MINIMISING THERMAL LOSSES FROM

PULVERIZED COAL PIPE LINES

INTRODUCTION
At NCPS-Dadri, the 4x210 MW Units supplied by BHEL
are equipped with XRP-883 Bowl Mills. Originally these
mills were supplied for the first time in our country.
The raw coal supply is received from North Karanpura
Coal Fields.
From April97 onwards washed coal (Ash 34%) supply
commenced from Piparwar washery to NCPS Dadri.

TECHNICAL SPECIFICATION OF XRP883 BOWL MILL

Max. Mill capacity with design coal-47.9 T/Hr.
Input acceptable coal size - 20 mm.
Fineness - 70% through - 200 BS Sieve.
Pulveriser Speed - 43 rpm.
No. of mills working when firing worst coal-5.
Driver Motor - 425 KW, 6.6 KV, 600 rpm.
Max. Air Flow - 76.75 T/Hr.
Mill inlet air temp. for design coal-275 C.
Mill outlet temp. - 77 C.
Grinding roll size - 43.
No. of mills per boiler - 6.
No. of mills working when firing design coal-4.

DESIGN ASPECTS OF XRP-883

BOWL MILL
STEADY FINENESS THROUGHOUT THE LIFE OF
GRINDING ELEMENTS IS MAINTAINABLE DUE TO
CAPACITY MARGIN.
NO CONTAMINATION OF GEAR BOX OIL DUE TO BETTER
SEALING SYSTEM.
FAST RESPONSE TO BOILER LOAD DEMAND.
TROUBLE FREE EXTERNAL LUBRICAION SYSTEM.
BETTER LAYOUT FOR EASY APPROACH TOWARDS
MAINTENANCE AND HOUSE KEEPING.

DESIGN ASPECTS OF XRP-883 BOWL

MILL [Contd]
[A]

FRONT MILL LAYOUT TG-MILL-BLR-APH-ESP-CHIMNEY

Note : Congested for maintenance activity.
[Example - RAMAGUNDAM 200 MW UNITS]
[B] REAR MILL LAYOUT - 1
TG-APH-BLR-MILL-ESP-CHIMNEY
[Example : VIJAYWADA 210 MW UNITS]
Note : 1.25 times costlier than normal boiler
[C] REAR MILL LAYOUT -2
TG- BLR-APH-MILL-ESP-CHIMNEY
[Example : DADRI 210 MW UNITS]

SALIENT CONSTRUCTIONAL FEATURES

OF XRP-883 BOWL MILL
External lubrication oil system for Gear Box.
Continuous flow of oil to bearings and gears is
ensured.
Vertical shaft oil hole for lubrication of top radial
bearing through in built pump is eliminated. (Hole in
the shaft weakens the V.S. and leads to premature
failure.)
Mechanical face seal provided in place of dust guard seal
to prevent air and dust leakage from mill side housing to
atmosphere.
Heavy duty cylindrical shaft instead of earlier tapered shaft
design averted shaft failures. Reliability and availability of
mill is ensured through longer life of vertical shaft.

SALIENT CONSTRUCTIONAL FEATURES OF

XRP-883 BOWL MILL (Contd.)
Tall top classifier design for improvised fineness of
pulverised fuel thereby reducing the carbon loss in the
furnace bottom ash.
Ceramic lined Venturi vanes and Ni-hard classifier blades
for higher life against erosion.
Ceramic lined Venturi vanes and Ni-hard classifier blades
for higher life against erosion.
Internally ceramic lined classifier cone for longer life and
consistent performance of pulveriser.
Single
journal stop bolt design instead of 2
(XRP 803) for better adjustment.

SALIENT CONSTRUCTIONAL FEATURES OF

XRP-883 BOWL MILL (Contd.)
Bearing less horizontally mounted heavy duty spring
assy. for journals.
Large diameter roll (43) in place of 36/37 dia for XRP
803 mill.
Replaceable wear ring on journal shaft is provided to
avoid groove formation in oil seal seating area.
Better design of heavy duty insulation cover plate
(25mm thk) instead of 12mm in XRP 803 Mill.
Cast steel Mill Bottom instead of C.I.

SALIENT CONSTRUCTIONAL FEATURES OF

XRP-883 BOWL MILL (Contd.)
Heat shield arrangement is provided for bowl hub. No
such type of arrangement is provided in XRP 803 Mill.
Heavy duty two row tapered roller bearing (Torrington
97 TSDI 452 BD 1482 H5) for journal assy. Upper
bearing Instead of single row tapered roller bearing In
XRP 803 Mill.

