Obra Presentaton Ash Handling Sysytem 28032023.pptx

Ash handling Systems By Mr. Deepak Rai

1. OBRA-C 2x660 MW ASH HANDLING SYSTEM PRESENTATION ON Ash Handling System

2. IM&HCSD Silo BA Hopper O/F Tank& Pump Coase Ash Tank& Pump Buffer Tower#2 Vacuum Pump House#2 Vacuum Pump House!#1 Buffer Tower#1 Ash Slurry Sump House Ash Compressor House Clarifier & Chemical House Ash Water Pump House Terminal Silo APR-1 APR-2 APR-3 APR-4 APR-5 APR-6 APR-7 APR-8 APR-9 COMPOSITE LAYOUT OF ASH HANDLING SYSYTEM

3. Ash Water Pump House BAHP (AWPH to Bottom Ash Hoppe#01&02) Φ 450NB BALP (AWPH to Bottom Ash Hopper#01&02) Φ 500NB FAHP (AWPH to Collector Tank in Buffer Hopper Tower#01&02) Φ 500NB-550NB HCSD flushing line to HCSD Silo Φ 300NB Flushing Water line (AWPH to Ash Slurry Sump) Φ 400NB TAC (To Air lock tank Buffer Hopper#01) Φ 300NB IAC Φ 100NB-200NB (To Buffer Hopper tower, BAH, HCSD silo & Terminal Silo) Vacuum line (Vacuum Pump to Collector tank#01) Φ 200NB Fluidizing air blower pipes (From air blower to ESP#01 fluidizing pads, Buffer Hoppers#01) Φ 100NB From Bottom Ash Overflow Tank Φ 300NB U#01 & 02 Pipe Rack (By Arch Dept) FLWP HCSDWP HCSDWP HCSDWP FAHP FAHP BALP BALP BALP BAHP BAHP BAHP APR-02 FAHP Clarifiers B A Buffer Hopper Tower U#01 Pass-A Buffer Hopper Tower U#01 Pass-B Buffer Hopper Tower U#01 Pass-C Buffer Hopper Tower U#01 Pass-D Buffer Hopper Tower U#01 Pass-E Buffer Hopper Tower U#01 Pass-F ESP- F ESP- F ESP- E ESP- E ESP-D ESP-D ESP-C ESP-C ESP-B ESP-B ESP-A ESP-A BAH Bottom Ash Slurry Lines to Ash Slurry Pump House Φ 200NB Bottom Ash Overflow Lines to Clarifier Φ 300NB Coarse Ash Lines to ASPH Φ 350NB TAC (To Air lock tank Buffer Hopper#02) Φ 300NB APR-03 Sludge pit to Ash Slurry Sump Φ 100NB Ash Slurry Pump House Ash Water Sump To IM/HCSD Silo & Terminal Silo Φ 400mm Air Blower Vacuum Pumps #01 TAC TAC TAC TAC IAC IAC TAC TAC TAC TAC APR-08 Ash Compressor House APR-09 IAC Maintenance Bay Eco Hoppers APH Hoppers SCR Hoppers Eco Hoppers to BAH Φ 250NB APH Hoppers to Coarse Ash Tank Φ 200NB SCR Hoppers to Coarse Ash Tank Φ 400NB Sludge Pit LP Seal water pumps Section 1-1 (Showing only for Unit#01 ) 12 lines of Φ 200NB (Collector tank discharge to Ash Slurry Pump House) 1 line of Φ 550NB (FAHP) 6 lines of Φ 200NB (Vacuum Line) 4 lines of Φ 300NB (TAC line to ESP & air lock tank in buffer hopper tower) 2 lines of Φ 100NB (ESP drainpipes) 4 lines of Φ 300NB (FA line discharge) 1 line of Φ 500NB (BALP Pipes to BAH) 1 line of Φ 450NB (BAHP Pipes to BAH) 2 lines of Φ 350NB (Coarse Ash pipes to Ash Slurry Pump house) 1 line of Φ 300NB (BA Overflow tank to clarifier) 3 lines of Φ 200NB (BA discharge) 1 line of Φ 150NB (LP Seal water pipe) Section 2-2 1 line of Φ 300NB (Bottom Ah Overflow pipes) 2 lines of Φ 400NB (Recovery water line) 1 line of Φ 4000NB (Flushing pipe) 1 line of Φ 550NB (FAHP) 1 line of Φ 500NB (BALP Pipes to BAH) 1 line of Φ 450NB (BAHP) 1 line of Φ 300NB (HCSD LP pipe) 1 line of Φ 550NB (Recovery water line) 8 lines of Φ 300NB (TAC line to air lock tank in buffer hopper tower) 1 line of Φ 200NB (IAC line) 1 line of Φ 100NB (Sludge pipe to Ash Slurry Sump) 1 line of Φ 100NB (Vacuum pump area drain line) Section 3-3 1 line of Φ 550NB (Recovery water line) 2 lines of Φ 400NB (Recovery water line) 1 line of Φ 50NB (Seal water line) 1 line of Φ 100NB (Drainpipe Silo Area) 1 line of Φ 300NB (HCSD LP pipe) 6 lines of Φ 400NB (Ash disposal lines) Ash Slurry lines Φ 200NB X 12lines (from collector tank to Ash Slurry Sump) Ash water recovery lines (2 lines of Φ 400NB & 1 line of Φ 550NB (from ash dyke area) LP seal water lines to clinker grinder, BAOF pump, coarse ash pump & vacuum pump sealing Φ 150NB LP seal water lines Φ 150NB to BAHP seal water pump 1 1 2 2 3 3 Duct Support Structure 10 1 2 3,4&5 3,4&5 6 Buffer Hoppers to IM/TM Silo (4lines Φ 300NB) 7, 8 & 9 42-46 11-41 51-52 49 2 4 8 50 47 1 line of Φ 100NB (Vacuum pump area drain line)

