![Page 1: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/1.jpg)
Activities adopted for Performance Improvement
3 x 250 MW Thermal Power PlantISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 certified
Budge Budge Generating Station
![Page 2: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/2.jpg)
Agenda
Brief introduction of CESC Limited & BBGS
Performance parameters & Trends
Activities undertaken for improvement
Awards & Accolades
![Page 3: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/3.jpg)
About CESC Limited & BBGS……
![Page 4: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/4.jpg)
New Cossipore 1949100 MW
Titagarh 1983-84240 MW
Southern 1990-91135 MW
Budge Budge 1997,1999 & 2010
750 MW
• a RP-Sanjeev Goenka group Company in the business of generation & distribution of electricity since 1899
• Total licensed area : 567 sq kms, in & around Kolkata
• Consumer base : over 2.5 million
• Total Generation capacity : 1,225 MW
CESC Limited
![Page 5: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/5.jpg)
Major Landmarks Unit - 1 Unit - 2 Unit - 3
Trial synchronization 16.09.97 06.03.99 12.07.09
Commercial generation 07.10.97 01.07.99 28.02.10
Full load generation 26.02.98 09.08.99 29.09.09
BBGS is the latest, largest & most modern power plant of CESC
ISO 14001:2004ISO 9001:2008 OHSAS 18001:2007
![Page 6: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/6.jpg)
Performance parameters ……
![Page 7: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/7.jpg)
70
75
80
85
90
95
100
105
75.0
9
75.8
4 79.8
5
86.3
8
99.6
1
99.7
7
100.
43
100.
53
93.7
5
82.7
8
90.1
6
Plant Load Factor (%)
Plant Load Factor (%) and Generation (Mu)
3000
3500
4000
4500
5000
5500
6000
6500
3,28
9
3,32
2
3,50
7 3,78
4
4,36
3
4,37
0
4,41
1
4,40
3
4,28
6
5,43
9
5,94
0
Generation (Mu)
![Page 8: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/8.jpg)
Activities – to improve PLF
Export during night lean periods due to trading opportunity in power as per Indian Electricity Act, 2003
5% overloading of machines with the concurrence of OEM keeping all parameters within limits
Ensuring reliability of Units
![Page 9: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/9.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
270
75
80
85
90
95
100
105
0
100
200
300
400
500
600
70074
.04
75.0
9
75.8
4 79.8
5
86.3
8
99.6
1
99.7
7
100.
43
100.
53
93.7
5
82.7
8
90.1
6
0 0 0 7.5
160
418458 441
301
159107 126
PLF % Export (Mu)
PLF (%) vis-à-vis Export (Mu)
![Page 10: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/10.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
280
85
90
95
100
92.7
1
93.0
9
94.6
6
91.7
4
92.7
4
97.4
7
97.0
4
97.3
9
97.5
4
94.6
1
91.8
9 95.2
Plant Availability Factor (%)
![Page 11: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/11.jpg)
Activities – to improve PAF
Reduction of Annual overhauling period● Annual overhaul period from 28 days to 12 days
● Use of sky climbers
● Replacement of wind-box internals which were earlier repaired
● Engagement of multiple contractors 24x7 hrs
● TG major overhauling every 6 years
● Ancillary plants overhaul throughout the year
![Page 12: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/12.jpg)
Activities – to improve PAF
Improved Maintenance Practices● Daily maintenance planning meetings for planned jobs
● CFT for condition based monitoring & predictive maintenance
● Renewal of Boiler back-pass tubes in a planned manner to reduce
Boiler tube leakages
● Proactive identification of Boiler tube leakages vide Acoustic Tube
leak Detection System
![Page 13: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/13.jpg)
Activities – to improve PAF
Improved Operational Practices● 3-tier checklist system for monitoring equipment health
● Strict parameter deviation monitoring by operation personnel
● Installation of ELC machines for online oil conditioning
● Installation of chute vibrators to prevent chute chokage during
monsoon
● Forced air cooling of Turbine to reduce downtime
● Standard operating procedures
![Page 14: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/14.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
27.60
8.10
8.60
9.10
9.60 9.33 9.189.39
9.048.69
8.328.13 8.03 8.00
8.268.62
8.25
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
270
75
80
85
90
95
100
74.04 75.09 75.8479.85
86.38
99.61 99.77 100.43 100.53
93.75
82.78
90.16
Specific Energy Consumption (%) vis-à-vis PLF (%)
![Page 15: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/15.jpg)
Activities – to improve Specific Energy consumption
● dP across feed control station has been reduced from original
8 Kg/cm2 to 1.8 Kg/cm2 thus minimizing throttling loss
● Optimizing number of CW Pump operation depending on
seasonal temperature, maintaining design vacuum
● Modification of Furnace draft control logic related to ID Fan
vane and scoop control by making the vane operation band
dynamic with respect to the scoop position
● Optimizing Compressor loading / unloading
![Page 16: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/16.jpg)
Activities – to improve Specific Energy consumption
● Stage blinding in Condensate Extraction Pump
● Use of dual speed CT fan motors to allow running at lower
speed during winter
● Intermittent operation of ISS hopper drains thus reducing
running hrs of Intake pump
● Timer circuit has been incorporated to control outdoor
lighting and use of energy efficient lights at control room
![Page 17: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/17.jpg)
Activities – to improve Specific Energy consumption
● Use of energy efficient motors
● Installation of Energy monitoring system to monitor energy
consumption of electrical boards and HT drives and thus
enabling to take corrective measures proactively
Future Plans● Installation of VVVF drives for PA fans
● Use of LED lamps
![Page 18: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/18.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
20.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0.74
0.61
0.60
0.30
0.23
0.12 0.13
0.13 0.15
0.33
0.88
0.39
Higher oil consumption is due to trial synchronization and stabilization of Unit-3
Specific Oil consumption (ml/Kwh)
![Page 19: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/19.jpg)
Activities – to improve Specific Oil consumption
● Higher reliability & lesser Outages
● Trial of Oil guns without oil consumption
● To check sequence of operation
● To ensure scavenge takes place thus clearing the oil tips
![Page 20: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/20.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
21.50
1.70
1.90
2.10
2.30
2.50
2.70
2.90
2.67
2.28
2.24 2.
