AMIE Project

INDEX
SL.NO.
COMPONENTS
Certificate.
Declaration.
Acknowledgement.
Project Synopsis
FINAL PROJECT REPORT
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
Title of the Project.

Objective of the Study.
Methodology of the Study.
A brief Introduction about NTPC.
A brief Introduction about TSTPS, Kaniha.
A brief Review of Thermal Power Plant.
Ash.
7.1 Types of Ash.
7.2 Need of Ash Handling.
Ash Disposal System.
8.1 Bottom Ash.
8.2 Fly Ash.
8.3 Wet Ash Evacuation System.
8.4 Dry Ash Evacuation System.
8.4.1 Need of Dry System.
8.4.2 Operation.
8.4.3 Components of Dry Ash System.
8.4.4 Functions of Different Components.
Statement of the Problems.
9.1 Crack Formation.
9.2 Collapsing of Bag.
Analysis of the Problems.
Effects of the Problems.
Remedies / Modifications.
12.1 Modification to Overcome Crack Formation.
12.2 Modification to Overcome Collapsing of Bag.
Safety Precautions taken during Modifications.
Benefits on Implementation.
Conclusion.
Scope for Future Study.
THE INSTITUTION OF ENGINEERS (INDIA)
PAGE NO.
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CERTIFICATE
This is to certify that the project entitled A Study on Problems in Dry Ash-
Evacuation System of TSTPS, NTPC, Kaniha being submitted by Mr.

JAGANNATH DAS, Membership No.: ST-518844-5 in partial fulfilment of the
requirement for the award of degree of THE INSTITUTION OF ENGINEERS
(INDIA) in discipline Mechanical Engineering, is authentic work carried out by
him under my supervision and guidance.
Date:
Er. B. Pradhan
MIE
Page
DECLARATION
I do hereby declare that the project work on A Study

on Problems in Dry Ash Evacuation System of TSTPS, NTPC,
Kaniha has been done by me under the esteemed guidance of Er. B.
Pradhan, and is an original one and has not been submitted to any
other Institute, University or Publication.
(JAGANNATH DAS)
ST-518844-5
Mechanical Engg, IEI (I)
Page
ACKNOWLEDGEMENT
I am thankful to The Director (EEA), IEI (I), Kolkata for giving me a scope to
undertake this project work for partial fulfilment of the requirement for
completion of degree in Mechanical Engineering.
I would like to thank Er. B. Pradhan, my project supervisor for his
guidance, support, motivation and encouragement throughout the project. His
readiness for consultation at all times, his educative comments, his concern and
assistance even with practical things have been invaluable.
I would like to thank all my colleagues, who helped me directly or indirectly
in completing this project, and parents for their moral support throughout the
project.
Date:
JAGANNATH DAS
ST-518844-5
Mechanical Engg., IEI (I)
Page
SYNOPSIS
OF
THE
PROJECT
Page
SYNOPSIS
1. TITLE OF THE PROJECT:
Study on Problems in Dry Ash Evacuation System of Talcher Super Thermal

Power Station (TSTPS), NTPC, Kaniha
2. OBJECTIVE OF THE STUDY:

To maintain the vacuum of Buffer Hopper.
To modify the system for continuous operation with less breakdown and
also for easy maintenance.

To avoid pollution and also to keep the pollutant with in control limits.
To increase the efficiency of the ESP.
Always availability of the Dry Ash Evacuation System.
Effective utilization of the Ash.
To implement the major and minor safety precaution during system
handling and also positive isolation.
3. RATIONALE FOR THE STUDY:
Page
A 3000MW power plant produces 15000-18000 tons ash per day which
consists of around 20% Bottom Ash and remaining 80% Fly Ash.
If the fly ash is not evacuated properly, some ash is carried away by the flue
gas to the atmosphere through chimney thereby polluting the environment
and affecting the living organisms.

If such huge amount of ash is not evacuated, the total fly ash level in the
ESP goes on increasing and damaging it. Thus function of ESP stops.
An ESP hoppers have a capacity to store ash up to 8hrs10%. After 8hrs of
continuous operation fly ash needs to be evacuated.

Such huge amount of fly ash cant be evacuated to the Ash pond/dyke as
dyke will get full very soon. Also removing of ash from dyke is very difficult
and utilizing the ash from dyke needs processing which is not cost effective.
If any evacuation system is not available, the ash should be dumped on the
floor. After dumping ash on the floor, clinker forms and ash becomes sticky.
To remove the ash from the floor is again difficult and this clinker ash cant
be directly used.
So it may be concluded that the ash should be evacuated in the dry form to
utilize it. Also the dry ash transported very easily through compressed air.
Hence a dry ash evacuation system is necessary for uninterrupted power
generation.
4. DETAILED METHODOLOGY TO BE USED FOR CARRYING OUT THE

STUDY:
Visiting the ash handling unit of NTPC, Kaniha.
Study the system design, operation circuit and observation.
Direct involvement in the Overhauling Job, Operation and Project of dry
ash evacuation system.
Analytical and Comparative study of resources available in manuals,
modification location and after modification results.
Meeting and discussion with Professionals of NTPC.
Page
5. THE EXPECTED CONTRIBUTION FROM THE STUDY:

The expected contribution from the study is following: Continuous operation of Dry Ash Evacuation System.
Expected high reliability and availability of the system, thereby ensuring
uninterrupted power generation.

