Technical Specification For Ash Handling System [PDF]

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TENDER DOCUMENT For ASH HANDLING SYSTEM For 108 MW CAPTIVE POWER PLANT



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED Peddapuram, East Godavari District, Andhra Pradesh



TECHNICAL SPECIFICATION



MARCH 2012



Snyder Energo Private Limited No. 301, VITC Model Export Park, #488, 14th Cross, 4th Phase, Peenya Industrial area, Bangalore – 560 058, India E-mail: [email protected]



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



TECHNICAL SPECIFICATION FOR ASH HANDLING SYSTEM



REVISION NO.



R0



ISSUED FOR



FOR TENDERING



PREPD.BY/DATE



SRN / 02.03.2012



CHKD. BY/DATE



GN/ 05.03.2012



APPD. BY/ DATE



BRC/ 07.03.2012



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



Section



TITLE



Page No.



1



GENERAL



01



2



PROJECT SPECIFIC INFORMATION



03



3



GENERAL REQUIREMENTS



06



4



SYSTEM DESCRIPTION



09



5



DESIGN CRITERIA



12



6



SCOPE OF WORK SERVICES, TERMIANL POINT & EXCLUSIONS



18



7



DETAILED TECHNICAL SPECIFICATION



27



8



TOOLS & TACKLES AND SPARES



52



9



QUALITY ASSURANCE PLAN



53



10



PAINTING SYSTEM



54



11



ERECTION, TESTING AND COMMISSIONING



59



12



PERFORMANCE GUARANTEES & AVAILABILITY



62



13



DOCUMENTATION



64



14



LIST OF APPROVED MAKES



66



Annexure-I



DATA TO BE FURNISHED BY TENDERER



Annexure-II



SPECIFICATION DRAWINGS



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



Index



i



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



1.0



GENERAL



1.1



Intent of Specification



1.1.1



This specification covers the design, engineering, manufacturing, inspection, and delivery at site, unloading, storing at site, erection and commissioning, performance guarantee tests, and handing over of complete Ash handling system for two (2) nos. of 36 MW Captive Power Plant, for Shri Girija Alloy & Power (I) Private Limited., (SGAPIPL) at Peddapuram Village, East Godavari District, Andhra Pradesh. The scope of work and services shall include all necessary work and supply of equipment and material whether mentioned in these specifications or not, but are necessary for the satisfactory, reliable safe operation and maintenance of the system and required for achieving guaranteed performance of the system.



1.1.2



All the equipment/plant will conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation up to the Tenderer’s guarantees in a manner acceptable to the Purchaser/Purchaser’s representative, who will interpret the meaning of specifications and drawings to ensure that all the work and materials are in full accordance therewith.



1.1.3



The extent of supply under this contract includes all items shown in the appropriate sketches/drawings notwithstanding the fact that such items are not covered in specification or schedules within the terminal points. Similarly, the extent of supply also includes all items mentioned in the specification and/or schedule, notwithstanding the fact that such items are not shown in the sketches/drawings.



1.1.4



All specialised equipment/services necessary for proper testing, commissioning and performance testing of all items of the plant covered under this contract will be arranged by the Tenderer. The cost of the same will be included in the contract price



1.1.5



The precision instrument/equipment required for the performance testing of all items of the plant covered under this specification as per code requirement will be furnished by Tenderer on returnable basis.



1.1.6



All necessary coordination with regard to sub-contracted equipment will be carried out by the Tenderer. The Purchaser/Purchaser’s representative will communicate only with the Tenderer for all matters pertaining to this contract.



1.1.7



The total price quoted for this contract will be firm lump-sum all-inclusive basis and will cover all items and services necessary for the successful completion of the contract. Even if all components of a system included in this specification are not explicitly identified and/or listed herein, these will be supplied under this contract to ensure completeness of the system and facilitate proper operation and easy maintenance of the plant.



