1.

Purpose
The purpose of the SOP “hammer mill & Clinker Grinder” Operation is to train and guide operating personnel for
safe, right & correct procedures & optimum performance of the system.

2. Scope
This SOP defines the lineup, pre checks, permissive, operation procedure, Post startup checks, interlocks &
protections for hammer mill & Clinker Grinder.
3. Responsibility matrix
Sl
n Jobs Responsibility Competency Desired output / efficiency
o
1 Distribution Head- Operation
2 Compliance Station in charge/ Shift in To ensure that Bottom de-
charge/desk engineers ashing is done in the shift
Ensure Evacuation of bottom
Ash Plant (O) Supervisor Complete knowledge of ash hopper to avoid any
Bottom de-Ashing Furnace disturbance.
Field operators Field knowledge for
Bottom de-Ashing
procedure.

4. Environment health & safety matrix

Hazards Environmental Safety Precautions PPEs required
considerations
 Burn due to Flooding of area Safe distance
spillage of with ash slurry Removal Of LOTOTO
hot wet ash Water spillage Ensure grinder gland sealing.
 Fall / slip Ensure proper housekeeping.
due to oil Timely de-ashing of bottom
spillage ash hopper.

5. Legal and regulatory requirements: Not Applicable

FOR CLAUSE NO. 6, 7, 8 9,10,11,12,13,14 refer annexures

- For Aditya : ANN_MAH_E39_AHSOP_06( Applicable for Hammer Mill)
- For Dahej : NA
- For Hirakud : NA
- For Mahan : ANN_MAH_E39_AHSOP_06
- For Muri : NA
- For Renukoot : ANN_RKT_E39_AHSOP_06
- For Renusagar: ANN_RPD_E39_AHSOP_06
- For Utkal : ANN_UAL_E39_AHSOP_06

6. O & M parameters: Refer annexure

7. Checks before start up: Refer annexure

8. Startup sequence: Refer annexure

9. Operation monitoring & control: Refer annexure

10. Shutdown Procedure: Refer annexure

.
11. Best practices followed (If any) : Refer annexure

12. Exception/ Emergency handling: Refer annexure

13. Dos & Don’ts: Refer annexure

14. Performance KPI’s: Refer annexure

15. Abbreviation: Refer annexure

- For Aditya : ANN_MAH_E39_AHSOP_06( Applicable for Hammer Mill)

6. O & M parameters
No. & Capacity: 1 Nos. (1no hammer mill for each unit).

 HAMMER MILL Details

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR
1 MAKE Ecoman

2 MOTOR SPEED RPM 1480

3 MOTOR POWER RATED 160

(KW)
4 VOLTAGE 415
5 MILL SPEED 875

6 CURRENT AMP 267

- For Utkal : ANN_UAL_E39_AHSOP_06( Applicable for Clinker Grinder)

No. & Capacity: 2 Nos. Clinker Grinders for each unit(Below Bottom Ash Hopper)

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd

2 MOTOR Rating 5.5 KW x 1440 RPM

3 Grinder Roll Speed 54RPM

4 Fluid Fluidomat/ SM3 Type
Coupling(Manufacturer/Type
 )
5 Gear Power Build/Inline Helical Gear Box, Type 72 PII/ 15.47:1)
Box(Manufacturer/Type/Gear
ratio)

No. & Capacity: 2 Nos Clinker Grinders above Agitated Retention Tank

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd

2 MOTOR Rating 15 H.P x 1440 RPM

No. & capacity: 2 Nos Clinker Grinders above Dewatering Bin

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd

2 MOTOR Rating 7.5 KW x 1440 RPM

3 Grinder Roll Speed 100RPM

4 Fluid Fluidomat/ Const. Oil Fill type
Coupling(Manufacturer/Type
)
5 Gear Elecon/6 Inches/ 15:1
Box(Manufacturer/Size/Gear
ratio)

7. Checks before start up

7.1 Physical Checks
1. Ensure Power supply and control power supply available.
2. Local emergency push button should be in release Condition.
3. Open all isolation valves of instruments.
4. Selected compressor should be healthy condition.
5. No leakage in suction/discharge pipeline.
6. Stage2 & bottom ash silo vent fan should be running condition.
7. Compressor Seal water line should open condition.
8. Conveying discharge valve should open condition.

