INDIA POWER CORPORATION (HALDIA) LIMITED

HALDIA THERMAL POWER PROJECT

UNITS [3 x 135 MW]

EPC PACKAGE

OVERALL CONTENTS

VOLUME-I : CONDITIONS OF CONTRACT

VOLUME-II : TECHNICAL SPECIFICATION

VOLUME-III : BID PROPOSAL SHEETS [TECHNICAL PART]

VOLUME-IV : BID PROPOSAL SHEETS [PRICE PART]

(PCA.CD-003.368309013.doc)
 CONTENTS

VOLUME : II TECHNICAL SPECIFICATIONS

VOLUMES DESCRIPTION

VOLUME II-A : LEAD SPECIFICATION

VOLUME II-B : SPECIFICATIONS FOR STEAM GENERATOR & AUXILIARIES

VOLUME II-C : SPECIFICATIONS FOR TURBINE-GENERATOR, AUXILIARIES &

OTHER FEED CYCLE EQUIPMENT

VOLUME II-D : SPECIFICATIONS FOR POWER CYCLE & OTHER PIPING,

VALVES & SPECIALTIES

VOLUME II-E : SPECIFICATIONS FOR CONTROLS & INSTRUMENTATION

VOLUME II-F/1 & : SPECIFICATIONS FOR ELECTRICAL EQUIPMENT AND

VOLUME II-F/2 ACCESSORIES [IN TWO VOLUMES]

VOLUME II-F/3 : SPECIFICATIONS FOR SWITCHYARDS

VOLUME II-G/1 & : SPECIFICATIONS FOR CIVIL, STRUCTURAL AND

VOLUME II-G/2 ARCHITECTURAL WORKS [IN TWO VOLUMES]

VOLUME II-H : SPECIFICATIONS FOR ASH HANDLING SYSTEM

VOLUME II-I : SPECIFICATIONS FOR MAIN & AUXILIARY COOLING WATER

SYSTEM AND ACCESSORIES

VOLUME II-J : SPECIFICATIONS FOR AUXILIARY SYSTEMS VIZ.

COMPRESSED AIR, VENTILATION & AIR-CONDITIONING,
D.G. SET, FIRE PROTECTION ETC.

VOLUME II-K : SPECIFICATIONS FOR SUMP PUMPS, MISCELLANEOUS

CRANE & HOISTS, ELEVATORS, WORKSHOP EQUIPMENT,
LABORATORY EQUIPMENT, GAS CYLINDERS, ETC.

VOLUME II-L : SPECIFICATIONS FOR COAL HANDLING SYSTEM

VOLUME II-M : SPECIFICATIONS FOR PLANT WATER AND EFFLUENT

MANAGEMENT SYSTEM

VOLUME II-N : TENDER DRAWINGS

(PCA.CD-003.368309013.doc)
 VOLUME : IIH

TECHNICAL SPECIFICATIONS
FOR
ASH HANDLING SYSTEM

(PCA.CD-003.368309013.doc)
 CONTENT

VOLUME : IIH SPECIFICATIONS FOR ASH HANDLING SYSTEM

SECTIONS DESCRIPTION

SECTION-I SYSTEM DESCRIPTION

SECTION-II DESIGN CRITERIA

SECTION-III OPERATION & CONTROL PHILOSOPHY

SECTION-IV SCOPE OF WORK TERMINAL POINTS & EXCLUSIONS

SECTION-V DATA SHEET

SECTION-VI PAINTING & LUBRICATION

(PCA.CD-003.368309013.doc)
 VOLUME : IIH

SECTION-I

SYSTEM DESCRIPTION

1.00.00 The ash handling system under this specification to be provided by the
Contractor will be complete & comprehensive for handling and removal of
total ash in form of Bed Ash, APH Hopper Ash & Fly Ash generated from
three CFBC Boilers (3 x 135 MW) of INDIA POWER CORPN (HALDIA) LTD
at Haldia, Midnapur. The plant shall be designed to cater for 100% PLF and
ash content of worst coal as 45%.

1.01.00 Ash Collection Data for each 135 MW unit

Following information are typical for a steam generator of 135 MW capacity

CFBC Boiler unit in regard to the ash collection in its various sections

Input Data Basis of Quantity Margin Quantity considered

design (TPH per for AHP system
135MW design( TPH per
unit) 135MW unit)
Coal required per Worst coal 115
boiler When firing
operating at full load.
Maximum Ash in 45% 51.75
Coal
Bed ash collection 45%(% of 23.2875 20% 27.945 (rounded up
total ash) figure 28TPH)

Ash collection in 5%(% of 2.587 40% 3.62 (rounded So total fly

Air Pre-heater total ash) up figure 4TPH) ash
hoppers generated
Fly ash 55%(% of 28.4625 40% 39.85(rounde considered
collection in total ash) d up figure 40 as 44TPH
ESP s TPH)

1.02.00 Description of Ash Handling Scheme

1.02.01 Bed Ash Removal System up to silos

Evacuation, transportation and storage of Bed Ash System have been

discussed below.

Each steam generator (CFBC Boiler) will be provided with bed ash coolers
that cools the bed ash coming out of fluidized bed and the same will be fed
into bed ash surge hoppers (one no for each of 135 MW unit).

The scope of ash handling vendor starts from outlet of bed ash surge hopper.
There shall be one individual bed ash surge hopper for each boiler unit. Each

(PCA.CD-003.368309013.doc) V.IIH/S-I : 1
 bed ash surge hopper is sized for at least 8 hrs storage capacity. Under each
bed ash surge hopper there shall be one opening with isolation plate /knife
gate valve. From this isolation plate valve, the scope of supply of ash handling
bidder starts. There will be a vibratory screen, situated below each bed ash
surge hopper, which separates the oversized, & acceptable size (size<3 mm)
ash particles. The oversized ash particles will be fed to feeding hopper for re
circulating the same into bed ash surge hopper after crushing (to make the
size below acceptable limit) with the help of a crusher. Crushing capacity of
crusher will be selected around 6TPH.

It is envisaged that the vibratory screen capacity will be 28 TPH (minimum).

There will be a rotary vane feeder between isolation plate valve & vibratory
screen through which bed ash from bed ash surge hopper will be fed on to the
vibratory screen in a controlled manner.

Screened bed ash particles of size (-) 3 mm will be feed into a storage tank,
namely buffer hopper. It is envisaged that under the buffer hopper, two
opening shall be provided with isolation plate valve and controlled feed control
valve/dome valve . Each opening will be connected to one bed ash conveying
vessel. Conveying capacity of each bed ash conveying vessel will be 14TPH
( minimum). One bed ash-conveying pipe will emerge from each bed ash
conveying vessel and will dispose bed ash to intermediate bed ash silo.
However beneath buffer hopper, instead of two opening, one opening can be
provided and hence one no conveying vessel will convey the screened bed
ash to intermediate bed ash silo @ 28 TPH.

There shall be total six no bed ash conveying line emerging from six bed ash
conveying vessel for 3X135MW units and all the six conveying lines will be
working simultaneously & continuously. Each pressure conveying stream shall
convey dry bed ash @ 14 TPH to the intermediate bed ash surge hopper.
However, incase of conveying vessel selected @28TPH, then total three
number bed ash conveying line (total for 3X135MW units) emerging from
three number conveying vessel shall dispose bed ash to intermediate bed ash
surge hopper.

