VOCATIONAL TRAINING AT CESC LIMITED

(BUDGE BUDGE GENERATING STATION)

Name: ROHIT BARUA

Branch: MECHANICAL ENGINEERING

Institute: NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR

Year: 2022

Duration Of Training: 2 Weeks

From Date: 24.05.22

To Date: 04.06.22

1
 ACKNOWLEDGMENT

This report on CESC Limited, BBGS is a result of the constant help and support
which I have received during my training session from the competent personnel
of this esteemed company.
I would like to express my sincere appreciation and gratitude to all of them for
their constant encouragement and to every other staff of CESC Budge Budge for
their constant guidance and inspiration.
Lastly, I would like to acknowledge with gratitude, my professors and friends,
for their valuable contribution, without which this report would have been
incomplete.

2
 CESC LIMITED
BUDGE BUDGE GENERATING STATION

DETAILS OF STUDENT:

NAME: ROHIT BARUA

BRANCH: MECHANICAL ENGINEERING

INSTITUTE: NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR

DURATION OF TRAINING: 2 WEEKS

FROM DATE: 24.05.22

TO DATE: 04.06.22

3
 OVERVIEW OF CESC LIMITED

INTRODUCTION

The Calcutta Electric Supply Corporation or CE SC is an Indian electricity

generating company serving the area administered by the Kolkata Municipal
Corporation. It also serves parts of the Howrah, Hoogly, 24 Parganas (North), and 24
Parganas (South) districts of West Bengal. On 7 January 1897 Kilburn & Co. secured
the Calcutta (Now Kolkata) electric lighting license as agents of The Indian Electric
Company Limited. The first power generating station was begun on April 17, 1899,
near The Princep Ghat. Three new power generating stations were started by 1906.
The company was shifted to the Victoria House in Dharmatala in 1933 and still
operates from this address. Load-shedding was common in Kolkata during the 1970s
and 1980s. In 1978 the company was christened The Calcutta Electric Supply
Corporation (India) Limited. It was associated with The Calcutta Electric Supply
Corporation (India) Limited from 1989, and the name was changed from The
Calcutta Electric Supply Corporation (India) Limited to CESC Limited.
Recently the Calcutta power grid has seen crescively better performance and fewer
outages. Presently CESC Ltd is the flagship company of RP-SANJIV GOENKA
GROUP. Its salient feature lies in the fact that it utilizes a tunnel under Ganga for
power transmission. Initially provided with a licensed area of only 14.44 sq. km,
CESC is claimed to have been brought to Calcutta 10 years after it came to London.
In 1989, CESC became a part of the RPG Group. In 2011, CESC became a part of
RP-Sanjiv Goenka Group.

HISTORY

CESC operated from April 1899 from its small DC station at Emambaugh Lane. Its
latest station, Budge Budge Generating Station, is the largest ever private industrial
investment in West Bengal, having a capacity of 750MW.

4
 GENERATION

GENERATING YEAR OF CAPACITY FEATURE OF

STATION COMMISSIONING BOILER
SOUTHERN(SDGS) 1991 135MW PULVERISED
FUEL
BUDGE 1997 750MW PULVERISED
BUDGE(BBGS) FUEL

PROJECT PROFILE

Capacity 750 MW (3 x 250 MW)

Location PUJALI, BUDGE BUDGE, 24 PGS(S), WEST
BENGAL
Fuel source ECL, BCCL, ICML & Imported Coals
Fuel requirement 2.45 million tonnes of coal per annum
Mode of Rail
transportation
Water source River Hooghly
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 the 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, ISO 45001:2021 & ISO 50001:2018 certified

5
 BOILER

TYPE Horizontal Single Drum, Natural Circulation, Water Wall Tube,

Two Pass, Balanced Draft, Single Reheat, Pulverised Fuel Boiler
with Common Cold PA Fan.
M/S ABB ABL Limited, Durgapur, W.B.(Unit#1&2), M/S BHEL
MANUFACTURING (Unit#3)

UNIT #1&2 UNIT #3

WIDTH 17940mm 14326mm

DEPTH 17173mm 11506mm

Superheater Primary/LTSH, Platen, Final

No. of Safety Valves

Unit#1&2 - (Total- 10 nos.) At Drum – 2, At MS Line – 2, At CRH –
4, At HRH- 2
Unit#3 - (Total- 10 nos.) At Drum – 3, At MS Line – 2, At CRH –
1, At HRH- 4
No of Air heater Unit#1&2 – 3 nos Unit#3 - 2 nos
No of F.D Fan/unit (#1,2 & 3) 2
No of I.D Fan/unit Unit#1&2 – 3 Unit#3 - 2
No. of P.A. Fan/unit (#1,2 & 3) 2
No. of Coal Mills/unit Unit #1&2 - 6 Unit #3- 5

Steaming Parameter at 100% BMCR

R/H Max. Working
50
Evaporation Of Boiler 805 Te/Hr Pressure Kg/Cm2g
Max. Working Pressure 184 R/H Inlet Steam 39.8
Of Boiler Kg/Cm2g Pressure Kg/Cm2g
Final S/H Outlet 152-155 R/H Inlet Steam
Steam Pressure Kg/Cm2g Temperature 353 OC

Final S/H Outlet R/H Outlet Steam 37.8

540 OC
Steam Temp Pressure Kg/Cm2g
Feed Water R/H Outlet Steam
247 OC 540 OC
Temperature Temp
700 Te/Hr(unit#1&2) & 692.2
R/H Steam Flow
Te/Hr(unit#3)

6
 TURBINE:-

No Of Cylinders HP - 1 Single Flow; IP - 1 Single Flow; LP - 1 Double

Flow

SV Pressure & Temp 146.0 Kg/Cm2 Abs & 5370C

Reheat Pressure &

35.7 Kg/Cm2 Abs & 5350C
Temp

Speed 3000 Rev/Min

Number Of Blading
Unit#1&2 Unit#3
Stages
1no – Impulse & 18 nos. -50%
HP: 25 nos. - Reaction
Reaction)
IP: 16-50% Reaction 17- Reaction
4-50% Reaction Per Flow, 3-
LP: 8- Reaction per-flow
Variable

Steam conditions at 100% ECR load

HP Turbine : Inlet Unit#1&2 Unit#3
146.0 Kg/Cm2 Abs
Pressure & Temp 147.0 Kg/Cm2 Abs &
& 537°C
HP Turbine : Outlet
41.53 Kg/Cm2 Abs
Pressure & Temp 39.56 Kg/Cm2 Abs &
& 349°C
IP Turbine: Inlet
37.35 Kg/Cm2 Abs
Pressure & Temp 35.62 Kg/Cm2 Abs &
& 535°C
IP Turbine: Outlet
4.93 Kg/Cm2 Abs 6.72 Kg/Cm2 Abs &
Pressure & Temp
& 252°C 3040C
LP Turbine Inlet
4.71 Kg/Cm2 Abs 6.72 Kg/Cm2 Abs &
Pressure & Temp
& 255.4°C 3040C
LP Turbine: Outlet
76 Mm Hg Abs &
Pressure & Temp 76 Mm Hg Abs & 44.20C
480C

7
 Unit#1& Unit#3
GENERATOR:- 2
Maximum Continuous 250 MW 250 MW
Rating
Maximum Continuous 294 MVA 294
Rating MVA
Rated Power Factor 0.85 0.85
Rated Terminal Voltage 16500V 16500V
Rated Current 10291A 10291A
Frequency 50 Hz 50 Hz
Number Of Phases 3 3

GENERATOR TRANSFORMER
Phase, No Of
Make Frequ Unit/Gener Rated Rated
voltage(kV) current(amps)
ency ator
HV LV HV LV
Unit#1& 1Ph, 50 138/√
TELK 3 Nos., 1 Ph 16.5 1318 6364
2 Hz 3
3Ph, 50
Unit#3 BHEL 1 No, 3 Ph 235 16.5 773.9 11022.14
Hz

STATION TRANSFORMER
No Of
Phase,
Make Unit/ Rated voltage(kV) Rated current(amps)
Frequency
Generator
HV LV1 LV2 HV LV1 LV2
Unit# 3 Ph, 50
CGL 1 No, 3 Ph 132 6.9 6.9 262.4 2510.2 2510.2
1&2 Hz
Unit# 3 Ph, 50
BHEL 1 No, 3 Ph 220 6.9 6.9
3 Hz

UNIT TRANSFORMER
No Of
Phase, Unit/ Rated Rated
Make current(amps)
Frequency Generat voltage(kV)
or
LV LV
HV HV LV1 LV2
1 2
Unit# 3 Ph, 50 1410. 2094. 1256.
HHE 1 No, 3 Ph 16.5 6.9 6.9
1&2 Hz 3 3 6
3 Ph, 50
Unit#3 BHEL 1 No, 3 Ph 16.5 6.9 6.9
Hz

8
 Water Consumption Pattern (M3/Day) For Three units.

Avg. Effluent Water

Produced After
Avg. River Water Intake 33000 Regeneration Of DM Plant 100
Vessels
Avg. Evaporation (At 100%
33450 Avg. DM Water Produced 1000
PLF)
Avg. Water Used For
Avg. Waste Water (As
Service Water, Fire Water & 5500 450
Sludge) Produced
Ashing Purposes
Avg. Holding Pond Water
Avg. Clarified Water Intake 1100 8000
Intake To
For DM
Plant ISS (Recycled Water)

COAL HANDLING PLANT

Capacity:-

960
Design Rated 800 T/Hr
T/Hr
No Of Wagon Tippler No Of Track 1
2
Primary Crusher:
Rotary
Quantity 2 Nos. Type
Breaker
Secondary Crusher:
Ring
Quantity 2 Nos. Type
Granulator

Stacker-Cum-Reclaimer:

Slewing And Luffing Boom Stacker With Bucket Wheel

TYPE Reclaimer, Rail Mounted, Suitable For Reversible Yard
Conveyor.
Nos. 2 Height Of Pile 10.5
Total Travel (M) 308 M Material Semi Crushed Coal

Lump Size (-)100 Mm Lump size (-)100 mm

9
ASH HANDLING SYSTEM

Fly Ash Handling System: Fly Ash Evacuation Rate - 80 Mt/Hr

Capacities of Tank / Vessel:

Air Heater 57 Litres ESP 3 147 Litres

ESP 1 & 2 485 Litres ESP 4 To 7 85 litres

Bottom Ash System: Bottom Ash Cleaning Rate - 60 MT/Hr

Effective Storage Capacity:

150 MT 1670 CUM

Bottom Ash Hopper Surge Tank
(Approx) (Approx)
432 MT Overflow Transfer
De-Watering Bin 21 CUM (Approx)
(Approx) Tank
Decant Water
1240 CUM
Settling Tank Transfer 35 CUM (Approx)
(Approx)
Tank

10
 INTRODUCTION

POWER PLANT

A power plant or powerhouse, and sometimes generating station or generating plant,

is an industrial facility for the generation of electric power. Most power plants contain
one or more generators, a rotating machine that converts mechanical
power into electrical power. The relative motion between a magnetic field and
a conductor creates an electrical current. The energy source harnessed to turn the
generator varies widely. Most power stations in the world burn fossil fuels such
as coal, oil, and natural gas to generate electricity. Fossil-fuel power stations may also
use a steam turbine generator or in the case of natural gas-fired plants may use
a combustion turbine.

Using a nuclear fission reaction and uranium as fuel, nuclear power plants generate
a high amount of electricity. As nuclear power plants are considered to be a low-
carbon energy source, the technology is widely thought of as a more environmentally-
friendly option. Hydroelectricity is produced by harnessing the gravitational force of
flowing water. Coal-fired power plants use steam coal as a source to generate
electricity and consequently emit a significant amount of harmful gases into the
atmosphere. The three main types of geothermal plants include dry steam power
stations, flash steam power stations, and binary cycle power stations, all of which use
steam turbines to produce electricity. A gas-fired power plant burns natural gas – a
rapidly growing energy source across the world – to generate electricity. Solar energy
plants convert energy from the sun into thermal or electrical energy using one of the
cleanest and most abundant renewable energy sources.

THERMAL POWER PLANT

A thermal power plant or steam power plant is a generating station that converts
the heat energy of fossil fuels into electrical energy. Generally, bituminous, brown,
or peat-type coal is used as the fuel of a coal-based thermal power plant. In
a thermal power plant, coal is burnt in a big boiler which produces steam at high
pressure and temperature. This steam is passed through a steam turbine which
converts steam's heat energy into mechanical energy. The steam turbine acts as a
prime mover and is coupled to an alternator. Now alternator collects the mechanical
energy from the steam turbine and converts it into electrical energy. In this power
plant, a steam turbine sometimes acts as auxiliary equipment like pumps, strokes,
etc. The greatest variation in the design of thermal power stations is due to the
different fuel sources.

11
Diagram of Coal-based Thermal Power Plant

Labeled Keys:

1. Cooling tower 8. Condenser 15. Coal Hopper 22. Air intake

2. Cooling water 9. Intermediate 16. Pulverised fuel

23. Economiser
pump pressure turbine mill
3. Pylon
(termination 10. Steam governor 17. Boiler drum 24. Air preheater
tower)
4. Unit 11. High-pressure
18. Ash hopper 25. Precipitator
transformer turbine

26. Induced draught

5. Generator 12. Deaerator 19. Superheater
fan

6. Low-pressure 20. Forced draught

13. Feed heater 27. Chimney stack
turbine fan

7. Boiler feed
14. Coal conveyor 21. Reheater
pump

12
 OPERATION
INTRODUCTION

Budge budge generating station is a coal-based steam power plant. The basic
operating principle behind steam power plants is the Rankine Cycle. In steam power
plants, the heat of combustion of fossil fuels eg. Coal, oil, or gas is utilized by the
boiler to raise the temperature of steam at high pressure and temperature. The steam
so produced is used in driving the steam turbines or sometimes steam engines
coupled to generators and thus in generating electrical energy.
In the operation department, the entire process of generating electricity through
various techniques is being controlled. It is done in the control rooms. Generally, PLC
(Programmable Logic Control) is used for controlling the variables needed for the
entire process.
There are 3 control rooms are used in BBGS (Each control room for each unit). The
operation of the control rooms is separated from each other. But one core control
room is controlled by these three.

