HRM1700M Vertical Roller Coal Mill

Operation Manual

Hefei Cement Research & Design Institute

Hefei Zhongya Cement Machine Plant
July, 2001
 Contents

Sections One: HRM1700M VRM Installation

Ⅰ. Introduction

Ⅱ. Technical Parameters and Performances

Ⅲ. Structure and Working Principle

Ⅳ. Equipment Installation

Ⅴ. Acid Pickling and Installation of Hydraulic & Lube Oil System

Section Two: HRM1700M VRM Test Run & Commissioning

Ⅰ. Introduction

Ⅱ. Test Run of the VRM in Separate Units

Ⅲ. No Load Test Run of the VRM

Ⅳ. Load Test Run of the VRM

Ⅴ. Personnel Training

Ⅵ. Operation of the VRM

Ⅵ. Possible Problems & Solving Ways

Section Three: HRM1700M VRM Maintenance & Reparation

Ⅰ. Introduction

Ⅱ. Maintenance & Reparation of the VRM

Ⅲ. Lubricating Oil Table

Section Four: Drawings

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Section One: HRM1700M VRM Installation

Ⅰ. Introduction

HRM1700M VRM is an honor product of Hefei Zhongya Cement Plant under Hefei
Cement Research and Design Institute. This type of the mill has been tested in
production practice for many years. With the product performance constantly
improved it is one of the most advanced products in the world and finds favor with
many users at home and aboard.

HRM1700M VRM is a technical advance’s drying and grinding equipment for coal
which can be widely used in such industries as building material, light industry,
chemical industry, firepower generating etc. This type of mill has many advantages:
high grinding efficiency, low power consumption, coarse feed size, easy adjusting
product fineness, simple technological process of equipment, small floor area, low
noise, a little dust emission, easy operation and maintenance, lower operating cost,
low wearing material consumption etc. The mill also has following specific
performances besides these:

1. Grinding rollers can be turned out of mill by a hydraulic device, it is convenient

to replace roller tyre, and the overhaul space of VRM is big and easy overhaul
working.

2. The rollers tyre can be used with another side to prolong the useful life of wear
resisting material,

3. Material needn’t be distributed on the grinding table before startup, and the mill
can be started under no-load condition to avoid difficulty in start.

4. A limiting position limiting device of the grinding rollers is used to avoid

violent vibration because of material breakdown during the mill working.

5. Having adopted a new sealing device for grinding rollers, the seal effect is better,
seal fan needn’t be used to reduce further oxygen content in the mill and the
performance of explosion-proof is better.

Ⅱ. Technical Parameters and Performances

2.1 Main Technical Parameters

Type: HRM1700M
Diameter of grinding table: Φ1700mm
Diameter of grinding roller: Φ1400mm
Number of grinding rollers: 2(piece)

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Rotating speed of grinding table: 34r/min
Grinding material: coal (HGI≥60)

Max. feed size: ≤50mm

Moisture of feed material: ≤10%

Product fineness: 90% passing 200 mesh

Output: 20t/h
Product moisture: ≤1%

Inlet air temperature: <350ºC

Outlet air temperature: 80-95ºC
Outlet air volume: 80000m3/h
Pressure drop of mill: 3000-4000Pa
Working pressure of hydraulic system: ≤12MPa

Dimension of VRM: length:4700mm

Width: 4450mm
Height: 8320mm
Total weight of mill: 85000kg

2.2 Main Motor

Type: YKK400-6
Power: 355kW
Rotating speed: 990r/min
Voltage: 11kV
Protective grade: IP54

2.3 Main Reducer

Type: ML30
Power: 370kW
Input rotating speed: 990r/min
Output rotating speed: 34r/min
Lube oil: Medium-load industrial gear oil N220
Oil supply: 200L/min
Motor power of oil pump: 2×5.5kW
Oil box volume:2m3
Cooling water temperature: ≤28ºC

Cooling water: 20m3/h

Electric heater: 6x3kW

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2.4 Separator
Rotor rotating speed: 30-220r/min
Motor type: YVP225M-4
Motor power: 45kW
Motor rotating speed: 0-1500r/min
Reducer type: B2SV4B
Reducer power:
Reducer ratio: 6.3
Lube oil: Industrial gear oil No.220

2.5 Hydraulic System

Type: HY17-22-350AI
Motor power of hydraulic pump: 7.5kW
Working pressure: ≤12MPa

Max. Pressure: 16Mpa

Flow: 22L/min
Hydraulic oil: N46
Oil box volume: 350L

Ⅲ.Structure & Working Principle

3.1 The structure diagram sees as follows:

(discharge port, separator unit, feed opening, grinding device, driving arm, pressure
device, limiting position, overhaul oil cylinder, driving device.)
HRM1700M VRM serves as a new & energy saving grinding equipment, the working
principle is as follows:
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Motor starts, the grinding table is rotated by reducer. Material to be ground is
conveyed the center of rotating grinding table by air lock feeder. Under centrifugal
force action, material moves towards the grinding table periphery and enters into
grinding roller patch. Extruded, ground and sheared material is crushed under
grinding rollers pressure action, at the same time, hot air in the air ring of surrounded
grinding table jets up at constant high speed. Material after ground is blown up by
high-speed air flow from the air ring, on the one hand coarse material falls on the
grinding table to grind again, one the other hand suspended material is dried, fine dust
is brought into separator by hot air and separated, qualified find dust discharges out of
the mill together with air flow and is collected by dust collector, collected find dust is
product. Unqualified coarse dust returns to the grinding table again under separator
blade action and is ground together with new fed material. Above process is whole
grinding work process.