STARTING PERMISSIVE:

7.2 Permissive for start up

1. Ready to start.
2. Suction & discharge valve in open condition.

7.3 Interlocks & Protections

Interlocks
1. Hammer mill will trip on over load relay.
2. Compressor unloads when conveying line pressure above 1.8 kg/cm2.
3. If discharge line pressure reaches 1.5 kg/cm2 then air lock tank bottom RSV will gets closed and
line will be kept in flushing mode.

8. Startup sequence

Stage1 to stage2 conveying:

1. Ensure local line-up is cleared and system is ready to be taken into service.
2. Start the stage2 vent fan & bag filter purge.
3. Start & selected bottom ash compressor with checking healthy.
4. Check compressor pressure with 0.5-0.6 kg/cm2 then start the air lock tank sequence respected
conveying line.
5. Start the hammer mill from plc & check current.
6. Open the manual gate v/v as needed.

Stage2 to main bottom ash silo conveying:

1. Ensure local line-up is cleared and system is ready to be taken into service.
2. Start the bottom ash silo vent fan & bag filter purge.
3. Start & selected bottom ash compressor with checking healthy.
4. Check compressor pressure with 0.5-06 kg/cm2 then start the air lock tank sequence respected
conveying line.
5. Open the manual gate v/v as needed.

9. Operation monitoring & control

1. Check discharge pressure.
2. Monitor any abnormalities like vibration, sound from hammer mill. Check any conveying line
leakage

10. Shutdown Procedure

STAGE#1 TO STAGE#2 CONVEYING:

1. Ensure stage#1 level should be down then close the manual gate v/v.
2. Stop the hammer mill from plc.
3. Stop the air lock tank sequence after should be air lock tank empty.
4. Stop the selected compressor after flushing conveying line.

STAGE#2 TO MAIN BOTTOM ASH SILO CONVEYING:

1. Check the stage#2 level should be down then close the manual gate v/v.
2. Stop the air lock tank sequence after air lock tank empty.
3. Stop the selected compressor after flushing the conveying line.

11Best practices followed (If any):

12. Exception/ Emergency handling :

It is necessary to shut down the hammer mill in case of emergency

1. Bottom ash conveying line leakage.
2. Hammer mill leakage.
3. Bearing temperature is going above rated value.
4. Compressor trip.
5. Hammer mill high vibration.

13. Dos & Don’ts

DO’s DON’Ts
1. Don’t start air lock tank sequence without
1. Maintain conveying line pressure 1.2 starting air compressor.
kg/cm2. 2. Don’t start hammer mill without start air lock
2. Arrest ash conveying line leakage tank sequence.
immediately after detection.

14.Performance KPIs

 At 150 MW:
o Stage1 empty : 180min
o Operating current : 95Amps
o Power consumption : 160KW

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 LOTOTO Lock out tag out try out

- For Mahan : ANN_MAH_E39_AHSOP_06

- For Renukoot : ANN_RKT_E39_AHSOP_06

6. O & M parameters
 It is also applicable in B#1,3 & 4
  Clinker Grinder Details
Sl No. DESCRIPTION Clinker Grinder
1 Make M/S Melco
2 Size 610 x 610
3 Capacity 60 TPH
4 Speed 45 RPM
MOTOR
1 Make Crompton Grieves
2 Motor Type 3-phase Induction Motor
3 Power Capacity (HP) 10
4 Voltage (V) 415
7 Motor speed (RPM) 1460 RPM
8 Full Load current (AMPS) 18

7. Checks before start up

7.1 Physical checks
1. Ensure that HP Ash Pump is running.
2. Ensure HP ash pump discharge line isolating valve is open.
3. Ensure sealing water pressure is in between 1.5 – 2.5 Kg/Cm2.
4. Ensure power supply of Clinker Grinder is ON.

7.2 Permissive for start up

1. Sealing water pressure = 1.5 – 2.5 Kg/Cm2
2. Service air pressure > 5.0 Kg/Cm2

7.3 Interlocks & Protections

Interlocks Protection
1. Sealing water pressure = 1.5 – 2.5 Kg/Cm2

8. Operating procedure
1. Switch ON the Electrical power to the control panel.
2. Open sealing water.
3. Start HP Ash Pump.
4. Open HP Ash Pump Discharge valve.
5. Flush the Bottom ash discharge line to Ash Pond approx. 10 min.
6. Open Clinker Grinder Feed Gate.
7. Start LP Ash Pump for flushing the hopper with nozzles.
8. Open both side nozzles one by one for flushing the clinkers.
9. Open side nozzles one by one for proper flushing.
9. Operation Monitoring &control
10. Shutdown Procedure

1. When furnace flame started looking from Clinker grinder looking glass then Feed gate closed.
2. Stop the Clinker Grinder.
3. Close the Sealing water line valve.
 4. Fill the Bottom Ash Hopper through LP ash pump water.
5. Flush the Bottom Ash discharge line for approx. 10 min to clear the discharge line.
6. Stop the HP Ash Pump.
7. When Bottom Ash Hopper started overflowing LP Ash Pump stops.
8. Stop the LP Ash Pump.

