Mill Performance Assessment Test: S P Karna, Agm (Cenpeep)

Mill Performance Assessment Test
S P Karna, AGM(CenPEEP)
Click to edit Master title style
PRESENTATION OUTLINE
 Overview of Mill PG Test
 PG Test Conductance & Evaluation
 Routine Mill Performance Test
Copyright © 2016 Your Company All Rights Reserved. 2
Mill PG Test Click to edit Master title style
Standard: ASME PTC 4.2
1.Capacity tests of Mill Typical data for 800 MW Unit
a. Demonstration of the capacity at 100% mill loading at Capacity Test
rated pulverized coal fineness with specified design coal 100% mill loading 98.53 TPH
with new set of grinding elements.
90% mill loading 88.68 TPH
a. Demonstration of the capacity at 90% of guaranteed value
of mill loading with the originally installed grinding Mill wear life
elements in nearly worn‐out condition or at the end of
guaranteed wear life of the grinding elements, whichever Classifier vanes 25000 hrs
occurs first. Mill Discharge Valves 15000 hrs
2.Mill Wear Life Assessment
Classifier cone/ 25000 hrs
1. Classifier vanes: xxx Hrs Ceramic Material
2. Classifier Cone: xxxxx Hrs
3. Mill Discharge Valves : xxxxx Hrs Grinding elements 7600 hrs
4. Ceramic Material: xxxxx Hrs .
5. All other parts coming in contact with coal: xxxx Hrs Seals 20000 hrs
6. Grinding Rolls: xxxxxxHrs
7. Grinding Ring I Race I Segment: xxxxx Hrs Mill Noise Level 85 dB
3.Mill Noise Level: 85 dB (A) @ 1.0 m from the equipment
Check list for Mill PG Test
1. Availability/Thoroughness of the test ports (two test ports in each coal pipe) for Isokinetic coal sampling
2. Proper airline connection to each corner & coal pipes
3. Raw coal sampling test port at Feeder inlet
4. All feeders (test mills) to be calibrated
5. All mill parameters to be available in control room (Mill current/Coal flow/Inlet temp/Outlet temp/Mill DP/
Mill PA flow/PF fineness/classifier setting)
6. Validation of PA flow transmitters and Mill inlet temperature
7. Mill reject system healthiness for collection of rejects during test
8. Adequate mill running hours for 100% & 90% capacity test.
9. Full load schedule during the test,
10. Availability of near design coal,
11. Adequate safety measures during tests
12. Cross functional team(Operation/EEMG/Chem/EMD/BMD/safety) for PG Test
Mill PG Test Guidelines
• The tests will be conducted after the Contractor has completed final
pulverizer set‐up and optimization adjustments, which may require
preliminary testing.
• The test with “new grinding elements” will be conducted on one (1) pulverizer
(mutually selected) which shall be in new or like‐new condition as determined
by internal inspection just prior to testing
• The test with “nearly worn grinding elements” will be conducted on four (4)
pulverizers (Employer’s choice) which shall have operated with the installed
grinding elements for the guaranteed wear life or with grinding elements in
nearly worn‐out condition, whichever is earlier, at the time of testing. The
wear condition of the grinding elements shall be determined by internal
inspection just prior to testing.
Mill PG Test Guidelines
• The steam generator to be operating above 90% MCR at steady‐state
conditions for the tests.
• Station instrumentation will be used for data measurement through the
DCS. All instrumentation that will be recorded during test must be
checked and calibrated to insure that it is operating and labeled correctly.
• The pulverizer airflow measuring devices and Raw Coal Feeders shall be
calibrated prior to the test. Airflow, temperature, and classifier controls
shall be properly adjusted.
• The test coal characteristics shall be as close to design coal as possible,
but must be no worse than the specified worst coal
MILL PG TEST: REFERENCE CONDITIONS
Raw Coal conditions are as follows:
Pulveriser Guarantee condition (Design)
A) Total Moisture (%) : 15
B) HGI : 55
Other Mill Operating Parameters:
C) PF Fineness : 70% thru 200 Mesh & 99% thru 50 mesh
D Mill Outlet Temp (°C) : 66 ‐ 90 °C
E Mill Air Flow (T/hr) : 141.8
F) Bowl Differential Pressure : up to 450 mmwc
Mill PG Test Objective
a) The objective of the test is to establish the mill capacity (100% of

guaranteed value) for the guarantee coal (design coal) condition.
b) The objective of the test is to establish the mill capacity (90% of

guaranteed value) for the guarantee coal (design coal) condition for
Four Coal Pulverizes (required for 100% TMCR load) per Unit.
The guaranteed wear life of the grinding elements is 6000 hours for the range
of coal specified in the contract.
Mill PG Test: Instruments & Facilities required
A) Sampling device for collecting pulverised coal.
B) Sieves for analyzing PF fineness.
C) Manometer, thermocouple and temperature indicator.
NTPC provides laboratory facilities for PF fineness, Total Moisture and other
analysis, as applicable.
Mill PG Test Procedure
a)Check pulverised fuel fineness and make the adjustments (like Spring
compression, Classifier Position, Ring‐roll setting etc.) to get the desired fineness
b)Check the Raw Coal Hardgrave Grindability Index (HGI) and Total Moisture
(TM) from Customer/Site record.
c)Ensure that the calibration of Raw Coal Feeder is done before and preferably not
more than 30 days from the Test date. Otherwise, RC Feeder to be calibrated.
d)Load the Mill to maximum possible condition with rated parameters.
e)It is preferable that the steam generator is operating above 90% MCR at steady
state conditions for the tests with required no. of mills in service, as recommended.
f)Run the Mill at the stable condition for Two (2) hour and record the mill operating
parameters
Mill PG Test Procedure
i) Coal Sampling (as per ASME PTC 4.2)
1. Pulverized coal sample shall be collected once during the test using Iso‐kinetic
method (ISO 9931).
2. Raw coal sample once during the test for TM & HGI.
3. Collect Mill rejects for one hour, weigh & record the same.
j) Analyse for Fineness of Pulverized Coal and Total Moisture of raw coal at plant
Lab as per the Standard Procedure given in O & M Standard.
k) For HGI analysis, collected raw coal will be made into 3 parts after coning &
quartering. First part shall be for BHEL, second for customer and third to be sealed
and kept with customer Site as neutral sample.
l) Correct the mill output for change in coal grindability, total moisture and
pulverized coal fineness.
Rotary Sampler For Pulverised Fuel Sampling
• 64‐point Rotary Sampler is preferred due to ease of use and because it requires less straight
lengths
• Instruments for on line measurement of PF flow based Electrostatic detection, Microwave
injection and Acoustics are commercially available.
PF fineness Click to edit Master title style
Fineness is expressed as the percentage pass through a
200‐mesh screen (74µm).
Coarseness is expressed as the percentage retained on
a 50‐mesh screen (297µm).
Typical Value 200 mesh ‐ 70% and 50 mesh ‐ 1%
Typical Mill Correction Curves
Mill Capacity Correction
a) Mill output shall be corrected to design coal HGI as per the correction curve‐ I.
Correction factor is taken as ratio of % Mill capacity for Test coal HGI and % Mill capacity
for design coal HGI.
b) Mill output shall also be corrected to design coal total moisture as per the correction
Curve‐II. Correction factor is taken as ratio of % mill capacity for Test coal total moisture
content and % Mill capacity for design coal total moisture content.
c) Mill output shall also be corrected to design coal output product fineness as per the
correction Curve‐III. Correction factor is taken as ratio of % mill capacity for output
product fineness achieved during the test and % Mill capacity for design coal output
product fineness.
d) Total correction factor is the product of all the above three correction factors.
Methodology for Correction in Mill Capacity
Mill Wear Life Assessment
Mill Wear Life Assessment: The objective of this test is to assess the achieved
wear life of the grinding elements and other Mill components, as per the
guarantee schedule for the range of specified coal.
1. Classifier vanes 25000 hrs
2. Mill Discharge Valves 15000 hrs
3. Classifier cone/ Ceramic Material 25000 hrs
4. Grinding elements 7600 hrs
5. Seals 20000 hrs
Mill Noise Level Click to edit Master title style
Mill Noise Level: 90 dB (A) @ 1.0 m from the equipment (Appendix‐A)
Performance Test Code: IS12065‐1987
(Noise can be measured at any operating mill load, as recommended. The
measured noise level shall be corrected wrt the background noise)
1. Sound level shall be measured at 1.0 m from the Mill body & 1.5m above
mill maintenance platform at 6 locations.
2. Shut‐down the mill and repeat the above step for obtaining background
noise (Sampling Location should be same as 1)
3. All the values should be tabulated in Format
4. All values should be in dB(A)
5. Average dB(A) should be calculated as follow
𝐴 𝐵 𝐶 𝐷 𝐸 𝐹
1010 1010 1010 1010 1010 1010
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝐵 𝐴 10 log 10
6
Mill Noise Level Measurement
Typical Noise Measuring Points Background Noise correction curve (Ref: IS: 12065)
Mill Performance Test
Routine Mill Performance test
Mill Performance Parameters
Key Outputs Important Factors
• Mill Capacity • Mill Air Flow & Velocity
• Fineness • Air Inlet Temperature
• Power Consumption • Fuel Moisture & HGI
• Size of Input Raw Coal Feed
• Maintenance Condition of Mill
• Pressure on Grinding Elements
• Classifier Setting
• Component Wear Rate
• Reject Rate
Coal flow distribution in Four Corners
NON‐ UNIFORM
• Non optimum
combustion
• Higher fuel
consumption
• Higher CO/CO2
Coal Pipes Bad Flame
UNIFORM
• Optimum
combustion
• Lower fuel
consumption
• Lower CO/CO2
Good Flame
Mill Performance Test
• Clean air Test
• Dirty air Test
• Iso kinetic PF sampling test
Clean Air Tests
Clean Air: Air going through the fuel lines, at FLOW
normal operating temperatures and pressures Pitots
Clean air velocities are indicative of the

‘transport’ energy in the PF pipes and should be
Pressure
Static
within +/‐ 2% of the mean.
Total Pressure
Static Pressure
10” Incline
Manometer
Clean Air Test
Taps
Dirty Air Tests
•Dirty Air: Coal Air mixture going through
the fuel lines with mill in service
•Dirty air velocities are measured in each
fuel line to determine airflow and coal
flow in each fuel line
•Dirty air velocities should be within +/‐ 5%
of the mean.
1 ¼ ” F u ll P o r t e d
B a ll V a lv e
Dirty Air Imbalance (Test 1) reduced
D u s t le s s C o n n e c t o r
D ir t y A ir P r o b e
after classifier adjustments (Test 2)
P o in t e r
D e n o te s H P
S id e
L P C o n n e c to r
H P C o n n e c to r
C o a l/ A i r F lo w
In c lin e d G a u g e O il
M a n o m e te r
Iso‐kinetic Coal Sampling
Coal flow distribution should be within +/‐ 10% of the average of fuel pipes.
Isokinetic: When the velocity of dirty air entering the collection nozzle is equal to the velocity of the
flow in the fuel line
24 m/s 30 m/s 19 m/s

24 m/s 24 m/s 24 m/s
Iso‐Kinetic Super Iso‐ Sub Iso‐Kinetic
Sampling Kinetic Sampling
The particles Sampling The gas velocity is
flow into the The particles are less than the
sampler at the pulled into the sample rate
same rate as sampler at a allowing fines to
the coal in the higher rate than escape.
pipe the pipe velocity
(more fines)
Rotary Sampler For Pulverized Fuel Sampling
• 64‐point Rotary Sampler is preferred due to ease of use and because it requires less
straight lengths
• Instruments for on line measurement of PF flow based Electrostatic detection,
Microwave injection and Acoustics are commercially available.
COAL PIPE INSTRUMENTS AND MEASUREMENT ACCURACY
Measurements in
Coal Pipes
Complicated Because
of Roping
(ISO-9931)
Comparison of Sampling Grids

PF fineness
Fineness is expressed as the percentage pass through a
Coarseness is expressed as the percentage retained on a
Typical Value 200 mesh ‐ 70% and 50 mesh ‐ 1%
PF fineness influenced by
• Coal Quality, Mill settings, mill problems
• PA flows / velocities ‐ Optimum Air/Fuel Ratios
• Sampling Techniques ‐ Cyclone / 64 point rotary sampler
• Sampling location – Near burner from the vertical pipes
• Testing – Motorized sieve shaker
• Mill loading – Sampling at Nominal / defined mill loading only
Test Instruments Matrix
Sl.no. Test Instruments required Remarks
1 L Type Pitot Tube, Inclined Clean Air balancing
Clean air test/ manometer
2 Dirty air test Dirty Pitot tube & Dirty air balancing

Manometer, Temp Read
out
3 Isokinetic sampling Rotary Sampler PF sampling for
fineness & coal flow
balancing
Divider 1
Thank You

Mill Performance Assessment Test: S P Karna, Agm (Cenpeep)

Uploaded by

Copyright:

Available Formats

You might also like

Mill Performance Assessment Test: S P Karna, Agm (Cenpeep)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mill Performance Assessment Test: S P Karna, Agm (Cenpeep)

Uploaded by

Copyright:

Available Formats

Mill Performance Assessment Test

3.Mill Noise Level: 85 dB (A) @ 1.0 m from the equipment

a) The objective of the test is to establish the mill capacity (100% of

b) The objective of the test is to establish the mill capacity (90% of

normal operating temperatures and pressures Pitots

Clean air velocities are indicative of the

24 m/s 30 m/s 19 m/s

Comparison of Sampling Grids

Sl.no. Test Instruments required Remarks

2 Dirty air test Dirty Pitot tube & Dirty air balancing

You might also like