AHP INTRODUCTION The write up outlines the design and operation of ash handling system indicating broadly the

basic operating conditions/functions of various equipments for 2*300 MW !" thermal power station# $amuna nagar %nits & '(2 for collection# handling ( disposal of bottom ash# coarse ash and fly ash and its associated systems i)e) ash water# ash water recovery# clarification# instrument ( fluidi*ing air system) DETAILS OF PLC/CONTROL PANELS +or controlling the ash handling system %nit & '(2# under noted control panels are provided,./ 01! based control panel 2/3 rac4s , ' no) 5!ommon for %nits/ location, .60 control room 2) 7ottom ash control panel ash 3) silo control panel the ,2 nos)5one for each %nit/ location, near bottom hopper ,'no)5common for both

') Main control des4 both

8ilos/ 1ocation, 8ilo operating floor 9) 2/3 rac4 ash water pump house both unit/ ,' no)5common for 1ocation, compressor house :) 2/3 rac4 ash slurry pump house both , 'nos)5common for %nits/ location, compressor house ;) 2/3 rac4 <80 unit/ <80 area 7/ "elay based control panels , ' no) location, Water pump house electrical room MAIN CONTROL DESK Main control des4 will be located in ash handling control room) 2 nos) pc with 2'= 1! 5MM2/ will be provided on the des4 for the following, a/ engineering/operating station b/ engineering/operating station .ll the operation of individual drives ( system will be achieve from MM2 ,2 nos)5one for each 1ocation, each

') "ecovery water control panel recovery

BOTTOM ASH CONTROL PANELS These panels will be located near the bottom ash hopper of respective unit) The panels will have the push buttons for manual controls> no auto operation is envisaged for 7. system from the MM2) SILO CONTROL PANEL 8ilo control panel will be located at the silo area) the panel will have the push buttons for manual controls# mimic with indication for drive status ( alarm annunciators)<ach drive ( valve required to operate silo system 5ash unloading in dry/semi wet mode in close/open truc4s/ can be achieved in manual mode from the push buttons provided) ?o operation is envisaged from MM2)however status can be monitored in the MM2) I/O RACK # AWPH This remote 2/3 rac4 will be located in ash water pump house) The 2/3s# power supplies etc) will be mounted in the rac4) 2/3s related to ash water pump house equipment will be provided in the rac4) no operation is envisaged from this panel) I/O RACK # ESP This remote 2/3 rac4 will be located near <80 of respective unit )the 2/3s# power supplies etc) will be mounted in the rac4) 2/3s related to <80 hopper valves# switches will be provided in the rac4) no operation is envisaged from this panel)

I/O RACK # ASPH This remote 2/3 rac4 will be located in ash slurry pump house )The 2/3s# power supplies etc) will be mounted in the rac4) 2/3s related to ash water pump house equipments will be provided in this rac4) ?o operation is envisaged from this panel) EQUIPMENT DESCRIPTION %nder noted equipments /drive are controlled from 01! panels) EQUIPMENTS PROVIDED PER UNIT i/ !lin4er grinder wor4ing @ 2 ii/ 7ottom ash overflow drain pump wor4ing @ iii/ <conomi*er water pump wor4ing @ ' SYSTEM DESCRIPTION bottom as ! "oa#s$ as a%&'(%) s*st$m , 9 nos)52 8tandby/per unit , 2 nos)5' 8tandby/per unit , 2 nos) 5' 8tandby/per unit

The free falling ash from boiler furnace is collected ( stored in a W shaped water impounded bottom ash hopper provided below the boiler furnace for its periodic removal once in a shift of 5A/ hours per unit)

The hot ash from the furnace gets quenched as it enters into the water minimi*ing the clin4er formation) The miBture of ash ( water stored in the hopper is discharged through feed gate to clin4er grinder to crush the oversi*e clin4ers) The crushed clin4er along with water which forms bottom ash slurry is conveyed to ash slurry sump through hdroeCector 5Cet pumps/ for further disposal to ash disposal pond through ash slurry disposal pumps) Water required for Cet pumps is supplied from high pressure 560/ ash water pumps located in ash water pump house) !oarse ash from economi*er hoppers is eBtracted continuously and miBed with water in flushing boB provided below each hopper ( collected in bottom ash hopper for periodic removal along with bottom ash) Water required for miBing economi*er ash is provided through separate economi*er ash water pumps) 7ottom ash ( economi*er ash would be removed once in a shift of eight 5A/ hours in a approB D: min) per unit including : minutes flushing under maBimum continuous rating condition)

