O&M Manual - Part 1 of 5 PDF

OPERATION & MAINTENANCE ::- .
;:-
= -= -=
MANUAL
MAHARASHTRA POWER GENERATION COMPANY

LIMITE D
1 x 210 MW, UNIT #6

KORADI THERMAL POWER STATION
OPERATIONAL & MAINTENANCE MANUAL
OF
BOTTOM ASH HANDLING SYSTEM
Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA
ISO: 9001:2008 Company CHECKED BY : GAURA V SINGH

Faridabad-121 003 APPROVED BY: G.K.NAIR
OPERATION & MAINTENANCE . .
- -
MANUAL
INDEX
Me/co India Pvt. Ltd., PREPARED BY : SANDEEP SHARMA

ISO: 9001:2008 Company CHECKED BY : GAURAV SINGH
Faridabad- 121 003 APPROVED BY: G.K.NAIR
OPERATION & MAINTENANCE
MANUAL
SR.
DESCRIPTION NO. OF SHEETS
NO.
1) System Description
2) Control Write-up
3) Operation Instruction of Clinker Grinder
4) LCP of Clinker Grinder & Jet Pump 12
5) Protection & Interlocking System for Clinker Grinder
SR.
BHEL MIPL
NO. OF
DRAWING DRAWING DESCRIPTION
NO. SHEETS
NO. NO.
1. Bottom Ash Hopper
a. 2 Instructions
MIPL-15-0 1-
b. 1-726-09-40-029 GADrawings
M-GA-01
2. Feed Gate Housing
a. 2 Instruction
MIPL- 15-01 -
b. 3-726-09-40-037 GA Drawings
M-EQ-02
3. Air W ater Converter Tank
MIPL-15-01 -
a. 3-726-09-40-036 GA Drawings
M-EQ-01
4. Clinker Grinder
a. 9 Instruction
MIPL-15-01 -
b. 3-726-09-40-038 GADrawings
M-EQ-03
Melco India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

- - -
MANUAL
MIPL-I5 -0 I-
c. 3-726-09-40-039 I GA of Drive Unit
M-EQ-04
d. 86 Fluid Coupling Catalogue Manual
e. IO Gear Box Catalogue Manual
5. Jet Pump
a. 3 Instruction
MIPL- I5 -0I -
b. 3-726-09-40-04I I GADrawings
M-EQ-06
6. Feed Sump
MIPL-15-01 -
a. 3-726-09-40-040 1 GADrawings
M-EQ-05
7. ACI Fittings
MIPL- 15-01-
a. 3-726-09-40-04 2 1 GA Drawings
M-EQ-07
8. Sleeve Coupling Assembly
MIPL- 15-01-
a. 3-726-09-40-044 1 GA Drawings
M-EQ-09
9. Cast iron Pipe
a. 2 Description
MIPL-15-01-E-
b. 3-726-09-40-07 6 2 Data Sheet
V-06
10. Pneumatic Cylinder
a. 2 Instruction
11. Refractory
a. 2 Description & Instruction
12. Motor
a. 20 Catalogue

M ANUAL
b. 3-726-09-40-078 MIPL-15 -01 - 7 Data Sheet

B-V-08
13. Contactor & Thermal Overload Relay

'
a. Catalogue
14. Grinder Motor Controller
a. 2 Description & instruction
b. Diagram
15. Over Current Relay
a. 2 Description & instruction
b. Diagram
16. Pressure Switches
a. Catalogue
17. Solenoid Valve
a. Catalogue
18. Phase Failure Relay
a. Catalogue
19. Cable Schedule
MIPL-15-01 - Flow Diagram- Bottom Ash Handling

1. 1-726-09-40-025
M-FD-01 System, Unit # 6
MIPL-15-01 - Layout Bottom Ash Handling System Unit

2. 1-726-09-40-031
M-LA-01 #6
MIPL-15-01 - Water piping around B.A. Hopper area Unit

3. 1-726-09-40-032
M-lA-02 #6


MANUAL
SYSTEM
DESCRIPTION

MANUAL
SYSTEM DESCRIPTION
MANUAL FOR OPERATION & MAINTENANCE
The Ash Handling Plant at Koradi Thermal Power Station Unit # 6 Consist of specially
designed Bottom Ash System for 1 x 210 MW Pulverized coal fired Steam Generator of
BHELMake.
A detailed desctiption of the system is given in the following paragraphs:
1. GENERAL
The water filled bottom ash hopper receives the bottom ash from the furnace, where it is
stored and petiodically discharged to the clinker grinder. The ash slurry from clinker will
be discharged to ash slurry sump through Hydro jet pump and transport pipe once in every
eight (8) hours shift. A maximum of 12.820 tones/hour of bottom ash will be collected in
the Bottom Ash Hopper in every shift. The bottom ash system is capable for disposed of
ash within 75 minutes in each shift.
BOTTOM ASH SYSTEM
The free falling ash from Boiler furnace is collected and stored in a double 'V' shaped
water impounded bottom ash hopper provided below the boiler furnace for its periodical
removal once in a shift of eight (8) hours per shift. The hot ash from the furnace gets
quenched as it enters in to the water minimizing the clinker formation. The mixture of ash
and water stored in the hopper is discharged through feed gate housing to clinker grinder to
crush the oversize clinker. The crushed clinker along with water, which forms bottom ash
slurry, is conveyed to Slurry sump through Jet Pump for further disposal to ash disposal
area through Ash slurry disposal pumps. Water required for jet pump is supplied from
Clear water pumps located in Ash Water Pump house.
Bottom ash would be removed once in a shift of eight (8) hours in approx. 75 min. per unit
including five (5) minute flushing under maximum continuous rating conditions.
Water seal trough arrangement is provided at the top of the bottom ash hopper for effective
furnace seal and to prevent ingress of air in to the furnace. A cooling trough arrangement is
also provided at the top of the hopper. Refractory cooling water supplied to the cooling
trough will overflow continuously to provide continuous refractory cooling to enhance the
life of the refractory. Flushing header with nozzles provided at the end of bottom ash
hopper slopping walls agitates and removes settled ash from the hopper.
Continuous water will be fed in the bottom ash hopper for the purpose of maintaining
water temperature below 60-degree C. the make - up will result in continuous overflow of
water (60 deg. Max.), which will be led in to an overflow seal box. The overflow seal box
will maintain the necessary sealing between the furnace and the atmosphere.
2. HYDROJET (JET PUMP) WATER VALVE (PNEUMATIC OPERATED)
Two (2) nos. Uet pump) water valves have been provided with four (04) Nos. Hydro-jets. Each
actuator valve is driven by a cylinder. These valves are controlled from Bottom Ash control panel
in 'Manual' mode of BA evacuation. However open & close Selectors SW have also been provided
on BAPanel.

MANUAL
CONTROL
WRITE-UP
Melco India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

MANUAL
1. CONTROL WRITE UP FOR ASH HANDLING SYSTEM

The Controls for the complete ash handling systems have been categorized in four (4) stages as given
below:
i) BOTTOM ASH CONTROL PANEL
This panel shall be located near to bottom ash hopper of unit # 6 and controls for the following
shall be provided.
a. Clinker Grinder Motors 4 Nos.
b. Hydro-jet water valve (Pneumatic Operated) 2 Nos.
c. Bottom Ash handling system 4 Streams
The start I stop push buttons, indicating lamps (Red, green and amber) selector switches, mimic
diagram and a solid state alarm annunciation shall be provided on this panel.
ii) EXISTING AHS CENTRAL CONTROL PANEL
The Desk - cum- control panel shall be located at Main Ash Control Room adjacent to Ash
disposal & ash water pump house. Controls for the following shall be provided on this panel.
a) Clear Water Pump
b) RC Water pumps
c) Filter Water Pump
All above Equipments shall control from Existing Customer Control Panel.
iii) BOTTOM ASH CONTROL PANEL (BOTTOM ASH HANDLING SYSTEM - LOCAL)
3. CLINKER GRINDER & MOTOR
1.0 GENERAL
1.1 Total 4 Nos. Clinker Grinder (2 Nos. Working and 2 Nos. Standby) to be provided with
Forward & Reverse mode of Operation.
1.2 Operation of Clinker Grinder to be controlled from 1 no. Relay Based Local Control Panel
(LCP).
1.3 The operation mode of the Clinker Grinder can be selected from the 3 position
"Manual/Open I AUTO" Selector Switch mounted on the control panel. '
2.0 FIELD I NSTRUMENTS PROVIDED FOR EACH CLINKER GRINDER
2.1 Pressure Switch
a. 1 No. Clinker grinder gland seal water pressure switch.
b. 1 No. Jet Pump water line (BAHP) pressure switch.
Melco India Pvt. Ltd., PREPAREDBY : SANDEEPSHARMA

