1

WISHING A VERY HAPPY AND PROSPEROUS NEW YEAR DECEMBER 2009 TS TIDINGS

Published by Technical Services / PSSR

For internal circulation

SINGRAULI TPS
H I G H L I G H T S
BELLARY UNIT 1 :

DECEMBER 2009
VOLUME : 13.07

ESP PG TEST
KRL KOCHI :

WAS COMPLETED.

GT WAS CRANKED.
NALCO UNIT 10 :

CHEMICAL CLEANING WITH EDTA WAS COMPLETED,

BHUSHAN STEEL UNIT 3 :

SAFETY VALVE FLOATING WAS COMPLETED.

RAICHUR UNIT 8 :

BOILER WAS LIGHTED UP.

NINL, DUBURI :

ALKALI BOIL OUT WAS COMPLETED

TECHNICAL SERVICES / PSSR

DECEMBER 2009
INSIDE

TS TIDINGS

1. STATUS OF PROJECTS COMMISSIONED DURING 20022003 & 2003-2004 AND PG TESTS TO BE CARRIED OUT.

2. STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED DURING 2006-2007, 2007 - 2008, 2008 2009 & 2009 - 2010.

3. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT CLOSING/ CUSTOMER TRAINING .

4. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED

5. FEED BACK ON EQUIPMENTS FROM SITES

6. LET US KNOW -

COAL CLEANING OR COAL WASHING

Feed backs and suggestions from all departments of BHEL for improvement of TS TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER (TSX)/BHEL-PSSR/CHENNAI

TECHNICAL SERVICES / PSSR

DECEMBER 2009

TS TIDINGS

STATUS OF PROJECTS COMMISSIONED DURING 20022003 & 2003-2004 AND PG TESTS TO BE CARRIED OUT. INDUSTRIAL PROJECTS: BANNARI AMMAN SUGARS LTD: Unit is running at 18 MW, as per the requirement of customer. SCM SUGARS : Unit is running around 22 MW, as per the requirement of customer. KMCL, DUBURI : GT is under shut down for want of Coke Oven Gas (COG customer scope ). STATUS OF SETS COMMISSIONED / TO BE COMMISSIONED DURING 2006 2007, 2007 2008, 2008 2009 & 2009 2010: RAYALASEEMA TPP UNIT 3 : Unit is running around full load. RAYALASEEMA TPP UNIT 4 : From 15.12.09 - 17.12.09, boiler tube leakage. From 19.12.09 - 20.12.09, boiler tube leakage. unit unit was was shut down due to shut down due to

TECHNICAL SERVICES / PSSR

DECEMBER 2009
From 22.12.09 - 26.12.09, boiler tube leakage. unit was

TS TIDINGS

shut down due to

Unit is running around full load on all other days. SIPAT STPP UNIT 4 : Unit was shut down on 03.12.09 due to and for Boiler PG test preparations. ID fan B failure

Unit was resynchronized on 06.12.09 and loaded to 350 MW. From 09.12.09 unit is running at full load. TG PG test preparations were completed on 22.12.09. TG PG tests were commenced on 29.12.09. PG test at 500 MW, 400 MW, valve wide open and at 300 MW were completed. Condenser back pressure demonstration test was completed. SIPAT STPP UNIT - 5: Unit is running at full load. BELLARY UNIT 1 : ESP PG test was completed on 18.12.2009.

Unit was shut down on 23.12.2009 due to steam leakage in one of the impulse lines of HP Turbine. Turbine barring gear got stopped after shut down. During restart, HPCV-1 did not open. This problem was analysed and jamming of main pilot valve of HPCV-1 was cleared by servicing the same. Unit was resynchronized on 28.12.09. Presently unit is running at 460 500 MW.

