3.

813m
3.813m CEMENT MILL

ERECTIONOPERATION AND MAINTENANCE INSTRUCTION

K4536.00 SM

South Kalimantan Indonesia Conch Cement

Company Limited

09A01a.b.c
EQUIPMENT NO09A01a.b.c

GSB12028
ORDER NOGSB12028

Shanghai Heavy Machinery Plant Co.,Ltd

0
February2013

1800

021-54721141

021-54721132

200245

Name of Company: Shanghai Heavy Machinery Plant Co.,Ltd

Address: NO1800 Jiangchuan road,Minhang,Shanghai

Tel: 021-54721141

Fax: 021-54721132

Postcode: 200245

CONTENTS
1 .................................................................................................................................. 1
Preface ............................................................................................................................. 1
2 .................................................................................................................. 1
Main Technical Parameter ............................................................................................. 1
3 .......................................................................................................................... 4
Working principle ............................................................................................................ 4
4 .......................................................................................................................... 6
Configuration summarize............................................................................................... 6
5 ........................................................................................................................ 11
Installation ..................................................................................................................... 11
6 ............................................................................................................................ 28
Commissioning.............................................................................................................. 28
7 ........................................................................................................ 32
OperationMaintenance& Overhaul......................................................................... 32
A ........................................................................................... 40
Appendix A. Installation of Coal Mill Barrel Liner .............................................................. 40
B ....................................................................... 42
Appendix B. Installation Requirement of Bolts, Nuts and Tightening Torques ................... 42
C ....................................................................................... 45
Appendix C. Lubrication Sketch Map and Lubricant List .................................................... 45
D .............................................................................................................. 47
Appendix D. Attached Drawing Catalog .............................................................................. 47
E

............................................................................................................... 48

Appendix E. Spare Parts list ................................................................................................. 48

Organized

Checked

Approved

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Preface

1.1
The users or the responsible person should carefully read this instruction and fully
understand the installation, maintenance and usage of the instruction.
1.2
All personnel responsible for the installation should have safety training and fully
understand their tasks and the equipment as well.
1.3

This instruction specifies detailed construction measures and job contents of the equipment
hereby and its accessories and recommends the general installation orders.
1.4
The instruction should not entirely replace the on-site guidance job of our companys
professional erecting guiders.
1.5

Professional erecting guiders of our company may consider modifying the installation steps
or take methods different from this specification to carry on the construction work according
to the actual conditions.
1.6
The user (company) should establish the system of operation, maintenance and management
for the equipment while combines the requirements of the instruction with the actual
conditions.
1.7

Any consequence caused by the absent achievement of the values set by the instruction or
operations against the instruction, our company shall take no responsibility.
1.8
Some methods described in the instruction are some of the recommendations. What we
emphasis is the result.

Main Technical Parameter

2.1 Main parameter
Specification

3.813m

Effective Barrel Diameter

3570mm

Effective Barrel Length

12847mm

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Coal Mill Rotate speed

Operating Rotate Speed

16.6 r/min

Disc Mill Rotate Speed

0.178r/min

2.2
Purpose: to abrade the powder of cement clinker
2.3
Production feature: closed-circuit
2.4

180t

Grinding load:

180t

2.5 75t/h25mm95% 3600cm 2/g

Production capability75t/hentry abrasive particle size25mm95% passingsurface
area of finished products 3600cm 2/g
2.6
Driving mode: center driving
2.7 Main Motor
Motor type

YRKK900-8

Rated power

2500KW

Rated rotary speed

746r/min

Rated voltage

10kV

2.8 Main motor oil station

Type

XYZ-25G

Nominal flow

25L/min

Supply pressure

0.6MPa

Oil temperature

28

Relevant parameters shall be in line with instruction of oil station purchased by the user.
2.9 Reducer system
2.9.1 Main reducer
Type

JS130-C

Transmission power

2500KW

Input rotary speed

746r/min

Output rotary speed

16.6r/min

Weight

48t

2.9.2 Slow driving motor

Type

HMS660

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Motor power

37KW

Motor rotary speed

740r/min

Transmission ratio

93:1

Weight

4.5t

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2.9.3 Diaphragm coupling

Type

JL130-C

Weight

11.5t

(
)
Reducer supply also includes fasteners, such as bolts connected with the mills pipe
connecting flanges, adjustable diaphragm and couplings linked up with main motor.
2.9.4 Main reducer oil station
Type

XRZ-300

Nominal flow

300L/min

Motor power

11KW

Motor rotary speed

1460r/min

Cooling area

16m 2

Heater power

4x6KW

Weight

3.5t

Please check the instruction of oil station for detailed parameters.

2.10 ()
The high and low pressure oil station of Sliding shoe bearing (parameters for each oil
station)
Oil station model

XGD-A2.5x2/80P

() High-pressure section (double high pressure)

High-pressure oil rated flow

2.5x2L/min

High-pressure oil rated pressure

31.5Mpa

High-pressure pump motor power

2.2X2( set)=4.4KW

low-pressure section (one for use and the other for spare part)
low-pressure oil rated flow

80L/min

low-pressure oil rated pressure

0.6Mpa

low-pressure pump motor power

2.2x2=4.4KW

Relevant parameters shall be in line with instruction of oil station purchased by the user.

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2.11 ()
Sliding shoe bearing electric parameters (each sliding shoe bearing)
Pillow and slip ring temperature measuring component:
Type
Quantity
Temperature range:
Index No
Resistance value

WZPM-201
3
-100~150
Pt100
1000.12(0)

( )
Oil box temperature measurement component (oil station instruction purchased by the user
shall prevail)
Type
Quantity
Index No.

WZP-26S
1
Pt100

( )
Oil tank electric heater (oil station instruction purchased by the user shall prevail)
Type
Quantity
Power

HRY2-220/2
2
2KW220V

2.12 Cooling water consumption

Main motor oil station

1.5 m 3/h

Reducer oil station

27m 3/h

Sliding shoe bearing oil station

3.8x2m 3/h

Sliding shoe bearing

3.5x2m 3/h

Working principle

3.1 Main feature

3.1.1

The driving mode of this mill is center driving with sliding shoe bearing support structure
(welding slip rings) in both sides, which helps it to shorten the mill span, well carry
burden, stably support the structure, and reduce the thickness of the barrel, thereby
reducing the cost. The simple way of manufacturing, small amount of parts, user-friendly
operation and easy maintenance save the expense of operation.

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3.1.2

The mill is closed-circuit mill that applies the classifying liner structure of new diaphragm
plates and discharge grate plates, which enables more reasonable grinding process of the
material in the grinding chamber, consequently improving the grinding ability.
3.1.3
Less variety of the wearing parts, easy maintenance and low maintenance costs.
3.1.4

Feeding device adopts the oblique air intake shutter structure, which increases the mill
ventilation and decreases the air intake resistance in order to make the feeding smoother.
The adoption also includes shortcut and convenient dynamo-electric adjusting air door
structure.
3.2 Working principle

The mill adopts center driving mode, namely, the main motor transmits dynamic to
diaphragm couplings through the main reducer, and then mill barrel turns around driven by
diaphragm couplings. Low-speed driving system arrangement is equipped with the main motor
to prepare for the usage of drive the mill when any installation, repair and maintenance work to
be done.

Material is fed into the coarse grinding compartment inside the barrel directly from the
incoming chute in the feeding device. The great grinding impact of the grinding body (steel ball)
with longer average diameter helps to crush the material. While the material is crushed to a
certain size, it enters into combined diaphragm plates through the gap between coarse sieve
plates in diaphragm plates. At the same time, the grinding body in the coarse grinding
compartment is blocked by the coarse sieve plates of diaphragm plates. In the combined
diaphragm plates, material gets the further sieve analysis by fine sieve plates. During the

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process, material of too coarse size is to be screened out and returned back to the coarse
grinding compartment and material of small size less than a fine sieve plate is raised by the
scatter plates into the fine grinding compartment and got further grinding by the small grinding
body. Powder material reached the process requirements will be discharged through the
discharge grate plate and discharge barrel into the discharge device and gets into the high
efficiency separator in the system for powder selection. Residual slag of fine grinding body
will be discharged from the discharge port out of discharge device.

