Cement manufacturing Ball mill presentation

Ball mill

1. MAINTENANCE
MANAGEMENT OF
BALL MILL

2. 
All industries are working in a highly competitive All industries are working in a highly competitive
environment, which is quality and price sensitive .environment, which is quality and price sensitive .

It is imperative that industries are work at a very high level It is imperative that industries are work at a very high level
of production with maximum quality, at minimum cost of production with maximum quality, at minimum cost

Present scenario is demanding increased output, it means Present scenario is demanding increased output, it means
getting more out of plant and machinery getting more out of plant and machinery

If the plant and machinery are to be geared up for If the plant and machinery are to be geared up for
increased output at minimum cost, it calls for proper increased output at minimum cost, it calls for proper
maintenancemaintenance

Organizations are seeking newer methods to adopt to the Organizations are seeking newer methods to adopt to the
current situation for their survivalcurrent situation for their survival
IMPORTANCE OF IMPORTANCE OF
MAINTENANCEMAINTENANCE

3. 
Inventory cost are subjected to in-depth analysis Inventory cost are subjected to in-depth analysis

In view of the above circumstance, preventive In view of the above circumstance, preventive
maintenance becomes necessary to maintain maintenance becomes necessary to maintain
equipment availabilityequipment availability
IMPORTANCE OF IMPORTANCE OF
MAINTENANCEMAINTENANCE

4. 
RAW MILL IS TO PRODUCE SUFFICIENT RAW FEED FOR RAW MILL IS TO PRODUCE SUFFICIENT RAW FEED FOR
KEEPING THE KILN IN OPERATION. IF THE RAW MILLIS NOT KEEPING THE KILN IN OPERATION. IF THE RAW MILLIS NOT
ABLE TO PRODUCE KILN FEED DURING SUFFICIENTLY ABLE TO PRODUCE KILN FEED DURING SUFFICIENTLY
LONG TIME, THE KILN FEED WILL HAVE TO BE REDUCED .LONG TIME, THE KILN FEED WILL HAVE TO BE REDUCED .

SOMETIMES IT MAY BE NECESSARY TO STOP THE KILN .SOMETIMES IT MAY BE NECESSARY TO STOP THE KILN .
IT IS COSTLY AFFAIR TO STOP THE KILN AND THE LINING IT IS COSTLY AFFAIR TO STOP THE KILN AND THE LINING
WILL SUFFER FROM TEMPERATURE STRESS DURING STOP WILL SUFFER FROM TEMPERATURE STRESS DURING STOP
AND START.AND START.
1.1.ALSO CLINKER QUALITY WILL BE AFFECTED DURING ALSO CLINKER QUALITY WILL BE AFFECTED DURING
STOPS AND RESTART OF THE KILN WHICH NEEDS EXTRA STOPS AND RESTART OF THE KILN WHICH NEEDS EXTRA
CARE FOR MIXING SLOWLY WITH HIGH QUALITY CLINKER CARE FOR MIXING SLOWLY WITH HIGH QUALITY CLINKER
WHEN BEING FED TO CEMENT MILL.WHEN BEING FED TO CEMENT MILL.
IMPORTANCE OF MILL IMPORTANCE OF MILL
AVAILABILITYAVAILABILITY

5. 
IMPORTANCE OF MILL AVAILABILITY IS TO IMPORTANCE OF MILL AVAILABILITY IS TO
ENSUREENSURE

A HIGH RUN FACTORA HIGH RUN FACTOR

A HIGH CLINKER OUTPUT IN TONNESA HIGH CLINKER OUTPUT IN TONNES

A HIGH AND CONSTANT CLINKER QUALITYA HIGH AND CONSTANT CLINKER QUALITY

LOWEST POSSIBLE COST OF KILN LININGS AND LOWEST POSSIBLE COST OF KILN LININGS AND
OTHER CONSUMABLESOTHER CONSUMABLES

LOWEST POSSIBLE FUEL CONSUMPTION.LOWEST POSSIBLE FUEL CONSUMPTION.

