Technical Description

Cooling Water Pumps

Kostolac Power Station

Replacement of Ash Slurry System TEKo A

CBD Ref: C06292

ISSUE: 00
DATE: 03 April 2014
BY: C Reading

Clyde Bergemann
Lakeside Boulevard
Lakeside
Doncaster, South Yorkshire
DN4 5PL, ENGLAND
Tel: +44 (0) 1302 552200
Fax: +44 (0) 1302 369055
www.cbmh.co.uk
 TECHNICAL DESCRIPTION Sheet: 2 of 3
Date: 03/04/14
C06292 – Kostalac Power Station Issue: 00
By: C Reading

COOLING WATER PUMPS

The requirement for cooling water to the Submerged Scraper Chain Conveyors (SSCs) is as follows:-
 Flow to 4 x SSC on unit A1 Max 15 m3/hr
Min 7.5 m3/hr
Total 60 – 30 m3/hr

 Flow to 1 x SSC on unit A2 Max 85 m3/hr

Min 50 m3/hr

 Total pump flow Max 145 m3/hr

Min 30 m3/hr

PRESSURE DROP CALCULATIONS

Using the maximum figures quoted as a basis for design, the calculated pressure drop will be as
follows:-
 Flow rate to unit A1 60 m3/hr, Pipeline DN100 total head 261 kPa
 Flow rate to unit A2 85 m3/hr, Pipeline DN100 total head 329 kPa
The above figures include an allowance of 100 kPa for the pressure drop through the manual
throttling valves.

PIPELINE CONFIGURATION

There will be a single suction connection into the ‘Clean Side’ of the process water pipe with a
DN150 suction header. There will be 2 pumps connected into this header arranged in parallel with
one working, one standby.
The pumps will connect into a common DN150 discharge header. From the discharge header there
will be separate DN100 delivery lines running to unit A1 and A2. To balance the head losses in the 2
DN100 lines there will be an orifice plate in the line to unit A1 approximately 52 mm.
There will be pressure and temperature transmitters in the pump discharge header. The pressure
transmitter will be used in closed loop control with the pump speed to maintain constant pressure in
the header. The temperature transmitter will be for information only as requested by the client.

PUMP SELECTION

The pump selected for the duty is a Warman/Weir 4/3AH capable of a range from 36 – 150 m 3/hr at a
head of 329 kPa. The pump is similar to the process water supply pumps (00TJ21 D01/D02). The
pump performance will be :-

Flow rate m3/hr Pressure kPa Speed rpm Abs power kW

145 329 1800 20
85 329 1700 12
60 329 1650 8.5
36 329 1600 5
 TECHNICAL DESCRIPTION Sheet: 3 of 3
Date: 03/04/14
C06292 – Kostalac Power Station Issue: 00
By: C Reading

NB – Warman will have to confirm the above selection.

SYSTEM FLOW CONTROL

The pump speed will be controlled to maintain constant pressure in the discharge manifold. Flow rate
to the individual SSCs will be manually set by throttling valves at each SSC. Once set, the valves
should not be adjusted, constant pressure in the header should give consistent flow into the SSC.
There is no detriment to over feeding cooling water to the SSC should the ash conditions change.
Changing the setting of the throttling valves could seriously affect the stability of the level control in
the bottom ash sump. The throttling valves will be set as follows based on a 100 kPa pressure drop :-
 Unit A1 - 4 x DN32 Saunders ‘A’ type diaphragm valves (1 per SSC) set at 60% open
for 15 m3/hr – 30% open for 7.5 m3/hr
 Unit A2 – 1 x DN65 Saunders ‘A’ type diaphragm valve set at 80% open for 85 m 3/hr
– 40% open for 50 m3/hr.
There will be flow meters, with local indication, mounted close to the SSCs to assist with setting up
the throttling valves.

BOTTOM ASH SUMP LEVEL CONTROL

SSC overflow water enters the ash sluiceway, with the bottom ash, and then flows into the bottom ash
sump and becomes a constituent of the slurry pumped by the bottom ash pumps. Although the bottom
ash pumps are variable speed, there is no automatic pump speed control to regulate sump level.
During commissioning the pump speed will be set to just greater than sump inflow rates. As a result
the level will slowly drop. When a low level is reached the sump make-up supply will open and the
sump level will slowly rise until high level is reached.
The capacity of the make-up system is 4.0 m3/hr. Any change greater than this in the amount of
cooling water added to the SSCs will result in the make-up system not coping and the sump will
either overflow or run dry.

RE-ISSUE NOTES

Issue No Date Page Description of Change

00 03-04-14 All First issue