KBE CIRCLE -GREEN HOUSE

TOPIC -AIR AND FLUE GAS SYSTEM

Cold primary air system consist of the following components:

01.Silencer.

02. Motor operated louver damper.

a) Operation of full open and close problem
b) Motor Tripping on overloading during start of fan

03. Primary air fan.

a) PA fan unloading during operation (renusagar)
b) Problem of heavy vibration in B- side PA fan discharge ducting and inability to
carry full load.
c) IGV wrong orientation – Parichha site
d) Vibration, Noise and stalling
e) Reverse rotation of fan
f) Sustaining with single PA fan operation during trip out of one PA fan

04.Motor operated Gate.

a) Operation of full open and close problem
b) Slow opening, not opening/ closing.

05.Primary Air Common Duct.

a) Guide vane not installed properly, guide vane erosion
b) PA duct vibration- Panipat 110 mw 1&2, Paricha unit 3&4.
c) Vibration

06.Cold PA Header
a) Inadequate size
Hot primary air system consist of the following components

01.Motor Operated louver damper.

a) Not operating, passing.

02.Regenerative primary air pre-heater.

a) High pressure drops in hot primary airside from air heater outlet to mill inlet
(airside).
b) AH leakage,
c) Bearing failure,
d) Chocking
e) Cold end corrosion.
f) Erosion
g) Accumulation of ash during single stream operation in the upstream in duct.

03.Motor operated damper

04.Hot Primary Air header
a) Ash accumulation
b) Low header pressure

05.Hot Air Gate

a) Not operating,
b) Slow operation.
c) Operation time is high
06.Pneumatic operated damper

07.Cold air duct

a) Inadequate size

08.Pneumatic operated gate.

a) Not opening/ closing, slow movement.

09.Pneumatic operated damper.

a) Not opening or closing fully, passing.

10.Hot & cold air Mixing duct.

a) Improper mixing

11.Venturi
a) Improper flow measurement
b) Calibration not ok

12.Mill (Bowl & Tubular)

a) Liner torn out condition
b) Wearing of balls
 c) Fineness power
d) Classifier chocking
e) Malfunctioning of gravity damper

13.Hot PA interconnection duct

a) The hot PA interconnection duct failed by burst opening at the topside towards
chimney. The top middle portion of the fabric failed (Ramagundam).
b) NMEJ failure due to improper restraints.

14.Purge air for tube mill

a) Duct size optimization
b) Common purge air damper locking at 20% to avoid PA header pressure low.
c) Common purge air damper to be treated in horizontal duct
d) Individual purge air damper to coal pipe to be changed to knife edge gate.
e) No proper dry being released with actuator connection.
Secondary air system consist of the following components

01. Silencer

02.FD Fan
a) Standby fan running reverse
b) FD fan vibration at IOCL Panipat.
c) Inadequate capacity, Stalling.
d) High auxiliary power

03. Motor Operated Biplane Damper (MOBD)

a) Motor Tripping on over load while starting

04.Ducting from MOBD to Common Cold Secondary Air Duct (CCSAD)

05.Common Cold Secondary Air Duct (CCSAD)
06.Motor Operated Louver Damper (MOLD)

07.Steam Cooled Air Pre-Heater (SCAPH)

a) Chocking
b) Pressure drop

08. Re-generative Air Pre-Heater (APH)

a) Chocking
b) Heavy air ingress than predicted
09.Common Hot Secondary Air header (CHSAD)
a) Ash accumulation

10.Aerofoil
a) Improper measurement.
b) Wearing problem
c) Calibration required
11.Common Bus Duct & Wind box
a) Inadequate to control air at low loads
b) Ash accumulation
12.Pneumatic Operated Louver Damper (Regulating) (POLD)

Flue gas system consist of the following components

01.Ducts
a) Wear
b) Leakage
c) Ash accumulation
d) Vibrations
e) Erosion

02.Expansion joints (Metallic & Non-metallic)

a) NMEJ failure, it should be arrested from its lateral movement at Rihand unit 3.
b) Failure was mainly due to heavy accumulation of ash inside the bellow fabric
cloth was not capable of taking ash load. (Talcher)
c) Loose glass wool covered with chicken mesh placed inside the bellows as
bolster were not tightly packed and were blown off while the unit was running
giving space for accumulation of ash. (Talcher)
d) Severe leakages have been noticed in all these bellows since commissioning
(Bakreshwari).
e) Leakages

03.Motor operate louver damper

04.Air pre-heater (Regenerative and tubular)
a) Tubular air preheater chocking at Renukoot and Renusagar.
b) Chocking
c) Leakage
d) Erosion

05.Motor operate louver damper

06.FG common duct
a) Erosion
b) Ash accumulation

07.Guillotine gates
a) Gate blade fallen down at Bathinda 2x250 mw.
b) Not opening/ closing
c) Slow movement
d) Stuck up

08.ESP
 a) Higher emission

09.Guillotine gates
10.Opacity monitor
a) Reading not reliable

11.FG common bus duct

12.Guillotine gates
13.ID Fans
a) Vibration
b) Inadequate capacity
c) Ash accumulation
d) High auxiliary power
e) Overloading

14.Guillotine gates with integral seal air fan

15.Stack
16.NMEJ
a) NMEJ failure
17.SADC
a) Pneumatic dampers feed back not there

Scanner Air system consist of the following components

01.Duct
02.Duplex air filter
a) Chocking

03.Pneumatic operated damper

04.Hand operated dampers
05.AC operated Fan
06.DC operated Fan
a) Motor not running at the required rpm at paricha unit 3&4

07.Auto transfer gate

Seal air system consist of the following components

01.Ducts
02.Filters (Dynavane filter /Viscous filter)
a) Chocking of dyna vane filter at simhadri.
03.Hand operated dampers
04.Seal air fans
a) Noise
b) Bearing failure.
c) Vibration.

05.Auto transfer gate

06.Auto viscous damper
a) No O&M instruction from sub-vendor.