Automatic Mill Scheduler

- A PE-C&I Initiative
NTPC EOC
NOIDA
Automatic Mill Scheduler
1. MAIN OBJECTIVE:
i) Automatic start up and shutdown of coal mills as per load demand
➢ Automatic opening/closing of CAD/HAD at optimum rate
➢ Automatic loading/unloading of feeders at optimum rate
2. Mill scheduler shall be available between 55% to 105% load range
3. Based on BHEL’s FSSS write up and pulveriser auto start/auto stop logic
4. Maintenance of associated field devices and final control elements

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Implementation approach
➢Mill scheduler ON/OFF
control
➢Mill selection Mill auto start/stop
➢Operator priority sequence
selection
➢When to start the mill • Sequential Mill Hot PA
➢Ramp rates starting/stopping of mills flow
• Opening and closing of control
HAD/CADs Mill outlet
Mill scheduling logic temperature
• Ramping of feeder
control
• Switching of HAD, CAD and
Feeders in Auto/Manual Feeder
Speed
control

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Mimic of Automatic Mill Scheduler

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Coal quality estimation
Specific Coal = Total coal flow ÷ Actual MW
Time average for past 1 hour

Reference documents:
• Predicted performance for best, design and worst coal (1450-001R-SGHY-PVM-U-013)
• Mill sizing calculation and performance curve (1450-001R-SGTR-PVM-W-006)

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Criteria for deciding optimum no. of mills
Best coal Design coal Worst coal

Reference documents:
• Predicted performance for best, design and worst coal (1450-001R-SGHY-PVM-U-013)
• Mill sizing calculation and performance curve (1450-001R-SGTR-PVM-W-006)

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When to initiate mills start?
Optimum no. of Mills to achieve target load > No. of mills in service

• First mill start command shall be initiated 6 mins* before the starting of next
time block.
• Second mill start sequence shall be initiated, once the first mill become self
sustainable (Feeder Proven and Speed>50%)

* Shall be tuned based on operator experience and trial run results

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When to initiate mills stop?
Optimum no. of Mills to achieve target load < No. of mills in service

• First mill stop command shall be initiated at the beginning of next block.
• Second mill stop command shall be initiated (if required), once the first mill
stop sequence completes.

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Which mill to be started/stopped?
1) Operator Priority
2) Through Auto Logic
Auto priority criteria:
➢ Time Avg. MS, RH and MTM temp values
➢ Position of final control elements like Spray valve position and burner tilt

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Mill Start Up/Shutdown (AUTO MODE)
• Ensuring availability of ignition energy
• Elevation oil guns shall be taken in service in auto to establish ignition permissive, if
required.
✓ Furnace Pressure check

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 Mill Start Up sequence (AUTO MODE)
STEP-1: Seal air valve opens: Seal air to bowl DP adequate
Step-2: Pulveriser motor start
STEP-3: Feeder Seal air valve open, Feeder Outlet gate open
✓ PA header pressure control in AUTO
STEP-4: Hot air gate (HAG) Open.
STEP-5: Command initiated to put Hot air dampers (HAD) and cold air dampers (CAD) in auto.
✓ Minimum PA inlet flow maintained.
✓ Pulveriser outlet temperature > Min.
STEP-6: Feeder START
STEP-7: After 50 seconds, feeder output included in the totalizing circuit.
STEP-8: Feeder loading at default rate or rate set by the operator.
✓ Feeder loading rate shall be regulated depending on time average MS, RH and MTM temperatures.
✓ Time average shall be calculated for 1 mins.
✓ Loading shall HOLD or reduced in case mill outlet temperature < Min.
Step-9: Feeder speed switch to auto when (Fuel master demand-Feeder demand) < 5%

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Mill Stop sequence (AUTO MODE)
Step-1: Reduce Mill outlet temperature SP to Min value
✓ PA header pressure control in auto
Step-2: Feeder shall transfer to manual and start unloading
✓ Unloading rate shall be default rate or rate set by the operator.
✓ Rate shall be regulated depending on time average MS, RH and MTM temperatures.
Step-3: Feeder speed at min. → Command to close HAD
Step-4: Close hot air gate→ Command to open CAD to 100%
Step-5: Pulveriser outlet temperature < Min. → Feeder stop
Step-6: Feeder off for 3 minutes, Pulveriser will auto stop
Step-7: Close CAD to <=5% open

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Benefits:
1) Support flexible operation
2) Optimize no. of running mills at various loads
3) Minimize operator intervention during Mill start up and shutdown

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