ball mill trunnion bearing lube system
On a 11-6 x 22-0 Ball Mill, thetrunnion bearing lubrication system provides continuous low pressure flood oil for cooling and lubrication of the bearings, and high pressure oil for hydrostatic lift of the feed and discharge trunnions during start-up of the mill. System monitors including pressure switches and flow monitors are provided, along with temperature sensors that monitor the condition of the lube system. The signals from any of these monitors will alarm or trip the system depending on the deviation from the operating parameters.
The ball millslow pressure oil system pumps oil from the reservoir through a filter assembly to clean the oil before the flow is sent to the trunnion bearings.
During start-up, the oil is also pumped to the high pressure pump. Dual cartridge filters, connected in parallel, continually clean the oil. The duplexconfiguration of the filters allows for uninterrupted operation of the mill during filter cartridge replacement and maintenance. Flow monitors in the trunnion bearing supply lines monitor oil flow to the bearings and will alarm and trip the mill is low flow is indicated.
The ball mills high pressure oil system is designed to lift the trunnions during start-up by supplying high pressure oil. The high pressure pump is programmed to shut-down after the mill has been running for a predetermined amount of time.The high pressure pump pumps oil through the high pressure supply lines to the trunnion bearings. Pressure transmitters in the high pressure oil supply lines monitor the supply of oil to the bearings and provide interlock signals for mill operation to the control system.
The breakaway pressure is influenced by the amount of residual oil present in the trunnion bearings. Pressure can vary by as much as 3000 psi (207 bar) between a dry bearing and a bearing that had just operated. Start-up may have to be delayed to allow the weight of the mill to squeeze out excessive oil and achieve enough back pressure to satisfy the PSH. PSH setpoint must be set between breakaway pressure and floating pressure.
The trunnion bearings have temperature sensor assemblies to monitor the operating temperature of the trunnions. The readings of the temperaturesensors are sent to the control system where they are monitored automatically. If the operating temperature exceeds the programmed alarmand trip levels, the mill will be shutdown automatically. It is difficult to predict the exact operating temperature of trunnion bearings.
Experience has shown that each bearing stabilizes to its own temperature, ranging between 90F(32C) and 125F(52C). Many factors, such asambient temperature, quantity of oil, viscosity, bearing clearance, alignment, etc., contribute to the final operating temperature. If bearing temperatures do not stabilize after 5 hours of operation within this parameter, the mill must be shut down and corrective action taken.
The instrumentation must be calibrated before starting the mill. The easiest and safest way to adjust the instrumentation is to very carefully monitor all bearing temperatures during start-up and under normal grinding conditions. Adjust the individual set points for each bearing 10F(5.5C) higher than the stabilized temperature for alarm, and 15F(8C) for shut down.
Maintaining the ball mill charge and monitoring the feed rate will help to ensure maximum efficiency of the grinding system. System interlocks monitor the operating condition of the grinding mill and will shut down the mill if conditions deviate from operating parameters. Regular monitoring of the feed rate, ore hardness, mill power draw, mill charge volumes (charge weights), and periodic visual checks of the ball volume (with the charge ground out of the mill and the mill stopped) will give the trends of ball consumption per ton of material ground. With the information gathered per the above, a schedule of ball charge addition (quantity and intervals) can be established and maintained.
ball mills losing high & low lube pressure - grinding & classification circuits - metallurgist & mineral processing engineer
One of our Ball Mills keeps losing pressure on the high pressure pump. It will run fine when starting the Mill and suddenly after a while sometimes 1hrs the pumps will loose pressure. We have just grinded the journal and installed new white metal bearings. After startup this afternoon after about 1hrs the pumps low and high just lost pressure. We have cleaned the whole lube system and filled with new Carter XEP 460 oil. We had in Carter 320 before and had no problem, problems started right after the oil change. We did put in new HP pumps and it lasted 1 day. Please help!
It "sounds" like you have a problem with the oil filter - either by-passing or not meeting the necessary micron spec. I changed to a cheaper filter (Pall) once with the same micron spec as the original, but it wasn't doing the job and I burned out all of the Bosch HP pumps of their kind in North America before the problem was corrected (WIX).
