How a coal power station works

This video showing about power generation using coal plant. Enjoy and learn from this...

What is coal crusher?

Coal is a fossil fuel, one of the largest source that has been used by nationwide in generate electricity. Coal is extracted from underground by mining.

Coal crusher is using in power plant to resize coal from stone into small particles so that it can be easily handled and processed.

Coal crusher is a type crusher of ore crushing equipments used for crushing coal. Coal crusher is acknowledged well in coal processing industry for a long time. It is used widely in coal mining and coal processing because of its advantages.

Malaysia drops 300MW coal-fired Sabah power plant project

KOTA KINABALU, Feb 17 (Bernama) -- The more than 3.3 million people in Sabah can now heave a big sigh of relief as the government has made a final decision not to build coal-fired power plants in the state.

The long-awaited decision proved beyond doubt that the government subscribed to the 1Malaysia concept which prioritised the people's interests.

In delivering the good news yesterday, Chief Minister Datuk Seri Musa Aman said the Barisan Nasional (BN) government under the leadership of Prime Minister Datuk Seri Najib Tun Razak was "a government that always listens to the voice and feels the pulse of the people".

The timely announcement was made all the more sweet because the Federal and state governments had also agreed to use liquefied natural gas (LNG) to generate power instead of coal-fired energy.

"This is a perfect new year gift for the people of Sabah. This decision is correct and it reflects the BN's sensitivity to the grouses of the people.

"It means that our Chief Minister is listening and we in Parti Bersatu Sabah (PBS) certainly welcome this decision," said PBS secretary-general Datuk Henrynus Amin to Bernama, here Thursday.

For this, he congratulated Musa on his bold decision to cancel out the proposed coal plant project in Lahad Datu for the good of the people.

"We believe that the state government must have taken into account all factors before making the decision," he said.

Local political analyst Edward Kandok perceived this development as another "plus point" for the BN to further strengthen its position in Sabah, dubbed as a "fixed deposit" for Barisan.

"This is the kind of government we want. I believe the majority of the local people are happy with the government's decision that finally put the coal plant issue to rest," he said.

In September 2009, Najib disclosed Felda Sahabat in Lahad Datu as the proposed site for the construction of the coal-based power plant.

Currently, the electricity supply capacity in the eastern coast of Sabah is 200 megawatts from a diesel-based power plant.

Environmental groups such as Green Surf have protested against the construction of the coal-based power plant, which they consider as "dirty" energy, and called on the government to scrap the plan.

However, in August last year, the Environment Department had rejected the Detailed Environmental Impact Assessment (DEIA) for the project but Tenaga Nasional Bhd (TNB), in its 2010 Annual Report, mentioned that "a reviewed DEIA report will be submitted for study and approval" for a 300MW plant.

-- BERNAMA

What is Coal Ash?

What is Coal Ash?

Coal combustion byproducts (CCBs) are considered to be four distinct and extremely different materials.

FLY ASH

Fly ash is the finest of coal ash particles. It is called "fly" ash because it is transported from the combustion chamber by exhaust gases. Fly ash is the fine powder formed from the mineral matter in coal, consisting of the noncombustible matter in coal plus a small amount of carbon that remains from incomplete combustion. Fly ash is generally light tan in color and consists mostly of silt-sized and clay-sized glassy spheres. This gives fly ash a consistency somewhat like talcum powder. Properties of fly ash vary significantly with coal composition and plant-operating conditions.

Fly ash can be referred to as either cementitious or pozzolanic. A cementitious material is one that hardens when mixed with water. A pozzolanic material will also harden with water but only after activation with an alkaline substance such as lime. These cementitious and pozzolanic properties are what make some fly ashes useful for cement replacement in concrete and many other building applications.

BOTTOM ASH

Coal bottom ash and fly ash are quite different physically, mineralogically, and chemically. Bottom ash is a coarse, granular, incombustible byproduct that is collected from the bottom of furnaces that burn coal for the generation of steam, the production of electric power, or both. Bottom ash is coarser than fly ash, with grain sizes spanning from fine sand to fine gravel. The type of byproduct produced depends on the type of furnace used to burn the coal.