Structure Summarize

The mill is composed of material feeding device, sliding shoe bearing, sliding shoe bearing
lubrication device, rotating unit, discharge device, driving device and sliding shoe installation
device, etc.
4.1 Feeding device

The material is fed into the mill through feeding device which is composed of feeding
pipes, air incoming pipes and brackets. The device adopts the oblique air intake shutter
structure, which improves the smoothness of material feeding. Changeable liners are paved in
the feeding pipes. The shortcut and convenient dynamo-electric adjusting air door structure is
also set up. Adjustable shims can be put between air incoming pipes and brackets so as to
conveniently adjust the center height of feeding device if necessary.
4.2 Sliding shoe bearing

The mills structure is double sliding shoe bearings. The feeding end can be designed as
movable sliding shoe bearings according to the actual operating condition. When the thermal
expansion and cold contraction happen to the barrel, the rotating unit can move axially. The
discharge end is fixed sliding shoe bearings.
30

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Two pillows of sliding shoe bearings support slip rings of the mill on the angle of 30 with
the vertical direction. Each pillow is equipped with concave and convex spherical body
structure on the bottom side. The convex spherical surface body is located within the ball and
socket of the concave spherical surface body while the spherical contact is functioned between
these bodies. In this case, it is possible to execute the automatically location adjustment when
the mill turns around. The whole sliding shoe pillow of the feeding end locate on the support
roller through the spherical surface body so that it can make axial movement with the barrel
rotating unit when thermal expansion and cold contraction happen to the barrel. The pillows of
sliding shoe bearings in the discharge end which are near the up side of rolling hoop locate in
the fixed support to ensure sliding shoe bearings in the driving end of the mill having a locating
function. This kind of support structure guarantees the good contact between pillows and the
slip rings.

The pillow body is a casting piece and lies with bearing alloy lining. The internal diameter
of the pillow should be slightly larger than the outside diameter of the slip ring so that an oil
wedge is able to form. Since the surface roughness has high requirement, it is no need to do
pillow scraping as long as the machining process meets the design requirements. The pillow
surface has oil capsule, which enables the entrance of high pressure oil into the pillow and
forms a high pressure chamber between the pillow and the slip ring, lifting the barrel and then
operating startup and normal work.

Sliding shoe bearings is set with high-voltage-started lubricating device, one set for each
sliding shoe bearing. High pressure lubrication system is applied for start-up, stop and repair of
the mill, namely, use the method of static pressure to form a layer of oil film between their
respective pillows and slip rings, reducing the mill start-up and shutdown friction and avoiding

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burnout of pillow alloy surface because of the linear velocity of slip rings is too slow to form a
hydrodynamic oil film, which happens at the mill start and stop period. Each sliding shoe
bearing lubrication system has two sets of high pressure oil supply systems, supplying two
pillows separately. Low pressure lubrication system is the one that using low pressure pump to
transport two oil pans, one placed in the bottom of the slip ring and the other placed in front of
the pillow (upper front of the rotating direction) , to the sliding shoe bearings. Slip rings can dip
in oil in the oil pan. When mill rotates, oil is brought to the midst of the slip ring and the pillow.
So far, the hydrodynamic lubrication is formed. Each sliding shoe bearing lubrication device
has two sets of low pressure pumps, one for work and the other for spare parts.

Both sides of the slip rings should be installed with an oil scraper brush to prevent
lubrication oil outflow. The oil scraper brush is strained by the spring on the rod, which can be
adjusted by the installation so that the oil scraper brush can well stick to both sides of the slip
rings.

In order to prevent the pillow from getting over temperature during the mill operation, and
to ensure the normal operation of the mill, water cooling shall be applied to the pillow. Cooling
water inlet is at the lowest point of the pillow. The water comes out through a pipe and a hose
coupling to the drainage box installed outside the bearing cover, and drains from here.
Temperature measurement devices are also installed for the direct and convenient monitor of the
temperature.

Above each slip ring there is a temperature measuring device, equipped with temperature
measurement elements, which can monitor the temperature of the slip ring at any time during the
mill operation. Linked with the main motor, the temperature measuring device can send out the
alarm signal once the temperature exceeds the set value until the main motor stops running.

Sliding shoe cover is made of welding sheet steel with inspection hole for daily operation,
maintenance and inspection. Rubber pads and sealants shall be used between sliding shoe bottom
cover and base plate. Maintenance shall be strengthened during the operation to prevent it from
oil leakage.

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4.3 Rotation unit

Rotation unit is the main body of the mill. The material is pulverized and grinded in the
barrel of the rotation unit which is composed of the barrel, diaphragm plates, discharge grate
plates, liners, cover liners, and feed cones, etc.
4.3.1 Barrel

Barrel is an important component of the rotation unit, made of welding steel plate roll. The
inlet and outlet ends of the barrel apply the welding structure that the slip rings are welded with
the barrel steel plates. Slip rings are the two fulcrums of the barrel and the barrel relies on the
support of the feeding and discharges slip rings and stays on the sliding shoe bearings.
Discharge pipe is the place where material is discharged like the finished product is discharged
from the hole of discharge pipe, and is the position where the mill and the reducer connect with
each other. There is a combined diaphragm plate between coarse grinding storehouse and fine
grinding storehouse. Discharge grate plate is set at the discharge end. The inner surface of the
barrel is equipped with barrel liner and liner ends. One storehouse has a manhole door and two
storehouses have two manhole doors for staff passing in and out under the grinding body
loading and unloading, internal parts replacing and examining condition.
4.3.2 Diaphragm plates

The diaphragm plate is composed of coarse sieve plates, fine sieve plates, support plates,
center grilles and liners. Leave gap between radial and circumferential direction of each coarse
sieve plate to form coarse sieve. Only milled material is allowed to pass through the coarse
sieve. The coarse sieve can block the grinding body and large material in the kibble storehouse

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to avoid the direct wear of the subsequent fine sieve. Milled material gets into the separation
chamber of combined diaphragm plate in the condition without ball feeding pressure and they
are screened by the fine sieve. The fine sieve is made of porous thin steel plate with the
effective passage area larger than the diaphragm plate of common cement mill, which is
extremely favorable of improving the ability of passing through the diaphragm plate. Fine
material is sent to the fine grinding storehouse through the fine sieve plate by scatter plate.
Coarse material that can not pass through return to the coarse storehouse under the function of
scatter rib bars in the separate chamber and center cone of center grizzly for continue grinding.
4.3.3 Discharge grate plate

Discharge grate plate is composed of grate plates, center sieve plates, and support frames
and so on. The grate plate is made by wear-resistant alloy cast steel. Finely ground material
enters the discharge chamber through the gap of grate plate. The ribs with lifting function lift
the material and send it to the discharge body and enter into the discharge device.
4.3.4 Barrel liner

The barrel coarse grinding chamber applies the ring groove ladder liner while the fine
grinding chamber applies the double ladder grading liner. To reduce the heat impact to the slip
ring, the heat insulation pad should be installed between liner at the slip ring and the barrel.
4.3.5 Transmission device

Driving device includes main motor, main motor oil station, main reducer; main reducer
oil station, low-speed driving system, diaphragm coupling, coupling, etc. Check relevant
technical documents respectively for more detail.
4.4 Sliding shoe bearing lubrication device

It is necessary to establish high and low pressure lubrication systems to ensure the regular
operation of sliding shoe bearing and work of the barrel. The system consists of sparse oil
station with double high pressure start-up and low pressure lubrication and pipeline system.
High pressure system is for mill start-up, parking and maintenance and low pressure system is
for mill lubrication under the normal operation.

