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Operation & Maintenance Manual

Customer Model No. Machine No. NE Job No. Astaldi Sucursal Chile ETM-50 x 2 units 990153 & 990154 J12-7029

Please hand over the manual to the performer of erection job. Read the manual well before the election job, and assemble the tower mill correctly after exactly understanding. Be careful, it will possible to make dangerous accident, if you take mistake.

REV 0

DATE 22/Dec/2012

APPR HI

PROC AK

REMARK

CONTENTS

1. 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 2. 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7.

Operation Construction of Tower Mill Preparation of Operation Start and Run Stop Re-start Additional Ball Charge Maintenance Daily Inspection Periodic Inspection Ball Discharge Handling of the screw Lubrication List Bearing Box and Bushing Box Spare Parts List

Page 3 5 5 6 7 7

8 9 14 15 18 19 21

APPENDIX A Layout Drawing B C D E F Static & Dynamic Load, Weight Specification Drawing LEVEL SENSOR Operating Instruction MOTOR Operating Instruction GEAR REDUCER Operating Instruction COUPLING Operating Instruction

1. Operation
1.1.
Construction of Tower Mill Tower Mill consists of a mill shell, upper housing, screw, coarse classifier, gear reducer and motor. Tower Mill is a vertical media agitating mill. A double helical screw is hung in the

cylindrical shell and rotates by driving device installed at the top of the mill. Shell grid liners are equipped inside wall of mill shell for preventing from abrasion and for noise reduction. The screw liners are fastened with bolts and nuts so that only worn out liners can be easily replaced.

The material and water are fed into mill shell from the inlet chute at the upper part. And the ground material is at first classified by the up-flow in the mill shell. particles are returned to the mill shell by the recirculation pump. size reduction so as not to overgrind. Balls filled in the mill shell are carried upwards and struck simultaneously by the rotating screw. Tower mill grinds material by percussive motion of balls in contact with each other by stirring effect of screw. After classified, coarse And Tower Mill provides effective

1.2. Preparation of Operation 1.2.1. Refill specific oil in the lubrication unit for gear reducer and the bearing box in the upper
housing. Note! The bushing is a oil-less metal, it does not require oil. Refill grease in the gear couplings and motor.

1.2.2. Check for oil leakage, bolt looseness, and other irregularities. 1.2.3. Open the suction valve of the recirculation pump. 1.2.4. Feed water in the mill shell and coarse classifier until water overflows from coarse classifier. 1.2.5. Check the mill shell door, ball discharge cover and piping system, etc., for leakage.
Note! Operator must check the condition at mill site. Operator must start Tower Mill with the main switch at mill site first, not in the control room.

1.3. 1.3.1.

Start and Run At the start-up, technically qualified personnel must be at the mill site for the check of all equipment and make sure of all valve position correct.

1.3.2. 1.3.3. 1.3.4. 1.3.5.

Open the discharge valve of the recirculation pump and start the recirculation pump. Check the water-flow between the mill shell and coarse classifier at mill site. Start up the main drive motor. Check the direction of rotation. Record the motor ampere and the status of all gauges, etc. Then, charge the mill shell with balls through ball charge nozzle. Record the current ampere at the each 1 ton charge. Note! Please keep empty ball drums for future use as discharging ball receptacle. WARNING!!! DONT CHARGE BALLS WITHOUT RUNNING THE SCREW.

In completion of charging with a required amount of balls, record the load current. material and water.

Start feeding the

1.3.6.

Check the product particle size (analyzed by wet sieving) and concentrate (weight %) with sampling the cyclone over flow slurry.

1.3.7.

When operation becomes steady at a specific density and particle size, record the load current of the motor as a reference current.

1.4. 1.4.1.

Stop Short time stop

1.4.2.

Stop the feeding the material and water. Keep running the Tower Mill, the recirculation pump for about 60 minutes so as to grind the material in the mill under 100 micron meter. Stop the motor. Run the Tower Mill for 5-10 minutes every 4 hours.

Long time stop

1.4.3.

Stop feeding the material. Feed make up water to the mill shell and dilution water to the mill shell bottom for weakening the slurry and replacing slurry with water. After the density in the circuit comes less than 10%, stop the motor. Close the discharge valve of recirculation pump and stop the recirculation pump. Flush inside of the piping systems and the recirculation pump with water. For the safety reason, run Tower Mill for several minutes once a day.

