BALL TUBE MILL BBD 4772

GENERAL COMMISSIONING AND OPERATING PROCEDURE

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GENERAL COMMISSIONING AND OPERATING PROCEDURE

1.1 SALIENT FEATURES OF MILLING PLANT:

Mill type - Pressurised, double ended Ball Tube Mills

- BBD 4772

No. of Mills/unit - Three

Capacity - Design Coal -84.5 Tons/hr
Ball load 81 Tons

Worst coal - 107 Tons/hr

Ball load 108 Tons

(Based on HGI & Moisture of coal performance of Mill with fineness of 70%
thru 200 mesh)

Number of pulverisers for design Coal 100% BMCR = 2

Number of pulverisers for worst coal = 2

1.2 MILL OPERATION PRINCIPLE

Primary air in the case of Tube Mill has dual function to perform. It is used as
drying as well as transporting media and by regulating the same the Mill output is
regulated. Governed by the pulverized fuel outlet temperature requirement the
combination of cold air and hot air damper are regulated to have proper primary
air temperature. In addition to raising the coal temperature inside the Mill for
drying and better grinding, the same air works as carrying media for pulverized
coal through annular space between fixed trunnion tube and rotating hot air tube
on way to classifier. Coal-laden air passing through Double cone static classifiers
with adjustable classifier vanes for segregation into pulverized fuel of desired
fineness and continues its journey towards coal burners for combustion. Coarse
particles rejected in classifier find their way back to mill for another cycle of
grinding.

In order to avoid excess sweeping of coal from mill only part of the primary air,
directly proportional to the boiler load demand, is passed through Mill. further to
ensure and maintain sufficient velocity of pulverized fuel and to avoid setting in
P.F. pipes an additional quantity of primary air is fed in to mixing box on raw coal
circuit. This by-pass air tapped from the primary air duct going in Mill makes
appreciable contribution for drying of raw coal by flash drying effect in addition to
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picking up the pulverized fuel from Mill outlet for its transportation towards
classifiers.

Tube mill output while responding to boiler load demand is controlled by

regulating primary airflow. Such regulation by sweeping away of pulverized fuel
from Mill being very fast, rather well comparable with oil firing response, needs
coal level to be maintained in the Mill. Mill level control circuit sensing the
decreased coal level in Mill increases the speed of raw coal feeder and vice versa.
Maintaining the coal level in Mill offers built-in-capacity cushion of pulverized
fuel to take care of short interruption in raw coal circuit.

1.3 The mill is pressurized and the tightness is ensured by plenum chambers around
the rotating trunnions filled with pressurized seal air. Bleeding seal air from
plenum chamber to Mill provides air cushion between pulverized fuel in the Mill
and the outside atmosphere. Inadequacy or absence of seal air will allow escape of
pulverized fuel into atmosphere.

On the other hand excess of seal air leaking into Mill will affect the Mill outlet
temperature. As such the seal air is controlled by a local control damper by
maintaining just sufficient differential pressure for sealing.

1.4 DESCRIPTION OF CONTROL SYSTEM:

1.4.1 Temperature control of the P.A and P.F. mixture at the classifier output.

This is controlled by the regulated opening and closing of the hot and cold
air dampers. The P.A. temperature is controlled to keep the P.F. outlet
temperature in between acceptable limits.

1.4.2 Total primary air flow control.

The analog control loop allows the correct proportioning of airflow

through the Mill and by-pass, according to Mill load requirements.

A signal, for the required air, is sent from the master controller

- the Mill air controller, which adjusts the air quantity through the Mill,
according to the load (P.F. output)

- the by-pass air controller, which adjusts the by-pas air quantity, according
to the load.
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1.4.3 Adjustment of coal level in the Mill for different load conditions.

The P.F. output of the Mill varies according to the load requirement of the
boiler. The quantity of raw coal introduced in the Mill must be varied in
the same manner.

Whatever the load of the Mill is, the level of the coal inside the Mill is to
be kept constant.

Mill level control is achieved by means of level detection. There are two
ways of achieving this.

By means of controlling Differential Pressure between two points inside

the Mill.

The pressure drop across these points inside the Mill (which is a function of
coal level), is maintained constant by the controller acting on the feeder
speed actuator.

The difference between set point and actual pressure drop measured in the
Mill, is sent to the feeder sped actuator.

By means of a Sound Transmitter (Electronic Ear)

The system is based on a permanent control principle of inputs and outputs.

In order to realize the level control, which is based mainly on the noise
level, one must take into consideration inlet P.A. flow and feeder speed.

1.4.4 Automatic control system.

Should a fault occur during operation, the Mill is provided with the
necessary safety devices permitting automatic protection of the installation.

Should tripping of the boiler occur, the emergency shut down is activated.
There are other safety devices designed specifically for the Mill itself, such
as lubrication not correct, bearing temperature high, etc.

When the system is stopped, a system of gates placed up and also down
stream of the Mill permits the Mill to become completely isolated.

In addition to above protections the Mill is provided with fire protection to

meet any eventuality. Unscheduled/unexpected tripping or stopping of Mill
filled with pulverized fuel may develop some hot spots to cause ignition
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inside the Mill. In such case the inching device automatically pouts into
service will rotate the Mill at very low speed and thus avoid any
temperature build-up leading to fire. Never the less the fire, if caused in
the Mill, for any reason can be detected promptly and can be extinguished
by injection of steam followed by water spray, if need arises.

1.4.5 Half Mill Operation.

This design also provides facility for half Mill operation to feed one burner
elevation.

2. FIRST COMMISSIONING OF THE MILL.

2.1 Preliminary Operation

2.1.1 Visual checking

A general inspection of the unit must be performed prior to

starting the Mill, check that

- all the elements of the grinding unit are in place, so that no important
equipment is missing. The unit can then be started safely.
- no visible damage has occurred and that all equipment's are in good
condition .
- no mistake has been made during erection or reassemble and that the
plant, is erected according to drawing specifications. In case of doubt the
erection check charts should be referred to.
- no foreign matter (tools, pieces of iron or wood etc.) has been left in to
equipment

2.1.2 Piping Preparation

All the components of the piping lines must be checked and prepared for
operation as follows:
- the operation of all the valves are tested and the direction of rotation is
checked. These valves are then put in their working position for start up
(open or closed), as may be required.
- the availability of all utilities (water, compressed air) and their characteristics
(temperature and pressure) are checked.
- the pressure reducers are adjusted so that utilities are available to equipments
at the right pressure.
- after draining all the pipes, close drain valves.
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2.1.3 Electrical and Instrumentation checking

A general inspection of the electrical and instrumentation equipments should

be performed as indicated below:

- all writing should be checked (power, control and instrumentation).

- cable glands should be properly installed and fitted with collars.
- the instruments operation like flow switch /pressure switch and
opening/closing of gates /dampers should be tested where ever possible.
- all junction boxes and cabinets should be opened and checked for
condensation.
- the fuses being disconnected, all interlocks should be blank tested. All
alternatives should be studied.
- the idle-running of Electric drives in uncoupled condition should be done.
No load current and direction of rotation should be checked.

The power consumption for all electrical drives with special attention to
main Mill drive in de-coupled conditions must be recorded during
operation.

2.1.4 Mechanical checking

The first operation consists of checking the tightness of the foundation bolts of the
main equipment as well as of auxiliary equipments.

The conditions of the gear train must then be inspected , if necessary , the
couplings disassembled and their alignment checked.

2.1.5 Oil and grease fillings

Check that all lubrication pipes are clean.

The equipment should be lubricated. The grades and quantities used are indicated
in the erection manual.

Proceed with the oil and grease fillings.

2.1.6 Hand rotation.

Wherever possible , various equipments should be rotated by hand to check

that no abnormal hindrances or jamming exist.
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3 FIRST ROTATION.
Precautions:

To enable individual equipment start up operation, the necessary interlocks can be

disconnected or by passed.

The first rotation must be performed without load as far as the raw product and
the ball load is concerned and also boiler protections disconnected but mill
mechanical protection in circuit.

3.2 General principles

If possible, the apparatus shall be started in sequence, in the order of the

interlocks. An apparatus should not be started unless the previous one has been
running satisfactorily for sometime and unless all the operation parameters are
completely stabilized.

Instrument operation and set points should be checked.

During this operation, personnel must be positioned close to the equipment to

check that everything is running normal, i.e. :

- temperatures (e.g. bearings) are not too high.

- no abnormal noise exists
- the power consumption figures of the motors are close to the
calculated values.
- No leaks (oil, water etc.) exist.
- Oil levels are correct.
- No abnormal. Vibration exists.
- Check thickness of oil film of Mill main bearing i.e. records
Mill lift by operating main bearing jacking oil pump.

