Part 2 - Sec 1.6.4 - 11 2010 K G RPT 2210 - Final

2x600 MW Long Phu 1 Technical Design Document
PART-2 : SECTION-1
1.6.4 : ASH HANDLING SYSTEM
(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc)
INDEX
CLAUSE NO. DESCRIPTION
1.00.00 INTRODUCTION
2.00.00 PLANT REQUIREMENT
3.00.00 DESIGN BASIS
4.00.00 DESCRIPTION OF ASH HANDLING SYSTEM
5.00.00 POLLUTION CONSIDERATIONS
6.00.00 CONTROL LOCATIONS, CONTROL PHILOSOPHY AND

OPERATIONAL REQUIREMENTS
7.00.00 NOTE ON PLANT CONFIGURATION
8.00.00 ELECTRICAL SYSTEM
9.00.00 INSTRUMENTATION AND CONTROL SYSTEM
ATTACHMENT-I SELECTION OF SYSTEM PARAMETERS
REFERENCE DRAWINGS
11/2010-K-M-DWG-2037 : SCHEME – DRY BOTTOM ASH HANDLING SYSTEM
11/2010-K-M-DWG-2038 : FLOW DIAGRAM – DRY FLY ASH SYSTEM, ESP TO

ISH
11/2010-K-M-DWG-2039 : FLOW DIAGRAM – DRY FLY ASH SYSTEM, ISH TO

SILO
11/2010-K-M-DWG-2040 : FLOW DIAGRAM – ARRANGEMENT FOR FLY ASH

SEGREGATION
11/2010-K-M-DWG-2041 : FLOW DIAGRAM – FLY ASH SILO AREA
11/2010-K-M-DWG-2042 : FLOW DIAGRAM - LEAN SLURRY & COMMON

SYSTEMS
11/2010-K-M-DWG-2043 : ASH CONVEYING SYSTEM
11/2010-K-M-DWG-2131 : LAYOUT AND SECTIONAL DETAILS OF ASH DYKE Rev-C
(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc)
1.00.00 INTRODUCTION
Two numbers Steam Generators (2x600 MW) of Thermal Power Plant at Soc
Trang, Vietnam shall fire pulverized coal imported from Indonesia/Australia.
The power plant shall operate at supercritical condition of steam. In the
Steam Generating Plant, ash will be collected mainly in three areas and have
to be removed by mechanized means. These areas are
a) Bottom ash in Clinker form, under Furnace.
b) Coarse ash in grit form, under Economizer.
c) Fly ash in powder form, under ESP and Air Preheater.
This report intends to establish the design philosophy of the Ash Handling
Plant covering collection, removal and disposal of all types of ash stated
above.
Enclosed Schematic Drawing illustrates the general concept of Ash Handling

and associated Systems.
Preliminary locations of various facilities of Ash Handling Plant as envisaged

have been indicated in the enclosed Plot Plan Drawing. The location shall be
finalized in course of time once the Ash handling system vendor is finalized.
Design philosophy, equipment sizing and facilities discussed in this section

cover Ash Handling System of two (2) 600 MW steam generating units to be
installed under Phase–I (Long Phu I). The equipment parameters as indicated
shall be fine-tuned during detail engineering.
2.00.00 PLANT REQUIREMENT
Following aspects have been given primary consideration in selecting the

plant:
a) Capability of handling entire ash produced in the two boilers during

MCR operation considering worst coal firing and with reasonable
margin.
b) Selection of system configurations with dry system.
c) Quality of effluent from the plant shall conform to prevailing norms of

Environment Pollution Control in Vietnam.
d) Efficient system with high reliability and redundancies and low

interaction and involvement of operator.
(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.4 : 1

3.00.00 DESIGN BASIS
3.01.00 Ash Collection Data
Following information are typical for a steam generator of 600 MW capacity in

regard to the ash collection in its various sections as furnished by boiler
manufacturers.
Input Data Basis of Quantity

Design (Te/Hour/unit)
Coal required per boiler Worst Coal 279.84

during MCR Operation. firing
Maximum Ash in Coal 15% 44.35

(INCL1%UNBURNT COAL)
Bottom Ash Collection 20% 8.87
(% of total ash)
Coarse Ash Collection in 5% 2.22

Economiser (% of total ash)
Fly Ash Collection in Air 10% 4.43

Pre heaters (% of total ash)
(Incl. duct hoppers, if any)
Fly Ash Collection in ESP 90% 40.0
and chimney (% of total ash)
Stack Ash (% of total ash) 0.5% 0.22
From the above information some overlapping may be noted in regards to the
total ash collection.
Design of the Ash Handling Plant shall, therefore, be carried out considering
following distribution rates (% of Total Ash):
a) Bottom Ash : 20%
b) Coarse Ash : 5%
c) Fly Ash : 100%
d) Stack Ash : 0.5%
It may be noted that both Bottom & Fly Ash Handling Systems and equipment
there of are independent of each other. Hence, even for higher collection of
ash in any collection point over the aforesaid figures, there shall be no
difficulty in removing it with the same equipment with longer duration of
operation only as long as the total ash generated by the plant remains within
design consideration.

3.02.00 Overall Concept
a) The total ash handling system consist of following:
1. Conveying of dry bottom ash & economizer coarse ash to

Stage-I intermediate bottom ash silo/hopper by mechanical
conveying.
2. Conveying of dry bottom ash & economizer coarse ash from

Stage-I intermediate bottom ash silo to remote BA storage silo Rev-C
by pneumatic pressure conveying.
3. Collection of fly ash from APH and ESP hoppers by pneumatic

vacuum conveying and deliver to Remote silo by pneumatic
pressure conveying
4. Fly ash and bottom ash barge loading arrangement
5. Lean slurry system below remote silos and water recovery

from ash pond area for recycling to plant area
b) Separate schemes for Bottom / Coarse Ash and that for Fly Ash
Handling have been envisaged. Accumulation of ash in stack hopper
being extremely nominal, only manual cleaning is envisaged and stack
hopper is not connected with the pneumatic system being envisaged
for other fly ash hoppers.
c) Operation of the Bottom Ash and Coarse ash Handling Plant for each
unit shall normally be continuous, whereas cleaning/removal of fly ash
shall be done periodically and sequentially.
Capacity of equipments for BA and Coarse ash shall be such that in

extreme condition ash will be evacuated in four (4) hours time, by
speed adjustment this will enable to accommodate any downtime for
maintenance.
d) Fly Ash of each boiler shall be evacuated by operating the plant six
hours in a shift including 10 minutes down times and purging time.
Capacity and equipment ratings have been decided accordingly.
e) Evacuation and transportation of Bottom & Coarse Ash shall be done

with dry metallic conveyor. From the boilers, ash duly cooled shall be
transported in dry form to nearby stage-I intermediate bottom ash silo.
Thereafter, ash will be transported to the terminal BA storage silo (by
pneumatic pressure conveying system) for onward disposal either by Rev-C
trucks / tankers, if necessary, by lean slurry disposal system to remote
ash pond area located adjacent to power plant area.
f) Fly ash shall be handled in dry form by pneumatic (vacuum-pressure

