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WELCOME TO MACAWBER
MACAWBER

BEEKAY, INDIA
07.06.2018

PRESENTED BY

LALIT GUJRAL,

GENERAL MANAGER (MKTG.)

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About the Company
 Established in 1986 as a JV with Simon Macawber Ltd of UK, was the first company to bring
technology of Dense Phase Pneumatic Conveying for transfer of bulk materials, especially Dry Fly
Ash, to India.

 Part of well-known BSBK Group, which started its activities way back in 1918 in the field of civil
engineering & construction and later gradually diversified into other areas.

 Headquarter is in Noida (Uttar Pradesh) India.

 Manufacturing unit is in Keshwana (Rajasthan) India, fully equipped with the state of art of
manufacturing, painting and testing facilities.

 Specializes in providing Ash handling solutions on turnkey basis throughout the power industry for
solid fuel-fired boilers of size upto 1000 MW.

 Also offers turnkey solutions to core Industries like Cement, Alumina, Steel, Chemicals, Sugar,
Paper, Foundry, etc. for bulk materials handling within the Plant.

 Since the Company was the formed in mid-eighties, it’s reputation has grown from strength to
strength as the list of applications and industries that are benefitting continue to grow.
100 Years – A Century Old Legacy MACAWBER

OPENING CEREMONY OF CHAKKI BRIDGE (YEAR 1927)

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BEEKAY HOUSE, C-450, SECTOR – 10, NOIDA (UTTAR PRADESH) INDIA

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MANUFACTURING FACILITIES AT KESHWANA, RAJASTHAN, INDIA.

Infrastructure MACAWBER

ASSEMBLY SHOP AT KASNA, GREATER NOIDA, INDIA.

ISO 9001 : 2008 MACAWBER
ISO 14001 : 2004 MACAWBER
OHSAS 18001 : 2007 MACAWBER
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Our Strength

 Proven & established conveying technology for ash handling.

 Systems are versatile to handle various types of ash generated at boiler zones.

 Our systems are highly efficient and reliable with availability factor of 100%.

 Extensive experience of dry ash handling for different types of Boilers viz PF fired,
Travelling Grate, CFBCs, AFBCs, WHRBs, etc.

 Enjoy more than 80% of market share in dry fly ash handling and are established
market leaders in India.

 Manufacturing facility located at Keshwana, Rajasthan, with the total area of

around 44,000 sq. mtr with covered area of 27,600 sq. mtr. and equipped with
state of art machinery which include ROBOTIC Welding, Plasma Cutting, etc

 Latest IT infrastructural facilities use HP Blade Server and also have complete
Disaster Recovery Management with alternative site at CTRLS, Hyderabad, India.
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Manpower Strength

Strong dedicated team of

1300 personnel
Our Services for Power MACAWBER
Industry

Bottom Ash Fly Ash Handling Slurry Disposal

Fly Ash Handling Coal Mill Rejects
Handling: System: System:
System: Handling System

Jet Pump System, Lean Slurry

Submerged System,
Scrapper Chain Dense Phase High
Conveyor Pressure System, Long Distance Silo Concentration
To Silo System Slurry System
De-watering Bins Vacuum System
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Our Services

Bottom Ash Handling:

Jet Pump System,

Submerged Scrapper Chain Conveyor
De-watering Bins
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Jet Pump System
 Macawber Beekay’s product profile includes Jet Pumping System for intermittent removal of
bottom ash collected at furnace bottom of PF type boilers. System comprises of water impounded
refractory lined Bottom Ash Hopper (BAH) of adequate capacity with water seal trough and dip
plates, allowing free expansion of the furnace without any air ingress. BAH is of structural steel,
complete with hydraulically operated feed gates, refractory lining along with its cooling
arrangement, hopper overflow, water seal boxes, sluicing headers with nozzles, seal trough
overflow connection, access doors, inspections glass windows, poke holes and supporting steel
structuring platforms, stairs and accessories. Continuous water make-up and overflow system
keeps the temperature less than 60DegC in the BAH. Intermittently, de-ashing is done through
operation of the inclined hydraulically operated feed gates, clinker crushers and jet pumps. High
pressure water supplied to Jet Pumps act as motive water to pump the bottom ash slurry to
dewatering bins/slurry sump for further disposal.
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Jet Pump System
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Submerged Scrapper Chain Conveyor
 For projects demanding continuous removal of bottom ash collected at furnace bottom, Macawber
Beekay offers Submerged Scraper Chain Conveyor (SSCC) System. The system comprises of dry
type Bottom Ash Hopper (BAH) of adequate capacity with water seal trough and dip plates,
allowing free expansion of the furnace without any air ingress. BAH is of steel structure, complete
with hydro- pneumatically operated hopper isolation gates, refractory lining along with its cooling
arrangement, seal trough with overflow connections, access doors, inspections glass windows,
poke holes, quenching nozzles and supporting steel structures platforms, stairs and other
accessories.

