Retrofit mill 8F May

09-22,
2018

Retrofit Mill 8F
Report

By
Sukri
Billy CP

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I. INTRODUCTION

POMI was embarking on a mill refurbishment program, in an effort to regain

the mill design capacity. This

include a complete mill internal inspection and replacement/repair of damage

areas and components. As

well as replacement of the following parts of the mill with a mix of original
components from OEM and

modified components from third party.

Coal pipe orifices

Classifier blades

Return cone

Journal assemblies (including trunnion assemblies, 1 set C1)

Grinding rolls

Journal spring assemblies

Liners

Table segment (bull ring segments)

Vanewheel and lower baffle plates

Mill underbowl scrapper

GE has been asked to carry out the mill internal inspection, repair of damage
components (where possible),

installation of newly supplied components (supplied from various vendors)

and conducting pre- and post-

refurbishment grinding fineness test at the reference classifier position (6).

This report details the inspection results, installations of the parts, including
the difficulties and deviation of

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third party parts with the original OEM parts, mill grinding fineness results
and mill air flow (MAF) data

analysis. Repairs were implemented after full consultation and agreement

with POMI representative.

Installation and modification of third party parts are under instruction from
POMI.

II. MILL RETROFIT RECOMMENDATION AND COMPONENT

INSTALLATION SUMMARY

1. RECOMMENDATION

Below are some recommendations to improve mill performance and

safety:

a. Based severe coining on the bowl which causing bull ring

segments broken into three pieces and chipping, it is
recommended to replace the pulverizer bowl on the next
opportunity to eliminate any potential broken segments
ejection during mill in operations.

b. Severe wears were found on the upper section of the inner

cone, especially on mill 8F operation.

c. Severe wears were also found on the mill top separator,

above the classifier blades. Those wears can be repaired by
patch weld and grind flush and it is recommended to be
done during the next 4000 hrs.

d. Journal head thrust plate were found good, especially on

the leading section. At the moments, additional fabricated
rings are installed for the temporary repair. However, thrust
plate replacement are recommended to avoid journal head
shifting.
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e. Some temporary orifices installed on the orifice box have

different inside diameter compared to the original orifice.
Clean airflow test and dirty air flow test are recommended
to ensure pipe to pipe balance and minimize furnace
imbalance.

f. POMI separator top are welded to the mill body and need to
be removed for the bowl replacements. During this time,
POMI should consider implementing other major changes
such as Dynamic Classifier which will also eliminate the
need of the inner cone replacements, separator wear repairs
and also can increase mill capacity and operation
flexibilities.

g. The MAF curve generally follows the GE curve, however,

there are instances where there appears to be significant
variation to the air flow which would have significant
impact on the mill’s internal dynamic. This needs to be
methodically investigated further to ensure optimum mill
performance at the desire capacity.

2. MILL COMPONENTS INSTALLATION SUMMARY

1. Components :
1 set of classifier blades (Par Alloy), (without accessories)
3 sets of journal heads existing ( on C1 ex. Unit 7 (GE) with
new grinding rolls (Refurbish and New journal liners (Par Alloy)
3 sets of journal spring assemblies (Par Alloy)
1 set of bull ring segments (Par Alloy) with existing the
extension rings
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1 set of vanewheels (Par Alloy)

1 set of scrapper assemblies (Par Alloy)
1 set of deflector body (Par Alloy)
1 set of coal pipe orifices box complete with the orifice plates
(Par Alloy)
1 set of lower baffle plates (Par Alloy)

2. STORM Engineering
Suggestion about air flow circulating in grinding rolls area by to
cutting inner cone and resetting clearance innervated cone
The decision of the parts to be installed on each mill were decided
by POMI.
.
III. MILL INSPECTIONS and COMPONENTS INSTALLATION
The scope for the mill refurbishment include a set program of mill parts
replacement in conjunction with a mill inspection of the mill internals,
covering the areas, detailed in the introduction. Details of the findings
during the various mill inspections are detailed in this section, together
with the various issue encountered during the replacement of the mill
parts, which included parts from GE, PAR Alloys and Storm
Technologies. No installation issue for all mill components supplied by
GE, but for other vendor, some modification should be done on some
parts to enable the installations. Below are the summaries of mill parts
installation on unit #8

1. Coal Pipe Orifices

Existing coal pipe are still in good condition,

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Although most of the orifices are still in good conditions, all coal
pipe orifices were replaced with quick change orifice boxes
supplied by PAR Alloy.

