ERECTION 70010182_A-P________1.0_EN

Atox mill 32.5 - 52.5

Erection instructions

Approved date: 28-04-2011 Created by: PSP Approved by: BL

Doc. No.: 70010182-1.0

Atox mill 32.5 - 52.5 70010182-1.0

Table of contents Page 1 General infor mation ............. .............. ............ ............. .............. .............. ....... 4

2

1.1 Scope........................................................................................................... 4 1.2 Design ......................................................................................................... 4 1.3 Normative references ..................................................................................... 5 1.4 Documentation .............................................................................................. 5 1.5 Definitions and abbreviations .......................................................................... 5 1.6 Legend ......................................................................................................... 5 Design and operating principle ........................................................................ 6

3

2.1 Construction ................................................................................................. 6 2.2 Operating principle ........................................................................................ 7 Safety instructions ........................................................................................ 8

4

Erection ...................................................................................................... 9

5

4.1 Mounting of foundation parts .........................................................................10 4.2 Mounting of mill housing................................................................................13 4.3 Mounting of gear unit ....................................................................................15 4.4 Mounting of grinding table and nozzle ring .......................................................16 4.5 Mounting of grinding rollers ...........................................................................18 4.6 Mounting of grinding rollers on centre piece .....................................................19 4.7 Mounting of the tensioning system..................................................................20 4.8 Mounting of the torque arms and buffers .........................................................24 4.9 Adjustment of rollers on the grinding table ...................................................... 25 4.10 Mounting of sealing air/oil/water connection .................................................... 27 4.11 Final erection ...............................................................................................28 Operation ................................................................................................... 28

6

Maintenance ................................................................................................

7

KEY TO APPENDICES .............. .............. ............ .............. .............. ........... ...... 29

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

28

Atox mill 32.5 - 52.5 70010182-1.0

List of appendices Appendix 1 ................................................................................................................. 32 Appendix 2 ................................................................................................................. 34 Appendix 3 ................................................................................................................. 36 Appendix 4 ................................................................................................................. 38 Appendix 5 ................................................................................................................. 40 Appendix 6 ................................................................................................................. 42 Appendix 7 ................................................................................................................. 44 Appendix 8 ................................................................................................................. 46 Appendix 9 ................................................................................................................. 48 List of figures Figure 1. Positioning of cylinder brackets ........................................................................ 12 Figure 2. Nozzle ring .................................................................................................... 16 Figure 3. Mounting of joint head .................................................................................... 21 Figure 4. Positioning of joint head .................................................................................. 22 Figure 5.Taper sleeve adaptation Figure 6. Locking plate adaptation ............................................................................... 22 Figure 7. Adjustment of position for roller assembly......................................................... 26 Figure 8. Positioning of roller assembly .......................................................................... 26

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0

NOTE! Reference by seller to any international or national standard does not incur an obligation on seller to provide any recipient, reader or user of the documentation with samples or copies of the said standard(s). Hence, any recipient, reader or user of the documentation is expected – at his own cost – to obtain necessary knowledge of the contents of any of the standards referred to.

NOTE! The present instruction manual is concerned with the situations which, acc

ording to the

experience FLSmidth, are the most likely to occur. An exhaustive enumeration of and all conceivableof situations, which may occur during manufacture, installation, operation maintenance of the equipment, cannot be provided. is not foreseen in the Consequently, if a situation should arise, the occurrence of which instruction manual, and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without undue delay for a dvice on appropriate action.

1

General information 1.1

Scope The present instruction manual deals with the erection of Atox mills. The instruction manual is general for Atox mills, but since this mill type is available in various sizes depending on the grinding job concerned, some sections in the manual may be ignored. The instruction manual must be considered as being a master manual, because extensive reference is made to detail instruction manuals for the individual mill components. The present and other relevant instruction manuals must be studied carefully prior to starting erection. Erection procedures are often of a general character, because many relevant factors relate to specific or local conditions, and a detailed and comprehensive description hereof is therefore not possible in an instruction manual. All work in connection with the erection of the Atox mill must only be performed by qualified, skilled personnel who are familiar with the mill structure and operating principle and related safety equipment. All modifications and changes relative to the srcinal design are unless FLS has been informed and has approved the changes.

prohibited,

The mill plant dealt with comprises also various separate instruction manuals containing detailed information about erection and safety related to the other machines or arrangements of the mill plant. For installation of mill gear unit, reference is made to separate instruction manuals from the supplier of these machines.

1.2

Design The Atox mill is a vertical air-swept mill designed for grinding of raw materials. The raw materials are fed into the mill via the rotary sluice from where it is directed on to the rotating grinding table by the feed chute. The grinding process takes place between a and 3 rollers turning on fixed shafts.

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horizontal, rotating grinding table

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 The grinding pressure is generated partly by the weight of the rollers and the centre piece and partly by the three hydraulic cylinders which thrust the rollers down against the grinding table. Hot air is supplied to the mill through a nozzle ring, which is mounted around the grinding tabl e. The air stream carries the ground m aterial up to an air separator, that lets the final product proceed to the mill outlet while returning the coarse fraction to the table for further grinding. Having left the mill at the top, the final product continues with the air to a c yclone or a bag filter where it is collected.

1.3

Normative references The Atox mill is prepared deployment in aby cement whichauthorities should be and approved according to thefor standards applied the plant, regulatory FLSmidth. Local regulations take precedence over instructions manuals. For dated references to any publication, subsequent amendment s to or revisions of any of these publications apply to this instruction only when incorporated in it by amendment or revision. For undated references the latest edition of apply.

1.4

the publication referred to shall

Documentation Since the present instruction manual must be considered as a master erection manual, extensive reference is made to detail instruction manuals for the mill components concerned. Moreover, reference is made to s eparately forwarded outline and load drawings and erection drawings.

1.5

1.6

Definitions and abbreviations Authorized person

An authorized person is a skilled person, who is qualified and who by either the responsible manager or a qualified person is entrusted with certain tasks.

External expert

A specialist is educated and trained in an equipment supplier company and may be educated as either a skilled person or an engineer.

Internal expert

A specialist is educated and trained in the cement manufacturing plant and may be educated as either a skilled person or an engineer.

Certified person

A person, who is skilled and authorized from any legal authority to perform tasks, which must be certified by a third party or w hich requires a legal authorization to perform.

Skilled person

A person, who after an education as a craftsman, is capable of doing skilled work.

NA

Not applicable

O&M

Operation and maintenance

Legend

Mandatory! This symbol appears in the instruction manual to indicate dangers which, in case of non-observance, may cause fatal or serious injuries!

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0 Attention! This sign is shown in the instruction manual where specific attention and caution is needed to avoid damage to or destruction of the equipment and/or parts of the installation.

