1. Presented by Dipl. Ing. Andreas Gajewski / Vikas Vaish
Customer Service
Senior Commissioning Engineer / Process
Loesche GmbH, Germany
gajewski@loesche.de
www.loesche.com
Training on The Job
Trouble Shooting
Loesche Vertical Roller Mill
LM 56.4 / LM 35.3 D / 56.3 + 3 C/S
for
Pearl Dhar Cement plant
3. 25-Apr-23 3
Some of the figures are illustrations and do not illustrate the built version.
For specific details please consult the documentation.
Compliance with safety instructions is mandatory.
4. 25-Apr-23 4
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
5. 25-Apr-23 5
âȘ A grinding system is optimised to the surrounding conditions
âȘ Material properties
âȘ Product qualities
âȘ External heat sources
âȘ Etc.
âȘ Optimum conditions are achieved by optimum adjustments
(mechanical and process wise).
âȘ Mechanical optimisation
âȘ Spring stiffness tuning
âȘ Fitting the grinding force to the related conditions
âȘ Dam ring and support ring optimisation
âȘ Process optimisation
âȘ Utilisation of PID loops
âȘ Optimum tuning of PID control loop
âȘ Use of master group/expert system
General
6. 25-Apr-23 6
âȘ A plant will operate continuously and with highest efficiency and reliability
under the above mentioned conditions.
âȘ Apart from smooth operation reliability is one of the most beneficial factors
of an automated process.
âȘ Without well planned and scheduled maintenance trouble shooting witll
become costly.
General
7. 25-Apr-23 7
âȘ A VRM reacts within minutes or even seconds
âȘ Immediate and sometimes major actions / adjustments are needed
âȘ During upset conditions typically vibrations occur, ignore until going out of hand
âȘ Best case reaction: reduction of working pressure
âȘ Worst case: mill trips
âȘ Feed stops
âȘ Mill motor stops
âȘ Rollers raise and stay raised in stand-by mode
âȘ Mill fan and HGG are reduced to minimized operation (stand-by)
âȘ Dampers go to stand-by adjustments (TBD)
âȘ Identify reason for mill trip â do not restart tripped mill
âȘ Immediate restart possible since mill is still hot:
âȘ Increase fan to > 70 %
âȘ Adjust dampers to feed start position
âȘ Start mill drive
âȘ Start feed, rollers will lower automatically
âȘ If operator is available plant will be back to full production in < 15 min
General
8. 25-Apr-23 8
Normal mill operation
Possible factors of disturbance
Lack of mechanical
maintenance
Frequent changes of
feed properties
Improper sealed
electrical connections
Lack of E,C&I maintenance
Operatorâs misinterpretation of
operating conditions
General
9. 25-Apr-23 9
âȘ Comparison of operating data, trend and frequent inspection / maintenance
will give information on slowly developing problems.
As for e. g.:
âȘ Wear
âȘ Drift of indications of operation parameters
âȘ Clogging of filters
âȘ Pollution of oil
âȘ etc.
General
Prevention is the key
10. 25-Apr-23 10
âȘ Process Parameters:
Properties that are important to the process but cannot be adjusted directly.
Examples: temperature, gas pressure,âŠ
âȘ Process Control Parameters:
Properties that can be adjusted and will influence / control the process and hence the
process parameters. Examples: damper position, fuel rate, ..
âȘ Quality Parameters:
Properties of the final Product that cannot be adjusted directly .
Examples: Blaine value, residue on sieves, âŠ
âȘ Quality Control Parameters:
Properties that can be adjusted and will influence / control the final product quality.
Examples: classifier rpm, gas flow, ..