3.2 Structure Properties and Working Principle of Main Parts

a. Driving device
The driving device of VRM consists of main motor, coupling and reducer. It is
erected the bottom of the mill. The device not only makes the grinding table rotate but
also bears the weight of the grinding table, material and grinding rollers, and the
grinding pressure that pressure device exerts on the grinding rollers, so it is one of the
most important parts in VRM. Lube oil system uses independent oil station with an
automatic protection system for oil pressure and oil temperature, the operation of the
complete equipment is safe and reliable. The reducer has many advantages: small
volume, light weight, big reduction ratio and high driving efficiency etc. With respect
to the structure and working principle etc of the main reducer please carefully refer to
“ML30 Reducing Gear Box of VRM Use and Maintenance Manual”.

b. Grinding Device
The grinding table and the grinding rollers are all important grinding parts, their
shapes design must make grinding material form a steady material bed on the grinding
table, so reasonable grinding table shape must fit with proper grinding rollers, this
point has an extremely important action in steadying material layer, increasing
grinding efficiency and decreasing grinding consumption. Though much investigation
and analogy, we use tyre shape grinding roller, the roller tyre is symmetric structure,
other surface of roller tyre can be turned out and used after worn to a certain extent, in
order to prolong its useful life.

c. Pressure Device
The action force (hydraulic pressure) that the pressure device exerts on material is
controlled by automatic or manual hydraulic control system. The hydraulic pressure
can automatically change with material grindability, so that the mill can often
maintain the run under the most economic condition. This not only reduces the

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consumption of no-work but also prolongs the useful life of the roller tyre and the
liners, at the same time, because a stored energy unit has the butter action, the
hydraulic pressure that the hydraulic cylinder exerts on the grinding rollers has bigger
elasticity and self-adjustment etc functions. The grinding rollers can be sprung up
when big and hard material is met, in order to avoid the breakdown of the grinding
parts and the driving device because of heavy load.

d. Position Limiting Device

The unique position limiting device for VRM may make the mill start up at light load
and the gap between the grinding rollers and the grinding table may be adjusted. So it
can both keep the stability of the material layer thickness and increase grinding
efficiency and guarantee that the rollers don’t contact directly with the table under
abnormal conditions such as the unstable feeding materials to avoid the mill vibration
and protect the reducer.

e. Separator Device

The separator is a mechanical drive and adjustable rotating speed separator. The
separator rotates at the high speed by the cone rotors. Though dashing between the
blade and coarse materials, make the materials quicker circular velocity produce
bigger centrifugal force for separating the materials. Fine particles leave the mill
though the gap of the separator blades and are collected by the bag filter. The
classification efficiency of the separator is high. The adjustable range is big.

f. Grinding Roller Device

The grinding roller device adopts a pair of titling roller bearing. When designing,
calculate the same service life for the bearings. The bearing seal cavities extend for
outside the shell and don’t contact with dust containing gas, so only if some simple
fillers are used for sealing, can’t the roller bearings enter dust. The roller tyres are
pressed with wedge shaped ring, so the changover of the tyres are very convenient.

Ⅳ. Mill installation

4.1 Preparations

a. Horizontal gauge

b. Frame level (precision: 0.02mm/m)

c. Lifting appliance, all kinds of common tools

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d. Feeder gauge (0.05～1.00mm)

e. Packing irons (specifications: 200×100×18), some wedge irons

f. Foundation drawing lines

First, clean up the mill foundation, especially there don’t have to be water, wood
blocks and crushed stones in the foundation bolt holes. To the tight bond for the
second grout, the foundation surface must be roughened and the foundation periphery
should be filled flat and be tamped.

Secondly, see the civil construction diagram, installation diagram and the actual size
of the mill, check and accept the mill foundation: check whether the central line and
level point provided by the civil unit are right; according to the equipment and process
diagram, check whether the outline dimension, the level size and the geometric size of
the base holes for foundation are right.

According to the coordinate position of the design drawings, measure the central line
of the mill foundation with the steel tape, fix the longitudinal and horizontal central
line on the central scale, or draw lines on the foundation with the ink line and pay
attention to reserving the central lines during the installation.

4.2 Installation

a. According to the foundation diagram requirements for HRM 1700M VRM, check
whether the foundation hole position and the preformed cavity size coincided with the
mill.

b. Check the size of the foundation holes for the mill, coordinate the deviations of
all the foundation holes and determine the relative center.

c. Installation for drive device

According to the civil construction diagram, find ±0.00 plane face and make the level
of the mill installation meet the process construction diagram requirements.

Install the base plate of the reducer at first, then punch though the bolt holes of
foundation. The bolts should respectively be in the centers of all the foundation holes
in the natural condition.

The installations of the main reducer and the base plate are the core of the whole mill
installation. The installations of other parts must regard the main reducer as the
standard. So the fixed position of the main reducer should be accurate. The main

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reducer center should coincide with the foundation center. The deviation is not more
than ±5.0 mm.

When installing the base plate of the main reducer, put a group of packing irons by
each foundation bolt. Each group packing irons shouldn’t be more than four irons,
among them there is the tilting packing iron. The length of tilting packing iron
stretched out of the base plate is 30mm. The connection between packing irons should
be tight, so is the connection of the packing iron and the base plate. The foundation
bolts inside the holes should be naturally dropped and shouldn’t contact the hole
bottom and hole walls. The bolts should stretch two to three screw threads out of bolt
nut.

Before grouting the foundation holes, water the hole walls, confirm whether the base
plate position and level are right again. When grouting, tamp the concrete and avoid
the askew foundation bolts. After grouting, daily maintain with water until the
concrete strength reach 75% of the stipulated strength

When tightening the foundation bolts, make each foundation bolts evenly stressed.
When adjusting the base plate level, use packing iron for adjusting. Don’t have to use
tightening and loosing foundation bolts methods for adjusting. Its levelness should
reach 0.1mm/m. after finishing, the connection between packing irons and the
pocking iron and the base plate should be fixed with spot welding.

When connecting the reducer and the base plate, install the locating pins at first, and
then install the connecting bolts. When tightening the bolts, make each bolt evenly
stressed.

When installing the main motor, the main motor should be connected with the base
plate with the at first, and then 2.0mm thick pad should be added between of the main
motor and the base board. Put a group of packing irons by the foundation bolts of
each base plate. The foundation bolts should naturally drop inside the holes. Align the
center of the main motor with the main reducer. After fixing the position, grout and
tamp in the foundation holes. When the concrete strength reach 75% of the stipulated
strength by maintaining, tighten the foundation bolts, adjust the main motor to the
horizontal position by the packing irons, make the main coupling meet the stipulated
requirements (see ML30 VRM Reducing Gear Box Operation manual). After
finishing the installation, the connection of packing irons and the packing iron and
base plate should be fixed by spot welding.

