ntpc limited talcher kaniha units # 1 to 6 orissa...

NTPC LIMITED

TALCHER KANIHA

UNITS # 1 TO 6

ORISSA

FEASIBILITY REPORT

FOR

ASH DISPOSAL SYSTEM

Job No. D–0328 Name/ Sign Date

DESEIN PRIVATE LIMITED

DESEIN HOUSE

GREATER KAILASH – II

NEW DELHI – 110 048

Prepared By GG 05.05.2012

Checked By KSA 05.05.2012

Approved By V. GEORGE 05.05.2012

Document No. D-0328-01 Rev. No. 03

DESEIN INDEX

ISO 9001:2000 Registered Company

Certificate No. 07/170/J

A Development Serv ice for Industr ies & Ut i l i t ies

FEASILBILITY REPORT

FOR

ASH DISPOSAL SYSTEM

AT

NTPC KANIHA THERMAL POWER STATION

UNITS # 1 TO 6 (Phase#1 + Phase#2)

INDEX

Sl. No. DESCPRITION Sheet No

1. Introduction 1

2. Abbreviation 1

3. Objective of Study 1

4. Back ground of investigation 2

5. Description of Existing Ash Disposal system 2

6. Description of Existing Ash Extraction system for Phase #1 2

7. Description of Existing Ash Extraction system for Phase #2 3

8. Capacity of Existing system 4

9. Alternative Systems for Ash Disposal 4

10. Description Proposed ash slurry Disposal system 15

11. Layout Aspects 18

12. Electrical & Instrumentation Aspects 19

13. Design Aspects 20

14. Major Equipments 24

15 Scope of work 28

16. Project Schedule for Ash Slurry Disposal system 28

17 Estimated cost for Ash Slurry Disposal system 29

18. Summary 34

DESEIN INDEX




Annexure

Annexure-I Implementation Schedule 1 Sheet

Annexure-II Existing System Capacity 4 Sheet

Annexure-III System Capacity Proposed system 1 sheet

Drawings

1. D-0328-SKT-01A - Flow diagram Ash Disposal System

2. D-0328-SKT-02A - Indicative Layout of Ash Disposal System

3. D-0328-SKT-03A - Piping Corridor – Ist Stage pumping system

4. D-0328-SKT-04A - Piping Corridor –IInd Stage pumping system

5. D-0328-SKT-05A - Slurry Pump House

6. D-0328-SKT-06A - Flow Scheme Dry Ash system

7. D-0328-SKT-07A - Route survey

Attachments

1. Photo - Quarry No: VIII Jagannath Mine

2. Photo – Ash Slurry filling in mine

3. Photo – Ash Filled mine - 1

4. Photo – Ash Filled mine - 2

5. Photo – Slurry Disposal system in Jagnath mine

DESEIN Page 1 of 37 SH 1 OF 1




FEASILBILITY REPORT

FOR

ASH SLURRY DISPOSAL SYSTEM

FROM

NTPC TALCHER KANIHA PLANT

1.0 INTRODUCTION

This report covers the study of technical feasibility for Ash Disposal system

for two (2) phases of NTPC Kaniha plant to Jagannath mines located

approximately 30KM away from plant in the State of Orissa. NTPC Kaniha

Thermal Power Station consists of two (2) Phases. Phase-I consists of two

(2) units (Units # 1 to 2) and Phase-II consists of four (4) units (Units # 3 to 6).

All units of Phase-I and Phase-II are under commercial operation. Each unit is

having dedicated ash handling system within the plant area and an Ash

Disposal system from the plant area and up to an ash pond located

approximate 7KM away. The present study is for disposing the ash generated

from six (6) boilers up to the Coal mines for filling.

1.1 ABBREVIATIONS.

a. Phase # 1 – Unit # 1 & 2

b. Phase # 2 – Unit # 3 to 6

c. Ist Stage – From Plant up to Intermediate Collection point.

d. IInd Stage – From Intermediate collection point to destination (Quarry no.8)

1.2 Objective of the Study

The main objective of the study is investigate and study the various

feasibilities of disposing the ash by utilising the existing systems to coal

mines for future filling of voids in the mine area. This will reduce the load on

existing ash pond which is almost 90% filled condition and ash pond is likely

to overflow within two (2) years.





1.3 Background of Investigation

Mahanadi Coal Field Ltd (MCL) operating the Jaganath mines for commercial

coal selling under Coal india Ltd. regulations. Hazards in the area is back

filling of the voids generated after extraction which leads to the operational

difficulty like transportation unbalanced earth movement etc. In view of the

above Mahanadi coal ltd allotted the void-8 of Jaganath mines to NTPC

Kaniha plant for back filling with plant ash.

By considering the commercial operation of the plant in full capacity for two

(2) decades Ash extraction and disposal is the major concern for officials due

to non availability of land as per Govt norms. Kaniha plant is generating

twenty thousand (20,000) ton of ash in a day which is a huge quantity and

needs more care in handling before disposal as the norms of pollution board

has to be taken in consideration.

2.0 DESCRIPTION OF EXISTING ASH EXTRACTION SYSTEM

2.1 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

PHASE#1 (UNITS # 1 & 2)

2.1.1 Each boiler is equipped with various collection points mainly furnace bottom,

Air Pre Heater (APH) and Electrostatic Precipitators (ESP) at various

locations. Ash generated in boiler is distributed in each collection points as

follows.

Furnace bottom – 15%

APH-5%

ESPs – 90%

2.1.2 Furnace bottom is equipped with specially designed water impounded

storage bottom ash hopper which is allowed to collect the furnace bottom ash

along with water. Collected ash is removed using Jet pump with water mixing

and conveyed to a Common Ash Slurry sump for further disposal using

horizontal centrifugal pumps.





2.1.3 For extraction of APH and ESP ash collection vacuum conveying system is

envisaged up to intermediate collection point of Collector tank system from

where the water mixed ash slurry is routed up to Common ash slurry sump for

further disposal using horizontal centrifugal pumps.

2.1.4 Ash slurry from the above described points is collected in a common ash

slurry sump provided for Phase-I. A separate pump house equipped with

Horizontal centrifugal Slurry duty pumps as follows.