 BAH protects the SSCC from the direct impact of hot ash which is smoothly gravitated to the water
bath of the SSCC through horizontal gates provided at discharge of BAH. The discharge chute at
the hopper outlet remains dipped into water slag bath of SSCC ensuring sealing of furnace
bottom. Storage capacity of BAH permits sufficient maintenance time for SSCC as well as reduces
the extraction load on SSCC. Within SSCC, a temperature of less than 60DegC is always
maintained by continuous water make-up and overflow system. Bottom ash is extracted from the
trough continuously using high quality chains, sprockets and bars. After the dewatering at the
sloping portion, moist ash is discharged to clinker crusher for onward disposal either through
hydraulic sluice way to slurry pond or through belt conveyors to bottom ash storage silo for onward
disposal. For higher capacity SSCC hydraulic drive units, hydraulic chain tensioning units and
motorized traverse drives are provided. A standby SSCC should be installed adjacent to the
working SSCC. The standby SSCC is not connected to the boiler and is brought under boiler
when working SSCC is to be taken out for maintenance etc. The SSCCs are provided with racks,
wheels and motorized propulsions arrangement to facilitate removal from under the boiler and its
replacement with standby SSCC. Macawber Beekay’s SSCC systems are designed for plant
capacity upto 1000 MW.
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Submerged Scrapper Chain Conveyor
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Submerged Scrapper Chain Conveyor
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De-Watering Bin System
 In certain applications which call for bottom ash available in slurry form to be disposed-off either
through trucks or through high concentration slurry disposal system along with fly ash, Macawber
Beekay’s De-watering Bin System takes precedence. De-watering bins with the decanting system
remove water from the bottom ash and this water can be recycled through a set of settling tanks,
surge tanks, transfer pumps, etc. The bottom ash collected in the bin can be either periodically
removed through trucks or fed to high concentration slurry disposal system for disposal in paste
form along with fly ash, as per plant’s requirement.
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De-Watering Bin System
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Our Services

Fly Ash Handling System:

Dense Phase Pressure System,

Vacuum System
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Vacuum System
 Macawber Beekay’s product profile includes Vacuum System for extraction of dry fly ash collected
at ECO / Air Pre-Heater / Duct / Electrostatic Precipitator hoppers of PF type boilers. Vacuum
System is generally adopted when the extraction distance is less, numbers of ESP hoppers are
more and plant layout demands two-stage conveying. Vacuum System includes conveying of fly
ash from various fly ash hoppers up to the intermediate / buffer / surge hopper (ISH) located near
ESP. A second stage system - positive pressure system is employed to convey fly ash from ISH to
main FA Silo(s).

 Vacuum system envisages conveying of dry fly ash from ash hoppers by vacuum pumps and
collection in ISH. Each vacuum pump, dedicated to a stream, can convey both coarse and fine
ash. The vacuum conveying system operates so as to allow sequential ash discharge from ash
hoppers into conveying stream which is in continuous operation.

 Vacuum System relies upon an air stream generated by partial vacuum drawn on the receiving
station, by means of mechanical exhausters (vacuum pumps), material being dragged into the
pipeline by vacuum created and moving in suspension. A bag filter unit with air lock unit, separates
the fly ash from the air at the receiving station and collects Fly Ash in Intermediate Surge Hopper,
for onward conveying to remote silos / for hydro sluicing. Dome Valves used as Ash Intake Valves,
offer 100% sealing at ash hopper outlet.
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Vacuum System
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Vacuum System
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Dense Phase Pressure System
 Macawber Beekay specializes in Dense Phase Pneumatic Conveying System for collecting and
conveying of dry coarse/fine fly ash collected at Economizer / Air Pre Heater / Duct / Electrostatic
Precipitator hoppers. Dense Phase Pneumatic Conveying System is generally adopted on
account of many of its advantages like positive pressure system, low material conveying velocity,
lesser erosion rates, conveying of fine and coarse ash separately as collected (thus increasing
utility of fly ash), capability to convey longer distances in a single stretch etc. The system consists
of installation of Ash Conveying Vessels directly below the fly ash hoppers. The conveying vessels
are equipped with our unique Dome Valve at inlet. Expansion Joint and isolation valve are
provided above dome valve. Numbers of conveying vessels are connected to conveying pipe. To
reduce number of conveying pipes from ash hoppers, it is possible to join them together. There
are different ways to join the conveying lines, either as directed by the Client/Consultant or in view
of optimized design. At FA Silo(s), suitable vent filters are provided to vent out clean air. Level
sensors are provided in silos and ash hoppers. FA Silos are equipped with “dry” and “wet”
unloading system for disposal of fly ash in trucks. The system operates on a batch mode for the
first stage conveying system and on a continuous mode for second stage transportation system.
Compressed air from compressors is used as medium of conveying. Instrument air from a
separate source is required for dome valve operation and for instrumentation purpose.
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Dense Phase Pressure System
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Dense Phase Pressure System
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Our Services

Ash Slurry Disposal System:

Lean Slurry System,

High Concentration Slurry System
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Lean Slurry System
 Lean Slurry Disposal System and Ash Water Recovery System have been conventionally used for
disposal of ash slurry in dilute form, generated at various power plants and are still in demand.
Macawber Beekay offers such systems which comprise of centrifugal slurry pumps for disposal
and clarifloculator / tube settler for recovery of the ash water from slurry pond.

 The Lean Slurry Disposal System consists of:-

 Stream of horizontal ash slurry disposal pumps complete with drive, variable speed hydraulic
coupling for first stage pumps and fixed belt drive arrangement for subsequent stages. No. of
streams and No. of stages of pumps depend upon the slurry handling capacity and pumping
distance.

 Ash slurry transportation pipes from slurry pumps upto ash dyke including garlanding of the dyke.

 Valves at suction and discharge of ash slurry transportation pumps.

 Ash slurry sump with intake valves, ACI liners, jetting nozzles, etc.

 Drainage pumps with piping, valves & fittings.

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Lean Slurry System
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Lean Slurry System
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Lean Slurry System
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Lean Slurry System
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High Concentration Slurry System
 Conventional Lean Slurry Disposal System and Ash Water Recovery System have
limitations/disadvantages on account of higher amount of water wastage/contamination, ground
water pollution, potential threat of ash pond collapse, vast land required for ash dykes, higher
costs for ash pond construction and higher power consumption. These limitations have led to the
adoption of new environment friendly ash disposal technologies like High Concentration Slurry
Disposal (HCSD) Systems. We have been pioneer in adopting the best of this technology in India
by commissioning the HCSD System for a combination of fly ash and bottom ash, first of its kind in
India.

 HCSD System comprises of controlled and monitored feeding system for fly ash and bottom ash
followed by a homogenous mixing in an adequately designed Agitator Retention Tank (ART).
Proper monitoring of the slurry properties is the key to success of the system. HCSD pump
transports the highly concentrated slurry from the ART to the ash disposal area through carbon
steel pipelines. These pumps have mechanism for capacity variation depending on the
characteristics of the slurry. De-blocking facility is also considered either by the HCSD pump itself
or through a separate water pump.

 HCSD System operates on a higher concentration of about 60% thereby water consumption is
drastically reduced and literally no water is released at the disposal area. The ash slurry disposal
takes place based on a sloped disposal concept thereby spreading over a substantial area and
solidifies, leaving hardly any ash to fly off.
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High Concentration Slurry System
 Key Advantages of HCSD System:

 HCSD System comprises of controlled and monitored feeding system for fly ash and bottom ash
followed by a homogenous mixing in an adequately designed Agitator Retention Tank (ART).
Proper monitoring of the slurry properties is the key to success of the system. HCSD pump
transports the highly concentrated slurry from the ART to the ash disposal area through carbon
steel pipelines. These pumps have mechanism for capacity variation depending on the
characteristics of the slurry. De-blocking facility is also considered either by the HCSD pump itself
or through a separate water pump.

 Ash spreads in layers enabling vertical filling, hence land requirement is reduced.

 Pumping at higher concentration, hence low water consumption.

 Slurry flow rate is drastically reduced, hence lower pipeline sizes.

 Literally no water releases out, hence no need for water retaining walls or recovery system in pond
area.

 Reduced leaches at the ash disposal area.

 Lower operating power consumption.

 Lower velocity, hence longer life for pipe line.

