KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant

KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 7

STANDARD OPERATING PROCEDURE

FOR

DRY ASH
PRESSURE
CONVEYING SYSTEM

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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 7

SOP FOR DRY ASH PRESSURE COVEYING SYSTEM

OBJECTIVE: For Smooth Operation ofDry ash pressure conveying system.

SCOPE: This SOP is applicable for 48no’s Buffer hopper ash transportation.

INTRODUCTION: This System is needed to evacuate fly ash from buffer hopper to fly ash silo
through positive air pressure, this system called as fly (Dry) ash pressure conveying system.

PRE CHECKS:
DRY ASH PRESSURE COVEYING SYSTEM TECHNICAL DATA:-
Make SEPCO. Quantity 24 sets
Blow tank (Air lock 8 no’s/unit Maximum Capacity 240 t/h
vessel)
Air pressure 2.35 kg Blow tank volume 10 m3
Cycle time 225 sec No’s of pipe 2
Auxiliary required for operation:-
Air compressor For instrument air Transport air Air Dryer

Fluidizing blower Silo ventilation system Dust collector Valves

RESPONSIBILITY:Desk Engineer and Field Engineer.

SAFTEY PRECAUTIONS:
1. Ensure no permit to work is pending on regarding this system by checking with EE/MRSE.

SAFTEY PPE’s: Ear Plugs, Safety Goggles, Hand Gloves, etc.

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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 7

PRECHECKS ON FIELD ENGINEER

S No Description Ok Not Ok Remarks

1 Work permit on various Blow tank and Fly ash silo

equipment’s such as Dust collector (Bag filter), FF Blower,
FF Motor, Switch Valves, Safety Valves, Dome valves,
balance valves, feed valves, line valves and discharge
valves, fluidizing lines, fluidizing pads & conveying line
etc. are cancelled.

2 Check all maintenance work stop in blow tank area,

conveying line & silo top area.

3 Check fluidizing blower running & heater is in service.

4 Check all fluidizing line header valve open.

5 Blow tank manual ash inlet valve open.

6 Silo ventilation fan is running.

7 Dust collector purging system is in service.

8 Silo top diversion valve open.

9 Check conveying line manual header valve open.

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Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 7

PRECHECKS AND ACTION BY DESK ENGINEER

S No Description Ok Not Remarks

Ok

Work permit on various Blow tank and Fly ash silo

equipment’s such as Dust collector (Bag filter), FF Blower,
FF Motor, Switch Valves, Safety Valves, Dome valves,
balance valves, feed valves, line valves and discharge
valves, fluidizing lines, fluidizing pads&conveying line etc.
1 are cancelled.

2 Ensure power supply to all the equipment’s is healthy.  

Check transport air compressor is running & receiver

3 tank air pressure normal.  

Check instrument air compressor is running,dryer in

4 service & receiver tank air pressure normal.  

5 Check silo ventilation system is running.  

6 Check fly ash silo level normal.  

7 Start one fluidizing blower for buffer hopper.  

OPERATING PROCEDURE -

Sr. RESPONSIBILITY
Description
No. DE FE EE
PRE- START CHECKS:
1 All permits and cross permits have been returned.
2 Power supply and control power supply of all relevant auxiliary
available.
3 Silo ventilation system is running.
4 At least one fluidizing blower is running.

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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 7

5 Instrument air compressor & transport air compressor is running.

START PERMISSIVE :

1 Silo ash level normal.

2 Silo ventilation system running.

3 Receiver tank air pressure normal.

4 Blow tank ash inlet manual isolation valve open.

5 Buffer hopper ash level not low.

DRY ASH PRESSURE COVEYING SYSTEM START UP SEQUENCE :

1 Check instrument air pressure normal, then start transport air
compressor & stand receiver air pressure more than 3.5 bar.
2 Start fluidizing air blower one no.
3 Start silo ventilation fan & bag filter purging system.
4 Start ash evacuation system in remote sequence.
SHUTDOWN SEQUENCE:
1. PLANNED SHUTDOWN :
1 The dry ash pressure conveying system can be shut down only after the
buffer hopper level low & ESP evacuation system stop or silo ash level
high.
2 First to flush the blow tank & conveying line to insure no ash in blow
tank & ash conveying line before stopping system.
3 After stopped the system stop transport air compressor.

4 Stop silo ventilation system.

5 Stop fluidizing blower.

2. EMERGENCY SHUT DOWN:

1 There is the apparent abnormal condition during operation.

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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 7

2 Silo ventilation system suddenly stop or trip.

3 Silo ash level high.
4 When endangering the safety of person and equipment.

INTERLOCKS : Remarks

1 Silo ventilation system suddenly stop or trip.

2 Silo ash level high or silo DP high.
3 Instrument air pressure low.

ABRIVIATIONS / NOTATIONS:-
o SOP: StandardOperating Procedure
o UCE: Unit Control Engineer
o DE: Desk Engineer
o FE: Field Engineer
o EE: Electrical Shift Engineer

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Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
KMPCL/OPR/DAPCS/01
Power from knowledge SOP FOR DRY ASH PRESSURE CONVEYING SYSTEM

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 7 of 7

DO’s & DONT’s :

DO’s :

1. Ensure Instrument Air Header & Service Air Header Pressure is healthy before starting of the system.

2. Ensure loading & unloading of Service Air Compressor is happening properly.

3. Ensure Air Dyer is properly working (i.e. dew point is to be properly monitored).

4. Before starting, ensure that the conveying line is flushed (i.e. free from residual ash).

5. Close the Air Valve immediately in case of tendency of Line jamming.

DONT’s :

1. Don’t run the system if Inlet Valve Seal pressure is low.

2. Don’t disturb the pressure setting recommended by OEM.

3. Don’t run the system if Silo Vent fan is not running.

4. Don’t run the system in case of any leakage in the conveying line.

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