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    Coal Mill Startup and Shutdown

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    Anonymous W9VINoTza
    This document provides a standard operating procedure for starting up and shutting down coal mills at a power plant. It outlines the steps to take for normal coal mill start up including ensuring proper pressure and flow, opening gates and valves, starting the mill and gradually increasing coal feed rate. It also describes the procedure for an immediate or "hot" restart of a mill after tripping as well as the shutdown procedure. Key parameters for safe mill start up are listed and conditions that would lead to an automatic mill trip are provided.

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    © All Rights Reserved
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    Coal Mill Startup and Shutdown

    Uploaded by

    Anonymous W9VINoTza
    767 views6 pages
    This document provides a standard operating procedure for starting up and shutting down coal mills at a power plant. It outlines the steps to take for normal coal mill start up including ensuring proper pressure and flow, opening gates and valves, starting the mill and gradually increasing coal feed rate. It also describes the procedure for an immediate or "hot" restart of a mill after tripping as well as the shutdown procedure. Key parameters for safe mill start up are listed and conditions that would lead to an automatic mill trip are provided.

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    1. Coal Mill Startup and Shutdown

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    This document provides a standard operating procedure for starting up and shutting down coal mills at a power plant. It outlines the steps to take for normal coal mill start up including ensuring proper pressure and flow, opening gates and valves, starting the mill and gradually increasing coal feed rate. It also describes the procedure for an immediate or "hot" restart of a mill after tripping as well as the shutdown procedure. Key parameters for safe mill start up are listed and conditions that would lead to an automatic mill trip are provided.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    767 views6 pages

    Coal Mill Startup and Shutdown

    Uploaded by

    Anonymous W9VINoTza
    This document provides a standard operating procedure for starting up and shutting down coal mills at a power plant. It outlines the steps to take for normal coal mill start up including ensuring proper pressure and flow, opening gates and valves, starting the mill and gradually increasing coal feed rate. It also describes the procedure for an immediate or "hot" restart of a mill after tripping as well as the shutdown procedure. Key parameters for safe mill start up are listed and conditions that would lead to an automatic mill trip are provided.

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    You are on page 1of 6

    OPGS POWER GUJARAT PVT. LTD.

    2X150MW

    Title:

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down

    Procedure for Coal Mill Start-up:


    Revision status Record:
    Revisio
    n No.

    Date

    Page no.

    Details of Changes

    Reason for
    changes

    Document Approval sheet:


    Prepared by

    Signature

    Reviewed by
    (HOD)

    Signature

    Issued& Controlled by
    (Site MR)

    Signature

    Approved by
    (Head-O&M)

    Signature

    Standard Operating Procedure

    Page 1 of 6

    OPGS POWER GUJARAT PVT. LTD. 2X150MW

    Title:

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down

    Standard Operating Procedure

    Page 2 of 6

    OPGS POWER GUJARAT PVT. LTD. 2X150MW

    Title:

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down

    1.0 Purpose:
    This Procedure is intended to provide guidance and instructions for carrying out the
    Coal Mill Start-up
    2.0 Scope:
    a) This Procedure is applicable to Coal Mills in Unit-1 & 2 of OPGS.
    3.0 Responsibility:
    a) All the personnel involved in carrying out /supervising the above activities are required to
    ensure implementation of this procedure and may consult any other relevant documents
    indicated under Reference section below.
    b) In the event of any changes required in the procedure such changes may be requested
    with Site MR, who would take appropriate action with approval from respective
    departmental heads.
    4.0 Procedure:

    4.1

    Definition:

    OPGS Unit-1&2 is provided each unit with 5 Mill vertical roller type coal pulverizes (HP 803).
    During starting of these mills, special precaution to be taken for smooth and accident free
    operation. This procedure provides the guide lines for safe operation of these coal mills.

    4.2

    Scope of application

    This procedure is applicable to all DCS operators and shift engineers for following the right
    procedure during starting/stopping of coal Pulverizer. DGM (Operation) is responsible for
    implementation of this procedure.
    4.3

    COAL MILL NORMAL STARTING PROCEDURE


    4.3.1

    Ensure PTW returned

    4.3.2

    Normalize power supply for mill, feeder, lube oil pump system, all dampers and

    gates.
    4.3.3

    line up mill lube oil and cooling system

    4.3.4

    Ensure lube oil level normal.

    4.3.5

    Ensure PA header pressure and Seal air Header pressure OK.

    Standard Operating Procedure

    Page 3 of 6

    OPGS POWER GUJARAT PVT. LTD. 2X150MW

    Title:

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down

    4.3.6

    Open bunker outlet gate and feeder seal air valve

    4.3.7

    Open all Mill Discharge Valve. Ensure isolation gates at furnace end in open

    condition.
    4.3.8

    Open seal air valve and ensure seal air/PA DP low switch reset.