Definition of different parameters :
General
11. 25-Apr-23 11
Process parameters and related control parameters
(in sequence of importance)
âȘ Gas flow: mill fan rpm / damper position
âȘ Mill outlet temperature: HGG fuel / fresh air / recirculation gas flow rates
âȘ Mill differential pressure: feed rate / working pressure / gas flow
âȘ Mill inlet pressure: stack / recirculation / fresh air damper positions
âȘ Mill vibration: various reasons
âȘ Power consumption: feed rate / working pressure / position of S-rollers
âȘ Grinding bed depth: Feed rate / working pressure / position of S-rollers
General
12. 25-Apr-23 12
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
14. 25-Apr-23 14
Measured by
âȘ Venturi tube
âȘ Various sensors
âȘ Mill fan motor power consumption
Influenced by
âȘ Mill differential pressure
âȘ Recirculation
âȘ Stack / fresh air damper positions
âȘ HGG on / off
Controlled by
âȘ Mill fan rpm
âȘ Mill fan damper
SecondaryInfluences
âȘ Feed rate
âȘ HSLM working pressure
âȘ Classifier rpm (mill differential pressure)
âȘ Control mill inlet pressure
(Stack/Recirculation Dampers)
âȘ Control mill outlet temperature (HGG
function / FreshAir Damper)
Automated control loop necessarydue to multiple influences and major importance
of gas flow for the entire process and product quality
Process gas flow
15. 25-Apr-23 15
Observation Analyse reasons Possible measures
Gas flow increases checking of
â feed
â control loop
â venturi pipe / pitot tube
â product fineness
â classifier
â false air
â closing fan inlet damper or
â decreasing fan speed
Gas flow decreases checking of
â instrumentation
â reject
â control loop
â Î P (mill or filter / cyclone)
â opening fan inlet damper or
â increasing fan speed
Gas flow < LL checking of
â control loop
â function of fan damper âCâ (only RM)
â venturi / pitot tube measurement
â stopping mill feed
Process gas flow
16. 25-Apr-23 16
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
18. 25-Apr-23 18
Measured by
âȘ Thermometer
âȘ Thermocouple
âȘ PT100 in mill outlet duct
Controlled by
âȘ HGG fuel flow rate
âȘ Position of fresh air damper: open
Influenced by
âȘ Feed temperature
âȘ Water injection
âȘ Recirculation gas
SecondaryInfluences
âȘ Mill differential pressure control (feed rate â temperature)
âȘ Vibration control (water injection)
âȘ Control of mill inlet pressure (stack / position of damper in recirculation duct)
Automated control loop necessarydue to multiple influences and major importance of gas
temperature for the entire process / product quality
Mill outlet temperature
19. 25-Apr-23 19
âȘ Possible reasons
âȘ Temperature control loop failed
âȘ Water injection failed
âȘ HGG failed
âȘ FreshAir damper blocked
âȘ âŠ
âȘ Mill outlet temperature too hot > 100 °C (except Slag Mill, where limit is > 110 °C)
âȘ Usually resulting in mill vibration due to gas flow capacity reduction (gas too
thin to lift sufficient material from table => grinding bed too high, table too full)
âȘ Mill outlet temperature too cold < 60 °C
âȘ Usually resulting in quality problems with cement strength and low Blaine
value, vibration also possible (gas too dense, lifting too much material from
table => grinding bed too thin, table too empty)
In both cases large correction steps are needed by increasing / decreasing the HGG
fuel flow and / or adjusting the fresh air damper more close / open.
Remark: in Clinker/Slag Mills; Water injection is NOT meant for temperature control!
Mill outlet temperature too hot / too cold
20. 25-Apr-23 20
Observation Analyse reasons Possible measures
Temperature
increases
Temperature > HH
checking of
â control loop
â water injection
â HGG / hot gas supply
â fresh air damper blockage
â blockage of feed system
â feed moisture
â start water injection
Coal mills:
â reduce booster fan speed
â open hot air damper
CS and RM mills:
â open damper âZâ
â reduce HGG load
â quick stop
Temperature
decreases
Temperature < LL
checking of
â control loop
â water injection
â HGG / hot gas supply
â fresh air entrance
â feed rate
â feed moisture
â reduce water injection
Coal mills:
â increase booster fan speed
â close hot air damper
CS and RM mills:
â close damper âZâ
â increase HGG load
â stop mill feed
Mill outlet temperature
21. 25-Apr-23 21
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
23. 25-Apr-23 23
Measured by
âȘ Pressure measurements before / after mill (pressure transmitters)
Controlled by
âȘ Mill feed rate
âȘ Weigh feeder speed
Influenced by
âȘ HSLM working pressure
âȘ Gas flow rate
âȘ Classifier rotor rpm
âȘ Gas temperature
SecondaryInfluences
âȘ Quality control (classifier rpm, hydraulic pressure)
âȘ Mill fan rpm / damper control (gas flow rate)
âȘ HGG fuel rate / fresh air damper position (mill outlet temperature control)
Feed Rate is kept constant, the other parameters are to be adjusted
Mill differential pressure
24. 25-Apr-23 24
Observation Analyse reasons Possible measures
Î P increases checking of
â working pressure
â feed rate
â classifier speed
â air flow
â temperature
â reduce feed rate
Î P decreases checking of
â feed
â classifier speed (product fineness)
â air flow
â working pressure
â temperature
â increase feed rate
Î P > HH checking of
â product quality
â working pressure
â wear of grinding parts
