-1-1) Application,for conveying fly ash from outlet of ESP, Eco, APH Ash Hoppers to

inlet of fly ash silo.2) Material free flow, Type of feed Gravity, Bulk Density of coal 600 kg/m3,

Moisture content Nil.3) Temperature / Ash Collection Data ( Design Ash Collection )

ESP ECO/APH Bed Zone150 / 6573

kg/hr300 / 300 /

4) Type of system - Dense Phase Pneumatic Conveying 5) Vessel size

Bed Eco APH ESP 1 ESP 2 ESP 3 ESP 45 cft 3 cft 3 cft 8 cft 8 cft 4 cft 4 cft

9) Conveying line size Bed Eco Esp1,2 Esp3,4100 NB 80 NB 100 NB 80 NB

6) No of Collection Points= 10 nos7) Bulk Density

Bed Ash Eco/ APH/ESP1.2-1.4 T/m3 0.7 T/m3

11) Air VolumeInstrument Conveying1.25 m3/min 16.2 m3/min

8) Silo Volume Bed Ash Fly Ash150 m3 350 m3

Ash Conditioner Capacity

Bed Ash Fly Ash10 TPH 40 TPH

9) Cooling Water Supply Pr. 1.5- 2 Kg/cm2,Fluidizing Blower Pr. 0.5 Kg/cm2 10) Surge Hopper Volume

Bed Ash Eco/ Aph10 cft 9.5 cft

11) Air Receiver Capacity = 6 m3,Inlet Dome valve size 200 NB 12) ABR= After Bend Reducer, OBCR = Over Bend Circulating Reducer

13) Orifice Hole Dia 5 mm

SN APH / ECO

BED ESP ESP

ABR

OBCRMAIN

14) Timings in seconds

SN APH / ECO BED ESP ESPI/V Opening Cycle Gap Conveying

15) Pr. Switch setting Seal Pr. 5 kg/cm2,Pr. Switch setting Vessel Pr 0.3-.0.7 kg/cm2 ,Instrument Pr. 6-7 Kg/cm2,Conveying Pr. 3.5- 4 Kg/cm2

Dense Phase Pneumatic Conveying system for Bed Ash, Eco, APH & ESP,Boiler Ash gets collected in various Ash Hoppers which includes 3 nos Bed, 2 nos Eco/ APH, 4 nos ESP,Ash collected in Bed Ash, Eco/APH, and ESP Hoppers is conveyed to existing coarse Ash storage Bed Ash, fly Ash silo through Dense Phase Pneumatic Conveying system.-2-There are 2 multivessel conveying systems, There are 6 nos Independent single vessel conveying system,Multivessel conveying system consisting of 1 no Master Vessel & one no slave vessel connected through a common conveying line,Multivessel conveying system & Independent system consisting of vessel complete with accessories & pneumatic panel.Ash from each conveying system gets conveyed to the respective storage silo through there respective conveying pipes. The Ash is discharged in to Ash storage silo through respective Terminal end Box & the conveying Air is cleaned through Reverse pulse Jet Bag filter is then discharged in to atmosphere,The conveying system are provided with water cooled surge Hopper of 10 / 9.5 cft volume in Bed Ash, ECO/APH & Knife Gate Valve for Maintenance Isolation & Inlet valve with water cooled Top plate,The conveying system below Hopper is provided with adopter cum down comer pipe, expansion Joint, All the conveying systems are provided with level switch for interlocking with the pneumatic conveying system. All the ESP Hoppers are provided with fluidizing arrangement for free discharge of material in downstream equipment activated through compressed air conveying.Conveying Air compressors are provided by user to meet the conveying air requirement for the ash handling system conveying air receivers is provided to meet the air surge during peak demand period of conveying of ash in to storage silo. The existing Bed Ash & Fly ash storage silos are provided with Radar type continuous level monitor, Pr. Relief valve, Bag filter for discharge of clean conveying air in the atmosphere. The silos are provided with silo extraction system. The Dense Phase Pneumatic conveying system for ash from various ash Hoppers of Boiler to respective storage silo is centrally controlled through a common DCS based control system, the normal operation of the plant is through DCS. However some controls & indications are provided in local pneumatic panel attached to conveying vessels namely system start/ stop selector switch, line purge push Button, probe override push

button, & system on Indication, The Pneumatic panel houses the solenoid valve (5/2 single solenoid- ¼”) & Pr. Switch Pr. Gauges as required for the electro pneumatic control of the conveying vessel, The DCS is provided with start/ stop selector probe/ Timer ode selection. Line Purge selection & Probe override selection for each conveying system, In Probe mode of operation, availability of material is sensed by the level probes fitted in the Hoppers which initiates the conveying cycles.In timer mode of operation, the system goes on continuous cycles after a preset time interval even if there is a little or no material to convey.Probe override operation takes place i.e. one complete conveying cycle takes place irrespective of operating mode and/or availability of material to convey.

The DCS & Local pneumatic Panel is provided with pressed one conveying cycle’s takes place without opening of inlet valve. Pneumatic panel attached to each vessel has - 1 no Pr. Indicator for seal pr.- 1 no Pr. Indicator for vessel pr.- 1 no system on/off selector switch - 1 no In circuit / By pass selector switch - 1 no Probe override push Button- 1 no system on Indication

Prior to start of conveying cycle the following pre conditions should be established.- Silo Bag Filter On - Silo level not High- Inlet valve closed & sealed- Conveying Air receiver Pr. OK.- Inst. Air Receiver Pr. OK- Conveying vessel Pr.low- Both the on/off selection ( DCS & Local pneumatic Panel are in ON mode )- Line Purging not under progress - Probe override not under progress - The other conveying system interlocked with the concerned system is not under

progress.

- Now, the conveying system will address to the operating mode selection for level probe / Timer mode.

- Filter & Lubricator is provided for clean air to electro pneumatic panel & dry air to avoid moisture content in the instrument supply air.

- Fluidizing pads used in silo & surge Hopper for free flow of ash from silo to ash conditioner & conveying vessel.

- Inlet valve accessories are Quick exhaust valve, seal, Dome Air- Limit switch, Air cylinder, Blow valve, Ball valve in conveying Air pipe of vessel.

- Rotary vane feeder is used for Ash discharge from Silo to Ash conditioner.- Ash conditioner is used for unloading of silo’s ash in a tractor trolley.- Fly ash particles- Particle size Indian coal ( % ) Particle size Rice Husk + Biomass

- < 44 U 25.72 < 100 U 8%- < 77 U 53.6- < 105 U 72.9 < 500 U 29%- < 149 U 92.78- < 250 U 96.80- < 297 U 97.80

-3-- < 595 U 99.63 < 1190 U 92%- < 1190 U 99.92-

All particle size less than 1200 U at all location.Bed Ash Particles Normal less than 6mm – 100 % at all locations Less than 3mm – 50 % at all locations Ash AnalysisDescription Indian coal Petcock Rice Husk

Silica 52-55 60.1 91.42 Iron 7-10 7.27 0.14 Titanium 0.15- 0.19 1.96 0.02

Sulpher Anhydrate 0.4 0.33 0.72

Alumina 29.21 28.59 0.78

Lime 0.22 0.33 3.2

Manganese 1.13 0.26 0.01

Alkali’s (Na2 O + K2 O) 2.05 0.79 3.91

Phosphate Traces 0.26 Traces

Chlorides 0.6-0.85

Traces Traces

Vanadium Traces 0.11 Traces

Nickel Traces Traces Traces

Silo Extraction SystemThe Fly ash Storage silo is provided with silo extraction system and is controlled locally through its silo extraction system Local control panel and is detailed below.

a) The discharge end of the storage silo is provided with Fluidizing arrangement consisting of Fluidizing pads activated through compressed air for conveying for free flow of ash into downstream equipment. The fluidizing arrangement is operated manually as & when required.

b) 1 no Adopter cum Down comer pipe is provided at the outlet of siloc) 1 no manually operated knife Gate valve is provided downstream to the adopter

cum down comer pipe which can be opened & closed manually as per requirement.

d) One no ash conditioner is placed downstream to the knife Gate valve and is operated through its start & stop push Buttons provided in the silo extraction Local Control panel.