Higher efficiency of ESP to remove ash from flue gas to avoid pollution.
Effective utilization of ash.
Uninterrupted power generation by maintaining vacuum.
Dont form clinker by providing hot air to the buffer hopper.
6. LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE PROJECT:

Following are the main activities to be carried out to complete the project:
Activity 1:- Selection of the project.
Activity 2:- Preparation of the synopsis.
Activity 3:- Site visited, direct involvement in the overhauling of ash handling
units, observations from study.
Activity 4:- Data collection from manuals, scheme tracing and measurement at
site.
Activity 5:- Discussed among professionals of NTPC regarding problems, their
causes, effects and pros and cons of the action to be taken.
Activity 6:- Analysis of information gathered & prepared draft of the project
report.
Activity 7:- After finalising the project by my project guide it was submited.
Page
DURATION OF PROJECT 30 DAYS
SL.
ACTIVITIES
NO
1
2
3
4
DURATION
(Days)
Selection of the project

Preparation of the synopsis.
observations from study
Data collection from manuals, scheme tracing and
1
2
3
3
measurement at site.
5
Discussed among professionals of NTPC regarding
problems, their causes, effects and pros and cons of the

6
action to be taken
Analysis of information gathered & prepared draft of the
project report.
7
After finalising the project by my project guide it was
10
submited
Page
ACTIVITIES VS DAYS
ACTIVITIES
7
6
5
4
3
2
1
0
10
12
DAY
S
7. PLACES/LABS/EQUIPMENTS & TOOLS REQUIRED & PLANNING OF
ARRANGEMENTS:
Page 10
Submitted By:
Approved By:
JAGANNATH DAS
Er. B. PRADHAN
ST-518844-5
MIE
Mechanical Engg.
(PROJECT GUIDE)
FINAL
Page 11
PROJECT
R E P O RT
1. T IT L E O F THE PROJE CT:

STUDY
ON
PROBLEMS
IN
DRY
ASH
EVACUATION
SYSTEM
OF
TALCHER SUPER THERMAL POWER STATION (TSTPS), NTPC, KANIHA.
2 . O B J E C T I V E O F T H E S T U D Y:
The cause of inefficiency of Dry Ash Evacuation System.

To maintain the vacuum of the buffer hopper.
Always availability of the dry ash system for effective utilization of ash.
To avoid pollution and also to keep the suspended particles within limits as
per the norms of pollution free board control.

The major and minor safety precaution is to be taken during system
handling and also to implement positive isolation.
Page 12
3 . M E T H O D O L O G Y O F T H E S T U D Y:
Visiting the ash handling unit of NTPC, Kaniha.
Study the system design, operation circuit and observation.
Direct involvement in the Overhauling Job, Operation and Project of dry
ash evacuation system.
Analytical and Comparative study of resources available in manuals,
modification location and after modification results.
Meeting and discussion with Professionals of NTPC.
4. A BRIEF INTRODUCTION ABOUT NTPC:

Indias largest power company and a Maharatna company NTPC was set up in
1975 to accelerate power development in India. It is emerging as an Integrated
Power Major, with a significant presence in the entire value chain of power
generation business. Apart from power generation, which is the mainstay of the
company, NTPC has already ventured into consultancy, power trading, ash
utilisation and coal mining.
The total installed capacity of the company is 41,184 MW (including JVs) with 16
coal based and 7 gas based stations, located across the country. In addition
under JVs, 7 stations are coal based & another station uses naptha/LNG as fuel
and 2 renewable energy projects.
The company has set a target to have an
installed power generating capacity of 1,28,000 MW by the year 2032. The

capacity will have a diversified fuel mix comprising 56% coal, 16% Gas, 11%
Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032,
non-fossil fuel based generation capacity shall make up nearly 28% of NTPCs
portfolio. NTPC has also formulated its business plan of capacity addition of
about 1,000 MW through renewable resources by 2017.
Page 13
5. A BRIEF INTRODUCTION ABOUT TSTPS, KANIHA:

Talcher Super Thermal Power Station (TSTPS) has an installed capacity of 3000
MW (5006 units) at Kaniha, Angul. The beneficiary states from power generation
are Odisha, Bihar, Sikkim, Assam, Tripura & Damodar Valley Corporation, WB,
Jharkhand from Stage I (500MW2 units) and Andhra Pradesh, Kerala,
Karnataka, Tamil Nadu, Pondichery from Stage II (500MW4 units).
6. A BRI E F SUMM ARY OF THE RM AL POWE R PL ANT:

In thermal power plant, heat energy is converted into mechanical energy in a
prime mover called Steam Turbine and the same mechanical energy is converted
into electrical energy through a Generator.
Thermal power plant works on Rankine Cycle. The schematic of a Thermal Power
Plant is shown in figure 1. It consists of 4 circuits.
Page 14
A. Coal & Ash Circuit:

The coal from the storage is fed to the boiler through coal handling equipments
for generation of steam. Ash produced due to combustion is collected in the
bottom of the boiler called bottom ash. The ash goes with the flue gas and collects
in the ESP hoppers called fly ash.
B. Air & Flue Gas Circuit:

Air is supplied to the combustion chamber by a Force Draught (F.D.) Fan through
air preheater. The flue gas is produced by the combustion of coal is supplied to
the super heater, reheater, economiser and air preheater to increase the efficiency
of the plant. The flue gas is exhausted to the atmosphere by an Induced Draught
(I.D.) Fan through Chimney after the removal of fly ash and suspended particles
in ESP.
C. Feed Water & Steam Circuit:

The demineralised water boils in the boiler, steam forms and the steam is super
heated by adding enthalpy to it through flue gas. The superheated steam expands
in the H.P. turbine. After expansion in the H.P. turbine, the steam passes through
the reheater to reheat the steam to its initial condition to develop more power. The
reheated steam expands in the I.P. and L.P. turbine to generate power. The low
pressure steam is then condensed in the condenser. The condensate is reheated
by the bled steam to raise the temperature of the feed water in the feed water
heater. The boiler feed pump delivers the feed water to the boiler. To neglect the
losses, demineralised water is supplied as make up.
D. Cooling Water Circuit:

The exhaust steam from turbine is passed through the condenser where the
steam is condensed by circulating the cooling water. The cooling water is supplied
to the condenser from the cooling tower through the circulating water pumps.
Generally surface condensers are used in thermal power plants. In surface
condenser, cooling water is flowing through the tubes and the steam is circulating
around the tubes of the condenser.
Page 15
FIGURE: 1
(SCHEMATIC DIAGRAM OF A THERMAL POWER PLANT)
1. Cooling tower
2. Cooling water pump
3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Condensate extraction pump
8. Condenser
9. Intermediate pressure turbine
10. Steam governor valve
11. High pressure turbine
12. Deaerator
13. Feed heater
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Coal hopper
Pulverised fuel mill
Boiler drum
Ash hopper
Superheater
Forced draught fan
Reheater
Air intake
Economiser
Air preheater
Precipitator
Induced draught fan
Chimney Stack.
Page 16
14. Coal conveyor
7. ASH:
Coal contains impurities, volatile matter and some residual minerals. Coal
doesnt burn completely with oxygen due to the presence of these materials.
These residue oxidized materials formed after the burning of coal is called
ash.
Typical ash composition: SiO2, Al2O3, Fe2O3, CaO, MgO, etc.
Ash melting point > 14000C (when coal contains more SiO2 & Al2O3)
Ash melting point < 11000C (when coal contains more Fe2O3, CaO & MgO)
7.1 TYPES OF ASH:

There are two types of ash is formed in a power plant
1. Bottom Ash:
When coal burns inside the furnace of the boiler, the ash is formed. Some
ash fall down due to its own weight to the bottom of the furnace or boiler.
The ash collected at the bottom of the boiler is called bottom ash.
2. Fly Ash:
Major quantity of ash carried away by the flue gas after the burning of coal
is called fly ash. These fly ash collected in ESP.
Out of the total ash produced in the power plant, about 20% is bottom ash and
remaining 80% is fly ash.
7.2 NEED OF ASH HANDLING:

Indian coal used in power plant contains about 30 to 40% ash. A 3000 MW power
station produces around 15000 18000 Tons of ash per day. This huge amount
of ash needs to be disposed off continuously for uninterrupted power generation.
8. ASH DISPOSAL SYSTEM:
Page 17
8.1 BOTTOM ASH:

The Bottom Ash Disposal System is shown in figure 2.
The bottom of the furnace is filled with water up to a level of seal trough. Ash
formed after burning of coal falls in the water due to gravity. S-panel directs the
ash to water. Due to higher temperature of S-panel pipe ash doesnt stick to it.
After falling in the water ash particles join together and clinker forms. When
Bottom Ash Hopper Gate (BAHG) opens, clinker discharges to Clinker Grinder.
Clinker Grinder consists of two rollers rotating in the opposite direction having
small beads on it. When the bigger size clinker passes through the gap between
clinker grinder, it grinds the clinker to form ash slurry.
The ash slurry is then passed through the hydro ejector. The throat of the hydro
ejector creates vacuum and responsible for the evacuation of bottom ash. The
clinker grinder and Hydro Ejector Water Valve run at the same time. When clinker
grinder starts, high pressure water is passed through the hydro ejector and
flushes out the ash slurry with high velocity. The ash slurry is transferred to ash
slurry sump through Bottom Ash Discharge Valve (BADV).
The sequence of operation is as follows:
1)
2)
3)
4)
Opening BADV.
Opening HEWV.
Starting Clinker Grinder.
Opening BAHG.
8 . 2 F LY AS H :
The major portion of fly ash is collected in ESP (Electro Static Precipitator)
through the process of Ionization and collected in the ESP hoppers.
Each 500MW unit ESP consists of four passes (A, B, C & D) to collect fly ash
effectively from the flue gas. Each pass consists of 18 nos. hoppers. So a 500 MW
unit consists of 72 nos. (18nos. 4 passes).
The fly ash evacuation consists of two systems.
A. Wet Ash Evacuation System.
B. Dry Ash Evacuation System.
Page 18
8 . 3 W E T A S H E VAC U A T I O N S Y S T E M :
The schematic layout of wet ash evacuation system is shown in figure 2.
Each wet ash unit is provided for each ESP pass. Therefore each 500MW unit has
4 wet ash units.
When Material Handling Valve (MAV) opens, the fly ash goes to the wetting unit of
collecting tank due to vacuum created by the vacuum pump.
The wetting unit has nozzle valve which sprays water to the fly ash in the same
direction and the ash is dumped in the collecting tower. The fly ash is flown away
due to the action of vacuum and may choke the vacuum pump thereby stopping
the wet ash system. In order to avoid this problem, an air washer is provided. In
air washer, water is sprayed and the fly ash is again collected in the collecting
tower.
The bottom of the collecting tower has a seal box containing water to maintain the
vacuum in the system. The collecting tower has a baffle plate which directs the
ash to fall in the seal box thereby preventing the damage to the seal box.
The flowing water in the seal box prepares the ash slurry and discharges in to the
ash slurry trench. The ash slurry in the trench further discharges in to the ash
slurry sump.
The ash slurry series pumps contain 3 centrifugal pumps in series and suck the
ash slurry from ash slurry sump. The series pump develops 12 kg/cm 2pressure
to transfer the ash slurry to ash pond.
From the ash pond, water is recirculated through recirculation pump after
settling of ash and is reused in the plant after filteration.
8 . 4 D R Y A S H E VAC U A T I O N S Y S T E M :
8.4.1 NEED OF DRY SYSTEM:
Out of the total ash produced in the power plant, around 80% is fly ash. This
huge amount of fly ash needs to be evacuated. If such huge amount of ash is not
evacuated, the total fly ash level in the ESP goes on increasing and damaging it.
ESP hoppers have a capacity to store ash up to 8hrs10%. After 8hrs of
continuous operation fly ash needs to be evacuated.
Page 19
Such huge amount of fly ash cant be evacuated to the Ash pond/dyke as dyke
will get full very soon. Also removing of ash from dyke is very difficult and
utilizing the ash from dyke needs processing which is not cost effective.
If any evacuation system is not available, the ash should be dumped on the floor.
After dumping ash on the floor, clinker forms and ash becomes sticky. To remove
the ash from the floor is again difficult and this clinker ash cant be directly used.
So it may be concluded that the ash should be evacuated in the dry form to
utilize it. Also the dry ash transported very easily through compressed air. Hence
a dry ash evacuation system is necessary.
D R Y A S H E VAC U A T I O N S Y S T E M :
The schematic layout of dry ash evacuation system is shown in figure 2 and also
in figure 3.
In dry ash evacuation system, fly ash should be evacuated in the dry form and
transferred to the silo. From silo, fly ash can be directly used in various
purposes.
8.4.2 OPER ATI ON :

Each 500MW unit has four flue gas passes such as A, B, C and D. Each pass
consists of one dry ash system i.e. one 500MW unit consists of four dry ash
systems.
After passing through heat recovery equipments, flue gas finally enters ESP
(Electro Static Precipitator) for dust collection before discharges into the
atmosphere. In ESP, flue gas ionizes and dust is separated from the flue gas and
collected in the ESP bottom hoppers.
The dry ash system is connected to a vacuum pump which helps in evacuating
the ash from the ESP bottom hoppers. When the pneumatic Material Handling
Gate (MHG), opens, the ash is transported to the buffer hopper due to presence of
vacuum. The dry ash is dumped in the buffer hopper due to gravity. Some of the
ash particles flow away through the dust collector to the vacuum pump and may
damage it.
Page 20
To avoid this difficulty, bag filters are provided in the dust collector. The flowing
ash particles strike the wall of the bags and the momentum of ash particles
become zero. The ash particles fall down to the buffer hopper due to gravity.
The equalizing valve connects the air lock vessel to the ESP inlet duct and
vacuum pressure remains same as the ESP so that when Ash Intake Valve (AIV)
opens, the airlock vessel is under more vacuum than buffer hopper to evacuate
the ash from buffer hopper.
To evacuate the buffer hopper, Ash Intake Valve (AIV) opens for 20-30 seconds
and the dry ash dumps into the air lock vessel. After dumping dry ash, first
equalizing valve closes and after that AIV closes.
Fluidizing Valve (FV) is provided at the bottom of the air lock vessel. When FV
opens, compressed air from Transfer Air Compressor (TAC) enters the air lock
vessel at the bottom and gets mixed with the dry ash to prepare a mixture for
easy transportation to the silo. After pressurization and mixture preparation,
discharge valve opens. The dry ash is now transported to the silo with the aid of
compressed air.
After ash transportation, air lock vessel remains empty. First FV closes and then
discharge valve closes so that equalizing valve opens to make the system under
vacuum to intake ash from buffer hopper through AIV. Hence the cycle is
repeated.
At the bottom of the buffer hopper, hot air is provided to avoid the formation of
the sticky ash and clinker which may choke the discharge pipe.
The elevation, plan and side view of dry system is shown in figure 7.1 and 7.2.
8.4.3 COMPONENTS OF DRY ASH SYSTEM:

The following are the components of one dry ash system for one flue gas pass. The
position of this components are shown in figure 3.
1.
2.
3.
4.
5.
6.
7.
ESP one pass consists of 18 nos. bottom hoppers.

BUFFER HOPPER 01 no.
DUST COLLCTOR 01 no.
BAG FILTER consists of 141 nos. bags.
VENTURI mounted on the top of the each bag (141 nos.).
AIR LOCK VESSEL 02 nos.
FLUIDIZING VALVES (FV) 02 nos.
Page 21
8. EQUALIZING VALVES 02 nos.

9. BHDV- 02 nos.
10.
DISCHARGE VALVES 02 nos.
11.
VACUUM PUMP 02 nos.
12.
SILO 1no. (for one 500MW unit)
13.
TRANSFER AIR COMPRESSORS 3nos. (for one 500MW unit)
8.4.4 FUNCTIONS OF DIFFERENT COMPONENTS:
A. Electro Static Precipitator (ESP):

It is a device used to separate the dust and suspended particles from the flue gas
before discharge to the atmosphere to reduce chimney emission. The sequence of
operation is shown in figure 4 and the position of electrode is shown in figure 5.
It consists of rows of electrically grounded vertical plates called collecting
electrodes between which the dust laden gas flows. The wire electrodes called
emitting electrodes are centrally located between each pair of collecting
electrodes. The wires carry an uni-directional negatively charged high voltage of
30-60KV D.C. from an transformer and rectifier.
When this high voltage D.C. is supplied, a blue luminous glow called corona is
produced around the emitting electrodes. Electrical forces in the corona
accelerate the free electrons present in the flue gas so that they ionize the gas
molecules, thus forming more electrons and positive (+ve) gas ions. It results in a
chain reaction.
The positive ions travel to the negatively charged wire electrodes. The electrons
follow the electrical field towards the grounded electrodes, but their velocity
decreases as they move away from the corona region around the wire electrodes
towards the grounded plates.
Gas molecules capture the low velocity electrons and become negative ions. As
these ions move to the collecting electrodes, they collide with the fly ash particles
in the gas stream and give them negative charge. The negatively charged fly ash
particles are driven to the collecting plate by the force which is proportional to the
product of this charge and strength of the electric field.
When the particles collected on the grounded plate, they loose their charge. The
electrical resistivity of the particles tends to hold the particles due to only their
Page 22
partial discharging. When enough dust has accumulated, the collectors are
shaken to dislodge the dust, causing it to fall with the force of gravity to hoppers
provided below ESP.
TECHNICAL SPECIFICATION OF ESP:

Sl no
1
2
3
4
5
6
7
8
9
10
Description
No of fields
Efficiency
Gas flow rate
Gas velocity through ESP
Inlet Dust concentration
Outlet Dust concentration
PRESSURE DROP across the precipitator
Total No of collecting electrodes/gas
stream
Collecting electrode material
11
Total no of emitting electrodes/ gas

stream
Emitting electrode material
12
13
14
Hopper capacity
Heating
Removal of ash from electrodes
15
Treatment time
Stage - II
4 x 18 = 72
99.97%
777.75m3/s
0.857m/s
63.387gm/Nm3
20.00gm/Nm3
17mmwc
2862
Ms rolled sheet
(750*14550*1.25m
m)
25,272
Spiral, selftensioned, Stainless
steel of grade UH904L (dia2.7mm,
height 14550mm)
8hrs +10%
Provided at bottom
Rapping mechanism
through rapping
motors
47.28 seconds
Page 23
Figure :- 5
B. BUFFER HOPPER:
It is a closed cylindrical vessel made up of mild steel of 120T capacity having
trapezoidal shape at the bottom. The dust collector is mounted at the top of the
buffer hopper. The buffer hopper is connected to the ESP bottom hopper to collect
the fly ash under vacuum. It stores the fly ash just to evacuate the ESP hopper
and acts as a buffer unit.
Hot pressurized air is provided at the side and bottom of the buffer hopper to
keep the fly ash in hot condition to avoid the formation of sticky ash and ash
clinker. If clinker forms, these will choke pipeline, valves and also causes the
breakdown of the equipments.
At the bottom of the buffer hopper, there are one manual valve and one
pneumatic operated Ash Evacuation Valve (AIV). When these valves open, fly ash
dumps into the airlock vessel.
C. DUST COLLECTOR:
It is a cylindrical vessel welded on the top of the buffer hopper. The suction pipe
of the vacuum pump is connected to the top of the collector tank. Due to running
of the vacuum pump, the system is under negative (-ve) pressure. So the fly ash is
flown away to the vacuum pump through the collector tank.
Page 24
The collector tank contains 141nos. bags to collect the fly ash flew away from the
buffer hopper. Bag filter restricts the flow of fly ash to the vacuum pump, thereby
preventing the damage of vacuum pump, choking of pipe, valves, etc.
The bags are mounted on a cage and at the top of each bag, nozzles are provided.
When the fly ash flows away due to vacuum, sticks to the bag and the ash
particles are fall down due to the force of gravity. Some of the ash particles are
still stick to the bag and creates difficulty in maintaining vacuum.
13nos. purge air valves are provided at the top of the bag filter. In regular
interval, these purge air valves are opened and air purges through the nozzles to
the bag filter in the opposite direction to the flow of ash to clean the bag. At the
outlet of nozzle, the air velocity increases due to reduction in area. Now the high
velocity air strikes the wall of each bag from inside and forces it to expand. Due to
the flow of air, the bag expands and contracts about the cage, thus a shaking
movement is provided to clean the bag.
The bag and its cleaning procedure is shown in figure 6.
D. AIR-LOCK VESSEL:
Airlock vessel is a closed cylindrical vessel provided at the bottom of the buffer
hopper.
The function of airlock vessel is to fluidize the fly ash with the help of compressed
air and makes a pressurized mixture before transferred to the dry ash silo.
When Ash Intake Valve (AIV) opens, fly ash dumps to the airlock vessel. After
closing of AIV, Fluidizing Valves (FV) open which are provided at the bottom of the
airlock vessels. The compressed air flows through the fluidizing valve and
prepares a homogeneous mixture. The compressed air helps in transferring the
fly ash to the silo after the opening of pneumatically operated discharge valve.
Two nos. airlock vessels are provided for each buffer hopper. Each airlock vessel
contains an equalizing valve at the top of it which connects it to the ESP inlet
duct.
E. VACUUM PUMP:
Page 25
Each 500MW unit is provided with 4nos. vacuum pump. Vacuum pump creates
and maintains a negative (-ve) pressure in the system so that fly ash is evacuated
from the ESP bottom hoppers.
The mechanism of operation of vacuum pump is shown in the figure 6.
The impeller is mounted eccentrically to the casing, i.e. the centre of impeller and
the centre of casing are different. Two-third portion of the casing is filled with
water. The impeller is running inside the water.
Due to the eccentricity, the area between impeller and the casing is minimum at a
point. That particular location is connected to the suction line of dry ash system.
As the area is minimum, velocity is maximum and pressure is minimum. Due
this minimum pressure, vacuum is created in the system.
Impeller rotates inside the casing and air is sucked from the system and hence
the air-water mixture is also rotating with the impeller. As mixture is rotating, the
centrifugal force is acting on it whose tendency is to throw away the mixture from
the centre of rotation. Centrifugal force varies directly as the distance from centre
of rotation, so its value increases with the increase in centre distance.
At the maximum contact area between the impeller and casing in rotation, the
centrifugal force is maximum. At that particular location of maximum contact
area, a vent is provided in the casing which connects the vacuum pump to the
atmosphere. As the impeller is immersed in water, the water acts as a seal
between the dry system and the outside atmosphere.
As the impeller is rotating inside water, air is sucked from the system at the
minimum area due to minimum pressure. Air-water mixture rotates along the
impeller inside the casing. Due to rotation centrifugal force is developed which
throws away the mixture towards the casing. Centrifugal force is maximum at the
maximum contact area. Hence at the maximum contact area, the air is released
from the pump via vent provided at the top due to the pressure is above
atmospheric.
Due to the continuous rotation of impeller in water, work is done on the water. So
water gets heated. Make-up water is continuously provided which is able to
maintain the water level in the vacuum pump and make-up the losses.
F. EQUALIZING VALVE:
Page 26
Equalizing valve connects the airlock vessel to the ESP inlet duct. ESP inlet duct
is under more vacuum pressure than buffer hopper. Thus, when equalizing valve
opens, fly ash from the buffer hopper dumps into the airlock vessel through Ash
Intake Valve (AIV).
G. SILO:
It is a cylindrical vessel which stores the fly ash for further utilization of ash.
From the silo, the fly ash is unloaded to the truck and transported to the various
location for further utilization of ash. There are two silo each capacity of 750tons
provided for 1000MWs (Unit- III and Unit- IV).
9 . S T AT E M E N T O F T H E P R O B L E M :
9. 1 CRACK FORM ATI ON:
The schematic diagram is shown in figure 7.1. The buffer hopper (5) is made up
of mild steel. The dust collector (6) is a hollow cylindrical vessel made up of mild
steel welded at the top of the buffer hopper.
Cracks formed at buffer hopper roof and also at the welded joint between buffer
hopper and dust collector. Because of the crack formation, there was a loss of
vacuum and the buffer hopper was opened to atmosphere, as a result of which fly
ash didnt evacuate from the ESP bottom hoppers (2) and the level of fly ash
raised and ESP (1) stopped functioning thereby stopping power generation.
Sometimes ESP bottom hoppers opened and fly ash dumped on the floor to
continue power generation. It was difficult to evacuate the huge amount of fly ash
from the floor. The elevation, plan and side view of the dry system is shown in
figure 7.2 and 7.3.
9.2 COLLAPSING OF BAG:

