ARAVALI POWER COMPANY PRIVATE LIMITED .

INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

STAGE-1,UNITS #1, 2 & 3 (3x500 MW)
ASH HANDLING SYSTEM

CONSULTANT- NTPC LIMITED

OPERATION & MAINTENANCE MANUAL

ASH HANDLING SYSTEM

NTPC DOCUMENT NO. 0330- 162- PVM- X- 001
DCIPS DOCUMENT NO. 28POI- 1A- Z- 102
REV - 01

VOL-I : SYSTEM OPERATION MANUAL

PLANT SUPPLIER
Digitally signed
Signature
DC INDUSTRIAL PLANT SERVICES PVT. Not
by N.Verified
LTD. K. GUPTA
Park Centre, 5th floor, 24 Park Street, Kolkata-700016 Date: 2018.01.15
16:58:53 IST
Phone: +91 33 2226-3672/7225/8233/8234/9173, Fax-+91 33 2249-5138
E- mail : mail@dcips.com ; dcipscal@cal.vsnl.net.in Reason: CAT I
Website : http://www.dcips.com Location:
NTPCEOC
 REV NO DATE DESCRIPTION PRPD. BY CHKD.BY
Revised as per NTPC Comments and Highlighted
1 5/12/2012 AC AC
REVISIONS in Blue Fonts

TITLE :
OPERATION & MAINTENANCE MANUAL

ARAVALI POWER COMPANY PRIVATE LIMITED

INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE - I, UNIT # 1,2&3(3 X 500 MW UNITS),
ASH HANDLING SYSTEM

DC INDUSTRIAL PLANT SERVICES PVT. LTD.

KOLKATA
PREPD. A. Chakraborty CHKD. AC DATE 05.12.2012
DEPT. HEAD Rana sengupta
DCIPS DOC. NO. 28P01-1A-Z-102 JOB NO. 28P01
NTPC DOC. NO. 0330-162-PVM- X - 001 COVER+ REV.NO. 01
 ARAVALI POWER COMPANY PRIVATE LIMITED
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-1, UNITS #1,2 & 3 ( 3X500 MW )
ASH HANDLING SYSTEM

OPERATION AND MAINTENANCE MANUAL

ASH HANDLING SYSTEM

OPERATION & MAINTENANCE MANUAL IS PRESENTED IN THE

FOLLOWING VOLUMES:

VOLUME DESCRIPTION

VOLUME - I SYSTEM OPERATION MANUAL

VOLUME – II - DRAWING STATUS

- LUBRICATION SCHEDULE
- LIST OF MANDATORY SPARES
- VALVE SCHEDULE
- EQUIPMENT SCHEDULE

VOLUME - III - MECHANICAL EQUIPMENT MANUAL

VOLUME – IV ELECTRICAL EQUIPMENT MANUAL

PLANT SUPPLIER  DC INDUSTRIAL PLANT SERVICES PVT. LTD.

 INDEX

VOL–1; SYSTEM OPERATION MANUAL

SECTION DESCRIPTION PAGE NO.

SECTION - 1 DESCRIPTION OF SYSTEM 1:1 To 1:51

SECTION - 2 SCHEDULE OF INSTRUMENTS COVER + 22

SECTION - 3 CONTROL WRITE-UP PLANT CONTROL

OPERATION & MONITORING

PART – A BOTTOM ASH AND COARSE ASH COVER + 31

HANDLING SYSTEM

PART – B FLY ASH EVACUATION SYSTEM COVER + 44

PART – C SILO UNLOADING SYSTEM COVER + 20

PART- D WATER & SLURRY PUMPING SYSTEM COVER + 26

SECTION - 4 TESTING AND ADJUSTING SYSTEM PRIOR 4:1 To 4:19

TO INTIAL HANDLING OF ASH

SECTION - 5 INSTRUCTION FOR SYSTEM OPERATION 5:1 To 5:11

SECTION - 6 ABNORMAL CONDITION IN ASH 6:1 To 6:16

HANDLING PLANT OPERATION

SECTION - 7 DCIPS EQUIPMENT SAFETY, OPERATION & 7:1 To 7:14

MAINTENANCE

SECTION - 8 DCIPS DRAWINGS / DOCUMENT 8.1 To 8:1

 ANNEXURE – 1

Ref :- NTPC DOCUMENT NO. 0330- 162- PVM- X- 001

DCIPS DOCUMENT NO. 28POI- 1A- Z- 102

SYSTEM OPERATION MANUAL

All the corrections are highlighted here in Blue Fonts. RESOLUTION - 01

SL. NO. NTPC Comments DCIPS Reply

Details comments given in rev 0 have Please note that only volume-1, System operation
1. neither been incorporated nor manual has been submitted completely, follow
clarified point wise Index of volume one.

Volume-1 consist of 8 sections (Section-1 to

Only Vol-1 has been submitted which
Section-8) Section-3 is control write up, which is
2. contains only reproduction of control
a part of O&M Manual, Please refer Index
write up, this is not an O&M manual.
Details.

Please incorporate the final operation

3. Available in section-I
Philosophy.

Please include all Equipment drawing

Will be submitted shortly through Volume-II &
4. ,Data Sheet, Catalogues, Maintenance
Volume-III.
manual etc.

Please check haphazard numbering of

5. Corrected in document.
clauses in page 19-23.

Please submit the hard copy of

document which shall be reviewed & Will be submitted after complete documentation
6.
signed by departmental heads in & soft copy checking.
DCIPS before Submission to NTPC
 SECTION - 1

DESCRIPTION OF MAJOR SYSTEM

 INDEX

SECTION - 1

SL. NO. DESCRIPTION PAGE NO.

1.00.00 INTRODUCTION 1:1

2.00.00 BOTTOM ASH HANDLING & COURSE ASH 1:2

SYSTEM

3.00.00 FLY ASH HANDLING 1:18

4.00.00 ASH SLURRY DISPOSAL SYSTEM 1:29

5.00.00 FLY ASH REMOVAL SYSTEM FROM STATION 1:34

SILO

6.00.00 HIGH CONCENTRATED SLURRY DISPOSAL 1:40

SYSTEM

7.00.00 INSTRUMENT AIR SYSTEM 1:41

8.00.00 GENERAL COMMENTS ON ASH CONVEYING 1:44

SYSTEM MAINTENANCE
 INDEX

SECTION - 1

SL. NO. DESCRIPTION PAGE NO.

4.00.00 ASH SLURRY DISPOSAL SYSTEM 1:29

4.01.00 CONTROL & OPERATION OF DRIVES / EQUIPMENTS 1:29

4.02.00 ASH SLURRY SUMP MAKE-UP VALVE 1:33

4.03.00 ASH SLURRY DRAIN PIT EJECTOR 1:33

5.00.00 FLY ASH REMOVAL SYSTEM FROM STATION SILO 1:34

5.01.00 The System 1:34

5.01.01 CONTROL DEVICES & LOCATION 1:35

5.02.00 SILO FLUIDISING BLOWER 1:35

5.03.00 SILO AREA DRAIN PUMPS 1:36

5.04.00 ROTARY FEEDER: 1:37

5.05.00 PNEUMATIC KGV ABOVE ROTARY FEEDER 1:37

5.06.00 CONDITIONING WATER PUMP 1:37

5.07.00 SILO WATER TANK MAKE-UP VALVE 1:38

WET (CONDITIONED) ASH UNLOADING
5.08.00 1:38

5.09.00 DRY ASH UNLOADING

1:39

6.00.00 HIGH CONCENTRATED SLURRY DISPOSAL 1:40

SYSTEM

6.01.00 HCSD SILO: 1:41

6.02.00 MIXING TANK 1:41

6.03.00 HCSD SILO FLUIDISING BLOWER 1:41

6.04.00 HCSD SILO AREA DRAIN PUMP 1:41

INDEX

SECTION -1

SL. NO. DESCRIPTION PAGE NO.

7.00.00 INSTRUMENT AIR SYSTEM 1:41

7.02.00 AIR DRYER SYSTEM 1:43

8.00.00 GENERAL COMMENTS ON ASH CONVEYING SYSTEM 1:44

MAINTENANCE
 INDEX

SECTION -1

SL. NO. DESCRIPTION PAGE NO.

4.06.00 ESP & BUFFER HOPPER FLUIDIZING BLOWER 1:35

4.07.00 ESP FLUIDIZING HEATER 1:35

4.08.00 VACUUM PUMP 1:36

4.09.00 WETTING HEAD, COLLECTOR TANK & AIR 1:37

WASHER

4.10.00 FLY ASH INTAKE VALVE 1:37

4.11.00 VACUUM BREAKER / VACUUM RELIEF VALVE 1:38

4.12.00 BRANCH HEADER VALVE 1:38

4.13.00 ASH TRANSMITTER 1:38

4.14.00 TRANSPORT AIR COMPRESSOR 1:39

4.15.00 FLY ASH SYSTEM OPERATION SEQUENCE 1:40

4.16.00 MANUAL MODE CLEANING OF STREAM 1:44

4.17.00 PRESSURE MODE AUTO SEQUENCE FOR A 1:46

STREAM
 INDEX

SECTION -1

SL. NO. DESCRIPTION PAGE NO.

4.00.00 FLY ASH HANDLING 1:27

4.01.01 FLY ASH VACUUM CONVEYING SYSTEM 1:28

4.02.00 WET MODE 1:28

4.02.01 WET MODE OPERATION 1:29

4.02.02 WET MODE STOP COMMAND 1:29

4.03.00 DRY MODE SELECTION STREAM 1:30

4.03.01 DRY MODE OPERATION 1:30

4.03.02 DRY MODE STOP COMMAND 1:31

4.04.00 ESP HOPPER FLUIDIZING SYSTEM 1:31

4.05.00 PRESSURE MODE OPERATION 1:32

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DESCRIPTION OF SYSTEM

1.00.00 INTRODUCTION:

Aravali Power Company Private Limited is a Joint Venture Company between NTPC
Ltd.,Haryana Power Generation Corporation Ltd. (HPGCL), and Indraprastha Power Generation
Co. Ltd.(IGPCL).

1.01.00 THE PROJECT:

The Joint Venture project, INDIRA GANDHI SUPER THERMAL POWER PROJECT-
JHAJJAR, Stage-1, Unit#1, #2 and #3 (3X500MW) is situated in Jhajjar district of Haryana
state, India.

Aravali Power Company awarded Ash Handling System Package contract to DCIPS.. The Ash
Handling Package is engineered, supplied and erected by M/s. DC Industrial Plant Services Pvt.
Ltd. (DCIPS), Kolkata.

The present document elaborates operation & maintenance features of Bottom Ash, Coarse Ash ,
Fly Ash Handling System and Ash water recovery system of Stage-1 (3X500 MW) Indira Gandhi
Super Thermal Power Project.

1.02.00 THE SYSTEM:

The Bottom Ash, Coarse Ash & Fly Ash Handling system of Unit #1, #2 and #3 are furnished
with necessary in-built facilities and devices for removal of ash, accumulated in various hoppers
& discharge them to a distant ash dump area out side of the power station.

The system is designed to clean bottom ash, in every eight (08) hrs. Interval (once in every shift)
by means of hydraulic jet pump for each unit.

Bottom Ash falls down into water impounded hopper, namely “Bottom Ash Hopper”. The ash
gets cooled & stored therein and is hydraulically removed with the help of jet pulsion pump in
slurry state from the BA hopper into in-plant combined ash slurry sump followed by further
transportation to a remote ash pond.

The Coarse Ash System is designed to clean the Coarse ash from economiser hopper. The Eco
Ash shall be continuously removed in bottom ash hopper and shall be cleaned along with bottom
ash cleaning operation for respective unit.

The Fly Ash System is designed to clean of ESP Hoppers (160 hoppers in each unit) & APH (8
hoppers in each unit) once in every eight (08) hrs.interval by means of Dry Mode ash removal
system. From Fly ash silo, ash can be collected in dry form into close tanker & in semi wet form
in open truck for ultimate end use. Alternatively, ash can be collected in High concentration
slurry disposal silo and after mixing with water is pumped by HCSD pump to slurry disposal
area.

The fly ash dry conveying system is divided in two parts, vacuum conveying system up to bag
filter with buffer hopper & pressure conveying system from nuvafeeder to silo.

In Vacuum Conveying System, Vacuum Pump generates sufficient vacuum to evacuate ash from
ESP Hoppers.

In pressure conveying system, screw type conveying compressor generates adequate pressure for

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conveying dry ash from Nuva feeder to silo.

The entire system is operated and monitored in controlled manner through PC base HMI & LVS
system. Detailed elaboration has been made elsewhere.

Water required to run the system (bottom, coarse) for sealing, flushing , are catered through LP,
HP, Eco water pump, seal water pump etc.

Necessary water pumping facilities are also included in the system to cater the water requirement
at various consumption points during system operation.

Necessary slurry pumping facilities are provided in the system for disposal of bottom ash, coarse
and fly ash from the in-plant combined ash slurry sump to distant ash pond by ash slurry
pumping system.

NOTE: The entire system is operated and monitored in controlled manner through PC based HMI &
LVS system. Detailed elaboration has been made elsewhere.

1.03.00 Ash handling System is mainly divided in six parts, viz, Bottom Ash and Coarse Ash system;
Fly Ash evacuating System; Slurry pumping System; and Silo unloading System; High
Concentrated slurry disposal system; Instrument air system.

2.00.00 BOTTOM ASH AND COARSE ASH HANDLING SYSTEM:

2.01.00 BOTTOM ASH :

2.01.01 Bottom Ash Hopper:

Water impounded, self-supported bottom ash hopper is installed directly beneath the furnace for
each unit. The bottom ash hopper has storage capacity of 554 Cu.m of dry ash. It is continuously
supplied with make-up water to cool the ash from furnace temperature down to a substantially
lower temperature permissible inside the hopper.

Seal trough is fitted on the top portion of bottom ash hopper. Seal plates are submerged all
around the BA. Hopper.

The water in the seal-trough is constantly maintained at a level, through continuous make-up
water supply into the trough, so that the seal plates always remain dipped into the water
(maintaining necessary clearance from trough bottom and side) to accommodate expansion to
achieve perfect sealing inside the boiler furnace against atmosphere.

The bottom ash hopper belongs to a W-type configuration with a common rectangular section at
the upper part and two integral “V” sections at lower part of the hopper.
 Each “V” section of the BA Hopper has sloping walls and is provided with two (02) bank of
jetting nozzles located at two different locations. There are six- (06) nos. upper banks of
jetting nozzles provided at the opposite wall of each “V” section.

 In the lower bank three-(03) nos. of jetting nozzles are provided at the opposite wall of each
“V” section.

 Two (02) nos. emergency door-jetting nozzles are provided at the opposite wall of each “V”
section.

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 One (01) no. Perforated dilution spray water line is provided with water connection for each
feed gate.

All nozzles in a particular group are energized at a time by operating the common group of
isolation valve (plug valve).

Each “V” section is furnished with two (02) sets of ash discharge equipment consisting of feed
gate, clinker crusher, feed sump, air water converter tank and jet pulsion pump.

Four (04) nos. slurry discharge lines from four (04) jet pulsion pumps of both “V” sections, go
to Bottom Ash slurry sump.

Out of the two-(02) sets of ash discharge equipment for each “V” section, one is normally utilized
for cleaning of ash and other set remain as stand-by.

2.01.02 Seal-trough make-up / flushing arrangement:

The make-up / flushing water to the seal trough flushing as stated earlier is supplied through pre-
determined numbers of nozzles strategically located inside the trough all along its periphery. LP
water source is normally utilised to cater to seal-trough make-up, water requirement. While
provision for water requirement of intermittent flushing is met from HP water supply, which is
normally in closed condition.

The seal-trough is provided with drain connections at the bottom with individual plug valve for
isolation, which are to be opened, as and when required for draining of seal-trough to over flow
weir box during boiler shut-down. The plug valves are strictly to remain closed as long as boiler
is in operation.

2.01.03 Refractory Cooling Arrangement:

The refractory cooling arrangement provided on top of the BA Hopper. Refractory cooling water
supply is from LP water header. LP water falls down continuously on top of refractory wall. The
ring header is having perforation, which sprays water and falls down on top of refractory.
Provision for water requirement of refractory flushing is met from HP water supply, which is
normally kept closed.

2.01.04 Overflow Weir Box:

Two (02) no. overflow weir box are provided for “W” shape BA hopper on upper rectangular
portion of one wall at the back side for each unit. Generally, water level inside the hopper is
maintained at certain level by means of globe valve in LP water line. However, in case level is up
for any operational reason the overflow water get drained through overflow weir box.

When the feed gates are kept closed BA hopper gets filled with water, the overflow water is
discharged to overflow weir box and seal-trough drain lines water is also discharged to overflow
weir box. The overflow water gets discharged to BA overflow transfer sump from where water is
pumped to Settling Bin by 2 nos. BA overflow water pumps.

2.01.05 Feed Gate:

There are total four (04) nos. feed gate for each unit

Two (02) nos. feed gates are mounted on each “V” shaped parallel wall on two opposite sides of

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BA. Hopper. There are four (04) nos. feed gates which are hydro-pneumatically operated by
means of Air-oil/water through an air oil/water converter tank (AOCT), and a 4-way solenoid
operated valve installed in the air line to each feed gate actuating cylinder. In each “V” section
one-gate is working and other remaining stand-by.

2.01.06 Ash Crusher:

There is one (01) no. Ash crusher (single roll) fitted below each feed gate of BA hopper. Total
four (04) nos. clinker crushers for each unit. Out of total four crushers two are working and other
two remains stand-by.

TYPE: The clinker crusher is heavy-duty single roll reversible type crusher, which is driven
by electric motor through fluid-coupling, reduction gearbox and chain sprocket
drive arrangement.

2.01.07 Feed Sump:

Feed sump is fitted below the clinker crusher and above the jet pump. Out of total four nos. feed
sump two (02) feed sumps are working and other remains as stand-by.

2.01.08 Jet Pump:

There is one (01) no. jet pump fitted below each feed sump of BA hopper. Total four (04) nos. jet
pump for each unit.

Four (04) nos. individual discharge lines from jet pulsion pumps in each unit flow to Bottom Ash
slurry sump. The jet pulsion pump is hydraulically operated with HP ash water supply at inlet of
jet pulsion pump and conveys bottom ash in the form the slurry to the in-plant common slurry
sump.

2.01.09 Air Oil / Water Converter Tank:

The Air oil / water converter tank is fitted near feed gate area of BA hopper. Each feed gate has
one Air oil / water converter tank for the smooth operation of feed gate. There are total four (04)
nos. Air oil / water converter tank for each unit.
A valve station comprising two nos. valves and non return valves are provided on air line from
each AOCT to the corresponding actuating cylinder for achieving desired speed of gate opening
or closing. The AOCT is having a gauge glass for indication of water level in the tank. An
external position indicator with scale is also provided on the feed gate to indicate the extent of
opening or closing of feed gate.

2.01.10 BA Slurry Conveying Line:

Outlets of jet pulsing pumps are connected with BA slurry conveying lines. HP water along with
bottom ash passes through slurry conveying line and slurry is discharged to common trough of
combined ash slurry sump. Ultimately, slurry is discharged to ash pond via ash slurry pumping
system.

2.02.00 BA SYSTEM START UP;

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Before starting the furnace, the hopper is filled with water at a level to allow just overflow from
the hopper. The water required for such initial filling is supplied normally from LP through
adequately sized make-up connection provided on the hopper wall. During feeding of ash into the
hopper, an adequate quantity of make-up water supply is maintained for effective cooling of
hopper content. The hopper water level is thus maintained constant at the overflow level, to
maintain maximum possible ash level in the hopper, all along the boiler operation.

To restrict air ingress inside furnace generally seal-trough remains full of water. For filling /
draining / flushing there is arrangement with proper isolation plug valves. These are to be
operated as and when required. The seal-trough make-up valve to be kept open during operation
of boiler to ensure certain amount of overflow. However, “plug valves on drain line are strictly
kept closed as long as boiler is in operation.” During boiler shutdown seal-trough to be cleaned
thoroughly.

The make-up water to the seal trough as stated earlier is supplied through pre-determined nos. of
nozzles strategically located inside the trough all along its periphery. The low-pressure ash water
source is normally utilized to cater to the requirement of seal trough make-up water and
intermittent flushing.

2.02.01 BA Cleaning process:

Bottom ash cleaning is conducted from local panel designated as “Bottom Ash local operator
console” (BALOC), located near respective Bottom Ash Hopper. The BALOC is facilitated with
necessary actuators, indications related to operation of bottom ash handling system. However,
actuation of LP & HP is done through Purchaser’s HMI.

The selected ash discharge equipment along with the bottom ash conveying lines for the each “V”
section are identical and work simultaneously under normal mode of ash cleaning operation for
each unit.

During initial period of ash cleaning operation, jetting nozzles need not be operated, These are to
be operated before the end of bottom ash cleaning. If there is any accumulation of ash on the
sidewalls is observed, through sight glass then the sidewall Jetting nozzles are to be operated. A
detail of jetting nozzles operation is given in chapter 2.02.05.

The overflow water from bottom ash hopper is continuously discharged into the overflow weir
box, which maintains required water seal between the hopper and atmosphere.

The water from weir box transferred to BA overflow transfer sump. The refractory cooling water
supplied to weir plate arrangement and cooling header drain line is connected into the overflow
weir box. The overflow water from seal trough is also led into the bottom ash overflow weir box
and transferred to BA overflow transfer sump, through piping header.

2.02.02 Jetting Nozzle Operation:

During initial period of ash cleaning operation, these jetting nozzles need not to be operated.
When major quantity of ash stored inside the hopper is already cleaned, the above slop jetting
nozzles are to be operated in the following sequence, however they can also be operated
individually suiting specifies requirement.

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 The six (06) nozzles of two sets at upper bank of slope nozzles on one wall for one “V”
section is charged for about 2-3 minutes followed by operation of three (03) nozzles of two
sets of lower bank and other two (02) bank of two sets for emergency door nozzles on the
same wall for about 2-3 minutes.

 Similarly, upper / lower bank of slope nozzles on the opposite walls of same “V” section are
there after charged in the above sequentially.

 The slop nozzles on the walls of other “V” section are substantially energized in the same
sequence, i.e. first the upper bank of nozzles and then the lower bank of nozzles.

Hence, it is clear that for sloping walls for bottom ash hopper, only one bank of nozzles on one
wall is to be activated at a time and slop nozzles on other walls (especially the opposite wall of
same “V” section) are to be kept off. The charging periods of slop nozzles as indicated above.
However, subject to adjustment to suit exact system requirement.

NOTE: Please refer the Single Line flow Diagram, DCIPS Dwg. # 25P04–M –1D-101

2.03.00 THE PUMPS ASSOCIATED WITH BA CLEANING:

The operational features of the following pumps will be discussed in this section:

 LP Water Pumps
 HP Water Pumps
 Eco Water pumps
 Seal Water Pumps
 Ash Water Make-up pumps
 BA Overflow Transfer Pumps

2.03.01 LP WATER PUMPS :

There are five (05) nos .BALP water Pump common for three units. Three pumps working and
other two remains as stand-by

LP water Pumps take suction from ash water sump through individual isolation valve connected
to each LP water pump suction header. LP water pumps are located at the common “Ash Water
Pump House” .

The discharge of all five-(05) nos. LP water Pumps connected to a common LP water header
through individual isolation valve and non-return valve. The discharge header is divided into
various branches and sub-branches as per the single line flow diagram to cater to water
requirement as stated above.

Each LP water pumps driven by electric motor. The LP water system is operated from
purchaser’s HMI . The LP water system is provided with all piping, valves and instruments as
necessary for system operation.

The LP water pumps cater to water at the following areas for two units:

 Bottom ash hopper filling / make-up.

 Seal trough make- up for refractory cooling.
 Make-up water to ash slurry sump compartments.

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 Make-up water to bottom ash overflow.
 Make-up water to fly ash drain sumps ( if required ).
 Suction of ECO water pump.

Selector & Actuator

SELECTOR : Auto standby – A / Auto standby – B / Auto standby – C / Auto
standby – D / Auto standby – E / Manual (For BALP Pumps) : at
purchaser’s HMI
ACTUATION : START / STOP pushbutton for all the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local PB
station.

OPERATION:

At first operator shall start the pumps through START actuation putting selector in manual
position. The discharge valve shall be subsequently opened manually. Keep the selector in auto
standby mode for the pump to be brought in auto service. Discharge valve for standby pump shall
be kept open for auto standby operation.
Note: For initial start, during commissioning or after long shut down, when discharge line is
empty; pump shall be started keeping discharge valve in closed condition. There after all restart /
auto start of pump shall be with discharge valve in open condition.

In auto mode of operation, the standby pump (kept selected) automatically starts
 if running pump/s stops due to electrical trip feedback and / or
 Due to non availability of discharge header pressure at or above preset setting for a preset
time as detected by pressure transmitters for BALP pumps
 Due to decrease of discharge header pressure in case the discharge header pressure falls
below a normal set point level and persists for a preset time during normal running of the
other pump.

In case of auto starting of standby pump due to decrease in discharge header pressure, one of the
pumps may be stopped as per operator’s discretion. However, in case the standby pump is
stopped, ‘auto standby starting’ logic will start functioning only if discharge header pressure
attains it’s normal level at least once during running of the pumps, after starting of standby
pump.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]

NOTE: The pump shall continue to operate as per interlock & protection. Normal status will be
reflected in mimic. Various alarms & shall be in HMI / CCC as per annunciation list given with
control write-up.

For initial start, during commissioning or after long shutdown, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart of
pump shall be with discharge valve open.

2.03.02 HP WATER PUMP:

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There are three (03) nos. HP water Pumps common for three units. Two pumps working and
one remain as stand-by

HP water Pumps take suction from ash water sump through individual isolation valve connected
to each HP water pump suction header. HP water pumps are located at the common “Ash Water
Pump House”.

The discharge of all three (03) nos. HP water Pumps connected to a common HP water header
through individual isolation valve and non-return valve. The discharge header is divided into
various branches and sub-branches as per the single line flow diagram to cater to water
requirement as stated above

Each HP water pump driven by electric motor. The HP water system is operated from HMI. The
HP water system is provided with all piping, valves and instruments as necessary for system
operation.

The HP water pumps cater to water at the following areas.

 Motive water for BA jet pulsion pump.

 Jetting / filling water requirement for bottom ash hopper.
 Seal troughs flushing as and when necessary.
 Water supply to wet head during FA evacuation in wet mode.
 Water supply to clarifier for occasional flushing.
 Jetting water supply to ash slurry sump compartments.
 Air washer.
 Flushing of ash slurry discharge line

Selector & Actuator

SELECTOR : Auto standby – A / Auto standby – B / Auto standby – C / Manual
(For BAHP Pumps) : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for all the individual pumps : at
purchaser’s HMI
EMERGENCY STOP: Emergency stop push button (One no for each motor) on Local PB
station.

OPERATION:
At first operator shall start the pumps through START actuation putting selector in manual position.
The discharge valve shall be subsequently opened manually. Keep the selector in auto standby mode
for the pump to be brought in auto service. Discharge valve for standby pump shall be kept open for
auto standby operation.
Note: For initial start, during commissioning or after long shut down, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart / auto start of
pump shall be with discharge valve in open condition.

In auto mode of operation, the standby pump (kept selected) automatically starts
 if running pump/s stops due to electrical trip feedback and / or
 Due to non availability of discharge header pressure at or above preset setting for a preset time as
detected by pressure transmitters for BAHP pumps
 Due to decrease of discharge header pressure in case the discharge header pressure falls below
a normal set point level and persists for a preset time during normal running of the other pump.

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In case of auto starting of standby pump due to decrease in discharge header pressure, one of the
pumps may be stopped as per operator’s discretion. However, in case the standby pump is stopped,
‘auto standby starting’ logic will start functioning only if discharge header pressure attains it’s normal
level at least once during running of the pumps, after starting of standby pump.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
Keeping selection in manual position, any pumps can be started through their respective START
buttons.

NOTE: The pump shall continue to operate as per interlock & protection. Normal status will be
reflected in mimic. Various alarms shall be in HMI / CCC as per annunciation list given with
control write-up.

For initial start, during commissioning or after long shut-down, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart of
pump shall be with discharge valve in open condition.

2.03.03 ECO WATER PUMP:

There are two (02) nos. ECO water Pumps common for three units. One pump working one
stand-by

Eco water Pumps take suction from discharge header of LP water pumps through individual
isolation valve connected to each Eco water pump suction header. Eco water pumps are located at
the common “Ash Water Pump House”.

The discharge of ECO water Pumps connected to a common Eco water header through individual
isolation valve and non-return valve. The discharge header is divided into various branches and
sub-branches as per the single line flow diagram to cater to water requirement as stated above

Each Eco water pumps driven by electric motor. The Eco water system is operated from HMI.
The Eco water system is provided with all piping, valves and instruments as necessary for system
operation.

The ECO water pumps cater to water at Flushing boxes and as conveying water for ash slurry
discharge from eco. Hoppers.

ACTUATOR:

EWP Pumps, i.e., EWP #1, EWP #2 selection for common three units.

 Actuation – START / STOP Pushbutton for all the pumps: at HMI.

- START / STOP push button (One set for each pump) : on CCC.

 Emergency stop – Mushroom head emergency STOP & START push button (One set for
each motor) : on Local PB station .

OPERATION:

At First choose any One (01 ) out of two ( 02 ) pumps to be kept in service.

Start the pumps by manual command through START actuation on HMI at Central Control
Console (CCC ) .

Before taking this pump in service LP pump discharge header pressure should be normal.

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Eco water discharge header pressure status will be monitored in HMI as well as in BALOC, as
generated from respective pressure transmitter.

NOTE: The pump shall continue to operate as per interlock & protection. Normal status will be
reflected in mimic. Various alarms shall be in HMI / CCC as per annunciation list given with
control write-up.

For initial start, during commissioning or after long shutdown, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart of
pump shall be with discharge valve in open condition.

2.03.04 BA SEAL WATER PUMP:

There are two (02) nos. Seal Water Pumps common to all three units. One pump is working and
other remains as stand-by.

The two (02) nos. SWP take their suction from purchaser’s service water source at adequate inlet
pressure with individual isolation valve connected to each Seal Water pump suction header. Seal
Water pumps are located at the common ‘Ash water pump house.

The discharge of SWP Pumps is connected to a common Seal Water header with individual
isolation valve and non-return valve. The discharge header is divided into various branches and
sub-branches as per the single line flow diagram to cater to water requirement as stated above

Each SWP pump is driven by electric motor. The SWP water system is operated from “Central
Control Console” (CCC). The seal water system is provided with all piping, valves & instruments
as necessary for system operation.

The SWP water pump (for SWP #A or SWP #B) cater water at the following areas for two units:

 Gland sealing of 2 nos. BA Overflow water pumps.

 BA Overflow pump fluid coupling cooling
 Ash crusher gland sealing water.

SELECTOR & ACTUATOR:

SWP Pump, i.e., SWP #A & SWP #B selection for all three units.

 Selector – Auto standby #A / Manual / Auto standby #B :at HMI as well as on CCC

 Actuation – START /STOP push button for both pumps : at HMI.

 Emergency stop – Emergency STOP & START push button ( One set for each motor ) : on
Local PB station .

OPERATION:

First operator should decide the pump to be taken in service i.e. either SWP pump #A or SWP
pump #B.

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Consider SWP pump #A is to be started & SWP pump #B is to be kept in Auto standby mode,
then operator should put selector of SWP pump #B at auto standby mode. Start SWP pump #A
through ‘START’ actuation on HMI at Central Control Console (CCC) and vice versa.

Discharge valve of running SWP pump should subsequently be opened automatically.

In auto mode of operation, the standby pump automatically starts if running pump stops due to
electrical trip feedback and / or due to non availability of discharge header pressure at or above
preset setting as detected by pressure switch for seal water pumps header.

In case the discharge header pressure falls below a normal set point level and persists for a preset
time during normal running the other pump kept in auto mode shall take auto start.

In case of auto starting of standby pump due to decrease in common discharge header pressure,
any one of the pumps may be stopped as per operator’s discretion. In case the auto started
standby pump is to be stopped ; then , before stopping , it should be ensured that , discharge
header pressure attain its normal level at least once during running of standby pump to avail next
auto start at the discretion of operator.

Manual mode operation, Keeping selection in manual position, any or both, the pumps can be
started through their respective START button on HMI. Other operational logic remains
unaltered.

NOTE: The pump shall continue to operate as per interlock & protection. Normal status will be
reflected in mimic. Various alarms shall be in HMI / CCC as per annunciation list given with
control write-up.

For initial start, during commissioning or after long shutdown, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart/auto-
start of pump shall be with discharge valve open

2.03.05 BA OVERFLOW WATER PUMP :

There are two (02) nos. BA Overflow Water Pumps for each of the three units. One pump is
working for each unit and other remains as stand-by.

The two-(02) nos. BAOWP Pumps take their suction from BA Overflow transfer hopper. BA
Overflow water pumps are located below near Bottom Ash Hopper area.

The discharge of two-(02) nos. BA Overflow transfer pumps connected to a common header with
individual isolation valve and pressure indicator for each unit. The overflow transfer pump
discharges to settling bin.

Generally one of these pumps is to be kept in service while respective unit is in running condition.

Each BA Overflow water pumps driven by electric motor. The BAOWP water system is operated
from “Central Control console” (CCC). The BA overflow water system is provided with all
piping, valves & instruments as necessary for system operation.

SELECTOR & ACTUATOR:

BAOWP Pumps A or B selection for unit #1, #2 & #3.

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 Selector – Auto standby #A / Auto standby #B / Manual : at HMI through selection.

 POP UP SELECTOR – Auto / Manual for individual pump : at HMI

 Actuation – START / STOP push button for all the individual pumps : at HMI.

 Emergency stop – Mushroom head emergency STOP push button & de-interlock trial mode
push button (One no for each motor) : on Local PB station.

OPERATION:

At first suction valve of the respective pump will be opened with the actuation of start command.
Subsequently seal water valve will be opened followed by selection of the pump ‘A’ or ‘B’ for
each unit, and all other starting permissive is through. The seal water supply from nearest to BA
hopper area is from seal water header.

The BA Overflow Water Pump to be start for each unit. Each BA Overflow Water Pump
discharge valve manually opened.

In auto mode of operation, the standby pump automatically starts if running pump stops due to
electrical trip and / or due to non availability of discharge header seal water pressure or as
detected by pressure switch for BA Overflow Water Pumps header.

However, in auto mode operation, the stand-by pump will be auto started in case of tripping of
the running pump.

Keeping selection in manual position, any or both the pump can be started through their
respective ‘START’ button on HMI.

Normal discharge header pressure status will be displayed, from discharge header pressure
switch. This pressure indication will start flashing in case discharge header pressure falls below
the set level and persists for a preset time during normal running of any one or both pumps.

NOTE: The pump shall continue to operate as per interlock & protection. Normal status will be
reflected in mimic. Various alarms shall be in HMI / CCC as per annunciation list given with
control write-up.

For initial start, during commissioning or after long shutdown, when discharge line is empty;
pump shall be started keeping discharge valve in closed condition. There after all restart/auto-
start of pump shall be with discharge valve in open

2.03.06 BA OVERFLOW SLUDGE PUMP :

There is one settling bin and one surge bin for each unit. The discharge of BA overflow water pump is
received in settling bin and overflow of this bin is given to surge bin. The ash particles are first
collected in settling bin and fine particles are accumulated in surge bin. Final overflow from surge bin
goes to ash water sump for further use. There are two nos. (1 working and 1 standby) BA overflow
sludge pumps to transfer sludge from bins to ash slurry common trough for onward disposal to ash
pond. The suction of BA overflow sludge pumps are connected with common suction header of both
the bins.

Selector & Actuator:

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SELECTOR : Pump – A / Off / Pump – B : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at purchaser’s
HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local PB station.

These pumps are run on continuous basis except during BA cleaning in “Draw down mode” and seal
water requirement is cater from LP seal water pump. Both the pumps having common suction header
with individual bins outlet valves. Settling bin and surge bin jetting is taken from the common
discharge header of pumps.
Sequence of operation :
 Selection of pump A or B
 Start command of selected Pump.
 Suction valves of pump will open simultaneously as per pre-set logic with the actuation of start
command.
 Once, any suction valve has opened then seal water solenoid valve shall open after some
predetermined time delay.
 Sensing of normal seal water pressure of pump.
 Pump shall take start after meeting of all staring permissive.
 After starting of the pump, within a preset time, discharge valve opens
 Sludge water discharge header pressure as detected by discharge header pressure transmitter is
established to normal,

 Discharge valve remains open & pump will continue to run.

Normal discharge header pressure status will be displayed, as generated from discharge header
pressure transmitter. This pressure indication will start flashing in case discharge header pressure falls
below the set level and persists for a preset time during normal running of any one pump.

2.04.00 JET PULSION PUMP INLET WATER VALVE:

Motive water from BAHP sources is supplied through remote operated valves for functioning of jet
pulsion pump. There are four nos. of such valves provided in each unit; one of such valve is associated
with each set of ash crusher / jet pulsion pump. Functioning of jet pulsion pump starts after opening of
this valve.

Operation:
Actuation through individual open / close push button. : at purchaser’s HMI

2.04.01 BA JET PULSION PUMP:

There are four (04) nos. BA Jet Pulsion Pumps in each unit. Two Jet pumps are working and other
two remains as stand-by .

2.05.00 ASH CRUSHER:

There are four-(04) nos. clinker crusher (CR) for each unit, two (02) nos. Clinker crushers are
working and others two remain as stand-by.

 In each unit two (02) nos. clinker crusher are in operation. There is one dilution spray HP
water line connection to each crusher. Dilution spray water line is having perforations, water
is allowed to flow before operation of the Clinker Crusher, and shall continue to flow as long
as crusher is in operation.

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 When selected HP water at inlet of jet pump pressure is normal; and start-cleaning permission
is available at Bottom Ash Local Operator’s Console ( BALOC), operator can open respective
seal water valve of clinker crusher.

 Crusher sealing water pressure “Normal” will be sensed at selected crusher and shall act as
prerequisite for starting of clinker crusher from BALOC control room for each unit.

 Selected bottom ash slurry conveying path is through (‘valve open’ feed back of respective
discharge valve).

SELECTOR & ACTUATOR:

 Selector : Auto / Manual reversing Mode: at BALOC.

 Actuation : Forward start / Reverse start / Stop push button for all clinker crusher at
BALOC

 Selection : Normally operator gate selected through clinker crusher (CR) selection, : at
HMI for each unit

 Emergency Mushroom head emergency STOP & START push button (One no. for each
Stop : motor) : on local push button station (LPBS) One set for each motor.

OPERATION:

Each Ash crusher is provided with AUTO / MANUAL reversing facility to remove jamming. Seal
water of each running ash crusher is provided from seal water header.
Upon selection of Bottom Ash Jet pump inlet water valve by control room operator and subsequent
receipt of BA cleaning permission from control room and also availability of required starting
permissive, BALOC operator should give forward run command of the respective Ash crusher after
selecting Auto or Manual mode of crusher reversal through “AUTO-MANUAL” reversal mode
selector.

2.05.01 Auto Reversing Cycle – Ash crusher Motor

After a time gap of 30 secs from the last reversal rotation in the auto reversing cycle, the respective Ash
crusher will again start in forward direction. However at this moment if the jamming still persists, as
sensed by zero speed switch, then further operation of the crusher will be locked out with “CRUSHER
TRIPPED” indication for subsequent manual intervention. After jam is cleared, restarting of the
cleaning operation shall follow the normal sequence.
During auto mode reversal period in case jamming is cleared, then after completion of cycle time
crusher will continue to run in forward direction and “Ash crusher Jammed” indication will disappear
after running of crusher in forward direction at normal speed for preset time. Thereafter respective feed
gate should be opened manually to commence de-ashing.
2.05.02 Manual Reversing - Mode:

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During manual reversing mode (“AUTO-MANUAL” selector on “Manual” position), in the event of
overloading and subsequent slowdown of crusher towards forward run for a preset time period, “ASH
CRUSHER JAMMED” indication will appear on BALOC and after another preset time duration, the
running crusher will trip. Thereafter STOP push button is to be pressed to reset trip indication and then
it will be possible to rotate the crusher in reverse direction to dislodge the jammed material by inching
operation through actuation of “REVERSE” pushbutton on BALOC. During reverse inching rotation,
speed change will not be monitored in logic. After jam is cleared, the jam indication will disappear after
the Ash crusher rotates in the forward direction for preset time without any jam feedback from zero
speed switch.

2.06.00 BOTTOM ASH FEED GATE:

Accumulated bottom ash in each V-section hopper is periodically cleaned through bottom ash feed
gates. For the purpose, there are four (04) nos. of bottom ash gates. Two nos gates are placed at each
part of V section of BA hopper. These gates are individually connected with four (04) nos. of bottom
ash discharge lines. Normally, during bottom ashing one no. feed gate is selected from each V-Section
of BA hopper.

Operation of feed gate:

Having completed the following activities / interlock the gate can be operated.
Opening Permissive:

o At least one HP water pump is running

o Jet pulsion pump inlet valve open feed back available.
o HP water pressure normal at inlet of Jet pulsion pump.
o Ash crusher seal water pressure normal.
o Ash crusher is running in forward direction.
o Ash crusher Jam feed back not persisting.
o BA Disposal line pressure normal

SELECTION:
 Normally, gates A & C or gates B & D can be operated at HMI through proper selection for
each unit.

 Feed Gate opening / closing through OPEN / CLOSE push button from Local Push Button
Station (LPBS) nearest to BA Hopper area for each unit.

 Selection of gates from BALOC through two (02) nos. selector namely GATE #A / OFF /
GATE #B & GATE #C / OFF / GATE #D with selection of gate; gate automatically selected
it’s corresponding jet pump inlet & outlet valve for each unit gate automatically selected.

 For each “V” section one feed gate (FG) is selected and the other gate in parallel remains as
fully closed for each unit.

 Starting & Running Respective clinker crusher froward running condition without
Permissive: jamming. Open the feed gate by pressing open push button located at
nearest to respective gate in bottom ash hopper area for each unit.

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 Stopping & closing Respective feed gate can be closed by pressing close push button
Permissive: located at nearest to respective gate. After which clinker crusher will
automatically be stopped. In case; running clinker crusher trips or for
any other reason; BA cleaning is suspended/stopped; the
corresponding gate/gates also shall be closed automatically.

OPERATION:
First operator should decide the two feed gates to be taken in service for each unit.

Each feed gate opening / closing through OPEN / CLOSE push button of local push button station
(LPB).

Selection of gates from BALOC through two nos. selector actuator namely GATE #A – OFF–
GATE #B & GATE #C–OFF – GATE #D with selection of gate; it’s corresponding crasher
sealing water valve, jet pump inlet & outlet valve shall be open.

 During opening of gate, oil contained in the AOCT is pressurized by application of pneumatic
pressure over oil, which in turn generates upward movement of the feed gate. The downward
movement of the gate during closing operation is achieved through application of the
pneumatic pressure on the topside of actuating cylinder. Such application of pneumatic air
pressure is achieved through actuation of 4-way solenoid valve.

 In case of non-conformity of running permissive, immediately feed gate shall be closed.

NOTE:  For cleaning of bottom ash hopper, feed gate is to be operated essentially under close
supervision by the operator. So, that the feed gate opened gradually to establish the flow of
ash smoothly.

Process:
During ash cleaning operation, the bottom ash mixed with water, is allowed to be discharged from
the hopper by opening the feed gate as described earlier. The mixture is further diluted by high-
pressure spray water from dilution water pipe. With the help of clinker crusher; big clinkers of
bottom ash are fragmented into smaller sizes convenient for pipe line transportation and are fed
into the jet pump via feed sump located below. The jet pump is hydraulically operated by means of
high-pressure water supply, conveys the input bottom ash in the form of slurry to the in-plant
common trough of ash slurry sump, and BA slurry discharged to remote ash pond by ash slurry
pumping system.

 BA cleaning over signal from BALOC control room to HMI unit. Operator stop the feed gate
from local push button station for nearest BA hopper area and after closing the crusher by
BALOC operator operate console sequentially.

2.07.00 BA SYSTEM OPERATION SEQUENCE:

Prior to starting of BA cleaning the following are to be ensured:

 To check running permissible of the following drives by CCC.

 HP water Pump running condition & Pressure is “Normal”.

 LP water Pump running condition & Pressure is “Normal”.

 Seal Water Pump running condition & Pressure is “Normal”.

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 BA Overflow Water Pump running condition.

 HP & LP Seal Water Pump running condition & Pressure is “Normal”.

 Ash Slurry Pump Series running condition & Pressure is “Normal”.

 Instrument Air Compressor running condition & Pressure is “Normal”.

The bottom ash cleaning operation is carried out from “Bottom Ash Local Operator’s Console”
(BALOC) per the following step / sequence, as also incorporated in annexed sequence operation
flow chart in control write-up.

 Opening of selected Jet Pump slurry discharge valve (cylinder operated KGV), and inlet HP
water valve (cylinder operated butter fly valve) from CCC, then proper gate selection at
BALOC and check availability of normal pressure at jet pump.

 Start BA Cleaning request signal from BALOC to CCC.

 Check Jet Pump discharge line pressure is “Normal”.

 “BA Cleaning Permission” by CCC operator to BALOC through HMI push button.

 Bottom Ashing start permission is received at BALOC from CCC.

 Sealing water line valve open through BALOC, selector actuator for clinker crusher of
selected feed gate.

 To check availability of normal sealing water pressure.

 Forward runs commend for corresponding crusher of selected gate.

 To check non availability of crusher jam indication.

 Inches opening of respective feed gate through “OPEN / CLOSE” push button of LPB.

2.08.00 COARSE ASH HANDLING:

2.08.01 COARSE ASH HOPPER:

There are four (04) nos. economizer hoppers in each unit. There is no control operation in
Economiser hoppers cleaning process.

Coarse ash is collected in economizer hoppers, Each four-(04) nos. of economizer hopper fitted
for equal distribution of ash and placed nearest to economizer areas in boiler. Four (04) nos. of
ash hoppers each fitted and equally distributed on two (02) nos. flue gas path “A” & “B” before
connected to two (02) ESP path.

These coarse ash hoppers are of “V” type at the bottom and upper portion is rectangular. Each
hopper ash discharge outlet connection having manual isolation (KGV) valve, adapter, bellow
(ss) type expansion joint and flushing box with Eco/ unloader water collection.

2.08.02 COARSE ASH HOPPER OPERATION:

Each coarse ash hopper is connected with a flushing box fitted at the bottom. The outlet from

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four (04) hoppers is connected to a common piping header (for each path).which drains into
respective bottom ash hopper by gravity and accumulated ash slurry is being cleaned during BA
cleaning process. All the flushing box and conveying header have ECO. Water supplies
connection with adequate pressure.

2.09.00 ECO. HOPPER OPERATION:

For cleaning operation; the following steps may be followed:

 Check all the water nozzle of flashing apparatus is clear free from dirt.

 Open ECO. Water valve for individual header. (R-1)

 While flow of clear water through flushing apparatus is established, manual KGV of at the
hopper discharge to be opened gradually to observe smooth ash flow. Please do not open the
valve at once to avoid spillage / chockage of lines.
NOTE:  Bottom Ash Handling System will be operated once every shift of eight hours but Coarse
Ash Handling System shall continuously run. If the ECO water falls below adequate
pressure, then operator should manually stop the hopper manual isolation valve and wait
for adequate ECO water pressure, to commence further operation. Coarse Ash handling
system operation will be carried out from the Central Control console (CCC) located in
control room. CCC is provided with two No. PC based HMI station.

3.00.00 FLY ASH HANDLING:

3.01.00 OVERALL SYSTEM ARRANGEMENT

Accumulated fly ash in ESP hoppers, (160 Nos. in each Unit), Primary Air Heater Hoppers (04
Nos. in each Unit) & Secondary Air Heater Hoppers (04 Nos. in each Unit) are evacuated by
vacuum process from respective hoppers and conveyed through bag filter & collected in buffer
hopper in dry form. This dry ash through Nuva feeder below buffer hopper is pressure conveyed
to silo through pressure conveying system to ash silo. Dry ash collected in silo is unloaded in dry
form or in semi wet form as the case may be, to closed / open truck respectively for ultimate use.
There is an alternate arrangement of collecting dry ash in HCSD silo, mixing with water and
pumping it in disposal area by HCSD pump. Pressure system runs in proper co-ordination with
vacuum system in Dry mode.

In bag filter ash gets separated from ash-air mixture & accumulated in buffer hopper. Vacuum
Conveying Air from bag filter is finally released in atmosphere through vacuum pump.

The vacuum pump runs in water sealed condition to produce adequate vacuum to pull ash from
ESP hoppers, Primary Air Heater Hoppers & Secondary Air Heater Hoppers. Similarly, in
pressure conveying system, transport air compressor (TAC) produces motive air pressure for
Transport ash from buffer hopper to silo, through Nuva feeder.

There are five nos. silo of 1000 MT capacity each. Each silo is equipped with its own unloading
arrangement of dry as well as in semi wet mode.

Alternatively Dry ash can also be collected to five (5) nos of HCSD Silos of capacity 250T.
Each HCSD silo is equipped with High Concentrated Slurry Disposal (HCSD) unloading system
and also provision for disposal through Telescopic Chute for truck loading.

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Hot air from fluidizing blower (with associated heater arrangement) is provided on 1st to 4th field
hopper of ESP & buffer hopper during evacuation in order to aid fluidizing effect of fly ash.
Opening /closing of fluidized airline valves are controlled automatically. For silo, separate
fluidizing arrangement is provided with silo fluidizing blower.

Instrument air free from dirt scale at adequate pressure will be used for operation of pneumatic
actuation for various valves, gates and other pneumatic equipment under the system.

3.02.00 ESP STREAM & BRANCHES:

There are total 160 nos. ESP hoppers suitably grouped in four (4) nos. of streams viz. Stream-
FL A, Stream-FL B, Stream-FL C & Stream-FL D. Each stream having four (4) nos. branches
and each of which comprises of ten (10) nos. hoppers (one hopper from each of 1st to 10th field).
Stream- FL A & Stream- FL D are connected to two nos. primary air heater and secondary air
heater streams, each stream is connected to 02 nos. each primary air heater & secondary air
heater hoppers.
ESP :
[(4 STREAMS) X (4 BRANCHES IN EACH STREAM) X (10 HOPPERS IN EACH
BRANCHES) = 160 HOPPERS]
PRIMARY AIR HEATER :
[(2 STREAMS) X (2 HOPPERS IN EACH BRANCHES) = 4 HOPPERS]
SECONDARY AIR HEATER :
[(2 STREAMS) X (2 HOPPERS IN EACH BRANCHES) = 4 HOPPERS]
The Isolation:
Every branch of vacuum conveying system can be isolated by a pneumatically operated isolating
valve named branch header valve (TERSG). While de-ashing sequence is in progress, only one
branch isolating valve (TERSG) of a stream will be in open condition and other branch isolating
valves shall remain closed.
The Ash Intake valve:
Every hopper is having one remote operated ash intake valve. Actual flow of ash occurs when
this particular valve is in open condition.

At a time Fly ash evacuation from all the four streams can be performed. Any stream can be
engaged in dry collection through adequate isolation.

Ash collection in dry mode is done through bag filter arrangement, placed on top of buffer
hopper. Buffer hopper is used as intermittent storage of ash before transport to silo through
Pressure Conveying by NUVAFEEDER system with aid of conveying air provided by Transport
Air Compressor.

Ash collection to Buffer Hopper through Vacuum conveying System, vacuum is generated
through water ring vacuum pump. Each stream is connected with two nos. of vacuum pump; one
in running & other as stand by.

All solenoid operated air / electric valve under fly ash system will be normally operated /
controlled from control room in remote interlock mode.

3.03.00 VARIOUS VALVES OF FA SYSTEM & THEIR CONTROL PHILOSOPHY

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3.03.01 Bag Filter Path Selection Valve
This valve will operate under the conditions. Each stream is connected with two Bag Filter
Group BF-A1 & A2 for stream – A , similarly for other Stream- B to D. At a time only one Bag
Filter Group is in working condition and other Group is kept as standby.

3.03.02 Vacuum Pump Suction Valve

This valve will operate under following condition.
Selection of vacuum pump and Bag Filter
Opening of this valve will make vacuum line through with the selected vacuum pump of
evacuation.

3.03.03 Vacuum breaker / Vacuum Relief Valve

For each vacuum conveying stream, there is vacuum breaker / vacuum relief valve attached with
in each Bag Filter and will be closed.

3.03.04 Branch Header Valve :

This valve will operate under following condition :
Any branch header valve of the stream is selected in purchaser’s HMI in manual mode. In auto
mode selected branch header valve will open as soon as SYSTEM START command given in
purchaser’s HMI.

3.03.05 Ash Intake Valve:

Only one no. ash intake valve of hopper of selected branch of each stream will open at a time in
auto as well as manual mode of extraction.
In AUTO mode the ash intake valve of hopper of the selected branch will open as per logic
sequence after actuation of “SEQUENCE START” push button at purchaser’s HMI if all other
permissive are available.

3.03.06 ESP Hopper Fluidizing Valve :

Fluidizing air in hot condition is provided to ESP hoppers of 1st field to 4th field. In each branch
of ESP hoppers, first two (02) fields hopper are connected with one fluidizing valve and 3rd & 4th
fields hopper with another fluidizing valve. These valves will open sequentially while cleaning of
respective connected ESP hoppers with getting opening pulse of respective branch header valve.
The sequence of operation of these valves is given in this document elsewhere.

3.03.07 Buffer Hopper Fluidizing Air Valve:

There are eight (08) Nos. buffer hoppers below the bag filters. Ash from bag filter gets collected
in these hoppers. To bring fluidizing effect in buffer hoppers, fluidizing air valve shall open with
the opening of top gate of working Nuva feeder (ash transmitter) for a particular stream.

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3.03.08 Pressure Conveying Stream Valves:
There are 04 (four ) nos. solenoid operated pneumatic plug valves for unit # 1 / 2 / 3) at the
upstream of ash Nuva feeder / ash transmitters ( down stream of Transport air compressors) on
X , Y & Z conveying lines of each unit.

Pressure Conveying line – X is connected with Pair of Nuva Feeders (Ash transmitters) of
buffer hoppers A & B , pressure conveying line – Y is connected with Pair of Nuva Feeders (
Ash transmitters ) of buffer hoppers C & D. Similarly, pressure conveying line - Z is connected
with Pair of Nuva Feeders ( Ash transmitters ) of buffer hoppers A & B and C & D.

There are pneumatic operated knife gate valves for unit # 1 / 2 / 3) at the down stream of ash
transmitters on pressure conveying lines X , Y & Z towards fly ash silos . Also seven nos.
pneumatic operated knife gate valves( silo transfer line valve ) are provided as inter connection
valves between silos nos. S-1, to S-5 respectively.
These knife gate valves are suitably opened / closed along with selection for individual silo.

3.03.09 Silo Discharge Valves:

There are five nos. FA Silos. For Ash Disposal in HCSD mode, there are five (5) nos. HCSD
Silos. Fly ash from transfer lines “X” , “Y” & “Z” will be discharge to either FA Silo or HCSD
Silo, silo-1 to S-5, respectively and connected silo discharge valves will open with opening of
same silo transfer line valves either for FA Silos or HCSD Silos. However, transfer line “Y” &
“Z” can discharge dry fly ash to silo – 4 & 5

3.04.00 VARIOUS DRIVES / EQUIPMENTS / SUB-SYSTEM / LINES OF FA SYSTEM:

3.04.01 ESP & BH FLUIDISING BLOWER:

Selection & Actuation
ACTUATION : START / STOP pushbutton for each blower : at Purchaser’s HMI
EMERGENCY STOP : One STOP push button (One no for each motor) : on Local PB station
(by purchaser)
Operation :
Prior to start ESP de-ashing, fluidizing blower along with its associated heater is to be taken in
service. Fluidizing air blower with associated heater will cater hot air to ESP as well as Buffer
hopper to create fluidizing effect inside hoppers. Out of two blowers, one will be working for
each unit..
With actuation of blower start command (after putting cleaning selection in manual mode) the
fluidizing valve 1 or 2 (timer based sequence) of selected branch will open. Fluidizing blower
will operate continuously during ash cleaning from ESP hoppers, If there is any trouble in
blower under running condition, the other one should be taken in service manually.
There is one no. differential pressure switch provided across the blower suction filter. If
differential pressure across filter is above the permissible limit, the blower will trip with
annunciation in HMI. Blower can again re-started after attending fault.

3.04.02 ESP & BH FLUIDISING BLOWER HEATER:

Selection & Actuation :
ACTUATION : START / STOP pushbutton for each blower : at Purchaser’s HMI
EMERGENCY STOP : One STOP push button (One no for each motor) : on Local PB station
(by purchaser)

Operation:

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After blower is taken into service, its corresponding heater can be put into service. There is one
no. temperature element (for TE HI & TE HIHI temperatures) provided on common header to
keep fluidizing air temperature within pre-set normal band as well as to prevent overheating of
air beyond a pre-set “HIGH HIGH” by means of automatic cut-in / cut-out control of heating
elements.

3.04.03 ESP FLUIDISING SYSTEM:

For effective de-ashing hot pressurized air from fluidizing blower is injected in ESP hoppers
through pneumatically operated valve.

While de-ashing in ‘MANUAL’ mode, the fluidizing line pneumatic Valve-1 / 2 of a branch will
open according to the selection of hopper. When cleaning of ash from 5th to 10th field hopper in
same header is in progress, Valve-1 remains open. While opening of next branch header valve,
Valve-1 opens & then Valve-1 of previous branch header closes with closing of same branch
header valve.

The fluidizing air supply to ESP hoppers will remain activated even when fly ash cleaning
operation is not in progress. During this period, the fluidizing air supply valves-1 or 2 of all the
streams & branches will operate in a timer based sequence (timer based sequence will activated
with getting close signal of branch header valves of all the streams) to supply fluidizing air to
respective fields of ESP hoppers.

3.04.04 VACUUM PUMP:

There are four (04) pairs of vacuum pumps. Each pair is dedicatedly connected to individual
stream. Every pair is having two pumps, out of which one is working & another is standby.

Selection & Actuation

SELECTOR : Working Pump selection – at Purchaser’s HMI
ACTUATION : START / STOP pushbutton for All the pumps : at Purchaser’s HMI
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

Operation:
At first operator will select the working pump through Purchaser’s HMI selection facility. Along
with the selection, the respective suction valve of the selected vacuum pump will be opened and
the suction valve of the other pump of the same pair will be closed.
After proper selection of vacuum conveying path for a stream, selected vacuum pump can be
started through respective START / STOP push button at Purchaser’s HMI.
On actuation of start button,
 The seal water valve of respective selected vacuum pump opens.
 Thereafter the seal water pressure will be established
 Subsequently the respective vacuum pump will be started if seal water pressure becomes
NORMAL as sensed by pressure switch within preset time and selected “VACUUM
CONVEYING PATH IS THROUGH”, then the respective vacuum pump will be started.

3.04.05 THROUGH CONDITION OF VACUUM CONVEYING PATH :

To start fly ash evacuation it is mandatory to satisfy through condition of vacuum conveying
path. Suction line of selected vacuum pump is either open to atmosphere through respective
vacuum breaker / vacuum relief valve or suction

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line is sucking air from atmosphere through selected branch header, air intake valve. While,
interconnected valves associated with other paths and suction valve of the other vacuum pump of
the same pair are closed.

Following are the through condition of vacuum conveying path:-

 Cleaning through a particular stream :

 Group selected from stream A to D

 Bag filter discharge valve is open.
 Selected branch header valve is open.
 Selected Vacuum pump suction valve is open.
 Fluidizing blower is in running condition
In case the vacuum conveying path of selected stream is not through, an alarm indication will
appear at Purchaser’s HMI “VACUUM PATH NOT THROUGH”

3.04.06 BAG FILTER:

Fly Ash air mixture conveyed by each fly ash conveyor line under vacuum system gets separated
in dry form in bag-filter, and gets stored temporarily in the buffer hopper directly below the bag
filter. There are eight (08) sets of bag filter and buffer hoppers of each unit. Every stream of dry
collection is associated with two such bag filter assembly.

The pulse jet cycle will be started during dry ash cleaning with “SYSTEM START” command
of the respective stream from HMI. The ash particle which gets accumulated on the walls of
filter bags is cleaned at an interval by auto pulse air jet system. The ash particles get loosened
from surface of filter bag and collected in the buffer hopper. The pulse jet cycle will stop
automatically (after a preset time) with actuation of “System Stop” command on HMI or
stoppage of vacuum pump.

Fluidizing pads are provided at the buffer hopper and continuous flow of fluidizing air from
buffer hopper fluidizing blower is maintained in order to keep the accumulated ash in fluidizing
condition. A level switch is provided in the buffer hopper to sense high level of ash accumulated
in buffer hopper.

If dust in the filter bags do not get dislodged fully by the pulse air jet system then the differential
pressure across the bag builds up.
3.04.07 Differential Pressure Switch (DPS)

A differential pressure switch is provided across the dirty air & clean air plenums of each bag
filter, which is set to operate at about 300 mm water gauge differential. When differential
pressure becomes 300 mm water gauge, an indication is provided in Purchaser’s HMI indicating
bag filter pressure differential “HIGH”. If the differential remains high for 60 seconds, the ash
feed circuit gets de-energised, and if it still remains high for another 60 seconds, the vacuum
relief valve opens for 120 seconds with an alarms, “Bag filter diff. pr. HIGH”. After this period,
vacuum relief valve closes and the differential is checked after 10 seconds. If the same is below
300 mm water gauge, the ash feed circuit is energised.

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If the differential is still above 300 mm water gauge, the vacuum relief valve opens for another
120 seconds. After this period, vacuum relief valve closes and the differential is again checked
after 10 seconds. If the same is below 300 mm water gauge, the ash feeding resumes. If it is still
above 300 mm water gauge, the system is shut down with “FLY ASH VACUUM SYSTEM
TRIPPED” annunciation.

3.04.08 ASH TRANSMITTER (NUVA FEEDER)

Dry fly ash collected in buffer hopper is pneumatically pressure conveyed to silo through ash
transmitters (Nuva feeders). There are two (02) nos. of ash transmitters (Nuva Feeders)
connected in each bag filter / buffer hopper.
Dry ash is pressure conveyed to selected silo # 1 to 5. Ash transmitter pairs of A streams are
connected with ‘X’ conveying line and ‘Z’ conveying line, Ash transmitter pairs of B streams are
connected with ‘X’ conveying line and ‘Z’ conveying line, Ash transmitter pairs of C streams are
connected with ‘Y’ conveying line and ‘Z’ conveying line and. Ash transmitter pairs of D
streams are connected with ‘Y’ conveying line and ‘Z’ conveying line. In each pair, one ash
transmitter is in working condition and other remains standby.

Operation sequence of ash transmitter valves & gates:

Ash transmitter sequence will start with actuation of ‘PRESSURE CONVEYING SEQUENCE
START’. Operation of Ash transmitter's pneumatically operated valves and gates will be as per
following sequence.-

Vent Valve:
 Vent valve opens for venting of air from ash transmitter, and pressure equalizing
between Buffer hopper top zone & ash transmitter for a preset time duration
(VENTING).
Top Gate:
 After a preset time gap, top gate opens for a preset duration (irrespective of ash level in
transmitter vessel under timer-mode, or subject to ash level in transmitter vessel below
“HIGH” under probe-mode) to allow ash feeding from the Buffer hopper into the transmitter
vessel (FILLING).
 Top gate closes followed by closing of vent valve (Fluidizing air supply for bottom gate and
transmitter vessel automatically turns on).

Equalizing Valve:
 After closing of vent valve, equalizing valve opens for a preset duration to equalize pressure
between ash transmitter vessel and ash conveying line (EQUALIZING).
Bottom Gate:
 After a preset time gap, bottom gate opens for a preset time duration (if conveying line
pressure rises above pre-set value, bottom gate if open will close immediately and remains
close until line pressure falls below the pre-set value) to allow discharge of ash from
transmitter vessel into ash conveying line (UNLOADING).
 Bottom gate closes followed by closing of equalizing valve.
Fluidizing Valve:
(a) The fluidizing valves of transmitter vessel and bottom gate will open with closing of vent
valve and remains open during closing duration of vent valve.

3.04.09 TRANSPORT AIR COMPRESSOR (TAC):

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There are three (03) nos. screw type Transport air compressors. Discharge from these
compressors are connected with three (03) nos. conveying streams X , Y. & Z. X and Y are
working stream and Z is standby.

This screw type Transport air compressor unit will have their Integral Micro Processor
Controller to process the permissive & interlock logics of the machine on stand alone basis
involving the instruments & actuators integrally mounted with the compressors. The strategic
actuation & monitoring signal exchange with main ash handling DCS will be through potential
free contacts (PFC) facilitating operation & strategic monitoring of these compressors from
purchaser’s HMI screen.
Selector & Actuator:
ACTUATOR: START / STOP for individual compressor.
Emergency STOP push button mounted integral with each compressor
Starting Permissive:

 Open feed back of conveying line relief valve.

 Open feedback of TAC discharge valve.
 Pressure conveying path through (proper opening of conveying line valves)
 And as per manufacturer’s recommendation.
Trip Conditions :
 Close feed back of TAC discharge valve or
 Pressure conveying path is not through (proper opening of conveying line valves) or
 Other, as per manufacturer’s recommendation.
Operation :
Compressors can be started from respective “START” / “STOP” push buttons located in
purchaser’s HMI on fulfillment of starting permissive.
With START command of TAC the solenoid operated cooling water valve on cooling water inlet
line will automatically open for the selected compressor. For safe starting / stopping of
compressor, two (02) no. timer based butterfly valve (relief valve) placed on common header of
compressor discharge line (as applicable for the selected compressor) will open with start / stop
command and remains open for preset time. With open feed back of butterfly valve, the
compressor shall take start / stop.

With this, if all other starting permissive are through as per manufacturer’s control write up.
The TAC will get started and continue to run if no trip condition fulfilled.

During running of TAC,

1. In case, the line pressure reaches higher safety set point value, the relief valves will open and
remains open till the line pressure reaches lower safety point of the differential band within
the pre-set time duration. If the line pressure does not reach lower safety point value within
the pre-set time duration. The relief valve shall close irrespective of pressure value being
above low set point & shall remains closed for preset time duration. If the line pressure
remains above low set point and reaches the high set point, it will again open for preset
duration. This cycle will repeat once again and if the line pressure does not reaches low set
point thereafter relief valves remains open position with alarm on HMI “conveying line
overload and relief valves open”. Now, operator’s intervene is required for further action.

On having successful starting of Transport air compressor, normal Transport air pressure will
establish & “PURGING ON” indication will turn on. This (initial) line purge continues for a
pre-set (adjustable) duration and indication will turn off.
Thereafter, Ash transmitter pair will be started with actuation of “PRESSURE CONVEYING
SEQUENCE START”.

3.05.00 SYSTEM OPERATION SEQUENCE:

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All ESP hoppers have been grouped in four (04) streams viz. Stream A to D and Bag filter group
1 & 2. Fly ash cleaning process of any stream for those hoppers can be done in bag filter group 1
or 2 depending on selection from purchaser’s HMI. Before starting the evacuation in any group
following are the pre-requisite :

 ESP & Buffer hopper fluidising blower & heater running (In manual selection mode)
 Instrument air pressure healthy at FAE tower area.
 Fly ash pressure system is ready for operation .
 Vacuum pump is ready to start.
 Transport air compressor is ready to start .
 Silo vent fan and filter in operation .

FLY ASH VACUUM SYSTEM:

3.05.01 Fly ash from ESP, Primary & Secondary Air Heater hoppers can be cleaned either in auto or
manual operation as per requirement.
SELECTION:
 Select AUTO mode through AUTO / MANUAL selection facility in purchaser’s HMI.
 Select Branch evacuation sequences in purchaser’s HMI.
 Select Bag filter group BF-1/BF-2/Off selection facility from purchaser’s HMI.

When BF-1 or BF-2 has been selected.

 Isolating valve in respective bag filter path will open.
 Isolating valve in BF –1 / BF-2 path closes.

 Select working vacuum pump for the respective stream through purchaser’s HMI
selection facility.
 Vacuum pump suction valve of selected group will open .
 Start the selected vacuum pump.
System Start:
Once vacuum pump is running smoothly.
Actuation of ‘SYSTEM START’ in purchaser’s HMI following operation will take place.
 Selected branch header valve of respective stream will open, if in auto mode.
 Thereafter respective Relief Valve will close.
 Once vacuum pump is running & respective vacuum relief valve is closed, while path
selection is proper, line vacuum will start rising to match header vacuum in between Vs1
& Vs2. This may be noted here that for normal evacuation from ESP, Primary &
Secondary Air Heater hoppers, vacuum shall be maintained between VS2 & VS3 setting.

Note :- For Dry Fly Ash System.

Line vacuum should be maintained between 60 mmHg to 90 mmHg.
VS1- Setting should be dependence on line vacuum Setting.
VS2- Setting should be maintained 180 - 200 mmHg for hopper plug.
VS3- Setting should be maintained 260 - 320 mmHg.

 Fluidizing header air valve will operate in a manner explained in respective section.
 Bag filter “Pulse jetting” will be started with pulse jet ‘ON’ indication in purchaser’s
HMI.
 Differential pressure across the bag filter bags should be less than the set value for
normal operation.
 Level of dust sensed by dust sensor in vacuum conveying line (suction line of vacuum
pump) should be within set value.`
 Vacuum conveying ‘SYSTEM ON’ indication will appear on purchaser’s HMI.

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Sequence start:
Once the system is running smoothly & vacuum level is more than Vs1 of selected branch,
therefore with actuation of ‘SEQUENCE START’ in purchaser’s HMI following action will take
place. Please read Vacuum relief valve instead of Vacuum breaker.

 Ash intake valve of first field of the selected branch will open subject to fulfillment of
conditions. “ SEQUENCE ON “ indication will appear on purchaser’s HMI.
 With evacuation of ash through ash intake valve, system vacuum will gradually rise as sensed
by vacuum transmitter and ash intake will close with attaining vacuum Vs3 set point. Ash
intake valve will open again when vacuum reaches below Vs3 level.
 Conveying from hopper will continue untill line vacuum falls below the preset value (Vs1)
sensed by vacuum transmitter and persists for a preset time (adjustable)
 The above condition implies ‘ HOPPER EMPTY’ status on purchaser’s HMI and the
respective ash intake valve will close. Ash intake valve for the next hopper of the selected
branch will open thereafter, and thus sequence continues.
 After the fly ash hoppers connected with specific branch are cleaned in above sequence, the
next branch header valve as per pre-selection in purchaser’s HMI will open first and then
action branch header valve will close. Ash from the hoppers of next branch header will be
cleaned in similar sequence and transfer sequence of ash intake valve opening will be
controlled automatically by the vacuum level as sensed by vacuum transmitter.
 Opening / closing of fluidising air valve of branch header shall be as per sequence mentioned
in this document elsewhere.
 If required, at any point of time of ash evacuation though a particular hopper, the ash intake
valve of the next hopper can be opened with closing of ash intake valve of the previous
hopper by actuation of ‘ JOG’ PB ( in auto mode) from purchaser’s HMI . Action of jog PB
will override the control of vacuum level feed back the particular hopper.
 With the action of system STOP purging of vacuum line starts for a pre- set time then
vacuum breaker will open and branch header valve will close to conclude that fly ash vacuum
system operation over.
 With the actuation of system STOP command, purging of vacuum line and pulse jetting of
bag filter remains on for a pre-set time, then vacuum breaker will open and branch header
valve will close to conclude that fly ash vacuum system operation over.
 Vacuum pump is to be stopped manually.

If necessary the fly ash system operation for each stream can be stopped / suspended at any
moment of “AUTO” sequential operation by actuation of corresponding “SEQUENCE STOP”
command in purchaser’s HMI. When this command is given, the cycle will stop at its present
position, the opened branch header valve will remain open but the operating ash intake valve will
be closed. Again with the “SEQUENCE START” command from purchaser’s HMI, the fly ash
evacuation will be started from the same hopper. However “SYSTEM STOP” command will
reset the cycle to its home position.
3.05.02 MANUAL MODE OF CLEANING OF A STREAM:
Under manual mode, the fly ash cleaning can be carried out independently from any one or
selective hopper stream. The selection of the particular hopper of branch for a stream can be
made by means of corresponding “BRANCH” selection and “HOPPER” selection respectively
through purchaser’s HMI. Other pre-requisites & steps are identical to that of auto sequence
operation as mentioned earlier.

After proper selection of BRANCH, selected branch header valve opens. Thereafter, following
actions shall be taken to carry out ash cleaning from the selected hopper.
 Select either BF-1 / BF-2 Bag filter group.
By actuating corresponding “SYSTEM START with the fulfillment of required permissive

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following action will take place
 Vacuum breaker / relief valve as the case may be will close
 Fluidizing air valve will operate as per sequence mentioned earlier & pulse jet system for bag
filter will start .
 Select vacuum pump and start the selected pump as mentioned earlier.
 With actuation of SEQUENCE START command, ash intake valve for the selected hopper
with the fulfillment of required permissive will open.

 After getting hopper empty indication, the next hopper will be selected manually through
‘Hopper’ and ‘Branch’ selection from purchaser’s HMI as mentioned above.

3.05.03 PHENOMEN0N PERTAINING DURING ASH EVACUATION:

Plugged Hopper
During normal ash cleaning process, the conveying line vacuum will remain within the preset
(adjustable) band of vacuum sensing device i.e. vacuum transmitter. In case line vacuum is >Vs1
but < Vs2 and remains there for a pre-set duration (adjustable), will imply “HOPPER
PLUGGED” status. For manual attendance or bypassing the plugged hopper “JOG” push-button
(for auto-sequential cleaning) is to be actuated. This actuation will automatically select the next
hopper in sequence. Monitoring of the said condition will be effective for auto-sequential cleaning
as well as for manual cleaning.
LOAD CONTROL:
During fly ash cleaning operation, in auto or in manual mode if the conveying line vacuum rises
above the preset value Vs3, operating ash intake valve will close instantaneously to stop further
feed of ash into the line, and remain closed until the line vacuum falls below aforementioned
preset value. This will provide “Load Control” of the ash conveyor. However, if the line vacuum
persists above Vs3 for duration (around 3 minutes, adjustable), vacuum conveyor
“OVERLOADED” status will be annunciated in purchaser’s HMI. The above “Load control”
will be effective irrespective of auto or manual cleaning.

3.06.00 FLY ASH PRESSURE CONVEYING SEQUENCE FOR FA SILO / HCSD SILO:

Dry ash collected in buffer hopper is conveyed through Ash transmitter to dry ash silo by means
of a pneumatic fly ash pressure conveying system. The pressure conveying system can be
operated simultaneously with dry extraction of vacuum system. Transport air compressors (TAC)
provide pressurized air for such conveying.
Fly ash collected in silo is ultimately disposed through trucks / tankers for end use. To start fly
ash pressure conveying system, following are the steps to be followed:-
 Buffer hopper fluidizing air valve opens with opening of working ash transmitter top gate
of respecting vacuum stream.
 Select the pressure conveying stream.
 Select the working ash transmitter from individual selector.
 Select the transfer line with the help of valve selector & silo (if required).
 Start the silo vent fan of selected silo.
 If the selection is improper then annunciation on purchaser’s HMI “TRANSPORT
PATH IMPROPER”.
 SYSTEM START command from purchaser’s HMI, pulse jetting of vent filter will start.
 START Selected Transport air compressors from purchaser’s HMI.
 With proper selection & operation ‘PRESSURE TRANSPORT ON’ indication will be
available on purchaser’s HMI.
 If Transport line pressure found normal with respect to pre-set value on pressure transmitter;
actuate “PRESSURE TRANSPORT SEQUENCE ON “in HMI. This will start selected ash
transmitters cycle leading to ash transport from ash transmitter to silo.

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 With the silo level high feedback ash transmitter top gate will close immediately and
‘SILO LEVEL HIGH’ will be annunciated. With this condition selection of alternative
silo may be explored after stopping the system.
 The ash transmitter will keep on operating on pre-set time cycle sequence until the ash
transmitter of pressure Transport system becomes empty sensed by pressure transmitter
of the respective Transport line subject to the condition that corresponding fly ash
vacuum conveying system is stopped. If this condition persists for a predetermined time
(around 10 minutes adjustable) (NO LOAD CONDITION) then the following action will
be performed.
 The top gates for all the ash transmitters get closed
 The bottom gates will operate in normal sequence for one complete cycle. There after ash
transmitter cycle will stop in totality, turning off the "“PRESSURE TRANSPORT
SEQUENCE ON” indication.
 After a further preset time duration allowed for “FINAL LINE PURGE” pressure
Transport “SEQUENCE OVER” status will be annunciated.
 There after the operating compressor will be stopped manually from purchaser’s HMI.
 The top gates for all the ash transmitters get closed
 The bottom gates will operate in normal sequence for one complete cycle. There after ash
transmitter cycle will stop in totality, turning off the "“PRESSURE TRANSPORT
SEQUENCE ON” indication.
 After a further preset time duration allowed for “FINAL LINE PURGE” pressure
Transport “SEQUENCE OVER” status will be annunciated.
 There after the operating compressor will be stopped manually from purchaser’s HMI.
The fly ash pressure Transport can be stopped / suspended, if necessary, at any moment of
system operation through’ actuation of corresponding “PRESSURE CONVEYOR SEQUENCE
STOP “ command in purchaser’s HMI. With actuation of this command, the top gates along with
the vent valves for the operating Ash transmitters will close instantaneously. The operation of the
corresponding transmitters, however, will continue for one complete cycle only opening the
bottom gates. However Transport cycle can again be started through actuation of ‘SEQUENCE
START’ from purchaser’s HMI.

LOAD CONTROL
During fly ash pressure Transport, if the Transport line pressure rises above the pre-set value
sensed by the respective pressure transmitter of Transport line, the bottom gates of all the ash
transmitters on the operating ash Transport line (if open) will close immediately, and remain
closed until the line pressure falls below the full load set value, thus providing “LOAD
CONTROL” during fly ash pressure Transport.
If the Transport line pressure remains above the “FULL LOAD” set value for a pre-set
duration (adjustable), fly ash pressure Transport “OVERLOADED” status will be annunciated
on purchaser’s HMI.

4.00.00 ASH SLURRY DISPOSAL SYSTEM:

The Ash slurry disposal System furnished with necessary equipment and facilities for disposal of
ash slurry from common trough of ash slurry sump to remote ash pond by ash slurry pumping
system.

Bottom ash and coarse ash of all three units discharges in BA slurry sump through four nos. BA
slurry lines in each unit. BA overflow from all three units after falling in settling bin and surge
bin are pumped by 02 nos sludge pump into BA slurry sump. Also BA slurry drain pump
discharges into BA slurry sump.

. There are two (2) Nos. slurry sump compartments below the common trough. Each sump
compartment is connected with four slurry chain of two pumps in series onward disposal to ash

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pond

4.01.00 CONTROL & OPERATION OF DRIVES / EQUIPMENTS

4.01.01 Flushing Water pump:

The flushing water pump is energized to cater to occasional flushing water requirement for slurry
disposal lines. Its suction is from ash water common sump.

Flushing water pump can be started when any one of the slurry series is selected in flushing mode
and water level of ash water common sump is > low set point. Once flushing mode is selected for
a particular slurry chain, suction valve of respective pump closes & discharge valve of the chain
opens automatically.
Operation of flushing water pump will be carried out from purchaser’s HMI thru’ actuation of
respective “START” & “STOP” push buttons.
Once flushing water pump is running & its adequate discharge pressure is sensed; the slurry
series start permissive energizes with a predetermined time delay & with all other regular
interlock & protection as per normal mode. The chain can now be taken in service for flushing of
slurry discharge line
Over & above of normal protection of slurry pump, in case, flushing water pump trips during
flushing; its corresponding series pump shall trip instantaneously.

Selector & Actuator:

SELECTOR : Normal / Flushing mode of each slurry series : at purchaser’s HMI
ACTUATION : START / STOP push button of motor : at Purchaser’s HMI
Series START / Series STOP push button : at Purchaser’s HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.
4.01.02 FAHP Water pump:
The FAHP water pumps (FAHP#A, FAHP#B, FAHP#C, FAHP#D & FAHP#E) supplies water
for following activities.
1) Water supply to HCSD System.
Three nos. FAHP water pumps can cater to the need one for each unit.
4.01.03 ECONOMISER Water pump:
The ECONOMISER water pump (ECO#A & ECO#B ) supplies water for following activities.
1) Water requirement of slurry sumps jetting.
2) Water requirement of common trough jetting.
3) Water requirement of ash slurry drain sump jetting.
4) Water requirement of economiser flushing boxes.
5) Water requirement of ECO. slurry pipe jetting.
One (1) no. ECO. water pumps can cater to the need of three units.
Suctions of FAHP & ECO. water pumps are taken from ash water common sump.

Selector & Actuator:

For FAHP Water Pump
SELECTOR : Auto standby – A / Auto standby – B
/ Auto standby – C / Auto standby – D / Auto standby – E / Manual: at
purchaser’s HMI
For ECO. Water Pump
SELECTOR : Auto standby – A / Auto standby – B / Manual: at purchaser’s HMI

For FAHP & Eco. Water Pump

ACTUATION : START / STOP push button for all the individual pumps : at
Purchaser’s HMI
EMERGENCY STOP : Emergency STOP push button

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(One no for each motor) : on Local PB .

Operation:
FLWP/FAHP / ECO. pumps are having identical selection & logic of operation
At first operator shall start the pumps through START actuation putting selector in manual
position. The discharge valve shall be subsequently opened manually. Keep the selector in auto
standby mode for the pump to be brought in auto service. Discharge valve for auto standby pump
shall be kept open for auto standby operation.
Note: For initial start, during commissioning or after long shut down, when discharge line is
empty; pump shall be started keeping discharge valve in partially opened condition. There after
all restart / auto start of pump shall be with discharge valve in open condition.
In auto mode of operation, the standby pump (kept selected) automatically starts
 if running pump/s stops due to electrical trip feedback and / or
 Due to non availability of discharge header pressure at or above preset setting for a preset
time as detected by pressure transmitters for FAHP / ECO. pumps
 Due to decrease of discharge header pressure in case the discharge header pressure falls
below a normal set point level and persists for a preset time during normal running of the
other pump.
In case of auto starting of standby pump due to decrease in discharge header pressure, one of the
pumps may be stopped as per operator’s discretion. However, in case the standby pump is
stopped, ‘auto standby starting’ logic will start functioning only if discharge header pressure
attains it’s normal level at least once during running of the pumps, after starting of standby
pump.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
Keeping selection in manual position, any pumps can be started through their respective START
buttons.
Indication & Alarm:
1) Running pump tripped / running status
2) Ash water sump level high.
3) Ash water sump level low.
4) Ash water sump level danger low.
5) Discharge header pressure high.
6) Discharge header pressure low.

4.01.04 HP & LP SEAL WATER PUMP :

HP & LP Seal water pumps (HPSWP#A / HPSWP#B & LPSWP#A / LPSWP#B) will supply
water for following requirement
 Gland sealing of ash slurry Disposal pumps.
 Gland sealing of sludge pump (by LP seal water pump)
 Gland sealing of drain pump in ash slurry pump house (by LP seal water pump)
To cater the need of three units one of the each seal water pump will run.
Selector & Actuator:
SELECTOR : Auto standby – A / Manual / Auto standby – B : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for both pumps : at purchaser’s HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.
.
(One no for each motor) : on Local PB station
NOTE: Actuation & selection of both the clear / seal water are identical.

Operation:
The HP seal water pump is operated to supply seal water for 2nd stage and the LP seal water
pump is operated to supply seal water for 1st stage of slurry disposal pumps of operating slurry

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pump series. Suction of both pumps is taken from common suction header of seal water tank. The
source of water for seal water tank is from purchaser’s service water source. There is separate re-
circulation valve for HP/LP pump set to take care minimum adequate flow during adverse
operational situation. Operator should keep the valve adjusted as per requirement. Generally one
no pump of each type is required for running of the three units.
Auto Mode
In auto mode, during running of one pump, the standby pump automatically starts if
 Running pump stops due to electrical trip feedback and / or
 Non-availability of discharge header pressure at or above preset setting as detected by
pressure transmitter

In case the discharge header pressure falls below normal set point and persists for a preset time
during normal running of the other pump; the pump selected in auto standby mode will take auto
start at the discretion of operator.
[The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
In case of auto starting of standby pump due to decrease in discharge header pressure, any one of
the pumps may be stopped which is as per operator’s discretion.
However, in case the standby pump is stopped, ‘auto standby starting’ logic will start functioning
only if discharge header pressure attains it’s normal level at least once during running of both the
pumps, after starting of standby pump.
Manual operation:
Keeping selection in manual position, any or both the pumps can be started through their
respective START button on HMI.

4.01.05 BA ASH SLURRY DISPOSAL PUMPS

Slurry accumulated in ash slurry sump shall be pumped out to distance ash pond through ash
slurry chain pumping. There are four (4) series each having two (2) nos. of pump in a series. At
least one as slurry chain for each unit should be in operation before commencement of any
deashing activities.
SELECTON / ACTUATION :
SELECTION : Normal / Flushing mode of each slurry series : at purchaser’s HM
ACTUATION : Series START / Series STOP pushbutton : at purchaser’s HMI
: Suction valve CLOSE actuation facility : at purchaser’s HMI
EMERGENCY : Emergency STOP push button (One no for each motor) : on Local PB
STOP station.

The operation of the ash slurry pump series will be carried out from purchaser’s HMI through
respective “Series Start” & “Series Stop” push buttons.

Operation
All the first stage pumps are coupled with drive motor through gear box – fluid coupling. Second
stage of each chain is belt driven types.

The cooling water for fluid coupling for 1st stage pump is provided from purchaser’s cooling
water header. There shall be temperature element provided with each fluid coupling system for
monitoring & protecting oil temperature.

With actuation of “SERIES START” button the respective stage wise pumps with associated
suction & discharge valve and the seal water / cooling water lines will energise in steps as per the
sequence indicated below; maintaining a predetermined time interval between two successive
steps of operations.

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Suction valve opens (If closed).
 Cooling water line valve for fluid coupling of the 1st stage pump motor will open and normal
pressure will be established.
 Seal water valve of all the pumps of the series will open.
 1st stage pump motor will start.
 1st stage pump seal water pressure will be normal within a preset time.
 Discharge valve opens within a preset time from starting of the 1st stage pump
 2nd stage pump motor will start within a preset time from opening of discharge valve..
 2nd stage pump seal water pressure will be normal within a preset time.
 Non-performance of any of the steps within respective preset time, will suspend series
starting attempt resulting in tripping of the series.
With actuation of “Series Stop” push button of 2nd stage ash slurry disposal pumps in series will
stop and thereafter the discharge valve will close after a preset time. Thereafter, 1st stage pump
will stop. Stopping of pumps will close seal & cooling water line valves. The pump suction valve
however will remain opens.
In the event of tripping or stopping of any one pump in the series, other pump in series will stop
instantaneously. Thereafter the discharge valve will close after a preset time from stopping of
pumps with subsequent closure of seal & cooling water line valves. The pump suction valve
however will remain open. The suction valve can be closed through purchaser’s HMI actuation
for the same.
The status of the individual pumps, normal pressure status of seal / cooling water line, open /
close status of suction & discharge valve and level of respective BA slurry sump compartment
will be monitored on purchaser’s HMI along with annunciation for abnormality for the same.
Flushing Of BA Slurry disposal Series / Line

Respective BA slurry disposal series initially should be in OFF condition & also should be
selected at flushing mode from HMI. Operator should then start the FLUSHING water pump
through START push button at HMI. Subsequently Series Start for the particular series is to be
actuated and then following action takes place sequentially.
 Suction valve of the series closes. (if found open)
 Thereafter the sequence of operation will be similar to BA slurry disposal pump normal
operation as indicated in para 3.2.5.2.1 except operation of suction valve.

