Bab 4

COAL MILL
maintenance
▪ General Maintenance
▪ Atox Mill
▪ Maintenance Program and
Inspection
▪ Trouble Shooting
▪ Safe Operation
Maintenance
Umum Semua aktivitas untuk memeriksa dan
menjaga peralatan pada kondisi yang
diinginkan

Basic Maintenance
Break-down Maintenance
Preventive Maintenance

Preventive Maintenance
Periodic Prev. Maintenance
Condition Based Prev. Maintenance
Fungsi Maintenance

Fungsi Utama Maintenance

◼ Availability

◼ Cost
MaintenanceYang Baik

▪ Availability meningkat
▪ Reliability meningkat
▪ Efisiensi meningkat
▪ Downtime / Laju Failure mill
menurun
▪ Operasi lancar
Kondisi Peralatan
Dapat dievaluasi dari monitoring

▪ Temperature
▪ Vibration
▪ Noise
▪ Kondisi fisik (inspeksi visual)
Aktivitas Maintenance

Aktivitas ▪ Cleaning
Utama ▪ Lubrication
▪ Overhaul
▪ Replacement
▪ Functional test
Rangkuman
Sistem Preventive Predictive Breakdown

• Inspection Scheduled
• Lubrication Scheduled
Maintenance • Machine service/cleaning
Activity • Adjustment/minor repair Unscheduled
• SOP

• Condition • Damage
Maintenance Life Time Abnormal
• Trend • Failure
Base

• Replacement / Major Repair

• Overhaul / Recondition Corrective
Repair Activity Breakdown
• Modification repair
Repair
Konsep Availability

Full Campaign Period – Calendar Time

No Demand

Scheduled
Scheduled Production Time

Capacity
Excess
Maint.

Hours
Peak
Break Down
Available Production Time Elec Mecha
trical nical
Stop caused by
Real Production Time operator

Directly In-
directly
Effective Prod. Var.probls.
Availability = 1 – Break Downs
Time with other
Scheduled Production Time
install
Kinerja Maintenance

Indikator Utama Kinerja

▪ Availability
▪ Mean Time Between Failure (MTBF)
▪ Plan Attainment (%)
▪ PMR (%)
▪ Unplanned (%)
▪ Overdue (h)
▪ Overtime (%)
Kinerja Maintenance

Availability
Pengukuran waktu total Operating Time + Idle Time
x 100 %
potensial peralatan Calendar Time
dioperasikan

Aktual Availability
Pengukuran utilisasi Operating Time
x 100 %
peralatan, merefer Calendar Time
kepada waktu operasi
Kinerja Maintenance

Mean Time Between Failure - MTBF

▪ Frekuensi Kegagalan dihubungkan Actual Operating Time

dengan waktu operasi peralatan Failure(s) # + 1
▪ Untuk menentukan efektivitas
overall dari strategi Maintenance
preventif
Kinerja Maintenance

Plan Attainment
▪ Pengukuran penyempurnaan rencana
Maintenance
▪ Digunakan untuk memonitor pencapaian
rencana Maintenance mingguan

Estimated hours completed on planned work orders

x 100 %
Total Estimated Hours
Kinerja Maintenance

Preventive ▪ Rasio Preventive Maintenance Rutin sebagai

Maintenance persentase terhadap seluruh pekerjaan
maintenance
Routine
▪ Digunakan untuk memonitor tingkat
preventive maintenance yang direncanakan

Actual Labor Hours on completed PMR Work Orders

x 100 %
Available Labor Hours
Kinerja Maintenance

Unplanned ▪ Pengukuran tingkat aktivitas unplanned

maintenance activities terhadap beban
kerja total maintenance
▪ Digunakan untuk memonitor
kecenderungan pemakaian kerja reactive
(emergencies)

Actual hours on completed unplanned work orders

x 100 %
Actual hours on all completed work orders
Kinerja Maintenance

Overdue ▪ Jumlah total jam kerja yang

dibutuhkan untuk menyelesaikan
semua wo
▪ tingkatan pekerjaan tidak
terselesaikan pada waktu yang
ditentukan
Sum of Estimated Labor Hours on all overdue Work Orders
Kinerja Maintenance

