Presentation on Coal Mill Operation,

Protection and Interlocks

Contents
• Combustion Theory
• Coal Properties
• Coal Mill GA
• Interlocks & Protections
• Mill
• Feeder
• Operation
• Pre-operational Check
• Startup
• Shutdown
• Troubleshoot
• Emergency handling
• Case Study
Combustion
Combustion refers to the rapid oxidation of fuel accompanied by the production of heat, or heat
and light. Complete combustion of a fuel is possible only in the presence of an adequate
supply of oxygen.
Rapid fuel oxidation results in large amounts of heat. Solid or liquid fuels must be changed to
a gas before they will burn. Usually heat is required to change liquids or solids into gases. Fuel
gases will burn in their normal state if enough air is present.
Nitrogen reduces combustion efficiency by absorbing heat from the combustion of fuels and
diluting the flue gases. This reduces the heat available for transfer through the heat exchange
surfaces. It also increases the volume of combustion by-products, which then have to travel
through the heat exchanger and up the stack faster to allow the introduction of additional fuel
air mixture. This nitrogen also can combine with oxygen (particularly at high flame temperatures) to
produce oxides of nitrogen (NOx), which are toxic pollutants.

C + O2 CO2 + 8084 kCals/kg of Carbon

2C + O2 2 CO + 2430 kCals/kg of Carbon
2H2 + O2 2H2O + 28,922 kCals/kg of Hydrogen
S + O2 SO2 + 2,224 kCals/kg of Sulphur

Each kilogram of CO formed means a loss of 5654 kCal of heat.(8084-2430).

Coal Properties
Fixed carbon:
Fixed carbon is the solid fuel left in the furnace after volatile matter is distilled off. It consists
mostly of carbon but also contains some hydrogen, oxygen, sulphur and nitrogen. Fixed carbon gives a rough
estimate of heating value of coal.
Volatile Matter:
Volatile matters are the methane, hydrocarbons, hydrogen and carbon monoxide, and incombustible
gases like carbon dioxide and nitrogen found in coal. Thus the volatile matter is an
index of the gaseous fuels present. Typical range of volatile matter is 20 to 35%.
• Proportionately increases flame length, and helps in easier ignition of coal..
• Influences secondary air requirement and distribution aspects.
• Influences secondary oil support
Ash Content:
Ash is an impurity that will not burn. Typical range is 5 to 40%
• Reduces handling and burning capacity.
• Affects combustion efficiency and boiler efficiency
• Causes clinkering and slagging.
Moisture Content:
Moisture is an evident property in coal as all coals are mined wet. Since it replaces combustible matter, it
decreases the heat content per kg of coal. Typical range is 0.5 to 10%.
• Increases heat loss, due to evaporation and superheating of vapour
Coal Properties
Proximate Analysis Unit Design Coal
Fixed carbon % 42
Volatile matter % 29
Moisture % 15
Ash % 14
Grindability index HGI 50
HHV kcal/kg 5450
Ultimate Analysis
Carbon % 57.10
Hydrogen % 3.43
Sulphur % 0.61
Nitrogen % 1.3
Oxygen % 8.56
Moisture % 15
Ash % 14
Carbonates % 0.19
Mill General Arrangement

• Coal Mills are used to grind the coal into fine particles before placing into a boiler, to ensure
efficient combustion. The coal is fed into the coal mill through a central inlet pipe where gravity is
used to lead the coal to the bottom of the mill, where the grinding table pulverizes the coal to
particles. The primary air flow to the furnace is fed through the mill, with the purpose of heating and
lift the coal particles into the funace. If the particles are too heavy they will drop to the bottom of the
mill and will be pulverized once more.
• Functions:
• The main functions of coal mill are as follows.
I. Pulverization
II. Drying
III. Classification
Bowl Mill

• Bowl mills are employed to pulverize the pre-crushed raw coal to the required fineness before it is
admitted into the boiler furnace for combustion. The mill output can be easily varied, as per the
turndown ratio from its minimum to maximum load and it will operate for long periods without
mechanical problems or stoppages for cleaning, oiling or adjusting. Crushed raw coal at a controlled
rate is fed into the revolving bowl of the Bowl Mill. Centrifugal force feeds the coal uniformly over the
replaceable grinding ring where independently spun rolls exert the required grinding pressure. The
rolls do not touch the grinding ring even when the mill is empty.
• This mill is designated as XRP 1003 Bowl Mill where
• X – 3 Phase, 50 Hz Supply,
• R – Raymond (Inventor of the mill),
• P – Pressurized,
• 100 – Nominal dia. of the Bowl (inches)
• 3 – Number of the Grinding Rolls.
PLANETARY GEAR BOX AND BOWL HUB ASSEMBLY