2

Design and operating principle 2.1

Construction The ATOX mill essentially consists of a drive station, grinding machinery, nozzle ring and an ai r separator. In regard to the dynamic separator RAR-L, reference is made to separate FLS instruction manual “Separator RAR-L ”. For gear unit, see separate instruction manual. The drive station consists of motor (09), c oupling and gear unit (08). The torque of the motor is transmitted to the grinding table of the mill via the gear unit. The gear unit is a bevel gear unit. A segmental thrust bearing is mounted on the gear unit to support the grinding table and grinding rollers. The w eight of the grinding machinery and the grinding pressure are transmitted to the gearbox through this thrust bearing, and the pressure is subsequently transmitted to the foundation of the mill. The grinding machinery consists of the grinding table (03), the grinding rollers (01), the centre piece (02) and hydraulic tensioning system. The grinding table assembly feature s a circular grinding track which c onsists of segments manufactured from wear-resistant white cast iron with a chromium alloy. The segments are fitted on the grinding table by means of a number of retainer clamps with through-going bolts to force the segments down against the grinding table. Along the periphery of the grinding table is fitted a dam ring to retain the material to be ground on the grinding track, thus forming a grinding bed of a certain thickness. A segmented seal and a s ealing ring are fitted at the point where the grinding table extends through the partition of the mill housing. Fitted to the lower part of the grinding table are scrapers which are used to divert any material and foreign objects - dropping through the nozzle ring onto the bottom plate - to the spillage outlet where extraction of such material takes place. The three grinding rollers are stationary in relation to the mill housing but rotatable about the roller shafts, which are fixed to centre piece. The rollers rotate around the roller shaft in oil-lubricated roller bearings. The rollers are provided with wear segments which are fixed by means of retainer clamps and through-going rod screws. The roller shaft is equipped with polished wear rings and shaft seals, the function of which is partly to retain the oil charge of the roller and partly to prevent ingress of dust into the roller. The seals of the rollers are also protected against dust infiltration by means of a sealing air system; the air intake of the latter is equipped with a filter. From the wall of the mill housing the s ealing air duct is connected to the centre piece. From the centre piece, the sealing air passes through drillings in the centre piece and roller shafts to the air seals of t he three rollers. These seals consist of rings, which form c hambers around the shaft seals. The pressure in the sealing air chambers is always higher than in the mill housing. This will

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 prevent ingress of material into the shaft seals, thereby eliminating the risk of damage to the seals. In the tube for oil, the circulating oil s ystem feed and drain piping connect the rollers to the outside piping. For a full description of the lubrication system, see separate instruction manual. The same duct will have the water injection pipe from the pump station to the manifold attached to the bottom of the centre piece: from where water is branching out and spray over the grinding track at three places in front of the rollers. The hydraulic tensioning device consists of a tensioning s ystem and hydraulic equipment; a description of the latter is given in separate instruction manual. The tensioning system consists of three tension rods and three torque rods. The tension rods and the torque rods are attached to the joint heads, which in turn grip the end of the roller shafts. The tension rods are directly connected to the piston rods in three hydraulic cylinders. Through the tension rods the hydraulic cylinders deliver a pulling force, which, in conj unction with the weight of rollers, centre piece and tension rods, generates the necessary grinding pressure. The hydraulic tensioning mechanism can also be used to from the grinding track.

lift the rollers away

The hydraulic cylinders are connected to nitrogen-charged pressure accumulators which act as grinding pressure springs. The torque rods retain the rollers in their positions during the rotation of the grinding table. They are connected to the rollers through the joint heads and to the mill hous ing through rubber buffers. The nozzle ring directs the

air stream around the grinding table.

The ring consists of a rim of segments fixed with bolts to the supporting ring in the gap between grinding table and supporting ring. The nozzle ring area can be adjusted by welding on plates. The separator is installed above the mill housing, being connected to the latter through an air-tight flanged joint. See s eparate instruction manual for air separator.

2.2

Operating principle Feeding of material to the mill is handled by the rotary sluice, w hich feeds the material into the mill, while, simultaneously, the unit functions as an air sluice. See separate instruction manual for the rotary sluice. From the rotary sluice the material drops down onto the grinding table through the inlet chute and slides onto the grinding track where it is s ubjected to grinding in response to the c ontact pressure and seizure between the grinding rollers and grinding track, and, eventually, the centrifugal force will cause the material to be thrust beyond t he outer edge of the grinding table. The finer part of the ground material is entrained in the hot gas stream from the nozzle ring ducts and is carried up to the separator. The tailings are dropping through the nozzle ring and are returned through the external mechanical conveying system to the grinding track for additional grinding. The material to be s eparated passes through the guide vanes of the s eparator and continues into the rotor of the separator. The guide vanes will ensure that the material is evenly distributed across the entire height of the rotor, while, simultaneously, it provides an effective pre-separa tion of the grinding material by bringing into rotation the mixture of gas and ground material. The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0 While the finest fraction passes through the rotor and on through the outlet, the coarser particles are thrown towards the guide vanes due to the centrifugal force or due to the impact with the rotor blades, causing them to drop into the reject cone below the rotor, wherefrom they are returned to the grinding table for additional grinding. The fineness of the finished product can be adjusted by varying the speed of the rotor. The grinding pressure, and hence the production rate of mill, can be raised or lowered by increasing or decreasing the hydraulic pressure in the cylinders. See also process instruction manual for the entire mill plant. During start-up and in active operation, a certain amount of material, i.e. the grinding bed, must be maintained between the grinding rollers and grinding track to avoid direct contact between the grinding rollers and the grinding track.

Mandatory! Any one assigned to work on the mill must be familiarized with the relevant safety regulations and the specific requirements to be met. This applies also to any person(s) not directly employed by the plant, for example workers assigned to perform duties in the proximity of mill or on the mill itself.

ATTENTION! 1) Where specific request for ERECTION CHECK is made in this erection manual, this means that the erection supervisor must inspect and approve the parts installed before the erection work can be continued. 2) When welding, the earthing terminal must never be placed so that the electrical current will pass through any parts of the hydraulic system, bearing pads, roller bearing or plain bearings. 3) Rotation of the grinding table must never occur unless the pump station of the gear is in operation.