Overtime ▪ Pengukuran jam overtime terhadap jam

kerja normal
▪ Digunakan untuk mengontrol biaya buruh

Overtime Hours
x 100 %
Normal available hours + Actual overtime hours worked
Sumberdaya Maintenance

▪ Personnel : Kualifikasi, Kemampuan, Jumlah

▪ Tools : Cukup, Tersedia, Akurat
▪ Spare parts : Available, Memenuhi Spesifikasi
▪ Consumables

Contoh Spare Part

▪ Wearable parts : liner, roller, bearing,
impeller, etc
▪ Hydraulic unit / part
▪ Consumables : bolt-nut, welding rod,
etc
Indikasi Kebutuhan
Maintenance
◼ Kapasitas mill menurun
◼ Tumpahan material meningkat
◼ Coal fineness tidak terpenuhi
◼ Level kebisingan
Atox Mill
• Jumlah roller 3 buah
dihubungkan dengan yoke
• Table flat
• Tekanan dg silinder
hydraulic
• Cage rotor separator dg
guide vane yg adjustable
• Nozzle louvre ring
adjustable
 Atox Mill

Sizes: available up to ATOX 60, 660 [t/h] of raw

Make: material, built up to ATOX 50
ATOX 50 ↓ Table diameter DT = DN ♦ Design features:
(nominal) [dm] ∗ No. of rollers: always 3
♦ Application: ∗ Axles of the rollers interconnected in a rigid
∗ Raw material center yoke
∗ Coal ∗ Hydraulic cylinders with pull rods connected to
♦ Dimensioning parameters: Atox each axle tip
mills are totally geometrical: ∗ Pull rods arranged outside grinding area
DM = 0.8 x DT [m] ∗ Roller axis with 3 degrees lag of the table center
DR = 0.6 x DT [m] in rotating direction
WR = 0.2 x DT [m] ∗ Tangential thrust absorbing torque arms and
c = 50.1 [-] bearings fixed to the mill body
k = 800 [kN/m2] dim. / ∗ High-efficiency cage rotor separator SEPAX type
≤ 700 [kN/m2] operation with adjustable guide vanes
∗ Nozzles of louvre ring adjustable with inserts
Bagian-Bagian Mill
31 Intermediate ring
32 Wear liner
33 Threaded tension rod
34 Outer bearing spacer ring
35 Inner bearing spacer ring
37 Fixation piece
38 Shaft
39 Threaded bolt
40 Center piece
41 Disassembly sleeve
42 Spherical roller bearing
43 Retention plate
44 Locking screw
45 Hydraulic nut
46 Cylindrical roller bearing
47 Sealing ring (round cross-section)
48 Sealing ring (round cross-section)
49 Plug
50 Screw
51 Sealing ring (round cross-section)
52 Bearing lid
53 Sealing air outer ring
54 Sealing air ring
55 Outer cover
Bagian-Bagian Mill
8 Shutter ring
9 Intermediate ring
10 Support ring
11 Fixation
12 Grinding Table
13 Threaded hole for liner disassembly
14 Scraper
15 Ring for joint surrounding table
16 Joint surrounding table
17 Central cover lid
18 Liner
19 Locking pin
 Roller
• Roller berputar pada poros horisontal fix
pada light weight center yoke. Bantalan
roller dilumasi oleh sirkulasi minyak. Segel
bibir dilindungi oleh sealing air. Partikel
yang jatuh melalui nozzle yang dikumpulkan
oleh scrapers berputar dengan meja dan
dibawa ke dua chutes oleh with air tight
gates.
Roller Convergence
• Bantalan roller terkespos pada gaya radial
• Roller silindris tersegmentasi (dg wear liners)
• Segmen roller dapat diputar (180°) untuk memperpanjang
lifetime

Keuntungan
• Kemungkinan untuk mengangkat roller dan menghilangkan
tekanan pada saat start-up
Sistem hidrolik Sederhana
Handal / kontrol vibrasi yang baik (seperti Loesche dan O & K)

Kerugian
• Akses internal terbatas
Wearable Part

▪ Grinding rolls
▪ Bull ring segments
▪ Separator body liners
▪ Direction vanes
▪ Bowl extension ring
▪ Scrappers
▪ Mill side liner
▪ Mill discharge valves
Pemeriksaan Mekanikal
▪ Table parts and scrapers

