SECTION: D 1.

EXHIBIT A TECHNICAL SPECIFICATION

TITLE

ASH HANDLING SYSTEM

1.0

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SCOPE
The scope shall include complete ash handling system comprising
bottom ash handling system, fly ash handling system, bottom ash
storage silo, fly ash storage silo and equipment below silo. The ash
handling system and equipment to be supplied shall be as per the
system description and flow diagram enclosed. The ash handling
system shall be complete in all respects with all mechanical, civil,
structural, electrical and instrumentation.
The extent of supply under the contract includes all items shown in
the drawings, not with standing the fact that such items may have
been omitted from the specifications or schedules. Similarly the
extent of supply also includes all items mentioned in the
specification and / or schedule not with standing the fact that such
items may have been omitted in the drawings.

2.0

SYSTEM DESCRIPTION
Independent ash removal systems are proposed, one for bottom
ash( submerged scraper chain conveyor, clinker grinder and belt
conveyor system) and another for fly ash(pressure pneumatic
conveying system). The descriptions of ash handling systems are
furnished below:

2.1

Bottom ash handling system

2.1.1

( 2 x 77 MW Units )
( Refer flow diagram No. TCE.4084A-570-FD-1007 & plot plan
drawing No. TCE.4084A -100-GA-1001)
Bottom ash generated shall be collected in the dry type refractory
lined bottom ash hopper. Bottom ash from refractory lined ash
hopper shall be conveyed to the silo as shown in the flow diagram.
Bottom ash collected in the silo shall be loaded into the open trucks
through feeder for further disposal by others. Clinker
grinders( 1w+1s), belt conveyors from the outlet of clinker grinder to
the common conveyor shall be Unitwise.The conveyor to Bottom
Ash silo and the bottom ash silo are common for both the units.

2.1.2Fly ash handling system

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ASH HANDLING SYSTEM

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(Refer Flow Diagram No.TCE.4084A -570-FD-1009 & plot plan No.

TCE.4084A-100-GA-1001)
The fly ash collected at the air preheater hoppers, economiser
hoppers, ESP hoppers and stack hopper shall be gravity fed into
individual transmitter vessels provided below each hopper.
On
initiation of dry fly ash collection system, the inlet valve shall open
and allow the fly ash to be fed into the transmitter vessel for predetermined time after which the inlet valve shall close. Afterwards,
the compressed air shall be allowed to flow into the transmitter
vessel by opening the air inlet valve. Once the desired conveying
pressure is reached inside the vessel, the fly ash shall be conveyed
to the fly ash storage silo through transport piping. The conveying
air shall be vented through the bag filters mounted on top of the silo
in order to limit the dust concentration in the vented air below 100
mg. / N.cu.m. The hoppers if connected to a common conveying line
along the gas path, they shall be cleared one after another. The
clearance from any hopper shall continue cycle after cycle till ash in
the hopper reaches to low level. Removal of fly ash from any
particular hopper shall be initiated whenever the level of ash in that
hopper reaches predetermined level. This level is fixed in such a
way that the volume of ash collected will be adequate for conveying
in one cycle. Thus in this system, the fly ash hoppers are always
kept empty. Therefore the removal and conveying of fly ash to the
fly ash silo shall be done in cyclic manner on a continuous basis.
The dry fly ash collected in storage silo will be disposed into the
open trucks / closed container through conditioner / retractable
chute in dry form for further disposal to ash disposal area or for
utilisation in nearby cement plants by others. Fly ash silo and
disposal equipment are common for both the units.
Normally the fly ash conveying system shall operate continuously
but with time gaps between cycles. The vessel sizes are selected in
such a way as to get specified capacity. The fly ash removal
system shall be designed on a continuous basis with 20 cycles per
hour and during emergency with 40 cycles per hour (i.e., ash
collected in 8 hours time shall be evacuated in 4 hrs time). The
level probe shall be provided in each hopper in such a way that the
ash collected in the hopper shall be equal to the volume of the ash
transmitter vessel. This level probe shall initiate the ash evacuation
cycle from any hopper. The timer based operation shall back up in
case the level probe fails to initiate the ash evacuation cycle. There
shall be one manually operated isolating valve (knife gate type)

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ASH HANDLING SYSTEM

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below each fly ash hopper which shall be used during maintenance
of the ash transmitter vessel.
Three (3) reciprocating compressors, one standby,one operating for
two units during normal operation and two operating for both units
during rapid evacuation shall be provided to meet the conveying air
requirements of fly ash handling system of 2 x 77 MW Units .