Emergency stop In case of emergency stop of the motor caused by electric trouble, etc.

Turn off the power supply, before check and investigation to avoid accident. Stop feeding the material. Open the drain valve of the mill lower port, and drain the slurry and flush all the piping and Tower MIll. Disassemble the recirculation pump piping, and discharge the slurry and ball from pipe line and flush with water. In case the long recovery is estimated for the investigation of the problem cause, discharge balls from the mill shell.

1.5. 1.5.1. 1.5.2. 1.5.3. 1.5.4. 1.5.5.

Re-start Make sure that slurry or water is filled in the mill shell. Start up the recirculation pump. Check the circulation of slurry or water between the mill shell and the recirculation pump. Start up the main motor. Start feeding of material and water.

1.6. 1.6.1.

Additional Ball Charge Check the load current of the tower mill main motor. If the load current is lower than the reference current, add balls till the load current rises to the reference current.

1.6.2.

Additional ball charge shall be carried out to make up for worn out balls at regular intervals, and record the weight of additionally charged balls.

1.6.3.

After long time operation, the screw liners are also worn out and the load current is fallen accordingly in this case. charge amount. The fall of the load current is made up for the increase of ball

2. Maintenance
2.1. 2.1.1. 2.1.2. 2.1.3. 2.1.4.
Daily Inspection Check the load current of tower mill main motor. Check the mounting bolts and fastening bolts of each components for looseness. Check the condition of each component (bearings, gears, casing etc.) for abnormal noise. Check the temperature of each component and lubrication oil. Make sure of checking the following part certainly.

Bearing box in upper housing. Casing of gear reducer, lubrication oil and cooling water. Casing of main motor.

Note ! Bushing is an oil-less metal. Temperature of this bushing may be high momentarily at the initial stage of operation, however, this is not a problem in operation.

2.1.5.

Check the lubrication oil level of bearing box and gear reducer, when the Tower Mill is stopped.

2.1.6.

Check bearing box and gear reducer for lubrication oil leakage. Conceivable causes are :

Oil level is too high. Seals or packing are broken. Fastening bolts are loosened.

WARNING !!! DONT ENTER THE UPPER HOUSING IN OPERATION.

2.2. 2.2.1.

Periodic Inspection Wear of Screw Flight Liners and Screw Tip Liners Discharge slurry and the balls out of the mill shell. WARNING !!! TURN OFF THE CIRCUIT BREAKER OF MAIN MOTOR BEFORE OPENING THE MILL SHELL DOOR. Open the mill shell door and clean the inside of the mill shell. Check the circumference of the screw flight liners. (A) of the liner becomes less than approx. 40 mm. Check the circumference of the screw tip liners. Tip liner is serviceable till the dimension Liner is serviceable till the dimension

(B) of the liner becomes less than approx. 40 mm. Check the liner fastening bolts and nuts for looseness.

2.2.2.

Wear of Shell Grid Liners Discharge slurry and balls out of the mill shell. Clean the inside of mill and take out the screw if necessary. WARNING!!! TURN OFF THE CIRCUIT BRAKER OF MAIN MOTOR BEFORE OPENING THE MILL SHELL DOOR. Inspect wear of Shell Grid Liner visually. In case ribs are worn out to the dimension C=less than 20 mm, weld plates to the worn sections. Slight worn sections shall be repaired by welding.

In case the wear is too severe to repair and/or the wall plate was holed by wear, replace the whole Shell Grid Liners to new ones.

approx. max 80 kg/pc Removal / replacement of Shell Grid Liner Shell Grid Liners are comprised of 8 segments: Mill Shell Body : 6 segments Door : 2 segments Shell Grid Liners are lined up on the inner surface of Mill Shell Body / Door by fixing them to the rib of Mill Shell Body / Door with the bolts and nuts. (Mill shell body M16x70-78sets, Door M16x70-15sets) To fix or remove Shell Grid Liner, loosen these bolts one by one and use chain block (0.2t~).

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2.2.3. Wear of Recycle Inlet Nozzle Discharge slurry and balls out of the mill shell. Clean the inside of mill and take out screw if necessary. WARNING!!! TURN OFF THE CIRCUIT BRAKER OF MAIN MOTOR BEFORE OPENING THE MILL SHELL DOOR. Inspect wear of nozzle tip visually. In case nozzle is worn out to the dimension D=less than 25 mm, ( E=less than 508mm ) replace the nozzle to new one.

Installation and disinstallation of Recycle inlet Nozzle.: Loosen 4 sets of M16 bolts on the connection flange (2) of the primary side piping. Dismantle the primary side piping to secure adequate space to pull out Nozzle. Loosen 8 sets of M20 bolts on the flange (5) connecting Nozzle to the Mill shell. Pull out Nozzle. Above order shall be opposite in case of assembly.

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2.2.4. Wear of Bushing Loosen adjust bolts of bushing case and remove springs. covers and split the busing box. diameter of busing. In case the diameter is worn out to 132 mm dia. And/or total operation hours reaches 16,000 hours, replace bushing to new one. Reference dimensions of new parts are as follows. Drive shaft outer dia. : 130 0 -0.063 mm Bushing inner dia. : 130 +0.3mm +0.2 Disassemble upper and lower Take out bushing out of the box and measure the inner

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2.2.5. Recommended Schedule for Inspection and Maintenance During the 1st year Month Inspection Screw liner Screw liner Shell liner Recycle nozzle Bushing Oil seal Downtime (days) [Mark] : Inspection : Change the position or replace worn parts with new ones. After the 1st year Month Inspection Screw liner Screw liner Shell liner Recycle nozzle Bushing Oil seal Downtime (days) [Mark] : Inspection : Change the position or replace worn parts with new ones. (8) inlet grind tip flight 1 2 3 4 5 6 7 8 9 10 11 12 (3) (3) (3) (8) inlet grind tip flight 1 2 3 4 5 6 7 8 9 10 11 12

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2.3.

Ball Discharge Stop the material feed and continue water supply and running of Tower Mill to make the material in mill shell fine and dilute the slurry density. After confirming the density coming less than 10%, open the drain valve and discharge slurry out of the mill shell and stop Tower Mill.

2.3.1. Discharge of slurry

2.3.2. Ball discharge Before opening the ball discharge cover, place the ball receiving box. Remove the plug of the ball discharge cover. Disassemble fastening hinge bolts of ball discharge cover except left upper side corner bolt on the cover. The remain corner bolt should be loosen slightly in order to move the ball discharge cover. Control quantity of discharging balls by sliding the cover up and down. When the discharging of ball stops, close the ball discharge cover and run the screw of Tower Mill for several seconds. And reopen the ball discharge cover to discharge remaining balls.

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2.4.

Handling of the screw

2.4.1. Take out the screw from the mill shell.

! WARNING
Turn off the electric power source before screw handling job, to avoid electric miss movement, miss operate of other person. Take the suitable lifting tool and method, the screw weight is around 1100 kg . Dont stand under the lifting screw. Be careful your body is crushed between the lifting screw and the mill shell. The job is high position. Make the firm working deck, before the screw handling job. The Screw weight : around 1100kg

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1) There are located the lifting lugs upper of the inner mill shell. Put the chain block lifting tool on the lifting lug by shackle. Dont put the wire rope on the lifting lug directly, to avoid the damage of rope. 2) Round the wire rope to the screw with protector, then connect the end of wire rope to the chain block lifting tool. 3) Hoist the chain block gradually, when the wire rope lifts the screw weight, hold the condition. Attention: Dont hoist too much upper force to the drive shaft, otherwise the bearing parts may be broken due to strong force. 4) Disassemble the flange connecting bolts of the screw, lifting down the screw gradually on the mill floor with protector. Put the wire rope on the screw from the mill outside. ( Bolts : M30x200 6 sets ) 5) Pull out the screw by the wire rope , loose the wire rope at the same time, make a good balance of rope. Consider the lift point on the screw. Attention :* Dot hit the screw to the rubber lining of inner mill shell and door, to avoid damage the rubber. *Dot put the shock force to the screw liner, otherwise the screw liner may be broken.

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2.4.2. Installation the screw in the mill shell 1) Clean the mounting surface ( the drive shaft flange surface, the screw flange surface, the key groove). 2) There are located the lifting lugs upper of the inner mill shell. Put the chain block lifting tool on the lifting lug by shackle. Dont put the wire rope on the lifting lug directly, to avoid the damage of rope. 3) Lift the screw by the wire rope, and bring to the front of door. Round the wire rope to the screw with protector, then connect the end of wire rope to the chain block lifting tool. 4) Bring the screw in the mill shell by the good balance lifting of wire rope. 5) Put off the wire rope, after the screw brings in the mill shell. Lift the screw gradually, and adjust to the flange and key groove. Insert the flange connecting bolt from screw side, assemble and tighten slightly. 6) After tighten the all bolts slightly, put off the wire rope. Then, tighten the bolts firmly. ( Bolts : M30x200 hammering wrench. 6 sets ) 7) After the mounting flange surface is contacted each other, tighten the bolts more torque by the

M30 x 200 6sets

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2.5.

Lubrication List
Parts REDUCER LOW SPEED COUPLING BEARING BOX

Items Pour Points Type of Bearing Self aligning roller bearing Deep groove ball bearings Needle roller bearing Bearing Face of Tooth Bearing Box of Tower Mill

Self aligning thrust roller bearing Self aligning radial roller bearing

and Maker

Lubricants

ISO Grade

ISO Viscosity Grade 220

ISO 6743-9 1998

ISO Viscosity Grade 220

Japanese Brand Name Pouring Method Quantity per

Mobil SHC630 SHELL ALVANIA GREASE EP No.1 (VG220Synthetic) Manual Manual Upper side 490 Manual SHELL OMALA OIL 220

g 9.5 liters g
Every 6 month

Once Pouring Gal.

52 liters
Lower side 320 500Hr (First time only) 500Hr (First time only) Every 6 month

Term and Procedure Oil Exchanging Every 6 month

Quantity Gal.

52 liters

Upper side 490g Lower side 320g

25 liters

Remarks

Term and Procedure Oil Make-Up

Every month Check the oil level by gauge and

Every month Check the oil level by gauge and

Quantity Gal. add oil if necessary

add oil if necessary -

Remarks

Graphic Sketch

BEARING BOX OF TOWER REDUCER COUPLING MILL

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2.6. 2.6.1.

Bearing Box and Bushing Box Bearing Box No. Part Name 1. 2. 3. 4. 5. 6. 7. 8. 9. Bearing box Bearing lower case Bearing upper case Packing case Packing cover (Split) Sleeve Oil pan Clamp collar (Split) Bolt, Nut and Disk washer No. Parts Name 13. Oil seal (TB13016014) 14. Oil seal (TB20024020) 15. Ground packing (13016517.5) 16. O-ring (G130) 17. Oil level indicator 18. Drain valve 19. Drain valve 20. Air breather 21. O-ring (P190) 22. Packing 23. O-ring (P355)

10. O-ring (P335) 11. Self-aligning radial roller bearing (22230E2) 12. Self-aligning thrust roller bearing (29326E)

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2.6.2.

Bushing Box No. Part Name 31. Bushing case 32. Bushing box (Split) 33. Packing case (Split) 34. Packing cover (Split) 35. Bushing (Split) 36. Adjusting bolt (M42), nut 37. Oil seal (MG13016014) 38. Ground packing (13016517.5) 39. Spring (4070)

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2.7.
Ref# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Spare Parts List


Application Bushing box Bushing box Bearing box Bearing box Bearing box Bearing box Bearing box Bearing box Bearing box Screw Screw Screw Mill shell Mill shell Mill shell door L.S. gear couplings L.S. gear couplings No. 35 37 16 13 14 23 21 11 12 Part name Bushing Oil seal O-ring Oil seal Oil seal O-ring O-ring Radial roller bearing Thrust roller bearing Flight liner Tip liner end plate Recycle nozzle Shell grid liner P-shape seal rubber O-ring Rubber-ring Parts No. T201340189 T201340191 T201340138 T201340133 T201340134 T201340137 T201340135 T201340155 T201340165 T201350131 T201350132 T201350140 T201510130 T201530100 T201520125 T201140108 T201140109 Required q'ty / unit 1 1 1 1 2 2 1 1 1 22 2 1 1 1 1 2 1

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