1.2



Codes and standards



1.2.1



The design and manufacturing of the ash handling system shall comply with the requirements of applicable standards such as the following and those standards specified therein, so far as they apply.



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



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SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



•



IS 800



:



Code of practice for Construction in steel



•



IS 875



:



Code of practice for design loads for Buildings/structures



•



IS 1893



:



Criteria for earthquake resistance design of structures.



•



BS 4592



:



Industrial type metal floors, walkways and stair



•



BS 5395



:



Stairs, ladders and walkways.



•



IS 8130



:



Conductors for insulated electrical cables and flexible chords



•



IS 3975



:



Mild steel wires, strips and tapes for armoring of cables



IS 2633



:



IEC 540 & 540A



:



• •



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



Methods of testing weight, thickness and uniformity of coating on hot dipped galvanized articles Test methods for insulation and sheaths of electric cables & chords.



2 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



2.0



PROJECT SPECIFIC INFORMATION



2.1



Project 1.



Purchaser



Shri Girija Alloy & Power (I) Private Limited No. 88-3-5, Gadalamma Nagar, Morampoudi, Rajahmundry - 533 103, East Godavari District, Andhra Pradesh.



2.2



2.



Project



108 MW Captive Power Plant



3.



Purchaser’s Consultant



SNYDER ENERGO PRIVATE LIMITED, No. 301, VITC Model Export Park, # 488, 14th Cross, 4th Phase, Peenya Industrial Area, Bangalore – 560 058, India.



Location The power project site is located at Peddapuram, East Godavari District, Andhra Pradesh. The locational details of the power project site are as indicated below:



2.3



Latitude



17˚ 04’ 17” N



Longitude



82˚ 07’ 32” E



Height above mean sea level



52.00 m



Seismic Zone



Zone – II



Nearest town



Peddapuram – 1.3 km



Nearest City



Kakinada – 18 km



Nearest national highway



NH–5 - 5 km in the East



Nearest Railway station



Guduprati – 4.5 km Samalkot – 5.2 km



Nearest airports



Rajahmundry – 35 km



Nearest seaports



Kakinada – 18 km Vizag – around 55 km



Climatic data Highest daily temperature



36.9 (degree C)



Lowest daily temperature



23.8 (degree C)



Annual mean of daily temperature



31.7 (degree C)



Extreme highest temperature



40 (degree C)



Relative Humidity: Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



Maximum



81 %



3 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



Minimum 24 hour highest rainfall



233.9 mm



Monthly highest rainfall



781.1 mm



Normal wind speed



10.4 km/h



2.4



Water System



2.4.1



Auxiliary cooling water



2.5



61 %



i)



Inlet temperature



: 34 degree C



ii)



Outlet temperature



: 42 degree C



iii)



Pressure



: 4 kg/cm2 (a)



Power supply The power supplies for distribution and auxiliaries shall be as under: Sl. No



Parameter



Description



i)



LT distribution



415V ±10%, 3ph, 4W, 50Hz + 5% to –5%, solidly grounded system.



ii)



Motor rated above 200W and below 180 kW and all motorized actuators.



415V ±10%, 3 ph, 50Hz +5% to - 5%.



iii)



For motors equal and below 200W; panel space heating, lighting and small power distribution



240V ±10%, 1ph, 50Hz + 5% to –5%, solidly grounded.



iv)



Control supply for relay panel/MV breakers/LV breakers and DC emergency lighting.



110V DC, 2-wire ungrounded system.



v)



DC power for control & instrumentation (if required.)



+24V DC (20V-30V), - VE side grounded.



vi)



Control supply for 415V Motor contactors/AC Control circuits [to be generated in MCC/ panel by Tenderer with control transformers]



110V AC ±10%, 50Hz + 5% to –5%.



vii)



Diesel Generator emergency supply



415V ±10%, 3ph, 3W, 50Hz +5% to –5%.



