PERFORMANCE OPTIMIZATION OF PULVERIZING MILLS IN SIMHADRI THERMAL POWER PLANT" WORK CARRIED AT Nationl termal power corporation ltd.

, Simhadri, visakhalpatnam By

Project submitted for the partial fulfillment of B.TECH mechanical engineering d egree of Pragati engineering College ,embodies the work done by them under the s upervision of SHRI. DSGSS. BABJI, Sr. Superintendent NTPC, VISAKHAPATNAM

PRAGATI ENGINEERING COLLEGE, SURAMAPALEM,KAKINADA.

INTRODUCTION The Emerging New Force Of Indians Power Horizon

Crowning NTPCs superlative saga of power , simhadri thermal power project comes a live on the power map of the country with the synchronization of the first 500MW unit . racing against time in project implementation, the simhadri thermal powe r project has set a new bench mark for green-field project of the size and earne d the distinction of being the only power project in the country to commission t he 500MW unit in a record time of 39 months from the data of main plant order ,a feat that will probably remain unsurpassed. Spread over an area of 3,384 acres near Paravada in Visakhapatnam district of Andhra Pradesh. The 10,000MW Simhadri thermal power project has two units of 500MW capacity each. The entire power ge nerated from the station is supplied to Andhra Pradesh. The erstwhile Andhra Pra

desh state electricity boar had signed a power purchase agreement with NTPC on F ebruary 4,1997. The Simhadri power project will provide bountiful power to Andhr a Pradesh. The land of myriad opportunities. While commissioning the Simhadri pr oject is one step ahead, generation of reliable and quality power in large quant ities form this station will forever keep Andhra Pradesh for going a head in the country as well as globally. UNIQUE FEATURES The Simhadri power project is the first coastal coal fired Thermal power project of NTPC. The biggest in take well in country has been installed inside the bay of Bengal to draw seawater for in cooling system as make of water. Two natural draft-cooling towers of 165 meters height each are the in Asia and sixth biggest in world. First coal-based project of NTPC from which entire power is allocated To the home state i.e., Andhra Pradesh. Simhdri project has created new benchmark of excellence by commissioning the 500 MW unit in 39 months. Simhadri thermal power project achieved the boiler light up of 500MW unit of 35 months, which is a national record. The mist modern project in India having the state of art control and instrumenta tion system.

PROJECT LOCATION Paravada Mandal in Viskhapatnam district has the pride of being the location for Simhadri thermal power project. The project is approximately 40KM from visakhap atnam city and is approachable by NH-5 via Elamanchilli-Visakhapatnam road and f urther from Paravada to Vadacheepurupalli by road. The nearest railway station i s Duvvada on Howrah-Chennai main line. The project name simhadri comes from the name Simhachalam, the hill top temple of lord Varaha Lakshiminarasimhaswamy, which is 16KM from Visakhapatnam. The projec t was originally conceived by the erstwhile Andhra Pradesh state electricity boa rd, which subsequently, demography and socio-economic surveys, NTPC obtained Tec hno-economic clearance from the CEA in September 1996. The public investment boa rd of government of India gave its approval in February 1997. the cabinet commit tee on economic affairs accorded approval for the project in July 1997.

Setting up the simhadri thermal power project, a fast-track project has been a d aunting task. A total of 3,384 acres of land has been acquired for construction of this project. A great deal of courage to take bold decision, transform concep ts into real tasks, sound material, contractual, financial and manpower manageme nt helped in commissioning the project well ahead of schedule. For achieving speedy implementation, NTPC adopted a unique packaging concept at he project. The entire works were executed under 13 packages as compared to earl ier of 45 to 48 packages. The main plant turnkey contract was awarded to Bharat heavy electrical ltd., in November 1998. The scope of the main plant turnkey con tract include design manufacturing, engineering, civil construction, erection, t esting and commissioning. The massive task of installation of the project started with leveling works on D ecember 6th , 1998. the site leveling involved massive earth filling to the tune of more than 82 lakh cubic meter, which was completed in 16 months against a sc hedule of 17 months. This is the first coastal Greenfield project, where additio nal works were required to be done due to massive earth filling and deeper found ations as well of preparing structural designs that were suited for high wind zo ne and serene atmosphere to give protection for various structures, piping and e quipment. The entire construction, erection and commissioning works have been executed ens uring quality and efficiency. As the works progressed, the project has set new b enchmarks in project implementation by achieving several milestones well ahead o f schedule. One of the major miles stone achievements in unit-I boiler light upo n November 6th , 2001 in 35 months , which is a national record. The biggest intake well has been constructed offshore of the bay of Bengal for d rawing sea water for using in the cooling system for condenser cooling as make u p water. A275-meter tall chimney, which has been built for wide dispersal of flu e gases , is now towering over the area. Two natural draft-cooling towers with a height of 165 meters, which are the biggest in asia and 6th biggest in the worl d, have been constructed. Synchronization of the first 500MWunit in a record tim e 39 months is a challenge turned into mega reality through hard work, innovatio n , determination and courage in the face of the odds of the entire NTPC team. T oday, the project stands a mammoth power complex.

