This document is, unless otherwise agreed in writing, the property of TECPRO SYSTEMS LIMITED, and shall
not be reproduced, copied, disclosed to any third party or used any purpose other than that for which it is
supplied or disclosed.
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REVISED AS PER
1 DOC. Approval P.K.M. SOURAV S.M. 18.07.11
COMMENTS
0 FIRST SUBMISSION DOC. Approval P.K.M. SOURAV S.M. 31.05.11
REASONS
PREPARED CHECKED APPROVED
REV. STATUS TYPE FOR DATE
BY BY BY
REVISION
INDIA KMPCL 6X600MW Sub Critical Coal – Fired Power Station Project
OWNER
KSK MAHANADI POWER CONSTRUCTION CO. LTD.
:
OWNER'S ENGINEERS DEVELOPMENT CONSULTANTS PVT. LTD.
CONSULTING ENGINEERS
: KOLKATA, MUMBAI, CHENNAI, NEW DELHI
CONTRACTOR
SEPCO ELECTRIC POWER CONSTRUCTION CORP.
JINAN , CHINA
:
CONTRACTOR'S
ENGINEERS: NORTHEAST ELECTRIC POWER DESIGN INSTITUTE
(OF CHINA POWER ENGINEERING CONSULTING GROUP)
Changchun, China
TECPRO SYSTEMS LTD.
(ASHTECH DIVISION)
T KOLKATA PUNE
CONTROL WRITE UP
TSL DOC. No. 563-C&I-203
REV.NO.: 1
29/7/2011
B. G. Zarbade CLIENT DOC. No. KMP-0-AHS-
V404-N-203
Space for Approval Stamp
As attached
TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
CONTROL WRITE – UP
CHAPTER – I
1.0 HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM
1.1 INTRODUCTION
Ash handling system is provided with High concentration slurry
disposal system for which two common Fly ash silos for each 3x600
MW unit are provided. This Fly ash Silos will feed ash to three
independent streams of HCSD system. Two streams shall normally
be working and one stream will be available as standby. The silo
shall have three openings. These three openings of Fly ash silo will
be connected to three independent streams of high concentration
slurry disposal system for continuous disposal of high concentrated
slurry to ash disposal area with 65‐70% ash concentration. Water is
added in mixing tank with moist ash in a controlled manner through
continuous automatic “Instrument Based” monitoring system to
ensure that the basic slurry parameters remain constant during the
transportation of slurry through the pipe line.
The pump speed shall be varied through VFD drive over the range of
10% to 100% of maximum flow rate. Necessary remote and manual
speed control provision is there. There are two nos. of dedicated
transformer to feed the power supply to VFD and after VFD to HCSD
motor.
The following aspects govern the basic arrangement of high
concentration slurry system.
a) Controlled Ash Feed.
b) Controlled water supply to maintain proper slurry density.
c) HCSD Pump.
d) Disposal Pipe line.
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
There are many control features, which have to work for guaranteed
monitoring of proper slurry density in a continuous manner so that
the slurry pump can operate uninterruptedly.
1.2 MAJOR EQUIPMENTS FOR HCSD SYSTEM
• ROTARY FEEDER WITH VFD [ SEPCO SCOPE]
One (1) no. Rotary Feeder is provided in upstream of each screw
Feeder and takes fly ash input from HCSD silo. It is to be noted that
the Rotary Feeder has variable speed control and have ash disposal
capacity of 225 TPH. The speed of Rotary Feeder is automatically
adjusted as per the reading of Mass Flow meter to maintain required
ash flow for slurry consistency (60% ‐ 70%).For variation of Rotary
Feeder speed a VVVF drive is provided. Mass flow meter is
continuously monitor the feeding rate of fly ash from Rotary Feeder
to Mixer tank through Screw Feeder and Paddle Feeder and thus
control of ash feeding rate into the system is achieved.
• SCREW FEEDER [ SEPCO SCOPE]
Screw Feeder is provided in between Rotary Feeder and Paddle
Feeder for transportation of dry fly ash from Rotary Feeder to
Paddle Feeder because of their eccentric location. The capacity of
Screw Feeder shall be same as Rotary Feeder.
• PADDLE FEEDER [ SEPCO SCOPE]
This is a twin Paddle mixture unloader having capacity 225 TPH. This
is provided in upstream of Slurry mixing tank where dry fly ash is
been moist and discharge to ART (Agitated Retention Tank).
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
• AGITATED RETENTION TANK (ART) [ TSL SCOPE]
The ART is a rubber lined cylindrical tank with vertical spindle, twin
blade, dual impeller type high torque agitator. The output of Paddle
Feeder fed into ART where required slurry concentration and
rheology is maintained and monitored. The ART is provided with
Level Transmitter for continuous level control measurement,
Nucleonic and Non‐nucleonic type Density meter for density
measurement and PH meter for measurement of PH value of ash
slurry. The ART is provided with proper flushing and drain
connection.
The mixing tank (ART) will have five level controls.
a) High High Level (90 %).
b) High Level (80%)
c) Operating level (70%).
d) Low level (10%).
e) Danger low level (0%).
Zero level (0%) is set at the start of the lower part of tank. The 90%
level is the maximum slurry level allowable in the tank.
• CHARGE PUMP [ SEPCO SCOPE]
Total Three (3) nos. charge pump, one for each HCSD stream has
been providing at the suction of HCSD pumps for each 3X600 MW
unit. The pump parameters are 265 cu.M/Hr. @30 MWC.
Charge pump can be started under the following condition:
o Either suction valve or water line valve should be open.
o If suction valve is open, then agitator tank level should be
high.
o If water line valve is open, then water pressure should be
above preset value.
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
The pump will trip is the above conditions are not fulfilled.
• MEASURING LOOP PUMP [ TSL SCOPE]
One Hose pump each having capacity 1.5 cu.M/Hr. @30 MWC
provided with each slurry mixing tank for measuring the slurry
density of a mixing tank by non nucleonic density meter.
1.3 HCSD PUMP [ SEPCO SCOPE]
There are three sets of HCSD Pump (2W + 1S) each having ash
disposal of 225 TPH (Dry ash basis) for two Fly ash silo with motor
and VFD are provided for total three streams. Capacity of HCSD
Pump is 265cu.m/hr @ 300 MWC. Among the three independent
high concentration slurry disposal streams, two are working for two
F.A Silo and one is common standby. Three HCSD Pumps are
connected with three nos. slurry disposal line with necessary
interconnection and instrumentation.
The starting permissive of HCSD Pump from HCSD PLC are as follows:
• HCSD Pump not failed.
• HCSD Pump ready to run (Feed back from HCSD PLC to main PLC)
under the following condition:
a) VFD ready to run.
b) Pump ready to run.
c) Propelling pump on.
d) Lub pump on.
e) Suction flow normal.
f) Propelling liquid pressure normal.
g) Air pressure normal.
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
• HCSD Pump Auto/manual selection from HCSD SCADA.
The starts permissive of HCSD Pump from main PLC are as follows:
• Manual suction valve open.
• Mixture run feed back.
• Mixture tank level not low.
• IAC Pressure normal.
• HCSD PLC ready.
• Paddle feeder health.
• Rotary feeder healthy.
• Mixing tank density (minimum) below preset value.
• VFD Ready to RUN
*****************
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
CHAPTER II
Control Systems
1. HCSD CONTROL SYSTEM
The entire HCSD system for unit‐1,2,3,4,5&6 is PLC based control system.
The overall control and sequential operation of the total HCSD system is
achieved through this main programmable logic controller (SEPCO Scope).
The control of the HCSD system is basically from main system PLC and
HCSD pump PLC when the ART control panel shall act as a local panel with
local actuation facility of Agitator and Measuring loop pump with local
feedback and annunciation.
The ART control panel (TSL SCOPE) shall be connected with main system
PLC through hardwire cable (By SEPCO). PLC of HCSD system shall correct
the speed of the pump, control ash feeding from silo and for other
necessary action on the feedback given by ART control panel.
The Agitator and Hose pump shall be running from main PLC as well as
through ART control panel.
All interlocks / annunciations from field instruments related to ART tank
provided by TSL shall be demonstrated during commissioning.
The control and Instrumentation scope for the HCSD System is limited to
the supply of Control panels & field Instruments related to ART Tank as per
P&ID 563‐01‐02 REV 3.
Various voltages / currents for the system are as follows.
1) ART Panel Output for lamp: 24V DC
2) ART Panel light, space heater: 240V AC
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TECPRO SYSTEMS LTD. KSK MAHANADI THERMAL POWER PROJECT CONTROL WRITE UP
(ASHTECH DIVISION) HCSD SYSTEM CLIENT DOC. NO.: KMP-
(6 x 660 MW) 0-AHS-V007-N-203 REV.-1
CHAPTER III
PROTECTION AND INTERLOCK
Protection and interlock for the HCSD System is attached herewith.
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PROTECTION INTERLOCK
Ref. Interlocks Controls Controlled
S.N. Equipment Annunciation Indications/ Mimic
Drg. Starting Permissive Running Permissive Provided From
1 2 3 4 5 6 7 8 9
Start / Stop P.B.
1.Manual suction valve open. 1.Manual suction valve open. 1.VFD Trip (OS) 1.HCSD Pump ON Red Lamp (OS)
Switch (OS)
2.HCSD Pump OFF Green Lamp
2.Agitatot run feed back. 2.Agitatot run feed back. 2.HCSD Pump Failed (OS)
(OS)
3.Agitatot tank level above Danger 3.Mixing Tank Level Danger 3.GEHO Pump Trip Amber Lamp
3.Agitatot tank level not low.