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31.5MPa 2.5x2L/min
0.6MPa 80L/min
High pressure system of lubrication system set two dynamoelectric high pressure pumps
for oil supply to two pillows of sliding shoe bearing respectively. The maximum oil supply
pressure is 31.5MPa with 2.5x2L/min of flow quantity. Low pressure system has two
low-pressure pumps, one for work and the other for spare parts. Supply pressure of the low
pressure system is 0.6MPa with 80L/min of flow quantity.

Check relevant technical documents for more detail.

The lubrication system and main motor have interlocks. In this case, the main motor is not
able to start-up if the parameters of the high and low pressure system can not reach the set value.
During the operation, if the high and low pressure system or other components go wrong, and
the parameter can not reach the set value, give an alarm and automatically stop the main motor.
4.5 Discharge device

Discharge device is mainly composed of parts such as covers and brackets. The covers are
fixed directly on the groundwork supporting by the brackets. The inside is equipped with screen
barrel that rotates with the barrel in order to weed out the broken iron slag and other debris. Top
hood of the discharge device has air vent and bottom hood has discharge opening. Near the
discharge opening there is taphole.
4.6 Sliding shoe installation tool

Sliding shoe installation tool helps fixing and aligning for sliding shoe bearing installation
and is one of the recommended methods for the successful and correct installation of sliding
shoe bearings.

Installation Requirement
JCJ03

The mill installation should be in accordance with JCJ103 Construction and Acceptance

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Rules of Cement Machinery Equipment Installation, and comply with the relevant technical
requirements of the drawing.
5.1 Preparation work before installation
5.1.1

Basic acceptance should be strictly in accordance with the related requirements in

Construction and Acceptance Rules of Cement Machinery Equipment Installation. See
table 1 for acceptance items.
:
Table 1: deviation of equipment different basic parts

Serial

Item

(mm)
Tolerance(mm)

No.

1
2

3
4
5

()
Basic coordinate position ( vertical and horizontal centerline)

Basic elevation on different planes

-20

Basic top surface shape dimension

Level of basic top surface

Perpendicularity of basic vertical plane

30
Per meter

Reserved for anchor bolt hole

10

Per meter

Total length

Depth
/
Vertical /meter

Pre-buried anchor bolt

Total length

Center position
6

20

Top elevation

Center distance

Distance between center lines

20
10
+20
0
5
+10
0
2
1

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Construction party must provide settlement observation point to installation unit and
erection unit. After the basic checkout is qualified, shovel hemp the basic surface to ensure the
stability of the secondary pouring layer.
5.1.2 Several points need attention for foundation marking:
u 10200100

Center standard plate must be pre-buried before marking equipment foundation. Center
standard plate is made of steel plate with 10 200 100. Mark the locating datum point on
the center standard plate.
u
0.5mm
Use precision theodolite to release the longitudinal axis (namely mill centerline) according
to positioning reference point with precision tolerance less than 0.5mm.
u
Release all the transverse center line according to the dimension in the drawing (check the
real size of the item also).
u

Measure the foundation line. Check the level of the vertical and transverse locating center
standard plate as well as the foundation horizontal plane of supports at two ends of the mill
by a spirit level.
u

If center distance of slip ring in the discharge ends of the barrel is inconsistent with the
theoretical center distance, the actual centerline should be prevailed as the reference for
foundation marking.
5.1.3

Check the condition of the important components such as barrel, sliding shoe bearing,
electromotor and reducer. Measures should be taken to repair any damage, deformation or
dimension error and ensure the qualified result before installation. Revise the relevant
installation dimension when necessary.
5.1.4

Clean the anti-dust paint on the important cooperate surface of parts such as barrel slip

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ring, barrel ended mouth, sliding bearing, sliding bearing chocks and base and dirt with a
cleaning agent (such as gasoline). No dirt should be allowed during the installation.
5.2 Installation of anchor bolts
u

Clean all the dust and oil on the anchor bolts before installation. Check whether the fitting
of anchor bolts and nuts is good or not and coat anti-rust grease on the thread surface.
u
No debris is allowed to be found in the anchor bolts before installation. Prevent debris from
falling into the foundation hole during installation.
u 1/1000
Make the anchor bolts plump when install the anchor bolts. The tolerance out of the vertical
degree is 1/1000.
u
B
Screw down the anchor bolts on the cross angle and use force evenly. The action of
tightening one side and then tightening the other side is prohibited. After screw down the
nuts, recheck once and make sure that all nuts have been tightened. Check appendix B for
more detail requirements.
5.3 Sliding shoe bearing installation
5.3.1 Preparation of sliding shoe bearing installation
u

Assemble pillow, concave and convex sphere, and the sphere seat for test. The total error
should be within the design requirements and matching mark must be made.
u 0.63MPa 20min
Make water pressure test of 0.63Mpa to the cooling water channel of pillow for 20 minutes.
No leakage is allowed.
u

Contact surface between the concave and convex sphere should be coated with
molybdenum disulfide. After assembly, the contact should be in good condition and flexible
rotation without eccentric shake.
u
500500mm
Check the casting connection between bearing alloys and pillows to see whether it is sealed

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and firm without defects like shelling, crack, or pores, especially in the 500 500mm
range of tile surface regarding oil nozzle as the center.
5.3.2
Alignment Sliding shoe bearing bottom plate and preparation of grouting
u
75mm
Check the bearing foundation according to the drawing. First grouting of the foundation
surface can be grouted at about 75mm lower than underside of the base plate as shown in
the assemble drawing. The rest grouting can be carried on after the complete alignment.
u

Adjust the assembly dimension of the bearing base plate according to the real dimension of
the slip rings and the actual fitting dimension of the pillows. The centerline of the mill must
be unchangeable.
u
Start the alignment according to elevation shown in the inspection foundation drawing of
the mill centerline location.
u 1 1 JCJ03
20 48h

Use 1 share of high-grade cement, 1 share of middle sand and proper amount of water to
produce sand pier (see JCJ03). Install the equipment after watering conservation for 48
hours under the environment of 20 C. Put the base plate on the iron pillows during the
installation. The arrangement of these iron pillows should meet the requirements of the
design drawing.
V

For the sake of security, support the middle of the sliding shoe bearing foundation of
the V-shaped mouth, top frames of both inner sides of two base plates, and adjust screws, to
prevent the base plate from sliding down.

3 2 30 1

0.5mm:
Carry on the alignment. Make sure that one centerline of the base plate is parallel to
the centerline of the mill, and the other centerline is perpendicular to the centerline of the

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mill. Use water level 3, straight ruler 2 and 30 measurement block 1 provided with the mill
sliding shoe bearing installation tool to find alignment. Put measurement block on the
sliding shoe bearing base plate according to Figure 1 and adjust the location of the sliding
shoe bearing base plate. Make sure the deviation of assembly dimension as shown is less
than 0.5mm. Meanwhile guarantee:
a. 0.1/1000
0.5mm
The tolerance of sliding shoe bearing base plate level in the barrel axes direction is no
more than 0.1/1000. The tolerance of the relative elevation of corresponding points both
ends of the base plate is 0.5 mm. No allowance of the lower feeding end than the
discharge end.
b. 0.5mm
1mm 0.5/1000
The vertical centerline misalignment of the sliding shoe bearing base plates on both ends
is not more than 0.5mm. The difference of the transverse centerline distance and the
actual measured center distance of two slip rings is not more than 1 mm. The tolerance
of parallelism is not more than 0.5/1000.

