MADHYA PRADESH POWER GENERATING COMPANY LIMITED SANJAY GANDHI THERMAL POWER STATION (2x210MW) PH-I, BIRSINGHPUR

TECHNICAL SPECIFICATION FOR COMPLETE OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ASSOCIATED AUXILIARIES 1. Intent of Specification: - This specification is intended to cover complete operation and maintenance of ash handling system and associated auxiliaries of power house no. I of SGTPS, Birsinghpur. 2. It is not the intent to specify completely herein all the details of equipments, its design, construction and assembly of the components & accessories. However any material required in order to meet the intent of this specification and to make the required system functional in an acceptable manner is under the scope of bidder, whether the same is specifically indicated or not. 3. It is deemed that technical bid shall be submitted by the bidder complete in all respects after the bidder fully understood about the scope of work and the requirement of the specification. Hence no deviation shall be entertained after the opening of the bid. For this purpose, MPPGCL shall be pleased to have technical discussion with the bidders, if bidder so desire, prior to submission of bids. Also MPPGCL will entertain the bidders visits to the concerned power plants if it helps them to understand the exact scope of work. As the O&M shall have to be carried out, it is advised that bidders shall visit the site, make them fully conversant with the job, site conditions. GENERAL INFORMATION Sanjay Gandhi Thermal Power Station consists of three power houses i.e. PH-I, PH-II comprises of (2x210MW) each each & ( 1 x 500 MW) PH-III. The O&M covered under this specification shall have to be carried out in PH-I. The brief details of which are as under:-

Steam Generator(Boiler)
Make:Type:ACC Babcock Limited Natural circulation membrane type, water cooled furnace, Radiant type, two pass, opposed fired.

01 Qualifying Requirement
The bidder must fulfill the following minimum qualifying requirement for the participation in this Bida) Bidder should submit Proof of having at least three years experience of O&M work of Ash Handling System of 210 MW units or higher capacity. b) Original equipment manufacturer who have success fully commissioned ash handling system and put the system in operation thereafter at any of thermal power station shall be exempted from the condition stipulated in 2 (a)above. The Bidder should submit audited accounts for at least two years along with latest income tax clearance certificates. Bidder should submit copy of service tax, EPF code registration, and valid labor license from competent authority. Bidder should submit annual turn over certificate of Rs 3 Crore or above from any nationalized / reputed Bank as a Proof of financial soundness to make payments of at least Six months.

1.

2. 3. 4.

02 SCOPE OF WORK
COMPLETE OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS AUXILARIES (2 X 210MW), UNIT # 1&2 DESCRIBED AS UNDER 1.0
1.1 1.2 1.3 2.0 ASH GENERATION POINTS:-The Ash generated in the boiler is collected under different zones as indicated below:Furnace ash is collected at the bottom of the furnace hence called the bottom ash. Coarse Ash is collected in the economizer hoppers provided in unit 1 & 2 only. There are 8 no. hoppers are provided to collect the coarse ash in each unit. Fly ash is collected in 42 ESP Hoppers and 12 Air Heater Hoppers, per unit. MODE OF DISPOSAL:disposed off, as belowDifferent types of Ash stored at various locations are

2.1

2.2

2.3

The Bottom Ash is stored in water impounded hoppers, at the bottom of the furnace, removed intermittently by operating Clinker Grinder and Jet Propulsion pump to dispose off the Bottom Ash unto the Ash Slurry Sump located at Ash Pump House through 04 Nos. 200 NB pipeline. The coarse ash is collected in through Economizer hoppers by Vacuum conveying system by using hydraulic exhauster and slurry is formed. Coarse ash evacuation is intermittent and the slurry is removed through separate jet pump. This facility is provided in unit 1 & 2 only. The Fly Ash from ESP & Air Heater Hoppers is collected in a dry from through Vacuum Conveying system and transported unto the surge tank. From the Surge Tank Pressure System conveys the fly ash unto the far away station silo. In case the silo is full or any maintenance is being carried out in silo then the silo can be bypassed and fly ash can be evacuated in ash slurry sump. A 350 NB line is used to dispose of the fly ash unto the ash slurry sump and a 400 NB line is used to transport the fly ash from ash slurry pump house to silo. The present facilities in the silo are provided for conditioning unloading through which ash can be disposed in the dry form (duly moistened and suitable for open truck disposal). Dry ash evacuation

system is also provided with slurry pumping facilities. Moreover blanked discharge pointes are also provided for future. 2.4 Presently, Both the Bottom Ash and Fly ash thus dumped in ash slurry sump is pumped to the ash pond with the help of Ash Slurry Pump, which is situated around 3.5 km ash pump house through four numbers of lines of 300 NB each. New ash pond is under construction ahead of bout 2 Km of existing pond. After completion/ commissioning of this pond, the wet ash will be dumped their in near future. Silo by passed system has also been added subsequently only recently even after construction of the building & sumps, which has been fitted at the end of the pressure conveying system which allows fly gas removal in slurry pumps directly without taking the fly ash into the silos.

2.5

3.0 ASH REMOVAL CAPACITIES:3.1 Ash Generated and system capacities. Specified Ash data : ASH GENERATION (AT 100% MCR WITH WORST COAL) BOTTOM ASH HOPPER : 39 TPH ECONOMISER HOPPER : 6 TPH AIR HEATER HOPPER : 6 TPH ESP HOPPER : 58 TPH STACK HOPPERS : 3 TPH 112 TPH 3.2 EVACUATION CAPACITIES PER UNIT:-

3.2.1 BOTTOM ASH System (From B.A. Hopper to Ash slurry sump):2x60 TPH through each of 200 NB MS Pipes. 3.2.2 COARSE ASH System: A. VACUUM ( C.A.HOPPER TO C.A. TANK 2X30 TPH) through each of 8 BS pipe. B. SULLRY ( C.A.TANK TO SLURRY PUMP HOUSE ) through each of 12 BS MS pipes. 3.2.3 FLY ASH SYSTEM : A. VACUUM (ESP & A/H HOPPERS TO SURGE TANK):- 2x60 TPH through 8 & 9 CI & 250 NB MS Pipe. B. PRESSURE (SURGE HOPPER TO SILO/ASH SLURY SUMP):- 1X120 TPH through 14 & 16 MS Pipe combination. 3.2.4 SLURRY SYSTEM COMMON FOR:- 2x210 MW Unit. A. FOR TRANSPORTING BOTTOM ASH (from slurry sump to ash dam) 1x120 TPH through 300 NB MS Pipe. B. FOR TRANSPORTING FLY ASH (from silo slurry sump to ash dam) 1x120 THP through 300 NB MS pipe. Along with the O&M work, the rotation of pipes once in a year shall also be in the contractor scope. 4.0 ASH CLEANING TIME (PER UNIT):The Ash Handling System is envisaged to operate for the following duration for each of the units. 4.1 BOTTOM ASH:- Approximately 1 Hrs per 8 hours and operate once per shift per unit.

4.2 COARSE ASH:- The duration of coarse cleaning is approximately 1 hr per 8 hrs shift . 4.3 FLY ASH:Approximately 4.5 hrs per shift of 8 hours per unit. 5.0 OPERATION PHILOSPHY & STANDBY EQUIPMENT 5.1 BOTTOM ASH:Bottom Ash are evacuated in sequence by operation two diagonally opposite clinker grinder, jet pump and eccentric crusher while keeping other two diagonally opposite sets clinker grinder, jet pump and eccentric crusher as stand by i.e. 100% standby. Bottom Ash is evacuated to ash slurry sump through 200 NB MS Pipe. In all there are four 200 NB lines, two on each side. During normal operation two evacuates bottom ash through 200 NB lines while other two remain as standby. 5.2.1 COARSE ASH:- In unit each unit of PH-I, Coarse ash hoppers has X and y with 4 no. hoppers in each side. The hoppers are evacuated in sequential manner in the slurry form and dumped in the Coarse Ash Tank. The slurry then transported to ash sump through 300 NB lines.

5.3 FLY ASH:i) VACUUM SYSTEM:Sequential cleaning from ESP & Air Heater Hoppers up to the surge tank. Two Bag Filters Operate, keeping other two as standby per unit. Two Sets of water ring type Mechanical Exhauster run for 120 TPH for removal of fly ash from ESP & Air Heater Hoppers. Two sets of water ring type Mechanical Exhauster remains as standby. ii) PRESSURE CONVEYING SYSTEM:Fly Ash from surge hopper to silo is transported by air pressure supplied by one number of conveying compressors. One number of conveying compressors remains as stand by per unit. For transporting fly ash from surge hopper to silo/ash sump pressure conveying line is used. For four numbers of Nuva feeder are used for feeding fly ash from surge hopper to pressure conveying line, while other four remain as standby. iii) WATER AND SLURRRY SYSTEM:One chain of H.P. Water pump and one chain of Ash Slurry pump are run per unit for removal of ash slurry from ash slurry sump and transporting it to ash dam. One set of H.P. Water Pump and one set of Ash slurry pump remain as standby. 6.0 BRIEF EQUIPMENT DESCRIPTION 6.1.0 BOTTOM ASH SYSTEM 6.1.1 BOTTOM ASH HOPPER:Each unit is provided with one number of water-impounded Bottom ash hoppers with holding capacity of 160 tones of bottom ash. 6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGE ARRANGEMENT:Bottom Ash Hopper is W type each V section of the W is provided with two discharge gates, out of which normally one is to operate during ash removal leaving other one as standby. 6.1.3 BOTTOM ASH EQUIPMENT:Each discharge gate is provided with one (1) No. of Eccentric Crusher and one (1) No. of Jet Pump along with other accessories. In all there are four nos. of discharge gates. Eccentric crusher can move both the direction i.e. backward and forward. 6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-

Two (2) pipes of 200 NB (MS) per unit are provided for transporting ash slurry from bottom ash hopper to slurry sump. 6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:There are three (3) numbers of Overflow Transfer Pumps situated just near bottom ash hopper. These Pumps transfer the over flow water from the bottom ash hopper, which is collected in an overflow sump, is then transferred to either ash slurry sump or clarifoculator through one no. 200 NB line. At a time only one pump is in operation. 6.1.6 BOTTOM ASH PIT CLEANING FACILITY:There are two nos. of Jet Pumps for bottom ash pit cleaning through two nos. 65 NB line from pit to over flow sump. 6.2 COARSE ASH SYSTEM:Coarse ash is collected through 2 nos. of hydraulic exhausters operating intermittently. The slurry is formed in the exhauster. 6.2.1 ASH COLLECTION FROM VARIOUS HOPPERS:Ash collected in hoppers is evacuated in coarse tank through conveying lines under vacuum maintained by hydraulic exhausters operating intermittently. The slurry is formed in the exhausters. 6.2.2 SLURRY COLLECTION AND DISPOSAL: There is one no coarse ash tank with 50 ton capacity is provided for this in each unit. 6.2.3 DISPOSAL OF SLURRY FROM COARSE ASH TANK:One no. jet pulsion pump with one no. disposal pipeline of 300 NB up to slurry sump is provided to keep in the operation while second stream is kept as stand by. The system is to operate in intermittently during ash evacuation hydraulic exhauster. 6.3.0 FLY ASH SYSTEM:6.3.1 REMOVAL OF ASH FROM HOPPERS:Vacuum in the lines connecting ESP & Air Heater Hoppers is created with the help of mechanical exhauster as a result of which when the gates of the hoppers open sequentially the ash from the ESP & Air Heater Hoppers get sucked and get transferred to surge hopper through bag filter and transfer hopper. In all there are two streams, in one stream, 21 nos. of ESP hoppers and 06 nos. of Air Heater hoppers are connected. At a time both the stream is in operation. 6.3.2 DUST COLLECTOR ARRANGEMENT:In all there are four nos. of Dust Collector. Each dust collectors consists of 126 nos. filter bags. The mixture of ash and air conveyed through pipelines enter the selected dust collector on conveying circuit. The combination of filter separator and transfer hopper arrangement is used for continuous separation of fly ash from the conveying air and unloading of the free air into the intermediate surge hopper without interruption of the conveying operation. Out of four dusts collector, at a time only two nos. is in operation. 6.3.3 MECHANICAL EXHAUSTER:In all there are 4 sets of Water Ring type Mechanical Exhauster for each unit. In general two sets are in operation for each unit. When operated they create vacuum, which helps in removal and conveying of fly ash from ESP & Air Heater hoppers to intermediate surge hopper. 6.3.4 FLY ASH VACUUM TO PRESSURE TRANSFER:-

Atmospheric surge hopper is provided below dust collector with surge capacity of 60 tons/section of surge hopper. There are two such section in one surge hopper provided per unit. 6.3.5 PRESSURE FEEDER:Each section of surge hopper tank is provided with four nos. feeders. The feeders operate in cycle to discharge fly ash into the pressure conveying lines of 350 NB, in a regular manner. The pressure conveying system evacuates ash in fly ash from surge hopper to silo/ash slurry sump. The second section of surge hopper provided with another four feeders, which remain as standby. 6.3.6 PRESSURE CONVEYING PIPELINE:There are two pressure conveying pipe lines 350 NB/400 NB, for each unit for transportation of ash from boiler area to station silo/ash slurry sump. One pipe operates, keeping the other as standby. 6.3.7 PRESSURE CONVEYING BLOWER:Four nos. twin lobe types conveying blower are provided, two for each units. At a time only one blower is in operation for each unit. 6.4.0 ASH SLURRY DISPOSAL FACILITY 6.4.1 SLURRY PUMPS ARRANGEMENT:All the slurry from the plant is received in a distribution chamber. There are four slurry pump compartment and the distribution chamber has individual isolating gates with pipe for discharging slurry into the desired pump. 6.4.2 SLURRY PUMP:There are four series of slurry pump. Presently there are two stage of slurry pump in each series for future extension of disposal point. 6.4.3 SLURRY DISPOSAL:Each series is rated for 120 TPH Ash Slurry Disposal. One such series has to be operated for removing Bottom Ash from one unit. Fly Ash in slurry from the silo or silo-bypass system can be removed thereafter in a sequential manner. Two series of slurry pump operate, one for each unit while the other two remain as standby. 6.4.4 DISPOSAL PIPELINE:Four nos. of 300 NB M.S. disposal pipelines are provided through which slurry is transported. Two such pipes are operating for both the units. 7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:7.1 FLY ASH:Fly ash stored in various hoppers is conveyed unto silos (1A+1B) or silo-bypass system located in Ash Slurry Pump House of PH-II, through a vacuum-pressure combination system followed by pressure system. The transition of vacuum system to pressure system takes place adjacent of ESP at a transfer point where the separator isolates the fly ash from the air and allows it to pass out through the Mechanical Exhauster (Vacuum Pump), where vacuum is created, and those equipments are located adjacent to ESP and Fly Ash equipment building. Dust separator is located over set of Hopper known as surge hopper. The fly ash thereafter gets transferred to pressure system feeders below the surge hopper, where from it is transported, to plant boundary silo or silo bypass system through pressure conveying system. 7.2 DISPOSAL FROM SILO:-

Each of two silo(1A& 1B) of sized for 1700 tons dry ash storage capacity(11.5 M Dia x 31.5 M height)having capacity for storing one ash generation . Silo contains auxiliaries like vent fan vent filter and silo blowers. To dispose ash from these silo there are two options i. Truck unloading to un loaders. ii. Converting dry to slurry and pumping it out through pumps. 8.0 INSTRUMENT AIR SYSTEM:In PH-I, there are three nos. Instrument Air Compressor Compressors make: Kirloskar Pneumatic Ltd. Each Compressor is complete with electric motor and other inbuilt features and accessories are provided to cater to instrument air requirements, for ash handling system. Out of three Instrument Air Compressors, normally one operates to deliver the instrument air requirements for entire system, constituting unit # 1&2. Two nos. of Air Drier units each complete with its own features and accessories, are also provided and located at discharge of Instrument Air Compressor, out of which, one Air Drier unit normally operates with the operation of one no. compressor, keeping the other as stand-by. The instrument air is catered to actuate all pneumatically operated valves, bellows, ash hopper feed gates, Nova feeder gates, dust separator gates, and other equipment as well as to meet pulsing air requirement for vent filters. Continuous cooling water requirements for the operating I.A. Compressor, Intercoolers, after coolers, etc. is catered from plant clarified water system and the cooling water return is discharged into the seal water sump. 9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and seal water trough (LP water pumps/service water pump) overflows from the hopper and is received in respective over flow transfer sump. The bottom ash overflow transfer pumps are operated to pump out this water into the common clarified system. Water over flow from the clarifier is received into collection well and is pumped beck into the ash water sump, by means of Re-cycle water transfer pumps, as the normal input to the Makeup Water Pump/HP water pumps. In addition, recovery water from ash pond as and when available through existing recovery water system will be recycled back into to the ash water sump clarifier) by means of recycle water transfer pumps to provide normal input to LP&HP water pumps during bottom ash and fly as cleaning. The return water form mechanical exhauster and air-washer during fly ash cleaning operation is received in respective drain transfer sump and is discharged into the bottom ash, overflow transfer sump, by means of Drain Transfer pumps, for further pumping into the clarifier. The sludge pumps belonging to be the clarifier is operated to pump-out the accumulated sludge from the clarifier, sludge pit into the ash slurry sump. The seal water pumps are energized to cater to water requirement for operating pumps/equipment-having requirement of external seal water. 10. CLEANING: 10.1 Ash/Coal dust spread below the coarse ash hopper, air heater, and ESP hoppers has to be cleaned daily. Fine ash dust collected has to be done either in coarse ash tank or ash slurry sump of unit 1 &2 directly. The area covered under this will start from back side of P.A. Fan duct around Bottom ash Hopper, Air heater hopper and up to chimney on the ground flower and below coarse ash hopper at rear side firing floor. Firm also has to ensure clearness of all three trenches of bottom & coarse ash and pipe lines regularly to facilitate fast maintenance work.

10.2 Cleaning of wet ash on the floor due to economizer tube leakage: Several times economizers are clogged with wet ash and mud due to tube leakage in economizer zone. The wet ash in the economizer & fly ash hoppers cannot be handled with ash handling system and ash has to be dumped on the floor. This wet ash is to be cleaned subsequently by manual and trucks by the contractor at free of cost. 10.3 The contractor has to ensure emptiness of hoppers. During short shut down of units, physical inspection of all the hoppers shall be carried out. In case of accumulation found inside the hoppers, the same shall be cleared/ cleaned through the system or manual as per instruction of engineer in-charge. 11.ASH MANAGEMENT Ash management at ash dyke shall cover diversion of water toward floating barge (Recovery Pump house) by making /maintaining earthen walls with send bags /ash bags by engaging manual labors. Lifting & minor adjustment or shifting of Barge in the vicinity of existing location shall also be in the scope of contract. No extra payment shall be made for above work. ANY MODIFICATION, FRESH CONSTRUCTION i.e. LAYING OF NEW PIPE LINES, CONSTRUCTION OF BRICKS WALL FOR MAKING EMBANKMENT AT ASH DAM FOR ASH SLURRY AND ALSO FOR THE ADJUSTMENT OF WATER OVERFLOW THROUGH FILTER SHAFT WILL NOT COVER UNDER THE SCOPE OF THIS CONTRACT. OTHERTAN ANY CIVIL CONSTRUCTION SHALL BE DONE SEPERATELY.

12.ELECTRICAL AND INSTRUMENT:12.1 CONTROL SYSTEM:- Necessary remote and local control panels and control stations are provided at strategic locations to offer a duly interfaced and synchronized control for the overall ash handling system. The System controls are provided to offer necessary operating interfaces among the various sub-systems to achieve a duly coordinated system operation from various control panels and control stations. An electromagnetic relay/PLC based control network is interlocks associated with the system operation and control.

12.2. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:There are two numbers of PLC units, one for each unit. This microprocessor-based unit is configured with Central Processing Unit, power supply unit and set of logic necessary to operate and control the fly ash system in remote interlocked mode. One additional CPU is provided for each PLC unit to operate as hot stand by to operating one. The PLC systems of both the units are supplied with a common PC based programming station for access to the Proven logic, uploading and down loading of process control software and programmed print out. The PLC system of both the units is located in the control room of the fly ash equipment building. Maintenance of following equipment is also in the scope of contractor. (i). AIR CONDITONERS:There are six no air conditioner are provided in the control room to maintain the adequate temperature of PLC unit and operator console. Any type of repair/ servicing of A.C.s along with gas filling shall be in the contractors scope.

(ii) LOCAL PANNEL:- All local panels are located near auxiliaries. 13. ELECTRICAL POWER FEEDING NETWORK:The power feeding network under system is composed of necessary switchgears, MCCs etc. provided at strategic location to establish efficient power distribution network. The maintenance & testing of all such equipments like:1. H.T. SUPPLY 6.6 KV SUPPLY. 2. L.T. SUPPLY 415 V SUPPLY. 3. CONTROL SYSTEM SUPPLY 240 V SUPPLY 4. D.C. SUPPLY 220 V SUPPLY. 5. ALL H.T., L.T., MOTORS. 14. MAINTENANCE & CALIBERATION OF INSTRUMENTS:1. Pressure Gauge. 2. Limit Switch. 3. Level Indicator. 4. Level Probe. 5. Pressure Switch. 6. Pneumatic Actuators. 7. Motorized Actuators. 8. Various types of solenoid valves. 9. Vacuum Gauges. 10. Diaphragm Valves. 11. Temperature Gauges. 12. Electrical Instruments such as CT, PT, Ammeter, Voltmeters etc. 15. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance, Testing & Calibration of all 0.415KV and 6.6 KV relays of bus MCC and Breaker. 16. Repair and maintenance of the 33 KV supply lines going to barge shall be in the contractors scope However, assistance like permit etc. shall be provided by the MPPGCL.

THE DETAILS OF AREAS OF WORK ARE AS UNDER

1. Bottom ash hopper, hopper feed gates, air water converter tanks, eccentric crusher, jet pumps, overflow transfer pumps and bottom ash slurry lines. 2. Fly ash handling system In this system each units has following equipments:a. ESP hopper including diffuser feeders, ash and air intake valves along with other associated fittings. b. Air pre heater hopper including diffuser feeder, ash and air intake valves along with other associated fittings. c. Branch feeder isolating valves (TERSG). d. Vacuum and pressure conveying lines. e. Mechanical exhauster, air washer and bag filters with associated piping valves etc. f. Surge hopper including vents etc. g. Transfer hopper with associated valves. h. Nova feeder along with associated valve and piping. i. Hydraulic exhauster system.

3. Ash slurry line pumps are in series with slurry piping valves sump etc. 4. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumps etc. 5 Conveying Compressor, ESP Fluidizing Blower, Nova Feeder Fluidizing Blower, Silo Blowers & Blower heaters etc. Instrument Air compressor (KPL make) with air drying units along with associated piping valves, coolers and fittings. 5. Silo by-pass arrangement with hydraulic exhauster etc. 6. All make up water Pumps, drain and overflow transfer pumps with piping, valves. 8. All pumps and valves along with the pipelines incorporated in the clarifoculator system. 9. The slurry disposal pipelines unto the disposal point and all associated valves. 10. Electrical maintenance including gas filling of Air-Conditioner. 11. Silo Blowers, Vent Fans in case of U#1&2

THE SCOPE OF CONTRACT ALSO INCLUDES

A. a. PURCHASE OF SPARE AND CONSUMABLE:- The contractor shall assist with planning and procurement of all needful spares, replacement and other consumables and furnish a list of spares indicating quantity required for efficient operation of plant for one year duration well in advance to enable MPPGCL to purchase. However the contractor has to submit the list of record of all purchased free of supply spare/consumable per month basis to OIC along with bill. The list submitted shall be verified and duly signed by OIC and only necessary spares will be purchased for smooth O&M of AHP. The record of spares indented, consumed and balance stock should be maintained in M.A.S. register and unserviceable spares must be returned to the O&M stores. The monthly rate will cover the provision of consumables like gasket, electrodes and DA & Oxygen gases etc., required for execution of the said O&M job, excluding the supply of lubricant oil, grease and chemicals required for clarifoculator plant, which shall be arranged by MPPGCL, free of cost. However the firm has to maintain the proper consumption record of the consumables and spares supplied by the MPPGCL. (I) GASKET The gasket, which is considered as a spare i.e., formed gasket will be provided by MPPGCL, free of cost. The contractor shall arrange other gaskets. (II) ELECTRODE General type electrodes and (if required) to run system smooth, special purpose electrodes shall also be purchased & used by the contractor at their own cost. b. All spares of the Ash Handling system required for unit # 1&2, at SGTPS site shall be provided to the firm by MPPGCL, free of cost, for the smooth running of the units.

However the firm will prepare and submit the list of required spares to MPPGCL, will in advance to enable them to take procurement action. Firm will also extend necessary assistance in this regard. c. Carrying out routine and preventive maintenance work of running units is within the contractors scope. In case of any major breakdown/overhauling job required to be carried out on the following critical bought out items where specialist services are required from suppliers, the cost involved shall be borne by MPPGCL as per requirement of the MPPGCL. Contractor shall extend assistance and co-operation for the items as mentioned below:(i) Mechanical Exhauster (Vacuum Pump). (ii) Ash Slurry Pumps. (iii) Conveying Compressors. (iv) H.P. Water Pump. (v) PLC (Programmable Logic Control). (vi) Transformers. (vii) H.T. Motors. (viii) MCC. (ix) Switch Gears. (x) H.T. Cranes (xi) UPS (xii) Various types of Relays. (xiii) Instrument Air Compressor. d. The repairing of diffuser feeder seats and discs, vent and equalizing valve discs and seats, TERSG slides, discs and seats of swing gate valves, pulse jetting cards, pressure and vacuum switches, various gauges etc. due to non availability of spares will be carried-out by the contractor without additional claim. e. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with transportation cost is in contractors scope at no extra cost. f. Repairing of Filter Bags There are 1516 Nos. of bags in Bag Filter of Unit # 1&2. The necessary repairing of these bags by stitching, replacement of cloth for the defective portion, changing of collars etc., at any place will be carried-out by contractor free of cost. g. Maintenance of 33 KV over head lines (supply to barge) shall be in the scope of contractor. They have to keep trained certified staff for maintenance; however work shall carried out with MPPGCLs consent and approval. (Permit to work on the line shall provided by MPPGCL) h. Annual Overhauling The cost towards the annual overhauling of any units should be included by contractor in their monthly rate. In case of annual overhauling of any units, overhauling of ash handling system has to be carried out by the contractor on our advice; no additional payment will be reimbursed by MPPGCL. i. The contractor shall keep the area of the work i.e. Bottom ash area of boiler, overflow tank, Air heater, ESP, and all pump house, neat and tidy. Contractor shall engage labour regularly for cleaning the area. The arrangement for watch and ward personnel as may be required for AHP inside and outside of powerhouse shall remain in contractor scope. The watch and ward of

j.

the barge pump house and associated auxiliaries and pipelines going to dam are covered in this scope. Watch & ward of ash slurry pipelines recovery water pipe lines shall also in the contractor scope. k. Any major modification, fresh construction i.e. laying of new pipe lines, construction of brick walls etc., will not cover under the scope of this contract. l. The contractor must have arrangement of desired vehicle for shifting of material/crape from store to site or vice versa.