LOWEST POSSIBLE CONSUMPTION OF ELECTRICAL LOWEST POSSIBLE CONSUMPTION OF ELECTRICAL
ENERGYENERGY
IMPORTANCE OF MILL IMPORTANCE OF MILL
AVAILABILITYAVAILABILITY

6. 
To establish routine maintenance of plant & machinery To establish routine maintenance of plant & machinery
based on visual inspection and study of workloads based on visual inspection and study of workloads

To ensure inspection and overhaul schedules are To ensure inspection and overhaul schedules are
maintained for all major equipment covering standard maintained for all major equipment covering standard
of tolerance, dimensions, wear, and performance of tolerance, dimensions, wear, and performance

To make sure that spares parts and extra machinery To make sure that spares parts and extra machinery
requirements available in timerequirements available in time
SCOPE OF PREVENTIVE SCOPE OF PREVENTIVE
MAINTENANCEMAINTENANCE

7. 
In spite of all the above procedures laid down and In spite of all the above procedures laid down and
being followed, breakdowns become inevitable in an being followed, breakdowns become inevitable in an
industry functioning continuously industry functioning continuously

Breakdown leads to huge losses as a result of Breakdown leads to huge losses as a result of

1. High replacement cost1. High replacement cost

2. Long down time 2. Long down time

3. Loss of production and hence loss of profit3. Loss of production and hence loss of profit
BREAKDOWN BREAKDOWN
MAINTENANCEMAINTENANCE
During a breakdown, what do we look During a breakdown, what do we look
for? for?

8. 
We look at the following We look at the following

1. Immediate technical help in salvaging the 1. Immediate technical help in salvaging the
situation situation

2. Easy availability of the salvage material 2. Easy availability of the salvage material

3. Technical competency in getting the job 3. Technical competency in getting the job
donedone
BREAKDOWN BREAKDOWN
MAINTENANCEMAINTENANCE
We should have good knowledge on maintenance
and repair and well trained to address all these
needs

9. 
Raw Meal GrindingRaw Meal Grinding

Coal GrindingCoal Grinding

Cement Grinding Cement Grinding

APPLICATION OF BALL BILLSAPPLICATION OF BALL BILLS

10. FUNCTIONSFUNCTIONS
DRYING DRYING
BY INBUILT ARRANGEMENTBY INBUILT ARRANGEMENT
BY EXTERNAL ARRANGEMENTBY EXTERNAL ARRANGEMENT
GRINDINGGRINDING
BY IMPACT & ATTRITIONBY IMPACT & ATTRITION
ADVANTAGESADVANTAGES
RELIABLERELIABLE
RELATIVELY SIMPLE TO OPERATERELATIVELY SIMPLE TO OPERATE
EASY TO MAINTAINEASY TO MAINTAIN
APPLICATION OF BALL BILLSAPPLICATION OF BALL BILLS

11. 
CENTRAL DISCHARGE MILLSCENTRAL DISCHARGE MILLS

END DISCHARGE MILLSEND DISCHARGE MILLS

AIR SWEPT MILLSAIR SWEPT MILLS

SEMI-AIR SWEPT MILLSSEMI-AIR SWEPT MILLS

TANDEM GRINDING CIRCUITTANDEM GRINDING CIRCUIT
TYPES OF BALL MILL TYPES OF BALL MILL

12. Central Central Discharge MillsDischarge Mills
Two grinding compartments
One drying compartment
Drying capacity is good
Material discharge from mil
through peripheral outlets

13. CENTRAL DISCHARGE MILL

14. End Discharge MillsEnd Discharge Mills
Low ventilation gases
Drying capacity is low
Separate drying arrangement
may require
Low power consumption

15. Air Swept Air Swept MillsMills
One drying & grinding
Suitable for raw material
having high moisture
Material discharge from mill is
through ventilating air stream
Suitable for utilizing great
amount of waste gas
More power consumption

16. SemiSemi Air Swept Air Swept MillsMills
One drying & grinding
Suitable for raw material
having low moisture
content
Ground material is
transported to separator
party by ventilating air
and partly by B/E

17. Coal GrindingCoal Grinding
•Coal grinding is generally performed in Air Swept Coal grinding is generally performed in Air Swept
ball mills.ball mills.

Contains Drying & Grinding chambers.Contains Drying & Grinding chambers.

Hot gas from Pre-heater exhaust is used for Hot gas from Pre-heater exhaust is used for
drying.drying.

