STAGE-I HCSD SYSTEM:-

The fly ash from the 2x500 MW CPP is collected in dry form in 3 nos. HCSD silos.
Each

HCSD silo is having two types of dry fly ash unloading system. One (1) no. dry

unloading system & two (2) nos. wet (Slurry) unloading systems for High

Concentration Ash Slurry Disposal system are provided.

Major Systems :
The High Concentration slurry disposal system can be divided into two major
sections.

First : Slurry preparation system:

⦁ Extraction and dosing of fly ash from the silos.

⦁ Mixing of the fly ash with water in ash mixers to form thick slurry.

⦁ Mixing and homogenization of high density ash slurry in ARTs.

Second : Slurry transportation system:

⦁ Charge pumps.

⦁ HCSD piston diaphragm pumps.

⦁ Main pipelines.

Systems for controlling of Feed/HCSD system :

⦁ FA Feed Start button

⦁ FA Feed Stop button/ Shut Down button

⦁ Emergency Stop

⦁ Flushing Cycle Start (Time base Adjustable in Mins. )

Flushing Cycle Stop (Stop Command or Time whichever is first)

SPECIFICATION:

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Capacity of HCSD SILO : 3 Nos. X 350 TONN
⦁ HCSD CHARGE PUMP DETAILS (3 Nos.):-

- PUMP CAPACITY - 265 M3/Hr.

- MOTOR RATING - 75 KW

⦁ HCSD PUMP DETAILS (3 Nos.):-

-HCSD SYSTEM CAPACITY :- 190 TPH

-DESIGN CONCENTERATION :- 60% + 5%

-RATED CAPACITY OF P/P :- 223 M3/Hr.

⦁ MIXING TANK/ RETENTION TANK (3 Nos.):-

- NO. / HCSD SILO :- ONE

- CAPACITY:- 30 MIN. RETENTION

- ELECTRICALLY DRIVEN MECHANICAL AGITATOR

⦁ UNLOADING EQUIPMENT PER SILO:-

- RVF (Rotary Vane Feeder) 2 NOs. / SILO , Capacity- 190 TPH

- Dry RVF for Unloading Sprout 1 NO. , Capacity- 100 TPH

⦁ -ASH CONDITIONER : 2 Nos. / SILO , Capacity- 190 TPH

⦁ HCSD SILO BLOWER WITH HEATER DETAILS:-

-3 NOs. (2W + 1 S/B) ,

-Cap:- 996 M3/Hr

-Heater Capacity- 18 kW per Blower

PRE START CHECKS:

⦁ Ash water sump is above low level (>2.7 M ).

⦁ Sump makeup valves are operational,supply is normal and working in auto.

⦁ HT/LT swgr for the HCSD and other assosiated auxiliaries and water pumps to be
run is in charged condition.

⦁ Any FAHP pump is running and pressure ok.

⦁ Any fluidising blower in running condition.

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⦁ Instrument air for valve operation is available and pressure ok.

⦁ Pumps bearing and motor bearing temperature are normal at local.

⦁ Earthing strip of motors are connected.

⦁ Local guages are in charged condition and healthy.

⦁ HCSD pump oil level are normal,no alarm persisting.

⦁ All manual valves are in open condition of HCSD system being taken in service.

UNLOADING SYSTEM:
In dry unloading system fly ash unloads via plate valve (manual & cylinder operated),

rotary vane feeder & telescopic spout to the trucks.

In Wet (slurry) unloading system fly ash unloads via a surge hopper ,inlet dome
valve,

bin weighing system, rotary Vane Feeder, solid flow meter and an ash Mixer to the

agitated Mixing Tank (ART).

Dry unloading System:

For unloading of fly ash from each HCSD silo one no. set of equipments are proved
for

dry unloading of ash to the truck. Equipments are:

⦁ Manual operated Plate valve.

⦁ Pneumatically operated plate valve.

⦁ Dry unloading rotary feeder (Variable Frequency Drive controlled).

⦁ Telescopic unloading spout

The system will be operated from Local HCSD silo dry unloading Panel only.

Check Points

Before starting the system operation, check and confirm the following:

⦁ Ensure that the truck is placed in position.

Starting Sequence

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⦁ Start Silo Fluidizing blowers . (If not already ON).

⦁ Start Silo Fluidizing heaters . (if not already ON).

⦁ Start respective HCSD Silo telescopic spout down.

⦁ After a “Telescopic spout down position indication” at Panel, start dry unloading
spout fan(Status-ON).

⦁ Dry unloading spout filter timer unit also starts automatically.

⦁ Start dry unloading rotary feeder(Status-ON).

⦁ Open dry unloading system unloading plate valve.

When the spout truck full level is achieved, operator to stops the unloading system
in

following sequence:

Stopping Sequence

⦁ Close dry unloading system unloading plate valve .

⦁ Stop dry unloading rotary feeder ,then telescopic spout can be raised UP.

⦁ When the spout reaches its UP position dry unloading spout Fan and its timer
unit are automatically stopped.

⦁ The unloading system has stopped and can be started again when the next truck is
available.

Dry fly ash weighing and dosing system:

System will comprise of following main components for each silo:

⦁ Two fly ash dosing and weighing systems.

⦁ Two Ash conditioners under each dosing and Weighing system.

⦁ One ART’s equipped with vertical mixers.

⦁ One water dosing lines for each ART.

⦁ One slurry control loops for each ART.

⦁ One Charge pumps.

⦁ One Suction strainers.

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⦁ One Mainline HCSD pump piston diaphragm slurry pumps.

⦁ One Slurry transport pipelines with distribution system on storage area.

Wet System Operating sequence:

FA feed sequence:

First select the desired system to unload. Then operator will provide a
“Preconditions Check” Command to Main PLC and then system will check all the
healthy conditions given below:-

Pre-conditions:

⦁ Discharge Dome valve at silo outlet is not under fault.

⦁ Bin weighing system is not under fault.

⦁ VFD controlled Rotary Vane feeder is not under fault.

⦁ Ash Mixer is not under fault.

⦁ Ash mixer is in remote mode.

⦁ Fly ash water header flow OK.

⦁ Instrument air pressure OK.

⦁ Bag Filter is in remote and not under fault or Bag filter already ON by operator.

⦁ ART agitator is in remote mode & not under fault or already running.

⦁ Charge pump is in Remote & not under fault.

⦁ HCSD pump in Remote selected from Main PLC SCADA screen & not under any
fault.

⦁ When all above preconditions are OK, then “FA feed System Ready” will come.

Sequence to start the FA feed, if the preconditions are OK:

⦁ Make up water valve is opened to start filling the ART.

⦁ When water level in ART is above min. level (say 10-15%), open Ash conditioner
header water valve.

⦁ At the same time, agitator is also started.

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⦁ Now make up water valve is closed.

⦁ Ash mixer is started.

⦁ Discharge Dome valve Shall Open to take Ash in Surge Hopper.

⦁ After getting Surge hopper filled signal from Load Cell.

⦁ Close Dome valve.

⦁ Rotary vane feeder below Surge hopper shall start & fluidizing valve for Air Slide
shall open. (In addition Bag filter fan must start if not already started.)

⦁ Water Valve will operate as per Slurry parameters required.

⦁ After getting proper ash rate sample calculations, give a start command to Hose
Pump.

⦁ Exact fly ash feed rate will be adjusted by varying the rotary vane feeder speed as
per the signal received from SFM .

⦁ Flushing water requirement will also be met by opening the branch valves and
controlling the motorized control valve.

⦁ Now FA feed system will be operating as an integral part of the HCSD system.

Parameter to set

⦁ Fly ash rate to be fed to ART (in TPH)

⦁ Slurry concentration desired to be prepared in ART (in %)

Pump System
Before starting the system, following parameters shall be set / checked :

⦁ Slurry Concentration.

⦁ Fly ash TPH to be conveyed.

⦁ Normal working pressure.

For operation of HCSD system there are few facilities provided below:

⦁ HCSD Prestart Button .

⦁ HCSD System Start.

⦁ HCSD System Stop.