combination) system and stored in remote silos. If required for
merchandising fly ash, there will be separate coarse ash and fine ash Rev-C
silos. Fly ash from hoppers in ESP first field and second field (when
ESP first field will be out) shall be taken into a classifier system so that
fine ash present in the coarse ash shall be taken to fine ash silo and
coarse ash accumulates in the coarse ash silo. Fly ash from hoppers

in ESP third to last field and also second field in case first field is not
out and second field grain size is in acceptable range shall be taken
directly to fine ash silo. From the fine ash silo further removal of ash
shall be done in closed Trucks/browser. Both Coarse ash and fine ash
silo shall have arrangement of truck disposal as well as lean slurry
disposal system.
For Phase-I, one (1) remote Bottom ash silo, one (1) remote coarse
ash silo and one (1) fine ash silos have been envisaged.
EPC bidder will have the option to make an alternate proposal also
considering one number BA silo and one number FA silo without
Rev-C
classifier in FA system. A final decision on number of ash silo and
associated system will be taken subsequently.
g) Evacuation and transportation of both Bottom & Coarse ash shall be

based on two unit concept, i.e., Ash handling of two boiler units shall
be clubbed and shall have independent handling system up to
Intermediate silo.
h) Evacuation and transportation of both Fly ash & APH hopper ash shall
be two unit concept, i.e., Ash handling of two boiler units shall be
clubbed and shall have independent handling system.
Ash storage, slurry pumping and water supply system shall, however,
be common for all the units.
i) Single stage pneumatic (pressure) transportation of bottom ash from

intermediate bottom ash silo to the remote bottom ash storage silo
Rev-C
shall be used.
j) Both bottom ash and fly ash handling system normally being dry,
water requirement for the plant will be nominal except for ash
conditioning and delivering coarse fly ash/Bottom ash in lean slurry
form in emergency. Raw water shall be used as make up to the water
system. Clear water as necessary for equipment sealing shall be
tapped from station clarified water system. Sealing water for vacuum
pumps in fly ash system shall be taken through a settling unit and
clear water obtained shall be recirculated. Cooling water will be taken
from ACW system and will be returned to ACW return header.
k) Instrument air system and water supply system shall, also be common
for the two units.
l) Remote ash silos shall be located away from the main plant area up to
the extent possible keeping in view of maximum BA pneumatic Rev-C
pressure conveying distance possible.
m) Single stage pneumatic pressure transportation of fly ash from

intermediate surge hopper to the remote silos shall be used. Rev-C
n) Density of ash shall be taken as follows.
Density of Bottom Ash For volume 650 Kg/Cu.M

consideration
Density of Bottom Ash For load 1600 Kg/Cu.M
consideration
Density of Fly Ash for ESP/APH/ECON 750 Kg/Cu.M
hopper volume and hopper outlet area
computation as well as volume for
intermediate surge hopper/buffer hopper.
Density of Fly Ash for Silo volume 750 Kg/Cu.M
computation
Density of Fly Ash for strength 1600 Kg/Cu.M
computation
Concentration of Ash in slurry 25%
Note: Crusher and vibrating screen shall be suitably provided so
that BA/CA particle size can be reduced less than 4mm to
ease pneumatic conveying
4.00.00 DESCRIPTION OF THE ASH HANDLING SYSTEM
4.01.00 Bottom Ash System
4.01.01 From Bottom Ash Hopper to Intermediate Bottom Ash silo
a) The furnace bottom of each unit shall be provided with a refractory

lined dry type hopper collecting all bottom ash and leading to an
enclosed metallic conveyor installed below. The bottom ash hopper
shall have multiple hydraulically operated refractory lined gates at
bottom to isolate the hopper for carrying out maintenance in the
metallic conveyor. The main conveyor (primary carrying conveyor /
Extractor)* carrying side arrangement shall have adequate
permeability to allow air to pass for cooling the clinker ash. There
should be a suitable arrangement for scrapping below the main
conveyor and collect spillage from the top and deliver into main flow.
The conveyors are slow moving to allow cooling of ash during the
passage to discharge end. The conveyors are totally enclosed in a
casing with the enclosure having multiple openings with preferably
positively controlled dampers allowing air to pass through the bottom
of conveyor. The negative draft in furnace will cause atmospheric air
to enter into the conveyor enclosure through the controlled openings,
cool the ash, the resultant hot air entering the furnace. The unburnt
carbon in clinkers also completes the combustion with added oxygen
being supplied with the incoming air. Thus heat will be recovered
improving the efficiency of the boiler.
Alternative proven dry bottom ash handling system employing the

above operating principle with cooling air traveling along the surface of
the hot bottom ash on steel plate conveyor in counter flow direction
can also be considered.
2x100% primary crushers (with pre-crushers) will be provided after the

primary carrying conveyors for crushing clinker to a size (-) 20 mm
size. Primary crusher unit, as mentioned, shall be equipped with
(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.4 : 5 Rev-C

adequate system to prevent pollution during crushing. The primary

crusher shall discharge the partially cool clinkers into a secondary
cooler conveyor either common for both units or one for individual unit.
** The cooler conveyor will cool the clinkers to acceptable temperature
and discharge into intermediate bottom ash silo-Stage-I. Particle size
disposed to intermediate BA silo shall be around (-) 4 mm and
necessary crusher (namely secondary crusher) & vibrating screening
arrangement shall be provided at the discharge point of cooler
conveyor, (i.e. at the entry point of intermediate bottom ash silo) to
achieve the same. The temperature of bottom ash at entry to
intermediate bottom ash silo shall not be more than 65 deg C at worst
ambient temperature considering extreme boiler operating conditions.
At least 50% margin shall be provided in design capacity over rated

capacity of conveyor.
Note:
* The primary carrying conveyor will be placed offset with the

furnace centerline so that the impact of falling clinkers do not
come on to the moving conveyor directly.
** It shall ensure that there will be no imbalance in individual

furnace draft and shall provide necessary airlock if applicable.
Bidder may provide individual secondary cooler conveyor for each

unit.
b) The enclosures of the metallic conveyors carrying BA and Economizer

ash is connected with the flue gas system. The cooling of BA and
Economizer ash during its passage through enclosed metallic
conveyor is undertaken by atmospheric air entering into the enclosure
under negative draft. This nominal effect on flue gas system shall be
taken care by the boiler manufacturer during boiler design. Bidder
shall explicitly spell in their offer the interfacing points with boiler
design to ensure that boiler performance is not unduly affected due to
installation of the bottom ash handling system.
c) Each BA Hopper shall be sized for at least eight (8) hours storage
capacity. The bottom ash hopper shall have multiple bottom gates
operated by hydraulic power pack. The gates shall be adequately tight
shut off to enable maintenance of the conveyor with the boiler in
operation. The hopper is not envisaged to have any by pass to the
conveyor. However primary carrying conveyor / extractor mounted on
rails for removing the extractor away from furnace / hopper bottom
during maintenance may be provided. The supporting arrangement for
BA hopper shall be wide enough to enable such movement,
Bottom ash shall be cleared from each of the hopper as above

