The document provides details on the ash handling system for a 2x660 MW power plant, including diagrams and descriptions of the: 1) Bottom ash, coarse ash, and fly ash handling subsystems. It describes the major equipment involved in collecting, transporting, and disposing of ash in slurry form. 2) Fly ash vacuum conveying system which uses vacuum pumps to transport fly ash from ESP hoppers to collector tanks for mixing with water and disposal as slurry. 3) Piping, instrumentation, and equipment required to be installed for continuous wet mode operation of the bottom ash, coarse ash, and fly ash vacuum conveying systems. The pressure conveying system to intermediate and terminal silos

1. OBRA-C 2x660 MW
ASH HANDLING SYSTEM
PRESENTATION ON
Ash Handling System

2. IM&HCSD Silo
BA Hopper
O/F Tank& Pump
Coase Ash Tank&
Pump
Buffer Tower#2
Vacuum Pump
House#2
Vacuum Pump
House!#1
Buffer Tower#1
Ash Slurry Sump
House
Ash Compressor House
Clarifier & Chemical House
Ash Water Pump
House
Terminal Silo
APR-1
APR-2
APR-3 APR-4 APR-5
APR-6
APR-7
APR-8
APR-9

3. Ash Water Pump House
BAHP (AWPH to Bottom Ash Hoppe#01&02) Φ450NB
BALP (AWPH to Bottom Ash Hopper#01&02) Φ500NB
FAHP (AWPH to Collector Tank in Buffer Hopper
Tower#01&02) Φ500NB-550NB
HCSD flushing line to HCSD Silo Φ300NB
Flushing Water line (AWPH to Ash Slurry Sump) Φ400NB
TAC (To Air lock tank
Buffer Hopper#01)
Φ300NB
IAC Φ100NB-200NB (To Buffer
Hopper tower, BAH, HCSD silo
& Terminal Silo)
Vacuum line
(Vacuum Pump
to Collector
tank#01)
Φ200NB
Fluidizingair blower pipes (From air blower to ESP#01 fluidizing
pads, Buffer Hoppers#01) Φ100NB
From Bottom Ash Overflow Tank Φ300NB U#01 & 02
Pipe
Rack
(By
Arch
Dept)
F
L
W
P
H
C
S
D
W
P
H
C
S
D
W
P
H
C
S
D
W
P
F
A
H
P
F
A
H
P
B
A
L
P
B
A
L
P
B
A
L
P
B
A
H
P
B
A
H
P
B
A
H
P
APR-02
F
A
H
P
Clarifiers
B
A
Buffer
Hopper
Tower U#01
Pass-A
Buffer
Hopper
Tower U#01
Pass-B
Buffer
Hopper
Tower U#01
Pass-C
Buffer
Hopper
Tower U#01
Pass-D
Buffer
Hopper
Tower U#01
Pass-E
Buffer
Hopper
Tower U#01
Pass-F
E
S
P
-
F
E
S
P
-
F
E
S
P
-
E
E
S
P
-
E
E
S
P
-
D
E
S
P
-
D
E
S
P
-
C
E
S
P
-
C
E
S
P
-
B
E
S
P
-
B
E
S
P
-
A
E
S
P
-
A
BAH Bottom Ash Slurry Lines to
Ash Slurry Pump House
Φ200NB
Bottom Ash Overflow Lines
to Clarifier Φ300NB
Coarse Ash Lines to
ASPH Φ 350NB
TAC (To Air lock tank
Buffer Hopper#02)
Φ300NB
APR-
03
Sludge pit to Ash Slurry Sump Φ100NB
Ash
Slurry
Pump
House
Ash Water Sump
To IM/HCSD Silo & Terminal Silo
Φ400mm
Air Blower
Vacuum
Pumps
#01
TAC
TAC
TAC
TAC
IAC
IAC
TAC
TAC
TAC
TAC
APR-08 Ash Compressor House
APR-09
IAC
Mainten
ance Bay
Eco
Hoppers
APH
Hoppers
SCR
Hoppers
Eco Hoppers to
BAH Φ250NB
APH Hoppers to Coarse
Ash Tank Φ200NB
SCR Hoppers to Coarse
Ash Tank Φ400NB
Sludge
Pit
LP Seal water
pumps
Section 1-1 (Showing only for Unit#01 )
1) 12 lines of Φ200NB (Collector tank discharge to Ash Slurry Pump House)
2) 1 line of Φ550NB (FAHP)
3) 6 lines of Φ200NB (Vacuum Line)
4) 4 lines of Φ300NB (TAC line to ESP & air lock tank in buffer hopper tower)
5) 2 lines of Φ100NB (ESP drainpipes)
6) 4 lines of Φ300NB (FA line discharge)
7) 1 line of Φ500NB (BALP Pipes to BAH)
8) 1 line of Φ450NB (BAHP Pipes to BAH)
9) 2 lines of Φ350NB (Coarse Ash pipes to Ash Slurry Pump house)
10) 1 line of Φ300NB (BA Overflow tank to clarifier)
11) 3 lines of Φ200NB (BA discharge)
12) 1 line of Φ150NB (LP Seal water pipe)
Section 2-2
1) 1 line of Φ300NB (Bottom Ah Overflow pipes)
2) 2 lines of Φ400NB (Recovery water line)
3) 1 line of Φ4000NB (Flushing pipe)
4) 1 line of Φ550NB (FAHP)
5) 1 line of Φ500NB (BALP Pipes to BAH)
6) 1 line of Φ450NB (BAHP)
7) 1 line of Φ300NB (HCSD LP pipe)
8) 1 line of Φ550NB (Recovery water line)
9) 8 lines of Φ300NB (TAC line to air lock tank in buffer hopper tower)
10) 1 line of Φ200NB (IAC line)
11) 1 line of Φ100NB (Sludge pipe to Ash Slurry Sump)
12) 1 line of Φ100NB (Vacuum pump area drain line)
Section 3-3
1) 1 line of Φ550NB (Recovery water line)
2) 2 lines of Φ400NB (Recovery water line)
3) 1 line of Φ50NB (Seal water line)
4) 1 line of Φ100NB (DrainpipeSilo Area)
5) 1 line of Φ300NB (HCSD LP pipe)
6) 6 lines of Φ400NB (Ash disposal lines)
Ash Slurry lines Φ200NB X 12lines (from collector tank to Ash Slurry Sump)
Ash water recovery lines (2 lines of Φ400NB & 1
line of Φ550NB (from ash dyke area)
LP seal water lines to clinker grinder, BAOF pump, coarse ash
pump & vacuum pump sealing Φ150NB
LP seal water lines Φ150NB to BAHP seal water pump
1
1
2 2
3 3
Duct Support Structure
Buffer Hoppers to
IM/TM Silo (4lines
Φ300NB)
1 line of Φ100NB (Vacuum pump area drain line)

4. ASH HANDLING SYSTEM:
• BOTTOM ASH & ECONOMISER ASH COLLECTED IN BOTTOM ASH HOPPER AND
COARSE ASH COLLECTED IN APH AND SCR HOPPERS SHALL BE DISPOSED IN
SLURRY FORM TO ASH DYKE.
• FLY ASH COLLECTED IN ESP HOPPERS CAN BE DISPOSED IN BOTH IN SLURRY FORM
TO ASH DYKE THROUGH WET SYSTEM OR IN DRY FORM TO FLY ASH SILOS
THROUGH PRESSURE CONVEYING SYSTEM (DRY SYSTEM). THE WET SYSTEM
CONSISTS OF BOTH OPTIONS i.e LEAN SLURRY & HCSD SLURRY STSTEM.
• EQUIPMENT REQUIRED TO BE INSTALLED FOR CONTINUOUS OPERATION OF UNIT-1
IN WET MODE IS EXPLAINED IN FOLLOWING SLIDES

5. ASH HANDLING SYSTEM CONFIGURATION DIAGRAM
BOTTOM ASH COARSE ASH FLY ASH
BOTTOM ASH AND
ECONOMISER HOPPERS
ASH SLURRY SUMP
ASH DYKE
SCR HOPPERS
COARSE ASH TANK
APH HOPPERS ESP HOPPERS
COLLECTOR TANK BUFFER HOPPER
INTERMEDIATE SILOS
WET SYSTEM
DRY SYSTEM
HCSD SILOS
ASH DYKE TERMINAL SILOS

6. FLY ASH SYSTEM CONFIGURATION
ASH 191.68 TPH
ASH REMOVAL
CAPACITY -360 TPH
BUFFER
HOPPER
AIR LOCK TANK
COLLECTOR
TANK
ESP HOPPER
DRY SYSTEM
WET SYSTEM
- FLY ASH COLLECTED IN APH AND ESP HOPPERS FOR 8
HOURS SHALL BE REMOVED IN – 4.5 HOURS
- TOTAL FLY ASH COLLECTION IN 8 HOURS = 202.34X8=
1618.72 TONS
- FLY ASH REMOVAL CAPACITY = 1618.72/4.5 = 360.0TPH
- ESP IS DIVIDED INTO 6 STREAMS. HENCE REMOVAL
CAPACITY OF EACH STREAM IS 60 TPH
ASH REMOVAL
CAPACITY -360 TPH
ASH SLURRY PUMP
(1060m3/hr ≡ 𝟑𝟔𝟎TPH @ Fly Ash)
TO ASH DYKE
HCSD SLO
HCSD SLURRY PUMP`
TO ASH DYKE
IM SILO Terminal
SILO
ASH SLURRY SUMP

7. The design concept for Fly Ash to wet ash preparation
Back-up
For fly ash to wet ash preparation INDURE is using
wetting head and each wetting head having 22 nos.
high pressure nozzles with water flow-95
m.cu/hr.@35 MWC and dry capacity is 63 TPH
(Reference same system is running in LARA project
also)

8. The design concept for Fly Ash to wet ash preparation
Back-up
Elevation at Buffer hopper / collector tank (DP16004-XA00-90ETK-510077)
Wetting
Head
Collector Tank
20THK.Alloy CI LINER(400BHN)

9. ASH HANDLING SYSTEM
ASH HANDLING SYSTEM CAN BE BROADLY DIVIDED INTO THE FOLLOWING SUB SYSTEMS:
• BOTTOM ASH HANDLING SYSTEM
• COARSE ASH HANDLING SYSTEM
• FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM
• FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM
• ASH WATER SYSTEM
• ASH SLURRY DISPOSAL SYSTEM
• HCSD SLURRY DISPOSAL SYSTEM
• ASH WATER RECIRCULATION SYSTEM
• INSTRUMENT AIR SYSTEM

10. BOTTOM ECONOMISER & COARSE ASH HANDLING SYSTEM
(DRG. NO. DP16004-XG08-90ETA-510001, SH 1 OF 2)
ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P
& ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION
IN WET MODE OF UNIT 1

11. BOTTOM ECONOMISER & COARSE ASH HANDLING SYSTEM
(DRG. NO. DP16004-XG08-90ETA-510001, SH 2 OF 2)
ALL THE EQUIPMENT, PIPING AND
INSTRUMENTATION SHOWN IN THIS P &
ID SHALL BE COMPLETELY INSTALLED
FOR CONTINUOUS OPERATION IN WET
MODE