Any abnormality noted during initial startup must be carefully observed, correctly
analyzed and should be promptly attended to, Nothing should be left to
speculation or assumptions. Remember that "STITCH IN TIME, SAVES
NINE'

3.2.1 Specific instructions for the various equipments

In addition to the general instructions given in the preceding chapter, the

following must be adhered to:
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3.2.1.1 Bearing lubrication unit

The lubrication units are completely shop tested but must be

deported with oil. Switch on the electrical heaters and make the
cooling circuit also ready. When oil temperature is satisfactory,
start pumps and check priming (If priming is not achieved within 1
minute then stop the pump and check).

Check that oil spray on trunnions is satisfactory (approximately

equal on each end) and return oil circuit is alright.

Check the H.P. oil pressure and note the Mill lift on both ends one
by one.

Inspect levels in tank and make sure that closed oil loop is able to
maintain the level.

The L. P. pump discharge filter must be cleaned regularly.

3.2.1.2 Reducer lubrication system

Start motor and check priming

Clean filter as often as necessary
If possible check the oil spray inside the reducer by opening inspection
hole.

3.2.1.3 Girth gear lubrication unit

Check compressed air pressure and ensure that it should not have any
moisture.

Start cycle on time.

Check operation of all the components, especially the spray on the wheel.
Spray nozzles should cover the entire width of gear with uniform film.

Adjust timing and pressure if necessary. Quantity requirement during

initial trials / commissioning is normally double of normal operation
requirement.
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3.2.1.4 Mill

Caution: The Mill must be started without ball load and product
load, start girth gear housing seal air fan, start motor and
reducer.

During the Mill rotation, bearing liner temperature must be carefully monitored
and the Mill stopped if it becomes too high. Trunnions and oil film must also
be inspected through door of bearing housing.

Check operation of girth gear and bearings.

Note and record power consumption of Mill drive.

3.2.1.5 Mill Main Motor

Check the bearing temperature

Check the motor winding temperature

3.2.1.6 Screw Conveyors

Check for satisfactory operation particularly for any rubbing sound between
ribbon flights and trunnion tube.
Check temperature rise for conveyor supports bearing.

3.2.1.7 Check for satisfactory operation of all the Mill control components i.e.
C&I(Temperatures, pressure, air flow)

3.2.1.8 Check the raw coal feeder as per the instructions of manufacturer / supplier.

3.3.1 Checking after first rotation

When all the equipments forming the milling system have been started and are
running smoothly, the plant must be kept running for between 6 and 8 hours.
The unit is then stopped, defects recorded and repaired it necessary.

The whole plant is then checked, i.e. fixations in respect of mechanical parts,
filters clogging, condition of lubrications, etc.
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4 RUNNING IN

The only apparatus of the grinding unit, which requires running in, is the Mill
itself. This is performed by progressively increasing the ball load in three stages
i.e. one-third quantity at each stage of ball charge indicated against the specific
type of coal to be used for coal firing

IMPORTANT: In order to avoid the risk the running must be performed without
the raw product .

It is of utmost importance to record the ball quantities poured into the Mill.

All the characteristics of the operation ( motor power, oil pressure etc ) should be
recorded.

Mill to run for ¼ hour to ½ hours maximum.

Initial ball charging into mill as described herein after should be done through one
of the man hole only and not through ball feeding system meant for make up
charge.

4.1 First step (One third ball load)

The mill must first be loaded with approximately 33% of the total theoretical ball
charge, which can be done in the following way:'

Through one inspection door of the mill. Having placed this door in the upper
position just below the sound hood opening with bearing lubrication in operation.
Mill body should be locked in this position with electromagnetic brakes to avoid
mill rotation to suit its changed center of gravity due to ball charging.
Alternatively the support bearing lubrication can be started just before releasing
the brakes to avoid any metal to metal contact. Load the mill with grinding media
with the help of crane and place back the inspection door of the mill.

Starts the whole unit: lubrication units, P.A. fans and sealing air fans.

During unit operation, check that everything is normal, particularly bushing

temperatures.

After 45 minutes of steady operation, stop the unit and allow to cool down.
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4.2. Second step (one third of ball loads).

Charge the mill as earlier mentioned with approximately another one third
quantity of balls. As previously indicated, start unit and check for satisfactory
operation. After 45 minutes, stop unit allow to cool down.