4. ASH HANDLING SYSTEM: BOTTOM ASH & ECONOMISER ASH COLLECTED IN BOTTOM ASH HOPPER AND COARSE ASH COLLECTED IN APH AND SCR HOPPERS SHALL BE DISPOSED IN SLURRY FORM TO ASH DYKE. FLY ASH COLLECTED IN ESP HOPPERS CAN BE DISPOSED IN BOTH IN SLURRY FORM TO ASH DYKE THROUGH WET SYSTEM OR IN DRY FORM TO FLY ASH SILOS THROUGH PRESSURE CONVEYING SYSTEM (DRY SYSTEM). THE WET SYSTEM CONSISTS OF BOTH OPTIONS i.e LEAN SLURRY & HCSD SLURRY STSTEM. EQUIPMENT REQUIRED TO BE INSTALLED FOR CONTINUOUS OPERATION OF UNIT-1 IN WET MODE IS EXPLAINED IN FOLLOWING SLIDES

5. ASH HANDLING SYSTEM CONFIGURATION DIAGRAM BOTTOM ASH COARSE ASH FLY ASH BOTTOM ASH AND ECONOMISER HOPPERS ASH SLURRY SUMP ASH DYKE SCR HOPPERS COARSE ASH TANK APH HOPPERS ESP HOPPERS COLLECTOR TANK BUFFER HOPPER INTERMEDIATE SILOS WET SYSTEM DRY SYSTEM HCSD SILOS ASH DYKE TERMINAL SILOS

6. FLY ASH SYSTEM CONFIGURATION ASH 191.68 TPH ASH REMOVAL CAPACITY - 360 TPH BUFFER HOPPER AIR LOCK TANK COLLECTOR TANK ESP HOPPER DRY SYSTEM WET SYSTEM FLY ASH COLLECTED IN APH AND ESP HOPPERS FOR 8 HOURS SHALL BE REMOVED IN – 4.5 HOURS TOTAL FLY ASH COLLECTION IN 8 HOURS = 202.34X8= 1618.72 TONS FLY ASH REMOVAL CAPACITY = 1618.72/4.5 = 360.0TPH ESP IS DIVIDED INTO 6 STREAMS. HENCE REMOVAL CAPACITY OF EACH STREAM IS 60 TPH ASH REMOVAL CAPACITY - 360 TPH ASH SLURRY PUMP (1060m 3 / hr TPH @ Fly Ash)   TO ASH DYKE HCSD S LO HCSD SLURRY PUMP` TO ASH DYKE IM SILO Terminal SILO ASH SLURRY SUMP