1 2.5 0.8mm

After the final alignment, install the studs connecting the base plates and the foundation.
Screw down the nuts of the studs and check the alignment condition. Tighten the nuts to
the specified torque if no error shall be found. Then carry on the secondary grouting of
anchor bolts carefully. The concrete ingredients include 1 share of cement to 2.5 to 3
share of sand (particle size 0.8mm).

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1. Measurement block (provided with mill) 2. Ruler 3. Water level 4.iron pillow
1

Figure 1

5.3.3 Installation of sliding shoe bearing pillows

u Inspection
Ra1.6

The inner diameter of the sliding shoe bearing sliding surface is designed as a ring
larger than the outer diameter of the mill barrel. If the surface roughness reaches Ra 1.6,
and meets the processing requirements, generally scraping is not necessary.

0.050.1mm 20mm

2050mm

Put the pillow on the top of the slip rings. Check two ends of the pillow with plug
gauge. The slight gap between the slip rings and pillows is about 0.05 to 0.1 mm
(approximately 20mm from pillows end edge), otherwise scraping is needed. However, the
area of 20 to 50mm outside two ends of the pillow is allowed to do the scraping. Scrap on
the rest surface is not allowed though it can increase the contact area. In theory, the slip ring
contacts the bottom line of the pillow.

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Coat a thin layer of color markers to check the contact of the pillow in entire width.

Aseal4803
Clean the base plate and install the chassis of sliding shoe cover. Fill up the rubber
gasket between chassis and base plate. Install the items after coat the import 4803 sealant or
plane anaerobic adhesive sealant of Loctite Company.
u Installation

First, make sure the base plate has been seriously cleaned up. Then install the support
roller, the sphere seat and the concave sphere. Use swinging rings for installation.
0.5mm
Cross centerline of the bearing base plate should be aligned to the center target plate.
The deviation should be not more than 0.5mm.

Then use the sliding shoe installation tool provided with the mill to install the pillows
which are installed into the convex sphere. The surface of the convex sphere must be located
in the concave sphere, and can move freely. Use molybdenum disulfide lubricant to
lubricate the sphere. If pillows are fixed, put them on the fixed support at top side of the slip
rings.

The position and inclination of pillows must be as close to the final position as
possible. Put the steel wire rope through swinging ring screws on top end of pillows and tie
the pillows. Let sliding surfaces of pillows face towards the center. When sliding shoe
bearings get into the mill, and before slip rings touch pillows, remove the steel wire rope so
that the mill is in the right place and can be self-adjusting.

Check whether the spacer plate can shift in the tank free from any constraints. Check
whether the rollers are free to rotate without any extrusion phenomenon.

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Install lubricating pump station and finish its mechanical and electrical connections.
Check the drawing for sliding shoe bearing piping and the lubricating pump station fuel
supply system.

The mill must be able to rotate during the alignment process. When the mill is
rotating, high pressure pump must work. Therefore, lubricating pump station must be tested
and proved to be qualified before the alignment.
5.3.4 Barrel alignment
u
Well place the barrel and let the slip rings enter into the sliding shoe bearing. Remember to
release the pillow.
u
After confirm the high-pressure pump can work under the normal condition when the mill
rotates, take the alignment according to the following steps:
1) 0.1mm
Put a spirit level (0.1mm) on slip rings along the mill axial direction and record the
horizontal deviation.
2) 180

180

Open the slow drive so that the mill rotates 180 (high-pressure pump must be under
working condition). And then put the spirit level on the slip ring, and record the
horizontal deviation. The algebra sum of twice deviations must be zero. The alignment
data is correct through confirmation. Otherwise, further adjustment of the sliding shoe
bearings must be taken and then repeat the spirit level measurement (the mill barrel need
reverse 180 again) until satisfied results could be found in all positions.
3)
0.2mm
Use a level detection device to measure whether the same part of two slip rings can
achieve same level. Take horizontal alignment by fine-tuning oblique iron pillows under
the base plate. The relative radial circular run-out tolerance slip rings of mill both ends
are 0.2mm.
4)
Check whether the locating of the base plate is correct or not. If it is incorrect,
re-calibration must be done.

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5) 0.15mm
Use a feeler gauge to check the gap between slip rings and plywood of pillows. This gap
must be not less than 0.15 mm.
6)

0.15mm
Check slip ring axial run-out with a dial gauge while the mill slow drive is at work. If
the total axial run-out exceeds the measuring gap, it is necessary to insert the gaskets
between the side of pillows and the plywood. Thickness of the gaskets must be equal to
the total axial run-out plus 0.15mm and then minus the measuring gap.
5.3.5 Base plate pouring
u
Clean the area where the base plate contacts the foundation before pouring, especially the
oil and grease.
u
3040mm
Carefully pour the bottom plate. Make sure that the cavity between the base plate and the
first foundation is filled with cement mortar. Use special cement with a stable performance
to pour until 30 to 40 mm above the bottom edge all around the base plate has been poured.
u
Take comprehensive check to ensure nothing is wrong.
5.3.6 Sliding shoe covers and oil piping installation
u
20mm
Install the oil pan. Use adjusting nuts to align oil pan. Make sure the edge is horizontal, and
align the height of the oil pan according to the reference of slip ring bottom edge. Make slip
rings immerse into oil of 20mm.
u
Connect the internal circulation piping from the oil pan to fabric oil groove. Connect the
outside tubing to the circulation oil pump and the cooling water pipe.
u

Install the contact area of sliding shoe covers and foundation base plates. Pay attention to
the installation of the gaskets between covers and base plates and each cover section. The
gaskets should be coated with vibratility plane anaerobic adhesive sealant series produced

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by Loctite Company. Then clean the base plates and clean the sliding shoe covers with the
cleaner. Check the sealing condition of the kerosene. Be careful not to use water for check.

The sliding shoe cover is composed of several cover section with similar shape
connected by flanges and bolts for sealing pad.

L
L

Align each cover section when install the sliding shoe covers. The radial spacing
between the sliding shoe covers and slip ring sealing surface shall be equal to each other.
When install top of the sliding shoe cover, lubricating oil should be poured on the surface of
the slip ring. Install the L-shape sealing ring and ensure the evenly contact of seal ring and
slip ring on the circumference and coat sealing sealant on both sides. Coat thread fastening
agents of Loctite company when install the bolts for fixing L-shape sealing ring for locking
processing.
u
Install the joint from low-pressure lubricating oil pipeline to top location of the sliding shoe
cover.
u

Install electric control part of the oil flow signal. The signal of cycle oil pump oil flow
failure and fuel shortage or oil-break signal must be emitted to the operators room. (Check
the sliding shoe bearing lubrication device instruction for detail).

Start high and low-pressure pump station. The oil pan and oil groove of sliding shoe
bearing are filled with oil. Meanwhile, confirm the high pressure oil on pillow is normal.
Then start the mill.

After the mill operates, stop the lubrication pump station. Check the oil flow signal to
see whether it can cause automatically stop the control room from grinding (Check whether
it meet the requirements of self-locking). Make sure restart the mill motor after the oil flow

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signal emits the normal signal.