MANUAL
OPERATING
INSTRUCTION
OF
CLINKER
GRINDER

MANUAL
CLINKER GRINDER OPERATION:
1.1 CG START
Each Clinker Grinder is provided with one no of 3 positions selector switch with ("Manual/Open
I AUTO") position on LCP. Open seal water, Jet pump Water valve manually for auto and
manual condition.
a) To start motor manually select the AIM selector switch in manual position and push
Forward Start push button. Motor run in forward direction (When no overload /over
cunent condition exists). Push stop push button to stop the motor. In Jammed condition
push reverse start push button to start the motor in reverse direction to release the jammed
condition of Clinker Grinder manually.
b) To start the motor in auto mode, select the AIM switch in "AUTO" position/ mode then
the following condition exist through Grinder Motor Controller (which is a Solid State
microcontroller based Electronic device for Control & Automation of the grinding
process).
1.1 Operating supply 240 VAC
1.2 If all the pressure s/w's connected in series are closed, forward contact will close.
1.3 If the overload signal is received, forward contact will get open and LED no 1 will
get on indicating first over load.
1.4 After 5 sees reverse contact will close for I 0 sees and after 5 sees again forward
contact will close and continue.
1.5 If the overload signal is again received within cycle time (adjustable up to 2mnts)
forward contact will get open and LED, no 2 will get on indicating 2"d over load and
the reversing cycle will be repeated.
1.6 If within the cycle time overload signal is again received the forward contact will
open and LED, no 3 get on and trip contact will close and remain closed till 240
V AC is disconnected.
1.7 If no overload signal is received within cycle time the overload LED's will get off.
1.8 If during the above operation any of the pressure s/w's gets open for more than the
off delay (Adjustable up to 60 sees) again the trip contact will close and remain
closed till 240 VAC is disconnected.
1.2 CG STOP
1.1 When selector switch is selected in "Manual" position & corresponding stop
pushbutton pressed (without any interlock Logic).
1.2 When selector switch selected in "Auto" position and following condition exist.
a) Motor trip signal anived
b) Selector switch selected in open position
c) Any one of the conditions mentioned for start condition is not satisfied.
1.3 CG TRIP
1.1 Motor Thermal overload when it is running due to any fault in motor.
1.2 Motor over cunent when it is running due to CG jammed.

MANUAL
LCP OF CLINKER
GRINDER&
JET PUMP

OPERATION & M AINTENANCE
MANUAL
LOCAL CONTROL PANEL:
The Local panel in provided with following indications & annunciations for screen wash system.
Sr. No. L ist of Indication Lamp s L amp C olour
I. Clinker Grinder-A Forward Run Green Lamp
2. Clinker Grinder-A Reverse Run Blue Lamp
3. Clinker Grinder-A Stop Red Lamp
4. Clinker Grinder-A Trip Amber lamp
5. Clinker Grinder-B Forward Run Green Lamp
6. Clinker Grinder-B Reverse Run Blue Lamp
7. Clinker Grinder-B Stop Red Lamp
8. Clinker Grinder-B Trip Amber lamp
9. Clinker Grinder-C Forward Run Green Lamp
10. Clinker Grinder-C Reverse Run Blue Lamp
11. Clinker Grinder-C Stop Red Lamp
12. Clinker Grinder-C Trip Amber lamp
13. Clinker Grinder-D Forward Run Green Lamp
14. Clinker Grinder-D Reverse Run Blue Lamp
15. Clinker Grinder-D Stop Red Lamp
16. Clinker Grinder-C Trip Amber lamp
17. Seal line valve - CG A OPEN. Red Lamp
18. Seal line valve - CG B OPEN. Red Lamp
19. Seal line valve - CG C OPEN. Red Lamp
20. Seal line valve- CG D OPEN. Red Lamp
21. Jet pump Inlet water Header valve-CG A OPEN. Red Lamp
22. Jet pump Inlet water Header valve-CG B OPEN. Red Lamp

O PERATION & MAINTENANCE
MANUAL
23. Jet pump Inlet water Header valve-CG C OPEN. Red Lamp
24 . Jet pump Inlet water Header valve-CG D OPEN. Red Lamp
25 . Pressure OK CG A Red Lamp
26. Pressure OK CG B Red Lamp
27 . Pressure OK CG C Red Lamp
28. Pressure OK CG D Red Lamp
29. Control supply Healthy Red Lamp
Annunciation Window- (Audio & Visual)
Sr. No. List of Annunciation Window
1. Clinker Grinder - A Seal Water Pressure Low
2. Clinker Grinder - A Jet Pump Pressure Low
3. Clinker Grinder - A Trip/Jammed
4. Clinker Grinder- B Seal Water Pressure Low
5. Clinker Grinder - B Jet Pump Pressure Low
6. Clinker Grinder - B Trip/Jammed
7. Clinker Grinder - C Seal Water Pressure Low
8. Clinker Grinder - C Jet Pump Pressure Low
9. Clinker Grinder - C Trip/Jammed
10. Clinker Grinder - C Seal Water Pressure Low
11. Clinker Grinder - C Jet Pump Pressure Low
12. Clinker Grinder - C Trip/Jammed
Note: -
Acknowledge, reset and test push buttons have been provided for the faults .
"Acknowledge" push button may be used to silence the hooter. As soon as the fault is removed "Reset"
push button should be pressed to set the annunciation system again.

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FRONT VIEW INTERNAL FRONT VIEW INTERNAL REAR VI EW REAR VI EW SIDE VIEW
NOTES:-
1. SHEET STEEL - 2 MM THICK 7. 2 NOS STUD FOR PLANT EARTH CO NN ECTION
l-4001 11400- 2. ENCLOSURE - DUST AND VERMIN PROOF WITH GASKET DOOR 8. NAM E PLATE WILL BE WHITE ENGRAVED LETIER ING ON
300 300 - AND COVERS AS PER SPEC. IP - 55 FLOOR MOUNTED 1'r'PE BLACK ANODISED ALUMINUM PLATE 2 NOS STUD FOR
1-50 PLANT EARTH CONNECTION
SUITABLE FOR INDOOR INSTALLATION
I II 3. PAINT SHED - RAL 7032 EXTERIOR AND BRILLIANT WHITE 9. ALL DIMENSION ARE IN MM
1000 INTERIOR AVERAGE PAINT THICKNESS IS NOT LESS THAN 75
MICRON 10. 1.5 sqmm(Grey) FRLS CU WIRE FOR CONTROL WIRING
j-----40<>-;jj 4. ALL DOORS/OPENN INGS WI LL BE COVERED BY NEOPRENE
21o I II 2Ao RUBBER GASKET.
T 5. GLAND PLATE - 3mm THICK REMOVABLE BOLTED 1'r'PE
UL
I I (UNDRI LLED) PROVIDED AT BOTIOM OF CABLE ENTRY
6. 25X3MM CU EARTH BUS WILL BE PROVIDED AT BOTIOM OF PROJECT: I RENOVATION & MODERNISATION OF 1 x 210MW. UNIT N0.6.
THE PANEL FULL LENGTH OF BOTIOM KORADI TPS OF MAHARASTRA STATE
' -- - - - 1100- - - ---' POW ER GENERATION COMPANY LIMITED (MSPGCL)
FOUNDATION PLAN MAHARASTRA STAT£ POWER GENERATION COMPANY UMITED {MSPG CL)
"""""
BHARAT HEAVY ELECTRICALS LTD
II R&M PROJECT DIVISION , BHOPAL
~ IM ELCO INDIA PVT. LTD.l =-"'""'
I '• '• • PLOT N0.-4, SECTOR-27A =-""'
._. FARIDABAD-121 003.
1111..C BOTIOM ASH HANDLING- LCP & WI RIN G
SCHEME
06 I FOR REFERENCE & RECORDS ONLY K.lliAI. I JSINCH IPCJOSHI)'c.JOS!t[_2J.oa18 1 "" SCAli jBHEL ORG. NO. J3· 726.o9-40-7 1-& 3· 726-09-40.072l RfV8 NO.
DESCRIPT ION j DRAJIN Jo=jcHKD jJ.PPD ji)IJE 1 A3 l'lTS lvaco DRC. No} MIX.-Is-ot -E.v..ot & MIPL.- IS-0\-~~~~I:\~~~:
f~NO~
' ' '
LEGENDS SLD
NAM E PLATE DETAIL
CLINKER GRINDER-A
COMMON FOR CG - ABC D 1. AK1 FORWARD POWER CONTACTOR FOR CLINKER GRINDER- A
CLINKER GRINDER - C
1. BA LOCAL CONTROL PANEl 2. AK2 REVERSE POWER CONTACTOR FOR CLINKER GRINDER- A
2. ANNUCIATOR 7C. CLINKER GRINDER-C SEAL LINE VLV OPEN 3. AK3 OVERLOAD RELAY FOR CLINKER GRINDER-A
3. CONTROL SUPPLY HEALTHY INDICATION (RED) 8C. CLINKER GRINDER-C JET PUMP IN LET WAT ER HEADER VLV OPEN
' 4. AKO POWER CONTACTOR FOR OLR BASE CLINKER GRINDER - A
4. TEST P.B (YELLOW) 9C. FEED GATE CG-C OPEN G~OLR
5. GRINDER MOTOR OVER CURRENT RELAY FOR CG-A
5. ACK P.B (BLUE) 10C. 3 POS. AUTO MANUAL SELECTOR SW. FOR CG-C
6. GMCR GRINDER 1.10TOR CONTROL RELAY FOR CG- A
6. RST P.B BLACK) 11C. OPEN CLOSE SELECTOR SW. FOR SEAL LINE VLV CG-C
7. AR1 - AR7 AUX RELAY FOR CLINKER GRINDER- A
12C. OPEN CLOSE SELECTOR SW. FOR IN LET WAT ER HEADER VLV CG- C
CLINKER GRINDER - A 8. AK3X AUX RELAY FOR CLINKER GRINDER- A
' 13C. OPEN CLOSE SELECTOR SW. FOR FEED GATE CG - C
CLINKER GR INDER-S
7A. CLINKER GRINDER-A SEAL LINE VLV OPEN 14C. CG-C TRIP (AMBER)
1. 8K1 FORWARD POWER CONTACTOR FOR CLINKER GRINDER-S
8A. CLINKER GRINDER-A JET PUMP INLET WATER HEADER VLV OPEN 15C. CG-C FORWARD RUNNING (GREEN)
16C. 2. 8K2 REVERSE POWER CONTACTOR FOR CLINKER GRINDER- S
9A. FEED GATE CG-A OPEN CG-C REVERSE RUNN ING (B LUE)
10A. 3 POS. AUTO MANUAL SELECTOR SW. FOR CG - A 17C. CG - C STOP (RED) 3. BK3 OVERLOAD RELAY FOR CLINKER GRINDER - S
1 1A. OPEN CLOSE SELECTOR SW. FOR SEAL LINE VLV CG - A 18C. 4. BKO POWER CONTACTOR FOR OLR BASE CLINKER GR INDER-S
RESET PUSH BUITON CG-C OVER CURRENT RELAY ( RED)
' 12A. OPEN CLOSE SELECTOR SW. FOR INLET WATER HEADER VLV CG-A 19C. 5. GMOLR GRINDER MOTOR OVER CURRENT RELAY FOR CG-8
FORWARD START PUSH BUITON CG-C (GREEN)
13A. OPEN CLOSE SELECTOR SW. FOR FEED GATE CG-A 20C. REVERSE START PUSH BUITON CG-C (BLUE) 6. GMCR GRINDER MOTOR CONTROL RELAY FOR CG- 8
14A. CG-A TRIP (AMBER) 21C . STOP PUSH BUITON CG-C (RED) 7. BR1 - BR AUX RELAY FOR CLINKER GRINDER-S
15A. CG-A FORWARD RUNNING (GREEN) 8. BK3X AUX RELAY FOR CLINKER GRINDER-S
L 16A. CG-A REVERSE RUNNING ( BLUE) CLINKER GR IN DER - D CLINKER GRINDER- C
17A. CG-A STOP (RED) 1. CK1 FORWARD POWER CONTACTOR FOR CLINKER GRINDER- C
18A. RESET PUSH BUITON CG-A OVER CURRENT RELAY (RED) 7D. CLINKER GRINDER-D SEAL LINE VLV OPEN 2. CK2 REVERSE POWER CONTACTOR FOR CLINKER GRINDER- C
19A. FORWARD START PUSH BUITON CG-A (GREEN) 8D. CLINKER GRINDER - D JET PUMP IN LET WATER HEADER VLV OPE N
3. CK3 OVERLOAD RElAY FOR CLINKER GRJNDER- C
20A. REVERSE START PUSH BUITON CG-A (BLUE) 9D. FEED GATE CG-D OPEN
4. CKO POWER CONTACTOR FOR OLR BASE CLINKER GRINDER-C
21A. STOP PUSH BUITON CG-A (RED) 10D. 3 POS. AUTO MANUAL SELECTOR SW. FOR CG - D
' 5. GMOLR GRINDER MOTOR OVER CURRENT RELAY FOR CG - C
11D. OPEN CLOSE SELECTOR SW. FOR SEAL LINE VLV CG-D
6. GMCR GRINDER ~OTOR CONTROL RELAY FOR CC- C
CLINKER GRINDER - B 12D. OPEN CLOSE SELECTOR SW. FOR INLET WATER HEADER VLV CG-D
13D. OPEN CLOSE SELECTOR SW. FOR FEED GATE CG - D 7. CR1 -CR AUX RELAY FOR CLINKER GRINDER- C
78. CLINKER GRINDER-S SEAL LINE VLV OPEN 8. CK3X AUX RElAY FOR CLINKER GRINDER- C
14D. CG-D TRIP (AMBER)
88. CLINKER GRINDER-S JET PU MP IN LET WATER HEADER VLV OPEN 15D. CG-D FORWARD RUNNING (GR EEN) CLINKER GRINDER-D
' 98. FEED GATE CG-B OPEN 1. DK1 FORWARD POWER CONTACTOR FOR CLINKER GRINDER- D
16D. CG - D REVERSE RUNNING ( BLUE)
108. 3 POS. AUTO MANUAL SELECTOR SW. FOR CG-B 17D. CG-D STOP (RED) 2. DK2 REVERSE POWER CONTACTOR FOR CLINKER GRINDER-0
118. OPEN CLOSE SELECTOR SW. FOR SEAL LINE VLV CG-B 18D. RESET PUSH BUITON CG - D OVER CURRENT RELAY ( RED ) 3. DK3 OVERLOAD RELAY FOR CLINKER GRINDER-D
128. OPEN CLOSE SELECTOR SW. FOR INLET WATER HEADER VLV CG -B 4. DKO POWER CONTACTOR FOR OLR BASE CLINKER GRINDER- 0
19D. FORWARD START PUSH BUITON CG-D ( GREEN)
138. OPEN CLOSE SELECTOR SW. FOR FEED GATE CG-B 5. GMOLR GRINDER MOTOR OVER CURRENT RELAY FOR CG-0
20D. REVERSE START PUSH BUITON CG-D (BLUE)
' 148. CG-B TRIP (AMB ER ) 6. GMCR GRINDER MOTOR CONTROL RELAY FOR CG-D
21D. STOP PUSH BUITON CG-D (RED)
158 . CG-B FORWARD RU NNING (G REE N) 7. DR1 - DR AUX RELAY FOR CLINKER GRINOER-0
168. CG-B REVERSE RUNNING (BLUE) 8. OK3X AUX RELAY FOR CLINKER GRlNOER- 0
178. CG-B STOP (R ED)
188. RESET PUSH BUITON CG- B OVER CURRE NT RELAY (RED)
198. FORWARD START PUSH BUITON CG -B (GREEN)
208. REVERSE START PUSH BUITON CG-B ( BLUE)
2 18. STOP PUSH BUITON CG-B ( RED)
K
PROJECT: RENOVATION & MODERNISATION OF 1 x 210MW. UNIT N0.6.
KORAOI TPS OF MAHARASTRA STATE
POWER GENERATION COMPANY LIMITED (MSPGCL)
MAHARASTRA STATE POWER GENERAnON COMPANY LIMITED (MSPGCL)
"'""" BHARAT HEAVY ELECTRICALS LTD
. II R&M PROJECT DIVISION , BHOPAL
~ I MELCO IN D IA PVT. L TD. I €Hit

