Control Write Up R1 - Khaperkheda PDF

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1 Approval Documents DCPL Comments PG SM SM 2.11.09
0 Approval Documents Initial Submission PG SM SM 26.10.09
PREPARED CHECKED APPROVED

REV. STATUS TYPE REASONS FOR REVISION DATE
BY BY BY
KHAPERKHEDA THERMAL POWER STATION (1 X 500 MW)

PROJECT :
MAHARASTRA, INDIA
MAHARASTRA STATE POWER GENERATION CO. LTD.

MUMBAI
DEVELOPMENT CONSULTANT PVT. LTD.,

MUMBAI
BGR ENERGY SYSTEMS LIMITED,

POWER PROJECTS DIVISION
CHENNAI, INDIA
TECPRO ASHTECH LTD.

(FORMERLY KNOWN AS MAHINDRA ASHTECH LTD.)
KOLKATA - PUNE
DOC. NO : 543-E-02
TITLE :
CONTROL WRITEUP REV.NO.:R 1
COMP FILE : COVER SHEET

TECPRO ASHTECH LTD. KHAPERKHEDA T.P.S
EXPANSION PROJECT
(1 X 500 MW)
CONTROL WRITE UP
TATL DOC. No. 543-E-02
REFERENCE DRAWINGS
1. Bottom Ash & Coarse Ash P&ID 543-01-01, R-06
2. Fly Ash Evacuation System P&ID 543-01-02, R-05
3. Fly Ash Conveying System P&ID 543-01-03, R-05
4. Fly Ash Silo P&ID 543-01-04, R-05
5. Ash water and Ash Slurry Disposal System P&ID 543-01-05, R-05
6. PLC Configuration Drawing 543-C&I-04,R-03
7. HCSD System P%ID 543-01-01 R-04
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CHAPTER I
1.0 INTRODUCTION
The Ash Handling Plant consists of the following primary

services/sub system :
Bottom Ash System and Bottom Ash Overflow System.

Coarse Ash System consisting of Economiser Hopper, Duct
Hopper and APH Hopper.
Stack Hopper Evacuation system.
Fly ash vacuum extraction system.
Fly ash vacuum extraction and Pressure conveying system.
Ash slurry disposal pumping system.
Vacuum Pump, Instrument air compressors and Transport air
compressor system.
Ash water Pumping system.
Seal water pumping system.
Silo unloading system.
Buffer Hopper and Silo Fluidizing Air system.
Misc. Drainage System.
HCSD System.
1.1 The control facility of the entire system is a PLC based

arrangement. The operation/ complete control of Ash handling
system is possible from HMI located in Compressor house.
Status of all equipment shall be available in main control
desk/MMI. Some of the systems / equipment have local control
arrangements. The details of such facilities are described in
chapter III hereinafter.
2.0 The normal ash removal requirement is as below.
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Bottom ash generated in eight (08) hours will be cleared in

about 2 hour 10 minute including line flushing and other down
time for feed gate operation etc
Under each V-Section of B.A. Hopper, there shall be two (2)

outlets. Each outlet shall be fitted with a feed gate, clinker
grinder, feed sump, jet pump and a set of piping and valves
designed for minimum 75 TPH capacity
Capacity of Coarse ash tank will be adequate enough to store

coarse ash from Economiser, Duct and Air Pre Heater Hopper
ash generated for eight (08) hours or more.
Coarse ash tank will be provided with three (03) number jet
pump, each having conveying capacity minimum 75 TPH
capacity.
Coarse ash generated in eight (08) hours will be cleared in

about 1 hour 10 minute including line flushing and other down
time for valve opening/ closing operation etc.
The total fly ash generated will be conveyed in four (4) streams
operating simultaneously and in parallel.
Each stream shall have a capacity of minimum 60 TPH.
Each Buffer Hopper will have a capacity of 20 MT for storage

of fly ash which can be removed by each vacuum conveying
stream over a minimum period of twenty (20) minutes.
Ash in pressure conveying will be conveyed through four (4)

Pressure conveying streams (Four working simultaneously)
each having a capacity of minimum 60 TPH with the aid of
Five(6) screw type conveying compressors (Four working and
two standby).
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Two (2) nos of fluidizing blowers (1W+1S) each of 100%
capacity will be provided for easy dislodging of ash from all the
ESP and Buffer hoppers.
There are total 3 nos. fly ash silos each having storage
capacity of 1125 MT each. Out of total 3 nos. Silo, 2 nos. are
for direct ash disposal in dry form and other one for HCSS.
Fly ash generated in eight (08) hours will be cleared in about 5

hour 30 minute including line purging.
2.1 The sequence of operation to be followed under normal ash

removal is as below :
Ash water pumps are to be operated ensuring that at least one

discharge valve in the parallel heads connection of the
respective designated pump is open.
The slurry pumps are operated after the input to slurry sump is
activated. In case of Bottom ash removal, the operation of two
Jet pumps is activated from two different section.
Stack Hopper ash slurry is also disposed to the ash slurry
disposal sump through the jet pump.
The seal water pumps are operated before starting of slurry
pumps.
The cooling water supply is ensured before starting of Vacuum
Pump, Instrument air compressors, Transport air compressors,
Clinker Grinders, Sludge pump and various Drain Sump
pumps.
The operation of Bottom ash or Fly ash is activated as per
control system write up for their respective sub systems.
The Silo unloading arrangement is activated as per the ash
discharge/transportation arrangement required from the silos.
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3.0 CONTROL FACILITIES
The Control System is described in the following Chapters

enclosed herewith.
CHAPTER II
The detail Write up and Control Philosophy of individual

subsystems is furnished under this chapter.
CHAPTER III
The details of PLC System, Various panels and Remote I/O

Cabinets have been furnished under this Chapter.
CHAPTER - IV
The Protection, Interlocks, Annunciation and Indication of the

total system have been described in this chapter.
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CHAPTER II
CONTROL PHILOSOPHY AND SEQUENCE OF OPERATION
1.0 The respective sequence of operation , control philosophy and

different interlocks for various system / sub system and major
equipments have been detailed in this part of the control write
up.
2.0 BOTTOM ASH AND COARSE ASH CLEANING SYSTEM :
2.1 The Bottom ash is stored in water impounded B.A. hoppers.

The coarse ash from Economiser hopper, Duct hopper and
APH hopper is first conveyed to the coarse ash tank and then
transported to the ash slurry disposal sump.
2.2 The Bottom ash and Coarse ash cleaning system are mainly
carried out from Bottom Ash Local Control Panel (BALP) and
Coarse ash local control panel located in the boiler area. The
main equipments covered under this system relate to Clinker
Grinder, Bottom Ash Jet pumps, B.A Overflow transfer pump,
B.A Sump Jet pumps, Coarse ash Feeder Ejectors, Coarse
ash disposal jet pumps, various water line valves (Pneumatic
operated), Bottom ash Feed Gates etc.
The evacuation of Bottom ash is carried out in sequential

manner. The Bottom ash hopper has two sections and each
section is provided with two (2) nos. Clinker Grinder, two (2)
nos. Jet Pumps, two (2) nos. Feed Gate housing. Discharge of
each Jet Pump transport slurry from Bottom ash hopper to
common ash slurry disposal sump.
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Any one Feed Gate/Jet Pump from each section of B.A Hopper
can be operated at a time. Only the feed gate whose clinker
grinder is ON can be opened.
2.3 For initiating the bottom ash evacuation operation the operator
will ensure that at least one BAHP water pump is running.
2.4 There are four individual ash disposal lines corresponding to

the discharge of each jet pump. Only one jet pump from each
section is operated depending upon the selected Clinker
Grinder. Interlock is provided to ensure that only one Clinker
Grinder of each section of B.A. hopper is operating at a time.
2.5 It is to be noted that for each section of hopper, there is one

Cyl. operated water line valve for both the Jet pump of same
section are connected. Jet pump is to be selected manually.
Once the water flow to Jet pump of B.A Hopper is established,
the seal water line valve to the Clinker Grinders will be open.
2.5 After all the above mentioned valves are opened and
respective water line pressure (BAHP water pressure and seal
water line pressure to Clinker Grinder) are above pre set value,
the Clinker Grinder can be started in forward direction. Once
the Clinker Grinder operation is ensured, the Feed Gate can be
opened from the panel for effecting ash removal operation. In
case water pressure falls below the required value either for
Jet pump or for Clinker Grinder seal water, the entire system
will stop in the following sequence.
Close Feed Gate

Stop Clinker Grinder.
Under the normal mode of operation the closing sequence is

same as above.
2.6 There can be a jamming in the Grinder due to excess clinker or
large size of clinker or material other than bottom ash clinker. In
such events if the Clinker Grinder is in auto mode, the Clinker
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Grinder will automatically run in reverse direction. This reverse

direction operation can take place only if the pressure of seal
water line is above the desired level. The reverse rotation of the
Clinker Grinder will be of Inching Nature for about 20 sec and
immediately thereafter the grinder will stop and automatically
start in forward direction if the entire perquisites permissive are
available for forward running. In case the grinder jamming is not
cleared even after three times of such Forward/Reverse
operation, the grinder will stop and Clinker Grinder Jammed
annunciation will be sounded in BALP as well as in
compressor house HMI.
3.0 BOTTOM ASH MAKE-UP, COOLING WATER AND B.A

OVERFLOW SYSTEM.
3.1 The operation of bottom ash system have continuous

requirement of make up/ cooling water system and intermittent
requirement of ash removal system, for Bottom ash hopper
overflow, Bottom ash overflow Transfer pump to be operated.
3.2 The B.A make up / Refractory cooling water system and

bottom ash overflow pump can be operated in the following
manner:
The make up valve in the bottom ash L.P. water line and
Refractory cooling water line to bottom ash hopper is generally
kept open when the boiler is in operation. The cooling water
flows to bottom ash hopper to keep the wall of refractory cool.
Overflow from the bottom ash hopper carrying the heat is
discharged into the B.A Overflow Sump. B.A Overflow pump
discharges water to Tube Settler and Ash Disposal sump.
Overflow from tube settler is taken into Ash water disposal
sump as make up. The settled solid sludge from the tube
settler is drained into sludge sump, here it is mixed with water
from the HP water pump and the tube settler sludge pump then
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conveys this slurry to the ash slurry disposal sump. However,
the B.A Overflow transfer pump will be stopped during bottom
ash removal operation.
After the bottom ash hopper is emptied the bottom ash hopper
make up valve is immediately opened to allow the water inside
the hopper. Additionally, 2 to 3 nos. B.A Hopper jetting nozzle
are also kept opened for about 10 minutes to provide additional
filling make up from BAHP water line to reduce the bottom ash
filling time.
3.3 The bottom ash overflow water along with seal trough make up
water is taken upto overflow tank. Two (2) nos. overflow pumps
(1 W+1S) are provided. The sequence of operation is as
below.
4.0 BOTTOM ASH OVERFLOW TRANSFER PUMP
4.1 There are two (2) nos. (1W+1S) Bottom Ash Overflow Transfer
Pump provided per unit to cater transferring of bottom ash
overflow water to tube settler tank.
4.2 To start Bottom Ash Overflow Transfer Pump the seal water
line valve to that particular B.A Overflow Transfer pump to be
opened first.
4.3 The selected Bottom Ash Overflow Transfer Pump is now

started if the water level inside the overflow water tank is above
preset level.
4.4 In the event of seal water available pressure is less than the
preset value after laps of initial time 30 sec the operating pump
will trip.
4.5 There is a make up line with remote operated valve from

bottom ash refractory cooling water line to the B.A Overflow
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tank, which can be operated through an auto/ manual selector

switch. For this purpose an auto/manual selection switch is
provided in Bottom ash local control panel.
5.0 TUBE SETTLER AND SLUDGE PUMPING SYSTEM
5.1 The tube settler and Sludge pumps are located near Ash water
pump house. The B.A. overflow water from B.A Overflow sump
is transferred to the tube settler, the sludge deposited in tube
settler is drained into the sludge sump which is continuously
removed by sludge pump and transported to ash slurry
disposal sump. Only one sludge pump is to operate at a time.
5.2 At a time only one B.A Overflow Transfer Pump has to run.
Sludge pumps are provided with seal water. If seal water
available pressure is less than the preset value after laps of
initial time 30 sec the operating pump will trip. There are two
(2) nos. sludge pump (1W+1S) provided for cleaning of settled
ash of tube settler. Normally one Sludge pump will operate.
The sludge pump will take start when the respective seal water
pressure is normal and the Sludge tank water level is above
preset level.
6.0 COARSE ASH DISPOSAL TO COARSE ASH TANK
6.1 Coarse ash are collected from Duct Hopper, Economiser

