Magaldi Power S.p.A.

Via Irno 219, 84135 Salerno, Italy

Tel. +39-089-688.111
Fax +39-089-481.766

Bottom Ash Handling System

OPERATION & MAINTENANCE MANUAL
SECTION ‘Z’
Components - Reference Documentation

POWER STATION OPG THERMAL POWER PLANT

PROJECT MP.2012.0131 – GUMMIDIPOONDI (OPG #4)
CUSTOMER OPGS POWER PVT.LTD.
OPERATION & MAINTENANCE MANUAL
DOCUMENT TITLE
SECTION Z – COMPONENTS REFERENCE DOCUMENTATION
EQUIPMENT BOTTOM ASH HANDLING SYSTEM

KKS No.: -

EQUIPMENT CODE

MAGALDI IMP003284

CUSTOMER -
DOCUMENT CODE
MAGALDI MP.2012.0131-OMM_SZ
Revision Record

Rev Date Object of Revision Drafter Verifiers Approval Technical Director

A.DONNARUMMA D. CASILLO UT F. ZUBINI
0 05/05/2014 First issue G. SETARO P. BRUNO
R. LA CERRA
The sole owner of this document is Magaldi Power S.p.A. located in Salerno, Italy.
The non-authorized distribution of this document is forbidden and it is punishable according to the laws in force.

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

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Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

MAC System O. & M. Manual – GENERAL INDEX

Customer Code : -
MAGALDI Code : MP.2012.0131-OMM

Section Component MAGALDI

Title MAGALDI Doc. Code
ID Main KKS Nr. Component Code

A General Maintenance Concept IMP003284 MP.2012.0131-OMM_SA

B Ash Hopper & Bottom Doors BTD01 VDF000033 MP.2012.0131-OMM_SB

C MAC MAC01 MAC000108 MP.2012.0131-OMM_SC

D Precrusher 54” PCS01 FRT267071 MP.2012.0131-OMM_SD

E Crusher 54” CRS01 FRT267072 MP.2012.0131-OMM_SE

F Postcooler PSC01 ECO000099 MP.2012.0131-OMM_SF

G O-Chain PSC01 CAT003517 MP.2012.0131-OMM_SG

H Vibrating Feeder ALM01 ALM900025 MP.2012.0131-OMM_SH

K Mixer Unloader 500 MXR01 MIX000041 MP.2012.0131-OMM_SK

Components
Z - - MP.2012.0131-OMM_SZ
Reference Documentation

IMPORTANT NOTES

In the present Manual the

“Bottom Ash Handling System”
1)
could be called:
“MAC System”
The Annexes Z1...Z6 are contained in the “Section Z”.
2)
Ref. to the “General Index”

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

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Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

Table of contents

MAC System O. & M. Manual – GENERAL INDEX...............................................................3 

IMPORTANT NOTES ..............................................................................................................3 
Machine identification ...........................................................................................................6 
1.  Use and storage of the Manual......................................................................................7 
1.1  Purpose of the Manual ......................................................................................................................... 7 
1.2  Updates.................................................................................................................................................. 7 
1.3  Requests of copies and revision ........................................................................................................ 8 
1.4  MAGALDI Customer Service Department .......................................................................................... 8 
2.  Documentation of components – Annex List ..............................................................9 
Annex Z1 - Mechanical Seal – O.&M. Manual
Annex Z2 - Hydraulic Systems Components Ref. Doc.
Annex Z3 - Drives and Gearboxes Ref. Doc.
Annex Z4 - Pneumatic Take-up System Ref. Doc.
Annex Z5 - Machine Sensors Ref. Doc.
Annex Z6 - Process Control Instruments Ref. Doc.

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

Machine identification
For any contact with the manufacturer you are recommended to mention the data indicated in
the following plates:

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

1. Use and storage of the Manual

Caution!
Before starting any operation and maintenance activity on the machine read this
manual carefully and completely.

The manual should be fully read and understood by all the operators in charge of any activity
to perform on the machine, either periodically or occasionally.
The Safety Plant Manager should train the personnel on the risks of accidents, on the
devices arranged for the safety of the operator and on the general accident prevention rules
provided by international directives and by the legislation of the Country where the machine
should be installed.
The customer is always responsible for any accident which may occur to unauthorized
personnel or who, in any way, has not been previously informed on the safety measures
mentioned in this manual.
The manual should be carefully kept in the vicinity of the machine, in a protected, dry location
which can be easily and quickly reached for any future consultation.

1.1 Purpose of the Manual

The purpose of this manual is to inform the machine users, through explanation texts and
figures, on the prescriptions and the essential criteria relevant to the allowed uses,
mentioned in par.2.1 of the same.
The manual reflects the technique state at the time of the machine sale and it cannot be
considered inadequate if, following new experiences, it has been subject to subsequent
updates. For this purpose the manufacturer reserves the right to update the production and
the relevant manuals without any obligation to update the previous production and manual,
unless in exceptional cases.
In case of doubt, please contact directly the SERVICE by Gruppo Magaldi.
This manual is provided, in the annex part, with Operation and Maintenance Manuals
concerning the trade components installed on the machine.

1.2 Updates
The information contained in this manual will be updated with all the available information
connected with project modifications.
The manufacturer commits for the continuous optimization of his own product. For this
reason Magaldi would like to receive any information or proposal designed to improve the
manual and/or the machines.
Any request for information can be sent to the following address:

MAGALDI POWER SPA

Via Irno, 219
84135 SALERNO
Tel +39 089 688 111
Fax +39 089 481 766
service@magaldi.com

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

1.3 Requests of copies and revision

Copies of this Manual or its Revisions can be requested to:

MAGALDI POWER SPA

Via Irno, 219
84135 SALERNO
Tel +39 089 688 111
Fax +39 089 481 766
service@magaldi.com

1.4 MAGALDI Customer Service Department

Gruppo Magaldi, by means of its Service Department, provides a wide range of services,
from a simple inspection to a full ordinary and extraordinary maintenance on all the national
and international territory.

In addition, the Magaldi’s Service Department provides an on line service which operates 24
hours a day to answer any question and/or request for intervention that the customer may
require.

The addresses of the Service Department are indicated below.

Service Department
HEAD OFFICE +39 089 688 111
FAX +39 089 481 766
E-MAIL service@magaldi.com
HELP ON LINE service.helponline@magaldi.com

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

2. Documentation of components – Annex List

ANNEX RELEVANT MAGALDI
COMPONENT KKS No.
ID EQUIPMENT/FUNCTION CODE
Z1 Mechanical Seal – O.&M. Manual - GME000067
Z2 Hydraulic Systems Components Ref. Doc.
Z2.1 Hydraulic Unit Bottom Doors BTD01 OLD000276
Z2.2 Hydraulic Unit Precrusher PCS01 OLD000277
Z2.3 Hydraulic Components Hydraulic Systems Bottom Doors / Precrusher
Z3 Drives and Gearboxes Ref. Doc.
MAC Extractor - Superbelt COT0964
Z3.1 Gearbox
Postcooler COT001546
Z3.2 Gearbox MAC Extractor – Spill-chain COT0984
Z3.3 Gearbox O-Chain COT001577
Z3.4 Gearbox Crusher 54” COT0719
Elastic coupling
Z3.5 Crusher 54” MEC133B
Motor/Gear
Z4 Pneumatic Take-up System Ref. Doc.
Z4.1 Pneumatic System MAC Extractor Superbelt / Spill-chain MAC01 ACC003878
Z4.2 Pneumatic System Secondary Cooling Conveyor / O-Chain PSC01 ACC003879
Z4.3 Pneumatic System Silo Pneumatic Valve PNM #3 CLP000303
Z4.4 Pneum. Components Pneumatic Panels
Z4.5 Pneumatic Cylinders Pneumatic Take-up Systems
Z5 Machine Sensors Ref. Doc.
ICE3805+
Primary Crusher Device Availability CRS01-ZSL01
ICE3806
Z5.1 Safety switch MAC Extractor Emergency Tail Door Open MAC01-ZSL01
ICE3805+
MAC Extractor Emergency Head Door Open MAC01-ZSL02
ICE000067
Postcooler Emergency Tail Door Open PSC01-ZSL01
MAC Extractor Superbelt High stretch detecting MAC01-ZIH01
MAC Extractor Superbelt Zero-speed monitoring MAC01-ZIH02
MAC Extractor Spill Chain High stretch detecting MAC01-ZIH03
Z5.2 Proximity Switch ICE3692
MAC Extractor High Ash Level detecting MAC01-ZIH04
Postcooler High stretch detecting PSC01-ZIH01
O-Chain High stretch detecting PSC01-ZIH02
BTD01-ZSH01÷12
Z5.3 Mechanical Switch Bottom Doors (No.6+6) open/closed SNS000037
BTD01-ZSL01÷12
Pre Crusher Cylinder 1-2 – Open/Close Position PCS01-ZSH01/ZSL01
Z5.4 Limit Switch Pre Crusher Cylinder 3-4 - Open/Close Position PCS01-ZSH02/ZSL02 ICE0058
Slide Gate Valve - Open/Close Position VLV01-ZSH01/ZSL01
MAC Extractor Spill Chain Zero-speed detecting MAC01-SSL01
Primary Crusher Zero-speed monitoring CRS01-SSL01
Z5.5 Zero Speed Switch Postcooler Zero-speed detecting PSC01-SSL01 ICE0003
O-Chain Zero-speed detecting PSC01-SSL02
Mixer Unloader Zero-speed monitoring MXR01-SSL01
SNS000053 +
Z5.6 Single Coil Solenoid Valve Mixer Unloader Water Valve Operating MXR01-SV01
ACE000219
Z6 - Process Control Instruments Ref. Doc.
Level switch + Ceramic SNS000134 +
Z6.1 Big ash lump detecting in Discharge chute MAC01-HLS01
Window ACE000338
Z6.2 Level switch Silo Very High Level Detecting SIL01-VHLS01 SNS000246

Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00

 Magaldi Power S.p.A.
Via Irno 219, 84135 Salerno, Italy
Tel. +39-089-688.111
Fax +39-089-481.766

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Operation & Maintenance Manual – Section Z – MP.2012.0131-OMM_SZ-R00