ROUTINE TESTING

Performance Tests at Dadri Coal Station

Background
Dadri Coal Selected as Candidate Plant under GEP
Project: May1996
Performance Optimisation Test of Boiler: Sept1996.
High Volume Sampler Test: Sept1996.
CEGRIT Sampler: Oct1996
High Velocity Thermocouple Test: Oct1996
Air-Fuel Ratio Test: Oct1996
Clean Air Flow Test: April1995

Performance Tests at Dadri Coal Station

Background
Turbine, HP/LP Heater, Condenser & BFP Test:
Nov1996
Helium Leak Detection Test: July1997
EPA Method-5 Test of ESP: Sept1997
CONCO Condenser Tube Cleaning: April1997
CW Dye Dilution Test in Unit-4: May1999
64-Point Rotary Coal Sampler Test: March2002

Performance Tests at Dadri Coal Station

PERFORMANCE & EFFICIENCY TEST 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04
BOILER
BOILER EFFICIENCY TEST
HIGH VELOCITY THERMOCOUPLE TEST
SEAL LEAK TEST
RAPH PERFORMANCE TEST
CEGRIT SAMPLER / HVS TEST
UNBURNT CARBON TEST
C.A.V.T TEST

8
16
16
16
60
16
-

8
8
16
16
60
60
-

8
8
48
48
256
96
-

8
8
48
48
231
96
-

8
10
48
48
209
96
2

4/8
2/10
34/60
96/220
58/96
-/4

48
24
24

96
18
7

96
24
24

96
24
10

102
26
16

33/90
6/26
7/18

64
16

32
12

40
16

40
16

40
16

12/40
4/16

8
8
-

12
12
-

16
12
-

16
28
-

16
12
-

9/16
5/8
10/10

24
40

8
8

4
4

4
6

8
8

4/16
5/8

COOLING TOWER PERFORMANCE TEST

5/8

CERC TEST
TOTAL NO. OF EFFICIENCY TESTS

44

32/48

388

373

708

687

717

326/702

COAL MILLS
AIR-FUEL RATIO TEST
CLEAN AIR FLOW TEST
HOT AIR FLOW TEST

ESP
THIMBLE TEST
GAS DISTRIBUTION TEST

CONDENSER
HELIUM LEAK DETECTION TEST
CONDENSER PERFORMANCE TEST
CONDENSER FLOW MEASUREMENT TEST

TURBINE & HEATERS

TURBINE CYLINDER EFFICIENCY TEST
HP/LP HEATER PERFORMANCE TEST

COOLING TOWER

NB: In year 2003-04, number of tests are indicated as [ No of Test Done / No. of Test Envisaged]

NEW
TECHNOLOGY

Hot Air Traverse Test in Coal Mill-2B

Background
A gap of 8-10 T/Hr was noticed between P.A Flow
UCB indication and 'Air-Fuel' ratio test measurement.
It was expected phenomenon because of change of
venturimeter characteristic due to wear of venturimeter
'throat' which in turn was due to its continuous use
since first commissioning of unit on 01/02/1994.
Such venturi would
produce
lesser DP and
consequently give lower PA flow indication in UCB for
same quantity of actual PA Flow.

Hot Air Traverse Test in Coal Mill-2B

Test & Measurements
Hot Air Traverse Test was done using calibrated
'sealed' type-S & type-L pitot, inclined manometer,
K-Type Thermocouple etc.
Pitot DP was measured and PA flow was calculated
at the downstream of venturimeter.
PA Flow venturimeter DP was measured.
3 number of Test runs were done i.e. PA Flow and
venturi DP were measured at 3 different Air Loads.