Water seal through arrangement is provided at the top of the bottom ash hopper for effective furnace seal ( to prevent ingress of air into the furnace) a cooling trough arrangement is also provided at the top of the hopper) Water supply to the cooling trough will overflow continuously to provide continuous refractory cooling to enhance the life of refractory) +lushing header with no**les provided at the end of bottom ash hopper sloping walls agitates ( removes settled ash from the hopper) !ontinuous water will be fed in the bottom ash hopper for the purpose of maintaining water temp) below ;0 deg) !) the ma4e up will result in continuous overflow of water 5;0 deg !/# which will be led into an overflow weir boB) The overflow weir boB will maintain the necessary sealing between the furnace ( the atmosphere) ischarge from weir boB will be ta4en to bottom ash overflow sump) Water from this overflow slump shall be ta4en to ash slurry sump or clarifloculator tan4 through bottom ash overflow pump) F'* As Ha%&'(%) S*st$m+

+ly ash carried along with the flue gas from the boiler is collected continuously in .06# <80 hoppers and 8tac4s hopper hoppers) There are total ;: fly ash collecting hoppers) <ight 5A/ .06# fifty siB 5:;/ <80 and one 5'/ 8tac4 hopper) .ll these groups are connected to the main transport line through .ir <lectric segregating slide valves) <ach fly ash hopper is providing with one no) electro E pneumatic operated material handling valve# witch segregates the hopper from the branch transport line) <Btraction transportation and disposal of fly ash from <80 6oppers are in two stages) 2n first stage ash collected and stored in <80 hoppers is eBtracted in dry thru pneumatic vacuum eBtraction system using the mechanical eBhauster 5vacuum pumps/ and ta4en either in collector tan4 thru wetting head for wet disposal or# to intermediate buffer hopper for further transportation to ash silos) .sh collected in buffer hopper in transported by dry pneumatic pressure conveying system to fly as silo by a set of air loc4 tan4s) .ir required for transportation of the ash from buffer hopper is ta4en from transport air compressors)

+luidi*ing

air

blowers

are

provided to supply hot air for fluidi*ing the ash in <80 hoppers and buffer hopper for effective conveying of the dry fly ash) S('o Loa&(%) a%& U%'oa&(%), MiBture of air and ash transported from buffer hopper is discharged to either of the two fly ash storage silos) 3n discharge into silo# air gets separated from ash and clean air is vented out in to atmosphere thru vent provided on top of silos) <ach silo is provided with three outlets) 3ne outlet is provided with a manual isolation valve and hydro miB dust conditioner to unload the dry ash in conditioned from into open truc4 for further transportation/ disposal) 8econd ( third outlet is provided with a manual valve# a pneumatic operated 4nife gate valve and rotary feeder to unload dry ash in closed tan4ers using telescopic chute for further transportation to ash utili*ation centers) 8ilo aeration blower along with heaters is provided to assist in maintaining the fly ash in fluidi*ed condition during unloading operation)

6ydro miB conditioner water pumps are provided near silo to supply water to hydro miB dust conditioners) As s',##* D(s-osa', +our 59/ series of slurry pumps are provided to pump bottom# coarse and fly ash slurry to disposal pond) 7ottom/ course/ fly ash slurry received from respective systems is discharged into a common sump) +rom common sump is ta4en to main sump having four separate compartments) 0lug valves are provided for division slurry from one compartment to another) <ach compartment is connected to one series of ash slurry pumps consisting of three pumps) +our series of pumps are connected to each of the three ash disposal line to convey the ash slurry to disposal pond) . first pump of each series is directly driven thru gear and fluid coupling and a second series pump is driven thru belt drive arrangement) Manual cross over valves are provided to drive the ash slurry from any of the series to any of the three disposal lines) As .at$# s*st$m, 60# 10 and fly ash water pumps are provided in ash water pumps house for supply of water

to various points of respective systems) 8uction to these pumps is ta4en from ash water sump) 10 ( 60 water pumps are provided in ash slurry disposal pumps house for supply of seal water to gland seal of slurry pumps and clin4er grinders) 8uction to seal water pumps is ta4en from plant service water system) R$"o/$#* As Wat$# S*st$m, .sh water from ash pond shall be ta4en bac4 to the ash handling plant thru "ecovery .sh Water 8ystem) "ecovery water pumps shall pumps the ash water to the clarifloculator located with in the plant near ash water sump) . !larifier is provided for treating the recovered ash water and overflow/ drain water from .sh handling plant) .lum/ poly electrolyte will be do*ed in to the clarifier to settle the suspended solids in the ash water to reduce the suspended solids)!lear water shall be ta4en to ash water sump for further use in the ash handling system)8ludge from clarifier shall be ta4en to ash slurry sump by ash sludge pumps)

 8ophisticated sensors 8ensors are unaffected by material type and need no calibration ?on-contact measurement ma4es system appropriate for even the most sensitive materials 8ystem also has built-in temperature sensor that detects interior temperature inside the silo and compensates for influence of temperature on signal running time .ccuracy ?o more guesswor4 or inaccurate calculations) 3 mapping delivers true and absolute surface level values# volume and mass inside a silo or open bin)