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High Concentration Slurry System
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Our Services

Coal Mill Rejects Handling System

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Coal Mill Rejects Handling System
 Macawber Beekay is pioneer in deploying Dense Phase Pneumatic Conveying concept for
handling difficult materials like rejects (sizes upto 40 mm) from Coal Pulverizing Mills to bunkers in
power plants. Our Pneumatic Mill Rejects Handling System with distinct merits such as negligible
maintenance and recurring costs, requirement of very less floor area for installation, conveying
pipes travel overhead thus leaving plant movement unhindered. The totally enclosed system
ensures no spillage of mill rejects and individual system is provided for each mill. Dense Phase
Pneumatic Conveying System with proven track record for mill rejects handling in power plants is
now an established technology and enjoys wide spread acceptance of power plant engineers.

 Pneumatically operated knife gate valve at outlet spout of the Mill.

 Pyrite hopper complete with sizing grid, flexible/expansion joint at its inlet, rupture disc, by pass
chute, oversize material chute, inspection window, water spray nozzles & supporting structures.
 Field instruments like Level switch, Temperature Switch in pyrite hopper.
 Pneumatically operated knife gate valves at pyrite hopper outlet and at oversize discharge chute.
 Denseveyor vessel complete with pneumatically operated inlet Dome valve and local control
panel.
 Set of MS ERW pipe for mill reject conveying from Denseveyor vessel to Mill Rejects Storage
bunker, with Alloy CI bends and other fittings.
 Terminal boxes on bunker top for terminating the reject conveying pipes
 Mill reject bunker(s) along with structure and manually operated bunker discharge gate at bunker
outlet and bag filter, level sensors on the top of bunker.
 Conveying air compressors with drive motor, local control panel and other accessories.
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Coal Mill Rejects Handling System
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Coal Mill Rejects Handling System
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TIPS FOR MAINTENANCE & INSPECTION

