Budge Budge Generating Station

Rajib Nath
Meghnad Saha Institute Of Technology

Two weeks vocational Training Program

 ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the Budge Budge
Generating Station for their sincere guidance I received to uphold my theoretical as
well as practical knowledge about various operation conducting in the powerplant.

First of all, thanks to my parent for giving encouragement, enthusiasm and

invaluable assistance to me. Without all this, I might not be able to complete this
subject properly.

Second, I would like to thanks to Mr. D. Maitra (Vice President, HR),

Mr. S. Samaddar (Vice President, BBGS), Mr. S. Roy (General Manager, BBGS),
Mr. S. Banerjee (Dy. General Manager, BBGS) and Mr. K. Choudhury (Dy. General
Manager, BBGS) for give us the opportunity to undergo industrial training Budge
Budge Generating Station. They also give me their guidance and support.

Thirdly, I also want to express my deepest thanks to Mr. Debashis Chatterjee

(Manager, OPS), Mr. Richiek Mittra (Asst. Manager, OPS), Mr. Anandamoy Pal
(Manager, FAO), Mr. Rajdeep Jana (Dy. Manager, FAO), Mr. Suman Sengupta
(Manager, PLG), Mr. Ratan Argha Chakraborty (Sr. Engr, PLG), Manish Chaman (Sr.
Manager, MMD), Mr. Tilak Sen (Dy. Manager, MMD), Mr. Susovan Narayan
Choudhury (Sr. Manager, E_I), and Mr. Animesh Dan (Dy. Manager, E_I) as industry
training advisory for respective Department that has helped me a lot in dealing with
industrial training placement. they had supported to me by showing different
method of information collection about the Power Plant. They helped all time when
we needed and They gave right direction toward completion this report.

Besides, I would like to thank Mr. Siddhartha Shankar Dey (Consultant, HRD)
and Mr. Sanjoy Roy (Sr. Asst. Engineer, HRD) for sharing their knowledge and
experience. They guide us throughout the training session and helped us to
understand better about the operation and processes of this Power Plant.
Finally, I apologize all other unnamed who helped me in various ways to have a
good training.
 About CESC
CESC is India’s first fully integrated electrical utility company and it has been on
an epic ride ever since 1899 in generating and distributing power in Kolkata and
Howrah.
It has private participation in generation, transmission and distribution of
electrical power. CESC is the sole distributor of electricity within an area of 567sq km
of Kolkata & Howrah and serve 2.9 million consumers which include domestic,
industrial and commercial users. It owns & operate three thermal power plants
generating 1125 MW of power. These are Budge Budge Generating Station (750
MW), Southern Generating Station (135 MW), & Titagarh Generating Station (240
MW). From our three generating stations, we accomplish 88% of our customer’s
electricity requirement and remaining 12% is achieved by purchase of electricity from
third parties. More than 50% of coal is sourced from captive mines for generation of
electricity in our generating stations.
CESC owns & operate the Transmission & Distribution System through which it
supplies electricity to consumers. This system comprises of 474 km circuit of
transmission lines linking the company’s generating & receiving stations with 105
distribution stations, 8,211 circuit km of HT lines further linking distribution stations
with LT substations, large industrial consumers and 12,269 circuit km of LT lines
connecting the LT substations to LT consumers.
In diurnal course, CESC have verged upon renewable sources. It has brought
forth three projects in three different areas of renewable sources. These are Gujarat
Solar, which is a solar plant in Gujarat’s Kutch generating 9MW solar energy, Hydro
Power Venture (Papu Hydropower Projects Limited & Pachi Hydropower Projects) in
Arunachal Pradesh, generating 146 MW energy and Wind Power Operation, a 24 MW
project at Dangi in Rajasthan.
CESC also installed two thermal power plants to meet the requirement of our
electricity. These are Chandrapur Thermal Plant which is 600 MW project at
Chandrapur, Maharastra and Haldia Thermal Plant which is 600 MW project at
Haldia, West Bengal.
With the continuous effort to accomplish the requirement of their consumers
and make them easily avail all their services from their premises, they have employed
value added online services. By online services, work can be done from consumer’s
premises and the consumers don’t have to visit offices for any work. All our services
can now be accessed online.
 About BBGS
PROJECT PROFILE: -
CAPACITY 750 MW (3 x 250 MW)
LOCATION Pujali, Budge Budge, 24 PGS(S), West Bengal.
FUEL SOURCE ECL, BCCL, IMCL & Imported coals.
FUEL REQUIREMENT 2.45 million tonnes of coal per annum.
MODE OF TRANSPORT Rail
WATER SOUREC River Hoogly
LAND AREA 225 acres
ASH DUMPING AREA 91 acres

UNIQUE FEATURES: -
 Largest coal fired thermal power station of CESC Ltd.
 Use of clarified water for condenser and other auxiliaries.
 Vertical Down-Shot fired boilers having Non-Turbulent, Low NOx Burners.
 Use of gas re-circulation in boiler.
 Use of Hydrogen Cooling and Stator Water Cooling for Generator (first in CESC)
 Use of Cooling Towers for Closed Circulating Water System. (first in CESC)
 Use of Zero Discharge System for Bottom Ash Disposal.
 Incorporation of Zero Effluent System.
 Installation and Operation of a High Concentration Slurry System. (HCSS)
 ISO 9001:2008, 14001:2004 & OHSAS 18001:2007 certified by TUV.