When installing the main motor and the reducer, require the diameter runout of the
coupling is not more than 0.08mm, the lateral runout is not more than 0.08mm. (see
the Reducer Installation Manual)
d. Installation of the Lower Housing and the Grinding Table

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Because of hoisting and transporting, the lower housing of the HRM 1700M VRM
should adopt site welding, and the site installation shall be in accordance with the
assembly marks made by the equipment manufacturer.

When installing the lower housing, take the central line of the reducer outlet axis as
the basis. The error between the central line of the lower housing and that of the outlet
axis shouldn’t exceed ±2.0mm.

(1) The lower housing is hoisted and installed on the correspondent foundation
according to the marks on the lower housing. The proper positions of two supports are
determined according to the drawing. The supports firstly are welded together by U
steel and hung by foundation bolts.

(2) The shell of the lower housing is hoisted on the supports.

The concentricity between the shell center and the central line of the reducer outlet
axis is determined by cross wires. The supports and the shell are welded together. The
weld is of continuous fillet and 15-20mm in height. The type and size of slope
opening shall fulfill the requirements of GB985-88.

(3) The grinding table is slowly hoisted on the reducer and located in the proper
position, fixed with positioning pins and evenly tightened joint bolts. The adjustment
of the lower housing position is to make the radial clearance between the grinding
table and air ring basically consistent (The error is no more than ±2.0mm, selecting

symmetric 8 points around the grinding table for checking). In the meantime, check
the axial distance on the top surface between the flange and the grinding table on the
lower housing. The designed axial distance on the top surface between the flange and
the grinding table on the lower housing of the HRM 1700M VRM is -50±10mm, it

can be adjusted by packing irons.

(4) The foundation bolt holes of the supports are grouted for one time, excluding
several foundation bolts used together by pressuring and positioning pedestals.

(5) Seven days later, the levels of the lower housing and four bearing pedestals are
accurately corrected. The error in height of the four bearing pedestals is no more than
2mm.

At last, the foundation bolts are tightened.

e. Installation of the Upper Housing, Grinding Rollers and Drive Arms

The upper housing is hoisted and installed on the lower housing according to the
requirements of the equipment drawing. After the upper housing locates in the proper

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position, the joint bolts are evenly fastened. The prepared grinding rollers and drive
arms are hoisted on the bearing pedestals of the lower housing supports and the rollers
are lightly set on the grinding table. The slide bearings are coated with lubricating oil,
the joint bolts on the bearing pedestals are tightened, and then a sealing door to the
grinding rollers is installed with great care over the sealing property.

f. Installation of the Position Limiting Device and Separator

The position limiting device is assembled in advance and located in the proper
position according to the size requirement of the equipment foundation drawing. The
positioning bolts are screwed out to contact with the positioning head. After
positioned, the foundation bolts are grouted and fixed. Tighten the foundation bolts

after mortar solidifying. Then screw out the positioning bolts to make the distance
between grinding roller and grinding table be 5-10mm. Then we will install separator:
First, we will hoist the pre-assemblied separator to the upper housing and find proper
level; then tighten connecting bolt by even force. The connecting faces of flange must
be strictly sealed.

g. Installation for Pressure Equipment

Putting the pressure equipment that is pre-assemblied to the position according to

drawing and connect with main body of the grinding mill then find level. Checking
the distance between the two center holes of work cylinder and inspecting cylinder
according to drawing .The foundation bolt will be fixed by grouting method. When
the sand mortar solidifies, then tighten bolt.

h. Installation for Hydraulic System and Lubricating System

Getting all the varied specification oil pipe of hydraulic and lubricating systems ready,
according to practice conditions of equipment installation on site. Blow the pipe holes
with compressed air and carefully wash them, then assembly and install them
respectively according to requirement.

When making pipe lines, the welding sew should be very closed. After the pipe lines
finished, each pipe line should be belown over and over, then cleaned by dilute
hydrochloric acid, finally washed by cleaning oil. For installing main reducer to return
oil pipe line of the lubrication station, there should be a slope ≥3/100 in order to

ensure return oil moving smoothly. The connecting flanges of pipe lines of lubricating
system and pipe joints of pipe lines of hydraulic system should be closely sealed
and without oil leakage. Connecting parts of hydraulic system pipeline, which are
used for connecting the hydraulic system pipeline to main oil cylinder or inspecting
cylinder, should be soft pipes of high pressure. Accumulator is fixed on the racks

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under mill near oil cylinder by supporter, The pipeline of hydraulic system is fixed by
pipe clampers in each distance of 1~2m.

Finally, a second grout for the whole equipment foundation should be performed (The
water drainage pipes should be pre-laid in the inside of the two racks of the low
housing).

Ⅴ. Acid pickling for hydraulic and lubricating system

The installation of hydraulic pipeline should be performed in two steps. The first step
is pre-assembly (for auxiliary pipes); the second is formal installation. The
pre-assembly is the preparation for the formal installation, which is important step for
guarantee installation quality.

What to do on site based on the hydraulic principle drawings and indicator drawings
of pipe installation are as follows:

5.1 Pre-assembly (preparation pipe)

a. HRM 1700M type series vertical mill’s hydraulic pipe line system are usually
fitted by seamless steel pipes, high pressure rubber soft pipes. The seamless steel pipe
has an external diameter of 18mm, thickness of 3-4mm (prepared by User). The high
pressure rubber soft pipes, pipe joints, seal rings are supplied by manufacturer.

b. Firstly definition hydraulic station position according to technology design and

concrete situation on site.

c. Preparation pipe, the pipe joint and main pipe welding should flat and direct and
welding sew should even and not permit gas hole, crack etc weakness exist that will
influence pipe line pressure, if the plant have capacity should carry out pressure force
test.

d. Making marks .for each pipe then dismantle them prepare for wash.

e. Acid cleaning

Generally according following process

Degreasing→water cleaning→acid cleaning→neutralization→water cleaning→below

by dry air→smear hydraulic oil.

Concrete step as follow

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(1) Using hammer beat the oil pipeline point by point, especially for welding place in
order to reach cleaning out oxide skin, welding slug, burr of inner pipe.