▪ Wear protection of the key parts, roller, joint

head and torque rod

▪ General wear protection and lining of the mill

and separator housing

▪ Hydraulic and lubrication systems, filters,

valves, pumps, flow, function

▪ Mill motor and gear unit (optional)

Pemeriksaan Mekanikal
▪ Wear segments untuk roller dan meja, serta wear profiles

▪ Ketinggian dan kondisi dam ring

▪ Posisi dan kondisi injeksi air

▪ Ukuran luas dan distribusi cincin nozzle, baling-baling, dan

air guide cone

▪ Tekanan kerja dan pengaturan akumulator dari sistem

tensioning

▪ Fungsi sistem hidrolik selama operasi

▪ Kekencangan rotary sluice dengan masuknya low false air

Program Maintenance
dan Inspeksi
Tipe maintenance
▪ Maintenance Harian
▪ Maintenance Mingguan
▪ Shutdown maintenance
Program Maintenance
dan Inspeksi
▪ Maintenance Harian :
Check the gear case oil level,
Gear case oil bath temperature,
Coal and oil leakages
▪ Maintenance Mingguan
Greasing of spring adjusting bolt
Greasing of journal stop bolt.
Check gear case oil for contamination

▪ Shutdown Maintenance setelah 6 atau 8 bulan

Oil level in journal dan kualitasnya
All internal clearances
Greasing the gear coupling
Inspeksi Harian
Inspeksi Harian
Program Maintenance
dan Inspeksi
Inspeksi Saat Mill Beroperasi
Checks ▪ Operational parameters
▪ Material and oil leaks
▪ False air
▪ Vibrations of gear drive and mill
casing
▪ Wear, holes and cracks
▪ Separator
▪ Sealing air fan
▪ Lubrication system
Program Maintenance
dan Inspeksi
Inspeksi Saat Mill Stop
∗ wear parts (table, rollers, nozzles, dam ring, bearings
exposed to material/gas flow, feed gate, etc.)
∗ bearings, roller bearings, bearing sealings
∗ air locks, sealing air system for bearings
∗ lubrication systems (filters, oil conditions)
∗ hydraulic pressure system, include. accumulators
∗ gear device, clutch
Program Maintenance
dan Inspeksi
Inspection during standstill
Inspeksi external dan internal

Untuk mendapatkan gambaran menyeluruh,

termasuk bagian yang perlu diganti
Untuk mendeteksi ancaman sebelum menjadi
masalah seperti:

▪ Masalah lubrikasi Wear on rollers

and table
▪ Retakan di wear segments dan clamps
Program Maintenance
dan Inspeksi
Inspeksi separator
Merupakan bagian penting
yang menentukan kinerja sistem
sehingga perlu diperiksa secara
regular

Evaluation of rotor and

louvres (guide vanes)
Program Maintenance
dan Inspeksi
Inspeksi Gearbox
Pengukuran vibrasi untuk
mendapatkan gambaran akurat
tentang kondisi gearbox
Program Maintenance
dan Inspeksi
Maintenance checks
▪ Clearance grinding rolls dan bull ring segments
▪ Spring gap adjustment (antara journal head dan head of
spring assembly)
▪ Spring tension.
▪ Kondisi kerucut (eroded/punctured)
Program Maintenance
dan Inspeksi
Maintenance checks
▪ Kondisi classifier
▪ Ketinggian dan kondisi venturi
▪ Sealing arrangement pada insulation plates (kerusakan akibat
perbedaan temperatur)
▪ Clearance antara scrapper dan insulation plate
Preventive Maintenance
Contoh Program Maintenance VRM di Baturaja
Contoh Program Maintenance VRM di Baturaja
Program Maintenance
dan Inspeksi
Maintenance checks
▪ Check the condition of oil in gearbox
▪ Check level of oil
▪ Flush the oil coolers if required.
Overhaul
Servicing of journal assembly
▪ Lower the journal assembly (lower edge touches floor)
▪ Remove the set screw or strips welded on the roll lock nut
▪ Remove the roll lock nut
▪ Lift the assembly by sliding over journal head assembly
▪ If unable to remove use jack and assembly
Roller Overlay
Up-grade
Ribs
▪ Chrome carbide traction
ribs tegak lurus pada arah
travel akan menjaga rolls
dari skidding di dalam mill.
▪ Menyebabkan amperage
draw meningkat dan
keausan tidak merata
Roller Overlay
Up-grade
Continuous Tungsten Carbide
Chip Wear Band
▪ Oleskan tungsten carbide chip
wear band ke seluruh area high-
wear dari roller.
▪ Memperpanjang life time
Roller Damage
Worn Spalling
Bearing Damage
Trouble Shooting
Masalah Kehalusan Coal
Possible Cause Corrective Action
Uneven deflector blade settings Calibrate the blades properly