SUPERINTENDING ENGINEER (MM)-I SGTPS, MPPGCL, BIRSINGHPUR

SCOPE OF WORK
OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS AUXILARIES, UNIT # 3&4 (2 X 210MW) SGTPS,BIRSINGHPUR
1.0 ASH GENERATION POINTS:-The Ash generated in the boiler is collected under different zones as indicated below:1.1 Furnace ash is collected at the bottom of the furnace hence called the bottom ash. 1.2 Fly ash is collected in 24 ESP Hoppers and 12 Air Heater Hoppers, per unit. MODE OF DISPOSAL:- Different types of Ash stored at various locations are disposed off, as below-

2.0

2.1 The Bottom Ash is stored in water impounded hoppers, at the bottom of the furnace, removed intermittently by operating Clinker Grinder and Jet Propulsion pump to dispose off the Bottom Ash upto the Ash Slurry Sump located at Ash Pump House through 04 Nos. 200 NB pipeline. 2.2 The Fly Ash from ESP & Air Heater Hoppers is collected in a dry form through Vacuum Conveying system and transported upto the surge tank. From the Surge Tank,Pressure System conveys the fly ash upto the far away station silo. In case the silo is full or any maintenance is being carried out in silo then the silo can be bypassed and fly ash can be evacuated in ash slurry sump. A 350 NB line is used to dispose off the fly ash upto the ash slurry sump and a 400 NB line is used to transport the fly ash from ash slurry pump house to silo. 2.3 Both the Bottom Ash and Fly ash thus dumped in ash slurry sump is pumped to the ash pond with the help of Ash Slurry Pump, which is situated around 2.5 km from ash pump house through 04 Nos. of 300 NB each lines.

3.0

ASH REMOVAL CAPACITIES:3.1 ASH GENERATED AND SYSTEM CAPACITIES.

Specified Ash data Bottom Ash Hopper Air Heater Hopper ESP Hopper Total

: Ash Generation (At 100% MCR with worst coal) : 39 TPH : 12 TPH : 63 TPH : 114 TPH

3.2 EVACUATION CAPACITIES PER UNIT:-

3.2.1 Bottom Ash System (From B.A. Hopper To Ash Slurry Sump):2x60 TPH Through Each of 200 NB MS Pipes.
3.2.2 FLY ASH SYSTEM :

Vacuum (ESP & A/H Hoppers to Surge Tank):- 2x60 TPH through 8 & 9 CI & 350 NB MS Pipe. B. Pressure (Surge Hopper to Silo/Ash Slurry Sump):- 1X120 TPH through 14 & 16 MS Pipe combination. 3.2.3 SLURRY SYSTEM COMMON FOR:- 2x210 MW Unit. For Transporting Bottom Ash (from slurry sump to ash dam) 1x120 TPH through 300 NB MS Pipe.

A.

4.0

ASH CLEANING TIME The Ash Handling System is envisaged to operate the following duration for each of the units. 4.1 Bottom Ash:- Approximately 1 Hrs per 8 hours and operate once per shift per unit. 4.2 Fly Ash :- Approximately 4.5 hrs per shift of 8 hours per unit. OPERATION PHILOSPHY & STANDBY EQUIPMENT

5.0

5.1

BOTTOM ASH:- Bottom Ash are evacuated in sequence by operation two diagonally opposite clinker grinder, jet pump and eccentric crusher while keeping other two diagonally opposite sets clinker grinder, jet pump and eccentric crusher as stand by i.e. 10% standby. Bottom Ash is evacuated to ash slurry sump through 200 NB MS Pipe. In all there are four 200 NB lines, two on each side. During normal operation two evacuates bottom ash through 200 NB lines while other two remain as standby.

5.2 FLY ASH:5.2.1 VACUUM SYSTEM:- Sequential cleaning from ESP & Air Heater

Hoppers up to the surge tank. Two Bag Filters Operate, keeping other two as standby per unit. Two Sets of water ring type Mechanical Exhauster run for 120 TPH for removal of fly ash from ESP & Air Heater Hoppers. Two sets of water ring type Mechanical Exhauster remains as standby.
5.2.2 PRESSURE CONVEYING SYSTEM:- Fly Ash from surge hopper to silo

is transported by air pressure supplied by one number of conveying compressors. One number of conveying compressors remains as stand by per unit. For transporting fly ash from surge hopper to silo/ash sump pressure conveying line is used. For four numbers of Nuva feeder are used for feeding fly ash from surge hopper to pressure conveying line, while other four remain as standby.
5.2.3 WATER AND SLURRRY SYSTEM:- One chain of H.P. Water pump and

one chain of Ash Slurry pump are run per unit for removal of ash slurry from ash slurry sump and transporting it to ash dam. One set of H.P. Water Pump and one set of Ash slurry pump remain as standby.

6.0 BRIEF EQUIPMENT DESCRIPTION

6.1.0 BOTTOM ASH SYSTEM 6.1.1 BOTTOM ASH HOPPER:-

Each unit is provided with one number of water-impounded Bottom ash hoppers with holding capacity of 160 tones of bottom ash.
6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGE ARRANGEMENT:-

Bottom Ash Hopper is W type each V section of the W is provided with two discharge gates, out of which normally one is to operate during ash removal leaving other one as standby.
6.1.3 BOTTOM ASH EQUIPMENT:-

Each discharge gate is provided with one (1) No. Eccentric Crusher and one (1) No. Jet Pump along with other accessories. In all there are four nos. discharge gates. Eccentric crusher can move both the direction i.e. backward and forward.
6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-

Two (2) pipes of 200 NB (MS) per unit, are provided for transporting ash slurry from bottom ash hopper to slurry sump.
6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:-

There are three (3) numbers Overflowing Transfer Pump situated just near bottom ash hopper. These Pumps transfer the over flow water from the bottom ash hopper, which is collected in a overflow sump, is then transferred to either ash slurry sump or clarifoculator through one no. 200 NB line. At a time only one pump is in operation.
6.1.6 BOTTOM ASH PIT CLEANING FACILITY:-

There are two no. Jet Pumps for bottom ash pit cleaning through two nos. 65 NB line from pit to over flow sump.
6.2.0 FLY ASH SYSTEM:6.2.1 REMOVAL OF ASH FROM HOPPERS:-

Vacuum in the lines connecting ESP & Air Heater Hoppers is created with the help of mechanical exhauster as a result of which when the gates of the hoppers open sequentially the ash from the ESP & Air Heater Hoppers get sucked and get transferred to surge hopper through bag filter and transfer hopper. In all there are two streams, in one stream, 12 nos. ESP hoppers and 06 nos. Air Heater hoppers are connected. At a time both the stream is in operation.
6.2.2 DUST COLLECTOR ARRANGEMENT:-

In all there are four nos. of Dust Collector. Each dust collectors consists of 126 nos. filter bags. The mixture of ash and air conveyed through pipelines enter the selected dust collector on conveying circuit. The combination of filter separator and transfer hopper arrangement is used for continuous separation of fly ash from the conveying air and unloading of the free air into the intermediate surge hopper without interruption of the conveying operation. Out of four dusts collector, at a time only two nos. is in operation.
6.2.3 MECHANICAL EXHAUSTER:-

In all there are 4 sets of Water Ring type Mechanical Exhauster for each unit. In general two sets are in operation for each unit. When operated they create vacuum, which helps in removal and conveying of fly ash from ESP & Air Heater hoppers to intermediate surge hopper.
6.2.4 FLY ASH VACUUM TO PRESSURE TRANSFER:-

Atmospheric surge hopper is provided below dust collector with surge capacity of 60 tons/ section of surge hopper. There are two such section in one surge hopper provided per unit.
6.2.5 PRESSURE FEEDER:-

Each section of surge hopper tank is provided with four nos. feeders. The feeders operate in cycle to discharge fly ash into the pressure conveying lines of 350 NB, in a regular manner. The pressure conveying system evacuates ash in fly ash from surge hopper to silo/ash slurry sump. The second section of surge hopper provided with another four feeders, which remain as standby.
6.2.6 PRESSURE CONVEYING PIPELINE:-

There are two pressure conveying pipe lines 350 NB/400 NB, for each unit for transportation of ash from boiler area to station

silo/ash slurry sump. One pipe operates, keeping the other as standby.
6.2.7 PRESSURE CONVEYING BLOWER:-

Four nos. twin lobe types conveying blower are provided, two for each units. At a time only one blower is in operation for each unit.
6.3.0 ASH SLURRY DISPOSAL FACILITY 6.3.1 SLURRY PUMP ARRANGEMENT:-

All the slurry from the plant is received in a distribution chamber. There are four slurry pump compartment and the distribution chamber has individual isolating gates with pipe for discharging slurry into the desired pump.
6.3.2 SLURRY PUMP:-

There are four series of slurry pump. Presently there are two stage of slurry pump in each series for future extension of disposal point.
6.3.3 SLURRY DISPOSAL:-

Each series is rated for 120 TPH Ash Slurry Disposal. One such series has to be operated for removing Bottom Ash from one unit. Fly Ash in slurry from the silo or silo-bypass system can be removed thereafter in a sequential manner. Two series of slurry pump operate, one for each unit while the other two remain as standby.
6.3.4 DISPOSAL PIPELINE:-

Four nos. of 300 NB M.S. disposal pipeline are provided through which slurry is transported. Two such pipes are operating for both the units.