PROJECT COST AND FINANCING VALUE OF MONEY The Simhadri thermal power project is being constructed at 3,650.79 crore. The p roject is being financed with debt equity ratio of 70:30 and it is funded to a l arge extent by Japanese bank for international co-operation (JBIC) loan of 59,48 4 million Japanese yen comprising of three trances (1st trance 19,817 million Ja panese yen, 2nd trance 12,194 million Japanese yen and 3rd trance of 27,473 mill ion Japanese yen),equivalent to Rs.2,225 crore and the balance funds have been a rranged by NTPC through internal resources and market borrowings. COAL LINKAGE AND TRANSPORTATION FUEL SYSTEM The primary fuel of coal for the project is being sourced from Talcher of Mahana ndi coal fields in Orissa. 5.79 million tones of coal would be retired annually for the project. The coal will be moved to the project site by the rail route Ta lcher in Orissa thorough Talcher Sambalpur-Titlagarah-Vijayanagaram-Visakhapatna m route.

Constructions of railway siding with associate rail line have already been compl eted well in advance. The first phase of railway siding of 21 KM length with tak e off point at Duvvada Railway station has been completed .The railway siding ha s an improved track structure. The project has also started receiving coal at th e site from December 12, 2001 itself much before synchronization of the units. C oal handling plant, coal conveyor system, coal mills , etc., have been made read y to achieve coal firing immediately after synchronization.

SEA WATER FOR COOLING SYSTEM

For the first time in the history of NTPC, seawater, which is available in abund ance, is being used for cooling water requirements. A closed loop cycle cooling water system using sea water for make up water is implemented at Simhadri. Seawater is drawn from an well pump hose constructed at 700 meter, offshore of B ay of Bemgal. The intake well is located at Tikkavanipalem about 5 KM from plant site. Two pumps with a capacity of 9100 cubic meters per hour ( one working and one stand by) to meet the make up water requirement for 25000 MW units have bee n installed. This is the biggest intake well sinking technology. A 700- meters l ong approach jetty from the shore to make well has been constructed to connect t he pump house. Make up water from the sea water intake pump shall be pumped to The de-silting basin ion the plant through two pipelines of 1300NB and clear Water from the de-siling basin will be further taken to cooling pump house throu gh channel by gravity .the most important aspect of seawater pipes is that these pipes are protected from corrosion and degradation by coating with polyurethane . The requirement of seawater for would for make up would be 9100 cubic meters p er hour

Sweet water requirement

THE VITAL ELEMENT Sweet water requirement for boilers and other plant equipment as well as drinkin g water shall be from yeluer main canal, which is 11 km from the main plant swee t water pump house has been constructed near tadi village to pump fresh water fr om yelure canal .sweet water will be drawn by gravity to the de-silting basin an d into the pump house as the yelure canal would be closed for carrying out the a nnual maintenance work, an in plant reservoir ebullient to two months of sweet w ater requirement has been constructed in the plant area. The approximate fresh w ater requirement is 600 cubic meters per hour.

ASSOCITED TRANSMISSION NETWORK REACHING OUT Power Will be transmitted from the station through 400KV double circuit lines of AP TRANSCO. From the Simhadri Thermal Power Will be transmitted to Vizag poolin g sub-station at Kalpaka, which is the biggest in Asia. Further, it Will be tran smitted through 400KV double circuit Vizag Khammam Hyderabad line of approximately 590KM. SIMHADRI PLANT PROJECT PROFILE

Approved capacity : 1000MW (2*500 mw) Location : Paravada Mandal , Visakhapatnam, A.P. Project cost : Rs36590.79 crore Source of finance : JBIC Loan and internal resources Fuel requirement : 5.04 million tones of coal per annum. Mode of transportation : by rail Sweet water requirement : 600 cubic meter per hour

Source : yeluru Seawater requirement & Source : 9100 cubic meter per hour, bay of Bengal Land requirement : 3,384 acres Main plant turnkey Package : Awarded to BHEL ON NOV. 23RD , 1998 TRANSMISSION : through 400 KV system of APTRANSCO 400KV double ckt vizag-khammam-nunn line 400 KV double ckt vizag khammam line 400 KV double ckt Khammam - Hyderabad Commissioning Schedule : 500 MW Unit-1- March 2002 : synchronized pm February 22, 2002 : Ahead of schedule : 500 mw unit 2 December 2002 Beneficiary State : Andhra Pradesh

In thermal power generation, to generate stream from water, the fuel used for fi ring in furnace is coal. The raw coal nearest coal mines are transported to the plant railway system round the clock to meet the requirement of boiler furnace f iring capacity. The raw coal is crushed to small size by crushers and then groun d to very fine powder to required fineness with the help of coal pulverizes (coa l mills), and then fed to furnace through burners where the firing of coal takes place. So, for of the e there eration udy and complete combustion to take place inside the furnace and to recover most heat output from the coal, the pulverizes are playing a vital role. Sinc are a number of mills required to be operated continuously for steam gen and the mills are most power consuming equipment in power plants, the st optimization of coal pulverizes are essential on power plant.

COMBUSTION AND COMBUSTION EQUIPMENT FOR BOILERS. The fuel supplied to the boiler is fired in a confined space called furnace which is surrounding by water walls (paneled tubes) all four sides of the boiler. An e

fficient boiler receives the air fuel prepared for burning and ignites them, and the fire completely consumes all the combustible elements in the fuel. In order to withstand a very high temperatures in boiler furnace, the wall are provided with water tubes. For complete complete combustion to take place, the solid fuel like coal is pulverized by coal mills to fine powder and then fed to boilers al ong with primary air through coal burners at Different elevations. The primary air helps in drying the moisture in coal and a lso carries the pulverized coal powder to furnace through coal pipes. 2.THE CONDITIONS FOR PROPER COMBUSTION The following four conditions must be established to burn the fuel completely in the boiler. 1. high flame temperature. 2. turbulent mixing of fuel (coal) andair. 3.the correct ratio of fuel and air. 4. sufficient time to complete the burning process 1. Furnace flame temperature must be high enough to ignite The incoming raw fuel and air. Ignition raises the temperature of both fuel and air to the level where these quickly react with Each other to produce heat .the process needs a finite time. Some times supplying air at too great rate can blow out of the Fire by cooling the fuel and stopping the ignition . The ignition Temperature of various elements of fuel are listed below. The Energy of the ignition comes from fuel already burning in the furnace.

