You are on page 1of 21

MILL PERFORMANCE

May 24, 2012 PMI Revision 00 1

The Purpose of a Pulverizer:


.

Must be able to pulverize consistently the design quantity of coal suitable for combustion. Able to dry wet coal up to the design wetness even at full output condition. Able to maintain the The Pulverizers are the HEART of products within the a 00 May 24, 2012 Pulverized Coal Fueled Boiler! PMI Revision desired grading

PULVERIZER DESIGN CRITERIA


PULVERIZERS SIZE & TYPE ARE SELECTED TO PROVIDE A GRINDING CAPACITY BASED ON COAL CHARACTERISTICS MARGINS IN CAPACITY ARE BASED ON EXPECTED WEAR LIFE AND RANGE OF COAL TO BE FIRED OPERATING CAPACITY AFFECTED BY COAL MOISTURE, INLET AIR TEMPERATURE AND AIR FLOWS.
May 24, 2012 PMI Revision 00 3

MILL PERFORMANCE INDICATORS


MILL OUTLET TEMPERATURE MILL OUT PUT MT/H MILL FINENESS FRACTIONS MILL AIR FLOW MILL PRESSURE DROP (D.P) MILL REJECT RATE MILL MOTOR AMPERES WEAR PART LIFE
PMI Revision 00 4

May 24, 2012

CAUSE OF MILL PERFORMANCE DETORIARATION QUALITY OF COAL (MOISTUR, HGI ETC.) UN BALANCED FLOW IN COAL PIPES. SETTLEMENT OF COAL IN COAL PIPES. POOR COAL FINENESS LOW PA TEMPERATURE FOREIGN MATERIAL INGRESS. LOSS THROUGH REJECTION WEAR PART LIFE
PMI Revision 00 5

May 24, 2012

MILL PERFORMANCE - IDENTIFICATION METHODS NO LOAD RUN CLEAN AIR FLOW TEST DIRTY PITOT TUBE TEST MILL FINENESS SAMPLING TRENDING OF COAL PIPE METAL TEMPERATURE

May 24, 2012

PMI Revision 00

OBJECTIVE OF TESTING
CLEAN AIR BALANCING BETWEEN BURNERS DIRTY AIR BALANCING BETWEEN BURNERS FUEL BALANCING BETWEEN BURNERS FINENESS TESTING OF PF BETWEEN BURNERS SETTLEMENT OF COAL PARTICLE IN COAL PIPE.
May 24, 2012 PMI Revision 00 7

CLEAN AIR FLOW TESTS


STEPS INVOLVED ARE DETAILED IN THE TEST PROCEDURE STANDARD L TYPE PITOT IS USED. CLEAN AIR FLOW BALANCE IS COMPUTED BETWEEN COAL PIPES DEVIATION OF +\- 2% INDICATES A SATISFACTORY FLOW BALANCE AND FURTHER TRENDING IS REQUIRED.

May 24, 2012

PMI Revision 00

May 24, 2012

PMI Revision 00

Acceptance range
Clean air flow distribution to be with in +/-2.5%. Dirty air flow distribution to be with in +/- 5.0%. PF distribution to be with in +/-10%. Guarantees to be established for end mills with unequal length in fuel piping

May 24, 2012

PMI Revision 00

10

Clean Air Balancing, A Vital First Step to Fuel Line Balancing


Fuel lines balanced to each burner by Clean Air test 2% or better.

May 24, 2012

PMI Revision 00

11

COAL FINENESS ANALYSIS


FINENESS SAMPLE ANALYSIS NEEDS TO BE CARRIED OUT IMMEDIATELY TO AVOID COAGULATION IN CASE OF HIGH MOISTURE COALS MINIMUM FOUR STANDARD MESH SCREENS TO BE USED TVA DEVELOPED SOFTWARE ENABLES REVIEW OF MILLS PERFORMANCE DATA TO FOCUS ON VARIOUS TRENDS
May 24, 2012 PMI Revision 00 12

Accurate weighing and sieving of the samples through 4 sieves is also important. Why four sieves? Because, with the desired near zero on 50 mesh sieve, at least three points are needed on the Rosin-Rammler Chart to plot the fineness Results. Four sieves of 50, 100, 150 and 200 mesh are recommended for fineness sampling. 70 % in 200mesh
May 24, 2012 PMI Revision 00

13

May 24, 2012

PMI Revision 00

14

May 24, 2012

PMI Revision 00

15

UNIT CAPABILITY GOVERENED BY MILL PERFORMANCE BOILER AND COMBUSTION SYSTEM PERFORMACE AFFECTED BY QUALITY OF PF COAL AND ITS DISTRIBUTIION RELIABLE FEEDBACK SHOULD FOCUS ON TIMELY MILL OVERHAUL VERY EFECTIVE CROSS CHECK OF THE STATION INSTRUMENTS FEEDBACK
May 24, 2012 PMI Revision 00 16

WHY IS MILL PERFORMANCE TESTING IMPORTANT?

USE OF METAL TEMPERATURE IN FUEL PIPE TO MONITOR CHOCKING


FUEL PIPING METAL TEMPERATURE IS BEING MONITORED IN FARAKA TO MONITOR FUEL PIPE CHOCKING. RECENT STUDIES SHOWED THAT LOWER THAN MILL OUT LET TEMPERATURE IS NOT NECESSARILY AN INDICATION OF PIPE CHOCKING. DIFFERENCE OF 7 TO 8 C WAS OBSERVED BETWEEN COAL AIR TEMPERATURE METAL TEMPERATURE FOR A PIPE WHICH WAS CLEAR.

May 24, 2012

PMI Revision 00

17

Pulverizer Troubleshooting-Matrix
LACK OF CAPACITY OR HIGH POWER CONSUMPTION HIGH MOISTURE LOW GCV INCREASED RAW COAL SIZE. GRINDING TOO FINE EXCESSIVE BED DEPTH INSTRUMENT ERROR

May 24, 2012

PMI Revision 00

18

Pulverizer Troubleshooting-Matrix
EXCESSIVE MILL REJECTS CHANGE IN COAL GRINDABILITY, SULFUR & ASH. IMPROPER COAL/AIR RATIO THROAT GAP WEAR.

May 24, 2012

PMI Revision 00

19

Pulverizer Troubleshooting-Matrix
LOW COAL \AIR TEMPERATURE HIGH MOISTURE LOW PA INLET TEMPERATURE PASSING OF COLD AIR. LOW A.H INLET TEMPERATURE

May 24, 2012

PMI Revision 00

20

THANK YOU

May 24, 2012

PMI Revision 00

21