Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 1 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES LOG SHEET

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 2 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 1.0 1.1 PLANT DETAILS There are 9 (Nine) mills provided for each Unit of 500 MW Capacity. These mills are of XRP 1003 type and are provided with individual lub-oil system. These mills are designated as A,B,C,D,E,F,G,H and J with Unit No. as prefix. There are 4 (four) coal pipes emanating from each mill from mill outlet point with individual mill discharge valve (MDV) and coal pipe shut-off gate near the coal bumer assembly. These coal pipes are subjected to clean air flow test to ensure uniform flow in all the coal pipes. The mills are pressurized mills with primary air fans supplying the air flow and the head required for overcoming milling system resistance. To maintain the required air flow through the mill, a control system comprising cold and hot dampers is provided, which measures and controls air flow to a specified set point.

1.2

1.3

1.4

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 3 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 1.5 Technical Specification of Mills and its lub-oil system are given below. XRP 1003 Mills a. Type b. Make & No. c. Capacity d. Motor KW e. Motor Speed f. System Lub-oil System a. b. c. d. e. 1.6 Pump Make/Type Capacity Speed Relief Valve Setting Motor Rating : : : Alekton / Screw 70 LPM 970 RPM : 7.0 KSC : 3.7 KW : : : : : : XRP 103 BHEL 9 66.3 TPH 525 KW 600 RPM Cold PA

Since, Primary Air Fans and mills are available for this test, the required plant item completion list, for mechanical, Electrical and C & I to be prepared at site prior to test.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 4 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 2.0 OBJECTIVE Clean Air flow test in milling system is carried out to check velocity variation between the pulverized coal pipes of a mill is within allowable limit and there by to ensure that correct size orifices are installed in coal pipes for equalizing the Air flow and there is no foreign material pluggage inside the pulverised coal pipes. 3.0 3.1 3.2 PROPOSAL Clean Air flow tests shall be conducted in all the mills individually with Cold Air. The test will be conducted by running primary air fan and mill and flow measurement will be taken at specified locations and ensured that completion criteria (Section 9.0) is achieved. SERVICES REQUIRED Availability of man power with required tools for attending to any leakage in the system. Availability of operating personnal to coordinate the activities Availability of lighting arrangements and communication in the operating floor.

4.0 4.1 4.2 4.3

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 5 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 4.4 4.5 4.6 4.7 4.8 5.0 5.1 5.2 5.3 5.4 5.5 Availability of portable fire fighting equipment near test area. Availability of auxiliary cooling water for mills & fans. Availability of instrument air supply Availability of LT supply Availability of HT supply SAFETY PRECAUTIONS Debris is and around milling system shall b e removed. Approach / Staircase / Platform wherever required are made available especially near the pitot tube traversing location. First aid kit available near test. The test team should be aware of the procedure adopted. Other agencies working near the test area are informed / cleared as per requirement. EMERGENCY PROCEDURE The test team should be aware of the steps to be taken to trip the running equipment in case any emergency / abnormal observations are notified to them. Signatures NTPC BHEL

6.0

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 6 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 6.2 6.3 The test team should be aware of actions to be taken in case of injury to any personnel. The test team should be aware of operating instructions of portable fire extinguishers. STATE OF THE PLANT The trial run of the mill which is selected for the test, is completed and is ready for operation from remote. One set of ID, FD & PA fan is commissional and ready for operation from remote. The corresponding raw coal feeder is erected and is boxed up property to avoid any air escape from mill through these feeders. Mill dischage damper is commissioned and kept opened fully. Mill and Coal pipes seal air dampers are commissioned and kept fully closed. The Coal Pipes isolation gate near the burner end (in all 4 corners) are kept opened fully. Two suitable size tapping points at 90 degrees apart in the same plane provided in the vertical straight portion of the all the 4 P.C. pipies of the mill.

7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 7 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 7.8 7.9 7.10 Proper access platform provided for taking pilot tube differential pressure measurement. Pilot tube differential pressure gauge, Thermometer (0-100 Deg. C), polethene tubes of sufficient length, are made available. 10 markings are made on the pilot tube at a distances as given below. At 0.0436 R, 0.135 R, 0.238 R, 0.358 R, 0.507 R, 1.492 R, 1.642R, 1.762R,1.816 Rand 1.956 R, (R-Inside radius of the Coal Pipe) All gates and dampers in Primary Air and Milling circuits are commissioned and ready for operation. All leakage points in the milling circuit are arrested. Reliable communication system among the test team members is made available. The classifier assembly is serviced thoroughly and all the vanes are set uniformly at desired position to facilitate air flow required for conducting the test. METHOD Start ID, FD & PA fans and establish furnace draft and air flow through the selected mill. Mill also started and kept running.

7.11 7.12 7.13 7.14

8.0 8.1 8.2

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 8 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO 8.3 8.4 8.5 Air flow through the mill is in creased by opening hot air damper and loading PA fan accondingly. PA header pressure shall be maintained at 750-800 mmwc. Select a Coal Pipe of average length, and insert the pilot tube to the center of the pipe and adjust the air flow to produce the calculated pilot tube differential pressure (approx imetely 110% flow) Velocity profile in each Coal Pipe shall be obtained by traversing the pilot tube at two directions, 90 0 apart at the center of equal areas. Record mill air temperature, mill air flow indication mill differential pressure, PA header pressure at control room. If control room indications not available, suitable measuring arrangements to be made at local. Convert the pilot tube differential pressure reading (velocity head) into air velocity inside the Coal Pipe by using the formula V = 0.2365227 h. (t)

8.6

8.7

8.8

Where V - air velocity in m/Sec h Pilot tube dift. Pr. in mmwc t Air temp in 0 K 8.9 Calculate the average velocity. Find the maximum and minimum velocity and the deviation shall be within plus or minus 5% of the average velocity.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0012 NTPC Ref no SIM/1/TS/1/010

Sheet 9 of 10

Plant area: BOILER PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES STATUS SL.NO % Max. deviation = Max.Velocity - Ave.Velocity x 100 Ave. Velocity % Minimum deviation = Ave.Velocity Min.Velocity x 100 Average Velocity 9.0 9.1 COMPLETION CRITERIA The clean air flow test for Coal Pipes completed after achieving the following criteria. a) Velocity variation of maximum and minimum velocity is within plus or minus 5% of average velocity.

Signatures NTPC BHEL

Sheet 10 of 10 10.0 LOG SHEET DATE: PROJECT UNIT ACTIVITY : : : Corner 2 A B Vh V Vh V Corner 3 A B Vh V Vh V Corner 4 B V Vh V

Corner 1 S.No Vh 1 2 3 4 5 6 7 8 9 10 11 Ave.Vel Air Flow 1. 2. 3. 4. 5. 6. 7. Air Temperature Coal Pipe ID PA HDR Pressure Furnace Pressure Max. Velocity Average Velocity Min. Velocity : : : : : : : A V Vh B V

A Vh

(Tolerance +5%) (Tolerance 5%)

Signatures NTPC BHEL

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES