NTPC

Ramagundam

This Booklet is prepared incorporating practical experiences

encountered while running Dry ash collection system in
Unit 7 since commissioning of the Unit.
Contribution by Sincere and hard working employees
Shri KSN Raju (Junior Engineer Gr-1 Ash Handling
Maintenance) & Shri CLHLN Sanjiva Rao (Junior Engineer
Gr-2 Operation Department) in maintaining the system is
well appreciated.
The booklet contains all the required Optimized settings to
run the system in Dry or in Wet mode. Booklet also contains
necessary spares required and assists maintenance in
preparing scheduled works and also suggests operation to
carryout time bound operations for smooth running of the
system.
I wish this booklet will help both Operation and
Maintenance Departments for improving the reliability and
performance of Ash Handling Systems of Stage 3.

BB Tripathy
AGM (O&M)

STAGE 3 ASH HANDLING SYSTEM

INTRODUCTION:
Unit 7 generates 500MW with a normal coal firing of 350 T/Hr and
generates nearly 140 T/Hr ash. 20% of the total ash is collected in the
bottom ash hoppers, 3% in the Economiser hoppers and 77%will be
carried away by flue gas which is called as fly ash. As the flue gas passes
through ESP fields, fly ash will be collected in the ESP hoppers. These
hoppers are to be emptied regularly. In stage-2 fly ash evacuation is by
means of water ejector principle. But in stage-3 this is by means of
vacuum evacuation system.

ASH EVACUATION SYSTEM:

This system contains the following:
1. Vacuum pumps
2. Air washer units
3. Wetting units
4. Collecting tanks
5. Vacuum breaker
6. Bag hopper & filter
7. Ash & air handling lines
8. Water lines

WORKING PRINCIPLE:

FAHP water lines are charged to wetting unit & air washer units

Vacuum pump once started, it creates vacuum in the ESP hopper

outlet header.

Air intake valve is opened to create air flow in the above header.

ESP hopper outlet gates are opened one by one.

Ash flows from hopper to header due to vacuum and is transported

to Bag filter/wetting unit

Wet ash system: In wetting unit water is injected & ash slurry in
collected in the collector tank from where it flows to ash slurry
sump.
Dry ash system: in the bag filter ash is separated from air &
collected in buffer hopper & transported to ash SILO by means of
transport air compressor

SCHEMATIC DIAGRAM OF FLY ASH

DEASHING SYSTEM

DRY ASH SYSTEM:

Ash from the ESP hoppers is conveyed by vacuum conveying system to

BUFFER HOPPER. Ash gets separated in dry form in bag filter, and gets
stored temporarily in the buffer hopper directly below. Dry ash collected in
the buffer hopper is thereafter conveyed up to dry ash silo by means of a
Nuva Feeders & pneumatic fly ash PRESSURE conveying system. Two fly
ash pressure conveying streams operate parallel. Fly ash collected in dry ash
silo is ultimately disposed through trucks/tankers.\
Below each buffer hopper 4 NUVA Feeder are provided (X1, X2, Y1 & Y2).
Out of the above Nuva Feeder X1 & X2 under each buffer hopper are
connected to fly ash pressure conveying stream P, whereas Nuva Feeder
Y1 & Y2 under each buffer hopper are connected to fly ash pressure
conveying stream Q. Out of the above X1 & X2, one is operating and
other is stand-by, and similar in the case of Y1 & Y2. After the fly ash
extraction tower P & Q streams are interconnected to another stand-by
pressure conveying line namely R.
Three (3) numbers of transport air compressors (TAC) are provided, out of
which two are operating and another one will act as common stand-by. One
compressor for each conveying stream. TAC will unload at 1.5 Ksc and load
at 1.2 Ksc.

BUFFER HOPPER & NUVA FEEDER:

The NUVA FEEDER operation shall be of cyclic order having the following
sequence:
VENTING: vent valve opens for venting of air from Nuva Feeder, and
equalizes the vacuum between the buffer hopper and the Nuva Feeder.
FILLING: top gate opens and remains open for 40 seconds.
Top gate closes followed by closing of vent valve.
EQUALISING: equalizing valve opens thereafter for pressure equalization
between the Nuva Feeder and the pressure conveying stream.

UNLOADING: bottom gate opens and remains open for one minute to allow
discharge of ash from Nuva Feeder into conveying stream.
Bottom gate closes followed by closing of equalizing valve.
The above sequential events together make one complete operating cycle of
Nuva Feeder. The duration of each cycle is two minutes. The operating
sequence of the Nuva Feeder on a stream is staggered equally spread over
the total cycle period in order to provide an even flow of ash through the ash
conveyor.
To start the with pressure conveying system, the pulsejet cycle of silo vent
filter is to be started. Once the TAC is loaded the selected Nuva Feeder
sequence starts. Under dry mode selection the pulse jet in the bag filter
starts.
From dry ash silo dry ash is unloaded through rotary unloader to tankers and
wet ash is unloaded through rotary Feeder to open trucks

IMPORTANAT SETTINGS

Set points:
1)

FPA No. Load (PS1) = 0.04

2) FPA Conveyor Empty (PS2) = 0.70

3)

FPA Full Load (PS3) = 0.90

Permissive/ VS 2A Set VS 3A Set Point

Empty
Point 180
260 (Dry) /290 (wet)

Vacuum BKR-A

110
100

VS 2B Set VS 3B Set Point

Point 180
260 (Dry) /290 (wet)

Vacuum BKR-B

110
100

VS 2C Set VS 3C Set Point

Point 180
260 (Dry) /290 (wet)

Vacuum BKR-C

110
100

VS 2D Set VS 3D Set Point

Point 180
260 (Dry) /290 (wet)

Vacuum BKR-D

Wet Mode: 290 - 450

360 (Dry) /450 (wet)

360 (Dry) /450 (wet)

360 (Dry) /450 (wet)

360 (Dry) /450 (wet)

Dry Mode: 260 - 360

Ash Transmitter Settings:

T1 Delay 3.5 sec (all valves in close condition)

T2 Vent Valve opens by - 4 sec
T3 Nuva Feeder Filling from Buffer Hopper (Top gates open time)
40 Seconds.
--Vent valve and Top gate closes.
T4 Delay 3.5 sec (all valves in close condition)
T5 Equalizing valve opens by 9 seconds
T6 Nuva Feeder Bottom gate opens for
60 seconds
- Bottom gate and equalizing valves close.
T1 again sequence starts
Total cycle time 2 minutes.

Change over Procedure Wet to Dry:

Index actuators mode selection
Select Stream A / B / C / D

Stop Deashing.

Open Vacuum Breaker.

Stop Vacuum Pump.

Give wet to Dry Command from mode selection.

Ensure Dry mode value open.

Ensure wet mode value close.

Ensure AW CT (air washer to collecting tank) valve close.

Ensure AWBF (air washer to Bag filter) value open.

After path though coming start vacuum pumps.

Close relief valve.

Start Nova Feeders.

Check wetting Unit water Pressure 'O' (zero).

Check Air washer water pressure 3.0 kg/cm2

Start pulse get.

Change Set points 290 to 260 and 450 to 360

Start Deashing.

10

Change Over Procedure from Dry to Wet:

Index actuators mode selection

Select Stream A / B / C / D

Stop Deashing.

Open relief value.

Stop vacuum pump.

Give Dry to wet command from mode selection.

Ensure Dry mode value close.

Ensure wet mode value open.

Ensure AWBF value close position.

Ensure AWCT value open position.

After path through coming start vacuum pump.

Close vacuum breaker.

Check wetting Unit water pressure 3.Kg / cm2.

Check Air washer water pressure 5.Kg / cm2.

Change set point 260 to 280 and 360 to 450.

Start Deashing.

Stop pulse jet.

11

Stop Nova Feeders.

Problems Encountered In Dry Collection

1) Slow Deashing:
Causes:

Hopper fluidizing lines Jam. hopper valves keep open for a long
time -- ash fails to drop down from Hopper.
Material like spring, clinkers are stuck-up in Ash in take valves-hopper valves keep open for a long time -- ash fails to drop down
from Hopper.
Other VS value passing. Header Vacuum high > 250MM
Vacuum leak though common header couplings. sufficient vacuum
not available - - 100MM at test conditions
Pulse jet not OK. ESP Hopper valves fail to open if supply to
pulse jet fails.
Bag fillers choking. vacuum high continuously > 250MM
Vacuum pump Transmitters problem Transmitter choking
Air washer nozzles chokage. Ash quantity high in Vacuum pump
discharge.
Branch Header value passing. Header frequent jamming.
Poor pulse jet instrument air pressure > 5.0Ksc
Vacuum at test conditions to be set Dry Healthy 120 MM
Dry OK - 140MM

Dry - > 140MM bag Filters cleaning / vacuum header water

flushing and drying.

12

2).

Slow Evacuation (Nova Feeder to silo)

Indication: Transport lines / Ash Conveying lines Presure High > 0.7
Ksc
At 0.9 Ksc Nuva Feeder Bottom gates will close.
Causes:

Check vent value opening and closing or passing. High Vacuum

as bag filter tend to choke because of vent valve passing & ash
enters back with pressure from transportation lines.
Buffer hopper outlet Valve. High Vacuum as bag filter tend to choke
because of vent valve passing & ash enters back with pressure from
transportation lines.

Check Equalizing value operation and passing.- High Vacuum as bag

filter tend to choke because of vent valve passing & ash enters back
with pressure from transportation lines.

Check bottom gate passing and operation. High Vacuum as bag filter
tend to choke because of vent valve passing & ash enters back with
pressure from transportation lines.
i) Ash returns back to Branch lines Branch lines will come under
pressure.

13

ii) Vacuum becomes very poor / very good.