~ PlOT N0.-4, SECTOR-27A
fARlDABAD- 121 003.
1111£ BOTIOM ASH HANDLING - LCP & WIRING
SCHEME
06 FOR REFERENCE & RECORDS ONLY IWAAI. J.SINGH PC.JOSH1 UISIII2.l.oB.18 Sl2! SCAJ.E ]BHEL DRG. NO. ]J-726-09-40-7 1..& 3-726-09..40.0721 R£116 NO.
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41 5V, 50HZ SUPPLY 41 5V, 50 HZ SUPPLY 415V, 50H Z SUPPLY 41 5V, 50HZ SUPPLY
AHP MCC 18F1 FROM AH P MCC 18F3 FROM AHP MCC 1F2 FROM AHP MCC 1F4
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G~ GMCR
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10 :.: GMCR J, o ! ~gR oJo " ..,. FWO~~~ER PWD
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GMCR Sl II 3 GM CR GMCR
~ :: GMCR REV s:! ~ O lti!V REV
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g
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... 3 REV GMCRT Sl 050 G MCRT
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~M i[; (\_M
0-..:::
CG- B CG - C CG - D PROJECT: I RENOVATION & MODERNISATION OF 1 x 210MW. UNIT N0.6,
7 .5KW KORADI TPS OF MAHARASTRA STATE
7.5KIV 7.5KW POW ER GENERATION COMPANY LIMITED (MSPGCL)
DID USDt MAHARASTRA STATE POWER GENERATION COMPANY UMITED (MSPGCL)
BHARAT HEAVY ELECTRICAlS LTD

R&M PROJECT DIVISION , BHOPAL
~ IM ELCO IN D IA PVT. LTO. ,

I ., ., 0 PLOT N0.- 4, SECTOR- 27A ~
• ._,.
111tC
fARIOABAD-121 1101
BOTIOM ASH HANDLING • LCP & W IRI NG
SCHEME
KAllAl I J.SI<GH IPC.JOSHli'ulSKI2J.D8.181 SIZE SCALE IBHO. DRG. NO. j .J --726-09~0-7 1 -&J-726-09-'0-07~ REVSMl.
06 I FOR REfERENCE & RECOROS ONLY
REV.NO.I DESCRIP TION I DRAWN I DESIGN I CHKO. I APPO I ll<TE I A3 NTS lwo..co oRG. t<()~ MtP!.-ts.ot -E-v-at e. MtPL- ts-ot -E-V-0'21 ~~~~-
16A,~:E
sP TO co A c ONTRo L cKT
~ ' Rl TO CG B CONTROL CKT
FROM TO CG C CONTROL CKT
CUSTOMER TO CG D CONTROL CKT
230 V AC
SOURCE TO PANEL LIGHT
@}--,N
: : - - - - - - - - -- 70 CG CONTROL CKT AND PANEL LIGHT
~ESET
A2 220V AC SUPPLY
~ Tll-b m -b
®
CDI ~I CDI @ @i ©I ®
SWPS (A) HPWHPS SPARE A MANUAL -.. AUTO
VALVE
:.~ ~ J~i~~~ VALVE FEED
GATE ~ AK l ARl \ AR2 AR4
OPEN SS OPEN SS OPEN SS TI2T (A)
(A) @) (Al @) (A) @)
TI OT Tl4T
~'" . @
?··.l® '"-·
AR2
As I A6 l A7 1 A8
A31 A3 A3 5l A36 A37
Ml A l2 Al3
~·~ REMOTE
EM-STOP
T3 TS
"1 T7 PB.
SEAL J ET PUMP
WAT ER WAT ER FEED GATE AR3
VALVE (A) HEADER (A) Al
A23
T4l<:l TX~VE (A) TS
A ll
®
AK I
@
z
~
"'0
"'
~ ~
@ @ @ ©I @ ij 0
!;; "'
AK3X ~
0 / L TRI P FWD REV OFF ~
(@ @lARS <BJJ AR6 <8JI AR7 <
" ~ @
"'"' OLR
BASE
(AKO )
N
N
CG - A
CONTROL WIRING DIAGRAM
PRO.£CT: RENOVATION & MODERNISATION OF 1 x 210MW. UNIT N0.6,