Planetary gear box is used to give required torque to the bowl

& bowl hub assembly which is directly mounted and bolted to
the gear box top table. The direction of torque transmission in
planetary gear box changed from horizontal to Vertical. The
bowl assembly consists of Bull ring assembly (mounted on the
bowl), Skirt & Scrapper Assembly and vane wheel assembly
(attached to the bowl).
MILL SIDE AND LINER ASSEMBLY

The hot primary air for drying and carrying

pulverized coal enters into the mill side and
air inlet housing. The mill side and liner
assembly is insulated internally to prevent
heat loss from primary air to the
atmosphere, or to the gearbox.
SEPARATOR BODY ASSEMBLY:

The separator body holds the components that give

necessary grinding pressure (journal spring
assembly), journal assembly and also the
components that direct the coarse sized coal
particles back to the bowl for re grinding
ROLLER JOURNAL ASSEMBLY:
The roller assembly consists of journal shaft, journal bearings, and journal housings, Grinding roll,
journal head, trunion shaft assembly

Oil Seal
Bearings
Seal air port

Page 11
MILL DISCHARGE VALVE ASSEMBLY
The mill discharge valve assembly consists of four
multiport outlet and mill discharge valves mounted
on the multiport outlet plate. Air cylinders operate
the flaps in the mill discharge valves. Solenoid
valves and limit switches are provided to effect
and indicate the open or close position of the flap.
This assembly does the distribution of pulverised
fuel into four pipes and also it isolates the mill from
boiler when required.

Animation
Coal Feeder
• Coal Feeder is one equipment that regulates the amount of coal to supplied into the coal mill.
• The amount of coal is regulated according to the needs in the boiler combustion
• The number regulation system in the coal feeder can be done in two ways based on the type,
namely by weight fraction(Gravimetric) or coal volume fraction(Volumetric)

Page 13
MILL INTERLOCKS AND PROTECTIONS
COAL MILL START PERMISSIVES:

• Seal air header DP adequate > 250 mmwc (½ logic )

• Pulveriser ready
• Pulveriser off
• Ignition Permit available
• Switchgear not disturb
• Switchgear available
• EPB Operated
• Pulveriser no trip
• PLOS Healthy
• Steam inerting completed or disable Trip Conditions
Pulverizer Ready
• Pul/Feeder Start Permit
• PLOS Healthy
• MDV open (4/4)
• Mill outlet temp not high <77°C
• CAG Open
• No auto unsuccessful start(MFT or Mill man)
• Tramp iron gate open
• PA fan permit available or any mill on
• Bunker O/L gate and Feeder I/L gate open
• Coal Feeder selector switch in remote
• Burner isolation gate open 4/4
• Pulveriser no trip condition
back
 Pul/Fdr Start Permit:

A
No MFT N permit
D
Any Feeder Proven(A to F) O
Any oil in service(AB,CD,EF) R

Air flow <40% A

N
Burner tilt 50% D

back

Page 16
PLOS Healthy:

• Input Shaft temp not ok < 75°C (6/6)

• Any LOP on and run for 15 min & LO pressure okay > 0.8 Kg/cm²
• Lube oil flow ADQ >120 LPM
• Lube temp ADQ > 30°C (2/2)
• Lube oil filter clean (<2kg/cm²)

back
PA fan permit available or any mill on:
Pulveriser on
0
PA air permit available: R PA fan/mill on permit
PA Hdr pressure not v low 2/3, 500 mmwc A
N
5 sec
PA Hdr pressure not low 2/3, 625 mmwc D

PA A/B not off A

N
0
FD A/B not off D
R

PA fan A/B on condition

FD fan A/B not off A
N
D
3 or More Coal EL in Service

back

18
Ignition permit available

A
N
Boiler Load > 30% D

Adjnt Feeder Proven >50% :