Low. Low (OS) (OS)
4.Mixure Tank Level Danger Low
4.IAC Pressure normal. 4.IAC Pressure normal. 4.Density Low (OS)
563-01-02
HCSD PUMP Red Lamp (OS)
1 OS
[ 6 nos.] 5.Mixure Tank Level Low Red
5.HCSD PLC ready. 5.HCSD PLC ready. 5.Density High (OS)
Lamp (OS)
6.Mixure Tank Level High Red
6.Paddle feeder health. 6.Paddle feeder health.
Lamp (OS)
7.Rotary feeder healthy. 7.Rotary feeder healthy. 7.Density High Red Lamp (OS)
8.Mixing tank density (minimum) 8.Mixing tank density (minimum)
8.Density Low Red Lamp (OS)
below preset value below preset value
9.VFD Ready to RUN 9.VFD Ready to RUN
1.Start Command Initiated 1.Stop Command NOT Initiated 1.Mixure Tank Level Low (OS) 1.Start Red Lamp (OS/ ART Panel)
2.Agitator TRIP (OS / ART 2.Stop Green Lamp (OS/ ART
2.MCC Available 2.MCC Available
Panel) Panel)
MIXING 3.Mixure Tank Level Danger 3.Trip Amber Lamp (OS/ ART
563-01-02
3.MCC Not disturbed 3.MCC Not disturbed Start / Stop P.B.
TANK Low (ART Panel) Panel) OS / ART
2 Switch (OS /
AGITATOR 4.Tank Level above DANGER 4.Mixure Tank Level Low (ART 4.Tank Level Danger Low Red PANEL
4.Tank Level above LOW ART Panel)
[ 6 nos.] LOW Panel) lamp (OS)
5.Mixure Tank Level High (ART
5. Remote Selected from OS 5. STOP push button not pressed. 5.Tank Level Low Red lamp (OS)
Panel)
6.Tank Level High Red Lamp (OS)
PROTECTION INTERLOCK
Ref. Interlocks Controls Controlled
S.N. Equipment Annunciation Indications/ Mimic
Drg. Starting Permissive Running Permissive Provided From
1 2 3 4 5 6 7 8 9
1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
2. MCC available. 2. MCC available. 2.Seal water Pressure LOW (OS) 2.Stop Green Lamp (OS)
563-01-02
CHARGE
3. Seal water Pressure NORMAL. 3. Seal water Pressure NORMAL. 3.Trip Amber Lamp (OS) Start / Stop P.B.
3 PUMP OS
4. MCC NOT Disturbed. 4. MCC NOT Disturbed. Switch (OS)
[ 6 nos.]
5. Agitator Tank Disc. valve open 5. Agitator Tank Disc. valve open
6. Agitator tank Level above LOW 6. Agitator tank Level above
Start / Stop P.B.
ROTARY 1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
563-01-02
Switch (OS)
FEEDER 2.MCC not disturbance. 2.MCC not disturbance. 2.Stop Green Lamp (OS)
4 OS
VFD
3. VFD ready to run 3. VFD ready to run 3.Trip Amber Lamp (OS)
[ 6 Nos.]
4. Screw feeder RUNNING 4. Screw feeder RUNNING
Start / Stop P.B.
1.Start command initiated. 1.Stop command not initiated. 1.TRIP (OS / ART Panel) 1.Start Red Lamp (OS/ ART Panel) Switch (OS/
ART PANEL)
MEASURIN
2. Discharge Pressure HIGH (OS 2.Stop Green Lamp (OS/ ART
563-01-02
G LOOP 2.MCC not disturbance. 2.MCC not disturbance.
/ ART PANEL) Panel) OS / ART
5 PUMP /
3.Trip Amber Lamp (OS/ ART PANEL
HOSE PUMP 3.MCC available. 3.MCC available.
Panel)
[ 6 Nos.]
4.Mixing tank Level above 4. Discharge Pressure HIGH Red
4.Mixing tank Level above LOW
DANGER LOW Lamp (OS)
5. Discharge pressue Not LOW 5. Discharge Pressure NORMAL
Red Lamp (OS)
Start / Stop P.B.
1.Start command initiated. 1.Stop Command NOT Initiated 1.TRIP (OS) 1.Start Red Lamp (OS)
563-01-02
SCREW Switch (OS)
6 FEEDER OS
2.MCC not disturbance. 2.MCC not disturbance. 2.Stop Green Lamp (OS)
[ 6 Nos.]
3. VFD ready to run 3. VFD ready to run 3.Trip Amber Lamp (OS)
4. Paddle feeder RUNNING 1 4. Paddle feeder RUNNING
