A REPORT OF THE VOCATIONAL TRAINING

FOR THE PERIOD OF TWO WEEKS

FROM 15-JUNE-2015 TO 27-JUNE-2015

At

BUDGE BUDGE GENERATING STATION

PUJALI, BUDGE BUDGE, 24 PARGANAS(S), PIN-700138
OF

UNDER

SUBMITTED BY

DIPTARAG SAHA
From
NETAJI SUBHASH ENGINEERING COLLEGE, GARIA, KOLKATA
DEPT-ELECTRICAL ENGINEERING

CONTENTS

Acknowledgement
Signature page
About CESC
About BBGS
Main plant operation
Boiler
Equipments associated with boiler
DM water system
Schematic representation of other important cycles taking
place in the power plant.
Fuel and ash
Planning and environment department
Mechanical maintenance department
Electrical & instrumentation department
References
Conclusion

ACKNOWLEDGEMENT
An endeavor over a long period can be successful only with the
advice and guidance of all the well-wishers, some directly through their
technical assistance and some through their encouragement and help.
I take this opportunity to convey my heart-felt thanks and deep sense
of gratitude to all who encouraged and stood by my side in completing
this project.
I present my humble thanks to:
MR. D. MAITRA (GENERAL MANAGER, HR)
MR. A. SAHA (GENERAL MANAGER, BBGS)
MR. S. SAMADDAR (DY. GENERAL MANAGER, BBGS)
MR. S. ROY (DY. GENERAL MANAGER, BBGS)
I would also like to pay my deepest gratitude to:
MR. MONOTOSH CHOUDHURY (ASST. MANAGER, HRD)
MR. KAUSHIK CHAUDHURI (MANAGER, OPS)
MR. SHIBSHANKAR ADHIKARI (ASST. MANAGER, FAO)
MR. ARIJIT GHOSH (MANAGER, PLG)
MR. SAMIR BANERJEE (SR. MANAGER, MMD)
MR. SUMIT GHORUI
for providing me the opportunity to undergo the training at BBGS.
I would also like to thank Mr. Nilay Saha & Mr. Debashish for giving
me their valuable time from their busy schedule & constantly supporting
me during the training period.
I would also like to express my thanks to all the staffs and
employees working at BBGS.
It was a privilege to get hand to hand experience & knowledge on
the working of a power plant under expert advisors that helped me to
have a better understanding of the subject.

SIGNATURE PAGE:
DEPT: OPS
NAME: SIGNATURE:
DEPT: F&A
NAME: SIGNATURE:
DEPT: MMD
NAME: . SIGNATURE:
DEPT: E&I
NAME: . SIGNATURE:
DEPT: PLG
NAME: .. SIGNATURE:
DEPT: PTC
NAME: SIGNATURE: .

ABOUT CESC
CESC is Indias first fully integrated electrical utility company that
participates privately in generation, transmission and distribution of
electrical power over a wide range of area in Kolkata and Howrah in
West Bengal. It brought electricity to Kolkata 10 years after it came in
London. Now it is a part of the renowned RP- SANJIV GOENKA Group. It
almost produces 1225 MW of power from its four generating stations
to supply electricity within an area of 567sq km to serve almost 2.9
million consumers which includes domestic, industrial and commercial
uses. The four generating stations are Budge Budge Generating Station
(750 MW), Southern Generating Station (135MW), Titagarh Generating
Station (240 MW) and New Cossipore Generating Station (100 MW). It
owns and operates the transmission and distribution systems through
which it supplies electricity to consumers.
This system comprises of 474 km circuit of transmission lines
linking the companys generating and 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 Limited has verged upon renewable
sources. Three projects in three different areas of renewable sources
have been brought forth. These are Gujarat Solar, which is a solar plant
in Gujarats 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.

ABOUT BUDGE BUDGE GENERATING STATION (BBGS)

CAPACITY: 750 MW (3X250 MW)

LOCATION: PUJALI, BUDGE BUDGE, 24 PGS(S), WEST BENGAL
FUEL SOURCE: ECL, BCCL, ICML AND IMPORTED COALS
FUEL REQUIREMENT: 2.45 MILLION TONNES PER ANNUM
MODE OF TRANSPORTATION: RAIL
WATER SOURCE: RIVER HOOGHLY
LAND AREA: 225 ACRES
ASH DUMPING AREA: 91 ACRES

Trial Synchronization
Commercial generation
Full Load Generation

Unit #1
16.09.97
07.10.97
26.02.98

Unit #2
Unit #3
06.03.99 12.07.09
01.07.99 28.01.10
09.08.99 29.09.09

UNIQUE FEATURES
Largest coal fired thermal power station of CESC limited.
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.

SOME AWARDS:

Selected for Silver Shield for the year 2013-14 in the

category of Environment Management Award scheme for
Coal based Thermal Power Station by Central Electricity
Authority (CEA).
Bronze Shield for the year 2013-14 in the category of
Performance of Thermal Power Station by Central
Electricity Authority (CEA).
Won Gold Award for outstanding achievements in
Environment Management in the thermal power sector in
15th Annual Greentech Environment Award 2014.
Silver Certificate of Merit in The Economic Times of
India Manufacturing Excellence Awards 2014.
CII National Energy Management Award 2014.
Re-Engineering India Award 2014 Awarded to Budge
Budge Generating Station, which has become the 1st coal
fired thermal power station in the world to register two
of its environment friendly works with United Nations`
Framework Convention for climate change.

MAIN PLANT OPERATION

Most of the power plants are run on the Rankine Cycle that is a
thermodynamic cycle which converts heat into work. The heat is
supplied externally to a closed loop, which usually uses water as the
working fluid. To increase the efficiency Modified Rankine Cycle is used
in the modern thermal power plants that uses the concept of reheating
and regeneration.
Some of the most important equipments found in a thermal power
plant are
BOILER
TURBINE
GENERATOR
COAL MILLS
DFFERENT TYPES OF FANS, HEATERS etc.
A schematic representation of a typical thermal power plant and its
overall power generation cycle may be represented as:

BOILER:
A boiler is a fuel-burning apparatus or container for heating. The
boilers used at BBGS are water tube boilers of natural circulation,
balanced draft two pass, downshot fired, single reheat drum type in
units 1 & 2 and in unit 3 natural circulation, balanced draft, two pass,
corner fired, single reheat drum type boiler is used.
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 unit3, etc. The pulverized coal is taken to the furnace
by the PA fans and fresh air that is containing oxygen is inserted inside
the boiler that helps combustion is done by FD fans and ID fans
maintain a negative pressure inside the boiler and thus the 3TS i.e.
time, temperature and turbulence of the boiler is maintained.
The schematic diagram of the downshot fired and corner fired
boiler used at BBGS may be represented as:

THE IMPORTANT EQUIPMENTS ASSOCIATED WITH BOILER

BOILER DRUM
The steam drum is made up of high carbon as its thermal stress is
very high. There is a safety valve in the drum, which may explode if the
temperature and the pressure of the steam are beyond a set value. It is
a part of a bigger set named Pressure Safety Valve (PSV) or Pressure
Relief Valve (PRV). The boiler drum has the following
It stores and supplies water to the furnace wall headers and the
generating tubes.
It acts as the collecting space for the steam
The separation of water and steam takes place here. Any
necessary blow down for reduction of boiler water concentration
is done from the drum. Next the steam goes to super heater.

SUPER HEATER
The super heater rises the temperature of the steam above its
saturation point i.e. saturated steam or wet steam into dry steam and
there are two reasons for doing this:
There is a thermodynamic gain in the efficiency.
The super-heated steam has fewer tendencies to condensing the
last stages of the turbine.
The superheater used at BBGS is of primary/LTSH, platen and final type.

AIR PRE-HEATER
The air heater is placed after the economizer in the path of the
boiler flue gases and preheats the air for combustion. They are simply
heaters that heats the air before it enters the combustor, hence result
in the fuel consumption and increasing the thermal efficiency. The fuel
savings are nearly directly proportional to the air temperature rise in
the pre-heater. Air pre-heater are also a requirement for the operation
of pulverized-coal furnaces to dry that fuel.
There are 3 types of air preheaters: Tubular type, rotary type and
plate type.

ECONOMIZER
The heat of the flue gas is utilized to heat the boiler feed water.
During the start up when no feed water goes inside the boiler water
could stagnate and over heat in the economizer. To avoid this,
economizer re circulation is provided from the boiler drum to the
economizer inlet. The feed water coming out from deaerator passes
through to special shape of pipes inside the economizer. The special
shapes of tubes provide increase the contact surface area between the

flue gas and the feed water, so that maximum heat exchanging can take
place.

ELECTROSTATIC PRECIPITATOR
It is a device that separates fly ash from outgoing flue gas before
it is discharged to the stack. There are four steps in precipitation:
Ionization of gases and charging of dust particles.
Migration of particle to the collector.
Deposition of charged particles on collecting surface.
Dislodging of particles from the collecting surface.
By the electrostatic discharge the ash particles are charged due to
high voltage between two electrodes. Generally maximum amount of
ash particles are collected in the form of dry ash, stored inside the SILO.
Rest amount of ash (minimum) are collected in the form of bottom ash
about 20% ash and stored under the water inside HYDROBIN.