KORADI TPS OF MAHARASTRA STATE
MAHARASTRA STATE POWER GENERATION COMPANY LIMITED (MSPGCL}
""""' BHARAT HEAVY ELECTRICALS LTD
R&M PROJECT DIVISION • BHOPAL
MELCO IND IA PVT. LTD . I ~
PLOT N0.- 4, SECTOR- 27A
• ®
1TTt£o
FARlOABAll- 121 003.
BOTIO M ASH HAN DLIN G- LCP & W IRI NG
SCHEM E
06 IFOR Rm:RENCE & RECORDS ONLY
REV.NO.I D E SCR I P TI O N
6A,MCBSP r ___ - ----,
RESET
~~·~~~ 220V AC SUPPLY
CD
p \I GMCRT(S)
@I
~ Til$ Tl3$ @ BKl ©I ®i e
SWP$(8} HPWHPS SPARE
~~~: ~~~ GATE
'.AUTO BKl BK2 RBl \ BR2 BR4
OPEN SS OPEN SS OPEN SS ·-4:
(B)® IB)® IB)®
.~:.ut I@
\ BR2 BK2
B10
~BK3 B3 B4 BS B6 B7 B8
@
=l·:t ~j 'T T'"J 831 832 834 8351 836 837
B12 813
REMOTE
EM-STOP
T3S TSS T7 PB.
SEAL JET PUMP
WATER WATER FEED GATE BR3
VALVE HEADER B14
VALVE
T4~(B) T6& (B) T8'f::l(S)
Bll
®
8K1
®
@I BK3X
I BR3 BR4 BRS BR6 BR7 8K2
8 K ,@
@ @ 0/LTR!P @825 @830
Q31 I Q3 BRl
~~ ~~~~- ~ ~ BR2 Q3 @ @ Q3 :~ @
~ 'OLR
~ ~ ~ ~FWD ~REV ~OFF ~~ ~~ ~
BASE
I I I I I I I I I I I I I I I 1 (AKO)
I I N
N
CG - B
PRO..[CT: RENOVATION & MODERNISATION OF 1 x 210MW, UNIT N0.6,

KORAOI TPS OF MAHARASTRA STATE
00,... MAHARASTRA STATE POWER GENERATION COMPANY LIMITED (MSPGCL)
BHARAT HEAVY ELECTRICALS LTD

ifj R&M PROJECT DIVISION . BHOPAL
MELCO INDIA PVT. LTD. I ~
PLOT N0.-4, SECTDR- 27A
~ fARIDABIJ)-)21 003.
1111-" BOITOM ASH HANDLING - LCP & WIRING
SCHEM E
06 I FOR REFERENCE & RECORDS ONLY
REV.NO. DESCRIPTION
RESET
C2 220V AC SUPPLY
'CRl IS I I
<DI <DI Tll-b m-b '\ CR7 GMOLR(C) CR7 @ @ CKl
~~
w~"¢..~ J~~ ~~~~
~
SWPS HPWH"g SPARE C9 MANUAL
? '-, AUTO
IIGMCRT(C)~g 1 Ci6 6crJ®
~ Cl9
~ :J C27 \ CKl \ CK2
~ ©I ®I
\ CRl \ CR2
®I
\ CR4
VALVE VALVE OPEN SS TID (C) Tl2 I ) Tl4
OPEN SS OPEN SS (C)
(C) ® (C) ® 0 ©
-
\ CR2 @)~.~ ~VS C:R.s ® ~ CK2
~ CIO
l 1 1 1 1
~m " " co co c' " m I lm I ,----- -I ~ ''"'I " ' ' c"l c'< c'" "" c"
T3 TS T7
WATER WATER
-~ FEED GATE \~ I I c 14
VALVE HEADER {C)
T.~C)
- T¥~~~) T8~ I I II ®
Clll I CKl
©I
CK3X CR3 CR4 CRS ~ @ CR6 CR7
(@ (@ (@ (@ ~ ' 0 / L TRlP ~5 @ 'f FWO 'f REV 'fOFF T::; @
<BI I I I ~R~~R~ ~~~ ~30 T~ T~ ~
~OLR
BASE
I I I I I I I I I I I I I I I I I I @ (AKO)
I I N
00 N/ L N
CG - C
PROJECT: I RENOVATION & MODERNISATION OF i x 210MW. UNIT N0.6.

KORAO! TPS OF MAHARASTRA STATE
00 1IS1R: MAHARASTRA STATE POWER GENERAn ON COMPANY UMITED (MSPGCL)
BHARAT HEAVY ELECTRICAIS LTD

R&M PROJECT DIVISION , BHOPAL
MELCO INDIA PVT. LTO. I -=--""'
PLOT N0. - 4, stCTOR- 27A -=-w
•~
nnr,
fAR1D.I!Wl- 121 003.
BOTIOM ASH HAN DLING - LCP & WIRING
SCHEME
06 I FOR REfERENCE & RECORDS ONLY
REV.NO., DESCRIPT ION
6A,MCB SP RESET
~- r- -- -----
~~R
~ l • Tl T2,•Dt D'2 220V AC SUPPLY
'' '
L _ _EM.STOP
_ _____ J'
CD
I'GMCRT(D)
CDI T9~ Tll~ Tl3 ~ DR?
SE:AL CDI JET PUMP CDI DR? ® DKl ©I ®I @
FEED SWPS!D) H?WHPS SPARE
~GMOLR(O)
WAT ER WATER o MANUAL ·. AUTO
VALVE
GATE ;_oH~ @ 0 19 27 \ DKl \ DK2 \ DR l \ DR2 \ DR4
VALVE !
OPEN SS OPENSS
OPEN SS ~ 1I ~- ~
(D) ® (D) ® (0) ®
\ DR2
@ dDK2
r (· 1@ ~T"' 1 7 ~\~;~5 ~ I I
03 04 OS 06 07 08 0!01 ~ STOP
"'1 l ~~~~O) PB. J<. I;: V\U/1
~0~ I D31l 0321 0341 03:'1 0361 037
012 0 13
ns
SEAL
TSS
JET PUMP
TIS
T"'J I I I I
~REMr:rTE
EM-STOP
PB.
WATER WATER FEED GATE ) DR3

VALVE HEADER 01 4 1
(D) I I 02
T4~ (D) ¥~LVEID)
~1f
1f 011
DR3 DR4 DRS ~ DR6 @ DRZ

~DK3X I ~ DRl DR2 ~ ~ ~ ~ ~ ~ , 0/LTRIP ~25 ~30 r FWD r · EV rOFF r~ T::l @
I I T~
OLR
i~~~~ ~ ~ BA SE
I I I I I I I I I I I I I I I 1 ( AKO)
I I N
00 NIL N
CG - D
PROJECT: RENOVATION & MODERNISATION OF 1 x 2 10MW, UNIT N0.6.

POWER GENERATION COMPANY U MITED (MSPGCL)
001&> MAHARASTRA STATE POWER GENERATION COMPANY LIMITED (MSPGCL )
BHARAT HEAVY ELECTRICAlS LTD

II R&M PROJECT DIVISION . BHOPAL
MELCO IND IA PVT . LTD. [ .=....a>.
PLOT N0.- 4, SECTOR- 27A =:row
~ FARIDABA!l-121 003.
mu,
BOTTO M ASH HAN DLING - LCP & WI RI NG
SCHE M E
06 I FOR REFERENCE & RECORDS ONLY
RE.V.NO., D ES CRI P TION
XP XP XP XP
Rl BRl CRl
Al Bl Cl ______ ~ STOP Dl
A3 B3 C3 3
SEAL WATER EALWATER EALWATER D ~EAL WATER
N VALVE OPEN N VALVE OPEN N VALVE OPEN N VALVE OPEN
A4 B4 C4 D4
JET PUMP WATER JET PUMP WATER JET PUM P WATER ~JET PU MP WATER
N HEADER VALVE OPEN N HEADER VALVE OPEN N HEADER VALVE OPEN N HEADER VALVE OPEN
AS BS cs DS
FEED GATE OPEN FEED GATE OPEN FEED GATE OPEN ~ FEED GATE OPEN
N N N N
A2 B2 C2 D2
~ SWPS SWPS SWPS ~ SWPS
1:1
~~ A6 B6 C6 D6
::t
A2 B2 C2 D2
HPWPS HPWPS HPWPS 1-.!..!..j HPWPS
A7 B7 C7 D7
A2 B2 C2 D2
SPARE SPARE SPARE ~ SPARE
~'l A8 B8 C8 D8
A22 B22 C22 D22

J
3P IN SOCKET
SWITCH
A23
REMOTE
STOP B23
REMOTE
STOP C23
REMOTE
STOP D2 3
~~--; REMOT E
: STOP
A23 B23 C23
REMOTE REMOTE REMOTE D23 f-Ui~--: REMOTE
A24 __J _ ~ ~ ______ " FORD B24 FORD C24 FORD D 24 · FO RD
N1
PROJECT: I RENOVATION & MODERNISATION OF 1 x 210MW, UNIT N0.6,

00 USER; MAHARASTRA STATE PQINER GENERATION COMPANY LIMITED {MSPGCL)

II R&M PROJECT DIVISIO N , BHOPAL
MELCO INDIA PVT. LTO. I ~ ""'
PLOT N0. - 4. SECTOR- 27A -=-""'
~ fARlii.\SI!l-121 1103.
BOITOM ASH HANDLI NG- LCP & WIRIN G
- SCHE M E
06 I fOR REfERENCE & RECORDS ONLY
REV.NO .. DESCR I PTION
<
' ' ' " 6A,MCBSP
'
--
®----'!-6
ll OV AC SUPPLY F'ROM CUSTOMER SOURCE
'Rl N
34 42 12 37 44 14
\ R1 R2 \ R7 \ R1 \ R2 R7
@
HOOTER
COMMON FOR
35 43 13 36 45 15
BOTH
ANNUNClATOR)
-
I I I I I I I I I I I I
CG -1 SEAL CG- 1 JET CG- 1 CG- 2 SEAL CG- 2 JET CG- 2 POWER
SPARE SPARE SPARE SPARE
WATER PR PUM P PR T RIP/JAM MED WATE R PR PUMP PR TRIP/J AMM ED HOOTER
SUPPLY
LOW LOW LOW LOW
"
ANNUN CIATOR
CG- 3 SEAL CG- 1 JET CG- 1 CG- 4 SEAL CG- 4 JET CG- 4
SPARE SPARE SPARE
WATER PR PUMP PR TRI P/ JAM MED WATER PR PU MP PR TRIP/ JAMM ED TEST ACCEPT RESET
~
LOW LOW LOW LOW
I I I I I I I I I I I I
3
5 11
38 46 16 40 48 18 - 11
ASS ~ AS: ~ AS:S1~
j. R1 j_ R2 I R7 R1 /. R2 R7
2
~ Ql Q
39 47 17 41 49 19
PROJECl
. RENOVATION & MOOERNISAnON OF 1 x 210MW, UNIT N0.6.
POWER GENERATION COMPANY UMITED (MSPGCL)
00""" MAHARASTRA STATE POWER GENERATION COMPANY UMITEO (MSPGCLJ

II R&M PROJECT DIVISIO N , BHOPAL
MELCO IN DIA PVT. LT O. , ~

PLOT N0.- 4, SECTOR- 27A
.:- FArnllABAIH 2llllll.
BOTIO M ASH HANDLIN G - LCP & WIRING
- SCHE M E
FOR REFERENCE & RECORDS ONLY KAI<IL J.slNGH PC.KlSHI .IOSII13.0&18 saE SCAJ.! jBHEl DRG. NO. 13-72b-O'J-4Q-7 1·& 3-72b-09-.;o-o721 R(Vfs NO.
06
