This document is, unless otherwise agreed in writing, the property of TECPRO SYSTEMS LIMITED, and shall

not be reproduced, copied, disclosed to any third party or used any purpose other than that for which it is
supplied or disclosed.
5
4
3
2
REVISED AS PER
1 DOC. Approval P.K.M. SOURAV S.M. 18.07.11
COMMENTS
0 FIRST SUBMISSION DOC. Approval P.K.M. SOURAV S.M. 31.05.11
REASONS
PREPARED CHECKED APPROVED
REV. STATUS TYPE FOR DATE
BY BY BY
REVISION

INDIA KMPCL 6X600MW Sub Critical Coal – Fired Power Station Project

OWNER

KSK MAHANADI POWER CONSTRUCTION CO. LTD.

:
OWNER'S ENGINEERS DEVELOPMENT CONSULTANTS PVT. LTD.
CONSULTING ENGINEERS
: KOLKATA, MUMBAI, CHENNAI, NEW DELHI
CONTRACTOR
SEPCO ELECTRIC POWER CONSTRUCTION CORP.
JINAN , CHINA
:
CONTRACTOR'S
ENGINEERS: NORTHEAST ELECTRIC POWER DESIGN INSTITUTE
(OF CHINA POWER ENGINEERING CONSULTING GROUP)
Changchun, China

TECPRO SYSTEMS LTD.

(ASHTECH DIVISION)
T KOLKATA PUNE

CONTROL WRITE UP

TSL DOC. No. 563-C&I-203

REV.NO.: 1
29/7/2011

B. G. Zarbade CLIENT DOC. No. KMP-0-AHS-

V404-N-203
Space for Approval Stamp

As attached
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

CONTROL WRITE – UP

CHAPTER – I
 
1.0    HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM 
 
1.1   INTRODUCTION 

Ash  handling  system  is  provided  with  High  concentration  slurry 

disposal system for which two common Fly ash silos for each 3x600 
MW  unit  are  provided.  This  Fly  ash  Silos  will  feed  ash  to  three 
independent  streams  of  HCSD  system.  Two  streams  shall  normally 
be  working  and  one  stream  will  be  available  as  standby.  The  silo 
shall  have  three  openings.  These  three  openings  of  Fly  ash  silo  will 
be  connected  to  three  independent  streams  of  high  concentration 
slurry disposal system for continuous disposal of high concentrated 
slurry to ash disposal area with 65‐70% ash concentration. Water is 
added in mixing tank with moist ash in a controlled manner through 
continuous  automatic  “Instrument  Based”  monitoring  system  to 
ensure that the basic slurry parameters remain constant during the 
transportation of slurry through the pipe line. 
 
The pump speed shall be varied through VFD drive over the range of 
10% to 100% of maximum flow rate. Necessary remote and manual 
speed  control  provision  is  there.  There  are  two  nos.  of  dedicated 
transformer to feed the power supply to VFD and after VFD to HCSD 
motor. 

The  following  aspects  govern  the  basic  arrangement  of  high 

concentration slurry system. 
 
a) Controlled Ash Feed. 
b) Controlled water supply to maintain proper slurry density. 
c) HCSD Pump. 
d) Disposal Pipe line. 

1
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

 
There are many control features, which have to work for guaranteed 
monitoring of proper slurry density in a continuous manner so that 
the slurry pump can operate uninterruptedly. 
 
1.2  MAJOR EQUIPMENTS FOR HCSD SYSTEM 
 
• ROTARY FEEDER WITH VFD [ SEPCO SCOPE] 
 
One  (1)  no.  Rotary  Feeder  is  provided  in  upstream  of  each  screw 
Feeder and takes fly ash input from HCSD silo. It is to be noted that 
the Rotary Feeder has variable speed control and have ash disposal 
capacity  of  225  TPH.  The  speed  of  Rotary  Feeder  is  automatically 
adjusted as per the reading of Mass Flow meter to maintain required 
ash  flow  for  slurry  consistency  (60%  ‐  70%).For  variation  of  Rotary 
Feeder  speed  a  VVVF  drive  is  provided.  Mass  flow  meter  is 
continuously monitor the feeding rate of fly ash from Rotary Feeder 
to  Mixer  tank  through  Screw  Feeder  and  Paddle  Feeder  and  thus 
control of ash feeding rate into the system is achieved.  
 