TECHNICAL SERVICES / PSSR

DECEMBER 2009

TS TIDINGS

AMARKANTAK UNIT 5: Station Transformer 5 filtration was carried out on 03.12.09. DGA value was slightly less, oil and the transformer was charged

CHP: Works in primary crusher area, secondary crusher area and track hopper area are in progress. Plough feeder - 1 & 2 was commissioned, 3 & 4 commissioning works are in progress. Trial run of conveyors - 21A & B, 22A, 23B,24 A & B, VFD 2A, 2B and 3 were completed. Trial run of secondary crusher ( Main ) was completed on 19.12.09. Coal feeding from track hopper to bunker bypassing the primary crusher was tried for the first time on 30.12.09 and stabilization is in progress. Ash slurry pump house civil works are in progress. Unit tripped on 09.12.09 due to drum level high. Unit was resynchronized on 10.12.09 and loaded to 155 MW. Unit was shut down on 16.12.09 due to Generator earth fault and resynchronized on 18.12.09. Presently unit is running around 180 MW. NALCO UNIT 9 : Unit was hand tripped on 29.12.09 due to Boiler tube leakage. Unit was lighted up on 03.12.09, after attending to the same. Turbine rolling through ATRS was demonstrated on 03.12.09. Auto synchronizer was commissioned on 04.12.09 for the first time and loaded to 107 MW with four mills in service. Load Shedding Relay kept in service. was commissioned on 04.12.09 and

TECHNICAL SERVICES / PSSR

DECEMBER 2009

TS TIDINGS

BHEL/Ranipet Engineer has attended the problem in Air preheater. APH gear box and vibration readings were taken and found to be normal. Remote operation of LRSBs was demonstrated to customer. Over load control valve was commissioned. Back-up panel was commissioned. Exhaust temperature / trimming device was commissioned and taken into service. TSE controller was taken into service. Unit was shut down on 19.12.09 due to Boiler tube leakage. Repair works were completed and shut down pending works are in progress. NALCO UNIT 10 : BASH and TASH were charged on 04.12.09.

Boiler fill pump was commissioned on 13.12.09. Furnace leak test was carried out and leakages were attended. Super heater non-drainable hydro test was completed internally on 20.12.09. Cleaning of control oil from drum to drum with ELC machines commenced on 24.12.09. BFP 10B lube oil flushing was completed on 23.12.09.

ESP 10B internal inspection was carried out. APH guide bearing and support bearing lube oil flushing was completed on 28.12.09. EDTA reached site on completed on 29.12.09. completed on 30.12.09. BFP 10B motor was 28.12.09. Boiler hot Chemical cleaning with rinsing EDTA was was

bumped on 29.12.09.
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DECEMBER 2009

TS TIDINGS

BHUSHAN STEEL AFBC BOILER UNIT 2 : OCC & SCC of HVR - 2 & 3 were completed and were charged. fields

RAPCON panel was charged on 09.12.09. ESP transformer 1 & 2 oil filtration was carried out. ESP works are in progress. Unit start up held up due to inputs from customer / BHEL like APH evacuation system, nonavailability of husk, feeder - VFD processor and burner corner 1 isolation valve. BHUSHAN STEEL AFBC BOILER UNIT 3 : Cold fluidization completed. was completed. Interlock checks were

Boiler was lighted up on 03.12.09, coal fired and fluidized. Trial steam blowing was carried out on the same day. PA fan motor vibration problem was attended on 04.12.09. During coal firing on 06.12.09, bed material was spilling out near the third compartment rear end and the Boiler was stopped. Boiler was lighted up using paddy husk on 12.12.09. Boiler was lighted up on 17.12.09 and safety valve floating was completed on 18.12.09. Fluidized and coal fired in start up compartment 1 and steam was supplied to customer for running turbo blower. During starting second compartment, bed temperature came down drastically and boiler was hand tripped on 19.12.09. One no. SH safety valve was serviced on 20.12.09 and the same was floated on 22.12.09.

TECHNICAL SERVICES / PSSR

DECEMBER 2009

TS TIDINGS

Coal firing could not be established beyond the temperature of 700 deg.c. as husk supplied by customer had lot of moisture. NALCO-DAMANJODI : FD fan 5B lube oil flushing was completed. Lube oil flushing of completed. support bearing and guide bearing was

CRE-05, CRE-07, CRE-11, CRE-13 & CRE -15 panels were charged. Valve and damper MCC was charged. FD fan 5A checked. lube oil pump interlock and protections were

Acid cleaning and steam blowing of lube oil lines of ID fan A was completed. SILK ROAD SUGARS : GT was run as per customer requirement (for Sugar plant commissioning works ) with HSD fuel and loaded upto 1.2 MW. KRL KOCHI : Mark VI panel charging was held up due to high earth resistance. Earth resistance value of 0.6 ohms was achieved by adding nine nos. of earth pits. Mark VI panel was charged on 09.12.09. Warren lube oil system pressure adjustments was completed. Warren EOP was commissioned. Warren lube oil AOP to EOP change over was checked.