SAFETY VALVE
A safety valve is a valve mechanism which automatically releases
a substance from a boiler, pressure vessel, or other system, when the
pressure or temperature exceeds preset limits. It is one of a set of
pressure safety valves (PSV) or pressure relief valves (PRV), which also
includes relief valves, safety relief valves, pilot-operated relief valves,
low pressure safety valves, and vacuum pressure safety valves. Vacuum
safety valves (or combined pressure/vacuum safety valves) are used to
prevent a tank from collapsing while it is being emptied, or when cold
rinse water is used after hot CIP (clean-in place) or SIP (sterilization-inplace) procedures.
No of Safety valves:

At drum
At CRH
No of air heater
No of F.D Fan
No of I.D Fan
No of P.A Fan
No of coal mills

Unit#1&2
2
2
3
2
3
2
6

Unit#3
3
4
2
2
2
2
5

TURBINE
Turbine is a rotating device which converts heat energy of steam
into mechanical energy. At BBGS it is a machine of impulse reaction
type comprising of a single flow high pressure turbine, single flow
intermediate pressure turbine and a double flow low pressure turbine.
The H.P., I.P. AND L.P. turbine shaft and the generator are all rigidly
coupled together, the assembly being located axially by a thrust bearing
at the inlet end of H.P. turbine. The turbine receives high pressure

steam from the boiler via two steam chests. The H.P. turbine cylinder
has its steam inlets at the end adjacent to the no. one bearing block,
the steam flow towards the generator.

Exhaust steam passes through twin over-head pipes to the L.P.

turbine inlet belt where the steam flows in both directions through the
L.P. turbine where it exhausts into under slung condenser. Steam is
extracted from both the H.P. & L.P. turbine at various expansion stages
& fed into four feed water heaters. Here spherically seated Journal
Bearing is used. The main turbine is a Tandem Compounded, Three
Cylinder, single reheat, double Flow LP cylinder, Condensing Type with
uncontrolled extraction. The turbine utilizes an electro-hydraulic
governing system. The startup, shut-down and loading of the turbine
can be achieved automatically.

The turbine throttle pressure is 146Kg/Cm2 (abs.), the main steam

temperature is 537C and the reheat steam temperature is 535C. The
individual pressure and temp stats vary for the 3 different units.

CONDENSER
Condenser is a device used for converting a gas or vapour to
liquid. Condensers are employed in power plants to condense exhaust
steam from turbines. In doing so, the latent heat is given up by the
substance and it will be transferred to the condenser coolant. A surface
condenser is a shell and tube heat exchanger installed at the outlet of
every steam turbine in thermal power stations. The cooling water flows
through the tube side and the steam enters the shell side where the
condensation occurs on the outside of the heat transfer tubes. The
condensate drips down and collects at the bottom, in a pan called hot
well. Initial air extraction from the condenser and steady vacuum inside
the condenser is achieved by two nos. motor driven, water sealed, air
extraction pumps commonly 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. 2 nos. separate condensate
storage tanks, interconnected to each other, are provided for the three
units. Condensate storage tanks receive demineralized water from DM
Plant.

FEEDWATER HEATER
Feed water heaters are used in power plants to preheat water
delivered hot steam to the generating boiler. Preheating the feed water
reduces the irreversibilitys in steam generation and hence improves
the efficiency of the system. This method is economical and reduces
thermal shock when the feed water is introduced back in the cycle.
Feed water is taken from the De-aerator, a feed water storage tank, by
motor driven feed water pumps, and discharged through two stages of
high pressure re generative feed water heaters and flue gas heated
economizer into the boiler drum.

DEAERATOR
Deaerator is a device widely used for the removal of oxygen and
other dissolved gasses from the feed water. It mostly uses low pressure
steam obtained from an extraction point in their steam turbine system.
They use steam to heat the water to the full saturation temperature
corresponding to the steam pressure in the deaerator and to scrub out
and carry away dissolved gases. Steam flow may be parallel, cross, or
counter to the water flow. The deaerator consists of a deaeration
section, a storage tank, and a vent. In the deaeration section, steam
bubbles through the water, both heating and agitating it. Steam is
cooled by incoming water and condensed at the vent condenser. Non
condensable gases and some steam are released through the vent.

Most of the steam will condense, but a small fraction must be vented to
accommodate the stripping requirements. Normal design practice is to
calculate the steam required for heating and then make sure that the
flow is sufficient for strip pin gas well.

COOLING TOWER
Cooling towers are heat removal units used to transfer process
waste heat to the atmosphere. Cooling towers may either use the
evaporation of water to remove process heat and cool the working fluid
or, in the case of closed circuit dry cooling towers, rely solely on air to
cool the working fluid. The primary use of large, industrial cooling
towers is to remove the heat absorbed in the circulating cooling water
systems used in power plants. The circulation rate of cooling water in a
typical 700 MW coal-fired power plant with a cooling tower amounts to
about 71,600 cubic meters an hour and the circulating water requires a
supply water make up rate of perhaps 5 percent. Facilities such as
power plants, steel processing plants use field erected type cooling
towers due to their greater capacity to reject heat. With respect to the
heat transfer.

