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INTRODUCTION
At NCPS-Dadri, the 4x210 MW Units supplied by BHEL
are equipped with XRP-883 Bowl Mills. Originally these
mills were supplied for the first time in our country.
The raw coal supply is received from North Karanpura
Coal Fields.
From April97 onwards washed coal (Ash 34%) supply
commenced from Piparwar washery to NCPS Dadri.
ROUTINE TESTING
8
16
16
16
60
16
-
8
8
16
16
60
60
-
8
8
48
48
256
96
-
8
8
48
48
231
96
-
8
10
48
48
209
96
2
4/8
2/10
34/60
96/220
58/96
-/4
48
24
24
96
18
7
96
24
24
96
24
10
102
26
16
33/90
6/26
7/18
64
16
32
12
40
16
40
16
40
16
12/40
4/16
8
8
-
12
12
-
16
12
-
16
28
-
16
12
-
9/16
5/8
10/10
24
40
8
8
4
4
4
6
8
8
4/16
5/8
5/8
CERC TEST
TOTAL NO. OF EFFICIENCY TESTS
44
32/48
388
373
708
687
717
326/702
COAL MILLS
AIR-FUEL RATIO TEST
CLEAN AIR FLOW TEST
HOT AIR FLOW TEST
ESP
THIMBLE TEST
GAS DISTRIBUTION TEST
CONDENSER
HELIUM LEAK DETECTION TEST
CONDENSER PERFORMANCE TEST
CONDENSER FLOW MEASUREMENT TEST
COOLING TOWER
NB: In year 2003-04, number of tests are indicated as [ No of Test Done / No. of Test Envisaged]
NEW
TECHNOLOGY
Details
Run - I Run - II
Run - III
UCB P.A.Flow
80.31
72.00
47.10
Test P.A.Flow
83.76
74.09
51.28
238.10
258.88
269.50
Test Venturimeter DP
107.0
83.0
57.0
119.96
89.42
60.20
109.49
81.61
54.95
104.05
77.56
52.22
99.02
73.81
49.70
94.84
70.69
47.60
100
Venturimeter
Characteristics
80
40
20
0
0
20
40
60
80
100
120
140
160
180
Corrective Action
1 Corrected Venturi DP corresponding to 300 C and 90 T/Hr PA Flow
was provided to C&I for recalibration of DP Transmitter.
2 Initial DP Transmitter setting for 90T/Hr flow and 300 C was 158
mmWC.
3 New DP Transmitter setting for 90T/Hr flow and 300 C is 141
mmWC.
S.No Parameters
Unit
Process Parameter
[Old Characteristic Curve]
1 P.A.Flow
2 HAD Opening
3 CAD Opening
4 Mill Outlet
Temp
5 Mill DP
6 Coal Flow
7 Unit Load
8 Total Coal Flow
9 Total SA Flow
10 Total PA Flow
11 Total Air Flow
12 ID Fan Current
13 FD Fan
Current
14 PA Fan
Current
15 Mill Current
Process Parameter
Impact
Tons/Hr
%
%
C
76.2
30.4
40.3
83.9
80.4
30.2
39.8
84.5
+ 4.2 T/Hr
-
mmWC
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Amps
Amps
195
31.0
145.6
104.7
415
287
702
94.6 / 95.6 = 189.9
72.9 / 70.4 = 143.3
196
30.9
147.5
102.7
416
292
708
94.1 / 95.2 = 189.3
72.6 / 71.1 = 143.7
+ 5 T/Hr
+ 6 T/Hr
-
Amps
Amps
34.1
33.7
Unit
Process Parameter
[New Ch Curve: Unoptimized]
1 P.A.Flow
2 HAD Opening
3 CAD Opening
4 Mill Outlet
Temp
5 Mill DP
6 Coal Flow
7 Unit Load
8 Total Coal Flow
9 Total SA Flow
10 Total PA Flow
11 Total Air Flow
12 ID Fan Current
13 FD Fan
Current
14 PA Fan
Current
15 Mill Current
Process Parameter
Impact
Tons/Hr
%
%
C
80.4
30.2
39.8
84.5
69.4
29.8
20.8
87.2
- 11 T/Hr
-0.4%
-19%
+ 2.7 C
mmWC
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Amps
Amps
196
30.9
147.5
102.7
416
292
708
94.1 / 95.2 = 189.3
72.6 / 71.1 = 143.7
174
30.9
147.7
104.2
422
280
702
93.1 / 93.9 = 187.0
71.3 / 69.5 = 140.8
- 22 mmWC
+ 6 T/Hr
- 12 T/Hr
- 6 T/Hr
- 2.3 Amps
- 2.9 Amps
Amps
+ 0.8 Amps
Amps
33.7
33.8
Results
1 PA Flow in Mill-2B reduced by 11 T/Hr, 4.2 T/Hr due to calibration
and 6.8 T/Hr due to further optimization. It is an improvement of
13.7% .
2 HAD & CAD opening reduced from 30.2% to 29.8% and 39.8% to
20.8% respectively. It is an improvement of 1.3% and 47.7%
respectively.
3 Mill outlet temperature improved by 2.7C which is an improvement
of 3.2%.
4 Mill DP reduced by 22 mmWC which is improvement of 11.2%.
5 Fan current reduced by 4.4 Amps without any adjustment in O2
setpoint which is an improvement of approximately 1%.
NEW
TECHNOLOGY
was to further tighten the Clean Air balance below +/- 2% and to
inspect & replace the Coal Pipe Orifices.
New Approach
New approach is to create a calculated and controlled imbalance in
Pipe-1
Pipe-2
Pipe-3
Pipe-4
Mill-E
78.15
66.87
43.29
54.57
Pipe-1
Pipe-2
Pipe-3
Pipe-4
Mill-E
Pipe-1
Pipe-2
Pipe-3
Pipe-4
Mill-E
[1650, 1350]
Cr-2
Cr-3
Cr-4
Test Coal
Sample [Grm]
390.31
367.31
701.81
435.81
Coal Flow
Distribution [%]
20.6
19.4
37.0
23.0
20
20.6
15
23.0
17.6
12
10
19.4
5
0
-5
37.0
Max
Min
-5.6
-10
Cr 1
Cr 2
Cr 3
Cr 4
Span
Max
Min
Span
Corner
No
Old
Orifice Size
New
Orifice Size
1
2
3
4
463
448
437
430.5
389.7
396.2
2.7110
2.7110
85.9721
119.4707
2.3060
3.5500
93.2179
104.4035
1.4299
5.4849
118.3791
83.9934
1.9098
4.5586
102.4309
92.1324
Loss Coef
[K-Pipe]
8.0046
6.7606
3.9496
5.3558
Loss Coef
[K-Orifice]
0.0000
1.2440
4.0550
2.6488
Loss Coef
[K-Total]
8.0046
8.0046
8.0046
8.0046
Old
Velocity
84.4905
91.9361
120.2817
103.2917
New
Velocity
100.00
100.00
100.00
100.00
Cr-2
Cr-3
Cr-4
Test Coal
Sample [Grm]
397.81
269.81
502.31
443.31
Coal Flow
Distribution [%]
24.7
16.7
31.1
27.5
16.7
31.1
Cr 1
Cr 2
Cr 3
Cr 4
Cr-2
Cr-3
Cr-4
Test Coal
Sample [Grm]
428.31
292.81
459.81
293.31
Coal Flow
Distribution [%]
29.1
19.9
31.2
19.9
Cr-2
Cr-3
Cr-4
Test Coal
Sample [Grm]
466.81
353.31
522.81
261.31
Coal Flow
Distribution [%]
29.1
22.0
32.6
16.3
29.1
31.2
19.9
Cr 1
Cr 2
Cr 3
Cr 4
32.6
22.0
Cr 1
Cr 2
Cr 3
Cr 4
Cr-2
Cr-3
Cr-4
Test Coal
Sample [Grm]
430.98
305.31
494.98
332.64
Coal Flow
Distribution [%]
27.6
19.5
31.7
21.3
21.3
20
17.6
15
10
12.2
12
6.7
5
0
19.5
31.7
-5
-10
Cr 1
Cr 2
Cr 3
Cr 4
Max
Min
-5.5
Re-Sized Orifice
Span
-5.6
Original Orifice
NEW
TECHNOLOGY
At NCPS-Dadri, all the 6 coal mills are located at the rear of the
Boiler in M-N Bay.
Problem Experienced:
Study was done for full one year to observe the pattern of loss of
thermal energy from coal pipes both in Winter as well as in
Summer season.
All four coal pipes of one coal mill [Mill 1E] was insulated with
25mm Mineral wool pad for trial purpose.
Measurement of following parameters were done:
Coal-Air mixture Temperature: (a) Insulated & Un-Insulated
Coal Pipe (b) Mill end & Burner End (c) Winter & Summer
Season
Coal-Pipe Surface Temperature: (a) Insulated & Un-Insulated
Coal Pipe (b) Mill end & Burner End (c) Winter & Summer
Season
Length of coal pipes were taken from manufacturers drawing.
Heat loss was computed for both insulated and uninsulated coal
pipe for winter as well as summer season.
Average saving of Thermal energy was done assuming four
winter months and eight summer months.
Findings:
Rupees
500,000
400,000
300,000
200,000
100,000
0
50
100
150
200
250
300
350
400
No of Days of Operation
Cost of Insulation
Cost of Sheeting
The findings were also vetted by M/s NPC & during ISO Audit.
After the study, Coal Pipes of Mill-1B,1C,1D,1E were also insulated.
Readings obtained from the above Mills has also confirmed the findings.
Unit-1
Unit-2
Unit-3
Unit-4
Unit2,3&4
6176402896
6176402896
6176402896
6176402896
18529208689
6176402896
13521974781
11923471273
12334291396
37779737450
0
7345571885
5747068377
6157888499
19250528761