3 X 250 MW Coal Based Thermal Power Plant

1. Budge Budge Generating Station 3 X 250 MW Coal Based Thermal Power Plant ISO 9001:2015, ISO 14001:2015 & OHSAS 18001:2007 certified

2. Performance Metrics of BBGS Plant Availability Factor (%) Plant Load Factor (%) Specific Energy Consumption (%) Specific Oil Consumption (ml/Kwh)

3. On-line Decision Support System for Unit Operation

4. The need • Why anomaly was detected so late ? • Why actual cause detection took so much time ? • Should have done ….. • Should not have done ……

5. Traditional Tools • DCS pages with hundreds of parameters • DCS Alarms (Parameter limit exceed and quality checks) • BUP Facia (with audible alarm) • Trainings (CEP,Simulator)

6. Limitations • Doesn’t tell what to do • Doesn’t tell how to do • Doesn’t indicate deterioration so that proactive action can be taken DSS was conceived to address above issues with existing infrastructure

7. Probable Solutions Challenges • Difference in Experience of operating personnel • Varying Perception leading to non uniformity in decisions with varied reaction time • Reactive approach to mode of operation • Provide on-line support of collective experiences in-built • Standardize and provide customized problem analysis and solution • Proactive approach to mode of Operation in terms of process efficiency improvement and acting prior to alarming situations

8. Modules in DSS • Proactive approach to mode of Operation in terms of process efficiency improvement and acting prior to alarming situations • Provide on-line support of collective experiences in-built • Standardize and provide customized problem analysis and solution • Any parameter sudden change • Any control loop unhealthy • Emergency Situation Handling • Start-up / Shutdown Guide • Post Trip Fault Validation

9. Decision Support System : How it looks like :

10. Benefits achieved • DMCW pressure control deviation • Root Cause – Poor pump performance • Mill outlet temperature control deviation • Root Cause – Change in coal quality • Load control deviation • Root Cause – Frequency influence and change in coal quality • GT winding temperature rise • Root Cause – Cooler bank trouble

11. Opportunity for further development • Critical parameters for Fast ramp up and down can be configured for close monitoring • New malfunctions can be added - Scalability • Integration with IoT based devices

12. Thank You

13. An Emergency Situation Occurs Probability of asset damage Probability of saving asset Probability of asset damage Any Emergency Situation A Pre-defined Emergency Situation Occurs Alarm A Alarm B Alarm C Alarm N Correlating & Root Cause analysis by Operator Alarm in decision support system with correct root cause analysis Faulty Analysis Correct And timely action Delayed Analysis Correct & timely action taken by operator Probability of saving the asset increased by 66.67%

14. Typical Emergency Situations • 220V Battery Charger Trouble • Both ICT off and any 220kV Outgoing Feeder undercurrent • Both 220kV Outgoing Feeder undercurrent • TG on House load • Load Shedding Relay Operated • Any Air Heater Tripped, Dampers open and Boiler running • 220kV Shutdown • Emergency Board dead (Any or Both section) • Turbine tripped and GCB Closed • Turbine tripped, GCB open and Field breaker Closed • Unit Board section-A/B Dead • Station Board section-A/B Dead • Unit Auxiliary Board Section A / B Dead

15. Sequential Unit Start-up / Shut Down • Scope: • Pertains to start up and shutdown of unit • Purpose: • To standardize the OEM practices during Unit Start Up and Shut Down and ensuring execution of the recommended practices • To reduce downtime independent of the efficiency of the operating personnel. • To ensure asset safety during Start Up & Shut Down.

18. Post Trip Fault Validation • Scope: • Pertains to all equipments and parameters related to safety of assets • Purpose: • To ensure Safety of Assets • Any anomaly after Unit Trip can be identified immediately at the assigned page without the operator having to rack his brains.

19. Boiler Trip Turbine Trip but boiler live

20. ANY PARAMETER SUDDEN CHANGE GENERATOR COLD GAS TEMPERATURE STARTS RISING COLD GAS TEMP. HIGH ALARM IN DECISION SUPPORT SYSTEM RISE IN COLD GAS TEMPERATURE ABOVE THRESHOLD ALARM AT BACK UP PANEL ROOT CAUSE ANALYSIS BY OPERATOR PROBABILITY OF GENERATION LOSS DEPENDING ON OPERATOR’S SKILL AND AVAILABLE TIME ACTION TAKEN BY OPERATOR HIGHER PROBABILITY OF SUSTAINING GENERATION

21. ANY PARAMETER SUDDEN CHANGE COLD GAS TEMP. HIGH This grey dot turns into red if deviation becomes high.

22. Control Loop Unhealthy BFP CONTROL OIL PRESSURE LOW DECREASE IN SPEED WHILE SCOOP INCREASED TO MAX(High loop deviation) DRUM LEVEL DEVIATION ALARM IN DECISION SUPPORT SYSTEM WITH EXACT ROOT CAUSE REDUCTION IN FEED FLOW DROP IN DRUM WATER LEVEL BELOW THRESHOLD ALARM AT BACK UP PANEL ROOT CAUSE ANALYSIS BY OPERATOR ACTION TAKEN BY OPERATOR PROBABILITY OF GENERATION LOSS DEPENDING ON OPERATOR’S SKILL AND AVAILABLE TIME HIGHER PROBABILITY OF SUSTAINING GENERATION

23. Any control loop unhealthy • DOWN COMER BLOW OFF OPEN. • FEED WATER PATH BLOCKED. • RUNNING BFP REC. V/V OPEN • ALL SCOOP OR V/V IN MAN. • ANY BFP WO PR. LOW • ANY SCOOP OR V/V DEV. HIGH • ANY V/V OR SCOOP IN AUTO MAX/MIN. DRUM LEVEL DEVIATION This grey dot turns red if deviation becomes high.

24. Critical Control Loops • Mill PA Flow • Auxiliary PRDS Pressure • Auxiliary PRDS Temperature • Hot well Level • Deaerator Level • DMCW Pressure • DMCW Booster Pressure • Furnace Pressure • Drum Level 3 Element • Air Flow • PA Header Pressure • Unit Load Control • Super heater Temperature • Reheater Temperature • Mill O/L Temperature