Number of pumping series provided – Four (4)

Number of pumping series working – Two (2)

Number of piping streams provided - Two (2)

Number of pumps in One (1) series – Three (3)

2.2 DESIGN PARAMETERS OF EXISTING ASH EXTRACTION SYSTEM FOR

PHASE#2 (UNITS # 3 TO 6)

2.2.1 Each boiler is equipped with various collection points mainly furnace bottom,

economizer, APH and ESP at various locations. Ash generated in boiler is

distributed in each collection points as follows.

Furnace bottom – 20%

Economizer – 5%

APH-5%

ESPs – 80%

2.2.2 Furnace bottom is equipped with specially designed bottom ash hopper with

water impounded storage which is allowed to collect the furnace bottom ash

along with Economizer ash. Collected ash is removed using Jet pump with

water mixing and conveyed to a Common Ash Slurry sump for further

disposal using horizontal centrifugal pumps.

2.2.3 For extraction of APH & ESP ash collection vacuum conveying system is

envisaged up to intermediate collection point of Collector tank system from





where the water mixed ash slurry is routed up to Common ash slurry sump for

further disposal using horizontal centrifugal pumps.

2.2.3 Ash slurry from the above described points is collected in a common ash

slurry sump provided for Phase-II. A separate pump house equipped with

Horizontal centrifugal Slurry duty pumps in the following passion.

Number of pumping series provided – Six (6)

Number of pumping series working – Four (4)

Number of piping streams provided - Four (4)

Number of pumps in One (1) series – Four (4)

2.3 CAPACITY OF EXISTING SYSTEM

Refer Annexure-II

The above figures are based on average basis of 20,000 ton ash generation per day.

3.0 VARIOUS SYSTEMS FOR OF ASH DISPOSAL.

3.1 The following are the various options for Ash Slurry Disposal system for

Phase-I and Phase-II

Following systems were taken into consideration and concluded the above

system as techno economical due to the reasons.

High Concentration Slurry Disposal System – HCSD system is designed with

concentration of 55% – 65 % (w/w). Dry ash from the source silos are fed to the

mixing unit for getting the required slurry concentration before entering to the main

pump. Depending on the type of pump used there are various methods to feed the

main pump. After the proper mixing of the ash and water in the required

concentration this will be disposed by the positive displacement pump provided. In

general practice various type of ash is mixed in a proper ratio in the pumps for

achieving the required efficiency and performance. The mixing units for the HCSD

system are placed above the ground level with a storage capacity of 30minutes of

pump capacity. The concentration for the system is maintained by the inlet water





control regulation. These pumps are working at high pressure; hence seamless pipes

are required for the cross country piping with high thickness to maintain the life of the

pipe. Following equipments are required to envisage the HCSD system.

1. Dry ash collection unit. (Silo, hopper etc…)

2. Ash conveying equipment to Mixing unit (Conveyor, screw feeder, air slide etc...)

3. Mixing unit with 30minutes storage capacity.

4. Feeding system to the Main pump.

5. Strainers at pump suction.

6. Pump suction valves.

7. Piston operated Main pump.

8. Slurry line discharge valves.

9. MS seamless pipe.

10. Instruments. (Density meter, flow meter, pressure transmitters etc...)

To achieve a HCSD system Dry Fly ash is required and Ash has to be fed

from Dry ash silo. The existing ash removal system below the hoppers of

boilers is not suitable for this system. Since there is no proven disposal

system of not more than 11KM and not more than 300TPH we have not

included any details of the system in this study. The longest system

installed is Base water system at Australia. Since the Existing facilities are

suiting the operation of HCSD system the feasibility of this is not

considered.

Truck unloading system – Non availability of sufficient roads, Facilities.

Frequent truck movement will fully congest the area and existing removal

system below hoppers of boiler is not suitable for the system. Details are

included below.

Railway Wagon Disposal system-This will slow down and arrest the whole

train movement. Practical difficulties for implementation. Details are

included below.





Conveyor system. Details of the scheme with included below.

Lean phase ash slurry disposal system. – Details are included below.

3.2 Estimated Cost of Various Ash Disposal Systems:

For implementing the above alternative systems completely new dry ash collection system

with silos for fly ash and dewatering bins for Bottom ash has to be installed similar to the

system installed in NTPC DADDRI. A viable flow scheme is attached as Sketch number D-

0328-SKT-06A.

Details of the system to installed and the cost and operation viability study is as follows.

3.3 Tentative BOQ for Complete dry system (Prices are in Lacs)

Fly ash Silos 1500 MT capacity along with ash un-loaders, blowers etc - 2

sets/ unit x 6 =12 sets

Buffer hoppers and associated valves and piping - 4 sets/ unit x 6 =24

sets

Conveying air compressors with air driers - 3 sets / unit x 6 =18

sets

Bag filters -4 sets/ unit x 6

=24 sets

Vent filters & vent fans -2 sets / unit x 6 =12

sets

Dry fly ash conveying pipes - lot (qty depends on

location of Silos)

Pipe racks and Buffer hopper supporting structure - lot (qty depends

on location of Silos)

Hydro bins(Dewatering bins ) for Bottom ash- -3 sets / unit x 6 =18

sets

BA slurry piping along with slurry duty valves - lot (qty

depends on location of Bins)

Replacement of BAHP pumps with higher discharge pressure -2sets/ unit x 6 =12

sets

Electrical and C&I system





Costing

(i) Steel silo (320 MT each @ Rs80/Kg) = Rs 240 Lacs x 12------ = Rs 3072 Lacs

(ii) Dewatering bins(200 MT each @ Rs 80/Kg) Rs 160 Lacs x 18---Rs2880 Lacs

(iii) Settling tank & Surge tank(160 MT each set@Es 80/Kg) Rs 128 Lacs x4

sets=Rs 512 Lacs

(iv) Vent filter & vent fan Rs 9 lacs each x 12-----------------------= Rs 108 Lacs

(v) Buffer hopper with airlock tanks and valves Rs 10 lacs each x 12= Rs 120

lacs

(vi) Bag filters Rs 6 lacs each x 12------------------------------------------- = Rs 72

lacs

(vii) Silo air blowers with motors Rs 8 lacs x 2/ silo x 12 ---------------= Rs 192

lacs

(viii) 2 KM pipe rack + Buffer hopper supporting structure 1000 MT

@ Rs 70/Kg = Rs 700Lacs

(ix) Conveying pipes 300 NBx 9.52 thk 3 lines / unit 750 mts eachx 6 =4500 mts

@ Rs 3700/ mtr--------------------------------------------------------=Rs 166.5 Lacs