continuously. However the equipment capacity, motor power etc shall
be such that in emergency condition eight (8) hours BA & Coarse ash
generation can be cleared in four (4) hours with speed adjustment.
d) Capacity of each BA Primary carrying conveyor shall be 22.0 TPH dry

ash (approx.) maximum and 11.0 TPH continuous. Capacity of each

BA Secondary cooler conveyor, (if any common for two units) shall be
44 TPH dry ash (approx.) maximum and 22 T/Hr continuous and all
connected equipment like clinker grinder etc shall be suitable for this
load. For individual cooler conveyor capacity shall be matching with
primary conveyor/extractor and Eco ash carrying conveyor.
If Individual secondary cooler conveyor is used for each unit, capacity

will be selected on one unit basis. However this will be decided during
detail engineering stage.
Conveyors will be sized to clear the 8 Hrs accumulation of bottom ash

& Eco ash in 4 Hrs to accommodate maintenance downtime in case of
emergency.
Two boiler units shall have intermediate bottom ash silo of 2 Hrs
capacity (in 1st stage) (44 Ton common silo in case of common cooler Rev-C
conveyor or individual silo for each unit with 22.0 Ton capacity).
Intermediate BA silo shall be adequately sloped conical bottom design

with conical portion having stainless steel lining.
e) Bottom Ash pneumatic Pressure Conveying-
The Intermediate BA silo shall be suitably equipped with pressure

relief valve, access door, One (1) set of Vent Filter with all accessories
for venting within the stipulated limits of ash emission and one LT for
continuous level detection. Minimum 450 slope shall be maintained at
the bottom portion of the BA Int. Silo. No fluidization has been
envisaged.
The intermediate bottom ash silo- shall be connected with four no

(1W+1S/B for each unit) pressure conveying vessel which in turn will
discharge ash in two no (1W+1S/B) pressure conveying line (one Rev-C
working and one stand by line common for two units). Two number air
compressors (1W + 1 S/B), shall generate necessary pressurized air
for discharging the bottom ash into remote BA silo.
It is envisaged that in case of emergencies in bottom ash handling

system of a unit requiring evacuation of ash in 4 hours time (instead of
normal 8 hrs), the standby stream with a standby compressor shall be
put into operation along with normal stream simultaneously.
f) Remote BA storage Silo
Remote bottom ash silo, having storage capacity equivalent to forty

eight (48 Hrs) hours BA and Coarse ash generation for two boiler
units, shall have one dry (telescopic spout-rotary feeder arrangement)
as well as two moist unloading (by rotary un-loader/dust conditioner)
facilities. Each type unloading arrangement shall have unloading
capacity 150Te/Hr. Two openings shall be provided beneath BA Silo
for directing Bottom ash into slurry system and another opening shall
be kept blank for future use. For pneumatic conveying of bottom ash
from remote silo to barge loading silo there shall be provision below
remote silo for installation of suitable ash transporter vessels. BA silo
will be provided with pressure relief access door, vent filter, unloading

equipments, etc. One (1) set of Vent Filter with all accessories for
venting within the stipulated limits of ash emission. BA silo shall also
be equipped with the following:-
• Access door to provide entrance to silo interior for

maintenance or inspection.
• Level detection devices to indicate ash level.
• Relief valve to handle any unusual pressure surges in the silo
4.01.02 Coarse Ash System

(From Economiser Hoppers to Bottom Ash Hopper)
a) There shall be tentatively two (2) hoppers under the Economiser

section of each boiler. Each individual Economiser hopper shall be
provided with manual isolation valve, metallic expansion joint, ash
extractor delivering into air slides carrying the ash either to the primary
bottom ash conveyor or the ash cooler in a manner so that the furnace
draft and air flow in the conveyor/cooler is not disturbed. The metallic
seal shall be provided so that there is no infiltration of atmospheric air
into the Economiser.
b) The Economiser Coarse Ash system shall run continuously.
c) The Economiser Coarse ash shall be handled out of the BA hopper

through the BA hopper's secondary cooler conveyor and shall be led
to the Intermediate BA Silo.
4.02.00 Fly Ash System
Evacuation & transportation of Dry Fly ash shall be done in two stages, i.e.
from collection hoppers to the intermediate buffer hopper and from the buffer
hopper to remote storage silos. There shall also be a slurry disposal system,
taking feed from remote silos.
4.02.01 From Fly Ash Hoppers to Buffer Hopper
a) The fly ash removal from Air Heaters and Electrostatic Precipitators
shall be achieved in dry form by Vacuum Conveying System.
b) It is envisaged that there shall be total four (4) hoppers in

Air-Preheater and forty (40) hoppers in ESP of each boiler plant. Rev-C
Hoppers of Air Preheater shall be arranged in one row and those of
ESP in five fields. The number of hoppers and number of ESP fields
as mentioned are only tentative and shall be finalized as per OEM
standard during detail engineering.
c) One vacuum conveying stream is envisaged to emerge from each

unit. Each stream has a conveying capacity around 60 TPH so that
total ESP fly ash and air pre-heater hopper ash generated in eight (08)
hours shift can be carried within 6 Hours including purging & down
time.

There shall be identical three (3) sets (2 W / 1 S for two units) of liquid
ring Vacuum pumps for VCS located in ESP area/fly ash equipment
building. For each vacuum stream/unit one set shall be in operation.
The two vacuum streams will have interconnection upstream of the
ash separators so that ash from any unit can be directed to any of the
ash separator/vacuum pump unit.
d) The vacuum conveying line emanating from each unit shall have ash
separator (bag filter with buffer hopper). Each ash separator shall be
connected with a vacuum pump. There will be an additional vacuum
pump installed as a common standby for the two streams. In normal
case ash from each unit shall be evacuated independently in 6Hrs
every shift. However with the interconnection of vacuum streams ash
from both the units can be evacuated sequentially in a shift with the
help of a single ash separator cum bag filter.
f) Two sets of blowers (1 W +1 S) with discharge air heater shall be

provided per unit for ESP and Buffer Hopper fluidization.
g) Vacuum ash conveying lines of each unit will be connected to the two
(2) nos. ash separators (one no. of ash separator connected to each
stream). The top of the ash separator shall be provided with bag filter
and at bottom there shall be pair of air lock vessels engaged in cyclic
tandem operation. The dust separator will separate ash continuously
and the separated ash discharges freely into airlock vessels below.
The conveying air after discharging most of the ash will further pass
through a bag filter to be cleaned before escaping to the vacuum
pump. The bag filter clearing will be reverse pulse jet type. The air
required for the pulse jet will be taken from the Instrument Air
Compressor system.
h) There shall be two (2) sets of continuous dust separators combined

with bag filter to ensure clean air entry to Mechanical Vacuum
Exhauster for two unit. Ash holding Capacity of each combined filter Rev-C
separator (dust separators) and buffer hopper shall be 20Te (or 20
minutes collection of FA from one vacuum stream whichever is
higher).
i) Each buffer hopper shall have a venting system consisting of ducts

and valves connected to the ESP inlet.
4.02.02 From Buffer Hopper to Remote Storage Silo
a) The air lock vessels below each buffer hopper shall be connected with
Pressure Conveying Stream (PCS). There shall be two (2) (1W / 1S)
pressure conveying streams common for two units
The pressure conveying line shall connect to both silo (course or fine
ash) via ash classifier
Two , 100% capacity oil free screw compressors (1W+1 S/B) shall be
provided to supply conveying air to air lock vessels for pneumatic
pressure conveying of dry ash up to the remote silos.