Unit #1 Unit #2 Unit #3

Trail Synchronization 16.9.97 06.03.99 12.07.09
Commercial Generation 07.10.97 01.07.99 28.01.10
Full load Generation 26.02.98 09.08.99 29.09.09
 MAIN PLANT OPERATION
Working Cycles in the plant:
The cycles working in the power plant are as follows: -
 Air & flue gas cycle.
 Feed water cycle.
 Condenser cycle.
 CTCW-DMCW.
 Compressed air cycle.
 Regenerating heater cycle.

A steam power plant using steam as working substance works basically On

Rankine cycle, and the CESC Budge -Budge Generating Station works on the principle
of Modified Rankine Cycle.
 The main plant operation department mainly takes care of the Coal Circuit
(feeding of the coal), Feed Water Circuit, the Cooling Water Circuit, the Air and Gas
circuit, and hence the Power Generation with the help of Generator and Turbine.

POWER GENERATION CYCLE:- Heat for the power cycle of CESC,

Budge -Budge Generating Station Unit no. #1 and #2 is derived from burning
pulverized coal in a Natural Circulation, Balanced Draft, Two pass, Down-Shot fired,
Single Reheat Drum type boiler and Unit #3 is Natural Circulation, Balanced Draft,
Two pass Corner fired, Single Reheat Drum type boiler. However, during Light-up LDO
is used for support and stabilization. For unit 1 and 2 each unit has a 250 MW Rolls
Parsons turbo-generator, an Acc-Babcock make PF boiler and unit 3 has 250 MW
BHEL make turbo-generator and PF boiler with a maximum continuous rating of
805T/hr of steam, and all auxiliary systems and equipment to make a complete
generating unit.
Each boiler has been provided with two forced draft (F.D) fans, three induced
draft (I.D) fans for unit 1&2 and two induced draft fans for unit 3, two primary Air
(P.A) fans, one primary tubular air heater, two secondary tubular air heater for unit 1
and 2 and two rotary air heaters for unit 3, six Ball and Race type pulverisers, six
Volumetric coal feeders for unit 1 and 2 and five bowl pulverisers, five Gravimetric
coal feeders for Unit 3, etc. Soot blowing is done by steam. Main and reheat steam
temperature is maintained from full load to 60% load. The boiler is capable of
sustained stable operation down to 2 Mills at 30% capacity without oil support for
flame stabilization. 25% BMCR requirements can be achieved by burning LDO alone.
The main turbine is a Tandem Compounded, three cylinders, Single Reheat,
Double Flow LP cylinder, Condensing Type with uncontrolled Extraction.
Feed water is taken from the De-aerator, a feed water storage tank, by motor
driven feed water pumps, and discharge through two stage of high-pressure
regenerative feed water heaters and flue gas heated economizer into the boiler
drum. Boiler water by natural circulation flows from the boiler drum through the
furnace water walls back to the drum. Separation of steam and water is
accomplished in the drum, and the steam is conveyed through super-heater sections
of the boiler and intermediate two stages of the de-superheating stations.
Thereafter, the steam is expanded through the high-pressure cylinder of the tandem
compounded steam turbine. After expanding through the high-pressure turbine, the
steam is led back to the re-heater and reheated to the initial temperature which is
again expanded through an intermediate pressure turbine and low-pressure turbine
to a surface condenser. A closed cycle cooling water system remove latent heat from
the low-pressure turbine exhaust steam entering the condenser, and transports this
waste heat to the Induced Draft cooling tower from where finally dissipated to the
atmosphere. The condensate from the Condenser hot-well is again transported to
the de-aerator by motor driven Condensate extraction pumps through four stages of
low-pressure regenerative feed- water heaters of Unit 1 and 2 and three stages of
low-pressure regenerative feed- water heater of Unit 3.
The steam turbine drives a 250 MW, 3phase Alternator with Hydrogen cooled
Rotor and Stator Core and DM water cooled Stator Windings (Unit 1&2) at a speed of
3,000 RPM. The turbine shafts and generator rotor are rigidly coupled together. The
generator field is excited from a static excitation system. Power is generated at 16.5
kV and is stepped up to a voltage of 132 kV (unit 1&2) and 220 kV (unit 3) in a
generator transformer for onward transmission to the system and there is an inter
connection between 132 kV switchyard and 220 kV switchyard and 220 kV switchyard
thru' ICT (Inter Connecting transformer).
The turbine utilizes an electro-hydraulic governing system. The start-up,
shutdown and loading of the turbine can be achieved automatically. The turbine
throttle pressure is 146 kg/cm2 (abs.), the main stream temperature is 537° C, and
the reheat steam temperature is 535°C.
To facilitate cold-start up and quick reloading of the unit after a temporary
turbine outage, a 60% capacity HP-LP turbine bypass system has been provided.
The turbine cycle includes two stages of feed-water pumping (boiler feed pumps
and condensate extraction pumps), consisting seven stages of regenerative feed-
