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Procedure for Coal mill changeover

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Because the life of the grinding section varies with the coal properties and the operation conditions etc. liners. Also. the maintenance of abrasive parts is also extremely important. Therefore. in addition to conventional abrasionresistant cast iron. studies have been conducted to develop abrasion-resistant materials and to simplify the replacement of roll rings. Operation and maintenance The operation of mill is simple and start/stop operation can be completely automated. but recently some types of upright mills have become available for high-turndown operation up to 30% or less. the wide range of the mill operation load adjustment is important for coal boiler operability. etc.The coal pulverizer is the most important equipment to govern the operability and reliability of coal burning boilers.. curing cladding-welding material with several times abrasion-resistance of cast iron has also been used. As for the material of rolls. it is necessary to measure periodically the abrasion depth . The upright mill is available for 40-50% turndown. So. For mills operation. an optimum mill type must be selected from the comprehensive view point according to the coal properties and the operation conditions.

Generally. mill changeover operation is done in which the faulty mill is shut down and the load is transferred to the standby mill. In case of emergencies.of the rolls or segments of each plant and to schedule the intervals of replacement. rolls/rings/liners replacement is conducted in such a manner that one unit of extra mill per boiler is installed. and each mill is maintained sequentially. and maintenance intervals are set. .


Review primary airflow curves to ensure safe operation throughout the operating range. close the mill and start primary airflows.Measure and record internal clearances. tolerances.C. • Support ignition energy is removed Within 3 minutes of feeder starting. Procedure for the changeover is: Steps prior to putting the mill in service: 1. supply for more than 2 secs. • Motor protection operates. 2. Fan trips (mill in excess of 3 will trip starting from bottom).A.After thoroughly checking mechanical tolerances and clearances. 4.Functionally check the full movement and position indication of all dampers. 3. In such a case the changeover to the other mill takes place. Warm the mill to normal operating temperature of 150F . 5. ensuring adequate minimum airflow as well as proper air-to-fuel ratios when operating above minimum airflow.Check and calibrate the coal feeders.Mill tripping might take place due to one of the following reasons: • Mill discharge valves are closed • Loss of elevation D. • One P. and spring preloads.

Conduct a PA airflow measurement traverse by manual pitot tube to verify that the indicated PA is correct across the boiler operating range. This test should include isokinetic coal sampling and dirty airflow measurements through each fuel line to determine air/fuel balance and coal fineness. Bunker level Satisfactory.C.Begin the normal pulverizer start sequence. 6. Once normal coal flow is applied to the mill. 10. a full mill test should be conducted. 7.C feeder and mill properly boxed up and no maintenance staff working. 8. 9. .  R. Primary airflow "HotK" calibrations of the primary airflow measuring element should also be conducted Other pre start checks: LOCAL (to be made by local operator)  Ensure R. All coal pipes (and flows to all of the burners from each respective pulverizer) should be balanced and within ±2% of the mean flow.  Gear box oil level normal.Perform a seal air check.Conduct "clean air" 24-point traverses of all of the fuel lines to measure and compare the balanced airflows through each pipe.mill outlet temperature (bituminous coal) and airflow at minimum (normal minimum primary air [PA] flow).

 Get the electrical supply for the mill. Take out emergency push button and give clearance to UCB for starting.P zones have been charged (for first mill ).  Inform turbine operator of mill start up. Mill firefighting system ready.      Lub. Seal air valve open. Cold air gate open. Start the mill. Check the header pressure for both primary and seal air is normal.  Check that mill start permissive as per FSSS are satisfied (for the help of operator these permissive are written on FSSS panel and when the condition is satisfied it is indicated by a glowing bulb). oil coolers charged.  Inform the local operator to be near mill for start up. Hot air gate closed.  Check that mill ignition energy is O.B: (to be made by desk operator)  Ensure no PTW pending.C.  Ensure attemperation valves are ready for operation. U.A fan and a seal air fan is in service. Tramp Iron Gate open. Mill outlet valve open.  Ensure E.  Ensure at least one P.K. .

. (Especially for first mill).  Open hot air gate.C feeder and load the mill gradually.  Keep the air flow through mill-54 T/hr.  Start the R.  Keep watch on mill differential to avoid mill chocking.  Maintain mill outlet temperature between 75 degree Celsius to 80 degree Celsius.  Warm up the mill. temperature of main steam shoots up with coal firing proper check should be kept on these parameters.POST START CHECKS LOCAL  Check no abnormal sound from mill. U.  As the pressure.  Check return oil flow from upper bearing is satisfactory.  Check all the rollers are rotating and the rate of reject is normal (after the mill is loaded). Ensure that they are normal.B  Check mill starting time and current.C.