Check Top gate and bottom gates --fluidizing air lines choke.
Silo Bag Filters choke silo relief valve opens ( > 0.9 Ksc).
Silo Level High - manual checking.
Nuva Feeder Bottom gate Fluidising pads fixing Anabond fails
Ash comes in air line to Pads.

Check P, Q lines Transmitters.

3. Slow Air pre heater Hopper Deashing.

Causes:

APH Common header line Vacuum leakage.

Wetness in APH ash because of APH Soot blowing.
APH washing / Fire lines Passing makes ash wet.
Vacuum leakage through another hopper values.

4. Header Vacuum high (> 150MM)

Causes:

Buffer Hopper level high.

Bag fillers choking.
Header Lines Choke.
Vacuum pump sealing problem more seal water.
Vacuum pump suction header Jam.
Vacuum Pump Transmitter Problem getting fixed in same value.

14

Vacuum transmitters to be cleaned after every water flushing of vacuum

suction headers.

5. Header Vacuum Very Good (< 100MM)

Causes:

Vacuum leakage through couplings.

Header Values passing.

6. De ashing slow in wet mode:

Causes:

Wetting unit Nozzle choke.

Collecting tank inlet pipe jam.
AW inlet pipe jam.
Vacuum pump suction header chokes.
TRG valves passing ( branch isolation / Tower valves )
Tower changeover valves passing.
If A or D pass check passing of APH deashing valves.

Ash slurry series change over procedure:

Start HP and LP seal water pumps (other than running HP, LP seal
Water Pumps).
Open series suction value.
Open HP, LP Series seal water values.
Start Series.
Open plug value.
15

Check scoop and adjust to sample.

* NOTE: - Before stopping the running series 1hour flushing to be done.

Schedule of O&M Practices for Dry Ash Collection

S.No

Activity

Schedule

Remarks

Pass A: All Branches Every Monday 12 Hrs

Hopper 4 to 9 & APH-A in wet mode
( A5)Hoppers

Pass B: All Branches

Hopper 4 to 9

Every Tuesday 8 hrs

in wet mode

Pass C: All Branches

Hopper 4 to 9

Every Tuesday 8 hrs

in wet mode

Pass D: All Branches Every Tuesday 12 Hrs

Hopper 4 to 9 & APH-A in wet mode
( A5)Hoppers

All Main Hoppers 1,2,3 , Everyday

4
Hoppers Fluidizing
lines checking to ensure
Hopper is are empty.

To ensure that
Hopper is empty
Feedback
for
hopper empty
Fluidising return
line to discharge
air

16

Vacuum pumps suction Once in a month

lines flushing

Wetting unit
nozzles cleaning

towers Once in 15 days

S.No

Activity

Schedule

Buffer Hopper bag filter

cleaning -

Once in a month

Vacuum pumps PM Once in a week

Jobs Minor

In service pumps
Greasing and
gland adjustment

Vacuum pumps PM Once in a month

Jobs Major

Suction
header
flushing cleaning ,
Foundation bolts ,
belts
,glands
replacement ,

Spare
Nuva
inspection

Fluidizing pads ,
vent valves &
equilising valves
discs , Bottom and
top gates

10

Feeder Every Saturday

11

Conveying lines flushing

12
13

Remarks

Every morning
shift
for
30
minutes

ESP Fluidising blowers Every month

PM

Oil level , belts ,

heater , suction

17

filter cleaning
14
S.No

IA Drier air filters Once

in
candles replacement
months
Activity

Schedule

Remarks

15

Silica Gel

Once in 2 years

16

PQR valves inspection

Every 6 months

17

branch header coupling Every 3 months

bolts tightening

18

ESP Pass isolating and Every 6 months

pass inspection for ash
build up

19

Silo bag filters cleaning

20

Vent valves / equilising Every 15 days

valves speed regulation
valve check

21

Solenoid
valves 5 nos per day _ Replace
and
inspection in total flyash air lines and
inspect internals
system

22

Pulse jet valves

23

TERG ( totally enclosed Once

in
rotating gates ) valves months
inspection

Once in a month

Once in a month
3 Greasing

18

Important Spares To Be Maintained

S.No

Spare

Quantity

Bag Filters

300 ( Silo 156 , Each Buffer

Hopper 65

Fluidising pads

50 Nos

Vent valves and equalizing

valves disc and seat ring

In use 16 + 16 ( spares required

100 Nos)

Solenoid valves

50 Nos

Pulse jet solenoid valves

20 Nos

Pulse jet electronic system

02 Nos

Diffuse Feeders ( Nuva

Hopper TOP/Bottom) gates discs and seat rings

In use 32nos ( spares required

100 Nos)

ESP 1,2,3 Hoppers outlet

gates disc and seat ring

In use 48 - --( spares rqd: 50 nos)

TERG ( totally enclosed

rotating gates ) valves

In use ( 9 inches 16 nos ; 11

inch 10 nos ) spares plates
16 & 10nos) Belts 50 Nos

19