water heating by turbine bled steam, viz, two high pressure regenerative closed feed-
water heaters at the boiler feed pump discharge, four low pressure closed feed-
water heaters at the condensate extraction pump discharge and one direct contact
heater (de-aerator) for unit 1&2 and two high pressure regenerative closed feed-
water heaters at the boiler feed pump discharge, three low pressure closed feed-
water heaters at the condensate extraction pump discharge and one direct contact
heater (de-aerator) for unit 3. All feed-water heaters are of horizontal type. The two
(2) lowest pressure heaters LPH-1&2 (unit 1& 2) and LPH-1 (unit 3) are located inside
the neck of the condenser and LPH-1 is provided with an external drain cooler.
Each feed-water heater drain is normally cascaded to the next lower pressure
heater and the lowest pressure heater drain cascades to the condenser thru’
condensate drain flash box. Emergency drain of each feed-water heater (except LPH-
4 of unit 1&2) is cascaded to the condenser thru’ condenser drain flash box. All
heater drains are gravity type except LPH-3 drain (unit 1& 2) which is handled by
drain pump. Steam for regenerative feed- water heating is extracted from the turbine
cycle at the exhaust from the high-pressure turbine (cold reheat steam), one
intermediate stages of the intermediate pressure turbine, and one from the exhaust
of the intermediate pressure turbine, and three intermediate stages of the low-
pressure turbine of unit 3.
Condensate is extracted from the condenser hot well and pumped through the
turbine gland steam condenser, external drain cooler, and four progressive stages of
low-pressure regenerative feed-water heating (unit 3) and sprayed into a direct
contact de-aerator heater, two 100% capacity vertical type condensate extraction
pumps have been provided for this purpose.
Provision is kept for condensate bypassing of LP heaters in two groups in the
event of heater flooding so that the turbine is protected from water ingress viz. LP
Heaters-2 and 1 and drain cooler as one group, and LP Heaters-3and 4 as the other
unit 1&2 and LP Heaters-1 and drain cooler as one group, and LP Heaters-2 and 3 as
the individual of unit 3.
 LP Heater-2 drain is cascaded to LP Heater-1 via a Flash Box, while LP Heater 1
drain is cascaded to the condenser-drains flash box via the drain cooler. LP Heater-4
drain is similarly cascaded to LP Heater-3, while LP Heater-3 normal drain is pumped
forward by a 1 x 100% drain pump via control valves to LP Heater-3 main condensate
outlet of Unit 1& 2.
LP Heater-2 drain is cascaded to LP Heater-1 and alternate drain to LP Heater
flash box, while LP Heater -1 drain is cascaded to the condenser-drains flash box via
the drain cooler. LP Heater-3 drain is similarly cascaded to LP Heater-2 and alternate
drain to LP Heater flash box.
Initial air extraction from the condenser and steady vacuum inside the condenser is
achieved by two nos. motor driven, water sealed, air extraction pump called NASH
pump. During normal operation of the plant, vacuum is maintained by the circulating
water flowing inside the condenser and the non-condensable gases are extracted by
one of the NASH pumps.
Each unit is provided with a Reserve Feed Water Tank (RFW tank). It holds a
supply of dematerialized water from condensate storage tanks thru' condensate
transfer pumps. RFW tanks provide the means of filling the de-aerator and condenser
and maintain the condensate level within the condenser. It also supplies water to the
condenser air extraction system and condensate extraction pump seals. In addition,
the RFW tanks receive the surplus condensate when there is an excess in the system.
2 nos. separate condensate storage tanks, interconnected to each other, are
provided for the three units. Condensate storage tanks receive dematerialized water
from the DM plant. Condensate storage tanks provide water supply for boiler filling,
RFW tank makeup, de-aerator filling, cooling water head tank makeup, condenser
emergency makeup, storage cooling makeup and chemical feed system for both the
units thru' set of pumps.
The twin-flow LP turbine low pressure exhaust has been connected to a single
shell, horizontal, two pass, divided water box surface condenser. The split design of
the cooling water side of the condenser enables one half to be isolated for inspection
while the other half remains in service. The water boxes are lined with coal tar epoxy
counteract the corrosive qualities of the cooling water in addition sacrificial
magnesium anodes, provide in each water box, gives backup corrosion protection by
means of electrolytic reaction between dissimilar metals.
The condenser for each unit is supplied with circulating water from the cooling
tower basin by 2 x 50% CW Pumps (Unit 1&2) and by 3 x 50% CW Pumps (Unit3)
which pump water through the condenser and discharge it back to the CT basin thus
forming a closed cycle cooling. The CW supply headers of units 1&2 cross connected
and that of unit 3 is separate.