2.3

Storage Silos and Disposal of ash from silos

2.3.1

Bottom ash storage silo

There shall be one bottom ash storage silo common for both the
Units. The silo shall be sized to store bottom ash generated in a
day from both the units- based on firing of imported (worst) coal.
Bottom ash collected in the silo shall be loaded into the open trucks
through feeder for further disposal by others.

2.3.2

Fly ash storage silo

There shall be one fly ash silo common for both the Units. The silo
shall be sized to store fly ash generated in a day from both the units
based on firing of imported ( worst) coal. Fly ash silo shall be
provided with two outlets. One outlet shall be used to load ash into
the open trucks ( open trucks by others) in conditioned form for
further disposal by others into the disposal area. For this purpose a
rotary feeder and ash conditioner shall be provided. The other
outlet shall be used to dispose ash in closed containers ( by others)
for utilisation. This outlet shall be provided with rotary feeder and a
motor operated retractable chute.

3.0

SYSTEM CAPACITY

3.1

Bottom Ash Handling System

3.1.1
The minimum rate of generation of bottom ash shall be considered
as 20 % of total ash generated from worst coal. The rated capacity of the
scraper conveyor for each unit shall be based on 150 % margin over bottom
ash generation rate based on Imported worst coal. Accordingly, the capacities
of clinker grinder and all belt conveyors shall be determined. Clinker grinder
and belt conveyors shall be common for both the units.

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3.1.2

The rated capacity of disposal equipment below the ash silo shall
be 30 TPH.

3.2

Fly Ash Handling System

3.2.1
The rate of generation of fly ash shall be considered as 90 % of total
ash generated from the Imported worst coal. Normally the fly ash
conveying system shall operate continuously with time gaps
between cycles. However, the capacity of fly ash handling system
shall be designed to clear the ash collected in 8 hours in about 4
hours time considering imported worst coal and Indian coal.
Accordingly all the equipment shall be sized.
3.2.2

The rated capacity of disposal equipment below fly ash silo shall be
30 TPH.

4.0

DESIGN & OTHER GENERAL REQUIREMENTS

4.1

Bulk Density of Ash

(a)

(b)

Bottom ash
(i)

For volume calculation

(ii)

For design of structural and support

: 1600 kg/cu.m

Fly ash
(i)

(ii)
4.2

800 kg/cu.m

For selection of pneumatic

handling system
kg/cu.m
Type of material
For design of structural and support

500-800

: Abrasive
:

1600 kg/cu.m

The pneumatic handling system for fly ash shall be of dense phase
and the velocity of air ash mixture shall not exceed 10 m/s.

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4.3

All the bends in the pneumatic handling system shall be provided

with wear back of either Ni-hard or stone box type.

4.4

High and low level probes shall be provided in each ash hopper for
measuring the evacuation rate during PG test.

4.5

In case vent valves are provided for the transmitter vessels this vent
connection shall be provided above the highest ash level in the
hopper.

4.6

The movements of the fly ash hoppers, due to the expansion shall
be considered and the Contractor shall include suitable expansion
joints as necessary in the fly ash pipe lines. The expansion joints
shall be of stainless steel construction.

4.7

The radius of 900 bends shall be minimum 5 times the pipe diameter.

4.8

Fluidising pads in fly ash silos, ESP hoppers and other vessels shall
be preferably of woven stainless steel and should withstand
temperature upto 170C.

4.9

Ash silos shall be provided with access ladder inside the silos and
external staircase from ground level to different platforms.

4.10

The material of construction of all parts of rotary feeder coming in

contact with ash shall be of alloy CI as per IS-4771 type 1a with
minimum hardness of 340 BHN.

4.11

The motor rating for all the equipment shall have a margin of 10%
over the BKW. The service factor for selection of gearboxes,
resilient couplings, flexible couplings, brakes etc., shall be 1.5
minimum on the motor rating.

4.12

The type of high speed coupling between motor and gear box shall
be as follows :
(a)

For motor rating upto 30 kW

: Resilient type

(b)

For LT motors of above 30 kW rating : Traction type

fluid coupling

4.13

The emission level at the outlet of the bag filter shall be limited to
100 mg / cu.m

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ASH HANDLING SYSTEM

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5.0

LAYOUT AND, MAINTENANCE REQUIREMENTS

5.1

Layout Requirements

5.1.1

The layout of ash water pumps shall be such that it shall be

possible to maintain any pumpset without disturbing the operating
pump set and also it should not be necessary to dismantle the
discharge piping for removing any water pump.

5.1.2

The layout of water piping for the ash handling system shall ensure
that all valves are located so as to be conveniently accessible. All
the water piping from the pump house to bottom ash hopper area,
scraper feeder, fly ash storage silo area shall be routed in the
overhead pipe rack only. In no case, the water pipes shall run in
the trench.

5.1.3

The piping shall have a minimum working clearance of 2.5m above

the walkways and working areas.

5.1.4

All piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves
and other piping accessories required for operation and
maintenance.
All pipe joints to be provided inside the ash water pump house shall
be flanged type with suitable gaskets.

5.1.5

5.1.6

A minimum clear head room of 5.50m shall be provided below ash

silo platform floor for the movement of trucks.

5.1.7

A minimum clearance of 7 m shall be provided below the pipe rack

at the road crossing. The minimum head room required at the rail
track crossings shall be as per Indian Railway requirements. The
contractor shall obtain approval from the concerned railway
authorities before taking up such works.

5.1.8

Access walkways in the pump house, control room, compressor

room, etc., shall be minimum 1000mm wide. Suitable hand railing
shall be provided for personnel safety, wherever required.

5.1.9

All local panels, distribution boards, lighting panels, junction boxes,

terminal boxes, marshalling boxes, push button stations, etc., shall
be located in accessible locations permitting maintenance.
Wherever rear access is required, minimum rear space for local
panels and distribution boards shall be 1000mm from the nearest
obstruction. Cabling shall be done clearing any interference
between collars, greasing points and dust collection. There shall be
minimum 2.2 metres headroom below runoff cable trays.

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5.1.10

Local control panels requiring operators attention shall not be

located in dust prone areas. Silo unloading panel shall be
locatedon the silo platform with suitable enclosure protection. Local
panels in each area shall be housed in a dust proof cabin to
minimise dust nuisance.

5.2

Maintenance Requirements

5.2.1

Facilities for carrying out online and off-line maintenance of ash

handling plant and auxiliaries shall be provided. In general, this
should include adequate handling equipment, working space,
platforms and safety devices.

5.2.2

One complete set of erection and maintenance tools required for

ash handling plant shall be included.

5.2.3

The Clinker grinders shall be mounted above ground level on rails

to enable easy removal/replacement.

5.2.4

Inspection windows shall be provided for bottom ash hopper. Water

jet connection shall be provided for each of the glass windows for
cleaning.

5.2.5

Maintenance platform of minimum one meter width with handrails

and access ladders shall be provided below hoppers of economiser,
air pre-heater and duct.
Segregating valves in each of the water lines at an easily accessible
location shall be provided for the lines going towards bottom ash
hopper area and to the equipment located below fly ash storage silo
for easy maintenance.
Instrumentation and Control (I&C) system

5.2.6

6.0
6.1

The I&C system shall consist of a microprocessor based 16/32 bit

programmable logic controller (PLC) system, operator cum
engineering consoles, local control panels, local instruments,
remote sensors, I&C cables and erection hardware. The PLC
system shall include cabinets, processor cards, I/O cards,
conditioning cards (if applicable), power supply modules and
associated hardware.

6.2

Operation philosophy
A microprocessor based PLC system with one (1) no. PC shall be
provided for the safe operation, control and monitoring of the entire
ash handling plant from the ash handling system control room. This
PC shall be used during start-up and commissioning. Suitable, RS
485 MODBUS links shall be provided to the main control room DCS

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ASH HANDLING SYSTEM

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for start / stop operation and monitoring of the plant during normal
operations. However, fly ash silo unloading system and bottom ash
silo unloading system shall be operated from the respective control
panel provided locally with the equipment / system with the
indication in the AHS control room and DCS.
6.3

Microprocessor based programmable logic control (PLC) system

6.3.1

The microprocessor based PLC shall be configured with hot backup redundancy for CPU,Power supply and communication ports for
PLC-DCS link. However, the IO cards, IO racks, rack power supply
shall be non-redundant. The system shall provide for sequencing of
automatic start-up / shutdown, bringing standby equipment into
operation on failure of main equipment and manual intervention
(auto / manual) facility for all the equipment from PLC. The PLC
shall be provided with one (1) no. operating cum programming
stations to perform operation and software changes. The input
/output modules shall be configured in non-redundant mode.