NOTE: a) All equipment shall be suitable for 10% combined voltage and frequency variation [absolute sum] b) Any other power supply requirement shall be derived by the Tenderer from Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



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SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



Sl. No



Parameter



Description



the above available power supplies



2.6



viii)



Design ambient temperature for electrical equipment and devices



ix)



Fault levels



50 degree C.



220 kV



40 kA



11 kV



40 kA



415V



50 kA



Instrument air (Oil free) Pressure at the terminal point



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



: 5 ~6 kg/cm2 (a)



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SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



3.0



GENERAL REQUIREMENTS



3.1



The Bed and Fly ash handling systems shall be dry type dense phase pneumatic system. The function of the Bed and Fly Ash Handling is to remove coarse / fly ash from Bed ash coolers, Mechanical dust collector, air pre-heater hoppers, ESP hoppers and transport it to the storage silos. This should be carried out by pneumatic system. The equipment should be suitable to handle the ash burden from the specified fuel under all loading conditions.



3.2



Typical schematic for conveying pipes up to silo shall be provided as per the drawing No. 33614-100-043. The same type of arrangement shall be provided for both the boilers.



3.3



It shall be possible to selectively discharge the fly ash from any of collection point to fly ash silo.



3.4



The ash handling system shall be fully automatic. The system shall be designed in such a way that the ON cycle time of the system shall be kept to the minimum and OFF cycle time shall be maximum. All the equipment shall be designed for continuous duty of 24 hours per day. During normal running, the system operates with 10 cycles / hour and 20 cycles / hour during emergency. The size of the vessel below the ash hopper is selected based on number of cycles per hour specified.



3.5



ESP hoppers & Silo’s shall be provided with fluidisation pads and required fluidizing air blowers and accessories for proper flow of material.



3.6



Silo shall be provided with fluidization pads, isolation gates and RF type level probes and necessary instruments for safe and easy operation of the system.



3.7



All the pneumatically operated valves shall be controlled from Purchaser DCS system.



3.8



Two (2) nos. screw air compressors of suitable capacity (1W + 1S) with necessary instruments / accessories, receiver tank common for both boilers for pneumatic conveying of ash up to silo shall be provided. The compressor shall be sized considering 25% margin on the total conveying air requirement. Adequate capacity of air receiver shall be provided with necessary accessories / instruments. Air receiver should be normally large enough to supply air without pressure fluctuations.



3.9



Two (2) nos. Hopper / silo fluidizing air blower of suitable capacity (1W + 1S) with heaters and necessary instruments / accessories for both boilers for fluidization of ash silos and ESP hoppers. The blowers shall be sized considering 10% margin on the total fluidizing air requirement. Adequately sized Heaters will be provided on discharge lines of these blowers for heating the air before is let into the silo / hopper.



3.10



The design of equipment shall ensure maintenance of noise and vibration levels within the limits specified below:



3.10.1



Measured noise level produced by any rotating equipment shall not exceed 85 dB at a distance of 1.5 m from it in any direction.



3.10.2



Amplitude of vibration at bearings of rotating equipment shall confirm to the latest editions of ISO: 2372.



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



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SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



3.10.3



Vibration isolators of proven performance shall be provided as part of supply for preventing transmission of vibration from one equipment to the other neighboring equipment and structures.



3.11



All parts subject to wear shall be provided with quick and easily replaceable parts. The estimated life of such parts shall be stated clearly when it is less than 10000 operational hours. Wear parts must be more than 15000 operational hours.



3.12



The ash handling system shall be designed and constructed in view of dust free operation. Fugitive dust emission in any area shall not exceed 50 mg/Nm3 for all solid particles.



3.13



Sampling points for Ash sample collection shall be provided at the hoppers/conveying lines.



3.14



The conveying pipes shall be MS Black ERW heavy duty pipes as per IS: 1239 upto 6’’ and above 6’’ as per IS 3589 heavy duty pipes. Pipe shall be in 7mm (thickness) and 6 M lengths (maximum) with flanged joints at both ends. The flanges shall be welded to the pipe from inside as well as outside.