â hydraulic and N2 pressure
â feed
â stop mill feed
Mill differential pressure
25. 25-Apr-23 25
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
27. 25-Apr-23 27
Measured by
âȘ Pressure measurements before mill (pressure transmitters)
Controlled by
âȘ Recirculation damper
âȘ Stack damper
Influenced by
âȘ Mill differential pressure
âȘ Fan pressure/rpm
âȘ Fresh air damper position
SecondaryInfluences
âȘ Feed rate
âȘ HSLM working pressure
âȘ Classifier rpm (mill differential pressure)
âȘ Temperature control mill outlet (HGG function / freshair damper)
âȘ Gas flow control (fan rpm)
Typically an automatic control loop is used to keep this parameter constant
REMARK: Overuse of recirculation gas may cause dew point problems
Mill inlet pressure
28. 25-Apr-23 28
Observation Analyse reasons Possible measures
pressure increases
(going to positive)
CS & Coal mills; check:
â damper âSâ is open
(it should never be closed more than 50%)
â enough wet gas can exit the system
â false air
â position of damper âRâ
RM mill; check:
- gas amount from preheater-tower or kiln and
- position of damper âBâ
- position of damper âCâ
- position of damper âRâ
â close damper âRâ
pressure
decreases
(going to negative)
CS & Coal mills; check:
- damper âSâ is open
(it should never be closed more than 50%)
- position of damper âRâ
RM mill; check:
- position of damper âBâ
- position of damper âCâ
- position of damper âRâ
â open damper âRâ
Mill inlet pressure
29. 25-Apr-23 29
Observation Analyse reasons Possible measures
pressure > 2 mbar CS & Coal mills; check:
- if damper âSâ is open
(it should never be closed more than 50%)
- ring duct
- position of damper âRâ
- false air
RM mill; check:
- position of damper âBâ
- position of damper âCâ
- position of damper âRâ
- gas flow through the mill
- ring duct
â stop mill feed
Mill inlet pressure
30. 25-Apr-23 30
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
32. 25-Apr-23 32
Measured by
âȘ Vibration sensor mounted at the mill body
Influenced by
âȘ Grinding bed depth
âȘ Grinding bed fineness
âȘ Grinding bed moisture
âȘ S-roller position / rpm
âȘ Water injection flow
âȘ HSLM working pressure / counter pressure
SecondaryInfluences
âȘ Wear of rollers / table (dam ring)
âȘ Mill too empty / full (differential pressure, grinding bed depth)
âȘ Feed size
âȘ Product quality (grinding bed fineness)
âȘ Feed moisture (grinding bed moisture)
âȘ Nitrogen accumulator charge
REMARK: Changing conditions of feed and wear profile need constant vigilance
Mill vibration
33. 25-Apr-23 33
âȘ Increased mill vibration is the most typically upset condition.
âȘ If the vibrations exceed level 1 i.e. H alarm, the computer interlocking will try to raise the
rollers in fast mode followed by re-lowering of the rollers.
âȘ If this is too late and the vibrations exceed level 2 i.e. HH alarm, the computer interlocking
will stop the feed and the mill motor, keep the rollers raised and adjust the gas ways to
the stand-by mode.
âȘ If the vibrations are higher than normal, but not yet at level 1 i.e. H alram, the operator
needs to identify the reason and perform the countermeasures as described in next slide.
Mill vibration
34. 25-Apr-23 34
Observation Analyse reasons Possible measures
Mill vibrations > HH Process disturbances:
- feed material too fine
- working pressure too high
- feed rate too low
- process gas flow too low
Mechanical disturbances:
- metal separator and / or metal
detector do not work properly
- iron parts inside in the mill more,
mill has to be cleaned & checked:
classifier, roller, table, lining
â stop mill motor
Mill vibrations
35. 25-Apr-23 35
Possible causes / indications / countermeasures
Mill too empty / too full
Indications:
âȘ Mill differential pressure too low / too high
âȘ Grinding bed too low / too high
Countermeasures:
âȘ Increase / decrease feed rate
âȘ Decrease / increase working pressure (may change product quality)
âȘ n. a. / increase water injection rate
âȘ adjust position of S-rollers
âȘ Increase / decrease classifier rpm (will change product quality)
âȘ Decrease / increase gas flow rate
Mill vibrations
36. 25-Apr-23 36
Possible causes / indications / countermeasures
Material on grinding table too wet / dry (too wet unlikelyfor CS mills)
Indications:
âȘ M-roller position (grinding bed depth) shaky (frequently jumping up / down)
âȘ S-roller rpm in position - control shaky
âȘ S-roller position in rpm - control shaky
âȘ Mill outlet temperature too low / too high or less / more fresh air required
Countermeasures for too dry material:
âȘ Adjust S-roller position (plant specific, TBD)
âȘ Decrease HSLM working pressure (may change product quality)
Mill vibrations
37. 25-Apr-23 37
Possible causes / indications / countermeasures
Mechanical or maintenance reasons
âȘ Nitrogen accumulators leaky, loss of pressure, loss of shock absorbing
âȘ Internal wear of grinding plate / roller tires without re-calibration of roller position
Indications
âȘ Excessive wear of grinding plate / roller tires
âȘ Faulty indication of gas flow (re-calibration needed)
âȘ Mechanic damage to the dam ring (e. g. by tramp metal)
âȘ Mechanic damage to the grinding plate / roller tires (e. g. by tramp metal)
âȘ âŠâŠ
Preventive maintenance helps avoiding vibrations due to mechanical reasons.
