PWP71 Feasibility Report Ash Disposal System

NTPC LIMITED
TALCHER KANIHA
UNITS # 1 TO 6
ORISSA
FEASIBILITY REPORT
FOR
ASH DISPOSAL SYSTEM
Job No. D–0328 Name/ Sign Date
Prepared By GG 05.05.2012
Checked By KSA 05.05.2012

DESEIN PRIVATE LIMITED
Approved By V. GEORGE 05.05.2012
DESEIN HOUSE
Document No. D-0328-01 Rev. No. GREATER KAILASH – II

03
NEW DELHI – 110 048
DESEIN INDEX
FEASILBILITY REPORT
FOR
ASH DISPOSAL SYSTEM
AT
NTPC KANIHA THERMAL POWER STATION
UNITS # 1 TO 6 (Phase#1 + Phase#2)
INDEX
Sl. No. DESCPRITION Sheet No
1. Introduction 1
2. Abbreviation 1
3. Objective of Study 1
4. Back ground of investigation 2
5. Description of Existing Ash Disposal system 2
6. Description of Existing Ash Extraction system for Phase #1 2
7. Description of Existing Ash Extraction system for Phase #2 3
8. Capacity of Existing system 4
9. Alternative Systems for Ash Disposal 4
10. Description Proposed ash slurry Disposal system 15
11. Layout Aspects 18
12. Electrical & Instrumentation Aspects 19
13. Design Aspects 20
14. Major Equipments 24
15 Scope of work 28
16. Project Schedule for Ash Slurry Disposal system 28
17 Estimated cost for Ash Slurry Disposal system 29
18. Summary 34
A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es
ISO 9001:2000 Registered Company

Certificate No. 07/170/J
DESEIN INDEX
Annexure
Annexure-I Implementation Schedule 1 Sheet

Annexure-II Existing System Capacity 4 Sheet
Annexure-III System Capacity Proposed system 1 sheet
Drawings
1. D-0328-SKT-01A - Flow diagram Ash Disposal System

2. D-0328-SKT-02A - Indicative Layout of Ash Disposal System
3. D-0328-SKT-03A - Piping Corridor – Ist Stage pumping system
4. D-0328-SKT-04A - Piping Corridor –IInd Stage pumping system
5. D-0328-SKT-05A - Slurry Pump House
6. D-0328-SKT-06A - Flow Scheme Dry Ash system
7. D-0328-SKT-07A - Route survey
Attachments
1. Photo - Quarry No: VIII Jagannath Mine

2. Photo – Ash Slurry filling in mine
3. Photo – Ash Filled mine - 1
4. Photo – Ash Filled mine - 2
5. Photo – Slurry Disposal system in Jagnath mine

DESEIN Page 1 of 37
FEASILBILITY REPORT
FOR
ASH SLURRY DISPOSAL SYSTEM
FROM
NTPC TALCHER KANIHA PLANT
1.0 INTRODUCTION
This report covers the study of technical feasibility for Ash Disposal system
for two (2) phases of NTPC Kaniha plant to Jagannath mines located
approximately 30KM away from plant in the State of Orissa. NTPC Kaniha
Thermal Power Station consists of two (2) Phases. Phase-I consists of two
(2) units (Units # 1 to 2) and Phase-II consists of four (4) units (Units # 3 to 6).
All units of Phase-I and Phase-II are under commercial operation. Each unit is
having dedicated ash handling system within the plant area and an Ash
Disposal system from the plant area and up to an ash pond located
approximate 7KM away. The present study is for disposing the ash generated
from six (6) boilers up to the Coal mines for filling.
1.1 ABBREVIATIONS.
a. Phase # 1 – Unit # 1 & 2
b. Phase # 2 – Unit # 3 to 6
c. Ist Stage – From Plant up to Intermediate Collection point.
d. IInd Stage – From Intermediate collection point to destination (Quarry no.8)
1.2 Objective of the Study
The main objective of the study is investigate and study the various
feasibilities of disposing the ash by utilising the existing systems to coal
mines for future filling of voids in the mine area. This will reduce the load on
existing ash pond which is almost 90% filled condition and ash pond is likely
to overflow within two (2) years.

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1.3 Background of Investigation
Mahanadi Coal Field Ltd (MCL) operating the Jaganath mines for commercial
coal selling under Coal india Ltd. regulations. Hazards in the area is back
filling of the voids generated after extraction which leads to the operational
difficulty like transportation unbalanced earth movement etc. In view of the
above Mahanadi coal ltd allotted the void-8 of Jaganath mines to NTPC
Kaniha plant for back filling with plant ash.
By considering the commercial operation of the plant in full capacity for two
(2) decades Ash extraction and disposal is the major concern for officials due
to non availability of land as per Govt norms. Kaniha plant is generating
twenty thousand (20,000) ton of ash in a day which is a huge quantity and
needs more care in handling before disposal as the norms of pollution board
has to be taken in consideration.
2.0 DESCRIPTION OF EXISTING ASH EXTRACTION SYSTEM
2.1 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

PHASE#1 (UNITS # 1 & 2)
2.1.1 Each boiler is equipped with various collection points mainly furnace bottom,
Air Pre Heater (APH) and Electrostatic Precipitators (ESP) at various
locations. Ash generated in boiler is distributed in each collection points as
follows.
Furnace bottom – 15%

APH-5%
ESPs – 90%
2.1.2 Furnace bottom is equipped with specially designed water impounded

storage bottom ash hopper which is allowed to collect the furnace bottom ash
along with water. Collected ash is removed using Jet pump with water mixing
and conveyed to a Common Ash Slurry sump for further disposal using
horizontal centrifugal pumps.

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2.1.3 For extraction of APH and ESP ash collection vacuum conveying system is
envisaged up to intermediate collection point of Collector tank system from
where the water mixed ash slurry is routed up to Common ash slurry sump for
further disposal using horizontal centrifugal pumps.
2.1.4 Ash slurry from the above described points is collected in a common ash
slurry sump provided for Phase-I. A separate pump house equipped with
Horizontal centrifugal Slurry duty pumps as follows.
Number of pumping series provided – Four (4)

Number of pumping series working – Two (2)
Number of piping streams provided - Two (2)
Number of pumps in One (1) series – Three (3)
2.2 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

PHASE#2 (UNITS # 3 TO 6)
2.2.1 Each boiler is equipped with various collection points mainly furnace bottom,
economizer, APH and ESP at various locations. Ash generated in boiler is
distributed in each collection points as follows.
Furnace bottom – 20%

