Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure Commissioning Procedure for Mill
Purpose of Document For Execution/Information
Document No. JPL Reference No: Boiler/Comm./005

Rev No. 00 Prepared By Reviewed By Approved By Date

Name

Sign

Copy No:

Issued To:
Station: JPL, Tamnar Page 2 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

List of Contents

1.0 Plant Details

2.0 Objectives

3.0 Proposals

4.0 Services Required

5.0 Safety Precautions

6.0 Emergency Procedures

7.0 State of the Plant

8.0 Method

9.0 Completion Criteria

10.0 Log Sheet

Signatures

JPL BHEL
Station: JPL, Tamnar Page 3 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

1.0 PLANT DETAILS

The Bowl Mill supplied to this project is of XRP Design. Each

mill is provided with independent forced lube-oil system to
ensure lubrication and cooling of mill bearings. In this XRP
1103 type mill the coal is fed in the center onto a revolving
bowl. Heated air enters the mill side housing below the bowl
and directed upwards. The primary air thus entering the mill
does the drying of pulverized coal as well as transport the coal
to the furnace.

1.1 Technical Specifications

1.2 Bowl Mills - 8 Nos

1.3 Lub oil system for mills - 8 Sets (External)

1.4 Classifier assemblies - 8 Sets

1.5 Mill discharge gates - 8 Sets

1.6 Type of Mill - XRP 1103

1.7 Capacity - 66.3 TPH

1.8 Motor - 680 KW

1.9 System - Cold PA

1.10 External Lub-oil System

a. Pump Make/Type : Alekton / Screw

b. Capacity. : 200 LPM

c. Motor Speed : 1460 RPM

d. Operating Pressure : 5.1 KSC

e. Relief Valve Setting : 7.0 KSC

f. Motor Rating : 3.7 KW

2.0 OBJECTIVE

To commission the pulverizer and make available for coal

firing of the boiler.

Signatures

JPL BHEL
Station: JPL, Tamnar Page 4 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

3.0 PROPOSAL

3.1 Commissioning of the mill is proposed in the following steps.

3.2 Commissioning of mill Motor

3.3 Commissioning of Mill

4.0 SERVICES REQUIRED

4.1 Availability of man power with required tools for attending any
leak and cleaning of filters.

4.2 Availability of operating personnel to carryout/co-ordinate

activities.

4.3 Availability of lighting arrangements and communication

facilities in the operating floors / Mill.

4.4 Availability of portable fire fighting equipment near test area.

4.5 Availability of LT/HT Power Supply

4.6 Availability of auxiliary Cooling Water supply.

5.0 SAFETY PRECAUTIONS

5.1 Debris in and around mills shall be removed.

5.2 First Aid Kit is available near the test area

5.3 Operation of local start/stop push button shall be ensured for

perfect operation to facilitate for stopping of equipment in
case of necessity.

5.4 Approach / staircase / platform wherever required are made

available.

5.5 The inert steam / water quenching system for fighting in the
milling system may be commissioned and made ready for use
in case of emergency. (To be made ready before coal firing)

5.6 Portable fire fighting system made available at test area.

Signatures

JPL BHEL
Station: JPL, Tamnar Page 5 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

6.0 EMERGENCY PROCEDURES

6.1 The test team should be aware of the procedure to be adopted

in case of damage to machinery/injury of any personnel
connected to the activity.

6.2 The test team should be well aware of the procedures to be

adopted in case of any abnormality in the activity.

7.0 STATE OF THE PLANT

7.1 Mill and lube oil system are erected as per recommended
drawing.

7.2 Acid cleaning of mill lube oil lines completed as per the
procedure given in the testing procedure and the lines are
then normalized.

7.3 All local instrumentation of lube oil system, completed with

proper calibration.

7.4 Power supply system for the lube at pumps are available for
operation

7.5 Instrument and service air line for the milling system are
erected and the air is made available for operation.

7.6 Cooling Water lines to Mill gear box are erected, flushed
sufficiently and clear water flow established. CW line charged
subsequently for mill commissioning.

7.7 Required local / Remote C & I inputs for mills are made
available (List to be prepared at site).

7.8 The old preservative oil from the mill gear box removed and
new oil filled up to the normal level (refer O & M Manual)

7.9 All erection Log Sheets are followed up / signed by concerned

agencies with respect to mill internal clearances and mill
alignment.

