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OPERATION DIVISION

OPERATION GUIDANCE NOTE:COS-ISO-00-OGN/OPS/CHEM/014

Rev. No. : 0 Date : November, 1998

COAL AS FIRED SAMPLING


PROCEDURE

Approved for
Implementation by B.N.Ojha.
Director (Operation)
Date : 5.11.98..
Enquiries to : Executive Director, Operation Services, EOC, Noida

COAL AS-FIRED SAMPLING PROCEDURE


CONTENTS
Page Nos.
1.0

Introduction

2.0

Superseded Document

3.0

Scope

4.0

Sampling Procedure

4.1

Sampling Location

4.2

Quantity of Sample

4.3

Moisture Sample

4.4

Reduction of Gross Sample

4.5

Laboratory Sample

5.0

Review

6.0

Bibliography

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COS-ISO-00-OGN/OPS/CHEM/014
Rev. No. 0
COAL AS FIRED SAMPLING PROCEDURE
1.0

INTRODUCTION
NTPC purchases coal on a quality specification, i.e. either required by the
equipment manufacturer or set by coal supply agreement. In coal fired
thermal power station, operational efficiency of the plant is profoundly
influenced by the coal quality.
Further in NTPC, coal fired units of varying capacity from 60 MW to 500
MW are in operation at different sites. After the coal is dispatched from
different mines, it is being received through MGR system, then crushed to
20-30 mm size by crushers for bunkering and subsequent pulverising to
200 mesh size for final combustion in boiler furnaces.
For practical purposes, this crushed coal of 20-30 mm size is termed as
Coal-as-fired. This Operational Guidance Note deals exclusively with
sampling procedure of Coal as-fired.

2.0

SUPERSEDED DOCUMENT

: Nil

3.0

SCOPE

: All stations using coal.

4.0

SAMPLING PROCEDURE
Coal-as-fired sampling procedure as envisaged in this Operational
Guidance Note deals with sampling location, quantity of sample to be
collected, moisture sample, reduction of sample and laboratory sample
preparation.

4.1

Sampling Location:
The sampling point for coal-as fired sample has to be safe, easily
accessible and convenient for collecting the sample. Here, the following
alternatives are to be considered on priority basis depending on site
condition:a)

Coal-as-fired sample can be collected from sampling ports at the


volumetric feeder from the bunker to individual mill. This represents
the most realistic coal-as-fired sample for a given day.

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COS-ISO-00-OGN/OPS/CHEM/014
Rev. No. 0
b)

4.2

Coal-as-fired sample can also be collected from conveyor belt


before bunkering by various means.
i)

Coals as fired sample can be collected from automatic


sampler installed in the main conveyor belts going to the
coal bunkers. This ensures uniformity and representative
coal sample, hence, is preferred first.

ii)

If the conveyor belt of bunkering system can be stopped


without significantly disrupting operation, stop belt method is
also a good choice. Here, coal sample can be collected from
a prefixed portion of the conveyor belt.

Quality of Sample:
In order to have better representation, the sample should be collected in
each shift. The un-used sample after preparation and analysis can be sent
back to coal handling system for re-cycling. The quantity of sample for
different lot size of coal being burnt per day are as follows:-

4.3

Lot Size
(MT)

Min. Quantity of
Sample to be
collected (kg.)
(in 24 hours)

Total No.
of increment in
each shift

Weight of
sample in
each
increment
(Kg.)

10,000
15,000
20,000
25,000
30,000

640
640
640
640
640

22
22
22
22
22

10
10
10
10
10

Moisture Sample:
Since it is necessary to know the moisture content of the original coal,
about 5 kg of coal sample be collected by not less than 10 approximately
equal increments in 24 hrs., i.e. at least three times in a shift before
crushing. Coal sample for moisture determination should be kept in an
airtight container. Total moisture of coal comprises of surface moisture

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COS-ISO-00-OGN/OPS/CHEM/014
Rev. No. 0
inherent moisture. It is determined in two stages:- Stage-one is by air
drying, i.e. determining surface moisture and next is by oven drying, i.e.
determining inherent moisture. The combination of these two gives the
total moisture.
4.4

Reduction of Gross Sample:The gross sample shall be crushed to 3.35 mm in two steps through 12.5
mm by a jaw crusher and finally to 3.35 mm by a Palmac type of reduction
mill. The crushed materials shall be reduced by coning and quartering
using a coal sample riffler till 2 kg. sample is obtained. The same may be
schematically represented as follows:ORIGINAL
-5cm

-12.5mm
( BY JAW CRUSHER)
-3.35mm
(BY PALMAC TYPE OF MILL)
RETAINED
REDUCED
REPEATEDLY

1111

3
2kg
At some places, the above reduction process is carried out manually. In
this, there is always a chance of spillage of fine coal particles during
crushing, thereby making the sample un-representative. Hence, manual
reduction of gross sample should be avoided.
This 2 kg sample should not be excessively grinded while preparing the
sample to pass through 212 micron sieve. If has been observed that
excessive grinding is harmful.

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COS-ISO-00-OGN/OPS/CHEM/014
Rev. No. 0
4.5

5.0

Laboratory Sample:- Finally, the above 2 kg sample for analysis purpose


should be grinded in such a manner that the grinded coal should have the
following approximate particle size distribution:
a)

Passing 212 micron I.S. Sieve and retained on 125 micron IS Sieve
35%.

b)

Passing 125 micron IS Sieve and retained on 63 micron IS Sieve


30-35%.

c)

Passing 63 micron IS Sieve remainder.

REVIEW
The Executive Director (Operation Services) will be responsible for
reviewing this document on 2-yearly basis.

6.0

BIBLIOGRAPHY
IS:436 (Part-I/Sec-2) 1976.