3.15



The pipe bends shall be made of wear resistant cast basalt / Ni-Hard bends with 550 BHN. The bends shall be easily accessible for maintenance.



3.16



A target box will be provided on ash silo’s which will be connected to the ash air mixture conveying pipes. The target box allows the bed ash to get discharged into the silo. The material of construction of target box body shall be as per IS 2062 / Gr. A and the deflector shall be Alloy CI, 500 BHN.



3.17



The fly ash separated by the bag filter will be collected into a buffer hopper, which will have 30-minute surge storage capacity. The buffer hopper will be part of the bag filter assembly. Below the buffer hopper there will be special pressure feeders/air lock vessels, which will be used for further transportation of ash pneumatically through pipeline to silo.



3.18



A bag filter vent unit is mounted on top of the silo to filter exhaust air before leaving it to atmosphere. Compressed air for reverse jet cleaning of bags is supplied from plant compressed air system. To safeguard the silo from over pressure on the silo top, a pressure relief vent will be provided. This is suitably rated to open at a predetermined pressure and discharge the air to atmosphere. A level probe is provided to give alarm annunciation when bed ash reaches high level.



3.19



Bag filter shall be designed considering a maximum air to cloth ratio of 1:1.3 m3/mini/m2 and in conformity to the following parameters:



3.19.1



Efficiency



: 99.5 % and above for sizes – 0.2 microns



3.19.2



Max. pressure drop



: 75mm WC through bag filter



3.19.3



Bag filter shall be provided with minimum 15% more cloth area than the designed requirement. The bag material may be polypropylene, polyester nylon, nomex or glass fibre with / without antistatic properties depending on the air / gas and dust handled, temperature etc.,



3.20



The system including silo ash removal should be designed to function with minimum operator intervention



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



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SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



3.21



As per the bed ash particle distribution (Maximum expected size shall be 3 inch), Tenderer to confirm the requirement of clinker grinder.



3.22



Bed ash temperature at the outlet of bed ash cooler shall be 250 Deg. C, Tenderer to confirm the requirement of Water cooled surge hopper.



3.23



Moisture may be present in the ash collection plant during cold starts of the boiler. The ash handling plant must be designed to cope with this eventuality.



3.24



All the major components should have inspection and cleaning facilities in the event of system blockage. It should be possible to isolate each section of the system for maintenance whilst retaining the remainder of the system in service. The entire plant should be capable of smooth starting after a reasonable stoppage of the system (which tripped during its full load operation for some system disturbance). The bends in the pipe work system should have material of construction proven in service. Wear resistant linings should also be considered where appropriate. Components subject to high temperatures should be insulated to protect personnel.



3.25



The ash hopper isolation valve, surge hopper isolation valves which handle ash are to be of knife gate type with plate made of stainless steel conforming to SS 304 stellited to minimum 1 mm thickness. Body and seat should be made of alloy cost iron with minimum hardness being 350 BHN.



3.26



Electrical



3.26.1



All motors considered for the system shall be LT.



3.26.2



The motor terminal box shall be complete with cable gland & lugs Starters, lockable push button stations, MCC, all cabling including galvanized cable trays, equipment /body earthing etc.



3.26.3



Lighting and lightening arrester engineering, supply, erection and commissioning for complete ash handling system including silos.



3.27



Instrumentation and controls



3.27.1



Control System including local control panel for ash unloading from silo the sequential operation with inter phase facility to communication with the purchaser DCS system.



3.27.2



Local instruments including switches, instrument cables terminal boxes, cable trays & accessories, as required to make the system complete.



3.28



General



3.28.1



Consumable materials as required for erection & commissioning including electrodes, first fill lubricants, flushing oil, etc.