4.3. Third step ( one third of ball load)

Repeat the process to make the a ball charging complete.

After running 45 minutes stop the unit and Check tightness of liner bolts in hot
condition. As soon as the mill can be stopped, a general inspection will be
performed as described in paragraph 3.3.1 above

5. OPERATION INSTRUCTIONS FOR TUBE MILLS.

Tube mills although equipped with enough control and instrumentation for safe or
proper operation, various interlocks are provided to take care of any mal-
operation but nevertheless the operator at site in addition to control desk operator
should be conversant thoroughly about the behavior of equipment and its place in
overall scheme.

5.1 Checks to be made before a mill is started up

Before a Mill is put into service, ensure that the various equipments and sub
assemblies stared up are in a normal condition and can operate without risk.

In particular, the following shall be checked.

- The mechanical condition of the moving parts of the Mill and of its
auxiliaries, in particular : raw coal feeders , Mills, fans, sealing circuits,
shut off and control gates, dampers for the fuel, air and air / fuel mixture
circuits.
- Various control provided to ensure proper lubrication in particular for oil
levels, pressures and temperatures should be in operation.
- The temperature inside the Mill, the circuits leading to the burners and the
air ducts should be normal.
- the remote controls should be in a normal operating condition.
- the alarm systems and safety devices should be in working order and
adjusted to set point values of Document titled " Schedule of Local
Instruments- Alarm and Trip Set Points.
- the power circuit for electric motors (with breaker raked-in) should be
ready for closing on command.
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- the monitoring instruments, indicators and automatic equipments like

selector switches should be in desired operating condition.
- the load support fuel oil burners shall be put in to service and in sufficient
numbers to ensure the stability of combustion in the furnace throughout
the period, during which disturbances in combustion may possibly
develop.
- in case of fire in the mill the steam inerting and water injection system, for
fire protection should be available, if need arises.

Any abnormalities or non-compliance to ideal condition must systematically be

recorded in equipment Log Book as well as in control Room Log Book .

Considering the gravity of situation and fault the decision should be taken for
operation of or attending to equipment. This is done so that the person
responsible for operation can be informed and particular steps to be taken can be
indicated to him. The extent of the tolerances permitted in these conditions
should also be mentioned, as should, measures be taken if these tolerances are
exceeded.

- check that the shut off gates of the raw coal hoppers is closed (open only after
starting the feeders.)
- safety devices actuating "NO COAL FLOW" alarm in raw coal feeder should be
checked.
- open the gate located at the outlet of the raw coal feeders.
- check that the water cooling system for the lubricating stations is satisfactory.
Check the water cooling circulation by means of the signal lights to see if the
cooling circuit is being fed .

- adjust the Mill sealing circuits, which are to be started up. It should also be
ensured that seal air to idle Mills are stopped in order to avoid pressurization of
these Mills and unnecessary loading of seal air fan drive.
- check that the probes for monitoring the coal level in the Mill are correctly fed
with monitoring air.
- check that the gates and dampers for the different air and P.F. circuits are closed.

6 STARTING UP OF A MILL WITHOUT COAL

6.1 Case of first Mill start -up after fuel oil firing

"Mill containing no coal" means that a Mill which has already been used with
coal, but which, during the shut down operation, has been ventilated so that it is
no longer possible to reduce the quantity of coal contained in the Mill.
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The following recommendations apply both to a hot and cold Mill the only
difference being the fact that it will take longer to obtain proper operating
conditions (stabilizing of flow rates and temperatures) with a cold Mill than with
a hot Mill. The period necessary for stabilizing must therefore be taken into
consideration.

In all cases the operator must ensure before initiating action for coal firing that
the load of the unit is sufficient, to avoid during start-up, an accumulation of un-
burnt fuel in the furnace, which would carry the risk of explosion.

During initial start up extreme care must be taken. The boiler must be loaded to
the maximum with the fuel oil equipment. Subsequently, it must be determined
experimentally how much this load can be reduced without causing serious risk
to the boiler due to temporary instability of the pulverized coal combustion..

To start or restart a Mill containing no coal, the following procedure shall be

adopted after the recommendations of Chapter 3 have been carried out and after
it has been ensured that all the conditions imposed by the interlocks and safety
devices are correct and that they authorize the Mill to be started up.