It also could be yourlow PSI pump is cavitating and can't get the oil out fast enough as it it too weak for the new thicker oil you got... check that and maybe alsoincrease the diameter of the pump suction piping to ease the inlet delivery.
That said, the oil change should have prolonged the life of the HP pump, but the viscosity change now points to a more likely suspect - the HP pump is starving and cavitation is destroying the tolerances in the pump internals. If the HP pump is gravity fed (from a separate "clean oil" sump) then it may be necessary to increase the diameter of the pump suction piping to ease the inlet delivery. If the HP pump is fed directly from the LP pumps (via filters), then check the pressure drop across the filter, the setting on the pressure relief valve (may be by-passing), and the suction piping diameter on the LP pumps (they may be cavitating also, or simply not delivering enough volume).
If the bearings have a built-in dynamic wedge, it my not be necessary to keep the lift pumps on when the mill is running (short-term fix perhaps). This dynamic lift could also be relieving the HP pump discharge pressure and exacerbating the cavitation.
Another short or long-term fix may be to revert back to the lower (or an intermediate) viscosity lubricant until the system can be modified to handle the thicker stuff - larger pipes, more suction head (raise sump or lower pump to increase suction head), and perhaps a different HP pump altogether.
And last suggestion, though obvious and likely already considered, the oil level in the reservoir...the marks on the sight glass should indicate "running" and "idle" conditions to account for oil line filling and drain-back. If there is room to bump the level up a bit, this could help with the cavitation.
A single 1" manifold was supplying a 1" suction hose to the LP pump and two 3/4" suction hoses to the HP pumps, starving all 3... I replaced with a 2" manifold and 1 X 1.5" LP and 2 X 1" HP suction hoses - problem solved.
Another indication that your pumps are cavitating is noise - if your pumps are howling, growling, whining or are otherwise abnormally loud, they are probably starving. If you make a change and the pumps get quieter, you are probably onto the solution...
First question is why the oil type change, is it bypassing into tank, what do the filters look like, is there excess oil leaking from the trunnion area and simplest is the rotation correct on the new pump, if grinding took place did the mill trunnion sump get cleaned, not knowing the type of mill this is where we start.
I knowGibraltar had lube pumps and (I call them) dip cups, which were cups attached to the trunnion that would turn with the mill filling with oil pouring over the trunnion as the mill was turning. this is old school.
One final note: Pressure is resistance to flow, so youare saying there is no pressure, that would mean there is no flow which would mean your pump is not pumping. some pump design are made to by pass internally. thats why I ask what type of pump.
The HP pump we are using is a gear pump and the reason for the oil change on the lube from 460 to 320 was that for around 6 years we have used Carter XEP 460 on the fix side and Carter EP 320 on the float side. As we wanted to go to a common oil and recommended by supplier we opted for 460 on both sides. The problem with the HP started straight after we changed to that. As if the pump could not get suction.As we were loosing to much run time trying to sort the problem and obviously running out of pumps I instructed to go for the thinner oil and we had no problem since. Very strange as I do not feel comfortable with this as it does not make sense because the HP runs 100% on the fix side with 460 oil. I definitely like the flooded suction idea as our pump are positioned on top of the tank with a suction pipe leading into the pump from the bottom.
Must add that the instruction was given to keep the tank level full at all times even when running, that could have been one of our problem that the oil level in the tank was low and the pump was making a vortex at the suction but we are still going through all and the help from all are definitely implemented as well.
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ball mill gear box lubrication | circor
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Coal plants use a mill machine to finely pulverize coal before burning. These mills use large speed reducers between the motor drive and the mill and pumped or forced oil lubrication systems lubricate this equipment. Lubrication pump(s) may be driven from the reduction gear box or separately driven using electric motors.
Three screw pumps are commonly used to provide lubrication oil in ball mill gear box applications. The primary benefit that the 3-screw pump delivers in this application is its high resistance to contaminated fluids as the highly abrasive fine pulverized coal will migrate into the gears and the lube oil reservoir.
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