Feeder rate 50% A
N
D
Feeder on and run for 50 sec
O
R
permit

Oil Gun in service

AB elevation ¾ guns proven

AB elevation LO gun proven O

R
AB elevation HO gun proven
back

19
 Steam Inerting Completed or Disable

Inert Disable condition 0

R

Steam inerting completed:

Block valve limit switch open 5min t on A
N
D
Steam inerting start memory set
Steam inert enable A
N 2 sec
D
Start inerting

back

20
MILL TRIP CONDITIONS:

• MFT
• Trip From PLOS
• Pulveriser discharge vlv not open
• Ignition energy required not available
• Electrical trip
• Pulveriser Seal air Hdr pressure DP low < 200mmwc, 1min (1/2)
• Burner Isolation gate not open
• Loss of Primary air <625 mmwc 5 sec (or) < 500 mmwc (or) PA/FD trip
• Pulveriser start fail
• HAG closed / CAG not open
• Pulveriser Bearing temp v.high > 80 °C
• Pulveriser winding temp V.high > 85 °C
Coal Feeder
• Pulveriser trip from inerting
PLOS Fail
Both LOP Not On
LO Temp Aft CLR V Hi >65°C 1/2
GB/IP Shaft Temp V Hi >85°C 1/2 O
R
Any Pump On & Lo Pressure Aft CLR V LOW 0.5bar, 1 sec

LO Flow to GB V Low (105 LPM) 1/2 5 sec Delay

Page 22
Trip from PLOS

• Both LOP Not On

• LO Temp Aft CLR V Hi >65°C 1/2
• GB/IP Shaft Temp V Hi >85°C 1/2
• Any Pump On & Lo Pressure Aft CLR V LOW (0.5 bar, 1 sec)
• LO Flow to GB V Low (105 LPM, 5 sec) 1/2

back

23
Ignition Energy Required, not available

ING required,not available

• Pulveriser no ING Permit: A
N
D
AB elv 3/4 nozzle valve not open O
R
Boiler Load > 30% A
N
Adjsnt Feeder Speed >50% D

• Pulveriser ING spport required :

Feeder Off FB A
N 180 sec
D
Feeder A on t 5 sec
O
Start feeder auto R back
Pulv manual and feeder start
Pulveriser trip for inerting

Steam inert mov not close A

Pulv On and Feeder gets tripped: N Trip
5sec D

Feeder not auto stop

A
N
Feeder off pulse 1 sec D

Fdr Stop Pressed A 3sec

N
Pulve Out temp >55 °C ½ D

back

25
COAL FEEDER INTERLOCKS AND PROTECTIONS

Feeder Start permissives:

IGN Support reqd and available
Pulveriser ready
Feeder speed to min < 20%

No MFT

Feeder in remote
A Feeder start
Pulveriser on
N
FDR Seal air valve open D

FDR outlet gate open

Pulveriser air flow >60% (66 TPH

HAG open temp adeq > 50°C
FDR no off command

COB,FDP& Trip from control panel

26
Coal Feeder trip protections:

Pulveriser off
No coal flow trip:
Pulveriser current low <52 amps A
FDR no coal on belt N
D

FDR command open O

R O
FDR on condition
R Trip
MFT
FDR not in remote
FDR seal air valve not open
Pulv air flow <60%
Feeder outlet gate closed
Feeder ING permit and ING support

27
28
PRE OPERATIONAL CHECKS
 
Coal feeder line – up

• No PTW is pending.
• Feeder front and rear doors are closed.
• Check sufficient coal in bunker.
• Ensure Bunker outlet gate power supply on and gate open.
• Ensure bunker rod gate open
• Ensure feeder inlet gate open
• Bunker emptying pipe is dummied
• Ensure Feeder Seal air valve open condition
• Feeder module is ON and Feeder selection is in Remote (on feeder panel).
• Clean out conveyor is in ON position. (On feeder panel)
  Coal Mill line – up

• No PTW is pending
• All inspection doors are closed
• Following are lined up with Instrument Air: MDV, HAG, HAD, CAG, CAD and Tramp iron valve
& Outlet Gate, Mill SAG
• Ensure PA Fan and Seal air fan are running normal.
• Open Mill seal air damper and ensure Seal air DP > 700mmWC
• Fire Fighting steam MOV power supply ON
• Ensure HAG,CAG,HAD,CAD is closed condition in Local and ensure closed feedback
received in DCS.
• Ensure burner inlet gates open (4Nos) and feedback showing in DCS
• Ensure Mill motor EPB released condition
• Line up any one of lube oil filter
• Open lube oil cooler DMCW inlet & outlet MIVs
• Ensure mill lube oil motor supply is healthy.
• Start Electric heater & ensure it automatically cut off at 40 C
• If lube oil temp > 30oC then start lube oil pump and ensure lube oil pressure > 2 kg/cm2 and
flow >120 Lpm
• Keep another LOP in standby mode
START UP PROCEDURE
 