(x) Conveying pipes 400 NBx 9.52 thk 3 lines / unit 750 mts eachx 6 =4500 mts

@ Rs 4700/ mtr--------------------------------------------------- =Rs 211.5 Lacs

(xi) Transport air compressors with air dryers and receivers 3sets / unit

@Rs 70 Lacs x 6-----------------------------------------------------= Rs 1260 Lacs





(xii) Instrument air compressors( 600 m3/ hr FAD) with air dryers and air receivers

dedicated for dry system 4 sets @Rs 35 Lacs--------------------=Rs 140 Lacs

(xiii) Drain pumps in Silo area with piping 3 sets x 3.5 lacs --------= Rs. 10.5 lacs

TOTAL FOR MECHANICAL JOBS---------------------------------------- =Rs 9444.5 Lacs

(xiv) Civil jobs LS ------------------------------------------------------- = Rs 2914.58 Lacs

3.3.2 Civil Work Costing

Sl.

No. CIVIL WORKS DETAILS Qty Unit

Unit Rate

Rs Total Rate

1

TAC Buidings ( 3 buidings @ 1 per

2 units) Size 45 Mtr x 12 Mtrsx 3

nos. --Concrete(700 M3x3)

2100 M3 20000 42000000

2

Silo Utility building 60 mtrx15mtr

Concrete(900 M3x1)

900 M3 20000 18000000

3

Hydro bin Recirculation water PH

35 Mtr x 12 Mtrs-Concrete(420

M3x1)

420 M3 20000 8400000

Architectural works for the

above@ 22% of concrete cost

3420 M3 4400 15048000

4

Silo Foundations Concrete

275 M3 x 12

3300 M3 17000 56100000

5

Hydro bin Foundations Concrete

235 M3 x 18

4230 M3 17000 71910000

6

Drain sump & miscellaneous

works

500 M3 17000 8500000





7

Surge tanks Foundation concrete

250 M3x 4 nos.

1000 M3 17000 17000000

8

Settling tank Foundation concrete

250 M3x 4 nos.

1000 M3 17000 17000000

9

Concrete flooring/ paving around

Silos & Hydrobins450 + 550 Sq

mtr

15000 M2 2500 37500000

TOTAL 291458000 291458000

Electrical and C&I jobs- LS-------------------------------------------------------------= Rs 955 Lacs

3.3.3 Electrical Work Costing

Sl.

No. Electrical work detail QTY

Unit

rate Total

1 3.3 KV HT Switch gear with 1 no. 140 140

2 incomer panels

1 Bus coupler panel

20 nos. TAC motor feeders(18+2 sp)

4 nos. Transformer feeders (3+1 sp)

2

220 V, DC system along with battery banks and

battery charger(2x 100% charger & 100%

battery)

1 set 30 30

3 3300/415 V , 2000 KVA Transformers 3 nos. 20 60

4 LT Switch gear WITH 1 no 65 65





Sl.


Unit

rate Total

incomers 2 nos.

1 bus coupler

150 KW motor feeders 8 nos.






5 KW feeders 12 nos.

63A Switch fuses units 32 nos.

5 3.3 HT cables lot 70 70

From client's SWGR to proposed SWGR 2x 1500

mtrs

3000 mtrs

Power Cables for HT motors 18 x 150 mtrs 2700 mtrs

6 LT Cables lot 250

LT cables for 150 KW motors 8x 200 mtrs 1600 mtrs






Sl.


Unit

rate Total



LT cables for32 KW motors 13x 350 mtrs 4550 mtrs



LT cables for 63A 8x 200 mtrs for motor

actuators

1600 mtrs

LT cables for 132A sw fuse unuts 1x 200 mtrs 200 mtrs

Motor heater cables 5000 mtrs

Control cables for motors 5000 mtrs

7 Cable accessories Lot

15 15

8 Cable trays and supports lot 50 50

9 Junction boxes & LCS lot 10 10

10 LDB/ LP/ ACDB LOT 55 55

11 Earthing lot 25 25

12 PLC Panel with MMIs (1 set for 2 units) 3 sets 70





Sl.


Unit

rate Total

13 UPS 25

14 Instrument cables 30000 mtrs 35

15 Instruments lot 55

Vacuum transmitters 24 nos.

pressure transmitters 32 nos.

Vacuum gauges, Pr gauges and Temp gauges 350 nos.

pr switches 80 nos.

Temp switches 24 nos.

TOTAL 955

TOTAL COST OF ELECTRICAL MRCH & CIVIL =Rs 13314.08 Lacs

ERECTION COST 26000 MTX Rs20000 =Rs 5200 Lacs

TOTAL COST OF INSTALLING DRY SYSTEM =Rs 18514 Lacs

Annual O&M cost would be approximately 5% = Rs 85 Lacs

Approximate minimum time period for executing this job shall be 30 months.

Probable methods for ash conveying from silos & hydro bins up to the mines are as under.

This detailed system described earlier is common for the below describing alternatives from

Silo up to mines. All the cost, advantage and disadvantages of the whole system will be

added with this description and below detailed alternative.





3.4 Ash Disposal options from Dry Ash Silo

(i) By road using dumper trucks

Assuming average capacity of each dumper truck to be 20 MT, 1000 trips per day is

required to transfer the total ash of 20000 MT per day.

To and fro travelling distance between plant and mines------------------------= 60 KM

Travelling time assuming an average speed of 40KM/ Hr= 60/40--------------=1.5

Hours

Loading time per dumper truck-------------------------------------------------------= 15 minute.

Unloading time---------------------------------------------------------------------------= 15 minutes

Therefore time taken for one trip of dumper truck------------------------------- = 2 hours

Assuming truck movement from 8 AM to 8 PM operating time--------------- = 12 hours

Maximum number of trips one truck can make per day = 12/2------------------= 6 trips

Quantity of ash that can be transported using one truck = 6x 20----------------= 120 M

Therefore number of trucks required for transporting 20000 MT

of ash= 20000/120- = 167

Assuming 8 trucks for maintenance replacement total number of

dumper trucks of 20 MT capacity -----------------------------------------------------------= 175

Note:- Considering 15 minutes loading time+ 10 minutes for truck to move in position

& move out per truck and simultaneous loading of 6 trucks

Number of trucks that can be loaded in 12 hours (8AM to 8 PM) = 720/25 x6= 172.8

Furthermore a heavy duty 2 lane road 30 KM long with required culverts , rail

crossing flyovers etc ; has to be constructed up to the mines for free





movement of trucks or existing roads to be revamped for free movement of

dumper trucks.

