HIGH CONCENTRATION SLURRY DISPOSAL OF ASH

AT KHAPERKHEDA T.P.S.
AN OVERVIEW OF KHAPERKHEDA TPS ASH HANDLING PLANT
Khaperkheda TPS project presently comprises of four units each of 210 MW. The whole
ash handling system may be divided into two broad categories dry fly ash conventional system
and high concentration slurry discharge system. Conventional system is installed for unit one &
two, high concentration slurry disposal system is installed for unit 3 & 4.
M/s Mahindra Ash Tech Ltd has provided HCSD systems. The fly ash is collected in ESP
hoppers, air heater hoppers, Economiser hopper and stack hoppers, which is carried away to fly
ash silos by pressure conveying system. From ash storage silo the ash is taken to the slurry-
mixing tank through rotary feeder and dust conditioner. From ash slurry mixing tank ash is
transported to ash disposal yard by GEHO make reciprocating type pump in high concentrated
form of slurry.
Quantity of water requirement of the high-density slurry concentration system is very
nominal. Therefore there is no need of ash water recovery system, which regenerate clear
water from ash pond and returns back it to ash water tank normally located in plant area of
other plant with ash water recovery system.
The central control panel located in the control room of ash slurry pump house complex
has been installed to provide remote operation of ash handling system and all other accessories
/ equipments shall be controlled from this panel. Local panels installed near fine ash silo platform
do unloading of fly ash from fine ash silo.

I: PLANT DESCRIPTION
Entire ash handling pant can be divided into various subsystems for easy understanding
and further reference in the following way.
A) Fly ash removal system
B) Silo fluidizing system
C) Fly ash silo unloading system
D) Ash water system
E) Instrument air system

A: FLY ASH REMOVAL SYSTEM

Fly ash removal system is of pneumatic pressure conveying type. There are two numbers
of fly ash compressors connected to two numbers of common air receivers. Each air receiver is
dedicated to two pass of one unit. The motive power required carry away the ash particle from
hoppers to silo is supplied through this compressed air.
Each unit consist of fifty seven numbers of fly ash hoppers and all the ash is removed
through six numbers of streams.
The compressed conveying air coming from air receiver is divided into two streams at
pressure control station. One stream is for airlock vessels for ash fluidisation as well as discharge,
and other is for ash transport pipeline. The pressure controller decides the pressure and
quantity of airflow for these streams. From each row of hoppers ash is extracted to common
ash transport header via airlock vessels.
All the conveying air and ash transport pipelines are made from mild steel. There are six
main conveying ash pipelines, and each ash transport pipeline is 125 NB MS ERW heavy grade pipes.

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 Normally the fly ash is automatically and sequentially extracted from fly ash hoppers.
This operation of each unit is remote controlled from ash handling main control panel located in
electrical cum control room at ash slurry pump house complex. The fly ash is removed at the
rate of 80 T/hr in normal operating condition.
The six numbers of ash transport streams discharge their contents directly to fly ash silos. The
air of air-ash mixture comes out from fly ash silo to atmosphere through bag filter and vent fan.

B: SILO FLUIDIZING SYSTEM

Fly ash silo fluidizing system has been envisaged to supply hot air to fly ash silos during
ash unloading operation. There are two numbers of blowers and two numbers of heaters for all
the silos. One is in service and the other one is standby.

C: FLY ASH SILO UNLOADING SYSTEM

Four numbers of outlets have been provided for both fly ash silos. One outlet of each is
connected to one dedicated slurry mixing tank (1&3) and one outlet of each silo is connected
to a common slurry mixing tank (2). Normally silo 1& silo 2 controls the discharging ash to mixing
tank 1 & 3 respectively through rotary feeder and dust conditioner. If there is any problem in
either one of the tank no 1&3 tank no 2 may be charged as a standby of tank no 1 & 3. Total
three numbers slurry pipelines are running from the slurry pumps. The slurry lines are 125 NB MS
seamless 9.5 thick and fully welded. The total length of slurry pipeline is approximately 8.0 Kms.

D: ASH WATER SYSTEM

Three numbers of ash water pumps are provided to supply water from ash water sump
to all the mixing tanks and the dust conditioner located at silo platform. The supply of pressurized
water is also required to flush the slurry pipeline. The ash water pump supplies the water to
bottom ash system.

E: INSTRUMENT AIR SYSTEM

Pressurized dry clean air is required to operate all the cylinder operated remote control
valves, pulse air supply to bag filter of fly ash silos and the GEHO pump. Instrument air
compressors supply this air. There are three numbers of compressors. One compressor per unit
and the remaining one standby. The fly ash hopper air operated valves, water and slurry line
valves etc, are connected with the instrument air system at a pressure of 6 bar (approximately).

