection can avoid costly
maintenance and repair. Only after all the above measuring values meet the
requirement can the next step of erection be carried out.
4.4.4 the installation of bearing cover and second grouting (after shell
section taking position)
After the adjustment has been accepted, equip the bearing cover at the bearing
housing with the connecting parts which have been marked in the bearing assembly
drawing. Before the erection of bearing cover, make sure that the elevation of sleeve
shaft at the two ends accord with the specification, and the shaft neck and bearing
housing have been completely cleaned without any useless pieces left.
a. After the housing cover has been put into its position, the three tongue
rubber seal ring and the lubrication piping system should be equipped. The seal ring
should be longer than the actually required and the unwanted part can be cut off.
When installation, adjust the seal ring to keep it concentric with sleeve shaft through
the adjusting bolt beside the sealing clamp plate of the bearing housing and bearing
cover. The edges of seal ring should be touched slightly with the sleeve shaft and take
measurement with a gap gage to make sure the contact should be uniform when
without load.
b. Install the seamless pipe joint and connecting pipe for adding grease of sealing.
The seamless pipe joint in the three tongue rubber seal ring cannot touch the sleeve
shaft. According to the drawing, add lubricant grease into the groove of rubber seal
ring, and at the same time, check whether the pipe line for adding grease goes
smoothly. In any event, if the mill works, the lubrication system of the main bearing
must be put into operation. The grease-adding system for sealing can ration the grease
in timing to the main bearing to ensure the effect of sealing. For more detailed
information of installation, please take the instruction of grease-adding system for
sealing as a reference.
c. The installation of temperature detector
According to the assembly drawing of main bearing, equip the thermal resistance
of end face at the copper bushing on the temperature detecting support and the
thermal resistance must keep close to with the copper plate. Pay attention to the
installation direction of the temperature detector and it should be equipped at the
back-out side of the mill.
Adjust the temperature detector support of thermal platinum resistance carefully
and make it stick to the surface of sleeve shaft. Connect the wire of temperature
detecting to the terminal box of bearing, and then contact with the control system.
d. The second grouting of the main bearing base plate
The second grouting of main bearing cannot be carried out until the shell has
been taken its position and all data have been accepted. The specific grouting
method can be referred to the item 4.5.9. The second grouting cannot be taken
until shell has not taken its position.
4.5 The installation of shell section
4.5.1 The general description
The shell section consists of the shell and the end cap at the two ends. Because of
the restriction of transportation, the shell of mill shall be divided into three parts at the
direction of length. During the manufacture, there are marks for assembly between the
end cap and shell section, which should be paid more attention. Particularly, the
worker for erection must take great care for those marks and ensure the correct
erection of mill according to the assembly drawing(take the assembly diagram of shell
section for reference). the high-strength bolts should be used to make the shell part,
especially the parts between shell and end cap, connected together into the whole. The
end cap and sleeve shaft shall be jointed to be a whole by the means of high-strength
bolts.
Note: all the bolts between the shells, or between the end cap and shell must
be tighten according to the specific torque and elongation by the means stated in
the appendixⅠafter the manual, which plays important part in improving the
reliability of mill.
The support inside the shell means to prevent deformation during transportation.
They cannot be removed until the shell part has been assembled and located at the
main bearing. The support cannot be used for lifting.
There are lifting lugs at the shell and end cap for lifting.
The tightening of the connecting bolts for flanges plays important part in the
construction of solid platform for work of two people in a group.
Before the assembly of parts, the wooden block, the anti-rust painting and the
steel strip for protection should be removed. But the wooden plate around the
machined surface of sleeve shaft for protection cannot removed until the sleeve shaft
has been installed on the shell.
The safety measures should be taken for protection during the assembly of
shell. Enough lumber skid should be put under the bracket to ensure no
displacement caused in the shell and the jacking bracket when jacking is up,
since the imbalanced load will put force torque on the jacking bracket of mill
when the parts are assembled. During the work, no operation shall be taken
under the bracket.
4.5.2 The preliminary work
a. Before the installation, clean the shell flange and the mating surface of end
cap completely; get rid of oil dirty and burr and remove the anti-rust oil on the surface
of flange and connecting holes. Check the flatness of the mating surface of the flange
and rabbet with steel ruler separately. No projection part is allowed to exist. If the
cleaning work has been finished and the assembly cannot be done right away, a layer
of anti-rust oil grease must be painted on the machined surface, then pack them up.
Check whether the connecting bolts, nuts, studs and the screw holes are damaged. If
find, clean carefully and repair. The bolts, nuts, studs and screw holes must not be
loose and have any burrs.
Before the installation, all the bolts, nuts, studs, and screw holes should be
cleaned clearly and keep them dry. No oil or other dirty things is allowed to exist.
Number the bolts with same standard and list them to make a record when
checking.
b. Measure the length of shell precisely, and it will help to measure actually the
space between the two centers of sleeve shaft after the end cap of shell has been
assembled. Measure the size of each rabbet, if possible, take the pre-assembly and
check the holes position and the concentricity. Pay attention to check the aligning
marks.
c. Make four locating pins for the assembly of shell and end cap. Their diameters
should be 0.2 mm less than the bolt holes, and their length bigger than the total
thickness of tightening flange. The two ends are in a shape of cone, which helps to
lead in the bolt hole.
d. During the assembly of the shell section, pay attention to the correction
assembly order of the end cap of feed end, shell section and end cap of the
discharge end.
4.5.3 The assembly of shell
Before the assembly of shell, equip the cog timbering suiting for the end cap and
shell units. Adjust the position of hydraulic jack for shell and put into its position to
make the shell fall on the bracket of jack when assembling.
According to the assembly drawing, put the middle section of shell on the cog
timbering or a jack bracket. Then assemble the shell sections at the feed end and
discharge end with the middle section. Before that, level and align the shell and make
the hight of shell section 100 mm higher than the required of design to prevent the
damage of copper bushing when adjustment. Equip the four locating pin at the flange
holes one in every 90°. Divide the circle into 12 parts evenly and put 12 bolts through
the holes and measure the joint condition of the two flanges with a micrometric depth
gage or a vernier clipper and adjust it. Then measure the clearance gap between two
flanges with a gap gage at the 12 points evenly distributed on the circle. Adjust the
clearance uniformly and make the flanges level, then tighten the 12 bolts to make the
shell parts joint together. After that, make a precise adjustment of the concentricity of
the two shell and keep the flange concentricity 0.25 mm. The following method can
be adopted: tie a small leveling rule closely to the buldged flange, and then check the
clearance between the underside of leveling ruler and the other flange with a gap
gage.
Note: the discharge end of shell shall be at the side with the drive unit, while
the feed end is at the other end.
All the connecting surface of flange must be dry, and no sealant can be used.
After the concentricity has been adjusted well, tighten all the bolts. The bolts
shall be tightened only with the aligned spanner symmetrically and evenly, and the
specific method for installation can refer to the appendixⅠ.
Align the torque spanner with a horizontal microscope of bolt, if necessary, check
the tightened bolts with a horizontal microscope individually and make a record
according to each number.
4.5.4 The assembly of the shell section with the feed and discharge end cap
Arrange the lifting lugs according to its position on the end cap. The two lugs on
the end cap play main part in the end cap lifting while the other lugs works as the
auxiliary means. Put the locating pin through the bolts hole in the end cap and shell
and joint them together, then put a quarter of all bolts into the holes and tighten them.
Among those bolts, one third of them should be half tightened. Adjust the
concentricity within the range of 0.25 mm( the same method as the joint of shells),
then tighten them. After checking to be acceptable, tighten all the bolts with the
required torque. But pay attention to that connecting bolts shall avoid the connecting
hole of the gear when equipping the end cap at the discharge end. After the
installation, the clearance between flanges cannot be inserted with the gap gauge of
0.03mm.
4.5.5 Erection of the shell section and end caps on the main bearing
Before the assemblies of shell and end caps have been erected on the main
bearing, the bearing housing must be adjusted to meet the relevant requirement.
Assemble the end cap and the shell together, and check it to make sure that there is no
error. Then measure the assembled shell: its total length and the length between the
two axle journal centers shall be compared with the center distance of bearing housing.
if find the result is in unconformity, adjust the bearing housing or the position of main
base plate.
Before the shell has been equipped at the main bearing, clean the inner part of
main bearing and the axle journal of end caps once more. When installation of the
shell section, steel wire is not allowed to tie to the axle journal of end caps to prevent
scratch of surface of axle journal. During the installation, no dust or other dirty things
is allowed to fall down the surface of bearing.
The clearance between the fillet of end cap of the feed and two sides of main
bearing bushing is showed as follows:
15~16mm
Figure 5
Make the shell assemblies fall on the bearing slowly with jacking device and
take good measure to take the shell's correct position. The space between the sleeve
shaft of fixed end and the bearing liner is the size of fit. During the process, take good
care and enough patience. Before that, spray the lubricant oil into the copper bushing
and make the whole surface coated with oil film to prevent the damage of its surface.
Make sure that oil pipe line keeps clean to prevent damage of step brass
surface.
After the shell has been installed on the main bearing, check it again. The
two bus bar of end caps' axle journal shall be of the same level. And its relative
elevation error shall not be more than 1mm, while the feed end shall be higher than
the discharge end.
Cover the main bearing with cover, and tighten the connecting bolts
suitably. Make sure that there is clean and no dirty things on the sleeve shaft and
inside the bearing house before the bearing cover is equipped.
Remove the support inside the shell, and take care that do not hurt the shell.
Disassemble the cog timbering and lifting lug.
4.5.6 The installation of bearing cover
Equip the bearing cover and other accessories according to the requirement in the
item 4.4.4.
4.5.7 The second grouting in the base plate of main bearing
The fine stone concrete with non-contractibility or cement mortar is required to
use when the second grouting in the main base plate. Put all the necessary tools and
materials within where needs to be grouting as possible.
Remove the unnecessary cement and keep its surface rough. There is not any
grease and oil, dirty things and loose grains on the surface. Remove all the oil, paint
and iron rust on the main base plate which contacts the second grouting layer. 24
hours before the grouting, clean the foundation with enough water to get rid of all the
unnecessary water or loose material fell on the surface.
After the base plate is adjusted well, fix and support the solid template around the
base plate. There shall be a clearance of 150mm between the base plate and the side of
the template where is ready to pour the mortar. Caulk the template to prevent leakage
of mortar. Clean the sleeve pipe of foundation bolts before the grouting.
Pour the epoxy resin mortar into the space between underneath dummy club and
foundation groove. Its compression strength get up to 650~862kg/cm2. And the
composition of epoxy resin mortar and its construction method shall be decided by the
construction department independently.
Mix the mortar according to the requirement of the design department for
foundation. Firstly, pour mortar into all the sleeve pipe of foundation bolts. Then pour
the mortar into one side of base plate continuously. Pay special attention to that, fill all
the shear resistance groove firstly, and make it solid when pouring, and no clearance
is allowed. Pouring the mortar until it rises equally to the template. The second
grouting layer is required to be 20--50mm higher than the bottom surface of main
base plate. If necessary, remove the template after 12--18 hours and recondition the
grouting layer.
Maintain all the open grouting by covering with wet cloth or sack pieces.
Normally the hardening period will last at least for 72 hours. After the mortar has
been hardened to the required strength, paint water glass twice on the surface of
mortar layer and foundation to prevent the oil erosion.
4.6 The installation of lubrication system and the relevant electrical unit
4.6.1 Preliminary work before installation
a. Before the installation of the oil lubrication station of bearing, clean the oil
tank completely. After check to be accepted, the installation can be carried out.
b.When the lubrication station is installed, the oil drain hole of oil tank must be
extended outside the foundation, and the distance shall be not less than 300mm from
the ground, or the oil drain will not go well. The lubrication system shall close to the
center of the two main bearing as possible, while the pipe line shall be as short as
possible.
4.6.2 The field installation and pipe arrangement
a. Before the final installation, take the acid pickling to the steel pipe of
lubrication pipe line (the preliminary connecting of pipe between lubrication station
and main machine has been carried out as advanced) with sulfuric acid solution or
hydrochloric aid solution of 20% concentrication to soak for 40--60 minutes. After the
rust has been removed, soak the pipe into the limewater of 3% concentrication to
neutralize for 30 minutes. Then wash it with clean water and make it dry by blowing
compressed air (oxygen cannot be used). Finally pour lubricant oil into the pipe to
prevent rust again, while the two ends of pipe shall be blinded to avoid the dirty things
in. The above operation shall be done continuously. No welding work is allowed to do
after the acid pickling.
Referring to the parallelled or crossed pressure pipe, there shall be certain space
between two pipe walls to prevent the interference of vibration.
The return line must be inclined to the oil tank, and its slope shall be 85/1000～
100/1000.
b. After the assemble of lubrication system, the pressure testing shall be carried
out. The pressure for each cooling water pipe is required not to be less than 0.45Mpa
and there is no leakage within 30 minutes. The testing pressure for high-pressure pipe
shall be not less than the rated pressure of high pressure which shall last for 10
minutes.
c. The high-pressure flow meter and pressure gauge of main bearing shall be
equipped at the high pressure sucker nearby the main bearing according to the
specified position in the high-pressure pipe line drawing. When installation, pay
attention to make the indicating panel of pressure gauge and flowmeter outward to
observe conveniently for the workers.
d. The cleaning of lubrication system
The pure hydraulic oil shall be used to clean the whole lubrication system.
Inject oil into the tank according to the mark on it, and about 3000L will be
needed. Dismantle the high pressure sucker line of main bearing and change to use the
tube to make the oil flow into the bearing house through the checking door. Flushing
oil is not allowed to flow the sleeve shaft or step brass.
Check the low-pressure pump whether it works well by making it on and off. If
there is pressure indicated on the pressure gauge at the oil outlet of the pump, that is
to say, the rotating direction of pump is correct. Only make sure the low-pressure
pump works well, then the high-pressure pump and low-pressure pump of the pinion
can be started up. Check the rotating direction of the high-pressure pump with the
same method.
Start up the high pressure pump, and check the flow of each bearing. Wash the
system, and check whether there is leakage.
Make the each pump of the high and low pressure system work alternatively, each
pump works for about 2 hours. Check the indicator of oil filter, if the indicator shows
that oil filter is dirty, change the oil and make it flow through another filter. Dismantle
the dirty filter and change a new one. When the oil filter begins to keep a clean state
for a long time, stop the pump, and make all the oil return to the tank, finally clean or
replace all the dirty parts.
Connect the oil pipe of main bearing again, and dismantle the drain plug in the
bearing house to discharge all the extra oil and the remain. Seal the washed parts and
tighten all the oil drain plug screw. Discharge the oil in the tank of the lubrication
station into the oil can. Drain the oil in the heat exchanger off and then tighten the
plug screw. Clean the tank, shut off the oil drain valve, tighten all the plug screw,
replace with the new filter core and finally add the clean oil.
e. The following items shall be carried out only after the pinion sets have taken
their position:
l The assemblies of low-pressure flowmeter of the pinion bearing are
equipped at the oil inlet pipe around the two pinion bearing where is easy to
observe.
l Repeat the item a. in the 4.6.2.
l The pressure testing of pipe line
l Dismantle the oil supply pipe line at the pinion bearing, and connect
the oil inlet pipe with the outlet pipe through the tubing to make the oil flow
return to tank without passing by the bearing.
l Start up the low-pressure pump of the pinion, and make the oil flow
through the field pipe line and return to the oil tank. Clean the low-pressure
system and check whether there is leakage.
4.6.3 The installation of electrical control unit
Arrange the wire and cable relevant to the lubrication station and install the
control system. More detailed information refers to the specification of electrical unit
DM850.
4.6.4 the no-load circulation of system
a. Injection of lubricant oil
The filtered lubricant oil from the oil filter is injected into the tank by the upper
limit level and filtered repeatedly through the filter. The filter precision shall be not
less than that of system. After the filtering of 1-- 2 hours, check the cleanness of oil
and make sure there is no visible solid dirt in the oil filter.
b. The low-pressure lubrication system no-load circulation
Deliver electricity to lubrication system, and start up the chosen low-pressure
pump. Make the pump in circulation and check whether there is leakage.
Check the pressure through the oil filter. Check the oil quantity at each end of
pinion bearing. Check the oil return condition of each bearing. Check whether each
inspection instruments works well. The circulation lasts for about 2 hours.
c. The high-pressure lubrication system no-load circulation
After the low pressure pump works well, start up the chosen low-pressure pump.
Make the pump in circulation and check whether there is leakage.
Check the oil quantity at each end of main bearing. Check the oil return condition
of each bearing. Check whether each inspection instruments works well. The pressure
of the high pressure pump cannot be over 12MPa. The circulation lasts for about 2
hours.
No oil is allowed to inject in the tank during the operation of system lest for the
overflow of oil when the oil from oil supply pipe returns to the oil tank, after the
system stops working.
More detailed information refers to the operation manual for the static-pressure
bearing hydraulic station of mill.
4.7 The installation of gear unit
Only after the lubrication system of main bearing has been installed and able
to supply oil from it, the shell can be rotated in the bearing.
This unit cannot be installed until the shell is able to rotate. The life span and
performance of the mill gear unit mostly depend on its installation and adjustment, but
also relate closely to the lubricating when operation and the daily maintenance. When
installing the gear unit, if the shell needs to rotate, the lubrication system of main
bearing must be started to form a layer of oil film between the step brass and sleeve
shaft.
4.7.1 The preparation work for installation
All the teeth surface and surface for installing must be cleaned completely before
the installation, especially the split surface of gear, the contact surface between gear
and shell. All the burr and damages shall be got rid of the surface.
Clean all the necessary connecting parts, including bolts, nuts, washer, studs and
so on. Pay special attention to that, tighten the connecting parts between the gear
contact surfaces with the special tools to fix according to the required steps in its
specification.
Before the gear unit is equipped at the shell, firstly put the underneath cover of
gear and that of the right and left sides into their position, and then check the gear
cover, if find some leakage or deformation, solve it at once, and keep the inside clean.
Equip the adjusting screw at the relevant hole of gear according the assembly
drawing of gear unit. After the final adjustment, the adjusting screw shall be in loose
condition since the edge of gear teeth may be deformed by the adjusting screw.
4.7.2 The installation of the first half gear
When lifting the half gear, use two lifting wire with equal length to put through
the space of spoke from the two sides. The protection backing shall be added between
the lifting wire and gear to prevent damage of gear. During the installation, add the
support on the foundation to support the shell and prevent the rotation of it (insert a
round bar into the hole at the upper end of support and the screw hole of shell to make
it together), as showed in figure 6.
Figure 6
Put the first half gear upside down above the shell, and make the connecting
screw holes of the shell flange and gear flange at the same level. After the holes are
aligned, put three location pins through the flange holes and all the bolts should be
fitted. Tighten one bolt adequately every five bolts(not be extremely fastened). And
tighten the rest bolts with hands, then equip the half gear at the shell flange. Adjust the
position of gear by the adjusting screw.
Rotate the shell by steel wire with a crane, make the first assembled half gear fall
down slowly below the center line of the mill(refer to figure 6). The falling of half
gear shall be slow and stable to prevent great swing of gear and shell which may
cause heavy impact of steel wire.
Note: take careful measures to make sure the shell cannot rotate itself
during the installation.
The matching surface of two gear shall be staggered with that of two
end caps by 90 degrees.
4.7.3 Installation of another half gear
Take the final check whether there is damage and burr on the mating face of shell
flange and half gear. Assemble another half gear and make sure all the marks are
corresponded. Use the forth bolts in each group of four bolts to fix the half gear and
the shell flange. All the bolts shall be tightened adequately, but the half gear must be
allowed to move slightly. The adjusting jackscrew is used to adjust the position of
gear. Align the inner part of split surface and the calibrated holes as possible by the
way of moving the downside half gear with screwjack and hydraulic jack.
Note: observe the appearance by eye that the finished holes have been aligned.
The taper pin bolts are not used to align the gear but to keep the split gear aligned,
which should be solved by labour.
4.7.3.1 Insert the pierced bolts into faying face, and tighten it with spanner and
make the two parts of gear close together. Pay special attention to that, the finished
holes shall be aligned, and the pierced bolts cannot be over tightened and it's enough
to only make the two parts split together. Align the finished holes in the faying surface
and observe the appearance to make sure they are aligned. The seamy expansion
sleeve cannot inserted until finished holes are ensured to be aligned exactly.
4.7.3.2 The installation of taper bolts
When fitting the tapper pin bolts, firstly, coat the inside and outside of the shell
with supramoly or similar dry lubricant. Insert the seamy expansion sleeve into the
hinge hole and make the flange seat locate at the countersink. Insert the taper pin bolt
into the seamy expansion sleeve, the larger end against the flange end of collet, and
knock the taper pin bolt to make it tightened by a copper bar and hammer, pay
attention to protection screw from damage. Equip the other three taper pin bolts by the
same way. Then fit the washer and single nuts at the smaller end of taper pin bolts.
Equip the washer and single nuts at the larger end and fasten tightly with a spanner to
prevent loose. During the operation, the nuts can protect screw and help to dismantle
taper pin bolts in future, but if the nuts are over tightened, it may open the taper pin
bolts at the sleeve. Check the alignment of two half gears, make sure the displacement
error of two half gear shall be not more than 0.1mm. After meeting the requirement,
fit the lock nuts of taper pin bolts to prevent loose when operation. Check the
clearance of contact seam, and with gap gage of 0.05mm, the depth of gap gage
cannot be inserted more than 20mm. If not, the two half gear must be dismantle, and
check whether there are anti-rust painting, scratch, or burr. If find, remove all the
unnecessary thing, and install again. Check again with the gap gage, until meeting the
requirement.
Please note that, the screw length at the two ends of bolts shall be equal, and its
tightening method refers to "appendix 1".
4.7.4 Check the alignment of ring gear
Check the alignment of rim according to the assembly drawing with a horizontal
micrometer and gap gage. That is to say, faying face of 0.05mm makes the gap gage
unable to insert, while the displacement of faying face cannot be more than 0.07mm.
If not suitable, check it again whether there is damage, burr and other foreign body.
After the finished bolts are installed, if the horizontal split surface is accepted, the
pierced bolts can be fastened. Firstly, adjust the pierced bolts and make the up and
down open parts of bolts equal. Tighten all the pierced bolts by the way of crossed
fastening, detailed as the " appendix 1".
If the horizontal split surface is not accepted, do as the following steps:
Relax the piercing bolts of the two half pre-assembled gear.
Relax the taper pin bolts of the two half pre-assembled gear.
Check whether holes, taper pin bolts, and taper pin sleeve are damaged, and
whether holes are aligned, then make a suitable alignment according to the
requirement.
Figure 7 sketch drawing for

