Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) STANDARD DESIGN CRITERIA/GUIDELINES FOR BALANCE OF PLANT OF THERMAL POWER PROJECT 2x (500MW OR ABOVE) SECTION-3: ASH HANDLING PLANT 3.1 INTRODUCTION In a coal based thermal power plant, huge amount of ash is generated which has to be disposed off continuously. Typically for a 2x500 MW plant based on indigenous coal, the amount of ash generated is around 300 to 400 TPH depending on gross calorific value and ash content of worst coal. The ash handling system covers evacuation of ash and disposal in wet, semi wet and dry form, ‘The ash is produced in two forms viz. fly ash which is of fine texture and bottom ash which is comparatively coarser. The ash entrained in the flue gases and captured in electro-static precipitator (ESP) is termed as fly ash and the ash which falls at the bottom of the boiler furnace is known as bottom ash. Small quantities of ash are also collected in the air pre- heater, economizer and stack. ‘The design of ash handling system in a power station is based on the following considerations: i) Station capacity , gross calorific value and ash content of worst coal Station capacity, gross calorific value, BMCR requirement and ash content of worst coal determine the quantum of ash to be handled and thus the sizing of the equipment in Ash Handling Plant. ii) Utilisation potential and mode of ash disposal As per MOEAE stipulations, full capacity dry fly ash extraction system is provided to facilitate utilization of fly ash in dry form. Wet slurry system is additionally provided to cater to 100% ash and is used to dispose the balance unutilized fly ash tll its full utilization is achieved, Alternatively high concentration slumy disposal system (HCSD) may be adopted. In cases where full utilization of fly ash is possible from the inception of the power plant on continuous basis, wet slurry disposal can be avoided for fly ash. The bottom ash is, however, disposed off in slurry form in most of the power stations. In some of the power stations, semi-wet method of disposing bottom ash is adopted by use of hydro-bins and the ash collected is then disposed off directly from hydro bins for end use. Lately dry bottom ash collection and disposal has been adopted in one of the power stations in the country. 341Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) iti) Layout, conveying/pumping distances etc. Sizing of transport compressors for transporting ash up to silo, vacuum pumps / conveying compressors for ash evacuation from ESP, slurry pumps for transporting wet ash slurry upto ash pond depend upon layout of the plant, conveying/pumping distances, topography of the area, routing of pipelines etc, For example, elevation and distance of ash pond from pump house affects the size of the slurry pumps. Higher distance and elevation can lead to requirement of booster pumping in some cases. As such the size of various ash handling equipment is site specific and depends on various factors as above. 32 SYSTE! ‘The ash handling system of a power station normally consists of the following: 3.2.1 Bottom Ash (BA) System i) Bottom ash of each boiler is collected either in a water impounded hopper for disposal using jet pumps or in a dry type hopper using submerged scraper conveyor system as described below. a) Bottom ash of each boiler is collected in a water impounded, storage type, double V/°3-V" shaped hopper for intermittent removal. It is pertinent to note that shape of hopper depends on furnace configuration as well as amount of bottom ash generation, which varies from project to project, based on source of coal. Each bottom ash hopper has provision for continuous make-up and overflow. Two (2) discharge outlets (one working and one standby) are provided under each V- section. Each outlet is fitted with a feed gate and clinker grinder. The ash at the exit of the clinker grinder gets mixed with the water to form slurry while pumping with the jet pump. Each jet pump is provided with independent bottom ash slurry transportation pipeline upto common ash (fly ash & bottom ash) slurry pit for pumping finally to the ash poné. Alternatively, semi-wet method of disposing bottom ash is adopted by use of hydro-bins and the ash collected is then disposed off directly from hydro bins in semi-dry form for end use. b)_ Dry type hopper with submerged scraper conveyor system is provided which evacuates bottom ash on continuous basis. The bottom ash slurry in this case may be sent to a bottom ash slurry sump through the ash slurry trench by the use of gravity flow to the extent possible. The bottom ash slurry may be pumped from bottom ash slurry sump to main ash slurry sump by use of centrifugal pumps, if gravity flow is not possible. The system consists of dry type bottom ash hoppers, hydraulic cylinder operated horizontal type hopper outlet gates, submerged serapper conveyors, clinker grinders, bottom ash slurry sump / trench upto common slurry sump ete. 32Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) ii) ii) 3.23 ii) AS an alternative to disposal of bottom ash in slurry form, the ash may be conveyed in semi-wet form through belt conveyors to the ash dyke. ‘The coarse ash collected from the economizer hoppers is connected to the bottom ash hopper top (above the maintained water level) by means of an adequately sized sloping pipe (for transporting slurry by gravity) in case of jet pump system. However if calcium content is high in economizer ash or bottom ash hopper storage capacity is not adequate, then economizer ash is disposed off separately. For submerged scraper conveyor (SSC) system, normally the ash from economiser, is evacuated and conveyed continuously in wet form and the ash slurry is led to ash slurry pump house, through trenches, Fly Ash System (ESP, Air preheater) Evacuation and transportation