Mill Training Manual Alstom

6 x HP 1063 Mills
Doosan Babcock Energy Ltd

Louisville Gas & Electric
Trimble County # 2
Doosan PO # 74232/06350/A
LG&E Energy Service Company

Trimble County Generating Station, Unit 2
1 x 750 MW Supercritical Coal Fired Steam Generator
Purchase Order No. 25191
Doosan Babcock
Crawley, Great Britain.
Document Title: Operator Training Manual

Project: 06350 Trimble County Unit 2 No of Units in Project: 1
Purchaser’s Document No: 06350/CALS/OI/34100/2/0027 Rev: A
Buyer’s Document No:
ALSTOM Power Inc.

Air Preheater Company
Milling Systems
Contract No. 06-143106
Student
Information HP PULVERIZER INTRODUCTION
Manual LG&E Trimble Unit No. 2
ABCD Power
Services
HP PULVERIZER INTRODUCTION ABCD
INDEX DISCLAIMER
1. HP PULVERIZER PERFORMANCE & OPERATION................................................................. 1 "This Student Information Manual and any training material, whether written or oral, furnished as part of
2. RP-963 vs. HP-1063 ARRANGEMENT DIFFERENCES.......................................................... 13 any course presented by ALSTOM Power, Inc. is for general, informational purposes and is not intended to
be used as a comprehensive instruction for operation or maintenance of equipment. By enrollment, the
3. MAJOR COMPONENTS & THEIR PM’S.................................................................................. 34 attending company staff agrees that (i) ALSTOM Power, Inc. shall not be liable in contract or negligence or
4. PULVERIZER AUXILIARY LUBE OIL SYSTEMS.................................................................... 54 other cause of action for any damages of any kind and, in particular, for any special, incidental or
consequential damages, including, but not limited to, loss of profits and revenue and loss due to business
5. PULVERIZER AUXILIARY SEALING SYSTEMS .................................................................... 59
interruption and (ii) ALSTOM Power, Inc. provides information without express or implied warranties or
6. PULVERIZER AUXILIARY PYRITE REJECT SYSTEM........................................................... 60 guarantees of any kind, and that use of any information furnished by ALSTOM Power, Inc. is at the sole
7. FINENESS PERFORMANCE – DYNAMIC CLASSIFIER ........................................................ 62 risk of the attending company."
8. PULVERIZER PERFORMANCE TROUBLESHOOTING ......................................................... 66
ALSTOM Power, Inc. Training for Purchaser’s Document No: 74232/06350A © COPYRIGHT 2008 i
List of Figures Figure 40: HP Internal Wear............................................................ 27 List of Tables

Figure 1: Types of Pulverization ........................................................1 Figure 41: RP Pulverizer Coal Classification................................... 28 Table A: Selected HP Pulverizer Capacity Data ................................5
Figure 2: Grinding Zone .....................................................................1 Figure 42: HP Pulverizer Coal Classification................................... 29 Table B: Recommended Mill Outlet Temperature..............................9
Figure 3: Hardgrove Grindability Index ..............................................1 Figure 43: RP Discharge Valves ..................................................... 30 Table C: Lube Oil Specifications and Guidelines.............................57
Figure 4: Historic Milling System Drying Requirements .....................2 Figure 44: HP Discharge Valves ..................................................... 31 Table D: Recommended Dynamic Classifier Maintenance Intervals
Figure 5: Fineness Testing Screens, Static vs. Dynamic Classifier ...2 Figure 45: RP Rejection of Tramp Iron............................................ 32 .................................................................................................62
Figure 6: Particle Size Distribution from a Static Classifier................2 Figure 46: HP Rejection of Tramp Iron............................................ 33 Table E: Data Sheet for Milling System ...........................................64
Figure 7: Particle Size Distribution from a Dynamic Classifier...........2 Figure 47: Scraper Assembly .......................................................... 34 Table F: Dynamic Classifier Fineness Results ................................65
Figure 8: Suction System Schematic .................................................3 Figure 48: Planetary Gear Box........................................................ 35
Figure 9: Pressurized System Schematic ..........................................3 Figure 49: Bowl, Bullring and Scraper Assembly ............................ 36 List of Drawings
Figure 10: Exhauster Fan Damper Drive ...........................................4 Figure 50: Two-Piece Bowl-Hub...................................................... 39 Drawing 1: HP-1063 Pulverizer Sectional, E-PLVE-0852................12
Figure 11: Theoretical Milling System Performance Curves ..............4 Figure 51: Ring-Roll Wear Patterns ................................................ 39 Drawing 2: Bowl, Hub, & Vane Wheel Assembly, D-PLVD-2526 ....37
Figure 12: Coal Rank .........................................................................5 Figure 52: Early HP Vane Wheel Design w/Air Restriction Segments Drawing 3: Scraper Assembly, C-PLVC-3169 .................................38
Figure 13: Mill Fires ...........................................................................5 (Pre-Wing Tips) ....................................................................... 40 Drawing 4: Vane Wheel Segments, D-PLVD-2330..........................41
Figure 14: Worn Grinding Rolls..........................................................6 Figure 53: Development of the Wing Tip......................................... 42 Drawing 5: Journal Assembly, D-PLVD-2150 ..................................47
Figure 15: Tramp Iron Rejects from a Pulverizer ...............................6 Figure 54: Assessment of Gaps and Coal Hideout Zones .............. 42 Drawing 6: Journal Spring Assembly, D-GP-8580...........................48
Figure 16: Coal Spillage.....................................................................6 Figure 55: Separator Body .............................................................. 43 Drawing 7: Dynamic Classifier Assembly, E-PLVE-0845 ................51
Figure 17: RB Pulverizer....................................................................7 Figure 56: Discharge Deflector........................................................ 43 Drawing 8: Dynamic Classifier Drive, D-PLVD-2419 .......................52
Figure 18: RS Pulverizer....................................................................7 Figure 57: Measurement Chart for Coal Pipe Distribution............... 43 Drawing 9: Dynamic Classifier Rotor, C-PLVC-3782.......................53
Figure 19: RP Pulverizer....................................................................7 Figure 58: Journal Assembly ........................................................... 44 Drawing 10: Unit No. 2 Lube Oil System P&ID, D-3929-01 .............56
Figure 20: HP Pulverizer....................................................................7 Figure 59: Journal Pressure Spring................................................. 44
Figure 21: Air to Coal Flow Character..............................................10 Figure 60: Journal Assembly Exploded View .................................. 45
Figure 22: Millside Below-Bowl Area ...............................................10 Figure 61: Journal Pressure Spring Assembly Exploded View ....... 46
Figure 23: Nozzle Connection Arrangements ..................................10 Figure 62: Mill Discharge Slide Gate Valve ..................................... 49
Figure 24: HP Pulverizer Sectional View .........................................11 Figure 63: Dynamic Classifier – Pressurized Pulverizer.................. 49
Figure 25: RP-963 Pulverizer with Static Classifier .........................13 Figure 64: Dynamic Classifier Sprocket Drive & Labyrinth Seal Gap
................................................................................................. 49
Figure 26: HP-1063 Pulverizer with Dynamic Classification ............13
Figure 65: Dynamic Classifier Rotor Gap ........................................ 49
Figure 27: RP Hot Air Inlet ...............................................................14
Figure 66: Dynamic Classifier Rotor Drive ...................................... 50
Figure 28: HP Hot Air Inlet ...............................................................15
Figure 67: Typical Gearbox Lube Oil System (Dual Lube Pumps).. 55
Figure 29: RP Bowl Perimeter Flow.................................................16
Figure 68: Journal Lube System ..................................................... 58
Figure 30: HP Bowl Perimeter Flow.................................................17
Figure 69: Seal Air Supply System.................................................. 59
Figure 31: RP Bowl Drive.................................................................18
Figure 70: Journal Seal Air System ................................................. 59
Figure 32: HP Bowl Drive.................................................................19
Figure 71: Dynamic Classifier Seal Air ............................................ 59
Figure 33: RP Lower Grinding Zone ................................................20
Figure 72: Millside Rejection Zone .................................................. 60
Figure 34: HP Lower Grinding Zone ................................................21
Figure 73: Scraper Detail ................................................................ 60
Figure 35: RP Upper Grinding Surface ............................................22
Figure 74: Trimble Unit No. 2 Pyrite Hopper ................................... 61
Figure 36: HP Upper Grinding Surface ............................................23
Figure 75: Screen Set for Testing Dynamic Classifier..................... 63
Figure 37: RP Initial Grinding Compression.....................................24
Figure 76: Value Which Corresponds To .5% + 50 Mesh ............... 64
Figure 38: HP Initial Grinding Compression.....................................25
Figure 77: 200 Mesh Fineness vs. Classifier RPM.......................... 64
Figure 39: RP Internal Wear ............................................................26
Figure 78: Plot Classifier RPM Versus Feed Rate .......................... 64
ALSTOM Power, Inc. Training for Purchaser’s Document No: 74232/06350A © COPYRIGHT 2008 i
1. HP PULVERIZER PERFORMANCE & OPERATION between the bowl and the rolls, power consumption is far less.
The combination of the two grinding processes with the power
Before coal can be effectively burned in a pulverized coal firing
savings results in a very good T/E ratio for these mills.
furnace, several things have to happen: Coal must be metered,
crushed, dried, moved at a minimum safe velocity. The
following topics help to explain the challenge. 1.3 Factors Affecting Pulverizer Capacity
1.1 Raw Coal Quality The capacity or output of any pulverizer is affected by three
After mining, the coal must be partially cleaned of rock, shale, factors relating to the coal quality; how easily it grinds, how wet
debris and mining components. When handled well, the coal it is, and how fine an output the burners and furnace require.
will meet ‘proximate analysis’ quality levels for: Grindability
• Heating value (calories per pound) This describes the ease with which a coal can be pulverized
• Grindability (relative hardness) when compared with other coals (Figure 3).
• Volatiles content (gasses that burn easily) • High grindability index number (60-100) indicates "easy-
to-grind" coal.
• Carbon content (primary chemical energy source) Figure 1: Types of Pulverization
• Low grindability index number (30-50) indicates "hard-
• Sulfur (environmental pollutant burden) to-grind" coal.
• Ash content (non-combustible burden, expressed
relative to heating value and melting character)
• Moisture (non-combustible burden)
Historically, the ‘proximate analysis’ is the standard for the
price paid for the fuel. A more complex ‘ultimate analysis’ is
applied as well to coal, and ash, as a subset to design the
power plant system capacities.
1.2 Pulverization
The coals surface area has to be greatly increased. The first
factor to be considered is how that is done. There are three
types of processes by which coal is pulverized. (Figure 1)
• Impact: Breaking up due to sudden high pressure
resulting from strike by single fast moving surface.
• Crushing: Breaking or grinding resulting from gradual
pressure increase between two surfaces.
• Attrition: Formation of small particles from friction Figure 3: Hardgrove Grindability Index
between two larger pieces. NOTE: When blending to coals, initial settings should favor the
The selection of milling process type is based primarily on the Figure 2: Grinding Zone lower grade ‘hard to grind’ coal.
size of the incoming coal and the desired size quantity and
distribution of the final product.
Different milling processes and equipment have different ratios Moisture
ALSTOM Mills use a combination of crushing between the for "tons processed per energy used" (T/E ratio). The T/E ratio
grinding roll and bullring (Figure 2), and attrition of coal-on-coal This is the amount of water retained by the coal. It is usually
is an indicator of how much material is processed for a given expressed as a percentage of a coal sample's weight.
in the small gap between these two grinding surface. amount of power. Comparing the T/E ratios of similar systems
will show which system provides the greatest amount of Moisture slows down the grinding process, since a larger
desired product using the least amount of power. Coal is volume of hot air or a longer residence time for the coal in the
subjected to a grinding force between a rotating bowl and three mill is required to properly dry and grind the coal. Hence, mill
grinding rolls. Since there is no metal-to-metal contact capacity (pounds per hour) is reduced.
ALSTOM Power, Inc. Training for Purchaser’s Document No: 74232/06350A © COPYRIGHT 2008 1
Storage in a coal pile can have both adverse and positive carefully sized screens. Testing suggests the relative percent Normal coarseness values are between 1 and 2%.
effects on coal moisture. Long-term storage in good weather of coal that achieves the desired fineness. • Higher values indicate worn internals or improper
helps to dry out the coal before it enters the plant, but can also • 50-100-200 mesh screens can be used for static settings.
drive off valuable combustible volatile components. classifiers • High percentages can lead to incomplete combustion of
Outdoor storage in wet weather increases the surface moisture • 50-70-100-200-325 mesh screens can be used for the larger particles and increased carbon loss.
of the coal, which then causes flow problems and requires dynamic classifiers
more hot air to dry in the pulverizer.
Historic numbers suggest how much heat and air heater
temperatures are required, depending on the coal rank. In the
figure below, note that Eastern Bituminous coal is normally dry,
requiring less heat. Western Sub-Bituminous coals from
Wyoming and Montana’s Powder River Basin (PRB) require far
more heat
Figure 6: Particle Size Distribution from a Static Classifier
Figure 4: Historic Milling System Drying Requirements Figure 5: Fineness Testing Screens, Static vs. Dynamic Classifier
Figure 7: Particle Size Distribution from a Dynamic Classifier

