WORK INSTRUCTION

Doc No: OPN/WI/99 OPERATION

Issue no- 01 DEPARTMENT
Date: 20.09.2018 Revision No: 00

STAGE#1 FLY ASH SYSTEM

SYSTEM OPERATION & CONTROL PHILOSOPHY:
Fly ash extracted from ESP hoppers to buffer hoppers through vacuum system. Ash from buffer
hoppers transported to dry ash silo or HCSD silo using pressure transport system.
There are total 144 ESP hoppers and 8 APH hoppers in each of the Unit for with a dedicated
ash evacuation system.
ESP hoppers of each unit are grouped in four nos. of streams viz Stream-A/B/C/D
corresponding to ESP Pass-A, B, C, D.
Each stream is having four branches and each of the branches is having nine ESP hoppers.
Every branch is having a pneumatically operated isolating valve named BRANCH HEADER
VALVE. Each ESP hopper is having one pneumatic/cylinder operated Ash intake dome valve
and one manual plate isolation valve (for maintenance purpose). Actual flow of ash from any
ESP hoppers occurs when its ash intake valve is in open condition. There will be one air intake
valve in each branch, which will allow requisite amount of air drawn into the system as per
requirement.
Following equipment’s are associated with fly ash system for Fly Ash (Vacuum + Pressure)
Conveying System:

• Vacuum Pumps.

• Vacuum Breaker.

• Buffer Hoppers.

• Bag Filters.

• Switch Valves.

• Vacuum Conveying.

• ESP & Buffer Hopper Fliuidising Blowers and Heaters.

• D pumps.

• Transport Air Compressors

• Instrument Air Compressors.

• Transport Air Dryers.

• Instrument Air Dryers.

Vacuum pumps and associated valves: There are four (04) pairs of vacuum pumps in each
unit. Each pair is dedicated for one pass of vacuum system (36 ESP hoppers) .Each vacuum
pumps connects with individual Buffer Hopper.
Start permissive: All conditions listed below shall be satisfied:
1) Pump seal water pressure is normal i.e. NOT LOW (1 ksc).
2) Dust sensor value is NOT HIGH.
3) Corresponding vacuum path is THROUGH.
Protection stop conditions: Pump will trip if any of the conditions listed below occurs:
1) Pump seal water pressure is LOW.
2) Dust sensor value is HIGH.
3) Vacuum conveying path is NOT THROUGH.

THROUGH CONDITION OF VACUUM CONVEYING PATH:

1) Ash line to BH diversion valve of Selected Buffer hopper’s is OPEN and corresponding
valve of stand by BH is CLOSED.
2) Vacuum line valve near selected Bag filter is OPEN.
3) Selected vacuum pump suction valve near to vacuum pump is OPEN.
4) Any fluidizing blower is ON.
5) Dense Phase Conveying Path is through.
6) In case the vacuum conveying path of selected pass is not through, an alarm indication will
appear at HMI “VACUUM PATH NOT THROUGH”

Vacuum Pump Seal Water Valve: Valve will operate from start command of corresponding
vacuum pump when the pump selected for operation.
Buffer hopper / bag filter end vacuum line valve and Vac pump end vacuum line valve:
Valve will operate & align automatically as soon as that buffer hopper and corresponding
vacuum pump selected for operation.
Vacuum Breaker at vacuum pump end and at buffer hopper end:
For each vacuum conveying line one number vacuum breaker is at suction side of vacuum
pump and one number vacuum breaker at buffer hopper end.
Closing of Vacuum breaker: The vacuum breaker will be closed (under both “Auto” and
“Manual” operation) through’ actuation of “SYSTEM START” command for the conveying
stream connected with the said conveying path.
Close permissive conditions: All conditions listed below shall be satisfied:
1) Associated Vacuum conveying path is through.
2) Selected vacuum pump is running.
3) Vacuum level (VAC-LL) achieved in line.
Protection open conditions: Breaker will trip/open if any of the conditions listed below
occurs:
1) Activate system stop command.
2) Associated Vacuum Conveying Path is not through.
3) Operating Vacuum pump is tripped/OFF.
Auto close conditions:
1) System Start initiation from HMI.

