ABSTRACT

I am extremely grateful to the management of DAMODAR VALLEY CORPORATION,

DURGAPUR, especially to Chief Engineer who allowed me to undergo in-plant training
from 16th Dec 2014 to 31s t Dec 2014.

During my training experience I studied Design Details of Fly Ash Silos,

Compressor House from Pile Foundation to Roof Slab.

I express my gratitude to Mr. SALIL MOHAN BALI Sir (S.E Civil) and his colleagues and
heartiest thanks to Mr. Rajeev Sir (Assistant Engineer Civil), who escorted at every
construction site and explained details about drawing design of construction.

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CONTENTS
About Damodar Valley Corporation (D.V.C)
History
Power Generation
Functions

About Damodar Thermal Power Station (D.T.P.S)

Fly Ash
Introduction
Fly Ash Reuse
Fly Ash Collection System for Units 3 & 4

Compressor House
SILO
Introduction
Silo Types
Advantages of Concrete SILOS over Metal Welded OR Bolted
SILOS Details of Utility Building

SILO at DTPS
G.A & R.C Details of SILO Utility Building

Construction Of SILO at DTPS

Soil Investigation
Design details of pile at SILO Site
Design of SUB-STRUCTURE

Conclusion

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ABOUT
DAMODAR VALLEY CORPORATION
History:
DVC, a legacy to the people of India, emerged as a culmination
of the attempts made over a whole century to control the wild
and erratic Damodar River. The river spans over an area of
25,000 km2 covering the states of Jharkhand & West Bengal
.The Corporation came into existence on 7 July 1948, by the
Damodar Valley Corporation Act (Act No. XIV of 1948) passed
by the Central Legislature in March 1948, as the first
multipurpose river valley project of independent India.

Power Generation:
Entrusted with the responsibilities of providing the vital input
power for industrial growth in the resource rich Damodar
Valley region, DVC has been practically operating as a pioneer,
using latest available technologies to supply bulk power at
reasonable rates to the major industries. DVC has maintained
its lead role in the eastern region by adopting itself to the
challenges of time and technology during the course of last 64
years. DVC has been generating and transmitting power since
1953 and has succeeded not only in meeting the needs of
consumers but has also helped to increase the demand of
power which itself is an index of development.
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WATER RESOURCE MANAGEMENT:

For flood control

and irrigation, DVC has developed a network of brief details at

exhibit-I. The barrage at Durgapur and Canal Network has
been handed over to the Government of West Bengal for
management and operation 1964.
DVC Dams are capable of moderating floods of 6.5 Lakh cusecs
to 2.5 Lakh cusecs. The gross irrigation command area of DVC
reservoirs at Mathon and Panchet for Flood moderation,
irrigation

and

supply to

other

consumers is made

in

consonance with the decisions arrived at, by Damodar Valley

Reservoir

Regulation

Committee

(DVRRC)

based

on the

collected data and flood forecasting by the Flood forecasting

Unit (FFU) and the Reservoir Operation and Control Unit
(ROC)

at

Mathon. The Committee functions under the

Chairmanship of Member (RM), Central Water Commission

with members from State Government of West Bengal and
Jharkhand and from DVC.

ECO-CONSERVATION AND AFFORESTATION:

DVC happens to be the first river valley authority to take up
watershed management and related activities on a regular and
substantial basis. Watershed Management is mainly oriented at
control of soil erosion in the upper valley area.
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7. Ash handling Plant

8. Fuel Handling Plant
9. Boiler, Turbines, Generators, Transformers and Auxiliaries
10. Switch Yard
11. Instrumentation And Control
12. Compressor House
13. Pumps
14. Stores
15. Ancillary Facilities
16. Laboratory & Workshop