5.3.7 Installation of sliding shoe bearing cooling system

Install the cooling water pipes according to the piping system drawing and components
and parts list. The three-way stopcock should be installed in the inlet to make sure shutting
down the bearing cooling water and at the same time connecting to the sewer so that the
water can be drained out from bearing which avoids bearing damage from frost.
5.3.8

Installation of the sliding shoe bearing oil scraping brush

0.4kg

Install an oil scraping brush on both sides of revolve out ends on the pillows of two
slip rings to prevent from leaking out. Springs drawn two scraping brushes to the slip rings
must be able to generate 0.4kg tensile pressure on the side of the slip rings. If it cant, it
must be adjusted in order to acquire the necessary tension.
5.3.9 Problems require attention during installation
u 0.63MPa 20min

1.25 15min
Hydraulic pressure test of 0.63MPa shall be done after the complete installation of sliding
shoe bearing cooling water system for 20minutes. No leakage is allowed at the pipe
connection and pillows. Take the Lubricant oil circulation and hydraulic test pressure of the
lubricating pipeline. The test pressure is 1.25 times of the working pressure. The test lasts
15 minutes. No leakage is allowed.
u 32MPa 10min

The oil pressure test not less than 32MPa must be carried out to the high pressure oil
pathway after the assembly. The dwell time is not less than 10min.
Special Notice: When install the pillows of sliding shoe bearing, after the test of the high
pressure (before install the barrel), the oil plug shall be moved out of the high pressure oil
capsule (tubing sealing) of the pillow.
u

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The location of oil scraping brush and oil shower pipe in the bearing are all related with the
mill rotation direction. Please pay attention during the installation. In addition, the surface
of the oil scraping brush and slip ring should be grinded smoothly and firm.
u
Cooling water pipeline of bearing should be expedited. The untreated water supply is not
allowed to use.
u
Launching position of the drainpipe, the rest pipes and the water funnel are equipped by the
user.
5.4 Installation of the rotation part
5.4.1
The barrel is a oversized parts. Pay special attention to the lifting security during
installation.
5.4.2 A
Check appendix A for installation of barrel liner.

Installation of barrel diaphragm plate (Check diaphragm plate components drawing and
liner layout drawing)
5.4.3.1 Preparation of diaphragm installation

Clean the barrel inner surface of installation part thoroughly. Remove dust, rust and
residual oil. Clean all the component parts with the same method. Pay attention to all the
contact surfaces and remove all the burs and surface scars and defects.
5.4.3.2 Installation of fastening block
u
Check the contact surface to see whether there are any burrs and scar defects.
u
Stick rubber plate to the protruding rib side of the fastening block with epoxy resin glue.
u
Use bolts to tighten the fastening block to the mill barrel and make sure the fastening block
has good joint with the barrel.
5.4.3.3 Installation of support plate and front plate
u
Remove rust, burrs and defects of the contact surface on the support plate and the front
plate with the fastening block to make them in good contact.

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u 30
30
Use eight 30 steel bars (thread cutting on both ends ) getting through the support plate,
the sector fastening block, and the front plate. Fix two ends of steel bars with nuts to
prevent of slipperiness. Check Chart 2. Eight30 bars distribute at the circumferential
direction evenly.

Fastening
block
Sheet support

Front plate

Chart 2

Chart 3

Install steel bars at every area and ensure safety. Then, the connecting bolts between
support plate, front plate and barrel can be dismantled. Cut the dead plate for temporary
fastness. The barrel shall absolutely not be cut into. Polish the barrel surface smoothly.
Slide the support plate and the front plate to fastening block along the steel bars.
u 30

Fix the support plate and front plate with the fastening block by using bolts and nuts. See
Chart3. Dismantle eight30 steel bars and install the rest bolts and nuts.
5.4.3.4 Installation of backboard

Center backboard is of two-piece-structure which assembled into a round circle. It is

embedded into the relevant parts of the front plate and the support plate and tightened
gradually through crossing, and then spot welded firmly.
5.4.3.5
u

Installation of center frame and center sieve plate

Installation of center frame

1)

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Put center sieve plate between center frame and backboard according to the drawing.
2)
Temporarily fix the center frame, the center sieve plate and the backboard with bolts and
nuts at the centerline.
3)

Adjust the fastening screws of center frame, the center sieve plate and the backboard.
Coat threads on the screws with anaerobic adhesive sealant and install spring washers.
Fix center frame, center sieve plate and backboard.
4)
Weld two half center frames into one piece according to the drawing.
u Installation of sieve plate
1)

Clean sieve plate and check the flatness at the same time. Make sure the sieve plate is in
good contact with the front plate. If any deformation happens, proofread the flatness.
2)

Fix the sieve plate to the front plate with layering, briquetting and screws. And then
check whether the holes in the sieve plates are in line with bolt holes in the support plate,
the front plate connected with coarse sieve plate and sector liner. Bolt fastening and
loosening are the same as the above.
5.4.3.6 Installation of coarse sieve plate and sector liner
u
The throughout bolt connects the coarse plate on the front plate and sector liner on the
support plate. No tilt or shake is allowed.
u
During installation, try to guarantee the gap of circumferential and longitudinal direction of
coarse plate and sector liner is equal.
u

The connecting bolts of coarse sieve plate and sector liner should be installed in the hole
and can move freely and is perpendicular to coarse sieve plate as well as sector liner
according to the requirements. Tighten the bolts and use a hammer to gently knock the bolts
at the same time.
u A

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After that, tighten the bolts according to the requirements of tightening torque table in
Appendix A to the specified value.
5.4.3.7
Retighten bolts of the coarse sieve plate and the sector liner
u
Re-tighten all bolts connecting the coarse sieve plate and sector liner.
u 2

Retighten for the first time after start for two hours. Then tighten once every two hours until
the specified torque remains unchanged. All the nuts and bolts should be welded firmly.
5.4.3 Installation of discharge grating plate
5.4.4.1 Installation preparation

Clean the barrel inner surface of installation part thoroughly. Remove dust, rust and
residual oil. Clean all the component parts with the same method. Pay attention to all the
contact surfaces and remove all the burs and surface scars and defects.
5.4.4.2 Installation of bearing frame
27 12 18 GB11
3
First take radial adjustment with No. 27 screws (totally 12 pieces) in the rotation part.
Totally 18 pieces two rings of GB11 bolts are connected to the webs (aligning holes of three
rings liner correctly) and fixed.
5.4.4.3 Installation of sector liner
5.4.3.6 5.4.3.7
Carry on according to the requirements of 5.4.3.6 and 5.4.3.7.
5.4.4
All nuts installed inside the barrel should be tightened repeatedly in the loading test and
spot welded firmly to avoid breaking off during the operation.
5.4.5
Check rotation part drawings and technical requirements for the rest installation
requirements.
5.5 Installation of feeding device

1.5
Since the mill feeding end is the travelling end of inflatable barrel after the mill

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temperature rises. Therefore, it is a must to guarantee there is enough thermal expansion

space in the barrel when install the feeding device. Generally consider it according to 1.5
center distance of two slip rings.
5.6 Installation of discharge device
K4536.5.0SM
Follow related requirements in attached drawing K4536.5.0SM feeding device.
5.7 Installation of lubricating device
u 20%
3% 1
2

Clean all oil and water pipe before installation. The method is using 20% sulfuric acid or
hydrochloric acid solution to wash. Investigate from time to time during the washing
process. When the rust has been cleaned out, immerse the pipe into 3% lime water solution
for one to two hours to neutralize, and then rinse them with water, blow to dry with
compressed air (not with oxygen), and finally fill lubricating oil into the pipes to prevent
them from getting rust again. Block both ends of pipes from the dirt. The operation should
be carried out continuously.
u
1:10
Install the lubricating oil station near the lubrication points. The piping system should be
equipped according to the actual situation of the site and oil stations to ensure smooth oil
return and the inclination of return pipe should be greater than 1:10.
u
Carry on according to the relevant technical documents and drawings purchased by the user.
5.8

Installation of main motor, main reducer, auxiliary transmission and electrical control
equipment for mill driving device shall follow the relevant technical documents and
drawings purchased by the user.
5.9

To parts of the barrel liner and the oil scraping brush inside the sliding shoe bearing which
have the direction requirement, special attention should be paid to the mill rotation direction
during installation.