(2) Grouting sodium hydroxide solution that density is 8-10% into pipeline immerse
3-4 hours then use water cleaning.

(3) Grouting hydrochloric acid solution which density is 15% into oil pipe line,
immersing 6-8 hours then pour out acid solution then grouting again soda solution
that density is 10% about one hours, use water cleaning and dry by compress air,
machine oil immerse one hour.

(4) Dry by dry air

5.2 Formal installation

a. Pipe line after acid pickling put it to originate place according to mark and fixed hy
relatively pipe clamper.

b. Connecting soft pipes of high pressure, accumulator.

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Section Two HRM1700M VRM Test Run and Commissioning

Ⅰ. Introduction

The HRM1700M VRM will have a test run and commissioning after having been
erected, which includes two tasks: no load test run and load test run. The purposes of
the test run are: firstly, to examine the inherent quality of the VRM and to remove
hidden troubles of the equipment; and secondly, to examine the erection quality of the
VRM, to train the operating personnel on site, and to make the VRM appropriate to
the materials to deal with; and at last, to reach or even to exceed the economical and
technical targets set in the Contract.

During the test run and commissioning period, there would be various problems.
Perhaps, it’s inevitable. Our opinion is that in this period, we should find problems
and hidden troubles as fully as possible and do our best to solve them and that is the
guarantee of the VRM safely operating for a long time in future. So, whatever
problems arise in this period, we shouldn’t be impatient or act rashly. What we should
do is to gather engineers and technicians to analyze carefully the problems and to
work out the workable resolving plans, and finally to solve these problems or hidden
troubles.

While carrying out the test run and commissioning, we should prepare all necessary
tools and materials in advance, such as spanners, three major electrical tools, cleaning
materials, lubricating oil (grease) and all kinds of forms and tables for noting down
the data of the test run, etc. The periphery of the VRM and the workshop should be
kept clean and tidy. Everything on the test run ground should be put in order. The
inside of the VRM, especially the dark positions and positions difficult to inspect,
should be examined seriously without any carelessness. There should not be any
inutile things left in it, such as bar, brick, cement block, wood, bolt, spanner or cotton
yarn etc.

Please read the Manual carefully and perform the test run in sequence. If the last test
run isn’t accepted with success, the next one shouldn’t be carried out.

Ⅱ. Test Run of VRM in Separate Devices

2.1 Separator

The lubricating oil sites of the separator should be poured with the lubricating oil or
grease of corresponding brand and grade.

The separator motor should run alone for 2hours. During this period, adjust the motor
speed to 400, 800, and 1200r/min respectively, and make the motor run at each of
these speeds for 20minutes. The requirement is that the motor runs steadily without

13
abnormal sound and that its frequency speeder presents flexibility and reliability in
speed conversion.

Turn manually the belt pulley at the input of the reducer to make the separator’s rotor
rotate for several rotations. All turning parts shouldn’t stick and have metal friction
sound. Put on the triangle belt and stretch it correctly, then turn once again the belt
pulley by hand for checking if everything is OK.

Adjust the motor speed to zero and start the motor. Then regulate gradually the motor
speed to 400, 800 and 1200r/min respectively and make the motor run at each of these
speeds for 30minutes. After this, adjust the motor to the speed of 700r/min for running
8 hours, in which there are at lest 4 hours for continuous running. Note down the
motor currents corresponding to different rotating speeds. The requirements are that
the rotor runs smoothly without abnormal sound and the motor has normal heat
radiation.

2.2 Pressuring Equipment

please refer to Operation and Maintenance Manual of HY17-22-350AI.

2.3 Drive Units

2.3.1 Main Motor

Firstly, check the main motor for its insulation conditions.

Connect the main motor with the power source to know its rotation direction and wire
the main motor in the correct rotation direction.

The main motor should run alone for 4 hours, in which at lest 2 hours for continuous
running. The main motor should run smoothly without any abnormal phenomenon.

2.3.2 Lubricating Oil Station

Connect respectively two oil pump motors with the electric source to know the
rotation direction, and wire them in the correct rotation direction.
Start one of the oil pump motors. Regulate gradually the oil pressure to 0.18MPa for
running for 8 hours, in which 4 hours for continuous running. The lubricating oil
station should operate steadily with oil leakage-free and easy oil return. Refer to
Lubricating Oil Station Operation and Maintenance Manual.

With the same method, start another oil pump motor for the test.

2.3.3 Main Reducer

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Start the lubricating oil station to feed the main reducer with lubricating oil. Regulate
the oil feeding pressure and temperature for starting the main reducer. Refer to
Operation and Maintenance Manual for the ML30 Reducer Gear Box of the VRM.
Make the main reducer run for 4 hours continuously.

Under the condition of grinding rollers lifted, start up the motor of the lubricating oil
station to feed the reducer, and then make the grinding roller turn a rotation by hand at
the coupling. Pay attention to observe if there is abnormal phenomenon, as metal
friction sound etc.

Install the coupling between the main motor and the main reducer, and check if the
two grinding rollers are lifted. Start the lubricating oil station and start up the main
motor, the reducer will drive the grinding table into rotation in the clockwise direction.
The main reducer should run in non-load conditions for 24hours, in which there
should be at lest 12 continuous running hours. The running should be smooth and free
of abnormal sound, and there is no oil leakage in main reducer, lubricating oil station
or oil pipeline. Please note down parameters such as oil pressure, oil temperature,
main motor current and temperature of bearing bush etc every hour. Attention! Don’t
stop the lubricating oil station immediately after stopping the main motor, keep
it running continuously for about 10 minutes. If the main reducer will be
restarted in a short time, it isn’t necessary to stop the lubricating oil station.

Ⅲ. No Load Test Run of the VRM

Before the no load test run of the complete VRM, please check with care whether the
lube oil volume at all lubricating sites is in the given range, whether the examining
and control instruments are in normal conditions, whether the two grinding rollers are
lifted and left from grinding table, and whether all connecting bolts are tightened up,
especially for the bolts on rotating parts.