Worn or damage deflector blades Inspect repair and /or replace

deflector blades as soon as possible

Low or high spring compression Check the compression and change as

required.

Grinding process Inspect repair by patching the holes or

replacing the cone as soon as possible
Trouble Shooting
Noise above bowl
Possible Cause Corrective Action
Reject material on bowl Stop the pulverize, inspect and
remove the material.

Failed grinding roll Stop the pulverize, repair or replace

the journal assembly.

Uneven spring pressure Check the spring pressure, change

if required (250 kg/cm2)

Heavy reject material Stop the pulverized, remove the

material and check the damage
Operasi Yang Aman
Operasi coal mill yang tidak sesuai prosedur
keselamatan akan memicu ledakan
▪ Metode penimbunan coal berupa tumpukan kecil untuk
menghindari pembakaran spontan
▪ Penurunan gap bar grate untuk mengurangi kecepatan angin dan
meningkatkan kecepatan pengeringan.
▪ Settling chamber antara coal mill dan pipa mencegah bubuk coal
panas memasuki coal mill
▪ Tambahkan explosion-proof valve pada bukaan
▪ Naikkan kehalusan coal dari 10% menjadi 15%.
▪ Safety rules
Operasi Yang Aman
Ketika beroperasi
▪ Aerasi ok

▪ Tidak overfeeding atau underfeeding

▪ Temperatur tidak melebihi batas

▪ Prosedur start dan stop coal mill ok

▪ Temperatur udara dari coal mill lebih tinggi dari dew point.
Operasi Yang Aman
Ketika Terjadi
Ledakan

Emergency ▪ Tutup valve udara panas dan valve pneumatic

plan
▪ Cegah bubuk coal panas masuk dust collector

▪ Jika temperatur melebihi 80 °C, start carbon

dioxide extinguisher
Operasi Yang Aman
Jika coal mill stop 3 hari

▪ Kosongkan hopper batubara atau menempatkan

lapisan serbuk di permukaan untuk mengisolasi
batubara dari oksigen sebelum stop coal mill

▪ Kosongkan batubara di coal mill sebelum stop coal

mill

▪ Tutup katup udara panas dan buka katup angin baru

kemudian stop feeding

▪ Tidak untuk menghentikan kolektor segera.

Operasi Yang Aman
Isolasi Mill
▪ Hot air shut off gates
▪ Cold air shut off gate
▪ Seal air shut off valves
▪ Mill discharge valve should be closed
▪ Mill and feeder motor breakers are
to be left open.
▪ Disconnect the electricity
Jangan Lakukan
◼ Jangan masuk ke dalam mill ketika motor tidak
terisolasi dan katup pembuangan ditutup

◼ Jangan gunakan palu baja pada gulungan

◼ Jangan menggunakan obor api langsung untuk

perakitan bantalan
Jangan Lakukan
◼ Jangan meninggalkan peralatan kerja di dalam coal mill

◼ Jangan mengubah setting classifier, pengaturan pegas

kompresi, pengaturan roll ring, roll ring clearance dll

◼ Jangan melakukan pekerjaan pemeliharaan di dalam

pabrik tanpa peralatan keselamatan yang tepat

◼ Jangan mengelas pada mangkuk atau bagian yang

melekat padanya kecuali mesin las digrounded untuk
mangkuk untuk mencegah lengkung pada permukaan
Terimakasih
Major Breakdowns – Roller Bearing
Major Breakdowns – Gearbox
Rekondisi Permukaan
Roller dan Table
Table, Dam Ring, Nozzle Ring
Wear Resistance Material Alternatif
 Contoh Sheet Walk By Inspection
No Description Standard Yes No
1 Coupling condition normal
2 Reducer noise & Vibration normal
3 Oil reducer temperature max 60 ° C
4 Reducer oil level normal
5 Reducer oil pipe line tidak bocor
6 mill body vibration 5 - 9 mm/sec
7 Pressure operation 20 - 30 kg/cm
8 wall liner bolt tidak kendor
9 Grinding Roller 1 noise normal
Grinding Roller 1 blander tidak bocor
Grinding Roller 1 casing cone tidak bocor
Grinding roller rubber seal tidak bocor
grinding roller 1 bolt tidak kendor
Grinding roller 1 big door bolt tidak kendor
 Contoh Sheet Walk By Inspection
10 Rocker arm 1 bearing noise normal
Rocker arm 1 bolt pin tidak kendor
Rocker arm 1 bearing bolt tidak kendor
11 Rocker arm 2 bearing noise normal
rocker arm 2 bolt pin tidak kendor
Rocker arm 2 bearing bolt tidak kendor
12 rocker arm 3 bearing noise normal
rocker arm 3 bolt pin tidak kendor
rocker arm 3 bearing bolt tidak kendor
 Contoh Sheet Walk By Inspection
14 Hydraulic spring seal tidak bocor
Hydraulic spring seal rod end tidak bocor
Hydraulic spring flexible hose tidak bocor
Hydraulic spring pin rod end tidak lepas
Hydraulic spring bearing rod
end tidak aus
Hydraulic spring 4 bolt clamp tidak kendor
15 Roller oil return pressure max 4 mmHg
80 - 120
Roller oil return flow from roller L/min
Roller oil supply pressure 40 psi
Roller oil supply flow from roller 10 - 40 L/min
 Contoh Sheet Stop Inspection

NO PART OF EQUIPMENT STANDARD CONDITION REMARKS

1 OIL REDUCER LEVEL NORMAL

2 PONDATION BOLT TIGHT

3 COUPLING CONDITION NO CRACK

4 GRINDING TABLE WEAR MAX 66%

5 ROLLER TIRE WEAR MAX 66%

6 SAFETY BOLT TIRE COND. NO MISSING

7 COVER SEAL BOLT NO MISSING

8 LINER BODY MAX. 70%

9 LINER BODY BOLT TIGHT

10 LOUVRE RING INSERT NO WEAR

 Contoh Sheet Stop Inspection

NO PART OF EQUIPMENT STANDARD CONDITION REMARKS

11 LOUVRE RING SEGMENT NO WEAR

12 LINER SEGMENT NO WEAR

13 CROWN HALF NO WEAR

14 SEAL SHAFT NO WEAR

15 CUP SEAL NO WEAR

16 SHEALD NO WEAR

17 CHUTE NO WEAR

18 BLADE SCRAPPER NO WEAR

19 LINER BLADE SCRAPPER NO WEAR

TIGHT & NO
20 LINER SCRAPPER BOLT WEAR
 Contoh Sheet Stop Inspection
NO PART OF EQUIPMENT STANDARD CONDITION REMARKS

21 RUBBER SEAL BIG DOOR NO MATL SPIL

22 CLEARENCE BRG ROCKER ARM MAX 0.008"

23 GREASE LINE NO LEAKAGES

24 CLASIFIER BLADE NO WEAR

25 CLASIFIER BOTTOM NO WEAR

26 CLASIFIER SUPPORT COND. NO WEAR

27 CLASIFIER COUPLING COND. NORMAL

28 CLASIFIER REDUCER OIL LEVEL NORMAL

29 HYD. SPRING CONDITION NO LEAKAGES

30 HYD. SPRING BEARING COND. MAX 0.008"

31 HYD. FLEXIBLE HOSE COND. NO LEAKAGES

32 RODE END COND. NORMAL

33 RODE END BEARING COND. NORMAL

34 RODE END CLAMPING BOLT. NO MISSING

35 BEARING ROCKER ARM NORMAL