Ball & Race mill

Namendra Anand
Sr. Engineer (BM/RM)
Ramagundam Super Thermal Power Station
NTPC Limited
nanand@ntpc.co.in
Ramagundam Super Thermal Power Station
NTPC Limited
Milling system maintenance is a challenge
as it requires to use all kinds of
maintenance practices to run the system
effectively….

Its an opportunity as it provides vide scope

to implement betterment activites….

Ramagundam Super Thermal Power Station

NTPC Limited
 OBJECTIVE OF PULVERIZER

• To reduce the coal size up to 70

micron size

Ramagundam Super Thermal Power Station

NTPC Limited
ARRAMENT OF MILL & PA FAN
BALL& RACE MILL (E TYPE)
1. Raw coal inlet pipe
2. Pulverized coal outlet pipe
3. Adjustable classifier blades
4. Oversize particles return
chute
5. Hollow grinding balls
6. Rotating lower grinding ring
7. Primary air inlet
8. Loading cylinders
9. Spider guide
10.Stationary upper ring
11.Air regulating ring
12.Gear box
13.Reject door

Ramagundam Super Thermal Power Station

NTPC Limited
 VARIOUS PARTS OF COAL MILL
1. Mill gear box to motor coupling
2. Reduction Gear Box
3. Mill lub oil system
4. G/B out put coupling
5. Yoke
6. Turn plate
7. Bottom track/ring
8. Coal drop plate
9. Grinding ball
10. Top track/ring
11. Spider/ loading ring
12. Loading System
13. Classifier Assembly
14. Pulverized coal outlet pipe
15. Coal inlet pipe
16. Pyrites discharge Syste
Ramagundam Super Thermal Power Station
NTPC Limited
 REDUCTION GEAR BOX

Gear Box

Gear unit Lub System

First reduction one pair

of Spiral bevel gears External Internal

Second reduction one pair Gear Pump Oil distribution

of Single Helical gears & other system &
arrangement Spray nozzles

Ramagundam Super Thermal Power Station

NTPC Limited
MILL GEAR BOX
MILL GEAR BOX CROSS SECTION
MILL GEAR BOX INPUT PINION
MILL GEAR BOX I STAGE GEAR
MILL GEAR BOX I STAGE GEAR &
II STAGE PINION
MILL GEAR BOX II STAGE GEAR
MILL GEAR BOX EXTERNAL LUB OIL SYSTEM
MILL GEAR BOX INTERNAL LUB OIL LINES
MILL GEAR BOX LABYRINTH SEAL
 REDUCTION GEAR BOX

• Speed : 970 / 40.185 rpm

• Lub System :
– Roloid gear pump
– G/B sump Capacity is 210 liter

Ramagundam Super Thermal Power Station

NTPC Limited
 HYDRO PNEUMATIC LOADING SYS.
Purpose : exercise a constant load on the ball
mills & compensate the wear on same

The system is composed of two parts :

1. Pneumatic plant: Determines reqd. load
2. Oil system : Lubricate cylinder bushes &
keep the gasket in pressure for perfect seal

Ramagundam Super Thermal Power Station

NTPC Limited
MILL LOADING SYSTEM
MILL LOADING SYSTEM
MILL LOADING SYSTEM CABINET
LOADING CYLINDER
TOP & BOTTOM RING
GRINDING BALL
GRINDING BALL (NEW & WORN OUT)
LOADING RING
INLET COAL PIPE WITH INVERTED CONE
CLASSIFIER CONE WITH SKIRT PLATES
CLASSIFIER VANES
CLASSIFIER VANES
CLASSIFIER VANES
RELIEF GATE (CLOSED)
RELIEF GATE (CLOSED)
RELIEF GATE (OPENED)
REJECT GATE
 CASE STUDY

PROBLEMS FACED
&
IMPROVEMENT ACTIONS TAKEN

Ramagundam Super Thermal Power Station

NTPC Limited
Problem faced Improvement actions

Longer mill 1. Highly skilled maintenance

overhaul period practices were developed for
mill overhauling
2. Spare mill top housing is being
kept ready before hand
3. Readiness of mill bay hoist is
ensured

 These resulted in reduction of

mill overhauling duration from
360 hrs to 72 hrs
Ramagundam Super Thermal Power Station
NTPC Limited
SPARE MILL TOP BODY ASSEMBLY
Problem faced Improvement actions

Longer mill Day 0 : Ensure healthiness of hoist

Spare mill top body housing is renovated
overhaul period
All new spares are available near mill
Erection of necessary approach platforms
Day 1 : Removal of coal pipes
Removal of top mill body assembly
Removal of loading ring
Removal of top ring
Removal of grinding balls
Day 2 : Cutting & removal of air regulating rings
Removal of bottom ring
Removal of coal drop plate
Replacement of middle shell wear plates
Loading of new bottom ring
Ramagundam Super Thermal Power Station
NTPC Limited
Replacement of U clamps, knee assy.
Problem faced Improvement actions