6.1.1 Place all the grinding circuit controls onto manual mode of operation.

6.1.2 Ensure that all of the control dampers located on the air circuits, the pulverized
coal ducts, the raw coal circuit and the ball-feeding device of the Mill, are
properly closed.

6.1.3 Check that there are no abnormal temperatures in the various circuits and
equipment to be used during operation.

6.1.4 Start up the various lubricating systems, in particular that of the Main reducer,
Mill bearings, greasing of girth gear etc.

6.1.5 If there is any doubt the free rotation of the Mill , start-up the inching gear for a
few minutes and then shut it down.

6.1.6 Check that the blow down system of the probes measuring the pressure and coal
level in the Mill is in operation.

6.1.7 Check that the fire fighting system for protection against fire in the Mill is in
good working order.

6.1.8 Start up the girth gear housing sealing air fan.

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6.1.9 Start up the sealing air fans and check supply to plenum chambers, P.F. Gates
and conveyor bearing sealing.

6.1.10 Ensure that all the fuel oil burners corresponding to Mill to be started are in
operation and that combustion is stable.

6.1.11 Purge the pulverized coal ducts to burners with cold purge air as the victaulic
couplings in P.F. pipes may not withstand the high temperature of hot air.

6.1.12 Adjust the opening of the secondary air blades on the burner elevation
corresponding to the Mill to be started up.

6.1.13 Adjust the total flow rate of combustion air and check that the pressure in the
burner wind box is correct.

6.1.14 Check that the temperature of primary air feeding the Mill is greater than 150º C.

6.1.15 Start up the Mill by activating the control on the board and check that the
differential pressure of the monitoring air and sealing air have normal values.

NOTE: 1 Above operations are in fact started by automatic Mill management

system. i.e., furnace safeguard supervisory system. It is the duty of
operating personnel to check that all the steps are correctly carried out.

6.1.16 Check locally the automatic purge blowing of the Mill level probes.

6.1.17 Check that the circuits feeding that burners are properly arranged and that the
gates feeding the Mill.

6.1.18 Open primary air to a flow rate of 13.0 kg per second app. on each side of the
Mill, and adjust the by-pass air to obtain a sufficient speed of conveyance in the
pulverized coal pipes to the burners.

Approximate Distribution of Primary Air.

- through Mill: 2.0kg per second

- through by-pass:11.0kg per second

6.1.19 Adjust the temperature of the mixture (hot air +cold air) at the Mill inlet so as
maintain P.F. temperature at classifier outlets around 80º C.

6.1.20 Start up raw coal feeder and adjust flow rate to around 50% of normal load. Open
the manual slide gate between hopper and feeder. The signal of the electric ear
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decreases. When it reaches 40% decrease the feeder speed to minimum (around
15%)

6.1.21 Monitor the temperature at the classifier outlet and keep it at normal value either
by feeding the mill with colder or hotter air or, if this is not possible, by
adjusting the coal flow rate. Check the stability and the quality of combustion.

6.1.22 Adjust the secondary airflow to the coal burners in order to obtain good
combustion.

6.1.23 Watch the filling of the Mill and switch the feed over to automatic when delta P
measurement is available remains normal. Adjust the secondary air to the
burners.

6.1.24 Progressively increase the raw coal flow rate on condition that the classifier outlet
temperature remains normal. Adjust the secondary air to the burners.

6.1.25 When the classifier outlet temperature reaches its normal value, the set point
change over it onto automatic control.

6.1.26 Progressively place all the control devices onto automatic control as soon as the
parameters reach the normal operating range and are stabilized.

6.1.27 After passing over to automatic control, progressively increase the boiler load and
monitor the stability of operation and the different control parameters. Intervene
manually if necessary to remove all disturbances, which could affect the operation
of the Mill or combustion stability.

6.1.28 Ensure that purge air blowing for Mill level sensing probes is at regular intervals.

6.2 Start up of a Mill containing no coal, other than the first Mill

Before starting up the remaining Mills following the first Mill, it is advisable to
proceed with the general checks as defined on chapter 3 and chapter 5.1

After having checked that the boiler load and its programming permit the mill to
be started up:

6.2.1 Start up the fuel oil burners on the pulverized coal burner elevation. Check that
they are properly ignited and that flame stabilization is good. Check that flame
scanners are working properly and should not give false indication for fire-out,
check the cleaning system.
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6.2.2 Having started up, adjust the secondary air at the burner stage. Adjust the total air
flow rate.