DM WATER PLANT
It plays an important role in the power plant as it is used for
generator cooling as well as the steam is generate from this water.
Demineralized water is used as it removes all types of cations and
anions present so that the boiler as well as the other components can
be saved from corrosion. Different cation and anion exchange resins
are used as well as activated carbon to achieve dm water

Schematic representation of the other important systems

occurring in the power plant are as follows:

FUEL AND ASH (FAO)

The Fuel and Ash department is responsible to supply pulverized
coal (PF) to the boiler. It also stores some coal in stack ward for use in
difficult times when inflow of coal is not sufficient for the plant. It also
receives and stores the Light Diesel Oil (LDO) that is used during lightups. Its second purpose is to manage the fly ash and bottom ash that is
produced during the combustion of coal. All the major equipment are
controlled from the control rooms. This department can be divided into
two parts Fuel (Coal + LDO) handling operation and fly ash and
bottom ash handling operation.

SPECS OF COAL HANDLING PLANT AT BBGS:

CAPACITY: Design: 960 T/hr.
Rated: 800 T/hr.
Number of Wagon Tipplers: 2
Number of Track Hopper: 1
PRIMARY CRUSHER: Quantity: 2 in numbers
Type: Rotary Breaker
SECONDARY CRUSHER: Quantity: 2 in numbers
Type: Ring Granulator
STACKER-CUM-RECLAIMER MACHINE:Type: slewing and boom stacker with bucket wheel reclaimer, rail
mounted, suitable for reversible yard conveyor.
Numbers: 2
Total travel distance: 308 M
Lump Size: (-) 100 mm

 Height of Pile: 10.5m

TYPE OF MATERIAL HANDLED
Material: Semi Crushed Coal
Lump size: (-) 100 mm
Each day the amount of coal required is about 11500 tonnes when
the power plant is working on 100% load for 24 hours. The coal comes
from ECL, BCCL, ICML, and imported coal from Indonesia. Coal having
ash content less than 30% is used in power plant. The coal coming from
Indonesia has an ash content less than 5%.The coal comes via railway in
BOBR and BOX-N wagons. The coal unloading is done by two methods
they are Rota side Wagon Tippler and Track Hopper.

Track hopper wagon system for unloading coal is BOBR type

system. Among the two systems, it is more advantageous. It has 33
parts and the total time taken unload the coal is 2hr 15 minutes. Each
wagon has 3200 tons of coal. From the Track hopper system the coal
goes to belt conveyor 101 A & B. They contain two RDB (Rotary

Discharge Belt) each. The coal is the transferred to belt conveyor 1A &
1B (depending on position of chute gate).

Wagon tippler has two tipplers having 3 hoppers each. Each of the
three hoppers has a VFD. The second tippler has 1C conveyor belt
below it. First tippler has 1D conveyor belt. They transfer the coal to 1A
& 1B, the coal then comes to Transfer Point 1(TP 1). 1A will give the
coal to RBF (Reverse Belt Feeder) 4A&1B will give to RBF 4B. At the top
floor there is there is head end of conveyor belts 1A & 1B. Below it,
there is RBF 4A, 4B which gives coal to 2A & 2B conveyor belt. 2A & 2B
gets into the primary crusher house. Coals from 2A will go to Rotary
Breaker 1A (RB-1A) and RB-1A will lead the coal to RBF 1A. There is a
bypass chute called the grizzly feeder through which coals of size
30mm to 40mm are passed and they then go to RB 1A. RB 1A throw
away the boulders through the chute RBF present in the 1st floor.

Coals from 2B conveyor belt will go to RB 2B. RB 2B will lead the

coal to RBF 2B. The smaller coals will be bypassed in the same way as
before and will then go to RB 1B which throws away the boulders
through chute RBF present in the 1st floor.
RBF 1A when moves forward gives the coal to belt conveyor 3A,
3B at ground floor. If it moves in reverse direction it will give coal to 8A,
8B belt conveyor. They go to stack yard. Belt conveyor 3A, 3B have
head end at secondary crusher house at 3rd floor. At 2nd floor there is
DDVS (Double Deck Vibrating Screen) 1A, where the coal is taken. In the
1st floor there is screen crusher 1A through which the coal falls to 4A,
4B belt conveyor. From DDVS 1B, coal is taken to screen crusher 1B,
and then to belt conveyor 4A, 4B. From DDVS, the coal is passed to 4A,
4B by bypass chute. The screen crusher has 16 pairs of hammers in
each of the 4 rows.