Fineness Coarse particles (sand sized particles) that are retained on the
coarse mesh (percentage "plus 50 and/or 70") are an
This is the measurement that specifies the percentages of a
indication of the internal condition of the pulverizer. NOTE: Figure 6 approximates particle size distribution from a
coal sample, which pass through a set of test sieves (Figure 5).
Fineness is an indicator of how well the mill is performing. static classifier. Figure 7 is representative of a dynamic
classifier. Note that dynamic classifier have the potential for
A sample of pulverized coal is obtained from piping
very fine coal dust processing.
downstream of the mill, dried, and shaken through a set of
Air Supply The hot air passes up around the perimeter of the bowl to The arrangement of the flow area around the bowl perimeter is
The primary air (PA) is the name given to the transport air that either pick up small particles or return larger pieces to the such that the velocity of the air should not allow coal particles
sends the coal particles into the furnace. The PA volume bowl. to fall through the air stream.
required for the drying and transport of the pulverized coal The differential pressure across the bowl ("bowl delta-P") is
enters the mill below the bowl. The primary air entering the used as an indicator of the flow characteristics through the mill.
furnace with the pulverized coal accounts for approximately Normal values are in the range of 4-6 in. w.g. Low values may
15% of the total air required in the boiler for complete and be an indicator of insufficient velocity of flow. High values may
efficient combustion of the coal. indicate restrictions to proper flow.
Possible air system designs to perform this function come in at A combination of coal mat thickness and the force induced by
least two types: journal pressure springs creates suitable conditions for very
• Suction Systems small particle production. As the coal particle size is reduced
during the grinding process, more surface area is exposed
• Pressurized Systems from which moisture is flash-dried. Moisture is vaporized by
In HP pulverizer suction systems, with attached exhausters, the heat in the primary air and is therefore carried out of the
the primary air entering the mill is a combination of hot air mill with the coal and air. Absorption of heat by moisture
taken off of the secondary air supply to the furnace windboxes, reduces overall temperature of mixture leaving the mill.
and cold or "tempering" air drawn from ambient (Figures 8). Fines entrained in air leaving the bowl area are carried up to
The hot air is mixed with cooler ambient air admitted through the top of the mill. The classifier section modifies flow,
the barometric damper. The desired mill outlet temperature inducing heavier (larger) particles to drop out of the dust
and the moisture content and temperature of the incoming coal stream. Heavier particles return to the bowl area for additional
determine the ratio of hot-to-cold air. The hot air control size reduction (grinding). Lighter (smaller) particles are carried
damper is positioned to control the mill outlet temperature, and out of the mill top to the coal piping.
the barometric damper positions itself to admit tempering air
according to the suction imposed on the mill inlet by the Transport Through Piping
exhauster. Figure 8: Suction System Schematic The pulverized coal leaving the mill is given the required
In another HP Mill pressurized pulverizer system (closer to energy to pass through piping up to the furnace by the
what is found on Trimble Unit No. 2), the air enters the mill exhauster, or by the primary air fans in an HP Milling System.
from the primary air fan. This fan is located ahead of the air Two factors that influence the ability of the pulverized coal to
heater and is the primary air source for both the cold and hot be transported are:
air to the pulverizer (Figure 9). • Mixture temperature
The total primary air required is a function of the number of • Air-to-Coal mass ratio
pulverizers in operation. Due to the possible variations of load A low mill outlet temperature may indicate or result in
and coal moisture content between pulverizers, it is necessary insufficient drying of the coal. Insufficient drying can lead to
to control not only the total airflow but also the temperature of pluggage of coal piping, as moist particles conglomerate into
the individual pulverizers. This is accomplished with control larger, heavier particles and settle out of the flow, creating
dampers located in both the hot and cold primary air ducts for blockages. Under normal conditions, mill outlet temperatures
each mill as well as the inlet damper to the primary air fan. in the range of 140°F to 170°F result in adequate drying.
The airflow requirements for each pulverizer are met by the Coals from Eastern U.S. tend to function well above 150° F,
sum of flow through both the hot and cold air ducts. Properly where the Western coals, i.e. PRB, can safely be processed at
proportioning the flow through the hot and cold air duct the lower temperatures. The pulverizer outlet temperature
dampers control the temperature. range must be determined by testing to confirm the high and
Mill Internal Mixing and Grinding low temperature limits chosen for a given coal that is practical
for all plant specific operating conditions. The outlet
The raw coal is distributed onto the rotating bowl from the
temperature range depends on a number of variables including
center, passing between the three journal grinding roll
the coal type (rank), coal volatility and mechanical condition of
assemblies and the wear surface on the bowl.
the pulverizer.
Figure 9: Pressurized System Schematic
Usually the ‘Safe” temperature is between 140°F (High Volatile Care must be taken when setting these minimum and
Western Coal) and 170°F (Eastern Bituminous), depending on maximum positions to prevent possible damage to the linkages
operating experience with and the volatility of the coal. and/or positioners.
Consistently low temperatures could also cause moist coal to
collect in areas of the mill, providing a possible starting point
for combustion within the mill.
In some HP Pulverizer systems, the exhauster suction damper
modulates to control the quantity of airflow pulled through the
mill. Other HP systems have the airflow control damper
located at the inlet of the pulverizer.
A minimum air-to-coal weight ratio of 1.5:1 is desired at full
load. The ratio could be higher at lower loads (more air per
pound of coal). Failure to provide adequate airflow through the
mill can result in spillage of coal.
The exhauster discharge pressure is an indicator of flow and
velocity through the coal piping. Opening the exhauster
suction damper tends to increase exhauster discharge
pressure as more flow is delivered by the exhauster. Raising
exhauster discharge pressure can increase mill capacity, but
may result in increased mill and/or piping wear due to higher
velocities.
In the HP Pressurized Mill pulverizer systems, the hot and cold
air dampers at the inlet of the mills control the total airflow.
Clean airflow tests are used to establish the following: Figure 10: Exhauster Fan Damper Drive
• Verify that the total airflow capability of the mill system is

within specification 1.4 Pulverizer Output Summary
• Check the distribution of airflow between coal pipes to The following performance curve for a typical coal milling Figure 11: Theoretical Milling System Performance Curves
furnace system identifies the following:
• Verify suitable line velocities through piping • Percent of base mill capacity, as affected by coal Field-testing is always required to convert design theory to
The exhauster suction damper should be set for minimum and Grindability practical application.
maximum positions. The minimum stop prevents airflow • Percent of base mill capacity, as affected by mill
"starvation" while the maximum stop prevents over-travel out of discharge fineness
control range and subsequent lack of response.
• Percent of maximum mill capacity, as affected by coal
Airflow quantity and distribution are among the most critical moisture
items to successful operation of the ALSTOM mill. Mill outlet
• Minimum air temperature requirements, eastern coal
temperature can usually be slipped a few degrees if it makes a
difference in the total quantity of airflow available. • Minimum air temperature requirements, mid-western
NOTE: It is important to know that the minimum and maximum coal
stops are installed to keep the exhauster inlet damper within a • Minimum air temperature requirements, western coal
pre-determined operating range, however the stops will not
prevent the damper positioner from over-traveling and possibly
The following chart (Figure 11) suggests to the system
snapping off the stops. The damper positioner travel must be
designer what happens to capacity and required inlet
set between the two pre-determined operating points prior to
temperatures when considering various coals.
installing the stops.
1.5. Base Design Capacity Capacity can also be limited by Non-combustibles still need to 1.6 Operational Phases and Terms
The “Base Capacity” of any mill design is the amount of coal be factored in. For the pulverizer, the impact of changing coal Mill Puff
the mill will process under the specified design conditions of can mean:
A mill puff refers to an explosion in the pulverizer caused by
coal with a Hardgrove Grindability Index of 55, and a final • Increased erosion from sand operational problems, which create an explosive combination
product fineness of 70% passing through the 200-mesh • Increased impact damage from rock of fuel, air, and temperature.
screen. Coal milling system output is significantly affected by
• Increased journal spring deflection from residual clay Mill Fires
coal characteristics. It is also affected by the condition of the
grinding surfaces, and product fineness requirements. building up on the bowl Mill fires consist of the active and ongoing combustion of coal
• Increased moisture leading to the loss of mills from and/or debris in the pulverizer. Mill fires are not considered to
severe pluggage be a normal part of pulverizer operation and are preventable
EXAMPLE: If coal grindability goes from”55” (at 190,000 through judicious maintenance practices and proper operating
lb./hr.) to “60”, theoretically there will be a 7% increase in mill Additionally, the furnace may find that the ash removal procedures.
capacity (more coal ground per hour) to approximately 203,000 systems cannot handle the higher volumes of non-
combustibles. With some coals, it is often the backend The presence of combustible materials in the milling system
lb/hr is possible. has been determined to be the single largest prime contributor
systems that overload, leading to reduced unit airflow or higher
In general, a one percent change in the percent through the to the occurrence of mill fires. Collections of foreign material in
opacity. Lastly, when factoring in coal heating value (HHV)
200-mesh screen produces approximately 1.5% change in mill inner cones and other points above the bowl should be
when switching to a coal of lesser heating value (Figure 12), it
capacity. removed whenever the mill is out of service between
is obvious that more coal must be transported into the furnace
Moisture can also impact capacity, but the designer’s initial to achieve the same level of chemical energy. Where there scheduled inspections and overhauls.
concern is with the temperature of the incoming air. The may have been a spare mill available at all times for Excessive accumulations of coal anywhere in the mill or in the
following design curve is a start point for design estimates. maintenance PM's before the switch, there probably won't be millside area and air inlet duct should be investigated and
Field-testing is required to confirm potential capacity losses one after. removed. The pyrite removal system should be maintained to
from a lack of heat from the air heater. Further complicating the allow any material to be discharged from the millside area/air
capacity estimating is the discovery of Lignites, and some Sub- inlet duct.
bituminous coals have grindability values that are not constant.
When the coal is very moist, a higher grindability number from
the test is recorded. When the coal is very dry, again a higher
grindability number is recorded. Mid-moisture levels produce
the lower grindability values. Again, field-testing must be used
to determine the actual capacity potential.
The table below is selected HP Mill capacity lists for coal with a
Hardgrove Grind Index (HGI) of 55.
Mill Size Capacity lb/hr
HP-643 44,500
Figure 12: Coal Rank
HP-863 106,000
HP-963 138,000
Figure 13: Mill Fires
HP-983 144,000 WARNING: In the event of a mill fire tell the operations shift
supervisor if you discover a mill that you think is on fire.
HP-1003 150,000 Symptoms are the following: high mill outlet temperature,
sparks discharging from the pyrite reject chute, paint peeling, a
HP-1063 190,000
hot sweet odor, or an area of the mill or coal piping that is
Table A: Selected HP Pulverizer Capacity Data
glowing red. Stay clear of the mill and feeder area until
operations has eliminated all traces of the fire and the mill has
cooled.
Roll Plowing Spillage

Another capacity term that is often used is "plowing" resulting The term "spillage" is used to describe the condition whereby
from a grinding roll that does not turn. Plowing may result in raw coal passes over the edge of the bowl and is rejected
rapid capacity loss. The most common cause is a failed or through the pyrite chute instead of being picked up by air
seized journal bearing, but other causes are possible. stream. Possible causes of spillage include, but are not limited
Troubleshooting is often required. to:
Any of the following conditions could be responsible for the
occurrence of spillage:
• Low total airflow through mill
• Improperly distributed airflow through mill (worn
components at bowl perimeter)
• Improperly set inverted cone clearance
• Low spring pressure
• Improperly set spring seats
• Worn grinding elements
• Seized journal bearing
• Overfeeding mill
Figure 14: Worn Grinding Rolls • Classifier deflector blades closed off too much
Pyrites
The term "pyrite" specifically refers to a compound frequently
found in coal, which is made of iron and sulfur (FeS2). It is also
known as "fool's gold" because of its hardness and
appearance, which is similar to gold.
More generally, the term pyrite is used to refer to any material
rejected from the mill including not only the compound pyrite,
but also rocks, clay, etc.
Tramp Iron
"Tramp iron" refers to any pieces of metal, which enter the
pulverizer along with the normal coal feed. Examples are
tools, nuts, bolts, scrap steel, etc.
Tramp iron may be introduced at the mine, picked up on the
way to the plant, or may be the result of careless handling of
the coal pile. It is considered detrimental to mill operation
Figure 16: Coal Spillage
because it is not grindable and induces shock loading on the
journal assembly, gearbox components and bearings.
Internal Gap Settings
"Roll-to-Ring gap" is one of the gap clearances between the
grinding rolls and grinding ring. This clearance is generally set
based on experience with the coal being ground and required
mill output fineness. Indications that adjustment is needed
include a gradual reduction in mill capacity as indicated by an Figure 15: Tramp Iron Rejects from a Pulverizer
increase in spillage or an Increase in coarse particles showing
in fineness samples.
NOTE: The original pulverizer series designations were: 1.7 HP Pulverizer Features
• RB - Raymond Bowl Mill (Figure 17) The HP pulverizer (Figure 20) represents a new generation The primary features of this new pulverizer design are:
• RS - Raymond Suction Mill (Figure 18) of ALSTOM pulverizers incorporating the latest design of • Planetary gear drive assembly is comparatively lighter
proven components. The HP pulverizer is the standard and stronger than the gearboxes previously used.
• RPS - Raymond Pressurized Suction Mill (Visually offering on all new units. Components and materials of the Lightweight and independence allow the drive to be
Similar to the RS) HP pulverizer have been selected to extend grinding removed from under the mill for ease of maintenance
• RP - Raymond Pressurized Mill (Figure 19) element life, reduce replacement part cost, reduce and repair. Because the gear drive is independent, it
maintenance and reduce down time. can be sealed from the dirty mill environment and is not
affected by the high temperatures within the mill. A
forced lubrication system supplies cooled and filtered oil
to all critical points in the gear drive.
• Heavily insulated millside area that reduces the potential
hazard to personnel and improves the thermal
efficiency.
• Improved scraper assembly, which is lighter, stronger
and more resistant to wear.
Figure 17: RB Pulverizer • Vane wheel designed to improve the processing of coal.
• Journal assemblies designed for minimal maintenance
and easier access.
• Grinding ring case from a wear resistant material.
• External spring assemblies.
• Advanced classifier technologies for improved discharge
fineness management.
NOTE: The features added to Trimble No.2’s HP pulverizers

go beyond this list. Refer to Sections 2 and 3 for more detail.
Figure 18: RS Pulverizer
Figure 20: HP Pulverizer
Designation of the 1063 HP pulverizer

• The "106" indicates the approximate bowl diameter in
inches 106".
• The "3" indicates the number of journal assemblies in
the mill.
• The "HP" indicates the High Performance style of
ALSTOM pulverizer.
Figure 19: RP Pulverizer
1.8 Operational Overview 2. Lighter particles are carried by the rising air stream to the coal in suspension. If coal settles it can cause fuel pipe
ALSTOM HP pulverizers are designed to reduce the size of the separator top, where the second stage of classification occurs. plugging and fires.
incoming raw coal to a fineness that will result in good furnace Here, the dynamic classifier uses aerodynamic and centrifugal • Operating a pulverizer with airflow above specification is
performance. The maximum capacity of a pulverizer is forces to separate the fine output product from the larger considered less then optimal; the higher airflow will
dependent on the following: particles. As the particles approach the dynamic classifier, they increase internal wear in the fuel pipe and pulverizer. It
meet centrifugal forces that throw the particles outward. The can also cause a reduction in the pulverized coal
• Pulverizer size amount of aerodynamic force produced by the primary airflow fineness.
• Raw coal properties - Hardgrove index and moisture and centrifugal force generated by the classifier rotation
imparted on a particle are related to the size of the particle. • Operating a pulverizer with the pyrite discharge gate
• Pulverized coal fineness closed is prohibited because it prevents the normal
The raw coal is fed into a rotating bowl via a center feed pipe. If the centrifugal force is greater than the aerodynamic force, discharge of rejects. When the gate is closed for
The rate of coal feed is normally determined automatically by a the particle will not pass through the classifier, and it will fall extended periods of time, material normally discharged
combustion control system, taking into account the MW back down into the grinding zone for further size reduction. If will be retained in the millside. The scraper assemblies
demand on the unit, coal quality, and the number of pulverizers the centrifugal force is less than the aerodynamic force, the can be severely damaged and the potential for a
in service. Centrifugal force causes the coal in the bowl to particle will pass through the classifier and exit the pulverizer. pulverizer fire is increased.
move radially outward, building up a bed of coal on the At the pulverizer exit, the coal-air stream is distributed directly
• Operating a pulverizer with one or more coal discharge
grinding ring. The bed of coal passes under pivoted grinding to the coal pipes. The difficult-to-grind foreign material that falls
valves not fully open is considered hazardous since it
assemblies called journals. Here, spring produced loads are through the air stream into the millside is moved by rotating
will increase the pulverizer pressure drop, adversely
imparted to the coal by the rotating rolls. Size reduction takes scraper assemblies to an opening in the millside floor. The
affect coal fineness and cause an unbalance to the coal
place in the localized area between the grinding ring (called the rejected foreign material falls out of the pulverizer and enters
pipe distribution which could result in coal pipe pluggage
bull ring) and journal roll through crushing and a process know the pyrite system.
and/or burner overheating.
as attrition or friction grinding. The radial and circumferential The rejected material usually consists of rock found as over or
movement of the coal carries the pulverized coal up over the • Inadequate warm up of the pulverizer prior to feeding
under burden in the coal seam and/or other ungrindable
edge of the bowl into the path of the hot air stream. coal is hazardous since moist coal may plate out on the
material (mining tools, etc.) entering with the raw coal feed.
“cold" internals of the pulverizer and fuel piping. This
The air supplied to the pulverizer has two primary functions:
increases the potential for a fire in the milling system.
• Hot air dries the coal. 1.9 Improper Pulverizer Operation • Inadequate cool down of pulverizer prior to shutting off
• Air recirculates and transports coal within the mill and to Listed below are incorrect and hazardous operating conditions, coal flow is hazardous since temperatures may exceed
the furnace. which should be avoided. a safe limit for the remaining coal/air mixture. This
As the coal is continuously reduced in size, the smaller/lighter • Excessive coal spillage is a hazardous situation that can increases the likelihood of a pulverizer or coal pipe
particles are swept from the bowl by the hot air. The primary air plug the pyrites discharge chute thus allowing a coal fire/puff to occur.
fans provide hot air and cool tempering air. The air is admitted buildup in the millside and increasing the potential for a • Operating a pulverizer with too high an output fineness
below the pulverizer bowl into an area known as the millside pulverizer fire. is considered less then optimal as increased fineness
and air inlet. The millside is at a positive pressure. results in lower pulverizer capacity and higher pulverizer
• Operating a pulverizer for an extended period of time
From the millside, the air flows upward around the outside with outlet temperature below specification is hazardous motor power consumption. In some cases, excessively
diameter of the rotating bowl. Vanes attached to the bowl since the coal may not be properly dried and will plate high fineness may result in unusually high mill vibration.
(vane wheel) change the airflow to a vertical direction. At the out inside the pulverizer and in the fuel piping. Fuel pipe • Operating a pulverizer with too low an output fineness is
edge of the bowl, smaller/lighter particles of coal are entrained plugging and pulverizer or fuel pipe fires can result. considered less then optimal as low pulverized coal
in the air stream and are carried upward, while dense, difficult- fineness will adversely affect furnace operation.
to-grind foreign material is rejected downward through the air • Operating a pulverizer with the outlet temperature above
stream into the millside. specification is hazardous because high outlet • Operating a pulverizer with suspected or obvious
temperatures can drive volatile gases from the fuel thus mechanical problems with items such as a journal,
Above the bowl, the lighter airborne coal particles undergo a increasing the fuel's potential to ignite. The control spring assembly, scraper assembly, gear box, classifier,
two-stage classification process. system should automatically close the hot air shutoff etc. should be avoided due to the potential of extensive
1. The first stage of classification takes place just above bowl gate if the pulverizer outlet temperature rises to 20°F mechanical damage and potentially hazardous
level. Stationary air deflectors mounted on the separator body above the specified normal outlet temperature. operating conditions.
cause the heaviest coal particles to abruptly change direction. • Operating a pulverizer with reduced airflow (below
They loose momentum and are returned directly to the bowl for specification) is hazardous since velocity in the fuel
further size reduction. pipes may not be adequate to maintain the pulverized
1.10 Pulverizer Operation & Controls 1.11 Sequence for Pulverizer Start
Interlocks are required for providing a safe operating To put a pulverizer in service, the following conditions must be 1.12 Sequence of Normal Shut Down
sequence. The required ignition energy for the pulverized fuel satisfied: 1. Close the hot primary air damper, while maintaining air flow.
must be present before starting a pulverizer and feeder. • No boiler trip condition present.
Adequate primary air system pressure must be available. The 2. Reduce feeder load to minimum.
Dynamic Classifier must be started prior to starting the • Ignition energy available. 3. Reduce Dynamic Classifier speed to minimum.
pulverizer. The pulverizer must be started before the feeder. • Pulverizer discharge valves open. 4. Allow the feeder to run until the pulverizer has cooled until
The feeder motor should be started independently of the • Primary air supply adequate. the mill outlet temperature is below 130°F or has dropped 20
pulverizer motor. The hot air damper cannot be opened before degrees F from set point, which ever is lower, and then stop
the pulverizer is started nor left open when the pulverizer is • Lubrication oil system start permissive. the feeder.
shut down. • Steam inerting pressure available. 5. Stop the pulverizer motor after the mill is emptied of coal.
• Seal air on and proven. When the mill motor amps no longer decrease, the mill has
Interlocking systems: • Primary air isolation gate open. been emptied of coal. When automating the mill sequence, a
time delay of 3 minutes will allow adequate time for the mill to
• Coal Feeder (which is interlocked to a safe burner • Tramp iron valve open. empty. After the mill has stopped the airflow should be reduced
management system to light and warm the boiler with a
• Feeder gates are open. to 5% open on the cold air damper. The hot air damper should
stable fire)
• Pulverizer outlet temperature <200° F. be 100% closed.
• Mill Seal Air System (which is pressurized to protect
6. Stop the Dynamic Classifier.
dynamic classifier seals, journal housing seals, and
gearbox to millside seals.) 1. Start the dynamic classifier motor. 7. Seal air dampers and discharge valves to remain open
unless the pulverizer is isolated for internal maintenance.
• Mill air inlet isolation systems (feeding both hot and cold 2. Start the pulverizer motor.
air to the pulverizers) 3. Place the Hot and Coal air dampers in automatic and
• Mill discharge isolation system (connecting to coal choose set points for proper airflow and pulverizer outlet NOTE: These shutdown procedures are general in nature.
transport piping and burner nozzles) temperature (Table B). They do not necessarily reflect and steam inerting practices
that will be locally determined during commissioning tests.
• Drive Motor (providing rotational force for the grinding 4. Pre-warm the pulverizer for 30 minutes.
table or bowl) 5. Start the feeder at minimum speed.
1.13 Sequence for Emergency Shut Down
• Mill Fire Explosion Inerting Steam (not by Alstom) 6. Increase the feed rate to 50% of maximum as soon as
practical. The pulverizer "stop" switch or a fuel "trip" interlock will stop
the pulverizer motor. Interlocks shall be provided to stop the
Interlocking controls are similarly associated to: feeder, stop the Dynamic Classifier, and close the gates.
• Variable speed drive that controls a dynamic classifier U.S. Coal Classification: Recommended Max.
(which will be calibrated during commissioning, Mill Outlet Temp
WARNING: Before stopping the mill, announce to the
basically, faster speeds result in finer coal, but with Eastern Bituminous 180°F workforce, which mill is shutting down and that the mill’s area
more amp consumption. Slower speed improves mill
Mid - Western Bit. 170° F should be temporarily cleared.
capacity, but coarser coal discharge may not burn out
increasing flue gas LOI (Loss on Ignition). Sub - Bituminous 150° F
• Pyrite rejection and removal systems (which cycle to
Table B: Recommended Mill Outlet Temperature
keep up with the removal on tramp iron and other hard
debris found in all coal supplies).
• Mill clearing and fire fighting and explosion prevention
system (which employs steam to displace oxygen from
the mill, and water to pull heat from fire sources, or flush
coal from a mill with a suspected fire source).
1.14 Milling System Primary Air Flow Control is used to control the required airflow set point. Both air flow
Primary air is used for transport of the pulverized coal from the and temperature must be maintained in automatic. Correct
pulverizer to the furnace. For the primary air to perform its Primary airflow indication is critical for good performance of the
function of drying coal in the pulverizer, provisions must be pulverizer. Care should be taken in selecting and installing this
made to heat a portion of the air. This is accomplished by hardware.
utilizing a segment of the air side of the air heater(s). The
primary air fan(s) discharges into a duct leading to the air WARNING: the loss of Dynamic Classifier rotor rotation will
heater. A duct, taken off the main duct, bypasses a portion of result in an unloading of the fine coal reserve in the mill. This
the air around the heater to be utilized as tempering air. The unloading will result in a surge of coal in the boiler. The rate at
balance of the air goes through the primary air heater and into which this unloading will occur depends on the deceleration
the hot air duct. rate of the rotor speed (slower the deceleration, the smaller the
Primary airflow to each pulverizer is to be ramped from the surge). The rate of deceleration (and acceleration) of the rotor
minimum flow to the maximum flow as the coal flow thru the can be controlled by programming the variable frequency drive
mill varies from minimum to maximum. Typically, airflow control to have long deceleration and acceleration times.
follows a non-linear curve, where feed rate is true to linear
(Figure 21). Programming the controls to hold airflow as close
to linear as possible benefits pulverizer performance. 1.15 Fire Fighting & Mill Clearing
The purpose of the pulverizer fire fighting system is to
extinguish fires in the pulverizer. The mill clearing system is
used to clean out the coal in the mill following an inerting or fire
fighting sequence. Ensuring the safety of plant personnel
during a potentially hazardous situation is of primary concern.
The fire fighting system is intended to work in conjunction with
a steam inerting system. The supply and operating procedure
of the steam inerting system is by others.
ALSTOM Power is supplying two spray water systems. One for
fire fighting and a separate Swirl system to wash the
underbowl area clean after the fire fighting water has carried
coal into the underbowl area.
Figure 21: Air to Coal Flow Character
As the system resistance changes due to variations in furnace

pressure and weight of the transported coal, the airflow control
air damper(s) shall modulate to maintain the required airflow.
Primary airflow should be monitored at the pulverizer inlet.
Temperature compensation should be supplied to assure the Figure 22: Millside Below-Bowl Area
proper mass flow of primary air as its temperature changes Figure 23: Nozzle Connection Arrangements
over the operating range of the air heater. The hot air damper
Figure 24: HP Pulverizer Sectional View
Drawing 1: HP-1063 Pulverizer Sectional, E-PLVE-0852
2. RP-963 vs. HP-1063 ARRANGEMENT DIFFERENCES

2.1 Applying Alstom Equipment to a Doosan-Babcock
Boiler
Trimble Unit No. 1 is a tangentially fired Alstom boiler fitted
with RP 963 series pressurized pulverizers. The Trimble Unit
No. 2 application is, however, an HP-1063 pressurized
pulverizer design being applied to a non-Alstom boiler. The
one unusual design feature is with the discharge piping. This is
arranged to match the Doosan-Babcock Front-Rear burner
firing system arrangement.
• Alstom pressurized pulverizers typically have four pipes
• Babcock firing system needs five discharge pipes.
This design difference will have minimal effect on the overall
performance. Coal line distribution testing (dirty air tests) can
confirm that pipe-to-pipe distribution is similar in mass flow.
2.2 Comparisons Between RP and HP Series Pulverizers

For those who operate the coal milling air systems and
pulverizer, differences between the coal preparation systems
of the two units may be minor. Both coal preparation system
designs are pressurized and need boosted seal air auxiliary
fans. Both designs have air flow design concepts that are
similar. One difference will be with the Static Classified vs. the
Dynamic Coal Particle Classification System. Before coal flow
is permitted in Unit No. 2, a minimum air flow indication after
the dynamic classifier rotor starts will show that the rotor’s
reverse flow is overcome.
Figure 25: RP-963 Pulverizer with Static Classifier
The follow ten points are aimed at explaining how redesign of Figure 26: HP-1063 Pulverizer with Dynamic Classification
the Alstom pulverizer from RP to HP will positively impact
maintenance and performance: 2.3 Technical Data Comparison
Mill Model Number: HP1063
• Hot air inlet • Bowl Diameter: 110”
• Bowl perimeter flow Mill Model Number: RP 963 • Classifier Design: Dynamic™ Classifier
• Bowl drive • Bowl Diameter: 100” • Dynamic™ Classifier Motor: 60 HP
• Classifier Design: Static • Design Coal: PRB-Eastern Bituminous Blend 70/30
• Lower grinding zone
• Design Coal: Eastern Bituminous • 53 HGI & 17.5% Blend Moisture
• Upper grinding surface
• 50 HGI & 9.46% Blend Moisture • Coal & Air Relationship:
• Initial grinding compression • Coal & Air Relationship: • Maximum Coal Flow (lb/hr) 186,969 (lb/hr)
• Internal wear • Maximum Coal Flow (lb/hr) 138,000 (lb/hr) • Minimum Coal Flow (lb/hr) 50,000 (lb/hr)
• Pulverizer coal classification • Minimum Coal Flow (lb/hr) 34,500 (lb/hr) • Air Flow @ Max. Coal Flow 4284 (lb/min)
• Discharge valves • Air Flow @ Max. Coal Flow 3480 (lb/min • Air Flow @ Min. Coal Flow 2760 (lb/min)
• Air Flow @ Min. Coal Flow 2200 (lb/min) •
• Rejection of tramp iron Mill Outlet Temperature 150 (°F)
• Mill Outlet Temperature 170 (°F)
• Mill Motor: 883 HP, 900 RPM
• Mill Motor: 600 HP, 600 RPM
2.4 RP HOT AIR INLET

The “millside and air inlet” surrounds the bowl and the bowl hub and support the separator body. It’s
square shape and low profile can permit coal rejects accumulation in the inlet duct, which can lead to
mill explosions. The older design may have induced inlet duct accumulation.
Figure 27: RP Hot Air Inlet
2.5 HP HOT AIR INLET

The “millside and air inlet” surrounds the bowl and the bowl hub and support the separator body. It’s
rectangular shape and raise position greatly reduces coal rejects into the inlet. The new millside
dimensions prevent inlet duct accumulation.
Figure 28: HP Hot Air Inlet
2.6 RP BOWL PERIMETER FLOW

The “vane wheel assembly,” is a retrofit design that is installed to replace the separator body liners.
Initial vane wheel installations and competitors designs increased spillage and had fastener reliability
concerns. This added to inlet duct accumulation concerns. Original vane wheel velocities were
relatively high (`>120 fps) in select locations. Erosion could be severe.
Figure 29: RP Bowl Perimeter Flow
2.7 HP BOWL PERIMETER FLOW

The “vane wheel assembly,” which is attached to the bowl, directs the coal/air mixture within the
grinding zone of the pulverizer by uniformly distributing the transport air through the bowl OD and
separator body annulus. The HP pulverizer was designed from day one with the ‘vane wheel’
concept. Ambient velocities are much lower (> 90 fps). Distribution of hot air is less stratified.
Fasteners are inherently stronger.
Figure 30: HP Bowl Perimeter Flow
2.8 RP BOWL DRIVE

The “gearbox,” is a worm drive, which must drop motor speeds of 600 RPM to approximately 42
RPM bowl speed in one step. A pumped lube oil system cools and distributes oil to protect bearings
and gear contact surfaces. Stresses could concentrate in the main vertical shaft in upper bearings.
Gearbox rebuilds, when major cyclic damage occurred in the drive could lead to rebuilds. Rebuilds
must be done in place requiring 2-3 weeks down time.
Figure 31: RP Bowl Drive
2.9 HP BOWL DRIVE

The “gearbox,” is a low friction planetary gear arrangement turning at a bowl speed of 33 RPM.
A pumped lube oil system cools and distributes oil to protect bearings and gear contact surfaces.
Placing a large thrust bearing at the top of the box and eliminating the main shaft has removed a key
fatigue concern. If service is needed, rapid removal of the gearbox for off-site repair is possible.
Delays from gearbox maintenance have been greatly reduced.
Figure 32: HP Bowl Drive
2.10 RP LOWER GRINDING ZONE

The “bowl-hub" is the table upon which the coal is crushed. The main vertical shaft under the hub
induces lateral stress on the upper radial bearing. Shaft and bearing failure has been a concern.
The thrust bearing is relatively small and can deteriorate under high dynamic load. Increased use of
chrome in bowl segments has improved life.
Figure 33: RP Lower Grinding Zone
2.11 HP LOWER GRINDING ZONE

The “bowl-hub" is the table upon which the coal is crushed. The main vertical shaft has been
replaced with a hollow hub spanning a large thrust bearing surface within the gear drive top. Main
vertical shaft failures are a thing of the past. The lower grinding zone is inherently much more solid.
Wear is still a concern, but new materials, and improved fastening methods have doubled
component life.
Figure 34: HP Lower Grinding Zone
2.12 RP UPPER GRINDING SURFACE

Three independent, spring loaded “journal assemblies” are suspended from the separator body and
overhang the bowl. The journal assembly grinding rolls are free to rotate in a three bearing
arrangement, and do so, when the coal being pulverized fills the space between the rolls and the
bowl. Roll-to-Ring wear life has typically been 2-3 years. Journal maintenance requires removal
and handling of heavy components. At a typical plant there may be 18 journals. Removal over a ten
year period can range from 70-100 times. Note that the circumference of the grinding roll is about
one-half that of the bullring (bowl liner segments).
Figure 35: RP Upper Grinding Surface
2.13 HP UPPER GRINDING SURFACE

Three independent, spring loaded “journal assemblies” are suspended from the separator body and
overhang the bowl. The journal assembly large circumference rolls are free to rotate in a double
opposed arrangement, and do so, when the coal being pulverized fills the space between the rolls
and the bowl. Roll-to-Ring wear life has been maximized to where grinding surface life approaches
7-9 years. Journal roll tilt out handling means roll removal may not ever be required. Note that the
circumference of the grinding roll is about the same as the bullring (bowl liner segments).
Figure 36: HP Upper Grinding Surface
2.14 RP INITIAL GRINDING COMPRESSION

The vintage of RP pulverizers installed on Trimble No. 1 had evolved to hydraulically loaded
journals. Pro’s and Con’s for springs versus hydraulics are mixed from facility-to-facility. Time to set
hydraulics can be lengthy. Springs have a smoother response.
Figure 37: RP Initial Grinding Compression
2.15 HP INITIAL GRINDING COMPRESSION

In the present HP design, spring assemblies in a pressurized canister offer a smooth response to
both coal crushing and the occasional rejection of tramp iron. Seal air keeps dust out of the spring
assembly. Adjustment of initial compression with a jack and cylinder system assures uniform
resistance.
Figure 38: HP Initial Grinding Compression
2.16 RP INTERNAL WEAR

Studies have found that erosion is exponentially proportional to velocity. Theoretically a 30%
increase in velocity doubles wear rate. RP internal velocities can be higher and recirculation from
static classification (6:1) greatly increases internal wear. Ceramics are recommended in several
locations.
Figure 39: RP Internal Wear
2.17 HP INTERNAL WEAR

Theoretically a 30% decrease in velocity cuts wear rate in half. HP internal velocities and lower
recirculation from dynamic classification (2:1) greatly reduces internal wear. Ceramic liners are not
needed in many cases. Some dynamic classifier vane wear is possible, but with softer coals, the
wear has been found to be minimal.
Figure 40: HP Internal Wear
2.18 RP PULVERIZER COAL CLASSIFICATION

The large “separator top” on Trimble No. 1 mills contains a static classifier separating the coarse
coal particles from the fine ones and returns them to the bowl for further grinding. When vanes are
adjusted for high fineness, capacity can be 10-15% lower. Coarse particles (anything larger than 50
mesh size) may result in poor coal burn out (LOI) particularly when firing for low NOx.
Figure 41: RP Pulverizer Coal Classification

2.19 HP PULVERIZER COAL CLASSIFICATION

The smaller HP “separator top” contains a variable speed motor-driven dynamic classifier separating
the coarse coal particles from the fine ones and returns them to the bowl for further grinding. When
run near minimum speeds, capacity can be 10-15% higher. When run near the upper rotational
speed, 90% through 200 mesh is possible. Coal burn out (LOI) is far better, even when firing for low
NOx. Even slagging on walls can be reduced. Discharge deflectors can be set to provide more
uniform flow to each coal transport pipe.
Figure 42: HP Pulverizer Coal Classification
2.20 RP DISCHARGE VALVES

Flapper discharge valves were the standard. Turbulence induced wear is a concern. The mass was
significant. The valves can be difficult to move during a mill disassembly.
Figure 43: RP Discharge Valves
2.21 HP DISCHARGE VALVES

Knife gate valves have become the standard. The gate is fully pulled from the coal dust stream
eliminating turbulence and wear. Were it necessary to remove these valves, their smaller size
presents less of a challenge. Note that the Discharge Valves are not in Alstom’s scope.
Figure 44: HP Discharge Valves
2.22 RP REJECTION OF TRAMP IRON

A millside rejection zone that was only a few inched below the inlet duct allowed coal rejects to
accumulate in the inlet duct. This can cause inlet explosions that can tear the duct from the mill.
The new scraper is lighter in weight. The heavy scraper assembly was difficult to maintain.
Figure 45: RP Rejection of Tramp Iron
2.23 HP REJECTION OF TRAMP IRON

A recessed millside rejection zone with a small low point hopper prevents rejects from being
deposited in the inlet. A lightweight spring loaded scraper is very effective, reliable and easy to
maintain.
Figure 46: HP Rejection of Tramp Iron
3. MAJOR COMPONENTS & THEIR PM’S A cylindrical roller bearing and a pair of tapered roller bearings assembly, mounted on a horizontal pin, oriented radially
support the input shaft and pinion. A cylindrical roller bearing outward from the bowl hub, and supported from above by a
and a pair of tapered roller bearings also support the bevel support stud attached to the underside of the bowl.
3.1 Pulverizer Motor And Drive Couplings gear shaft. The sun gear of the planetary stage is connected The scraper rotates on the pin so as to swing upward out of the
The motor and coupling supply the necessary force to rotate to the bevel gear shaft by means of a crowned gear type way if a foreign object becomes lodged in the millside area.
the gearbox input shaft, allowing for a slight degree of axial coupling. The gear coupling allows for both axial and radial The torsion spring helps to return and maintain the scraper in
and radial misalignment between motor and gearbox. The movement. the vertical position. The scraper is equipped with an abrasion
electric motor is directly coupled to the gearbox. The planet gears are supported by self-aligning roller bearings resistant replaceable wear plate.
Motor PM so that they can adapt to the load pattern of their teeth. The
The motor windings should be kept clean. Remove dust floating sun and planet gears ensure equal load distribution on
periodically by vacuuming. the meshing teeth, distributing the horsepower equally among
Do not start and stop too often within a short period of time. the three planets.
This shortens winding insulation life. Always check motor The forces from the grinding process are transmitted through
rotation after electrical repairs have been performed and the thrust bearing to the mill foundation. The thrust bearing
before the motor is coupled to the mill and exhauster. Refer to has temperature sensors interlocked to the mill operation to
the manufacturer's manual on the motor for other routine prevent damage to the thrust bearing. The gearbox is ruggedly
maintenance notes. designed and will normally run for 5-10 years before a
Couplings scheduled overhaul is recommended.
The function of the gearbox coupling is to join the motor shaft 3.3 Millside Area
to the input shaft assembly and allow for a small amount of The function of the millside (Figure 49) is primarily to allow an
shaft misalignment area for hot air to enter the milling system and provide an area
• Gearbox coupling hub with torsionally flexible bushing where foreign material can be rejected from the mill.
• Motor coupling hub Components:
Figure 47: Scraper Assembly
• Flanged coupling extension • Millside housing
Clean out any debris that has collected in the air inlet duct.
The limited end flow coupling connects the motor to the • Millside insulation
This debris may collect as a result of excessive spillage from
gearbox. A typical HP mill gearbox is rated for 600-900 HP, • Bowl/Bowl hub the bowl, and will prevent the proper discharge of material
900-1000 RPM input drive shaft speed, and ~40 RPM output • Air inlet vanes through the reject chute.
table (bowl) speed.
The HP mill has a heavily insulated millside area in order to Replace mill bottom liners when worn through or if buckled so
3.2 Planetary Gearbox minimize the potential hazard to personnel and to maximize that they do not bind with the scrapers.
The function of the planetary gearbox (Figure 48) is to transfer the thermal efficiency of the mill. Replace worn or damaged millside liners
the driving force from the motor to the bowl through a planetary 3.4 Scraper Assembly Inspect the mill floor for wear and replace the floor if severely
gear reduction system.
The function of the scraper (Figure 47) is to keep the millside grooved or holes exist.
• Input shaft area clear of debris such as pyrites and coal resulting from Inspect the hot air duct debris screen for wear and replace if
• Input gear set rejects and spillage. holes are evident.
• Planetary gear set • Scraper Support Plate Inspect the hot air duct directional vanes. Replace if worn thin
• Planetary carrier • Scraper Support Block or holes are evident.
• Hydro-Dynamic thrust bearing • Scraper Wear Plate Maintain the proper gap under the scraper. The gap should be
not less than 1/4” or more than 5/8” inches.
• Output adapter • Scraper Pin
Inspect the bowl hub insulation covers for wear or broken and
The independent gearbox allows for easy removal from under • Torsion Spring missing fasteners. Replace the insulation covers and/or
the mill, it is sealed from potential contaminants and is not • Reject chute fasteners if damaged or missing.
affected by the high air inlet temperatures. The gearbox
Two pivoting scrapers attached to the bowl hub sweep material Confirm that no material is jammed in the pyrite reject chute
consists of a spiral bevel gear stage and a planetary gear
rejected from the bowl into the reject chute for disposal. Each (like tramp iron).
stage in a vertical arrangement.
scraper assembly consists of a scraper and wear plate
Figure 48: Planetary Gear Box
Figure 49: Bowl, Bullring and Scraper Assembly
Drawing 2: Bowl, Hub, & Vane Wheel Assembly, D-PLVD-2526
Drawing 3: Scraper Assembly, C-PLVC-3169
3.5 Bowl Assembly NOTE: The vane wheel parts may vary depending on the style
The function of the bowl and Hub (Figure 50) assembly is to of vane wheel on your specific pulverizer.
provide the surface for crushing of the incoming raw coal. • Vane Wheel Segments
Rocks, pyrites, tramp iron and other non-crushable materials • Block-off Liner
are dropped over the edge of the bowl to the millside area for
rejection. • Vane Wheel Support Lugs
• Two-piece Bowl and Hub • Vane Wheel Adjustable Shroud
• Bull ring segments • Vane Wheel Wear Shroud
• Bowl hub cover • Vane Wheel Air Restriction Segments
• Bowl extension ring
• Bull ring clamping ring Several years were required to design a vane wheel assembly
that was both reliable in a harsh environment and performed
Depending on the mill size, the mill bowl and bowl hub are correctly for a given air flow volume. Internal thermal and
either a single piece or a two-piece design. The bowl is erosive forces required redesigns during the early years of this
completely lined with replaceable bullring segments cast from systems development.
an abrasion resistant, high chrome material. The bullring
segments are installed as a matched set. Vane Wheel care includes:
Ribbed segments are designed to "hold" the coal mat in place Inspect the vane wheel segments thoroughly. Replace the
during the grinding process. A recessed ridge in a bullring vane wheel segments when they become excessively worn,
segment tends to aid in starting the rotation of the journals
Figure 51: Ring-Roll Wear Patterns thinned, and/or develop holes.
when cold. The bullring segments are "locked" in place by a Replace bullring segments if wear depth is at or beyond a 3/4 • Inspect the vane wheel fasteners, if accessible, for
combination of the bullring clamping ring and the bullring end to 1" indentation at the worst point. A grinding segment excessive wear.
shim. The bowl hub cover is protected by the bowl hub cover measurement gauge can be made to check the segments for
• Inspect the vane wheel support lugs for broken welds of
wear plate. A mill bowl extension ring surrounds the interior patterns of wear (Figure 51).
fasteners.
circumference of the mill bowl to protect the mill bowl from coal Excessive segment cracking can lead to premature loss of
erosion. The vane wheel segments are also attached to the segment, and wallowed out boltholes can lead to premature • Inspect the mill bowl extension ring for excessive wear.
mill bowl extension ring. assembly failure. The vane wheel fasteners screw into the mill bowl
extension ring, if the extension ring is excessively worn,
NOTE: High-chrome alloy replacement segments provide the vane wheel bolts will break and allow the vane
extended wear life. wheel to detach.
• Inspect the vane wheel segment wear shroud, if
3.6 Vane Wheel Assembly applicable, for excessive wear and detachment. These
The function of the vane wheel (Figures 52-54) is to Increases wear plates are designed to protect the vane wheel
coal classification efficiency by promoting better air distribution fasteners. If this wear shroud must be replaced, inspect
through the mill and by utilizing the entire area within the the vane wheel fasteners at this time.
separator body. Also minimizes the wear to components within • Inspect the adjustable outer shroud, if applicable, for
the separator body. thinning and detachment, a replace as necessary.
The vane wheel consists of a series of vanes attached to and
rotating with the bowl. The vane wheel is also equipped with The following series of graphics explains both where the
removable block-off liners that are used to adjust the free area design’s origins were and what the present design technology
around the bowl. These are designed and possibly modified has achieved.
Figure 50: Two-Piece Bowl-Hub
during initial construction to set the pressure drop across the
bowl.
Additional liners can be used with the vane wheel to protect the
separator body, journal and journal opening from the potential
effects of erosion.
Figure 52: Early HP Vane Wheel Design w/Air Restriction Segments (Pre-Wing Tips)
Drawing 4: Vane Wheel Segments, D-PLVD-2330
Figure 53: Development of the Wing Tip

Figure 54: Assessment of Gaps and Coal Hideout Zones
3.7 Separator Body Replace the deflector liners, intermediate liners, and vane
The function of the separator body (Figure 55) is to contain the wheel liner assemblies when worn and excessively thinning.
coal being pulverized. Some pulverizers are supplied with ceramic or other types of
internal liners, their degree of wear will vary considerably from
• Separator body one installation to another and sometimes between pulverizers
• Separator body access doors at the same plant.
• Separator body deflector and intermediate liners Excessive use of trowel-applied, wear-resistant materials, such
• Separator journal door frame liners as epoxies and acrylics in pulverizers is not recommended.
Because this material is not firmly bonded to the mill parts, it
In addition to containing the pulverized coal, the separator can create voids where coal can accumulate, or lead to
body houses and supports the journals and the dynamic pluggage of the rejection chute. Both of these conditions can
classifier. lead to a mill fire and explosion. Fillers can be used to seal
gaps between liners, patch broken tiles, and fill weld plug holes
in ceramic tile.
When replacing the liners, be sure to fill all voids with some
type of high heat compound, otherwise coal will find edges and
openings and cause a wear problem. To protect loss of liners
all attachment fasteners showing evidence of wear must be
replaced. Be sure ceramic weld hole plugs are securely
epoxied in place.
NOTE: A deflector assembly has been positioned below each

coal pipe inlet.
Figure 57: Measurement Chart for Coal Pipe Distribution
3.8 Journal Assemblies

The function of he journal assembly (Figures 58 & 60) is to
provide support for the grinding roll.
• Journal head
• Trunnion shaft assembly
• Journal housing
• Journal shaft
• Journal shaft skirt assembly (liners)
• Oil seals
• Seal air rings and passages
• Roller bearings
• Grinding roll
Figure 56: Discharge Deflector
Figure 55: Separator Body
The journal assembly is equipped with a tilt-out feature for Spring compression can be checked and set with the spring in
ease of maintenance. In the tilt-out position the grinding roll place.
can be changed, oil drained, oil seals replaced and the endplay • Spring stud bearing assembly
checked.
• Spring stud locknut
The spring-loaded journal assembly, along with the weight of
the grinding roll, provides the necessary force for grinding the • Journal pressure spring
coal. The journal pivots on the trunnion shaft. Each journal • Spring stud adapter
assembly has an internal lubrication system providing
• Journal spring housing
lubrication to the two bearings.
• Spring preload stud
Oil seals prevent oil from leaking out of the journal. Seal air is
used to protect the journal head preventing coal dust from • Retaining ring
seeping in. • Spring stud insert
When inspecting rolls for possible replacement, do not allow • Journal opening cover
wear to exceed 1-1/4". Be sure the grinding roll is grounded
When setting spring compressions, be sure all springs on one
before performing any welding on roll, locknut, or housing.
mill are compressed equally.
Rolls are overlaid with wear-resistant weld material to extend
life. NOTE: Spring compression on the three Journals in the
pulverizer should be set within a 1,000 pound limit (one-half
Journal bearing failures usually can be traced back to any of
ton) to prevent undue stress on other pulverizer components.
the following causes:
For example, if one spring is compressed to 35,000 pounds
• Contaminated oil and the second to 35,500 pounds, the third spring must be set
• Excessive end play at no more than 36,000 pounds nor less than 34,500 pounds.
• Bearing preload
• Outer races turning in housings Inspect springs to be sure that the springs have not annealed
or work hardened and that the studs are not cracked or broken.
The result of a journal bearing failure and the effects on mill
Checking the free lengths of the springs would be a good
operation can include:
indicator if the springs are weakened, for example; the
• Loss of pulverizer capacity HP 1023-1103 Pulverizer springs have free lengths of
Figure 58: Journal Assembly
• Excessive spillage 31.17” inches +/- 0.25”. Check with ALSTOM Technical
Services for this information if it is not included in your site-
• Plowing specific pulverizer manual.
• High motor amps
3.9 Journal Pressure Springs
• Improper fineness
The function of the journal springs (Figures 59 & 61) is to
Journal bearing failures may be prevented through careful supply equal forces to the three journal assemblies, to assure
maintenance practices including: proper grinding. Spring also absorbs shock caused by foreign
• Changing of the oil according to recommended material passing between the roll and bullring.
schedule The single spring, mounted externally to the journal opening
• Maintaining proper oil level cover, maintains a constant force on the journal during
operation. The external location eliminates the potential for
• Careful inspection of bearings and replacement if there
erosion and the potential for spring damage in the event of a
is any doubt as to their quality
mill fire.
• Replacement of bearings if turning of the outer bearing
races is evident
• Keeping all seal air passages open and clean Figure 59: Journal Pressure Spring
Figure 60: Journal Assembly Exploded View
Figure 61: Journal Pressure Spring Assembly Exploded View
Drawing 5: Journal Assembly, D-PLVD-2150
Drawing 6: Journal Spring Assembly, D-GP-8580
3.10 Slide Gate Discharge Valves of abrasion-resistant plate. The classifier is belt driven by a
The function of the slide gate discharge valves (Figure 62) is to variable speed electric motor.
provide isolation of an idle pulverizer from the hot gases of the The Dynamic Classifier effectively reduces the recirculation of
operating unit. The discharge valves are located on the top of fine coal particles within the mill for greatly improved grinding
the separator body at the multi-port outlets. efficiency and mill capacity. This process uses aerodynamic
Each of the four discharge valves consists of a valve body with and centrifugal forces to separate the fine output product from
a stainless steel slide gate. An external air cylinder positions the larger particles.
the valve pneumatically. The valve is designed so that the The bearings on the bearing and drive assembly are pre-
slide gate is retracted out of the flow path when the valve is packed full of grease prior to installation. For easy access,
open. future lubrication of the bearings is through external fittings.
If possible, cycle the discharge valves open and closed during Basic Care
outages to check for binding and full operation of the valves. • Refresh the grease during each pulverizer maintenance
period.
• Inspect the rotor every three months.
• Periodically check the alignment of the sheaves with a
straight edge.
• Check tension of the belts for the drive motor.
Figure 64: Dynamic Classifier Sprocket Drive & Labyrinth Seal Gap
Figure 62: Mill Discharge Slide Gate Valve

3.11 Classifier Assembly
The classifier is the final control point for particle size
distribution leaving the pulverizer. Both static and dynamic
designs provide adjustment to compensate for changing coal
quality or furnace combustion requirements.
Dynamic Classifier Assembly
The Dynamic Classifier (Figures 63-66) improves control of
coal fineness and classification for more efficient fuel
preparation and improves furnace operations. The Dynamic
Classifier is designed for pulverized coal units that have
experienced high carbon loss or decreased pulverizing
capacity as a result of routine operations, fuel switching, and/or
the retrofitting with low NOx burners.
The Dynamic Classifier consists of one rotating wheel
assembly, with clockwise rotation, supported by a bearing
assembly that is located external to the mill. The rotor wheel
contains the blades for generating particle separation and the
feed pipe for raw coal input. The rotor blades are constructed Figure 65: Dynamic Classifier Rotor Gap
Figure 63: Dynamic Classifier – Pressurized Pulverizer
Figure 66: Dynamic Classifier Rotor Drive
Drawing 7: Dynamic Classifier Assembly, E-PLVE-0845
Drawing 8: Dynamic Classifier Drive, D-PLVD-2419
Drawing 9: Dynamic Classifier Rotor, C-PLVC-3782
4. PULVERIZER AUXILIARY LUBE OIL SYSTEMS reservoir back to the lube oil tank when the pump is turned off. The pulverizer lube system controls and instrumentation
4.1 Function of Lubrication System The check valve also permits work to be performed on the normally include the following:
pump without draining the oil from the gearcase. The filter is • Lube oil pump motor START/STOP control switch
The gear case lubrication system provides forced lubrication of equipped with a differential pressure switch that will indicate
all critical components, as well as filtering and cooling of the the need for filter replacement. • Heater START/STOP control switch
oil.
From the filter, the oil is directed through a tube bundle type • Lube oil level switch
Generally speaking, the function of a lubrication system is to heat exchanger. The oil cooler removes heat and maintains • Lube oil temperature
provide a film or slippery surface on which moving parts can the oil temperature within the proper operating range.
travel. • Lube oil filter differential pressure indicator
A thermostatically controlled electric heater is used in the lube
A properly designed lubrication system: • Lube oil supply pressure switch
oil tank. The heater goes into service when needed for start-
• Will remove heat generated by friction in gear contact up and operation, typically following extended shutdown or • Lube oil supply temperature switch (mill start permitted
and bearing contact cold weather conditions. at minimum temperature setpoint, lube system shut
• Will remove sludge, scale, and fines which may Pressure gauges, thermometers, oil level and oil flow down at high temperature setpoint)
contaminate the oil indicators provide local visual observation of the lube oil • Lube oil flow indicator and switch (mill stop at low flow
• Will prevent metal-to-metal contact between moving system conditions. setpoint)
parts Pressure switches, level switches, and temperature sensors • Local temperature indicators
• Should assure adequate distribution of the lubricant provide for both audible and visual alarms. Signals from these • Oil level sight indicator
switches are used as mill start-up permissives and can cause a
4.2 Major Systems pulverizer or lube oil system shutdown. • Duplex oil filter pluggage indicator
There are two major lubrication systems associated with the The control logic (in conjunction with various switches and • Oil pressure gauges
pulverizer. sensors) provides interlocks between the pump, heaters, • Cooling water temperature and flow indication
• Planetary Gearbox lubrication system filters, and the sensors for oil level, oil temperature, and oil Before operating:
• Journal lubrication system pressure to aid in proper operation of the lube system. This
ensures adequate lubrication of the pulverizer gearbox. 1. Oil tank level and temperature are OK.
Beyond this, there are several miscellaneous areas requiring However, routine operator inspections must also be performed 2. Lube system start permits OK.
grease. to assure proper operation of the lube system components. 3. When operating, check the oil flow, oil temperature, and
The pulverizer lube system may include the following: oil pressure; start the pulverizer as conditions permit.
Planetary Gearbox Lubrication System 4. Periodically check oil flow, oil temperature, and oil
• Pulverizer lube oil control cabinet
The gearbox lubrication system is a combination oil bath and pressure, at least once per shift.
• Lube oil storage tank
spray with external cooling and in-line filtering unit capable of
removing any particle larger than 40 microns. An oil pump • Immersion-type oil heater
driven by an electric motor provides the forced circulation. CAUTION: If the lube system is shut down, the pulverizer will
• Lube oil-circulating pump powered by motor, equipped automatically trip. After the pulverizer has been shut down, the
The gear case is supplied with pressurized oil from an external with relief valve and check valve at the discharge. lube system should be kept in operation to continue the filtering
lubrication system. Each bearing is equipped with an • Duplex lube oil filter with check valves and differential of oil, lubrication of bearings, and maintenance of oil flow.
individual oil supply, spray nozzles, or flood lubrication. An pressure switches.
external storage tank may or may not be provided, depending If the pulverizer is to be down for a long period of time, then the
on the design selection. • Lube oil heat exchanger lube system should be shut down. During an extended
shutdown, the lube system should be run for three hours every
The roller or Kingsbury tilting pad-type thrust bearing is month in order to protect the gears and bearings.
submerged in an oil bath in which oil is introduced through a
spray ring. The oil level is kept constant by overflow dams.
A relief valve, installed between the pump and filter, provides
protection from over pressurization and also allows for oil
recirculation during heat up of the lube oil system.
Oil is discharged from the pump, through a check valve, and
through a duplex-type oil filter arrangement. The check valve
prevents oil from draining out of the main roller thrust bearing
Figure 67: Typical Gearbox Lube Oil System (Dual Lube Pumps)
Drawing 10: Unit No. 2 Lube Oil System P&ID, D-3929-01
Component Sub-Component Lube Type Frequency Quantity
Gearbox Bearings & Gears EP ISO 320 Mineral Oil Shipped in preservative oil (drain -flush) 270 gallons
First oil change @ 600 hours
Analysis at 1000 hours, then after 5000 hours
Change at 18 months, unless analysis shows problem earlier
Drive Motor GTS ISO 46 First oil change @ 600 hours 1.1 gallons
Rust & Oxidation Inhibiting Analysis at 1000 hours, then after 5000 hours
Gearbox Lube Pump Motor NLGI#2 Dura Lith EP Regrease yearly As needed
Dynamic Classifier Gearbox 800/220 VG 220 Synthetic Oil First oil change @ 1000 hours 5.5 Gallons
Change at 6000-12000 hours, unless analysis shows a problem earlier
Dynamic Classifier Motor NGLI#2 Grease Regrease at 2000 hour intervals As needed
Dynamic Classifier Rotor bearing NGLI#2 Grease Every 3 months As Needed
Journal Roller Bearings 8EP ISO 680 Gear compound First oil change for new or rebuilt assembly after 400 hours, 8 gal (running)
EP - Sulfur phosphorous and every 6 months thereafter Level @ 70°F 11.46 – 12.96”
Level @ 180°F 12.15 – 14.15”
Journal Stop Bolt NGLI#2 Grease Initially, and after each adjustment As needed
Journal Trunnion Shafts Heat resistant NGLI#2 EP After initial, every 6 month @ two locations (Circumference & Vent) 8.8 oz.
Grease w/350°F drop point
Table C: Lube Oil Specifications and Guidelines
Journal Lubrication System