TECHNICAL SERVICES / PSSR

DECEMBER 2009
Raw water completed. charged run in was CW system and

TS TIDINGS

flushing was

Diesel engine idle

completed on 02.12.09.

GT was put on ratcheting manually on 03.12.09, after adjusting the ratchet pump relief valve. AOP to EOP change over was checked and GT was put on ratcheting from Mark VI on 10.12.09. DCS panels 06.12.09. were charged and communication established on

CW pump -1 motor trial run was completed on 07.12.09. Kero forwarding pumps completed on 08.12.09. 1 & 2 motor trial run was

Instrument air receiver was charged on 09.12.09. Turbine compartment vent fans trial run was completed. Trial run of exhaust blowers - 1 & 2 was completed. GT was cranked successfully on 14.12.09. HRSG MCC was charged. Kero II and Naphtha lines were normalized after card board blasting. Kero II was charged from BPCL and flushing of Kero-II lines was completed. Inlet guide vane ( IGV ) calibration was completed. Foaming demo around fuel tank was completed. Kero- II tank was charged upto 50%. Kero II forwarding pump 1 was commissioned. Kero- II tank level control valve was commissioned.

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DECEMBER 2009
Generator bus duct

TS TIDINGS

hi-pot test was completed.

Modification of cooling water lines for diesel engine as per revised BHEL/Hyderebad scheme was completed. Trial run of seal air fan 1 of All compartment completed. vent fans GD, DD were completed. from Mark VI was

operation

Kero II pressure and commissioned from DCS.

recirculation control valves were

Generator Transformer test was completed. DAVR lamp load test was completed for both channels. Trial run of cooling was completed. tower fans 1 & 2, DM water pump 1

Trip oil was build up checked.

and

fuel

stop valve

operation

was

GRP testing is in progress. checking is in progress.

Filter skid

area instruments

loop

Kero- II drain tank pumps ( except one pump ) near filter skid and storage tank area were commissioned with water in the tank. RAICHUR UNIT 8 :
,

CW system flushing for ID fan - A was completed 01.12.09. Both channels of VFD were made ready 01.12.09.

on on

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DECEMBER 2009
ID fan 8B motor was run on was completed on 03.12.09. Acid cleaning of 02.12.09 and

TS TIDINGS

its

trial

run

BFP 8B lube oil lines

was completed.

Boiler internal hydro test was completed on 05.12.09. Final hydraulic test of Boiler was completed on 14.12.09 in the presence of Joint Director of Boilers. Trial run of 07.12.09. CEP 8A & 8B motors was completed on

BFP 8B oil flushing was started on on 28.12.09.

08.12.09 and completed

LDO pump A was run on long recirculation and its trial run was completed. maxDNA panels - A, B, C & D were charged on 10.12.09. Checking of blade pitch control of FD fan A was completed. ID fan A was run for four hours and FD fan A was run for half an hour on 14.12.09. Boiler was lighted up on 15.12.09. lube oil flushing was completed on

APH A guide bearing 22.12.09. NINL, DUBURI HRSG :

HRSG soot blower seal air fan motor trial run was completed. Fan trial was completed. Diverter damper completed. seal air fan - 2 motor trial run was

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DECEMBER 2009

TS TIDINGS

Internal hydro test was completed on 07.12.09. Commissioning of motor operated valves is in progress. DCS panel CRA 4 was charged. Diverter damper operation was checked from local 15.12.09. It was checked from remote on 18.12.09. Provisional order received from generation of steam in HRSG. Gas turbine Boiler Inspector on

for

was run and checked for readiness.

HRSG hot water flushing was completed on 22.12.09. Alkali boil out was completed on 23.12.09. Preparation for steam blowing is in progress. KUTTIYADI UNIT 1 : Unit is ready for mechanical spinning.

