DESIGN BASIS REPORT –BALANCE OF PLANT EQUIPMENTS

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

ITEM CODE DBR001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT

Typical chemical composition of ash, % by mass:

Composition Unit
Silica as SiO2 % 52.32
Alumina as Al2O3 % 29.52
Iron oxide as Fe2O3 % 9.42
Titanium Oxide as TiO2 % 3.88
Calcium Oxide as CaO % 0.76
Magnesium as MgO % 0.69
Sodium Oxide as Na2O % 0
Potassium Oxide as K2O % 1.09
Manganese Oxide MnO % 0
Sulphate as SO3 % 0
Phosphorus as P2O5 % 0
Chloride as Cl % 0
Strontium Oxide Sro % 0.06
Zinc Oxide (ZnO) % 0.08
Copper Oxide % 0.18
Loss of Ignition % 2

 Separate Fly ash silo and Bed ash silo is not applicable for this extension power plant.
Existing fly and bed ash silo shall be utilized.

Dense phase ash handling control Philosophy

The Dense Phase Pneumatic Conveying System of Fly Ash from Ash Hoppers to Fly Ash Storage
Silo is centrally controlled through DCS Based Control System provided.

Each Conveying Vessel is provided with a Local Electro Pneumatic Panel which houses the
Pressure Switches, Pressure Gauges, Solenoid Valves, Selector Switches, Push Buttons, Indication
lamps … etc.

The normal operation of the Plant is through DCS. However some controls & indications are
provided in Local Pneumatic Panel attached to the Conveying Vessels namely System Start/Stop
Selector Switch, Line Purge Push Button, Probe Override Push Button & System ON Indication.

The DCS is provided with System Start/Stop Selection, Probe/Timer Mode Selection, Line Purge
Selection and Probe Override Selection for each conveying system.

Detailed control philosophy shall be submitted during detail engineering.

PROJECT :
1 X 50MW EXTN. THERMAL POWER PLANT FOR
PROJECT ID : JP0025
M/s. SPECTRUM COAL & POWER LIMITED.
PREPARED BY VERIFIED BY APPROVED BY DATE : 06.01.15
S.VIJAYASEKAR T. THANAPAL BRR SHEET : 40 of 68
 DESIGN BASIS REPORT –BALANCE OF PLANT EQUIPMENTS

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

ITEM CODE DBR001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT

07.06.00 Ash Distribution Sheet

No. of Quantity of ash in

Location Temperature Density Remarks
points each point - kg/h

Normal Design Normal Design (Typical)

Bed ash 3 7555 11331 200-250 350 650
Air heater Below
2 944 3777 245 300 650
Economiser ash
Air heater in pass
2 944 3777 140-150 200 650
II ash Ash
ESP Ash quantities
collection provided
ESP first field 1 41738 49102 140-150 200 650 are per
hopper
ESP second field 1 6261 49102 140-150 200 650 only.
ESP third field 1 939 3777 140-150 200 650
ESP fourth field 1 141 3777 140-150 200 650
ESP fifth field 1 21 1888 140-150 200 650
ESP Sixth field 1 3 1888 140-150 200 650
ESP Seventh field 1 0.56 1888 140-150 200 650
Total ash per
58546 130310
hopper
Total Ash 75543 160526

Ash particle size distribution

Sieve analysis % by Air heater below Air heater ash

Bed ash ESP ash
mass Economiser ash in pass II
0-63 micron 0.21 54.36 59.72 77.66
63-75 micron 0.13 33.65 21.19 12.99
75-150 micron 9.87 11.61 17.32 8.68
150-300 micron 26.59 0.36 1.22 0.33
300-600 micron 31.61 0.02 0.4 0.21
600micron -1.18 mm 10.03 - 0.15 0.13
1.18-2.36 mm 12.95 - - 0
2.36-4.75 mm 6.06 - - -
4.75 – 25 mm 2.55 - - -

PROJECT :
1 X 50MW EXTN. THERMAL POWER PLANT FOR
PROJECT ID : JP0025
M/s. SPECTRUM COAL & POWER LIMITED.
PREPARED BY VERIFIED BY APPROVED BY DATE : 06.01.15
S.VIJAYASEKAR T. THANAPAL BRR SHEET : 39 of 68
 DESIGN BASIS REPORT –BALANCE OF PLANT EQUIPMENTS

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

ITEM CODE DBR001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT

(heavy class, as per IS: 1239) complete with M.S. flanges, gaskets, M.S. fasteners and
long radius (R=5D) Alloy C.I. bends (in segments of 45º or to suit). Each ash conveying
line shall terminate on top of existing Fly Ash silo of 750 m3 with the help of terminal
boxes.
07.02.03 The capacity calculation is attached below.

07.02.04 The schematic drawing is attached as Drg no: JP0025-75990200-PFD-002

07.03.00 CONVEYING AIR COMPRESSORS

07.03.01 Common 3 No. (2W+1S) screw type oil lubricated compressors with receivers has been
considered for supplying Conveying air to transmit the ash from respective collection
points to silo and fluidization of ash hoppers.

07.03.02 Conveying air compressor capacity shall be selected in such a way that to convey the
total actual ash collected with 30% margin.

07.03.03 Conveying air requirement calculation for worst coal @ BMCR condition, Conveying
air compressor capacity & PID of conveying air compressor shall be submitted during
detail engineering.

07.04.00 Bulk density:

Bed ash Fly ash

For capacity calculation 650 kg/m3 650 kg/m3
For Load calculation 1600 Kg/m3. 1600 Kg/m3.

07.05.00 Sizing calculation

100 % Worst Coal – 1416 Kcal /

Description Unit
Kg. GCV (BMCR)
Total fuel fired kg/hr 107918

Design Ash % % 70%

Total ash generated kg/hr 75543

PROJECT :1 X 50MW EXTN. THERMAL POWER PLANT FOR

PROJECT ID : JP0025
M/s. SPECTRUM COAL & POWER LIMITED.
PREPARED BY VERIFIED BY APPROVED BY DATE : 06.01.15
S.VIJAYASEKAR T. THANAPAL BRR SHEET : 38 of 68
 DESIGN BASIS REPORT –BALANCE OF PLANT EQUIPMENTS

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

ITEM CODE DBR001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT

07.02.00 FLY ASH HANDLING SYSTEM

07.02.01 System below ECO/APH Hoppers:

07.02.01.1 Fly Ash shall be evacuated from ECO Hopper and APH Hopper. Beneath each
collection hopper, suitable M.S. Surge Hopper, manually operated isolation plate valve
and Ash conveying Vessel are provided. RF Type Level Probe is provided in the surge
hopper for initiation of conveying cycles.

07.02.01.2 The Ash Conveying Vessel shall be connected through common conveying pipeline of
suitable size (100 NB) M.S. ERW (heavy class, as per IS: 1239) complete with M.S.
flanges, gaskets, M.S. fasteners and long radius (R=5D) alloy cast iron bends of 400 to
450 BHN hardness (in segments of 45º or to suit).

07.02.01.3 Pipeline shall terminate on top of existing fly ash Silo of 700 m3 with the help of
Terminal Box arrangement. . Suitable opening shall be provided on top of silo for this
purpose.
07.02.01.4 Cast iron Ash conveying vessel shall be of 9 CFT or 12 CFT capacity with operating
pressure of 4.5 kg/cm2 (g) shall be provided. Ash conveying vessels shall be kept in
above ground only.

07.02.01.5 Metallic expansion joint (SS) shall be provided between hopper and ash vessel.

07.02.01 Suitable capacity of Reverse pulse jet Bag filter and level probe (High) will be
provided at top of Fly ash silo.
R3
07.02.02 System below ESP Hoppers:
07.02.02.1 There shall be seven fields in ESP having two hoppers per field. Beneath each ESP
hopper, suitable M.S. adopter / suitable capacity surge chute, a manually operated
isolation plate valve and an Ash Conveying Vessel shall be provided. Set of fluidizing
pads shall be provided in surge hoppers for free flow of ash into ash conveying vessel.
RF type level probe shall be provided in ash conveying vessel to initiate the conveying
cycles. Suitable opening shall be provided on top of silo for this purpose.

07.02.02.2 The Ash Vessels below ESP 1st field & ESP 2nd field hoppers shall be connected
through individual ash conveying pipelines. The vessels beneath ESP 3rd, 4th, 5th, 6th&
7th field hoppers shall be connected in series through a common ash-conveying
pipeline in two rows. Each ash conveying pipelines shall be of suitable size M.S. ERW

PROJECT :
1 X 50MW EXTN. THERMAL POWER PLANT FOR
PROJECT ID : JP0025
M/s. SPECTRUM COAL & POWER LIMITED.
PREPARED BY VERIFIED BY APPROVED BY DATE : 06.01.15
S.VIJAYASEKAR T. THANAPAL BRR SHEET : 37 of 68