The bag filter is shown in figure 7.1. There was another problem occurred very
frequently. Bags from the bag filter (7) collapsed. There was no manhole provided
in the buffer hopper. So after collapsing, the bag fell down in the buffer hopper.
The collapsed bag carried along with the fly ash resulting in chokage of discharge
pipe, Ash Intake Valves (AIV) (12), discharge valves (16). Thus, the fly ash didnt
evacuate from ESP thereby stopping the dry ash system. It was difficult to locate
Page 27
the bag in the discharge pipe. For taking out the bag and also clearing the
chokage, the system was down for 1(one) day.
These problems repeatedly occurred very frequently on an average of 8-10 times
in a month causing interruption and reduction in power generation. In addition,
problems such as difficulty in ash evacuation, and environmental issue due to
higher emission rate were also occurred. Sometimes power generation stopped
due to breakdown of dry ash evacuation system and also due to failure of ESP.
1 0 . A N A LYSI S O F TH E PR O B L E M :
After breakdown of dry ash system, the buffer hopper, dust collector and various
pipes are observed.
The following factors may be attributed to the crack formation of buffer hopper
roof:
1.
2.
3.
4.
Buffer hopper was unable to withstand the weight of the drum.

Vacuum pressure didnt withstand by buffer hopper.
Cracks formed due to erosion by the fly ash.
The increased in vacuum pressure due to the ash percentage increase in
coal day-by-day.
5. The sulphur content of the ash corroded the mild steel vessel.
6. The failure due to the geometry of the bag filter, dust collector and buffer
hopper.
7. Bag filter got supported at buffer hopper. To restrict fly ash go to vacuum
pump, the fly ash stroked at high velocity to the bag due to which the
momentum changed to zero and fly ash fell down to the buffer hopper. Fly
ash stroke at high velocity about 141 nos. bags. Due to this impact, crack
may occur at the buffer hopper roof.
8. Inadequate support of buffer hopper roof.
The following factors may be attributed to the collapsing of bag from bag filter:
1. The bag mounted on the cage and the cage made up of wire. Bag may
collapse due to erosion of cage by fly ash.
2. The bag may collapse due to high impact velocity of ash to the bag.
3. Bag may fall down due to wear of bag.
Page 28
11. EFFECTS OF THE PROBLEMS:

The following difficulties were appeared due to crack formation of buffer hopper
roof:
Due to crack formation, the system was no under vacuum and hence no
ash evacuation was possible from ESP bottom hoppers. So the level of fly
ash increased in ESP which was lead to failure of ESP.
As the level of fly ash in ESP increased, the performance of ESP was
deteriorated and hence, the emission of suspended particles to atmosphere
increased thereby, polluting environment.
Power Generation stopped due to ESP failure.
To continue power generation, ESP hoppers opened once in 8hours to dump
the ash on the floor until the dry ash system was available. The fly ash
particles adhered each other and clinker formed. To evacuate this huge
quantity
of
ash
was
difficult
and
created
problems
in
executing
maintenance jobs.
Ash is toxic in nature which causes health hazards.
The following difficulties were appeared due to collapsing of bag from bag filter:
Due to collapsing of bag, the bag choked in the discharge pipe thereby
stopping the dry ash system.
Discharge valve and pipe damaged.
It was difficult to locate the bag in the pipe and was a time consuming
process.
It was very difficult to escape out the bag from pipe and to clear the
blockage of pipe due to ash.
12. REMEDIES / MODIFICATIONS:

1 2 . 1 M O D I F IC ATI O N S TO O VE R C O M E C R A C K F O R M ATI O N :
After breakdown, observations were made and according to those observations
following modifications were done.
The major causes are the high vacuum pressure, the weight of the dust collector
and also the high impact of fly ash to the bag filter.
Four square bars of 15mm15mm were welded inside the buffer hopper at a
distance 200mm from the top of the buffer hopper as shown in figure 8. Out of
four, two square bars welded across the other two square bars forming a grid.
Page 29
These were welded in such a way that the welded structure formed a square at
the centre of side equal to 3078mm. The plan of grid is shown in figure 9.
The channels of 200mm75mm and 500mm length were used which were welded
from the dust collector outer periphery and touching the grid made by square
bars and also welded at the square bars. Total 8 nos. channels were inserted from
the top of the buffer hopper through cutting the buffer hopper roof so that these
channels were touched the grid at the bottom and welded at the periphery of the
dust collector making a symmetrical section. The length of weld above the buffer
hopper roof is 300mm. 8 nos. channels were uniformly placed at the outer
periphery of the dust collector and welded to the dust collector outer shell and
also welded at the bottom position touching to the square bars. These eight
channels can withstand more load without failure.
Channels were used instead of using angles because equivalent channel sections
have a higher value of section modulus than those of angle sections. So, higher
load can be carried out by channels.
To uniformly place the channel around the periphery of dust collector, following
calculations were used and shown in figure 10.
Inner diameter of dust collector = 3048mm.
Thickness of dust collector shell = 8mm.
So, Outer diameter of dust collector = 3048 + (28) = 3064mm.
Perimeter of dust collector = outer diameter
= 3064 = 9626mm
Depth of channel = 200mm
Distance between two centre line of channel when placed vertically along the
periphery = 9626/8 = 1203mm
Hence, distance between each channel along the periphery = 1203-200 =
1003mm.
The details of formed grid by welding square bars are shown in figure 9.
PROCEDURE:
Cleaning of buffer hopper inside shell and both side shell of dust collector.
Page 30
Cutting of eight nos. M.S. channel each of length 500mm. Channel

dimension 200mm75mm12mm (depthwidthweb).
Forming the girder at a distance of 200mm from the buffer hopper roof.
Placing of channel around the periphery of dust collector. Distance between
each channel = 1003mm. The bottom of each channel touched the girder.
Welding the channel to the dust collector outer shell, buffer hopper roof
and the girder. Electric Arc Welding carried out with the help of E-6013
electrode of 4mm diameter.
After welding, chipping and cleaning action carried out.
SPECIFICATION OF ELECTRODE USED:

E6013 is a low-carbon steel electrode coating and can be used on AC or DC. It
has excellent welding technological properties. The arc is stable. The spatter is
small. The slag viscosity is moderate. It can be used freely. The slag is easy to
clean. The welded seam is smooth and fine and easy to restrike the arc.
E
E: Electrode.
60: Tensile Strength in PSI 1000 i.e. 60000 PSI.
1: Positional Capabilities. 1 shows that this electrode can be used for welding in
all positions.
3: Flux Coating and Electrical Characteristics. This electrode has a titania
potassium flux. This electrode can be used for both DC (straight and reverse
polarity) and AC supply.
ELECTROD
E
E-6013
0.20
ELECTROD
E
CHEMICAL COMPOSITION (in %age)

Mn
Si
P
S
Ni
Cr
Mo
<0.04
<0.03
1.20 1.00
0.30 0.20 0.30
0
5
V
0.08
MECHANICAL PROPERTIES
Yield Strength at 0.2% of
Tensile Strength
Elongation
Proof Stress,
PSI / MPa
(in %age)
PSI/ MPa
Page 31
B u ff e r H o p p e r R o o f
E-6013
60000/430
48000/330
17
WELD:
Fillet weld was carried out on the both sides of the channel. Consider a portion of
the dust collector on which the channel welded is shown in figure 11.
Let, s = Leg or size of the weld,

t = Throat thickness,
G r i d i n s i d e B u ff e r H o p p e r
Channel
l = Length of weld.
s = 8mm,
Fi l le t We l d
t = s sin 450 = 0.707s

= 0.707 8 = 5.656mm
l = 500 200 = 300mm
Area of weld = Throat thickness Length of weld
= t l = 0.707s l
Area of weld A = 5.656 300 = 1696.8 mm2
Dust Collector
Page 32
I N S T A L L A TI O N O F VAC U U M B R E A K E R :
One vacuum breaker installed in the suction line of the vacuum pump to limit the
operating vacuum so that there shouldnt any failure or rupture of material of any
component of the system.
It is an automatic pneumatic valve provided in the suction line of the vacuum
pump. When the vacuum pressure falls below 325mm Hg, vacuum breaker
automatically opens and connects the system to atmosphere.
Before starting of maintenance job, vacuum breaker is also operated manually to
connect the system to atmosphere for safety protection.
It is an automatic pneumatic operated valve controlled by logical functions. It is
automatically operated when line choked and vacuum pressure falls below
325mm Hg. It acts as a safeguard to the system to prevent the material stressed
beyond the ultimate point causing rupture.
One 100NB pipe welded to the 250NB suction line of the vacuum pump near the
dust collector. 100NB air operated automatic valve connected to the 100NB pipe
and is shown in figure 8. The Vacuum Breaker is controlled by Instrument Air
supplied by Plant Air Compressor (PAC) having a pressure of 6kg/cm2.
12.2 MODIFICATIONS TO OVERCOME COLLAPSING OF BAG:

The bags were collapsed due to high vacuum pressure, high velocity impact of fly
ash, erosion due to ash.
The following modifications were done to take out the collapsed bag easily so that
the system down time reduces to the minimum possible duration.
Page 33
In the original design of the manufacturer one manhole has been provided on the
wall of the dust collector at a location above the bag filter for maintenance
activities such as installation of bag, replacement and cleaning of bag, repairing
and replacement of purge air valves, etc. In original design no manhole was
provided in the buffer hopper and at the bottom of the dust collector.
After observations from breakdown, two manholes were provided one at the
bottom of the bag filter and other at the buffer hopper to take out the collapsed
bag as shown in figure 8.
8mm diameter rods were welded inside the dust collector shell and prepared a
mesh which provided at the bottom of the bag filter. When bag fell down, it
stopped by the mesh. One manhole of 500mm 500mm was provided at the
bottom of the bag filter. When bag fell down, it was restricted by the mesh and
collected through the manhole. The plan of the mesh is shown in figure 12.
Other benefits from dust collector manhole:
Easy replacement of bag.

Proper cleaning of bag.
Proper inspection and replacement of worn out parts.
Internal maintenance such as cleaning, painting, checking, etc.
Another manhole of 600mm600mm provided at the side of the buffer hopper at

a distance 1000mm from the bottom of the buffer hopper as shown in figure 7.
When bag collapsed and mesh ruptured, bag directly fell down on the buffer
hopper and collected through this manhole.
Other benefits from buffer hopper manhole:
When blower failed, fly ash became cold and sticky and clinker formed.
Buffer hopper manhole helped to clear the chokage due to fly ash.
Internal maintenance of buffer hopper such as cleaning, painting, replacing
the wear out portion of vessel, etc.
Inspection.
1 3 . S A F E T Y P R E C A U T I O N TAK E N D U R I N G M O D I F I C ATI O N :
Before modification, all the structures inspected thoroughly and corrective

measures were taken for worn out parts.
Page 34
Personal Protective Equipments (such as safety helmet, safety shoes, hand

gloves, safety goggles, dust mask, ear plug,) were used by all workers
during the modification.

Before modification training was given to all workers regarding operation of
the system, safety, six direction hazards, etc.