' REV NO.I D ESC R IPT I ON I DRAWN I OESQi I CHKO mot [)I,JE A3 NTS j ~.tELCO DRC. NO~Y.I?'...- ! S.OH;.~.Ol &l>9Pl.- 15--0L ·E-\'-<r- l ~rt~-
j
' ' ' ' ' '
j ,,
' ' ' "
I BILL OF MATE ~IAL
S. No. Item Description II Rating Cat tjllo. Qty Unit Make
1 TPMCB I 40A c4o 4 Nos L&T
2 SP MCB I 16A ci 6 1 No L&T
;
3 SP MCB 6A ' 6 No Schneider

C9
4 TP Power Contactor 2SA MNX2S 12 Nos L&T
Aux Contact block SA '
MNXA1 8 Nos L&T
s
;
6 Overload Relay 14-23A M~2 4 Nos L&T

7 Over Current Relay 230V AC - 4 Nos PIC
_, I
8 Grinder Motor Control Relay 230V AC 4 Nos PIC
' 9 Current Transformer I 60/S CL-SP20 - 12 Nos AE
10 Selector Switch II SA, 230V AC 61q27 4 Nos Sa lzer
I
11 Select or Switch i SA, 230V AC 61001 12 Nos Sa lzer
L
12 Push Button Green 22.SMM Dia I 230V AC 2A~3 4 Nos Teknic
13 Push Button Blue 22.SMM Dia 230V AC 2Af6 s Nos Teknic
14 Push Button Red 22.SMM Dia 230V AC 2AF4 8 Nos Teknic
1S Push Button Yellow 22.SMM Dia 230V AC 2Af8 1 Nos Teknic
F
16 Push Button Black 22.SMM Dia 230V AC 2A~2 1 Nos Teknic
17 Push Button Element NO 230V AC S:J. 11 Nos Teknic
18 Push Button Element NC 230V AC S? 8 Nos Teknic
; _,
19 Indicating Light Red 22.SMM Dia 230V AC 17 Nos Schneider(Telemecanique)
I
20 Indicating Light Green 22.SMM Dia 230V AC -j 4 No Schneider(Telemecanique)
21 Indicat ing Light Blue 22.SMM Dia 230V AC - 4 No Schneider(Telemecanique)
22 Indicating Light Amber 22.SMM Dia I 230V AC - 4 No Schneider(Telemecanique)
'
23 Relay Base I 230V AC RXZE:J!M2C 8 Nos Schneider
I
,...- 24 Aux Relay SA, 230V AC RXM2LB2P7 8 Nos Schneider
i
2S Relay Ba se I 230VAC RXZE ~M4C 32 Nos Schneider
26 Aux Relay I SA, 230V AC RXM2 4B4P7 32 Nos Schneider
I
r- 27 SPPR 41SV AC VSP !Dl 4 Nos Minilac

I
28 Anno unciator I 24 Window PAL-2Q53-I 1 No Pro co n
K PRQJECT:
- Phonix RENOVATION & MODERNISATION OF 1 x 210MW. UNIT N0.6.
29 Terminal Block 6sqmm 26 Nos KORADI TPS OF MAHARASTRA STATE
POW ER GENERATION COMPA NY LIMITED {MSPGCL)
I 98 Nos Phonix
30 Terminal Block I 2.S sqmm - 00""' MAHARASTRA STATE POWER G ENERA nON COMPANY LIMITED (MSPGCL)
I- I
1 Over Current Relay (Spare) i 230V AC - 1 Nos PIC BHARAT HEAVY ELECTRICALS LTD
. I R&M PROJECT DIVISION , BHOPAL
' 2 Grinder Motor Control Relay (Spare) 1 230V AC - 1 Nos PIC II
~ IM ELCO IN D IA PVT. LTD. I ~
~ PLOT N0.-4, SECTOR-2/ A
FARIDI.BAD-121 003.
r- TIT1.£ BOTIOM ASH HANDLING- LCP & WI RI NG
SCHEME
1WAA1. J.SINGH PC.JOSHl c..wtl23.08.18 SIZ[ I sc.+.I..E IBHEL DRG. NO. 13-726-09-40-71 -&.3-726-09-40-0721 REVS tl>.
06 FOR REFIRENCE & RECORDS ONLY
IREV.NOI DESCRIPTION I DRAWN J OESK;N I CHKO. APPO I !li.TE A.3 1 NTS I"'ELCO oRC. HO~ MIPL-1$-0I ·E.:.v-oJ & MJPI.-Js-oJ-E:-v-U'.!I io~tti·
0 0 1'1
-,
' ' "
= -= -=
MANUAL
PROTECTION
AND
INTERLOCKING
SYSTEM FOR
CLINKER
GRINDER
Me/co India Pvt. Ltd., PREPAREDBY: SANDEEPSHARMA

MANUAL
PROTECTION AND INTERLOCKING SYSTEM FOR CLINKER GRINDER
PROTEC TIVE INTERLOCKS/ANNUNC IATIO N/INDIC ATIO NS & CONTROLS
Interlocks
Sr. E quip me Annunciatio Controls Controlle
Ref. Drg. Indications
No. nt n Provided dForm
Permissive R unning
1 2 3 4 5 6 7 8 9
i) Forward
Continuous to run provided push
Starts provided I. Clinker grinder gland seal water pr. is adequate. button
i) Red Lamp (CGLC
i) Clinker grinder II. On auto mode of operation if -grinder
i) Grinder P)
gland seal water I. NM selector switch selected in Auto mode & drive rotate in forward · operating
pr. is adequate seal ii) Reverse
direction. in forward
water pr. push
I. Flow ii) Jet pump header 2. Grinder gets Jam & grinder stops. direction
low button
diagrams adequate (CGLCP) I
3. Over current relay sensed. (CGLCP (CGLC
BA pressure. ii) Green Bottom
Clinker ) I
4. Motor starts to run in reverse direction for a preset time. lamp- P) Ash
Grinder handling ii) Water
1 iii) Over current 5. stops Grinder & re-runs in forward direction after a further preset time. grinder Local
system. header iii) Stop
CG-A to relay not sensed stopped Control
6. The same sequence is repeated if grinder is again over loaded. pressure push
D 2. CG Block (bypassed (CGLCP) Panel
Low. button
logic during start). 7. However, if interval between two consecutive overload is less than a iii) Blue lamp
iii) Clinker (CGLC
diagram. preset time then grinder gets locked electrically and is to be re-started -grinder
iv) Overload is not Grinder P)
manually. running in
actuated. - Trip I
reverse iv) Auto-
III. ·On Manual mode of operation if. Jammed
v) Start com directions Manual
initiated I. Forward push button Pressed & drive rotate in forward direction. (CGLCP) selector
CGLCP) 2. Reverse push button Pressed & drive rotate in reverse direction. switch
(CGLC
3. Stop only after initiating the stop command through stop push button. P)
Me/co India Pvt Ltd., PREPARED BY: SANDEEP SHARMA
ISO: 9001:2008 Company CHECKEDBY: GAURA V SINGH

MANUAL
PROTECTION AND INTERLOCKING SYSTEM FOR CLINKER GRINDER
PROTECTIVE INTERLOCKS/ANNUNC IAT ION/INDICATIONS & CONTROLS
Interlocks
Sr. Equipme Annunciatio Controls Controlle
Ref. Drg. Indications
No. nt n Provided d Form
Permissive Running
1 2 3 4 5 6 7 8 9
i) Forward
Continuous to run provided push
Starts provided I. Clinker grinder gland seal water pr. is adequate. button
i) Red Lamp (CGLC
i) Clinker grinder II. On auto mode of operation if -grinder
i) Grinder P)
gland seal water l. AIM selector switch selected in Auto mode & drive rotate in forward operating
pr. is adequate seal ii) Reverse
direction. in forward
water pr. push
l. Flow ii) Jet pump header 2. Grinder gets Jam & grinder stops. direction
low button
diagrams adequate (CGLCP)
3. Over current relay sensed. (CGLCP (CGLC
BA pressure. ii) Green Bottom
Clinker 4. Motor starts to run in reverse direction for a preset time. ) P)
handling lamp - Ash
Grinder iii) Over current ii) Water
1 system. 5. stops Grinder & re-runs in forward direction after a further preset time. grinder iii) Stop Local
relay not sensed header
CG-A to stopped push Control
(bypassed 6. The same sequence is repeated if grinder is again over loaded. pressure
D 2. CG Block (CGLCP) button Panel
logic during start). 7. However, if interval between two consecutive overload is less than a Low.
iii) Blue lamp (CGLC
diagram. preset time then grinder gets locked electrically and is to be re-started iii) Clinker I
