ASH DISPOSAL PUMP HOUSE COMPLEX

The ash disposal pump complex comprises an ash water pump house where H.P & L.P water pump are located and an ash slurry pump house where slurry pumps are provided.
ASH WATER PUMP HOUSE

The ash water pump house is located on the right side of ash pump house complex . 4 low pressure water pumps ,4 High pressure water pumps and 2 seal water pumps are located in a room of area 22.1 m X9.6m .this pump house is built in with an underground pit of 5.6meters and a water level of 4.6 meters is maintained in this pit. the front right corner of the pit for an area of 4.6 mX 4.1m is separately isolated and service water pumped by bore well pump is supplied here. This service as the suction sump for the seal water pumps. the other portion of the pit ,from which LP & HP water pumps have their suction gets its water supply from the circulating water system through 6 pipelines ,2from each unit . one of these two lines is tapped from circulating water system A side before the condenser .this water at the rate of 300 m/hr pumped by lub oil cooler booster pump ,passes through lub oil coolers and comes to the pit . Another line is tapped from B side after the condenser and a flow of upto 900 m/hr can be taken up in this line .this quantity is variable according to demands. the capacity of the seal water sump is 87 m and that of the ash water sump is 889 m LOW PRESSURE WATER PUMPS Out of the four LP water pumps located in the right rear side 3 will be running and one is a stand y .this is a four stage vertical turbine pump of capacity 650 m/hr. capable of developing by a 415V ,140KW ,3 motor ( maximum current 252 Amps) Each pump has an immersed strainer at the suction .A non return valve and an isolating valve are provided at the discharge .the delivery of all the four pumps are connected to a common bus ,from which is distributed for the following purposes. 1. Ash mixing vessels of Electro static Precipitator (50 m/hr ) 2. AMVS of Air preheated .( 20 m/hr ) 3. AMV provided below boiler second pass hopper (39 m/hr )

4. AMV of chimney 5. Ash slurry sump agitation 6. In case of necessities LP water can be supplied as level make up in ash slurry sumps through motor operated valves provided in the line 7. At starting points of channels LP water pipe is provided through which large quantities of LP water can be dumped onto the ash channel to clear the channel deposits ( or choke, if any) The L P bus in the boiler has a motor operated isolating valve for quick isolation .A pressure gauge is provided in the unit LP bus to indicate the pressure of LP water HIGH PRESSURE WATER PUMPS Four HP water pumps are located in the left rear of the ash water pump house .three of them will be normally in service while the fourth one is a standby .the capacity of the pump is 450 m/hr .and the discharge pressure is 8.5 kg/cm. It is a six stage vertical turbine type pump driven by a 415 V ,147 KW , 3 electric motor ( max .current 265 Amp.) .the discharge of the pump is fed to a common bus from where it is distributed for the following ssurpose.

1) Jets in Air preheater AMVs 2)Jets in EP AMVs 3)Jets in chimney AMV 4)Jets for flushing in channels 5)Agitation of sumps 6)Area cleaning.

- 8 m / hr. -95 m/hr -1 m/hr -302 m/hr

HP bus also has a motor operated isolation valve for each unit and a pressure guage.Both L.P And H.P buses form closed loops. With interconnection in between the Boilers.The interconnection are provided with motor operated isolating valves.Tappings are provided for agitation of ash slurry and a motor operated valve. 6.3 Seal Water Pumps. Two seal water pumps each of capacity 75 m/hr are located in the front right side of the ash Pump house. It

is a 10 stage vertical Turbine pump capable of developing a pressuer of 11 Kg/cm (Should be Above AD pump discharge pressure of 10.2KSC by atleast 0.7 KSC) in order to ensure effective sealing.The pump is driven by a 415 v , 3 ,37 KW Motor at 1475 rpm (Max currnt 70 amps.) Seal water is supplied for gland sealing of the following. 1).Running ash slurry pumps (Normally 3 sets) 36 m/hr. 2)3 Numbers L>P Pumps -12 m/hr. 3)3 Numbers H.P pumps -12 m/hr.

ASH SLURRY PUMP HOUSE

The ash slurry pump house is in the eastern side portion of the ash pump house complex.15 ash disposal pumps find place here.3 pumps are connected in series forming one set and there are 5 sets out of which one set per unit will have to be in normal service. The ash dump area is sufficiently far away from the pump house and is formed as an artificial lake by bund walls of high rise. Hence ash slurry is to be discharged through a long course of pipeline and has also to be taken to a surface at a higher elevation i.e over th bund wall. This calls for a higher delivery pressure which may be achieved by either a multistage pump or a number of pumps connected in series. Ah slurry handled is of abrasive nature and hence necessitates the use of a wearable inner casing arrangement to protect the main casing from ash erosion. Also the pump has to be run at a lower speed compared to centrifugal pumps handling plain water. Considering the above aspects , number of single stage pumps connected in series is preferable to a single multistage pump.