Air and fuel must be thoroughly mixed to burn the fuel completely. Various arran gements of burners do this with pulverized fuel. Turbulent mixing of air and fue l helps in burning the fuel completely. The rate of supply of both air and fuel must be closely regulated to achieve the proper fuel air ratio of excess air. Automatic combustion control systems (burn er management system) do this in modern boilers. Sufficient time must be allowed to complete the burning process in furnace. This is primarily a matter of properly proportioning the furnace dimensions in gener al the taller the furnace, the longer the time available for completing combusti on before the gases reach the boiler convection surface.

CHAPTER -2 PULVERIZED COAL FIRING SYSTEM TYPES OF COAL COAL PROPERTIES

PULVERIZED COAL FIRING SYSTEM The first pulverized coal firing operation was successfully in 1895 in a manufac turing company and the first use of pulverized coal for boiler was around year 1 910. Later in year 1918, the pulverized coal along with primary air and secondar y air were used in generating steam in boiler as an experiment basis and found t he result was successful. To achieve the required fineness of coal SYSTEM IS TO PULVERIZE THE COAL, DELIVE R IT TO THE FUEL BURNING EQUIPMENT AND ACOMPLISH COMPLETE COMBUSTION IN THE FURN ACE WITH A MINIMUM OF EXCESS AIR. The system must operate as a continuous proces s and, within specified limitations, the coal supply or feed can be varied as ra pidly and as widely as required for combustion. A small portion of the required air for combustion about 15% to 20% is used to d ry and transport the pulverized fine coal to the burners. This air is known as p rimary Air (P.A) . The remainder o combustion air 80% to 85% is introduced at th e burner via air preheater and is known as Secondary Air. The two basic components of Pulverized Coal System are: The Pulverizer which pulverizes the coal to required fineness. The burner, which accomplishes the mixing of fine coal dust primary air mixture with secondary air in right portion at the furnace. Other necessary requirements for the pulverizing system are: Hot air for drying the coal for effective grinding. Fans to supply sufficient air to pulverizes and to deliver the coal-air mixture to the burners. Coal feeders, coal and air conveyance lines etc.

The following arrangement shows the schematic diagram of our direct coal firing system incorporated in the plant.

CLASSIFICATION OF COAL: The coal is classified on the basis of their moisture, volatile matter and heat value contents as per ASTM CODE. The following are the coal classifications. S.No CLASS GROUP Fixed carbon/HV ON Minteral matter free basis 1 PEAT 2 LIGNITE Brown Coal Moisture-50 to 60% HV-4600 Kcal/Kg 3 SUBBITUMINOUS A B C Moist C.V. 6100-7100 Kcal/Kg Moist C.v 5200-6100 Kcals/Kg

Moist C.v. 4600-5200 Kcals/kg 04 BITUMINOUS High Volatile Med . Volatile Low Volatile Dry V.M. 31% , FC 69 to 78% Moist CV 6100 7700 Kcal/kg Volatiles 20-30% Voltiles 14-20% 05 AMTJRACTOE Semi Anthracite Dry FC-86-92% CV 8200 Kcal/kg Dry FC-92-98% VM-2-8% The Indian coals generally comes under categories of sub bituminous and bituminou s. PROMIMATE AND ULTIMATE ANALYSIS OF COAL USED IN THE PLANT PROXIMATE ANALYSIS Moisture - 14% Volatile matter - 22% Ash content - 40% Fixed carbon - 24% ULTIMATE ANALYSIS

Moisture - 14.00% Mineral Matter(ash) - 40.00% Carbon - 35.00% Hydrogen - 2.30% Sulphur - 0.28% Nitrogen - 0.83% Oxygen - 7.24% Carbonates -0.30% Phosphorous - 0.05%

PROPERTIES OF PULVERIZED COAL The pulverized fine coal dust when mixed with air at certain temperature, behave s like a fluid. It can be transported in pipes like any other fluid and can be b urnt in suspension inside the boiler furnace. The characteristics of coal play a vital role in the ignition and combustion of the pulverized coal in the furnace . The combustion in the furnace is effectively achieved by controlling temperatu re of furnace, turbulence created at burner for the air and coal dust mixture, a nd time taken by the coal dust in floating condition before settling down at the bottom of furnace. So for complete combustion to take place, coal dust must be in very fine condition so that the suspension time may be such that the entire c oal dusts are being burnt. The grind the coal to the required designed finesses of 70% through in 200-mesh sieve with designed coal, the pulverizes are designed and installed in all plant s.