The PCS shall convey the total Fly Ash from the buffer hopper to
remote storage silos, which will be tentatively located as shown in plot
plan, the conveying capacity for pressure conveying lines shall be
around 120 T/Hr.
b) There shall be one (1) no fine fly ash silos, one (1) no coarse FA silo
and one (1) bottom ash silos for two units. Each CA storage silo shall
have capacity to store 48 hours of corresponding ash. Fine fly ash
silos each shall be capable of storing 48 hours of fine fly ash. The
bottom ash silo shall have capacity to store bottom ash generated in
48 hours. Each silo will be provided with pressure relief access door,
vent filter, fluidizing pad (for fly ash silos), unloading equipments, etc.
Bottom ash storage silo is not expected to require any fluidizing
arrangement. The bottom of bottom ash silo shall be adequately
sloped (around 70 deg.) and lined with SS to ensure proper material
flow.
c) After classifier conveying stream carrying fine fly ash shall be taken to
fine ash silos under normal mode of operation. Under normal mode of
operation, conveying streams below classifier carrying coarse ash
shall be taken to coarse ash silo. There will be two (2) classifier units
(100% capacity each) installed above coarse ash silo (1 working +1
stand by). If coarse ash is passed through classifier then classifier will
separate ash particles larger than a specified particle size (normally
45-50 micron) which will accumulate in the coarse ash silo below. The
smaller particles shall be conveyed to the adjacent fine ash silo and
arrested in bag filter thereafter accumulating in fly ash silo below. Both
the pressure conveying headers (coarse and fine together) shall have
connection with both the fine ash silos & coarse ash silo to enable
storage of ash without segregating in emergency.
d) Dry FA transportation by trucks and barge is envisaged. There shall

be three (3) unloading points, (one in dry mode for closed tanker, one
moist unloading to open truck and one to a pneumatic transporter
vessel for further conveying the ash to barge loading unit).
The silo shall also be provided with one (1) opening dedicated for
slurry system and one connection will be left blank for future use.
e) Each coarse FA, fine fly ash and bottom ash silo shall be provided
with following:
i) Rotary Conditioners cum Unloaders (as indicated in the flow

diagram) for providing necessary water spray during loading of
Dry Ash in open Trucks at minimum 150 T/Hr discharge
capacity. Unloaders shall have metering cut off gate in
upstream connection to silo.
ii) Telescopic chute with scavenger fan (as indicated in the flow
diagram) also be provided at the bottom of the silo for
unloading ash into closed road tankers at minimum 150 T/Hr
discharge capacity. There shall be rotary feeder on ash
discharge line from silo.

iii) One outlet provided with manual valve and pneumatic isolation
valve for delivering ash to pneumatic ash transporter vessel.
iv) One (1) additional blanked discharge connections with

manually operated valves on each silo will be provided to
enable installation of additional unloading arrangement in
future.
v) Required number discharge connections with manually

operated valves and pneumatically operated valves on each
silo will be provided to enable feeding to slurry system.
vi) Silo fluidizing arrangement comprising three(3) twin lobe type

blowers (2W+1 common S/B) for two(2) FA silos (there will be
no fluidization in the bottom ash silo) and all related
accessories (like motors, air heaters, necessary piping and
valves). The capacity of the blower shall be decided in such a
manner that for full ash discharge of one silo, one (1) blower is
required for operation. The blowers and other accessories
related to silo shall be located within the silo complex / silo
utility building).
vii) Bottom ash silo shall have conical bottom provided with SS
liner.
viii) One (1) set of Vent Filter with all accessories for venting within
the stipulated limits of ash emission.
ix) Access door to provide entrance to silo interior for

maintenance or inspection.
x) Level detection devices to indicate ash level.
xi) Relief valve to handle any unusual pressure or vacuum surges

in the silo.
xii) All silos will be provided with at least 8.5 m clear head room
below the operating floor of silo (from bottom of beam to top of
road/grade).
EPC bidder will have the option to make an alternate proposal also
considering one number FA silo without classifier in FA system. A final
decision on number of ash silo and associated system will be taken Rev-C
subsequently.
4.02.03 Wet Disposal Mode (Emergency)
Slurry disposal system is envisaged for emergency situation when dry ash
unloading from silos through trucks / tankers is not possible.
Each of the fly ash and bottom ash silos shall have a wetting arrangement
called feeder ejector below silo where high pressure water will be
administered. The vacuum created within it will draw ash which will be mixed
with water in the combination tube at discharge to form slurry and discharge
in the collector tank (acting as a surge hopper) below. The slurry from the

collector tank shall be delivered to slurry sump either by gravity flow or with a
jet pump in case slurry sump is located distant.
Two chains of slurry pumps (one working) have been envisaged to convey
the ash slurry to ash dump area.
Ash disposal area will be located approximately 3 KM away from power block
area (considering the farthest slurry outlet on ash dyke). Rev-C
Single discharge pipe for each pump series with interconnection will be
routed up to the proposed ash dumping area. Provision of suitable discharge
spouts (adequate numbers) with slurry duty valves is considered.
Necessary water required for slurry system (HP & LP) shall be provided by
two (1W and one stand by) sets of HP & LP Water Pumps”. These pumps will
take their suction from a water sump near slurry system. Two nos. (1W +1
stand by) conditioning water pump shall also take its feed from this sump.
Make up Water input for the said sump will be from raw water and recyle
water.
Ash slurry will be disposed in the ash pond area. The head of slurry pump
shall be designed to enable discharge at furthest point in the dyke area up to
ultimate dyke height. Provision of additional pump stage shall be there to take
care of future expansion of ash pond/rise of dyke height
The slurry pond will gradually get filled up with deposited ash and provisions
shall be there to shift the slurry discharge point(s) from time to time such that
an efficient filling of the entire ash pond is ensured. Proper garlanding on the
ash dyke shall be made.
1W+1S/B Vertical, Centrifugal, single stage, semi-open (or open non-