The plant equipment cooling water system meets the requirement of the
auxiliary coolers, other than the main condenser. The whole system is subdivided
into two sub systems. The primary circuit uses DM water and is of closed loop type.
This is employed to pick up the heat load from the various auxiliary coolers under T.G
& boiler packages and to reject the same to a set of plate heat exchangers. The open
loop secondary circuits use clarified water and is employed to pick up the heat load
from above plate heat exchangers and to reject the same to maintain circulating
water header and ultimately to cooling towers. Requirement of cooling water to TG
oil coolers are met thru' Aux. cooling Water Pumps (ACW pumps). The auxiliary
cooling water headers for unit 1 and 2 are cross-connected and that of unit 3 is
separate.
The primary fuel for these units is bituminous coal supplied from coal mines.
The coal handling plant has been designed for 960 MHT coal of (-) 300 mm size which
is generally received at the site from the mines. Coal is unloaded in the yard either by
Rota side wagon tipplers or in the track hopper through bottom discharge wagon.
The coal is crushed in two stages before it is fed into the boiler bunkers. In the final
stage it is crushed to (-)100 mm size by primary crushers and finally to () 20 mm by
secondary crushers 2 x 100% parallel chains of conveyors are provided to convey coal
from the coal yard to boiler bunkers.
LDO is used during light up of boilers. It is also used during low load operation
of the boilers and for support and stabilization. Unloading, storage and transferring
facility of fuel oil system have been provided for the station.
The complete ash handling system is divided as Bottom ash removal system and
Fly ash removal system. The fly ash removal system is continuous, whereas Bottom
Ash removal is intermittent and carried out once per shift.
Bottom Ash Removal system is a wet system. The bottom ash of each unit is
crushed and hydraulically conveyed in the form of slurry form bottom ash hopper to
Dewatering bins/Ash tanks. Decanted water separated from the bins is further re-
circulated in the system. Collected bottom ash at the bins is removed by the trucks.
Ash controlled in ESP and Air heater hoppers is removed in dry form by dense
phase pneumatic conveying system in two stages. In the first stage, fly ash collected
in the above hoppers is pneumatically conveyed with compressed conveying air to
Intermediate Surge Hoppers. In the second stage, the dry fly ash is further conveyed
from Intermediate Surge Hoppers to Fly Ash Silos is removed by trucks through rotary
un-loader. A high concentration slurry system (HCSS) has been incorporated at BBGS
with technology from Netherlands to handle the fly ash in form of thick slurry using
special pumps and transport the same to distant location. The ash settles in the form
of mounds over which suitably identified plantation will take place to convert the
entire place into an environment friendly greenery zone. Provision has been made to
unload the ash from the Intermediate Surge Hoppers to trucks through unloading
system in case of emergency.
A majority of the fly ash is at present exported to Bangladesh through barges
for use in their cement plant.
Major Equipment: -
BOILER: Boiler is a closed vessel in which water is converted into steam by the
application of heat. Usually boilers are coal or oil fired. The boiler has to produce
steam at high purity, pressure and temperature required for the steam turbine that
drives the electrical generator. The typical boiler pressure is in the range 80-160 bar,
steam temperature of the order of 540 C and superheated steam temperature ranges
from 600-900 C.
A boiler should fulfil the following requirements: -
(i) Safety- The boiler should be safe under
operating conditions.
(ii) Accessibility- The various parts of the
boiler should be accessible for repair and
maintenance.
(iii) Capacity- The boiler should be capable of
supplying steam according to the
requirements.
(iv) Efficiency- To permit efficient operation,
the boiler should be able to absorb
maximum amount of heat produced due
to burning of fuel in the furnace.
(v) The boiler should be capable of quick
starting and loading.
The performance of a boiler may be measured in terms of its evaporative capacity
also called power of a boiler. It is defined as the amount of water kg of fuel burnt or
kg/hr/m2 of heating surface. evaporated or steam produced in kg per hour. It may
also be expressed in kg per According to flow of water and hot gases. 1. Water tube.
2. Fire tube. combustion flow over these tubes. In water tube boilers, water
circulates through the tubes and hot products of combustion flow over these tubes.
Steam Turbines: - The superheated steam from the super heater is fed to the steam
turbine via controllable inlet valve. The expansion of steam in the turbine causes its
heat energy to be converted into mechanical energy at the turbine shaft.
 The exhausted steam is
condensed in the condenser
which is kept cool by
circulating water. Keeping the
condenser cool helps to
condense the exhausted steam
thereby creating a pressure &
temp. Difference, both of
which will help to improve the
conversion ratio. In BBGS the
main turbine is a Tandem
Compounded, three cylinders,
Single Reheat, Double Flow LP
cylinder, Condensing Type with uncontrolled Extraction. The steam turbine drives a
250 MW, 30 Alternator with Hydrogen cooled Rotor and Stator Core and DM water
Cooled Stator Windings at (Unit #1 & unit #2) speed of 3000 rpm.
Generator: A turbo generator set or turbine
generator set is the compound of a steam
turbine or gas turbine shaft-connected to a fast
running electric generator for the generation
of electric power. Generators do not produce
electricity on their own, they must first collect
mechanical energy from an outside source.
SUPERHEATER: -Super-heater is a component of steam generating unit in which
steam, after it has left the boiler drum, is heated above its saturation temperature.
The amount of superheat added to the steam is influenced by the location,
arrangement and amount of superheat surface installed, as well as the rating of
boiler.
FEEDWATER HEATERS: -The steam coming out of the turbine is condensed and the
condensate is fed back to the boiler as feed water. Before feeding this water into the
boiler it is necessary to heat it due to the following reasons: 1. Feed water heating
improves overall plant efficiency. 2. The dissolved oxygen and carbon dioxide which
would otherwise cause boiler corrosion are removed from feed water. 3. Thermal
stresses due to cold water entering the boiler drum are avoided. 4. Quantity of
steam produced by the boiler is increased.
REHEATER: -Re-heater is also steam boiler component in which heat is added to this
intermediate pressure steam, which has given up some of its energy in expansion
through the high-pressure turbine. The steam after reheating is used to rotate the
second steam turbine where the heat is converted to mechanical energy.
DEAERATOR: -A steam generating boiler requires that the boiler feed COOLING
TOWER water should be devoid of air and other dissolved gases, particularly
corrosive ones, in order to avoid corrosion of the boiler tubes. Generally, power
stations use a de-aerator to provide for the removal of air and other dissolved gases
from the boiler feed-water.

