1

Operation & Maintenance Manual

Customer Astaldi Sucursal Chile

Model No. ETM-50 x 2 units

Machine No. 990153 & 990154

NE Job No. 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 DATE APPR PROC REMARK

0 22/Dec/2012 HI AK

2

CONTENTS

1. Operation Page

1.1. Construction of Tower Mill ・・・ 3

1.2. Preparation of Operation ・・・ 5

1.3. Start and Run ・・・ 5

1.4. Stop ・・・ 6

1.5. Re-start ・・・ 7

1.6. Additional Ball Charge ・・・ 7

2. Maintenance

2.1. Daily Inspection ・・・ 8

2.2. Periodic Inspection ・・・ 9

2.3. Ball Discharge ・・・ 14

2.4. Handling of the screw ・・・ 15

2.5. Lubrication List ・・・ 18

2.6. Bearing Box and Bushing Box ・・・ 19

2.7. Spare Parts List ・・・ 21

APPENDIX

A Layout Drawing

B Static & Dynamic Load, Weight Specification Drawing

C LEVEL SENSOR Operating Instruction

D MOTOR Operating Instruction

E GEAR REDUCER Operating Instruction

F COUPLING Operating Instruction

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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.

4

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. After classified, coarse

particles are returned to the mill shell by the recirculation pump. And Tower Mill provides effective

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.

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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. Refill grease in the gear couplings and motor.

Note!

The bushing is a oil-less metal, it does not require oil.

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. Start and Run

1.3.1. 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. Open the discharge valve of the recirculation pump and start the recirculation pump.

1.3.3. Check the water-flow between the mill shell and coarse classifier at mill site.

1.3.4. Start up the main drive motor. Check the direction of rotation.

1.3.5. 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!!!

DON’T CHARGE BALLS WITHOUT RUNNING THE SCREW.

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In completion of charging with a required amount of balls, record the load current. Start feeding the

material and water.

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. Stop

1.4.1. Short time stop

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.

1.4.2. Long time stop

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.

1.4.3. 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.

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1.5. Re-start

1.5.1. Make sure that slurry or water is filled in the mill shell.

1.5.2. Start up the recirculation pump.

1.5.3. Check the circulation of slurry or water between the mill shell and the recirculation pump.

1.5.4. Start up the main motor.

1.5.5. Start feeding of material and water.

1.6. Additional Ball Charge

1.6.1. 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. The fall of the load current is made up for the increase of ball

charge amount.

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2. Maintenance

2.1. Daily Inspection

2.1.1. Check the load current of tower mill main motor.

2.1.2. Check the mounting bolts and fastening bolts of each components for looseness.

2.1.3. Check the condition of each component (bearings, gears, casing etc.) for abnormal noise.

2.1.4. 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 !!!

DON’T ENTER THE UPPER HOUSING IN OPERATION.

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2.2. Periodic Inspection

2.2.1. 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. Liner is serviceable till the dimension

(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

(B) of the liner becomes less than approx. 40 mm.

Check the liner fastening bolts and nuts for looseness.

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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.:

① Loosen 4 sets of M16 bolts on the connection flange (2”) of the primary

side piping.

② Dismantle the primary side piping to secure adequate space to pull out

Nozzle.

③ Loosen 8 sets of M20 bolts on the flange (5”) connecting Nozzle to the Mill shell.

④ 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. Disassemble upper and lower

covers and split the busing box. Take out bushing out of the box and measure the inner

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

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2.2.5. Recommended Schedule for Inspection and Maintenance

During the 1st year

Month 1 2 3 4 5 6 7 8 9 10 11 12

Inspection ▽ ▽ ▽ ▽

Screw flight

liner

▼

Screw tip

liner

▼

Shell grind

liner

▼

Recycle inlet

nozzle

▼

Bushing

Oil seal

Downtime (days) (3) (3) (3) (8)

[Mark] ▽ : Inspection

▼ : Change the position or replace worn parts with new ones.

After the 1st year

Month 1 2 3 4 5 6 7 8 9 10 11 12

Inspection ▽

Screw flight

liner

▼

Screw tip

liner

▼

Shell grind

liner

▼

Recycle inlet

nozzle

▼

Bushing

Oil seal

Downtime (days) (8)

[Mark] ▽ : Inspection

▼ : Change the position or replace worn parts with new ones.

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2.3. Ball Discharge

2.3.1. Discharge of slurry

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.

2.3.2. 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 . Don’t

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.

Don’t put the wire rope on the lifting lug directly, to avoid the damage of rope.

2) Round the wire rope①② 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 rope①② lifts the screw weight, hold the

condition.

Attention: Don’t 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 rope③ on the screw from the mill outside.

( Bolts : M30x200 6 sets )

5) Pull out the screw by the wire rope③ , loose the wire rope①② at the same time, make a good

balance of rope①②③. Consider the lift point on the screw.

Attention :* Do’t hit the screw to the rubber lining of inner mill shell

and door, to avoid damage the rubber.

*Do’t 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.

Don’t put the wire rope on the lifting lug directly, to avoid the damage of rope.

3) Lift the screw by the wire rope③, and bring to the front of door.

Round the wire rope①② 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 rope③, 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 rope①②.

Then, tighten the bolts firmly.

( Bolts : M30x200 6 sets )

7) After the mounting flange surface is contacted each other, tighten the bolts more torque by the

hammering wrench.

M30 x 200 6sets

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2.5. Lubrication List

Parts

Items REDUCER LOW SPEED COUPLING BEARING BOX

Pour Points Bearing Face of Tooth Bearing Box of Tower Mill

Type of Bearing

Self aligning roller bearing

Deep groove ball bearings

Needle roller bearing

- Self aligning thrust roller bearing

Self aligning radial roller bearing

Lubr

ican

ts

and

Mak

er ISO Grade ISO Viscosity Grade 220 ISO 6743-9 1998 ISO Viscosity Grade 220

Japanese Brand

Name

Mobil SHC630

(VG220Synthetic) SHELL ALVANIA GREASE EP No.1 SHELL OMALA OIL 220

Pouring Method Manual Manual Manual

Quantity per

Once Pouring Gal. 52 liters

Upper side 490 g

Lower side 320 g 9.5 liters

Oil

Exc

hang

ing

Term and Procedure 500Hr (First time only)

Every 6 month

500Hr (First time only)

Every 6 month Every 6 month

Quantity Gal. 52 liters Upper side 490g Lower side 320g 25 liters

Remarks - - -

Oil

Mak

e-U

p

Term and Procedure Every month - Every month

Quantity Gal. Check the oil level by gauge and

add oil if necessary -

Check the oil level by gauge and

add oil if necessary

Remarks - - -

-

Gra

phic

Ske

tch

REDUCER COUPLING

BEARING BOX OF TOWER

MILL

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2.6. Bearing Box and Bushing Box

2.6.1. Bearing Box

No. Part Name No. Parts Name

1. Bearing box 13. Oil seal (TB130×160×14)

2. Bearing lower case 14. Oil seal (TB200×240×20)

3. Bearing upper case 15. Ground packing

4. Packing case (Φ130×Φ165×□17.5)

5. Packing cover (Split) 16. O-ring (G130)

6. Sleeve 17. Oil level indicator

7. Oil pan 18. Drain valve

8. Clamp collar (Split) 19. Drain valve

9. Bolt, Nut and Disk washer 20. Air breather

10. O-ring (P335) 21. O-ring (P190)

11. Self-aligning radial roller bearing 22. Packing

(22230E2) 23. O-ring (P355)

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 (MG130×160×14)

38. Ground packing (Φ130×Φ165×□17.5)

39. Spring (Φ40×70)

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2.7. Spare Parts List

Ref# Application No. Part name Parts No. Required q'ty / unit

1 Bushing box 35 Bushing T201340189 1

2 Bushing box 37 Oil seal T201340191 1

3 Bearing box 16 O-ring T201340138 1

4 Bearing box 13 Oil seal T201340133 1

5 Bearing box 14 Oil seal T201340134 2

6 Bearing box 23 O-ring T201340137 2

7 Bearing box 21 O-ring T201340135 1

8 Bearing box 11 Radial roller bearing T201340155 1

9 Bearing box 12 Thrust roller bearing T201340165 1

10 Screw Flight liner T201350131 22

11 Screw Tip liner T201350132 2

12 Screw end plate T201350140 1

13 Mill shell Recycle nozzle T201510130 1

14 Mill shell Shell grid liner T201530100 1

15 Mill shell door P-shape seal rubber T201520125 1

16 L.S. gear couplings O-ring T201140108 2

17 L.S. gear couplings Rubber-ring T201140109 1