RANKINE CYCLE

The Rankine Cycle is a mechanical cycle commonly used in power plants to

convert the pressure energy of steam into mechanical energy through steam
turbines. The Rankine Cycle’s major components include a rotating steam turbine,
a boiler pump, a stationary condenser, and a boiler. The heat is supplied externally
to a close loop, which usually uses water as the working fluid. This cycle generates
about 80% of all-electric power used throughout the world. It has been named after
William Johnson Macquorn Rankine.

DESCRIPTION OF RANKINE CYCLE

A Rankine cycle describes a model of the operation of steam heat engines most
commonly found in power generation plants. Common heat sources for power plants
using the Rankine cycle are coal, natural gas, oil, and nuclear.
The Rankine cycle is sometimes referred to as a practical Carnot cycle as, when
an efficient turbine is used, the TS diagram will begin to resemble the Carnot cycle.
The main difference is that a pump is used to pressurize liquid instead of gas. This
requires about 100 times less energy than that compressing gas in a compressor (as
in the Carnot cycle).
The efficiency of a Rankine cycle is usually limited by the working fluid. Without
the pressure going super critical, the temperature range the cycle can operate over is
quite small, turbine entry temperatures are typically 565°C (the creep limit of
stainless steel) and condenser temperatures are around 30°C. This gives a theoretical
Carnot efficiency of around 63% compared with the actual efficiency of 42% for a
modern coal-fired power station. This low turbine entry temperature (compared with
a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in
combined-cycle gas turbine power stations.

13
 The working fluid in a Rankine cycle follows a closed loop and is reused
constantly. The water vapor often seen swelling from power stations is generated by
the cooling systems (not from the closed-loop Rankine power cycle) and represents
the waste heat that could not be converted to useful work. Note that steam is invisible
until it comes in contact with cool, saturated air, at which point it condenses and
forms the white billowy clouds seen leaving cooling towers. While many substances
could be used in the Rankine cycle, water is usually the fluid of choice due to its
favourable properties, such as non-toxic and unreactive chemistry, abundance, and
low cost, as well as its thermodynamic properties.
One of the principal advantages it holds over other cycles is that during the
compression stage relatively little work is required to drive the pump, due to the
working fluid being in its liquid phase at this point. By condensing the fluid to liquid,
the work required by the pump will only consume approximately 1% to 3% of the
turbine power and so give a much higher efficiency for a real cycle. The benefit of this
is lost somewhat due to the lower heat addition temperature. Gas turbines, for
instance, have turbine entry temperatures approaching 1500°C. Nonetheless, the
efficiencies of steam cycles and gas turbines are fairly well matched.

Process of the Rankine cycle

There are four processes in the Rankine cycle, each changing the state of the working
fluid. These states are identified by the number in the diagram.

 Process 1-2: The working fluid is pumped from low to high pressure, as the
fluid is a liquid at this stage the pump requires little input energy.

 Process 2-3: The high-pressure liquid enters a boiler where it is heated at

constant pressure by an external heat source to become a dry saturated vapor.

 Process 3-4: The dry saturated vapor expands through a turbine, generating
power. This decreases the temperature and pressure of the vapor, and some
condensation may occur.

 Process 4-1: The wet vapor then enters a condenser where it is cooled at
constant pressure and temperature to become a saturated liquid. The pressure
and temperature of the condenser are fixed by the temperature of the cooling
coils as the fluid is undergoing a phase change.

In an ideal Rankine cycle, the pump and turbine would be isentropic, i.e., the pump
and turbine would generate no entropy and hence maximize the net work output.
Processes 1-2 and 3-4 would be represented by vertical lines on the T-s diagram and
more closely resemble that of the Carnot cycle. The Rankine cycle shown here
prevents the vapor from ending up in the superheat region after the expansion in the
turbine, which reduces the energy removed by the condensers.

14
 T-s diagram of a typical Rankine cycle operating between pressures of 0.06bar and 50bar

Real Rankin cycle (non-ideal)

In a real Rankine cycle, the compression by the pump and the expansion in the
turbine are not isentropic. Therefore, these processes are non-reversible and entropy
is increased during the two processes. This somewhat increases the power required
by the pump and decreases the power generated by the turbine.
In particular, the efficiency of the steam turbine will be limited by water droplet
formation. As the water condenses, water droplets hit the turbine blades at high speed
causing pitting and erosion, gradually decreasing the efficiency of the turbine. The
easiest way to overcome this problem is by superheating the steam. On the T-s
diagram below, state 3 is above a two-phase of steam and water so after expansion,
the steam will be very wet. By superheating, state 3 will move to the right of the
diagram and hence produce dryer steam after expansion.

Variations of the real Rankine cycle

The overall thermodynamic efficiency can be increased by raising the average heat
input temperature of that cycle. Increasing the temperature of the steam in the
superheat region is a simple way of doing this. There are also variations of the basic
Rankine cycle which are designed to raise the thermal efficiency of the cycle in this
way; two of these are described below.

Regenerative Rankine cycle

The regenerative Rankine cycle is so named because after emerging from the
condenser (possibly as a sub-cooled liquid) the working fluid is heated by steam
tapped from the hot portion of the cycle. On the diagram shown, the fluid at 2 is
mixed with the fluid at 4 (both at the same pressure) to end up with the saturated
liquid at 7. The Regenerative Rankine cycle (with minor variants) is commonly used
in real power stations.

15
Another variation is where 'bleed steam' from between turbine stages is sent to feed
water heaters to preheat the water on its way from the condenser to the boiler.

Rankine cycle with superheat Regenerative Rankine Cycle

Major equipment used in Thermal Power Plant:-

a) BOILER

A Boiler is an enclosed pressure vessel in which water is converted into steam

by gaining heat from external sources. The boiler accumulates the steam and
builds up a pressure to expand it into a turbine and convert thermal energy
into mechanical energy. The generator which is connected to the turbine
converts mechanical energy to electrical energy.

Types of Boiler:
 Based on tube content:

1. Fire Tube
2. Water Tube

 Based on operating pressure:

1. Ultra-supercritical boiler: Pressure ≥ 27.0MPa or rated outlet

temperature ≥ 590 ℃ boiler
2. Supercritical boiler: 22.1MPa ≤ Pressure ≤ 27.0MPa
3. Subcritical boiler: 16.7MPa ≤ Pressure ≤ 22.1MPa
4. Ultra-high pressure boiler: 13.7MPa ≤ Pressure ≤16.7MPa
5. High-pressure boiler: 9.8MPa ≤ Pressure ≤ 13.7MPa
6. Sub-high pressure boiler: 5.4MPa ≤ Pressure ≤ 9.8MPa
7. Medium pressure boiler: 3.8MPa ≤ Pressure≤ 5.4MPa

16
  Based on fuel used:
1. Solid Fuel Fired
2. Stoker Fired Boilers
 Pulverized Fuel Boilers
 Fluidized Bed Combustion (FBC) Boilers
3. Oil Fired
4. Gas Fired Boilers

 Based on the draught system:

1. Natural Draught
2. Mechanical Draught
 Forced Draught System
 Induced Draught System
 Balanced Draught System

Water Tube Boiler Fire Tube Boiler

The layout of the Boiler and Location of Various Equipment:

An arrangement of these is shown
1. Economizer
2. Boiler Drum
3. Downcomers
4. Water walls
5. Water wall plates (used for low-pressure
boilers)
6. Primary superheater
7. Platen superheater
8. Final Superheater
9. Reheater
10. Burner
11. Ignitors

17
Basic Function of the equipments:

1. Economizer

In boilers, economizers are generally heat exchangers which are designed

to exchange heat with the fluid, generally water. Economizers are provided in the
Boilers to improve the efficiency of the Boiler by extracting the heat from flue gases
and adding it as either sensible heat alone or sensible heat and latent heat to the feed
water before the water enters the evaporating surface of the Boiler.
An economizer consists of a large number of closely spaced parallel steel tubes
connected by headers and drums. The feed water flows through the tubes and the
flue gases flow outside. A part of the heat of flue gases is transferred to feed water,
thus raising the temperature of the latter.