Economizer – 5%
APH-5%
ESPs – 80%
2.2.2 Furnace bottom is equipped with specially designed bottom ash hopper with
water impounded storage which is allowed to collect the furnace bottom ash
along with Economizer ash. Collected ash is removed using Jet pump with
water mixing and conveyed to a Common Ash Slurry sump for further
disposal using horizontal centrifugal pumps.
2.2.3 For extraction of APH & ESP ash collection vacuum conveying system is
envisaged up to intermediate collection point of Collector tank system from

DESEIN Page 4 of 37
where the water mixed ash slurry is routed up to Common ash slurry sump for
further disposal using horizontal centrifugal pumps.
2.2.3 Ash slurry from the above described points is collected in a common ash
slurry sump provided for Phase-II. A separate pump house equipped with
Horizontal centrifugal Slurry duty pumps in the following passion.
Number of pumping series provided – Six (6)

Number of pumping series working – Four (4)
Number of piping streams provided - Four (4)
Number of pumps in One (1) series – Four (4)
2.3 CAPACITY OF EXISTING SYSTEM
Refer Annexure-II
The above figures are based on average basis of 20,000 ton ash generation per day.
3.0 VARIOUS SYSTEMS FOR OF ASH DISPOSAL.
3.1 The following are the various options for Ash Slurry Disposal system for
Phase-I and Phase-II
Following systems were taken into consideration and concluded the above
system as techno economical due to the reasons.
High Concentration Slurry Disposal System – HCSD system is designed with

concentration of 55% – 65 % (w/w). Dry ash from the source silos are fed to the
mixing unit for getting the required slurry concentration before entering to the main
pump. Depending on the type of pump used there are various methods to feed the
main pump. After the proper mixing of the ash and water in the required
concentration this will be disposed by the positive displacement pump provided. In
general practice various type of ash is mixed in a proper ratio in the pumps for
achieving the required efficiency and performance. The mixing units for the HCSD
system are placed above the ground level with a storage capacity of 30minutes of
pump capacity. The concentration for the system is maintained by the inlet water

DESEIN Page 5 of 37
control regulation. These pumps are working at high pressure; hence seamless pipes
are required for the cross country piping with high thickness to maintain the life of the
pipe. Following equipments are required to envisage the HCSD system.
1. Dry ash collection unit. (Silo, hopper etc…)
2. Ash conveying equipment to Mixing unit (Conveyor, screw feeder, air slide etc...)
3. Mixing unit with 30minutes storage capacity.
4. Feeding system to the Main pump.
5. Strainers at pump suction.
6. Pump suction valves.
7. Piston operated Main pump.
8. Slurry line discharge valves.
9. MS seamless pipe.
10. Instruments. (Density meter, flow meter, pressure transmitters etc...)
To achieve a HCSD system Dry Fly ash is required and Ash has to be fed
from Dry ash silo. The existing ash removal system below the hoppers of
boilers is not suitable for this system. Since there is no proven disposal
system of not more than 11KM and not more than 300TPH we have not
included any details of the system in this study. The longest system
installed is Base water system at Australia. Since the Existing facilities are
suiting the operation of HCSD system the feasibility of this is not
considered.
Truck unloading system – Non availability of sufficient roads, Facilities.

Frequent truck movement will fully congest the area and existing removal
system below hoppers of boiler is not suitable for the system. Details are
included below.
Railway Wagon Disposal system-This will slow down and arrest the whole
train movement. Practical difficulties for implementation. Details are
included below.

DESEIN Page 6 of 37
Conveyor system. Details of the scheme with included below.
Lean phase ash slurry disposal system. – Details are included below.
3.2 Estimated Cost of Various Ash Disposal Systems:
For implementing the above alternative systems completely new dry ash collection system
with silos for fly ash and dewatering bins for Bottom ash has to be installed similar to the
system installed in NTPC DADDRI. A viable flow scheme is attached as Sketch number D-
0328-SKT-06A.
Details of the system to installed and the cost and operation viability study is as follows.
3.3 Tentative BOQ for Complete dry system (Prices are in Lacs)
Fly ash Silos 1500 MT capacity along with ash un-loaders, blowers etc - 2
sets/ unit x 6 =12 sets
Buffer hoppers and associated valves and piping - 4 sets/ unit x 6 =24
sets
Conveying air compressors with air driers - 3 sets / unit x 6 =18
sets
Bag filters -4 sets/ unit x 6
=24 sets
Vent filters & vent fans -2 sets / unit x 6 =12
sets
Dry fly ash conveying pipes - lot (qty depends on
location of Silos)
Pipe racks and Buffer hopper supporting structure - lot (qty depends
on location of Silos)
Hydro bins(Dewatering bins ) for Bottom ash- -3 sets / unit x 6 =18
sets
BA slurry piping along with slurry duty valves - lot (qty
depends on location of Bins)
Replacement of BAHP pumps with higher discharge pressure -2sets/ unit x 6 =12
sets
Electrical and C&I system

DESEIN Page 7 of 37
Costing
(i) Steel silo (320 MT each @ Rs80/Kg) = Rs 240 Lacs x 12------ = Rs 3072 Lacs
(ii) Dewatering bins(200 MT each @ Rs 80/Kg) Rs 160 Lacs x 18---Rs2880 Lacs
(iii) Settling tank & Surge tank(160 MT each set@Es 80/Kg) Rs 128 Lacs x4
sets=Rs 512 Lacs
(iv) Vent filter & vent fan Rs 9 lacs each x 12-----------------------= Rs 108 Lacs
(v) Buffer hopper with airlock tanks and valves Rs 10 lacs each x 12= Rs 120
lacs
(vi) Bag filters Rs 6 lacs each x 12------------------------------------------- = Rs 72

lacs
(vii) Silo air blowers with motors Rs 8 lacs x 2/ silo x 12 ---------------= Rs 192
lacs
(viii) 2 KM pipe rack + Buffer hopper supporting structure 1000 MT

@ Rs 70/Kg = Rs 700Lacs
(ix) Conveying pipes 300 NBx 9.52 thk 3 lines / unit 750 mts eachx 6 =4500 mts
@ Rs 3700/ mtr--------------------------------------------------------=Rs 166.5 Lacs
(x) Conveying pipes 400 NBx 9.52 thk 3 lines / unit 750 mts eachx 6 =4500 mts
@ Rs 4700/ mtr--------------------------------------------------- =Rs 211.5 Lacs
(xi) Transport air compressors with air dryers and receivers 3sets / unit
@Rs 70 Lacs x 6-----------------------------------------------------= Rs 1260 Lacs