11. Best Practices followed (if any): Proper flushing of Clinkers from Both side nozzles & side nozzles.

12. Exception/Emergency handling:

13. Dos & Don’ts

Dos Don’ts
1. Flushing of Bottom Ash discharge line before & after 1. Don’t avoid flushing of hoppers through side nozzles.
the de-ashing.

14. Performance KPIs

15. Abbreviation

S. NO. Abbreviation used Stands For

1. HP Ash Pump High Pressure Ash Pump
2. LP Low Pressure
3. HP Horse Power
4. RPM Revolution per minute
5. AMPS Ampere

- For Renusagar: ANN_RPD_E39_AHSOP_06

 Applicability to generating unit(s) : unit #1 to #10

 Scope : This annexure covers the 6 to 15 clauses of SOP E39_AHSOP_06

6. Technical specification
 No. & Capacity: 1 per unit, each with 100% Unit Load
 Pump Details
Sl No. DESCRIPTION H.P.Pump Clinker grinder
1 Pump Type VERTICAL GREAVES LTD U -
600
2 Liquid Pumped Water Slurry
3 Suction Temperature (oC) 30 100
4 Flow Rate (M3/Hr) 300 300
5 Specific Weight of Feed Water (Kg/M3) 916.0 916.0
6 Suction Pressure (Kg/M3) 5.43 14.40
3
7 Discharge Pressure (Kg/M ) 9.0 3.0
Operating Speed (RPM) 1440 1450
MOTOR 415 415
1 Power, KW 110 9.3
 2 Voltage 415 415
3 Current, Amp 185 18.8
4 Speed, RPM 1480 1450
5 Insulation Class F F

7. Checks before start up

7.1 physical Check ups
5. Ash Plant Operator ask LDAD control center for line clearance.
6. Ensure that H.P Pump is running.
7. Emergency push button of clinker grinder is in released condition.
8. Electrical supply available to clinker grinder.
9. Ensure that Ash slurry pump is running.
7.1-Physical checks

7.3 Interlocks & Protections

Interlocks Protections
1. If LDAD is not running then Bottom de-Ashing Clinker grinder trips in case of :
will not take place. - Jamming
- Overload current (21.8 amp)
- Seal Pressure low i.e. < 6 Kg/cm2

8. Start up sequence
1 Inform the control room for bottom ash de ashing.
2 Open hydro ejector water I/L valve (> 6.0 kg/cm2).
3 Open clinker grinder gland sealing water valve.
4 Start the clinker grinder.
5 Open the feed gate & as a consequence bottom ash de ashing starts.
6 Open the water valve for inspection window.
7 When all the ash from hopper is evacuated, HP water nozzles should be opened sequentially for complete
flushing of bottom ash hopper.
8 Inspect the hopper to be empty & inform the same to the control engineer.
9. Operation Monitoring & control
1. Check grinder chamber evacuate in time.
2. Ensure bottom ash sampling.
3. Check for noise & vibration.
4. Check for oil & ash leakages, if any.

10. Shutdown Procedure

1 After inspection by control engineer, close the feed gate.
2 Stop the clinker grinder and its gland sealing valve.
3 After about 2 minutes delay. Close the hydro ejector water I/L valve.
4 Open the filling valve & when the hopper is filled, close the same and maintain the overflow.
5 Close the water valve for inspection glass cooling.

11. Best Practices followed:

1. Before the start of Bottom de-ashing, line flushing is ensured for safe operational perspective.
2. Before opening the bottom Hopper hydraulic gate, clinker accumulation is ensured through inspection
hole.
3. After the completion of Bottom de-ashing, Corresponding unit control engineer and site In-charge ensure
that hopper is completely evacuated and flame is visible. (Triple Layer Safety)
12. Exception/ Emergency Handling:
If clinker grinder trips at any abnormal condition, hydraulic gate is closed manually at the very instant and
hydro ejector still in running condition so that we ensure line flushing to avoid any possible chockage of line
and tripping of slurry pump.

