Ash Conditioner Automation

Ash Conditioner Automation
THERMAX LIMITED – O&M SITE: J K LAKSHMI CEMENT, SIROHI 3X18 MW CPP
FLY ASH SILO
KNIEF GATE VALVE
RAV
WATER VALVE
ASH CONDITIONER
TRUCK
Existing operation:
Shift wise Silo operator has to ensure proper truck position on ground floor, then on the first floor
he has to manually start Ash conditioner and operate water ON/OFF Actuator, monitor water
pressure and then start RAV & also physically inspect Ash flow to regulate SOV operated Plate
valve. Also has to keep monitoring on truck level (on ground floor) and instruct truck driver to
move truck which is time consuming and results in Ash spillage.
Scope of Modification:
Truck position limit switch will be installed to ensure proper truck position, position feedback will
be taken in permissive to start Ash conditioner and its working will be ensured by ZSS. After a time
delay of 5 seconds water actuator will operate and after 30 seconds RAV will operate whose
running will be ensured by ZSS. After smooth running of RAV and time delay of 30 seconds knife
gate valve will be operated 30% and can also be controlled/ regulated from DCS.
Advantages:
1) No need to physically verify the Truck position.
2) No need to physically monitor water pressure.
3) No need to watch truck level (will be monitored by level sensor).
4) Knife gate valve will be operated manually or can be controlled from DCS.
5) Shift wise operator can be used for other job or reduced manpower.
Required material :
1) Knife gate valve
2) 2 no’s of camera
3) Truck Limit switch
4) Level probe with controller
SILO AUTOMATION PROJECT
 As soon as truck driver will place truck in correct position (permissive taken from limit switch) ash
conditioner Start permissive will get healthy.
 Now truck driver will press START button from local Push button.
 Ash conditioner will start.
 Ash conditioner screw working is ensured by ZSS.
 After 5 seconds (healthy running of Ash conditioner), water line actuator will open.
 After 30 seconds RAV will start.
 RAV working is ensured by ZSS
 After 30 seconds (healthy running of RAV), knife gate valve will open to 30%
 After 10 seconds knife gate valve opening will be increased to 40%.
 As per Ash flow RPC cylinder can be controlled /Operated from DCS.
 Truck level will be sensed by level probe and once level detected Ash conditioner will trip.
Unit-1 Ash conditioner automation:

 Ash dumper/truck position confirmation is taken by Limit switch and used as permissive to
start ash conditioner.
When all the permissives are healthy, Ash conditioner will start by pressing START button from
Local. For ensuring Ash Conditioner screw’s working ZSS has been installed and its feedback will be
used to avoid jamming. Its running feedback is used as permissive for RAV Start.
After 5 seconds of Ash conditioner run water line actuator will open, Also Pressure switch is
confirming the water pressure in line. And its healthiness is taken in trip interlock of ash
conditioner operation.
After 30 seconds of Ash conditioner Run and ensuring water pressure is healthy, RAV will start. For
ensuring Silo unloading RAV operation ZSS has been installed and its feedback will be used to
avoid empty run of Ash conditioner.
For controlling Ash flow from silo RPC cylinder installation done. After 30 seconds of RAV run, KGV
will open by 30%, also as per ash flow cylinder can be operated/controlled from DCS.
2 No’s of Dom type rotating Cameras will be installed for observation of complete operation.
Also one emergency local push button is given to stop system & taken in interlock of ash
conditioner working to avoid spillage.
One level probe is installed to ensure truck level. As soon as truck level is high, level probe will give
feedback to stop Ash conditioner and complete system will trip.
GRAPHICAL REPRESENTATION IN DCS
BILL OF MATERIAL
S.
Material Quantity
No
1. RF Level probe with controller 1
2. Limit switch lever type 1
3. Dome type camera 2
4. Knife gate valve 1
5. Signal Cables As req.

Ash Conditioner Automation

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Ash Conditioner Automation

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Ash Conditioner Automation

THERMAX LIMITED – O&M SITE: J K LAKSHMI CEMENT, SIROHI 3X18 MW CPP

FLY ASH SILO

KNIEF GATE VALVE

Unit-1 Ash conditioner automation:

1. RF Level probe with controller 1

2. Limit switch lever type 1

3. Dome type camera 2

4. Knife gate valve 1

5. Signal Cables As req.

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