7. The design concept for Fly Ash to wet ash preparation Back-up For fly ash to wet ash preparation INDURE is using wetting head and each wetting head having 22 nos. high pressure nozzles with water flow-95 m.cu/hr.@35 MWC and dry capacity is 63 TPH (Reference same system is running in LARA project also)

8. The design concept for Fly Ash to wet ash preparation Back-up Elevation at Buffer hopper / collector tank (DP16004-XA00-90ETK-510077) Wetting Head Collector Tank 20THK.Alloy CI LINER(400BHN)

9. ASH HANDLING SYSTEM ASH HANDLING SYSTEM CAN BE BROADLY DIVIDED INTO THE FOLLOWING SUB SYSTEMS: BOTTOM ASH HANDLING SYSTEM COARSE ASH HANDLING SYSTEM FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM ASH WATER SYSTEM ASH SLURRY DISPOSAL SYSTEM HCSD SLURRY DISPOSAL SYSTEM ASH WATER RECIRCULATION SYSTEM INSTRUMENT AIR SYSTEM

10. BOTTOM ECONOMISER & COARSE ASH HANDLING SYSTEM (DRG. NO. DP16004-XG08-90ETA-510001, SH 1 OF 2) ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION IN WET MODE OF UNIT 1

11. BOTTOM ECONOMISER & COARSE ASH HANDLING SYSTEM (DRG. NO. DP16004-XG08-90ETA-510001, SH 2 OF 2) ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION IN WET MODE

12. BOTTOM ASH AND COARSE ASH SYSTEM THE BOTTOM ASH AND CORASE ASH SYSTEM IS UNITISED. ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN IN PREVIOUS TWO SLIDES SHALL BE COMPLETELY INSTALLED. MAJOR EQUIPMENT TO BE INSTALLED : BOTTOM ASH HOPPER COMPLETE WITH EQUIPMENT, WATER PIPING, VALVES AND INSTRUMENTATION BOTTOM ASH SLURRY PIPE LINES WITH VALVES AND INSTRUMENTAION UPTO ASH SLURRY SUMP BOTTOM ASH OVERFLOW TANK BOTTOM ASH OVERFLOW PUMPS WITH PIPING, VALVES AND INSTRUMENTATION DRAIN JET PUMPS, PIPING, VALVES AND INSTRUMENTION ECONOMISER HOPPERS: FLUSHING APPARATUS, WATER AND SLURRY PIPING, VALVES AND INSTRUMENTATION APH HOPPERS, SCR HOPPERS: FEEDER EJECTORS, WATER AND SLURRY PIPING, VALVES AND INSTRUMENTATION COARSE ASH TANK COARSE ASH SLURRY PUMPS WITH PIPING, VALVES AND INSTRUMENTATION

13. FLY ASH VACUUM CONVEYING & WET CONVEYING SYSTEM (DRG. NO. DP16004-XG08-90ETK-510002, SH 1 OF 2) ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION IN WET MODE

14. FLY ASH VACUUM CONVEYING & WET CONVEYING SYSTEM (DRG. NO. DP16004-XG08-90ETK-510002, SH 2 OF 2) ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION IN WET MODE

15. FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM THE FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM IS ALSO UNITISED. FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO WETTING HEAD INSTALLED AT COLLECTOR TANK OR BUFFER HOPPER BYMEANS OF VACUUM CONVEYING SYSTEM AND IN WETTING HEAD FLY ASH MIXES WITH FAHP WATER AND DISPOSED IN SLURRY FORM TO ASH SLURRY SUMP FOR FURTHER DISPOSAL TO ASH DYKE ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN IN PREVIOUS TWO SLIDES SHALL BE COMPLETELY INSTALLED. MAJOR EQUIPMENT TO BE INSTALLED : ADOPTER, ISOLATION VALVES, MATERIAL HANDLING VALVES, CI PIPE LINE ALONG WITH ACI FITTINGS, BRANCH SEGREGATING VALVES ETC FROM ESP AND APH HOPPERS TO COLLECTOR TANK/ BUFFER HOPPER COLLECTOR TANK AND BUFFER HOPPER TOWER STRUCTURE COLLECTOR TANK, WETTING HEAD AND TAIL PIPE AND AIR WASHER FAHP WATER PIPE WORK ALONG WITH VALVES AND INSTUMENTATION UP TO WETTING HEAD, AIR WASHER AND JET NOZZLES. INSTRUMENTATION PIPE WORK TO VARIOUS PNEUMATIC OPERATED VALVES ALONG WITH VALVES, INSTRUMENTATION VACUUM PUMPS AND VACUUM AIR PIPE WORK FROM VACUUM PUMPS TO AIR WASHER/ BUFFER HOPPER ALONG WITH VALVES SEAL WATER AND DRAIN WATER PIPING FOR VACUUM PUMPS FLY ASH SLURRY PIPE WORK FROM COLLECTOR TANK DISCHARGE TO ASH SLURRY SUMP ESP/BH FLUIDISING AIR BLOWERS AND HEATERS, PIPE WORK WITH VALVES FROM BLOWERS TO ESP/ APH HOPPERS

