Intent of Specification This specification is intended to cover the following activities and services in respect of all the equipment

of Ash Handling Plant for (2 x 500 MW) units. 2.1.0 Scheme of Ash Handling System: 2.1.1 Bottom Ash Handling System The Bottom Ash handling system shall be of Wet type with water impounded hopper and jet pumps for intermittent removal. The bottom ash resulting from the combustion of coal in the boiler shall fall into a W-type water impounded (water filled) ash storage hopper provided under the furnace bottom. The bottom ash hopper discharge gates shall be opened twice in a shift of eight (8) hrs. and the stored ash shall be removed by means of jet pumps and transported in slurry pipe lines to the ash slurry sump, integral in the ash slurry pump house for its further disposal to the dump area by means of ash slurry disposal pumps. Each section of the bottom ash hopper shall be provided with two (2) nos. ash gates, two (2) nos. clinker grinders and two (2) nos. jet pumps complete with feed gate housings. Only one set of equipment under each section shall be in operation during the ash removal operation, with the other set as standby. 2.1.2 Economiser and Air Preheater Ash Removal System Ash collected in economiser, economiser bypass duct, primary air heater and secondary air heater hoppers will drop continuously through suitable vertical pipe connections to the flushing connections provided beneath each of the hoppers. The flushing equipment serves to mix the ash with the water and discharge the ash in the form of slurry. The slurry from flushing equipments shall be led to economiser & air preheater slurry trench, which in turn shall be connected to ESP fly ash slurry trench. The economiser and air preheater ash slurry alongwith ESP fly ash slurry shall be conveyed to the sump of combined ash slurry pump house through ESP fly ash slurry trench. 2.1.3 Dry Fly Ash Extraction and Transportation System : The dry fly ash handling system consist of ESP and duct hopper ash removal systems. A two stage conveying system shall be provided. The first stage shall include extraction of dry fly ash from under the various ESP / duct hoppers to the intermediate surge/buffer hoppers / collector tanks located near the ESPs. In the second stage ash shall be conveyed/transported from under these buffer hoppers to the storage silos located outside plant boundary. A vacuum system shall be provided for extraction of dry fly ash in the first stage, for second stage, viz., transportation of dry fly ash to the main storage silos, located outside plant boundary shall be necessarily by the pressure conveying system only. 2.1.4 Fly Ash Extraction System The first stage vacuum extraction system shall include extraction by vacuum of ash from various ESP and duct hoppers to the intermediate surge/buffer hoppers/collector tanks located near the ESPs. First stage vacuum extraction shall have the feature of segregation of ash from various fields of ESP and duct hoppers. The scheme envisages extraction of dry fly ash from under the ESP and duct hoppers by four (4) nos. of normal working vacuum pumps with 100% standby for each unit i.e. a total of eight (8) nos. for each unit. However, interconnection between the dedicated standby vacuum pumps of adjacent streams is envisaged to improve the availability & flexibility in operation of the streams. Each vacuum pump dedicated to a stream, shall extract both the coarse and fine fly ash. The vacuum extraction shall operate so as to allow sequential ash discharge from ESP and duct hoppers into the conveying system which shall be in continuous operation. On completion of ash removal from all the ESP and duct hoppers connected to a vacuum pump stream, the deashing shall be reinitiated automatically.

For each ash extraction stream one number surge/buffer hopper is envisaged. Fly ash can be either collected in buffer hoppers and conveyed to storage silos or fed to wetting head and collector tank units provided through the tap off upstream of respective buffer hoppers. In the wetting head and collector tank unit the fly ash is mixed with water and resultant slurry is discharged for further conveying it to the combined ash slurry disposal pump house sump via pipelines and slurry trenches. Water for wetting head and collector tank units shall be drawn from discharge of fly ash HP water pump. One working and one standby wetting head and collector tank unit shall be provided for each ash extraction stream. The surge/buffer hoppers shall be equipped with primary collectors/ secondary collectors/target box alongwith bag filter as applicable to vacuum extraction system. Air blowers for each unit shall be provided to aerate ash inside the buffer hoppers to facilitate free flow of ash. Instrument air compressor, for each unit shall also be provided to meet the complete instrument air requirements i.e. valve actuation, bag filter cleaning etc. of the ash handling system. 2.1.5 Dry Fly Ash transportation System For second stage conveying each surge/buffer hopper shall be provided with locks/pumps tank/ash transporters of adequate number and capacity. Three (3) nos. pressure conveying pipe lines for one unit shall be provided, two (2) working and the third line as standby, to continuously transport the dry fly ash (both coarse and fine) from surge/buffer hoppers to storage silos. Transport of fly ash from each unit surge/buffer hoppers to the storage silos, located outside plant boundary, shall be with the help of 350% transport air compressors suitably sized and designed to cater to the ash evacuation requirements of one unit. However, the same set of 350% transport air compressors shall be used for catering to the ash evacuation requirements of the second unit also. Adequate space provisions shall be kept within the dry fly ash transportation pipe trestle, compressor house & the associated MCC room for further extension, if required. 2.1.6 Dry Fly Ash Storage For dry ash storage two (2) silos are envisaged. Each silo shall have the minimum effective capacity to store 1000M of dry fly ash. Provisions in the feed system shall be kept to facilitate inter change. In case of increased demand of fly ash Purchaser proposes to add additional silos of same or higher capacity. Bidder shall keep the provisions in Ash Handling Plant for future addition of silos such that additional silos can be added without affecting the existing system operation. For each of the main storage silos four (4) outlets at the bottom shall be provided. One outlet shall be fitted with Ash conditioner for loading the ash into open trucks. Second outlet shall be provided with telescopic chute and rotary feeder for loading the ash into closed tankers, third and fourth connection at present shall be blanked connection and shall be provided with isolation valve. One of the blanked connection will be used in future for adding pneumatic equipment for transportation of fly ash to third party. Other connection shall be used in future for wetting head with suitable pumping arrangement to bring the ash slurry from silo area to the combined slurry disposal pump house. Layout provision for above facilities shall be kept in silo area. The storage silos shall be fitted with bag filters and fans for cleaning the vent air before discharging to the atmosphere. Each storage silo shall be provided with a dedicated aeration system. 2.1.7 Ash Disposal System For both the units, bottom ash from discharge of jet pumps, economiser and air preheater slurry from discharge of flushing apparatus and fly ash slurry from wetting head, collector tanks and airwasher units provided upstream of buffer hoppers shall be led to a common slurry sump of combined ash slurry disposal pump house which will have two (2) compartments each serving for two (2) streams of slurry disposal pumps. From the sump, the slurry shall be continuously pumped to the disposal area by means of slurry pump sets and

disposal pipes. The ash slurry disposal system envisages four (4) identical streams (series) of ash slurry pumps connected to four (4) nos. disposal pipe lines. Of the four (4) pump streams and associated disposal pipe lines provided, two (2) nos. will be working continuously and out of the remaining two streams, and associated disposal pipelines one will always be available as standby even when the other is under maintenance. No interconnection between the slurry discharge lines are to be provided. Provision shall be kept to supply water at each of the slurry disposal pump stream suction for flushing the disposal line by running the slurry disposal pumps stream (series) prior to shut down of a pump stream. For supplying the raw water at the suction of slurry disposal pumps stream, flushing water pumps shall be provided and the water connection shall be made on down stream of the suction valve of the slurry pump series alongwith necessary piping and valves. 2.1.8 Water Facilities It is proposed to operate the ash water system in a closed circuit. The ash water from the ash dyke shall be re-used after treating a part of the same in a side stream lime softening plant. During recirculation mode the make up to ash water system (to compensate for the ash water blow down and evaporation loss) shall be supplied from the CW system blow down water. For the purpose of water supply to the ash handling system, water pumps taking suction from overground RCC sump shall be installed in the ash water pump house envisaged. Water supply to ash water pump house shall be tapped from following sources : (a) Recirculated ash water from ash pond area as the normal water supply, whenever available. (b) CW System Blowdown : This water shall be used for the purpose of supplying make up to the normal water supply, i.e. when the ash handling system is operating on recirculation mode. CW blow down alongwith raw water shall be used during once through mode i.e. when recirculated ash water from ash pond is not available. (c) Raw Water make up : The raw water alongwith CW blow down water shall be used for initial period or during emergency period when recirculated ash water from ash pond area is not available. (d) The fly ash slurry disposal water requirements for disposal of fly ash in slurry form, from the wetting head and collector tank is to be met from fly ash water pumps to be located in the ash water pump house. 2100% fly ash water pumps for each unit are envisaged for the purpose. The bottom ash hopper overflow water shall be led to an overflow tank in case of water impounded hopper system. Bottom ash over flow water pumps shall take suction from over flow tank/sump and pump the water to the required treatment facilities where the water shall be treated so that outlet water quality is having TSS < 100 ppm. This treated water shall be led to sump of ash water pump house, through gravity flow. (f) Sealing Water Sealing water for ash slurry pumps, vacuum pumps, clinker grinder etc. shall be from CW system blow down. The maximum temperature of seal water shall be 36oC. No seal water shall be wasted. After sealing, the seal water shall be led to sump of slurry pump house, to be used as make up. (g) Cooling Water Demineralised water (DM) shall be provided to meet cooling water requirements of various heat exchangers, intercoolers, after coolers etc. The inlet temperature of 39oC and outlet temperature of 43oC of DM water, for sizing various heater exchanger shall be considered. PH of DM water shall be 9.5. Inlet pressure of DM water shall be 10 kg/cm2(g). Heat exchangers etc. shall be sized for 10 kg/cm2(g) inlet pressure of DM water and 3.5 kg/cm2(g) pressure drop in the system. All valves,

piping, fittings and equipments handling DM Water shall be of suitable construction material. 2.1.9 Ash Dyke Water Recirculation and Side Stream Filtration System Ash dyke decanted water shall be recirculated back from ash dyke to plant for treatment and reuse in ash handling system. The decanted ash water from ash dyke shall be recirculated in the ash handling system after treatment. Decanted water shall be pumped to the sump of ash water pump house through a single pipeline. A tapping shall be taken from this header to the side stream treatment plant.