4.01.06 BOTTOM ASH SLURRY DRAIN PUMP :

Drain / leakage water out of equipment within slurry pump house will accumulate in ash slurry drain
sump inside pump house. Ash Slurry Drain Pump shall be used to pump out such water to ash slurry
sump.
Selector & Actuator:

SELECTOR : Auto standby – A / Manual / Auto standby – B : at purchaser’s HMI

POP UP SELECTOR : Auto / Manual for individual pump : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at purchaser’s
HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local PB station.

Operation
 At first choose pump to be kept in service by putting selector in manual position.
 Start the pumps by manual command through START actuation and put the selector on Auto
(pop up selector) for level based start & stop of running and auto standby pump on
purchaser’s HMI
 The moment pump is started by satisfying all the starting permissive, its seal water valve will be
opened. If, preset seal water pressure is established within a preset time, as detected by pressure
switch the pump will continue to run; otherwise the pump shall trip with annunciation in

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purchaser’s HMI.
 Keep the selector in auto stand by mode for the pump to be brought in auto service,
 Incase, running pump trips, the pump already selected for auto-standby will take auto start
Once pump has taken a successful start and pop up selector (Auto/Manual) of running & auto standby
pump is put on ‘Auto’ position, operating pump will automatically start / stop depending on its sump
level i.e. stop when sump level reaches to low level & start when sump level reaches high. This ‘Auto’
logic will be active for the pump, which is in operation. If auto standby pump started once then ‘Auto’
logic will be active for stand by pump till operator’s intervene.
In case first pump is running in auto mode, and even then the sump level is not coming down within
preset duration from HIGH level condition, the second pump (pump selected for auto-standby
operation) will be started automatically, with purchaser’s HMI alarm as ‘Standby pump auto started
due to sump high level” and shall continue to operate till level is just below low, when both the pump
will stop. However 1st pump will be restarted again at sump high level and logic shall be as mentioned
above.
Auto standby Mode:

In auto standby mode of operation, the standby pump automatically starts if

 Any of the running pump trips (electrical trip feed back) and
 sump level is above low
Keeping selection in manual position, any or both the pumps can be started through their respective
START button on purchaser’s HMI.

4.02.00 ASH SLURRY SUMP MAKE-UP VALVE:

There is two (02) nos. ash slurry sump make-up valve for each sump compartment. The ash
slurry sump make-up valve is energized to cater to occasional make-up water requirement for
ash slurry sump compartment. It’s source from LP water pump header.

Each compartment is provided with one solenoid operated valve to supply make up water from
LP water source. The valve operates through PLC automatically in following manner.

Selection : Auto / Open / Close selector in HMI.

AUTO OPERATION:

While selector in auto position LP water make up valve:-

 Opens at sump level low
 Closes at sump level high

4.03.00 ASH SLURRY DRAIN PIT EJECTOR:

A drain pit is provided inside the ash slurry pump house and two (02) nos. jet pumps are located
into the drain pit. High-pressure water connection is provided at the inlet of each jet pump
through a solenoid operated valve.

The discharge lines from jet pumps are independently led back into the common slurry trough.

The liquid from various equipment leakages, if any, inside the pump house is accumulated into
the drain pit and is pumped back into the common slurry trough by operating the jet pumps, as
and when necessary.

A level switch is provided in the drain pit for sensing “ High” liquid level in the drain pit and
providing necessary control in the jet pump operation as described in controls and interlocks
write-up.

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The ash slurry disposal system is operated from “water & slurry pumping system panel” in co-
ordination with other panels as described in controls & interlocks write-up. The system is
provided with piping, valves and instruments as required for system operation.

With actuation of “SERIES STOP” push button all the slurry pumps in series will stop and
thereafter the discharge valve will close after a preset time from stopping of pumps with
subsequent closure of seal & cooling water line valves. The pump suction valve however will
remain opens.

In case of tripping or stopping of any one pump in the series, other pump in series will stop
instantaneously. Thereafter the discharge valve will close after a preset time from stopping of
pumps with subsequent closer seal water and cooling water line valves. The pump suction valve
will remain in open condition.

When the motors of any series stop due to stop commend or due to tripping, thereafter if
required, the suction valve can be closed through HMI actuation for the same.

START / STOP actuation facility of individual pump motor will be provided in HMI for de-
interlocked running of individual motor.

At the end of ash slurry pumping operation, respective ash slurry pumps and disposal line will
be flushed out for a pre-determined time by keeping series ‘OFF’ condition. The water for
flushing the disposal line is provided by HP water pump.

During system operation high pressure, jets from HP water line is supplied continuously into the
slurry sump for necessary churning of the slurry at the pump suction. Make-up water supply as
required is also maintained into the sump from system LP water supply. The solenoid operated
butter fly make-up valves, which are interlocked the sump operating levels and opens / closes
automatically are provided to control the sump level with level transmitter. By-pass arrangement
is provided for the above make-up line connecting LP water line with sump by a globe valve
(normally closed) in order to maintain the make-up water requirement in case of insufficiency of
water flow from the solenoid operated valves.

The ash slurry sump is provided with liners to take care of damages in sump walls by abrasive
nature of slurry.

The series of ash slurry disposal system is operated from CCC through HMI.

5.00.00 FLY ASH REMOVAL SYSTEM FROM STATION SILO:

5.01.00 The System

The silo unloading system provided under this contract, is designed for periodic removal of ash
collected in Silo during dry mode conveying from ESP hoppers,4 nos primary air hoppers and
4nos secondary air hoppers.
Under the system arrangement, fly ash collected in five silos will be cleared at periodic interval
or as and when required. There is one no motorised winch operated telescopic spout or one no
rotary unloader in each silo. Ash is unloaded. into tanker (for dry ash unloading) / open truck
(for moist ash unloading) as applicable. The fly ash thus collected in open truck / close tanker
will be transported out of plant for ultimate use.
Fly ash from ESP hoppers and APH hoppers can be collected in any of the five silos. Ash
unloading from each of the silos also can be done either through respective rotary unloader or
telescopic spout as per requirement.

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Instrument air from station IA compressors, free from dirt, scale & moisture at a desired
pressure will be used for operation of pneumatic actuation for various valves, gates, pulse
jetting etc.

5.01.01 CONTROL DEVICES & LOCATION

THE PROCESS CONTROL:

Logic relating to remote interlocked operation of the ash handling system will be executed
through Purchaser’s DCS. The subject DCS will hook-up the operator’s interfaces in control
room as well as in the Silo area to offer a composite and integrated facility for software driven
plant control and monitoring system. Logic processing as associated with actuations, indications
and annunciations on Silo Area System Panel (SASP) as well as actuations & indications on
local wet / dry unloading stations (LWUS / LDUS) will be at DCS unit.
Following operator’s interface in silo area will be provided to have local silo unloading related
selections and actuation with associated monitoring.
 A panel designated, as Silo Area System Panel (SASP) will be located inside electrical room
of silo utility building. This panel will have fiber glass painted LED spot illuminated mimic
and annunciator lamp boxes. Various pumps, blowers and air heaters under the silo
unloading system will be operated from this panel.
 Column / structure mounted Local unloading station for each set of wet and dry outlet
equipment located on silo unloading floor near respective unloading equipment. One no
Local Wet Unloading Station (LWUS) for each Wet Outlet and One no Local Dry
Unloading Station (LDUS) for each Dry Outlet will be provided.
Strategic status indications of dry/wet unloading equipment located at silo unloading floor i.e. of
various equipment / drives related to Wet & Dry outlet as well as strategic status indications of
silo roof valves and silo vent fan with associated pulse jetting for all the silos will be provided on
SASP.
In addition to above, facility is provided for emergency stop of the various remote controlled
motor drives and heaters through Local Push Button Stations having one no Mushroom head
emergency stop push button, to be located near to each drive.

5.02.00 SILO FLUIDISING BLOWER:

There are 06 nos. Silo Fluidising blowers and 06 nos. heaters. Each blower is connected to one
heater. Normally Blower-A will be connected to Silo-1, Blower-B will be connected to Silo-2,
Blower-C will be connected to Silo-3, Blower-D will be connected to Silo-4, Blower-E will be
connected to Silo-5, and blower-F can be connected to any of the silos (i.e. common stand by) if
the blower dedicated for the particular silo is not in operation. These blowers will provide
fluidising air to all the silos. One no blower with associated heater is required for operation of
one no Silo.

SELECTOR : For FASFB F : S1 / S2 / S3 / S4 / S5 / OFF

ACTUATION : START / STOP pushbutton for all Blowers : at SASP
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

Starting Permissive
 One out of two fluidizing valve is open.
Trip condition
 Differential pressure across suction filter is high.

Operation:
Silo-fluidizing blower-heater assembly will be utilised for fluidizing arrangement of all the five
silos. So long as dry ash is kept accumulated in silo, this fluidizing system should run. The
fluidizing system shall also remain energized during unloading from silo. In case of tripping of

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running blower, the stand by blower shall be taken in service in respective line after human
intervention for over all healthiness of the system.
Normally the connection interface will be as indicated below.
 BLOWER# A with associated heater will be connected to silo-1
 BLOWER# B with associated heater will be connected to silo-2
 BLOWER# C with associated heater will be connected to silo-3
 BLOWER# D with associated heater will be connected to silo-4
 BLOWER# E with associated heater will be connected to silo-5

BLOWER# F can be connected to any of the silo-1 or silo -2 or silo-3 or silo–4 or silo-
5 as per requirement with the help of associated pneumatic actuated ball valves. During running
condition if there is trouble in any of the blower-heater assembly, the standby blower-heater
assembly will have to be put in service with desired opening / closing of the associated valves.

Required blowers will be started from SASP though the respective Start push button. After
giving start command, silo aeration valves respective silo shall opens.

5.02.01 SILO FLUIDISING BLOWER HEATER

ACTUATION : START / STOP pushbutton for all heaters : at SASP

EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

Operation:
After blower is taken into service, respective heater will be put into service in following manner
to maintain temperature. There is one no. temperature element (TE) HI & (TE) HIHI provided
on each air heater to keep fluidizing air temperature within pre-set normal band as well as to
prevent overheating of air beyond a pre-HIGH set by means of automatic cut-in / cut-out control
of heating elements.

5.03.00 SILO AREA DRAIN PUMPS

To clear drainage water from drain sump near silo area, two nos. of Drain pumps are provided.
Out of two pumps one is working and other is standby. Wash water pump will cater seal water
requirement of Silo area drain pumps. Discharges of such pumps are given to slurry sump.

SELECTOR : Manual / Auto : at SASP

ACTUATION : START / STOP pushbutton for both pumps : at SASP
EMERGENCY STOP : Emergency stop push button (One no for each motor) : on Local PB
station (by purchaser)

Operation:
Keeping selector at manual position any pump can be started through START actuation from
SASP. Then selector can be put in Auto mode continuous level based START / STOP of pump.
In case of tripping of running pump, the other pump will be taken into service at the discretion of
operator.
With actuation of START command in SASP following actions will take place:-.
First seal water valve will OPEN with start actuation followed by starting of the pump.
Subsequently seal water pressure will be established.

With the selector switch at “MANUAL” position, any one of the pumps can be operated
independently by means of respective “START” & “STOP” push buttons in SASP, subject to
fulfillment of starting permissive. The pump started in “MANUAL” mode will stop
automatically, if the drain sump level reaches “LOW” level & remain below low level for preset
duration.

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5.04.00 ROTARY FEEDER:

The Rotary Vane Feeder operates at a variable speed and provides a reasonable uniform ash
feed rate for the Dry unloading unit installed below. The Rotary Feeder is suspended from top
for proper functioning of the expansion joint installed below the Feeder.

Selection & Actuation:

Speed selector : Increase / decrease push button for rotary feeder placed at LDUS.
Actuator: Forward / Reverse / STOP actuator at LDUS.
Enable/off selector at SASP is selected at enable position.

5.05.00 PNEUMATIC KGV ABOVE ROTARY FEEDER

One no. pneumatically controlled knife gate valve (KGV) is provided above rotary feeder for
start / stop feeding of dry ash into tanker through rotary feeder.
Opening permissive of KGV:
 Silo Fluidising blower is running
 Vent filter fan (for telescopic spout) running & pulse jet is ON
 Silo fluidising valve open impulse.
 Tanker ash level is low
 Rotary feeder is running.
Close conditions of KGV:
 Vent filter fan (for telescopic spout) tripped or
 Pulse jet is Off or
 Tanker ash level is high with pre set time duration or
 Rotary feeder tripped

Operation:
Place the tanker in position, & lower the telescopic spout in position before actuating Open push
button of KGV from LDUS, then increase / decrease the speed of rotary feeder.
Once tanker level is full as sensed by tanker level sensor, first knife gate valve closes & then
rotary feeder stops (optional) with predefined time delay.

5.06.00 CONDITIONING WATER PUMP:

ACTUATION : START / STOP pushbutton for all the pumps :at SASP
: Auto – open – close selector actuator of leak – off valve : at SASP
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

Operation:
There are six (6) no. conditioning water pumps located at silo area, suction of which are from
Silo Area Water Sump. This pump will cater water requirement for rotary unloaders for
conditioning of ash. One no. pump is generally required to put into service during unloading of
ash for each silo through Rotary Unloader and one is common stand by for all the silos.
These pumps will be operated from SASP through actuation of respective “START” & “STOP”
Push buttons.
Starting permissive & trip conditions of conditioning water pump.

 Starting permissive : Silo water sump level > LOW & leak-off valve selected at Auto.
 Trip condition : Silo water sump level is below Danger Low

One re-circulation line is connected from discharge header of conditioning water pump to silo
water sump through a leak off valve. At auto mode operation selection of this leak-off valve,
initially will be opened with the start command of the first conditioning water pump. It will
normally remains open. However it will be closed only when any one or all the conditioning

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water valves of rotary unloader will be opened. At manual mode the leak-off valve can be
operated through open / close selection of the selector actuator.

5.07.00 SILO WATER TANK MAKE-UP VALVE

The silo tank make-up water shall be provided from Purchaser’s nearby service water header.
One no make-up valve will be provided at silo water tank, which is to be operated from SASP,
depending on level signal from the level transmitter in auto mode.
In Auto mode selection from SASP through auto / open / close selector switch, the valve will
open if the level is low and it will be closed automatically when the level is high. In manual
mode, with close / open selection at SASP, the valve can be operated manually. However in
manual mode also the valve will be closed automatically when the level will be high. After
closing of the valve in manual mode at ‘High’ level condition, selection is to be changed to
‘Close’ position and thereafter it is to be selected again at ‘Open’ position.

5.08.00 WET (CONDITIONED) ASH UNLOADING

Actuation & Indication :
 Silo unloading permission ENABLE / OFF lockable selector switch (one no. each for silo 1
to 5) : at SASP
 Start & stop push button for Rotary unloader (one no. each for silo 1 to 5) : at LWUS.
 Open / close actuators for orifice feeder (one no. each for silo 1 to 5) : at LWUS
 Auto / open / close selector switch for water supply valve (one no. each for silo 1 to 5) : at
LWUS
 Conditioned water pressure normal indication (one no. each for silo 1 to 5) : at LWUS
 Rotary unloader tripped indication (one no. each for silo 1 to 5).
5.08.01 Operation : Wet (Conditioned) Ash Unloading Operation :

Wet (conditioned) ash unloading operation is carried-out in the following manner from
respective column / structure mounted ‘Local Wet Unloading Station’ (LWUS) located near
respective Rotary unloader.
Followings are the sequence of operation.
 The Silo unloading permission ENABLE / OFF selector for the respective silo at SASP is to
be put on ENABLE position. This will allow to operate from local unloading station before
starting operation.
 Start silo-aeration blower (if not running) from SASP.
 Opening of silo aeration valves.
 Open truck to be placed at right position under rotary unloader.
 Rotary unloader is to be started from LWUS by actuation of respective START push
button.
 Conditioning water pump is to be started from SASP, if not running
 Selector actuator for the water valve is to be put at auto mode
 Ensure normal water pressure in conditioned water line. (Pl. See note given below).
 KGV above orifice feeder to be open manually.
 Open orifice feeder.

Opening of orifice feeder will be depending on following permissives.

 Running of rotary unloader
 Normal conditioned water pressure.
 Conditioned ash will be collected in open truck.
Note : With positioning of orifice feeder open / close selector on ‘Open’ position, the rotary
unloader conditioning water valve opens first, if normal water pressure is established, the orifice
feeder opens. In case, orifice feeder does not open within a preset time period from actuation of
orifice feeder selector, the rotary unloader water supply valve shall be closed automatically.

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 For suspending the operation, first orifice feeder will be close followed by stopping of rotary
unloader, selecting off from LWUS.
 If the selector actuator of water valve is not put at auto position, the same can be operated
through open / close position of selector actuator.
5.09.00 DRY ASH UNLOADING

ACTUATION & INDICATION :

 Silo unloading permission ENABLE / OFF lockable selector switch (one no. each for silo 1
TO 5 ) : at SASP
 Silo unloading permission ‘Enable’ indication : at LDUS
 Start & stop push button for vent fan : at LDUS.
 On / Off selector & On indication for pulse jetting : at LDUS
 Forward, Reverse & Stop push button of rotary feeder : at LDUS
 Open / Close selector actuator for Knife gate isolation valve (KGV) : at LDUS
 Up, Down & stop push button for telescopic spout : at LDUS.
 Tanker level high indication : at LDUS.
 Rotary feeder tripped indication : at SASP
 Rotary feeder speed increase / decrease push button : at LDUS
Note : Strategic indication of equipment & drives installed at silo unloading floor, will be
provided on Silo Area System Panel (SASP) located at electrical room of Silo Utility Building.

5.09.01 Operation : Dry Ash Unloading

Dry ash unloading operation is carried-out in the following manner from respective column /
structure mounted ‘Local Dry Unloading Station’ (SULS).
Followings are the sequence of operation.

 The Silo unloading permission ENABLE / OFF selector for the respective silo at SASP is to
be put on ENABLE position. This will allow to operate from local unloading station before
starting operation.
 Start silo-aeration blower (if not running) from SASP.
 Opening of silo aeration valves.
 Tanker to be placed at right position under telescopic spout.
 Vent fan is to be started from LDUS by actuation of respective Start push button.
 Start pulse jetting from LDUS by actuating respective On / Off selector. High pressure air
jets in filter bags through actuation of a set of solenoid valves one after is provided.
 Telescopic spout is to be lowered up to the tanker by inching actuating through down push
button.
 Rotary feeder is to be started from LDUS by actuation of respective forward push button
 Manual KGV above Rotary feeder to be open.
 Open cylinder operated knife gate valve (KGV) from LDUS.
 Dry ash will be collected in closed tanker.
 During ash filling of the closed tanker with the availability of feedback from tanker high
level switch, as sensed by the tanker level switch, cylinder operated knife gate valve will
automatically Closes and again automatically Opens if feedback is not present with preset
time delay.
 After filling of the particular tanker is completed, the cylinder operated knife gate valve
selector is to be put at ‘Close’ position. Thereafter the telescopic spout is to be raised by
actuation of respective selector actuator at LDUS. This filling cycle shall be repeated for
other tankers.

HIGH CONCENTRATED SLURRY DISPOSAL SYSTEM:

6.00.00 The fly ash collected in various ESP hoppers and primary and secondary air pre-heater hoppers

1 : 40
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INDUSTRIAL...
PLANT SERVICES
are subsequently pneumatically conveyed through vacuum system up to the buffer hoppers and
then pneumatically conveyed through pressure system to fly ash silo or to silos meant for HCSD
system

Fly ash from HCSD silos is fed to mixing tank/agitator retention tank provided below silo
through weighing unit, rotary feeder and ash conditioner. The conditioned fly ash is further
wetted out by adding water in the mixing tank and then the entire ash is blended to a uniform
consistency by mixer. The quantities of ash and water are controlled in mixing tank for
achieving the right concentration of slurry.

The slurry from mixing tank/agitator retention tank shall be transferred to a positive
displacement type high concentrated ash slurry disposal pump. The HCSD pump shall discharge
the concentrated fly ash slurry up to ash dyke through seamless pipe lines.

Operating and control philosophy:

System Description

Dry fly ash from three (3) boilers will be stored in five (5) silos. Underneath each silo one (1)
ash slurry mixing system and pumping unit will be located.

The high density slurry system can be divided into two major system:
First, the slurry preparation system:
 Extraction, dosing and weighing of fly ash from the silos.
 Conditioning of fly ash and water in ash conditioner.
 Mixing and homogenization of high concentrated ash slurry in ATM’s.

Second, the slurry transportation:

 Booster Pumps
 GEHO piston diaphragm pumps.
 Main pipe lines
 Storage area for storing high concentration slurry

Extraction, dosing, weighing and mixing of fly ash

Each fly ash silo is equipped with two fly ash dosing, weighing and conditioner units which will
be in simultaneous operation. Fly ash is extracted and dosed at a controlled rate to the
conditioners by rotary feeders and mass flow meters. The moisturized fly ash is gravity fed into
the AMT located below the silo.
.
Agitated Mixing Tank:
Ash from two outlet pipes after rotary feeder is conditioned with Fly Ash HP water. The
conditioned ash falls in mixing tank where ash is mixed with water in right proportion and is
blended by agitator fixed with the tank.
The AMT’s duty is to:
 Mix the moist fly ash with water to a homogenous slurry
 Optimise the slurry consistency.
 Keep the ash slurry in a homogenous suspention
 Serve as a buffer capacity for the pumps.
Booster Pumps:
The booster pumps take suction directly from the ATMs and will feed and provide suction
pressure to the GEHO pumps. Booster Pump requires seal water for gland cooling. A flush
water line is provided in the suction of booster pump for flushing the line before start up.

1 : 41
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PLANT SERVICES
Suction Strainers:
An in-line strainer is installed at the discharge line of booster pump.This strainer will prevent
oversized ash lumps debris, scale pieces and foreign material from entering the HCSD pump and
avoid risk of blocking of pump inlet.The strainers are equipped with a flushing water connection
and a drain valve.
Mainline GEHO Pumps:
Five (5) nos GEHO duplex double- acting crankshaft driven piston diaphragm pumps size ZPM
800 are installed. Each pump is designed for a normal operating flow of 225m3/h ( based on
specified designed concentration of 60% ) and a maximum effective flow of 225 m3/h at a
discharge pressure of 47 bar. Each GEHO pump is provided with two air over slurry type
pressure vessel for the suction side of pump and nitrogen charged pulsation damper at the
discharge line.

6.01.00 HCSD SILO:

There are five nos HCSD silo each of capacity 250T for collecting ash carried pneumatically by
pressure conveying system from U# 1,U#2 and U#3. Ash line from three streams # X, # Y and
#Z is branched off from near Fly Ash Silo and flow towards HCSD silo.

Each HCSD silo is connected with vent filter and vent fan at the top.
From the bottom three pipe lines emerges out. Ash can be collected in closed truck from one pipe
line through rotary feeder and telescopic chute.

The other two pipes, each with manual isolating valve and cylinder operated isolating valve and
a rotary feeder goes to a mixing tank.

6.02.00 MIXING TANK:

Ash from two outlet pipes after rotary feeder is conditioned with Fly Ash HP water. The
conditioned ash falls in mixing tank where ash is mixed with water in right proportion and is
blended by agitator fixed with the tank.

6.03.00 HCSD SILO FLUIDISING BLOWER

There are four nos. silo fluidizing blowers, one working for each silo and one common stand by.
The four blowers are connected to four HCSD silo and one line from common header is
connected to the fifth silo.

6.04.00 HCSD SILO AREA DRAIN PUMP

There are 2 nos HCSD silo area drain pump, one working and one standby. The discharge from
drain pumps fall into BA slurry sump.

7.00.00 INSTRUMENT AIR SYSTEM :

There are two (02) nos .Instrument Air compressors each of 600 cuM/hr capacity and 8Kg/cm2
head, along with two (02) nos. air drying plant in each unit. Six sets of compressors along with
air dryers are housed in TAC house. Instrument airline from common discharge of air receiver of
each unit is connected to 80Nb header. Three 80nb Piping are further connected by a 100nb
header from where air lines are branched off to serve the requirement of all three units.

7.01.00 The instrument air compressor is energized to cater the instrument air in the following system /
areas / equipment -

i) To ash water pump house area.

ii) To ash slurry pump house area.

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INDUSTRIAL...
PLANT SERVICES
iii) To fly ash silo area.
iv) To FAE tower.
v) To bag filter.
vi) To fly ash vacuum conveying actuator.
vii) To wetting unit area.
viii) To bottom ash handling system.
ix) To ash transmitter ( nuvafeeder)
x) To changeover valve.
xi) To vacuum pump house area.
xii) To BA Overflow water Pump
xiii) To BA Overflow Sludge Pump
xiv) To BA Overflow Transfer Hopper area.

7.01.01 SELECTION :

Common selection for instrument air compressor.

Selection : Auto standby #A / Manual / Auto standby #B : at HMI

Actuation : Start / Stop push button for both IA Compressor at HMI.
Stop push button (one no. for each motor) on CCC.
Emergency Mushroom head emergency stop push button (one no. for each motor) on local
Stop : PB station.

7.01.02 OPERATION :

Out of two IA compressors provided for each unit, one would normally be working with the
other as standby in auto mode. However in manual mode, both the compressors can be operated
together. In auto mode of operation, the standby compressor will start, in case of tripping of the
running compressor subject to availability of all starting & running permissive.

In auto mode of running at first auto selection is to be at HMI & thereafter the selected
compressor in auto mode should be started (In case of auto mode the first compressor to run will
be compressor #B if the mode selected at auto standby #A and vice versa) through START
actuation on HMI at CCC putting selector in desired position.

When the air receiver pressure goes below the lower set value sensed by the pressure transmitter,
a solenoid valve on the pulse air line (from air-receiver) gets energized and the pulse air supply
to the compressor cylinder suction is cut-off. The compressor thereby runs at LOADED
condition.

When the air receiver pressure reaches at the higher set value sensed by the pressure transmitter,
a solenoid valve gets de-energized and the pulse air supply (from air-receiver) keeps the
compressor cylinder suction valve is open. The compressor thereby runs at UNLOADED
condition.

Loading & Unloading process shall be in 3 steps. For example, please consider where air
receiver reaches at or above maximum set pressure say P2, the compressor shall run 0% loading
& when it reaches at minimum set pressure say P1 the compressor shall run at 100% loading
where as when it reaches at set pressure in between P1 & P2 the compressor shall run at 50%
loading.

1 : 43
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INDUSTRIAL...
PLANT SERVICES
With actuation of start command, at first solenoid operated valve on cooling water supply line
will automatically open and subsequently cooling water supply line pressure as well as flow in
cooling water return line from the coolers and cylinders will be established.

Cooling water from after cooler and inter cooler will go back to return water header.

After starting, the compressor will continue to run if the lubricating oil pressure becomes normal
within a preset time.

The compressor will always remain unloaded during starting. It will start getting loaded after a
preset time (adjustable) form the starting of the motor. Under “Load-unload” regulation, the
drive motor will run continuously.

In auto mode operation (say compressor A is running & B is in standby mode, i.e. selection at
Auto Standby-B) if A trips, then compressor B will start automatically subject to availability of
all starting & running permissive for compressor B. Under this condition, manual intervention is
required for rectification of “A” compressor. Once “A” compressor is ready for operation, one
should change auto selection from Auto Standby-B to Auto Standby-A, so that compressor “A”
will now be under standby mode.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
Keeping selection in manual position, any compressors can be started through their respective
START button on HMI.

To protect compressor against over pressurization in respect to upper limit of design pressure of
compressor jacket, a pressure reducing device (PRD) is provided on cooling water inlet line to
HP & LP cylinder jacket. This PRD will regulate the cooling water pressure to inlet of cylinder
jacket so that the pressure remains within permissible design value. But in case of eventual rise
of this pressure as sensed by the High pressure switch on cooling water line, the inlet solenoid
valve will close automatically to disconnect compressor from water source resulting in tripping
of the compressor.

Solenoid operated auto drain trap with in built cyclic timer will be provided with inter cooler and
after cooler for periodic draining of accumulated water.

7.02.00 AIR DRYER SYSTEM :

Two (02) nos. Regenerative heater type Air Drying Plant (ADP) is provided for each instrument
air compressor. Each ADP has two nos. drying towers with pre and after filters. Out of two air
dryer provided, one operates to meet one instrument air compressor requirement, as said above,
and the other remains as stand-by under normal operating condition

Blower selection of each ADP for each unit.

Selection :
Blower #1 & Blower #2 at HMI for each unit.

Actuation : Start / Stop command actuation facility for both ADP at HMI.
Stop push button (one no. for each ADP) on CCC.
Emergency Mushroom head emergency stop push button (one no. for each blower & heater)
Stop : on local PB station.

OPERATION :

1 : 44
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INDUSTRIAL...
PLANT SERVICES
Each air dryer comprises two drying towers filled with desiccant. When one tower is put into
drying cycle, the other one is subjected to regeneration as per preset time cycle. For a particular
tower, time cycle consisting of absorption-regeneration-absorption cycle. After completion of
absorption there will be de-pressurization then regeneration & ventilation when blower & heater
shall be taken in service, there after before starting absorption it shall be purged out.

Each air dryer also comprises of two nos reactivation blowers out of which one is working as
per HMI selection and the other remains standby. In case of tripping of the running blower, the
other one is to be put into service manually. Besides this each ADP unit also consists of one no
heater.
 ADP unit can be started when the respective up-stream I.A. Compressor is running.
 ADP heater will be started when
 Any of the respective blower is running.
 Flow of air from blower discharge header through heater is normal.
 Heater discharge air temperature < High.
Out of two nos. tower, one tower will be in drying cycle for 8 hours and at the same time the
other one will be in regenerative cycle. At the end of 8 hours time the operation of the towers
will be just interchanged.
Air from blower will be conveyed to the tower under regeneration through the heater. The heater
will be on / off as per the feed back from the TIC controller of the ADP depending on the
temperature of the discharge air from heater to maintain the temperature within a band. However
in case of very high temperature heater will be tripped with respective annunciation.

Time period of this cyclic drying-regenerative Sequence for the ADP will be as under
 After the changeover from drying into regeneration, the respective tower is de-pressurized to
atmosphere by opening the de-pressurization valve, which remains open for a preset time.

 After a preset time from starting of de-pressurization, the selected reactivation blower will
be started and the ADP heater will be on.
 After another preset time, the heater will be switched-off.

 However the blower runs continuously for prefixed time and even after the heater is
switched off at the end of preset time duration as per time cycle to bring down the
temperature. Then the blower will be switched-off after end of preset timing for blower as
per the time cycle.

 After the blower is stopped, the regenerated tower is re-pressurized to line pressure for a
preset time by opening the re-pressurization valve followed by automatic changeover into
drying cycle at the end of 8 hours regeneration cycle.

8.00.00 GENERAL COMMENTS ON ASH CONVEYING SYSTEM MAINTENANCE :

Successful operation of the ash conveying system depends upon careful observation,
maintenance and proper attention in due time. A slight delay in attaining a simple fault may
cause damage to the entire system.

Because of varying degrees of abrasives of ash, it is difficult to predict the part or parts, which
will be subjected to greatest wear and earliest failure. It is, therefore necessary for the
maintenance personnel to detect the worn-out part or parts causing mal-operation of the system

8.01.00 1) BOTTOM ASH SYSTEM :

1 : 45
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INDUSTRIAL...
PLANT SERVICES
Bottom Ash System is normally meant for intermittent operation. As such maintenance,
work can be carried out when the system remains inoperative. A stand-by set of feed gate,
clinker crusher, jet pulsion pump has been provided for V-shaped of bottom ash hopper.
The clinker crusher may be shifted from its position for maintenance keeping the bottom
ash system operation through the stand-by set of equipment.

8.02.00 2) FLY ASH SYSTEM :

The fly ash system is also normally meant for intermittent operation. As such
maintenance, work can be carried out when the system remains inoperative. As such,
maintenance of work for the defective equipment can be accomplished keeping the system
operation “ON” through the stand-by equipment. In case maintenance of a particular
stream of vacuum conveying line is to be carried out, the same may be closed and ash
cleaning from all other streams may be continued while the defective stream/equipment
may be rectified/replaced as quickly as possible. It may be necessary to isolate a hopper
for maintenance purpose but storing ash for a period more than the storage capacity of the
hoppers will need emergency unloading of ash from hoppers.

1 : 46
 SECTION - 2

SCHEDULE OF INSTRUMENTS
 ANNEXURE-I
(16.08.2011)

Clarification / confirmation to NTPC’s comment on “Consolidated Instrument

Schedule” NTPC Doc. No.: 0330-162-PVI-H-004, Rev-04

We re-clarify and re-confirm that Sensors & Gauges integral to various power electrics
items including drive motors are separately recorded under project electrical documents.
According the same are not incorporated in process instrument schedule.

We, however, re-confirm that the HT Motors including HT Motors as mandatory spares
are having (per contract specification) winding embedded PT100 RTDs (3 nos. for use
plus 9 nos. spare), (1 nos. use plus 3 nos. spare) PT100 RTDs and 1 no. Bearing
Temperature Dial in each of the two end bearing housing.
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM

INSTRUMENT SCHEDULE
NTPC DOC. NO.0330-162-PVI-H-004, REV-05
DCIPS DOC. NO. 28P01-1A-D-053, REV-05

INDEX
PART-1 MECHANICAL INSTRUMENT SCHEDULE
MECHANICAL INSTRUMENT SCHEDULE FOR HCSD
PART-2
SYSTEM
PART-3 ELECTRONICS INSTRUMENT SCHEDULE
ELECTRONICS INSTRUMENT SCHEDULE FOR HCSD
PART-4
SYSTEM
PART-5 INSTRUMENTS OF BROUGHT OUT ITEMS
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM
INSTRUMENT SCHEDULE
NTPC DOC. NO.0330-162-PVI-H-004, REV-05
DCIPS DOC. NO. 28P01-1A-D-053, REV-05

INDEX
PART-1 MECHANICAL INSTRUMENT SCHEDULE
Sl. No. ANNEXURE TITLE

1 ANNEXURE- A BOURDON TYPE PRESSURE / VACUUM GAUGE

2 ANNEXURE- B DIAPHRAGM TYPE PRESSURE / VACUUM GAUGE

3 ANNEXURE- C DIFFERENTIAL PRESSURE GAUGE

4 ANNEXURE- D DIFFERENTIAL PRESSURE SWITCH

5 ANNEXURE- E DISPLACER TYPE LEVEL SWITCH

6 ANNEXURE- F LEVEL INDICATOR

7 ANNEXURE- G PRESSURE SWITCH

8 ANNEXURE- H TEMPERATURE INDICATOR

9 ANNEXURE - I SIGHT FLOW INDICATOR

 ANNEXURE-A
INSTRUMENT SCHEDULE
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-05
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE TOTAL INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) (NOS.) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
AT VACUUM LINE NEARLY TO 254mmHg(g) 760mmHg(g)
102

1 FVO BOURDON VACUUM AIR 80 (-1) - 0 200 8 8 8 _ D.O.L.

VACUUM PUMP HOUSE (VI) (Vacuum) (Vacuum)

INSTRUMENT
105

2 AIO AT AIR FILTER STATION BOURDON _ _ 60 (-1) - 0 125 2 2 2 _ D.O.L.

AIR

30

AT B.A. SEAL WATER PUMP SUCTION B.A. SEAL

101

3 WSO BOURDON 0.30 1.00 45 0-1 150 _ _ _ 1 D.O.L.

LINE WATER
ESP /
AT ESP & BUFFER HOPPER
BUFFERHOPP
102

4 AFH FLUIDISING BLOWER DISCHARGE BOURDON 0.40 0.44 150 0-1 100 1 1 1 _ D.O.L.
ER FLIDISING
LINE
AIR
MANIFOLD AT DISCHARGE LINE OF SILO
103

5 AFS BOURDON 0.60 0.66 150 0-1 _ _ _ _ 1 D.O.L.

SILO FLUIDISING BLOWER FLUIDISING AIR
104

6 WSL SEAL WATER TANK DISCHARGE BOURDON SEAL WATER 0.20 1.00 45 0-1 100 _ _ _ 1 D.O.L.

ECO WATER LINE TO ECO HOPPER

101

8 WEP BOURDON ECO WATER 3.00 9.30 45 0 - 10 40 4 4 4 _ D.O.L.

FLUSHING BOX

INSTRUMENT
101

9 AIO AIR FILTER STATION OUTLET BOURDON 6.00 8.80 60 0 - 10 25 _ _ _ 1 D.O.L.

AIR

INSTRUMENT
103

10 AIO AT AIR RECEIVER FOR SILO AREA BOURDON 5.00 8.80 60 0 - 10 _ _ _ _ 2 2 D.O.L.
AIR
1 1 1
INSTRUMENT
103

11 AIO INSTRUMENT AIRLINE TO SILO AREA BOURDON 5.00 8.80 60 0 - 10 80 _ _ _ 2 D.O.L.

AIR 2

AT AIR RECEIVER FOR BAG FILTER INSTRUMENT

103

12 AIO BOURDON 5.00 8.80 60 0 - 10 _ 2 2 2 _ D.O.L.

PULSE JETTING SYSTEM AIR

AT DISCHARGE LINE OF CONDITIONING

103

13 WGO BOURDON 4.50 5.20 45 0 - 10 80 _ _ _ 6 D.O.L.

CONDITIONING WATER PUMP WATER

DISCHARGE HEADER LINE OF CONDITIONING

103

14 WGO BOURDON 4.50 5.20 45 0 - 10 50 _ _ _ 1 D.O.L.

CONDITIONING WATER PUMP WATER

CONDITIONING WATER LINE TO SILO CONDITIONING

103

15 WWS BOURDON 4.10 5.20 45 0 - 10 15 _ _ _ 2 D.O.L.

AREA DRAIN PUMP SEALING WATER

16 DELETED

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 1 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-05
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE TOTAL INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) (NOS.) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)

17 DELETED

AT DISCHARGE LINE OF L.P. SEAL L.P.SEAL

104

18 WSL BOURDON 6.50 9.00 45 0 - 10 80 _ _ _ 2 D.O.L.

WATER PUMP WATER

AT R.C. LINE FOR L.P. SEAL WATER L.P.SEAL

104

19 WSL BOURDON 6.50 9.00 45 0 - 10 50 _ _ _ 1 D.O.L.

PUMP WATER

AT L.P. SEAL WATER LINE FOR L.P.SEAL

104

20 WSL BOURDON 2.60 9.00 45 0 - 10 15 _ _ _ 2 D.O.L.

O'FLOW SLUDGE PUMP SEALING WATER

AT L.P. SEAL WATER LINE FOR B.A L.P.SEAL

104

21 WSL BOURDON 2.50 9.00 45 0 - 10 25 _ _ _ 2 D.O.L.

SLURRY DRAIN PUMP SEALING WATER
DM WATER LINE FOR 1st STAGE OF
COOLING
104

22 WEO ASH SLURRY DISPOSAL PUMP FC BOURDON 2.00 5.00 45 0 - 10 40 _ _ _ 4 D.O.L.

WATER
COOLING
AT F.A.H.P. WATER PUMP DISCHARGE F.A.H.P.
104

23 WHF BOURDON 6.20 7.00 45 0 - 10 150 _ _ _ 5 D.O.L.

LINE WATER
AIR RECEIVER TOP AT IAC INSTRUMENT
105

24 AIO BOURDON 6.00 8.80 60 0 - 10 _ 2 2 2 _ D.O.L.

DISCHARGE (AIR) AIR
INSTRUMENT
105

25 AIO AIR RECEIVER OUTLET (AIR) BOURDON 6.00 8.80 60 0 - 10 100 1 1 1 _ D.O.L.
AIR
IA COMPRESSOR COOLING INLET COOLING
105

26 WCO BOURDON 2.50 7.00 45 0 - 10 40 2 2 2 _ D.O.L.

(WATER) WATER

IA COMPRESSOR COOLING RETURN COOLING

105

27 WCO BOURDON 2.50 7.00 45 0 - 10 40 4 4 4 _ D.O.L.

(WATER) WATER

INSTRUMENT
105

28 AIO AFTER COLLER OUTLET(IA PACKGE) BOURDON 6 8.8 50 0 - 10 65 2 2 2 _ D.O.L.

AIR

81

AT DISCHARGE LINE OF H.P. SEAL H.P. SEAL

104

34 WSH BOURDON 11.00 13.00 45 0 - 16 80 _ _ _ 2 D.O.L.

WATER PUMP WATER

AT L.P. SEAL WATER LINE FOR 1 st

L.P.SEAL
104

35 WSL STAGE OF ASH SLURRY DISPOSAL BOURDON 5.65 9.00 45 0 - 16 25 _ _ _ 4 D.O.L.

WATER
PUMP SEALING
H.P. SEAL WATER LINE FOR 2nd
H.P. SEAL
104

36 WSH STAGE OF ASH SLURRY DISPOSAL BOURDON 9.80 13.00 45 0 - 16 25 _ _ _ 4 D.O.L.

WATER
PUMPS SEALING
AT DISCHARGE LINE OF ECO WATER ECO ASH
104

37 WEP BOURDON 7.00 9.30 45 0 - 16 200 _ _ _ 2 D.O.L.

PUMP WATER

12

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 2 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-05
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE TOTAL INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) (NOS.) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)

B.A.H.P.
101

38 WHB AT B.A. JET PUMP WATER INLET LINE BOURDON 11.50 12.00 45 0 - 20 150 4 4 4 _ D.O.L.
WATER

AT R.C. LINE FOR H.P. SEAL WATER H.P. SEAL

104

39 WSH BOURDON 12.50 13.80 45 0 - 20 40 _ _ _ 1 D.O.L.

PUMP WATER

AT DISCHARGE LINE OF B.A.H.P. B.A.H.P.

104

40 WHB BOURDON 11.50 12.00 45 0 - 20 250 _ _ _ 3 D.O.L.

WATER PUMP WATER

16

AT B.A.SEAL WATER LINE FOR ASH B.A. SEAL

101

41 WSO BOURDON 1.50 3.90 45 0-4 25 4 4 4 _ D.O.L.

CRUSHER SEALING WATER
PURCHASER'S SERVICE WATER LINE
B.A. SEAL
101

42 WEO FOR B.A. O'FLOW PUMP FLUID BOURDON 2.00 3.90 45 0-4 40 2 2 2 _ D.O.L.
WATER
COUPLING COOLING
WATER LINE HEADER TO VACUUM BA AREA SEAL
102

43 WEO BOURDON 2.00 3.90 45 0-4 80 1 1 1 _ D.O.L.

PUMP WATER

WATER LINE FOR VACUUM PUMP BA AREA SEAL

102

44 WEO BOURDON 1.00 3.90 45 0-4 40 8 8 8 _ D.O.L.

SEALING WATER

AIR RECEIVER AT DISCHARGE LINE TRANSPORT

103

45 ACO BOURDON 1.75 2.75 160 0-4 _ 3 3 3 _ D.O.L.

OF TRANSPORT AIR COMPRESSOR AIR

AT TRANSPORT AIR LINE TO STREAM TRANSPORT

103

46 ACO BOURDON 1.75 2.75 160 0-4 200 3 3 3 _ D.O.L.

LINE AIR

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 3 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-05
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE TOTAL INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) (NOS.) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
AT FLUSHING WATER PUMP FLUSHING
104

47 WFP BOURDON 1.80 2.60 45 0-4 350 _ _ _ 1 D.O.L.

DISCHARGE LINE WATER

64

AT RING HEADER SEAL TROUGH B.A.L.P.

101

48 WLB BOURDON 2.30 2.90 45 0-6 150 1 1 1 _ D.O.L.

MAKEUP / FLUSHING LINE WATER

B.A.L.P.
101

49 WLB REFRACTORY COOLING LINE BOURDON 2.30 2.90 45 0-6 150 1 1 1 _ D.O.L.
WATER

AT B.A. SEAL WATER PUMP B.A. SEAL

101

50 WSO BOURDON 3.50 3.90 45 0-6 150 _ _ _ 2 D.O.L.

DISCHARGE LINE WATER

AT B.A. SEAL WATER PUMP B.A. SEAL

101

51 WSO BOURDON 3.50 3.90 45 0-6 200 _ _ _ 1 D.O.L.

DISCHARGE HEADER LINE WATER
AT B.A.SEAL WATER LINE TO B.A. B.A. SEAL
101

52 WSO BOURDON 2.90 3.90 45 0-6 25 2 2 2 _ D.O.L.

O'FLOW WATER PUMP SEALING WATER
AT CONDITIONING WATER LINE TO CONDITIONING
103

53 WGO BOURDON 2.50 5.20 45 0-6 65 _ _ _ 5 D.O.L.

DUST CONDITIONAR WATER
AT DISCHARGE LINE OF WASH
103

54 WWS BOURDON WASH WATER 2.50 3.10 45 0-6 80 _ _ _ 2 D.O.L.

WATER PUMP
PURCHASER'S
104

55 WSL SEAL WATER TANK INLET BOURDON SERVICE 1.50 6.00 45 0-6 150 _ _ _ 1 D.O.L.
WATER
AT DISCHARGE LINE OF B.A.L.P. B.A.L.P.
104

56 WLB BOURDON 2.30 2.90 45 0-6 350 _ _ _ 5 D.O.L.

WATER PUMP WATER
28
COOLING
105

58 WCO INTER COLLER OUTLET (WATER) BOURDON 2.5 7.00 45 1 - 10 20 2 2 2 _ D.O.L.

WATER
6

NOTE : ALL PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 4 of 4

 ANNEXURE-B
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DIAPHRAGM TYPE PRESSURE/ VACUUM GAUGE, REV-05
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE (kg TOTAL
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) /cm2) (NOS.)
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
AT DISCHARGE LINE OF ASH SLURRY
104
1 SDO DIAPHRAGM ASH SLURRY 9.00 10.80 60 0 - 16 350 _ _ _ 4
DISPOSAL PUMP

AT B.A. O'FLOW WATER PUMP B.A. O'FLOW

101

2 DPB DIAPHRAGM 1.40 1.80 60 0-4 250 2 2 2 _

DISCHARGE LINE WATER

AT DISCHARGE LINE OF B.A. O'FLOW O'FLOW

104

3 DPB DIAPHRAGM 1.60 1.80 45 0-4 100 _ _ _ 2

SLUDGE PUMP SLURRY

AT PI CONNECTION OF B.A. SLURRY

104

4 DPO DIAPHRAGM DRAIN WATER 1.00 1.20 60 0-4 100 _ _ _ 2

DRAIN PUMP DISCHARGE

10
101

5 BJO AT B.A. JET PUMP DISCHARGE LINE DIAPHRAGM B.A. SLURRY 2.00 3.00 60 0-6 200 4 4 4 _

AT DISCHARGE LINE OF SILO AREA SILO DRAIN

103

6 DPS DIAPHRAGM 2.60 2.90 45 0-6 150 _ _ _ 2

DRAIN PUMP WATER

14

NOTE : 1) ALL THE PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

2) ALL THE PRESSURE GAUGES ARE DIRECT MOUNTED TYPE.

M:/BARH / INSTRU SCHEDULE / PRESS VAC GAUGE Page 1 of 1

 ANNEXURE-C
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-I, (3 X 500 MW) UNIT #1,#2,#3
DCIPS JOB NO.: 28P01
DIFFERENTIAL PRESSURE GAUGE, REV-05
DESIGN
P& I INSTRUMENT RANGE PIPE SIZE QTY FOR QTY FOR QTY FOR QTY FOR
SL NO. TAG LOCATION FLUID MEDIUM PRESSURE TEMP.(Deg. C) REMARKS
DIAGRAM TYPE (mmWC) 2 (NB) #1 #2 #3 COMMON
(Kg/ cm )
ASH
AT DIFFERENTIAL PRESSURE ACCROSS FREE &
1 103 ACO DIAPHRAGM CONTAMINETED 0 - 1500 300 mm of Hg 150 15 8 8 8 _
DUST AIR OF BAG FILTER
AIR
ASH
AT DIFFERENTIAL PRESSURE ACCROSS FREE &
2 103 ACO DIAPHRAGM CONTAMINETED 0 - 1500 1.4 150 15 _ _ _ 5
DUST AIR OF VENT FILTER SILO
AIR
ASH
3 103 LUO VENT FILTER ON TELESCOPIC SPOUT DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
AIR
ASH
AT MAIN SILO FLUIDISING BLOWER SUCTION
4 103 AFS DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 _ _ _ 6
FILTER 2
AIR
ASH
AT ESP - BUFFER HOPPER FLUIDISING BLOWER
5 102 AFH DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 2 2 2 _
SUCTION FILTER 2
AIR
ASH
6 103 ACO AT TAC SUCTION FILTERS DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 3 3 3 _
2
AIR
ASH
7 105 AIO AT IA COMPRESSOR SUCTION FILTER DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 2 2 2 _
2
AIR
ASH
8 105 AIO AT AIR DRYING PLANT BLOWER SUCTION FILTER DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 2 2 2 _
2
AIR
ASH
9 105 AIO AT PRE FILTER & AFTER FILTER OF ADP DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 8 8 8 _
2
AIR

TOTAL 91

NOTE : ALL DIFFERENTIAL PRESSURE GAUGES ARE DIRECT MOUNTED TYPE

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-D
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01

DIFFERENTIAL PRESSURE SWITCH, REV-05

INSTRUMENT PIPE TOTAL
SL P& I INSTRUMENT ACTUATION RANGE TEMP.
TAG LOCATION FLUID MEDIUM SET POINT SIZE QTY REMARKS
NO. DIAGRAM TYPE REASON (mmWC) (Deg. C)
(mm WC) (NB) (NO.)
5 NOS FOR
ASH
ACROSS VENT FILTER ON TELESCOPIC COMMON
1 103 ACO DIAPHRAGM CONTAMINETED PR. HIGH 50 - 600 200 150 15 5
SPOUT FOR MAIN SILO SYSTEM (GM -
AIR
301)
2 NOS PER
ESP / BUFFER HOPPER FLUIDISING ATM.
3 102 AFH DIAPHRAGM ATM. AIR 50 - 600 200 50 100 6 UNIT (GM -
BLOWER INLET FILTER PRESSURE
301)
6 NOS FOR
MAIN SILO FLUIDISING BLOWER INLET ATM. COMMON
4 103 AFS DIAPHRAGM ATM. AIR 50 - 600 200 50 125 6
FILTER PRESSURE SYSTEM (GM -
301)
2 NOS PER
6 105 AIO PRE FILTER OF AIR DRYING PLANT DIAPHRAGM INSTRUMENT AIR PR. HIGH 50 - 600 200 50 50 6 UNIT (GM -
301)
2 NOS PER
DRY INSTRUMENT
7 105 AIO AFTERFILTER OF AIR DRYING PLANT DIAPHRAGM PR. HIGH 50 - 600 200 150 50 6 UNIT (GM -
AIR
301)
2 NOS PER
INSTRUMENT AIR COMPRESSOR INLET ATM.
8 105 AIO DIAPHRAGM ATM. AIR 50 - 600 200 50 _ 6 UNIT (GM -
FILTER PRESSURE
301)
2 NOS PER
ATM.
9 103 ACO AT TAC SUCTION FILTERS DIAPHRAGM ATM. AIR 50 - 600 200 50 _ 9 UNIT (GM -
PRESSURE
301)

44

NOTE : ALL DIFFERENTIAL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-E
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DISPLACER TYPE LEVEL SWITCH, REV-05

INVERT TOP OF
DENGER LOW GUIDE PIPE
P&I FLUID TEMP HIGH LEVEL LOW LEVEL LEVEL OF SUMP / TOTAL
SL NO. TAG NO. SERVICE LOCATION LEVEL EL LENGTH REMARKS
DIAGRAM .( 0C ) EL (mm) EL (mm) SUMP / TANK TANK QTY (NO.)
(mm) (mm)
EL (mm) EL (mm)

ASH
SILO AREA DRAIN AS
1 103 DPS CONTAINMINA 50 (-) 600 (-) 1450 - (-) 2300 (-)300 1
SUMP REQUIRED
TED WATER
ASH
AS
2 104 DPA CONTAINMINA SEAL WATER TANK 50 (+) 5600 (+) 3300 - (+) 2800 (+)6000 1
REQUIRED
TED WATER

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-F
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
LEVEL INDICATOR, REV-05
INVERT LEVEL TOP OF SUMP /
DENGER
FLUID HIGH LEVEL LOW LEVEL OF SUMP / SUMP / TANK QTY. FOR QTY. FOR QTY. FOR QTY. FOR
SL NO. P & I DIAGRAM TAG NO. SERVICE LOCATION LOW LEVEL REMAKS
TEMP.(0C) EL (mm) EL (mm) TANK EL TANK EL DEPTH #1 #2 #3 COMMON
EL (mm)
(mm) (mm) (mm)
BA OVERFLOW
1 101 SB ASH WATER TRANSFER 60 (+) 5550 _ (+) 1650 (+) 1150 (+) 5950 4800 1 1 1 _
HOPER

2 104 SDO ASH WATER SURGE BIN 60 (+) 6800 _ (+) 1550 (+) 550 (+) 6900 6350 _ _ _ 1

SEAL WATER
3 104 DPB ASH WATER 45 (+) 5600 (+) 4300 (+) 3300 (+) 3000 (+) 5900 3100 _ _ _ 1
TANK

ASH WATER
4 104 DPO WATER 45 (+) 2825 (+) 1300 (-) 500 (-) 1800 (+) 3325 5125 _ _ _ 1
SUMP

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-G
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE SWITCH, REV-05
SHUT OFF/ MAX.
INSTRUMENT PIPE QTY FOR QTY FOR QTY QTY FOR
SL P&I INSTRUMENT ACTUATION WORKING ACTUATION TEMP. RANGE TOTAL
TAG NO. LOCATION FLUID MEDIUM SET POINT SIZE #1 #3 FOR #2 COMMON REMARK
NO DIAGRAM TYPE REASON PRESSURE TYPE (Deg. C) (kg /cm2) (NOS.)
(Kg / cm2) (NB) (NO.) (NO.) (NO.) (NO.)
(kg/cm2) 2

BA SEAL WATER PUMP FIXED DIFF. PRESSURE PURCHESER

101

1 WHB 1.00 0.25 FALLING 45 0.2 - 1 150 _ _ _ 1 GM - 201

SUCTION LINE BELLOW TYPE LOW SERVICE WATER

1.00

B.A. O'FLOW WATER PUMP FIXED DIFF. PRESSURE B.A. SEAL

101

2 WSO 3.92 2.20 FALLING 45 0.4 - 4 25 2 2 2 _ GM - 201

SEALING BELLOW TYPE LOW WATER

TO B.A. O'FLOW PUMP FLUID FIXED DIFF. PRESSURE B.A. SEAL

101

3 WSO 3.92 1.70 FALLING 45 0.4 - 4 40 2 2 2 _ GM - 201

COUPLING BELLOW TYPE LOW WATER

HEADER LINE FOR VACUUM FIXED DIFF. PRESSURE BA AREA SEAL

102

4 WEO 3.92 1.70 FALLING 45 0.4 - 4 80 1 1 1 _ GM - 201

PUMP SEALING BELLOW TYPE LOW WATER

FLUID COUPLING OF 1ST

FIXED DIFF. PRESSURE COOLING
104

5 WCO STAGE ASH SLURRY DISPOSAL 2.50 1.70 FALLING 45 0.4 - 4 40 _ _ _ 4 GM - 201
BELLOW TYPE LOW WATER
PUMP

FOR O'FLOW SLUDGE PUMP FIXED DIFF. PRESSURE L.P. SEAL

104

6 WSL 4.00 2.60 FALLING 45 0.4 - 4 15 _ _ _ 2 GM - 201

SEALING BELLOW TYPE LOW WATER

21.00

BA SEAL WATER PUMP FIXED DIFF. PRESSURE B.A. SEAL

101

7 WSO 3.92 3.52 FALLING 45 0.6 - 6 200 _ _ _ 1 GM - 201

DISCHARGE LINE BELLOW TYPE LOW WATER
2

SILO AREA DRAIN PUMP FIXED DIFF. PRESSURE CONDITIONING

103

8 WGO 5.20 3.81 FALLING 45 0.6 - 6 15 _ _ _ 2 GM - 201

SEALING BELLOW TYPE LOW WATER
2

3.00

FIXED DIFF. PRESSURE

103

9 AIO TO SILO AREA INSTRUMENT AIR 8.80 5.00 FALLING 50 1 - 10 80 _ _ _ 2 GM - 201

BELLOW TYPE LOW

2.00

NOTE : 1) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT EXACT SYSTEM REQUIREMENT.
2) ALL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL Page 1 of 1

 ANNEXURE -H
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
TEMPERATURE INDICATOR, REV-05

P&I MAX FLUID INSTRUMENT PIPE SIZE QTY FOR QTY FOR QTY FOR QTY FOR TOTAL
SL NO TAG NO LOCATION SERVICE REMRKS
DIAGRAM TEMP DEG. C RANGE (NB) #1 #2 #3 COMMON (NOS.)

1 DELETED

WATER OUTLET AT 1st

2 105 SDO COOLING WATER 45 0 - 100 20 2 2 2 _
STAGE CYLINDER

WATER OUTLET AT 2nd

3 105 SDO COOLING WATER 45 0 - 100 20 2 2 2 _
STAGE CYLINDER

4 105 SDO AFTER COOLER OUTLET COOLING WATER 45 0 - 100 40 2 2 2 _

5 105 AIO AIR RECEIVER AT SILO TOP INSTRUMENT AIR 50 0 - 100 65 2 2 2 _

24

AT ESP & BUFFER HOPPER

6 102 AFH FLUIDISING BLOWER FLUIDISING AIR 150 0 - 200 100 1 1 1 _
HEATER DISCHARGE
AT DISCHARGE LINE OF SILO
7 103 AFS FLUIDISING BLOWER FLUIDISING AIR 150 0 - 200 80 _ _ _ 6
HEATER
MANIFOLD AT DISCHARGE
8 103 AFS LINE OF SILO FLUIDISING FLUIDISING AIR 150 0 - 200 100 _ _ _ 1
BLOWER

9 105 AIO AFTER COOLER OUTLET INSTRUMENT AIR 80 0 - 200 65 2 2 2 _

10 105 AIO AFTER COOLER OUTLET INSTRUMENT AIR 50 0 - 200 65 2 2 2 _

22

1st STAGE DISCHARGE OF IA

11 105 AIO 2 INSTRUMENT AIR 145 0 - 250 65 2 2 2 _
COMPRESSOR

2nd STAGE DISCHARGE OF IA

12 105 AIO INSTRUMENT AIR 160 0 - 250 65 2 2 2 _
COMPRESSOR
2

12

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-I
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
SIGHT FLOW INDICATOR, REV-05
NORMAL MAX.
P&I FLOW RATE QTY. FOR QTY. FOR QTY. FOR QTY. FOR
SL NO. TAG NO. SERVICE LOCATION SIZE (NB) WORKING WORKING REMARKS
DIAGRAM (CUM/HR) #1 #2 #3 COMMON
PR. (Kg/cm2) PR. (Kg/cm2)

BA OVERFLOW WATER
1 101 WEO BA SEAL WATER 4 40 3.5 3.9 2 2 2 _
PUMP F.C. COOLING

ASH CRUSHER
2 101 WSO BA SEAL WATER 4 25 3.5 3.9 4 4 4 _
SEALING

BA OVERFLOW WATER
3 101 WSO BA SEAL WATER 3.5 25 3.5 3.9 2 2 2 _
PUMP SEALING

VACUUM PUMP
4 102 WEO BA SEAL WATER 4 40 3.5 3.9 8 8 8 _
SEALING

CONDITIONING SILO AREA DRAIN

5 103 WGO 1.5 15 4.5 5.3 _ _ _ 2
WATER PUMP SEALING

BA OVERFLOW
6 104 WSL LP SEAL WATER SLUDGE PUMP 1.15 15 6.5 8.1 _ _ _ 2
SEALING

ASH SLURRY DRAIN

7 104 WSL LP SEAL WATER 2.3 25 6.5 8.1 _ _ _ 2
PUMP SEALING

COMBIND ASH
SLURRY DISPOSAL
8 104 WEO COOLING WATER 10 40 2.5 5 _ _ _ 4
PUMP FC COOLING
(1 st stage)
 NORMAL MAX.
P&I FLOW RATE QTY. FOR QTY. FOR QTY. FOR QTY. FOR
SL NO. TAG NO. SERVICE LOCATION SIZE (NB) WORKING WORKING REMARKS
DIAGRAM (CUM/HR) 2 2 #1 #2 #3 COMMON
PR. (Kg/cm ) PR. (Kg/cm )

COMBIND ASH
SLURRY DISPOSAL
9 104 WSL LP SEAL WATER 4 25 6.5 8.1 _ _ _ 4
PUMP SEALING (1
st stage)

COMBIND ASH
SLURRY DISPOSAL
10 104 WSH HP SEAL WATER 4.6 25 11 12.2 _ _ _ 4
PUMP SEALING
(2nd stage)

IA COMPRESSOR
COOLING WATER
11 105 WCO COOLING HEADER 14.4 40 2.5 5 2 2 2 _
SUPPLY HEADER
RETURN

LP SEAL WATER HCSD SILO DRAIN

12 110 WSL 2.3 25 6.5 8.1 0.0 0.0 0.0 2
PUMP SEALING LINE
LP SEAL WATER HCSD BOOSTER PUMP
13 110 WSL 2.87 25 6.5 8.1 0.0 0.0 0.0 5
SEALING LINE
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM
INSTRUMENT SCHEDULE
NTPC DOC. NO.0330-162-PVI-H-004, REV-05
DCIPS DOC. NO. 28P01-1A-D-053, REV-05

INDEX
MECHANICAL INSTRUMENT SCHEDULE FOR HCSD
PART-2
SYSTEM
Sl. No. ANNEXURE TITLE

1 ANNEXURE- A BOURDON TYPE PRESSURE / VACUUM GAUGE

2 ANNEXURE- B DIAPHRAGM TYPE PRESSURE / VACUUM GAUGE

3 ANNEXURE- C DIFFERENTIAL PRESSURE GAUGE

4 ANNEXURE- D DIFFERENTIAL PRESSURE SWITCH

7 ANNEXURE- E PRESSURE SWITCH

8 ANNEXURE- F TEMPERATURE INDICATOR

 ANNEXURE-A
INSTRUMENT SCHEDULE
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE (FOR HCSD SYSTEM), REV-05
SHUT OFF/
NORMAL
MAX. QTY. QTY. QTY. QTY. FOR INSTALL
P&I INSTRUMENT WORKING TEMP. RANGE PIPE TOTAL
SL NO TAG NO. LOCATION FLUID MEDIUM WORKING FOR FOR FOR COMMON ATION REMARK
DIAGRAM TYPE PRESSURE (Deg. C) (kg /cm2) SIZE (NB) (NOS.)
PRESSURE UNIT#1 UNIT#2 UNIT#3 SYSTEM TYPE
(kg/cm2)
(kg/cm2)
MANIFOLD AT DISCHARGE
109

1 AFL LINE OF HCSD SILO BOURDON FLUIDISING AIR 0.4 0.44 150 0-1 100 - - - 1 D.O.L.
FLUIDISING BLOWER
1

WATER HEADER FOR

109

2 WHF BOURDON FAHP WATER 3 7 45 0 - 10 150 - - - 5 2 D.O.L.

DOSING - HCSD

LP SEAL WATER LINE TO

109

3 WSY BOURDON L.P.SEAL WATER 4 9 45 0 - 10 35 - - - 10 D.O.L.

BOOSTER PUMP - HCSD
WATER HEADER FOR
109

4 WHF DOSING & FLUSHING - BOURDON FAHP WATER 3 7 45 0 - 10 200 - - - 5 D.O.L.

HCSD
IA LINE FROM INSTRUMENT
109

5 AIO BOURDON 5.00 8.80 60 0 - 10 50 - - - 1 D.O.L. 1

INSTRUMENT AIR HEADER AIR

AT AIR RECEIVER IN HCSD INSTRUMENT

109

6 AIO BOURDON 6 8.8 60 0 - 10 80 - - - 2 D.O.L. 1

SILO AREA IA HEADER AIR

23

AIR VISSEL AT HOSE PUMP AIR MEDIA OF

109

7 SH BOURDON 0-10 10 60 0-10 50 - - - 5 D.O.L.

DISCHARGE HOSE PUMP 1

5
AT IA HEADER IN HCSD
INSTRUMENT
109

8 AIO SILO AREA TO PNEUMATIC BOURDON 6 8.8 60 1 - 10 80 - - - 2 D.O.L. 1

AIR
ACTUATORS
2

NOTE : ALL PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

 ANNEXURE-B
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DIAPHRAGM TYPE PRESSURE/ VACUUM GAUGE (FOR HCSD SYSTEM), REV-05
SHUT OFF/
NORMAL
MAX. QTY. QTY. QTY. QTY. FOR
P&I INSTRUMENT FLUID WORKING TEMP. RANGE PIPE TOTAL
SL NO TAG NO. LOCATION WORKING 2 FOR FOR FOR COMMON REMARK
DIAGRAM TYPE MEDIUM PRESSURE (Deg. C) (kg /cm ) SIZE (NB) (NOS.)
2 PRESSURE UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm ) 2
(kg/cm )
AT AIR VESSEL IN ASH
109

1 SH DIAPHRAGM 10.00 10.00 60 0 - 16 50 _ _ _ 5

DISCHARGE OF HOSE PUMP SLURRY

2
5

HCSD
AT DISCHARGE OF HCSD
109

2 SHD DIAPHRAGM SILO 1.80 2.00 60 0 - 2.5 150 _ _ _ 2

DRAIN PUMP
DRAIN

NOTE : 1) ALL THE PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

2) ALL THE PRESSURE GAUGES ARE DIRECT MOUNTED TYPE.

 ANNEXURE-C
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-I, (3 X 500 MW) UNIT #1,#2,#3
DCIPS JOB NO.: 28P01
DIFFERENTIAL PRESSURE GAUGE (FOR HCSD SYSTEM), REV-5
DESIGN
P& I INSTRUMENT RANGE TEMP.(Deg. PIPE QTY FOR QTY FOR QTY FOR QTY FOR
SL NO. TAG LOCATION FLUID MEDIUM PRESSURE REMARKS
DIAGRAM TYPE (mmWC) C) SIZE (NB) #1 #2 #3 COMMON
(Kg/ cm 2)
VENT FILTER ON ASH
1 109 LUO TELESCOPIC SPOUT - DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
HCSD AIR
ASH
AT VENT FILTER FOR
2 109 LUO DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
HCSD SILO
AIR
AT HCSD SILO ASH
3 109 AFH FLIUDISING BLOWER DIAPHRAGM CONTAMINETED 0 - 1500 1.0054 50 15 _ _ _ 4
2
SUCTION FILTER AIR

TOTAL 14

NOTE : ALL DIFFERENTIAL PRESSURE GAUGES ARE DIRECT MOUNTED TYPE

 ANNEXURE-D
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01

DIFFERENTIAL PRESSURE SWITCH, (FOR HCSD SYSTEM) REV-05

INSTRUMENT PIPE TOTAL
P& I INSTRUMENT ACTUATION RANGE TEMP.
SL NO. TAG LOCATION FLUID MEDIUM SET POINT SIZE QTY REMARKS
DIAGRAM TYPE REASON (mmWC) (Deg. C)
(mm WC) (NB) (NO.)
5 NOS FOR
AT TELESCOPIC SPOUT ASH
COMMON
1 109 ACO VENT FILTER FOR HCSD DIAPHRAGM CONTAMINETED PR. HIGH 50 - 600 200 150 15 5
SYSTEM (GM
SILO AIR
- 301)
4 NOS FOR
HCSD SILO FLUIDISING ATM. COMMON
2 109 AFS DIAPHRAGM ATM. AIR 50 - 600 200 50 100 4
BLOWER INLET FILTER PRESSURE SYSTEM (GM
- 301)

NOTE : ALL DIFFERENTIAL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE

 ANNEXURE-E
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE SWITCH (FOR HCSD SYSTEM), REV-05
SHUT OFF/
MAX. INSTRUMENT RANGE PIPE QTY QTY QTY QTY FOR
P&I INSTRUMENT ACTUATION FLUID ACTUATION TEMP. TOTAL
SL NO TAG NO. LOCATION WORKING SET POINT (Kg (kg SIZE FOR #1 FOR #3 FOR #2 COMMON REMARK
DIAGRAM TYPE REASON MEDIUM TYPE (Deg. C) (NOS.)
PRESSURE / cm2) /cm2) (NB) (NO.) (NO.) (NO.) (NO.)
(kg/cm2) 2

HCSD MIXING TANK FIXED DIFF. PRESSURE

109

1 WFP FAHP WATER 7.00 3.91 FALLING 50 0.6 - 6 150 _ _ _ 5 GM - 201

DOSING LINE BELLOW TYPE LOW
2
5.00

HCSD BOOSTER FIXED DIFF. PRESSURE LP SEAL

109

2 WSL 9.00 4.54 FALLING 50 1 - 10 25 _ _ _ 5 GM - 201

SEALING BELLOW TYPE LOW WATER

HCSD SILO AREA DRAIN FIXED DIFF. PRESSURE LP SEAL

109

3 WSL 9.00 2.80 FALLING 50 1 - 10 15 _ _ _ 2 GM - 201

PUMP SEALING BELLOW TYPE LOW WATER

AT IA HEADER LINE IN FIXED DIFF. PRESSURE INSTRUMENT

109

4 AIO 8.80 5.00 FALLING 50 1 - 10 80 _ _ _ 2 GM - 201

HCSD SILO AREA BELLOW TYPE LOW AIR

9.00

NOTE : 1) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT EXACT SYSTEM REQUIREMENT.

2) ALL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE.

 ANNEXURE -F
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
TEMPERATURE INDICATOR (FOR HCSD SYSTEM), REV-05

P&I MAX FLUID TEMP INSTRUMENT PIPE QTY FOR QTY FOR QTY FOR QTY FOR TOTAL
SL NO TAG NO LOCATION SERVICE REMRKS
DIAGRAM DEG. C RANGE SIZE (NB) #1 #2 #3 COMMON (NOS.)

AT DISCHARGE LINE OF HCSD

FLUIDISING
1 109 AFS SILO FLUIDISING BLOWER 150 0 - 200 150 _ _ _ 4
AIR
HEATER
MANIFOLD AT DISCHARGE
FLUIDISING
2 109 AFS LINE OF HCSD SILO 150 0 - 200 100 _ _ _ 1
AIR
FLUIDISING BLOWER

5
 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM

PART-3: ELECTRONIC INSTRUMENT SCHEDULE , Rev 05

INDEX

Sl. No. ANNEXURE TITLE

1 ANNEXURE- A PRESSURE TRANSMITTER

2 ANNEXURE- B PRESSURE TRANSMITER (IA PACKAGE)

3 ANNEXURE- C LEVEL TRANSMITTER

4 ANNEXURE- D TEMPERATURE ELEMENT

5 ANNEXURE- E TEMPERATURE ELEMENT(IA PACKAGE)

6 ANNEXURE- F DUST SENSORS

7 ANNEXURE- G LEVEL PROBE

8 ANNEXURE- H DEW POINT METER

9 ANNEXURE- I DIFFERENTIAL PRESSURE TRANSMITTER

R

Kausiksengupta\D\NTPC-Jhajjar Page 1 of 1
 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE / VACUUM TRANSMITER

SHUT OFF/ FUNCTION (INPUT

QTY. FOR
SL P&I INSTRUMENT SET POINT MAX. WORKING TEMP. (Deg. RANGE (kg TO ALARM / TRIP PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
TAG NO. LOCATION FLUID MEDIUM 2 COMMON REMARK
NO DIAGRAM TYPE (kg/cm ) PRESSURE C) /cm2) INTERLOCK / (NB) UNIT# 1 UNIT# 2 UNIT# 3
UNIT
(kg/cm2) REGARDING)

AS PER
101

1 WHB JET PUMP INLET (UNIT #1) BAHP WATER 7.50 12.00 45 150 8 _ _ _
SPECIFICATION

AS PER
101

2 WHB JET PUMP INLET (UNIT #2) BAHP WATER 9.50 12.00 45 150 _ 8 _ _
SPECIFICATION

AS PER
101

3 WHB JET PUMP INLET (UNIT #3) BAHP WATER 10.50 12.00 45 150 _ _ 8 _
SPECIFICATION

JET PUMP OUTLET TO BA SLURRY SUMP AS PER

101

4 BJO SLURRY 1.20 3.00 60 200 4 _ _ _

(UNIT #1) SPECIFICATION

JET PUMP OUTLET TO BA SLURRY SUMP AS PER

101

5 BJO SLURRY 1.50 3.00 60 200 _ 4 _ _

(UNIT #2) SPECIFICATION

JET PUMP OUTLET TO BA SLURRY SUMP AS PER

101

6 BJO SLURRY 2.00 3.00 60 200 _ _ 4 _

(UNIT #3) SPECIFICATION

ASH
AS PER
101

7 DPB AT B.A. O'FLOW WATER PUMP DISCHARGE LINE CONTAMINATED 1.40 1.80 60 250 2 2 2 _
SPECIFICATION
WATER

AS PER
101

8 WEP TO ECO HOPPER FLUSHING BOX ECO. WATER 3.00 9.30 45 100 1 1 1 _
SPECIFICATION

SEE NOTE 1

SEE NOTE 2
AS PER
101

9 WSO ASH CRUSHER SEALING BA SEAL WATER 1.50 3.92 45 25 4 4 4 _

SPECIFICATION

10 DELETED

ESP /
AT ESP & BUFFER HOPPER FLUIDISING BLOWER AS PER
102

11 AFH BUFFERHOPPER 0.40 0.44 150 100 1 1 1 _

DISCHARGE LINE SPECIFICATION
FLIDISING AIR

AS PER 254mmHg(g) 760mmHg(g)

102

12 FVO AT VACUUM LINE VACUUM AIR 80 15 8 8 8 _

SPECIFICATION (Vacuum) (Vacuum)

AS PER BA SEAL WATER

102

13 WSO TO VACUUM PUMP SEALING 1.00 3.92 45 40 8 8 8 _

SPECIFICATION PUMP

AS PER
103

14 ACO AT TRANSPORT AIR LINE TO STREAM LINE TRANSPORT AIR 1.75 2.75 160 200 3 3 3 _
SPECIFICATION

AT DISCHARGE LINE OF CONDITIONING WATER AS PER CONDITIONING

103

15 WGO 4.50 5.20 45 150 _ _ _ 1

PUMP SPECIFICATION WATER

AT CONDITIONING WATER LINE TO DUST AS PER CONDITIONING

103

16 WGO 2.50 5.20 45 65 _ _ _ 5

CONDITIONAR SPECIFICATION WATER

MANIFOLD AT SILO FLUIDISING BLOWER AS PER

103

17 WGO FLUIDISING AIR 0.60 0.66 150 100 _ _ _ 1

DISCHARGE SPECIFICATION

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\ELECTRICAL ITEM\final Page 1 of 2

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE / VACUUM TRANSMITER

SHUT OFF/ FUNCTION (INPUT

QTY. FOR
SL P&I INSTRUMENT SET POINT MAX. WORKING TEMP. (Deg. RANGE (kg TO ALARM / TRIP PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
TAG NO. LOCATION FLUID MEDIUM 2 COMMON REMARK
NO DIAGRAM TYPE (kg/cm ) PRESSURE C) /cm2) INTERLOCK / (NB) UNIT# 1 UNIT# 2 UNIT# 3
UNIT
(kg/cm2) REGARDING)

AS PER
104

18 SSB SLUDGE PUMP DISCHARGE SLURRY 1.60 1.80 45 80 _ _ _ 2

SPECIFICATION

AS PER
104

19 WHF AT F.A.H.P. WATER PUMP DISCHARGE LINE F.A.H.P. WATER 6.20 7.00 45 250 _ _ _ 2
SPECIFICATION

AS PER
104

20 WLB AT DISCHARGE LINE OF B.A.L.P. WATER PUMP B.A.L.P. WATER 2.30 2.90 45 700 _ _ _ 2
SPECIFICATION

AS PER
104

21 WHB AT DISCHARGE LINE OF B.A.H.P. WATER PUMP B.A.H.P. WATER 11.50 12.00 45 400 _ _ _ 2
SPECIFICATION

AS PER
104

22 WFP AT FLUSHING WATER PUMP DISCHARGE LINE FLUSHING WATER 1.80 2.60 45 350 _ _ _ 2
SPECIFICATION

AS PER
104

23 WEP ECONOMISER WATER PUMP DISCHARGE ECO. WATER 7.00 9.30 45 200 _ _ _ 2
SPECIFICATION

SEE NOTE 1

SEE NOTE 2
AT DISCHARGE LINE OF MAIN ASH SLURRY AS PER
104

24 SDO ASH SLURRY 9.00 10.80 60 350 _ _ _ 4

DISPOSAL PUMPS SPECIFICATION

AS PER
104

25 WSL AT DISCHARGE LINE OF L.P. SEAL WATER PUMP L.P.SEAL WATER 6.50 9.00 45 100 _ _ _ 2
SPECIFICATION

AS PER
104

26 WSH AT DISCHARGE LINE OF H.P. SEAL WATER PUMP H.P. SEAL WATER 11.00 13.00 45 80 _ _ _ 2
SPECIFICATION

AS PER
104

27 WSL SEAL WATER TANK OUTLET SEAL WATER 0.20 1.00 45 100 _ _ _ 2
SPECIFICATION

AS PER
104

28 WSL BA SLURRY DRAIN PUMP SEALING LP SEAL WATER 2.50 9.00 45 25 _ _ _ 2

SPECIFICATION

ASH SLURRY PUMP SEALING (1St AS PER

104

29 WSL LP SEAL WATER 5.65 9.00 45 25 _ _ _ 4

Stage ) SPECIFICATION

ASH SLURRY PUMP SEALING (2nd AS PER

104

30 WEO H.P. SEAL WATER 9.80 13.00 45 25 _ _ _ 4

Stage ) SPECIFICATION

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE- UP.

3) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\ELECTRICAL ITEM\final Page 2 of 2

 ANNEXURE-B
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE / VACUUM TRANSMITER (IA PACKAGE)

SHUT OFF/ FUNCTION (INPUT

QTY. FOR
SL P&I INSTRUMENT SET POINT MAX. WORKING TEMP. (Deg. RANGE TO ALARM / TRIP PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
TAG NO. LOCATION FLUID MEDIUM COMMON REMARK
NO DIAGRAM TYPE (kg/cm2) PRESSURE C) (kg /cm2) INTERLOCK / (NB) UNIT# 1 UNIT# 2 UNIT# 3
UNIT
(kg/cm2) REGARDING)

AS PER
105

1 WCO COOLING WATER SUPPLY TO COMPRESSOR COOLING WATER 2.00 10.00 45 40 2 2 2 _

SPECIFICATION

AS PER 80
105

2 _ MAIN LUB OIL GEAR PUMP OIL 2.00 3.00 20 2 2 2 _

SPECIFICATION (Max)

SEE NOTE 1

SEE NOTE 2
AS PER
105

3 AIO AFTER COOLER OUTLET(AIR) INSTRUMENT AIR 6.00 8.80 60 65 4 4 4 _

SPECIFICATION

AS PER
105

4 AIO AFTER COOLER INLET (AIR) INSTRUMENT AIR 6.00 8.80 60 _ 2 2 2 _

SPECIFICATION

AS PER
105

5 AIO AIR DRYING PLANT OUTLET INSTRUMENT AIR 6.00 8.80 60 65 2 2 2 _

SPECIFICATION

AS PER
105

6 AIO AIR RECEIVER OUTLET INSTRUMENT AIR 6.00 8.80 60 100 1 1 1 _

SPECIFICATION

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE- UP.

3) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\ELECTRICAL ITEM\final Page 1 of 1

 ANNEXURE-C
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
LEVEL TRANSMITER
INVERT
DANGER SUMP QTY FOR
TEMP. HIGH LEVEL LOW LEVEL LEVELOF TOP LEVEL QTY FOR QTY FOR QTY FOR
SL NO P & I DIAGRAM TAG NO. TYPE SERVICE LOCATION LOW LEVEL DEPTH COMMON UNIT REMARK
Deg.C EL (mm) EL(mm) SUMP EL(mm) UNIT #1(NO) UNIT #2(NO) UNIT #3(NO)
EL(mm) (mm) (NO)
EL(mm)

ULTRASONIC BA HOPPER OVERFLOW BA OVERFLOW TRANSFER

1 101 SB 60 (+) 5550 _ (+) 1650 (+) 1150 (+) 5950 4800 1 1 1 _
TYPE WATER HOPPER

ULTRASONIC OVER GROUND RCC TANK IN

2 103 WGO WATER 45 SEE NOTE 1 3000 _ _ _ 1
TYPE SILO AREA

ULTRASONIC
3 103 AFH DRY ASH BUFFER HOPPER 100 (+) 10169 (+) 6625 _ (+) 6425 (+) 10669 4244 8 8 8 _
TYPE

ULTRASONIC ASH CONTAMINATED

4 104 DPA BA SLURRY DRAIN SUMP 60 (-) 300 (-) 1500 _ (-) 1955 0 1955 _ _ _ 1
2 TYPE WATER

ULTRASONIC ASH CONTAMINATED

4A 109 _ HCSD SILO DRAIN SUMP 60 (-) 600 (-) 1550 _ (-) 2300 (-) 300 2000 _ _ _ 1
TYPE WATER

ULTRASONIC
5 104 SDO WATER SURGE BIN 45 SEE NOTE 1 5170 _ _ _ 1
TYPE

ULTRASONIC
6 104 DPO WATER ASH WATER SUMP 45 (+) 2825 (+) 1300 (-) 500 (-) 1800 (+) 3325 5125 _ _ _ 3
TYPE

ULTRASONIC
7 104 SDO ASH SLURRY MAIN ASH SLURRY SUMP 45 (+) 3175 (+) 1500 (-) 750 (-) 1500 (+) 3675 5175 _ _ _ 4
TYPE

ULTRASONIC
8 104 LUO DRY ASH AT SILO TOP 120 (+) 26618 (+) 12000 _ (+) 11350 (+) 27560 16210 _ _ _ 5
TYPE

NOTE : 1) LEVELS WILL BE INFORMED LATER .

2) SET POINT ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SYSTEM REQUIREMENT.

D:\NTPC-Korba\Instrument\KAUSIK for vendor\ELECTRICAL ITEM Page 1 of 1

 ANNEXURE-D
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
TEMPERATURE ELEMENT
MAX. FUNCTION QTY. FOR
SL INSTRUMENT INSTRUMENT (INPUT TO PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
P & I DIAGRAM TAG NO. LOCATION SERVICE FLUID COMMON REMARK
NO TYPE RANGE (0C) ALARM / TRIP (NB) UNIT# 1 UNIT# 2 UNIT# 3
TEMP. UNIT
INTERLOCK/
AT DISCHARGE LINE OF ESP &
AS PER
1 102 AFH BUFFER HOPPER FLUIDISING FLUIDISING AIR 150 0-200 80 1 1 1 _
SPECIFICATION
BLOWER HEATER

SEE NOTE 1
MANIFOLD AT DISCHARGE LINE AS PER
2 103 AFS FLUIDISING AIR 150 0-200 100 _ _ _ 1
OF SILO FLUIDISING BLOWER SPECIFICATION R

AT DISCHARGE LINE OF SILO AS PER

3 103 AFS FLUIDISING AIR 150 0-200 150 _ _ _ 6
FLUIDISING BLOWER HEATER SPECIFICATION

NOTE : 1) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE-UP.

2) THE SET POINT SHALL BE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\ELECTRICAL ITEM\final Page 1 of 1

 ANNEXURE-E
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

UNIT # 1,2 & 3 (3 X 500 MW)

DCIPS JOB NO.: 28P01

TEMPERATURE ELEMENT (IA PACKAGE)

FUNCTION (INPUT
TO ALARM / TRIP QTY. FOR
SL INSTRUMENT INSTRUMENT PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
P & I DIAGRAM TAG NO. LOCATION SERVICE INTERLOCK/ COMMON REMARK
NO TYPE RANGE (0C) (NB) UNIT# 1 UNIT# 2 UNIT# 3
REGARDING) UNIT

AS PER
1 105 WCO COOLING WATER HEADER COOLING WATER 0-100 65 _ _ _ 1
SPECIFICATION

AS PER
2 105 _ MAIN LUB OIL GEAR PUMP OIL 0-100 20 2 2 2 _
SPECIFICATION

AS PER
3 105 AIO INTER COOLER OUTLET (AIR) INSTRUMENT AIR 0-200 185 2 2 2 _
SPECIFICATION R
AS PER
4 105 AIO AFTER COOLER INLET(AIR) INSTRUMENT AIR 0-250 185 2 2 2 _
SPECIFICATION
R
AS PER
5 105 AIO AFTER COOLER OUTLET(WATER) COOLING WATER 0-100 40 2 2 2 _
SPECIFICATION

SEE NOTE 1
AS PER
6 105 AIO AFTER COOLER OUTLET(AIR) INSTRUMENT AIR 0-200 65 2 2 2 _
SPECIFICATION

AS PER
7 105 WCO HP CYL COOLING COOLING WATER 0-100 20 2 2 2 _
SPECIFICATION

AS PER
8 105 WCO HP CYL COOLING (RTD) COOLING WATER 0-100 20 2 2 2 _
SPECIFICATION

AS PER
9 105 WCO LP CYL COOLING COOLING WATER 0-100 20 2 2 2 _
SPECIFICATION

AS PER
10 105 WCO LP CYL COOLING (RTD) COOLING WATER 0-100 20 2 2 2 _
SPECIFICATION

AS PER
11 105 AIO AIR RECEIVER OUTLET (RTD) INSTRUMENT AIR 0-100 80 1 1 1 _
SPECIFICATION

NOTE : 1) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE-UP.

2) THE SET POINT SHALL BE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\ELECTRICAL ITEM\final Page 1 of 1

 ANNEXURE-F
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DUST SENSORS
NORMAL MAX QTY. FOR
INSRUMENT QTY. FOR QTY. FOR QTY. FOR
P&I ASH LEVEL PIPE SIZE TEMP. WORKING PR. WORKING PR. COMMON
SL NO. TAG NO. SERVICE LOCATION RANGE 0 UNIT# 1 UNIT# 2 UNIT# 3 REMARKS
DIAGRAM (PPM) (NB) ( C) mm of Hg (g) mm of Hg (g) UNIT
(PPM) (NO.) (NO.) (NO.)
(Vacuum) (Vacuum) (NO.)

VACUUM PUMP
1 102 FVO VACUUM LINE 20 - 25 10 - 1000 250 80 254 760 8 8 8 _
INLET
 ANNEXURE-G
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
LEVEL PROBE (RF TYPE)

QTY. FOR QTY. FOR QTY. FOR QTY. FOR

SL P&I TEMP. PROB LENGTH
LOCATION PROBE TYPE FLUID MEDIUM MOUNTING TYPE ORIENTATION PRESSURE UNIT# 1 UNIT# 2 UNIT# 3 COMMON REMARK
NO DIAGRAM (Deg. C) (mm)
(NO.) (NO.) (NO.) UNIT
103

1 NUVA FEEDER (HIGH LEVEL) RIGID DRY ASH FLANGED HORIZONTAL (-) 0.1 TO 2 Kg/Cm2 150 300 16 16 16 _
104

2 TELESCOPIC SPOUT FLEXIBLE DRY ASH SCREWED 45 0 ATMOSPHERIC 100 300 _ _ _ 5

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE- UP.