Alignment of gear
Note: check one taper pin bolts once, while other pierced bolts and taper pin bolts
shall remain in their position to fix gear.
After all is accepted, tighten the taper pin bolts and piercing bolts again according
to the procedure.
4.7.5 Check the radial run-out of gear
After the gear has been fixed, tighten all the connecting bolts in the gear, shell,
and end caps. Adjust the radial position of ring gear with the radial adjusting screw
jack at the gear.
The following two points shall be considered when checking the radial
installation run-out of ring gear: the first one is the total radial installation run-out, and
the other is the change of installation run-out between the measured points. The total
radial run-out of gear in the mill cannot be more than 0.60mm. Inspect 18 points
distributed in the circle evenly and the allowance error between two measured points
cannot be more than 0.18mm.
Divide the teeth of gear into 18 points, and make marks at the rim surface of gear.
Align the radial run-out with instruments within the range of 30mm beside the two
sides of gear excircle with a micrometer(see A and B in figure 7). The steel support
for fixing the micrometer shall be rigid enough. The steel support cannot be fixed at
the bearing house but at the foundation. Rotate the gear slowly, make a record of each
indicated value, after one circle rotation, the hand of micrometer shall be directed into
zero. The error shall be not more than 0..8mm, or it may be wrong, recheck it. If
beyond the limit error, adjust it by the way of loosing the connecting bolts of flange
and adjust radially the adjusting bolts on the gear.
Note: during the measurement and calculation, conform to the correct using habit
of common symbols（±）. If neglecting the symbols, serious disalignment of gear will
be caused.
The total installation radial run-out can be calculated now, the maximum value of
installation radial run-out minus the minimum value of that, the result must be within
the required range(0.60mm).
The run-out between measured points can be obtained by the way that the run-out
value of the latter measured point minus the value of the former one. 17 values
measured between the measured points can be obtained. All the values shall be within
Check the run-out values of the total installation and the value measured between
the measured points, and make sure they are within the range limit. If one of the
values is beyond the limit, correct it by the alignment of gear with the adjusting screw,
hydraulic jack or screw jack. Adjust the gear to the minimum installation run-out
value and repeat the procedure of checking the radial run-out. Check the set bolts of
the shell if the error still cannot correct.
If all the radial run-out values are within the required range, equip the rest flange
bolts. The equipped torque shall be 50% of the specified value. The procedure of
tightening bolts refers to " appendix 1".
4.7.6 Check the end cap run-out of gear
The following two points shall be considered when checking the end cap run-out
of ring gear: the first one is the total end cap installation run-out, and the other is the
change of installation run-out between the measured points. The total end cap run-out
of gear in the mill cannot be more than 0.60mm. Inspect 18 points distributed in the
circle evenly and the allowance error between two measured points cannot be more
than 0.18mm.
The measured position of micrometer refers to figure 8. Note that, the hand "C"
shall be directed the same as the direction of hand "D" and "E", while the hand "D"
and "E" shall be kept the angle of 180 degree. Rotate the gear slowly, and make a
record of the three indicated values at each measured points. After one circle rotation,
the hand of micrometer shall be directed into zero. The error shall be not more than
0.08mm, or it may be wrong, please recheck it.
The total installation radial run-out can be calculated now, the maximum value of
installation radial run-out minus the minimum value of that, the result must be within
The run-out between measured points can be obtained by the way that the run-out
value of the latter measured point minus the value of the former one. 17 values
measured between the measured points can be obtained. All the values shall be within
Check the run-out values of the total installation and the value measured between
the measured points, and make sure they are within the range limit. If one of the
values is beyond the limit, correct it by adding washers between the gear and installed
flange. Adjust the gear to the minimum installation run-out value and repeat the
procedure of checking the rim run-out.
4.7.7 The installation of the final flange bolts
Tighten all the connecting bolts in the shell, end caps and gear according to the
"appendix 1".
4.8 The installation of pinion axle sets
Before the installation of pinion axle sets, locate the beneath cover and the right
and left cover of the pinion cover at their position in the base of pinion axle sets.
There shall be a temporary support between the underneath connecting flange of
pinion cover and the foundation to prevent interference of pinion cover and axle.
4.8.1 Cleaning
Open the upper cover of the bearing, check the location of seal ring and whether
the jackscrew is fastened or not, aligned with labyrinth seal groove. Ensure the seal
ring and the labyrinth seal groove not interfere with each other. Pay attention to
collate the oil holes. Examine the lock nuts of the bearing are fixed or not and whether
the floating end of the bearing is in the middle of the bearing base or not. Completely
clear the lubricating grease and the filth both in the bearing bases and the bearing
cover, so as to avoid contaminating the lubricating oil in the thin oil station. Then
close the bearing covers.
Notice: Please ensure that the bearing basses and bearing covers are not
interchanged and must be placed according to their original matching assemblies.
Screw the nut onto the bolt firmly. After the installation, seal the oil inlet temporarily
to avoid filth.
Check and make sure that the external ring of the pinion shaft not be jammed by
the opening bearing box. The interfaces of both the upper and the lower semicircle
holes should be adjusted according to the rotating bearing assembly requirement.
Completely wash the base and bearing housing, etc. All the components should be
free from burrs and scratches so as not to affect the installation.
4.8.2 Installation of the base plate of the pinion shaft unit
Clean the loose cement and excessive moisture on the pinion base. Decide the
location of the base with the determined the vertical center line and the horizontal
center line.
According to 4.4.2, handle the foundation bolts.
According to 4.4.3.1, install and adjust the sub base plates.
According to procedure a~d in 4.4.3.2, install the main base plates.
Adjust the base of the pinion shaft unit with the thin filler piece. The height error
can not exceed 0.08mm/m. Besides, the vertical level and the horizontal level of the
contact surface with the bearing base can not exceed 0.1mm. In addition, the
horizontal level of the base can not exceed 0.15mm. The deformation of the bearing
box base caused by the concave-down and the convex-up is likely to cause the bearing
generate heat.
4.8.3 Installation of lower-speed shaft coupling half
After the complete clearance, measure the size of the mating holes, shafts and the
shrink range. Then, according to the shrink range and the size of the particles, fix the
heating temperature, heating time and heating preservation time. After heating the
particles, get the respective swell increments with the inside caliper, so as to avoid the
installation difficulty caused by the inadequate swell increments.
The coupling half on the pinion shaft is already installed before dispatching from
the manufactory factory.
4.8.4 Installation of the pinion shaft unit
Clean the contact surface between the pinion base and the base plate. Carefully
hang the gear shaft to the base plates with the traveling trolley and the nylon rope
hanged below. Then adjust the bolt holes and align the pinion surface with the gear
surface.
4.8.5 Alignment of the pinion shaft unit
Through horizontal measurement and filler piece of the bearing base, make sure
the horizontal center line is parallel with axis of the geared ring. It is recommend to
install the filler pieces under each base, with the lowest thickness 0.1mm. Adjust the
filler piece in the future, if necessary. The filler piece should be made of steel which
can support the whole base frame.
4.8.5.1 Alignment of the pinion backlash
Consider two points of pinion backlash: 1. pinion backlash should include the
backlash required by the pinion itself and the backlash required by the rising
temperature in the normal operation of the pair of pinions. 2. The measuring point of
the pinion backlash should be at maximum that geared ring runs out forward.
a. Preliminary alignment
Make the pinion and the gear ring engage with each other and observe the
engagement trace. Adjust the engagement elasticity to reach the balanced engagement
effect. Then, obtain the original setup by the micrometer gauge and the same
recession amount of two pinions.
b. The pitch circles of both the gears and the pinions are already marked
mechanically on the terminal surface. Observe the pitch circle lines and get the right
backlash as drawing 1 and 2 in drawing 9. The measuring point of the pinion backlash
should be at the pitch circle line, so that it is reliable.
According to table 10, measure the pinion backlash. The pinion backlash should
be confined to 3.380mm~3.630mm. Examine the contact surface and the backlash
surface at the engagement points of each measuring point. Get the two backlashes
X1、X2，between the contact surface and the backlash surface, which is on the left side
of the engaged pinion teeth, as well as X3、X4 between contact surface and the
backlash surface, which is on the right side of the engaged pinion teeth. It is required
that 3.380mm≤X1+X2≤3.630mm, 3.380mm≤X3+X4≤3.630mm. If the room
temperature is high, select the smaller value. While, if the room temperature is low,
select the larger value. Also it should satisfied that -0.3mm≤（X1+X2）-(X3+X4)
≤0.3mm. Since the pinion backlash is 3.380mm~3.630mm, it is better to select the
larger value.
Adjust the bearing base, try to make the left and right engagement error is 0, that
is（X1+X2）-(X3+X4) is 0. If it doesn't exceed the calculated permissible error
mentioned above, the left backlash and the right backlash are nearly the same in the
regulated range.
As the pinions run out radially, the sum of the left engagement and left backlash
at each position are different from the sum of the right engagement and right backlash
at the same position. However, all the pinions should run out in the permissible radial
run-out range.
c. The second adjustment of the pinions
Calculate the data at each position before the adjustment, otherwise more errors
are emerged when correcting one by one. Find a method to correct the engagements
and backlashes at all the positions.
Under loading circumstance, allow for the shell deformation which would affect
the correction of the pinions. Therefore, in order to achieve the perfect engagement
effect, must take the shell deformation into consideration.
After the installation of the pinions, put the micrometer gauge on the moving base
frame to measure the position changes. The micrometer gauge is installed before the
bearing base bolts are flexible. In this way, we can know the variations of bearing
base when adding or reducing the filler pieces. Screw the bolt tightly again and check
the micrometer gauge.
4.8.5.2 Check the contact surface area
After the second adjustment of the pinions, the base is fixed. Then check whether
the teeth engagement attained the accurate correction or not. Spread a thin layer of red
lead powder smoothly at tooth 5 and tooth 6 (which are already cleaned). Ensure all
the flank profile and tooth width surface are spread. Roll and engage the pinions
forward and backward several times and leave the engagement trace on the pinions.
The requirements of the contact surface area are: the direction of tine length 70%
contact and the direction of tooth depth 45% contact. If it fulfills these requirements,
check the engagement on 3 different positions of the pinions with the same number of
teeth. Make little adjustment on the pinions to attain the average engagement of the
gear.
4.8.6 Final adjustment
After the final adjustment, all the bolts should be fixed at their final torque. When
the pinion is connected with the reducer through the coupling, all adjustments should
be carried out on the reducer. The position of the pinions cannot be changed to ensure
correct mesh of the pinion teeth.
4.8.7 Installation of the accessory components of the pinion shaft unit
Each pinion shaft unit is equipped with a thermal resistance to monitor the
temperature of pinion bearing. The pinion shaft unit is also equipped with SKF
vibration measuring apparatus to monitor the vibration of pinion bearing.
According to the assembly drawing, install the thermal resistance, vibration
measuring apparatus and vent cap at the designate position.
Notice: Install all the mentioned components at the access to observe and
maintain.
When connecting the lubrication feed pipe and oil return pipe, at least connect
two of four oil return ports on two sides of the bearing base. Install the seal greasing
pipeline according to the drawing.
Install the temperature detector WZP2-231A double-way platinum thermal
resistance which should be mounted outside the mill to make it easier to connect the
wires. Connect the temperature measuring wires to the control system.
Install the seal greasing pipelines and the thin lubricating oil pipelines according
to the seal greasing instruction and the static lubricating station instruction. Notice
that handling all the pipe fittings used in the pipelines according to 4.6.2 and testing
the pressure according to 4.6.2 b.
4.8.8 Secondary Grouting for the pinion base plate
Secondary Grouting for the pinion base plate should be carried out after the
adjustment of reducer, main electric motor, the inching drive device, referring 4.5.7
for the grouting method.
4.9 Installation of gear cover
Gear cover provides full protection for the rotating gears and pinions. Gear cover
should adopt the welded structure and labyrinth seal to prevent dirt falling into the
gear. Gear cover composes of multiple segments. In addition, the gear cover is
designed to have the space to install two sets of oil spray nozzle in the drying oil spray
lubricating device and tooth surface temperature detector for two sets of pinion shafts.
Only use one set of the drying oil spray lubricating device. The other unused should
be sealed with the covering plate and the plug screw. There are oil drainage holes at
the bottom of the gear to prevent the lubricant and sewage from heading up in the gear
cover.
Because the large size and inferior rigidity of the gear cover, it is likely to be
distorted in the transportation. So before the installation, check the all parts of the gear
cover according to the size in the drawing and install the seal ring for the gear
according to the requirements of the drawing. Collision sound is not allowed when
turning the engine. After the installation, check the rigidity of the gear cover. Since the
external diameter of the gear is large and the machine is two-pinion drived, at least
add two supporting and fixing points after the field installation. Keep the same
clearance between gear cover and the gear, which can be obtained by adding and
reducing some filler pieces between the connecting flanges, if necessary. Before the
pinion assembled in the shell, install all the bottom segments of the gear cover.
Besides, install the seal ring on the gear. Check the skewness and correct the skewed
part before assembling all parts of the gear covers.
Notice: Install the section with index tag on directly over gear.
There are mating marks on each section of the gear covers, referring the gear
cover assembly drawing for the concrete marks.
Before the assembly, clear the greasy dirt and burrs on the contact surfaces and
clear the possible filths in the gear covers. Check whether there are collisions and
distortions at each part of the gear covers. If any, remove it. Possibly consolidate the
gear cover beforehand.
Assemble each gear section according to assembling marks.
Crossly pre tight all the bolts. Then tightly screw all the bolts after assembling all
the gear covers.
The spraying lubrication system should adopt the production of FARVAL
Company in America. The spray gun unit should be installed in the gear cover. The
spray nozzle should be installed at the place where it can spray the lubricating cream
on the working flank of tooth of the gear. The gear spray controller and the lubricating
cream pump should be installed at a certain distance from the gear cover by the
installation company.
Install the drying oil spray lubricating device, the relevant pipes, the
automatically controlled device, the relevant wires and cables according to the drying
oil spray lubricating device specification. The mill only equipped one set of drying oil
spray lubricating device for two pinion shafts of the mill. The unused interface on the
other side should be sealed by the covering plate and the plug screw.
The infrared ray temperature detector should adopt the production of FARVAL
Company in America to monitor the temperature of the engagement surface of the
pinions. Once the engagement surface temperature of the pinions exceeds the
regulated temperature range, the temperature detector would send alarm signal to be
treated, so as to avoid the damage.
Install the infrared ray temperature detector device, the relevant pipes, the
automatically controlled device, the relevant wires and cables according to the
infrared ray temperature detector device specification.
4.10 Installation of reducer, coupling, main electric motor and inching drive
system
4.10.1 Installation of the reducer and its lubrication station
Adjust the reducer, taking the central line of the pinion shaft as the base-line.
Refer the reducer operating specification, reducer lubricating station specification and
coupling installation and operation specification offered by FLENDER Company for
detail information.
4.10.2 Installation of inching drive
The reducer in the inching drive system has already been tested and adjusted in
the factory. So there is no need to open the reducer on site. Clean all the components
and remove any burrs on them. Align the central line of inching drive, taking the
already aligned and fixed high-speed shaft of the reducer as the base-line. Refer the
inching drive installation and operation specification offered by FLENDER Company
for concrete installing procedures. After the installation, the shank should be moved
flexibly.
It is very dangerous for a loaded system to cut off the inching drive. To make the
mill achieve a balanced condition, the inching drive must rotate forward and/or
reversely. The inching drive cannot be disconnected until the mill is in balance.
4.10.3 Installation of the main electric motor system
The main electric motor should adopt the asynchronous machine of the YRkk
series manufactured by Shanghai electric motor factory. Align the electric motor,
taking the high-speed shaft of reducer as the base-line. It is required that the
non-concentricity of the main electric motor and the inching drive is no more than
0.2mm. If the requirement conflict with the specification, execute the main electric
motor specification. Refer the main electric motor specification offered by Shanghai
electric motor factory and coupling installation and operation specification offered by
FLENDER Company for detail information.
Install the main electric motor lubricating system according to the specification
for dynamic and static pressure lubricating station of the electric motor shaft offered
by CITIC Company, referring the main shaft static pressure lubricating station item
4.6.
Adjust and install the base plates of the main electric motor according to 4.43.2
step a~d.
4.10.4 Secondary grouting for the reducer base, inching drive base and the
electric motor base
After all the drive systems listed above have been installed and checked, carry out
the secondary grouting for the pinion base plate, main electric motor base plate,
reducer base plate and inching drive base plate. Conduct secondary grouting
according to the grouting method and procedures in 4.5.9.
4.10.5 Install the control system of the reducer, main electric motor and inching
drive, the instruments, the lubricating system according to certain specifications.
4.11 Installation of other parts
Through the above procedures, the main parts of the mill are already installed. In
order to make the mill operate normally, other parts should be installed. These parts
include the feed inlet and discharge outlet of the shell, the rubber lines of the shell,
feeding part, protecting cover and so on. These parts play an important role in the
normal operation of the mill, so pay more attention to the installation.
4.11.1 Installation of the quill bushings
Before the installation, completely wash the matching surfaces between the quill
and the bushing and remove the greasy dirt and the burrs, the rust-preventative oil on
the flange surface and connecting holes. Check the levelness of the matching surface
between the flange and the rabbet with the stainless steel ruler section by section.
Local projection is not allowed. If it can not be assembled immediately after the
clearance, spray a layer of rust-preventative oil and pack it. Check whether the bolts,
nuts, double-screw bolts and the threads damaged or not. If any, carefully wash and
repair them. Make sure that all the he bolts, nuts, double-screw bolts and the threads
are fastened, without burrs. Before the installation, wash and dry the surface of all the
bolts, nuts, double-screw bolts and the threads. Greasy dirt or other dirts are not
allowed.
Put the rubber sealing strip on the bushings and then put both of them in the quill.
Ensure that the matching cylinder surface and the rabbet concentrate with the quill.
Tighten the bushings flange and the feed quill and make sure that there is no clearance
between them. After the adjustment, tightly and crossly screw the bolts according to
the regulated torque value. The screwed torque is the unreceipted screwed torque in
the appendix 1. After the installation and the adjustment, seal the clearance between
the inner end of the quill and the matching cylinder surface with the Hutian 902HT
silica gel. Under the assembly and delivery circumstance, reexamine all the
connecting bolts with the full torque on the site.
Install the bushings and hydro-extracting ring on the quill according to the
assembly drawing.
Notice: At the moment, the feed inlet can not be installed unless the liner is
installed completely, for it’s the pass way for the manipulator to deliver the liners. If
the feed inlet is in the assembly state, remove the feed inlet.
4.11.2 Installation of the discharge outlet, discharge horn mouth and cylinder
trommel
Install the discharge, discharge horn mouth and cylinder trommel according to the
installation method of the feed quill bushings.
Install the bushings and hydro-extracting ring on the quill according to the
assembly drawing.
Reexamine whether the bolts between the discharge rubber liners and the
discharge outlet, as well as the bolts between the horn mouth liners and the horn
mouth are fastened or not. Fasten the loose ones.
4.11.3 Installation the liners
The 6mm rubber gaskets have been laid on the inside wall of the shell and the
inside wall of the head by the manufacturing factory. However, it is required to stick
the rubber gaskets on the supporting steel plate of the shell, the lifting lugs outside the
shell and the head, the joint interfaces between the shells, quills, the joint interfaces
between the quills and the heads on the site.
Before laying rubber gaskets, clean the corrosions and pollutants on the surface of
the steel plate with the steel brush. Then completely wash the steel plate with the
solvent and carry out shot blast. Cut the rubber gaskets to the right size and right
shape, polish the rubber surface with rough grinding wheel. Then clean the polished
the surface with the solvent. Stick the rubber gaskets on the heads, shells and the
inside wall of the quill with the proper glue, then roll evenly. The 50mm diameter
steel roller is recommended to use rolling symmetrically from the center to two sides
and evacuate the air. The joint should be connected with no gaps and shell heads are
not allowed to be exposed. Cut 45° oblique angles between the rubber gaskets, stick
firmly and flatly to make them transit smoothly at least. Relevant bolt holes shall be
made after sticking the rubber to the shell. A hammer is commonly used to make holes
along the edge of holes. Holes and flange edges are not allowed to be at the joint
interfaces of the rubber gaskets. Align the rubber gaskets which laid under the feed
and discharge quills with the inner ring of both the feed inlet and the discharge outlet.
The joint must not be on the matching surface between the feed inlet and the quill, so
that the rubber gaskets can cover all the clearances on the matching surface.
The rubber gaskets should be fully adhered to substrate; the air between the
adjoining layers should be completely evacuated. Ensure that there is no tensioning,
bridging, bubble or other defects on the surface of the rubber gaskets. And the final
surface should be very smooth in order to avoid changing the flow condition, such as
turbulent flow. Check the rubber gaskets laid in the manufacturing plant. If such states
occurred, repair them.
Because the material used has a high inflammability, safety measure must be
taken. When installing the rubber gaskets and liners, any lighting used inside the mill
shall adopt the power below 36V to ensure safety.
Install the feed side lines, shell liners, corner liners, discharge end liners
according to the assemble drawing. May use a liner manipulator offered by
MCLELLEAN Company to improve the installation efficiency. Refer the on- engine
operation specification for the fixing, operation, employment and matters need
attention. Check whether each liner has been correctly installed or not. Check the
clamping surface of each liner. There should be no lumps, burrs or irregularities on
the clamping surface, otherwise grind it. Depending on the conditions, fix the liners
by adding thin steel plates.
It is recommended that install 1/4 circle mill liners at one time, after tightening all
the 1/4 circle mill liner bolts, rotate the mill 1/4 circle, install the next ¼ circle mill
liners.
When installing liners, pay attention to the safety, otherwise personal injury may
occur. The mill is not allowed to rotate before the liners have been fixed with bolts.
Also the mill is not allowed to rotate without the lubricating system running. Use the
brake in the inching drive to ensure the mill cannot rotate before personnel entering
the mill. At the same time, take measures to ensure the mill shell can not rotate in the
installing process, so as to avoid the inching drive failure.
Symmetrically install the liners along the axial line of the mill and try to maintain
balance in the mill during liner installation.
All bolts should be checked after installation. According to the shell assembly
drawing, install the sealing part and water outlet cover of the bolt force of the liners.
4.11.4 Installation of the feed inlet
Confirm that all the liners of the lining part have been installed. Then install the
rubber liners on the feed inlet and install the feed inlet on the bushings of the feed
quill according to the assembly marks.
4.11.5 Installation of the feeding part
The feeding part of the mill consists of the feed groove, feed support and the
frame. Clear the contact surfaces to make sure there are no greasy dirt and burrs.
Wash all the relevant bolts, nuts and pats. Check whether the liners in the feed bin are
fixed tightly or not and whether the clearances between the liners are appropriate or
not. If the clearances are too large, fill them by adding steel plates. If the bolts are
loose, tighten all the bolts which connected the liners according to the regulation.
Tightly fix the frame on the foundation or the rail. Then assemble the stock bin, upper
feed inlet and the feed pipes. The top feed inlet should be connected with the
technological feed pipes.
After the installation of the trolley, push the trolley to the feed inlet along the rail
and insert the locating stud of the trolley into the locating fit of the foundation. Check
whether the feed pipe level is concentric with the feed inlet. If there is large difference
between the feed pipe level and the feed inlet, adjust it by the filler pieces for the
stock bin support and the frame of the feed trolley. Ensure the concentricity error of
the feed pipe level and the feed inlet is no more than 2mm.
Notice: Since the gravity of the trolley is too high, remember fixing the bottom
frame before the installation.
Pay attention to the inclination of the trolley, take measures to prevent the trolley
from overturning.
4.11.6 Installation of the feed sealing part
The design of the feed sealing part takes the slurry floating conditions inside the
shell and the high-abrasive requirement into consideration. The feed seal ring adopts
rubber composite high-abrasive ceramic wafer structure to ensure certain elasticity
and adequate abrasion resistance. The seal ring adopts the overlapped high-abrasive
two-layer rubbers. The external layer rubber seal ring is used to prevent steel ball in
the shell from smashing the ceramic wafer in the seal ring. The internal layer mainly
plays a sealing role. When the slurry in the mill surge up to the feed pipe, it can tightly
compress the seal ring.
The feed seal ring should be installed from the discharge outlet to the shell. First,
set the seal ring on the feed bend pipe and adjust to the appropriate location. Then
fix the seal ring on the feed bend pipe with the set collar. Later, tightly compress the
two-layer rubber seal ring onto the seal ring with the extended bolts.
4.11.7 Installation of the protecting cover
The protecting cover includes the shaft head cover of the pinion, low-speed
coupling cover, high-speed coupling cover, inching drive clutch cover, inching drive
coupling cover and the rain-proof cover. The shaft head cover of the pinion has been
installed in the section 4.8.
After the installation of the protecting cover, it is required to tightly connect, so as
to not interfere with the rotating parts.
4.11.8 Installation of the remaining electric components
Install the wires, cables, holding wires of all the electric components of the mill.
Refer the electric components specification and the installation and operation
specification offered by relevant manufacturers for detailed installation.
4.12 Reexamination
After the full installation, reexamine the mill. The reexamination includes：
a. Reexamine all the connecting bolts, especially the foundation bolts, two bolts
between two gears, the connecting bolts between the shells, the connecting bolts
between the head and the shell, the connecting bolts between the shell head and the
gear, the fixed bolts between the liners, the fixed bolts between the feed inlet and
discharge outlet and the quill, etc.
b. Reexamine whether there are uninstalled parts on the device, and whether there
are missed parts or damaged parts.
c. Reexamine whether all the parts offered by the manufactory installed or not,
except the spare parts.
d. Reexamine whether all the oil circuits, air circuits and water circuits are
connected or not and whether there are leakages.
e. Reexamine whether all the electric wires, cables and holding wires are installed
or not.
f. Reexamine whether there are interference between the static parts and the
moving parts.
g. Reexamine other ought to be reexamined parts.
Find out the sources of discovered problems in the reexamining process and
correct them completely. Ensure the device can be operated safely and reliably.
4.13 Clearance and completion of the field installation, such as painting
After the above work, the installation of the device has finished. The next step is
to clear and complete the field installation. Clear all the barriers, rubbish and filths.
Clear the greasy dirty to prevent personnel from slipping. Erect banisters at the
dangerous area and the potential dangerous area.
Repair and paint the collisions, scratches and the paint-shedings. Repaint the
devices, if necessary.
5. Trial run
5.1 Preparations and checks before the trial run of the mill
Do an overall check before the mill is started, the mill cannot be started until the
following requirements are met.
5.1.1 Mechanical unit
a. Each part of the mill has been installed completely according to the instructions;
the erection schedule of each part meets all the requirements of the installation
operation manual. If any abnormalities are found, adjust them again until the
requirements of the installation are met.
b. Main bearing
1) The installation of the platinum resistance for temperature measuring should be
correct; and the wiring of the temperature measurement should be correct.
2) Connection of the lubricating pipe lines should be correct; the installation of
the instruments and gauges such as the flow meter, manometer, and the pressure
sensor should be correct.
3) Jackscrew at the two ends of the main bearing has been pushed tightly.
c. Shell Assembly
1) Randomly recheck whether the joint bolts at each part is tightened correctly,
especially the connecting bolts between heads to shell and the connecting bolts
between shells. Make sure the connecting bolts between shells, heads and gears have
been reached and the pre tightened torques and the extension meets the requirement.
2) Check that there is no debris or other things in the shell. There should be no
loose bolts, nuts or any other small parts in the shell.
3) Check the direction of the spiral at the feed and discharge end. Associated with
the direction of the mill rotation, judge whether it installed correctly or not.
4) Check the direction of the spiral of the shaft screen. Associated with the
direction of the mill rotation, judge whether it installed correctly or not.
5) Check whether the bolts connected the liners are tightened firmly or not and
check the bolt force holes are closed or not.
d. Drive unit
1) Check whether the final installation records of the gear and pinion at meet the
requirements or not, including the radial run-out, transverse run-out, teeth contact,
backlash, as well as the joint clearance. Check and adjust again if there is any doubt.
2) Check whether the position of the temperature sensors and its wiring at the two
sides of the pinion are correctly installed or not.
3) Check whether the lubricating pipelines of pinions at both sides are correctly
connected or not. Check whether the flow meter is correctly installed or not and
whether the brand of lubricating oil is correct or not.
4) The radial and axial run-out of couplings at the head of the pinions should
meet the requirements of the installation precision.
5) The jackscrew of pinions should be adjusted tightly.
6) The vibration detecting wires of the pinions should be correctly installed.
7) Reexamine whether the joint bolts at each part have been fastened tightly or
not.
8) Check whether there is any debris or other objects in the gear covers or
coupling covers, which will damage the equipments or personnel when it is running.
9) Coat the lubricant on the teeth surface of the gear (use the same lubricant as the
gear spray lubrication); the lubricant brand of the gear spray should be correct.
10) The infrared ray temperature detecting device and its wires should be
correctly installed.
11) The oil circuit system and the air circuit system of the spray lubricating
device should be correctly connected.
e. Reducer device
1) Check whether the lubricating pipelines are installed correctly or not according
to the drawing.
2) Check whether the instruments are installed and set up correctly or not
according to the drawing.
3) Check for the possible leaks in the pipelines.
f. Inching drive
1) The brand of lubricant for inching drive reducer should be correct; and the oil
level must meet the required standard.
2) Check the position of the interlocking protection switches of the inching drive
clutch and make sure meet the requirement of the interlocking protection.
3) Carefully examine the connecting of the whole mechanical, electrical, and
lubricating system, and make sure they are safe and reliable.
4) Make the equipment rotate manually without obstruction.
g. Main electric motor unit
1) Check whether the lubricating pipelines are installed correctly or not according
to the drawing.
2) Check whether the instruments are installed and set up correctly or not
according to the drawing.
3) Check for the possible leaks in the pipelines.
5.1.2 electricity
(1)Cabinet electric components are not broken or lost.
(2)All component connections in the cabinet should be tightened by
screwdriver or spanner again to ensure them fixed.
(3)All the connections in the cabinet are correct.
(4)All assembly connections in site are correct.
(5)Carry out insulation test on all low-pressure motors.Insulation
resistance should be over 0.5MΩ for less than 10kW motor.
(6)Ensure carry out pressure-tight test on high-pressure cabinet.And
pressure value is up to related standards.Should carry out 32000V pressure-tight test
on 6000V power supply(standard) and 42000V pressure-tight test on 10000V power
supply(standard).Record the actual pressure value.
(7)Ensure carry out pressure-tight test and insulation test by tramegger on
high-pressure motor and high-pressure cable recently .And record pressure value and
insulation value.Energize and debug them after installation company and user
approve .
5.1.3 lubricating station of main bearing
(1)Check and confirm lubricating station pipeline and assembly correct as
per the drawing.
(2)Check and confirm all the pumps，valves and control instruments no
impact and no damage on lubrication station,all pipeline valve flexible,reliable and no
leakage.
(3)Check and confirm the connections of related electric control
components and control instruments correct.
(4)Check and confirm intermediate piping connection between the mill
and lubricating station completed,pickled,neutralized and washed clean.Test oil
cleanness to meet the standard requirements described in ISO4406-18/15.( The test
report is provided by the user ).
(5)Check and confirm the filtered oil with stipulated code designation has
been added to oil tank to reach stipulated level scale.
5.1.4main motor system
Relative attached components are installed in place and the lube are added as per
requirements after finishing the assembly and connection for main motor system.
5.1.5User engineering department , assembly company and supervising
department identically confirm that there are provided with debugging conditions .
5.2 test run for component
5.2.1 electricity
a. debug energized low-pressure cabinet with no load
(1)Must check the leading-in power supply and voltage before total power supply
of the cabinet is braked.The leading-in power supply and voltage must accord with
drawing requirements.
(2)Release all open electricity of the motor from leading-out end of the
cabinet.
(3)Check each contactor with no load when energized and closed.The
contactor closes 3－5 times when below50A.The contactor closes 5－10 times when
above50A.And check whether the circuit is closed good.
(4)Check whether transfer switch,signal light and label letters of display
device on the cabinet accord with the drawing or not.If not,adjust the re-routes
consistent.
(5) Set mill main bush temperature,pinion bearing temperature,reducer bearing
temperature ,alarming values and trip values of main motor stator and bearing
temperature(see the table below)and working and stopping temperature values of
lubricating station temperature(heating and cooling)(see lubricating station
specification ).And check alarming and trip relay after adjust testing value low to
ensure the light bright and trip relay action.Also,adjust the heating and cooling relay
actions of controlling lubricating station.
name alarming value（℃） shutdown value（℃）
Main bearing temperature 60 65
pinion bearing temperature 75 80
reducer bearing temperature See reducer specification
main motor bearing temperature

