DOCUMENT COVER SHEET

PROJECT NAME

: BARH STPP (3 x 660MW) SG Package

CONTRACT NO.

: XXXXXXXX

ITEM

: Performance Procedure

DOCUMENT TITLE : Procedure for Clean air flow test of coal pipes

For approval
REV.

DATE

DESCRIPTION

DGN

CHECK

REVW

APPR

NTPC Limited.
(A Government of India Enterprise)

CONTRACTOR
DOOSAN POWER SYSTEMS INDIA PRIVATE LIMITED
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION Co., Ltd. Korea
CATEGORY

Approval
DOOSAN

DOCUMENT NO.

NTPC

REV.

SHEET

BARH STPP
DOC.No.
(3 x 660MW)
XXXXXXXXXXXXXXXX
Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

TABLE OF CONTENS

SL. NO.

DESCRIPTION

1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICE REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDIX

Sheet
1 of 9

BARH STPP
DOC.No.
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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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1.0 PLANT DETAILS

1.1 Total 10(Ten) mills are provided with each Unit of 660 MW Capacity. These mills are designated as A, B, C,
D, E, F, G, H, J ,K.
1.2 4 (four) coal pipes emanate from each mill and terminate at four of the coal burner assembly. These coal pipes
are subjected to clean air flow test to ensure uniform flow in all the coal pipes. The size of coal pipe is like
below.
- Straight portion : I.D (
mm) / O.D (
mm)
- Bending portion : I.D (
mm) / O.D (
mm)
2.0 OBJECTIVE
2.1 Initial verification of mill air flow with cold air
3.0 For each of Mill A through K, to verify the air mass distribution to each burner of the boiler, and make
certain that the distribution complies for acceptance. Percentage flow deviation between burners must not
exceed +/- 5 %.)(To be confirmed by Tyazmash / TKZ)
3.1 PROPOSAL
3.2 Clean Air flow tests shall be conducted individually for all the mills with cold air.
3.3 Primary air Fan shall be run and measurements shall be taken at specified locations of coal pipes using Pitot
tube. (Pitot tube tapping points are to be at a distance of minimum 1 times internal diameter of coal pipe in
the downstream and minimum 5 times internal diameter of coal pipe in the upstream as per ISO:9931)(To be
confirmed by Tyazmash)
4.0 SERVICES REQUIRED
4.1 Availability of Pitot tube with required accessories.
4.2 Availability of man power with required tools for attending any leakage in the system.
4.3 Availability of operating personnel.
4.4 Availability of lighting arrangements and communication facility at the burner floor.
4.5 Availability of portable fire fighting equipment near test area.
4.6 Availability of instrument air supply
5.0 SAFETY PRECAUTIONS
5.1 First aid kit should be available in the test area.

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PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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5.2 The test team members should be aware of the procedure being adopted.
5.3 Other agencies working near the test area should be informed of the activity.
5.4 All compressed air hoses and fitting are in good condition; inspect hoses and fittings daily.
5.5 Wear protective goggles or face shield during measuring.
5.6 Wear protective gloves during measuring.
5.7 Avoid direct contact with hot surfaces.
5.8 Keep the work area clean and neat. Electrical hoses should be laid flat and out of work areas
5.9 Always hold connectors firmly and away from workers face when connecting and disconnecting
5.10 Do not modify the Dirty Air Pitot System in any way. Contact the manufacturer before conducting any
maintenance or repair.
5.11 Proper approach will be available for taking measurement.
6.0 EMERGENCY PROCEDURE
6.1 The test team should be aware of the steps to be taken to stop the running equipment in case of any
emergency / abnormal observations.
6.2 The test team should be aware of actions to be taken in case of injury to any personnel.
6.3 The test team should be aware of operating instructions of portable fire extinguishers.
7.0 STATE OF THE PLANT(To be confirmed by Tyazmash / TKZ)
Pitot tube to be used for clean air flow test is a calibrated one and calibration certificate will be made available
7.1 Open the hot air gates and cold air gates for only the test mill.
7.2 Open hot air damper to nominal 30% and cold air damper to nominal 15% on the test mill. Make final trim
adjustment in this position as advised after inspection of operating condition.
7.3 Provide a flow path for the cold air and hot air from the PA fans to the mills.
7.4 Make sure the mill discharge gates for test mill to be separately are open and the burner shutoff gates are open
at coal burners for the test mill.
7.5 Start mill seal air fans and open seal air dampers to the test mill.

