DOC NO:

OPGS POWER GUJARAT PVT LTD

OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

OBJECTIVE

This procedure covers all the operational activities related to starting, changing over
and shut down of coal crusher which are carried out by an operation personnel for safe operation
of equipment and which will improve the equipment availability always.

DESCRIPTION
The efficiency of coal mill solely depends on size of coal which supplied to it and
coal crusher plays vital role for that process. So it is mandatory to crush the receiving coal and
supply it with desired size (say 0-50mm).
There are 2nos of Ring granulator hammer type crusher present in our CHP and it
crush material by a combination of impact and rolling compression.
The crushing action is performed when material is dropped through the feed opening
where it struck in mid air by the multiple rings which are being driven round by the rotor discs
in direction towards the breaker plate. The rings are mounted on suspension bars and when the
rotor is set in the motion centrifugal forces brings the ring out against material to be crushed.
As material is fed to the machine the rings are forced back towards the rotor center
until bar is encountered by the ring internal surface and a forward driving force is exerted. The
material is broken and discharged through the cage bars or screen plates thus easing the load
and allowing the ring to move out until it is held again by suspension bar before encountering
the incoming feed once again.
The rings are thus held in deep contact with the bed of material on the cage bars or
screen plates and they revolve with planet like motion relative to the direction of rotor rotation.
This positive rolling feature provides a constant effective crushing action which in turn ensures
a granular product sizing. The size of crushed coal is determined by the size of hole in screen
plate and clearance.

SAFETY PRECAUTIONS

 Hazard Identification and risk assessment of the activity shall be made available
to the operation.

 Only authorized person is allowed to operate the equipment.

 All the access to the equipment shall be kept clear.
 All the persons operating the equipment shall be provided with the proper
training.
 All the guards and coverings of the equipment shall be covered.
 No flammable material or oil shall be scattered or spilled around the equipment.
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

 Field operator should wear the relevant personal protective equipment like safety
shoes, helmet, safety hand gloves, safety goggle, nose mask, and others.

TECHNICAL DETAILS

OIL PUMP MOTOR:

MACHINE NO 263DJ
FRAME ND100L
Kw(HP) 2.20(3)
SPEED 1430RPM
CURRENT 4.61A
BRG.DE/NDE 6206ZZ/6205ZZ
DUTY S1
IP 55
REF MEG 1966
EFF (FL) 82
VOLT 415±10%
INSL CLASS F

SCOOP OIL FILTER:

TYPE BASKET
MODEL SSK150
SR NO 13-0025
SIZE 40NB
FLOW 100LIT/MIN
PRESSURE 5KSC
MESH SIZE 60MICRONS

OIL COOLER FAN:

DUTY S1

IP 55
VOLT 415V
POWER 3.75Kw
AMP TEMP 50˚C
SPEED 1430RPM
CURRENT 7.40A
EFFICIENCY 85%
FREQUENCY 50Hz
CONNECTION DELTA
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

SCOOP:

POWER 315Kw
SPEED 750RPM

CRUSHER MOTOR:

3P SQ CGE IND
MOTOR MOTOR
P.F 0.9
INSULATION F
IP 55
VOLT 6600±-10
POWER 315Kw
AMP TEMP 50˚C
SPEED 743RPM
CURRENT 36A
EFFICIENCY 95%
FREQUENCY 50Hz±-5
WEIGHT 3.5T

CRUSHER:

RING HAMMER
TYPE CRUSHER
ROTOR DIA 1600mm
ROTOR LENGTH 1977mm
DELIVERY GRAVITY <300mm
DISCHARGE
GRAVITY <25mm
POWER 315Kw
WORK CAPACITY 500T/HR
SPEED 740RPM
WEIGHT 19.6T

BYPASS MOTOR:

MOTOR 3P IND MOTOR

INSULATION B
POWER 0.75Kw
IP 44
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

SPEED 1470RPM
CURRENT 1.98A
P.F 0.75

ROLLER SCREEN MOTOR:

IP 5
INSULATION F
SHAFTS 9NO
VOLT 240DELTA/415STAR
POWER 21Kw(9×3)
WORK CAPACITY 500T/HR
SPEED 1470RPM
CURRENT 95.6A
MESH SIZE 90*30mm
FREQUENCY 50Hz
WEIGHT 12.7 TONNES

PRECHECKS

Following Engineer checks required before starting the Equipment.

FIELD ENGINEER CHECKS

 Ensure no work permit is opened.

 Ensure the equipment and areas are cleaned for safe operation.
 Ensure temperature sensors are clear from dust and coal deposits.
 Ensure there is no oil spillages near the oil pump and scoop systems.
 Check scoop oil pump discharge valve open.
 Check emergency push buttons are released, if not release the same.
 Ensure oil cooling fan and scoop system panels are healthy.
 Ensure protections on downstream belts are reseted and healthy.
 Ensure oil level in scoop oil tank sight glass is between the Min. & Max. Mark.
 Ensure greasing done in DE and NDE bearings.
 Check oil leakages, oil level, oil condition and cleanliness of gear box.
 MFG Gates are opened at respected screens and coal crusher.
 Ensure all the chutes are clear from coal jammed and should be clear.
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

SWITCH GEAR ENGINEER CHECKS

 Ensure no work permit is opened.

 Check 6.6KV circuit breaker healthiness, spring charging condition, trip circuit
healthy, rated bus voltage.
 All the supplies from feeder to equipment’s are healthy.
 If above conditions are ok, give clearance to control room engineer.

CONTROL ROOM ENGINEER CHECKS

 Check all the permits are returned for the equipment.

 Following conditions should be satisfied before starting the crusher.
 Ensure all the protections of belts are healthy.
 Crusher motor winding temperature should not be high.
 Oil cooler fan, scoop oil pump controls, OLR are healthy and remote mode on
PLC screen.
 Scoop control must be disengaged.
 Screen bypass gates should be closed and must be open towards screen.

STARTING PROCEDURE

 Start oil cooler fan and see any abnormal sound from fan motor
 After 5secs, start the scoop oil pump.
 Observe any leakages or abnormal sound and ensure pump will achieve 3.5kg
pressure from local.
 Start coal crusher motor and see any abnormal sound, vibrations from local.
 After 10-15secs, engage the scoop system so that speed of crusher will increase
gradually.
 Then start the roller screen from PLC & ensure all the 9 motors are running and
no abnormal sound coming from local.

CHANGE OVER PROCEDURE

NOT APPLICABLE.

SHUT DOWN PROCEDURE

 Stop oil cooler fan and pump.

 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-08-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR COAL CRUSHER REV NO 0 DATE 23-07-2018

 Scoop system will disengage automatically and crusher motor speed will reduce
gradually.
 Stop the crusher motor.
 Press emergency push button from local( if any emergency).

CONCLUSION

The purpose of this procedure is for proper understanding about the safe operating of start up
and shutdown of coal crusher and hence increase the availability of equipment.
.

RECORD

CHP desk log book.