• SCREW FEEDER [ SEPCO SCOPE] 
 
Screw  Feeder  is  provided  in  between  Rotary  Feeder  and  Paddle 
Feeder  for  transportation  of  dry  fly  ash  from  Rotary  Feeder  to 
Paddle  Feeder  because  of  their  eccentric  location.  The  capacity  of 
Screw Feeder shall be same as Rotary Feeder. 
 
• PADDLE FEEDER [ SEPCO SCOPE] 
 
This is a twin Paddle mixture unloader having capacity 225 TPH. This 
is  provided  in  upstream  of  Slurry  mixing  tank  where  dry  fly  ash  is 
been moist and discharge to ART (Agitated Retention Tank). 
 
 
 

2
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

• AGITATED RETENTION TANK (ART) [ TSL SCOPE] 
 
The ART is a rubber lined cylindrical tank with vertical spindle, twin 
blade, dual impeller type high torque agitator. The output of Paddle 
Feeder  fed  into  ART  where  required  slurry  concentration  and 
rheology  is  maintained  and  monitored.  The  ART  is  provided  with 
Level  Transmitter  for  continuous  level  control  measurement, 
Nucleonic  and  Non‐nucleonic  type  Density  meter  for  density 
measurement  and  PH  meter  for  measurement  of  PH  value  of  ash 
slurry.  The  ART  is  provided  with  proper  flushing  and  drain 
connection. 
 
The mixing tank (ART) will have five level controls. 
a) High High Level (90 %). 
b) High Level (80%) 
c) Operating level (70%). 
d) Low level (10%). 
e) Danger low level (0%). 
 
Zero level (0%) is set at the start of the lower part of tank.  The 90% 
level is the maximum slurry level allowable in the tank. 
 
• CHARGE PUMP [ SEPCO SCOPE] 

Total  Three  (3)  nos.  charge  pump,  one  for  each  HCSD  stream  has 
been  providing  at  the  suction  of  HCSD  pumps  for  each  3X600  MW 
unit. The pump parameters are 265 cu.M/Hr. @30 MWC. 
 
Charge pump can be started under the following condition: 
 
o Either suction valve or water line valve should be open. 
o If  suction  valve  is  open,  then  agitator  tank  level  should  be 
high. 
o If  water  line  valve  is  open,  then  water  pressure  should  be 
above preset value. 

3
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

 
The pump will trip is the above conditions are not fulfilled. 
 
• MEASURING LOOP PUMP [ TSL SCOPE] 
 
One Hose pump each having capacity 1.5 cu.M/Hr. @30 MWC  
provided with each slurry mixing tank for measuring the slurry 
density of a mixing tank by non nucleonic density meter. 
   
1.3  HCSD PUMP [ SEPCO SCOPE] 
 
There  are  three  sets  of  HCSD  Pump  (2W  +  1S)  each  having  ash 
disposal  of  225  TPH  (Dry  ash  basis)  for  two  Fly  ash  silo  with  motor 
and  VFD  are  provided  for  total  three  streams.  Capacity  of  HCSD 
Pump  is  265cu.m/hr  @  300  MWC.  Among  the  three  independent 
high concentration slurry disposal streams, two are working for two 
F.A  Silo  and  one  is  common  standby.  Three  HCSD  Pumps  are 
connected  with  three  nos.  slurry  disposal  line  with  necessary 
interconnection and instrumentation. 
 
