Operational problem of MRS (Mill Reject System)

Mr. Devendra Pal Singh

Assistant Engineer/TSX-C&I

System information:
Mill reject system (MRS) handles Coal mill rejects and is part of Mill
system. The rejects are transported in the form of ‘SLUG’ to destination
point (called Bunker/Silo) through compressed Air (called Conveying Air)
generated by a compressor.
Pneumatic handling of bulk material meets the need of most of the power
plants. Use of air as medium to convey material totally enclosed in pipes
thereby eliminating spillage and dust nuisance and the inherent
advantage to route the piping without any layout problem clearly make
pneumatic handling the most widely acceptable method of bulk material
handling.

MAIN PART OF THE SYSTEM:

1. Material conveying system

2. Convey air system

3. Spray water system

4. Instrument air system

5. Power & Control system

Material Conveying System:

Consist of Material collection, Conveying & Discharge.
A Pyrite Hooper with isolation Plate Valve (PV), a permissive level probes,
transport vessel (Denseveyor) together form the collection and conveying
equipment. At the terminal end, reject is discharged into the bunker silo
(Bag filter) equipped with a number of solenoid valve (with Timer Card
called Terminal Box) for effective dust removal from the air prior to
venting in to Truck/Atmosphere and a level switch for high level sensing &
system control.

Convey Air System

Comprise of air compressor with drive & air receiver (02 Nos), this
essentially provide the pressurized air required for the material
conveying.
Spray Water System
Temperature of the reject from mill is around >50 deg C so we need to
reduce the same for further transportation like in trucks. This system
consists of solenoid operated spray valve tapped in the plant water supply
line. This system activate when the temperature of pyrite hopper reach
the >60 Deg C or when the Dome valve in open condition (Means reject is
transported from Hopper to Denseveyor)

Instrument Air System

It is a Tap-off point from main plant compressor (Instrument Air). Used
for conveying system and controlling all pneumatic operated valves.

Power and Control system

Comprise of HT/LT S/G, MCC, Local Control Panel, DCS/PLC, Control &
Signal Cables, Trays, Earthling, LPB etc.

Operational modes of system: A brief introduction

This system works on two modes first “PROBE MODE” and second is
“TIMER MODE”

Probe Mode:
Material availability in the hopper is sensed by level probes (set at a level
to give permissive signal
to the system) and the
dome valve on transport
vessel (Denseveyor) is
signaled to open. Material
is gravity fed in to the
Denseveyor. On preset fill
time lapse, dome valve is
closed. Pressurized air is
injected in to the
Denseveyor.
Material resistance builds
up pressure and conveyed
in to the form of ‘Slug’ or
‘Reject’ by compressed air
to the destination silo and discharge via terminal box. Once conveying is
completed, vessel (Denseveyor) pressure return to near atmospheric and
air supply to vessel is cut off. System is reset to accepted next cycle. One
screen is placed between hopper and Denseveyor to separate big particles
via manually (PV-3, 4). Manual Inspection can be done through a hole
provided in Pyrite hopper.
Timer Mode:
Timer mode logic neglects the probe level and ensures the SYSTEM ON
permissive condition. When we start in timer mode first INITIAL PURGE
starts for the time given to clean the pipe line from Denseveyor to bunker
inlet and then system starts in the pre-defined cycle (if line is chocked
and not clear during initial purging/Conveying then the system will stop
and LINE BLOCK fault is initiated).
After initial purging completion Dome valve & water spray valve opens
and material is gravity fed in to the Denseveyor. On preset fill time lapse,
dome valve & water spray valve is closed. Pressurized air is injected in to
the Denseveyor. Material resistance builds up pressure and conveyed in to
the form of ‘Slug’ or ‘Reject’ by compressed air to the destination silo and
discharge via terminal box.

General Mimic of MRS (Photo-Unit#2A NSPCL Bhilai)

Next cycle starts after completion Cycle Reset Timer (TR) & CYCLE GAP
TIMER (TCG). All the timers (TCG-CYCLE GAP TIME, TDVO-DOME VALVE
OPENING TIME, TMC-MINIMUM CONVEYING TIME, TR-RESET TIME, TLB-
LINE BLOCKAGE TIME, TSF-SEAL FAIL TIME, TCF-CYCLE FAIL TIME, and
TIP-INITIAL PURGE TIME) are configurable and designed to improve
systems life with better efficiency.
Operational Problems:
During the On-Load/No-Load system checking of Unit-2 MRS the following
problems are observed:

1. Mill-D-- Line Blockage Problem

As per the document this faults occurs when vessel pressure low is not
achieved even after expiry of line block timer.
Observation:
It was observed that vessel
pressure Low is achieved but
still the problem is faced
frequently because of leakage of
conveying air in conveying line,
so it can’t convey reject in an
effective manner to bag filter.
After resolving problem again
found that the conveying press
at the end of pipe is too low
resulting unwanted chocking of
line.
Solution:
After full line checking it was found that the orifice provided in conveying
line is partially blocked by dust particle present in air supply to prevent
this we used air filter regulator to filter the supplying air and drain pot to
prevent unwanted chocking of orifice.

2. Mill-A—Denseveyor Chocking (Observation & Prevention)

This problem was observed in NO-LOAD condition of MRS for Mill-A. This
problem arises when Dome valve opened for long time resulting reduction
of life of the system. To prevent this effect we must regularly monitor the
system timings.
Coal reject solidifies with the interference of moisture. Denseveyor
consisting moisturized reject so we need to convey it fast as fast as
possible. Monitoring of water spray valve and temperature switch can also
help in prevention of this problem.

3. Mill-C—Manual Plate Valve Opening Problem (Observation &

Prevention)

In Mill-C temperature switch

damaged during operation
resulting no high
temperature alarm showing
in DCS resulting plate valve
material deformation and
damaging of handle threads
because of high temperature
of the reject.
To prevent this problem
regular monitoring of water
spray valve, water supply
line valve and temperature
switch checking is required.
Frequent Greasing / Oiling of manual valve is also good method to
prevent this problem.

4. Mill-B—Convey Air Fail And Seal Fail (Observation &

Prevention)

Frequent failure of seal and conveying air was observed on NO LOAD

testing of MRS for Mill-B of Unit#2 Bhilai Site.
According to documents SEAL FAIL fault occurs when Dome valve close
command is given and seal pressure OK signal is not achieved for the
given time and CONVEY AIR FAIL fault occurs when conveying air supply
pressure is low achieved for the given time.
After physically checking it was found that the sealing of dome valve is
damaged due to simultaneous operation of conveying and dome valve
opening resulting damage of seal of dome valve.
Frequent Conveying air fail fault occurs because of chocking of instrument
air line, choking of vessel orifice.

Conclusion:
To prevent all of the above mentioned operational problems first ensure
that all pressure switches are correctly calibrated and set at the point
mentioned in the instrumentation Schedule. Ensure the Piping work is
correctly done by vendor. To avoid line block Local Purge and HMI Purge
is provided which can be used frequently during Cycle Gap Timing to
protect the system.
Frequent checking of main part of the system like Orifice, Manual Plate
Valves, Instrument air supply pressure (>6.5kg), Temperature Switches,
Terminal Box, Water Spray Valves, Dome Valve Opening Timing and all
timing of the main cycle to meet the requirement in effective manner .