CHAPTER-III PULVERIZERS IN POWER

PLANTS Types of Pulverizes Construction of Bowl mill Principle & Operation of Bowl mill

PULVERIZERS IN POWER PLANTS DIFFERENT TYPES OF COAL PULVERIZERS IN POWER PLANTS The pulverizer mills are generally classified as slow, medium, and high-speed ma chines w.r.t their running speeds. But in thermal power plants in our country, w e have three types of coal mills: SLOW SPEED MILLS- Horizontal Ball and Tube mills. MEDIUM SPEED MILLS Vertical spindle, B & welcome Design Ball & RACE MILLS & C.E. design BOWL MILL, supplied by M/s. BHEL. A brief description on these three types of mills used in the power plants is gi ven below. 1. BALL & TUBE MILLS: A ball & Tube mill basically consists of a hollow large di ameter horizontal cylindrical drum that rotates in its axis. Wear resistant cast steel liners are fitted inside the cylindrical shell, which is filled to half o f its diameter . the drum is rotated at a speed of 20-35 rpm by an electric prim e mover. The coal along with air is fed into the drum at some high temperature. Coal is ground to fine powder and then is being carried a way to furnace by tran sport air. These types of mills are suitable for high ash content coal and abras ive type of ash. Maintenance of this mill is easy and changing of balls is less time taking. But this mills consumes more electrical energy. Approximately this mill will take 21 -23 kwh/tonne of coal pulverized.

2. BALL & RACE MILLS: The Ball & Race mills of B & W design are vertical spindle mills, which are classified under medium speed mills. This mill is having three cylindrical sections in which the bottom one is supporting the entire mill unit and housing the motor at base. The middle portion is occupied by the grinding r ings (bottom & top) and grinding balls of bigger size, which is known as grindin g zone. And the top section consists the discharge classifier cone assembly and coal pipes. The grinding is of Ni-Hard-4 material having a hardiness of about 35 0 BHN. These types of mills are also called E type mills designed by B &W, U.K. Th e sizes of the balls are between 650mm -730 mm and the speed of the mil is 40-50 rpm. The mill outlet temperature has to be maintained around 70-100 degree centigrade . In this mill the power consumption is 15.3 kwhr perton of coal pulverized whic

h is low when comparing to the ball tube mills. This type of mill is suitable fo r pulverizing every grade of bituminous coal and its output & fitness is maintai ned consistently throughout the normal life of the grinding elements. It s perfo rmance is maintained even up to 15% of moisture in coal. BOWL MILLS : The BOWL mills of combustion engineering design and manufactured M/ S, BHEL in India, are also a vertical spindle type and medium speed type mills. Not in the case of Ball & Race mills, in these mills there is no contract betwee n metal to metal in the grinding elements. The grinding element comprises of rot ating bowl lined with wear resistant segmented liners and three rolls mounted on fixed position journal assemblies above rotating bowl 120 degrees. The power co nsumption for this type of mill is approximately 16.2 kwhr/kg of coal pulverizxe d. In NTPC there are Ball & race mills in some plants and Bowl Mills in most of the plants. 4. BOWL MILLS-XRP-1003 IN SIMHADRI NTPC: These type of Bowl mills are medium speed mills with a speed about 50rpm and mai ntaining the rim speed around 370 m/min. IN Simhadri Power Plant, Bowl mills of M/s. BHEL manufactured were installed. The technical specifications of our pulve rizers are given below PULVERIZER: Type of pulverizer : Bowl Mills, XRP 1003 Number of Mills/Boiler : Nine Number of Mills at 100% BMRC (for Design Coal) : Seven Design capacity of Mill : 66.3 Tph for pulverized Coal fineness of 70% Through 200-mesh sieve With a raw coal of hgi-55 Total moisture of 14% Speed of Pulverizer : 50 Motor Rating : 525 Kw MILL MOTOR: Manufacture : M/s BHEL, BHOPAL Motor type : Synchronous,cage motor Rated voltage : 3.3 KV Rated Speed : 589 rpm Full load current : 137 amps

Bearing type at drive end : Nu 230 M6230 C3. Bearing type at non-rive end : NU 226 Recommended lubricant : Grease Servo gem-3 [IOC] BOWL MILL CONSTRUCTION The Bowl Millis a medium speed pulverizer in which the bowl rotates with a speed of 50 rpm. The bowl is lined with hard-faced wear ring segments, which canbe re placed after getting their life. The other grinding parts comprising of stationa ry rolls, pre loaded by adjustable spring pressure of hydraulic system and free to rotate on their own axis when it comes in contact with the rotating bowl. The re are three umbers of such roller assemblies mounted on each mill at an equal s pacing of 120 degree a part. When the mill is in operation, the coal enters the mill at center of the rotating bowl and thrown a way due to centrifugal force to the outer segment of the bowl where the coal is crushed between bowl and the ro ller assemblies, to fine powder, Generally the coal undergoes number of such pas ses in between the grinding elements and thus ground to the required fitness of 70% through 200 mesh. The hot air(Primary Air), which is introduced into the gri nding zone, provides heat to dry to coal and also carries the fine coal dust alo ng with coarser particles up to classifier cone. As the mixture enters the class ifier, which as adjustable blades/vanes, the coarser particles are deflected dow n by the vanes and again crushed until required finenesses achieved and transpor ted thought coal pipes. The spring pressure on the rolls is adjustable and is required to be set as the grinding wear out and also when the coal output fitness is required. As there is a gap between the grinding roll and the bowl, the pressure automatically gets i ncreased when more coal is being fed into the grinding zone. The mail is therefo re quickly responding to the increased fuel demand. Finally the coal dust is carried by the hot primary air thought the coal pipes, to the coal pipes, to the burners where the dust being fired at different elevat ions. The cross sectional view of the BOWL MILL at out station and the detailed drawin gs of mill internals are given in ANNEXURE. PAPER-3 Reduction in the quantity of primary air. The greater fitness of the coal partic les exposes more surfaces for the combustion reaction . Reduction in primary air leaves more of the total air supplied as secondary or tertiary air to promote t urbulence and to completely burn out. Theoretically, hardly sufficient air to bu rn the volatile matter should be supplied but the quantity should not be reduced so much that there is tool low a velocity in the fuel pipes and separation of c oarse and fine particles occurs. NUMBER OF MILLS TO OPERTE FOR OPTIMUM EFFICIENCY: Boilers are normally provided with at least one more mill than the number requir ed for full load so that mill maintenance can be carried out without reducing th e boiler load. After a certain length of time the wear of the grinding elements will be such that the output and finness of the product will fall way and the qu antity rejects to increase and also the power for grinding increase. The stand b y mill should then be grought into service for maintenance. Normally, therefore