For filling the mine voids ash can be directly dumped and spreading and

compacting can be done by bulldozers. Minimum 6 nos. of bulldozers would

be required.

Costing

(i) Cost of dumper trucks- 175 x 25.7lacs = 45 Crores

(ii) Cost of Construction/ revamping of existing roads = 75 Crores

(iii) Cost of 6 nos. bull dozers = 6 X 60lacs = 3.6 Crores

(iv) Total cost for implementing Transportation by Dumper trucks = 123.6 Crores.

The above cost is for implementation of truck system for which complete dry

system is also added up for total cost implication.

Estimated duration for implementing the system would be approximately Three (3) years.

(ii) By using rail wagons of MGR system

For proper and efficient loading of wagons silos and hydro bins of all the units shall

be located in line and rail lines are to be routed below as shown in the attached

sketch-2.

Alternately a conveyor system with bunkers and discharge chutes can be installed

for loading the wagons.

Loading of wagons

Number of wagons per rake = 38

Capacity of each wagon= 60 MT

Capacity of each rake=38 x 60 =2280 MT

Number of rake trips required =20000/2280= 8.77 say 9 rake trips





Capacity of each silo unloading sprouts= 200 MT/ hr maximum

Assuming simultaneous loading of 4wagons thru 4 sprouts unloading

capacity= 200 x 4 =800 MT/hour

Total operating time of unloading sprouts for loading one rake= 2280/ 800=2

Hrs 51minutes

Time required for moving and aligning wagons below loading sprouts= 15

minutes

Total loading time of one rake = 3 hrs 6 minutes.

Time required for loading 9 rakes = 28 hours

Which means only 7 rakes can be loaded in a day even if operated round the

clock. ie; only 7x 2280= 15960 MT which is less than the requirement of

transferring 20000 MT/ day.

For Unloading of wagons and filling of mine voids a track hopper/ hoppers along

with conveyor system and 1 no. Shift able conveyor systems (as installed at NTPC

Dadri ash mound area) are required to be constructed / installed. Suitable water

spraying system shall be installed for preventing dust pollution.

Spreading and compacting can be done by bulldozers. Minimum 6nos. of

bulldozers would be required

Or alternate

Cost of 4km conveyors from Silos to wagons on existing railway track+ 6 KM rail

lines+ 2 shift able conveyors at mines end

Since the feasibility of above system is nil and rail costing is not possible costing has

not been envisaged.

(iii) Conveyor system





Open conveyors are not suitable as the distance is too long and one transfer station

at every will have to be constructed at an interval of 1 KM. Furthermore

environment pollution cannot be avoided. Therefore tubular conveyor system would

be a viable option.

One no. 20KM long conveyor along with supporting structure and drive accessories

would be required.

Three (3) sections with two (2) transfer stations are envisaged with 7km each length.

Each section requires Four (4) drive motors as detailed below.

1. Drive # 1 – 600KW

2. Drive # 2 – 600KW

3. Drive # 3 – 550KW

4. Drive # 4 – 550KW

This results to a power consumption of 2300KW per section totaling 6900KW for

20KM conveyor system.

Cost of the same would be approximately Rs. 350000 Lacs (This value excludes the

Electrical, Civil works which shall be added separately.

Break up of Cost.

1. Conveyor – 1.5 lacs /Meter (including drive and motor assembly)

2. Structural work – 300Kg/m

Spreading and compacting can be done by bulldozers. Minimum 6 nos.

of bulldozers would be required Operation and maintenance

Considering the above case study of the various ash disposal schemes the most feasible,

economical and viable option is found as lean slurry disposal of total ash by utilizing the

existing pumping facilities without disturbing the plant operation.

4.0 DESCRIPTION OF PROPOSED ASH SLURRY DISPOSAL SYSTEM:

plantAs per the various discussions and final resolution in Meeting held on

24.02.2012 at NTPC EOC/Noida, the scheme to be adopted is disposal of

phase # 1 ash t the Mine voids and Phase # 2 ash will be disposed to the

existing Ash pond utilizing the current facilities.





4.1 Please read this document in conjunction with following drawings.

D-0328-SKT-01A - Flow diagram Ash Disposal System

D-0328-SKT-02A - Indicative Layout of Ash Disposal System

D-0328-SKT-03A - Piping Corridor – Ist Stage pumping system

D-0328-SKT-04A - Piping Corridor – IInd Stage pumping system

D-0328-SKT-05A - IInd stage Slurry Pump House

4.1.1 For Disposal of Ash generated in the two (2) boilers as per the parameters

mentioned above we are proposing lean phase Slurry disposal system

through pipe lines. Proposed system consists of two (2) stage pumping

system with horizontal centrifugal slurry duty pumps of adequate capacity

and pressure rating. Pumping streams has to be decided according to the

final requirement of customer according to the operation and maintenance

point of view. Detailed system philosophy is as follows.

Proposed system consists of two (2) stage lean phase slurry pumping

system. From plant vicinity the ash slurry collected in Ash slurry sumps will

be pumped to an intermediate booster station where the Slurry will be

collected for pumping through horizontal centrifugal pumps to the mines.

4.1.2 IST STAGE PUMPING SYSTEM

For first stage pumping system the existing pumping system described above

in para 2.1 is to be utilized to discharge the slurry in to the second stage Ash

slurry sump located 8 KM away from the plant boundary. This location will be

TP-14 of routing map. As described earlier the pumping streams starts from

Phase # 1 Ash Slurry pump house. Total three (3) streams emerging from

phase # 1 has to be extended approximate 8km from the pump houses. Out

of three (3), two (2) streams will be working and One (1) stream will remain

standby. One (1) tapping point from each of the existing line along with

suitable isolating valve for routing up to the second stage pumping streams

will be provided.