• Ensure all Four MDV’s are opened
• Ensure lube oil flow(>120lpm) and pressure > 1.5 bar & second pump in interlock
• Give open command for CAG and ensure gate is opening in local.
• After CAG open feedback received open CAD gradually to 100 % by maintaining PA Header pressure.
Ensure CAD is fully opened in local.
• Ensure mill pyrite hopper inlet valve open and outlet valve is closed
• Ensure mill start permissive is available
• Ensure SADC fuel air damper in AUTO or else open manually > 20% for respective coal mill.
• Start Coal mill and monitor motor current, mill parameters are normal.
• Inform field operator to check for any abnormalities in local.
• Give open command for HAG and ensure gate is opening in local.
• Gradually open HAD and close CAD to maintain PA flow about 95 TPH and mill outlet temperature as 55⁰C.
• Open coal feeder Outlet gate and ensure gate is opening in local.
• Ensure mill outlet temp around 55⁰C before feeding coal
START UP PROCUDURE

• Start coal feeder & ensure feed rate is 15 TPH (min)

• Gradually increase the feed rate (max 62 TPH) by maintaining mill outlet temperature.
Continuously monitor mill Current and other parameters while loading.
• Check for any coal leakages, fire or hot spots in local.
• Check mill flame condition at field and DCS Screen (Intensity>80%)
• Adjust Mill inlet PA flow (maximum 130 TPH) according to coal flow and maintain mill outlet
temperature about 58 to 62 degC.
• Periodically remove mill rejects by opening KGV-2 & KGV-3 and ensure mill rejects in local are
minimum.
• Do not exceed mill inlet PA temperature > 250 Deg C
• According to mill loading monitor boiler critical parameters
• Monitor the mill critical parameters regularly. Maintain Mill DP about 150 mmw
SHUTDOWN PROCEDURE
 
• Ensure all parameters are normal such as furnace draft, coal, air flow, drum level.
• Increase the feed rate in other mills if required
• Reduce the coal flow first and Then reduce the air flow to avoid blocking of coal
• Gradually minimize the coal feeder feed rate and maintain PA flow, mill outlet temp by adjusting
hot/cold air damper.
• If required increase the coal feed in other mills to maintain load.
• Reduce coal feed rate to minimum value (<15 TPH)
• Close Hot air damper, open CAD & maintain Mill O/L temp < 55 ⁰ C
• Close bunker outlet gate and stop the feeder
• Ensure HAG,HAD and feeder outlet gate close in auto.
• Open CAD & maintain Mill O/L temp < 55 ⁰ C for purging 5minutes
• Open the mill reject hopper gates & empty out the reject chamber
• Run the mill idle for 5 minutes until the mill gets empty
• Ensure inert is enable
• Stop the mill and inert will start in auto for 9 minutes
• Stop lube oil pump after all bearing temp of Mill reaches below 30⁰C
Trouble Shooting
Mill vibration Under Load:
1. Spring Compression too high - Reset Spring Compression
2. Improper assembly of bull ring segments - Assemble properly
3. Excessive wear of Bowl and extension ring - Replace Extension Ring. Build up bowl by weld deposit
4. Loosening of Separator body bolts - Tighten the Separator body bolts.
5. Roll to Bowl clearance - Adjust roll to bowl clearance.
6. Foreign material in mill - Take mill offline and remove foreign material

Mill Fire
1. High Mill outlet Temperature - Do not exceed mill o/l temp. recommend as per
volatile matter content in coal.
2. Coal settlement in mill - Do not leave coal in idle mill. Remove the coal either
manually or taking the mill in service.
3. Rapid change in moisture content of coal - Keep a close watch at mill outlet temperature.