BOILER SLAG

Boiler slag is coarser than conventional fly ash and is formed in cyclone boilers, which produce a molten ash that is cooled with water. Boiler slag is generally a black granular material with numerous engineering uses.

FGD GYPSUM

Flue gas desulfurization (FGD) gypsum is also known as scrubber gypsum. FGD gypsum is the byproduct of an air pollution control system that removes sulfur from the flue gas in calcium-based scrubbing systems. It is produced by employing forced oxidation in the scrubber and is composed mostly of calcium sulfate. FGD gypsum is most commonly used for agricultural purposes and for wallboard production.

More details: What is coal ash? (source)

Electrostatic Precipitator ESP and Pre-Heater Blow Tanks Pressure Gauges

List of WIKA Pressure Gauges:

Items: Pressure gauge
Bourdon tube pressure gauge, stainless steel series
Manufacturer: Wika
Model: 232.50
Measuring system: Stainless steel
Case: Stainless steel with pressure vent
Bezel ring: Cam ring (bayonet type), stainless steel
Accuracy class: NS63: class 1.6; NS 100/160: class 1.0
Nominal size: 100 mm
Scale range: 0 kPa...400 kPa
Process connection: Diaphragm seal
Connector position: Lower mount
Window: Laminated safety glass
Pointer: Standard black
with integrated Alarm Contact, Electronic Sensor Series Model 830 E
first switch operation: breaks (2)
second switch operation: breaks (2)
Electrical connection: plug sidewise
Flange type: Flushed diaphragm
Model: 990.27
Process connection: ANSI 2” class 150# RF
Material of wetted parts: Stainless steel 316 series
Assembly: Direct assembly with PTFE lining
Fill fluid: KN2 Silicon oil

Items: Pressure gauge
Bourdon tube pressure gauge, stainless steel series
Manufacturer: Wika
Model: 232.50
Measuring system: Stainless steel
Case: Stainless steel with pressure vent
Bezel ring: Cam ring (bayonet type), stainless steel
Accuracy class: NS63: class 1.6; NS 100/160: class 1.0
Nominal size: 100 mm
Scale range: -10 kPa...10 kPa
Process connection: G ½ B (male), 22mm flats
Connector position: Lower mount
Window: Laminated safety glass
Pointer: Standard black
with integrated Alarm Contact, Magnetic Snap-Action Contacts, Model 821.3, SPDT
Electrical connection: plug sidewise
Maximun contact rating with non-inductive load
Maximum voltage: 250 V
Current ratings: Make rating: 1.0 A; Break rating: 1.0 A; Continous load: 0.6 A
Maximum load: 20 W 20 VA
No of contact sets: 1
Switch version: L
Liquid filling: Glycerine 99.7%

Item: Pressure gauge
Bourdon tube pressure gauge with liquid filling and stainless steel series
Manufacturer: Wika
Model: 233.50
Design: EN 837-1
Nominal size: 100 mm
Accuracy class: NS 100: 1.0
Scale range: 0 … 15 bar
Working pressure: Steady: full scale range
Operating temperature: Ambient: -20 … + 60 °C gauges with glycerine filling
Temperature effect: When temperature of the pressure element deviates from reference temperature (+20 °C): max. +0.4 %/10K of treu scale value
Ingress protection: IP65 per EN 60 529/IEC 529
Pressure connection: Stainless steel 316L
Connector position: Lower Mount (LM); NS 100 mm: G ½ B (male), 22 mm flats
Movement: Stainless steel
Dial: White aluminium with black lettering
Pointer: Black aluminium
Case: Natural finish stainless steel, with pressure relief in case back.
Window: Laminated safety glass.
Bezel ring: Cam ring (bayonet type), natural finish stainl. Steel.
Liquid filling: Glycerine 99.7%