Electronic earthing cabling work was completed. VIJAYAWADA UNIT 7 : New GT R phase reached site on 30.11.09.

HV & LV neutral turret CT testing was completed. New GT internal inspection was completed. Modified diverter switch was replaced. Surge arrestor and surge capacitor meggering was completed. Ratio test, magnetizing current check and polarity checks were carried out. 48 hours vacuum test was completed.
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DECEMBER 2009

TS TIDINGS

Redundant HV differential protection was introduced. GT protection system thoroughly checked. GT was back charged on 10.12.09. Unit was synchronized on 11.12.09. HP heaters were taken into service. Load raised to 400 MW on 12.12.09. Unit was shut down on 13.12.09 due to Boiler tube leakage ( near radiant roof tube). Eleven tubes were cut and repaired. Hydraulic test was done after attending Boiler tube leakage. GT bushing for completed. R, Y & B phases Tan-delta test was

PA fan B motor bearing failed and inspected by BHEL/Bhopal and recommended for replacement of motor due to under size of rotor. Motor was arranged from Kothagudam site. Plate Heat Exchanger ( PHE ) cleaned. of TG-DMCW system was

ST - 6 oil drained with N2 capping and internals were inspected with BHEL/Jhansi representative. Core was touching with supporting frame at one location. It was rectified and additional insulation sheet was provided. Oil purification was carried out and oil filling is in progress. Unit was synchronized on 24.12.09. HP heaters were taken into service. Wall blowers pressure setting completed. blowers remote operation was completed. 82/88 wall

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DECEMBER 2009

TS TIDINGS

Unit is running at 400 420 MW. Load limited handling restriction by M/s APGENCO.

due to

ash

TDBFP A barring gear did not come after attending casing drain leak. Booster pump wearing ring having burrs and less clearance. Burrs were removed and pump was re-assembled. SOx, NOx panels were calibration was completed. inspected and charged. Probe

SERVICES RENDERED TO CUSTOMER /SAS/MUs: Shri M.V. Bhaskaran, Senior Manager/Technical Services was deputed to FACT, Cochin for pre-overhaul study of parameters for 16 MW STG commissioned in 1987. Shri P. Muthu, SDGM/Kakatiya site was deputed to Raichur thermal Power Station for balancing of unit 3 Generator ( 210 MW Russian design Generator). The vibration level was reduced from 20 mm/s. to 4 mm/s. at full load by balancing, using Generator front and rear fan planes. CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED: Shri M.V. Bhaskaran, Sr. Manager/Technical Services was deputed to Thermal Training Institute, TNEB, North Chennai on 21.12.09 as Guest Faculty for delivering lecture on Factors for influencing the performance of the Turbine and Turbine losses and improving the Turbine Heat Rate in Thermal Power Station. The programme was attended by Operation and Maintenance Executives of various Power Stations of TNEB. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :

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DECEMBER 2009
FEED BACK NO.1

TS TIDINGS

Project:

Karnataka power corporation, Bellary, unit 1, 500 MW

Problem: During start up of the unit on 25/12/09, HPCV-1 did not open and observed not responding to even maximum secondary oil pressure. Problem details: Bellary unit 1 (500 MW) is in continuous operation after completion of reliability run in march 2009. The unit was shut down on 23/12/09 for attending to the leakage developed in one of impulse line of HP Turbine. During restart it was observed that the HPCV 1 is not opening. It was reported that the valve is operating sluggish since commissioning. The auxiliary pilot valve was serviced recently by BHEL,Hardwar technicians. Operation of the control valve: (refer the figure) The servomotor consists of auxiliary pilot valve (14), pilot piston (4), main pilot valve (3), feed back linkages, servo piston (9) and disc springs (10). The secondary fluid pressure controls the auxiliary pilot valve (14) and directs control fluid to the pilot piston. The pilot piston operates the main pilot valve through lever (5). The main pilot valve (3) admits/drains the oil from underside of servo piston (9). Under steady state auxiliary pilot is in middle position. When the secondary fluid pressure varies, auxiliary pilot valve deflects from middle position and allow control fluid to pilot piston and moves in one direction. The connecting lever transmits the movement to the main pilot valve causing the oil flow to the servo piston. The movement of the valve is transmitted back to the aux pilot valve through linkages. The cam in the servomotor spindle returns the pilot valve to its middle position. The degree of proportionality of pilot control system can be adjusted by the feed back linkage pivot. The aux pilot valve is kept in rotation by the fluid jet from the tangential holes of the pilot
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DECEMBER 2009

TS TIDINGS

disc. The spring above the linkages preload it to avoid slackness and play.