AIR PREHEATER: -The remaining heat of the flue gases is utilized by the air pre-
heater. It is a device used is steam boilers to transfer heat from the flue gases to the
combustion air before it enters the furnace.
Cooling towers: -The condensate water after condensation is initially at high
temperature. The hot water is passed to cooling tower. It is a tower in which
atmospheric air circulates in
direct or indirect contact
with warmer water and the
water is thereby cooled.
Water, acting as a heat
transfer fluid, gives up heat
to atmospheric air, and thus
cooled is re-circulated to the
system.
CONDENSER: -The condenser does the job of condensing the steam exhausted from
the turbine. Thus, it helps in maintaining low pressure (below atmospheric) at the
exhaust, thereby permitting expansion of steam in the turbine to a very low pressure.
The exhaust steam is used as feed water for the boiler. Modern power plants mostly
use surface condenser. A surface condenser consists of an air-tight cylindrical shell
having a chamber at each end. Water tubes extend between the chambers. The shell
is made of welded steel plate construction and the tubes are made of copper zinc
alloy. Cooling water flows through the tubes. The steam is admitted from the top and
gets condensed due to contact with the tube surfaces. The condensate leaves from
the bottom. For efficient operation, the temperature rises in cooling water passing
through the condenser should be around 10° C.
ECONOMISER: -Flue gases coming out of the boilers carry a lot of heat. An
economizer extracts a part of the heat from the flue gases and uses it for feeding
heat water. The use of economizer results in saving coal consumption and higher
boiler efficiency but needs extra investment and increases maintenance. Costs and
floor area required for the plant. In an economizer large numbers of small diameter
thin walled tubes are placed between two ends. Feed water enters the tubes through
one end and leaves through the other end. The economizer chamber should be leak
proof against air infiltration; otherwise boiler drought may be adversely affected.

RAW WATER & DM PLANT SYSTEM

Raw water usually has fewer organic contaminants; deionization does not
remove uncharged molecules such as viruses or bacteria.

DM PLANT SYSTEM: -The water which is used in thermal power plant is

demineralized water. This water is almost free from minerals. In D.M Plant, process
water is allowed to pass through pressurized bed filter, carbon bed filter, cat-ion
exchanger, anion exchanger, de-gasifier and mixed bed exchanger. At the outlet of
mixed bed water is found minor acidic. The pH level is about 6.2 to 6.8. Finally,
morpholine is dozed to make it alkaline. Such DM water can arrest / prevents
corrosion of “boiler tubes”. In alkaline environment a layer of magnetic oxide may be
formed, which protects the iron from corrosion.
 FUEL AND ASH DEPARTMENT

Fuel and Ash operation department handles the processing of coal from arrival, to its
pulverization, storing and providing to the furnace for combustion. This department
also takes care of the combustion residue, i.e. ash and collects and manages it
properly. This department operates separately as Fuel handling and maintenance and
Ash collection operations.

COAL HANDLING SYSTEM: In a coal based thermal power plant, the

initial process in the power generation is coal handling. Generally, Budge Budge
Generating Station requires 10,000-11,000 tons of coal every day. And, non-coking
type bituminous coal is used. At a time, the number of arriving wagons is about 58-
59. The coal is supplied to the power station through railways.

There are mainly two types of wagons available:

Box-n type: This type has only the top portion open. This is discharged using wagon
tipplers. For placing the wagons, sometimes SIDE ARM CHARGER (SAC) is used. It can
rotate the wagon up to 160 degrees (usually 135-140 degrees). It takes about 7-7.5
hours to discharge.

BOBR type (bottom open rapid discharge): In this type of wagon, there are two gates
in the bottom of the wagon. It is discharged by track hopper. At a time, 18 wagons
can be unloaded at a time. There are 300x300 meshes below the track. The bigger
ones are broken using manual hammer and boulders are separated by BOBCAT. It
takes usually 2.5 hrs to unload.
The process is described as follows:
 After unloading through primary and vibrating feeder the care put into
conveyor belt 1A or 18 and 1C or in respectively thrower
 Then it is passed through two electromagnets in any metal elements
 Then the coal is put into primary crusher of rotary breaker ty. Here the coal is
crushed up to 100 mm size. Other rocks are dumped into rejection bins.
 Through reversible belts the coal is sent to either stack yard or the secondary
crusher.
 The coal in the stack yard can be reclaimed under emergency condition by
reclaim hoppers.
 After primary crusher the coal is passed through DDVS (double deck vibration
screen) where the coal is separated into two parts one having size less than 20
mm and another greater than 20 mm.
 The coal having size less than 20 mm is sent to 2A or 28 through a bypass line.
 The coal having size >20mm is passed through secondary crusher of ring
granulator type. Here the coal is reduced to a size up to 20 mm.
 Then the coal is passed through two electromagnets and a GCV (gross calorific
value analyser).
 Then the coal is temporarily stored in the bunker and sent to pulveriser.
 Unit #1 & #2 contains Ball and Race type mills, and Unit #3 has Bowl Mills,
where the coal is grinded to dust.