2. Boiler Drum

It is a reservoir of water/steam at the upper end of the tube of water. Drums keep
the steam produced in the water tubes and act as a phase separator for mixed
steam/water.
In a sub-critical re-circulation boiler, the drum plays an important functional role.
The functions of the drum are:
 Separate steam from water.
 Act as a water storage tank and a proper place
for water supply so that water can circulate.
 The proper place for Boiler water treatment so
that boiler water quality can be maintained.
 Any necessary Blow down for reduction of boiler
water concentration (silica and sludge) is usually
done from the drum.

18
 3. Riser and Downcomer

The function of the downcomer is to supply water from the drum to the ring header
at the bottom of the furnace, riser tubes supply water from the ring header to left,
right, front and rear headers at top of the furnace which is again connected to the
drum top. Downcomers are outside the furnace as their function is only to supply
water at the ring header.
Riser tubes are inside the furnace so that heat transfer can take place and
water will flow in an upward direction due to the density difference between hot and
cold water. For maximum heat transfer, it is always preferred to expose the maximum
area of the system. So, increasing the no of tubes will increase the total surface area
inside the furnace hence maximum heat transfer.
At different loads, risers and downcomers may change their property. There is
a natural circulation of water in the riser and downcomers due to different densities
of the water and the steam-water mixture. As the heat is supplied, the steam is
generated in the risers; due to this density of the steam and water mixture is greater
in the riser than in the down comer and a continuous flow of water takes place.

Fig. Riser and Downcomer

19
 4. Boiler Furnace

A boiler furnace is that space under or adjacent to a boiler in which fuel is burned
and from which the combustion products pass into the boiler proper. It provides a
chamber in which the combustion reaction can be isolated and confined so that the
reaction remains a controlled force. In addition, it provides support or enclosure for
the firing equipment. The boiler furnace walls are made up of refractory materials
such as clay, silica, kaolin, etc. These materials have the property to resist changes
in shape, weight, or physical properties at high temperatures.

5. Burners

The burner is the key equipment component for combustion control systems,
providing the heat required for a boiler to convert water into steam. Initially during
the starting up oil is fired when the coal used is of inferior quality. Light Diesel Oil
(LDO) is used for the initiation of ignition for pulverized coal. The LDO is charged into
the furnace through the oil burners. The burning capacity of the pulverized coal
increases. Heavy fuel oil passes through the
pumping and heating unit to reduce the
viscosity as required for firing.
Regardless of the type of fuel used, the
burner must perform these functions:

1. Deliver fuel to the combustion chamber

2. Deliver air to the combustion chamber

3. Mix the fuel and air

4. Ignite and burn the mixture

5. Remove the products of combustion

20
 6. Superheater

The superheater is used in boilers to increase the temperature of the steam above the
saturation temperature. The dry saturated steam generated in the boiler is passed
through a set of tubes placed in the path of the flue gases, in which it will be heated
further by the hot gas to increase its temperature about the saturation temperature.
This increases the overall efficiency of the plant. A superheater consists of groups of
tubes made up of special alloy steels such as chromium-molybdenum.

7. Reheater

A reheater has derived its name from reheating the steam at a stage after expansion
to certain pressure (not till the condenser pressure). The main objective of the
reheater is to increase the dryness fraction (moisture content of the steam at the last
blade of the turbine). But due to this additional work also is extracted from the turbine
due to two-stage expansion. So, work output increases. But also the steam uses extra
heat to raise its pressure in the second stage after the first expansion. So, an increase
or decrease in efficiency is dependent on which of the above is more.

8. Air Pre-heater

The air preheater is an accessory that recovers the heat in the exhaust gas by heating
the air supplied to the furnace of the boiler. Supplying preheated air into the furnace
produces a high furnace temperature and accelerates the combustion of the fuel.
Thus the thermal efficiency of the plant will be increased. The advantages of air pre-
heater are increasing the steam generation rate, better combustion with less soot,
smoke, and ash, and low-grade fuels can be used.

Depending upon the method of heat transfer, they are of two types:
Recuperative type and Regenerative type.
The recuperative type consists of a group of steel tubes. The flue gases are passed
through the tubes while the air flows externally to the tubes. The heat of flue gases is
transferred to the air.
The regenerative type consists of a slowly moving drum made up of corrugated metal
plates. The flue gases continuously flow on one side of the drum and air on the other
side. This action permits the transference of heat of flue gases to the air being
supplied to the furnace for coal combustion.

21
 9. Cyclone Separator

Cyclone separators are separation devices that use the

principle of inertia to remove particulate matter from
flue gases.
Cyclone separators are generally able to remove
somewhere between 50-99% of all particulate matter
in the flue gas. How well the cyclone separators are
able to remove this matter depends largely on particle
size.
So, it separates the coal from the air when it entering
into the boiler. It is a conical-shaped instrument. It is
a very important instrument for the combustion of coal
if air comes mixed with coal; it can cause a bad effect
on the combustion process.

10. Electro Static Precipitator

ESP is a device that filters out particles such as

fumes, fly ash, and suspended dirt from the gas
stream before releasing them out of the chimney.
The key principle of the devices is to use a very high
voltage negative charged electrostatic force.
The flue gas emitted from the boiler furnace
contains suspended impurities. Thus, the gas can’t
be directly exhausted into the atmosphere because
of government norms. ESP is used to separate the
particles from the flue gases. It uses the
mechanism of high discharge. The flue gases pass
between two plates. They are charged with high
voltage DC. This high voltage charges the particles in the flue gas, and they get
accumulated on the plates. Now the plates are vibrated so the particles can fall and
get collected at the bottom.

22
 11. Feeder

A feeder is a speed control device for coal. It controlled the speed of the coal going
towards the coal mills. The incoming coal from the secondary crusher house is
stored temporarily in the bunkers. After that, it comes towards the feeders. Then
into the feeder, a rotating shaft is used to control the rate of coal going towards the
combustion chamber.