The starting permissive of HCSD Pump from HCSD PLC are as follows: 
  
• HCSD Pump not failed. 
• HCSD  Pump  ready  to  run  (Feed  back  from  HCSD  PLC  to  main  PLC) 
under the following condition: 
 
a) VFD ready to run. 
b) Pump ready to run. 
c) Propelling pump on. 
d) Lub pump on. 
e) Suction flow normal. 
f) Propelling liquid pressure normal. 
g) Air pressure normal. 
 
 

4
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

• HCSD Pump Auto/manual selection from HCSD SCADA. 
   
The starts permissive of HCSD Pump from main PLC are as follows: 
 
• Manual suction valve open. 
• Mixture run feed back. 
• Mixture tank level not low. 
• IAC Pressure normal. 
• HCSD PLC ready. 
• Paddle feeder health. 
• Rotary feeder healthy. 
• Mixing tank density (minimum) below preset value. 
• VFD Ready to RUN 
 
 
 
 

*****************

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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

CHAPTER II
Control Systems
 
1. HCSD CONTROL SYSTEM 
 
The entire HCSD system for unit‐1,2,3,4,5&6 is PLC based control system. 
The  overall  control  and  sequential  operation  of  the  total  HCSD  system  is 
achieved through   this main programmable logic controller (SEPCO Scope). 
The  control  of  the  HCSD  system  is  basically  from  main  system  PLC  and 
HCSD pump PLC when the ART control panel shall act as a local panel with 
local  actuation  facility  of  Agitator  and  Measuring  loop  pump  with  local 
feedback and annunciation.
 
The  ART  control  panel  (TSL  SCOPE)  shall  be  connected  with  main  system 
PLC through hardwire cable (By SEPCO). PLC of HCSD system shall correct 
the  speed  of  the  pump,  control  ash  feeding  from  silo  and  for  other 
necessary action on the feedback given by ART control panel. 
 
The  Agitator  and  Hose  pump  shall  be  running  from  main  PLC  as  well  as 
through ART control panel.  
 
All  interlocks  /  annunciations  from  field  instruments  related  to  ART  tank 
provided by TSL shall be demonstrated during commissioning. 
 
The  control  and  Instrumentation  scope  for  the  HCSD  System  is  limited  to 
the supply of Control panels & field Instruments related to ART Tank as per 
P&ID 563‐01‐02 REV 3.  
 
Various voltages / currents for the system are as follows. 
   
1)  ART Panel Output for lamp: 24V DC 
2)  ART Panel light, space heater: 240V AC 
 

6
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1

CHAPTER III

PROTECTION AND INTERLOCK

 
 
 
 
 
 
 
 
 
 
Protection and interlock for the HCSD System is attached herewith.