Pipe size





From Phase # 1- 400NB (2nos)

4.1.3 IIND STAGE PUMPING SYSTEM

From three (3) streams of Ist stage pumping the ash slurry will be collected in

the IInd stage Ash slurry sump located 8km away from the plant vicinity. For

pumping the Ash slurry collected in the Ash slurry sump three (3) series of

horizontal centrifugal ash slurry pump will be provided. Out of three (3), two

(2) series of pumps will be working and one (1) series will be standby. There

will be two (2) dedicated streams of pipes working up to the destination

(Quarry No.8). In case of any chocking or maintenance in the IInd stage

pumping the Ash slurry can be diverted to Ash pond through the existing

system. Incase of any problem in this two (2) lines, the third line can be made

in to operation or divert to the Existing ash pond.

One pump will be provided with a provision of future pump in each series to

achieve the required pressure rating of the pumping. The first pump in series

will be driven with fluid coupling and gear box for achieving the speed

variation during operation if required. This speed variation shall be at least (+)

15% and (-) 40% of rated speed of the pump. Future provision pumps in

series shall be V-belt driven. Motor operated Knife gate valve shall be

provided at the discharge of the pumping streams. Also necessary manually

operated Knife gate valves shall be provided for interconnection.

Other than ash slurry pump following equipments are required for the system

operation.

Seal water pump: - Horizontal centrifugal type water pumps shall be

provided to cater the seal water requirement of the Ash slurry pumps.

One (1) separate water sump will be provided in the pump house for

suction of this pump. Minimum two (2) number pumps shall be

provided for this duty.

Flush water pump: - Horizontal centrifugal type water pumps shall be

provided to cater the flushing water requirement of Slurry pump

discharge piping during chocking and maintenance. This pump shall





be designed to flush the stream for line clearance up to the

destination in case of chocking. Minimum one (1) pump shall be

provided for this duty. This pump shall also take suction from the

water sump.

Tube Well Pump (Optional in case of water source is not available) –

Vertical tube well pumps has to install near the pump house for water

requirement of sealing. This water can be purified for the potable

water system for the pump house utility. Minimum two (2) pumps have

to be installed for this duty.

Make up water pumps – Water required for the makeup of Slurry

sump and flushing shall be provided from plant water system. For

achieving the water requirement two (2) water pumps shall be

provided at plant getting suction from the plant water source.

The aspect of water recovery system from the mines is to be further explored since

the quantity of water available in the mines is a huge quantity which may tend to spill

out from the mines during back filling with ash. There are various modes of water

recovery schemes available in the market for recalculating the water dumped with

slurry and other applications. In the scheme described here is provided with a

provision of such pipe routing if required from mines to plant. Scheme and mode of

transport are not elaborated here since the study is concentrated in disposal system

only.

5.0 LAYOUT ASPECTS

5.1 The major concern in the system is Layout aspects. Tentative layout of the

system is attached in drawings (D-0328-SKT-02). Cross country piping of the

system is to be decided according to the feasibility and availability of land as

per the existing area aspects. The major layout concerns to be taken in to

consideration are as follows.

Cross country piping from tapping point of Existing pumping stream up

to IInd stage pump house. 8km routing.





Approach road for IInd stage pump house along with cross country

piping corridor.

Above ground electrical transmission line up to IInd stage pump house.

IInd stage pump house along with five (5) ash slurry collection

compartments, one (1) ash water sump and one (1) operation and

control room.

IInd stage cross country pipe pedestals from IInd stage pump house up

to destination (Quarry no.8).

Road, rail and village area crossing at various locations up to the

destination.

5.2 Cross country piping pedestals from tapping point of existing line up to the

IInd stage pump house as per attached sketch (D-0328-SKT-02) is required

for the system, along with this pipe pedestal above ground electrical

transmission line has to be installed to feed the electrical equipments. As a

mandatory requirement and access point of view one (1) dedicated road of

adequate width has to provide along with the pipe routing. One (1) IInd stage

pump house to accommodate the equipments shall be provided along with

operator station and slurry and water collection sumps. From IInd stage pump

house the slurry disposal pipes can be routed in pedestals up to required

destination.

5.3 All the electrical – HT and LT Switchgear, Dry Type Transformers etc and

PLC Control Room for IInd stage pumping will be located in Electrical Building

on the Pump house.

6.0 ELECTRICAL AND INSTRUMENTATION ASPECTS

NTPC shall make available HT feeders to meet the requirement of IInd stage

Slurry pumping system. Dry type transformers will be provided to derive the

LT power supply required for the system. One (1) HT switchgear, one (1) LT





MCC and dry type transformers will be located in Electrical Room located in

the IInd stage pump house.

220 V DC power supply for protection purpose shall be made available by

NTPC.

All the required controls, instrumentation and protections necessary for safe,

efficient and trouble free operation of the equipments/systems will be provided.

One (1) microprocessor based PLC systems with 100% hot backup and 100%

redundant input power supply will be provided to control and monitor IInd stage

slurry pumping system. The PLC Control Panel will be provided with mimic

along with status indication of various drives /equipments and annunciation

(Audio-Visual) system.

7.0 DESIGN ASPECTS

The Disposal system is to be designed considering 2080 Cum/h (1040Cum/h

per stream) Ash slurry disposal per day. The basic design aspect of the

system is that the existing system is running continuous for 24hours for all

two (2) boilers. In case of non availability of ash necessary make up water

system is to be operated if the system needs continuous running. The system

is designed on the concept that the pipe routing from IInd stage pumping up to

Jaganath mines has to be done along the forest area indicated in the layout

scheme (D-0328-SKT-03). Total pumping distance from plant area up to the

mines is considered as twenty (20) Kilometers (aprox.). Out of twenty (20) KM

total length, Eight (8) Km shall be covered by utilizing the existing system as

described earlier. Hence the second stage is to be designed for a length of

minimum twelve (12) KM.

7.1 SIZING CRITERIA

7.1.1 IST STAGE PUMPING SYSTEM UP TO IIND STAGE PUMP HOUSE

7.1.1.1 PHASE # 1





Sl

No

Description Formula Value

1 Slurry Pump capacity ‘A’ = 1040Cum/h

2 Number of pumps working ‘B’ = 2 Nos.

3 Number of Streams from Phase

# 1 to IInd stage pump house.

‘C’ = 2 Nos.

4 Flow per stream ‘D’ = A = 1040 Cum/h

5 Total line length ‘E’ = 8 Km

5 Total Friction loss per stream

(Calculated)

‘F’ = 94 mwc

6 Static rise

Plant elevation = 110

Elevation at TP14 = 121

‘G’ = 13 m

7 Total head required per stream ‘J’ = F + G = 106 mwc.

8 Head available from Existing

pump

‘F’ = 13.8 Kg/Sqcm

SINCE HEAD AVAILABLE IS HIGHER THAN THE REQUIRED HEAD,

SELECTED LOCATION IS O.K

7.1.2 IInd STAGE PUMPING SYSTEM UP TO QUARRY NO.8

Sl

No

Description Formula Value

1. Ash Slurry disposal pump

capacity, Phase # 1 ‘A’ = 1040 Cum/h





2. Number pumping series working

‘B’ = 2nos.

3. Number working hours per day

‘C’ = 24h

4. Total ash slurry collected per day

in IInd stage Slurry Sump from

phase # 1

‘D = A x B x C’ = 49920 Cum

5. Total ash slurry collected per day

in IInd stage Slurry Sump

‘I = D = 49920 Cum

6. Number of working hours per day

- IInd stage Slurry Pumps

‘J’ = 24hrs

7. Total pumping capacity of IInd

stage pumping

‘K = I / J’ = 2080 Cum/h

08. Number of pumping series

working in IInd stage

‘L’ = 2nos

09. Capacity of each pumping stream

‘M = K/L’ = 1040Cum/h

10. Total Friction loss ‘FL’ = 154 mwc

11 Static rise

Elevation at TP14 = EL(+) 121

Elevation at Quarry no.8=(+)60 60

‘SR’ = -60 mwc

12 Total head required ‘HR’ = FL + SR = 94 mwc

13. Total pressure required to reach

the destination

‘N’ = 94Kg/Sqcm*1

14. Number of pumps in each series

‘P’ = 3nos





15. Discharge pressure of Pump

selected

‘Q = N/P’ = 3.2 Kg/Sqcm

*1. Pressure requirement is calculated on assumption that the mine area is

located at 60m lower elevation from the IInd stage pump house.

8.0 MAJOR EQUIPMENT

The following major equipments are proposed for Ash slurry Disposal system:

Sl.

No

EQUIPMENT Quantity

A Ist Stage Pumping System

1 400 NB Motor operated Knife Gate Valves 4Nos.

2 400 NB MS ERW Pipe 9.52mm thick 36 Km

3 400NB Cast iron fittings 2 lot

4 400NB Sleeve couplings 2 lot

5 Electrical items 1 lot

B IInd Stage Pumping System

1 Plug valves for Ash Slurry sump isolation 3 nos.

2 Liner for Ash Slurry Sump 1 lot





Sl.

No

EQUIPMENT Quantity

3 Flushing nozzles for Slurry sump jetting 1 lot

4 400NB motor operated Knife Gate valve 3 nos.

5 Horizontal Centrifugal Slurry duty pumps 9 nos.

6 Fluid coupling for Ash Slurry pump 3 nos.

7 Gear Box for Ash Slurry Pump 3 nos.

8 Motor for Ash Slurry Pump – 200KW 9 nos.

9 400NB manual operated Knife gate valve 9 nos.

10 400NB MS ERW pipe 36km

11 ACI Fittings for IInd Stage pumping 3 lots

12 Horizontal Centrifugal Water pump along with

motor for Seal water

2 nos.

13 Horizontal Centrifugal Water pump along with

motor for Flushing

1 no.





Sl.

No

EQUIPMENT Quantity

14 Tube well pump 2 nos.

15 Make up Water pump 2 nos.

16 5ton EOT crane for Pump house 1 no.

17 HT Switchgear 1 no.

18 LT Switchgear 1 no.

19 Dry Type Transformers 2 Nos.

20 PLC Control Panel 1 No

21 Power and Control Cables Lot

22 Instruments Lot

23 Earthing and Lighting Lot

24 Dry type ventilation system for Pump house Lot

25 Air Conditioning system for PLC Control Room Lot





C Civil and Structural Works

1 Pipe Pedestals for Ist stage Pumping 1000nos.

2 Support for Transmission line 1 lot

3 IInd stage Pump house with electrical and control

room

1 no.

4 Pipe Pedestals for IInd stage Pumping 1500 Nos.

5 4m Wide access road up to IInd stage Pump house 8km

6 4m Wide access road from to IInd stage Pump

house to destination (Quarry no.8) – Optional

12 km

7 Equipment foundations Lot

9.0 SCOPE OF WORK

This shall be decided by Customer according to the feasibility and fund

availability.

10.0 PROJECT SCHEDULE FOR ASH SLURRY DISPOSAL SYSTEM

Estimated time required for designing and engineering of Ash Slurry System,

soil investigation and route survey is four (4) months from the date of

placement of order. Procurement of bought out of equipment & materials and

manufacturing of self fabricated equipment and materials will take six (6)

months after engineering. Despatch and receipt of materials and equipment

at site will take nine (9) months starting seventh month onwards from the date





of procurement. Civil works will take minimum fourteen (14) months provided

the fully mobilized team and fast track working basis. Erection of equipment

could be started after four (4) months from the start date of despatches. The

duration of erection of equipment is estimated fourteen (14) months. Testing

and commissioning activity will take last two (2) months after completion of

erection of equipment. Total time period for completion of Ash Disposal

System is proposed as twenty (24) months from the issue of LOI on

successful bidder provided the environmental conditions, availability of land

and local supports from other departments.

11. COST ESTIMATE FOR PROPOSED ASH SLURRY DISPOSAL SYSTEM

(i) Mechanical

Sl. No.

EQUIPMENT UOM Quantity Unit price

Total price

A Ist Stage Pumping System

1 400 NB Motor operated Knife Gate Valves Nos. 3 600,000 1,800,000

2 400 NB MS ERW Pipe 9.52mm thick M 16000 5,200 83,200,000

3 400NB fittings & couplings Lot 1 30,000 1,950,000

B IInd Stage Pumping System

1 Plug valves for Ash Slurry sump isolation, slurry sump liner, flushing nozzles, Pulleys, V-belts etc.

Lot 1 2,320,000 2,320,000

4 400NB motor operated Knife Gate valve Nos. 3 600,000 1,800,000

5 Horizontal Centrifugal Slurry duty pumps Nos. 9 850,000 2,550,000

6 Fluid coupling and gear box for Ash Slurry pump

Nos. 3 450,000 1,350,000

9 Motor for Ash Slurry Pump – 200KW Nos. 9 500,000 4,500,000

11 400NB manual operated Knife gate valve Nos. 9 520,000 46,800,000





Sl. No.