of dry fly ash is done in two stages, ie. from ESP collection hoppers to the intermediate surge hoppers by vacuum conveying system/ pressure conveying system and from the intermediate surge hoppers to storage silos near plant boundary by pneumatic pressure conveying. Air pre-heater and duct hoppers ash can be conveyed pneumatically, and connected to intermediate surge hoppericollector tanks of ESPs. Alternatively, ash from air preheaters and duct hoppers can be evacuated and conveyed continuously in wet form and the ash slurry led to ash slurry pump house, through trenches, In addition, wet disposal system (to be operated during initial period of plant operation till 100% fly ash utilization is achieved or during emergency when dry disposal is not possible) for fly ash is also provided which directs the fly ash to wetting units to form the slurry and thereafter pumping the same to common slurry pit using jet pumps. Wet disposal system can be medium slurry type or high concentration slurry type. The ash for HCSD disposal can be taken from silo or Intermediate surge hopper, based on the site layout. Ash Water System The entire water requirement of the ash handling system is met from cooling tower blow down of the station and decanted recovery water from the ash pond. A connection from raw water is also provided for fast fill and emergency makeup purposes. Clear water as necessary for equipment sealing and cooling is provided from station clarified water. DM. water may also be used for cooling purposes in closed cycle. In case of once through system in coastal stations using sea water, water for ash handling is tapped from return header of CW system. Ash water system consists of ash water sump, HP water pumps, LP water pumps, economiser ash water pumps etc BAHP (bottom ash high pressure) water pumps are used to extract bottom ash from both units intermittently and sequentially in case of jet pump system and continuously in case of SSC system. In case of jet pump system, BAHP pump supply water for jet pumps, BA hopper flushing, seal trough & gate housing flushing etc. In case of SSC system, BAHP 33Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) 3.2.4 pumps supply water for quenching, BA trench jetting, seal trough flushing, gate cooling, BA sump agitation etc. In case of jet pump system, BALP (bottom ash low pressure) pumps supply water for refractory cooling, BA hopper cooling water to maintain hopper water at 60 deg.C, BA hopper fill and make up, seal trough make up/fill, slurry sump hopper make up water etc. In case of SSC system, BALP pumps supply water for refractory cooling, cooling water for upper trough of SSC to maintain water temp. at 60 deg.C, seal trough make up, cooling water to inspection windows, wash water to grinder, BA sump make up, ash slurry sump make up etc. Fly ash HP water pumps (FAHP) supply water to wetting heads, air washers, F.A. slurryftrench jetting, combined ash slurry sump make up, combined ash slurry sump agitation etc. Seal/cooling water pumps are provided for gland sealing of sturry pumps, vacuum pumps cooling of compressors and sealing water requirement of clinker grinders. Alternatively, plant DM water can be used in closed cycle for cooling purpose. In order to conserve water used in wet ash disposal, an ash water recovery system is provided to recirculate the decanted water from the ash pond and re-using this water for ash handling purposes. BA hopper cooling water overflow can also be re-circulated after treating in settling tank and surge tank ‘Ash Disposal System Dry disposal ‘The dry fly ash from ESP hoppers is conveyed to intermediate surge hoppers by vacuumpressure conveying, which are located as close to the ESP as possible. Fly ash collected in intermediate surge hoppers is pneumatically conveyed to storage silos in a separate area near the plant boundary, with independent access from where itis unloaded into the oper” closed trucks or in railway wagons. Wet disposal While bottom ash handling and disposal shall be in wet mode, wet disposal of fly ash is to be resorted during initial period of plant operation till 100% fly ash utilization is achieved or during emergency when dry disposal is not possible. Fly ash and bottom ash slurry is led to common ash slurry sump. Pre-treatment plant clarifier sludge is also discharged into common ash slurry pit. This combined slurry is then pumped to the ash pond through ash slurry pipelines by centrifugal type low speed ash slurry pumps. ‘The ash slurry pumps may be required to be placed in series (maximum four) for meeting. high head requirement while pumping to long distances and higher elevations. In case of excessively high head requirement of ash slurry pumping a booster station may also be required between ash slurry pump house and ash pond. Ash slurry is discharged in the ash 34Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) 3.25 3.2.6 dyke at strategic locations to ensure even filling of ash pond using pipe garlanding around the dyke. Altematively, high concentration slurry disposal (HCSD) system is employed, which uses, the slurry concentration between 55 % - 70 % depending on specific slurry rheology. Ash Handling System Operation The MOESF notification dated 03.11.2009, stipulates for a 100% ash utilization within four years of commissioning for new plants and reduced land area (50 hectares for a 500MW unit using 45% ash coal) for emergency ash pond. The ash handling plant should therefore, adopt the following modes (option I & option II) of operation: Option 1 1. Flyash disposal: Dry mode (normal continuous operation) and in wet slurry mode (initial operation period till 100% dry fly ash utilization is achieved and emergency operation when dry disposal is interrupted ) 2. Bottom ash disposal: Wet or semi- wet mode Option IT 1. Flyash disposal: Dry mode (normal continuous operation) and in HCSD mode (initial operation period till 100% dry fly ash utilization is achieved and emergency operation when dry disposal is interrupted ) 2. Bottom ash disposal: Wet or semi - wet mode ‘Typical scope of work for 2x500 MW thermal power project is attached at Annexure 3A, Typical flow diagrams (as listed below) of ash handling system for 2 x 500 MW are enclosed 1. Drawing no: CEA-TETD-AHP-001 (Typical flow diagrams for fly ash handling system - 2.x SOOMW coal based thermal power plant (vacuum system)) 2. Drawing no:CE, )-AHP-002 (Typical flow diagrams for fly ash handling system- 2 x SOOMW coal based thermal power plant (pressure system) 3. Drawing no:CEA-TETD-AHP-003 (Typical flow diagrams for bottom ash handling, ash disposal - 2 x SOOMW coal based thermal power plant (submerged scraper chain conveyor system) 4, Drawing no:CEA-TETD-AHP-004 (Typical flow diagrams for bottom ash handling, ash disposal - 2 x SOOMW coal based thermal power plant (jet pump system) 35Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) 3.3. DESIGN CRITERIA AND BROAD FEATURES Capacity of ash handling system 4) Bottom ash disposal system (water impounded hopper type) ‘The water impounded hopper system employs a storage type of hopper and the ash is extracted on an intermittent basis by means of jet pumps. ‘The number of hours of storage of ash in the hopper is determined by calculating the hopper volume considering the following aspects: i) ‘The maximum water level in the hopper under hot conditions shall be as per the recommendations of the boiler manufacturer. ii) The effective ash level shall be considered at least 300 mm below the maximum water level. However, this needs to be decided in consultation with boiler supplier to avoid water splashing on the furnace tubing, iii) The angle of inclination of hopper walls with horizontal shall be 45° (min.) iv) For the purposes of calculation of hopper volume, the bulk density of bottom ash shall be considered as 0.65 ton/m’, ¥y) All the equipments (clinker grinders, jet pumps & piping) shall be located preferably above ground and accordingly the bottom of the hopper shall be kept 1.5m or more above ground. ))__“Inkpot’ shape of the hopper shall be discouraged to the extent possible. ‘The determination of volume with above criteria dictates the no. of times the hopper is to be emptied in one shift. Whereas it shall be endeavored to maximize the storage capacity of B.A. hopper, the ‘minimum acceptable storage capacity shall not be less than 5 hours. If the capacity available is more than 8 hours then the hopper would be emptied once in a shift in 90 minutes period and if the volume available is less than 8 hours but more than 5 hours then the hopper would be emptied twice in a shift Each unit shall have two jet pumps working simultaneously, in case the shape of hopper is double V ( generally for 500 MW units) and three jet pumps working simultaneously, in case the shape of hopper is triple V (generally for 600/660/800 MW units). The choice of having double “V" type or triple “V’ type water impounding hoppers depends on the evacuation capacity per outlet of the hopper based on the available capacity of jet pumps (present maximum capacity of jet pumps:105 tonnes per hour on dry ash basis). 36Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) b) ° d Bottom ash disposal system (submerged scrapper conveyor type) In case of continuous type bottom ash removal system employing submerged serapper chain conveyors (SCC), the system shall be capable of removing bottom ash continuously at a normal rate equal to the bottom ash generated (when firing worst coal on BMCR basis), from furnace bottom of each unit, However, the continuous maximum operating capacity of SCC shall be 25% higher than the amount of BA generation rate, to take care of soot blowing, shutdown, breakdown ete. ‘The minimum operating depth of water in the upper water filled trough of the scraper conveyor shall be 2.0 metres. Dry Fly ash disposal system Fly ash system shall be designed to remove fly ash from each unit in maximum 6 hours per shift of 8 hours while firing worst coal. However system will operate continuously under normal running condition. Ash slurry disposal system i) Ash slurry disposal rate from ash slurry sump to dyke shall be sum of bottom ash conveying rate and fly ash conveying rate as given below: ‘+ Bottom ash conveying rates arrived at as per the criteria mentioned at Clause a) above if the water impounded hopper system alternative is adopted OR Normal bottom ash collection rates as at Clause b) if the submerged scraper chain conveyor system alternative is adopted. During soot blowing conditions, the slurry concentration shall increase. ‘+The fly ash handling system shall be assumed to operate continuously and the fly ash collection rates shall be same as the rales considered for sizing pneumatic conveying system, for the purpose of sizing of the disposal system. ii) The slurry line velocities shall not exceed 2.8mvsec. iii) The value of °C’ factor to be considered for arriving at the pressure drop shall be 140. iv) In case HCSD system is used for ash slurry transportation, the following shall be taken into account: ‘+ Range of concentration for ash slurry pumping shall be 55% to 70% by weight. = System d gn shall be based on 60% slurry concentration by weight. 37Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) e r) + One common HCSD stream shall be provided as standby which can be used for de-blocking with water under choking conditions of disposal pipeline. + The HCSD pump maximum discharge pressure shall consider the discharge pressure requirement during normal operating condition while discharging slurry at design concentration of 60% and a minimum 50% margin shall be provided in the pump discharge pressure as De-blocking pressure requirement over the normal discharge pressure while pumping at 60% concentration, + The high concentration ash slurry disposal pump shall be positive displacement type. ‘+ The HCSD pump shall have variable speed drive. ‘+ HCSD pump operating range — 10% to 100% of rated flow. + The HCSD pump electric motor shall have output rating corresponding to the maximum de-blocking pressure requirement along with motor kW margin of 20% (minimum). + 1 no, mixing tank and I no, independent disposal pipeline shall be provided for each HCSD pump. + Mixing tank effective volume between high level and low level shall be for 30 minutes of HCSD pump capacity at 60% concentration. + Shutdown restart capability for pumping operation — 6 hrs to 12 hrs depending on slurry rheology. + The high concentration slurry shall be disposed in disposal area such that no significant free water is released from the slurry. + Ash pipe line velocity — 1.8 m/sec. maximum at 60% concentration. ‘* The HCSD disposal pipeline shall be made from seamless steel pipe having a minimum wall thickness as per Schedule 80, Bends shall have minimum - 3D radius. made from seamless steel pipe of same thickness, Fly ash storage silos ‘The storage silos shall have sixteen (16) hours storage capacity based on fly ash generation with design coal at 100% MCR. Ash water recovery system Recovery water collection arrangement from pond will be designed for collection of 70% water delivered through slurry pumping. Typical ash handling system capacities ‘Typically for a2 x 500 MW power stations the system capacities shall be worked out on per unit basis as under: 38Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) Unit Capacity Heat Rate PLE GCV of Worst Coal Specific coal requirement Daily Coal Requirement Daily Coal Requirement Peak daily coal requirement for BMCR flow Ash Percentage Ash Generated per Unit ESP Ash APH Ash Chimney Ash Total fly ash Evacuation Time per shift Fly ash system evacuation capacity per unit Furnace Bottom ash Economiser ash 33.2 Design Requirements 3.3.2.1 Mechanical Equipment / Systems General 500.00 2450.00 100 3150.00, 0.78 416.50 46% 191.59 172.43 9.58 0.96 182.97 243.96 say 240 419 96 Mw KCal/kWh % KCal/kg ke/kWh Tons TPH ‘TPH TPH TPH TPH TPH TPH TPH ‘TPH TPH @90% @5% 0.5% @2s% @s% Ash collections at various points expressed as percentage of total ash generated when firing worst coal on BMCR basis. a) Bottom ash collection b) Ash collection in economiser ©) Fly ash collection in air pre heaters 4) Flyash collection in ESP ©) Fly ash collection in chimney hopper Basis of various tanks capacities shall be as below a) Common slurry pit (each compartment) b) Ash water sump ©) Bottom ash over flow tank 4) Drain sumps ©) Recovery water sump Density of ash in kg/m’ shall be taken as follows. 1) For volume consideration a) Bottom Ash 39 25% 5% 5% 90% 0s% 650Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) iv. b) Fly Ash 750 2) For load consideration a) Bottom Ash 1600 b) Fly Ash 1600 3). The particle density for ash conveying systems shall be taken as 2000 kg/m’ Conventional lean slurry concentrations ‘The ash concentration (w/w) shall be as given below: a) For combined slurry disposal 28% max. b) Forfly ash slurry disposal 30% max. ©) For bottom ash slurry disposal 25% max. Design capacity for vacuum pumps & compressors shall have 10% margin. Slurry pumps shall have 10% margin over and above total friction head requirement. Water pumps shall be provided with 15% margin in capacity Standby arrangement for Ash handling system Bottom Ash System 100% standby for clinker grinders, jet pumps with independent pipelines for each jet pump outlet or 100 % standby for submerged scrapper conveyor (SSC) and clinker grinders Fly Ash System 100% standby for vacuum pumps (or conveying air compressors), collector tanks, wetting heads. 100% standby for blowers for intermediate surge hopper and storage silos, instrument air compressors, air locks/pump tanks. 50% standby for transport air compressors. Minimum one (1) number standby pneumatic conveying line for each unit. Ash slurry disposal One pump stream as operating standby and one pump stream. as maintenance standby. Independent pipetines for each pump stream Water system 100 % standby for BAHP pumps, BA overflow pumps, Seal water and sludge pumps. Minimum 50 % standby for BALP, FAHP and cooling water pumps. Bottom Ash Hopper ‘The hopper shall be made from tested quality mild steel plates of thickness not less than 10 mm (1S:2062) and suitably stiffened with rolled steel sections. The top 1100 mm of 3:10Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) the hopper including seal trough shall be constructed of 6 mm thick SS : 316. In case of sea water application, the entire hopper including seal trough shall be 6 mm thick of 'S8:316. Hopper shall be lined with monolithic castable refractory of minimum thickness 230 mm. Bottom Ash Water Impounded Hoppers Discharge Gates Each gate shall be capable of discharging 100% (percent) of the contents of one hopper section, within the specified time, The gate size shall be minimum 900mm x 900mm. Electric drives for gate operation are not acceptable. The material of gates shall be as below: Gates Cast Iron 18:210, Gr.FG-260. Gate wear liners 6 mm thick SS : 316 Housing wear _plates/_| 25 mm thick Cast Iron IS: 210, Gr FG 260 Impingement Plates Housing 10 mm thick ( fn.) Mild steel IS :226 or IS: 2062 Clinker Grinders The clinker grinder shall be single roll / double roll type and its speed shall not exceed 40 rpm and the grinder drive motor speed shall not exceed 1000 rpm. The clinker grinders shall be provided with a reversing mechanism to reverse the direction of the grinder rolls should an obstruction stall the grinder. ‘The clinker grinder shall crush large