12. Soot Blower

A soot blower blasts air, steam, or water (or a

combination) to remove soot and ash from the
interior walls of the boiler heating surfaces. The soot
blower can be set to operate automatically at timed
intervals or be controlled manually. It is done by
shooting super-heated steam into the pipe with high
velocity & pressure. A soot blower can minimize the
risk of soot fire. Such a fire can cause hotspots to
appear in the furnace tubes, which can then reach
a temperature to weaken the structural integrity of
the tubes. It is done by shooting super-heated steam
into the pipe with high velocity and pressure. There
is an Orifice Plate placed into it for measuring the
pressure.

13. Hopper

A hopper is a water-filled steel tank with a protective lining used to collect bottom ash
and slag from a steam-generating boiler. It can be in the shape of a V, or it can be a
multileveled, flat-bottom type. The ash-hopper lining is made of brick or refractory,
or a combination of the two, and is used to protect the ash-hopper plate. The slag,
ash, and slurry mix content can be very corrosive to the lining materials because of
the surface porosity of the lining material. The slag, ash, and slurry can penetrate the
surface of the lining and cause its deterioration.

23
 14. Hydrastep

Hydrastep is an electronic gauging system that

determines and displays both the water and steam
level within the steam drum. It is designed to give
outstanding reliability, with unparalleled fault
tolerance and a fail-safe design.

15. Stack

Stack is equipment to take out the product of combustion at a sufficiently high

elevation to prevent disturbance caused by ash, low flying smoke, and soot and to
disperse the combustion gases.

b) SAFETY VALVE

A safety valve is used to guard the boiler against

the excessive-high pressure of steam inside the
drum. If the pressure of steam in the boiler drum
exceeds the working pressure then the safety valve
allows the blow-off of the excess quantity of steam
into the atmosphere. Thus the pressure of steam
in the drum falls. The escape of steam makes an
audio noise to warm the boiler attendant. It is a
part of the bigger set named Pressure Safety Valves
(PRV) or Pressure Relief Valve. The other parts of
the set are named relief valves, safety relief valves,
low-pressure safety valves, and vacuum pressure
safety valves.

24
 c) STEAM TURBINE

A Steam Turbine is a mechanical device that extracts thermal energy from pressurized
steam and transforms it into mechanical work. Because the turbine generates rotary
motion, it is particularly suited to driving electrical generators. Sir Charles A. Parsons
invented the first modern turbine, a reaction turbine, in 1884.

The basic parts of stream turbines are blades and rotors. Due to its greater thermal
efficiency and higher power-to-weight ratio, it was replaced by a reciprocating piston
steam engine. Because the turbine generates rotary motion, it is particularly suited
to be used to drive an electrical generator – about 80% of all electricity generation in
the world is by use of steam turbines.

 Types

a) Blade and stage design

Turbine blades are of two basic types, blades, and nozzles. A turbine
composed of blades alternating with fixed nozzles is called an impulse
turbine. A turbine composed of moving nozzles alternating with fixed
nozzles is called a reaction turbine.

b) Steam Supply and Exhaust Conditions

These types include condensing, noncondensing, reheat, extraction, and

induction turbines.

 Condensing Turbine: - The condensing turbines take high-pressure

steam, expand it in turbine nozzles and blades, and exhaust it to a
condenser at lower than atmospheric pressure. It is principally used
when power must be generated with minimum steam consumption. The
condensing turbine may also have bleed points (uncontrolled extractions)
to satisfy steam demands at medium intermediate pressures.

25
 Noncondensing turbine: - In noncondensing turbines, steam leaves the
turbine at above atmospheric pressure and is then used for heating or
other required processes before being returned as water to the boiler.
Noncondensing turbines are therefore an economical means of
generating power (cogeneration) when substantial amounts of heating or
process steam are already needed.

 Reheat Turbines: - In a reheat turbine, steam flow exits from a high-

pressure section of the turbine and is returned to the boiler where
additional superheat is added. The steam then goes back into an
intermediate pressure section of the turbine and continues its expansion.

 Extraction Turbines: - Extraction-type turbines are common in all

applications. In some applications, when required, steam can be
extracted from the turbine before steam flows through the last stage,
named extraction turbine. It improves overall cycle efficiency. Extraction
flows may be controlled with a valve or left uncontrolled.

26
 c) Casing or shaft arrangements

These arrangements include single casing, tandem compound, and cross

compound turbines.
A single casing turbine has all its stages in one casing and all are
connected to a common drive shaft. Steam is fed into the high-pressure
turbine and expands through the turbine as the rotor blades become bigger
until exiting and passing onto the next stage.
A tandem compound turbine is a multi-cylinder steam-turbine
arrangement in which several machines running on the same shaft are
connected in series to a generator. These are used where two or more
casings are directly coupled together to drive a single generator.
In a cross-compound steam turbine, the superheated steam enters the
high-pressure stage, expanding through the rotor blades before exiting to
the intermediate pressure stage, both turbine rotors being on the same
drive shaft.

d) Impulse Turbine and Impulse Turbine

In an impulse turbine, the steam flows through the nozzle and strikes the moving
blades. Steam strikes the buckets with kinetic energy. During the flow of steam
through moving blades, its pressure remains constant. The steam may or may not be
admitted to the whole circumference. The blades of the impulse turbine are
symmetrical. While gliding over the
blades the relative velocity of steam
remains constant. For the same power
developed, the number of stages
required is less. The direction of
steam flow is radial to the direction of
the turbine wheel. It is suitable for low
discharge.

In the reaction turbine, first, the

steam flows through the guide
mechanism and then flows through
the moving blades. The steam glides
over the moving blades with both
pressure and kinetic energy. During
the flow of steam through moving
blades, its pressure reduces. The
steam must be admitted over the
whole circumference. The blades of the reaction turbine are not symmetrical. In a
reaction turbine, while gliding over the blades the relative velocity of steam increases.
For the same power developed, the number of stages required is more. The direction
of steam flow is radial and axial to the turbine wheel. It is suitable for medium and
high discharge.

27
 d) ELECTRIC GENERATOR

Electric generators, also known as dynamos is an electric machine that converts

mechanical energy into electrical energy. The electric generator’s mechanical energy
is usually provided by steam turbines, gas turbines, and wind turbines. Electrical
generators provide nearly all the power that is required for electric power grids.
Generators use the mechanical energy supplied to them to force the movement of
electric charges present in the wire of its windings through an external electric circuit.
This flow of electrons constitutes the output electric current supplied by the
generator.

 Types of Electric Generators

The classification of electric generators depends on the type of electrical energy that
is produced, which is either direct current or alternating current.

 AC generators: - AC generators are known as single-phase generators and are

limited to 25 kW.
 DC generators: - These generators are divided into three categories, and they
are shunt, series, and compound-wound. Shunt generators are used in battery
chargers. Series generators are used in street lights. While most of the DC
generators are compound-wound.

 Major Parts of an Electric Generator

The two main parts of a generator or motor can be described in either mechanical or
electrical terms:

 Mechanical:

 Rotor: The rotating, cylindrical part of an electrical machine, placed

inside the stator with a narrow air gap in between to allow for smooth
rotation.

 Stator: The stationary part of an electrical machine. There are many

windings inside the stator.

28
 Electrical:

 Armature: The power-producing component of an electrical machine. In

a generator, alternator, or dynamo the armature windings generate the
electrical current. The armature can be on either the rotor or the stator.

