Operational Energy Group India Pvt Ltd.

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Troubleshooting / Analysis of Coal Feeders
Project site : 1 x 63 MW, SV Power Limited, Renki Village, Korba
Equipment: 250 TPH CFBC (10.9 mpa), Wuxi boiler
Date : 16/06/2012
Prepared by : K. Arun Kumar, Operational Energy Group India Pvt. Ltd.

Aim: Frequent failures of Sweeping (Scrapper) motors and sweeping mechanisms are
experienced affecting the plant generation. This study is aimed to bring down the
failures and increase the reliability of coal feeders.
Observations: The plant was operating at 33 MW and with steam flow of 160 TPH, which
is 64% of rated flow. The following were the observations made
1. Whenever the failure / stoppage occurred the coal feeder bottom was observed to be
filled with coal dust.
2. There are five (5) sealing air connections for each coal feeder and four (4) (except
on the top of coal feeder) were in service (full open condition) out of five (5).
3. The coal inlet pipe to furnace recorded around 50 degC and the pipe was
approachable with bare hands.
4. All the coal feeders were observed with puffing of coal dust with pressurized air.
5. With the local gauges it was observed that the seal air pressure is around 300
mmWC
6. Frequent hammering are carried out at the RAV area (Pocket feeders) for ensuring
coal flow
Analysis: The coal inlet pipe to furnace has recorded only around 50 degC, which indicates
that the flow is happening from coal feeders to the furnace and not the hot flue gas
entering coal pipe. Hence the 300 mmWC pressure at coal feeders is excess / adequate
for the operating load of 33 MW.
Also the accumulation of dust was of coal fines and not of ash particles, which again
confirms to the adequate seal air pressure.
Why coal dust should accumulate ?
It can be seen from the below illustration (before modification) that the seal air #4 & 5 are
connected at the outlet of coal feeder forcing the falling coal dust from the conveyor to
accumulate towards rear side due to flow of air thro leakages, thus increasing the dust
load on sweeping mechanism. A trial was made by closing the seal air #4 & 5 and it was
observed with increase in dust load in the coal feeders compared to seal air #4 & 5 in
service.
This indicates thus the flow of air is happening from the coal inlet pipe to furnace towards
the coal feeders in the opposite direction of coal flow.

Operational Energy Group India Pvt Ltd.
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Coal feeder seal air arrangement before modification



Operational Energy Group India Pvt Ltd.
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Coal feeder seal air arrangement Proposed Modification


Modification: The seal air ports of #4 & 5 shall be shifted to rear of the coal feeder as
illustrated in the above picture and front ports are dumied.
Conclusion: The shifting of air ports from front to rear as explained above will enable seal
air to flow from the rear to front thus sweeping the dust towards furnace inlet. This will
reduce the dust load on the sweeping mechanism and will also increase the life of rear
bearings. The leaking areas will be seen with clean air instead of dusty.
Also to increase the reliability of chains, double sprocket system with combined row chain
shall be used with higher rating of drive. High seal air pressure of 300 mmWC can be a
reason for constrained flow of coal from pocket feeders. The seal air pressure shall be
regulated after measurements of furnace pressure at coal pipe inlet level.