see motor specification
main motor stator temperature
(6)Test low-pressure electrically operated system after shutoff and trip and
confirm trip relay action.
b. energize and debug low-pressure cabinet with load
(1)Adjust protective values of all relays and rated values on motor nameplate
consistent.
(2)Energize oil pump motor of all lubrication stations to check whether the
turning direction is correct or not.If not correct,adjust two-phase connection of motor
stator.
(3)Energize oil tank heater manually and automatically to check whether oil
tank temperature rises or not.
(4)Energize slow-driven motor to check whether the turning direction is
correct or not.If not correct,adjust two-phase connection of motor stator.
c.See low-pressure electrically operated specification for detailed debugging
5.2.2 debug mill lubricating station
Pay special attention to:The mill does not start when all lubricating systems
don't operate normally.
a. adjust high-pressure hydraulic control value
(1)High-pressure circuit mainly serves the function of pushing high-pressure lube
into bearing load area to establish a certain film thickness and make the mill float
consisting of high-pressure pump,,check valve,high-pressure filter,etc;On the process
of mill operation,high-pressure system is always under normal operation.
(2)When the mill stops and high-pressure pump does not work,supply a dial
indicator on both ends of mill respectively to test the floating value on both ends of
mill(oil film thickness on both ends of mill≥0.20mm）.
(3)When the mill stops,point and drive two high-pressure pump motors
respectively,confirm motor direction accords with oil pump indication direction
again.(If the direction is correct,the high-pressure gauge will indicate).
(4)When the mill stops,start high-pressure pump on oil-supplying state.
(5)When the mill stops and rated flow of lubrication station is correct,use a dial
indicator to measure the floating values of mill quill shaft with no load, 30％load，60
％load，90％load and 100％ load respectively,i.e.,oil film thickness and record
corresponding oil pressure values.Minimum floating value on each end of mill should
be over 0.20mm no matter which kind of load it is.Stable pressure value which
pressure gauge indicates is the normal pressure value Pf with 100% load .
(6)alarming value of pressure sensor ： Set value is 70% work
pressure,i.e.,70%Pf.When below 70%Pf,give a low-pressure alarming signal.If below
this value when start,then electrically operated mill does not start.(set values above
are all recommended data,detailed data should be determined according to site work
condition.)
(7)shutdown value of pressure sensor:Set value is 50% work
pressure,i.e.,50%Pf.When below 50%Pf,electrically operated ball mill will delay
stopping turning.It's required to examine the troubles after shutdown or switch the
spare pump.(set values above are all recommended data,detailed data should be
determined according to site work condition.)
(8）High-pressure oil control is mainly inspected by four digimatic oil monitors
installed in oil inlet pipeline of four high-pressure oil chambers on two bearing seats
to monitor the oil-supplying for each bearing .
（ 9)When any oil value decreases to intermediate set value,give an
acousto-optical alarming signal,should take measures to eliminate the alarming signal
in site;the mill stops if oil value decreases to set value .
b. set low-pressure oil：
(1)Low-pressure circuit mainly consisting of low-pressure pump,safe
valve,check valve,filter and cooler,etc; lubricating and cooling main bearing and
pinion shaft group serves the function of circularly cooling the lube when the mill
operates normally.
(2)Low-pressure pump is always working on the process of mill operation.
(3)Set pressure value of safe valve:0.63Mpa（generally debug the test well before
ex works)
c. pinion low-pressure oil control adjustment
(1)Pinion low-pressure oil control is mainly inspected by two digimatic oil
monitors ,respectively installed near horizontal oil inlet pipeline of two pinion bearing
lubricating points where it is convenient to observe so as to monitor oil-supply of each
bearing.
(2)When any oil value decreases to intermediate set value,give an
acousto-optical alarming signal,spare pump is put into use.When the oil gets back to
normal value, eliminate the alarming signal.When any oil value decreases to low set
value,the mill will stop.It's required to examine the troubles after shutdown or switch
the spare pump.
d. control and adjust oil temperature
There are 2 platinum thermal resistances to monitor oil temperature change in oil
tank.When return side tempearture of oil tank is below 25℃,electric heater will be
automatically energized.When oil tempearture is above 30℃,electric heater will
automatically shut off.It's allowed to start low-pressure oil pump when oil temperature
is above 27℃. Low-pressure pump must stop working when oil temperature is below
22℃.Electric heater controls energizing and shutoff on the cabinet manually. It will
alarm when the temperature of oil tank on return side is above 50℃.The mill must
stop operating when the temperature is above 55℃.
When the temperature of high-pressure oil side on oil tank is below 35℃,electric
heater will be automatically energized.When oil tempearture is above 38℃,electric
heater will automatically shut off..Start high-pressure oil pump when the oil
temperature is up to 38℃.It will alarm when oil temperature is above 45℃.The mill
must stop operating when the temperature is above 50℃.Electric heater can control
energizing and shutoff on the cabinet manually.
Temperature control valve on cooler waterway adjusts water intake automatically
according to oil-out temperature of cooler to ensure about 38℃oil-out temperature.
There is a controller on oil returning side and oil absorbing side of the tank used
to monitor the level in oil tank.When the level is up to the upper limit ,the light will
flash;When the level is up to the lower limit ,it will give a lower acousto-optical
alarming signal of oil tank level ,the mill stops and oil pump stops operating.
f pressure difference control
There is a differential pressure switch on all oil filters.When pressure difference
for oil inlet and oil outlet on the filter is over the set value,it will give a
acousto-optical alarming signal of filtering core jam .Clean or replace the polluted and
jammed filtering core in time.
g main point of debugging the electrical control
(1)Start the mill system. The high-pressure system and low-pressure system
must work firstly. When the mill shell stops working completely, high- pressure
system and low-pressure system stop (manually control or set the delay time
according to actual condition); When the mill stops and cools down, start high-
pressure system and low-pressure system every half an hour manually, lasting 2
minutes. Jack up the mill shell and release the additional load formed during cooling
process until quill shaft temperature decreases to room temperature.Note: before this
lubricating system starts high-pressure system, low-pressure system must be
started.It's forbidden to directly start high pressure at first to avoid damaging
high-pressure screw pump.
(2)For the low-pressure lubrication system of pinion bearing, if the oil pressure
is low(or cutout), it should alarm and delay the mill shutdown . Must make an analog
test of oil flow if the situation above occures.
(3)The high pressure system is the crucial part of the lubricating station. The
alarming value of overlow oil pressure in high pressure system or controlling point
of mill stopping should be depended on site actual measurements . Must make an
analog test of oil pressure.
(4)Before the mill starts, if the procedure detects low temperature of oil tank on
lubricating station , high temperature of oil outlet and low oil level, it is not allowed to
start the mill. It must analyze the reasons, find out the faults and repair them, then it
can operate.
(5) Set temperature control of oil tank (control the heater on or off), control
point of the oil level and alarm.
(6)Set the control point of oil filter differential pressure sensor (indicat that the oil
filter is plugged and needs changing the filter cartridge).
h. See lubricating station specification for detailed debugging.