Orifice (GE) before Orifice after retrofit (PAR Alloy)

retrofit

Orifice after retrofit (PAR Alloy), Open position C1:0, C2:1.5, C3: 2, C4:

2. Classifier Blades
As Found Classifier Blades:
Blades thinning were found on the existing classifier, especially on
the bottom edge of the blades. The worst thinning was found on
mill 8F which has reduce to half of its original thickness.

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Thinning of the classifier blades on mill 8F is less and should last

until the next years with current wear rate until it reaches half
thickness and need replacements.
Localize erosion were also found on the mill top separator body,
above the classifier.
constrains, those wears were temporary repaired by applying
Duromar. Those wears should be permanently repaired by weld
and grind flush on the next opportunity.

New Classifier Blades Installations:

During retrofit, all the curved classifier blades were replaced with
PAR flat design classifier. Previously, during the 3rd phase of the
retrofit, classifier installed on mill 8F was PAR classifier (copy of
original design)
Due all those mills will be tuned by PAR, POMI decide to replace
classifier blades on mill 8F with PAR classifier design during the
second phase (during remaining orifice box installation). Only the
blades were replaced, all the accessories which include hinge, link
levers, bushings, support, shafts, link rod are a combination of
new and existing OEM parts (GE).
As per (PAR) setting procedure, blade-to-blade clearance at closed
position (position 10) should be within 1”- 1.5”. Due to particle
guide installed on the blades overlap with the adjacent shaft bolts,
the closest clearance achieved at fully closed position (position 10)
is 38 mm (1.5”). The clearance between the top of the blades edge
to the drum opening at position 4 (60% opening) was measured at
16 cm, while at position 0 (100% opening), the blades edge to drum
opening was measured at 24.5 cm.

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Old blades classifier New blades classifier (PAR Alloy) after retrofit, new type
(GE) before retrofit blade

3. Inner Cone
Original thickness of the inner cone was 16 mm, wear resistance
plate (Cruesabro), the estimated remaining life on the mill 8F are
less than 10 years. It is recommended to replace those inner cones
with new one to avoid inner cone collapse or flow bypass during
operation. Erosion was also found on the inner side of the cone,
especially at the weld joints. These areas of erosion were repaired
by weld during retrofit.
The existing inner cone was modified as per STORM design
recommendation. The inner cone
opening was widened to 34.5 inch, the feed pipe was cut so the
perpendicular distance between the feed pipe to inner cone set to
12.5 inch and the inverted cone was raised so the opening become
10

Inner cone 8F Before Inner cone after

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Modified Inner cone 8F after Retrofit

4. Journal Head
As Found Journal Head Severe wear was found on the lower
section of journal head ribs C1, where the support for the journal
liner will no longer hold the bolts. All other journal heads were
relatively still in good conditions. Only one on C1 to replace take
ex. journal heads (ex .unit 7), (1 ea local fabrication trunnion due
to spare only 1 ea)

Process install new trunnion of journal C1 during retrofit ( 1 ea part

Journal Head Installations

Install Existing journal heads (ex .unit 7), supplied by GE journal
head were installed on mill 8F. No problem found during GE
journal head installation.

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On the trunnion shaft (1ea fabrication on local) and trunnion

housings, On the original design, this gap was designed so the
seal air will bleed to prevent the coal entering the shaft.

The fully assembled journal assembly, when installed and tilted

into position,

After all three grinding rolls were installed and tilted in placed,
it was noticed that no more thread left on the stop bolts to achieve
desired ring to roll clearance.

  It was also noticed that the contact point between stop bolt and
journal head are not even between the right and the left side . The
right contact point position is more forward compared to the
left which causing the right contact point to bear a higher journal
assembly weight.

