Technical & Simulator

Training Programme”
at BKTPP
(Bakreswar Thermal Power
Plant)
By
Chiranjit Halder, Yuvraj Sanyal, Aditya Mohan Datta,
Subham Naha & Souvik Roy Chowdhury
from MSIT (Meghnad Saha Institute of Technology)
Content
i. Introduction

ii. Overview of the BkTPP

iii. About the BkTPP Simulator

iv. Technical Specification of Bk.T.P.S.

v. Simplified Diagram of a Power Plant

vi. Mechanical Operations

vii. Electrical Operations

viii. Pollution and Environment

ix. Conclusion
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 Introduction
West Ben­gal Power Devel­op­ment Cor­po­ra­tion Lim­ited (WBPDCL) is a com­pany
owned by the Gov­ern­ment of West Ben­gal with the goal to carry on inter­alia the busi­
ness of elec­tric power gen­er­a­tion and sup­ply in the state of West Ben­gal, India. The
ther­mal power plants under WBPDCL are in Kolaghat, Bakreswar, Sagardighi,
Santaldih,and Bandel.
WBPDCL Formed in July, 1985 with only one gen­er­at­ing unit at Kolaghat hav­ing
turnover of Rs.64 Crore paced up fur­ther to Rs.2728 Crores in 2007-​08 with 20
units at Kolaghat, Bandel, Bakreswar, San­taldih and Sagardighi. Kolaghat Ther­mal
Power Sta­tion involves a total installed capac­ity of 1260 MW. Installed capacity of
Kolaghat Thermal Power Station is 1260 MW., Bakreshwar Thermal Power Station
is 1050MW , Sagardighi Thermal Power Project is 1600MW, Bandel Thermal
Power Station is 330 MW and Santaldih Thermal Power Station is 500 MW.
WBPDCL works in tan­dem with West Ben­gal State Elec­tric­ity Distribution
Company Limited (WBSEDCL) and Cal­cutta Elec­tric Sup­ply Cor­po­ra­tion (CESC).
 Overview of the BkTPP

BkTPP (Bakreswar Ther­mal Bakreshwar Dam and

Power Project), under WBPDCL
(West Ben­gal Power Devel­op­ Reservoir Project are
ment Cor­po­ra­tion Lim­ited), is constructed across river
one of the most reli­able and pres­ti­
gious coal-​fired power plants in Bakreshwar.
West Ben­gal and in India as well.
In two stages the total capac­ity of It is an integral part of
the plant is (05 X 210) MW. Bakreshwar Thermal
Funded by the Over­seas Eco­
nomic Co-​Operation Fund Power Project, which
(OECF) of Japan Govt. — sub­se­ relies on the reservoir for
quently constituted as Japan Bank
for Inter­na­tional Co-​operation fulfilling its raw water
(JBIC) — this project is one of requirements during the
the first Fast Track projects to be
suc­cess­fully com­pleted within months of April, May and
sched­uled time. June.

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About the BkTPP
Simulator
BkTPP is installed in 2002 by GSE Power System Inc., USA,
BKTPP Training Simulator has conducted countless training
sessions to cater various needs of different organizations of
national and international repute.

Situated inside the BKTPP Township premise, the main feature

of the simulator are:

• Full size replica of control room

• Workstation computers as soft panel

• Conventional hard panel

• PLC for interfacing between soft and hard panel

• Field device terminal

• Instructor station
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 Technical Specification of Bk.T.P.S.
The Installed Capacity of Bk.T.P.S. are as following…
1. Total number of Units: 5 x 210MW each
2. Total Energy Generation: 1050MW
3. Source of Water: Tilpara Barrage (on Mayurakshi River), Bakreshwar Dam
(on Bakreshwar River)
4. Sources of Coal: Different Collieries situated in eastern India through
Railway.
Simplified Diagram of a Power Plant
Mechanical Operations

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1. Coal Handling Plant (CHP)

In Bk.T.P.S. coal comes

Paddle Feeder is used to feed
through railway in BOBR
(Bottom open box rake) and the coal to conveyor belt
NBOX type containers. from Track Hopper. Then a
BOBR type containers are network of Conveyor Belts
easy to unload. Using carries the coal towards
pressurized air, the bottom Crushers House. In each line,
gates of BOBR containers two conveyor belts are
are opened and the coal then
present (one running, one
fell into the Track Hopper
due to gravity. NBOX standby). If the amount of
containers are bigger sized coal comes through rail is
container then BOBR but excess, then some coal is
there is no gate available in stacked in uncrushed coal
the bottom of those boxes. area.