7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:- Fly ash stored in

various hoppers is conveyed unto silos (1A+1B) or silo-bypass system located in Ash Slurry Pump House of PH-II, through a vacuum-pressure combination system followed by pressure system. The transition of vacuum system to pressure system takes place adjacent of ESP at a transfer point where the separator isolates the fly ash from the air and allows it to pass out through the Mechanical Exhauster (Vacuum Pump), where vacuum is created, and those equipments are located adjacent to ESP and Fly Ash equipment building. Dust separator is located over set of Hopper known as surge hopper. The fly ash thereafter gets transferred to pressure system feeders below the surge hopper, where from it is transported, to plant boundary silo or silo bypass system through pressure conveying system.

8.0 INSTRUMENT AIR SYSTEM:-In PH-II, there are three nos. K.G. Khosla
Compressors Ltd., make Instrument Air Compressor each complete with electric motor and other inbuilt features and accessories are provided to cater to instrument air requirements, for ash handling system. Out of three Instrument Air Compressors, normally one operates to deliver the instrument air requirements for entire system, constituting unit # 3&4. Two nos. Air Drier units each complete with its own features and accessories, are also provided and located at discharge of Instrument Air Compressor, out of which, one Air Drier unit normally operates with the operation of one

no. Compressor, keeping the other a stand-by. The instrument air is catered to actuate all pneumatically operated values, bellows, ash hopper feed gates, Nova feeder gates, dust separator gates, and other equipment as well as to meet pulsing air requirement for vent filters. Continuous cooling water requirements for the operating I.A. Compressor, Intercoolers, after coolers, etc. is catered from plant clarified water system and the cooling water return is discharged into the seal water sump.

9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and seal
water trough (LP water pumps/service water pump) overflows from the hopper and is received in respective over flow transfer sump. The bottom ash overflow transfer pumps are operated to pump out this water into the common clarified system. Water over flow from the clarifier is received into collection well and is pumped beck into the ash water sump, by means of Re-cycle water transfer pumps, as the normal input to the LP&HP water pumps. In addition, recovery water from ash pond as and when available through existing recovery water system will be recycled back into to the ash water sump clarifier) by means of recycle water transfer pumps to provide normal input to LP&HP water pumps during bottom ash and fly as cleaning. The return water form mechanical exhauster and air-washer during fly ash cleaning operation is received in respective drain transfer sump and is discharged into the bottom ash, overflow transfer sump, by means of Drain Transfer pumps, for further pumping into the clarifier. The sludge pumps belonging to be the clarifier are operated to pump-out the accumulated sludge from the clarifier, sludge pit into the ash slurry sump. The seal water pumps are energized to cater to water requirement for operating pumps/equipment-having requirement of external seal water.

10. ELECTRICAL AND INSTRUMENT:10.1 CONTROL SYSTEM:- Necessary remote and local control panels and control stations are provided at strategic locations to offer a duly interfaced and synchronized control for the overall ash handling system. The System controls are provided to offer necessary operating interfaces among the various sub-systems to achieve a duly co-ordinated system operation from various control panels and control stations. An electromagnetic relay/PLC based control network is interlocks associated with the system operation and control.

Maintenance of the following Equipments

1. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:-

There are two numbers of PLC unit, one for each unit. This microprocessor based unit is configured with Central Processing Unit, power supply unit and set of logic necessary to operate and control the fly ash system in remote interlocked mode. One additional CPU is provided for each PLC unit to operate as hot stand by to operating one. The PLC systems of both the units are supplied with a common PC based programming station for access to the Proven logic, uploading and down loading of process control software and programmed print out. The PLC system of both the units is located in the control room of the fly ash equipment building. Maintenance of following equipments.

2.

OPERATORS CONSOLE:-

There are two operator consoles, one for each unit. This PC based operator console is hooked up to the respective PLC unit for control and monitoring of the fly ash system operation. The operators console is also located in the control room of the fly ash equipment building.
3. AIR CONDITONERS :-

There are five no air conditioners are provided in the control room to maintain the adequate temperature of PLC unit and operator console. Any type of repair/ servicing of A.C.s along with gas filling shall be in the contractors scope.
4. LOCAL PANNEL:- All local panels are located near auxiliaries.

10.2.

ELECTRICAL POWER FEEDING NETWORK:The power feeding network under system is composed of necessary switchgears, MCCs etc. provided at strategic location to establish efficient power distribution network. The maintenance & testing of all such equipments like:1. H.T. Supply 6.6 KV Supply. 2. L.T. Supply 415 V Supply. 3. Control Syatem Supply 240 V Supply 4. D.C. Supply 220 V Supply. 5. All H.T., L.T., Motors. MAINTENANCE & CALIBERATION OF INSTRUMENTS:1. Pressure Gauge. 2. Limit Switch. 3. Level Indicator. 4. Level Probe. 5. Pressure Switch. 6. Pneumatic Actuators. 7. Motorized Actuators. 8. Various types of solenoid valves. 9. Vacuum Gauges. 10. Diaphragm Valves. 11. Temperature Gauges. 12. Electrical Instruments such as CT, PT, Ammeter, Voltmeters etc. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance, Testing & Calibration of all 0.415KV and 6.6 KV relays of bus MCC and Breaker.

10.3

10.4.

THE DETAILS OF AREAS OF WORK ARE AS UNDER

1. Bottom ash hopper, hopper feed gates, air water converter tanks, eccentric crusher, jet pumps, overflow transfer pumps and bottom ash slurry lines. Fly ash handling system In this system each units has following equipments:a. ESP hopper including diffuser feeders, ash and air intake valves along with other associated fittings.

2.

3. 4. 5.

6. 7. 8. 9. 10.

b. Air pre heater hopper including diffuser feeder, ash and air intake valves along with other associated fittings. c. Branch feeder isolating valves (TERSG). d. Vacuum and pressure conveying lines. e. Mechanical exhauster, air washer and bag filters with associated piping valves etc. f. Surge hopper including vents etc. g. Transfer hopper with associated valves. h. Nova feeder along with associated valve and piping. i. Hydraulic exhauster system. Ash slurry line pumps are in series with slurry piping valves sump etc. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumps etc. Conveying Compressor, ESP Fluidizing Blower, Nova Feeder Fluidizing Blower & Blower heaters etc. Instrument Air compressor (Khosla make) with air drying units along with associated piping valves, coolers and fittings. Silo by-pass arrangement with hydraulic exhauster etc. All make up water, drain and overflow transfer pumps with piping, valves. All pumps and valves along with the pipelines incorporated in the clarifoculator system. The slurry disposal pipelines unto the disposal point and all associated valves. Electrical maintenance including gas filling of Air-Conditioner.

THE SCOPE OF CONTRACT ALSO INCLUDES

I. PURCHASE OF SPARE AND CONSUMABLE:a. The contractor shall assist with planning and procurement of all
needful spares, replacement and other consumables and furnish a list of spares indicating quantity required for efficient operation of plant for one year duration well in advance to enable MPPGCL to purchase. However the contractor has to submit the list of record of all purchased free of supply spare/consumable per month basis to OIC along with bill. The list submitted shall be verified and duly signed by OIC and only necessary spares will be purchased for smooth O&M of AHP. The record of spares indented, consumed and balance stock should be maintained in M.A.S. register and unserviceable spares must be returned to the O&M stores. The monthly rate will cover the provision of consumables like gasket, electrodes and DA & Oxygen gases etc. required for execution of the said O&M job, excluding the supply of lubricant oil, grease and chemicals required for clarifoculator plant, which shall be arranged by MPPGCL, free of cost. However the firm has to maintain the proper consumption record of the consumables and spares supplied by the MPPGCL. Gasket The gasket, which is considered as a spare i.e., formed gasket will be provided by MPPGCL, free of cost. The contractor shall arrange other gaskets. Electrodes General purpose and special purpose electrodes required to carryout the work shall be arranged by the contractor at their own cost.

b. c.

d.

II.

All spares of the Ash Handling system required for unit # 3&4, at SGTPS site shall be provided to the firm by MPPGCL, free of cost, for the smooth

running of the units. However the firm will prepare and submit the list of required spares to MPPGCL, will in advance to enable them to take procurement action. Firm will also extend necessary assistance in this regard. III. Carrying out routine and preventive maintenance work of running units is within the contractors scope. In case of any major breakdown/ overhauling job required to be carried out on the following critical bought out items where specialist services are required from suppliers, the cost involved shall be borne by MPPGCL as per requirement of the MPPGCL. Contractor shall extend assistance and co-operation for the items as mentioned below:(i) Mechanical Exhauster (Vacuum Pump). (ii) Ash Slurry Pumps. (iii) Conveying Compressors. (iv) H.P. Water Pump. (v) PLC (Programmable Logic Control). (vi) Transformers. (vii) H.T. Motors. (viii) MCC. (ix) Switch Gears. (x) H.T. Cranes (xi) UPS (xii) Various types of Relays. (xiii) Instrument Air Compressor. The repairing of diffuser feeder seats and discs, vent and equalizing valve discs and seats, TERSG slides, discs and seats of swing gate valves, pulse jetting cards, pressure and vacuum switches, various gauges etc. due to non availability of spares will be carried-out by the contractor without additional claim. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with transportation cost is in contractors scope at no extra cost. Repairing of Filter Bags There are 1008 bags in Bag Filter of Unit # 3&4. The necessary repairing of these bags by stitching, replacement of cloth for the defective portion, changing of collars etc., at any place will be carried-out by contractor free of cost. Annual Overhauling The cost towards the annual overhauling of any units should be included by contractor in their monthly rate. In case of annual overhauling of any units, overhauling of ash handling system has to be carried out by the contractor on our advice; no additional payment will be reimbursed by MPPGCL. The contractor has to ensure emptiness of all hoppers. During short shutdown of units, Physical inspection of the hoppers shall be carried out. In case of any accumulation found inside the hoppers the same shall be cleared/ cleaned through the system or manual as per instruction of engineer in-charge. The arrangement for watch and ward personnel as may be required for AHP inside and outside of powerhouse shall remain in contractor scope. The watch and ward of the barge pump house and associated auxiliaries and pipelines going to dam are covered in this scope. Watch & ward of ash slurry pipelines recovery water pipe lines shall also in the contractor scope.

IV.

V. VI.

VII.

VIII.

IX.

Along with the O&M work, the rotation of pipes once in a year shall also be in the contractor scope. XI. Any major modification, fresh construction i.e. laying of new pipe lines, construction of brick walls etc., will not cover under the scope of this contract. XII. The contractor must have arrangement of desired vehicle to shift the material/scrap from stores to site or vise versa for which no extra cost shall be reimbursed. XIII. CLEANING:- The contractor shall engage labours regularly for cleaning the area of their scope of work. Ash spread below the bottom ash area of boiler, overflow tank, air heater, and ESP hoppers all pump house etc. has to be cleaned daily. Fine ash dust collected has to be dump in ash slurry sump (if required) of unit 3&4 directly. The area covered under this will start from backside of P.A. fan duct near bottom ash hoppers, air heater hoppers & up to the last ESP hopper in the ground floor. Firm also has to ensure clearness of all trenches of ash pipe lines regularly to facilitate fast maintenance work. The decision of Engineer-In-Charge shall be final in this regard Superintending Engineer (MM)-II SGTPS, MPPGCL, Birsinghpur.

X.

GENERAL TERMS & CONDITIONS

a. The employees/workers shall not any circumstances take their claim for employment in MPPGCL. b. During the contractual period the contractor shall be adhere to the deployment the manpower under various categories proportionately. It is clearly understand the one number each Mechanical & Electrical Engineer and Supervisor must be deployed round the clock for smooth running of AHP of PH-I. c. Contractor shall be responsible for all accident to the labour employed by him. d. The contractor shall be responsible for any damage to the equipment due to improper operation, fitting, and misalignment, lack of supervision and negligence etc. by him or his workmen. Any such damage during the operation and maintenance work, the same shall be made good by the contractor. Any damage to any other equipment of the thermal station caused due to negligence of the contractor and his workmen during operation and maintenance of AHP shall be made good by the contractor as assessed by the Engineer-in-charge.

e. The contract shall be govern by the Factory Act, Minimum wage Act, EPF Act, workmen compensation Act, contractors Labours Act & other relevant act & rule as applicable to the labours employed by him. f. The contractor shall modified the wages period and place, time of disbursement to the workmen engaged on the work as per the payment of wages act and contract act. g. To felicitated prompt payment, the contractor shall obtain insurance policy to cover all labour insurance and submit copy of all documents to the officer-incharge. h. Any accident shall be notified instantly to the officer-in-charge and the contractor shall comply with the instruction issued in this behalf by the MPPGCL. i. The contractor shall maintain all the register and documents envisaged in the contract labour act and rules made their under. He shall also send a monthly statement of workers engaged by him classified according to the skilled and strength to the officer-in-charge. He shall also allow the verification of register and documents maintained by him to the inspecting staff of MPPGCL/Govt. The contractor shall note that the labour engaged by him will be working in the vicinity of running equipments and therefore he shall proper instruction to cautious to the entire worker under their control. The MPPGCL shall not responsible for any accident that may occur and for any compensation that may arise out of the accident.

j.

k. No child labour shall be engaged. l. No advance shall be paid for the subject job/work.

m. Contractor shall obtain license from the appropriate authority under labour act for undertaking the work and for engaging the workmen. Such license shall be renewed from time to time. n. In case of failing to follow statutory rules and regulation the board will be at liberty to recover such amounts from the bills or security deposit of the contractor and also reserve the right to impose suitable penalty. o. The contract is liable for termination within 30 days notice if the work carried out by the contractor is not found satisfactory, security shall also be forfeit. p. Contractor shall arrange insurance for its own men and material only. q. Contractor shall deploy required manpower and if required shall schedule their area of work for smooth and uninterrupted plant operation. Contractor shall be responsible for any accident that may occur and for any compensation that may arise of the accident.

r. In case of delay on contractors part at any stage during the scheduled period, the MPPGCL shall have the option of insuring completion of the job by any other means and the charges accounted on this shall be recovered from the contractors bill or security deposit. s. In case of failure to abide by statutory rules/regulations, the MPPGCL is at liberty to recover such amounts as required from the bills or security deposit of the contractor. t. Furnishing adequate technical backup by the contractor including periodical visit to site by the Engineer for ensuring smooth operation and maintenance of AHP. u. The contractor shall be responsible for any damage to the equipment due to improper operation, fitting, and misalignment, lack of supervision and negligence etc. by him or his workmen. Any such damage during the operation and maintenance work, the same shall be made good by the contractor. Any damage to any other equipment of the thermal station caused due to negligence of the contractor and the contractor as accessed by the Engineer-in-charge shall make his workmen during operation and maintenance of AHP shall be made good by the contractor as assessed by the Engineer-In-charge. In case of failure in doing so, a penalty @5% of the order value (maximum) shall be imposed on the contractor. v. In case of generation loss on account of ash handling system occurred penalty @ 10% shall be imposed on pro-rata basis.

w. The contractor has clean the site daily. In case, the site is not found cleaned in 24 hours a penalty @ 10% of contract value maximum shall be imposed on pro-rata basis. x. Mobile crane required for loading & unloading shall be provided by MPPGCL free of cost, if available. (B) The rules & regulation of M.P. Pollution control board shall be strictly complied and any violation thereof shall be dealt seriously. If any penalty imposed by district/state/central Govt. pollution control authority due to pure maintenance of stack emission or water effluent same shall be recovered by from the monthly running bill of contractor.

SUPERINTENDING ENGINEER (P&W) SGTPS, MPPGCL, BIRSINGHPUR

Part-B SCOPE OF WORK

OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS AUXILARIES, UNIT # 3&4 (2 X 210MW) SGTPS,BIRSINGHPUR
1.0 ASH GENERATION POINTS:-The Ash generated in the boiler is collected under different zones as indicated below:1.1 Furnace ash is collected at the bottom of the furnace hence called the bottom ash. 1.2 Fly ash is collected in 24 ESP Hoppers and 12 Air Heater Hoppers, per unit. MODE OF DISPOSAL:- Different types of Ash stored at various locations are disposed off, as below2.1 The Bottom Ash is stored in water impounded hoppers, at the bottom of the furnace, removed intermittently by operating Clinker Grinder and Jet Propulsion pump to dispose off the Bottom Ash upto the Ash Slurry Sump located at Ash Pump House through 04 Nos. 200 NB pipeline. 2.2 The Fly Ash from ESP & Air Heater Hoppers is collected in a dry form through Vacuum Conveying system and transported upto the surge tank. From the Surge Tank,Pressure System conveys the fly ash upto the far away station silo. In case the silo is full or any maintenance is being carried out in silo then the silo can be bypassed and fly ash can be evacuated in ash slurry sump. A 350 NB line is used to dispose off the fly ash upto the ash slurry sump and a 400 NB line is used to transport the fly ash from ash slurry pump house to silo. 2.4 Both the Bottom Ash and Fly ash thus dumped in ash slurry sump is pumped to the ash pond with the help of Ash Slurry Pump, which is situated around 2.5 km from ash pump house through 04 Nos. of 300 NB each lines.

2.0

3.0

ASH REMOVAL CAPACITIES:3.1 ASH GENERATED AND SYSTEM CAPACITIES.

Specified Ash data Bottom Ash Hopper Air Heater Hopper ESP Hopper Total

: Ash Generation (At 100% MCR with worst coal) : 39 TPH : 12 TPH : 63 TPH : 114 TPH

3.3 EVACUATION CAPACITIES PER UNIT:-

3.2.1 Bottom Ash System (From B.A. Hopper To Ash Slurry Sump):2x60 TPH Through Each of 200 NB MS Pipes.

3.2.3 FLY ASH SYSTEM :

Vacuum (ESP & A/H Hoppers to Surge Tank):- 2x60 TPH through 8 & 9 CI & 350 NB MS Pipe. B. Pressure (Surge Hopper to Silo/Ash Slurry Sump):- 1X120 TPH through 14 & 16 MS Pipe combination. 3.2.3 SLURRY SYSTEM COMMON FOR:- 2x210 MW Unit. For Transporting Bottom Ash (from slurry sump to ash dam) 1x120 TPH through 300 NB MS Pipe.