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(xii) Instrument air compressors( 600 m3/ hr FAD) with air dryers and air receivers
dedicated for dry system 4 sets @Rs 35 Lacs--------------------=Rs 140 Lacs
(xiii) Drain pumps in Silo area with piping 3 sets x 3.5 lacs --------= Rs. 10.5 lacs
TOTAL FOR MECHANICAL JOBS---------------------------------------- =Rs 9444.5 Lacs
(xiv) Civil jobs LS ------------------------------------------------------- = Rs 2914.58 Lacs
3.3.2 Civil Work Costing
Sl. Unit Rate

CIVIL WORKS DETAILS Qty Unit Total Rate
No. Rs
TAC Buidings ( 3 buidings @ 1 per

2 units) Size 45 Mtr x 12 Mtrsx 3
1 2100 M3 20000 42000000
nos. --Concrete(700 M3x3)
Silo Utility building 60 mtrx15mtr

2 Concrete(900 M3x1) 900 M3 20000 18000000
Hydro bin Recirculation water PH

35 Mtr x 12 Mtrs-Concrete(420
3 420 M3 20000 8400000
M3x1)
Architectural works for the

above@ 22% of concrete cost 3420 M3 4400 15048000
Silo Foundations Concrete

4 275 M3 x 12 3300 M3 17000 56100000
Hydro bin Foundations Concrete

5 235 M3 x 18 4230 M3 17000 71910000
Drain sump & miscellaneous

6 works 500 M3 17000 8500000

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Surge tanks Foundation concrete

7 250 M3x 4 nos. 1000 M3 17000 17000000
Settling tank Foundation concrete

8 250 M3x 4 nos. 1000 M3 17000 17000000
Concrete flooring/ paving around

Silos & Hydrobins450 + 550 Sq
9 15000 M2 2500 37500000
mtr
TOTAL 291458000 291458000
Electrical and C&I jobs- LS-------------------------------------------------------------= Rs 955 Lacs
3.3.3 Electrical Work Costing
Sl. Unit
Electrical work detail QTY Total
No. rate
1 3.3 KV HT Switch gear with 1 no. 140 140
2 incomer panels
1 Bus coupler panel
20 nos. TAC motor feeders(18+2 sp)
4 nos. Transformer feeders (3+1 sp)
220 V, DC system along with battery banks and

battery charger(2x 100% charger & 100% 30
2 1 set 30
battery)
60
3 3300/415 V , 2000 KVA Transformers 3 nos. 20
65
4 LT Switch gear WITH 1 no 65

DESEIN Page 10 of 37
Sl. Unit
No. rate
incomers 2 nos.
1 bus coupler
150 KW motor feeders 8 nos.
5 KW feeders 12 nos.
63A Switch fuses units 32 nos.
70
5 3.3 HT cables lot 70
From client's SWGR to proposed SWGR 2x 1500

mtrs 3000 mtrs
Power Cables for HT motors 18 x 150 mtrs 2700 mtrs
250
6 LT Cables lot
1600 mtrs
LT cables for 150 KW motors 8x 200 mtrs
400 mtrs

Sl. Unit
No. rate
750 mtrs
32500 mtrs
4550 mtrs
LT cables for32 KW motors 13x 350 mtrs
3200 mtrs
2800 mtrs
LT cables for 63A 8x 200 mtrs for motor

actuators 1600 mtrs
200 mtrs
LT cables for 132A sw fuse unuts 1x 200 mtrs
5000 mtrs
Motor heater cables
5000 mtrs
Control cables for motors
Lot
7 Cable accessories 15 15
50
8 Cable trays and supports lot 50
10
9 Junction boxes & LCS lot 10
55
10 LDB/ LP/ ACDB LOT 55
25
11 Earthing lot 25
70
12 PLC Panel with MMIs (1 set for 2 units) 3 sets

Sl. Unit
No. rate
25
13 UPS
35
14 Instrument cables 30000 mtrs
55
15 Instruments lot
Vacuum transmitters 24 nos.
pressure transmitters 32 nos.
Vacuum gauges, Pr gauges and Temp gauges 350 nos.
pr switches 80 nos.
Temp switches 24 nos.
TOTAL 955
TOTAL COST OF ELECTRICAL MRCH & CIVIL =Rs 13314.08 Lacs
ERECTION COST 26000 MTX Rs20000 =Rs 5200 Lacs
TOTAL COST OF INSTALLING DRY SYSTEM =Rs 18514 Lacs
Annual O&M cost would be approximately 5% = Rs 85 Lacs
Approximate minimum time period for executing this job shall be 30 months.
Probable methods for ash conveying from silos & hydro bins up to the mines are as under.
This detailed system described earlier is common for the below describing alternatives from
Silo up to mines. All the cost, advantage and disadvantages of the whole system will be
added with this description and below detailed alternative.

3.4 Ash Disposal options from Dry Ash Silo
(i) By road using dumper trucks
Assuming average capacity of each dumper truck to be 20 MT, 1000 trips per day is
required to transfer the total ash of 20000 MT per day.
To and fro travelling distance between plant and mines------------------------= 60 KM
Travelling time assuming an average speed of 40KM/ Hr= 60/40--------------=1.5

Hours
Loading time per dumper truck-------------------------------------------------------= 15 minute.
Unloading time---------------------------------------------------------------------------= 15 minutes
Therefore time taken for one trip of dumper truck------------------------------- = 2 hours
Assuming truck movement from 8 AM to 8 PM operating time--------------- = 12 hours
Maximum number of trips one truck can make per day = 12/2------------------= 6 trips
Quantity of ash that can be transported using one truck = 6x 20----------------= 120 M
Therefore number of trucks required for transporting 20000 MT

of ash= 20000/120- = 167
Assuming 8 trucks for maintenance replacement total number of

dumper trucks of 20 MT capacity -----------------------------------------------------------= 175
Note:- Considering 15 minutes loading time+ 10 minutes for truck to move in position
& move out per truck and simultaneous loading of 6 trucks
Number of trucks that can be loaded in 12 hours (8AM to 8 PM) = 720/25 x6= 172.8
 Furthermore a heavy duty 2 lane road 30 KM long with required culverts , rail
crossing flyovers etc ; has to be constructed up to the mines for free

movement of trucks or existing roads to be revamped for free movement of

dumper trucks.
 For filling the mine voids ash can be directly dumped and spreading and
compacting can be done by bulldozers. Minimum 6 nos. of bulldozers would
be required.
Costing
(i) Cost of dumper trucks- 175 x 25.7lacs = 45 Crores
(ii) Cost of Construction/ revamping of existing roads = 75 Crores
(iii) Cost of 6 nos. bull dozers = 6 X 60lacs = 3.6 Crores
(iv) Total cost for implementing Transportation by Dumper trucks = 123.6 Crores.
The above cost is for implementation of truck system for which complete dry
system is also added up for total cost implication.
Estimated duration for implementing the system would be approximately Three (3) years.
(ii) By using rail wagons of MGR system
For proper and efficient loading of wagons silos and hydro bins of all the units shall
be located in line and rail lines are to be routed below as shown in the attached
sketch-2.
Alternately a conveyor system with bunkers and discharge chutes can be installed
for loading the wagons.
Loading of wagons
Number of wagons per rake = 38
Capacity of each wagon= 60 MT
Capacity of each rake=38 x 60 =2280 MT
Number of rake trips required =20000/2280= 8.77 say 9 rake trips

Capacity of each silo unloading sprouts= 200 MT/ hr maximum
Assuming simultaneous loading of 4wagons thru 4 sprouts unloading

capacity= 200 x 4 =800 MT/hour
Total operating time of unloading sprouts for loading one rake= 2280/ 800=2
Hrs 51minutes
Time required for moving and aligning wagons below loading sprouts= 15
minutes
Total loading time of one rake = 3 hrs 6 minutes.
Time required for loading 9 rakes = 28 hours
Which means only 7 rakes can be loaded in a day even if operated round the
clock. ie; only 7x 2280= 15960 MT which is less than the requirement of
transferring 20000 MT/ day.
For Unloading of wagons and filling of mine voids a track hopper/ hoppers along
with conveyor system and 1 no. Shift able conveyor systems (as installed at NTPC
Dadri ash mound area) are required to be constructed / installed. Suitable water
spraying system shall be installed for preventing dust pollution.
 Spreading and compacting can be done by bulldozers. Minimum 6nos. of

bulldozers would be required
Or alternate
Cost of 4km conveyors from Silos to wagons on existing railway track+ 6 KM rail
lines+ 2 shift able conveyors at mines end
Since the feasibility of above system is nil and rail costing is not possible costing has
not been envisaged.
(iii) Conveyor system

Open conveyors are not suitable as the distance is too long and one transfer station
at every will have to be constructed at an interval of 1 KM. Furthermore
environment pollution cannot be avoided. Therefore tubular conveyor system would
be a viable option.
One no. 20KM long conveyor along with supporting structure and drive accessories
would be required.
Three (3) sections with two (2) transfer stations are envisaged with 7km each length.
Each section requires Four (4) drive motors as detailed below.
1. Drive # 1 – 600KW
2. Drive # 2 – 600KW
3. Drive # 3 – 550KW
4. Drive # 4 – 550KW
This results to a power consumption of 2300KW per section totaling 6900KW for
20KM conveyor system.
Cost of the same would be approximately Rs. 350000 Lacs (This value excludes the
Electrical, Civil works which shall be added separately.
Break up of Cost.
1. Conveyor – 1.5 lacs /Meter (including drive and motor assembly)

2. Structural work – 300Kg/m
Spreading and compacting can be done by bulldozers. Minimum 6 nos.

of bulldozers would be required Operation and maintenance
Considering the above case study of the various ash disposal schemes the most feasible,
economical and viable option is found as lean slurry disposal of total ash by utilizing the
existing pumping facilities without disturbing the plant operation.
4.0 DESCRIPTION OF PROPOSED ASH SLURRY DISPOSAL SYSTEM:

plantAs per the various discussions and final resolution in Meeting held on
24.02.2012 at NTPC EOC/Noida, the scheme to be adopted is disposal of
phase # 1 ash t the Mine voids and Phase # 2 ash will be disposed to the
existing Ash pond utilizing the current facilities.

4.1 Please read this document in conjunction with following drawings.
D-0328-SKT-01A - Flow diagram Ash Disposal System

D-0328-SKT-02A - Indicative Layout of Ash Disposal System
D-0328-SKT-03A - Piping Corridor – Ist Stage pumping system
D-0328-SKT-04A - Piping Corridor – IInd Stage pumping system
D-0328-SKT-05A - IInd stage Slurry Pump House
4.1.1 For Disposal of Ash generated in the two (2) boilers as per the parameters
mentioned above we are proposing lean phase Slurry disposal system
through pipe lines. Proposed system consists of two (2) stage pumping
system with horizontal centrifugal slurry duty pumps of adequate capacity
and pressure rating. Pumping streams has to be decided according to the
final requirement of customer according to the operation and maintenance
point of view. Detailed system philosophy is as follows.
Proposed system consists of two (2) stage lean phase slurry pumping
system. From plant vicinity the ash slurry collected in Ash slurry sumps will
be pumped to an intermediate booster station where the Slurry will be
collected for pumping through horizontal centrifugal pumps to the mines.
4.1.2 IST STAGE PUMPING SYSTEM
For first stage pumping system the existing pumping system described above
in para 2.1 is to be utilized to discharge the slurry in to the second stage Ash
slurry sump located 8 KM away from the plant boundary. This location will be
TP-14 of routing map. As described earlier the pumping streams starts from
Phase # 1 Ash Slurry pump house. Total three (3) streams emerging from
phase # 1 has to be extended approximate 8km from the pump houses. Out
of three (3), two (2) streams will be working and One (1) stream will remain
standby. One (1) tapping point from each of the existing line along with
suitable isolating valve for routing up to the second stage pumping streams
will be provided.
Pipe size

From Phase # 1- 400NB (2nos)
4.1.3 IIND STAGE PUMPING SYSTEM
From three (3) streams of Ist stage pumping the ash slurry will be collected in
the IInd stage Ash slurry sump located 8km away from the plant vicinity. For
pumping the Ash slurry collected in the Ash slurry sump three (3) series of
horizontal centrifugal ash slurry pump will be provided. Out of three (3), two
(2) series of pumps will be working and one (1) series will be standby. There
will be two (2) dedicated streams of pipes working up to the destination
(Quarry No.8). In case of any chocking or maintenance in the IInd stage
pumping the Ash slurry can be diverted to Ash pond through the existing
system. Incase of any problem in this two (2) lines, the third line can be made
in to operation or divert to the Existing ash pond.
One pump will be provided with a provision of future pump in each series to
achieve the required pressure rating of the pumping. The first pump in series
will be driven with fluid coupling and gear box for achieving the speed
variation during operation if required. This speed variation shall be at least (+)
15% and (-) 40% of rated speed of the pump. Future provision pumps in
series shall be V-belt driven. Motor operated Knife gate valve shall be
provided at the discharge of the pumping streams. Also necessary manually
operated Knife gate valves shall be provided for interconnection.
Other than ash slurry pump following equipments are required for the system
operation.
Seal water pump: - Horizontal centrifugal type water pumps shall be

provided to cater the seal water requirement of the Ash slurry pumps.
One (1) separate water sump will be provided in the pump house for
suction of this pump. Minimum two (2) number pumps shall be
provided for this duty.
Flush water pump: - Horizontal centrifugal type water pumps shall be

provided to cater the flushing water requirement of Slurry pump
discharge piping during chocking and maintenance. This pump shall

be designed to flush the stream for line clearance up to the

destination in case of chocking. Minimum one (1) pump shall be
provided for this duty. This pump shall also take suction from the
water sump.
Tube Well Pump (Optional in case of water source is not available) –

Vertical tube well pumps has to install near the pump house for water
requirement of sealing. This water can be purified for the potable
water system for the pump house utility. Minimum two (2) pumps have
to be installed for this duty.
Make up water pumps – Water required for the makeup of Slurry

sump and flushing shall be provided from plant water system. For
achieving the water requirement two (2) water pumps shall be
provided at plant getting suction from the plant water source.
The aspect of water recovery system from the mines is to be further explored since
the quantity of water available in the mines is a huge quantity which may tend to spill
out from the mines during back filling with ash. There are various modes of water
recovery schemes available in the market for recalculating the water dumped with
slurry and other applications. In the scheme described here is provided with a
provision of such pipe routing if required from mines to plant. Scheme and mode of
transport are not elaborated here since the study is concentrated in disposal system
only.
5.0 LAYOUT ASPECTS
5.1 The major concern in the system is Layout aspects. Tentative layout of the
system is attached in drawings (D-0328-SKT-02). Cross country piping of the
system is to be decided according to the feasibility and availability of land as
per the existing area aspects. The major layout concerns to be taken in to
consideration are as follows.
Cross country piping from tapping point of Existing pumping stream up

to IInd stage pump house. 8km routing.

Approach road for IInd stage pump house along with cross country
piping corridor.
Above ground electrical transmission line up to IInd stage pump house.
IInd stage pump house along with five (5) ash slurry collection
compartments, one (1) ash water sump and one (1) operation and
control room.
IInd stage cross country pipe pedestals from IInd stage pump house up
to destination (Quarry no.8).
Road, rail and village area crossing at various locations up to the

destination.
5.2 Cross country piping pedestals from tapping point of existing line up to the
IInd stage pump house as per attached sketch (D-0328-SKT-02) is required
for the system, along with this pipe pedestal above ground electrical
transmission line has to be installed to feed the electrical equipments. As a
mandatory requirement and access point of view one (1) dedicated road of
adequate width has to provide along with the pipe routing. One (1) IInd stage
pump house to accommodate the equipments shall be provided along with
operator station and slurry and water collection sumps. From IInd stage pump
house the slurry disposal pipes can be routed in pedestals up to required
destination.
5.3 All the electrical – HT and LT Switchgear, Dry Type Transformers etc and
PLC Control Room for IInd stage pumping will be located in Electrical Building
on the Pump house.
6.0 ELECTRICAL AND INSTRUMENTATION ASPECTS
NTPC shall make available HT feeders to meet the requirement of IInd stage
Slurry pumping system. Dry type transformers will be provided to derive the
LT power supply required for the system. One (1) HT switchgear, one (1) LT

MCC and dry type transformers will be located in Electrical Room located in
the IInd stage pump house.
220 V DC power supply for protection purpose shall be made available by

NTPC.
All the required controls, instrumentation and protections necessary for safe,
efficient and trouble free operation of the equipments/systems will be provided.
One (1) microprocessor based PLC systems with 100% hot backup and 100%
redundant input power supply will be provided to control and monitor IInd stage
slurry pumping system. The PLC Control Panel will be provided with mimic
along with status indication of various drives /equipments and annunciation
(Audio-Visual) system.
7.0 DESIGN ASPECTS
The Disposal system is to be designed considering 2080 Cum/h (1040Cum/h

per stream) Ash slurry disposal per day. The basic design aspect of the
system is that the existing system is running continuous for 24hours for all
two (2) boilers. In case of non availability of ash necessary make up water
system is to be operated if the system needs continuous running. The system
is designed on the concept that the pipe routing from IInd stage pumping up to
Jaganath mines has to be done along the forest area indicated in the layout
scheme (D-0328-SKT-03). Total pumping distance from plant area up to the
mines is considered as twenty (20) Kilometers (aprox.). Out of twenty (20) KM
total length, Eight (8) Km shall be covered by utilizing the existing system as
described earlier. Hence the second stage is to be designed for a length of
minimum twelve (12) KM.
7.1 SIZING CRITERIA
7.1.1 IST STAGE PUMPING SYSTEM UP TO IIND STAGE PUMP HOUSE
7.1.1.1 PHASE # 1

Sl
No Description Formula Value
1 Slurry Pump capacity ‘A’ = 1040Cum/h
2 Number of pumps working ‘B’ = 2 Nos.
3 Number of Streams from Phase ‘C’ = 2 Nos.

# 1 to IInd stage pump house.
4 Flow per stream ‘D’ = A = 1040 Cum/h
5 Total line length ‘E’ = 8 Km
5 Total Friction loss per stream ‘F’ = 94 mwc

(Calculated)
6 Static rise ‘G’ = 13 m

Plant elevation = 110
Elevation at TP14 = 121
7 Total head required per stream ‘J’ = F + G = 106 mwc.
8 Head available from Existing ‘F’ = 13.8 Kg/Sqcm

pump
SINCE HEAD AVAILABLE IS HIGHER THAN THE REQUIRED HEAD,

SELECTED LOCATION IS O.K
7.1.2 IInd STAGE PUMPING SYSTEM UP TO QUARRY NO.8
Sl Description
Formula Value
No
1. Ash Slurry disposal pump
‘A’ = 1040 Cum/h
capacity, Phase # 1

2. Number pumping series working ‘B’ = 2nos.
3. Number working hours per day ‘C’ = 24h
4. Total ash slurry collected per day ‘D = A x B x C’ = 49920 Cum

nd
in II stage Slurry Sump from
phase # 1
5. Total ash slurry collected per day ‘I = D = 49920 Cum

nd
in II stage Slurry Sump
6. Number of working hours per day ‘J’ = 24hrs

nd
- II stage Slurry Pumps
7. Total pumping capacity of IInd ‘K = I / J’ = 2080 Cum/h

stage pumping
08. Number of pumping series ‘L’ = 2nos

working in IInd stage
09. Capacity of each pumping stream ‘M = K/L’ = 1040Cum/h
10. Total Friction loss ‘FL’ = 154 mwc
11 Static rise ‘SR’ = -60 mwc

Elevation at TP14 = EL(+) 121
Elevation at Quarry no.8=(+)60 60
12 Total head required ‘HR’ = FL + SR = 94 mwc

13. Total pressure required to reach ‘N’ = 94Kg/Sqcm*1
the destination
14. Number of pumps in each series ‘P’ = 3nos

15. Discharge pressure of Pump ‘Q = N/P’ = 3.2 Kg/Sqcm

selected
*1. Pressure requirement is calculated on assumption that the mine area is

located at 60m lower elevation from the IInd stage pump house.
8.0 MAJOR EQUIPMENT
The following major equipments are proposed for Ash slurry Disposal system:
Sl. EQUIPMENT Quantity

No
A Ist Stage Pumping System
1 400 NB Motor operated Knife Gate Valves 4Nos.
2 400 NB MS ERW Pipe 9.52mm thick 36 Km
3 400NB Cast iron fittings 2 lot
4 400NB Sleeve couplings 2 lot
5 Electrical items 1 lot
B IInd Stage Pumping System
1 Plug valves for Ash Slurry sump isolation 3 nos.
2 Liner for Ash Slurry Sump 1 lot


No
3 Flushing nozzles for Slurry sump jetting 1 lot
4 400NB motor operated Knife Gate valve 3 nos.
5 Horizontal Centrifugal Slurry duty pumps 9 nos.
6 Fluid coupling for Ash Slurry pump 3 nos.
7 Gear Box for Ash Slurry Pump 3 nos.
8 Motor for Ash Slurry Pump – 200KW 9 nos.
9 400NB manual operated Knife gate valve 9 nos.
10 400NB MS ERW pipe 36km
11 ACI Fittings for IInd Stage pumping 3 lots
12 Horizontal Centrifugal Water pump along with 2 nos.

motor for Seal water
13 Horizontal Centrifugal Water pump along with 1 no.

motor for Flushing


No
14 Tube well pump 2 nos.
15 Make up Water pump 2 nos.
16 5ton EOT crane for Pump house 1 no.
17 HT Switchgear 1 no.
18 LT Switchgear 1 no.
19 Dry Type Transformers 2 Nos.
20 PLC Control Panel 1 No
21 Power and Control Cables Lot
22 Instruments Lot
23 Earthing and Lighting Lot
24 Dry type ventilation system for Pump house Lot
25 Air Conditioning system for PLC Control Room Lot

C Civil and Structural Works
1 Pipe Pedestals for Ist stage Pumping 1000nos.
2 Support for Transmission line 1 lot
3 IInd stage Pump house with electrical and control 1 no.

room
4 Pipe Pedestals for IInd stage Pumping 1500 Nos.
5 4m Wide access road up to IInd stage Pump house 8km
6 4m Wide access road from to IInd stage Pump 12 km

house to destination (Quarry no.8) – Optional
7 Equipment foundations Lot
9.0 SCOPE OF WORK
This shall be decided by Customer according to the feasibility and fund

availability.
10.0 PROJECT SCHEDULE FOR ASH SLURRY DISPOSAL SYSTEM
Estimated time required for designing and engineering of Ash Slurry System,
soil investigation and route survey is four (4) months from the date of
placement of order. Procurement of bought out of equipment & materials and
manufacturing of self fabricated equipment and materials will take six (6)
months after engineering. Despatch and receipt of materials and equipment
at site will take nine (9) months starting seventh month onwards from the date

of procurement. Civil works will take minimum fourteen (14) months provided
the fully mobilized team and fast track working basis. Erection of equipment
could be started after four (4) months from the start date of despatches. The
duration of erection of equipment is estimated fourteen (14) months. Testing
and commissioning activity will take last two (2) months after completion of
erection of equipment. Total time period for completion of Ash Disposal
System is proposed as twenty (24) months from the issue of LOI on
successful bidder provided the environmental conditions, availability of land
and local supports from other departments.
11. COST ESTIMATE FOR PROPOSED ASH SLURRY DISPOSAL SYSTEM
(i) Mechanical
Sl. Unit
EQUIPMENT UOM Quantity Total price
No. price
A Ist Stage Pumping System

1 400 NB Motor operated Knife Gate Valves Nos. 3 600,000 1,800,000
2 400 NB MS ERW Pipe 9.52mm thick M 16000 5,200 83,200,000
3 400NB fittings & couplings Lot 1 30,000 1,950,000
B
IInd Stage Pumping System
1 Plug valves for Ash Slurry sump isolation, Lot 1 2,320,000 2,320,000
slurry sump liner, flushing nozzles, Pulleys,
V-belts etc.
4 400NB motor operated Knife Gate valve Nos. 3 600,000 1,800,000
5 Horizontal Centrifugal Slurry duty pumps Nos. 9 850,000 2,550,000
6 Fluid coupling and gear box for Ash Slurry Nos. 3 450,000 1,350,000
pump
9 Motor for Ash Slurry Pump – 200KW Nos. 9 500,000 4,500,000
11 400NB manual operated Knife gate valve Nos. 9 520,000 46,800,000

Sl. Unit
EQUIPMENT UOM Quantity Total price
No. price
12 400NB MS ERW pipe m 36000 6,000 216,000,000
13 Fittings & Couplings for IInd Stage pumping Nos. 45 25,000 2,555,000
14 Horizontal Centrifugal Water pumps Nos. 4 1,000,000 4,000,000
17 EOT crane for Pump house Nos. 1 1,000,000 1,000,000
C Common System
1 450NB Make water line (1nos) 6.3mm thick Nos. 8000 3,000 24,000,000
2 Make up water pump with motor Nos. 2 1,100,000 2,200,000
3 Miscellaneous lot 1 2,000,000 2,000,000
Total for Mechanical 3,981 Lacs
(ii). Civil and Structural
Sl Unit
Details QTY Unit Total Rs
no. Rate Rs
From In plant Pump House to Booster PH
A 8KM
Pipe pedestals 7.5 M wide 8000/7= 1150 x

1 6 M3 (RCC) 5500 M3 20000 110000000
Rail crossing pipe rack 3 nos. max 100 M

2 span
RCC 6x25
(a) 150 M3 20000 3000000
4320000
(b) Structural steel 100x0.6 60 MT 72000
20 mtr span Road crossing culverts 3 nos.
3 - RCC 3x100 300 M3 20000 6000000
4 25 mtr span Nalla crossing 2 nos.
(a) RCC 4x25 100 M3 20000 2000000
(b) Structural steel 50x0.6 30 MT 72000 2160000

Sl Unit
no. Rate Rs
5 Thrust blocks 15 nos. x30 450 M3 20000 9000000
From Booster Pump House to mine void

B
12KM
Pipe pedestals 4 M wide12000/7= 1725 x

1 6500 M3 20000 130000000
3.75 M3 (RCC)
Rail crossing pipe rack 3 nos. max 100 M

2
span
(a) RCC 6x25 150 M3 20000 3000000
20 mtr span Road crossing culverts 6 nos.