Start up the oil pump motor in lubrication station. Adjust the oil pressure and
temperature in order to start the VRM. Start separator motor and adjust it to a speed of
1000r/min. If all is normal, start the main motor, and the main reducer drives the
grinding table and rotates together with it.
The driving gear and separator should run together for 24 hours, continuous operating
time in which is 12 hours or over. After the separator runs alone for 6 hours during
these 24 hours at 1000r/min, adjust the motor speed respectively to 400, 800,
1000r/min respectively and make it operate at each of these speeds for 3 hours.

In the whole test run process, the VRM should operate stably and not create any
abnormal sound. The heating parts like motors and bearings etc shouldn’t be in
overtemperature conditions. Make an operation record every two hours.

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Ⅳ. Load Test Run of the VRM

The load test run of the VRM should be performed only after the no load test run of
every equipment in the VRM system and the no load test run of the whole VRM are
completed. The stable run of the VRM system must be ensured during the first stage
of the load test run, it isn’t necessary to concentrate on economical and technical
targets like output with intensive attention. What to do is to keep the equipment in a
stable operating condition, and then adjust gradually the equipment and technological
parameters in order to make the VRM and system equipment in a best operating state.

Operators should carefully read HRM1700M VRM Operation Manual and relative
technical documents and data before the test run of VRM with load, and work out a
feasible plans according to the practical conditions.

4.1 Test Run of VRM with 70 Percent Load

Feed quantity is 14.0t/h: the operating time should not be less than 100 hours, in
which there are 50 hours for consecutive operation;

4.2Test Run of VRM with 85 Percent Load

Feed quantity is 17t/h: the operating time should not be less than 100 hours, in which
there are 50 hours for consecutive operation;

4.3 Test Run of VRM with 90Percent Load

Feed quantity is 18t/h: the operating time should not be less than 100 hours, in which
there are 50 hours for consecutive operation;

During the whole test run of VRM with load above-mentioned, the equipment should
operate steadily and not produce any abnormal sound; all parts of equipment should
not have overtemperature phenomenon. Then the test run of VRM with full load
begins.

NOTE: Before each test run with load, we should carefully check whether all
connecting bolts are well screwed, and take into the inside of the mill for
checking whether the grinding rollers, the grinding table, and the rotor of
separator are in normal conditions; and analyze carefully the operating record
of the last test run, and work out the test run plan for the following one.

It’s necessary to explain that the feed quantity of test run with load of VRM is
estimated as per practical experience. It could be properly increased or decreased in
the practical operation due to the different coal qualities and varieties from different
areas, to ensure the electrical current value of main motor approximate to its rated
current percent. For example, during the test run of VRM with 70 percent load, or

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with a feed quantity of 14.0t/h, if the electrical current of main motor in practical
operating is below 70% of its rated current, the feed quantity should be increased
properly; if the electrical current of main motor in practical operation is above 70% of
its rated current, the feed quantity should be decreased properly. Thereto, during the
test run of each stage (VRM with load), each test run should reach the required
operating time for beginning the following test run. But it doesn’t mean that the
following test run must begin as soon as the operating time of the last test run is
reached. Each factory could prolong the operating time of each test run stage
according to the practical conditions like production management and personnel
training etc.

Ⅴ. Personnel Training

Personnel training should be put in the first position because operating ability of
operators is the key factor of normal operating of VRM. Before the test run of VRM,
the operators should receive necessary theoretical training. In addition, if possible, the
operators should be sent to the some or similar factories to be trained on the spot. So
during test run and commissioning of VRM, the personnel training is also a very
important task while the test runs and commissioning work of the Manual are
performed. In the test run of VRM without load, operators should be given enough
time to operate equipment until their working skill increased. During the test run of
VRM with load, specifically with lower load, the process is a very good practical
operating chance for operators. If the equipment is under normal operating condition,
operators should independently operate and adjust equipment, and technologist could
direct operator’s operating and adjustment. Before VRM is officially put into
production, operators must reach the correspondent operating level, and can
individually find and solve the problems that possibly occur during the operation.
Only this can ensure safe-stable operation of VRM, and finally reach and exceed
economical and technical index.

Ⅵ. Mill Operation

6.1 Working principle

The main motor drives the grinding table by the main reducer. At the same time, the
hot gas from the inlet enters the mill. The material from the throat opening falls on the
center of grinding table. Under the influence of the centrifugal force, the material
moves to the edge of the grinding table and is grounded by the grinding rollers in the
grinding zone. The material ground further moves to the edge of the grinding table
until taken away by the gas current at the air ring zone. Some large particle blown
back on the grinding table is re-ground, other larger and heavier particle (including
hard impurity) falls to the bottom shell of the mill by the air ring, scraped into the
material discharge by the blade and discharged outside the mill at last. The powdered
material goes up with the air current and enters the separating zone of the separator by
the top shell of the mill. Under the action of the rotor blades of the separator, coarse

17
falls back on the grinding table to be re-ground. The qualified fine powder comes out
of the mill with the air current by the air outlet. Coarse is collected in the dust
collection equipment. The moisture of the material is dried in the full contact process
with air and solid to reach the required moisture of the product.

The VRM can be used for grinding, drying, separating and pneumatic conveying. All
the parts must mutually be coordinated t form the organic integration and play the full
pole of the VRM. In addition, when operating, the following questions shall be paid
attention.

·Stable material bed

The VRM performs the method of grinding in material bed, so stable material bed is
very important to the safe operation of the VRM. Under the normal circumstances, the
thickness of the material bed is about 20~30mm. At the moment, the operation of the
mill is smooth, the mill sound is soft, the external circulation of the material basically
constant. If there is no external circulation, small impurity (iron blocks, gangue) is
only discharged at the material discharge. If the material bed is too thin, the vibration
of the mill is decreased due to the big load. When serious, the mill shall result in the
violent vibration.

• Material Balance
The operation of VRM can efficiently be directed by analyzing questions at the angle
of the material balance. The feed volume, the grinding capacity, the conveying
volume of the air current, the discharge volume and the external circulation volume
should be in the balance conditions. Under the circumstances of the constant feed
volume, if the grinding capacity is insufficient, a great deal material shall be
discharged. At the moment the working pressure of the high- pressure oil station shall
be properly added to strength the grinding capacity, or the feeding volume shall be
properly decreased. On the contrary, the grinding capacity is too high, so the material
layer becomes gradually thin resulting in the vibration of the mill at last. At the
moment, the working pressure shall be properly decreased, or the feeding volume is
increased. Under another circumstances, if the grinding capacity is suitable, but the
conveying capacity of the air volume is insufficient, a great deal material shall be
discharged alike. If the fine powder content is bigger, the air volume shall be added
and the conveying capacity shall be strengthened at the moment. So the use of
material balance principles can find out the problems in advance in the operation of
the VRM. The corresponding measures shall be taken to avoid the unnecessary
shutdown.

• Air Volume and Air Temperature

This VRM adopts the negative operation .A great deal hot air is used for conveying
the material, classifying and drying. The air volume must first meet the requirements
of conveying the material. If the air volume is too small, a great deal qualified fine

18
powder fails to be discharged out of the mill in time. The big air volume causes not
only waste, but also the big particle of the product. The high or low temperature
shall be determined according to moisture of the mill feed material. If the moisture
content is high, the air temperature shall be increased. If the moisture content is low,
the air temperature shall be decreased. But the mill feed air temperature shall be equal
to or less then 350℃. In addition, the outlet air temperature shall be controlled within

the range of 80 to 100℃ to avoid the dew formation of the coal mill bag filter.

6.2 Preparation before Starting up

First, conform whether the corresponding brand lubricating oil has been poured into
the reducer of the separator, the main reducer, the mill rollers and the other parts of
the mill, and ensure that the rotating parts of the table have no the phenomena of
sticking and metal friction. If necessary the belt may be turned by hand to check the
rotating condition of the rotor of the separator. The mill rollers are turned a circle by
hand within the mill to check the flexibility of the grinding roller rotating (the
grinding rollers shall be lifted in advance). The coupling in the main reducer is turned
by hand to check the rotation of the grinding table. Attention！The lubrication oil

station shall be started up in advance to pour oil into the main reducer. No
turning without oil!

In addition, it is very necessary to check thoroughly the operating condition of the

pressuring device. For example, the accumulator is checked for filling the
corresponding nitrogen of pressure; the oil leakage of the high pressure oil station and
the pipeline; the normal adjusting of the working pressure of the high pressure oil
station and the reliability and effectiveness of the change of the change valve.

If the VRM runs with coal material for the first time, a no load trial test for the VRM
must be carried out in advance.
6.3 Starting-up Sequence

6.3.1 Starting Lubricating Oil Station

Adjust oil supply pressure and observe the temperature of oil supply whether to reach
the stipulated requirements; if the oil supply temperature is lower, open heating
device please; if the oil supply temperature is very high, please supply cold water to
cooler. The operation and requirements of lubricating oil station refer to “Lubricating
Oil Station Utilization and Maintenance Manual“.

6.3.2 Lifting Grinding Rollers

The two grinding rollers are lifted to leave from the grinding table, ensuring the main
motor can no –load start. Before these the limiting position limiting device should be

19
adjusted. Attention: The lifting height of the grinding rollers is limited and
generally doesn’t exceed 80 mm.

6.3.3 Starting up Separator Motor

Adjusting the speed governing controller to zero, starting the motor, and then
adjusting the motor rotating speed slowly until to the required rotating speed. During
this process closely pay attention to the operation conditions of the separator.

6.3.4 Starting up Main Motor.

Pay attention to the no-load electrical current, checking whether the mill in
idle-running has abnormal sound and checking the lubricating supply condition again.

6.3.5 Feeding Material and Falling Grinding Rollers

After feeding material for about 30-60 sec. (specific time should depend on feeding
material volume), we can fall the grinding rollers by operating the high pressure oil
station, then open the liquid pressure oil pump (setting up the working pressure of
high pressure oil station in advance). As soon as the mill normally operates, stop the
motor of the high -pressure oil pump.

Summarizing the above mentioned, the starting up sequence of the VRM is:
Starting lubricating oil station → lifting grinding rollers →starting up separator →

main motor →feeding material and falling grinding rollers.

6.4 Monitoring and Operating of the Mill in Running

When the VRM is in the stable running conditions, it need not specific operation and
can run for long time. Only when some process or equipment parameters change need
the relative process or equipment parameters to be appropriately adjusted in order to
adapt to the changed parameters and keep the VRM steadily and continuously running.
Instruments and meters in the control room can help productive personnel accurately
understand these process and equipment parameters. For example, output, temperature,
pressure, electric current, etc. In addition, productive personnel need often make
circuit inspection on site and check the equipment connecting bolts whether to be
loose, listen to equipment sound whether to be abnormal and observe the equipment
running whether to be stable. It has proved that monitoring instruments and meters as
well as making circuit inspection on site are indispensable to the successful
production.

The operation record of equipment is an important means for production managing, it

can help the technical and operating personnel analyze and solve the problems arisen
in the mill running and direct operation in future as well as improve the operating

20
level. So in the normal conditions a record should be made every hour, when the
process and equipment parameters frequently change the recording times should be
increased. In addition, the malfunctions should be recorded in detail.

6.5 Shut Down Process

The shut down of VRM is divided into normal shut down and emergency shut down.
The normal shut down carry out under the organized and planned conditions, but the
emergency shut down under the unexpected conditions when the mill normally
operating, for example, mechanical trouble, iron pieces enter into the mill, etc. So the
emergency shut down means is adopted to avoid greater damage.

Normal Shut Down

Stop feeding materials at first and carefully observe the electric current of main motor.
When the mill electric current have rapidly declined, open the by pass unloading
valve of the high pressure oil station at once, and then stop the main motor and
gradually drop the separator rotating speed to zero and finally stop the separator
motor. Pull the handle of change value and make it in the lifting grinding roller
condition, start the motor of high- pressure oil pump (the high pressure stopper valve
of the oil filling and returning pipeline corresponding to two working cylinders shall
be fully opened at normal working time). Attention: As far as possible ensure the
two grinding rollers lift at the same time, when the rollers get to position, close the
high pressure stopper valve and finally close the motor of the lubricating oil station.

Attention: when the main motor stops, don’t stop the lubricating oil station
operating at once and let it continuously run for about ten minutes. If we want to
restart the VRM in a short time, there is no need to stop the running of the lubricating
oil station.