EQUIPMENT UOM Quantity Unit price

Total price

12 400NB MS ERW pipe m 36000 6,000 216,000,000

13 Fittings & Couplings for IInd Stage pumping Nos. 45 25,000 2,555,000

14 Horizontal Centrifugal Water pumps Nos. 4 1,000,000 4,000,000

17 EOT crane for Pump house Nos. 1 1,000,000 1,000,000

C

Common System

1 450NB Make water line (1nos) 6.3mm thick Nos. 8000 3,000 24,000,000

2 Make up water pump with motor Nos. 2 1,100,000 2,200,000

3 Miscellaneous lot 1 2,000,000 2,000,000

Total for Mechanical 3,981 Lacs

(ii). Civil and Structural

Sl no.

Details QTY Unit Unit

Rate Rs Total Rs

A From In plant Pump House to Booster PH 8KM

1 Pipe pedestals 7.5 M wide 8000/7= 1150 x 6 M3 (RCC)

5500 M3 20000 110000000

2 Rail crossing pipe rack 3 nos. max 100 M span

(a) RCC 6x25

150 M3 20000 3000000

(b) Structural steel 100x0.6 60 MT 72000 4320000

3 20 mtr span Road crossing culverts 3 nos. - RCC 3x100

300 M3 20000 6000000

4 25 mtr span Nalla crossing 2 nos.

(a) RCC 4x25 100 M3 20000 2000000






Sl no.


Rate Rs Total Rs

5 Thrust blocks 15 nos. x30 450 M3 20000 9000000

B From Booster Pump House to mine void 12KM

1 Pipe pedestals 4 M wide12000/7= 1725 x 3.75 M3 (RCC)

6500 M3 20000 130000000

2 Rail crossing pipe rack 3 nos. max 100 M span

(a) RCC 6x25 150 M3 20000 3000000


3 20 mtr span Road crossing culverts 6 nos. - RCC 6x100

600 M3 20000 12000000

4 30 mtr span Nalla crossing 4 nos.

(a) RCC 8x25 200 M3 20000 4000000


5 Thrust blocks 15 nos. x35 525 M3 20000 10500000

C Booster PH9 30Mx16M x 9M ht) 800 M3 28000 22400000

D 4 mtr wide asphalted road from plant to Booster PH 8 KM

(a) Road construction 8000 x4 32000 M2 1500 48000000

(b) Shoulders for above !M wide both sides 5600 x 2

16000 M2 650 10400000

E 4 mtr wide WBM road from booster PH to Mine void

(a) Road construction 12000 x4 48000 M2 850 40800000





Sl no.


Rate Rs Total Rs

(b) Shoulders for above !M wide both sides 12000 x 2

24000 M2 650 15600000

TOTAL 4418 lacs

(iii). Electrical and C & I

Sl. No.

ELECTRICAL SYSTEM FOR SLURRY BOOSTER SYSTEM FOR 6X 500 MW

Unit rate Total Rs in lacs

1 3.3 KV transmission line 8 KM long with complete accessories like isolators, earthing, lightning arrestors

8 KM 42 336

2 3.3 KV Switch Gear with 1 set 90 75

1 incomer

Motor feeders 200 KW x 9+2 spares = 11

Transformer feeders 2

3 Transformers 3300V/ 415V, 630 KVA 2 10 20

4 220 V, DC system along with battery banks and battery charger

25 25

5 LT Switch gear with 1 set 30 30

Motor feeders 150 KW- 2

40 KW motor feeders- 4

32A Switch fuse units for valve motor actuators-8

32A Lighting feeders-2

63 A Switch fuse units-4

6 HT cables lot 30





Sl. No.

ELECTRICAL SYSTEM FOR SLURRY BOOSTER SYSTEM FOR 6X 500 MW

Unit rate Total Rs in lacs

From HT Switch gear to 350 KW motor 250 Mtrs x6

1500 mtrs

From HT Switch gear to Transformers 100 mtrs x2

200 mtrs

7 LT cables lot 40



LT cables for 63A 6x 200 mtrs for motor actuators

1600 mtrs

8 Cable trays, supports and cable accessories lot 10 10

9 LDB/ LP/ACDB LOT 20 20

8 Earthing lot 10 10

9 PLC Panel with MMI + 8 KM FO cable 1 set 55 55

10 UPS 1 15 15

11 Instrument cables 2000 mtrs.

12.5 25

12 Instruments Lot 6 6

Pr gauges and Temp gauges 15 nos.

pr switches 15 nos.

Level switches 2 sets

TOTAL

697 lacs.

(iv). Erection testing and commissioning

1. Estimated cost of erection---- = 2950 lacs





Total estimated cost for Ash Slurry disposal system = 3985+4418+697+2950 = 12050

lacs

“The above slurry system pricing is done with MS ERW pipe, incase of Basalt pipes

are used in the system a price implication of Rs. 6843/- lacs will be added up to the

total mentioned above. Also 10% additional to be considered to the erection and

commissioning and additional handling charges.”

11.0 Summary

Following three feasible options are summarized and found the most feasible option as

Slurry pumping system.

Sl.

no

Details of

System

Approximate

Cost

Duration for

execution Advantages Disadvantages

1 Slurry

Pumping

system

Rs. 120.5

Crore

24 months 1. Easy

Installation

2. Less

operation

and

maintenance

cost.

3. Less initial

installation

cost.

4. Easy

installation.

5. Easy

operation

and

maintenance

1. Water

consumption.

2 Road

transportati

on by

dumper

305 Crores. Minimum

30months for Dry

system and

another 36

1. Water

saving.

1. The system is not

feasible as around

175 trucks would

be required to run





Sl.

no

Details of

System

Approximate

Cost

Duration for

execution Advantages Disadvantages

trucks months for

balance work

during the day

time (8.0 am to

8.0p.m). Loading

of such large

number of trucks

and truck

movement

through the

villages on the

route to the mine

would also not be

feasible.

2. High installation

cost.

3. High Operation

and maintenance

cost.