There shall be one common Intermediate bed ash surge hopper for three
units. Total six ash conveying pipes( Or three number ash conveying pipe as
stated in the alternative option) shall emerge from 3X135MW boiler units and
dispose bed ash to near by Intermediate bed ash surge hopper. The
Intermediate bed ash surge hopper shall have storage capacity of 60 minutes
of bed ash coming out from all three units i.e. ash storage capacity of 84 Ton
(dry ash basis). Bed ash intermediate surge hopper shall be equipped with
adequately sized vent filter (face velocity 1M/min, maximum) to remove
excess air to atmosphere. Bed ash ISH shall be of enclosed steel
construction to avoid dust nuisance. Intermediate bed ash surge hopper shall
be positioned judicially so that conveying length from bed ash surge hopper to
intermediate bed ash surge hopper for all three units becomes nearly equal
and bed ash conveying to remote ash silo from intermediate bed ash surge
hopper can be carried out with ease..

The bed ash from intermediate bed ash surge hopper will be conveyed to
remote bed ash silo through second stage of pressure conveying system. Five
bed ash conveying vessel (3 W+2 S/B) is envisaged to be provided beneath
intermediate bed ash surge hopper. Each vessel shall have discharging
(PCA.CD-003.368309013.doc) V.IIH/S-I : 2
 capacity 28TPH. From each of this ash conveying vessel one bed ash
conveying pipe shall emerge. Conveying capacity of this pipe emerging from
above mentioned ash conveying vessel shall be 28TPH.Thus total five (3 W+2
S/B) bed ash pipe shall emerge from intermediate bed ash surge hopper to
dispose bed ash to remote bed ash silo. (Note; Bidder may provide total three
(2W+1S/B) bed ash conveying pipe emerging from intermediate surge hopper
to BA silo if it is found suitable. It is to be noted that in any case of the
proposed alternative, total conveying capacity, as stated above, shall be
maintained).

There shall be one number of bed ash silo and one number fly ash silo. All
bed ash conveying pipes emerging out from intermediate bed ash surge
hopper shall disposed bed ash to bed ash silo. However arrangement shall be
made with pneumatically operated isolation valves in such a way that bed ash
can also be disposed to fly ash silo , as and when required .

The compressed air required for conveying of bed ash to bed ash silo via
intermediate bed ash surge hopper shall be provided by conveying air
compressors dedicated for 3 X 135 MW units. There shall be five number
(3W+2 S/B) oil free type screw compressor to cater the purpose. However
bidder may provide alternative number of compressors as per their design
suitability with 50% standby (minimum).

The pressurized ash conveying lines shall be MS ERW. Pipe fittings shall be
Ni Hard / chrome alloy CI (maximum 450 BHN) with integral wear back and
connected with sleeve coupling.

1.02.02 Fly Ash Removal System up to silo

Fly ash is envisaged to be collected in Air Pre-heater (APH), & Electrostatic

Precipitator (ESP) hoppers. There are two (2) APH hoppers and thirty two (32)
ESP hoppers in each unit. In each unit there shall be 8 fields of ESP hopper
(approx) and each field constitutes of four (4) no ESP hoppers. Master- slave
arrangement is envisaged for disposing ash collected in hoppers to remote
silos. Fly ash from ESP hoppers & APH shall be transported to RCC silo in two
stages i.e. from ESP & APH hopper to surge hopper (namely intermediate fly
ash surge hopper) and from the said surge hopper RCC FA silo by means of
pressure conveying system.

Six (6) no ash conveying stream shall emerge from ESP & APH hoppers and
same shall be utilized to evacuate the total ash from each unit up to common
ash silo. Tentative pipe connection, hopper arrangement etc has been
indicated in the enclosed P& ID for fly ash transportation. Six (6) no stream
shall work simultaneously. Total capacity of six conveying stream shall be
44TPH (minimum). However bidder may provide any other alternative as per
their design standard. It is to be noted that in any case of the proposed
alternative, total conveying capacity, as stated above, shall be maintained.

Total eighteen ash conveying pipes shall emerge from 3X135MW boiler units
and dispose fly ash to suitably placed intermediate fly ash surge hopper.
Capacity of this intermediate fly ash surge hopper shall be 99 Te ( 45 minutes
storage capacity considering three units). Intermediate fly ash surge hopper
shall be positioned judicially so that conveying length from ESP & APH hopper
(for 3X135 MW units) to intermediate fly ash surge hopper for all three units
(PCA.CD-003.368309013.doc) V.IIH/S-I : 3
 becomes nearly equal and conveying from ISH to remote fly ash silo can be
carried out with ease. Five fly ash conveying vessel (3W+2 S/B) is envisaged
to be provided beneath intermediate fly ash surge hopper. Each vessel shall
have discharging capacity 44TPH. From each of this ash conveying vessel
one fly ash conveying pipe shall emerge. Conveying capacity of each of
these pipes emerging from above mentioned ash conveying vessels shall be
44TPH.Thus total five fly (3W+2 S/B) ash pipes shall emerge from
intermediate fly ash surge hopper to dispose fly ash to remote fly ash silo.
(Note; Bidder may provide total three (2W+1S/B) fly ash conveying pipe
emerging from intermediate surge hopper to FA silo if it is found suitable. It is
to be noted that in any case of the proposed alternative, total conveying
capacity , as stated above, shall be maintained).There shall be one number of
fly ash silo. Arrangement shall be provided with pneumatically operated knife
gate valves in such a way that fly ash from any fly ash pipe can also dispose
fly ash to bed ash silo under emergency condition.

The compressed air required for conveying of fly ash to fly ash silo via
intermediate fly ash surge hopper shall be provided from conveying air
compressors dedicated for 3 X 135 MW units. Same shall be provided through
five number (3W+2 S/B) oil free type screw compressor. However bidder may
provide alternative number of compressors as per their design suitability with
50% standby (minimum).

The pressured ash conveying lines shall be MS ERW. Pipe fittings shall be Ni
Hard / chrome alloy CI (maximum 450 BHN) with integral wear back and
connected with sleeve coupling.

1.2.3.1 Ash Disposal System

Coal required per boiler When operating 115TPH (per 135MW unit)
at full load with Worst coal firing.
Maximum Ash in Coal 45%

Maximum ash generated per 135MW unit 51.75TPH

Total maximum ash generated in 3X 155.25TPH
135MW unit
Bed ash collection @45%(% of total ash) 69.86TPH
for 3X135MW units
Fly ash collection @55%(% of total ash) 85.39TPH
for 3X135MW units
Retention time in Silo considered 24Hrs
Total bed ash generated for 3X135MW 1676.64Ton
units in 24 Hr duration
Total fly ash generated for 3X135MW 2049.36Ton
units in 24 Hr duration
Number of silo selected One no for fly ash and one no for
bed ash. However in all silos both
bed ash and fly ash can be
discharged as and when
necessary .
Capacity of fly ash silo 2000Te
Capacity of bed ash silo 1725Te
Note-Bed ash density is 650Kg/CuM, Hence bed ash silo volume will be
(PCA.CD-003.368309013.doc) V.IIH/S-I : 4
 around 2653CuM. Similarly fly ash density is 750Kg/CuM and fly ash silo
volume will be around 2666CuM.

One no of common bed ash silo shall be provided to store bed ash generated
from 3X135 MW CFBC units. Similarly One no of common fly ash silo shall be
provided to store fly ash generated from 3X135 MW CFBC units. Silos shall be
of RCC construction.

In normal condition bed ash will be stored in bed ash silo & fly ash will be
stored in fly ash silo. But Arrangement & interconnection with pneumatically
operated isolation valves shall be provided in such a way that any pressure
conveying pipe emerging out from any one of the intermediate surge hopper
(dedicated for fly ash and bed ash system) can dispose ash in any of the two
(2) ash silos as & when required under emergency condition.

Arrangement of ash deposition in various silos is depicted in corresponding

flow diagram.

Each silo will be provided with pressure relief access door, vent filter, fluidizing
pad, unloading equipments, etc.

RCC FLY ash silo shall be provided with the following as described herein
under:

i) One (1) Rotary Conditioners cum un loaders having unloading capacity

180 TPH (dry ash basis) for each silo. Rotary conditioner arrangement
is needed for moist unloading of ash into open truck.

ii) Two (2) telescopic chute having unloading capacity 180 TPH (dry ash
basis) with scavenger fan and rotary feeder. Telescopic spout
arrangement is needed for dry unloading of ash in closed tanker.

iii) Three (3) no lean slurry arrangement below fly ash silo to dispose fly
ash in slurry form at ash dump area through jet pump arrangement
during exigency condition. Each lean slurry arrangement capacity will
be 75 TPH minimum (dry ash basis). In this case it is to be noted that
during initial phase of operation, one jet pump arrangement may cater
the system requirement while two jet pumping arrangement may be
required when ash disposal area bund height gets increased.

iv) One (1) for future provision, (opening with blank flange ) which shall
be, remains close.

v) Adequately sized access door to provide entrance to silo interior for

maintenance or inspection.

vi) One level transmitter and one level probe for ash level monitoring. The
level transmitter will be for continuous ash level monitoring inside silo
and level probe will be for high ash level sensing .

vii) Relief valve to handle any unusual pressure surges in the silo.

(PCA.CD-003.368309013.doc) V.IIH/S-I : 5
 viii) Suitable no. of vent fan for venting within the stipulated limits of ash
emission (less than 50 mg/nm3).

ix) Silo fluidising arrangement along with fluidizing pads, fluidizing air
isolation valves etc. In this context, it is to mention that blower will be
selected in such a way that one (1) fluidizing blower should be able to
fluidise ash of fly silo under full load condition.

RCC BED ash silo shall be provided with the following as described herein
under:

i) Two (2) Rotary Conditioners cum un loaders having unloading capacity

180 TPH (dry ash basis) for each silo. Rotary conditioner arrangement
is needed for moist unloading of ash into open truck. These two rotary
conditioner arrangement fitted below each silo are envisaged to work
simultaneously.

ii) One (1) telescopic chute having unloading capacity 180 TPH (dry ash
basis) with scavenger fan and rotary feeder. Telescopic spout
arrangement is needed for dry unloading of ash in closed tanker.

iii) Two (2) no lean slurry arrangement below bed ash silo to dispose bed
ash in slurry form at ash dump area through jet pump arrangement
during exigency condition. Each lean slurry arrangement capacity will
be 75 TPH minimum (dry ash basis).

iv) One (1) for future provision, (opening with blank flange ) which shall
be, remains close.

v) Adequately sized access door to provide entrance to silo interior for

maintenance or inspection.

vi) One level transmitter and one level probe for ash level monitoring. The
level transmitter will be for continuous ash level monitoring inside silo
and level probe will be for high ash level sensing .

vii) Relief valve to handle any unusual pressure surges in the silo

viii) Suitable no. of vent fan for venting within the stipulated limits of ash
emission (less than 50 mg/nm3).

ix) Silo fluidising arrangement along with fluidizing pads, fluidizing air
isolation valves etc. In this context, it is to mention that blower will be
selected in such a way that one (1) fluidizing blower should be able to
fluidise ash of bed silo under full load condition.

Slurrification units installed below fly ash and bed ash silo shall contain
isolation valve, feeder ejector, collector tank and jet pump with associated
slurry pipe to common ash dump area. Ash from silo shall be taken into the
collector/mixing tank through vacuum created by feeder ejector In mixing
tank ash shall be mixed with water and from mixing tank slurry will be
disposed to ash disposal area via jet pump.
(PCA.CD-003.368309013.doc) V.IIH/S-I : 6
 Slurry disposal system for fly/bed ash shall be utilized under exigency.
.
Total five (5) number of slurry lines from two silos will dispose lean slurry to the
ash dump area.