Hot Air Traverse Test in Coal Mill-2B

S.No

Details

Run - I Run - II

Run - III

UCB P.A.Flow

80.31

72.00

47.10

Test P.A.Flow

83.76

74.09

51.28

Test Air Temperature

238.10

258.88

269.50

Test Venturimeter DP

107.0

83.0

57.0

Corrected Venturimeter DP | 300 C

119.96

89.42

60.20

Corrected Venturimeter DP | 250 C

109.49

81.61

54.95

Corrected Venturimeter DP | Design=224 C

104.05

77.56

52.22

Corrected Venturimeter DP | 200 C

99.02

73.81

49.70

Corrected Venturimeter DP | 180 C

94.84

70.69

47.60

Hot Air Traverse Test in Coal Mill-2B

Venturimeter Characteristic Curve & DP Trasnmitter
Settings[ 300 C Temp]
120
y = 0.3166 x (DP-89.42) +74.09

P.A Flow [Tons/Hr]

100

New DPT Settings:

141 mmWC

Venturimeter
Characteristics

80

Old DPT Settings:

158 mmWC
60

40

20

0
0

20

40

60

80

100

120

Corrected Venturimeter DP [mmWC]

140

160

180

Hot Air Traverse Test in Coal Mill-2B

Observations
1 The gap between measured P.A Flow and UCB indication is not
constant. It varies with PA Flow as well the PA Temperature.
2 The gap in PA Flow measurement varies from approximately 4
T/Hr to 6 T/Hr depending on air load of mill.
3 There is a temperature difference of 25C-80C between Test & UCB
PA Temperature depending on the CAD opening.

Corrective Action
1 Corrected Venturi DP corresponding to 300 C and 90 T/Hr PA Flow
was provided to C&I for recalibration of DP Transmitter.
2 Initial DP Transmitter setting for 90T/Hr flow and 300 C was 158
mmWC.
3 New DP Transmitter setting for 90T/Hr flow and 300 C is 141
mmWC.

Hot Air Traverse Test in Coal Mill-2B

Impact of New Characteristic Curve of Venturimeter

S.No Parameters

Unit

Process Parameter
[Old Characteristic Curve]

1 P.A.Flow
2 HAD Opening
3 CAD Opening
4 Mill Outlet
Temp
5 Mill DP
6 Coal Flow
7 Unit Load
8 Total Coal Flow
9 Total SA Flow
10 Total PA Flow
11 Total Air Flow
12 ID Fan Current
13 FD Fan
Current
14 PA Fan
Current
15 Mill Current

Process Parameter

Impact

[New Characteristic Curve]

Tons/Hr
%
%
C

76.2
30.4
40.3
83.9

80.4
30.2
39.8
84.5

+ 4.2 T/Hr
-

mmWC
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Amps
Amps

195
31.0
145.6
104.7
415
287
702
94.6 / 95.6 = 189.9
72.9 / 70.4 = 143.3

196
30.9
147.5
102.7
416
292
708
94.1 / 95.2 = 189.3
72.6 / 71.1 = 143.7

+ 5 T/Hr
+ 6 T/Hr
-

Amps

46.2 / 44.9 = 91.1

46.2 / 45.2 = 91.4

Amps

34.1

33.7

Impact of Optimization with New Characteristic Curve of Venturimeter

S.No Parameters

Unit

Process Parameter
[New Ch Curve: Unoptimized]

1 P.A.Flow
2 HAD Opening
3 CAD Opening
4 Mill Outlet
Temp
5 Mill DP
6 Coal Flow
7 Unit Load
8 Total Coal Flow
9 Total SA Flow
10 Total PA Flow
11 Total Air Flow
12 ID Fan Current
13 FD Fan
Current
14 PA Fan
Current
15 Mill Current

Process Parameter

Impact

[New Ch Curve: Optimized]

Tons/Hr
%
%
C

80.4
30.2
39.8
84.5

69.4
29.8
20.8
87.2

- 11 T/Hr
-0.4%
-19%
+ 2.7 C

mmWC
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Tons/Hr
Amps
Amps

196
30.9
147.5
102.7
416
292
708
94.1 / 95.2 = 189.3
72.6 / 71.1 = 143.7

174
30.9
147.7
104.2
422
280
702
93.1 / 93.9 = 187.0
71.3 / 69.5 = 140.8

- 22 mmWC
+ 6 T/Hr
- 12 T/Hr
- 6 T/Hr
- 2.3 Amps
- 2.9 Amps

Amps

46.2 / 45.2 = 91.4

47.1 / 45.1 = 92.2

+ 0.8 Amps

Amps

33.7

33.8

Hot Air Traverse Test in Coal Mill-2B

Confirmatory Test
Confirmatory Hot Air Traverse Test was done on 20th-June'2K3.
Following was the result: Test PA Flow - 71.07 T/Hr, UCB PA Flow
- 70 T/Hr, Venturimeter DP - 76 mmWC.

Results
1 PA Flow in Mill-2B reduced by 11 T/Hr, 4.2 T/Hr due to calibration
and 6.8 T/Hr due to further optimization. It is an improvement of
13.7% .
2 HAD & CAD opening reduced from 30.2% to 29.8% and 39.8% to
20.8% respectively. It is an improvement of 1.3% and 47.7%
respectively.
3 Mill outlet temperature improved by 2.7C which is an improvement
of 3.2%.
4 Mill DP reduced by 22 mmWC which is improvement of 11.2%.
5 Fan current reduced by 4.4 Amps without any adjustment in O2
setpoint which is an improvement of approximately 1%.

NEW
TECHNOLOGY

Coal Pipe Orifice Re-sizing

Background
Coal Mills are located in MN Bay between Boiler & ESP.
4 number of coal pipes emerge from each of the coal mills and
terminate at 4 burner blocks of Boiler.
Hence, length on Coal Pipe to each corner is different and
consequently so is theFlow Resistance.
Orifices are installed in Coal Pipes to equalise the Coal Flow.
Clean Air Flow Test is done in each Coal Mill after the Unit
overhaul. Clean Air balance is achieved between +/- 2%.
Air-Fuel Ratio Test is done in On-Load condition. Following
balancing is expected: Hot Air balance between +/- 5% & Coal
Flow balance between +/- 10%.
However, coal flow distribution of 25% in each Coal Pipe is
generally not achieved.

Coal Pipe Orifice Re-sizing

Present Approach
Upto now, the approach to achieve the desired Coal & Hot PA balance

was to further tighten the Clean Air balance below +/- 2% and to
inspect & replace the Coal Pipe Orifices.

New Approach
New approach is to create a calculated and controlled imbalance in

Cold condition in a way to achieve Balanced Coal Flow & Hot PA

Flow in On-Load condition.
It is to be done by changing the size and profile of Orifice.

Development & Trial of New Approach

This new approach has been developed by Prof. Sastry Munukutla of
Tennessee Technological University - USA
Dadri Coal Station provided all the Geometrical & Process details to
TTU-CEP, US for calculations of new Orifice sizes.

Coal Pipe Orifice Re-sizing

Station desired that the location of Orifice should remain same.
One Coal Mill [Mill-3E] was selected for trial.
1 set of 3 number of SS Orifices were fabricated at station.
1 Baseline test was done to find out Coal Flow distribution in all the
4 pipes with new Orifices of existing design & dimension.
New SS Orifices of resized dimension were installed.
3 runs of Air-Fuel Ratio Test & 2 runs of 64 Point Rotary Coal
Sampler Test were done to determine Coal Flow distribution in
pipes with new re-sized Orifices.
TOTAL LENGTH OF COAL PIPES [Meters]
Mill No

Pipe-1

Pipe-2

Pipe-3

Pipe-4

Mill-E

78.15

66.87

43.29

54.57

SIZE & NUMBER OF ORIFICES IN COAL PIPES

Mill No

Pipe-1

Pipe-2

Pipe-3

Pipe-4

Mill-E

463 mm at 1 Mtr distance

448 mm at 1 Mtr distance

437 mm at 1 Mtr distance

448 mm at 40 Mtr distance

TYPE & NUMBER OF BENDS IN COAL PIPES

Mill No

Pipe-1

Pipe-2

Pipe-3

Pipe-4

Mill-E

5 nos. of following angle (in degrees)

3 nos. of following angle (in degrees)

2 nos. of following angle (in degrees)

4 nos. of following angle (in degrees)

[1650, 900, 1600, 1600, 1350]

[1650, 900, 1350]

[1650, 1350]

[1200, 1600, 1600, 1350]

Coal Pipe Orifice Re-sizing

Base Line Test - Dirty Pitot Test : 28th May'2003
Cr-1

Cr-2

Cr-3

Cr-4

Test Coal
Sample [Grm]

390.31

367.31

701.81

435.81

Coal Flow
Distribution [%]

