Presentation on

Balance of Plants (BOP) in Thermal Power Plants

Fuel Handling Plant Ash Handling Plant Plant Water Systems & Cooling Towers Compressed Air Systems

A Brief Profile of Budge Budge Generating Station, CESC Limited

• Location : Pujali, Budge Budge, 24 Prgs(S), W.B. • Capacity : 3 X 250 MW Sub-critical Units • Coal source : ECL, BCCL, MCL, ICML & Indonesian

Coal • Water source : Raw water from river Ganges • YTD Performance Figures (as on 12.03.2013) a) PLF : 88.02% b) AVF : 93.52% c) Aux : 8.35% d) Coal Figure : 0.613 Kg/KW-Hr e) Oil Figure : 0.294 ml/KW-Hr

Main Objectives of Fuel Handling Plant

• To Meet The Generation target

• Monitoring health of Plant & Equipments.

• Quantity & Quality control of Fuel

• Maintaining High level of safety

• Efficient management of Environment

• Optimization of cost

Steps of LDO Unloading

• Initial oil level of desired tank for unloading is taken.

• Desired tank is lined up with the unloading pipe line.

• Dip stick measurement reading of the burge oil level from all compartment is taken.

• Unloading line is lined up with the unloading line of burge by connecting flexible hose.

• Unloading of oil starts by running unloading pump in the burge.

• After completion of unloading final dip stick reading is taken.

• Final oil level of loading tank is taken.

• Flexible hose is disconnected from the pipe line of burge.

• Loading tank supply valve is made shut.

Track Hopper

Wagon Tippler

Stacker-Reclaimer

Reclaim Hopper

Steps of BOBR Unloading

• Brake van is de-coupled after arrival at BBGS inplant yard.

• Railway engine places last 18 wagons (1st lot) over Track Hopper via In-motion weigh bridge.

• Wagons are unloaded one by one by opening the bottom doors after connecting air hose with nipple of servo cylinder and opening air valve.

• Bottom doors are closed after getting full empty of wagon.

• During 1st lot unloading Railway engine is decoupled and shunted at the other end of the rake via bypass line.

• After that Brake van reversal is done by our own shunting engine.

• Railway engine places the next lot after completion of 1st lot and unloading is done in similar way.

• After unloading of all wagons empty rake formation is done and rake is released.

Line-3

Line-2

Tippler Bypass

Line-4

Line-1

WT-1

Track Hopper

WT-2

Track Hopper Bypass Line

Tippler Bypass

10 5

5

15

14

Track layout of BBGS

Placement of BOBR rake at Track Hopper

Wagon Tippler

Rota side Tippler Rope driven Tippler

Specification of Wagon Tipplers

Wagon Tippler-1 Wagon Tippler-2

Type Rotaside Wagon Tippler Gear Sector

Rope driven weighing type

Make M/S Elecon Engg. Co. Ltd. M/S TRF Limited

Motor rating 90 kw 63 kw

Maximum Gross Weight

110 Ton 150 Ton

Tippling time per cycle (sec)

Weighing gross: 5 Tippling: 49 Pause: 5 Return: 49 Weighing tare 5 Total time: 113

Weigh full wagon: 15 Tippling wagon: 65 Pause: 10 Return: 65 Weigh empty wagon: 15 Total Time: 180

Tips/Hr 18 10

Max. angle of rotation

160 degrees 150 degrees

Wagon clamping type

Hydraulic Mechanical

Steps of BOXN unloading

• Brake van is de-coupled after arrival at BBGS inplant yard.

• Inspection for Buldge wagon(If any)

• 15 wagons placed in WT-2 by inplant railway shunting engine

• 12 Wagons placed in WT-1 by BHEL LOCO.

• Wagon placed in WT table is detached from other wagons

• Wooden edges are placed under the wheels to prevent rolling from table.

• After field checking Tip clearance is given to WT Control room.

• Tip command is given by control room operator.

• Wooden edges are removed after completion of tippling.

• Empty wagon is replaced by loaded wagon.

• Tippling is carried out following the above steps.

• Shunting operation is done by SAC for WT-1 but the same is done by the Inplant shunting engine (Railway).

Initiatives and Improvements • BOBR Brake van reversal by our own shunting Engine.

• Reduction of rake formation time by deploying Ex-serviceman of Railways.

• Full engagement of Inplant shunting Engine for BOXN unloading.

• Reduction of time for lot placement at both WTs and empty wagons removal by using two shunting engines.

• Introduction of Rock Breakers at WT-2 for lump breaking.

• Introduction of another BOBCAT for boulder removal from T/H gratings and WT area.

• Introduction of dry fog system at WTs to restrict the fugitive emission during BOXN unloading.

• Introduction of CCTV camera at strategic location for remote monitoring of plants.

• Zone wise classification of CHP with defined owner &

introduction of zone wise checklist for better cleanliness &

defect identification

• Introduction of incentive scheme for BOBR & BOXN unloading

for Foreman & Workman with variable rate.

• Introduction of by-pass chute of both Rotary Breakers to

maximize the availability of unloading chain during outage of

Rotary Breakers.

• Introduction of chute jam switch.

• Online monitoring of Bunker levels.

• Remote operation of Tripper Trolleys.

• Schedule thermography at stock plies for identification of hot spot.

Initiatives and Improvements

Initiatives and Improvements

• Zone wise classification at stock piles for stacking the

different coal.

• Better fire management by using sprinkling systems and fire monitors.

• Decided to install pull cord switch sensors.

• Decided to install digital display of coal flow rate at track

hopper for Operator.

Coal bunkering and stacking

Unloading from wagons Size<300mm

Conveying by Belts

Separating magnetic materials at EM-1 / 2

Primary Crushing Size <100mm

Conveying by Belts Coal Bunker Conveying

by Belts

Separating magnetic materials at EM-3 / 4

Secondary crushing size <20mm

Separating magnetic materials at ILMS-1 / 2

Conveying by Belts

Stacking by Stacker-reclaimer

Coal stock pile

Coal Reclaiming Chain

BC-12A

BC-12B

BC-10A

BC-10B

FG-8A

BC-13 VFD-7 & 8

FG-8B

VFD-9 & 10

Coal Pile-2

Reclaim Hopper

BC-11A

BC-11B

Thank You