3.28.2



One set special tools & tackles required for operation & maintenance, inspection & repair of equipment supplied. O & M Manuals, drawings, calculations, certificates as required.



3.28.3



Two coats of epoxy primer, one coat of finished epoxy paint & final epoxy painting at site.



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



8 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



4.0



SYSTEM DESCRIPTION



4.1



The ash handling system consists of the following sub systems: i)



Bed ash handling system



ii)



Fly ash handling system



iii)



Bed ash disposal system



iv)



Fly ash disposal system



v)



Auxiliary enabling systems



Refer: Process flow diagram for Ash handling system Drawing No: 3-3614-100-043. 4.1.1



Bed ash handling system Bed ash is collected in 2 Nos. of Bed ash collection cooler hoppers in each boiler. Since the maximum expected size of the bed ash shall be 3 Inches, Tenderer to confirm the requirement of Clinker Grinder. A surge hopper, which is water cooled, is provided below the crusher if required. The ash discharges from the surge hopper to the denseveyor. The inlet valve to the denseveyor is closed and conveying air is admitted into the denseveyor. This pressurises the denseveyor. The admission air inlet valve is closed and the discharge valve of the denseveyor is opened. The bed ash is carried along by the air stream up to the Bed ash silo. The ash separates out and gets collected in the silo. The air escapes through the bag filter, which is provided to minimise dust escape to atmosphere. Separate denseveyor cum piping arrangement is provided for each hopper.



4.1.2



Fly ash handling system i)



Mechanical dust collector hoppers (1 No. per boiler)



ii)



Air-preheater hoppers (2 Nos. per boiler)



iii)



ESP field 1, 2, 3, 4 and 5 hoppers (5 fields per boiler)



Fly ash collected in the hopper gets discharged to denseveyor. The ash inlet valve to the denseveyor is closed. The conveying air is admitted into the denseveyor and it is pressurised. The conveying air valve is closed and the denseveyor discharge valve is opened. The fly ash is conveyed to the Fly ash intermediate storage silo along with the air. In the silo the fly ash gets separated and gets collected. The escaping air from the silo passes through a bag filter to minimise dust pollution. 4.1.3



Bed ash disposal system Bed ash silo shall be provided with 3 Nos. of outlet at the bottom:



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



9 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



i)



For disposal in dry form into closed trucks 1 No. of outlet of bed ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and flexible unloading spout. The unloading spout is directly connected to the closed truck and the ash is unloaded onto the truck.



ii)



For disposal in wet form into open trucks 1 No. of outlet of bed ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute.



iii)



For emergency discharge of bed ash: 1 No. of outlet of bed ash silo is fitted with plate valve for emergency discharge



4.1.4



Fly ash disposal system i)



Fly ash intermediate silo shall be provided with 3 Nos. of outlet at the bottom: For fly ash into denseveyor 1 No. of outlet of fly ash intermediate silo is fitted with hand operated knife gate valve, bellows and denseveyor. Fly ash collected in the intermediate silo gets discharged to denseveyor. The ash inlet valve to the denseveyor is closed. The conveying air is admitted into the denseveyor and it is pressurised. The conveying air valve is closed and the denseveyor discharge valve is opened. The fly ash is conveyed to the main fly ash storage silo along with the air. In the silo the fly ash gets separated and gets collected. The escaping air from the silo passes through a bag filter to minimise dust pollution For fly ash into open trucks 1 No. of outlet of intermediate fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute. For emergency discharge of fly ash: 1 No. of outlet of fly ash intermediate silo is fitted with hand operated knife gate valve for emergency discharge of fly ash from intermediate fly ash silo to atmosphere.