6.3.2

The operating consoles shall also be provided with CD read-write

device and floppy disk drive.

6.3.3

PLC based control system shall consist of measurement system (if

applicable), interlock, protection and sequential control system,
annunciation system and data bus system for control and
communication required for AHP. The operator interface includes
one (1) no. 21 color CRT with keyboard and one (1) no. medium
speed printer.

6.3.4

The latest versions of software, as applicable, shall be included..

The same shall include system software, application software to
meet all the specified requirements, serial link software etc.
Application software shall be built based on approved drawings.

6.4

One local control panel shall be provided for control of silo

unloading operation of ash silos. These shall be located near the
respective silos. These panels shall be of vertical column mounted
type. These panels shall incorporate all the control required for
intended operation of fly ash unloading system (both dry and wet
type), annunciation, indications, relays, and other hardware
required for protections / safety ash unloading system.

6.5

Specific I&C requirements

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ASH HANDLING SYSTEM

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6.5.1

Degree of protection for all field instruments, panels, local panels,

junction boxes shall be as follows: IP30 for indoor air-conditioned
and non-A/C ventilated areas, IP54 for indoor non-A/C non
ventilated areas and IP65 for outdoor areas.

6.5.2

All junction boxes, power supply distribution boards, marshalling

cabinets, instrument erection materials, interposing relays,
accessories and process hook-up hardware shall be supplied.

6.5.3

Standalone UPS of adequate capacity with one (1) hour battery

back-up shall be provided for the PLC and MMI equipment.

6.5.4

Individual pair shielded and overall shield twisted pair copper cables
shall be used for analog signals and overall shielded cables shall be
used for digital signals. Individual and overall screened triplex shall
be used for RTDs. All the cables shall be armoured. The wire size
shall be 0.5 sqmm and the color coding shall be as per IEC. The
insulation including overall sheath shall be FRLS quality.

6.5.5

The makes, model and technical features of all major instruments,

PLC etc. supplied by Contractor shall be subject to Owners
approval.

6.5.6

Local push button station with de-interlock switches shall be

provided for all equipment to enable maintenance of the equipment.

6.6

Any other control and instrumentation equipment not specifically

mentioned but required for the successful operation of the plant and
system shall be supplied as required.
DATA / DRAWINGS TO BE SUBMITTED

1.0
1.1

Water balance for ash handling system operation.

1.2

Technical data sheets of all equipment including characteristic curves

for pumps.

1.3

Flow diagram of the system indicating complete scope of equipment

pipe line sizes, instrumentation, valves and major parameters of the
equipment for bottom ash handling system, fly ash handling system and
ash disposal equipment.

1.4

General arrangement - Plans and Sections of the following subsystems:

(a)

Bottom ash handling system

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TITLE

ASH HANDLING SYSTEM

(b)
(c)
(d)
(e)
(f)
1.5

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10

Fly ash handling system

Fly ash silo unloading system & bottom ash silo unloading
system
Fluidising system for fly ash hoppers and silo
Pressurised ventilation system for MCC room
Ash water pumping system

General arrangement - Plan and Sections of the following structures:

(a)
(b)
(c)
(d)
(e)
(f)

Ash Water pump / Compressor room complex

Ash Handling System Control/MCC Room
Bottom Ash Hopper
Fly ash silo and bottom ash silo
Pipe racks
Control & Switchgear room layout.

1.6

QAP and PG test procedure.

1.7

Control and operation philosophy.

2.0

DATA / DRAWING TO BE SUBMITTED FOR INFORMATION /

RECORDS

2.1

Following piping arrangement drawings:

(a)
(b)
(c)
(d)

2.2

Fly ash piping layout from fly ash hoppers to fly ash silo.
Seal Water Piping
Compressed air piping
Water piping for fly ash collection system (to blower
and dust conditioner)

GA drawings for the following equipment :

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)

All pumps
Transmitter vessel
Fly ash valves
Pipe fittings
Dust conditioner
Rotary feeder
Clinker grinder
Blowers
Air Compressors
Fly ash collectors
Sump / drain pumps