a boiler steming at full load would be operated with a number of mills the makes intended to be sued for full load but as these mills will have a margin of capa city they will not be working at full output. The most economical way of laoding the mills is to have good mills loaded to their normal capacity and worm mills working at smaller output. The electrical energy required by a mill group per to n of coal ground is lowest when the mill is working at its normal output so that only minimum number of mills necessary to provide the required output should be in service. If conditions are favorable, say because of soft coal, then it may be possible to steam the boiler with one less than the normal number of mills. I f this can be done it will reduce the total milling power. Quite often considera tions other than minimizing milling power pre dominate and determine which mill should be run. It may bee that steam temperature is affected by mill operation b ecause in some installations each row of burners associated with one mill to giv e some measure of steam temperature control . In other cases certain combination s of mills and their associated burners will give an unbalanced furnace. General ly speaking, however, mill should be well loaded to give their economical perfor mance. 6) CONTROLLABLE FACTORS As the coal is being supplied from a fixed mine, (TALCHER ORISSA state) the char acteristics of that coal cannot be changed at plant. So the factors discussed ab ove are un-controllable and hence we have to study and try to introduce some mar ginal changes in the controllable factors to achieve the optimum performance of cal pulverisers. The following are the controllable factors, which influence the performance of mills. a) MOISTURE IN COAL The moisture content of coal can be classified into two types as inherent moistu re and surface moisture. The inherent moisture is the integral constituent of co al where as the surface moisture mainly depends on the surrounding seasonal cond itions. The surface moisture must be removed from the coal before it is being pu lverized in the mill. The drying of moisture in the coal is done by supplying at air at designed temperature in certain ratio along with the mill. After removin g the surface moisture, the coal is ground to reuired fineness and carried to th e burner by the hot primary air. So it is very important to maintain the outlet temperature of coal-air-mixture above the dew point temeperature of air, to avoi d the chocking of the mill and hence to maintain performance of the mill. In pla nt mills the temperature of hot air introduced into the grinding zone is about 2 500 C -3000C and the mill outlet moisture is removed in the furnace during firin g of coal dust. So certain amount of heat available in the coal is being used to dry the inherent moisture. Higher the moisture in the coal, lower the heat avai lable in furnace and also lower the mill output. b) THE RATIO OF CAOL-AIR MIXTURE: The hot primary air supplied to mill is having three main fuctions i.e. to dry t he coal, to mix the coal dust inside the mill for better grinding and finally to carry the fine coal dust to the furnace of boiler. The quantity of the primary air should be designed such that the velocity of that air and coal mixture is wi thin the required level. If the velocity of the air is high, then the coarse par ticles will also carried to the burner. On the other hand if we maintain low vel ocity in the mill, the transportation of the coal dust will be suffered and the mill choking will be very frequent, hence affect the milling performance. The pr imary air required for mill is 15-30% of the total air required for the combusti on of the coal in the furnace. In general the quantity of primary air required i s expressed in terms of weight of air per weight of coal supplied to the mill. A s per the design coal and the XRP-1003 mill in the plant, the coal-air, ratio is maintained between 1.18-1.22, By changing the flow of primary air a minimum vel

ocity of 20 m/s has to tbe maintained in the mill to avoid the settling of coal dust in the mill and 24-27 m/sec velocity in the coal piping improve the transpo rtation of the coal dust. c) FITNESS OF COAL AT MILL OUTLET: The performance of the coal mill is also measure by the fineness of coal at mill outlet and by varying the following within parameters within certain range the fineness of cal at mill outlet ca be controlled. Adjusting the spring pressure of the boiler assembly over the bowl ring, Adjusting the air port gap between ring and stationery mill body, this controls the flow pattern of air and coal dust inside the mill (turbulence), Setting the classifier vanes at optimum position which restrict the exist of coa rser particles from the mill, Loading the mill such that no choking of mill will take place and also at high l oading, the fitness will be lower. After the life of grinding elements (after-worn-out), they may be replace with t he new ones and thus the grind ability of mill can be improved.

CHAPTER-V MILL PERFORMANCE OPTIMIZATION Performance testing on mill Optimization

MILL PERFORMANCE OPTIMISATION PROCEDURE Collect one or more sets of milloperating parameters from the Unit Control Board , Raw coal analysis data, pulverized fuel fineness detail, quantity and quality of mill rejects etc. Check and endure the requirements of raw coal feeder, condition of mill DP & oth er instruments, primary air flow and the coal flow. Thefollowing adjustments may be carried out to maintain the required DP, PF fine ness quantity and quality of mill rejects and thus the performance optimization of coal mills can be achieved. AJUSTMENTS One or more of the following ollect one or more sets of milloperating parameters from the Unit Control Board, Raw coal analysis data, pulverized fuel fineness d etail, quantity and quality of mill rejects etc. Check and endure the requirements of raw coal feeder, condition of mill DP & oth er instruments, primary air flow and the coal flow. Thefollowing adjustments may be carried out to maintain the required DP, PF fine ness quantity and quality of mill rejects and thus the performance optimization of coal mills can be achieved. AJUSTMENTS One or more of the following may be required while carrying out the mill optimiz ation. Area of opening around bowl for primary air flow to maintain desired DP Across t he bowl. Height of the venture collar to maintain the desired PF fineness and DP across t he bowl. Spring compression to control the fineness of coal and reject level. Classifier vane position settings to get the fineness and reduce the coarser par ticles enter into the burner. Ring-Roll clearance to reduce bed formation on the bowl and to reduce reject rat e. Spring seat gap to ensure equal load on bowl by spring assemblies. Inverted cone gap to maintain the pulverized coal fineness. By maintaining optimum loading of mill , number of required for rated boiler loa d my be reduced and there by auxiliary power consumption of extra mill can be sa ved.

In addition to the above discussed procedures and adjustments, for optimizing th e performance of the coal mills, The PERFORMANCE TESTING of individual mill has to be carried out to ensure the u niform flow of coal-air mixture throught the coal pipes and the efficiency of th e mills. And also by PROPERLY PLANNED / SCHEDULED MAINTANENCE procedures & practices, the performance of the milling system can be improved and so the plant efficiency. PERFORMANCE TESTING (MONITORING) OF COAL MILL In a coal fired thermal power station , the milling system availability and its performance have paramount importance and signify direct bearing on power genera tion . The overall boiler combustion regime optimization has emerged as one of t he key options that offer a heat rate improvement of around 50 Kcal/ Kwh in coal fired units . So for taking up the boiler optimization , the milling system per formance testing plays a vital role . a brief description of mill performance te sting isgiven below , through which mill performance optimization can be done The performance degradation on pulverizes and burners is routinely monitored bas ed on loss on ignition (LOI) data from fly ash and causes of excess over of carb on are identified The performance data to be monitored on mill are: Number and location of mill in service. Mill outlets temperature. Mill motor Amps. PA flow/tempering air flow SADC setting. Mill different pressure(pressure drop) Mill inlet air temperature Recording of performance data as mentioned above is generally considered to be a dequate for performance trending however to analyses any performance degradation are to carry out a route cause analysis of any malfunction related to mill outp ut some specification tests are to be carried out using accurate offline instrum ent at site PULVERISER TESTING: Pulversers are selected to provide a required grinding capacity, based upon a se t of design criteria, which include the required coal particle finess and coal c harctetstics the require pulviser capacity is determined by the boiler heat inpu t requirement , which some addition allowance added to account for the wear of t he mechanical parts the required finess is a function of specific coal propertie s such as the voloties in the burners firing system and furnace size coal charac teristics that determine the mill performance are the grind ability of coal and moistures in coal and moisture in the coal. Pulveriser capacity shall vary according to the current operating conditions as

required for time to time . Fig 1.1 depicts the relationship between mill mechan ical capacity, coal grind ability and coal fineness. Higher grind ability means that mill can grind more coal to same fineness or it can grind the same amount o f coal to a greater fineness. Pulveriser capacity is mostly affected by such factors as moisture in coal and t he available primary air inlet temperature and flow. To a lesser extent, ambient temperature and raw coal temperature will also affect the mill thermal performa nce. Similarly high ash content in coal result in greater loading on pulversier and erosion causes performance degradation and subsequently reduces the life of grinding elements inside the mill. PROCESS DISCRIPTION: The procedure provide guidelines for conducting various performance checks on pu lverizes. Implementation of this procedure will result in identification of pulv erize system deficiencies and possible optimization of the coal pulveriser syste ms. Performance guarantee tests are conducted on mills to conform the systems per formance at all the stations and keep records as base line data. OBJECTIVE: The objective of this procedure is to establish testing methodology for conducti ng various performance checks related to the pulveriser system. Clean air balancing between coal transport pipes. Dirty air balancing between coal transport pipes. Fuel balancing between coal transport pipes. Fitness testing on coal transport. For achieving the above performance results, the clean air flow test and the dir ty air flow tests are to be conducted on nilling system as briefly described bel ow. References: ASME Performance test code 4-2-1969, coal pulverisers ASME performance test code 4.1-1964, steam generating units. DS/ISO-9931 sampling of pulversised coal conveyed by gases in direct fired coal system. CLEAN AIR FLOW TEST: PROEDURE: Clean air curves Clean air curves are a plot of mill differential verses stationary pitot tube di fferential with no coal flow. It represents the pressure drop thought the mill d

ue to its internal componts. As such, it gives an indication of wears by compari ng clean air curves over the time. The number of hours of operation of the pulve riser or increased spillage is generally used to determine maintenance requireme nt. Increased usage of primary air is normally tried s a solution to reduce mill s spillage, which result in, increased internal wear and deterioration in +50 me sh fractions. Clean Air Flow Test: Following steps to demonstrate a clean air flow test to determine the uniform fl ow of air in the mill pipe outlets. Step-I Test tapes are installed on coal pipes to facilitate clean air and dirty air tra versing using pitot tubes and dirty probes. Optimum locations for these tapes sh ould be between 5-10 times the diameter the down stream and upstream of the near est elbow or change of direction. A minimum of two tests tapes 900 apart is requi red per coal pipe. Step-II: Traverse points on the pitot tube are marked on an equal area grid in accordance to ASME performance test for traversing circular ducts or pipes. The ASME stand ard for coal transport pipes with 10 or more diametersis illustrated infigure. Step-III Two equal lengths of tygon tubing sections are cut to decide length. Then tapped are bound together on one tube is marked on both ends to indentity as the highpressure length or impact line. Remaining tube is then employed as low-pressure line or static line.