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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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7.6 Before the test, Boiler will be operated as the following sequence.
(GAH -> IDF -> FD FAN -> SEAL AIR FAN)
7.7 Start one set of ID and FD fans and make certain the furnace pressure control is stable.
7.8 Start one PA fan and adjust the hot air duct pressure to nominal 813 mm wg. Check that the hot air duct to
furnace differential pressure is stable and nominally 825 mm wg.
7.9 Hold the settings for the duration of the clean air flow tests. No adjustments are permitted to the mill PA
dampers while the clean air flow tests are in progress.
7.10 After the clean air flow tests are complete, the PA fan can be stopped and the test mill PA gates closed. The
seal air fans should then be stopped and the ID and FD fans shutdown in the nominal manner.
8.0 Method
8.1 Connect the pitot tube lines to the tube umbilical and to the manometer. Ensure that the high pressure line is
connected to the positive side of the Bluetooth meter and the low pressure line to the negative side of the
Bluetooth meter.
8.2 Connect the pitot tube thermocouple plug to the tube umbilical and to the thermocouple plug on the
Bluetooth meter
8.3 Zero the pressure transducer using the following steps.
8.3.1 Place the tip of the pitot tube in a still area, with no air currents, so there is zero velocity at the probe tip.
8.3.2 Press the Menu/Save button on the Bluetooth meter (this is the center button with a white dot, located
below the text Menu on the screen).
8.3.3 From the menu items, select Zero Pressure and then press the Enter button (the large oval button at
center with arrow).

BARH STPP
DOC.No.
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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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8.4 Installation of the pitot tube;

8.4.1 Connect a compressed air line to the Fast-Lock Seal Air
Fitting(SAF-FL). Air will now flow into the SAF-FL. The
compressed air should be heard flowing inside the fitting. If
no flow is present, check operation of the compressed air
source.
8.4.2 Open the ball valve while standing to the side and ensuring
no other personnel is in the vicinity of the port. CAUTION
seal air will blow out of the test port and may
contain residual coal fines or other particulate.
8.4.3 Insert the pitot tube through the SAF-FL and fasten the two handles of the Fast-Lock Dustless Connector.
8.4.4 Turn off the air supply to the SAF-FL.
8.5 Position of the pitot tube to the first traverse point by pushing it gently into the fuel pipe until it touches the
opposite wall of the fuel pipe. These points are indicated on the Traverse Rod, which is attached to the probe
and Fast-Lock Dustless Connector.

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PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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8.6 Traverse the cross-section and for each measuring point;