The journal lubrication system (Figure 68) is a self-contained circulating system, in
which circulation is induced by the pumping action of the bearings.
Oil is contained in the space between the lower journal housing and the journal shaft.
This space serves as the reservoir. Both the upper and lower bearings are fully
immersed in oil at all times.
As the roller journal turns during operation of the mill, the roller bearings induce a
pumping action that, in turn, causes a flow of oil through the journal assembly.
• Oil flows from the space surrounding the journal shaft and is pumped by the
lower bearing to a cavity located between the bottom of the journal shaft and the
lower mill housing.
• The journal shaft has a hollow core, which permits the oil to flow upward through
the center of the shaft to a point about halfway between the upper and lower
bearings where it exits the shaft through a hole.
• At this point, the oil flows both upward to the top bearing as well as down to the
lower bearing.
• Oil that flushes through the upper bearing returns to the center of the shaft
through the hollow center core to complete the cycle.
When shipped from the factory, the journals are completely filled with oil. The journals
should also be completely filled with oil for storage. Oil used, in both cases is the
normal operating oil.
Before a journal is placed in the mill, the oil level should be checked with a dipstick and
adjusted as necessary.
Oil level should be checked whenever the journal is accessible or at least every 3
months.
In the event of a pulverizer fire, the oil in each journal should be checked for
degradation through lab analysis.
Figure 68: Journal Lube System
5. PULVERIZER AUXILIARY SEALING SYSTEMS Seal air is typically drawn from ambient by either of two seal air The seal air entering the journal flows around the journal head
5.1 Air Supply booster fans. Normally, one fan is in use and one is a spare. and between the upper and lower air seal rings. The air then
A filter is provided in the seal air system to prevent dirt and exits around the journal dust cover.
Filtered seal air (Figure 69) is used in the pulverizer system to
prevent contamination of the journal and gearcase lubrication dust from contaminating the critical areas of the pulverizer. In flowing through this area, the air pressurizes the area and
systems and to protect the bearings in these areas during The booster fans raise the air pressure of the seal air above prevents coal dust from entering.
normal operation. the operating pressure of the mill. A small line delivers seal air up to the spring housing to
In addition, unfiltered seal air from the cold primary air ducts is From the discharge of the seal air fan, the clean seal air is prevent contamination by coal dust from inside the pulverizer.
admitted to the coal feeders and the coal piping downstream of directed to the ring header of each pulverizer. 5.3 Gearbox Seal Air System
the pulverizer discharge valves to prevent hot furnace gases A filtered seal air system provides clean air to an air seal
from flowing back down the piping into the mills during chamber surrounding the bowl hub to prevent hot air and coal
maintenance or normal shutdown periods. 5.2 Journal Seal Air System
dust from escaping to the atmosphere or contaminating the
The journal shaft and spring seal air system (Figure 70) gear case.
prevents coal dust from contaminating the journal lube oil
system or spring coil housing (see Figure 62).
The filtered seal air is supplied to the journal through the end of 5.4 Dynamic Classifier Seal Air System
the trunnion shaft and journal head. Seal air is used to pressurize the area around the bearings
(Figure 71) in order to prevent dust contamination.
NOTE: Except for mill isolation during maintenance, the seal
air system should be in operation at all times.
Typically, seal air should be supplied to the bearing housing
ring header at ~300 SCFM and at a pressure of 8" wg above
the highest expected under bowl pressure. The seal air should
originate from a clean, cool source (filtered air is preferred, but
not required). Seal air from the cold side of the primary air fan
or forced draft fan is usually acceptable.
Figure 71: Dynamic Classifier Seal Air
Figure 69: Seal Air Supply System
Figure 70: Journal Seal Air System
6. PULVERIZER AUXILIARY PYRITE REJECT SYSTEM 6.2 Reject Systems Functional Description
The function of the pyrite system is to move tramp iron and any Large chunks of foreign material can sometimes jam the chute,
other difficult to grind material from the mill to a storage hopper and, as noted above, prevent the free flow of rejects from the
for removal. mill and leading to other potential problems.
Tramp iron or other dense, difficult to grind foreign material Pyrite Hopper
normally found in the coal is carried over the top of the bowl The function of the pyrite system (Figure 74) is to transfer
where it drops out through the air stream to the mill bottom tramp iron and other difficult-to-grind material from the mill to a
(Figure 72). storage bin or slurry system for removal. This removal process
6.1 Millside Functional Description occurs when the heavier non-crushable material falls out of the
Pivoted scrapers, attached to the bowl hub (Figure 73), rotate bowl to the millside area below
with the bowl and sweep foreign material from the mill bottom The pivoted scraper assemblies attached to the bowl hub
around to the tramp iron discharge opening (tramp iron spout) sweeps the foreign material around to the reject chute. The
where it falls into the pyrite hopper. reject chute directs the material out of the millside area and
into the pyrite hopper or some other type of storage bin to be
further removed.
In HP systems, the material falls through a seal door into a
pyrite hopper where it is stored for slurry transfer.
Once outside of the mill, the pyrites are periodically removed.
Under normal operating conditions, material from the reject
chute should be strictly pyrites or rocks and miscellaneous
foreign material, with only a very small percentage of larger
coal chunks.
NOTE: If magnets on the raw coal conveyer system are not
supplied or are not in operation, various kinds of metallic
foreign material will appear with the rejects. Large objects can
cause damage to the journal bearings and the main vertical
Figure 73: Scraper Detail shaft bearings due to shock loading.
Excessive accumulations of pyrite, coal and other flammable In the HP pressurized systems, a sizing grid is located inside
Figure 72: Millside Rejection Zone material can result in a serious mill fire. the reject hopper. Small pieces pass through the grid and are
Excessive accumulations can also lead to a restricted primary stored in the bottom of the hopper until the jet pump transfers
If coal (spillage) is discharged into the pyrite hopper, it is the reject material to a waste storage area.
usually an indication of over feeding the mill, too little pressure airflow into the millside. As the pyrite scrapers turn, they can
on the rolls, too low an airflow or too low of a pulverizer outlet push excessive accumulations into the hot air duct if the reject A floodlight is installed in the interior of the hopper so that the
temperature. Excessively worn parts or improper adjustment chute is plugged, thereby restricting the airflow. This reduces operator may observe through the handhole observation port,
can also cause coal to be discharged. Excessive spillage the available airflow around the bowl that will subsequently the accumulation of oversized pyrite on the sizing grid. The
indicates that a pulverizer is not functioning properly and steps increase spillage, compounding the problem. observation port/handhole enables the operator to access the
should be taken as soon as possible to correct the situation. Check the scraper assemblies for wear. The scraper wear grid so that heavy accumulations of oversized pyrite may be
Because excessive spillage can be a first step toward a plate is cast from an abrasion resistant alloy. When the removed by hand.
pulverizer explosion, it is strongly recommended that this be scraper wear plate becomes excessively worn and rounded, WARNING: On the pressurized mills, never open the
addressed quickly. replace it. observation port/handhold when the hopper isolation valve is
Inspect the millside and air inlet for accumulations of coal Clearance between the bottom and the scraper should be set open. Doing so will expose personnel in the area to hot
and/or other rejected material. If accumulations exist, inspect at 0.375", ± 0.25”). This clearance is sufficient to prevent pulverizer air that can cause serious injury.
the reject chute for pluggage. It is important to maintain dragging and sparking and yet remove materials from the mill.
unrestricted flow of reject material through the reject chute to Check the spring tension on the scraper assemblies. Also
prevent accumulation of material in the millside. check the 45° degree swing to ensure the scraper swings open
far enough to allow large tramp metal to pass.
Check the reject chute. Large chunks of foreign material can

sometimes jam the chute preventing the free flow of rejects from
the mill, leading to other potential problems.
With the pressurized systems, once in the storage bin the pyrites
are removed at least once every shift. Removal of the foreign
material is accomplished through the suction action of a
jet-pump. The storage bin should be kept clear of heavy
accumulations.
Pluggage of HP Pressurized Pyrite Hopper System

Under normal operating conditions, material from the reject chute
should be strictly pyrites or rocks and miscellaneous foreign
material. The continuous flow of coal may be a mechanical or
airflow problem. This continuous flow can eventually lead to a
pluggage of the overflow system, which prevents the jet pump
action from working correctly.
CAUTION: This high volume of water flow can be associated

with a mill flush on shutdown.
Figure 74: Trimble Unit No. 2 Pyrite Hopper
7. FINENESS PERFORMANCE – DYNAMIC CLASSIFIER Start-up 7.3 Dynamic Classifier Maintenance

7.1 General 1. Open the discharge valves. Overview
Where static classifiers are a single point mechanical 2. Start the pulverizer motor. 1. The bearings on the bearing and drive assembly are
adjustment of a deflector regulator for control of primarily the 3. Establish airflow and warm the pulverizer for a minimum pre-packed full of grease prior to installation. For easy access,
through 200 mesh fineness (with a side-effect of lowering of 20 minutes. future lubrication of the bearings is through external fittings.
coarse particles), a dynamic classifier adjustment involves the 2. Inspect the rotor every three months.
4. Start the Dynamic Classifier. The classifier motor may
entire system. The fineness setting is the collective effort of
be started three (3) seconds after establishing airflow. 3. Periodically check the alignment of the sheaves with a
balancing feed rate, airflow and rotor speed to achieve an
5. Start the feeder when the pulverizer is up to its proper straight edge. Also check tension of the belts for the drive
output that is ultra fine, reducing both coarse and fine particle
operating temperature. motor.
output.
Shutdown 4. If rebuilding of the bearing and drive assembly is
7.2 Dynamic Classifier Set-Up And Operation
required, follow the listed procedures.
A variable speed AC motor, through an adjustable frequency 1. Reduce feeder speed to minimum and close the hot air
drive and programmable controller drives the Dynamic gate.
Classifier. The speed of the Dynamic Classifier is based on 2. Reduce the Dynamic Classifier to minimum speed. Component Maintenance Intervals (Hours)
feed rate, as feeder speed increases, the classifier speed will 3. Run the pulverizer at minimum feed until the outlet is Motor Bearing Lubrication 3,000
also increase. reduced to 130°F. Classifier Bearing Lubrication 3,000
Set-up 4. Stop the feeder and allow the pulverizer to cool to Belt Alignment and Tensioning 6,000
The speed of the classifier is controlled by relating the feed 120°F.
Belt Replacement 20,000
rate of the mill to the speed of the classifier. The classifier 5. Stop the Dynamic Classifier.
drive can be controlled by potentiometer, mA signal, or VDC Oil Seal Replacement 20,000
signal. During the commissioning process, an experimentally 6. Stop the pulverizer.
Rotor Rebuild 50,000
determined graph is to be developed which will relate the feed Alarms and Trips
Motor Cleaning/Rebuild 100,000
rate and the classifier speed for the contract fineness. This If airflow is lost during operation, an alarm will sound, and the
graph should be then automated and used to control the speed classifier motor will trip. Classifier Bearing Assembly Rebuild 100,000
of the classifier in an automatic mode. If it is necessary to Table D: Recommended Dynamic Classifier Maintenance Intervals
If either bearing temperature is greater than 200°F for more
operate a mill, which has not had its calibration graph
than two seconds, an alarm will sound, and the classifier motor
experimentally, determined, set the classifier speed to a
will run back to its minimum speed. 7.4 Mill Set-Up
constant 50 RPM for all rates.
If either bearing temperature is greater than 225°F for more Purpose
If the classifier trips while the feeder is operating, it is not
than two seconds, an alarm will sound, and the classifier motor
necessary to trip the feeder. The mill may continue to run but To develop the operating curves for the dynamic classifier and
will trip.
will provide poor fineness control. to verify that the pulverizer will achieve the guaranteed
NOTE: This logic is in addition to that which is used with a fineness.
The Pulse Width Modulation (PWM) drive is programmed so
static classifier.
that the acceleration and deceleration rates will result in the Mill Set-Up
drive changing the frequency at the rate of 60 Hz/180 seconds. NOTE: The variable speed classifier drive (PWM) can be
Prior to testing the mill, the internals must be inspected to
Additionally, the programming will allow the drive to catch and controlled either by a potentiometer (manual mode) or by a 4-
verify settings and adjustments. This inspection should include
stop a reversed spinning load. 20 mA reference signal (automatic mode) which relates
the separator body liner assemblies, the air inlet vanes, the
classifier speed as a function of mill fineness to feeder speed.
The PWM drive is to be programmed so that if there is a loss of grinding rolls, and the bullring. The ring-to-roll clearance and
load (no load motor current) the drive will trip. journal spring compression should also be checked.
The PWM drive is to be programmed so that the drive will trip if All of the instrumentation, which will be used in the process of
the power (motor current) exceeds the motor nameplate rating. testing, must be calibrated and all sensing lines should be
NOTE: Refer to the drive controller vendor manual for purged and checked for leaks.
additional set-up details.
Mill Test Conditions Development Of System Calibration Curve The procedure is as follows:
All mill testing is to be done with the mill in a steady state A calibration curve is typically constructed to regulate the 1. Using the relationship between the % on 50 mesh and
condition (equilibrium), and with one coal. A mill is considered classifier RPM as a function of coal flow to maintain a desired the unburned carbon (carbon loss), select a % on 50 mesh
to be in a steady state condition if the bowl differential product fineness. If there is plant data available that correlates value that will satisfy the desired unburned carbon value. If
pressure, mill power, and mill outlet temperature are all in furnace exit unburned carbon to pulverizer discharge fineness there are no particles on 50, use the on 70 data
equilibrium: levels, this should be used to select the fineness that the 2. Using all of the fineness data taken, construct a graph of
1. The bowl differential pressure is in equilibrium if two 30 classifiers should maintain. % on 50 mesh vs. % through 200 mesh. From this graph,
second averages taken 30 minutes apart differ by less than select the % through 200 mesh that corresponds to the desired
1%. % on 50 mesh from step 1.
2. The pulverizer power is in equilibrium if two 30 second 3. For each of the four feed rates tested, construct a graph
averages (watt meter or motor current) taken 30 minutes apart of fineness (% through 200 mesh) vs. classifier rotor speed
differ by less than 1%. 4. Using the % through 200 mesh numbers from step 2
3. The mill outlet temperature is in equilibrium if two and the graphs from step 3, construct a graph of classifier
instantaneous temperature measurements taken 30 minutes speed vs. feed rate.
apart differ by less than 3 degrees. 5. Generate the final system calibration graph by taking
Boiler Test Conditions the graph from step 4 and imposing on the curve the
All pulverizer testing is to be done with the boiler operating at a requirement that there shall be at least a 10 RPM margin
steady MCR condition with all mills in service. between the final system calibration graph and the maximum
speed obtained during the testing. This margin is used to
account for variability in factors such as moisture, airflow, and
Pulverizer Test Procedure measurement accuracy.
A pulverizer is considered to be at its limit if one of the NOTE: If the HGI of the coal varies more than + 5 points, then
following conditions exists: it will be necessary to repeat this test with each of the different
1. The coal spillage is in excess of the plant standard rate coals and develop a system calibration curve for each coal.
or 50 lb/hr. Fineness is heavily dependent on not only classifier speed but
2. The pulverizer outlet temperature cannot be maintained. also airflow. If the relationship between airflow and feed rate is
3. The pulverizer motor is at its power limit. changed, it will be necessary to repeat this procedure so that a
new system calibration curve can be generated.
4. The pulverizer experiences unusual vibration.
The following procedure is to be followed at each of the four
test conditions, minimum, guarantee, moderate and low flow: Example:
1. Set the classifier at 50 RPM. Once the pulverizer has Plant data suggests that acceptable unburned carbon level
reached equilibrium, record the test data. occurs with maximum of .5 % +50 mesh retention.
2. Set the classifier at 60 RPM. Once the pulverizer has NOTE: All Data in Graphs below are for illustration only. The
reached equilibrium, record the test data. values shown are not based on data collected during an actual
system calibration.
3. Set the classifier at 70 RPM. Once the pulverizer has
reached equilibrium, record the test data. Step 1 – Plot 50 mesh (or 70) retention versus 200 mesh
fineness for all tests.
4. Set the classifier at 80 RPM. Once the pulverizer has
reached equilibrium, record the test data. Step 2 – Select 200 mesh value which corresponds to .5% +
50 mesh. This equals approximately 71% through 200 mesh.
5. Continue this procedure (making 10 RPM speed
increments) until the pulverizer reaches its limit or until the
classifier has reached its maximum speed.
Figure 75: Screen Set for Testing Dynamic Classifier
NOTE: If one of the limits is reached before the maximum
classifier speed is reached, make the last steps in 5 RPM
increments.
DYNAMIC CLASSIFIER
CUSTOMER: TEST NO.
PLANT: ENGINEER
MILL NO. DATE
TIME
FEEDER SPEED (%) EXHAUSTER INLET PRESSURE (IN WG)