linkers to suitable size [normally to (-) 25 mm for transportation through pipeline. The ‘material of construction shall be as under: Grinder Chamber Carbon Steel (1S:2062) ,10 mm thick. Wear Plates 12-14% (percent) Mn. Austenitic steel plates to 18:276, 10 mm thick Grinder Rolls & Teeth Hadfield’s Manganese steel (ASTM A128, 12- 14% Min) casting shop hardened to 300-BHN at all working surfaces and work hardened to 400 BHN at ste Grinder shaft Stainless Steel 304/EN-8 Shaft sleeve Hardened stainless steel 410/416 Clinker outlet chute 10mm thk mild steel (18:2062) lined with wear resistant liners as above. ‘Sea water applications shall have suitable materials 31Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) Jet Pumps ‘The Jet pumps shall be designed so that it will convey ash at the rated capacity with a minimum of 25 mm wear margin on the diameter of the throat. The material shall be ‘wear resistant and proven type. Typically, the material shall be as per below: Inlet Section, Throat and Discharge/Tail | Alloy Cast iron as per 18:4771 type I (a) piece minimum 4.5% (percent) Nickel with hardness of minimum 500 BHN. Nozzle inlet CLL. Grade FG-260 as per I8:210 Nozzle tip Ceramic lined Stainless Steel /Tungsten carbide Bottom Ash Hopper overflow Tank Each overflow tank shall have an effective storage capacity of minimum ten (10) minutes. For volumetric calculations the density of stored contents shall be taken as 1 ‘tm! and for load calculations the density of stored contents shall be considered as 1.1 Um, ‘The tanks shall be constructed of tested quality mild steel plates for minimum 10 mm thickness. The tanks shall be complete with all make-up, drain, overflow and other associated piping and valves. Submerged Scraper Chain Conveyor Scrapper chain conveyors shall be 2x100% (1 working + one standby) or 4x50% (2 working + 2 standby) for each boiler. ‘The scraper chain shall be Cr-Ni based alloy steel with minimum hardness of 750 HV (equivalent to 63 RC or 690 BN). The upper surface of the chain shall be case hardened to a depth of minimum 3mm to offer abrasion resistance. The size of the chain shall be provided with a factor of safety of minimum five (5) over the required chain pull during startup condition with the upper trough being filled with ash up to maximum water level. In no case the dia of the chain shall be less than 26mm. The drive of SCC shall be provided with variable speed. Vacuum Pumps ‘The vacuum pump shall be of the low speed liquid ring type driven by an electric motor. ‘The design shall also take into account the possibility of vacuum pumps sucking in flue ‘gas containing SO; and SO, from the ash collection chutes.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) xvi. xviii, xxi, Wetting Heads Wetting head shall be constructed of alloy cast iron while the water nozzles shall be constructed of hardened stainless steel 400 series with minimum 500 BHN. Intermediate Surge Hopper ‘The capacity of the Intermediate Surge Hopper shall be adequate to store 30 minutes fly ash collection of a unit. It shall be complete with all other equipment needed for ash intake, ash discharge and fluidisation etc. The material of construction shall be 10 mm. thick M.S. to IS:2062 with 20 mm thick abrasion resistant alloy C.l/ 10mm thick SS liners of 300-350 BHN hardness at sloping surfaces and outlet area. Vent Filters/ Bag Filters ~ Pulse jet type Bag Filters shall be provided in vacuum conveying line above intermediate surge hoppers and vent filters with pulse jet system at silo top. These filters shall have adequate capacity to achieve 50 mg/Nm’ air quality at filler outlet. Vent fans shall be provided complete with drive motor and accessories. The material of bag shall be suitable for 140 °C continuous temperatures. Adequate “anti-static” protection will be taken (if required) in design to prevent any possibility of “dust explosion” within the silo/bag, filter. The performance of the bag filter shall not get affected with 10% of the bags plugged. Fluidizing Air Blowers 2x100% fluidizing blowers shall be provided for fluidizing ESP hoppers and intermediate fly ash silos with dedicated heating units to maintain the temperature of fly ash about 140°C for establishing free flow. Air lock vessels and valves Material of construction for air lock vessel shall be minimum 10mm thick MS plates to IS: 2062 and shall be designed as per ASME section VIII or IS: 2825 with a corrosion allowance of minimum 3 mm. Ash intake/ ash discharge valves shall be dome type/ rotary segregating type/ cone type! swing disc type. The size of ash intake/ash discharge Valves shall be as per system requirements. Material of construction shall be as below: Body : Alloy cast iron with 250 BHN minimum hardne: b. Domelsegregating slide/cone/dise: Minimum 10mm thick SS/alloy CI 300- 350BHN. ©. Seat (as applicable) : Replaceable type alloy CI ot SS smooth finished, hardened to 250 BHIN minimum. Valves shall be provided with suitably located poking port/access plug/panel if, applicable.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) xxii, XXW. All valves shall be subjected to cycle testing for at least 15 cycles on-off operation to ensure smooth operation. Transport and Conveying Air Compressors Compressors shall be sctew type. At least 10% margin shall be provided on compressor capacity over and above the maximum flow requirement, 50 Degree C ambient and a RH ‘of 100% shall be considered for design of capacity of compressors. Instrument Air Compressors, Air Receivers, Air Drying Plants 2x100% (percent) capacity instrument air compressors shall be provided for each unit Each compressor shall be provided with an air receiver of ample size so that delivered air pressure is kept with in 15% (percent) of rated pressure without excessive start/stop operation in the working cycle. Air receivers shall be located convenient to compressor discharge. The receivers and associated fittings shall comply with BS:5169 and BS:1123 or other approved standards. Air drying plants shall provide reliable, moisture free compressed air supply. Vacuum and pressure conveying pipes for dry fly ash Following materials shall be used for dry fly ash conveying: ‘Vacuum conveying: Class-D cast iron pipes conforming to IS : 1536 or BS:1211 Pressure conveying system upto 3.5 Class-D cast iron pipes conforming to IS : 1536 bars or BS:1211 Pressure conveying system >3.5 MS pipes to IS:3589 of 9.5 mm wall thickness bars or Class-D cast iron pipes conforming to IS 1936 or BS:1211 BAHP, BALP and FAHP Water Pumps ‘The two units shall have in common 2x100% BAHP, 3x50% BALP, and 3x50‘% FAHP water pumps with adequate capacity and head. ‘The pumps shall be of horizontal, centrifugal direct driven type. The HP water pumps shall be sized on the basis of the flow and head requirement of the ash handling system as required, The material for the BAHP, BALP and FAHP water pumps shall be as below: a. Casing ~ 2% Ni Cast iron to IS:210 Gr. FG 260, b. Impellers ~ Stainless Stecl to ASTM A351 Gr. CF8M / Bronze - Grade LTBI, 18318, ©. Shaft - Stainless steel type 410 hardened /Carbon Steel EN-8 / Equivalent d. Shaft Sleeves - Stainless steel type 316 / 410. ©. Bolts/Nuts - Steel ASTM A 193/194.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) Ash Slurry Pumps The slurry pumps shall essentially be slow rpm pumps. The rotational speed of the impeller at design point shall not exceed 1000 rpm. These shall be designed to pump the slurry upto the ash pond taking into account the distance and ultimate height of the ash pond embankment. The first stage of slurry pumps shall have a variable speed drive. ‘The ash disposal pumps shall be designed limiting the impeller tip speed to 28 to 30 msec. The ash disposal pumps shall be constructed of materials that equal or exceed the corrosion-erosion resistance of the following materials:~ Casing (inner & | Outer casing shall be of cast steel to ASTM-A216 or spheroidal Outer) Graphite Ductile iron to ASTMA-536, 65-45-12 Inner casing (Volute liners) shall be of chrome nickel cast iron (composition to NI hard-IV) of 550 BHN OR 24% chromium cast iron of 550 BHN Tmpeller/wear | Chrome nickle cast Iron (composition to NChard IV) of 550 BAN, plate OR 24% chromium cast iron of 550 BHN Shaft Carbon steel to AISI K-I040/EN-8 ‘Shaft sleeves SS410 Slurry Line Valves Adequately sized motor operated or solenoid operated pneumatically actuated metal to ‘metal seated knife edge gate valves, the valves shall strictly meet the testing requirements of MSS-SP 81 code for seat leakages. The material of construction shall be as under: Body/Cover: Cast iron FG-260 to IS:210¢min. 10. mm thickness) with alloy C.L/S.8 Deflection cone (minimum 400 BHN hardness) for knife edge gate valves OR Carbon steel to ASTM — A — 216 Gr WCB (0.3% carbon max.) for WCB for plug valves. Gate/Plug Stainless steel with min. 400 BHN Hardness on wear surface for knife edge gate valves OR Carbon steel to ASTM-A-216 Gr. WCB with hardness of 400-450 BHN suitably impregnated for low friction, Stem. Stainless steel (SS-316) for knife edge gate valves OR IS:1875 Class C made out of ASTM- A-105 (forged carbon steel) and will be suitably impregnated for low friction.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) xxviii, xl. xii xii aii Dry Fly Ash Storage Silo ‘The main fly ash storage silos shall be of reinforced concrete/ steel construction with flat/ conical bottom. It shall have facilities for dry ash unloading into covered road tankers or covered wagons and conditioned fly ash in open road tankers with two blanked connections along with isolation valves shall also be provided in the silo for future. Silo arrangement shall be such that the free space between silo columns is adequate to allow movement of 2 nos. trucks side by side to be loaded simultaneously from any 2 of the 4 outlets as ‘mentioned above. ‘The unloading conditioners and chutes individually, shall unload ash at a rate not less than amount of fly ash generated at BMCR conditions. ‘The storage silo shall be designed to provide a clear headroom of 6 m for a road tanker to ccome under the silo and receive the ash from the retractable chutes. It may be noted that unloading system from Silo shall be suitable for both rail wagon unloading and closed tanker/open truck unloading. ‘The dust loading from the outlet of the bag filters shall not exceed 50 mg per Ni any operating condition with 10 per cent bags plugged. Silo Fluidizing Air Blowers Each main fly ash silo shall be provided with adequately rated 2x100% silo fluidizing blowers with dedicated heating units for maintaining temperature of fly ash about 140°C. for establishing free flow. Materials for Water and Air piping ‘The material for instrument air pipe shall be Gl. ‘The material for conveying air pipes shall be MS. Water piping shall be MS ERW pipes heavy grade upto 150 NB confirming to I8:1239 and MS ERW pipes above 150 NB confirming to 18:3589 of thickness 9.4mm, Slurry Pipes and fittings Slurry piping from bottom ash hopper to slurry sump: 20mm thick cast basalt lined MS pipe (MS shell 6mm thickness). Slurry piping from slurry sump to disposal area: 9.52. mm thick (minimum). MS pipes of ‘min. 6 mm thick with 20mm thick cast basalt lining may be used for sea water applications.