The coal pulverizer is the most important equipment to govern the

operability and reliability of coal burning boilers. Therefore, an

optimum mill type must be selected from the comprehensive view
point according to the coal properties and the operation conditions.

Operation and maintenance

The operation of mill is simple and start/stop operation can be
completely automated. Also, the wide range of the mill operation load
adjustment is important for coal boiler operability. The upright mill is
available for 40-50% turndown, but recently some types of upright
mills have become available for high-turndown operation up to 30%
or less. For mills operation, the maintenance of abrasive parts is also
extremely important. So, studies have been conducted to develop
abrasion-resistant materials and to simplify the replacement of roll
rings, liners, etc. As for the material of rolls, in addition to
conventional abrasion-resistant cast iron, curing cladding-welding
material with several times abrasion-resistance of cast iron has also
been used. Because the life of the grinding section varies with the coal
properties and the operation conditions etc., it is necessary to
measure periodically the abrasion depth of the rolls or segments of
each plant and to schedule the intervals of replacement. Generally,
rolls/rings/liners replacement is conducted in such a manner that one
unit of extra mill per boiler is installed, and maintenance intervals are
set, and each mill is maintained sequentially. In case of emergencies,
mill changeover operation is done in which the faulty mill is shut
down and the load is transferred to the standby mill.

Mill tripping might take place due to one of the following reasons:
Mill discharge valves are closed
Loss of elevation D.C. supply for more than 2 secs.
Support ignition energy is removed Within 3 minutes of feeder
starting.
Motor protection operates.
One P.A. Fan trips (mill in excess of 3 will trip starting from
bottom).
In such a case the changeover to the other mill takes place. Procedure
for the changeover is:
Steps prior to putting the mill in service:
1. Measure and record internal clearances, tolerances, and spring
preloads.
2. Check and calibrate the coal feeders.
3. Functionally check the full movement and position indication of
all dampers.
4. Review primary airflow curves to ensure safe operation
throughout the operating range, ensuring adequate minimum
airflow as well as proper air-to-fuel ratios when operating above
minimum airflow.
5. After thoroughly checking mechanical tolerances and clearances,
close the mill and start primary airflows. Warm the mill to
normal operating temperature of 150F mill outlet temperature

(bituminous coal) and airflow at minimum (normal minimum

primary air [PA] flow).
6. Conduct a PA airflow measurement traverse by manual pitot tube
to verify that the indicated PA is correct across the boiler
operating range.
7. Conduct "clean air" 24-point traverses of all of the fuel lines to
measure and compare the balanced airflows through each pipe.
All coal pipes (and flows to all of the burners from each
respective pulverizer) should be balanced and within 2% of the
mean flow.
8. Perform a seal air check.
9. Begin the normal pulverizer start sequence.
10.
Once normal coal flow is applied to the mill, a full mill test
should be conducted. This test should include isokinetic coal
sampling and dirty airflow measurements through each fuel line
to determine air/fuel balance and coal fineness. Primary airflow
"Hot-K" calibrations of the primary airflow measuring element
should also be conducted

Other pre start checks:

LOCAL (to be made by local operator)
Ensure R.C. Bunker level Satisfactory.
R.C feeder and mill properly boxed up and no maintenance
staff working.
Gear box oil level normal.
Lub. oil coolers charged.

Tramp Iron Gate open.

Cold air gate open. Hot air gate closed.
Mill outlet valve open.
Seal air valve open.
Mill firefighting system ready.

Take out emergency push button and give clearance to UCB for
starting.
U.C.B: (to be made by desk operator)
Ensure no PTW pending.
Ensure at least one P.A fan and a seal air fan is in service. Check
the header pressure for both primary and seal air is normal.
Check that mill ignition energy is O.K.
Check that mill start permissive as per FSSS are satisfied (for the
help of operator these permissive are written on FSSS panel and
when the condition is satisfied it is indicated by a glowing bulb).
Ensure E.P zones have been charged (for first mill ).
Ensure attemperation valves are ready for operation.
Inform turbine operator of mill start up.
Get the electrical supply for the mill.
Inform the local operator to be near mill for start up.
Start the mill.

POST START CHECKS

LOCAL
Check no abnormal sound from mill.
Check return oil flow from upper bearing is satisfactory.
Check all the rollers are rotating and the rate of reject is normal
(after the mill is loaded).

U.C.B
Check mill starting time and current. Ensure that they are
normal.
Open hot air gate.
Warm up the mill.
Start the R.C feeder and load the mill gradually.
Keep the air flow through mill-54 T/hr.
Keep watch on mill differential to avoid mill chocking.
Maintain mill outlet temperature between 75 degree Celsius to
80 degree Celsius.
As the pressure, temperature of main steam shoots up with coal
firing proper check should be kept on these parameters.
(Especially for first mill).