4. Putting burning coal in mill - Empty the bunker and remove smoldering coal.
Trouble Shooting
Mill Coal spillage High
1. Over feeding - Reduce feeder speed/ coal feed to mill
2. Insufficient primary air flow - Correct the primary air flow quantity.
3. Jamming of rolls - Service the bearings and oil seals
4. Low Mill outlet temperature - Reduce Cold air, increase hot air supply.
Reduce feeder s feed/coal feed to mill.
5. Worn grinding roll - Replace roll/or Ring and adjustment.
6. Classifier set for higher fineness - Reset classifier Blades towards open position.

Mill outlet temperature High

5. Interrupted coal flow - Check & take necessary action
2. Hot air flow high - Open cold air and reduce hot air.
3. Fire in mill/ coal fed to mill - Check mill/feeder for fires, check coal flow is optimum
If this measure are not fruitful and temperature
continuous to rise, isolate mill & spray firefighting steam to quench
fire.
Case Study
Trip Report @ CEPL dated 29.06.2016
The sequence of event as recorded in DCS are as follows
1. 18.30.00 Hrs - Unit#1 was running at 300MW export with Mills B,C,D&
E in service. Further export load to be increased to 452MW from
19.00Hrs. Mill-A startup activities initiated.
2. Mill -1A Started at : 18Hrs .40 Min .17sec
3. Mill-1A puffed at : 18 Hrs . 41 Mins.36 Hrs
4. Extent of damage:
a) Corner 3 & 4 of Mill A expansion joint gave away at one location on each
corner.
b) Feeder – A lifted from its position.
c) At the corners mouth (3 &4) protective skin tear off.
SOE
Description DCS observation Remarks
  Time status  
Local Check   Normal  
DCS Mill start up permissive    OK  
Steam quenching activity 18.33.15 to   Mill reject Py. Hopper o/L
18.33.44 valve open condition and
water seen and quenching
stopped
Mill-A outlet fast valves in open 18.34.23 opened  
condition
Cold PA gate opening feed back 18.34.23 opened 18.35.54-45% flow 57T
18.37.06-80% flow 102T
Hot PA gate opening feedback 18.38.39 opened  
Mill reject valve open 18.38.50 opened  
Mill sealing Air & PA Diff Pressure 18.40.00 8.5 Kpa  
More than 2 Kpa
Mill Inlet PA flow More than 90 18.40.00 173 T/Hr 18.41.06 – Damper Open-5%-
T/Hr 170T,
18.41.38- Damper Open-5%
Mill A Roller Bearing Temp less 18.40.00 72.9 Deg C  
than 90 Deg C
Mill A out let temp more than 55 18.40.00 60.37 Deg C  
Deg C
Mill A out let temp less than 100 18.40.00 60.37 Deg C  
Deg C
Mill-A Lub oil system normal 18.40.00 Normal  
SOE

Description DCS observation Remarks

Coal Layer –A ignition 18.40.00 Available  
permission
MillA Hydraulic oil pump 18.40.00 Roller up  
running/ roller up condition condition

Breaker Available 18.40.00 Available  

Mill Motor start command 18.40.17   Mill current normal

Feeder outlet open 18.40.33 Normal  

Feeder start 18.40.35 Normal  

Feeder inlet open 18.40.57 Normal Full open time

Minimum coal feed rate 18.40.56 25 T/Hr  

ensured
Hot PA Damper opening 18.40.56 0%  

Coal Damper opening 18.40.56 85%  

PA flow 18.40.56 172.3  
PA inlet pressure 18.40.56 4.09 Kpa  

PA temp 18.40.56 80.8  

Mill outlet pressure 18.40.56 1.5Kpa  
Mill Outlet temp 18.40.56 60.7  
 Observations on DCS datas
• Mill –A was taken as per standard operating procedure.
• All the parameters are normal until -18.41.36 hrs when mill-A puffed.
• Air velocity on Corner # 1, 2, 3 & 4 at 18:41:20 were 23, 26, 23, 20.5 m/s respectively

  Possible reason.
• Operator ensured steam quenching as per normal operation procedure (i.e., ensuring water leaving the
reject hopper). However ,it might be not enough to quench amount of combustible gases present in the
system.
Remedial measures for future
• Steam quenching time to be increased but at the same time operator should not allow roller
temperature/ mill outlet temperature to raise in addition to the normal practice of ensuring water leaving
the reject hopper.
• Keep the furnace pressure around -150pascal while taking mill
• HEI supplied CO monitoring system to be installed & commissioned with support of WOM.
 Yo u
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