The normal shut down sequence is as follows:

Stop feeding materials → discharge grinding rollers → stop main motor → stop

separator motor →lift grinding rollers→stop lubricating oil station motor.

Emergency Shut Down

Shut down sequence is:
Stop main motor→stop feeding materials →lift grinding rollers→stop separator

motor→stop lubricating oil station motor.

Ⅶ. Problems and Solutions

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If operation and maintenance are correct, the VRM should not have any problems and
failures, however, if it has problems, we should immediately discover and solve it.

Depending on our experience, there could be the following problems in operation.

.
7.1 VRM Vibration
Causes Solutions
The materials layer is unstable Check the feeding materials volume
whether to be stable. If the height of inlet
end ring is inappropriate, appropriately
increase or decrease the height of the inlet
end ring.
Air volume is not enough Check the entering mill air duct whether to
have blocks, increase the air volume of fan
Foreign matters on the grinding table Clean foreign matters and check iron
remover whether to have malfunctions.

7.2 Mill Pressure Difference Rising

Causes Solutions
Examine the system malfunctions Check the detection and indicator meter
whether to have malfunctions.
Feeding material volume is over bigger Decrease the mill feeding material volume.
If the main motor rated power admits,
appropriately increase the working pressure
of the high- pressure oil station.

7.3 Mill Outlet Air Temperature Descent

Causes Solution
Large moisture of material Increase the entering mill air
temperature.
Reduce the circulating air volume.
Decrease the mill feed.
Air leakage of mill Check mill flange, seal of grinding
roller door and air lock feeder for air
leakage.
7.4 The Products of Unqualified Fineness
Causes Solutions
Separator rotating speed is set up Improve the rotating speed
inappropriately.
Transmission belt slips Adjust and draw tight the belt
The air volume of entering mill is Reduce the fan load and set lower air
excessively bigger volume

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Section Three HRM1700M VRM Maintenance and Reparation
Ⅰ. Introduction

The maintenance of VRM is the key link to ensure the safe and efficient operation of
the equipment. It should be attached very great importance. In operation, the
equipment might cause some abnormal phenomena due to the change of the
conditions or the other causes such as the looseness of foundation bolts and other
fastening pieces, the loss of lubricating oil and the wear of parts and dirt. These
should worsen the equipment condition. If these problems are not handled in time, the
wear and the serious malfunction of VRM should occur, thus decreasing the service
life of the equipment.

HRM1700M VRM is a drying and grinding equipment with integrated technologies,

including mechanism, electricity, hydraulics, materials, thermal engineering and so on.
Seeing that the maintenance of HRM1700M VRM is more important than other
cement equipment, so the more perfect systems of operation and maintenance, the
three-level circuit inspections and the personal responsibility should be made out to
stop thoroughly the phenomena of oil leakage.

Ⅱ. Maintenance and Inspection of VRM

The maintenance and inspection of HRM1700M VRM should put emphasis on

lubrication, hydraulic pressure, adjustment, tightness and so on. The following should
detail the maintenance and inspection of HRM1700M VRM.

2.1 Circuit Inspection

The whole mill should routinely be inspected to avoid the emergency stop due to the
improper maintenance and lubrication. The wearing parts may be replaced in time in
the circuit inspection to ensure the running rate of the equipment.

Normal Inspection

2.1.1 Daily Inspection

a. Observe the mill for the abnormal noise and vibration during the normal
operation, and check the looseness of the foundation bolts and all fastening parts, and
the oil levels of the mill and the reducer;

b. Check the thin oil station and the oil pump for the oil pressure, the temperature
and the cooling water;

c. Check the lubricating sites of the moving parts of the separator and the air lock
feeder, and add oil according to the set lubricating oil system.

23
2.1.2 Weekly Inspection
a. Check the seal of the hydraulic pull rod of VRM and the oil levels of the
hydraulic station and the thin oil station;

b. Check all seals. If necessary, the air lock feeder and rubber boards should be
replaced. When stopping, the wear of grinding roller tyres and liners is to be checked
carefully, especially for their crack and collapse. Pay attention to use the another
surface of the grinding roller tyres in time. The looseness of the fastening parts of the
mill are to be seriously checked;

c. Check the wear of the separator blades

2.1.3 Key Inspection after Stopping for a Long Time

Some inspecting items are the same as weekly inspection. In addition, the following
items should be supplemented:

a. Check the wear and lubrication of the two grinding rollers;

b. Check the tightness of wear parts on the grinding table;

c. Check the wear of grinding rollers, grinding table, liners, air rings and other
components;

d. Check the hydraulic cylinder for oil leakage. If necessary, the sealing parts should
be replaced;

e. Check the wear of air outlet duct of mill;

f. Check the wear of the air lock feeder. If necessary, the sealing rubber board should
be replaced and the wear position should be re-welded;

g. Check the seals of all the inlet holes, inspecting doors and flanges. If necessary, the
seals should be replaced.

2.2 Maintenance and Reparation

2.2.1 Separator

The separator, located on the top of VRM, is a rotating one with a lower resistance. It
possesses the advantages of high classifying efficiency, reliable operation and easy
adjustment of product fineness etc. It consists of the main parts like motor, belt pulley
and triangle belts, main shaft and bearing rotor, housings and air outlet etc.

24
 Maintenance
Conditions for normal operation
Checks before start and in operation
1. The motor current couldn’t be larger 1. The tightness of connecting bolts of
than the rated current value. motor and reducer.
2. In the case of sudden crack of one or 2. The volume and quality of lubricating
more driving triangle belts, stop oil on lubricating points.
immediately for the replacement. 3. Check and adjust the tightness of
3. In the case of crack or fall of blades triangle belts.
of separator, stop for the 4. Look for causes of current fluctuation
replacement. of motor, if there is.
4. The reducer has not to run if it 5. Correspondence of the rotating speed
produces an abnormal sound and of the motor shown on control
vibration. instrument with the real motor rotating
speed.

Reparation
Troubles Resolving measures
The product fineness is not up to 1. Check whether the real rotating speed
standard, even if the separator runs at the is the same as that shown on the
greatest speed. control instrument.