Proper work permit was taken regularly for better communication of work.
Before starting of the work, Positive Isolation of drives, valves were done to
avoid accident. In Positive Isolation, the energy sources to the system,
drives, valves, etc. were locked so that no one was able to start the system
to avoid accident.
Face shields were used during welding. Fire extinguishers were kept to
avoid any fire caused during welding.

Air from blower was provided to the buffer hopper for available of oxygen
during welding in the buffer hopper and dust collector.

Safety belts were used when worked at height.
1 4 . B E N E F I T S O N I M P L E M E N T AT I O N :
I.
Before modification, dry ash systems were unavailable 8-10 days in a

month. Sometimes power generation stopped. After modification, the
system is unavailable for 1day in a month for inspection, checking, repair,
removal of collapsing bag and insertion of new bag thereby increasing its
efficiency availability.
Availability of dry system in a month before modification = 30-10 = 20 days
= 2024 hours.
Existing availability per month = (2024) (3024) = 66.67%
Availability of dry system in a month after modification = 30-1 = 29 days
=2924 hours
System availability after modification per month = (2924) (3024) =
II.
96.67%
After modification, trial run was taken and the dry system was gradually
III.
loaded and the dry system run smoothly without failure.

By providing mesh below the bag filter, chokage due to bag totally
IV.
V.
eliminated.
The collapsed bag easily removed from the system through the manhole.
By providing manholes, it is easy to carryout inspection, checking and
maintenance work.
Page 35
VI.
After modification, flushing of pipeline is carried out once in a day for
VII.
smooth running of the system and also to clear the chokage due to fly ash.
Increasing the number of hot air lines from 4 to 8 reduces the chances
VIII.
clinker formation and choking of the system.

Smooth running of dry ash evacuation system reduces the chances of ESP
IX.
failure and prevents the interruption in power generation.

Good performance of dry ash evacuation system results in less emission of
suspended particles to atmospheres which are within the norms of
X.
pollution free board control, thereby generating green power.

Proper implementation of safety standards didnt cause any accident during
modification.
16. CONCLUSION:
With the above modification, the dry ash evacuation system runs successfully
without failure.
The rupture of buffer hopper roof was due to the increase in vacuum pressure,
load of the dust collector and also due to impact of fly ash to the bag filter.
Observations were made on the basis of the problem and the above modifications
were taken place.
The system now handles more quantity of ash due to the increase in ash
percentage in coal. The material has to withstand this load. The material is to be
tested in the laboratory and strength is to be calculated.
1 7 . SC O PE O F FU T U R E ST U DY:
In the present scenario, Dry Ash Evacuation System is very essential to generate
pollution free power.
So, for efficient Dry Ash Evacuation System, renovation and improvement in
design of the system is required. All the techno parameters such as discharge,
vacuum pressure, pressure of compressed air, temperature of fly ash are required
for smooth operation of the system. These parameters should be properly
maintained for better performance of Dry Ash Evacuation System.
The material strength of the buffer hopper and dust collector are to be tested
from time to time to ensure its capability.
Page 36
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What is the objective of the study?

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INDEX

Title of the Project.

THE INSTITUTION OF ENGINEERS (INDIA)

Evacuation System of TSTPS, NTPC, Kaniha being submitted by Mr.

THE INSTITUTION OF ENGINEERS (INDIA)

I do hereby declare that the project work on A Study

THE INSTITUTION OF ENGINEERS (INDIA)

THE INSTITUTION OF ENGINEERS (INDIA)

Study on Problems in Dry Ash Evacuation System of Talcher Super Thermal

2. OBJECTIVE OF THE STUDY:

also for easy maintenance.

3. RATIONALE FOR THE STUDY:

THE INSTITUTION OF ENGINEERS (INDIA)

and affecting the living organisms.

continuous operation fly ash needs to be evacuated.

4. DETAILED METHODOLOGY TO BE USED FOR CARRYING OUT THE

THE INSTITUTION OF ENGINEERS (INDIA)

5. THE EXPECTED CONTRIBUTION FROM THE STUDY:

uninterrupted power generation.

6. LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE PROJECT:

THE INSTITUTION OF ENGINEERS (INDIA)

DURATION OF PROJECT 30 DAYS

Selection of the project

Discussed among professionals of NTPC regarding

problems, their causes, effects and pros and cons of the

After finalising the project by my project guide it was

THE INSTITUTION OF ENGINEERS (INDIA)

THE INSTITUTION OF ENGINEERS (INDIA)

THE INSTITUTION OF ENGINEERS (INDIA)

1. T IT L E O F THE PROJE CT:

TALCHER SUPER THERMAL POWER STATION (TSTPS), NTPC, KANIHA.

The cause of inefficiency of Dry Ash Evacuation System.

per the norms of pollution free board control.

THE INSTITUTION OF ENGINEERS (INDIA)

4. A BRIEF INTRODUCTION ABOUT NTPC:

The company has set a target to have an

installed power generating capacity of 1,28,000 MW by the year 2032. The

5. A BRIEF INTRODUCTION ABOUT TSTPS, KANIHA:

6. A BRI E F SUMM ARY OF THE RM AL POWE R PL ANT:

A. Coal & Ash Circuit:

B. Air & Flue Gas Circuit:

C. Feed Water & Steam Circuit:

D. Cooling Water Circuit:

THE INSTITUTION OF ENGINEERS (INDIA)

(SCHEMATIC DIAGRAM OF A THERMAL POWER PLANT)

14. Coal conveyor

7.1 TYPES OF ASH:

7.2 NEED OF ASH HANDLING:

8. ASH DISPOSAL SYSTEM:

THE INSTITUTION OF ENGINEERS (INDIA)

8.1 BOTTOM ASH:

THE INSTITUTION OF ENGINEERS (INDIA)

8.4.2 OPER ATI ON :

THE INSTITUTION OF ENGINEERS (INDIA)

8.4.3 COMPONENTS OF DRY ASH SYSTEM: