OPGS POWER GUJARAT PVT. LTD.

2X150MW

Title:

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

Procedure for Coal Mill Start-up:

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Standard Operating Procedure

Page 1 of 6

OPGS POWER GUJARAT PVT. LTD. 2X150MW

Title:

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

Standard Operating Procedure

Page 2 of 6

OPGS POWER GUJARAT PVT. LTD. 2X150MW

Title:

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out the
Coal Mill Start-up
2.0 Scope:
a) This Procedure is applicable to Coal Mills in Unit-1 & 2 of OPGS.
3.0 Responsibility:
a) All the personnel involved in carrying out /supervising the above activities are required to
ensure implementation of this procedure and may consult any other relevant documents
indicated under Reference section below.
b) In the event of any changes required in the procedure such changes may be requested
with Site MR, who would take appropriate action with approval from respective
departmental heads.
4.0 Procedure:

4.1

Definition:

OPGS Unit-1&2 is provided each unit with 5 Mill vertical roller type coal pulverizes (HP 803).
During starting of these mills, special precaution to be taken for smooth and accident free
operation. This procedure provides the guide lines for safe operation of these coal mills.

4.2

Scope of application

This procedure is applicable to all DCS operators and shift engineers for following the right
procedure during starting/stopping of coal Pulverizer. DGM (Operation) is responsible for
implementation of this procedure.
4.3

COAL MILL NORMAL STARTING PROCEDURE

4.3.1

Ensure PTW returned

4.3.2

Normalize power supply for mill, feeder, lube oil pump system, all dampers and

gates.
4.3.3

line up mill lube oil and cooling system

4.3.4

Ensure lube oil level normal.

4.3.5

Ensure PA header pressure and Seal air Header pressure OK.

Standard Operating Procedure

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OPGS POWER GUJARAT PVT. LTD. 2X150MW

Title:

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

4.3.6

Open bunker outlet gate and feeder seal air valve

4.3.7

Open all Mill Discharge Valve. Ensure isolation gates at furnace end in open

condition.
4.3.8

Open seal air valve and ensure seal air/PA DP low switch reset.

4.3.9

Open Cold air gate

4.3.10

Ensure ignition permissive for Mill starting.(If ignition permissive not came then

take support 3 oil guns)

4.3.11

While start mill ensure tramp Iron Gate should be open condition.

4.3.12

Start the mill after all permissive is OK. Open mill reject repeatedly till reject is

normal.
4.3.13

Gradually increase primary air to mill by seeing PA HDR Pressure. Maintain

furnace ve draft.
4.3.14

Open hot air gate. Increase hot air damper & bring the temp to 65Deg.C. PA flow

should be more than 30tph.

4.3.15

Open feeder inlet and outlet gates.

4.3.16

Start feeder (When all permissive are OK) and increase the feed rate to more

than 10%.
4.3.17

Ensure Mill Loading and coal flow normal in feeder.

4.3.18

Adjust the cold air & hot air dampers to maintain PA flow and mill outlet temp.

4.3.19

Check mill reject is normal. Mill is normal at field. Check flame condition at local

as well as on DCS screen.

4.3.20
4.4

Gradually load the mill by increasing feed rate and maintain PA/Coal feeding.

COAL MILL START UP PROCEDURE IMMEDIATE AFTER TRIPPING OF SAME MILL

/ HOT START UP.

4.4.1

Ensure furnace draught is normal, PA header Pr and seal air header Pr. Normal.

4.4.2

Ensure all HAD, CAD, HAG, CAG closed.

4.4.3

Open Mill discharge gates.

4.4.4

Open mill seal air valve.

4.4.5

Purge the mill with inerting steam for few minutes.

4.4.6

Open cold air Gate & Damper and reduce the mill outlet temp below 70deg.C

4.4.7

Take oil guns for ignition permissive.(if necessary)

Standard Operating Procedure

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OPGS POWER GUJARAT PVT. LTD. 2X150MW

Title:
4.4.8

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

Maintain mill outlet temp 60Deg.C and air flow >30TPH by adjusting Hot air and cold air

dampers.
4.4.9

Start the mill and follow mill normal starting procedure from SL No 11 onwards.
4.5

MILL SHUTDOWN PROCEDURE

4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.5.8

First reduce the mill outlet temp gradually to < 65deg.C

Reduce the coal feed rate by maintaining mill outlet temp < 65 Deg.C
Reduce coal feed rate to minimum (10 to 15%). with Maintain primary air flow.
Open cold air damper to max. Required & close hot air damper.
Stop the feeder.
Purge the mill with cold air until mill outlet temp reduces to < 55 Deg.C
Cut off PA flow & Stop the mill and ensure MDV close and seal air close.
Check PA header pressure and in case off any PAF stalling so adjust the PCD to

remove stalling.
4.5.9
Open MOV inerting steam for 5 minutes to purge out any combustible gas.

4.6

MILL START UP REQUIRED PARAMETERS.

4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
4.6.8

4.7

Lube oil level Adq.(Normal)

Lube Oil Pr.> 4.5 Bar.
Pulverizer O/L Temp <80 C
Mill Seal Air to PA DP Adq. (Normal)>245mmwc
Tramp Iron valve open condition.
Mill Bearing temperature <50C.
Motor Winding Temp. <50C
CAG open condition.

MILL TRIPPING CONDITION:

4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9
4.7.10
4.7.11

Loss of any PA fan or PA HDR Pr. Low <500MMWC.

Lube Oil Pr. V. Low <3.0 Bar.
HAG Close And CAG Not Open.
Mill Bearing temperature >80C.
Motor bearing temperature >80C.
Motor winding temperature >90C.
System protection with MFT/Run back.
Motor electrical protection act.
MDV Close Feedback.
Seal Air to PA DP Low <245MMWC.
Any Burner Isolation Gate Close feedback.

Standard Operating Procedure

Page 5 of 6

OPGS POWER GUJARAT PVT. LTD. 2X150MW

Title:

Document No.

Issue No/Date

Revision No/Date

OPGS/OPN/SOP/01

01/27.08.2016

00/27.08.2016

Procedure for Coal mill start-up and shut down

5.0 References
5.1 Coal Mill O & M Manual

6.0 Records
6.1 Shift in Charge Engineer log book(OPGS/OPN)
6.2 Boiler DCS Engineer log sheet (OPGS/OPN)

Standard Operating Procedure

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