3 600 M3 20000 12000000
- RCC 6x100
4 30 mtr span Nalla crossing 4 nos.
(a) RCC 8x25 200 M3 20000 4000000
5 Thrust blocks 15 nos. x35 525 M3 20000 10500000
C Booster PH9 30Mx16M x 9M ht) 800 M3 28000 22400000
4 mtr wide asphalted road from plant to

D
Booster PH 8 KM
(a) Road construction 8000 x4 32000 M2 1500 48000000
Shoulders for above !M wide both sides

(b) 16000 M2 650 10400000
5600 x 2
4 mtr wide WBM road from booster PH to

E
Mine void
(a) Road construction 12000 x4 48000 M2 850 40800000

Sl Unit
no. Rate Rs
Shoulders for above !M wide both sides

(b) 24000 M2 650 15600000
12000 x 2
TOTAL 4418 lacs
(iii). Electrical and C & I
Sl. ELECTRICAL SYSTEM FOR SLURRY

Unit rate Total Rs in lacs
No. BOOSTER SYSTEM FOR 6X 500 MW
3.3 KV transmission line 8 KM long with

1 complete accessories like isolators, 8 KM 42 336
earthing, lightning arrestors
2 3.3 KV Switch Gear with 1 set 90 75
1 incomer
Motor feeders 200 KW x 9+2 spares = 11
Transformer feeders 2
3 Transformers 3300V/ 415V, 630 KVA 2 10 20
220 V, DC system along with battery banks

4 25 25
and battery charger
5 LT Switch gear with 1 set 30 30
Motor feeders 150 KW- 2
40 KW motor feeders- 4
32A Switch fuse units for valve motor

actuators-8
32A Lighting feeders-2
63 A Switch fuse units-4
6 HT cables lot 30

Sl. ELECTRICAL SYSTEM FOR SLURRY

Unit rate Total Rs in lacs
No. BOOSTER SYSTEM FOR 6X 500 MW
From HT Switch gear to 350 KW motor 250 1500

Mtrs x6 mtrs
From HT Switch gear to Transformers 100 200

mtrs x2 mtrs
7 LT cables lot 40
400
mtrs
750
mtrs
LT cables for 63A 6x 200 mtrs for motor 1600

actuators mtrs
8 Cable trays, supports and cable accessories lot 10 10
9 LDB/ LP/ACDB LOT 20 20
8 Earthing lot 10 10
9 PLC Panel with MMI + 8 KM FO cable 1 set 55 55
10 UPS 1 15 15
2000
11 Instrument cables 12.5 25
mtrs.
12 Instruments Lot 6 6
15
Pr gauges and Temp gauges
nos.
15
pr switches
nos.
Level switches 2 sets
TOTAL 697 lacs.
(iv). Erection testing and commissioning
1. Estimated cost of erection---- = 2950 lacs

Total estimated cost for Ash Slurry disposal system = 3985+4418+697+2950 = 12050
lacs
“The above slurry system pricing is done with MS ERW pipe, incase of Basalt pipes
are used in the system a price implication of Rs. 6843/- lacs will be added up to the
total mentioned above. Also 10% additional to be considered to the erection and
commissioning and additional handling charges.”
11.0 Summary
Following three feasible options are summarized and found the most feasible option as
Slurry pumping system.
Sl. Details of Approximate Duration for

Advantages Disadvantages
no System Cost execution
1 Slurry Rs. 120.5 24 months 1. Easy 1. Water
Pumping Crore Installation consumption.
system 2. Less
operation
and
maintenance
cost.
3. Less initial
installation
cost.
4. Easy
installation.
5. Easy
operation
and
maintenance
2 Road 305 Crores. Minimum 1. Water 1. The system is not
transportati 30months for Dry saving. feasible as around
on by system and 175 trucks would
dumper another 36 be required to run

Sl. Details of Approximate Duration for

Advantages Disadvantages
no System Cost execution
trucks months for during the day
balance work time (8.0 am to
8.0p.m). Loading
of such large
number of trucks
and truck
movement
through the
villages on the
route to the mine
would also not be
feasible.
2. High installation
cost.
3. High Operation
and maintenance
cost.
4. Atmospheric
Pollution.
5. Local risk factors.
5 Tubular Rs. 600 Minimum 1. Water 1. Huge power
Conveyor Crore 30months for Dry consum consumption.
System system and 24 ption. 2. Huge operation
months for cost.
balance. 3. Huge Initial
installation cost.
4. Risk factor.

Study # 0328
ANNEXURES
Study # 0328
ANNEXURE - I
IMPLEMENTATION SCHEDULE
DESEIN SH 1 OF 1
ANNEXURE - I
ASH SLURRY DISPOSAL SYSTEM
IMPLEMENTATION SCHEDULE
Activity Months
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1. Release of Order
ZERO DATE
2. Design & Engineering
3. Procurement &
Manufacturing
4. Civil Works
5. Dispatch & Receipt at

Site
6. Erection
7. Testing &
Commissioning

Study # 0328
ANNEXURE - II
EXISTING SYSTEM CAPACITY
ANNEXURE-II
EXISTING UTILITIES - PHASE # 1
Quantity
Motor
SI Capacity
Equipment Head rating Remark
no Work Stand Cum/hr
Total mwc in KW
ing by
1 Ash slurry disposal pump 2 2 4 1040 46 325
2 BALP Pump 3 2 5 740 20 55
3 BAHP Pump 1 1 2 550 73 150
4 Flushing water Pump 1 Nil 1 1040 14 55
5 LP Seal water pump 1 1 2 22.5 18 4.4
6 HP Seal water pump 1 1 2 33 111 22
1 of 4
EXISTING UTILITIES - PHASE # 2
Quantity
Motor
SI Capacity
Equipment Worki Stan Head rating Remark
no Total Cum/h
ng dby mwc in KW
Ash slurry disposal

1 4 2 6 1220 37.5 300
pump
2 BALP Pump 6 4 10 615 23 60
3 BAHP Pump 2 2 4 600 100 260
4 Flushing Water Pump 2 Nil 2 1220 15 75
5 Sump Jetting pump 1 1 2 50 43 10
6 LP Seal water pump 1 1 2 60 55 18.5
7 HP Seal water pump 1 1 2 36 135 30
2 of 4
EXISTING SYSTEM PARAMETERS.
PHASE # 1
A Ash Collection data
1 Worst Coal Consumption of Boiler