Longer mill Day 3 : Replacement of air regulating ring

Full welding of middle shell wear plates &
overhaul period air regulating rings with protection bars.
Loading of new grinding balls
Loading new top ring
Loading of spider ring
Assembly of U clamp and knee assy.
Replacement of mill top body assy. with
spare top body assy.
Re-fixing of coal inlet pipe
Re-fixing of PF discharge pipe

Ramagundam Super Thermal Power Station

NTPC Limited
Problem faced Improvement actions

Frequent 1. Rack & pinion arrangement

choking / were taken out side of the
jamming of tramp iron gate assembly
reject passages 2. Stone pickers are introduced in
CHP

 This eliminated the problem of

choking / jamming

Ramagundam Super Thermal Power Station

NTPC Limited
Problem faced Improvement actions

Frequent mill 1. Highly skilled maintenance

gear box break practices were developed for
downs mill gear box servicing.
2. Scheduled replacement of
gear box was adopted.
3. Stringent QP for procurement
4. Photos

 These resulted in elimination

of mill gear box break down.
Ramagundam Super Thermal Power Station
NTPC Limited
 Problem faced Improvement actions

Pre-mature failure 1. Machining of Turn Plate at

of grinding rings landing surface
2. Banding of bottom rings
3. Photos

 These resulted in
reduction of premature
failure of grinding rings.

Ramagundam Super Thermal Power Station

NTPC Limited
Problem faced Improvement actions

Mill outages 1. Replacement of original carbon

due to PF steel PF pipes by ceramic pipes
leakage 2. Minimizing flanged joint by direct
welding, wherever possible
3. Ensuring proper machined mating
surface at flanged joint

 This resulted in elimination of mill

outages due to PF leakages

Ramagundam Super Thermal Power Station

NTPC Limited
 MAINTENANCE PRACTICES

AT

RAMAGUNDAM SUPER THERMAL POWER STATION

NTPC LIMITED

Ramagundam Super Thermal Power Station

NTPC Limited
 OBJECTIVE
OF
MAINTENANCE MANAGEMENT SYSTEM
• To maximize availability of generating units with
minimum maintenance cost and downtime.

• To carry out maintenance jobs as per laid down

procedures within stipulated time.

• To plan for overhauls, statutory inspection and to

obtain statutory certificate from the competent
authority for the safe running of the equipment.

• To ensure safety during isolation, maintenance

and re-commissioning.
Ramagundam Super Thermal Power Station
NTPC Limited
 MAINTENANCE STRATEGY

Our philosophy is for Zero breakdown between

overhaul to overhaul by adopting various new
initiatives like
– Outage preparedness index.
– Activity Based planning and monitoring
– Contract rationalization
– Rolling plan of equipment.
– REAP

Ramagundam Super Thermal Power Station

NTPC Limited
 MAINTENANCE PRACTICES

 Preventive Maintenance.
 Predictive Maintenance.
 Proactive Maintenance.
 Planned maintenance
(Overhaul/Servicing)
 Break Down Maintenance
 Life Assessment.

Ramagundam Super Thermal Power Station

NTPC Limited
PREVENTIVE MAINTENANCE

Ramagundam Super Thermal Power Station

NTPC Limited
 PREVENTIVE MAINTENANCE

PM is time based maintenance. The frequency

& scope is based on-

OEM Recommendation
Site Experience
After SRCM, this frequency and scope have
been revised. This is mainly based on failure
modes.

Ramagundam Super Thermal Power Station

NTPC Limited
 MAINTENANCE PRACTICES :
DURING 4 WEEKLY PM CHECKS :

1. Mill Internal inspection & Repair.

2. Mill gear box Internal Inspection.
3. Loading system rectification.
4. Mill coupling Healthiness
5. Checking.
6. Measurement of Grinding Rings & Balls.
7. Checking of Plough brush assly.

Ramagundam Super Thermal Power Station

NTPC Limited
PREDICTIVE MAINTENANCE

Ramagundam Super Thermal Power Station

NTPC Limited
 PdM EXISTING PRACTICE

Technologies in use :
 Vibration analysis
 Infrared thermo graphy
 Motor current signature analysis
 Wear debrisanalysis

Ramagundam Super Thermal Power Station

NTPC Limited
 VIBRATION ANALYSIS

Vibration monitored at pre determined

frequencies and abnormalities reported
are for corrective action.

Trending done for critical equipments to

keep a track of the equipment behavior.

