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    MPSP Mill - Simhadri1

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    santoshkumar777
    This presentation summarizes the milling system for the NTPC Simhadri power plant. It includes specifications for the mill, coal characteristics, construction and design features of the mill, comparisons between CE and MPSP mill designs, factors that influence mill performance like capacity and fineness, maintenance practices, and optimizations made to improve mill performance at Simhadri. The actual mill parameters are meeting the rated specifications.

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    MPSP Mill - Simhadri1

    Uploaded by

    santoshkumar777
    219 views18 pages
    This presentation summarizes the milling system for the NTPC Simhadri power plant. It includes specifications for the mill, coal characteristics, construction and design features of the mill, comparisons between CE and MPSP mill designs, factors that influence mill performance like capacity and fineness, maintenance practices, and optimizations made to improve mill performance at Simhadri. The actual mill parameters are meeting the rated specifications.

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    MPSP Mill -Simhadri1

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    This presentation summarizes the milling system for the NTPC Simhadri power plant. It includes specifications for the mill, coal characteristics, construction and design features of the mill, comparisons between CE and MPSP mill designs, factors that influence mill performance like capacity and fineness, maintenance practices, and optimizations made to improve mill performance at Simhadri. The actual mill parameters are meeting the rated specifications.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    219 views18 pages

    MPSP Mill - Simhadri1

    Uploaded by

    santoshkumar777
    This presentation summarizes the milling system for the NTPC Simhadri power plant. It includes specifications for the mill, coal characteristics, construction and design features of the mill, comparisons between CE and MPSP mill designs, factors that influence mill performance like capacity and fineness, maintenance practices, and optimizations made to improve mill performance at Simhadri. The actual mill parameters are meeting the rated specifications.

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    WELCOME

    TO

    THE PRESENTATION
    ON

    MILLING SYSTEM NTPC - SIMHADRI

    MILLING PLANT SPECIFICATION


    TYPE OF MILL NO OF MILLS PER BOILER NO OF MILLS REQUIRE FOR FULL LOAD MILL CAPACITY PF FINENESS XRP 1003 (MPSP) 9 6 66.2 TPH 70% THROUGH -200 MESH 42 RPM 525 KW, 3.3 KV, 589 RPM 230 C 2 NOS 2 NOS

    MILL SPEED MILL MOTOR RATING


    MILL INLET AIR TEMP PA FANS (COMMON) SEAL AIR FANS (COMMON)

    COAL CHARACTERISTICS
    GCV ASH 3450 3600 KCAL/KG > 40 %

    VM
    CARBON MOISTURE

    20 24 %
    20 33 % 12 16 %

    HGI

    55

    CONSTRUCTION & DESIGN FEATURES

    SIMHADRI IS THE FIRST COASTAL BASED COAL FIRED THERMAL POWER PROJECT OF NTPC
    BHEL HAS PROVIDED MILLS WITH MPSP (MILL PLANT SUPER PERFORMANCE) SYSTEM AT DESIGN STAGE, FIRST TIME IN NTPC TALL TOP CLASSIFIER MODIFIED VENTURI ( ALSO CERAMIC LINED) FLAP TYPE MILL DISCHARGE VALVE (CERAMIC LINED) BEARINGLESS SPRING LOADING DOUBLE BEARING JOURNALS MODIFIED VANE WHEEL ASSEMBLY CERAMIC LINED BENDS, INNER CONE, ORIFICES CERAMIC CARBIDE DUO CAST GRINDING ROLLS

    CONSTRUCTION & DESIGN FEATURES


    SPRING LOADED FLOATING FOUNDATION HIGH CHROME BULL RING SEGMENTS BURNER INLET ISOLATION VALVES FEEDER DISCHARGE ISOLATION VALVE DUST GAURD SEAL JOURNAL TILTING

    CE VS MPSP DESIGN
    S.NO 1 PARAMETERS GRINDING ROLL (GR) CE NI-HARD MPSP DUO CAST WITH CERAMIC CARBIDE INSERTS

    2
    3 4 5 6

    BULL RING SEGMENT (BRS)


    VANE WHEEL EXPECTED RUNNING HOURS PM SCHEDULE COST OF GRINDING ELEMENTS (GR + BRS)

    NI-HARD
    45 3000 BI-WEEKLY ~ 3 LACS

    HIGH CHROME
    30 11000 FOUR WEEKLY ~ 13 LACS

    MILL MAINTENANCE PRACTICES & STRATEGIES


    REGULAR AND PERIODIC PREVENTIVE MAINTENANCE CONDITION / WALKDOWN BASED MAINTENANCE

    PLANNED MAINTENANCE (MAJOR)


    BREAKDOWN MAINTENANCE

    TIMELY PLANNING OF SPARES AND CONTRACTS


    OPTIMIZATION / MODIFICATIONS

    MILL MAINTENANCE PRACTICES & STRATEGIES


    REGULAR AND PERIODIC PREVENTIVE MAINTENANCE CONDITION / WALKDOWN BASED MAINTENANCE

    PLANNED MAINTENANCE (MAJOR)