20.6

19.4

37.0

23.0

Coal Flow Distribution Test

20

20.6

15

23.0

17.6
12

10
19.4

5
0
-5

37.0

Max

Min
-5.6

-10
Cr 1

Cr 2

Cr 3

Cr 4

Span

Max

Min

Span

Corner
No

Old
Orifice Size

New
Orifice Size

1
2
3
4

463
448
437

430.5
389.7
396.2

CLEAN AIR BALANCING CALCULATIONS

Loss Coeff Velocity
Velocity
Pipe Loss Coef
[K-Old]
[K-New]
[%-Old]
[%-New]
No
1

2.7110

2.7110

85.9721

119.4707

2.3060

3.5500

93.2179

104.4035

1.4299

5.4849

118.3791

83.9934

1.9098

4.5586

102.4309

92.1324

COAL-AIR MIXTURE BALANCING CALCULATIONS

Pipe
No
1
2
3
4

Loss Coef
[K-Pipe]
8.0046
6.7606
3.9496
5.3558

Loss Coef
[K-Orifice]
0.0000
1.2440
4.0550
2.6488

Loss Coef
[K-Total]
8.0046
8.0046
8.0046
8.0046

Old
Velocity
84.4905
91.9361
120.2817
103.2917

New
Velocity
100.00
100.00
100.00
100.00

Coal Pipe Orifice Re-sizing

Dirty Pitot Test No. 1: 15th July'2003
Cr-1

Cr-2

Cr-3

Cr-4

Test Coal
Sample [Grm]

397.81

269.81

502.31

443.31

Coal Flow
Distribution [%]

24.7

16.7

31.1

27.5

Coal Flow Distribution Test No. 1

24.7
27.5

16.7

31.1

Cr 1

Cr 2

Cr 3

Cr 4

Dirty Pitot Test No. 1 : 18th July'2003

Cr-1

Cr-2

Cr-3

Cr-4

Test Coal
Sample [Grm]

428.31

292.81

459.81

293.31

Coal Flow
Distribution [%]

29.1

19.9

31.2

19.9

Dirty Pitot Test No.2 : 18th May'2003

Cr-1

Cr-2

Cr-3

Cr-4

Test Coal
Sample [Grm]

466.81

353.31

522.81

261.31

Coal Flow
Distribution [%]

29.1

22.0

32.6

16.3

Coal Flow Distribution Test No. 1

19.9

Coal Flow Distribution Test No. 2

16.3
29.1

29.1

31.2

19.9

Cr 1

Cr 2

Cr 3

Cr 4

32.6
22.0

Cr 1

Cr 2

Cr 3

Cr 4

Coal Pipe Orifice Re-sizing

Dirty Pitot Test Summary
Cr-1

Cr-2

Cr-3

Cr-4

Test Coal
Sample [Grm]

430.98

305.31

494.98

332.64

Coal Flow
Distribution [%]

27.6

19.5

31.7

21.3

Coal Flow Distribution After

Orifice Resizing
27.6

21.3

20

17.6

15
10

12.2

12

6.7

5
0
19.5
31.7

-5
-10

Cr 1

Cr 2

Cr 3

Cr 4

Max

Min
-5.5

Re-Sized Orifice

Span

-5.6
Original Orifice

NEW
TECHNOLOGY

Insulation of Coal Pipes

At NCPS-Dadri, all the 6 coal mills are located at the rear of the
Boiler in M-N Bay.

The total length of coal pipe for Mill B, C, D, E is 242.88 meter

and for Mill A & F is 266.46 meter respectively.

All the coal pipes were uninsulated in original design.

This inordinately long coal pipe has caused a significant loss of

thermal energy and drop in coal- air mixture temperature near
the entry point of furnace.

Traditionally, no temperature measurement is provided in

individual coal pipes near furnace end.

Hence, this phenomenon was not identified and established up to

the point when tests like Air-Fuel ratio test were conducted and
the findings were confirmed with Thermal imaging of coal pipes.

Insulation of Coal Pipes

Initial Observations:
Average Temperature drop from Mill end to Burner end
Summer Season, Un-Insulated Coal Pipe = 5.5 Degree C
Winter Season, Un-Insulated Coal Pipe = 8.0 Degree C

Problem Experienced:

Significant loss of Thermal energy from coal pipes.

Average Heat loss in Winter = 34,212,495,360 Kcal / Year
Average Heat loss in Summer = 23,521,090,560 Kcal / Year
Average Annual Heat loss = 27,084,892,160 Kcal / Year

Insulation of Coal Pipes

Methodology Adopted:

Study was done for full one year to observe the pattern of loss of
thermal energy from coal pipes both in Winter as well as in
Summer season.
All four coal pipes of one coal mill [Mill 1E] was insulated with
25mm Mineral wool pad for trial purpose.
Measurement of following parameters were done:
Coal-Air mixture Temperature: (a) Insulated & Un-Insulated
Coal Pipe (b) Mill end & Burner End (c) Winter & Summer
Season
Coal-Pipe Surface Temperature: (a) Insulated & Un-Insulated
Coal Pipe (b) Mill end & Burner End (c) Winter & Summer
Season
Length of coal pipes were taken from manufacturers drawing.