Silo Extraction System Operation & Controlsa) During starting - Start ash conditioner- Open Knife Gate valve- In case flow of ash is erratic, open Fluidizing Valve- Open / Throttle water line valve as per requirementb) During Truck Transfer

- Close knife Gate valve c) Once Truck Transfer is complete - Reopen Knife Gate valve d) During Stopping Please follow reverse of starting sequence

- Close Knife Gate Valve - Stop Ash Conditioner- Close Water line valve at a suitable time to avoid draining of water from Ash

Conditioner. Identification & Nomenclature

1) Identification & Nomenclature of all Dome Parts.2) Identification of all tools & tackles of Dome valve assembly3) Assembly of Dome- Valve- Body finishing Dome Body- Painting- Dome finishing & Painting- Fitting of Shaft seal - Fitting of Driven Shaft- Fitting of Dome- Fitting of inner Dowell pin- Placing Gasket 2.4 mm- Placing of spigot Ring- Placing of spigot O Ring- Insert Ring- Insert O Ring- Fitting of Rubber seal

- Fitting of Top Plate- Fig of Gap adjustment & Positioning of seal - Maintenance & overhauling of Dome valve

a) Gap adjustment, b) Seal Placing

Final assembly of Dome valve along its various stages Telescopic Chute One No Telescopic Chute is provided below RVF. This Telescopic chute is fitted with a reversible geared motor, rotating at reduced speed. The bottom of the Telescopic chute rests n the top of the tanker. One No Pendent control is provided for raising & lowering the Telescopic Chute and is provided with following controls / indications.

- One No Down Push Button- One No up Push Button - One No Level High / Tanker Filled indication- One No Emergency Stop Push Button With Lock- One No Control ON Indication

Following Controls / indications are provided on silo extraction local control panel for telescopic chute.

- 1 no 3 position selector switch for telescopic chute pendent control/ off/ Ready for Discharge selection ( Black )

Note: Once Pendent Control is selected, The Telescopic Chute can be raised / lowered on the tanker opening. Once Ready for Discharge is selected, then only i) The Bag filter Unit of telescopic chute will start automatically, and ii) Dust extraction fan , iii) RVF & iv) plate valve can be started sequentially from the silo extraction local control panel Lowering / Raising of the telescopic chute is done from the pendent control by selecting pendent control mode from silo extraction local control panel Telescopic chute can be connected to the opening of receiving tanker with the help of Down Position, up Position Push Buttons & Emergency Stop Push Buttons with Lock. Once the truck is put in position and the system is ready, Down Position PB is pressed. Now spout starts lowering down. As soon as the spout touches the top of the truck and gets properly connected to the opening, the rope goes slack and the slack cable limit switch will stop the motor.If the operator wants to readjust the fitment of spout on the opening of the truck, he can do the same using these up/ down and stop buttons.Telescopic chute Bag filter unit with integral Dust extraction fan To avoid any ash pollution, 1 no bag filter unit with fan is fitted with Telescopic Chute. Bag filter unit is also fitted with a timer control unit for automatic purging of filter bags. Following controls / indications are provided on silo extraction Local control Panel for Dust extraction fan:- 1 no Telescopic Chute Dust Extraction Fan Start Push Button ( Green )- 1 no Telescopic chute Dust Extraction Fan Stop Push Button ( Red )- 1 no Telescopic chute Dust Extraction Fan ON Indication ( Red )- Telescopic chute Dust Extraction Fan Fault Tripped ( Amber )

Dry ash extraction operation & controlsThe silo extraction system will be operated from silo local control panel. Before starting the system, operator should ensure that the following precondition is satisfied: Silo bag filter ON Unloading spout is fitted on to tanker after selection of “pendent Control “mode.

Once Unloading spout is fitted to the tanker, the ‘Ready to Discharge’ mode is to be selected & Telescopic Chute Bag Filter is started automatically. The system is then started automatically. The system is then started in the following sequence from silo extraction Local control panel.

- Dust Extraction Fan is started by pressing Start push Button from Silo Local Control Panel.

- RVF is started by pressing START PB from silo Extraction Local Control Panel.- Pneumatic cylinder operated Knife Gate valve is opened by pressing open from

silo extraction local control panel.- Now the ash unlading is in progress.- When Tanker level probe gets covered, indication comes on the silo Extraction

Local control Panel & Pendent Control.- Pneumatic Cylinder Operated Knife Gate Valve shall close immediately- Thus the unloading operation is completeAfter few seconds, ‘Pendent Control’ mode should be selected from silo extraction Local control panel & the following operations are completed.- dust extraction Fan & RVF will stop- After 10 seconds, Telescopic Chute Bag Filter will be stopped- After 5 seconds, Telescopic Chute can be lifted upThe Dust Extraction Fan &

Rotary van Feeder can be stopped manually from the silo Extraction Local control panel also using their respective stop push button after closing the knife Gate valve For raising of Telescopic Chute, the ‘Pendent Control’ mode must be selected from silo extraction Local control panel