Items: Pressure gauge
Bourdon tube pressure gauge, stainless steel series
Manufacturer: Wika
Model: 232.50
Measuring system: Stainless steel
Case: Stainless steel with pressure vent
Bezel ring: Cam ring (bayonet type), stainless steel
Accuracy class: NS63: class 1.6; NS 100/160: class 1.0
Nominal size: 100 mm
Scale range: 0 … 6 bar
Process connection: Diaphragm seal
Connector position: Lower mount
Window: Laminated safety glass
Pointer: Standard black
Flange type: Flushed diaphragm
Model: 990.27
Process connection: ANSI 2” class 150# RF
Material of wetted parts: Stainless steel 316 series
Assembly: Direct assembly with PTFE lining
Fill fluid: KN2 Silicon oil

List of Instruments at SSC Hydraulics Power Packs

List of Instruments at SSC Hydraulics Power Packs

• Items: Float switch
  Manufacturer: Fozmula
  Type: T/LL/70/9268
  HD Number: Z21049
  Electrical: Switching N/O
  Fitting: Standard 1” BSP

• Items: Pressure Gauge
  Manufacturer: T.J Williams
  Type: 0-40Mpa 63mm ¼” bsp
  HD Number: 016-81033-0

• Items: Pressure Switch
  Manufacturer: Telemecanique
  Type: XML-A160-D1S11
  HD Number: Z21049

• Items: Pressure Gauge
• Manufacturer: T.J Williams
• Type: 0-15Mpa 63mm ¼” bsp
• HD Number: Z21049

• Items: Pressure Switch
  Manufacturer: Telemecanique
  Type: XML-A500-D1S11
  HD Number: Z21049

• Items: Pressure Transducer
• Manufacturer: Haenni
• Type: ED505/314.221/155 0-400 bar
• HD Number: Z21163

• Items: Cooler Temp. Switch
  Manufacturer: Trafag
  Type: ISNT 11015
  HD Number: Z21049

• Items: Speed Encoder
• Manufacturer: Hagglunds Drives
• Type: SPLL85A-02
• HD Number: 378-1445-813

• Items: Pressure Gauge
  Manufacturer: T.J Williams
  Type: 0-25Mpa 63mm ¼” bsp
  HD Number: Z21049

• Items: Denison Multifunction Proportional Valve Dual Driver
  Manufacturer: Denison Hydraulics U.K Ltd.
  Model: 027-22070-0

• Items: SLC500 Analog Output Card
  Manufacturer: Allen Bradley
  Model: 1746-N041

• Items: Speed Indicator Unit
  Manufacturer: Redlion UK
  Part No: P4810000
  Dimension : 50mm x 50mm x 60mm
  Input : 4 - 20 mA
  Supply : 24 Vdc

Replacement of Level Transmitter mA Module for U3 Intermediate Bin

The item for the replacements are as below:

• Item: Level Transmitter Guided level radar
• Manufacturer: Endress + Hauser
• Model: FMP40-AAA2GNJG21CA1
• Certificates: For non-hazardous area
• Probe version, material: 4mm rope, predominantly bulk solids, 316
• Probe length: 7000 mm, 4mm rope, 316
• Sealing: Viton O-ring
• Process connection & material: 1 ½” NPT, 316L
• Electronic insert/communication: 4-wire, 90…250VAC, 4-20mA
• Display: With display VU 331 incl. on-site operation
• Remote electronic: Standard compact device
• Housing and cable gland/entry: Aluminium F12-housing, coated, IP68

Stacker Reaclaimer at the Coal Stock Yard

Stacker Reaclaimer at the Coal Stock Yard

Air Regulator Leak and Pressure Gauge Cover Broken at the Dust Extraction Area

Dust Extraction Area

Air Regulator Leak

Pressure Gauge Cover Broken

Inductive Sensor IC5005 ICE3040-FPKG IFM Electronics

Inductive Sensor IC5005 ICE3040-FPKG IFM Electronics

This inductive sensor or limit switch currently used at the Fly Ash Silo Cone Closing System to give signal open/close to PLC for ash to disharge to the tanker.

