PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

PROJECT:M/s RAMAGUNDAM

UNIT 7 (500 MW )

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

PROJECT

M/s. RAMAGUNDAM UNIT 7, 500 MW

PROCEDURE

PROCEDURE FOR CLEAN AIR FLOW TEST OF

COAL PIPES

PURPOSE OF
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT NO.

PS:TSX:173:00:03

COPY NO:
ISSUED TO:

00
Rev. No.

KJ

KPTM

KB

04.08.2003

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

Station: NTPC
RAMAGUNDA
M

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 1 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SLNO
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
LOG SHEET

Station: NTPC
RAMAGUND
AM

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 2 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
1.0

PLANT DETAILS

1.1

There are 10 (Ten) mills provided for each Unit of 500 MW

Capacity. These mills are of XRP 1003 type and are provided with
individual lub-oil system. These mills are designated as
A,B,C,D,E,F,G,H, J and K with Unit No. as prefix.

1.2

There are 4 (four) coal pipes emanating from each mill from mill
outlet point with individual mill discharge valve (MDV) and coal
pipe shut-off gate near the coal bumer assembly. These coal
pipes are subjected to clean air flow test to ensure uniform flow in
all the coal pipes.

1.3

The mills are pressurized mills with primary air fans supplying the
air flow and the head required for overcoming milling system
resistance.

1.4

To maintain the required air flow through the mill, a control

system comprising cold and hot dampers is provided, which
measures and controls air flow to a specified set point.

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUNDA
M

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 3 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
1.5

Technical Specification of Mills and its lub-oil system are given

below.
XRP 1003 Mills
a. Type
b. Make & No.
c. Capacity
d. Motor KW
e. Motor Speed
f. System

:
:
:
:
:
:

XRP 103
BHEL 9
66.3 TPH
525 KW
600 RPM
Cold PA

Lub-oil System
a.
b.
c.
d.
e.
1.6

Pump Make/Type
Capacity
Speed
Relief Valve Setting
Motor Rating

:
:
:
:

Alekton / Screw
70 LPM
970 RPM
7.0 KSC
:
3.7 KW

Since, Primary Air Fans and mills are available for this test, the
required plant item completion list, for mechanical, Electrical and
C & I to be prepared at site prior to test.

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUND
AM

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 4 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
2.0

OBJECTIVE
Clean Air flow test in milling system is carried out to
i.
check velocity variation between the pulverized coal
pipes of a mill is within allowable limit and there by to
ensure that correct size orifices are installed in coal
pipes for equalizing the Air flow and
ii.
there is no foreign material plugged inside the
pulverised coal pipes.

3.0

PROPOSAL

3.1

Clean Air flow tests shall be conducted in all the mills individually
with Cold Air.

3.2

The test will be conducted by running primary air fan and mill and
flow measurement will be taken at specified locations( ref. s 7.7 &
7.10) and ensured that completion criteria (Section 9.0) is
achieved by placing required sizes of orifice plates in p.c.
pipelines.
Note :
The complete responsibility for conducting the test in a safe and
systematic manner following the approved procedure as well as
making the system ready are in the BHELs scope.

4.0

SERVICES REQUIRED

4.1

Availability of man power with required tools for attending to any

leakage in the system.

4.2

Availability of operating personnal to coordinate the activities

4.3

Availability of lighting arrangements and communication in the

operating floor.

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUNDA
M

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 5 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
4.4

Availability of portable fire fighting equipment near test area.

4.5

Availability of auxiliary cooling water for mills & fans.

4.6

Availability of instrument air supply

4.7

Availability of LT supply

4.8

Availability of HT supply

4.9

Pitot Tube

5.0

SAFETY PRECAUTIONS

5.1

Debris is and around milling system shall be removed.

5.2

Approach / Staircase / Platform wherever required are made

available especially near the pitot tube traversing location.

5.3

First aid kit available near test.

5.4

The test team should be aware of the procedure adopted.

5.5

Other agencies working near the test area are informed / cleared
as per requirement. SRCC will be enforced.

6.0

EMERGENCY PROCEDURE

6.1

The test team should be aware of the steps to be taken to trip the
running equipment in case of any emergency / abnormal
observations are notified to them.

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUND
AM

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 6 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
6.2

The test team should be aware of actions to be taken in case of

injury to any personnel.

6.3

The test team should be aware of operating instructions of

portable fire extinguishers.

7.0

STATE OF THE PLANT

7.1

The trial run of the mill which is selected for the test, is completed
and is ready for operation from remote in all respect . The milling
system should be clean and all air leakage points have been
arrested.

7.2

Both set of ID, FD & PA fan is commissioned and ready for

operation from remote along with respective air heaters, gate &
dampers.

7.3

The corresponding raw coal feeder is erected and is boxed up

property to avoid any air escape from mill through these feeders.

7.4

Mill discharge damper is commissioned and kept opened fully.

7.5

Mill and Coal pipes seal air dampers are commissioned and kept
fully closed.

7.6

The Coal Pipes isolation gate near the burner end (in all 4
corners) are kept opened fully.

7.7

Two suitable size tapping points at 90 degrees apart in the same

plane provided in the vertical straight portion of the all the 4 P.C.
pipies of the mill. (Tapping points are preferably located at a
distance of 10-D and 5-D away from any bend in the upstream
and down stream respectively. This is to suitably decided at site
giving consideration to approach to coal pipe lay-out and
personnel safety. D is the diameter of the coal pipe)

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUNDA
M

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 7 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
7.8

Proper access platform provided for taking pilot tube differential

pressure measurement.