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) xliv. Fittings for slurry pipes: Ni-chrome alloy C.1. or eqvt. with minimum hardness 400 BHN. Integral wear back of minimum 20 mm thickness or 20 mm thick cast basalt lined MS fittings - (MS shell 6mm thick) 3.3.2.2 Electrical System For design requirements of Electrical System, Section 8 of this document may be referred to, Control and Instrumentation System ‘The control system for Ash Handling System shall either be Programmable Logic Controller (PLC) based or shall be implemented through micro-processor based distributed control system (DCS). For design requirements of Control & Instrumentation system, Section 8 of this document may be referred to, 3.3.2.4 Civil Works For design requirements of Civil works, Section 9 of this document may be referred to, .5 Layout and Maintenance requirements i, While deciding the layout of buildings namely ash slurry pump house, ash water pump house, air compressor house, silo complex the following parameters shall be considered: a) — Minimum clear working space around the equipment shall be 1200 mm, * In case of vertical suction / discharge pumps, the distance between edges of pedestals of adjacent pumps & the same shall be 1200 mm. * Incase of horizontal/suction discharge pumps distance between outer of suction pipe of one pump & outer of discharge pipe of another pump shall be 1200 mm ‘minimum, * Distance between inside face of column to edge of pump/pedestal shall be 1200 b) Suction & discharge header shall preferably be routed i ide the building. €) In case of two (2) rows of pumps/equipment located in parallel, minimum distance between the equipment shall mect the following criteria. * Clear distance between edges of pedestals/motors of pump located parallel shall bbe 2000mm. * In case of space provided is acting as the handling space for the equipment by overhead crane the space shall be maximum size of equipment being handledStandard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) plus the clearance of 500 mm minimum on either side with the stationary equipment. ‘© Withdrawal spaces of equipment. In case of provision of crane inside the building, provision of minimum 550 mm clear walkway at crane rail level on both the side of the building. Building height shall take care of the following parameters ‘© Head room for the piping/cabling shall be 2500 mm (minimum). © In case of handling of the equipment one over the other, the clearance between moving & stationary equipment shall be 500 mm (minimum), ‘© In case of handling of the equipment on the side of the other equipment, ground clearance of moving equipment shall be 2500 mm (minimum). Head room of 2100 mm over crane rail level walkways. Pipes & cables shall be routed overground inside/outside the building. No pipe trenches are to be routed overground inside or outside the building However, cable slits can be provided for routing of cables from the over head cable trays to the respective motor of the equipment cable slits shall be finished to surrounding floor level with adequate cushioning of sand, One maintenance bay of 6m (minimum) x the width of the building shall be provided in slurry pump house, air compressor house and ash water pump house. ‘Two (2) nos. of rolling shutters of size 4000 x 4000 mm (min) shall be provided one at the entrance and the other at exit of maintenance bay. In case entrance & exit of maintenance bay is common ie. on the same side, only one rolling shutter of size 4000 x 4000 can be provided, Valves shall be located such that they are accessible from the regular floor of the building, as far as possible. Valve operating platform’s alongwith approach ladder/cage ladder shall be provided for the valves which are not accessible from the floor of the building. Each equipment room shall be provided with alternative exits in case of fire/accidents as per requirement of factories act and statutory bodies/insurance companies. Hoist maintenance platforms alongwith approach ladder shall be provided, preferably at the end of the building. Fresh air supply/exhaust air fans shall be located at a minimum height of 2500 m. It is preferable to raise the elevation of wetting unit / collector tower such that discharged slurry pipelines are routed through over head pipe trestle and all the slurry pumps are installed at ground level only. This is however site layout dependent. The following criteria in addition to those specified above shall be followed for sizing the various buildings.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) A) b) ° d) °) ° a) b) Ash slurry pump house Ash slurry pit shall have be two sump compartments with one common trough at the inlet with 2 nos, adequately sized manually operated / motorised plug gates. Each sump compartment shall be sized for five (5) minutes of storage capacity of total slurry flow between high & danger low level. Not more than two pump streams shall take suction from one sump. Independent sump for each slurry pumping stream may also be adopted. Hand railing shall be provided all around the sump top. Two (2) nos, access ladders 600 mm wide shall be provided to access bottom of the sump 1.5 M (clear) wide RCC passage way shall be provided along the length of pump house, after last pump in each stream, ‘Two (2) nos. 1200 mm wide staircase shall be provided, one on either end of the Pump house for entry into dry pit i. bay housing first stage pumps, for such layout where first stage pumps are located in a pit below ground level. ‘Two nos. rolling shutters of 4 m x 4m (min) size shall be provided. Ash slurry sumps shall be clear of intermediate columns, Further the pump house shall also be provided with columns only at periphery without any intermediate columns, ‘Ash Water Pump House ‘Sump shall be provided along the entire length of the building. Hand railing shall be provided all around the sump top. Ash water sump shall be clear of intermediate columns. Further the pump house shall also be provided with columns only at periphery without any intermediate columns. ‘Two (2) nos. 1200 mm wide staircase shall be provided on either side of the sump, to reach on the top of the sump, ‘Two (2) number access ladders 600 mm wide