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2. Raw Water System

The required water is taken from two places...

A. Tilpara Barrage B. Bakreshwar Dam

This Barrage is situated in Mayurakshi River This water reservoir is specially made for this plant on
approximately 12KM from Bk.T.P.S. In a year 9 Bakreshwar River approximately 6KM from Bk.T.P.S.
months, the plant fulfils its water demand from Tilpara Bakreshwar Intake Pump House is used for 3months in
Intake Pump House. It has 6 no. Intake Pump, 6 no. a year to supply water in the plant. This pump house 2
Dual Flow travelling water screen, 3 no. Screen Wash Intake Pump.
Pump.
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3. DM (De-mineralization) Plant
In De-mineralised Plant, the filter water of Water Treatment Plant is passed through the
Pressure Sand Filter (PSF) to reduce turbidity and then through Activated Charcoal
Filter (ACF) to absorb the residual chlorine and iron in filter water. And then, the water
is passed through Cation and Anion Exchange Resin Beds which removes all unwanted
ions from the water.
4. Boiler & Auxiliaries
Boiler is device for generating steam for power processing or
heating purposes. Boiler is designed to transmit heat from an
external combustion source contained within the boiler itself.

There are various boiler accessories such as…

i) Boiler Furnace
ii) Boiler Drum
iii) Economizer
iv) Super Heater
v) Pre-Heater
vi) Burners

vii) Induced Draft (ID) Fan

viii) Forced Draft (FD) Fan

ix) Primary Air (PA) Fan/Exhauster Fan
x) Coal Mill/Pulveriser

xi) Fuel Oil System

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5. Ash Handling Plant
(AHP)

A large quantity of ash is, produced in steam

power plants using coal. Ash produced in about
10% to 20% of the total coal burnt in the
furnace. Handling of ash is a problem because
ash coming out of the furnace is too hot, it is
dusty and irritating to handle and is
accompanied by some poisonous gases. First
this ash is collected from ESP (Fly Ash, 80% of
total Ash) and from the bottom of the Boiler
(Bottom Ash, 20% of total Ash).

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6. Steam Turbine & Auxiliaries

This turbine has 3 sections…

A Steam Turbine is a
a) High Pressure Turbine (HPT): it has
mechanical device that extracts 23 stages.
thermal energy from b) Intermediate Pressure Turbine
pressurized steam, and (IPT): it has 17 stages.

converts it into useful c) Low Pressure Turbine (LPT): it has

8 stages in each side.
mechanical work.
There are various steam turbine accessories
such as…
In Bk.T.P.S. 210MW FUJI
i) Regenerative Heaters
makes three Casing Tandem
ii) Pumps
Compounding Re-heat a. BFP (Boiler Feed Pump)
Regenerative Condensing b. CEP (Condenser Extraction Pump)
Reaction-type Turbine is used c. CW (Cooling Water) Pump
in each unit as a prime mover d. ACW (Auxiliary Cooling Water)
of the alternator. Pump
iii) Turbine Gland Seal
iv) Condenser

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7. Cooling Water System

Cooling towers cool the warm water discharged

from the condenser and feed the cooled water
back to the condenser. They reduce the cooling
water demand in the power plants.

In Bk.T.P.S., ID Cooling Towers are used. In

this type of Cooling Towers has one ID Fan is
placed in the top of the tower which sucks the
air horizontally through the vertically falling
hot water. In this time, the water releases its
heat to the atmosphere and cool down.

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8. Chimney
A Chimney may be considered as a cylindrical hollow tower made of bricks or steel. In
Bk.T.P.S., the chimneys of five units are made of bricks. Chimneys are used to release
the exhaust gases (coming from the furnace of the boiler) high up in the atmosphere.
So, the height of the chimneys is made high, approximately 220m.
Electrical Operations

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1. Turbo Generator
This Turbo Generator is basically a Synchronous Alternator. The stator houses the Armature
Windings and the rotor houses the Field Windings. DC voltage is applied to the Field
Windings through the Brushless Excitation System. When the rotor is rotated the lines of
Magnetic Flux cut through the Stator Windings. This induces an e.m.f. in the Stator
Windings.