Step-IV A 5-10 vertically inclined manometer is set up on a level and stable work area. Th e tygon tubing is connected to the high and low side tapes on the manometer as i ndicated below. A digital manometer can be used in line of the inclined manomete r if available. The following data should be recorded for each test: Coal pipe design Individual velocity head for each traverse point(two ports/days 24 pipes) Temperature and static pressure for each transport.

Step-V Prior to inserting the pitot tube into the flow ensure the manometer is in level and has been served. Insert the pitot tube into the first Measurement point allow the readings to stabilize, record the data and move to t he next measurement point. Repeat the same predure for all measurement points. After traversing all ports on the coal transported, a static pressure measuremen t is recorded using a U type manometer a single length of tygon tubing and singl e length of metal tubing inserted into the middle of the coal pipe from one of t he test ports. After recording static pressure at each coal transport pipe, the temperature sha ll be measured by inserting a thermocouple into each coal transport pipe. Note: A clean air test is peformed with aprimary air to the mill at the full loa d normal conditions with the mill out of series. (Full PA flow and no fuel flow) Calculate velocity in each fuel line and ascertain clean air balancing after rec ording all those above data. The clean air balancing should be expressed as a de viation for the means elocity of all the pulveriser indidivudal coal transport p ipes. A maximum deviation of +/- 2% indicated a satisfactory clean air flow bala nce. DIRTY AIR TEST A dirty air test is performed with puplversiser operating at normal full load co nditions(under recommended air to fuel ratio ram curve). Repeat the steps from I to V of clean air test.

Install a dustless connector with a ball valve outlet to endure coal containment in transport pipe during traverse. Insert the dirty air probe through the dustless connector. Open the full ported ball valve fully while inserting the dirty air problem and place the probe on fi rst measurement point. Allow the manometer radiant to stabilize record the data and move to the next measurement points. Repeat this process for all other 12 te sts points and record the data. Blowing is needed to be done effectively in case of low mill outlet temperature, which normally leads to chocking of dirty pitot tubes. After traversing both the ports, a static pressure is taken suing a I SS tube whi ch has SS tube for measuring temperature. Calculate the velocity of each fuel lin e and ascertain dityair balance. The dirty air balance should be expressed as a mean velocity of all the pulverisers individual coal transport pipes( A maximum deviation of +/- 5% indicates a satisfactory dirty air balance). By conducting the above test for clean air flow and dirty air flow the uniform f low of air and fuel mixture though the outlet pipes of each mills can be establi shed by which the optimum performance of coal mills can be achieved.

CHAPTER-VI Maintenance Preventive Maintenance Major Overhalvings

MAINTENANCE ROLE OF MAINTENANCE IN OPTIMISING THEMILL PERFORMANCE By optimizing the mill performance, the capacity of the mill can be effectively utilized andhence improving the availabiltof the milling system. So the proper m aintenance practice will improve the mill performance and hence the overall perf ormance of the plant. The milling system is to be maintained and operated as per

the recommendations of the manufacturer of the equipment. To keep the milling s ystem healthy and getting optimum output from mills, the following operation and maintenance procedure are to be followed. To maintain adequate spares for mills: At least for two years as per BHEL, spare s are to be kept at site for maintenance in case of any break down. To monitor the performance of spares supplied by different firm critically with regards to longer life. To study the wear pattern in the critical components of mill such as grinding ro ll, bull ring segments, vane wheel linear assembly, mill internal liners etc. Prepare an optimum preventive maintenance schedule base upon the study of wear p attern of mill internals so as to avoid unforeseen break down and to reduce the duration of maintenance time for each mill. To arrive at a definite time schedule and nor for preventive maintenance activit iy. To develop the maintenance crew for effective maintenance with adequate training and product knowledge. PREVENTIVE MAINTENANCE: Mill preventive maintenance has to be planned as per the running hours of the pa rticular mill or based on the conditions of the mill or in a fixed interval of t ime as required by the system time to time. IN Simhadri Thermal Power Plant, pre ventive maintenance is carried out every fortnightly. During the preventive main tenance the following jobs are to be carried out. a). Check for erosion of mill internals b) Checking of oil quantity of journals assemblies c) Checking and repairing of scraper of scraper chamber liners d) Condition of vane wheel arrangement e) Condition of rollers and bull ring segments f) Inspection and repairing of reject system h) Setting of ring roll clearance and spring gap Roll Ring Clearance: The most common indications of need for roll-ring clearance adjustment are the f alling off of pulversier capacity, rumbling and increased coal spillage. Adjustm ent of clearance and/or spring compression should be considered in the even of a ny prolonged coal side pulveriser operating difficulties if difficulties do not exist, adjustments are not recommended. The entire journal assembly fig.5 including the roll, pivots about the center of the trunnion shaft and can be raised or lowered with the journal stop bolts. Co ntinue to make stop bolt adjustments until they arte no longer effective.

Trunnion shaft bushings in the trunnion shaft end caps support the trunnion shaf t so that when the end caps are rotated from position 1-4, the location of the c enter of the trunnion shaft is change and this alters the position of the entire journal assembly. The trunnion shaft end caps can be used to make roll-ring cle arance adjustments after the stop bolt adjustments are no longer effective. MILL CLEARNANCE: Vertical gap between body liner segment and rotating vane 5-10 mm. Gap between inverted cone and inner cone 100 mm. Gap between center feed pipe lower and inner cone 115 Mm Gap between roller and bullring segments 3-5 mm. JORNAL SPRING COMPRESSION: ... [Message clipped] View entire message sarath bnsd sarath.324@gmail.com 4/4/10 to mecharunn projectwork Message from sarath.324@gmail.com: The journal compression must be set before the pulveriser is placed in serve. Th e initial compression setting should be checked and if necessary, the springs sh ould be compressed using the spring compression fixtures supplied. If some coal or load characterstic causes poor operation changing the spring compressionshoul d be considered. To prevent unde stress on pulveriser components, spring compression on threejour nals in one pulveriser should check with in 450 kg. The most common reasons (and action) for changing spring compression are: Rough operation at low loads (reduce the compression). High or unstable power consumption(increase thecompression). Vibration at high loads(increase the compression). RECOMMENDED SPRING LOADING Mill Size Spring rate Spring load to be registered at

(In Kg/Cm) Pressure gauge inkg. 100 XRP 535 9500 Major Overhauling of Mills: Once in a year or based on the running hours or wear pattern of the mill, a mill has to be planned for major / complete overhauling of that particular mill to e nsure the performance again up to the optimum level. So during the overhauling p eriod of mill the following works are to be done.

Servicing of the journal assemblies and changing rolls. Changing bullring segments Servicing pressure spring assembly and stop bolt Changing dust guard seal. Servicing of mill discharge valve. Serving and checking the scraper assembly, mill inside linear and cover plate. Chanding the mill base oil nd cleaning the mill base. Overhaul separator bodyline assembly(Body liner, supports, pipes, cover plates, choral plate and air direction valves) Set the gap between separator bottom liner and the bowl. Check bowl extension ring and change if worn-out. Overhaul of classifier assembly, venture. Clearance between mill bottom and lower skirt(5-8mm). Clean airflow test. Tramp iron spout and pyrite hopper servicing Blue matching of worm gear/shaft assembly. Checking pump clearance and servicing the pump

Coupling inspection, alignment without and greasing of coupling. Oil cooler cleaning and testing. Worm shaft bearing inspection and replacement if necessary. Vertical shaft bearing inspection and replacement.

CHAPTER-VII MODIFICATIONS & IMPROVEMENTS Modification Improvements

MODIFICATIONS AND IMPROVEMENTS In addition to the above scheduled maintenance procedures, to improve the mill p erformance, the following practice are to be ensured during the operation of bow l mills. . Maintaining specified ring and roll clearances. Maintaining correct compression for the journal springs and daily check for such deflection by about 6-12 mm. Taking periodical samples for testing the finess of the coal. Making periodical adjustments of the classifier vane and hence the predicted fin eness of the pulverized coal.

Maintaining the correct airflow thought the mill and the mill outlet temperate. Feeding correct quantity of coal into the mill. Reliable operation of reject handling system and maintaining the mill area clean and dust free. MODIFICATIONS & IMPROVEMENTS Modification of valve wheel segments (RSTPS) In one of four NTPC units at RSTPP the same type of mill i.e XRP -1003 are insta lled in 500 MW units capacity of the mill is 63.5 tons/hr The milling system faces various problems as given below.

High down time of mills, which reduces the availability of system. High rejects about 1% Mill loading restrictions(50-55 TPH) High auxiliary power consumptions. Less grinding rollslife (1400-1600 hrs) The problem was caused due to frequent damage of vane wheel segments. Breakage o f paper assemblies rejects package chocking, etc. The time taken to replace the vane wheel segments frequently was affecting the availability of the mills and a lso increase in maintenance cost. Also the performance of mill is degraded due t o frequent chocking and high reject. In order eliminate this problem, The rotating vane whell assemblies were removed and fixed air Regulating ring annular gap of 90 mm was provided. Venturi collar height of the mill is reduced from 22 to 20. Dynamic open vanes are installed along with static air regulating ring. The fineness of the mill outlet was reduced from 70% to 60% of 200-mesh sieve. By implementing the above modifications, the loading of mill was improved, amper age of mill drive was considerably reduced and the down time of the milling syst em was also reduced and hence the performance of individual mill is also enhance d.

2. Other modifications: Over the years, a steady degradation has occurred on the coal supply to power st ation. This has led to an increasing coal quantity required to be ground, in ord er to meet the installed capacity of the station. And also due to the high wear 7 tear of the milling system, the spare consumption rate was very high and the m aintenance cost and duration also at high. To enhance the life of milling components and to get the optimum performance fro m the mills, M/S. BHEL has developed so many solutions by the filed- tested modi fications and improvements in the existing pulveriser design and the same modifi ed version of mills are being supplied to our NTPC stations including simhadri. The following retrofit modifications ere done by BHEL in the BOWL MILL. Rotating or stationary vane wheel arrangement : Instead of separator body liner arrangement of older design mills were replaced with vane wheel arrangement. The benefit of this system: Improved coal classification/ air distribution enables better fineness control, Reduction in bowl DP and so in consumption, Lower velocity results in less wear and tear and even distribution of coal- air mixture, Improved pyrite rejection and lesser coal spillage. b) Comb alloy-N classifier vanes (deflector blades): These vanes are mounted on the outlet top classifier cone to return back the coa rser particles again to the bowl for further grinding and hence the fineness of ground coal can be controlled. So the vanes are subjected to high abrasion and w ear and tear . To avoid such problems, the materials of these vanes were changed to high abrasion resistance Comb alloy-N ( Nikel alloyed cast iron) is 500-550 BHN. c) Ceramic lined classifier cones. d) Mill outlet up gradation with modified venture and flap type discharged valve .