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Ash problems
 

Ash problems

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Ash handling plant issues encountered at bellary site....

Ash handling plant issues encountered at bellary site....

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    Ash problems Ash problems Presentation Transcript

    • ASH HANDLING PLANT PROBLEMS
      JISHNU V
      EMP NO-6106188
      BHEL ISG
    • PREVIEW
      EXCESSIVE COAL PILE DUST
      SPECS AND TESTS TO GET BETTER COAL
      UNEXPECTED COSTS IN BURNING COAL
      CUTTING COAL MAINTENANCE
      OLD PIPING SYSTEM
    • 1) EXCESSIVE COAL PILE DUST
      Problem description: Dust from coal pile blowing out to nearby houses- coal pile is a strip which is 1000ft long and 80 ft deep- Capacity of pile is around 30K tons now
      My suggestions:
      Occasional water spraying (install permanent water sprinkler)
      Dead storage should have semi permanent surface protection
       Use of fugitive dust control polymers
       Provision for thermal expansion and contraction of coal pile
    •  Construction of concrete enclosure for coal pile
       Use of chemical sprays/petroleum resin/water emulsion
       Chemical crusting as dust controller
      Proper compacting of pile to ensure competent base for crust
       2:1 slope for sides, sharp edges and ridges for piles
       Tank truck with a pump that can develop enough pressure to spray all portions of stock pile
       Weathering of coal piles can be prevented by latex polymer
    • 2) SPECS AND TESTS TO GET BETTER COAL
      Problem description: The quality of coal in the last delivery has been below par. The reliable methods for weighing various factors to compare coals are not properly implemented.
      My suggestions:
      • Following test analysis should be performed asap before the next delivery
      a) ASTM NO D-409 (Coal grindability)
      b) ASTM NO D-441 (fritability)
      c) ASTM NO D-1857 (Ash fusibility)
      d) ASTM NO D-3173 (Moisture content)
    • e) ASTM NO D-3174 (Moisture content)
      f) ASTM NO D-3179 (Nitrogen content)
      g) ASTM NO D-3177 (Total sulfur)
      h) ASTM NO D-2015 (Gross calorific value)
      • NB: Samples should be taken for test, when coal is in motion
      • Bonus penalty arrangements
      • Review of coal specs: Ash softening temperature, grindability and delivery methods emphasized
    • Check if fuel saving equipment like economizer was initially added or not in stage I
    • 3) UNEXPECTED COSTS IN BURNING COAL
      Problem description: Excessive money invested in setting up big coal stack pile resulting in a delusion of safety. The flexibility in ash handling arrangement (ASHA) is really low
      My suggestions:
       The only possible solution is complete rework of the philosophy
    • 4) CUTTING COAL HANDLING MAINTENANCE
      Problem description:
      Maintenance of conveyors, crushers, vibrating feeders, elevators are really expensive
       Abrasion and belt wear seems to be really high
       Conveyor roller bearings are to changed at a frequency of 1 in 8 days
       Corrosion issues are more frequent
    • My suggestions:
      A) Predictive maintenance
       Operators should be alerted with noisy bearings, small breaks in belting and vibration in drives
       Lubrication, filter cloth replacement and induced draft fan cleaning program should be more frequent
      B) Predictive maintenance
      • i) Equipment adjustment
      • ii) Repairs
    • iii) Overhaul
       iv) Lubrication
      • Other possible solutions are listed below
      • Use of impact idlers
      • Coal from coal chute should be fed at the speed of conveyor belt movement
      • In order to get rid of excessive belt sagging, idler spacing and belt tension should be appropriate. The associate calculation sheets are attached
      • Prevent coal build up in the belt; scrappers can help
    • Avoid belt misalignment
      Effective bearing assembly scaling
    • 5) OLD PIPING SYSTEM
      Problem description: Inadequate capacity in some sections, corrosion and internal deposits, poor line supports, leaking valves and joints
      My suggestions:
      A) Stop line joint leakage
      B) Replace leaking valves, traps; batch repair for small valves
      C) Making up more hangers and supports
      D) Assign 1 more survey engineers
    • QUERIES
    • THANK YOU