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DECEMBER 2009

TS TIDINGS

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DECEMBER 2009

TS TIDINGS

Analy0sis/trouble shooting: The signal pressure (HP secondary fluid pressure) was varied and found no response of the valve. The rotation of the auxiliary pilot was ensured. To identify whether it is servomotor problem or valve problem, the servomotor was decoupled. The secondary fluid pressure was then varied and found again no movement of the servomotor spindle. To check the freeness of the auxiliary pilot, the linkage was moved manually (in addition to the secondary fluid pressure) and it was noticed that the main pilot valve is not moving at all. Also, there is no flow of fluid observed from the pilot valve. The movement of the linkage manually and pilot valve/main valve movement along with flow changes could be seen in the healthy control valve number 2. Suspecting jamming of the main pilot valve in one position, it was decided to dismantle and service the main pilot valve of HPCV 1. To remove the main pilot valve, the linkage assembly & helical spring was taken out of its position and the main pilot was pushed away from the control valve casing. The pilot came out by around 20 mm and got struck up. It was again taken back to original position and the process was repeated but the pilot never came out beyond 20 mm. After consulting with BHEL Hardwar it was decided to remove the main pilot along with the liner and bush. The whole assembly (pilot with liner) was then removed from position. For removal of the assembly, Liner it was pushed towards the control valve casing. After taking the assembly away, it was tried to remove the pilot by hammering with a wooden piece. In the process the pilot came out by 40 mm, but there was no further movement by this process. At this stage it was observed that for the last 20 mm there was a Black powdered soot type material deposited on the inside surface of the bush which is the cause for jamming. The sample of this material was
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DECEMBER 2009

TS TIDINGS

collected for further examination. The photographs are attached along with this report. The problem was discussed telephonically with BHEL Hardwar and it was decided to apply force with a jack. A 40 MT jack was used for this purpose. The pilot came out by another 20 mm after applying this force and then a change of arrangement was needed to take it out further. After changing of the arrangement the pilot could not be moved any further as the force from the jacks was getting dissipated in other directions. Even after repeated attempts the pilot never came out beyond 62 mm.Then it was decided to resort to somewhat heavy hammering. Initially 5 hammer blows were given and the progress was measured by a vernier.It was observed that the pilot has moved by another 4 mm. So this process was continued till the pilot came out totally. During this process intermediate progress was being checked with a vernier. All this while, the black material kept coming out of the periphery of Bush. After removal of the pilot it was checked for damages and scoring marks and none were found on either the Pilot or Bush. The pilot and bush were then cleaned thoroughly and assembled together. The free movement of the pilot was ensured. The liner was assembled inside the servomotor. During assembly of the liner, the defective o rings were replaced with locally made rings, as there was no spare available (3 numbers -rings of 170X5.5mm were damaged during liner removal). After assembling the servomotor, control fluid lines were charged and the operation of the servomotor was checked. The servomotor was coupled with the valve and was checked for operation. Unit was started on 28/12/09 and is running without problem.

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DECEMBER 2009

TS TIDINGS

Conclusion and suggestions: The black material was causing for jamming of the main pilot valve. As it was reported for sluggish operation since commissioning, this could have accumulated over a period. The samples of the material needs to be examined thoroughly for ascertaining the source of the material. It is suggested that sufficient care should be taken at works to ensure that no foreign material enters in between liner and pilot during its assembly. Control oil samples are to be tested for moisture and sediments regularly. Regenerative system should be kept in service continuously. Spare O ring shall be made available for servcing requirements.