clogging type) impeller type drain pumps shall be provided in slurry system
area. This drain pump will discharge the drain to slurry sump.
The arrangement of slurry system is shown in enclosed scheme drawing.
Ash Water Recovery system
Ash pond shall be provided with suitable collecting well which will collect
water from top surface of accumulated slurry. Suitable launders provided with
sluice gate shall guide the collected water to a stilling pond for precipitation of
ash carry-over. The stilling pond will be connected with RCC water recovery
sump through pipes and valves. Two nos recovery water pumps (one
working) shall deliver the water to a clarifier unit located near main plant.
Suitable chemical house having arrangement for chemical dosing shall be
provided for required treatment of the water. Water duly treated / clarified will
be taken to the ash water sump by gravity flow or by another pumping
arrangement if ash water sump can not be located adjacent.
4.02.04 Ash pond area : With lean slurry (assuming 1.1 T/CuM effective design
density) the selected area of 35 He for ash storage will be able to store cent
percent ash 2m height/year with 85% plf and 85% filling capacity. Thus with
10m height of ash dyke it will be able to store cent percent ash for 5 years.
The storing time will increase depending upon ash utilization in other

avenues. Proper ash management may enable rising ash dyke even further
which will increase the effective ash storage.
The layout and arrangement of the Ash Dyke is shown in attached dwg. No.
11/2010-K-M-DWG-2131. Rev-C
4.03.00 Barge loading of Ash
For transporting dry ash (both Bottom ash as well as fly ash) barge (upto
capacity 300 dwt ) shall be used and a dedicated berth shall be constructed
on Hau river adjacent to plant area. The ash silos (bottom ash as well as fly
ash) shall have a pneumatic ash transport vessel below the silo. In the ash
port an ash silo approximately 150 Ton capacity shall be erected on a jetty.
The silo shall have a bag filter on top which will be connected with ash Rev-C
transport line emanating from the ash transporter vessels at main plant silos.
Dry ash from main plant silos shall be pneumatically pressure conveyed to
the bag filter on jetty silo. Two numbers conveying air compressors (one
operating and one standby) shall be provided alongwith all accessories to
supply compressed air for transportation of ash to the jetty silo from plant
silos. The ash collected in bag filter shall be accumulated at silo which will Rev-C
have an extended boom screw conveyor for loading ash onto barge. The
discharge of screw conveyor shall pass through a cascading chute to enable
ash loading onto the barge in a dustless manner. The beam supporting the
discharge screw conveyor shall have flexibility in mounting for slewing and
luffing to enable maneuver loading ash on barge. Two such units each having
capacity to handle ash 150 T/Hr shall be installed with proper distance in
between so that both the units can simultaneously load the barge.
The barge loading units shall have provision for receiving ash from future
units also.
4.04.00 Common System
There shall be Common Water System and Common Compressed Air

System for Ash Handling System.
4.04.01 Common Water Supply System
a) Water Requirement For Ash Handling System (Both Bottom ash and
Fly ash system being dry type water requirement in normal operation
is envisaged to be very nominal.)
As mentioned earlier the total requirement of water in emergency

condition for BA and FA slurry for the Ash Handling System shall be
met from the following sources:
i) Raw water (desalinated)
ii) Clarified Water System of the station (for seal water

requirement).
iii) Auxiliary Cooling water System for supply of cooling Water
The raw water and the supply of water from clarified water will be the
net consumption of water. There shall also be extensive re-cycling of

water in the plant. Re-use of the sealing water for sealing duties and
re-use of miscellaneous drains for ash slurry make-up will be effected.
The plant shall be sized for the maximum drawal of water during
start-up and occasional surge operation.
b) Ash Water system
i) For lean slurry system which may operate in emergency,

recovery water system shall be operated to optimize overall
water consumption.
ii) Clarified water required for Ash Handling plant shall be tapped
from clarified water and discharged to a sump in vacuum pump
area for sealing pumps to take suction from this sump.
iii) There shall be two (2) number Seal Water pumps (one working
and one stand by for 2x600 MW units) for sealing of slurry
pumps, vacuum pumps, sealing of drain pumps and other
miscellaneous uses. The desalinated raw water will be
discharged to a sump provided in Silo area. HP, LP ash water
pumps will take suction from this sump. This sump will also
supply water for pumps spraying water to rotary ash
conditioners. These pumps will also supply water for
occasional floor washing.
c) Classification of Consumers within Ash Handling Plant
i) Following plant requirements in general shall be met from Ash

Water Sump:
o Water requirement for drain jetting for various drain pits

provided in silo area.
o Water required for Slurry System
o Spray water for rotary unloaders at silos
o Silo floor washing
o Water requirement for drain jetting provided in Vacuum
pump area.
The estimated ash water requirement for slurry disposal will be

400 CuM/Hr
ii) Clarified water shall be required for the following services in

general :
o Seal water for various pumps & mechanical exhausters

in the plant which require external clarified water for
sealing.
The estimated clarified water requirement will be 30CuM.Hr
iii) Cooling water will be required for cooling of compressors in fly

ash compressor building.

The estimated cooling water requirement will be 60 CuM/Hr
4.04.02 Compressed Air Supply System
The compressed air requirement (Instrument Air Quality) of the Ash Handling
Plant shall be met from the Screw type (non-lubricated) compressors installed
in the Ash Handling plant specifically for this purpose. The air shall be
required to operate pneumatically operated cylinders, diaphragms associated
with valves and gates of the plant.
2x100% duty compressors with all accessories and 2x100% duty refrigeration
type Air Drying Plants with all accessories shall be provided
4.04.03 Sump Pumps, Hoisting Equipment, Air Conditioning and Ventilation system
The same shall be provided, as required, in the plant. However the following
minimum requirement shall be fulfilled:
a) Vacuum pump House drain pump.
b) Silo Area drain pump (1W+1S/B).
Bottom Ash Hopper area of each unit shall be provided with two nos. drain
pumps and shall discharge into clarifier.
Semi EOT crane (hand operated LT, pendant operated CT and hoist) of
capacity 3.5 ton (approx) shall be provided for fly ash compressor building
(containing compressor, vacuum pumps etc.) and silo utility building.
Selection of crane capacity shall be guided by 110% of heaviest load to be
handled. Slurry pump house crane capacity shall be 5.0 ton (approx).
Monorail with chain pulley block shall be provided on top of silo.
Control room shall be air conditioned with window / package air conditioners.
Electrical room for MCC shall be pressurized ventilated
4.04.04 Some Important Features of Plant and Equipment
a) Material Selection
i) Material of construction of pipe and fittings
Materials for Pneumatic Ash Ash Slurry

Conveying Piping Conveying Piping &
up to buffer hopper pneumatic pressure
conveying pipe from
buffer hopper to silo.
Pipe (straight run) Cast iron M.S. ERW/ spirally
ANSI/AWWA C151 welded pipe of 9.52
AWWA manual mm thickness
M41 BS 1121 ASTM A53/ API 5L
Fittings (with Minimum 3D radius Alloy C.I. of min.
integral wear Ni hard/ chrome BHN 500 through
back) alloy C.I. of min. out metal thickness,

BHN 500 through having proven

out metal thickness, metallurgy MS fitting
having proven for the pipes at dyke
metallurgy. end
ii) Intermediate Surge Hopper / BA silo - Steel welded/RCC

construction;
iii) Remote Ash storage Silo – RCC construction.
iv) Capacity of Storage Silo-
a) Eff. Capacity of Coarse FA storage Silo - 2850 CuM.