12. BOTTOM ASH AND COARSE ASH SYSTEM
• THE BOTTOM ASH AND CORASE ASH SYSTEM IS UNITISED.
• ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN IN PREVIOUS TWO SLIDES
SHALL BE COMPLETELY INSTALLED.
• MAJOR EQUIPMENT TO BE INSTALLED:
• BOTTOM ASH HOPPER COMPLETE WITH EQUIPMENT, WATER PIPING, VALVES AND
INSTRUMENTATION
• BOTTOM ASH SLURRY PIPE LINES WITH VALVES AND INSTRUMENTAION UPTO ASH SLURRY SUMP
• BOTTOM ASH OVERFLOW TANK
• BOTTOM ASH OVERFLOW PUMPS WITH PIPING, VALVES AND INSTRUMENTATION
• DRAIN JET PUMPS, PIPING, VALVES AND INSTRUMENTION
• ECONOMISER HOPPERS: FLUSHING APPARATUS, WATER AND SLURRY PIPING, VALVES AND
INSTRUMENTATION
• APH HOPPERS, SCR HOPPERS: FEEDER EJECTORS, WATER AND SLURRY PIPING, VALVES AND
INSTRUMENTATION
• COARSE ASH TANK
• COARSE ASH SLURRY PUMPS WITH PIPING, VALVES AND INSTRUMENTATION

13. FLY ASH VACUUM CONVEYING & WET CONVEYING SYSTEM
(DRG. NO. DP16004-XG08-90ETK-510002, SH 1 OF 2)
ALL THE EQUIPMENT, PIPING AND INSTRUMENTATION SHOWN IN THIS P
& ID SHALL BE COMPLETELY INSTALLED FOR CONTINUOUS OPERATION
IN WET MODE

14. FLY ASH VACUUM CONVEYING & WET CONVEYING SYSTEM
(DRG. NO. DP16004-XG08-90ETK-510002, SH 2 OF 2)
ALL THE EQUIPMENT, PIPING AND
INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE
COMPLETELY INSTALLED FOR CONTINUOUS
OPERATION IN WET MODE

15. FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM
• THE FLY ASH HANDLING SYSTEM – VACUUM CONVEYING SYSTEM IS ALSO UNITISED.
• FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO WETTING HEAD INSTALLED AT
COLLECTOR TANK OR BUFFER HOPPER BYMEANS OF VACUUM CONVEYING SYSTEM AND IN WETTING
HEAD FLY ASH MIXES WITH FAHP WATER AND DISPOSED IN SLURRY FORM TO ASH SLURRY SUMP FOR
FURTHER DISPOSAL TO ASH DYKE
• ALL THE EQUIPMENT, PIPING WORK AND INSTRUMENTATION AS SHOWN IN PREVIOUS TWO SLIDES SHALL
BE COMPLETELY INSTALLED.
• MAJOR EQUIPMENT TO BE INSTALLED:
• ADOPTER, ISOLATION VALVES, MATERIAL HANDLING VALVES, CI PIPE LINE ALONG WITH ACI FITTINGS,
BRANCH SEGREGATING VALVES ETC FROM ESP AND APH HOPPERS TO COLLECTOR TANK/ BUFFER
HOPPER COLLECTOR TANK AND BUFFER HOPPER TOWER STRUCTURE
• COLLECTOR TANK, WETTING HEAD AND TAIL PIPE AND AIR WASHER
• FAHP WATER PIPE WORK ALONG WITH VALVES AND INSTUMENTATION UP TO WETTING HEAD, AIR WASHER
AND JET NOZZLES.
• INSTRUMENTATION PIPE WORK TO VARIOUS PNEUMATIC OPERATED VALVES ALONG WITH VALVES,
INSTRUMENTATION
• VACUUM PUMPS AND VACUUM AIR PIPE WORK FROM VACUUM PUMPS TO AIR WASHER/ BUFFER HOPPER
ALONG WITH VALVES
• SEAL WATER AND DRAIN WATER PIPING FOR VACUUM PUMPS
• FLY ASH SLURRY PIPE WORK FROM COLLECTOR TANK DISCHARGE TO ASH SLURRY SUMP
• ESP/BH FLUIDISING AIR BLOWERS AND HEATERS, PIPE WORK WITH VALVES FROM BLOWERS TO ESP/ APH
HOPPERS

16. FLY ASH PRESSURE CONVEYING SYSTEM
(DRG. NO. DP16004-XG08-90ETG-510003, SH 1 OF 2)
VACUUM AIR AND FLY ASH TRANSPORT PIPE WORK AND
VALVES IN THE BLUE BOX SHALL BE INSTALLED FOR
CONTINUOUS OPERATION IN WET MODE

17. FLY ASH PRESSURE CONVEYING SYSTEM(IM SILO)
(DRG. NO. DP16004-XG08-90ETG-510004, SH 2 OF 2)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION AS SHOWN ARE NOT
NECESSARY TO BE INSTALLED FOR WET
MODE OPERATION.

18. FLY ASH PRESSURE CONVEYING SYSTEM(TERMINAL SILO)
(DRG. NO. DP16004-XG08-90ETG-510004, SH 1 OF 2)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION AS SHOWN ARE NOT
NECESSARY TO BE INSTALLED FOR WET
MODE OPERATION.

19. FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM
• THE FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM IS UNITISED UP TO HSCD,
INTERMEDIATE & TERMINAL SILOS.
• FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO WETTING HEAD
INSTALLED AT COLLECTOR TANK OR BUFFER HOPPER BYMEANS OF VACUUM CONVEYING
SYSTEM AND FROM BUFFER HOPPER, FLY ASH IS TRANSPORTED TO FLY ASH SILOS BYMEANS
OF COMPRESSED AIR SUPPLIED BY TRANSPORT AIR COMPRESSORS.
• VACUUM CONVEYING SYSTEM FOR EXTRACTION AND TRANSPORTATION OF FLY ASH TO
BUFFER HOPPER AND COLLECTOR TANK IS COMMON
• VACUUM AIR AND FLY ASH TRANSPORT PIPE WORK AND VALVES HIGHLIGHTED IN THE BLUE
BOX SHALL BE INSTALLED FOR CONTINUOUS OPERATION OF FLY ASH SYSTEM IN WET MODE.
• INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED ISOLATION VALVES ON VACUUM AIR
AND FLY ASH TRANSPORT PIPE LINES `

20. FLY ASH PRESSURE CONVEYING SYSTEM(HCSD SILO)
(DRG. NO. DP16004-XG08-90ETA-510007)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION AS SHOWN ARE NOT
NECESSARY TO BE INSTALLED FOR WET
MODE OPERATION

21. HCSD SYSTEM
• THE FLY ASH HANDLING SYSTEM – PRESSURE CONVEYING SYSTEM IS UNITISED
UP TO HSCD SILOS.
• FLY ASH COLLECTED IN ESP HOPPER IS EXTRACTED AND TRANSPORTED TO
WETTING HEAD INSTALLED AT COLLECTOR TANK OR BUFFER HOPPER
BYMEANS OF VACUUM CONVEYING SYSTEM AND FROM BUFFER HOPPER, FLY
ASH IS TRANSPORTED TO HCSD SILOS BYMEANS OF COMPRESSED AIR
SUPPLIED BY TRANSPORT AIR COMPRESSORS.
• EACH HCSD SILO CONSISTS OF HYDROMIX DUST CONDITIONER, MIXING TANK,
ETC
• THE FLYASH IS DISPOSED OFF IN WET MODE BY BOOSTER/ CHARGE PUMP AND
HCSD PUMP. UPTO ASH DYKE.

22. ASH SLURRY & ASH WATER SYSTEM
(DRG. NO. DP16004-XG08-90ETN-510006, SH 1 OF 2)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION IN THE BLUE BOX
SHALL BE INSTALLED FOR CONTINUOUS
OPERATION IN WET MODE OF UNIT 1

23. ASH WATER SYSTEM
• ASH WATER SYSTEM IS COMMON FOR BOTH UNITS.
• FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING
EQUIPEMNT AND PIPE WORK, HIGHLIGHTED IN THE BLUE BOXES SHALL BE
INSTALLED.
• BALP WATER PUMPS – 2 NOS (1W+1S)
• BAHP WATER PUMPS – 2 NOS (1W+1S)
• BAHP SEAL WATER PUMPS – 2 NOS (1W+1S)
• FAHP WATER PUMPS – 2 NOS (1W+1S)
• FLUSHING WATER PUMP – 1 NO
• COMPLETE PIPE WORK FROM THE ABOVE PUMPS TO RESPECTIVE
CONSUMERS ALONG WITH VALVES.
• INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED VALVES
• ASH WATER SUMP MAKEUP LINES FROM VARIOUS SOURCES

24. ASH SLURRY & SSH WATER SYSTEM
(DRG. NO. DP16004-XG08-90ETN-510006, SH 2 OF 2)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION IN THE RED BOXES ARE
NOT NECESSARY TO BE INSTALLED FOR
CONTINUOUS OPERATION IN WET MODE OF
UNIT 1.

25. ASH SLURRY DISPOSAL SYSTEM
• ASH SLURRY DISPOSAL SYSTEM IS COMMON FOR BOTH UNITS.
• FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING
EQUIPEMNT AND PIPE WORK SHALL BE INSTALLED.
• ASH SLURRY PUMPS – 4 NOS I.E 2 SERIES (1SERIES W + 1 SERIES S)
• DRAIN PUMPS – 2 NOS (1W+1S)
• ASH SLURRY DISPOSAL PIPE WORK FROM THE ABOVE PUMPS TO ASH DYKE
ALONG WITH VALVES.
• SEAL WATER AND COOLING WATER LINES ALONG WITH VALVES AND
INSTUMENTATION
• INSTRUMENT AIR PIPE LINE TO PNEUMATIC OPERATED VALVES
• ASH SLURRY SUMP FLUSHING/ MAKEUP WATER LINES FROM VARIOUS SOURCES

26. INSTRUMENT AIR SYSTEM
(DRG. NO. DP16004-XG08-90ETY-510009)
ALL THE EQUIPMENT, PIPING WORK AND
INSTRUMENTATION IN THE RED BOXES ARE
NOT NECESSARY TO BE INSTALLED FOR
CONTINUOUS OPERATION IN WET MODE OF
UNIT 1.

27. INSTRUMENT AIR SYSTEM
• INSTRUMENT AIR SYSTEM IS COMMON FOR BOTH UNITS.
• FOR CONTINUOS OPERATION OF UNIT-1 IN WET MODE, THE FOLLOWING EQUIPEMNT AND
PIPE WORK, HIGHLIGHTED IN RED COLOUR ARE NOT NECESSARY TO BE INSTALLED.
• INSTRUMENT AIR COMPRESSORS – 2 NOS (1W+1S)
• INSTRUMENT AIR DRYER - 2 NOS (1W+1S)
• AIR RECEIVERS – 2 NOS (1W+1S)
• INSTRUMENR AIR PIPE WORK VARIOUS PNEUMATIC OPERATED VALVES WITH VALVES
AND FITTINGS
• COOLING WATER LINES WITH VALVES AND INSTUMENTATION

28. ASH WATER CLARIFIER SYSTEM
(DRG. NO. DP16004-XG08-90ETN-510008)
ALL THE EQUIPMENT, PIPING AND
INSTRUMENTATION SHOWN IN THIS P & ID SHALL BE
COMPLETELY INSTALLED FOR CONTINUOUS
OPERATION IN WET MODE

29. ASH WATER RECIRCULATION SYSTEM
• ASH WATER RECIRCULATION SYSTEM IS COMMON FOR BOTH UNITS.
• ALUM AND LIME DOSING TANKS, PUMPS, PIPE WORK WITH VALVES AND INSTRUMENTATION IS
REQUIRED TO BE INSTALLED TO TREAT BOTTOM ASH OVERFLOW AND DRAIN WATER COLLECTED IN
CLARIFIER.
• COMPLETE STILLING CHAMBER, CLARIFIER, BRIDGE MECHANSM, SLUDGE PUMPS, PIPE WORK WITH
VALVES AND INSTRUMENTAION IS REQUIRED TO BE INSTALLED

30. BOTTOM ASH HOPPER
EQUIPMENT