2. Replace the blades of the separator:

Stop VRM and the equipment of the
grinding system, and put up a make shift
working table in the inside of VRM.
Remove the damaged blades and replace
them by the new ones. Then turn the rotor
for observing its running. If the rotor
rotates with a great eccentricity, the
blades on the rotor should be adjusted till
the latter realizes its equilibrium.
Vibration, noise and “fume” of the 1 1.The contact of gears is not good. Open
separator’s reducer the re-
d ducer to adjust the contacting surface is
nece-
ssary.

2. The high-speed shaft shakes in the

axial direction. The gears are worn
gravely or even broken.
2.
3. Bad lubrication or bad lubricating oil
(grease) quality.

Sudden increase in the motor current of The upper and lower bearings on the
the separator main shaft are damaged.

Stop the VRM and the other equipment

25
 of the grinding system. Firstly, open the
inspecting door of the reducer to know
whether the upper bearing is damaged. If
it’s really so, hoist apart the reducer to
replace the damaged bearing. Secondly,
put up a makeshift working table in the
inside of VRM, and demount the blades
and revolving drum of the separator in
order to replace the lower bearing.
The Users could make out the concrete repairing plan based on the practical
conditions. Please refer to Drawings of Separator Parts HRM13-01.

2.2.2 Upper Housing

The upper housing is a fixed section. The replaceable parts are sealing felts used for
doors of the grinding rollers, linings of the housing and upper air rings. The Users
could decide the replacement or no of these parts according to the concrete conditions.

2.2.3 Grinding Rollers

Maintenance
Please check regularly wearing of the grinding tyres, lubrication of the bearings, and
thermo-device of the bearings.

Reparation
The roller tyres and bearings on the grinding rollers are wearing parts. When the roller
tyres are worn to a grave degree, turn them over for continuous use. If the reverse
sides are worn again, and that results in a great decrease in VRM output, stop the
VRM to replace them by new ones.

The following procedures should be followed in the replacement of the roller tyres or
the bearings:
a. Read carefully the drawings of relative parts such as the grinding rollers,
transmission arms, and the principle drawings of the hydraulic pressure and drawings
of other relevant parts;

b. Demount the grinding rollers’ doors on the upper housing;

c. Depressure the operating cylinder in order that the assembly of grinding rollers
falls on the grinding table by its sole weight;

d. Demount the connecting axis pins between the moving arms and swing arms;

e. Connect the inspecting cylinder with the swing arms by pins for the hydraulic
pressure system being in a repairing state. Start the motor of the hydraulic pump, and
turn the grinding rollers out of the machine. When the assembly of grinding roller is
in a vertical state, close immediately the high-pressure spherical core cut-off valve

26
located on the high-pressure oil duct line of this inspecting cylinder. After the remove
of the studs and pressing rings used for fixing, the roller tyres can be demounted
easily (In the case of replacement of the bearings, the assembly of the grinding rollers
should be removed out of the swing arms and carried to the machine repair shop for
reparation). Then install new roller tyres or turn over the existing ones. When
installing, the parts should be cleaned up in advance; and after installing, it’s
necessary to check the contacting surfaces for their contact by a feeler gauge. When
the replacement is over, the assembly of the grinding rollers can be returned into the
inside of VRM according to a procedure opposite to that for roller tyres demounting.

2.2.4 Grinding Table

Maintenance
Please check regularly the scraper device, the linings and feed end rings of the
grinding table.

Reparation
a. Turn the assembly of the grinding rollers out of VRM according to the procedure
used for repairing of the roller tyres or bearings;

b. Open the inspecting doors of the lower housing, then check or replace the scraper
blades of the scraper device;

c. Loosen the bolts on the pressing rings of the grinding table linings and those on
the gland, and remove the glands. Pry up the old linings with a crowbar and hoist
them out of the inside of VRM, then install the new ones. When installing the new
linings, we should do our best to keep the linings fitted straightly and evenly. Each
pressing ring should press its corresponding lining without any loose. The gaps
between the linings should be filled with asbestos ropes. Filling the gaps with metal
pieces is forbidden.

2.2.5 Driving Unit

Maintenance
For the maintenance of motor, thin oil station and reducer, please refer to the
corresponding “Operation and Maintenance Manual”.

Reparation
In this paragraph, only how to remove the reducer from the lower section of VRM
will be described in detail:

a. Be sure to stop VRM and all of the other equipment of the grinding system:

b. Take off the connecting bolts and positioning pins of the grinding table ;

c. Weld an eye ring at the upper flange (where the inspecting door is) of the upper

27
housing (turning the grinding rollers out of VRM shouldn’t be influenced).

d. Take off the connecting bolts of the motor and the coupling, and as well as the
lubricating oil supplying and returning ducts, then remove apart the motor and the
coupling;

e. Suspend the grinding table by a manual pulley of capacity 5t, and make it leave
the reducer;

f. Take off the connecting bolts of the reducer, and remove away the reducer from
the lower section of VRM for reparation in the machine repair shop.

2.2.6 Hydraulic Pressure System

The hydraulic pressure system compounds hydraulic pressure pipe-line, operating oil
cylinders, inspecting oil cylinders and hydraulic pressure station…

Maintenance
The maintenance of the operating oil cylinder, inspecting oil cylinder will be done in
referring to its Operation and Maintenance Manual.

Ⅲ. Lubricating Oil Table

No Lubricating Sites Lubricating Oils Grade Standard No. Oil Change or Pour
1 Main reducer See “Operation Manual
of Main Reducer and
Lubricating Oil Station”
2 Bearings of grinding roller Universal lithium No,3 GB7324-87 check every week
base lubricating
grease
3 Bearings of rotor of Universal lithium No,3 GB7324-87 Once a shift
separator base lubricating
grease
4 Reducer of separator ulfur phosphorous N220 GB5903-19 Once every 1-3
95 months
industrial full
pressure gear oil
with middle load
5 Sliding bearings of Universal lithium No,3 GB7324-87 Once a shift
transmission arms base lubricating
grease
6 Oscillating bearings of Universal lithium No,3 GB7324-87 Once a shift
two ends of oil cylinder base lubricating
grease

28
Section Four. Drawings

29