5.2.3reducer and lubricating station debugging
a.Before debugging, it is necessary to read the operating manual supplied by
FLENDER company.
b.Check whether temperature sensor installation is correct or not and sensor
installation is correct or not.
c. Check whether lubricating system pipeline is pickled as per requirements or not
and pipeline connection is correct or not.
d.Carry out as per assembly and operation manual supplied by other FLENFDER
companies.
5.2.4debug the gear spray lubricating device
a. Before debugging, it is necessary to read the operating instruction and
controlling principle of spray lubricating device.
b. Main motor starts , then spray lubrication starts to spray;Main motor stops ,
then spray lubrication stops
c. See the details in Operating Instructions for open gear grease spray system
5.2.5main motor debugging
a. Before debugging, it is necessary to read the operating instruction supplied by
motor plant.
b. Check whether connections of main motor stator ,thermometric sensor and
dehumidification heater of bearing are correct and fixed or not.
c. Test run the motor singly for 8 hours and record relevant parameters of the
motor operation such as bearing and stator temperatures, operating current and
voltage.
d. Adjust and check as per assembly and operation specification
requirements supplied by Shanghai Motor Plant.
f. See other debugging requirements in assembly and operation manual of the
Motor.
5.2.6 dynamic and static pressure lubricating station of motor bearing
a. adjust controlling value of high-pressure oil
（1）High-pressure circuit serves the function of pushing high-pressure lube
into bearing load area to establish a certain film thickness and make the motor turning
section float mainly consisting of high-pressure pump,safe overflow valve and
high-pressure filter,etc; High-pressure system should start before the motor starts
firstly and stop after the motor starts and normally operates 15min. Firstly,
high-pressure system should start before the motor stops and high-pressure pump
stops after the motor stops operating 15min.
（2）When the motor stops and high-pressure pump does not work,supply a dial
indicator on both ends of motor shaft respectively to test the floating value on both
ends of motor shaft (oil film thickness on both ends of motor shaft≥0.20mm）.
（3）When the motor stops,point and drive two high-pressure pump motors
respectively,confirm motor direction accords with oil pump indication direction
again.(If the direction is correct,the high-pressure gauge will indicate).
（4）When the motor stops,start high-pressure pump on oil-supplying state.
（5）When the motor stops and rated flow of lubrication station is correct,use
dial indicatorto measure the floating value of motor shaft ,i.e.,oil film thickness and
record corresponding oil pressure values. Stable pressure value which pressure gauge
indicates is the normal pressure value Pf after comparing with minimum floating
value of each end the motor requires.
（ 6 ） alarming value of pressure sensor ： Set value is 70% work
pressure,i.e.,70%Pf.When below 70%Pf,give a low-pressure alarming signal.If below
this value when start,then electrically operated mill does not start.(set values above
are all recommended data,detailed data should be determined according to site work
condition.)
（ 7 ） shutdown value of pressure sensor:Set value is 50% work
pressure,i.e.,50%Pf.When below 50%Pf,electrically operated ball mill will delay and
stop turning.It's required to examine the troubles after shutdown or switch the spare
pump.(set values above are all recommended data,detailed data should be determined
according to site work condition.)
（8）High-pressure oil control is mainly inspected by two digimatic oil monitors
installed in oil inlet pipeline of two high-pressure oil chambers on two bearing seats
to monitor the oil-supplying for each bearing .
（ 9 ） When any oil value decreases to intermediate set value,give an
acousto-optical alarming signal,should take measures to eliminate the alarming signal
in site;the mill stops if oil value decreases to set value .
b. set low-pressure oil：
（1）Low-pressure oil control is mainly inspected by two digimatic oil
monitors ,respectively installed near level oil inlet pipeline of two motor bearing
lubricating points where it is convenient to observe so as to monitor oil-supply of each
bearing.
（2）When any oil value decreases to intermediate set value,give an
acousto-optical alarming signal,spare pump is put into use.When the oil gets back to
normal value, eliminate the alarming signal.When any oil value decreases to low set
value,the mill will stop.It's required to examine the troubles after shutdown or switch
the spare pump.
c.See detailed debugging in motor bearing dynamic and static pressure
lubricating station specification.
5.2.7slow drive device