"eliability and urability esigned and built for reliable# constant performance) %ses three independent channels to transmit and receive) <ase of use The systemFs easy-to-read 3- map# and the broad range of data it provides# ma4e it the most convenient and efficient tool for level measurement on the mar4et .0M Technology 6ow it wor4s The 3 1evel8canner employs a 2-dimensional array beam-former to transmit low frequency pulses and to receive echoes of the pulses from the contents of the silo# bin or other container

The deviceGs igital 8ignal 0rocessor samples and analy*es the received signals) +rom the estimated times of arrival and directions of received echoes# the processor obtains and generates a 3-dimensional image of the surface that can be displayed on a remote screen This unique device can then accurately determine the volume and mass of material# enabling an unrivaled degree of process measurement and inventory control) Traditional sensors with single transducer are only capable of measuring a single point on the contents surface) .0M implements a circular array of three transducers for beam forming both at reception and transmission) The sensor estimates the echoesF time delay and spatial direction by using 3. 5 irection of .rrival/ algorithms) 7y derivation from the geometrical structure of the bin 5entered by user/# all echoes from contents surface are considered# while echoes silo walls are discarded) 1ow frequency implementation usually suggests 6igh beam widths and poor ability to avoid echoes from silo walls) 1arge antennas with large dead *ones)

.0MFs three transducers implementation and 3. algorithms enable use of low frequency pulses with cancellation of walls echoes and small dead *ones .0MFs sensor use low frequency pulses 53-: H6*/ for wide angle coverage and good performance at rough conditions) The attenuation graph has a 4nee at :Hh*) The low frequency implementation results in good performance at dusty highly moisturi*ed environments) elays and spatial directions of the received echoes are displayed in a 3 surface map) 8urface map enables accurate estimates of volume and mass# even at high surface irregularity conditions +requency, 3-: H6* 7eam angle, 30-D0 degrees 2nterval, I 2s .ccuracy, ': mm Measuring "ange, 0):-D0m Temperature .ccuracy, 0):JH

0rocess temperature, -90J E K:J! 0rocess pressure, -0)2 E ' bar 0rotection, 20 ;;/;D 0ower supply, '9-30L <<B# '9-3;L ?on-<<B# 520-3;L 9W/ 2nterface, 9M20 m.# 6."T 9w .#7# streams running in dry)

! stream line to be connected to standby 7' buffer hopper) A' bag filters in one buffer hopper K pulse air Cet solenoid valves 6ydroeCector is a gravity fed Cet pump which propels a miBture of water and soild granular material in to a pipeline ) < type material handling vale is fitteb below ash hopper ) 6opper is isolated from transport piping by slide gate of M6L ) Two air inlet chec4 valves provided between hopper outlet and slide gate to miB air in to dry ash when needed ) 8lide gate isolatd <80 hopper branch lines from main transport piping ) Lacuum brea4er brea4s vacuum in hydrovectros system when water pr falls approB ' 4g/cm2 below operating pr ) 6ydro miB dust conditioner miBes water to dry fly ash to avoid dust nuisance while dicharging material from stoeage bins in to truc4s etc ) "otary feeder controls discharge rate of fly ash from silo to truc4s ) .ir loc4 valve transfers dry ash from one pr *one to other pr *one while maintaining isolation between pr *ones ) 2'0 MW 7ottom ash '')2: <co ash 2)2: .06 ash '): <80 ash ;0 Total ash D: :00 MW 2A ; 9 '99 'A0 ;;0 MW 3; D : 'K2 290

 20 N 3f the ash falls at the bottom of the furnace 4nown as 7ottom .sh 57./) A0 N of the ash carried away with flue gas 4nown as +ly .sh) ESP ASH REMOVAL SYSTEMS L.!%%M T$0< 8$8T<M8 - 8%2T< +3" "<M3L2?O M.T<"2.1 +"3M M.?$ !311<!T23? 032?T8 .? 28!6."O< T3 3?< 032?T5<80/ - M.T<"2.1 !3?L<$< .8 . 8%80<?823? 2? T6< 020< .T 62O6 L<13!2T2<8 VACUUM TYPE SYSTEMS 0 PROS AND CONS 82M01< 1.$3%T E 3<8 ?3T "<P%2"< M%!6 6<. "33M 7<13W <80 82M01< 2? 30<".T23? ?3 1<.H.O< 3+ .86 <.8$ T3 M.2?T.2? 62O6 W<." .? T<." #<80<!2.11$ .T L.1L<8 .? 7<? 8 "<8T"2!T23? 3? !3?L<$2?O ".T</ 28T.?!< E M.Q) ;0 T06/':0 M

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