4A, 4B come to TP 2 coming out of the secondary crusher. Coal

from 4A will go to conveyor belt 5A or RBF 2A & that from 4B will go 5B
or RBF 2B. RBF 2A, 2B will give coal to belt conveyor 6A, 6B. Each of 6A
& 6B has a tipper trolley which give coal to all 6 parts of the first bunker
(A, B, C, D, E, and F).
TP2 have 5A, 5B as tail end & they go to TP3. From TP3, 5A and 5B
get divided. 7A & 7B move reverse and forward. They have tipper
trolley. They give load to 2nd bunker. TP3 have tail end of 102 A-B &
TP3/1 have their head end. The load from TP3/1 will go to TP3/2. TP3/1
has tail end of 103 A&B and TP3/2 have head end of 103 A&B.
In the 3rd bunker there are 104 A & B. Each of the have a tipper
trolley which give load to the bunker part A, B, C, D, E.
From the primary crusher house, the coal is carried to belt conveyor
8A, 8B and then to TP4. Coal from 8A or 8B goes to 10A or 10B. If coal is

on 10A then it will go to number 1 stacker cum reclaimer using tipper

trolley mechanism. There is an Intermediate Belt Converter just above
the stacker. Then the coal is carried to boom conveyor and then to
stack gear. The coal from the stack gear is carried to the pile. There are
two piles, viz. pile 1 and 2 (length-350m and breadth- 60 to 70 m). If the
coal falls in number 9B and 9C.Above 10B, IBC & boom conveyor is
present.

During reclaiming in stacker no. 1, the coal is carried from the

stacker to the boom conveyor, then to 10A conveyor belt. This belt
moves in reverse order. The coal is the moved to TP4. Through the
chute it is passed to 11A-B conveyor belt. Coal from 11A and 11B are
carried to 12A and 12 B respectively through TP6. Then they are taken
to primary crusher house and then to 3A and 3B.
Again from the 2nd stacker, the coal is carried to the boom
conveyor and then to 10B belt which moves in reverse direction. It
carries the coal to TP5 and through the chute, the coal is taken to 13C
and then to TP4. After that the coal reaches 11A/B.

There is a second way. The coal is taken from pile 2. Between TP4 and
TP6 there are 4 hoppers (7, 8, 9, and 10). The coal from 7 and 8 reach
11A and then to 12Athrough TP6 and the coal from 9 and 10 reach 11B
and then to 12B.

ASH HANDLING PLANT

FLY ASH HANDLING SYSTEM: Fly Ash Evacuation Rate: 80 Mt/hr.
Capacities of Tank / Vessel: Air Heater: 57 Liters
ESP 1 & 2: 485 Liters
ESP 3: 145 Liters
ESP 4 To 7: 85 Liters
BOTTOM ASH SYSTEM: Bottom Ash Cleaning Rate: 60 MT/hr.
Effective Storage Capacity: Bottom Ash Hopper: 150 MT (Approx.)
De Watering Bin: 432 MT (Approx.)
Settling Tank: 1240 CUM (Approx.)
Surge Tank: 1670 CUM (Approx.)
Overflow Transfer Tank: 21 CUM (Approx.)
Decant Water Transfer Tank: 35 CUM (Approx.)
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. Bottom Ash Removal
system is a wet system. The bottom ash of each unit is crushed by a
convergent nozzle which is used to achieve high speed and hydraulically
conveyed in the form of slurry by divergent nozzle which is used to
increase the pressure of the water from bottom ash hopper to

Dewatering bins/Ash tanks. Decanted water separated from the bins is

further re-circulated by sending the water and ash mixture into the
settling tank, where the ash settles down and clear water is taken out
of it and moved into the surge tank and then again the water is taken to
clear the slurry. Collected bottom ash at the bins is removed by trucks.
This method is called Zero discharge system.
Fly ash collected in ESP & Air heater hoppers is removed in dry
form by dense phase pneumatic conveying system in two stages. In the
first stage, the flue gas enters the ESP which consists of both negative &
positive plates which are charged with 75kv DC supply. The dust from
the flue gases get negatively charged and attaches with the positively
charged plates which are then removed by hammer, and collected in
the hopper. Fly ash collected in above hoppers is pneumatically
conveyed with compressed conveying air called Makeover system to
Intermediate Surge Hoppers (ISS). In the second stage, the dry fly ash is
further conveyed from ISS to Fly Ash Silos or river side Burge to export
as to Bangladesh cement industry by P.D. 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 which has a viscosity thinner than toothpaste and thicker than
glue is produced (amount of water mixed is very important) 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 (ISH) to trucks through unloading system
in case of emergency. A majority of the fly ash is at present exported to
Bangladesh though barges for use in their cement plant.

PLANNING AND ENVIRONMENT DEPARTMENT

The planning department of BBGS CESC Limited is the department
which controls every aspect of the progress of the company and
supervises on the work of every department. This kind of management
is maintained by the data which is provided by the respective
departments. It not only monitors the progress of the company but also
all the details of every person of the company including employees and
workers. Routine maintenance, breakdown maintenance, and
predictive maintenance are also being planned and supervised by this
department. Economics of this company is taken care by this
department. Environment, emergency plan, health and safety as well as
computer defect, training, infrastructure request, are being supervised
by this department. The planning department of BBGS not only
manages other departments and economy, it also manages the details
of the executives of its own departments which includes officers
transport, strength, record, leave repots, leave summery, along with
the computers in the whole unit of BBGS. Each and every department
starting from coal unloading to generation of electricity has its own
monthly and yearly targets. This target is set by the planning
department in BBGS and the end of the respective year it is seen that
the target is being achieved or not and the required regulation is taken
according to it. This determination is very valuable because it is
important to determine the position of the power plant among the
others in India .Apart from this planning department also makes a
record of unit trips, leaks of tube, heat rate, total generation loss, and
environment related failures. One of the employees of any department
can raise an issue regarding any machinery in the plant planning
department takes the issue into account and checks whether the issue
is being solved or not and take steps according to the progress of the
work in design.

MECHANICAL MAINTENANCE DEPARTMENT

Maintenance is a set of organized activities that are carried out in
order to keep equipment in its best operational condition with
minimum cost acquired. It includes performing routine actions which
keep the device in working order or prevent trouble from arising.
MAINTENANCE TYPES:
Broadly speaking, there are three types of maintenance in use:
Preventive Maintenance: 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.
Corrective Maintenance: 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.
The major divisions in this department include:
Maintenance of Boiler & its auxiliaries: Boiler ID Fan, FD Fan,
PA Fan, Coal Mill, Various Pumps, etc.
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.
Maintenance of Fuel and Ash: Conveyor System Rotary Breakers
Crusher Wagon Tipplers Track Hoppers Bottom & Fly Ash While

performing maintenance activities, it is important we maintain a

schedule for the same, take in to safety considerations, keep all
necessary tools and equipment in the vicinity of the equipment,
ensuring only skilled man power to handle the machine. Also the
various maintenance activities should be practiced in a sequential
manner and proper note be taken. Given below are checklists for
HPLP Bypass Maintenance and for Cooling Tower Fan
Maintenance.

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 inter posing a lubricant between
the surfaces to carry or to help carry the load between the opposing
surfaces. Lubrication purposes to:
Lubricate: Reduces Friction by creating a thin film (Clearance)
between moving parts (Bearings and journals)
Cool: Picks up heat when moving through the engine and then
drops into the cooler oil pan, giving up some of this heat.
Seal: The oil helps form a gastight seal between piston rings and
cylinder walls
Clean: As it circulates through the engine, the oil picks up metal
particles and carbon, and brings them back down to the pan
Absorb Shock: When heavy loads are imposed on the bearings,
the oil helps to cushion the load.
Absorb Contaminants: The additives in oil helps in absorbing the
contaminants that enter the lubrication system.

ELECTRICAL & INSTRUMENTATION DEPARTMENT

B.B.G.S. Generator:

Maximum Continuous Rating

Maximum Continuous Rating
Rated Power Factor
Rated Terminated Voltage
Rated Current
Frequency
Number of phases

Unit 1&2
250 MW
294 MVA
0.85
16500V
10291A
50 Hz
3

Unit 3
250MW
294MVA
0.85
16500V
10291A
50 Hz
3

The generators at BBGS are hydrogen and DM water cooled type.

The outer part of the cylinder has hydrogen operated coolers while the
inner part has the core and the windings. DM water is circulated all
along the cylinder by two AC pumps. The stator core and the rotors are
cooled by hydrogen circulated by centrifugal pumps mounted on each
side of the generator. The rotor is made with alloy forgings with steel at
the exciter end. The rotor windings are formed from copper strips. Each
end of rotor shaft is supported by journal bearings, lubricated from
Turbine Lube Oil system. Exciter end bearing pedestal is fully insulated
to prevent eddy current circulation through bearing and oil films. The
generator field current is supplied by a static excitation system. The
current is supplied by an excitation transformer and a thyristor
controlled rectifier. The turning gear drive is coupled to the generator
rotor and when meshed, allows turbine and generator shafts to be
rotated slowly before run up and after shut down to prevent rotor
distortion due to uneven heating.

There are 3 types of transformers in the plant namely

GT (Generator Transformer) - used to step up the voltage
generated (16.5KV) to 132KV in case of unit#1 &2, 16.5KV to
220KV in case of unit#3.
ST (Station Transformer)- are used for in-plant power of BBGS for
meeting the power requirements of the auxiliaries such as FD Fan,
PA Fan, ID Fan, coal mills, conveyors, centrifugal pumps, CW
Pump etc. as well as the lighting loads of the various buildings of
the plant.
UT (Unit Transformer)-The startup power of the plant is provided
by the UT which steps down the voltage from 16.5KV to 6.6K.
Each and every equipment associated with the unit takes the
power from this UT.
The specifications of the various transformers of unit#1 &2 are as
follows:

GENERATOR TRANSFORMER:

Make
Phase
Frequency
No. of unit /generators
Rated voltage (kV)
Rated current (A)

UNIT#1&2

UNIT#3

TELK
1
50 Hz
3 Nos, 1 Ph.
138/3 HV, 16.5 LV
1318 HV, 6364 LV

BHEL
3
50 Hz
1 No, 3 Ph.
235 HV, 16.5 LV
11022.14 LV

STATION TRANSFORMER:
UNIT#1&2

UNIT#3

Make
CGL
BHEL
Phase
3
3
Frequency
50 Hz
50 Hz
No. of unit /generators
1 No, 1 Ph.
1 No, 3 Ph.
Rated voltage(kV) 132 HV,6.9 LV(1&2)
220 HV,6.9 LV(1&2)
Rated current (A)
262.4HV, 2510.2 LV(1&2)

