DRY ASH EVACUATION SYSTEM

AND
HCSD SYTEM
(CPP,NALCO)

MANOJ KUMAR SINGH

AGM (Elect)
Operation Department
 Basic Ash Flow In Power Plant

ECO & APH ASH

OPERATION DEPARTMENT,CPP 2 Tuesday, April 9, 2024

 Ash Generation In Power Plant
Ash(40-50%)

Bottom Ash Fly Ash

(15-20%) (80-85%)

Wet Ash APH , Eco & Chimney ESP (90%)

Hopper (10%)

Wet Ash Dry Ash Wet Ash

OPERATION DEPARTMENT,CPP 3 Tuesday, April 9, 2024

 Ash Flow And Collection In Power Plant

Fly Ash
ESP
Chimney

Dry Ash Dry

Ash
Boiler SILO
Collection

ASH
SUMP
Bottom Ash POND
Ash Slurry
Hdr.

OPERATION DEPARTMENT,CPP 4 Tuesday, April 9, 2024

 Dry Ash Generated in One Unit of CPP/Day
In one UNIT
2000-2400
Ton/Day Coal

Ash Quantity

800 -1200 50 trucks of ash load

Ton/Day

Wet Ash Dry Ash

190-340 610-860
Ton/Day Ton/Day

OPERATION DEPARTMENT,CPP 5 Tuesday, April 9, 2024

 Why Dry Ash is required

OPERATION DEPARTMENT,CPP 6 Tuesday, April 9, 2024

 What is ASH ???

Silica (SiO2 ) 38-58 %

Alumina (Al2 O3 ) 20-40 %

Iron Oxide (Fe2 O3 ) 6-16 %

Calcium 2-10 %

Magnesium 1-3.5 %

Sulphate(SO3 ) 0.5-5 %

OPERATION DEPARTMENT,CPP 7 Tuesday, April 9, 2024

 BASIC DRY ASH CONVEYING
In CPP we adopt pressurized dry ash conveying system

OPERATION DEPARTMENT,CPP 8 Tuesday, April 9, 2024

 DRY ASH EVACUATION SYSTEM
IN
UNIT#9-10

OPERATION DEPARTMENT,CPP 9 Tuesday, April 9, 2024

 CONVEYING AIR TO UNIT-9,10 : CONFIGURATION

DRYER
CAC-A -A
AIR
TO #9

DRYER
FROM CAC-B -B

ATM TO #10
DRYER
CAC-C
-C

AIR RECEIVER TANK

 CONVEYING AIR COMPRESSOR

DISCHARGE
V/V

STAGE-2 STAGE-1

MOTOR

SUCTION V/V SUCTION

SHAFT AIR
EMISTER + FILTER DRIVEN FILTER
PUMP

OIL FILTER BYPASS V/V

OIL TANK

STAGE COOLERS

ACW IN
LOP
ACW OUT
OIL COOLER
UNIT-9 UNIT-10
1 1

2 2

3 3

4 4

5 5

6 6

7 7

CONVEYING INLET VALVE

FIELD DISCHARGE VALVE

SILO DUMP VALVE

1 FIELD NO.
SILO-5 SILO-6
 BASIC DRY ASH CONVEYING
CONVEYING LINE ARRANGEMENT IN UNIT- 9 AND 10
#9 1ST field

#9 2nd field

#9 3rd to 7th field SILO-5

#9 APH & ECO

#10 1ST field

#10 2nd field

#10 3rd to 7th field

#10 APH & ECO
D-PUMP-1 SILO-6
D-PUMP-2

D-PUMP-3
D-PUMP-4
OPERATION DEPARTMENT,CPP 13 Tuesday, April 9, 2024
 SILO FOR UNIT-9,10

UNIT#9
UNIT#9
UNIT#10
UNIT#10
D1,D2,
D1,D2,
D3,D4
D3,D4
SILO-6
SILO-5

TRUCK TRUCK HCSD

HCSD

ASH ASH
POND POND

OPERATION DEPARTMENT,CPP 14 Tuesday, April 9, 2024

 VESSEL

Level Switch (H.High)

Vent Line

Level Switch
Vent Valve
(High)
Fluidising Air
Hopper Heater(4 X 3) Plate Valve
Loading/Unloading
Valve
Filling Air

Transport Vessel

Fluidising Air

Loading/Unloading
Valve
Conveying Air
To Silo
OPERATION DEPARTMENT,CPP 15 Tuesday, April 9, 2024
 BASIC DRY ASH CONVEYING
The Dome valve