16. FLY ASH PRESSURE CONVEYING SYSTEM (DRG. NO. DP16004-XG08-90ETG-510003, SH 1 OF 2) VACUUM AIR AND FLY ASH TRANSPORT PIPE WORK AND VALVES IN THE BLUE BOX SHALL BE INSTALLED FOR CONTINUOUS OPERATION IN WET MODE

17. FLY ASH PRESSURE CONVEYING SYSTEM(IM SILO) (DRG. NO. DP16004-XG08-90ETG-510004, SH 2 OF 2) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN ARE NOT NECESSARY TO BE INSTALLED FOR WET MODE OPERATION.

18. FLY ASH PRESSURE CONVEYING SYSTEM(TERMINAL SILO) (DRG. NO. DP16004-XG08-90ETG-510004, SH 1 OF 2) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN ARE NOT NECESSARY TO BE INSTALLED FOR WET MODE OPERATION.

19. FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM THE FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM IS UNITISED UP TO HSCD, INTERMEDIATE & TERMINAL SILOS. FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO WETTING HEAD INSTALLED AT COLLECTOR TANK OR BUFFER HOPPER BYMEANS OF VACUUM CONVEYING SYSTEM AND FROM BUFFER HOPPER, FLY ASH IS TRANSPORTED TO FLY ASH SILOS BYMEANS OF COMPRESSED AIR SUPPLIED BY TRANSPORT AIR COMPRESSORS. VACUUM CONVEYING SYSTEM FOR EXTRACTION AND TRANSPORTATION OF FLY ASH TO BUFFER HOPPER AND COLLECTOR TANK IS COMMON VACUUM AIR AND FLY ASH TRANSPORT PIPE WORK AND VALVES HIGHLIGHTED IN THE BLUE BOX SHALL BE INSTALLED FOR CONTINUOUS OPERATION OF FLY ASH SYSTEM IN WET MODE. INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED ISOLATION VALVES ON VACUUM AIR AND FLY ASH TRANSPORT PIPE LINES `

20. FLY ASH PRESSURE CONVEYING SYSTEM(HCSD SILO) (DRG. NO. DP16004-XG08-90ETA-510007) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN ARE NOT NECESSARY TO BE INSTALLED FOR WET MODE OPERATION

21. HCSD SYSTEM THE FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM IS UNITISED UP TO HSCD SILOS. FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO WETTING HEAD INSTALLED AT COLLECTOR TANK OR BUFFER HOPPER BYMEANS OF VACUUM CONVEYING SYSTEM AND FROM BUFFER HOPPER, FLY ASH IS TRANSPORTED TO HCSD SILOS BYMEANS OF COMPRESSED AIR SUPPLIED BY TRANSPORT AIR COMPRESSORS. EACH HCSD SILO CONSISTS OF HYDROMIX DUST CONDITIONER, MIXING TANK, ETC THE FLYASH IS DISPOSED OFF IN WET MODE BY BOOSTER/ CHARGE PUMP AND HCSD PUMP. UPTO ASH DYKE.