II: CONTROL & OPERATION PHILOSOPHY OF HCSD SYSTEM

THE PLANT
The HCSD system control is a semi-intelligent process facility where dry ash is mixed
with water in a control manner to develop the high concentrated slurry. The ash slurry developed
will be pumped through reciprocating pumps (GEHO PUMPS) for long distance conveying in a
manner where the slurry behavior is controlled within a stipulated range. The fly ash is stored in
two silos from both the units. Each silo has two independent discharge arrangements for ash
flow to the HCSD system. There are three HCSD slurry mixing and pump streams. Therefore,
two of these streams receive ash from any one silo while the middle stream can receive ash
from any one silo. Nevertheless, only one stream of ash discharge will be initiated at a time for
the middle HCSD system. Operation of the HCSD pumping facility can be started manually or
automatically in a controlled pumping and sequencing manner initiated by data base in the
control system or the high level switches of ash silo.

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Basic control facility
1. For the middle stream of HCSD system, there will be selection facility for silo-1 or silo-2.
however, such selection is not applicable for other two stream of HCSD pumping.
2. The initiation of any HCSD pumping can be sequential either from a time based auto-
sequencing control facility or from manual console.

The requirement of these two controls will be as below:

• The ash slurry behavior and its nature for settlement during intermission of two pumping
through a pipe line will initiate the automatic starting of HCSD

• Pumping facility of any particular pipeline: This is a complete auto operation and operates
with ash discharge from the fly ash silo and the complete pump operation includes the intermediate
equipment. In case the pipeline is purged with clean water such automatic starting is not
required and the particular stream/ pipeline will be put under “Stand by” mode. Under such
situation there will be no auto initiation of pumping. Under such condition the system will be
started as below.

During manual selection of starting of any one stream of HCSD pumping is to be initiated
when the ash level of the silos are above the minimum level. The ash level in the silo if becomes
high then the HCSD pumping stream will be automatically operated/ initiated in the same
manner as explained under “auto” mode. If the selection is kept under “manual” mode, there
shall be alarm to initiate the pump starting.
The primary consideration for HCSD system is to monitor the proper control on slurry
density during the operation. Solid flow rate from fly ash silo is continuously measured.

The water flow to the dust conditioner is measured.

• The density of slurry is measured in the mixing tank.
• The flow of slurry is measured before suction of the pump.
• The pressure at the slurry pump discharge is measured at two points through two
pressure transmitters. The second pressure point designated as SP2 is at certain distance from
the discharge of the pump.

There are some other measurements for secondary control and feedback. However, we
are concerned to only the relevant parameters, which are used in direct and monitoring system.
During initiation of the plant the availability of ash, water, and instrument air is ensured.
The drive system for rotary feeders and slurry pump is checked and ensured. The operation is
initiated in the following sequence when starting with an empty mixing tank and pipeline.
• 1. The control system determines that the mixing tank is empty. The slurry density and
level in the mixing tank are brought up to the desired values by an automatic sequence. When
the level and density are correct the rest of the pumping and mixing plant is started as per
normal automatic start-up.
• During the intermittent operation of slurry disposal with the mixing tank filled up with
slurry, the initiation of every pumping operation will be carried out as per following steps.
• The slurry suction valve is opened and slurry pump is operated. The slurry pump will
operate initially with slow speed and depending upon the pressure built-up the speed will be
increased to provide the full flow.
• Depending upon the slurry pump speed at any operating point the rotary feeder speed

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will be controlled and fly ash will be allowed in the desired quantity into the dust conditioner.
• Depending upon the solid flow rate, the water will be allowed into dust conditioner and
mixing tank to maintain the density within the stipulated range.
• With the above steps the ash input and water flow to the mixing tank will duly balanced
and the level is maintained near the full operating level under normal condition.
• As the slurry pump speed is increased to reach the full flow the operating speed of
rotary feeder will also be increased to effect rated ash flow. The water control valve will also
be increased to effect the rated ash flow. The water control valve will allow the stipulated
water as described below :