ASH DISPOSAL PUMPS

The ash disposal pumps are designed with 50% extra capacity taking the ash content as 12 % . The minimum ratio of ash slurry to ash by weight is 25 : 1 . Specific gravity of ash slurry handled is 1.02. The ash slurry velocity in the pipe line is in the range of 2.5 to 3 m/Sec which is optimum to keep the pressure loss due to friction low. The sump capacity is chosen to hold the quantity discharged in a time duration of 5 minutes.

Pressure gauges are provided at the delivery of each pump (incase of pump C after discharge valve). Each set has a NRV after the discharge valve. This NRV prevents reverse flow from the delivery line in case of tripping of one series of pumps. The five discharge lines coming out of the pump house take a 90 bend to the left. From here there are only four delivery lines and the pump discharges are connected to the delivery lines by means of suitable short length pipe bends with flanged ends. One series of pumps will remain isolated without discharge pipe. Possibilities of inter connections are as follows. Delivery line Discharge of

I First or second set II Second or Third set III Third or Fourth set IV Fourth or fifth set The above arrangement makes the system flexible and at the same time saves one length of pipe line to bund. The delivery lines are provided with expansion joints at every 50 M intervals. A monorail chain pulley block arrangement is provided for changing the inter connecting pieces. Ash slurry is carried by pipe lines of 400mm dia to the ash dump area. The pipes are made of spirally welded steel sheets and the length of the pipe lines is about 2.5KM which is likely to get extended up to 3.9KM subsequently. The ash bund is of capacity 3.25 million cubic metres-sufficient for 10 years. It is of shape approximately a square formed by walls varying from 11 to 15 metres height. 7.2 DRAIN PUMPS: There are 2 drain pumps each of capacity 100m/hr, located in the northwest of the slurry pump house. Each pump is driven by a 415V,3, 10KW motor running at 1440 rpm and is capable of developing pressure of 1.5ksc. Discharge line divides into three and each line with a valve joints one slurry pump. (Outside the slurry pump house). Each delivery line has a valve in it. This arrangement facilitates discharge of the drain pump to be diverted to the slurry pit. Each slurry pit has as drain arrangement in the form of a downward bent pipe with a dummied flange end. The sump is to be isolated first by means of sand bags and is to be drained by opening of the drain pipe. Works on A pumps or in the sump itself can be taken up only after such isolation. At a time, maintenance work on one sump or the pumps connected to it only can be taken up. The drain from the slurry pit will get collected in the sump pit will get collected in the sump pit at minus level and can be pumped back by drain pumps.

7.3 CRANES: Two 5 tonnes capacity EOT cranes are provided in the ash slurry pump house, one for the pumps at 9.7 ML elevation and the other for the pumps at 0 ML elevation. A 3 tonne EOT crane is provided for the ash water pump house. 7.4 CONTROL ROOM OF ASH PUMP HOUSE AND POWER SUPPLY: Ash pump house control room is located in the centre of it. Three numbers 1600KVA 6.6/0.4KV transformers located in the northern side take care of the power needs of Ash disposal pump house complex. Two independent buses are there through which power is fed to the various pumps. The breakers are provided at 0ML and the control panel is at +5 ML.

8. INSTRUMENTS, ANNUNCIATIONS AND INTERLOCKS 8.1 SLURRY PIT LEVEL PROTECTION SYSTEM: The pit level protection system consists of a compressed air operated bubbler tube. The bubbler tube is supplied with compressed air at a constant pressure of 7.8 ksc. The other end of the tube is immersed in ash slurry in the sumps. Continuously a small amount of air escapes from the bubbler tube bottom in the form of bubbles. The compressed air pressure in the bubbler tube varies according to the water level of the sumps because the resistance offered by the slurry to compressed air escaping varies with water level height. There are six pressure tappings from the outlet of the bubbler tube. The tappings are meant for the following purposes. 1. Low level alarm 2. Low level trip 3. High level alarm 4. High level trip 5. Level indicators- 2 Nos Pressure switches are provided in the first four tappings to achieve the required purpose. 8.2 FLOW MEASUREMENTS IN LP&HP WATER SYSTEM: In L.P and H.P water discharge lines flow meters are provided to measure the quantity of L.P/H.P water consumption. The flowmetres provided are Turbine flowmetres type, which consists of a free running rotor mounted co-axially on the pipe center line in the discharge line of the H.P/L.P bus.