8.6.1 Position the probe at Traverse Point 1 by withdrawing
the probe until the top of the first triangle on the
Traverse Rod is visible, and aligned with the guide
block on the probe.
8.6.2 Take pressure (and temperature) readings using the Bluetooth meter. The Bluetooth meter is set up at the
factory to sample for 5 seconds and display the average value over the 5 second sample period. Sampling is
initiated by pressing the Enter button. The display will then show the average pressure and temperature
values.
8.6.3 Write down the measured values on a data sheet or use the Save feature of the Bluetooth meter.
8.6.4 Proceed to next measuring point in the pipe. By withdrawing the probe slowly until the tip of the next
triangle on the Traverse Rod is visible. Continue taking pressure and temperature readings for each point of
the Traverse Rod (16 points total)
8.6.5 After all velocity measurements have been taken, measure the static pressure with the following steps.
Position the probe so the tip is at the pipe centerline. Remove the LOW pressure line from the Bluetooth
meter so that only the high pressure line is measured. Write down the pressure value displayed. This value,
called PH, is not the static pressure, but is used with the equations of Section 2.5 to determine the static
pressure in the pipe.
8.6.6 After all measurements have been taken, turn on the compressed air supply to the Fast-Lock Seal Air
Fitting. Confirm that air is flowing by listening to the fitting, then unlatch the handles of the Fast-Lock
Dustless Connector and remove the probe. Close the ball valve, then turn off the compressed air supply.
Testing of this port is completed.l
8.7 Repeat steps 4, 5, and 6 for the other test port on the coal pipe. The traverse is now complete.
8.8 Velocity Calculation(To be confirmed by Tyazmash / TKZ)
The differential pressure readings can be converted into air velocities using the following basic formula.
V = C x [(2xP/ )] for the velocity
Where;
C = Dirty Air Pitot Tube calibration coefficient
P = Measured differential dirty air pitot pressure [Pa]
= Air or gas Density at actual gas/air conditions [kg/m3]
V= Air/gas flow velocity (m/s)
If manometer displays P in Pascal conversion has to be done; Converting the P [Pa] to P[mmWG],
insert 9.81xP[mmWG] for P[Pa]
V = C x [(2x9.81xP)/ ], where; P unit = mmWG
= C x (2x9.81) x (P/ ) = 4.42 x C x (P/ )
= ( 0 x T 0 x P) / (P 0 x T) for the gas density
Where;

= Air Density at actual duct conditions [kg/m3]

T = Actual absolute temperature [K]
Ps = Static pressure = PH (Cp x C x P)
PH = Pressure measured on high side line only, per Step 8.6.5 of procedure

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DOC.No.
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PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

Sheet
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C = Dirty Air Pitot Tube calibration coefficient (0.9~1.1)

Cp = Probe static pressure calibration coefficient (0.45~0.65)
P = Actual pressure [Pa]
= Static duct overpressure (Ps , [mmWG]) + Barometric pressure (Pb ,[mmWG])
Converting formula units by inserting the followings
0 = 1.292 [kg/m3], P0 = 101325 [Pa] = 10332.27[mmWG], T0 = 273.15 [K] at 0C, 1 atm Air
= [1.292 x 273.15 x (Ps + Pb)]/ (10332.27 x T) = (Ps + Pb)/ (29.28 x T)
Using the above formulas, preferably in a spreadsheet format , the velocity can be calculated at each traverse
point. This allows the average air velocity in each individual coal pipe to be calculated.
Subsequently, the flow balance of all five coal pipes of the test mill can be calculated. Determine the minimum
& maximum variation from average velocity for five (5) coal pipes of one(1) mill. Allowable tolerance for this
variation is 5 percent from the average.
( Max. Velocity Average Velocity )
% Maximum Variation =

X 100

------------------------------------------------

Average Velocity
( Min. Velocity Average Velocity )
% Minimum Variation =

X 100

-----------------------------------------------

Average Velocity
8.9 Air flow calculation
Mass Flow rate, kg/s = * A * V,

(V=4.42 x C x (P/ ) ) , [kg/m3] A[m2] V[m/s]

9.0 Completion Criteria

9.1 The clean air flow test for Coal Pipes of a Mill is declared complete if the maximum and minimum
percentage deviation in velocity of air is within + 5.0 % of the average velocity.
9.2 In case the deviation is not within the allowable limit, orifice shall be adjusted.
Figure 1. 16 Position Traverse in 27 inch Pipe

BARH STPP
DOC.No.
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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

Sheet
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PULVERIZER CLEAN PRIMARY AIR FLOW TEST

THERMAL POWR PLANT

DATE
UNIT NO.
PULVERIZER NO.
PULVERIZER LOAD

T/H simulated feed rate or mmwg DP at Venturi

PIPE DIMENSION AT TRAVERSE

CROSS SECTIONAL AREA OF TRAVERSE;

m2

m
CONTROL ROOM DATA;
START

FINISH

AVERAGE

TIME
ATMOSPHERIC TEMP.