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5.10 B
Check Appendix B for installation requirements of bolts and nuts and tightening torques.
6

Commissioning

Test run should be carried out after the qualified inspection of the mill installation or
overhaul. Test run should be carried out according to the following steps.
6.1 Preparation before test run
1)
Check whether all the lubrication pipelines are assembled.
2)
C
Fill proper amount of lubricating oil with correct trademark in two sliding shoe bearings,
main motor bearings and reducer according to the drawing requirements. Check Appendix
C for lubricating oil trademark.
3)
C
Fill proper amount lubricating oil with correct trademark in each oil tank of oil station
according to technical documentation requirements. Check Appendix C for lubricating oil
trademark.
4)

C
The right choice of lubricating oil is an important guarantee to ensure the normal
operation of the mill as well as improvement of operation life. Therefore, technical
guideline such as trademark on the lubricating oil certification, standard number and
viscosity value should be checked before fill in the lubricating oil to see whether they are
complying with the requirements of Appendix C.
5)

Before the mill starts, try to open the lubrication system and high pressure starting device
first to check whether there is abnormal vibration or oil leakage; whether oil quantity
meets the requirements and the oil besprinkle is normal; whether mill body can float up
and oil return is good; whether each machine can operate properly.
6)
If the test run happens in winter, heat up the lubricating oil in advance in order to avoid the

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oil solidification affecting the normal running of equipments.

7)
0.5MPa 10

Check the cooling water system to see whether water runs smoothly, pipelines are without
leakage or water penetration. For cooling water pipelines of sliding shoe bearing, take
0.5MPa hydraulic test after assembly for 10 minutes. No leakage is allowed. Especially
joints inside the bearing must be sealed and reliable.
8)
1.25 15
After all the lubrication piping system has been installed, oil circulation and oil pressure
test should be performed with the test pressure of 1.25 times working pressure for 15
minutes without the leakage.
9)
Check whether the directional parts meet the installation requirements.
10)
Check whether all the connecting bolts and anchor bolts are tightened.
11)
All the sealing parts must be sealed well without friction between metals.
12)
Motor and control system, instruments, lighting, signal device should be complete well.
13)
All the auxiliary equipments should run normally.
14)
Material warehouse should have enough material reserves.
15)

Before commissioning, record the following measurements: elevation of settlement

observation point, the position of mill center line and height of reducer base plate.
16)

During the commissioning, the operators shall stay in the safety area. No sundries
should be left over inside the equipment. Any workpiece disturbed the operation of
equipment is not allowed to be placed around it.
6.2 Empty load test run

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Empty load test run should be carried out after the qualified inspection of the mill.
1)

Start the lubrication system (including the lubrication of main motor and reducer system
devices) and high pressure starting system before the empty load test, making the barrel
float and the lubricating oil enter into the friction pair.
2) 12

Start the slow driving device. Slowly rotates the barrel for one to two turns without
collision and distribution of normal operation according to the requirements. Stop
grinding and disconnect slow driving clutch. Finally start the main motor.
3)

1
Operate the empty load running after start the main motor (without the grinding body or
feeding material) to ensure the correct rotation direction of the barrel. No reverse is
allowed. Rotate with empty load for an hour. Give inspection during this period and
meet the following requirements:
a.
The startup, operation and interlocking devices of each part in the motor electric control
system are working normally;
b.
Lubricating devices of each part and cooling system are working normally. Each
monitoring testing instrument reacts normally;
c.
Temperature of each lubricating point is normal;
d.
The mill rotation should be stable. Reducer and motor are without abnormal vibration
and noise;
e.
Liners and rotating parts are without loosening;
f.
All lubrication system and water cooling system should not have oil leakage or oil
seepage, water leakage or water seepage.

Once the above issues are found, stop the mill at once for inspection, adjustment and
treatment.
4)

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During the empty load test run, the high pressure lubricating system is not allowed to
stop running.
6.3 Load test run

After the empty load test run is confirmed to be out of question, the load test run can be
performed.
1)
Before the load test run, start other auxiliary equipment of powder grinding system first.
2)
Load test run should be performed gradually according to the loading program, and feed
the material of relative amount at the same time.
a. 30% 24
Put in 30% rated load of the grinding media. Run for 24 hours.
b. 50% 72
Put in 50% rated load of the grinding media. Run for 72 hours.
c. 75% 120
Put in 75% rated load of the grinding media. Run for 120 hours.
d. 100% 96
Put in 100% rated load of the grinding media. Run for 96 hours continuously.
3)

During the load test run, in addition to the relevant inspection according to the empty
load test run, the inspection of whether the motor current fluctuation is normal should
also be taken. The motor current shall not exceed the rated value; otherwise the loading
capacity should be reduced appropriately. Check whether bolts here and there are
loosening or not. Check whether feeding device and discharge device have material
leakage or ash leakage problem. Check whether airproof condition is good or not. The
bearing temperature should not exceed the set value.
4)
During the load test run, the running must be stopped immediately once the abnormal
condition occurs and treatment should be taken.
6.4
Conduct according to the respective technical documents to match parts such as the
transmission parts, sliding shoe bearing lubrication device and electric control parts.

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Operation, Maintenance and Repair

7.1 Operation

The mill can be put into use after the test run and qualified inspection. The mill should
be operated by special person. The operators should be familiar with the main structure of
the mill, equipment performance and operation points.
7.2 Mill starting

The starting order of the mill and its auxiliary equipment is as follows:
a.
Lubrication system of high and low pressure lubrication devices and driving devices of
sliding shoe bearings and cooling system;
b.
Dust collector, powder separator and its discharge conveyer equipment;
c.
Mill discharge conveyer equipment;
d.

Mill main motor (barrel rotation);

e.
Feeding system;
f.
After the mill runs normally, high pressure lubrication system of the sliding shoe bearings
can be stopped.
7.3 Mill operation

Attention should be paid to the following during mill operation period:

a. 15

Mill can not run for a long period of time (usually not more than 15 minutes) without
feeding material so as not to damage the liners and consume steel balls;
b.

Feeding material evenly is one of the important conditions for the mill to obtain stable
production. The mill operator should adjust material feeding quantity according to
conditions carefully;

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c.
Adjust air flow and blast temperature according to the moisture of the material in a
timely manner;
d.
Strictly control particle size and moisture of the material getting into the mill. The
particle size and moisture can not exceed the design requirements;
e.

Adjust grinding body gradation according to working conditions, supply the grinding
body into the barrel in a timely manner and keep the loading capacity and gradation of
grinding body always in the best condition;
7.4 Emergency mill stop

When following unusual circumstances occur during the mill operation, contact the
relative post, stop the mill in a specified order, and check the reason and get rid of the
trouble:
a. 60
When sliding shoe bearing lubrication or cooling system fails, and the bearing
temperature exceeds the set value (60 C) and continue to rise;
b.
When connecting bolts become loosen, broken or dropped off;
c.
When the parts inside the mill drop off;
d.

When the diaphragm plates and discharge grate plates affect production because of
clogging in holes (stop feeding system immediately and decide according to the
condition);
e.

When the reducer and its lubrication system have abnormal situation (check relative
documents of reducer and its lubrication system for detail);
f.

When the motor and its lubrication system have abnormal situation (check relative
documents of the motor and its lubrication system for detail);
g.

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If the power off occur during the mill operation, switch off the power of mill and its
auxiliary equipment in case of the accident happens when the power is back.
7.5 Mill stop sequence
a.
Feeding system
b.
Main motor
c.
Mill discharge conveyer system
d.
Dust collection system, powder separator
e.
Discharge conveyer equipment of dust collection system
f.
After the mill, sliding shoe bearing, reducer and motor cools down to the room
temperature, stop the lubrication and cooling system.
7.6
Items to be notice before and after mill stop
a. 10

Ten minutes before the mill stops operation, the sliding shoe bearing high pressure
device should be started to prevent bearing alloy from damage when the cooling of mill
cause contraction until the mill is completely cooled to room temperature (ambient
temperature);
b.
Lubrication and water cooling system are not allowed to stop before the mill and sliding
shoe bearing cools down to the room temperature.
c.
180

To avoid the deformation of mill barrel, start slow driving device to rotate mill
according to the time interval of Chart 4 after stop mill. Rotate mill to 180each time
until the mill temperature cools down to the room temperature. The customer can
confirm the time interval of rotating mill according to real condition.
d.
When the mill stops for a long period of time, disassemble the grinding body inside the

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barrel to avoid deformation of barrel.

e.

When the mill stops for a long period of time, drain off the cooling water everywhere
(cooling water in pillow water pipe, best use compressed air to blow off) to avoid
equipment cracking from freezing.

Time interval

10min

10min

20min

20min

30min

60min

60min

Stop mill
Reverse time

Chart 4

7.7 Maintenance and Repair

7.7.1

The routine maintenance periodic inspections of mill are the important measures to
ensure the well performance of the equipment and long-term safe operation. Therefore,
specially assigned person should give inspection and maintenance by shifts day-to-day.
The specific schedule can be made according to the user party. In addition, the device will
inevitably cause some wear and tear during operation. When the wears reach certain
degree, safe and normal operation can not be guaranteed. In order to maintain the good
performance of the device, the worn parts must be timely repair or replaced. The specific
maintenance plan can be made according to the relevant technical document
requirements.
7.7.2
Pay attention to the main items regarding maintenance and repair
a.
Pay close attention to pillow temperature changes of sliding shoe bearing;
b.

Check the sliding shoe bearing, reducer and lubrication system operation condition of

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motor from time to time and give timely treatment to ensure that the equipment is running
under normal operating conditions.
c. 25

When the ambient temperature is low and deal with oil supply or change, maintain the oil
temperature at about 25 C.the deteriorated or uncleaned lubrication oil is not allowed to
be usded;
d. 12

To the sliding shoe bearing pillows just put into use or changed, the lubricantion oil should
be discharged totally after the mill operation for one to two months. Clean the oil tank and
replace it with new oil (carry out the reducer and motor according to the respective
technical documents regulations);
e.

Check whether connecting bolts and anchor bolts of the important parts are loosening or not
from time to time. Check whether the reducer and sliding shoe bearing have any abnormal
vibration and noise. Once the problem occurs, stop the mill immediately for inspection and
treatment:
1)
Check the elevation of foundation settlement observation point to estimate the
condition of settlement;
2)

Whether the reasons of foundation settlement, iron pillows or anchor bolts loosening
lead to accuracy change of the original installation. If installation accuracy decreases,
retification and adjustment should be exectued to the equipment. The mill cannot
start until it meets the design requirements;
f.
Check whether the cooling system is smooth or not from time to time;
g.

Check the airproof condition of feeding and discharge devices. If the wear and tear is
serious or the sealing effect is affected by it, adjustment, replacement should be maken or
take other measures in a timely manner. Pay attention to the timely grease supplyment;
h.
Check whether instruments of all kinds, signal, lighting and control system are sensitive

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and complete;
i.

Check whether the connecting bolts and anchor bolts of liners are loosening, broken or
broken off. Make frequently inspection at the initial stages when these items are newly
replaced or after their installation to prevent them from loosening.
j.
Check whether the mill barrel interferes with the feeding device after the thermal
expansion;
k.
Pay attention to deformation of parts, expansion and temperature rise due to thermal
expansion.
l.

Check the wear condition of each liner periodically. Timely replace the worn out and
broken liner. Screw down and replace the loosening or broken liner bolts to avoid the wear
of barrel and ash leakage.
m.

Well maintain environmental health and clean regularly. Follow the rules of no oil, water, or
ash leakage; no oil dirt; no loosening bolts; no debris around the device;
n.
Carry out the lubrication device, reducer and motor according to the relevant technical
documents.
7.7.3 Maintanance

During the process of equipment operation, the consumption of mechanical wear and
exhaustion parts is necessary. Some parts reduce from the original accuracy or even are
been damaged so that the equipment safety normal operation can not longer be guaranteed.
The worn parts and components must be repaired or replaced. Regular maintenance is the
regular preventive repair and replacements designedly before the parts lose their original

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accuracy and the ability to work in accordance with the wear and fatigue law of equipment
parts. The user should make a reasonable maintenance plan based on the specific
circumstances of the equipment and prepare enough stand-by and spare parts. Regular
maintenance is divided into three type i.e. minor repair, periodic repair and heavy repair, as
described below:
7.7.3.1 Minor Repair
12
Generally minor repair is carried out once every one to two months. It can be carried out at
any time in case any special circumstances occur. The maintenance projects are as follows:
a.
Include all items of daily inspection;
b.
Examine and repair oil pump, oil filters and lubrication piping in the lubrication device.
Change lubrication oil and clean the oil tank;
c.
Check connecting bolts everywhere and change the bolts with defects;
d.
Check reducer and make records. Check wearing parts such as couplings;
e.
Clean, examine and repair of ventilation systems to maintain the tightness of the sealing
device;
f.
Check, repair and replace the wearing parts of feeding and discharge device;
g.
Check the barrel liner. Remove inclusions in the grate seam to make the grate seam smooth;
h.
Check usage condition of the pillow and the sealing parts in the sliding shoe bearing device.
7.7.3.2 Periodic Repair
12
Generally, the period of periodic repair is once every twelve month. Items to be repaired are
in the following list:
a.
Include all the minor repair items;
b.
Change liners, diaphragm plates and discharge grate plates;
c.

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Inspect and adjust the level position of the mill, inspect the coaxial of transmission shaft,
reducer and motor.
7.7.3.3 Heavy repair
10
Generally, the period of heavy repair is once every ten year. Items to be repaired are in the
following list:
a.
Include items of periodic repair, minor repair and daily repair;
b.
Replace pillows of the sliding shoe bearing;
c.
Check, repair or change the barrel and the transmission pipes;
d.
Repair the foundation. Readjust the alignment and perform the secondary pouring.
7.7.3.4 Notice for maintenance
a.
Prepare the stand-by and spare parts in advance for this repair;
b.
Strictly prohibit people stand on both sides of the mill when assemble the grinding body;
c.
Cut off all power of the main motor and other area during the maintenance. No one is
allowed to switching in to start without approval of the assigner;
d.
All maintenance personnel must wear a safety helmet;
e.
Before encapsulation of mill door holes, make sure no person, tool and debris is in the mill.
7.8 C
Check Appendix C for recommendation of lubricating oil and dosage.
7.9 D
Provide a set of drawings and documents with the instruction for the convenience of users
installation, maintenance and overhaul. Check Appendix D List attached catalog.

3.8x13m 3.8x13mCement mill

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page 40 of 48

Appendix A. Installation of Coal Mill Barrel Liner

a. Installation
1mm
10mm
The liner must be placed correctly and carefully with the gap not more than 1 mm away
from the contact surface of barrel to make sure the grinding body load evenly distributed to the
contact surface. The gap between the adjacent liners is not more than 10 mm.
u
Installation of double ladder liner and ring groove ladder liner

Pay attention to the direction of the liner when install the double ladder liners. Do not
install wrongly. There is a row of liners without bolts under the slip rings of both ends. There
is gap between every two liners as well as the liners of both sides which must be filled and
wedged by steel plate with proper thickness. In addition, a layer of heat insulation sole plate
should be installed between the barrel near the slip rings on both sides and the liners. Check
mill rotation part assembly drawing for more detail.
u Installation of grinding head liner

Check whether the combination of the bolt hole surrounding area is flat or not carefully
when install grinding head liners. Remove the casting defects of liner surface.

1mm
To the contact surface of grinding head liners, keep the well contact of grinding head
liners and webs of the slip rings. The gap should be not more than 1 mm.
u Installation direction of liner

Pay attention to the direction of ladder liners and grade liners during the installation
period. Check liner assembly drawing in the mill rotation part. Meet the following
requirements in the picture.

3.8x13m 3.8x13mCement mill

Mill rotary direction

K4536.00SM

Feeding end

page 41 of 48

Discharge end

b. Fastening

Connect the liners and the barrel with oval head bolts. Oval head must have good
contact with liner oval hole. Avoid the unilateral stress phenomenon. Install corresponding
sealing washers and pressure loop on the bolts projecting outside the barrel. Tighten the bolts
to the specified torque according to the Appendix C. Screw down through several
readjustments until the tightening torque value keeps unchanged. The bolts in the barrel
should go through test run and be tightened time after time. Spot weld the bolts after confirm
they are in good contact and screwed down.
c. Inspection

Welding seams inside the barrel should be grinded to flat. Repair the defects in the
barrel. No casting defects that will influence the installation and the intensity of the liners are
allowed. If the liners have the defects that will influence the installation, repair the defects
before installation.

3.8x13m 3.8x13mCement mill

K4536.00SM

page 42 of 48

Appendix B. Installation Requirement of Bolts, Nuts and Tightening Torques

All the connecting bolts should be tightened to the torque value required in the
tightening torque table. Inspection with torque spanner is recommended.

Check all bolts and nuts before installation. Make sure the frictional between them is the
smallest one. In addition, use motor oil to lubricate thread and mix molybdenum disulfide
lubricant into the motor oil.

The bolts can be classified into following five types according to the strength
requirement of connecting position:
I.

8 12

Bolts for installation main parts on the mill barrel, such as connecting bolts for sliding
shoe bearings, etc. should be tightened within 8 hours after assemble, rotate and operate
the mill for a period of time for the first time. After that, tighten the bolts once every 12
hours until the torque keeps the constant required value.

II.
2
12

Bolts for installation bracket of diaphragm plate, scatter plate of discharge grating plate,
liner and grating plate of diaphragm plate, etc. must be tightened by the torque spanner for
fixture. Turn the mill. Tighten the bolts within less than 2 hours. After that, tighten again
every 12 hours until the torque keeps the constant required value. The bolts connecting
blind plate of diaphragm plate and grating plate should be tack welded after tightening.
III.
8
12
Bolts for barrel liner and grinding head liner should be tightened by torque spanner for
their extending out of the mill barrel. After the grinding body and material is loaded into
the mill and rotated, tighten the bolts again within less than 8 hours. Tighten the bolts
every 12 hours until the torque keeps the constant required value.

3.8x13m 3.8x13mCement mill

K4536.00SM

page 43 of 48

IV.
8 12

Common bolts and anchor bolts for installation of mill feeding device, discharge device,
and sliding shoe cover should be tightened within 8 hours after the grinding body and
material is loaded into the mill and rotated. Tighten the bolts every 12 hours until the
torque keeps the constant required value.
V.

M33x212.9 2000 Nm
2h 12h

Connecting bolts M33x2Grade12.9with 2000 Nm tighten torque of fixing block (in the
diaphragm plate) and barrel should be tighten within 2 hours after the mill runs. Tighten
the bolts every 12 hours until the torque keeps the constant required value.

Tightening torque table of bolts and nuts

Bolt size

(N.m)
Tightening torque

Bolt size

(N.m)
Tightening torque

M24

270

350

220

M10

11

M30

540

700

450

M12

19

M332

730

950

600

M16

47

M362

850

1150

700

M20

93

M423

1450

1900

1200

M24

157

M483

2200

M30

315

M564

3400

M36

570

M584

3800

M42

960

M644

5200

M48

1400

M684

6300

M64

3350

M744

7500

M764

9000

M804

10500

3.8x13m 3.8x13mCement mill

K4536.00SM

page 44 of 48

80% 75%

Special attention:
Before install all the coupling bolts, deburr and clean flap edge at all the coupling bolts holes
on both sides according to the requirements. The contact surface should be clean and without dust
or debris. Chamfer all the edges of coupling bolts holes on both sides according to the
requirements as well so that the reasonable installation of coupling bolts is guaranteed. To the
place applying double nuts structure, the thick nut should be put on the top of the thin nut. The
bottom nut should achieve the 80% value in the tightening torque table. The top nut should
achieve the value in the tightening torque table. The anchor bolt can not be tightened until the
concrete reach 75% of the design intension.

3.8x13m 3.8x13mCement mill

K4536.00SM

page 45 of 48

Appendix C Application table of lubricants

Lubrication point

Name

Lubrication
method

Allowable
temperature

Sliding
shoe
bearing

Circulating
lubrication

See notes

Seal
feeding
and
discharge
material
device

Serial

Lubricant

No.

Name

Standard
code

Oil changing
period
68

Reducer

Motor

N320N460
N680

GB5903-95
Industrial
gear oil

12
6-8 months
(1-2 months
in the
beginning
stage)

2# complex
calcium
lubricating
grease

Check
from
Grease
SH/T0370-95
time to time,
lubrication
supply more
when
necessary

Execute according to the specification in the technical documents provided

by the reducer manufactory.

Execute according to the specification in the technical documents provided

by the reducer manufactory.

Note: Choose lubrication oil trademark of the sliding shoe bearing according to the oil working
temperature. Normally oil working temperature depends on grinding material temperature,
environment temperature and cooling water temperature. Connection between oil working
temperature (namely temperature of end face thermo resistance) and oil trademark is listed in the
following table for the reference of the customers.

3.8x13m 3.8x13mCement mill

K4536.00SM

page 46 of 48

Connection between oil working temperature and oil trademark

Oil working
temperature()

Oil trademark

Alarm
temperature()

Stop temperature of
main motor()

4065

N320

65

70

6585

N460

85

90

8595

N680

95

100

N460()
6585
Normally oil N460 will be chosen for sliding shoe bearings. If the temperature changes
during the working period (for example, summer or winter) and the temperature is not within the
range of 65 to 85, the oil can be changed according to recommendation of the table 3.

3.8x13m 3.8x13mCement mill

K4536.00SM

page 47 of 48

D 16
Appendix D. Attached Drawing Catalog (Totally 16 drawings)

Serial
No.

Dwg No.

K4536.00 SM

K4536.1.0 SM

Name
3.813m
3.813mCement mill

Quantity

Material

Remark

drawing
2

Feeding device

K4536.2.0 SM

Sliding shoe bearings at the

K4536.2.2.0 SM

Sliding shoe cover parts

5

K4536.2.8.0 SM

K4536.3.0 SM

K4536.3.4.0 SM

Sliding shoe bearings at

K4536.5.0 SM

Discharge cover

K4536.6.0 SM

Sliding shoe installation

device

Component

10

Component

discharge ends
9

Component

K4536.4.0 SM

Component

Liner parts

Component

Rotation unit
7

Component

Piping system
6

Component

feeding ends
4

Component

General

Component

3.8x13m 3.8x13mCement mill

K4536.00SM

page 48 of 48

Appendix E. Spare part list

Serial No.

Dwg No

K4536.3.4-9

Name

standard Ring groove

Quantity

Position

Coarse grinding

ladder line

compartment

K4536.3.4-20

Double ladder liner1

Fine grinding
compartment

K4536.3.4-21

Double ladder liner2

Fine grinding
compartment

20
4

Liner bolts&accessories

Each of
the 20

Pt-100
5

Platinum resistance

Pt-100
6

10

The liner and bolts at

the feeding ends

The liner and bolts at

the Coarse grinding
compartment

The liner and bolts at

the Fine grinding
compartment

The liner and bolts at

the Diaphragm plates

The sealing ring at the

Sliding shoe cover

Liner parts

Sliding shoe
bearings pillow

3 sets

Feeding ends

1
1 sets

Coarse grinding
compartment

0.5
0.5 sets

Fine grinding

3 sets

Diaphragm
plates

compartment

2
2 sets

Sliding shoe
bearing

Remark