  Journal head in contact with the stop bolt is thinner compared

to the existing journal. The Existing journal head area, supplied
journal head having 91 mm thickness

5. Journal Shaft, Grinding Rolls and Journal Liners As Found

Journal Shaft End-play of all the installed journal bearing
assemblies were checked to assess the bearing condition.
The maximum allowable end-play is 0.381 mm, before the journal
has to be disassembled for detail inspection and replacement, if
necessary.

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It was recommended to refurbish and replace the journal bearing

on the mentioned journal shaft above, but POMI decide to replace
the journal shaft with the new one,
As Found Grinding Rolls Wear on the installed grinding rolls
measured with the new grinding rolls template to assess the
existing condition. The maximum grinding rolls wear depth is
25.2mm

Wear on mill 8F grinding rolls not exceeded 25.2 mm and need

replacements. POMI decide to replace all the grinding rolls with the
new one.

Grinding Rolls assembly Grinding Rolls assembly

(GE) before retrofit (GE) after retrofit

Old Grinding Rolls (GE) before New (Refurbish)Grinding

retrofit (max. deep 25.2mm) Rolls (GE) after retrofit

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End play Bearings of Grinding Roll

As Found Journal Liners

Journal liner were still in relatively good condition, with minor
wear on the lower section of trailing segments, as a results these
were not replaced with new ones

Existing journal liner Reused

Existing Journal Shaft Assembly Installations, while three new GE

journal shaft assemblies were installed on mill 8F. Before journal
and grinding rolls installed, end-play check on the new grinding
rolls were done with the result presented.

With maximum allowable end-play is 0.381mm all above journal

shaft end-play value were found to be within the acceptable limit.
Maximum splatter height was measured to be 0.25mm, while the
gap between ring to roll should be maintained at 4.5 mm at the
highest point.

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Existing journal shaft Reused

.

6. Journal Spring Assembly

As Found Spring Assemblies
Existing spring assemblies were visually still in good conditions,
with the signs of journal shifting in the spring stud. No spring
travel test and spring re-tension on the existing springs during
retrofit. It was recommended to open the existing spring, clean the
spring, travel test and re-tension the spring if the spring will be re-
used, but POMI decide to replace all the springs with the new one.

New Spring Installations

PAR spring assembly were used on mill 8F, no problem was
encountered during the installation and setting of the GE spring
assemblies. On the other hand, some difficulties during the
installation of the the PAR spring

Assemblies:

 New Spring constant between the first test and second test
were no different (PAR). Spring travel at 3000 psi hydraulic
pressure.

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Those spring then locked and release again after at least 3

days. On the second test, the spring travel was near to 1
inch as expected spring were to have the same spring
constant as the original design. Spring constant and spring
tension setting had to be repeated at least twice to get
consistent value.

Due to inconsistent spring travel on PAR Springs, it is

recommended to check these spring travel after mill have
had the chance to run in.
Due to the high coal level of coal reject during mill low load,
all spring stud to journal head gap was set to 0 (zero to
provide grinding force during low load.

Journal spring assembly Journal spring assembly

(GE) before retrofit (PAR alloy) after retrofit

Journal spring assembly (PAR Alloy) before retrofit

7. Bull Ring Segments and Grinding (PAR)

As Found Bull Ring Segments
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Most of bull ring segments were broken, but some were found to
be crack. According to GE recommendation, segments which are
found broken and cracked has a high risk of dislodgement during
operation and as such is recommended for replacement.

Bull Ring Segment (GE) before Bull Ring Segment (PAR Alloy) after

As Found Grinding Table (Bowl)

Coining damage were found on all grinding tables, especially on
the middle sections. Thee coining is the cause of three pieces
broken segments found during inspection. Temporary
actions have been taken to avoid three pieces segments broken by
applying hybrid shims on the flat sections of the table. The table
need to be replaced with the new one to avoid three pieces (or
more) broken segments and segments ejection for the safety
reason.

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Table (GE) before New bull Ring segment (PAR Alloy)

New Bull Ring Segments Installations

PAR Bull Ring Segments were installed on mill 8F, while GE
segments were installed on mill. No issue arises during GE
segments installation. Some differences between PAR segments
and the original segments were noted as follows:

  All bull rings segments supplied by PAR are plain and not
equipped with the ribbed Segments.GE original design for the bull
ring segments are equipped with the 8 (eight) ribbed segments,
installed at every 40 degrees. Those ribs were originally designed to
aid in initiating the grinding rolls to turn at start up.