Deg.C

SIMULATED FEED RATE

T/H

PULV. EXIT TEMP.

Deg.C

PULV. PA FLOW

kg/s

PULV. PA INLET TEMP.

Deg.C

HAD POSITION

Precent

CAD POSITION

Percent

PULV. BOWL DP

mmwg

PA. TO FURN. DP

mmwg

FURNACE PR.

mmwg

FIELD DATA;
VENTURI DP(manometer)

mmwg

VENTURI DP(XMTR.-01)

Percent

VENTURI DP(XMTR.-02)

Percent

VENTURI DP(XMTR.-03)

Percent

Table 1. Test Data Sheet 1 of 3

BARH STPP
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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

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PULVERIZER CLEAN PRIMARY AIR FLOW TEST

THERMAL POWR PLANT

m2

PIPE SECTIONAL AREA (A)

STANDARD GAS DENSITY ( 0)
PITOT TUBE COEFFICIENT (C)

kg/cm2

PF PIPE NO

#1

TEMP (T)
Deg.C
POSITION
1-1

mmwg

1-2

mmwg

1-3

mmwg

1-4

mmwg

1-5

mmwg

1-6

mmwg

1-7

mmwg

1-8

mmwg

1-9

mmwg

1-10

mmwg

1-11

mmwg

1-12

mmwg

1-13

mmwg

1-14

mmwg

1-15

mmwg

1-16

mmwg

2-1

mmwg

2-2

mmwg

2-3

mmwg

2-4

mmwg

2-5

mmwg

2-6

mmwg

2-7

mmwg

2-8

mmwg

2-9

mmwg

2-10

mmwg

2-11

mmwg

2-12

mmwg

2-13

mmwg

2-14

mmwg

2-15

mmwg

2-16

mmwg

PRESS at
HINGESIDE (PH)
STATIC
PRESS (Ps)

mmwg

#2
P

#3
P

#4
P

mmwg

Table 2. Test Data Sheet 2 of 3

#5
P

BARH STPP
Doc.No.
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Plant Area: BOILER
PROCEDURE FOR CLEAN AIR FLOW TEST OF COAL PIPES

Sheet
9 of 9

PULVERIZER CLEAN PRIMARY AIR FLOW TEST

THERMAL POWR PLANT

DATE
UNIT NO.
PULVERIZER NO.
PULVERIZER LOAD

T/H simulated feed rate or mmwg DP at Venturi

AIR FLOW CALCULATIONS;

PF PIPE NO

SUM SQRT P
AVERAGE SQRT P
DENSITY AT TRAVERSE ()
AVERAGE AIR VELOCITY IN PIPE
VOLUMETRIC FLOW RATE
MASS FLOW RATE
PRECENT FLOW DEVIATION

kg/m3
m/s
m3/s
kg/s

percent

AVERAGE AIR FLOW PER PIPE

TOTAL MASS FLOW OF PR&SEAL AIR
TOTAL MASS FLOW OF PA

kg/s
kg/s
kg/s

VENTURI DP : ACTUAL vs. INSTURMENT

ACTUAL VENTRUI DP(manometer)

mmwg

FLOW XMTR 10s

INSTRUMENT VENTRUI DP (XMTRs)
PRECENT DEVIATION FROM ACTUAL

01

02

03
mmwg
percent

INDICATED AIR FLOW vs. ACTUAL AIR FLOW;

INDICATED FLOW
T/H

CORNER
PERCENT FLOW DEVIATION

ACTUAL FLOW
T/H

CORRECTION
FACTOR

5
percent

Table 3. Test Data Sheet 3 of 3