Kausiksengupta\D\Jhajjar Page 1 of 1
 ANNEXURE-H
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

UNIT # 1,2 & 3 (3 X 500 MW)

DCIPS JOB NO.: 28P01

DEW POINT METER

LINE PRESSURE
MAX. LINE
MAX. FLUID RANGE(0 C) QTY. FOR
SL PIPE SIZE QTY. FOR QTY. FOR QTY. FOR
P & I DIAGRAM TAG NO. LOCATION SERVICE 2
PRESSURE 0 (Corresponding to 1 COMMON REMARK
NO ( Kg/ Cm ) TEMP.( C ) (NB) UNIT# 1 (NO.) UNIT# 2 (NO.) UNIT# 3 (NO.)
( Kg/ Cm 2 ) ata pressure) UNIT (NO.)

AT TRANSPORT AIR COMPRESSOR

1 103 ACO CONVEYING AIR 1.75 2.75 180 (-)50 TO 0 250 3 3 3 _
OUTLET

2 105 AIO IA COMPRESSOR OUTLET INSTRUMENT AIR 8 8.8 60 (-)50 TO 0 65 2 2 2 _

Kausiksengupta\D\Jhajjar Page 1 of 1
 ANNEXURE-I
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-I,UNIT #1,#2,#3
DCIPS JOB NO.: 28P01

DIFFERENTIAL PRESSURE TRANSMITTER

INSTRUMENT PIPE
SL P& I INSTRUMENT ACTUATION RANGE TEMP. QTY. QTY. QTY. QTY. FOR
TAG LOCATION FLUID MEDIUM SET POINT SIZE REMARKS
NO. DIAGRAM TYPE REASON (mmWC) (Deg. C) FOR #1 FOR #2 FOR #3 COMMON
(mm WC) (NB)
ASH
AT DIFFERENTIAL PRESSURE ACROSS

SEE NOTE 1
1 103 ACO DIAPHRAGM CONTAMINETED PR. HIGH 300 150 15 8 8 8 _
FREE & DUST AIR OF BAG FILTER
AIR

ASH
AT DIFFERENTIAL PRESSURE ACROSS
2 103 ACO DIAPHRAGM CONTAMINETED PR. HIGH 500 150 15 _ _ _ 5
FREE & DUST AIR OF VENT FILTER SILO
AIR

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM

PART-4: ELECTRONIC INSTRUMENT SCHEDULE FOR HCSD SYSTEM, REV-

05

INDEX

Sl. No. ANNEXURE TITLE

1 ANNEXURE- A CONTROL VALVE

2 ANNEXURE- B DENSITY TRANSMITTER

3 ANNEXURE- C FLOW TRANSMITER

4 ANNEXURE- D LEVEL SWITCH

5 ANNEXURE- E LEVEL TRANSMITER

6 ANNEXURE- F MAGNETIC FLOW TRANSMITTER

7 ANNEXURE- G MASS FLOW METER

8 ANNEXURE- H PRESSURE TRANSMITTER

9 ANNEXURE- I DIFFERENTIAL PRESSURE TRANSMITTER

NOTE:
FOR OTHER INSTRUMENTS OF HCSD PUMP AS SUPPLIED BY WMN, PLEASE REFER ALREADY
APPROVED DOCUMENT ENTITLED: "COMSOLIDATED INSTRUMENT SCHEDULE: HCSD SYSTEM",
NTPC DOC. NO.: 0330-1620PVI-G-001.

Kausiksengupta\D\NTPC-Jhajjar Page 1 of 1
 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
CONTROL VALVE (FOR HCSD SYSTEM)

NORMAL MAX.
FLOW RATE (CUM/HR) TOTAL
P&I WORKING WORKING
SL NO. TAG NO. SERVICE LOCATION SIZE (mm) QTY. SIGNAL REMARKS
DIAGRAM PR. PR.
(NO.)
(Kg/cm2) (Kg/cm2)
NORMAL MAX

4-20 mA INPUT
WATER DOSING LINE SIGNAL
1 110 SHD WATER 0-75 150 100 4 6 10
TO MIXING TANK 4-20 mA FEED BACK
SIGNAL
4-20 mA INPUT
DUST CONDITIONING SIGNAL
2 110 SHD WATER 0-20 35 65 4 6 10
WATER SUPPLY LINE 4-20 mA FEED BACK
SIGNAL

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL

 ANNEXURE-B
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

UNIT # 1,2 & 3 (3 X 500 MW)

DCIPS JOB NO.: 28P01

DENSITY TRANSMITTER (FOR HCSD SYSTEM)

NORMAL
MAX. TOTAL
P&I FLOW RATE PIPE SIZE WORKING
SL NO. TYPE TAG NO. SERVICE LOCATION DENSITY TEMP. (OC) WORKING QTY. MAKE INSTALLATION OUTPUT SIGNAL REMARKS
DIAGRAM (M3/Hr) (mm) PR.
PR. (Bar) (NO.)
(Bar)

SINGLE HIGH Endress & Hauser In a vertical MS

SLURRY CONTROL DN 40 2 Wire-4-20 mA
1 110 TUBE SHD CONCENTRATED 1.5 1.0 -1.6 60 10 12 5 (Alternate Source pipe line of 40 mm SEE NOTE 1
LOOP (FULL BORE) (Density & Temp.)
CORRIOLIS FLY ASH SLURRY not acceptable dia

HIGH to be Mounted on
BOOSTER PUMP 200 (Sch. Pipe line Pr Pipe line Pr
2 110 NUCLEONIC SHD CONCENTRATED 0-250 1.0 -1.6 60 5 _ outside of 4-20 mA
DISCHARGE 80 MS Pipe) = 5.0 =6
FLY ASH SLURRY horizeontal pipe line

NOTE 1: a) TYPE OF METER : PROMASS 831.

b) PROCESS CONNECTION : ANSI B16.5 Class 150

c) CALIBRATION : DENSITY

d) POWER SUPPLY : 24 V DC

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL

 ANNEXURE- C
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
FLOW TRANSMITTER (FOR HCSD SYSTEM)
FLOW RATE
NORMAL MAX. TOTAL
P&I (CUM/HR) PIPE SIZE OUTPUT
SL NO. TAG NO. SERVICE LOCATION WORKING WORKING QTY. REMARKS
DIAGRAM (NB) SIGNAL
NORMAL MAX PR. (Kg/cm2) PR. (Kg/cm2) (NO.)

4-20 mA
WATER DOSING LINE
1 110 SHD WATER 0-75 150 100 4 6 10 FEED BACK
TO MIXING TANK
SIGNAL

4-20 mA
DUST CONDITIONING
2 110 SHD WATER 0-20 35 65 4 6 10 FEED BACK
WATER SUPPLY LINE
SIGNAL

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL

 ANNEXURE-D
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01

LEVEL SWITCH (HCSD SYSTEM)

TANK
ROOF OF 100% HIGH 80% HIGH 70% 10% LOW 0% LOW
SL TEMP. BOTTOM TOTAL QTY
P & I DIAGRAM TAG NO. TYPE SERVICE LOCATION TANK HIGH LEVEL LEVEL OPERATING LEVEL LOW LEVEL REMARK
NO Deg.C LEVEL (NO)
EL(mm) (mm) (mm) LEVEL (mm) (mm) (mm)
EL(mm)

TO MEASURE LEVEL
OF HIGH MOUNTING ON TOP OF
1 110 SHD RF TYPE 60 "00" (-) 300 (-) 1240 (-) 1710 (-) 4530 (-) 5000 (-) 6994 5
CONCENTRATION MIXING TANK
SLURRY INSIDE TANK

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL Page 1 of 1

 ANNEXURE-E
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01

LEVEL TRANSMITER (HCSD SYSTEM)

TANK
ROOF OF 100% HIGH 80% HIGH 70% 10% LOW 0% LOW
SL TEMP. BOTTOM OUTPUT TOTAL
P & I DIAGRAM TAG NO. TYPE SERVICE LOCATION TANK HIGH LEVEL LEVEL OPERATING LEVEL LOW LEVEL REMARK
NO Deg.C LEVEL SIGNAL QYT. (NO)
EL(mm) (mm) (mm) LEVEL (mm) (mm) (mm)
EL(mm)

TO MEASURE LEVEL
ULTRASONIC 4-20 mA (for Endress &
OF HIGH MOUNTING ON TOP OF
1 110 SHD TYPE OR 60 "00" (-) 300 (-) 1240 (-) 1710 (-) 4530 (-) 5000 (-) 6994 0% level to 5 Hauser or
CONCENTRATION MIXING TANK
RADAR 100% level) equivalent
SLURRY INSIDE TANK

ULTRASONIC
2 110 SHD DRY ASH AT SILO TOP 120 (+) 22341 (+)21292 _ _ _ _ (+) 14331 _ 5
TYPE

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL Page 1 of 1

 ANNEXURE-F
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

UNIT # 1,2 & 3 (3 X 500 MW)

DCIPS JOB NO.: 28P01

MAGNETIC FLOW TRANSMITTER (FOR HCSD SYSTEM)

NORMAL
MIXURE MAX. TOTAL
P&I FLOW RATE TEMP PIPE SIZE WORKING OUTPUT
SL NO. TAG NO. SERVICE LOCATION Sp. WORKING QTY. REMARKS
DIAGRAM (CUM/HR) (0C) (mm) PR. SIGNAL
GRAVITY PR. (Kg/cm2) (NO.)
(Kg/cm2)

HIGH CONCENTRATION
200
SLURRY, FLY ASH MIXED DISCHARGE OF
1 110 SHD 1 - 1.6 0-250 60 (SCH. 80 MS 5 6 5 4-20 mA
WITH WATER (0 TO 70% FLY BOOSTER PUMP
PIPE)
ASH CONCENTRATION)

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL

 ANNEXURE-G
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR

UNIT # 1,2 & 3 (3 X 500 MW)

DCIPS JOB NO.: 28P01

MASS FLOW METER (FOR HCSD SYSTEM)

TOTAL
P&I FLOW RATE
SL NO. TAG NO. SERVICE LOCATION INLET SIZE (NB) QTY. REMARKS
DIAGRAM (TON /HR)
(NO.)

1 110 SHD HCSD FLY ASH HCSD SILO OUTLET 40-100 BY VENDOR 10
2

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL

 ANNEXURE-H
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO. : 28P01
PRESSURE TRANSMITER (HCSD SYSTEM)

SHUT OFF/ FUNCTION

NORMAL
MAX. (INPUT TO PIPE TOTAL
SL P&I WORKING TEMP. RANGE OUTPUT
TAG NO. LOCATION INSTRUMENT TYPE FLUID MEDIUM WORKING 2 ALARM / TRIP SIZE QTY REMARK
NO DIAGRAM PRESSURE (Deg. C) (kg /cm ) SIGNAL
PRESSURE INTERLOCK / (mm) (NO.)
(kg/cm2)
(kg/cm2) REGARDING)

PTFE OR RUBBER
DIAPHRAGM TYPE
HIGH TWO LINED FOR
FOR SLURRY INLINE, FLUSH
110

1 SHD CONCENTRATED _ 15.00 60 0-10 WIRE 25 10 RESISTANCE

CONTROL LOOP MOUNTED POWER
FLY ASH SLURRY 4-20 mA AGAINST
SUPPLY=24 V DC
ABRASION

PTFE OR RUBBER

SEE NOTE 2
DIAPHRAGM TYPE , DN HIGH TWO LINED FOR
AT BOOSTER PUMP
110

2 SHD 50 , RUBBER LINED CONCENTRATED 3.50 6.00 60 0-10 WIRE 50 5 RESISTANCE

OUTLET
WITH EXTENDED SEAL FLY ASH SLURRY 4-20 mA AGAINST
ABRASION

PTFE OR RUBBER
DIAPHRAGM TYPE , DN HIGH TWO LINED FOR
AT HCSD PUMP SEE
110

3 SHD 50 , RUBBER LINED CONCENTRATED 44.00 60.00 60 WIRE 50 5 RESISTANCE

DISCHARGE NOTE 1
WITH EXTENDED SEAL FLY ASH SLURRY 4-20 mA AGAINST
ABRASION

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) FUNCTIONAL REQUIREMENT SHALL BE AS PER ELECTRICAL SCHEME / CONTROL WRITE- UP.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR HCSD SYSTEM\ELECTRICAL Page 1 of 1

 ANNEXURE-I
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-I,UNIT #1,#2,#3
DCIPS JOB NO.: 28P01

DIFFERENTIAL PRESSURE TRANSMITTER (HCSD SYSTEM)

INSTRUMENT PIPE TOTAL
SL P& I INSTRUMENT ACTUATION RANGE TEMP.
TAG LOCATION FLUID MEDIUM SET POINT SIZE QTY. REMARKS
NO. DIAGRAM TYPE REASON (mmWC) (Deg. C)
(mm WC) (NB) (NO.)
AT DIFFERENTIAL PRESSURE ACROSS ASH
SEE
1 110 ACO FREE & DUST AIR OF VENT FILTER SILO DIAPHRAGM CONTAMINETED PR. HIGH 500 150 15 5
NOTE 1
FOR HCSD SYSTEM AIR

NOTE : 1) INSTRUMENT RANGE AS PER SUPPLIER STANDARD.

2) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT ACTUAL SYSTEM REQUIREMENT.
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
ASH HANDLING SYSTEM
INSTRUMENT SCHEDULE
NTPC DOC. NO.0330-162-PVI-H-004, REV-05
DCIPS DOC. NO. 28P01-1A-D-053, REV-05
INDEX
PART-5 INSTRUMENTS OF BROUGHT OUT ITEMS

Sl. No. ANNEXURE TITLE

1 ANNEXURE- A INSTRUMENTS FOR IAC

2 ANNEXURE- B INSTRUMENTS FOR FLUIDISING BLOWERS

3 ANNEXURE- C INSTRUMENTS FOR FLUID COUPLINGS

4 ANNEXURE- D INSTRUMENTS FOR TRANSPORT AIR COMPRESSOR

5 ANNEXURE- E INSTRUMENTS FOR AIR DRYING PLANT

 ANNEXURE-A
INSTRUMENTS FOR IAC:
Total quantity of IAC : 6 NOS.

Instrument Qty for 1

Name of Total Qty Scope of
Sl. No. NTPC Drg. No. Medium Sl. No. in Range Location Item
Instrument (Nos.) Supply
drawing (Nos.)

PRESSURE 0 - 6 KG / SQ
1 PVM-L-058 AIR PI-1 AT INTER COOLER 1 6 KIRLOSKAR
INDICATOR CM

PRESSURE 0 - 16 KG /
2 PVM-L-058 AIR PI-2 AT AFTER COOLER 1 6 KIRLOSKAR
INDICATOR SQ CM

TEMPERATURE 0 - 250 DEG

3 PVM-L-058 AIR TI-1 AT INTERCOOLER INLET 1 6 DCIPS
INDICATOR C

TEMPERATURE 0 - 200 DEG

4 PVM-L-058 AIR TI-2 AT INTERCOOLER OUTLET 1 6 DCIPS
INDICATOR C

TEMPERATURE 0 - 200 DEG

5 PVM-L-058 AIR TI-4 AT AFTER COOLER OUTLET 1 6 DCIPS
INDICATOR C

TEMPERATURE 0 - 250 DEG

6 PVM-L-058 AIR TI-8 AT HP CYLINDER OUTLET 1 6 DCIPS
INDICATOR C

TEMPERATURE 0 - 200 DEG

7 PVM-L-058 AIR TI-9 AT AFTER COOLER OUTLET 1 6 DCIPS
INDICATOR C
LEVEL
8 PVM-L-058 WATER LI-1 - AT INTER COOLER 1 6 DCIPS
INDICATOR
LEVEL
9 PVM-L-058 WATER LI-2 - AT AFTER COOLER 1 6 DCIPS
INDICATOR
VACUUM (-) 1 - 0 KG /
10 PVM-L-058 AIR VI AT IAC SUCTION LINE 1 6 DCIPS
INDICATOR SQ CM
TEMPERATURE 0 - 100 DEG
11 PVM-L-058 WATER TI-5 AT LP CYLINDER OUTLER 1 6 DCIPS
INDICATOR C
TEMPERATURE 0 - 100 DEG
12 PVM-L-058 WATER TI-6 AT HP CYLINDER OUTLET 1 6 DCIPS
INDICATOR C

TEMPERATURE 0 - 100 DEG

13 PVM-L-058 WATER TI-7 AT AFTER COOLER OUTLET 1 6 DCIPS
INDICATOR C

AT COOLING WATER OUTLET

14 PVM-L-058 WATER FS-1 FLOW SWITCH 0 - 500 LPM 1 6 DCIPS
TO COOLING WATER HEADER

AT COOLING WATER OUTLET

15 PVM-L-058 WATER FS-2 FLOW SWITCH 0 - 500 LPM 1 6 DCIPS
TO COOLING WATER HEADER

PRESSURE 0 - 6 KG / SQ
16 PVM-L-058 OIL PI-5 AT LUBRICATING OIL LINE 1 6 KIRLOSKAR
INDICATOR CM
TEMPERATURE 0 - 100 DEG
17 PVM-L-058 OIL TI-3 AT LUBRICATING OIL LINE 1 6 KIRLOSKAR
INDICATOR C
PRESSURE 0 - 10 KG /
18 PVM-L-058 AIR PS-1 AT IAC DISCHARGE LINE 1 6 KIRLOSKAR
SWITCH SQ CM
PRESSURE 0 - 10 KG /
19 PVM-L-058 AIR PS-2 AT IAC DISCHARGE LINE 1 6 KIRLOSKAR
SWITCH SQ CM

REFERENCE OF OTHER INSTRUMENTS IN NTPC DOCUMENT NO.: 0330-162-PVM-L-058:

ALL PRESSURE TRANSMITTERS SUCH AS PT-3, PT-4, PT-5, PT-1 AND PT-2 ARE INCLUDED IN INSTRUMENT SCHEDULE. REFER PART-3:
1)
ELECTRONICS INSTRUMENT SCHEDULE, ANNEXURE-B, PRESSURE TRANSMITTER (IA PACKAGE)
PRESSURE INDICATOR SUCH AS PI-6 ARE INCLUDED IN INSTRUMENT SCHEDULE. REFER PART-1: MECHANICAL INST. SCHEDULE, ANNEXURE-
2)
A: BURDON TYPE PRESSURE / VACUUM GAUGE. SL NO. 28.
PRESSURE INDICATOR SUCH AS PI-3 & PI-4 ARE INCLUDED IN INSTRUMENT SCHEDULE. REFER PART-1: MECHANICAL INST. SCHEDULE,
3)
ANNEXURE-A: BURDON TYPE PRESSURE / VACUUM GAUGE. SL NO. 56 AND 26 RESPECTIVELY.

ALL TEMPERATURE ELEMENTS SUCH AS TE-1, TE-2, TE-3, TE-4, TE-5, TE-6 AND TE-7 ALONG WITH RTD-1 AND RTD-2 ARE INCLUDED IN
4)
INSTRUMENT SCHEDULE. REFER PART-3: ELECTRONICS INSTRUMENT SCHEDULE, ANNEXURE-E, TEMPERATURE ELEMENT (IA PACKAGE)
 ANNEXURE- B
INSTRUMENTS FOR FLUIDISING BLOWERS:

ESP / BUFFER HOPPER FLUIDISING BLOWER:

Total quantity : 6 NOS.

Qty for 1
NTPC Drg. Instrument Sl. Name of Total Qty Scope of
Sl. No. Medium Range Location Item
No. No. in drawing Instrument (Nos.) Supply
(Nos.)
PRESSURE 0 - 1 KG /
1 PVM-B-014 AIR 15 AT BLOWER DISCHARGE. 1 6 KULKARNI
INDICATOR SQ CM

MAIN SILO FLUIDISING BLOWER:

Total quantity : 6 NOS.

Qty for 1
NTPC Drg. Instrument Sl. Name of Total Qty Scope of
Sl. No. Medium Range Location Item
No. No. in drawing Instrument (Nos.) Supply
(Nos.)
PRESSURE 0 - 2 KG /
1 PVM-B-012 AIR 15 AT BLOWER DISCHARGE. 1 6 KULKARNI
INDICATOR SQ CM

HCSD SILO FLUIDISING BLOWER:

Total quantity : 4 NOS.

Qty for 1
NTPC Drg. Instrument Sl. Name of Total Qty Scope of
Sl. No. Medium Range Location Item
No. No. in drawing Instrument (Nos.) Supply
(Nos.)
PRESSURE 0 - 1 KG /
1 PVM-B-070 AIR 15 AT BLOWER DISCHARGE. 1 4 KULKARNI
INDICATOR SQ CM
 ANNEXURE- C
INSTRUMENTS FOR FLUID COUPLINGS:

FLUID COUPLING FOR BA SLURRY DISPOSAL PUMP:

Total quantity : 4 NOS.

Instrument Qty for 1

Sl. NTPC Drg. Name of Total Qty Scope of
Medium Sl. No. in Type Range Location Item
No. No. Instrument (Nos.) Supply
drawing (Nos.)
AT OIL COOLER OF BA
TEMPERATURE 70 - 150
1 PVM-B-024 OIL 5 - SLURRY DISPOSAL PUMP 1 4 PREMIUM
SWITCH DEG C
FLUID COUPLINGS

AT OIL COOLER OF BA
70 - 150
2 PVM-B-025 OIL 6 THERMOCOUPLE - SLURRY DISPOSAL PUMP 1 4 PREMIUM
DEG C 4
FLUID COUPLINGS
AT OIL COOLER OF BA
TEMPERATURE 0 - 150
3 PVM-B-024 OIL 6 - SLURRY DISPOSAL PUMP 1 4 PREMIUM
INDICATOR DEG C
FLUID COUPLINGS

FLUID COUPLING FOR BA OVERFLOW WATER PUMP:

Total quantity : 6 NOS.

Instrument Qty for 1

Sl. NTPC Drg. Name of Total Qty Scope of
Medium Sl. No. in Type Range Location Item
No. No. Instrument (Nos.) Supply
drawing (Nos.)
AT OIL COOLER OF BA
TEMPERATURE 70 - 150
1 PVM-B-006A OIL 5 - OVERFLOW WATER PUMP 1 6 PREMIUM
SWITCH DEG C
FLUID COUPLINGS

AT OIL COOLER OF BA
71 - 150
2 PVM-B-006A OIL 6 THERMOCOUPLE - OVERFLOW WATER PUMP 1 6 PREMIUM
DEG C 4
FLUID COUPLINGS
AT OIL COOLER OF BA
TEMPERATURE 0 - 150
3 PVM-B-006A OIL 6 - OVERFLOW WATER PUMP 1 6 PREMIUM
INDICATOR DEG C
FLUID COUPLINGS
 ANNEXURE-D
INSTRUMENTS FOR TRANSPORT AIR COMPRESSOR:
Total quantity of TAC : 9 NOS.

Instrument Qty for 1

Name of Total Qty Scope of
Sl. No. NTPC Drg. No. Medium Sl. No. in Type Range Location Item
Instrument (Nos.) Supply
drawing (Nos.)
SUCTION
(-) 1 TO
1 PVM-Y-007-01 AIR PT 1 PRESSURE - AT SUCTION OF TAC 1 9 AERZENER
(+) 1 BAR
TRANSMITTER
FINAL PRESSURE (-) 1 TO
2 PVM-Y-007-01 AIR PT 4 - AT DISCHARGE LINE OF TAC 1 9 AERZENER
TRANSMITTER (+) 5 BAR

PRESSURE (-) 1 TO
3 PVM-Y-007-01 OIL PI 8 - AT LUBRICATING OIL LINE 1 9 AERZENER
INDICATOR (+) 5 BAR

PRESSURE (-) 1 TO
4 PVM-Y-007-01 OIL PT 8 - AT LUBRICATING OIL LINE 1 9 AERZENER
TRANSMITTER (+) 5 BAR
(-) 10 TO
TEMPERATURE
5 PVM-Y-007-01 OIL TI 7 - (+) 300 AT LUBRICATING OIL LINE 1 9 AERZENER
INDICATOR
DEG C
(-) 10 TO
TEMPERATURE
6 PVM-Y-007-01 OIL TT 7 - (+) 300 AT LUBRICATING OIL LINE 1 9 AERZENER
TRANSMITTER
DEG C
LEVEL
7 PVM-Y-007-01 OIL LG 11 - # AT LUBRICATING OIL TANK 1 9 AERZENER
INDICATOR
(-) 10 TO
TEMPERATURE AT COMPRESSOR DISCHARGE
8 PVM-Y-007-01 AIR TT 5 - (+) 300 1 9 AERZENER
TRANSMITTER LINE
DEG C
PRESSURE (-) 1 TO AT COMPRESSOR DISCHARGE
9 PVM-Y-007-01 AIR PI 4 - 1 9 AERZENER
INDICATOR (+) 5 BAR LINE

PRESSURE AT COMPRESSOR DISCHARGE

10 PVM-Y-007-01 AIR PT 9 - # 1 9 AERZENER
TRANSMITTER LINE
4

# RANGE AS PER SUPPLIERS STANDARD.

 ANNEXURE-E
INSTRUMENTS FOR AIR DRYING PLANT:
Total quantity of : 6 NOS.

Instrument Qty for 1

Sl. Name of Total Qty Scope of
NTPC Drg. No. Medium Sl. No. in Type Range Location Item
No. Instrument (Nos.) Supply
drawing (Nos.)
PRESSURE 0 - 16 KG / SQ
1 PVM-L-015 AIR PI-01 BURDON IA INLET LINE TO ADP PRE FILTER 1 6 SUMMITS
INDICATOR CM
PRESSURE 0 - 1600 MM
2 PVM-L-015 AIR PI-05, PI-06 BURDON ADP BLOWER DISCHARGE 2 12 SUMMITS
INDICATOR OF WC
PRESSURE 0 - 1600 MM
3 PVM-L-015 AIR PI-07 BURDON ADP BLOWER DISCHARGE LINE 1 6 SUMMITS
INDICATOR OF WC
4 PVM-L-015 AIR FS-01 FLOW SWITCH - # ADP BLOWER DISCHARGE LINE 1 6 SUMMITS
TEMPERATURE
5 PVM-L-015 AIR TS-01 - # HEATER DISCHARGE 1 6 SUMMITS
SWITCH
6 PVM-L-015 AIR TIC-01 - - # HEATER DISCHARGE 1 6 SUMMITS
TEMPERATURE
7 PVM-L-015 AIR TE-01 - # HEATER DISCHARGE 1 6 SUMMITS
ELEMENT
TEMPERATURE
8 PVM-L-015 AIR TI-05 - 0 - 250 DEG C HEATER DISCHARGE 1 6 SUMMITS
INDICATOR
TEMPERATURE
9 PVM-L-015 AIR TI-01, TI-02 - 0 - 250 DEG C AT TOWER-1 2 12 SUMMITS
INDICATOR
PRESSURE 0 - 16 KG / SQ
10 PVM-L-015 AIR PI-02 BURDON AT TOWER-1 1 6 SUMMITS
INDICATOR CM
PRESSURE 0 - 16 KG / SQ DISCHARGE LINE FROM PRE
11 PVM-L-015 AIR PI-08 BURDON 1 6 DCIPS
INDICATOR CM FILTER
TEMPERATURE DISCHARGE LINE FROM PRE
12 PVM-L-015 AIR TI-06 - 0 - 100 DEG C 1 6 DCIPS
INDICATOR FILTER
TEMPERATURE
13 PVM-L-015 AIR TI-03, TI-04 - 0 - 250 DEG C AT TOWER-2 2 12 SUMMITS
INDICATOR
PRESSURE 0 - 16 KG / SQ
14 PVM-L-015 AIR PI-03 BURDON AT TOWER-2 1 6 SUMMITS
INDICATOR CM
TEMPERATURE
15 PVM-L-015 AIR TE-02 - # DISCHARGE LINE FROM TOWER-2 1 6 DCIPS
ELEMENT
TEMPERATURE
16 PVM-L-015 AIR TI-07 - 0 - 100 DEG C DISCHARGE LINE FROM TOWER-2 1 6 DCIPS
INDICATOR
PRESSURE 0 - 16 KG / SQ AT DISCHARGE LINE FROM AFTER
17 PVM-L-015 AIR PI-09 BURDON 1 6 SUMMITS
INDICATOR CM FILTERS
PRESSURE AT DISCHARGE LINE FROM AFTER
18 PVM-L-015 AIR PT-01 - # 1 6 DCIPS
TRANSMITTER FILTERS
TEMPERATURE AT DISCHARGE LINE FROM AFTER
19 PVM-L-015 AIR TI-06 - 0 - 100 DEG C 1 6 SUMMITS
INDICATOR FILTERS

# RANGE AS PER SUPPLIERS STANDARD.

REFERENCE OF OTHER INSTRUMENTS IN NTPC DOCUMENT NO.: 0330-162-PVM-L-015:

ALL DIFFERENTIAL PRESSURE INDICATORS SUCH AS DPI-01, DPI-02, DPI-03 AND DPI-04 ARE INCLUDED IN INSTRUMENT SCHEDULE. REFER PART-1:
1)
MECHANICAL INSTRUMENT SCHEDULE, ANNEXURE-C, DIFFERENTIAL PRESSURE GAUGE, SL NO.: 8 & 9.
ALL DIFFERENTIAL PRESSURE SWITCHS SUCH AS DPS-01 AND DPS-02 ARE INCLUDED IN INSTRUMENT SCHEDULE. REFER PART-1: MECHANICAL
2)
INST. SCHEDULE, ANNEXURE-D: DIFFERENTIAL PRESSURE SWITCH. SL NO. 6 & 7.
 ANNEXURE-A
INSTRUMENT SCHEDULE
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-2
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
B.A.H.P.
101

1 WHB AT B.A. JET PUMP WATER INLET LINE BOURDON 11.50 12.00 45 0 - 20 150 4 4 4 _ D.O.L.
WATER

AT RING HEADER SEAL TROUGH B.A.L.P.

101

2 WLB BOURDON 2.30 2.90 45 0-6 150 1 1 1 _ D.O.L.

MAKEUP / FLUSHING LINE WATER
B.A.L.P.
101

3 WLB REFRACTORY COOLING LINE BOURDON 2.30 2.90 45 0-6 150 1 1 1 _ D.O.L.
WATER
AT B.A. SEAL WATER PUMP SUCTION B.A. SEAL
101

4 WSO BOURDON 0.30 1.00 45 0-1 150 _ _ _ 1 D.O.L.

LINE WATER

AT B.A. SEAL WATER PUMP B.A. SEAL

101

5 WSO BOURDON 3.50 3.90 45 0-6 150 _ _ _ 2 D.O.L.

DISCHARGE LINE WATER

AT B.A. SEAL WATER PUMP B.A. SEAL

101

6 WSO BOURDON 3.50 3.90 45 0-6 200 _ _ _ 1 D.O.L.

DISCHARGE HEADER LINE WATER

AT B.A.SEAL WATER LINE FOR ASH B.A. SEAL

101

7 WSO BOURDON 1.50 3.90 45 0-4 25 4 4 4 _ D.O.L.

CRUSHER SEALING WATER

AT B.A.SEAL WATER LINE TO B.A. B.A. SEAL

101

8 WSO BOURDON 2.90 3.90 45 0-6 25 2 2 2 _ D.O.L.

O'FLOW WATER PUMP SEALING WATER
PURCHASER'S SERVICE WATER LINE
B.A. SEAL
101

9 WEO FOR B.A. O'FLOW PUMP FLUID BOURDON 2.00 3.90 45 0-4 40 2 2 2 _ D.O.L.
WATER
COUPLING COOLING
2 2 2
ECO WATER LINE TO ECO HOPPER
101

10 WEP BOURDON ECO WATER 3.00 9.30 45 0 - 10 40 4 4 4 _ D.O.L.

FLUSHING BOX

INSTRUMENT
101

11 AIO AIR FILTER STATION OUTLET BOURDON 6.00 8.80 60 0 - 10 25 _ _ _ 1 D.O.L.

AIR

AT VACUUM LINE NEARLY TO VACUUM 254mmHg(g) 760mmHg(g)

102

12 FVO BOURDON VACUUM AIR 80 (-1) - 0 200 8 8 8 _ D.O.L.

PUMP HOUSE (VI) (Vacuum) (Vacuum)

WATER LINE HEADER TO VACUUM BA AREA SEAL

102

13 WEO BOURDON 2.00 3.90 45 0-4 80 1 1 1 _ D.O.L.

PUMP WATER

WATER LINE FOR VACUUM PUMP BA AREA SEAL

102

14 WEO BOURDON 1.00 3.90 45 0-4 40 8 8 8 _ D.O.L.

SEALING WATER
ESP /
AT ESP & BUFFER HOPPER
BUFFERHOPPE
102

15 AFH FLUIDISING BLOWER DISCHARGE BOURDON 0.40 0.44 150 0-1 100 1 1 1 _ D.O.L.
R FLIDISING
LINE
AIR

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 1 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-2
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
INSTRUMENT
103

16 AIO AT AIR RECEIVER FOR SILO AREA BOURDON 5.00 8.80 60 0 - 10 _ _ _ _ 1 D.O.L.
AIR

INSTRUMENT
103

17 AIO INSTRUMENT AIRLINE TO SILO AREA BOURDON 5.00 8.80 60 0 - 10 80 _ _ _ 1 D.O.L.

AIR

AT AIR RECEIVER FOR BAG FILTER INSTRUMENT

103

18 AIO BOURDON 5.00 8.80 60 0 - 10 _ 2 2 2 _ D.O.L.

PULSE JETTING SYSTEM AIR

AT DISCHARGE LINE OF CONDITIONING

103

19 WGO BOURDON 4.50 5.20 45 0 - 10 80 _ _ _ 6 D.O.L.

CONDITIONING WATER PUMP WATER

DISCHARGE HEADER LINE OF CONDITIONING

103

20 WGO BOURDON 4.50 5.20 45 0 - 10 50 _ _ _ 1 D.O.L.

CONDITIONING WATER PUMP WATER
AT CONDITIONING WATER LINE TO CONDITIONING
103

21 WGO BOURDON 2.50 5.20 45 0-6 65 _ _ _ 5 D.O.L.

DUST CONDITIONAR WATER
AT DISCHARGE LINE OF WASH
103

22 WWS BOURDON WASH WATER 2.50 3.10 45 0-6 80 _ _ _ 2 D.O.L.

WATER PUMP
CONDITIONING WATER LINE TO SILO CONDITIONING
103

23 WWS BOURDON 4.10 5.20 45 0 - 10 15 _ _ _ 2 D.O.L.

AREA DRAIN PUMP SEALING WATER
SILO
MANIFOLD AT DISCHARGE LINE OF
103

24 AFS BOURDON FLUIDISING 0.60 0.66 150 0-1 _ _ _ _ 1 D.O.L.

SILO FLUIDISING BLOWER
AIR
PURCHASER'S DM WATER LINE TO TA COOLING
103

25 WEO BOURDON 2.50 5.00 45 0 - 10 100 _ _ _ 1 D.O.L.

COMPRESSOR WATER
PURCHASER'S DM WATER LINE FOR COOLING
103

26 WEO BOURDON 2.50 5.00 45 0 - 10 40 3 3 3 _ D.O.L.

TA COMPRESSOR COOLING WATER

AIR RECEIVER AT DISCHARGE LINE TRANSPORT

103

27 ACO BOURDON 1.75 2.75 160 0-4 _ 3 3 3 _ D.O.L.

OF TRANSPORT AIR COMPRESSOR AIR

AT TRANSPORT AIR LINE TO STREAM TRANSPORT

103

28 ACO BOURDON 1.75 2.75 160 0-4 200 3 3 3 _ D.O.L.

LINE AIR
PURCHASER'S
104

29 WSL SEAL WATER TANK INLET BOURDON SERVICE 1.50 6.00 45 0-6 150 _ _ _ 1 D.O.L.
WATER
104

30 WSL SEAL WATER TANK DISCHARGE BOURDON SEAL WATER 0.20 1.00 45 0-1 100 _ _ _ 1 D.O.L.

AT DISCHARGE LINE OF L.P. SEAL L.P.SEAL

104

31 WSL BOURDON 6.50 9.00 45 0 - 10 80 _ _ _ 2 D.O.L.

WATER PUMP WATER

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 2 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-2
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
AT R.C. LINE FOR L.P. SEAL WATER L.P.SEAL
104

32 WSL BOURDON 6.50 9.00 45 0 - 10 50 _ _ _ 1 D.O.L.

PUMP WATER

AT L.P. SEAL WATER LINE FOR L.P.SEAL

104

33 WSL BOURDON 2.60 9.00 45 0 - 10 15 _ _ _ 2 D.O.L.

O'FLOW SLUDGE PUMP SEALING WATER

AT L.P. SEAL WATER LINE FOR B.A L.P.SEAL

104

34 WSL BOURDON 2.50 9.00 45 0 - 10 25 _ _ _ 2 D.O.L.

SLURRY DRAIN PUMP SEALING WATER

AT DISCHARGE LINE OF H.P. SEAL H.P. SEAL

104

35 WSH BOURDON 11.00 13.00 45 0 - 16 80 _ _ _ 2 D.O.L.

WATER PUMP WATER

AT R.C. LINE FOR H.P. SEAL WATER H.P. SEAL

104

36 WSH BOURDON 12.50 13.80 45 0 - 20 40 _ _ _ 1 D.O.L.

PUMP WATER
DM WATER LINE FOR 1st STAGE OF
COOLING
104

37 WEO ASH SLURRY DISPOSAL PUMP FC BOURDON 2.00 5.00 45 0 - 10 40 _ _ _ 4 D.O.L.

WATER
COOLING
AT L.P. SEAL WATER LINE FOR 1 st
L.P.SEAL
104

38 WSL STAGE OF ASH SLURRY DISPOSAL BOURDON 5.65 9.00 45 0 - 16 25 _ _ _ 4 D.O.L.

WATER
PUMP SEALING
H.P. SEAL WATER LINE FOR 2nd
H.P. SEAL
104

39 WSH STAGE OF ASH SLURRY DISPOSAL BOURDON 9.80 13.00 45 0 - 16 25 _ _ _ 4 D.O.L.

WATER
PUMPS SEALING
AT F.A.H.P. WATER PUMP DISCHARGE F.A.H.P.
104

40 WHF BOURDON 6.20 7.00 45 0 - 10 150 _ _ _ 5 D.O.L.

LINE WATER

AT FLUSHING WATER PUMP FLUSHING

104

41 WFP BOURDON 1.80 2.60 45 0-4 350 _ _ _ 1 D.O.L.

DISCHARGE LINE WATER

AT DISCHARGE LINE OF B.A.L.P. B.A.L.P.

104

42 WLB BOURDON 2.30 2.90 45 0-6 350 _ _ _ 5 D.O.L.

WATER PUMP WATER

AT DISCHARGE LINE OF ECO WATER ECO ASH

104

43 WEP BOURDON 7.00 9.30 45 0 - 16 200 _ _ _ 2 D.O.L.

PUMP WATER

AT DISCHARGE LINE OF B.A.H.P. B.A.H.P.

104

44 WHB BOURDON 11.50 12.00 45 0 - 20 250 _ _ _ 3 D.O.L.

WATER PUMP WATER

INSTRUMENT
105

45 AIO AT AIR FILTER STATION BOURDON _ _ 60 (-1) - 0 125 2 2 2 _ D.O.L.

AIR

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 3 of 4

 INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
BOURDON TYPE PRESSURE/ VACUUM GAUGE, REV-2
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE INSTALLATION
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) (kg /cm2) TYPE
(NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm2)
(kg/cm2)
AIR RECEIVER TOP AT IAC INSTRUMENT
105

46 AIO BOURDON 6.00 8.80 60 0 - 10 _ 2 2 2 _ D.O.L.

DISCHARGE (AIR) AIR

INSTRUMENT
105

47 AIO AIR RECEIVER OUTLET (AIR) BOURDON 6.00 8.80 60 0 - 10 100 1 1 1 _ D.O.L.
AIR

IA COMPRESSOR COOLING INLET COOLING

105

48 WCO BOURDON 2.50 7.00 45 0 - 10 40 2 2 2 _ D.O.L.

(WATER) WATER

IA COMPRESSOR COOLING RETURN COOLING

105

49 WCO BOURDON 2.50 7.00 45 0 - 10 40 4 4 4 _ D.O.L.

(WATER) WATER

COOLING
105

50 WCO INTER COLLER OUTLET (WATER) BOURDON 2.5 7.00 45 1 - 10 20 2 2 2 _ D.O.L.

WATER
INSTRUMENT
105

51 AIO AFTER COLLER OUTLET(IA PACKGE) BOURDON 6 8.8 50 0 - 10 65 2 2 2 _ D.O.L.

AIR
109

52 WHF WATER HEADER FOR DOSING - HCSD BOURDON FAHP WATER 3 7 45 0 - 10 150 - - - 6 D.O.L.

LP SEAL WATER LINE TO BOOSTER L.P.SEAL

109

53 WSY BOURDON 4 9 45 0 - 10 35 - - - 10 D.O.L.

PUMP - HCSD WATER
MANIFOLD AT DISCHARGE LINE OF FLUIDISING
109

54 AFL BOURDON 0.4 0.44 150 0-1 100 - - - 1 D.O.L.

HCSD SILO FLUIDISING BLOWER AIR
WATER HEADER FOR DOSING &
109

55 WHF BOURDON FAHP WATER 3 7 45 0 - 10 200 - - - 5 D.O.L.

FLUSHING - HCSD
IA LINE FROM INSTRUMENT AIR INSTRUMENT
109

56 AIO BOURDON 5.00 8.80 60 0 - 10 50 - - - 1 D.O.L.

HEADER AIR 2

AIR VISSEL AT HOSE PUMP AIR MEDIA OF

109

57 SH BOURDON 0-10 10 60 0-10 50 - - - 5 D.O.L.

DISCHARGE HOSE PUMP 2

NOTE : ALL PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL\PRESSURE GAUGE-1 Page 4 of 4

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DIAPHRAGM TYPE PRESSURE/ VACUUM GAUGE, REV-1
SHUT OFF/
NORMAL
MAX. PIPE QTY. QTY. QTY. QTY. FOR
SL P&I INSTRUMENT WORKING TEMP. RANGE (kg
TAG NO. LOCATION FLUID MEDIUM WORKING SIZE FOR FOR FOR COMMON REMARK
NO DIAGRAM TYPE PRESSURE
PRESSURE
(Deg. C) /cm2)
2 (NB) UNIT#1 UNIT#2 UNIT#3 SYSTEM
(kg/cm ) 2
(kg/cm )
AT B.A. O'FLOW WATER PUMP B.A. O'FLOW
101

1 DPB DIAPHRAGM 1.40 1.80 60 0-4 250 2 2 2 _

DISCHARGE LINE WATER
101

2 BJO AT B.A. JET PUMP DISCHARGE LINE DIAPHRAGM B.A. SLURRY 2.00 3.00 60 0-6 200 4 4 4 _

AT DISCHARGE LINE OF SILO AREA SILO DRAIN

103

3 DPS DIAPHRAGM 2.60 2.90 45 0-6 150 _ _ _ 2

DRAIN PUMP WATER

AT DISCHARGE LINE OF B.A. O'FLOW O'FLOW

104

4 DPB DIAPHRAGM 1.60 1.80 45 0-4 100 _ _ _ 2

SLUDGE PUMP SLURRY

AT PI CONNECTION OF B.A. SLURRY

104

5 DPO DIAPHRAGM DRAIN WATER 1.00 1.20 60 0-4 100 _ _ _ 2

DRAIN PUMP DISCHARGE

AT DISCHARGE LINE OF ASH SLURRY

104

6 SDO DIAPHRAGM ASH SLURRY 9.00 10.80 60 0 - 16 350 _ _ _ 4

DISPOSAL PUMP
109

7 SH AT DISCHARGE OF HOSE PUMP DIAPHRAGM ASH SLURRY 10.00 10.00 60 0 - 16 50 _ _ _ 5

AT DISCHARGE OF HCSD DRAIN HCSD SILO

109

8 SHD DIAPHRAGM 1.80 2.00 60 0 - 2.5 150 _ _ _ 2

PUMP DRAIN WATER

NOTE : 1) ALL THE PRESSURE GAUGES ARE GLYCERINE FILLED TYPE.

2) ALL THE PRESSURE GAUGES ARE DIRECT MOUNTED TYPE.

M:/BARH / INSTRU SCHEDULE / PRESS VAC GAUGE Page 1 of 1

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
STAGE-I, (3 X 500 MW) UNIT #1,#2,#3
DCIPS JOB NO.: 28P01
DIFFERENTIAL PRESSURE GAUGE, REV-1
DESIGN
P& I INSTRUMENT RANGE PIPE QTY FOR QTY FOR QTY FOR QTY FOR
SL NO. TAG LOCATION FLUID MEDIUM PRESSURE TEMP.(Deg. C) REMARKS
DIAGRAM TYPE (mmWC) SIZE (NB) #1 #2 #3 COMMON
(Kg/ cm2)
ASH
AT DIFFERENTIAL PRESSURE ACCROSS FREE &
1 103 ACO DIAPHRAGM CONTAMINETED 0 - 1500 300 mm of Hg 150 15 8 8 8 _
DUST AIR OF BAG FILTER
AIR
ASH
AT DIFFERENTIAL PRESSURE ACCROSS FREE &
2 103 ACO DIAPHRAGM CONTAMINETED 0 - 1500 1.4 150 15 _ _ _ 5
DUST AIR OF VENT FILTER SILO
AIR
ASH
3 103 LUO VENT FILTER ON TELESCOPIC SPOUT DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
AIR
ASH
4 109 LUO VENT FILTER ON TELESCOPIC SPOUT - HCSD DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
AIR
ASH
5 109 LUO AT VENT FILTER FOR HCSD SILO DIAPHRAGM CONTAMINETED 0 - 1500 200 mm of Hg 150 15 _ _ _ 5
AIR

NOTE : ALL DIFFERENTIAL PRESSURE GAUGES ARE DIRECT MOUNTED TYPE

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01

DIFFERENTIAL PRESSURE SWITCH, REV-1 (30.04.2010)

INSTRUMENT PIPE TOTAL
SL P& I INSTRUMENT ACTUATION RANGE TEMP.
TAG LOCATION FLUID MEDIUM SET POINT SIZE QTY REMARKS
NO. DIAGRAM TYPE REASON (mmWC) (Deg. C)
(mm WC) (NB) (NO.)
ASH 5 NOS FOR
ACROSS VENT FILTER ON TELESCOPIC
1 103 ACO DIAPHRAGM CONTAMINETED PR. HIGH 50 - 600 200 150 15 5 COMMON
SPOUT FOR MAIN SILO
AIR SYSTEM
ASH 5 NOS FOR
AT TELESCOPIC SPOUT VENT FILTER
2 109 ACO DIAPHRAGM CONTAMINETED PR. HIGH 50 - 600 200 150 15 5 COMMON
FOR HCSD SILO
AIR SYSTEM

ESP / BUFFER HOPPER FLUIDISING ATM. 2 NOS PER

3 102 AFH DIAPHRAGM ATM. AIR 50 - 600 200 50 100 6
BLOWER INLET FILTER PRESSURE UNIT

6 NOS FOR
MAIN SILO FLUIDISING BLOWER INLET ATM.
4 103 AFS DIAPHRAGM ATM. AIR 50 - 600 200 50 125 6 COMMON
FILTER PRESSURE
SYSTEM
4 NOS FOR
HCSD SILO FLUIDISING BLOWER INLET ATM.
5 109 AFS DIAPHRAGM ATM. AIR 50 - 600 200 50 100 4 COMMON
FILTER PRESSURE
SYSTEM

2 NOS PER
6 105 AIO PRE FILTER OF AIR DRYING PLANT DIAPHRAGM INSTRUMENT AIR PR. HIGH 50 - 600 200 50 50 6
UNIT

DRY 2 NOS PER

7 105 AIO AFTERFILTER OF AIR DRYING PLANT DIAPHRAGM PR. HIGH 50 - 600 200 150 50 6
INSTRUMENT AIR UNIT

INSTRUMENT AIR COMPRESSOR INLET ATM. 2 NOS PER

8 105 AIO DIAPHRAGM ATM. AIR 50 - 600 200 50 _ 6
FILTER PRESSURE UNIT

NOTE : ALL DIFFERENTIAL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
DISPLACER TYPE LEVEL SWITCH, REV-1

INVERT TOP OF
HIGH DENGER LOW TOTAL GUIDE PIPE
P&I FLUID TEMP LOW LEVEL LEVEL OF SUMP /
SL NO. TAG NO. SERVICE LOCATION LEVEL EL LEVEL EL QTY LENGTH REMARKS
DIAGRAM .( 0C ) (mm)
EL (mm)
(mm)
SUMP / TANK TANK
(NO.) (mm)
EL (mm) EL (mm)

ASH
SILO AREA DRAIN AS
1 103 DPS CONTAINMINA 50 (-) 600 (-) 1450 - (-) 2300 (-)300 1
SUMP REQUIRED
TED WATER
ASH
AS
2 104 DPA CONTAINMINA SEAL WATER TANK 50 (+) 5600 (+) 3300 - (+) 2800 (+)6000 1
REQUIRED
TED WATER
ASH
HCSD SILO DRAIN AS
3 109 - CONTAINMINA 50 (-) 600 (-) 1550 - (-) 2300 (-)300 1
SUMP REQUIRED
TED WATER

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
LEVEL INDICATOR, REV-1
INVERT LEVEL TOP OF SUMP /
LOW DENGER
P&I FLUID HIGH LEVEL OF SUMP / SUMP / TANK QTY. QTY. QTY. QTY. FOR
SL NO. TAG NO. SERVICE LOCATION LEVEL EL LOW LEVEL REMAKS
DIAGRAM TEMP.(0C) EL (mm) TANK EL TANK EL DEPTH FOR #1 FOR #2 FOR #3 COMMON
(mm) EL (mm)
(mm) (mm) (mm)
BA OVERFLOW
1 101 SB ASH WATER TRANSFER 60 (+) 5550 _ (+) 1650 (+) 1150 (+) 5950 4800 1 1 1 _
HOPER

2 104 SDO ASH WATER SURGE BIN 60 (+) 6800 _ (+) 1550 (+) 550 (+) 6900 6350 _ _ _ 1

SEAL WATER
3 104 DPB ASH WATER 45 (+) 5600 (+) 4300 (+) 3300 (+) 3000 (+) 5900 3100 _ _ _ 1
TANK

ASH WATER
4 104 DPO WATER 45 (+) 2825 (+) 1300 (-) 500 (-) 1800 (+) 3325 5125 _ _ _ 1
SUMP

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
PRESSURE SWITCH, REV-1 (30.04.2010)
SHUT OFF/
INSTRUMENT PIPE QTY FOR QTY QTY QTY FOR
SL P&I INSTRUMENT ACTUATION MAX. WORKING ACTUATION TEMP. RANGE
TAG NO. LOCATION FLUID MEDIUM SET POINT SIZE #1 FOR #3 FOR #2 COMMON REMARK
NO DIAGRAM TYPE REASON PRESSURE TYPE (Deg. C) (kg /cm2)
(Kg / cm2) (NB) (NO.) (NO.) (NO.) (NO.)
(kg/cm2)

B.A. O'FLOW WATER PUMP FIXED DIFF. PRESSURE B.A. SEAL

101

1 WSO 3.92 2.20 FALLING 45 0.4 - 4 25 2 2 2 _ GH - 901

SEALING BELLOW TYPE LOW WATER

TO B.A. O'FLOW PUMP FLUID FIXED DIFF. PRESSURE B.A. SEAL

101

2 WSO 3.92 1.70 FALLING 45 0.4 - 4 40 2 2 2 _ GH - 901

COUPLING BELLOW TYPE LOW WATER

PURCHESER
BA SEAL WATER PUMP FIXED DIFF. PRESSURE
101

3 WHB SERVICE 1.00 0.25 FALLING 45 0.2 - 1 150 _ _ _ 1 GM - 201

SUCTION LINE BELLOW TYPE LOW
WATER

BA SEAL WATER PUMP FIXED DIFF. PRESSURE B.A. SEAL

101

4 WSO 3.92 3.20 FALLING 45 0.7 - 7 200 _ _ _ 1 GH - 901

DISCHARGE LINE BELLOW TYPE LOW WATER

HEADER LINE FOR VACUUM FIXED DIFF. PRESSURE BA AREA SEAL

102

5 WEO 3.92 1.70 FALLING 45 0.4 - 4 80 1 1 1 _ GH - 901

PUMP SEALING BELLOW TYPE LOW WATER

FIXED DIFF. PRESSURE INSTRUMENT

103

6 AIO TO SILO AREA 8.80 5.00 FALLING 50 1 - 10 80 _ _ _ 2 GH - 901

BELLOW TYPE LOW AIR

SILO AREA DRAIN PUMP FIXED DIFF. PRESSURE CONDITIONING

103

7 WGO 5.20 3.50 FALLING 45 0.7 - 7 15 _ _ _ 2 GH - 901

SEALING BELLOW TYPE LOW WATER

FLUID COUPLING OF 1ST

FIXED DIFF. PRESSURE COOLING
104

8 WCO STAGE ASH SLURRY DISPOSAL 2.50 1.70 FALLING 45 0.4 - 4 40 _ _ _ 4 GH - 901
BELLOW TYPE LOW WATER
PUMP

FOR O'FLOW SLUDGE PUMP FIXED DIFF. PRESSURE L.P. SEAL

104

9 WSL 4.00 2.60 FALLING 45 0.4 - 4 15 _ _ _ 2 GH - 901

SEALING BELLOW TYPE LOW WATER

HCSD MIXING TANK DOSING FIXED DIFF. PRESSURE

109

10 WFP FAHP WATER 7.00 3.60 FALLING 50 0.7 - 7 150 _ _ _ 5 GH - 901

LINE BELLOW TYPE LOW

FIXED DIFF. PRESSURE

109

11 WSL HCSD BOOSTER SEALING LP SEAL WATER 9.00 4.54 FALLING 50 1 - 10 25 _ _ _ 5 GH - 901
BELLOW TYPE LOW

HCSD SILO AREA DRAIN PUMP FIXED DIFF. PRESSURE

109

12 WSL LP SEAL WATER 9.00 2.80 FALLING 50 1 - 10 15 _ _ _ 2 GH - 901

SEALING BELLOW TYPE LOW

NOTE : 1) THE SET POINTS ARE SUBJECT TO FINER ADJUSTMENT AT SITE TO SUIT EXACT SYSTEM REQUIREMENT.
2) ALL PRESSURE SWITCHES ARE DIRECT MOUNTED TYPE.

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL Page 1 of 1

 ANNEXURE-A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
SIGHT FLOW INDICATOR, REV-1
NORMAL MAX.
P&I FLOW RATE WORKING WORKING QTY. FOR QTY. FOR QTY. FOR QTY. FOR
SL NO. TAG NO. SERVICE LOCATION SIZE (NB) REMARKS
DIAGRAM (CUM/HR) PR. PR. #1 #2 #3 COMMON
2 2
(Kg/cm ) (Kg/cm )
BA OVERFLOW
1 101 WEO BA SEAL WATER WATER PUMP F.C. 4 40 3.5 3.9 2 2 2 _
COOLING

ASH CRUSHER
2 101 WSO BA SEAL WATER 4 25 3.5 3.9 4 4 4 _
SEALING
BA OVERFLOW
3 101 WSO BA SEAL WATER WATER PUMP 3.5 25 3.5 3.9 2 2 2 _
SEALING

VACUUM PUMP
4 102 WEO BA SEAL WATER 4 40 3.5 3.9 8 8 8 _
SEALING

CONDITIONING SILO AREA DRAIN

5 103 WGO 1.5 15 4.5 5.3 _ _ _ 2
WATER PUMP SEALING
BA OVERFLOW
6 104 WSL LP SEAL WATER SLUDGE PUMP 1.15 15 6.5 8.1 _ _ _ 2
SEALING

ASH SLURRY DRAIN

7 104 WSL LP SEAL WATER 2.3 25 6.5 8.1 _ _ _ 2
PUMP SEALING

COMBIND ASH
SLURRY DISPOSAL
8 104 WEO COOLING WATER 10 40 2.5 5 _ _ _ 4
PUMP FC COOLING
(1 st stage)
COMBIND ASH
SLURRY DISPOSAL
9 104 WSL LP SEAL WATER 4 25 6.5 8.1 _ _ _ 4
PUMP SEALING (1
st stage)
COMBIND ASH
SLURRY DISPOSAL
10 104 WSH HP SEAL WATER 4.6 25 11 12.2 _ _ _ 4
PUMP SEALING
(2nd stage)

IA COMPRESSOR
COOLING WATER
11 105 WCO COOLING HEADER 14.4 40 2.5 5 2 2 2 _
SUPPLY HEADER
RETURN
LP SEAL WATER HCSD SILO DRAIN
12 110 WSL 2.3 25 6.5 8.1 0.0 0.0 0.0 2
PUMP SEALING LINE
 NORMAL MAX.
P&I FLOW RATE WORKING WORKING QTY. FOR QTY. FOR QTY. FOR QTY. FOR
SL NO. TAG NO. SERVICE LOCATION SIZE (NB) REMARKS
DIAGRAM (CUM/HR) PR. PR. #1 #2 #3 COMMON
(Kg/cm2) (Kg/cm2)
LP SEAL WATER HCSD BOOSTER
13 110 WSL 2.87 25 6.5 8.1 0.0 0.0 0.0 5
PUMP SEALING LINE
 ANNEXURE - A
INDIRA GANDHI SUPER THERMAL POWER PROJECT-JHAJJAR
UNIT # 1,2 & 3 (3 X 500 MW)
DCIPS JOB NO.: 28P01
TEMPERATURE INDICATOR, REV-1

P&I MAX FLUID INSTRUMEN PIPE SIZE QTY FOR QTY FOR QTY FOR QTY FOR
SL NO TAG NO LOCATION SERVICE REMRKS
DIAGRAM TEMP DEG. C T RANGE (NB) #1 #2 #3 COMMON

AT ESP & BUFFER HOPPER

1 102 AFH FLUIDISING BLOWER FLUIDISING AIR 150 0 - 200 100 1 1 1 _
HEATER DISCHARGE
AT DISCHARGE LINE OF
2 103 AFS SILO FLUIDISING BLOWER FLUIDISING AIR 150 0 - 200 80 _ _ _ 6
HEATER
MANIFOLD AT DISCHARGE
3 103 AFS LINE OF SILO FLUIDISING FLUIDISING AIR 150 0 - 200 100 _ _ _ 1
BLOWER

COOLING
4 105 SDO COOLING WATER INLET 45 0 - 100 40 _ _ _ 1
WATER

WATER OUTLET AT 1st COOLING

5 105 SDO 45 0 - 100 20 2 2 2 _
STAGE CYLINDER WATER

WATER OUTLET AT 2nd COOLING

6 105 SDO 45 0 - 100 20 2 2 2 _
STAGE CYLINDER WATER

COOLING
7 105 SDO AFTER COOLER OUTLET 45 0 - 100 40 2 2 2 _
WATER

INSTRUMENT
8 105 AIO 1st STAGE DISCHARGE 145 0 - 250 65 2 2 2 _
AIR

INSTRUMENT
9 105 AIO 2nd STAGE DISCHARGE 160 0 - 250 65 2 2 2 _
AIR

INSTRUMENT
10 105 AIO AFTER COOLER OUTLET 80 0 - 200 65 2 2 2 _
AIR

INSTRUMENT
11 105 AIO AFTER COOLER OUTLET 50 0 - 200 65 2 2 2 _
AIR

INSTRUMENT
12 105 AIO AIR RECEIVER AT SILO TOP 50 0 - 100 65 2 2 2 _
AIR

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 AT DISCHARGE LINE OF
13 109 AFS HCSD SILO FLUIDISING FLUIDISING AIR 150 0 - 200 150 _ _ _ 4
BLOWER HEATER
MANIFOLD AT DISCHARGE
14 109 AFS LINE OF HCSD SILO FLUIDISING AIR 150 0 - 200 100 _ _ _ 1
FLUIDISING BLOWER

D:\NTPC-JHAJJAR\INSTRUMENTS\FOR MAIN PLANT\MECHANICAL

 SECTION - 3

CONTROL WRITE-UP PLANT CONTROL,

OPERATION & MONITORING

PART-A: BOTTOM AND COARSE ASH

HANDLING SYSTEM

PART-B: FLY ASH EVACUATION SYSTEM

PART-C: WATER AND SLURRY SYSTEM

PART-D: SILO UNLOADING SYSTEM

PART-E: INSTRUMENT AIR SYSTEM

 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -1-
DCIPS Job No. 28P01

-
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -2-
DCIPS Job No. 28P01

INDEX

SL. NO. DESCRIPTION PAGE NO.

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY 5
2.0.0 CONTROL DEVICES & LOCATION 6
3.0.0 BA DRIVES / EQUIPMENT : OPERATION / CONTROL PHILOSOPHY 7

3.1.0 DRIVE UTILISATION CHART 7

3.2.0 IDENTIFICATION OF DRIVES FOR BA – SYSTEM 8
3.3.0 CONTROL & OPERATION OF DRIVES AND EQUIPMENT 10

4.0.0 SYSTEM OPERATION SEQUENCE: 24

5.0.0 ECONOMISER HOPPERS CLEANING 25
6.0.0 OPERATION SEQUENCE FLOW DIAGRAM 26

7.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS 28

8.0.0 CONTROL IDENTIFICATION DIAGRAM (Shall be submitted later on)
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -3-
DCIPS Job No. 28P01

Ash handling process has been divided in following manners.

1. PART A: Bottom & Coarse ash handling system

2. PART B: Fly ash evacuation system
3. PART C: Water & slurry system
4. PART D: Silo unloading system
5. PART E: Instrument air system
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -4-
DCIPS Job No. 28P01

In this part of document we shall explain the PART A : i.e. Bottom & Coarse ash
handling system.
Operation & control of equipments related to cleaning of Bottom & Coarse ash have
been dealt here sequentially. Following equipments are associated with bottom &
Economiser ash cleaning system.
1. BALP Water Pumps
2. BAHP Water Pumps
3. ECO Water Pumps
4. BA Seal Water Pumps
5. HP Seal Water Pumps
6. LP Seal Water Pumps
7. Ash Slurry Disposal Pumps
8. BA Overflow Water Pumps
9. BA Overflow Sludge Pumps
10. Instrument Air Compressors.
11. Feed Gates
12. Ash Crushers

Item Sl No 3, 5 to 7 shall be covered in part C where as Sl No 10 shall be covered in

part E & rest are being covered in this section.
Entire documentation has been created in following manner.
1.0 For equipment : Following items are covered.
1.1 Location of actuators & their selection procedure.
1.2 Operational control with associated starting & running permissives.
1.3 Operational status, Signal, message etc.

2.0 For System : It has been represented in following manner.

2.1 Sequential operation
2.2 System /sub system flow chart.

Associated documents:

1. This write-up shall be read in conjunction with :

 Single line flow (DCIPS Drg. # 28P01 –1E-M-101)
diagram:

2. Remote operated Field Devices are also identified in the enclosed “CONTROL
IDENTIFICATION DIAGRAM”.
[This control identification diagram is developed from Single line diagram drawing no.
0330-162-PVM-L-001 to identify the Electrics & Electrical controls associated with the
Bottom Ash & Coarse Ash handling system]
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -5-
DCIPS Job No. 28P01

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY

In this chapter the bottom & Eco. ash handling system & its control philosophy have
been briefly discussed.
1.1.0 The System :
1.1.1 The Bottom ash handling system provided under this contract is designed for periodic
removal of ash generated in furnace of Unit #1, 2 & 3 through their respective water
impounded bottom ash hoppers.

1.1.2 Under the system arrangement, bottom ash generated in boiler furnace of each unit is
collected in respective water impounded bottom ash hopper and is cleaned once in
every four (04) hours interval by means of hydraulic jet pulsion pumps. The bottom ash
is cleaned and conveyed through four nos. of slurry transport lines (Line#1 to Line#4
to ash slurry common trough. Out of four slurry transport lines, normally maximum of
two (2) slurry transport lines shall be in operation one for one unit.

1.1.3 Excepting water and slurry pumping devices, the bottom ash cleaning devices are
generally unit wise & independent. BA cleaning of the three units will be sequential
maximum two (2) units shall be in operation.

1.1.4 Coarse ash from economiser hoppers shall be continuously removed in bottom ash
hopper, and shall be cleaned along with bottom ash cleaning operation for respective
units.

1.1.5 Water and slurry pumping devices are utilised as common facilities for cleaning of ash
from all the units.

1.1.6 The service water systems are operated to meet system input water requirement for de-
ashing and other auxiliary purposes

1.1.7 The slurry disposal pumps and associated facilities are energised for disposal of ash
slurry from inside the plant to remove ash pond. The slurry disposal pumping system is
common to bottom ash cleaning.

1.1.8 Compressed Instrument air free from dirt, scale & moisture will be used for operation of
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -6-
DCIPS Job No. 28P01

pneumatic actuation for various valves, gates and other pneumatic equipment under
the system.
1.1.9 Over flow from bottom ash hopper shall be pumped from each unit to common settling /
surge bins with the help of bottom ash over flow water pump. From the settling / surge
bins sludge is transferred to common BA slurry sump and overflow water from surge bin
is transferred to ash water sump for re-use of water.
2.0.0 Control Devices & Location:
2.1.0 BOTTOM ASH LOCAL OPERATOR’S CONSOLE (BALOC):
For local extraction related selections and actuations with associated monitoring in
bottom ash area will be from a local panel (One no for each unit) designated as ‘Bottom
Ash Local Operator’s Console’ hence forth called as BALOC. BALOCs for all the units`
shall be placed near bottom ash area of respective unit..
The primary operator’s interface from BALOC1, BALOC2 & BALOC3 for unit 1, 2 & 3
respectively shall be done through BALOC in proper co-ordination with ‘Ash control
room’. This panel will operate in conjunction with further downstream hopper gate
control local push button stations for respective unit.
Each BALOC will also consist of necessary actuators, selectors & indications related to
operation and control of Bottom Ash System equipment for respective unit.
Each of these panels (BALOC) will have painted LED spot illuminated mimic and
annunciator lamp boxes.
2.1.1 ‘Gate control local push button’ (GCLPB) of each feed gate will be provided with One
no each of OPEN & CLOSE pushbutton, and one no ON/OFF push button.

2.2.0 THE PROCESS CONTROL:

Logic relating to remote interlocked operation of the ash handling system will be
executed through purchaser’s DDCMIS.

2.3.0 CONTROL EQUIPMENT:

All drive motors & pneumatic valves will be controlled from respective purchaser’s
remote panel & BALOC with starting interlocks & permissives in remote mode.
2.4.0 SIGNALS/ INDICATION:
Location wise details of actuators, indications and anunciations have been furnished in
the annexed table titled “TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS
at the end of document.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -7-
DCIPS Job No. 28P01

3.0.0 BA DRIVES / EQUIPMENT : OPERATION / CONTROL PHILOSOPHY

3.1.0 Drive Utilisation Chart:

DRIVES FOR BA – CLEANING

COMMON DRIVES
FOR ASH
DRIVES / EQUP.
HANDLING SYSTEM
FOR BA
SYSTEM ONLY

IA COMPRESSOR

COMMON DRIVES
DRIVES / EQUIP.
REQUIRED DURING UNIT
DRIVES / EQUIP. RUNNING AND ALSO
REQUIRED BA CLEANING
DURING BA 1. ASH SLURRY
CLEANING ONLY DISPOSAL PUMPS
1. BAHP WATER PUMPS 2. LP SEAL WATER
2. BA SEAL WATER PUMPS
PUMPS 3. HP SEAL WATER
3. BA OVER FLOW PUMPS
1. ASH CRUSHERS TRANSFER PUMPS 4. ECO / APH WATER
2. FEED GATES 4. BA OVERFLOW PUMPS
3. BA JET PUMP INLET SLUDGE PUMPS 5. BALP WATER PUMPS
VALVE. 5. BALP WATER PUMP
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -8-
DCIPS Job No. 28P01

3.2.0 IDENTIFICATION OF DRIVES FOR BA – SYSTEM

DRIVE NO OF DRIVES TO
WORK FOR
SL.NO. TAG REMARKS
DESIGNATION UNITWISE BA
IDENTIFICATION
SYSTEM
BAHP#A
Two working for all three
1 BAHP Water Pump BAHP#B 1
units
BAHP#C
BALP#A
BALP#B
Three working for three
2 BALP Water Pump BALP#C 1
units out of each unit.
BALP#D
BALP#E
BAOP#1A
BAOP#1B
BA Overflow Water BAOP#2A
3 1 One for one unit.
Pump BAOP#2B
BAOP#3A
BAOP#3B
SLGP#A - One working for all
4 Sludge Pump
SLGP#B three units
EWP#A one working for all three
5 ECO Water Pump -
EWP#B units
CR#1A
CR#1B
CR#1C
CR#1D
CR#2A
BA cleaning operation of
CR#2B
6 Ash Crusher 2 the three units will be
CR#2C
sequential
CR#2D
CR#3A
CR#3B
CR#3C
CR#3D
BA Seal Water BASWP#A One Common for three
7 -
Pump BASWP#B units
LP Seal Water LPSWP#A One Common for three
8 -
Pump LPSWP#B units

HPSWP#A
One Common for three
HP Seal Water
9 - Units
Pump
HPSWP#B
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System -9-
DCIPS Job No. 28P01

BAASP#A1
BAASP#A2 Two pumps in one series.
BAASP#B1 Maximum two slurry
BA Ash Slurry BAASP#B2 disposal streams will
10 -
Disposal Pump BAASP#C1 operate for three units
BAASP#C2 while ash (BA & CA )
BAASP#D1 cleaning
BAASP#D2
IAC# 1A
IAC# 1B
Instrument Air IAC# 2A
11 1 One for one unit.
Compressor IAC# 2B
IAC# 3A
IAC# 3B
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 10 -
DCIPS Job No. 28P01

3.3.0 CONTROL & OPERATION OF DRIVES AND EQUIPMENTS:

3.3.1 BA OVER FLOW WATER PUMP :

The water overflowing from the bottom ash hopper of each unit is received into BA
overflow transfer hopper of respective unit. This pump of individual unit is to transfer BA
overflow water to settling bin. BA seal water pump will cater to the seal water requirement
of this pump. Generally one of these pumps is to be kept in service while respective unit
is in running condition. However, this pump will not in operation during BA cleaning in
“Draw down mode” as there is no overflow of water from BA hopper.
3.3.1.1 Selector & Actuator:
SELECTOR : Auto standby – A / Manual / Auto standby – B : at purchaser’s
HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local
PB station.

3.3.1.2 Permissive

F/C COOLER SERVICE WATER ADEQUATE PRESSURE

BA OVERFLOW TRANSFER HOPPER LEVEL > LOW LEVEL
PUMP SUCTION VALVE IS OPEN
WORKING BA SEAL WATER PUMP IS RUNNING
BA SEAL WATER PRESSURE IS NORMAL
* RUNNING PUMP IS TRIPPED
* (FOR THE PUMP M OTOR IN WAITING MODE)

BA OVERFLOW TRANSFER HOPPER LEVEL > DANGER LOW LEVEL

DISCHARGE VALVE OPENS WITHIN A PRESET TIME FROM
PUMP STARTING AND REMAINS OPEN
SUCTION VALVE IS OPEN
PUMP SEAL WATER PRESSIRE IS NORMAL
FLUID COUPLING OIL TEMP < TRIPPING VALUE
DISCHARGE HEADER PRESSURE IS NORMAL
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 11 -
DCIPS Job No. 28P01

3.3.1.3 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Suction valve BAOP**SVSO
2 Suction valve open BAOP**SVLO
3 Suction valve close BAOP**SVLC
4 Discharge valve BAOP**DV
5 Discharge valve open BAOP**DVLO
6 Discharge valve close BAOP**DVLC
7 Seal water Valve BAOP**SWVSO
8 Seal water pressure switch BAOP**SWPSL
9 F/C oil cooler service water header pressure switch BAOP*FCPSL
10 F/C oil cooler DM water valve BAOP**FCVSO
11 F/C oil cooler temperature BAOP**FCRTD
12 Discharge header pressure transmitter BAOP*DPT
13 BA overflow transfer hopper make up valve BAOH*MVSO
14 BA overflow transfer hopper level transmitter BAOH*LT
Read first * as unit no, namely 1 or 2 or 3 and read second * as drive identification i.e. A or B
3.3.1.4 Operation
Initially operator will select any pump (In case of auto mode the first pump to run will be
Pump # B if the mode is selected at Auto standby-A and vice versa) to be taken in
service. Once any pump is selected its respective solenoid valve installed in oil cooler
cooling water line will open and adequate water pressure will be sensed at pressure
switch.
Now start the pump through START actuation at HMI.
 Suction valve of the respective pump will be open.
 Seal water valve will be opened.
 After starting of the pump, within a preset time, if desired seal water pressure is
established, as detected by pressure switch, discharge valve opens in pre set time
and other running permissive are through, then the pump will continue to run.
Otherwise it will be tripped with annunciation.
However in auto standby mode operation, the standby pump will be auto started in case
of tripping of the running pump or decrease in discharge header pressure. One of the
pump may be stopped as per operator’s discretion.
Keeping selection in manual position, any or both the pumps can be started through their
respective START button.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 12 -
DCIPS Job No. 28P01

3.3.2 BA OVERFLOW SLUDGE PUMP :

There are two nos. bins namely settling bin and surge bin are provided for three units.
The discharge of BA overflow water pump is received in settling bin and overflow of this
bin is given to surge bin. The ash particles are first collected in settling bin and fine
particles are accumulated in surge bin. Final overflow from surge bin is given to ash
water sump for further use. There are two nos. (1 working and 1 standby) BA overflow
sludge pumps are provided to transfer sludge from bins to ash slurry common trough for
onward disposal to ash pond. The suction of BA overflow sludge pumps are connected
with common suction header of both the bins.

3.3.2.1 Selector & Actuator:

SELECTOR : Pump – A / Off / Pump – B : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local
PB station.

3.3.2.2 Permissive

STARTING PERMISSIVE

SURGE BIN WATER LEVEL > LOW LEVEL

AT LEAST ONE SUCTION VALVE IS OPEN
ONE NO LP SEAL WATER PUMP IS RUNNING
LP SEAL WATER HEADER PRESSURE IS NORMAL
SECOND PUMP IS NOT RUNNING
"DISCHARGE VALVE OF SECOND PUMP IS CLOSE"
ONE NO BA OVERFLOW PUMP IS RUNNING

RUNNING PERMISSIVE

SURGE BIN WATER LEVEL > LOW LEVEL

AT LEAST ONE SUCTION VALVE IS OPEN
PUMP SEAL WATER PRESSURE IS NORMAL
DISCHARGE VALVE OPENS WITHIN A PRESET TIME
FROM PUMP STARTING AND REMAINS OPEN
ONE NO BA OVERFLOW PUMP IS RUNNING
SECOND PUMP IS NOT RUNNING
"DISCHARGE VALVE OF SECOND PUMP IS CLOSE"
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 13 -
DCIPS Job No. 28P01

3.3.2.3 Operation:
These pumps are run on continuous basis except during BA cleaning in “Draw down
mode” and seal water requirement is cater from LP seal water pump. Both the pumps
having common suction header with individual bins outlet valves. Settling bin and surge
bin jetting is taken from the common discharge header of pumps.
Sequence of operation :
 Selection of pump A or B
 Start command of selected Pump.
 Suction valves of pump will open simultaneously as per pre-set logic with the
actuation of start command.
 Once, any suction valve has opened then seal water solenoid valve shall open after
some predetermined time delay.
 Sensing of normal seal water pressure of pump.
 Pump shall take start after meeting of all staring permissive.
 After starting of the pump, within a preset time, discharge valve opens
 Sludge water discharge header pressure as detected by discharge header pressure
transmitter is established to normal,
 Discharge valve remains open & pump will continue to run.
Normal discharge header pressure status will be displayed, as generated from
discharge header pressure transmitter. This pressure indication will start flashing in
case discharge header pressure falls below the set level and persists for a preset time
during normal running of any one pump.

3.3.2.4 Associated Control Item Nomenclature

SL NO ITEM TAG
1 Suction valve at outlet of settling bin STBOVSO
2 Suction valve open at outlet of settling bin STBOVLO
3 Suction valve close at outlet of settling bin STBOVLC
4 Suction valve at outlet of surge bin SGBOVSO
5 Suction valve open at outlet of surge bin SGBOVLO
6 Suction valve close at outlet of surge bin SGBOVLC
7 Suction valve of sludge pump SGP*SVSO
8 Suction valve open of sludge pump SGP*SVLO
9 Discharge valve SGP*DVSO
10 Discharge valve open SGP*DVLO
11 Discharge valve close SGP*DVLC
12 Seal water valve SGP*SWVSO
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 14 -
DCIPS Job No. 28P01

13 Seal water pressure switch SGP*SWPSL

14 Pump header discharge pressure transmitter SGPDPT
15 Surge bin level transmitter SGBLT
Read * as drive identification i.e. A or B
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 15 -
DCIPS Job No. 28P01

3.3.3 BAHP / BALP ASH WATER PUMP :

3.3.3.1 There are three nos. BAHP pumps are provided to cater BA water requirement for BA
cleaning operation. BAHP water pump is energized for Jetting / flushing water
requirement for bottom ash hopper, seal troughs, refractory cooling header etc as and
when necessary. Its suction is from ash water common sump. One BAHP water pump
can cater to bottom ash cleaning of one unit. Out of three (3) nos. of BAHP water
pumps, two (2) nos. BAHP pumps shall be in operation when BA cleaning for two (2)
units.
The BALP water pumps (05 Nos.) are operated to cater normal continuous water
requirement at bottom ash hopper filling / make up, seal trough make up, refractory
cooling. In addition, these pumps are used to supply necessary make-up water to
common ash slurry sump as well as BA overflow transfer hopper. Its suction is from
ash water common sump. three nos BALP pump in general are required to put into
service for running of three units.
3.3.3.2 Selector & Actuator
SELECTOR : Auto standby – A / Auto standby – B / Auto standby – C /
Manual (For BAHP Pumps) : at purchaser’s HMI
: Auto standby – A / Auto standby – B / Auto standby – C /
Auto standby – D / Auto standby – E / Manual (For BALP
Pumps) : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for all the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local
PB station.

3.3.3.3 Permissive

S T A R T IN G P E R M ISS IV E

A N Y O N E JE T PP IN L E T V /V O P E N
ASH W ATER SUM P LEVEL > LOW LEVEL

D IS C H A R G E H E A D E R P R . L O W
(F O R PR E S E T T IM E )
E L E C T R IC A L T R IP P IN G O F O P E R A T IN G PU M P

(F O R T H E P U M P M O T O R IN A U T O W A IT IN G M O D E )

R U N N IN G P E R M IS S IV E

ASH W ATER SUM P LEVEL > DANGER LOW

 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 16 -
DCIPS Job No. 28P01

3.3.3.4 Associated Control Item Nomenclature

SL NO ITEM TAG
1 Ash water sump level transmitter AWSLT
2 BAHP discharge header pressure BAHPDHPT1
3 BAHP discharge header pressure BAHPDHPT2
4 BALP discharge header pressure BAHPDHPT1
5 BALP discharge header pressure BALPDHPT2

3.3.3.5 Operation:
At first operator shall start the pumps through START actuation putting selector in
manual position. The discharge valve shall be subsequently opened manually. Keep
the selector in auto standby mode for the pump to be brought in auto service.
Discharge valve for standby pump shall be kept open for auto standby operation.
Note: For initial start, during commissioning or after long shut down, when discharge
line is empty; pump shall be started keeping discharge valve in closed condition. There
after all restart / auto start of pump shall be with discharge valve in open condition.
In auto mode of operation, the standby pump (kept selected) automatically starts
 if running pump/s stops due to electrical trip feedback and / or
 Due to non availability of discharge header pressure at or above preset setting for a
preset time as detected by pressure transmitters for BAHP / BALP pumps
 Due to decrease of discharge header pressure in case the discharge header
pressure falls below a normal set point level and persists for a preset time during
normal running of the other pump.
In case of auto starting of standby pump due to decrease in discharge header pressure,
one of the pumps may be stopped as per operator’s discretion. However, in case the
standby pump is stopped, ‘auto standby starting’ logic will start functioning only if
discharge header pressure attains it’s normal level at least once during running of the
pumps, after starting of standby pump.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
Keeping selection in manual position, any pumps can be started through their
respective START buttons.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 17 -
DCIPS Job No. 28P01

3.3.4 BA SEAL WATER PUMP :

There are two nos. BA seal water pump are provided to cater the seal water
requirement of BA overflow water pumps and all running ash crushers. Generally one of
these pumps is to be kept in service. 2 nos. of BA Seal water pumps are located near
BA Hopper Unit#1, one (1) working and one (1) standby common for all three units.
3.3.4.1 Selector & Actuator
SELECTOR : Auto standby – A / Manual / Auto standby – B : at HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local
PB station.

3.3.4.2 Permissive

STARTING PERMISSIVE

BA SEAL WATER SUMP LEVEL > LOW LEVEL

DISCHARGE HEADER PR. LOW

ELECTRICAL TRIPPING OF OPERATING PUMP

(FOR THE PUMP MOTOR IN AUTO WAITING MODE)

RUNNING PERMISSIVE

BA SEAL WATER SUMP LEVEL > LOW LEVEL

3.3.4.3 Associated Control Item Nomenclature

SL. NO. ITEM TAG

1 BA seal water suction header pressure BASWPSPSL

2 BA seal water discharge header pressure BASWPDPSL
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 18 -
DCIPS Job No. 28P01

3.3.4.4 Operation:
BA seal water pump receives clear water by purchaser’s service water source near BA
area.
Initially operator will select any pump (In case of auto mode the first pump to run will be
Pump # B if the mode is selected at Auto standby-A and vice versa) to be taken in
service. Now start the pump through START actuation. Pump will start if all the starting
permissive are through & if other running permissive are through, then the pump will
continue to run.
However in auto standby mode operation, the standby pump will be auto started in case
of tripping of the running pump or decrease in discharge header pressure. One of the
pump may be stopped as per operator’s discretion. However, in case of auto stanby
pump is stopped, ‘auto standby starting’ logic will start functioning only if discharge
header pressure attains it’s normal level at least once during running of the both the
pumps, after starting of standby pump.
Keeping selection in manual position, any or both the pumps can be started through their
respective START button.

Normal discharge header pressure status will be displayed, as generated from discharge
header pressure switch. This pressure indication will start flashing in case discharge
header pressure falls below the set level and persists for a preset time during normal
running of any one or both the pumps.

3.3.5 JET PULSION PUMP INLET WATER VALVE:

Motive water from BAHP sources is supplied through remote operated valves for
functioning of jet pulsion pump. There are four nos. of such valves provided in each unit;
one of such valve is associated with each set of ash crusher / jet pulsion pump.
Functioning of jet pulsion pump starts after opening of this valve.

3.3.5.1 Operation:
Actuation through individual open / close push button. : at purchaser’s HMI
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 19 -
DCIPS Job No. 28P01

3.3.5.2 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Bottom Ash jet pump inlet water valve JP**WVSO
2 Bottom Ash jet pump inlet water valve open JP**WVLO
3 Bottom Ash jet pump inlet water valve close JP**WVLC
4 Bottom Ash jet pump inlet water pressure transmitter JP**WPT1
5 Bottom Ash jet pump inlet water pressure transmitter JP**WPT2
6 Bottom Ash jet pump discharge slurry pressure transmitter BA*SL*PT
Read first * as unit no, namely 1 or 2 or 3 and read second * as feed gate identification i.e. A to D / 1 to 4

3.3.6 ASH CRUSHER SEAL WATER VALVE:

Ash crusher gland sealing, water from discharge of BA seal water pump is provided
through this valve.
3.3.6.1 ACTUATION : Individual valve OPEN / CLOSE at BALOC

Operator can open respective seal water valve of Ash crusher. Seal water pressure
“NORMAL” will be sensed at pressure switch; shall act as permissive for starting of Ash
crusher.
3.3.6.2 Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 Ash crusher seal water valve CR**SWVSO
2 Ash crusher seal water pressure CR**SWPT
Read first * as unit no, namely 1 or 2 or 3 and read second * as feed gate identification i.e. A to D

3.3.7 ASH CRUSHER

For crushing the bottom ash of BA hopper for onward hydraulic conveying. There are four
nos. ash crushers placed in between feed gate & jet pulsion pump for each unit. Ash
crusher corresponding to the gate already selected can be started for which following are
the selection :
3.3.7.1 Selector & Actuators
SELECTOR : Auto – Manual reversing mode : at BALOC
ACTUATION : FORWARD START / REVERSE START / STOP pushbutton for
all the Ash crusher: at BALOC.
EMERGENCY STOP : Emergency STOP push button near motor
(One no for each motor) on Local PB station.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 20 -
DCIPS Job No. 28P01

3.3.7.2 Permissives:

 Respective Jet pump water inlet valves are open (Open feedback of respective
valves) and motive water pressure is normal.
 Respective Seal water pressure is normal.

R E S P E C T IV E JE T P U M P IN L E T W A T E R V A L V E O P E N F E E D B A C K
R E S P E C T IV E JE T P U M P IN L E T W A T E R P R E S S U R E IS N O R M A L
A T L E A S T O N E B A S E A L W A T E R P U M P IS R U N N IN G
A SH C RU SH ER SEA L W A TER V A L V E O PEN

R E S P E C T IV E JE T P U M P IN L E T W A T E R V A L V E O P E N F E E D B A C K
R E S P E C T IV E JE T P U M P IN L E T W A T E R P R E S S U R E IS N O R M A L

A S H C R U S H E R S E A L W A T E R P R IS N O R M A L
JA M F E E D B A C K N O T A V A IL A B L E

3.3.7.3 Associated Control Item Nomenclature

SL. NO. ITEM TAG

1 JAM FEED BACK CR**ZSS
Read first * as unit no, namely 1 or 2 or 3 and read second * as feed gate identification i.e. A to D

3.3.7.4 Operation:
Each Ash crusher is provided with AUTO / MANUAL reversing facility to remove
jamming. Seal water of each running ash crusher is provided from seal water header.
Upon selection of Bottom Ash Jet pump inlet water valve by control room operator and
subsequent receipt of BA cleaning permission from control room and also availability of
required starting permissive, BALOC operator should give forward run command of the
respective Ash crusher after selecting Auto or Manual mode of crusher reversal
through “AUTO-MANUAL” reversal mode selector.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 21 -
DCIPS Job No. 28P01

Auto-Mode:
In auto-mode (“AUTO-MANUAL” selector on “AUTO” position), if the forward rolling
speed of crusher goes below the presetted speed sensed by speed sensor (provided
on output shaft of gear box) for a predetermined time, in such case “ASH CRUSHER
JAMMED” indication will appear on BALOC mimic followed by closing of respective
feed

gate. After another preset time duration, the crusher will stop automatically followed by
auto-sequential reverse-forward-reverse rotation with in between stop cycle as detailed
in the Auto reversing cycle diagram.
In the event of ash crusher gets tripped under any protection, the respective indication
will appear as flickering on HMI screen.