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DECEMBER 2009

TS TIDINGS

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DECEMBER 2009
FEED BACK NO. 2

TS TIDINGS

PROJECT : PROBLEM :

NALCO, ANGUL, UNIT 9, 120 MW TURNING GEAR SLOWING DOWN

Problem details: This 120 MW unit is provided with a hydromotor to drive the turbine on turning gear. The normal speed of the machine during turning gear is 110 RPM. On 12/09/09 at 10.15 hrs it was observed that the turbine turning gear speed was suddenly going down from 110 rpm to 96 rpm, and after some fluctuations in speed , it decreased and finally came to zero ( the turbine rotation stopped physically) with rubbing noises in the LP turbine seals. Immediate checks showed no abnormal conditions i.e. lifting oil pressure, vacuum , seal steam pressures and temperatures were normal. After thirty minutes, with hand barring, it was made free, and turning gear was restored. Analysis and resolution: The trends of turbine speed with various parameters like seal steam parameters, vacuum, lifting oil and lube oil pressures were collected for studying behaviour of the speed drop. It was seen that there was no influence of any of these parameters. Further search and analysis revealed that one hour before speed reduction, LP Exhaust hood spray had opened on protection at LP Exhaust temperature of 90 C. This temperature immediately dropped to 33 C and was seen maintaining at this value because of the continuation of LP exhaust hood spray. The restoration of turning gear was done after closing this spray. The next time when unit was tripped and turbine came to turning gear, the same behavior was observed. Turbine speed started reducing from 110 rpm to 95 rpm and then started to rise after closing the exhaust hood spray manually.
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DECEMBER 2009

TS TIDINGS

Further study of trends of turning gear speed with seal steam parameters, vacuum, lifting oil , lube oil, and LP Exhaust hood temperature, it was observed that speed drop was significantly affected by LP Exhaust Hood spray only i.e.Turning gear speed dropped when LP Exhaust temperature went below 40 degrees due to opening of LP Exhaust hood spray valve, and then recovered when LP Exhaust spray was cut off. This slowing down behavior was seen repeatedly (observed at least five consecutive times) during trip outs with vacuum and seal steam in service. The turning gear speed could be restored to normal by simply cutting off LP Exhaust Spray manually. Trends of turning gear showing speed reduction and restoration with LP exhaust temperature is enclosed for reference. The original logic given by BHEL, Hyderabad was checked. The auto close command is given when speed less than 1850 RPM or load more than 10% provided LP exhaust temperature is less than 90 deg C. The auto closing of LP exhaust spray valve was additionally given at site with temperature lower than 50 deg C. The auto logic with opening of LP Exhaust spray valve at 90 C and closing of the valve at 50 C of LP Exhaust temperature was ensured. CONCLUSION: No such fluctuation in turning gear speed has happened since this logic was implemented in end September 2009. LP Exhaust temperature was maintaining between 90 to 50 degrees with LP Exhaust spray opening and closing in auto mode as per the above logic. The problem is thus resolved.

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DECEMBER 2009

TS TIDINGS

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DECEMBER 2009

TS TIDINGS

COAL CLEANING OR COAL WASHING

Seventy percent of total installed capacity of electricity generation in the country is from coal based thermal power plants. Increased dependence of power sector on the inferior quality of coal has been associated with the emissions from the power plants in the form of particulate matter, toxic elements, flyash, oxides of nitrogen, sulphur and carbon besides large volume of water for cooling and land requirement for ash disposal. Only twenty percent of total coal transported to the power plants is of superior grade with ash content of 24% or less and remaining eighty percent is of inferior grade with ash ranging from 24 to 50 percent In India many plants are located more than 1000 km away from mines and the coal is transported through wagons and ships. Transporting the high ash coal will involve huge transportation cost . Besides this high ash coal needs larger capacities of coal and ash handling system in a power plant. Added to this the disposal of ash is also a Himalayan task. To overcome this, large utilities like NTPC and mining companies installed /installing coal washeries at their pit heads to wash the coal , and reduce the ash to around 20 to 30% . Then the washed coal is transported to the power plants. WET PROCESSES In practice high-density liquids are not used, but they are simulated by a mixture of finely divided solids kept suspended in water-like "liquid mud". Such liquids are not suitable for floating small coal particles since they would get irretrievably mixed with the medium, and in practice no pieces of coal of less than 1/2 inch. in size (usually 1 inch.) can be processed in this way.
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DECEMBER 2009