a. Must carefully read the operating manual supplied by FLENDER Company
before debugging.
b. Examine the limit switch and machinery interlock of slow drive. Achieve the
interlock protection between inching drive and motor i.e. if the slow drive runs , the
main motor can not work; If the main motor works ,slow drive can not work.See
application method of specific machinery interlock in relevant specification
requirements.
c. Check whether the slow drive brake is open or not when switched on. If closed,
should check the brake circuit . Once the brake is damaged, slow drive can not start.
d. Check whether the clutch is off and combined smoothly or not,limit switch can
give a normal signal or not.
e. Slowly test run 8 hours with no load when the clutch is off.
f.See details in assembly and operation manual supplied by FLENFDER
Company.
5.3dynamic monitor of pinion temperature
Must always monitor pinion tooth temperature when test run because pinion
tooth temperature is the direct embodiment of endured load and reflects the
installation situation of pinion shaft group.Incorrect pinion group alignment will cause
non-uniform distribution of tooth mesh load and produce higher running temperature
on highest load part. The same temperature of both ends of pinion tooth shows
uniform load distribution and good alignment.the different temperature shows poor
gear group alignment.The part with higher load distribution has higher running
temperature.
The equipment must operates at least 24 hours in order to measure gear mesh
temperature so that the system temperature can be stable.Tooth temperature
distribution can be confirmed by infrared radiation thermometer installed on gear
cover
5.3.1 steps for measuring pinion tooth temperature
fig.11 the position of infrared thermometer
a. Calibrate the thermometer according to the specification before using
infrared thermometer to ensure
measuring temperature correct and
precise.
b. The meshing distance from
infrared thermometer to gear group is
about 1 m,aiming at 3 measuring points
on pinion tooth,see fig.11.Position 1 is
non-driving end of pinion when choose
measuring point.Otherwise,infrared
thermometer should aim at pinion shaft
axis, not aim at pitch line of tooth side.
5.3.2 Judge pinion installation alignment precision from temperature difference
If the temperature difference between Position 1 and Position 3 is 0,it indicates
good pinion shaft alignment.If temperature difference is over 22°C，it indicates that
pinion alignment precision is very low and must be adjusted again.If temperature
difference is within 8°C,it indicates that pinion alignment accords with requirements.
If temperature difference is over 8°C, it's suggested to horizontally or vertically
move pinion bearing seat to adjust.
Note:if there is a bidirectional rotary gear,must supply running data from two
directions ,the gear operates 24 hours respectively in two directions at least to achieve
stable system temperature.
The pinion operates 24 hours at least after adjustment,then check the temperature
difference again.Align the pinion again if necessary.
Note:Adjust bearing seat will cause other parts of the coupling and equipment
invalid.Check and align these parts again after pinion alignment . Apply final load
distribution check on bidirectional gear from two directions.
It's suggested to check gear mesh at timed intervals.
Monitor the temperature at timed intervals when operate for first month from
different loads and different rotary directions (if bidirection)If temperature reading
indicates calibration qualified,then should fix pinion bearing baseplate position
permanently.
5.4 test run of system
After installation and passing through all the inspections, make preparation for
test run of mill. Start the mill (for the first time including many test runs) as per the
operational procedures. The important steps for the test run as follows:
Increase load gradually
Pay full attention to the operation conditions of motor and main bearing
Those steps can guarantee the gear and motor running normally and adjusting
well.
5.4.1 Test run with no load
a. Withdraw slow drive clutch , start slow drive device operating 30min and
watch whether slow drive system operates normally or not.
b.Close the slow drive clutch ,start lubricating system of main bearing ,lubricating
system of reducer ,dynamic pressure and static pressure lubricating station of motor
bearing and startup slow drive motor for slow jigger . Check whether between the
gear and gear guard as well as between the coupling and safe cover interfere each
other or not;Check whether mill rotation direction is correct or not, if there is any
abnormality , stop the mill and repair it.
c. Withdraw the slow drive device and install a dial gauge at the bottom of quill
shaft of feeding end and discharging end . Start the lubricating system of main bearing
(firstly start low-pressure ,then start high-pressure system ); record the floating value
of mill quill shaft ,i.e.,the reading of dial gauge. After that, remove the pointer of dial
gauge and record the relevant parameters of high-pressure and low-pressure
lubricating system (once half an hour is required).
d. Start lubricating system of main bearing.
e. Start lubricating system of reducer.
f. Start dynamic pressure and static pressure lubricating station of motor bearing.
g. Spray lubricating system enters armed state.
h.Start main motor and record the starting current. Observe the main motor, if it
starts normally, continue the next step; if the start-up is abnormal, stop the motor and
repair it.
i.If there is no abnormality, run about 8 hours, and record the correlative
parameters every half an hour as per the data sheet of test run including main bearing
temperature, the temperature at the sealed site of main bearing, pinion bearing
temperature, temperature of motor stator and bearing, relevant parameters of main
motor, relevant parameters of various lubricating station and so on, which should be
all within their respective setting range. When running with no load, the temperature
of mill main bearing should not exceed 50℃. Each driving part runs well, the bolt is
not loose, check the lubrication state of each site. The oil leakage is not allowed in
each sealing site, if there is any abnormality, stop the mill and repair it.
Note：pay attention to monitoring the meshing sound and vibration of gear and
pinion and pinion tooth temperature(may monitor by infrared thermometer),if there is
any abnormality, stop the machine to repair it and adjust it again.
j. Mill stopping sequence: main motor stops →Spray lubricating devices
stops → Lubricating station of the reducer delays stopping →Dynamic pressure and
static pressure lubricating station of motor bearing delays stopping→High pressure
and low pressure oil pump of lubricating station of main bearing delays stopping.
k. All discovered problems should be completely solved after test run with no
load.
5.4.2test run with water
a. After the test run with no load is acceptable, pour water into the mill shell and
carry out test run with water.
b. Firstly carry out test run procedure of slow drive (keep control system in
manual drive state)
（1）Install the dial gauge at the bottom of quill shaft of feed end and discharge
end. Start the high pressure and low pressure lubricating system, and record floating
value of mill quill shaft ,relevant parameters of high pressure and low pressure of
lubrication system.
（2）Pour water into the mill shell until the water overflows from the discharge
end, and record the floating value of quill shaft again, then remove the dial gauge.
（3）Start reducer lubricating station , high pressure and low pressure lubricating
station of motor bearing.
（4）Close the slow drive clutch; start the slow drive motor; Rotate the mill
about 2~5 rounds by slow drive device.
（5）Check the state of every part; especially check whether there is any water
leakage from shell or not. If there is any abnormality, should repair it immediately. If
there is no any abnormality, stop the slow drive and withdraw the slow drive clutch.
c. test run with water of main motor
（1）Start the lubricating system of main bearing and inject water into the mill
shell continuously until the water flows out of mill discharge end.
（2）Start dynamic pressure and static pressure lubricating station of motor
bearing and lubricating station of reducer.
（3）Spray lubricating system enters armed state.
（4）Start the main motor and record the starting current. Observe the main
motor, if it starts normally, continue the next step; if the start-up is abnormal, stop the
motor and repair it in time.
（5）Test run with water about 4 hours and check whether there is any water
leakage in each sealing site, whether the pinion and gear can work smoothly and
normally (well-distributed sound, and no periodical impact noise). The temperature of
each bearing should be stable and not over the alarming value. If there is something
abnormal, stop the machine and repair it. Record the relevant parameters every half an
hour as per data sheet of test run .
（6）stopping sequence: water supply stops → main motor stops →spray
lubricating devices stop →lubricating station of reducer delays stopping→ Dynamic
pressure and static pressure lubricating station of motor bearing delays stopping →
high pressure and low pressure oil pump of lubricating station delays stopping.
h. All discovered problems should be completely solved after test run with water
5.4.3 test run with 30% load
a. Add 30% steel balls and materials as per the indication of assembly
drawing after finishing the test run with load and dealing with problems (The filling
rate of steel balls and materials should be confirmed as per process requirements or
demands.Assembly drawing only indicates the design value. )
It is not allowed to run the mill without material, because it would lead to
fast wear and tear of mill liners and steal balls when there are no any materials only
with steal balls.
b. Install the dial gauge at the bottom of quill shaft of feed end and discharge end.
c. It's Suggested that the control system should be place in the automatic control
position and start all kinds of lubricating system (Start the high pressure and low
pressure system according to the regular program). Record relevant parameters of
high pressure and low pressure system of lubricating system and floating value of mill
quill shaft. After that, remove the dial gauge.
d. As per the procedures of test run with water, carry out test run with load at least
8 hours until the parameters such as temperature become stable and record the
opearting parameter per hour.
e. Test run with load should meet the following requirements: working smoothly,
no violent periodic vibration; The current value of main motor should be within the
permissible range;There is no leakage of material from all the bolts of each liner . The
bolts must be tightened immediately if there is any leakage. Check whether the bolts
in each site are loose , break or fallen off or not .The temperature of the main bearing
is less than 60℃, the temperature of return oil is less than 50℃.
5.4.4 test run with 60% load
After the test run with 30% load is successful, carry on the test run with 60% load
as per the same procedure (The definition of 60% load is the same as the definition of
30% load in 5.33.The similar definition is also applied to the 90% load in
5.35 ) ,operate at least 24 hours until the parameters ,such as temperature are
stable.Record the operating parameters per hour.
5.4.5 Running with load of 90%

a. If commissioning with load of 60% is successful suggests to make further
with another 30% of ball and materials to reach load of 90% commissioning with
remaining 10% which shall be fed by feeding unit as per actual requirement and
according to the actual running situation make calibration of mill to reach
optimization of power and production.
b. Commissioning sequence is same with load of 30%.
c. Commissioning with load of 90% is at least 72 hours till the temperature and
other parameters is stable and made record of parameters per hour.
d. During running with load the record must be made at least one hour for the
temperature of pinion on two sides which is measured by infrared pyrometer. Mill
must be stopped and make adjustment of pinions if the pinion temperature difference
of two sides is over 22℃ and it's limit is within 8℃ for the pinion temperature
difference of two sides ( with load of 100%).
e. If bearing temperature is unstable after 5 hours running then the mill must be
stopped for checking.
f. Commissioning with load would probably make loose of some fastening then
after that it is necessary to check and tighten all the foundation bolt and shell
connecting bolt including trunnion liner fastening.
Notice: All commissioning data log refer to appendix Ⅱ.
6 Normal operation and usage

6.1 Start and stop
6.1.1 Starting sequence
Main bearing static pressure lubrication station→gear box lubrication station→
motor bearing static and dynamic pressure lubrication station→spray lubrication
system under state of stand by→ main motor→ feeding unit
Usually it is not allowed to start the mill 2 times within 1 hour.
6.1.2 Stopping sequence

Stopping feeding unit→ stopping main motor→ stopping spray lubrication
system→ delayed stopping gear box lubrication station →delayed stopping motor
bearing static and dynamic pressure lubrication station→delayed stopping static
pressure lubrication station after mill stopping and then manually open static pressure
pump for 2 minutes in every 30 minutes till shell temperature reaches to ambient
temperature.
6.1.3 Short term stopping

(1) Wash mill with water till the material coming out are tolerably clean and
running time is within 2 or 3 minutes otherwise mill liner would be damaged and
worn by empty running too long.
(2) Stopping as per sequence.
(3) Starts lubrication station to make oil circulation 10 minutes once a day after
stopping of mill to ensure that oil pump is available and meanwhile observe the
pressure gauge.
(4) After starting of lubrication station drive in inch the mil to 90°to make mill
stopping in different positions.
6.1.4 Long term stopping

(1) Wash mill with water till the slurry coming out are very lucid and running
time is within 5 to 10 minutes otherwise mill liner would be damaged and worn by
empty running too long and balls shall be removed out of mill to avoid permanent
deformation of shell.
(2) Starts lubrication station to rise up the main bearing and by bracket and
hydraulic jack raise up the mill to make separation of trunnion and bearing bush with
bolster to support the shell.
(3) To cut off power for mill and auxiliary equipment.
(4) To drain off the oil in bearing choke and keep it in sealing oil tank if it is
clean.
(5) To drain off water in cooling pipe to avoid damage by frozen.
(6) To keep dust out of lubrication station, motor, air clutch and inch drive but
be aware of that too air tight surrounding would lead to water condensation which
shall be avoided by using heater or heating bulb.
(7) To place spray lubrication pump into light and anti indurative oil and starts it
till the oil sprays out to ensure that oil induration and clogging in pipe and nozzle
would not happen.
(8) To put desiccant in control and electric panel to avoid water condensation.
Notice : Whatever short term or long term stopping it is good opportunity to make
overhauling and maintenance.
6.1.5 Breakdown
Breakdown stopping as normal stopping sequence and possible failure as
following:
(1) Feeding unit abnormality
(2) Vibration booming up as main motor, main bearing, pinion and gear box etc.
(3) Meshing abnormality of gear and pinion with strange noise.
(4) Bolt loosen, broken or falling out of liner or shell.
(5) Foundation bolt is loosen in main bearing, drive unit and main motor.
(6) Abnormal behaviour in main bearing lubrication station, gear box lubrication
station, motor bearing lubrication station and spray lubrication system and stand by
system is not available.
(7) Temperature booming up in main bearing, pinion bearing, motor bearing and
stator bearing and parameters of main motor is abnormal.
(8) Material leakage in feeding and discharging unit and shell also.
(9) Electric control system failure.
To stop feeding materials right after breakdown and cut off power for motor and
other power supply immediately to carry out trouble shooting and hanging out the
warning plate. Mill is not allowed starting again without permission of authorized
person.
6.1.6 Emergency stop

Emergency stop and long term stop are all different from normal stopping
sequence. Mill stop caused by power supply failure is different to mill breakdown
stopping, for example temperature somewhere in mill is too high. Operator must be
concerning with how long of the stopping shall be and characteristics of mill product
and other relevant factors and what is time necessary for proper action before starting
mill again.
Dealing with emergency stop shall be same with normal stopping. If emergency
stop is due to problem of mill itself so it is not allowed to start again before proper
action is taken to solve the problem.
6.1.7 Starting again