6.2.3 Ensure the efficiency of the purge blowing of the Mill level monitoring taps.

6.2.4 Ensure that all the circuits concerning the Mill and combustion are properly
arranged.

6.2.5 Ensure that lubrication to the various equipment is normal.

6.2.6 Start up primary air fan and establish primary airflow to obtain normal
temperature at the classifier outlet with sufficient velocity in the pulverized coal
ducts for an airflow rate disallowing deposits to form in the ducting.

6.2.7 Start up the Mill.

6.2.8 Start up the raw coal feeders and adjust the flow rat to about 50% of the nominal
flow rate (refer 6.1.20).

6.2.9 Adjust the coal flow rate to maintain normal temperature at the classifier outlet.

6.2.10 Avoid excessive air flow through the Mill as this delays filling to a normal level.
Progressively increase the coal flow rate on condition that the Mill outlet
temperature remains normal.

6.2.11 Ensure that combustion is stable and of good quality.

6.2.12 When the coal level is detected in the Mill, pass it over to automatic control.

6.2.13 Adjust the secondary air flow to the burners as the mill flow rate progressively
increases.

6.2.14 Adjust the cold air and hot air dampers to have required Mill outlet temperature
at classifier outlet and change over to auto operation.

6.2.15 Watch the level in the Mill as well as its monitoring device.

6.2.16 Intervene manually if necessary to normalize the controls or eliminate

disturbances, which could affect the operation of the Mill or combustion of the
fuel.
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7 START UP OF A MILL FILLED WITH COAL (PLANNED STOPPAGE

FOR SHORT DURATION OR AFTER TRIP CONDITIONS)

Before the successive starting up of the various Mills, proceed with the general
checks as defined in chapters 3 and 4.1

Proceed in the following manner after checking that the boiler load and its
programming permit the Mill to be started up.

7.1 Case of start up of the first mill (i.e. No other Mill in operation)

7.1.1 Change all the controls of the grinding circuit and burners of the Mill in question
to manual mode of operation.

7.1.2 Start up all the fuel oil burners corresponding to Mill to be taken in to service and
check the stability of ignition and combustion.

7.1.3 Adjust the secondary air control on coal burner elevation to be started up.

7.1.4 Start the primary air fan.

7.1.5 Check that the level probes for Mill level sensing are operating correctly .

7.1.6 Check lubrication.

7.1.7 Start Mill.

7.1.8 Ensure that the temperature at the classifier outlet is normal and that the velocity
in the pulverized coal ducts is sufficient to avoid deposits.

7.1.9 If the Mill is cold (duration of shut down more than 24 hours) the air temperature
shall be adjusted equal to 150 degree C at the Mill inlet.

7.1.10 If the Mill is hot, the scavenging air temperature shall be adjusted so that the
temperature of the mixture at the classifier outlet remains normal.

7.1.11 As mentioned in 6.1.18, the by-pass air flow rate should be adjusted to ensure
transport to the burner of the pulverized coal.

7.1.12 As soon as the coal level has started to decrease in the Mill, the feeders shall be
started up by progressively increasing their flow rate while maintaining a normal
temperature at the classifier outlet.

The primary air flow rate shall be adjusted to stabilize the level in the Mill.
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7.1.13 Adjust the secondary air flow to the burners.

7.1.14 When the classifier outlet temperature stabilizes at its normal value, change over
to automatic control.

7.1.15 Intervene manually, if necessary , to normalize the adjustment or to eliminate

disturbances which could affect the operation of the Mill or combustion of the
fuel.

7.1.16 After starting the Mill, the maximum running time without air flow must not
exceed 10 minutes and beyond this limit stop the Mill and put it on barring until
the problem is solved.

7.1.17 After starting the Mill, the maximum running time without raw coal feed should
not exceed 10 minutes maximum-beyond this time stop the Mill and put it on
barring.

7.2 Case of start up of other Mills

Proceed in the same manner as in (7.1) taking the precaution before commencing
the operation, to start up the fuel oil burners corresponding to the pulverized coal
burners, to be put into service.

The load of the fuel oil burner must be sufficient to obtain combustion stability.

8 SHUT DOWN OF A TUBE MILL USED FOR DIRECT FIRING

In consideration of boiler load requirement the coal Mills can be either stopped
systematically or compelled by unforeseen circumstance like actuation of any
safety interlock the Mill may trip suddenly leaving no time for emptying out.

