Snehasis Bhattacharyya ,

Sr. Supdt. (C&I) , NTPC Ltd, Farakka

Arendra Kumar Arya,
Sr.Engineer (C&I) , NTPC Ltd, Farakka
PERFORMANCE IMPROVEMENT
BY AUTOMATIC OPERATION OF STAGE-1
MILL REJECT SYSTEM AT
NTPC, FARAKKA
Indian Power Stations 2011
13 15 February , New Delhi
Farakka
Farakka
PRESENTATION ROADMAP
INTRODUCTION
DESCRIPTION OF MILL REJECT SYSTEM
NATURE OF PROBLEM
INNOVATIVE APPROACH
IMPROVEMENT ACHIEVED
CONCLUSION
Introduction
NTPC,Farakka has 3X200MW units
and 2 X 500 MW units

Each 200 MW unit consists of:-
I. 6 no. Bowl Mill
II. Model XRP-803
III. Capacity 45.8 Ton/hr
IV. Speed 53 rpm
V. Crushed coal at inlet 25 mm


Farakka
Introduction
The source of coal used at Farakka is
coming from 23 different open cast
mines

In pulverized coal the coal is ground
so that about 70 % will pass through
200 mesh ( 0.075 mm) and 99 % will
pass through 50 mesh (0.300 mm)

Farakka
Introduction
The coal supply carries a certain
percentage of over burden of stone
pieces get leached and come directly
into the mills through the bunker
though manual stone picking system
deployed at coal handling plant



Farakka
Introduction

When these come under the roller, the
roller lifts up allowing these to pass under.

Then scrapped by scrapper through tramp
iron spout to pyrite hopper

Removed periodically. Any material having
a bulk density 1.2 tonnes/m3 should be
rejected (for coal it is 0.8 tonnes/m3).
However sometimes the material to be
ground is also rejected

Farakka
Introduction
Each mill has one Inlet & one Outlet Reject
Gate


Periodic operation & proper functioning of
reject gates is very much essential.







Farakka
INLET REJECT GATE
Farakka
I/L Power
Cylinder
OUTLET REJECT GATE
Farakka
O/L GATE
POWER
Cylinder
Reject
Chamber
Nature of Problem

In stage-1 ,each gate is opened/closed by
the pneumatically operated power cylinder

Accumulation Cycle : Inlet gate is opened &
outlet gate is closed for some time.

Rejection Cycle : Inlet gate is closed &
outlet gate is opened for some time.

Farakka
Farakka
SCHEME FOR MANUAL OPERATION
IA AIR SUPPLY
Manual Switch
Manual Switch
Inlet
power
cylinder
Outlet
power
cylinder
Nature of Problem

In stage-1, Inlet and Outlet gates were
operated with the help of a manual switch

Operation by experience & communication
from control room.

Continuous deputation of operator

Frequent operation of reject gates required
during high rejection
Farakka
Nature of Problem
This results:-

Hot air containing coal dust coming out of
the rejection chamber

Increase the chance of failure of control
instruments and has potential to catch fire
in control cable.

Transportation of rejects from the mill
become troublesome & unsafe for the
operation personnel
Farakka
Innovative Approach
Operation from newly installed DDCMIS
was felt

Remote as well as automatic operation of
reject gates can be done efficiently from
Unit Control Room

Continuous deputation of operator not
required in the mill area



Farakka
Farakka
FACE PLATE FOR MILL REJECT GATE OPERATION
LOGIC DETAILS
Farakka
Farakka
DO
CARD
CH - 1
INLET GATE CMD
FROM LOGIC
24 V
RELAY
Ph
N
24 V
O/P
AUX RELAY - 1
AIR SUPPLY
DO
CARD
CH - 1
24 V
RELAY
Ph
N
24 V
O/P
AUX RELAY - 2
AIR SUPPLY
OUTLET GATE
CMD FROM LOGIC
SOLENOID VALVE
SOLENOID VALVE
Inlet
power
cylinder
Outlet
power
cylinder
Modified Scheme
Innovative Approach
In Manual mode both gates can be opened
independently

Auto mode is having priority

In Auto mode Inlet gate will remain open for
T1 time and outlet gate will remain close.
After T1 time is elapsed inlet gate will close
and outlet gate will open for T2 time .

Farakka
Improvement
Operational Flexibility

Deputation of Manpower for local operation
is nil.

Opening & Closing time (T1 & T2) of Inlet &
Outlet gate can be tuned based on
requirement

Avoidance of Mill operation in Blasting
mode
Farakka
GAIN



TANGI BLE GAI N :-

I ) ENERGY LOSS CALCULATI ON: -

When mills are operating with open pyrite gate condition allowing bleeding of hot
primary air through pyrite system.

ASSUMPTIONS:

A) Quantity of hot primary air, bleeding through pyrite box at a pressure of about
700 mmwc (M
air
) 10 T/hr

B) Average bleed air temperature at full load (T
1
) = 280
0
c = 553 K

C) Average ambient temperature (T
2
) = 30
0
c = 303 K

D) Specific heat of hot air at constant pressure (S
air
) = 1.006 KJ/Kg/K

E) Average calorific value of coal = 3200 KCal/Kg

F) Cost of coal = Rs. 4.0/kg






Farakka
GAIN



TANGI BLE GAI N (contd..)


CALCULATION:

q Energy Loss Per Mill (Q
LOSS
) = M
AIR
x S
AIR
x (T
1
T
2
)

q Q
LOSS
= 10 x 1000 x 1.006 x (553-303) KJ/HR

q Q
LOSS
= 2515000 KJ/HR = 600697 KCAL/HR

q Q
LOSS
= 600697/3200 = 188 KG/HR Of Coal Equivalent

q Q
LOSS
= Rs. 752/- PER HR

q Annual Q
LOSS
= 752 X 365 = Rs. 2,74,480/- Per One
Blasting Hour/Mill/Day

At Farakka , normally 5 mills are in service.


Farakka
GAIN



TANGI BLE GAI N (contd..)


II) COST SAVING ON ACCOUNT OF MANPOWER

ASSUMPTIONS:

A) At least 4 nos. of skilled manpower required for round the clock reject
gate operation

B) Cost of 1 skilled manpower = Rs. 325.00

CALCULATION:

Annual Manpower cost = Rs. 325 X 4 X 365= Rs. 4,74,500.00


Total Annual Saving (I +II) = Rs. 7,48,980.00





Farakka
CONCLUSIONS
Continual process.




Intangible Gains :

Employee satisfaction,
Better plant personnel safety,
Reduction in frequency of mill chocking
Minimizing chance of dust ingress in UCR


Farakka
ACKNOWLEDGEMENT
Sri P Tiwari, AGM (O&M) ,

Sri A K Mukherjee , AGM (Maintenance) ,

Sri A Ghosh, AGM (C&I) ,

Sri C K Sarkar , DGM(C&I)

EEMG & Operation Department.




Farakka
THANK YOU
Farakka
Farakka