ORISSA POWER GENERATION CORPORATION LTD.

IB THERMAL POWER STATION, BANHARPALI

STANDARD MAINTENANCE PRACTICE FEEDER CALIBRATION

Document No: SMP / C&I 29 Filed At: Control & Instrumentation Dept The purpose of the SMP - Feeder Calibration is to train and guide maintenance personnel to ensure safe and efficient maintenance of the system. Responsibility: Team Leader, C&I Other Department To Be Intimated: (Main Plant Operation, Mech. Maint) Details of Hazards Involved 1. Dust 2. Noise 3. Fall from height 4. Electric shock 5. Falling Objects Safety Precautions Required 1. Ensure use of PPEs while working 2. Put the feeder run switch in off position at field (local panel). 3. Put the feeder in local mode at remote panel in MCR Permit Type: Permit To Work Order Permit Approving Authority: Shift in charge (Main Control Room) Isolation Procedure 1. Close feeder inlet chain gate. SMP - Feeder Calibration 1

2. Empty the coal from feeder belt by keeping the R.C. Gate open 3. Put mill in barring and start feeder. 4. After emptying the coal from feeder belt, R.C. Gate should be made close. 5. Open the four doors with the help of people from Mechanical Maintenance Team and carry out the tracking & leveling. T & Ps including special ones 1. Multi meter. 2. Watch maker screwdriver. 3. Feeder calibration kit that includes. (i) Two nos calibration pick up unit. (ii)Three cables. (iii) One calibration unit. 4. Four nos. of retro-reflecting tape. 5. One no. of chalk. 6. Hand Lamp Frequency of maintenance: Annual Outage / During Tripping / In case of failures. WORK INSTRUCTIONS PROCEDURE 1. Apply 4 strips of retro-reflecting adhesive tape from calibration kit to the right-toothed segment of the feeder belt. Each strip should be oriented vertically on the belt curb and located entirely between two flexing slits in the curb, rather than spanning over a slit. Place the 4 strips at approximately equal distance from each other, to assure that they are spaced at a distance greater than one calibration probe span length from each other. 2. Open the feeder electronics compartment. 3. The calibration should be in off position. SMP - Feeder Calibration 2

4. Remove the two bolts adjacent to the weigh span roller grease fittings for insertion of the calibration probes. 5. Remove the protective caps from the calibration probes and insert one probe into each access port in the feeder body, taking care to align the detention pins on the probe with the machined holes in the feeder. Although the two probes are not dedicated to a particular location, note that the probe location nearest to the feeder inlet is designated START OR A & the probe location nearest to the discharge is designated STOP OR B. 6. Connect the two probe cables to the probes and to the calibration instrument. 7. Connect the feeder cable to both the calibration instrument and the feeder. 8. Verify that the calibration weight is off the weighing roller. Start the feeder by placing the feeder mode selector switch (SSF) in the local position and the local mode switch (SLF) to Run. Maintain the speed at 900 + 200 RPM. The speed setting is not critical, but the higher RPM setting speeds up calibration procedure. 9. Set the calibration instrument as follows. i. Mode selector switch to the belt position. ii. Feed rate code digit switches to the same feed rate code as set on the thumb wheel switches of the load cell amplifier card, A2, in the feeder control cabinet electronics assembly. iii. Event select to 4, the no. Of reflective tape markers on the belt. 10.Press the Reset button on the calibration instruments. After a delay, the display starts to accumulate counts and stops counting after one complete belt revolution. A. After every cycle, the instrument stores this number and uses it as a reference to adjust the tare signal. Press the reset button to repeat this SMP - Feeder Calibration 3

step several times, a repeatability of + 10 counts should be obtained. This gives an indication that the instrument is operating correctly. Poor repeatability indicates that one of the following conditions may exist; an incorrect no. of reflective tapes may have been installed on the belt, the tapes are closer together than the calibration probe span, the weigh span is located beneath the drive pulley at above the inlet belt support roller or there may be binding of one or more of the load cell assemblies. Once repeatability is achieved, do not reset the calibration instrument before proceeding to the next step. 11.Adjust tare as follows. A. Place the mode selector switch to the tare position and press the reset button. After a delay, counts are subtracted from the number stored. During this test use a DVM to measure the voltage between test points TP8 (Green) and TP9 (Black) on the load cell amplifier card, A2. After one complete belt revolution, the instrument stops subtracting. The result can be positive or negative (indicated by flashing lamp). Positive number Tare adjust too low. Tare adjust too high. Negative number -

12.To adjust the tare signal, two potentiometers are provided on the load cell amplifier card, A2 coarse adjust (R33) and fine adjust (R 34). For each, a clockwise turn increases the signal. 13.Continue to readjust the potentiometers as necessary to obtain a tare reading of Zero 5 courts. 14.Engage the calibration weight. 15.Adjust the span as follows: i. Place the mode selector switch to the span position. ii. Press reset and the calibration instrument display will indicate 100.00. After a delay, the display will start four counting cycles and display a final number. The displayed number represents the SMP - Feeder Calibration 4

span calibration error in percent. As before display implies a negative result. Error Positive Error Negative Increase Span. Reduce Span.

16.To adjust the span, two potentiometers are provided on the load cell amplifier card, A2: coarse adjust (R19) and fine adjust (R20). For each a clockwise turn increases the span. 17.Place the instrument mode selector switch in the Tare Position and measure the voltage between test points TP8 and TP9 on the load cell amplifier card, A2. 18.Adjust the voltage by the percentage indicated on the calibration instrument using the span adjust potentiometer, R19 and R20. Do not adjust the tare adjust potentiometers, R33 and R34. 19.After the span adjustment is over, disengage the test weight and remove the calibration instrument and probes from feeder. completed. 20.Control Room Calibration: Calibration is

Control Panel adjustment:

1. Before adjustment in control panel, the loops are to be made at following terminals and standard weight i.e. 86.7 Kg is placed on belt. i. TB No. 5 ii. TB No. 1 iii. TB No. 1 Terminal No. 50, 51 Terminal No. 2,15 Terminal No. 7,9 No coal on belt No coal on belt Remote contact from FSSS

2. After making above connections feeder is to be made ON from remote. a. Apply 0% demand command from A/M station. Observe that feed rate should be 12 T/H. If not, then adjust minimum rate potentiometer R 23 of ISF card .

SMP - Feeder Calibration

b. Apply 100% demand command from A/M station. Observe that feed rate should be 60 T/H. If not, then adjust the maximum rate potentiometer R 45 of ISF card.

3. After adjustment in control panel is over, remove all the connecting loops and remove the standard weight from the belt.
Checks before release of Permit 1. For defects action should be taken as per the requirement. 2. After ensuring the completion of feeder calibration, the doors are to be closed, PTW may be returned. 3. All T & Ps and manpower are removed

Revision No & Date

Prepared By S. Mohanty

Verified By Technical Committee

Approved By Director (Operation)

SMP - Feeder Calibration