Silo unloading floor height from paved ground level shall be 5.5 M minimum.
Silo area shall be paved and a peripheral drain shall be provided. The
discharge of this peripheral drain shall be to silo area drain sump.

Ash from the silo will be fed by rotary feeder and ash conditioner into the
open tank. This conditioned ash will be used for mine back filling purpose.
Moisture content in moistened ash will be around 18 to 20% by weight.

In dry disposal arrangement ash from silo will be fed by rotary feeder and
telescopic spout into closed tanker. This dry ash will be transported to cement
plant for selling.

Arrangement shall be provided beneath each silo so that two closed tankers
can receive dry/ moistened ash simultaneously side by side from two
telescopic spout/ ash conditioning arrangement as mentioned above.
Provision of free movement of ash unloading trucks are also envisaged.
Approaching roads to silos shall be wide enough with long bends (at road
junction) for easy truck movement.

In this connection it is to note that only dry ash is envisaged to be used for
selling purpose presently.

1.02.04 Common System

There shall be Common Water System, and Common Compressed Air

System, cooling water system etc for Ash Handling System.

A. COMMON WATER SUPPLY SYSTEM

Consumers Requiring Ash Water

a) Jet pumps for wet disposal system (during exigency lean slurry
system)

b) Intermittent demand for de-sludging, line flushing, jetting etc (during

exigency lean slurry system)

c) Mixing tank, feeder ejector for wet disposal system (during exigency
lean slurry system)

d) Intermittent demand for ash conditioning etc

The total requirement of ash water for the Ash Handling System shall be
mainly met from the following sources:
(PCA.CD-003.368309013.doc) V.IIH/S-I : 7
 i) Cooling Tower Blow down/Raw water make up

ii) Clarified Water/seal water make up

iii) Ash pond recovery water on due clarification

There shall be an over ground RCC sump for the storage of water namely ash
water sump near silos to meet the needs of ash handling system. Effective
capacity( between high and low level) of ash water sump shall be minimum 60
minutes considering one HP ash water pump under full load condition.

Requirement of ash conditioning water will be around 35CuM/Hr (average) for

3x135MW units. However if 24 hour ash is being evacuated in 10 hours, then
during ash unloading, peak conditioning water requirement will be around 82
CuM/Hr for three boiler units for ash conditioning purpose only . However, the
same is to be verified during detail engineering.

There shall be two (2) no (1W +1 S/B) conditioning water pumps to cater
water requirement for moist unloading system.

During exigency lean slurry disposal system, 1150 CuM/Hr water is estimated
to be required considering three jet pumping arrangement under operating
condition.

Two no (1W+1 S/B) HP ash water pumps shall be provided to cater water
requirements of wet ash disposal system.

There shall be raw water make up and make up from cooling tower blow-down
and make up from ash pond recovery water to the ash water sump.

B. INSTRUMENT AIR SUPPLY SYSTEM

2X100% duty oil free screw compressor (1 working & 1 standby) with
2x100% (1 working & 1 standby) duty refrigerant type Air Drying Plant will be
installed in the Ash Handling Plant for supplying instrument air (I.A.) for
different actuation purpose for 3X135 MW CFBC units . These compressors
with air drying unit will preferably be installed in common compressor house of
ash handling system.

Necessary tapping with suitable isolation valve will be provided on this Ash
Handling Plant's I.A. header at strategic location so that same can be
interconnected with Main Plant I.A. header, if it is feasible to do so. The
instrument air supply for remote location e.g. silo, shall have suitable air
receiver along with moisture separator aided with maintenance free auto drain
trap.

C. COOLING WATER SYSTEM

(PCA.CD-003.368309013.doc) V.IIH/S-I : 8
 Cooling water required for ash handling system will be tapped from main plant
ACW header at one suitable point near compressor house and return water
will be fed to return water header. Pipes, fittings, valves etc beyond this
single suction and discharge point as mentioned above to various
consumption points of ash handling system is under scope of ash handling
vendor.

D. SEAL/CLARIFIED WATER SYSTEM

Consumers Requiring Clean & Clarified Water/ Seal water

a) Seal water for HP ash water pumps.

b) Seal water for drain pumps.

c) Seal water for conditioning water pumps

d) Seal water for recovery water pumps

.
All of the above requirements will be met from clarified/ seal water supply
header (for Ash Handling system) provided seal water source. There shall be
two no (1W + 1S/B) booster seal water pumps to supply seal water to
different consumption point of ash handling system. These pumps will take
their suction from clarified/seal water supply header (for ash handling
system). In this context, it is to noted that sealing connection for Conditioning
water pump and HP ash water pumps are envisaged because it is assumed
that recovery water from ash disposal area pond will contain considerable
amount of ash/ soil contamination.

Seal/clarified water required for ash handling system will be tapped from main
plant clarified water header at one suitable point @ 1 Kg/sq cm(approx).
Pipes, fittings, valves, necessary boosting water pumps(100% stand by) etc
beyond this single point to various consumption points of ash handling system
is under scope of ash handling vendor.

1.02.05 Compressed air supply system

Total five number (3 working + 2 common stand by) oil free screw compressor
shall provide compressed air needed for transportation of fly ash and bed ash
for 3X135MW units to remote silos via intermediate fly ash surge hopper &
intermediate bed ash surge hopper respectively. The compressors shall be of
identical duty condition and will be situated in AHP compressor room
dedicated for 3X135 MW units. In order to provide identical duty condition
compressor for pneumatic ash transportation, any alternative number of
compressor, if suggested by bidder can be accepted based on system
suitability and subject to submission of detail calculation.

Three adequately sized air receiver shall be provided near ESP of respective
units for receiving pressurized conveying air from conveying compressors and
for subsequent distribution of the same.
(PCA.CD-003.368309013.doc) V.IIH/S-I : 9
6.1.1.1 Fluidising air system

a) Three (3) - adequately sized (capacity and pressure) Silo fluidising blowers
(twin lobe type) with all related accessories (like motors, air heaters,
necessary piping and valves) to supply fluidising air required for silo
fluidization. The capacity of each blower shall be selected in such a
manner that it can fluidise one silo at a time with full load condition.
Fludising blowers shall be air cooled one. Connection with adequate
isolation valves( plug /ball valve as indicated in corresponding flow
diagram) shall be provided in such a way that any heater can be
accessed by any blower as and when required. In this connection, it is
to be noted that bed ash silo generally does not need fluidization.
Hence under normal condition, one silo fluidizing blower will be under
working condition for fly ash silo. However, if fly ash is being disposed
to bed ash silo under emergency situation, then, two slio fluidising
blower shall be under working condition.

b) For ESP hopper fluidization purpose there shall be two (2) no (1W +
1S/B) ESP hopper fluidizing blowers with all related accessories (like
motors, air heaters, necessary piping and valves) to supply fluidising
air required for each 135 MW unit. Total six (6) no (3W + 3S/B) blower
with all related accessories will be supplied for 3X135 MW units. These
ESP fluidising blowers shall be of identical duty condition and will be
placed in a shed near ESP field of the respective unit. Fludising
blowers shall be air cooled one. Connection with adequate isolation
valves (plug /ball valve as indicated in corresponding flow diagram)
shall be provided in such a way that any heater can be accessed by
any blower as and when required.

c) Fluidizing air for intermediate fly ash surge hopper will be supplied
from conveying compressor (dedicated for 3X135 MW units) discharge
header.