-grinder P)
iv) Overload is not manually. Grinder
running in
actuated. -Trip I iv) Auto -
III. On Manual mode of operation if. reverse
Jammed Manual
v) Start com directions
initiated l. Forward push button Pressed & drive rotate in forward direction. (CGLCP) selector
CGLCP) Reverse push button Pressed & drive rotate in reverse direction. switch
2.
(CGLC
3. Stop only after initiating the stop command through stop push button. P)
PREPARED BY: SANDEEP SHARMA

Melco India Pvt Ltd.,
CHECKEDBY: GAURA V SINGH
ISO: 9001:2008 Company
APPROVED BY: G.K.NAIR
Faridabad-121 003
MANUAL
MAINTENANCE
INSTRUCTIONS

- - -
MANUAL
BOTTOM ASH HOPPER

MANUAL
MAINTENANCE INSTRUCTIONS.
COMPONENT PART BOTTOM ASH HOPPER
Function: -
The Bottom Ash hopper is a storage receptacle, located at the bottom of the furnace, which
acts as a seal of the furnace and provides storage for the ash that issue from the furnace. It
not only provides storage but allows for the efficient periodic removal of the ash with a
minimum of effect on the operation of the furnace . In the maintained water level hopper,
the water serves to chill the hopper ash and prevent clinkering of the same.
Description: -
The Bottom ash hopper bottom is of double 'V' shaped self supported stepped construction.
Feed and flushing nozzles are provided for movement of ash towards ash feed gate, during
Bottom ash evacuation. Vertical wall and bottom portion have 230 mm thick Monolithic
refractory lining. The refractory lining protects the outer steel shell from the furnace heat
and resist the abrasive action of the ash. The water level in the hopper is maintained by the
sealed overflow seal box at a rate that will maintain the level and remain at a temperature
that will adequately chill the ash. The water will also serve to shield the refractory from the
furnace heat. Flushing nozzles and feed nozzles are also provided for complete effective
removal of collected ash through feed gate to the ash transport system. Poke doors are
provided to permit access to large clinkers that will not move by the action of gravity or
force of the water flow. Cylinder operated feed gates are provided for sealing the ash
hopper and to have a discharge port for the ash in to the transport system. Four (4) nos. feed
gates are provided in the hopper.
Maintenance: -
Periodic inspection of Bottom ash hopper to determine the extent of
maintenance during the outage.
A. Inspection of the hopper refractory
1. When the water level is down, look for broken, spoiled, and worn
refractory.
B. Replace or patch the damaged refractory.
1. Observe the accompanying refractory instruction.
C. The overflow water temperature must not exceed 60C.
D. Inspection of the flushing header.
1. When hopper water level is down, tum on the water supply and observe
the nozzle streams.
Each stream should be paralleled to the refractory and directed to the center outlet of the
hopper.
Me/co India Pvt. Ltd., PREPARED BY: SANDEEPSHARMA

ISO: 9001:2008 Company CHECKEDBY: GAURAV SINGH

OPERATION & MAINTENANCE -
-
- - -
MANUAL
Drawings:-
• G.A & Reinforcement Details of Bottom Ash Hopper Foundation
• 200 NB Inspection Window
• Flushing Header
• 200 NB Poke Door
• Over Flow Seal Box

N!
t
SECTION' B-B
_l '"'
150(TYP.) JOOO
i
i
i
-- --- - - - -- -- - --:----------------- --Ht+ir''-'"""""
!I
69Z _i892
NOTE:-
, _ .ILL [)I,()S(lt,.'S a: u:ro.s « ~ r.\!!1
& REFERENCE DRAWINGS:

1.~155e7_Rl(I.A'Itl.llrFDMIDI}
Z.CDO.AL.I.ItP.ANIDIOITti!Cw.cslA!ti'R!CJ'IIAlta
1 DOS-&4~'-2> t.A aoncu ~ Hlf>I'El!
' · 1-n54-~DSI!tto. 1 {l.=,owl of llo~toon .1$1 ~ 5!'1~ IW'Jii)
S. ~~7555'-~-Dl(loyoulo1tol6~0uo'.)
&
BHEL ORAWlNG NO., D1-726-1l9- 4D-D29-RO ·
DRAWINGS APPROVED CAT-A ON OAm~ OS/DJ/2DI5.
~lEST PO. NO.: 9648574 OA.TED 14.01.2015
&
VIEW-CC BHEL ORAWlNG _NOc D1-726- 09- 40- D29-Rl RENOVATION & MODERNISATION OF 1 x 210MW, UNIT N0.6.
AGANIEST PO. N0.,9668626 OATEO 22.02.2017 KORAOI TPS OF MAHARASTRA STATE
POVVER GENERATION COMPANY LIMITED (MSPGCL)
lAs BUILTI
-=
- -
-A
-
-~ ~
MANUAL
900MM X 600MM
INCLINED ASSEMBLY OF
FEED GATE HOUSING

O PERATION & MAINTENANCE - - -
- - -
MANUAL
MAINTENANCE INSTRUCTIONS
COMPONENT PART ASSY. 900MM X 600MM INCLINED FEED
GATE HOUSING
Functions:
The gate is a controlled port through which the material is passed from the storage hopper
into the conveying system.
Description
On the machined seats of doors & frame stainless steel wear plates are securely bolted.
These wear plates are ground and finally matched by hand scraping within close tolerances,
thus affecting the seal. It is mounted on rollers which permit case of travel and seating of
the gate. The rollers are mounted on eccentric shafts which permit adjustment of the gate
seal. A cylinder provides the power for operation of the gate.
Maintenance
Extensive operation of the gate generally leads to wear of the sealing points, as well as
gradual reduction in size of the gate rollers, resulting in excessive clearance between the
gate and frame with attendant increased leakage. The leakage can be corrected by re-
adjustment of the gate. The eccentricity between the roller axle centerline and the ro ller
centerline will permit clearance adjustment by rotation of the roller axle. Flats have been
provided on the axle for a wrench.
A. Adjustment of the Gate.
1. Close gate completely.
2. Adjust roller as fo llows.
a. Loosen set screws looking the roller axles.
b. Rotate all roller axles in the same direction as the roller will tum on closing
stroke of gate. This rotation of roller axles will push the gate, eliminating all
eliminating all clearance.
c. Match-mark all roller axles with roller supports as reference points for no
clearance.
d. Rotate all axles until match-marks are 1/8" Part
e. Tighten all set screws.
CAUTION: Set Screw must seat in the slots provided on eccentric shafts.
f. Try operating gate, If the gate is still locked, open match-mark gap 1/16" more.
Important: Tighten set screw
g. Repeat until gate moves . Hold all match gaps equal.

ISO: 9001:2008 Company CHECKEDBY : GAURAV SINGH

MANUAL
h. Operate gate Opposite side rollers should roll together. Adjust individual roller
to provide this condition.