428 tph
2 Bottom ash hopper 58 T/Hr
3 ESP hoppers 172T/Hr
4 Duct hoppers 08 T/Hr
5 APH hoppers 10 T/Hr
B Ash Removal System
Water impounted Bottom ash hopper with Conventional Jet Pump

1 Bottom Ash System
system up to Ash Slurry Sump
Vacuum System through wet surry system up to Ash Slurry

2 Fly Ash System
Sump.
Four (4) series (2W+2S) pumping stream up to Ash Dyke located

3 Ash disposal System
6km way from plant. Each series having three (3) pumps.
1. Ash water recovery

4 Ash water System 2. CW Blow down
3. RAW Water (Only for emergency)
C Density of Ash
1 Bottom Ash 0.65 ton/Cum
2 Fly Ash 0.75 ton/Cum
3 of 4
EXISTING SYSTEM PARAMETERS.
PHASE # 2
A Ash Collection data
1 Worst Coal Consumption of Boiler 428 tph
2 Bottom ash hopper 58 T/Hr
3 ESP hoppers 172T/Hr
4 Duct hoppers NA
5 APH hoppers 10 T/Hr
B Ash Removal System
Water impounted Bottom ash hopper with Conventional Jet Pump

1 Bottom Ash System
system up to Ash Slurry Sump
Vacuum System through wet surry system up to Ash Slurry

2 Fly Ash System
Sump.
Six (6) series (4W+2S) pumping stream up to Ash Dyke located

3 Ash disposal System
6km way from plant. Each series have four (4) pumps.
1. Ash water recovery

4 Ash water System 2. CW Blow down
3. RAW Water (Only for emergency)
C Density of Ash
1 Bottom Ash 0.65 ton/Cum
2 Fly Ash 0.75 ton/Cum
4 of 4
Study # 0328
DRAWINGS
CHIMNEY
(EL(+)110M) TP-1 STARTING POINT
TP-2
TP-3
TP-4 ASH PIPE LINE

DETAIL-D
TP-5
TP-6
400 NB SLURRY PIPE - 1st STAGE
TP-7
TP-8
TP-9
TP-10
TP-11 BOOSTER
WATER PUMP
TP-12
TP-13
TP-14
TP-15
FGL
TP-16
TP-17
VIEW - AA
RAIL LINE
TP-18
(UPTO BOOSTER PUMP HOUSE)
AS H DISPOSAL LINE
400NB SLURRY PIPE

TP-19
600NB RECOVERY PIPE
TP-20
TP-21
TP-22
TP-23
FGL
CL
TP-24
FGL
TP-25
TP-26
VIEW - BB (DETAIL - D)
(AFTER BOOSTER PUMP HOUSE) TYPICAL RAIL CROSSING
(EL(+)60M)
END POINT
QUARRY
NO.08
NOTES:-
1.DRAWING IS INDICATIVE ONLY.
2.FOR FLOW SCHEME DETAILS REFER DRG. NO. D-0328-SKT-01B.
3.LOCATION OF BOOSTER PUMP STATION-1 = 10Km AWAY
FROM PLANT.
4.LOCATION OF BOOSTER PUMP STATION-2 = 13Km FROM
BOOSTER PUMP STATION-1
400NB SLURRY PIPE
600NB RECOVERY PIPE

(OPTIONAL)
FGL
PIPING CORRIDOR-IInd STAGE PUMPING

AFTER BOOSTER PUMP HOUSE
NOTES:-
1.- DRAWING IS INDICATIVE ONLY.
2.-FOR FLOW SCHEME DETAILS REFER DRG. NO. D-0328-SKT-01.
3.- PHYSICAL CHECKING HAS TO BE CARRIED
OUT FOR FINALISATION OF ROUTING.
NOTES:-
1.- ALL DIMENSIONS ARE IN mm.
2.- LAYOUT SHOWN IS INDICATIVE ONLY.
Study # 0328
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NTPC LIMITED

ASH DISPOSAL SYSTEM

Job No. D–0328 Name/ Sign Date

Checked By KSA 05.05.2012

Document No. D-0328-01 Rev. No. GREATER KAILASH – II

Sl. No. DESCPRITION Sheet No

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

Annexure-I Implementation Schedule 1 Sheet

1. D-0328-SKT-01A - Flow diagram Ash Disposal System

1. Photo - Quarry No: VIII Jagannath Mine

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

1.2 Objective of the Study

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

1.3 Background of Investigation

2.0 DESCRIPTION OF EXISTING ASH EXTRACTION SYSTEM

2.1 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

Furnace bottom – 15%

2.1.2 Furnace bottom is equipped with specially designed water impounded

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

Number of pumping series provided – Four (4)

2.2 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

Furnace bottom – 20%

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

Number of pumping series provided – Six (6)

2.3 CAPACITY OF EXISTING SYSTEM

3.0 VARIOUS SYSTEMS FOR OF ASH DISPOSAL.

High Concentration Slurry Disposal System – HCSD system is designed with

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

1. Dry ash collection unit. (Silo, hopper etc…)

3. Mixing unit with 30minutes storage capacity.

4. Feeding system to the Main pump.

5. Strainers at pump suction.

6. Pump suction valves.

7. Piston operated Main pump.

8. Slurry line discharge valves.

10. Instruments. (Density meter, flow meter, pressure transmitters etc...)

Truck unloading system – Non availability of sufficient roads, Facilities.

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

Conveyor system. Details of the scheme with included below.

3.2 Estimated Cost of Various Ash Disposal Systems:

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

(ii) Dewatering bins(200 MT each @ Rs 80/Kg) Rs 160 Lacs x 18---Rs2880 Lacs

(vi) Bag filters Rs 6 lacs each x 12------------------------------------------- = Rs 72

(viii) 2 KM pipe rack + Buffer hopper supporting structure 1000 MT

@ Rs 3700/ mtr--------------------------------------------------------=Rs 166.5 Lacs

@ Rs 4700/ mtr--------------------------------------------------- =Rs 211.5 Lacs

@Rs 70 Lacs x 6-----------------------------------------------------= Rs 1260 Lacs

A D ev e l op m e nt S erv ic e for I n dus tr i es & Ut i l it i es

ISO 9001:2000 Registered Company

TOTAL FOR MECHANICAL JOBS---------------------------------------- =Rs 9444.5 Lacs

(xiv) Civil jobs LS ------------------------------------------------------- = Rs 2914.58 Lacs

3.3.2 Civil Work Costing

Sl. Unit Rate

TAC Buidings ( 3 buidings @ 1 per

Silo Utility building 60 mtrx15mtr