7.10 Mill journal springs are loaded equally as per the

recommendations given in O & M manual

7.11 Mill classifier assembly serviced for free operation. All vanes
in the classifier assembly set at equal openings.

7.12 Mill discharge gates (4 Gates / Mill) are serviced and

commissioned for remote operation.

Signatures

JPL BHEL
Station: JPL, Tamnar Page 6 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

7.13 Oil level in the journal assemblies are checked with dip stick
for correct level.

7.14 It is ensured that the Trunnion shaft end caps are rotated
such a way that No 1 on the end caps line up with the arrow
indication in the journal cover.

7.15 All the three rollers are lifted up by tightening the stop bots so
that rollers do not touch the bowl during initial mill trial run.

7.16 The tramp iron spout dampers are commissioned and

available for operation.

7.17 Scrapper guard assembly erected and ensured for free

movement.

7.18 Hot and cold air ducts connections to the mill are completed
and the ducts are cleaned off any loose material, debris and
foreign materials. Expansion bellows connected to mill shall
be checked for removal of all temporary arrestors.

7.19 Seal air lines with Solenoid operated dampers are erected and
commissioned for remote operation.

7.20 Cold & Hot air dampers at the mill inlet serviced for freeness
of operation ( Optional )

7.21 Filters in the lube oil system are cleaned and put in position.

7.22 Mill motor checked for its IR value and cleared for
commissioning.

Signatures

JPL BHEL
Station: JPL, Tamnar Page 7 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

8.0 METHOD

8.1 Commissioning of Mill

8.1.1 Ensure that the motor is aligned with mill and the readings
are logged and cleared for coupling.

8.1.2 Check the meggar value of motor and ensure that the
insulation value is satisfactory.

8.1.3 Check the winding resistance of the motor and confirm that
the values are satisfactory.

8.1.4 Ensure all motor protections are available at the HT/LT

Breaker.

8.1.5 Ensure motor winding & bearing temperature indications are

available at control room / local.

8.1.6 Bump the motor and ensure correct direction of rotation.

8.1.7 Start the motor and complete 8 Hrs trial run.

8.1.8 During trial run, record the no load current, bearing and
winding temperature at every one hour interval. Motor
vibration to be noted once during the trial run.

8.1.9 After completion of the motor trial, the motor shall be coupled
to the mill.

8.1.10 Ensure that the lube oil lines are restored after acid cleaning

8.1.11 Ensure oil level in the gear box is sufficient.

8.1.12 Start the lube oil pump and charge cooling water.

8.1.13 Ensure oil return flow from upper and lower bearings through
the flow sight glass.

8.1.14 Ensure that mill is completely boxed up and there is no

foreign material left inside the mill.

8.1.15 Ensure all foundation bolts are tightened properly.

8.1.16 Start the Mill and run for 8 hrs trial run.

8.1.17 Observe for any mechanical rubbing. Record mill starting

current no load current, bearing temperature of mill and
motor, in log sheet.

Signatures

JPL BHEL
Station: JPL, Tamnar Page 8 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

8.1.18 While mill is in running condition, Ring/ roll clearance for all
the 3 rollers shall be set as per the procedure given in the O &
M manual.

8.1.19 After Ring/roll clearance setting is completed, adjust 1mm

clearance between journal head and spring assembly seat.
This shall be done when the mill is at stopped condition. I.e.
after 8 Hrs. trial run.

8.1.20 The same procedure is followed for commissioning other Mills.

9.0 COMPLETION CRITERIA

Commissioning of the mill completed by carrying the

proposals given in Section 3.0

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JPL BHEL
Station: JPL, Tamnar Page 9 of 9
JPL Reference no: Boiler/Comm./005
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Mill

10. Log Sheet

Parameter
S. Lub Oil System Motor

Pump in service

Cooler O/L Oil Temp.

DE Brng. Temp

NDE Brng. Temp

DE Brng Vib.

NDE Brng Vib.

Lube Oil Flow
Pump Dis pressure

Filter O/l Pressure

Cooler I/L Oil Temp.

No

Filter DP
Unit A/B Kg/cm Kg/cm Kg/c LP oC oC oC oC mm/ mm/s
2 2 m2 M s

Signatures

JPL BHEL