Hopper and APH Hopper. There are four (4) nos. Duct
Hoppers, four (4) nos. economizer hoppers and four (4) nos.
APH hoppers.
6.2 Each coarse ash hopper has an ash discharge pneumatic

valve. There is a water line valve common for two nos.
Hopper/Feeder Ejector.
The operator first ensures that the H.P. water supply to the
feeder ejectors from the B.A.H.P. pump is available, once this
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is established the ash discharge valve of the hoppers are

opened. All the discharge lines of the duct hopper feeder
ejectors are connected to a common disposal line, through
which the coarse ash slurry of these hoppers is transported to
coarse ash tank. Similar arrangement is available for the
disposal of Economiser Hopper ash, and APH Hopper ash. The
Coarse ash from any four hoppers is collected into coarse ash
tank through four Feeder Ejector at a time.
7.0 COARSE ASH JET PUMP SYSTEM
7.1 There are three 3 nos. (2W+1S) coarse ash disposal jet pumps
for disposal of ash slurry from coarse ash tank to ash slurry
disposal sump. Water requirement of these jet pumps is
fulfilled by the B.A.H.P. water pump. Once the water pressure
to these pumps is adequate, the Jet pump inlet valve is
opened. There are three individual pneumatically operated
water line valve for each jet pumps. The discharge line of each
jet pump is independent of each other. The ash slurry is
conveyed to the ash slurry disposal sump through these jet
pumps.
8.0 ASH SLURRY DISPOSAL TO DISPOSAL AREA
8.1 There are two (2) series (1W + 1S) of Ash Slurry Pumps. Each
series in turn consists of five stages of pump. The first stage
pump driven with fluid coupling. The subsequent stages are
belt driven.
8.2 The ash slurry in the common ash slurry disposal sump
collected from the bottom ash, coarse ash and stack hopper.
Ash is conveyed to the ash disposal area by the two series of
ash slurry pumps. Each series has a pneumatic suction and
discharge valve. Out of the two series one is working and one
is standby. Each stage pump is provided with seal water valve
and pressure switch. For initiating the ash slurry disposal pump
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series, the suction valve, fluid coupling cooling water valve

and seal water valve of the series to be opened. Once the fluid
coupling oil temperature is below set level and suction valve is
open, the pump series is operated provided the ash slurry
disposal sump level is above low level and the discharge valve
of the series is closed. The subsequent stage pump starts after
getting the running feed back from the first stage pump. All the
individual pump series starts operating within preset time
delay. The second stage pump running feedback also opens
the series discharge valve. If at any point the seal water
pressure of any one pump in the series falls below the
adequate level, the complete series will trip .The discharge of
each series is connected to a pressure transmitter.
9.0 STACK HOPPER ASH DISPOSAL
9.1 There is one (1) no. stack hopper. The ash from this hopper is
transported to a collecting tank through feeder ejector system.
From this tank the ash is conveyed to ash slurry disposal sump
through one (1) no. jet pump. The ash inlet valve of Feeder
Ejector will open only when the water line pressure to Jet pump
is adequate. There is a common header water line valve for
both the stack hopper feeder ejector and jet pump.
10.0 FLY ASH SYSTEM
10.1 Basic Facility
a. Fly ash removal system comprises of dry Ash collection,

transportation and storage facility.
The fly ash system is operated once in a shift to evacuate eight

(8) hours collection of fly ash with in 5 hours 30 minutes with
line flushing. The ash removal from various hoppers is carried
out sequentially. Normally only one hopper is evacuated from
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each stream of vacuum conveying. The fly ash can be

evacuated simultaneously from all streams of vacuum
conveying. The fly ash is collected in complete dry form in silo.
b. In providing the above fly ash removal facility from all the fly
ash hoppers four (4) nos. independent vacuum conveying
streams have been envisaged. Each vacuum conveying
stream is ultimately provided with one (1) no. Mechanical
Exhauster, two (2) nos. mechanical exhausters are common
standby for the four vacuum conveying streams.
Each ash evacuation stream is connected to Buffer Hopper.
Ash collection system consists of buffer hopper/dust collector

collect the ash from vacuum system. The fly ash from buffer
hoppers is discharged into air lock vessels. A compressed air
system is provided to convey this ash from air lock vessel to
silo. Compressors are the major equipments which are to run
simultaneously with the vacuum conveying system for dry ash
collection.
Four (4) nos. pressure conveying streams have been provided.

The four independent streams convey ash simultaneously. The
total capacity of the four streams of pressure conveying system
is equivalent to the total fly ash removal capacity of all four
streams of vacuum conveying system. Each buffer hopper is
connected to two (2) nos. air lock vessels. Both the ALV of a
particular stream will be operating sequentially as per control
logic provided in PLC System.
All the four pressure conveying lines of each unit are

connected to both the remote silos and HCSD Silo by providing
suitable valve arrangement. Flexibility of operation will be in
built in PLC based control system. At any instant of operation,
each conveying line will feed ash to only one silo.
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10.2 Sequence of operation :
The operation of fly ash is initiated from HMI in the following

sequence.
The vacuum pump (working and stand by) is selected from

HMI.
There is one number buffer hopper provided for each stream.
Moreover pressure conveying stream is to be established by
operating transport air compressor, buffer hopper and air lock
vessel for ensuring steady conveying of fly ash to silos.
Silo vent filter purging system should be switched on.
Buffer Hopper bag filter purging system should be started.
The sequence of pressure conveying system by operating the
air lock vessel is to be started. It is to be noted that for each
beginning of pressure conveying system of one stream the
total pressure conveying line and the vessels are initially
purged for some pre determined duration before fresh fly ash
can be loaded into pressure conveying system.
Once the vacuum conveying stream and the pressure

conveying stream is established, de-ashing is taken up from
different hoppers in predetermined sequence. There are four
nos. pressure conveying stream provided for total ash removal
from four nos. vacuum conveying stream. However, four (4)
nos. pressure conveying stream can be operated
simultaneously. Each pressure conveying stream has
independent control scheme. Six (6) nos. Transport air
compressors (4W+2S) are to be provided to cater the
requirement of four (4) nos. pressure conveying stream.
10.3 Control of Fly Ash System :
The various list of actuators selection option have been

described in Control Write Up, Chapter-V. The primary control
facilities through these actuator / selection option are described
below:
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The selection of operating and standby vacuum pump can be

carried out by the respective selection option in HMI.
Corresponding vacuum pump suction valve and seal water

line valve shall be automatically open through the selection of
vacuum pump from HMI.
One set of start/stop P.B. shall be provided for

starting/stopping purpose of vacuum pump.
There are two number ALVs connected in one pressure

conveying line. Eight nos. ALV at a time will convey ash to
silo. The corresponding T.A.C. line valve to be opened from
HMI.
To start the pressure conveying system, one set of start/stop

P.B. shall be provided for initiating the cyclic operation of ALV
of each stream.
10.4 Vacuum System
Following are the primary steps for operating fly ash vacuum
conveying system. The description is applicable for all the
streams.
Fly ash system can be initiated if the following permissive are

available :
Availability of instrument air pressure above set point.
The vacuum conveying system to any particular Buffer Hopper

cannot be initiated in case ash level of Buffer Hopper is at
higher level.
Ash level of the selected silo is below high level.
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The vacuum conveying can be carried out either in auto or

manual mode. In auto operation, the cleaning of various
hoppers is taken up in a predetermined sequence.
Under manual mode any hopper can be selected through the

selection switches provided in HMI. However only one hopper
can be operated manually at a time for ash removal of a
particular stream.
10.4.1 Once the sequence of cleaning of all hoppers are over under
auto mode the sequence can either be repeated on its own or
an annunciation Sequence Over can be initiated depending
upon the selection in the HMI by the operator. This is to
facilitate the option that the fly ash can be continuously
evacuated or it can be operated intermittently if some running
maintenance is required between the two operations.
10.4.2 The set point of vacuum conveying system are as follows:
No load vacuum (Mechanical setting by adjusting air

intake valve): 100 mm Hg
Hopper valve open : 280 mm Hg
Hopper valve close: 300 mm Hg
Hopper empty: 80 mm Hg
Hopper plugged: 200 mm Hg to 230 mm Hg.
10.5 Pressure System and Dry Ash Collection
10.5.1 The basic system:
For the subject project there are four vacuum conveying

streams. Each vacuum conveying stream has one dedicated
buffer hopper. However each buffer hopper is provided with
two nos. Air lock vessel. During normal dry ash collection two
nos. vessel per dust collector operates simultaneously (one
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filling and other in conveying mode). Both the vessels of the
one buffer hopper are connected to the same pressure
conveying line.
10.5.1 Initiation of Pressure Conveying System:
The pressure conveying system is to operate first prior to

operation of any vacuum conveying system.
Selection will be in auto sequence.
The silo ash level has been checked to be not at high level.
The corresponding ash isolation valve of respective silo has
been kept open. Other valves in the line directed to other silo
have been kept closed.
The respective compressors have been started based on

individual interlock and it has been ensured that the
compressor runs in load condition.
After ensuring the mode selection as well as compressor run in

load condition, press the system start push button from HMI.
As soon as the system start push button press, line purging

starts first. Fluidizing air inlet valve and ALV discharge valve as
well as equalizing valve and ash inlet valve of the selected
vessels are closed. Only the transport air line valve will remain
open.
After completion of line purging for a predefined time and

subject to line pressure goes down to no load pressure value of
the total pipeline, respective vessels purging starts. The
operation for the ALV takes place for four nos. vessels which
are connected to the four transportation line.
For vessel purging, both the fluidizing air and ALV discharge
valve of respective vessels open.
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As soon as the line purging starts, as stated above, the
respective line vacuum pump also starts (subject to its own
interlock for restricting vacuum). Simultaneously, respective
hopper valves of connected streams also start opening

sequentially. As a result ash flow continues in the buffer
hopper. This ash flow remains continuous only with the
exception when ash level of buffer hopper reaches high level.
In the eventuality of high level sensor of respective buffer

hopper getting energized, hopper valve will close immediately.
Respective hopper valve will again open subject to the signal
that ash level of buffer hopper come down from maximum ash
level. This process of ash loading to the buffer hopper is
continuous based on above said interlock and is independent
of the down stream pressure conveying system.
After completion of line purging and vessel purging, as stated

in the earlier points, ash starts loading in Airlock vessels. At
that time vessel fluidizing valve and vessel discharge valve will
remain close. Equalizing valves and ash intake valves of ALV
will remain open. The equalizing valve will open slightly before
the ash intake valve is open. This process of ash loading is
continued till either the ash level in the vessel reaches the high
level or attains predetermined time.
On completion of vessel loading as per above point, either by

level or by time, the ash inlet valve and equalizing valve closes
simultaneously and the fluidizing air line valve of the one
vessel (For one particular stream) is open. After a certain
period of time the ALV discharge valve will open and ash is
being conveyed to silo through the transport line up to a certain
time or line pressure goes down to a predefined value as the
case may be. Only one working ALV will operate per stream
independently.
The sequential process of loading and conveying continued for

the total period of operation. In the eventuality of line pressure
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shoots up higher than the value defined for ash conveying, the
ALV discharge valve and fluidizing valve will be closed till the
line pressure comes down below the set value.
This pressure conveying system remains in operation as long

as silo ash level reaches high level or operator decides to stop
the pressure conveying system. In that situation conveying
from vessels as well as extraction through vacuum system
stops. After stopping the pressure conveying system those
respective silo isolation valves closes and finally the vent filter
purging system should stop by HMI.
11.0 ASH WATER SYSTEM
There are several types of water pumps under operations. The

interlocks and sequence of operation for these pumps are
indicated below.
11.1 SEAL WATER PUMP
There are four nos. (2LP+2HP) Seal water pump for catering to
the seal water requirements of ash slurry pumps and drain
pumps near ash slurry pump house. The rated parameters of
seal water pumps are, LP Seal Water Pump: 31 cu.m/hr @ 126
MWC and HP Seal Water Pump: 14 cu.m/hr @ 152 MWC.
Seal water is started before starting of the above mentioned
equipments.
Out of the four pumps one pump each of HP seal water and LP
seal water is under stand by mode. The working/stand by
mode is selected from Compressor house HMI. The pump
which is selected in stand by mode automatically starts when
the operating pump trips and the starting permissive are
available.
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The seal water pump trips if the suction water pressure is
below the set point.
11.2 BALP WATER PUMP
There are two (2) nos. (1W+1S) BALP pumps provided for
catering to cooling water requirement of B.A Hopper and make-
up under various mode of operation for two units. The rated
parameter of BALP pumps are 260 cu.m/hr. @ 25 MWC. The
pumps can be started from Compressor house HMI. Each of
the pump can be started only if the water level in ash water
sump is above the preset level. The operating pump will trip if
the water level in the sump goes lower than preset level.
11.3 BAHP WATER PUMP
There are two (2) nos. (1W+1S) BAHP water pumps provided
to cater the requirement of Bottom ash Jet pump, Flushing &
Jetting for two units. The rated parameters of BAHP water
pumps are 540 cu.m/hr. @ 73 MWC. The BAHP water pumps
operate only when the Jet pumps of B.A system / Feeder
Ejector/ C.A Jet pump and ash slurry sump jetting is to operate.
As such, BAHP water pump operation is intermittent. Other
starting and running permissive of BAHP water pump is same
as BALP water pump.
11.4 REFRACTORY COOLING WATER PUMP
There are two (2) nos. (1W+1S) RCW water pumps provided to
cater the cooling water requirement of B.A. hopper refractory
cooling of two units. The rated parameter of RCW water pumps
are 357 cu.m/hr. @ 25 MWC.
The pumps can be started from Compressor house HMI. Each
of the pump can be started only if the water level in ash water
sump is above the preset level. The operating pump will trip if
the water level in the sump goes lower than preset level.
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11.5 HCSD WATER PUMP
There are two nos.(1W+1S) L.P Water pump provided for

HCSD System. The rated parameter of HCSD Water pump are
150 cu.m/hr.@ 15 MWC. The pumps can be started from Ash
slurry pump house HMI. Each of the pump can be started only
if the water level in ash water sump is above the preset level.
The operating pump will trip if the water level in the sump goes
lower than preset level.
12.0 ASH SLURRY PUMING SYSTEM
12.1 There are two series (1W+1S) of ash slurry pumps provided for
ash slurry pumping system. The ash slurry sump has three
compartments. Each series has five pumps. Any one series will
take care of handling slurry of both the units. The first stage of
slurry pump is provided with fluid coupling having variable
speed drive arrangement. The operation of all the series is
similar. The sequences of operation, interlocks and per
missives are explained in the following clauses.
12.2 The entire operation of one series can be initiated through one
set of group start/group stop push button provided in Ash slurry
pump house HMI. Or else individual equipment in the series
can be started and stopped through individual switch option in
HMI. The selection between the auto operation of the entire
group or the manual operation of individual equipment will be
carried out from HMI.
12.3 Prior to starting of any slurry pump series the following is to be

ensured.
Seal water pumps are started first before starting of first series
of slurry pump.
Slurry level in respective slurry sump is above the preset level.
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12.4 Under group auto operation, the sequence and the permissive
of starting of all the equipment in the series are as below :
The suction valve will open first.
The seal water solenoid valve to all the six pumps in a series
shall open.
The cooling water pressure to respective Fluid coupling is
normal.
The first pump will not start unless the suction valve has
opened and the water level in the sump is above preset level.
The first stage pump will start.
After starting of the first pump there shall be a preset delay
after which the second stage pump will be started. It is to be
noted that normally this time delay will be provided 15 sec.
While the same may slightly vary during actual operation.
The other four pumps in series will take start as per earlier
sequence.
The discharge valve shall open after some preset time (5 sec.)
after starting of Second stage pump.
12.5 On completion of the above operation, interlocks checks back

the following and in case any of the requirement have not been
fulfilled ,the entire series trips.
If seal water pressure is not available to any of the slurry

pump in a particular series.
If any of the slurry pump in the series have not started.
If discharge valve not open after laps of preset time.
In addition, the slurry pump will also trip in case:

The sump level is below preset level.
The pressure of cooling water to Fluid coupling is below the
preset level.
The temperature of cooling water is higher than the preset
value.
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It is to be noted that the running permissive and tripping

permissive explained as above are applicable for both auto and
manual operation of slurry pump series.
12.6 Under manual selection of slurry pump series, the following

steps are to be carried out in the sequence indicated below.
The suction valve is to be opened.
All seal water valves are to be opened.
After about 60 sec. the first stage pump is to be started.
After 10 sec. from start of first pump, second stage pump is
to be started.
After about 5 sec. from start of second stage pump, the
discharge valve is to be opened.
After about every 10 sec. the subsequent stage pumps are

to be started.
The above time interval will be finally selected during

commissioning of the plant and shall be indicated in instruction
manual.
12.7 During stoppage of entire series under group auto operation,

all the pumps in a series will stop, the seal water valve will
close and discharge valve as well as suction valve will close
simultaneously when ever Group Stop button is pressed from
HMI.
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13.0 DRAINAGE SYSTEM
13.1 BOTTOM ASH SUMP JET PUMP
Two nos. Jet pump (1W + 1S) are provided for dewatering of
ash slurry from bottom ash hopper area. Suction of these jet
pumps are from B.A. area drain sump and this jet pump will
also discharge ash slurry to BA overflow sump.
13.2 DRAIN PUMP FOR ASH SLURRY & ASH WATER PUMP
HOUSE AREA
Two nos. drain sump pump (1W + 1S) has been provide near
ash slurry pump house for dewatering of collected water from
ash slurry pump house. This drain pump will discharge the
collected water to ash slurry sump. The drain pump can be
operated from Compressor house HMI. The pump parameters
are 27 cu.M/Hr. @17 MWC
Drain pump can be started under the following condition:

Seal water pressure is above the preset value.
Drain sump level is above low.
The pump will trip is the above conditions are not fulfilled.
13.4 DRAIN PUMP FOR VACUUM PUMP HOUSE AREA
vacuum pump house for dewatering of collected water from
vacuum pump area. This drain pump will discharge the
collected water to ash slurry sump. The drain pump is to be
operated from compressor house HMI. The pump parameters
are 50 cu.M/Hr. @15 MWC.

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Drain sump level is above low.
13.4 DRAIN PUMP FOR REMOTE SILO AREA
remote silo area for dewatering of collected ash water of silo
area. This drain pump will discharge the collected ash water to
ash slurry sump. The drain pump is to be operated from silo
control panel. The pump parameters are 20 cu.M/Hr.
@25MWC.

Drain sump level is above danger low.
13.4 DRAIN PUMP FOR HCSD SILO AREA
remote silo area for dewatering of collected ash water of silo
area. This drain pump will discharge the collected ash water to
ash slurry sump. The drain pump is to be operated from
compressor house HMI. The pump parameters are 20 cu.M/Hr.
@25 MWC.

Drain sump level is above danger low.
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14.0 FLUIDIZING AIR SYSTEM
14.1 ESP/BUFFER HOPPER FLUIDIZING BLOWER
Two nos.(1W + 1S) air blowers are provide for catering the
fluidizing air requirements of ESP hoppers and buffer hoppers
of each unit. The rated parameter of ESP/Buffer hopper
fluidizing air blower is 750 cu.m/hr. @ 4000 MMWG.
The basic sequence of operation interlocks and per missives is

as below:
The above blowers are to be operated from HMI located at

compressor house. One selection option is provided in HMI for
selecting the working /standby of fluidizing blower.
One no. air heater is provided on discharge header of each air

blower. Two. Nos. temperature switch is also provided for
automatic ON/OFF purpose of the fluidizing blower. Initially the
heater can be on by the operator from HMI located in
compressor house. Whenever the temperature in the fluidizing

airline is above the preset value the heater will automatically
OFF. If it is below the preset value, the heater will be
automatically ON. The heater which is in standby blower line,
cannot be started.
14.2 HCSD SILO AERATION BLOWER
Three nos.(2W + 1S) air blowers are provide for catering the
fluidizing air requirements of HCSD silo. The rated parameter
of HCSD silo air blower is 1000 cu.m/hr. @ 6000 mmwc.
The basic sequence of operation interlocks and per missives is

as below:
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The above blowers are to be operated from HMI located at
compressor house.
blower. Two. Nos. temperature switch is also provided for
automatic ON/OFF purpose of the fluidizing blower. Initially the
heater can be on by the operator from HMI located in ash
slurry pump house. Whenever the temperature in the fluidizing
airline is above the preset value the heater will automatically
OFF. If it is below the preset value, the heater will be
automatically ON. The heater which is in standby blower line
cannot be started.
14.3 SILO FLUIDIZING BLOWER
Three nos. (2W + 1S) air blowers are provide for catering the
fluidizing air requirements of two nos. silos. The rated
parameter of silo fluidizing air blower is 1000 cu.m/hr. @ 6000
mmwc.
The basic sequence of operation interlocks and permissive is

as below:
The above blowers are to be operated from silo RIO panel.

blower. Two .Nos. temperature switch is also provided for
automatic
ON/OFF purpose of the fluidizing blower. Initially the heater

can be on by the operator from HMI located in silo RIO panel.
Whenever the temperature in the fluidizing airline is above the

preset value the heater will automatically OFF. If it is below the
preset value, the heater will be automatically ON. The heater,
which is in standby blower line, cannot be started. Normally
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one no. air blower will cater the requirement of fluidizing air of
one silo.
15.0 SILO UNLOADING SYSTEM
15.1 DUST CONDITIONING WATER PUMP
There are two (2) nos. (1W+1S) Dust conditioning water pump
provided to cater the requirements of conditioning water to
Dust conditioner for unloading of moist ash to open truck from
the two nos. dry fly ash storage silo. The rated parameter of
D.C water pump are 58 cu.m/hr. @ 53 MWC.
The entire operation, control philosophy, sequence and
interlocks of D.C water pump is as below:
There is a Start/Stop push button provided in silo control panel

located in Silo utility building for all the D.C pumps. The pump
can start if the following start permissive are as available as
below :
If the level in silo area wash water sump is above the low
level.
In case the water level in the sump goes below danger low
level, the pump will trip.
15.3 DRY ASH UNLOADING TO CLOSE TANKER THROUGH

DRY ASH UNLOADING SPOUT
One no. dry ash unloading spout is provided in each Fly ash
remote silo for dry ash unloading to close tanker. There are two
nos. limit switch provided for full up and full down position of
dry ash unloading spout (as well as to stop the higher run and
lower run operation). There are three nos. push buttons
provided in silo unloading panel for dry ash unloading spout
operation. If lower run is required then press lower push button.
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Lower run lamp glows till the lower run is completed, lamp
goes off. If higher run is required then press the raise push
button. Raise lamp glows till the higher run is completed. Then
lamp goes off. If intermediate stop is required, then press the
stop push button, the stop lamp glows.
One no. scavenger fan is provided for each dry ash unloading
spout for unloading dry ash to close tanker. The scavenger fan
can start from silo utility control desk through start/ stop push
button only when the dry ash-unloading spout full down limit
switch is actuated.
One no. Rotary Feeder is provided in the upstream of each dry

ash unloading spout. Once the dry ash unloading spout full
down limit switch is actuated and the scavenger fan is
operated, then only the rotary feeder can start from the silo
unloading panel through the respective start/stop push button.
If scavenger fan and rotary feeder run feedback is present,

then only the remote operated knife gate valve can be open
through the open/close selection switch of KGV located in silo
unloading panel. KGV on the upstream of rotary feeder is
automatically closed if tanker full signal has come or to rotate
the selection switch in close position.
Stop Sequence
The stopping sequence of dry ash unloading through dry ash

unloading spout is as below.
First close the remote operated KGV from selection
switch.
Press the rotary feeder stop push button.
Stop scavenger fan.
Press raise push button of dry ash unloading spout.
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15.4 DRY ASH UNLOADING TO OPEN TRUCK THROUGH

PADDLE FEEDER
One no. Paddle Feeder is provided in each silo for moist ash
unloading to open truck. For moist ash unloading to open truck
through the Paddle Feeder, first open the Paddle Feeder water
line valve from open/close selection switch located in silo utility
control desk. Then the Paddle Feeder shall be started from silo
unloading panel through the respective start/stop push button if
unloader conditioning water pressure is above the preset
value.
One no. Rotary Feeder is provided in the upstream of each

Paddle Feeder. Once the unloader conditioning water line
valve is open and Paddle Feeder run feedback is available,
then only Rotary Feeder can be started from the silo-unloading
panel through the respective start/stop push button.
If Paddle Feeder and Rotary Feeder run feedback is present,

then only the remote operated knife gate valve can be open
through the open/close selection switch of KGV located in silo
unloading panel.
Stop Sequence
The stopping sequence of dry ash unloading through Paddle

Feeder is as below.
First close the remote operated KGV from selection
switch.
Press the rotary feeder stop push button.
Close water line valve.
Stop Paddle Feeder.
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16.0 VACUUM PUMP
There are six (6) nos. vacuum pumps (4W+ 2S). Normally one
vacuum pump will be operated from HMI located at
compressor house for one vacuum stream. Vacuum pump can
be started if the following conditions are fulfilled.
Suction valve of standby vacuum pump is fully closed.

Seal water pressure of respective vacuum pump above
preset value.
Vacuum breaker is open.
The vacuum pump will trip under following conditions:
The suction valve of the running vacuum pumps is not

open within preset time period.
Suction valve of standby vacuum pump is open.
Seal water pressure of respective vacuum pump below
preset value.
The rated parameter of vacuum pump is 3800 cu.m/hr. @

16Hg.
17.0 INSTRUMENT AIR COMPRESSOR
There are two (2) nos. (1W+1S) Instrument air compressor

provided for catering the requirement of instrument air of the
entire ash handling system including remote silo area.
Instrument air compressor is to be started before starting ash
evacuation through any system of any unit. For Instrument air
system, reciprocating compressor is to be used. The rated
capacity of IAC are 510 cu.m/hr. @ 84 MWC.The compressor
is provided with loading unloading facility to control net total
discharge through the compressor depending upon the system
requirement. At the initial starting of compressor, the lube oil
pressure is not energized and accordingly, the interlock for
tripping the compressor at loss of Lub. Oil pressure is
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bypassed at the starting. The pressure switch in the control
manifold (having the discharge air pressure) will trigger a
mechanism of keeping the suction open when no discharge of
air is required. However, with the consumption of air from the
air receiver tank the pressure falls below the preset level and
accordingly, unloading mechanism is deactivated. Therefore,
the suction valve opens as per stroke position allowing
discharge of air from compressor.
The Lub. Oil pressure switch is brought into circuit after a few
moments of starting the compressor. By this time the lub. Oil
pressure is fully developed.
The basic sequence of operation, interlocks and permissive of

IAC is as below :
The operation of IAC is initiated from HMI located at

compressor house in the following sequence. One (1) no.
Working/ Standby selection option is provided for each
compressor in HMI. The compressor which one is already
selected in standby mode cannot be stopped from the HMI.
The standby compressor automatically starts when the

operating Instrument air compressor trips and all the starting
permissive explain below are available. Before starting IAC, the

Working/Standby option of the selected IAC is to be kept in
working position in HMI. Then only the IAC can be started by
respective start/stop push button provided in HMI.
17.1 START SEQUENCE AND INTERLOCKS
The Instrument air compressor will start only when the

intercooler outlet air temperature is not at high level, discharge
air pressure is below the high preset value, discharge air
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temperature is below the preset value, after cooler outlet
temperature is not at high level, receiver air pressure is not at
high level, cylinder jacket cooling water outlet temperature is
not at high level, cooling water outlet flow is not less than the
desired level, lub oil pressure is available.
It is to be noted that initially the lub.oil pressure switch is

bypassed. However, there shall be time duration of 10 sec. to
allow shaft driven gear oil pump to build the oil pressure. If the
lub oil pressure is below the preset value after the above time
duration the compressor will be tripped. The operating IAC will
automatically trip in case any of the above mentioned
interlocks are not available or abnormal.
The primary alarm and interlocks is provided on the following

aspects of Instrument air compressor.
Inter cooler outlet air temperature high.
Discharge air temperature high.
Discharge air pressure high.
Discharge air pressure low (only alarm).
After cooler outlet air temperature high.
Cylinder Jacket water outlet temperature high.
Cooling water inlet common header pressure low.
Cooling water outlet temperature is below preset value.
Return flow of cooling water normal.
Lub. Oil pressure low.
Two nos. (1W + 1S) refrigerant type air driers are provided for
supply of moisture free compressed air to various instruments.
The control of these air drier are from HMI located at
compressor house. The air drier can be started under the
following condition:
Corresponding I.A.C. running.
The drier will trip under following conditions:

Corresponding I.A.C. is not running.
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Required due point temperature is achieved.
18.0 TRANSPORT AIR COMPRESSOR
There are five (6) nos. (4W + 2S) transport air compressor
provided for catering the conveying air requirement for
transportation of dry fly ash from buffer hopper to silo. The
T.A.Cs are to be started before the dry ash evacuation through
pressure conveying system. The rated parameter of T.A.C. are
2895 cu.m/hr. @ 45 MWC. There are four streams of pressure
conveying system which are independent of each other. One
no. compressor will be running per stream and there is a
common air receiver provided for
each stream. The basic sequence of operation, interlocks and

permissive of T.A.C is as below.
The operation of T.A.C. is initiated from HMI located in

compressor house.
The T.A.C. starts under following conditions:

Air temperature is not high.
The differential pressure across suction air filter is not at
high level.
Discharge air pressure is not at high level.
If the above conditions are not fulfilled, the compressor will trip.
18.1 LOAD/UNLOAD OPERATION OF TRANSPORT AIR

COMPRESSOR
The load/ unload operation is controlled by setting off the

pressure switch. The actuator cylinder for suction control valve
activated when the pressure builds up as a total air flow to the
system is less than the compressor capacity. Upon reaching
the required discharge from the compressor, the valve is
reactivated to allow compression of fresh air.
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19.0 AIR FLOW CONTROL FACILITY
The total conveying air is spited into two segments. While one
part of air is directly provided to the conveying line and the
other part of air is allowed to enter the Air Lock Vessel from the
bottom. Referring to the construction detail of Air Lock Vessel,
it can be observed that the air induced into the vessel fluidizes
the ash and conveys the same through outlet of the vessel into
the transport line. As such, the two air are called Transport Air
and Fluidizing Air for regular reference.
There is a control requirement between the preparation of
Fluidizing Air and Transport Air. Accordingly, there are two
control valves to control the respective air flow. There is one
Pressure Transmitter provided at outlet of conveying line
control valve which indicate the back pressure of ash
conveying line. It is to be noted that the back pressure of
conveying air line is dependent on the actual flow condition of
ash in the transport air line. If the ash conveying is on the
higher side, the back pressure will be high and when the
transportation of ash comes down, it is generally assumed that
the ash flow has been reduced. PLC Control panel monitors
opening/closing of control valves as per the feed back received

from PT.
The PLC provides a single command of pre-set opening of the

two control valves in the air line as explained above. During
normal ash conveying, a portion of transport air is allowed in
the air lock vessel. The same air is discharged through the
outlet pipeline of air lock vessel taking along the ash from air
lock vessel. The discharge of Air lock vessel is connected to
the main conveying line, accordingly the vessel is emptied in
every cycle. It is to be noted that the back pressure will
increase, if the ash discharge from the air lock vessel is
considerably high. Under such situation PLC will signal to
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reduce the opening of fluidizing line control valve and increase
the opening of transport air line control valve. As such, the ash
discharge from the air lock vessel will reduce and system will
balance an optimum level. On the other hand back pressure
will drop in case there is less ash discharge from the air lock
vessel. Under such situation the fluidizing line control valve is
open to a higher percentage but upto the limit, allowing more
air to go in the air lock vessel. This will result in higher rate of
ash discharge from ALV. Correspondingly, conveying line back
pressure will increase and the PLC signal will reverse. With this
adjustment the ash conveying from pressure vessels will be
carried out pneumatically in a optimized condition and to
achieve desired ash flow capacity.
20.0 HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM
20.1 INTRODUCTION
Ash handling system is provided with High concentration slurry

disposal system for which one no. HCSS Silo is provided. This
HCSS Silos will feed ash to three independent streams. Two
streams shall normally be working and one stream will be
available as standby. The silo shall have three openings.
These three openings of HCSS silo will be connected to three
independent streams of high concentration slurry system. and

The HCSS System shall take fly ash input from HCSS Silo and
dispose it continuously as high concentrated slurry to ash
disposal area with 65-70% ash concentration. Water is added
in mixing tank with moist ash in a controlled manner through
continuous automatic Instrument Based monitoring system to
ensure that the basic slurry parameters remain constant during
the transportation of slurry through the pipe line.
The pump speed shall be varied through VFD drive over the
range of 10% to 100% of maximum flow rate. Necessary
remote and manual speed control provision is there. There are
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two nos. of dedicated transformer to feed the power supply to
VFD and after VFD to HCSS motor.
The following aspects govern the basic arrangement of high

concentration slurry system.
a) Controlled Ash Feed.

b) Controlled water supply to maintain proper slurry density.
c) HCSD Pump.
d) Disposal Pipe line.
There are many control features, which have to work for

guaranteed monitoring of proper slurry density in a continuous
manner so that the slurry pump can operate uninterruptedly.
20.2 MAJOR EQUIPMENTS FOR HCSS SYSTEM
ROTARY FEEDER WITH VFD
One (1) no. Rotary Feeder is provided in upstream of Paddle

Feeder and take fly ash input from HCSS silo. It is to be noted
that the Rotary Feeder has variable speed control and have
ash disposal capacity of 150 TPH. The speed of Rotary Feeder
is automatically adjusted as per the reading of Mass Flow
meter to maintain required ash flow for slurry consistency (65%
- 70%).For variation of Rotary Feeder speed a VVVF drive is
provided. Mass flow meter is continuously monitor the feeding

rate of fly ash from Rotary Feeder to Mixer tank through Paddle
Feeder and thus control of ash feeding rate into the system is
achieved.
PADDLE FEEDER
This is a twin Paddle mixture unloader having capacity 150

TPH. This is provided in upstream of Slurry mixing tank where
dry fly ash is been moist and discharge to ART (Agitated
Retention Tank).
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AGITATED RETENTION TANK (ART)
The ART is a rubber lined cylindrical tank with vertical spindle,

twin blade, dual impeller type high torque agitator. The output
of Paddle Feeder fed into ART where required slurry
concentration and rheology is maintained and monitored. The
ART is provided with Level Transmitter for continuous level
control measurement, Non-nucleonic type Density meter for
density measurement and PH meter for measurement of PH
value of ash slurry. The ART is provided with proper flushing
and drain connection.
The mixing tank (ART) will have five level control.
a) High High Level (90 %).

b) High Level (80%)
c) Operating level (70%).
d) Low level (10%).
e) Low low level (0%).
Zero level (0%) is set at the start of the lower part of tank. The
90% level is the maximum slurry level allowable in the tank.
20.3 HCSD PUMP
There are five sets of HCSD Pump (4W + 1S) each having ash
disposal of 150 TPH (Dry ash basis) with motor and VFD are
provided for total five streams. Capacity of HCSD Pump is
156cu.m/hr @ 1500 MWC. Among the five independent high
concentration slurry disposal stream, two are working for each
unit and one is common standby. Five HCSD Pumps are
connected with four no. slurry disposal line with necessary
interconnection and instrumentation.
The starting permissive of HCSD Pump from HCSD PLC are

as follows :
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HCSD Pump not failed.

HCSD Pump ready to run (Feed back from HCSD PLC to main
PLC) under the following condition:
a) VFD ready to run.

b) Pump ready to run.
c) Propelling pump on.
d) Lub pump on.
e) Suction flow normal.
f) Propelling liquid pressure normal.
g) Air pressure normal.
HCSD Pump Auto/manual selection from HCSD SCADA.
The start permissive of HCSD Pump from main PLC are as follows :
Silo Fluidizing Blower on.

LP Water tank level normal.
Manual suction valve open.
Mixture run feed back.
Mixture tank level not low.
IAC Pressure normal.
HCSD PLC ready.
Paddle feeder health.
Silo level not low.
Mixing tank level above pre set value.
Rotary feeder healthy.
Mixing tank density(minimum) above preset value.
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CHAPTER III
Control Systems
The PLC based control system is envisaged for operation,

monitoring and control of Ash Handling System of both the units.
The PLC system will be located at AHP control rooms.
The control and sequential operation of the total system is
achieved through programmable logic control (PLC) system.
Ash Handling System is controlled with the help of three nos.

dedicated PLC System, consisting of two (2) nos. processors.
These processors are configured in hot standby mode in such a
way that in case one master processor fails; slave processor
takes over the controls bumplessly.
Required numbers of I/O modules, power supply modules,

communication modules and UPS backed by batteries have
been provided.
There are in total three nos. of control rooms for the entire Ash
Handling System as follows:
1. Compressor House Control Room: This is the main control

room for the entire Ash Handling Plant. The Unit Fly Ash PLC,
Ash Slurry PLC and HCSD PLC are located in this room. There
are four nos. Work Stations and two nos. Engineering Station
for control and monitoring.
2. Bottom Ash Control Room: This house is near the B.A.

Hopper. The bottom ash control room houses the B.A. PLC.
3. Silo Control Room: The silo control room is located in the silo
utility building. This room consists of a silo RIO cum control
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panel. A Mimic and annunciation window is provided in the

control panel. For monitoring the silo system.
There are also two nos. silo unloading panel located near the
silo platform. These panels are for operating the silo ash
unloading system.
Local Emergency Stop push buttons for drives/ equipment of

ash handling system shall be provided near the respective
drives/ equipment and the same will be directly wired up to the
respective MCC.
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COMPRESSOR HOUSES CONTROL ROOM
The under listed drives are controlled by the compressor houses

control room.
HP Seal Water Pump 2 Nos.

LP Seal Water Pump 2 Nos.
BA Over Flow Pump 2 Nos.
Clinker Grinder 4 Nos.
Drain Pump 2 Nos.
Motor Optd. Plug Gate Valve 2 Nos.
ESP Hopper Fluidising Blower 2 Nos.
ESP Hopper Fluidising Air Heater 2 Nos.
Plant Area IA Compressor 2 Nos.
Vacuum Pump (Mechanical Exhauster) 6 Nos.
Mechanical Exhauster Drain Sump Pump 2 Nos.
Transport Air Compressor 6 Nos.
BA/CA Ash LP Water Pump 2 Nos.
Reftactory Cooling Water Pump 2 Nos.
HCSD LP Pump 2 Nos.
Drain Pump 2 Nos.
Sludge Pump 2 Nos.
HCSD Blower 2 Nos.
HCSD Blower Heater 2 Nos.
HCSD Paddle Feeder 3 Nos.
Ash Slurry Mixer 3 Nos.
Rotary Feeder 3 Nos.
ASH SLURRY PUMP (STAGE-II - V)
8 Nos.
SLURRY PUMP, STAGE-I
2 Nos.
IAC Drier 2 Nos.
43
EXPANSION PROJECT
(1 X 500 MW)
CONTROL WRITE UP
SILO CONTROL ROOM
The under listed drives are controlled by the Silo control room.
Dust Conditioner Water Pump 2 Nos.

Silo Fluidising Blower 3 Nos.
Silo Fluidising Air Heater 3 Nos.
Paddle Feeder 2 Nos.
Telescopic Spout Winch 2 Nos.
Rotary Feeder 2 Nos.
Telescopic spout fan 2 Nos.
Drain Pump 2 Nos.
44
EXPANSION PROJECT
(1 X 500 MW)
CONTROL WRITE UP
ALV CYCLE GRAPH
110
70 60
100
TIME (SEC.)
60
60
70
FLUSHING MODE PRESSURE CONVEYING MODE

NORMAL MODE
Line Equalizing Ash Intake Fluidizing Ash

Flushing air Intake Conveying
Remarks: Time cycle may vary during actual commissioning of the

system
45
EXPANSION PROJECT
(1 X 500 MW)
CONTROL WRITE UP
*****************
PROTECTION AND INTERLOCK

CHAPTER IV
46
PROJECT: KHAPERKHEDA T.P.S. TATL DOC. NO.: 543-E-02
REV-R0
PACKAGE NAME: ASH HANDLING SYSTEM CONTROL WRITE-UP PROJECT NAME: Khaperkheda thermal Power Station extn:- 500
MW
PROTECTION INTERLOCK
CHAPTER IV
Interlocks Controlled
S.No. Equipment Ref. Drg. Annunciation Indications/ Mimic Controls Provided
Starting Permissive Running Permissive From
1 2 3 4 5 6 7 8 9
i) Seal water suction pressure i) Seal water suction pressure i) Discharge Water Pressure "Low" i) Red LAMP for pump "Start" i) Start & Stop push
above preset valve above preset valve (OS) (OS) button (OS)
ii) Green LAMP for pump ii) Auto Manual
ii) MCC module not disturbance ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) "Stop" (OS) selector switch (OS)
HP & LP iii) Amber LAMP for pump
Seal Water iii) Start command initiated iii) LPBS not pressed iii) Inlet water Pressure Low (OS) "Trip" (OS)
Pump iv) Stop push button not iv) Red LAMP for Seal water
1 [Total 4 Nos. Dwg. No.: 543-01-iv) Remote Selection pressed. iv) Individual seal water pump fail (OS) inlet pressure Normal(OS) OS
(2W+2S) 01 v) Red LAMP for Seal water
Common for Discharge Pressure Normal
both units] v) LPBS not pressed (OS)
Note: v) No electrical trip
i) If selected pump is failed, then
another pump selected on standby
will start automatically subject to
i) MCC module not disturbance i) Seal water pressure normal i) Seal water pressure "Low" (OS) i) Red LAMP for pump "Start" i) Start & Stop push
(OS) button (OS)
ii) Start command initiated ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) ii) Green LAMP for pump
Drain Sump "Stop" (OS)
Pump iii) Drain sump water level above iii) Stop push button not iii) Drain sump water " Danger Low" iii) Amber LAMP for pump
(Ash Slurry low pressed. (OS) "Trip" (OS)
P/H Area) iv) Drain sump water level iv) Drain sump pump "Failed". iv) Red LAMP for drain sump
2 Dwg. No.: 543-01- OS
[Total 2 Nos. iv) Remote Selection above danger low level "Low" (OS)
01
(1W+1S) v) Red lamp for Seal water
Common for v) LPBS not pressed v) LPBS not pressed pressure Normal (OS)
both units] vi) No electrical trip iv) Red LAMP for drain sump
level "High" (OS)
iv) Red LAMP for drain sump
level "Danger Low" (OS)
i) MCC module not disturbance i) Seal water pressure normal i) Seal water pressure "Low" (OS) i) Red LAMP for pump "Start" i) Start & Stop push
(OS) button (OS)
ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) ii) Green LAMP for pump
ii) Remote Selection "Stop" (OS)
Sludge Pump iii) Start command initiated iii) Stop push button not iii) Sludge pump "Failed". iii) Amber LAMP for pump
(Settling pressed. "Trip" (OS)
47
PPD. BY: P.G. CONTROL WRITE UP
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
Tank) iv) Settling tank water level above iv) Settling tank water level iv) Settling Tank Level 'Danger Low'
3 [Total 2 Nos. Dwg. No.: 543-01- low above danger low (OS) iv) Red LAMP for Settling OS
(1W+1S) 01 Tank Level "Danger Low" (OS)
Common for v) Red lamp for Seal water
both units] v) LPBS not pressed v) LPBS not pressed pressure Normal (OS)
vi) No electrical trip iv) Red LAMP for sump level
"High" (OS)
iv) Red LAMP for drain level
"Danger Low" (OS)
i) Ash water sump level above i) MCC module not disturbance i) Ash water sump level "High" (OS) i) Red LAMP for pump"Start" i) Start & Stop push
low (OS) button (OS)
ii) MCC module not disturbance ii) Stop push button not pressed. ii) Ash water sump level "Low" (OS) ii) Green LAMP for pump
"Stop" (OS)
iii) Start command initiated iii) Ash Water Sump level iii) Ash water sump level "Danger iii) Amber LAMP for pump
above danger low Low" (OS) "Trip" (OS)
iv) Bearing temp. not high iv) MCC module "Disturbance" (OS) iv) Red LAMP for Ash water
iv) LPBS not pressed sump level "Danger Low" (OS)
v) Winding temp. not high v) No electrical trip v) Discharge Water Pressure "Low" for v) Red LAMP for Ash water
BAHP Water
common header (OS) sump level "High" (OS)
Pump [Total
4 Dwg. No.: 543-01- vi) Bearing temp. not too high vi) Electrical Trip (OS) vi) Red LAMP for Ash water OS
2 Nos.
05 vi) Remote Selection sump level "Low" (OS)
(1W+1S) ]
vii) Winding temp. not too high vii) Red LAMP for pump
discharge Water Pressure
vii) LPBS not pressed vii) Discharge pressure low.(OS) "Normal" (OS)
viii) MCC module available viii) Bearing temp. High (OS) viii) Read out of Bearing Temp
(OS)
ix) Winding temp. High (OS) ix) Read out of Winding Temp
(OS)
x) Individual pump failed (OS)
i) Ash water sump level above i) MCC module not disturbance i) MCC module "Disturbance" (OS) i) Red LAMP for pump "Start" i) Start & Stop Push
ii) MCC module not disturbance ii) Stop push button not pressed. ii) Discharge Water Pressure "Low" for ii) Green LAMP for pump
common header (OS) "Stop" (OS)
iii) Start command initiated iii) Ash Water Sump level iii) Amber LAMP for pump
above danger level "Trip" (OS)
48
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
BALP Water iv) MCC module available iii) Ash water sump level "High" (OS)iv) Red LAMP for pump
Pump [Total discharge Water Pressure
5 Dwg. No.: 543-01- OS
2 Nos. iv) LPBS not pressed "Normal" (OS)
05
(1W+1S) ] v) No electrical trip iv) Ash water sump level "Low" (OS) v) Red LAMP for Ash water
v) Remote Selection sump level "Danger Low" (OS)
v) Ash water sump level "Danger Low" vi) Red LAMP for Ash water
vi) LPBS not pressed (OS/ANN) sump level "High" (OS)
vi) Individual pump failed (OS) vii) Red LAMP for Ash water
sump level "Low" (OS)
vii) Discharge pressure low.(OS)
i) Ash water sump level above i) MCC module not disturbance i) MCC module "Disturbance" (OS) i) Red LAMP for pump "Start" i) Start & Stop Push
iii)) Start command initiated iii)) Ash Water Sumpp level iii)) Amber LAMP for pump
p p
above danger level iii) Discharge pressure low.(OS) "Trip" (OS)
Refractory iv) No electrical trip iv) Electrical Trip (OS/ANN) iv) Red LAMP for pump
Cooling discharge Water Pressure
6 Water Pump Dwg. No.: 543-01- iv) Remote Selection "Normal" (OS) OS
[Total 2 Nos. 05 v) MCC module available v) Ash water sump level "High" (OS) v) Red LAMP for Ash water
(1W+1S) ] v ) LPBS not pressed sump level "Danger Low" (OS)
vi) Ash water sump level "Low" (OS) vi) Red LAMP for Ash water
vi ) LPBS not pressed sump level "High" (OS)
vii) Ash water sump level "Danger vii) Red LAMP for Ash water
Low" (OS/ANN) sump level "Low" (OS)
viii) Individual pump failed (OS)
i) Suction valve open i) Respective sump i) MCC module "Disturbance" (OS) i) Red LAMP for pump "Start" i) Start & Stop push
compartment above danger (OS) buttons for each series
level & fluid-coupling oil
pump (OS)
ii) Respective sump compartment ii) Seal water pressure Normal ii) Slurry sump level "High" (OS) ii) Green LAMP for pump
level above low level "Stop" (OS)
iii) Discharge Valve closed iii) Pump trip if the discharge iii) Slurry sump level "Low" (OS) iii) Amber LAMP for pump
valve fails to open within a "Trip" (OS)
preset time.
49
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MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
iv)Fluid coupling cooling water iv) All/individual pumps of the iv) Slurry sump level "Danger Low" iv) Red LAMP for Slurry sump
pressure normal series start operating within a (OS/ANN) level "Danger Low" (OS)
preset time.
v) As soon as start command is v) Fluid coupling oil pump v) Fluid coupling oil pump Tripped v) Red LAMP for Slurry sump
initiated for any series, respective "Running" for first pump. (OS) level "High" (OS)
fluid coupling oil pump motor
will start automatically.
vi) Fluid coupling oil temp not vi) Slurry pump fluid coupling cooling vi) Red LAMP for Slurry sump
Ash Slurry vi) Remote Selection high water pressure "Low" (OS) level "Low" (OS)
vii) Fluid coupling oil temp below vii) MCC module not vii) Fluid coupling oil temp "High" vii) Red LAMP for pump OS
Pump
8 Dwg. No.: 543-01-high disturbance (OS) discharge slurry Pressure
[Total 5 X 2
05 "Low" (OS)
Nos. ]
viii) MCC module not viii) Stop push button not viii) Electrical Trip (OS) viii) Fluid coupling oil pump
disturbance pressed. Tripped (OS)
ix) Start command initiated ix) No electrical trip ix) Slurry pump fluid coupling
cooling water pressure "Low"
(OS)
x) second stage pump start after ix) Pump discharge slurry pressure x) Fluid coupling oil temp.
getting the running feedback of "Low" (OS) "High" (OS)
first stage pump considering all
the start permissive within preset
time delay. x ) LPBS not pressed
x) Slurry pump individual series failed viii) Red Lamp for pump seal
xi ) LPBS not pressed (OS) Water Pressure "normal" (OS)
Note: xi) Seal water pressure "Low" (OS)
i) Second stage pump run
feedback will open the discharge
valve.
ii) Other series of pumps starts
after preset time delay.
i) Open/Close Selector
i) Red lamp for valve open (OS) switch (OS)
Ash Slurry ii) Green lamp for valve close
Pump (OS)
Suction Dwg. No.: 543-01-
9 OS
Valve 05
[Total 3 Nos.
]
50
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
]
Second pump running Series not trip i) Red lamp for valve open (OS) i) Open/Close Selector
Ash Slurry Note: ii) Green lamp for valve close switch (OS)
Pump (OS)
Discharge Dwg. No.: 543-01-valve opens after preset time OS
10
Valve 05 delay of 2nd series pump start
[Total 3 Nos. command
]
i) In Auto Mode Ash Slurry Sump i) In Auto Mode closes i) Red lamp for valve "Open" i) Open- Close- Auto
's water level low automatically when ash slurry (OS) selector switch (OS)
sump level reaches high level
Ash Slurry
only.
Sump Make
Dwg. No.: 543-01-or or ii) Green lamp for valve "Close"
11 up water OS
05 (OS)
valve
[Total 1 No ] ii)Through selector switch at ii)Through selector switch at
"Open" position "Close"position (OS)
i) BA Overflow Sump level above i) Seal water pressure "Normal" i) Seal water pressure "Low" (OS) i) Red Lamp for Pump "Start" i) Stop Push button
low (OS/BALP) (BALP)
ii) MCC module not disturbance ii) MCC module not disturbance ii) Discharge water pressure "Low" ii) Green LAMP for pump ii) Pump# 1or 2
(OS) "Stop" (OS/BALP) selector switch (BALP)
iii) Start P.B. switch actuated iii) Respective BAOF sump iii) BA Overflow sump level "High" iii) Amber LAMP for pump
level above danger level (OS) "Trip" (OS)
iv) Stop push button not iv) BA Overflow sump level "Low" iv) Red LAMP for BAOF sump
BA Overflow iv) Remote Selection pressed. (OS) level "High" (OS/BALP)
Pump v) BA Overflow sump level "Danger v) Red LAMP for BAOF sump
12 Dwg. No.: 543-01- BALP
[Total 2 Nos. v ) LPBS not pressed v ) LPBS not pressed Low" (OS) level "Low" (OS/BALP)
01
(1W+1S) ] vi) No electrical trip vi) Individual BA Overflow pump vi) Red LAMP for BAOF sump
failed (OS) level "Danger Low"
(OS/BALP)
51
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
vii) MCC module "Disturbance" (OS) vii) Red Lamp for pump
discharge Water Pressure
"normal" (OS/BALP)
The Following Starting & Running Permissive will be applicable i) Grinder seal water pressure "Low" i) Red Lamp - grinder running i) Forward push button
for Clinker Crusher irrespective of mode of reversal (OS) in forward direction (OS/ (BALP)
BALP)
ii) MCC module "Disturbance" (OS) ii) Green lamp - grinder ii) Reverse push button
stopped (OS/ BALP) (BALP)
i) Seal water pressure for corresponding grinder "Normal" iii) Clinker Grinder "Jammed" iii) Blue lamp - grinder running iii) Stop push button
(OS/ANN BALP) in reverse directions (OS/ (BALP)
BALP)
ii) MCC module not "Disturbance" iv) BA jet-pump inlet water pressure iv) Amber LAMP for grinder iv) Auto-Manual
"Low" (OS) "Trip" (OS) selector switch (BALP)
(2 nos)
iii) Start P.B. switch actuated v) Red Lamp BA jet-pump inlet v) Grinder selector
water pressure "Normal"(OS/ switch (BALP) (2 nos)
BALP)
iv) Standby Clinker Grinder of same section of B.A. hopper not vi) Red Lamp Clinker Grinder
Clinker
running seal water pressure
Grinder
13 Dwg. No.: 543-01- "Normal"(OS/ BALP) BALP
[Total 4 Nos.
01 v) Jet pump inlet water pressure for corresponding grinder vii) Amber lamp for Clinker
(2W+2S) ]
"Normal" Grinder Jammed (OS)
vi) Remote Selection
vii) No electrical trip
Note: In Auto mode of operation in the event of tripping of the
clinker grinder motor due to its overloading, the motor will
automatically reverse in rotation, subject to availability of seal
water pressure, in short impulse to remove the jammed
material. Reversal operation will continue for a preset time
period after which the motor will again start rotating in normal
direction. Even if after three times consecutive forward and
reverse rotation, overload persists due to jamming after or if
not the motor had already tripped during reversal operation,
the motor will trip with parallel closure of feeder gate. The
Clinker grinder can be restarted only after judiciously selected
preset time period
52
REV-R0
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CHAPTER IV
1 2 3 4 5 6 7 8 9
i) BA Jet Pump Water Suction valve i) Red Lamp valve open (OS/ i) Open/Close Selector
"Failed" (OS) BALP) switch (BALP)
ii) Green Lamp valve closed
BA Jet Pump (OS/ BALP)
Water line
14 valve Dwg. No.: 543-01- BALP
[Total 2 01
Nos.]
i) Other gate connected to same V i) Clinker Grinder is Running in i) Red Lamp feed gate fully i) Open/Close selector
section is fully closed. forward direction. i) Hopper Feed Gate "Failed" (OS) open (OS/ BALP) switch (BALP)
ii) Clinker Grinder is running in ii) Selector Switch not in Close ii) Green Lamp feed gate fully
forward direction Position closed (OS/ BALP)
BA Hopper iii) Selector Switch in Open
Feed Gate Position
15 Dwg. No.: 543-01- BALP
[Total 4 Nos.
01
(2W+2S)]
i) In Auto Mode BA Overflow i) In Auto Mode closes i)Overflow Sump make-Up Valve i) Red lamp for valve "Open" i) Open- Close- Auto
Sump 's water level is at low automatically when BA "Failed" (OS/BALP) selector switch (BALP)
overflow sump level reaches
high level only.
BA Overflow
Sump Make- Dwg. No.: 543-01-or or (OS)
16 ii)Through selector switch at ii)Through selector switch at ii) Green lamp for valve "Close" BALP
Up valve 01
[Total 1 No ] "Open" position "Close" position (BALP) (OS/BALP)
53
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CHAPTER IV
1 2 3 4 5 6 7 8 9
i) MCC module not disturbance i) Seal water pressure above low i) Seal water pressure "Low" (OS) i) Red LAMP for pump "Start" i) Start & Stop push OS
(OS) button (OS)
ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) ii) Green LAMP for pump
ii) Remote Selection "Stop" (OS)
iii) Start command initiated iii) Sump level above danger iii) Individual Drain sump pump failed. iii) Amber LAMP for pump
Drain Sump
low "Trip" (OS)
Pump
iv) Sump level above low iv) Stop push button not iv) red LAMP for sump level
(Mechanical
17 Dwg. No.: 543-01- pressed. 'High' (OS)
Exh. Area)
02 iv) Drain Sump Level 'High' (OS) v) Red LAMP for sump level
[Total 2 Nos.
v ) LPBS not pressed v ) LPBS not pressed 'Danger Low' (OS)
(1W+1S) ]
vi) No electrical trip Discharge pressure "Low" (OS) vi) Red LAMP for sump level
'Low' (OS)
vi) Drain Sump Level 'Danger Low' vii) Red Lamp for pump seal
(OS) Water Pressure "normal" (OS)
Open one at a time Remains open provided Ash Intake Valve Failed (OS) LAMP Display unit i) By pass facility for OS
forindicating the hopper each A/I valve through
number which is under OS.
operating in red colour.
in sequence per stream provided For Manual Mode: Hopper Plugged (OS)
For Manual Mode: i) Vacuum Breaker closed
i) Vacuum Breaker closed ii) Selected branch header valve
open
ii) Selected branch header valve iii) Vacuum pump running
open
iii) Vacuum pump running iv) Silo ash level below high
iv) Vacuum is established v) Buffer hopper ash level

below high
Ash Intake v) Silo ash level below high vi)Vacuum level not high.
Valve
18 Dwg. No.: 543-01-vi) Buffer hopper ash level below
[Total 144 high
02
Nos. ] vii) Open command initiated For Auto Mode:
For Auto Mode: i) Vacuum Breaker closed
54
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CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Vacuum Breaker closed ii)Vacuum Pump running
ii)Vacuum Pump running iii) System start command

initiated
iii) System start command iv) Silo ash level below high
initiated
iv) Silo ash level below high v) Buffer hopper ash level
below high
v) Buffer hopper ash level below vi)Vacuum level below preset
high value
i) Vacuum Breker Close i) Vacuum Breker Close Branch Header Valve Failed (OS) i) Red lamp for valve Open
(OS)
ii)) Vacuum pump

p p is operating
p g for ii)) Vacuum pump
p p is operating
p g ii)) Green lampp for valve Close
respective stream of hoppers for respective stream of hoppers (OS)
Branch
19 Header Valve Dwg. No.: 543-01- OS
[ 12 Nos. ] 02
i) Seal water pressure is adequate i) Seal water pressure is i) Seal water pressure "Low" (OS) i) Red LAMP for pump "Start" i) Start & Stop Push
adequate (OS) Buttons (OS)
ii) MCC module not disturbance ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) ii) Green LAMP for pump
"Stop" (OS)
Vacuum iii) Amber LAMP for pump
Pump iii) Remote Selection iii ) LPBS not pressed "Trip" (OS)
20 Dwg. No.: 543-01-iv) Start command initiated iv) Stop push button not iii) Individual pump failed (OS) iv) Red Lamp for pump seal OS
[Total 6 Nos.
02 pressed. Water Pressure "normal" (OS)
(4W+2S) ]
v) Vacuum breaker open v) No electrical trip
vi) Suction valve of standby
vacuum pump is closed
vii ) LPBS not pressed
55
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CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Corresponding vacuum pump i) Corresponding vacuum pump Vacuum Pump Suction Valve Failed i) Red lamp for valve Open Open/ Close selector
running running (OS) (OS) switch (OS)
ii) Green lamp for valve Close
Vacuum
(OS)
Pump
21 Dwg. No.: 543-01- OS
Suction
02
Valve
i) Start command initiated. i) MCC module not disturbance i) MCC module "Disturbance" (OS) i) Red LAMP for blower "Start" i) Start & Stop Push
(OS) Buttons (OS)
ESP & ii) MCC module not disturbance ii) Discharge pressure "low" ii) Green LAMP for blower
Buffer ii ) LPBS not pressed "Stop" (OS)
Hopper
pp iii)) Stopp push
p button not iii)) Amber LAMP for blower
22 Fluidizing Dwg. No.: 543-01-iii) Remote Selection pressed. "Trip" (OS) OS
Blower 02 iv ) LPBS not pressed iv) No electrical trip
[Total 2 Nos.
(1W+1S) ]
i) Corresponding air blower is i) Till start permissive are i) Fluidizing blower air heater i) Red Lamp for heater ''ON' i)Start & Stop Push
running available If temp. in header temperature "Low-" (OS) (OS) Buttons (OS)
crosses the preset value heater
ESP & ii) Heater temp. is below preset will be 'OFF' and restarts after ii) Green lamp for heater 'OFF'
Buffer value droppingdown temp. below (OS)
Hopper iii) Start command initiated. preset value. iii) Red lamp for temperature
Fluidizing Dwg. No.: 543-01- normal (OS)
23 OS
Blower Air 02
Heater iv) MCC module not disturbance ii) MCC module not disturbance iv) Red Lamp for outlet
[Total 2 Nos. pressure normal(OS)
(1W+1S) ] v) Outlet air pressure is above iii) MCC module available
preset value
vi) Remote Selection iv ) LPBS not pressed
vii ) LPBS not pressed v) No electrical trip
i) All start pernissive are i) Red lamp for Ash Intake i) Start-Stop PB for
i) Instrument air pr. Is adequate available. i) Hopper empty (OS) Valve Open (OS) each stream (OS)
56
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CHAPTER IV
1 2 3 4 5 6 7 8 9
ii) In case transport air line
pressure increases above preset
value running fluidzing valve to
airlock vessel will close and ii) Auto / Manual
ii) Start command is initiated reopens as soon as pressure ii) Red lamp for Branch Header Selection through
through start push button. drops down to preset value ii) Vacuum breaker open (OS) valve open (OS) monitor (OS)
iii) Green lamp for Branch iii) Silo selector switch
iii) Silo is selected iii) FA Hopper plugged (OS) Header valve closed (OS) common system (OS)
Fly Ash
24 Dwg. No.: 543-01- iii) As soon as "silo is selected OS
System
02 and "start" comand of respective
group is initiated operation of iv) Transport air line
ALV will start sequentially. stream selection valve
open/ close selection
iv) No load vacuum established switch(OS)
v) Vacuum pump is running &
corresponding
di vacuum breaker
b k
close
iv) Transport air line stream
selection valve is open.
i) Vacuum Pump is operating i) Vacuum Pump is operating Vacuum Breaker Failed (OS) i) Red Lamp for Breaker i) Open/Close Selector
ii) Vacuum level not very high ii) Vacuum level not very high Close (OS) switch (OS)
Vacuum
Breaker
25 (Dry system) Dwg. No.: 543-01- OWS
[Dry System 03
Total 4 Nos. ]
57
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CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Bag filter differential pressure high i)Start & Stop Push
i) Plant IA pressure is adequate i) Pulse valves remain open (OS) i) Red Lamp for timer ON (OS) Buttons (OS)
sequentially for a preset time
Bag Filter Note: ii) Plant IA pressure is adequate

Pulse Timer Purging system will operate
26 for buffer Dwg. No.: 543-01-sequentially OS
hopper 03 within preset time.If differential
[Total 4 Nos. pressure
is high, purging sequence time

will be
50% redused of preset time
i) The compressor starts,

provided i) The compressor continue to i) MCC module "Disturbance" (OS) i) Red LAMP for TAC i) Start & Stop
Pressure at air receiver is below operate till all start permissive ii) Air Receiver pressure "Low" (OS) "Start" (OS) push button (OS)
preset value. are available. iii) Cooling water pressure "Low" (OS) ii) Green LAMP for TAC
ii) Discharge temp. normal ii) Compressor can be started iv) Return water Temp. "High" (OS) "Stop" (OS)
iii) Cooling water pressure above
low through push button & v) Diff. Pressure across iii) Amber LAMP for TAC
Transport Air
iv) Return line Temp. normal continue to run between load & suction filter "High" (OS) "Trip" (OS)
Compressor
27 (TAC) Dwg. No.: 543-01-v) Diff. Pressure across unload condition through vi) Individual TAC Trip (OS) iv) Cooling water pressure OS
[Total 6 Nos. 03 suction filter normal pressure switch. vii) Bearing temp. High (OS) "Low" (OS)
(4W+2S) ]
iii) Stop push button not v) Return water Temp. " High"
vi) MCC module not disturbance pressed. viii) Winding temp. High (OS) (OS)
vii) Remote Selection iv ) LPBS not pressed vi) Diff. Pressure across
viii) Start command initiated v) No electrical trip suction filter "High" (OS)
ix) No electrical trip vii) Air Receiver pressure
58
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CHAPTER IV
1 2 3 4 5 6 7 8 9
x) Bearing temp. not too high "Low" (OS)
xi) Winding temp. not too high viii) Bearing temp. High (OS)
xii ) LPBS not pressed ix) Winding temp. High (OS)
Remains open for preset time or
upto ALV level high whichever i) Red Lamp for valve "Open" i) Open/Close Selector
is earlier Air Lock Ash Intake Valve Failed (OS) (OS) switch (OS)
i) ALV cycle start command is ii) Green Lamp for valve
Air lock inlet initiated i) stop command not pressed "Close" (OS)
valve ii) Respective buffer hopper iii) Red lamp for ALV level
28 Dwg. No.: 543-01-selected ii) ALV not deselected high (OS) OS
[Total 8 Nos.
03
] iii) ESP Fluidizing Blower
running iii) Silo level not high
iv) ALV ash level below high
v) Silo level not high
i) Red Lamp for valve "Open" i) Open/Close Selector

i) Equilizer valve fully closed. Remains open for preset time Air Lock Discharge Valve Failed (OS) (OS) switch (OS)
i) Conveying air pressure not ii) Green Lamp for valve
ii) Air lock inlet valve is fully high "Close" (OS)
Air lock closed. ii) ALV Fluidizing valve open
discharge iii) TACs are running
Dwg. No.: 543-01-iv) TAC discharge pressure
29 valve OS
03 above Low
[Total 8 Nos.
] v) Respective ALV iselected
vi) Conveying air pressure not
high
vii) ALV Fluidizing valve open
i) Red Lamp for valve "Open" i) Open/Close Selector

i) Discharge valve is close. Remains open Air Lock Vent Valve Failed (OS) (OS) switch (OS)
Air lock vent
ii) Green Lamp for valve
valve Dwg. No.: 543-01-
30 ii) Fluidzing valve is close. for preset time "Close" (OS) OS
[Total 8 Nos. 03
iii) Ash inlet valve close.
]
59
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MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
Remains connected for preset i) Red Lamp for valve "Open" i) Open/Close Selector
i) Discharge valve is close. time Air Lock Fluidising Valve Failed (OS) (OS) switch (OS)
Air lock
ii) Equilizer valve fully closed.
fluidzing
Dwg. No.: 543-01-iii) Air lock inlet valve is fully ii) Green Lamp for valve
31 valve OS
03 closed. "Close" (OS)
[Total 8 Nos.
iv) Conveying air pressure not
]
high
i) Red Lamp for valve open

Trans port Air Line Valve Failed (OS) (OS)
ii) Green Lamp for valve close
i) Transport line selected (OS)
Transport Air
ii) Silo selected.
Line Valve Dwg. No.: 543-01-
32 OS
[VTL-1 to 3 03
]
i) The compressor starts, i) The compressor continue to i) Red LAMP for IAC "Start" i) Start & Stop push
provided operate till all start permissive i) MCC module "Disturbance" (OS) (OS) button (OS)
are available. In manual mode ii)Air Receiver Pressure 'Low' ii) Green LAMP for IAC "Stop"
Pressure at air receiver is below compressor can be started (OS/ANN) (OS) ii)Auto-Manual
through push button &continue iii) Amber LAMP for IAC iii) IAC#1&2 selctor
preset value. to run between load &unload iii) Cooling water pressure "Low" (OS) "Trip" (OS) switch (OS)
condition through pressure iv) Return water Temperature " High" iv) Red lamp for Air Receiver
ii) Discharge temp. normal switch. In auto mode (OS) Pressure 'Low' (OS)
compressor will start v) Red lamp for Cooling water
iii) Lub. oil pressure above low automatically below preset v) IAC "Failed" pressure "normal" (OS)
iv) Cooling water pressure above pressure and will continue to vi) Red lamp forReturn water
low run till pressure reaches above vi) Lub oil pressure Low (OS) temperature "High" (OS)
v) Return water temperature preset pressure
below high vii) Diff. Pressure across suction
vi) Diff. Pressure across filter High (OS)
suction filter normal
I t t
60
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
Instrument
Air
vii) MCC module not disturbance
Compressor
Dwg. No.: 543-01-viii) Remote Selection
33 (In Plant OS
03
Area)
[Total 2 Nos. ii) Compressure will continue to
(1W+1S) ] run on full capacity and after
reaching the unloading point
Compressor will automatically
unload with the help of
ix) Start command initiated unloading pressure switch.
iii) During starting lubricating
oil pressure is bypassed for
preset time delay. The
compressor will trip if lub oil
pressure is not normal within
v ) LPBS not pressed preset time.
Note:
In auto mode if one compressor
trips the standby compressor
starts after preset time if other iv) Stop push button not
start permissives are available pressed.
v ) LPBS not pressed
i) Monitor & indications on Dryer local i) Red lamp IAC dryer
i) Respective IAC is running i) Respective IAC is running panel operating (OS)
Instrument ii) Green LAMP for IAC Drier
Air Dryer ii) MCC module not disturbance ii) MCC module not disturbance ii) Instrument air dryer "Failed" "Stop" (OS)
(In Plant Dwg. No.: 543-01- iii) Amber LAMP for IAC Drier
34 OS
Area) 03 iii) MCC module not disturbance "Trip" (OS)
[Total 2 Nos.
(1W+1S) ]
61
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MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
Conveying
Line Control Dwg. No.: 543-01-iii) start command initiated i) Stop command not actuated
35
Valve [4 03
Nos.]
Fluidizing
Line Control Dwg. No.: 543-01-iii) start command initiated i) Stop command not actuated
36
Valve [4 Nos. 03
]
i) Start command initiated. i) MCC module not disturbance i) MCC module "Disturbance" (OS) i) Red LAMP for blower i) Start & Stop
ii) MCC module not disturbance ii ) LPBS not pressed ii) Discharge pressure "low" "Start" (OS/ SCP) Push Buttons (SCP)
Silo Aeration
iii) Stop push button not
Blower
37 Dwg. No.: 543-01-iii) Remote Selection pressed. iii) Blower failed ii) Green LAMP for blower SCP
[Total 3 Nos.
04 iv) No electrical trip
(2W+1S) ]
ii ) LPBS not pressed "Stop" (OS/SCP)
iii) Amber LAMP for blower
"Trip" (OS)
i) Corresponding air blower i) Till start permissive i) Red lamp heater i) On & Off
is running are available If temp. in header "ON" (OS/SCP) push button (SCP)
crosses the preset value heater
ii) Heater temp. is below will ii) Green lamp heater
Sil A i
62
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
Silo Aeration be 'OFF' and restarts after
Heater [Total
38 Dwg. No.: 543-01-preset value dropping OFF' (OS/SCP) SCP
3 Nos.
04
(2W+1S) ] iii) Start command initiated. down temp. below preset value. iii) Amber LAMP for heater
iv) MCC module not disturbance ii) MCC module not disturbance "Trip" (OS)
v) Remote Selection iii) No electrical trip
i) MCC module not disturbance i) Seal water pressure above low i) Seal water pressure "Low" (OS) i) Red LAMP for pump i) Start & Stop
ii) Remote Selection ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) "Start" (OS/SCP) push button (SCP)
Drain Sump iii) Start command initiated iii ) LPBS not pressed iii) Drain sump water level ii) Green LAMP for pump
Pump iv) Drain sump water level above iv) Stop push button not
(Ash Silo
39 Dwg. No.: 543-01-low pressed. "Danger Low" (OS) "Stop" (OS/SCP) SCP
Area)
04 v ) LPBS not pressed v) Drain sump water level iv) Drain sump pump iii) Amber LAMP for pump
[Total 2 Nos.
(1W+1S) ] above danger low "Failed" "Trip" (OS)
vi) No electrical trip iv) Red LAMP for drain sump
level "Danger Low" (OS/SCP)
v)Red lamp for seal water
pressure
normal (OS)
i)MCC module not disturbance i) MCC module not disturbance i) Discharge Water Pressure "Low" i) Red LAMP for pump i) Start & Stop
ii) Remote Selection ii ) LPBS not pressed for common header (OS) "Start" (OS/SCP) push button (SCP)
iii) Stop push button not
iii) Start command initiated pressed. ii) MCC module "Disturbance" (OS) ii) Green LAMP for pump
iv) Silo area Ash water sump iv) Silo Ash water sump iii) Dust conditioner water pump "Stop" (OS/SCP)
level above low level above danger low "Failed" iii) Amber LAMP for pump
Dust
Conditioner v) Atleast one isolation valve v) Atleast one isolation valve iv) Ash water sump level "High" (OS) "Trip" (OS)
63
REV-R0
MW
CHAPTER IV
1 2
Conditioner 3 4 5 6 7 8 9
40 Water Pump Dwg. No.: 543-01- iv) Red LAMP for pump SCP
[Total 2 Nos. 04 for dust conditioner open for dust conditioner open v) Ash water sump level "Low" (OS) discharge
(1W+1S) ] vi) No electrical trip Water Pressure "Normal"
vi ) LPBS not pressed (OS/SCP)
v) Red LAMP for Ash water
"Danger Low" (OS/ANN) sump
level "Danger Low" (OS/SCP)
vi) Red LAMP for Ash water
sump
level "High" (OS/SCP)
vii) Red LAMP for Ash water
sump
level "Low" (OS/SCP)
Ash Water Sump Makeup Valve failed
i)Through
) g selector switch. i)Through
) g selector switch. ( )
(OS) i)) Red lampp for valve i)) Open-
p Close
when sump level reaches low when sump level reaches low
Ash Water
level level "Open" (OS/SCP) selector switch (SCP)
Sump
Dwg. No.:543-01- or or ii) Green lamp for valve
41 Make- Up SCP
04 through selector switch in open through selector switch in open ii) Auto Manual
valve
position position "Close" (OS/SCP) selector switch (SCP)
[Total 1 No]
i) "STOP" command is not

i) "START" command initiated i) MCC module "Disturbance" (OS) i) Red Lamp RF i) Start and stop
Rotary
Feeder above
is initiated ii) MCC module not disturbance operating (SULP) push button (SULP)
Rotary
42 Dwg. No.: 543-01-ii) MCC module not disturbance iii ) LPBS not pressed ii) Green Lamp RF SULP
Unloader
04 iii) Remote Selection iv) No electrical trip stopped (SULP)
[for each Silo
unit] iv ) LPBS not pressed v) Paddle feeder ON iii) Amber Lamp for Trip (os)
v) Paddle feeder ON
64
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) "STOP" command is not
i) "START" command initiated i) MCC module "Disturbance" (OS) i) Red lamp for RF i) Start and stop
Rotary is initiated ii) MCC module not disturbance operating (SULP) push button (SULP)
Feeder above ii) MCC module not disturbance iii ) LPBS not pressed ii) Green lamp for not in
Silo iii) Remote Selection iv) No electrical trip operation (SULCP)
43 Telescopic Dwg. No.: 543-01- v) Tellescopic spout full SULP
chute 04 iv ) LPBS not pressed lowered. iii) Amber Lamp for Trip (os)
[for each Silo
unit] v) Tellescopic spout full lowered.
i) Respective 'RF'
RF is operating i)Rotary feeder is operating KGV Above Rotary Feeder Failed (OS) i) Red lamp for valve open i) Open and Close
KGV above ii) Close command is not
Rotary ii) Open command is initiated. initiated. (SULP) push button (SULP)
Feeder and iii) Dust conditioner is running ii) Green lamp for valve close
44 Rotary Dwg. No.: 543-01-iii) Dust conditioner is running (SULP) SULP
Unloader 04
[Total 1 No
for each silo]
i) Respective 'RF' is operating i)Rotary feeder is operating KGV Above Telescopic Spout Failed i) Red lamp for valve open i) Open and Close
KGV above ii) Close command is not
Rotary ii) Open command is initiated. initiated. (OS) (SULP) push button (SULP)
Feeder and
Silo iii) Scavanger fan is running. iii) Scavanger fan is running. ii) Green lamp for valve close
45 Dwg. No.: 543-01- SULP
Telescopic iv) Ash level of close tanker is not
04
chute [Total high. iv) High level of close tanker (SULP)
1 No for each
silo] is not achieves.
65
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Forward and reverse are

i) Down (Forward) or Up depends on command till
(Reverse) extreme L/s is actuated. i) MCC module "Disturbance" (OS) i) Red Lamp - chute operating i) Forward and Reverse
command is initiated. in forward direction (SULP) push button (SULP)
Silo
Telescopic ii) MCC module not disturbance ii) Green lamp - chute
46 chute [Total Dwg. No.: 543-01- SULP
1 No for each 04
unit] iii) Remote Selection ii) MCC module not disturbance stopped (SULP)
iv) Scavenger fan running iii ) LPBS not pressed

