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Published

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

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

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  • 1. ASH HANDLING PLANT PROBLEMS
    JISHNU V
    EMP NO-6106188
    BHEL ISG
  • 2. PREVIEW
    EXCESSIVE COAL PILE DUST
    SPECS AND TESTS TO GET BETTER COAL
    UNEXPECTED COSTS IN BURNING COAL
    CUTTING COAL MAINTENANCE
    OLD PIPING SYSTEM
  • 3. 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
  • 4.  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
  • 5. 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)
  • 6. 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
    • 7. Bonus penalty arrangements
    • 8. 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
  • 9. 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
  • 10. 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
  • 11. 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
    • 12. ii) Repairs
  • iii) Overhaul
     iv) Lubrication
    • Other possible solutions are listed below
    • 13. Use of impact idlers
    • 14. Coal from coal chute should be fed at the speed of conveyor belt movement
    • 15. In order to get rid of excessive belt sagging, idler spacing and belt tension should be appropriate. The associate calculation sheets are attached
    • 16. Prevent coal build up in the belt; scrappers can help
  • Avoid belt misalignment
    Effective bearing assembly scaling
  • 17. 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
  • 18. QUERIES
  • 19. THANK YOU