(Considering 48hours storage)
b) Eff. Capacity of Fine FA storage silo - 2850 CuM (each)

(Considering 48 hours storage)
c) Eff. Capacity of Bottom ash storage silo - 1625 CuM.

(Considering 48 hours storage)
Note: FA collected in the 1st field ESP hoppers shall be considered

as coarse FA. Bidder shall consider coarse FA ash collection
around 80% of total ESP ash for the 1st field ESP hoppers.
Bidder shall consider transfer of around 70% of total coarse FA

collection to the Fine FA silo through the classifier. The classifier will
be selected accordingly.
iv) Vacuum pumps
a) Casing : CI, FG-260 as per IS-210

b) Rotor : SS-316
c) Shaft : Forged steel BS 970 type EN-8
d) Shaft sleeve : SS
e) Bearing : Steel
f) Base plate : MS
g) Gland : CI
b) Conveying Equipment
i) The type of Pressure Pneumatic Conveying Compressors shall

be selected by the manufacturer of the system consistent with
distance of conveying, material characteristic, tonnage rate
etc. The type shall be oil free screw compressor.
ii) Mechanical Exhausters for VCS shall be rotary positive

displacement type (water ring type).
c) Slurry pump, Vacuum pump seal water pumps, Clarified / Seal water
pumps, HP, LP Water Pumps, FA/BA dust conditioning water pumps

Description Ash medium slurry disposal HP, LP, Seal water,

pumps, and sludge pumps and and other horizontal
recovery water pumps water pumps
Type Horizontal, single stage Horizontal, single or
centrifugal type (all identical multi stage centrifugal
pumps shall be type (all identical
interchangeable) pumps shall be
interchangeable).
Horizontal split casing
for single stage and
multistage pumps.
Duty Continuous
Fluid to be Highly abrasive slurry. Pump Raw Water/Clarified
pumped shall be designed to handle
maximum ash lump size
expected at the outlet of
crusher
Parameters:- As per design guidelines contained in accompanying
Flow & Head specifications
Suction Flooded suction with suction lift of 2m
condition
Pump speed 1,000 rpm 1,500 rpm
(max.)
Impeller tip 1676 meters / min. (max.) As per mfgr. Std.
speed
Type of Variable speed Hydraulic Directly driven
coupling coupling with speed reduction through coupling.
by means of speed reduction
gear box in first stage. Speed
variation +10% - 45% with
respect to rated design point in
case of ash disposal pumps
For the subsequent stage
through belt drive.
Material of construction
Casing Outer casing shall be of cast steel Cast Iron to IS:210,
to ASTM-A216 or spheroidal Grade FG-260.
Graphite Ductile iron to ASTMA-
536, 65-45-12. Inner casing
(Volute liners) shall be of chrome
nickel cast iron (composition to Nl
hard-IV) of 550 BHN.
Or
24% chromium cast iron of 550
BHN.
BA overflow pump : CI FG 260(in
case single casing pump)

Impeller Chrome nickel cast iron Bronze Gr.I to

(composition to Nl-hard IV) of 550 IS:318/SS
BHN
Or
24% chromium cast iron of 550
BHN.
Wear - do- Bronze Gr.I to
plate/ IS:318/SS or
liners equivalent.
wear
rings
Shaft Carbon steel to AISI -1040 / EN-8 Carbon steel to AISI
K-1040 / EN-8
Shaft Hardened and ground stainless As per manufacturer
Sleeve steel (550-BHN) SS 410 BHN for standard.
BA overflow pump
Base Steel to IS:226 upto 20mm thickness and IS:2062 and over
plate 20mm thickness.
Drive 15% margin over and above the maximum load demand in
motor the entire operating range of pump at 50 Deg. C. 10% for
rating water pump with HT drives & 15% with LT drives.
Drive Not exceeding 1500 rpm
motor
peed
Note Reducer at suction side, if required, preferably be eccentric
type (for all application).
d) Velocity consideration for air, water and slurry line selection shall be
limited to
Velocity, M/Sec
Sl Pipe size Pipe sizes of
Service Pipe sizes of
No below 50 200 mm and
50 to 150 mm
mm above
a) Water pump
0.6-0.9 1.2-1.5 1.2-1.5
suction
b) Water pump
0.9-1.8 1.5-2.4 1.8-2.8
discharge
c) Compressed air
below 2kg/cm2 15-20 20-30 25-35
(g)
d) Compressed air
2 kg/cm2 (g) 20-30 25-40 35-45
and above
e) Min/Max Velocity in Ash Slurry lines (lean slurry) 1.8/2.8 m/sec
f)
Rev-C

e) Various tank capacities shall be ( the value of capacity in CuM shall be

ascertained during detail engineering based on pump capacity
finalized)
Seal Water sump : 30 min
Ash Water Sump in HCSD area : 60 min considering two HP,

LP water pump working
Drain sump : 10 min
f) For selection of operating parameters 5% margin on flow rate and 5%

margin on head as per design condition shall be taken for pumps,
compressors and blowers.
g) The slurry disposal system shall be designed based on the following:
Design concentration for

slurry (Dry ash % by
weight in slurry) : 25%.
Bottom & Fly ash generation

rate for two units : 50 t/hr
Slurry flow rate : To be selected based on

above, but not less than ash
conveying capacity
Route length of ash pipe line : 3Km (approx.) upto disposal

point) Rev-C
4.04.05 Plant levels
a) Grade level of CPP area : +3.15 m above MSL
b) Grade level of Ash Dump Area : +3.15m above MSL

(approx)
5.00.00 POLLUTION CONSIDERATIONS
5.01.00 Liquid Effluent
Under normal condition, there will be no liquid effluent as complete dry

disposal is being envisaged. The wet disposal, in the case of emergency, will
be effected by lean slurry method and recycling of recovery water will be
made on proper treatment to arrive acceptable quality.
5.02.00 Thermal Pollution
Since the system design is such, a large surface area (provided in the Ash
Dump) shall adequately cool the ash and the stipulation of thermal pollution
shall therefore be met.