The rotor is rotated at 3000 rpm by the Turbines to generate electricity at a frequency of 50
Hz. Because, this is a 2-pole machine. Due to this huge speed, the “TURBO” term is used.

The components of Turbo Generator are Rotor, Rotor Winding, Stator Core, Stator Winding.

There are three types of cooling system for Turbo Generator, such as…
i) Rotor Cooling System
ii) Hydrogen Cooling System
iii) Stator Cooling System
2. Excitation System
Excitation System is used to send the Field Current in the Stator Winding of an Alternator. Here
we have Brushless Excitation System for this purpose.
In Brushless Excitation System, two systems namely Pilot Exciter and Main Exciter are
connected to the common shaft of the Turbo Generator’s Prime Mover.
3. Transformers
The transformers used in a power station have its sides abbreviated as Low Voltage (LV) and
High Voltage (HV) rather than primary and secondary.
In a power station, the major transformers are as following…
i) Generator Transformer (GT)
ii) Unit Auxiliary Transformer (UAT)
iii) Station Transformer (ST)
iv) Inter-Bus Transformer (IBT)
4. Switch Yard
It is a switching station which has the following credits…
i) Main link between Generating plant and Transmission system, which has a large influence on
the security of the supply.
ii) Step-up and/or Step-down the voltage levels depending upon the network node.
iii) Switching ON/OFF Reactive Power Control devices, which has effect on quality of power.
In Bk.T.P.S., they have 3 different Switch Yard for
different voltage level, such as…

a) 400 KV Switch Yard

b) 220 KV Switch Yard
c) 33 KV Switch Yard

The equipments of Switch Yard are as following…

d) Transformers
e) Circuit Breakers (52)
f) Isolators (29)
g) Current Transformer (CT)
h) Potential Transformer (PT)
i) Capacitive Voltage Transformer (CVT)
j) Earth Switch
k) Lightning Arrestors (LA)
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5. Switch Gear
Switchgears are basically the controlling circuits using which that used to control any system from Remotely
Situated Control Room.
i) HV Switchgears: Indoor metal clad draw out type switchgears with associated protective and control
equipments are employed. Air brake, air blast circuit breakers and minimum oil circuit breakers could
still be found in some very old stations.
ii) LV Switchgears: LV switchgears feed power supply to motors above 110KW and upto 160KW rating
and to Motor Control Centre’s (M.C.C.). LV system is also a grounded system where the neutral of
transformers are solidly connected to ground.
6. Protection
The purpose of generator protection is to provide protection against abnormal operating
condition and during fault condition. In the first case, the machine and the associated circuit may
be in order but the operating parameters and beyond the specified limits. Such abnormal running
condition would result in gradual deterioration and ultimately lead to failure of the generator.
Protection under abnormal running conditions:
a) Over current protection
b) Over load protection
c) Over voltage protection
d) Unbalance loading protection
e) Loss of prime mover protection
Protection under fault conditions:
f) Differential protection
g) Back up impedance protection
h) Stator earth fault protection
i) 95% stator earth fault protection
j) 100% stator earth fault protection
k) Rotor earth fault protection
7. DC Power System
DC Power System is a very important part of a power plant. In Bk.T.P.S., the DC
current majorly used at 220V. This DC supply is produced by converting 220V AC
into DC using rectifier. Battery Bank acts as the DC Power Source in case of Total
Power Failure in Bk.T.P.S.
 Pollution and Environment
Environmental issues in thermal power plant projects primarily include the following…
a) Air emissions
b) Energy efficiency and Greenhouse Gas emissions
c) Water consumption and aquatic habitat alteration
d) Effluents
e) Solid wastes
f) Hazardous materials and oil
g) Noise
 Conclusion
The practical experience that we have gathered during the Vocational Training of Bakreshwar
Thermal Power Station having a capacity of 1050MW for Unit #I to #V in two weeks (10-23
December) will be very useful as a stepping stone in building bright professional career in future
life. It gave us large spectrum to utilize the theoretical knowledge and to put it into practice. The
trouble shooting activities in operation and decision making in case of crisis made me more
confident to work in the industrial atmosphere.
Moreover, this Vocational Training has also given a self-realization & hands-on-
experience in developing the personality, interpersonal relationship with the
professional executives, staffs and to develop the leadership ability in industry
dealing with workers of all categories. I would like to thank everybody who has
been a part of this project, without whom this project would never be completed
with such ease.
Thank You!