B Ball Mill Inspection

Page 1 PartschW 11 Oct 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROMUE\Training\Presentation\B Ball Mill Inspection.
ppt
Ball Mill Inspection, Servicing and Trouble shooting
Dipl.-Ing.
Wolfgang Partsch
Page 2 PartschW 11 Oct 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROMUE\Training\Presentation\B Ball Mill Inspection.ppt
Ball Mill Inspection general

Tightening torques for bolts
If not stated otherwise in the drawings, the following specifications apply:
The specifications refer to bolts with standard thread of quality grade 8.8
Threads and contact surfaces are cleaned and slightly oiled (no molybdenum disulphide!).
Bolt diameter (mm) Tightening torque (Nm)

M 24 625
M 30 1265
M 33 1755
M 36 2230
M 39 2935
M 42 3620
M 48 5455
M 52 7155
M 56 8870
CAUTION:
These values are not valid for the fixing bolts of the mill lining (4.0).
Ball Mill Inspection general

NOTE:
The opening of flaps and flanges as well as the elimination of blockages may only be carried out by competent
and authorized personnel.
Do not remove or open any covers or protection devices before all rotating parts have stopped.
No. Work to be performed Frequency Comments
1 General visual inspection for leaks daily
2 General visual inspection for cracks and damage every 4 weeks
3 Check for wear of the parts protected by rubber every 4 weeks every time the lining is replaced
lining.
4 Check of the mill lining (4.0) for wear, damage and see the manufacturers specifications
cracks
5 Inspection work at the mill drive system (6.0) see the documentation of the supplier
6 Inspection work at the mill bearing arrangement (5.0) see separate machine manual
7 Inspection work at the inlet device (2.0) see separate machine manual
8 Inspection work at the outlet (3.0) see separate machine manual
9 Inspection work at the brake (7.0) see the documentation of the supplier
Ball Mill Servicing general

1 Check the mill shell (1.0) for cracks Annually Recommendation:
Ask for POLYSIUS service
2 Topping up of grinding media as required The quantity of grinding media
to be topped up depends on the
power consumption of the mill
drive
3 Replace the mill lining as required see manufacturers instructions
4 Maintenance work on the parts wear- as required
protected by rubber lining.
5 Maintenance work at the inlet device see separate machine manual
6 Maintenance work at the outlet see separate machine manual
7 Maintenance work at the mill drive system see the documentation of the
(6.0) supplier
8 Maintenance work at the mill bearing see separate machine manual
arrangement (5.0)
9 Maintenance work at the brake (7.0) see the documentation of the
supplier
Ball Mill Trouble Shooting general

The most important functions of the tube mill are monitored during operation.
Any trouble occurring in these functions will trigger an alarm and/or stop the tube mill.
Fault Cause Elimination

Escape of ground The fastening of the Retighten the fixing bolts with
material at the mill shell liner plates is leaky the stipulated tightening
torque; replace special seals, if
necessary.
Full grinding insufficient grinding Check of the grinding ball
compartment charge for wear; refill new
grinding balls
insufficient supply of Check the material to be
process water ground and the solids content
of the pulp
If faults occur which are not described above, additional information on troubles, their causes and elimination are
included in the documentation of the sub suppliers or in the machine manuals:
Mill bearing arrangement,

Mill drive system,
Inlet device and
Outlet
Ball Mill Inspection Inlet device

No. Work to be performed Frequency
1 General visual inspection for leaks daily
2 Check the wear protection lining weekly

(1.2 and 3.2) for signs of wear
3.2
3 Check the seal (4.0) for correct functioning weekly
4 Check the flushing pipe (4.1) for signs of wear monthly
5 Check the seal (4.3) for signs of wear monthly
1.2
Ball Mill Servicing Inlet device

