Ash problems

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

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Ash problems

  1. 1. ASH HANDLING PLANT PROBLEMS<br />JISHNU V<br />EMP NO-6106188<br />BHEL ISG<br />
  2. 2. PREVIEW<br />EXCESSIVE COAL PILE DUST<br />SPECS AND TESTS TO GET BETTER COAL<br />UNEXPECTED COSTS IN BURNING COAL<br />CUTTING COAL MAINTENANCE<br />OLD PIPING SYSTEM<br />
  3. 3. 1) EXCESSIVE COAL PILE DUST<br />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<br />My suggestions: <br /> Occasional water spraying (install permanent water sprinkler)<br /> Dead storage should have semi permanent surface protection<br />  Use of fugitive dust control polymers<br />  Provision for thermal expansion and contraction of coal pile<br />
  4. 4.  Construction of concrete enclosure for coal pile<br />  Use of chemical sprays/petroleum resin/water emulsion<br />  Chemical crusting as dust controller<br /> Proper compacting of pile to ensure competent base for crust<br />  2:1 slope for sides, sharp edges and ridges for piles<br />  Tank truck with a pump that can develop enough pressure to spray all portions of stock pile<br />  Weathering of coal piles can be prevented by latex polymer<br />
  5. 5. 2) SPECS AND TESTS TO GET BETTER COAL<br />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. <br />My suggestions: <br /><ul><li>Following test analysis should be performed asap before the next delivery</li></ul>a) ASTM NO D-409 (Coal grindability)<br />b) ASTM NO D-441 (fritability)<br />c) ASTM NO D-1857 (Ash fusibility)<br />d) ASTM NO D-3173 (Moisture content)<br />
  6. 6. e) ASTM NO D-3174 (Moisture content)<br />f) ASTM NO D-3179 (Nitrogen content)<br />g) ASTM NO D-3177 (Total sulfur)<br />h) ASTM NO D-2015 (Gross calorific value)<br /><ul><li>NB: Samples should be taken for test, when coal is in motion
  7. 7. Bonus penalty arrangements
  8. 8. Review of coal specs: Ash softening temperature, grindability and delivery methods emphasized</li></li></ul><li>Check if fuel saving equipment like economizer was initially added or not in stage I<br />
  9. 9. 3) UNEXPECTED COSTS IN BURNING COAL<br />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<br />My suggestions:<br /> The only possible solution is complete rework of the philosophy<br />
  10. 10. 4) CUTTING COAL HANDLING MAINTENANCE<br />Problem description: <br />Maintenance of conveyors, crushers, vibrating feeders, elevators are really expensive<br /> Abrasion and belt wear seems to be really high<br /> Conveyor roller bearings are to changed at a frequency of 1 in 8 days<br /> Corrosion issues are more frequent<br />
  11. 11. My suggestions: <br />A) Predictive maintenance<br /> Operators should be alerted with noisy bearings, small breaks in belting and vibration in drives<br /> Lubrication, filter cloth replacement and induced draft fan cleaning program should be more frequent<br />B) Predictive maintenance<br /><ul><li>i) Equipment adjustment
  12. 12. ii) Repairs</li></li></ul><li>iii) Overhaul<br /> iv) Lubrication<br /><ul><li>Other possible solutions are listed below
  13. 13. Use of impact idlers
  14. 14. Coal from coal chute should be fed at the speed of conveyor belt movement
  15. 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. 16. Prevent coal build up in the belt; scrappers can help </li></li></ul><li>Avoid belt misalignment<br />Effective bearing assembly scaling<br />
  17. 17. 5) OLD PIPING SYSTEM<br />Problem description: Inadequate capacity in some sections, corrosion and internal deposits, poor line supports, leaking valves and joints<br />My suggestions: <br />A) Stop line joint leakage<br />B) Replace leaking valves, traps; batch repair for small valves<br />C) Making up more hangers and supports<br />D) Assign 1 more survey engineers<br />
  18. 18. QUERIES<br />
  19. 19. THANK YOU<br />

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