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of silicon dioxide (SiO2) (both amorphous and crystalline) and

calcium oxide (CaO), both being endemic ingredients in many
coal bearing rock strata.
Constituents depend upon the specific coal bed makeup, but
may include one or more of the following elements or
substances found in trace quantities (up to hundreds ppm):
arsenic, beryllium, boron, cadmium, chromium, hexavalent
chromium, cobalt, lead, manganese, mercury, molybdenum,
selenium, strontium, thallium, and vanadium, along with
dioxins and PAH compounds.
In the past, fly ash was generally released into the atmosphere,
but pollution control equipment mandated in recent decades
now requires that it be captured prior to release.
In the US, fly ash is generally stored at coal power plants or
placed in landfills. About 43% is recycled, often used as a
pozzolan to produce hydraulic cement or hydraulic plaster or a
partial replacement for Portland cement in concrete
production.
Pozzolans ensure the setting of concrete and plaster and
provide concrete with more protection from wet conditions
and chemical attack. Some people have expressed health
concerns about using concrete containing fly ash.

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In some cases, such as the burning of solid waste to create

electricity (resource recovery facilities a.k.a. waste-to energy
facilities), the fly ash may contain higher levels of contaminants
than the bottom ash and mixing the fly and bottom ash
together brings the proportional levels of contaminants within
the range to qualify as nonhazardous waste in a given state,
whereas, unmixed, the fly ash would be within the range to
qualify as hazardous waste.

Fly ash reuse

There is no U.S. governmental registration or labelling of fly
ash utilization in the different sectors of the economyindustry, infrastructures and agriculture. Fly ash utilization
survey data, acknowledged as incomplete, are published
annually by the American Coal Ash Association. Coal ash uses
include (approximately in order of decreasing Importance.
1) Concrete production, as a substitute material for Portland
cement and sand
2) Embankments and other structural fills (usually for road
construction)
3) Grout and Flow able fill production
4) Waste stabilization and solidification
5) Cement clinkers production - (as a substitute material for
clay)
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6) Mine reclamation
7) Stabilization of soft soils
8) Road sub base construction
9) As Aggregate substitute material (e.g. for brick production)
10) Mineral filler in asphaltic concrete
11) Agricultural uses: soil amendment, fertilizer, cattle
feeders, soil stabilization in stock feed yards, and agricultural
stakes
12) Loose application on rivers to melt ice
13) Loose application on roads and parking lots for ice control
14) Other applications include cosmetics, toothpaste, kitchen
counter tops, floor and ceiling tiles, bowling balls, flotation
devices, stucco, utensils, tool handles, picture frames, auto
bodies and boat hulls, cellular concrete, geo-polymers,
roofing tiles, roofing granules, decking, fireplace mantles,
cinder block, PVC pipe, Structural Insulated Panels, house
siding and trim, running tracks, blasting grit, recycled
plastic lumber, utility poles and cross arms, railway sleepers,
highway sound barriers, marine pilings, doors, window
frames, scaffolding, sign posts, crypts, columns, railroad ties,
vinyl flooring, paving stones, shower stalls, garage doors,
park benches, landscape timbers, planters, pallet blocks,
molding, mail boxes, artificial reef, binding agent, paints and
undercoatings, metal castings, and filler in wood and plastic
products.

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Fly Ash Collection System for Units 3 & 4

Fly Ash

is collected

with the help of ESP(Electrostatic

Precipitator) and is conveyed pneumatically under negative

pressure through specially designed valves and pipelines from
Fly Ash Hopper to Silo or to Intermediate surge tank for Dry
ash storage and removal in dry or semi-dry condition or to
Wetting Unit/Collector Tank /Hydraulic Exhauster for removal
in wet slurry from directly to ash dump area or to slurry
sump for onward slurry pumping to ash dump area.
When Dry or semi dry Fly ash collection and disposal is
desired, Silos of RCC or Steel construction collect the Ash from
Conveying System either directly or through Dust Separator.
Silos are provided with fluidising arrangement for easy
discharge of Ash through the bottom outlets.
Ash Unloading System options from Silos are:1. Complete Dry Unloading into enclosed tankers/Wagons.
2. Semi Dry unloading to open Trucks/Wagons.
3. Dry/Semi Dry unloading to Belt Conveyor Systems.
4. Wet unloading through Feeder Ejectors for Ash disposal in
slurry form.
The Ash sisposed off into transport vehicle are carried out to
different plants namely Cement making plant foe extensive use
as an admixture. Also it

can be used as backfill for areas

where coal is extracted thereby reducing the hazardous effect

of underground fire.

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COMPRESSOR HOUSE

Compressors are the mechanical means to increase vapour

pressure, as pumps are used to increase liquid pressure.
There are two basic types of Compressor
a) Reciprocating
b) Centrifugal
Reciprocating compression is the force converted to pressure by
the movement of the piston in cylinder.
Centrifugal compression is the force converted to pressure
when a gas is ejected by an impeller velocity.
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with digital display and printer. This allows any quantity of

cement or powder discharged from the silo to be controlled
and also provides an accurate indication of what remains
inside the silo. The static upright silos have capacities from 20
to 80 tons. These are considered a low-maintenance option for
the storage of cement or other powders. Cement silos can be
used in conjunction with bin-fed batching plants.

Silo types
a) Cement storage silos
b) Tower silo
i. Concrete stave silos
ii. Low-oxygen tower silos
c) Bunker silos
d) Bag silos
e) Bins
f) Sand and salt silos
g) Fabric silos

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ADVANTAGES OF CONCRETE SILOS

OVER METAL WELDED OR
BOLTED SILOS
1) Concrete silos are typically lower in cost than metal silos.
2) Concrete silos have good resistance to corrosion. This includes
both corrosion of internal walls due to the stored bulk solid
and also external corrosion caused by moisture. Metal
corrosion is a well-known problem.
3) No need for expensive painting of silos due to corrosion thus
lowering operational cost.
4) There is no concern about electrolytic effects at welds or
liner connections.
5) Careless detailing of metal walls may leave inward facing
ledges or welds, which can obstruct flow and increase wall
pressures. This is avoided with concrete.
6) Concrete is better able to resist abrasive wear than most
metals.
7) Concrete is more robust and thus better able to withstand
internal pressure loads and impact loads.
8) Concrete has higher wall friction angles with most bulk solids
than most metals. This results in higher frictional drag down

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the cylinder walls and hence lower pressures acting normal

(i.e. perpendicular) to cylinder and hopper walls.
9) There is no concern about weld quality or stress risers, such
as bolted connections.
10) There is no concern about leakage to the environment,
which can be a problem when storing fine powders in bolted
silos.

Conclusion: Concrete always beats steel!

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SILO AT DTPS

G.A & R.C DETAILS OF SILO UTILITY BUILDING

FOR FOOTING MKD.F1:
LAYOUT-

1800 X 1800

COLOUMN-

350 X 450

DIAMETER OF ROD- 16mm & 20 mm

TOTAL DEPTH-

4000 mm

FOR FOOTING MKD.F2:

LAYOUT-2400 X 2400 mm
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CONSTRUCTION of SILO at
DTPS
During training I underwent through design details of the
pilling, their pile cap, pedestal, raft and column raised over
them. Although their construction were over but king guidance
of engineer sir made me understand about their design details.

Soil Investigation
Geotechnical investigations are performed by geotechnical
engineers or engineering geologists to obtain information of
physical properties and characteristics like bearing earthworks
and foundations for proposed structures. Methods of observing
the soils below the surfaces, obtaining samples, and
determining physical properties of the soils and rocks include
Tests Pits, Trenching (particularly for locating faults and slide
planes), and Boring and in-situ tests.

The extensive soil investigation conducted by the engineers

clearly suggested that the soil is clayey along with sandy soil
found in some patches around the site area.
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Based on soil condition it is highly recommended a

foundation and

deep

also due to very heavy design loads.