UNIT TRANSFORMER:
UNIT#1&2

UNIT#3

Make
HHE
BHEL
Phase
3
3
Frequency
50 Hz
50 Hz
No. of unit /generators
1 No, 1 Ph.
1 No, 3 Ph.
Rated voltage(kV) 16.5HV,6.9 LV(1&2)
16.5HV,6.9 LV(1&2)
Rated current (A)
1410.3HV, 2094.3 LV 1& 1256.6 LV2

The GT is having vector notation Yd 11(30deg lag between prim. &

sec. side) which is used generally as a convention The alternators(3phase)of the Turbine-Generator set is STAR-connected so that during
earth fault the fault current(the sum of the currents in the 3 phases is
not equal to zero during earth fault) flows into the ground through the
neutral wire without hampering the generator. The LV side (16.5KV) of
the GT is delta connected. This is because if there is an earth fault on
the LV side of the GT then using STAR connection will cause the fault

current to flow through the neutral wire. This fault current may enter
into the generator circuit through the neutral wire of the STAR
connected generator & hamper the generator. To avoid such a situation
LV side (16.5KV) of the GT is delta connected. The HV side of the GT
which is connected to the transmission line is STAR connected. The
neutral wire for bypassing the fault current is connected to NGT
(Neutral Grounding Transformer) which steps down the current to a
smaller value so that the fault current does not hamper any devices.
The UT takes the tapping from the 16.5 kV generated before GT. It is
used to run all the equipments that are associated with the single unit
by stepping it down to 6.6 KV. The UT has two LV sides namely LV1 &
LV2 having voltage rating of 6.6 KV each. These two LV sides are used to
charge the UB-1A & UB-1B (Unit Board) through the incomers which
are connected to UT-1.The UT is used to charge the UB-1A & UB-1B.
The UB#1A & UB#1B are charged by UT- 1. The UB caters to the
independent drives (coal mills, CW PP, FD FAN, ID FAN etc.) which are
different for each unit. We observe that UB#1A caters to a number of
auxiliaries such as PD FAN, IDFAN, COAL MILL, CW PP, ACW PP etc.
whereas the UB#1B caters to BFP only. This is because the BFP is rated
with high wattage consumption whereas the other auxiliaries are of
considerably lower power consumption. Thus if BFP & the other
auxiliaries are present on the same UB then the total power available
on the UB will the consumed by the auxiliaries itself leaving the BFP unoperated. Thus the BFP is present in a separate UB. Now if due to shut
down or failure of the UT#1, the LV sides of the UT are unable to charge
the UB#1A & UB#1B, then the SB#1A (Station Board 1A) & theSB#1B
(Station Board 1B) are used to charge the UB#1A & UB#1B respectively
with the help of a tie between the SB & UB.
The ST meets the power requirements of the auxiliaries such as FD
Fan, PA Fan, ID Fan, conveyors, centrifugal pumps, CW Pump etc. as

well as the lighting loads of the various buildings of the plant. The SB#
1A &SB#1B are charged by the ST-1.Similar is the case for unit# 2. The
SB caters to the dependent drives (Intake PP, coal plant etc.) which are
the same for all the units.

Overview of the Electrical Network in B.B.G.S:

There are 2 switchyards in B.B.G.S., a 132 kV switchyard for Unit#

1 & 2 and a 220 kV switchyard for Unit# 3. There are 2 ICTs
(Interconnecting Transformers) for connecting (electrically) two
switchyards. In each section there are 2 main buses M1 and M2. There
is another bus named Transfer Bus which is used during the change in
load of M1 and M2 or during maintenance, for uninterrupted power
supply. For the 132 kV switchyard M1 is fed from one GT
(Generating Transformer) and M2 from the GT of other unit.
There is MBC (Main Bus Coupler) in both the switchyards for coupling
M1 and M2. From M1 and M2 of each switchyard power is supplied to
the Feeder# 1, 2, 3, 4 (132 kV switchyard) and Feeder# 5 & 6 (220 kV

