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