7

Ref.
S.N. Equipment
Drg. Starting Permissive
1 2 3 4
1.Manual suction valve open.
2.Agitatot run feed back.
3.Agitatot tank level not low.
4.IAC Pressure normal.
563-01-02
HCSD PUMP
1 OS
[ 6 nos.]
5.HCSD PLC ready.
6.Paddle feeder health.
7.Rotary feeder healthy.
8.Mixing tank density (minimum)
below preset value
9.VFD Ready to RUN
1.Start Command Initiated
2.MCC Available
MIXING
563-01-02
3.MCC Not disturbed
TANK
2 Switch (OS /
AGITATOR
4.Tank Level above LOW
[ 6 nos.]
5. Remote Selected from OS
PROTECTION INTERLOCK
Interlocks Controls Controlled
Annunciation Indications/ Mimic
Running Permissive Provided From
5 6 7 8 9
Start / Stop P.B.
1.Manual suction valve open. 1.VFD Trip (OS) 1.HCSD Pump ON Red Lamp (OS)
Switch (OS)
2.HCSD Pump OFF Green Lamp
2.Agitatot run feed back. 2.HCSD Pump Failed (OS)
(OS)
3.Agitatot tank level above Danger 3.Mixing Tank Level Danger 3.GEHO Pump Trip Amber Lamp
Low. Low (OS) (OS)
4.Mixure Tank Level Danger Low
4.IAC Pressure normal. 4.Density Low (OS)
Red Lamp (OS)
5.Mixure Tank Level Low Red
5.HCSD PLC ready. 5.Density High (OS)
Lamp (OS)
6.Mixure Tank Level High Red
6.Paddle feeder health.
Lamp (OS)
7.Rotary feeder healthy. 7.Density High Red Lamp (OS)
8.Mixing tank density (minimum)
8.Density Low Red Lamp (OS)
below preset value
9.VFD Ready to RUN
1.Stop Command NOT Initiated 1.Mixure Tank Level Low (OS) 1.Start Red Lamp (OS/ ART Panel)
2.Agitator TRIP (OS / ART 2.Stop Green Lamp (OS/ ART
2.MCC Available
Panel) Panel)
3.Mixure Tank Level Danger 3.Trip Amber Lamp (OS/ ART
3.MCC Not disturbed Start / Stop P.B.
Low (ART Panel) Panel) OS / ART
4.Tank Level above DANGER 4.Mixure Tank Level Low (ART 4.Tank Level Danger Low Red PANEL
ART Panel)
LOW Panel) lamp (OS)
5.Mixure Tank Level High (ART
5. STOP push button not pressed. 5.Tank Level Low Red lamp (OS)
Panel)
6.Tank Level High Red Lamp (OS)
 PROTECTION INTERLOCK

Ref. Interlocks Controls Controlled

S.N. Equipment Annunciation Indications/ Mimic
Drg. Starting Permissive Running Permissive Provided From
1 2 3 4 5 6 7 8 9
1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
2. MCC available. 2. MCC available. 2.Seal water Pressure LOW (OS) 2.Stop Green Lamp (OS)

563-01-02
CHARGE
3. Seal water Pressure NORMAL. 3. Seal water Pressure NORMAL. 3.Trip Amber Lamp (OS) Start / Stop P.B.
3 PUMP OS
4. MCC NOT Disturbed. 4. MCC NOT Disturbed. Switch (OS)
[ 6 nos.]
5. Agitator Tank Disc. valve open 5. Agitator Tank Disc. valve open
6. Agitator tank Level above LOW 6. Agitator tank Level above
Start / Stop P.B.
ROTARY 1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
563-01-02

Switch (OS)
FEEDER 2.MCC not disturbance. 2.MCC not disturbance. 2.Stop Green Lamp (OS)
4 OS
VFD
3. VFD ready to run 3. VFD ready to run 3.Trip Amber Lamp (OS)
[ 6 Nos.]
4. Screw feeder RUNNING 4. Screw feeder RUNNING

Start / Stop P.B.

1.Start command initiated. 1.Stop command not initiated. 1.TRIP (OS / ART Panel) 1.Start Red Lamp (OS/ ART Panel) Switch (OS/
ART PANEL)
MEASURIN
2. Discharge Pressure HIGH (OS 2.Stop Green Lamp (OS/ ART
563-01-02

G LOOP 2.MCC not disturbance. 2.MCC not disturbance.

/ ART PANEL) Panel) OS / ART
5 PUMP /
3.Trip Amber Lamp (OS/ ART PANEL
HOSE PUMP 3.MCC available. 3.MCC available.
Panel)
[ 6 Nos.]
4.Mixing tank Level above 4. Discharge Pressure HIGH Red
4.Mixing tank Level above LOW
DANGER LOW Lamp (OS)
5. Discharge pressue Not LOW 5. Discharge Pressure NORMAL
Red Lamp (OS)

Start / Stop P.B.

1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
563-01-02

SCREW Switch (OS)

6 FEEDER
2.MCC not disturbance.
[ 6 Nos.]
3. VFD ready to run
4. Paddle feeder RUNNING
OS
2.MCC not disturbance. 2.Stop Green Lamp (OS)
3. VFD ready to run 3.Trip Amber Lamp (OS)
1 4. Paddle feeder RUNNING