switchyard). Output of the generator (16.5 kV) is fed to the primary of

the GT which steps up the voltage to 132 kV (Unit#1 & 2) or 220 kV
(Unit# 3). Output of the generator is also fed to the primary of the UT
(Unit Transformer) which steps down it to 6.6 kV which is used to
supply different parts of a unit. ST (Station Transformer) is fed from the
132 kV and the 220 kV bus and ST steps down it to 6.6 kV. This ST is
used to supply common parts of different units of the Generating
Station, e.g. lighting etc. In case if due to any fault any of the two
switchyard supplies is disconnected from the GT then that switchyard is
supplied by the other one through ICT. There are both Isolators and
Circuit Breakers in the switchyard. Circuit Breakers are operated in onload condition whereas isolators are operated in off load condition. So,
during the connection of any bus the sequence of operation is- firstly,
isolator is closed, then the corresponding CB (circuit breaker) is closed.
Reverse sequence is followed during the opening of a certain bus.
Major components of a Switchyard
1. Circuit Breaker.
2. Bus Isolators with & without Earth switch.
3. Line Isolators with Earth switch.
4. CT.
5. PT with PT Isolator & Earth switch.
6. Main Bus.
7. Transfer Bus etc.
ISOLATOR
Two types of Isolators used:
Horizontal double end break, center post rotating, motorized,
mechanically ganged type with one earth switch.
Pantograph type, motorized without earth switch:

1. Rated current: 1600 Amp.

2. 245 KV rated, 3 phase.
3. Suitable to connect with ACSR Moose conductor & Al bus pipe.

DC ELECTRICAL NETWORK
DESCRIPTION:
220 V. DC power supply is provided in each unit to provide stable
DC supply to following:
1. Generator auxiliaries DC seal oil pump, Excitation Cubicle, Generator
back up panel
2. Generator Relay Panel
3. Turbine auxiliarys Emergency lub oil pump, Jacking oil pump, Misc.
solenoids.
4. Emergency lighting.
All above loads are supplied from D.C. distribution board
charged from Battery Bank consisting of lead cells, constantly under
charging by battery charger, Ac power to which are supplied either
from station auxiliary LT board (0.4 kV) and unit wise emergency MCC.

UPS SYSTEM
A power station is meant for supply power to the user. Normally
the power flows from the generating station to the load end. But in an
adverse situation when any unit or the power station is dead
suddenly it requires adequate planning to restore from the adverse
situation keeping the process parameters & the equipments safe.
NORMAL MODE: When the utility is normal, the UPS powers the
load through the rectifier and inverter and charges the batteries
at the same time.

 BATTERY MODE: When the utility fails, the battery will power the
load through the inverter. When utility becomes normal, it
automatically returns to the normal mode.

PLC & DCS SYSTEM

PLC: Programmable Logic Controller
DCS: Distributed Control System
We use DCS in analog and digital system both. PLC only used in
digital system. PLC is fast response than DCS. DCS system consists CPU,
Ethernet switch, controller, analog input or analog output (AI/AO) card,
DI/DO card, field instrument. PLC system consists of similarly CPU,
Ethernet switch, controller, DI/DO card, field instrument.

The physical quantity to be controlled is measured by means

of a transducer, which converts a mechanical variable (usually
pressure) to an electrical signal, i.e., current within a range of 420 mA .The value of 4mA corresponds to the lowest value of the
quantity, while 20mA corresponds to the highest value of the quantity.
The current signal is fed to the CPU, which consists of many cards,

which converts the analog signal into an equivalent ASCII or hex code.
The signal is then controlled by a PID controller present in the CPU; this
ASCII code is reconverted to a current signal in the range of 4-20 mA by
means of another set of cards. These cards are of various types like
analog input analog output (AIAO) etc. The current signal is
converted to pressure signal by means of an I-to-P converter (i.e.,
an actuator). This pressure signal is compared with another pressure
signal calibrated in the range of 0.2-1 Kg/Cm2 to produce a positioner
signal, which causes movement of the corresponding valve to bring the
input value nearer to the set point, thus producing the desired
output. The parameter values are controlled from the Control rooms,
while the logic may be changed from the Engineers room.

The controllable parameters for example are boiler temperature,

drum level etc. Each parameter consists of two cards (A & B), one for
operation and the other for standby, so that complete shutdown of the
control system does not occur. The various cards within a particular
CPU communicate with each other by means of a switch. Again, a
parameter of particular equipment (e.g. boiler) may require a signal

from a parameter of another equipment (e.g. turbine). Thus,

interconnection among the various CPUs is necessary, and this is
achieved by a core switch. All the CPUs are also connected to form a
network by means of another switch. This network is known as DCS
(Distributed Control System).

REFERENCES
Information gathered from:
1. Observation during the training.
2. Plant training center.
3. Various engineers of the various departments .

CONCLUSION
Working with CESC Ltd as a vocational trainee was a very nice
experience. I learnt a lot about designing basic systems in electrical,
instrumentation and the working of electrical power generation,
maintenance and operation. I also practiced what I learnt in the college
and applied it on field. Working with Electrical & instrumentation
department enhanced my major understanding. All in all, a thermal
power plant is a very large establishment with many components
and its awesome to see how all the components work in a
synchronized manner.
In addition, I gained a good experience in term of self-confidence,
real life working situation, interactions among people in the same field
and working with others with different professional background. I had
an interest in understanding basic engineering work and practicing
what has been learnt in the class. Also, the training was an opportunity
for me to increase my human relation both socially and professionally.