A. During the slurry pumping operation after initiation of the primary control facility based
on which the output signals will be given to all equipments/ controls.
The operation is indicated in the following steps.
• The speed of the rotary feeder will be monitored to ensure the desired solid flow rate
(SF1) which is derived from the slurry flow rate (SF2) continuously during operation the actual
mass flow requirement for ash is computed from SF2 & DS1 (density of slurry). Once the desired
ash flow rate is attained, the water quantity is around 30% of the total mass flow of slurry. This
is to be finally adjusted during system operation. Some of the total water requirement will be
passed through the dust conditioner so that proper mixing of ash and water is achieved prior to
discharge into the mixing tank.
• The balance water requirement computed from the density requirement is passed through
the other control valve for make-up water flow to mixing tank.
• Therefore, the correlation of parameters SF1, SF2, DS1 & WF1 is utilized in the above
manner to control the ash flow and water flow to match the total slurry flow at any point of
pump operation.
• It is to be noted that the requirement of slurry pumping during different conditions of
ash flow or depending upon the gap between two intermittent operation of slurry pumping, may
call for nominal value of pressures SP1 & SP2 described above.
• With the controlling and monitoring facility the primary operating speed of slurry pump
and rotary feeder is monitored.

There are many other secondary controls and check points which are described under
below.
The level of the slurry tank is to be maintained within a close range to ensure that the
blades of the mixer are always immersed into slurry. In case of decrease in the level both ash
flow and water flow is nominally increased to allow more inflow to the tank. On the other hand
the ash flow and water flow is decreased in case of increasing trend of level in the tank.
The slurry pump operating pressure is monitoring continuously through SP1 & SP2. In
case of increasing trend of the pressure, the slurry pump speed is reduced to remove the
blocking pressure. The operating speed of the slurry pump is restored to provide the design flow
rate.
The Ph of slurry is to be maintained within the specified stipulation. Accordingly, the Ph
meter has been given. In case of the Ph value is reduced from the stipulated specification,
necessary dozing facility may have to be incorporated.
In case of tripping/ stoppage of mixing tank-rotating blade the speed switch will trip the
system.

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III: OTHER SYSTEMS INVOLVED ARE AS PER THE FOLLOWING
i) FLY ASH CLEANING
a) Overall checking before starting the fly ash system :
• All the valves in the instrument airline up to the air receiver are in order.
• Air dryer in “Auto” mode & no annunciation present on the local control panel.
• Cooling water supply pressure of compressor cooling water pump is normal i.e. pressure
shown is at least 4 Kg.
• Check bearing lubrication of all rotating machines (generally once in a month)
• Check lub oil level etc.

b) Equipment run sequence/ start-up procedure (Fly ash cleaning)

• Start compressor cooling water system: To confirm whether the valves in cooling waterline
are open.
• To check all the necessary interlocks are fulfilled in MMI page. Press the “Start” push
button of instrument air compressor & check the corresponding indication glowing in “Red” for
run condition.
• Check all the necessary interlocks are OK & start transport air compressors.
• Press start push button of FLY ash compressor and check corresponding indication
glowing red for run condition.
• Check selection switch of vent fan.
• Start vent fan of the fly ash silo to be used. Normally fly ash silo-1 is for unit 3 and fly
ash silo-2 is for unit 4, confirm open/ close state of the pneumatic valves at the silo top are in
order. Confirm the ash conveying line from each unit has got dual entry to the silo by silo
change over valves.
• Check vent filter selection switch in ON position of respective silo.

c) Manual cleaning of fly ash hoppers

• Select manual mode position by clicking Auto/ Manual switch.
• Select branch selection switch of the ESP row/ branch to be cleaned.
• Select hoppers selection switch to SELECT position.
• To follow the filling & cleaning valve operation sequence in a particular, branch. First
open/ click ash discharge header valve & air inlet valve & close when back-pressure is 0.3 Kg/
cm2. This is called line flushing. Then open ash intake valve & vent valve. Then close ash intake
& vent valve. This is called filling of vessel & then click open fluidizing & discharge valve. When
back-pressure of the conveying line goes to 0.3 Kg/cm2, close discharge valve & fluidizing
valve. This is called cleaning of vessel.
• After completion of ash cleaning of the selected branch/ hoppers (it may include repetition/
cycles for the branch) press control station stop push button.
• Select other branch selection switch to SELECT position and it hopper selection switch
also to SELECT position.
• Again press control system start push button.
• After completion press system stop push button.
• Continue in the same way for all the branches/ hoppers and finally press control system
stop push button.
• During hopper cleaning by manual mode observe whether indications are glowing red or
not.