OPERATION DEPARTMENT,CPP 16 Tuesday, April 9, 2024

 BASIC DRY ASH CONVEYING
The Dome valve

OPERATION DEPARTMENT,CPP 17 Tuesday, April 9, 2024

1ST - 2ND FIELD CONVEYING
1ST & 2ND FIELD CONVEYING LINE PRESSURE TRENDS
 DRY ASH EVACUATION SYSTEM
IN
UNIT#7-8

OPERATION DEPARTMENT,CPP 20 Tuesday, April 9, 2024

 CONVEYING LINE ARRANGEMENT IN UNIT- 7

1A1,1A2 2A1,2A2
ESP 1st & 2nd FIELD ARE INTERLOCKED

1B1,1B2 2B1,2B2

3A1,3A2,3B1,3B2
4A1,4A2,4B1,4B2

5A1,5A2,5B1,5B2
6A1,6A2,6B1,6B2

OPERATION DEPARTMENT,CPP 21 Tuesday, April 9, 2024

 CONVEYING LINE ARRANGEMENT IN UNIT- 8

1A1,1A2
ESP 1A & 2A FIELD ARE INTERLOCKED

2A1,2A2

1B1,1B2
ESP 1B & 2B FIELD ARE INTERLOCKED
2B1,2B2

3A1,3A2,3B1,3B2
4A1,4A2,4B1,4B2

5A1,5A2,5B1,5B2
6A1,6A2,6B1,6B2

OPERATION DEPARTMENT,CPP 22 Tuesday, April 9, 2024

 CONVEYING AIR COMPRESSOR & DRYER
(ASPH-4)
23

OPERATION DEPARTMENT,CPP Tuesday, April 9, 2024

 SILO FOR UNIT-7,8

UNIT#7 UNIT#8
ESP ESP

SILO-1 SILO-2 SILO-3 SILO-4

D1 D2 D3 D4

TO UNIT-9,10 SILO-5 OR SILO-6

OPERATION DEPARTMENT,CPP 24 Tuesday, April 9, 2024

 D-PUMP CONVEYING

25

OPERATION DEPARTMENT,CPP Tuesday, April 9, 2024

 HCSD SYSTEM
IN
CAPTIVE POWER PLANT

OPERATION DEPARTMENT,CPP 26 Tuesday, April 9, 2024

 HCSD OVERVIEW

SILO 2 NOS

SURGE
HOPPER 2 NOS

ASH CONCENTRATION
60 % ASH 2 NOS ASH MIXER

40 % WATER
TO ASH POND
ART 2 NOS
HCSD PUMP
CHARGE PUMP
3 NOS
4 NOS

OPERATION DEPARTMENT,CPP 27 Tuesday, April 9, 2024

 SILO
FW TO ASH SURG
MIXTURE E
HOPP
AIR ER
SLIDE

ASH
MIXTUR
E
FW TO
ART
ART MAKE-UP
TO
ASH GEHO
POND PUMP

PNEUMA FW TO
TICFLUS CHARGE P
HING PUMP T
VALVE FLUSHING

CHAR SUCTION R/C

GE VALVE 1 2 3
PUMP
FLUSHING WATER
FW TO CHARGE PUMP GLAND PUMPS
SEALING
 HCSD OVERVIEW
VALVE-01
LINE-01

VALVE-02 HCSD PUMP-1

TO
ASH
POND
HCSD PUMP-2
VALVE-03

LINE-02 VALVE-04

HCSD PUMP-3

OPERATION DEPARTMENT,CPP 29 Tuesday, April 9, 2024

 THE HCSD SYSTEM

OPERATION DEPARTMENT,CPP 30 Tuesday, April 9, 2024

 HCSD OVERVIEW

OPERATION DEPARTMENT,CPP 31 Tuesday, April 9, 2024

 Working principle: Suction stroke

The diaphragm (F) moves

backward. The resulting low
pressure in the slurry
chamber (E) forces the
discharge valve (G) to close,
the suction valve (C) to open.
The slurry fills the slurry
chamber (E) of the diaphragm
housing unit through the
suction line (D).

OPERATION DEPARTMENT,CPP 32 Tuesday, April 9, 2024

 Working principle: Discharge stroke

The diaphragm (F) moves

forward. The resulting high
pressure in the slurry chamber
(E) of the diaphragm housing
unit forces the suction valve
(C) to close, the discharge
valve (G) to open. The slurry
leaves the slurry chamber (E)
through the discharge line (H).

OPERATION DEPARTMENT,CPP 33 Tuesday, April 9, 2024

 Working principle

OPERATION DEPARTMENT,CPP 34 Tuesday, April 9, 2024

 HCSD SPECIFICATIONS

HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM

1. Make : GEHO WEIR MINERAL, NETHERLAND

2. Model : TZPM1200
3. No. of pumps : 3
4. Pump capacity : 16-160 M3/hr (can cater 4 unit ash)
5. Pump disc. Pressure: 160Bar
6. Ash to water ratio : 60:40
7. Silo capacity : 2 x 1000T

OPERATION DEPARTMENT,CPP 35 Tuesday, April 9, 2024

 HCSD SPECIFICATIONS
Equipment Actual Motor Rating (KW)
Description
HCSD Pump 900/690V/944A
Flushing Water Pump 45
Charge Pump 55
Ash Conditioner 22
Agitator 75

Equipment Flow Rate Discharge

Description (m3/hr) Pressure

HCSD Pump 160 160bar

Flushing Water Pump 160 50MWC

Charge Pump 160 34MWC

OPERATION DEPARTMENT,CPP 36 Tuesday, April 9, 2024

 HCSD SPECIFICATIONS
Alarm/Trip Settings of GEHO Pump:
Sl. No. Parameter Alarm Value Trip Value

1 GEHO Pump Operating Pressure >16800 Kpa (Hi) >17600 Kpa (Hi Hi), GEHO Pump Trips

2 Propelling Liquid Pressure <700 Kpa (LO), Pump stroke will go Zero

3 Instrument Air Pressure <450 Kpa (Lo) <400 Kpa (Lo Lo), GEHO Pump Trips

4 GEHO Suction Pressure <200 Kpa (Lo Lo), GEHO Pump Trips

5 Lubricating Oil Flow LED 7 RED (Lo) LED 5 RED (Lo Lo), GEHO Pump Trips

6 Propelling Liquid Oil Flow LED 7 RED (Lo) LED 5 RED (Lo Lo), GEHO Pump Trips

<800 Kpa, SV-15 ON Close), >1300 Kpa, SV-15 OFF (Open),

7 Propelling liquid accumulator
Accumulator Filling will start. Accumulator Filling will stop.

OPERATION DEPARTMENT,CPP 37 Tuesday, April 9, 2024

 Ordinary People Extra
OPERATION DEPARTMENT,CPP 38 ordinary Attitude
Tuesday, April 9, 2024