(1) If mill stops over 1 hour it is possible for material to solidified so that before
starting again the mill shall be inching about 2 circles with adding of water. Every
system will varied with working condition and material solidification time. By
experience the requirement of 1 hour could be modified but result of which shall not
be over material solidification time.
(2) Inching drive shall be watched out with all the interlock programs and after
that starts the mill as starting sequence.
6.2 Regular running

Maintaining of mill load and monitoring of material feeding can help improving
of grinding efficiency. Periodic monitoring of material feeding, mineral hardness,
actual power rate, mill load ( grinding agent weight) and view of ball volume ( take
out ball of mill and views it) as well as determination of steel ball losing for ground
material and by all of above mentioned factors to make ball feeding plan ( feeding
quantity and interval) and make modification of the plan all the time.
Even and uniform material feeding is one of most important condition for high
mill production therefore operator must make proper material feeding quantity to
reach high and stable production. Water content in material will obviously influence
material motion in shell and bring down the grinding capability so in order to keep a
throughput of material the ball diameter could be bigger to decrees the filling ratio.
If other terms are same the feeding quantity determines material resident time in
mill. If other parameters are same the more quantity of material feeding and more
coarse of product grinding, so vice versa.
Grinding agent filling ratio can seriously influence the grain size of product that
is to say more grinding agent and more finer of grain otherwise more coarse of grain.
In actual practice filling ratio is regarded as important way to regulate the mill
production for different requirement of grinding capability of mill.
6.1.5 Operator must abide to following items in regular running:

(1) It is not allowed to long run without material to avoid damage of liner and
wearing of ball.
(2) Operator must keep even and uniform of material feeding.
(3) Periodically check wearing of liner and ball to make replacement of it if any
worn or broken to be found. Any bolt loosen or broken also shall be replaced or
tightened to avoid wearing out of shell.
(4) Check all the lubrication spot all the time ( pinion bearing and main bearing
rubber sealing ring etc) to ensure there are enough and clean oil ( grease). Returning
oil filter on oil station shall be cleaned for every 3 months according to the filter
contamination and make inspection of oil quality for 6 months and replacement of oil
if necessary.
(5) Always check engagement of gear and pinion and also fastening of
connecting bolt.
(6) Adding quantity and grade of ball are subject to ground material and
requirement of grain size. Compensation of ball shall be at opportune moment to keep
best status of ball in mill and compensation size of ball shall be maximum in the first
batch (smaller balls are also allowed in case of that the ball compensation has not
been taken for long time).
(7) Protective guard for mill shall be safe and reliable and warning plate shall be
hang up in hazardous zone.
(8) Detachment and maintenance are not allowed whenever mill is running.
Maintenance inside shell ought to be watched and monitored for safety's sake. While
mill is running pay special attention to main shaft to avoid being scraped by bolt on
end wall.
(9) Only LV illumination equipment is allowable for inspection and maintenance
of mill. Earthing provision shall be taken for welding on mill to avoid electric burning
on gear face and shaft bush.
(10) According to allowable bearing temperature to determine temperature on
main bearing and all the oil station cooling water as well as water quantity actually
with proper modification.
(11) To establish periodic inspection plan to perform maintenance.
(12) To perform thorough maintenance of mill and cleaning of surrounding
without any finding out of water leakage, slurry leakage, oil smear, bolt loose and
promiscuous articles.
7 Maintenance and repairing

Mill maintenance shall be a very important every day work in association with
mill operation and repairing therefore require someone dedicated to this job which
includes inspection of mill lubrication and grease sealing, shell, main bearing and
drive unit etc.
7.1 Mill lubrication and grease sealing

7.1.1 Main bearing and motor bearing lubrication are very important for mill
life and efficiency therefore lubrication oil (grease) must be clean and in sealing with
proper filling quantity. Oil must be filtered prior to filling into the oil station.
7.1.2 Oil replacement frequency

All the outer lubrication system and main bearing require periodic cleaning and
replacement of oil. Oil replacement period is 30 days for first time and after that 12
months will do actually with consideration of local ambient condition. Most of oil
producer will be available for oil testing. Economical oil replacement will be
favorable.
Make cleaning of oil chamber inner wall prior to oil replacement and oil
previously heating to 20℃ if replacement and adding of oil in winter. Oil deteriorated
or contaminated are not allowed to use.
7.1.3 Through oil station the lubrication oil come to main bearing and pinion. Oil
requires that good anti friction under extreme pressure, good viscosity and warmness,
good oxidation and thermo stability, good anti emulsification, good anti rusty and
erosion, and low friction factor. Suggests following oil:
Viscosity : N220
Oil brand: MOBILGEA 630 or MOBILSHC 630
GREATWALL YP4406 ( VG220) or GREATWALL L-CKD (VG220)
7.1.4 Gear and pinion lubrication

Using of discontinuous spray lubrication which requires lubrication agent sticking
firmly on gear face as mill is running. The formation of oil film on gear shall not be
squeezed out in interval of oil filling and which film must be anti pressure and anti
friction. Oil deposition and oil induration are not allowed on gear root.
Oil consumption is 11-40 L every week which is subject to gear size and oil
quality. Experience tells us spray of short interval with small oil quantity is better that
long interval with more oil quantity. Suggests spray interval to be less than 20 minutes
( less than 5 minutes for grease spray) and spray time is equivalent to 1 circle of gear
( it is 5 seconds for this mill).
Common lubrication agent type: Pitch group lubrication agent, oil and grease.
Brief introduction:
(1) Major ingredient in pitch group lubrication agent comes from petroleum
residue heavy compound and with addition of extreme pressure additive and diluent
which agent achieves high viscosity and good load capability and adherence therefore
it is regarded as reliable and long used product. Actually it is used with diluent which
prevents contamination of nuzzle and deposition on tooth root and gear guard but in
consideration of environment protection it is used less gradually. Suggests
ENVIROLUBE of mid load open gear oil or Mobiltac 325 NC for surrounding
temperature of less than 10℃ and ENVIROLUBE of heavy load open gear oil or
Mobiltac 375 NC for over 10℃.
Open gear lubrication for example of Brugarolas S.A. Of Spanish:

Temp. On Power ≤1500KW Power ＞1500KW
gear face
Primer oil G.Beslux Crown H-1/R G.Beslux Crown H-1/R
≤60℃ Break in oil G.Beslux Crown H-00/R G.Beslux Crown H-00/R
Running oil (a)G.Beslux Crown H-3000 (a)G.Beslux Crown Heavy Mill
(b)G.Beslux Crown M-Fluid (b)G.Beslux Crown H-3000
Primer oil G.Beslux Crown H-1/R G.Beslux Crown H-1/R
＞60℃ Running oil (c)G.Beslux Crown Heavy Mill Plus
(d)G.Beslux Crown Heavy Mill
Notice: There are "a" or "b" in the form out of which "b" would be chosen on the occasion of
less power, less temperature on gear face or less ambient temperature.
Running requirement:
1. Break in lubrication: totally 350 hours divided into stages of 30%, 55%, 80%, 95% and
100% of load increasing gradually; spray interval 3-5 minutes with quantity of 8-12 g / ( cm tooth
width hour); setting of post blowing time to 3-5 seconds;
2. Running lubrication: spray interval 5-8 minutes with quantity of 3-6 g / ( cm tooth width
hour); setting of post blowing time to 3-5 seconds;
3. Spray unit: always check spray unit to avoid gear damage caused by spray unit's failure.
(2) Oil is mineral oil or synthetic oil with additives of extreme pressure agent
some of which oil play the leading role in lubrication technology. It features viscosity
varied with temperature and working pressure and oil film formed on gear and pinion
face. In case of obtaining proper atomizing effect it is required to provide temperature
controlling and heater. Probably diluent shall be added for pumping. Suggests using of
ENVIROLUBE of open gear lubrication agent or MOBILGEAR SHC 22 M or
MOBILGEAR SHC 46M ( using of 46M need heating ).
(3) Grease is mixture of densifier and mineral oil or synthetic oil with
characteristic of plasticity and is often added with solid lubrication agent and extreme
pressure additive by application of which gear and pinion are allowed to work under
marginal lubrication condition which means gear meshing with pinion almost directly
with very thin oil film. In addition to extreme pressure additive the solid lubrication
agent is also added like graphite all of which will ensure the minimum damage on
tooth under marginal lubrication condition.
7.1.5 The sealing grease is applied to pinion shafts and main bearing in mill and
adding of sealing grease shall be under requirement of quantity and interval as well as
cleanness of oil and pipe. Details refer to attached documents.
7.1.6 Always checks lubrication and cooling system and ensures every part in
good working condition.
7.2 Shell
7.2.1 After mill running 1-3 weeks under full load checks all the bolt's torque for
rotary parts and tightens the bolts then 6 months later checks again after that at
interval of 6 moths carry out random inspection ( bolts picked up on every flange ) if
these bolts are all loosen so all the bolts shall be tightened.
7.2.2 Newly erected liner is subject to loose so it needs be checked all the time.
7.2.3 Regular measurement and record for liner must be made to establish the
consumption rate to keep adequate spare part. Wash out slurry to replace the liner and
check abrasion mark and other abrasion to ensure the liner in good working condition
otherwise replace it.
7.2.4 Liner can be replaced by manipulator and liner bolt punch which are
supplied with mill. Liner bolt punch is used to remove liner from shell and
manipulator is used to take old liner out of shell and put new liner into the place.
Manipulator and liner bolt punch can greatly relieve physical labour and improve the
liner replacement efficiency but it's usage, maintenance and repairing shall be strictly
under relevant requirement and it's user shall be trained.
7.3 Main bearing

Clean and proper lubrication can save much repairing work for main bearing and
preventative maintenance like greasing constantly on main bearing seal is required.
Main bearing's life is very uncertain even short time shortage of lubrication can
lead to bearing failure. Proper maintenance and correct lubrication system operation
will make it's life much longer. Periodically checks grease and abrasion situation of
bearing seal and make replacement of it if deterioration and damage were found on
seal.
7.4 Transmission unit
Under full load the pinion temperature shall be checked by infrared pyrometer for
first 12 hours and tooth surface by flash meter; following 2 weeks the checking shall
be performed once a shift and after that once a week. If temperature difference is over
8℃ suggests readjusting pinion and stops the mill immediately if any danger are
found on tooth face. Meanwhile make adjustment of oil quantity on gear and pinion
by view measurement.
Watch out carefully the temperature and vibration values measured on pinion
bearing and make elimination of faults if the values are over the setting values.
7.5 Others
Wearing out will be found on feeding and discharging unit so that it must be
checked and replacement must be made if it is necessary.
Lubrication system includes all the assemblies used for maintenance of main
bearing. Adding of proper grease shall be carried out periodically for HP and LP pump.
Differential pressure gauge on filter indicates the filth of the filter so that replacement
of it shall be made if it is necessary.
Maintenance and repairing on gear box, main motor, oil station, inch drive and
electric system refer to separate manual.
Mill running of 30 to 60 days we suggests special attention shall be paid to

tightness of bolt. Foundation setting and grouting may be made readjustment if
necessary. Suggests to make record of every details including what happened
henceforward to keep necessary information for later diagnosis and remedies.
8 Maintenance, often failure and troubleshooting

8.1 Control philosophy
Surveillance and control system safety interlock protection are provided to
monitor main motor, spray on gear and oil station and to sent alarm or stopping signal
to control system.
The surveillance and interlock system provided by CITIC HIC as below:
8.1.1 Main motor system
Main motor system includes main motor and HV starting panel. Main motor
consists of stator and bearing temperature transmitter which part is used to monitor
working temperature and sent alarming and stopping signals to control system and
setting values of which signal refer to motor manual provided by SHANGHAI
MOTOR.
8.1.2 Spray lubrication system

Spray lubrication system involves counting monitor to sent fault signal which
may be caused by inadequate air pressure to pump or low oil level in tank or valve
problem.
8.1.3 Main bearing and lubrication system

End thermistor on main bearing are used to monitor trunnion surface temperature
and sent alarming and stopping signals.
Surveillance system setting value
Main bearing platinum thermistor 60℃ alarming
Main bearing platinum thermistor 65℃ stopping
Continuous monitoring on tank temperature by platinum thermistor and on oil
level by level sensor to give alarm for low oil level and alarming signal gives starting
order. Filter with differential pressure switch to give blocking alarm signal if pressure
reach higher.
8.1.4 Drive system

Drive system involves gear and pinion, main motor, pneumatic clutch, inch drive
etc. Among that alarming temperature for pinion bearing is 80℃ and stopping
temperature is 85 ℃. Differential temperature on pinion face is within 8℃. Other
technical specification like vibration of pinion bearing, lubrication and vibration of
gear box, lubrication and vibration of main motor refer to manuals respectively.
8.2 Check and repairing job

Check and repairing in time are very important for mill running successfully so
that check and repairing plan shall be established including periodic plan and
preventative plan herein recommendation is given.
8.2.1 Liner
Liner bolt is subject to loose in running of mill particularly the new liner and
loosened bolt would scrape the hole more large even falling out of the hole so that it is
required to stop the mill and tighten the bolt or make repairing of it if necessary.
Regular measurement and record for liner must be made to establish the
consumption rate to keep adequate spare part. Wash out slurry to replace the liner and
check abrasion mark and other abrasion to ensure the liner in good working condition
otherwise replace it.
8.2.2 Main bearing

Clean and proper lubrication can save much repairing work for trunnion bearing.
Main bearing's life is very uncertain even short time shortage of lubrication can
lead to bearing failure. Proper maintenance and correct lubrication system operation
will make it's life much longer.
8.2.3 Main bearing oil station
Lubrication system includes all the assemblies used for maintenance of main
bearing. Adding of proper grease shall be carried out periodically for HP and LP pump.
Differential pressure gauge on filter indicates the filth of the filter so that replacement
or cleaning of it shall be made if it gives alarming. Details refer to manuals.
8.2.4 Transmission system

Transmission system involves gear and two group of pinion, gear housing and
lubrication unit, sealing, monitor for temperature and vibration, main motor,
pneumatic clutch and auxiliaries like lubrication and air pipe etc. Good lubrication
and adequate monitoring can greatly improve the performance of transmission system
and promote it's life therefore it is required to check gear and pinion periodically to
solve the problem right after anything to be found.
8.2.5 Tightening bolt

Bolt tightening is very important particularly for bolt between shells, shell and
end wall, gears, gear and end wall as well as foundation bolt also, bolt failure or
loosing on these sections will bring on equipment damage even disastrous
consequence on equipment or human being so it requires to check periodically and
make repairing of it if anything like bolt failure or loosing are found.
8.3 Matters for attention during troubleshooting

Preparatory work for troubleshooting must be done. In this way, troubleshooting
schedule can be finished on time or in advance. Tools to be used in troubleshooting
shall be prepared firstly, and then to prepare required material used in troubleshooting,
such as back block of simplified form, end back block and bolts based on
troubleshooting schedule. The following points need to be attention during
troubleshooting:
Both sides of mil should be without person when grinding element is cleared.
Prior to troubleshooting you must inform electrician on duty to cut power and to
hang troubleshooting warning plate. Without admission from assigned person nobody
can start-up motor.
Troubleshooting person must wear safety helmet.
Mill only can be moved when there is nobody or tool in mill after
troubleshooting.
Workers who operate robot manipulator of back block and bolt forcer must
receive training. For the operating post which need person who must have
certification you must arrange person who is qualified.
8.4 Troubleshooting schedule
Troubleshooting for mill is divided into two parts: maintenance inspection and
preventive maintenance.
Troubleshooting schedule of mill