3

Safety instructions The directions outlined in instruction manual No. 32031 "General safety regulati ons at erection site" must be strictly observed at the site of erection. The ATOX Mill has been designed in accordance with applicable standards and recognized safety regulations.

the

Nevertheless, the ATOX Mill may pose a potential risk to the life and health of the operator or any third party and may cause damage to the machine and other objects. The ATOX Mill must only be used subject to the correct technical circumstances as defined in existing instruction manuals. FLSmidth must be notified immediately of any functional irregularity, particularly any irregularities which may affect the safety of the machine. Failing such notification, FLSmidth will disclaim responsibility for any functional irregularities and any consequences hereof.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 The erection, operation, maintenance, repair and transport of the equipment must be carried out by specialized personnel having the necessary skills. In this context, it is essential to ensure that all relevant rules and regulations for the prevention of accidents are held available at all times. It is a prerequisite for the performance of any repair work, assembly operations and maintenance work that the ATOX Mill has been taken out of operation. When carrying out such activities, it is essential to ensure that it will be impossible to restart the ATOX Mill, e.g. by means of a remote control unit. FLSmidth will not assume responsibility for any damage resulting from abuse/improper operati on/inadequate maintenance of the ATOX Mill or its operation or maintenance by unqualified personnel, including personnel who have not acquired the skills required to operate the machine on the basis of the directions provided in the technical documentation. The liability of FLSmidth is restricted to the terms and conditions laid down in the tender/contract. The safety-related information contained in this manual and all other relevant safety regulations must be observed for all types of application of the ATOX Mill. Strict enforcement of the procedures and regulations outlined in ultimate responsibility of the user.

the manual is the

If technical information beyond that provided in the present manual should be required, please contact FLSmidth.

4

Erection

Mandatory! The directions outlined in instruction manual No. 32031 "General safety regulations at erection site" must be strictly observed at the site of erection. This instruction manual must be scrutinized by the client, the erection contractor and FLS representatives, before erection work is started.

The concrete work on the foundation must be carried out according to the instruction manual: Structural design and erection. During erection, some mill parts, especially mill housing and nozzle ring, may require some adjustments. If an excessive amount of adjustments seem to be required, please contact FLS for remedial action.

Mandatory! The erection/maintenance activities described in the following sections must only be carried by skilled machine specialists or subject to the supervision of such specialists.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0

4.1

Mounting of foundation parts See Appendices 1, 2, 3 and the foundation drawing. The foundation parts consist of the gear plate (13), three brackets (11) for the tensioning device and foundation rails (15) for the mill motor. 4.1.1 Execute a concrete block-up between the mass concrete and the gear plate. Block –up to consist of a number of foundation plates with embedded bed plates to support the adjusting screws (14) of the gear plate. At the same time execute concretethe block-up between the concrete and mill housing, placed inabetween foundation holes of mass the housing. Height of block-up to be such that the gear plate can be levelled by means of the adjusting screws. ERECTION CHECK Proceed as follows: Mark out the centrelines of the mill on the positioning of the foundation bolt holes.

base foundation and check the

For reference, mark out an elevation point close to the base foundation and check the height of the base foundation. ERECTION CHECK Establish the correct position for the concrete blockings (under the adjusting screws of the gear plate) and use chalk or the like to mark out the position on the base foundation. Determine the centre height h c of the gear unit, i.e. the distance from the horizontal centreline of gear unit to the lower edge of the gear plate. See Appendix 2. ERECTION CHECK Establish the level for the centreline of gear unit, and use levelling instrument and the distance h c to determine the level for the upper edge of the bedplates which are to be embedded in the concrete blockings. For alignment purposes, space must be allowed for intermediate plates with a thickness of about 10 mm.

Bedplates and intermediate plates should be fabricated at site.

Execute a number of wooden frames, approx. 200 mm larger than the bedplates on all sides. Place the frames in the designated positions on the base foundation. Then fill the frames with a relatively stiff cement mortar. Place the bedplates on the mortar and force them down until they are placed at the correct height. Use a spirit level to check that the plates are placed horizontally.

The grouted concrete blockings must be allowed a few days to harden in order to acquire the necessary strength before the gear plate is mounted on the bedplates. The compressive strength of the concrete blockings must be equivalent to that of the base foundation. 10{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

Mount the gear plate on the foundation with the adjusting screws resting on the bedplates and with the foundation bolts inserted in their holes.

Always remember to clean and degrease the foundation bolts before they are mounted and grouted. The concrete must be v ibrated during grouting to ensure that the foundation hole is filled completely. ERECTION CHECK Align the gear plate in relation to the mill centre, and level the gear plate by means of the adjusting screws. ERECTION CHECK Grout the foundation bolts so that the concrete is lower than the upper edge of the mass concrete, refer also to the instruction manual: Structural design and erection. ERECTION CHECK Wait 3-4 days a nd then execute the fine alignment of the

gear plate.

Execute a block-up consisting of sectional irons and intermediate plates between bedplates and gear plate. Place the blockings as close to the foundation bolts as possible to avoid distortion of the gear plate during alignment. Adjust the number of intermediate plates and check the level and alignment very carefully by means of a levelling ins trument. Slacken the adjusting screws and t ighten the foundation bolts following each check-up. Use the supplied tools. In connection with the performance of adjustments and measurements, attention must be given to the correlation between sunshine exposure and a temperature increase of the frame. Such exposure may cause substantial deflection of the frame. Subsequent to grouting, the height variation A on the gear plate must not exceed the maximum limit indicated in the table below:

ATOX MILL A in mm

32.5 0.20

35.0

40.0

45.0

37.5

42.5

47.5

0.20

0.30

50.0 0.40

52.5 0.50

ERECTION CHECK Enter the values applying prior to grouting on the inspection form for the gear plate.

A copy of inspection form is s hown in Appendix 3.

The gear plate shown on the inspection form may be different from that supplied in this particular cas e due to a different gearbox design. The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0

Always remember that it is the height differential which must be indicated on the form. For example, the l owest point should be awarded the valu e 0 so that the height differential is directly indicated by the other values.

A straightedge and precision spirit level can be used for checking provided that information about the distance between measuring points, the graduation of spirit level and the position of the level bubble is given on the inspection form. 4.1.2 Place the twelve supporting profiles (12), included in the supply, on the mass concrete, across the holes of the foundation bolts for the brackets (11). Carefully clean and degrease the foundation bolts prior to grouting. Place the brackets on the supporting profiles (12) with foundation bolts and anchor plates (10) inserted in the holes. See also assembly drawing for

the brackets.

In order to ensure correct positioning of the brackets, the following procedure can be a dopted: 1. Determine the centre of gear plate (mill) by running strings, or piano wire, through the two centre lines a and b of the gear plate. See Fig. 1 Rectangularity must be ensured!

Figure 1. Positioning of cylinder brackets

2. Set off D 0 (c) at right angles on both sides of c entreline b. (D 0 represents the diameter of the grinding table. The example in Fig. 1 is taken from an ATOX 20 mill, i.e. D = 2000 mm). Set off D at the centre of mill and again at 0 0 distance of D 0 / 2 x 1.1 55 mm (d) from the centre. Check by diagonal measurement that the dimensions are set off in parallel. 3. The centreline for roller I and III is lying in the two diagonals as shown in Fig. 1. The centreline for roller II is lying in the centreline “a” of the mill.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 4. Place the centre of the brackets on the three centrelines at the distance from mill centre specified on the assembly drawing. Grout the foundation bolts in place so that the concrete is lower than the upper edge of the mass c oncrete, refer to the instruction manual: Structural design and erection. Use a vibrator. Move the supporting profiles close up against the foundation bolts after the concrete has set so that they provide maximum support for the brackets, and align the brackets until they are lying in the same plane as level 0. See foundation drawing. Shim pads for supports must be made at site. Use a sledge hammer to apply a few blows to the supporting brackets so as to ensure that possible projections in the concrete under the supporting profiles are eliminated. Tighten the foundation bolts lightly, and check that the brackets are resting on the shim pads when the level is correct. The final tightening of the foundation bolts must not take place until regrouting has been executed, following complete embedment of the bracket. The bolts must be tightened according to the specifications on the assembly drawing. 4.1.3 Mount motor foundation rails (15) and foundation bolts and align them so that they are lying at the same plane as the foundation plate of the gear unit. Fix the foundation rails to the gear plate by welding as indicated on the assembly drawing.

ATTENTION! The embedment of most foundation parts should not take place until the mill housing has been mounted. However, it may be advantageous to execute the embedment of the gear plate, and possible the brackets, before the mill housing is mounted. Check that no points project above the rails between the foundation rails or in the immediate proximity of the rails, since this might prevent the rails from functioning as sliding rails in connection with the installation of gear unit and a withdrawal of gear unit. ERECTION CHECK Enter ascertained values subsequent to grouting indicated on the form for the gear plate, and forward the form to FLS.

4.2

inspection

Mounting of mill housing 4.2.1 If the mill housing (04) arrives at site dissembled into sections requiring weldup at site, welding must be performed in accordance with the following guidelines: Welding must be performed by certified welders or welding operators holding similar qualifications who are capable of meeting the standards of welding quality stipulated on drawings. For standards of quality, see general workshop instructions 520530.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0 Use the shims with a thickness of 2-4 mm, during weld-up of components in order to compensate for the contraction which occurs during welding and chipping. Use the so-called “adjusting irons” for alignment of the plate edges prior to welding (these irons are included in the supply). After welding the “adjusting irons” must be burnt off approximately 5 mm above the housing wall. The remaining part must be removed very carefully by grinding. Weld scars on the housing wall must not occur. This applies also when removing welded-on bracings. ERECTION CHECK Cut off the section of the base flange of the mill housing which, for the reasons of transportation, has not been cut

(in the gear opening) off in the workshop.

4.2.2 The base flange of the mill housing is equipped with bolt holes for the foundation bolts and bolts used to fix the mill housing against the brackets (11). The mill housing is also provided with adjusting screws (14) at the brackets, see Appendix 2. Place the foundation bolt in the holes in the base drawing.

flange. See also assembly

Place the mill housing on the brackets (11), with the foundation bolts suspended from their holes, so that the centrelines of mill housing and gear unit coincide. For optimum efficie ncy of the seal around the grinding table i t is essential to ensure that the housing is centred exactly around the mill/gear unit centre. Use a plumb line as benchmark for measurements. As an alternative, the foundation bolts can be inserted in their holes before the mill housing is placed on the brackets. The bolts must then be guided into place in the holes of the base flange. Align the mill housing by means of the adjusting screws and insert shim pads between the base flange of mill housing and the brackets and between the base flange and the embedded bedplates. Relieve the adjusting screws and fix the mill housing to the brackets. Grout the foundation bolts in place. Check the position and alignment of the mill housing, and tighten the foundation bolts lightly after the concrete has set.

ERECTION CHECK The bolts must not be tightened up until the grouting of the base flange has been complete d. For correct torqu e level/force, consult drawing. Also check the planeness of the intermediate floor. For optimum efficiency of the seal around the grinding table, it is essential that the intermediate floor has the required degree of planeness and that it is welded horizontally into the housing.

ERECTION CHECK Measure the distance between the intermediate floor of mill housing and the gear plate. The distance is stated on the foundation drawing. If this distance is 14{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 inadequate, it must be adjusted by inserting shim pads of appropriate thickness between the base flange of the mill housing, brackets and bedplates.

ERECTION CHECK Relieve the adjusting screws, and bolt

the mill housing and brackets together.

All shim pads must be carrying loads when the foundation bolts are tightened lightly.

4.2.3 Embedment of foundation parts and the base of the mill housing must be carried out immediately after the final alignment and check. ALWAYS REMEMBER to remove loose rust and grease, if any, prior to embedment. Vibrate the concrete thoroughly to ensure that all cavities are filled. The surface of the concrete must be positioned at lower point than the foundation rails to ensur e unrestricted entry and withdrawal of g ear unit. See also specific layout drawings for plant concerning concrete surfaces etc. After the concrete has been allowed a period of 3-4 days to set, the foundation bolts must be tightened to torque level/force specified on the assembly drawing. 4.2.4 See Appendix 4 Mount the labyrinth seal (20) loosely on the intermediate floor of the mill housing before the grinding table is mo unted on the gear flange. Align a nd mount the seal subsequent to the installation of gear unit and grinding table. ERECTION CHECK 4.2.5 Install the DENSIT lining on the intermediate floor as indicated on the assembly drawing. See separate instruction manual for t he installation.

4.3

Mounting of gear unit 4.3.1 Gear unit The gear unit can be mounted before the mill housing is mounted, but, in the following, it is a foregone conclusion that the gear unit is mounted subsequent to the installation of the mill housing. See separate instruction manual for gear unit.

4.3.2 Mill motor Before the gear unit and motor are connected, check that the grinding table is rotating in clockwise direction at the foreseen direction of rotation of the mill motor shaft. The gear unit and the coupling between gear unit and motor must be installed and adjusted as directed in s eparate instructions. The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill 32.5 - 52.5 70010182-1.0

4.4

Mounting of grinding table and nozzle ring Refer to Appendices 1,4 and Fig.2. 4.4.1 Grinding table Clean the contacting faces between grinding table and gear unit. Screw the 3 supplied lifting eyebolts into the threaded holes on the surface of the grinding ta ble. Insert the bolts very carefully so that bending stresses are avoided when lifting the table. Lift the grinding table onto the

gear flange.

Be very careful because of the loosely mounted labyrinth seal (20). Tighten the bolts in the flange between gear unit and grinding table to the correct tor que level/force. See assembly drawing. Use the hydraulic tools included in the supply. ERECTION CHECK Carry out the final adjustment of the seal and fasten it around the grinding table. Mount sealing r ing (19) for l abyrinth seal (20). 4.4.2 Nozzle ring Assemble the segments for Nozzle ring (30) and supporting ring (31) in pairs. See Fig. 2. Place the assembl ed segments o n the flat iron fl ange (33) which is welded in place inside the mill housing. Position of s egments relative to grinding table to be adjusted by inserting shims between the nozzle ring and grinding table until the distance along the entire circumference of the table corresponds to that specified on the assembly drawing. ERECTION CHECK Weld the supporting ring onto the mill housing as indicated on the assembly drawing, and remove the shims. Mount the remaining part of nozzle ring, including the guide cone (29), in accordance with directions given on assembly drawing.

Figure 2. Nozzle ring

16{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 Adjust the flow area to the desired value (see drawing/parts list or discuss with commissioning person) by mounting the supplied adjusting plates (32) in the nozzle ring. Initially tack weld the adjusting plates to the nozzle ring vanes. After optimizing the mill operation, final weld can be done as described in the assembly drawing. Adjustment of flow area cannot be made prior to commissioning of mill, since the adjustment depends on the nature and lump size of the material and other operational parameters as well. 4.4.3 Grinding track A partial assembly of the grinding track may have been made in the workshop, if not it must be assembled as follows: Clean the grinding table. Mount the internal bolts for fixation of the wear segments from the interior of the grinding table. Mount the locking nuts (28) on the grinding table. See appendix 4 and the assembly drawing. Mount the central cover (16) and fix it. Mount the loc grinding track.

king pins (18) in the

Use the supplied tools to lift the grinding segments (17) onto the grinding track and pull them, one at a time, towards the inner edge on the grinding table, and insert distance irons (27), see also assembly drawing. If necessary insert shims between table and clamp, see also assembly drawing. Note that the segments are extremely wear-resistant with a hardness, but with low toughness characteristics.

high degree of

The brittleness of the parts is such that the parts may break if handled improperly. Extreme care is needed in c onnection with all transportation and erection procedures. Rough handling of the parts involves significant risk of breakage. Check that the segments bear well against the grinding table over the entire contact face. Use a feeler gauge for checking. If the contact between the segments and the inner edge of the grinding table has to be improved, this can be done by grinding the segments; however, this must only be done if specifically agreed with FLS. Due to risk for crack formation grinding of the castings must be done only i exceptional circumstances, subject to prior agreement with FLS.

n

It must be strongly emphasized that the process of grinding must not under any circumstances involve heating of the segments. Fix segments with clamps (26) both on the inside and outside as shown on the assembly drawing. Retighten all screws to the correct torque level. See assembly drawing. Then mount the dam ring on the edge of the grinding table. First mount the eight segments (25) of the supporting ring on the grinding table by means of the appertaining screws. Place the intermediate rings (23) and dam ring (22) on the supporting ring. Ensure that they are m ounted through staggered bonding. Variation in the thickness of the supplied sections may occur, and therefore, the height can be adjusted within a range of 10mm. Then the bolts (24) are tightened as specified in the assembly drawing. ERECTION CHECK The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

17 49

Atox mill 32.5 - 52.5 70010182-1.0 ATTENTION! Always remember to retighten the bolts used for retention of grinding table segments and the dam ring after 8 hours, and again for every 24 hours of operation, to the correct torque level until the torque remains constant. Check that height of the dam ring is correct in relation to the grinding track (see drawing/parts list or discuss with commissioning person). The height can be adjusted by using intermediate rings (23) of varying thickness. 4.4.4 Scrapers Mount the scrapers (21) under the grinding table. The grinding table is provided with threaded holes for the scrapper screws, which, when tightened , must be secured through tack-weldin g. Check that the scraper skims the top surface of the densit lining in intermediate floor, without touching it, when the table is rotating. The number of incorporated scrapers may vary from mill to mill, see drawings. ERECTION CHECK ATTENTION! The grinding table must NEVER be the gear unit is in operation.

4.5

rotated unless the pump station of

Mounting of grinding rollers Refer to Appendix 1 and 5. 4.5.1 Grinding roller The grinding rollers normally arrive at site in the assembled state. When unpacking the parts, check that all sealing air and lubrication channels in t he rollers and centre piece are closed. Do not remove the plastic plugs until it is absolutely necessary to do so. ERECTION CHECK In case the openings in c entre piece and rollers have not been covered by plastic plugs or cover plates, there is a risk that the parts have been contaminated, and it is absolutely essential to ensure that all contaminants are removed before the parts are mounted. If contamination of the grinding rollers is suspected, it will be necessary to dismantle the rollers in order to check, and if necessary to cl ean, bearings, seals etc. before the rollers are rea ssembled. It is very important th at all openings are closed with plugs when the rollers are re-assembled. The rollers have been dismantled and ass embled in accordance with the procedure outlined in operation and maintenance manual. 4.5.2 Rollers are delivered to site w ith or without assembled wear segments. ATTENTION! If the rollers are supplied with the wear segments shop-fitted, the tightening rate must be checked before the mill is put into operation. If the wear segments are not assembled, mounting can be done before or the rollers are fixed to the centre piece as per the following procedure:

18{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

after

Atox mill 32.5 - 52.5 70010182-1.0 Mounting of wear segments on

grinding rollers

Use the screw (47) to fit the retainer clamps (46) on the

roller hub.

Smear the conical faces of the retainer clamp with grease containing a molybdenum disulphide additive. Mount the pin (37) on the cylindrical surface of the ro

ller hub.

Use the available lifting gear to position one wear segment (36) on the top of the cylindrical face of the roller so that the line of symmetry of the retainer piece coincides with the c entreline of the segment. Check that the segment lies true against the cylindrical contact face of the roller. If this is not the case, the underlying cause must be identified and remedied. Grinding on segments must not take place unless sanctioned by FLS. ERECTION CHECK Screw two rod screws (35) into the retainer clamp at the wear segment. The end of the screws must be flush with the s urface of the retainer clamp. ERECTION CHECK Before fixing clamp (34), mount a glass cord around the ingress of raw meal into the bolt hole.

rod screw to prevent

Place a retainer clamp (34) on the two rod screws. Smear the conical face of the retainer clamp and the thread of the rod screws with grease containing a molybdenum disulphide additive. Fit nuts on the screws and tighten the nuts, while easing the clamp slightly, with the hydraulic tool, applying a force at 50 per cent of the specified level. ERECTION CHECK Mount all the wear segments on the three rollers in similar manner. The segments must be evenly distributed over the circumference of the roller hub. Tighten the rod screw nuts one more time, this time applying the full tightening force level, and check s imultaneously, that the segments lie true against the roller hub. Check that the clamp with double conical surface is correctly positioned without gaps between the conical s urfaces of the clamp and segment. ERECTION CHECK Fit the protective caps (39) for the nuts after full tightening of the bolts. ATTENTION! Retighten the rod screws to the correct tightening force level after 8 hours and again after every 24 hours of operation until the tightening force remains constant.

4.6

Mounting of grinding rollers on centre piece Refer Appendix 5. Thorough cleaning all parts is needed before the rollers mounted the centre piece. The of contact faces m ust be dry and withoutare any form of on grease. ERECTION CHECK Place the centre piece (02) on the supplied supports which is to be fixed with grinding table. Fix the c entre piece on the supports. The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

19 49

Atox mill 32.5 - 52.5 70010182-1.0 Insert the O-rings (43) for sealing air, breather line and oil connections grooves of the flange of the roller shaft. O-rings must be greased.

in the

O-rings which have been employed as seals during transportation must not be used. Position the journal so that its flange is resting on the recess on the centre piece. Avoid displacement of the journal rel ative to the centr e piece when the faces make contact. Such displacement w ill normally result in dam age to the O-ring (43), involving consequent risk of damage to the roller bearings of the roller. Use the hydraulic bolt tensioner to clamp the flanges together to tension level. Refer to assembly drawing for tightening force.

the specified

ERECTION CHECK Mount the protective caps (39) for the nuts. ATTENTION! Retighten the rod screw nuts to the correct torque level after 8 hours and again for every 24 hours of operation until the torque remains constant.

4.7

Mounting of the tensioning system See Appendix 1 and 6. 4.7.1 Spherical plain bearings The spherical plain bearings are used for the hydraulic cylinder/bracket connection, the joint head/roller shaft, the joint head/torque rod connection and the torque rod/buffer connection. While the spherical plain bearing for bearings are s teel/steel.

the cylinder is Teflon-coated, the other

Unpacking of the individual spherical plain bearings should not take place until mounting is about to begin. It is ess ential to avoid use of cleaning liquids for cleaning the spherical plain bearings; instead use a clean cotton cloth to wipe off the bearings. ERECTION CHECK The outer race of the bearing features a dividing slot, and, at the stage of mounting, this slot must be offset through 90° in relation to the load direction. The bearing (56) for the joint head/roller shaft connection is equipped with a tapered sleeve (61). The sleeve must be inserted into the bearing before the bearing is mounted into the joint head. Make sure that the end of the tapered sleeve (61) which has the smallest inside diameter is flush with the bearing. A tight fit is applied between the bearing and joint head. It may become necessary to heat the joint head with a lazy flame to approximately 80°C above the ambient temperature before mounting the bearing. Hold a tube having the same diameter as the outer race of the bearing, and drive the bearing into the joint head bore by means of light hammer blows. In the joint head, the "open" end (sleeve end with larger inner diameter) of the inner race must face the roller shaft. 4.7.2 Hydraulic cylinders 20{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 Clean the eyes on t he brackets (11) ve ry carefully. well as the pin are thoroughly degreased.

Ensure that the eye s as

Mount pin and cylinder in the brackets. To prevent rotation of the pin during operation, corrosion-inhibiting grease, for example NeverSeez, should not be applied. Remember the spacer rings, see assembly drawing. Support the cylinders so that they

are placed in reasonably correct position.

4.7.3 Mounting of tension rod heads on the journals of the

rollers

See Appendices 5 and 6. Mount sealing air ring (51) on the joint

head (50).

Clean the conical surface on the roller shaft (42) and the inner fac tapered sleeve very carefully. Apply Klüber ALTEMP Q NB 50. Push the joint head over the journal of

e of the

the roller shaft (42).

Mount the locking tool plate (45) on the s haft end, and tighten it lightly. The tool plate, which is provided with hole for oil injection tube, must be replaced by the permanent plate (44) after forcing-in. See Fig.3.

Figure 3. Mounting of joint

head

Pump in hydraulic oil through the shaft end for expansion of the inner race of the spherical plain bearing, and, at the same time, tighten screws of the locking plate until the plate lies true against the end of the roller shaft. Then, while maintaining the hydraulic pressure on the shaft end, tighten all screws to the specified torque level. The oil pressure must be maintained right up to the point where all screws have been tightened, subsequently removing the hoses. The tool plate must then be replaced with the permanent locking plate. Check that the air gap between the sealing air ring (51) and sealing air ring (41) is close to 0.5 mm. While the joint head is pressed onto the shaft it must be c that the joint head is free to move by hand.

hecked several times

ERECTION CHECK The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

21 49

Atox mill 32.5 - 52.5 70010182-1.0

Figure 4. Positioning of joint head

For correctly positioned joint head the distance X should be zero, see Fig. 4.

If the joint head is partly or completely locked before the joint head is pushed to the correct position, see Fig. 4, where the tapered sleeve is not flush with the roller shaft, adaptation must take place.

Two different ways can be used a) machining of tapered sleeve or b) machining of locking plate. For the method a) the tapered sleeve should be removed from the bearing inner ring. To ensure attainment of the c orrect (minimum) clearance in the bearing the sleeve should be machined X+0.7 mm at the thick end of the s leeve. Then the tapered sleeve should be mounted as described above.

Figure 5.Taper sleeve adaptation

Figure 6. Locking plate adaptation

For the method b) the tapered sleeve should carefully be drifted outward to the distance X+0.7 mm, see Fig.5. Before the joint head is remounted a new tool plate provided with a groove with a depth X+0.7 mm must be machined to compensate for the protruding end ofplate sleeve, see Fig.be 6. provided Permanent locking plate (44) which is replacing the tool also must with a groove with same depth. As described above the mounting of the joint head has been foreseen for the tapered sleeve mounted in the spherical plain bearing.

22{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 In case it seems necessary for sleeve adaptation the joint head can be mounted without pre-assembling of the sleeve inside the spherical plain bearing. The joint head must be supported and carefully positioned so the inner edge of the bearing is touching the chest of the shaft. Be sure that the shaft is not scratched or damaged. The outside of the sleeve and shaft and inside of s applied with Klüber ALTEMP Q NB 50. The tapered sleeve is inserted into

leeve and bearing must be

the gap and pressed lightly.

The polar position of the joint head might be adjusted slightly to obtain centering of the joint head. By means of printing blue it is ensured that the sleeve is the shaft.

supporting evenly to

In case, no indication of uneven support due to lack of machining the tool is mounted. Pressing in the tapered sleeve must be done as for the joint head with the sleeve inserted. Use the injection oil during pressing in the sleeve. When the joint head starts to show tendency to lock stopped.

the pressing procedure is

After stop of oil injection it must be ensured that the joint head is rotate.

free to

In case the sleeve is protruding the groove must be machined in the locking plate (44). Remark that the added 0.7 mm as described in Fig.6 should not be machined as the bearing is still free to rotate. Check that the air gap between the sealing air ring (51) and sealing air ring (41) is close to 0.5 mm. Before the end cover (82) of the joint head is mounted grease should be filled in outside the joint head. The purpose is to grease bottom part of bearing enabling free movement of bearing parts when lifting and lowering the roller. 4.7.4 Mounting of tension rods Following the finish–mounting of the joint heads, and with the rollers placed on the grinding table, the tension rods (07) must be lifted through the hatches at each head and fitted to the joint heads by means of the retainer rings (52) and stay bolts. Clean the contact faces. Use the supplied hydraulic bolt tensioner to tighten the stay bolts. Clean the bolt and nut. Check that the nuts of the bolt can be turned by hand. If the nut is provided with a stamped mark, the mark must face away from the contact face. Use the tool to tighten the nuts lightly in c The tightening force stipulated on the ass observed.

rosswise sequence. embly drawing must be strictly

The bolts of the flanged joint must be tightened crosswise and in three stages to eliminate risk of the flanges being distorted. ERECTION CHECK The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

23 49

Atox mill 32.5 - 52.5 70010182-1.0

ATTENTION! If welding is to be performed in proximity of the parts of the tensioning system, it is very important to ensure that adequate precautions are taken to avoid infliction of undercuts on the parts. A high-alloy material, which has been subjected to heat treatment, is used in the tensioning system, and any undercuts caused by welding will act as major stress raisers which may eventually cause ruptures in the system.

Caution is also needed in connection with the handling and transportation of the tension rods.

Place the wear bushing (48) on the tension rod and mount with the directions given on the assembly drawing.

it in accordance

Pull the flanges on the tension rod (07) and the piston rod (53) of the cylinder close together. If operational, the hydraulic system can be used.

Place the retainer rings (52) and the stay bolts in the flanges; tightening to be done as described for the joint head/tension rod bolts and nuts.

Mount the tension rod seal (49) as indicated on the assembly drawing.

4.8

Mounting of the torque arms and buffers See Appendix 7. Mount the brackets (58) of the buffers in accordance with the directions given on assembly drawing s. Check that the he ight corresponds to the connection for the tension rod h ead when the roll ers are mounted on the table. See assembly drawing. ERECTION CHECK Tack-weld the brackets to the mill housing.

Connect the torque arm (55) to the eye in the joint head (50) and to the (59). Apply corrosion-inhibiting grease, for example NeverSeez. For the joint head connection the split pin is tools. See assembly drawing.

buffer

mounted by using the supplied

Align rollers and the centre piece on the grinding table, and place torque arms and buffers in the co rrect positions indicated on the drawing. Remember the shims (60). If the rollers are not centred on the table when the tensioning system is assembled, the centring of the rollers can be carried out as described in 4.9. ERECTION CHECK

Mount the wear protection (54) brackets (58).

24{49

for torque arms and joint

heads. All-weld the

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

4.9

Adjustmen t of ro llers on the grinding table It is a precondition for adjusting the position of the rollers on the grinding table that the hydraulic pump station as well as the pump station of the gear unit is in active operation so that it will be possible to turn the grinding table and to raise and lower the rollers.

The position of the rollers is adjusted by means of shims (60), which are inserted between the buffers (59) and the bracket (58).

The position of the rollers is c hecked by lowering the rollers onto the grinding table - without application of grinding pressure – allowing the table to be turned slightly. The table can be turned manually by turning the coupling between the gear unit and motor when the gear unit pump station is in operation. It may be quite difficult to move the grinding table when the rollers are placed on the table, but the very fact that the torque rods have been aligned will make it less likely that a renewed alignment will have to be made following the initial start-up. ATTENTION! The grinding table must NEVER be the gear unit is in operation.

rotated unless the pump station of

The purpose of the roller adjustment procedure is to ensure that the segments of the grinding track are centred in relation to the segments of the rollers.

See Figs. 7 and 8.

The shims (60) will affect the position of the following way:

Insertion of a shim with the thickness

rollers on the grinding table in the

t under the buffer at roller No. 1 will

cause roller No. 2 to be moved t/ 3 inwards in direction of the centre of the mill, and roller No. 3 will be moved away from the centre to the same extent.

However, in case shims of identical thickness t are inserted (or removed), this will not affect the centring, but the position of the pulls rods in the seals will be altered to the extent of distance t.

In order to determine the immediate position of the rollers on the grinding table, the distances S must be measured at all three rollers (see Fig. 7).

To obtain centring of the rollers, it is essential to ensure modification of the shims at two locations, for example at No. 1 and No. 2. This will give the following thicknesses: (- indicates need to remove shims): t1 = - (2 x S2 - S1 - S3)/ t2 = + (2 x S1 - S2 - S3)/ t3 = 0 (+ t

offset

3 (+ toffset ) 3 (+ toffset )

)

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

25 49

Atox mill 32.5 - 52.5 70010182-1.0 If it is not poss ible to remove shims at No. 1, it will suffice to add an identical thickness t offset for all three buffers. Following the centring of rollers, the position of the pull rods must be adjusted as described above. With reasonable care and some desk calculations it will be possible to make the entire adjustment in one single operation. On completion of adjustment procedure, the S-dimensions s by more than 5 mm relatively to one another.

hould not deviate

ERECTION CHECK

Figure 7. Adjustment of position for

roller assembly

Figure 8. Positioning of roller assembly

26{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 During adjustment control that the tension rods are more or less vertical and that the wear bushing (48) is more or less c entred in the duct without involving risk of physical c ontact. If the rollers are retained in the same position after start-up, this means that the adjustment made is correct; otherwise the adjustment procedure must be repeated.

4.10 Mounting of sealing air/oil/water connection 4.10.1 Mounting of sealing air connection See Appendices 8 and 9. Clean the sealing air pipes very carefully prior to mounting. Mount the connecting piece (70) and the protective cap (62) on the centre piece (02). A minor adaptation of the bend in the connecting piece may be required. Fix the adapted bend by weldi ng to the loose flange s on both sides. Mount bearing locking plate (64), spherical plain bearing (65) and the spherical ring (67) on the sealing air pipe (66), and loc k the parts in the correct position by welding on the locking rings (63) and (69). Push the sealing air pipe (66) into correct position and fix bearing by means of the locking plate.

the spherical plain

Mount the wear bushing (68) in the mill housing. The sealing air pipe is prevented by rotating by means of the bars (78) which are welded to pipe. Mount the wear plate at the bottom for the sealing air pipe. Mount the flexible hose (79) for the sealing air with retainer clamps. Mount the external pipeline for sealing a Mount the sealing air fan (81).

ir.

See assembly drawings. ATTENTION! Prior to the initial start-up of the sealing air fan, it will be necessary to dismantle the sealing air pipe at the centre piece and the pipe is blown clean. ERECTION CHECK 4.10.2 Mounting of oil connection 4.10.2.1 Mounting of protective pipe for lubricating oil hoses Mount bearing locking plate (72), spherical plain bearing (71) and the spherical ring (75) on the protective pipe (74), and lock the parts in the c orrect position by welding on the locking rings (73) and (76). Mount the protective pipe and fix the spherical plain bearing by means of the locking plate. Mount the wear bushing (77) in the mill housing. The protective pipe is prevented by rotating by means of the bars (78) which are welded to the pipe. The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

27 49

Atox mill 32.5 - 52.5 70010182-1.0

4.10.2.1 Mounting of lubricating oil hoses The flexible oil hoses are marked with letters and numbers which correspond to the letters and numbers stamped on the centre piece, as shown on the assembly drawing. ERECTION CHECK Once all hoses have been led through the protective pipe, they must be mounted on the centre piece and on the external bracket. See assembly drawings. Sharp bends must not occur on any hos es, and a bending radius of less than 200 mm must be avoided. All roller lubrication lines must have uninterrupted decline from the mill down to the lubrication station. See separate instruction manual for the roller lubrication station. ERECTION CHECK 4.10.3 Mounting of water connection Mount the water injection piping as shown on the assembly drawing. See separate instruction manual for the water pump station.

4.11 Final erection The remaining parts of mill, separator etc. must be installed in accordance with directions given on assembly drawings or in separate erection manuals.

5

Operation Description of the operation procedure is given in a separate FLS instruction manual: Operation and maintenance.

6

Maintenance Description of the maintenance procedure is given i manual: Operation and maintenance.

28{49

n a separate FLS instruction

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

7

KEY TO APPENDICES 01

Grinding roller

02

Centre piece

03

Grinding table

04

Mill housing

05

Hydraulic accumulator

06

Hydraulic cylinder

07

Tension rod

08

Gear unit

09

Motor

10

Anchor plate

11

Bracket for hydraulic cylinder

12

Supporting profile

13

Gear plate

14

Adjusting screw

15

Foundation rails

16

Central cover

17

Wear segment, grinding table

18

Pin for wear segment

19

Sealing ring

20

Labyrinth seal

21

Scraper

22

Dam ring

23

Intermediate rings

24

Screw for dam ring

25

Supporting ring

26

Clamp for wear segment (for fixation)

27

Clamp for wear segment (between segment and table)

28

Locking nut

29

Guide cone

30

Nozzle ring segment

31

Supporting ring

32

Adjustment plate

33

Flat iron flange

34

Retainer clamp

35

Rod screw

36

Wear segment, grinding roller The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

29 49

Atox mill 32.5 - 52.5 70010182-1.0 37

Pin for wear segment

38

Roller hub

39

Protective cap

40

Stay bolt for centre piece

41

Sealing air ring

42

Roller shaft

43

O-ring

44

Locking plate

45

Tool plate

46

Retainer clamp

47

Screw

48

Wear bushing

49

Tension rod seal

50

Joint head

51

Sealing air ring

52

Retainer ring

53

Piston rod

54

Wear protection

55

Torque rod

56

Spherical plain bearing

57

Spherical plain bearing

58

Bracket

59

Buffer

60

Shim

61

Tapered sleeve

62

Protection box

63

Locking ring

64

Locking plate

65

Spherical plain bearing

66

Sealing air pipe

67

Spherical ring

68

Wear bushing

69

Locking ring

70

Connecting pipe

71

Spherical plain bearing

72

Locking plate

73

Locking ring

74

Tube for oil

75 30{49

Spherical ring The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0 76

Locking ring

77

Wear bushing

78

Flat bars

79

Flexible hose

80

Outer sealing air pipe

81

Sealing air fan

82

End cover

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

31 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 1 01

Grinding roller

02

Centre piece

03

Grinding table

04

Mill housing

05

Hydraulic accumulator

06

Hydraulic cylinder

07

Tension rod

08

Gear unit

09

Motor

32{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

33 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 2 10

Anchor plate

11

Bracket for hydraulic cylinder

12

Supporting profile

13

Gear plate

14

Adjusting screw

15

Foundation rails

34{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

35 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 3

36{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

Plant Sent by

Atox mill type

U4581-02 Order No.

Page 1/1

Measuring Measuredvalue+/point Before grouting After grouting 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Level variation tolerances, see Atox Mill Erection manual The above sketch is typical and may have different shape. Centre point may have different level for some mills The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

37 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 4 16

Central cover

17

Wear segment, grinding table

18

Pin for wear segment

19

Sealing ring

20

Labyrinth seal

21

Scraper

22

Dam ring

23

Intermediate rings

24

Screw for dam ring

25

Supporting ring

26

Clamp for wear segment (for fixation)

27

Clamp for wear segment (between segment and table)

28

Locking nut

38{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

39 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 5 02

Centre piece

34

Retainer clamp

35

Rod screw

36

Wear segment, grinding roller

37

Pin for wear segment

38

Roller hub

39

Protective cap

40

Stay bolt for centre piece

41

Sealing air ring

42

Roller shaft

43

O-ring

44

Locking plate

46

Retainer clamp

47

Screw

40{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

41 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 6 07

Tension rod

41

Sealing air ring

48

Wear bushing

49

Tension rod seal

50

Joint head

51

Sealing air ring

52

Retainer ring

53

Piston rod

56

Spherical plain bearing

61

Tapered sleeve

82

End cover

42{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

43 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 7 50

Joint head

51

Sealing air ring

54

Wear protection

55

Torque rod

56

Spherical plain bearing

57

Spherical plain bearing

58 59

Bracket Buffer

60

Shim

44{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

45 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 8 62

Protection box

63

Locking ring

64

Locking plate

65

Spherical plain bearing

66

Sealing air pipe

67

Spherical ring

68

Wear bushing

69

Locking ring

70

Connecting pipe

71

Spherical plain bearing

72

Locking plate

73

Locking ring

74

Tube for oil

75

Spherical ring

76

Locking ring

77

Wear bushing

78

Flat bars

46{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

47 49

Atox mill 32.5 - 52.5 70010182-1.0

Appendix 9 79

Flexible hose

80

Outer sealing air pipe

81

Sealing air fan

48{49

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disc losed or utilized without written consent from FLSmi dth.

Atox mill 32.5 - 52.5 70010182-1.0

80

79

81

---o0o---

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

49 49