1 Replacement of the wear protection lining (3.2) as required
2 Replacement of the flushing pipe (4.1) as required

3.2 3 Replacement of the sealing (4.3) as required
4 Replacement of inlet pipe (1.5) with wear as required

protection lining
Inlet pipe
1.2
Ball Mill Trouble shooting inlet device
Leakage of feed The seal (4.3) is worn out Replace the seal
material
The inlet has not been correctly - Check the tie downs (2.8)
positioned
Overfilling of the inlet The material feed rate is too high Check the material feed rate
regulation;
The process water supply has been Check the regulation;

interrupted repair the water piping
Ball Mill Inspection Outlet

1 General visual inspection for leakage daily
2 Check for wear: weekly
of the wear lining (1.2)
of the filler (1.4)
of the material return screw (2.2)
3 General visual check for cracks and damage monthly
Detail - Y
2. 3
Ball Mill Servicing Outlet

1 Fill the gap under the wear protection (1.2) and as required
under the baffle plate with filler
2 Replacement of: as required
the wear lining (1.2)
the material return screw (2.2)
Detail - Y
2. 3
Ball Mill Trouble shooting Outlet
Grinding balls are discharged Material return screw (2.2) is worn out Replace material return screw
through the outlet
Finished product is not discharged Screen is clogged Clean or replace Screen

through the screen surface
Dam Ring is worn out or damaged Replace Dam Ring
Ball Mill Inspection Oil supply system
No. Work to be performed Frequency Remarks

1 Check the double filter for contamination weekly optical display and electrical
monitoring equipment
2 Check the locally installed instruments weekly
(temperatures, oil pressures)
3 Check the oil pipes for leaks weekly

4 Check the oil level weekly
5 Check initial filling pressure in the hydraulic every 6 weeks check with oil pumps
accumulators switched off
6 Inspection work at the oil supply systems see manufacturers
instructions
Ball Mill Servicing Oil supply system
No. Work to be performed Frequency Remarks

1 Change of the filter inserts as needed recognizable due to multicolor
display and electrical
differential pressure indicator
2 Take an oil sample and check for lubricity every 26
weeks
3 Maintenance work at the oil supply systems see manufacturers
instructions
Ball Mill Trouble Shooting Oil supply system

Oil supply system does not start up insufficient oil in the oil top up the oil
tank
Indicator: the oil temperature is wait until the oil temperature has risen over
level switch below 15 C 15 C due to the oil heating
Drive unit of the entire machine can not leak in the piping repair the leak,
be switched on system if necessary replace defective part
one or more oil pumps change over to standby pump and replace
Indicator: Flow monitor, speed monitor
are defective defective oil pump
and/or pressure switch
Frequent contamination of double housing sealing of the repair housing sealing (see machine manual
change-over filter sliding shoe bearing sliding shoe bearing arrangement)
arrangement is not tight
Indicator: Multicolor display at the
oil lubricity is not change the oil
double change-over filter and alarm
sufficient
Drive unit of the entire machine fails leak in the piping repair the leak, if necessary replace defective
during operation system part
one or more oil pumps change over to standby pump and replace
Indicator I: Flow monitor, speed monitor
are defective defective oil pump
and/or pressure switch
insufficient oil in the oil Top up the oil and check the piping system for
Indicator II: Level switch tank leaks
Oil temperature too high insufficient cooling check cooling water supply and adjust the
water regulation
Ball Mill Inspection Bearings

1 Check the condition of the slide ring surfaces every 4 weeks Only when the machine
is at a standstill
2 Check the instruments installed locally weekly
(temperatures, oil pressures)
3 Check the housing seal for proper functioning weekly Y-seal (3.2)
V-seal (3.7)
4 Check the oil conveying piping for leaks weekly
5 Check the oil flow dividers (6.6) for proper weekly
functioning
Ball Mill Servicing Bearings

1 If necessary, adjust or replace the Yseal (3.2) every 26 weeks
2 Check all oil supply connections inside the housing annually
3 Check and record the gaps between the bearing shoes annually see form in section
and the slide rings Measurement records
4 If necessary, replace the V-seal (3.7) every 4 weeks
Ball Mill Trouble shooting Bearings