13. Dos & Don’ts

DO’s DON’Ts
1. Ensure all permissive and protections are in 1. By pass any interlock and protection of equipments at any
service. time.
2. Monitor vibrations and sound.
3. Monitor motor current.

14. KPI (Key Performance Indicators):

KPI Action Taken

Ash Slurry Pump current should be If Current decreases then there can be
around its normal operation (approx. 135 problem in the chockage of suction or
Amp.) discharge line which can affect the entire
Bottom de-Ashing process.

15. Abbreviation:

Sl. No. Abbreviation Used Stands For

1 LOTOTO Lock Out Tag Out Try Out
2 LDAD Long Distance Ash Disposal
3 HP High Pressure

For Utkal : ANN_UAL_E39_AHSOP_06( Applicable for Clinker Grinder)

Technical specification

No. & Capacity: 2 Nos. Clinker Grinders for each unit(Below Bottom Ash Hopper)

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd
2 MOTOR Rating 5.5 KW x 1440 RPM

3 Grinder Roll Speed 54RPM

 4 Fluid Fluidomat/ SM3 Type
Coupling(Manufacturer/Type)
5 Gear Power Build/Inline Helical Gear Box, Type 72 PII/ 15.47:1)
Box(Manufacturer/Type/Gear
ratio)

No. & Capacity: 2 Nos Clinker Grinders above Agitated Retention Tank

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd

2 MOTOR Rating 15 H.P x 1440 RPM

No. & capacity: 2 Nos Clinker Grinders above Dewatering Bin

Sl No. DESCRIPTION FLY ASH TRANSFER AIR COMPRESOR

1 MAKE BSBK Engineers Pvt Ltd

2 MOTOR Rating 7.5 KW x 1440 RPM

3 Grinder Roll Speed 100RPM

4 Fluid Fluidomat/ Const. Oil Fill type
Coupling(Manufacturer/Type
)
5 Gear Elecon/6 Inches/ 15:1
Box(Manufacturer/Size/Gear
ratio)

. Checks before start up

7.1 Physical checks
10. Ensure that HP Ash Pump is running.
11. Ensure HP ash pump discharge line isolating valve is open.
12. Ensure sealing water pressure is in between 2.5 – 5 Kg/Cm2.
13. Ensure power supply of Clinker Grinder is ON.

7.2 Permissive for start up

1. Sealing water pressure = 2.5 – 5 Kg/Cm2
2. Service air pressure > 5.0 Kg/Cm2

7.3 Interlocks & Protections

Interlocks Protection
1. Sealing water pressure = 2.5 – 5 Kg/Cm2

8. Operating procedure
10. Switch ON the Electrical power to the control panel.
11. Open sealing water.
12. Start HP Ash Pump.
 13. Open HP Ash Pump Discharge valve.
14. Flush the Bottom ash discharge line to Ash Pond approx. 10 min.
15. Open Clinker Grinder Feed Gate.
16. Start LP Ash Pump for flushing the hopper with nozzles.
17. Open both side nozzles one by one for flushing the clinkers.
18. Open side nozzles one by one for proper flushing.
9. Operation Monitoring &control
10. Shutdown Procedure

1. When furnace flame started looking from Clinker grinder looking glass then Feed gate closed.
2. Stop the Clinker Grinder.
3. Close the Sealing water line valve.
4. Fill the Bottom Ash Hopper through LP ash pump water.
5. Flush the Bottom Ash discharge line for approx. 10 min to clear the discharge line.
6. Stop the HP Ash Pump.
7. When Bottom Ash Hopper started overflowing LP Ash Pump stops.
8. Stop the LP Ash Pump.

11. Best Practices followed (if any): Proper flushing of Clinkers from Both side nozzles & side nozzles.

12. Exception/Emergency handling:

13. Dos & Don’ts

Dos Don’ts
1. Flushing of Bottom Ash discharge line before & after 1. Don’t avoid flushing of hoppers through side nozzles.
the de-ashing.

14. Performance KPIs

15. Abbreviation

S. NO. Abbreviation used Stands For

1. HP Ash Pump High Pressure Ash Pump
2. LP Low Pressure
3. HP Horse Power
4. RPM Revolution per minute
5. AMPS Ampere