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⦁ HCSD Emergency Stop.

Preconditions:

Set Parameters as mentioned above.

⦁ HCSD Pump PLC is in remote mode.

⦁ HCSD Pump PLC is not under fault.

⦁ Fly ash feed system is ready to run or already running.

⦁ Fly ash water pressure is OK.

⦁ Instrument air pressure is OK.

⦁ VFD for HCSD pump is not under fault.

⦁ Lubrication & propelling pumps for selected HCSD system in remote & not under

fault or in running condition manually.

⦁ Charge Pump Ready to Start/Remote mode & not under fault.

⦁ Suction valve for Charge pump not under fault.

⦁ Level in ART is more than 20-25% (adjustable).

System Startup Sequence:

⦁ Open Suction Knife gate valve for charge pump.(open,then)

⦁ Open seal water solenoid to charge pump.(pr. Ok,then)

⦁ Start the charge pump .

⦁ When sufficient suction pressure is available , Pre-start command to HCSD

system.

⦁ HCSD Pump will provide start request for Power end lubrication pump &

propelling pump.(if both pp on,then)

⦁ Main PLC will provide run signal to HCSD.

⦁ HCSD Pump PLC will check for other healthy conditions and give Pump ready to
start signal to Main PLC.

⦁ Now only Main PLC will give the HCSD pump start command to HCSD Pump PLC.

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⦁ HCSD Pump will start at 10% speed and ramp-up to 20% at a preset rate defined in
the VFD and hold.

Ramp-up Sequence:-

⦁ Limit of 20% can be adjusted from PC based on exact slurry behavior at site.

⦁ Line pressure is monitored continuously.

⦁ If the pressure is not stable and is shooting up but within limits, pressure can be

allowed to increase.

⦁ If the pressure further increases, the pump trips (HCSD system only goes into Shut
down Mode).

⦁ When the pressure starts reducing and comes down, fly ash can be introduced
into the system.

⦁ Now start taking Fly ash into the ART at full preset TPH.

⦁ Water feed rate will also increase accordingly to maintain the slurry concentration.

⦁ When slurry level reaches 30% in the ART, further ramp-up of the pump starts.

⦁ Slurry level in the ART is finally maintained near 65-70% while maintaining the FA
feed rate at the set value.

⦁ Monitoring of Slurry control loop is started at this point.

⦁ If the fly ash is not available, water need to be increased to maintain the flow.

⦁ After this time, operator can decide to run the system at reduced flow with
normal

FA feed or at full flow with max. FA feed.

⦁ Slurry system can be stopped in regular shutdown if sufficient fly ash is not
available for conveying.

System Stop Sequence:

Depending upon the conditions, system may have to be stopped in following

different

ways:

⦁ Normal System Stop

⦁ Emergency Stop

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a) Normal System Stop

Each time a normal system stop is executed; system shall follow the sequence as

follows:

⦁ At first, HCSD silo Dome valve is closed.

⦁ Then Rotary Vane feeder is stopped after clearing/emptying of Surge Hopper

(Confirmed by Load cell assembly).

⦁ After another 5 minutes of Rotary Vane feeder stop, ash Mixer is stopped after it
is cleaned by feeding only process water (100% opening of Motorized valve).

⦁ At this point hose pump (Control Loop sequence) is also stopped.

⦁ The makeup water valve is opened and fills the ART to 50-70% level.

⦁ The HCSD pump will ramp up to maximum capacity (50 spm).

⦁ The system will pump water for 20-30 minutes (Flushing Time), after which
makeup water to ART is stopped.

⦁ Charge pump and HCSD pump will stop when “low low level” in the ART is
reached.

⦁ The level in the ART is allowed to lower until “low level” is reached.

⦁ Now Agitator shall Stop and then after stop feedback.

⦁ After 1 sec., suction valve of the charge pump is closed.

Emergency System Stop

An automatic emergency system stop can be generated when one of the

components in

the system will suddenly stop operating or an instrument will give a signal which will

initiate an emergency stop. When it is expected that the system stop will last for

several hours the operator is advised to clear the line of slurry.