Fly Ash Silo

Fly Ash Silo

Fly ash is one of the residues in coal fired power plant. At the Electrostatic Precipitator, fly ash is trapped and be removed periodically from the the ash hopper collector. Generally, the fly ash is pneumatically transported to storage silos which is called Fly Ash Silo for subsequent transport by trucks or railroad cars.

Parabolic Antena Vegapuls 68 Solid Radar Level Transmitter

Parabolic antenna is another type of the solid radar level transmitter. We just testing today how this new pattern of this level transmitter work. You may see the different between this and the horn antenna.

Parabolic Antenna Solid Radar Level Transmitter Vegapuls 68

Parabolic Reflector

"At the focal point of the parabolic reflector is the well-protected ‘feed system’. Microwave signals are radiated from the feed system and focused via the antenna surface. The entire antenna system can be detached for easy mounting."

Solid Radar Level Transmitter Vegapuls 68

A coal processing power plant always create problems during coaling to the bunker. The main problem that normally happened on our instrumentation field device is a difficulty to monitor coal bunker level when coaling or during receiving unprocessed coal to the bin either the level will fluctuating or just static at the certain level. The ultrasonic signal or any wave will affected by surface angle, air turbulence, temperature and spray dust. Therefore the reading will unstable for the sometimes. The accuracy of the coal bunker level reading should be very reliable to enable operator monitor the available capacity for the next tripper car bunkering. Do you all facing this problem in your coal fired power plant? The instrumentation guys should be a responsible person due to this problem. Haha... How do you tackle this problem?

Solid Radar Level Transmitter Vegapuls 68

This very sensitive narrow focused microwave beam Vega radar level transmitter using 'horn antenna' is unaffected by spray dust, air movement, temperature and vapors.

Specifications;
- Using microwave pulse
- Beam angle 22, 18, 10 and 8 degree
- Pressure 40 bars
- Temperature until 200 degree C
- Up to 70 meter application
- 2 wire 4...20mA/HART, Profibus PA and Foundation Fieldbus electronics

Horn Antenna

The microwaves are radiated to the horn antenna via a PTFE cone in the antenna junction and focused in the direction of the product surface. The inflected antenna rim ensures low antenna noise and thus high sensitivity at close range. Please refer Vega website.

Applications;
- Power plant as coal ash or fly ash
- Building material as cement, gravel and sand
- Food industry as sugar, flour, rice and grain
- Steel production as blast furnace, molten iron and coal

The non-contact radar level transmitter can save maintenance and service cost, increase sensor lifetime and can be more reliable. This entry post just to share with you all on how we as instrumentation technician reduce the problem that frequently happened. In the future, I will post why the old level transmitter can give a lot of problem to us. Therefore make sure you will come back and not miss the post. Thanks...

Wet Coal Cause Bunker Level Transmitter Fluctuate

The bunkers level start problem when bunkering with new coal. The situation seems that the problem occurred due to dust extraction filters too dirty which are covered with wet coal. Therefore the dust extraction filters have been cleaned and serviced by coal and ash maintenance team. After that bunkers level reading back to normal.

I am suspected that hot coaling had caused condensation in bunkers atmosphere and make dust inside the bunker becomes wet. When dust extraction does not function efficiently, wet coal dust accumulates at the bunker level transmitter. On Instrument side, temporary solution for the time being is to service and clean the level transmitter very often.

Bunker Level Transmitter Faulty

Unit No.1 Bunker 20

Unit No.2 Bunker 60 and 70

Remove bunker level transmitter and found transmitter detector dirty with wet coal dust. Service and clean then install back to bunker. Reading under monitoring by maintanance team. Picture attached for reference. As per maintanance team suspect dust extraction not working as well.