1.02.07 Drain pumping system

a) Total two (2) no (1W+1S/B) Vertical, Centrifugal, single stage, semi-

open or (open non-clogging) type impeller type drain sump pumps are
to be provided at the remote silo area drain sump for 3X135MW units.
Water from silo area floor drain is accumulated in the drain sump and
these pumps discharge the drain water from drain sump to main plant
drain or at ash disposal area .

b) Two drain pumps (1W+1 S/B) shall preferably be provided at the

center of ESP area of 3X135 MW units . This drain pumps will
discharge the drain water from drain sump to main plant drain or at
other places as desired by client.

c) The ash water sump for 3X135 MW CFBC units situated in silo area
(dedicated for 3X135 MW units) shall also contain two (1W+1S/B)
vertical type drain pump to dispose sludge settled into this sump to ash
dump area/main plant drain.

d) The recovery water sump for 3X135 MW CFBC units situated near ash
(PCA.CD-003.368309013.doc) V.IIH/S-I : 10
 dump area (dedicated for 3X135 MW units) shall also contain two
(1W+1S/B) vertical type drain pump to dispose sludge settled into this
sump to ash dump area.

1.02.08 Hoisting Equipment Air Conditioning and Ventilation system

The same shall be provided, as required, in the plant. However the following
requirement shall be fulfilled.

a) Semi EOT crane (hand operated LT, pendant operated CT and hoist)
of suitable capacity shall be provided for fly ash and bed ash
equipment building (containing conveying air compressors, IA
compressors etc). If compressor room is wide enough and one row of
central column is required to be provided in the said room to sustain
width, then two semi EOT crane is envisaged in compressor room.
Selection of crane capacity shall be guided by 110% of heaviest load
to be handled

b) Similar crane 3.5(approx) ton capacity shall be installed for ash water
pump house( near silo). Capacity of the cranes are tentative, however
selection of crane capacity shall be guided by 110% of heaviest load to
be handled. Electrically operated hoist shall be provided on top of silo.
All control room shall be air conditioned with window/ package air
conditioners. Electrical room for MCC shall be pressurized ventilated.
Adequate ventilation fans are to be provided in the equipment building/
rooms associated with ash handling system.

c) Suitable lifting equipment shall be provided for Crusher, Vibrating

screen and bowers( for blowers not situated in compressor house),
recovery water pumps and for drain sump pumps.

1.02.09 Ash Dump Area - Equipment and Facilities

Ash disposal area (4.5 Hectre), which is approximately 150 M away from silo,
will be divided in two segments, one will be used as ash disposal area and
another compartment will be used as settling pond.

The Ash slurry pipes (total five no, 3W +2S/B) shall discharge slurry into the
ash pond.

The Main slurry pond will gradually get filled up with deposited ash and
provisions shall be there to shift the slurry discharge point(s) from time to time
such that an efficient filling of the entire ash pond is ensured. Proper
garlanding on the ash dyke shall be made for this purpose.

The entire Ash Slurry will be retained within this Ash Dump. It is also intended
to retain the entire precipitation received by the Dyked area within the
reservoir itself.

An ash water recovery, collection and transfer system is to be provided near

ash pond area. The overflow ash water from the ash pond will be collected in
the settling pond situated next to ash pond. This over flow ash water will be
settled in the settling pond. From there, settled water will be overflowed into
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 the recovery water sump (situated at one end of settling pond). There after the
settled water will be conveyed to ash water sump through recovery water
pumps.

Two no (1W+1S/B) recovery water pump and one number recovery water
pipe will be provided to bring back the water to ash water sump.

The recovery water pumping system (one pump working for three units and
one common standby each pump rated for 80% recovery of ash water
considering both bed ash and fly ash are disposed in lean slurry form @
25% concentration and flushing water along with rain water.) will recycle the
entire quantity of settled water back to the plant ash water sump near silo.

The system shall have provision of chemical dosing system at settling pond
at ash disposal area as necessary for coagulation and efficient settlement of
ash carryover as well as keeping Ph of recovery water slightly above neutral
level ( ie above 7).

Based on the above guidelines, the Bidder is invited to offer a practical,

effective and functional system backed up by his past experience. The
tender offer must contain drawings and detailed write-ups depicting the
overall Ash Dump Area operation, development and management scheme as
envisaged by him indicating details.

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