    BREAKDOWN MAINTENANCE

    TIMELY PLANNING OF SPARES AND CONTRACTS


    OPTIMIZATION / MODIFICATIONS

    MILL PERFORMANCE FACTORS


    MILL CAPACITY PF FINENESS MILL REJECTS MILL OUTLET TEMPERATURE MILL BOWL DP MILL POWER CONSUMPTION

    MILL PERFORMANCE FACTORS


    MILL CAPACITY DEPENDS UPON FOLLOWING FACTORS HARD GROOVE INDEX TOTAL MOISTURE CONTENT AIR FLOW PF COAL FINENESS

    MILL PERFORMANCE FACTORS


    PULVERISED COAL FINENESS
    THE RECOMMENDED PF COAL FINENESS IS ABOVE 70% AND 98.0 % THROUGH 200 MESH AND 50 MESH RESPECTIVELY INITIAL FINENESS ACHIEVED : 60 TO 70% THROUGH 200 MESH &MORE THAN 2% RETENTION ON 50 MESH ADJUSTMENTS DONE DURING PG TEST: INCREASE IN SPRING COMPRESSION : 9.5 TO 11.5 TONS INCREASE IN VENTURY COLLOR HEIGHT : 50 MM REDUCTION IN INVERTED CONE CLEARANCE : 30 MM REMOVAL OF AIR RESTRICTION PLATE CLASSIFIER SETTING : FROM 3 TO 5

    MILL PERFORMANCE FACTORS


    MILL REJECTS DENSITY BASED SEPARATION ON THE BOWL LEADS TO MILL REJECTS AT SIMHADRI, THE MILLS ARE REJECTING THE MATERIALS WHICH ARE DIFFICULT TO GRIND LIKE STONES AND PYRITES. THE TOTAL MILL REJECTS ARE AROUND 2-10 KG PER HOUR STONE IS VERY LESS IN RAW COAL

    MILL PERFORMANCE FACTORS


    MILL OUTLET TEMPERATURE GENERALLY THE RECOMMENDED VALUE OF MILL OUTLET TEMPERATURE IS 100-X (X = % OF VOLATILE MATTER IN THE COAL) AT SIMHADRI WE ARE MAINTAINING THE MILL OUTLET TEMP AT 75 TO 85C AS THE VOLATILE MATTER IN OUR COAL IS LESS AND THE MOISTURE IS HIGH

    MILL PERFORMANCE FACTORS


    MILL BOWL DIFFERENTIAL PRESSURE THE RECOMMENDED VALUE BOWL DP IS 300 MMWC AT FULL LOAD HIGHER ASH CONTENT, HIGHER REJECTION, LOW AIR FLOW, EXCESS FINENESS AND ERODED MILL INTERNALS LEAD TO HIGHER BOWL DP

    POWER CONSUMPTION
    THE POWER CONSUMED BY THE MILL MOTOR SHOULD NOT EXCEED THE RATED CAPACITY. AT SIMHADRI THE CURRENT DRAWN BY MILL MOTOR AT FULL LOAD IS WELL WITHIN THE LIMITS

    OPTIMISATION OF BOWL MILL PARAMTERS


    IT IS ALWAYS SUGGESTED THAT BOWL MILL PARAMETERS SHOULD BE OPTIMIZED FOR SATISFACTORY PERFORMANCE OF THE MILLS AND TO IMPROVE THE LIFE OF MILL COMPONENTS AT SIMHADRI PG TEST IS JUST COMPLETED. OPTIMIZATION OF SPRING COMPRESSION IS IN PROGRESS

    MODIFICATIONS
    THE FOLLOWING MODIFICATIONS WERE DONE WITHOUT AFFECTING THE MILL DESIGN/FLOW CONDITIONS (DURING ERECTION & COMMISSIONING) :
    LUBE OIL SKID RELOCATION INCREASE OF DISCHARGE PIPE DIA OF LUBE OIL SYSTEM FRO TO 1DURING COMMISSIONING

    LOCKING SYSTEM MODIFICATION OF JOURNAL STOP BOLT


    EXTENSION OF SPRING SHAFT

    PROVISION OF ON-LINE MILL REJECT CHOKING REMOVAL PORT

    DATA FOR MILL PERFORMANCE FACTORS AT SIMHADRI S.NO. 1) DESCRIPTIOIN Capacity Fineness X Passing through200 mesh) 02) Retention on 50 mesh 03) 04) Mill outlet Temp. Bowl DP 2.00% 87 deg c Maxm 300 mm WC <1% 80-85 deg c 300 to 340 mmWC RATED PARAMETERS 66.3 tph >70%

    ACTUAL PARAMETERS
    65 >80%

    05)
    06) 07)

    Mill Amperage Mill


    Rejects OTHERS, Volatile matter

    137A

    120-125A
    Low

    22min 12.00% 265 deg c 95 tph 55 3300 Kcal/kg ~40

    <22%

    Moisture
    Mill air inlet temp. PA Flow HGI GCV Ash

    .12-14 %
    250 -270 deg c 90-105 tph >55 ~3300 k cal/kg >40

    THANK YOU

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