4. Atmospheric

Pollution.

5. Local risk factors.

5 Tubular

Conveyor

System

Rs. 600

Crore

Minimum

30months for Dry

system and 24

months for

balance.

1. Water

consum

ption.

1. Huge power

consumption.

2. Huge operation

cost.

3. Huge Initial

installation cost.

4. Risk factor.

Study # 0328

ANNEXURES

Study # 0328

ANNEXURE - I IMPLEMENTATION SCHEDULE

DESEIN SH 1 OF 1




ANNEXURE - I ASH SLURRY DISPOSAL SYSTEM

IMPLEMENTATION SCHEDULE

Activity Months

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1. Release of Order

2. Design & Engineering

3. Procurement & Manufacturing

4. Civil Works

5. Dispatch & Receipt at Site

6. Erection

7. Testing & Commissioning

ZERO DATE

Study # 0328

ANNEXURE - II EXISTING SYSTEM CAPACITY

Work

ing

Stand

byTotal

1 Ash slurry disposal pump 2 2 4 1040 46 325

2 BALP Pump 3 2 5 740 20 55

3 BAHP Pump 1 1 2 550 73 150

4 Flushing water Pump 1 Nil 1 1040 14 55

5 LP Seal water pump 1 1 2 22.5 18 4.4

6 HP Seal water pump 1 1 2 33 111 22

ANNEXURE-II

Capacity

Cum/hrRemark

EXISTING UTILITIES - PHASE # 1

SI

noEquipment

QuantityMotor

rating

in KW

Head

mwc

1 of 4

Worki

ng

Stan

dbyTotal

1Ash slurry disposal

pump4 2 6 1220 37.5 300

2 BALP Pump 6 4 10 615 23 60

3 BAHP Pump 2 2 4 600 100 260

4 Flushing Water Pump 2 Nil 2 1220 15 75

5 Sump Jetting pump 1 1 2 50 43 10

6 LP Seal water pump 1 1 2 60 55 18.5

7 HP Seal water pump 1 1 2 36 135 30

EXISTING UTILITIES - PHASE # 2

Capacity

Cum/hRemark

Quantity

SI

noEquipment

Motor

rating

in KW

Head

mwc

2 of 4

A Ash Collection data

1 Worst Coal Consumption of Boiler428 tph

2 Bottom ash hopper 58 T/Hr

3 ESP hoppers 172T/Hr

4 Duct hoppers 08 T/Hr

5 APH hoppers 10 T/Hr

B Ash Removal System

1 Bottom Ash SystemWater impounted Bottom ash hopper with Conventional Jet Pump

system up to Ash Slurry Sump

2 Fly Ash SystemVacuum System through wet surry system up to Ash Slurry

Sump.

3 Ash disposal SystemFour (4) series (2W+2S) pumping stream up to Ash Dyke located

6km way from plant. Each series having three (3) pumps.

4 Ash water System

1. Ash water recovery

2. CW Blow down

3. RAW Water (Only for emergency)

C Density of Ash

1 Bottom Ash 0.65 ton/Cum

2 Fly Ash 0.75 ton/Cum

EXISTING SYSTEM PARAMETERS.

PHASE # 1

3 of 4

A Ash Collection data

1 Worst Coal Consumption of Boiler 428 tph

2 Bottom ash hopper 58 T/Hr

3 ESP hoppers 172T/Hr

4 Duct hoppers NA

5 APH hoppers 10 T/Hr

B Ash Removal System

1 Bottom Ash SystemWater impounted Bottom ash hopper with Conventional Jet Pump

system up to Ash Slurry Sump

2 Fly Ash SystemVacuum System through wet surry system up to Ash Slurry

Sump.

3 Ash disposal SystemSix (6) series (4W+2S) pumping stream up to Ash Dyke located

6km way from plant. Each series have four (4) pumps.

4 Ash water System

1. Ash water recovery

2. CW Blow down

3. RAW Water (Only for emergency)

C Density of Ash

1 Bottom Ash 0.65 ton/Cum

2 Fly Ash 0.75 ton/Cum

EXISTING SYSTEM PARAMETERS.

PHASE # 2

4 of 4

Study # 0328

DRAWINGS

TP-1

TP-2

TP-3

TP-4TP-5

TP-6TP-7

TP-8

TP-9

TP-10

TP-11

TP-12

TP-13

TP-14

TP-15

TP-16TP-17

TP-18

TP-19

TP-20

TP-21

TP-22

TP-23

TP-24

TP-25

TP-26

END POINT

STARTING POINT

(EL(+)60M)

QUARRYNO.08

(EL(+)110M)

BOOSTERWATER PUMP

ASH PIPE LINE

(DETAIL - D)TYPICAL RAIL CROSSING

DETAIL-D

CHIMNEY

FGL

NOTES:- 1.DRAWING IS INDICATIVE ONLY. 2.FOR FLOW SCHEME DETAILS REFER DRG. NO. D-0328-SKT-01B. 3.LOCATION OF BOOSTER PUMP STATION-1 = 10Km AWAY

FROM PLANT. 4.LOCATION OF BOOSTER PUMP STATION-2 = 13Km FROM

BOOSTER PUMP STATION-1

C L

400 NB SLURRY PIPE - 1st STAGE

VIEW - AA

FGL

(UPTO BOOSTER PUMP HOUSE)

VIEW - BB(AFTER BOOSTER PUMP HOUSE)

400NB SLURRY PIPE

600NB RECOVERY PIPE

FGL

RAIL LINE

AS H DISPOSAL LINE

400NB SLURRY PIPE

PIPING CORRIDOR-IInd STAGE PUMPINGAFTER BOOSTER PUMP HOUSE

600NB RECOVERY PIPE(OPTIONAL)

FGL

NOTES:- 1.- DRAWING IS INDICATIVE ONLY. 2.-FOR FLOW SCHEME DETAILS REFER DRG. NO. D-0328-SKT-01. 3.- PHYSICAL CHECKING HAS TO BE CARRIED OUT FOR FINALISATION OF ROUTING.

NOTES:- 1.- ALL DIMENSIONS ARE IN mm. 2.- LAYOUT SHOWN IS INDICATIVE ONLY.

Study # 0328

ATTACHMENTS

ntpc limited talcher kaniha units # 1 to 6 orissa...

Documents