In the situation where the Mill is shut down full of coal (totally full or partially
full), it will always be necessary for the mill to driven by its inching device, so as
to avoid a fire inside the Mill.

If, of the contrary , the shut down is scheduled or planned and can be executed
with complete freedom of operation, it will then be possible to make a choice
between shut down of the Mill at normal coal level or empty of coal.

In general, the conditions of use of Mill after a shut down will permit a choice to
be made between the two possibilities.
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Generally speaking, it is always recommended that whenever possible the Mill be

shut down empty of coal.

In case the Mill is emptied of its coal before shut down, the advantage will lie in
the fact that it will not be necessary to operate the Mill on the inching device, and
on the other hand the very small quantity of fuel remaining inside the Mill will
virtually remove the risk of auto-ignition or of its distillation with considerable
production of combustible gas which could sometime lead to an explosive internal
atmosphere.

On the other hand, it is also obvious, that during the re-starting of an empty Mill,
it will be necessary, before the Mill can achieve its nominal pulverized coal
production, to reconstitute the inside load of the Mill with the grain size which
characterizes it in normal operation. In this case, it will therefore be necessary to
re-start the boiler sufficiently early, so that it can ensure the desired production in
the required time. By way of an estimation, for a Mill, which is without coal and
hot at the time it is re-started, about one hour is required to reach the full load. If
the Mill is shut down with coal inside, the saving in time will be about 15-30
minutes approximately.

If the Mill is cold, there is virtually no difference in time in reaching the nominal
load, whether the mill is full or empty when re-started. Time anticipated to reach
full load in this can be one hour approximately.

The particular condition which may exist when the Mill is re-started with regard
both to the moisture of the fuel used and to the temperature of the hot air used for
drying , can have a very great influence on the duration of the start up period
until nominal load is reached.

It is necessary to empty the Mill before shut down if the Mill cannot be operated
on the inching device. If this is not possible, all precautions must be taken to
avoid an internal fire.

Mill loaded with coal, which has been shut down following accidental tripping,
always be operated on the inching device without loss of any time whatsoever.

In view of the above mentioned observations, it can be recommended that the

decision of leaving the Mill with or without coal should be guided by following
conditions.
 BALL TUBE MILL BBD 4772
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Idle Mill left without coal

- If the inching device is not available,

- If the shutdown is planned for more than 12 hours,

- If during re-starting, enough time is available to recreate the

normal operating conditions like Mill outlet temperature and
coal level in Mill etc.

- If it is necessary to attend some job inside the Mill or on the

grinding circuit.

- If a Pulverized coal pipe to the burners has to be attended.

- If there is a risk, during shutdown, or ventilation by air due to

defective sealing.

- If the fire protection system is not immediately available.

Idle Mill left with coal

- If the conditions defined in the previous chapter cannot be met,

- If the Mill is to be re-started after a short outage.

It is obvious that all the specific cases which could lead to a decision to shut down a full
or empty Mill cannot be included in the list of recommendations above and that,
depending on the circumstances and the way they develop, the person responsible for
operation who is familiar with operation and control of the installation can alone, with
full knowledge of the case, may decide the procedure to be adopted for taking out/ taking
in of the Mill.

During the shut down period, particular attention shall be paid to the temperature existing
in the various enclosures constituted by the grinding circuits, as well as their evolution, in
order to detect any abnormality or risk of fire in time.

Before beginning the Mill shut down process (Mill full or empty) always light up, if not
in service all the fuel oil burners corresponding to the pulverized coal burner level. All
the fuel oil burners of the level in question shall imperatively remain in operation until
completion of the purging of the pulverized coal piping to the burners.
 BALL TUBE MILL BBD 4772
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9. EMPTYING A MILL OF THE COAL IT CONTAINS

Generally speaking and as for as possible, the Mills should be shut down empty in
accordance with the procedure defined below.

9.1 Light-up at a load sufficient to obtain stability of combustion, all the fuel
oil burners corresponding to the pulverized coal burner level of the Mill to
be shut down.

9.2 Check for good stabilization of the flame of the fuel oil burners.

9.3 Place the primary air flow rate control onto manual.

9.4 Close the slide gate between hopper and feeder.

9.5 Progressively bring the primary air flow rate close to the minimum
permissible flow rate.

9.6 Monitor the classifier outlet temperature and intervene manually if

necessary to stabilize it at a normal value (for this purpose, intervene on
the temperature of the mill scavenging air).