 MAINTENANCE AND INSPECTION SCHEDULE
MACAWBER
DAILY CHECKS-
 Check the oil level in air lubricator and oil feeding one drop in two or three cycles.
 Drain out the condensed water from the air filter provided in the instrument airline
on pneumatic control panel.
 Check the operation of water auto drain trap provided on air receiver once in a shift.
Also, check availability of water in side receiver by opening the manual valve
provided parallel with the auto drain trap.
 Check pulsing of each bag filter provided on Silo top and buffer hoppers.
WEEKLY CHECKS-
 Check function of level probes. If required calibrate the same.
 Check for any leakage in Vacuum/Instrument/Conveying air lines and ash conveying
lines. If required attend the same.
MONTHLY CHECKS-
 Grease the dome valve shafts by recommended grease.
 Clean the air filter and lubricator and fill the fresh oil in the lubricators.
 Check the operation and adjustment of the air limit switch. If required adjust the
same as per recommendation.
 Check the timer settings. If required set right the same as per recommendation.
 Check the tightness of the terminals in pneumatic panel etc.
 MAINTENANCE AND INSPECTION SCHEDULE
MACAWBER
HALF YEARLY CHECKS-
 Calibration of all switches/ gauges/ transmitters/timer/level switch etc.
 Check PU-6 tubes / R6FH for its hardness/damage inside and out side pneumatic panel.
 Check the function of fluidizing arrangement provided in Hoppers / silos etc.
 Check the orifice plates for any damage or blocking of holes.
 Check timer / pressure switch settings. If required set right the same as per recommendations.
YEARLY CHECKS-
 Servicing of dome valve and replacing the rubber insert seal. If found damage/ hard replace as
per recommended procedure.
 Check the gap between dome and rubber insert seal. It should be maintained 0.5 to 1 mm.
maximum.
 Check the centering of dome valve in close condition.
 Servicing the blow valve / air limit switch and replacing the seal. If required.
 Servicing of the solenoid valve and replacing the seal, if required.
 Servicing the air cylinder, actuator and replacing the seal, if required.
 Checking the operation of bag filter and bags for their chocking / damage. If required replace
the bags.
 Calibration of the pressure switch / pressure transmitter / pressure gauge as per local norms
and set right as per recommendations.
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Awards & Recognitions
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Awards & Recognitions
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Awards & Recognitions
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Awards & Recognitions
Few Major clientele in Power Industry (Domestic)
 Adani Power Ltd.
 Adhunik Power and Natural Resources Ltd.
 Ahmedabad Electricity Co. Ltd.
 Andhra Pradesh Power Generation Corporation Ltd.
 Aryan Coal Beneficiations (I) Ltd.
 Associated Cement Co. Ltd.
 Bajaj Infrastructure Development Company Ltd.
 BGR Energy Ltd.
 Bharat Aluminium Co. Ltd.
 Bharat Heavy Electricals Ltd.
 Birla Corporation Ltd.
 Chettinad Cement Corporation Ltd.
 CESC Ltd.
 Chattisgarh State Power Generation Co. Ltd.
 Coastal Energen Pvt. Ltd.
 Damodar Valley Corporation
 Doosan Power System India Pvt Ltd
 EDAC Engineering Limited
 Essar Projects (India) Limited
 GHCL Limited
 Grasim Industries Ltd.
 Gujarat State Electricity Corporation Ltd.
 GMR Energy Jharkhand Ltd.
 Haryana Power Generation Corporation Ltd.
 Hindalco Industries Ltd.
 Hirakud Power Company Limited
 HPCL Mittal Energy Limited
 Indiabulls Infrastructure Company Ltd.
 ISGEC
 JSW Energy Ltd.
 Jindal Steel and Power Ltd.
 Jaiprakash Power Ventures Ltd.
 Karnataka Power Corporation Ltd.
MACAWBER
 Lafarge India Pvt. Ltd.
 Larsen & Toubro Ltd.
 Lanco Infratech Limited
 Meenakshi Energy Pvt. Ltd.
 Maharashtra Power Generation Co. Ltd.
 Madhya Pradesh Power Generating Co. Ltd.
 Madhya Pradesh Electricity Board.
 Maithon Power Limited.
 NTPC Limited
 National Aluminium Company Ltd.
 Orissa Power Generation Corporation Ltd.
 Punjab State Electricity Board
 PMC Projects (India) Pvt. Ltd
 Raj West Power Ltd.
 Rajasthan Rajya Vidyut Utpadan Nigam Ltd.
 Rattanindia Power Limited
 Reliance Industries Limited
 RSPL Limited
 Sesa Sterlite Limited
 Shree Cement Ltd.
 SMS India Pvt. Limited
 Spectrum Coal & Power Limited
 Talwandi Sabo Power Ltd.
 Tamil Nadu Electricity Board
 Tata Power Co. Ltd
 Tata Iron & Steel Co. Ltd.
 Tata Projects Ltd.
 Thermax Limited
 U.P. Rajya Vidyut Utpadan Nigam Ltd.
 Utkal Alumina International Ltd.
 Vedanta Alumina Ltd./BALCO
 W.B. Power Development Corporation Ltd.
Few Major clientele in Power Industry (International) MACAWBER

 2x1000 MW Central Java TPP, Indonesia thru’ Mitsubishi Hitachi, Dubai

 1x1000 MW (UNIT-4) Janamanjung TPP, Malaysia thru’ Alstom, USA/China
 1x1000 MW (UNIT-4) Tanjung Bin TPP, Malaysia thru’ Alstom, USA/France/India
 2x800 MW, Talin TPP, Taiwan A/c. IHI / CTCI thru‘CBMHL, UK/China
 3x800 MW Linkou TPP, Taiwan A/c. CTCI thru’ CBMHL, China
 3x700 MW Janamanjung TPP, Malaysia A/c ABB Alstom Power thru’ CBMHL, UK
 1x696 MW Mae Moh TPP, Thailand thru’ ALSTOM, USA
 2x600 MW Long Phu-1 TPP, Vietnam thru’ Power Machines, Russia/ CBMHL, UK
 2x600 MW Song Hau-1 TPP, Vietnam thru’ Lilama, Vietnam
 2x600 MW Wangqu TPP, China thru’ CBMHL, UK
 2x600 MW Hancheng TPP, China A/c Harbin Power thru’ CBMHL, UK
 2x550 MW Taichung TPP, Taiwan A/c Mitsui Babcock, U.K. thru’ CBMHL, UK
 1x430 MW Pagbilao Expn. TPP, Philippines thru’ Daelim, Korea
 2x150 MW Therma Visayas TPP, Philippines thru’ Hyundai, Korea
 2x135 MW CFBC Boiler, PT Cikarang, Indonesia thru’ Metso
 2x103 MW CEBU TPP, Indonesia A/c KEPCO SPC Power thru’ Doosan, Korea
 3x18 MW KPC PT Kaltim Prima Coal, Indonesia thru’ Punj Llyod
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Visit us at www.mbl.in for more details