 Field: The magnetic field component of an electrical machine. The

magnetic field of the dynamo or alternator can be provided by either
electromagnet or permanent magnets mounted on either the rotor or the
stator.

Fig. Stator

Fig. Rotor

29
 POWER GENERATION CYCLE AT BBGS

Heat for the power cycle of CESC, Budge Budge Generating Station Unit No. 1 & 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, and Single Reheat Drum
Type Boiler. However, during Light-up LDO is used for support and stabilization. For
units 1 & 2 each unit has a 250 MW Rolls-Parsons turbo-generator, an Acc-Babcock
make P.F boiler and unit 3 has a 250 MW BHEL make turbo-generator & P.F 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 fans (F.D), three induced draft
fans (I.D) for unit 1&2 & two induced draft fans (I.D) for unit 3, two primary air fans
(P.A), one primary tubular air heater, two secondary tubular air heaters for unit 1 &
2 and two rotary air heater for unit 3, six Ball & Race type pulverizers, six Volumetric
coal feeders for unit 1 & 2 and five Bowl type pulverizers, 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 requirement can be achieved by burning
LDO alone.

The main turbine is a Tandem Compounded, Three-Cylinder, Single Reheat,

Double Flow LP cylinder, Condensing Type with uncontrolled Extraction.
The turbine drives a 250MW, 3 phase alternator with a hydrogen cooled rotor and
stator core and DM water-cooled stator windings (unit 1 & 2) at a speed of 3000rpm.
The turbine shafts and generator are rigidly coupled together. The generator field is
excited from a static system.
The turbine utilizes electro-hydraulic controls. The start-up, shut-down, and loading
of the turbine can be achieved automatically. The turbine throttle pressure is 146
kg/cm2 (abs), the main steam 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 H.P-L.P turbine bypass system has been provided.

Each unit is provided with a reserve feed water tank (RFW tank). It holds a supply of
demineralized water from condensate storage tanks through condensate transfer
pumps. RFW tank provides the means of filling the de-aerator and condenser and
maintains 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 tank receives the surplus condensate when there is an excess in the system.
2 separate condensate storage tanks, interconnected to each other, are provided for
both the units. Condensate storage tanks receive demineralized water from the DM
plant. Condensate storage tanks provide water supply for boiler filling, RFW tank
makeup, deaerator filling, cooling water head tank make-up, condenser emergency
makeup, stator cooling make-up, and chemical feed system for both the units through
a set of pumps.

30
Fig. Schematic diagram of BBGS

31
FOUR BASIC CYCLES ON WHICH A POWER GENERATING PLANT OPERATES

Any COAL FIRED Power Generating Plant operates on the following four basic cycles:

1. Coal & Ash cycle

2. Air & Flue Gas cycle

3. Feed Water & Steam cycle

4. Cooling Water cycle

NOTE:

Of all the above four mentioned cycles, the first two i.e. COAL & ASH CYCLE & AIR
& FLUE GAS CYCLE are called OPEN CYCLES.

The next i.e. WATER & STEAM CYCLE is a CLOSED CYCLE.

The fourth and the last mentioned cycle i.e. the COOLING WATER CYCLE occurs in
the condenser.

 Coal and Ash Cycle:

The primary fuels for these units are bituminous coal supplied from coal mines. The
coal handling plant has been designed such that 960 MTH coal of (-) 300mm size, is
received at sites from coal mines. Coal is unloaded in the yard either by roadside
wagon tipplers or in the track hopper through bottom discharge wagons. The coal is
crushed in two stages before feeding into the boiler bunkers. In the first stage, it is
crushed to (-) - 26 - 100mm size by primary crushers and finally to (-) 200mm size by
secondary crushers. 2*100% conveyors are provided to convey coal from the yard to
boiler bunkers.

LDO and HFO/LSHS are used as fuel oil. LDO will be used during the light-up of
boilers, HFO/LSHS will be 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 into a Bottom Ash Removal system & Fly
Ash Removal System.
The fly ash removal system is continuous whereas the bottom ash removal system is
intermittent and carried out once per shift.
The bottom ash removal system is a wet system. The bottom ash of each unit is
crushed and is hydraulically conveyed in the form of slurry from the bottom ash
hopper to dewatering bins/Ash tanks. Decanted water separated from the bins is
32
further re-circulated in the system. Collected bottom ash at the bins is removed by
trucks.

Fly ash collected in ESP and air heater hoppers is removed in dry form by a dense
phase pneumatic conveying system in two stages. In the first stage, the fly ash
collected in the hoppers is pneumatically conveyed with compressed conveying air to
Intermediate Surge Hoppers. In the 2nd stage, the dry fly ash is further conveyed
from Intermediate Surge Hoppers to Fly Ash Silos by P.D pumps. Ash collected in Fly
Ash Silos is removed by trucks through a rotary unloader. A HCSS system has been
incorporated at BBGS with technology from the Netherlands to handle the fly ash in
the form of thick slurry using special pumps and transport the same to a distant
location. This 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 Intermediate Surge
Hoppers to trucks through the unloading system in case of emergency.
A majority of the fly ash is at present exported to Bangladesh through barges for their
use in cement plants.

 Air and Flue Gas Cycle:

The air is drawn from the atmosphere by a forced draft fan or an induced draft fan,
through the air preheater, in which it is heated by the heat of flue gases passing to
the chimney and then admitted to the furnaces. The flue gas after passing through
the boiler tubes and superheater tubes is drawn by the induced draft fan through a
dust collector (or precipitator), economizer, and air pre-heater and finally exhausted
into the atmosphere through the chimney.
Fig. below represents schematically air and flue gas path flow.

33
  Feed Water and Steam Cycle:

Feed water is taken from a deaerated feed water storage tank by motor-driven feed
water pumps and discharged through 2 stages of high-pressure regenerative feed
water - 27 - heating and flue gas economizer feed water heater into boiler drum. Boiler
water is in natural circulation 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 superheater sections of the boiler and intermediate 2
stages of desuperheating stations. Thereafter, the steam is expanded through the
high-pressure cylinder of the tandem compound generator. 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 removes latent heat from the low-pressure turbine exhaust steam entering
the condenser and transports this waste heat to the Induced draft cooling tower where
it is finally dissipated into the atmosphere. The condensate from the condenser Hot-
well has again transported to the de-aerator by motor-driven Condensate Extraction
pumps through 4 stages of low pressure regenerative feed-water heating system.

The turbine includes 2 stages of feed water pumping (boiler feed pumps and
condensate extraction pumps), composed of 7 stages of regenerative feed water
heating by turbine blade steam i.e. 2 high pressure regenerative closed feed water
heaters at the boiler feed pump discharge, 4 low pressure closed feed water heaters
at the condensate extraction pump discharge and 1 direct contact heater (de-aerator).
All the feed water heaters are of horizontal type. The 2 lowest pressure heaters LPH-
1 & LPH-2 are located in 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 heaters drains are cascaded to the condenser through the
condenser flash box. The emergency drain of each feed-water heater (except LPH-4)
is cascaded to the condenser through the condenser drain flash box. All heater drains
are gravity type except LPH-3 drain, which is handled by a 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), 2 intermediate stages of the
intermediate pressure turbine, 1 from the exhaust of the intermediate pressure
turbine, and 3 intermediate stages of the low-pressure turbine.