Insulation of Coal Pipes

Methodology Adopted (contd) :

Heat loss was computed for both insulated and uninsulated coal
pipe for winter as well as summer season.
Average saving of Thermal energy was done assuming four
winter months and eight summer months.

Techniques & Instruments Used:

AirFuel ratio test: Measurement of coal flow, airflow, static

pressure, air velocity and temperature in individual coal
pipes.
Thermovision Camera: Thermal imaging of insulated and
uninsulated coal pipes.
Non-Contact
Infra-Red
Thermometer:
Extensive
measurement of surface temperature of coal pipes.
Shielded K-type Thermocouple: Measurement of Coal-Air
mixture temperature in coal pipes.

Insulation of Coal Pipes

Final Observations:
Average Temperature drop from Mill end to Burner end
Summer Season, Insulated Coal Pipe = 2.8 Degree C
Winter Season, Insulated Coal Pipe = 3.2 Degree C

Findings:

Thermal energy from coal pipes after its insulation.

Average Heat loss in Winter = 13,684,998,144Kcal / Year
Average Heat loss in Summer = 11,974,373,376 Kcal / Year
Average Annual Heat loss = 12,544,581,632 Kcal / Year
Avg. Saving due to Insulation = 14,540,310,528 Kcal / Year
Average Annual Saving of Eqv. Oil = 1,454 KL / Year
Average Annual Saving of Eqv. Coal = 3,930 Tons / Year

Insulation of Coal Pipes

Cost of Insulation of Insulation and Cladding:

Cost of 25 mm Mineral Wool insulation = 38 Rs/Sq.Mtr

Surface Area of 4 Coal Pipes of a Coal Mill = 650 Sq. Mtr

Cost of insulation of Coal Pipes of 1 Coal Mill = Rs.

24,700 /- [Cost of 25 mm M.W insulation = 38 Rs/Sq.M,
Surface Area of 4 Coal Pipes = 650 Sq.M]

Cost of sheeting of Coal Pipes of 1 Coal Mill = Rs.

1,46,900 /- [Cost of 0.91 mm G.I.Sheet = 38 Rs/Sq.M,
Surface Area of 4 Coal Pipes = 650 Sq.M]

Total cost of insulation and sheeting of Coal Pipes of 1

Coal Mill = Rs. 1,71,600 /-

Insulation of Coal Pipes

Cost Benefit Analysis:

Cost of insulation of coal pipe of one coal mill = Rs. 24,700

Cost of cladding of coal pipe of one coal mill = Rs. 1,46,900
Cost of insulation and cladding of coal pipe of one coal mill =
Rs. 1,71,600
Monetary saving from one coal mill in Winter season = Rs.
1,710 / Mill / Day
Monetary saving from one coal mill in Summer season = Rs.
962 / Mill / Day
Average annual monetary savings = Rs. 1,211 / Mill / Day
Pay back period during Summer = 178 Days
Pay back period during Winter = 100 Days
Average pay back period = 142 Days

Insulation of Coal Pipes

Break Even Analysis
700,000
600,000

Rupees

500,000
400,000
300,000
200,000
100,000
0

50

100

150

200

250

300

350

400

No of Days of Operation

Cost of Insulation

Cost of Sheeting

Cost of Insulation + Sheeting

Cum. Saving: Summer

Cum. Saving: Average

Cum. Saving: Winter

The findings were also vetted by M/s NPC & during ISO Audit.
After the study, Coal Pipes of Mill-1B,1C,1D,1E were also insulated.
Readings obtained from the above Mills has also confirmed the findings.

Findings of M/s NPC : Insulation of Coal Pipes

Heat loss and Saving Potential

Unit No Present Heat
Loss [Kcal]

Heat Loss After Saving [Kcal]

insulation [Kcal]

Unit-1
Unit-2
Unit-3
Unit-4
Unit2,3&4

6176402896
6176402896
6176402896
6176402896
18529208689

6176402896
13521974781
11923471273
12334291396
37779737450

0
7345571885
5747068377
6157888499
19250528761

Annual Energy Saved: 19250528761 Kcal,

Monetary Saving: Rs 1,08,00,228,
Pay Back Period: 69 Days