Note: iv) No electrical trip
It tanker level is high, chute
operated in upward direction
i) MCC module not disturbance i) MCC module not disturbance i) MCC module "Disturbance" (OS) i) Red Lamp for fan Start-Stop P.B. (SULP)
Scavanger iii) Remote Selection iii ) LPBS not pressed "Start" (SULP)
Fan
47 Dwg. No.: 543-01-iii) Start initiated iii) stop not pressed ii) Green Lamp for fan SULP
[Total 1 No
04 iv) Lower limit switch of iv) No electrical trip
for each unit]
telescopic spout actuated "Stop" (SULP)
iii ) LPBS not pressed
Red Lamp for timer "ON"

i) Silo IA pressure is adequate i) Silo IA pressure is adequate i) Bag filter differential pressure high. (OS/SCP) i) Start and stop
Vent Filter (OS) push button (SCP)
Pulse Timer Note:
and IA inlet Purging system will operate
48 valve for Dwg. No.: 543-01-sequentially within preset time. If SCP
silos 04 differential pressure is high,
[Total 1 No purging sequence time will be
for each silo] 50% redused of preset time
66
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Corrsponding silo selected i) Corrsponding silo selected Ash Inlet Valve to Silo Failed (OS/) i) Red lamp for i) Close-open selector
ii) Corresponding ash inlet valve ii) Corresponding ash inlet valve open (OS/SCP) switch (SCP)
Ash Inlet
Valve to Silo of other silo close valve of other silo close ii) Green lamp for valve
49 Dwg. No.: 543-01- SCP
[Total 4 Nos. close (OS/SCP)
04
for each silo]
i) MCC module not disturbance i) MCC module not disturbance i) MCC disturbance (OS) i) Red Lamp for fan i) Start and stop
iii) Remote Selection iii ) LPBS not pressed ii) Rotary unloader failed (Gr. Ann) "Start" (SULP) push button (SULP)
Rotary iii) Start command initiated iii) Stop command not initiated ii) Green Lamp for fan
50 Unloader Dwg. No.: 543-01- SULP
iv) Inlet water pressure normal iv) Inlet water pressure normal "Stop" (SULP)
[ 2 nos.] 04
iii ) LPBS not pressed v) No electrical trip
i) Red lamp for valve open

i) Start command initiated i) Stop command not initiated (SULP) i) Close-open selector
Water line
valve to switch (SULP)
51 rotary Dwg. No.: 543-01- iii) Red lamp for inlet pressure SULP
unloader [ 2 04 normal (SULP)
nos.]
67
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) GEHo Pump ON Red Lamp Start / Stop P.B. Switch
i.) VFD Ready to Run i.) VFD Ready to Run i) VFD Trip (OS) (OS) (OS)
ii) GEHO Pump OFF Green
ii). Silo Fluidizing Blower ON ii). LPBS not pressed ii) GEHO Pump Failed (OS) Lamp (OS)
iii) Mixure Tank Level Danger Low iii) GEHO Pump Trip Amber
iii) Agitator ON iii) Agitator ON (OS) Lamp (OS)
iv) Mixure Tank Level above iv) Mixure Tank Level Low
iv) Mixure Tank Level normal Low iv) Density Low (OS) Red Lamp (OS)
HCSD Pump iv) Mixure Tank Level High
52 Dwg. No.: 550-01-
[ 3 nos.] v) IAC Pressure Normal v) IAC Pressure Normal iv) Density High (OS) Red Lamp (OS)
01
vi) GEHO PLC Ready vi) GEHO PLC ON v) Density Low Red Lamp (OS)
iv) Mixure Tank Level Danger
vii).Dust Conditioner Healthy vii) No Electric Trip Low Red Lamp (OS)
viii) Silo Level not Low viii) Silo Level not Low v) Density High Red Lamp
ix). Rotary Feeder Healthy ix) Manual suction Valve Open
x) Mixing Tank Density more x) Mixing Tank Density more
than preset value than preset value
xi) Remote Selection
xii) Manual suction Valve Open OS
Start / Stop P.B. Switch
i) Start Command Initiated i) Stop Command not Initiated i) Mixure Tank Level Low (OS) Start Red Lamp (OS) (OS)
Agitator ii) MCC Not disturbance ii) MCC Not disturbance ii) Agitator Failed (OS) Stop Green Lamp
53 (HCSD) Dwg. No.: 550-01-iii) Remote Selection iii) LPBS not pressed iii) Trip Amber Lamp (OS)
[ 3 nos.] 01 iv) Tank Level normal iv) Tank Level not Low Tank Level Low Red lamp (OS)
v) Tank Level High Red Lamp
iii) LPBS not pressed v) No Electric Trip (OS) OS
i) HCSD water sump level above i) MCC module not disturbance i) MCC module "Disturbance" (OS)
i) Red LAMP for pump "Start" i) Start & Stop Push
low
(OS) button (OS)
iii) Start command initiated iii) Ash Water Sump level iii) HCSD LP water pump "Failed" iii) Amber LAMP for pump
above danger level (Gr.ANN) "Trip" (OS)
HCSD LP iv) MCC module available iv) HCSD water sump level "High" iv) Red LAMP for pump
54 Pump [ Dwg. No.: 550-01- (OS) discharge Water Pressure OS
2 nos.] 01 iv) LPBS not pressed "Normal" (OS)
v) No electrical trip v) HCSD water sump level "Low" (OS) v) Red LAMP for Ash water
v) Remote Selection sump level "Danger Low" (OS)
vi) HCSD water sump level "Danger vi) Red LAMP for Ash water
Low" (OS/ANN) sump level "High" (OS)
vii) Individual pump failed (OS) vii) Red LAMP for Ash water
iv) LPBS not pressed sump level "Low" (OS)
68
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
69
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) MCC module not disturbance i) Seal water pressure above low i) Seal water pressure "Low" (OS) i) Red LAMP for pump i) Start & Stop
ii) Remote Selection ii) MCC module not disturbance ii) MCC module "Disturbance" (OS) "Start" (OS) push button (OS)
iii) Start command initiated iii ) LPBS not pressed iii) Drain sump water level ii) Green LAMP for pump
iv) Drain sump water level above iv) Stop push button not
HCSD Drian
low pressed. "Danger Low" (OS) "Stop" (OS)
55 Pump [ 2 Dwg. No.: 550-01- OS
iii ) LPBS not pressed v) Drain sump water level vi) Drain sump pump iii) Amber LAMP for pump
nos.] 01
above danger low "Failed" (Gr. ANN) "Trip" (OS)
vi) No electrical trip iv) Red LAMP for drain sump
level "Danger Low" (OS)
Red lamp for seal water
pressure
normal (OS)
i) Start
S commandd initiated.
i ii d i) MCC module
d l not disturbance
di b i) MCC module
d l "Disturbance"
"Di b " (OS) i) Red
R d LAMP ffor bl
blower "S
"Start"" i) Start
S & Stop
S P
Pushh
(OS) Buttons (OS)
HCSD
ii) MCC module not disturbance ii) Green LAMP for blower
Blower [
56 Dwg. No.: 543-01- ii ) LPBS not pressed "Stop" (OS) OS
2 nos. per
04 iii) Stop push button not iii) Amber LAMP for blower
unit]
iii) Remote Selection pressed. "Trip" (OS)
ii ) LPBS not pressed iv) No electrical trip
i) Corresponding air blower is i) Till start permissive are i) Fluidizing blower air heater i) Red Lamp for heater ''ON' i)Start & Stop Push
running available If temp. in header temperature "Low-" (OS) (OS) Buttons (OS)
ii) Heater temp. is below presetcrosses the preset value heater ii) Green lamp for heater 'OFF'
value will be 'OFF' and restarts after (OS)
HCSD iii) Start command initiated. droppingdown temp. below iii) Red lamp for temperature
Blower preset value. normal (OS)
57 Dwg. No.: 543-01- OS
Heater [ 2 iv) MCC module not disturbance ii) MCC module not disturbance iv) Red Lamp for outlet
04
nos. per unit] pressure normal(OS)
v) Outlet air pressure is above iii) MCC module available
preset value
vi) Remote Selection iv ) LPBS not pressed
iv ) LPBS not pressed v) No electrical trip
70
REV-R0
MW
CHAPTER IV
1 2 3 4 5 6 7 8 9
i) Red Lamp for valve open
Coarse Ash
i) Water Line Pressure not low (OS)
Hopper Ash
ii) Water line valve Open
58 Intake Valve Dwg. No.: 543-01- OS
Water line valve of other hoppers
[12 nos. per 01
will not open if any two water
unit]
line valve is open.
Ash Water Sump Makeup Valve failed
i)Through selector switch. i)Through selector switch. (OS) i) Red lamp for valve i) Open- Close
Ash Water when sump level reaches low when sump level reaches low OS
59 Sump Dwg. No.: 543-01-level level "Open" (OS) selector switch (OS)
Makeup 05 or or ii) Green lamp for valve
Valve [ 2 through selector switch in open through selector switch in open ii) Auto Manual
Nos.] position position "Close" (OS) selector switch (OS)
i)) Red Lampp for valve open
p
C
Coarse Ash
Ah
i) Water Line Pressure not low (OS)
Jet Pump Ash
ii) Water line valve Open
60 Intake Valve Dwg. No.: 543-01- OS
Water line valve of other hoppers
[Total 3 Nos. 01
will not open if any two water
per unit]
line valve is open.
71

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This document is, unless otherwise agreed in writing, the property of TECPRO ASHTECH LIMITED, and shall not be

1 Approval Documents DCPL Comments PG SM SM 2.11.09

0 Approval Documents Initial Submission PG SM SM 26.10.09

PREPARED CHECKED APPROVED

KHAPERKHEDA THERMAL POWER STATION (1 X 500 MW)

MAHARASTRA STATE POWER GENERATION CO. LTD.

DEVELOPMENT CONSULTANT PVT. LTD.,

BGR ENERGY SYSTEMS LIMITED,

TECPRO ASHTECH LTD.

COMP FILE : COVER SHEET

1. Bottom Ash & Coarse Ash P&ID 543-01-01, R-06

2. Fly Ash Evacuation System P&ID 543-01-02, R-05

3. Fly Ash Conveying System P&ID 543-01-03, R-05

4. Fly Ash Silo P&ID 543-01-04, R-05

6. PLC Configuration Drawing 543-C&I-04,R-03

7. HCSD System P%ID 543-01-01 R-04

The Ash Handling Plant consists of the following primary

Bottom Ash System and Bottom Ash Overflow System.

1.1 The control facility of the entire system is a PLC based

2.0 The normal ash removal requirement is as below.

Bottom ash generated in eight (08) hours will be cleared in

Under each V-Section of B.A. Hopper, there shall be two (2)

Capacity of Coarse ash tank will be adequate enough to store

Coarse ash generated in eight (08) hours will be cleared in

Each stream shall have a capacity of minimum 60 TPH.

Each Buffer Hopper will have a capacity of 20 MT for storage

Ash in pressure conveying will be conveyed through four (4)

Fly ash generated in eight (08) hours will be cleared in about 5

2.1 The sequence of operation to be followed under normal ash

Ash water pumps are to be operated ensuring that at least one

3.0 CONTROL FACILITIES

The Control System is described in the following Chapters

The detail Write up and Control Philosophy of individual

The details of PLC System, Various panels and Remote I/O

The Protection, Interlocks, Annunciation and Indication of the

CONTROL PHILOSOPHY AND SEQUENCE OF OPERATION

1.0 The respective sequence of operation , control philosophy and

2.0 BOTTOM ASH AND COARSE ASH CLEANING SYSTEM :

2.1 The Bottom ash is stored in water impounded B.A. hoppers.

The evacuation of Bottom ash is carried out in sequential

2.4 There are four individual ash disposal lines corresponding to

2.5 It is to be noted that for each section of hopper, there is one

Close Feed Gate

Under the normal mode of operation the closing sequence is

Grinder will automatically run in reverse direction. This reverse

3.0 BOTTOM ASH MAKE-UP, COOLING WATER AND B.A

3.1 The operation of bottom ash system have continuous

3.2 The B.A make up / Refractory cooling water system and

4.0 BOTTOM ASH OVERFLOW TRANSFER PUMP

4.3 The selected Bottom Ash Overflow Transfer Pump is now

4.5 There is a make up line with remote operated valve from

tank, which can be operated through an auto/ manual selector

5.0 TUBE SETTLER AND SLUDGE PUMPING SYSTEM

6.0 COARSE ASH DISPOSAL TO COARSE ASH TANK

6.1 Coarse ash are collected from Duct Hopper, Economiser

6.2 Each coarse ash hopper has an ash discharge pneumatic

is established the ash discharge valve of the hoppers are

7.0 COARSE ASH JET PUMP SYSTEM

8.0 ASH SLURRY DISPOSAL TO DISPOSAL AREA