1. Operate gate several times. This will provide minimum with gate movement.
J. Adjust the indicator to the corresponding gate position.
B. Gate Notes:
1. It is advisable to keep a set of door and door frame wear strips in stock for quick
replacement when worn.
C. Cylinder- For instructions please see Vendor's Brochure Section.
D. Lubrication:
The roller axles are fitted with 1/8" pressure lubrication fittings . A good grade of
calcium base or moisture resistant grease should be used weekly or bi- weekly as
conditions warrant.

.... -: ·~~ . "'J
"tl
,. .
VI EW - DD
L-~~?=t-~ SECTION-AA &,
OTHER PARAllrn:R:-
M/s. MAHARASHTRA PO'v\'ER GENERATION COMPANY ltd.
'"" """""'
1. I REQUIRED QUAlfi'm': 4 NOS. KORADI THERMAL POWER STATION·UNIT 6·1x210 MW
2. I lOCAtiON. BO'ITOK ASH 1m GATE ROUSING. BOTTOM ASH HANDLING SYSTEM OF
MAJN PlANT PACKAGE OF ENERGY EFACIENT RENOVATION_&
3. I APPilCAnON. TO Dtm.OP HrDROSI'A11C FORCE. MODERNAZATION (EE R&M ) OF KORAOI T?S Utm 6
4.1 PAllmNG. I.S PER APPRO'IEll PAINtiNG SCHEDULE/ QAP
VIEW '"-- · EE . 'fA.'tA CONSULTING ENGINEERS LIMITED
5.1 TEST I.S PER .IPPRO'Il!D QAP
8-'.NCAL.ORE
HOUSING. 6. ll!AKE llll.CO I!!D!A PVT. LTD.
SHARAT HEAVY ELECTRICALS LIMITED
UNIT: R&:M PROJECT DIVISION , BHO?AL
MELCO INDIA PVT. LTO.

REV. NO. I DATE REVI SI ON REVISED I CHECKED APPROVED
03.02.15 FOR APPROVAL ........ $.SHAllA C.KNMI:
27.02.15 EV. AS PER TEC COMI.-lENT 6846A-ME- VOT- 134 (RMSG) ........ S.BHAnA C.XNA!R
1
ATE : 23-02- 2015
3-726-09-40-037
MIPL-15-D 1-M-EQ-02
~ ....,_SI![ u
. ,
MANUAL
AIR WATER
CONVERTER TANK

,,
9EO""OT6Q-9U-£ ~ - 75
(3) - 13/16 DIA. HOLES
FOR 3/4" DIA. BOLTS
.;/, WATER FIL

CONN.(20 NB)
---p -r-----...,
~r ~I
I 0
"'"' ~r
I
®
--¥® - !k(!) I :
I
®
400 IO.D.
0 180 RAD. 100 SQ.x 10 THK. PLATE
"'"" TANK VIEW- 'A' - 'A'

I ASSY.NO.
I MAC50 - R MAC -50L
;: TANK SL.NO. QTY. DESCRIPTION PART NO.
"' --r--- I
0"'~10"'~I
1 1 RESERVIOR TANK AWC R AWC L
1 2 1 GAUGE GLASS 3 4"STD.
I
0 0 3 5 GATE VALVE 20 NB
0 I
~ I ;: 4 2 90 BEND 20 NB
I
I 5 1 REDUCING BUSHING 32 NBx20 NB
"'0 I 6 1 FLANGED NIPPEL 20 NB
"" I 7 1 PIPE PLUG 20 NB
I B 1 NIPPEL 2 0 NB
- 1[01.::1 I '..t 20 NB. WATER 1 REDUCING BUSHING 25 NBx20 NB
9
I SUPPY TO CYL. 10 1 REDUCING BUSHING DOUBLE-TAP 50 NBx25 NB
11 1 AIR DIFFUSER -
I PORT CONN.
50 DIA. 12 2 RUBBER GASKET 3THK.x4 1/2"0.Dxl "!.D
I I 13 B HEX. HEAD BOLT 5 B"B.S.Wx2"LG.
I I
DETAIL-B 14 B HEX. NUT 5/B"B.S.W.
15 B WASHER 5/B"DIA. B.S.W.
::;
"'
MATERIAL OF CONSTRUCTION:- 10mm.THK.MS .PLATE.
OTHER PARAMETER:-
~ I. REQUIRED QUANTITY. 4 NOS. (2Nos. L - H) (2Nos. R- H)

~
I ...I0
2. LOCATION. BOTTOM ASH FEED GATE HOUSING.
3. APPLICATION. TO DEVELOP HYDROSTATIC FORCE.
4 . PAINTING. AS PER APPROVED PAINTING SCHEDULE/QAP
5. TEST AS PER APPROVED QAP
6. MAKE MELCO INDIA PVT LTD,
------
JPP. HAND. AS SHOWN

~ "'~'-TANK ..........
o•--"""""'""""""'" ASSY. - MAC -50-R ASSY. MAL- :>U-L Mls. MAHARASHTRA POWER GENERATION COMPANY Ltd.
=..":'::'~=~ , KEY PLAN KORADI TH ERMAL POWER STATION-tJNIT6-1x210 MW
AIR WATER CONVERTER TAN cco...~-noWo:11i111:merfaldup ~
BOTTOM ASH HANDLING SYSTEM OF
MAIN PLANT PACKAGE OF ENERGY EFFICIENT RENOVATION &
co??==~~b l
-::M~~:J.:.'!!.~:l.i.-~<oll-21r'.5._, ~ MOOERNAZATION {EE R&M) OF KORA01 TPS UNTT 6
OE~fn.~~~~ ~ TATA CONSULTING ENGINEERS LIMITED

0"F'CotNCtOl1ghiilr:lfll>ed!!NI'I~IU j
tll~f>UfClM".rt:erU..-Id~Jtlw~. ; BANGALORE
03~~:ltlcA!Nt~meb [
=~~':~~ ] BHARA T HEAVY ELECTRICAL$ LIMITED
-~ : UNIT: R&M PROJECT DIVISION . BHOPAL
OH~I'IMIM*I.;vwtm:r
Cl~~~ MELCO INDIA PVT. LTD.

'"''""""'""""""- . . IREV.NOj DATE I REVISION REVISED !CHECKED PLOT N0. - 4, SECTOR- 27A. FAR!OASA0- 12100.3.
- 03.02.15 FOR APPROVAL KAIW. S.SHATIA G.K NAR

GEN. ARRGT. AIR WATER
CONVERTER TANK
~bt/..$.~.~~11l«i.t.~':..?:l!.~ f 3-726-09-40-036 I~
MIPL- 15-01 -M-EQ-01
18 ,U.. Sl:l[

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OPERATION & MAINTENANCE ::- .

MAHARASHTRA POWER GENERATION COMPANY

1 x 210 MW, UNIT #6

OPERATIONAL & MAINTENANCE MANUAL

BOTTOM ASH HANDLING SYSTEM

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

ISO: 9001:2008 Company CHECKED BY : GAURA V SINGH

Me/co India Pvt. Ltd., PREPARED BY : SANDEEP SHARMA

3) Operation Instruction of Clinker Grinder

4) LCP of Clinker Grinder & Jet Pump 12

5) Protection & Interlocking System for Clinker Grinder

1. Bottom Ash Hopper

2. Feed Gate Housing

3. Air W ater Converter Tank

Melco India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

ISO: 9001:2008 Company CHECKED BY : GAURA V SINGH

Faridabad- 121 003 APPROVED BY: G.K.NAIR

d. 86 Fluid Coupling Catalogue Manual

e. IO Gear Box Catalogue Manual

8. Sleeve Coupling Assembly

9. Cast iron Pipe

10. Pneumatic Cylinder

a. 2 Description & Instruction

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

b. 3-726-09-40-078 MIPL-15 -01 - 7 Data Sheet

13. Contactor & Thermal Overload Relay

14. Grinder Motor Controller

a. 2 Description & instruction

15. Over Current Relay

a. 2 Description & instruction

16. Pressure Switches

17. Solenoid Valve

18. Phase Failure Relay

19. Cable Schedule

MIPL-15-01 - Flow Diagram- Bottom Ash Handling

MIPL-15-01 - Layout Bottom Ash Handling System Unit

MIPL-15-01 - Water piping around B.A. Hopper area Unit

Me/co India Pvt. Ltd., PREPARED BY : SANDEEP SHARMA

Faridabad- 121 003 APPROVED BY: G.K.NAIR

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

Melco India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

1. CONTROL WRITE UP FOR ASH HANDLING SYSTEM

Melco India Pvt. Ltd., PREPAREDBY : SANDEEPSHARMA

ISO: 9001:2008 Company CHECKED BY : GAURAV SINGH

Faridabad- 121 003 APPROVED BY: G.K.NAIR

Me/co India Pvt. Ltd., PREPARED BY : SANDEEP SHARMA

CLINKER GRINDER OPERATION:

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

Me/co India Pvt. Ltd., PREPARED BY: SANDEEP SHARMA

LOCAL CONTROL PANEL:

Sr. No. L ist of Indication Lamp s L amp C olour

I. Clinker Grinder-A Forward Run Green Lamp

2. Clinker Grinder-A Reverse Run Blue Lamp

3. Clinker Grinder-A Stop Red Lamp

4. Clinker Grinder-A Trip Amber lamp

5. Clinker Grinder-B Forward Run Green Lamp

6. Clinker Grinder-B Reverse Run Blue Lamp

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