Mill vibrations
38. 25-Apr-23 38
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
39. 25-Apr-23 39
Vital for roller tires
and grinding plate
Metal detection and separation
Raw material
Metal
Reject material
40. 25-Apr-23 40
âȘ Metal detector has to be properly fine tuned to detect even small tramp metal pieces
without being too sensitive
âȘ The timing between getting the alarm and switching the pneumatic gate over is critical:
âȘ If it opens too slow â tramp metal passes by
âȘ If it closes back too fast â tramp metal passes by
âȘ If it opens too soon and / or stays open too long â waste of clinker
âȘ Over-belt magnetic separator typically on a transport before the detector to separate
most of the magnetic metal
Metal detection and separation
41. 25-Apr-23 41
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
42. 25-Apr-23 42
Observation Analyse reasons Possible measures
Power
Consumption
increases
Checking of
- working pressure too high
- feed rate too high
- blockage in reject transport (ring duct)
- wear of grinding parts
- raw material grindability
- lower temperature
- lower process gas flow
- higher feed moisture
- higher water injection
- higher material bed height
- Take appropriate action
according to analysed
reason
Power consumption - Mill motor
43. 25-Apr-23 43
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
44. 25-Apr-23 44
Observation Analyse reasons Possible measures
External material
recirculation rate too
high
Checking of
- gas flow too low
- mill inlet temperature too low
- working pressure too low
- feed rate too high
- wear of dam ring
- wear tires / table liner
- Take appropriate action
according to analysed reason
External material recirculation i.e Reject System
45. 25-Apr-23 45
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
46. 25-Apr-23 46
âȘ If - for any reason - the mill feed drops below a safe level interlocking will automatically
raise the rollers and adjust the grinding system to a stand-by mode until the operator
adjusts the gas ways for a re-start and starts the feed.
âȘ In case of the feed dropping to a level too low for good operation but above the
interlocked limit the mill reacts with vibration (too empty) until interlocking try to raise
the rollers (fast mode) and to adjust the stand-by mode.
If the roller raising takes too long the mill will trip.
âȘ A good operator catches the potential mill trip (alarms) and pro-actively re-adjusts the
feed rate back to normal (in the beginning slightly above to refill the mill) or initiates a
mill stand-by mode before the computer does so.
Mill feed starvation
47. 25-Apr-23 47
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
48. 25-Apr-23 48
âȘ Possible malfunctions
âȘ Pressure set points for HSLM working / counter pressure are not followed =>
system either unable to built up pressure or unable to drain pressure
âȘ Position or rpm set points for the S-Rollers are not followed => System unable
to pressurise one side or unable to drain pressure from the other side
âȘ Leakages in hydraulic cylinders / ring line or cabinet
âȘ In any one of these cases the control system will sound an alarm and if the deviation
is not fixed within a programmed time the control system will stop the feed and adjust
the mill to a safe stand-by mode.
âȘ If the malfunction is severe typically vibrations occur.
âȘ A good operator catches the alarms and initiates a controlled mill stop before the
control system takes over.
âȘ Due to the complexity of the hydraulic system an expert should review the
malfunction before a re-start.
Hydraulic malfunction
49. 25-Apr-23 49
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
50. 25-Apr-23 50
âȘ It is highly recommended that any alarm related to the mill drive (motor and gearbox)
is immediately reported to be reviewed by experienced personnel.
âȘ If the condition moves from alarm level to shutdown level and the mill trips, it is
highly recommended not to re-start until an experienced person has reviewed the
trend lines, alarms and general conditions on site and has given the âgood to goâ.
Mill drive alarms
51. 25-Apr-23 51
General
Process gas flow
Mill outlet temperature
Mill differential pressure
Mill inlet pressure
Mill vibrations
Metal detection & seperation
Power consumption â Mill motor
External material recirculation i.e. Reject system
Mill feed starvation
Mill Hydraulic malfunction
Mill drive alarms
Product Quality (Fineness)
Table of contents
52. 25-Apr-23 52
Observation Analyse reasons Possible measures
Product too coarse Checking of
- wear of grinding parts, dam ring & classifier
- classifier drive (broken coupling)
- working pressure
- gas flow
- increase classifier speed
- increase working pressure
- reduce gas flow
Product too fine Checking of
- classifier speed indication
- working pressure
- gas flow
- reduce classifier speed
- reduce working pressure
- increase gas flow
Change in PSD
- want to steepen
(i.e. less residue)
Increase working pressure +
classifier rpm + gas flow in
appropriate combination
Change in PSD
- want to flatten
(i.e. more residue)
Reduce working pressure +
classifier rpm + gas flow in
appropriate combination
Product Quality (Fineness)