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. 2. 3. 4. Raw coal inlet pipe Pulverized coal outlet pipe Adjustable classifier blades 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 dischargeSuper Thermal Power Station Ramagundam Syste
NTPC Limited

REDUCTION GEAR BOX

Gear Box

Gear unit First reduction one pair of Spiral bevel gears Second reduction one pair of Single Helical gears

Lub System

External Gear Pump & other arrangement

Internal Oil distribution system & 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 Longer mill overhaul period

Improvement actions 1. Highly skilled maintenance 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 Longer mill overhaul period

Improvement actions
Day 0 : Ensure healthiness of hoist Spare mill top body housing is renovated 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 Longer mill overhaul period

Improvement actions
Day 3 : Replacement of air regulating ring Full welding of middle shell wear plates & 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 Frequent choking / jamming of reject passages

Improvement actions 1. Rack & pinion arrangement were taken out side of the tramp iron gate assembly 2. Stone pickers are introduced in CHP This eliminated the problem of choking / jamming

Ramagundam Super Thermal Power Station NTPC Limited

Problem faced Frequent mill gear box break downs

Improvement actions 1. Highly skilled maintenance practices were developed for 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 Pre-mature failure of grinding rings

Improvement actions 1. Machining of Turn Plate at 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 due to PF leakage

1. Replacement of original carbon steel PF pipes by ceramic pipes 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 Ramagundam Super and re-commissioning.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 onOEM 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. 2. 3. 4. 5. 6. 7. Mill Internal inspection & Repair. Mill gear box Internal Inspection. Loading system rectification. Mill coupling Healthiness Checking. Measurement of Grinding Rings & Balls. 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. 2. 3. 4. 5. Daily report Weekly report Monthly report Yearly report 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 regulating ring to distribute fineness 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 sound from mill Most probable is the entry of 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 & ash rejects 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 pressure low Lub oil pump is not developing 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 failure Over load in mill due to some 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 power consumption High moisture Low GCV Increased raw coal size Grinding too fine Excessive wear out of race

Ramagundam Super Thermal Power Station NTPC Limited

Pulverizer Troubleshooting
Low coal / air temperature at mill outlet High moisture in coal Low PA inlet temperature Passing of cold air damper Mill got unloaded

Ramagundam Super Thermal Power Station NTPC Limited

THANK YOU
Ramagundam Super Thermal Power Station NTPC Limited