So the type of foundation used for silo is PILE FOUNDATION. The

pile foundation chosen is CAST-IN SITU R.C.C BORED PILE which
acts as a FRICTION PILE due to the presence of clayey soil in the
strata. It also acts as an END BEARING PILE for some part of the
soil strata owing to the presence of sandy soil.

Design details of pile at SILO Site

There were 144 piles, 36 piles in one group at fixed grid.
Piles are bored cast in-situ concrete piles conforming to

IS:2911(PART-1/SEC-2).
Reinforcement are HYSD bars Fe-500 conforming to
IS:1786.
Diameter of PILE 500 mm
Depth of pile 24 m
Due to unavailibility of 24 m long bar, two types of bar
are provided.
o 7 numbers of 20mm diameter Fe500 HYSD Bars are
reinforced up to 3700mm from pile cut-off level.
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o 7 numbers of 16mm diameter Fe500 HYSD Bars are

provided below that
Laps are staggered alternatively having Lap length 50
times bar dia.
Fe500 HYSD Bars are supported by 8mm diameter of ring
bars arranged as spiral ring provided at 150 mm c/c.
Clear covers to longitudinal reinforcement are 60 mm for
pile and pile cap, 50 mm for column and beam.
Pile integrity test on job piles are done as per specification.
In one eow 12 piles are alligned,each pile is spaced at

1500mm c/c.
Over One pile group three coloumns have to be raised to
distribute the load evenly on all piles. 1300 mm of Pedestal
and 1200 mm of raft are constructed.
Top concrete in a pile are brought about yhe cut-off level
to permit removal of all laitance and weak concrete before
capping and to ensure good concrete at the cut-off level
for embedment in to pile cap.However concrete are done
up to at leat 1000mm above cut-off level.
Exposed reinforcement are properly embedded in pile cap.
M25 grade concrete are used as per IS:456-2000 with
minimum cement concrete as 400 kg/m 3
Ordinary cement with C3A content between 5 to 8% are
used.
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Design of SUB-STRUCTURE

Coloumn MKD c2-1300 mm x 1300 mm-1 No.

a) 8mm dia lateral ties @ 100 c/c.

b) 14 Nos per set.
c) 4 Nos 32mm dia and 28Nos 25mm dia.
d) Laps staggered and not more than 50% Bars are
splied at one section.

Coloumn MKD c1-1000 mm x 1000 mm-2 No.

a) 8mm dia lateral ties @ 100 c/c.

b) 10 Nos per set.
c) 8 Nos 28 mm dia and 16Nos 25 mm dia.
d) Laps staggered and not more than 50% Bars are
splied at one section.

Tie beams TB1, TB2 & TB3 (500 X 750)

a) 3-25 mm dia & 2-28 mm dia ALTH. At top of beam.

b) 3-20 mm dia & 2-16 mm dia ALTH. At bottom of
beam.

c) 2L-8 mm dia @150 c/c from the face of coloumn c1

upto 1400 mm span at both sides of beam i.e from
column c2.

d) 2L-8 mm dia @250 mm c/c .

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Tie beams TB4 & TB6(300 X 450)

a) 3-20 mm dia ALTH. Both sides top and bottom.

b) 2L-8 mm dia supported Fe500 HYSD BARS @175 c/c
.

c) 2L-8 mm dia are provided @ 100 mm c/c .

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CONCLUSION
The practical experience that we gathered during the training
is very helpful in our coming practical life. It gives us very
wide spectrum to utilize the theoretical knowledge to put
into practice.
The trouble shooting activities during the operation and
decision making in case of crisis make us confident to work in
industrial atmosphere.
Moreover, working in the industry along with Engineers,
workers, staff members, and superiors give us a chance to
enhance our interpersonal relationship.
I hope that in the future also D.T.P.S will teach youngsters the
same way as it is teaching now.
Looking forward for a better future...
THANK YOU D.T.P.S....

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