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



10 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



ii)



Main Fly ash silo shall be provided with 3 Nos. of outlet at the bottom: For disposal in dry form into closed trucks 1 No. of outlet of Main fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and flexible unloading spout. The unloading spout is directly connected to the closed truck and the ash is unloaded onto the truck For disposal in wet form into open trucks 1 No. of outlet of Main fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute. For emergency discharge of main ash: 1 No. of outlet of main fly ash silo is fitted with plate valve for emergency discharge



4.1.5



Auxiliary enabling systems The following systems, which are auxiliary systems for the ash handling system, are considered: i)



Two (2) nos. screw air compressors of suitable capacity (1W + 1S) with necessary instruments / accessories, receiver tank common for both boilers for pneumatic conveying of fly ash to silo shall be provided. Adequate capacity of air receiver shall be provided with necessary accessories / instruments. (Common for both boilers)



ii)



Two (2) nos. Hopper / silo fluidizing air blower of suitable capacity (1W + 1S) with heaters and necessary (Common for both boilers)



iii)



It is to be noted that the instrument air requirement required for Ash handling system shall be provided by purchaser at 5~6 kg/cm2 (a) at terminal point and therefore no separate instrument air compressors are envisaged for Ash handling system



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



11 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



5.0



DESIGN CRITERIA



5.1



The Tenderer shall study the specification and satisfy himself thoroughly regarding the workability and suitability of the equipment and system supplied by him to satisfy this specification. He shall take full responsibility for the guaranteed and satisfactory performance of the system i.



Fuel



100% Indonesian coal, 100% Indian coal, 60% Indonesian coal + 40% Indian coal



ii.



Type of Boiler



IR-CFBC



iii.



Number of Boilers



Two



iv.



Boiler Capacity



160 TPH (each)



v.



Main steam pressure



105 Ata



vi.



Main steam temperature 540±5 °C



The design criteria per boiler are furnished below. The same shall be considered for the second boiler also. 5.2



Ash collection at Bed ash outlet hoppers: Sl.No.



Description



Unit



Design



1.0



Total bed ash collected per hopper



kg/hr



1250



2.0



Design capacity per ash vessel



kg/hr



1500



3.0



No of hoppers/No. of ash vessel



No



02 / 02



4.0



Number of openings per hoppers



No



01



5.0



Ash Density



kg/m3



1000-1400



6.0



Ash Temperature (Design)



7.0



Conveying Distance



8.0



Hopper O/L pipe bottom elevation



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



o



C



300



mts



As per the Ash collection point detail drawing 3-3614-100-044



m



+3.0 above FFL



12 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



5.3



Ash collection at Mechanical Dust Collector outlet hoppers: Sl.No. 1.0 2.0 3.0 4.0



5.4



Description Total Fly ash collected per hopper Design capacity per ash vessel No of hoppers/No. of ash vessel Number of openings per hoppers



5.0



Ash Density



6.0



Ash Temperature (Design)



7.0



Conveying Distance



8.0



Hopper O/L pipe bottom elevation



Unit



Design



kg/hr



5800



kg/hr



14000



No



02 / 01



No



01



kg/m3



800-1000



o



C



320



mts



As per the Ash collection point detail drawing 3-3614-100-044



m



+3.0 above FFL



Ash collection at Air-preheater outlet hoppers:



Sl.No.



Description



Unit



Design



1.0



Total Fly ash collected per hopper



kg/hr



750



2.0



Design capacity per ash vessel



kg/hr



1500



3.0



No of hoppers / No. of ash vessel



No



02 / 02



4.0



Number of openings per hoppers



No



01



5.0



Ash Density



kg/m3



600-800



6.0



Ash Temperature (Design)



7.0



Conveying Distance



8.0



Hopper O/L pipe bottom elevation



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



o



C



250



mts



As per the Ash collection point detail drawing 3-3614-100-044



m



+3.0 above FFL



13 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



5.5



Ash collection at ESP hoppers: Sl.No.



