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1) Application,for conveying fly ash from outlet of ESP, Eco, APH Ash Hoppers to
inlet of fly ash silo.
2) Material free flow, Type of feed Gravity, Bulk Density of coal 600 kg/m3,
Moisture content Nil.
3) Temperature / Ash Collection Data ( Design Ash Collection )
ESP ECO/APH Bed Zone
150 / 6573 300 / 300 /
kg/hr
4) Type of system - Dense Phase Pneumatic Conveying
5) Vessel size
Bed Eco APH ESP 1 ESP 2 ESP 3 ESP 4
5 cft 3 cft 3 cft 8 cft 8 cft 4 cft 4 cft
9) Conveying line size
Bed Eco Esp1,2 Esp3,4
100 NB 80 NB 100 NB 80 NB
6) No of Collection Points= 10 nos
7) Bulk Density
Bed Ash Eco/ APH/ESP
1.2-1.4 T/m3 0.7 T/m3
11) Air Volume
Instrument Conveying
1.25 m3/min 16.2 m3/min
8) Silo Volume
Bed Ash Fly Ash
150 m3 350 m3
Ash Conditioner Capacity

Bed Ash Fly Ash

10 TPH 40 TPH

9) Cooling Water Supply Pr. 1.5- 2 Kg/cm2,Fluidizing Blower Pr. 0.5 Kg/cm2
10) Surge Hopper Volume

Bed Ash Eco/ Aph

10 cft 9.5 cft

11) Air Receiver Capacity = 6 m3,Inlet Dome valve size 200 NB

12) ABR= After Bend Reducer, OBCR = Over Bend Circulating Reducer

13) Orifice Hole Dia 5 mm

SN APH / BED ESP ESP

ECO
ABR
 OBCR
MAIN

14) Timings in seconds

SN APH / ECO BED ESP ESP

I/V Opening
Cycle Gap
Conveying

15) Pr. Switch setting Seal Pr. 5 kg/cm2,Pr. Switch setting Vessel Pr 0.3-.0.7
kg/cm2 ,Instrument Pr. 6-7 Kg/cm2,Conveying Pr. 3.5- 4 Kg/cm2
Dense Phase Pneumatic Conveying system for Bed Ash, Eco, APH & ESP,
Boiler Ash gets collected in various Ash Hoppers which includes 3 nos Bed, 2 nos
Eco/ APH, 4 nos ESP,
Ash collected in Bed Ash, Eco/APH, and ESP Hoppers is conveyed to existing coarse
Ash storage Bed Ash, fly Ash silo through Dense Phase Pneumatic Conveying
system.-2-
There are 2 multivessel conveying systems, There are 6 nos Independent single vessel
conveying system,Multivessel conveying system consisting of 1 no Master Vessel &
one no slave vessel connected through a common conveying line,Multivessel
conveying system & Independent system consisting of vessel complete with
accessories & pneumatic panel.
Ash from each conveying system gets conveyed to the respective storage silo through
there respective conveying pipes. The Ash is discharged in to Ash storage silo
through respective Terminal end Box & the conveying Air is cleaned through Reverse
pulse Jet Bag filter is then discharged in to atmosphere,
The conveying system are provided with water cooled surge Hopper of 10 / 9.5 cft
volume in Bed Ash, ECO/APH & Knife Gate Valve for Maintenance Isolation &
Inlet valve with water cooled Top plate,
The conveying system below Hopper is provided with adopter cum down comer pipe,
expansion Joint, All the conveying systems are provided with level switch for
interlocking with the pneumatic conveying system. All the ESP Hoppers are provided
with fluidizing arrangement for free discharge of material in downstream equipment
activated through compressed air conveying.
Conveying Air compressors are provided by user to meet the conveying air
requirement for the ash handling system conveying air receivers is provided to meet
the air surge during peak demand period of conveying of ash in to storage silo.
The existing Bed Ash & Fly ash storage silos are provided with Radar type
continuous level monitor, Pr. Relief valve, Bag filter for discharge of clean conveying
air in the atmosphere. The silos are provided with silo extraction system. The Dense
Phase Pneumatic conveying system for ash from various ash Hoppers of Boiler to
respective storage silo is centrally controlled through a common DCS based control
system, the normal operation of the plant is through DCS. However some controls &
indications are provided in local pneumatic panel attached to conveying vessels
namely system start/ stop selector switch, line purge push Button, probe override push
button, & system on Indication, The Pneumatic panel houses the solenoid valve (5/2
single solenoid- ¼”) & Pr. Switch Pr. Gauges as required for the electro pneumatic
control of the conveying vessel, The DCS is provided with start/ stop selector probe/
Timer ode selection. Line Purge selection & Probe override selection for each
conveying system, In Probe mode of operation, availability of material is sensed by
the level probes fitted in the Hoppers which initiates the conveying cycles.
In timer mode of operation, the system goes on continuous cycles after a preset time
interval even if there is a little or no material to convey.
Probe override operation takes place i.e. one complete conveying cycle takes place
irrespective of operating mode and/or availability of material to convey.

The DCS & Local pneumatic Panel is provided with pressed one conveying cycle’s
takes place without opening of inlet valve.
Pneumatic panel attached to each vessel has
- 1 no Pr. Indicator for seal pr.
- 1 no Pr. Indicator for vessel pr.
- 1 no system on/off selector switch
- 1 no In circuit / By pass selector switch
- 1 no Probe override push Button
- 1 no system on Indication

Prior to start of conveying cycle the following pre conditions should be established.
- Silo Bag Filter On
- Silo level not High
- Inlet valve closed & sealed
- Conveying Air receiver Pr. OK.
- Inst. Air Receiver Pr. OK
- Conveying vessel Pr.low
- Both the on/off selection ( DCS & Local pneumatic Panel are in ON mode )
- Line Purging not under progress
- Probe override not under progress
- The other conveying system interlocked with the concerned system is not under
progress.

- Now, the conveying system will address to the operating mode selection for level
probe / Timer mode.
- Filter & Lubricator is provided for clean air to electro pneumatic panel & dry air
to avoid moisture content in the instrument supply air.
- Fluidizing pads used in silo & surge Hopper for free flow of ash from silo to ash
conditioner & conveying vessel.
- Inlet valve accessories are Quick exhaust valve, seal, Dome Air- Limit switch, Air
cylinder, Blow valve, Ball valve in conveying Air pipe of vessel.
- Rotary vane feeder is used for Ash discharge from Silo to Ash conditioner.
- Ash conditioner is used for unloading of silo’s ash in a tractor trolley.
- Fly ash particles
- Particle size Indian coal ( % ) Particle size Rice Husk + Biomass
 - < 44 U 25.72 < 100 U 8%
- < 77 U 53.6
- < 105 U 72.9 < 500 U 29%
- < 149 U 92.78
- < 250 U 96.80
- < 297 U 97.80
-3-
- < 595 U 99.63 < 1190 U 92%
- < 1190 U 99.92
-
All particle size less than 1200 U at all location.
Bed Ash Particles
Normal less than 6mm – 100 % at all locations
Less than 3mm – 50 % at all locations
Ash Analysis
Description Indian coal Petcock Rice Husk

Silica 52-55 60.1 91.42

Iron 7-10 7.27 0.14
Titanium 0.15- 0.19 1.96 0.02

Sulpher Anhydrate 0.4 0.33 0.72

Alumina 29.21 28.59 0.78

Lime 0.22 0.33 3.2

Manganese 1.13 0.26 0.01

Alkali’s (Na2 O + K2 O) 2.05 0.79 3.91

Phosphate Traces 0.26 Traces

Chlorides 0.6- Traces Traces

0.85
Vanadium Traces 0.11 Traces

Nickel Traces Traces Traces

Silo Extraction System

The Fly ash Storage silo is provided with silo extraction system and is controlled locally
through its silo extraction system Local control panel and is detailed below.
a) The discharge end of the storage silo is provided with Fluidizing arrangement
consisting of Fluidizing pads activated through compressed air for conveying for
free flow of ash into downstream equipment. The fluidizing arrangement is
operated manually as & when required.
 b) 1 no Adopter cum Down comer pipe is provided at the outlet of silo
c) 1 no manually operated knife Gate valve is provided downstream to the adopter
cum down comer pipe which can be opened & closed manually as per
requirement.
d) One no ash conditioner is placed downstream to the knife Gate valve and is
operated through its start & stop push Buttons provided in the silo extraction
Local Control panel.
Silo Extraction System Operation & Controls
a) During starting
- Start ash conditioner
- Open Knife Gate valve
- In case flow of ash is erratic, open Fluidizing Valve
- Open / Throttle water line valve as per requirement
b) During Truck Transfer
- Close knife Gate valve
c) Once Truck Transfer is complete
- Reopen Knife Gate valve
d) During Stopping
Please follow reverse of starting sequence
- Close Knife Gate Valve
- Stop Ash Conditioner
- Close Water line valve at a suitable time to avoid draining of water from Ash
Conditioner.
Identification & Nomenclature

1) Identification & Nomenclature of all Dome Parts.

2) Identification of all tools & tackles of Dome valve assembly
3) Assembly of Dome- Valve
- Body finishing Dome Body
- Painting
- Dome finishing & Painting
- Fitting of Shaft seal
- Fitting of Driven Shaft
- Fitting of Dome
- Fitting of inner Dowell pin
- Placing Gasket 2.4 mm
- Placing of spigot Ring
- Placing of spigot O Ring
- Insert Ring
- Insert O Ring
- Fitting of Rubber seal

- Fitting of Top Plate

- Fig of Gap adjustment & Positioning of seal
- Maintenance & overhauling of Dome valve
a) Gap adjustment, b) Seal Placing
 Final assembly of Dome valve along its various stages
Telescopic Chute
One No Telescopic Chute is provided below RVF. This Telescopic chute is fitted with a
reversible geared motor, rotating at reduced speed. The bottom of the Telescopic chute
rests n the top of the tanker. One No Pendent control is provided for raising & lowering
the Telescopic Chute and is provided with following controls / indications.

- One No Down Push Button

- One No up Push Button
- One No Level High / Tanker Filled indication
- One No Emergency Stop Push Button With Lock
- One No Control ON Indication
Following Controls / indications are provided on silo extraction local control panel for
telescopic chute.
- 1 no 3 position selector switch for telescopic chute pendent control/ off/ Ready for
Discharge selection ( Black )
Note: Once Pendent Control is selected, The Telescopic Chute can be raised / lowered
on the tanker opening. Once Ready for Discharge is selected, then only i) The Bag
filter Unit of telescopic chute will start automatically, and ii) Dust extraction fan , iii)
RVF & iv) plate valve can be started sequentially from the silo extraction local
control panel
Lowering / Raising of the telescopic chute is done from the pendent control by
selecting pendent control mode from silo extraction local control panel
Telescopic chute can be connected to the opening of receiving tanker with the help of
Down Position, up Position Push Buttons & Emergency Stop Push Buttons with
Lock. Once the truck is put in position and the system is ready, Down Position PB is
pressed. Now spout starts lowering down. As soon as the spout touches the top of the
truck and gets properly connected to the opening, the rope goes slack and the slack
cable limit switch will stop the motor.
If the operator wants to readjust the fitment of spout on the opening of the truck, he
can do the same using these up/ down and stop buttons.
Telescopic chute Bag filter unit with integral Dust extraction fan
To avoid any ash pollution, 1 no bag filter unit with fan is fitted with Telescopic
Chute. Bag filter unit is also fitted with a timer control unit for automatic purging of
filter bags. Following controls / indications are provided on silo extraction Local
control Panel for Dust extraction fan:
- 1 no Telescopic Chute Dust Extraction Fan Start Push Button ( Green )
- 1 no Telescopic chute Dust Extraction Fan Stop Push Button ( Red )
- 1 no Telescopic chute Dust Extraction Fan ON Indication ( Red )
- Telescopic chute Dust Extraction Fan Fault Tripped ( Amber )
Dry ash extraction operation & controls
The silo extraction system will be operated from silo local control panel. Before starting
the system, operator should ensure that the following precondition is satisfied:
Silo bag filter ON
Unloading spout is fitted on to tanker after selection of “pendent Control “mode.
Once Unloading spout is fitted to the tanker, the ‘Ready to Discharge’ mode is to be
selected & Telescopic Chute Bag Filter is started automatically. The system is then
started automatically. The system is then started in the following sequence from silo
extraction Local control panel.
- Dust Extraction Fan is started by pressing Start push Button from Silo Local
Control Panel.
- RVF is started by pressing START PB from silo Extraction Local Control Panel.
- Pneumatic cylinder operated Knife Gate valve is opened by pressing open from
silo extraction local control panel.
- Now the ash unlading is in progress.
- When Tanker level probe gets covered, indication comes on the silo Extraction
Local control Panel & Pendent Control.
- Pneumatic Cylinder Operated Knife Gate Valve shall close immediately
- Thus the unloading operation is complete
After few seconds, ‘Pendent Control’ mode should be selected from silo extraction
Local control panel & the following operations are completed.
- dust extraction Fan & RVF will stop
- After 10 seconds, Telescopic Chute Bag Filter will be stopped
- After 5 seconds, Telescopic Chute can be lifted upThe Dust Extraction Fan &
Rotary van Feeder can be stopped manually from the silo Extraction Local control
panel also using their respective stop push button after closing the knife Gate
valve For raising of Telescopic Chute, the ‘Pendent Control’ mode must be
selected from silo extraction Local control panel