Auto Reversing Cycle – Ash crusher Motor

CRUSHER WILL
CRUSHER JAMMED

TRIP IN THIS
ZSS OPERATED

INDICATION

PERIOD IN CASE
JAM PERSISTS,
OTHERWISE
CONTINUES TO
RUN
FORWARD
30 S 20 S 30 S F 20 S 30 S F RUN
10S 10S
OFF
R 20 S 30 S R 20 S

REVERSE
RUN
TOTAL CYCLE UNDER EACH AUTO REVERSE OPERATION
(DECREASE IN SPEED WILL NOT BE MONITORED BY LOGIC DURING THIS PERIOD)
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 22 -
DCIPS Job No. 28P01

LEGEND
R – CRUSHER IN REVERSE RUN
F – CRUSHER IN FORWARD RUN
ZSS – ZERO SPEED SWITCH
S – TIME IN SECOND
(INDICATED FOR CONCEPTUAL PURPOSE MAY VARY AS PER ACTUAL
REQUIREMENT)
NOTE:
1. TIME GAP (APPROX. 2S) BETWEEN ZSS CONTACT ACTUATION AND JAM
INDICATION HAS BEEN CONSIDERED TO RESTRICT INTERMEDIATE FALSE
SIGNAL.
2. AUTO REVERSE CYCLE WILL START AFTER 2S (APPROX.) OF JAM INDICATION.

After a time gap of 30 secs from the last reversal rotation in the auto reversing cycle,
the respective Ash crusher will again start in forward direction. However at this
moment if the jamming still persists, as sensed by zero speed switch, then further
operation of the crusher will be locked out with “CRUSHER TRIPPED” indication for
subsequent manual intervention. After jam is cleared, restarting of the cleaning
operation shall follow the normal sequence.
During auto mode reversal period in case jamming is cleared, then after completion of
cycle time crusher will continue to run in forward direction and “Ash crusher Jammed”
indication will disappear after running of crusher in forward direction at normal speed
for preset time. Thereafter respective feed gate should be opened manually to
commence de-ashing.
Manual Reversing - Mode:
During manual reversing mode (“AUTO-MANUAL” selector on “Manual” position), in
the event of overloading and subsequent slowdown of crusher towards forward run
for a preset time period, “ASH CRUSHER JAMMED” indication will appear on BALCP
and after another preset time duration, the running crusher will trip. Thereafter STOP
push button is to be pressed to reset trip indication and then it will be possible to
rotate the crusher in reverse direction to dislodge the jammed material by inching
operation through actuation of “REVERSE” pushbutton on BALOC. During reverse
inching rotation, speed change will not be monitored in logic. After jam is cleared, the
jam indication will disappear after the Ash crusher rotates in the forward direction for
preset time without any jam feedback from zero speed switch.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 23 -
DCIPS Job No. 28P01

3.3.8 BOTTOM ASH GATES:

Accumulated bottom ash in each V-section hopper is periodically cleaned through
bottom ash feed gates. For the purpose, there are four (04) nos. of bottom ash gates.
Two nos gates are placed at each part of V section of BA hopper. These gates are
individually connected with four (04) nos. of bottom ash discharge lines. Normally,
during bottom ashing one no. feed gate is selected from each V-Section of BA
hopper.

3.3.8.1 Operation of feed gate

Having completed the following activities / interlock the gate can be operated.

Opening Permissives:
 At least one HP water pump is running
 Jet pulsion pump inlet valve open feed back available.
 HP water pressure normal at inlet of Jet pulsion pump.
 Ash crusher seal water pressure normal.
 Ash crusher is running in forward direction.
 Ash crusher Jam feed back not persisting.
 BA Disposal line pressure normal

The operation:
Now by Opening from local push button station (LPB) placed near the corresponding
gate; it can be opened through OPEN / CLOSE Push button.

Running Permissives:

 In the event of non-conformity of opening permissives immediately, feed gate

shall close.
 When crusher is jam for pre determined time / corresponding feed gate shall
close immediately.
In case of closer of feed gate due to jamming / tripping of Ash crusher, it is to be
reopened again by subsequent sequence of operation as explained above.
3.3.8.2 Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 Bottom Ash Feed Gate Open FG**SO
2. Bottom Ash Feed Gate Close FG**SC
3. Bottom Ash Feed Gate Open feed back FG**LO
4. Bottom Ash Feed Gate Close feed back FG**LC
Read first * as unit no, namely 1 or 2 or 3 and read second * as feed gate identification i.e. A to D
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 24 -
DCIPS Job No. 28P01

4.0.0 SYSTEM OPERATION SEQUENCE:

 There are three units viz.; unit No. 1, 2 & 3

 Bottom Ash Cleaning of three units is being carried out sequentially.

Bottom Ash Cleaning System:

Prior to starting of BA cleaning followings are to be ensured by control room operator.

 LP water pump in running condition feed back.
 Instrument Air pressure is normal.
 BA seal water pump running feedback.
 LP & HP Seal water pump running feedback.
 Required nos. of slurry disposal pumping stream in operation.
The bottom ash cleaning operations are carried out from “Bottom Ash Local
Operator’s Console “ (BALOC) as per the following steps/sequence, which are also
incorporated in annexed sequence operation flow chart.
The Activities:

At Ash Handling Control Room:

 Opening of jet pulsion inlet BAHP water valve.
 Start HP water pump & check availability of normal water pressure at selected Jet
pulsion pumps inlet.

Sequence of Activities at BALOC

 “BA cleaning permission request’ from BALOC operator to ash handling control
room operator.
 Start Bottom ash cleaning permission is received at BALOC from ash handling
control room.
 Ash crusher Seal water valves are to be opened through BALOC selector actuator
of selected feed gates.
 Check availability of normal Ash crusher seal water pressure.
 Forward run command to corresponding ash crusher of selected gates.
 Observe smooth running of crusher and normal HP water flow.
 Opening of respective Feed gates through OPEN push button of feed gate LPB.

The bottom ash cleaning process starts and associated equipment continues to run as
per protection & interlock.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 25 -
DCIPS Job No. 28P01

The bottom ash cleaning can be achieved either in “draw-down” mode or in

“maintained level” mode.

Draw-Down Mode:
In “draw-down” cleaning, the entire hopper will be made empty. The hopper make-up
water supply will be discontinued by closing make up water valve and thereafter
opening of the same after bottom ash cleaning operation is over in “draw-down” mode.

Maintained level:

In “maintained level” cleaning, the hopper water level will be maintained during the ash
cleaning. The full make-up to the bottom ash hopper is provided during entire period.

When bottom ash cleaning is over, BALOC / control room operator will take the
following action:

 Closing of BA feed gates by pressing close push button in LPB and to allow some
time delay for bottom ash slurry line to get flushed properly.
 Observed normal BA disposal line pressure.
 There after, the running Ash crushers will be stopped by actuating the respective
STOP push button at BALOC followed by closing of its seal water valves.
 Subsequently “BA CLEANING OVER” signal through BALOC push button to
control room.
 Operator of control room then STOP HP water pump (as per requirement) &
CLOSES respective inlet water valves of both the jet pumps.
 In case running of HP water pump required to be continued for Bottom ash
cleaning of other unit, then before closing of Jet pump water inlet valve of this
particular unit, similar valve for other unit shall be opened to avoid shut-off head of
HP water pump.

5.0.0 ECONOMISER HOPPERS CLEANING:

There is no control operation in Economiser hoppers cleaning process.

Continuous evacuation of ash from four nos. (04) economiser ash hoppers in each unit
is through the flushing boxes provided below the hoppers. Motive water is taken from
discharge of Economiser water pumps.

Economiser hoppers & air pre-heater hoppers ash slurry is disposed to respective
bottom ash hopper by gravity and accumulated ash slurry is being cleaned during BA
cleaning process.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 26 -
DCIPS Job No. 28P01

6.0.0 OPERATION SEQUENCE FLOW DIAGRAM

TO
NEXT
PAGE
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 27 -
DCIPS Job No. 28P01

FROMPREVIOUS
PAGE
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 28 -
DCIPS Job No. 28P01

7.0.0 TABULAR CHART : INTERLOCKS, ACTUATORS, INDICATIONS, ALARMS

SL. EQUIPMENT BALOC CONTRO ROOM REMARKS

NO. IDENTIFICATION ACTUATOR MIMIC ALARM HMI SCREEN HMI SCREEN ALARM
& PERMISSIVES INDICATOR WINDOW ACTUATOR INDICATOR ALARM LOG

1. ASH CRUSHER FORWARD FORWARD ASH

RUN PB RUN / CRUSHER
FORWARD
REVERSE TRIPPED ASH CRUSHER
RUN
RUN (COMMON) TRIPPED
(FLICKERING)
STOP PB STOP OFF
ASH CRUSHER
JAMMED
ASH
ASH
REVERSE CRUSHER
CRUSHER
RUN P.B. REVERSE
JAM
RUN

AUTO / ASH
MANUAL ASH CRUSHER
REVERSAL CRUSHER JAMMED JAM / TRIP
MODE TRIP (COMMON)
SELECTOR
ACTUATOR AUTO /
MANUAL
STATUS

2. ASH CRUSHER
OPEN / SEAL WATER CLINKER SEAL WATER CLINKER
SEAL WATER
CLOSE PR. NORMAL GRINDER SW PR. NORMAL GRINDER SW
VALVE SELECTOR PR. LOW (individual) PR. LOW
(COMMON)
SEAL WATER
VALVE OPEN /
CLOSE
3. FEED GATE OPEN / JET PP INLET
CLOSE
CLOSE PB OPEN WATER
(MOUNTED PRESSURE
ON LPB) LOW

CLOSE

4. JET PUMP INLET

WATER VALVE OPEN JET PUMP OPEN PB OPEN JET PUMP
INLET WATER INLET WATER
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 29 -
DCIPS Job No. 28P01

SL. EQUIPMENT BALOC CONTRO ROOM REMARKS

NO. IDENTIFICATION ACTUATOR MIMIC ALARM HMI SCREEN HMI SCREEN ALARM
& PERMISSIVES INDICATOR WINDOW ACTUATOR INDICATOR ALARM LOG

PR. LOW PR. LOW

(COMMON)
CLOSE PB CLOSE

5. BA OVERFLOW ON ON / BA OVERFLOW
START P.B. OFF / WATER PUMP
WATER PUMP
TRIP TRIPPED

SEAL WATER
PR NORMAL
STOP PB
DISCHARGE
AUTO PR NORMAL
STANDBY
–A/ SUCTION /
MANUAL / DISCHARGE
AUTO VALVE
STANDBY STATUS
–B

6. BA OVERFLOW OPEN /
TRANSFER CLOSE BA OVERFLOW
HOPPER MAKE UP TRANSFER
AUTO /
HOPPER
VALVE MANUAL
LEVEL
SELECTION DANGER LOW
FACILITY
BA
OVERFLOW
TRANSFER BA OVERFLOW
HOPPER TRANSFER
LEVEL HOPPER
OPEN /
CLOSE LEVEL LOW

BA OVERFLOW
TRANSFER
HOPPER
LEVEL HIGH

7. BA OVERFLOW START / ON / OFF SURGE BIN

SLUDGE PUMP STOP LEVEL LOW
SEAL WATER
PR NORMAL SURGE BIN
LEVEL HIGH
DISCHARGE
PR NORMAL

SUCTION /
DISCHARGE
VALVE
STATUS
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 30 -
DCIPS Job No. 28P01

SL. EQUIPMENT BALOC CONTRO ROOM REMARKS

NO. IDENTIFICATION ACTUATOR MIMIC ALARM HMI SCREEN HMI SCREEN ALARM
& PERMISSIVES INDICATOR WINDOW ACTUATOR INDICATOR ALARM LOG

8. AUTO BA SEAL
ON / OFF /
BA SEAL WATER STANDBY – WATER PUMP
TRIP
PUMP A / MANUAL TRIPPED
/ AUTO
DISCHARGE
STANDBY – BA SEAL
PR NORMAL
B WATER SUMP
SELECTION LEVEL LOW
FACILITY
BA SEAL
START / WATER SUMP
STOP LEVEL HIGH

9. AUTO BAHP TRIPPED

BAHP WATER STANDBY – BAHP
PUMP A / AUTO STARTED SUMP LEVEL
STANDBY – LOW
B / AUTO BAHP
STANDBY – TRIPPED SUMP LEVEL
C / MANUAL HIGH

START / BAHP
STOP DISCHARGE
PR HIGH

BAHP
DISCHARGE
PR LOW

10. BALP WATER AUTO BALP BALP TRIPPED

PUMP STANDBY – STARTED
A / AUTO SUMP LEVEL
STANDBY – BALP LOW
B / AUTO TRIPPED
STANDBY – SUMP LEVEL
C / AUTO HIGH
STANDBY –
D / AUTO BALP
STANDBY – DISCHARGE
E / AUTO PR HIGH
STANDBY –
F / AUTO BALP
STANDBY – DISCHARGE
G/ MANUAL PR LOW

START /
STOP
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -A: BOTTOM & COARSE ASH HANDLING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage –1,Units # 1, # 2 & # 3 (3 x 500 MW) Rev. No. – 0
Ash Handling System - 31 -
DCIPS Job No. 28P01

NOTE:

1. COLOUR OF INDICATION FOR PURCHASER’S HMI.

RED / STEADY (S) : OPEN / ON / PR, LVL, TEMPARATURE, PROCESS NORMAL

RED / FLICKERING (F) : PR, LVL, TEMPARATURE, PROCESS ABNORMAL / ASH CRUSHER REVERSE
RUN, DRIVE TRIP
AMBER / STEADY (S) : LEVEL HIGH / LEVEL LOW / LEVEL DANGER LOW
GREEN / STEADY (S) : OFF / CLOSE
BLUE :DRIVE MOTOR SELECTED FOR DE-INTERLOCKED TRIAL OPERATION
(DE-INTERLOCKED TRIAL OPERATION OF DRIVE MOTORS WILL BE
SELECTED FROM A PASSWORD PROTECTED PAGE OF HMI. IN THIS MODE
ELECTRICAL PROTECTION OF MOTORS WILL BE IN OPERATIVE MODE.
HOWEVER, PROCESS INTERLOCK OF THE PARTICULAR DRIVE WILL BE BY-
PASSED)
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -1-
DCIPS Job No. 28P01
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -2-
DCIPS Job No. 28P01

INDEX

SL. NO. DESCRIPTION PAGE

NO.
1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY 5
2.0.0 CONTROL DEVICES & LOCATION 7
3.0.0 FA DRIVES 8
3.1.0 DRIVE UTILISATION CHART 8
3.2.0 IDENTIFICATION OF DRIVES FOR FA SYSTEM 9
3.3.0 CONTROL AND OPERATION OF DRIVES / EQUIPMENT 10
3.3.1 VARIOUS VALVES OF FA SYSTEM & THEIR CONTROL PHILOSOPHY 10

3.3.2 VARIOUS DRIVES / EQUIPMENTS / SUB-SYSTEM / LINES OF FA 18

SYSTEM
4.0.0 SYSTEM OPERATION SEQUENCE: 31
5.0.0 OPERATION SEQUENCE FLOW DIAGRAM 38
6.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS 40
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -3-
DCIPS Job No. 28P01

Ash handling system has been divided in following manner.

1. PART A: Bottom ash & coarse ash evacuation system

2. PART B: Fly Ash evacuation system
3. PART C: Water & slurry pumping system
4. PART D: Silo unloading system
5. PART E: Instrument air system
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -4-
DCIPS Job No. 28P01

In this part of document we shall explain the PART B i.e. Ash evacuation system.
Operation & Control of equipment related to cleaning of Ash have been dealt here
sequentially. Following equipments are associated with the ash evacuation system.
1. BA Seal Water pumps
2. Vacuum Pumps
3. ESP & Buffer Hopper Fluidising Blowers & Heaters
4. Transport Air Compressors (TAC)
5. Instrument Air Compressors.
6. Ash Transmitters (Nuva Feeders)
7. Bag Filters
8. Silo Vent Fans

The documentation has been created in following manner.

1.0 For equipment: Following are the topics have been covered.
1.1 Location of actuator & their selection procedure.
1.2 Operational control with associated starting & running permissives.
1.3 Operational status, Signal, message etc.

2.0 For System: Following are the topics have been covered.
2.1 Sequential operation
2.2 System / sub-system flow chart

D) Associated documents:
1. This write-up shall be read in conjunction with :
 Single line flow diagram: [DCIPS Drg. # 28P01 –1E-M-102 & 103]

2. Remote operated field devices are also identified in the enclosed “CONTROL
IDENTIFICATION DIAGRAM”.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -5-
DCIPS Job No. 28P01

[This control identification diagram is developed from Mechanical Single line drawing no.
28P01-1E-M-102 & 103 Rev-1 respectively to identify the Electrics & Electrical controls
associated with the Ash evacuation system and may not cover all flow lines, having only
field manual controls. In case of conflict, the content of Mechanical Single line diagram will
prevail.]

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY:

The System:
Accumulated fly ash in ESP hoppers (160 Nos. in each Unit), Primary Air Heater Hoppers (
04 Nos. in each Unit ) & Secondary Air Heater Hoppers ( 04 Nos. in each Unit ) are
cleaned on continuous basis through fly ash evacuation system in dry form.
1.1.0 Dry Mode:
Accumulated fly ash in ESP hoppers, Primary Air Heater Hoppers & Secondary Air Heater
Hoppers are evacuated by vacuum process from respective hoppers and conveyed
through bag filter & collected in buffer hopper in dry form. This dry ash through Nuva
feeder is pressure conveyed to silo through pressure conveying. Dry ash collected in silo is
unloaded in dry form or in semi wet form as the case may be, to closed / open truck
respectively for ultimate use. Pressure system runs in proper co-ordination with vacuum
system in Dry mode.
1.2.0 In bag filter ash gets separated from ash-air mixture & accumulated in buffer hopper.
Vacuum Conveying Air from bag filter is finally released in atmosphere through vacuum
pump.
1.3.0 The vacuum pump runs in water sealed condition to produce adequate vacuum to pull ash
from ESP hoppers, Primary Air Heater Hoppers & Secondary Air Heater Hoppers.
Similarly, in pressure conveying system, transport air compressor (TAC) produces motive
air pressure for Transport ash from buffer hopper to silo, through Nuva feeder.
1.4.0 ASH LOADING SYSTEM
There are five nos. silo of 1000 MT capacity each. Each silo is equipped with its own
unloading arrangement of dry as well as in semi wet mode.

1.5.0 Alternatively Dry ash can also be collected to five (5) nos of HCSD Silos of capacity 250T.
Each HCSD silo is equipped with High Concentration Slurry Disposal (HCSD) Unloading
system and also provision for disposal through Telescopic Chute for truck loading.
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PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -6-
DCIPS Job No. 28P01

1.6.0 Hot air from fluidizing blower (with associated heater arrangement) is provided on 1st to 4th
field hopper of ESP & buffer hopper during evacuation in order to aid fluidizing effect of fly
ash. Opening /closing of fluidized airline valves are controlled automatically. For silo,
separate fluidizing arrangement is provided with silo fluidizing blower.

1.7.0 Instrument air free from dirt, scale at adequate pressure will be used for operation of
pneumatic actuation for various valves, gates and other pneumatic equipment under the
system.
1.9.0 ESP Streams & Branches:
There are total 160 nos. ESP hoppers are suitably grouped in four (4) nos. of streams viz.
Stream-FL A, Stream-FL B, Stream-FL C & Stream-FL D. Each stream having four (4) nos.
branches and each of which comprises of ten (10) nos. hoppers (one hopper from each of
1st to 10th field).
Stream- FL A & Stream- FL D are connected to two nos. primary air heater and secondary
air heater streams, each stream is connected to 02 nos. each primary air heater &
secondary air heater hoppers connected.
ESP :
[(4 STREAMS) X (4 BRANCHES IN EACH STREAM) X (10 HOPPERS IN EACH
BRANCHES) = 160 HOPPERS]
PRIMARY AIR HEATER :
[(2 STREAMS) X (2 HOPPERS IN EACH BRANCHES) = 4 HOPPERS]
SECONDARY AIR HEATER :
[(2 STREAMS) X (2 HOPPERS IN EACH BRANCHES) = 4 HOPPERS]
The Isolation:
Every branch of vacuum conveying system can be isolated by a pneumatically operated
isolating valve named branch header valve (TERSG). While de-ashing sequence is in
progress, only one branch isolating valve (TERSG) of a stream will be in open condition
and other branch isolating valves shall remain closed.
The Ash Intake valve:
Every hopper is having one remote operated ash intake valve. Actual flow of ash occurs
when this particular valve is in open condition.
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PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -7-
DCIPS Job No. 28P01

1.10.0 At a time Fly ash evacuation from all the four streams can be performed vacuum conveying
in dry mode stream wise. Any stream can be engaged in dry collection through adequate
isolation.

Ash collection in dry mode is done through bag filter arrangement, placed on top of buffer
hopper. Buffer hopper is used as intermittent storage of ash before transport to silo through
Pressure Conveying by NUVAFEEDER system with aid of conveying air provided by
Transport Air Compressor.
Ash collection to Buffer Hopper through Vacuum conveying System, vacuum is generated
through water ring vacuum pump. Each stream is connected with two nos. of vacuum
pump; one in running & other as stand by.
1.11.0 All solenoid operated air / electric valve under fly ash system will be normally operated /
controlled from control room in remote interlock mode.

2.0.0 CONTROL DEVICES & LOCATION:

2.1.0 THE PROCESS CONTROL:
Logic relating to remote interlocked operation of the ash handling system will be executed
through Purchaser’s DDCMIS.

2.2.0 CONTROL EQUIPMENT:

All drive motors, actuator & pneumatic valves will be controlled from respective
Purchaser’s remote panel with starting interlocks & permissives in remote mode

2.3.0 SIGNALS/ INDICATION:

Location wise details of actuators, indications and annunciation have been furnished in the
annexed table titled “TABULAR CHART: ACTUATORS, INDICATIONS, ALARMS at the
end of document.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -8-
DCIPS Job No. 28P01

3.0.0 FA DRIVES

3.1.0 Drive Utilisation Chart:

DRIVES FOR FA – CLEANING

COMMON DRIVES
FOR ASH HANDLING
SYSTEM
DRIVES / EQUP.
FOR FA
SYSTEM ONLY
COMMON DRIVES
INSTRUMENT AIR FA & FOR FA HCSD
COMPRESSOR SILO

DRIVE FOR DRY

MODE DISPOSAL
ONLY

1. TRANSPORT AIR COMPRESSORS

2. ESP & BH FLIDISING BLOWERS
3. VACUUM PUMPS
4. BA SEAL WATER PUMPS
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -9-
DCIPS Job No. 28P01

3.2.0 IDENTIFICATION OF DRIVES FOR FA SYSTEM

DRIVE NO OF DRIVES TO
SL.NO. TAG WORK FOR FA REMARKS
DESIGNATION SYSTEM
IDENTIFICATION

ESP & BH Fluidising ESPB# A One working & one

1. 1 standby
Blowers ESPB# B
ESP & BH Fluidising ESPH#A One working & one
2. 1 standby
Blowers Heaters ESPH#B
VP#A1
VP#A2
VP#B1
VP#B2
3. Vacuum Pumps 4 One for each stream
VP#C1
VP#C2
VP#D1
VP#D2
TAC#X
Transport Air Two working & one
4. TAC#Y 2
Compressors standby
TAC#Z
IAC# 1A
IAC# 1B
Instrument Air IAC# 2A One working & one
11 1
Compressor IAC# 2B standby for each unit
IAC# 3A
IAC# 3B

FAS1VF
FAS2VF
12 Silo Vent Fan FAS3VF
FAS4VF
FAS5VF
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PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 10 -
DCIPS Job No. 28P01

3.3.0 CONTROL & OPERATION OF DRIVES / EQUIPMENTS

3.3.1 VARIOUS VALVES OF FA SYSTEM & THEIR CONTROL PHILOSOPHY

3.3.1.1 Bag Filter Path Selection Valve (S**PVSO) Read 1st * for Unit no,namely 1 or 2 or 3 and read
second * as Bag Filter group 1 / 2 of Stream A/B/C/D

 This valve will operate under the conditions. Each stream is connected with two Bag
Filtter Group BF-A1 & A2 for stream – A , similarly for other Stream- B to D. At a time
only one Bag Filtter Group is in working condition and other Group is kept as standby.

 Path Selection (S**PVSO) of Selected Bag Filter. Read 1st * for Unit no, namely 1 or 2 or 3
and read second * as Bag Filter group 1 / 2 of Stream A/B/C/D

3.3.1.2 Vacuum Pump Suction Valve (VP**SV) : Read 1st * for Unit no, namely 1 or 2 or 3 and read second
* as Bag Filter group 1 / 2 of Stream A/B/C/D
This valve will operate under following condition.
 Selection of vacuum pump and Bag Filter

Opening of this valve (VP**SVLO) will make vacuum line through with the selected vacuum
pump of evacuation.

3.3.1.3 Vacuum Pump Seal Water Valve (VP**SWV) : Read 1st * for Unit no, namely 1 or 2 or 3 and read
second * as Bag Filter group 1 / 2 of Stream A/B/C/D
This valve will operate under following condition.
 BA Seal water header pressure (FA*SWPSL) is normal.
 Start command of Selected vacuum pump.

Opening of this valve (VP**SWVSO) will give rise to seal water pressure & will be sensed
by pressure transmitter (VP**PT) having pre set value.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 11 -
DCIPS Job No. 28P01

3.3.1.4 Vacuum breaker / Vacuum Relief Valve (BF**VRV): Read 1st * for Unit no, namely 1 or 2 or
3 and read second * as Bag Filter group 1 / 2 of Stream A/B/C/D

(i) For each vacuum conveying stream, there is vacuum breaker / vacuum relief
valve attached with in each Bag Filter and will be closed.

Closing of vacuum breaker / vacuum relief valve;

While vacuum pump is running smoothly, one should close vacuum breaker / vacuum relief
valve. The vacuum breaker for selected dry conveying path will be closed (under both
“Auto” or “Manual” cleaning) through’ actuation of “SYSTEM START” command for the
conveying stream connected with the said conveying path.

Vacuum breaker/Relief valve shall be closed under following conditions.

VACUUM RELIEF VALVE CLOSING PERMISSIVE

DRY MODE IS SELECTED

SELECTED VACUUM PUMP IS RUNNING

ASSOCIATED VACUUM CONVEYING PATH IS THROUGH

SYSTEM START COMMAND IS GIVEN (PULSE)

* VACUUM RELEIF VALVE WILL OPEN IN CASE OF NON AVAILABILITY OF ANY OF THE ABOVE
CONDITIONS AND ALSO IF VACUUM LEVEL IS > VS3 AND PERSISTS FOR PREDERTERMINED
TIME (VACUUM SYSTEM ASH CONVEYING OVERLOADED) OR WHEN VERY HIGH VACUUM
IS ATTAINED OR SYSTEM STOP COMMAND IS GIVEN
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 12 -
DCIPS Job No. 28P01

Associated Control Item Nomenclature for Sl Nos. 3.3.1.1 to 3.3.1.9

SL. ITEM TAG REMARKS
1 Bag Filter path isolation valve S**PVSO
2 Stream isolation valve in dry mode close feed back S**PVLC
3 Stream isolation valve in dry mode open feed back S**PVLO
4 Vacuum pump suction valve open VP**SVSO
5 Vacuum pump suction valve open feed back VP**SVLO
6 Vacuum relief valve close BF**VRVSC
7 Vacuum relief valve close feed back BF**VRVLC
8 Vacuum pump seal water valve open VP**SWVSO
9 Vacuum pump seal water pressure transmitter VP**PT
10 Dust sensor VP**DS st
1 * for stream A to D
11 Vacuum transmitter VP**VT nd
& 2 * for group 1/2
12 Bag Filter area instrument air pressure transmitter
13 FA Seal water pump header pressure switch FA*SWPSL
st
Read 1 * for Unit no, namely 1 or 2 or 3 and read second * as Bag Filter group 1 / 2 of Stream A/B/C/D

3.3.1.5 Branch Header Valve :

This valve will operate under following condition :
Any branch header valve of the stream is selected in purchaser’s HMI in manual mode. In
auto mode selected branch header valve will open as soon as SYSTEM START command
given in purchaser’s HMI.

3.3.1.6 Ash Intake Valve :

Operation of Ash Intake Valve as follows:
 Only one no. ash intake valve of hopper of selected branch of each stream will open at
a time in auto as well as manual mode of extraction.
 In AUTO mode the ash intake valve of hopper of the selected branch will open as per
logic sequence after actuation of “SEQUENCE START” push button at purchaser’s HMI
if all other permissives are available.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 13 -
DCIPS Job No. 28P01

 In MANUAL mode the ash intake valve of a particular hopper will be selected in
following manner from purchaser’s HMI.
 Selection of branch
 Selection of hopper required to be cleaned.

OPENING PE RM ISSIVE FOR ASH INT AKE VAL VE FO R ASH EVAC UATION

VA CUUM REL IEF VAL VE OF T HE

SE LE CT ED ST RE AM PAT H IS C LOSED
BUFFER HOPPE R L EVE L NOT HIGH
B AG FIL TE R PUL SE JET TING IS ON
B AG FIL TE R DIFFER ENT IAL PRE SSUR E NOT HIGH FOR PRE SET DURAT ION
VACU UM HIGH SET (VS3) > L INE VAC UUM > LOW VAC UUM SE T (VS1)
HOPPER IS NOT BY PASSED (IN AUT O M ODE )
RUN FEE D BA CK OF ESP & BH FL UIDISING BL OW ER
SE LE CT ED VAC UUM PUM P RUNNING FEE D BAC K

3.3.1.7 ESP Hopper Fluidizing Valve :

Fluidizing air in hot condition is provided to ESP hoppers of 1st field to 4th field. In each
branch of ESP hoppers, first two (02) fields hopper are connected with one fluidizing valve
and 3rd & 4th fields hopper with another fluidizing valve. These valves will open sequentially
while cleaning of respective connected ESP hoppers with getting opening pulse of
respective branch header valve. The sequence of operation of these valves is given in this
document elsewhere.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 14 -
DCIPS Job No. 28P01

Associated Control Item Nomenclature 3.3.1.10 to 3.3.1.12

SL.NO. ITEM TAG
1 Ash Intake valve S**B*H*SO
2 Branch header valve S**B*VSO
3 Branch header valve open feed back S**B*VLO
4 ESP hopper fluidizing valve for 1st & 2nd fields (valve-1) S**B*FV1SO
5 ESP hopper fluidizing valve for 1st & 2nd fields (valve-1) S**B*FV1LO
open feed back
6 ESP hopper fluidizing valve for 3rd & 4th fields (valve-2) S**B*FV2SO
st nd
7 ESP hopper fluidizing valve for 1 & 2 fields (valve-2) S**B*FV1LO
open feed back
st rd th
Read 1 * for Unit no, namely 1 or 2 or 3 and read second * as stream A/B/C/D, 3 * as branch 1 - 4 & 4 * as hopper
of ESP field identification namely 1 to 10.

3.3.1.8 Buffer Hopper Fluidizing Air Valve:

There are eight (08) Nos. buffer hoppers below the bag filters. Ash from bag filter gets
collected in these hoppers. To bring fluidizing effect in buffer hoppers, fluidizing air valve
shall open with the opening of top gate of working nuva feeder (ash transmitter) for a
particular stream.
Associated Control Item Nomenclature:
SL No ITEM TAG
1 Buffer hopper fluidizing valve open BH*FVSO
2 Buffer hopper fluidizing valve open feed back BH*FVLO
3 Bag filter differential pressure switch BF***DPT
4 Bag filter pulse jet valve open BF***PJONC
5 Bag filter pulse jet valve close BF***PJCON
6 Level transmitter BH***LT
( For Buffer Hopper High & Low )
rd
Read 1st * for Unit no, namely 1 or 2 or 3 , 2nd * as stream A/B/C/D, 3 * as Bag Filter group 1 / 2 of Stream A/B/C/D .
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 15 -
DCIPS Job No. 28P01

3.3.1.9 Pressure Conveying Stream Valves:

There are 04 (four ) nos. solenoid operated pneumatic plug valves ( CLV1U*, CLV2U*,
CLV3U*, CLV4U*, Read * for unit 1 / 2 / 3) are provided at the upstream of ash Nuva
feeder / ash transmitters ( down stream of Transport air compressors) on X , Y & Z
conveying lines of each unit.
Pressure Conveying line – X is connected with Pair of Nuva Feeders (Ash transmitters) of
buffer hoppers A & B , pressure conveying line – Y is connected with Pair of Nuva
Feeders ( Ash transmitters ) of buffer hoppers C & D. Similarly, pressure conveying line -
Z is connected with Pair of Nuva Feeders ( Ash transmitters ) of buffer hoppers A & B and
C & D.
There are pneumatic operated knife gate valves ( CL*XFASVSO, CL*YFASVSO &
CL*ZFASVSO, Read * for unit 1 / 2 / 3) are provided at the down stream of ash
transmitters on pressure conveying lines X , Y & Z towards fly ash silos . Also seven nos.
pneumatic operated knife gate valves( silo transfer line valve ) (TL*XFAS*VSO,
TL*YFAS*VSO, TL*ZFAS*VSO, TL*YFAS*VSO, TL*ZFAS*VSO, TL*YFAS*VSO,
TL*ZFAS*VSO, Read 1st * for unit 1 / 2 / 3 and 2nd * for silo no.) are provided as inter
connection valves between silos nos. S-1, to S-5 respectively.
These knife gate valves are suitable opened / closed along with selection for individual silo.

3.3.1.10 Silo Discharge Valves:

There are five nos. silo, viz. SILO#1 (S-1) , SILO#2 (S-2) , SILO#3 (S-3) , SILO#4 (S-4) ,
SILO#5 (S-5) for FA Silos. .
For alternatively Ash Disposal in HCSD mode, there are five (5) nos. HCSD Silos viz
Silo#1, Silo#2, Silo#3, Silo#4 & Silo#5. Dry fly ash from transfer lines “X” , “Y” & “Z” will be
discharge to either FA Silo or HCSD Silo, silo-1 to S-5, respectively and connected silo
discharge valves will open with opening of same silo transfer line valves either for FA Silos
or HCSD Silos. However, transfer line “Y” & “Z” can discharge dry fly ash to silo – 4 & 5
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 16 -
DCIPS Job No. 28P01

Associated control item nomenclature (3.3.1.14 to 3.3.1.15):

SL NO ITEM TAG NO
1 Conveying Line valve open (to X- line) CL*XVSO
2 Conveying Line valve open feed back CL*XVLO
3 Conveying Line valve close feed back CL*XVLC
4 Conveying Line valve open ( to Y- line) CL*YVSO
5 Conveying Line valve open feed back CL*YVLO
6 Conveying Line valve close feed back CL*YVLC
7 Conveying Line valve open (to Z- line) CL*XZVSO
8 Conveying Line valve open feed back CL*XZVLO
9 Conveying Line valve close feed back CL*XZVLC
10 Conveying Line valve open (to Z- line) CL*YZVSO
11 Conveying Line valve open feed back CL*YZVLO
12 Conveying Line valve close feed back CL*YZVLC
13 Pressure conveying line valve open (X line-silo) CL*XFASVSO
14 Pressure conveying line valve open feed back(X line-silo) CL*XFASVLO
15 Pressure conveying stream valve close feed back (X line-silo) CL*XFASVLC
16 Pressure conveying line valve open (Y line-silo) CL*YFASVSO
17 Pressure conveying line valve open feed back(Y line-silo) CL*YFASVLO
18 Pressure conveying stream valve close feed back (Y line-silo) CL*YFASVLC
19 Pressure conveying line valve open (Z line-silo) CL*ZFASVSO
20 Pressure conveying line valve open feed back(Z line-silo) CL*ZFASVLO
21 Pressure conveying stream valve close feed back (Z line-silo) CL*ZFASVLC
22 Silo transfer line valve open (X line-silo-1) TL*XFAS*VSO
23 Silo transfer line valve open feed back(X line-silo-1) TL*XFAS*VLO
24 Silo transfer line valve close feed back (X line-silo-1) CL*XFAS*VLC
25 Silo transfer line valve open (Y line-silo-1) TL*YFAS*VSO
26 Silo transfer line valve open feed back(Y line-silo-1) TL*YFAS*VLO
27 Silo transfer line valve close feed back (Y line-silo-1) CL*YFAS*VLC
28 Silo transfer line valve open (Z line-silo-1) TL*ZFAS*VSO
29 Silo transfer line valve open feed back(Z line-silo-1) TL*ZFAS*VLO
30 Silo transfer line valve close feed back (Z line-silo-1) CL*ZFAS*VLC
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 17 -
DCIPS Job No. 28P01

31 Silo transfer line valve open (Y line-silo-4) TL*YFAS*VSO

32 Silo transfer line valve open feed back(Y line-silo-4) TL*YFAS*VLO
33 Silo transfer line valve close feed back (Y line-silo-4) CL*YFAS*VLC
34 Silo transfer line valve open (Z line-silo-4) TL*ZFAS*VSO
35 Silo transfer line valve open feed back(Z line-silo-4) TL*ZFAS*VLO
36 Silo transfer line valve close feed back (Z line-silo-4) CL*ZFAS*VLC
37 Silo transfer line valve open (Y line-silo-5) TL*YFAS*VSO
38 Silo transfer line valve open feed back(Y line-silo-5) TL*YFAS*VLO
39 Silo transfer line valve close feed back (Y line-silo-5) CL*YFAS*VLC
40 Silo transfer line valve open (Z line-silo-5) TL*ZFAS*VSO
41 Silo transfer line valve open feed back(Z line-silo-5) TL*ZFAS*VLO
42 Silo transfer line valve close feed back (Z line-silo-5) CL*ZFAS*VLC
43 Level transmitter at Silo -1 FAS1ALT
44 Level transmitter at Silo –2 FAS2ALT
45 Level transmitter at Silo –3 FAS3ALT
46 Level transmitter at Silo –4 FAS4ALT
47 Level transmitter at Silo -5 FAS5ALT
48 Silo vent filter pulse jet valve open FAS*VFPJON
( Read * for silo no.)
49 Silo vent filter pulse jet valve close FAS*VFPJONC
( Read * for silo no.)
50 Silo vent filter differential pressure switch FAS*DPT
( Read * for silo no.)
nd
Read * for Unit no. and 2 * for silo no.
Similar Philosophy shall be applicable for HCSD System associated control item
nomenclature.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 18 -
DCIPS Job No. 28P01

3.3.2 VARIOUS DRIVES / EQUIPMENTS / SUB-SYSTEM / LINES OF FA SYSTEM

3.3.2.1 ESP & BH FLUIDISING BLOWER:

Selection & Actuation
ACTUATION : START / STOP pushbutton for each blower : at Purchaser’s HMI
EMERGENCY STOP : One STOP push button (One no for each motor) : on Local PB
station (by purchaser)

Operation :
Prior to start ESP de-ashing, fluidizing blower along with its associated heater is to be
taken in service. Fluidizing air blower with associated heater will cater hot air to ESP as
well as Buffer hopper to create fluidizing effect inside hoppers. Out of two blowers, one will
be working for each unit..

With actuation of blower start command (after putting cleaning selection in manual mode)
the fluidizing valve 1 or 2 (timer based sequence) of selected branch will open. Fluidizing
blower will operate continuously during ash cleaning from ESP hoppers, If there is any
trouble in blower under running condition, the other one should be taken in service
manually.
There is one no. differential pressure switch provided across the blower suction filter. If
differential pressure across filter is above the permissible limit, the blower will trip with
annunciation in HMI. Blower can again re-started after attending fault.

3.3.2.2 ESP & BH FLUIDISING BLOWER HEATER:

Selection & Actuation :
ACTUATION : START / STOP pushbutton for each blower : at Purchaser’s HMI
EMERGENCY STOP : One STOP push button (One no for each motor) : on Local PB
station (by purchaser)
Operation:
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 19 -
DCIPS Job No. 28P01

After blower is taken into service, its corresponding heater can be put into service. There is
one no. temperature element (for TEHI & TEHIHI temperatures) provided on common
header to keep fluidizing air temperature within pre-set normal band as well as to prevent
overheating of air beyond a pre-set “HIGH HIGH” by means of automatic cut-in / cut-out
control of heating elements.

START PERMISSIVES

RUN F/B OF CONNECTED FLUIDISING BLOWER

HEATER OUTLET TEMP IS LESS THAN TEHI SET POINT

OUTLET TEMPERATURE (T) F/B BELOE 'HIHI' SET POINT

TRIP CONDITIONS

OUTLET TEMPERATURE (T) F/B ABOVE 'HIHI' SET POINT

OUTLET TEMP (T) TSHI FOR SET POINT

STOP F/B OF CONNECTED FLUIDISING BLOWER

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 20 -
DCIPS Job No. 28P01

Operation of the heater :

 Actuation of “ON” push button from Purchaser’s HMI will start the selected heater after
fulfillment of starting permissives and remains on condition according to running
permissives.

Cut-in permissives:
 T  TEHI

Cut-out permissives:
 T  TEHIHI
 T  HI & Preset time delay
Where T= Heated air out let temperature
The heating elements of the heater bank will be energised when air temperature is lower
than or equal to TEHI with feedback from TEHI.

Again, it will automatically get de-energised when air temperature equals or exceeds TEHI
with the feedback from TEHI. Thus air temperature at heater outlet will be maintained
within a pre-set normal band.

 In case, heater does not de-energised even after attaining TEHI and continues in
energised condition, TEHIHI will operate and trip the heater followed by alarm “ heater
tripped” in Purchaser’s HMI.

 To reset from trip condition and to start heater, at first STOP push button is to be
pressed and thereafter START push button is to be actuated provided other
preconditions are true.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 21 -
DCIPS Job No. 28P01

Associated Control Item Nomenclature :

SL. NO. ITEM TAG
1 Temperature element of heater ESPB*DRTD
2 Header Pressure Transmitter ESPB*DPT
3 Differential pressure across suction filter ESPB**DPS
4 ESP hopper fluidising heater suction valve open feed back ESPFH*SVLO
5 ESP hopper fluidising heater discharge valve open feed back ESPFH*DVLO
Read first * as unit identification i.e. 1/2/3 and second * as blower no.

3.3.2.3 ESP FLUIDISING SYSTEM:

For effective de-ashing hot pressurized air from fluidizing blower is injected in ESP hoppers
through pneumatically operated valve.
In AUTO mode, fluidizing air pneumatic valve (valve-1) associated with 1st and 2nd field
hoppers of the selected branch will open automatically by default with the opening of
branch header valve of a particular stream.
Now sequence of operation of these valves will be as follows:

1. Valve-1 remains open till ash cleaning from 1st / 2nd field hopper.
2. Valve-2 opens with opening of 3rd / 4th field hopper, then valve-1 closes.
3. Valve-2 remains open till ash cleaning from 3rd / 4th field hopper.
4. Then, Valve-1 opens again followed by closing of Valve-2.
5. Valve-1 remains open till opening of branch header valve (TERSG).
6. With opening of next branch header valve, next branch Valve-1 opens & then Valve-1
of previous branch header closes with closing of same branch header valve.
7. Further operation shall be as per above sequence.

While de-ashing in ‘MANUAL’ mode, the fluidizing line pneumatic Valve-1 / 2 of a branch
will opens according to the selection of hopper. When cleaning of ash from 5th to 10th field
hopper in same header is in progress, Valve-1 remains open. While opening of next branch
header valve, Valve-1 opens & then Valve-1 of previous branch header closes with closing
of same branch header valve.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 22 -
DCIPS Job No. 28P01

The fluidizing air supply to ESP hoppers will remain activated even when fly ash cleaning
operation is not in progress. During this period, the fluidizing air supply valves-1 or 2 of all
the streams & branches will operate in a timer based sequence (timer based sequence will
activated with getting close signal of branch header valves of all the streams) to supply
fluidizing air to respective fields of ESP hoppers.
3.3.2.4 VACUUM PUMP:
There are four (04) pairs of vacuum pumps. Each pair is dedicatedly connected to
individual stream. Every pair is having two pumps, out of which one is working & another is
standby.
Selection & Actuation
SELECTOR : Working Pump selection – at Purchaser’s HMI
ACTUATION : START / STOP pushbutton for All the pumps : at Purchaser’s HMI
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

Operation:

At first operator will select the working pump through Purchaser’s HMI selection facility.
Along with the selection, the respective suction valve of the selected vacuum pump will be
opened and the suction valve of the other pump of the same pair will be closed.

After proper selection of vacuum conveying path for a stream, selected vacuum pump can
be started through respective START / STOP push button at Purchaser’s HMI.
On actuation of start button,
 The seal water valve of respective selected vacuum pump opens.
 Thereafter the seal water pressure will be established
 Subsequently the respective vacuum pump will be started if seal water pressure
becomes NORMAL as sensed by pressure switch within preset time and selected
“VACUUM CONVEYING PATH IS THROUGH”, then the respective vacuum pump will
be started.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 23 -
DCIPS Job No. 28P01

START PERM ISSIVES OF VACUUM PUM P

VACUUM PUM P SEAL W ATER PRESSURE IS NORM AL

VACUUM CONVEYING PATH THROUGH

TRIP CONDITIONS OF VACUUM PUM P

VACUUM PUM P SEAL W ATER PRESSURE IS ABNORM AL

VACUUM CONVEYING PATH IS NOT THROUGH

3.3.2.5 THROUGH CONDITION OF VACUUM CONVEYING PATH :

To start fly ash evacuation it is mandatory to satisfy through condition of vacuum conveying
path. Suction line of selected vacuum pump is either open to atmosphere through
respective vacuum breaker / vacuum relief valve or suction
line is sucking air from atmosphere through selected branch header, air intake valve.
While, interconnected valves associated with other paths and suction valve of the other
vacuum pump of the same pair are closed.

Following are the through condition of vacuum conveying path.

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 24 -
DCIPS Job No. 28P01

 Cleaning through a particular stream :

 Group selected from **-1/ **-2/Off selector (Read 1st * for unit no. and 2nd * for stream A
to D
 Bag filter discharge valve is open.
 Selected branch header valve is open.
 Selected Vacuum pump suction valve is open.
 Fluidizing blower is in running condition
In case the vacuum conveying path of selected stream is not through, an alarm indication
will appear at Purchaser’s HMI “VACUUM PATH NOT THROUGH”
3.3.2.6 BAG FILTER:
Fly Ash air mixture conveyed by each fly ash conveyor under vacuum system gets
separated in dry form in bag-filter, and gets stored temporarily in the buffer hopper directly
below the bag filter. There are eight (08) sets of bag filter and buffer hoppers of each unit.
Every stream of dry collection is associated with two such bag filter assembly. The pulse
jet cycle will START during de-ashing, command of the respective stream and bag filter
group from Purchaser’s HMI and the same shall also stop automatically (after a pre-set
time) with actuation of “SYSTEM STOP” or incase of de-selection command on
Purchaser’s HMI.
Differential Pressure Switch (DPS):
A differential pressure switch (BF**DPS ,Read 1st * for unit no. and 2nd * for stream A to D)
is provided across the dirty air & clean air plenums of each bag filter, which is set to
operate at about 300 mm water gauge differential. When differential pressure becomes
300 mm water gauge, an indication is provided in Purchaser’s HMI indicating bag filter
pressure differential “HIGH”. If the differential remains high for 60 seconds, the ash feed
circuit gets de-energised, and if it still remains high for another 60 seconds, the vacuum
relief valve opens for 120 seconds with an alarms, “Bag filter diff. pr. HIGH”. After this
period, vacuum relief valve closes and the differential is checked after 10 seconds. If the
same is below 300 mm water gauge, the ash feed circuit is energised.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 25 -
DCIPS Job No. 28P01

If the differential is still above 300 mm water gauge, the vacuum relief valve opens for
another 120 seconds. After this period, vacuum relief valve closes and the differential is
again checked after 10 seconds. If the same is below 300 mm water gauge, the ash
feeding resumes. If it is still above 300 mm water gauge, the system is shut down with
“FLY ASH VACUUM SYSTEM TRIPPED” annunciation.

3.3.2.7 ASH TRANSMITTER (NUVA FEEDER)

Dry fly ash collected in buffer hopper is pneumatically pressure conveyed to silo through
ash transmitters (nuva feeders). There are two (02) nos. of ash transmitters (Nuva
Feeders) connected in each bag filter / buffer hopper.
Dry ash is pressure conveyed to selected silo # 1 to 5. Ash transmitter pairs NF*A1X/A1Z
(Read 1st * for unit no.) of A streams are connected with ‘X’ conveying line and ‘Z’
conveying line, Ash transmitter pairs NF*B1X/B1Z (Read 1st * for unit no.) of B streams are
connected with ‘X’ conveying line and ‘Z’ conveying line, Ash transmitter pairs
NF*C1Y/C1Z (Read 1st * for unit no.) of C streams are connected with ‘Y’ conveying line
and ‘Z’ conveying line and. Ash transmitter pairs NF*D1Y/D1Z of D streams are connected
with ‘Y’ conveying line and ‘Z’ conveying line. Similarly, Ash transmitter pairs NF*A2X/A2Z
(Read 1st * for unit no.) of A streams are connected with ‘X’ conveying line and ‘Z’
conveying line, Ash transmitter pairs NF*B2X/B2Z (Read 1st * for unit no.) of B streams are
connected with ‘X’ conveying line and ‘Z’ conveying line, Ash transmitter pairs
NF*C2Y/C2Z (Read 1st * for unit no.) of C streams are connected with ‘Y’ conveying line
and ‘Z’ conveying line and Ash transmitter pairs NF*D2Y/D2Z of D streams are connected
with ‘Y’ conveying line and ‘Z’ conveying line. In each pair, one ash transmitter is in
working condition and other remains standby.

Operation sequence of ash transmitter valves & gates:

Ash transmitter sequence will start with actuation of ‘PRESSURE CONVEYING
SEQUENCE START’. Operation of Ash transmitter's pneumatically operated valves and
gates will be as per following sequence.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 26 -
DCIPS Job No. 28P01

Vent Valve:
 Vent valve (NF****VVSO; use 1st * for unit no 1/2/3 , 2nd * for streams A to D ; 3rd for NF
group 1/2 ; 4th * for conveying line X,Y & Z) opens for venting of air from ash
transmitter, and pressure equalizing between Buffer hopper top zone & ash transmitter
for a preset time duration (VENTING).
Top Gate:
 After a preset time gap, top gate (NF****TGSO; use 1st * for unit no 1/2/3 , 2nd * for
streams A to D ; 3rd for NF group 1/2 ; 4th * for conveying line X,Y & Z) opens for a
preset duration (irrespective of ash level in transmitter vessel under timer-mode, or
subject to ash level in transmitter vessel below “HIGH” under probe-mode) to allow ash
feeding from the Buffer hopper into the transmitter vessel (FILLING).

 Top gate closes followed by closing of vent valve (Fluidizing air supply for bottom gate
and transmitter vessel automatically turns on).
Equalizing Valve:
 After closing of vent valve, equalizing valve (NF****EVSO; use 1st * for unit no 1/2/3 ,
2nd * for streams A to D ; 3rd for NF group 1/2 ; 4th * for conveying line X,Y & Z) opens
for a preset duration to equalize pressure between ash transmitter vessel and ash
conveying line (EQUALIZING).
Bottom Gate:
 After a preset time gap, bottom gate (NF****BGSO ; use 1st * for unit no 1/2/3 , 2nd * for
streams A to D ; 3rd for NF group 1/2 ; 4th * for conveying line X,Y & Z); opens for a
preset time duration (if conveying line pressure rises above pre-set value, bottom gate
if open will close immediately and remains close until line pressure falls below the pre-
set value) to allow discharge of ash from transmitter vessel into ash conveying line
(UNLOADING).
 Bottom gate closes followed by closing of equalizing valve.

Fluidizing Valve:
 The fluidizing valves of transmitter vessel and bottom gate will open with closing of vent
valve and remains open during closing duration of vent valve.

The above sequential events together make one complete operating cycle of ash
transmitter. The duration of each cycle is two (2) minutes (approx.).
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 27 -
DCIPS Job No. 28P01

Mode of Operation for Ash transmitter:

Ash transmitter’s Top gate can be operated in Probe or Timer mode. There shall be
PROBE / TIMER selector in purchaser’s HMI for each pair of Ash transmitters.

TOP G ATE CLO SIN G LO GIC OF N UV A FEEDER

1. TIM ER M O DE

TIM ER M OD E SELECTED

EN D O F PRESET OPENN IN G TIM E O F TO P GATE

2. PROBE M OD E

PROB E M OD E SELECTED

N UV A FEEDER HIGH LEVEL FEED BA CK

W ITHIN PRESET OPENING TIM E CY CLE

END OF PRESET O PEN NING TIM E OF TOP GA TE

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CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 28 -
DCIPS Job No. 28P01

Permissive:
The following start permissive will be effective for cyclic operation of Ash transmitter.

 Silo ash level is below “HIGH”

 Respective silo vent fan running and Silo vent filter pulse jet cleaning sequence is “ON”
 The Transport Air compressor is in operation and conveying air header pressure is
“NORMAL”
 Pressure conveying line path is through (Selected conveying line valves, silo selection
valves, TAC discharge & interconnection valves & transfer line selection valves are in
open / close condition. Pulse jetting are on and vent fan running for selected silo)
 Pressure conveying line relief valve is close.

The failure of attaining any of the above permissive during system operation will stop the
ash transmitter cycle and thereby the conveying operation, followed by “FLY ASH
PRESSURE SYSTEM TRIPPED” annunciation.
Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 Ash transmitter top gate open NF****TGSO
2 Ash transmitter bottom gate open NF****BGSO
3 Ash transmitter vent valve open NF****VVSO;
4 Ash transmitter equalising valve open NF****EVSO
5 Ash transmitter high level switch NF***LSH
6 Ash transmitter fluidising valve open NF***FVSO
st nd
use 1 * for unit no 1/2/3 , 2 * for streams A to D ; 3 for NF group 1/2 ; 4th * for
rd

conveying line X,Y & Z

3.3.2.8 TRANSPORT AIR COMPRESSOR (TAC):
There are three (03) nos. screw type Transport air compressors viz. TAC** (1st * for unit no.
1/2/3 ; 2nd * for compressor X or Y or Z). Discharge from TAC X , Y & Z are connected
with three (03) nos. conveying streams X , Y. & Z . Transport air compressor Z shall be
kept as standby compressor for each conveying stream.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 29 -
DCIPS Job No. 28P01

This screw type Transport air compressor unit will have their Integral Micro Processor
Controller to process the permissive & interlock logics of the machine on stand alone basis
involving the instruments & actuators integrally mounted with the compressors. The
strategic actuation & monitoring signal exchange with main ash handling DCS will be
through potential free contacts (PFC) facilitating operation & strategic monitoring of these
compressors from purchaser’s HMI screen.

Selector & Actuator:

ACTUATOR: START / STOP for individual compressor.

Emergency STOP push button mounted integral with each compressor

Starting Permissive:
 Open feed back of conveying line relief valve.
 Open feedback of TAC discharge valve.
 Pressure conveying path through (proper opening of conveying line valves)
 And as per manufacturer’s recommendation.
Trip Conditions :
 Close feed back of TAC discharge valve or
 Pressure conveying path is not through (proper opening of conveying line valves) or
 Other, as per manufacturer’s recommendation.
Operation :
Compressors can be started from respective “START” / “STOP” push buttons located in
purchaser’s HMI on fulfillment of starting permissive.
With START command of TAC the solenoid operated cooling water valve on cooling water
inlet line will automatically open for the selected compressor. For safe starting / stopping of
compressor, two (02) no. timer based butterfly valve (relief valve) placed on common
header of compressor discharge line (as applicable for the selected compressor) will open
with start / stop command and remains open for preset time. With open feed back of
butterfly valve, the compressor shall take start / stop.
With this, if all other starting permissive are through as per manufacturer’s control write up.
The TAC will get started and continue to run if no trip condition fulfilled.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 30 -
DCIPS Job No. 28P01

During running of TAC,

1. In case, the line pressure reaches higher safety set point value, the relief valves will
open and remains open till the line pressure reaches lower safety point of the
differential band within the pre-set time duration. If the line pressure does not reach
lower safety point value within the pre-set time duration. The relief valve shall close
irrespective of pressure value being above low set point & shall remains closed for
preset time duration. If the line pressure remains above low set point and reaches the
high set point, it will again open for preset duration. This cycle will repeat once again
and if the line pressure does not reaches low set point thereafter relief valves remains
open position with alarm on HMI “conveying line overload and relief valves open”. Now,
operator’s intervene is required for further action.

On having successful starting of Transport air compressor, normal Transport air pressure
will establish & “PURGING ON” indication will turn on. This (initial) line purge continues for
a pre-set (adjustable) duration and indication will turn off.
Thereafter, Ash transmitter pair will be started with actuation of “PRESSURE CONVEYING
SEQUENCE START”.

Tag No of Associated Control Equipment:

SL NO DESCRIPTION TAG NO
1. Transport air compressor TAC**
2. Transport air compressor X manual discharge valve open feed back TAC*XDVLO
3. Transport air compressor X manual discharge valve close feed back TAC*XDVLC
4. Transport air compressor Y manual discharge valve open feed back TAC*YDVLO
5. Transport air compressor Y manual discharge valve close feed back TAC*YDVLC
6. Transport air compressor Z manual discharge valve open feed back TAC*ZDVLO
7. Transport air compressor Z manual discharge valve close feed back TAC*ZDVLC
8. Transport air compressor X-Y manual discharge valve open feed back TAC*XYDVLO
9. Transport air compressor X-Y manual discharge valve close feed TAC*XYDVLC
back
10. Transport air compressor Y-Z manual discharge valve open feed back TAC*YZDVLO
11. Transport air compressor Y-Z manual discharge valve close feed TAC*YZDVLC
back
12. TAC discharge line relief valve X close CL*XPRVSC
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 31 -
DCIPS Job No. 28P01

13. TAC discharge line relief valve X close feed back CL*XPRVLC

14. TAC discharge line relief valve Y close CL*YPRVSC

15. TAC discharge line relief valve Y close feed back CL*YPRVLC
st nd
Read 1 * for unit no. 1/2/3 ; 2 * for compressor X or Y or Z

4.0.0 SYSTEM OPERATION SEQUENCE:

All ESP hoppers have been grouped in four (04) streams viz. Stream A to D and Bag filter
group 1 & 2. Fly ash cleaning process of any stream for those hoppers can be done in bag
filter group 1 or 2 depending on selection from purchaser’s HMI. Before starting the
evacuation in any group following are the pre-requisite :

Common for any of evacuation:

 ESP & Buffer hopper fluidising blower & heater running (In manual selection mode)
 Instrument air pressure healthy at FAE tower area.
 Fly ash pressure system is ready for operation .
 Vacuum pump is ready to start.
 Transport air compressor is ready to start .
 Silo vent fan and filter in operation .

4.1.0 FLY ASH VACUUM SYSTEM:

Fly ash from ESP, Primary & Secondary Air Heater hoppers can be cleaned either auto or
manual operation as per requirement.

4.1.1 SELECTION OF FLY ASH VACUUM SYSTEM :

 Select AUTO mode through AUTO / MANUAL selection facility in purchaser’s HMI.
 Select Branch evacuation sequences in purchaser’s HMI.
 Select Bag filter group BF-1/BF-2/Off selection facility from purchaser’s HMI.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 32 -
DCIPS Job No. 28P01

When BF-1 or BF-2 has been selected.

 Isolating valve in respective bag filter path will open.
 Isolating valve in BF –1 / BF-2 path closes.

4.1.1a  Select working vacuum pump for the respective stream through purchaser’s HMI
selection facility.
 Vacuum pump suction valve of selected group will open .
 Start the selected vacuum pump.
System Start: :
Once vacuum pump is running smoothly.
Actuation of ‘SYSTEM START’ in purchaser’s HMI following operation will take place.
 Selected branch header valve of respective stream will open, if in auto mode.
 Thereafter respective Relief Valve will close.
 Once vacuum pump is running & respective vacuum relief valve is closed, while path
selection is proper, line vacuum will start rising to match header vacuum in between
Vs1 & Vs2. This may be noted here that for normal evacuation from ESP, Primary &
Secondary Air Heater hoppers, vacuum shall be maintained between VS2 & VS3
setting suiting site conditions.
 Fluidizing header air valve will operate in a manner explained in respective section.
 Bag filter “Pulse jetting” will be started with pulse jet ‘ON’ indication in purchaser’s HMI.
 Differential pressure across the bag filter bags should be less than the set value for
normal operation.
 Level of dust sensed by dust sensor in vacuum conveying line (suction line of vacuum
pump) should be within set value.`
 Vacuum conveying ‘SYSTEM ON’ indication will appear on purchaser’s HMI.

4.1.1b Sequence start:

Once the system is running smoothly & vacuum level is more than Vs1 of selected branch,
therefore with actuation of ‘SEQUENCE START’ in purchaser’s HMI following action will
take place. Please read Vacuum relief valve instead of Vacuum breaker.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 33 -
DCIPS Job No. 28P01

 Ash intake valve of first field of the selected branch will open subject to fulfillment of
conditions. “ SEQUENCE ON “ indication will appear on purchaser’s HMI.
 With evacuation of ash through ash intake valve, system vacuum will gradually rise as
sensed by vacuum transmitter and ash intake will close with attaining vacuum Vs3 set
point. Ash intake valve will open again when vacuum reaches below Vs3 level.
 Conveying from hopper will continue untill line vacuum falls below the preset value
(Vs1) sensed by vacuum transmitter and persists for a preset time (adjustable)
 The above condition implies ‘ HOPPER EMPTY’ status on purchaser’s HMI and the
respective ash intake valve will close. Ash intake valve for the next hopper of the
selected branch will open thereafter, and thus sequence continues.
 After the fly ash hoppers connected with specific branch are cleaned in above
sequence, the next branch header valve as per pre-selection in purchaser’s HMI will
open first and then action branch header valve will close. Ash from the hoppers of next
branch header will be cleaned in similar sequence and transfer sequence of ash intake
valve opening will be controlled automatically by the vacuum level as sensed by
vacuum transmitter.
 Opening / closing of fluidising air valve of branch header shall be as per sequence
mentioned in this document elsewhere.
 If required, at any point of time of ash evacuation though a particular hopper, the ash
intake valve of the next hopper can be opened with closing of ash intake valve of the
previous hopper by actuation of ‘ JOG’ PB ( in auto mode) from purchaser’s HMI .
Action of jog PB will override the control of vacuum level feed back the particular
hopper.
 With the action of system STOP purging of vacuum line starts for a pre- set time then
vacuum breaker will open and branch header valve will close to conclude that fly ash
vacuum system operation over.
 With the actuation of system STOP command, purging of vacuum line and pulse jetting
of bag filter remains on for a pre-set time, then vacuum breaker will open and branch
header valve will close to conclude that fly ash vacuum system operation over.
 Vacuum pump is to be stopped manually.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 34 -
DCIPS Job No. 28P01

4.1.2 If necessary the fly ash system operation for each stream can be stopped / suspended at
any moment of “AUTO” sequential operation by actuation of corresponding “SEQUENCE
STOP” command in purchaser’s HMI. When this command is given, the cycle will stop at
its present position, the opened branch header valve will remain open but the operating ash
intake valve will be closed. Again with the “SEQUENCE START” command from
purchaser’s HMI, the fly ash evacuation will be started from the same hopper. However
“SYSTEM STOP” command will reset the cycle to its home position.

4.1.3 MANUAL MODE OF CLEANING OF A STREAM:

Under manual mode, the fly ash cleaning can be carried out independently from any one or
selective hopper stream. The selection of the particular hopper of branch for a stream can
be made by means of corresponding “BRANCH” selection and “HOPPER” selection
respectively through purchaser’s HMI. Other pre-requisites & steps are identical to that of
auto sequence operation as mentioned earlier.

After proper selection of BRANCH, selected branch header valve opens. Thereafter,
following actions shall be taken to carry out ash cleaning from the selected hopper.
 Select either BF-1 / BF-2 Bag filter group.
By actuating corresponding “SYSTEM START with the fulfillment of required permissive
following action will take place.

 Vacuum breaker / relief valve as the case may be will close

 Fluidizing air valve will operate as per sequence mentioned earlier & pulse jet system
for bag filter will start .
 Select vacuum pump and start the selected pump as mentioned earlier.
 With actuation of SEQUENCE START command, ash intake valve for the selected
hopper with the fulfillment of required permissive will open.

 After getting hopper empty indication, the next hopper will be selected manually through
‘Hopper’ and ‘Branch’ selection from purchaser’s HMI as mentioned above.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 35 -
DCIPS Job No. 28P01

4.1.4 PHENOMENA PERTAINING DURING ASH EVACUATION:

Plugged Hopper
During normal ash cleaning process, the conveying line vacuum will remain within the
preset (adjustable) band (Vs1, Vs2, Vs3 wherein Vs3>Vs2>Vs1) of vacuum sensing device
i.e. vacuum transmitter. In case line vacuum is >Vs1 but < Vs2 and remains there for a pre-
set duration (adjustable), will imply “HOPPER PLUGGED” status. For manual attendance
or bypassing the plugged hopper “JOG” push-button (for auto-sequential cleaning) is to be
actuated. This actuation will automatically select the next hopper in sequence. Monitoring
of the said condition will be effective for auto-sequential cleaning as well as for manual
cleaning.
Load Control:

During fly ash cleaning operation, in auto or in manual mode if the conveying line vacuum
rises above the preset value Vs3, operating ash intake valve will close instantaneously to
stop further feed of ash into the line, and remain closed until the line vacuum falls below
aforementioned preset value. This will provide “Load Control” of the ash conveyor.
However, if the line vacuum persists above Vs3 for duration (around 3 minutes, adjustable),
vacuum conveyor “OVERLOADED” status will be annunciated in purchaser’s HMI. The
above “Load control” will be effective irrespective of auto or manual cleaning.

4.2.0 FLY ASH PRESSURE CONVEYING SEQUENCE FOR FA SILO / HCSD SILO:
Dry ash collected in buffer hopper is conveyed through Ash transmitter to dry ash silo by
means of a pneumatic fly ash pressure conveying system. The pressure conveying system
can be operated simultaneously with dry extraction of vacuum system. Transport air
compressors (TAC) provides pressurized air for such conveying.
Fly ash collected in silo is ultimately disposed through trucks / tankers for end use. To start
fly ash pressure conveying system, following are the steps to be followed.

 Buffer hopper fluidizing air valve is opens with opening of working ash transmitter top
gate of respecting vacuum stream.
 Select the pressure conveying stream.
 Select the working ash transmitter from individual selector.
 Select the transfer line with the help of valve selector & silo (if required).
 Start the silo vent fan of selected silo.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 36 -
DCIPS Job No. 28P01

If the selection is improper then annunciation on purchaser’s HMI “TRANSPORT PATH

IMPROPER”.
 SYSTEM START command from purchaser’s HMI, pulse jetting of vent filter will start.
 START Selected Transport air compressors from purchaser’s HMI.
With proper selection & operation ‘PRESSURE TRANSPORT ON’ indication will be
available on purchaser’s HMI.
 If Transport line pressure found normal with respect to pre-set value on pressure
transmitter; actuate “PRESSURE TRANSPORT SEQUENCE ON “ in HMI. This will start
selected ash transmitters cycle leading to ash transport from ash transmitter to silo.
 With the silo level high feedback ash transmitter top gate will close immediately and
‘SILO LEVEL HIGH ‘ will be annunciated. With this condition selection of alternative
silo may be explored after stopping the system.
 The ash transmitter will keep on operating on pre-set time cycle sequence until the ash
transmitter of pressure Transport system becomes empty sensed by pressure
transmitter of the respective Transport line subject to the condition that corresponding
fly ash vacuum conveying system is stopped. If this condition persists for a
predetermined time (around 10 minutes adjustable) (NO LOAD CONDITION) then the
following action will be performed.
 The top gates for all the ash transmitters get closed
 The bottom gates will operate in normal sequence for one complete cycle.
There after ash transmitter cycle will stop in totality, turning off the
"“PRESSURE TRANSPORT SEQUENCE ON” indication.
 After a further preset time duration allowed for “FINAL LINE PURGE”
pressure Transport “SEQUENCE OVER” status will be annunciated.
 There after the operating compressor will be stopped manually from purchaser’s HMI.
 The fly ash pressure Transport can be stopped / suspended, if necessary, at any
moment of system operation through’ actuation of corresponding “PRESSURE
CONVEYOR SEQUENCE STOP “ command in purchaser’s HMI. With actuation of this
command, the top gates along with the vent valves for the operating Ash transmitters
will close instantaneously. The operation of the corresponding transmitters, however,
will continue for one complete cycle only opening the bottom gates. However Transport
cycle can again be started through actuation of ‘SEQUENCE START’ from purchaser’s
HMI.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 37 -
DCIPS Job No. 28P01

LOAD CONTROL
During fly ash pressure Transport, if the Transport line pressure rises above the pre-set
value sensed by the respective pressure transmitter of Transport line, the bottom gates of
all the ash transmitters on the operating ash Transport line (if open) will close immediately,
and remain closed until the line pressure falls below the full load set value, thus providing
“LOAD CONTROL” during fly ash pressure Transport.

If the Transport line pressure remains above the “FULL LOAD” set value for a pre-set
duration (adjustable), fly ash pressure Transport “OVERLOADED” status will be
annunciated on purchaser’s HMI.
If the differential pressure across the vent filter bags is more than the set value, and
remains for pre set period, then annunciation will be appeared like “VENT FILTER
DIFFERENTIAL PRESSURE HIGH”.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 38 -
DCIPS Job No. 28P01

5.0.0 OPERATION SEQUENCE FLOW DIAGRAM

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 39 -
DCIPS Job No. 28P01
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 40 -
DCIPS Job No. 28P01

6.0.0 TABULAR CHART : INTERLOCKS, ACTUATORS, INDICATIONS, ALARMS

SL. EQUIPMENT CONTROL ROOM REMARKS

NO. IDENTIFICATION PURCHASER’S PURCHASER’S ALARM
HMI SCREEN HMI SCREEN
ALARM LOG
ACTUATOR ACTUATOR
1 ESP & BH START ON ESP & BH FLIDISING
FLUIDISING STOP OFF BLOWER TRIPPED
BLOWER TRIP (INDIVIDUAL)

FLUIDISING HEADER SUCTION FILTER

INTERLOCK / DE-
PRESSURE NORMAL DIFFERENTIAL
INTERLOCK MODE
SELECTION PRESSURE ABNORMAL
SUCTION FILTER
DIFFERENTIAL FLUIDISING HEADER
PRESSURE NORMAL PRESSURE ABNORMAL

2 ESP & BH START ON HEATER HIHI

FLUIDISING HEATER STOP OFF TEMPERATURE TRIP
FLUIDISING HEATER FLUIDISING HEATER
TEMPARATURE HI TEMPARATURE HI

FLUIDISING HEATER FLUIDISING HEATER

TEMP. HIHI TEMP. HIHI
SUCTION VALVE
OPEN
DISCHARGE VALVE
OPEN
3 VACUUM PUMP START ON VACUUM PUMP TRIPPED
STOP OFF (INDIVIDUAL)
WORKING PUMP SEAL WATER VALVE
SELECTION OPEN / CLOSE
FACILITY FOR
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 41 -
DCIPS Job No. 28P01

EACH STREAM VACUUM PUMP SEAL

INTERLOCK / DE- PRESSURE FAULT
INTERLOCK MODE
SELECTION SEAL WATER VACCUM PATH NOT
PRESSURE NORMAL THROUGH (INDIVIDUAL)
SUCTION VALVE
OPEN / CLOSE
VACUUM LEVEL OF
TRANSMITTER
4 TRANSPORT AIR START ON / OFF /TRIP TRANSPORT AIR
COMPRESSOR STOP STATUS FOR COMPRESSOR TRIPPED
(FOR INDIVIDUAL INDIVIDUAL COMP. (INDIVIDUAL)
COMP.) DISCHARGE VALVE
OPEN / CLOSE

INTERCONNECTION
DISCHARGE VALVE
OPEN / CLOSE
7 VACCUM BREAKER VACUUM BREAKER VACUUM BREAKER
OPEN / CLOSE OPEN

8 VACCUM RELIEF VACCUM RELIEF VACCUM RELIEF VALVE

VALVE VALVE CLOSE OPEN
9 FLY ASH VACUUM BF-1/ BF-2/ OFF INTERCONNECTION FLY ASH VACUUM
SYSTEM SELECTION VALVE OPEN / CONVEYING AUTO
FACILITY CLOSE SEQUENCE OVER

AUTO / MANUAL VACUUM CONVEYOR

SELECTION OVERLOAD
FACILITY

SYSTEM START BH FLUIDISING HOPPER PLUGGED

VALVES OPEN /
CLOSE
BH LEVEL STATUS HOPPER EMPTY
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 42 -
DCIPS Job No. 28P01

SYSTEM STOP BAG FILTER PULSE FLY ASH VACUUM

JET ON SYSTEM TRIPPED
SEQUENCE (INDIVIDUAL)
START SYSTEM ON

SEQUENCE STOP
BRANCH BAG FILTER BAG FILTER
SELECTION DIFFERENTIAL DIFFERENTAL
(FOR MANUAL PRESSURE STATUS PRESSURE HIGH
MODE) (INDIVIDUAL)

HOPPER BRANCH HEADER BH LEVEL HIGH

SELECTION VALVE OPEN STATUS
(FOR MANUAL (INDIVIDUAL)
MODE)
JOG PB SELECTED ASH BAG FILTER PULSE JET
INTAKE VALVE OPEN FAILURE (INDIVIDUAL)
STATUS
SELECTED HOPPER IN
AUTO

ESP FLUIDISING
VALVE OPEN STATUS
SEQUENCE ON
SEQUENCE OVER
HOPPER EMPTY
VACUUM CONVEYOR
OVERLOAD
PLUGGED HOPPER

10 FLY ASH PRESSURE PRESSURE PRESSURE FLY ASH PRESSURE

TRANSPORT TRANSPORT TRANSPORT ON SYSTEM OVERLOADED
SYSTEM (FOR FA SYSTEM START (INDIVIDUAL)
SILO / HCSD SILO) PRESSURE TRANSPORT LINE, FLY ASH TRANSPORT
TRANSPORT AND SILO SELECTION SYSTEM TRIPPED
SYSTEM STOP (INDIVIDUAL)

SILO VENT FAN VENT FAN ON / OFF / VENT FAN TRIP

START / STOP TRIP (INDIVIDUAL)
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 43 -
DCIPS Job No. 28P01

PRESSURE FLY ASH TRANSPORT

TRANSPORT SYSTEM AUTO
SEQUENCE ON SEQUENCE OVER
(INDIVIDUAL)
ASH ASH TRANSMITTER SILO LEVEL HIGH
TRANSMITTER PNEUMATIC GATES /
OPERATING PAIR VALVES STATUS
SELECTION
(INDIVIDUAL)
SILO VENT FILTER ASH TRANSMITTER
PULSE JET ON / LEVEL HIGH
OFF
PRESSURE TRANSPORT LINE
TRANSPORT INITIAL PURGE ON SILO VENT FILTER
SEQUENCE DIFFERENTIAL

START PRESSURE HIGH

(INDIVIDUAL)
PRESSURE TRANSPORT LINE
TRANSPORT FINAL PURGE ON
SEQUENCE STOP

CONVEYING LINE SILO PULSE JET ON / PRESSURE

SELECTION OFF STATUS CONVEYING LINE
X / Z/ OFF & Y / Z SILO HIGH / LOW RELIEF VALVE OPEN
OFF LEVEL (INDIVIDUAL)
CONVEYING LINE
SILO –1 / SILO –2 OVERLOAD & RELIEF
/ SILO –3 / SILO – VALVE OPEN
4 / SILO –5 / OFF
ASH PRESSURE
TRANSMITTER CONVEYING PATH IS
PROBE / TIMER NOT THROUGH
MODE
SELECTON

NOTE:
1. COLOUR OF INDICATION FOR PURCHASER’S HMI.
RED / STEADY (S) : OPEN / ON / PR, LVL, TEMPARATURE, PROCESS NORMAL
RED / FLICKERING (F) : PR, LVL, TEMP, PROCESS ABNORMAL, DRIVE TRIP
GREEN / STEADY (S) : OFF / CLOSE
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART -B: FLY ASH EVACUATION SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-01
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030A
Stage – 1, Units # 1, # 2. # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 44 -
DCIPS Job No. 28P01

BLUE :DRIVE MOTOR SELECTED FOR DE-INTERLOCKED TRIAL OPERATION

2. DE-INTERLOCKED TRIAL OPERATION OF DRIVE MOTORS WILL BE SELECTED FROM A PASSWORD PROTECTED
PAGE OF HMI. IN THIS MODE ELECTRICAL PROTECTION OF MOTORS WILL BE IN OPERATIVE MODE. HOWEVER,
PROCESS INTERLOCK OF THE PARTICULAR DRIVE WILL BE BY-PASSED
3. HMI SCREENS HAVING POP-UP FOR ALL DRIVES SHOWING STARTING PERMISSIVES & EMERGENCY PUSH
BUTTON (EPB) STATUS.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -1-
DCIPS Job No. 28P01
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -2-
DCIPS Job No. 28P01

INDEX

SL. NO. DESCRIPTION PAGE NO.

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL 5
PHILOSOPHY
2.0.0 CONTROL DEVICES & LOCATION 6
3.0.0 WATER & SLURRY SYSTEM DRIVES / EQUIPMENT : 7
OPERATION / CONTROL PHILOSOPHY
3.2.0 CONTROL & OPERATION OF DRIVES / EQUIPMENT 8
4.0.0 OPERATION SEQUENCE FLOW DIAGRAM 22
5.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS 24
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -3-
DCIPS Job No. 28P01

Control philosophy of entire process has been divided in following manner.

1. PART A: Bottom ash & Coarse ash evacuation system

2. PART B: Fly ash evacuation system
3. PART C: Water & slurry system
4. PART D: Silo unloading system
5. PART E: Instrument air system
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -4-
DCIPS Job No. 28P01

In this part we shall explain the PART C: i.e. Water & slurry system.
Operation & control of equipments related to water required to run bottom ash & fly
ash system have been dealt here. Following are the pumps associated with the
water & slurry system.
1. BA HP Water Pumps
2. BA LP Water Pumps
3. Flushing Water Pump
4. Economiser Water Pumps
5. Sludge Pump
6. FA HP Water Pump
7. LP Seal Water Pumps
8. HP Seal Water Pumps
9. BA Ash Slurry Disposal Pumps
10. Bottom Ash Slurry Drain Pumps
Item Sl no 3,4 & 6 to 10 shall be covered in part C.
Entire documentation has been created in following manner.
1.0 For equipment:
1.1 Location of Hardware actuator & their selection procedure.
1.2 Operational control with associated starting & running permissives.
1.3 Operational status, Signal, message etc.

2.0 For System:

2.1 Sequential operation
3.2 System flow chart

Associated documents:
1. This write-up shall be read in conjunction with :

 Single line flow diagram: [NTPC Drg. # 0330-162-PVM-L-004]

 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -5-
DCIPS Job No. 28P01

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY

1.1.0 The System:

1.1.1 Service / motive water required for carrying out following functions.
1) Bottom ash cleaning,
2) Eco. ash cleaning.
3) BA Ash Slurry sump, common trough & drain sump jetting.
4) BA Ash slurry Disposal Line jetting.
5) BA hopper make up.
6) Sludge pipe jetting.
7) Water for sealing requirement of various pumps / equipment.
8) Silo unloading in wet form.(By Rotary Unloader)
9) Cooling water requirement of pumps / equipment.
10) Make-up water for sumps.
11) Seal Trough / Refractory cooling.
To cater the needs following pumps are required.
1) BALP water pump.
2) BAHP water pump
3) Economiser water pump.
4) Sludge pump.
5) Flushing water pump.
6) FAHP water pump.
7) Bottom ash overflow water pump.
8) BA seal water pump.
9) LP seal water pump
10) HP seal water pump

1.1.2 Ash slurry from bottom ash system, drain pumps, sludge drain pumps, etc. shall be
accumulated in ash slurry sump. There are two (2) Nos. slurry sump compartments
below the common trough. Each sump compartment is connected with two slurry
chain of two pumps in series onward disposal to ash pond.
1.1.3 Contaminated water accumulated in ash slurry drain sump, Silo drain sump will be
transported to slurry sump for onward disposal to ash pond.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -6-
DCIPS Job No. 28P01

1.1.4 BAHP water pumps, BALP water pumps, Flushing water pump, Economiser water
pumps, & FA HP water pumps are Supply’s water to system. And source of water
to ash water sump are from purchaser’s raw water, CW blow down & ash water re-
circulation source, and in plant Recycled water from surge bin.
1.1.5 BA, HP & LP seal water source of water is from purchaser’s service water.

2.0.0 CONTROL DEVICES & LOCATION

2.1.0 THE PROCESS CONTROL:

Logic relating to remote interlocked operation of the ash handling system will be
executed through Purchaser’s DDCMIS.

2.2.0 CONTROL EQUIPMENT:

All drive motors, actuator & pneumatic valves will be controlled from respective
Purchaser’s remote panel with starting interlocks & permissives in remote mode

2.3.0 SIGNALS/ INDICATION:

Location wise details of actuators, indications and anunciations have been
furnished in the annexed table titled “TABULAR CHART: ACTUATORS,
INDICATIONS, ALARMS at the end of document.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -7-
DCIPS Job No. 28P01

3.0.0 WATER & SLURRY SYSTEM DRIVES / EQUIPMENT:

3.1.0 IDENTIFICATION & OPERATION OF DRIVES FOR WATER & SLURRY SYSTEM

SL. DRIVE
NO. DESIGNATION TAG REMARKS
IDENTIFICATION
FAHP#A
FAHP#B Maximum three pumps will
1. FAHP WATER PUMP FAHP#C operate for 3 units, one for one
FAHP#D unit.
FAHP#E
Common for all slurry pump
FLUSHING WATER
2. FLWP#A series, one chain operating at
PUMP
a time.
ECONOMISER WATER ECO#A
3. One working for all 3 units
PUMP ECO#B
LP SEAL WATER LPSWP#A One working Common for all
4.
PUMP LPSWP#B slurry pump series
HP SEAL WATER HPSWP#A One working common for all
5.
PUMP HPSWP#B slurry pump series
BASP#A1
BASP#A2
BASP#B1 Two pumps in one series.
BOTTOM ASH
BASP#B2 Maximum two slurry chains will
6. SLURRY DISPOSAL
BASP#C1 operate for 3 units ash (BA &
PUMPS
BASP#C2 CA) slurry disposal
BASP#D1
BASP#D2
BOTTOM ASH BASDP#A
7. SLURRY DRAIN One common for three units
BASDP#B
PUMPS
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -8-
DCIPS Job No. 28P01

3.2.0 CONTROL & OPERATION OF DRIVES / EQUIPMENTS

3.2.1.0 FLUSHING, FAHP & ECONOMISER WATER PUMPS
3.2.1.1 Flushing Water pump:
The flushing water pump is energized to cater to occasional flushing water
requirement for slurry disposal lines. Its suction is from ash water common sump.

Flushing water pump can be started when any one of the slurry series is selected
in flushing mode and water level of ash water common sump is > low set point.
Once flushing mode is selected for a particular slurry chain, suction valve of
respective pump closes & discharge valve of the chain opens automatically.
Operation of flushing water pump will be carried out from purchaser’s HMI thru’
actuation of respective “START” & “STOP” push buttons.
Once flushing water pump is running & its adequate discharge pressure is sensed;
the slurry series start permissive energizes with a predetermined time delay & with
all other regular interlock & protection as per normal mode. The chain can now be
taken in service for flushing of slurry discharge line
Over & above of normal protection of slurry pump, in case, flushing water pump
trips during flushing; its corresponding series pump shall trip instantaneously.

Selector & Actuator:

SELECTOR : Normal / Flushing mode of each slurry series : at
purchaser’s HMI
ACTUATION : START / STOP push button of motor : at Purchaser’s HMI
Series START / Series STOP push button : at Purchaser’s
HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.

3.2.1.2 FAHP Water pump:

The FAHP water pumps (FAHP#A, FAHP#B, FAHP#C, FAHP#D & FAHP#E)
supplies water for following activities.
1) Water supply to HCSD System.
Three nos. FAHP water pumps can cater to the need one for each unit.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -9-
DCIPS Job No. 28P01

3.2.1.3 ECONOMISER Water pump:

The ECONOMISER water pump (ECO#A & ECO#B ) supplies water for following
activities.
1) Water requirement of slurry sumps jetting.
2) Water requirement of common trough jetting.
3) Water requirement of ash slurry drain sump jetting.
4) Water requirement of economiser flushing boxes.
5) Water requirement of ECO. slurry pipe jetting.
One (1) no. ECO. water pumps can cater to the need of three units.
Suctions of FAHP & ECO. water pumps are taken from ash water common sump.
3.2.1.4 Selector & Actuator:
For FAHP Water Pump
SELECTOR : Auto standby – A / Auto standby – B
/ Auto standby – C / Auto standby – D / Auto standby – E /
Manual: at purchaser’s HMI
For ECO. Water Pump
SELECTOR : Auto standby – A / Auto standby – B / Manual: at
purchaser’s HMI

For FAHP & Eco. Water Pump

ACTUATION : START / STOP push button for all the individual pumps :
at Purchaser’s HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB .
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 10 -
DCIPS Job No. 28P01

3.2.1.5 Permissives: (For FLWP, FAHP & Eco. Water Pump)

A SH W AT ER SU M P LEV EL > L OW

D ISC HA RG E H EA DER PR. LO W

(FO R PR ESET TIM E)

E LEC TRICA L TR IPPIN G O F OPER AT ING PUM P

(FO R TH E PU M P M O TO R IN A UTO W A ITIN G M O D E)

A SH W A TER SUM P LEV EL > D AN G ER LO W

3.2.1.6 Associated Control Item Nomenclature

SL. ITEM TAG

1 DISCHARGE HEADER PR *DHPT1

DISCHARGE HEADER PR *DHPT2
2 ASH WATER SUMP LEVEL AWSLT
2 ASH WATER SUMP RAW WATER INLET VALVE OPEN AWSRWMVSO
4 ASH WATER SUMP CW BLOW DOWN INLET VALVE OPEN AWSCWMVSO
5 ASH WATER RECIRCULATION INLET VALVE OPEN AWSRSMVSO
Read * for FLWP/FAHP / ECO.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 11 -
DCIPS Job No. 28P01

3.2.1.7 Operation:
FLWP/FAHP / ECO. pumps are having identical selection & logic of operation
At first operator shall start the pumps through START actuation putting selector in
manual position. The discharge valve shall be subsequently opened manually.
Keep the selector in auto standby mode for the pump to be brought in auto service.
Discharge valve for auto standby pump shall be kept open for auto standby
operation.
Note: For initial start, during commissioning or after long shut down, when
discharge line is empty; pump shall be started keeping discharge valve in partially
opened condition. There after all restart / auto start of pump shall be with discharge
valve in open condition.
In auto mode of operation, the standby pump (kept selected) automatically starts
 if running pump/s stops due to electrical trip feedback and / or
 Due to non availability of discharge header pressure at or above preset setting
for a preset time as detected by pressure transmitters for FAHP / ECO. pumps
 Due to decrease of discharge header pressure in case the discharge header
pressure falls below a normal set point level and persists for a preset time
during normal running of the other pump.
In case of auto starting of standby pump due to decrease in discharge header
pressure, one of the pumps may be stopped as per operator’s discretion. However,
in case the standby pump is stopped, ‘auto standby starting’ logic will start
functioning only if discharge header pressure attains it’s normal level at least once
during running of the pumps, after starting of standby pump.
[ The auto start command will be withdrawn after a short time of it’s initiation or it
will be withdrawn with the run feed back of the respective drive, whichever happens
earlier ]
Keeping selection in manual position, any pumps can be started through their
respective START buttons.
3.2.1.8 Indication & Alarm:
1) Running pump tripped / running status
2) Ash water sump level high.
3) Ash water sump level low.
4) Ash water sump level danger low.
5) Discharge header pressure high.
6) Discharge header pressure low.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 12 -
DCIPS Job No. 28P01

3.2.2.0 ASH WATER SUMP:

Input water to sump:
There are four sources :
1) From purchaser’s CW blow down.
2) From purchaser’s raw water source.
3) From purchaser’s ash water re-circulation.
4) From overflow of surge bins.

The control:
Out of above sources, only SL No. 1, 2 & 3 shall be automatically controlled
SELECTION: Auto / Open / Close selector in purchaser’s HMI
In Auto mode:
While the selector in auto position; the cylinder operated valve placed on the line
shall operate in following manner.
 Raw water source valve remains open.
 CW blow down inlet valve opens first at sump level low condition and if low
level persists for the preset duration then ash water recirculation raw water
valve opens.

3.2.3.0 HP & LP SEAL WATER PUMP :

HP & LP Seal water pumps (HPSWP#A / HPSWP#B & LPSWP#A / LPSWP#B) will
supply water for following requirement
 Gland sealing of ash slurry Disposal pumps.
 Gland sealing of sludge pump (by LP seal water pump)
 Gland sealing of drain pump in ash slurry pump house (by LP seal water pump)
To cater the need of three units one of the each seal water pump will run.
3.2.3.1 Selector & Actuator:
SELECTOR : Auto standby – A / Manual / Auto standby – B : at
purchaser’s HMI
ACTUATION : START / STOP pushbutton for both pumps : at purchaser’s HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.
.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 13 -
DCIPS Job No. 28P01

3.2.3.2 Permissive:

S T A R T I N G P E R M IS S IV E

SEAL W ATER TANK LEVEL > LO W

D IS C H A R G E H E A D E R P R . L O W

E L E C T R I C A L T R IP P IN G O F O P E R A T I N G P U M P

(F O R T H E P U M P M O T O R I N A U T O W A I T I N G M O D E )

R U N N I N G P E R M I S S IV E

SEA L W A TER TA NK LEVEL > DAN GER LO W

3.2.3.3 Operation:

The HP seal water pump is operated to supply seal water for 2nd stage and the LP
seal water pump is operated to supply seal water for 1st stage of slurry disposal
pumps of operating slurry pump series. Suction of both pumps is taken from
common suction header of seal water tank. The source of water for seal water tank
is from purchaser’s service water source. There is separate re-circulation valve for
HP/LP pump set to take care minimum adequate flow during adverse operational
situation. Operator should keep the valve adjusted as per requirement. Generally
one no pump of each type is required for running of the three units.

Auto Mode
In auto mode, during running of one pump, the standby pump automatically starts if
 Running pump stops due to electrical trip feedback and / or
 Non-availability of discharge header pressure at or above preset setting as
detected by pressure transmitter
In case the discharge header pressure falls below normal set point and persists for a
preset time during normal running of the other pump; the pump selected in auto
standby mode will take auto start at the discretion of operator.
[The auto start command will be withdrawn after a short time of it’s initiation or it will
be withdrawn with the run feed back of the respective drive, whichever happens
earlier ]
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 14 -
DCIPS Job No. 28P01

In case of auto starting of standby pump due to decrease in discharge header

pressure, any one of the pumps may be stopped which is as per operator’s
discretion.
However, in case the standby pump is stopped, ‘auto standby starting’ logic will start
functioning only if discharge header pressure attains it’s normal level at least once
during running of both the pumps, after starting of standby pump.
Manual operation:

Keeping selection in manual position, any or both the pumps can be started through
their respective START button on HMI.

Indication & Alarm:

1) Pump tripped/running status.

2) Seal water tank level high.
3) Seal water tank level low.
4) Seal water tank level danger low
5) HP / LP Discharge header pressure high.
6) HP / LP Discharge header pressure low.
All the operating pump trips at sump level danger low, with an alarm.

3.2.3.5 Associated Control Item Nomenclature

SL. NO. ITEM TAG

1 SEAL WATER TANK LEVEL HIGH SWTLSH
2 SEAL WATER TANK LEVEL LOW SWTLSL
3 SEAL WATER TANK LEVEL DANGER LOW SWTLDL
4 HP SEAL WATER DISCHARGE HEADER PR LOW HPSWDPT1
5 HP SEAL WATER DISCHARGE HEADER PR LOW HPSWDPT2
6 LP SEAL WATER DISCHARGE HEADER PR LOW LPSWDPT1
7 LP SEAL WATER DISCHARGE HEADER PR LOW LPSWDPT2

3.2.4.0 BA SLURRY SUMP:

Ash slurry from following sources is to accumulate in the ash slurry sump common
trough.
1) Bottom ash slurry from maximum two (2) of the units.
2) Drain water from ash slurry pump house drain pumps.
3) Sludge from BA overflow sludge pumps of all the units.
4) Sludge from purchaser’s clarifier sludge line.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 15 -
DCIPS Job No. 28P01

From common trough slurry can be diverted to any of two (2) nos. of identical
compartment, through isolating type manual plug gate.
Every compartment is equipped with level transmitter with make up water supply
arrangement from BALP water source. Common trough and individual slurry
compartments jetting water source is taken from Eco water pump. Each of the
compartments is connected to suction of one slurry pump chain.
3.2.4.1 Ash Slurry Sump Level:
Each compartment is provided with one solenoid operated valve to supply make up
water from BALP water source. The valve shall operate through customer DDCMIS
automatically in following manner.
SELECTON: Auto / Open / Close selector in purchaser’s HMI
The Auto Operation:
While selector in auto position BALP water make up valve:-
 Opens at sump level low.
 Closes at sump level high.

3.2.5.0 BA ASH SLURRY DISPOSAL PUMPS

Slurry accumulated in ash slurry sump shall be pumped out to distance ash pond
through ash slurry chain pumping. There are four (4) series each having two (2) nos.
of pump in a series. At least one as slurry chain for each unit should be in operation
before commencement of any deashing activities.

SELECTON / ACTUATION :

SELECTION : Normal / Flushing mode of each slurry series : at purchaser’s HM

ACTUATION : Series START / Series STOP pushbutton : at purchaser’s HMI

: Suction valve CLOSE actuation facility : at purchaser’s HMI
EMERGENCY : Emergency STOP push button (One no for each motor) : on Local
STOP PB station.

The operation of the ash slurry pump series will be carried out from purchaser’s HMI
through respective “Series Start” & “Series Stop” push buttons.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 16 -
DCIPS Job No. 28P01

3.2.5.1 Permissives

Starting permissive of 1st stage pump of any slurry series.

Slurry sump level > low.

LP seal water header pressure > normal value.

Normal mode selected.

RUNNING PERMISSIVE OF 1st STAGE PUMP OF ANY SLURRY SERIES

SLURRY SUMP LEVEL > DANGER LOW

PUMP GLAND SEAL WATER PR. IS NORMAL
LEVEL WITHIN A PRESET TIME FROM STARTING OF PUMP

SUCTION VALVE OF THE SERIES IS OPEN

DISCHARGE VALVE OF THE SERIES IS OPENED WITHIN A
PRESET TIME FROM STARTING OF THE 1st STAGE PUMP.

FLUID COUPLING COOLING WATER PRESSURE IS NORMAL

FLUID COUPLING OIL TEMPERATURE IS NORMAL
DOWNSTREAM PUMP IS STARTED WITHIN A PRESET TIME
SLURRY SERIES SELECTION IN NORMAL MODE
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 17 -
DCIPS Job No. 28P01

STARTING PERMISSIVE OF 2nd STAGE PUMP OF ANY SLURRY SERIES

SLURRY SUMP LEVEL > LOW

HP SEAL WATER HEADER PR. > SET VALUE

UPSTREAM PUMP OF THIS CHAIN IS RUNNING

DISCHARGE VALVE OF THE SERIES IS OPEN

RUNNING PERMISSIVE OF 2nd STAGE PUMP OF ANY SLURRY SERIES

SLURRY SUMP LEVEL > DANGER LOW

PUMP GLAND SEAL WATER PR. IS NORMAL
LEVEL WITHIN A PRESET TIME FROM STARTING OF PUMP
DISCHARGE VALVE OF THE SERIES IS OPEN

DOWNSTREAM PUMP IS STARTED WITHIN PRESET TIME

(EXCEPT FOR 3rd STAGE PUMP)
UPSTREAM PUMP OF THIS CHAIN IS RUNNING
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 18 -
DCIPS Job No. 28P01

3.2.5.2 Operation
All the first stage pumps are coupled with drive motor through gear box – fluid coupling.
Second stage of each chain is belt driven types.

The cooling water for fluid coupling for 1st stage pump is provided from purchaser’s cooling
water header. There shall be temperature element provided with each fluid coupling system
for monitoring & protecting oil temperature.

3.2.5.2.1 With actuation of “SERIES START” button the respective stage wise pumps with associated
suction & discharge valve and the seal water / cooling water lines will energise in steps as
per the sequence indicated below; maintaining a predetermined time interval between two
successive steps of operations.

Suction valve opens (If closed).

 Cooling water line valve for fluid coupling of the 1 st stage pump motor will open and
normal pressure will be established.
 Seal water valve of all the pumps of the series will open.

 1st stage pump motor will start.

 1st stage pump seal water pressure will be normal within a preset time.

 Discharge valve opens within a preset time from starting of the 1st stage pump

 2nd stage pump motor will start within a preset time from opening of discharge valve..

 2nd stage pump seal water pressure will be normal within a preset time.

 Non-performance of any of the steps within respective preset time, will suspend series
starting attempt resulting in tripping of the series.

3.2.5.2.2 With actuation of “Series Stop” push button of 2nd stage ash slurry disposal pumps in series
will stop and thereafter the discharge valve will close after a preset time. Thereafter, 1st stage
pump will stop. Stopping of pumps will close seal & cooling water line valves. The pump
suction valve however will remain opens.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 19 -
DCIPS Job No. 28P01

In the event of tripping or stopping of any one pump in the series, other pump in series will
stop instantaneously. Thereafter the discharge valve will close after a preset time from
stopping of pumps with subsequent closure of seal & cooling water line valves. The pump
suction valve however will remain open. The suction valve can be closed through
purchaser’s HMI actuation for the same.

The status of the individual pumps, normal pressure status of seal / cooling water line, open /
close status of suction & discharge valve and level of respective BA slurry sump
compartment will be monitored on purchaser’s HMI along with annunciation for abnormality
for the same.
3.2.5.2.3 Flushing Of BA Slurry disposal Series / Line

Respective BA slurry disposal series initially should be in OFF condition & also should be
selected at flushing mode from HMI. Operator should then start the FLUSHING water pump
through START push button at HMI. Subsequently Series Start for the particular series is to
be actuated and then following action takes place sequentially.
 Suction valve of the series closes. (if found open)
 Thereafter the sequence of operation will be similar to BA slurry disposal pump normal
operation as indicated in para 3.2.5.2.1 except operation of suction valve.

3.2.5.3 ASSOCIATED CONTROL ITEM NOMENCLATURE:-

SL. NO. ITEM TAG

1 BA Slurry sump make-up valve open BASS*MVSO
2 BA Slurry sump level transmitter BASS*LT1
3 BA Slurry sump level transmitter BASS*LT2
4 BA Slurry disposal series suction valve BASS*SVSO
5 BA Slurry disposal series suction valve open BASS*SVLO
6 BA Slurry disposal series suction valve close BASS*SVLC
7 BA Slurry disposal series discharge valve BASS*DVSO
8 BA Slurry disposal series discharge valve open BASS*DVLO
9 BA Slurry disposal series discharge valve close BASS*DVLC
10 BA Slurry disposal series discharge pressure transmitter BASSP*DPT
11 1st stage BA slurry disposal pump fluid coupling cooling water valve BASP*1FCSO
12 1st stage BA slurry disposal pump fluid coupling cooling water BASP*1FCPSL
13 1st BA slurry disposal pump fluid coupling temperature high BASP*1FCRTD
14 1st stage BA slurry disposal pump seal water valve BASP*1SWVSO
st
15 1 stage BA slurry disposal pump seal water pressure transmiter BASP*1SWPT
16 2nd stage BA slurry disposal pump seal water valve BASP*2SWVSO
nd
17 2 stage BA slurry disposal pump seal water pressure transmiter BASP*2SWPT
Read * as slurry series and sump identification, namely (A, B, C, D & E ) and ( 1/2 )
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 20 -
DCIPS Job No. 28P01

3.2.6.0 BOTTOM ASH SLURRY DRAIN PUMP :

Drain / leakage water out of equipment within slurry pump house will accumulate in ash slurry
drain sump inside pump house. Ash Slurry Drain Pump shall be used to pump out such water
to ash slurry sump.
3.2.6.1 Selector & Actuator:
SELECTOR : Auto standby – A / Manual / Auto standby – B : at purchaser’s HMI
POP UP SELECTOR : Auto / Manual for individual pump : at purchaser’s HMI
ACTUATION : START / STOP pushbutton for both the individual pumps : at
purchaser’s HMI
EMERGENCY STOP : Emergency stop push button (One no for each motor) on Local PB
station.

3.2.6.2 Permissive

SUM P LEV EL > LOW

ELEC TR IC AL TR IPPIN G OF O PERA TING PUM P

LEV EL HIGH FEED BA CK PER SISTS FO R PR ESET TIM E

AFTER A UTO M OD E STAR TING OF FIRST PUM P

(FO R THE PUM P M OTOR IN AUTO W AITING M ODE)

SUM P LEVEL >DANGER LOW

SEAL W ATER PRESSUR E IS NOR M AL
W ITH IN PRESET TIM E
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 21 -
DCIPS Job No. 28P01

3.2.6.3 Operation
 At first choose pump to be kept in service by putting selector in manual position.
 Start the pumps by manual command through START actuation and put the selector on
Auto (pop up selector) for level based start & stop of running and auto standby pump on
purchaser’s HMI
 The moment pump is started by satisfying all the starting permissive, its seal water valve will
be opened. If, preset seal water pressure is established within a preset time, as detected by
pressure switch the pump will continue to run; otherwise the pump shall trip with
annunciation in purchaser’s HMI.
 Keep the selector in auto stand by mode for the pump to be brought in auto service,
 Incase, running pump trips, the pump already selected for auto-standby will take auto
start
Once pump has taken a successful start and pop up selector (Auto/Manual) of running & auto
standby pump is put on ‘Auto’ position, operating pump will automatically start / stop depending
on its sump level i.e. stop when sump level reaches to low level & start when sump level
reaches high. This ‘Auto’ logic will be active for the pump, which is in operation. If auto standby
pump started once then ‘Auto’ logic will be active for stand by pump till operator’s intervene.
In case first pump is running in auto mode, and even then the sump level is not coming down
within preset duration from HIGH level condition, the second pump (pump selected for auto-
standby operation) will be started automatically, with purchaser’s HMI alarm as ‘Standby pump
auto started due to sump high level” and shall continue to operate till level is just below low,
when both the pump will stop. However 1st pump will be restarted again at sump high level and
logic shall be as mentioned above.

Auto standby Mode:

In auto standby mode of operation, the standby pump automatically starts if

 Any of the running pump trips (electrical trip feed back) and
 sump level is above low
Keeping selection in manual position, any or both the pumps can be started through their
respective START button on purchaser’s HMI.

3.2.6.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Seal water Valve BASDP*SWVSO
2 Seal water pressure transmiter BASDP*PT
3 sump level transmiter BASDSLT
Read first * as drive identification i.e. A or B
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 22 -
DCIPS Job No. 28P01

4.0.0 OPERATION SEQUENCE FLOW DIAGRAM

PRE CONDITION
SEAL WATER PUMP RUNNING
SEAL WATER PR > SET VALUE
SUMP LEVEL > LOW
START

CHOOSE
CHAIN TO SUCTION VALVE OPENS
BE IN SERVICE F/C WATER V/V OPENS
SEAL WATER V/V OPENS

ACTUATE
SERIES F/C
START COOLING
WATER
PR>SET
CHECK VALUE
SUMP LEVEL YES NO
> LOW
NO F/C
OIL
YES
TEMPR>SET
SEAL VALUE
WATER
HDR.PR>SET
YES NO
VALUE
NO
YES GLAND
SEAL
WATER PR>SET
VALUE

YES NO

GO TO NEXT PAGE
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 23 -
DCIPS Job No. 28P01

FROM PRE PAGE

STOP SERIES

NO
1> 1ST STAGE PUM P ,SEAL WATER 1
PR>NORMAL WITHIN
PRESET TIM E & MOTOR STARTS
YES

NO
2> DISCHARGE VALVE
2
OPENS W ITHIN
PRESET TIME

YES

3> 2ND STAGE M OTOR STARTS NO

WITHIN PRESET TIME 3
FROM OPENING OF
DISCHARGE VALVE

YES

NO
4
4> 2ND STAGESTAGE PUM P ,SEAL W ATER
PR>NORMAL WITHIN
PRESET TIM E

YES

SERIES CONTNUES
TO RUN AS PERMISSIVES

WITH STOP ACTUATION

2ND STAGE M OTOR TRIPS
& DISCHARGE VALVE CLOSES
THEN 1ST STAGE MOTOR TRIPS
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 24 -
DCIPS Job No. 28P01

5.0.0. TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS

SL. EQUIPMENT CONTROL ROOM REMARKS

PURCHASER’S
NO. IDENTIFICATION PURCHASER’S HMI ALARM
HMI SCREEN
SCREEN INDICATOR ALARM LOG
ACTUATOR
ON HP SEAL WATER
START
PUMP TRIPPED
STOP OFF
(INDIVIDUAL)
AUTO STANDBY-A /
AUTO STANDBY-B / TRIP
1 HP SEAL WATER MANUAL/ OFF
PUMP SELECTION AUTO / MANUAL HP SEAL WATER
FACILITY STATUS HEADER PRESSURE
ABNORMAL
HP SEAL WATER
TANK LEVEL
ABNORMAL
ON LP SEAL WATER
START
PUMP TRIPPED
STOP OFF
(INDIVIDUAL)
AUTO STANDBY-A /
AUTO STANDBY-B / TRIP
2 LP SEAL WATER MANUAL/ OFF
PUMP SELECTION AUTO / MANUAL LP SEAL WATER
FACILITY STATUS HEADER PRESSURE
ABNORMAL
LP SEAL WATER
TANK LEVEL
ABNORMAL
FLUSHING WATER
START / STOP ON / OFF / TRIP PUMP TRIPPED

NORMAL / FLUSHING WATER

3 FLUSHING WATER FLUSHING MODE HEADER PRESSURE
PUMP SELECTION ABNORMAL
FACILITY
4 ASH WATER SUMP AUTO / OPEN / OPEN / CLOSE
ASH WATER SUMP
MAKE-UP CLOSE
LEVEL ABNORMAL
VALVE
AUTO / OPEN /
CLOSE SELECTION
FACILITY

START /
ON / OFF / TRIP FAHP WATER
STOP
HEADER PRESSURE
AUTO STANDBY-A/ ABNORMAL
AUTO STANDBY-B/
AUTO STANDBY-C/ FAHP WATER
5 FAHP WATER PUMP AUTO STANDBY-D/ AUTO / MANUAL PUMP TRIPPED
STATUS (INDIVIDUAL)
AUTO STANDBY-E
MANUAL
SELECTION
FACILITY
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 25 -
DCIPS Job No. 28P01

SL. EQUIPMENT CONTROL ROOM REMARKS

PURCHASER’S
NO. IDENTIFICATION PURCHASER’S HMI ALARM
HMI SCREEN
SCREEN INDICATOR ALARM LOG
ACTUATOR

ECO / APH WATER

START / ON/OFF/ TRIP HEADER PRESSURE
STOP ABNORMAL

6 ECO. WATER PUMP AUTO / MANUAL ECO. WATER PUMP

AUTO STANDBY-A/ STATUS TRIPPED
AUTO STANDBY-B/ (INDIVIDUAL)
MANUAL SELECTION
FACILITY

INDIVIDUAL ON,
OFF & TRIP
SERIES START / INDICATION FOR ASH SLURRY PUMP
SERIES STOP MOTORS OF SERIES TRIPPED
1ST TO 3RD STAGE
PUMP MOTOR

NORMAL / INDIVIDUAL SEAL

FLUSHING MODE WATER VALVE SEAL WATER
SELECTION OPEN / CLOSE PRESSURE LOW
FACILITY STATUS FOR STATUS OF
BA SLURRY PUMP OF INDIVDUAL SLURRY
ST ND
7 DIPOSAL PUMP 1 &2 STAGE PUMP
INDIVIDUAL SEAL
WATER FLUID COUPLING
PRESSURE COOLING WATER
NORMAL PRESSURE LOW
INDICATION FOR (INDIVIDUAL
PUMP OF SERIES)
ST ND
1 &2 STAGE

FLUID COUPLING
INDIVIDUAL STOP FLUID COUPLING
COOLING WATER
PB OF OIL
PRESSURE
TEMPARATURE
NORMAL
MOTORS OF HIGH (INDIVIDUAL
ST ND (INDIVIDUAL
1 &2 STAGE SERIES)
SERIES)
FLUID COUPLING
SUCTION VALVE OIL
OPEN / CLOSE TEMPARATURE
SELECTION FOR STATUS
EACH SERIES INDIVIDUAL
SERIES)
INDIVIDUAL
SUCTION VALVE
OPEN / CLOSE
STATUS FOR
EACH SERIES
 DC INDUSTRIAL PLANT SERVICES PVT. LTD
CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING
PART -C: WATER & SLURRY SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030-03
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330-162-PVM-U-030C
Stage –1, Units #1, # 2 & #3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 26 -
DCIPS Job No. 28P01

SL. EQUIPMENT CONTROL ROOM REMARKS

PURCHASER’S
NO. IDENTIFICATION PURCHASER’S HMI ALARM
HMI SCREEN
SCREEN INDICATOR ALARM LOG
ACTUATOR
DISCHARGE
VALVE
OPEN/CLOSE
STATUS FOR
EACH SERIES
INDIVIDUAL
OPEN / CLOSE
STATUS
(INDIVIDUAL
AUTO / OPEN / SLURRY SUMP
SUMP)
CLOSE SELECTION LEVEL ABNORMAL
SLURRY SUMP
BA SLURRY SUMP FACILITY (INDIVIDUAL SUMPS)
8 LEVEL STATUS
MAKE UP VALVE
(INDIVIDUAL
SUMPS)
AUTO / MANUAL
STATUS
(INDIVIDUAL)

ON / OFF / TRIP
START / STOP SLURRY DRAIN
SEAL WATER PUMP TRIP
PRESSURE (INDIVIDUAL)
NORMAL
AUTO STAND BY- A / SEAL WATER
ASH SLURRY DRAIN
AUTO STAND BY-B / SLURRY DRAIN PRESSURE
9 PUMP
MANUAL SELECTION SUMP LEVEL ABNORMAL
FACILITY STATUS (INDIVIDUAL)

AUTO / MANUAL SLURRY DRAIN

POP UP SELECTION SEAL WATER SUMP LEVEL
FACILITY VALVE OPEN / ABNORMAL
CLOSE STATUS

1. COLOUR OF INDICATION FOR PURCHASER’S HMI.

RED / STEADY (S) : OPEN / ON / PR, LVL, TEMPARATURE, PROCESS NORMAL

RED / FLICKERING (F) : PR, LVL, TEMPARATURE, PROCESS
ABNORMAL / ASH CRUSHER REVERSE RUN, DRIVE TRIP
AMBER / STEADY (S) : LEVEL HIGH / LEVEL LOW / LEVEL
DANGER LOW
GREEN / STEADY (S) : OFF / CLOSE
BLUE :DRIVE MOTOR SELECTED FOR DE-INTERLOCKED
TRIAL OPERATION (DE-INTERLOCKED TRIAL OPERATION
OF DRIVE MOTORS WILL BE SELECTED FROM A
PASSWORD PROTECTED PAGE OF HMI. IN THIS MODE
ELECTRICAL PROTECTION OF MOTORS WILL BE IN
OPERATIVE MODE. HOWEVER, PROCESS INTERLOCK OF
THE PARTICULAR DRIVE WILL BE BY-PASSED)
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -1-
DCIPS Job No. 28P01
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -2-
DCIPS Job No. 28P01

INDEX

SL. NO. DESCRIPTION PAGE NO.

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY 4
2.0.0 CONTROL DEVICES & LOCATION 4
3.0.0 SILO UNLOADING SYSTEM DRIVES / EQUIPMENT : OPERATION / 6
CONTROL PHILOSOPHY
3.1.0 DRIVE UTILISATION CHART 6
3.2.0 IDENTIFICATION & OPERATION OF DRIVES 6

4.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS 18

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -3-
DCIPS Job No. 28P01

:Note:
A) Control philosophy of entire process has been divided in following manner.
1. PART A: Bottom ash & Coarse ash evacuation system
2. PART B: Ash evacuation system
3. PART C: Water & slurry pumping system
4. PART D: Silo unloading system
5. PART E: Instrument air system
B) In this part of document we shall explain the PART D i.e. Silo unloading system.
Operation & Control of equipment related to silo unloading system have been dealt here
sequentially. Following are the equipments are associated with the silo unloading system.
1. Silo Aeration Blowers
2. Silo Aeration Blower Heaters
3. Silo Area Drain Pumps
4. Dust Conditioners (Rotary Unloaders)
5. Wash Water Pumps
6. Conditioning Water Pumps
7. Rotary Feeder for Telescopic Spout
8. Vent Fan for Telescopic Spout
9. Silo Vent Filters
10. Silo Vent Fans
11. Instrument Air Compressor & ADP
C) Item Sl No. 1 to 10 have been dealt in this Part D & where as Sl no. 11 shall be covered in Part- E.
Entire documentation has been created in following manner.
1.0 For equipment:
1.1 Location of Hardware actuator & their selection procedure.
1.2 Operational control with associated starting & running permissives.
1.3 Operational status, Signal, message etc.

2.0 For System:

2.1 Sequential operation
3.2 System flow chart

D) Associated documents:

1. This write-up shall be read in conjunction with :

 Single line flow diagram: [DCIPS Drg. # 28P01–1E-M-103]

Remote operated field devices are also identified in the enclosed “CONTROL IDENTIFICATION
DIAGRAM”.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -4-
DCIPS Job No. 28P01

[This control identification diagram is developed from Mechanical Single line drawing no. 28P01-
1E-M-103 Rev-0 respectively to identify the Electrics & Electrical controls associated with the
Silo unloading system and may not cover all flow lines, having only field manual controls. In case
of conflict, the content of Mechanical Single line diagram will prevail.]

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY

1.1.0 The System

1.1.1 The silo unloading system provided under this contract, is designed for periodic removal of ash
collected in Silo during dry mode conveying from ESP hoppers.

1.1.2 Under the system arrangement, fly ash collected in two nos. silos i.e. Silo # I (S-1) & Silo # II (S-
2) & Silo # III (S-3) & Silo # IV (S-4) & Silo # V (S-5) will be cleared at periodic interval or as and
when required by means of one no motorised winch operated telescopic spout or one no rotary
unloader of each silo into tanker (for dry ash unloading) / open truck (for moist ash unloading) as
applicable. The fly ash thus collected in open truck / close tanker will be transported out of plant
for ultimate use.
1.1.3 Out of five (05) silo unloading paths, telescopic spout is meant for dry ash unloading into tanker
and rotary unloader for wet (conditioned) ash into open truck.
1.1.4 Fly ash from ESP hoppers can be collected in any of the five silos. Ash unloading from each of
the silos also can be done either through respective rotary unloader or telescopic spout as per
requirement.
1.1.5 Instrument air from station IA compressors, free from dirt, scale & moisture at a desired pressure
will be used for operation of pneumatic actuation for various valves, gates, pulse jetting etc.
2.0.0 CONTROL DEVICES & LOCATION

2.1.0 THE PROCESS CONTROL:

Logic relating to remote interlocked operation of the ash handling system will be executed
through Purchaser’s DCS. The subject DCS will hook-up the operator’s interfaces in control
room as well as in the Silo area to offer a composite and integrated facility for software driven
plant control and monitoring system. Logic processing as associated with actuations, indications
and anunciations on Silo Area System Panel (SASP) as well as actuations & indications on local
wet / dry unloading stations (LWUS / LDUS) will be at DCS unit.
2.2.0 Following operator’s interface in silo area will be provided to have local silo unloading related
selections and actuation with associated monitoring.
 A panel designated, as Silo Area System Panel (SASP) will be located inside electrical room
of silo utility building. This panel will have fiber glass painted LED spot illuminated mimic and
annunciator lamp boxes. Various pumps, blowers and air heaters under the silo unloading
system will be operated from this panel.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -5-
DCIPS Job No. 28P01

 Column / structure mounted Local unloading station for each set of wet and dry outlet
equipment located on silo unloading floor near respective unloading equipment. One no
Local Wet Unloading Station (LWUS) for each Wet Outlet and One no Local Dry Unloading
Station (LDUS) for each Dry Outlet will be provided.
2.3.0 Strategic status indications of dry/wet unloading equipment located at silo unloading floor i.e. of
various equipment / drives related to Wet & Dry outlet as well as strategic status indications of
silo roof valves and silo vent fan with associated pulse jetting for all the silos will be provided on
SASP.
2.4.0 In addition to above, facility is provided for emergency stop of the various remote controlled motor
drives and heaters through Local Push Button Stations having one no Mushroom head emergency
stop push button, to be located near to each drive.

2.5.0 SIGNALS/ INDICATION:

Location wise details of actuators, indications and anunciations have been furnished in the
annexed table titled “TABULAR CHART: ACTUATORS, INDICATIONS, ALARMS at the end of
document.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -6-
DCIPS Job No. 28P01

3.0.0 SILO UNLOADING SYSTEM DRIVES / EQUIPMENT : OPERATION / CONTROL

PHILOSOPHY
3.1.0 Drive Utilisation Chart

DRIVES FOR SILO UNLOADING SYSTEM

COMMON DRIVES COMMON DRIVE

FOR ASH SILO AREA FOR UNLOADING
HANDLING SYSTEM DRAIN PUMP FROM SILO
OPERATION

1. IA COMPRESSOR SILO AERATION

2. AIR DRYING PLANT 1. DRAIN PUMP BLOWER &
3. SILO VENT FILTER 2. WASH WATER PUMP ASSOCIATED
4. SILO VENT FAN HEATER

WET
(CONDITIONED)
UNLOADING DRY UNLOADING

1. ROTARY UNLOADER 1. VENT FAN FOR

2. CONDITIONING TELESCOPIC SPOUT
WATER PUMP 2. ROTARY FEEDER

** WASH WATER PUMP WILL BE PUT INTO SERVICE AS AND WHEN IT WILL BE REQUIRED FOR FLOOR
CLEANING OPERATION OF SILO AREA

3.2.0 IDENTIFICATION & OPERATION OF DRIVES FOR SILO UNLOADING SYSTEM

DRIVE NO OF DRIVES TO
SL.NO. TAG WORK FOR SILO REMARKS
DESIGNATION UNLOADING SYSTEM
IDENTIFICATION
FASFB#A One no is required for
FASFB#B operation of one silo& one
SILO AERATION FASFB#C common stand by, however
1 5
BLOWER FASFB#D fluidizing system will be in
FASFB#E service when silo is not
FASFB#F empty
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -7-
DCIPS Job No. 28P01

FASFH#A
FASFH#B
SILO AERATION FASFH#C
2 5 - do -
BLOWER HEATER FASFH#D
FASFH#E
FASFH#F
FADP#A One working & one
3 SILO DRAIN PUMP 1
FADP#B standby
FAWWP#A One working & one
4 WASH WATER PUMP 1
FAWWP#B standby
FACWP#A
FACWP#B
One no is required for
CONDITIONING WATER FACWP#C
5 5 operation of one silo& one
PUMP FACWP#D
common stand by.
FACWP#E
FACWP#F
FADCRU#1 Dust conditioner Rotary
FADCRU#2 Unloader system will be in
DUST CONDITIONER
6 FADCRU#3 service when silo operating
ROTARY UNLOADER
FADCRU#4 and ash unloading in open
FADCRU#5 truck.
FADUWM# 1
FADUWM# 2
Telescopic spout with winch
FADUWM# 3
motor system will be in
TELESCOPIC SPOUT
7 FADUWM# 4 service when silo operating
WITH WINCH MOTOR
and dry ash unloading in
FADUWM# 4
close truck.

FADUWM# 5
8 FADUVF#1
FADUVF#2
VENT FAN FOR
FADUVF#3
TELESCOPIC SPOUT
FADUVF#4
FADUVF#5
9 FAWURF# 1
FAWURF# 2
ROTARY FEEDER FOR
FAWURF# 3
TELESCOPIC SPOUT
FAWURF# 4
FAWURF# 5
10
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -8-
DCIPS Job No. 28P01

3.3.0 CONTROL & OPERATION OF DRIVES AND EQUIPMENT:

3.3.1 SILO AERATION BLOWER:

3.3.1.1 There are 06 nos. Silo aeration blowers and 06 nos. heaters. Each blower is connected to one
heater. Normally Blower-A will be connected to Silo-1, Blower-B will be connected to Silo-2,
Blower-C will be connected to Silo-3, Blower-D will be connected to Silo-4, Blower-E will be
connected to Silo-5, and blower-F can be connected to any of the silos (i.e. common stand by)
if the blower dedicated for the particular silo is not in operation. These blowers will provide
fluidising air to all the silos. One no blower with associated heater is required for operation of
one no Silo.

3.3.1.2 SELECTOR : For FASFB F : S1 / S2 / S3 / S4 / S5 / OFF

ACTUATION : START / STOP pushbutton for all Blowers : at SASP
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

3.3.1.3 Starting Permissive

 One out of two fluidizing valve is open.

Trip condition

 Differential pressure across suction filter is high.

3.3.1.4 Operation:
Silo-aeration blower-heater assembly will be utilised for fluidising arrangement of all the five
silos. So long as dry ash is kept accumulated in silo, this fluidising system should run. The
fluidizing system shall also remain energized during unloading from silo. In case of tripping of
running blower, the stand by blower shall be taken in service in respective line after human
intervention for over all healthiness of the system.
Normally the connection interface will be as indicated below.

 BLOWER# A with associated heater will be connected to silo-1

 BLOWER# B with associated heater will be connected to silo-2
 BLOWER# C with associated heater will be connected to silo-3
 BLOWER# D with associated heater will be connected to silo-4
 BLOWER# E with associated heater will be connected to silo-5

BLOWER# F can be connected to any of the silo-1 or silo -2 or silo-3 or silo–4 or silo-5 as
per requirement with the help of associated pneumatic actuated ball valves. During running
condition if there is trouble in any of the blower-heater assembly, the standby blower-
heater assembly will have to be put in service with desired opening / closing of the
associated valves.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System -9-
DCIPS Job No. 28P01

3.3.1.5 Required blowers will be started from SASP though the respective Start push button. After
giving start command, silo aeration valves respective silo shall opens.

3.3.2 SILO AERATION BLOWER HEATER

3.3.2.1 ACTUATION : START / STOP pushbutton for all heaters : at SASP

EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)

3.3.2.2 Operation:

After blower is taken into service, respective heater will be put into service in following manner
to maintain temperature. There is one no. temperature element (TE) HI & (TE) HIHI provided
on each air heater to keep fluidizing air temperature within pre-set normal band as well as to
prevent overheating of air beyond a pre-HIGH set by means of automatic cut-in / cut-out
control of heating elements.

START PERMISSIVES

RUN F/B OF CONNECTED FLUIDISING BLOWER

HEATER OUTLET TEMP IS LESS THAN TEHI SET POINT

OUTLET TEMPERATURE (T) F/B BELOE 'HIHI' SET POINT

TRIP CONDITIONS

OUTLET TEMPERATURE (T) F/B ABOVE 'HIHI' SET POINT

OUTLET TEMP (T) TSHI FOR SET POINT

STOP F/B OF CONNECTED FLUIDISING BLOWER

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 10 -
DCIPS Job No. 28P01

3.3.2.3 Operation of the heater (Single bank):

 Actuation of “ON” push button from SASP will start the selected heater after fulfillment of
starting permissives and remains on condition according to running permissives.

Cut-in permissives:
 T  (TE) HI

Cut-out permissives:
 T  (TE) HIHI
 T  HI & Preset time delay
Where T= Heated air out let temperature
The heating elements of the heater bank will be energised when air temperature is lower
than or equal to (TE) HI with feedback from temperature element (TE) HI.

Again, it will automatically get de-energised when air temperature equals or exceeds (TE) HI
with the feedback from temperature element (TE) HI and shall remain HI for pre-set duration.
Thus air temperature at heater outlet will be maintained within a pre-set normal band.

 In case, heater does not de-energised even after attaining (TE) HI set point and
continues in energised condition and reaches HIHI set point then the heater will trip the
heater followed by alarm “ heater tripped” in purchaser’s HMI & SASP.

 To reset from trip condition and to start heater, at first STOP push button is to be pressed
and thereafter START push button is to be actuated provided other preconditions are
true.

3.3.2.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Temperature element ‘HI’ of individual heater FASFB*RTD
2 Pressure Transmitter of Common header ( Manifold ) FASFAPT
3 Temperature element ‘HI’ of common heater FASFARTD

Read first * as heater identification i.e. A, B ,C , D , E, & F

3.4.3 SILO AREA DRAIN PUMPS

3.4.3.1 To clear drainage water from drain sump near silo area, two nos. of Drain pumps are
provided. Out of two pumps one is working and other is standby. Wash water pump will cater
seal water requirement of Silo area drain pumps. Discharges of such pumps are given to
slurry sump.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 11 -
DCIPS Job No. 28P01

3.4.3.2 SELECTOR : Manual / Auto : at SASP

ACTUATION : START / STOP pushbutton for both pumps : at SASP
EMERGENCY STOP : Emergency stop push button (One no for each motor) : on Local PB
station (by purchaser)
3.4.3.3 Operation:
Keeping selector at manual position any pump can be started through START actuation from
SASP. Then selector can be put in Auto mode continuous level based START / STOP of
pump. In case of tripping of running pump, the other pump will be taken into service at the
discretion of operator.

3.4.3.4 Permissives:

Starting:
 Sump level > LL
 In auto mode sump level  HL
Running:
 Sump level >LL for preset duration.
 Seal water pressure “NORMAL” after a pre-set time.

STARTING PERMISSIVE FOR ANY OF THE TWO B SILO DRAIN PUMPS

MANUAL MODE SELECTED

WATER LEVEL > LOW

AUTO MODE SELECTED

WATER LEVEL AT OR ABOVE HIGH

TRIP CONDITION FOR ANY OF THE TWO SILO DRAIN PUMPS

IN MANUAL MODE
WATER LEVEL IS BELOW DANGER LOW
FOR PRESET DURATION
SEAL WATER PR. ABNORMAL FOR PRESET DURATION

IN AUTO MODE
WATER LEVEL IS BELOW DANGER LOW
FOR PRESET DURATION
SEAL WATER PR. ABNORMAL FOR PRESET DURATION
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 12 -
DCIPS Job No. 28P01

3.4.3.5 With actuation of START command in SASP following actions will take place.
 First seal water valve will OPEN with start actuation followed by starting of the pump.
Subsequently seal water pressure will be established.

3.4.3.6 With the selector switch at “MANUAL” position, any one of the pumps can be operated
independently by means of respective “START” & “STOP” push buttons in SASP, subject to
fulfillment of starting permissives,. The pump started in “MANUAL” mode will stop
automatically, if the drain sump level reaches “LOW” level & remain below low level for
preset duration.
3.4.3.7 Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 Silo drain sump high level SDSLSH
2 Silo drain sump low level SDSLSL
2 Silo drain pump seal water valve FASDP*SWVSO
3 Silo drain pump seal water pressure switch FASDP*SWPSL
Read * as A & B Pumps
3.4.4 ROTARY FEEDER:
The Rotary Vane Feeder operates at a variable speed and provides a reasonable uniform
ash feed rate for the Dry unloading unit installed below. The Rotary Feeder is suspended
from top for proper functioning of the expansion joint installed below the Feeder.
3.4.4.1 Selection & Actuation:
Speed selector : Increase / decrease push button for rotary feeder placed at LDUS.
Actuator: Forward / Reverse / STOP actuator at LDUS.
Enable/off selector at SASP is selected at enable position.
B) PNEUMATIC KGV ABOVE ROTARY FEEDER
One no. pneumatically controlled knife gate valve (KGV) is provided above rotary feeder for
start / stop feeding of dry ash into tanker through rotary feeder.
3.4.4.2 Opening permissives of KGV:
 Silo Aeration blower is running
 Vent filter fan (for telescopic spout) running & pulse jet is ON
 Silo fluidising valve open impulse.
 Tanker ash level is low
 Rotary feeder is running.
3.4.4.3 Close conditions of KGV:
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 13 -
DCIPS Job No. 28P01

 Vent filter fan (for telescopic spout) tripped or

 Pulse jet is Off or
 Tanker ash level is high with pre set time duration or
 Rotary feeder tripped
3.4.4.4 Operation:
Place the tanker in position, & lower the telescopic spout in position before actuating Open
push button of KGV from LDUS, then increase / decrease the speed of rotary feeder.
Once tanker level is full as sensed by tanker level sensor, first knife gate valve closes & then
rotary feeder stops (optional) with predefined time delay.
3.4.5 CONDITIONING WATER PUMP:
3.4.5.1 ACTUATION : START / STOP pushbutton for all the pumps :at SASP
: Auto – open – close selector actuator of leak – off valve : at SASP
EMERGENCY STOP : Emergency stop push button
(One no for each motor) : on Local PB station (by purchaser)
3.4.5.2 Operation:
There are six (6) no. cnditioning water pumps located at silo area, suction of which are from
Silo Area Water Sump. This pump will cater water requirement for rotary unloaders for
conditioning of ash. One no. pump is generally required to put into service during unloading
of ash for each silo through Rotary Unloader and one is common stand by for all the silos.

3.4.5.3 These pumps will be operated from SASP through actuation of respective “START” &
“STOP” Push buttons.

3.4.5.4 Starting permissive & trip conditions of conditioning water pump.

 Starting permissive : Silo water sump level > LOW & leak-off valve selected at Auto.
 Trip condition : Silo water sump level is below Danger Low
3.4.5.5 One re-circulation line is connected from discharge header of conditioning water pump to silo
water sump through a leak off valve. At auto mode operation selection of this leak-off valve,
initially will be opened with the start command of the first conditioning water pump. It will
normally remains open. However it will be closed only when any one or all the conditioning
water valves of rotary unloader will be opened. At manual mode the leak-off valve can be
operated through open / close selection of the selector actuator.
3.4.5.6 Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 Conditioning water pump Discharge Header Leak off Valve FACWLOV

2 Conditioning water pump Discharge Header pressure transmitter FASCWPT

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 14 -
DCIPS Job No. 28P01

3.4.6 SILO WATER SUMP MAKE-UP VALVE

3.4.6.1 SELECTOR - ACTUATION : Auto / Open / Close selection facility : at SASP

3.4.6.2 The silo sump make-up water shall be provided from Purchaser’s nearby service water
header. One no make-up valve (FASWSMVSO) will be provided at silo water sump, which
is to be operated from SASP, depending on level signal from the level transmitter in auto
mode.
3.4.6.3 In Auto mode selection from SASP through auto / open / close selector switch, the valve
will open if the level is low and it will be closed automatically when the level is high. In
manual mode, with close / open selection at SASP, the valve can be operated manually.
However in manual mode also the valve will be closed automatically when the level will be
high. After closing of the valve in manual mode at ‘High’ level condition, selection is to be
changed to ‘Close’ position and thereafter it is to be selected again at ‘Open’ position.

3.4.6.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Silo water sump level transmitter FASWSLT
2 Silo water sump make-up valve FASWSMVSO

3.4.7 WET (CONDITIONED) ASH UNLOADING

3.4.7.1 Actuation & Indication :

Silo unloading permission ENABLE / OFF lockable selector switch (one no. each for silo

1 to 5) : at SASP
 Start & stop push button for Rotary unloader (one no. each for silo 1 to 5) : at LWUS.
 Open / close actuators for orifice feeder (one no. each for silo 1 to 5) : at LWUS
 Auto / open / close selector switch for water supply valve (one no. each for silo 1 to 5) :
at LWUS
 Conditioned water pressure normal indication (one no. each for silo 1 to 5) : at LWUS
 Rotary unloader tripped indication (one no. each for silo 1 to 5).
3.4.7.2 Operation : Wet (Conditioned) Ash Unloading Operation :
Wet (conditioned) ash unloading operation is carried-out in the following manner from
respective column / structure mounted ‘Local Wet Unloading Station’ (LWUS) located near
respective Rotary unloader.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 15 -
DCIPS Job No. 28P01

3.4.7.3 Followings are the sequence of operation.

 The Silo unloading permission ENABLE / OFF selector for the respective silo at SASP is
to be put on ENABLE position. This will allow to operate from local unloading station
before starting operation.
 Start silo-aeration blower (if not running) from SASP.
 Opening of silo aeration valves.
 Open truck to be placed at right position under rotary unloader.
 Rotary unloader is to be started from LWUS by actuation of respective START push
button.
 Conditioning water pump is to be started from SASP, if not running
 Selector actuator for the water valve is to be put at auto mode
 Ensure normal water pressure in conditioned water line. (Pl. See note given below).
 KGV above orifice feeder to be open manually.
 Open orifice feeder.

Opening of orifice feeder will be depending on following permissives.

 Running of rotary unloader
 Normal conditioned water pressure.

 Conditioned ash will be collected in open truck.

 Note : With positioning of orifice feeder open / close selector on ‘Open’ position, the
rotary unloader conditioning water valve opens first, if normal water pressure is
established, the orifice feeder opens. In case, orifice feeder does not open within a
preset time period from actuation of orifice feeder selector, the rotary unloader water
supply valve shall be closed automatically.

 For suspending the operation, first orifice feeder will be close followed by stopping of
rotary unloader, selecting off from LWUS.
 If the selector actuator of water valve is not put at auto position, the same can be
operated through open / close position of selector actuator.

3.4.7.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Rotary unloader orifice feeder FAWU*RF
2 Rotary unloader orifice feeder open feed back FAWU*RFLO
3 Rotary unloader manual KGV FAWU*KGVSO
3 Rotary unloader manual KGV open feed back FAWU*KGVLO
Read * for SILO 1 / 2 / 3 / 4 / 5
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 16 -
DCIPS Job No. 28P01

3.4.8 DRY ASH UNLOADING

3.4.8.1 ACTUATION & INDICATION :

 Silo unloading permission ENABLE / OFF lockable selector switch (one no. each for
silo 1 TO 5 ) : at SASP
 Silo unloading permission ‘Enable’ indication : at LDUS
 Start & stop push button for vent fan : at LDUS.
 On / Off selector & On indication for pulse jetting : at LDUS
 Forward, Reverse & Stop push button of rotary feeder : at LDUS
 Open / Close selector actuator for Knife gate isolation valve (KGV) : at LDUS
 Up, Down & stop push button for telescopic spout : at LDUS.
 Tanker level high indication : at LDUS.
 Rotary feeder tripped indication : at SASP
 Rotary feeder speed increase / decrease push button : at LDUS

Note : Strategic indication of equipment & drives installed at silo unloading floor, will be
provided on Silo Area System Panel (SASP) located at electrical room of Silo Utility
Building.
3.4.8.2 Operation : Dry Ash Unloading

Dry ash unloading operation is carried-out in the following manner from respective column
/ structure mounted ‘Local Dry Unloading Station’ (SULS).
3.4.8.3 Followings are the sequence of operation.

 The Silo unloading permission ENABLE / OFF selector for the respective silo at SASP
is to be put on ENABLE position. This will allow to operate from local unloading station
before starting operation.
 Start silo-aeration blower (if not running) from SASP.
 Opening of silo aeration valves.
 Tanker to be placed at right position under telescopic spout.
 Vent fan is to be started from LDUS by actuation of respective Start push button.
 Start pulse jetting from LDUS by actuating respective On / Off selector. High pressure
air jets ( FADU*PJON / FADU*PJONC Read * for SILO no. ) in filter bags through
actuation of a set of solenoid valves one after is provided.
 Telescopic spout is to be lowered up to the tanker by inching actuating through down
push button.
 Rotary feeder is to be started from LDUS by actuation of respective forward push
button
 Manual KGV above Rotary feeder to be open.
 Open cylinder operated knife gate valve (KGV) from LDUS.
 Dry ash will be collected in closed tanker.
 During ash filling of the closed tanker with the availability of feedback from tanker high
level switch, as sensed by the tanker level switch, cylinder operated knife gate valve
will automatically Closes and again automatically Opens if feedback is not present with
preset time delay.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 17 -
DCIPS Job No. 28P01

 After filling of the particular tanker is completed, the cylinder operated knife gate valve
selector is to be put at ‘Close’ position. Thereafter the telescopic spout is to be raised
by actuation of respective selector actuator at LDUS. This filling cycle shall be repeated
for other tankers.
Note : The Rotary feeder speed can be decreased or increased to get the tonnage variation in
dry unloading system.

3.4.8.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 Telescopic spout orifice feeder for Dry unloading FADU*RF
1 Telescopic spout Level switch for Dry unloading FADU*ALS
1 Telescopic spout with winch motor for Dry unloading FADU*RF
Telescopic spout Tanker Level switch for Dry unloading FADU*TSU
3 Telescopic spout vent filter pulse jetting FADU*PJON
4 Cylinder operated KGV above rotary feeder Dry unloading FADU*KGVSO
5 Cylinder operated KGV open feed back Dry unloading FADU*KGVLO
4 Cylinder operated KGV above rotary feeder Wet unloading FAMU*KGVSO
5 Cylinder operated KGV open feed back Wet unloading FAMU*KGVLO
7 Telescopic spout up position
8 Silo area Instrument air pressure switch SAIAPSL
st
Read 1 * as SILO 1 / 2 / 3 / 4 / 5
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CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 18 -
DCIPS Job No. 28P01

4.0.0 TABULAR CHART : INTERLOCKS, ACTUATORS, INDICATIONS, ALARMS

SL. EQUIPMENT LWUS / LDUS SASP HMI INDICATION

NO. IDENTIFICATION ACTUATOR INDICATOR ACTUATOR INDICATOR ALARM
WINDOW
1 SILO TRANSFER SILO LEVEL HI
LINE SILO (FOR
VALVE OPEN INDIVIDUAL
SILO HIGH / SILO )
LOW LEVEL
2 INSTRUMENT AIR IA IA PRESSURE
PRESSURE LOW
NORMAL
3 SILO AERATION START BLOWER ON BLOWER TRIP BLOWER ON
BLOWER PB (FOR
STOP PB INDIVIDUAL
SILO )
SILO OPEN FOR
AERATION S1 / S2 / S3 /
BLOWER F S4 / S5
S1 / S2 / S3 /
S4 / S5 OFF

4 SILO AERATION HEATER HEATER ON

BLOWER START HEATER ON TRIPPED
HEATER PB SUCTION (COMMON)
VALVE OPEN
AIR SUCTION
STOP PB TEMPERATU VALVE OPEN
RE
HIGH
DISCHARGE
DISCHARGE VALVE OPEN
VALVE OPEN
SUMP LEVEL DRAIN PUMP
SILO AREA START / PUMP ON ABNORMAL ON
5
DRAIN PUMP STOP
DRAIN PUMP
AUTO / SEAL WATER TRIPPED
MANUAL PRESSURE
SELECTOR NORMAL
6 ROTARY START PB WATER ROTARY ROTARY
UNLOADER PRESSURE UNLOADER ROTARY UNLOADER ON
NORMAL ON UNLOADER
MANUAL KGV TRIPPED
OPEN (COMMON)
STOP
PB WATER
PRESSURE
NORMAL
7 ORIFICE FEEDER OPEN / OPEN
FOR ROTARY CLOSE
UNLOADER
8 TELESCOPIC TELESCOPIC WINCH MOTOR
SPOUT SPOUT UP TRIPPED
& PB / DOWN TANKER
TANKER LVEL PB LEVEL HIGH
SWITCH
STOP PB
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CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 19 -
DCIPS Job No. 28P01

9 TELESCOPIC
TELESCOPIC START PB
SPOUT VENT
SPOUT VENT
FAN TRIPPED
FAN STOP PB
(COMMON)

10 SILO VENT SILO VENT

FILTER PULSE FILTER
JETTING PULSE
JETTING ON
11 TELESCOPIC TELESCOPIC
SPOUT VENT SPOUT VENT
FILTER PULSE FILTER
JETTING PULSE
JETTING ON

12 ROTARY FEEDER FW PB / REV ROTARY ROTARY DRY

FOR PB / STOP FEEDER ON FEEDER UNLOADING
TELESCOPIC PB TRIPPED ON
SPOUT SPEED
INCREASE /
DECREASE
13 KG VALVE FOR OPEN / KGV OPEN
TELESCOPIC CLOSE
SPOUT MANUAL KGV
OPEN
14 CONDITIONING START PB / PUMP ON PUMP TRIP PUMP ON
WATER PUMP STOP PB PUMP TRIP (COMMON)
(INDIVIDUAL)
15 CONDITIONING AUTO-OPEN OPEN /
WATER PUMP -CLOSE CLOSE
LEAK OFF VALVE
16 SILO WATER LEVEL HIGH / LEVEL
SUMP LEVEL LOW / ABNORMAL
TRANSMITTER DANGER
LOW
17 SILO WATER AUTO-OPEN OPEN /
SUMP MAKE UP -CLOSE CLOSE
VALVE
18 SILO WASH START PB / ON SILO WASH PUMP ON
WATER PUMP STOP PB WATER PUMP
TRIPPED
20 ROTARY AUTO /
UNLOADER OPEN /
WATER VALVE CLOSE
21 SILO VENT FAN ON / DPS
HIGH
22 SILO FLUIDISING OPEN /
VALVE CLOSE
23 SILO UNLOADING PERMISSION PERMISSIO
ENABLED N ENABLE /
DISABLE

NOTE:
1. COLOUR OF INDICATION FOR PURCHASER’S HMI.
RED / STEADY (S) : OPEN / ON / PR, LVL, TEMPARATURE, PROCESS NORMAL
RED / FLICKERING (F) : PR, LVL, TEMP, PROCESS ABNORMAL, DRIVE TRIP
GREEN / STEADY (S) : OFF / CLOSE
BLUE :DRIVE MOTOR SELECTED FOR DE-INTERLOCKED TRIAL OPERATION
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CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –D : SILO UNLOADING SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01 - 1A – D - 030
INDIRA GANDHI SUPER THERMAL POWER PROJECT- JHAJJAR NTPC Doc. No. 0330 – 162 – PVM – 0 - 030
Stage – 1 , Units # 1, # 2, # 3 ( 3 x 500 MW ) Rev. No. – 0
Ash Handling System - 20 -
DCIPS Job No. 28P01

2. DE-INTERLOCKED TRIAL OPERATION OF DRIVE MOTORS WILL BE SELECTED FROM A PASSWORD

PROTECTED PAGE OF HMI. IN THIS MODE ELECTRICAL PROTECTION OF MOTORS WILL BE IN OPERATIVE
MODE. HOWEVER, PROCESS INTERLOCK OF THE PARTICULAR DRIVE WILL BE BY-PASSED
3. HMI SCREENS HAVING POP-UP FOR ALL DRIVES SHOWING STARTING PERMISSIVES & EMERGENCY PUSH
BUTTON (EPB) STATUS.
4. DRIVE TRIP INDICATION AT LWUS WILL APPEAR IF ROTARY UNLOADER TRIPS & DRIVE TRIP INDICATION AT
LDUS WILL APPEAR IF ROTARY FEEDER / VENT FAN / WINCH MOTOR TRIPS
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -1-
DCIPS Job No. 28P01
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -2-
DCIPS Job No. 28P01

INDEX

SL. NO. DESCRIPTION PAGE NO.

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY 5
2.0.0 CONTROL DEVICES & LOCATION 5
3.0.0 INSTRUMENT AIR SYSTEM : OPERATION / CONTROL PHILOSOPHY 6

4.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS 13

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -3-
DCIPS Job No. 28P01

Control philosophy of entire process has been divided in following manner.

1. PART A: Bottom ash & Coarse ash evacuation system

2. PART B: Fly ash evacuation system
3. PART C: Water & slurry system
4. PART D: Silo unloading system
5. PART E: Instrument air system
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -4-
DCIPS Job No. 28P01

In this part we shall explain the PART E i.e. Instrument air system.
Operation & Control of equipment related to silo unloading system have been dealt
here sequentially. Following are the equipments associated with the instrument air
system.
1. Instrument Air Compressors
2. Air Drying Plants

Entire documentation has been created in following manner.

1.0 For equipment:
1.1 Location of Hardware actuator & their selection procedure.
1.2 Operational control with associated starting & running permissives.
1.3 Operational status, Signal, message etc.

2.0 For System:

2.1 Sequential operation
3.2 System flow chart

Associated documents:

1. This write-up shall be read in conjunction with :

 Single line flow diagram: [DCIPS Drg. # 28P01-1D-M-105]

[NTPC Drg. # 0330-162-PVM-L-005]

 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -5-
DCIPS Job No. 28P01

1.0.0 OVERALL SYSTEM ARRANGEMENT & CONTROL PHILOSOPHY

The System
1.1.0 The Instrument Air System comprises Instrument Air Compressors (IAC), air drying
plants (ADP) and Air receiver along with all necessary instruments and accessories to
cater to the instrument air requirement for operation of various pneumatic equipment
under the ash handling system including bag filter pulse jetting & silo system.
1.2.0 Two nos instrument air compressors (one no working and one no stand by) and two sets
(one no working and one no stand by) of Air drying plants are provided for each unit i.e.
Six nos instrument air compressors and six sets of Air drying plants for Units # 1, 2 & 3.
Besides instrument air requirement for unit wise devices/equipment, instrument air
requirement for common water & slurry system as well as these I.A compressors also
provides silos (Main silo and HCSD silo) area devices/equipments. These Six nos
instrument air compressor and six sets of Air drying plant are located in the equipment
building. Six nos. Air receivers are placed adjacent to this building.
2.0.0 CONTROL DEVICES & LOCATION

2.1.0 THE PROCESS CONTROL:

Logic relating to remote interlocked operation of the ash handling system will be
executed through PLC.

2.2.0 CONTROL EQUIPMENT:

All drive motors, actuator & pneumatic valves will be controlled from respective HMI with
starting interlocks & permissives in remote mode

2.3.0 SIGNALS/ INDICATION:

Location wise details of actuators, indications and anunciations have been furnished in
the annexed table titled “TABULAR CHART: ACTUATORS, INDICATIONS, ALARMS at
the end of document.
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CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -6-
DCIPS Job No. 28P01

3.0.0 INSTRUMENT AIR SYSTEM :OPERATION / CONTROL PHILOSOPHY

3.1.0 IDENTIFICATION & OPERATION OF DRIVES FOR INSTRUMENT AIR DISTRIBUTION SYSTEM

SL. DRIVE NO OF DRIVES TO WORK

NO. DESIGNATION TAG FOR THREE UNITS REMARKS
IDENTIFICATION
IAC# A
IAC# B
Instrument Air IAC# C
1 3
Compressor IAC# D
IAC# E
IAC# F
ADP RB# A1 & A2
ADP RB# B1 & B2
Reactivation Blower ADP RB# C1 & C2 3
2
for Air Drying Plant ADP RB# D1 & D2
ADP RB# E1 & E2
ADP RB# F1 & F2
ADP H# A1 & A2
ADP H# A1 & A2
Heater for Air Drying ADP H# A1 & A2 3
3
Plant ADP H# A1 & A2
ADP H# A1 & A2
ADP H# A1 & A2

3.2.0 INSTRUMENT AIR COMPRESSOR:

3.2.1 SELECTOR : Auto standby – A / Auto standby – B / Auto standby – C / Auto
standby – D/ Auto standby – E/ Auto standby – F / Manual: at HMI
ACTUATION : START / STOP pushbutton for all the compressors : at HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -7-
DCIPS Job No. 28P01

STARTING PERMISSIVE : INSTRUMENT AIR COMPRESSOR

COOLING WATER VALVE OPENS WITH START COMMAND

A PRESET TIME FROMOPENING OF COOLING WATER VALVE

AIR TEMP NORMAL AT INTER COOLER
COMPRESSOR IS IN UNLOAD CONDITION
COOLING WATER PRESSURE AT INLET OF CYLINDER JACKET IS NORMAL
* RUNNING INSTRUMENT AIR COMPRESSOR IS TRIPPED
(FOR IA COMPRESSOR IN AUTO WAITING MODE)
DIFFERENTIAL PRESSURE ACROSS SUCTION FILTER IS NORMAL

TRIP CONDITIONS

COOLING WATER PRESSURE AT INLET IS LOW FOR PRESET DURATION

LUBRICATING OIL PRESSURE BECOMES LOWFOR PRESET DURATION
CYLINDER JACKET COOLING WATER PRESSURE HIGH
AIR TEMPARATURE AT INTERCOLER IS HIGH FOR PRESET TIME DURATION
DIFFERENTIAL PRESSURE ACROSS SUCTION FILTER IS HIGH

3.2.2 Associated Control Item Nomenclature

SL.
ITEM TAG
NO.
1. COOLING WATER LINE SOLENOID OPERATED VALVE IAC*CWSO
2. COOLING WATER LINE PRESSURE SWITCH IAC*CWPSL
3. COOLING WATER PRESSURE SWITCH AT INLET TO CYLINDER JACKET IAC*CYCWPSH
4. LUB OIL PRESSURE SWITCH IAC*LOPSL
5. AIR TEMPERATURE ELEMENT AT INTERCOOLER IAC*ICATRTD
6. LOAD – UNLOAD SOLENOID IAC*LU1SO
7. LOAD – UNLOAD SOLENOID IAC*LU2SO
8. DIFFERENTIAL PRESSURE SWITCH ACROSS SUCTION FILTER IAC*DPS
9. PRESSURE TRANSMITTER AT DISCHARGE OF AIR RECEIVER IACHDRPT
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -8-
DCIPS Job No. 28P01

10. DEW POINT METER AFTER AIR DRYING UNIT IAC*DP

11. AUTO DRAIN TRAP AT INTER COOLER IAC*ADT1
12. AUTO DRAIN TRAP AT AFTER COOLER IAC*ADT2
Read * for IAC A / B / C / D / E / F

3.2.3 Operation:
3.2.3.1 Out of six (06) Instrument air compressors provided for three units, three nos. would be
normally working and one will be as standby in Auto mode. However in manual mode,
all the compressors can be operated simultaneously in parallel. In auto mode of
operation, the standby compressor will take start in the event of tripping of the running
compressor subject to availability of all starting permissives non-availability of trip
conditions.
3.2.3.2 At first operator will start the selected compressor in manual mode, then keep the
selector in auto standby mode for the compressor to be brought in auto standby mode.

3.2.3.3 With actuation of start command, at first solenoid-operated valve on cooling water
supply line will automatically open and subsequently cooling water supply line pressure
will be established. The cooling water source is provided from purchaser’s cooling water
header.
3.2.3.4 After starting, the compressor will continue to run if the lubricating oil pressure becomes
normal within a preset time.
3.2.3.5 The compressor will always remain unloaded during starting. It will start getting loaded
after a preset time (adjustable) form the starting of the motor. Under “Load-unload”
regulation, the drive motor will run continuously.
3.2.3.6 When the air-receiver pressure goes below the lower set value sensed by the pressure
transmitter, a solenoid valve on the pulse air line (from air-receiver) gets energized and
the pulse air supply to the compressor cylinder suction valves is cut-off. The
compressor thereby runs at loaded condition.

3.2.3.7 Similarly when the air-receiver pressure reaches the higher set value sensed by the
same pressure transmitter, the solenoid valve gets de-energized and the pulse air
supply (from air receiver) keeps the compressor cylinder suction valves open. The
compressor thereby runs at unloaded condition.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System -9-
DCIPS Job No. 28P01

3.2.3.8 Loading and unloading process shall be in 3 steps.

 For example please consider when air receiver reaches at or above maximum set
pressure say P2 the compressor shall run at 0% loading &
 when it reaches at minimum set pressure say P1 the compressor shall run at 100%
loading where as
 When it reaches at a set pressure in between P1&P2 the compressor shall run at
50% loading.
This shall be further detailed in manufacturer’s document.
3.2.3.9 In auto mode operation, if any one compressor trips, then compressor kept in stand by
mode will start automatically subject to availability of all starting permissives. Under this
condition, manual intervention is required for rectification of tripped compressor. Once
tripped compressor is ready for operation, one should change an Auto Standby-
selection is put on that compressor and this compressor shall become Auto stand by
compressor.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]

Keeping selection in manual position, any or all the four compressors can be
started through their respective START push button on HMI.

3.2.3.10 To protect compressor against over-pressurization in respect to upper limit of design

pressure of compressor jacket, a pressure-reducing device (PRD) is provided on cooling
water inlet line to HP & LP cylinder jacket. This PRD will regulate the cooling water
pressure to inlet of cylinder jacket so that the pressure remains within permissible
design value. But in case of eventual rise of this pressure as sensed by the High-
pressure switch on cooling water line, the inlet solenoid valve will close automatically to
disconnect compressor from water source resulting in tripping of the compressor.

3.2.3.11 Solenoid operated auto drain trap with in built cyclic timer will be provided with inter
cooler and after cooler for periodic draining of accumulated water.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 10 -
DCIPS Job No. 28P01

3.3.0 AIR DRYING PLANT:

3.3.1 SELECTOR : Blower Selection of each ADP

Blower1 / Blower2 : at HMI
ACTUATION : START / STOP pushbutton for all the ADP : at HMI
EMERGENCY STOP : Emergency STOP push button
(One no for each motor) : on Local PB station.

3.3.2 There are six (06) nos. Regenerative heated type blower reactivated air drying plant
(ADP) for all the units, out of which three nos. ADP are in operation during running of
three nos. instrument air compressors. One ADP is dedicated to one IA compressor.

3.3.3 Functional Write up on Heated Type Air Dryer

The advantage of this dryer is no purge loss and air is available for use continuously.
Please refer the P&I diagram along with this write-up for better understanding. The
Principle of Operation is as Follows:-
3.3.3.1 (A) Tower 1 Drying & Tower 2 regenerating: - (0 – 8 Hrs.)

0- 8 hours - The saturated air flows through the pre-filter (3), the solid particles are
removed, enters into the drying tower 1 through the main three way valve (13) and
leaves through the top left check valve (36) and through the after filter (4) to utility.
0 – 10 min – The right side de-pressurization valve (38), opens and gradually vents out
the pressurized air from tower 2 to atmosphere through the silencer. This operation
avoids sudden exhaust of the tower and safe guards the desiccant from attrition losses.
10 min – 7 hr 20 min - The blower (07) starts and the air from the blower enters into the
heating chamber (05), gets heated to 180 Deg.C leaves the heater, enters through the
bottom right side (36) check valve into the tower 2 from top to bottom, regenerates the
saturated desiccant and leaves through the right side regeneration valve (15). The
regeneration valve is in open condition from 10 min to 7-hr 40 min. The heater is in
operation from 12 min to 5-hr 12 min. During this period the temperature controller
controls the heating temperature from 175 to 180 Deg.C.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 11 -
DCIPS Job No. 28P01

7-hr 20 min – 8 hr – The re-pressurization valve (17) opens and feeds dry air from tower
1 to tower 2. The first 20 minutes of 40 minutes, the dry air purges out the tower 2 and
leaves through right side regeneration valve (15). During the second 20 minutes, the
regeneration valve (15) closes and the dry air re-pressurizes the tower 2 to full operating
pressure.
Summary of valves & other critical components Conditions:-

- 3 way main valve - 0 – 8 hrs.in ‘De-energized’

- Regeneration Valve (left side) - 0 – 8 hr 10 min ‘De-energized’
- Regeneration Valve (right side) - 10 min – 7 hr 40 min ‘energized’.
- Heater - 12 min – 5 hr 12 min ‘energized’
- Blower - 10 min – 7 hr 20 min ‘energized’
- De-pressurization Valve (left side) - 0 – 8 hr ‘De-energized’
- De-pressurization Valve (rt. side) - 0 – 10 min ‘energized’
- Re-pressurization Valve - 7 hr 20 min – 8 hr ‘energized’
(B) Tower 2 Drying & Tower 1 regenerating: - (8 – 16 Hrs.)
8- 16 hours - The unsaturated air flows through the pre-filter (3), the solid particles are
removed, enters into the drying tower 2 through the main three way valve (13) and
leaves through the top right check valve (36) and through the after filter (4) to utility.
8 hr – 8-hr 10 min – The left side de-pressurization valve (38), opens and gradually
vents out the pressurized air from tower 1 to atmosphere through the silencer. This
operation avoids sudden exhaust of the tower and safe guard the desiccant from
attrition losses.

8 hr 10 min – 15 hr 20 min - The blower (07) starts and the air from the blower enters
into the heating chamber (05), gets heated to 180 Deg.C leaves the heater, enters
through the bottom left side (36) check valve into the tower 1 from top to bottom,
regenerates the saturated desiccant and leaves through the left side regeneration valve
(15). The regeneration valve is in open condition from 8-hr10 min to 15-hr 40 min. The
heater is in operation from 8-hr12 min to 13-hr 12 min. During this period the
temperature controller controls the heating temperature from 175 to 180 Deg.C.

15-hr 20 min – 16 hr – The re-pressurization valve (17) opens and feeds dry air from
tower 2 to tower 1. The first 20 minutes of 40 minutes, the dry air purges out the tower 1
and leaves through right side regeneration valve (15). During the second 20 minutes,
the regeneration valve (15) closes and the dry air re-pressurizes the tower 1 to full
operating pressure.
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 12 -
DCIPS Job No. 28P01

Summary of valves & other critical components Conditions:-

- 3 way main valve - 8 – 16 hrs.in ‘energized’
- Regeneration Valve (left side) - 8 hr10 min – 15hr40min ‘energized’
- Regeneration Valve (right side) - 8hr – 16 hr ‘De-energized’.
- Heater - 8hr12 min – 13 hr 12 min ‘energized’
- Blower - 8hr10 min – 15 hr 20 min ‘energized’
- De-pressurization Valve (left side) - 8hr – 8hr10min ‘energized’
- De-pressurization Valve (rt. side) - 8hr – 16hr ‘De-energized’
- Re-pressurization Valve - 15 hr 20 min – 16 hr ‘energized’

3.2.4 Associated Control Item Nomenclature

SL. NO. ITEM TAG
1 3-Way automatic inlet changeover valve ADP*ICVSO
2 2-Way automatic exhaust changeover valve ADP*ECV*SO
3 2-Way depressurization valve ADP*DPV*SO
4 2-Way re-pressurization valve ADP*RPVSO
5 Pre-filter auto drain trap ADP*ADT*SO
6 Regeneration line flow switch ADP*FS
7 Temperature controller ADP*TIC
8 Discharge pressure switch ADP*PSL
Read 1 * for ADP A / B / C / D / E / F and 2nd * for valve 1 / 2
st
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 13 -
DCIPS Job No. 28P01

4.0.0 TABULAR CHART : ACTUATORS, INDICATIONS, ALARMS

SL. EQUIPMENT CONTROL ROOM REMARKS

NO. IDENTIFICATION PURCHASER’S PURCHASER’S ALARM
HMI SCREEN HMI SCREEN LOG
ACTUATOR INDICATOR
1 INSTRUMENT AIR START ON INSTRUMENT AIR
COMPRESSOR STOP OFF COMPRESSOR
AUTO STANDBY-A / TRIP TRIPPED
AUTO STANDBY-B / AUTO / MANUAL IAC AUTO STARTED
AUTO STANDBY-C / STATUS
AUTO STANDBY-D /
AUTO STANDBY-E / IAC AUTO STARTED
AUTO STANDBY-F /
MANUAL /
SELECTION FACILITY

COOLING WATER COOLING WATER

PRESSURE PRESSURE LOW
COOLING WATER COOLING WATER
PRESSURE AT INLET PRESSURE HIGH AT
TO CYLINDER INLET TO CYLINDER
JACKET JACKET
LUBRICATING OIL LUBRICATING OIL
PRESSURE LOW PRESSURE LOW
AIR TEMPERATURE AIR TEMPERATURE
AT INTERCOOLER AT INTERCOOLER
OUTLET OUTLET HIGH

DIFFERENTIAL DIFFERENTIAL
PRESSURE ACROSS PRESSURE ACROSS
SUCTION FILTER SUCTION FILTER
HIGH
AIR PRESSURE AT AIR PRESSURE LOW
AIR RECEIVER AT AIR REVEIVER
OUTLET OUTLET
IAC AUTO STARTED
2 AIR DRYING PLANT START / STOP DISCHARGE
PRESSURE LOW
3 ADP BLOWER START ON ADP BLOWER
TRIPPED
STOP OFF
BLOWER-1 / TRIP
BLOWER-2
SELECTION FACILITY
4 ADP HEATER START ON ADP HEATER
TRIPPED ON HIGH
TEMPERATURE
STOP OFF ADP
REGENERATION AIR
TEMPERATURE
HIGH
ADP
REGENERATION AIR
FLOW LOW
 DC INDUSTRIAL PLANT SERVICES PVT. LTD

CONTROL WRITE-UP : PLANT CONTROL, OPERATION & MONITORING

PART –E : INSTRUMENT AIR SYSTEM
Aravali Power Company Private Limited. DCIPS Doc. No. 28P01-1A-D-030
INDIRA GANDHI SUPER THERMAL POWER PROJECT - JHAJJAR NTPC Doc. No. 0330-162-PVM-O-030
STAGE – 1, Unit # 1, 2 & 3 (3 x 500 MW ) Rev. No. – 0
Ash Handling System - 14 -
DCIPS Job No. 28P01

SL. EQUIPMENT CONTROL ROOM REMARKS

NO. IDENTIFICATION PURCHASER’S PURCHASER’S ALARM
HMI SCREEN HMI SCREEN LOG
ACTUATOR INDICATOR
ADP CHANGEOVER
FAILURE

NOTE:

1. COLOUR OF INDICATION FOR PURCHASER’S HMI.

RED / STEADY (S) : OPEN / ON / PR, LVL, TEMPARATURE, PROCESS NORMAL

RED / FLICKERING (F) : PR, LVL, TEMP, PROCESS ABNORMAL, DRIVE TRIP
GREEN / STEADY (S) : OFF / CLOSE
BLUE :DRIVE MOTOR SELECTED FOR DE-INTERLOCKED TRIAL
OPERATION
2. DE-INTERLOCKED TRIAL OPERATION OF DRIVE MOTORS WILL BE SELECTED FROM A
PASSWORD PROTECTED PAGE OF HMI. IN THIS MODE ELECTRICAL PROTECTION OF MOTORS
WILL BE IN OPERATIVE MODE. HOWEVER, PROCESS INTERLOCK OF THE PARTICULAR DRIVE
WILL BE BY-PASSED.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

Document title:
Operating and Control Philosophy

Project name : NTPC Jhajjar Aravali ash handling

Customer name : Aravali Power Company Private Limited

Indira Ghandi Super Thermal Power Project – Jhajjar
Stage – 1, Units # 1,2&3 (3 x 500 MW)
Ash handling system

Consultant :

NTPC Limited

Main Contractor :

DC Industrial Plant Services PVT. LTD

Vendor :

Weir Minerals Netherlands b.v.

Project number: 201124

Location : Jhajjar, state of Haryana, India

03 220609 Revised acc. NTPC comments ETV PGT

02 200309 Revised acc. NTPC comments ETV PGT
01 101008 Revised acc. DCIPS comments ETV PGT
00 250908 Initial issue ETV PGT
Rev. Date Description of requisition issue Made by / prepared Checked by / approved

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 1 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

Content

1 Introduction 3
2 Associated Documents 3
3 List of abbreviations 3
4 System Description 4
4.1 General 4
4.2 Extraction, dosing, weighing and mixing of fly ash 5
4.3 AMT 5
4.4 Slurry control loop 5
4.5 Booster Pumps 6
4.6 Suction Strainers 6
4.7 Mainline GEHO Pumps 7
4.7.1 Air vessel, suction 7
4.7.2 Pulsation damper, discharge 8
4.8 Pipeline 8
5 System Operation and Control 10
5.1 General 10
5.2 System Start Up (R3) 10
5.3 Fly ash dosing, weighing and mixing (R3) 11
5.4 AMT operation and level control (R3) 12
5.5 Slurry control loop (R3) 13
5.6 Suction Pressure Monitoring (R3) 14
5.7 Mainline Pump Operation 14
5.7.1 Local/remote mode 14
5.7.2 Overpressure protection 15
5.7.3 Mainline pump tripping 15
5.8 Pipeline Operation 16
5.8.1 Introduction 16
5.8.2 Monitoring pump discharge pressure 16
5.9 Slurry Dilution Sequence 17
5.10 Normal System Stop 17
5.11 Emergency System Stop 18
5.12 Deblocking 18
6 System control procedures (R3) 19
6.1 Automatic system start up 19
6.2 Automatic system stop 21
6.3 Slurry clearing 22
6.4 Loop controls and interlocks 23

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 2 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

1 Introduction
Aravali Power Company Private Limited (a joint venture between NTPC, HPGCL and IPGCL) are in
the process of designing and erecting a 1500 MW coal fired power plant. The plant will consist of
three (3) boilers of 500 MW each. The dry fly ash generated by the plant (ESP ash and primary and
secondary air pre heater ash) will be collected in five ash silos. For mixing and transportation of ash
slurry to the storage area a High Concentrated Slurry Disposal (HCSD) system will be erected.

The system will comprise of five (5) mainline piston diaphragm pumps and five main pipelines to the
storage area. Three pumps will be operating while two will serve as standby pumps.

The intention of this document is to serve as a basis for the system design, development of system
control software and for the creation of required operator manuals.

2 Associated Documents
This document must be read in conjunction with:
Basic system P&ID, document number 809.201249.051, generated by WMN (NTPC document 0330-
162-PVM-L-010).
Design basis, document number 809.201249.052, generated by WMN (NTPC document 0330-162-
PVM-U-042).
Piping basic design, document number 809.201249.053, generated by WMN (NTPC document 0330-
162-PVM-041)
P&ID of GEHO pump, document number 814.201249.03, generated by WMN (NTPC document
0330-162-PVM-L-111).
Control description of GEHO pump; document number 814.201249.20, generated by WMN (NTPC
document 0330-162-PVM-U-046).
Slurry Control Unit manual, document number 809.200000.409, generated by WMN (NTPC
document 0330-162-PVM-U-045).

3 List of abbreviations
WMN: Weir Minerals Netherlands b.v.
DCIPS: D.C. Industrial Plant Services PVT. LTD.
AMT: Agitated Mixing Tank
HCSD: High Concentrated Slurry Disposal
SCU: Slurry Control Unit

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 3 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

4 System Description

4.1 General
Dry fly ash from three (3) boilers will be stored in five (5) silos. Underneath each silo one (1) ash slurry
mixing and pumping line will be located.

From the silos it will be dosed to ash conditioners in a controlled rate where also a small amount of
water will be added, thus minimising dust production when the conditioned ash is discharged in the
agitated mixing tank (AMT). In the AMT the remainder of the water is added to the ash and mixed to
homogeneous slurry by the vertical mixer. A control loop is installed on the AMT to verify the slurry
quality by means of pipe pressure drop and density. The SCU PLC will monitor the quality of the
slurry and initiate required adjustments to the slurry composition through the main system controls.

The high-density slurry is taken from the AMT and fed to the connected mainline pump for transportation
to the storage area.

The proposed high-density slurry system can be divided into two major sections. First the slurry
preparation system:
• extraction, dosing and weighing of fly ash from the silos
• conditioning of fly ash and water in the ash conditioners
• mixing and homogenisation of high concentrated ash slurry in AMT’s

Second the slurry transportation system:

• booster pumps
• GEHO piston diaphragm pumps
• main pipelines
• storage area for storing high concentrated slurry

In general the system will comprise following main components:

ten (10) fly ash dosing and weighing systems, two for each fly ash silo
ten (10) ash conditioners, two located under each dosing and weighing system
five (5) AMT’s equipped with vertical mixers.
five (5) water dosing lines, one for each AMT
five (5) slurry control loops, one for each AMT
five (5) slurry booster pumps
five (5) suction strainers
five (5) mainline GEHO piston diaphragm slurry pumps, three (3) operating and two (2) stand by
five (5) slurry transport pipelines with distribution system on storage area

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 4 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

The project goal is to generate a constant quality of high concentrated ash slurry. As a result of this the
user will have a developing dry stack on the storage site (R3).

4.2 Extraction, dosing, weighing and mixing of fly ash

It is of major importance that the fly ash flow from the silo will be constant and free of surges. Each fly
ash silo is equipped with two (2) fly ash dosing, weighing and conditioner units, which will be in
simultaneous operation. Fly ash is extracted and dosed at a controlled rate to the conditioners by
rotary feeders and mass flow meters. The fly ash is gravity fed to the constant speed conditioners for
pre wetting the fly ash with a controlled amount of water, thus creating a moisturised fly ash, free of
lumps. The moisturised fly ash is gravity fed into the below located AMT.

4.3 AMT
The AMT’s duty is to:
• mix the moist fly ash with water to a homogeneous slurry
• optimise the slurry consistency
• keep the ash slurry in a homogeneous suspension
• serve as buffer capacity for the pumps.

Therefore the volume of the tank is (R3) such that all system variances can be levelled in this AMT.
The moist fly ash falls through a water curtain on top of the AMT. The water curtain is generated by
four (4) nozzles with an upstream water feed line. The water feed line will be equipped with a flow
control valve, flow meter and other required instruments to accurately control the water flow. In
addition it is required to equip the AMT with a minimum of:
• three (3) blade level vertical mixer
• baffle plates
• flush water inlet connection and automatically controlled valve for tank flushing
• slurry control loop and SCU
• level transmitter
• isolation valve in the suction line to each booster pump
• drain valve underneath the tank for drainage of the tank
• overflow line directed towards the station sump

4.4 Slurry control loop

The slurry control loop PLC will monitor control loop differential pressure and slurry density and will
provide feed back information for the system controls. The slurry control loop will be equipped with:
• shut off valve in the suction to the hose pump
• constant speed drive hose pump
• pulsation damper with compressed air connection
• water flush connection with shut off valve in the suction and discharge line of the hose pump
• two (2) pressure transmitters
• pressure indicator

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 5 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

• density meter

The hose pump will take suction from the AMT lower section and will feed the slurry to the control
loop. A strainer mesh will have to be provided (R3) on the inside of the tank at the inlet of the hose
pump to prevent foreign materials from entering the pump and damage the rubber hose. Downstream
the hose pump an air over slurry air damper vessel will be installed. The control loop will continue as
a circular horizontal section of approximately 10-m length pipe. One pressure transmitter is located at
the beginning of this section and the second pressure transmitter is located at the end of this section.
Following the horizontal section the control loop will change to vertical where a density meter will be
installed. The control loop will end at the top of the AMT discharging back into the tank.

4.5 Booster Pumps (R3)

The booster pumps take suction directly from the AMT’s and will feed and provide suction pressure to
the mainline GEHO pumps. The suction line to the booster pump will be as short as possible. The
booster pumps will operate at fixed capacity/speed, generating sufficient suction pressure and flow for
the mainline pump. Each AMT will be equipped with one booster pump.
The booster pump will be equipped with a gland type seal which requires seal water for gland cooling.
The seal water line to the booster pump will be equipped with a seal water flow switch as a minimum,
to prevent the booster pump from running without seal water flow available. In order to control the
usage of seal water a manual operated ball valve will be used as a variable restriction. The seal water
pressure required should be 0.3 bar above the maximum head as generated by the booster pump.
However, it should be monitored that not too much water is passing the gland seal and thus diluting
the passing slurry.

An actuated flush water valve will be provided in the suction of the booster pump. This will enable the
system or operator to quickly respond in the event of a sudden pressure raise in the discharge line. It
will also be used as flush water inlet for priming the system and pump and for preparing the system
and pump for a stop or maintenance after running on slurry.

In the discharge line of each booster pump a flow meter will be installed. In addition a nucleonic style
density meter will be installed on the outside of the piping.

4.6 Suction Strainers

An in-line strainer will be installed in the suction piping of each mainline pump. This strainer will prevent
oversized ash lumps, debris, scale pieces and foreign material from entering the mainline pump and
avoids possible risk of blocking the pump inlet or outlet non-return valves or damaging the diaphragms.
The strainers are equipped with a flush water connection and drain valve, so back flushing and cleaning
of the strainer can be done without removal of the strainer basket.
Clogging of the filter will cause the mainline pump suction pressure to drop. The suction pressure is
monitored at the suction air vessel.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 6 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

A by pass piping arrangement will be provided (R3). When the suction pressure of the GEHO pump will
drop below the minimum level, the system can switch to the by pass line for a short period without
stopping the pump. During this period the strainer can be flushed or removed for maintenance (R3).
It should be noted that such an in-line screen is very limited in storing capacity and it can only safeguard
against a low amount of incoming oversized material. Its function is to only monitor possible release of
scale from the mixing tank and foreign materials.

The GEHO pump minimum suction pressure (NPSHr) is 2.2 bar gauge on slurry. In case the suction
pressure will come below this value the GEHO pump plc will give an alarm, but will continue to operate. It
is expected that the pressure drop over a clean strainer will be 0.1-0.2 bar. The pressure drop over a
clogged strainer is expected to be 1.0 bar (R3).

4.7 Mainline GEHO Pumps

As mainline pumps five (5) GEHO duplex double–acting crankshaft driven piston diaphragm pumps size
ZPM 800 will be installed. Each pump is designed for a normal operating flow of 198 m³/h (based on the
specified design concentration of 60%) and a maximum effective flow of 225 m3/h against a maximum
discharge pressure of 47 bar. Each GEHO pump is provided with two air over slurry type pressure vessel
for the suction side of the pump and one nitrogen charged pulsation damper at the discharge side of the
pump. The air vessel provides a pulsation free operation for the booster pump, the discharge damper
serves to reduce the pressure pulsations in the discharge line. All diaphragm chambers are protected
against over-pressurisation by an integral pressure relief valve. The instrument air supply line will be
equipped with a pressure switch. When instrument air pressure will drop under the set value this
pressure switch will initiate the GEHO pump to stop.

4.7.1 Air vessel, suction

Two air over slurry suction vessels are provided at each mainline pump suction lines to protect the
booster pump from the pulsating flow characteristics of the mainline pump. The vessels are connected by
a common line. The air vessels do not require level control. The vessels will be equipped with:
pressure gauge (on one of the vessels)
pressure transmitter (on one of the vessels)
emergency air supply connection (not to be permanently connected to the compressed air grid)

A suction air vessel functions on the basis of having a confined air volume inside a vessel. When the
pressure increases, the air volume will decrease and vice versa. In this way it serves as a buffer opposite
to the pulsating flow characteristic generated by the pump on the suction side (R3).

The air supply connection at the top of one of the vessels allows for hand operated filling of compressed
air, in order to allow lowering the slurry level if air were lost.

The pressure transmitter enables continuous monitoring of the suction pressure. Low suction pressure
will trigger an alarm.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 7 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

4.7.2 Pulsation damper, discharge

One pulsation damper is provided at the discharge manifold to protect the discharge line from the
pulsating flow characteristics generated by the mainline pump. The pulsation damper will have following
equipment:
high-pressure nitrogen connection
pressure gauge
pressure transmitter

The nitrogen supply connection at the top of the damper allows for hand operated pre-charging of
nitrogen.

A pulsation damper functions in general on the same basis as a suction air vessel with these differences
that in this case nitrogen is used a gas, it is pre-charged, and there is a rubber diaphragm separating the
nitrogen from the slurry (R3).

The pressure transmitter will enable continuous monitoring of the discharge pressure. High discharge
pressure (49 bar) will trigger an alarm. Too high discharge pressure (52 bar) will cause an automatic
shutdown of the electric motor of the GEHO pump.

Nitrogen will have to be pre-charged at 60-70% of the expected operating pressure. In case it is
expected that the system operating pressure will change, for example due to a change in discharge
point, the pre-charge pressure needs to be adapted on basis of the expected operating pressure. This
can only be done before the system and pump is started. During commissioning the pre-charge level will
be determined (R3).

4.8 Pipeline
The discharge pipelines can carry the full flow generated by each pump. The proposed line is an eight (8)
inch nominal diameter and will have a minimum design pressure of 56 bar, this being equal to the pump
relief valve set pressure.

Each pipeline is dedicated to one GEHO pump. No direct interconnections are planned at this moment.
Three (3) pumps are in operation while two are stand by. It is advised to provide interconnection of a
stand by GEHO pump with a slurry pipeline that is in operation for emergency purposes, on the
discharge as well as the suction side of the pumps (R3).

In each GEHO discharge line a pipeline isolation valve will be installed. It is also required to install a drain
valve downstream each GEHO pump in the discharge line, just upstream the isolation valve. This drain
valve will be used for priming of the pump (R3) and to drain the system from water or slurry, prior to
maintenance.

The maximum allowable time at which the slurry can remain idle inside the pipeline will be depending
on the homogeneity of the slurry. The tender specifies a time period of 12 hours. Hands on experience

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 8 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

will dictate the maximum period allowable for the pipeline to be in idle mode on slurry (R3) otherwise the
pipeline has to be completely flushed with clean water. After flushing, the pump will be stopped and there
will be no pressure left in this pipe, except for some minor static head.

Whenever the pipeline at the disposal will have to split into two directions, the use of spool pieces is
required in order to avoid dead pockets which can be blocked by settled or solidified slurry. The
maximum pumping distance equals approximately 3200 meters.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 9 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

5 System Operation and Control

5.1 General
As already indicated in the Introduction, this document is intended to function as a basis for the system
design, development of system control software and for the creation of required operator manuals.

The system is designed to operate semi-automatic by controlling the equipment and devices from the
control room. However, the operation of spool pieces and most valves is not automated. Conditions that
might cause a major system shutdown are automated to the extend possible as are start-up, operation
and shutdown in accordance with predetermined sequences.

The mainline pumps are of such complexity that they require dedicated controls. Therefore each mainline
pump will be controlled by a dedicated PLC. Relevant signals and data will be made available to the
main control system. The main system control will monitor, control and execute all relevant actions. It will
also generate all information required for the operator to run the system adequately, by means of a
graphical user interface. System component status, system settings and system alarms can be derived
from this screen.

It is required to install the pump control cabinet and touch screen as close to the pump as possible,
preferably at the same side and near to the location of the auxiliary motors and propelling liquid filling and
relief valves.

Pump signals can be transferred to the main system PLC through hard wired signals.

In addition to the five (5) GEHO pump plc’s there will be five (5) SCU plc’s. The SCU is a dedicated unit
for controlling the slurry quality inside the AMT. SCU signals will also be transferred to the main system
PLC through hard wired signals (R3).

5.2 System Start Up (R3)

When initially starting up or when the system in not filled with water after maintenance, the piping
system up the GEHO pump discharge manifold has to be filled with water. Filling proceeds through
opening of the flush valve in the booster pump suction while the AMT outlet valve and main discharge
line isolation valve are closed. The system is fully filled if an air free water flow is drained from the
flushing drain in the discharge of the mainline pump. After the system is properly filled the mainline
drain valve and the flush water inlet valve are closed.

When a GEHO pump is stopped after running on slurry, at least the system up to and including the
pump discharge header will have to be flushed with water. Slurry can remain idle inside the main
pipeline, depending on the time at which it can still be restarted without operational problems.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 10 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
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NTPC Jhajjar Aravali ash handling

For a normal start-up after the system has been operated and stopped previously, the entire
discharge line will either be filled with slurry or with water.

The operator will set the fly ash capacity and solids concentration by hand (numerical input) at the
main system plc (MPLC). Based on these settings the MPLC will calculate quantity of water to be
added to the fly ash and the main pump speed. Make up water will be added at two locations: at the
ash conditioners and the AMT. The water added to the ash conditioners will merely have the purpose
to pre wet the fly ash and avoid dusting. It is expected that 20% of the water balance will be added in
the ash conditioners, of which two (2) will be working for each line. The remainder of the water will be
added in the AMT, where there will be two (2) inlets, one for each conditioner outlet. The MPLC will
transmit the calculated speed to the mainline pump PLC.

An example: when the fly ash handling tonnage will be set at 170 tph and the solids concentration at
65%, the total slurry flow is 176.5 m3/h and the quantity of water to be added is 91.5 m3/h (based on a
specific gravity of the fly ash of 2.0 and make up water of 1.0). When the percentage of water to be
added to the ash conditioner is 20% this equals 18.3 m3/h, 9.2 m3/h for each conditioner. In the AMT
the remainder of water will be added. This equals 73.2 m3/h, 36.6 m3/h for each AMT inlet.

The fly ash silo is filled (visual or other check). The mainline pump and the corresponding SCU plc
have to be set in “remote mode”. The GEHO pump will be given a pre-start signal by the MPLC, the
auxiliary motors are started and the mainline pump will give a signal “ready to run”. The SCU will be
given a start signal and when everything is in order it will also give a signal “ready to run”.

The isolation valves underneath the fly ash silo will be opened. A limit switch is installed on the
actuator operated valve to indicate the open position. Preparation of ash slurry is started at the set
solids concentration. The ash conditioner will feed the moist fly ash to the AMT at the set flow. In the
AMT the remainder of the water will be added. The vertical mixer in the AMT tank will start at
minimum level (see chapter 5.3) . When the slurry in the AMT has reached normal operating level, the
booster pump can start. While the booster pump is building up suction pressure the mainline pump
will automatically start upon sufficient available suction pressure and will ramp-up according a pre-set
time to the set stroke speed. The ramp-up time of the mainline pump can be adjusted in the VFD to
meet pipeline response. The ramp up time will be determined during commissioning based on actual
pipeline response. For a more detailed description of the mainline pump start up please refer to the
GEHO pump control description 814.201249.20.

5.3 Fly ash dosing, weighing and mixing (R3)

The amount of fly ash that will be fed to the system will be controlled by two rotary feeders and mass
flow meters working in parallel. The PLC will compare actual and set value and adjust the speed of
the rotary feeders if required.

The fly ash is pre wetted with water in the ash conditioner. A regulated water flow is added to the fly
ash flow. The water flow through the water supply line is measured by a flow meter and compared to
the set value. If required the main PLC will adjust the position of the control valve. The water flow to

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 11 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
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NTPC Jhajjar Aravali ash handling

each of the two (2) ash conditioners should be equal to the other, so the total flow is split in two. The
ash conditioners will need to generate a fully moisturised fly ash compound, free of any lumps.

When the main system PLC will indicate that there is no fly ash entering the ash mixer an alarm is
generated and the dosing of water is stopped. The system will stop operating when the AMT will
reach “low low level”. A slurry clearing sequence, which will be described later in this report, can be
started manually.

When the main system PLC will indicate that there is no process water entering the ash conditioner
an alarm is generated and the dosing of fly ash is stopped. The system will stop operating when the
AMT will reach “low low level”.

5.4 AMT operation and level control (R3)

The AMT will also be equipped with a water dosing unit for adding the remainder of water. The moist
fly ash will fall through a water curtain, generated by a controlled water flow through four (4) nozzles.
The water flow through the water supply line is measured by a flow meter and compared to the set
value. If required the main PLC will adjust the position of the control valve. The final required amount
of water should be added in the AMT. The AMT will have two (2) fly ash inlets. The water dosing unit
to the AMT is equipped with two (2) flow transmitters and control valves, one for each inlet. Also here
the total flow should be split in two, 50% for each inlet.

When the SCU PLC will initiate a signal to change the slurry composition, the control parameter will
be the water supply to the AMT. The variation and control of water supply is experienced to be more
stable and responsive then varying the mass flow of fly ash. When this parameter will reach its pre-
programmed control limits, an alarm warning will be given.

The AMT will have a suggested five level control:

-high high level (100 %)
-high level (90 %)
-operating level (70 %)
-low level (10 %)
-low low level (0 %)

Zero level (0 %) is set at the start of the concentric part of the ART. The 100% level is the maximum
slurry level allowable in the tank, just below the overflow opening.

The AMT operating level height will be controlled by the mainline pump speed within plus or minus
10% of the speed setting of the pump. Speed modification will be done proportionally to tank level,
where the gain factor can be modified in the MPLC. In case the GEHO pump will not be able to
maintain the slurry level in the AMT within the specified speed range the operator will have to find the
cause for the same.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 12 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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NTPC Jhajjar Aravali ash handling

When indicating “high level” or “low level” the main system PLC will give an alarm. The alarm will be
made visible to the operator at the MPLC screen. The system will remain in operation but the operator
is advised to find the cause for the alarm and/or change system settings.

When indicating “high high level” the slurry feed to the AMT is stopped. An alarm is made visible on
the MPLC screen. The vertical mixer, booster pump and mainline pump will remain in operation but
the slurry feed can only be restarted manually.

When indicating “low low level” an alarm is made visible on the MPLC screen and the system will be
stopped.

5.5 Slurry control loop (R3)

The SCU is to be considered as the main control feature and as a last line of defence before sending
the slurry into the main pipeline. Only minor changes in slurry preparation are possible with the SCU,
while successful application is depending on the size and volume of the AMT and the time available
to make changes effective.

In order to meet the requirements for system operation, the AMT will be provided with a density and
pressure measurement in the control loop. A hose pump is taking suction from an outlet of the AMT
and feeds the slurry into the slurry control loop. The control loop is a circulation loop, consisting of a
horizontal section and a vertical section back to the top of the tank. In the horizontal section two
pressure sensors will be installed. In the vertical section a density meter will be installed. The SU PLC
will be installed near to the AMT. This SCU will monitor and control loop instruments and components
and transfer required data to the MPLC.

Two pressure sensors that are located at a certain distance from one another, measure the pressure
in the control loop. The differential pressure is calculated. The pressure difference is an indication for
the flowing behaviour of the slurry and therefore a direct representation of the flowing behaviour on
the storage area. Based on this signal the MPLC will adjust the water flow to the AMT. The water flow
can only be increased or decreased until a pre-set value. When adjustment beyond these limits is
required, the SCU will generate an alarm but will continue operating. The operator is advised to find
the cause of the alarm. In case the actual pressure difference will exceed the pre set limits, the SCU
will generate an alarm. The system will continue operating, but the operator is to find the cause of the
alarm.

A direct drive, constant speed hose pump is utilised to generate positive and constant feed to the
control loop. This is of importance for the interpretation of the pressure signals derived from this
control loop.

Directly after the hose pump an air over slurry damper will be installed to decrease the pulsation level
generated by the hose pump. The pulsation will have a direct influence on the calculated differential
pressure. In order to provide a constant and representative measuring cycle, the pressure in the
control loop will be measured at certain time intervals. A pulse indicator, mounted on the hose pump,

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 13 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
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NTPC Jhajjar Aravali ash handling

will give a signal when the rotor head of the pump will pass. At a time interval of t1 seconds after this
signal the pressure will be measured during a controlled time span. This cycle will be repeated at
every indicator signal. In document 809.200000.409 a detailed description with respect to the control
loop plc operation and control can be found.

The density meter measures the density of the slurry using high frequency vibrations. The measured
density is displayed on the SCU screen. Using the measured density, the actual solids concentration
is calculated. This calculation will be based on pre-programmed specific weights for both the fly ash
and process water. Deviations are therefore possible. If the real solids concentration deviates from
the set value by more then 0.5%, the SCU will adjust the water flow signal to the main system PLC.
Based on this signal the main system PLC will adjust the water flow to the AMT. The water flow can
only be increased or decreased until a pre-set value. When adjustment beyond these limits is
required, the SCU will generate an alarm but will continue operating. The operator is advised to find
the cause of the alarm.

The differential pressure will be used as main control variable and the density meter reading will be
used as a monitor variable.

5.6 Suction Pressure Monitoring (R3)

The slurry booster pump located near to the AMT will feed the slurry at sufficient pressure to the
mainline pump. The suction pressure transmitter will signal the suction air vessel actual pressure. The
suction air vessel of the GEHO pump ensures that acceleration losses are avoided, as this provides
for an air / slurry buffer and provides for an improvement on NPSH required.

Monitoring of suction pressure is started upon activation of following three signals:

- running booster pump
- suction pressure 2.2 bar
- GEHO motor running

During normal operation the suction pressure is monitored and reported. When this pressure will
become too low, the GEHO PLC will generate an alarm but system will continue to operate. The
operator is advised to find the cause of the alarm.

5.7 Mainline Pump Operation

5.7.1 Local/remote mode

The pipeline flow is a function of and proportional to the mainline pump stroke rate. The mainline pump
drive motor speed and hence the stroke rate and flow rate are controlled with an input signal to the
mainline pump variable speed drive. In other words, the required capacity of the system will determine
the nominal stroke speed setting for the mainline pump.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 14 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
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NTPC Jhajjar Aravali ash handling

The operating system has facilities to adjust and maintain a pre-set minimum speed, a pre-set maximum
speed (i.e. normal operating range) and the ramp up time.

The pump control panel is provided with a software local / remote operating selector switch. In local
mode the operator can control the pump manually and can control for example the pump speed and
acceleration time. In remote mode the pump speed and acceleration will be controlled by the main
system PLC control. The maximum acceleration will be subject to the maximum discharge pressure of
the system. At maximum stroke speed neither the system on automatic, nor the operator can further
increase the speed (R3).

Relevant pump signals can be made available to the main system PLC through hard wiring.

5.7.2 Overpressure protection

The discharge pressure transmitter, located at the pulsation damper is monitoring the
discharge/pipeline entrance pressure continuously. The system will start diluting the slurry at a pre set
discharge pressure. The maximum continuous operating pressure of the pump is 47 bar. The pump
controls will generate an alarm at 49 bar and an automatic shutdown of the main motor at a pressure
of 52 bar. If the pressure would still increase, for instance immediately after shutdown, due to the
mass inertia of the unit, the pump internal safety relief valve will open at 56 bar. National or local
regulations could urge for the use of an additional pressure relief valve at the discharge line. Since
the pipeline will have an open connection to the mainline pump it is expected that there is no such
requirement.

5.7.3 Mainline pump tripping

The mainline pump will trip if during normal operation a trip signal is received from any of the following:
the pump control PLC
an emergency push button (local regulations prevail)
a trip signal from the motor or drive protection systems
the MPLC, based on programmed scenarios

Further trip conditions for the pump are given in WMN document 814.201249.20. Depending on the type
of stop, the same mainline pump may be available for restart and slurry clearing procedures.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 15 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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NTPC Jhajjar Aravali ash handling

5.8 Pipeline Operation

5.8.1 Introduction
The mainline pump is designed for normal operating conditions between a minimum and maximum
discharge pressure, based on slurry density and rheology limits. The pump is however capable of
generating a higher pressure than required for normal operation. A margin shall be preserved for any
emergency, which could cause the pipeline friction to increase beyond the maximum specified levels.

The mainline pump discharge pressure would increase typically in the following cases:
Increase of solids concentration
Restart of a slurry filled pipeline
Increased scaling, the effective pipeline diameter will decrease and slurry velocity will increase
Changing in the characteristics of the dry material and ditto slurry changes (changes in rheology)
Change of discharge point at the storage area.

5.8.2 Monitoring pump discharge pressure

The safe condition of the pipeline has to be verified continuously and can be derived from the pump
discharge pressure. The pump discharge pressure is monitored, by using the pressure transmitter
located on the pulsation damper. The pressure transmitter has a number of functions.
Prime function is to indicate actual pump discharge pressure, which is equal to the main pipeline inlet
pressure. It is advised to log this pressure against a time scale continuously. When the pump is
operating at constant conditions and the pressure increases slowly over time, this is an indication that
certain parameters of the slurry or the system are deviating or changing.

Apart from the pump controls, the MPLC can be programmed to monitor safe pipeline operation.
Based on actual operating conditions two pipeline operating pressures can be defined: a pre-alarm
pressure which indicates a pressure that is higher then normal expected operating pressure and a
slurry dilution pressure, which will initiate automatic slurry dilution. Both pressure settings will have to
be determined during the first period of operation of the system. When the pressure reaches the pre-
alarm pressure, the system will give a pre-alarm for increased discharge pressure. From this point on
the system operation has to be monitored very closely in order to prevent a sudden automatic dilution.
At the next set point of slurry dilution pressure an automatic slurry dilution sequence is started. The
amount of water added is to be maximised and is not designed to correct to a certain minimum solids
concentration. Whatever amount of water can enter the system will be used to dilute the slurry. This
provision is merely incorporated to prevent that the complete pipeline will be blocked.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 16 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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5.9 Slurry Dilution Sequence

This feature will be the final action for the system to avoid an automatic shutdown. Programmed stages
are:
Pre-alarm at 40 bar.
Start dilution of slurry at 44 bar.
Maximum operating pressure at 47 bar.
Discharge pressure high alarm at 49 bar.
Automatic shutdown of main motor at 52 bar.

When the average system operating pressure is exceeding 44 bar, it is assumed that the system is
heading towards maximum discharge pressure. This would be the moment to introduce an automatic
slurry dilution sequence in order to avoid an automatic system shutdown with the complete system
filled with wrongly conditioned slurry. The automatic slurry dilution has to take place in the AMT or
directly in the suction to the booster pump. In parallel sequence the dosing of fly ash is stopped
automatically. The main pump will receive the diluted slurry rather quickly, which will lead to a stop in
pressure increase and provisionally in a descending discharge pressure. When the pressure in the
pipeline has decreased to a pressure of 30 bar the slurry dilution is terminated and the system is
stopped. Whether or not the cause for this situation is known, the operator can consider a restart “on
the fly”. The system could be restarted, avoiding the need for a complete system slurry clearing
sequence. This sequence, however, should only be executed if the cause for the trip is absolutely
clear and that it is verified that a system restart is safe.

5.10 Normal System Stop

Each time a normal system stop is executed the fly ash valve is closed and rotary feeder emptied and
stopped. The ash conditioner is cleaned by feeding only process water and then stopped. The level in
the AMT is allowed to lower until “low low level” is reached and then the complete system is stopped.

The time relating characteristics of the slurry requires that each time the system will be stopped for a
prolonged period the complete system is cleared with water, by starting a slurry clearing sequence.
The process water feed on top of the AMT is opened. The mainline pump will ramp up slowly to
maximum capacity. The AMT together with the booster pump and the mainline pump will operate. The
system will pump process water for approximately half an hour, after which process water feed is
stopped and the AMT, the booster pump and the mainline pump will stop at “low low level” in the AMT
is reached.

The slurry clearing sequence can be initiated manually when there is a scheduled system stop.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 17 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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5.11 Emergency System Stop

An automatic emergency system stop can be generated when one of the components in the system
will suddenly stop operating or an instrument will give a signal which will initiate an emergency stop.
When it is expected that the system stop will last for several hours the operator is advised to clear the
line of slurry. Depending on the nature of the emergency system stop two different situations are
defined:
• The mainline pump and booster pump are operational.
• The mainline pump or booster pump are not operational
When the mainline pump and the booster pump are still operational a possible slurry clearing
sequence can be initiated using these two system components.

When the mainline pump or the booster pump is not operational, the clearing of the pipeline should be
done by a stand by GEHO pump in case cross over connections are provided (R3).

5.12 Deblocking
The mainline pumps are capable of deblocking the pipeline (within its maximum pressure rating).
Deblocking proceeds with the pumping of water, which is entering the pipe system at the suction of the
booster pump.

Deblocking sequence will always be in manual mode. The mainline pump speed will be manually
controlled while observing the pump discharge pressure and ensuring that this pressure will not exceed
47 bar. The mainline pump and its drive do allow operating, for a limited time, at maximum discharge
pressure for the whole speed range of the unit, from zero to maximum. Often a (partially) blocked
pipeline can become operational again by applying full pressure loading at low volume delivered.

Document title Doc. No. Rev. No. Page

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Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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6 System control procedures (R3)

6.1 Automatic system start up

It is ensured that sufficient fly ash is available in the FA silo
It is ensured that GEHO pump is primed, drain valve is closed, main isolation valve in discharge line
is opened, strainer by pass line isolation valves are closed, strainer isolation valves are opened,
strainer flush and drain valves are closed, manual operated gate valve to the suction of the booster
pump is opened
Is it ensured that entire system is ready to run from mechanical and electrical point of view and
everything is “safe”
GEHO pump PLC is in remote mode
Slurry Control Unit (SCU) PLC is in remote mode, values for specific gravity, differential pressure,
density and control mode are set in the SCU PLC
It is ensured that the Agitated Mixing Tank (AMT) is filled with water until “low low” level (intersection
of concentric and conical part of the AMT)
It is ensured that all plc signals of Main System PLC (MPLC) are healthy and no errors are appearing
in the MPLC screen
MPLC is set in auto mode
Ash handling tonnage and solids concentration have been set in MPLC. MPLC will calculate the
speed of the GEHO pump, the flow of water to the ash conditioners and the flow of water to the
Agitated Mixing Tank (AMT).
GEHO pump is given a pre start signal
GEHO pump will give ready to run signal as feed back
SCU plc is given a pre start signal
SCU plc will give ready to start feed back
Manual operated knife gate valves in silo discharge are opened
Actuator operated knife gate valve in silo discharge are opened and a limit switch will signal the open
position
Ash conditioners will start
Water dosing to ash conditioners and AMT will start, the flows will be measured by flow meters and
adjusted if required
Rotary feeders will start operating at the set flow, the flow is measured by the mass flow meters and
adjusted if required
Pre conditioned ash will be discharged in the AMT
The vertical mixer will start operating at “low” level
The SCU will be given a remote level start bit and the hose pump will start after the pre set timer in
the SCU plc has finished
The SCU will be given a remote reference signal for the water valve position by the main system PLC
When the hose pump will start the SCU water dosing signal should override the water dosing set
point of the main plc
The level in the tank will increase until “normal operating” level

Document title Doc. No. Rev. No. Page

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Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

The actuator operated knife gate valve in the suction of the booster pump will be opened and a limit
switch will signal the open position
The booster pump will start
Upon reaching sufficient suction pressure the GEHO pump will start automatically and ramp up until
the set speed according to the ramp up time programmed in the VFD
GEHO pump will operate at the set speed and control the level in the AMT by varying the pump
speed within +/- 10% of the set speed set point

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 20 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

6.2 Automatic system stop

The MPLC will be given an “auto stop” command
The actuated fly ash valve underneath the fly ash silo will be closed and will give a closed feed back
signal
The rotary feeder will continue to operate for 10 sec. until it is fully emptied and then it is stopped
The ash conditioner will continue to operate for 10 sec. until it is fully cleaned of slurry and then it is
stopped. Also the water dosing to the ash conditioners is stopped.
While the system continues to operate, only water is entering the tank through the AMT water inlets.
In this way the slurry is slowly diluted and when the AMT has “low low” level the vertical mixer is
stopped.
The slurry dilution valve in the suction of the booster pump is opened for 30 sec. and the piping
system up to and including the GEHO pump discharge header are cleared of slurry.
The GEHO pump is stopped
The booster pump is stopped

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 21 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

6.3 Slurry clearing

After the system has been given an auto stop, depending on the time it is allowed to leave the pipeline
filled with slurry, the system can be given an slurry clearing command.

GEHO pump speed for slurry clearing of pipeline and time for slurry clearing have been entered in
MPLC
MPLC is set in auto mode
The MPLC will be given an “slurry clearing” command
It is ensured that GEHO pump is primed, drain valve is closed, main isolation valve in discharge line
is opened, strainer by pass line isolation valves are closed, strainer isolation valves are opened,
strainer flush and drain valves are closed, manual operated gate valve to the suction of the booster
pump is opened
Is it ensured that entire system is ready to run from mechanical and electrical point of view and
everything is “safe”
GEHO pump PLC is in remote mode
It is ensured that the Agitated Mixing Tank (AMT) is filled with water until “low low” level (intersection
of concentric and conical part of the AMT)
It is ensured that all plc signals of Main System PLC (MPLC) are healthy and no errors are appearing
in the MPLC screen
GEHO pump is given a pre start signal
GEHO pump will give ready to run signal as feed back
Flush water valve at top of the tank will be opened
The vertical mixer will start operating at “low” level
The level in the tank will increase until “normal operating” level
The actuator operated knife gate valve in the suction of the booster pump will be opened and a limit
switch will signal the open position
The booster pump will start
Upon reaching sufficient suction pressure the GEHO pump will start automatically and ramp up until
the set speed according to the ramp up time programmed in the VFD
GEHO pump will operate at the set speed
Flush valve will be closed when the level in the tank has reached level “ high”
GEHO pump will operate until pipeline is cleared of slurry.
When the AMT has reached “low low” level the vertical mixer is stopped.
The GEHO pump is stopped
The booster pump is stopped

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 22 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

6.4 Loop controls and interlocks

Following devices modes are defined:
Auto : operated and controlled by main plc
Manu : operated by main plc
Loc : operated from field, locked by a key
Remote : auto or manual mode from main plc

Loop controls are only defined for auto mode.

There are three types of interlocks:

IA, operating interlock: validity in auto mode only
IP, operating interlock: validity in auto and manual mode
IB, blocking interlock: validity in auto and manual mode

Loop controls:
No. Action Condition
LCA1 Fly ash mass flow control through mass flow Actuator operated fly ash isolation valve is in
measurement open position
and
Ash conditioner motor is running
LCA2 Ash conditioners water control valves cascade Ash conditioner motor is running
control through water flow measurement. Flow and
set point through MPLC based on set point Rotary feeder is running
calculations.
LCA3 AMT water control valves cascade control Hose pump is not running
through water flow measurement. Flow set point and
through MPLC based on set point calculations Flush valve AMT tank is closed
LCA4 AMT water control valves cascade control Remote level start bit is high
through differential pressure measurement or and
density measurement. Initial water valves set Hose pump is running
point through MPLC. and
Flush valve AMT tank is closed
LCA5 AMT level cascade control through GEHO pump AMT level is not “low low”
speed. Initial speed set point through MPLC. and
Speed control range min. and max. 10% of GEHO pump is running
speed set point.

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 23 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 Confidential
Project 201249
NTPC Jhajjar Aravali ash handling

Interlocks:
No. Action Condition
IA1 Ash conditioner start Actuator operated fly ash isolation valve is in
open position
IA2 Slurry dilution valve open Booster pump is running
and
Mainline pump pressure > dilution activation
pressure
IA3 Slurry dilution valve close Mainline pump pressure < dilution deactivation
pressure
IP1 Booster pump start Seal water flow switch activated
and
Actuator operated AMT outlet valve is open
IP2 AMT motor start Level in the AMT > “low low”
IB1 Booster pump stop Booster pump is running
and
Seal water flow switch deactivated
or
Actuator operated AMT outlet valve is not open
IB2 AMT motor stop Vertical mixer is running
and
Level in the AMT < “low low”
and
(t = 10 min) after initiation

Document title Doc. No. Rev. No. Page

Operating and control philosophy 809.201249.050 03 24 of 24
Copyright © Weir Minerals Netherlands b.v. 2009. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used,
reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to
any person without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used
only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any
related corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
 SECTION - 4

TESTING AND ADJUSTING SYSTEM PRIOR TO INTINAL

HANDLING OF ASH
 INDEX

SECTION - 4

SL. NO. DESCRIPTION PAGE NO.

1.00.00 PREFACE. 4:1

2.00.00 WATER AND AIR DISTRIBUTION SYSTEM PUMP, 4:1

COMPRESSOR & VARIOUS EQUIPMENTS.

3.00.00 BOTTOM ASH HANDLING SYSTEM. 4:7

4.00.00 COARSE ASH HANDLING SYSTEM. 4:9

5.00.00 FLY ASH HANDLING SYSTEM 4:10

6.00.00 INSTRUMENT AIR COMPRESSOR. 4:14

7.00.00 ASH SLURRY DISPOSAL SYSTEM 4:15

8.00.00 PRIOR TO HANDLING OF ASH IN THE BOILER 4:18

 DC INDUSTRIAL...
PLANT SERVICES

TESTING AND ADJUSTING SYSTEM PRIOR TO INITIAL HANDLING OF ASH

1.00.00 PREFACE :

In order to achieve satisfactory operation of the Bottom Ash, Coarse Ash & Fly Ash Handling
System, a through inspection must be carried-out for all equipment, piping etc. prior to handling
any ash.

The major tests / inspection and adjustments to be carried-out prior to initial handling of ash have
been discussed in the following pages. However, it is strongly recommended that all involved
persons familiarize themselves thoroughly with the operation & maintenance features of the entire
ash handling system before doing anything whatsoever with the system. Emphasis is particularly
laid on strictly following all safety / precautionary steps to be taken for system operation and
maintenance.

2.00.00 WATER AND AIR DISTRIBUTION SYSTEM: PUMPS, COMPRESSOR & VERIOUS
EQUIPMENTS :

2.01.00 WATER AND AIR DISTRIBUTION SYSTEM :

Check thoroughly the complete water and air piping including valves, nozzles, orifices,
instrument etc. to match with the single line diagrams and layout drawings. Ensure that all check
valves are installed properly as per the correct direction of flow.

Conduct thorough flushing of all pipelines. Check each valve for proper and smooth mechanical
operation and lubricate as necessary. For remote-operated valves check the actuators for smooth
operation, first manually and thereafter through remote control from the Central Control Console.
When limit switches are provided, check the same for proper positioning and operation. Limit
switches should be checked for proper setting before trying the remote operation from Central
Control Console at HMI station.

Conduct thorough blowing of entire length of air pipes, as far as possible, removing all
instruments like pressure regulators, air filters etc. and air piping joints at the solenoid valve inlet
disconnecting them one by one. Then blow the lines after solenoid valves up to the inlet of
actuators of various valves / equipment’s.

The object of blowing the lines with air is to prevent the actuators, instruments etc. from getting
choked by dust or dirt left inside the piping during erection.

Adjust all the globe valves, pressure switches and all other controlling gauges of the water and air
lines during trial runs as per instructions given elsewhere in this manual so as to operate the
system properly.

Care must be taken so that under no circumstances waters / air pressure more than that specified
in the drawings or other instruction is applied to the different actuators. Also, the supply of air
must be free of water / moisture and dust for proper functioning of the instruments, solenoid
valves etc.

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Check that the entire Water & Airlines are 100% leak-proof. Leak in water lines & pressurized
airline can be easily detected, but in vacuum air line leakage can’t be easily detected. Hence,
special care should be taken to detect the leakage in vacuum pipeline.

2.02.00 WATER PUMP :

Check and apply oil / grease, as necessary, of required quantity to all the bearings and other
points of all the pumps, motors, valves etc. as recommended by respective manufacturers.

Before coupling the motors to the pumps, check insulation resistance, continuity etc. and run the
motors to check for direction of rotation with respect to that of the driven equipment. Interchange
the motor terminal connection if rotation is in the reverse direction. Restart and again check for
direction of rotation.

Run the motors idle for about six (06) to eight (08) hours. Monitor temperature rise of bearings
and other places. Check noise, vibration etc. at bearing & other places and take corrective
measure as necessary. Instead of measuring bearing temperatures directly (in case of any
difficulty) measure the lubricating oil (passing through the bearing) temperature by inserting the
thermometer in the lubricating oil of the corresponding equipment. This may indicate the
approximate rise in temperature during rotation and taken corrective measures as necessary.

Now couple the motors to the pumps align properly and check for freeness of rotating parts by
hands. Proper care must be taken for achieving correct alignment of pump-motor sets and free
rotation of motors in coupled condition. Accuracy in this matter is highly emphasized. Procedural
recommendation of the respective manufacturer / Hydraulic Institute standard should be followed
in this matter, as far as practicable.

After obtaining accurate alignment for both drive and driven equipment, fix the equipment firmly
to their foundations / bed plates and dowel suitably wherever necessary.

Check that gland seal water connections with seal water line valves, gauges, switches, etc. for
corresponding pumps have been made properly. Check for proper adjustment of pressure
switches. However, final adjustment in the set points may be done after running the corresponding
pumps. Opening of manually operated globe valve can be utilized for finer adjustments.

Check for positive supply of gland seal water to the ash slurry pump, BA overflow water pump,
ash slurry drain pump, silo area drain pump & purchaser’s through clear water supply of sealing
water to vacuum pump and screw type transport air compressor to where applicable. Check that
proper packing, have been provided in the pump glands and the water sealing are properly
tightened to prevent leakage.

Now check operation of each type of pump-motor set individually by applying power to the drive
motors as detailed below :-

- Check that all pump suction valves are fully open.

- Check that adequate water is available in Ash Water Sump (For HP & LP, & Eco. Water
Pumps are common collection for ash water sump). Check individually drain sump for ash
slurry drain pump, silo area drain pump. For the entire above-mentioned sump, check &
adjust level switches to bring the sump / well make-up valve to service.

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 DC INDUSTRIAL...
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- Check all the electrical connections for alarm / annunciation and system interlocks. Also
check the input source header water pressure (for make-up water) is within the specified
limit and adjust pressure switches, pressure indicator, if necessary.

Now do the following stepwise :

Check and ensure all HP Water Pump, LP Water Pump, Eco Water Pump, Seal water pump,
sump (water) level operational interlocks as per “Control Write-up on electrical controls &
interlocks of Part –C water & slurry system for ash handling plant”.

a) Check that ash water sump level is at or above preset “Low”.

b) Now Start the ash water pump.
c) Open the discharge valve, check through indication that corresponding red light is on the
hardwired mimic at CCC panel.

d) Check discharge pressure & ammeter reading of the pump. Observe rise in temperature,
noise, vibration etc. and continue operation two (02) hrs. Approximately to flush out entire
ash water line.

After stopping, check that all nozzles, orifice, valves etc. are cleared & functioning properly.
Check and adjust pressure switch setting as required.

Similarly, as per starting and running permissive (as mentioned in “Write-up” attached with this
manual) check the smooth running of all the individual pumps. Run each pump for approximate
two (02) hours and check for any abnormalities in discharge pressure, ammeter reading,
temperature rise in bearings, vibration, noise etc. and correct the same if necessary.

Now check for parallel operation of the pumps and ensure smooth operation of the pumping
system as a whole.

NOTE: While starting the seal water pumps check the header pressure of seal water pump suction of both
pumps are from common suction, connected to seal water sump. Pump suction header pressure
should be adequate. Keep the delivery valve open (10% to 15%) and all other valves at different
distribution point suitably open so the seal water pump never go to overload condition. All the
starting and running permissives of each seal water pumps to be checked and then start the pump.
Now open the delivery valve fully and wait for some time until the delivery line pressure come to
a steady seal water sump level.

2.03.00 ESP / BUFFER HOPPER AND SILO FLUIDIZING AIR BLOWER :

Check and apply oil / grease at motor and as well as in bearing and other parts of blowers as per
instruction manual of the corresponding sub vendor & lubrication schedule .

Disconnect blower and motor. Check insulation resistance, continuity etc. for all motors and run
each motor to check for direction of rotation with respect to that of the driven equipment.
Interchange motor terminal connection if rotation is in reverse direction. Re-start and again check
for direction of rotation.

Now run each motor idle for about 6 to 8 hrs. Check for temperature rise at bearing and other

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places, noise and vibration etc.

Mount the v-belts, align and provide required belt tension and rigidly fix the motor on base. For
multiple belt drive, ensure equal tension on all belts as far as practicable. Follow manufactures
instruction manual.

Now run each blower-motor set and check the operation of the safety valve. Ensure that the
safety valve has been adjusted properly (for all the blowers) to the set pressure.

Check operation of air heaters (for ESP / Buffer hopper fluidizing blower & silo fluidizing
blower) to ensure proper function of the temperature controls.

Check the air pressure developed in the pressure gauge at the blower outlet (pressure gauge
should be properly calibrated to ensure correct measurement).

Check operational interlock for all blowers as specified in "Write-up on remote controls,
interlocks, indication and annunciation".

Follow manufacturers' operation and instruction manual attached with this manual.

2.04.00 SCREW TYPE TRANSPORT AIR COMPRESSORS :

Check and apply oil / grease as required for the compressor and motors as recommended by the
manufacturer. Also refer to the lubrication schedule.

De-couple compressor and motor. Check for insulation resistance, continuity etc. for the motors
and run each motor to check for direction of rotation with respect to that driven equipment.
Interchange motor terminal connection if rotation is in reverse direction. Restart and again check
for direction of rotation. Then run the motor idle for 6 to 8 hours. Check for temperature rise at
bearings, noise, vibration etc and take corrective measure as necessary.

Now couple the compressor with motor after proper alignment and fix the equipment rigidly on
base as per the manufacturer's instruction.

Check compressor lubricating oil temperature and conveying air temperature. This should be
below the preset normal and high value respectively.

Now run each compressor ­ motor set and check the operation of safety valve. Ensure that the
safety valve has been adjusted properly to the set point.

Check discharge pressure and ammeter readings. Observe rise in bearing temperature, noise,
vibration etc. Continue operation of the compressor for at least 1 to 2 hours and check for smooth
performance.

Check operational interlocks (Both running and starting permissives) of the compressor specified
in "Write-up” on remote controls, interlocks, indication and annunciation.

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 DC INDUSTRIAL...
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Follow Manufacturer's instruction.

2.05.00 VACUUM PUMP :

Check and apply oil / grease for the Vacuum Pump and motor as recommended by
manufacturers. Consult lubrication schedule attached to this manual.

Disconnect motor from the Vacuum Pump, check for insulation resistance, continuity etc. for the
motors, and run each motor to check for direction of rotation with respect to that of driven
equipment. Interchange motor terminal connection, if rotation is in reverse direction. Restart and
again check for direction of rotation. Then run the motor idle for about 6 to 8 hours. Check for
temperature rise at bearings and other places, noise vibration etc. and take corrective action as
necessary.

Now couple the Vacuum Pump with motor after proper alignment, rigidly fix motor and vacuum
pump with base plate / foundation.

Follow Manufacturer’s Instruction Manual.

Check with sealing water connection to Vacuum Pump with all valves and instruments have been
made properly as per drawings. Check for proper adjustment of pressure switch on sealing water
line.

Establish water supply (from purchaser’s service / clarified water header) to the vacuum pump
and check for proper flow from each vacuum pump. Adjust globe valves on water lines, as
necessary to obtain required water flow.

The operation of vacuum pump is interlocked with the seal water supply pressure. Therefore,
constant uninterrupted flow of water at required pressure is essential, while the vacuum pump is
in operation.

Now run each vacuum pump and motors set and check the operation of safety valve. Ensure that
the safety valve has been adjusted properly to protect the vacuum pump in case line vacuum rises
to a high value (shut-off vacuum).

Check operational interlocks of the vacuum pump as specified in “control write-up” part – B, fly
ash evacuation system as per annunciation list.

Check vacuum indicator and ammeter reading. Observe rise in bearing temperature, noise and
vibration etc. Continue operation for two (02) hours and check for smooth performance.

Follow manufacturer's instructions.

2.06.00 BA. OVERFLOW WATER PUMPS:

Check that the BA overflow weir box and BA overflow transfer hopper is clean and free of any
construction debris/foreign materials.

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Check operation of BA overflow transfer hopper make-up water cylinder operated valves locally
by actuated of corresponding solenoid valve through in built manual override facility.

Check that BA overflow water pumping arrangement has been made properly. Check that
cylinder operated KGV valves, i.e. suction & discharge valve locally by actuation of respective
solenoid valves through in-built manual override arrangement.

In case of any jamming, mis-alignment, jerky or sluggish movement, then valve to be checked for
proper assembly and clean the parts thoroughly. Also, check operation of limit switches to ensure
that these actuate at desired valve positions (open / close) and do not generate any false signal.
Repeat the operation for each valve a number of times to establish smooth operation of the
valves.

Check that the BA overflow water pump gland seal water supply from BA seal water pump. This
connections has been made properly and all seal water line valves, gauges, switches etc. has been
placed as per drawings and pressure switches has been adjusted with proper setting values.
However, final adjustments in the set points may be required after running the pumps with water.

Now couple the pump with motor, align properly and fix the equipment firmly on base frame /
foundations.

For pumps, Check the fluid coupling strictly as per manufacturer’s instruction. Accurate
alignment between the drive and driven equipment is must for efficient operation of the pumping
system. Consult manufacturer’s instruction manual of fluid coupling, for the purpose of
installation / alignment as well as for oil filling of the coupling. Check that proper packing has
been provided in the pump glands and glands are properly tightened to prevent leakage.

Check and apply oil / grease, as necessary, of required quantity to all the bearings and other
points of all the pumps, motors, valves, etc. as recommended by respective manufacturers. The
basic lubrication data has been provided in the “LUBRICATION SCHEDULE”.

Before coupling the motors to the pumps, check insulation resistance, continuity, etc. and run the
motors to check for direction of rotation with respect to the driven equipment. Interchange motor
terminals if rotation is in reverse direction. Re-start and again check for direction of rotation.
Now, run the motors idle for about 6 hours. Monitor temperatures rise at bearings and other
places, noise, vibration etc. and take corrective measure as necessary.

Now couple the motor to the pump, align properly and check for freeness of rotating parts by
hand.

Now check operation of each pump-motor set individually as detailed below :-

- Check that pumps suction valve fully open.

- Check BA seal water valve is open for corresponding pump.

- Check that Pump started.

- Check delivery valves operation, pressure gauges functioning.

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 DC INDUSTRIAL...
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- Fill the BA overflow transfer hopper and adjust level switches. Check all electrical
connections for alarm annunciation and system interlocks.

- Ensure make-up water supply in the BA overflow transfer hopper.

- Now open the discharge valve and check normal discharge pressure and ammeter readings.
Observe rise in bearing temperature, vibration, noise etc. by running pump for 4 hours and
flush out entire water line.

2.07.00 SEAL WATER PUMP :

Check and apply oil / grease, as necessary, of required quantity to all the bearings and other
points of all the pumps, motors, valves etc. as recommended by respective manufacturers.

Before coupling the motors with the pump, check insulation resistance, continuity etc. and run the
motors to check for direction of rotation with respect of the driven equipment. Interchange the
motor terminal connection, if rotation is in the reverse direction. Restart and again check for
direction of rotation.

Run the motors idle for about six (06) to eight (08) hours. Monitor temperature rise of bearings
and other places. Check noise, vibration etc. at bearing & other places and take corrective
measure as necessary.

Now couple the motors to the pumps align properly and check for freeness of rotating parts by
hands. Proper care must be taken for achieving correct alignment of pump-motor sets and free
rotation of motors in coupled condition. Accuracy in this matter is highly emphasized. Procedural
recommendation of the respective manufacturer / Hydraulic Institute standard should be followed
as far as practicable.

After obtaining accurate alignment for both drive and driven equipment, fix the equipment firmly
to their foundations / bed plates and dowel suitably wherever necessary.

Check for proper adjustment of pressure switches at suction & discharge header. However, final
adjustment in the set points may be done after running the corresponding pumps.

Now check operation of each type of pump-motor set individually by applying power to the drive
motors as detailed below :-

- Check that all pump suction valves are fully open.

- Check that adequate water supply pressure is available from purchaser’s clear water source.
Check individual BA seal water pump. Check & adjust pressure switches.

- Check all the electrical connections for alarm annunciation’s and system interlocks. Also
check the input source header water pressure (from purchaser’s header water supply) is
within the specified limit and adjust pressure switches, pressure indicator, if necessary.

3.00.00 BOTTOM ASH HANDLING SYSTEM :

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 DC INDUSTRIAL...
PLANT SERVICES

3.01.00 BOTTOM ASH HOPPER & FEED GATE :

Check the seal trough, overflow line, bottom ash hopper and feed sump of jet pump and remove
any construction debris such as bricks, rags, tools etc.

Check the nozzle tips inside Bottom Ash Hopper and flush water piping. Inspect for leaks
specially at the joints of inspection doors and windows, etc. by water filling the hopper up to
overflow level. Also, check leakage of water from the feed sump of jet pump. Check for correct
operation for hopper overflow. Ensure sufficient water inflow into the hopper for maintaining
constant overflow.

Check that the clearances between hopper walls and seal & shield plates are as per drawing to
take care the expansion of the boiler both downward and horizontal directions. The water inside
the trough seal shall be maintained during the boiler in operation and the water supply should be
sufficient to maintain a constant overflow from the seal trough.

Check adequacy of water in air water converter tank. With push buttons on local panel, operate
4-way position controller (solenoid) valve for discharge gate. Adjust wedge located at the bottom
of roller guide channel of discharge gate if necessary to achieve proper gate sealing and smooth
movement of roller.

Apply specified lubricants in the plug valves and check for smooth operation of each valve
several times.

3.02.00 ASH CRUSHER :

Check that the Ash Crusher (single roll crusher) has been installed properly in accordance with
the drawings.

Check and apply oil / grease of required grade and required amount to all the bearings and other
points of the crusher, motor, gearbox, sprocket wheel and chain etc.
Check the crusher drive equipment i.e. motor, fluid coupling and gear box alignment and leveling.
Consult manufacturer’s instruction manual for fluid coupling, for the purpose of installation /
alignment as well as for filling of the fluid coupling. Use oil as per manufacturer’s
recommendation and select proper filling angle / level to avoid over loading the drive equipment.

Before running the motor with the driven equipment, check for proper direction of rotation. Now,
run the motor idle for 6 to 8 hours check temperature rise at bearings and other places, noise,
vibration etc.

Fix the chain with the driven equipment and motor and check for free right direction rotation of
crusher roll.

Check for proper seal water connection (from BA seal water pump) with the crusher sealing
points and all the water line valves, gauges, switches etc. have been erected as per the flow
diagram and the layout drawings. Check the direction of flow in the sight flow indicator.

Check the adequate BA seal water pressure in crusher sealing.

Check the forward rolling speed of crusher at lower set speed as sensed by zero speed switches.

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Check all interlocks of crushers by introducing abnormal conditions.

3.03.00 JET PUMP :

Check the operation of the jet pump by supplying water from HP water source through jet pump
nozzle. Simultaneously operate the crusher, open the feed gate and jetting nozzles inside the
hopper thereby creating a normal flow condition as far as possible.

Check the adequate water pressure at the inlet of jet pump and set the pressure switch
accordingly.

3.04.00 REMOTE OPERATED VALVES :

Check operation of the solenoid operated valves on jet pump water supply lines so that these open
and close fully. Check for smooth operation without any jerk or sluggishness.

All the water line valves, gauges, switches etc. has been erected as per the flow diagram and the
layout drawings.

Check for electrical connections of all cylinders operated valves & pressure switches and system
interlocks.

In addition, check operation of the solenoid operated valves on jet pump inlet & discharge lines
for smooth opening / closing.

Check operation of the valve limit switches to ensure that these actuate when the valves are in
appropriate position (open or close) and they does not generate any false signals.

3.05.00 BOTTOM ASH HOPPER FEED GATE :

Check smooth mechanical operation of Feed Gate through 4-way solenoid valve and air water
converter tank. Fill air water converter tank with water.

Adjust the gate wedges / rollers as necessary for achieving the best seals in closed condition of
gate. Check sealing of gate by filling the hoppers with water upto overflow level.

Check to operate gates number of times for smooth mechanical movement as well as sealing.
Adjust globe valves on the oil line between AWC tank and feed gate-actuating cylinder to achieve
slow gate movement.

Check electrical connection and working of the flood- lit at inspection window. Check for proper
functioning of feed gate open / close indicators.

4.00.00 COARSE ASH HANDLING SYSTEM :

4.01.00 ECONOMISER HOPPERS ASH HANDLING SYSTEM :

Check all the Eco water pump lines connected with Flashing apparatus, flush the Eco water lines
with water.

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Check the nozzles of Flashing apparatus and flush the apparatus.

Check the economizer hoppers ash piping are leak-proof.

Arrange appropriate water supply from Eco water pump & check availability of required
pressure.

Check the Eco water line to ash slurry pipe. Flush the line connected with the slurry pipe.

Check the operation of flushing apparatus and opening Eco water supply line. Slurry discharge in
bottom ash hopper by ash slurry pipe.

NOTE: The Coarse ash (economizer hopper ash handling) system is in continuous operation. When
the Eco water header pressure is below normal, then coarse ash hopper manually isolation
valve (KGV) have to close.

4.02.00 MANUAL OPERATED VALVES :

Check operation of the manual operated valves on coarse ash system for HP water supply lines so
that these valves opens and closes fully. Check for smooth operation without any jerk or
sluggishness.

5.00.00 FLY ASH HANDLING SYSTEM

Check all the fly ash hoppers are free from constructional debris, metallic items etc. It is
advisable to keep ash intake valves in closed position and to conduct entire cleaning from hopper
manhole.

Before handling fly ash, adjust the air intake valve at the end of each branch header to allow disc
to open suitably. If vacuum is too high adjust to allow disc to open wider. If too low, allow disc
to open less. Do not throttle the air intake unnecessarily. Pressure drop across air intake valve
should be around 12 mm. of Hg.

Check handling and controlling solenoid valves and instrument air piping to cylinders and other
actuators of all fly ash intake valves, header valves (TERSG), vacuum relief valve, dust
separator, ash transmitters, etc. as per the drawing furnished. Before testing and adjusting,
instrument air piping should be purged out with air. Remove any foreign material present in the
pipeline. Dust free and moisture free instrument air is to be used for all pneumatic controls and
actuators. Necessary checks should be made on the air supplying equipment.

Check all the fly ash intake valves / diffuser intake valves, be sure that they are absolutely free of
foreign materials.

All wetting units, collector tanks should be checked (specially the nozzles) to ensure that they are
free of foreign materials. Before operating the fly ash system, wetting unit nozzles should be
thoroughly flushed out after removing nozzle tips.

It is essential to inspect the fly ash conveying pipes as thoroughly as possible during erection to

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remove any debris present therein.

Check all joints in fly ash conveying pipe to make sure that all bolts in each joint are pulled-up
evenly. This is important as air leaks can seriously affect the operation of both vacuum and
pressure system.

Connect the set of vacuum switches, vacuum gauges and vacuum transmitter to vacuum line
through corresponding isolation valves/gauge cocks on vacuum impulse line as per scheme.
Check installation of dust check station on the vacuum line and check for proper direction.

Check that the vacuum transmitters have been adjusted to operate at different vacuum settings as
required for automatic control, and check electrical wiring to the vacuum transmitters done as per
scheme.

In dry ash collection system clean air return line emerging out from bag filter to the corresponding
vacuum pump through air washer by actuation of selector on panel. The electro- pneumatic
valves on water supply station for air washers are opened automatically according to selection of
conveying modes. Adjust setting of pressure switch on water line of air washer. Control globe
valve as necessary to achieve desired water pressure at air washer inlet.

Check for conveying line is made through and start vacuum pump from panel. Vacuum pump
sealing water tapped from service / clarified water header and will attain "Normal” water
pressure before mechanical exhauster starting. Check the same in CCC to indicate seal water
supply pressure to vacuum pump "Normal". Check vacuum reading for minimum and maximum
vacuum. Ensure that desired vacuum is achieved and there is no leakage in vacuum conveying
line. Check and adjust setting of various vacuum-switching devices. Similarly, connect other
vacuum pump sets with corresponding vacuum lines and operate with air to see the performance.

The equipment in wet ash disposal system under vacuum mode, as operated by mixing the
conveyed ash directly with ash water are also to be thoroughly checked. Check the wetting unit
and collector tank. If any debris is found, it is to be removed. Check and adjust ash water line
globe valve providing water to wetting head and adjust the pressure switch setting if required.
Also, check the setting and functioning of vacuum breaker corresponding to each conveying
stream.

5.02.00 REMOTE OPERATED VALVES :

Check operation of the solenoid operated butter fly valves on fly ash wet system HP water supply
lines so that these open and close fully. Check for smooth operation without any jerk or
sluggishness.

Check operation of the valve limit switches to ensure that these actuate when the valves are in
appropriate position (open or close) and do not generate any false signal.

5.03.00 CHECKING OF OPERATION OF BAG FILTER WITH BUFFER HOPPER:

Ensure that filter bags are installed properly and no foreign materials are left inside the
combination bag filter with buffer hopper.

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Check for instrument air piping and fluidizing air piping connections have been made properly
with all valves and instruments strictly as per drawing, check setting of all differential pressure
switches.

Check availability of instrument air with adequate pressure and carry out operation of gates of
each buffer hopper by utilizing manual override feature of on line solenoid valves. Establish
pressure/vacuum equalization as necessary for operation of the gates. In case of any jamming,
mis-alignment, jerky movement of gates, corrective measure are to be taken to maintain smooth
operation of the gates.

Repeat every operation a number of times to establish free and smooth operation of the gates.

Check that the entire unit and instrument air piping are leak proof.

Carry out pulse jet operation for each combination bag filter locally to purge the filter bags and
check smooth operation of the pulsing system.

Establish fluidizing air supply in the line and check that fluidizing air flows freely to the
fluidizing pads mounted in the buffer hoppers. All fluidizing pads are brittle in nature and needs
to be protected against impact and mechanical damage. This is very important for smooth
operation of the "Filter Separator” (bag filter) and fly ash system as a whole.

Check operations of various ash intake valves, TERSG, vacuum relief valves and of other
solenoid operated valves locally through manual override actuation of solenoid valves. For any
jamming/slugging operation or jerky movement or mis-alignment if detected in valve operation,
corrective action is to be taken. Repeat operation a number of times to establish free and smooth
operation of the valves/TERSG.

5.04.00 CHECKING OF OPERATION OF ASH TRANSMITTER ASSEMBLY & PRESSURE

CONVEYING WITH SILO UNLOADING SYSTEM:

Check that no foreign materials are left inside the Ash Transmitter vessel.

Ensure that all instrument air and fluidizing air connections have been made properly with all
valves and instruments strictly as per drawing.

Establish instrument air supply in the line and check operation of top gates and bottom gates by
actuating corresponding solenoid valves. In case of any jamming, jerky movement or mis-
alignment, rectification are to be carried out and smooth operation of the gates to be established.
Repeat operation a number of times to establish smooth performance.

Check proper flow of fluidizing air into inlet and outlet diffuser which is essential for healthy
operation of ash transmitters.

Check the operation of air cylinder operated valve on conveying air line, ash lines and water lines
locally for smooth mechanical operation and proper functioning of limit switches.

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Various controls and interlocks as described in "Write up on Plant Control, Operation &
Monitoring (Part-B)” have been provided in fly ash conveying system in order to ensure its safe
operation. Producing simulated conditions necessary for actuation of the interlock should check
proper functioning of each interlock.

Check proper functioning of the fluidizing pads. All fluidizing pads are brittle in nature and needs
to be protected against impact and mechanical damage. Before operating system, ensure
cleanliness of hoppers and pipe so as to guard against damage as nuts, bolts and iron pipes and
other debris get conveyed to the system. Keep careful watch at the bottom of all risers in the
system pipeline for any rattling/unusual sound. If such sound is observed stop the system and
clean the pipe immediately.

Check proper installation of pressure/vacuum relief valve, level probe, etc. over silo.

Check the operation of silo vent filter and its pulsation system.

Ensure cleanliness of the station silo. Remove all construction debris and foreign materials and
check proper monitoring of silo fluidizing pads. While doing so ensure that all silo outlet valves
are closed for protection of down stream equipment.

Check and ensure proper functioning of the arrangements provided in rotary feeder. Check for
smooth operation of the rotary feeder gate (Cylinder operated) valve.

Check proper alignment and positioning of dust conditioner (rotary unloader) drive equipment i.e.
alignment among motor and gear box, drive sprocket on gear box, driven sprocket on unloader
drum and idlers, etc.

Check smooth operation of drive equipment set before connecting to unloader drum.

Check proper positioning of the guide rollers and thrust rollers of unloader drum by rotating the
drum manually. Check drum seals at inlet to drum and at drum discharge.

Arrange appropriate water supply from dust conditioning water pump and check availability of
specified pressure. Flush unloader piping removing nozzles and reinstalls nozzles after complete
flushing of water pipe line.

Couple unloader with its drive equipment (through chain) and check for smooth no load
operation. Check rollers for proper contact/support. Check drum seals at inlet and discharge.

Check proper position of discharge of flexible chute arrangement with respect of close tankers
unloading.

Check level switch is properly installed at outlet of flexible chute arrangement.

Establish silo fluidizing airflow in line and check fluidizing airflow through the fluidizing pads
inside silo and silo outlet fluidizing pad.

5.05.00 CHECKING FOR SILO VENT FILTER OPERATION :

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Ensure that filter bags are installed properly and no foreign materials are left inside the silo vent
filter.

Check for instrument air piping connections have been made properly with all valves and
instruments strictly as per drawing, check setting of all differential pressure switches.

Check that the entire unit and instrument air piping are leak proof.

Carry out pulse jet operation for each vent filter locally to purge the filter bags and check smooth
operation of the pulsing system. This is very important for smooth operation of the "Filter
Separator” (vent filter) and fly ash system as a whole.

6.00.00 INSTRUMENT AIR COMPRESSORS :

Check and apply oil / grease as required for the compressor and motors as recommended by the
manufacturer. Also refer to the lubrication schedule attached to this manual.

De-couple compressor and motor. Check for insulation resistance, continuity etc. for the motors
and run each motor to check for direction of rotation with respect to that driven equipment.
Interchange motor terminal connection if rotation is in reverse direction. Restart and again check
for direction of rotation. Then run the motor idle for 6 to 8 hours. Check for temperature rise at
bearings, noise, vibration etc and take corrective measure as necessary.

Now couple the compressor with motor after proper alignment and fix the equipment rigidly on
base as per the manufacturer's instruction.

Check that cooling water connection to compressor with all valves, gauges etc. has been installed
properly as per the drawings. Check for proper adjustment of pressure switches.

Establish cooling water supply for the compressor and after cooler and check for proper flow.
Adjust globe valves on cooling water lines if necessary to obtain required water pressure.

The operation of air compressor is interlock with the cooling water flow. Therefore constant flow
of cooling water at required pressure to compressors is required, while the compressor is in
operation.

Check compressor lubricating oil temperature and air temperature. This should be below the
preset normal and high value respectively.

Now run each compressor ­ motor set and check the operation of safety valve. Ensure that the
safety valves have been adjusted properly to the set point.

Check discharge pressure and ammeter readings. Observe rise in bearing oil temperature, noise,
vibration etc. Continue operation of the compressor for at least 3 to 4 hours and check for smooth
performance.

Check operational interlocks (Both running and starting permissives) of the compressor specified
in "Write-up on Plant Control, Operation & Monitoring (Part-E)

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Follow Manufacturer's instruction.

6.02.00 AIR DRYER :

Check inlet of the Dryer for leak-proof pipe joint up to the air receiver & after cooler.

Check inlet air temperature is not more than 500 C. Incase inlet temp. is more, then contact
compressor manufacturer.

Check outlet of the dryer for leak-proof pipe joint.

Check the power supply.

Switch on the dryer and open the inlet shut off valve gradually. Check the outlet valve (shut off
valve).

Check the dryer operation cycle.

Check that dryer drain valves automatically open when the dryer is in operation.

Check the dryer valves operation, i.e. 3-way or 2-way valves and exhaust valves. These valves
are operated by solenoid valves and are controlled by the electronic controller.

Check and set the safety valves.

7.00.00 ASH SLURRY DISPOSAL SYSTEM :

7.01.00 GENERAL :

Check, all ash slurry piping leading to common trough of ash slurry sump as thoroughly as
possible and remove all construction debris such as bricks, rags, welding rods, tool etc.

Remove the jetting nozzle tips and flush out water piping. Check proper operation of the slurry
sump jetting nozzles.

Check and adjust all the slurry sump level indications and control equipment to bring the remote
operated slurry sump make-up valves in service. Check all electrical connections for alarm,
annunciation and system interlocks.

Check operation of all cylinder/ motor operated valves locally by actuation of respective solenoid
valves by in-built manual override arrangement. In case of any jamming, mis-alingment, jerky or
sluggish movement, then valve to be checked for proper assembly and clean the parts thoroughly.
Also, check operation of limit switches to ensure that these actuate at desired valve positions
(open / close) and do not generate any false signal. Repeat the operation for each valve a number
of times to establish smooth operation of the valves and gates.

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Check all the ash slurry pump gland seal water supply for 1st stage to 2nd stage pump. LP & HP
water connections have been made properly and all seal water line valves, gauges, switches etc.
have been placed as per drawings and pressure switches have been adjusted to the proper setting
values. However, final adjustments of the set points as required can be done after running the
pumps with water.

NOTE: The ash slurry pump casing should not be at shut-off pressure of seal water supplying to the
gland. Both suction and discharge valves of a slurry pump should not be closed at the same
time, while seal water is supply is on for the slurry pump.

7.02.00 SLURRY DISCHARGE PIPE LINE :

Check all slurry discharge line joints to make sure that all bolts are tight. Check the position of
each chains suction header connection to cylinder operated knife gate valve & pump discharge
header connection to cylinder operated plug valve against the detailed piping drawing and flow
diagram to make sure that the valves are installed correctly in relation to direction of flow of ash
slurry. Check all the valves for smooth operation.

Check that all the slurry line fittings such as elbows, laterals, valves etc. are supported rigidly as
shown in the drawings. Check for proper clamping of all the pipe foundations.

7.03.00 ASH SLURRY PUMP :

De-couple pump from motor and apply grease / oil as necessary to the bearings and other places
of pump and motor. Manufacturer’s recommendations should be followed in regard to lubrication
procedures in details. The basic lubrication particulars have also been furnished in the
LUBRICATION SCHEDULE attached to this manual.

Check insulation resistance, continuity etc. for the motors and start the motor to check direction
of rotation with respect to the driven equipment. Interchange motor terminals if rotation is in
reverse direction. Re-start and again check for direction of rotation.

Now run each motor idle for 6 to 8 hours to check temperature rise in bearings and other places.
Check vibration, noise etc.

Now couple the pump with motor, align properly and fix the equipment firmly on base frame /
foundations.

Check the 1st stage ash slurry pump is coupled with gear box, fluid coupling and motor. Align
properly and fix the equipment firmly on base frame / foundations for each chain.

For 1st stage pumps, Check the fluid coupling strictly as per manufacturer’s instruction. Accurate
alignment between the drive and driven equipment is necessary for efficient operation of the
pumping system. Consult manufacturer’s instruction manual for fluid coupling, for the purpose
of installation / alignment as well as for oil filling of the coupling. Check that proper packing
have been provided in the pump glands and the glands are properly tightened to prevent leakage.

Check the 2nd stage ash slurry pump coupled by v-belt driving arrangement with motor. Align
properly and fix the equipment firmly on base frame / foundations.

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7.04.00 TO START ASH SLURRY PUMP CHAIN :

Check the ash slurry pumping chain suctions are connected in ash slurry sump compartment
properly.

Check the ash slurry pumping chain is leak-proof. Check and set seal water line globe valve to
give required pressure. Check that the pressure switch is set to the required values.

Check the pump in following sequence :

 Sump in filled with water & make-up valve open (if required).
 Suction valve is open.
 Discharge valve closed (may be checked once for opening by simulating through CCC).
 Cooling water for fluid-coupling oil cooler & check adequate pressure & flow of clean water
through flow meter.
 Seal water header & individual line solenoid valves are properly opening on LP & HP seal
water line from CCC & check the water pressure.

Now, with actuation of “CHAIN START” push button on “Central Control console” (CCC), the
following functions are done automatically, maintaining a per-determined time interval between
two successive steps of operation.

- With the actuation of ‘Chain start’ sump-jetting valve of that particular sump will open.

- Suction valve opens if in close position (it is suggested to keep suction valve always open
condition).

- Seal water valve of corresponding pump opens.

- 1st pump started.
- Discharge valve opens after preset time.
-
- 2nd pump started.
-

-
With the actuation of ‘Chain Stop’ the operating slurry pump chain will stop and thereafter at
pre-set time interval the discharge valve will close with subsequent closing of seal water valve.

Operate the pumps for at least 2 hours, Check for bearing temperature rise, noise, vibration etc.

The seal water pump should start prior to starting of slurry pumps to supply gland seal water.

The slurry pump operation is interlocked with the pressure switch provided on pump gland seal
water line. Constant flow of seal water at required pressure is required while the pump is in
operation is therefore very important.

Check for alarm / tripping of slurry pump series by stopping water supply to pump gland seal.

7.05.00 REMOTE OPERATED VALVE :

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Check operation of the remote operated valves on various supply lines so that they open and close
fully. Check for smooth operation without any jerk or sluggishness.

Check operation of the solenoid operated valves on various supply lines for smooth opening /
closing fully.

Check operation the valve limit switches to ensure that these actuated when the valves are in
appropriate position (open or close) and do not generate any false signal.

8.00.00 PRIOR TO HANDLING OF ASH IN THE BOILER:

Before start-up of boiler, normal water supply to Bottom Ash Hopper and Seal-trough should be
ensured. The supply of LP water shall henceforth remain continuous and undisturbed.

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 SECTION - 5

INSTRUCTION FOR SYSTEM OPERATION

 INDEX

SECTION - 5

SL. NO. DESCRIPTION PAGE NO.

1.00.00 GENERAL 5:1

2.00.00 WATER PUMPING AND SLURRY DISPOSAL 5:2

SYSTEM

3.00.00 BOTTOM ASH SYSTEM OPERATION. 5:2

4.00.00 COARSE ASH SYSTEM OPERATION. 5:4

5.00.00 FLY ASH SYSTEM OPERATION. 5:4

6.00.00 FLY ASH PRESSURE CONVEYING 5:8

(DRY COLLECTION IN SILO).

7.00.00 DISPOSAL LINE FLUSHING 5:10

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INSTRUCTION FOR SYSTEM OPERATION

1.00.00 GENERAL :

The Ash Handling System clears the Bottom Ash from each unit once in every shift of eight (08)
hrs normal operating sequence. The bottom ash is collected in water impounded Bottom Ash
Hopper. Bottom Ash operating facilities are actuated from Bottom Ash Local Operator Console
(BALOC) in due coordination with Central Control console (CCC).

In each unit, the bottom ash is conveyed by two (02) disposal lines leading to ash slurry sump &
ultimately disposed to ash pond by slurry pumping system.

Coarse Ash generated in furnace and collected in hoppers i.e. ECO Hoppers is transported in
slurry form to bottom ash hopper and from there is conveyed to common ash slurry sump.

Fly Ash generated in furnace of three (03) units (#1, #2 & #3) and collected in hoppers, which is
ultimately conveyed to ash pond in slurry form or Silo in dry form through different operating
devices. Under fly ash system all solenoid operated air electric valve will be normally operated/
control from HMI / through DCS logic in remote interlock mode. However, local de-interlock
operation of the valves will be possible through actuation of manual override facility provided on
respective solenoid actuators.

Three type of water pump are provided for bottom ash, coarse ash & fly ash cleaning system,
i.e. LP & HP.

The Low Pressure (LP) Ash Water Pumps for three (03) units (#1, #2 & #3) are provided to
cater the water requirement for continuous cooling of bottom ash hopper ash, make-up for seal
trough and other system make-up water requirement, as and when necessary, during ash cleaning
operation.

The BA High Pressure (HP) Ash Water Pumps for three (03) units are provided to cater the
water requirement for hydraulic BA jet pumps and various other ash cleaning devices during
cleaning operation.

The Fly Ash Eco Water Pumps & HP water pumps for three (03) units are provided to cater the
water requirement for flushing apparatus and various other ash cleaning devices during cleaning
operation.

The BA ash slurry Disposal pumps (BASP) are provided for disposal of generated BA ash slurry
to ash pond during cleaning operation.

To achieve water balance based on specified operating condition the following operational
combination of various pumps may be used. LP pump is to be operated continuously round the
clock irrespective of whether the ash cleaning operation in progress or not to supply bottom ash
hopper and seal trough make-up water requirement .This may require further fine adjustment at
site depending on exact quantity of inflow and outflow.

The bottom ash hopper overflow water is received into the BA. Overflow sump & overflow water

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transfer to common ash slurry sump.

The various steps to be followed for operation of ash cleaning systems and water & slurry
pumping system are described in the following clauses and paragraphs.

2.00.00 WATER PUMPING AND BA ASH SLURRY DISPOSAL SYSTEM :

Various pumps (HP & LP water pump, Eco water pump, Seal water pump, Clarified water
pump, BA overflow pump, Ash slurry drain pump, Ash slurry pump,) are to be started and the
pumping system is required to be put into operation as per the following steps.

Pump suction water pressure is ‘Normal’ where as applicable.

Sump level is normal and inflow water valves are in open position whereas applicable.

Open fully the suction valve of the pump.

Check the suction and discharge pipes are free from foreign materials.

Check the online instruments are in working condition.

Keeps the discharge valve of the pump about 10% open or fully closed position (whereas
applicable).

Check the freeness of pump.

Check the water level / grease is properly provided.

Check the belt guards / coupling covers are provided.

Open the seal / cooling water connection valves of the pump whereas applicable.

Start the pump (individual pump will start / run as per starting / running permissive given in
Control write-up) and gradually open discharge valve (whereas applicable other wise opens
automatically after preset time) fully and check discharge header pressure, current, bearing
temperature, vibration, noise, etc.

3.00.00 BOTTOM ASH SYSTEM OPERATION :

Carry out the following steps for transportation of bottom ash from bottom ash hopper to slurry
sump. The following steps are applicable for both ‘draw down’ and ‘maintained level’ methods.
Whereas, in ‘ maintained level’ of BA cleaning the BA hopper make up valve is kept in open
condition throughout the evacuation period for maintaining the hopper level inside the BA hopper.

Make sure that all manual water supply valves on selected bottom ash conveying paths are fully
open. [Make sure that for each V-section, the inlet water valves before selected jet pump is open
and the same before stand-by jet pump is close].

Check that “Bottom Ash Local Operator Console ” (BALOC) instrument air supply pressure is
healthy.

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Select the operating gate for each V-section & position the selector accordingly.

“START PERMISSION REQUEST” signal is then transmitted to CCC (Central Control

Console) from BALCP. On receipt of above signal from BALCP, the CCC operator will open the
Jet pump discharge valves (sluice valves) and inlet water valve for the selected path and start the
slurry pumping systems as necessary. The CCC operator will then transmit “START
CLEANING” signal to BALOC.

With opening of pneumatic HP water supply valves before jet pumps, water flow will be
established through the jet pumps. Check for normal water pressures before jet pumps. Adjust
water globe valves before jet pump if required.

Open the seal water line valve line of operative crushers and check normal water pressures.
Adjust water globe valves before jet pump if required.

Put the “AUTO-MANUAL” reversal mode selectors for clinker crushers on desired position and
start the crushers.

Check level of water in the air water converter tanks for the operative feed-gates and fill-up if
necessary by opening the isolation valve from water line. Close the isolation valve after filling the
tank up to the desired level.

Make sure that the feed-gate dilution spray water line valves for the selected conveying paths are
fully open before opening the crushers.

Operate the spring return selector actuators to energise the solenoid operated 4-way direction
control valve suitably to raise the feed-gate. Bottom ash from the bottom ash hopper gets
discharged into the clinker crusher with the opening of the feed-gate and after crushing is
conveyed to slurry sump. Observe discharge condition through the inspection window of the feed-
gate enclosures, raise it enough to allow the clinkers to pass them gradually. Set the gate opening
to such a point where the materials are carried-away at desired rate of feeding.

Check the feed gate inspection window spray water isolation valve is open condition.

Adjust the water line globe valves before operating jet pumps, if necessary, to establish efficient
slurry flow.

Once the major accumulated ash have been cleaned, sequentially open the plug valves for upper
& lower slop jetting nozzles, one bank at a time starting with the top bank of nozzles.

In case of jamming or tripping of crusher during operation the feed-gate instantaneously closes.
For jamming of crusher, remove the jammed materials through automatic or manual reversal of
crusher rotation as explained in “SECTION - 1” and in “Control write-up (Part-A)”. If jamming
can not be cleared, open feed-gate enclosure manhole and manually break / remove the clinkers.

The bottom ash cleaning operation now continues. Inspect the bottom ash hopper through the
inspection windows and assure that clinkers from the hopper have been removed. Close all plug
valves on slop jetting lines. Then operate the solenoid operated 4-way valves on air line to close
the hopper feed-gates completely.

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Carry out seal-trough flushing by opening pneumatic HP water line valve & water flow control
globe valve as necessary and then close the valve.

Carry out BA hopper refractory flushing by opening of HP water line valve & water flow control
globe valve as necessary and then close the valve.

Keep the water supply through jet pumps on for about 5 minutes to allow purging of the
conveying lines.

Close the dilution spray water line valves after stopping the excentic crusher. Check from glowing
lamps that the crushers have stopped. Then close the solenoid-operated valves on seal water lines
to crusher.

Convey bottom ash cleaning over signal from BALOC to CCC (Central Control Console).

Close remote operated waterline valves from CCC & check from glowing lamps that the valves
are completely closed. The bottom ash sluice valves should then be closed from BALOC to
complete the operation. With the completion of bottom ash cleaning, the water & slurry pumping
system are to be deactivated / adjusted accordingly.

4.00.00 COARSE ASH SYSTEM OPERATION :

4.01.00 COARSE ASH (FROM “ECO. ASH HOPPER”) HANDLING SYSTEM :

Carry out the following steps for transportation of “ECO” ash from “ECO” hoppers, under
gravity falling into the flushing apparatus. Then ash with Eco water mixed and slurry transfers in
bottom ash hopper for onward discharge to common trough of ash slurry sump.

Establish the water flow in flushing apparatus of “ECO” hoppers. Then open the hopper isolation
valve (manual KGV).

With the opening of coarse ash i.e. “ECO.” hoppers valves along with corresponding flushing
apparatus / jetting water supply valves opening, the ash will mix with water in flushing apparatus
and discharge to bottom ash hopper. This coarse ash system is continuously running

5.00.00 FLY ASH SYSTEM OPERATION :

The fly ash system operation, control and monitoring is carried out from Central Control Console
(CCC), being located at the main control room.

This console will provide complete status indications / alarms and necessary actuation facilities,
for both the dry & wet fly ash system up to silo and ash slurry system on the PC based HMI Unit.
System will be actuated and monitored from CCC.

Each conveying stream in HMI will convey the fly ash collected in ESP hoppers through four nos.
fly ash streams (Stream # A to Stream # D). The fly ash cleaning carried out by combination of
Vacuum and pressure Conveying process.

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The fly ash collection in ESP hoppers and cleaning carried out by Bag filter and buffer Hopper
set & fly ash transmitted to silo by applying pneumatic pressure through Ash transmitters.

Select the vacuum pump to be operated for each stream by actuating selector in HMI viz.,
VP#A1/ OFF/VP#A2, VP#B1/ OFF/ VP#B2 , VP#C1/ OFF/ VP#C2 and VP#D1/ OFF/ VP#D2
are dedicated to individual stream, while the stand by pump i.e. VP#A2 ,VP#B2 ,VP#C2
&VP#D2 are stand by for each streams. This actuator will automatically open the sealing water
line valve of selected vacuum pump (from purchaser’s service / clarified water header supply)
along with opening of electro-pneumatic valve at suction of vacuum pump. Also ensure closure of
seal water line valve and suction valve for other vacuum pump connected to the same stream.

Various steps of checking to be initiated during each phase of cleaning operation are elaborated
below :-

5.02.00 FLY ASH VACUUM CONVEYING FROM ASH HOPPER

Fly Ash Vacuum Conveying Operation while handling "Dry” ash up to Bag filter and Buffer
hopper is to be initiated as per the following steps :-

Physically check that all isolation valves on water line to vacuum pumps, are open (The vacuum
pumps to be operated will be actuated by respective push buttons in HMI).

Check physically and carefully all manual isolation valves in instrument airline for jet pulse
system of Bag-filter is open. Also, check from indication, that instrument air supply pressure in
FA area is healthy from CCC.

Check physically and carefully that all isolation valves on fluidizing airline to selected buffer
hopper are open. Also check the pressure of fluidizing air for ESP / Buffer transfer hopper
fluidizing blower. If found abnormal, appropriate measures are to be taken.

For cleaning of fly ash the following steps will be followed -

i) The TERSG i.e. the stream valves on conveying path will open, keeping the identical valve
on other (stand by) conveying path close condition.

Check whether Sealing Water (from purchaser’s service / Clarified water header) supply to
vacuum pump is normal and selected vacuum conveying line is through.

ii) Now the starting of the vacuum pump is to be initiated by following steps :

 Make sure that the vacuum pump path is through. Also, check that the selected Bag
filter is connected with the corresponding Vacuum Pump.

 Check whether, required adequate sealing water pressure of vacuum pump from
service water header supply, is normal (from purchaser's service / clarified water
header source).

 Before starting the vacuum pump please carry out the following inspection / checking
:-

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- Inspect the vacuum pump inlet to make sure that the inlet screen are clean and
check that connections have been properly made and are free of debris.

- Make sure that the liquid discharge connection are not plugged & are free of
obstructions.

- Also check other pre-conditions while starting the vacuum pump, as written in the
“operation and maintenance manual” of the vacuum pump.

The ash cleaning in dry state from ESP hoppers to buffer hopper under vacuum system can be
carried out either in "AUTO" or in "MANUAL" mode. For automatic cleaning of ash starting
from the first hopper to the end hopper of the selected rows in stream can be done by selecting the
"AUTO” mode. In “AUTO” mode, the ash cleaning operation starts from a particular branch of
row to another in a predetermined sequence. If "MANUAL” mode is selected, the operation from
any branch & hopper can be decided independently out of sequence. The selection of particular
branch and the hopper on that branch can be made by means of corresponding "ROW” selector
and “HOPPER” selector.

The next step is to give "SYSTEM START" command to the operative stream, which will close
the vacuum breaker / vacuum relief valve according to the mode of selection.

 "DRY" mode selection, for the selected bag filter, the bag filter pulse jet sequence and
elector-pneumatic fluidizing line valve are also automatically started with actuation of
“SYSTEM START” command.

 In "AUTO" mode, the fly ash cleaning operation will be continued in automatic sequence and
would start by opening automatically the ash intake valve below the first field of ESP hopper
on the first branch header and automatic opening shall subject to fulfillment of required
permissive as well as availability of line vacuum above the preset value (sensed by vacuum
transmitters). With loading of ash in the line vacuum would rise to a value lying between a
preset bands.

 Conveying from that hopper will continue until the line vacuum in that stream falls below a
preset value (sensed by vacuum transmitters) and persists for a preset period around 15 secs.
The above condition would ensure hopper empty status at HMI and close the ash intake valve
located below that hopper and switch over to the next fly ash hopper by opening the
corresponding ash intake valve. The cleaning operation would be carried on as per the
cleaning operation of the previous hopper. Once all hoppers in that branch are cleaned, the
next branch header valve will automatically open followed by closing of previous branch
header valve. In the similar fashion the fly ash hoppers connected with second branch header
will be cleaned with the help of Vacuum transmitter.

 Fly ash cleaning operation will continue from one row to another in above sequence until it
reaches to the last fly ash hopper and after that the respective system will come back to its
initial position by reopening the first branch header valve to allow purging the ash conveying
line. On completion of the same "SEQUENCE OVER" annunciation would appear in the
Central Control console (CCC).

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In this fashion, cleaning of other streams will also be performed simultaneously. When the
vacuum conveying is complete, the vacuum pump will be stopped (by respective push-button in
CCC, the respective vacuum breaker/vacuum relief valve will get opened automatically, with
closure of first branch header valve. The vacuum breaker/vacuum relief valve can be opened at
any moment in case of emergency by actuation of corresponding "“SYSTEM STOP” command.

Under "AUTO-SEQUENTIAL" operation, if it is necessary to stop the system owing to

occurrence of some fault or any other unavoidable circumstances, the "SEQUENCE STOP" push
button is to be pressed. “SEQUENCE START” push button can be used to resume the operation.

On completing, the mode selector (i.e. "DRY- OFF") will be put on “OFF” position, the pulse jet
cycle of bag filter will be closed automatically after a preset duration for total shutdown of the
system.

If situation arise that cleaning of a particular hopper is required to be by-passed, (both in "AUTO
SEQUENTIAL" or "MANUAL" mode), press the "JOG" push button. It will override the
permissive being activated through vacuum switching device. The ash cleaning operation will be
shifted to the next immediate hopper.

5.03.00 HOPPER CHANGE OVER

After the fly ash hoppers for each stream, from which ash is being cleared becomes empty, the
conveying line vacuum corresponding to that stream drop below the preset setting. If this
condition persists for a period of around 15 seconds (adjustable), this will make the indication
"Hopper Empty" condition and cleaning will switch over to next hopper by opening of the next
ash intake valve in sequence. The timer in the circuit prevents shifting of the hopper under
momentary drop in vacuum in conveying line.

5.04.00 BRANCH CHANGE OVER

After cleaning of the last hopper of a particular branch, (Under "auto ­ sequential" mode) the fly
ash intake valve closes, and the fly ash header valve of the next branch opens with closing of the
previous fly ash header valve. Thereafter the fly ash intake valve of this next branch will open for
continuation of fly ash cleaning.

5.05.00 PLUGGED HOPPER CONDITION (BOTH FOR "AUTO-SEQUENTIAL" &

REMOTE "MANUAL" CLEANING)

"Plugged Hopper" condition appears when the ash arching occurs over hopper walls leaving a rat
hole inside the accumulated ash and ash does not flow freely into the conveying pipeline. At this
condition, the vacuum in the conveying line lies between the set points VS-1 and VS-2. If the
vacuum persists in this zone for approximately 1 min. (Adjustable), the vacuum switching device
will initiate annunciation "Hopper plugged" status through the audio-visual window annunciation
system. Accept the plugged hopper condition by pressing 'Accept' push button and follow actions
as per under-described procedure.

Press and release the "Jog" push button. The cleaning operation instantaneously shifts to open the
next ash intake valve and continue sequential cleaning as usual thereby by-passing the plugged
hopper.

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At the end of cleaning cycle from rest of hoppers in sequence, acknowledge Fly Ash Vacuum
Conveying "SEQUENCE OVER" annunciation. Start the Vacuum Pump "ON". Again press
"SYSTEM START" push button and bring the operation upto the plugged hopper. Remove the
poke hole cover of the plugged ash intake valve and insert-poking rod inside to break the formed
arching. Continue till ash flows freely in the conveying line from the plugged hopper and is
carried away.

After acknowledging the plugged-hopper alarm, the plugged hopper may also be cleared in the
following manner :-

 Press "SYSTEM STOP" push button to stop sequential cleaning operation.

 Poke & break the arch in the manner as explained above.

Again, press "SYSTEM START" push button to continue sequential cleaning operation from the
same hopper.

6.00.00 FLY ASH PRESSURE CONVEYING (DRY COLLECTION IN SILO)

Carry out the following steps for transportation of ash from Bag filter and buffer hopper to
station silo.

6.01.00 STEPS FROM CCC FOR FLY ASH PRESSURE SYSTEM

Check that ash level in selected station silo is below "HIGH".

Check that instrument air supply pressure is healthy.

Open buffer hopper fluidizing valve.

Select the conveying line and transfer line inter connection valves.

Silo selection of each transfer line to be done.

Select the working nuva feeders connected with conveying lines.

Start the vent fan of selected silo.

Pulse jet cycle of silo vent-filter is to be started. The above operations will be carried
automatically, if “AUTO / MANUAL” selector switch provided for pressure conveying system is
put on “AUTO” mode, otherwise those operations are to be carried out from CCC manually.

With proper operation “Pressure conveying on” indication will be available at on HMI.

6.02.00 NOW CARRY OUT THE FOLLOWING STEPS FROM CCC / SSCP :

The two-(2) Nuva feeders can operate simultaneously with initial phase lag, and respective
conveying compressor is to be operated corresponding to operation of each conveying line. Out of
the three-(3) fly ash conveying compressors, one is common standby, which can be utilized for
any line.

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But, while putting it into operation due care must be taken that no two (2)-conveying
compressors get connected to a particular conveying line. For this, manual isolation valves are to
be opened / closed properly.

Before starting of ash conveying to silo, the fluidizing system of the fly ash silo is to be kept
under energized condition. Therefore, out of the 4 nos. silo fluidizing blowers two can to be
operated from Silo System Control panel (SSCP), The silo-fluidizing heater is also to be activated
from SSCP. The operation of blower and heater is desirable to be continued so long, as there is
fly ash inside the silo.

Make sure that manual isolation valves on the discharge line(s) of selected fly ash screw type
conveying compressor(s) are open. Now, the conveying compressor(s) is (are) to be started from
CCC through’ respective push button. Out of the three (03) Nos. of fly ash conveying
compressors, two (02) will be working and one (01) will remain standby. Each conveying
compressor will cater to the air requirement in each fly ash pressure conveying line. The solenoid-
operated valve on cooling water inlet line will automatically open for each compressor with
starting of respective compressor.

For details operation of transport air compressors please refer “control write-up” of vendor /
manufacturer.

On having normal conveying air pressure, “PURGING ON” signal will turn on and this initial
line purge continues for a preset (adjustable) duration, and then signal will turn off. Thereafter,
ash transmitter cycle is to be started by respective actuator on CCC, subject to availability of
required permissive (i.e., line pressure), which turns on the “SEQUENCE ON” indication.

The ash transmitter will keep on operating with a preset timer based sequence, until the ash
conveyor becomes empty, sensed by pressure transmitter on the air line.

On sensing the no load pressure to pressure sensing device in the air line for a preset duration,
and subject to the condition that fly ash vacuum conveying dry system is stopped altogether, the
top gates of all transmitters will be closed. The bottom gates of ash transmitters will operate in
normal sequence for one complete cycle, and thereafter, “SEQUENCE OVER” status will be
annunciated. After which the ash transmitter cycle is to be stopped by respective actuator, which
will turn off the “SEQUENCE ON” indication, followed by final line purging for a preset time.
The operating conveying airline valve will then be closed automatically with stopping of
conveying compressor, if “AUTO” mode selector switch is selected for pressure conveying
system.

The fly ash transmitter operates either on probe mode or timer mode. For this mode selection,
selector(s) provided for the ash transmitters of each stream is (are) to be selected in a particular
mode. The details of ash transmitter operating cycle are provided in “control write-up” Part-B.

6.03.00 OVER LOADED STATUS :

During Ash Transmitter evacuation, if at any time ash gets accumulated in ash conveying line, the
pressure in the conveying line will rise, and will be sensed by pressure transmitter.

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If this condition (i.e. line plugging owing to ash accumulation) persists for certain time duration,
fly ash pressure conveying line OVER LOADED” status will be annunciated. In this case,
clearing of line plugging is done by repeated purging with air (provided by conveying air
compressor) and / or by manual intervention to clear the line.

7.00.00 DISPOSAL LINE FLUSHING :

After completion of ash cleaning operation through a slurry pump chains, the particular pump
chains along with its disposal line should undergo thorough flushing with water. The flushing of
the disposal line can be carried-out keeping the pump chains in operation and supplying flushing
water into the slurry sump compartment. The operating flushing pump will pump-out water
through its disposal line to flush.

However, when the flushing pump in operation and flushing of one disposal line is carried-out,
then carry out the following steps :

Close the suction valve of corresponding slurry pump chain to be flushed and open the manual
operated valves on flushing line and discharge valve of slurry chain.

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 SECTION - 6

ABNORMAL CONDITION IN ASH HANDLING

PLANT OPERATION
 INDEX

SECTION - 6

SL. NO. DESCRIPTION PAGE NO.

1.00.00 PREFACE 6:1

2.00.00 BOTTOM ASH HANDLING SYSTEM 6:1

3.00.00 COARSE ASH (ECO HOPPER ASH) HANDLING 6:2

SYSTEM

4.00.00 BA OVERFLOW WATER SYSTEM 6:2

5.00.00 FLY ASH HANDLING SYSTEM 6:3

6.00.00 ASH SLURRY DISPOSAL SYSTEM 6:7

7.00.00 MAJOR EQUIPMENT IN SYSTEM OPERATION 6:8

8.00.00 PERIODIC AND ROUTING ATTENTION 6:12

9.00.00 TOURBLE SHOOTING 6:12

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ABNORMAL CONDITIONS
IN ASH HANDLING PLANT OPERATION

1.00.00 PREFACE

Inspite of all the safeguards provided by design and the best care taken by the operating personnel,
abnormal conditions may occur in the operation of Ash Handling (Bottom Ash, Coarse Ash & Fly
Ash Handling) System.

Indication / annunciation’s are provided on Ash Handling PC based HMI units and is mounted on
Central Control Console (CCC) to appear, in the event of any abnormal condition arising from
malfunctioning / mal-operation of any of the major equipment, interlocking and protective devices
and/or abnormal conditions resulting from the process variable(s) exceeding the specified operating
limits, to alert the operator. The following pages highlight some indication / annunciation’s being
provided for the ash handling system together with the actions to be taken in broad outlines for
guidance of the operating personnel.

2.00.00 BOTTOM ASH HANDLING SYSTEM :

2.01.00 Tripping of Ash Crusher :

In case the Ash Crusher trips due to overload, indication appears on CCC, it is to be duly co-
ordinate by located control room with BA area & local “ Bottom Ash Local Operator Console ”
(BALOC) through glowing of amber lamp and corresponding hopper feed-gate closes on tripping of
crusher. On tripping of Crusher take the following steps :

Check the cause of crusher tripping. In case the crusher motor has tripped due to motor overload,
investigate for probable cause of overloading the motor. After rectifying the cause of motor
overloading, Clinker Crusher can be restarted.

When the Clinker Crusher motor has tripped due to reason other than overload, the interlocked
functions are to be investigated to determine the causes of the tripping. For guidance to the operator,
some of the causes of tripping of the crusher are given below, together with the actions to be taken.

2.02.00 Loss of H. P. Water Pressure :

 In the event of failure of high pressure water pressure, contacts of pressure switch on the water
supply line to jet pump will open to trip the clinker crusher. Check the reading of corresponding
pressure gauge. If the reading of the high pressure water is below the set point, check whether
there is any fault in the water supply line, i.e., any valve at up stream of the pressure gauge /
pressure switch might be closed. Also, more numbers water line valves than desired might have
been opened increasing numbers of flow paths and thereby decreases in water pressure. In case,
there is no fault in the incoming water supply, check the jet pump nozzle for wear. Locate and
rectify the fault to restore the high-pressure water supply pressure to the Jet Pump.

2.03.00 Jamming of Ash Crusher :

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 A zero-speed switch senses crusher jamming. In case of jamming, the crusher reverses
automatically for a short duration & resumes forward rotation. Automatic reversal will occur
twice and if the jamming persists, the crusher will trip with annunciation in both CCC &
BALOC. Manual attention is required locally to remove the cause of jamming. The crusher will
be restarted from the BALOC.

 During ash cleaning, the crusher roll may get jammed if abnormally hard clinkers or foreign
materials get lodged between the roll and wear plate. This will result in slip of the fluid coupling
or the motor will trip due to overload with consequent automatic closure of the feed-gate. Under
the conditions take of the following steps :

 In case there is only slip in fluid coupling because of jamming and the crusher motor continues
to run, as observed by red indicating light glowing on the bottom ash local control panel
(BALOC), stop the motor, check green indicating light glowing.

 If reserving the crusher does not clear the jamming, open the manhole of the gate enclosure and
take out manually the material causing jamming. Close the manhole. Now the crusher is ready
for normal operation.

 In case the crusher motor has tripped through overload relays because of jamming, with glowing
of indicating lamp on panel, reset the overload relay on panel when the light goes off. Now
follow the Reverse and Forward operations.

2.04.00 Loss of Crusher seal water supply pressure :

 In case, seal water supply pressure to operating crusher at any moment of system operation
losses, the crusher motor trips and hopper feed gate closes. Check the pressure gauge reading on
seal water line. Check mal-operation of seal water line valves, choking of seal water pipe etc.
Attend and rectify the fault until seal water supply pressure becomes normal.

3.00.00 COARSE ASH (ECO. HOPPERS OF ASH HANDLING SYSTEM :

3.01.00 Loss of Eco Water Pressure

In case of failure of pressure of Eco water supply to flushing apparatus ash slurry pipe, then close
the coarse ash hopper Isolation Valve. Check the reading of corresponding pressure gauge. If the
reading of the fly ash high pressure water is below the required pressure, check whether there is any
fault in the water supply line i.e., any valve at up stream of the pressure gauge switch might be
closed. Also more numbers water line valves than desired might have been opened increasing
number of flow paths and thereby decreases in water pressure. In case there is no fault in the
incoming water supply, check the flushing apparatus & ash slurry trench nozzle for jamming / weir.
Locate and rectify the fault to restore the fly ash high-pressure water supply to the flushing
apparatus & ash slurry pipe.

4.00.00 BA. OVERFLOW WATER SYSTEM :

In case of tripping of BA. Overflow water Pumps, check for the following reasons :-

4.01.00 MAL-FUNCTIONING OF BA. OVERFLOW WATER LINES VALVES

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Attend the entire BA. Overflow water lines valves and check whether they are in proper position.
Check air pressure supply to the valve cylinders through main pressure gauge reading as well as air
line piping to the valves. In addition, check solenoid valves on the airline for a probable mechanical /
electrical fault.

4.02.00 ABNORMAL CONDITION IN SEAL WATER SUPPLY TO BA. OVERFLOW WATER PUMP

Pressure of seal water supply (from seal water pump) to BA Overflow water Pump gland may
decrease. Check for mal-operation of water line valves, choking of water pipes. Also, check for some
abnormal opening in seal water supply paths causing excessive increase in seal water flow. Attend
and rectify the fault until adequate supply at required pressure is restored. Operating BA Overflow
water pumps without adequate seal water flow will result in rapid failure of gland packing and shaft
sleeves.

4.03.00 ABNORMAL BA OVERFLOW WATER LEVEL IN BA. OVERFLOW TRANSFER HOPPER:

The BA Overflow water Pump will trip in case of BA Overflow water level in BA Overflow
Transfer hopper reaches danger low level.

Overflow water level in BA Overflow Transfer hopper falls due to decreased in-flow into BA
Overflow Transfer hopper or increased discharge from BA Overflow Transfer hopper. Check the BA
Overflow water Pump discharge pressure and adjust the Pump speed if necessary to reduce the pump
discharge. It is to be ensured that there is no frequent start / stop of BA Overflow Pump due to level
increase / decrease in BA Overflow Transfer hopper. It is required to obtain a proper inflow in BA
Overflow Transfer hopper so that level almost remains steady. Check whether any BA Overflow
water Pump or piping of BA Overflow water Pump is damaged. Check that all pipes and fittings are
intact. If required, open make-up valve into BA Overflow Transfer hopper.

4.04.00 ABNORMAL CONDITION IN COOLING WATER SUPPLY TO FLUID COUPLING.

Keep watch on oil temperature of oil cooler of fluid coupling. Pressure of cooling water (from
purchaser’s DM water header) to fluid coupling oil cooler may decrease and rise the oil temperature.
Check for mal-operation of cooling water line valves & choking of cooling water pipes. Also cooling
water flow may fall or stop due to choking of water cooler tubes of oil cooler of fluid coupling.

5.00.00 FLY ASH HANDLING SYSTEM :

5.01.00 BY-PASSING / ISOLATING FLY ASH HOPPER CLEANING

Due to plugging or any such abnormal conditions, if it becomes necessary to bypass a hopper during
sequential cleaning operation, the following procedure may be adopted.

When a hopper is required to be by-passed, press the “Jog” push button. This will jog the operating
ash intake valve overriding permissive being activated through vacuum switching (VS-1). The auto
sequential operation will be shifted to the next immediate hopper, and then the onwards automatic
sequential operation will be carried out as before.

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5.02.00 FAILURE OF WATER PRESSURE AND / OR AIR PRESSURE :

In the event of failure of supply water pressure to air washer, pressure switches installed on ash
water (HP) header will de-energizes the fly ash cleaning by closing of ash intake valve and also
consequently "Fly ash vacuum system tripped" annunciation would appear on CCC. Acknowledge
the fault by pressing the "Accept" push button. The alarm will be silenced and flickering light will
become steady. After locating and rectifying the fault, the fly ash conveying may be restarted. In
case of low water pressure at air washer, check whether line has been choked and also check for
wear / chocking of nozzles and replace / clean, if required.

5.03.00 FAILURE OF CONTROL POWER IN CENTRAL CONTROL Console (CCC)

For maintenance or any other reason, if the power supply to the CCC is cut off, or the main fuse of
power supply line of fly ash system operating from Central Control Console (CCC) is blown off, all
electrically operated equipment and the fly ash conveying operation stop immediately. All the
indications/annunciation is on that CCC get off.

The fly ash conveying can be resumed after restoration of power supply to the CCC.

5.04.00 FALSE HOPPER PLUG ALARM :

A real plugged hopper alarm may be obtained only when ash cleaning from a hopper is started or in
progress. Such alarms at any other time are false, which may be ignored and audible alarm silenced
by pressing accept push button on the CCC.

5.05.00 VACUUM RISE FAILURE:

If the Vacuum in the pneumatic fly ash vacuum conveying system fails to reach the normal
operating level after the vacuum pump has been put into operation, CCC power supply is "ON"
and adequate air/water pressures are available, check the following :

5.05.01 VACUUM TRANSMITTER / VACCUM GAUGES :

(i) Check for vacuum transmitter impulse line connections and impulse valve position. Check
output vacuum signals are coming to CCC. Check vacuum gauges are mounted properly and
impulse line is clean.

(ii) Investigate for electrical or mechanical failure.

5.05.02 VACUUM RELIEF VALVE/VACUUM BREAKER:

If the Vacuum Relief Valve / vacuum breaker has not closed, inspite of all starting & running
permissive, check the followings:-

(i) Solenoid Valve may have failed electrically or mechanically. Attend the Solenoid valve.

(ii) Check for instrument air supply to air cylinder of valve.

(iii) Check that valve is properly closed, if not attend valve..

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5.05.03 VACUUM PUMP OPERATION:

Check that Vacuum Pump seal water pressure supply is healthy and selected vacuum conveying line
is "THROUGH". Check from Vacuum Pump drain outlets that water is drained in main slurry
trench by piping header, is released effectively. Also, check for proper setting / functioning of
Vacuum Pump safety valve, and proper power transmission through belts from motor to the
equipment.

5.05.04 FLY ASH CONVEYING LINE & VACUUM LINE:

(i) Check for leakage from joints, after the system has been in operation for some time. Check
for piping worn out and developed leakage.

(ii) Check for TERSGS / Valves connected to the operating Vacuum Conveying stream have
been properly closed. Rectify limit switch settings, if necessary. Check for leaks between the
slide plate and valve body and leaks through flanges. Also, check for wear on the slide.

(iii) Fly ash vacuum lines are never water washed, as presence of water will cause jamming of ash
in the pipeline. In case fly ash line get choked and can not be cleaned by the vacuum system
then lines to be dismantled and to be cleaned physically.

5.05.05 WETTING HEAD & AIR WASHER OPERATION:

 Check for wetting head nozzle tips, which may be plugged by debris. Also check for proper
water flow through’ those nozzles. In such case, water flow in wetting heads reduces / stops.
Take out the nozzles and clean immediately.

 Check whether Air-Washer nozzles are choked with debris. If it is found that the outflow of
water has been reduced, then all nozzles should be cleaned. Also, check for leakage from air
washer body / joints.

5.05.06 FLY ASH INTAKE VALVE:

i) If the valve is fully closed, check for leaks between flanges and gaskets and leaks through the
valve shaft bearings. Also, check for wear of the disc.

ii) If the valve has not closed, check the solenoid valve supplying air to the fly ash intake valve
cylinder as indicated in Control Write-up. Also, look for oversized or foreign material blocked
in valve body preventing the valve closing.

iii) If the valve fails to open, please check the following :

 Whether respective vacuum relief valve/vacuum breaker is actually close position other
wise take appropriate action to close it.

 Whether seal water supply valve / pressure to air washer is “OPEN” or Normal
respectively.

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 Whether bag-filter sequence and pulse jet cycle are "ON" (For dry mode vacuum
conveying).

 Whether instrument air supply pressure is “NORMAL” (above pre-set “LOW”).

 Whether buffer hopper ash level is below "HIGH" (For dry mode vacuum conveying).

 Line vacuum is above pre-set “LOW” (at starting, only on auto cleaning mode).

 Check the condition of filter bags against ash deposition.

 Check seal box water level.

 Selected Vacuum Pump is functioning normally.

 Water pressure to wetting heads & air washers for selected wet conveying path is
"NORMAL".

The ash intake valve will close automatically, if any of the above permissive is not available.
Also opening of any ash intake valve will not be possible unless the above permissive are
available.

5.05.07 ESP HOPPER FLUIDIZING:

Check proper fluidizing (pressure, airflow etc.) of ESP hoppers and diffuser intake valves and
temperature of fluidizing air.

5.06.00 FAILURE OF VACUUM TO DROP:

If the vacuum in the system fails to drop, when the Fly Ash System operation carried out from
CCC, check the following:

5.06.01 FLY ASH INTAKE VALVE:

If the valve has not actually closed, check for electrical or mechanical failures of the solenoid valve,
also check air supply to the valve actuator. If any abnormality is not found then check whether the
valve is malfunctioning owing to some mechanical failure.

5.06.02 FLY ASH TRANSPORT PIPES IN VACUUM SYSTEM:

Check the pipes and fittings to make sure that oversized materials or other obstructions are not
preventing ash flow. In addition, the lines may be choked due to any moisture is present in line. Line
blocks usually occurs in fittings & bends, if so, clear the same.

If the fly ash pressure conveying line pressure does not fall below “Overload" setting during system
operation, check the following :

5.07.00 FLY ASH TRANSPORT PIPES:

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i) Check the pipes and fittings to make certain that oversized materials or other obstructions are
not preventing ash flow. In addition, the lines may be choked from ash built-up, if moisture is
allowed to enter. Probabilities of occurrence of line block are more at fittings and hence check
the same.

ii) Check for proper actuation of safety valve of conveying compressor.

If the fly ash pressure conveying line pressure fails to rise during system operation, check the
following :

5.08.01 ASH-TRANSMITTER OPERATION:

(i) Check whether Ash-Transmitter (Nuva feeder) top and bottom gates are operating properly
as per logic sequence. Check the ash level in Transmitter vessel. Also, check for proper
fluidizing of top & bottom gate diffusers and Ash-Transmitter vessel.

(ii) Check proper setting/functioning of conveying compressor safety valve.

(iii) Check fly ash pressure conveying lines & valves for leak tightness.

(iv) Whether ash conveying line is "through"

(v) Ash level in selected silo is below "high".

(vi) Vent filter is operating properly.

5.09.00 EMERGENCY SHUT DOWN:

 In case some abnormal conditions arises in operation of any fly ash stream, it is necessary to
stop the stream immediately by actuation of corresponding “Sequence Stop” command, which in
turn will close the fly ash intake valve.

 If “SYSTEM STOP” command is given, instantaneously vacuum breaker / relief valve will open
along with stopping of Vacuum Pump.

 Take necessary steps to rectify the fault and then restart fly ash conveying of the stream by
actuation of “SEQUENCE START” push button provided in HMI.

6.00.00 ASH SLURRY DISPOSAL SYSTEM :

6.01.00 Ash Slurry Pumps:

In case of tripping of slurry pump chains, look for the following probable reasons.

6.02.00 Malfunctioning of Slurry Line Valves :

Attend all the slurry line valves and check whether they are in proper position. Check air pressure
supply to the valve cylinders through main pressure gauge reading as well as air line piping to the
valves. In addition, check solenoid valves on the airline for a probable mechanical / electrical fault.

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6.03.00 Abnormal Condition in LP & HP Seal Water Supply to Slurry Pump Gland :

Pressure of seal water supply to slurry pump glands of 1st & 2nd stage may decrease. Check for
maloperation of seal water line valves, choking of seal water pipes, etc. Also check for some
abnormal opening in seal water supply paths causing excessive increase in seal water flow. Attend
and rectify the fault until adequate seal water supply at required pressure is restored. Operating a
slurry pump without its seal water flow will result in rapid failure of gland packing and shaft sleeves
causes spillage of slurry from gland.

6.04.00 Abnormal Slurry Level in Slurry Sump :

The slurry pump chains will trip in case of slurry level in the individual slurry sump, reach danger
low level.

Slurry level in sump falls due to decreased in-flow to slurry sump or increased discharge from slurry
sump. Check the pump discharge pressure and adjust pump speed if necessary to increase / decrease
the pump discharge. Check that any pump or piping inside slurry pump house is not damaged.
Check that all pipe and fittings are intact. If required, open make- up valve into slurry sump. In
case disposal line is found damaged, immediately changeover to stand-by slurry pump series and
disposal line for ash disposal operation. Rectify the damaged disposal pipelines.

6.05.00 Abnormal condition in Cooling water supply to Fluid-Coupling :

Pressure of cooling water supply to fluid coupling may decrease. Keep watch on oil temperature of
oil cooler of fluid coupling. Pressure of cooling water to fluid coupling oil cooler may decrease and
rise the oil temperature. Check for mal-operation of cooling water line valves & choking of cooling
water pipes. Also cooling water flow may fall or stop due to choking of water cooler tubes of oil
cooler of fluid coupling.

7.00.00 MAJOR EQUIPMENT IN SYSTEM OPERATION :

7.01.00 HP / LP / ECO WATER / SEAL / CLEAR WATER PUMPS :

In case of tripping of HP / LP / ECO WATER / SEAL/ CLEAR water pumps, check for the
following probable reasons:

7.02.00 Malfunctioning of valves in the delivery line :

Attend the valve and check whether the same is in proper position. Check air pressure supply to
the valve cylinder through main pressure gauge reading as well as air line piping to the valve.
Also check solenoid valves on air line for a probable mechanical / electrical fault.

7.03.00 Abnormal level in water sump :

The pump will trip in case water level in water sump reaches danger low level.

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Water level in sump falls due to decreased inflow to sump or increased discharge from the sump.
Check that any pump or piping inside pump house is not damaged. If required, open make-up
valve into water sump. Also check that only required numbers of valves are opened and control
valves are properly positioned.

If the pump trips due to overload, immediately check whether opening more numbers of valves
than required has increased numbers of water flow paths. Close those valves and start the
pump.

7.04.00 FILTER SEPARATOR SEQUENCE :

During proper operation of Bag filter, the clean air will be exhausted from filter outlet.

After initial start-up of bag-filter system with ash, monitor differential pressure and frequency of
pulse cleaning. For the first few hours of operation, the requirement of pulsing is not much to
maintain a differential pressure (across the filter bags) between or below the set points. After one or
two days of operation, the rate of pulsing may be increase & then set the pulse duration properly and
a steady state pressure differential is maintained.

7.05.00 PULSE SYSTEM OPERATION :

Bag cleaning is accomplished by means of sequential pulse jetting to filter bags from instrument air
supply source thru’ pulse valves actuated by pilot valves. The cycle time and the time internal of
pulse are field adjusted to get proper pulse jet effect of filter bags.

7.06.00 ABNORMAL CONDITIONS :

The clean air and the dirty air plenums of each Bag Filter is provided with Differential Pressure
Switch. The setting values and consequent actions are described in this manual ‘Section-1’.
However, if there is chockage of filter bags or high differential pressure across filter bags, then
cleaning / replacement of filter bags is required. Under the above circumstances, the particular bag-
filter should be made out of service and attended for maintenance of filter bags.

7.07.00 SILO VENT FILTER SEQUENCE

Cleaning of filter bags for silo vent filter is governed by timer based pulsation system, controlled by
a Pulse Jet Controller. The pulse jet system is to be kept on when the silo is selected for ash loading.

When the silo vent filter pulse jet cycle Selector is kept on "ON" position, the same will energize the
local electronic controller to provide high pressure pulse air jet in filter bags through activation of
series of solenoid valves one after another in a pre-determined timer based sequence. The pulse jet
system operates on a preset “ON TIME” & a preset “OFF TIME”. This time can be adjusted to
achieve proper pulsing of silo vent filter.

Details for various controlling facility and allied timer adjustment facilities can be obtained from
manufacturer's instruction manual and pulse jet controller interface scheme drawing.

7.08.00 ABNORMAL CONDITIONS :

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Various abnormal conditions and their solution as discussed in operation of bag-filter separator are
also applicable for silo vent filter operation.

To avoid mal-operation of bag-filter / vent filters, the following preventive maintenance tasks may
be carried out on a monthly basis :-

1) Inspect Unit for leaks in instrument airlines.

2) Check for sufficient instrument air.
3) Verify that pneumatic lines are operating.
4) Ensure that sequential timers are operating. Check solenoid operation.
5) Check proper door closure for leaks.

7.09.00 ASH-TRANSMITTER OPERATION :

After operation with hot free flowing ash is established, the system should be relatively free from
trouble. however, regular checks should be made for the following :

 The conveying line should be checked for leakage.

 The ash-transmitters should be checked to ensure that they are filling to the proper level and are
emptying properly.

7.09.01 ABNORMAL CONDITIONS :

7.09.02 ASH-TRANSMITTER fails to operate or stops operating after the conveying compressor starts or
continues to operate.

 Check compressed air supply to ASH-TRANSMITTER gate cylinder.

 Check conveying line for high pressure, if high, check line for blockage, restriction, closed or
partially closed line valves.

 Check level probe.

7.09.03 INDIVIDUAL ASH-TRANSMITTER

If Material (ash) do not enter the ash-transmitter :

 Check operation of top gate. Probe failure can prevent gate operation (Under probe mode) or
the gate may be plugged/ restricted.

 The material in the buffer hopper may be moist or lumpy.

 Check compressed air supply to the upper gate cylinder.

 Upper diffuser may not be operating properly.

 The transmitter may not be depressurizing.

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Material does not fill the transmitter to predetermined level :

 The Upper gate may be partially blocked.

 The Upper gate cycle timing should be checked.

Material overfills the transmitter :

 Check lower gate for obstructions. The transmitter may not be emptying.

 Check upper gate for leakage.

 Check the diffusers. If diffusers are not operating, the transmitter may not be getting empty.

7.09.04 CHECKING ASH-TRANSMITTER OPERATION :

While checking ASH-TRANSMITTER operations, exercise care in making checks, use face and
body protection.

The chamber does not fill :

 The vent line could be plugged.

 If there is a strong blowing during the unloading cycle, the vent valve should be checked.

 If there is a strong puff when the unloading cycle ends and the transmitter vents, followed by a
strong blowing, the lower gate could be leaking or the valve controlling pressurization could be
leaking.

The transmitter does not fill or empty properly :

 Remove the test plugs at the diffusers. If the air discharged to the diffusers is on, but dirty, the
diffuser could be damaged or the diffuser gasket could be leaking.

7.10.00 VACUUM PUMP OPERATION :

If the Vacuum Pump trips during operation, check the following probable reasons :

i) The Vacuum conveying line connected to the vacuum pump not through

Check whether any valve on corresponding vacuum conveying line has been closed. Attend the
valve and rectify the fault.

ii) Loss of vacuum pump sealing water pressure

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In case of low sealing water supply pressure or less sealing water supply (from purchaser’s
supply source), check for mal-operation of sealing water line valves, choking of sealing water
pipes etc. Also check for leakage in sealing water supply paths or opening up of more number
of valves in sealing water line than originally designed for, causing fall in pressure. Attend and
rectify the fault until adequate sealing water supply at required pressure is restored.

7.11.00 FLY ASH TRANSPORT AIR CONVEYING COMPRESSOR OPERATION

If the Fly Ash Transport Air Conveying compressor trips during operation, please check for the
following probable reasons.

i) Fly Ash Pressure Conveying Path not through :

Check whether any valve on conveying path has been closed. Attend the valve and rectify the
fault.

ii) Loss of Cooling Water Pressure to compressor :

The cooling water supply (from purchaser’s DM water header supply) pressure to compressor
may decrease. Check for mal-operation of cooling water line valves & choking of cooling
water pipes. Some abnormal openings in cooling water supply paths may also cause fall of
water pressure, which should also be checked and rectified.

Cooling water flow through compressor is extremely important for efficient operation of the
compressor system. The cooling water flow may decrease or stop due to choking of
compressor water tubes. Therefore, the operator should regularly watch the discharge from
compressor and check the air outlet temperature.

8.00.00 PERIODIC AND ROUTINE ATTENTION

In order to keep all the equipment ready to attend any emergency situation check operation of stand-
by equipment (idle pump / blower / compressor motor sets, remote operated valves etc.) which are
not normally used during system operation at least for eight hours every month. This may however,
done conveniently one after another in a planned way while the system operation remains idle.

To find out whether interlocks are functioning properly or not, it is recommended that simulating
actuating condition once in every two months check the various interlocks. Checking of interlocks
may be suitably carried out along with periodical operation of idle pumps and motors.

As routine attention for all the pumps, motors under operation, check at least once in every two (2)
hours normal operation, proper lubrication of bearings, glands / bearings temperature, pump
discharge pressures, ammeter readings, operating voltage, compressed air supply pressure etc.

9.00.00. TROUBLE SHOOTING:

The following serves as a guide to determine some possible sources of trouble and their solution during
operation.

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:PRECUATION, RUNNING ABNORMALITIES & SAFETY MEASURES:

BOTTOM ASH:

PRECUATION Before bringing boiler into operation following precautions are to be taken.
 BAH is free from any foreign material
 Check all jetting nozzle/spraying nozzles are clear & discharging water when headers
are charged.
 BAH water level is maintained with proper overflow.
 Seal trough is cleaned and water is maintained.
 All valves, gates, instruments are in working condition.
FOLLOWING ARE THE FEW ABNORMALITIES MAY OCCURE DURING RUNNING CONDITION
SL
EQUIPMENT ABNORMALITIES POSSIBLE REASON
NO
Discharge pressure  Sump level low
1 HP/LP
low/ tripped  Electrical trouble

Level Not  Poor discharge from pump

2 SUMP
Maintaining  Check seat disc position of valves

 Check alignment of BA gate

 Check for foreign material if any
Not Closing fully  Check for Air leakage from bottom piston cylinder
 Cylinder Piston may be passing

 Large clinker might be seating near by gate opening

 Ash might have stuck up on wall
3 FEED GATE Ash Flow Poor  Ash might have formed bridge in side BAH
 Water spraying /jetting in adequate

 instrument pressure low

 HP pressure low
Closed  Grinder tripped
 BADL pressure HI

 check for proper oil level, refer F/C manual

 Check for proper function of zero speed sensors.
4 GRINDER Frequent tripping
 Check foreign material if any
 Check for looseness of cam bolt if any
 Check for normal water pressure
 Check for foreign material if any at the throat
5 JET PUMP Discharge Poor  Check for throat eroded or not
 Check for chokage at feed sump if any.
 Check for JET pump problem as above.
 Check for chokage of BA disposal line, if any
BA
6 Taking more time  Check whether seat of isolating valves are proper
EVACUATION
 Check for air ingress in pipe if any

Tripped  Refer BA gate closed

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 Do not open feed gate manhole while BA gate in open condition.

 Do not open looking glass while boiler in operation.
SAFTEY
7  Do not allow excess deposition in BA hopper.
MEASURE
 During cleaning apply BA jet in proper location to avoid formation of ash bridge
 Seal trough should be kept cleaned to confirm overflow

FLY ASH:
PRECUATION  Check /clean all the nozzles of air washer
 Healthiness of all on line instruments.
 Fly ash vacuum & pressure lines are clear.
 Check healthiness of dust sensor.
 Check healthiness of bag filter & PJ system.
 Check healthiness of water system, sealing system etc.

FOLLOWING ARE THE FEW ABNORMALITIES MAY OCCURE DURING RUNNING CONDITION

SL EQUIPMENT ABNORMALITIES POSSIBLE REASON

NO
 Tripped/  Sump level danger low
1 HP
discharge Pr low  Electrical tripping of operating pump

 Sump level low

 Fluid coupling oil temperature abnormal.(ref F/C manual)
2 SLURRY PUMP  Tripped  Seal water pump tripped/ discharge pr low
 Electrical tripping of any of the running pump

 Seal water pressure less than normal.

 Vac breaker opened/conveying path not through.
Tripped  Electrical tripping of operating pump
 Water pressure lower than normal set value at wetting
head/air washer.
 Seal water pressure inadequate
 Air ingress into the system through coupling, joints etc.
Vacuum maintains  Check speed of the pump
3 VACUUM PUMP inadequate  Check vacuum breaker / it’s seal etc.
 Hopper empty but not switching over.
 Pump may be checked mechanically.
Emission level high  Air washer nozzles need cleaning.
at the discharge of  Filter bags might have damaged; needs replacement / repar.
vacuum pump
 Hopper plugged
Vacuum maintains
high  Stream/branch header may have choked.

SL
EQUIPMENT ABNORMALITIES POSSIBLE REASON
NO

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 Conveying path not through

 Respective vacuum pump tripped
 Water pressure lower than normal set value
at the inlet of wetting head/air washer.
VACUUM Opened
 HP pump tripped
4 BREAKER/
 Malfunctioning of respective branch header
RELIEF VALVE
valve.
 Dust level higher than set value/dust
detector malfunctioning.
Not closing  Check as above.

Frequent alarm on differential pr  Filter bags need replacement

5 BAG FILTER
high  Buffer hopper level maintains high.

Malfunctioning  Check cycle time for sequential operation

 Check for proper function of all the
probes/timer

NUVAFEEDER / Buffer hopper level maintaining high  Nuva feeder malfunctioning

6 ASH  Silo level high
TRANSMITTER  Conveying line choked
 Leakage/passing from nuva feeder
top/bottom gate
 Ash discharge line choked
Evacuation less  Check nuva feeder malfunctioning/ buffer
level HI

 VS1, VS2, VS3 setting needs rechecking.

 ESP hopper needs checking for proper ash
flow/ fluidising/ heater/ rapping action etc.
ASH  Fluidising air pressure/ temperature
7 Inadequate
EVACUATION inadequate
 Foreign material may have stuck up at the
throat/bends/valves etc..
 Check nuva feeder ;sl no 6 as above.
 Check for adequate air pressure at the inlet
of nuvafeeder
 Line pressure inadequate
 Line leakage
Inadequate
 Line partially choked
 Foreign material might have stuck up at
PRESSURE bends etc.
8
CONVEYING  Buffer hopper empty
 TAC tripped
 Line pressure high
 Vacuum system tripped
Tripped
 Silo vent fan tripped
 Pulse jet system stopped
 Instrument air pressure inadequate

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 Vacuum pump tripped

 Vacuum breaker opened
VACUUM
9 Tripped  Hp tripped
CONVEYING
 HP water pressure lower than set value at
the inlet of air washer/wetting head.

Problem Possible Cause Solution

Ash Visible from o Bags improperly installed o Correctly install bags

10 outlet of Bag filter o Torn or damaged bags o Replace damaged bags
vent fan o leakage at tube sheet level
o Gas temperature higher than
 Correct reason for overheat condition
specified
Rapid deterioration o Damaged cages causing holes in
 Repair or replace defective cages & bags
of bags bags
o Improper earthing of bags & bag o Earth properly
cages
o Correct to required manifold pressure or
o Inadequate instrument air supply
increasing pressure
o Steady rush of air indicates open
O Improper solenoid valve operation valve. No air pulse indicates changed
valve ­ Repair or replace valve
o Improper pulse timer operation or o Check for voltage level and fuse and/or
pulse timer is not properly other associated defects regarding
sequenced timer.
o Correct cause of excess moisture and
replace bags. Carry-out pulsing system
High pressure drop
o Moisture blinding of filter bags occasionally even when the bag-filter is
across bags
not subjected to ash loading.

o Check pump manual for getting proper

o Faulty Vacuum Pump
function of the same
o Check and adjust as necessary. In order to
maintain a differential pressure. The pulse
o Demand pulsing set points
duration timer and the pulse frequency timer
improperly set.
should be set properly. Operating condition
may require that these settings be changed.
NOTE :

The bag-filter should be run through about 10 complete timer cycles before making additional changes, to allow
operation to stabilise. If the timer malfunctions, it should be replaced as a unit.

SAFETY:  While removing ash from Choked ESP hopper/pipe avoid spillage of ash by covering the area & avoid
standing below the hopper.
 Unloading of ash from Choked ESP hopper/pipe should be done carefully, since temperature of such
ash is sufficient to cause burn.
 Refer manual of pumps, compressors, blowers, valves, other equipment, etc. for its safe operation.
 For replacement of damaged bag
1. System shut down
2. Check for friendly environment inside bag filter.
3. Take sufficient precautions to move inside.
 For maintenance of valves etc. at odd location take enough safety measure such as safety belts/proper
scaffolding etc.

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 SECTION - 7

DCIPS EQUIPMENT SAFETY, OPERATION & MAINTENANCE

 INDEX

SECTION - 7

SL. NO. DESCRIPTION PAGE NO.

GENERAL COMMENTS ON ASH CONVEYING
1.00.00 7:1
SYSTEM MAINTENANCE

2.00.00 SAFETY IN OPERATION, MAINTENANCE, 7:1

INSPECTION & SERVICE

3.00.00 BOTTOM ASH HOPPER 7:2

4.00.00 BA. HOPPER FEED GATE 7:3

5.00.00 CLINKER CRUSHER 7:3

6.00.00 JET-PULSION PUMP 7:4

7.00.00 AIR WATER CONVERTER TANK 7:4

8.00.00 OVERFLOW WEIR BOX FOR BA. HOPPER 7:5

9.00.00 WETTING HEAD ASSEMBLY 7:5

10.00.00 AIR INTAKE VALVE 7:6

11.00.00 TOTALLY ENCLOSED ROTARY SLIDE GATE 7:6

VALVE (TERSG)

12.00.00 BAG FILTER / SEPARATOR 7:7

13.00.00 FLY ASH DIFFUSER INTAKE VALVE 7:10

14.00.00 FLY ASH INTAKE VALVE 7:11

15.00.00 ROTARY UNLOADER 7:11

16.00.00 ASH TRANSMITTER (NUVA FEEDER) 7:11

17.00.00 AIR WASHER 7:13

18.00.00 ASH SLURRY DISPOSAL PIPE LINE 7:13

19.00.00 MAINTENANCE OF DRY ASH, SLURRY PIPES 7:14

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1.00.00 GENERAL COMMENTS ON ASH CONVEYING SYSTEM MAINTENANCE :

Successful operation of the Ash Conveying System depends upon careful observation, maintenance
and proper attention in due time. A slight delay in attaining a simple fault may cause severe damage
to the entire system.

Because of varying degrees of wear in various zones, it is difficult to predict the part or parts,
which will be subjected to greatest wear and earliest failure. It is, therefore, necessary for the
maintenance personnel to detect the worn-out part or parts with reference to mal-operation of the
system. Leakages in various joints in the equipment also create trouble for operation of the system.

1.02.00 BOTTOM ASH HANDLING SYSTEM :

Bottom ash handling system is normally meant for intermittent operation. As such maintenance
work can be carried out when the system remains inoperative. A standby set of feed gate, clinker
crusher and jet pump has been provided for each section of Bottom Ash Hopper. The clinker
crusher may be shifted from its position for maintenance keeping the bottom ash system in
operation through the standby set of equipment. Follow maintenance instruction of individual
equipment attached under separate section.

1.03.00 COARSE ASH HANDLING SYSTEM :

The Coarse ash (Eco. Hoppers ash) handling systems are also meant for continuous operation. As
such maintenance work can be carried out when the system remains inoperative.

1.04.00 FLY ASH HANDLING SYSTEM :

The fly ash handling system ash system is also normally meant for intermittent operation. As such
maintenance, work can be carried out when the system remains inoperative. As such, maintenance
work for the defective equipment can be accomplished keeping the system operation “ON” through
the stand-by equipment. In case maintenance of a particular stream of vacuum/pressure conveying
line is to be carried out, the same may be closed and ash cleaning from all other streams may be
continued while the defective stream/ equipment may be rectified/ replaced as quickly as possible. It
may be necessary to isolation a hopper for maintenance purpose but storing ash for a period more
than the storage capacity of the hoppers will need emergency unloading of ash from hoppers.

1.05.00 ASH SLURRY DISPOSAL SYSTEM :

Maintenance work of the slurry pumping system can be carried out on standby set when those
remain inoperative. As such in case of trouble with any operating chains of pump / pipe line, the
standby pipe line and pumps can be used for normal system operation and necessary maintenance
work on damaged equipment can be carried out isolating the same from running system.

It is essential that operators are trained up adequately and efficient, experienced and skilled
maintenance personnel are employed. Necessary tools and tackles required for maintenance work
should always be kept handy so that any maintenance work can be taken up immediately as and
when required.

2.00.00 SAFETY IN OPERATION, MAINTENANCE, INSPECTION & SERVICES :

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Under normal conditions, the operations of Hydro-pneumatic Ash Handling Equipment are not
considered exceptionally hazardous to personnel and strict follow-up of Plant Safety Rules will
prevent injury.

However, during maintenance of equipment / system or in some other unusual conditions,

precautionary safety measures are recommended.

Areas around all equipment, feeding points should be kept clean, suitably illuminated and ventilated
at all times, so that operators may have an unobstructed view. All operating equipment, pipes etc.
should be inspected regularly. Worn out or corroded parts should be replaced promptly to avoid
possible damage and personal injury.

2.01.00 MOVING PARTS UNDER OPERATION BY ELECTRICITY, AIR, OIL OR WATER :

Equipment under this group is all driving mechanism, pumps, hopper valves, branch isolation
valves, doors and gates etc., whichever is applicable as being included in the system. When working
with them, the principal cause of injury may be (a) electric shock (b) crushing of hands or feet (c)
flying particles and (d) burning. To avoid personal injury and damage to equipment, the following
practices are recommended :

 Never do any adjustments or repair work while equipment is operating.

 When operation is stopped for adjustment or repair, all related valves must be closed. Put
“Danger” labels on valves and starting gears to indicate that they must not be operated until
repair work is completed, or adjustment is done.

 For electrically operated equipment, put “Danger” labels on lock-out switches wherever
provided.

 Before working on electrical device on any kind, isolate them from the power supply.

3.00.00 BOTTOM ASH HOPPER :

Inspect the bottom ash hopper at regular intervals especially the following :

3.01.00 Check that there is no leakage through the hopper especially the inspection windows, poke holes
and manhole.

3.02.00 Check for any broken or spilled refractory, which should be replaced or patched as soon as
possible.

3.03.00 Examine the nozzle tips from time to time especially for the first few times of operation to ensure
that all possible obstructions are removed. Replace worn out nozzle tips, if required.

3.04.00 Check periodically the water seal trough for accumulation of fine ash. Any such accumulation
should be flushed out by operating jetting nozzles and by draining the seal trough whenever the
boiler goes under shutdown.

3.05.00 Check cover glass of inspection windows and replace the same, if necessary.

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4.00.00 BA. HOPPER FEED GATE (DRG. NO. 28P01 -1B- T- 575)

4.01.00 The gate should be adjusted so that it ensures a reasonably water tight seal against the static head
of hopper water. Adjustment is provided by wedges. The wedges should be adjusted such that both
the rollers sit simultaneously on the wedges as the gate moves down thus achieving sealing. For
proper sealing, the piston should not come to the end of its stroke when the gate sits in position.
This will ensure a constant downward pressure supplied by piston. Gate is operated by 4-way
solenoid operated valve. If during closing operation of the gate small clinkers or ash are caught
between gate & frame, leakage will result. Raise the gate slightly & close again to clear. If this does
not stop leakage, scrap all contact surfaces to clean.

4.02.00 Apply a thick layer of heavy grease periodically to all the steel parts of the gate.

4.03.00 Tighten packing of position indicator rod just enough to prevent leakage & replace packing from
time to time as required. During packing replacement apply grease to the packing for lubrication.

4.04.00 If oil is discharged from cylinder through 4 -way valve during any period when piston is stationary,
the piston leather is leaking. Be sure that piston rod slides freely at all parts of the stroke. Keep
piston rod clean & thoroughly greased. Tighten packing gland just enough to stop leakage. Too
much tightening may cause excessive friction in piston rod movement.

4.05.00 If piston continues to move when 4 -way valve is in Neutral position, the valve or piston leather is
leaking. If the movement is upward, the valve is leaking and should be opened & cleaned.

4.06.00 For maintenance of cylinder, disconnect all cylinder piping and remove cylinder & cylinder head
together, then remove cup clamp, piston & packing cups. Before reinstalling the piston unit in the
cylinder, apply a light coating of grease on cylinder wall and packing for lubrication.

4.07.00 The packing gland should be checked periodically for leakage & tightened or replaced with spare
packing as required.

5.00.00 CLINKER CRUSHER ( DRG. NO. – 28P01-1B-T- 582)

5.01.00 Periodically apply grease through four (4) nos. grease nipples provided on the Crusher support
wheel shaft, two (2) nos. grease nipples of bearing housing on both the sides of crusher, chain and
sprocket drive of the crusher. Check that adequate Seal Water is flowing through the seal water
connections.

5.02.00 Any extensive maintenance on this type of crusher is best accomplished with the crusher removed
from its normal position to the maintenance area.

5.03.00 Removal & Replacement :

5.03.01 In order to remove the Crusher from installed position, check that hopper feed gate is seating tight
without any appreciable leakage. Disconnect BA seal water piping to the crusher after closing
isolation valve on water line. Remove crusher drive guard and chain. Take out the flange bolts
connecting crusher upper flange to bottom flange of hopper feed gate enclosure. Remove the
coupling of the feed sump to the suction of jet pulsion pump.

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5.03.02 Now remove the wedges, if any, placed below the crusher. The crusher assembly alongwith the feed
sump can now be pulled out to the maintenance area where necessary maintenance work can be
carried out after removing the flange bolts connecting crusher bottom flange to the feed sump upper
flange.

5.04.00 Replacement of Cam :

 Remove the sprocket from the shaft end.

 Remove the bearing after providing proper support to the shaft.

 Take out the slinger, gland packing flange and gland assembly.

 Remove shaft seal housing from the side of the crusher.

 Remove the side wear plate.

 Take out and replace the Cam group structure as required.

5.05.00 FLUID COUPLING FOR CLINKER CRUSHER (DRG NO. 28P01-9B-M-FS1) :

5.05.01 Check oil level every week or as recommended by manufacturer. Oil level in the fluid coupling shall
normally be kept to a filling angle of 40 Deg from vertical top position. Take care not to overfill oil
since this may cause damage to the Clinker Crusher.

6.00.00 JET-PULSION PUMP ( DRG. NO.28P01-1B-T-591 )

6.01.00 The Jet-pulsion pump should be checked periodically for wear as worn out parts will cause a drop
in pump efficiency. The following parts are to be checked :

 Body (Inlet piece)

 Nozzle.

 Combining tube.

6.02.00 To remove any part of the assembly, the rigidity of the piping layout should be considered. If the
conditions are such that the inlet piece and the nozzle holder can not be removed independently then
first dismantle the combining tube, remove the aligning ring after which inlet piece and nozzle
holder can be removed.

6.03.00 When reassembling the Jet Pump, replace all damaged gaskets and use sealing compound at all
joints to ensure leak proof system.

7.00.00 AIR WATER CONVERTER TANK (DRG. NO. 25P04-T-1B-703)

7.01.00 Periodically check the gasket provided between the top cover and the main body. If found damaged,
change the same, with a new one.

7.02.00 Check that whether oil air converter tank is adequately filled up with water. The socket connection,
gate valve, isolation gauge cock connecting gauge glass may be found leaking and water inside the
tank may drain out owing to this reasons. Tight / replace the joint as and when required.

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7.03.00 It should be thoroughly checked that no air leaking takes place from (Feed Gate) cylinder joints and
fittings. It will slow down the opening / closing of feed gate than that of designed rate. Check the
same. Replace / tight the leaking parts as and when required.

7.04.00 Maintain the transparency of gauge glass. It will help to identify water level inside the tank.

7.05.00 In spite of leak tightness, if feed gate is found operating in a slower speed than that of designed one
and feed gate & corresponding cylinder are found O.K., check –

 Instrument Air Pressure.

 Solenoid Valve.
 Pipes connecting air water converter tank & feed gate cylinder.
 If abnormalities are found, take the corrective action accordingly.

8.00.00 OVERFLOW WEIR BOX (SEAL BOX) FOR BA. HOPPER

( DRAWING NO. 25P04-T-1B-711 )

8.01.00 Overflow weir box receives overflow water from BAH and discharges the same to BA. Overflow
sump. The main utility of overflow weir box is to prevent back flow of air into the boiler through
BAH.

8.02.00 Overflow weir box requires almost no maintenance except preventing leakage owing to rust etc.
Check time to time so that BAH overflows water pipe discharge end is fully dipped into water and
there is no accumulation of ash inside it.

9.00.00 WETTING HEAD ASSEMBLY (DRG. NO. 25P04-T-1B-271 ) :

The “Wetting Head” is to be checked periodically for wear and jamming of nozzles and other parts
as these shall cause a drop in efficiency and may are to be checked :-

 Nozzle size.
 Outlet Section.
 Water Chamber.
 Inlet Section.
 Gaskets of various joints.
 Tail piece pipe (connected with the outlet section at its discharge end)

9.01.00 The frequently occurred problems are :

9.02.00 JAMMING / EROSION OF NOZZLES :

9.01.01 Nozzles may jam owing to suspended particles in raw water. It requires proper attention and to be
cleared at least once in a fortnight. To clear the nozzle, stop raw water, removed the handhold
cover, take out the nozzles to be cleared and fit them in original position by hand and / or by
proper tool. Replace the damaged / worn out nozzles with a new one. Now partially open the water
line gate valve and check, through hand hole opening, whether jetting through all the nozzles are
satisfactory. When found is OK, close the handhold cover.

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9.03.00 LEAKAGE THROUGH GASKETS :

9.03.01 Owing to frequent opening of handhole cover, the corresponding gasket is damaged frequently.
Therefore, it needs replacement when necessary. Generally, gaskets at other positions are not
damaged frequently.

9.04.00 EROSION OF TAIL PIPE PIECE :

9.04.01 Erosion of tail pipe piece mainly depends upon its mounting (with “outlet” section) accuracy.
More accurate the mounting, less the erosion and vice versa. The tail pipe piece is to be replaced if
it is found heavily damaged.

10.00.00 AIR INTAKE VALVE ( DRG. NO. 25P04-T-1B-011) :

10.01.00 The air intake valve requires very little maintenance. The valve shall be adjusted properly, so that
the required disc opening is obtained when the air is sucked in during ash cleaning operation.

10.02.00 Check that the machined surface of the “valve disc” (part no. 2, Ref. DWG.) is facing upwards.
Fix the disc with “valve steam” (part no. 4, Ref. DWG.) in position is shown by means of two
nuts.

10.03.00 Adjust screw at the top of valve steam to allow the “valve disc” to open 10 mm. Then lock it in
position above the “cover tube” (part no. 6, Ref. DWG.) by the lock nut. If vacuum is found too
high in air intake adjusted screw to allow opening wider. As regards exact disc, opening, final
adjustment data obtained at site during initial operation before handling of ash shall be followed.

10.04.00 Split pin and washer to be located in bottom hole on valve stem (as shown in drawing). For
achieving greater spring tension, rise to one of the holes above.

10.05.00 Place the rain-hood in position and fix it properly.

10.06.00 During running of the plant if any one of the valves creates trouble, that should be removed
immediately and replaced by a thoroughly checked spare valve. The replacement should be carried
out after closing the fly ash header valve of the particular branch only, when ash cleaning from
other branches may be continued. After removing the faulty valve, maintenance work as detailed
above / as necessary shall be carried out at shop.

11.00.00 FLY ASH HEADER VALVE (TERSG) [DWG. NO. 25P04-T-1B-040] :

Periodically apply high temperature grease through the grease nipples on both sides of the shaft of
the side gate. Grease the nipples once in a month and carefully avoid over-greasing.

Do not disturb the assembly until appreciable leakage or breakage of the parts occurs requiring
replacement.

11.01.00 Loosen the lock nut to adjust the yoke end (part no. 8, Ref. Dwg.) so that slide gate isolates
completely the ash flow path. Lock yoke end at this position with the M-20 Head. Nut.

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11.02.00 To prevent bending of slide, gate shall be installed in such manner that external forces do not act to
compress body. “Anchor” supports should be provided near the “TERSG” as per project piping /
support drawings so that no load (including loads due to thermal expansion / construction) from
the connected pipe work is transmitted to the “TERSG” under any condition.

11.03.00 One and half inch. (½”) BSPT air inlet connections have been provided on both the side plates.
Depending on erection orientation, the air inlet opening on the same side of the vacuum side shall
remain plugged. The air inlet passage opposite to the vacuum side must always be kept clean to
allow sucking in of air all the time so as to prevent packing of ash inside the valve.

12.00.00 BAG FILTER / SEPARATOR ( DWG. NO. 25P04-T-1B-381)) :

12.01.00 The filter separator provided under fly ash vacuum conveying system is a “Walk-In-Plenum, top
removal, continuous operation” type combination filter cum separator assembly. The unit is
vertically mounted over Buffer hopper for continuously removing fly ash particles from conveying
air and discharging the collected ash particles in buffer hopper without any interruption of vacuum
conveying operation. Using only one vessel, the unit performs the functions of a cycle one
separator and secondary bag filter.

12.02.00 The units as a whole comprises two key components a separator vessel and a buffer hopper. The
combination filter separator vessel is directly mounted to buffer hopper. The buffer hopper is
connected to the Ash Transmitter (Nuva feeder) through a diffuser feeder, and Ash Transmitter is
connected to the pressure conveying line through another diffuser feeder.

12.03.00 The separator vessel is a cylindrical fabricated shell built-up with three sections, the top section
serving as the clean air plenum. The middle section serving as a dirty air plenum and the bottom
section serving as the buffer hopper and inlet plenum.

12.04.00 During system operation, the conveying air laden with fine ash particles enters the inlet plenum. As
air rises above, heavier ash particles drop to the hopper. The air continues to rise carrying the finer
ash particles into the dirty air plenum.

12.05.00 This plenum is the filter zone which houses specific numbers of filter bags rigidly mounted in
tubular cages and arranged in rows. As the air passes through the bags, ash captured and lodged
on the bag exterior. The clean air passes across the filter into the clean air plenum and is vented
out through the outlet connection.

12.06.00 Discharge of ash from the combination filter separator into the buffer hopper is accomplished in an
automatic interlocked timer based sequence without any interruption conveying operation. The
buffer hopper located between the combination filter separator air lock vessel. The operating cycle
is thus repeated again and again as long as the vacuum conveying operation goes on to dislodge
ash from separator into the buffer hopper without interruption in system operation.

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12.07.00 As indicated earlier, finer ash particles are lodged on the bag exterior as the airflow through the
filter bags. Such ash build-up on the outside of bags causes a reduction in the porosity of the filter
bags resulting in an increase in pressure differential between the clean air and dirty air plenums. A
pair of differential pressure switches to turn on the ON-DEMAND pulsing sequence for cleaning
of the filter bags senses this increase in pressure differential. The pulsejet cleaning sequence and
various abnormal conditions and troubleshooting of dust-separator have been elaborated in
SECTION-6 under this manual. The following give some guide- lines for replacement /
maintenance and adjustment of some components of filter separator assembly :-

12.07.01 Pneumatic Speed Control Valves on Discharge Gates :

 Adjust all speed control valves to allow for smooth gate operation. If lines or valves shake
violently when gate operates, adjust for slower operation.

12.07.02 Filter Bags and Cages :

 To ensure optimum performance, worn or damaged bags should be replaced immediately.

Operating the filter / separator with a damaged bag may cause damage and excessive wear on
other equipment as also may affect the system operation.

12.07.03 To Replace Filter Bag

 Enter walk-in-plenum and remove blowpipe by disconnecting.

 To remove worn or damaged bag, lift bag cage straight up and out, then fold spring loaded
cuff at top of bag into a “U” shape and remove bag from tube sheet.

NOTE : If bag is accidentally dropped below tube-sheet, remove access port cover on lower part of vessel
and retrieves bags.

 Insert repaired or new bag into hole in tube sheet.

 Fold spring-loaded cuff at top of bags into a “U” shape and insert bag in tube sheet so that
center groove on bag fits into parameter of tube sheet hole. Release bag carefully so that cuff
audibly “snap” into place with the entire center groove in contact with the tube sheet. It may
be necessary to pull up on the bag cuff to ensure proper centering.

12.07.04 Cleaning of filter bags – Bags of the Bag Filters normally remain clean if pulse jet system
is working properly. It may need to adjust the timing of pulse jet system during
commissioning. Once these are set no further adjustments are required. However, for any
reason if the bags of Bag Filter get choked then system to be isolated. Bags to be removed
from the Bag Filter and bags are cleaned physically by light air pressure. Once bags are
cleaned these are to be assembled back in the Bag Filter.

12.08.00 CAUTION :

12.08.01 Failure to properly position center groove in tube sheet will result in the filter bag falling out of
tube sheet when the pulsing system is energized.

 Lower cage into bag and press into place until collar is flush against tube sheet.

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 Reinstall blowpipe by revering step (1).

12.09.00 WARNING :

Following safety precautions as indicated below before attempting to replace filter bags
:

12.09.01 SAFETY PRECAUTIONS :

Personnel involved with the filter / separator must be familiar with the equipment operation and
should be alert for unsafe conditions or potential hazards at all time.

The following precautions should be observed when in the clean air plenum :

 Only safety conscious personnel should have access to the clean air plenum.

 Work crews must always consist of two or more persons. Never allow personnel to work in
the clean air plenum above. The crew chief must make a final inspection of the clean air
plenum prior to activating the equipment. All personnel must be accounted for prior to start
up.

 All areas below the vessel must be restricted to unauthorized personnel when overhead work
is being performed. Personnel in the area must wear safety guards complying with plant
safety standards.

 Objects being lifted by crane or hoist must be securely fastened and carefully handled to
prevent injury to personnel.

12.10.0 Access Port Gasket :

The access port gasket should be checked whenever the access cover is removed. Rousing a
damaged gasket can result in an air leak.

12.11.00 Access Door Gasket :

If the door gasket is leaking, it should be replaced immediately.

 Remove accesses door by unscrewing latches.

2) Remove gasket.

3) Fit on new gasket if required.

4) Reinstall accesses door. Tighten latches until gasket seals.

5) Operate until and check for leaks.

6) If air leaks past gasket, tighten latches a little at a time until leak is sealed.

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12.12.00 WARNING :

Before opening the walk-in- plenum access door or any access port, the following precaution
should be observed.

Isolate the entire filter / separator from the conveying system.

Turn off all electrical circuits, including the timing mechanism. Install safety lockouts on all
circuit breakers and tag breakers with a sign warning that equipment under repair and not to be
operated.

 Shut off compressed air.

 Wear adequate protective guards including a respirator, if needed, when entering the clean
air plenum.

 Check that airflow through the filter / separator has ceased.

 Check the internal temperature of the clean air plenum for safe level.

12.13.00 SOLENOID VALVES & DIFFERENTIAL PRESSURE SWITCSES :

The solenoid valves and differential pressure switches should be replaced as complete
assemblies.

13.00.00 FLY ASH DIFFUSER INTAKE VALVE (DWG. NO. 25P04-T-1B-032 ) :

Periodically apply high temperature grease through the grease nipple on both sides of shaft
bearing of the valve disc. Grease the nipples once in a month and carefully avoid over greasing.

Tight the nuts periodically and excluding the same, do not disturb the assembly until appreciable
leakage or breakages of the parts occur requiring replacement.

Place a thoroughly checked spare valve duly fitted with cylinder actuator in place of the
defective valve removed. Check and replace all damaged gaskets between joints and apply high
temperature sealing compound to achieve leakproof joints. Now place bolts etc. in position,
gradually tighten the nuts and fix the valve firmly. Connect air piping and resume ash cleaning
of that branch.

14.00.00 FLY ASH INTAKE VALVE (DWG. NO. 25P04-T-1B-025) :

Periodically tighten the bolts, check the condition of gaskets, and replace them if necessary.
Periodically apply high temperature grease through the grease nipples on both sides of the shaft
bearings of the valve disc. Grease the nipples once in a month and carefully avoid over greasing.
(Please note excess grease after coming in contact with ash may jam the shaft bearing).

If the valve found defective, then remove the valve. Place a thoroughly checked spare valve duly
fitted with cylinder actuator in place of the defective valve removed. Apply high temperature
sealing compound to achieve leakproof joints. Now, connect air piping and resume ash cleaning
of that branch.

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15.00.00 ROTARY UNLOADER (DWG. NO. 25P04-T-1B-362) :

Most of the parts of the rotary unloader can be serviced with the rotary unloader installed in
position. The parts inside the rotary drum can be inspected through the doors of the front
discharge box.

To have accessed to the inlet end of the rotary drum, the inlet piece and the flange along with the
sealing arrangement need to be removed. To remove the drum from its installed position, the
geared motor supporting structure along with the truing wheels are to be removed. Now the
drum can be lifted from its position.

Check for wear, in general all the parts inside the rotary drum coming in contact with the ash
like scraper blade, spray water nozzles etc.

The clearances and alignment of the trunion wheels and the adjustable thrust wheels should be
checked. Check the seals for wear.

Lubricate trunion and thrust wheel bearings through grease nipple provided.

During operation of rotary unloader, the operator should control the quantity of spray water by
controlling the globe valve provided on the water supply line. The rate of flow of ash can be
regulated by operating the orifice feeder hand lever.

16.00.00 ASH TRANSMITTER (NUVAFEEDER) DWG. NO. 25P04-T-1B-460):

The Nuva feeder provided under fly ash pressure conveying system is basically an air lock used
to transfer fly ash from hopper, at or near atmospheric pressure, into a conveying line which is
at a much higher positive pressure. The NUVA-FEEDER mainly consists of a feeder vessel
(storage compartment) equipped with an airtight gate and a diffuser at both inlet and outlet.

The NUVA-FEEDER operates on an automatic interlocked timer based cycle (back up with
level probe) which basically consists of two segments of operation.

The first segment in operating cycle is basically identified as “FILLING” cycle. Under the
“Filling” cycle, a 2-way solenoid operated vent valve is energized to attain pressure equalization
between the ash hopper and the feeder vessel. Opening of the top gate follows this. The ash
from ash hopper flows through the inlet diffuser into the feeder vessel. This condition persists
for a preset duration (subject to adjustment at site) to allow required filling of the feeder vessel.
After this, the top diffuser gate closes followed by closing of vent valve. The second segment of
the operating cycle is basically an “UNLOADING” cycle, which is then activated, for unloading
the ash stored in the feeder vessel into the conveying line. Under this cycle, a solenoid operated
equalizing valve is energized to equalize pressure between the feeder vessel and conveying line
followed by opening of the bottom gate. The ash stored in the feeder vessel flows through the
bottom diffuser into the conveying line. The bottom gate remains open for a preset duration
(subject to final site adjustment) to allow the feeder vessel to become empty after which the
bottom gate closes followed by closing of the equalizing valve and re-opening of the vent valve
in the next operating cycle. The cycle is thus repeated again and again as long as the pressure
conveying system remains energized for transfer of fly ash from buffer hopper into the
conveying line.

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NOTE : If a Nuvafeeder is required to be checked, then it is to be isolated from the system and
also maintain the precautions as mentioned below :-

SAFETY WARNING :-

Exercise extreme caution in removing any access cover. Damaged Gate could allow hot air or
material (ash) to pass through and cause injury. Always open access covers from a safe position
that protects the person from direct exposure to possible gas or material discharge. If gate
leakage is observed, system must be shut down to make repairs.

1) Make sure that the inlet adapter chute (with/without) diffuser is empty. Disconnect
fluidizing air supply to upper diffuser. Open the access at the upper gate. SEE SAFETY
WARNING ABOVE.

a) Check upper gate for leakage. Exercise caution to checking the gate.

b) Place some dry fly ash on the diffuser. Turn on the diffusing air very slowly. Also,
turn on fluidizing air supply. The ash should flow freely from the diffuser. If the ash
does not flow, check the diffuser for damage or for plugging caused by material
building-up on upper or lower surface. Check the gasket for leakage or damage.

c) Replace the access cover.

2) Leave the top gate closed. Make sure that the feeder vessel and bottom diffuser are empty
and close the bottom gate. Turn-off diffusing air to be bottom diffuser. Disconnect air to
the bottom gate cylinder.

a) Open access cover at bottom gate

(SEE SAFETY WARNING ABOVE)

b) Check lower gate for leakage

(SEE SAFETY WARNING ABOVE)

c) Place some dry fly ash on the diffuser. Open the diffuser test plug. Blow hard into
the test plug. The ash should flow off the diffuser. If ash does not flow, check air in
part 1 (b) above.

17.00.00 AIR WASHER (DWG. NO. 25P04-T-1B-292 ) :

17.01.00 The Tangential Spray Air Washer is used as a secondary separator after the dust separator and
is meant to handle the normal carry over ash from such preceding separators. The air washer
uses centrifugal action, water sprays and deflectors for further separation of the finer ash from
the conveying air and discharges the separated ash in mixture with water. Special types of
nozzles are used in this equipment.

Ash separation in the air washer evidently, is dependent on adequate water spray and wetting of
the ash. The water flow for the spray nozzles are therefore monitored through globe valve,
pressure indicator and pressure switch installed on the water supply line and non-contaminated
water is used for minimizing nozzle/line blockage. Simultaneous proper functioning of both the

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dust-separator and air washer minimizes ash/dust entry into vacuum producer (Mechanical
Exhauster) thereby minimizing maintenance/replacement requirements therein.

17.02.00 Necessary electrical interlock is provided for air washer operation, which is described in the
Control Write-up. Air washer operation should not be attempted with any of the interlock by-
passed/inoperative because of the obvious dangers of excessive ash carry-over and/or
line/equipment plugging. It should be borne in mind that a mal-functioning dust-separator unit
could lead to air washer choke apart from excessive ash carry-over into the mechanical
exhauster.

17.03.00 Maintenance

The air washer normally requires very little maintenance.

17.03.01 The spray nozzles, however, should be periodically inspected as a routine procedure for choking
and/or wear, depending on the water quality. Any nozzle problems should be attended
immediately. Worn out nozzles should be promptly replaced.

17.03.02 Other internals may be occasionally inspected for wear and tear, and replaced as and when
necessary.

17.03.03 Access door, removal cover and clean-out ports are provided in the equipment for
inspection/maintenance and for cleaning in case of incidental choking. All such access-ways
must be made completely leak-tight before putting equipment back to service.
18.00.00 ASH SLURRY DISPOSAL PIPE LINE :

These pipe lines should be checked periodically for worn out pipes or fittings and for loose
joints. All the fittings should be examined especially since the wear is normally concentrated at
these points. Any section of pipe or fittings in ash slurry line which have been worn out should
be replaced at once because the leakages thus produced may reduce the slurry velocity as a
result of which the slurry will be settled down within the pipe line.

The leakages can be prevented by tightening the coupling or in worse case gaskets may be
changed. Extra life of the straight pipe lengths running horizontally or inclined may be obtained
by rotating the pipe one-quarter turn before the pipe becomes too badly worn at the bottom. This
requires periodically inspection of pipes for bottom wears.

19.00.00 MAINTENANCE OF DRY ASH, SLURRY PIPELINES AND FITTINGS

All the pipeline hanger supports and clamp supports of fly ash as well as slurry line should be
properly tight condition. All the flange joints should be tightened periodically. No minor leakage
should be left unattended. Always use new rubber gaskets for remaking any joint. Threads of
bolts and nuts should be properly greased. Use washer on both sides of the washers. Joints
should be tightened evenly.

20.00.00 PROCEDURE FOR OPENING MAN HOLES AND PRECAUTIONS

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Before opening of any manhole, work permit is required to obtain from the concerned
department. After obtaining work permit manhole cover bolts to be removed. Entry into the
vessel shall be done in presence of supervisor after wearing goggles, helmet, nose mask and hand
gloves as required. Only 24 V hand lamps should be used inside the vessels. At least one person
should be available at the outside of manhole till the completion of the job for raising the alarm,
incase of any emergency. Please make sure that all the tools, spares, debris, etc. has been
removed before closing of the manhole. For entering into the ESP hoppers, all electrical
isolations and earthing the electrodes is must before issuance of work permit.

7 : 14
 SECTION - 8

DCIPS DRAWINGS / DOCUMENTS

 MECHANICAL DRAWING LIST OF JHAJJAR PROJECT

SL. NO. TITLE DRAWING NO.

1 SINGLE LINE FLOW DIAGRAM : 0330-162-PVM-L-001
OF BOTTOM ASH AND COARSH
ASH HANDLING SYSTEM

2 SINGLE LINE FLOW DIAGRAM : 0330-162-PVM-L-004

OF COMMON WATER & SLURRY
SYSTEM

3 SINGLE LINE FLOW DIAGRAM : 0330-162-PVM-L-002

OF FLY ASH VACUUM
CONVEYING SYSTEM

4 SINGLE LINE FLOW DIAGRAM 0330-162-PVM-L-003

:OF FLY ASH PRESSURE
CONVEYING SYSTEM

5 SINGLE LINE FLOW DIAGRAM 0330-162-PVM-L-005

:OF INSTRUMENT AIR SYSTEM

6 SINGLE LINE FLOW 0330-162-PVM-L-009

DIAGRAM:HCSD SYSTEM
 ANNEXURE-I
(02-07-10)

Clarification / confirmation to NTPC’s comments on “Single Line Flow Diagram :

Bottom Ash & Coarse Ash Handling System”, NTPC Drg. No. 0330-162-PVM-L-001,
Rev.0

Sl.
NTPC COMMENTS DCIPS REPLY / CLARIFICATION
No.
MH
1) Please put following additional notes :

(i) Limit switches shall be provided for 25 Limit switches of 25 Nos. for Manually Operated
Nos. valves and indicate the same. Please valve shall be submitted separately for approval.
refer tender Drg.No.0330-162-POM-A-001

(ii) All water piping shall be provided with Noted & incorporated in Note no. 4
vents at the highest point and drain at the
lowest point along with vent valve and
drain plug
2) Pls put TAG nos. for valves and Incorporated
instruments

3) The capacity and head indicated for pumps Noted

are subject to approval

4) Please provide PT at detail-D as per Incorporated

tender Drg.No.0330-162-POM-A-001
detail-B
5) Air filter station shall be provided as per Noted, shall be incorporated in Single line flow
tender Drg.No.0330-162-POM-A-001 diagram : Instrument Air System, NTPC
Doc.No.0330-162-PVM-L-005
6) Pls provide PT at discharge of BA seal Kindly note PT is provided as per specific
water pumps and seal water pumps and requirement of Tender drg. # 0330-162-POM-A-001,
seal water & cooling water connection to Rev.A. As per Tender drawing there is no specific
BAOF pump and FC requirement of PT in case of discharge of BA Seal
water pump and also for seal water connection of
BAOF pump and fluid coupling. Thus the PT can not
be provided for the same.

However, as per your observation discharge line of

HP & LP seal water pump have been provided with
PTs as per Tender requirement. Please refer our
Single Line Diagram : Water & Slurry Disposal
System, NTPC Drg. # 0330-162-PVM-L-004.

As per your comment on the drawing one no. PT for

Crusher seal is already incorporated as per Tender
requirement.

\\Pcdc0047\d\SISHIR DOCUMENTS\ANNEXURE\Jhajjar\ANNEXURE-I (02-07-10).doc

 : 2 :

7) Other comments are marked on drg. Incorporated

8) DCIPS to confirm that the BAOF pump Confirm

shall be sized to take care of the refractory
cooling water also

9) Please provide pneumatically operated Kindly note as per Tender drg. # 0330-162-POM-A-
valve as marked 001, Rev.A, there is only one pneumatically operated
valve for Hopper make-up from BALP line and the
same is already provided.
C&I

A) Refer seal water lines to clinker grinder and BA Please refer our clarification of point no.6 of MH.
1) O/F pumps : Pressure switch is indicated for
seal water pressure measurements instead of
pressure transmitter requirement of
specification. Pl. correct

2) Pressure measuring instruments shown in the Incorporated.

slurry lines should be providing with diaphragm
seal. Pl. indicate diaphragm seal with all such
instruments
3) Refer water line to Eco hoppers : As per tender Incorporated and refer Detail “G”.
drawing one no. Pressure gauge should be
provided in water line to each of Eco hoppers
(one for each hopper). Pl. correct the drawing.
4) We understand that some of the manual valves Limit switches of 25 Nos. for Manually Operated
may be having open / close limit switches for valve shall be submitted separately for approval.
use in control system. Please indicate such
limit switches clearly in the drawing
5) Please indicate limit switches provided with Incorporated.
each of the pneumatic / solenoid valves e.g.
LSO for open limit switch, LSC for close limit
switch. If no limit switch is provided / required
for any solenoid valve write NO LIMIT SWITCH
for such valves.
6) We understand that level transmitter indicated Incorporated.
for BA O/F transfer hopper are ultrasonic type.
Pl. confirm and indicate type of LT in the
drawing

7) DCIPS is requested to clarify the changes if We confirm to provide similar arrangement as in

any in the type of DRIVES shown in this PID BARH-I.
w.r.t. system offered for BARH-I e.g. clinker
grinder, feed gates, B/A overflow pumps etc.

B) General comments for all drawings for making

review fast :

\\Pcdc0047\d\SISHIR DOCUMENTS\ANNEXURE\Jhajjar\ANNEXURE-I (02-07-10).doc

 1) DCIPS is requested to clearly mark the Incorporated.
changes in the next revision w.r.t. previous e.g.
mark R1 (inside a triangle) near each change
in Rev.1 w.r.t. Rev.0

2) DCIPS is requested to submit point wise reply / Furnish

compliance for each of comment

\\Pcdc0047\d\SISHIR DOCUMENTS\ANNEXURE\Jhajjar\ANNEXURE-I (02-07-10).doc

1.Pls indicate tag nos.
2.Pls correct note:6 " field wise collection"
3.Pls indicate PT in detail-E as per tender drawing
4.Pls indicate isolation valves for Each unit and each pass in
IA line.
 ANNEXURE-I
(30 Nov.’09)

Clarification / confirmation of NTPC’s comments on “Single Line Flow Diagram :

Fly Ash Pressure Conveying System”, NTPC Doc. # 0330-162-PVM-L-003,
REV.01

1) Incorporated.

2) Common header will not guarantee the distribution of flow of fluidising air at for all
operating silo. Thus, individual header is incorporated.

3) We have incorporated isolation valve in between NRV and heater in case of silo
fluidising blower. In case of TAC the same is not incorporated before ADP in
absence of ADP in the system. However, total no. of valves provided in the
pressure conveying line is much more than as envisaged in the Tender Drawing.

4) Pneumatic valves at fluidising line was necessary when the fluidising line to
individual silo is considered from common header as per Tender Drawing.

However, in order to facilitate effective fluidising we have incorporated separate

pipeline and isolation valve dedicated for each silo.

5) Incorporated.

6) Incorporated.

7) Incorporated.

C:\Documents and Settings\SG0791\Desktop\PATHAK-DA PLS SEND\Annexure-I (30 Nov'09).doc

 ANNEXURE-I
(10.09.2010)

Clarification / confirmation to NTPC’s comments on “Single Line Flow Diagram : Water

& Slurry Disposal System” NTPC Drg. No. 0330-162-PVM-L-004, Rev.02

As per your observation, we would like to clarify that AFR with individual pneumatic device
are not required as per standard proven practice and we confirm to pass rebate to NTPC for
this deviation w.r.t. NTPC specification.

\\Pcdc0047\d\SISHIR DOCUMENTS\ANNEXURE\Jhajjar\ANNEXURE-I (10.09.2010).doc

 ANNEXURE-I
(24.08.2010)

Clarification / Confirmation to NTPC’s comments on “Single Line Flow Diagram:

Instrument Air System” NTPC Drg. No.: 0330-162-PVM-L-005, Rev. 02

(1) Comments Incorporated.

 Weir Minerals Netherlands b.v.

A. Proceed
B. Proceed, change as noted and resubmit
C. Do not proceed

This authorization does not waive any agreement specified under the
purchase order and other relevant specifications / agreements between
Weir Minerals b.v. and Manufacturer / Supplier.

Department Signature Date

Systems

By Erik Vlot at 9:10 am, Sep 22, 2010

 ANNEXURE-I
(24.09.2010)

Clarification / confirmation to NTPC’s comments on “Single Line Flow Diagram : HCSD

System” NTPC Drg. No. 0330-162-PVM-L-009, Rev.01

Sl.
NTPC COMMENTS DCIPS REPLY / CLARIFICATION
No.
1. This drawing is neither WMN drawing / This drawing is approved by WMN.
nor vetted by WMN. DCIPS have just
stated ‘Noted’. Please submit as
commented in re.0

2. Mass flow meter and density meter to Please note that ‘Basic System P & ID HCSD System’,
be indicated. NTPC Doc.No.0330-162-PVM-L-010 incorporates HCSD
pump, related HCSD equipments & accessories including
Mass Flow meter and density meter which is already
vetted by WMN and subsequently approved by WMN.

This may specifically noted that in this SLD drawing we

have incorporated only the HCSD Silo Top equipments,
Fluidising system and silo unloading system other than the
HCSD System. ‘Basic System P & ID HCSD System’ as
already approved is indicated here to incorporate the
system as a whole.

As per your specific comment we would request you to

refer NTPC Doc. 0330-162-PVM-L-010, Rev.4 wherein
Mass flow Meter below Rotary Feeder & Density Meter in
slurry control loop and discharge of booster pump have
already incorporated and approved.

3. Please refer to tender drawing notes – Kindly note in tender drawing Note No.12 of ‘Single Line
all bag filters shall be provided with Flow Diagram for Fly Ash Handling System (Vacuum
DPT. This DPT for vent filters are system)’, NTPC Drg.No.0330-162-POM-A-003, Rev.A
applicable. indicates that “Bag Filters are to be provided with DP
Transmitter” but at the same time Note No.13 indicates
“Differential Pressure Gauges & Differential Switches are
to be provided across each Bag Filter, inlet suction filter
for compressor, blower etc.” Further mode in the SLD it is
indicated the type of DP instrument either DP switch or DP
transmitter and accordingly we have incorporated DPS or
DPT.

It shall be specifically noted that in “Single line flow

diagram for high concentration slurry disposal system”,
NTPC Drg.No.0330-162-POM-005, Rev.A no specific
requirement of DP instrument across vent filter of
telescopic spout of HCSD System is indicated.

We have incorporated DPS across Telescopic Vent Filter

in line with as supplied as standard requirement of earlier
NTPC projects for identical application.

\\Pcdc0047\d\SISHIR DOCUMENTS\ANNEXURE\Jhajjar\ANNEXURE-I (24.09.2010).doc

 ANNEXURE-II
(05.10.2020)

Clarification / Confirmation to NTPC’s comments on “Valve Schedule” NTPC Doc.

No.: 0330-162-PVM-H-003, Rev-01.

NTPC COMMENTS ON: DCIPS CLARIFICATION

1. Annexure-A, GM Gate valve (below For Pneumatically actuated Pressure Relief
50 NB) Sl. No.: 19, page 2 of 7: Line valve at TA Compressor outlet is of
should be from IA Compressor to Bag filter Pneumatic actuated Butterfly valve. The 15
NB Gate valve is for isolation of
Instrument Air and the service medium is
‘Instrument Air’ indicated in this schedule.
The location is Pressure relief valve at
TAC outlet line, which is in order.
2. Annexure-A, GM Gate valve (below Incorporated.
50 NB) Sl. No.: 45A, page 6 of 7: Please
specify location
3. Annexure-A, GM Gate valve (below Incorporated.
50 NB) Sl. No.: 45F, page 6 of 7: No inlet
valve for Settling & Surge Bin. Please
correct the description.
4. Annexure-B, GM Globe valve (below Incorporated
50 NB) Sl. No.: 6, page 1 of 2: Please
check the source
5. Annexure-B, GM Globe valve (below Quantity four (4) nos. in order. Kindly refer
50 NB) Sl. No.: 13, page 2 of 2: comments “Detail A” of SLD, NTPC Doc. No.: 0330-
on quantity is 8 Nos. 162-PVM-L-004, Zone: E-10, F-10, G-10
& H-10.
6. Annexure-D, CI Gate valve (50 NB & Incorporated.
above) Sl. No: 8, page 2 of 4: Valve size is
100 NB.
7. Annexure-E, CI Globe valve (50 NB & The Re-circulation line is designed on the
above) Sl. No.: 1, page 1 of 2: Valve size basis of flow quantity of around 40%-50%
is 100 NB. of the design flow. In view of pipe size
shall be lower, thus 50 NB is right selection
as per allowable velocity criteria.
8. Annexure-F, CI Swing Check valve Incorporated.
(50 NB & above) Sl. No.: 8, page 1 of 2:
Working pressure is 3.5 Kg/sqCm.
9. Annexure-H, Plug valve Sl. No.: 3, Incorporated.
page 1 of 2: Working pressure is 3.5
Kg/sqCm.
10. Annexure-K, Slurry Line KGV: Incorporated.
Please provide TAG nos.
11. Annexure-L, Dry Ash Line KGV: Incorporated.
location is HCSD area.
12. Annexure-N, Please specify Size of Incorporated.
Valve.
13. Add Note: Any other valve required as Noted in Cover page.
per approved P & ID’s and system
requirement shall be provided by M/s
DCIPS
INDIRA GANDHI STPP - JHAJJAR DC INDUSTRIAL PLANT SERVICES
STAGE- I, 3 X 500 MW PRIVATE LIMITED
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

VALVE SCHEDULE

NTPC DOC. NO.: 0330-162-PVM-H-003, REV-02

DCIPS DOC. NO.: 28P01-1A-D-054, REV-02

SL. NO. ANNEXURE TITLE

1 ANNEXURE-A GM GATE VALVE (BELOW 50 NB)
2 ANNEXURE-B GM GLOBE VALVE (BELOW 50 NB)
3 ANNEXURE-C GM SWING CHECK VALVE (BELOW 50 NB)
4 ANNEXURE-D CI GATE VALVE (50 NB & ABOVE)
5 ANNEXURE-E CI GLOBE VALVE (50 NB & ABOVE)
6 ANNEXURE-F CI CHECK VALVE (50 NB & ABOVE)
7 ANNEXURE-G BUTTERFLY VALVE
8 ANNEXURE-H PLUG VALVE
9 ANNEXURE-I BALL VALVE
10 ANNEXURE-J SOLENOID VALVE
11 ANNEXURE-K KNIFE GATE VALVE: SLURRY LINE
12 ANNEXURE-L KNIFE GATE VALVE: DRY ASH LINE
13 ANNEXURE-M SEGREGATION VALVE / TERSG
VERTICAL DISC GATE VALVE, FA INTAKE
14 ANNEXURE-N
VALVE & FA DIFFUSER INTAKE VALVE.
15 ANNEXURE-O HOPPER ISOLATION VALVE
16 ANNEXURE-P ISO GATE VALVE (HCSD)
17 ANNEXURE-Q PLATE VALVE AT DYKE END
18 ANNEXURE-R PULSE DIAPHRAGM VALVE
 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

VENT FOR FEED GATE CYLINDER AT

1 101 _ OIL CLASS 1 _ MANUAL 15
AIR-OIL CONVERTER TANK
5 8.8 50 12

CONDITIONING
2 103 WGO CLASS 1 _ MANUAL 15 SILO AREA DRAIN PUMP SEALING 4.5 5.3 50 2
WATER

3 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 SLUDGE PUMP SEALING LINE 6.50 9.00 50 2

1
3A 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 HCSD DRAIN PUMP SEALING 6.50 9.00 50 2 NEW ADD

18

FOR PNEUMATIC ACTUATED KGV AT

4 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 6
BAW PUMP OUTLET

FOR PNEUMATIC ACTUATED KGV AT

5 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 6
BAW PUMP INLET

FOR PNEUMATIC ACTUATED

6 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 BUTTERFLY VALVE AT BAWT HOPPER 5 8.8 60 3
MAKE UP
FOR PNEUMATIC ACTUATED
7 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 BUTTERFLY VALVE AT HOPPER MAKE 5 8.8 60 3
UP
FOR PNEUMATIC ACTUATED
8 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 12
BUTTERFLY VALVE AT JET PUMP INLET

FOR PNEUMATIC ACTUATED TRSG AT

9 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 48
ESP OUTLET

FOR PNEUMATIC ACTUATED BALL

10 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 96
VALVE AT ESP FLUIDISING

FOR PNEUMATIC ACTUATED TRSG AT

11 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 24
VACUUM PUMP INLET

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 1 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

FOR PNEUMATIC ACTUATED TRSG AT

12 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 24
ESP TO BAG FILTER

FOR PNEUMATIC ACTUATED TRSG AT

13 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 6
PRIMARY AIR HEATER TO BAG FILTER

FOR PNEUMATIC ACTUATED FA

14 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 DIFFUSER INTAKE VALVE AT 1 st TO 4 5 8.8 60 192
th FIELD ESP HOPPER
FOR PNEUMATIC ACTUATED FA
15 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 DIFFUSER INTAKE VALVE AT 5 th TO 10 5 8.8 60 288
th FIELD ESP HOPPER

16 102 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 PRI. /SEC. AIR PRE HEATER HOPPER 5 8.8 60 24

FOR PNEUMATIC ACTUATED VACUUM

17 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 24
RELIEF VALVE AT BAG FILTER

FOR PNEUMATIC ACTUATED BALL

18 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 VALVE AT TA COMPRESSOR LINE TO 5 8.8 60 24
BAG FILTER

FOR PNEUMATIC ACTUATED

19 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 PRESSURE RELIEF VALVE AT TA 5 8.8 60 6
COMPRESSOR OUTLET

FOR PNEUMATIC ACTUATED

20 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 BUTTERFLY VALVE AT 5 8.8 60 12
INTERCONNECTION LINE OF TAC

FOR PNEUMATIC ACTUATED KGV AT

21 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 39 1 QTY. CHANGED
INTERCONNECTION LINE TO SILO

FOR PNEUMATIC ACTUATED VALVE AT

NUVA FEEDER (ALONG WITH PNEU.
22 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 336 1 QTY. CHANGED
BALL VALVE CYLINDERS FOR
NUVAFEERER)

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 2 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

FOR PNEUMATIC ACTUATED

23 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 BUTTERFLY VALVE TO DUST 5 8.8 60 5
CONDITIONER

FOR PNEUMATIC ACTUATED HOPER

24 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 10
ISOLATION VALVE AT SILO DISCHARGE

FOR PNEUMATIC ACTUATED KGV AT

25 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 2
SETLING& SURGE BIN OUTLET

FOR PNEUMATIC ACTUATED KGV AT

26 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 2
SLUDGE PUMP INLET

FOR PNEUMATIC ACTUATED KGV AT

27 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 2
SLUDGE PUMP DISCHARE

FOR PNEUMATIC ACTUATED

28 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 BUTTERFLY VALVE AT BA SLURRY 5 8.8 60 2
SUMP MAKE UP

FOR PNEUMATIC ACTUATED KGV AT

29 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 4
BA SLURRY SUMP OUTLET

FOR PNEUMATIC ACTUATED KGV AT

30 104 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 4
BA SLURRY PUMP DISCHARGE

31 DELETED

FOR PNEUMATIC OPTD. KGVS AT HCSD

31A 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 21 1 NEW ADD
SILO INLET LINE

FOR PNEUMATIC OPTD. ISOLATION 1

31B 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 15 NEW ADD
VALVES AT HCSD SILO OUTLET

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 3 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

FOR PNEUMATIC OPTD. BUTTERFLY

31C 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 VALVE AT HCSD DUST CONDITIONER 5 8.8 60 5 1 NEW ADD
FROM FAHP LINE

FOR PNEUMATIC OPTD. BUTTERFLY

31D 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 VALVE AT HCSD MIXING TANK INLET 5 8.8 60 5 1 NEW ADD
DOSING LINE FROM FAHP WATER LINE

FOR PNEUMATIC OPTD. BALL VALVE

31E 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 FOR HCSD MIXING TANK FLUSHING 5 8.8 60 5 1 NEW ADD
FROM FAHP WATER LINE

FOR PNEUMATIC OPTD. BALL VALVE

31F 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 FOR HCSD BOOSTER PUMP SEALING 5 8.8 60 5 1 NEW ADD
FROM FAHP WATER LINE

FOR PNEUMATIC OPTD. ISO GATE

31G 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 5 8.8 60 5 1 NEW ADD
VALVE AT HCSD MIXING TANK OUTLET

FROM IA HEADER TO FLEXIBLE

31H 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 CONNECTION FOR SUCTION AIR 5 8.8 60 5 1 NEW ADD
VESSEL

FRON IA HEADER TO CHARGING OF

31I 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 ACCUMULATOR OF PROPLING LIQUID 5 8.8 60 5 1 NEW ADD
SYSTEM

TO PNEUMATIC OPTD. BALL VALVES AT

1
31J 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 MAIN SILO FLUIDISING LINE TO MAIN 5 8.8 60 5 NEW ADD
SILO FLUIDISING PADS

TO PNEUMATIC OPTD. BALL VALVES AT 1

31K 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 15 HCSD SILO FLUIDISING LINE TO HCSD 5 8.8 60 5 NEW ADD
SILO FLUIDISING PADS

1285

AIR-OIL CONVERTER TANK DRAIN

32 101 _ OIL CLASS 1 _ MANUAL 20 5 8.8 50 12
LINE

12

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 4 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

AIR FILTER STATION AT IA HEADER

33 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 5 8.8 60 12 1 QTY. CHANGED
LINE TO PNEUMATIC ACTUATORS

AT DUST CHECK STATION AT BAG 254mmHg(g) 760mmHg(g) 1

34 103 AIO VACUUM AIR _ PN 16 MANUAL 20 60 48 QTY. CHANGED
FILTER Vacuum Vacuum

AT DUST CHECK STATION AT VENT 254mmHg(g) 760mmHg(g)

35 103 FVO VACUUM AIR _ PN 16 MANUAL 20 60 10
FILTER Vacuum Vacuum

TO VACUUM RECORDER ON CONTROL 254mmHg(g) 760mmHg(g)

36 102 FVO VACUUM LINE _ PN 16 MANUAL 20 60 24
PANEL Vacuum Vacuum

AT DUST CHECK STATION OF MAIN 1

36A 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 5 8.8 60 10 NEW ADD
SILO VENT FILTER

FOR DUST CHECK STATION AT HCSD 1

36B 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 SILO TELESCOPIC SPOUT VENT 5 8.8 60 5 NEW ADD
FILTERS
AT DUST CHECK STATION FOR HCSD 1
36C 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 SILO VENT FILTER PULS JETTING 5 8.8 60 5 NEW ADD
SYSTEM
AT AIR FILTER STATION FROM IA 1
36D 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 HEADER TO HCSD SILO AREA 5 8.8 60 8 NEW ADD
PNEUMATIC ACTUATORS
AT AIR FILTER STATION AT IA LINE TO 1
36E 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 PNEU. OPTD. B/F VLVS AT TAC OUTLET 5 8.8 60 4 NEW ADD
LINE
1
IA LINE AT AIR FILTER STATION TO
36F 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 20 5 8.8 60 12 NEW ADD
BOILER AREA OF U#1, U#2 & U#3

138

37 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 25 FOR ASH CRUSHER SEALING LINE 3.50 3.90 50 12

FOR BA O'FLOW WATER PUMP

38 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 25 3.50 3.90 50 6
SEALING

39 101 AIO INSTRUMENT AIR CLASS 1 _ MANUAL 25 VENT FOR AIR-OIL CONVERTER TANK 5 8.8 50 12

40 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 BA SLURRY DRAIN PUMP SEALING LINE 6.50 9.00 50 2

ASH SLURRY DISPOSAL PUMP SEALING

41 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 4
LINE(1st stage)

1
41A 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 HP & LP SEAL WATER TANK DRAIN 1.00 1.00 50 1 NEW ADD

1
41B 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 FOR HCSD BOOSTER PUMP SEALING 6.50 9.00 50 5 NEW ADD

42

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 5 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

BAHP WATER TO OVERFLOW WEIR

42 101 WHB BAHP WATER CLASS 2 _ MANUAL 25 11.5 12.6 50 6
BOXES MAKE-UP LINE

ASH SLURRY DISPOSAL PUMP SEALING

43 104 WSH HP SEAL WATER CLASS 2 _ MANUAL 25 11 13 50 4
LINE(2nd stage)

10

INSTRUMENT AIR INLET TO FEED GATE

44 101 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 5 8.8 60 12
AIR-OIL CONVERTER TANK

FLUIDISING AIR LINE AT 1 st TO 4 th

45 102 AFH ESP FLUIDISING AIR _ PN 16 MANUAL 25 0.4 0.44 150 192
FIELD ESP HOPPER

FROM IA HEADER TO PNEUMATIC

ACTUATORS AT OUTLET OF AIR
1
45A 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 RECEIVER OF HCSD SILO AREA. 2 5 8.8 60 5 NEW ADD
(REFER DETAIL-B OF NTPC DOC. NO.
0330-162-PVM-L-009, ZONE: G-11)

FROM IA HEADER TO PNEUMATIC 1

45B 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 ACTUATORS & AIR VESSELS OF HCSD 5 8.8 60 5 NEW ADD
SLURRY CONTROL LOOP

1
AT INSTRUMENT AIR HEADER ARI
45C 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 5 8.8 60 2 NEW ADD
DECEIVER DRAIN LINE

1
45D 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 IAC AIR RECEIVER DRAIN LINE 5 8.8 60 6 NEW ADD

TO PNEUMATIC OPTD. B/F VALVES FOR

45E 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 PRESSURE RELIEF VALVES AT TAC 5 8.8 60 1 1 NEW ADD
OUTLET

ISOLATION VALVE IN IA LINE TO 1

45F 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 25 2 5 8.8 60 1 NEW ADD
SETTLING BIN & SURGE BIN AREA.

224

ASH SLURRY DISPOSAL PUMP FC

46 104 WCO COOLING WATER CLASS 1 _ MANUAL 40 2.5 2.75 50 4
COOLING LINE

47 105 WCO COOLING WATER CLASS 1 _ MANUAL 40 IAC COOLING LINE INLET 2.5 2.75 50 9

48 105 WCO COOLING WATER CLASS 1 _ MANUAL 40 IAC COOLING LINE OUTLET 2.5 2.75 50 3

TO BA O'FLOW WATER PUMP FLUID

49 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 40 3.50 3.90 50 6
COUPLING COOLING

50 DELETED

51 DELETED

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 6 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-A
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GATE VALVE (BELOW 50 NB) REV-02

Pressure Class / Rating Working Max. Working

Type of
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

TO BA O'FLOW WATER PUMP FLUID

52 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 40 3.50 3.90 50 6
COUPLING COOLING HEADER

53 102 WSO BA SEAL WATER CLASS 1 _ MANUAL 40 VACUUM PUMP SEALING 3.50 3.90 50 24

ECO WATER INLET TO ECONOMISER

54 101 WEP ECO WATER CLASS 1 _ MANUAL 40 7 9.3 50 12
HOPPER FLUSHING BOXES

64

IA HEADER LINE TO TELESCOPIC

55 103 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 5
SPOUT VENT FILTER

FROM IA HEADER TO TELESCOPIC 1

55A 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 5 NEW ADD
SPOUT VENT FILTERS

FROM IA HEADER TO HCSD SILO 1

55B 109 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 5 NEW ADD
TELESCOPIC SPOUT VENT FILTERS

IA LINT AIR FILTER STATION TO PNEU. 1

55C 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 OPTD VALVES IN ESP AREA OF U#1, 5 8.8 60 15 NEW ADD
U#2 & U#3
1
IA INLET LINE TO PNEU. OPTD. VALVES
55D 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 3 NEW ADD
IN ESP AREA OF U#1, U#2 & U#3

1
IA LINE TO PNEUMATIC OPTD. VALVES
55E 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 1 NEW ADD
AT BA SLURRY P/H AREA

1
IA LINE TO BOILER AREA OF U#1, U#2 &
55F 105 AIO INSTRUMENT AIR _ PN 16 MANUAL 40 5 8.8 60 3 NEW ADD
U#3

37

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 7 of 7

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-B
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GLOBE VALVE (BELOW 50 NB), REV-02

Pressure Class / Rating

Type of Working Max. Working
Service Quantity for 3 units
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
2 temp (oC) (NO.)
actuation (kg/cm ) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

1 101 WLB BALP CLASS 1 _ MANUAL 15 WINDOW SPRAY 2.30 2.90 50 12

2 101 WEP ECO WATER PUMP CLASS 1 _ MANUAL 15 ECO HOPER FLUSHING BOX 7 9.3 50 12

CONDITIONING
3 103 WGO CLASS 1 _ MANUAL 15 SILO AREA DRAIN PUMP SEALING 4.5 5.3 50 4
WATER

4 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 SLUDGE PUMP SEALING LINE 6.50 9.00 50 4

MOVE TO SL NO.
5
11A

1
5A 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 HCSD DRAIN PUMP SEALING 6.5 9 50 4 NEW ADD

2 MOVE FROM SL
5B 101 WHB BA SEAL WATER CLASS 1 _ MANUAL 15 CRUSHER COOLING 3.5 3.9 50 12
NO. 6

48

MOVE TO SL NO.
6
5B

1
7 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 25 BA OVERFLOE WATER PUMP SEALING 3.5 3.9 50 12 QTY. CHANGED

8 101 _ OIL CLASS 1 _ MANUAL 25 AIR OIL CONVERTOR TANK INLET 5 8.8 50 24

CONDITIONING
9 103 WGO CLASS 1 _ MANUAL 25 SILO AREA DRAIN PUMP FLUSHING 4.5 5.3 50 1
WATER

ASH SLURRY DISPOSAL PUMP

10 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 8
SEALING LINE(1st stage)

BA SLURRY DRAIN SUMP FLUSHING

11 104 WEP ECO WATER PUMP CLASS 1 _ MANUAL 25 7 9.3 50 1
LINE

BA SLURRY DRAIN PUMP SEALING 1

11A 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 4 FROM SL. NO.5
LINE

FAHP WAER TO SLUDGE PUMP 1

11B 104 WHF FAHP WATER CLASS 1 _ MANUAL 25 6.20 7.00 50 1 NEW ADD
DISCHARGE LINE FLUSHING

11C 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 HCSD BOOSTER PUMP SEALING 6.50 9.00 50 10 1 NEW ADD

11D 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 HCSD DRAIN PUMP FLUSHING 6.50 9.00 50 1 1 NEW ADD

MOVE FROM SL
11E 101 WHB BA SEAL WATER CLASS 1 _ MANUAL 25 CRUSHER SEALING 3.5 3.9 50 24 2 NO. 12

86

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 1 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-B
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
GM GLOBE VALVE (BELOW 50 NB), REV-02

Pressure Class / Rating

Type of Working Max. Working
Service Quantity for 3 units
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure Remarks
2 temp (oC) (NO.)
actuation (kg/cm ) (kg/cm2)
IS BS

1
IS : 778 BS : 5154

MOVE TO SL NO.
12
11E

ASH SLURRY DISPOSAL PUMP

13 104 WSH HP SEAL WATER CLASS 2 _ MANUAL 25 11 13 50 4
SEALING LINE(2nd stage)

MOVE TO SL
14
NO.23

BA OVERFLOE WATER PUMP FC

15 101 WSO BA SEAL WATER CLASS 1 MANUAL 40 3.5 3.9 50 12
COOLING

16 101 WEP ECO WATER PUMP CLASS 1 _ MANUAL 40 ECO HOPER FLUSHING BOX 7 9.3 50 12

17 101 WEP ECO WATER PUMP CLASS 1 _ MANUAL 40 ECO HOPER FLUSHING BOX JETING 7 9.3 50 6

18 102 WSO BA SEAL WATER CLASS 1 MANUAL 40 VACUUM PUMP SEALING 3.5 3.9 50 48

19 DELETED

ASH SLURRY DISPOSAL PUMP FC

20 104 WCO COOLING WATER CLASS 1 _ MANUAL 40 2.5 2.75 50 8
COOLING LINE

21 104 WEP ECO WATER PUMP CLASS 1 _ MANUAL 40 BA SLURRY SUMP FLUSHING LINE 7 9.3 50 4

22 104 WEP ECO WATER PUMP CLASS 1 _ MANUAL 40 BA SLURRY TROUGH FLUSHING LINE 7 9.3 50 2

FAHP LINE TO SETTLING BIN & SURGE

22A 104 WHF FAHP WATER CLASS 1 _ MANUAL 40 BIN MAKE-UP & SETTALIG BIN AND 6.2 7 50 4 1 NEW ADD
SURGE BIN OUTLET LINE FLUSHING

96

23 104 WSH HP SEAL WATER CLASS 2 _ MANUAL 40 HP SEAL WATER TANK RC LINE 11 13 50 1 1 FROM SL. NO.14

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-C
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Pressure Class / Rating

Type of Working Max. Working
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
2 temp (oC) units (NO.)
actuation (kg/cm ) (kg/cm2)
IS BS

1
GM CHECK VALVE FOR WATER LINE (BELOW 50NB) , REV-02
TYPE : LIFT CHECK TYPE
IS : 778 BS : 5154

CONDITIONING
1 103 WGO CLASS 1 _ MANUAL 15 SILO AREA DRAIN PUMP SEALING 4.5 5.3 50 2
WATER

2 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 SLUDGE PUMP SEALING LINE 6.50 9.00 50 2

HCSD SILO AREA DRAIN PUMP 1

2A 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 15 6.50 9,00 50 2 NEW ADD
SEALING

BA OVERFLOW WATER PUMP 1

3 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 25 3.50 3.90 50 6 QTY. CHANGED
SEALING

4 101 _ OIL CLASS 1 _ MANUAL 25 AIR OIL CONVERTOR TANK INLET 5 8.8 50 24

ASH SLURRY DISPOSAL PUMP

5 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 4
SEALING LINE(1st stage)

BA SLURRY DRAIN PUMP SEALING

6 104 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 2
LINE

HCSD BOOSTER PUMP SEALING 1

6A 109 WSL LP SEAL WATER CLASS 1 _ MANUAL 25 6.50 9.00 50 5 NEW ADD
LINE

HCSD HOSE PUMP SUCTION & 1

6B 109 WHF FAHP WATER CLASS 1 _ MANUAL 25 6.20 7.00 50 10 NEW ADD
DISCHARGE LINE FLUSHING

51

7 101 WHB BAHP CLASS 2 _ MANUAL 25 CRUSHER SEALING 11.5 12.6 50 12

ASH SLURRY DISPOSAL PUMP

8 104 WSH HP SEAL WATER CLASS 2 _ MANUAL 25 11 13 50 4
SEALING LINE(2nd stage)

16

BA OVERFLOE WATER PUMP FC

9 101 WSO BA SEAL WATER CLASS 1 _ MANUAL 40 3.50 3.90 50 6
COOLING

ASH SLURRY DISPOSAL PUMP FC

10 104 WCO COOLING WATER CLASS 1 _ MANUAL 40 2.5 2.75 50 4
COOLING LINE

10

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 1 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-C
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Pressure Class / Rating

Type of Working Max. Working
Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
2 2 temp (oC) units (NO.)
actuation (kg/cm ) (kg/cm )
IS BS

GM CHECK VALVE FOR AIR LINE (BELOW 50NB)

TYPE : SWING CHECK TYPE
AT HCSD HOSE PUMP DISCHARGE
1
1A 109 AIO INSTRUMENT AIR _ PN 20 MANUAL 15 AIR VISSEL INSTRUMENT AIR 5 8.8 60 5 NEW ADD
SUPPLY LINE

TO VACUUM RECORDER ON 254mmHg(g) 760mmHg(g)

1 102 FVO VACUUM LINE _ PN 20 MANUAL 20 60 24
CONTROL PANEL Vacuum Vacuum

FLUIDISING AIR LINE AT 1 st TO 4 th

2 102 AFH ESP FLUIDISING AIR _ PN 20 MANUAL 20 0.4 0.44 150 192
FIELD ESP HOPPER
AT DUST CHECK STATION AT MAIN
3 103 AIO INSTRUMENT AIR _ PN 20 MANUAL 20 SILO TELESCOPIC SPOUT VENT 5 8.8 60 10
FILTER
AT DUST CHECK STATION AT BAG 254mmHg(g) 760mmHg(g)
4 103 FVO VACUUM AIR _ PN 20 MANUAL 20 60 48 1 QTY. CHANGED
FILTER Vacuum Vacuum
MAIN SILO VENT FILTER PULSE
4A 103 AIO INSTRUMENT AIR _ PN 20 MANUAL 20 JETTING SYSTEM DUST CHECK 5 8.8 60 10 1 NEW ADD
STN.
HSCD SILO TELESCOPIC SPOIT
4B 109 AIO INSTRUMENT AIR _ PN 20 MANUAL 20 5 8.8 60 10 1 NEW ADD
VENT FILTER DUST CHECK STN.
HCSD SILO VENT FILTER PULSE
4C 109 AIO INSTRUMENT AIR _ PN 20 MANUAL 20 JETTING SYSTEM DUST CHECK 5 8.8 60 10 1 NEW ADD
STN.

304

FLUIDISING AIR LINE AT 1 st TO 4 th

5 102 AFH ESP FLUIDISING AIR _ PN 20 MANUAL 25 0.4 0.44 150 384
FIELD ESP HOPPER

FLUIDISING LINE TO SILO OUTLET

6 103 AIO SILO FLUIDISING AIR _ PN 20 MANUAL 25 0.6 0.66 150 20
HOPPER
1
HCSD SILO
6A 109 AIO _ PN 20 MANUAL 25 AT HCSD SILO OUTLET HOPPERS 0.4 0.44 150 20 NEW ADD
FLUIDDISING AIR

424

TO BUFFER HOPPER FLUIDISING

7 103 AIO SILO FLUIDISING AIR _ PN 20 MANUAL 40 0.6 0.66 150 48
PAD

8 103 AIO SILO FLUIDISING AIR _ PN 20 MANUAL 40 TO SILO FLUIDISING PAD 0.6 0.66 150 70 QTY. CHANGED

HCSD SILO 1
8A 109 AIO _ PN 20 MANUAL 40 TO HCSD SILO FLUIDISING PADS 0.4 0.44 150 3O NEW ADD
FLUIDDISING AIR

118

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR\RV Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-D
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GATE VALVE (50 NB AND ABOVE), REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
(kg/cm2) 2
actuation (kg/cm )

1
BS : 5150

ESP/B.HOPPER ESP/B.HOPPER FLUIDISING LINE

1 103 AFH PN 10 MANUAL 50 0.4 0.44 130 24
FLUIDISING AIR TO BUFFER HOPPER
NEARAEST STROM WATER
WATER FROM RCC
2 103 DPS PN 10 MANUAL 50 DRAINAGE FROM SILO AREA RCC 1.5 1.5 50 1
TANK
TANK
CONDITIONING CONDITIONING WATER LEAK OFF
3 103 WGO PN 10 MANUAL 50 4.5 5.3 50 1
WATER LINE
AIR RECEIVER OF FAE TOWER
4 103 AIO INSTRUMENT AIR PN 10 MANUAL 50 TO BAG FILTER PULSE JETTING 5 8.8 60 24
LINE
IA INLET LINE TO MAIN SILO VENT
5 103 AIO INSTRUMENT AIR PN 10 MANUAL 50 5 8.8 60 5
FILTERS
IA INLET TO HCSD SILO VENT 1
5A 109 AIO INSTRUMENT AIR PN 10 MANUAL 50
FILTERS
5 8.8 60 5 NEW ADD

PURCHASERS TO INSTRUMENT AIR 1

5B 105 _
COOLING WATER
PN 10 MANUAL 50
COMPRESSOR COOLING LINE
2.5 3 50 18 NEW ADD

78

CONDITIONING TO DUST CONDITIONER AT MAIN

6 103 WGO PN 10 MANUAL 65 4.5 5.3 50 5
WATER SILO
WATER DOSING LINE TO HCSD
6A 109 WHF FAHP WATER PN 10 MANUAL 65 6.2 7 50 10 1 NEW ADD
ROTARY UNLOADER
IA FROM IA COMPRESSOR 1
6B 105 AIO INSTRUMENT AIR PN 10 MANUAL 65 DISCHARGE LINE & IA TO ADP 5 8.8 60 6 NEW ADD
INLET INNE
IA FROM ADP OUTLET TO IA 1
6C 105 AIO INSTRUMENT AIR PN 10 MANUAL 65 5 8.8 60 6 NEW ADD
RECEIVER INLET LINE
IA FROM AIR RECEIVER OUTLET 1
6D 105 AIO INSTRUMENT AIR PN 10 MANUAL 65
LINE
5 8.8 60 6 NEW ADD

33

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 1 of 4

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-D
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GATE VALVE (50 NB AND ABOVE), REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
(kg/cm2) 2
actuation (kg/cm )

1
BS : 5150

BA OVERFLOW TRANSFER
7 101 WLB BALP WATER PN 10 MANUAL 80 2.30 2.90 50 3
HOPPER MAKE UP

8 MOVE TO SL NO. 23D

9 103 WWS WASH WATER PN 10 MANUAL 80 WASH WATER PUMP DISCHARGE 2.5 3.1 50 2

CONDITIONING CONDITIONING WATER PUMP

10 103 WGO PN 10 MANUAL 80 4.5 5.3 50 6
WATER DISCHARGE

11 103 AIO INSTRUMENT AIR PN 10 MANUAL 80 IA INLET LINE AT MAIN SILO AREA 5 8.8 60 2 1
QTY. CHANGED

12 104 WSH HP SEAL WATER PN 10 MANUAL 80 HP SEAL WATER PUMP SUCTION 0.20 1.00 50 2

TO F.C.COOLING OF 1ST STAGE

13 104 WCO COOLING WATER PN 10 MANUAL 80 2.5 2.75 50 1
BA SLURRY DISPOSAL PUMP

LP SEAL WATER PUMP

14 104 WSL LP SEAL WATER PN 10 MANUAL 80 6.50 8.10 50 2
DISCHARGE

15 MOVE TO SL NO. 23C

WATER DOSING LINE TO HCSD

15A 109 WHF FAHP WATER PN 10 MANUAL 80
ROTARY UNLOADER
6.2 7 50 5 NEW ADD

FAHP WATER LINE TO SETTLING 1

15B 104 WHF FAHP WATER PN 10 MANUAL 80 6.2 7 50 1
BIN & SURGE BIN

FROM IA HEADER TO HCSD SILO 1

15C 109 AIO INSTRUMENT AIR PN10 MANUAL 80
AREA
5 8.8 60 2 NEW ADD

15D 105 AIO INSTRUMENT AIR PN 10 MANUAL 80 IA LINE TO HCSD SYSTEM 5 8.8 60 1 1 NEW ADD

15E 105 AIO INSTRUMENT AIR PN 10 MANUAL 80 IA LINT TO MAIN SILO AREA 5 8.8 60 1 1 NEW ADD

IA LINE TO ESP AREA FAE 1

15F 105 AIO INSTRUMENT AIR PN 10 MANUAL 80
TOWERS OF U#1, U#2 & U#3
5 8.8 60 3 NEW ADD

31

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 2 of 4

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-D
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GATE VALVE (50 NB AND ABOVE), REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
(kg/cm2) 2
actuation (kg/cm )

1
BS : 5150

HP SEAL WATER PUMP

16 104 WSH HP SEAL WATER PN 16 MANUAL 80 11 13 50 2
DISCHARGE

MAIN SILO MAIN SILO FLUIDISING BLOWER 1

17 103 AFS PN 10 MANUAL 100 0.6 0.66 130 16 QTY. CHANGED
FLUIDISING AIR HEATER DISCHARGE

CONDITIONING CONDITIONING WATER PUMP

18 103 WGO PN 10 MANUAL 100 1 1 50 6
WATER SUCTION

19 103 WWS WASH WATER PN 10 MANUAL 100 WASH WATER PUMP SUCTION 1.5 1.5 50 2

20 104 WSL LP SEAL WATER PN 10 MANUAL 100 LP SEAL WATER PUMP SUCTION 0.20 1.00 50 2

BA SLURRY DRAIN BA SLURRY DRAIN PUMP

21 104 DPA PN 10 MANUAL 100 1.00 1.20 60 2
WATER DISCHARGE

22 104 WLB BALP WATER PN 10 MANUAL 100 FOR SLURRY SUMP MAKE-UP 2.30 2.90 50 2

ECO WATER PUMP DISCHARGE

23 104 WEP ECO WATER PN 10 MANUAL 100 7 9.3 50 3
TO ECONOMISER HOPPER

HCSD MIXING TANK WATER 1

23A 109 WHF FAHP WATER PN 10 MANUAL 100 6.2 7 50 20 NEW ADD
DOSING LINE

HCSD FLUIDISING LINE HEATER

23B 109 AFS HCSD FLUIDISING AIR PN 10 MANUAL 100 0.4 0.44 130 18 1 NEW ADD
INLET / OUTLET

ECO WATER PUMP DISCHARGE

23C 104 WEP ECO WATER PN 10 MANUAL 100 7 9.3 50 1 FROM SL. NO. 15
TO ASH SLURRY SUMP JETTING

ESP/B. HOPPER ESP FLUIDISING BLOWER

23D 102 AFH PN 10 MANUAL 100 0.4 0.44 130 12 2 MOVE FROM SL NO. 8
FLUIDISING AIR HEATER INLET & OUTLET

84 1

BA SEAL WATER PUMP

24 101 WSO BA SEAL WATER PN 10 MANUAL 150 3.5 3.9 50 2
DISCHARGE

MAIN SILO
25 103 AFS PN 10 MANUAL 150 TO MAIN SILO FLUIDISING PAD 0.6 0.66 130 5
FLUIDISING AIR

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 3 of 4

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-D
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GATE VALVE (50 NB AND ABOVE), REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
(kg/cm2) 2
actuation (kg/cm )

1
BS : 5150

26 DELETED

27 DELETED

28 104 WHF FAHP WATER PN 10 MANUAL 150 FAHP WATER PUMP DISCHARGE 6.20 7.00 50 5

WATER DOSING LINE TO HCSD

28A 109 WHF FAHP WATER PN 10 MANUAL 150 6.20 7.00 50 5 1 NEW ADD
ROTARY UNLOADER

17

29 101 WSO BA SEAL WATER PN 16 MANUAL 150 BA SEAL WATER PUMP SUCTION 1 10 50 2

30 101 WHB BAHP WATER PN 16 MANUAL 150 BAHP WATER INLET TO JET PUMP 11.5 12.6 50 12

14

FLUSHING WATER LINE TO HCSD

31 109 WHF FAHP WATER PN 10 MANUAL 200 6.2 7 50 5 NEW ADD
MIXING TANK

FAHP WATER SUPPLY LINE TO 1

32 109 WHF FAHP WATER PN 10 MANUAL 200 6.2 7 50 5 NEW ADD
HCSD SILOS

10

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 4 of 4

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-E
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GLOBE VALVE (50 NB AND ABOVE), REV-02

Type of Working Max. Working

Pressure Service Quantity for 3 units
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) (NO.)
actuation (kg/cm2) 2
(kg/cm )

1
BS : 5152

LP SEAL WATER PUMP RE-CIRCULATION

1 104 WSL LP SEAL WTER PN 10 MANUAL 50 6.5 9 50 1
LINE

CONDITIONING
2 103 WGO PN 10 MANUAL 65 DUST CONDITIONER OF MAIN SILO 4.5 5.3 50 10
WATER

10

FOR RING HEADER FOR SEAL TROUGH

3 101 WLB BALP WATER PN 10 MANUAL 80 2.3 2.9 50 3
MAKE-UP / FLUSHING

4 101 WLB BALP WATER PN 10 MANUAL 150 FOR REFRACTORY COOLING SUPPLY 2.3 2.9 50 3

FOR RING HEADER FOR SEAL TROUGH

5 101 WHB BAHP WATER PN 16 MANUAL 150 11.5 12.6 50 3
MAKE-UP / FLUSHING

6 101 WHB BAHP WATER PN 16 MANUAL 150 FOR REFRACTORY COOLING SUPPLY 11.5 12.6 50 6 1 QTY. CHANGED

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 1 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-E
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI GLOBE VALVE (50 NB AND ABOVE), REV-02

Type of Working Max. Working

Pressure Service Quantity for 3 units
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) (NO.)
actuation (kg/cm2) 2
(kg/cm )

1
BS : 5152

7 101 WHB BAHP WATER PN 16 MANUAL 150 FOR JET PUMP INLET 11.5 12.6 50 24

33

8 101 WLB BALP WATER PN 10 MANUAL 200 BA O'FLOW TRANSFER HOPPER MAKEUP 2.3 2.9 50 3

9 104 WLB BALP WATER PN 10 MANUAL 200 BA SLURRY SUMP MAKE-UP 2.3 2.9 50 2

OVER GROUND RCC TANK WATER

10 103 WEO SERVICE WATER PN 16 MANUAL 200 1.5 10 50 1
SUPPLY LINE AT SILO AREA

11 101 WLB BALP WATER PN 10 MANUAL 250 TO HOPPER MAKE-UP / FILLING 2.3 2.9 50 3

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-F
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI SWING CHECK VALVE (50 NB & ABOVE)REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
actuation (kg/cm 2) (kg/cm 2)

1
BS : 5153

IA OUTLET FROM AIR DRYING 1

1A 105 AIO INSTRUMENT AIR PN 10 MANUAL 65
PLANT
5 8.8 60 6 NEW ADD

1B 105 AIO INSTRUMENT AIR PN 10 MANUAL 65 IA OUTLET FROM IA RECEIVER 5 8.8 60 6 1 NEW ADD

12

WKG. PR.
1 103 WWS WASH WATER PN 10 MANUAL 80 WASH WATER PUMP DISCHARGE 2.5 3.1 50 2
CHANGED

TO RING HEADER FOR SEAL

2 101 WLB BALP WATER PN 10 MANUAL 80 2.3 2.9 50 3
TROUGH MAKE-UP / FLUSHING

CONDITIONING CONDITIONING WATER PUMP

3 103 WGO PN 10 MANUAL 80 4.5 5.3 50 6
WATER DISCHARGE

LP SEAL WATER PUMP

4 104 WSL LP SEL WATER PN 10 MANUAL 80 6.5 8.1 50 2
DISCHARGE

BA SLURRY PUMP FC COOLING 1

4A 104 WCO COOLING WATER PN 10 MANUAL 80 2.5 3 50 1 NEW ADD
WATER RETURN LINE

HCSD SUCTION STRAINER

4B 109 WHF FAHP WATER PN 10 MANUAL 80 6.2 7 50 5 1 NEW ADD
FLUSHING LINE

19

HP SEAL WATER PUMP

5 104 WSH HP SEAL WATER PN 16 MANUAL 80 11 13 50 2
DISCHARGE

BA SLURRY DRAIN BA SLURRY DRAIN PUMP

6 104 DPA PN 10 MANUAL 100 1.00 1.20 50 2
WATER DISCHARGE

FOR REFRECTORY COOLING

7 101 WLB BALP WATER PN 10 MANUAL 150 2.3 2.9 50 3
SUPPLY

MAIN SILO AREA MAIN SILO AREA DRAIN PUMP

8 103 DPS PN 10 MANUAL 150 3.5 2 3.7 50 2
DRAIN WATER DISCHARGE

BA SEAL WATER PUMP

9 101 WSO BA SEAL WATER PN 10 MANUAL 150 3.5 3.9 50 2
DISCHARGE

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 1 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-F
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
CI SWING CHECK VALVE (50 NB & ABOVE)REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
actuation (kg/cm 2) (kg/cm 2)

1
BS : 5153

10 104 WHF FAHP WATER PN 10 MANUAL 150 FAHP WATER PUMP DISCHARGE 6.2 7 50 5

1
10A 109 DPS HCSD DRAIN WATER PN 10 MANUAL 150 HCSD DRAIN PUMP DISCHARGE 1.8 2 50 2 NEW ADD

14

11 104 WEP ECO WATER PN 10 MANUAL 200 ECO WATER PUMP DISCHARGE 7 9.3 50 2

HCSD BOOSTER PUMP SUCTION 1

11A 109 WHF FAHP WATER PN 10 MANUAL 200 6.2 7 50 5 NEW ADD
LINE FLUSHING

API 594, TRANSPORT AIR INLET TO

12 103 ACO TRANSPORT AIR MANUAL 250 1.75 2.75 160 9 WAFFER TYPE
CLASS 125 STREAM LINE

13 104 WHB BAHP WATER PN 16 MANUAL 250 BAHP WATER PUMP DISCHARGE 11.5 12.6 50 3

FLUSHING WATER PUMP

14 104 AFH FLUSHING WATER PN 10 MANUAL 350 1.8 2.6 50 1
DISCHARGE

15 104 WLB BALP WATER PN 10 MANUAL 350 BALP WATER PUMP DISCHARGE 2.30 2.90 50 5

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-G
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
BUTTERFLY VALVE, REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure o REMARKS
Class / Rating 2 temp ( C) units (NO.)
actuation (kg/cm ) (kg/cm2)

BS : 5155 1

CONDITIONING TO MAIN SILO DUST

1 103 WGO PN 6 PNEUMATIC 65 4.5 5.3 50 5
WATER CONDITIONER

BA O'FLOW TRANSFER HOPPER

2 101 WLB BALP WATER PN 6 PNEUMATIC 80 2.3 2.9 50 3
MAKE-UP

FAHP WATER DOSING LINE TO

2A 109 WHF FAHP WATER PN 10 PNEUMATIC 80 6.2 7 50 5 1
HCSD ROTARY UNLOADER

5 NEW ADD

3 104 WLB BALP WATER PN 6 PNEUMATIC 100 BA SLURRY SUMP MAKE-UP 2.3 2.9 50 2

PRESSURE RELIEF FOR TAC

4 103 ACO TRANSPORT AIR PN 6 PNEUMATIC 150 1.75 2.75 160 6
DISCHARGE

FOR VACUUM RELIEF OVER BAG- 254mmHg(g) 760mmHg(g)

5 103 FVO VACUUM AIR PN 6 PNEUMATIC 150 80 24
FILTER (Vacuum) (Vacuum)

30

FAHP WATER DOSING LINE TO 1

5A 109 WHF FAHP WATER PN 10 PNEUMARIC 150 6.20 7.00 50 5
HCSD MIXING TANK

5 NEW ADD

6 101 WHB BAHP WATER PN 16 PNEUMATIC 150 TO JET PUMP INLET 11.5 12.6 50 12

12

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 1 of 3

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-G
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
BUTTERFLY VALVE, REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure o REMARKS
Class / Rating 2 temp ( C) units (NO.)
actuation (kg/cm ) (kg/cm2)

BS : 5155 1

7 104 WLB BALP WATER PN 6 MANUAL 200 BA SLURRY SUMP MAKE-UP 2.3 2.9 50 2

8 104 WEP ECO WATER PN 10 MANUAL 200 ECO WATER PUMP DISCHARGE 7 9.3 50 2

9 104 WEP ECO WATER PN 6 MANUAL 250 ECO WATER PUMP SUCTION 1 1 50 2

10 104 WHF FAHP WATER PN 6 MANUAL 250 FAHP WATER PUMP SUCTION 1 1 50 5

2
11 103 ACO TRANSPORT AIR PN 6 MANUAL 250 TAC DISCHARGE 1.75 2.75 160 24 QTY. CHANGED

24

INTERCONNECTION LINE FROM

12 103 ACO TRANSPORT AIR PN 6 PNEUMATIC 250 TAC DISCHARHE TO STREAM FP 1.75 2.75 160 12
LINE

13 101 WLB BALP WATER PN 6 PNEUMATIC 250 BA HOPPER MAKE-UP / FILLING 2.3 2.9 50 3

15

BAHP WATER PUMP

14 104 WHB BAHP WATER PN 16 MANUAL 250 11.5 12.6 50 3
DISCHARGE

BAHP WATER PUMP

15 104 WHB BAHP WATER PN 16 MANUAL 250 11.5 12.6 50 3
DISCHARGE LINE TO BA AREA

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 2 of 3

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-G
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
BUTTERFLY VALVE, REV-02
Type of Working Max. Working
Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure o REMARKS
Class / Rating 2 temp ( C) units (NO.)
actuation (kg/cm ) (kg/cm2)

BS : 5155 1

BALP WATER PUMP UNITWISE

16 104 WLB BALP WATER PN 6 MANUAL 300 2.3 2.9 50 3
ISOLATION

17 104 WHB BAHP WATER PN 6 MANUAL 350 BAHP WATER PUMP SUCTION 1 1 50 3

FLUSHING WATER PUMP

18 104 AFH FLUSHING WATER PN 6 MANUAL 350 1.8 2.6 50 1
DISCHARGE

BA SLURRY DISPOSAL PUMP

19 104 AFH FLUSHING WATER PN 6 MANUAL 350 1.8 2.6 50 4
SUCTION PIPE FLUSHING

20 104 WLB BALP WATER PN 6 MANUAL 350 BALP WATER PUMP DISCHARGE 2.3 2.9 50 5

13

21 104 WLB BALP WATER PN 6 MANUAL 500 BALP WATER PUMP SUCTION 1 1 50 5

FLUSHING WATER PUMP

22 104 AFH FLUSHING WATER PN 6 MANUAL 500 1 1 50 1
SUCTION

D:\NTPC-JHAJJAR\VALVE SCHEDULE - JHAJJAR Page 3 of 3

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-H
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
PLUG VALVE, REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure APPLICATION M.O.C. PATTERN REMARKS
Class / Rating temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)

1
BS : 5158

FOR PI & PT AT BA O'FLOW WATER ASH CONTAMINATED BODY : CS

1 101 DPB BA O'FLOW WATER CLASS 300 MANUAL 40 1.40 2.35 60 12 REGULAR
PUMP DISCHARGE WATER PLUG :CS
1

FOR PI & PT AT JET PUMP OUTLET BODY : CS

2 101 BJO BA SLURRY CLASS 300 MANUAL 40 2.00 3.00 60 24 SLURRY REGULAR
SLURRY LINE PLUG :CS
1

MAIN SILO DRAIN FOR PI AT MAIN SILO AREA DRAIN ASH CONTAMINATED BODY : CS
3 103 DPS CLASS 300 MANUAL 40 3.50 2 3.74 50 2 REGULAR
WATER PUMP DISCHARGE WATER PLUG :CS
1

FOR PI AT BA SLURRY DRAIN PUMP ASH CONTAMINATED BODY : CS

4 104 SBO BA DRAIN WATER CLASS 300 MANUAL 40 1.00 1.20 60 2 REGULAR
DISCHARGE WATER PLUG :CS
1

FOR PI AT HCSD SILO AREA DRAIN ASH CONTAMINATED BODY : CS

4A 109 SBO HCSD DRAIN WATER CLASS 300 MANUAL 40 1.80 2.00 60 2 1 REGULAR NEW ADD
PUMP DISCHARGE WATER PLUG :CS

FOR PI & PT AT SLUDGE PUMP BODY : CS

5 104 DPB SLUDGE CLASS 300 MANUAL 40 2.40 2.65 50 4 SLURRY REGULAR
DISCHARGE PLUG :CS
1
FOR PI & PT AT BA SLURRY BODY : CS
6 104 SDO BA SLURRY CLASS 300 MANUAL 40 9.70 10.80 60 8 SLURRY REGULAR
DISPOSAL PUMP DISCHARGE PLUG :CS
1
54

FOR EMMERGENCY DOOR NOZZLES BODY : CI PLUG

7 101 WHF BAHP WATER CLASS 125 MANUAL 65 11.5 12.6 50 12 WATER SHORT
IN BA HOPPER :CI

BODY : CI PLUG
8 105 AIO INSTRUMENT AIR CLASS 125 MANUAL 65 INSTRUMENT AIR LINE TO ADP 5 8.8 60 6 AIR SHORT
:CI

18

SEAL TROUGH DRAIN BODY : CI PLUG

9 101 DPS CLASS 125 MANUAL 80 FOR SEAL TROUGH DRAIN 1.5 2 50 24 WATER SHORT
WATER :CI

24

BS 5353; FOR HCSD PUMP DISCHARGE DRAIN 1 BODY : CS

9A 109 SHD HCSD SLURRY MANUAL 80 44 47 60 15 HCSD SLURRY SHORT NEW ADD
CLASS 300 LUNE PLUG :CS

15

M:\Barh\VALVES\Revised New Schedule Page 1 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-H
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
PLUG VALVE, REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Operation Size (NB) Location Pressure Pressure APPLICATION M.O.C. PATTERN REMARKS
Class / Rating temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)

1
BS : 5158

BODY : CI PLUG
10 101 WHF BAHP WATER CLASS 125 MANUAL 100 FOR SLOPE NOZZLES IN BA HOPPER 11.5 12.6 50 36 WATER SHORT
:CI

BODY : CI PLUG
11 101 WHF BAHP WATER CLASS 125 MANUAL 100 FOR DOOR NOZZLES IN BA HOPPER 11.5 12.6 50 12 WATER SHORT
:CI

48

BA HOPPER REFRACTORY COOLING HEADER BODY : CI PLUG

12 101 DPB CLASS 125 MANUAL 150 1.5 2 50 6 WATER SHORT
OVERFLOW DRAIN :CI

AT HCSD PUMP SILO AREA DRAIN 1

ASH CONTAMINATED BODY : CI PLUG
12A 109 SDO HCSD DRAIN WATER CLASS 125 MANUAL 150 1.8 2 50 2 SHORT NEW ADD
PUMP DISCHARGE WATER :CI

MAIN SILO DRAIN 1 ASH CONTAMINATED BODY : CI PLUG

12B 103 SDO CLASS 125 MANUAL 150 MAIN SILO DRAIN PUMP DISCHARGE 3.5 3.8 50 2 SHORT NEW ADD
WATER WATER :CI

10

BS 5353; 1 BODY : CS
12C 109 SHD HCSD SLURRY MANUAL 200 AT HCSD PUMP DISCHARGE 44 47 60 5 HCSD SLURRY SHORT NEW ADD
CLASS 300 PLUG :CS

BS 5353; TRANSPORT AIR INLET TO STREAM BODY : CS

13 103 ACO TRANSPORT AIR MANUAL 250 1.75 2.75 160 9 TRANSPORT AIR SHORT
CLASS 150 LINE PLUG :CS
1
9

NOTE : THE 250 NB VALVE SHALL BE PRVIDED GEAR OPERATED.

M:\Barh\VALVES\Revised New Schedule Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-I
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
BALL VALVE, REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating 2 temp (oC) units (NO.)
actuation (kg/cm ) (kg/cm2)

BS : 5351 1

FAHP WATER FLUSHING

CONNECTION TO SUCTION &
1A 109 WHF BALL FAHP WATER CLASS 800 MANUAL 25 6.2 7 50 10 NEW ADD
DISCHARGE OF HCSD HOSE
PUMP
1
10

TO NUVAFEEDER FOR VESSEL

1B 103 ACO BALL TRANSPORT AIR CLASS 800 PNEUMATIC 25 1.75 2.75 160 48 NEW ADD
FLUIDISING
2
48

ESP / BUFFER ESP / BUFFER HOPPER

1 102 AFH BALL HOPPER FLUIDISING CLASS 800 PNEUMATIC 40 FLUIDISING AIR INLET TO 1ST TO 0.4 0.44 150 96
AIR 4T FIELD OF ESP HOPPER

96

ESP / BUFFER HOPPER

ESP / BUFFER
FLUIDISING AIR INLET TO BAG
2 103 AFH BALL HOPPER FLUIDISING CLASS 150 PNEUMATIC 50 0.4 0.44 150 24
FILTER'S BUFFER HOPPER
AIR
FLUIDISING PADS
TO NUVAFEEDER FOR INLET &
2A 102 ACO BALL TRANSPORT AIR CLASS 150 PNEUMATIC 50 OUTLET DIFFUSER VALVE 1.75 2.75 160 48 NEW ADD
FLUIDISING

72 2

3 109 _ BALL HCSD SLURRY CLASS 150 MANUAL 50 HCSD HOSE PUMP SUCTION 3.4 3.8 60 5 NEW ADD

1
5

FAHP WATER DOSING LINE YO

4 109 WHF BALL FAHP WATER CLASS 150 MANUAL 65 6.2 7 50 10 NEW ADD
HCSD ROTARY UNLOADER
1

10

AT HCSD SUCTION STRAINER

5 109 WHF BALL HCSD SLURRY CLASS 150 MANUAL 80 3.4 3.8 50 10 NEW ADD
BYPASS LINE
1

10

AT DRAIN LINE OF HCSD

6 109 WHF BALL HCSD SLURRY CLASS 150 MANUAL 100 STRAINER / STRAINER BYPASS 3.4 3.8 50 10 NEW ADD
DRAIN
FAHP WATER DOSING LINE TO
7 109 WHF BALL FAHP WATER CLASS 150 MANUAL 100 6.2 7 50 20 NEW ADD
HCSD MIXING TANK

HCSD SILO
7A 109 AFS BALL CLASS 150 PNEUMATIC 100 HCSD SILO FLUIDISING LINE 0.4 0.44 150 5 2 NEW ADD
FLUIDISING AIR

35

M:\Barh\VALVES\Revised New Schedule Page 1 of 2

 INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
BALL VALVE, REV-02

Type of Working Max. Working

Pressure Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size (NB) Location Pressure Pressure REMARKS
Class / Rating temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)

MAIN SILO 2
7B 103 AFS BALL CLASS 150 PNEUMATIC 150 MAIN SILO FLUIDISING LINE 0.6 0.66 150 5 NEW ADD
FLUIDISING AIR

FAHP WATER LINE AT INLET OF

8 109 WHF BALL FAHP WATER CLASS 150 MANUAL 200 6.2 7 50 5 NEW ADD
HCSD BOOSTER PUMP

1
5

FAHP WATER TO HCSD MIXING

9 109 WHF BALL FAHP WATER CLASS 150 PNEUMATIC 200 6.2 7 50 5 NEW ADD
TANK FOR MAKEUP

FAHP WATER LINE AT INLET OF

10 109 WHF BALL FAHP WATER CLASS 150 PNEUMATIC 200 6.2 7 50 5 NEW ADD
HCSD BOOSTER PUMP
1
10

M:\Barh\VALVES\Revised New Schedule Page 2 of 2

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-J
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
( C) units (NO.)
PORT SIZE ORIFICE (kg/cm2) 2
(kg/cm )
(INCH) SIZE (MM)
1
2 WAY SOLINOED VALVE, REV-02
CONDITIONING TO MAIN SILO AREA DRAIN
1 103 WGO 0.5 15 2.50 5.30 50 2 1
WATER PUMP SEALING

2 104 WSL LP SEAL WATER 0.5 15 FOR SLUDGE PUMP SEALING 2.60 9.00 50 2 1

FOR HCSD SILO AREA DRAIN 1

2A 109 WSL LP SEAL WATER 0.5 15 2.60 9.00 50 2 1 NEW ADD
PUMP SEALING

3 101 WSO BA SEAL WATER 1 25 TO ASH CRUSHER SEALING 2.00 3.90 50 12 1

TO BA O'FLOW WATER PUMP

4 101 WSO BA SEAL WATER 1 25 2.00 3.90 50 6 1
SEALING

FOR 1st STAGE SLURRY

5 104 WSL LP SEAL WATER 1 25 5.65 9.00 50 4 1
DISPOSAL PUMP SEALING

FOR 2 nd STAGE SLURRY PUMP

6 104 WSH HP SEAL WATER 1 25 9.80 13.00 50 4 1
SEALING

BA SLURRY DRAIN PUMP

7 104 WSL LP SEAL WATER 1 25 6.50 9.00 50 4 1
SEALING

FOR HCSD BOOSTER PUMP 1

7A 109 WSL LP SEAL WATER 1 25 6.50 9.00 50 5 1 NEW ADD
SEALING

35

TO BA O'FLOW WATER PUMP FC

8 101 WSO BA SEAL WATER 1.5 40 2.00 3.90 50 6 1
COOLING

9 102 WSO BA SEAL WATER 1.5 40 TO VACUUM PUMP SEALING 2.00 3.90 50 24 1

M:\Barh\VALVES\Revised New Schedule Page 1 of 5

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-J
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
2 2 ( C) units (NO.)
PORT SIZE ORIFICE (kg/cm ) (kg/cm )
(INCH) SIZE (MM)
1

10 DELETED

PURCHASER'S FOR 1st STAGE SLURRY

11 104 DPB 1.5 40 2.00 7.00 50 4 1
COOLING WATER DISPOSAL PUMP F.C. COOLING

PURCHASER'S
12 105 DPB 1.5 40 FOR IA COMPRESSOR COOLING 2.00 7.00 50 6 1
COOLING WATER

40

INTERCONNECTION BETWEEN IA
13 105 DPB INSTRUMENT AIR 2 50 5.00 8.80 60 3 1
COMPRESSORS

4 WAY SOLINOED VALVE

FOR PNEUMETIC ACT.
1 101 AIO INSTRUMENT AIR 0.25 6 BUTTERFLY VALVE AT HOPPER 5.00 8.80 60 3 1
MAKE-UP / FILLING LINE

FOR PNEUMETIC ACT.

BUTTERFLY VALVE AT BA
2 101 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 3 1
O'FLOW TRANSFER HOPPER
MAKE-UP LINE

FOR PNEUMETIC ACT. KGV AT BA

3 101 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 6 1
O'FLOW WATER PUMP SUCTION

FOR PNEUMETIC ACT. KGV AT BA

4 101 AIO INSTRUMENT AIR 0.25 6 O'FLOW WATER PUMP 5.00 8.80 60 6 1
DISCHARGE

FOR PNEUMETIC ACT.

5 101 AIO INSTRUMENT AIR 0.25 6 BUTTERFLY VALVE AT BAHP 5.00 8.80 60 12 1
WATER INLET LINE TO JET PUMP

FOR PNEUMETIC ACT. TERSG AT

6 102 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 24 1
STREAM LINE TO BAG FILTER

FOR PNEUMETIC ACT. TERSG AT

PRIMARY & SECONDARY AIR
7 102 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 6 1
HEATER ASH LINE CONJUCTION
TO STREAM LINE

FOR PNEUMETIC ACT. TERSG AT

8 102 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 24 1
VACUUM PUMP SUCTION

M:\Barh\VALVES\Revised New Schedule Page 2 of 5

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-J
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
2 2 ( C) units (NO.)
PORT SIZE ORIFICE (kg/cm ) (kg/cm )
(INCH) SIZE (MM)
1
FOR PNEUMETIC ACT. BALL
VALVE AT FLUIDISING AIR INLET
9 102 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 96 1
LINE TO 1ST TO 4TH FIELD OF
ESP HOPPER

INST. AIR INLET TO PRIMARY &

10 102 AIO INSTRUMENT AIR 0.25 6 SECONDARY APH HOPPER 5.00 8.80 60 24 1
VERTICAL DISC GATE VALVES

INST. AIR INLET TO 5TH TO 10TH

11 102 AIO INSTRUMENT AIR 0.25 6 FIELD OF ESP HOPPERS ASH 5.00 8.80 60 288 1
INTAKE VLVS.

INST. AIR INLET TO 1ST TO 4TH

12 102 AIO INSTRUMENT AIR 0.25 6 FIELD OF ESP HOPPERS FA 5.00 8.80 60 192 1
DIFFUSER INTAKE VLVS.

FOR PNEUMETIC ACT. TERSG AT

13 102 AIO INSTRUMENT AIR 0.25 6 ESP HOPPERS FLY ASH CONV. 5.00 8.80 60 48 1
LINE

FOR PNEUMETIC ACT. VACUUM

14 103 AIO INSTRUMENT AIR 0.25 6 RELIEF VALVE ABOVE BAG 5.00 8.80 60 24 1
FILTERS

FOR PNEUMETIC ACT. BALL

15 103 AIO INSTRUMENT AIR 0.25 6 VALVE AT FLUIDISING AIR INLET 5.00 8.80 60 24 1
TO BUFFER HOPPERS

FOR PNEUMETIC ACT. PR.

16 103 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 6 1
RELIEF VALVE OF TAC

FOR PNEUMETIC ACT.

BUTTERFLY VALVES AT
17 103 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 5 1
CONDITIONING WATER INLET TO
DUST CONDITIONER
FOR PNEUMETIC ACT.
18 103 AIO INSTRUMENT AIR 0.25 6 ISOLATION VALVES AT MAIN SILO 5.00 8.80 60 10 1
OUTLET CHUTS
FOR PNEUMETIC ACT. KGV AT
STREAM LINE UPTO MAIN SILO &
19 103 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 39 1
INTERCONNECTION OF HCSD
SILO
FOR PNEUMETIC ACT. KGV
20 104 AIO INSTRUMENT AIR 0.25 6 BELOW SETTLING BIN & SURGE 5.00 8.80 60 2 1
BIN

FOR PNEUMETIC ACT. KGV AT

21 104 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 2 1
SLUDGE PUMP SUCTION

FOR PNEUMETIC ACT. KGV AT

22 104 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 2 1
SLUDGE PUMP DISCHARGE

M:\Barh\VALVES\Revised New Schedule Page 3 of 5

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-J
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
2 2 ( C) units (NO.)
PORT SIZE ORIFICE (kg/cm ) (kg/cm )
(INCH) SIZE (MM)
1
FOR PNEUMETIC ACT.
BUTTERFLY VALVE AT BALP
23 104 AIO INSTRUMENT AIR 0.25 6 5.00 8.80 60 2 1
WATER LINE FOR ASH SLURRY
SUMP MAKE-UP
FOR PNEUMETIC ACT. KGV AT
24 104 AIO INSTRUMENT AIR 0.25 6 ASH SLURRY DISPOSAL PUMP 5.00 8.80 60 4 1
SUCTION

FOR PNEUMETIC ACT. KGV AT

25 104 AIO INSTRUMENT AIR 0.25 6 ASH SLURRY DISPOSAL PUMP 5.00 8.80 60 4 1
DISCHARGE

FOR PNEUMATIC ACTUATED

25A 103 AIO INSTRUMENT AIR 0.25 6 BALL VALVE CYLINDERS FOR 5 8.8 60 96 1 1 NEW ADD
NUVAFEERER

FOR PNEUMATIC OPTD. KGVS AT

25B 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 21 1 1 NEW ADD
HCSD SILO INLET LINE

FOR PNEUMATIC OPTD.

25C 109 AIO INSTRUMENT AIR 0.25 6 ISOLATION VALVES AT HCSD 5 8.8 60 15 1 1 NEW ADD
SILO OUTLET
FOR PNEUMATIC OPTD.
BUTTERFLY VALVE AT HCSD
25D 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 1 NEW ADD
DUST CONDITIONER FROM FAHP
LINE
FOR PNEUMATIC OPTD.
BUTTERFLY VALVE AT HCSD
25E 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 1 NEW ADD
MIXING TANK INLET DOSING LINE
FROM FAHP WATER LINE
FOR PNEUMATIC OPTD. BALL
VALVE FOR HCSD MIXING TANK
25F 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 1 NEW ADD
FLUSHING FROM FAHP WATER
LINE
FOR PNEUMATIC OPTD. BALL
VALVE FOR HCSD BOOSTER
25G 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 1 NEW ADD
PUMP SEALING FROM FAHP
WATER LINE
FOR PNEUMATIC OPTD. ISO
25H 109 AIO INSTRUMENT AIR 0.25 6 GATE VALVE AT HCSD MIXING 5 8.8 60 5 1 1 NEW ADD
TANK OUTLET

FROM IA HEADER TO FLEXIBLE

25I 109 AIO INSTRUMENT AIR 0.25 6 CONNECTION FOR SUCTION AIR 5 8.8 60 5 1 1 NEW ADD
VESSEL

FRON IA HEADER TO CHARGING

25J 109 AIO INSTRUMENT AIR 0.25 6 OF ACCUMULATOR OF PROPLING 5 8.8 60 5 1 1 NEW ADD
LIQUID SYSTEM
TO PNEUMATIC OPTD. BALL
VALVES AT MAIN SILO 1
25K 103 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 NEW ADD
FLUIDISING LINE TO MAIN SILO
FLUIDISING PADS
TO PNEUMATIC OPTD. BALL
VALVES AT HCSD SILO 1
25L 109 AIO INSTRUMENT AIR 0.25 6 5 8.8 60 5 1 NEW ADD
FLUIDISING LINE TO HCSD SILO
FLUIDISING PADS

1033

INST. AIR INLET TO VENT VALVE

26 104 AIO INSTRUMENT AIR 0.25 8 5.00 8.80 60 144 1
AT NUVAFEEDERS.

144

M:\Barh\VALVES\Revised New Schedule Page 4 of 5

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-J
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
2 2 ( C) units (NO.)
PORT SIZE ORIFICE (kg/cm ) (kg/cm )
(INCH) SIZE (MM)
1

INST. AIR INLET TO DIFFUSER

27 103 AIO INSTRUMENT AIR 0.375 10 5.00 8.80 60 96 1
VALVE AT NUVAFEEDERS.

96

4 WAY SOLINOED VALVE (CENTER OFF TYPE)

BA HOPPER FEED GATE AIR
1 101 AIO INSTRUMENT AIR 1 25 5.00 8.80 60 12 2
RECEIVER OUTLET

12

M:\Barh\VALVES\Revised New Schedule Page 5 of 5

 . DC INDUSTRIAL
PLANT SERVICES

INDIRA GANDHI STPP, JHAJJAR

STAGE-I (3 x 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.28P01
ANNEXURE – K
KNIFE GATE VALVE SCHEDULE : SLURRY LINE, REV-02

Sl. Valve Type Type of Seat Qty. Size Location Mode of Maximum Valve
No. & Deflection (Nos.) (NB) (Relevant Single Line Diagram) Operation Working suitable for
Horizontal /
Cone Pressure Vertical
TAG NO.
[ Kg/cm2 (g) ]
Inclined
Installation
B.A.O’FLOW WATER PUMP
Knife Gate Pneumatic
Deflection 300 SUCTION
01. Valve 6 Cylinder 0.75 DPB
cone provided SLURRY TEMP MAX. =600C
(Unidirectional) Operated
(NTPC Drg No. : 0330-162-PVM-L-001
B.A.O’FLOW WATER PUMP
Knife Gate Pneumatic
Deflection DISCHARGE
02. Valve 6 250 Cylinder 1.8 DPB
cone provided SLURRY TEMP MAX. =600C
(Unidirectional) Operated
(NTPC Drg No.: 0330-162-PVM-L-001)
ASH SLURRY DISPOSAL PUMP
Knife Gate Pneumatic
Deflection SUCTION
03. Valve 4 350 0 Cylinder 0.75 SDO
cone provided SLURRY TEMP MAX. =60 C
(Unidirectional) Operated
(NTPC Drg No.: 0330-162-PVM-L-004)
ASH SLURRY DISPOSAL PUMP YES
Knife Gate Pneumatic
Deflection DISCHARGE
04. Valve 4 350 Cylinder 9.7 SDO
cone provided SLURRY TEMP MAX. =600C
(Unidirectional) Operated
(NTPC Drg No.: 0330-162-PVM-L-004)
Knife Gate OUTLET LINE OF SETTLING BIN Pneumatic
Deflection
05. Valve 2 100 SLURRY TEMP MAX. =600C Cylinder 1.0 DPB
cone provided
(Unidirectional) (NTPC Drg No.: 0330-162-PVM-L-004) Operated
Knife Gate SLUDGE PUMP SUCTION Pneumatic
Deflection
06. Valve 2 100 SLURRY TEMP MAX. =600C Cylinder 1.0 DPB
cone provided
(Unidirectional) (NTPC Drg No.: 0330-162-PVM-L-004) Operated
Knife Gate SLUDGE PUMP DISCHARGE Pneumatic
Deflection
07. Valve 2 100 SLURRY TEMP MAX. =600C Cylinder 1.8 DPB
cone provided
(Unidirectional) (NTPC Drg No.: 0330-162-PVM-L-004) Operated

\\Dbhattacharya\d\SISHIR DOCUMENTS\DATA SHEET\JHAJJAR\KNIFE GATE VALVE\Annex-II-K. G.Valve Schedule (purchase).doc

 INDIRA GANDHI STPP, JHAJJAR DC INDUSTRIAL
STAGE-I (3 x 500 MW) PLANT SERVICES
ASH HANDLING SYSTEM
DCIPS JOB NO.28P01

ANNEXURE – L
KNIFE GATE VALVE SCHEDULE: DRY ASH LINE, REV-02
Sl. Valve Type of Seat & Qty. Size Location Mode of Maximum Valve
No. Type Deflection Cone (Nos.) (Relevant Single Line Diagram) Operation Working suitable for
Pressure Horizontal /
TAG NO.
[ Kg/cm2 (g) ] Vertical
Inclined
Installation
SILO INLET VALVE / FLY ASH TRANSPORTATION PRESSURE CONVEYING LINE VALVE
Knife • Bidirectional
At Fly Ash Transport Pressure Line, Pneumatic
Gate • Resilient Rubber Seated 250
01. 12 Max. Ash temp. = 1500 C Cylinder 1.75 FPO
Valve NB
(NTPC Doc.# 0330-162-PVM-L-003) Operated
Knife • Bidirectional
At Fly Ash Transport Pressure Line, Pneumatic
01. Gate 300
• Resilient Rubber Seated 6 Max. Ash temp. = 1500 C Cylinder 1.75 FPO
A Valve NB
(NTPC Doc.# 0330-162-PVM-L-003) Operated
Knife • Bidirectional At Fly Ash Transport Pressure Line,
Pneumatic
02.
Gate • Resilient Rubber Seated 21
300 (Silo Inlet Valve)
Cylinder 1.75 FPO
Valve NB Max. Ash temp. = 1500 C
Operated
(NTPC Doc.# 0330-162-PVM-L-003)
FLY ASH STORAGE SILO OUTLET
• Unidirectional
Knife • Replaceable seat SS-
At Fly Ash Storage Silo Outlet, Pneumatic
Gate 304, hard facing, 300 YES
01. 10 Max. Ash temp. = 1500 C Cylinder 3 LUO
Valve hardness 250 BHN NB
(NTPC Doc.# 0330-162-PVM-L-003) Operated
• Deflection cone: To be
provided
FLY ASH STORAGE SILO (HCSD AREA)
• Biidirectional At Fly Ash Transport Pressure Line,
Knife Pneumatic
300 (HCSD Silo Inlet Valve)
01. Gate • Resilient Rubber Seated 21 Cylinder 1.75 FPO
NB Max. Ash temp. = 1500 C
Valve Operated
(NTPC Doc.# 0330-162-PVM-L-009)
• Unidirectional

Knife • Replaceable seat SS- At Fly Ash Storage HCSD Silo Outlet, Pneumatic
304, hard facing, 300
02. Gate 15 Max. Ash temp. = 1500 C Cylinder 3 LUO
hardness 250 BHN NB
Valve (NTPC Doc.# 0330-162-PVM-L-010) Operated
• Deflection cone: To be
provided

D:\SISHIR DOCUMENTS\DATA SHEET\JHAJJAR\KNIFE GATE VALVE\Annex-I-K. G.Valve Schedule2.doc

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-M
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
SEGREGATION VALVE / T.E.R.S.G.; REV-0

Type of Working Max. Working

Pressure Size Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Location Pressure Pressure REMARKS
Class / Rating (INCH) temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)

BS 1211, 254mmHg(g) 760mmHg(g)

1 102 FVO TERSG ESP FLY ASH PNEUMATIC 8" (C.I.) BELOW ESP 150 48
CLASS-D Vacuum Vacuum

IS 1536, AT STREAM LINE TO BAG 254mmHg(g) 760mmHg(g)

2 102 FVO TERSG ESP & APH FLY ASH PNEUMATIC 10" (C.I.) 150 30
CLASS-D FILTERS FROM ESP & APH LINE Vacuum Vacuum

254mmHg(g) 760mmHg(g)
3 102 FVO TERSG VACUUM AIR IS 3589 PNEUMATIC 10" (M.S.) AT VACUUM PUMP SUCTION 60 24
Vacuum Vacuum

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-N
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Type of Working Max. Working

Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size of valve Location Pressure Pressure REMARKS
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)
1

VERTICAL DISC GATE VALVE; REV-01

VERTICAL DISC AIR PREHEATER FLY REFER NTPC APPROVED DWG. BELOW PRIMARY & SECONDARY 254mmHg(g) 760mmHg(g)
1 102 FVO PNEUMATIC 150 24
GATE ASH NO. 0330-162-PVM-C-042 AIR-PREHEATER HOPPER Vacuum Vacuum

FLY ASH INTAKE VALVE; REV-01

ASH INTAKE REFER NTPC APPROVED DWG. AT 5TH TO 10TH FIELD OF ESP 254mmHg(g) 760mmHg(g)
1 102 FVO ESP FLY ASH PNEUMATIC 150 288
VALVE NO. 0330-162-PVM-C-012 HOPPERS Vacuum Vacuum

FLY ASH DIFFUSER INTAKE VALVE; REV-01

DIFFISER REFER NTPC APPROVED DWG. AT 1ST TO 4TH FIELD OF ESP 254mmHg(g) 760mmHg(g)
1 102 FVO ESP FLY ASH PNEUMATIC 150 192
INTAKE VALVE NO. 0330-162-PVM-C-013 HOPPERS Vacuum Vacuum

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-O
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
HOPPER ISOLATION VALVE; REV-0

Type of Working Max. Working

Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size (NB) Location Pressure Pressure REMARKS
temp (oC) units (NO.)
actuation (kg/cm2) (kg/cm2)

HOPPER
1 102 FVO ESP FLY ASH MANUAL 300 BELOW ESP 1.5 2 150 480
ISOLATION

HOPPER AIR PREHEATER FLY BELOW PRIMARY & SECONDARY

2 102 FVO MANUAL 300 1 2 150 24
ISOLATION ASH AIR-PREHEATER

HOPPER BELOW BUFFER HOPER &

3 103 FVO FLY ASH MANUAL 300 1 2 120 48
ISOLATION NUVAFEEDER INLET

HOPPER
4 103 SDH FLY ASH MANUAL 300 MAIN SILO OUTLET HOPPERS 1.5 2 120 20
ISOLATION

HOPPER
5 109 SDH FLY ASH MANUAL 300 HCSD SILO OUTLET HOPPERS 1.5 2 120 20
ISOLATION

HOPPER
6 101 CAO ECONOMISER ASH MANUAL 300 BELOW ECONOMISER HOPPER 1.5 2 450 12
ISOLATION

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-P
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
ISO GATEVALVE; REV-0

Type of Max. Working

Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size (NB) Location Pressure REMARKS
temp (oC) units (NO.)
actuation (kg/cm2)

1 109 SDO ISO GATE HCSD SLURRY MANUAL 200 HCSD MIXING TANK DRAIN LINE 6 50 5

2 109 SDO ISO GATE HCSD SLURRY MANUAL 200 HCSD MIXING TANK OUTLET 6 50 5

HSCD SUCTION DTRAINER

3 109 SDO ISO GATE HCSD SLURRY MANUAL 200 6 50 20
BYPASS LINE

30

4 109 SDO ISO GATE HCSD SLURRY PNEUMATIC 200 HCSD MIXING TANK OUTLET 6 50 5

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-Q
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01
PLATE VALVE AT DYKE AREA; REV-0

Type of Max. Working

Service Quantity for 3
Sl. No. Dwg. No. TAG. NO. Type of Valve Service Operation Size (NB) Location Pressure REMARKS
temp (oC) units (NO.)
actuation (kg/cm2)

BA SLURRY DISPOSAL PUMP

1 104 SDO PLATE VALVE BA SLURRY MANUAL 350 9.7 50 8
DISCHARGE LINE AT DYKE AREA

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 DC INDUSTRIAL PLANT SERVICES ANNEXURE-R
PVT. LTD. VALVE SCHEDULE
INDIRA GANDHI STPP - JHAJJAR
UNITS #1, #2 & #3 (3 X 500 MW)
ASH HANDLING SYSTEM
DCIPS JOB NO.: 28P01

Size (NB) Working Max. Working

Service temp Quantity for 3
Sl. No. Dwg. No. TAG. NO. Service Location Pressure Pressure o NO. OF COILS REMARKS
2 2 ( C) units (NO.)
VALVE SIZE ORIFICE (kg/cm ) (kg/cm )
(NB) SIZE (MM)

40 NB PULSE DIAPHRAGM VALVE

MAIN SILO VENT FILTER (TOP OF
1 103 AIO INSTRUMENT AIR 40 52 5.00 8.80 60 70 2
MAIN SILO)

HCSD SILO VENT FILTER (TOP OF

2 109 AIO INSTRUMENT AIR 40 52 5.00 8.80 60 70 2
HCSD SILO)

3 103 AIO INSTRUMENT AIR 40 52 FOR BAG FILTER 5.00 8.80 60 216 2

25 NB PULSE DIAPHRAGM VALVE

FOR MAIN SILO TELESCOPIC
1 103 / 109 AIO INSTRUMENT AIR 25 28 5.00 8.80 60 20 1
SPOUT

FOR HCSD SILO TELESCOPIC

2 109 AIO INSTRUMENT AIR 25 28 5.00 8.80 60 20 1
SPOUT

M:\Barh\VALVES\Revised New Schedule Page 1 of 1

 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, 2 & 3 ( 3X 500 MW )
ASH HANDLIN SYSTEM
SUB VENDOR LIST

SL. MODEL NO. / CODE

ITEM MAKE
NO. NO. ( IF ANY )
BOTTOM ASH HANDLIN SYSTEM :-
1. CLINKEK GRINDER M/S DCIPS
FLUID COUPLING (TRACTION TYPE)
2. M/S FLUIDOMAT LTD. TFV- 06
FOR BA CLINKER GRINDER
M/S NEW
3. GEAR BOX FOR CLINKER GRINDER ALLROYO
ALLENBERRY
VACUUM CONVEYING SYSTEM :-
4. VACUUM PUMP VACUNAIR 170
DRY MODE DISPOSAL :-
ESP & BUFFER HOPPER FLUIDISING KULKARNI POWER
5. SR 069
BLOWER TOOLS LTD.
6. AIR HEATER
PRESSURE CONVEYING SYSTEM :-
7. TRANSPORT AIR COMPRESSOR ATLAS COPCO ZA6F200
SILO ACCESSORIES AND UNLOADING :-
AIR CONDITIONING
8. SILO VENT FAN AW40
CORPORATION LTD.
9. ROTARY FEEDER M/S DCIPS
M/S NEW
10. GEARED MOTOR FOR ROTARY FEEDER
ALLENBERRY
11. ROTARY UNLOADER M/S DCIPS
GEARED MOTOR FOR ROTARY
12. M/S SANTHI GEARS F50Y – 1100/4
UNLOADER
13. TELESCOPIC SPOUT GEARED MOTOR M/S SANTHI GEARS.
AIR CONDITIONING
14. VENT FAN FOR TELESCOPIC SPOUT AW17
CORPORATION LTD.
M/S KAY
15. SILO FLUIDISING BLOWER 65 AC
INTERNATIONAL
16. AIR HEATER
WATER PUMPING SYSTEM :-
M/S FLOWMORE PVT.
17. ASH WATER PUMP
LTD.
M/S FLOWMORE PVT.
18. HP WATER PUMP F - 5826
LTD.
M/S FLOWMORE PVT.
19. LP WATER PUMP 5823
LTD.
 M/S FLOWMORE PVT.
20. ECO WATER PUMP S - 5922
LTD.
M/S FLOWMORE PVT.
21. SEAL WATER PUMP
LTD.
22. CLARIFIED WATER PUMP M/S SAM TURBO V0 – 80/360+TCH+N
GARDENRICH SHIP
23. RAW WATER PUMP BUILDERS AND 4116 X 2
ENGINEERING LTD.
24. FA AREA DRAIN PUMP M/S SAM TURBO V0 – 80/400+TCH+N
25. SILO AREA DRAIN PUMP M/S SAM TURBO V0 – 80/400+TCH+N
M/S FLOWMORE PVT.
26. DUST CONDITIONER PUMP S – 59922
LTD.
M/S FLOWMORE PVT.
27. RECOVERY WATER PUMP 5413 AWS
LTD.
M/S FLOWMORE PVT.
28. RECOVERY SEALWATER PUMP 5621
LTD.
29. BA OVERFLOW TRANSFER PUMP M/S SAM TURBO VO-150 / 400+TCH+N
ASH DISPOSAL SYSTEM :-
30. ASH SLURRY PUMP M/S SAM TURBO AR 150 / 510
M/S PREMIUM
31. FLUID COUPLING FOR ASH SLURRY PUMP ENERGY 20SCR 25B
TRANSMISSION LTD.
M/S PREMIUM
32. GEAR BOX FOR ASH SLURRY PUMP ENERGY H1 – 160 FC
TRANSMISSION LTD.
INSTRUMENT AIR COMPRESSOR :-
M/S KIRLOSKAR
33. INSTRUMENT AIR COMPRESSOR T – BTD - LM
PNEUMATICS
M/S DELAIR INDIA
34. AIR DRYING UNIT
( PVT) LTD.
CRANE :-
EOT CRANE FOR ASH WATER PUMP M/S REWA
35.
HOUSE INDUSTRIES
EOT CRANE FOR ASH SLURRY PUMP M/S REWA
36.
HOUSE INDUSTRIES
M/S REWA
37. EOT CRANE FOR VACUUM PUMP HOUSE
INDUSTRIES
38. MANUAL HOISTS
VALVES :-
39. KNIFE GATE VALVE CLY. OPERATED
M/S GALAXY
40. KNIFE GATE VALVE MANUAL OPTD.
CONTROL
M/S BDK PROCES
41. BUTTERFLY VALVE
CONTROLS PVT. LTD
M/S BDK PROCES
42. PLUG VALVE
CONTROLS PVT. LTD
M/S LEADER VALVES
43. GLOBE VALVE
LTD.
 M/S LEADER VALVES
44. CHECK VALVE
LTD.
M/S LEADER VALVES
45. GATE VALVE
LTD.
46. BALL VALVE M/S HABANIM – VASS
AUTOMATION
47. MANUAL PLUG GATE
INSTRUMENTS :-
M/S GE GAUGES PVT.
48. PRESSURE GAUGE
LTD.
M/S SWITZER
49. VACUUM SWITCH
INSTRUMENT LTD.
M/S GE GAUGES PVT.
50. VACUUM GAUGE
LTD.
M/S SWITZER
51. PRESSURE SWITCH
INSTRUMENT LTD.
M/S SWITZER
52 TEMPARATURE SWITCH
INSTRUMENT LTD.
53. PRESSURE TRANSMITTER
54. VACUUM TRANSMITTER
M/S ROTEX
55. SOLENOID VALVE
AUTOMATION
56. LEVEL SWITCH
57. LEVEL SWITCH, FLOATT TYPE
58. SIGHT FLOW INDICATOR
59. ELECTRONIC SPEED SWITCH
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

FIRST FILLING AFTER 500

AMOCAN-460 OF BHARAT
OPERATING HRS. &
ESP & BUFFER HOPPER KULKARNI POWER SERVO MESH SP-460 PETROLEUM /
1 SR 069 06 Nos. GEARED UNIT 2 LTRS 12 LTRS SUBSEQUENT FILLING
FLUIDIZING BLOWER TOOLS LTD. (IOCL) PARTHAN EP 460 OF
EVERY 4000 RUNNING
HINDUSTAN PETROLEUM
HRS.]
FIRST FILLING AFTER 500
AMOCAN-460 OF BHARAT
OPERATING HRS. &
SILO FLUIDISING KULKARNI POWER SERVO MESH SP-460 PETROLEUM /
2 SR 113 06 Nos. GEARED UNIT 5 LTRS 30 LTRS SUBSEQUENT FILLING
BLOWER TOOLS LTD. (IOCL) PARTHAN EP 460 OF
EVERY 4000 RUNNING
HINDUSTAN PETROLEUM
HRS.]
FIRST FILLING AFTER 500
AMOCAN-460 OF BHARAT
OPERATING HRS. &
HCSD SILO KULKARNI POWER SERVO MESH SP-460 PETROLEUM /
3 SR 052 04 Nos. GEARED UNIT 2 LTRS 8 LTRS SUBSEQUENT FILLING
FLUIDISING BLOWER TOOLS LTD. (IOCL) PARTHAN EP 460 OF
EVERY 4000 RUNNING
HINDUSTAN PETROLEUM
HRS.]

TOTAL REQUIREMENT OF SERVO

110 LTRS.
MESH SP-460 (IOCL)

GRADE ISOVG460
GEAR BOX FOR BA GEAR BOX AFTER 3000 RUNNING
4 NEW ALLENBERY SUMC 8" 12 Nos. (SERVOCYL C-460 OF 7.5 LTRS 15 LTRS Vitrea - 320 (shell)
CLINKER CRUSHER CASING HRS.
IOC MAKE)

TOTAL REQUIREMENT OF GRADE

ISOVG460 (SERVOCYL C-460 OF IOC 33 LTRS.
MAKE)
A. BEARING
HOUSING 2 NOS.
SZIE GREASE SERVOGEM- EVERY 2000 RUNNING
5 CLINKER CRUSHER DCIPS 12 No. GREASE NIPPLES 500 GMS 6000 gms (Approx) _
1050 X 1790 3 IOCL HRS. OF OPERATION
B. CHAIN
SPROCKET
BEARING (DE & GREASE SERVOGEM-
6 BA LP PUMP SAM TURBO TPS 300/320 05 Nos. 20 GMS 100 gms 2 MONTHS. _
NDE) 3 IOCL

STARFAK 3
2 MD 125 / BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
7 FA HP PUMP SAM TURBO 05 Nos. 50 GMS 250 gms NATRA 3
305V NDE) 3 IOCL HRS.
LITHON 2
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

STARFAK 3
BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
8 HP SEAL WATER PUMP SAM TURBO 8MD 80 / 205 02 Nos. 20 GMS 40 gms NATRA 3
NDE) 3 IOCL HRS.
LITHON 3

STARFAK 3
BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
9 LP SEAL WATER PUMP SAM TURBO 5MD 80 / 205 02 Nos. 20 GMS 40 gms NATRA 3
NDE) 3 IOCL HRS.
LITHON 3

BEARING (DE & GREASE SERVOGEM- STARFAK 3

10 BA SEAL WATER PUMP SAM TURBO 4 AD 14 02 Nos. 200 GMS 400 gms ONE MONTH.
NDE) 3 IOCL NATRA 3

BEARING (DRIVE
FLUSHING WATER GREASE SERVOGEM- AFTER 1500 RUNNING STARFAK 3
11 SAM TURBO MF 300 / 320 01 No. & NON-DRIVE 20 GMS 20 gms
PUMP 3 IOCL HRS. NATRA 3
END)
BEARING (DRIVE STARFAK 3
ECONOMISER WATER GREASE SERVOGEM- AFTER 1500 RUNNING
12 SAM TURBO 3MD 125 / 305V 02 Nos. & NON-DRIVE 50 GMS 100 gms NATRA 3
PUMP 3 IOCL HRS.
END) LITHON 3
BEARING (DRIVE STARFAK 3
CONDITIONING GREASE SERVOGEM- AFTER 1500 RUNNING
13 SAM TURBO 4 MD 80 / 205 06 Nos. & NON-DRIVE 20 GMS 120 gms NATRA 3
WATER PUMP 3 IOCL HRS.
END) LITHON 3
STARFAK 3
MAIN SILO AREA VG 100/500 + BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
14 SAM TURBO 02 Nos. 50 GMS 100 GMS NATRA 3
DRAIN PUMP TPS (5VO) NDE) 3 IOCL HRS.
LITHON 3
STARFAK 3
BA SLURRY P/H VG 80/300 + BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
15 SAM TURBO 02 Nos. 50 GMS 100 GMS NATRA 3
DRAIN PUMP TCH + N NDE) 3 IOCL HRS.
LITHON 3
STARFAK 3
HCSD SILO AREA VG 100/400 + BEARING (DE & GREASE SERVOGEM- AFTER 1500 RUNNING
16 SAM TURBO 02 No. 50 GMS 100 GMS NATRA 3
DRAIN PUMP TCH + N NDE) 3 IOCL HRS.
LITHON 3
BEARING (DE & GREASE SERVOGEM- AFTER 4000 RUNNING
17 MAIN SILO VENT FAN C. DOCTORS _ 05 Nos. 200 GMS 1000 GMS CASTROL AP-3
NDE) 3 IOCL HRS.
VENT FAN FOR MAIN
BEARING (DE & GREASE SERVOGEM- AFTER 4000 RUNNING
18 SILO TELESCOPIC C. DOCTORS _ 05 Nos. 200 GMS 1000 GMS CASTROL AP-3
NDE) 3 IOCL HRS.
SPOUT
BEARING (DE & GREASE SERVOGEM- AFTER 4000 RUNNING
19 HCSD SILO VENT FAN C. DOCTORS _ 05 Nos. 200 GMS 1000 GMS CASTROL AP-3
NDE) 3 IOCL HRS.
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

VENT FAN FOR HCSD

BEARING (DE & GREASE SERVOGEM- AFTER 4000 RUNNING
20 SILO TELESCOPIC C. DOCTORS _ 05 Nos. 200 GMS 1000 GMS CASTROL AP-3
NDE) 3 IOCL HRS.
SPOUT
WEIR MINERALS GREASE SERVOGEM- AS PER VENDOR'S
21 HCSD BOOSTER PUMP 8 / 6 EAH 05 Nos. LABYRINTH 600 GMS / PUMP 3000 GMS. CASTROL EPL2
(INDIA) 3 IOCL MANUAL
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

FIRST FILLING AFTER 500

OPERATING HRS. & GREASE HP TISONA-2 OF
ESP & BUFFER HOPPER KULKARNI POWER BEARING (DE & GREASE SERVOGEM-
1A SR 069 06 Nos. 200 gms 1200 gms SUBSEQUENT FILLING HPCL/SERVOGEM-HTXX OF
FLUIDIZING BLOWER TOOLS LTD. NDE) 3 IOCL
EVERY 4000 RUNNING BPCL
HRS.]
FIRST FILLING AFTER 500
OPERATING HRS. & GREASE HP TISONA-2 OF
SILO FLUIDISING KULKARNI POWER BEARING (DE & GREASE SERVOGEM-
2A SR 113 06 Nos. 200 gms 1200 gms SUBSEQUENT FILLING HPCL/SERVOGEM-HTXX OF
BLOWER TOOLS LTD. NDE) 3 IOCL
EVERY 4000 RUNNING BPCL
HRS.]
FIRST FILLING AFTER 500
OPERATING HRS. & GREASE HP TISONA-2 OF
HCSD SILO KULKARNI POWER BEARING (DE & GREASE SERVOGEM-
3A SR 052 04 Nos. 200 gms 800 gms SUBSEQUENT FILLING HPCL/SERVOGEM-HTXX OF
FLUIDISING BLOWER TOOLS LTD. NDE) 3 IOCL
EVERY 4000 RUNNING BPCL
HRS.]
TOTAL REQUIREMENT OF GREASE
38654 GRAMS.
SERVOGEM-3 IOCL
VACUUM PUMP BEARING (DRIVE EP-2 OF BPCL
LUBRAX CUP AFTER 6 MONTH / (4500
22 ( MECHANICAL VACUNAIR 170 24 Nos. & NON-DRIVE 500 GMS / PUMP 12000 gms (Approx) OR
GREASE-2 OF IOCL RUNNING HRS)
EXHASTER) END) LIPTHOL-2 OF HPCL
TOTAL REQUIREMENT OF LUBRAX
26400 GRAMS.
CUP GREASE-2 OF IOCL

BA OVERFLOW BEARING SERVO SYSTEM-46 TELLUS 29

23 SAM TURBO AR 150/500A 06 Nos. SAE 30 8 LTRS. 48 LTRS 4000 RUNNING HRS.
WATER PUMP HOUSING NVTO 48

BEARING SERVO SYSTEM-46 TELLUS 29

24 ASH SLURRY PUMP SAM TURBO AR 200 / 500 08 Nos. SAE 30 9 LTRS. 72 LTRS 4000 RUNNING HRS.
HOUSING NVTO 48

TOTAL REQUIREMENT OF SAE 30 264 LTRS.

MAIN SILO
BEARING (DE & SERVO GEAR HP140 AS PER VENDOR'S
25 TELESCOPIC SPOUT NEW ALLENBERY _ 05 Nos. 4 LTRS. 20 LTRS _
NDE) OF IOC MANUAL
GEARED MOTOR
MAIN SILO ROTARY
BEARING (DE & SERVO GEAR HP140 AS PER VENDOR'S
26 UNLOADER GEAR NEW ALLENBERY _ 05 Nos. 9 LTRS 45 LTRS _
NDE) OF IOC MANUAL
MOTOR
HCSD SILO
BEARING (DE & SERVO GEAR HP140 AS PER VENDOR'S
27 TELESCOPIC SPOUT NEW ALLENBERY _ 05 Nos. 4 LTRS. 20 LTRS _
NDE) OF IOC MANUAL
GEARED MOTOR
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

HCSD SILO ROTARY

BEARING (DE & SERVO GEAR HP140 AS PER VENDOR'S
28 UNLOADER GEAR NEW ALLENBERY _ 10 Nos. 9 LTRS 90 LTRS _
NDE) OF IOC MANUAL
MOTOR
MAIN SILO ROTARY SERVO GEAR HP140
29 NEW ALLENBERY _ 10 GEARED UNIT 5 LTRS. 50 LTRS _ _
FEEDER OF IOC

HSCD SILO ROTARY SERVO GEAR HP140

30 NEW ALLENBERY _ 15 GEARED UNIT 5 LTRS. 75 LTRS _ _
UNLOADER OF IOC

TOTAL REQUIREMENT OF SERVO

660 LTRS.
GEAR HP140 OF IOC
GEAR BOX FOR BA AS PER VENDOR'S
H1-140 FC GEAR BOX SERVO MESH SP-320
31 OVERFLOW WATER PREMIUM ENERGY 06 Nos. 6 LTRS 36 LTRS MANUAL / EVERY 6 VITREA - 320 (SHELL)
( HELICAL) CASING OF IOCL
PUMP CALENDER MONTHS.
AS PER VENDOR'S
GEAR BOX FOR ASH H1-200 FC GEAR BOX SERVO MESH SP-320
32 PREMIUM ENERGY 04 Nos. 18 LTRS 72 LTRS MANUAL / EVERY 6 VITREA - 320 (SHELL)
SLURRY PUMP ( HELICAL) CASING OF IOCL
CALENDER MONTHS.
TOTAL REQUIREMENT OF SERVO
237.6 LTRS.
MESH SP-320 OF IOCL

BEARING (DE & SERVO SYSTEM - 150 AFTER 3000 RUNNING ESSTIC - 55
33 BA HP PUMP SAM TURBO ZM II 530 / 02 03 Nos. 500 MLS 1500 mls.
NDE) [IOCL] HRS. TERESSO - 56

BEARING (DE & SERVO SYSTEM - 150

34 WASH WATER PUMP SAM TURBO TCH+N 50 / 300 02 Nos. 0.6 LTRS 1.2 ltrs 6 MONTHS. _
NDE) [IOCL]

BEARING SERVO SYSTEM - 150 AFTER 4000 RUNNING

35 SLUDGE PUMP SAM TURBO ARS 80 / 340 02 Nos. 2.5 LTRS 5 LTRS _
HOUSING [IOCL] HRS.

TOTAL REQUIREMENT OF SERVO

16.94 LTRS.
SYSTEM - 150 [IOCL]
 ARAVALI POWER COMPANY PVT. LTD.
INDIRA GANDHI SUPER THERMAL POWER PROJECT
UNIT # 1, #2 & #3 ( 3 X 500 MW ) Stage - 1
ASH HANDLING SYSTEM

LUBRICANT SCHEDULE

INITIAL FILL TOTAL QUANTITY

OTHER
SL. MODEL NO./ POINT OF RECOMMENDED PER FOR INITIAL FILL FREQUENCY OF
EQUIPMENT MANUFACTURER QTY. EQUIVALENT
NO. FRAME SIZE APPLICATION LUBRICANT EQUIPMENT (APPROX) TOP UP / CHANGE
LUBRICANT
(APPROX) LTRS / GMS

FLUID COUPLING FOR

FLUID SERVO SYSTEM-32 3.5 LTRS 42 LTRS AFTER 4000 RUNNING H.P.-ENKLO-46
36 BA CLINKER FLUIDOMAT LTD. TFV - 06 12 Nos.
COUPLING IOCL (approx) (approx) HRS. BHARAT-TELLUS-46
CRUSHER
TOTAL REQUIREMENT OF SERVO
92.4 LTRS.
SYSTEM-32 IOCL
Bharat Cobol 100 OR Bharat
INSTRUMENT AIR KIRLOSKAR BEARING (DE & SERVO PRESS - 100 AS PER VENDOR'S Turgona 30 of Bharat Petroleum.
37 2HA2TERT 06 Nos. 22 LTRS. 132 LTRS
COMMPRESSOR PNEUMATICS NDE) OF IOCL MANUAL ENKLO - 150 of Hindustan
Petroleum.
TOTAL REQUIREMENT OF
435.6 LTRS.
SERVOPRESS - 100 OF IOCL
FLUID COUPLING
AS PER VENDOR'S ENKLO-46 OF HPCL /
WITH OIL COOLER FLUID SERVOSYSTEM-46 OF 33.5 LTRS 201 LTRS
38 PREMIUM ENERGY 18SCR25B 06 Nos. MANUAL / AFTER 4000 TELLUS-46 OF BHARAT
FOR BA OVERFLOW COUPLING IOCL (approx) (approx)
RUNNING HRS. PETROLEUM
WATER PUMP
FLUID COUPLING AS PER VENDOR'S ENKLO-46 OF HPCL /
FLUID SERVOSYSTEM-46 OF 56.8 LTRS
39 WITH OIL COOLER FOR PREMIUM ENERGY 23SCR25B 04 Nos. 227.2 LTRS MANUAL / AFTER 4000 TELLUS-46 OF BHARAT
COUPLING IOCL (approx)
ASH SLURRY PUMP RUNNING HRS. PETROLEUM

TOTAL REQUIREMENT OF
942.04 LTRS.
SERVOSYSTEM-46 OF IOCL

SHELL MORLINA 10
AIR OIL CONVERTER OIL CONVERTER
40 _ _ 12 Nos. (BHARATSHELL 100 LTRS. 1200 LTRS _ _
TANK TANK
LIMITED)
TOTAL REQUIREMENT OF SHELL
MORLINA 10 (BHARATSHELL 2640 LTRS.
LIMITED)

NOTE: THIS SCHEDULE DOES NOT INCLUDE REQUIREMENT OF LUBRICANTS FOR TRANSPORT AIR COMPRESSOR, GEHO PUMP, HOSE PUMP AND VERTICAL MIXER.