Main motor of the machine fails during operation
Display I Excessive - Check the oil stream splitters (6.6) for proper functioning
Temperature sensor (4.4) in the bearing shoe (4.3) bearing - Check the contact surfaces at the slide ring
temperature - Check the oil supply system for proper functioning
- Check the cooling water supply system
Display II Excessive - Check the oil supply system for proper functioning
Temperature sensor (5.3) in the round sliding pad (5.1) bearing - Check the contact surfaces at the slide ring
temperature
Main motor of the machine can not be switched on Leak in the Seal the leak,
piping system replace the faulty parts
Fault in the See machine manual Oil supply system for hydrostatic sliding shoe
oil supply bearing arrangement
system
Frequent clogging of the oil filters in the oil supply Housing seal Check and adjust the Yseal, replace if necessary
system leaky
Scoring at the slide ring Housing seal Adjust the Yseal, replace if necessary
leaky
Damage to the Replace the damaged bearing shoe and inform POLYSIUS AG about
bearing shoes the damage
Fault in the Repair the oil supply system
oil supply
system
Repair work:
Before beginning any repair work, switch off the power supply to
all electrical components.
Ensure absolute cleanliness at all times during the repair work in order
to prevent dirt from entering the bearings, the drives, the hydraulic system
or other sensitive parts of the machine or plant.
Check that all piping is relieved of pressure and make sure that the oil supply
systems are switched off and safeguarded against restarting.
Do not remove or open any covers or protection devices before all rotating
parts have stopped.

Repair work:
Before beginning any repair work, switch off the power supply to all electrical components.
Ensure absolute cleanliness at all times during the repair work in order to prevent dirt from entering the bearings,
the drives, the hydraulic system or other sensitive parts of the machine or plant.
Check that all piping is relieved of pressure and make sure that the oil supply systems are switched off and
safeguarded against restarting.
Dismounting the axial guide (5.0):
- Dismount the dismounting flaps (1.2).

- Disconnect all piping to the axial guide and close the openings to prevent ingress of dirt.
- Dismount the temperature sensor (5.3) and close the openings to prevent ingress of dirt.
- Unscrew and remove the fixing bolts.
- Lift out the axial guide with a hoist.
Replacing the Yseal (3.2):
- Remove the V-seal (3.7).

- Unscrew the bolted connection of the clamps (3.4) and remove the segments of the clamping ring (3.1).
- Withdraw Y-seal from the contact surface.
- Thoroughly clean the contact surface of the Y-seal at the housing.
- Mount the new Yseal,
Dismounting bearing shoes:
- Dismount the dismounting flaps (1.2) on both sides of the segment of the lower housing section.
- Remove all piping to the bearing shoe and close the openings to prevent ingress of dirt.
- Dismount the temperature sensor (4.4) and close the openings to prevent ingress of dirt.
Dismounting a master shoe (4.1):
- Mount the inserting/retracting device (7.1.2).

- Mount the slide way (7.6).
- Mount the support (7.4).
- Position the dismounting table (7.1.1) on the slideway(7.6) and secure.
- Mount the safety stirrup (4.1.2).
- Lift the mill:
- Mark the position of the lock nut (4.2.4).
- Uniformly lift the two operating cylinders (4.2.7) by means of a pump until the air gap at the
master bearing shoe is adequate.
- Screw down the lock nut (4.2.4) until it engages.
- Reduce the oil pressure at the operating cylinder (4.2.7).
- Remove the fixing bolts at the bearing base (4.1).
- Push the master shoe (4.1) by means of the inserting/retracting device onto the dismounting table.
- As the stroke of the pull action/pressure cylinder (7.5) is limited, the support bracket (7.1.27) on the
grid bracket (7.1.25) must be repositioned.
- Mount the connecting rod (7.1.22) in the end position so that the master shoe can be completely pushed out.

- Fix the dismounting table extension (7.1.12).
- Shift the dismounting table (7.1.1) onto the
slide way (7.6).
- The master shoe can now be conveyed onward
by means of locally available hoists.
- Carry out the reinstallation in reverse order.

- The mill can be lowered when the bearing shoe
is in the correct position.
- Re-adjust the bearing arrangement

Dismounting a slave shoe (4.2)
- Mount the inserting/retracting device (7.1.2).