5.03.00 Particulate Emission
At Dry Ash unloading point, special water spray dust suppression equipment
shall be provided. For all dust collection points, the system adopted for Ash
Handling shall be "Vacuum" system, which precludes any chance of
particulate emission. Besides, Vent filters, Air scrubbers shall be provided at
logistic locations to take care of pollution.
5.04.00 Noise Pollution
Depending on the Noise creating equipment type and performance data,

average evaluated sound pressure levels shall be within 85 dB (A) measured
at a distance of one (1) metre from the equipment "following" ISO-85 Noise
Rating Curve.
6.00.00 CONTROL LOCATIONS, CONTROL PHILOSOPHY AND OPERATIONAL

REQUIREMENTS
Control & Operation of Ash Handling Plants (AHP) including Slurry Disposal
systems shall be integrated in Station Control & Monitoring System (SCMS)
through VDU based Man Machine Interface (MMI) located in respective unit
AHP Control Room as well as in Central Control Room (CCR). All Electrical
System monitoring & operation shall also be achieved in SCMS.
Ash disposal system from Silos shall be operated manually from local.
7.00.00 NOTE ON PLANT CONFIGURATION
The adoption of slurry system is to take care of non availability of barge /

truck fleets for dispatching ash to consumers and clearing the ash to dump
area. As such these systems are essential in case adequate barge / trucks
are not available and ash utilisation to the tune of 100% is not ensured.
8.00.00 ELECTRICAL SYSTEM
8.01.00 Electrical Power Distribution
8.01.01 The Electrical Power Distribution System for the Ash handling plant (AHP)
has been envisaged at 3000V, 400V & 230V level to supply the drives & other
electrical equipment/systems. 220V DC power & 230V AC uninterrupted
supplies have also been envisaged for control and monitoring of the Ash
Handling Plant equipment/system. The voltage levels are selected and the
distribution network is designed to ensure smooth operation of the plant and
to maintain the operating parameters of various equipment/devices within
allowable limits.
8.01.02 Power supply to electrical equipment in AHP shall be provided from 3000V
switchgears located at AHP electrical room & slurry pump house. Each of
these switchgears shall be powered from 3000V station switchgears, in power
house, through duplicate (2x100%) supplies. 3000V switchgear shall feed
3000V motor loads and shall also act as power source to 400V loads through

3000/420V oil filled step down service transformers, located outside AHP
electrical room and slurry pump house. At 400V level the distribution shall be
through 400V PMCCs. They will be located at AHP electrical room and slurry
pump house and shall feed power to 400V motors, distribution boards, local
starter panels, distributed over the ash handling plant. 220V DC power shall
be made available at 220V DCDB (through duplicate supplies) located at AHP
electrical room and slurry pump house, for further distribution to various
loads. 230V AC uninterrupted supply required for control, monitoring of AHP
equipment shall be derived from UPS, located in AHP control room and slurry
pump area.
Power supply to remote Ash Pond area earmarked for Ash storage mound
having no major equipment drive will require nominal power for lighting and
occasional constructional activities and will be arranged through a separate
overhead line to be originated from main plant area and routed along
proposed ash pipe corridor.
8.01.03 For continuity of supply under various conditions of plant operation

redundancy in electrical equipment has been envisaged as follows.
a. Two (2) nos. incomers and bus coupler each rated to carry the entire
load of 3000 bus (2x100%) shall be provided for 3000V AHP
Switchgear.
b. In case of 400V system each 400V PMCC shall be provided with two
(2) incomers and a bus coupler. Power supply to the incomer
(2x100%) shall be derived from upstream LT service transformer rated
for 100 % load of the entire bus.
c. Provision of bus sectionalizer at each switchgear (3000V and 400V)

ensures availability of supply to drives and other loads even in the
case of bus fault on either section of bus bars.
d. Spare feeders of each type and rating shall be provided in 3000V and
400V PMCC / MCC / DBs for future use.
8.02.00 Codes and Standards
8.02.01 All electrical equipment and material shall generally be designed,

manufactured and tested in accordance with the latest applicable Publications
of International Electro-Technical Commission (IEC) and “Vietnam standard”
Publications.
8.02.02 The electrical installation shall meet the requirement of Vietnam Electricity
Rules as amended up to date. In addition, other rules and regulations
applicable to the work shall be followed.
8.03.00 Ambient Conditions
8.03.01 The equipment shall be installed in hot, humid and tropical atmosphere highly
polluted at places by coal dust / fly ash. Electrical equipment shall be capable
of continuous full load operation under the following conditions:

Average Grade Level at CPP Area +3.15 m above MSL

Design ambient air temperature for 50 ºC
electrical equipment
Humidity Maximum RH of 99 %
Basic wind speed 20 m/s up to 10 meter above MSL
as per
Seismicity
8.03.02 Where the equipment are to operate in the vicinity of high temperature zone
or installed outside and exposed to direct sun rays, suitable de-rating shall be
taken into consideration for higher ambient temperature and rigorous weather
conditions, as applicable.
8.04.00 System Parameters and Variations
8.04.01 System parameters for utility systems are detailed below.
Sl.
System Volt. & Frequency Fault Level Grounding
No.
a) 3000V ±10%, 3Ph, 3 wire, 50 Hz ±5% 40 KA (1 sec) Non effectively
earthed
b) 400V ±10%, 3Ph, 4 wire, 50 Hz ±5% 50 KA (1 sec) Solidly earthed
Combined voltage and frequency variation 10% (absolute sum)
c) 220V DC (-)15% to (+)10%, 2 wire 25 KA Unearthed
8.04.02 During starting of large equipment the voltage may drop by a maximum of
20% for a period of 60 seconds depending upon the driven equipment
characteristic. All electrical equipment, while running, shall successfully ride
over such period without affecting system performance.
8.05.00 Voltage Levels
Following voltage levels shall be adopted for power station auxiliaries:
No. of
Voltage
Energy network apparatus phases & Grounding
(V)
frequency
AC motors (rated above 160 3000V ± 10% 3 Ph, 50 Hz, Non effectively
KW) ±5% earthed
AC motors (rated up to and 400V ± 10% 3 Ph, 50 Hz, Solidly earthed
including 160 KW), power ±5%
receptacles and three phase
AC loads
DC Motors 220V (+) 10% 2 wire DC Unearthed
to (-) 15%
Control, indication & 220V (+) 10% 2 wire DC Unearthed
protection circuits of circuit to (-) 15%
breakers
Control & indication for 230V ± 10% 1 Ph, 50 Hz, Solidly earthed
contactor operated 400 V ±5%
motor feeders

No. of
Voltage
Energy network apparatus phases & Grounding
(V)
frequency
Space heaters rated up to 230V ± 10% 1 Ph, 50 Hz, Solidly earthed
and including 1200 watt ±5%.
Space heaters rated above 400V ± 10% 3 Ph, 50 Hz, Solidly earthed
1200 watt ±5%.
Panel interior lighting, 230V ± 10% 1 Ph, 50 Hz, Solidly earthed
receptacles and general ±5%.
power
8.06.00 Major Electrical Equipment
Sizing and selection of major electrical equipment e.g. motors, switchgears,

cables, grounding and lightning protection system, cabling system etc. shall
be as per information furnished in main electrical part of Technical Design
Document and the same may be referred for further details
9.00.00 INSTRUMENTATION AND CONTROL SYSTEM
9.01.00 The Instrumentation and Control System envisaged shall be complete in all
respect and adequate for safe, reliable, efficient and commercial operation of
the Ash handling Plants under normal and worst service and environmental
conditions specified.
9.02.00 The design of I & C system shall be such that isolation of any piece of
defective equipment would be possible without shutting down the main
equipment or disturbing the operation of associated instrument & accessories.
9.03.00 Field Instruments
a) All Field Instruments such as Transmitters (shall be Smart Type with