Condensate is extracted from the condenser hot well and pumped through the turbine
gland steam condenser, external drain cooler, and 4 progressive stages of low-
pressure regenerative feed water heating and sprayed into a direct contact deaerating
heater. 2*100% capacity vertical condensate extraction pumps have been provided
for this purpose.

Provision is kept for condensate by-passing of LP heaters in 2 groups, in the event of

heater flooding so that turbine is protected from water ingress. LP heaters-1 & 2 and
drain cooler as one group and LP heaters 3&4 as the 2nd group.

LP heater-2 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
34
similarly cascaded to LP heater-3 while LP heater-3 normal drain is pumped forward
by a 1*100% drain pump via control valves to LP heater-3 main condensate outlet.

Deaerated feed water from the de-aerator feed water storage tank is pumped to the
boiler flue gas economizer by 2*100% capacity boiler feed pumps through HP heaters-
6&7. Each boiler feed pump consists of a booster pump and the main pump. The
suction side of the booster pump is connected to the de-aerator storage tank and
delivered to the main suction pump. Each HP heater can be bypassed individually
from the feed-water side in case of heater flooding. HP heater-7 drain is cascaded to
HP heater-6 while HP heater-6 is led to the de-aerator.
Initial air extraction from the condenser and steady vacuum inside the condenser is
achieved by 2 motor-driven, water-sealed, air extraction pumps. During the normal
operation of the plant, a vacuum is maintained by one of the pumps.
Fig. below represents schematically the feed water heating system of BBGS.

35
  Cooling Water Cycle:

The twin flow LP turbine, LP 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 to counteract
the corrosive qualities of the cooling water in addition to sacrificial magnesium
anodes, provided in each water box, which gives backup corrosion protection using
an electrolytic reaction between similar metals.

The condenser for each unit is supplied with circulating water from the cooling tower
basin by 2*50% CW pumps 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 are cross-connected.

The plant equipment cooling water system meets the requirement of the auxiliary
coolers, other than the main condenser. The whole system is subdivided into 2 sub-
systems:
The Primary Circuit and the Secondary Circuit.
The primary circuit uses DM water and is of a closed-loop type. This is employed to
pick up the heat load from various auxiliary coolers under T.G & boiler packages and
to reject the same to a set of plate heat exchangers.
The open-loop secondary circuit uses clarified water and is employed to pick up the
heat from the above plate heat exchangers and to reject the same to the main
circulating water return header and ultimately to cooling towers. Requirement of
cooling water to
T.G oil coolers are met through auxiliary cooling water pumps. The auxiliary cooling
water headers for units 1 & 2 are cross- S- connected.
Fig. below represents schematically the cooling water system of BBGS.

36
  DM PLANT

Boilers require clean and soft water for longer life and better efficiency. However, the
source of boiler feed water is generally a river or a lake that contains suspended and
dissolved impurities, dissolved gases, etc. suspended matter in the form of colloid and
some organic and inorganic impurities which make it necessary for chemical and
mechanical treatment in a water treatment plant before being used as clarified and
filtered water. These impurities are of two kinds, volatile & non-volatile.

Impurities in raw water input to the plant generally consist of Ca and Mg salts which
impart hardness to the water. Hardness in the makeup of the boiler will form deposits
which will lead to overheating and failure of the tubes. Therefore, it is very important
that water is first purified and softened by chemical treatment and then delivered to
the boiler.

The water from the source or supply is first stored in storage tanks. The suspended
impurities are removed through sedimentation, coagulation, and filtration. Dissolved
gases are removed by aeration and degasification. The water is then softened by
removing temporary and permanent hardness through a different chemical process.
The pure and soft water thus available is fed to the boiler for steam generation. This
treatment is done in the DM Plant or De-mineralization plant.

Process of DM Plant:

The basic DM plant must have a minimum of two resin columns, Cations, and Anions.
The cation unit contains resins that are in H+ form and the anion resins in the service
cycle are in OH- form. In the filtered raw water, when passed through a two-bed DM
plant, cation resins exchange all cations in water and the salts are converted to
respective acids. This acidic water is passed through the anion resins, which
exchange the anions and pure water is achieved. The water coming out of the Anion
unit generally has TDS less than 40PPM & hardness less than 1PPM.

Degasser tower- If the alkalinity in raw water is more, then the degasser tower is used
to mechanically remove the alkalinity. This is done by passing the water after the
cation unit into the tower filled with the media and the air is passed by using the
blower so that the water is scrubbed by air and the free carbon dioxide is removed
through the vent resulting in alkalinity reduction at the outlet.

Mixed bed ion exchanger- Some of the applications like pharma, high-pressure boilers,
etc, require superior quality than those available in basic DM plants. In such cases,
the mixed bed (MB) is used to further polish the water. The MB unit consists of 2
types of resins, cations, and anions in the same column. The resins are separated by
water during regeneration and mixed with air for the service cycle. The TDS after MB
is generally less than 1PPM.

37
Regeneration:

While the supply of exchangeable ions with the resin is exhausted, the quality of
treated water from the resin deteriorates & the resin requires regeneration. Strong
Acidic Cation (SAC) is regenerated with acid.
HCl is stored in BAT (Bulk Acid Tank). Weak Base Anion (WBA) & Strong Base Anion
(SBA) is regenerated with NaOH, which is stored in BCT (Bulk Caustic Tank).

SAC:
RNa + HCL → RH + NaCl
R2 + H2SO4 → 2RH+ MgS04

SBA:
RCl + NaOH → R0H + NaCl

WBA:
RHCl + NaOH → R + H2O + H2O

Fig. DM WATER PLANT of BBGS.

38
  COAL HANDLING PLANT

Coal is the primary fuel. The Source of coal varies from thermal power plants of CESC
as per the design parameters of the individual boiler.

Coal is used as fuel because of several reasons –

 Abundantly available in India

 Low cost
 Technology for power generation well developed
 Easy to handle transport & store

A good coal handling plant must perform two duties unloading the coal from railway
wagons as fast as possible and then transferring the unloaded coal either to coal
bunkers or in the stockpiles for storage and then feeding the coal from the stockpiles
to the bunkers when the railway wagons are not available.

 Requirement of coal daily in BBGS

Number of wagons required = 3.

Number of wagons required per unit=1.
Gross weight = 86 tons (approx).
Tear Weight=24 tons (approx)

 TRANSMISSION OF COAL:

Coal comes to BBGS in two types of wagon. They are:

1) BOB RM
2) BOXN

Coal comes in the BOBRM wagon are unloaded in the track hopper region. It is stored
in the hopper. According to the requirement we take coal with the help of
RDM in the belt conveyor 101a and 101b.

Coal comes in the BOXN wagon are unloaded in the wagon tippler region. The coal
comes directly to the belt conveyers 1c and 1d.

The coal from belt conveyers 1c, 1d and 101a, 101b comes to belt conveyers 1a and
1b. Then it passes through the transferring point 1and reversible belt feeder 1 and 2
to the belt conveyer 2a and 2b. It enters the primary crusher. The coal has a size of -
31 - 300mm. Here it is crushed to a size of 100mm with the help of a rotary breaker.

