Online Coal Analyzer: 6A/B Belt at TP6

Online Coal Analyzer: 6A/B belt at TP6
1) OVERVIEW OF COAL ANALYZER:

Traditional method of coal analysis by offline method is time consuming
and accurate results depends on sample preparation. Online coal
analysis given by coal analyzers installed on running conveyer belts will
be useful in getting accurate results immediately. Following parameters
are measured/derived by element analyzer: Ash, Moisture, Calorific
value, Sulphur, ash contents (e.g. CaO, SiO2, Al2O3, Fe2O3, TiO2, K2O,
Na2O) etc.
2) COMPONENTS OF ONLINE COAL ANALYZER:

Online Coal analyzer consists of three major components belt scale,
moisture analyzer and measuring unit. Output of all are connected to
signal processing cabinet.
2.1) Belt scale:

Belt scale is used to measure coal flow passing through coal analyzer.
Belt scale readings will be useful in calculating ash components.
Fig. : Belt scale
2.2) Moisture analyzer:
Fig.: Moisture analyzer

DF-MMA Microwave Moisture Analyzer is online non-contact type
material moisture analyzer. When the microwave passes through
material containing moisture, speed and intensity of microwave
changes. By detecting power attenuation and phase misalignment
material moisture content can be calculated.
Measurement system contains transmitting antenna, receiving
antenna, ultrasonic thickness sensor and main control unit.
Microwave signal generation, reception and analysis are performed
in main control unit.
2.3)Measuring Unit:
Neutron source and detector are installed in measuring unit.

Measuring principle is based on Prompt Gamma Neutron Activation
analysis (PGNAA).
Fig.: Measurement principle

Fig.: PGNAA analyzer
PGNAA analyzer mainly include following:
Neutron source, detector, measuring unit, signal processing cabinet,

network cabinet, host computer.
Components functions and details are listed below:

I. Detector
Detector receives characteristics energy gamma rays of
elements of materials and converts them into required
electrical signals. DFB-1115 detector model is used which
requires low voltage (+/-12V), high voltage (-1250~0V) power
supply and constant operating temperature (+/-6 degreeC/h)
for its working. These supplies are provided from signal
processing cabinet.
II. Signal processing cabinet
Signal processing cabinet provides power to analyzer and
pre-processes signal generated by detector. Following is
detailed layout of components inside signal processing
cabinet:
Fig. (g): Layout and chart of SPC
DFB-9220A power system provides high required for

detector. DFB-5103A temperature controller used to
maintain constant operating temperature for detector to
avoid measurement errors due to ambient temperature
changes. DFB-0402 digital multi-channel system used for
energy spectrum acquisition at high count rate.
III. Upper Computer
Function of the upper computer is to analyze data received
from signal processing cabinet, provide HMI and it is used for
remote troubleshooting also. Upper computer is installed in
CHP control room.
IV. UPS
Uninterrupted power supply of 220/230/240VAC has been
supplied with coal analyzer package. Total of 15 minutes of
power backup is provided by UPS when there is sudden power
shutdown.
Technical features include multi-element analysis every minute,
quick high accuracy real time data and trends, historian, system
status and alarms. Coal analysis typically used in coal blending
process.
3) LAYOUT, COMPONENTS AND FUNCTIONS OF ONLINE COAL

ANALYZER
Fig. : Layout
Coal analyzer components namely measuring unit, moisture
analyzer, belt scale are installed across the belt. Signal processing
cabinet used for processing of data received from all of the above.
Host computer can be used for remote access of data.
4) ERECTION OF ONLINE COAL ANALYZER
Following is detailed drawing for coal analyzers installed on Conveyor

6A and Conveyor 6B at NTPC Solapur.
Fig. : Coal analyzer detailed drawing for NTPC Solapur

5) COMMISSIONING, MAINTENANCE AND CALIBRATION
5.1) Analyzer commissioning
a) For first time switching on power supply make sure that all cable
connections are ok. Foreign material if there is any must be
removed from analyzer. After that switch on power supply.
b) Check running status of analyzer. For troubleshooting purpose
configuration of upper computer and lower computer can be
checked for proper communication.
c) For Detector healthy status following parameters must be within
range:
Temperature: 39-55 degreeC
High voltage: 300-1100V
Peak position: 221.8-222.8
Live time: 0.7-1
5.2) Analyzer calibration

a) Static calibration at factory is done before dispatching analyzer
from factory to site.
b) Static calibration at site can be carried out after assembling of
analyzer at site. It is necessary to verify static performance at site
to observe if there is any deviation because of transportation or
site conditions. Check analyzer normal running condition after
installation of source correctly. Communication of analyzer,
moisture meter, belt scale to SPC should be healthy. Every
standard sample testing under analyzer must be done for 1.5 hours
and Commissioning engineer will do parameters verification for
each sample.
c) After completion of static calibration at site we can move to
dynamic calibration.
. Confirm sampling plan: By auto sampler or manual
. Take subsamples
. Do lab test of coal sample
. Calculate and adjust the coefficients by comparing lab
results with analyzer results
5.3) Maintenance for analyzer
Hardware and software inspection is required for maintenance of
coal analyzer.
a) Following hardware should be inspected regularly for
maintenance of coal analyzer:
Fig. (j): hardware inspection
b) Software inspection:
. Checking of temperature indication, high voltage
indication, hydrogen peak and live time indication
. Check for any abnormal status alarms
6) Safety Operation
a) Ambient dose rate of source DF5703(A) must be monitored for
safe operation of analyzer. Radiation level at 1-meter distance
from industrial IRGD should be less than 2.5 uSv/Hr.
b) Source open/close and analyzer normal running indication LEDs
are provided above analyzer.
c) Radiation protection:
i) Radiation dose rate is inversely proportional to the square of
the distance from a source.
ii) Radiation dose is proportional to the amount of time exposed
to the source.
iii) Heavy metals or cement greatly attenuate intensity of rays
and same can be used as shielding material from source.
d) Electrical Hazards:
i) Do not take power supply for any other equipment from SPC.
ii) Turn off power supply before servicing any equipment
related to analyzer.
iii) Do not touch any electronics inside SPC as it contains built-
in high voltage power supply to avoid electric shock.
e) Emergencies: (In case source getting exposed)
. Turn off all power supply to analyzer.
. Notify on-site RSO.
. Restrict area around possible radiation area.
. Notify DFMC and other responsible government
authorities.

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Online Coal Analyzer: 6A/B belt at TP6

1) OVERVIEW OF COAL ANALYZER:

2) COMPONENTS OF ONLINE COAL ANALYZER:

2.1) Belt scale:

Fig. : Belt scale

2.2) Moisture analyzer:

Fig.: Moisture analyzer

Neutron source and detector are installed in measuring unit.

Fig.: Measurement principle

Neutron source, detector, measuring unit, signal processing cabinet,

Components functions and details are listed below:

Fig. (g): Layout and chart of SPC

DFB-9220A power system provides high required for

3) LAYOUT, COMPONENTS AND FUNCTIONS OF ONLINE COAL

4) ERECTION OF ONLINE COAL ANALYZER

Following is detailed drawing for coal analyzers installed on Conveyor

Fig. : Coal analyzer detailed drawing for NTPC Solapur

5.2) Analyzer calibration

Fig. (j): hardware inspection

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