  The back end on the new segments are almost flat and the
recess is very narrow
The recess on the existing segments are much deeper and designed
to
break to protect the table from the direct impact of the grinding
roll.

  PAR bull ring segments are thicker compared to the original

design. PAR segments thick is 71 mm, while original thickness is

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65 mm. This thicker segment also contributing in the short of

journal head stop bolts as explained on the section 4 above.

GE bull ring segments were designed for HP1103 installed on

Paiton #7 and #8 and manufactured to the dimensions and
tolerances of a new pulverizer bowl assembly, including the bowl
extension ring and clamping ring. Each bullring assembly then is
shop assembled and test fitted by assembling it into a fixture bowl
which is a duplicate of the
bowl of HP1103. With this method, the wear bowl wear on existing
mill will be known.
Maximum allowable shims should be less than 1” to eliminate any
possibilities of bull ring segments chiming loose during operation,
which will cause failure of the pulverizer with related damage to
the pulverizer drive and other pulverizer grinding components’. If
the
shims installed are exceeding 1” indicates that the bowl is
approaching the end of its service life and requires replacement in
the near future. For mill 8F, bowl wears are known because GE
bullring segments were installed on these mills. The shims
required for mill 8F
were 41.4 mm, were 35.4 mm which is more than 1” (25.4 mm).
With PAR bullring segments installed, the wear on the bowl are
unknown because the fixture used during fabrication are
unknown. However, if the bowl are of similar age, then it is safe to
say that these grinding tables are also approach their end of life.

During ring to roll setting, it was noticed that on PAR segments,

the difference of the clearance between inboard and outboard
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segments are high compared to GE. Ring to roll clearance setting

result

8. Extension Rings
Existing extension rings were reused on mill 8F. Before the
extension ring re-used, those rings were refurbished by removing
existing shims. PAR supplied extension rings could not be used
due to the following reasons:

  Shorter height compared to the existing ring (existing ring

height is 125 mm and PAR ring
height is 85 mm). The use of this lower design would create a chain
reaction and result in the lowering of the vane wheel position,
lower baffle plate position and will create gap
between baffle plate to deflector body if current position of deflector
body assemblies is maintained.

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The bolts used to install the extension ring to the bowl were
ordered to be used with existing design. Due to lower height of the
new extension ring, the bolts could not hold the ring tightly.

Reinstall Extension Ring and torque bolt 500Ft.lbs

9. Vane Wheels
As Found Vane Wheels
Minor to severe wear have been found on the vane wheel tip,
especially on the outboard edge.
Wingtips length also have been reduced from 82.5 mm to 80 – 69
mm. It was unknown why the wingtips length different, but during
4000 hrs maintenance interval, wear on some mills have been
repaired by patch weld by maintenance team. Existing vane wheels
condition.

New Vane Wheels Installations

Newly supplied vanewheel by PAR were installed on mill 8F. No
problems on GE vane wheels during installation. Some differences
between PAR supplied vane wheels and the original vanewheel .

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New vanewhell after retrofit

  PAR vane wheels are higher (272 mm) , compared to the original
(260 mm)
This higher vane causing the baffle plate installation to be lowered
by 12 mm compared to the previous installation. Fortunately, no
additional plate required to close the
gap between separator body with the baffle plate.

  PAR vane wheels are 10 mm wider compared to the existing.

PAR vane wheels wide is 240 mm, while existing vane wheels wide
is 230 mm. These wider segments caused 60-mm gap between the
last segments to the first segment on the baffle plate.
PAR vane wheel open area is greater compared to the original
design as the wide greater 196 mm than the original 184 mm

  PAR vane wheel segments need to be grinded by 4 mm (2 mm

on each edge) to enable tight installation between vane wheel with
the extension rings

  PAR vane wheels wing tips were shorter compared to GE vane

wheels. PAR wing tips width were 62 mm on the inboard and 72

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mm on the outboard while GE vane wheels wide were 82.5 mm on

the inboard and outboard side

Existing Vanewheel (GE) Hight:260mm, Wide:230mm, Open area:184mm

New Vanewheel (PAR) Hight:272mm, Wide:240mm, Open area:196mm

10. Deflector Body, Deflector Liners and Intermediate Liners

As Found Deflector Body and Liners
Existing deflector body were installed along with rolled plate liners.
These rolled plate were made of 20 mm wear resistance plate
(Creusabro). The conditions of existing deflector body and its liners

As Found Intermediate Liners

Thickness check have been done on the existing intermediate liner.