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Another older method of simulating a high density liquid is to float the coal in a mixture of sand and water. The sand and water are held together by rapid upward recirculation. In this method all coal below 1/16 inch. in size (approximately the sand particle size) must first be removed. This type of washer is known as the Chance Cone and it was developed in the days when coal was mined dry and could be screened at 1/16 inch. or 1/2 inch--the large +4 inch. being first removed for cleaning by hand selection: Small coal (below 2 inch. and below 1 inch. according to need) is most effectively cleaned in jig washers, which exploit the different rates of fall in water of coal and shale particles. These two main types of washer frequently operate side by side, the one dealing with the larger pieces and the other with the small. When smalls are washed, material below 30-mesh (1/2 mm) remains in the wash water and would accumulate. It can no longer be to rivers and all must be recovered. This discharged can be done after flocculation and settling, by vacuum filtration or filter press to yield a slurry. The oldest slurry separation process was to settle in ponds or lagoons (rather like P.F. fly ash disposal) and then drain off the water to recover the slurry by forming mounds or banks. Some slurry can be added and mixed back to the washed smalls product, but the amount may be limited by the percentage ash that can be tolerated and by the adverse effect that too large a percentage of slurry may have on handleability. Some coal fines can be effectively cleaned by the froth flotation process and this gives opportunity to dispose of more in a washed small coal. The process is expensive but valuable in connection with small coals to be used for metallurgical coke production, where the amount of fines present is not important, but the ash content is. Figure -1 shows the flow sheet of a typical coal preparation plant.
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(a) THE DENSE MEDIUM PROCESS Dense medium plants are generally used for cleaning coal in the size range 8 inch. to 1 inch. by using suspensions of finely divided magnetite, barytes, even the shale itself or sand in water. The dense medium must be carefully maintained at appropriate specific gravity levels. By this means separation into three products, coal, middlings and shale can be efficiently carried out. When raw coal is fed into a dense medium of specific gravity 14, clean coal separates and floats to the surface for easy removal by rakes or paddles. Middlings and shale sink, and are continuously removed from the bath by means of an elevator, to a second bath of dense medium say of specific gravity 18, in which the shale sinks and the middlings are recovered. These can then be crushed and rewashed in a jig washer along with raw coal of 1 inch. to dust size. (b) THE JIG WASHIG PROCESS Cleaner, less dense coal is separated from the heavier dirt when water is moved rapidly up and down through a bed of raw coal on a perforated plate. The pulsation may be produced by a mechanically driven piston or pneumatically as in a Baum JIG washer (see Fig-2) and Baum Jig washer Flow diagram (see Fig -3 ) The jig washer can handle coal of any close size range up to 6 inch. top size, but most installations are designed for coals below 2 inch. top size. Jig washers are frequently referred to as Baum or Acco boxes. The movement of the water causes dirt to settle out on the plate while clean coal forms an upper layer which is removed by a stream of water. Jig washers can yield three products if required-cleaned coal, middlings and discard, and are generally installed where there is a marked difference in specific gravity of the coal and dirt particles with few middlings. Smalls which cannot be washed efficiently can often be used without further treatment in power station boilers.
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(c) CYCLONE WASHERS Cyclone washers or hydrocylones as they are sometimes called, are something of an innovation and as yet are not in great use. It is claimed that for the treatment of smalls below 1 inch. no single washery system is known which can equal the accuracy of separation of the cyclone washers. They can handle coal up to 11/4 inch. in size or the very smallest sizes. (d) FROTH FLOTATION With increase in mechanisation in the coal industry, the production of fines of less than 1 mm in size has increased considerably. This fraction of coal may require special treatment in cleaning. For this purpose the froth flotation plant has been developed from a method used to reclaim metal ores. A foaming agent, usually creosote containing cresylic acid, is . added to the fine coal in water. A mixing impeller which also draws in air to the system, forms a stream of bubbles which adhere to the coal particles but not to the shale. The clean coal then floats to the surface as a "froth" whilst the dirt sinks to the bottom of the flotation cell. The coal "froth" is removed by paddles and is dewatered in a vacuum filter plant to give a cake of clean fine coal of 18-20 % free moisture content and an ash content of between 5-13%. This coal is then blended with other washed coal for the commercial market. The flotation process is most valuable for carbonisation coals. (e) FLOCCULATION PROCESS The fine -coal left in suspension in the water used in conventional coal washing plants is settled and the concentrate is flocculated by means of a suitable agent such as alkaline starch, or. the newer polyelectrolytes, which cause the fine coal particles to agglomerate and settle out more rapidly. The slurry so formed is finally dewatered in vacuum filters or sometimes filter presses.
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(f) DRY CLEANING Dry cleaning of coal, usually of size 2 inch. to dust, is achieved by passing the coal over a slightly inclined-shaking table with riffles and perforated plate, through which air is blown upwards. This fluidises the bed and shale sinks to the plate. By inserting a knife edge plate between the two layers, coal is separated from the shale. Dry cleaning plant, however, is not nearly as efficient as conventional wet washers. Because of this and the associated hazards to health, no new dry-cleaners are being installed and washers are replacing them. ADVANTAGES OF COAL CLEANING