Ball and Race Mills: This type

of coal mill consists of 10 steel
balls placed is circular track.
The ball keeps on rotating
along its axis 3 well as
revolving around the circular
track. The coal from the
Secondary Crusher is
transferred here in between
the balls. The rotatory motion
of the ball pulverises the coal
into coal of very small
dimension. The coal from here is either sent to the furnace or to the stack for future
use. This type of mill is used in Unit #1 and #2. These mills are 6 nos. where 5 of them
are always functional.
Bowl Type Mills: This type of coal mill consists of 3 rotating hammers placed 1200
apart. A bowl is placed under the hammer where the coal is placed for pulverization.
The coal is placed in between the rotating hammers so that the coal is grinded and
small pieces of coal gets collected inside the bowl. These types of mill are used in
Unit #3. They are 5 nos. where 4 of them are always functional. some of the
important equipment are described as follows:
Vibrating Feeder: The coal stored in a huge hub is collected on the belt through
vibrations created by this.
Flap Gates: This are used to channelize the path of coal to another belt if the
former is broken or unhealthy.
Reclaim hopper: It is present below the VFB 7, 8 and 9, 10. From where the goal
goes onto 11A and 11B, and then to 12A and 12B. The coal that
has been reclaimed goes to the Primary Crusher House onto 3A
and 3B, and then to the Secondary Crusher House.
Stacker-Cum-Reclaimer: It is used to stack and reclaim coal to and from the stack
yard and transfer it to the conveyor belts 10A, 10B. GCV
(GROSS CALORIFIC VALUE ANALYZER): This machine can
provide the calorific value of the coal mixture in a short
time interval, using radioactive source.

COAL MIXING: -
Different types and qualities of coal arrives at BBGS through the railway tracks. But,
for a nearly constant output different qualities of coal are mixed. High quality coals
such as HCECL have higher calorific value, higher volatile material content and lower
ash content whereas lower quality like SLS coals have lower calorific value and higher
ash content. The qualities are mixed such that the mixture should have a calorific
value about 4000 kcal
ASH HANDLING SYSTEM: -
The complete ash handling system is divided as Bottom Ash Removal system and Fly
Ash Removal system. The Fly Ash Removal system is continuous, whereas Bottom
Ash Removal system is intermittent and carried out once per shift. Upon fuel burning,
40% of the fuel mass is retrieved in the form of Ash.

To maintain a pollution free environment, the ashes must be collected

properly and dumped or recycled as per the demand. Here the FAO department plays
its role as ash handling and management team.
COLLECTION OF FLY ASH: Fly Ash present in the flue gas are collected by the ESP
(Electrostatic Precipitator). The flue gas generated is passed through the ESP, which
has two charged plates present. These charged plates keep the air in between the
plates charged. Due to corona discharge, the fly ash particles get charged. The flue
gas along with the charged fly ash is passed onto another chamber containing
charged plates. Now, the negatively charged ash particles gets attracted towards the
positive plate and vice versa. The ash particles are removed from the plates by
discharging the plates and gently hammering it. The ash then gets collected in a
hopper which then stores the ash to a vessel. The ashes from the vessel are removed
by high pressure air which is passed through pump, and the ashes are then sent to
Intermediate Surge Hopper (ISH). The ISH has a Push and Bypass mechanism, which
stores the ash and then bypasses it to the dumping valve using Pneumonic Discharge
Pumps (PD pumps). Approximately 3.3 tons of ash are collected per pass of the PD
pump.
An electrostatic precipitator (ESP) is a filtration device that removes fine
particles, like dust and smoke, from a flowing gas using the force of an induced
electrostatic charge minimally impeding the flow of gases through the unit. It collects
dry ash from the flue gas and stores the min the ash SILOS.
Fly ash flows with
the flue gas and is
captured by the ESP. In
the first stage, the flue
gas enters the ESP which
consists of positive plates.
The dust from the flue
gases is negatively
charged and hence gets
attracted to the positively
charged plates. Using PLC,
these plates are
automatically vibrated
and the dust collected in
a hopper. Fly ash collected in the hoppers is pneumatically conveyed with
compressed conveying air to Intermediate Surge Hoppers. In the second stage, the
dry fly ash is further conveyed from Intermediate Surge Hoppers to Fly Ash Silos or
river side Barges to export to Bangladesh cement industry by P.D (Pneumatic
Discharge) pumps. Ash collected in Fly Ash Silos is removed by trucks through rotary
unloader.
A High concentration slurry system (HCSS) has been incorporated at BBGS with
technology from Netherlands to handle the fly ash in the form of thick slurry using
special pumps after mixing it with a pre-calculated amount of water and transport
the same to a distant location (3 KMs away from BBGS) using a GEHO pump. This ash
settles in the form of mounds and form rocks. Plantations can be done on this land
later on. A majority of the fly ash is at present exported to Bangladesh though barges
for using in brick and cement industry.
COLLECTION OF BOTTOM ASH:
The Bottom Ash are those ash particles of larger dimensions which are accumulated
at the bottom of the boiler. These ashes are then passed on to water chamber called
Bottom Ash Hopper. The function of this hopper is to soften the ash and cool it
down. The ash particles get accumulated together after it is softened. The ash
particles are then removed from the bottom through tube by creating a negative
pressure column in it. The ash and water then go to Decant Water Bin, where the
ashes are settled and water is passed through tube. The water then is sent to Surge
tanks, where the water is chemically dosed to that the ash particles remaining gets
coagulated and settled at the bottom. The water after settling the ash particles are
sent to Settling tanks where the water is stored.
 PLANNING & ENVIRONMENT: -
The Planning and Environment department has the responsibility of coordinating all
the other departments and to create daily reports of plant operation. A key function
of the Planning department is to update this Management Information system MIS
on a regular basis which aids in the smooth cooperation of the different segments of
the plant. The analysis of all significant parameter stakes. The Planning department
enables coordination between the departments when maintenance work is to be
done. It checks heat rate, PLF (Plant Load Factor), PAF (Power plant Availability
Factor), Coal flow etc. It does the below jobs: -
 MIS (Management Information System) report generator daily.
 Annual plan preparation.
 Budget preparation.
 Maintenance planning.
 Software and Hardware maintenance.
 Feeder sample preparation.
 Award and Achievements.
 AC maintenance.
 SPM, SOx, NOx monitoring.
 Increase MTBF and decrease MTTR.
 Safety management.
 Pollution Control Board.