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New intermediate liner after retrofit

New Deflector Body, Deflector Liners and Intermediate Liners

Installations PAR Alloy deflector body installed on mill 8F.

PAR Alloy deflector liners installed on mill 8F,

Deflector liners on mill 8F installed with weld plug methods, while
on mill 8F the liners were installed using bolt and weld methods .
There was no problem found during PAR Alloy deflector body and
deflector liner installation.
  Total length deflector body was compared to the original body.
  The radius of fabricated separator body same from the existing
which causing the installation easily. Additional 10 mm round bar
were installed to close the gap between
upper separator body to the mill body
Due to new intermediate liners available were only 3 set, which
installed on mill 8F

Old separator body New separator body and deflector liner (PAR
(GE) before retrofit Alloy) after retrofit 22
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11. Lower Baffle Plate

As Found Lower Baffle Plate
Cracks have been found on the existing lower baffle plate segments
joints. Shims installation also found on the mill 8F baffle plate. All
existing lower baffle plate were never been replaced since the unit
commissioned.

New Lower Baffle Plate Installations

GE lower baffle plates were installed on mill 8F, while local
fabricated baffle plates were installed on mill 8F. PAR supplied
vane wheels were 10 mm wider compared to the original vane
wheels. On mill 8F, GE lower baffle plates were installed along with
PAR supplied vane wheels. GE lower baffle plates were designed to
be installed with GE vane wheels. When these lower baffle plates
installed with PAR vane wheels, there were 60 mm gap between the
first and the last segments of the lower baffle plates in order to
maintain 16 mm clearance between vane wheels with the lower
baffle plates.
These gaps then distributed evenly by giving 10 mm gaps between
each baffle plates and closed by installing round bar . When
replacement of the vane wheels required in the future, if
POMI have an intention to replace with the OEM vane wheels, the
clearance between vane wheels to lower baffle plates will be around
26 mm. 10 mm shims need to be installed on the lower baffle plate
in order to maintain 12 mm gaps between vane wheels to upper
baffle plates.

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Fabricated lower baffle plates were not rolled perfectly and still
having straight section on each edge . These straight sections were
causing difficulties in maintain the clearance between the vane
wheels to the baffle plate and the installation as well.

New Bevel vs vanewheel after retrofit (10mm) and uuper linner plate vs
vanewheel 12mm

12. Scrapper
As Found Scrapper

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Existing scrapper body were visually in good conditions. Minor to

medium wear of scrapper wear plates were found on existing
scrapper.

New Scrapper Installations

PAR new scrapper assembly were installed on mill 8F, while
existing scrapper were installed on mill 8F.
Torsion springs and wear plates were replaced with the new one on
the existing scrapper.

New scrapper and floor plate

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13. 4000 Hour maintenance

Lube oil 4000 hour service Replacement
Lubrication system must available so the Lube oil work scope
replacement :
  Replace SWG and paper gasket at flanges connection
  Clean up and Replace Lube oil filter 2 ea (duty and standby)
  Check valve inspection
  Cleaning Lube oil heat exchanger tubes by water and air as
properly
  Coupling and insert rubber coupling replacement as properly

New element filter Coupling pump of lubrication skirt

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Heat Exchanger Tubes Ex.insert rubber coupling

14. Planetary Gear

Planetary Gear Box Assembly
The function of the planetary gear box is to transfer the driving
force from the motor to the bowl through a planetary gear
reduction sstem.
Components:
 Input shaft
 Input gear set
 Planetary gears et
 Planetary carrier
 Roller bearing
 Thrust bearing
 Output adapter
The independent gearbox allows for easy removal from under the
mill, it is sealed from potential contaminant as and is not affected
by the high air inlet temperatures.
The gear box consists of a spiral bevel gear stage a nd a planetary
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Gear stage in a vertical arrangement.

The inputs haft and pinion are supported by a cylindrical roller
bearings and a pair of tapered roller bearings.
The bevel gear shaft is also supported by a cylindrical roller
bearing and a pair of tapered roller bearings. The sun gear of the
planetary stage is connected to the bevel gear shaft by means of a
crowned gear type coupling. The gear coupling allows for both axial
and radial movement.
The planet gears are supported by self aligning roller bearings so
that they can adapt to the load pattern of their teeth. The floating
sun and planet gears ensure equal load distribution on the
meshing teeth, distributing the horse power equally among the
three planets.
The forces from the grinding process are transmitted through the
hydrodynamic thrust bearing to the mill foundation. The thrust
pads associated with the thrust bearing have temperature sensors
interlocked to the mill operation to prevent thermal damage to the
thrust bearing.

Labyrinth Gear Box Input Shaft

As found oil leak at the input shaft planetary gearbox mill 8F
during retrofit do Inspection to make that indication labyrinth seal
was worn out or fatigue.
And labyrinth seal gearbox input shaft to prevent oil leak and
Visual Inspection bearing not found foreign material, dirt and
clean.
Bearing visual inspection still good condition

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Input shaft planetary gearbox and end cover

15. Fire Water Protection System

Performance test the fire system at the pulverizer 8F, end result
Fire water spray line and nozzle existing blocked after leak test ,
Unblocking and add union( 3 ea) at the line pipe that insert to
grinding area to easily unblocking next time, location C1, C2, C3,
Replace flexible houses )2 ea) at the fire water system due to was
found water leak during test , scrapper area, C1, C3 location
As found nozzle was damage and blockage on C1, C3

New flexible houses at C1,C3

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Install new union of fire protection grinding area on C1,C2, C3,

New Nozzle of fire protection after

16. Pyrite Hopper

Pyrite Rejection System (non-ABB supply)

Basic Function
Removes tramp iron and any other difficult to grind material from
the mill to a pressurized storage hopper for periodic removal.
Tramp iron or dense, difficult to grind foreign material normally
found in the coal is carried over the top of the bowl where it drops
out through the air stream to the mill bottom.

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Inside Screen and nozzle water spray for side glass

Replace packings of inlet and outlet slide gate

Add junction box and re-route instrumentation line of
pyrites hopper.
Clean up and repair screen bar
Install air line to flushing limit switch indication

17. Feeder
The feeder delivers the coal in to the pulverizer center feed pipe.
The pulverizer it self has no inherent way of regulating the
incoming raw coal flow.
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The equipment used for controlling the coal feed rate is the Stock
'Gravimetric' feeder. There is one feeder for each pulverizer.
Coal from the silo's downspout drops on to a belt which travels at a
speed dictated by the feeder speed control network in response to
loading signals from the boiler combustion control system and the
weight correction circuit. 'Gravimetric' means that the coal is
weighed to precisely calculate and control the desired feed rate.

Heavier( more dense)coal is passed along at a slower-than-

normal belt speed.
Lighter( less dense) coal is passed along at a quicker-than-
normal belt speed.
Each of the 1103 HP pulverizer expected to grind approximately
160,000 to180,000 lb/hr ( 73,000t o 82,000k g/hr

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Feeder Component
. Clean out Conveyor Take-Up Shaft,2 places: inspection and
replace pin were worn/broken
. Belt Take-Up Shaft, 1 per side: inspection and replace
bearings and apply grease (lubrication)
. Belt Take-Up Screw,2 places, : inspection and replace
bearings and apply grease (lubrication)
. Belt Drive Reducer as required: inspection and replace oil
(lubrication)
. Belt Drive Motor: inspection
. Belt Drive Motor Clutch: inspection and replace rubber insert
coupling (lubrication)
. Belt Drive Gear Reducer 1 ea, inspection and replace oil
(lubrication)
. Belt Drive Shaft, 1, on shaft, inspection and bearings and
grease (lubrication)