Ramagundam Super Thermal Power Station

NTPC Limited
 WEAR DEBRIS ANALYSIS

 Oil sample is collected from various equipment at

pre determined frequencies for wear debris
analysis
 Being done at site by condition monitoring group
 If required, sample of the oil is sent to R&D for
detail analysis
 Trending of the result being done to plan for
inspection
 Corrective action is taken up after receipt of report
Ramagundam Super Thermal Power Station
NTPC Limited
 MAINTENANCE PRACTICES :
DURING RUNNING :
1. Gear box Oil level and Oil Pressure checking
2. Gear box vibration, temperature and abnormal
sound checking
3. Monitoring operating parameters
4. Checking for PF Leakages
5. Checking for hot air leakage
6. Checking for any oil leakage
7. Any abnormal sound from mill
Ramagundam Super Thermal Power Station
NTPC Limited
PROACTIVE MAINTENANCE

Ramagundam Super Thermal Power Station

NTPC Limited
 PROACTIVE MAINTENANCE

Proactive maintenance is in the case of repeated

failures. We go in to root cause of failure & do
necessary correction by way of change in
operating practices / small modification in system
/ maintenance practices.

Ramagundam Super Thermal Power Station

NTPC Limited
PLANNED MAINTENANCE

Ramagundam Super Thermal Power Station

NTPC Limited
 PLANNED MAINTENANCE

Practices:
• Pre-overhaul
• During overhaul
• Post overhaul

Ramagundam Super Thermal Power Station

NTPC Limited
 PLANNED MAINTENANCE

Pre-overhaul:
• Preparing Engineering declaration of all the
units as per OPI guidelines.
• Identification of resources ( materials,
contracts & T&P).
• Review of the materials & contracts status.
• Distribution of engineering declaration to all
concerned before the start of overhaul

Ramagundam Super Thermal Power Station

NTPC Limited
 PLANNED MAINTENANCE

During overhaul:
 Ensuring proper isolation of the equipments
before start of the work.

 Making Quality check protocols

 Making Re-commissioning check sheets

 Maintaining Communication log book

Ramagundam Super Thermal Power Station

NTPC Limited
 PLANNED MAINTENANCE

During overhaul:
• Safety survey & training to agency personnel.
• Constituting Knowledge team
• Daily review meeting
• Review of works planned & actual done.
• Feed back to all concerned.

Ramagundam Super Thermal Power Station

NTPC Limited
 PLANNED MAINTENANCE

Post-overhaul:
• Preparing executive summary

• Preparation of Unit overhaul completion

report.

• Post overhaul review of improvement

• Pay back calculation

Ramagundam Super Thermal Power Station

NTPC Limited
BREAKDOWN MAINTENANCE

Ramagundam Super Thermal Power Station

NTPC Limited
 BREAKDOWN MAINTENANCE

• Defect registration is normally done by

operation group

• Emergency Nature : Respective Maintenance

to act immediately

• Other Jobs : Scheduled by MTP and then

maintenance to rectify the defect.

Ramagundam Super Thermal Power Station

NTPC Limited
 Management Information
System

1. Daily report
2. Weekly report
3. Monthly report
4. Yearly report
5. Unit overhauling report

Ramagundam Super Thermal Power Station

NTPC Limited
PULVERIZER TROUBLESHOOTING

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Reasons for Poor  Incorporated slots in air

fineness regulating ring to distribute
primary air in the mill properly
 Classifier cone may be eroded
 Incorrect adjustment of
classifier blades
 Excessive wear out of grinding
element
 Overloading of mill
 Fuel quality has deteriorated
 The Air/Fuel ratio is very high
 Increased through put

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Reason for abnormal  Most probable is the entry of

sound from mill foreign matter in the
grinding element
 Break down of some
internal parts, e.g. U clamp,
knee assembly

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Reason for High  Change in coal grindability, sulfur

rejects & ash
 The relief gate is jammed open
 The air regulating ring has too
much gap with bottom ring
 Grinding elements are in
precarious conditions & adding a
filler ball is the necessity

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Mill lub oil  Lub oil pump is not developing

pressure low pressure
 Leakage from lub oil lines
 Air suction in lub oil line
 Filter chockage
 Improper relief valve adjustment

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Mill coupling  Over load in mill due to some

failure foreign material
 Mill motor trouble
 Coupling material defect
 Mill gear box failure
 Lack of grease in coupling

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Lack of capacity or  High moisture

High power  Low GCV
consumption  Increased raw coal size
 Grinding too fine
 Excessive wear out of
race

Ramagundam Super Thermal Power Station

NTPC Limited
 Pulverizer Troubleshooting

• Low coal / air  High moisture in coal

temperature at  Low PA inlet temperature
mill outlet  Passing of cold air damper
 Mill got unloaded

Ramagundam Super Thermal Power Station

NTPC Limited
THANK YOU
Ramagundam Super Thermal Power Station
NTPC Limited