8.3 SEAL WATER SYSTEM 8.3.1 INSTRUMENT TAPPINGS 1. One pressure switch is provided at the common discharge of seal water pumps for annunciation of low header discharge pressure. 2. Level switches are provided in seal water sump for the provision of control indications for annunciations. 8.3.2 ANNUNCIATIONS 1. Seal water pump tripped one window provided for each pump. 2. Seal water discharge header pressure low 3. Seal water sump level high 4. Seal water sump level low 8.3.3 INTERLOCKS 1. Seal water pump will not start unless water level in the sump is above preset minimum level. 2. The operating pump will trip automatically in case the water level falls below the preset minimum level.

8.4 H.P WATER SYSTEM 8.4.1 INSTRUMENT TAPPINGS 3. One pressure switch is provided in the seal water line of each H.P water pump. 4. One pressure switch is provided at the common discharge header of H.P water pumps for annunciation. 5. Level switches are provided on ash water sump. 8.4.2 ANNUNCIATIONS 5. H.P water pump tripped one window provided for each pump. 6. H.P water discharge header pressure low 7. Ash water sump level high 8. Ash water sump level low 8.4.3 INTERLOCKS 1. H.P water pumps cannot be started unless water is available upto a preset minimum level in the ash water sump. 2. H.P water pumps cannot be started unless adequate seal water pressure is available at the pump. 3. The pump will trip in case the water level falls below the preset minimum level.

4. The pump will trip in case the seal water pressure falls below the preset value.

8.5 L.P WATER SYSTEM 8.5.1 INSTRUMENTS 1. One pressure switch is provided in the seal water line of each L.P water pump. 2. One pressure switch is provided at the common discharge header of L.P water pumps. 8.5.2 ANNUNCIATIONS 9. L.P water pump tripped one window provided for each pump. 10. L.P water discharge header pressure low 8.5.3 INTERLOCKS 5. L.P water pumps cannot be started unless water is available upto a preset minimum level in ash water sump. 6. L.P water pumps cannot be started unless adequate seal water pressure is available at the pump. 7. The pump will trip in case the water level falls below the preset minimum level. 8. The pump will trip in case the seal water pressure falls below the preset value. 8.6 ASH SLURRY PUMPS: 8.6.1 INSTRUMENTS 3. One pressure switch is provided in the seal water line of each slurry pump. 4. One pressure switch is there in each ash slurry sump for annunciation Low sump level and another for High sump level 5. One pressure switch is there in each ash slurry sump at trip level for control & interlock. 8.6.2 ANNUNCIATIONS 1. Set of slurry pumps tripped one window provided for each series. 2. Slurry sump level high one window provided for each sump. 3. Slurry sump level low one window provided for each sump. 8.6.3 INTERLOCKS: 1. Any slurry pump series cannot be started if the following conditions are not fulfilled. a) Preset seal water pressure available at each pump. b) The level of ash slurry sump is not below the trip level of the pump. c) Suction valve is open. 2. Each slurry pump series will trip in the event of following conditions a. any pump of the series is tripped

b. Preset seal water pressure is not available at any of the pumps c. The level of slurry sump falls below trip level. d. Suction valve is closed. e. Discharge valve doesnt open within a predetermined time from the starting of the slurry pump. 3. The first stage pump of the slurry pump series will be started from the panel. After a time delay of 30s and 40s the second and third pumps are started respectively. As soon as the third pump is started discharge valve is opened. If any if the second or third pump doesnt start within 50s of the starting of the first pump. Then the first pump automatically gets tripped. 4. The discharge valve of the operating pump series shall close as soon as the pump trips.

8.7 DRAIN PUMPS: 8.7.1 INSTRUMENTS TAPPINGS: 1. One pressure switch is provided in the seal water line of each drain pump. 2. Level switches are there on drain sump. 8.7.2 ANNUNCIATIONS: 1. Drain pump tripped- one window is provided for each pump. 2. Drain sump level high 3. Drain sump level low 8.7.3 INTERLOCKS: 1. Drain pumps cannot be started unless water in drain sump is available upto a preset minimum level. 2. The pump will not start unless adequate seal water pressure is available at the pump. 3. The pump will not start if the level of the ash slurry sump is high. 4. The pump will trip in case the water level in the drain sump falls below the preset minimum. 5. The operating pump will trip automatically if the seal water pressure falls below the preset value. 6. The pump will trip in case of ash slurry sump level is high.