The plant strictly examines the safety of working conditions by regularly contracting
teams in order to visit different sites across the generating station in order to judge
its current status in fields like use of PPES- Personal Protective Equipment, position of
people, Tools and equipment, Procedures, Training, Housekeeping, etc. The
subsequent reports along with suggested changes can be found on their module.
Pollution Control Activities:

The pollution control activities at our four Generating Stations include: -

 Emission control
 Effluent control and effluent recycling
 Ambient air monitoring
 Solid waste management
 Hazardous waste management.
 Plantation.
 MECHANICAL MAINTENANCE DEPARTMENT

Mechanical Maintenance needs to be done in order to keep the components

of the power station in efficient running conditions, to prevent breakdown and to
replace repair faulty parts. It includes performing routine actions which keep the
device in working order or prevent trouble from arising.

There are three types of maintenance:

1. Preventive: Preventive maintenance is the maintenance performed in an

attempt to avoid failures, unnecessary production loss and safety violations. It
includes scheduled maintenance (daily and routine) of the equipment and
includes activities like regularly monitoring the temperature and pressure of
the bearing, grease, windings, oil, air and gases, the flow of air, water and oil,
the rotation of bearing lubricating rings, moisture content in the gases, etc. It is
the maintenance before the breakdown occurs.

2. Breakdown: It is the maintenance where equipment is maintained after

break down. This maintenance is often most expensive because worn
equipment can damage other parts and cause multiple damage. The corrective
maintenance is carried out to bring it back the equipment in the working order.

3. Predictive: This kind of maintenance includes activities to foresee events in

the future that could lead to damage of the equipment or cause a failure in the
system.

Faults in any component can be detected by various methods of analysis

1. Visual Detection.
2. Vibrational Analysis.
3. Thermo graphic Analysis: This method uses Infrared rays in order to generate
heat signature of the subject. If any part has significantly higher temperature
than expected, a fault might occur.
4. Ferro graphic Analysis /Oil Sample Analysis: The oil in the machines is often
analysed chemically for its temperature, acidity (TAN) and other
characteristics which depict the health of the subject.
Faults in a machine may be of two kinds:
1. Operational
2. Functional

Operational Faults may cause a decrease in efficiency or unpleasant operation

of the subject, but the machine is still in a running condition. Functional faults render
a machine obsolete until breakdown maintenance is carried out. While operational
faults can be overlooked, functional faults result in a shutdown of the machine.
Proper predictive maintenance needs to be done in order to prevent operational and
more importantly, functional faults.

The major divisions in this department include:

1. Maintenance of Boiler & its auxiliaries:
 Boiler
 ID Fan
 FD Fan
 PA Fan
 Coal Mill
 Various Pumps, etc.
2. Maintenance of Turbine & its auxiliaries:
 Turbine
 CEP BFP
 NASH Pump
 HP_LP Bypass System
 Condensate Transfer Pump
 Circulating Cooling Water (CW) Pumps
 Service Cooling Water Pumps, etc.
3. Maintenance of Fuel and Ash:
 Conveyor System
 Rotary Breakers
 Crusher
 Wagon Tipplers
 Track Hoppers
 Bottom & Fly Ash