HART compatibility), Switches etc. shall be with minimum IP 65
protection class.
b) Normal Pressure Gauges bourdon tube and moving assembly shall be

stainless steel.
c) Ash Water line Pressure Gauges shall be provided with diaphragm

seal and pressure gauges on Pump discharge line shall be provided
with snubber.
d) All pressure Gauge and Pr. Transmitters Flow Transmitter shall be

installed with proper drain arrangement.
e) All the parameters shall be displayed and recorded in SI Units.
9.04.00 All instruments shall be compatible for hook up to Station Control &
Monitoring System (SCMS).
9.05.00 For further details refer Part-2, Section-3 of the Technical Design Document.
Rev-C

ATTACHMENT-I
SELECTION OF SYSTEM PARAMETERS
Quantity of coal consumption at BMCR = 279.84 T/Hr
Ash content of worst coal 15%
Unburnt carbon loss 1% (for ash handling plant design purpose)
Total ash generation Qash= Qcoal ((1-U%)XA%+U%)) = 44.35 T/Hr
Bottom Ash generation @20% = 8.87 T/Hr Economiser ash @5% = 2.22, Total 11.09
Bottom ash metallic conveyor capacity 11.0 T/Hr Continuous basis and 22.0 T/Hr maximum
to cater emergency
Capacity of pneumatic conveying stream of bottom ash with margin =25 T/Hr. In case of
emergency both the streams will run.
Generation of fly ash (ESP, Air heater/Duct) : 44.43 T/Hr /unit
Considering generation of ash for 8 Hrs/shift to be evacuated in 6 Hrs
Fly ash vacuum stream capacity 60 T/Hr
Capacity of pressure conveying stream connected with two units 120 T/Hr
Capacity of ash silo
Bottom Ash (48 Hrs storage) silo capacity one silo for two units.2X 48X11.0=1056 T
With BA density for volume consideration 0.65 T/CuM = 1625 CuM app
Fly Ash (48 Hrs storage) silo capacity two silo for two units, each 44.43X48=2132 Ton
With FA density for volume consideration 0.75 T/CuM = 2843CuM app 2850 CuM
Capacity of slurry system. Total ash generation form two units 88.7 T/Hr
Considering 8 Hrs ash generation to be cleaned in 6 Hrs , capacity 118 T/Hr = app 120 T/Hr
Ash pond area
Generation of ash from two boilers with 85% plf= 88.7X24X.85X365= 6604602 T per year
With effective density 1.1 T/CuM for ash volume 600418 CuM
With 85% utilization pond area available for ash storage 35X10000X.85=297500 SqM
Ash such with an elevation of ash pond dyke as 10m the area can accumulate total ash
generation of two units for five years.

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Part 2 - Sec 1.6.4 - 11 2010 K G RPT 2210 - Final

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2x600 MW Long Phu 1 Technical Design Document

1.6.4 : ASH HANDLING SYSTEM

CLAUSE NO. DESCRIPTION

2.00.00 PLANT REQUIREMENT

3.00.00 DESIGN BASIS

4.00.00 DESCRIPTION OF ASH HANDLING SYSTEM

5.00.00 POLLUTION CONSIDERATIONS

6.00.00 CONTROL LOCATIONS, CONTROL PHILOSOPHY AND

7.00.00 NOTE ON PLANT CONFIGURATION

8.00.00 ELECTRICAL SYSTEM

9.00.00 INSTRUMENTATION AND CONTROL SYSTEM

ATTACHMENT-I SELECTION OF SYSTEM PARAMETERS

11/2010-K-M-DWG-2037 : SCHEME – DRY BOTTOM ASH HANDLING SYSTEM

11/2010-K-M-DWG-2038 : FLOW DIAGRAM – DRY FLY ASH SYSTEM, ESP TO

11/2010-K-M-DWG-2039 : FLOW DIAGRAM – DRY FLY ASH SYSTEM, ISH TO

11/2010-K-M-DWG-2040 : FLOW DIAGRAM – ARRANGEMENT FOR FLY ASH

11/2010-K-M-DWG-2041 : FLOW DIAGRAM – FLY ASH SILO AREA

11/2010-K-M-DWG-2042 : FLOW DIAGRAM - LEAN SLURRY & COMMON

11/2010-K-M-DWG-2043 : ASH CONVEYING SYSTEM

11/2010-K-M-DWG-2131 : LAYOUT AND SECTIONAL DETAILS OF ASH DYKE Rev-C

a) Bottom ash in Clinker form, under Furnace.

b) Coarse ash in grit form, under Economizer.

c) Fly ash in powder form, under ESP and Air Preheater.

Enclosed Schematic Drawing illustrates the general concept of Ash Handling

Preliminary locations of various facilities of Ash Handling Plant as envisaged

Design philosophy, equipment sizing and facilities discussed in this section

2.00.00 PLANT REQUIREMENT

Following aspects have been given primary consideration in selecting the

a) Capability of handling entire ash produced in the two boilers during

b) Selection of system configurations with dry system.

c) Quality of effluent from the plant shall conform to prevailing norms of

d) Efficient system with high reliability and redundancies and low

(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.4 : 1

3.00.00 DESIGN BASIS

3.01.00 Ash Collection Data

Following information are typical for a steam generator of 600 MW capacity in

Input Data Basis of Quantity

Coal required per boiler Worst Coal 279.84

Maximum Ash in Coal 15% 44.35

Coarse Ash Collection in 5% 2.22

Fly Ash Collection in Air 10% 4.43

Stack Ash (% of total ash) 0.5% 0.22

a) Bottom Ash : 20%

c) Fly Ash : 100%

d) Stack Ash : 0.5%

(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.4 : 2

3.02.00 Overall Concept

a) The total ash handling system consist of following:

1. Conveying of dry bottom ash & economizer coarse ash to

2. Conveying of dry bottom ash & economizer coarse ash from

3. Collection of fly ash from APH and ESP hoppers by pneumatic

4. Fly ash and bottom ash barge loading arrangement

5. Lean slurry system below remote silos and water recovery

Capacity of equipments for BA and Coarse ash shall be such that in

e) Evacuation and transportation of Bottom & Coarse Ash shall be done

f) Fly ash shall be handled in dry form by pneumatic (vacuum-pressure

(Part-2_Sec-1.6.4_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.4 : 3