shall be provided to access bottom of the sump. General Grating shall be provided to cover the complete sump for all sumps including sumps in the combined ash slurry pump house, ash water pump house, silo area and surge and setting tanks in bottom ash overflow treatment area. Further the grating platforms required in any of the buildings housing ash handling system equipments shall also be supplied including the structural steel supports, Alll the RCC trenches and drains shall be provided with grating. Wherever the depth of the trench increases to 2.5 M, the trench shall be converted into underground tunnel. Suitable manhole covers with access ladders at suitable intervals shall be provided. Further the trench in between the (wo ESPs as also in passageways in boiler and ESP area shall be provided with heavy duty precast covers for movement of heavy duty equipment,Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) a ©) All the buildings shall be provided with columns only at periphery without any intermediate columns. 4) Fly ash silos shall be located in a separate area near the plant boundary, with independent access. ©) The vacuum pumps and conveying air compressors shall be kept as close to the ESP as possible to reduce energy requirement and better effectiveness of vacuum and compressed air used in pneumatic conveying. PERFORMANCE REQUIREMENTS Performance and Guarantee Tests }) Prior to conducting of PG test, the ash handling plant shall be on a trial operation for 14 ays (o establish full range operation of ash handling plant. b) The performance guarantee tests shall be conducted for three (3) days of operation of the 3.4.2 boiler at 80% to 100% load. In case of any major breakdown in any of the equipment disrupting the operation of Ash Handling Plant, the breakdown period shall be added to the testing period of 3 days. ) The performance guarantee test shall be conducted to prove uninterrupted operation of ash handling plant of each unit separately as they are completed and all units simultaneously when they are completed, The ash handling plant shall be operated with its normal auxiliaries, (as applicable commensurate with the number of boiler units in operation) ‘without using standby pumps or any other standby equipment. Performance Guarantees ‘The parameters guaranteed shall have no tolerance value whatsoever. The equipment and systems offered shall be guaranteed to meet the following performance. (a) Bottom Ash Handling System In case of intermittent type bottom ash removal system employing water impounded hopper and jet pumps, the system shall be guaranteed to meet the following performance: i) Continuous effective extraction, crushing and conveying of bottom ash generated during various modes of boiler operation to the ash slurry sump and the continuous effective pumping of combined slurry from this sump to the ash slurry dump area, The extraction of bottom ash shall be done as per frequency and collection rates specified as per clause 3.3.1.a) ii) Power consumption (kW) as measured at motor input terminals for all motors operating during continuous effective ash extraction rate as outlined in a (i) above. iii) Rated capacity at rated head of all pumps.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 3 (Ash Handling Plant) In case of continuous type bottom ash removal system employing submerged scrapper chain conveyors, the system shall be guaranteed to meet the following performances. i) Continuous effective discharge, crushing and sluicing of bottom ash generated during various modes of boiler operation to the bottom ash slurry sump and the continuous effective pumping of slurry from this sump to the main slurry sump in ash slurry pump house for onward effective pumping from main sump to the ash slurry dump area. ii) Conveying Capacity of submerged scraper chain conveyor: (a) Continuous normal conveying capacity 50 T/hr or 25 Tir (as the case may be) of the submerged scrapper chain conveyors with the linear speed of chain not exceeding 2.0 m/min, (guaranteed extraction rate). (b) Dead start capability of submerged scraper chain conveyor ice. it shall be able to start and discharge the bottom ash with water filled trough full of bottom ash upto maximum water level. iii) Power consumption (KW) as measured at motor input terminals for submerged scraper chain conveyors, ash crushers and pumps operating at the guarantet conveying rate. iv) Rated capacity at rated head of all pumps v) The continuous effective conveying and pumping as stated above shall be established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections and sequential operation working satisfactorily. (b.) Economiser and Air Pre-heater Ash Handling System Continuous effective conveying of ash collected in economizer in wet mode and continuous effective conveying of ash collected in air preheater in wet or dry mode, as ‘envisaged for the plant. The continuous effective conveying of ash as stated above shall bbe established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections working satisfactorily. (c)_ Fly Ash Handling System i) Continuous effective conveying of fly ash from all fly ash collection hoppers, in dry and wet form, ile, ESP hoppers, generated during various modes of boiler operation upto collector tank/ intermediate surge hoppers, from intermediate surge hoppers to ash storage silo and from collector tank to the ash slurry sump and the continuous effective pumping of ash slurry from this sump to dyke area. The fly ash collected in each unit in every shift of eight (8) hours corresponding to maximum ash collection rates shall be extracted in six (6) hours. ii) The continuous effective conveying and pumping as stated above shall be established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections and sequential operation working satisfactorily.