Maintenance items of maintenance Time interval State of mill
position
Main bearing Sealing Once a week Running or stop
Temperature sensor Once a month Running
Surface of bearing worn Once a year Stop
Lubrication system Oil level in tank Once a week Running
Instrumentation Once a week Running
Shell and bull gear Bull gear and gear shaft Once a week Running
Follower Once a month Running or stop
Gar shaft lubrication Seal and lubrication Once a month Running or stop
State of motor Once a day Running
Driving system State of reducer Once a day Running
State of load Once a day Running
Gear guard and Spraying state Once a month Stop
spraying system Spraying instrumentation and Once a week Running
pipeline
Grease leaking Once a week Running
Calibration pressure gauge Once a week Running
Grease drum Once a week Running or stop
Feed side Feed sealing inspection Once a week Running
Inspect inner lining of feed Once a month Stop
sleeve shaft
Discharge side Inspect inner lining of Once a month Stop
discharge sleeve shaft
Inspect wear-out of shaft Once a month Stop
screen
Preventive maintenance inspection plan
Maintenance Items of maintenance Time interval State of mill
position
Main bearing Sealing change According to need Stop
Shoe changing According to need Stop
Clean bearing support Once a year Stop
Lubrication Change oil filter According to need, pressure difference
system shown that oil filter is blocked or not
Low-pressure pump lubrication Once every 4 months Stop
High-pressure pump lubrication Once every 4 months Stop
Clean oil tank, flush pipeline Once a year Stop
and change oil product
Cylindrical Tighten connecting piece Test run shall accord to requirement. Stop
shell and bull When mill running for 1-3 weeks first
gear tighten shall be performed, retighten shall
be performed 6 months later. Afterwards,
tighten shall be performed at least one
year.
Follower changing According to wearing or outwear require Stop
Clean and inspect frank of Once a year Stop
tooth
Pinion and Bearing lubrication Once a month Run or Stop
drive shaft Inspection frank of tooth Once a year Stop
group Inspection of bearing Once a year Stop
Main motor lubrication for bearing of motor Once every 6 months Stop
Gear guard and Maintenance for instrument of Once a week Stop
spraying system gas source
Change collector of waste oil Once every 2 months Run or Stop
Clear grease of gear guard Once a year Stop
Flush and clear of spraying Once a year Stop
lubrication system
Feed side Feed sealing changing According to wearing or outwear require Stop
Inspect inner lining of feed According to wearing or outwear require Stop
sleeve shaft
Change follower of feed device According to wearing or outwear require Stop
Discharge side Change inner lining of According to wearing or outwear require Stop
discharge sleeve shaft
Change shaft screen According to wearing or outwear require Stop
Change discharge chute plate According to wearing or outwear require Stop
8.5 Troubleshooting of main bearing
Prior to troubleshooting of main bearing, manual and drawing concerned to main
bearing must be studied carefully. Main bearing is monitored by instrument. If you
want to bearing and mill continuous running in good condition parts of bearing must
be inspected regularly.
8.5.1 Regular inspection for instruments
Main bearing is provided with temperature sensor to measure temperature of
bearing. If temperature rising is above specified value for stopping, it shows that there
is something wrong with lubrication or alignment. Regular inspection of running
temperature can provide running reference in normal condition, and provide reference
caution.
If running temperature is rising, the following possibility should be checked.
Whether temperature and oil supply is right. Temperature of lubrication system
indicates oil temperature. Flow meter which is behind of oil allotter will monitor oil
mass provided to bearing. Lubrication system is normal but temperature is high,
alignment and clearance have to be checked. Alignment can be checked through
clearance gauge. Mill has to stop for a certain time prior to clearance gauge inserting
into, and let oil come out.
8.5.2 Regular inspection for equipment
Bearing liner shall be protected from polluted of dirty thing. Liner shall be
checked once a month to whether condition of it is ok or not, if it has worn away
replace it in time.
Liner can be replaced using standard tools such as wrench and clearance gauge.
Parts can be manual handling without gear wheel lifting. Refer to assembly drawing
of main bearing. If you want change bearing seal worn, sealing apron must be
dismantled (if required, pipe line of grease seal shall be dismantled too), and then
loose bearing cap and lift about 600mm, let joint of seamless pipe with grease come
out of rubber seal ring, in this way, it will not damaged when rubber seal ring
removing. Dismantle seal ring and sealing clamp which are outworn; clean area which
touched by old grease. Measure new rubber sealing ring and cut required length, and
hole ofΦ10 which is correspond to joint of seamless pipe shall be burned out. Place
sealing ring and clamp on right position and then lay down bearing cap, insert
seamless pipe joint into sealing ring which shall be tightened prior to inserting. In this
way, sleeve shaft can be protecting from touch. Finally, tighten bearing cap, and make
sure that sealing ring position is well under the aid of adjust bolts, Using clearance
gauge of 0.07mm to check. Radial contact shall be uniform when out of repressing
load.
Check whether pipe line of grease seal is unblocked or not and whether is leaking
or not.
Main bearing worn shall be checked once a year. And check surface of bearing to
see whether there is abnormal outworn and heat fading or not. Outworn brasses shall
be changed prior to sleeve shaft or watt surface damaged.
Mill must be lift 40-60mm when change brasses. Dismantle spacing board,
high-pressure oil pipe and draw out old brasses from bearing support. Prior to sliding
into bearing of mill grease shall be applied to new brasses.
Warning: brass only can be removed from bearing after high-pressure oil
pipe line dismantled.
Dirt removing and deposit clearing for bearing shall be performed at least once a
year. If you want to clean bearing, first you have to dismantle oil drain plug of bearing
support to discharge oil, and then dismantle inspection plate to clean bearing support.
When cleaning work finished install inspection plate and oil drain plug.
8.6 maintenance of lubrication system
Lubrication system of main bearing includes all parts which maintain full running
of main bearing, and running circuit of mill with suitable linkage.
Motor, reducer and slow acting lubrication system also need to check. Detail
information is in separate installation and operation manual.
8.7 Maintenance of drive system of mill
Drive system of mill consists of main motor, reducer, crowded pinion shaft and
slow-speed drive unit. Pinion engages with ring gear which is on the flange of mill to
drive mill.
8.7.1 Drive group of pinion shaft
Bearing of crowded pinion shaft is split-flow lubricated through low-pressure oil
of lubrication station for main bearing, is oil lubrication. You should pay attention for
back flow of oil flow prevent from leaking. It is better to connect oil return pipe
respectively on both ends of each bearing.
Gear shaft assembly dismantling: dismantle slow-speed coupling, record exact
position of bearing support prior to loosing bolts of bearing support. Make two
bearing supports get away from girth gear under the help of adjusting screws.
Dismantle the two bearing cap, using crane to carefully lift up gear shaft assembly.
The installation of spare pinion shaft: install spare pinion shaft which is clean
into bearing support using above mentioned tools. And then carefully install bearing
and seal in position. Locating ring of bearing shall be installed to correct position,
after that, install bearing cap. Cap and support have match marks, so cannot
interchange. Bearing support can be carry back to original position under help of
terminal strand, install bolts and tighten to specified torque rating.
Pinion and girth gear can be checked and adjusted based on concerned part in
installation and operation manual. When adjust pinion coupling shall be installed
again. If you want to check adjusting condition, bearing support shall be carried by
terminal stand. Check pre-tightens moment of cap and support. Adjusting condition
for gear and temperature for bearing shall be monitored carefully after started up, at
least 7 days.
Change of pinion shaft and spherical roller bearing: find out matched bearing
number from assembly drawing for bearing of pinion shaft. Radical clearance of used
bearing shall be ensured.
Dismantle outworn bearing: if inside bearing needs to be changed, half-coupling
must be removed. Half-coupling is shrinkage fitted in normal condition. So if you
want dismantle it suitable tools shall be used. If surface of shaft damaged during
dismantling, you had better to use oil stone to polish it. Diameter of shaft can not be
diminished.
Preparatory work for new bearing installing: prior to immediately installing,
original package of bearing must be maintained. Coating of bearing is not allowed to
remove. If package damaged the bearing will get dirty, must be cleaned using
kerosene. Hold up pinion shaft and install bearing to shaft in shrinkage fit method,
and then install sealing ring.
Heat bearing in clean oil which temperature is between 76°C－121°C for 15
minutes. Put support under bearing and keep away from heat source, in this way,
overheating can be prevented. If the bearing is too hot, hardness of it will reduce.
8.7.2 slow-speed drive device
Slow-speed drive is connected to another end of high-speed shaft of reducer.
Slow-speed drive consists of motor, coupling, reducer, clutch and brake. It can be
used to drive mill during installing and maintenance, it can let mill stop to required
position and receive install and maintenance.
Warning: mill must be kept in balance, when person enter into slow disk must be
braked. When liner changing, mill installing and dismantling must based on plan in
symmetric method. Dismantling and installing work for liner must be performed on
axial line. And keep mill balance and stillness. If you performed work based on the
above mentioned method, even if slow-speed brake is failure, moving of mill is very
little.
Lubrication system of slow-speed drive gear is thoroughly lubricated by oil-bath.
Maintenance inspection includes using oil gauge which is installed on case of reducer
to inspect oil level. Inspection only can be performed when reducer stops oil level. Oil
level shall be inspected prior to slow-speed start up at a time.
8.7.3 Maintenance of gear guard
Drive gear guard can provide 360° protection, can prevent person from touch
rotating gear. It also can protect gear from pollution. Gear guard, including many parts,
which is provided with mist lubrication and oil outlet in the button of gear guard
which is open type can discharge spend oil. Oil discharge outlet which is open type
can prevent lubricant from accumulation. Mist lubrication system can provide
automatic lubrication for bull gear.
Repair of gear guard is very few during normal operation. Feature of gear guard
is that open type discharge oil outlet to discharge spent oil. Oil outlet needs to be
checked regularly to protect from clogged. Gear guard shall be dismantled once a year
to clear grease in inner surface. Gear and pinion shall be cleaned during dismantling,
and to check damage and outworn condition of tooth.
Collecting drum which is under oil discharge outlet shall be cleared regularly,
once every two months. Container clearing time maybe more short depend on quantity
of lubricant and interval setting.
8.7.4 Maintenance of mist lubrication system
Maintenance focus for mist lubrication system is to keep unblocked from oil
drum to nozzle. Pump is driven by compressed air. Filter which is on gas path can
prevent steam entering into pump. Water collecting vessel of filter must be discharged
through drainage facility, at least once a week. Enough clean lubricant must be added
to gas path so as to ensure normal operation. Filter screen on oil supply line shall be
cleared up at least once a month.
Pump used for whole system and solution agent shall be cleaned at least once a
year. In order to perform this work spray gun shall be dismantled.
8.7.5 Maintenance of coupling, clutch and brake
In normal working condition coupling don’t need special attention. But brake will
become more important when equipment maintenance during machine stop. Every
time you use slow-speed drive you should check outworn condition of brake
especially fraction plate. Points for attention shall refer to concerned document
provided by FLENDER.
8.8 Maintenance of charge-and-discharge side device
8.8.1 Feed device
Feed device includes chute and feed lining. Feed chute can transfer material from
feed system of user to mill. Inner lining of feed can protect sleeve shaft from wear
out.
Alignment for feed chute and inner lining of sleeve shaft shall be checked
regularly.
Inner lining of sleeve shaft must be checked regularly, and it shall be changed
prior to fully worn out.
8.8.2 Discharge device
Discharge device includes of discharge door with rubber lining, horn mouth with
rubber lining and drum screen. Inner lining of sleeve shaft can prevent sleeve shaft
from contact to product and grinding medium. Inner rubber lining of discharge door is
provided with reclaim screw drum screen which can guide material on and on without
stop, and pour out product ground from mill.
Outworn condition for rubber lining of discharge door shall be checked regularly,
it shall be changed in time before fully outworn. Screen plate and screen opening of
drum screen shall be checked regularly. Drum screen shall be changed before it effect
on equipment of lower stage.
Horn mouth and sleeve shaft also need to be checked regularly. Fastened bolt for
discharge horn mouth and drum screen shall be checked regularly.
8.9 Treatment for common fault

Feedback signal of monitor system during mill running: high temperature, big
vibration or system interlock stop grinding has shown that parts are failure or
misalignment. The following is common trouble and solution.
Parts Fault displaying Possible reason Corrective measure
Main Temperature is high Alignment for bearing don’t Check bearing support and
bearing perform alignment of bearing shoulder
Small oil flow Correct oil flow
Sleeve shaft or brasses is Repair sleeve shaft and surface of
outworn brasses or change shoe.
Oil temperature is high Cooling is not enough Check temperature of oil outlet of
lubrication station and cooler
including control valve
Oil temperature is high Unfit to heat Check heating and control device
Oil flow is small Oil pump is failure Check pump
Oil pipe is leaking or Check pipeline
Lubrication plugged
system Oil filter is clogged Check oil filter, if necessary you
should change it.
Safety valve of oil pump is Check safety valve to see whether it
failure is right or not.
Flow meter is failure Check scale of flow meter and
running condition
Oil pressure is Pipeline is leaking Check pipe line
low(compare with
right oil pressure )
Bull gear Temperature/noise for Gear is misalignment Check alignment of gear, if
device frank of tooth is high, necessary, you should perform it
abnormal worn out again.
Lubrication is not enough Check lubrication pipeline and
nozzle
Pinion Temperature of Bearing is failure Check bearing
bearing bearing is high or Gear is misalignment Check alignment, if necessary you
assembly vibration should align again.
Load of gear shaft is not Adjust load of pinion
uniform
Foundation bolt is loose Check foundation bolt
Reducer Temperature of Bearing is failure Check bearing
bearing is high and Foundation bolt is loose Check foundation bolt
vibration Lubrication is not enough Check lubrication to see whether it
is right or not
Coupling Heating or big noise Installation is misalignment Check alignment, if necessary you
should align it.
Main motor Temperature of motor Bearing is failure Check bearing
is high or vibration Lubrication is not enough Check lubrication to see whether it
is right or not
Coupling is misalignment Check alignment of coupling
Foundation bolt is loose Check foundation bolt
Feed device Material leaking is Installation of feed device is Check position and alignment
serious at feed side not right or without
alignment
Installation of feed sealing is Check installing condition of
not right sealing
Feed bush is outworn Change feed bush, bush shall be
checked regularly, and change it
before sleeve shaft exposed.
Discharge Large particle material Screen opening of shaft Check and repair screen plate, if
device exists in ore pulp screen is damaged or failure. necessary you should change it.
9 Addition table
9.1Consumption and replacement material for tests and operation start-up list
№ NAME CODE QUANTITY SITE
1 BALLS Max:332t
2 Resistamce Viscosity 800L E593 电机轴承动静压润滑站 46 号汽轮机油

Hydraulic Oil 46 mm2/s L-TSA
3 Resistamce Viscosity 3000L E691 HYDROSTATIC BEARING
Hydraulic Oil 220 mm2/s HYDRAULIC STATION
4 VG320 800+185L OWTD09 V.8 减速器润滑站
5 VG320 130 REDUCER OF INCHING
6
7 Viscosity 200L GEAR LUBE SYSTEM
680 mm2/s
8 Viscosity 200L SEAL LUBRICATION SYSTEM
680 mm2/s
9 HF102 32～46 mm2/s 60L HYDRAULIC JACKING SYSTEM
10 HF101 32～46 mm2/s 8L (自带液压油)
HYDRAULIC TORQUE WITH SOCKETS
9.2 Spare Parts List For 2 Years（Only For Single）

NAME CODE QUANTITY MATERIAL WEIGHT（Kg）
SINGLE TOTAL
M8501-6P LINER PARTS 1 Set ASSEMABLY 1692 1692
M8501-20 LINER 1 Cr-Mo STELL 218 218