22. ASH SLURRY & ASH WATER SYSTEM (DRG. NO. DP16004-XG08-90ETN-510006, SH 1 OF 2) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION IN THE BLUE BOX SHALL BE INSTALLED FOR CONTINUOUS OPERATION IN WET MODE OF UNIT 1

23. ASH WATER SYSTEM ASH WATER SYSTEM IS COMMON FOR BOTH UNITS. FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING EQUIPEMNT AND PIPE WORK, HIGHLIGHTED IN THE BLUE BOXES SHALL BE INSTALLED. BALP WATER PUMPS – 2 NOS (1W+1S) BAHP WATER PUMPS – 2 NOS (1W+1S) BAHP SEAL WATER PUMPS – 2 NOS (1W+1S) FAHP WATER PUMPS – 2 NOS (1W+1S) FLUSHING WATER PUMP – 1 NO COMPLETE PIPE WORK FROM THE ABOVE PUMPS TO RESPECTIVE CONSUMERS ALONG WITH VALVES. INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED VALVES ASH WATER SUMP MAKEUP LINES FROM VARIOUS SOURCES

24. ASH SLURRY & SSH WATER SYSTEM (DRG. NO. DP16004-XG08-90ETN-510006, SH 2 OF 2) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION IN THE RED BOXES ARE NOT NECESSARY TO BE INSTALLED FOR CONTINUOUS OPERATION IN WET MODE OF UNIT 1.

25. ASH SLURRY DISPOSAL SYSTEM ASH SLURRY DISPOSAL SYSTEM IS COMMON FOR BOTH UNITS. FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING EQUIPEMNT AND PIPE WORK SHALL BE INSTALLED. ASH SLURRY PUMPS – 4 NOS I.E 2 SERIES (1SERIES W + 1 SERIES S) DRAIN PUMPS – 2 NOS (1W+1S) ASH SLURRY DISPOSAL PIPE WORK FROM THE ABOVE PUMPS TO ASH DYKE ALONG WITH VALVES. SEAL WATER AND COOLING WATER LINES ALONG WITH VALVES AND INSTUMENTATION INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED VALVES ASH SLURRY SUMP FLUSHING/ MAKEUP WATER LINES FROM VARIOUS SOURCES

26. INSTRUMENT AIR SYSTEM (DRG. NO. DP16004-XG08-90ETY-510009) ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION IN THE RED BOXES ARE NOT NECESSARY TO BE INSTALLED FOR CONTINUOUS OPERATION IN WET MODE OF UNIT 1.

27. INSTRUMENT AIR SYSTEM INSTRUMENT AIR SYSTEM IS COMMON FOR BOTH UNITS. FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING EQUIPEMNT AND PIPE WORK, HIGHLIGHTED IN RED COLOUR ARE NOT NECESSARY TO BE INSTALLED. INSTRUMENT AIR COMPRESSORS – 2 NOS (1W+1S) INSTRUMENT AIR DRYER - 2 NOS (1W+1S) AIR RECEIVERS – 2 NOS (1W+1S) INSTRUMENR AIR PIPE WORK VARIOUS PNEUMATIC OPERATED VALVES WITH VALVES AND FITTINGS COOLING WATER LINES WITH VALVES AND INSTUMENTATION

28. ASH WATER CLARIFIER SYSTEM (DRG. NO. DP16004-XG08-90ETN-510008) ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION IN WET MODE

29. ASH WATER RECIRCULATION SYSTEM ASH WATER RECIRCULATION SYSTEM IS COMMON FOR BOTH UNITS. ALUM AND LIME DOSING TANKS, PUMPS, PIPE WORK WITH VALVES AND INSTRUMENTATION IS REQUIRED TO BE INSTALLED TO TREAT BOTTOM ASH OVERFLOW AND DRAIN WATER COLLECTED IN CLARIFIER. COMPLETE STILLING CHAMBER, CLARIFIER, BRIDGE MECHANSM, SLUDGE PUMPS, PIPE WORK WITH VALVES AND INSTRUMENTAION IS REQUIRED TO BE INSTALLED

30. SOME SITE WORKS PHOTOGRAPH BOTTOM ASH HOPPER BOTTOM ASH HOPPER EQUIPMENT

31. SOME SITE WORKS PHOTOGRAPH VACUUM PUMP HOUSE ASH WATER SUMP

32. SOME SITE WORKS PHOTOGRAPH APR-06 PEDESTAL PIPING 400NB

33. SOME SITE WORKS PHOTOGRAPH APR-09 APR-08

34. THANK YOU FOR YOUR ATTENTION