The coal passes to the reversible belt conveyers 1a and 1b. Then it divides into two
paths.
The paths are:
1) To the stack yard
2) To the secondary crusher
If it goes to the stack yard the coal passes through the belt conveyer 8a and 8b. Then
it passes through the transfer point 10a to belt conveyer 10a and goes to the stacker.

39
The stacker goes through the intermediate belt conveyer and boom conveyor and falls
in piles 1 and 2 where it is stored. According to the requirement of the coal, the coal
from the stack yard through the belt conveyors 11a and 11b to belt conveyors 12a
and 12b go across the primary crusher without any crushing with the help of the belt
conveyer 3a and 3b to the secondary crusher. In the secondary crusher, it is crushed
to 25mm with help of the screen crusher and goes along the belt conveyor 4a and 4b
to the bunker. The coal from the bunker goes to the coal mill where it is crushed to a
powder form the size of 70 microns then with the help of a PA fan it is sent to the
furnace.

Fig. Coal Handling System of BBGS

 Major equipment for coal handling

1) Wagon tippler - In this region the BOXN wagon is

unloaded with the help of mechanical and hydraulic
equipment. In BBGS there are two wagons tipplers are
there. In the wagon tippler, 1 hydraulic equipment is
used in the wagon tippler 2 mechanical equipment is
used. Coal cannot be stored here.

40
2) Track hopper- In this region, the BOBRM wagon is unloaded. 18 bogies can be
unloaded at a time. Here coal can be stored.

3) Coal crusher-It is used to crush the coal to a desirable size so that it can be
completely combustible in the furnace. Coal is crushed in three steps in
BBGS.

4) Rotary breaker- In the primary crusher section coal is

crushed to 100mm from 300mm is done by the rotary breaker.
It has three chutes. The main chute passes the coal after
crushing, the bypass chute passes the coal which is not required
to crush and the third chute is used to pass the reject boulder.

5) Screen crusher- In the secondary crusher section coal is crushed to 25mm from
100mm is done by a screen crusher. Then from the screen crusher coal goes to the
coal mill where it is powdered to a size of 70 microns.

6) Coal mill- Here the coal is crushed to a powder of size 70 micron. Then with the
help of a PA fan, it is inserted into the furnace.

7) Tripper trolley- This is used to insert coal properly into the bunker from the belt
conveyor.

8) RDM (Rotary discharge machine) - It is used to take the stored coal from the track
hopper to the belt conveyors 101a and101b.

41
  ASH HANDLING PLANT IN BBGS

The main by-product that is formed during the combustion of coal is ash. Ash is
mainly of two types:
1) Bottom ash
2) Fly ash

Bottom ash is mixed with water in the hopper and then passed to dewater mill where
it is stored and ash is separated from the water. The water from the dewater mill is
passed to the settling tank here also the separation of water and ash takes place. A
small amount of water from dewater mill also goes to decant tank and passes directly
to the settling tank. The water then goes to the surge tank where again filtering takes
place and finally the water is sent to the hopper where it is mixed with ash. Ash
collected is transported out through an open damper for different uses. Mainly this
ash is sent to the cement industry.
Fly ash collected with the help of ESP is sent to SILO after cooling. The ash is
transported in a closed damper. In BBGS portion of this ash send to a field at a
distance of 3.5 km with the help of a booster and geho pump.

ELECTRICAL AND INSTRUMENTATION

 SWITCHYARD

A switchyard is a point in the power network

where transmission lines and distribution
feeders or generating units are
connected through circuit breakers and
other switchgear via bus bars and
transformers. The switchyard acts as an
interface between the power plant electrical
system and the electrical grid. The main
function of the switchyard is to transmit &
distribute the power at an incoming voltage

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from the generating station and provide facilities for switching with the help of
switchgear.

 SWITCHGEAR

The apparatus used for switching, controlling, and protecting the electrical circuits
and equipment is known as switchgear. Eg. Circuit breakers, fuses, switches, relays,
etc.

ESSENTIAL FEATURE OF SWITCHGEAR:

o Complete reliability:
When a fault occurs on any part of the system, the switchgear must operate to isolate
the faulty section from the remaining circuit.
o Certain discrimination:
It should be able to completely discriminate between the faulty and healthy sections.
When a fault occurs, it should isolate the faulty part without affecting the healthy
portion.
o Quick operation:
If the fault is not cleared quickly, it is likely to spread into the healthy parts, thus
endangering the complete shutdown of the system.
o Provision for manual control:
In case the electrical control fails, provision must be kept for manual control for the
required operation.
o Provision for instruments:
Instruments in the form of an ammeter or voltmeter on the unit itself or the necessary
current and voltage transformers for connecting to the main switchboard or a
separate instrument panel should be provided.

 PROGRAMMABLE LOGIC CONTROLLERS (PLC)

PLCs are used to control a process or a machine

in industries. They were developed to replace
hard-wired relay-based controls and improve
production, reliability, and safety. A typical PLC
system consists of a CPU or processing unit, a
power supply, a memory unit, an input, and
output interface, and a communication
interface for data exchange(between field
devices or PC).

PLCs need to be programmed based on their

application. They require an additional Human
Machine Interface to interact with the operator
and alarm reporting. Various communication
protocols such as Modbus, Profibus, Ethernet
TCP/IP, etc are also possible using additional hardware.

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PLC APPLICATION AT BBGS:

PLC is used in substations numbered from 1 to 6, divided into 4 zones.

The different substations are:
Zone 1:
Substation 1- MCC & Control desk I/ O’s and Oil storage system.
From nodes 1 to 8.
Zone 2:
Substation 2- MCC2 Stacker reclaimer I/ O. From nodes 11 to 13.
Zone 3:
Substation 3 & 4- Wagon Tripler & MCC3 & MCC4, paddle feeder I/Os. From nodes
17 to 20.
Zone 4:
Substation 5 & 6- Bunker level. Nodes 21 and 22.

 DISTRIBUTED CONTROL SYSTEM

A distributed control system is a collection of multiple control components distributed

throughout a plant. Unlike programmable logic controllers, DCS is used to control an
entire plant or a process that is continuous or batch-oriented. They are highly
scalable and can be used to control complex processes that require a lot of interaction
between multiple controllers.

A distributed control system is a collection of multiple redundant controllers, IO

modules, engineering stations, operator stations, historians, and communication
systems. They are capable of handling thousands of IOs at a reliable speed. They are
widely used in petrochemical industries, refineries, paper and pulp industries, power
plants, pharmaceutical manufacturing, and other areas where manufacturing and
process plants.

Fig. DCS Architecture

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 CONCLUSION
From the above-stated facts, we can get an in depth view of what a power
plant is, what it looks like, the various components in a power plant,
etc. This was organized by CESC, Kolkata 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. The faculty members have been extremely
helpful in explaining and clarifying our issues.

CESC’s environmental management system focuses on continuous

improvement and upgradation 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.

This training thus has been extremely helpful to me and I would

cordially thank everyone involved with me concerning the training. I am
grateful to CESC Limited for organising this vocational training.

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