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d) Auto cleaning of fly ash hoppers
• Select auto position of auto/ manual selection switch and observe mode (III) selected
in MMI page.
• Press control station 1 or 2 start push button. This initiates complete filling & cleaning
cycles of vessels of that stream. The high level switch of vessels overrides the filling time of
ash intake valve.
• Press sequence start push button.
• At the end of auto cleaning system over ash cleaning sequence will automatically goes
to the 1st cycle, if not stopped, as per the time cycle chart fed to the PLC.

e) Stop sequence for fly ash cleaning

Fly ash cleaning system shall be stopping following the reverse sequence as below.
• When the system is in manual mode cleaning of vessels & respective conveying line is to
be flushed before stopping the respective control station.
• Press stop push button of the compressors-red indication will go off.
• After two minutes stop vent fan-indication goes off.
• After ten minutes click vent filter selection switch to OFF position.

ii) FLY ASH UNLOADING FROM THE COARSE ASH SILOS (1&2)
Normally the cleaning of silo is required when the ash level in the silo is high. In case the
HCSD system is to be run in ‘Manual’ mode, the stream is to be selected through which ash from
silo will come to the mixing tank of rather which pump is to be operated i.e. selecting the line,
1 to 4. Any one line per unit (or per silo) is to be charged. The following sequence is to be
followed for charging of line from silo to the slurry discharge pump.
• LP pump is to be selected i.e. two LP pumps in parallel will run continuously (before
running the LP pump make-up water valve to the water sump water level of the sump are to be
checked.)
• All the manual valves in the LP water line for HCSD system is to be checked.
• Mixing tank level is to be checked (before charging mixing tank shall be at low level)
• Mixer is to start. (Seeing that the mixing tank level is low)
• Control valve of the dust conditioner is to be opened at 30%.
• Control valve of the mixing tank may be put to put to Auto PID loop for better level
control.
• One fluidizing blower is to be started along with its heater after checking the fluidizing
airline valves.
• Dust conditioner is to be started.
• Rotary feeder is to be started and to be operated at around 80% of speed to control the
flow of ash in the line @80-100 tons per hour.
• Manual KGV in dry ash line from silo is to be opened.
• Cylinder operated KGV in dry ash line from silo is to be opened.
• Cylinder operated KGV in slurry suction line is to be opened. (Normally manual KGV is
opened)

Before opening the cylinder operated KGV on slurry suction line the level of mixing tank
shall be around operating level.
The ash from silo will start flowing to the mixing tank. Ash will be moisturized.

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 In the dust conditioner (Ash flow in mass flow meter is to be checked and accordingly
speed of the rotary feeder is to be set) and fall into the mixing tank wherein slurry will be
formed.
Before starting the pump slurry in the mixing tank should reach the operating level.
(Propelling liquid lines, Instrument air, VFD drives are to be checked). As soon as the pump
starts the speed is to be raised from 19% to 94% within a span of 10 minutes (Motor should not
be started and run at 19% speed for more than one hour to accordingly pressure in the slurry
line is to be noted. Gradually the pressure in the slurry line will go to the zone of 55-60 bar
when the band of 1350 to 1400 grams/ ltr.
In “Auto mode” all the above sequence will be followed by the ladder logic written in the
PLC. Only start sequence is to be initiated.

iii) STOPPING SEQUENCE :

The stopping sequence of silo unloading goes in the reverse direction. Viz following
sequence is to be maintained.

• Cylinder operated KGV in dry ash flow line from silo is to be closed.
• After 2 minutes rotary feeder is to be stopped.
• After 2 minutes dust conditioner is to be stopped.
• After 2 minutes control valve for water supplying to dust conditioner is to be stopped.
• After 5 minutes control valve supplying make up water to slurry mixing tank is to be
stopped.
• Now the level of slurry mixing tank shall start falling and after it reacher the level of 0.8
Mtr. The pump will be stopped (by reducing the speed of the pump from 94% to 19% within 5
minutes)
• Cylinder operated valve in slurry suction line will be stopped.

This way the unloading of Fly ash through HCSD system becomes complete. If this slurry
pump is restarted within 4-5 hours after stopping there is no need of slurry line flushing (by
opening flushing valve) by clean water. Otherwise slurry line shall be flushed by clean water for
20-30 minutes before pump restarting.

iv) DESCRIPTION RESIPROCATING PUMP USED FOR ASH TRANSPORTING: GEHO PUMPS:
The GEHO piston diaphragm pump, model TZPM800 is a reciprocating, positive
displacement pump, designed to handle liquids, contaminated with solids like sludge, slurry and
mud, particularly where abrasive or aggressive materials are involved.
The pump design is such that the pumped liquid does not come in contact with moving
parts, such as piston and cylinder liner. This is done by means of a rubber diaphragm, which
effects a mechanical separation between the pumped liquid and the clean propelling liquid in
which the moving parts are running.
Parts such as piston seal rings, cylinder liner, piston rod are non-wearing parts. The only
wearing parts are the suction and discharge valves. The pump diaphragm is a replacement part.
The wearing and replacement parts are easily accessible for inspection and repair.

POWER END CONSTRUCTION:

The power end is of a welded, fabricated and is stress relieved after welding. A number
of recesses and covers are provided in the frame and are oil, dust and splash proof. Power

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transmission to the one-piece crankshaft is arranged via the pinion shaft (drive shaft) and a
gear, flanged on the crankshaft.
The gears have corrected double helical teeth. The bearings of the drive shaft are
cylindrical roller bearings without axial fixation to allow optimal alignment of the pinion with the
double helical gear. The crankshaft support bearings are self-aligning roller bearings. The big
end bearing of the forged steel connecting rods are cylindrical roller bearings with a convex
contact surface. These bearings have a two piece conical clamping sleeve, which enables it to
fit the bearing over the crankshaft. The inner rings of the bearings are fixed on the crankshaft
by means of these conical sleeves. The crosshead pin bearings are roller bearings. The crosshead
is made of ductile cast iron.
Crosshead liners and bearings can be inspected through the frame opening at the side,
and can be removed through the front opening from the power end.

POWER END LUBRICATION:

Two lubrication method are applied:

1. The splash lubrication of the gears, affected by their own movement in the oil sump.
2. The force feed lubrication system to lubricate points that are difficult to reach by the
splashed oil such as the anti friction bearings of the drive shaft and the crankshaft, the upper
and lower side to the crosshead liners and the piston rods at the power end of the dust cover.

LIQUID END :

GEHO reciprocating diaphragm pumps are designed to the modular principle with particular
attention given to simple, rapid replacement of wearing parts.
The liquid end, as a whole consists of three pump cylinders, each consisting of a
cylinder liner with piston and piston rod, the connecting piece between cylinder liner and
diaphragm housing, the diaphragm housing and the suction and discharge valve housings.
The discharge manifold interconnects the discharge valve housings. Pulsation dampeners
are mounted on top of the discharge manifold. The liquid end can be split up into the propelling
liquid section and the slurry section, which are mechanically separated by means of a rubber
diaphragm.
The propelling liquid section consists of the cylinder liner with the piston as well as the
connecting piece fitted to the diaphragm housing. This area is filled up with the propelling liquid.
The slurry section consists of the diaphragm housings, the valve housings, the discharge
manifold and the pulsation dampeners. Only these parts come in contact with the liquid to be
pumped.

DIAPHRAGM STROKE POSITION CONTROL SYSTEM (PROPELLING LIQUID SYSTEM)

The piston is connected via the piston rod to a crank drive. It is necessary to keep the
volume of the propelling liquid between the piston and diaphragm within limits. The change in
propelling liquid volume can occur through liquid leaking over the piston.

SLURRY SECTION:
PUMP DIAPHRAGM AND HOUSING:
The pump diaphragm is a preformed molded diaphragm with O-ring shaped clamping ring,
which prevents stress concentration in the clamping area. A cone plate is vulcanized into each

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diaphragm and connected to the monitoring rod. Under normal conditions the diaphragm does
not come in contact with the rear wall of the housing. The diaphragm housing cover clamps the
diaphragm. The diaphragm can be inspected or changed by removing the diaphragm housing
cover.

VALVES:
The valves are of the spring loaded cone type. Their valve seats are made of case
hardened steel. The valve seat is fixed in the valve housing with a press fit cone construction.
The valve seats and the valve housing covers can be mounted and demounted mechanically or
hydraulically.
When the slurry is very abrasive, the patented UP - TIME valve can be used. Seat and
cone are made of special hardened steel and both coated with a highly wear resistant elastomer.

DISCHARGE MANIFOLD:
The suction and discharge valves are interconnected by means of the suction and
discharge manifold. Both manifolds are of a welded, fabricated design and connections are
provided for suction and discharge line as well as for the pulsation dampener.

PULSATION DAMPENERS:
Because the pump is working with relatively constant pump pressures, the GEHO diaphragm
pulsation dampener has to be charged at 60 to 65 per cent of the minimum working pressure.
High pressure (+85%) related to working pressure gives the best dampening results, but can
cause damage to the metal insert by continuously hammering at the dampener bottom, when
working pressure is falling. When working with widely varying pressures it can be necessary to
precharge only 30 to 35 per cent of the maximum pressure.

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