COAL FLOW (LB/HR) EXHAUSTER OUTLET PRESSURE (IN WG)
EXHAUSTER dP (IN WG)
MILL MOTOR CURRENT (AMPS)
MILL MOTOR POWER (KW) UNDER BOWL PRES (IN WG)
ABOVE BOWL PRESS (IN WG)
HOT AIR DAMPER POSITION (% OPEN) CONVERTER HEAD PRESS (IN WG)
COLD AIR DAMPER POSITION (% OPEN)
INDICATED AIR FLOW (LB/MIN) BOWL dP (IN WG)
AIR FLOW CONTROLLER dP (IN WG) CLASSIFIER dP (IN WG)
AIR FLOW CONTROLLER TEMP (DEG F) MILL dP (IN WG)
AIR HEATER OUTLET TEMP. (DEG F) AIR SEAL PRESS (IN WG)
AIR HEATER OUTLET PRESSURE (IN WG) AIR SEAL dP (IN WG)
FD FAN DISCHARGE PRESSURE (IN WG)
FD FAN DISCHARGE TEMP. (DEG F) MILL INLET TEMP (DEG. F)
WB/FURNACE dP (IN WG) MILL OUTLET TEMP (DEG F)
FURNACE PRESSURE (IN WG)
VARIABLE SPEED DRIVE
NO. MILLS IN SERVICE OUTPUT FREQUENCY (HZ)
UNIT LOAD (MW) MOTOR SPEED (RPM)
MOTOR CURRENT (AMPS)
BOWL dP (IN WG) RATED TORQUE (%)
RATED POWER (%)
MILL OUTLET TEMPERATURE (DEG F)
Figure 76: Value Which Corresponds To .5% + 50 Mesh COAL FLOW COUNTER NO. (END)
TOTAL SPILLAGE (LB)
SPILLAGE TIME (MIN)
Figure 78: Plot Classifier RPM Versus Feed Rate COAL FLOW COUNTER (START) SPILLAGE RATE (LB/HR)
(This equals approximately 71% through 200 mesh) ELAPSED TIME (MIN)
COAL FLOW (LB/HR)
COAL PERCENTAGE (%)
COAL SPILLAGE (LB/HR)
Step 3 – Plot 200 mesh fineness versus classifier RPM for UPPER BRG TEMP (DEG F) PULVERIZED COAL SAMPLE
each of the coal flows. 7.5 Coal Fineness LOWER BRG TEMP (DEG F)
CLASSIFIER SPEED (RPM)
% +50 MESH (300 MICRON)
% - 70 MESH (212 MICRON)
A wide range of coal fineness levels can be obtained with the SPRING RATE (LB/IN)
SPRING PRELOAD (LB)
air separation concept of classification utilized in ALSTOM MOISTURE (%)
pulverizers. Firing coal with a higher percentage of fines can RAW COAL SAMPLE
HGI
reduce carbon loss and allow units to meet reduced NOx COMMENTS:
MOISTURE (%)
emission standards.
The pulverizers furnished on this contract are equipped with
Dynamic Classifiers, which use a combination of aerodynamic, Table E: Data Sheet for Milling System
and centrifugal forces to separate the fine coal particles from
the larger coal particles circulating within the pulverizer.
Dynamic Classifiers allow remote, on-line coal fineness In either case, adjustments should be made and fineness
adjustment, which is both, accurate and trouble free. should be set at the lowest level, which will result in acceptable
The size distribution of any particulate sample is measured as furnace performance, at design excess air levels.
the percentage of the material passing through a series of test Adjustment Of Fineness
sieves. ALSTOM recommends the use of 50, 70, 100, 200, A Dynamic Classifier establishes pulverized coal fineness by
Figure 77: 200 Mesh Fineness vs. Classifier RPM and 325 mesh (300, 212, 150, 75 and 45 µm) sieves when balancing the aerodynamic forces moving the coal particles
pulverizers are equipped with Dynamic Classifiers. against centrifugal forces imparted by the classifier rotor.
(For each of the coal flows)
From experience (based on coal type and furnace design), it Pulverized coal particles are picked up from the bowl by the
Step 4 – Determine required RPM to maintain 71% through has been determined that the recommended level of fineness stream of air passing through the pulverizer. The finer coal
200 mesh fineness for each coal flow. will provide acceptable furnace operation with regard to the particles are carried through the classifier rotor by the air
percent of unburned carbon, emissions, efficiency, and stream and enter the coal pipes. The classifier rotor imparts a
slagging. It is possible, however, that a higher level of fineness centrifugal force to the heavier coal particles causing them to
Step 5 – Plot Classifier RPM versus feed rate. Maintain
may be required to achieve the furnace performance goals. move away from the rotor and return to the bowl for additional
minimum of 10 RPM margin i.e. @ 105,000 lbs./hr max. RPM
was 90 RPM, @ 110,000 lbs./hr max. RPM was approximately Conversely, it is also possible that lower than specified grinding.
85 RPM thus max. RPM above 110,000 lbs./hr is 75 RPM. fineness will result in acceptable furnace operation. Coal fineness is affected by classifier rotor speed. As the
classifier rotor rotates faster, smaller and smaller coal particles
are rejected. This means the coal going to the furnace is also
much finer (smaller). If the coal fineness is too high then the
speed of the classifier rotor may be reduced.
The speed of the Dynamic Classifier drive motor is established • Pulverizer power is in equilibrium if two 30-second
and controlled by an Adjustable Frequency Drive (AFD) that power averages (watt meter or motor current) taken 30
switches a constant voltage supply on and off to make it Pulse minutes apart differ by less than 1%.
Width Modulated (PWM). • Since pulverizer outlet temperatures do not vary rapidly,
Initially, in AUTO control mode, the Dynamic Classifier rotor is a pulverizer is considered to be in temperature or
programmed to rotate at 50 to 70 rpm as a function of coal thermal equilibrium if two instantaneous measurements
feeder loading (4 to 20 mA input signal). When the unit is taken 30 minutes apart differ by less than 3°.
capable of being operated "at load," a testing program must be
• Due to the dynamics of pulverized coal systems, true
performed to determine the relationship between coal fineness,
constant values will never be obtained.
rotor speed, and coal feed rate. The control system must be
reprogrammed to provide the correct classifier rotor speed • If there is a pulverizer or unit upset during the testing Table F: Dynamic Classifier Fineness Results
(fineness) as a function of feed rate required to obtain the period, the coal sample should be discarded and new
desired furnace operating conditions (optimum O2, lowest samples should be obtained later. The total weight of the samples found on each sieve plus the
NOx, etc.). total weight of the samples in the pan (coal through the 325
mesh sieve) should total 49.50 to 50.50 grams. If the total
In MANUAL control mode the rotor speed is determined by the NOTE: Other pulverizers in the system may be left on weight is not within this range, the test should be rerun.
input signal generated by a potentiometer positioned by an automatic control to accommodate small swings in unit load.
operator. Since pulverizer performance is different at varying loads, coal
Results Reporting
fineness tests should always be run at the same pulverizer
Pulverized Coal Fineness Testing loading, that is, coal fineness samples taken at a 60% Upon completion of the sieving, pulverizer performance and
pulverizer loading should not be compared with samples taken coal fineness should be recorded for future reference. A
Coal sampling procedures should use good sampling suggested form is shown in Table E, all data should be
technique and consistent sampling locations. at 85% pulverizer loading.
recorded. Information such as initial weight of sample, Rotap
Location Pulverizers with obvious indications of trouble (heavy coal times weight of material discarded from the collection pan after
spillage, rumbling, etc.) should not be tested until problems are each Rotap times weight of coal remaining on each sieve,
The location where a pulverized coal sample is taken has a corrected.
definite effect on the coal fineness result. All samples should percentages of coal remaining on the sieves and percentages
be taken at the recommended location, just above the Sieving the Coal Sample of coal passing through the sieves should also be recorded. To
discharge valve in the valve adapter. Aspirated fittings, which NOTE: If a moisture test will be performed, then place one half check the validity of the test, the fineness results should be
will allow for proper sampling without expelling excessive coal of the gross sample from a pulverizer in an airtight container plotted on a Roslin-Rammler sieves chart. If the fineness
dust into the atmosphere, have been provided for the two after the rolling/mixing procedure has been completed. results do not plot on or close to a straight line, then the
locations. NOTE: Some coals that are high in moisture content will ball equipment or sampling procedures should be checked.
Pulverizer Loading up on the fine sieves. This is an indication that the coal is too
In order to obtain fineness test results that can be compared wet and it MUST be dried before sieving. Drying can be Troubleshooting
between pulverizers and are repeatable, it is necessary that accomplished by placing the coal in an appropriate drying oven Graph does not plot correctly
pulverizer and furnace conditions be maintained at set levels as outlined in the ASTM and ASME procedures.
1. Check for worn sieves or holes in sieves.
while the coal samples are being obtained. Unit load should Prepare a stack of five US (50, 70, 100, 200 and 325 mesh) or
be high enough that the pulverizer being sampled can be metric (300, 200, 150, 70 and 50 µm) sieves with the 50 mesh 2. Check for sieve blinding (material wedge in openings).
placed on manual control at or near its full load rating during on top, and the 325 mesh on the bottom. The sieves should 3. Sieves or brush contaminated with oil, water, etc.
the testing period. The pulverizer should be allowed to operate be thoroughly cleaned prior to use by brushing and tapping, or Clean thoroughly.
at that level until it reaches equilibrium. by blowing low pressure air through them. Place a catch pan 4. Balls forming on sieves. Coal is damp dry the sample.
NOTE: A pulverizer is in equilibrium when the bowl ∆P, on the bottom of the stack. Provide a tight fitting cover for the
top. 5. Scale not properly zeroed.
pulverizer motor power consumption, and pulverizer outlet
The weight of coal from each sieve is then added to the weight 6. Scale readings affected by air currents.
temperature are in equilibrium.
• Bowl ∆P is in equilibrium if two 30-second averages of coal from the previous sieve(s). These weights are then
taken 30 minutes apart differ by less than 1%. used to calculate the coal fineness as follows:
8. PULVERIZER PERFORMANCE TROUBLESHOOTING 8.4 Pulverizer Motor Current Low
8.1 Pulverizer Outlet Temperature High Possible Cause Corrective Action

No or reduced coal entering Check feeder operation
pulverizer Plugged feeder or feed pipe
Possible Cause Corrective Action
One or more journals seized Inspect journals
Pulverizer fire See Fire Fighting Procedures Broken motor shaft coupling Inspect
Hot air damper malfunction Close hot air gate, shut down mill, correct or repair Fineness too low Increase classifier position
as required Coal property change Check coal hardness and moisture
Cold air damper malfunction Open cold air damper manually, shut down mill, Current monitor failure Test / calibrate current transducer
correct or repair as required Low coal fineness Increase classifier speed / setting
Outlet thermocouple Verify readings - repair or replace as required Coal property change Check coal hardness and moisture
malfunction Air flow controller malfunction Shut down mill, correct or repair as required
Feeder malfunction / feed pipe Shut down mill, clear feed pipe and repair feeder Check temperature probe, dP sensor and
pluggage as required controller, correct or repair as required
8.2 Pulverizer Outlet Temperature Low 8.5 Bowl Differential Pressure High
Possible Cause Corrective Action Possible Cause Corrective Action

Hot air gate not open Check gate Overloaded pulverizer Reduce feed rate
Hot air damper malfunction Close hot air gate, shut down mill, correct or repair Check feeder calibration / failure
as required Check coal hardness
Cold air damper malfunction Open cold air damper manually, shut down mill, Excessive fineness Decrease classifier position
correct or repair as required Plugged pressure taps Clean as required
Outlet thermocouple Verify readings - repair or replace as required Transducer failure Recalibrate or replace
malfunction Air flow controller malfunction Shut down mill, correct or repair as required
Extremely wet coal Reduce feed rate Check temperature probe, dP sensor and
Increase air flow controller, correct or repair as required
Increase available hot primary air temperature Insufficient open area around Check wing tip sizing
Mill overload If hot air damper 100% open, lower feed rate bowl
8.6 Bowl Differential Pressure Low

8.3 Pulverizer Motor Current High

Reduced coal load in pulverizer Check feeder calibration / failure
Overloaded pulverizer or wet Reduce feed rate to pulverizer, check feeder Check coal hardness
coal calibration Low fineness Increase classifier position
Coal hardness or moisture change Plugged pressure taps Clean as required
Excessive coal fineness Reduce classifier setting Transducer failure Recalibrate or replace
Motor malfunction Test motor Air flow controller malfunction Shut down mill, correct or repair as required
Gear box failure Check gear box for gear or bearing failure Check temperature probe, dP sensor and
Current monitor failure Test / calibrate current transducer controller, correct or repair as required
Air flow controller malfunction Shut down mill, correct or repair as required Excessive open area around Check wing tip sizing
Check temperature probe, dP sensor and bowl
controller, correct or repair as required
8.7 No Coal Flow to Coal Nozzle(s) 8.9 Noise Above or Below Bowl
Possible Cause Corrective Action Possible Cause Corrective Action

Coal pipe blocked Clean pipe Tramp material on bowl Remove tramp material from bowl
Check air flow distribution and velocity Check feed system for proper tramp material
Blocked feeder or feed pipe Recalibrate feeder removal
Inspect feeder and feed pipe for blockage Identify source and remedy
No coal flow from silo Check coal supply to feeder Failed grinding roll Inspect rolls
Air flow controller malfunction Shut down mill, correct or repair as required Uneven grinding load Check spring rate
Check temperature probe, dP sensor and Check spring preload
controller, correct or repair as required Excessive gaps Check ring to roll gap
Blocked orifice or riffle Inspect orifices and riffles Check spring assembly to journal head gap
Discharge valve closed Check for closed valve or logic malfunction Dislodged bull ring segment Inspect bull ring assembly
Worn spring assembly Inspect all components for wear
Broken scraper assembly Repair or replace as required
8.8 Incorrect Coal Fineness Broken air inlet vanes Repair or replace as required
Possible Cause Corrective Action 8.10 Excessive Coal Spillage from Tramp Iron Spout
Air flow controller malfunction Shut down mill, correct or repair as required
Check temperature probe, dP sensor and
controller, correct or repair as required Possible Cause Corrective Action
Classifier position incorrect Check classifier position Excessive raw coal feed Check feeder and control system for malfunction
Incorrect sampling Check sampling equipment, location & procedure Excessive fineness Check fineness, open classifier blades
Classifier components worn Inspect components for wear Coal property change Check coal properties
Check gaps and clearances Worn rolls, bull ring or Inspect components for excessive wear
Mill set-up incorrect Check ring to roll gap extension ring
Check journal head to spring assembly gap Inadequate grinding force Check spring assembly for worn components
Coal property change Check coal properties Check spring preload
Spring malfunction Check preload Check spring rate
Check spring rate Journals / rolls not rotating Check journal bearings
Check journal oil for contamination
Journals / mill not warmed up adequately
Check journal oil properties
Increase raw coal feed size
Air flow controller malfunction Shut down mill, correct or repair as required
controller, correct or repair as required
Excessive open area around Check wing tip sizing
bowl
8.11 Rough Running Pulverizer / High Vibration

Journals / rolls not rotating Check journal bearings
Check journal oil for contamination
Journals / mill not warmed up adequately
Check journal oil properties
Increase raw coal feed size
Inadequate coal bed depth Increase coal flow
Check feeder for failure / calibration
Check for plugged feed system
Excessive grinding force Reduce spring preload
Incorrect clearances Check ring to roll gap
Check journal head to spring assembly gap
Insufficient raw coal size Increase raw coal size
Excessive Fineness Reduce fineness by reducing classifier position
Air flow controller malfunction
controller
Excessive coal flow
Check feeder for failure / calibration
Insufficient mill warm up time Verify warm up cycle is correct
Coal property change Check coal properties
Tramp material on bowl Remove tramp material from bowl and millside
Check feed system for proper tramp material
removal
Identify source and remedy
3.3 Millside Area .........................................................................................................................................................34
1. HP PULVERIZER PERFORMANCE & OPERATION...................................................................................................1 3.4 Scraper Assembly ................................................................................................................................................34
1.1 Raw Coal Quality ....................................................................................................................................................1 3.5 Bowl Assembly .....................................................................................................................................................39
1.2 Pulverization ...........................................................................................................................................................1 3.6 Vane Wheel Assembly .........................................................................................................................................39
1.3 Factors Affecting Pulverizer Capacity.....................................................................................................................1 3.7 Separator Body.....................................................................................................................................................43
1.4 Pulverizer Output Summary....................................................................................................................................4 3.8 Journal Assemblies ..............................................................................................................................................43
1.5. Base Design Capacity ...........................................................................................................................................5 3.9 Journal Pressure Springs .....................................................................................................................................44
1.6 Operational Phases and Terms..............................................................................................................................5 3.10 Slide Gate Discharge Valves..............................................................................................................................49
1.7 HP Pulverizer..........................................................................................................................................................7 3.11 Classifier Assembly ............................................................................................................................................49
1.8 Operational Overview .............................................................................................................................................8 4. PULVERIZER AUXILIARY LUBE OIL SYSTEMS ......................................................................................................54
1.9 Improper Pulverizer Operation ...............................................................................................................................8 4.1 Function of Lubrication System ............................................................................................................................54
1.10 Pulverizer Operation & Controls ...........................................................................................................................9 4.2 Major Systems ......................................................................................................................................................54
1.11 Sequence for Pulverizer Start...............................................................................................................................9 5. PULVERIZER AUXILIARY SEALING SYSTEMS.......................................................................................................59
1.12 Sequence of Normal Shut Down ..........................................................................................................................9 5.1 Air Supply .............................................................................................................................................................59
1.13 Sequence for Emergency Shut Down ..................................................................................................................9 5.2 Journal Seal Air System .......................................................................................................................................59
1.14 Milling System Primary Air Flow Control ............................................................................................................10 5.3 Gearbox Seal Air System .....................................................................................................................................59
1.15 Fire Fighting & Mill Clearing................................................................................................................................10 5.4 Dynamic Classifier Seal Air System .....................................................................................................................59
2. RP-963 vs. HP-1063 ARRANGEMENT DIFFERENCES ...........................................................................................13 6. PULVERIZER AUXILIARY PYRITE REJECT SYSTEM ............................................................................................60
2.1 Applying Alstom Equipment to a Doosan-Babcock Boiler....................................................................................13 6.1 Millside Functional Description .............................................................................................................................60
2.2 Comparisons Between RP and HP Series Pulverizers ........................................................................................13 6.2 Reject Systems Functional Description................................................................................................................60
2.3 Technical Data Comparison .................................................................................................................................13 7. FINENESS PERFORMANCE – DYNAMIC CLASSIFIER ..........................................................................................62
2.4 RP HOT AIR INLET ..............................................................................................................................................14 7.1 General .................................................................................................................................................................62
2.5 HP HOT AIR INLET ..............................................................................................................................................15 7.2 Dynamic Classifier Set-Up And Operation ...........................................................................................................62
2.6 RP BOWL PERIMETER FLOW............................................................................................................................16 7.3 Dynamic Classifier Maintenance ..........................................................................................................................62
2.7 HP BOWL PERIMETER FLOW............................................................................................................................17 7.4 Mill Set-Up ............................................................................................................................................................62
2.8 RP BOWL DRIVE .................................................................................................................................................18 7.5 Coal Fineness.......................................................................................................................................................64
2.9 HP BOWL DRIVE .................................................................................................................................................19 8. PULVERIZER PERFORMANCE TROUBLESHOOTING...........................................................................................66
2.10 RP LOWER GRINDING ZONE...........................................................................................................................20 8.1 Pulverizer Outlet Temperature High.....................................................................................................................66
2.11 HP LOWER GRINDING ZONE...........................................................................................................................21 8.2 Pulverizer Outlet Temperature Low......................................................................................................................66
2.12 RP UPPER GRINDING SURFACE ....................................................................................................................22 8.3 Pulverizer Motor Current High ..............................................................................................................................66
2.13 HP UPPER GRINDING SURFACE ....................................................................................................................23 8.4 Pulverizer Motor Current Low...............................................................................................................................66
2.14 RP INITIAL GRINDING COMPRESSION ..........................................................................................................24 8.5 Bowl Differential Pressure High............................................................................................................................66
2.15 HP INITIAL GRINDING COMPRESSION ..........................................................................................................25 8.6 Bowl Differential Pressure Low.............................................................................................................................66
2.16 RP INTERNAL WEAR ........................................................................................................................................26 8.7 No Coal Flow to Coal Nozzle(s) ...........................................................................................................................67
2.17 HP INTERNAL WEAR ........................................................................................................................................27 8.8 Incorrect Coal Fineness........................................................................................................................................67
2.18 RP PULVERIZER COAL CLASSIFICATION......................................................................................................28 8.9 Noise Above or Below Bowl .................................................................................................................................67
2.19 HP PULVERIZER COAL CLASSIFICATION......................................................................................................29 8.10 Excessive Coal Spillage from Tramp Iron Spout................................................................................................67
2.20 RP DISCHARGE VALVES .................................................................................................................................30 8.11 Rough Running Pulverizer / High Vibration........................................................................................................68
2.21 HP DISCHARGE VALVES .................................................................................................................................31
2.22 RP REJECTION OF TRAMP IRON....................................................................................................................32
2.23 HP REJECTION OF TRAMP IRON....................................................................................................................33
3. MAJOR COMPONENTS & THEIR PM’S....................................................................................................................34
3.1 Pulverizer Motor And Drive Couplings..................................................................................................................34
3.2 Planetary Gearbox................................................................................................................................................34

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What are the major components of the pulverizer system?

What are the major components of the pulverizer system?

What are the functions of the lubrication and sealing systems?

What are the functions of the lubrication and sealing systems?

6 x HP 1063 Mills

Doosan Babcock Energy Ltd

LG&E Energy Service Company

Document Title: Operator Training Manual

ALSTOM Power Inc.

List of Figures Figure 40: HP Internal Wear............................................................ 27 List of Tables

Figure 6: Particle Size Distribution from a Static Classifier

Figure 7: Particle Size Distribution from a Dynamic Classifier

• Verify that the total airflow capability of the mill system is

Mill Size Capacity lb/hr

Roll Plowing Spillage

NOTE: The features added to Trimble No.2’s HP pulverizers

Figure 20: HP Pulverizer

Designation of the 1063 HP pulverizer

Figure 19: RP Pulverizer

Figure 21: Air to Coal Flow Character

As the system resistance changes due to variations in furnace

Figure 24: HP Pulverizer Sectional View

Drawing 1: HP-1063 Pulverizer Sectional, E-PLVE-0852

2. RP-963 vs. HP-1063 ARRANGEMENT DIFFERENCES

2.2 Comparisons Between RP and HP Series Pulverizers

2.4 RP HOT AIR INLET

Figure 27: RP Hot Air Inlet

2.5 HP HOT AIR INLET

Figure 28: HP Hot Air Inlet

2.6 RP BOWL PERIMETER FLOW

Figure 29: RP Bowl Perimeter Flow

2.7 HP BOWL PERIMETER FLOW

Figure 30: HP Bowl Perimeter Flow

2.8 RP BOWL DRIVE

Figure 31: RP Bowl Drive

2.9 HP BOWL DRIVE

Figure 32: HP Bowl Drive

2.10 RP LOWER GRINDING ZONE

Figure 33: RP Lower Grinding Zone

2.11 HP LOWER GRINDING ZONE

Figure 34: HP Lower Grinding Zone

2.12 RP UPPER GRINDING SURFACE

Figure 35: RP Upper Grinding Surface

2.13 HP UPPER GRINDING SURFACE

Figure 36: HP Upper Grinding Surface

2.14 RP INITIAL GRINDING COMPRESSION

Figure 37: RP Initial Grinding Compression

2.15 HP INITIAL GRINDING COMPRESSION

Figure 38: HP Initial Grinding Compression

2.16 RP INTERNAL WEAR

Figure 39: RP Internal Wear

2.17 HP INTERNAL WEAR

Figure 40: HP Internal Wear

2.18 RP PULVERIZER COAL CLASSIFICATION

Figure 41: RP Pulverizer Coal Classification

2.19 HP PULVERIZER COAL CLASSIFICATION

Figure 42: HP Pulverizer Coal Classification

2.20 RP DISCHARGE VALVES

Figure 43: RP Discharge Valves

2.21 HP DISCHARGE VALVES