A.

4.0

ASH CLEANING TIME The Ash Handling System is envisaged to operate the following duration for each of the units. 4.1 Bottom Ash:- Approximately 1 Hrs per 8 hours and operate once per shift per unit. 4.2 Fly Ash :- Approximately 4.5 hrs per shift of 8 hours per unit. OPERATION PHILOSPHY & STANDBY EQUIPMENT
5.1 BOTTOM ASH:- Bottom Ash are evacuated in sequence by operation two diagonally opposite clinker grinder, jet pump and eccentric crusher while keeping other two diagonally opposite sets clinker grinder, jet pump and eccentric crusher as stand by i.e. 10% standby. Bottom Ash is evacuated to ash slurry sump through 200 NB MS Pipe. In all there are four 200 NB lines, two on each side. During normal operation two evacuates bottom ash through 200 NB lines while other two remain as standby.

5.0

5.2 FLY ASH:5.2.1 VACUUM SYSTEM:- Sequential cleaning from ESP & Air Heater

Hoppers up to the surge tank. Two Bag Filters Operate, keeping other two as standby per unit. Two Sets of water ring type Mechanical Exhauster run for 120 TPH for removal of fly ash from ESP & Air Heater Hoppers. Two sets of water ring type Mechanical Exhauster remains as standby.
5.2.2 PRESSURE CONVEYING SYSTEM:- Fly Ash from surge hopper to silo

is transported by air pressure supplied by one number of conveying compressors. One number of conveying compressors remains as stand by per unit. For transporting fly ash from surge hopper to silo/ash sump pressure conveying line is used. For four numbers of Nuva feeder are used for feeding fly ash from surge hopper to pressure conveying line, while other four remain as standby.
5.2.3 WATER AND SLURRRY SYSTEM:- One chain of H.P. Water pump and

one chain of Ash Slurry pump are run per unit for removal of ash slurry from ash slurry sump and transporting it to ash dam. One set of H.P. Water Pump and one set of Ash slurry pump remain as standby.

6.0 BRIEF EQUIPMENT DESCRIPTION

6.1.0 BOTTOM ASH SYSTEM 6.1.1 BOTTOM ASH HOPPER:-

Each unit is provided with one number of water-impounded Bottom ash hoppers with holding capacity of 160 tones of bottom ash.
6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGE ARRANGEMENT:-

Bottom Ash Hopper is W type each V section of the W is provided with two discharge gates, out of which normally one is to operate during ash removal leaving other one as standby.
6.1.3 BOTTOM ASH EQUIPMENT:-

Each discharge gate is provided with one (1) No. Eccentric Crusher and one (1) No. Jet Pump along with other accessories. In all there are four nos. discharge gates. Eccentric crusher can move both the direction i.e. backward and forward.
6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-

Two (2) pipes of 200 NB (MS) per unit, are provided for transporting ash slurry from bottom ash hopper to slurry sump.
6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:-

There are three (3) numbers Overflowing Transfer Pump situated just near bottom ash hopper. These Pumps transfer the over flow water from the bottom ash hopper, which is collected in a overflow sump, is then transferred to either ash slurry sump or clarifoculator through one no. 200 NB line. At a time only one pump is in operation.
6.1.6 BOTTOM ASH PIT CLEANING FACILITY:-

There are two no. Jet Pumps for bottom ash pit cleaning through two nos. 65 NB line from pit to over flow sump.
6.2.0 FLY ASH SYSTEM:6.2.1 REMOVAL OF ASH FROM HOPPERS:-

Vacuum in the lines connecting ESP & Air Heater Hoppers is created with the help of mechanical exhauster as a result of which when the gates of the hoppers open sequentially the ash from the ESP & Air Heater Hoppers get sucked and get transferred to surge hopper through bag filter and transfer hopper. In all there are two streams, in one stream, 12 nos. ESP hoppers and 06 nos. Air Heater hoppers are connected. At a time both the stream is in operation.
6.2.2 DUST COLLECTOR ARRANGEMENT:-

In all there are four nos. of Dust Collector. Each dust collectors consists of 126 nos. filter bags. The mixture of ash and air conveyed through pipelines enter the selected dust collector on conveying circuit. The combination of filter separator and transfer hopper arrangement is used for continuous separation of fly ash from the conveying air and unloading of the free air into the intermediate surge hopper without interruption of the conveying operation. Out of four dusts collector, at a time only two nos. is in operation.
6.2.3 MECHANICAL EXHAUSTER:-

In all there are 4 sets of Water Ring type Mechanical Exhauster for each unit. In general two sets are in operation for each unit. When

operated they create vacuum, which helps in removal and conveying of fly ash from ESP & Air Heater hoppers to intermediate surge hopper.
6.2.4 FLY ASH VACUUM TO PRESSURE TRANSFER:-

Atmospheric surge hopper is provided below dust collector with surge capacity of 60 tons/ section of surge hopper. There are two such section in one surge hopper provided per unit.
6.2.5 PRESSURE FEEDER:-

Each section of surge hopper tank is provided with four nos. feeders. The feeders operate in cycle to discharge fly ash into the pressure conveying lines of 350 NB, in a regular manner. The pressure conveying system evacuates ash in fly ash from surge hopper to silo/ash slurry sump. The second section of surge hopper provided with another four feeders, which remain as standby.
6.2.6 PRESSURE CONVEYING PIPELINE:-

There are two pressure conveying pipe lines 350 NB/400 NB, for each unit for transportation of ash from boiler area to station silo/ash slurry sump. One pipe operates, keeping the other as standby.
6.2.7 PRESSURE CONVEYING BLOWER:-

Four nos. twin lobe types conveying blower are provided, two for each units. At a time only one blower is in operation for each unit.
6.3.0 ASH SLURRY DISPOSAL FACILITY 6.3.1 SLURRY PUMP ARRANGEMENT:-

All the slurry from the plant is received in a distribution chamber. There are four slurry pump compartment and the distribution chamber has individual isolating gates with pipe for discharging slurry into the desired pump.
6.3.2 SLURRY PUMP:-

There are four series of slurry pump. Presently there are two stage of slurry pump in each series for future extension of disposal point.
6.3.3 SLURRY DISPOSAL:-

Each series is rated for 120 TPH Ash Slurry Disposal. One such series has to be operated for removing Bottom Ash from one unit. Fly Ash in slurry from the silo or silo-bypass system can be removed thereafter in a sequential manner. Two series of slurry pump operate, one for each unit while the other two remain as standby.
6.3.4 DISPOSAL PIPELINE:-

Four nos. of 300 NB M.S. disposal pipeline are provided through which slurry is transported. Two such pipes are operating for both the units.

7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:- Fly ash stored in

various hoppers is conveyed unto silos (1A+1B) or silo-bypass system located in Ash Slurry Pump House of PH-II, through a vacuum-pressure

combination system followed by pressure system. The transition of vacuum system to pressure system takes place adjacent of ESP at a transfer point where the separator isolates the fly ash from the air and allows it to pass out through the Mechanical Exhauster (Vacuum Pump), where vacuum is created, and those equipments are located adjacent to ESP and Fly Ash equipment building. Dust separator is located over set of Hopper known as surge hopper. The fly ash thereafter gets transferred to pressure system feeders below the surge hopper, where from it is transported, to plant boundary silo or silo bypass system through pressure conveying system.

8.0 INSTRUMENT AIR SYSTEM:-In PH-II, there are three nos. K.G. Khosla
Compressors Ltd., make Instrument Air Compressor each complete with electric motor and other inbuilt features and accessories are provided to cater to instrument air requirements, for ash handling system. Out of three Instrument Air Compressors, normally one operates to deliver the instrument air requirements for entire system, constituting unit # 3&4. Two nos. Air Drier units each complete with its own features and accessories, are also provided and located at discharge of Instrument Air Compressor, out of which, one Air Drier unit normally operates with the operation of one no. Compressor, keeping the other a stand-by. The instrument air is catered to actuate all pneumatically operated values, bellows, ash hopper feed gates, Nova feeder gates, dust separator gates, and other equipment as well as to meet pulsing air requirement for vent filters. Continuous cooling water requirements for the operating I.A. Compressor, Intercoolers, after coolers, etc. is catered from plant clarified water system and the cooling water return is discharged into the seal water sump.

9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and seal
water trough (LP water pumps/service water pump) overflows from the hopper and is received in respective over flow transfer sump. The bottom ash overflow transfer pumps are operated to pump out this water into the common clarified system. Water over flow from the clarifier is received into collection well and is pumped beck into the ash water sump, by means of Re-cycle water transfer pumps, as the normal input to the LP&HP water pumps. In addition, recovery water from ash pond as and when available through existing recovery water system will be recycled back into to the ash water sump clarifier) by means of recycle water transfer pumps to provide normal input to LP&HP water pumps during bottom ash and fly as cleaning. The return water form mechanical exhauster and air-washer during fly ash cleaning operation is received in respective drain transfer sump and is discharged into the bottom ash, overflow transfer sump, by means of Drain Transfer pumps, for further pumping into the clarifier. The sludge pumps belonging to be the clarifier are operated to pump-out the accumulated sludge from the clarifier, sludge pit into the ash slurry sump. The seal water pumps are energized to cater to water requirement for operating pumps/equipment-having requirement of external seal water.