Increased generation efficiency, mainly due to the reduction in energy loss as less inert material passes through the combustion process; Increased plant availability less ash percentage. Reduced investment costs due to reduced costs for fuel and ash handling equipment; Reduced operation and maintenance (O&M) costs due to less wear Reduced transportation costs due to less ash and more calorific value; Less impurities and a more even coal quality; Reduced load on the particulate removal equipment in existing plants; and Reduction in the amount of solid waste that has to be taken care of at the plant.

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FIG-1

COAL PREPARATION PLANT FLOW DIAGRAM

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FIG-2 BAUM JIG WASHER

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FIG-3 BAUM JIG WASHER FLOW DIAGRAM

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PERFORMANCE OF SR UNITS IN DECEMBER 2009

UNITS WHICH HAVE ACHIEVED 100% OA THERMAL 500 MW RAMAGUNDAM UNIT 6 & 7 TALCHER UNITS 3,4, 5 & 6 SIMHADRI UNIT 2 SIPAT UNIT - 5 210 MW MUDDANUR UNIT 1 & 3 METTUR UNIT - 1 & 2 TUTICORIN UNIT - 4 NORTH CHENNAI UNIT 1 & 3 NEYVELI UNITS 5, 6 & 7 UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100% 500 MW RAMAGUNDAM UNITS 4, 6 & 7 TALCHER UNITS 2, 5 & 6 SIMHADRI UNIT 1 & 2 SIPAT UNIT 5 210 MW MUDDANUR UNIT - 3
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UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100% THERMAL 500 MW RAMAGUNDAM UNIT 5 TALCHER UNITS 1,3 & 4

250 MW KOTHAGUDEM UNIT 210 MW VIJAYAWADA UNITS 3, 4, 5 & 6 MUDDANUR UNIT 1 RAICHUR UNITS 4, 5, 6 & 7 10

METTUR UNIT 1 & 2 TUTICORIN UNITS 4 & 5 NORTH CHENNAI UNIT 1 & 3 NEYVELI UNITS 5, 6 & 7

125 MW

JSL, DUBURI UNIT - 1

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PERFORMANCE OF BHEL THERMAL SETS IN SR (210 MW AND ABOVE) FOR THE PERIOD FROM 01/04/09 TO 31/12/09 COMPARED WITH THE CORRESPONDING PERIOD IN THE PREVIOUS YEAR. ( PLF IN PERCENTAGE )

STATION North Chennai Neyveli Raichur Tuticorin Ramagundam Muddanur Kothagudam Vijayawada Mettur Talcher Simhadri Sipat
120.00

2008 - 09 87.93 65.33 78.58 84.00 95.12 89.13 80.27 92.43 86.57 81.67 95.82 PLF

2009 - 10 88.03 82.65 78.04 77.21 91.74 83.14 90.45 90.83 88.11 87.30 95.35 93.18
2008 - 09 2009 - 10

100.00 PL F PER C EN T A G E

80.00

60.00

40.00

20.00

0.00
C he nn ai N ey ve li R ai ch ur Tu ti R am cor ag in un da m M ud da K nu ot r ha gu da m V ija ya w ad a M et tu r Ta lc he r S im ha dr i S ip at

N or th

UNIT

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