SUBJECT :

TUBE MILL INTERNALS,

INTERLOCKS & PROTECTIONS

PREPARED BY: M.K.DALEI/E3

BALL & TUBE MILL( TYPE BBD – 4722)

The ball & tube mills are low-speed Mills that grind
the coal with steel balls in a rotating horizontal
cylinder.
Due to its shape, people call it as Tube Mill &
Due to use of Grinding Balls for crushing, it is called
Ball Mill. These Mills are also designated as BBD-
4722, Where-
B - BROYER (Name of the inventor).
B - BOULET (French word for balls).
D - DIRECT (Firing used).
47-Length of the shell in decimeters (4.7 mtr)
22-Dia. of the shell in decimeters (2.2 mtr dia)
 CONSTRUCTION OF TUBE MILL

CLASSIFIER
ASSEMBLY
MIXER
BALL FEED
SYSTEM
CENTER COAL PIPE
MILL LINER
GIRTH GEAR BODY

HOT AIR BOX SCREW

CONVEYOR

MAIN REDUCER
AUXILLARY REDUCER
GRINDING MEDIA
 NTPC LIMIED, TSTPS-KANIHA
PULVERISING ACTION IN BALL TUBE MILLS
 Crushing by Impact as balls collide with each other
and coal particles.
 Fine Grinding By Attrition as balls roll over each
other as well as balls roll over liners with coal particle
in between.
Screw Conveyor Assembly
CYLINDRICAL SHELL LINER

SHORT CONICAL LINER

LONG CONICAL LINER

INLET LINER

SCREW CONVEYOR RIBBON

HOT AIR TUBE

CONNECTING ROD

INLET LINER WITH BOSS

DETAILS FOR SCREW CONVEYOR ASSEMBLY

RIBBON

REMOVABLE
SHAFT

ANGLE

CHAIN
&
CHAIN LINK
 DRIVING SYSTEM(BALL MILL)
GG FAN

MILL
BRAKE

MR
MM AR AM

COOLER

FILTER

REDUCER
SEAL P/P
AIR
 MILL COAL/AIR FLOW CIRCUIT

BUNKER

FEEDER

BURNER
CLASSIFIER

MILL
BYPASS PA

MAIN PA

MIXING BOX
COLD
HOT AIR
AIR
 FILTER
B/S
LOP

CLR
HP LOP

LP LOP

TANK MILL LUB OIL SYSTE

DRIVEN PULLEY

FEEDER CHAIN LINK

FEEDER OUTLET GATE

COAL PIPE TO
FURNACE INERTING LINE

PC GATE

PURGING LINE
CLASSIFIER
 GREASE DISCHARGE LINE

GREASE PUMP
ASSEMBLY INSIDE

GREASE DRUM

AIR SPRAY LINES

GREASE DISCHARGE
LINES

GREASE DISTRIBUTOR
SPECIFICATIONS :

MILL SECIFICATION
Type: Ball Tube Mill BBD 4722 bis
Nos: 05
Speed of Mill: 16 rpm
Mill O/L Temp : 90 Deg C
Wt of Ball Charge : 118.5 MT
Max Coal Output : 89.15 T/Hr
Max Mill Power : 2054 KW

LOP SPECIFICATION
LP HP B&S
Type Screw Screw PI CBN
No 02 04 02
RPM 750 965 1450
Pr(Bar) 10 80 70
Flow -- -- --
Supply 415V 415V 415V
SPECIFICATIONS :

RAW COAL FEEDER DATA

Type : Volumetric
Size of Coal : 0 – 50mm
Flow Rate : 28.8 to 72T/Hr
Initial Moisture : 12%

MISCELLENEOUS
Size of Ball : 30/40/50 mm
Ratio of Ball : 2:3:4
Ball Material : Hi-Chrome Steel
Liner Material : Hi-Chrome Steel
 BALL & TUBE MILL :MERITS & DEMERITS
Advantages :
Less maintenances.
No mill rejection.
Load Variations is very fast.
Less Un burnt due to better fineness.
Fuel air ratio is 1:1.2 is very less as compare to bowl mills.

Disadvantages:
High power consumptions.
More no. of auxiliaries.
More Starting time.
Outage of one mill reduce 25% load.
Only one mill can be kept as standby.
Beside these one major risk associated with these mills is if Mill

level DP and Noise does not respond properly there may be

explosion in these mills that lead to furnace pressurization and
unit tripping.
PROTECTIONS &
INTERLOCKS OF
TUBE MILL
 MILL START
SL NO PERMISSIVES:
DESCRIPTION SET POINT
1 BOILER MINIMUM FLOW FOR COAL FIRING (STEAM FLOW >15%) >15%
2 ASSOCIATED LIGHT UP BURNER IN SERVICE UPTO 25% LOAD >15%

3 MFT IS RESET RESET

4 PA HDR PRESSURE IS SUFFICIENT (>600MMWC) >600MMWC
5 NO STOP COMMAND EITHER FROM FGC OR MANUAL NO
6 BUNKER LEVEL IS ADEQUATE (NOT LOW) > ADQT
7 PURGE SEQUENCE IS COMPLETED COMPLTD

8 STEAM INERTING TO MILL & CLASSIFIER IS COMPLETED COMPLTD

9 BUNKER O/L GATE IS OPEN OPEN

10 ELECTRO MAGNETIC BRAKE IS LOCKED IN OPEN CONDITION LOCKED

11 GIRTH GEAR SEAL AIR FAN IS STARTED STARTED

12 MILL BRG/REDUCER LUBRICATION CORRECT & MEMORY IS SET SET
13 ALL PC PIPE CHECK VALVES ARE OPEN OPEN
SL NO DESCRIPTION SET POINT
14 ALL PC GATES ARE OPN OPEN
SEAL AIR FAN IS RUNNING & DP BETWEEN SA FAN DUCT & MILL >200
15 MMCW
HOT AIR BOX IS NOT LOW LOW.

16 AUX MOTOR IS STOPPED STOPPED

CONDITION FOR MILL

SL NO TRIPPING:
DESCRIPTION SET POINT
BOILER LOAD IS < 13% MCR OR <23% MCR FOR MORE THAN 10 <13%
1 OR
SEC & ASSOCIATED OIL BURNER LEVEL IS NOT LIT & DETECTED <23%
2 MILL MOTOR/MILL BEARING TEMP HI HI > 100C
3 AUX MOTOR CONTACTOR ENGAGED WITH MAIN MOTOR > 10 SEC

4 REDUCER/MILL LUBRICATION IS RESET RESET

5 ELECTROMAGNETIC BRAKE IS DETECTED LOCKED LOCKED
6 ‘GGG IS CORRECT’ IS CORRECT FOR >10 MIN & MAIN MOTOR ON RESET
SL NO DESCRIPTION SET POINT
7 GEAR CENTRIFUGAL CLUTCH IS DETECTED(High Speed Protection) High Speed
8 GG SAF TRIPPED WITH I MIN. TIME DELAY
MILL IS IN ONE SIDE SERVICE & 30 SEC AFTER CONTROL LOOP
9 <10 T/Hr
IN OPERATION, IF TOTAL AIR FLOW <40 T/Hr
10 EPB IS ACTUATED FROM PANEL OR OIS PRESSED
11 ANY FDR NOT STARTED 10 MIN. AFTER MAIN MOTOR STARTS > 12 MIN.
WITHIN 15 MIN. OF 1st FDR STARTING IF BOTH FDR TRIPS/OR
12 12 MIN.
1sT FDR TRIP & 2nd FDR NOT IN SERVICE
AFTER 15 MIN. OF 1st FDR START IF BOTH FDR TRIPS THEN MILL OPEN
13
WILL TRIP AFTER 12 MIN. (TO EMPTY THE MILL) 12 MIN.

14 SEAL AIR DP IS LO-LO < 50MMWC FOR >200 SEC <50 mmwc
15 RAW COAL BUNKER LEVEL LO-LO. LO-LO
16 PA HEADER PR LO-LO <400mmwc
17 RUN BACK SIGNAL FROM CMC RUNBACK
 FEEDER START
SL NO
PERMISSIVES:
DESCRIPTION SET POINT
1 MAIN MOTOR IS IN SERVICE In Service
2 PC GATES ARE OPEN (4/8), DEPENDING ON TYPE OF SELECTION OPEN

3 MILL O/L CECK VALVES ARE OPEN OPEN

4 BUNKER O/L GATES ARE OPEN OPEN

5 FEEDER O/L GATES ARE OPEN OPEN

6 NO MFT PREVAILING NO MFT
7 BOILER LOAD > 15% > 15%

8 CLASSIFIER O/L TEMP > 60° C FOR > 2 Min. > 60° C
 LP LUB OIL PUMP ( FOR DE & NDE BEARING)
START
SL NO DESCRIPTION SET POINT
1 START UP ORDER IS GIVEN FROM CR & LUB OIL TANK LVL IS NORMAL >50%
2 ON AUTO IT WILL TAKE START
a) If the stand by pump has tripped Or Tripped
b) Through SGC at step-3 Start
c) One pump is running & lub oil flow is low < 50%

STOP
SL NO DESCRIPTION SET POINT
1 By giving stop command from OIC if mill is not runnimg Stop
2 By pressing EPB Pressed

3 On it stops after the stand by pump has started on lub oil flow low Started
for > 30 Sec < 25 lpm
4 Any lub oil pump is running & flow lo lo < 20 lpm
5 Lub oil tank level lo lo < 40%
START HP BRG JACKING PUMP ( FOR DE & NDE BEARING)
SL NO DESCRIPTION SET POINT
1 START UP ORDER IS GIVEN FROM CR & LUB OIL TANK LVL IS NORMAL >50%
2 One LP pump is running Running
3 The temp at cooler O/L is normal from LP pump discharge is normal < 45°
4 The supply oil pressure from LP pump discharge is not LOW > .3KCS
5 Through SGC at step-3 Start
On auto stand by pump takes start if,
a) Runnig pump has tripped Tripped
b)Pump running & disch pr goes lo lo for > 10 sec < 20 kcs
STOP
SL NO DESCRIPTION SET POINT

1 By giving stop command from OIC if mill is not runnimg Stop

2 By pressing EPB Pressed
On it stops after the stand by pump has started on lub oil flow low Started
3
for > 30 Sec < 20 kcs
4 Any lub oil suction pressure goes lo lo for > 5 sec < .2 kcs
5 If the HP pump is running & pr goes lo lo for 2 sec < 17 kcs
START HP BRG JACKING PUMP ( FOR DE & NDE BEARING)
SL NO DESCRIPTION SET POINT
1 START UP ORDER IS GIVEN FROM CR & LUB OIL TANK LVL IS NORMAL >50%
2 One LP pump is running Running
3 The temp at cooler O/L from LP pump discharge is normal < 45°
4 The supply oil pressure from LP pump discharge is not LOW > .3KCS
5 Through SGC at step-3 Start
On auto stand by pump takes start if,
a) Running pump has tripped Tripped
b)Pump running & disch pr goes lo lo for > 10 sec < 20 kcs
STOP
SL NO DESCRIPTION SET POINT

1 By giving stop command from OIC if mill is not runnimg Stop

2 By pressing EPB Pressed
On auto it stops after the stand by pump has started on lub oil Started
3
flow low for > 30 Sec < 20 kcs
4 Any lub oil suction pressure goes lo lo for > 5 sec < .2 kcs
5 If the HP pump is running & pr goes lo lo for 2 sec < 17 kcs
START HP BALL & SOCKET PUMP ( FOR DE & NDE BEARING)
SL NO DESCRIPTION SET POINT
1 Start up order is given from CR & lub oil tank level is normal >50%
2 Any one LP pump is running Running
3 The temp at cooler O/L from LP pump discharge is normal < 45°
4 The supply oil pressure from LP pump discharge is not LOW > .3KCS
5 On auto stand by pump takes start if,
Tripped
a) Running pump has tripped
< 15 kcs
b)Pump running & disch pr goes lo lo for > 2 sec
STOP
SL NO DESCRIPTION SET POINT

1 By giving stop command from OIC if mill is not runnimg Stop

2 By pressing EPB Pressed
On auto it stops after the stand by pump has started on lub oil Started
3
flow low for > 30 Sec < 15 kcs
4 Any lub oil suction pressure goes lo lo for > 5 sec < .2 kcs
5 If the HP pump is running & pr goes lo lo for 10 sec < 12 kcs
THANK YOU
ALL
THANK YOU
ALL
NTPC LIMITED, TSTPS-KANIHA
COAL PIPES
 FILTER
B/S
LOP

CLR
HP LOP

LP LOP

TANK
MILL LUB OIL SYSTEM
 MILL COAL/AIR FLOW CIRCUIT

BUNKER

FEEDER

BURNER
CLASSIFIER

MILL BYPASS PA

MAIN PA

MIXING BOX
HOT AIR COLD
AIR
 DRIVING SYSTEM(BALL MILL)

GG FAN

MILL
BRAKE

MR
MM AR AM

CLR

FILTER

REDUCER
SEAL AIR P/P
MILL
 BALL & TUBE MILL (TYPE:BBD4722)
The ball & tube mills are low-speed Mills that grind the
coal with steel balls in a rotating horizontal cylinder.
Due to its shape, people call it as Tube Mill &
Due to use of Grinding Balls for crushing, it is called Ball
Mill. These Mills are also designated as BBD-4722,
Where-
B - BROYER (Name of the inventor).
B - BOULET (French word for balls).
D - DIRECT (Firing used).
47-Length of the shell in decimeters (4.7 mtr)
22-Dia. of the shell in decimeters (2.2 mtr dia)
 MILL SPECIFICATION
Type: Ball Tube Mill BBD 4722 bis RAW COAL FEEDER DATA
Nos: 05
Type : Volumetric
Speed of Mill: 16 rpm
Size of Coal : 0 – 50mm
Mill O/L Temp : 90 Deg C
Flow Rate : 28.8 to 72T/Hr
Wt of Ball Charge : 118.5 MT
Initial Moisture : 12%
Max Coal Output : 89.15 T/Hr
Max Mill Power : 2054 KW

LOP SPECIFICATION
MISCELLENEOUS LP HP B&S
Type Screw Screw PI CBN
Size of Ball : 30/40/50 mm No 02 04 02
Ratio of Ball : 2:3:4 RPM 750 965 1450
Ball Material : Hi-Chrome Steel Pr(Bar) 10 80 70
Liner Material : Hi-Chrome Steel Flow 116 10 03
Supply 415V 415V 415V