10. ELECTRICAL AND INSTRUMENT:10.1 CONTROL SYSTEM:- Necessary remote and local control panels and

control stations are provided at strategic locations to offer a duly interfaced and synchronized control for the overall ash handling system. The System controls are provided to offer necessary operating interfaces among the various sub-systems to achieve a

duly co-ordinated system operation from various control panels and control stations. An electromagnetic relay/PLC based control network is interlocks associated with the system operation and control.

Maintenance of the following Equipments

1. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:-

There are two numbers of PLC unit, one for each unit. This microprocessor based unit is configured with Central Processing Unit, power supply unit and set of logic necessary to operate and control the fly ash system in remote interlocked mode. One additional CPU is provided for each PLC unit to operate as hot stand by to operating one. The PLC systems of both the units are supplied with a common PC based programming station for access to the Proven logic, uploading and down loading of process control software and programmed print out. The PLC system of both the units is located in the control room of the fly ash equipment building. Maintenance of following equipments.
2. OPERATORS CONSOLE:-

There are two operator consoles, one for each unit. This PC based operator console is hooked up to the respective PLC unit for control and monitoring of the fly ash system operation. The operators console is also located in the control room of the fly ash equipment building.
3. AIR CONDITONERS :-

There are five no air conditioners are provided in the control room to maintain the adequate temperature of PLC unit and operator console. Any type of repair/ servicing of A.C.s along with gas filling shall be in the contractors scope.
4. LOCAL PANNEL:- All local panels are located near auxiliaries.

10.2.

ELECTRICAL POWER FEEDING NETWORK:The power feeding network under system is composed of necessary switchgears, MCCs etc. provided at strategic location to establish efficient power distribution network. The maintenance & testing of all such equipments like:1. H.T. Supply 6.6 KV Supply. 2. L.T. Supply 415 V Supply. 3. Control Syatem Supply 240 V Supply 4. D.C. Supply 220 V Supply. 5. All H.T., L.T., Motors. MAINTENANCE & CALIBERATION OF INSTRUMENTS:1. Pressure Gauge. 2. Limit Switch. 3. Level Indicator. 4. Level Probe. 5. Pressure Switch. 6. Pneumatic Actuators. 7. Motorized Actuators. 8. Various types of solenoid valves. 9. Vacuum Gauges.

10.3

10. Diaphragm Valves. 11. Temperature Gauges. 12. Electrical Instruments such as CT, PT, Ammeter, Voltmeters etc. 10.4. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance, Testing & Calibration of all 0.415KV and 6.6 KV relays of bus MCC and Breaker.

THE DETAILS OF AREAS OF WORK ARE AS UNDER

3. Bottom ash hopper, hopper feed gates, air water converter tanks, eccentric crusher, jet pumps, overflow transfer pumps and bottom ash slurry lines. Fly ash handling system In this system each units has following equipments:a. ESP hopper including diffuser feeders, ash and air intake valves along with other associated fittings. b. Air pre heater hopper including diffuser feeder, ash and air intake valves along with other associated fittings. c. Branch feeder isolating valves (TERSG). d. Vacuum and pressure conveying lines. e. Mechanical exhauster, air washer and bag filters with associated piping valves etc. f. Surge hopper including vents etc. g. Transfer hopper with associated valves. h. Nova feeder along with associated valve and piping. i. Hydraulic exhauster system. Ash slurry line pumps are in series with slurry piping valves sump etc. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumps etc. Conveying Compressor, ESP Fluidizing Blower, Nova Feeder Fluidizing Blower & Blower heaters etc. Instrument Air compressor (Khosla make) with air drying units along with associated piping valves, coolers and fittings. Silo by-pass arrangement with hydraulic exhauster etc. All make up water, drain and overflow transfer pumps with piping, valves. All pumps and valves along with the pipelines incorporated in the clarifoculator system. The slurry disposal pipelines unto the disposal point and all associated valves. Electrical maintenance including gas filling of Air-Conditioner.

4.

3. 4. 5.

6. 7. 8. 9. 10.

THE SCOPE OF CONTRACT ALSO INCLUDES

I. PURCHASE OF SPARE AND CONSUMABLE:a. The contractor shall assist with planning and procurement of all
needful spares, replacement and other consumables and furnish a list of spares indicating quantity required for efficient operation of plant for one year duration well in advance to enable MPPGCL to purchase. However the contractor has to submit the list of record of all purchased free of supply spare/consumable per month basis to OIC along with bill. The list submitted shall be verified and duly signed by OIC and only necessary spares will be purchased for smooth O&M of AHP. The record of spares indented, consumed and balance stock should be maintained in M.A.S. register and unserviceable spares must be returned to the O&M stores. The monthly rate will cover the provision of consumables like gasket, electrodes and DA & Oxygen gases etc. required for execution of the said O&M job, excluding the supply of lubricant oil, grease and chemicals required for clarifoculator plant, which shall be arranged by MPPGCL, free of cost. However the firm has to maintain the proper consumption record of the consumables and spares supplied by the MPPGCL. Gasket The gasket, which is considered as a spare i.e., formed gasket will be provided by MPPGCL, free of cost. The contractor shall arrange other gaskets. Electrodes General purpose and special purpose electrodes required to carryout the work shall be arranged by the contractor at their own cost.

b. c.

d.

II.

All spares of the Ash Handling system required for unit # 3&4, at SGTPS site shall be provided to the firm by MPPGCL, free of cost, for the smooth running of the units. However the firm will prepare and submit the list of required spares to MPPGCL, will in advance to enable them to take procurement action. Firm will also extend necessary assistance in this regard. Carrying out routine and preventive maintenance work of running units is within the contractors scope. In case of any major breakdown/ overhauling job required to be carried out on the following critical bought out items where specialist services are required from suppliers, the cost involved shall be borne by MPPGCL as per requirement of the MPPGCL. Contractor shall extend assistance and co-operation for the items as mentioned below:(i) Mechanical Exhauster (Vacuum Pump). (ii) Ash Slurry Pumps. (iii) Conveying Compressors. (iv) H.P. Water Pump. (v) PLC (Programmable Logic Control). (vi) Transformers. (vii) H.T. Motors. (viii) MCC. (ix) Switch Gears. (x) H.T. Cranes (xi) UPS

III.

(xii) Various types of Relays. (xiii) Instrument Air Compressor. The repairing of diffuser feeder seats and discs, vent and equalizing valve discs and seats, TERSG slides, discs and seats of swing gate valves, pulse jetting cards, pressure and vacuum switches, various gauges etc. due to non availability of spares will be carried-out by the contractor without additional claim. V. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with transportation cost is in contractors scope at no extra cost. VI. Repairing of Filter Bags There are 1008 bags in Bag Filter of Unit # 3&4. The necessary repairing of these bags by stitching, replacement of cloth for the defective portion, changing of collars etc., at any place will be carried-out by contractor free of cost. VII. Annual Overhauling The cost towards the annual overhauling of any units should be included by contractor in their monthly rate. In case of annual overhauling of any units, overhauling of ash handling system has to be carried out by the contractor on our advice; no additional payment will be reimbursed by MPPGCL. VIII. The contractor has to ensure emptiness of all hoppers. During short shutdown of units, Physical inspection of the hoppers shall be carried out. In case of any accumulation found inside the hoppers the same shall be cleared/ cleaned through the system or manual as per instruction of engineer in-charge. IX. The arrangement for watch and ward personnel as may be required for AHP inside and outside of powerhouse shall remain in contractor scope. The watch and ward of the barge pump house and associated auxiliaries and pipelines going to dam are covered in this scope. Watch & ward of ash slurry pipelines recovery water pipe lines shall also in the contractor scope. X. Along with the O&M work, the rotation of pipes once in a year shall also be in the contractor scope. XI. Any major modification, fresh construction i.e. laying of new pipe lines, construction of brick walls etc., will not cover under the scope of this contract. XII. The contractor must have arrangement of desired vehicle to shift the material/scrap from stores to site or vise versa for which no extra cost shall be reimbursed. XIII. CLEANING:- The contractor shall engage labours regularly for cleaning the area of their scope of work. Ash spread below the bottom ash area of boiler, overflow tank, air heater, and ESP hoppers all pump house etc. has to be cleaned daily. Fine ash dust collected has to be dump in ash slurry sump (if required) of unit 3&4 directly. The area covered under this will start from backside of P.A. fan duct near bottom ash hoppers, air heater hoppers & up to the last ESP hopper in the ground floor. Firm also has to ensure clearness of all trenches of ash pipe lines regularly to facilitate fast maintenance work. The decision of Engineer-In-Charge shall be final in this regard. IV.

Superintending Engineer (P&W) SGTPS, MPPGCL, Birsinghpur.