- Mount the dismounting table (7.1.1).
- Mount the compensating bridge (7.1.4).
- Mount the safety stirrup (4.2.2).
- Mount the stabilizer (7.1.12) onto the holding fixture for stabilizer
(7.2.15) which is installed in the direction of the mill centre
- Mark the position of the lock nut (4.2.4).
- Turn the lock nut (4.2.4) upwards.
- Lower the operating cylinder by means of a hand pump.
- Check and correct the positioning of the safety stirrup (4.2.2).
- Remove the fixing bolts at the operating cylinder (4.4.27).
-Push the slave shoe (4.2) by means of the inserting/retracting
device onto the dismounting table (7.1.1).
- As the stroke of the pull action/pressure cylinder (7.5) is limited,
the support bracket (7.2.27) on the grid bracket (7.2.25)
must be repositioned.
- Mount the slide way (7.6).
- Mount the support (7.4).
- Remove the safety stirrup (4.2.2).
- Lower the operating cylinder further by means of a hand pump
until the bearing shoe (4.3) is in contact with the slide way (7.6)
and is separated from the operating cylinder.

CAUTION
The axial pivoting bearing (4.6) could get jammed or fall out.
- Shift the bearing shoe (4.3) on the slide way to the side.
- Carry out the reinstallation in reverse order.

- When the bearing shoe is in the bearing housing, readjust the bearing arrangement.
Ball Mill Inspection, Servicing and Trouble shooting
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B Ball Mill Inspection

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Page 1 PartschW 11 Oct 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROMUE\Training\Presentation\B Ball Mill Inspection.

Ball Mill Inspection, Servicing and Trouble shooting

Ball Mill Inspection general

If not stated otherwise in the drawings, the following specifications apply:

Bolt diameter (mm) Tightening torque (Nm)

Ball Mill Inspection general

No. Work to be performed Frequency Comments

1 General visual inspection for leaks daily

2 General visual inspection for cracks and damage every 4 weeks

8 Inspection work at the outlet (3.0) see separate machine manual

Ball Mill Servicing general

No. Work to be performed Frequency Comments

Ball Mill Trouble Shooting general

Fault Cause Elimination

Mill bearing arrangement,

Ball Mill Inspection Inlet device

1 General visual inspection for leaks daily

2 Check the wear protection lining weekly

4 Check the flushing pipe (4.1) for signs of wear monthly

5 Check the seal (4.3) for signs of wear monthly

Ball Mill Servicing Inlet device

1 Replacement of the wear protection lining (3.2) as required

2 Replacement of the flushing pipe (4.1) as required

4 Replacement of inlet pipe (1.5) with wear as required

Ball Mill Trouble shooting inlet device

Fault Cause Elimination

The process water supply has been Check the regulation;

Ball Mill Inspection Outlet

3 General visual check for cracks and damage monthly

Ball Mill Servicing Outlet

Ball Mill Trouble shooting Outlet

Fault Cause Elimination

Finished product is not discharged Screen is clogged Clean or replace Screen

Ball Mill Inspection Oil supply system

No. Work to be performed Frequency Remarks

3 Check the oil pipes for leaks weekly

Ball Mill Servicing Oil supply system

No. Work to be performed Frequency Remarks

Ball Mill Trouble Shooting Oil supply system

Ball Mill Inspection Bearings

No. Work to be performed Frequency Comments

Ball Mill Servicing Bearings

No. Work to be performed Frequency Comments

Ball Mill Trouble shooting Bearings

Ball Mill Trouble shooting Bearings

Ball Mill Trouble shooting Bearings

Dismounting the axial guide (5.0):

- Dismount the dismounting flaps (1.2).

Replacing the Yseal (3.2):

- Remove the V-seal (3.7).

Ball Mill Trouble shooting Bearings

Dismounting bearing shoes:

Ball Mill Trouble shooting Bearings

Dismounting a master shoe (4.1):

- Mount the inserting/retracting device (7.1.2).

Ball Mill Trouble shooting Bearings

- Carry out the reinstallation in reverse order.

Ball Mill Trouble shooting Bearings

- Mount the inserting/retracting device (7.1.2).

Ball Mill Trouble shooting Bearings

- Carry out the reinstallation in reverse order.

Ball Mill Inspection, Servicing and Trouble shooting

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