1.0



Description



Unit



Design



Total Fly ash collected Below ESP hoppers.



kg/hr



6825



No



05



No



One



No. of field



2.0 3.0



No of openings (in the hopper) per field



4.0



Collection rate in Ist field (Design capacity)



kg/hr



7500



5.0



Collection rate in IInd field (Design capacity)



kg/hr



7500



6.0



Collection rate in IIIrd field (Design capacity)



kg/hr



750



7.0



Collection rate in IVth field (Design capacity)



kg/hr



75



8.0



Collection rate in Vth field (Design capacity)



kg/hr



10



9.0



Ash Density



kg/m3



600-800



10.0



Ash Temperature (Design)



11.0



Conveying Distance



12.0



Hopper O/L pipe bottom elevation



o



C



150



mts



As per the Ash collection point detail drawing 3-3614-100-044



m



+3.0 Above FFL



NOTE: TOTAL ASH GENERATION CONSIDERING ALL THE CASE SHALL BE 16625 KG/HR WITHOUT MARGIN. FOR COMPRESSOR DESIGN CONSIDERING 25% MARGIN ON ASH QTY, 20800 KG/HR IS RECOMMENDED



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



14 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



5.6



Ash Collection rate for bed silo, intermediate fly ash silo & Main fly ash silo Sl. No. 1.0 1.1 1.2 1.3 2.0 2.1



2.2 2.3 3.0 3.1 3.2 3.3 5.7



Description



Ash Collection rate (TPH)



Bed Ash Silo Capacity requirement of ash collection from the Outlet of bed ash silo into open truck Capacity requirement of ash collection from the Outlet of bed ash silo into closed trucks Capacity requirement of ash collection from the Emergency outlet Intermediate Fly Ash Silo Capacity requirement of ash collection from the Outlet of intermediate fly ash silo into the inlet of Main ash silo Capacity requirement of ash collection from the Outlet of intermediate fly ash silo into open trucks Capacity requirement of ash collection from the Emergency outlet Main Fly Ash Silo Capacity requirement of ash collection from the Outlet of main fly ash silo into open truck Capacity requirement of ash collection from the Outlet of main fly ash silo into closed trucks Capacity requirement of ash collection from the Emergency outlet



30 30 30



50



50 50



50 50 50



Bed ash particle distribution is given below: Size in microns 12500



% of Passing 100



6300



95.6



4750



91.7



2360



83



1180



69



850



62.5



710



58.5



600



53.4



500



48.2



425



43



300



29



212



16.1



150



5.9



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



15 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



Size in microns 75



% of Passing 0.5



53



0.4



45



0.3



Maximum expected size should be 3 inches. 5.8



5.9



Fly ash particle size at MDC outlet: Size in microns



Lower range (%)



Upper range (%)



0-10



2



5



up to 20



18



23



up to 30



23



30



up to 40



29



38



up to 50



35



45



up to 60



39



50



up to 70



42



57



up to 80



47



61



up to 90



50



68



up to 100



55



71



up to 200



82



98



up to 300



94



100



Fly ash particle size at Air-preheater and ESP hoppers: Size in microns 0 – 9.4 9.4 –18.8 18.8- 30 30 – 53 74 – 53 74-150 150-210



5.10



(%) 55.62 31.11 9.59 1.24 0.44 0.56 1.44



Ash Analysis: Sl. No



Characteristics



Value



i.



Aluminium as Al2O3



57.12 %



ii.



Calcium as CaO



4.36 %



iii.



Iron as Fe2O3



20.76 %



Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai



16 of 67



SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED



TECHNICAL SPECIFICATION FOR



108 MW CAPTIVE POWER PLANT



ASH HANDLING SYSTEM DOC. NO : 4 – 3614 – MECH – 011



Sl. No



5.11



Characteristics



Value



iv.



Magnesium as MgO



0.95 %



v.



Phosphorus as P2O5



0.05 %



vi.



Potassium as K2O



0.3 %



vii.



Sodium as Na2O



0.13 %



viii.



Sulphur as SO3



1.25 %



ix.



Titanium as TiO2



0.84 %



x.



Vanadium Pentaqxide V2O5