35
2.47
2.11
1.85 1.
89
1.87 1.90
2.10 2.
15
Specific Water Consumption (l/Kwh)
![Page 21: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/21.jpg)
Activities – to improve Specific Water consumption
● Increase of the cycle of concentration of CTCW system by
dosing corrosion inhibitors / anti-scalant special chemicals
and monitoring Calcium hardness level, thus decreasing CT
blow-down
● Changing the mode of operation of ISS hopper blow-down
from continuous to intermittent, thereby reducing the
Intake water consumption
![Page 22: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/22.jpg)
● All Volatile chemical treatment in power cycle water
thereby avoiding Boiler blow-down
● Utilization of CTCW blow-down as station service water
● Diversion of ACF backwash effluent to Holding pond for
recycling
● Recirculation of station effluent from holding pond to raw
water treatment plant
Activities – to improve Specific Water consumption
![Page 23: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/23.jpg)
Original Scheme
Cooling Water Forebay
Cooling Water Pumps
Condenser
Turbine
Cooling Tower
Hot Water
Cold Water
River Hoogli
Holding PondRaw Water Treatment
Plant
Station Services
CT Make-up
Canteen
Mun
icip
al D
rain
DM Plant
Fish Pond
Revised SchemeDischarge outside Plant
Modifications done
Sludge Pit
CT
Blo
wd
ow
n
Pump House
Control of Plant effluentWe are a Zero Effluent discharge Station
![Page 24: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/24.jpg)
Bottom Ash Zero Discharge System
Click to edit Master text stylesSecond level
Third levelFourth level
Fifth level
Click to edit Master text stylesSecond level
Third levelFourth level
Fifth level
0 - discharge system
0 - discharge system schematic
![Page 25: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/25.jpg)
CDM Projects
Reduction of Boiler Efficiency Loss due to blow down by achieving All Volatile Treatment (AVT)/ Zero Solid Treatment
Modification of Furnace draft control logic related to ID Fan vane and scoop control
Globally FIRST Thermal Power plant to register 2 of our Energy saving projects with UNFCCC
![Page 26: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/26.jpg)
00-0
1
01-0
2
02-0
3
03-0
4
04-0
5
05-0
6
06-0
7
07-0
8
08-0
9
09-1
0
10-1
1
11-1
20
20
40
60
80
100
120
140
160
141
129
119
110
67
58
46
34
50 48 48 43
Suspended Particulate Matter (mg/Nm3)
![Page 27: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/27.jpg)
Monitoring & Control SPM & RPM
Sl Systems implemented
1 Ammonia Dosing System
2 Water Fogging System
3 DE & DS System
4 Dry Fog System
5 Water Sprinkler System
Major Initiatives Towards
Ammonia Dosing Ammonia Dosing
Online SPM Online Stack
![Page 28: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/28.jpg)
Category Uses of ash
1 Bricks / Blocks / Tiles / Cement
2 Roads & Embankments
3 Structural filling
4 Land filling
Barge Silos HCSS
Intiatives towards 100% Ash utilisation
![Page 29: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/29.jpg)
Awards & Accolades ……
![Page 30: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/30.jpg)
Environment Excellence award – 2004 & 2006
![Page 31: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/31.jpg)
National Award for utilization of Fly ash, from Ministry of Power, Ministry of Environment & Forests and Department of Science & Technology in 2005
National Award for Excellence in Energy Management from CII in 2005
![Page 32: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/32.jpg)
National Award for Excellence in Water Management from CII in 2005
Gold award for Excellence in Environmental Management from Greentech Foundations in 2005, 2006 & 2007
![Page 33: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/33.jpg)
National Award from CEA in 2009-10 for meritorious performance amongst Thermal Power Plants in Environmental Management
Awarded by CEA for achieving highest Plant Load Factor in the country in 2005-06
![Page 34: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/34.jpg)
Award for Innovative Environmental Project (Dry Fog system at Wagon Tippler & Secondary Crusher House) from CII in 2012
Silver award for Best Environmental practices from CII for the year 2009 -2010
![Page 35: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/35.jpg)
Good Green Governance award from Srishti Publications in 2011
Asian Power Award for Best Environmental Management amongst all Power plants of Asia in 2010
![Page 36: Activities adopted for Performance Improvement · 3-tier checklist system for monitoring equipment health ... Installation of ELC machines for online oil conditioning ... Tippler](https://reader033.vdocument.in/reader033/viewer/2022041617/5e3ca6d0dd39602295655178/html5/thumbnails/36.jpg)
Thank You