FORCED DRAFT FAN (FD fan): An FD fan draws air from the atmosphere and forces it
into the furnace through a pre-heater. These fans are located at the inlet of the boiler
to push high pressure fresh air into combustion chamber, where it mixes with the
fuel to produce positive pressure. The most common centrifugal fans used as FD fans
are backward curved and aerofoil centrifugal fans. In power where coal is used as
fuel for combustion, FD fans are used as primary and secondary air fans to regulate
proper combustion and maximize the fuel efficiency of the process
A typical FD fan arrangement uses inlet and outlet dampers to control and
maintain the required air pressure inside the system. These fans have a wheel at the
centre that is hung on the shaft along with inlet boxes, silencer, filter and rain hood.
When compared to ID fan, FD fans are easier to maintain and have cleaner operating
conditions.
PRIMARY DRAFT FAN (PA fan): - A key component of the thermal power generation
plant is the boiler, which is also called as steam generator. The essence of the
thermal power generation plant is to create the steam in boilers or steamers; this
steam is sent at high pressure to a stationary turbine that generates electricity. The
coal is first crushed into minute particles using equipment called pulverizers. The
main function of the Primary air fan or PA fan is to carry the pulverized coal to the
furnace as fuel for combustion. This process is used to create the steam that is the
primary process in the thermal power plant.
In power plants, the PA fans supply air for conveying of the pulverized coal from
coal mills to the furnace area. These primary air fans produce a high pressure to push
the coal and air mixture through pulverizes into the furnace. The most common
configuration of the draught fans used as a PA fan is the backward curved centrifugal
fan. In power plants the PA fans play an important role in supplying air necessary for
fuel combustion and in the maintenance of furnace temperature.
INDUCED DRAFT FAN (FD fan): - Induced draft fan is normally located at the outlet
between dust collector and chimney. The fan takes hot flue gases from the boiler
through dust collector and delivers it to the chimney into the open atmosphere. ID
fan creates negative pressure or suction to discharge the gases out after combustion
from the furnace. Since ID fans can handle hot flue gases, they have more corrosion
and erosion problems even when used with Electrostatic precipitators. The most
common type of fans used as ID fans are the backward inclined blade centrifugal
fans.
SAFETY VALVE: -They are required to prevent any kind of accident due to increase in
pressure.
No. Of Safety Valves:
Unit#1&2 -(Total 10 No’s), At Drum-2, At MS Line-2, At CRH-4, At HRH-2.
Unit #3 - (Total 10 No’s): At Drum-3, At MS Line-2, At CRH-1, At HRH-4.
LUBRICATION SYSTEM
Lubrication is an essential activity for the healthy working of equipment. It is the
process or technique employed to reduce wear off one or both surfaces in close
proximity and moving relative to each other, by interposing a lubricant by interposing
a lubricant between the surfaces to carry or to help carry the load between the
opposing surfaces.
 ELECTRICAL DEPARTMENT
Transformer: A transformer is a static device which transfers electrical energy from
one circuit to another through the process of electromagnetic induction. It is most
commonly used to increase (‘step up’) or decrease (‘step down’) voltage levels
between circuits.
Station Transformer: Transformers are designed to provide low voltage control
power for substations, cell towers, and switching stations. They do this by tapping
from the high voltage line. They are normally grounded for a connection between the
ground and the phase.
Generator Transformer: The generator
transformer is the largest transformer on a power
station and connects the generator output to the
grid. There is a generator transformer for each
generating unit and it is rated according to the size
of that unit. Like any other oil-filled transformer,
the generator transformer should be located
within an outdoor compound.
Generator: A turbo generator set or turbine
generator set is the compound of a steam
turbine or gas turbine shaft-connected to a fast
running electric generator for the generation
of electric power. Generators do not produce
electricity on their own, they must first collect
mechanical energy from an outside source.
Bus Bar: A conductor or a group of conductors used for collecting electric power from
the incoming feeders and distributes them to the outgoing feeders. In other words, it
is a type of electrical junction in which all the incoming and outgoing electrical
current meets. Thus, the electrical bus bar collects the electric power at one location.
Circuit Breaker: A circuit breaker is an automatically
operated electrical switch designed to protect an electrical circuit from damage
caused by excess current from an overload or short circuit. Its basic function is to
interrupt current flow after a fault is detected. Unlike a fuse, which operates once
and then must be replaced, a circuit breaker can be reset (either manually or
automatically) to resume normal operation.
SF6 Circuit Breaker: Sulphur hexafluoride circuit breakers protect electrical power
stations and distribution systems by interrupting electric currents, when tripped by
a protective relay. Instead of oil, air, or a vacuum, a sulphur hexafluoride circuit
breaker uses sulphur hexafluoride (SF6) gas to cool and quench the arc on opening a
circuit.
Isolator: An isolator is a manually operated mechanical switch which separates a part
of the electrical power. Isolators are used to open a circuit under no load. Its main
purpose is to isolate one portion of the circuit from the other and is not intended to
be opened while current is flowing in the line. Isolators are generally used on both
ends of the breaker so that repair or replacement of circuit breaker can be done
without any danger.
Switchyard: A station in the power transmission
system at which electric power is transformed
to a conveniently used form. The station may
consist of transformers, switches, circuit
breakers and other auxiliary equipment. Its
main function is to receive energy transmitted
at high voltage from the generating station, by
either step-up or step-down the voltage to a
value appropriate for local use and provide
facilities for switching.
 Conclusion
CESC's environmental management system focuses on continuous
improvement and up gradation, with state-of-the-art principles and equipment,
setting high targets and reviewing its performances. CESC recognizes its responsibility
towards protecting the ecology, health and safety of the employees and consumers.

The vocational training has been organized by the CESC limited and has been
undertaken at the Budge Budge Generating Station. The purpose of the vocational
training is to get an industrial exposure in our engineering career.

Students can learn a lot from different books about various subjects such as
operations of a plant, various constituents of a plant, power production, power
distribution etc. but a practical experience helps in better understanding and
enhancement of knowledge in various subjects. I am grateful to CESC limited for
organizing this training.