Efficient drying system is essential as coal contains Efficient drying system is essential as coal contains
5 to 20 % moisture.5 to 20 % moisture.

Some mills have external heat generator Some mills have external heat generator
arrangement & external drying arrangement.arrangement & external drying arrangement.
BALL MILLSBALL MILLS

18. COMPONENTS OF BALL MILLCOMPONENTS OF BALL MILL

19. COMPONENTS OF BALL MILLCOMPONENTS OF BALL MILL
1.SHELL
2.TRUNION
3.DIAPHRAGMS
4.TRUNION BEARINGS OR SLIDE SHOE BEARINGS
5.SHELL LINERS
6.MILL HEAD LINERS
7.WATER COOLING ARRANGEMENT
8.MILL HYADRAULICS
9.MILL MOTOR
10.MILL GEARBOXES
11.TORSION SHAFT AND COUPLING
12.AUX DRIVE

20. SHELL: SHELL:
MILL SHELL IS THE PRIMARY MILL COMPONENT AND HOUSES THE ACTUAL MILL SHELL IS THE PRIMARY MILL COMPONENT AND HOUSES THE ACTUAL
GRINDING FUNCTION. SHELL MUST BE CIRCULAR TO MINIMISING ANY GRINDING FUNCTION. SHELL MUST BE CIRCULAR TO MINIMISING ANY
WOBBLE OR ECCENTRICITIES.WOBBLE OR ECCENTRICITIES.
LENGTH TO DIAMETER OF MILL SHELL FORLENGTH TO DIAMETER OF MILL SHELL FOR
ONE COMPARTMENT MILL- L/D= 1.5ONE COMPARTMENT MILL- L/D= 1.5
TWO COMPARTMENT MILL- L/D=3TWO COMPARTMENT MILL- L/D=3
THREE COMPARTMENT MILL L/D=4.5THREE COMPARTMENT MILL L/D=4.5
Material:Material:Fine grained structural steel plates Fine grained structural steel plates
or Boiler quality steel plates.or Boiler quality steel plates.
ThicknessThickness:: Ranges between 1/100 to 1/75 of mill diameter, Ranges between 1/100 to 1/75 of mill diameter,
depending upon diameter and length of tube.depending upon diameter and length of tube.
For long mills, the shell thickness increases from For long mills, the shell thickness increases from
both ends towards the mill center.both ends towards the mill center.
MAINTENANCE:MAINTENANCE:

Periodically inspect for cracks. Periodically inspect for cracks.

The area near manhole is quite vulnerable for cracks. Cracks may develop The area near manhole is quite vulnerable for cracks. Cracks may develop
due to fatigue after many years of service . There is a risk of complete due to fatigue after many years of service . There is a risk of complete
failure, if these cracks are allowed to propagate. failure, if these cracks are allowed to propagate.

Attend shell repair job at the earliest.Attend shell repair job at the earliest.
MaintenanceMaintenance of of
Ball millBall mill

21. Mill Heads:Mill Heads:
THE MILL HEAD FORMS A CONNECTING LINK BETWEEN THE MILL HEAD FORMS A CONNECTING LINK BETWEEN
MILL SHELL AND TRUNION. TIGHT FITTING BOLTS OF MILL SHELL AND TRUNION. TIGHT FITTING BOLTS OF
CHROMIUM NICKEL STEEL ARE USED FOR TRUNION AND CHROMIUM NICKEL STEEL ARE USED FOR TRUNION AND
MILL HEAD.MILL HEAD.

FLS mill heads and trunion are manufactured in two separate FLS mill heads and trunion are manufactured in two separate
parts. These are assembled by means of tight fitting bolts. Mill parts. These are assembled by means of tight fitting bolts. Mill
heads are welded to mill shell. heads are welded to mill shell.

MaterialMaterial: cast steel grade: GS -60.1. Recently with Nodular cast : cast steel grade: GS -60.1. Recently with Nodular cast
iron( SG).iron( SG).

MAINTENANCE:MAINTENANCE:

Periodically inspect for cracks. Periodically inspect for cracks.

Cracks propagate generally in between the drill holes meant for Cracks propagate generally in between the drill holes meant for
liners fixing.liners fixing.

Attend repair work at the earliestAttend repair work at the earliest
MaintenanceMaintenance of of
Ball millBall mill

22. SHELL LINERS:SHELL LINERS:

PURPOSEPURPOSE

To protect shell from wear.To protect shell from wear.

Improves tumbling action of grinding media.Improves tumbling action of grinding media.

Control size distribution of grinding media along the mill Control size distribution of grinding media along the mill
length length 

11
stst
Chamber: Lifter liner is employed for strong ball impact Chamber: Lifter liner is employed for strong ball impact

22
ndnd
chamber: Smooth or small ripple liners can be employed chamber: Smooth or small ripple liners can be employed

Classifying liners are generally in use for 2Classifying liners are generally in use for 2
ndnd
chamber chamber..

Liners design :Liners design :

Bolted linersBolted liners:: Fastened to the shell with one or two bolts perFastened to the shell with one or two bolts per
liner.liner.

Boltless linersBoltless liners:: Only four liners are bolted to the shell in each Only four liners are bolted to the shell in each
line. line. Remaining liners are locked in by the bolt less linersRemaining liners are locked in by the bolt less liners..
MAINTENANCEMAINTENANCE

23. SHELL LINERS ARRAGEMENTSHELL LINERS ARRAGEMENT
MAINTENANCE MAINTENANCE

24. CLASSIFYING LINERSCLASSIFYING LINERS
MAINTENANCE MAINTENANCE

CARMAN LINERSCARMAN LINERS
MAGGOTEUX LINERSMAGGOTEUX LINERS
FLS LINERSFLS LINERS

25. CLASSIFYING LINERSCLASSIFYING LINERS
MAINTENANCE MAINTENANCE

26. CLASSIFYING LINERSCLASSIFYING LINERS
MAINTENANCE MAINTENANCE

27. SURFACE SHAPES OF MILL LINERSSURFACE SHAPES OF MILL LINERS
MAINTENANCE MAINTENANCE

Single wave shell liners
Double wave shell liners

Corrugated shell liners
Wedge bar shell liners
Block type shell liner
Grooved shell liners

28. COMPARATIVE STATEMENT OF PERFORMANCE OF COMPARATIVE STATEMENT OF PERFORMANCE OF
DIFFERENT LINERSDIFFERENT LINERS
APPLICATIONAPPLICATION Mn STEEL LINERMn STEEL LINER Hi CHROME LINERHi CHROME LINER
RAW MILLRAW MILL >5 YEARS>5 YEARS >10 YEARS>10 YEARS
COAL MILL HEAD COAL MILL HEAD
LINERSLINERS
2 LAKHS MT2 LAKHS MT --
COAL MILL SHELL COAL MILL SHELL
LINERSLINERS
2.5 LAKHS MT2.5 LAKHS MT
CEMENT MILL HEAD CEMENT MILL HEAD
LINERSLINERS
5.5 LAKHS MT5.5 LAKHS MT 1.6 TO 2.0 TIMES1.6 TO 2.0 TIMES
CEMENT MILL CEMENT MILL
SHELL LINERS I SHELL LINERS I
CHAMBERCHAMBER
12 LAKHS MT12 LAKHS MT
CEMENT MILL CEMENT MILL
SHELL LINERS II SHELL LINERS II
CHAMBERCHAMBER
15 LAKHS MT15 LAKHS MT

29. CHEMICAL COMPOSITION OF LINERSCHEMICAL COMPOSITION OF LINERS
Mn steel IS 276, gr-3
C- 1.05 to 1.3 %
Si- 1.0 % max
Mn-11 to 14 %
S- 0.06%
P- 0.06%
Cr- 1.5 to 2.5%
Hardness- 229 BHN
Hi chrome Liner (Mill head)
C – 1 to 2 %
Cr- 10 to 14 %
Hardness- 56 RC
Hi Chrome Liner (Shell liner)
C – 0.2 TO 0.6%
Cr – 6 to 9%
Hardness- 52 RC

30.  No shearing of bolts.
 Elimination of liner breakage
 Reduces the slippage of balls
 Improved life
 Better efficiency due to increase in no. of
lifts
 Less specific power consumption
 Improvement in out put.
ADVANTAGES OF HIGH CHROME DOUBLE WAVE
BOLTLESS LINERS:

31. 
DiaphragmsDiaphragms

PURPOSEPURPOSE:: Separates grinding media sizes among the Separates grinding media sizes among the
chamberschambers

Controlling flow of material through one chamber to the Controlling flow of material through one chamber to the
next or discharge. (Control on retention time) next or discharge. (Control on retention time) 

Material:Material: Manganese steel IS 276 Gr: 3Manganese steel IS 276 Gr: 3  

Maintenance: Maintenance:

Clean clogged slots.Clean clogged slots.

Inspect for cracks and replace immediately if found.Inspect for cracks and replace immediately if found.

Use shear head bolts for liners fixing to ensure perfect Use shear head bolts for liners fixing to ensure perfect
tightening.tightening.

Replace lifting arms/ scooping plates, if wear Replace lifting arms/ scooping plates, if wear
observedobserved..
MAINTENANCEMAINTENANCE

32. MAINTENANCEMAINTENANCE

DIAPHRAGMSDIAPHRAGMS

33. MAINTENANCEMAINTENANCE

DIAPHRAGMSDIAPHRAGMS

34. MAINTENANCEMAINTENANCE

Fig: Frame of
diaphragm

35. 
Water Spray:Water Spray:

To maintain mill out let cement temperature between 100 To maintain mill out let cement temperature between 100
to 110 deg C.to 110 deg C.

If cooling requirement is more, spray directly inside the If cooling requirement is more, spray directly inside the
mill.mill.

Use automatic controls for the rate of spray.Use automatic controls for the rate of spray.

Avoid excess water spray, as it causes early hydration of Avoid excess water spray, as it causes early hydration of
cement, mill jamming, condensation in the ducts, cement, mill jamming, condensation in the ducts,
blanketing of filter bags.blanketing of filter bags.

Spray is generally from discharge end into the fine Spray is generally from discharge end into the fine
grinding compartment. If the clinker is too hot, say > 110 grinding compartment. If the clinker is too hot, say > 110
deg c, first compartment would also require water spray.deg c, first compartment would also require water spray.

MaintenanceMaintenance

Water spray nozzles have to be cleaned 15 days once to Water spray nozzles have to be cleaned 15 days once to
avoid cloggingavoid clogging

Water pumps have to be overhauled once in six month.Water pumps have to be overhauled once in six month.
MAINTENANCE MAINTENANCE

36. MAINTENANCE MAINTENANCE

WATER SPRAYWATER SPRAY

37. 
GIRTH GEAR:GIRTH GEAR:

  Periodically measure Backlash & Root clearance.Periodically measure Backlash & Root clearance.

  More BacklashMore Backlash: Replace/ reverse the girth gear : Replace/ reverse the girth gear

Excessive backlash creates increase in vibration, Excessive backlash creates increase in vibration,
aggressive wear of teeth, breakage of teeth.aggressive wear of teeth, breakage of teeth.

  Replace worn out pinion bearings.Replace worn out pinion bearings.

Inspect periodically for teeth wear, pittings, plastic Inspect periodically for teeth wear, pittings, plastic
deformation.deformation.

  Regularly inspect grease spray system for it’s Regularly inspect grease spray system for it’s
functioningfunctioning
MAINTENANCE MAINTENANCE

38. FIG:MILL GIRTH
GEAR

39. MAINTENANCE MAINTENANCE

40. MAINTENANCE MAINTENANCE

PINION BEARING

41. 
GIRTH GEARGIRTH GEAR

  Check grease spray pattern periodically.Check grease spray pattern periodically.

  Clean spray nozzles, filters, and distributors Clean spray nozzles, filters, and distributors
periodically.periodically.

Use correct grade of grease.Use correct grade of grease.

  Spray recommended quantity of grease.Spray recommended quantity of grease.

  Take care while replacing the barrel to avoid Take care while replacing the barrel to avoid
contaminationcontamination

  Compressed air should be free from moisture.Compressed air should be free from moisture.