M8501 M8501-21P FEED PIPE 1 ASSEMABL 800 800
FEED CHUTE M8331-23P WHEEL 1 ASSEMABL 116 116
M8331-25 COPPER SLEEVE 4 H62 6 24
GB1152-1979 M10x1 GREASE CUP 4 Product 0.03 0.12
WZPM2-201 TEMPERTURE GAUGES 2 Product 0.2 0.4
M8502 M8332-15 SEAL RING 4 RUBBER 15 60
MAIN M8502/52 HOSE PARTS 1 Product 3 3
BEARING JB/ZQ4224-1997 6 Product 0.0015 0.009
ASSEMBLY O MODEL SEAL RING 3.1×35
M8502-16 BUSHING 1 IBZ34 760 760
M8503-3 SEAL 8 RUBBER 22 176
M8503-6P FEED LINERS 1 ASSEMABLY 584.6 584.6
M8503
M8503-7 RUBBER SEAL 2 RUBBER 12 24
SHELL UNITE
M8503-23P RUBBER UNING 1套 PARTS 1560 1560
M8503-25P RUBBER LINERS 1 PARTS 460 460
M8503-44P RING SEAL 4 40 160
M8504- HEAD LINERS 1 16 Cr-Mo STELL 528 8448
M8504-2 HEAD LINERS 2 32 Cr-Mo STELL 271 8672
M8504-3 SHELL LINERS 32 RUBBER 18.5 592
M8504-4 SHELL LINERS 1 32 Cr-Mo STELL 639 20448
M8504
LINERS
M8504-9 HEAD LINERS 3 32 Cr-Mo STELL 260 8320
M8504-10 HEAD LINERS 4 16 铬钼钢 575 9200
Cr-Mo STELL
M8504-11 HEAD LINERS BOLT 1 64 CLASS 8.8 4.18 268
M8504-12 HEAD LINERS BOLT 2 64 8.8 级 4.07 261
CLASS 8.8
M8504-13 HEAD LINERS BOLT 3 64 8.8 级 4 256
CLASS 8.8
M8504-14 HEAD LINERS BOLT 4 64 8.8 级 3.74 240
M8504 CLASS 8.8
LINERS M8504-15 SHELL LINERS BOLT 1 576 8.8 级 2.98 1717
CLASS 8.8
M8504-16 SEAL RING 832 橡胶 0.55 458
RUBBER
M8504-16 PRESSING PLATE 832 Q235-A 1.1 915
M8504-18 PLUG 288 橡胶 0.085 24.5

RUBBER
M8506 TXCLTSF-TXXACAP 1 Product 0.1 0.1
GEAR GUADE INFRARED THERMOMETER
O-RING 2-461No.674 PARKER 2 Product 0.1 0.2

RUBBER SEAL BM1250-A0 VR400A 4 Product 0.5 2
Roll Bearing23284CA/C3/W33 2 SKF 535 1070
M8507
O-RING443.36x6.99 PARKER 2 Product 0.1 0.2
PINION
Seal BM1253-A0 VR450A 4 Product 0.525 2.1
ASSEMBLY
M8507-4 PINION 1 17CrNiMo6 4592 4592
WZP2-231A pt100 225x75 2 Product 0.1 0.2
TEMPERTURE GAUGES
M8508 TROMMEL LINERS 2 Set ASSEMBLY 3380 10140
TROMMEL
9.3Special devices and tools list(Single ball mill)

名称代号数量材料重量 WEIGHT（Kg）备注
NAME CODE QUANTITY MATERIAL 单重 SINGLE 总重 TOTAL REMARK
M8509 1Set ASSEMABLY 6590 6590 CITIC HIC
JACKING CRADLES
Hydraulic jacking system 1Set 1362 1362 ENERPAC

Hydraulic torque wrench 1Set 67 67 ENERPAC
with sockets
Ultrasonic bolts equipment 1Set 78 78 ST
Appendix one bolt fastening
1. Assembling method of bolts
Place of bolts connection is very important in structure of whole mill, especially,
bolt connation between cylindrical shells; shell and end cover, and between shell, end
cover and bull gear. Fault appears in bolt connection section is very common. But
such fault can be prevented through maintenance. If bolt is loose in connecting section,
strength of connection can be reduced. Running time will be reduced, even, serious
machine error and personnel injury will appear. So tightness of bolts shall be checked
regularly and periodically. Fastening for connecting section in rotary part and
pre-tightening torque shall be check again and again. Only when connecting part is
above horizontal center line of mill inspection can be performed. In this situation, load
of parts and mill will not effect on bolts.
1.1 Torque wrench
Torque wrench used must receive calibration. Bolt can reach to correct elongation
indicator through adjusting torque of torque wrench. Wrench can be calibrated in site
through measuring elongation indicator of bolt.
Preloaded torque between connection parts is large difference because there are
many concerned variable factors will effect on friction and connecting condition. So
use calibrated wrench can reduce such difference greatly.
Friction shall be controlled strictly. Flight surface shall be protected during
transportation, storage and assembly. Flash, burr and high spot must be cleared up
through file during connecting parts assembling. In this way, bolt damaged possible
will be prevented from increased friction of bolts. For bolts, nuts and washers, ash,
burr, loose and greasy dirt neither is nor allowed to be existed.
1.2 Measure elongation indicator of bolt
Using micrometer or ultrasonic bolt length measuring equipment separately to
measure length of bolt before and after fastened. In this way, you can get elongation
indicator of bolt. If both end of bolt can not be touched, ultrasonic method can be used.
You also can use calibration block of same thickness to simulate and fix actual torque
value. Mae and use Experiment flange of same size in site, use three bolts to calibrate
torque wrench on experiment flange, suitable elongation and torque value of bolt you
get from experiment flange, and then tighten bolts on product using measured torque
value.
Both ends of bolts must be machined to be smooth and parallel, only in this
situation micrometer or ultrasonic survey instrument can be used to measure bolts.
And measuring position must be same.
One of every 5-10 bolts shall be measured by micrometer or ultrasonic survey
instrument. In other words, at least 10 percent to percent bolts shall receive check. If
time of project allowed, it is better to check elongation indicator of all bolts. In this
way, you can get reliable results. Measuring bolt and position must be numbered and
marked (stamped mark on bolt head and flange or apply coat on flange). These marks
shall be permanent can not be wiped out. And record measured length and elongation
indicator, and such record can be permanently maintained. In this way, when repair
you can refer to it. Maintenance record also should be permanently maintained.
Preloaded torque and recommended elongation indicator for bolts which are bolts
of key position of mill in the following table. Preloaded torque of bolt which not list
you can refer to section 2-without preloaded torque.
Bolt for shell, end cover, sleeve shaft and bull gear
Pretightening torque and elongation amount
Elongation
Bolt Effective Thickness Pretighten
amount of
No. Position diameter length of flange ing torque Notes
bolt
mm mm mm N.m
mm
M48x3
1 Head and shell 247 200 5430 0.561~0.647
L=280
M48x3
2 Shell and shell 247 200 5430 0.561~0.647
L=280
Bull gear, Head and M48x3
3 347 300 5430 0.788~0.910
shell L=380
Inside
Screwed Double
M48x3 6305
4 on end 375 315 1.065~1.229 (5)
L=565 Outside
position stud
6789
of half
Taper M48x3
5 gear 375 315 6305 1.065~1.229 (5)
pin bolt L=600
6
Notes: (1) torque in table is for bolt with lubricant(recommend to use Molykote,
coefficient of frictionμ=0.14。).
(2) Effective length is equal to 1/3 height of bolt head add screwed
flange thickness add thickness of washer add 1/3 thickness of nut.
(3) Torque wrench can be adjusted according to allowable elongation
amount of bolt to decide actual torque value.
(4) If elongation value can not be measured, calibration block with same
thickness can be used to decide torque value.
(5) If elongation amount is calculated according to inside nut, outside nut
can prevent loose.
1.3 Tightening step of bolt
1.3.1 Clean and prepare
Dirty, rusty stain, scale and burr on all bolts and studs shall be removed and check
their thread to see whether they are damaged or not. Connector taken out of packing
transport case can not use directly. Because there are always some slight damage or
dirty thing on bolts and nuts.
Every bolt, stud and nut must receive inspection prior to using. Inspection step is
in the following:
(1) To clean then with metal cleaning agent.
(2) To check thread to see whether is damaged or not.
(3) Clear up notch and burr.
(4) Turn nut up and down, make assembly easily.
1.3.2 Assembly and tighten
When assembly bolt, stub and nut, nut they are matched shall be matched in
original check.
Pretigntening torque shall be done in three steps:
Firstly, all bolts shall tighten to halve torque value;
Secondly, all bolts tighten to full torque value;
Thirdly, recheck bolt based on entire torque value.
If you look the entire position as a clock, each step shall tighten to required torque
in following: 12:00、6:00、3:00、9:00、1:30、7:30、4:30、10:30、2:00、8:00、
5:00、11:00、4:00、7:00、1:00。In order to prevent bolt from turning during assembly,
bolt head must be fixed and then turn nut or fix nut to turn bolt head when tightening.
Torque value will indicate on torque wrench and then to adjust it. In this way,
suitable elongation amount can be reached when assembly high strength bolt.
Readings on torque wrench maybe difference even if wrench is same type and made
by same manufacture. Elongation amount of bolt shall be interval checked of 10%~20.
and make sure that elongation amount is within allowable range.
2、Pretightening torque value for bolt without marking

Property Nominal diameter of bolts
of bolt M20 M24 M30 M36 M42 M48 M56 M64
Class Tightening torque TA ， Unit ：N.m
Class 3.6 86 150 297 520 830 1247 2005 3021
Class 5.6 145 298 593 1037 1661 2495 4010 6042
class 8.8 307 530 1055 1845 2953 4435 7130 10741
Note: 1. Apply to coarse thread bolt and screw.
2. allowable allowance for pretightening torque is ±5%。
3. preloaded shall be calculated based on 0.7σs of material.
3. coefficient of friction: μ=0.14。
5. Given value is for bolt with lubricant. Pretightening torque for Bolt without lubricant is 133%
of value in table.
6. Torque vale for inside nut of double nuts shall reduce 5% from value in table.
3. Recheck
Connectors for rotary part of mill shall be rechecked Using full torque when
operated for one week under full load. Recheck again 6 months later. Random
inspection shall be performed every half year hereafter (check several bolts on each
flange). If pretightening torque of several bolts becomes small, all bolts shall be
retightened again.
Appendix two test run record table

Test run record
Site condition:
Name of user:
Place of erection: indoor outdoor
Limiting temperature of environment: °C maximum °C minimum
Environment temperature when start-up: °C.
Time of test run:
Addition table one: lubricant record for each part

Name of parts Trademark of lubricant Viscosity of maker Remarks
lubricant
Lubrication station of main
bearing
lubrication station of reducer
Lubrication station of main
motor
Mist lubrication of gear and
pinion
Slow-speed driving reducer
Slow-speed driving brake
Sealing and grease system
Rolling bearing for all kinds
of motor
Each grease sealing position
Addition table two: floating amount record for sleeve shaft (oil film
thickness)
Mill running Feed side of mill discharge side of mill Load weight Remarks
condition （mm）（mm）（t）
Zero load
Add water
30% load
60% load
90% load
100% load
Addition table three: lubrication station running record for main bearing
Mill condition： zero load □ add water □ 30% load □ 60% load □
90% load □ 100％ load □
High-pressure pressure High pressure flow Low pressure
Time MPa L/min flow L/min
charge 1 Charge 2 Dischar 1 Dischar 2 charge 1 Charge 2 Dischar 1 Dischar 2 Charge Dischar
Temperatur Temperature of low Return oil Pressure difference of Pressure difference

Time e of tank pressure outlet temperature high-pressure oil filter of low-pressure oil
℃ ℃ ℃ MPa filter MPa
1. Time interval can be determined according to test run condition and

lubrication station running condition.
2. Pay attention to oil level.
3. “Charge 1”is drive side of charge side; “charge 2”is non-drive side of charge
side.
4. “Discharge 1”is drive side of discharge side;“discharge 2“is non-drive side of
discharge side.
Addition table four：temperature running record for main bearing and

pinion bearing
Mill condition zero load □ add water□ 30% load □ 60% load □
90% load □ 100％load □
temperature sensor temperature sensor Temperature of pinion bearing
Time temperature of main temperature of main ℃
bearing of feed side bearing of discharge
℃ side ℃
1# 2# 3# 1# 2# 3# Drive side Non-drive side
Note ：1. Time interval can be determined according to test run running
condition.
2.1#、2#、3# is sequence from charge inlet to discharge inlet.
Addition table five：reducer and lubrication station running record

Mill condition: zero load □ add water□ 30% load □ 60% load□
90% load □ 100％ load □
Temperature Temperature Lubrication station for reducer
sensor of sensor of Pressure Oil output Temperature Filtration
Time high-speed shaft low-speed shaft of oil out of oil out pressure
bearing ℃ bearing ℃ difference
1# 2# 1# 2# Mpa L/min ℃ Mpa
condition.
2.1#、2# is sequence from input shaft side to output shaft side.
Addition table six：running record for bearing of main motor, temperature of

stator and low-voltage current
90% load □ 100％ load □
time Temperature of bearing℃ Temperature of stator℃ Voltage Current
Input side Non input side 1＃ 2＃ 3# V A
condition.
Addition table seven ：running record for bearing of main motor and
high-and-low pressure lubrication station
Lubrication station of motor
High Pressure Pressure Flow of low Pressure Pressure Return oil
Time pressure of high difference of pressure of low difference temperature
flow pressure high pressure L/min pressure of filter ℃
L/min MPa filter core MPa core
MPa MPa
condition.
Addition table eight：temperature record of pinion（℃）
locating
1 2 3
Drive side Non-drive side

Distance of point 1 and point 3
Temperature
From gear face is about 50mm.
measuring gun
Point 3 locates in center
position of gear.
Use infrared ray temperature measuring gun to measure temperature of gear

face.
90% load □ 100％ load □
Ti positi positi Positi Current Power of
me on1 on2 on 3 of motor A motor kW
Note: time interval can be determined according to running condition. Key point
is to analysis temperature whether is uniform.
Addition table nine：running record of vibration sensor

Pinion bearing
Time Non-drive side Non-drive side Drive side Drive side
of pinion of pinion of pinion of pinion
level Vertical level Vertical
Time Bearing of reducer Bearing of motor

Input side of Output side of Input side of Output side of Drive side Non-drive side
low-speed shaft low-speed shaft high-speed shaft high-speed shaft of motor of motor
Note ：1 Time interval can be determined according to test run running condition.

03-Φ5 - 5mx8 - 8m Overflow Ball Mill Manual－ENGLISH

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03-Φ5 - 5mx8 - 8m Overflow Ball Mill Manual－ENGLISH

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Φ5.5m × 8.

8m Overflow Ball Mill

Installation Operation and Maintenance Manual

for VALE BRUCUTU Project

MACHINE PART OF BALL MILL

CITIC Heavy Industries CO., LTD

1.4 Safety regulation

2. Handling and Storage

3.6.6 Driving unit

Fig. 1 Reference point and centre target drawing

Figure 7 sketch drawing for

name alarming value（℃） shutdown value（℃）

Main bearing temperature 60 65

pinion bearing temperature 75 80

reducer bearing temperature See reducer specification

main motor bearing temperature

h. See lubricating station specification for detailed debugging.

5.2.7slow drive device

5.4.5 Running with load of 90%

Notice: All commissioning data log refer to appendix Ⅱ.

6 Normal operation and usage

6.1.2 Stopping sequence

6.1.3 Short term stopping

6.1.4 Long term stopping

6.1.6 Emergency stop

6.1.7 Starting again

6.2 Regular running

6.1.5 Operator must abide to following items in regular running:

7 Maintenance and repairing

7.1 Mill lubrication and grease sealing

7.1.2 Oil replacement frequency

7.1.4 Gear and pinion lubrication

Open gear lubrication for example of Brugarolas S.A. Of Spanish:

7.3 Main bearing

7.4 Transmission unit

Mill running of 30 to 60 days we suggests special attention shall be paid to

8 Maintenance, often failure and troubleshooting

8.1.2 Spray lubrication system

8.1.3 Main bearing and lubrication system

8.1.4 Drive system

8.2 Check and repairing job

8.2.2 Main bearing

8.2.3 Main bearing oil station

8.2.4 Transmission system

8.2.5 Tightening bolt

8.3 Matters for attention during troubleshooting

Troubleshooting schedule of mill

8.7.4 Maintenance of mist lubrication system

8.9 Treatment for common fault

2 Resistamce Viscosity 800L E593 电机轴承动静压润滑站 46 号汽轮机油

9.2 Spare Parts List For 2 Years（Only For Single）

M8501-6P LINER PARTS 1 Set ASSEMABLY 1692 1692

M8501-20 LINER 1 Cr-Mo STELL 218 218

M8504-18 PLUG 288 橡胶 0.085 24.5

O-RING 2-461No.674 PARKER 2 Product 0.1 0.2

9.3Special devices and tools list(Single ball mill)

Hydraulic jacking system 1Set 1362 1362 ENERPAC

2、Pretightening torque value for bolt without marking

Appendix two test run record table