BAG FILTER:
Fly Ash air mixture conveyed by each fly ash conveyor under vacuum system separates in
dry form in bag-filter, and gets stored temporarily in the buffer hopper directly below the bag
filter. There are four (04) sets of bag filter and buffer hoppers corresponding to four streams
of each unit. Every pass of dry collection is associated with one such bag filter assembly.
Each bag filter is fitted with Solenoid valves. Each solenoid will purge the air for 100 millisec
(approx.) and time gap between two solenoids shall be 10 sec. (approx.). Once all the
Solenoids have purged in sequence i.e. one cycle is completed, another cycle of purging will
start only after a time gap of 40 sec. (approx.).
The pulse jet cycle of the selected buffer hopper / bag filter will START with the selection of
corresponding bag filter / buffer hopper and the same shall stop automatically (after a pre-set
time) with actuation of “SYSTEM STOP”.

FLY ASH FLUIDISING BLOWERS

Fluidizing blowers (1W+1S) is for fluidizing of dry ESP field hoppers & Buffer Hoppers.
Start standby fluidizing blower manually in case of working fluidizing blower trips
Starting permissive conditions
• DP across suction filter NOT HIGH.
Protection Stop condition
• DP across suction filter HIGH (200mm water gauge) (60 sec delay).
Fly Ash Fluidising Heaters
One no. fly ash fluidising Heater containing two heater banks is for each fly ash fluidizing
blower. Fly ash fluidizing heater started as soon as starting of fly ash fluidizing blower.
Each Fly Ash Fluidising heater is having two banks of heaters. Temperature controller has
provision for three set points namely temp. Low (TC1-80 deg.-Bank-2 ON), temperature Hi
(TC2-122 deg.-Bank -2 OFF) and temperature. Very Hi (TC3-160 deg.-Bank-1 &2 OFF).
Ash line to Buffer hopper diversion valve:
There are four nos. fly ash evacuation pipelines for conveying ash from ESP Hoppers to Buffer
Hoppers for each unit. Each evacuation pipe line is having one no. 1/2 way Pneumatically
operated dome diversion valve to divert the ash into working buffer hopper or standby buffer
Hopper ( say for Pass-A these will be A1 , A2) thru a separate pipe line.
Preconditions:
Current cycle of any system is not ON.
Destination Buffer Hopper level is not high.
Switch valve is not under fault.
Operation: These valves are solenoid energized to open type. So solenoid of route to be used
will energized and solenoid of other route will remain de-energized.
Confirmation: Open position confirms by open limit switch. Close position confirms by seal
pressure switch.
Control Action in case of valve fault.
1) Switch valve fault indication is raised.
2) System cycle, if in progress, continues undisturbed.
3) Next system cycle inhibits.
BRANCH HEADER SWITCH VALVES: Four nos. fly ash conveying pipelines for
conveying Fly ash from ESP Hoppers Branches to Buffer Hoppers of each pass. Each
conveying pipe line is having one no. 2/1 way switch valve for branch 1 & 2 and two (2) nos.
1/1 way Switch Valve for branch 3 & 4 of each ESP pass to convey the ash from selected
branch ESP hoppers to Buffer hoppers.
ESP HOPPER FLUIDIZING VALVE: Fluidizing air in hot condition is provided to ESP
hoppers of 1st field to 9th field. In each Branch of ESP hoppers all fields hopper are connected
with one solenoid operated fluidizing air valve. These valves will open sequentially by getting
opening pulse of respective branch header switch valve.
In AUTO mode, fluidizing air pneumatic valve associated with all fields hoppers of the
selected branch will open automatically by default with the aligning of respective branch
header switch valve.
Ash Intake valve:
Only one no. ash intake valve of hopper of selected branch of each stream will open at a time
in auto as well as manual model of extraction.
In auto mode the ash intake valve of hopper of the selected branch will open as per logic
sequence after action of “Sequence Start” push button.
 In Manual mode the ash intake valve of a particular hopper will be selected in the following
manner: Selection of branch, Selection of hopper required for cleaning, System Start
command.
OPEN PERMISSIVE conditions for ash intake valve: All conditions listed below shall be
satisfied:
1) Vacuum Breakers of selected stream path are closed.
2) Hopper is not bypassed (in auto mode).
3) Any fluidizing blower is ON.
4) Selected buffer hopper level is NOT HIGH.
5) Selected BH/bag filter PJT is ON.
6) Selected bag filter DP is NOT HIGH.
7) Selected vacuum pump is ON.
8) Line vacuum is >= VAC-P.

PHILOSOPHY OF OPERATION OF VACUUM HOPPERS CONVEYING

FLY ASH HOPPERS EVACUATION SYSTEM (VACUUM CONVEYING)
System operation sequence: - Sequence described below is for one stream. Similar will be
applicable for other streams also.
1) STREAM A VACUUM SYS – AUTO /MANUAL selection.
2) STREAM A – DRY MODE1 / DRY MODE2/OFF: - If mode1/2 is selected, buffer
hopper 1/2, vacuum pump 1/2 and associated valves will be working / aligned. In case
of OFF mode none of above will be selected.
3) Evacuate / Bypass selection switches for individual Hopper of ESP and APH. As well
as select/deselect all hoppers and select/deselect all hoppers of branch is provided. In
Evacuate mode system will evacuate ash from that hopper in Auto mode normally. But
if any hopper is selected in Bypass mode then Auto evacuation cycle will bypass this
hopper and will select to next selected hopper for evacuation in the same branch.
4) System Start/Stop selection switch for each Stream: This S/S is provided for Starting
and Stopping the process in Pass for all Branches (1, 2, 3 & 4) . If this S/S has been
put on Start position after checking and getting starting permissive OK then only
vacuum system will start evacuation of ash in sequence.
Pre-Condition Check Button for checking healthiness of various values.
5) Line Block Reset button :- In case branch blocked conditions arises then system will
stop evacuation process and Branch Blocked alarm will come. After clearing the
branch press the Branch Block Reset button to remove the alarm and after that only
operator can start the system again.
 6) Line Vacuum transmitter set point for smooth operation of the vacuum system:
• Line Vacuum permissive-115 mm Hg- Hopper Empty. Change Over to Other
Hopper.

• Line Vacuum permissive-130 mm Hg- MHV open for next hopper.

• Line Vacuum Permissive-270 mm Hg- MHV Open (Material Feeding

Start).Material Handling Dome Valve to close -330 mmHg .

• Line Vacuum Permissive-330 mm Hg -Air Intake Valve Open. Air Intake Valve
Close when Line Vacuum -270 mm Hg.

• Line Vacuum Permissive-360 mm Hg- Comman vacuum line(AI1) breaker

open.Comman vacuum line breaker close—340 mm Hg.

• Line Vacuum Permissive-500 mm Hg- Vacuum breaker open.

PRE -START CHECKS:

i) one instrument air compressor with air dryer running.
ii) one ESP Fluidising Blower is running.
iii)Evacuate / Bypass Selection for hoppers / branches are selected.
iv)Physically check that all manual valves are open or closed as per the system requirement.
vi) Start PJT of selected bag filter, if not already ON.
vii)Selected Buffer Hopper level is NOT HIGH.
viii) Associated valves of vacuum side and ash side isolation are open.
ix)Associated valves of other i.e. stand by buffer hopper/ vacuum pump side are not in fault.
x)Selected vacuum pump is ON.

Operation Sequences:
1. Branch header valve of first branch will open in auto. In manual mode the branch header
valve of selected branch will open. Fluidizing valve of corresponding branch will also open
with the open of header valve.
2. Vacuum Pump Starts & one ON delay Timer (5-10 Secs) Starts. On expiry of timer closes
the Vacuum Breakers of vacuum pump end and buffer hopper end. When line vacuum goes
up to 170mmHg VAC-P for around 30 secs it means Line Vacuum OK and system is ready to
take fly ash in line.
3. When vacuum level (VAC-P) reaches, ESP 1st field ash intake dome valve of selected first
Branch is opened.
4. Now fly ash is being conveyed from hopper through Fly ash line to the selected Buffer
Hopper.
5. Conveying from hopper will continue until line vacuum falls below VAC-L (115 mmHg)
and persists for a preset time (approx. 5 sec adjustable). This condition implies “HOPPER
EMPTY” status and respective ash intake valve will close & the same ,results vacuum build
up in vacuum line. A vacuum low preset timer also starts at the same time.System will recheck
again by opening MHV and vacuum fall below VAC-L.
6. If Vacuum low timer expires & Vacuum doesn’t reaches the permissive level (VAC-P) then
“Vacuum Low Alarm” will come.
7. When Vacuum reaches line running permissible level VAC-P (130mmHg) then Sequence
will jump to the next selected hopper of the branch and further sequencing will be same as in
case of Ist hopper.
8. After the fly ash hoppers of Ist branch are cleaned, the sequence will jump to next branch
and its branch header valve will open. The branch header valve of first branch will close with
the opening of branch header valve of next branch. In manual mode branch selection are to
be done manually and header valves opens based on branch selection.
9. Opening / closing of fluidizing air valves will be in correlation with branch header valves.
However, when no branch header valves are opened, this will be in timer mode.
10. If, required, at any point of time of ash evacuation through a particular hopper, the
sequence can be shifted to next selected hopper by pressing “ JOG PB” from screen. This will
close the ash intake valve of present hopper and shift the sequence to next selected hopper.
This PB is applicable for auto mode.
11. In auto mode - with the Actuation of “SEQUENCE STOP” push button the ash intake
valve of current hopper will close and sequence will retain at that hopper. Sequence will
resume from that hopper when sequence start is again pressed.
12. When SYSTEM STOP is pressed, purging of vacuum line starts for a preset time and them
the vacuum breakers opens and branch header valves closes to conclude that fly ash vacuum
system operation is over.
13. When line vacuum reaches to VAC-N (330mmHg) Air intake valve of the selected branch
will open. This will help in fast evacuation of ash and maintain the line vacuum with in limits.
Air intake valve closes when vacuum returns to 270mmHg.
14. If line vacuum keeps on rising and reaches VAC-H (340mmHg), comman VB will open
and when vacuum falls below (320 mm Hg) VB closes.
15. If vacuum level rises above a preset vacuum level VAC-HH (500mmHg) during the
process of evacuation of material through any hopper of selected branch, then this signifies
that Line is getting chocked and VB will open.
16. Shutdown Sequence / purge sequence:
All hopper selected in the system has been evacuated, then purge the line,after that system go
to shutdown mode.
 • Vacuum breaker opens and the system goes to shutdown mode.

• At first, Vacuum Pump is stopped.

• After a preset time (say 5 minutes), Bag filter is switched OFF.

17. Manual Operation: In manual model branch and individual hopper selection under a
stream is to be done by operator manually. However system will start operating with the
initiation of SYSTEM START button.
PHILOSOPHY OF OPERATION OF PRESSURE TRANSPORTATION SYSTEM
AND D-PUMP SYSTEM:-
For each unit two nos Buffer Hoppers are provided for each stream, so total eight nos. Buffer
Hoppers are present for each unit. Nomenclature of buffer hoppers are A1, A2, B1, B2, C1,
C2, D1, D2 respectively for Stream A, B, C, D. Each Buffer Hopper is provided with three
nos. D Pump vessels connected to separate pressure conveying line to evacuate the Dry ash
from Buffer Hoppers to Selected Fly Ash Silo or HCSD silo. Nomenclature of these pumps
of buffer hopper A1 will be A11, A12, and A13 and for buffer hopper A2, these will be A21,
A22, A23. Similarly for other buffer hoppers.
Each D-pump is having its inlet valve, outlet valve, vent valve, balancing valve and fluidizing
valve. Nomenclature of these valves will be in line with their associated buffer hopper.
There are 3 pressure conveying lines below buffer hoppers of each unit. Nomenclature of
these lines of unit will be CONY LINE1, CONY LINE2, CONY LINE3.
CONY LINE 1/2/3 can be connected to working transportation line or normal stand by
transportation line with the help of pneumatic actuated valves.
Each of the above mentioned 3 transportation lines are connected to each of the dry ash silo
as well as HCSD silo through pneumatic actuated valves.
There are 3 nos. transportation air compressors for each unit. Nomenclatures of these are
TAC-A, B, C. Normally two TAC shall be working and one will be stand by. TAC-A is
connected to TAC header-1 and TAC-C is connected to TAC header-2 through their respective
discharge valves. However TAC-B which is stand by can be connected to either TAC header-
1 or TAC header-2 through isolation valves.
TAC discharge header1 and TAC discharge header-2 will supply transport air to CONY LINE
1 and CONY LINE 3 respectively. However CONY LINE 2 can take transport air either from
header 1 or from header 2 depending on the selection.
First vessel is connected with Conveying air source and hence called Master vessel i.e. in case
of Unit-1, all three D Pump provided below Buffer Hopper#D1 or D2 are called the D Pump
Masters & each D Pump Master individually connected with separate conveying line.
However in case of Unit-2 D-pump corresponding to buffer hoppers A1 / A2 will be master.
The other vessels are using conveying air thru the first vessel hence called Slave vessels. Only
two pressure conveying line will convey Ash at a time & one convey line will act as a standby
line.
 Only two D Pump of operating Buffer Hopper with separate two nos. conveying line will be
in operation at one time out of eight nos. D Pumps of 4 selected buffer hoppers.
Conveying will be in rotation for all four sets i.e. after completion of one conveying cycle of
set say set-4(pass-D) D Pump Vessel, conveying cycle of set-3(pass-C) D Pump Vessel system
will start and so on till last set-1(pass-A) D Pump Vessel in consideration of enabling
conditions i.e. Only four vessels from four sets of buffer hoppers (1 to 8) will convey the ash
in close integration i.e. when one vessel is conveying; the other three vessels are in under
depressurizing ,filling , pressurizing and vice versa.
STANDARD PHILOSOPHY OF OPERATION FOR SUB SYSTEM SELECTION FOR
CONVEYING:
One system (say one vessel each from Set-1 to set-4) is considered having 4 systems operating
in firing sequence of 1+1+1+1. This means the system has 4 sub systems each comprising of
single vessel.
All the four sub systems will be operating in a sequence, based on Counter programmed in
the DCS. Only one sub system selected can convey at a time. Normal sequence of sub system
selection shall be starting from Set-4 then shifting to Set-3 followed by Set-2 and Set-1 and
then back to ash Set-4 again.
One no counter is used for the sub system selection procedure. Counter preset value is set as
per the sub system nos.
Starting Permissive check Button: This button will give the OPEN command to all
associated valves of all D Pump vessels & Crossover valves momentary for checking the
healthy conditions before starting the Dense phase system. If problem persist the related
system will be taken for Maintenance & healthy/Standby system shall select for operation
Healthy Conditions of Buffer Hoppers:All D Pump vessels associated valves (DV-1, DV-
2, DV-3, DV-4 & Vessel Fludising) of at least selected two conveying line shall be healthy for
operation.Crossover valves (DV-1, DV-2, DV-3, DV-4 & DV-5) mounted on conveying lines
shall be healthy. Two Conveying line for evacuation of Dry Ash from Buffer Hoppers to Fly
Ash Silo shall be selected by operator.
Dense Phase Path through condition is generated when buffer hopper and conveying line
selection is over.
Filling cycle of all vessels can start independently.
Vessel pressurization is also independent of each other.
However conveying (i.e. unloading) of all four vessels of four different sets will be in
succession only.
System Actuation:
One no start / stop selector switch provided on master Vessel pneumatic panel shall be select
in Start Position.
One set of start / stop push buttons is devised on DCS. System will start in the selected mode
as soon as the same is started from DCS
CONY LINE THROUGH PERMISSIVE FOR A LINE :- All conditions listed below shall
be satisfied.
i) Vent filter Fan on top of selected silo is running and its PJT is ON.
ii) Selected silo ash level NOT HIGH.
iii) Pressure conveying path is through for Line-1 i.e. all associated valves upto selected silo
for LINE-1 are open.
iv) TAC-A is ON & its discharger valve is open or TAC-A OFF & its discharge valve close &
TAC-B ON & its discharge valve to TAC header 1 open.
v)Any Fluidizing Blower is running.
vi)Permissive conditions for Line-2 and line-3 will be identical to LINE-1.
Enable conditions for D-pump:
1) Seal pressures of dome valves (DV-1, DV-2 & DV-4) are O.K.
2) Vent dome valve (DV-3) seal pressure is low.
3) Seal pressures of dome valves (DV-2 & DV-4) of other associated vessels on same
conveying line are O.K.
4) Associated Buffer Hopper’s Level is not low.
5) Vessel Pressure (PS-2) is OK.
Protection Stop:
i) Seal Pressure of dome valves (DV-1, DV-2 & DV-4) seal fails is raised.
ii) Seal pressures of dome valves (DV-2 & DV-4) of other slave vessels are not O.K.
iii) Selected Fly Ash Silo level is high.
iv) Convey air pressure is low (PS-4).
v) Line Block Alarm is raised during conveying.
vi) Seal pressure of crossover valves & dump valve seal fails is raised.
vii) Instrument air pressure for silo bag filter pulse jetting is low.

OPEARTION:
In case outlet dome valve & balance dome valve Seal pr. of one vessel are OK but any other
enabling conditions are not OK then the other Vessel can be started for feeding the material.
OPERATION CYCLES OF A D PUMP VESSEL
 It divided in 4 operating groups:
i) System Selection / Start Up
ii) Transfer / Filling and Conveying Cycle
iii) Routine Shut down Mode
iv) Shut Down Mode

Prepared By Approved By
Prashant Chandankhede DP Patra

DGM(operation) AGM(operation)