Interlock the spray system operation with mill driveInterlock the spray system operation with mill drive

Monitor teeth temperature & vibration periodically.Monitor teeth temperature & vibration periodically.
MAINTENANCEMAINTENANCE

42. 
MAINTENANCE OF DRIVE MAINTENANCE OF DRIVE

MOTORMOTOR

GEAR BOXGEAR BOX

COUPLINGCOUPLING

TORSION SHAFTTORSION SHAFT
MAINTENANCEMAINTENANCE

43. Mill BearingsMill Bearings::

Most of the bearings equipped with Sliding bearings Most of the bearings equipped with Sliding bearings
and some are equipped with Roller bearings.and some are equipped with Roller bearings.

Sliding bearingsSliding bearings::

Start up lubrication system is required. Start up lubrication system is required.

Less expensive. Less expensive.

Widely in use.Widely in use.
MaintenanceMaintenance

44. MAINTENANCEMAINTENANCE

TRUNION BEARING ARRANGEMENTTRUNION BEARING ARRANGEMENT

45. MAINTENANCEMAINTENANCE

TRUNION BEARING ARRANGEMENTTRUNION BEARING ARRANGEMENT

46. MAINTENANCEMAINTENANCE

SLIDE SHOE BEARING SLIDE SHOE BEARING

47. MAINTENANCEMAINTENANCE

ADVANTAGES OF SLIDE SHOE BEARING ADVANTAGES OF SLIDE SHOE BEARING
OVER CONVENTIONAL TRUNION BEARINGOVER CONVENTIONAL TRUNION BEARING
 
 
Heavy mill heads can be discarded and replaced by covers of
regular sheet metal, since they have nothing to bear.
By terminating the use of mill trunions, the mill becomes
shorter by the same length.
 
Because of the shorter bearing distance, the mechanical
stress of the mill cylinder is lower. Therefore, the cylinder can
be manufactured of thinner sheet metal.

48. Inspection & maintenance of bearings:Inspection & maintenance of bearings:

Continuous observation of bearing temperature.Continuous observation of bearing temperature.

Sensing device should be in direct contact with bearing metal, Sensing device should be in direct contact with bearing metal,
not with lubricating oil.not with lubricating oil.

  Use always same grade of oil for lubrication. Use always same grade of oil for lubrication.

Replace oil as recommended by OEM based on running Replace oil as recommended by OEM based on running
hours/duration.hours/duration.

  Clean the heat exchanger tubes periodically.Clean the heat exchanger tubes periodically.

  Ensure proper flow of oil to the bearings. Ensure proper flow of oil to the bearings.

Observe pressure difference across the filter. If it is abnormal, clean Observe pressure difference across the filter. If it is abnormal, clean
the filter/ replace. Observe the clogged particles for any metal the filter/ replace. Observe the clogged particles for any metal
particles.particles.

If wear or damage found to the bearing metal, replace the bearing & If wear or damage found to the bearing metal, replace the bearing &
rebabbit the white metal for the removed bearingrebabbit the white metal for the removed bearing
MaintenanceMaintenance

49. MaintenanceMaintenance
INTERNAL INSPECTION OF MILL
1.ALL GRINDING MEDIAS WHICH HAVE BECOME WEDGED AROUND THE
OPENING SHOULD BE REMOVED
2.CHECK OF ANY MISSING , BROKEN OR LOOSE LINING PLATE.
3.CHECK OF ANY GRINDING MEDIA STUCK ON THE SLOTS OF THE
GRATES WHICH HAVE TO BE REMOVED.
4.CHECK OF ANY SLOTS IN DIAPHRAGM IS CLOSED DUE TO SURFACE
DEFORMATION WHICH HAS TO BE RECTIFIED.
5.CHECK OF LINER PLATES IN GOOD CONTACT WITH MILL SHELL.
6.CHECK OF WEAR OF SHELL LINERS & DIAPHRAGM ASSEMLY .
7.CHECK OF NIPS AND COARSE MATERIAL STUCK IN THE SLOTS OF
DIAPHRAGM PLATES WHICH HAVE TO BE REMOVED.

50. MaintenanceMaintenance
NDT-NON DESTRUCTIVE TESTING
DYE PENTRANT TEST
MAGNETIC PARTICLE TEST
ULTRASONIC TEST

51. PREVENTIVE MAINTENANCE OF ROLLER PRESS HYADRAULICSPREVENTIVE MAINTENANCE OF ROLLER PRESS HYADRAULICS
1 .LUBRICATION.
2 .CLEANING
3 .INSPECTION AND ADJUSTMENT
4 .CHECKING OF CONDITIONS
5 .REPLACEMENT
6 .PERFORMANCE TEST.
POS TEXT 1 2 3 4 5 6
1 PUMP STATION 4A M 4A - -
2 OIL - - - - T 2A 4A
3 OIL FILTER - S - - - -
4 SIGHT GLASS - - - S - -
5 THERMOMETER - - - S - -
6 AIR FILTER - A - - T -
7 OIL COOLER- - T - - - -
8 FLOW INDICATOR - - - - - 2A
D- PER 8 HOUR OPERATION
S-WEEKLY
M-MONTHLY
A-YEARLY
T-SEE TEXT IN INSTRUCTION MANUAL.

52. Lubrication Monitoring Lubrication Monitoring

To identify To identify

1. Health of bearings1. Health of bearings

2. Adequate lubrication 2. Adequate lubrication

3. Free from contaminants 3. Free from contaminants

4. Minimum wear particle in the lubricant 4. Minimum wear particle in the lubricant

5. Absence of abnormal forces acting on the 5. Absence of abnormal forces acting on the
m/cm/c
MAINTENANCEMAINTENANCE

53. Lubrication Monitoring Lubrication Monitoring

Lubricating analysisLubricating analysis

1. Viscosity 1. Viscosity

2. Contamination 2. Contamination

3. Oxidation 3. Oxidation

4. Total Acid Number 4. Total Acid Number

5. Total Base Number 5. Total Base Number

6. Particle count6. Particle count

Lubricating oil analysis at periodical interval is very essential to Lubricating oil analysis at periodical interval is very essential to
determine the condition of lubricating oil / criticality of the determine the condition of lubricating oil / criticality of the
machine machine
MAINTENANCEMAINTENANCE

54. Effects of Misalignment Effects of Misalignment

On bearingOn bearing

Generates a torque which create a reaction Generates a torque which create a reaction
force in the bearing force in the bearing

20% load increase by misalignment reduce 20% load increase by misalignment reduce
the calculated bearing life by 50%the calculated bearing life by 50%
IMPORTANCE OF PROPER IMPORTANCE OF PROPER
ALIGNMENTALIGNMENT

On Oil sealsOn Oil seals
• Wear Wear
• Risk of intrusion of contaminants Risk of intrusion of contaminants

Risk of additional damage to the bearingRisk of additional damage to the bearing

55. Effects of Misalignment Effects of Misalignment

On Coupling and Shafts On Coupling and Shafts
•Overload and vibration generated by misalignment Overload and vibration generated by misalignment
stress the coupling & shaftstress the coupling & shaft

On energy consumption On energy consumption

Can go up to 20% Can go up to 20%
IMPORTANCE OF PROPER IMPORTANCE OF PROPER
SHAFT ALIGNMENTSHAFT ALIGNMENT
Types of misalignmentTypes of misalignment
1. Angular misalignment1. Angular misalignment
2. Parallel misalignment 2. Parallel misalignment
3. Axial ( float) 3. Axial ( float)

56. 
Better the initial alignment, more the Better the initial alignment, more the
capacity and life capacity and life

Take care of operational misalignment Take care of operational misalignment

Changes can occur throughChanges can occur through

1. Bearing wear1. Bearing wear

2. Settling of foundation 2. Settling of foundation

3. Base distortion 3. Base distortion

4. Thermal changes 4. Thermal changes

5. Vibration etc.,5. Vibration etc.,
¤Check alignment at regular interval to get Check alignment at regular interval to get
the potential life of couplings the potential life of couplings
FLEXIBLE COUPLINGSFLEXIBLE COUPLINGS

57. 
Human eyes Human eyes
Straight edge or feeler gauges (Quick Straight edge or feeler gauges (Quick
but inaccurate)but inaccurate)

Dial indicator method Dial indicator method

1. Reverse indicator 2. Face and rim 3. 1. Reverse indicator 2. Face and rim 3.
Across the flux element graphic analysisAcross the flux element graphic analysis
(Accurate but time consuming)(Accurate but time consuming)

Laser alignment Laser alignment
( Accurate & Quick)( Accurate & Quick)
TRADITIONAL TRADITIONAL
ALIGNMENT METHODS ALIGNMENT METHODS