    4.3.9

    Open Cold air gate

    4.3.10

    Ensure ignition permissive for Mill starting.(If ignition permissive not came then

    take support 3 oil guns)


    4.3.11

    While start mill ensure tramp Iron Gate should be open condition.

    4.3.12

    Start the mill after all permissive is OK. Open mill reject repeatedly till reject is

    normal.
    4.3.13

    Gradually increase primary air to mill by seeing PA HDR Pressure. Maintain

    furnace ve draft.
    4.3.14

    Open hot air gate. Increase hot air damper & bring the temp to 65Deg.C. PA flow

    should be more than 30tph.


    4.3.15

    Open feeder inlet and outlet gates.

    4.3.16

    Start feeder (When all permissive are OK) and increase the feed rate to more

    than 10%.
    4.3.17

    Ensure Mill Loading and coal flow normal in feeder.

    4.3.18

    Adjust the cold air & hot air dampers to maintain PA flow and mill outlet temp.

    4.3.19

    Check mill reject is normal. Mill is normal at field. Check flame condition at local

    as well as on DCS screen.


    4.3.20
    4.4

    Gradually load the mill by increasing feed rate and maintain PA/Coal feeding.

    COAL MILL START UP PROCEDURE IMMEDIATE AFTER TRIPPING OF SAME MILL


    / HOT START UP.

    4.4.1

    Ensure furnace draught is normal, PA header Pr and seal air header Pr. Normal.

    4.4.2

    Ensure all HAD, CAD, HAG, CAG closed.

    4.4.3

    Open Mill discharge gates.

    4.4.4

    Open mill seal air valve.

    4.4.5

    Purge the mill with inerting steam for few minutes.

    4.4.6

    Open cold air Gate & Damper and reduce the mill outlet temp below 70deg.C

    4.4.7

    Take oil guns for ignition permissive.(if necessary)


    Standard Operating Procedure

    Page 4 of 6

    OPGS POWER GUJARAT PVT. LTD. 2X150MW

    Title:
    4.4.8

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down


    Maintain mill outlet temp 60Deg.C and air flow >30TPH by adjusting Hot air and cold air

    dampers.
    4.4.9

    Start the mill and follow mill normal starting procedure from SL No 11 onwards.
    4.5

    MILL SHUTDOWN PROCEDURE


    4.5.1
    4.5.2
    4.5.3
    4.5.4
    4.5.5
    4.5.6
    4.5.7
    4.5.8

    First reduce the mill outlet temp gradually to < 65deg.C


    Reduce the coal feed rate by maintaining mill outlet temp < 65 Deg.C
    Reduce coal feed rate to minimum (10 to 15%). with Maintain primary air flow.
    Open cold air damper to max. Required & close hot air damper.
    Stop the feeder.
    Purge the mill with cold air until mill outlet temp reduces to < 55 Deg.C
    Cut off PA flow & Stop the mill and ensure MDV close and seal air close.
    Check PA header pressure and in case off any PAF stalling so adjust the PCD to

    remove stalling.
    4.5.9
    Open MOV inerting steam for 5 minutes to purge out any combustible gas.

    4.6

    MILL START UP REQUIRED PARAMETERS.


    4.6.1
    4.6.2
    4.6.3
    4.6.4
    4.6.5
    4.6.6
    4.6.7
    4.6.8

    4.7

    Lube oil level Adq.(Normal)


    Lube Oil Pr.> 4.5 Bar.
    Pulverizer O/L Temp <80 C
    Mill Seal Air to PA DP Adq. (Normal)>245mmwc
    Tramp Iron valve open condition.
    Mill Bearing temperature <50C.
    Motor Winding Temp. <50C
    CAG open condition.

    MILL TRIPPING CONDITION:


    4.7.1
    4.7.2
    4.7.3
    4.7.4
    4.7.5
    4.7.6
    4.7.7
    4.7.8
    4.7.9
    4.7.10
    4.7.11

    Loss of any PA fan or PA HDR Pr. Low <500MMWC.


    Lube Oil Pr. V. Low <3.0 Bar.
    HAG Close And CAG Not Open.
    Mill Bearing temperature >80C.
    Motor bearing temperature >80C.
    Motor winding temperature >90C.
    System protection with MFT/Run back.
    Motor electrical protection act.
    MDV Close Feedback.
    Seal Air to PA DP Low <245MMWC.
    Any Burner Isolation Gate Close feedback.

    Standard Operating Procedure

    Page 5 of 6

    OPGS POWER GUJARAT PVT. LTD. 2X150MW

    Title:

    Document No.

    Issue No/Date

    Revision No/Date

    OPGS/OPN/SOP/01

    01/27.08.2016

    00/27.08.2016

    Procedure for Coal mill start-up and shut down

    5.0 References
    5.1 Coal Mill O & M Manual

    6.0 Records
    6.1 Shift in Charge Engineer log book(OPGS/OPN)
    6.2 Boiler DCS Engineer log sheet (OPGS/OPN)

    Standard Operating Procedure

    Page 6 of 6

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