7.9

Pilot tube differential pressure gauge, Thermometer (0-100 Deg.

C), polethene tubes of sufficient length, are made available.

7.10

10 markings are made on the pilot tube at a distances of

0.0436 R, 0.135 R, 0.238 R, 0.358 R, 0.507 R, 1.492 R, 1.642R,
1.762R,1.816 R and 1.956 R, (R-Inside radius of the Coal Pipe)

7.11

All gates and dampers in Primary Air, Secondary air and Milling
circuits are commissioned and ready for operation from remote.

7.12

Reliable communication system among the test team members is

made available.

7.13

The classifier assembly is serviced thoroughly and all the vanes

are set uniformly at desired position to facilitate air flow required
for conducting the test.

7.14

Pitot Tube to be used for clean air flow test is calibrated one and
the calibration certificate is available.

7.15

All the required instruments of ID, FD and milling systems are

commissioned

8.0

METHOD

8.1

Start ID, FD & PA fans as per equipment O & M manual

instruction and establish furnace draft and air flow through the
selected mill.

8.2

Under Mill in off condition, start seal air fan and ensure discharge
pressure more than the mill inlet pressure by 100 mm wcl. Then
start the mill as per O & M manual instruction and keep it in
running condition.

Signatures
NTPC

BHEL

Station: NTPC
RAMAGUNDA
M

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 8 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
8.3
Based on the design air flow of the mill, calculate delta P to be set
across mill inlet air flow measurement device
8.4

Air flow through the mill is increased by opening hot /cold air damper
and loading PA fan accordingly.

8.5

PA header pressure shall be maintained at 750-800 mm-wcl.

8.6

Select a Coal Pipe of average length, and insert the pilot tube to the
center of the pipe and adjust the air flow to produce the calculated
pilot tube differential pressure (approximetely 110% flow)

8.7

8.8

8.9

Record mill air temperature, mill air flow indication mill differential
pressure, PA header pressure at control room. If control room
indications are not available for certain parameter, than suitable
measuring arrangements to be made at local. (If both are available,
cross check local and remote readings)
Velocity profile in each Coal Pipe shall be obtained by traversing the
pitot tube at the same plane in two directions (A and B), 90 0 apart at
the center of equal areas. (Suggested locations is as given in
section 7.7&7.10)
Convert the pilot tube differential pressure reading (velocity head)
into air velocity inside the Coal Pipe by using the formula
V = 0.2365227

h. (t)

Where V - air velocity in m/Sec

h Pilot tube differential Pr. in mm wcl
t Air temp in 0 K
Calculate the average air velocity in individual coal pipe(Vp).
Subsequently calculate the average of the velocities of all four coal
pipes of the test mill (Vm). Find the maximum & minimum velocity
and the deviation shall be with in + 5.0% of the average velocity of all
four pipes (Vm).
Signatures
8.10

NTPC

BHEL

Station: NTPC
RAMAGUND
AM

BHEL Ref No.PS-DC-202-500-0012

NTPC Ref no COS-COMM-RGM-Commg-PRO/011

Sheet 9 of 10

Plant area: BOILER

PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES
SL.NO
STATUS
% Max. deviation = Max.Velocity - Ave.Velocity
x 100
Ave. Velocity
% Minimum deviation = Ave.Velocity Min.Velocity
x 100
Average Velocity
8.11

Record air temperature and flow differential across the mill inlet
air measuring device. These values are to be frequently checked
and maintained throughout the test .

8.12

Repeat the above test for the remaining mills .

8.13

In case the deviation is not within the allowable limit, sizes of the
orifices plates will be adjusted and the test will be repeated till
deviation is within the limit.

8.14

Determine the Weight flow per minute through each coal pipe
using the equation: Air flow (Kg/min) = ( x D2/4)xV60X?
Where V = Air velocity m/sec
D = Coal pipe ID , m
? = Air density , Kg/m3 at test temperature.
Totalise the air flow for one mill.

9.0

COMPLETION CRITERIA

9.1

The clean air flow test for Coal Pipes completed after achieving
the following criteria.
a)

Velocity variation of maximum and minimum velocity is

within + 5% of average velocity.

Signatures
NTPC

BHEL

Sheet 10 of 10
10.0

LOG SHEET
DATE:

PROJECT
UNIT
ACTIVITY

:
:
:

Corner 1
S.No

A
h

B
V

Corner 2
A
B
h
V
h
V

Corner 3
A
B
h
V
h
V

Corner 4
A
B
h
V
h
V

1
2
3
4
5
6
7
8
9
10
11
Ave.Vel
(m/sec)
Air
Flow
(T/Hr)

1.
2.
3.
4.
5.
6.
7.

Design Air flow

% of Damper opening

Air Temperature
Coal Pipe ID
PA HDR Pressure
Furnace Pressure
Max. Velocity
Average Velocity (Vp)
Min. Velocity

:
:
:
:
:
:
:

(Tolerance +5%)
(Tolerance 5%)

Signatures
NTPC

BHEL

PROCEDURE FOR CLEAN AIR FLOW TEST

OF COAL PIPES