9.7 15 to 20 minutes after shut down of the coal feed, shut down the
pulverized coal supply to the Mill burners.

9.8 Shut down the Mill and isolate it.

9.9 Operate the purge air circuit for each P.F line going to burners before
starting and after stopping the Mill. Ensure use of coal air purge while
starting and hot air purging after stopping the mill to avoid exposing the
victaulic coupling on burners pipes to high temperature.

9.10 Take out of service (if necessary) the fuel oil burners corresponding to the
shut down Mill, after having checked the satisfactory stability of
combustion in the furnace with other burners in operation.

10. SYMPTOMS OF NO COAL IN THE MILL.

Combustion of following observations can be used for ascertaining the
emptiness of the Mill during shut down:

a) Detection of low coal level by Mill Level Control.

b) High noise level.
c) Sharp reduction in difference in temperatures at the Mill inlet and
that of classifier outlet.
 BALL TUBE MILL BBD 4772
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A N N E X U R E -A

COMPLEMENTARY INFORMATIONS

A-1 PURGE AIR DUCTS AND HALF MILL OPERATION.

Abrasiveness and velocity playing dominant role in erosion of P.F pipes, the velocity is
optimized to accomplish transportation without allowing the particles to settle. However
to deal with P.F particles settled, the purging of P.F pipes is recommended. The purging
shall however be a COLD PURGE.

In order to take care of thermal expansion of boiler, victualic joints have been used. Care
should be taken to ensure the velocity in P.C pipes within a correct range when using the
cold air purge circuit. Low velocity will allow the P.F to settle and a too high flow may
disturb the P.A circuit.

When only half a mill is in operation (side A for example) and due to the pressure inside
the Mill, there is a risk for the coal to enter the by-pass air ducts according to arrow V
(see scheme)

Upstream damper 2 side B, the pressure is more important than inside the Mill whereas
downstream this damper (point Y), depending upon leakages of dampers, the pressure
may be less than inside the Mill and a mixture of air and P.F can flow from the Mill. To
avoid this draw back, the damper 2 side B must be slightly opened so as to increase the
pressure at point X.

The degree of opening for this damper must be such a way that the pressure at point X is
slightly above the Mill pressure. The relevant test pockets for above pressure
measurements are PP 112 and PP 113. A too high pressure at point X would induce an
air flow (arrow W) which would be a non controlled flow to the Mill and therefore it
must be avoided.

A.2 BALL LOADING OF TUBE MILL

Ball charge in a mill, having important bearing on mill output, P.F fineness and of
course on power consumption, should be monitored closely. Make up ball
charging frequency is also guided by the drop in power consumption of Mill.
Generally adopted practice is to monitor the Mill power consumption and drop in
that by about five percent due to ball consumption calls for make up ball
charging. Quantity of ball charge is again dependent on power consumption and
balls are added till it reaches the normal figure. Hence the measurement of power
 BALL TUBE MILL BBD 4772
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Page 22 of 22

consumption by Mill is important right from the commissioning to normal

operation. Any major maintenance jobs on drive system will need a certificate
from power consumption figures. As such it is necessary to have reliable KW
meter preferably with recorder to monitor the power consumption. Clubbing the
power consumption recording with that of Mill level and sound transmitter
(electric ear) will offer better opportunity for analyzing the mill behavior under
different load condition.

A.3 SEAL AIR FOR TUBE MILLS

Tube Mills used for direct firing being pressurized, has been provided with air
cushion between various rotating and stationary parts for sealing purpose.
Pressurized seal air with nominal bleeding in to Mill compartments containing
fine pulverized fuel controls the P.F leakage into atmosphere as well as into
conveyor bearings. Like wise specially developed P.F shut of gates between
classifier outlet and burner with seal air barrier offer the effective isolation
between Mill and furnace.

Seal air consumers and consumption for each mill

(a) Mill trunnions (Plenum chamber): 2 x 2620 cubic mtr per hr.

(b) Conveyor bearings: 2 x 208 cubic mtr per hr.

(c) P.F gates 9 x 425 cubic mtr per hr

Total requirement 9 481 cubic mtr per hr.

Fan flow (including margin) 12 325 cubic mtr per hr.

(d) Raw coal feeder Depending upon type/make.