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. Clean out Conveyor Reducer: inspection and bearings and

grease (lubrication)
. Clean out Conveyor Gear Reducer, 2 places: inspection and
bearings and grease (lubrication)
. Clean out Conveyor Speed Reducer: inspection and bearings
and grease (lubrication)
. Clean out Conveyor Motor: inspection and replace oil
(lubrication)
. Weigh Roller Shaft,1 per side: inspection and bearings and
grease (lubrication)
. Weigh Span Roller Shafts,2 per shaft: inspection and bearings
and grease (lubrication)
. Belt Conveyor : install old belt after inspection still good
condition and test run
. Recalibration the belt feeder

Existing belt feeder 8F (still good)

18. Other
. Discharge slide gates (4 ea), replace packings.
. Manholes scrapper area (2 ea), Repair manholes
because hard to opened/closed
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09-22,
2018

. Alignment: Planetary gearbox and motor mush

inline/alignment

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 Retrofit mill 8F May
09-22,
2018

RECORD RETROFIT PROJECT PVR U8 F

9-23 May 2018

8BF-PVR-500F
No
Parts Description Remark
Access Door
Corner 1 Clean up, cut stop bolt
1
Corner 2 Clean up, cut stop bolt
Corner 3 Clean up, cut stop bolt
Journal Spring Assembly EXSISTING
Corner 1 Par Alloy 40,000 Lbs
2
Corner 2 Par Alloy ,Setting
Corner 3 Par Alloy Press.3,000 Psi
Journal Shaft Assembly New Parts
New Trunnion
Corner 1 GE (ex #7) 1ea,new trunnion
3
fabrication 1ea
Corner 2 GE /existing
Corner 3 GE /existing
Stop Bolt New Parts
Corner 1 New stop bolt (Par Alloy)
4
Corner 2 New stop bolt (Par Alloy)
Corner 3 New stop bolt (Par Alloy)
5 Journal Head New Parts
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 Retrofit mill 8F May
09-22,
2018

Corner 1 GE
Existing still good
Corner 2 GE
condition
Corner 3 GE
Journal Liner New Parts
Corner 1 Par Alloy
6
Corner 2 Par Alloy
Corner 3 Par Alloy
Grinding Roll Oil / O-Ring New Parts/refurbish
Relace Lube oil
Corner 1
OMALA680/ level 290-330
7 Relace Lube oil
Corner 2
OMALA680/ level 290-330
Relace Lube oil
Corner 3
OMALA680/ level 290-330
Grinding Roll End Play New Parts/refurbish
Corner 1 GE
8
Corner 2 GE
Corner 3 GE
Separator Body Liner New Parts
Corner 1 Par Alloy
9
Corner 2 Par Alloy
Corner 3 Par Alloy
Intermediate Liner New Parts
Corner 1 Par Alloy
10
Corner 2 Par Alloy
Corner 3 Par Alloy
11 Vane Wheel New Parts Par Alloy
12 Extension Ring Existing
Existing still good
13 Clamping ring New Parts Par Alloy
condition
14 Bowl center cover Existing
15 Bull Ring New Parts Par Alloy
16 Baffle Plate New Parts Par Alloy
17 Classifier Storm
18 Scapper Assembly New Parts Par Alloy
19 Floor Plate Repair /Replace segment
20 Gearbox seal air gland packing Replace
21 Orifice discharge Coal pipe New Parts PAR ALLOY
22 Inercone Modify
23 Inverted Cone Modify
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 Retrofit mill 8F May
09-22,
2018

24 Bowl Hub Cover No finding

25 PA Duct Screen none
26 Pyrites Inspected check and repair screen
27 Alignment Reading Alignment
Repalce Packing in and
28 Pyrites slide gate valve
oulet valves
29 Pyrites system Install new junction box
and Modified
instrumentation

. Planning is coal fineness sampling with operational

condition as follow:

- Coal mass flow 68TPH.

- Mill outlet temperature 63 – 65degC.
- No bias on PA flow.
- Steady 100% unit load to get optimum PA
temperature. Will follow production unit load planning.

Unit 8 mill retrofit coal fineness result and latest classifier

setting:

8F - #8 @40,000lbs journal spring 98.34% passing

50mesh, 86.78%passing 100mesh, 66.10% passing
200mesh.

38
Retrofit mill 8F May
09-22,
2018

39